Aston Martin DB7 Instruction manual

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WorkshopManual
(IssueII-Volume2)

ASTONMARTINLAGONDALIMITED
TickfordStreet,NeAfwrtPagneii,Buci<inghamshire,EnglandMK169AN
Telephone:[phone]Fax;[phone]
WhilsteveryefforthasbeenmadetoensuretheaccuracyofparticularscontainedinthisWorkshopManual,neitherthe
ManufacturersnortheDealer,bywhomthisManualissupplied,shallinanycircumstancesbeheldresponsibleforany
inaccuracyortheconsequencesthereof.
Allrightsreserved.Nopartofthispublicationmaybereproduced,storedina retrievalsystemortransmitted,inanyform,
elei:tronic,mechanical,photocopying,recordingorothermeanswithoutpriorwritienpermissionfromAstonMartinLagonda
Limited.
Themanufacturersreservetherighttovaryspecificationswithoutnoticeinaccordancewiththeirpolicyofcontinualproduct
improvetnent.
%
ProducedbytheTechnicalPublicationsDepartment
ASTONMARTINLACONDALIMITED
IssueII- 5/96 PartNo.- 43-83658

^? Introduction
# ••t
*<;'..
Introduction'-^;^'^<-~' ^--"^^zfjj^^T^""
WorkshopManualSections
The DB7 WorkshopManual is divided.jnto,9seGtipnsE.a&foli<aiw«>
1Engine
2. Fuel, EmissionControl and Exhaust
3.Transmission
4. Suspension and Steering
5.Brakes,Wheels and Tyres
6.Electrics
7.Chassis and Body
8. Air Conditioning
9.AstonMartinDiagnosticSystem
ProcedureNumbering
Theworkshopmanualprocedures are numberedusing the partslistnumbers asa key.The first two digits oi a
workshopmanualprocedurenumber are also the partslistnumber (e.g. 1.5.01 SumpRemovalrelates toPL1.5Oil
Pump and Sump).Thuswhencarrying outa procedure, youcan quicklylocate the relevantpartsillustration and
sparepartslist.
Toavoidexcessiverepetition,eachprocedurewill be fullydetailedonce inits appropriateplace inthe manual. In
anyotherlocationwherethisprocedure is required, it will be referencedonly byits title andits procedurenumber.
SpecialTools
Wherespecialservicetools are required to perform an operation, the toolnumber is recorded atthe point ofuse
within the procedure. An index and illustratedlist is provided in thissection forthe purpose of identifyingspecial
tools.
References
References tothe left,right,front or rear of thevehicle orof a component are alwaysmadeas if sitting inthe drivers
seatfacingforward. Any suchreferences to assembliesremovedfrom the vehicle aretothe normalorientation of
theassemblywhenfitted inthe vehicle.
Repairs and Replacements
Wherereplacementparts are required, itis essentialthatonlygenuineAstonMartinparts are used.Yourattention
isdrawn tothe followingpointsconcerningrepairs andthe fitting of genuineAstonMartinparts and accessories:
•Safetyfeaturesembodied inthe vehicle maybe impaired if otherthangenuineAstonMartinparts are fitted.
Incertainterritories,legislationprohibits the fitting of partswhich arenot produced tothe manufacturers
specification.
•Adhere to torquewrenchsettingsgiven in thismanual.
•Lockingdevices,wherespecified,must be fitted. Ifthe efficiency ofa lockingdevice is impairedduring
removal, it must be renewed.
• The vehiclewarranty maybe invalidated bythe fitting of otherthangenuineAstonMartinparts.
April 1997Hi

Introduction /^r"^^^^^3^ '"'P ?
SafetyPrecautionsL —^^^—^
SafetyPrecautions"
Allserviceworkshopsarea sourceofpotentialdangerandrepairworkshouldonlybeperformedbytechnically
trainedstafffollowingtheproceduresinthismanual.A safetyconsciousapproachtotheperformanceofallservice
proceduresmustbeobservedatalltimes.Statutoryrequirementsgoverningallaspectsofhealthandsafetyatwork
includingdirectivesfortheproperuseofmaterialsandequipmentmustbeimplemented.
Thefollowingcontainsa listofparticularsafetyprecautionswhichshouldbeobserved;itisnotintendedtobe
exhaustive.
AirConditioningSystem
Donotdisconnectanyairconditioningrefrigerantsystempipesunlesstrainedandinstructedtodo so. Therefrigerant
usedcancauseblindnessifallowedtocontactyoureyes.
ChemicalHandlingandStorage
Chemicalsusedintheservicingofmotorvehiclesincludeacids,adhesives,antifreeze,brakefluids,coolants,grease,
oil, paint,resinandsolvents.Exposuretocertainchemicalsthroughdirectcontactorinhalationcanbe fatal.
Potentialhazardsmayalsobepresentthroughtheincorrectuse,storageandhandlingofchemicalscausinga fire
risk.Thefollowingprecautionsshouldbeobserved.
1. Strictlyadheretohandlingandsafetyinformationfoundoncontainersandlabels.
2. Donotstorechemicalsinunlabelledorincorrectlylabelledcontainers.
3.Containersusedforstoringchemicalsshouldnotbeleft open; thereisa riskof spilling, orevaporationoffumes
whichmaybeinflammableortoxic.
4. Donotmixchemicalsunlessinstructedtodosofollowingmanufacturersguidelines.
5.Donotinhalechemicalmaterialstodetermineidentity,theymaybetoxic.
6.Donotusepetrol,kerosene,diesel fuel, gasoil,thinnersorsolventsforwashing skin.
7.Containerswhosecapacityisover25litres(5gallons)requirea bundwallinordertocontainspillages.
8.Chemicalsbasedonsolventssuchaspaintshouldnotbesprayedina confinedspace;workareasusedfor
suchoperationsshouldbewellventilatedandfumeextractionequipmentshouldbeutilised.
9.Ensurethatadequateventilationisprovidedwhenvolatilede-greasingagentsarebeingused.
WARNING: Fume extraction equipment must be in operation when solvents are used e.g. trichloroethane, white
spirit, SBP3, methylene chloride, perchlorethylene.
WARNING: Do not smoke in the vicinity of volatile de-greasing agents.
10. Avoidsplashingthe skin, eyesandclothing.
11. Cleanchemicalsfromtheskinandclothingassoonaspossibleaftersoiling.
12. Wearprotectiveclothingsuchasgoggles,nonporousglovesandapronwhenhand I ingbatteryacidandother
corrosiveandtoxicsubstances.
ivApril1997

//—-^ ^^^^5~^ ' -^ ^ Introduction
SafetyPrecautions
SafetyPrecautions(continued)
ElectricalEquipment
1. Ensurethatelectricalequipmentisinsafeworkingorderbeforeuse.
2. Inspectpowerleadsofallmainselectricalequipmentfordamageandsecurity,andcheckthatitisproperly
earthed.
3.Ensurethatelectricalequipmentisprotectedbya fuseofthecorrectcurrentrating.
4. Disconnectthebatterybeforecommencingrepairoperationstotheelectricalsystem,fuelsystemandengine
orwhenworkingbeneaththevehicle.
ExhaustFumes
Enginesshouldnotberuninconfinedspaces,exhaustfumescontainharmfulandtoxicsubstancesincludingcarbon
monoxidewhichcanprovefatalifinhaled.Enginesmustonlyberunwherethereisfumeextractionequipmentin
operationorwherethereisadequateventilation.
FirePrecautions
1. Ensurethata suitableformoffireextinguisherisconvenientlylocatedneartheworkarea.
2. Keepoils,solventsandcombustiblematerialsawayfromnakedflamesandothersourcesofignition.
3.EnsurethatNOSMOKINGsignsarepostedaroundareaswherecombustiblematerialsandvapourmaybe
presentandensurethatthewarningsarestrictlyobserved.
4. Ensurethatdrysandisavailabletosoakupanyspillageoffuelorotherflammablesolutions.
5.Fumeextractionequipmentmustbeavailableandinfullworkingordertoremovecombustibleandtoxic
vapours.
6.Allpersonnelshouldbeawareofthefiredrillproceduresandprecautions.
JackingandLifting
1. Therecommendedproceduresforlifting,jackingandtowingareincludedlatefinthisseetion-andmustbe
strictlyobservedtoensurepersonalsafety.
2. Alwaysusea vehiclehoist,ramporpitforworkingbeneaththecarinpreferencetd^&^cking
3.Neverrelyona jacktosupportacarindependently,useaxlestandsorblockscarefullypJaQedatthejacking
pointstoproviderigidsupport.
4. Whenworkingbeneatha vehicle,chockthewheelsaswellasapplyingthehandbrake.
5.Ensurethatthevehicleisstandingonfirmlevelgroundbeforejackingorlifting.
5.Checkanyliftingequipmentusedhasadequatecapacityfortheloadbeingliftedandisih"fdllworkingorder.
ToolsandEquipment
1. Donotleavetools,equipment,spiltoil,etc.aroundorontheworkarea.
2. Ensurethattoolsandequipmentusedareingoodcondition;donotusedamagedordefectivetoolsor
equipment.
3.Donotapplyheatinanattempttofreestiffnutsorfittings;aswellascausingdamagetoprotectivecoatings,
thereisa riskofdamagetoelectronicequipmentandbrakelinesfromstrayheat.
4. Usetherecommendedservicetoolwhereinstructedtodoso.
April1997v

Introduction//—">)^nir>^ ' ^ 1
SafetyPrecautionsL 1 .^—y^
SafetyPrecautions(continued)
UsedEngineOil
Prolongedandrepeatedcontartwithmineraloilwillresultintheremovalofnaturalfatsfromthe skin, leadingto
dryness,irritationanddermatitis.Inaddition,usedengineoiicontainspotentiallyharmfulcontaminantswhichmay
causeskincancer.Adequatemeansofskinprotectionandwashingfacilitiesshouldbeprovided.
Healthprotectionprecautions:
1. Avoidprolongedandrepeatedcontactwithoils,particularlyusedengineoil.
2. Wearprotectiveclothing,includingimperviousgloveswherepracticable.
3.Donotputoilyragsinpockets.
4. Avoidcontaminatingclotheswithoil.
5.Overallsmustbecleanedregularly.Discardunwashableclothesandoilimpregnatedfootwear.
6.Firstaidtreatmentshouldbeobtainedimmediatelyforopencutsorwounds.
7.Usebarriercreams,applybeforeeachworkperiodtohelptheremovalofoilfromthe skin.
8.Washwithsoapandwatertoensurealloilisremoved.Preparationscontaininglanolinreplacethenatural
skinoilswhichhavebeenremoved.
9.Donotusepetrol,kerosene,diesel fuel, gasoil,thinnersorsolventsforwashing skin.
10. Ifskindisordersdevelop,obtainmedicaladvice.
11. Wherepracticable,degreasecomponentspriortohandling.
12. Wherethereisa riskofeyecontact,eyeprotectionshouldbeworn,inaddition,aneyewashfacilityshould
beprovided.
EnvironmentalProtection
Itisillegaltopourusedoilontheground,downsewersordrains,orintowatercourses.Theburningofusedengine
oilinsmallspaceheatersorboilersisnotrecommendedunlessemissioncontrolequipmentis fitted; incaseofdoubt,
contacttheLocalAuthorityforadviceondisposalfacilities.
viApril1997

DB7
Contents
Introduction iii
SafetyPrecautions iv
April 1997

^=2^
April1997

[Em^^^? Electrics
RepairProcedures
6.1.01
6.1.02
6.1.03
6.1.04
6.1.05
6.2.01
6.3.01
6.3.02
6.5.01
6.5.02
6.5.03
6.5.04
6.5.05
6.5.06
6.5.07
6.5.08
6.6.01
6.6.02
6.6.03
6.6.04
6.6.05
6.6.06
6.6.07
6.6.08
6.7.01
6.7.02
6.7.03
6.7.04
6.7.05
6.7.06
6.7.07
HeadlampUnit
HeadlampAlignment
FrontIndicator/ParkingLampUnit
FrontFogLampAssembly
SideRepeaterLamps
WindscreenWiperMotor
Alternator
StarterMotor
SteeringWheelandHornSwitches
ColumnSwitches
IgnitionSwitch
InstrumentPanel
Radio
AirConditioningandSwitchPanel
CruiseControl,WindowandGearshiftSwitches
SeatControlSwitchPanels
FrontInteriorLamps
RearInteriorLamps
FrontSeatRemoval
FrontSeatRunnerAssembly
FrontSeatRailMotor
LumbarSupportMotor
SeatReclineMotor
SeatControlUnit
DoorEdgeLamps
RearLampCluster
DoorCentralLockingMotors
DoorWindowMotor
DoorMirrorAssembly
TransmissionControlModule- Renew(TCM)
BarometricPressureSensor- Renew
6-3
6-3
6-4
6-4
6-4
6-5
6-5
6-6
6-6
6-6
6-7
6-7
6-8
6-8
6-9
6-9
6-10
6-10
6-10
6-11
6-11
6-12
6-12
6-12
6-12
6-13
6-13
6-14
6-15
6-16
6-17
April1997 6-1

Electrics
ElectricalComponentLocationandWiringInformation- Upto97MY
ComponentIndex6-19
ComponentLocationDiagrams6-23
ElectronicControlUnitLocationDiagram6-38
RelayPanel,FuseboxandEarthPointLocationDiagram6-39
LoomLocationDiagrams6-40
WiringDiagramsandSpliceLists6-42
ElectricalComponentLocationandWiringInformation- 97MY
ComponentIndex6-43
ComponentLocationDiagrams6-47
RelayLocationDiagrams6-64
WiringDiagramsandSpliceLists6-68
AirbagSystem- RepairandDiagnosticProcedures6-69
SeatBeltPretensionerSystem- RepairandDiagnosticProcedures6-101
SecuritySystem(RestrictedCirculation)6-111
PATSSystem(RestrictedCirculation)6-121
97.5ModelYear
6.6.03SeatRemoval(97.5MY)
6.6.08SeatControlModule(97.5MY)
6-127
6-128
6-2 April!997

ES^^^?
Electrics
HeadlampUnit/ HeadlampAlignment
6.1.01HeadlampUnit
Procedure
1. Removethefrontapronundertrayandremovethe
completenoseassembly.
2. Releasetheheadlampplugfromthebodyclipand
disconnectthe plug.
Figure 7.Headlamp Removal
3.Remove 1 boltfromthefrontheadlampmounting.
4. Removethemainbeamlampaccesscoverand
loosentherearheadlampmountingbolt.
5.Liftofftheheadlampassembly.
5.Onrefittingtheheadlampassembly,carryoutthe
headlampalignmentprocedure.
6.1.02HeadlampAlignment
Data
MainBeamAlignment1.5°down
DippedBeamAlignment1.5°down
Tools
HeadlampAlignmentGauge
Procedure
1. Liftthebonnetandremovethemainbeamaccess
coverfromtheheadlampunit.
2. Usingthelargehexadjusters,aligntheouterdipped
beamstothecorrectpatternin a headlampalignment
gauge
Figure 1. Headlamp Alignment
3.Usingthesmallhexadjusters,settheinnermain
beamalignments so thatthebrightspot is centralised
and1.5°downinthealignmentgauge.Ifnecessary,
finetunetheadjustmenttosuitaveragevehicle
loadinganddriverrequirements.
DippedBeamConversion- UK-Europe-UK
1. Accessthedippedbeamlampsthroughthepanels
inthewheelarchliners.
2. Cutthetiestrapsecuringtherubbergaiterandpull
backthegaiter.
3.Slacken3 screwssecuringthelampbackplate
(Figure2)androtatetheplatetotherightforU K or
totheleftforEuropetothelimitoftheboltslots.
1 .ForEuropean(RH)Use
(BeamPattern_/)
2.ForUK(LH)Use
(BeamPattern^^)
Figure 2. Dipped BeamConversion UK-Europe
4. Tightenthethreescrews,replacethegaiterand
secureitwitha newtiestrap.
May1996 6-3

Electrics
FrontExteriorLamps- RemovalProcedures E::M^=2?
6.1.03FrontIndicator/Parking Lamp Unit6.1.05SideRepeaterLamps
Procedure
1. Releasethesinglecaptivescrewattheoutboard
endoftheassemblyandremovetheassemblyfrom
thefrontapron.
Procedure
1. Protectthesurroundingpaintworkandusea
screwdrivertolevertheassemblyfromthefront
wing.
Figure 7.Indicator/Parking Lamp Removal
2. Disconnectthe2 electricalplugsattherearofthe
assemblyandremovethelampunit.
6.1.04FrontFogLampAssembly
Figure /.Side Repeater Lamp Removal
2. Disconnectthewiringattherearofthelampand
removetheassembly.
Procedure
1. Removethefrontapronundertray.Accesstherear
ofthefoglightassembly
Figure 1. Front Fog Lamp Removal
2.
3.
Removetwoboltsandlowerthelampassembly
fromitsbracket.
Disconnectthelamploomandremovethefog
lampassembly.
6-4 May1996

[EM^^^
Electrics
WiperMotor/ Alternator- RemovalProcedures
6.2.01WindscreenWiperMotor 6.3.01Alternator
Procedure
1. Disconnectthebattery.
2. Disconnectthewipermotormulti-plug.
3.Removethenutandlockplate(Fig1-1)fromthe
motorgearboxshaftandreleasethedrivebracket
fromtheshaft.
Figure 1. Windscreen Wiper Motor
4. Removethreenuts(Fig 1 -2)andremovethemotor
fromitsmountingbracket.
Procedure
1. Disconnectthebatteryearth lead.
2. Usinga 3/8"ratchethandle,releasethedrivebelt
tension. Slipthebeltfromthewaterpumpdrive
pulleyandfromthealternatordrivepulley.
3.Releasetheignitionleadsfromthesupportonthe
alternatortopmounting.
4. Removethealternatoroutputleadcover,remove
thenutandwashersanddisconnectthealternator
output lead.
5.Disconnecttheelectricalplugontherearofthe
alternator.
6.Removethealternatorlowermountingbolt.
Figure 1. Alternator Mountings
7. Loosenthealternatoruppermountingbolt,support
thealternator,removetheupperboltandthe
alternator.
Replacementisthereverseoftheremovalprocedure.The
drivebeltistensionedautomaticallybythespringloaded
idleronrefittingthemaindrivebelt.
May1996 6-5

Electrics
StarterMotor/ SteeringWheel- RemovalProcedures ^n:M3^^2?
6.3.02StarterMotor
Procedure
1. Disconnectthebattery.
2. Removetheinletairtrunkins
Figure 1. Starter Motor Mountings
3.Disconnectthestartersolenoidconnectorandthe
startermotorpowerleadatthesolenoid.
4. Removethetopstartermotorsecuringbolt.
Note: The top bolt is from tlie engine side on auto cars
and from ttiegearbox side on manual cars.
5.Raisethecarona hoistandwhilstsupportingthe
motor,removethelowerstartermotorsecuring
bolt.
6.Liftthemotorfromthebellhousingandremoveit
fromthevehiclebypositioningitverticallyand
loweringitdowninfrontoftheoilfilter.
6.5.01Steering WheelandHorn Switches
Procedure
1. Removethesteeringwheelcentrepad.
Figure 1. Steering Wheel and Horn
2. Markthepositionofthesteeringwheelrelativeto
thesteeringcolumntoensurecorrectreplacement.
3.Removethesteeringwheelsecuringnutandremove
thesteeringwheel.
6.5.02ColumnSwitches
Procedure
1. Removethesteeringwheel.
2. Removethreescrewsandthecolumnswitchcover.
1^
Figure 1. Column Mounted Switches
3.Cutthetywrapssecuringtheswitchloomtothe
steeringcolumn.Disconnecttheloomplugs.
4. Release4 screwsand 1 ifttheswitchassemblyoffthe
steeringcolumn.
6-6 May1996

Em3^^^
Electrics
IgnitionSwitch/ InstrumentPanel- RemovalProcedures
6.5.03IgnitionSwitch 6.5.04InstrumentPanel
Procedure
1. Disconnectthebattery.
2. Removethreescrewsandthesteeringcolumn
lowercover.
Procedure
1. Disconnectthebattery.
2. Removethefourscrewsfromtheinstrumentpane!
surroundandremovethesurround.
Figure 7.Ignition Switch
3.
4.
Loosenthegrubscrewsecuringtheswitchandease
theswitchfromitslocation.
Disconnecttheswitchmulti-plugandremovethe
switch.
Figure 1. Instrument Panel Removal
3.Removetwoscrewsfromthetopedgeofthe
instrumentpanelandwithdrawthepanel.
4. Detachthethreeelectricalconnectorsandremove
theinstrumentpanel.
5.Panelwarninglampsare1.2Wbayonetfit.The
largerpanelilluminationlampsarealso1.2W
bayonetfit.
May1996 6-7

Electrics
Radio/ Air-ConSwitchPanel- RemovalProcedures [D:m3^^2?
6.5.05Radio
Procedure
1. Pressthereleasebuttonandremovetheradiofront
controlpanel.
Figure /.Radio Removal
2. Inserttheradioremovaltoolintotheslotsinthetop
edgeoftheradiobodytoreleasethecatches.Pull
forwardontheradioandremoveitfromthecentre
console.
3.Disconnectthespeaker,CD,aerial,powerand
earthconnectors.
6.5.06AirConditioningand Switch Panel
Procedure
1. Removetheradio.
2. Pullofftheairconditioningcontrolknobs.
3.Liftoftheconsolecontrolsfinisherpanel.
Figure h Air Conditioning Panel Removal
4. Removefourscrewsandpullforwardthecentre
consolecontrolpanel.
5.Disconnectthefiveconnectorsinthecentreconsole
wiringandremovethecentreconsolecontrol
panel.
6-8 May1996

lEM^-^? Electrics
ControlSwitch- RemovalProcedures
6.5.07CruiseControl,Windowand
GearshiftSwitches
Procedure
1. Protectthewoodfinisheraroundtheswitches.
6.5.08SeatControlSwitchPanels
Procedure
1. Removethewoodtrimabovethepassengerside
dash.
2. Removetheashtray(Fig 1 -1).
Figure 7.Switch Removal
2. Usinga suitablelever,raiseeachendoftheswitch
toreleasethespringclips.
3.Pulltheswitchclearoi thewoodfinisherand
disconnecttheswitchwiring.
Figure!. Ashtray and Ashtray Well
3.Removethegearselectorknob.
4. Releasethescrewintheashtraywell(Fig1-2)
securingthegearshiftandcentreconsolesurround.
5.Raisetheconsolesurroundandsupportittogain
accesstotheseatcontrolpanel.
6.Disconnectthemulti-plugintheseatswitchloom.
7.Remove2 screws(Fig2-1)andtheseatcontrol
switches.
Figure 2. Seat Control Switch Panel Removal
May1996 6-9

Electrics
InteriorLampsandFrontSeat- RemovalProcedures EM^^^
6.6.01FrontInteriorLamps
Procedure
1. Releasethequarterturnfasteneronthefrontinterior
lightassemblyandlowertheassemblyfromthe
roofliner.
Figure 7.Front Interior Lamp
2. Disconnecttheinteriorlampplugandremovethe
interiorlampassembly.
6.6.02RearInteriorLamps
Procedure
1. Releasetherearuppertrimpanel.
2. Removetwospirewashersandtherearinterior
lampassembly.
6.6.03FrontSeatRemoval
Procedure
1.
2.
Motorthefrontseatforwardandremovetherear
securingboltsfortheseatrails.
Motortheseattotherearandremovethefrontseat
railsecuringbolts.
Figure 1. Front Seat Removal
3.Liftthefootweilcarpet,releasetheaccessplate
securingscrewsandremovetheplatetogain
accesstotheseatcontrolunit.
4. Cutandremovethetywrapssecuringtheseatloom.
5.Disconnecttheseatharnessconnectorsatthe
controlunit.
6.Removetheseatassembly.
Figure 7.Rear Interior Lamps
3.Disconnectthelampwiringandremovethelamp
assembly.
6-10 May1996

Em3^^ Electrics
FrontSeatRunnerandRailMotor- RemovalProcedures
6.6.04FrontSeatRunnerAssembly
Procedure
1. Removetheseatfromthecar.
7>
Figure 1. Front Seat Runner Removal
2. Cutthetywraps(Fig1-4)securingtheseatbelt
buckleharnessanddisconnectthebuckleharness
plug(Fig1-5).
3.Positiontherunnerasrequiredandreleasethebolts
(Fig1-3)securingthefrontandrearoftheseat
frame.
4. Releasethefrontharnessfromitsretainingclips
anddisconnectthemulti-plugs(Fig1-8).
5.Removethecompleteseatrunnerassembly(Fig 1 -
6).
6.Removetheseatbeltbolttrimcoverandremove
theseatbeltbolt(Fig1-2),buckleandbuckle
bracket(Fig1-9).
7.Fitandsecuretheseatbeltbuckletothereplacement
seatrunnerassembly.
6.6.05FrontSeatRailMotor
Procedure
1. Removetheseatfromthevehicle.
2. Removethefrontseatrunnerassemblyfromthe
seat.
3.Removetheseatharnessclamp(Fig 1 -1).
4. Disconnecttheseatrailmotorplug(Fig 1 -10).
Figure 1. Front Seat Rail Motor Removal
5.Loosenthemotorsecuringscrews(Fig1-11)and
removethemotor/driveassembly.
May1996 6-11

Electrics
Lumbar Support,Recline MotorandSeatControlUnit- RemovalProcedures
6.6.06LumbarSupportMotor
Procedure
1. Removetheseatfromthecarandremovetheseat
backfinisherpanel.
2. Disconnectthelumbarmotorplugandthelumbar
diaphragmairline(Fig1)andremovethemotor.
Figure /.Lumbar Support Motor Removal
6.6.07SeatReclineMotor
6.6.08SeatControlUnit
Procedure
1. Liftthefootwellcarpet,releasetheaccessplate
securingscrewsandremovetheplatetogain
accesstotheseatcontrolunit.
Figure 1. Seat Control Unit Removal
2. Disconnectthemultiplugfromthecontrolunit.
3.Releasethesecuringscrewsandremovetheseat
controlunit.
Procedure
1. Removetheseatfromthecarandremovetheseat
backfinisherpanel.
2. Disconnectthereclinemotorconnector.
Figure 1. Seat Recline Motor Removal
3.Disconnectthetriggercablefromthemotor.
4. Loosentwoscrewsandremovethereclinemotor
fromitsbracket.
6.7.01DoorEdgeLamps
Procedure
1. Leverthelampassemblyfromthedoor edge, taking
precautionstoprotectthedoorpaintwork.
Figure 1. Door Edge Lamp Removal
2. Disconnectthelampwiringandremovethedoor
edgelampassembly.
6-12 May1996