1997 ASTON MARTIN DB7 heater

Electrics
Seat Belt Pretensioner ^?
060C Warning Lamp Short Circuit
060C will be logged if the nnonitor current flow
through the SRS/Airbag warning lamp is excessive.
The warning lamp circuit is normally at 12 volts and
is switched to ground by the airbag control module
or by the pretensioner control module when one of
these control modules detects a fault.
If either control module connector is displaced and
the ignition is switched on, the warning lamp will
be illuminated via the ground shorting link between

pins!
and 2 ofthe pretensioner controller connector
or pins 4 and 5 of the airbag controller connector,
both control modules must be checked for the
appropriate DTC to isolate which circuit is at fault.
Procedure

1.
Connect the PDU to the lower diagnostic socket
and access the pretensioner control module. Verify
that an 060C code is logged and note if the fault is
shown as intermittent. Note any other codes in the
DTC log and then clear all codes. Go to step 2.
If fault code 060C is not logged, go to the diagnostics
section of the airbag system.

2.
Check the security of the pretensioner control
module connector.
If the connector is secure, go to step 3.
If the connector isdisplaced,resecu re theconnector.
Clear all logged DTCs and retest the vehicle to
ensure that the problem is resolved.
3. Access the SRS/Airbag warning lamp and check the
lamp resistance.
If the resistance is approximately
120£2,
the lamp is

good.
Refit the lamp and go to step 4.
If the resistance of the lamp is significantly less than
approximately 120^, fit a new lamp and refit the
instrument panel. Clear the logged DTCs from the
pretensioner control module and retest the vehicle
to ensure that the problem is resolved.

4.
If the checks in step 3 are good, the low circuit
resistance must be in the instrument pack or in the
control module. Replace the pretensioner control
module and reconnect all components.
6. Switch on the ignition and then test the vehicle.
If the 060C code is logged again, replace the
instrument pack.
060D Warning lamp open circuit
060D will be logged if the monitor current flow
through the SRS/Airbag warning lamp is below the
normal monitor level.
The warning lampcircuit is normally at 12 voltsand
is switched to ground by the airbag control module
or by the pretensioner control module when one of
these control modules detects a fault.
Procedure
Connect the PDU to the lower diagnostic socket
and access the pretensioner control module. Verify
that an 060D code is logged and note if the fault is
shown as intermittent. Note any other codes in the
DTC log and then clear all codes. Go to step 2.
lffaultcode060D is not
logged,
gotothediagnostics
section of the airbag system.
Switch off the ignition. Access the SRS/Airbag
warning lamp and check the lamp resistance. The
resistance should be approximately 120Q.
If the resistance is 120i2, go to step 3.
If the lamp resistance is significantly lower than

120^2,
replace the lamp. Retest the vehicle to
ensure that the problem is resolved.
Wait 10 minutes after switching off the ignition to
ensure that the pretensioner firing capacitors have
fully discharged.
Disconnect the pretensioner control module and
temporarily cheat the warning lamp shorting link.
Note: The control module harness connector has a
shorting link which short circuits the warning lamp line
(pin 2)to ground
(pin
Dwhen
the
connector
is
displaced.
Carefully insert a suitable non-metallic cheater to remove
the
short
circuit
between
pins
1
and 2 before continuing
with fault
diagnosis.

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^ ^ ^ 1^1
Insert cheater hare
6-108
September
1996

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

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

^^2?
Body and Trim
Roof Sealing and Wind Noise
Roof Sealing and Wind Noise
Roof seals and side windows have been provided
with
a range
ofadjustments capable ofdealing with
any leaks which may occur.
The following information is divided into five
sections:

1.
A post and header sealing/roof lock adjustment

2.
Roof seals - adjustment
3. Cheater plate seals - adjustment/renewal

4.
Door glass - adjustment
5. Rear quarter glass - adjustment (9.1.01.2)
When a leak is
reported,
either wind noise or water
ingress, try to pinpoint the actual leak path using
any of the following methods:
• An ultrasonic leak detector
• An air flow
detector,
e.g.
Drager
smoke
tube
• Paper test strips at seal contact areas
9.2.01.5 - 'A' Post/Header Sealing and
Lock Adjustment
when a leak is detected at the top of the 'A' post
adjacent to the header rail
seal,
first
ensure
that the
roof lock is correctly adjusted.
If the lock is difficult to operate, it is probably
overtensioned. Release the retaining hook locknut

and extend
the hook
one full
turn.
Checkand repeat
the adjustment as necessary.
If the locking handle is loose, it is undertensioned.
Release the retaining hook locknut and screw the
hook inwards one full
turn.
Check and repeat the
adjustment as necessary.
Open the roof and check for obvious seal defects
i.e. collapse, damage or manufacturing faults.
Replace where necessary.lf the lock tension is
correct and a leak is still evident, it may be caused
by lack of pressure between the front frame and
header seals (Fig 2).

Increase seal pressure by inserting a
packer between
the front and rear frame seals (see DB7 Volante
parts manual).

Note:
After fitting
sea!
packers, check the locking
handle tension and adjust if necessary. If
a
leak is
still evident, go to 9.2.01.6.

Figure
2. Front and
Rear Seal Packers

Figure 1. Roof
Lock

May 1996 7-17

^?
Body and Trim
Cheater Panel Seals
9.2.01.7
Renew
Cheater Plate Seals - Adjust/
The contact line along the front edge of the door

glass,
and continuing via the cheater plate, is

critical.
Closer examination of the cheater plate
assembly (following leak path identification) may
reveal ridges where the upper and lower seals are

joined.
(Fig 5). The only solution is to carefully fit
new
seals using an
appropriate sealant
and
contact
adhesive.

Figure
5.
Cheater Panel Seals

If the leak is caused by incorrect positioning of the
door glass, carry out the adjustment procedure as
detailed in 9.2.01.8.
May 1996 7-19

^7
Air Conditioning
Contents
Repair Procedures
8.1.01.1 Compressor Removal/Renewal 8-51
8.1.02.1 Field Coil Renewal 8-52
8.1.03.1 Renew Gasket Kit 8-52
8.1.04.1 Valve Plate Renewal 8-53
8.1.05.1 Expansion Valve Renewal 8-54
8.1.06.1 Hose-Compressor to Evaporator Renewal 8-55
8.2.01.1 Air Conditioning Unit Renewal 8-55
8.2.02.1 Evaporator Unit Renewal 8-56
8.2.03.1 Upper Servo Feedback Potentiometer Renewal 8-57
8.2.04.1 Lower Servo Feedback Potentiometer Renew 8-57
8.2.05.1 Upper Flap Motor Assembly Renew 8-58
8.2.06.1 Lower Flap Motor Assembly Renew 8-58
8.2.07.1 Ambient Temperature Sensor Renew 8-59
8.2.08.1 Blower Motor Driver Side Renewal 8-59
8.2.09.1 Blower Motor Passenger Side Renewal 8-59
8.2.10.1 Blower Assembly Driver/Passenger Side Overhaul 8-60
8.2.11.1 Blower Motor High Speed Relay Renewal 8-61
8.2.12.1 Water Temperature Switch Renewal 8-62
8.2.13.1 Heater Matrix Renewal 8-62
8.2.14.1 Electronic Control Module Renew 8-63
8.3.01.1 Vacuum System Solenoid Renewal 8-63
May 1996 8-3

^^?
Air Conditioning
System Description
System Description
The in-car temperature and humidity are regulated by the electronically controlled air conditioning system. The
system comprises four subsystems:
• heater matrix, supplied with water from the engine cooling system
• refrigeration
• vacuum
• electronic control
Apart from the ambient temperature sensor and the aspirated in-car temperature sensor, most of the components
are housed in the air conditioning unit (Fig. 1) situated behind the dash board, or in the engine compartment.
Figure 1.
Key to Fig. 1 - Left Hand Air Conditioning Unit

1.
Upper feedback potentiometer

2.
Water temperature switch
3. Lower feedback potentiometer

4.
Vacuum valve block
5. Vacuum restrictor
6. Condensate drain tube
Figure 2.
Key to Fig. 2 - Right Hand Air Conditioning Unit

1.
Upper servo motor

2.
Electronic control module
3. Lower servo motor

4.
Evaporator sensor
5. Condensate drain tube
Special Servicing Tools and Equipment
1 PDU system
1 Charging station
1 Leak detector
1 Temperature test box
1 Sanden compressor service tool kit
1 CM Type compressor service tool kit
1 Digital voltmeter
1 Multimeter
May 1996 8-7

^7
Air Conditioning
Temperature Distribution System
Temperature Distribution System
The heating and ventilation unit case consists of three sections:
• the front, which contains the air conditioning system evaporator
• the rear section, which consists of two parts and contains the heater matrix and rotary flaps
• the lower outlets which direct air to footwell and rear passenger compartment and are removable.
Temperature variation within the car
is
achieved by all incoming air passing through the evaporator and then being
directed through or around the heater matrix by rotary flaps:
• Full heating (Fig.1)
• Defrost (Fig. 2)
• Full cooling (Fig. 3)
Blend (Fig. 4)
Figure 1.
Figure
2.

Figure
3.
Figure
4.
The rotary flaps are opened or closed by servo motors, as directed by the control system, and flap position
information is relayed to the ECM by feedback potentiometers.
(Solid arrow = Hot, Line arrow = Cold)
May 1996 8-9