1997 ASTON MARTIN DB7 ECU

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

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
Body Repair - RTM Body Panels
RTM Body Parts
Certain exterior panels of the vehicle are
manufactured from RTM as shown as shaded areas
in Figure 1. The Front and rear bumpers are made
from
R-RIM

Repair Procedures
Cosmetic Damage
Repair the paintwork using standard procedures.
Substrate surface
Where the defect does not affect the physical
strength of the panel, fill and repaint using standard
techniques.
Substrate Penetration
No reliable repair procedures are possible to correct
major physical damage to RTM panels. Any small
defect which do not affect the intgrity or security of
the panel may be filled and repainted at the owners
risk.
Uote: Becauseof the inherent flexibility of plastic panels,
hard filler may
crack.
Such repairs cannot
therefore
be
guaranteed.
Where the damage affects the security and or the
integrity of the panel, it must be replaced.
Precautions during Paint Operations
When any repair operation is being completed on
the DB7 paintwork, take particular care to protect
the leather upholstery and trim from paint
contamination.
Figure 1.
Damage Recognition
Before any remedial action is carried out the
damaged should be
assessed.
If the cover has been
holed or torn it must be replaced. Repair should be
attempted only if the damage falls into one of the
following three categories.
Cosmetic
Substrate surface
Substrate
penetration
Abrasion to the surface paint
finish
Deep scratches, gouges or
localised radial stress cracks.
Splits not exceeding 100 mm.
Splits radiating from a gouge
and accompanied by localised
stress cracks.
May 1996 7-5

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
Roof Removal/Replacement [D::M^=2?
9.0.02.1 - Roof Removal/Replacement

1.

2.

3.

4.

5.
6.
7.
8.
Move the front seats fully forward for access.
Remove the rear seat squab and cushion. Remove
the rear quarter trim panel.
Release the roof side curtain clips.
Release the rear window support bracket securing
bolts (Fig 1-2).
Remove the side curtain clips (2 per side).
Release the side curtain rods and move the curtains

aside.

Disconnect the heated rear window connector.
Release the rear window support bracket from the
body.
Figure 1. Rear Window Support Bracket
9. Release the roof catches.

10.
Select Manual on the roof motor control switch.
Lower the roof to the midway position. Select
Electric on the roof motor control switch - the roof
will remain in a raised position.

11.
Raise the trim and remove the cable securing nuts.

12.
Release the roof outer finisher securing screws and
remove the finisher.

13.
Release the cable and roof material from the body

channel.

cqD
Figure 2. Ram Mountings

14.
Select the Manual position on the roof motor control

switch.
Fold the roof and remove the ram to roof
securing pins.

15.
Remove the six roof to body securing bolts.

16.
Remove the roof assembly.
Refitting

1.
Fit the roof into position on the vehicle, aligned
with the fixing holes.

2.
Refit the six roof to body securing bolts.
3. Locate the rams to the pivot.

4.
Select Manual on the roof motor control switch.
Place the roof in the partially open position to
al
ign
the ram fixing holes. Fit but do not tighten the
securing bolts.
5. Fit the pivot pins and securing clips.
6. Finally tighten all bolts.
7. Position the rear window support bracket, fit and
tighten the securing bolts.
8. Fully raise the roof. Select Electric on the roof motor
control switch.
Figure 2. Cable Securing Nuts
7-10 May 1996

^=2?
Body and Trim
Roof Hydraulic Control System
9. Position the rear edge of the roof to the body.

10.
Position the rear cable to the roof lower edge.
Position the loops on the cable (approximately 17in
equi-spaced apart). Position the cable to the
mou nti ng
brackets,
fit but do not tighten the
secu
ring

nuts.

Figure 3. Cable, Roof Channel and Body Channel

11.
Align the rear edge of the roof material to the body
and commence tightening the cable nuts evenly.
Stop frequently and check that the cable and roof
channel
are
correctly bedding into the body channel.
Continue tightening and checking until the roof is
fully seated in the body channel.

12.
Fit and secure the roof finishers.

13.
Reconnect the heated rear window connector.

14.
Position the roof inner curtain. Fit clips to the
curtain rods. Fit and tighten the securing screws.

15.
Refit all trim and check the roof mechanism for
correct operation and fitting.
9.0.02.3 - Roof Hydraulic
Control
System
Procedure

1.
Move the front seats forward for access.
Fully lower the roof.
2.

3.

4.

6.
Remove the rear seat squab and cushion. Remove
the rear quarter trim panels.
Remove both the cylinder pivot pins. Release the
ram cylinder assemblies (take care not to kink the
pipes).
Remove the screws from the hydraulicpipegrommet
in the rear of the roof stowage
well.
Remove the
grommet.
Release the pipe securing clips.
Figure 2. Ram Mountings
7. Open the boot and remove the boot floor trim

panel.
Remove the pump mounting plate securing

bolts.

8. Release and remove the pump cover.
9. Disconnect the pump multi-plug.

10.
Releasethe pump mounting rubbers from the plate.

11.
Feed both ram cylinders into the boot through the
aperture in the roof well rear
wall.

12.
Remove the complete hydraulic system from the
boot.
Note: Check that the reservoir fluid level is correct.
Always bleed the hydraulic
system
before topping up.
Refitting is the reverse of the removal procedure.
On completion of the refitting, check the roof

operation.

May 1996 7-11