1997 ASTON MARTIN DB7 engine

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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

//—-^
^^^^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

Introduction //—">) ^nir>^ ' ^ 1
Safety Precautions L 1 .^—y^
Safety Precautions (continued)
Used Engine Oil
Prolonged and repeated contart with mineral oil will result in the removal of natural fats from the
skin,
leading to
dryness, irritation and dermatitis. In addition, used engineoii contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and washing facilities should be provided.
Health protection precautions:

1.
Avoid prolonged and repeated contact with oils, particularly used engine oil.

2.
Wear protective clothing, including impervious gloves where practicable.
3. Do not put oily rags in pockets.

4.
Avoid contaminating clothes with oil.
5. Overalls must be cleaned regularly. Discard unwashable clothes and oil impregnated footwear.
6. First aid treatment should be obtained immediately for open cuts or wounds.
7. Use barrier creams, apply before each work period to help the removal of oil from the
skin.

8. Wash with soap and water to ensure all oil is removed. Preparations containing lanolin replace the natural
skin oils which have been removed.
9. Do not use petrol, kerosene, diesel
fuel,
gas oil, thinners or solvents for washing
skin.

10.
If skin disorders develop, obtain medical advice.

11.
Where practicable, degrease components prior to handling.

12.
Where there is a risk of eye contact, eye protection should be worn, in addition, an eyewash facility should
be provided.
Environmental Protection
It is illegal to pour used oil on the ground, down sewers or drains, or into water courses. The burning of used engine
oil in small space heaters or boilers is not recommended unless emission control equipment is
fitted;
in case of doubt,
contact the Local Authority for advice on disposal facilities.
vi April 1997

Electrics
Starter Motor / Steering Wheel - Removal Procedures ^n:M3^^2?
6.3.02 Starter Motor
Procedure

1.
Disconnect the battery.

2.
Remove the inlet air trunkins
Figure 1. Starter Motor Mountings
3. Disconnect the starter solenoid connector and the
starter motor power lead at the solenoid.

4.
Remove the top starter motor securing bolt.
Note:
The
top bolt is from tlie
engine
side on auto
cars

and from ttie gearbox side on manual cars.
5. Raise the car on a hoist and whilst supporting the
motor, remove the lower starter motor securing
bolt.
6. Lift the motor from the bell housing and remove it
from the vehicle by positioning it vertically and
lowering it down in front of the oil filter.
6.5.01 Steering
Wheel and Horn
Switches
Procedure

1.
Remove the steering wheel centre pad.
Figure 1. Steering Wheel and Horn
2. Mark the position of the steering wheel relative to
the steering column to ensure correct replacement.
3. Removethesteeringwheelsecuringnutand remove
the steering wheel.
6.5.02 Column Switches
Procedure

1.
Remove the steering wheel.

2.
Remove three screws and the column switch cover.

1^

Figure 1. Column Mounted Switches
3. Cut the tywraps securing the switch loom to the
steering column. Disconnect the loom plugs.

4.
Release 4 screws and
1
ift the switch assembly off the
steering column.
6-6 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

Electrics
Electrical Component Location Index - Up to 97 MY
Component Name
Seat Belt Switch
Seat ECU - Driver
Seat ECU - Passenger
Seat Heater - Cushion Element
Seat Heater - Squab Element
Seat Heater Control Module
Seat Motor Potentiometer
Seat Pressure Pad
Seat Switch Pack - Driver
Seat Switch Pack - Passenger
Security System Aerial
Security System ECU
Side Marker Lamp - LH Front
Side Marker Lamp - RH Front
Speaker - Rear LH
Speaker - Rear RH
Speed Control Dump Valve
Start Inhibit Switch
Starter Motor Solenoid
Stop Lamp Fail
Stop Lamp/Cruise Disable Switch
Thermal Breaker - Window Lift
Throttle Potentiometer
Water Temp Sensor - Engine ECU
Water Temp Sensor - Temp Gauge
Wheel Speed Sensor - Front RH
Wheel Speed Sensor - Front LH
Wheel Speed Sensor - Rear RH
Wheel Speed Sensor - Rear LH
Window ECU - LH
Window ECU - RH
Window Switch - RH
Window Switch LH
Wiper Logic Module
Wiper Motor
Window Lift Motor
Location
Reference
13-2
6-2
6-2
12-5
12-4
6-3
9-7
12-6
6-8
6-8
2-12
15-2
5-5
5-5
6-10
6-10
1-4
10-9
3-14
15-10
11-8
4-7
3-15
3-5
3-4
13-4
13-4
13-1
13-1
12-11
12-11
2-5
2-5
4-5
1-1
12-10
Wiring Diag.
Reference
22-A3
16-A1
15-A1
22-A2
15/16-A4
22-A5
22-C2
22-D3
16-B1
15-B1
24-C2
26-B6
1-C2
1-A3
24-B2
24-C2
2-A2
21-C3
3-C2
25-A3
12-C5
9-C3
5-A3
5-C2
5-C2
29-C3
28-D4
28-D3
28-D2
17-D3
18-D3
19-A2
19-D2
9-A3
8-C3

Rep.
Op.
Reference

6.6.16.1
6.6.17.1

6.6.17.2

6.6.18.1

6.6.18.2

6.6.18.3

6.6.19.1
6.6.20.1
6.6.21.1
6.6.21.1
6.6.22.1

6.6.22.3

6.1.18.1
6.1.18.1
6.6.23.1
6.6.23.1
6.1.19.1
6.1.20.1

6.3.02.2

6.9.15.1
6.4.02.1
6.1.21.1

2.5.02.2

6.3.07.1

8.2.12.1

5.1.12.1
5.1.12.1
5.2.01.1
5.2.01.1

6.1.22.1
6.1.22.1
6.5.03.1
6.5.03.1
6.2.01.1

6.1.21.3

Notes
6-22 May 1996

#
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
o
o 3 •a o 3 n 3 O n Si 5 3

ere

3
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•o
o
-<
n

Electrics
Loom Location Diagrams - Up to 97 MY
Fig 5.

1.
Harness Sill

2.
Harness Console
3. Harness Fuse Box
Fig 6.

1.
Harness Engine

2.
Earth Engine Body
3. Harness Foward Right

4.
Rearward Harness
5. Harness Headlamp Link
Fig 7.

1.
Harness Seat
May 1996 6-41