brake fluid ASTON MARTIN V8 VANTAGE 2010 Owner's Manual

Brake Actuation System (06.06)
Brake System (06.00)
6-6-8 Workshop Manual May 2007
Rear Wheel Brake Front to Rear Tube
Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove RH/LH front an d rear road wheel(s).
3. Remove RH/LH front wheel arch liner (see Workshop
Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - LH - Renew).
4. Remove bleed nipple dust caps.
5. Position bleed container, connect bleed hose to RHR/ LHR Caliper, open bleed nipples (x1).
6. Position bleed container, connect bleed hose to RHF/ LHR Caliper, open bleed nipples (x1).
7. Depress brake pedal >60 mm and secure with support.
8. Tighten RHR/LHR bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
9. Tighten RHF/LHF bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
10. Remove screws (x5) securi ng RH/LH rear wheel arch
liner to body.
11. Ease wheel arch liner downwards to access brake tube rear in line connection. 12. Loosen and disconnect RH/LH rear brake tube union
from front line connection (see Fig. 1).
13. Loosen and disconnect RH /LH brake tube union from
rear in line connection (see Fig. 2).
14. Release brake tube from clips (x6), remove brake tube.
Installation
1. Install brake tube, connect unions, secure brake tube in clips (x6), torque tighten unions.
2. Position LH/RH rear wheel arch liner, install and tighten screws (x5).
3. Install RH/LH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - LH/RH - Renew).
4. Remove pedal support.
5. Top-up brake fluid.
6. Bleed brake Caliper with assistance.
7. Remove bleed bottle.
8. Install bleed nipple dust caps.
9. Clean off excess fluid.
10. Top-up brake fluid.
11. Install road wheel(s)).
Repair Operation Time (ROT)
Fig. 1
Fig. 2
A0606128
A0606135

Brake Actuation System (06.06)
Brake System (06.00)
6-6-10 Workshop Manual May 2007
10. Release brake tube from clips (x4), remove brake tube (see Fig. 3).
Installation
1. Install brake tube, connect unions, secure brake tube in clips (x4), torque tighten unions.
2. Remove pedal support.
3. Top-up brake fluid.
4. Bleed brake Caliper with assistance.
5. Remove bleed bottle.
6. Install bleed nipple dust caps.
7. Clean off excess fluid.
8. Top-up brake fluid.
9. Install Bulkhead heatsheild (see Workshop Manual procedure 02.06.BC Heatshield - Bulkhead - Renew).
Rear Wheel Brake Tube Assembly-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove LH/RH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - LH/RH - Renew).
4. Remove bleed nipple dust caps.
5. Position bleed container, connect bleed hose to RHR/ LHR Caliper, open bleed nipples (x1).
6. Position bleed container, connect bleed hose to RHF/ LHF Caliper, open bleed nipples (x1).
7. Depress brake pedal >60 mm and secure with support.
8. Tighten RHR/LHR bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
9. Tighten RHF/LHF bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
10. Loosen and disconnect RH/LH rear brake tube union from modulator (see Fig. 1).
Fig. 3
Repair Operation Time (ROT)
A0606134
WAR NI NG
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN
MEDICAL ATTENTION. IF BR AKE FLUID IS INGESTED,
OBTAIN IMMEDIATE MEDICAL ATTENTION.
WAR NI NG
BRAKE FLUID IS HYGROSCOPIC. IF KEPT IN OPENED CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINERS WHEN TOPPING-UP THE BRAKE FLUID RESERVOIR.
Caution
Brake fluid must not be allowed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Fig. 1
A0606127

Brake Actuation System (06.06)
Brake System (06.00)
May 2007 Workshop Manual 6-6-11
11. Loosen and disconnect RH/LH brake tube union from in line connection (see Fig. 2).
12. Release brake tube from clips (x2), remove brake tube.
Installation
1. Install brake tube, connect unions, secure brake tube in clips (x2), torque tighten unions.
2. Install LH/RH front wheel arch liner (see Workshop Manual procedure 01.02.FB/01.02.GB Wheel Arch
Liner - Front - LH - Renew
3. Remove pedal support.
4. Top-up brake fluid.
5. Bleed brake Caliper with assistance.
6. Remove bleed bottle.
7. Install bleed nipple dust caps.
8. Clean off excess fluid.
9. Top-up brake fluid.
10. Install road wheel(s)).
11. Lower vehicle on ramp.
Dynamic Stability Control Module-
Renew
Removal
1. Raise vehicle on ramp.
2. Disconnect vehicle battery.
3. Remove road wheel(s).
4. Remove bleed nipple dust caps.
5. Position bleed container, connect bleed hose to LHR Caliper, open bleed nipples (x1).
6. Position bleed container, connect bleed hose to LHF Caliper, open bleed nipples (x1).
7. Depress brake pedal >60 mm and secure with support.
8. Tighten LHR bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
9. Tighten LHF bleed nipple, disconnect bleed hose, remove bleed container and fit dust cap.
10. Remove LH front wheel arch liner (see Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
11. Disconnect modulator multiplug.
12. Mark brake pipe unions fo r assembly purposes. Loosen
and disconnect brake pipe un ions (x6) from modulator.
Plug modulator and pipe connections.
13. Remove Torx bolts (x3) securing modulator mounting bracket to body. Remove modulator.
14. Remove Torx bolts (x3) securing modulator to mounting bracket. Collect mounting bracket from modulator.
Installation
1. Install modulator to mounting bracket, install and torque tighten Torx bolts (x3).
2. Install modulator to body, install and torque tighten Torx bolts (x3).
3. Remove plugs. Install and torque tighten brake unions (x6) to modulator.
4. Connect modulator multiplug.
Fig. 2
Repair Operation Time (ROT)
A0606128
WA R N I N G
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN
MEDICAL ATTENTION. IF BRAKE FLUID IS INGESTED, OBTAIN IMMEDIATE MEDICAL ATTENTION.
WA R N I N G
BRAKE FLUID IS HYGROSCOPI C. IF KEPT IN OPENED
CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINERS WHEN TOPPING-UP THE BRAKE FLUID RESERVOIR.
Caution
Brake fluid must not be allo wed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Caution
Always plug pipe ends to prevent ingress of dirt or moisture into the system.

Power Brake System (06.07)
Brake System (06.00)6-7-2 Workshop Manual May 2007
Specifications
Maintenance
Brake Booster-RHD-Renew
Removal
1. Remove brake master cylind er (see Workshop Manual
procedure 06.06.EB Brake Master Cylinder Assembly
Renew).
2. Remove oil dipstick.
3. Remove vacuum hose.
4. Disconnect multiplugs (x2).
5. Remove pedal cover.
6. Remove clevis pin and clip.
7. Remove servo securing nuts (x4).
8. Remove servo assembly.
9. Remove brake light switch.
Installation
1. Install brake light switch.
2. Install servo assembly.
3. Install servo retaining nuts (x4) (torque).
4. Install clevis pin and clip.
5. Install pedal cover.
6. Connect multiplugs (x2).
7. Install vacuum hose.
8. Install dipstick. 9. Install brake master cylinder (see Workshop Manual
procedure 06.06.EB Brake Master Cylinder Assembly
Renew).
Brake Booster-LHD-Renew
Removal
1. Move drivers seat fully rearward.
2. Remove clevis pin and clip.
3. Remove booster securing nuts (x4).
4. Remove corner cross brace.
5. Move expansion tank aside for access (bolt x1, nut x1,
hose clips x2, multiplug x1).
6. Remove vacuum hose move aside.
7. Remove bolts (x2) from clutch pipe bracket and move aside.
8. Disconnect clutch reservoir feed pipe.
9. Disconnect multiplugs (x4).
10. Disconnect brake pipes from master cylinder (move aside).
11. Remove booster assembly.
12. Split components.
13. Remove reservoir securing screw (for access to securing nut).
14. Remove master cylinder from booster (nuts x2).
15. Re-fit components.
16. Install master cylinder to booster (nuts x2).
17. Install reservoir securing screw.
Torque Figures
DescriptionNm.lb. / ft.
Brake Booster Mount 21-24 15.5-18
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Brake Booster-Renew 06.07.AC
WAR NI NG
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN MEDICAL ATTENTION. IF BR AKE FLUID IS INGESTED,
OBTAIN IMMEDIATE MEDICAL ATTENTION.
WAR NI NG
BRAKE FLUID IS HYGROSCOPIC. IF KEPT IN OPENED CONTAINERS IT WILL ABSORB WATER VAPOUR. USE
ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINERS WHEN TOPPING-UP THE BRAKE FLUID RESERVOIR.
Caution
Brake fluid must not be allowed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.

Power Brake System (06.07)
Brake System (06.00)
May 2007 Workshop Manual 6-7-3
Installation
1. Install booster assembly.
2. Connect brake pipes to master cylinder.
3. Install bolts (x2) clutch pipe bracket.
4. Connect clutch reservoir feed pipe.
5. Connect multiplugs (x4).
6. Install vacuum hose.
7. Install expansion tank asid e (bolt x1, nut x1, hose clips
x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Install servo retaining nuts (x4) (torque).
10. Install clevis pin and clip.
11. Bleed Brakes (see Workshop Manual procedure 06.06.AD Pad Kit - Manual Brake and Clutch Pedal -
Renew).
12. Top-up coolant.
Brake Fluid Reservoir-Renew
Removal
1. Remove corner cross brace.
2. Move expansion tank aside for access (bolt x1, nut x1, hose clips x2, multiplug x1).
3. Disconnect clutch reservoir feed pipe.
4. Disconnect multiplugs (x2). 5. Disconnect brake pipes from master cylinder (move
aside).
6. Remove reservoir holding screw for access to master cylinder retaining nut.
7. Remove master cylinder from booster (nuts x2).
8. Remove reservoir from master cylinder.
Installation
1. Fit new seals and install reservoir to master cylinder.
2. Install master cylinder to booster (nuts x2).
3. Install reservoir holding screw for access to master cylinder retaining nut
4. Connect brake pipes to master cylinder.
5. Connect clutch reservoir feed pipe.
6. Connect multiplugs (x2).
7. Install expansion tank aside (bolt x1, nut x1, hose clips x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten
when vehicle on level floor).
9. Bleed Brakes (see Workshop Manual procedure 06.07.DD Brake Hydraulic System - Flush/Refill/Bleed).
10. Top-up coolant.
Brake Bleeding - AMDS
Use the AMDS to bleed the brakes if you are bleeding the
brake system after you replaced a major component, for
example: a modulator or a mast er cylinder or when filling
from empty.
If you are bleeding a caliper, you can use a manual brake-
bleed procedure.
1. Connect the AMDS.
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Power Brake System (06.07)
Brake System (06.00)6-7-4 Workshop Manual May 2007
2. Clean each caliper around the bleed screws. Remove the dust caps.
3. Prepare a bleed tube and a bottle that contains a small quantity of clean brake fluid.
4. If necessary, top up the brake fluid reservoir with brake fluid from a new container.
5. Switch on the AMDS and load the ‘Anti-lock braking diagnostics’ software.
6. Select ‘Brake Bleed’ and follow the AMDS instructions.
Brake Master Cylinder and Vacuum
Booster-Renew
Removal
1. Move drivers seat fully rearward.
2. Remove clevis pin and clip.
3. Remove booster securing nuts (x4).
4. Remove corner cross brace.
5. Move expansion tank aside for access (bolt x1, nut x1,
hose clips x2, multiplug x1).
6. Remove vacuum hose move aside.
7. Remove bolts (x2) from clutch pipe bracket and move aside.
8. Disconnect clutch reservoir feed pipe.
9. Disconnect multiplugs (x4).
10. Disconnect brake pipes from master cylinder (move aside).
11. Remove booster assembly.
Installation
1. Install booster assembly.
2. Connect brake pipes to master cylinder.
3. Install bolts (x2) clutch pipe bracket.
4. Connect clutch reservoir feed pipe.
5. Connect multiplugs (x4).
6. Install vacuum hose.
7. Install expansion tank aside (bolt x1, nut x1, hose clips x2, multiplug x1).
8. Install corner cross brace (torque) (only fully tighten when vehicle on level floor).
9. Install servo retaining nuts (x4) (torque).
10. Install clevis pin and clip.
11. Bleed Brakes (see Workshop Manual procedure 06.07.DD Brake Hydraulic System - Flush/Refill/Bleed).
WA R N I N G
BRAKE FLUID THAT CONTAINS WATER CAN AFFECT THE PERFORMANCE OF THE BRAKES AND CAUSE CORROSION IN THE BRAKE SYSTEM.
IF YOU KEEP BRAKE FLUID IN OPEN CONTAINERS, IT WILL ABSORB WATER VAPOUR.
USE ONLY BRAKE FLUID FROM NEW CONTAINERS
WHEN YOU TOP-UP THE BRAKE FLUID RESERVOIR..
When you bleed a brake caliper, always bleed the inner bleed screw first, followed by the outer bleed screw, then bleed the inne r bleed screw again.
Repair Operation Time (ROT)
WAR NI NG
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN
MEDICAL ATTENTION. IF BR AKE FLUID IS INGESTED,
OBTAIN IMMEDIATE MEDICAL ATTENTION.
WAR NI NG
BRAKE FLUID IS HYGROSCOPIC. IF KEPT IN OPENED CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINERS WHEN TOPPING-UP THE BRAKE FLUID RESERVOIR.
Caution
Brake fluid must not be allowed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.

Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
Issue 4, November 2008 Workshop Manual 6-9-3
Engine Intervention
In the event of wheel-slip the ABS / DSC module calculates
the torque, which should be applied by the engine to reduce
the wheel-slip (this torque does not exceed driver demand).
Engine torque reduction is then requested from the PCM via
the CAN bus. The PCM, in response to these signals, reduces
engine torque by controlling the ignition and fuelling. A
traction control gearshift pattern is automatically selected
within the automatic transmission software whenever
traction control is active.
Brake Intervention
This function operates by increasing the pressure in the
brake caliper of the slipping wheel, by closing the separation
valve and the inlet valve of the non-slipping wheel and
running the modulator pump. This takes fluid from the fluid
reservoir via the non-actuated master cylinder and
pressurizes the brake caliper. The pressure is modulated at
the caliper via the inlet and outlet valves to achieve the
desired wheel-slip target to maximize traction.
ABS / DSC Circuit
Specifications
SR,05UR,05YR,0.5NR,0.5
WR,05NR,05
YG,05WG,05
YU,05WU,05
W,05N,05
W,0.5U,0.5R,0.5
P,0.5Y,0.5
B,0.5WG,0.5GB,0.5
B,0.5BG,0.5
GW,0.5
P,0.5
U,0.5
U,3.0
BK,1.0BK,1.0
P,0.35P,0.35P,0.35 U,3.0
WG,05YG,05
WU,05
SR,05UR,05YR,0.5NR,0.5
WG,05YG,05
WU,05
WG,05YG,05
WU,05YU,05YU,05YU,05Module-ABS
OBD2-Body (B)
Earth-Module ABSEarth-Module ABS
C1184-18C2410-6
Sensor-Brake Pressure
Sensor-Brake Pedal Travel
Sensor-Rear ABS-LH
C0746-7C0746-6
C0746-5
Switch-Brake Boost
Sensor-Yawrate / Acceleration
C2411-6C2411-5C2411-4
C2411-3
C0144-7C0144-3
C0144-2
Sensor-Front ABS-LH
Sensor-Front ABS-RH
C2410-10C2410-9
C2410-8
Sensor-Rear ABS-RH
C0746-4C0144-1C2410-7
C0877-7
K-LINESPL50-KL/FA
C0362-1C0434-1
C2444-2
SIGC2444-1
GND
C2444-3
SENSP
C2446-2
GNDC2446-1
SENSPT
C2446-3
SIG
C0501-47
GNDC0501-16
GND
C0501-2K-LINE
C0501-24
GND
C0501-31
PWM
C0501-30
NC
C0501-25
CAN HS-
C0501-28
SIGC0501-27
NO
C0501-29
CAN HS+C0501-6
CLUST_SP
C0501-17
PWR
C0501-5
GND
C0501-32BATT FEED
C0501-7
SENSPT
C0501-3 SIG
C0501-20 SIGC0501-19
GND
C0501-18 SENSP
C0501-4IGN FEED
C0501-46
F/L/GNDC0501-45
F/L/SIG
C0501-42
R/R/GNDC0501-43
R/R/SIG
C0501-36
R/L/SIG
C0501-34
F/R/SIGC0501-33
F/R/GND
C0501-1
BATT FEEDC0501-37
R/L/GND
C2448-5
C2448-3
C2448-2C2448-1
C2448-4
C1656-3 CLUS_SPC1656-2
CAN HS+C1656-1 CAN HS-
C1656-5
GND
C0516-2-C0516-1+
C0517-2
-C0517-1+
C0502-1
+
C0503-2 -C0503-1+
C0502-2 -
Sensor
Steering Angle
Sheet 61
F4
30.0 AmpsRelay 1
Underbonnet Fusebox
DIODE 1
F28
10.0 Amps
F20
30.0 Amps
F19
30.0 Amps
Earth
Steering Angle
Sensor
C0576-1
C0577-4C2608-1 VBATT
C0573-2
C0571-3
C0573-3
C0578-8SPL5-VIGN/FOR
C1672-5
VPWRC1672-8
GND
011-6-003
Oils/Greases
Brake FluidCastrol Response Super Dot 4
Torque Figures
DescriptionNm.lb. / ft.
Modulator to Bracket 5 4
Modulator / Bracket to body 9 7
Brake hose unions 17 1413
10.5
17 Nm. 17 Nm.
17 Nm.
14 Nm.
14 Nm. 14 Nm.

Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
6-9-4 Workshop ManualIssue 4, November 2008
Maintenance
ABS Modulator - Remove and Install
Remove
1. Disconnect the vehicle battery.
2. Raise the vehicle and make it safe.
3. Remove the four road wheels.
4. Remove the dust caps from the four brake caliper bleed
nipples .
5. Put a container in position under the rear left-side caliper to collect brake fluid.
6. Connect a bleed hose to rear left-side caliper.
7. Open the bleed nipple.
8. Put a container in position under the front left-side caliper to collect brake fluid.
9. Connect a bleed hose to front left-side caliper
10. Open the bleed nipple.
11. Operate the brake pedal more than 60 mm and install a pedal clamp to hold it.
12. Tighten the two bleed nipples.
13. Disconnect the two bleed hoses.
14. Remove the two fluid containers.
15. Install the two dust caps.
16. Remove the five or six screws that attach the rear half of the front left wheelarch liner.
17. Remove the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
18. Move the wheel arch liner to get access. 19. Disconnect the electrical connector from the modulator.
20. Put a label on each brake pipe union for the assembly
procedure.
21. Loosen and disconnect the six brake pipe unions from
the modulator. Install plugs into the modulator and the
pipe connections.
22. Remove the three M8 Torx-head screws (1) that attach the modulator mounting bracket to the body.
23. Remove the modulator.
24. Remove the three M6 Torx-head bolts that attach the modulator to the mounting bracket. Remove the
mounting bracket from the modulator.
Installation
1. Install the modulator onto the mounting bracket.
2. Install and torque the three M6 Torx-head bolts.
3. Install the modulator to the body.
4. Install and torque the three M8 Torx-head screws.
5. Remove the sealing plugs.
6. Install and torque the six brake unions to the modulator.
7. Connect the electrical connector to the modulator.
8. Put the wheel arch liner back in the correct position.
9. Install the self-tapping screw that attaches the rear of the wheelarch liner into the wheelarch.
10. Install the five or six scre ws to attach the wheel arch
liner.
11. Bleed the braking system (Refer to ’Brake Bleeding - AMDS

Clutch Assembly (08.01)
8-1-2 Workshop Manual May 2007
Clutch (08.00)
Clutch Assembly (08.01)
Description
The clutch assembly consists of a balanced flywheel, a clutch
driven plate and a clutch cover.
The clutch is a single plate, diaphragm spring type assembly.
A concentric clutch slave cylinder is mounted around the
first motion shaft in the torque tube bell housing.
The clutch master cylinder is mounted on the engine
bulkhead and is operated directly by the clutch pedal.
A hydraulic connection from the master cylinder feeds
pressurised fluid to the slave cylinder. The slave cylinder has
an extension tube and bleed nipple extending from the left
side of the bell housing for bleeding the system after any
major work.
Specifications
Maintenance
Clutch and Flywheel Assembly-Renew
08.00.AA
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove torque tube assembly (see Workshop Manual procedure 05.01.CA Torque Tube Remove for Access
and Refit).
4. Remove bolts (x2) from inspection cover to lower crankcase and remove cover. 5. Install special tool SKAM14546 OT to restrain flywheel
and install and tighten bolts (x2) (see Fig. 1).
6. Remove bolts (x6) from clutch cover to flywheel (see Fig.
2).
7. Release clutch cover from dowels, remove cover and collect drive plate.
Clutch Fluid
Castrol/Girling Universal Brake and Clutch fluid.
Clutch Assembly
Clutch and flywheel are separately balanced.
Clutch Plate
Single 267mm driven plate.
Torque Figures
DescriptionNmlb/ft
Flywheel Bolts
Tighten the bolts in sequence. Loosen
the bolts and then torque, in even
stages, in the same sequence. 100 -
120
74-
88.5
Clutch Bolts
Tighten x6 equally-spaced bolts, in-
turn, to pull-down the clutch evenly.
Then torque all bolts in sequence. 65-75 48-55
Starter Motor Bolts 42.5-
57.531.5-
42.5
Repair Operation Time (ROT)
Fig. 1
Fig. 2
Warning
The clutch assembly is heavy. Ensure the clutch
assembly is supported befo re removing final bolts.



Clutch Assembly (08.01)
May 2007 Workshop Manual 8-1-5
13. Remove Diagnostic tool.
14. Lower vehicle on ramp.
Clutch Hydraulic System-Bleed
08.00.AF
1. Raise vehicle on ramp.
2. Remove fluid reservoir cap and ensure fluid level is correct.
3. Clean area around clutch bleed nipple.
4. Remove cap from bleed nipple.
5. Position bleed container cont aining clean hydraulic fluid
and connect hose to bleed nipple.
6. Depress clutch pedal to floor 3 times and hold pedal down on third application.
7. Loosen bleed nipple allowing any air/fluid to escape.
8. Tighten bleed nipple.
9. Repeat procedure until air-free fluid emerges.
10. Disconnect bleed hose, remove container and install dust cap to bleed nipple.
11. Top-up fluid reservoir.
12. Lower vehicle on ramp.
Master Cylinder to Slave Cylinder Tube
Assembly-Renew
08.00.AJ
-Sportshift Only
Removal
1. Disconnect vehicle battery. 2. Raise vehicle on ramp.
3. Remove torque tube (see Workshop Manual procedure
05.01.CA Torque Tube - Remo ve for Access & Refit).
4. Remove grommet sealing clutch pipe to torque tube.
5. Remove clip, disconnect clutch pipe from slave cylinder adaptor.
6. Release clip securing transmi ssion harness to clutch pipe
mounting bracket.
7. Release clips (x4) securing clutch pipe to transmission harness.
8 . R e m o v e c l u t c h p i p e f r o m t o r q u e t u b e .
Installation
1. Install clutch pipe to torque tube.
2. Secure clutch pipe to tran smission harness using clips.
3. Secure transmission harne ss to clutch pipe mounting
bracket using clip.
4. Install clip and refit clutch pipe to slave cylinder adaptor.
5. Install grommet sealing clutch pipe to torque tube.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube - Remo ve for Access & Refit).
7. Bleed clutch hydraulics (see Workshop Manual procedure 08.00.AE Clut ch Hydraulic System -
Sportshift - Bleed).
8. Lower vehicle on ramp.
9. Connect vehicle battery.
Repair Operation Time (ROT)
Warning
Avoid skin / eye contact or in gestion of clutch fluid. If
skin or eyes are sp lashed with clutch fluid, rinse the
affected area immediately with plenty of water and
obtain medical attention. If clutch fluid is ingested, obtain immediate medical attention.
Caution
Clutch fluid must not be allowed to contact vehicle paint work. Remove spilt clutch fl uid from the paint work by
rinsing away with running water.
Warning
Brake / Clutch fluid is hygroscopic. If kept in opened
containers it will absorb water vapour. Use only brake
fluid from freshly opened co ntainers when topping-up
the brake fluid reservoir.
Before proceeding to the next step, position cloth around
fluid reservoir to collect any spillage.
Repair Operation Time (ROT)
Warning
Always disconnect the battery earth (- ve) terminal first.
Warning
When raising the vehicle on a ‘two post’ ramp, ensure
that the rear end of the vehicle is securely strapped to
the ramp. Failure to strap the rear of the vehicle down may lead to the vehicl e falling off the ramp.
Warning
Observe all oil/fluid manufact urers safety instructions
when handling components that have been in contact with transaxle oil.
Warning
Always connect the battery ea rth (+ve) terminal first.