1997 ASTON MARTIN DB7 door

Body and Trim
Roof Seals - Adjustment
9.2.01.6 - Roof
Seals
- Adjustment
Seal adjustment is done in two stages. First stage -
lateral adjustment, and second stage - outward
adjustment. Seals are packed out using selected
packing strips.
Lateral Adjustment
Partially open the roof.
Front frame seal only: Remove the seal retaining

plate.
Remove the seal from the channel.
Slacken the channel securing screws and reposition
the channel as required, moving it on the slotted
screw holes (Fig 3-A). Tighten the channel securing
screws.
Apply soft soap to the seal and insert the outer seal
edge into the channel. Then press in the inner edge
to fully seat the
seal.

Refit the seal retaining plate.
Outward Adjustment
Partially open the roof.
Remove the seal retaining plate. Remove the seal
from the channel. Mark the position of the channel
for reference, release the screws and remove the

channel.

Select the appropriate packing (Figure 3-B)(see
DB7 Volante parts manual):
Rear frame seal foam strip
Front frame seal foam strip
Main column seal foam strip
Upper 'A' post seal foam strip
Note: The foam strips are for full length packing. For
packing at one end
only,
a shorter rubber
wedge
can be
used. (Fig 1-C)
Fit the foam strip/rubber wedge and channel. Align
the channel in the previously marked position. Fit
and tighten the securing screws.
Apply soft soap to the seal and insert the outer seal
edge into the channel. Then press in the inner edge
to fully seat the
seal.
Refit the seal retaining plate.
Note: It is imporrtant at all times to retain the overall
shapeoftheroofsealline(Fig4).
Wherea
leak necessitates

the
adjustment of only
one
or two
seals,
ensure
that
there
are
no
misalignments.
A more
satisfactory result
may be
obtained by adjusting the adjacent component, i.e. the
door
glass
or rear quarter glass.
The relationship between the roof seals is very
important. Two seals in very close contact will
promote leakage problems. Sealing will be far more
effective ifthe seals touch lightly or exhibit a small
air gap (Fig 4).
Figure 4. Seal Line and spacing
Figure 3. Front Frame Seal Adjustment
7-18 May 1996

^?
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

Body and Trim
Door Glass Adjustment ^?
9.2.01.8 - Door Glass Adjustment
The door glass can be adjusted in three planes. Lateral, Up and Down, and Front to Rear. It is advisable however
to avoid forward and rearward adjustment if possible,
as
this will affect the height and overall position of
the
glass
relative to the seals. Use this adjustment only to correct serious misalignment.
Lateral Adjustment
Remove the door trim pad. Partially lower the window to allow access to the glass channel mounting bracket (Fig
6-A). Slacken off the four nuts to allow lateral adjustment. Move the glass to the desired position and tighten the

nuts.
Close the
window
and
recheck the alignment.
Repeat the
adjustment until
the
optimum alignment
is
achieved.
Refit the door trim pad.
Upward Adjustment
Remove the door trim pad. Slacken off the regulator locknut (Fig 6-B). With the door
closed,
operate the window
to the fully closed position and tighten the locknut. Refit the door trim panel.
Front to Rear Adjustment
Remove the door trim pad. Partially lower the window to allow access to the glass channel mounting bracket (Fig

6C).
Slacken
the
four
screws
to allow
glass
movement.
Move
theglass
to the
required position
and tighten
the screws.
Close the window and recheck the alignment. Repeat the adjustment as necessary until the optimum front to rear
alignment is achieved. Refit the door trim pad.

Figure
6. Door
Class Adjustments

7-20 May 1996

Air Conditioning
Functional Check
Functional Check
This functional check procedure is provided as a simple system validation and is structured to augment the Portable
Diagnostic Unit (PDU).
Stage 1 (Cold engine only, if not proceed to Stage 2)
Procedure Normal System Reaction

1.
Ignition ON
Select MIN temperature, MAN, speed 3, Mid face.
(Engine Stationary) Fans Start

2.
Select MAX temperature Fans continue to run
3. Ignition OFF
Select MAX temperature and defrost
Ignition ON Fans start at maximum speed

4.
Select fan speed
1
Fan speed adjusts accordingly - system OK
Stage 2
Procedure Normal System Reaction

1.
Start up engine and warm up
Select fan speed 1, MAN, MAX TEMPERATURE
and mid face

2.
Open all vents Fans start after 3 seconds

2.
Select fan speed 2 Fan speed increases then stabilises
3. Select fan speed 3 Fan speed increases then stabilises

4.
Select defrost Fan speed steady at high
All air at screen and dash end
5. Re-select fan speed 1
Select AUX ignition key position
6. Slowly select MIN temperature Solenoids switch 1. centre vent

2.
water valve
3. Re-circulation
7. Re-select MID temperature
8. Select DEM Solenoid clicks
Air at screen
9. Select manual re-circulation Solenoid click

10.
Check flap for position

11.
Run Engine to normal temperature

12.
Select: MAN, 3/4 MAX heat and fan speed 2 Air from door vents
cool,

air temp from foot outlet slightly warm

13.
Select MAX temperature and air differential to hot face All vent outlets max temp except screen vent

14.
Select temperature
approx. 1/4 MAX heat and mid face level Cool air from centre vents

15.
Select MIN temperature Blower flaps at re-circulation position
All outlets blowing cold air except screen vent
May 1996 8-15

Air Conditioning
System Checking with the Manifold Gauge Set D'^?
Purging the Test Hoses

1.
With the manifold test set attached to the system.

2.
Purge the high pressure test hose by cracking open
the high pressure side hand valve on the manifold
gauge set for 3 to 5 seconds. This allows the system
refrigerant to purge the air from the test hose and
discharge through the manifold centre test hose.
Immediately cl ose the high pressure side hand

valve.

3. Purge the low pressure test hose in the same manner
by cracking open the low pressure side hand valve
manifold gauge
set
for 3 to 5 seconds, then close the
hand valve.
Stabilising the System
The manifold gauge set is now attached to the
system and the test hoses purged of air. With both
hand valves closed, the system must be operated
for a few minutes to stabilise all pressures and
temperatures throughout the system in order to
obtain accurate test gauge readings.
Proceed as follows:

1.
Place all test hoses, gauge set and other equipment
away from all engine moving parts. Also keep the
hoses from touching the hot engine manifold.

2.
Start the engine and adjust engine speed to fast idle
3. Turn on the air conditioning and set for maximum
cooling with blower fans on high speed

4.
Open the car doors and/or windows (to quickly
eliminate car interior heat).
5. Operate the system under these conditions for 5 to
10 minutes to stabilise the system ready for testing.
6. Check the system for full refrigerant by noting the
sightglass indications. Some refrigerant loss occurs
over a period of time.
Note: The air conditioning
system
must contain a full
refrigerant
charge
before an accurate
system
check can
be
made.
An insufficient
charge
is indicated by
a stream

of
bubbles
or
foam.
If
the
refrigerant charge is low, the

system
must
be
fullydischarged into
a
refrigerant recovery
station and recharged with the correct weight of refrigerant
82.30.08. Do not top up a
system
with refrigerant.
Leak Test
A high proportion of ail air conditioning work
consists of locating and repairing leaks.
Many leaks are located at connections and are
caused by vibration. They may only require the re-
tightening of a connection or clamp.
Occasionally a hose rubs on a structural part of the
vehicle and creates a leak, or a hose deteriorates
which will require a replacement.
The specified maximum leakage rate at each fitting
is 0.5 kg of R 134a in 40 years and a leak detector
capable of operating to this accuracy must be

provided.
To check place the leak detector probe at
the lowest pointofeach joint, pausefortwo seconds.
Do not wave the probe about as refrigerant is
heavier than air and flows to the lowest point. If a
leak is greater than 0-5 kg in forty years is detected
identify the leak point for rectification.
Check that the leaking fitting has been tightened to
the correct torque. If the torque is low, rectify and
repeat leak test. If the torque is satisfactory,
depressurise the system, dismantle the leaking
connection and check the quality of the fitting.
If the fitting is satisfactory, clean and reassemble
after applying a thin film of refrigerant to the seat of
aflarefitting, ora newoiled "O" ring to an "O" ring

fitting.

Tighten to the correct torque.
Charge the system with 200 g of El 34A and leak test
the rectified system. If the system is satisfactory,
depressurise, evacuate and recharge the system.
If the system is unsatisfactory, i.e. leakage greater
than 0.5 kg in forty years, depressurise and replace
the leaking assembly.
8-40 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

'=^
The Aston Martin Lagonda Diagnostic System
Installation Instructions
12 10
19 22 21 20
VIA A / /^^>^ I B T
A-XA^I'A® QA
13
16
18 29
Figure 7. The Aston Martin Diagnostic System
Key to Figure 1

1.

2.

3.

4.

5.
6.
7.

7.1.

7.2.
7.3.
7.4.
7.5.
7.6.
7.7.
8.
9.

10.

11.

LCD touch screen
Power on switch
Power off switch
Screen contrast control
Battery charge indicator (Orange/Yellow)
Power on indicator (Green)
PDU interface connectors
Black probe
Red probe
Current clamp
Pressure transducer
Vehicle battery adaptor (VBA)
VIA, base station, serial interface and system test
Temperature probe
Battery cover
Connector A for vehicle cable
VIA power input cable
Connector B for vehicle cable

12.

13.

14.

15.

16.

17.

18.
19.

20.

21.

22.

23.

24.

25.

26.

27.

28.
29.

Connector for PDU cable
VIA status indicator
Vehicle Interface Adaptor (VIA)
Portable Diagnostic Unit (PDU)
Base Station
Base station door
Base station door lock
Charging and loading data connector
Secondary charging connector
Power on indicator (Green)
Status Indicator (Red)
CD-ROM drive
Electronic module securing screws
CD-ROM eject button
CD-ROM drive active light
Audio output (not used)
Audio level (not used)
Base station drawer.
May 1996 9-3

The Aston Martin Lagonda Diagnostic System
Installation Instructions "^P
Component Identification
Base Station (Fig
1
-16)
The Base Station is a wall or bench mounted steel
unit on which up to two Portable Diagnostic Units
and a Vehicle Interface Adaptor can be stored.
Portable Diagnostic Unit (PDU) (Fig 1-15)
The PDU is a hand held diagnostic tool utilising a
touch sensitive screen and serial communications
capability
Electronics Module
The Electronics Module is located behind the base
station door (Fig
1
-17) and facilitates the charging
of the PDU battery. Also contained in the module

is
the CD-ROM drive (Fig
1
-23) for the storage of
al I

system software. The PDU must be connected to
the electronic modu le whenever it is located on the
base station.
Vehicle interface Adaptor (VIA) (Fig
1
-14)
The VIA enables the PDU to interface with vehicle
systems not equipped with serial communications.
Vehicle Battery Adaptor (VBA)
The VBA provides the correct voltage to power the
PDU from the vehicle battery and also protects the
PDU from any interference from the vehicles
electrical systems.
Controls
The Touching the Power On button (Fig 2-2) will
switch on the unit and bringon the screen backlight.
Also note that the Power On Indicator (Fig 2-6) will
illuminate.
Touching the Power Off button (Fig 2-3) will turn off
the unit, screen backlight and power on indicator.
The Touch Sensitive Screen (Fig 2-1) is used to
display information in digital or in graphic forms.
Program options are also displayed and may be
selected by touching the appropriate area of the

screen.

CAUTION:
The use of sharp pointed implements
will damage the touch sensitive screen. Use only
light finger pressure to operate the PDU.
To adjust the screen contrast, rotate the contrast
control (Fig 2-4) to the required position.
In order to preserve the battery charge, the power
to the screen backlight is automatically switched
off after 5 minutes of inactivity. In this state, the
Power On indicator (Fig 2-6) remains illuminated
to indicate that the PDU is in stand-by mode.
Touching the screen will return the PDU to normal
operating mode.
Diagnostic System Cables
Cables
The cables connecting the diagnostic system
elements together and to the electronic units of the
vehicle are identified in the following illustrations.
The cables should be stowed in the base station
drawer or in the pockets of the PDU and VIA
carrying cases.
CAUTION: Care must be taken when using the
vehicle cables since they are capable of
passing

high currents. Short Circuits are a fire
risk.

7 5 6
Figure 2. The Portable Diagnostic Unit
9-4 May 1996