Aston Martin DB9 Manuals

Aston Martin DB9 Manuals

Manuals and User Guides for Aston Martin DB9. We have 1 Aston Martin DB9 manual available for free PDF download: Workshop Manual

Aston Martin DB9 Workshop Manual

Aston Martin DB9 Workshop Manual (600 pages)

Brand: Aston Martin | Category: Automobile Accessories | Size: 53 MB

Table of Contents

Db9 Workshop Manual

3
- Table of Contents
  3
- Special Tools
  6
- Repairs and Replacements
  6
- Warnings, Cautions and Notes
  6
- Location References
  6
- Introduction
  6
- Numbering
  6
- Welcome
  6
- Chapter Navigation
  6
- Chapters
  6
- Air Conditioning (A/C) System
  7
- Safety Precautions
  7
- Battery Disconnection
  7
- Exhaust Fumes
  8
- Chemical Handling and Storage
  8
- Electrical Equipment
  8
- Fire Precautions
  9
- Tools and Equipment
  9
- Used Engine Oil
  9
- Health Protection Precautions
  9
- Environmental Protection
  9
- Lifting and Jacking
  10
- Safety
  10
- Jacking Points
  10
- Stands
  10
- Workshop Hoist
  10
- Towing an Automatic Vehicle
  11
- Push-Start
  11
- Towing by Another Vehicle
  11
- Towing Regulations
  11
- Front Suspended Tow
  11
- General
  11
- Vehicle Recovery
  11
- Rear Suspended Tow
  11
- Suspended Towing
  11
- Transporting
  11
- Vehicle Identification Number
  12
- Identification Numbers
  12
- Vehicle Identification Number (VIN)
  12
- VIN Number Location
  12
- Manual Gearbox
  13
- Automatic Gearbox
  13
- Gearbox Number
  13
- Engine Number
  13
Body System (01.00)

15
- Body Structure (01.01)
  17
- Overview
  19
- Front End (01.02)
  21
- Front Wing
  21
- Front Wings
  21
- Maintenance
  21
- Specifications
  21
- Body Closures (01.03)
  25
- Bonnet
  25
- Boot Lid
  25
- Doors
  25
- Specifications
  25
- Doors
  26
- Installation
  26
- Maintenance
  26
- Removal
  26
- New Door Assembly
  27
- Preliminary Hinge Setup
  27
- Boot Lid
  28
- Installation
  28
- Removal
  28
- Bonnet
  29
- Installation / Realignment
  29
- Removal
  29
- Installation Notes
  31
- Interior Trim (01.05)
  31
- IP Trim
  31
- Maintenance
  31
- Remove
  31
- Specifications
  31
- Installation
  32
- Removal
  32
- Roof Trim
  32
- Door Trim
  33
- Removal
  33
- Installation
  34
- Rear Trim
  35
- Removal (Coupe)
  35
- Install (Coupe)
  36
- Install (Volante)
  36
- Removal (Volante)
  36
- Boot Trim
  37
- Installation
  37
- Removal
  37
- Exterior Trim (01.08)
  39
- Installation
  39
- Maintenance
  39
- Removal
  39
- Side Trim
  39
- Installation
  40
- Remove
  40
- Sill Trim
  40
- Door Mirrors
  43
- Installation
  43
- Maintenance
  43
- Mirrors (01.09)
  43
- Removal
  43
- Specifications
  43
- Description
  45
- Front Seat - Remove and Install
  45
- Heated Seats
  45
- Maintenance
  45
- Remove
  45
- Seat Module
  45
- Seating (01.10)
  45
- Specifications
  45
- Front Seat Squab Cover Assembly (Each, from 08MY) - Remove and Install
  46
- Install
  46
- Remove
  46
- Seat Base Control Motors
  46
- Seat Module
  46
- Installation (Coupe)
  47
- Removal (Coupe)
  47
- Seat Module Calibration
  47
- Install
  48
- Installation (Volante)
  48
- Lumbar Pump for the Front Seat (from 08MY) - Remove and Install
  48
- Lumbar Valve for the Front Seat (from 08MY) - Remove and Install
  48
- Removal (Volante)
  48
- Remove
  48
- Install
  49
- Lumbar Bladder for the Front Seat (from 08MY) - Remove and Install
  49
- Remove
  49
- Description
  51
- Frameless Doors
  51
- Glass Regulator
  51
- Glass, Frame and Mechanism (01.11)
  51
- Maintenance
  51
- Removal
  51
- Specifications
  51
- Installation
  52
- Door Glass
  53
- Removal
  53
- Installation
  54
- Door Glass Setup
  56
- Installation
  57
- Rear Quarter Glass (Coupe)
  57
- Rear Quarter Glass (Volante)
  57
- Remove
  57
- Installation
  59
- Instrument Panel (IP) (01.12)
  61
- Maintenance
  61
- Removal
  61
- Specifications
  61
- Installation
  63
- Remove
  65
- Veneer Bezel for the Instrument Panel (IP) - Remove and Install
  65
- Centre Console Panel - Remove and Install
  75
- Install
  75
- Boot Emergency Release
  81
- Central Locking System
  81
- Description
  81
- Fuel Filler Assembly
  81
- Handles and Lock Mechanisms (01.14)
  81
- Manual Boot Release
  81
- Remote Transmitter
  81
- Vehicle Key/Remote Transmitter
  81
- Door Handle / Latch Unit
  82
- Maintenance
  82
- Removal
  82
- Specifications
  82
- Installation
  83
- Wipers and Washer System (01.16)
  85
- Driver's Side Wiper Blade - Remove and Install (12MY Onward)
  86
- Headlamp Washing
  86
- Maintenance
  86
- Remove
  86
- Install
  87
- Passenger's Side Wiper Blade - Remove and Install
  87
- Remove
  87
- Install
  88
- Remove
  88
- Windscreen Reservoir and Motor Assembly - Remove and Install (12MY Onward)
  88
- Headlamp Wash Motor and Pump Assembly - Remove and Install
  89
- Install
  89
- Low Level Water Sensor - Remove and Install
  89
- Removal
  89
- Remove
  89
- Install
  90
- Removal
  90
- Windscreen Wiper Motor
  90
- Installation
  91
- Removal
  92
- Wiper Arms
  92
- Installation
  93
- Convertible Roof (01.17)
  95
- Description
  95
- Specifications
  95
- Installation
  96
- Maintenance
  96
- Removal
  96
- Roof
  96
- Removal
  97
- Roof Material
  97
- Installation
  98
- Installation
  102
- Removal
  102
- Roof Pump
  102
- Weather Seals
  102
- Installation
  104
- Installation
  105
- Removal
  105
- Roof Lid Hydraulic Rams
  105
- Roof Module
  105
- Bumpers (01.19)
  107
- Front Bumper
  107
- Maintenance
  107
- Removal
  107
- Specifications
  107
- Installation
  108
- Maintenance
  109
- Rear Bumper
  109
- Removal
  109
- Specifications
  109
- Installation
  111
- Pre-Tensioner and Load Limiting Systems
  113
- Restraining Devices (01.20)
  113
- Seat Belts
  113
- Automatic Locking Retractor (ALR)
  114
- Emergency Locking Retractor (ELR)
  114
- Specifications
  114
- Airbag Deployment
  115
- Airbag System
  115
- Clockspring
  115
- Driver Airbag Module
  115
- Dual Inflation Technology
  115
- Passenger Airbag Module
  115
- Side Airbag Module
  115
- Driver Airbag
  116
- Impact Sensors
  116
- Maintenance
  116
- Passenger Airbag
  116
- Restrains Control Module (RCM)
  116
- Specifications
  116
- Side Impact Airbag
  117
- Deployable Rollbars
  118
- Maintenance
  118
- Rollbar Unit
  118
- Specifications
  118
- Rollbar Sensor
  120
Frame and Mounting (02.00)

121
- Front Subframe
  122
- Maintenance
  122
- Removal
  122
- Specifications
  122
- Subframes (02.01)
  122
- Subframes (02.03)
  122
- Installation
  123
- Rear Subframe
  124
- Removal
  124
- Installation
  128
Engine System (03.00)

131
- Description
  133
- Engine Assembly (03.00)
  133
- Engine
  134
- Maintenance
  134
- Removal
  138
- Engine Structure (03.01)
  145
- Inlet / Exhaust Manifolds
  146
- Cylinder Head
  147
- Maintenance
  147
- Lubrication System (03.02)
  159
- Oil Flow
  159
- Engine Oil Specification
  160
- Oil Drain
  160
- Oil Filter
  160
- Coolant Circuit
  165
- Cooling System (03.03)
  165
- Description
  165
- Coolant Reservoir
  166
- Cooling Fans
  166
- Engine Oil Cooler
  166
- In-Vehicle Heating
  166
- Radiator
  166
- Specifications
  166
- Thermostat
  166
- Water Pump
  166
- Coolant Drain / Fill
  167
- Cooling System
  167
- Maintenance
  167
- Pressure Cap
  167
- Pressure Tests
  167
- Radiator
  168
- Fuel Charging System (03.04)
  171
- Safety Precautions
  171
- Fuel Rails
  172
- Maintenance
  172
- Accessory Drive System (03.05)
  175
- Automatic Belt Tensioner
  175
- Drive Belt
  175
- Maintenance
  175
- Engine Cranking System (03.06)
  177
- Maintenance
  177
- Specifications
  177
- Starter Motor
  177
- Starting System
  177
- Description
  179
- Ignition System (03.07)
  179
- Specifications
  179
- Maintenance
  180
- Spark Plugs
  180
- Emission Control (03.08)
  181
- System Description
  181
- Valve Train (03.09)
  183
- Engine Sealing (03.10)
  189
- Power Conversion (03.11)
  197
- Air Charging (03.12)
  207
- Evaporative Emissions (03.13)
  211
- Engine Management System (03.14)
  213
- Throttle Control (03.16)
  219
Suspension (04.00)

221
- Maintenance
  222
- Road Wheel Alignment (04.00)
  222
- Specifications
  222
- Suspension (04.00)
  222
- Adjustment
  223
- Adjustment (Rear)
  223
- Camber Angle
  223
- Toe
  223
- Front Suspension (04.01)
  225
- Suspension Arms
  225
- Vertical Link
  225
- Symptoms
  226
- Maintenance
  227
- Ball Joints
  228
- Front Suspension
  228
- Inspection
  228
- Removal
  228
- Installation
  230
- Anti-Roll Bar
  232
- Installation
  232
- Removal
  232
- Installation
  233
- Removal
  233
- Vertical Link
  233
- Anti-Roll Bar
  235
- Description
  235
- Rear Suspension (04.02)
  235
- Suspension Arms
  235
- Vertical Link
  235
- Description
  243
- Installation
  243
- Removal
  243
- Shock Absorber System (04.03)
  243
- Specifications
  243
- Installation
  245
- Removal
  245
- Road Wheels and Tyres (04.04)
  247
- Maintenance
  248
- Safety
  248
- Temperature
  248
- Tread Wear
  248
- USA Tyre Gradings
  248
- Inspection and Verification
  249
- Tyre Replacement and Wheel Interchanging
  249
- Tyre Wear
  249
- Tyre Wear Diagnosis
  249
- Visual Inspection Chart
  249
- Winter (Snow) Tyres
  249
- Road Test
  250
- Symptoms
  251
- Tyre Damage
  251
- Care of Alloy Road Wheels
  252
- Repairs
  252
- Road Wheel Alignment
  252
- Alignment Precautions
  253
- Dynamic Balance
  253
- Misalignment Effects
  253
- Road Wheel and Tyre Balance
  253
- Static Balance
  253
- Pressure Sensing with Winter Wheels and Tyres
  254
- Tyre Pressure Sensing (Option)
  254
- Warnings
  254
- Connection and Normal Operation
  255
- Display Panel
  255
- Display Unit
  255
- Level 1 Programming
  255
- System Programming
  255
- Level 2 Programming
  257
- Level 3 Programming
  257
- Driveline (05.00)
  259
- Driveshaft (05.01)
  260
- Halfshafts (05.05)
  265
Brake System (06.00)

267
- Description
  269
- Front Disc Brake (06.03)
  269
- Installation
  270
- Maintenance
  270
- Removal
  270
- Brake Discs (Front and Rear)
  272
- Installation
  272
- Removal
  272
- Brake Pads (Front and Rear)
  273
- Installation
  273
- Removal
  273
- Brake Pad 'Bedding-In
  274
- Procedure
  274
- Description
  275
- Rear Disc Brakes (06.04)
  275
- Brake Discs
  276
- Brake Pads
  276
- Maintenance
  276
- Specifications
  276
- Description
  277
- Hand Brake (06.05)
  277
- Install
  278
- Maintenance
  278
- Remove
  278
- Specifications
  278
- Brake Pads
  279
- Install
  279
- Remove
  279
- Handbrake Cable
  280
- Remove
  280
- Adjustment
  281
- Install
  281
- Brake Actuation System (06.06)
  283
- Brake Fluid Reservoir
  283
- Description
  283
- Specifications
  283
- Tandem Master Cylinder
  283
- Installation
  284
- Maintenance
  284
- Removal
  284
- Brake Fluid Reservoir
  285
- Removal
  285
- Brake Bleeding - AMDS
  286
- Install
  286
- Brake Bleed - Manual
  287
- Preparation
  287
- Procedure
  287
- Brake Booster
  289
- Panic Brake Assist
  289
- Power Brake System (06.07)
  289
- Power Brake System (06.09)
  289
- Installation
  290
- Maintenance
  290
- Removal
  290
- Specifications
  290
- Concept
  291
- Functional Description
  292
- Operation Summary
  292
- System Overview
  292
- Traction Control
  292
- ABS / DSC Circuit
  293
- Brake Intervention
  293
- Engine Intervention
  293
- Specifications
  293
- Maintenance
  294
- Remove
  294
- Install
  295
Transmission (07.00)

297
- Automatic Transaxle (07.01)
  298
- Automatic Transmission (07.01)
  298
- Cooling
  298
- Description
  298
- Mechatronik Module
  298
- Transmission (07.00)
  298
- Gearbox
  299
- Specifications
  299
- Differential
  300
- Differential Oil Check / Fill
  300
- Maintenance
  300
- Transmission Oil Check / Fill
  300
- Automatic Transaxle
  301
- Remove
  301
- Install
  302
- Mechatronik Unit
  302
- Remove
  302
- Install
  303
- Differential
  305
- Install
  305
- Remove
  305
- Remove
  306
- Differential Output Seal (Right)
  307
- Install
  307
- Remove
  307
- Differential Oil Filter
  310
- Differential Speed Sensor
  310
- Install
  310
- Remove
  310
- Maintenance
  311
- Oil Cooler (Automatic Gearbox)
  311
- Remove
  311
- Specifications
  311
- Transmission Cooling (07.02)
  311
- Install
  312
- Remove
  312
- Thermostat (Automatic Gearbox)
  312
- Install
  313
- Oil Cooler (Automatic Transaxle Differential)
  313
- Remove
  313
- Install
  314
- Oil Cooler (Manual Transaxle)
  314
- Remove
  314
- Cooling
  315
- Description
  315
- Manual Transmission (07.03)
  315
- Drain / Fill
  316
- Maintenance
  316
- Specifications
  316
- Transaxle
  317
- Install
  318
- Differential Output Seal (Left Side)
  319
- Remove
  319
- Install
  320
- Differential Output Seal (Left Side)
  321
- Remove
  321
- Differential (Limited Slip)
  322
- Install
  322
- Remove
  322
- Install
  323
- Automatic Control System (07.05)
  325
- Description
  325
- Gearshift Procedures
  325
- Transmission Controls
  325
- Parking Lock
  326
- Hydraulic Shift Control Unit
  327
- TCM Monitoring Functions
  329
- Shift-By-Wire
  332
- TCM Supply Voltage
  332
- Install
  334
- Maintenance
  334
- Remove
  334
- Touchtronic Paddleshift Selector - Remove and Install
  334
- Transmission Plug Pin Assignment
  334
- Clutch (08.00)
  335
Exhaust (09.00)

339
- Exhaust Overview
  340
- Silencer Assembly (09.01)
  341
- Variable Flow Silencer Assembly
  341
- Exhaust System
  343
- Pipes and Supports (09.03)
  343
- Removal
  343
- Specifications
  343
- Installation
  344
Fuel (10.00)

345
- Description
  346
- Fuel Tank and Lines (10.01)
  346
- Fuel Tank
  347
- Fuel Pumps
  348
- Jet Pumps
  348
- Filler Neck and Check Valve
  349
- Valves and Sensors
  349
- Evaporative Loss System
  350
- Fuel System Schematic
  350
- System Operation
  350
- Safety Precautions
  352
- Specifications
  352
- Fuel Filter Assembly - Remove and Install
  353
- Maintenance
  353
- Pressure Test the Fuel System
  353
- Fuel Tank - Remove and Install
  355
- Fuel Pump - Remove and Install
  358
- Carbon Cannister Assembly - Remove and Install
  360
- Hose Assembly, Fuel Vapour - Remove and Install
  360
- Remove and Install
  361
- Sender Assembly for the Fuel Tank
  361
- Fuel Level Vent-Valve Assembly
  362
- Remove and Install
  362
- Left-Side - Remove and Install
  363
- Roll over Valve Assembly, Fuel Vapour
  363
Steering (11.00)

365
- Diagnostics
  366
- Steering Gear (11.01)
  366
- Symptom Chart
  366
- Ball Joint Inspection
  368
- Maintenance
  368
- Specifications
  368
- Wheel Bearing Inspection
  368
- Track-Rod Ends
  369
- Steering Rack
  370
- Description
  373
- Power Steering (11.02)
  373
- Maintenance
  374
- Specifications
  374
- Description
  375
- Maintenance
  375
- Specifications
  375
- Steering Column (11.04)
  375
- Maintenance
  381
- Steering Column Switches (11.05)
  381
- Column Controls
  382
- Maintenance
  387
- Specifications
  387
- Steering Wheel (11.06)
  387
Climate Control (12.00)

389
- Body Ventilation (12.01)
  390
- Body Ventilation System (12.01)
  390
- Inspection
  391
- Install
  391
- Maintenance
  391
- Airflow Mode Actuator
  392
- Inspection
  392
- Rhd
  392
- Blower Motor
  393
- Heater System (12.02)
  393
- Inspection
  393
- Maintenance
  393
- Air Conditioning (A/C) System (12.03)
  395
- Compressor
  395
- Condenser
  395
- Major Components
  395
- Receiver Drier
  395
- Trinary Switch
  395
- A/C Unit
  396
- Expansion Valve
  396
- Handling Compressor Oil
  397
- Handling Insufficient Refrigerant Level
  397
- Handling Refrigerant
  397
- Refrigerant System
  397
- Refrigeration Cycle
  397
- Storing Refrigerant
  397
- Capacities
  398
- Operation
  398
- Refrigerant and Lubricant
  398
- Specifications
  398
- Torque Figures
  398
- Diagnostics
  399
- Electrical Connectors
  399
- DTC Fault Codes
  400
- DTC Inspection
  400
- Using WDS
  400
- Charging
  402
- Connections
  402
- Evacuation
  402
- Maintenance
  402
- Recovery
  402
- A/C System Testing
  403
- Performance Test
  403
- Pressure Check
  403
- Vacuum Check
  403
- Leak Detection
  404
- Leaks
  404
- System Pressure Fault Classification
  404
- A/C Unit
  405
- Heater Matrix
  406
- Remove
  406
- Evaporator
  408
- A/C Compressor
  409
- Condenser
  411
- Inspection
  412
- Power Transistor
  412
- Receiver Drier Assembly
  412
- Evaporator Temperature Sensor
  413
- Inspection
  413
- Expansion Valve
  414
- Trinary Switch
  414
- Troubleshooting
  416
Information, Gauge and Warning (13.00)

419
- Driver Information Module (DIM) (13.01)
  420
- Instrument Cluster (13.01)
  420
- Information and Warning Lamps
  421
- DIM Display Layout
  422
- Gear Position Indicator Display (GPID)
  422
- Message Centre Left
  422
- Message Centre Right
  422
- Driver Information Module (DIM)
  423
- Maintenance
  423
- Removal
  423
- Installation
  424
Power Supply (14.00)

425
- Battery Connect Switch
  426
- Battery Disconnection and Alarm Activation
  426
- Battery System (14.01)
  426
- Power Supply (14.00)
  426
- +12 Volt Distribution
  427
- Charging Circuit
  427
- Battery
  429
- Maintenance
  429
- Specifications
  429
- Alternator
  431
- Alternator and Regulator System (14.02)
  431
- Description
  431
- Maintenance
  431
- Specifications
  431
- Installation
  432
- Audio System
  434
- Vehicle Entertainment (15.00)
  434
- Vacuum Distribution (16.00)
  436
Lighting (17.00)

437
- Front Lights (17.01)
  438
- Headlamp Unit
  438
- Lighting (17.00)
  438
- Maintenance
  438
- Specifications
  438
- Continental Conversion
  439
- Headlight Alignment
  439
- Bulb Renewal
  440
- Side Marker Unit
  442
- Side Marker Unit Bulb
  442
- Side Repeater Lamp Unit - Remove and Install and Replace Bulb
  442
- Interior Light Bulb
  445
- Interior Lighting (17.02)
  445
- Maintenance
  445
- Specifications
  445
- Light Cluster
  447
- Maintenance
  447
- Rear Lights (17.03)
  447
- Side Marker Units
  447
- Specifications
  447
- Front Level Sensor
  449
- Headlamp Levelling
  449
- Lighting Mechanisms (17.04)
  449
- Maintenance
  449
- Rear Level Sensor
  450
Electric Distribution/Electronic Control (18.00)

451
- Engine Bay Fuse / Relay Box
  452
- Fuse Listings
  452
- Wiring and Circuit Protection (18.01)
  452
- How to Read the Circuits
  454
- Stand Alone Fuses
  454
- Wires
  454
- Controller Area Network (CAN)
  455
- High Speed CAN Wire
  455
- Low Speed CAN Wire
  455
- Twisted Wires
  455
- Connectors
  456
- Splice Origin Page
  457
- Splices
  457
- Tracing Spliced Wires
  457
- Busbars
  458
- Fuses
  458
- Relays
  458
- Motors and Pumps
  459
- Normally Open Switch
  459
- Position Switch
  459
- Pump
  459
- Resistors
  459
- Switches
  459
- Diodes
  460
- Earth / Ground
  460
- Field Effect Transistor (FET)
  460
- Light Emitting Diode (LED)
  460
- Motor
  460
- Transistor
  460
- Fuel Tank Harness - Remove and Install
  467
- Install
  467
- Maintenance
  467
- Circuit Diagrams
  468
- Vehicle Control System (18.08)
  559
Electronic Features (19.00)

565
- Active Anti-Theft System (19.01)
  566
- Component Descriptions
  566
- Alarm Cycle
  567
- Door Open
  567
- Functional Description
  567
- General Setting
  567
- Overview - Alarm
  567
- Panic Alarm
  567
- Arming IPATS
  568
- Disarming IPATS
  568
- Ipats Led
  568
- Remote Transmitter
  568
- Alarm Siren Assembly - Remove and Install
  569
- Key Programming
  569
- Pats Tranceiver ECU (Pre-08 MY Only) - Remove
  569
- Mechanism for the Navigation Display Screen
  571
- Navigation (19.07)
  571
- Navigation Display Screen - Remove and Install
  576
Appendix & Glossary

581
- Diagnostic Ports
  582
- Fluids / Capacities
  582
- Fluids/Capacities
  582
- Special Tools - Pictorial Index
  583
- Terms
  583
- Front Mounts
  588
- Powertrain Trolleys (43-27981)
  588
- Specialist Tool Operation
  588
- Powertrain Trolleys Brace Bars
  589
- Rear Mounts
  589
- Ball Joint Splitter (43-26738)
  590
- Brake Hose Check (43-27822)
  590
- Front Brake Caliper
  590
- Vertical Link
  590
- Crankshaft Rear Oil Seal Remove (43-27831)
  591
- Crankshaft Rear Oil Seal Installer (43-27411)
  592
- Torque Figures
  594
- Torque Conversion Tables
  595

Advertisement

Advertisement

Related Products

Aston Martin Categories

Automobile Automobile Accessories Speakers

More Aston Martin Manuals