Aston Martin - DBS - Workshop Manual - 2015 - 2015

SB-10057897-7675 SB-19-0392V2 SERVICE BULLETIN To: For the attention of: Please copy to: All Dealers After Sales Manager Executive Manager Service Manager Sales Manager Warranty Technician(s) Parts Model: Vanquish, Rapide, DB9, DBS and Virage (Automatic Transmission only). VIN Range: All Subject: Ground Cable Modification for the Automatic Transmission Reference SB-19-0392V2 Issued: 02 March 2015 Page 1 of 43 Reason for Version 2 of this Service Bulletin (SB-19-0392) Version 2 of this Service Bulletin has been issued because we found the connectors in step 72 had the incorrect connector number. Some text errors have also been corrected. Amendments to this document have a black line against them in the left-side margin. Please destroy all copies of SB-19-0392 that you have and replace them with this Service Action SB-19-0392V2. Reason for this Service Bulletin If a Customer has one of the vehicles that follow with the 6-speed automatic transmission:  DB9 (all)  DBS  Virage  Rapide (including ‘S’)  Vanquish 13MY onwards, And the Customer complains that one of the problems that follow has occurred on their vehicle:  Warning Message “GEARBOX FAULT SERVICE REQUIRED”  Cannot easily select gears when parked or driving, by use of the PRND switches  The transmission changes to a different gear or neutral when the PRND switches are used to select a gear  Unexpected gear change when the switches or paddles have not been operated, Do the steps that follow: 1. Connect the AMDS to the vehicle. 2. Do a check for fault codes. 3. If you find a condition that follows:  There is only a P1712 code logged,  There are no codes logged,  The problem only occurs when the paddles are used for gear selection, Do the usual diagnostic procedures to find the fault. Note: In these conditions, you do not need to do the workshop procedure that follows. March 2015 Page 1 of 43 Service Bulletin 4. SB-19-0392V2 If you find one or more of the the codes that follow:  P0705, P2805, P1921, P1797 or P0863. and it is known or proven that the fault codes have not been caused by an incomplete or edge-push of a PRND switch, do the test that follows in “PRND Voltage Measurement”. PRND Voltage Measurement 5. Set the AMDS datalogger to monitor the signal voltages on PRND1 and PRND2. 6. Set the ignition to On. 7. Refer to Table 1. Push and release each PRND button and look at the AMDS to make sure that there is the correct change in the PRND signal values. If the voltage is 0.02 volts or more higher than the value shown in Table 1, do the Workshop Procedure that follows below. This procedure will install a new ground wire connection from the right Powertrain Control Module (PCM) to the Centre Console Module (CCM). Table 1 Note: Button PRND1 Ground PRND2 Ground Park (P) 0.45V 2.26V Neutral (N) 1.08V 2.26V Drive (D 1.74V 2.26V Reverse 2.16V 2.26V None 2.62V 3.71V Refer to Parts Data for the kit of parts that is available to do this modification. Workshop Procedure Part A – Remove the Powertrain Control Module (PCM) All Models: 1. Do the battery disconnect procedure (refer to Workshop Manual procedure 14.01.CA). 2. Do a check of the harness ground points (refer to Service Bulletin SB-18-0385). 3. Examine the bulkhead ground stud and eyelet assembly. 4. Undo and remove the ground eyelet attachment nut. Make sure that there is no insulation material near or around the ground stud or ground eyelets. 5. Install a new attachment nut for the ground eyelet. 6. Remove the front right side wheel arch liner (refer to Workshop Manual procedure 01.02.GB). March 2015 Page 2 of 43 Service Bulletin 7. SB-19-0392V2 Release the bases of the three fir-tree cable ties that attach the Powertrain Control Module (PCM) harness to the PCM bottom bracket (refer to Figure 1). Do not cut the cable ties. Figure 1 8. Release the base of the fir-tree cable tie that attaches the forward harness to the PCM bottom bracket (refer to Figure 2). Do not cut the cable tie. Figure 2 9. Release the electrical connector for the side repeater, from the clip that attaches it to the PCM bracket (refer to Figure 3). Figure 3 March 2015 Page 3 of 43 Service Bulletin 10. SB-19-0392V2 Disconnect the electrical connector from the indicator side repeater (refer to Figure 4). Figure 4 11. Release the forward harness from the fir-tree clip that attaches it to the body (refer to Figure 5). Figure 5 12. Remove the three bolts that attach the PCM bottom bracket and PCM to the PCM top bracket (refer to Figure 6). Figure 6 March 2015 Page 4 of 43 Service Bulletin 13. SB-19-0392V2 Remove the bolt that attaches the check-arm bracket for the front door, to the PCM bottom bracket (refer to Figure 7). Figure 7 14. Release the PCM bottom bracket (refer to Figure 8). Figure 8 15. Disconnect the three electrical connectors from the PCM (refer to Figure 9). Figure 9 March 2015 Page 5 of 43 Service Bulletin 16. SB-19-0392V2 Remove the PCM (refer to Figure 10). Figure 10 Part B – Remove the Centre Stack DB9, DBS and Virage Only: 17. Apply protective tape to the leather trim that surrounds the centre stack. 18. Use the special tool to release the veneer panel for the instrument panel (refer to Figure 11). Figure 11 CAUTION: 19. DURING THE STEP THAT FOLLOWS, BE CAREFUL WHEN YOU RELEASE THE VENEER BEZEL FOR THE IP. THE SURFACE FINISH CAN BE EASILY DAMAGED. Release the veneer bezel from the four clips that attach it to the IP (refer to Figure 12). Figure 12 March 2015 Page 6 of 43 Service Bulletin 20. SB-19-0392V2 Disconnect the electrical connectors from each of the four transmission control switches (refer to Figure 13). Figure 13 21. Disconnect the electrical connector from the ignition switch module (refer to Figure 14). Figure 14 22. Disconnect the electrical connector from the ignition switch module (refer to Figure 15). Figure 15 Note: Steps 23 and 24 that follow apply to 2014 Model Year onwards vehicles. March 2015 Page 7 of 43 Service Bulletin 23. SB-19-0392V2 Disconnect the two electrical connectors from the navigation display screen (refer to Figure 16). Figure 16 24. Remove the screw that attaches the two tethers to the veneer bezel (refer to Figure 17). Figure 17 25. Remove the veneer bezel (refer to Figure 18). Figure 18 26. Remove the centre console (refer to Workshop Manual procedure 01.12.DN). March 2015 Page 8 of 43 Service Bulletin 27. SB-19-0392V2 Remove the four screws that attach the centre stack assembly to the IP (refer to Figure 19. Figure 19 28. Move the centre stack assembly to get access to the electrical connectors (refer to Figure 20. Figure 20 29. Disconnect the two electrical connectors from the Infotainment Control Module (ICM) (refer to Figure 21). Figure 21 March 2015 Page 9 of 43 Service Bulletin 30. SB-19-0392V2 Disconnect the two electrical connectors from the HVAC control module (refer to Figure 22). Figure 22 31. Disconnect the four electrical connectors from the control switches (refer to Figure 23). Figure 23 32. Remove the centre stack assembly (refer to Figure 24). Figure 24 Rapide Only: 33. Apply protective tape to the leather trim that surrounds the centre stack. March 2015 Page 10 of 43 Service Bulletin 34. SB-19-0392V2 Use the special tool to release the veneer bezel for the Instrument Panel (IP) (refer to Figure 25). Figure 25 CAUTION: 35. DURING THE STEP THAT FOLLOWS, BE CAREFUL WHEN YOU RELEASE THE VENEER BEZEL FOR THE IP. THE SURFACE FINISH CAN BE EASILY DAMAGED. Release the veneer bezel from the four clips that attach it to the IP (refer to Figure 26). Figure 26 36. Disconnect the electrical connectors from each of the four transmission control switches (refer to Figure 27). Figure 27 March 2015 Page 11 of 43 Service Bulletin 37. SB-19-0392V2 Disconnect the electrical connector from the ignition switch module (refer to Figure 28). Figure 28 38. Disconnect the electrical connector from the ignition switch module (refer to Figure 29). Figure 29 39. Disconnect the two electrical connectors from the navigation display screen (refer to Figure 30). Figure 30 March 2015 Page 12 of 43 Service Bulletin 40. SB-19-0392V2 Remove the screw that attaches the two tethers to the veneer bezel (refer to Figure 31). Figure 31 41. Remove the veneer bezel (refer to Figure 32). Figure 32 42. Remove the two rubber base inserts from the cup holders (refer to Figure 33). Figure 33 March 2015 Page 13 of 43 Service Bulletin SB-19-0392V2 43. Remove the two screws that attach the rear centre stack assembly to the body (refer to Figure 34). Figure 34 44. Release the console panel and rear centre stack assembly from the centre console (refer to Figure 35). Figure 35 45. Disconnect the three electrical connectors from the rear centre stack assembly (refer to Figure 36). Figure 36 46. Remove the rear console panel and rear centre stack assembly from the centre console (refer to Figure 37). Figure 37 March 2015 Page 14 of 43 Service Bulletin SB-19-0392V2 47. Open the door for the rear stowage compartment (refer to Figure 38). Figure 38 48. Remove the rubber insert from the rear stowage compartment (refer to Figure 39). Figure 39 49. Remove the two nuts that attach the top panel assembly for the rear console to the body (refer to Figure 40). Figure 40 50. Open the door for the front stowage compartment (refer to Figure 41). Figure 41 March 2015 Page 15 of 43 Service Bulletin SB-19-0392V2 51. Remove the rubber insert (2) from the front stowage compartment of the console (refer to Figure 42). Figure 42 52. Remove the four Torx screws that attach the top panel assembly for the rear console, to the body (refer to Figure 43). Figure 43 53. Remove the two screws (1) that attach the front auxiliary plate (2) for the rear console to the top panel assembly for the rear console (refer to Figure 44). 54. Move the auxiliary plate assembly (2), to get access to the attachment nuts (3) for the centre console panel (4). 55. Remove the two nuts (3) from the studs that attach the centre console panel (4) and the console lower sides, at the front. Figure 44 56. Carefully release the tabs (1) of the console side panels (2) from the two mounting studs (3 and 4) and move the side panels away (refer to Figure 46). March 2015 Page 16 of 43 Service Bulletin SB-19-0392V2 Figure 45 57. Move the centre console assembly to get access to the electrical connectors (refer to Figure 46). Note: The stowage box is shown removed in the figure for visual aid only. Figure 46 58. Release the electrical connector from the clip that attaches it to the centre console (refer to Figure 47). Figure 47 March 2015 Page 17 of 43 Service Bulletin SB-19-0392V2 59. Disconnect the electrical connector from the park brake switch (refer to Figure 48). Figure 48 60. Disconnect the electrical connector from the driver's console assembly (refer to Figure 49). Figure 49 61. Remove the centre console (refer to Figure 50). Figure 50 March 2015 Page 18 of 43 Service Bulletin SB-19-0392V2 62. Remove the four screws that attach the centre stack assembly to the IP (refer to Figure 51). Figure 51 63. Move the centre stack assembly to get access to the electrical connectors (refer to Figure 52). Figure 52 64. Disconnect the two electrical connectors from the Infotainment Control Module (ICM) (refer to Figure 53). Figure 53 March 2015 Page 19 of 43 Service Bulletin SB-19-0392V2 65. Disconnect the two electrical connectors from the Centre Console Module (CCM) (refer to Figure 54). Figure 54 66. Disconnect the four electrical connectors from the control switches (refer to Figure 55). 67. Remove the centre stack assembly. Figure 55 Vanquish Only: 68. Remove the centre stack (refer to Workshop Manual procedure 15.01.CB). Part C – Install the New Ground Wire onto the Engine Harness All Models: 69. Under the front right wheel arch, cut and remove the fir-tree clip that attaches the PCM harness. 70. Remove the protective tape from the area of the harness (1) shown in Figure 56 to get access to the black/purple ground wire. 71. Remove the section of conduit from the harness. Figure 56 March 2015 Page 20 of 43 Service Bulletin CAUTION: 72. SB-19-0392V2 DURING THE STEP THAT FOLLOWS, MAKE SURE YOU HOLD THE CONNECTOR AS SHOWN. THE BLACK MOULDING CAN BE EASILY DAMAGED. Use an applicable tool to remove the anti backout retainer from connector number Y51AT (13MY onward vehicles) or C0634 (all other models) (refer to Figure 57). Figure 57 73. Use terminal removal tool 418-595 to remove terminal pin 41 from the connector housing (black/purple wire) (refer to Figure 58. Figure 58 74. Remove a 10 mm section of insulation from the black/purple wire at the position shown in Figure 59. Figure 59 75. Put the piece of heat shrink tube that was supplied in the kit, over the terminal onto the cable. 76. Remove 8 mm of insulation from one end of the new ground wire. March 2015 Page 21 of 43 Service Bulletin 77. SB-19-0392V2 Use the crimp from the kit to attach the new ground wire to the black/purple wire (1) (refer to Figure 60). Figure 60 78. Apply solder to the crimped joint (1) (refer to Figure 61). Figure 61 79. Move the heat shrink tube along wire to cover the joint (refer to Figure 62). 80. Use an applicable tool to shrink the heat-shrink tube (1) to protect the joint. Figure 62 81. Fully install pin 41 back into position in the connector housing. 82. Fully install the anti-backout retainer into the connector housing. March 2015 Page 22 of 43 Service Bulletin 83. Put the new overlay wire (1) along the harness in the direction of the bulkhead (refer to Figure 63). 84. Wind harness tape (2) around the harness to hold the new ground wire. SB-19-0392V2 Figure 63 85. Install the section of conduit over the harness that you removed in step 71. 86. Wind self-amalgamating tape around the conduit and harness to seal the harness. 87. Remove the screw (1) that attaches the bracket for the harness electrical connector (2) to the body (refer to Figure 64). 88. Move the harness and electrical connector (3) to get access. Figure 64 DB9, DBS, Virage and Vanquish: 89. Make a hole (1) in the harness grommet that is the correct diameter for the new ground wire (2) (refer to Figure 65). 90. Put the new overlay wire (2) through the grommet into the cabin. Figure 65 Rapide Only: 91. Put the grommet from the kit over the new ground wire. March 2015 Page 23 of 43 Service Bulletin 92. Find the hole in the bulkhead shown in Figure 66. If necessary, remove insulation material to get access. 93. Put the end of the new ground wire (1) through the hole in the bulkhead into the cabin 94. Install the grommet into the hole in the bulkhead. SB-19-0392V2 Figure 66 All Models: 95. Use cable ties (1) at approximately 75 mm intervals to attach the new ground wire (2) to the harness (refer to Figure 67). Figure 67 96. Apply an applicable sealant to the grommet to seal the new ground wire. 97. Install the screw (2) to attach the bracket for the harness electrical connector (1) to the body (refer to Figure 68). Figure 68 March 2015 Page 24 of 43 Service Bulletin 98. SB-19-0392V2 Put the PCM back into the correct position (refer to Figure 69). Figure 69 99. Connect the three electrical connectors to the PCM (refer to Figure 70). Figure 70 100. Align the PCM with the top bracket (refer to Figure 71). Figure 71 March 2015 Page 25 of 43 Service Bulletin 101. SB-19-0392V2 Install the bolt that attaches the check arm bracket for the front door to the PCM bracket. Torque the bolt to 23 Nm (refer to Figure 72). Figure 72 102. Install the three bolts that attach the PCM bottom bracket and PCM to the PCM top bracket. Torque the three bolts to 9 Nm (refer to Figure 73). Figure 73 103. Install the forward electrical harness into the fir-tree clip that attaches it to the body (refer to Figure 74). Figure 74 March 2015 Page 26 of 43 Service Bulletin 104. SB-19-0392V2 Connect the electrical connector to the indicator side repeater (refer to Figure 75). Figure 75 105. Install the electrical connector for the indicator side repeater into the clip that attaches it to the PCM bracket (refer to Figure 76). Figure 76 106. Install the fir-tree cable tie that attaches the forward harness, to the PCM bottom bracket (refer to Figure 77). Figure 77 March 2015 Page 27 of 43 Service Bulletin 107. SB-19-0392V2 Install the three fir-tree cable ties that attach the PCM harness to the PCM bottom bracket (refer to Figure 78). Figure 78 Part D – Install the New Ground Wire into the Centre Stack Harness All Models: 108. Remove the footwell insulation pad to get access to the electrical harness in the footwell. 109. Put the new ground wire (1) along the harness inside the cabin towards the console. Use cable ties (2) to attach the wire (refer to Figure 79). Figure 79 110. Put the new ground wire (1) through into the console/Central Control Module (CCM) area (2) (refer to Figure 80). Figure 80 111. Put the footwell insulation pad back into position. March 2015 Page 28 of 43 Service Bulletin 112. SB-19-0392V2 Find the black/purple wire (pin 8) in electrical connector C0430. Remove the tape from the harness that attaches the wire into the harness (refer to Figure 81). Figure 81 113. Remove a 10 mm section of insulation from the black/purple wire at the position shown (1) in Figure 82. 114. Remove 8 mm of insulation from the end of the new ground wire. 115. Use the crimp from the kit to attach the new wire to the black/purple wire. 116. Apply solder to the crimped joint. Figure 82 117. Wind self-amalgamating insulation tape around the soldered joint (refer to Figure 83). Figure 83 March 2015 Page 29 of 43 Service Bulletin SB-19-0392V2 Part E – Install the Centre Stack DB9, DBS and Virage 118. Put the centre stack loosely into position (refer to Figure 84). Figure 84 119. Connect the four electrical connectors to the control switches (refer to Figure 85). Figure 85 120. Connect the two electrical connectors to the HVAC control module (refer to Figure 86). Figure 86 March 2015 Page 30 of 43 Service Bulletin 121. SB-19-0392V2 Connect the two electrical connectors to the ICM (refer to Figure 87). Figure 87 122. Put the centre stack assembly into position (refer to Figure 88). Figure 88 123. Install and tighten the four screws that attach the centre stack assembly to the IP (refer to Figure 89). Figure 89 March 2015 Page 31 of 43 Service Bulletin 124. SB-19-0392V2 Put the veneer bezel for the IP loosely in position (refer to Figure 90). Figure 90 125. Connect the larger electrical connector to the ignition switch module (refer to Figure 91). Figure 91 126. Connect the smaller electrical connector to the ignition switch module (refer to Figure 92). Figure 92 March 2015 Page 32 of 43 Service Bulletin 127. SB-19-0392V2 Connect the two electrical connectors to the navigation display screen (refer to Figure 93). Figure 93 128. Connect the electrical connectors to each of the four transmission control switches (refer to Figure 94). Figure 94 129. Install the screw that attaches the two tethers to the veneer bezel (refer to Figure 95). Figure 95 130. Make sure the air vents are correctly aligned with the air ducts. March 2015 Page 33 of 43 Service Bulletin 131. SB-19-0392V2 Engage the four clips to attach the veneer bezel (refer to Figure 96). Figure 96 132. Install the centre console (refer to Workshop Manual procedure 01.12.DN). Rapide: 133. Put the centre stack loosely into position (refer to Figure 97). Figure 97 134. Connect the four electrical connectors to the control switches (refer to Figure 98). Figure 98 March 2015 Page 34 of 43 Service Bulletin 135. SB-19-0392V2 Connect the two electrical connectors to the CCM (refer to Figure 99. Figure 99 136. Connect the two electrical connectors to the Infotainment Control Module (ICM) (refer to Figure 100). Figure 100 137. Put the centre stack into its installed position (refer to Figure 101). Figure 101 March 2015 Page 35 of 43 Service Bulletin 138. SB-19-0392V2 Install and tighten the four screws that attach the centre stack assembly to the IP (refer to Figure 102). Figure 102 139. Engage the tabs (1) on the console side panels (2) onto the mounting studs (3 and 4) (refer to Figure 104). Figure 103 140. Install and tighten the attachment nuts for the side panels. 141. Put the centre console (1) loosely into position (refer to Figure 104). 142. Connect the two electrical connectors (2) to the centre console (1). Figure 104 March 2015 Page 36 of 43 Service Bulletin 143. SB-19-0392V2 Install and Torque the four Torx screws that attach the top panel assembly for the rear console to the body to 9 Nm (refer to Figure 105). Figure 105 144. Install the rubber panel into the front stowage compartment (refer to Figure 106). Figure 106 145. Close the door for the front stowage compartment (refer to Figure 107). Figure 107 March 2015 Page 37 of 43 Service Bulletin 146. SB-19-0392V2 Install and tighten the two nuts that attach the top panel assembly for the rear console to the body (refer to Figure 108). Figure 108 147. Install the rubber panel for the rear stowage compartment (refer to Figure 109). Figure 109 148. Close the door for the rear stowage compartment (refer to Figure 110). Figure 110 149. Put the rear centre stack assembly in position into the centre console (refer to Figure 111). Figure 111 March 2015 Page 38 of 43 Service Bulletin 150. SB-19-0392V2 Connect the three electrical connectors to the rear centre stack assembly (refer to Figure 112). Figure 112 151. Put the rear centre stack assembly into its installed position in the centre console (refer to Figure 113). Figure 113 152. Install the two screws that attach the rear centre stack assembly to the body (refer to Figure 114). Figure 114 153. Install the two rubber base inserts into the cup holders (refer to Figure 115). Figure 115 March 2015 Page 39 of 43 Service Bulletin 154. SB-19-0392V2 Put the veneer bezel for the IP loosely in position (refer to Figure 116). Figure 116 155. Connect the larger electrical connector to the ignition switch module (refer to Figure 117). Figure 117 156. Connect the smaller electrical connector to the ignition switch module (refer to Figure 118). Figure 118 March 2015 Page 40 of 43 Service Bulletin 157. SB-19-0392V2 Connect the two electrical connectors to the navigation display screen (refer to Figure 119). Figure 119 158. Connect the electrical connectors to each of the four transmission control switches (refer to Figure 120). Figure 120 159. Install the screw that attaches the two tethers to the veneer bezel (refer to Figure 121). Figure 121 160. Make sure the air vents are correctly aligned with the air ducts. March 2015 Page 41 of 43 Service Bulletin 161. SB-19-0392V2 Engage the four clips to attach the veneer bezel (refer to PRND Voltage Measurement). Figure 122 Vanquish: Install the centre stack (refer to Workshop Manual procedure 15.01.CB). 162. Part F – Complete the Procedure All models: 163. Install the front right wheel arch liner (refer to Workshop Manual procedure 01.02.GB). 164. Do the battery connection procedure (refer to Workshop Manual procedure 14.01.CA). 165. Do the PRND Voltage Measurement test again. If the values are still not correct, speak to AMTech. Part Data Description Transmission Ground Cable Modification Kit Note: Model Part Number Quantity DB9, DBS, Virage, Rapide and Vanquish FD33-37-10095 1 For information, the contents of the modification kit are shown in the list below. You do NOT need to order these parts separately. Contents of the Kit Description Part Number Quantity Wire, Yellow, 0.5 mm2. 706413 2 metres Bulkhead Grommet (Rapide Only) 706414 1 Cable Ties 706415 10 Crimps 706411 2 Heat shrink tube 706412 1 “Fir-Tree” Cable Tie 706416 1 Bulkhead Ground Stud Nuts 703164 2 Model Labour Time Vanquish 2.20 hours. Rapide 3.00 hours. Warranty Data Description Engine harness to centre console – new ground connection March 2015 Page 42 of 43 Service Bulletin SB-19-0392V2 DB9, DBS and Virage 2.30 hours. Failure Mode Description Select the failure modes that follow when you make a claim through the Warranty system: Subsystem Location Component Mode of Failure POWERTRAIN - DRIVETRAIN TRANSMISSION - AUTO - SWITCH / CONTROL GEAR SELECT HARNESS (PRND) - INOPERATIVE If you have any questions related to this Service Bulletin, please speak to: Aston Martin Technical Services on: +44 (0) 1926 644720, E-mail: [email protected] or speak to your After Sales Manager. The English version of this Service Bulletin is written in Simplified Technical English to ASD-STE100™. March 2015 Page 43 of 43