1997 ASTON MARTIN DB7 air condition

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Introduction
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Introduction '-^;^'^<-~'
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Workshop Manual Sections
The
DB7
Workshop Manual
is
divided .jnto,9seGtipnsE.a&foli
1 Engine

2.
Fuel,
Emission Control
and
Exhaust
3. Transmission

4.
Suspension
and
Steering
5. Brakes, Wheels
and
Tyres
6. Electrics
7. Chassis
and
Body
8.
Air
Conditioning
9. Aston Martin Diagnostic System
Procedure Numbering
The workshop manual procedures
are
numbered using
the
parts list numbers
as a key. The
first
two
digits
oi a

workshop manual procedure number
are
also
the
parts list number
(e.g.
1.5.01
Sump Removal relates
to PL 1.5 Oil

Pump
and
Sump). Thus when carrying
out a
procedure,
you can
quickly locate
the
relevant parts illustration
and

spare parts list.
To avoid excessive repetition, each procedure will
be
fully detailed once
in its
appropriate place
in the
manual.
In

any other location where this procedure
is
required,
it
will
be
referenced only
by its
title
and its
procedure number.
Special Tools
Where special service tools
are
required
to
perform
an
operation,
the
tool number
is
recorded
at the
point
of use

within
the
procedure.
An
index
and
illustrated list
is
provided
in
this section
for the
purpose
of
identifying special

tools.

References
References
to the
left, right, front
or
rear
of
the vehicle
or of
a component
are
always made as
if
sitting
in the
drivers
seat facing forward.
Any
such references
to
assemblies removed from
the
vehicle
are to the
normal orientation
of

the assembly when fitted
in the
vehicle.
Repairs
and
Replacements
Where replacement parts
are
required,
it is
essential that only genuine Aston Martin parts
are
used. Your attention
is drawn
to the
following points concerning repairs
and the
fitting
of
genuine Aston Martin parts
and
accessories:
• Safety features embodied
in the
vehicle
may be
impaired
if
other than genuine Aston Martin parts
are
fitted.
In certain territories, legislation prohibits
the
fitting
of
parts which
are not
produced
to the
manufacturers
specification.
• Adhere
to
torque wrench settings given
in
this manual.
• Locking devices, where specified, must
be
fitted.
If the
efficiency
of a
locking device
is
impaired during

removal,
it
must
be
renewed.
•
The
vehicle warranty
may be
invalidated
by the
fitting
of
other than genuine Aston Martin parts.
April
1997 Hi

Introduction
/^r"^^^^^3^
'"'P ?
Safety Precautions L —^ ^^—^
Safety Precautions "
All service workshops are a source of potential danger and repair work should only be performed by technically
trained staff following the procedures in this manual. A safety conscious approach to the performance of all service
procedures must be observed at all times. Statutory requirements governing all aspects of health and safety at work
including directives for the proper use of materials and equipment must be implemented.
The following contains a list of particular safety precautions which should be observed; it is not intended to be
exhaustive.
Air Conditioning System
Do not disconnect any air conditioning refrigerant system pipes unless trained and instructed to do
so.
The refrigerant
used can cause blindness if allowed to contact your eyes.
Chemical Handling and Storage
Chemicalsusedintheservicingofmotorvehiclesincludeacids,adhesives, antifreeze, brake fluids, coolants, grease,

oil,
paint, resin and solvents. Exposure to certain chemicals through direct contact or inhalation can be
fatal.

Potential hazards may also be present through the incorrect use, storage and handling of chemicals causing a fire
risk. The following precautions should be observed.

1.
Strictly adhere to handling and safety information found on containers and labels.

2.
Do not store chemicals in unlabelled or incorrectly labelled containers.
3. Containers used for storing chemicals should not be left
open;
there is a risk of
spilling,
or evaporation of fumes
which may be inflammable or toxic.

4.
Do not mix chemicals unless instructed to do so following manufacturers guidelines.
5. Do not inhale chemical materials to determine identity, they may be toxic.
6. Do not use petrol, kerosene, diesel
fuel,
gas oil, thinners or solvents for washing
skin.

7. Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages.
8. Chemicals based on solvents such as paint should not be sprayed in a confined space; work areas used for
such operations should be well ventilated and fume extraction equipment should be utilised.
9. Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.
WARNING: Fume extraction equipment must be in operation when
solvents
are
used
e.g.
trichloroethane, white
spirit, SBP3, methylene chloride, perchlorethylene.
WARNING: Do not smoke in the vicinity of volatile de-greasing agents.

10.
Avoid splashing the
skin,
eyes and clothing.

11.
Clean chemicals from the skin and clothing as soon as possible after soiling.

12.
Wear protective clothing such as goggles, non porous gloves and apron when hand
I
ing battery acid and other
corrosive and toxic substances.
iv April 1997

//—-^
^^^^5~^
' -^ ^ Introduction
Safety Precautions
Safety Precautions (continued)
Electrical Equipment

1.
Ensure that electrical equipment is in safe working order before use.

2.
Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly

earthed.

3. Ensure that electrical equipment is protected by a fuse of the correct current rating.

4.
Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine
or when working beneath the vehicle.
Exhaust Fumes
Engines should not be run in confined spaces, exhaust fumes contain harmful and toxic substances including carbon
monoxide which can prove fatal if inhaled. Engines must only be run where there is fume extraction equipment in
operation or where there is adequate ventilation.
Fire Precautions

1.
Ensure that a suitable form of fire extinguisher is conveniently located near the work area.

2.
Keep oils, solvents and combustible materials away from naked flames and other sources of ignition.
3. Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be
present and ensure that the warnings are strictly observed.

4.
Ensure that dry sand is available to soak up any spillage of fuel or other flammable solutions.
5. Fume extraction equipment must be available and in full working order to remove combustible and toxic
vapours.
6. All personnel should be aware of the fire drill procedures and precautions.
Jacking and Lifting

1.
The recommended procedures for lifting, jacking and towing are included latefin this seetion-and must be
strictly observed to ensure personal safety.

2.
Always use a vehicle hoist, ramp or pit for working beneath the car in preferencetd^&^cking
3. Never rely on a jack to support a car independently, use axle stands or blocks carefully pJaQed at the jacking
points to provide rigid support.

4.
When working beneath a vehicle, chock the wheels as well as applying the handbrake.
5. Ensure that the vehicle is standing on firm level ground before jacking or lifting.
5. Check any lifting equipment used has adequate capacity for the load being lifted and is ih"fdll working order.
Tools and Equipment

1.
Do not leave tools, equipment, spilt oil, etc. around or on the work area.

2.
Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or
equipment.
3. Do not apply heat in an attempt to free stiff nuts or fittings; as well as causing damage to protective coatings,
there is a risk of damage to electronic equipment and brake lines from stray heat.

4.
Use the recommended service tool where instructed to do so.
April 1997 v

[Em^^^?
Electrics
Repair Procedures

6.1.01

6.1.02

6.1.03

6.1.04

6.1.05

6.2.01
6.3.01

6.3.02

6.5.01

6.5.02

6.5.03

6.5.04

6.5.05

6.5.06

6.5.07

6.5.08

6.6.01

6.6.02

6.6.03

6.6.04

6.6.05

6.6.06

6.6.07

6.6.08

6.7.01

6.7.02

6.7.03

6.7.04

6.7.05

6.7.06

6.7.07

Headlamp Unit
Headlamp Alignment
Front Indicator/Parking Lamp Unit
Front Fog Lamp Assembly
Side Repeater Lamps
Windscreen Wiper Motor
Alternator
Starter Motor
Steering Wheel and Horn Switches
Column Switches
Ignition Switch
Instrument Panel
Radio
Air Conditioning and Switch Panel
Cruise Control, Window and Gearshift Switches
Seat Control Switch Panels
Front Interior Lamps
Rear Interior Lamps
Front Seat Removal
Front Seat Runner Assembly
Front Seat Rail Motor
Lumbar Support Motor
Seat Recline Motor
Seat Control Unit
Door Edge Lamps
Rear Lamp Cluster
Door Central Locking Motors
Door Window Motor
Door Mirror Assembly
Transmission Control Module - Renew (TCM)
Barometric Pressure Sensor - Renew
6-3
6-3
6-4
6-4
6-4
6-5
6-5
6-6
6-6
6-6
6-7
6-7
6-8
6-8
6-9
6-9
6-10
6-10
6-10
6-11
6-11
6-12
6-12
6-12
6-12
6-13
6-13
6-14
6-15
6-16
6-17
April 1997 6-1

Electrics
Radio / Air-Con Switch Panel - Removal Procedures [D:m3^^2?
6.5.05 Radio
Procedure

1.
Press the release button and remove the radio front
control panel.

Figure
/. Radio Removal

2.
Insertthe radio removal tool intothe slots in thetop
edge of the radio body to release the catches. Pull
forward on the radio and remove it from the centre
console.
3. Disconnect the speaker, CD, aerial, power and
earth connectors.
6.5.06 AirConditioningand
Switch
Panel
Procedure

1.
Remove the radio.

2.
Pull off the air conditioning control knobs.
3. Lift of the console controls finisher panel.
Figure h Air Conditioning Panel Removal

4.
Remove four screws and pull forward the centre
console control panel.
5. Disconnectthefiveconnectorsinthecentreconsole
wiring and remove the centre console control

panel.

6-8 May 1996

Electrics
Electrical Component Location Index - Up to 97 MY
Component Name
ABS ECU
Air Con Compressor Clutch
Air Con Fan Motor - LH
Air Con Fan Motor - RH
Air Conditioning Trinary Switch
Air Conditioning Unit
Air Pump
Air Temperature Sensor
Alarm Override Switch
Alarm Siren
Alternator
Ambient Temperature Sensor
Barometric Pressure Sensor
Boot Lamp
Boot Lamp
Boot Lock Actuator
Boot Release Switch
Brake Accumulator Pump
Bulb Fail Unit - Front Side Lights
Camshaft Sensor
Central Locking Unit
Cigar Lighter
Column Switchgear
Crankshaft Position Sensor
Cruise Control Brake Switch
Cruise Control Clutch Switch (LHD)
Cruise Control ECU
Cruise Control On/Off Switch
Cruise Control Pump
Cruise Control Set Switch
Cruise Control Inhibit Switch
Diagnostic Socket - Transmission
Dimmer Module
Door Lock Actuator
Door Mirror- LHD
Door Mirror- RHD
Door Mirror Switch LH
Door Mirror Switch RH
Door Speaker -LH
Door Speaker - RH
EDIS Coil Pack
EDIS Amplifier Module
Engine Diagnostic Socket
Engine ECU
Exhaust Temperature/Speed Warning
Fan Fuses
Fan Motor 1
Fan Motor 2
Fan Run-on Switch
Flasher Module
Fog Lamp - RH Front
Fog Lamp - LH Front
Location
Reference
15-1
3-20
8-2
8-6
10-6
8-3
8-4
3-13
1-8
11-7
3-2
1-12
11-1
5-2
5-2
13-8
2-10
7-4/8
4-6
3-10
9-4
8-1
13-3
3-3
11-8
12-9
6-3
12-7
1-2
12-8
10-8
10-7
4-16
12-12
2-4
2-8
2-3
2-9
6-4
6-9
3-1
1-10
10-5
7-3
4-3
1-21
7-6
7-7
7-5
4-13
14-10
14-9
Wiring Diag.
Reference
28-A1
5-D2
8-A5
13-C4
5-D3
11-82
1-C2
5-C3
1-C5
1-B3
5-D3
1-A2
4-A4
24-A5
24-C4
27-A5

l-i-C3

28-84
9-C2
6-C3
8-D1
19-D3
12-C5
5-D2
12-85
2-D4
20-A2
20-C3
2-A3
20-D3
21-D3
12-A4
13-A4
17/18-B1
17-A3
17-A5
17-D5
18-D5
17-C5
18-C5
5-D5
6-B2
6-D4
6-C5
11-C5
3-A3
3-A2
3-B2
5-A2
13-C2
1-A1
1-C1

Rep.
Op. Notes
Reference

5.1.11.1

8.1.07.3

8.2.09.1
8.2.08.1
8.1.11.1
8.2.01.1

2.3.01.2
2.2.06.1
6.1.06.1
6.2.03.1
6.3.01.1

8.2.07.1

3.3.08.2

6.9.04.1
6.9.04.1
6.9.06.1
6.5.09.1

5.1.08.1

6.4.01.1
2.5.06.1
6.7.03.1
6.5.10.1
6.5.02.1
2.5.06.3
6.4.02.1
6.1.08.1 Manual only
6.6.09.1
6.5.07.1
6.1.09.2
6.5.07.2

3.3.08.6

6.4.03.1
6.4.04.1
6.7.10.1
6.7.08.1
6.8.01.1
6.7.08.2
6.8.01.2
6.7.09.1
6.8.02.1
6.2.05.1
6.2.05.3
6.4.05.1
6.4.06.1
6.4.07.1 Multi-functio
6.2.06.1

1.7.17.1

1.7.17.2

1.7.16.4

6.4.08.1
6.1.04.1
6.1.04.2
May 1996 6-19

[n:m3^y

Component Name
Microwave Sensor
Mode Switch
Multifunction Module
Number Plate Lamp - LH
Number Plate Lamp - RH
Oil Pressure Warning Light Transducer
Output Speed Sensor (Auto)
Park Switch (Auto)
Purge Valve 1
Purge Valve 2
Radio Aerial
Radio Telephone Connector
Radio Tweeter
Radio Tweeter
Radio
Rear & Number Plate Bulb Fail Unit
Rear Fog Lamp LH
Rear Fog Lamp RH
Rear Lamp - LH
Rear Lamp - RH
Recline Motor Potentiometer
Relay - ABS Pump
Relay - Air conditioning clutch
Relay - Air Pump
Relay - Auxiliary Load
Relay - Boot Release
Relay - Courtesy Lights
Relay - Cruise Control On/Off
Relay - Drivers Seat Heater
Relay - Fan 1
Relay - Fan 2
Relay - Fan Run On
Relay - Front Fog Lamps
Relay - Fuel Pump 1
Relay - Fuel Pump 2
Relay - Gearbox Failure Warning
Relay - Headlamp Dipped Beam
Relay - Headlamps
Relay - Heated Rear Window
Relay - Horns
Relay - Ignition Load
Relay - Main
)
Location
Reference
12-1
7-9
4-2
5-3
5-3
3-17
11-12
10-1
10-3
10-4
15-4
15-3
6-7
6-5
6-6
15-11
14-2
14-5
14-1
14-6
9-7
4-8
1-17
4-14
4-4
15-9
4-11
6-1
12-3
1-20
1-19
1-18
1-6
15-7
15-8
4-9
1-5
1-7
4-15
1-16
4-10
4-12
Relays - Drivers/Passengers Seat Heaters 12-3
Relay - Rear Fog Lamps
Relay - Reverse Lamps
Relay - Sidelamps
Relay - Starter Solenoid
Relay - Stop Lamps
Reversing Lamp Switch (Man)
Reversing Light Switch (Auto)
Screen Wash Pump
4-17
15-6
1-9
1-15
15-5
11-3
10-2
1-13
Electrics
Electrical Component Location Index - Up to 97 MY
Wiring Diag.
Reference
24-C2
4-A3
8-C4
27-84
27-B6
5-C5
7-B3
21-B1
5-A4
5-A5
24-D2
25-B2
8-C3
14-C4
10-A2
25-C3
17-D2
18-D2
24-A5
24-C4
22-81
9-C4
3-A3
13-A5
9-D1
26-D3
13-A2
20-B1
16-D3
3-B6
3-B6
3-A5
1-B5
26-A2
26-A3
13-A1
1-B5
1-84
13-A4
3-A4
13-A2
13-A3
15-D3
13-A5
25-A4
1-B4
3-A4
25-A5
7-C5
21-C2
3-D1

Rep.
Op. Notes
Reference

6.6.14.2

6.5.07.4

6.4.12.1
6.9.03.1
6.9.03.1

1.5.08.1

3.4.02.2
Auto only

6.5.13.1
Auto only

6.1.14.1

6.1.14.2

6.9.08.1
6.9.09.1
6.5.17.1
6.5.17.1
6.5.05.1
6.9.10.1
6.7.02.1
6.6.07.1

5.1.15.1

6.2.06.1
6.4.13.1
6.4.14.1
6.9.11.1
6.4.15.1
6.5.18.1
6.6.15.1

1.7.16.3
1.7.16.3

1.7.16.4

6.1.04.3

6.9.12.1
6.9.12.1
6.4.16.1
Auto only

6.1.15.1
6.1.16.1
6.4.17.1
6.2.07.1
6.4.18.1
6.4.19.1

6.6.15.2

6.4.20.1
6.9.13.1
6.1.17.1
6.2.08.1
6.9.14.1
6.2.09.1

6.2.09.2

6.3.06.1

May 1996 6-21

#
ABS ECU Gearbox ECU Window ECU Central Locking ECU Engine Management ECU
Lamp Fail ECU
EDIS Amp
Security ECU Window ECU Seat ECU'S Air Conditioning ECU
Figure 17
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