1997 ASTON MARTIN DB7 wheel

^=2?
Electrics
Airbag System
Eye Protection
Chemical protective goggles are recommended
where there is a possibility of eye contact with the
propellant. Safety glasses with side shields are
recommended for all other operations.
Protective Clothing
Approved protective gloves, overalls and shoes/
boots should be worn.
Handling and Storage Precautions
Do not store airbag modules near live electrical
equipment or circuitry. Store in a dry environment
at ambient temperatures.
Good housekeeping and engineering practices
should be employed to prevent the generation and
accumulation of
dusts.
Store in compliance with all
local state and federal regulations.
Driver and Passenger Airbag Modules
Assembly/Removal/Service Instructions
WARNING: In the event of a vehicle impact where the
airbags and the seatbeltpretensioner (if fitted) are
deployed, the following actions MUST be
performed:
Check the condition of the seatbelts, steering

wheel,
steering column, all connections to airbags,
and the column switchgear connectors for integrity
and damage. If in any
doubt,
replace suspected
parts for new parts.
Replace both crash
sensors,
the
safing sensor
and
the seatbelt pretensioner module (if fitted).
On completion of all repair procedures, switch on
the ignition and check that the
Airbag/SRS
warning
light comes on when the ignition is switched on
and extinguishes after approximately six seconds
indicating satisfactory completion of the airbag
and pretensioner
system
self
tests.

WARNING: Before starting
work,
ensure
that the ignition
switch is in position 'O' and the ignition key is

removed.
Disconnect the battery negative lead
within 12 seconds of switching off the ignition to
prevent the alarm system triggering.
As the airbag control module is equipped with a
back-up power source and due to the risk of the
airbag being inadvertently deployed, wait one
minute or longer after disconnecting the battery
before starting work on the airbag module.
• Disconnectingthe battery negative cable cancels
the memory for the 'one-touch' window down
system and stops the vehicle clock. Reset the
window memory and the clock when work is

completed.

• Never use airbags from other vehicles, always
use new parts.
• After work is completed, reconnect the battery
and perform the airbag warning light check
• Never use electrical probes to check voltage or
electrical resistance of the airbag modules.
• Disconnect the airbag before carrying out any
work on, or in the vicinity of the module, or
when using electric welding equipment.
• Always ensure that the battery negative lead has
been disconnected for at least one minute before
commencing any removal procedure.
September 1996 6-71

'=2?
Electrics
Airbag System
4.5.01.3 Driver's Airbag Module Renew
Read and adhere to all warnings and safety
procedures quoted at the start of this section when
working on airbag modules.

1.
Ensure that the steering system is centralised and
that the steering wheel is in the lowest tilt position.

2.
Disconnect the vehicle battery and insulate the
battery lead to avoid accidental reconnection. Wait
for at least one minute before proceeding with work
on the removal of the airbag.
Hote: The vehicle battery
must be
disconnected within
12 seconds of switching off
the
ignition to avoid the alarm
siren sounding.
5. Carefully remove the module from the steering
wheel and disconnect the airbag module multi-

plug.

6. To ensure personal safety, double check that the
battery is still disconnected and the battery lead
safely insulated. Connect the new airbag module

multi-plug.
Fit and align the new module to the
steering wheel and tighten the two securing torx
screws. Return the steering to the straight ahead

position.

7. Remove the battery lead insulation and reconnect
the battery
lead.

Note:
The vehicle
clockandthe window control unitwill
need
resetting
after completion of
this
procedure.
8. Switch on the ignition and check that the airbag
warni ng
I
ight comes on when the ignition is switched
on and extinguishes after approximately sixseconds
indicating satisfactory completion of the airbag
system self tests.
Insert the ignition key and turn to position I. Turn
the steering wheel to the left, 90° from its straight
ahead position, and loosen thefirstmoduiesecuring
torx screw.
Turn the steering wheehSO" to the rightand loosen
the second module securing torx screw.
September 1996 6-75

Electrics
Airbag System ^^?

7.8.02.6

Renew
Passenger's Airbag Module
Read and adhere to all warnings and safety
procedures quoted at the start of this section when
working on airbag modules.
Disconnect the battery and wait for at least one
minute before proceeding with the airbag removal.
Note:
The
vehicle battery
must
be disconnected within
12
seconds
of switchingoff
the
ignition
to
avoid the alarm
siren sounding.
2. Open the passenger airbag deployment door.
3. Release four nuts and remove the airbag module.

4.
Disconnect the airbag harness multi-plug.
5. Connect and fit the new module and secure with
four nuts.
6. Refit the airbag deployment door.
Note:
The vehicle
clock and
the
window control unit will
need
resetting
after completion of
this
procedure.
7. Reconnect the battery. Switch on the ignition and
check that the airbag warning
I
ight comes on when
the ignition is switched on and extinguishes after
approximately six seconds indicating satisfactory
completion of the airbag system self tests.
6.1.23.1/6.2.10.1 Airbag
Crash
Sensors
Renew
Read and adhere to all warnings and safety
procedures quoted at the start of this section when
working on the airbag system.

1.
Disconnect the battery and wait for at least one
minute before working on the airbag system.
Note: The vehicle
battery
must be disconnected within
12
seconds
of switchingoff
the
ignition
to
avoid thealarm
siren sounding.

4.

5.
Raisethevehicleon a rampand remove the relevant
front roadwheel and wheel arch liner.
Disconnect the sensor connector and feed the
protected loom forward through the body aperture.
Open the bonnet and release two bolts securing the
crash sensor to the body.
Fit and secure the new sensor and feed the sensor
loom back through the body aperture.
Reconnect the sensor. Refit the wheel arch liner
and the roadwheel.
Note:
The vehicle
clock and
the
window control unit will
need
resetting
after completion of
this
procedure.
Reconnect the battery, switch on the ignition and
check that the airbag warning
I
ight comes on when
the ignition is switched on and extinguishes after
approximately six seconds indicating satisfactory
completion of the airbag system self tests.
6-76 September 1996

Electrics
Airbag System '=2?
Airbag System Diagnostics
System Description
The airbag system installation comprises:
Airbag Diagnostic Module
Driver and passenger airbag modules
Two front impact (crash) sensors
One 'safing' sensor
Dedicated wiring harness
SRS indicator/warning lamp
The system is designed to provide protection for
both driver and front seat passenger by automatical ly
deploying airbags in the event of
a
collision during
forward travel.
In the event of a collision, the crash and safing
sensors will operate, completing the firing circuit
and causing the airbags to inflate within 32
milliseconds. At least one crash sensor and the
safing sensor must operate to fire the airbags.
Any faults in system components, installation or
wiring will be indicated by a flashing code on the
SRS/AIRBAG warning lamp. Fault code information
may also be monitored using the PDU or scan
tool.

Component Descriptions
Airbag Diagnostic Module
The airbag diagnostic module is mounted on top of
the passenger airbag mountingcage.Thediagnostic
module contains the microprocessor which is
connected to the complete airbag system. The state
of the three system sensors, the two airbag modules
and the wiring harness is constantly monitored by
the microprocessor for faults and for sensor
activation (crash) conditions.
The diagnostic module also confirms correct supply
voltage by comparing
a
direct battery voltage input
with a similar input via the ignition switch.
The diagnostic module contains a reserve power
supply, enabling the airbags to fire even if the
supply voltage is lost due to collision damage. The
reserve power charge will be retained for
approximately one minute if the positive battery
supply is lost in a collision. An auxiliary internal
circuit known as the 'dwell enhancer' provides a
temporary ground if normal system ground was lost
in a collision.
Wiring Harness
A dedicated electrical wiring harness is used to
connect all system components to the bulkhead
harness. To allow free movement of the steering
mechanism, a cable reel cassette is used to connect
the drivers airbag in the steering wheel to the airbag
harness on the steering column.
Airbag Modules
The two airbag modules contain achargeof sodium
azide/copper oxide which wi
11
generate
a
sufficient
volume of nitrogen gas to fully inflate the airbag
when ignited by an electrical impulse. The volume
of gas is greater in the passenger side airbag due to
its larger size.
Both airbag modules, including the surrounding
trim of the drivers airbag, are non-serviceable and
once deployed, must be renewed as a complete
assembly.
Crash and Safing Sensors
The two crash sensors are mounted one at either
side of the bumper mounting cross member, outside
of the bonnet hinges.
The safing sensor is mounted in the base of the
drivers side 'A' post.
The two crash sensors and the safing sensor
determine when airbag deployment is necessary in
a crash condition.
The sensor contacts will only close when the vehicle
suffers a forward impact of sufficient force. At least
one crash sensor and the safing sensor contacts
must close before the airbags will deploy. The
doubletrigger strategy
is
used to prevent deployment
during trivial impacts such as contacts during

parking.

6-78 September 1996

Electrics //—>> ^^^^^^ • >^
Seat Belt Pretensioner I'•—
-"i-t.
^-^
JH—X

System Fault Strategy
No single fault may cause an unexpected deployment. The controller will supervise the pretensioner electrical
system in order to warn the driver should a fault occur. Any fault detected by the self diagnostics shall cause the SRS/
airbag warning lamp to be activated, and in some cases the pretensioner control module to enter shutdown mode.
In shutdown mode, the energy of the reserve capacitors shall be discharged to avoid unintended deployment.
As the ignition is switched on, the pretensioner controller will directly discharge the energy capacitors. When the
start up procedure is completed without detecting any faults, the DC/DC converter will be activated allowing the
capacitors to be charged. The system shall be fully active within
11
secondsafterswitchingthe ignition on providing
that no faults are detected.
All system faults monitored by the controller are filtered in software to avoid fault warnings due to transient electrical
disturbances.
If a fault which could lead to inadvertent deployment is detected by the microprocessor, a software shutdown will
be generated. However, a leakage to an earth or positive potential in the pretensioner output circuit shall not cause
the controller to enter shutdown mode.
If a permanent short of the ignition transistor occurs, a shutdown shall be generated by the hardware circuit. If a
shutdown occurs, the system shall be unable to deploy the pretensioner after a period of 3 seconds (i.e. capacitors
discharged to under minimum deployment voltage).
WARNING: To avoid the possibility of personal injury caused by accidental deployment of the pretensioner,
disconnect the vehicle battery and wait at least 10 minutes for all voltages to fully discharge before working on
the pretensioner
system.
This
covers the possibility of the normal capacitor discharge circuits being inoperative
and failing to discharge the capacitor when instructed to do so.
WA RNING: Do not make any electrical measurements on the pretensioner squib. Electrical measurement devices
can induce sufficient voltage to cause unintentional firing of the pretensioner assembly
If the module enters shutdown mode, all diagnostic functions are stopped, but the communications link remains

active.
A fault code corresponding to the cause of the problem may be read by the PDU.
Assembly/Removal/Service I nstructions
WARNING: In the event of a vehicle impact where the airbags and the seatbelt pretensioner (if fitted) are
deployed, the following actions MUST be performed:
Check the condition of the
seatbelts,
steering wheel, steering column, all connections to airbags, and the column
switchgear connectors for integrity and damage. If in any doubt, replace suspected parts for new parts.
Replace both crash
sensors,
the safing sensor and the seatbelt pretensioner module (if fitted).
On completion of all repair procedures, switch on the ignition and check that the Airbag/SRS warning light
comes

on when the ignition is switched on and extinguishes after approximately six seconds indicating satisfactory
completion of the airbag and pretensioner
system
self
tests.

Vehicles for the North American, Australian and Japanese markets are fitted with drivers seat belt pretensioner
systems and are fitted with a shorting plug in the yellow connector adjacent to the pretensioner control module.
Vehicles for other markets do not have drivers seat belt pretensioners fitted but have a blanking plug in the yellow
connector adjacent to the pretensioner control module.
6-102 September 1996

O" D^?
Body and Trim
Contents
Contents
Body and Trim
Body Repair
Potential Risks
Precautions
General Repair Notes
Steel Body Parts - Repair, Remove and Replace
RTM Body Parts
Body Panel and Trim Removal
Front Apron
Front Undertray
Wheel Arch Liners
Side Sills (top fixings)
Side Sills (bottom fixings)
Rear Bumper
Doors
Door Liners
Door Liner (components)
Steering Wheel
Column Switches
Instrument Panel (surround)
Instrument Panel
Facia Underscuttles
Glove Box
Facia Mountings (1)
Facia Mountings (2)
Console Instruments
Radio
Front Seats
Ashtray
Centre Console
Seat ECU Covers
Rear Console
Rear Seats and C Post Trim
Quarter Panels, B Post Panels, Parcel Shelf
Headlining
Roof System Description and Repair Procedures
Vol ante Roof
Roof and Rear Quarter Light Control
Roof Component Location
Roof Control System

9.0.02.1
Roof Removal/Replacement

9.0.02.3
Roof Hydrailic Control System

9.0.02.5
Bleeding the Roof Hydraulic System

9.1.01.1
Rear Quarter Window Renewal

9.1.01.2
Rear Quarter Glass Adjustment

9.1.01.4
Rear Quarter Window Lift Motor - LH

9.1.01.5
Rear Quarter Window Lift Motor - RH
Roof Sealing and Wind Noise

9.2.01.5
'A' Post/Header Sealing and Lock Adj

9.2.01.6
Roof Seals - Adjustment

9.2.01.7
Cheater Plate Seals - Adjust/Renew

9.2.01.8
Door Glass Adjustment
Alcantara Cleaning
7-1
7-2
7-2
7-3
7-3
7-4
7-5
7-6
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
Sheet 6
Sheet 7
Sheet 8
Sheet 9
Sheet 10
Sheet 11
Sheet 12
Sheet 13
Sheet 14
Sheet 15
Sheet 16
Sheet 17
Sheet 18
Sheet 19
Sheet 20
Sheet 21
Sheet 22
Sheet 23
Sheet 24
Sheet 25
Sheet 26
Sheet 27
7-7
7-7
7-8
7-9
7-10
7-11
7-12
7-13
7-14
7-15
7-16
7-17
7-17
7-18
7-19
7-20
7-21
May 1996 7-1

Body and Trim
Body Panel and Trim Removal 5^7
Body Panel and Trim Removal
The following diagrams show the fixings for all
removeable body and trim panels.
Sheet 1. Front Apron
Sheet 2. Front Undertray
Sheet 3. Wheel Arch Liners
Sheet 4. Side Sills (top fixings)
Sheets. Side Sills (bottom fixings)
Sheet 6. Rear Bumper
Sheet 7. Doors
Sheet 8. Door Liners
Sheet 9. Door Liner (components)
Sheet 10. Steering Wheel
Sheet 11. Column Switches
Sheet 12. Instrument Panel (surround)
Sheet 13. Instrument Panel
Sheet 14. Facia Underscuttles
Sheet 15. Glove Box
Sheet 16. Facia Mountings (1)
Sheet
1
7. Facia Mountings (2)
Sheet 18. Console Instruments
Sheet 19. Radio
Sheet 20. Front Seats
Sheet
21.
Ashtray
Sheet 22. Centre Console
Sheet 23. Seat ECU Covers
Sheet 24. Rear Console
Sheet 25. Rear Seats and C Post Trim
Sheet 26. Quarter Panels, B Post Panels, Parcel Shelf
Sheet 27. Headlining
7-6 May 1996

Body and Trim
Sheet 3
Wheel Arch
Liners