wheel torque ASTON MARTIN V8 VANTAGE 2010 Repair Manual

Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
6-9-2 Workshop Manual Issue 4, November 2008
difference between the ideal and actual response within a
tolerance band. This directly influences the forces on the
tires to generate a corrective yaw moment to reduce the side
forces of the tires where appropriate
System Overview
The DSC system embraces capabilities far beyond that of
ABS, or ABS and traction control combined, while relying on
the components of these systems. It also incorporates these
additional sensors for measur ing the vehicle’s motion and
brake system pressure:
Ya w r a t e s e n s o r - located centrally on the transmission
tunnel.
Lateral acceleration sensor - integrated with the yaw rate
sensor.
Steering angle sensor - located on the upper steering
column.
Pressure transducer - located on master cylinder.
The ABS / DSC module supports data exchange with other
vehicle electronic systems via the CAN network; the module
also enables diagnostic interrogation using WDS.
The following components register driver demand and the
ABS / DSC module processes their signals as a basis for
defining an ideal response:
PCM - position of accelerator pedal.
Brake master cylinder pressure transducer - driver’s
braking effort.
Steering angle sensor - position of steering wheel.
There are many supplementary parameters also included in
the processing calculations these include the coefficient of
friction and vehicle speed. The ABS / DSC module monitors
these factors based on signals transmitted by the sensors for:
• Wheel speed
• Lateral acceleration
• Brake pressure
• Yaw rate
Using these parameters, the function of the ABS / DSC
module is to determine the current vehicle status based on
the yaw-rate signal and the slip as estimated by the ABS /
DSC module. It then maintains the vehicle response within
a tolerance of the ‘normal’ behaviour, which is easily
controlled by the driver.
In order to generate the desired yaw behaviour the ABS /
DSC module controls the selected wheels using the ABS
hydraulic system and engine control system. In the event of
engine intervention, the ABS / DSC module calculates the
torque which should be supplied by the engine to the
wheels, and relays this request signal to the PCM which
implements the torque request.
The PCM receives signals from the DSC system via the CAN
bus and reduces engine torque as follows:
• The throttle is positioned to provide the requested engine target torque. • During the transient phase of torque reduction caused by
mechanical and combustion delays, other alternative
torque reduction methods are used to provide a quicker
response.
• The ignition is retarded and / or the fuel is cut-off at the injectors at selected cylinders.
• Ignition and fuelling are reinstated when the engine torque reaches the requested value
Operation Summary
• DSC is switched ‘ON’ when the engine is started
• When the system is operating , the DSC light in the instrument cluster will flash, at the rate of twice a second
• DSC can be switched ‘OFF / ON’ by pressing the DSC switch
• The DSC light in the instru ment cluster will illuminate
continuously when the system is switched ‘Off’.
• ‘DSC OFF’ will be displayed in the message centre right to indicate the system has been switched ‘OFF’
• A malfunction in the traction control system will be indicated to the driver by the following:
• The DSC light in the instru ment cluster will illuminate
continuously
• The message ‘DSC NOT AVAILABLE’ will be displayed in the message centre right
• If vehicle speed control is engaged it will automatically disengage when traction control is operating .
Traction Control
Traction control is a function of DSC, and is operated in
association with DSC. Traction control prevents excessive
wheel-spin at standing starts, or during acceleration. Wheel-
spin is usually caused by ex cessive use of the accelerator
pedal, or slippery, loose or bumpy road surfaces. To prevent
excessive wheel-spin and mainta in vehicle stability such
situations are overcome by the intervention of the traction
control system by:
• Braking the driven-wheel when it starts to slip
• And / or adapting the engine torque to a level corresponding to the traction available on the road
surface.
Functional Description
Traction control uses the ABS electronic and mechanical /
hydraulic hardware with additional valves to control the
braking pressure at the calipe rs. An engine interface also
enables the engine to respond to torque reduction requests
from the traction control. As with ABS, the signals from the
wheel-speed sensors are supplied to the ABS module, where
they are used to calculate the wheel-slip of the individual
wheels. Traction control intervention is initiated if the slip at
one of the wheels is excessive.

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

Manual Transmission (07.03)
Transmission (07.00)7-3-8 Workshop Manual Issue 5, January 2010
32. Install the exhaust front mount.
33. Clean the component mating faces.
34. Apply an applicable sealant to the component mating faces.
35. Install the exhaust centre pipe.
36. Install and tighten the four bolts that attach the exhaust centre pipe to the exhaust front mount.
37. Put the clamps into position on the exhaust pipes.
38. Loosely install the four bolts that attach the exhaust centre pipe to the rear silencer.
39. Align the exhaust assembly.
40. Tighten the two clamps that attach the exhaust centre pipe to the catalytic converters.
41. Install the cross brace.
Figure 24
42. Install and torque the four bolts that attach the cross brace to the rear subframe.
Figure 25
43. Remove the strap that attaches the vehicle to the lift.
44. Lower the vehicle until the wheels are 10 mm above the ground. 45. Connect the battery ground cable.
46. Start the engine.
47. Select first gear and let the wheels to turn for 10
seconds.
48. Stop the engine.
49. Lift the vehicle.
50. Remove the fill plug for the transaxle oil.
51. Make sure that the transaxle oil is level with the opening for the transaxle oil. Add more oil if necessary.
52. Install and tighten the fill plug for the transaxle oil.
53. Install the rear undertray (refer to Workshop Manual
procedure 01.02.PB - Rear Undertray).
Complete Sportshift Hydraulic Kit-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp and secure with straps.
3. Remove road wheel(s).
4. Remove rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
5. Roadster Only - Remove centre undertray (see
Workshop Manual procedure 01.02.MB Undertray -
Centre - Renew).
6. Remove bolts (x4), subframe cross brace.
7. Remove centre exhaust mounting bolts (x4).
8. Loosen clamp nuts (x2), release centre pipe from both catalysts.
9. Remove centre pipe and rear exhaust pipes as an
assembly.
WAR NI NG
THE EXHAUST CENTRE PIPE IS HEAVY. GET THE AID OF ONE MORE PERSON
TO DO THE STEP THAT FOLLOWS.
WAR NI NG
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YO U HANDLE COMPONENTS
THAT HAVE TOUCHED TRANSAXLE OIL.
Repair Operation Time (ROT)
ItemCode
Complete Sportshift Hydraulic Kit-
Renew 07.03.AB
WAR NI NG
ALWAYS DISCONNECT THE BATTERY EARTH (- VE)
TERMINAL FIRST.
WAR NI NG
WHEN YOU LIFT THE VEHICLE ON A 'TWO POST' LIFT MAKE SURE THAT YOU USE A STRAP TO HOLD THE REAR END OF THE VEHICLE TO THE RAMP. IF YOU
DO NOT, THE VEHICLE CAN FALL OFF THE RAMP AND CAUSE PERSONAL INJURY OR DEATH.
Caution
When using a ‘two post’ vehicle ramp, remove the
screws that secure the rear section of the wheel arch
liner to body. Hold back the rear section of the wheel
arch liner to correctly position the foot of the vehicle lift.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-11
36. Mark and disconnect valve-block connectors positions. Disconnect multiplugs (x5) (see Figure 10).
37. Remove bolt valve block to transaxle (see Figure 11).
38. Remove nuts (x3) securing valve block to transaxle and remove Sportshift hydrau lic kit (see Figure 12).
Install
1. Install Sportshift hydraulic ki t valve block to stud and fit
nuts.
2. Install bolt valve block to transaxle. 3. Connect multiplugs (x5) to valve block.
4. Connect dry break quick-fit connector to torque tube
pipe.
5. Install pump to transaxle.
6. Install ground eye to pump body.
7. Connect pump multiplug.
8. Clean mating faces and install new shifter unit gasket to dowels.
9. Ensure alignment of selector mechanism with shifter unit
and install shifter unit.
10. Install harness clip into shifter casing.
11. Secure hoses to support clip.
12. Connect gear position sensor to multiplug.
13. Install gear position sensor (screws x4).
14. Raise transaxle, install harness clip to subframe.
15. Connect transaxle breather pipe.
16. Raise transaxle to fitted position. Install transaxle mounting brackets and hydramounts, install and torque
tighten new bolts (x8).
17. Align hydramounts to subframe, lower lifter, install and torque nuts. Remove lifter.
18. Position reservoir to bracket and fit clamp (bolt x1).
19. Position reservoir hose and secure clips.
20. Remove plugs, connect and torque oil cooler unions.
21. Apply thread lock to new Allen bolts.
22. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
23. Position earth lead to transaxle, install and torque tighten bolt.
24. Install shear plate, install bolts (x8), tighten bolts to correct torque.
25. Install tunnel heatshield, install bolts/washers (x4),
tighten bolts to correct torque.
26. Install centre and rear exha ust pipe assembly, align to
both catalysts. tighten clamp nuts to correct torque.
27. Install bolts (x4) into centre mounting.
28. Install subframe cross brace, install bolts (x4) and torque.
29. Install rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Re move for Access & Refit).
30. Roadster Only - Install centre undertray (see Workshop
Manual procedure 01.02.MB Undertray - Centre -
Renew).
31. Install road wheel(s).
32. Lower vehicle on ramp, remove securing straps.
Figure 10
Figure 11
Figure 12
!
!
!
WA R N I N G
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS
SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
New Allen bolts should have a thread lock coating.

Manual Transmission (07.03)
Transmission (07.00)7-3-18 Workshop Manual Issue 5, January 2010
28. Remove and discard clips (x2) securing hoses into shifter assembly and disconnect hoses (see Figure 6).
29. Remove and discard clips (x3) securing hoses into valve block and disconnect hoses (see Figure 7).
30. Release hoses from support clips (x3) (see Figure 8).Install
1. Install hoses to support clips.
2. Install hoses into shifter unit and install clips.
3. Install hoses to valve block and install new clips.
4. Raise transaxle, install harness clip to subframe.
5. Connect transaxle breather pipe.
6. Raise transaxle to fitted position.
7. Install transaxle mounting brackets and hydramounts, install and torque tighten new bolts (x8).
8. Align hydramounts to subfra me, lower lifter, install and
torque nuts. Remove lifter.
9. Position reservoir to bracket and fit clamp (bolt x1).
10. Position reservoir hose and secure clips.
11. Remove plugs, connect and torque oil cooler unions.
12. Apply thread lock to new Allen bolts.
13. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
14. Position earth lead to transaxle, install and torque tighten bolt.
15. Install shear plate, install bolts (x8), tighten bolts to correct torque.
16. Install tunnel heatshield, install bolts/washers (x4), tighten bolts to correct torque.
17. Install centre and rear exhaust pipe assembly, align to both catalysts. tighten clamp nuts to correct torque.
18. Install bolts (x4) into centre mounting.
19. Install subframe cross brace, install bolts (x4) and torque.
20. Install rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
21. Install centre undertray (see Workshop Manual procedure 01.02.MB Undertray - Centre - Renew).
22. Install road wheel(s).
23. Lower vehicle on ramp, remove securing straps.
24. Connect vehicle battery.
25. Test drive vehicle.
26. Raise vehicle on ramp; check transaxle and Sportshift fluid.
27. Lower vehicle on ramp.
Figure 6
WAR NI NG
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YOU HANDLE COMPONENTS THAT HAVE TOUCHED TRANSAXLE OIL.
Figure 7
Figure 8
!
!
!
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE) TERMINAL FIRST.

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-21
14. Position earth lead to transaxle, install and torque tighten bolt.
15. Install shear plate, install bolts (x8), tighten bolts to correct torque.
16. Install tunnel heatshield, install bolts/washers (x4), tighten bolts to correct torque.
17. Install centre and rear exhaust pipe assembly, align to both catalysts. tighten clamp nuts to correct torque.
18. Install bolts (x4) into centre mounting.
19. Install subframe cross brace, install bolts (x4) and torque.
20. Install rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
21. Install centre undertra y (see Workshop Manual
procedure 01.02.MB Undertray - Centre - Renew).
22. Install road wheel(s).
23. Lower vehicle on ramp, remove securing straps.
24. Connect vehicle battery.
25. Bleed clutch system (see Workshop Manual procedure 08.00.AE Clutch Hydraulic System - Sportshift - Bleed).
26. Test drive vehicle.
Clutch Position Sensor-Renew-Roadster/
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 - Re move for Access & Refit).
4. Remove grommet sealing clutch position sensor harness to torque tube. 5. Disconnect multiplug between clutch position sensor
and transmission harness (see Figure 1).
6. Release clip securing clutch position sensor harness to top of torque tube.
7. Release clips (x2) securing clutch position sensor harness to side of torque tube (see Figure 2).
8. Remove bolts (x2) securing clutch position sensor to slave cylinder and remove sensor.
Install
1. Secure clutch position sensor to slave cylinder using bolts.
2. Install clutch position sensor harness to side of torque tube and secure with clips.
3. Secure clutch position sens or harness to top of torque
tube using clip.
4. Connect multiplug between clutch position sensor and transmission harness.
5. Install grommet sealing clutch position sensor harness to
torque tube.
6. Install torque tube (see Workshop Manual procedure 05.01.CA Torque Tube - Remo ve for Access & Refit).
7. Lower vehicle on ramp.
WA R N I N G
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
Repair Operation Time (ROT)
Figure 1
Figure 2
!
!

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-23
21. Remove nuts (x2), hydramounts to subframe mountings.
22. Position hydraulic lift er to support transaxle.
23. Remove and discard bolts (x8, 4 each side), mounting brackets to transaxle. Remove mounting brackets with
hydramounts.
24. Release drive shafts from transaxle and position aside.
25. Lower transaxle sufficien tly to access harness to
subframe clip, release harness to subframe clip (see
Figure 4).
26. Lower transaxle to approx. 420mm from fitted position and retain on hydraulic lifter (see Figure 5).
27. Remove gear position sensor (screws x4). 28. Disconnect gear position
sensor from multiplug (see
Figure 6).
Install
1. Connect gear position sensor to multiplug .
2. Install gear position sensor (screws x4).
3. Raise transaxle, install harness clip to subframe.
4. Connect transaxle breather pipe.
5. Raise transaxle to fitted position. Install transaxle mounting brackets and hydramounts, install and torque
tighten new bolts (x8).
6. Align hydramounts to subfra me, lower lifter, install and
torque nuts. Remove lifter.
7. Position reservoir to bracket and fit clamp (bolt x1).
8. Position reservoir hose and secure clips.
9. Remove plugs, connect and torque oil cooler unions.
10. Apply thread lock to new Allen bolts.
11. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
12. Position earth lead to transaxle, install and torque tighten bolt.
13. Install shear plate, install bolts (x8), tighten bolts to correct torque.
14. Install tunnel heatshield, install bolts/washers (x4),
tighten bolts to correct torque.
15. Install centre and rear exha ust pipe assembly, align to
both catalysts. tighten clamp nuts to correct torque.
16. Install bolts (x4) into centre mounting.
17. Install subframe cross brace, install bolts (x4) and torque.
18. Install rear exhaust silencer assembly (see Workshop Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Re move for Access & Refit).
19. Roadster Only - Install centre undertray (see Workshop
Manual procedure 01.02.MB Undertray - Centre -
Renew).
20. Install road wheel(s).
21. Lower vehicle on ramp, remove securing straps.
Figure 3
Figure 4
WA R N I N G
THE TRANSAXLE ASSEMBLY IS VERY HEAVY. GET THE AID OF ONE MORE PERSON WHEN YOU MOVE THE
TRANSAXLE. IF YOU DO NOT, PERSONAL INJURY CAN
OCCUR.
Figure 5
!
!
Figure 6
!

Manual Transmission (07.03)
Transmission (07.00)7-3-26 Workshop Manual Issue 5, January 2010
33. Remove bolt valve block to transaxle (see Figure 8).
34. Remove nuts (x3) securing valve block to transaxle and remove valve block from studs (see Figure 12).
Install
1. Install valve block to stud and fit nuts.
2. Install bolt valve block to transaxle.
3. Install hoses (x3) to valve block and install new clips.
4. Install pipe into valve bl ock and bolts (x2) pump to
transaxle (renew O-ring on hose).
5. Install clip pump hose to valve block.
6. Install reservoir hose to valve block and install new clip.
7. Connect multiplugs (x5) to valve block.
8. Connect dry break quick-fit connector to torque tube pipe.
9. Raise transaxle, install harness clip to subframe.
10. Connect transaxle breather pipe.
11. Raise transaxle to fitted position.
12. Install transaxle mounting brackets and hydramounts, install and torque tighten new bolts (x8).
13. Align hydramounts to subfra me, lower lifter, install and
torque nuts. Remove lifter.
14. Position reservoir to bracket and fit clamp (bolt x1).
15. Position reservoir hose and secure clips.
16. Remove plugs, connect and torque oil cooler unions.
17. Apply thread lock to new Allen bolts.
18. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
19. Position earth lead to transaxle, install and torque tighten bolt.
20. Install shear plate, install bolts (x8), tighten bolts to correct torque.
21. Install tunnel heatshield, install bolts/washers (x4), tighten bolts to correct torque.
22. Install centre and rear exhaust pipe assembly, align to both catalysts then tighten clamp nuts to correct torque.
23. Install bolts (x4) into centre mounting.
24. Install subframe cross brace, install bolts (x4) and torque. 25. Install rear exhaust silencer assembly (see Workshop
Manual procedure 09.00.KA Muffler & Bypass Valve
Assembly - Remove for Access & Refit).
26. Roadster Only - Install centre undertray (see Workshop
Manual procedure 01.02.MB Undertray - Centre -
Renew).
27. Install road wheel(s).
28. Lower vehicle on ramp, remove securing straps.
29. Connect vehicle battery.
30. Test drive vehicle.
Shifter Assembly Gasket-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp and secure with straps.
3. Remove gear position sens or (see Workshop Manual
procedure 07.03.AL Sensor - Transmission Assembly -
Sportshift - Renew).
4. Remove shifter unit fixings (bolts x6, nut x1), release from dowels (x2) and tie shifter aside (see Figure 1).
Figure 8
!
WAR NI NG
ALWAYS CONNECT THE BATTERY EARTH (+VE) TERMINAL FIRST.
Repair Operation Time (ROT)
ItemCode
Shifter Assembly Gasket-Renew 07.03.AN
WAR NI NG
ALWAYS DISCONNECT THE BATTERY EARTH (- VE) TERMINAL FIRST.
WAR NI NG
WHEN YOU LIFT THE VEHICLE ON A 'TWO POST' LIFT MAKE SURE THAT YOU USE A STRAP TO HOLD THE REAR END OF THE VEHICLE TO THE RAMP. IF YOU
DO NOT, THE VEHICLE CAN FALL OFF THE RAMP AND CAUSE PERSONAL INJURY OR DEATH.
Figure 1
!

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-33
43. Install the tunnel reinforcement plate.
44. Install and torque the eight bolts that attach the tunnel reinforcement plate to the body.
45. Install floor heatshield.
46. Install and tighten the four bolts that attach the floor heat shield to the body.
47. Install the exhaust front mount.
48. Clean the component mating faces.
49. Apply an applicable sealant to the component mating faces.
50. Install the exhaust centre pipe.
51. Install and tighten the four bolts that attach the exhaust centre pipe to the exhaust front mount.
52. Put the clamps into position on the exhaust pipes.
53. Loosely install the four bolts that attach the exhaust centre pipe to the rear silencer.
54. Align the exhaust assembly.
55. Tighten the two clamps that attach the exhaust centre pipe to the catalytic converters.
56. Install the cross brace.
Figure 24
57. Install and torque the four bolts that attach the cross brace to the rear subframe.
Figure 25
58. Remove the strap that attaches the vehicle to the lift.
59. Lower the vehicle until the wheels are approximately 10 mm above the ground.
60. Connect the battery ground cable.
61. Bleed the clutch system.
62. Use AMDS to do an ASM self-tune.
63. Start the engine, select first gear and allow the wheels to turn for 10 seconds.
64. Lift the vehicle.
65. Remove the fill plug for the transaxle oil.
66. Make sure that the transaxle oil is level with the opening for the transaxle oil. Add more oil if necessary.
67. Install and tighten the fill plug for the transaxle oil.
68. Do a check of the ASM fluid level.
69. Install the rear undertray (refer to Workshop Procedure 01.02.PB - Rear Undertray)
Removal
1. Position vehicle on ramp.
2. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
3. Position container to collect transaxle oil.
4. Remove transaxle drain plug and drain oil.
WA R N I N G
THE EXHAUST CENTRE PIPE IS HEAVY. GET THE AID
OF ONE MORE PERSON
TO DO THE STEP THAT FOLLOWS.
Repair Operation Time (ROT)