GEAR SELECTOR ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Instrument Panel (IP) (01.12)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-9-5
37. Manoeuvre and remove inst rument panel sufficient to
gain access to heater hose (see Figure 17).
38. Position container to collect coolant.
39. Release clip and disconne ct hose from heater unit.
40. Disconnect condenser hose from heater unit.
41. Manoeuvre and remove inst rument panel from vehicle
(see Figure 18).
42. Remove container.
Installation
1. With assistance, manoeuvre instrument panel into vehicle.
2. Connect condenser hose to heater unit.
3. Connect hose to heater and secure with clip.
4. With assistance, manoeuvre instrument panel into position aligning upper column to intermediate shaft.
5. Install new upper column pinch bolt (do not torque at this stage).
6. Install bolts (x6) through instrument panel to both A- posts (do not torque at this stage). 7. Install screws (x4) through
instrument panel to bulkhead
(do not torque at this stage).
8. Ensure instrument panel is correctly aligned and tighten screws (x4) and bolts (x6) to correct torque.
9. Loosen and release attachme nts from instrument panel
and with assistance, remove tool (501-F116) from
vehicle.
10. Tighten upper column pinch bolt to correct torque.
11. Install gaiter to bulkhead.
12. Connect multiplugs (x14) fr om instrument panel to main
body harness.
13. Apply adhesive and install instrument panel upper air
vents and secure in clips.
14. Position drivers side lower instrument panel and connect air temperature pipe.
15. Install panel in clips (x7).
16. Install steering column upper and lower shrouds and install and tighten screws (x7).
17. Install steering wheel (see Workshop Manual 11.06.AB Steering Wheel Renew).
18. Install and tighten bolt from heater fan to bulkhead.
19. Install and torque tighten bolts (x2) from instrument panel to tunnel.
20. Install footwell carpet.
21. Install drivers side carpet retaining plate to bulkhead.
22. Install and torque tighten Allen bolts (x4).
23. Install gear lever mechanism and install and tighten screws (x6).
24. Install selector cable ball joints to gear lever mechanism.
25. Install centre column switch panel and connect multiplugs (x8).
26. Install rear centre cons ole (see Workshop Manual
01.04.BB Centre Console Rear Renew).
27. Install LH and RH cant rail trim panels and install and tighten screws (x4).
28. Install trim finishers (x4) and install seals to door aperture.
29. Connect multiplugs (x11) from LH and RH A-post to
instrument panel.
30. Connect fuel filler flap release switch.
31. Install LH and RH A-post trim panels.
32. Install LH and RH A-post door trim plates.
33. Install rivets (x2), insta ll and tighten screws (x2).
34. Install seal to door aperture.
35. Install LH and RH side tread plates and tighten screws (x12).
36. Install LH and RH side tread plate badges and tighten screws (x4).
37. Install RH door (see Workshop Manual 01.03.EA Door Assembly - RH - Remove for Access and Refit).
38. Install RH front seat (see Workshop Manual 01.10.AA Seat Assembly - Front - RH - Remove for Access and
Refit).
Figure 17
Figure 18

Subframes (02.03)
Frame and Mounting (02.00)
May 2007 Workshop Manual 2-1-7
15. Use tool (206-103) and release each handbrake cable from mounting brackets, re lease inner cable eyelets
from calliper levers.
16. Remove bolts (x2) and nuts (x2), handbrake cables to subframe.
17. Use tool (206-103) and release handbrake cables from subframe brackets.
18. Release handbrake cable from clip, tie handbrake cable aside.
19. Loosen and disconnect each brake pipe from body bracket. Plug brake pipes
.
20. Remove bolt, fuel filler pipe to damper mounting.
21. Remove nut securing fuel fi ller pipe to body, tie filler
pipe aside.
22. Remove bolts (x4 each side), securing spring/damper assemblies.
23. Position drain tray to collect oil spillage.
24. Loosen and disconnect unions (x2), transaxle oil cooler.
Plug pipe connections.
25. Remove drain tray.
26. Disconnect multiplug, release harness clips (x2), transaxle harness, RH rear wheel arch.
27. Mark subframe position to body.
28. Position subframe trolley (303-F715), under subframe.
29. Lower vehicle until subfra me rests on support trolley.
30. Remove bolts (x6), securing subframe to body.
31. Raise vehicle to gain access to gear selector cables.
32. Using (308-642), release se lector cables (x2) from ball
joints, release selector cables from bracket.
33. Remove torque tube to transaxle bolts (x8).
34. Move subframe support trolley rearwards to give a clearance between torque tube and transaxle.
35. Carefully raise vehicle from subframe.
Installation
1. Clean transaxle and mating face on torque tube.
2. Position subframe assembly underneath vehicle.
3. Lower vehicle to align transaxle to propshaft splines.
4. Move subframe assembly forward, engage propshaft splines, locating dowels, transaxle to torque tube.
5. Install bolts (x8), torque tube to transaxle, torque tighten bolts.
6. Install gear selector cables on levers and in bracket.
7. Lower vehicle onto subframe mountings, align to marks, install and torque tighten bolts (x6).
8. Position spring/damper assemblies, install bolts (x8).
9. Position fuel filler pipe, install and torque tighten bolt.
10. Position fuel filler pipe to body, install and tighten nut to correct torque.
11. Position handbrake cables to subframe, install bolts (x4), torque bolts. 12. Install handbrake cables to callipers.
13. Remove plugs, install brake pipes.
14. Remove plugs, install transaxle oil cooler pipes, tighten
unions to correct torque.
15. Position earth lead to transaxle, install and torque tighten bolt.
16. Install transaxle harness multiplug, secure harness clips (x2).
17. Install shear plate, install and torque tighten bolts (x8).
18. Install heat shield, install and torque tighten bolts (x4).
19. Clean exhaust pipe connections, apply exhaust sealant to connections.
20. Install centre pipe to mountings and catalysts, torque tighten clamp nuts.
21. Install rear exhaust pipes to centre pipe, torque tighten clamp nuts.
22. Position subframe cross brace, install and torque bolts.
23. Install rear muffler (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve Assembly - Remove
for Access and Refit).
24. Install LH rear wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
25. Install RH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
26. Bleed brake system (see Workshop Manual procedure 06.07.DD Brake Hydraulic System - Flush/Refill/Bleed
27. Adjust handbrake (see Wo rkshop Manual procedure
06.05.DC Handbrake Cable Assembly - Adjust).
28. Install road Wheel(s).
29. Lower vehicle on ramp and remove safety equipment.
Rear Subframe-Remove/Refit
Removal
1. Disconnect vehicle battery.
2. Remove rear subframe asse mbly (see Workshop Manual
procedure 02.01.CA Subframe Assembly - Rear -
Remove for Access and Refit).
3. Mark driveshafts to transaxle flanges for assembly purposes.
4. Remove and discard Allen bolts (x12), collect plates (x6), driveshaft flanges to transaxle.
5. Attach slings to transaxle, connect suitable hoist and
take weight of transaxle.
6. Remove nuts (x2). hydramounts to subframe.
7. With assistance, raise and remove transaxle from subframe.
Caution
Always plug pipe connections to prevent ingress of dirt.
Repair Operation Time (ROT)

Manual Transmission (07.03)
Transmission (07.00)7-3-6 Workshop Manual Issue 5, January 2010
41. Use the special tool to release the gear selector cables from the ball joints.
Figure 16
42. Release the gear selector cables from the bracket.
Figure 17
Put a transmission jack in position below the torque tube.
Figure 18
43. Adjust the height of the transmission jack to hold the torque tube. 44. Remove the eight bolts that attach the torque tube to
the transaxle.
Figure 19.
45. Move the transaxle rearward to give clearance between the torque tube and the transaxle
46. Carefully lower the transaxle on the transmission jack to
remove the transaxle from the vehicle.
Figure 20
47. Clean the mating faces of the components.
Install
1. Move the transaxle on th e transmission jack, into
position below the vehicle.
2. Use the transmission jack to adjust the height of the transaxle to align the transaxle with the torque tube.
3. Install and torque the eight bolts that attach the torque tube to the transaxle.
4. Lower the transmission jack away from the torque tube.
5. Connect the gear selector cables to the ball joints.
6. Install the gear selector cables into the bracket.
WAR NI NG
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.
WAR NI NG
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.

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)
Issue 5, January 2010 Workshop Manual 7-3-13
6. Remove and discard gasket (see Figure 3).
7. Remove and discard hose O-rings (x3).
Install
1. Install new O-rings to hoses.
2. Clean mating faces and install new gasket to dowels.
3. Ensure alignment of selector mechanism with shifter unit and install shifter unit.
4. Install hoses into shifter unit and install clips.
5. Install harness clip into shifter casing.
6. Install Gear position se nsor (see Workshop Manual
procedure 07.03.AL Sensor - Transmission Assembly -
Sportshift - Renew).
7. Connect vehicle battery.
8. Test drive vehicle.
9. Raise vehicle on ramp; Check transaxle and Sportshift fluid.
10. Lower vehicle on ramp.
Reservoir Tank Assembly-Renew-
Roadster Only
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew). 4. Remove clips and release reservoir hoses from valve unit
and pump (place drain tray to collect fluid) (see Figure
1).
5. Release reservoir hoses from transaxle mounting clips
(x2) (see Figure 2).
Figure 2
Figure 3
WA R N I N G
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
Repair Operation Time (ROT)
!
Figure 1
WA R N I N G
TRANSAXLE OIL CAN BE HARMFUL.
OBEY ALL TRANSAXLE OIL MANUFACTURER’S SAFETY INSTRUCTIONS WHEN YOU HANDLE COMPONENTS THAT HAVE TOUCHED TRANSAXLE OIL.
Figure 2
!
!

Manual Transmission (07.03)
Transmission (07.00)
Issue 5, January 2010 Workshop Manual 7-3-27
5. Remove and discard gasket (see Figure 2).
Install
1. Clean mating faces and install new gasket to dowels.
2. Ensure alignment of selector mechanism with shifter unit and install shifter unit.
3. Install Gear position se nsor (see Workshop Manual
procedure 07.03.AL Sensor - Transmission Assembly -
Sportshift - Renew).
4. Connect battery.
5. Test drive vehicle.
6. Lower vehicle on ramp.
Transaxle Assembly - Sportshift Only -
Remove for Access & Install
Remove for Access
1. Set the transaxle to neutral.
2. Disconnect the battery ground cable.
3. Remove the rear undertray (refer to Workshop Manual procedure 01.02.PB - Rear Undertray). 4. Raise the vehicle and install straps to hold it to the lift
(refer to Figure 1).
Figure 1
5. Remove the four bolts that attach the cross-brace to the rear subframe.
Figure 2
6. Remove the cross brace.
7. Remove the four bolts that attach the exhaust centre pipe to the rear silencer.
8. Loosen the two clamps that attach the exhaust centre pipe to the catalytic converters.
9. Move the clamps along the exhaust pipes.
Figure 2
WA R N I N G
ALWAYS CONNECT THE BATTERY EARTH (+VE)
TERMINAL FIRST.
Repair Operation Time (ROT)
!
WA R N I N G
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER
OPERATION. LET THE EXHAUST COOL BEFORE YOU DO WORK. IF YOU DO NO T, PESONAL INJURY CAN
OCCUR.

Manual Control System (07.06)
Transmission (07.00)
May 2007 Workshop Manual 7-6-1
Transmission (07.00)
Manual Control System (07.06)
Maintenance
Gearshift Assembly Mechanism-Renew
Removal
1. Remove panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console -
Renew).
2. Using tool (308 - 642), release selector cable ball joints (x2) from gear lever mechanism.
3. Remove screws (x6), securi ng gear lever mechanism to
housing.
4. Remove gearshift assembly mechanism.
5. Remove gear knob, collect gaiter.
Installation
1. Clean gearshift mechanism.
2. Lubricate gearshift mechanism with recommended grease.
3. Install gearshift mechanism, install and tighten screws
(x6).
4. Install selector cables to gearshift mechanism.
5. Install panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console - Renew).
6. Install gear lever gaiter, install gear knob.
Transmission Gearshift Cable Assembly-
Renew
Removal
1. Disconnect vehicle battery.
2. Remove panel assembly - console.
3. Using tool 308 - 642, release selector cable ball joint from gear lever mechanism.
4. Remove horseshoe clip secu ring selector to bracket.
5. Raise vehicle on ramp and secure with straps. 6. Remove road wheel(s).
7. Remove rear exhaust muffl
er (see Workshop Manual
procedure 09.00.KA Silencer and Bypass Valve
Assembly - Re move for Access and Refit
8. Remove bolts (x4), subframe cross brace.
9. Loosen clamp nuts (x2), release centre pipe from both catalysts.
10. Remove centre pipe and rear exhaust pipes as an
assembly.
11. Remove bolts (x4), centre heatshield to body, remove heatshield.
12. Remove bolts (x8), shear plate to body, remove shear plate.
13. Remove bolt securing earth lead to transaxle.
14. Mark drive shaft to differential flanges for assembly purposes.
15. Remove and discard Allen bolts (x12), collect plates (x6), drive shaft flanges to transaxle.
16. Release drive shafts from transaxle and position aside.
17. Position drain container to collect oil spillage.
18. Loosen unions and disconnect oil cooler pipes (x2) from
transaxle interconnecting pipes. Plug pipe connections
(x4).
19. Remove drain container.
20. Remove nuts (x2), hydra mounts to subframe mountings.
21. Position hydraulic lifter to support transaxle.
22. Remove and discard bolts (x8 (4 each side), mounting brackets to transaxle. Remove mounting brackets with
hydra mounts.
23. Release reverse lamp switch multiplug from bracket, disconnect multiplug.
24. Lower transaxle sufficiently and use tool (308 - 642) to release selector cable ball joint from selector lever.
25. Remove horse shoe clip securing selector cable to mounting bracket, remove selector cable assembly.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
WA R N I N G
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUST SYSTEM TO COOL DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WA R N I N G
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
Caution
Plug oil cooler connections to prevent ingress of dirt or moisture into the system.
Caution
Ensure that the service tool No. 0308 - 642 is used to
release selector cable ball joints from selector levers.

Manual Control System (07.06)
Transmission (07.00)7-6-2 Workshop Manual May 2007
Installation
1. Install selector cable, connect to ball joint, install horseshoe clip.
2. Connect multiplug to reverse light switch, install multiplug in bracket.
3. Install reverse light harness clip in transaxle.
4. Install transaxle mounting brackets and hydra mounts, install and torque tighten new bolts (x8).
5. Align hydra mounts to subframe, lower lifter, install and torque tighten nuts (x2). Remove lifter.
6. Remove plugs, connect and torque oil cooler unions.
7. Apply thread lock to new Allen bolts.
8. Align drive shafts to transaxle flanges, clean and install plates (x6), install and torque tighten Allen bolts (x12).
9. Position earth lead to transaxle, install and torque tighten bolt.
10. Install shear plate, install bolts (x8), tighten bolts to correct torque.
11. Install centre heatshield, install bolts (x4), tighten bolts to correct torque.
12. Install centre and rear exhaust pipe assembly, align to both catalysts. tighten clamp nuts to correct torque.
13. Install subframe cross brace, install and torque tighten bolts (x4).
14. Install rear exhaust muffler (see Workshop Manual procedure 09.00.KA Silencer and Bypass Valve
Assembly - Remove for Access and Refit).
15. Install road wheel(s).
16. Lower vehicle on ramp, remove securing straps.
17. Position selector cable in bracket, install horseshoe clip.
18. Install selector cable ball jo int to gear lever mechanism.
19. Install panel assembly - console.
20. Connect vehicle battery.
21. Test drive vehicle.
22. Raise vehicle on ramp; Check transaxle oil level.

Electronics Training Programme
Bluetooth Contact List
A list of names and phone numbers can be stored wi thin the Bluetooth systems contact list. The list
can include up to 20 entries.
Note: A phone must be connected to the system be fore the contacts list can be accessed.

To add a new contact to the Bluetooth contact list:
Warning: When adding, deleting or listing contacts en sure that the vehicle is stationary with the
handbrake applied, and the gear selector in ‘P’ or ‘N’ (Automatic) or Neutral (Manual).
1. Press the button. When prompted, say ‘Contact List’.
a) If the system responds with ‘Contact list is empty. Do you wish to add a contact?’, say
‘Yes’.
b) If the system responds with ‘Contact li st. Please say a command’, say ‘Add contact’.
If the name sounds like one that is already stored, or if an error is detected, the system asks you to try
again.
2. The system responds with ‘Please say t he name’, recite the contact to be stored.
If the name is accepted, the system responds with ‘Please say the number for ’.
3. Dictate the phone number either as:
• An entire number (without pauses between digits)
• A series of segments (for example, say the 1st 3 digits, then the next 3, etc.), until you
have dictated the entire number
The system repeats the number it heard.
4. When the entire number has been correctly entered say ‘Store’. The system responds with
‘Contact added. Would you like to add another contact?’.
Say ‘No’ to return to the system’s ready state.
Say ‘Yes’ to add another entry.

To delete an entry:
1. Press the button. When prompted, say ‘Contact List’.
a) If the system responds with ‘Contact list. Please say a command’, say ‘Delete
’.
b) If the system responds with ‘Contact list is empty. Do you wish to add a contact?’, say
‘No’. The system then exits to ready state.
2. When the system responds with ‘Are you sure you want to delete the contact ?’,
say ‘Yes’. The system respon ds with ‘Contact deleted’.


To retrieve a list of stored contacts:
• Press the button. When prompted, say ‘Contact List’.
a) If the system responds with ‘Contact list ’. Please say a command’, say ‘List contacts’.
The system begins to list the stored entries.
b) If the system responds with ‘Contact list is empty. Do you wish to add a contact?’, say
‘No’. The system exits to ready state.
27

AML EOBD System Operation Summary

Rory O’Curry Aston Martin Lagonda CONFIDENTIAL 1 May 2009
[email protected] AML EOBD Monitors 07 ROC.doc Page 31 of 43

Comprehensive Component Monitor - Automatic Transmission

General

The MIL is illuminated for all emissions related electrical component malfunctions. For malfunctions
attributable to a mechanical component (such as a clutch, gear, band, valve, etc.), some transmissions are
capable of not commanding the mechanically faile d component and providing the remaining maximum
functionality (functionality is reassessed on each power up). In such case a non-MIL Diagnostic Trouble
Code (DTC) will be stored and, if so equipped, a Transmission Control Indicator Light (TCIL) will flash.
For example on the CD4E transmission, if a gear ratio is not properly obtained and verified due to a
mechanical malfunction, the unobtainable gear is no longer commanded for that power up, the DTC is
stored and the TCIL flashes.

Transmission Inputs

Transmission Range Sensor Check Operation:
DTCs P0705, P0708 (open/invalid pattern for digital TRS)
P0707, P0708 (opens/shorts for analog TRS)
Monitor execution continuous
Monitor Sequence none
Monitoring Duration 30 seconds

Typical TRS check entry conditions : Minimum Maximum
Gear selector position each position for up to 30 seconds 480 seconds

Typical TRS malfunction thresholds:
For digital sensor : Invalid pattern from 3 (or 5) digital inputs or 1 analog circuit open for 5 seconds
For analog sensor : Voltage > 4.8 volts or < 0.2 voltage for 5 seconds


Output Shaft Speed Sensor Functional Check Operation:
DTCs P0720
Monitor execution continuous
Monitor Sequence none
Monitoring Duration 30 seconds

Typical OSS functional check entry conditions : Minimum Maximum
Gear selector position drive
Engine rpm (above converter stall speed) OR 3000 rpm
Turbine shaft rpm (if available) OR 1500 rpm
Output shaft rpm 650 rpm
Vehicle speed (if available) 15 mph

Typical OSS functional check malfunction thresholds:
Vehicle is inferred to be moving with positive driving torque and OSS < 100 to 200 rpm for 5 seconds