bonnet ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

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

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

Front End (01.02)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-2-1
Body System (01.00)
Front End (01.02)
Front Wings
Specifications
Maintenance
Radiator Closing Panel - Remove and
Install
Removal
1. Remove the 12 Torx screws that attach the radiator
closing panel.
S-01-02-AA-01
2. Remove the radiator closing panel.
S-01-02-AA-02
Install
1. Install the radiator closing panel (refer to Figure S-01-02- AA-01).
2. Install and tighten the 12 Torx screws that attach the radiator closing panel.
Centre Undertray - Remove and Install
(Roadster Only)

Removal
1. Use the applicable equipment to lift the vehicle and make it safe.
2. Remove the 17 screws that attach the centre undertray to the body.
3. Remove the centre undertray.
Install
1. Put the rear undertray in positon.
2. Install and torque the 17 Torx screws that attach the rear undertray.
Wing Standard (mm)
Torque Figures
DescriptionNm
Wing Top 8
Wing Top Single nut Tight with ‘Threadlock’
Lower Rear 8
Slam panel 8
PCM Bracket 10
Bonnet Damper 25







Repair Operation Time (ROT)
Repair Operation Time (ROT)

Body Closures (01.03)
Body System (01.00)1-3-2 Workshop Manual May 2007
BonnetMaintenance
LH/RH Door Assembly-Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Remove LH door assembly (see Workshop Manual procedure 01.03.FA Door Assembly - LH - Remove for
Access and Refit).
3. Remove bolts (x2) securing door handle assembly to door panel (see Figure 1).
4. Remove door handle trim plate, disconnect door catch inner release cable from handle and outer cable from
retaining plate.
5. Remove hand le assembly.
6. Remove access plug s from door frame.
7. Remove screw securing trimboard to upper front of door frame.
8. Remove bolts (x5) securing trimboard to door frame.
9. Raise trimboard out and up to release from door frame clips, disconnect multiplugs (x2).
Bonnet Standard (mm)
Torque Figures
DescriptionNm.
Hinge to Body 25





Repair Operation Time (ROT)
ItemCode
Door Assembly-Renew LH01.03.DB
Door Assembly-Renew RH01.03.CB
Figure 1
A0103136

Body Closures (01.03)
Body System (01.00)1-3-14 Workshop Manual May 2007
3. Repeat remove and installa tion procedure for opposite
hinge (see Figure 1).
4. Check alignment of tailgate and adjust as necessary.
5. Fully tighten screws (x8) tailgate hinges.
6. Remove bodywork protection.
Hood Assembly - Renew
Removal
1. Open hood.
2. Disconnect windscreen wash pipe.
3. Remove cap nut, nut and release earth lead from hood.
4. Remove buffers from hood.
5. Remove Torx screws (x2) se curing striker plate to hood,
remove striker plate.
6. Remove Torx screws (x2) se curing safety catch to hood,
remove safety catch.
7. Remove hood sound insulation.
8. Remove cap nuts (x12) securing air intake grilles (x2) to
hood, remove grilles.
9. Disconnect screen washer hos e, reservoir to non-return
valve.
10. Loosen hood hinge bolts (4).
11. Disconnect gas struts and remove hinge bolts
12. With assistance, remove bolts (x4) and hood.
13. Remove ball studs from bonnet.
14. Remove screen washer jets (x2) and hoses from hood.
Installation
1. Install and torque tighten ball studs (x2).
2. Install screen washer hoses and jets (x2).
3. With assistance, position hood to hinges, install bolts
(x4). Do not torque tighten at this stage. 4. Install safety catch, install and torque tighten Torx
screws (x2).
5. Install striker plate, install and torque tighten Torx screws (x2).
6. Install air intake grilles (x2), install and tighten cap nuts (x12).
7. Install Buffers to hood.
8. Install sound insulation.
9. Align hood to aperture.
10. Raise hood and tighten up one hinge bolt either side.
11. Lower hood and check alignment
12. Raise hood and torque tighten hinge bolts (x4).
13. Install gas struts.
14. Install earth lead to hood, install and tighten nut and cap nut.
15. Connect screen washer hose.
16. Close hood to check enga gement of latch assembly,
adjust if necessary
17. Close hood and check operation of hood release lever.
Hood Hinge Assembly (Vehicle Set) -
Renew
Removal
1. Remove LH wing (see Workshop Manual procedure 01.02.LB Panel Assembly - Front Wing - LH - Renew).
2. Remove RH wing (see Workshop Manual procedure 01.02.KB Panel Assembly - Front Wing - RH - Renew).
3. Protect bodywork.
4. Mark position of hinges (see Figure 1).
Figure 1
Repair Operation Time (ROT)
A0103149
Repair Operation Time (ROT)
ItemCode
Hood Hinge Assembly (Vehicle Set)-
Renew 01.03.AE
Figure 1
A0103160

Glass, Frame and Mechanism (01.11)
Body System (01.00)
May 2007 Workshop Manual 1-8-3
3. Remove clamping bolts (x2) (see Figure 2).
4. Hold glass firmly and lift out of door, place on protective material in a safe place (see Figure 3).Installation
1. Install door glass with front edge into the channel, and position in clamps, install clamping bolts (x2) and lightly
tighten.
2. With power on, raise glass fully up and adjust position, drop glass fully down and readjust, when aligned raise
to access clamping bolts and tighten bolts to
recommended torque. Repeat until aligned.
3. Install door trimboard assembly (see Workshop Manual procedure 01.05.CB Trimbo ard Assembly - Door -
Remove for Access and Refit).
4. Install door trimboard assembly (see Workshop Manual procedure 01.05.CB Trimbo ard Assembly - Door -
Remove for Access and Refit).
Door Glass - Adjust/Reset
1. Open door.
2. Remove interior door handle securing bolts (x2).
3. Remove inner handle trim and disconnect door latch inner cable and remove secu ring bolts for the outer
cable.
4. Remove access plugs (x2), door trimboard.
5. Set glass to position to access clamping bolts (x2) through apertures in the trim panel.
6. Slightly loosen clampbolts (x2), raise glass and align, lower glass and check alignment. Raise and lower until
correct alignment is achieved.
7. Position glass for access to clamp bolts and tighten bolts.
8. Reset upper glass limit.
9. Reset lower glass limit.
Installation
1. Reconnect door latch inner and outer cable, refit inner handle trim.
2. Install door handle.
3. Reset lower glass limit.
4. Install plugs (x2), door trimboard.
Front Windshield - Renew
1. Open bonnet.
Figure 2
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.
Figure 3






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.
Repair Operation Time (ROT)
Repair Operation Time (ROT)

Glass, Frame and Mechanism (01.11)
Body System (01.00)1-8-4 Workshop Manual May 2007
2. Remove wiper arm drivers side (see Workshop Manual procedure 01.16.AD Arm Asse mbly - Wiper - Driver -
Renew).
3. Remove wiper arm passengers side (see Workshop Manual procedure 01.16.AE Arm Assembly - Wiper -
Passenger - Renew).
4. Remove plate and disconnect multiplug (x1) windshield (see Figure 1).
5. Close bonnet.
6. Remove interior mirror (see Workshop Manual procedure 01.08.FA Mirror Assembly - Rear Dipping -
Renew).
7. Protect external body work and internal trim adjacent to glass.
8. Place suitable covers over trim and bodywork.
9. Make hole in sealer and assemble cutting knife. 10. Cut out windshield and
remove (see Figure 2).
11. Remove sealer from body and original screen if refitting.
12. Clean and polish windshield.
13. Apply etch primer around windshield aperture.
14. Assemble applicator.
15. Attach suction handles to windshield.
16. Apply sealer to glass.
17. With assistance, lift windshield into place and align in aperture. Lightly press glass to sealer.
18. Remove suction handles from windshield.
19. Remove all protective covers and tape.
20. Check screen for leaks.
21. Connect multiplug (x1) to windshield and install plate.
22. Install wiper arm passengers side (see Workshop Manual
procedure 01.16.AE Arm Assembly - Wiper - Passenger
- Renew).
23. Install wiper arm drivers side (see Workshop Manual procedure 01.16.AD Arm Assembly - Wiper - Driver -
Renew).
24. Install interior mirror (see Workshop Manual procedure 01.08.FA Mirror Assembly - Rear Dipping - Renew).
Rear Windshield - Renew
1. Remove tailgate trim (see Workshop Manual procedure
01.05.EF Trim - Tailgate Lid Assembly - Renew).
Figure 1
WAR NI NG
PUT ON PROTECTIVE GLOVES AND EYE
PROTECTION WHEN YO U HOLD THE GLASS
COMPONENTS.
THE GLASS CAN BREAK EASILY AND CAUSE INJURY.
X



Figure 2
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 (ROT)
ItemCode
Rear Windshield-Renew 01.11.BE




Handles and Lock Mechanisms (01.14)
Body System (01.00)
May 2007 Workshop Manual 1-10-3
8. Remove bolts (x3) securing door latch (see Figure 1).
9. Feed interior latch handle cable through inner skin into door interior.
10. Remove latch and keylock mechanisms carefully through aperture.
Installation
1. Install latch and key lock mechanisms through door aperture and feed interior door latch handle cable
through aperture.
2. Align door latch, install and torque tighten bolts (x3).
3. Align key lock mechanism, install lower nut, torque tighten nuts (x2).
4. Install exterior door handle, install and torque tighten nuts (x3).
5. Connect latch inner and outer cable to exterior door handle.
6. Connect latch mechanism multiplug.
7. Refit inner glass seal and rubber rear cheater panel, secure with tree trim pins (x3).
8. Refit door aperture seal.
9. Install glass regulator (see Workshop Manual procedure 01.11.DA/01.11.1DB Regulato r - Door Glass - /LHRH -
Renew).
Bonnet Latch Assembly - Renew
Removal
1. Remove grille (see Workshop Manual procedure 01.08.AA Grille - Radiator - Renew
2. Remove slam panel (bolts x12).
3. Remove bolts (x4) securing PAS oil cooler.
4. Remove bolts securing crossmember to inner wing (x4).
5. Remove bolts and spacers securing crossmember to wing (x2).
6. Move crossmember to one side and lift up clear of location (protect paintwork). 7. Disconnect bonnet latch multiplug.
8. Remove switch from latch body (to access cable).
9. Disconnect bonnet latch cable.
10. Remove bonnet latch from
crossmember (screws x2).
Installation
1. Install bonnet latch to crossmember (screws x2).
2. Connect bonnet latch cable.
3. Install switch to latch body.
4. Connect bonnet latch multiplug.
5. Install crossmember (as removed).
6. Install bolts and spacers securing crossmember to wing
(x2).
7. Install bolts securing cros smember to inner wing (x4).
8. Install bolts (x4) securing PAS oil cooler.
9. Install slam panel (bolts x12).
10. Install grille (see Workshop Manual procedure 01.08.AA
Grille - Radiator - Renew).
Hood Release Cable Assembly - Renew
(Roadster Only)
Removal
1. Remove hood latch (see Wo rkshop Manual procedure
01.14.BD Latch Assembly - Hood - Renew).
2. Remove Torx screw securi ng hood release handle to
body.
3. Disconnect hood releas e cable from handle.
4. Release cable tie fir tree fr om body, remove cable tie
from release cable.
5. Tie a length of string to the handle end of release cable for assembly purposes.
6. Remove bolts (x4) securing corner cross brace, remove
cross brace.
7. Move expansion tank aside for access (bolt x1, nut x1. hose clips x2, multiplug x1.
8. Remove LH front wheel arch liner (see Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
9. Release clips (x2), release cable to under wing bracket and body.
10. Pull hood release cable th rough bulkhead, releasing
grommet from bulkhead.
11. Remove string from hood release cable, remove cable.
12. Remove grommet from release cable.
Installation
1. Install grommet on hood release cable.
2. Position hood release cable, tie string to cable.
3. Pull release cable through bulkhead, install grommet, remove string from cable.
Figure 1
Repair Operation Time
ItemCode
Bonnet Latch Assembly-Renew 01.14.BD
A0114142
Repair Operation Time
ItemCode
Hood Release Cable Assembly-Renew LHD01.14.BE

Handles and Lock Mechanisms (01.14)
Body System (01.00)1-10-4 Workshop Manual May 2007
4. Connect release cable to hand le, position handle, install
and tighten Torx screw.
5. Install and secure hood release cable with fir tree clip.
6. Install hood latch assembly (see Workshop Manual procedure 01.14.BD Latch Assembly - Hood - Renew).
7. Install and secure hood release cable with fir tree clips to under wing bracket and body.
8. Install expansion tank (bolt x1, nut x1, hose clips x2, multiplug x1.
9. Install corner cross brace, install bolts (x4)(torque tighten bolts with vehicle on level floor).
10. Install LH front wheel arch liner (see Workshop Manual
procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
11. Top-up cooling system.
Bonnet Secondary Latch Assembly -
Renew
Removal
1. Open bonnet.
2. Remove Torx screws (x2), securing secondary latch to bonnet (see Figure 1).
3. Remove secondary latch.
4. Remove sleeve from release lever.
Installation
1. Install sleeve on release lever.
2. Install secondary latch, install and torque tighten Torx screws (x2).
3. Close and re-open bonnet, check secondary latch for correct operation.
4. Close hood.
Tailgate Latch and Cable Assembly -
Renew
Removal
1. Remove trim - tailgate lid assembly (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly
- Renew).
2. Remove Torx screws (x2) securing latch assembly to
tailgate.
3. Manoeuvre latch from tailgate, disconnect multiplug, remove latch.
4. Release clips (x2), remove bezel from latch.
Installation
1. Install bezel on latch.
2. Install latch in tailgate, align manual release cable.
3. Install and torque tighten Torx screws (x2).
4. Connect multiplug to latch.
5. Install trim - tailgate lid assembly (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly -
Renew).
6. Check operation of tailgate opening and closing.
Fuel Filler Actuator Assembly - Renew
(Roadster Only)
Removal
1. Remove luggage compartment lid striker assembly (see Workshop Manual procedure 01.03.GE Striker
Assembly - Trunk Lid - Renew).
2. Remove front luggage compartment carpet (screws x4, trim clip x1).
Repair Operation Time
ItemCode
Bonnet Secondary Latch Assembly-
Renew 01.14.BF
Figure 1
A0114172
Repair Operation Time (ROT)
ItemCode
Tailgate Latch and Cable Assembly-
Renew 01.14.DC
Repair Operation Time (ROT)
ItemCode
Fuel Filler Actuator Assembly-Renew 01.14.FA

Wipers and Washer System (01.16)
Body System (01.00)1-11-2 Workshop Manual Issue 4,November, 2008
Specifications
Maintenance
Windscreen Wiper Motor Assembly -
Renew
Removal
1. Remove wiper linkage.
2. Remove arm from motor (nut x1).
3. Remove motor from plate (bolts x3).
Installation
1. Install motor to plate (bolts x3).
2. Ensure wiper motor is in the ‘PARK’ position.
3. Install arm from motor (nut x1), using special tool.
4. Install wiper linkage.
Wiper Linkage Assembly - Renew
Removal
1. Remove brake booster (see Workshop Manual procedure 06.07.DE/06.07.DG Master Cylinder and
Vacuum Booster - Brake - Renew).
2. Remove inlet manifold (see Workshop Manual procedure 03.01.BB/03.01.BF Gasket - Manifold
Assembly - Intake Upper - Renew).
3. Remove wiper arm drivers si de (see Workshop Manual
procedure 01.16.AD Arm Asse mbly - Wiper - Driver -
Renew).
4. Remove wiper arm passengers side (see Workshop Manual procedure 01.16.AE Arm Assembly - Wiper -
Passenger - Renew).
5. Unclip expansion tank hose for access. 6. Remove sound deadening (trim buttons x6).
7. Remove seal from spindle.
8. Remove nuts (x2) from heatshield to move aside.
9. Unclip wiper motor harness (x2) LHS.
10. Unclip windscreen heater harness RHS.
11. Disconnect motor multiplu
g and unclip harness (x2).
12. To prevent damage, protect A/C pipe with tape before
wiper linkage removal.
13. Remove plate securing scre ws (x10) (through plenum).
14. Remove plate securing bolts (x8) (under bonnet).
15. Remove wiper linkage.
Installation
1. Install wiper linkage.
2. Install plate securing bolts (x8) (under bonnet).
3. Install plate securing scre ws (x10) (through scuttle
panel).
4. Connect motor multiplug and clip harness (x2).
5. Clip harness LHS.
6. Clip harness RHS.
7. Refit heatshield and install nuts (x2).
8. Install seal to spindle.
9. Install sound deadening (re-stick, trim buttons x6).
10. Clip expansion tank hose.
11. Install wiper arm drivers side (see Workshop Manual procedure 01.16.AD Arm Assembly - Wiper - Driver -
Renew).
12. Install wiper arm passengers side (see Workshop Manual
procedure 01.16.AE Arm Asse mbly - Wiper - Passenger
- Renew).
13. Install inlet manifold (see Workshop Manual procedure 03.01.BB/03.01.BF Gasket - Manifold Assembly - Intake
Upper - Renew).
14. Install brake booster (see Workshop Manual procedure 06.07.DE/06.07.DG Master Cylinder and Vacuum
Booster - Brake - Renew).
Windshield Wash Tube - Renew
Removal
1. Remove RH wheel arch liner (see Workshop Manual Procedure 01.02.GB Wheel Arch Liner - Front - RH -
Renew).
2. Place container to catch fluid.
Torque Figures
DescriptionTorque Figure (Nm)
Wiper motor crank to motor 35-42Nm
Wiper motor to cowl panel 7-10Nm
Wiper assembly plate 6Nm (M6 Torx) 8Nm (M6 Bolt)
Brake servo nuts 21-24Nm
Brake master cylinder nuts 25
Wiper arm (Driver) 13-17Nm (M8 Nut)
Wiper arm (Passenger) 20-26Nm (M10 Nut) 5-7Nm (M6 Bolt)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Windshield Wash Tube-Renew 01.16.CB