SB-01-1011 Service Bulletin/Repair Instructions

ASTON MARTIN CLIENT SERVICES
SERVICE BULLETIN

Reference number:
SB-01-1011
Issued: 16 April, 2018
Subject:
Replacement of DB11 knee airbags
Model(s):
DB11
VIN Range:
All DB11 vehicles up to L04002.
Applicable to:
All Dealers
Distribute to:
After Sales Manager

Executive Manager

Service Manager

Sales Manager
Warranty Staff

Technician(s)

Parts Staff
Reason for this Service Bulletin

The design of the DB11 knee airbag has changed to make one of the points where it attaches to the vehicle “poka-yoke.”

The initial design of knee airbags are not available to order from Aston Martin Parts.

Figure 1 shows the initial design of knee airbag. The hole for the bolt is in the center of the long bracket that attaches the

knee airbag to the vehicle. In the initial design of knee airbag measurement “A” is 25 mm.
Figure 1

Figure 2 shows the new design of knee airbag. The hole for the attachment bolt is not in the center of the long bracket

that attaches the knee airbag to the vehicle. In the new design of knee airbag measurement “B” is 37 mm.
Figure 2

Note:
Figure 1 and Figure 2 show the knee airbag for LHD DB11 vehicles. The knee airbag for RHD DB11

vehicles has the same design change.
To align with the design change of the knee airbag the design of the DB11 cross-car beam assembly has changed. The

design of the bracket for the passenger knee airbag (LHD Federal specification only) has also changed.

If you need to replace the knee airbags on an early DB11 vehicle, do the Workshop Procedures that follow.
16 April, 2018
Page 1 of 8
SERVICE BULLETIN
SB-01-1011
Workshop Procedure

This workshop procedure has the parts that follow (where applicable):

•
Part A – Remove and install a new driver knee airbag – RHD
•
Part B – Remove and install a new driver knee airbag – LHD
•
Part C – Remove and install a new passenger knee airbag – LHD (Federal specification only)
WARNING:
HANDLE THE AIRBAG UNIT CAREFULLY. THE AIRBAG UNIT HAS AN EXPLOSIVE CHARGE IN

IT. IF YOU DO NOT HANDLE THE UNIT CAREFULLY, THE CHARGE CAN OPERATE AND CAUSE

INJURY.
Part A – Remove and install a new driver knee airbag – RHD

1.
Remove the driver knee airbag (refer to Workshop Manual procedure 01.20.CN).
Note:
2.
The procedure that follows is applicable for all DB11 vehicles to L03578. For DB11 vehicles L03579 thru

L04002 check the position of the knee airbag attachment bolt hole in the cross-car beam assembly. The

procedure is not necessary for vehicles with the new design of cross-car beam assembly.
Identify the position where the outboard end of the

driver knee airbag is attached to the cross-car beam

assembly (refer to Figure 3).
Figure 3

Figure 4 shows the initial design of the cross-car beam assembly. The hole (A) that has a thread for the M6 bolt is:

• 16.6 mm from the inboard edge (B)

• 23.3 mm from the rearward edge (C)
Figure 4
16 April, 2018
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SERVICE BULLETIN

Note:
SB-01-1011
If the vehicle has the initial design of cross-car beam assembly do steps 3 thru 7 before fitting a new

driver knee airbag.
Figure 5 shows the new design of the cross-car beam assembly. The hole (A) that has a thread for the M6 bolt is:

• 17.6 mm from the inboard edge (D)

• 11.2 mm from the rearward edge (E)
Figure 5

Note:
If the vehicle has the new design of cross-car beam assembly go to step 8.
3.
Mark the position of the new hole center with a center punch and hammer (refer to the dimensions from Figure

5).
4.
Make a 5.2mm hole through the cross-car beam assembly at the marked position.
5.
Cut a thread for an M6 bolt in the hole – use lubricant as required.
6.
Remove any rough edges and lubricant from the hole.
7.
Do a check that the M6 bolt fits correctly in the new hole.
8.
Install the new driver knee airbag (refer to Workshop Manual procedure 01.20.CN).
CAUTION:
MAKE SURE YOU USE THE NEW HOLE IN THE CROSS-CAR BEAM WHEN YOU REPLACE THE

KNEE AIRBAG. IF YOU DO NOT USE THE NEW HOLE THE KNEE AIRBAG WILL NOT BE

CORRECTLY ALIGNED IN THE VEHICLE.
Part B – Remove and install a new driver knee airbag – LHD

1.
Remove the driver knee airbag (refer to Workshop Manual procedure 01.20.CN).
Note:
The procedure that follows is applicable for all DB11 vehicles to L03578. For DB11 vehicles L03579 thru

L04002 check the position of the knee airbag attachment bolt hole in the cross-car beam assembly. The

procedure is not necessary for vehicles with the later design of cross-car beam assembly.
16 April, 2018
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SERVICE BULLETIN

2.
SB-01-1011
Identify the position where the outboard end of the

driver knee airbag is attached to the cross-car beam

assembly (refer to Figure 6).
Figure 6

Figure 7 shows the initial design of the cross-car beam assembly. The hole (A) that has a thread for the M6 bolt is:

• 16.6 mm from the inboard edge (B)

• 23.3 mm from the rearward edge (C)
Figure 7

Note:
If the vehicle has the initial design of cross-car beam assembly do steps 3 thru 7 before fitting a new

driver knee airbag.
16 April, 2018
Page 4 of 8
SERVICE BULLETIN
SB-01-1011
Figure 8 shows the new design of the cross-car beam assembly. The hole (A) that has a thread for the M6 bolt is:

• 17.6 mm from the inboard edge (D)

• 11.2 mm from the rearward edge (E)
Figure 8
Note:
If the vehicle has the new design of cross-car beam assembly go to step 8.
3.
Mark the position of the new design hole center with a center punch and hammer (refer to the dimensions from

Figure 8).
4.
Make a 5.2mm hole through the cross-car beam assembly at the marked position.
5.
Cut a thread for an M6 bolt in the hole – use lubricant as required.
6.
Remove any rough edges and lubricant from the hole.
7.
Do a check that the M6 bolt fits correctly in the new hole.
8.
Install the new driver knee airbag (refer to Workshop Manual procedure 01.20.CN).
CAUTION:
16 April, 2018
MAKE SURE YOU USE THE NEW HOLE IN THE CROSS-CAR BEAM WHEN YOU REPLACE THE

KNEE AIRBAG. IF YOU DO NOT USE THE NEW HOLE THE KNEE AIRBAG WILL NOT BE

CORRECTLY ALIGNED IN THE VEHICLE.
Page 5 of 8
SERVICE BULLETIN
SB-01-1011
Part C – Remove and install a new passenger knee airbag – LHD (Federal specification only)

1.
Remove the passenger knee airbag (refer to Workshop Manual procedure 01.20.CP).
Note:
The procedure that follows is only necessary for DB11 vehicles that do not have the new design of

passenger knee airbag support bracket. Do a check of which bracket is installed in the vehicle and only do

steps 2 thru 7 if applicable.
Figure 9 shows the initial design of the passenger knee airbag support bracket. Measurement “A” is 25mm.
Figure 9
Figure 10 shows the new design of passenger knee airbag support bracket. Measurement “B” is 37mm.
Figure 10
2.
Remove the passenger's bottom panel for the instrument panel (IP) (refer to Workshop Manual procedure

01.12.DV).
16 April, 2018
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SERVICE BULLETIN

3.
SB-01-1011
Remove the 8 bolts that attach the passenger knee

airbag support bracket to the passenger knee

protection plate and the IP assembly (refer to Figure

11).
Figure 11

4.
Carefully lift the passenger knee airbag support

bracket away from the passenger knee protection

plate and the IP assembly (refer to Figure 12).
Figure 12

5.
Remove the passenger knee airbag support bracket

(refer to Figure 13).
Figure 13

6.
Install the new passenger knee airbag support bracket. Follow the above procedure in reverse from step 5 to 3.
7.
Install the passenger's bottom panel for the instrument panel (refer to Workshop Manual procedure 01.12.DV).
8.
Install the new passenger knee airbag (refer to Workshop Manual procedure 01.20.CP).
16 April, 2018
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SERVICE BULLETIN
SB-01-1011
Part Data

Description
Part Number
Quantity
HY53-204A45-DB
1
Labour Time
ROT Code
Remove and install a new driver knee airbag – (RHD / LHD).
1.25 hours
01.20.CR
Remove and install a new passenger knee airbag (LHD - Federal

market only).
1.55 hours
01.20.CS
PASSENGER KNEEBAG SUPPORT BRACKET (LHD).
Warranty Data

Procedure and Labour Time

Description
If you have any questions related to this Service Bulletin, please contact: Aston Martin Technical Services

on: +44 (0) 1926 644720, email: [email protected],

Or contact your After Sales Manager.

The English version of this Service Bulletin is written in

Simplified Technical English to ASD-STE100™.
16 April, 2018
Page 8 of 8

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