2010 ASTON MARTIN V8 VANTAGE window

Safety Precautions
Issue 5, January 2010 Workshop Manual 0-0-7
Safety Precautions
All service workshops are a source of potential danger and
repair work should only be performed by technically trained
staff following procedures detailed in this manual. A safety
conscious approach to the performance of all service
procedures must be observed at all times. Statutory
requirements governing all aspects of health and safety at
work including directives for the proper use of materials and
equipment must be implemented.
The following contains a list of particular safety precautions
which should be observed; it is not intended to be
exhaustive.
Battery Disconnection
When a service manual procedure requires the vehicle
battery to be disconnected - always physically disconnect
the vehicle battery earth (Negative) lead.
Do not use the ‘Battery Disconnect Switch’.
After reconnecting the vehicle battery the following items
will have to be reset or re-learnt:
•Radio pre-sets
•Windows
• DTCs will be lost
Air Conditioning (A/C) System
Do not break into the A/C refrigeration system until the
refrigerant has been evacuated using the procedure detailed
in this manual. Do not disconne ct any A/C refrigerant system
pipes unless trained and instructed to do so. The refrigerant
used can cause blindness if allowed to contact your eyes.
Chemical Handling and Storage
Chemicals used in the servicing of motor vehicles include
acids, adhesives, antifreeze, brake fluids, coolants, grease,
oil, paint, resin and solvents. Exposure to certain chemicals
through direct contact or inhalation can be fatal.
Potential hazards may also be present through the incorrect
use, storage and handling of chemicals causing a fire risk.
The following precaution s should be observed.
• Strictly adhere to handling and safety information found on containers and labels.
• Do not store chemicals in unlabelled or incorrectly labelled containers.
• Containers used for storing chemicals should not be left open; there is a risk of spilling , or evaporation of fumes
which may be inflammable or toxic.
• Do not mix chemicals unless instructed to do so following manufacturers guidelines.
• Do not inhale chemical materials to determine identity, they may be toxic.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin.
• Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages. • Chemicals based on solvents such as paint should not be
sprayed in a confined space; work areas used for such
operations should be well ve ntilated and fume extraction
equipment should be utilised.
• Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.
• Avoid splashing the skin, eyes and clothing .
• Clean chemicals from the skin and clothing as soon as
possible after soiling .
• Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other
corrosive and toxic substances.
Electrical Equipment
• Ensure that electrical equipment is in safe working order before use.
• Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed.
• Ensure that electrical equipment is protected by a fuse of the correct current rating .
• Disconnect the battery before commencing repair operations to the electrical sy stem, fuel system and engine
or when working beneath the vehicle.
Exhaust Fumes
Engines should not be run in confined spaces as exhaust
fumes contain harmful and to xic substances including
carbon monoxide which can prove fatal if inhaled. Engines
must only be run where there is fume extraction equipment
in operation or where there is adequate ventilation.
Fire Precautions
• Ensure that a suitable form of fire extinguisher is conveniently located near the work area.
• Keep oils, solvents and combustible materials away from naked flames and other sources of ignition.
• Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be present
and ensure that the warnings are strictly observed.
• Ensure that dry sand is availabl e to soak up any spillage of
fuel or other flammable solutions.
• Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours.
• All personnel should be aware of the fire drill procedures and precautions. WAR NI NG
DO NOT SMOKE IN THE VICINITY OF VOLATILE DE- GREASING AGENTS.
WAR NI NG
FUME EXTRACTION EQUIPMENT MUST BE IN
OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE, WHITE SPIRIT, SBP3,
METHYLENE CHLORIDE, PERCHLORETHYLENE.

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

Exterior Trim (01.08)
Body System (01.00)1-5-2 Workshop Manual May 2007
RH Wing Side Strake - Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove mesh - RH side strake (see Workshop Manual procedure 01.08.CE Mesh - Side Strake - RH - Renew).
4. Remove Torx screw, (inside A-post) securing side strake to body.
5. Remove nut securing side strake to RH inner fender.
6. Remove side strake.
Installation
1. Install side strake, install and tighten nut and Torx screw.
2. Install mesh - RH side strake (see Workshop Manual procedure 01.08.CE Mesh - Side Strake - RH - Renew).
3. Lower vehicle on ramp.
4. Connect vehicle battery.
LH Wing Side Strake - Renew
Removal
1. Raise vehicle on ramp.
2. Remove mesh - LH side strake (see Workshop Manual procedure 01.08.CF Mesh - Side Strake - LH - Renew).
3. Remove nuts (x3) mesh to side strake.
4. Remove mesh.
5. Remove screw inside A-post side strake to body.
6. Remove nut side strake to wheel arch.
7. Remove side strake.
Installation
1. Install side strake, nut and screw.
2. Position mesh to side strake and install nuts (x3).
3. Install mesh - LH side strake (see Workshop Manual procedure 01.08.CF Mesh - Side Strake - LH - Renew).
4. Lower vehicle on ramp.
Channel Assembly Divider Bar - Renew
Removal
1. Remove window regulator (see Workshop Manual procedure 01.11.DA Regulator - Door Glass - RH -
Renew). 2. Remove fixed glass (see Workshop Manual procedure
01.11.BG Glass - Front Door - Fixed RH - Renew).
3. Remove seal.
4. Remove screw, divider bar to mirror (see Figure 1).
5. Remove nut (hold stud with Allen key) divider bar to door and remove (see Figure 2).
Installation
1. Install bar and nut (hold stud with Allen key).
2. Install screw, divider bar to mirror (Do not tighten at this point).
3. Install seal.
4. Adjust bar. Rotate Allen stud in centre in/out until desired alignment of bar is achieved, then torque fixings.
5. Install fixed glass (see Workshop Manual procedure 01.11.BG Glass - Front Door - Fixed RH - Renew).
6. Install window regulator (see Workshop Manual procedure 01.11.DA Regulator - Door Glass - RH -
Renew).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Figure 1
Figure 2
A0108170
A0108171

Mirrors (01.09)
Body System (01.00)1-6-2 Workshop Manual May 2007
2. Lift rear of fixed window, remove rubber surround at
top and pull out window (see Fig 1).
3. Remove the door mirror rubber cheater panel (see Fig 2).
4. Disconnect multiplug and release harness from fir tree clips (x2) and self adhesive clip (see Fig 3). 5. Remove Torx bolts (x3) and screw from glass channel,
remove mirror assembly (see Fig 4).
Installation
1. Position mirror, install and to rque tighten Torx bolts (x3)
and screw (glass channel).
2. Connect multiplug and secure harness fir tree clips (x2) and self adhesive clip.
3. Install rubber mirror cheater panel and insert rubber guttering.
4. Refit fixed window, ensure rubber surround is correctly installed.
5. Install door trimboard (see Workshop Manual procedure 01.05.CB Trimboard Assembly - Door - Remove for
Access and Refit).
Figure 1
Figure 2
Figure 3
A0108145
A0108144
A0108143
Figure 4
A0108143

Glass, Frame and Mechanism (01.11)
Body System (01.00)
May 2007 Workshop Manual 1-8-1
Body System (01.00)
Glass, Frame and Mechanism (01.11)
Description
Power to the door window regulator motor is available when
the ignition switch is at position ‘0’ and is supplied, through
a thermal cut-out, to the left and right window switches. The
switches are double pole earth so that the current through a
window regulator motor may be switched in either direction
to raise or lower the glass.
Frameless doors
To avoid damaging the body seals during door opening, the
door glass must be lowered before the door can be opened.
This function is controlled by the door modules.
The door module senses the rotation of the latch claw as the
door opens, the door module then drives the door window
regulator motor briefly to lower the door glass until it clears
the glass seals. After closing a door, the window regulator
motor operates to raise the door glass to seat against the
body seals.
Specifications
Maintenance
Glass Regulator - Renew
Removal
1. Remove door trimboard assembly (see Workshop Manual procedure 01.05.CB Trimboard Assembly -
Door - Remove for Access and Refit).
2. Remove screws (x4) securi ng switchpack to trimboard
assembly, remove switchpack.
3. Connect switchpack to door cable harness multiplug (x1).
4. With power on raise/lower gl ass to access glass clamping
bolts (x2).
5. Battery isolation switch ‘OFF’. 6. Mark the glass around the rear clamp.
7. Remove clamping bolts (x2)
and lift glass out of door
(see Figure 1).
8. Remove nuts (x4) securing door glass regulator mechanism (see Figure 2).
9. Disconnect multiplug from regulator motor.
WAR NI N G
PUT ON PROTECTIVE GLOVES AND EYE
PROTECTION WHEN YOU HOLD THE GLASS
COMPONENTS.
THE GLASS CAN BREAK EASILY AND CAUSE INJURY.
Torque Figures
DescriptionNm
Regulator mountings 9.0 (M6)
10-15 (M10)
Glass grip screws 5.0 - 6.0
Repair Operation Time (ROT)
WA R N I N G
PUT ON PROTECTIVE GLOVES AND EYE
PROTECTION WHEN YO U HOLD THE GLASS
COMPONENTS.
THE GLASS CAN BREAK EASILY AND CAUSE INJURY.
Figure 1
Figure 2







Glass, Frame and Mechanism (01.11)
Body System (01.00)1-8-6 Workshop Manual May 2007
Quarter Window Glass - Renew
Removal
1. Partially remove door aperture seal.
2. Protect external body work and internal trim adjacent to glass.
3. Remove the lower finisher around the fixed quarter
glass. Pull items 1, 2 and 3 and slide item 4 (see Fig 2).
4. Place suitable covers over trim and bodywork. 5. Make hole in sealer and assemble cutting knife.
6. Cut out glass and remove (see Figure 3).
7. Remove sealer from aperture.
Installation
1. Clean and polish glass.
2. Apply etch primer around aperture.
3. Assemble applicator.
4. Apply sealer to glass.
5. Position glass in aperture and lightly press glass to sealer.
6. Remove all protective covers and tape.
7. Install the lower finisher around the fixed quarter glass.
8. Install door aperture seal.
9. Check for leaks.
Passenger Window Lift Switch - Renew
Removal
1. Remove door trim board (see Workshop Manual
procedure 01.05.CB Trimboard Assembly - Door -
Remove for Access and Refit).
Repair Operation Time (ROT)










WAR NI NG
PUT ON PROTECTIVE GLOVES AND EYE
PROTECTION WHEN YOU HOLD THE GLASS COMPONENTS.
THE GLASS CAN BREAK EASILY AND CAUSE INJURY.
Figure 3
WAR NI NG
PUT ON PROTECTIVE GLOVES AND EYE
PROTECTION WHEN YOU HOLD THE GLASS COMPONENTS.
THE GLASS CAN BREAK EASILY AND CAUSE INJURY.
Repair Operation Time
ItemCode
Passenger Window Lift-Renew 01.11.FA




Glass, Frame and Mechanism (01.11)
Body System (01.00)
May 2007 Workshop Manual 1-8-7
2. Remove screws (x4) window lift switch to door trim
board and remove switch (see Figure 1).
Installation
1. Install window lift switch to door trim board.
2. Install door trim board (see Workshop Manual procedure 01.05.CB Trimboard Assembly - Door -
Remove for Access and Refit).
Driver Window Lift Switch - Renew
Removal
1. Remove door trim board (see Workshop Manual procedure 01.05.CB Trimboard Assembly - Door -
Remove for Access and Refit).
2. Remove screws (x4) window lift switch to door trim
board and remove switch (see Figure 1).
Installation
1. Install window lift swit ch to door trim board.
2. Install door trim board (see Workshop Manual procedure 01.05.CB Trimbo ard Assembly - Door -
Remove for Access and Refit).
Figure 1
Repair Operation Time
ItemCode
Driver Window Lift-Renew 01.11.FB
Figure 1







Fuel Tank and Lines (10.01)
Fuel (10.00)10-1-8 Workshop Manual May 2007
Maintenance
Fuel System
The fuel system must only be serviced by staff trained in fuel
handling.
Fuel Filter Assembly-Renew
Removal
1. Depressurise the fuel system (see Workshop Manual procedure 10.01.EK Fuel System - Depressurise).
2. Disconnect battery earth lead.
3. Release and remove luggage compartment rear floor carpet.
4. Remove luggage compartment front floor carpet retainers (x6).
5. Remove luggage compartment front floor carpet.
6. Remove fuel tank cover, clean off the sealant around the aperture.
7. Remove nuts (x7) and rele ase fuel tank service cover
and clamp. 8. Install the fuel tank drainage adaptor (see Fig. 1).
9. Connect the external pipe to a fuel recovery unit.
Recover the fuel in accordance with the recovery unit
instructions.
10. Release the fuel filter hoses (x2) quick release unions (see Fig. 2).
Repair Operation Time (ROT)
Warning
Read and follow all fuel handling instructions (at the beginning of the Fuel Syst em section) and the fuel
bowser manufacturers fuel handling documentation
before commencing work on the fuel system. Clean up
spillages immediately and disp ose of fuel contaminated
materials safely.
Warning
Ensure there is adequate ve ntilation inside the vehicle
(i.e. place the vehicle in a we ll ventilated area, with the
windows open).
Warning
Disconnect the battery earth lead before commencing work on the fuel system.
Caution
The following procedure is completed inside the vehicle
cabin area. Extra care must be taken to ensure no fuel or
fuel vapours come into contac t with the vehicle interior.
Fig. 1
Warning
Several litres of fuel remain in the fuel tank sump after
draining.
Fig. 2
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