Aston Martin DB7 Instruction manual

«
#
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