1997 ASTON MARTIN DB7 air condition

Air Conditioning Repair Procedures
Expansion Valve Renewal
ES^'^?

Figure 2.

11.
Position valve plate and gaskets (Fig. 2-1 and 2) on
the compressor and fit the cylinder head.

12.
Tighten the cylinder head securing bolts in the
order shown in Fig. 3.
Figure 3.

13.
Fit new 'O' rings to the outlet port blanking plate,
position the plate on the compressor and fit and
tighten the securing bolt.

14.
Check compressor oil and top up in necessary.

14.
Refit the compressor.

15.
Remove the wing mat and close the bonnet.
8.1.05.1 Expansion Valve Renewal

1.
Depressurise the air conditioning system.

2.
Undo the pipe to expansion valve clamp bolt and
retaining plate and disconnect the pipes (Fig. 1)
Figure 1.
3. Fit blanking plugs to the expansion valve and to the

pipes.

4.
Reposition the pipes to one side.
5. Unscrew the two torx head retaining screws and
remove the expansion valve from the air
conditioning unit (Fig.
1
-1).
6. Remove and discard the 'O' rings.
7. Fitting a new valve is the reversal of the removal
procedure.
8. Ensure new 'O' rings to all union connections are

fitted.

9. Evacuate the system.

10.
Recharge the system.
8-54 May 1996

^2?
Air Conditioning Repair Procedures
Hose - Compressor to Evaporator/Air-Con Unit Renew
8.1.06.1 Hose-Compressor
to
Evaporator
Renewal
Procedure

1.
Open the bonnet and fit a wing cover.

2.
Depressurise the air conditioning systenn.
3. Remove the hose to evaporator valve clamping

plate,
disconnect the hose from the valve, remove
and discard the 'O' ring
seal.

4.
Fit a blanking plug to the evaporator valve. Release
the evaporator hose securing clips.
5. Remove the compressor outlet port retaining bolt.
6. Disconnect the hose from the compressor, discard
the hose complete with 'O' ring seals.
7. Connect the hose to the evaporator valve and
tighten clamp onto the hose.
8. Route the hose to the compressor, fit a new 'O' ring
seal and connect it to the compressor.
9. Position the outlet port retaining plate on the
compressor, fit and tighten the securing bolt.

10.
Refit the hose to the clips.

11.
Charge the air conditioning system.

12.
Remove the wing cover and close the bonnet.
8.2.01.1 Air Conditioning Unit Renewal

1.
Disconnect the battery earth
lead.

2.
Drain the engine coolant into a suitable container.
3. Depressurise the air conditioning system.

4.
Disconnect the high and low pressure hoses and
expansion valve from the air conditioning unit (see
expansion valve renewal).
5. Slacken the coolant hose to the heater matrix pipe
securing clips and disconnect the hoses from the
matrix. (This will require the removal of the air
intake hose for access.)
6. Remove the following items from inside the car:
front seats
underscuttle panels/knee bolsters
glove box assembly
facia trim (walnut trim)
radio and ashtray
centre console switch panel assembly
instrument panel and surround trim
steering wheel and column
facia assembly complete
hoses - distribution box to door vents
facia support frame
Details and drawings of the above operations can
be found in the electrical and trim sections.
Disconnect the vacuum hoses from the blower
motors, water valve and reservoir.
Un-clip the electrical harness from the air
conditioningunit, release theelectrical connections
and reposition the harness to allow removal of the
unit.
Displace and remove the footwell ventilator ducts
and hoses (Fig. 1-1).
May 1996 8-55

Air Conditioning Repair Procedures
Air-Conditioning Unit Renew ^^?

10.
Disconnect the pliable trunking from the unit (Fig.
8.2.02.1
EvaporatOr Unit Renewal
1-2). ^

1.
Remove the air conditioning unit assembly.

2.
Remove the heater pipe guide plate securing screws
and remove the guide plate.
3. Remove the screws secu ri ng evaporator sensor and
withdraw the sensor from the evaporator.

4.
Remove the screws securing the solenoid mounting
plate and displace the mounting plates from the
unit.
5. Removetheharnesstocasingearthboltand displace
the harness.
6. Cut and remove the harness to casing securing
ratchet straps and displace the harness from the

casing.

7. Displace the vacuum hose from the casing.
8. Displace and remove the casing securing clips.
9. Splitthecasingandremovetheevaporatorfromthe
unit.

10.
Remove the expansion valve guide securing screws
and remove the plate.

11.
Displace and remove the plate from the evaporator.

12.
Fitting the new evaporator is the reversal of the
removal procedure.

13.
Refill the engine cooling system with coolant.

14.
Recharge the air conditioning system.
Figure 1

11.
Twistandpulloutthefourairconditioningunitstub
pipes (Fig. 1-3)

12.
Remove the screws securing the air conditioning
unit support stays.

13.
Displace the tunnel carpet for access to the lower
fixing bolts and remove the stays.

14.
Disconnect the condensate drain tubes.

15.
Peel off the tape securing the windscreen demist
duct to the distribution box (Fig.
1
-4).

16.
Remove the air conditioning unit to bulkhead
securing nuts.

1
7. Carefully lift out the air conditioning unit complete
with the distribution box.

18.
Remove the distribution box securing screws and
remove the assembly (Fig.
1
-5).

19.
Reverse the removal procedure to refit the air
conditioning unit.

Note:
Ensure new'O'rings
are
fitted toall air conditioning
tiose connections.
8-56 May 1996

^?
Air Conditioning Repair Procedures
upper/Lower Servo Feedback Potentiometer Renew

8.2.03.1
Upper Servo Feedback
Potentiometer Renewal

8.2.04.1
Lower Servo Feedback
Potentiometer Renew

1.
Disconnect the battery earth
lead.

2.
(On left hand cars) Remove the instrument paci<
and surround
trim.

2.
(On right hand cars) Remove the glove box
assembly.
3.
Remove the
securing screws
and
the potentiometer
assembly. Disconnect the electrical connector.

4.
Fitting a new potentiometer is the reverse of the
removal procedure.

1.
Disconnect the battery earth
lead.

2.
Un-clip and remove the left hand underscuttle

casing.

Figure 1.
3. Disconnect the electrical block connector
(Fig.
1).

4.
Remove the securing screw and the potentiometer
assembly.
5. Fitting a new potentiometer is the reversal of the
removal procedure.
May 1996 8-57

Air Conditioning Repair Procedures
Upper/Lower Flap Motor Renew [EB^^^?
8.2.05.1 Upper Flap Motor Assembly
Renew
8.2.06.1 Lower Flap Motor Assembly
Renew

1.
Disconnect the battery earth
lead.

2.
Remove the electronic control module.
3. Disconnect the motor block connector.

4.
Remove the securing screws and motor assembly

(Figl).

Figure
5.
5. Fitting a new motor is the reverse of the removal
procedure.

1.
Disconnect the battery earth
lead.

2.
Remove the right hand side underscuttle casing.
3. Remove the electronic control unit.

4.
Disconnect the block connector.
5. Remove the screws securing the motor to the air
conditioning unit.
6. Displace the'P'clip.
7. Withdraw and remove the motor from the air
conditioning unit.
8. Fitting a new motor is the reversal of the removal
procedure.
8-58 May 1996

'nzm^=2?
Air Conditioning Repair Procedures
Blower Motor Renewal
8.2.07.1 Ambient Temperature Sensor
Renew

?\gure
1.
The ambient temperature sensor is located in the
left hand side of the air plenum chamber under the
lower windshield panel (Fig. 1-1).
Procedure

1.
Disconnect the battery earth
lead.

2.
(On left hand cars) Remove the steering wheel
(mark the position on the column shaft for re­
assembly), instrument pack and surround
trim.

2.
(On right hand cars) Removethegloveboxlidand
liner.
3. Disconnect the hose from the distribution box to
the side vent outlet. Reposition the hose for access.

4.
Disconnect the sensor block connector.
The sensor has locating clips and is a push fit into
the plenum chamber.
5. Lever the sensor free.
8.2.08.1 Blower Motor Driver Side
Renewal
8.2.09.1 Blower Motor Passenger Side
Renewal

1.
Move seat
fu 1
ly rearward.

2.
Disconnect vehicle battery ground
lead.

3. Remove the under scuttle/knee pad bolster.

4.
Remove the lower brace bar/facia assembly
underscuttle knee pad.
Driver Side Only
5. Removetheinstrumentpack, bonnetreieasehandle
mounting bracket and steering column..
6. Disconnect the air hose from the facia side air
outlet.
Passenger Side Only
7. Remove the glove box lid and liner.
Both
8. Remove the nuts securing the component panel

(Fig.
1-1).
Figure 1.
9. Ease the component panel clear for access to the
blower assembly mounting bolts.

10.
Disconnect the pliable trunking from the stub pipes
on either side of the air conditioning unit
(Fig.
1
-3).

11.
Disconnect the blower motor electrical harness at
the block connector.
May 1996 8-59

Air Conditioning Repair Procedures
Blower Assembly Renewal o^s^-^?

12.
Disconnect the vacuum pipe from the flap actuator

(Fig.
1-4).

13.
Open the re-circulation flap in the base of the
blower assembly and fit a wedge to retain it in the
open position (Fig. 1-5).

14.
Remove the bolts securing the blower assembly
and ease the blower unit from its location (Fig.
1
-6).

15.
Remove the tape securing the ducting to the
assembly and remove the ducting (Fig.
1
-7).
Note: To remove the blower motor
assembly
from the
vehicle,
the
lower flap must be opened to allow the upper
flap to
disengage
from the upper body
aperture.

8.2.10.1 Blower Assembly Driver/
Passenger Side Overhaul

Note:
Blower
assemblies
under warranty must not be
dismantled.

1.
Remove the three selftapping screws
(Fig.
1-1) from
the air intake casing.
Figure 7.

2.
Part the air intake casing (Fig.
1
-2) from the motor
assembly (Fig. 1-2) and disconnect the electrical
connections at the lucar connectors (Fig.
1
-4).
Note: Mark the position of the
various components
with
paint or
a
scriber.
This
facilitates
re-assembly.

3. One lucar connector has a raised projection which
matches the aperture in the motor casing to ensure
that the connections are replaced correctly and that
the rotation of the motor is unaffected.

4.
Remove the bolts securing the motor mounting
bracket to the fan housing (Fig. 1-5).
5. Remove the motor and fan assembly from the fan

housing.

6. Remove the mounting bracket from the motor.
7. Using appropriate Allen key, remove the impellor
fan from the spindle.
Re-assembling

1.
Refit the fan to the motor and secure it to the
spindle.

2.
Refit the mounting bracket tot he motor.
3. Locate the fan and mounting assembly into the fan

housing.

8-60 May 1996

o --^ ^^?
Air Conditioning Repair Procedures
Blower Motor High Speed Relay Renewal
6.
7.
8.
Place the flap box assembly to the fan housing and
reconnect the electrical connections.
Fit and tighten the screws securing the flap box to
the housing.
Raise the re-circulation flap, fit and tighten the
remaining screw.
Refit the blower motor assembly.
Reconnect the battery earth-ground
lead.

8.2.11.1
Blower Motor
High Speed
Relay
Renewal

1.
Remove the blower motor assembly complete.
Figure 7.

2.
Open the flap for access.
3. Using a suitable tool remove the relay from the
blower assembly (Fig.
1
-1).

4.
Fit a
new relay
and
refit the blower motor assembly.
May 1996 8-61