lock ASTON MARTIN V8 VANTAGE 2010 Workshop Manual

Contents
Issue 5, January 2010 Workshop Manual 0-0-3
V8 Vantage Workshop Manual
Contents
IntroductionWelcome .............................................................. 0-0-6
Safety Precautions ................................................. 0-0-7
Lifting and Jacking ................................................. 0-0-9
Vehicle Recovery ................................................ 0-0-10
Vehicle Identification Number ............................ 0-0-11
Body System (01.00) Body Structure (01.01) .......................................... 1-1-4
Front End System (01.02) ...................................... 1-2-1
Body Closures (01.03) ........................................... 1-3-1
Interior Trim (01.05) ............................................. 1-4-1
Exterior Trim (01.08) ............................................. 1-8-1
Mirrors (01.09) ...................................................... 1-9-1
Seating (01.10).................................................... 1-10-1
Glass, Frame and Mechanism (01.11) .................. 1-11-1
Instrument Panel (IP) (01.12) . .............................. 1-12-1
Handles and Lock Mechanisms (01.14) ............... 1-14-1
Wipers and Washer System (01.16)..................... 1-16-1
Convertible Roof and Roof Opening
Subsystem (01.17)................ ...............................1-17-1
Bumpers (01.19) ................................................. 1-19-1
Restraining Devices (01.20) .... ............................. 1-20-1
Frame and Mounting (02.00) Subframes (02.03) ................................................. 2-1-2
Engine System (03.00) Engine Assembly....................................................3-0-3
Engine Structure (03.01)........................................ 3-1-1
Lubrication System (03.02).................................... 3-2-1
Cooling System (03.03) ......................................... 3-3-1
Fuel Charging System (03.04) ................................ 3-4-1
Accessory Drive System (03.05)............................. 3-5-1
Engine Cranking System (03. 06) ............................ 3-6-1
Valve Train (03.09) ............................................... 3-9-1
Engine Sealing (03.10)......................................... 3-10-1
Power Conversion (03.11)................................... 3-11-1
Evaporative Emissions (03.13) ............................. 3-11-1
Engine Management System (0 3.14).................... 3-14-1
Throttle Control (03.16) ...... ................................ 3-16-1
Foot Operated Control (03.18)............................ 3-18-1
Suspension (04.00) Road Wheel Alignment (04.00) ............................. 4-0-2
Front Suspension (04.01)....................................... 4-1-1
Rear Suspension (04.02)........................................ 4-2-1
Shock Absorber System (04.03) ............................. 4-3-1
Road Wheels and Tyres (04.04) ............................ 4-4-1
Driveline (05.00) Driveshaft (05.01) ................................................. 5-1-2
Halfshafts (05.05) .................................................. 5-2-1 Brake System (06.00)
Front Disc Brake (06.03) ....................................... 6-3-2
Rear Disc Brakes (06.04) ....................................... 6-4-1
Hand Brake (06.05) .............................................. 6-5-1
Brake Actuation System (06.06 ) ............................ 6-6-1
Power Brake System (06.07) ................................. 6-7-1
Anti-lock Braking System (06.09)........................... 6-9-1
Transmission (07.00) Transmission Cooling (07.02) ................................ 7-0-2
Manual Transmission (07.03) ................................ 7-3-1
Automatic Control System (07.05)......................... 7-5-1
Manual Control System (07.06) ............................. 7-6-1
Automatic Shifting Subsytem (07.11) .................. 7-11-1
Clutch (08.00) Clutch Controls (08.02) ......................................... 8-1-2
Exhaust (09.00) Exhaust Overview ................................................. 9-1-2
Silencer Assembly (09.01) ..................................... 9-1-3
Pipes and Supports (09.03) ................................... 9-2-1
Exhaust Protection (09.04) .................................... 9-3-1
Fuel (10.00) Fuel Tank and Lines (10.01) ................................ 10-1-2
Steering (11.00) Steering Gear (11.01) .......................................... 11-1-2
Power Steering (11.02)........................................ 11-2-1
Steering Column (11.04) ..................................... 11-4-1
Steering Column Switches (1 1.05) ....................... 11-5-1
Steering Wheel (11.06) ....................................... 11-6-1
Climate Control (12.00) Body Ventilation system (12.01) .......................... 12-1-2
Heater System (12.02) ........................................ 12-2-1
Air Conditioning (A/C) System (12.03) ................. 12-3-1
Information, Gauge and Warning (13.00) Instrument Cluster (13.01) .................................. 13-1-2
Power Supply (14.00) Battery System (14.01) ........................................ 14-1-2
Alternator and Regulator System (14.02) ............. 14-2-1
Vehicle Entertainment (15.00) Audio System (15.01)................................ ..........15-1-2
Antenna (15.02).................................................. 15-2-1
Vacuum Distribution (16.00) Body Vacuum System (16.01) ............................. 16-1-2
Lighting (17.00) Front Lights (17.01) ............................................. 17-1-2
Interior Lighting (17.02) ...................................... 17-2-1
Rear Lights (17.03) .............................................. 17-3-1
Lighting Mechanisms (17.04). .............................. 17-4-1

Welcome
0-0-6 Workshop Manual Issue 5, January 2010
Welcome
This Workshop Manual is part of a suite of technical manuals
provided for V8 Vantage. Other technical manuals include:
• Parts manual
• OBDII Diagnostic manual
• Man hour schedules
Chapters
Each chapter in this workshop manual is associated with a 4
digit number, i.e. Transmission (07.00). Each chapter is then
further broken into sections, i.e. Automatic Transmission
(07.01).
Chapter Navigation
Example 1:
Older workshop manuals would have Steering and
Suspension together in one chapter. The structure now used
places Steering and Suspension into their own chapters.
When required references are made out to other chapters.
Page Numbering
The page numbering system used within this workshop
manual is as follows:
Systems Classification Coding
Alongside the ‘System’ and ‘Sub system’ section titles appear
codes. For example Exhaust ‘ 09.00’ or Power Steering
‘ 11.02 ’. These codes relate to a Corporate Product Systems
Classification (CPSC) and are designed to segregate the parts
for engineering release and organise a variety of engineering
data.
Special Tools
Where special service tools are required to perform an
operation, the tool number is recorded at the point of use
within the procedure. Where the operation of a special
service tool is complicated or not obvious, refer to Appendix
and Glossary for detailed operation procedures. A pictorial
list of special service tools available for this vehicle can also
be found in Appendix and Glossary.
Location References
References to left, right, front or rear of the vehicle or of a
component are referenced from sitting in the drivers seat
facing forward. Any such refe rences to assemblies removed
from the vehicle are to the normal orientation of the
assembly when installed in the vehicle.
The following Warnings, Cautions and Notes are used within
this Owner’s Guide to call your attention to specific types of
information.
Warnings, Cautions and Notes
Warnings
Cautions
Notes
Repairs and Replacements
Where replacement parts are required, it is essential that
only genuine Aston Martin parts are used. Your attention is
drawn to the following points concerning repairs and the
fitting of genuine Aston Martin parts and accessories:
• Safety features embodied in the vehicle may be impaired if other than genuine Aston Martin parts are installed. In
certain territories, legislation prohibits the fitting of parts
which are not produced to the manufacturers
specification
• Adhere to torque wrench settings given in this manual
• Locking devices, where specified, must be installed. If the efficiency of a locking device is impaired during removal,
it must be renewed
• The vehicle warranty may be invalidated by the installation of other than genuine Aston Martin parts
3- 2- 5
System, i.e. Engine system
Subsystem, i.e. Engine lubrication system
Page Number, i.e. Number within subsystem
WAR NI NG
IDENTIFIES PROCEDURES WHICH MUST BE
FOLLOWED PRECISELY TO HELP AVOID THE RISK OF PERSONAL INJURY.
Caution
Provided to indicate procedur es which must be followed
precisely to reduce the possibility of damage to the vehicle.
Provided to indicate procedur es which will help to avoid
difficulties in the oper ation of the vehicle.

Lifting and Jacking
Issue 5, January 2010 Workshop Manual 0-0-9
Lifting and Jacking
Safety
•Recommended procedures for lifting, jacking and
towing must be strictly ob served to ensure personal
safety.
• Always use a vehicle hoist, ramp or pit for working
beneath the vehicle in preference to jacking.
• Never rely on a jack to supp ort a car independently, use
axle stands or blocks carefu lly placed at jacking points
to provide rigid support.
• When working beneath a vehicle, chock wheels as well
as applying handbrake.
• Ensure vehicle is standing on firm, level ground before
jacking or lifting.
• Check lifting equipment has adequate capacity for load
being lifted and is in full working order.
Jacking Points
This vehicle jacking points are at positions shown.
May also be jacked on the front subframe front crossmember
Always use a jack with a rubber contact pad. Avoid use of
jacks with sharp contact pads which would damage floor
pan Always chock the opposite road wheels as well as
applying the handbrake when using a hydraulic jack.
To prevent body distortion, av oid single point or one side
jacking with the tunnel shear panel removed.
Lifting
Workshop Hoist
Use of a workshop hoist is recommended for all operations
where vehicles must be raised. Follow manufacturers
instructions. If using an adjustable arm type, ensure lifting
pads are correctly positioned at the four jacking points
before lifting.
Workshop Jack
To avoid any danger of bodywork damage when using a
hydraulic jack, the vehicle must only be lifted at the jacking
points.
Stands
When carrying out work (other than a wheel change) which
requires a wheel to be raised, a stand must be used, located
at the jacking point, to provide a secure support for the
vehicle.
00-00-001

Vehicle Recovery
0-0-10 Workshop Manual Issue 5, January 2010
Vehicle Recovery
General
Preferred method of vehicle recovery is by flat bed
transporter.
The towing eye is primarily for emergency use when towing
for short distances, e.g. removing vehicle if it is causing an
obstruction or winching vehicl e onto a flatbed transporter.
If moving this vehicle in such a situation, install the towing
eye to the bracket in the lower grille aperture.
Transporting
If vehicle is to be transported on a trailer or flat bed
transporter the handbrake must be applied and the road
wheels must be chocked.
Suspended Towing
Take care when using 'spectacle frame' type towing
equipment that the towing device is well clear of front or
rear apron. Body damage may occur if vehicle passes over
uneven road surfaces.
Front Suspended Tow
1. Remove the ignition key from the ignition.
2. Raise the vehicle using a ‘spectacle frame’ type lifting device with a cradle positioned under each front wheel
as indicated below.
Rear Suspended Tow
1. Set the steering in the ‘straight ahead’ position.
Remove the ignition key from the ignition. Ensure the
steering is locked in the straight ahead position.
2. Raise the vehicle using a 'spectacle frame' style lifting device where a cradle is positioned under each rear
wheel as indicated below.
Adhere to Towing Regulations
In certain countries the regi stration number of towing
vehicle and an ‘ON TOW’ sign or warning triangle must be
displayed in a prominent position at the rear of vehicle being
towed.
To w i n g b y A n o t h e r V e h i c l e
This vehicle may be towed short distances by another
vehicle provided that a speed of 48 km/h (30 mph) is not
exceeded. Ensure the towed vehicle gear selection is in
‘Neutral’ with ignition key turned to position ‘II’ to release
steering lock and to render hor n, indicators and brake lights
operational.
Caution
Take care to protect the paint work when installing the towing eye. Ensure the towing eye is tight.
Caution
Do not tow with ‘sling’ type equipment as this
could result in damage to the bodywork.
WAR NI NG
WHEN THE ENGINE IS NOT RUNNING, THE STEERING WILL NO LONGER BE POWER-ASSISTED AND THE
BRAKE BOOSTER WILL BECOME INEFFECTIVE AFTER A FEW APPLICATIONS OF TH E BRAKES. BE PREPARED
FOR RELATIVELY HEAVY STEERING AND THE NEED
FOR GREATLY INCREASED BRAKE PEDAL PRESSURE.

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

Issue 5, January 2010 Workshop Manual 1-1-3
- Renew ............................................................. 12-33
RH Front Main Hydraulic Cylinder Pipe
- Renew ............................................................. 12-37
RH Rear Main Hydraulic Cylinder Pipe
- Renew ............................................................. 12-40
LH Front Hydraulic Cylinder Pipe - Renew........ 12-43
LH Rear Hydraulic Cylinder Pipe - Renew.......... 12-46
RH Front Hydraulic Cylinder Pipe - Renew ........ 12-50
RH Rear Hydraulic Cylinder Pipe - Renew ......... 12-53
RH/LH Rear Hydraulic Tonneau Cylinder Pipe
- Renew ............................................................. 12-56
LH/RH Front Hydraulic Tonneau Cylinder Pipe
- Renew ............................................................. 12-60
Hydraulic Cylinder Valve to Pump Pipe
- Renew ............................................................. 12-63
Wind Deflector - Renew .................................... 12-66
Tonneau Well Liner - Renew . ............................ 12-67
RH/LH Flex Shaft - Renew ................................. 12-69
Bumpers (01.19) .................................................. 1-13-1 Front Bumper ....................................................... 13-1
Rear Bumper......................................................... 13-1
Specifications........................................................ 13-2
Maintenance ......................................................... 13-2Front Bumper Cover - Renew .............................. 13-2
Rear Bumper Cover - Renew................................ 13-3
Restraining Devices (01.20)................................. 1-14-1 Seat Belts .............................................................. 14-1Emergency Locking Retractor (ELR) ...................... 14-2
Airbag System ....................................................... 14-3
Maintenance ......................................................... 14-4 Driver’s Airbag Module - Renew .......................... 14-4
LH Front Seat Belt - Renew .................................. 14-4
RH Front Seat Belt - Renew.................................. 14-5
Passenger Airbag - Renew .................................... 14-6
ARS Side Impact Sensor Assembly - B Pillar
- Renew ............................................................... 14-6
Side Impact Door ARS Sensor Assembly
- Renew ............................................................... 14-6
Front Impact Sensor Assembly - Renew ................ 14-7
Occupant Restraint Control Module Assembly
- Renew ............................................................... 14-7
RH/LH Roll Over Protection System - Renew ....... 14-8

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)

Front End (01.02)
Body System (01.00)1-2-2 Workshop Manual Issue 5, January 2010
Front Undertray-Remove and Install
Removal
1. Use the applicable equipment to lift the vehicle and make it safe.
2. Remove the 14 Torx screws that attach the front undertray to the body.
3. Remove the front undertray.
Install
1. Put the front undertray in position.
2. Install and torque tighen the 14 Torx screws trhat attach the front undertray to the vehicle.
3. Lower the vehicle.
Rear Undertray - Renew (Coupe only)
Removal
1. Raise the vehicle and make it safe.
2. Remove the 10 screws that attach the rear undertray to
the body.
S-01-02-PB-01
3. Remove rear undertray.
S-01-02-PB-02
Installation
1. Put the rear undertray in posiiton.
2. Install and tighten the 10 screws that attach the rear undertray to the vehicle.
S-01-02-PB-01
3. Lower the vehicle.
Rear Undertray - Renew (Roadster only)
Removal
1. Use the applicable equipment to lift the vehicle and make it safe.
2. Remove the 18 of the 21 screws that attach the rear undertray to the body.
3. Lower the vehicle wheels onto blocks to get access to the remaining screws that attach the rear undertray to
the body. 4. Remove the remaining three screws that attach the rear
undertray to the body.
5. Remove the rear undertray.
Install
1. Put the rear undertray in position.
2. Install and tighten the 21 scrwes that attach the rear undertray to the body.
3. Lift the vehicle.
4. Remove the blocks.
5. Lower the vehicle.
Undertray, Vehicle Set - Renew
Removal
1. Raise vehicle on ramp.
2. Remove front undertray (see Workshop Manual 01.02.NB - Front undertray - Renew).
3. Remove rear undertray (see Workshop Manual 01.02.PB - Rear undertray - Renew).
4. Remove centre undertray (see Workshop Manual 01.02.MB - Centre undertray - Renew).
Installation
1. With assistance, install centre undertray (see Workshop Manual 01.02.MB - Centre undertray - Renew).
2. With assistance, install front undertray (see Workshop Manual 01.02.NB - Front undertray - Renew).
3. With assistance, install rear undertray (see Workshop Manual 01.02.PB - Rear undertray - Renew).
4. Lower vehicle on ramp.
RH/LH Front Wheel Ar ch Liner - Renew
Removal
1. Remove centre undertray, Roadster only (see Workshop
Manual procedure 01.02.MB Undertray - Centre -
Renew).
2. Raise vehicle on ramp.
3. Remove road wheel(s).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
WARNING
THE REAR UNDERTRAY IS HEAVY. GET THE HELP OF ANOTHER PERSON WHEN YOU MOVE THE REAR
UNDERTRAY. IF YOU DO NOT YOU CAN BE INJURED.
Repair Operation Time (ROT)
ItemCode
Undertray Vehicle Set-Renew 01.02.PD
Repair Operation Time (ROT)
ItemCode
Wheel Arch Liner-Renew RH01.02.GB
Wheel Arch Liner-Renew LH01.02.FB

Body Closures (01.03)
Body System (01.00)1-3-4 Workshop Manual May 2007
19. Remove nuts (x4) and Torx screws (x3) securing door glass regulator to door frame (see Figure 6).
20. Carefully remove regulator mechanism through the larger door frame aperture.
21. Remove door mirror rubber cheater (see Figure 7).
22. Disconnect door mirror mult iplug, release harness fir
tree clips (x2) and self adhe sive clip (see Figure 8). 23. Remove Torx Bolts (x3) and screw from door glass
channel. Remove door mirror assembly.
24. Remove aperture seal from inner door frame.
25. Remove fir tree trim pins (x3), release/remove rear
weatherstrip from door frame/glass channel.
26. Disconnect door latch multiplug.
27. Release inner and outer cable from external door handle (see Figure 9).
28. Remove nuts (x3) securi ng external door handle,
remove door handle (see Figure 10).
29. Loosen upper nut, remove lower nut securing keylock mechanism to door frame.
Figure 6
Figure 7
Figure 8
A011139A
A0108144
A0108143
Figure 9
Figure 10
A0114138A
A0114138

Body Closures (01.03)
Body System (01.00)
May 2007 Workshop Manual 1-3-5
30. Remove Torx screws (x3) securing latch assembly to
door frame (see Figure 11).
31. Manoeuvre internal latch handle cable through inner door skin into door aperture.
32. Carefully remove latch and keylock mechanisms through door aperture.
33. Remove Torx screws (x4) securing trimboard support
brackets to door frame, remove brackets.
34. Drill out pop rivets (x2) securing rear trimboard support bracket, remove bracket.
35. Release door harness from inner door casing clips (x10) (see Figure 12). 36. Release door harness from outer door casing clips (x8)
(see Figure 13).
37. Release harness grommets (x2) from door casing.
38. Manoeuvre and remove ha rness from door casing.
39. With assistance, remove door from trolley (501 - F111).
40. Remove bolts (x2) securing hinges to door, remove
hinges (x2). Note fitted posi tions of shims (if fitted).
Installation
1. Carry out preliminary hinge setup.
2. Install hinges and shims (if fitted) on door, install bolts
(x2). Do not torque tighten at this stage.
3. With assistance, install door on vehicle.
4. Place a weight of 16 kg (to compensate weight of door fixings) hanging from inner door skin as illustrated.
5. Gently close door and check for an acceptable initial installation.
6. Align the door, manoeuvre the door to achieve correct gaps and flush fit (add / remove shims as required).
Open door, tighten bolts. Do not torque tighten bolts at
this stage.
7. Close door, re-check fitment and alignment.
8. Open door, torque tighten hinge bolts. Remove the door weight.
9. With assistance, remove door and install on door trolley
(501 - F111).
10. Manoeuvre and install harness in door, install grommets (x2).
11. Secure harness in door casing with clips (x18).
12. Position rear trimboard support bracket, secure with pop rivets (x2).
13. Position trimboard support brackets (x2), install and
tighten Torx screws (x4).
14. Install latch and keylock mechanisms in door.
15. Manoeuvre internal latch handle cable into position
16. Install and torque tighten latch Torx screws (x3).
17. Position keylock mechanism to door frame, install lower nut, torque tighten nuts (x2).
18. Install external door handle, install and torque tighten nuts (x3).
Figure 11
Figure 12
A0114142
A1801141
Figure 13
A011139B