2010 ASTON MARTIN V8 VANTAGE boot

Issue 5, January 2010 Workshop Manual 1-1-1
Body System (01.00)
Contents
Body Structure (01.01)........................................... 1-1-4Overview ................................................................ 1-4
Specifications.......................................................... 1-4
Maintenance ........................................................... 1-5Right Side Front Crush Bar for the Body
Reinforcement - Remove and Install ....................... 1-5
Left Side Front Crush Bar for the Body
Reinforcement - Remove and Install ....................... 1-5
Front Crush Brace - Remove and Install .................. 1-5
Front End (01.02) ................................................... 1-2-1 Front Wings ............................................................ 2-1Specifications ......................................................... 2-1
Maintenance ........................................................... 2-1 Radiator Closing Panel - Remove and Install ........... 2-1
Centre Undertray - Remove and Install
(Roadster Only) ..................................................... 2-1
Front Undertray-Remove and Install ....................... 2-2
Rear Undertray - Renew (Coupe only).................... 2-2
Rear Undertray - Renew (Roadster only) ................ 2-2
Install ..................................................................... 2-2.............................................................................. 2-2
Undertray, Vehicle Set - Renew ............................. 2-2
RH/LH Front Wheel Arch Liner - Renew ................ 2-2
RH/LH Rear Wheel Arch Liner - Renew ................. 2-3
RH Front Wing Panel Assembly - Renew ................ 2-4
LH Front Wing Panel Assembly - Renew ................ 2-6
Body Closures (01.03) ........................................... 1-3-1 Specifications.......................................................... 3-1Doors .................................................................... 3-1
Tailgate .................................................................. 3-1
Bonnet................................................................... 3-2
Maintenance ........................................................... 3-2 LH/RH Door Assembly-Renew ............................... 3-2
RH/LH Door Assembly-Remove/Refit ..................... 3-6
Front Door Hinge (One Side) - Renew ................... 3-6
Front Door Check Arm Assembly - Renew ............. 3-7
Boot Lid Assembly - Renew (Roadster Only) ........... 3-7
Boot Lid Hinge Assembly (Pair) - Renew
(Roadster Only) .................................................... 3-10
Boot Gas Strut (Pair) - Renew (Roadster Only) ...... 3-11
Boot Lid Striker Assembly - Renew
(Roadster Only) .................................................... 3-11
Exterior Boot Lid Switch Release - Renew
(Roadster Only) .................................................... 3-12
Tailgate Assembly - Renew ................................... 3-12
Tailgate Hinge Assembly (Pair) - Renew ................ 3-13
Hood Assembly - Renew ...................................... 3-14
Hood Hinge Assembly (Vehicle Set) - Renew ....... 3-14
Interior Trim (01.05).............................................. 1-4-1 Maintenance ........................................................... 4-1Rear Centre Console - Renew ................................ 4-1
Headlining - Renew (Roadster Only) ...................... 4-1
Header Panel As sembly - Renew
(Excluding Roadster)............................................... 4-6 Header Panel Assembly - Renew (Roadster Only)... 4-7
Front Header Console Assembly - Renew............... 4-7
RH/LH Upper Rear Pillar Panel Assembly
- Renew ................................................................. 4-8
RH Sun Visor - Renew ........................................... 4-8
LH Sun Visor - Renew ............................................ 4-8
Door Trimboard Assembly - Renew ....................... 4-9
Door Trimboard Assembly
- Remove for Access/Refit ...................................... 4-9
Lower Quarter Trim Panel Assembly - Renew
(Roadster Only)...................................................... 4-9
Side Carpet Kit (RHD) - Renew ............................ 4-11
Side Carpet Kit (LHD) - Renew ............................ 4-12
Top Rear Console Fini
sher Panel Assembly
- Renew (Roadster Only) ...................................... 4-14
RH/LH Bodyside Rear Trim Panel Assembly
- Renew (Roadster Only) ...................................... 4-14
Tonneau to Body Weatherstrip Assembly
- Renew (Roadster Only) ...................................... 4-15
Door Trim Weather Strip Assembly - Renew
(Roadster Only).................................................... 4-16
Exterior Trim (01.08) ............................................. 1-5-1 Maintenance ........................................................... 5-1RH/LH Applique Sill - Renew ................................. 5-1
RH Wing Side Strake - Renew................................ 5-2
LH Wing Side Strake - Renew ................................ 5-2
Channel Assembly Divider Bar - Renew ................. 5-2
Windshield Header Finisher - Renew
(Roadster Only)...................................................... 5-3
Mirrors (01.09) ...................................................... 1-6-1 Specifications ......................................................... 6-1
Maintenance ........................................................... 6-1RH Door Mirror Assembly - Renew ........................ 6-1
LH Door Mirror Assembly - Renew ........................ 6-1
Seating (01.10)....................................................... 1-7-1 Description ............................................................. 7-1Heated Seats ......................................................... 7-1
Specifications ........................................................ 7-1
Maintenance ........................................................... 7-1 RH/LH Front Seat - Remove and Install .................. 7-1
Front Seat Squab Cover Assembly
(Each, Pre-08MY) - Remove and Install .................. 7-1
Front Seat Squab Cover Assembly
(Each, from 08MY) - Remove and Install................. 7-3
Front Seat Cushion Cover Assembly (Each)
- Renew ................................................................. 7-3
6-Way Height Adjuster (Inc. Motors) - Renew ........ 7-4
Squab Motor Kit - Renew....................................... 7-6
Lumbar Support Kit - Renew .................................. 7-7
Side Airbag - Renew .............................................. 7-8
Front Seat Buckle Assembly - Renew...................... 7-9
Valance Heater and Lumbar Switch Assembly
- Renew ................................................................. 7-9
Seat Harness Kit - Renew ..................................... 7-10

1-1-2 Workshop Manual Issue 5, January 2010
RH/LH Seat Switchpack Assembly - Renew...........7-13
Lumbar Pump for the Front Seat (From 08MY)
- Remove and Install.............................................7-13
Lumbar Valve for the Front Seat (From 08MY)
- Remove and Install.............................................7-14
Lumbar Bladder for the Front Seat (From 08MY)
- Remove and Install.............................................7-14
Glass, Frame and Mechanism (01.11) .................. 1-8-1 Description .............................................................8-1 Frameless doors......................................................8-1
Specifications .........................................................8-1
Maintenance ...........................................................8-1 Glass Regulator - Renew .........................................8-1
RH/LH Door Glass - Renew ....................................8-2
Door Glass - Adjust/Reset .......................................8-3
Front Windshield - Renew ......................................8-3
Rear Windshield - Renew .......................................8-4
Quarter Window Glass - Renew .............................8-6
Passenger Window Lift Switch - Renew ..................8-6
Driver Window Lift Switch - Renew........................8-7
Instrument Panel (IP) (01.12)................................ 1-9-1 Specifications ..........................................................9-1
Maintenance ...........................................................9-1 Instrument Panel - Renew ......................................9-1
Airbag Panel and Door Assembly - Renew ..............9-6
Glovebox Assembly - Renew ..................................9-6
Instrument Centre Panel Asse mbly - Renew............9-7
Knee Protector - Renew .........................................9-7
Instrument Panel As sembly - Renew .......................9-7
Cluster Bezel Panel - Renew .................................9-10
Driver Panel Assembly - Renew ............................9-10
Instrument Panel Bezel A ssembly (With Sat. Nav.)
- Renew ...............................................................9-11
Instrument Panel Bezel Assembly
(Without Sat. Nav.) - Renew .................................9-11
Rear Console Panel Assembly - Renew .................9-12
Armrest Pad Assembly - Renew ............................9-13
Console Panel Assembly - Renew .........................9-13
RH/LH Rear Console Pa nel Assembly - Renew
(Roadster Only) ....................................................9-13
Centre Console Panel - Remove and Install
(Coupe Only) .......................................................9-15
Centre Console Panel - Remove and Install
(Roadster Only) ....................................................9-19
RH/LH Lower Quarter Panel Assembly - Renew
(Roadster Only) ....................................................9-29
Handles and Lock Mechanisms (01.14) .............. 1-10-1 Description ...........................................................10-1 Vehicle Key/Remote Transmitter...........................10-1
Central Locking System ........................................10-1
Remote Transmitter ..............................................10-1
Fuel Filler Assembly ..............................................10-1
Boot Emergency Release ....... ...............................10-1
Specifications ........................................................10-2
Maintenance .........................................................10-2 Ignition Cylinder Lock - Re new.............................10-2
RH/LH Front Door Latch As sembly - Renew .........10-2
Bonnet Latch Assembly - Renew...........................10-3
Hood Release Cable Assembly - Renew (Roadster Only) .................................................... 10-3
Bonnet Secondary Latch Asse
mbly - Renew ......... 10-4
Tailgate Latch and Cable Assembly - Renew ......... 10-4
Fuel Filler Actuator Assembly - Renew
(Roadster Only) .................................................... 10-4
Fuel Filler Release Cable - Renew (Roadster Only) 10-5
Fuel Flap Release Switch - Renew ........................ 10-6
RH/LH Tonneau Latch Motor - Renew
(Roadster Only) .................................................... 10-7
RH/LH Tonneau Latch - Renew (Roadster Only) ... 10-7
RH/LH Tonneau Cover Striker Assembly
- Renew (Roadster Only) ...................................... 10-8
Tailgate Latch Assembly-Renew (Roadster Only) ... 10-8
Wipers and Washer System (01.16) ....................1-11-1 Headlamp Washing .............................................. 11-1
Specifications ........................................................ 11-2
Maintenance ......................................................... 11-2 Windscreen Wiper Motor As sembly - Renew ....... 11-2
Wiper Linkage Assembly - Renew ........................ 11-2
Windshield Wash Tube - Renew .......................... 11-2
Windscreen Reservoir and Motor Assembly
- Remove and Install ............................................ 11-3
Low Level Water Sensor - Remove and Install ...... 11-4
Headlamp Wash Motor and Pump Assembly
- Renew ............................................................... 11-5
Headlamp Wash Tube Assembly - Renew ............ 11-5
Washer Fluid Reservoir - Renew........................... 11-6
Convertible Roof and Roof Opening Subsystem
(01.17)..................................................................1-12-1 System Description .............................................. 12-1
Maintenance ......................................................... 12-2 Hood Assembly-Renew ........................................ 12-2
Canopy Cover - Renew ........................................ 12-5
Header Latch Motor - Renew ............................... 12-9
Hydraulic Main Actuator Cy linder - Renew .......... 12-9
Hydraulic Tensrod Cylinder - Renew .................. 12-10
Hydraulic Tonneau Cylinder - Renew................. 12-11
Convertible Top ECU - Renew ........................... 12-13
Hydraulic Pump - Renew ................................... 12-13
Hydraulic Lock Valve - Renew............................ 12-16
RH/LH Front Cantrail Seal - Spare Part
- Renew ............................................................. 12-18
RH/LH Front Cantrail Seal Spare Part Kit
- Renew ............................................................. 12-18
RH/LH Middle Cantrail Seal Spare Part
- Renew ............................................................. 12-18
RH/LH Middle Cantrail Seal Spare Part Kit
- Renew ............................................................. 12-19
Rear Seal Spare Part Assembly Kit - Renew ......... 12-20
LH Fully Automatic Latching Kit - Renew............ 12-21
RH Fully Automatic Latching Kit - Renew ........... 12-22
Convertible Roof Hydraulic Pump
- Check Fluid Level ............................................ 12-23
Cantrail Cover Trim - Renew .............................. 12-25
B-Post Trim Cover - Renew ................................ 12-25
Tonneau Cover - Renew .................................... 12-27
LH Front Main Hydraulic Cylinder Pipe
- Renew ............................................................. 12-29
LH Rear Main Hydraulic Cylinder Pipe

Body Closures (01.03)
Body System (01.00)1-3-6 Workshop Manual May 2007
19. Install inner and outer cable to external door handle.
20. Connect multiplug to door latch.
21. Install rear weatherstrip to glass channel and door frame. Install fir tree trim pins (x3)
22. Install seal to inner door aperture.
23. Position door mirror, install and torque tighten Torx bolts (x3) and screw (glass channel).
24. Connect door mirror multip lug, secure harness with fir
tree clips (x2) and adhesive clip.
25. Install rubber cheater to door frame, secure with fir tree trim pins (x3).
26. Install glass regulator as sembly into door frame.
27. Install and torque tighten nuts (x4) and Torx screws (x3) securing regulator assembly to door frame.
28. Connect multiplug to glass regulator.
29. Install door glass, install clamp bolts (x2), align marks on glass to rear clamp. Do not torque tighten at this stage.
30. Install fixed glass, ensure rubber surround is correctly installed.
31. Connect multiplug to side impact sensor, position
mounting plate, install and torque bolts (x3).
32. Position door control modu le, connect multiplugs (x3).
Install and torque tighten bolts (x4).
33. Position door speaker, install and torque tighten screws (x3). Connect multiplug to speaker.
34. Position door trimboard, connect multiplugs (x2).
35. Install trimboard to door frame, secure in clips.
36. Install and tighten screws (x5).
37. Install LH door assembly (see Workshop Manual procedure 01.03.FA Door Assembly - LH - Remove for
Access and Refit).
38. Battery isolation switch ‘ON’.
39. Glass front door - LH - Adjust and reset (see Workshop Manual procedure 01.11.BD Glass - Front Door - LH -
Adjust and Reset).
RH/LH Door Assembly-Remove/Refit
Removal
1. Switch on ignition, set door glass to half-way down position (this is to access door glass screw clamps on
door renew - 01.05.CB).
2. Battery isolation switch ‘OFF’.
3. Raise vehicle on ramp.
4. Remove road wheel(s),
5. Release rear part of whee l arch liner, screws (x7),
disconnect door check rod.
6. Pull back sealing boot and disconnect door multiplug.
7. Loosen the door hinge Torx screws (x2). 8. With assistance, lift door off support studs.
9. Withdraw the door from the vehicle and install on Door
Service Trolley (501 - F111).
10. Remove and discard hinge Torx screws (Patchlok).
Installation
1. Protect vehicle bodywork.
2. Install new hinge Torx screws.
3. With assistance, remove door from trolley (501 - F111),
position door to vehicle.
4. Align door to upper and lower hinges and install on hinge studs.
5. Connect the door check rod and install wheel arch liner, screws (x7).
6. Tighten hinge Torx screws (x2) (torque).
7. Connect multiplug and install boot.
8. Battery isolation switch ‘ON’.
9. Install road wheel(s).
10. Lower vehicle on ramp.
Front Door Hinge (One Side) - Renew
Removal
1. Remove LH/RH door assemb ly (see Workshop Manual
procedure 01.03.FA/01.03.EA Door Assembly - LH/RH -
Remove for Access and Refit).
2. Remove bolts (x4) securing upper and lower door hinges to body.
3. Remove hinges, note position of shims (if fitted) collect
rubber seals (x2).
4. Remove bolts (x2) securing upper and lower hinges to door, remove hinges (x2). No te fitted position of shims
(if fitted).
Installation
1. Position hinges to body, install rubber seals (x2) and shims (if fitted).
2. Install bolts (x4) securing hi nges to body. Do not torque
tighten bolts at this stage.
3. Position hinges (x2) to door. Install bolts (x2). Do not torque tighten at this stage.
4. Install LH/RH door assemb ly (see Workshop Manual
procedure 01.03.FA/01.03.EA Door Assembly - LH/RH -
Remove for Access and Refit).
5. Carry out preliminary hinge set-up.
6. Gently close door and check for acceptable initial installation.
7. Align the door, manoeuvre the door to achieve correct gaps and flush fit; (add/remove shims as required).
8. Open door, tighten bolts. Do not torque tighten at this stage.
9. Close door, re-check fitment and alignment.Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Front Door Hinge (One Side) Renew 01.03.FB

Body Closures (01.03)
Body System (01.00)
May 2007 Workshop Manual 1-3-7
10. Open door, torque tighten bolts.
Front Door Check Arm Assembly -
Renew
Removal
1. Remove door assembly (see Workshop Manual procedure 01.03.EA/01.03.FA Door Assembly - RH/LH -
Remove for Access and Refit).
2. Disconnect door check arm from door.
Installation
1. Connect door check strap to door.
2. Install door assembly (see Workshop Manual procedure 01.03.EA/01.03.FA Door Assembly - RH/LH - Remove
for Access and Refit).
Boot Lid Assembly - Renew (Roadster
Only)
Removal
1. Open boot lid.
2. Remove bolt securing strap to boot lid and remove strap (see Figure 1).
3. Remove clip securing cable to release lever and remove cable.
4. Release clips (x8) and remove boot lid trim panel. 5. Release clip securing harn
ess to interior panel (see
Figure 2).
6. Remove bolts (x4) secu ring panel to boot lid.
7. Release multiplug from pa nel, disconnect multiplug
from antenna and remove panel (see Figure 3).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Figure 2
Figure 3

Body Closures (01.03)
Body System (01.00)1-3-8 Workshop Manual May 2007
8. Disconnect multiplugs from latch, boot lid release
switch, release solenoid and stop light (see Figure 4).
9. Release clips securing harn ess to boot lid, release
grommet and remove harness (see Figure 5). 10. Remove bolts (x2) securing harness to hinge and release
harness (see Figure 6).
11. Remove cable tie, remove bolts (x3) securing latch to boot lid and remove latch (see Figure 7).
12. Remove nuts (x2) securing stop light to boot lid and
remove stop light and recover washers (x2).
Figure 4
Figure 5
Figure 6
Figure 7

Body Closures (01.03)
Body System (01.00)
May 2007 Workshop Manual 1-3-9
13. Remove nuts (x2) securing re lease switch to boot lid and
remove switch (see Figure 8).
14. Remove boot lid buffers (x2) from boot lid (see Figure 9).
15. Remove badge from boot lid. 16. Mark outline of hinges on
boot lid using a suitable
marker to aid installation (see Figure 10).
17. Release clips (x2) securing gas struts to boot lid, release struts and support boot lid (see Figure 11).
18. Using assistance, support b oot lid, remove bolts (x4)
securing hinges to boot lid and remove.
Installation
1. Using assistance, position trunk lid to body, fit bolts (x4) securing hinges to boot lid.
2. Position gas struts to boot lid and secure with clips.
3. Install tailgate buffers (x2) to boot lid.
4. Install release switch and secure with nuts.
5. Install stop light and secure with nuts and washers.
6. Install latch and secure with bolts and cable tie.
7. Position harness to hinge and secure with bolts.
8. Install harness in boot lid, secure grommet and clips.
Figure 8
Figure 9
Caution
Protect surrounding paintw ork using suitable tape.
Figure 10
Figure 11

Body Closures (01.03)
Body System (01.00)1-3-10 Workshop Manual May 2007
9. Connect multiplugs to boot lid latch, boot lid release
switch, release solenoid and stop light.
10. Connect multiplug to antenna and fit to panel.
11. Install interior panel and secure with bolts.
12. Secure harness to interior panel using clip.
13. Install boot lid trim panel and secure with clips.
14. Connect cable to release lever and secure with clip.
15. Install strap and secure with bolt.
16. Close boot lid and check profile against body, adjust buffers as necessary.
17. Fit boot lid badge.
Boot Lid Hinge Assembly (Pair) - Renew
(Roadster Only)
Removal
1. Open boot lid.
2. Mark outline of hinge on boot lid using a suitable marker (see Figure 1). 3. Mark outline of hinge on body using a suitable marker
(see Figure 2).
4. Using assistance, support boot lid and remove bolts (x2) securing hinge to boot lid and bolts (x2) securing hinge
to body and remove hinge.
Installation
1. Install hinge, align to marked outline and secure to body and boot lid with bolts.
2. Open boot lid.
3. Mark outline of hinge on boot lid using a suitable
marker.
4. Mark outline of hinge on body using a suitable marker.
5. Remove clip securing gas strut to boot lid and release gas strut.
6. Using assistance, support boot lid and remove bolts (x2) securing hinge to boot lid and bolts (x2) securing hinge
to body and remove hinge.
7. Install hinge, align to marked outline and secure to body and boot lid with bolts.
8. Close boot lid.
Repair Operation Time (ROT)
Figure 2

Body Closures (01.03)
Body System (01.00)
May 2007 Workshop Manual 1-3-11
Boot Gas Strut (Pair) - Renew (Roadster
Only)
Removal
1. Open boot lid.
2. Release clip securing LH gas strut to boot lid and release
gas strut (see Figure 1).
3. Release clip securing LH gas strut to body and remove gas strut (see Figure 2).
Installation
1. Clean gas strut, install and secure with clips.
2. Release clip securing RH gas strut to boot lid and release gas strut. 3. Release clip securing RH ga
s strut to body and remove
gas strut.
4. Clean gas strut, install and secure with clips.
5. Close boot lid.
Boot Lid Striker Assembly - Renew
(Roadster Only)
Removal
1. Access luggage compartment and remove floor carpet.
2. Release clips securing warning triangle in place and remove (see Figure 1).
3. Remove 2 bolts securing wa rning triangle bracket to
body and remove (see Figure 2).
Repair Operation Time (ROT)
Repair Operation Time (ROT)