1997 ASTON MARTIN DB7 Workshop Manual

Electrics
Seat Belt Pretensioner
Check the continuity of
the
line from pretensioner
control module pin 2 to instrument pack green
connector pin 2.
If continuity is approximately
OQ,
go to step 5.
If the line resistance
is
significantly greater
than
OQ,
service the wiring as necessary. Reconnect all
components and test the vehicle to ensure that the
problem is resolved.
Ifthe lamp
and
wiring
checks are
good,
the
fault lies
in the instrument pack or in the control module.
Replace the control module and retest. Ifthe fault
persists, replace the instrument
pack.
Reconnectall
components and test the vehicle to ensure that the
problem is resolved.
Pretensioner Control Module Internal
Faults
The following codes indicate internal faults within the
pretensioner control module.
0209 Safing sensor error
030A Temperature sensor error
0D13 Capacitor voltage error
0D14 Capacitor capacitance
0D09 Energy reserve switch
0D1E Energy shutdown switch
050E Seatbelt pretensioner switch error
0109 Accelerometer function
01OA Acceleration out of range

01 OB
Acceierometer offset
OAOC Analogue voltage error
090A EEPROM not programmed
0909 EEPROM checksum
090C RAM check error
060E Warning lamp driver error
0A09 Communications error
OAOA External watchdog error
OAOB External watchdog time out
020A Safing sensor not closed
If any of the above codes are logged, replace the
pretensioner control module.
September 1996 6-109

September 1996
6-110

3-^?
Electrics
Seat Removal/Replacement 97.5 MY

6.6.03
Seat Removal 97.5 MY
Description
The 97.5 MY front seats are common to the DB7
Coupe
and
Volante
models.
Seat
switch
assembi ies

are located on the outboard side of both driver and
passenger
seats.
The front switch controls fore and
aft movement and the seat height adjustment. The
centre switch controls the recline adjustment. The

rear switch
controls
the
lumbar support adjustment.

The seat
heater switches are mounted on the centre
console, forward of the gear selector
lever.

Only one of
the
slide,
recline or height motors can
be driven under manual control at any one time.
Each seat switch pack is hard wired to the relevant

Seat Control
Module
beneath each
seat.
The
module
outputs are hard wired to the seat motors.
Removal
WARNING -
Seat
belt
Pretensioners
(if fitted):

To avoid the possibility
of
personal
injury
caused

by accidental deployment of the seat belt

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 detonator capacitor when
instructed
to
do
so.

Procedure

1.
Motortheseatto
its
maximum forward position and
remove the fixings at the rear of the slides.

2.
Motor the seat to its maximum rearward position
and remove the front seat slide fixings.
3. Disconnect the battery
ground
(black)
lead.
Wait at
least 10 minutes for the pretensioner power supply
to fully discharge before working on the seat if a
pretensioner is fitted.
Note: Disconnect the battery within 12 seconds of
switching off the ignition to avoid the alarm siren sounding.

4.
Disconnect the two harness connectors from the
seat control module. Also disconnect the yellow
connector from the pretensioner control module if
a pretensioner is fitted.
Figure 1. Control module connectors
5. Remove the tie straps and release the seat harness.
6. Remove the seat earth screw from the
sill.

7. Tip the seat forwards and remove from the vehicle.
Steps 10-12 Seat Belt Pretensioner vehicles only.
8. Remove the seat belt pretensioner cover (if fitted)
9. Disconnect the buckle fly-lead from the
pretensioner.

10.
Release
one
bolt at
the
base of the
seat
belt stalk and
remove the pretensioner assembly.
Reassembly and Replacement
Steps 1-3 Seat Belt Pretensioner vehicles only.

1.
Ensurethatthesafetyclipisfittedtothepretensioner
connector at the squib.

2.
Fit the assembly to the seat, locating the
anti-

rotation peg into the rear hole of the mounting

bracket.
Securethe
assembly with
one
bolttightened
to 35 Nm.
3. Route the pretensioner lead between the seat and

frame.
Refit the pretensioner
cover.

All vehicles

4.
Replace the seat in the vehicle. Reconnect and
secure the harnesses with tiestraps.
5. Reconnect the vehicle battery.
Note:
The vehicle clock and the window control units

will
need resetting after completion
of
this
procedure.

April 1997 6-127

Electrics
Seat Control Module Removal/Replacement 97.5 MY 'O "3^2?
Switch on the ignition and checi< that the airbag
warning lamp comes on when the ignition is
switched on and extinguishes after approximately
six seconds indicating satisfactory completion of
the pretensioner and airbag system self
tests.

Fit
the front
seat
retaining screws ensuring
a
1.2mm
gap between the screw heads
and
the
slides.
Power
the seat forward and refit the rear screws.
Caution:
Centralise the
rear
fixing holes
with the
body weld
nuts
prior to
inserting the
bolts.

Torque the rear screws to 25 Nm. Power the seat
backwards. Torque the front screws to 25 Nm.
Motor the seat through its full range of movement
to ensure correct
operation.

6.6.08
Seat Control Module 97.5 MY
Removal
WARNING -
Seat
belt
Pretensioners
(if
fitted):

To avoid the possibility
of
personal injury caused

by accidental deployment of the seat belt

pretensioner,
disconnect
the
vehicle battery and

wait at
least
10
minutes
for all
voltages
to fully

discharge
before
working
near the
pretensioner

system.
This covers
the
possibility
of
the
normal
capacitor
discharge circuits
being
inoperative and
failing to discharge the detonator capacitor when
instructed
to
do
so.

1.
Lower the door window and open the relevant
door. Disconnect
the
battery ground cableand wait
for 10 minutes if
a
pretensioner
is
fitted.
Otherwise,
proceed immediately to step 2.
(ei-SMiECu
Figure!.
Seat ECU Removal

2. Loosen two nuts securing the seat ECU. Slide the
ECU to the left and remove it from the front of the
seat.
3. Disconnect two connectors from the ECU.
Replacement

1.
Reconnect the two control module connectors. Fit

the seat control
moduleand
tighten
thetwo securing

nuts.

3. Reconnect the battery ground and test for correct
operation of the seat controls.
6-128 April 1997

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 //-->> ^izz^^ ' ^ ^
Body Repair ' —^^ '-^ >^-/
Body Repair
Introduction
This section contains information for the body repair and rectification of the vehicle. Wherever possible the vehicle
must be returned to its original manufactured condition. Following repair the vehicle must be fully checked and, if
necessary, the braking system and steering must be fully reset.
Health and Safety
Ensure that the correct working practices are established before beginning work.
Observe that the correct working practices are followed whether they be legislative or common sense.
Be aware of the potential risks of using materials used in the manufacture and repair of vehicles and take the
appropriate precautions.
Warning: Make sure that the working practices for the air conditioning
system
are followed: do not vent the refrigerant
directly into the atmosphere and always use the approved recovery/recycle /recharge equipment, always wear
suitable protective garments to prevent injury to the eyes and the skin.
Potential Risks
Paint
If the organic solvents, contained in paints, are inhaled for any length of time damage can be caused to the liver,
kidneys, respiratory tract and the digestive system.
Prolonged exposure to isocyanates can cause lung sensitisation and asthma-like symtoms can develop with
subsequent re-exposure to even low concentrations.
Solvent inhilation can cause dizziness or loss of consciousness.
Inhilation of spray dust and sanding debris can cause lung damage.
Paint activatorsand additives will damage the eyesor can cause dermatitis if allowed to splash and come into contact
with these areas. Peroxide and acid catalysts can cause burns.
Applied heat
There is considerable risk of damage to the eyes and skin when welding or flame cutting.
Fire is a serious danger as many materials and fluids in the vehicle are inflammable.
Toxic and dangerous fumes can be liberated when the following are subjected to heat; expanded foam, corrosion

protection,
adhesive and sealing compounds,
trim,
seat material and paints that contain isocyanates.
When heated to
a
temperature of 300°C, polyu rethane based compounds can
1
iberate small quantities of isocyanate.
Many types of nitrogen containing chemicals may be liberated as breakdown products, these chemicals can
contain isocyanates, oxides of nitrogen and hydrogen cyanide.
Potentially toxic or asphyxiant fumes and gases are produced by welding, for example; zinc oxide with zinc coated
panels and ozone gas from the MIC process.
Metal repair
There is considerable risk of damage to the eyes, ears and skin when metal cutting, forming and dressing is being
carried out.
Soldering may be hazardous because of heat generated fumes and skin contact with the materials.
7-2 May 1996

^"^
Body and Trim
Body Repair
Precautions
Paint
Ensure that there is efficient ventilation at all times. Paint spraying should be confined to spray booths.
Anyone with a history asthma should not be engaged in any process which involves the use of isocyanates.
Any operator working inside a spray booth where isocyanates are present must use air-fed breathing equipment.
Supplied air to the visor should be fed at the recommended pressure and filtered to remove oil, water and fumes.
Operators involved in handling, mixing or spraying should wear protective clothing, gloves and goggles to avoid
skin and eye contact. A Paticle mask or canister typr respirator should be worn when sanding.
Applied heat
When welding, flame cutting or brazing and so on, goggles, a mask or fume extractor and flameproof protective
clothing should be used always.
It is especially important when working with polyurethane compounds to use air-fed breathing equipment.
Ensure that at all times the appropriate fire fighting equipment isavailableand that personnel are trained in its use.
Metal repair
Wear appropriate eye and hand protection when sanding, drilling, cutting, chiselling, flatting or welding. Wear a
face mask or air-fed visor when sanding or flatting either body solder or
fillers.
When a soldering operation has been

completed,
remove swarf from the work area and wash your hands thoroughly.
General Repair Notes
The following precautions should be noted before any work is carried out:
• disconnect the vehicle battery ground
lead,
taking note of the reconnection procedures
• Make sure that you have read and understood the safety related procedures in this section.
Caution:
Electric arc
welding must not
be
used on the
vehicle as the high
voltages produced by
this process
will
cause
irreparable

damage
to the electrical control and
microprocessor
systems.

All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel
removal or replacement.
Welding and Gas Process Special Notes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated

metal.
The flanges of panels, which are to be welded together, must be clean, corrosion free and treated as
appropriate with either weld-through or inter-weld sealer.
The resistance spot welding equ ipment used in vehicle repair does not always produce
a
weld of
equ
ivalent strength
to that produced in manufacturing. This means that a single row of spot welds should be spaced on a pitch of 19-
25 mm, which will usually result in more spot welds than found in the original factory joint.
Use a resistance spot weld cutter to remove resistance spot welds. Where a new joint is to be MIC welded, cut the
old resistance spot welds from the panel that is to be retained; the resulting holes are then used for plug welding.
Suitable holes may be drilled or punched as follows:
• 8.0 mm for sections up to 1.5 mm thickness
• 10.0 mm for thicker sections.
Always refer to the welding equipment manufacturers diagrams and tables for the relevant procedure.
May 1996 7-3

Body and Trim
Body Repair ^^
Steel Body Parts - Repair^ Remove and
Replace
Removal

1.
Expose the resistance spot
weld.
For those spot
welds that are not obviously visible use a rotary
wire brush fitted to an air drill or a hand held wire

brush.

9.
Prepare the new panel joint edges for welding by
cleaning to bright metal, both interior and exterior
edges.
Apply weld through primer or inter-weld sealer to
all surfaces to be resistance spot welded.
Where appropriate, apply metal-to-metal adhesive
or sealer in accordance with the manufacturer's
instructions.
Caution: Do not
burn
off undersea I,
use a
'hot knife' or
a

suitable solvent.
2. Cut out the spot welds using aZipcutter or roto-Bor.
At this point it may be necessary to cut out the bulk
of a panel using a pneumatic saw.
Note: On
some
panels,
before removing the bulk of the
panel, brazed
areas
and MIC welded
seams
should be
removed.
3. Separate the spot welded joints and remove the
panel remnants.
Preparing Old Surfaces

1.
Remove the weld nuggets with a sander and 36 grit
disc.

2.
Clean all flanges to a bright smooth finish.
3. Straighten existing panel joint edges as required.
Preparing New Surfaces

1.
Mark off the area of the new panel and cut to size
leaving approximately two inches overlap on the
existing panel

2.
Offer up the new panel or section and align it with
the associated parts.
3. Clamp the panel into position.

4.
Where necessary, cut the new and original panels
to form a but joint.
5. Remove all clamps and the new panel.
6. If required, apply the inner panel protection and or
sound insulation.
Panel Alignment

1.
Align the replacement panel with the associated
panel and clamp it in position.

2.
With certain panels it may be necessary to tack
weld or use PK screws.
Welding

1.
MIC tack the butt joints.

2.
Re-check the alignment and the panel contours as
necessary.
3. Select the correct arms for resistance spot welding
and ensure that the tips are correctly trimmed.
Note: It
is
recommended that
the arms are
not more than
12 in (300 mm) in length.

4.
Test the equipment for satisfactory operation using
test coupons.
In the absence of test equ ipment
a
satisfactory weld
can be verified by pulling the test coupons apart
and viewing the welded condition.
5. Resistance spot weld where required. Note the
presence of zinc coated panels and treat as
previously described.
6. Dress back all MIC tack welds.
7. MIG seam weld the butt joints.
8. Dress all welds as required.
9. Final brazeand lead load as necessary priorto paint
preparation.
7-4 May 1996