1997 ASTON MARTIN DB7 manual transmission

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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

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

gn
NO COLOUR 206
OW
207
OR
ISS G 208
OP
210 08 210 OS 211 OK 212 ON 213 OU 214 OV 215 BU 216 R 217 U 218 G 219 N
PIN 1 2 3 4 5 6 7 8 9 10 II 12 13 14 IS 16 17 18 19 20
4RE4 7.A5 7.*5
7.42-220
7.45 7.45 7.45 7.45 7.45 7.45 7.45 7.45 7.45 7.45 7.45 7.45
4—« SHEET 4 AREA C3
GEARBOX CONNECTOR

M
Q HI Q
OUTPUT SPEED SENSOR
NO COLOUR PIN 216 R I
217
U 2
4RE4 7.41 7.41 INPUT SPEED SENSOR
NO COLOUR PIN 219 N I 218 C 2
4REA 7.41 7.41
NO COLOUR 207 OR 208 OP 2187 *H 211 OK 212 ON 213 OU 214 OV 215 BU 206 OW 2188 WR 209 08
210 OS
PIH 1 2 3 4 5 6 7 8 9 10 II 12 13 14
4REA 7.41 7.41
7.42-220
7.41 7.41 7.41 7.41 7.41 7.41
7.42-220
7,41
7.AI
NO COLOUR 830 8G 803
SLG
123 YU 831 YR
835
B
836 8G 831 YR 123 YU
PIN 1 2 3 4 5 6 7 8 9 10 fl 12 13
4RE4 7.C2 7.C5 7.CI 7.CI
C5 C2 7.CI 7. CI
123.830.831,836 TAPED IN LOOM
REVERSE LAMP SWITCH
I NO COLOUR PIN
ARET

1
803 SLG I 835 6 7.CI 7.CI
in::My^2? wiring Diagram
Model - Aston Martin DB7
Harness Title - Auto/Manual Transmission
Part No. - B37-84632
Revision - 0 Sheet 7 of 26 - 97 MY

The Aston Martin Lagonda Diagnostic System
Users Guide D-^?
Vehicle Features
The vehicle features screen illustrated below is used to
identify the vehicle particulars and the model year.
If Airbag - NO is selected, the vehicle is assumed to be 95
model year.
If Airbag - YES is selected, 97 model year is assumed. On
completing entries in the vehicle features screen, the
appropriate vehicle area screen will be displayed.
Vehicle Features
Transmission MANUAL IIBIE^^I
Airbag IDS^I NO
D
Vehicle Area
This screen allows selection of the vehicle system to be

accessed.
Only 4 systems may be accessed on 95 model
year vehicles, on 97 model year cars, 8 systems may be
accessed as follows:
Vehicle Areas
• Engine Diagnostic
• Engine Datalogger
• Transmission
• OBDII Scan Tool
• Climate Control
• Anti-Lock Braking System
• Airbag
. lb Axol
o
PI
mLM
n
WLM
El
Ku^

95 model year software
Zytek Engine Management
GM 4L80-E Transmission Controller
Teves Mk II Anti-Lock Braking System
Valeo Air Conditioning
97 model year software
EEC-V Engine Management
CM 4L80-E Transmission Controller with OBDII
Teves Mk IV Anti-Lock Braking System
Valeo Air Conditioning
PATS Engine Immobiliser
Megamoss security system
FMC Airbag system
Autoliv seatbelt pretensioner
9-30 September 1996

^27
The Aston Martin Lagonda Diagnostic System
Users Guide
Engine Diagnostics - 97 MY
Selecting Engine Diagnostics from the Vehicle Area screen
brings up the following Engine Diagnostics Screen.
Engine Diagnostic
• Diagnostic Trouble Codes
• KOEO on Demand Self Test
• KOER on Demand Self Test
• OBDII Readiness Tests
• Output State Control
• Throttle Checks
• Exit
o
Diagnostic Trouble Codes (DTCs)
On selecting DiagnosticTrouble
Codes,
the PCM memory
will be scanned and any recorded DTCs will be decoded
and displayed.
The engine and transmission DTCs are integral to the On
Board Diagnostics (OBDII) system and are ful ly described
in the DB7 OBD II Diagnostics Manual.
Before attempting to clear the logged DTCs, record all
logged DTCs for use in subsequent fault analysis.
All logged DTCs may be cleared by selecting the EEC-V
EMS DTCs
title.
This will bring up the Clear
(C)
icon which
may be selected and confirmed to clear all logged DTCs.
Note that on clearing all logged DTCs you will also clear
the associated timers, counters and fault history files (and
extinguish the engine management warning lightfor North
American vehicles). The OBD II readines test status will
also clear down and a PI 000 (OBD II readiness test
incomplete) trouble code will be set.. A full drive cycle
(see DB7 OBD II Diagnostics Manual) must be completed
to clear the PI 000 code if required. The PI 000 code will
clear automatically after some miles of driving when all
required tests have satisfactorily completed.
Caution: If a transmission code is logged in the PCM, the
TCM DTCs must be cleared first and then clear the PCM
DTCs. If the PCM DTCs are cleared without clearing the
TCM, the TCM code will immediately reset in the PCM
when power is restored.
Key On Engine Off (KOEO) and Key On Engine
Running (KOER) On Demand Self Tests
Before either the KOEO or KOER test will run, the engine
coolant temperature must be in excess of
BO'C.
Select and
confirm either the KOEO or KOER test. If the coolant
temperature is too low, the Pre Test Engine Warm Up
screen will appear. Start the engine and run until coolant
temperature is at 80+°C.
Pre Test Engine Warm Up
Value : 41°C
80 Engine Coolant Temperature {°C)
Waiting for engine to reach
normal operating temperature
o
KOEO Test
As coolant temperature rises through the BO'C level, the
technician will be requested to turn the ignition off and
then on again. The KOEO test will then commence. Static
inputs to the PCM will be checked and any faults detected
will be recorded and displayed as DTCs. If any DTCs other
than PI 000 are logged, go to the OBD II Diagnostics
Manual and resolve the concern(s) using the OBD 11
diagnostic procedures.
KOER Test
If coolant temperature level is below 80°C, the technician
will be prompted to start and run the engine until coolant
temperature rises above 80°C. As the temperature passes
the 80°C
level,
the KOERtest will commence automatically.
If coolant temperature is above the 80°C level, the
technician wi
11
be requested to start the engine. The KOER
test will commence as the engine is started. Dynamic
inputs to the PCM will be checked and any faults detected
will be recorded and displayed as DTCs. If any DTCs other
than PI 000 are logged, go to the OBD 11 Diagnostics
Manual and resolve the problem(s) using the OBD II
diagnostic procedures.
September 1996 9-33

The Aston Martin Lagonda Diagnostic System
Users Guide ^?
Engine Setup
- 95 MY

Two adjustments
may
beset with the aid of the PDU
on 95

MY vehicles.
• Throttle Potentiometer
• Idle Fuelling Trim
From
the 95 MY
Main Menu, make
and
confirm
the

following sequence
of
selections:
Diagnostics
/

Manual
or
Auto Transmission
/

Engine
/

Engine Setup
/

The following connection diagram will then be displayed.
Throttle Sensor Adjustment
- 95 MY

Note:
The
throttle stop
and
throttle cable adjustments
must
be
correct before setting
the
throttle potentiometer.
On completion
of the
engine setup connections
the
test
selection screen will
be
displayed.

1.
Select Throttle Potentiometer.

2.
Turn
the
ignition switch
to
position
II but do not

start
the
engine.
3. Monitorthethrottle potentiometer bargraph voltage
at fully closed
and
then
at
fully open throttle.

4.
The
throttle potentiometer voltage specifications

are:

Throttle Closed
0.57 -
0.59V

Throttle Full Open
4.00 +V

Cable Setup
Diagnostic Socket D
Engine Setup Connections
Tinrottle Position Sensor
Value
:
0.43V

570
600

Idle Voltage
(mV)
Make adjustments as
necessary

Throttle Potentiometer Voltage
5.
If
both voltages
are
either high
or low,
loosen
the

two throttle pot screws and adjust the potentiometer
until
the
specified voltages
are
achieved. Carefully
tighten both screws ensuringthat the potentiometer
does
not
move during tightening.
6.
If
either voltage
is
unstable
or if the
specified
voltages cannot
be
achieved, investigate the cause.
If
the
potentiometer
is
replaced,
set the new pot

using steps
3-5
above.
Note:
On
automatic vehicles,
the
kickdown switch
adjustment check follows the throttle
pot
adjustment.
9-38 September
1996

The Aston Martin Lagonda Diagnostic System
Users Guide ^7
TCCS Torque Convertor Clutch Solenoid
The torque converter clutch solenoid is mounted on the
valve body. The signal is Pulse Width Modulated at 32Hz
to provide closed loop control of the pressure across the
converter clutch plates. 1 bit = 0.39% Range 0 to 100%
TP Throttle Position
This is provided by the EECV Engine Management System
as a Pulse Width Modulated signal derived from the
throttle position signal read by that module from the
throttle position sensor.
TCS Torque Convertor Slip
Torque converter slip is defined
as
the difference between
the Input/turbine (ni) speed and the Engine speed (Ne):
Slip = Ne-Ni. The PWM duty cycle may increase from 0
to 100% when TCC is fully applied. In practice a 100%
duty cycle will be achieved only if
a
large slip is detected.
Normal ly only a 50 to 95% duty cycle will be required for
full application of the TCC. Slip is expressed in rpm. 1 Bit
- 1/8 rpm. Range -4096 to +4096 rpm.
TCSW Transmission Control Switch
A three position switch allows the driver to select Sport,
Normal or 1st Gear Inhibit mode. When 'Sport' is selected
gearshifts take place at higher engine revs. When '1st
Gear Inhibit' is selected, the transmission only operates in
the higher forward ratios to prevent wheel slip in icy
conditions.
TISSA Turbine Input Shaft Speed
Turbine speed is the speed of the input shaft of the
transmission measured by the input speed sensor mounted
on the transmission. An alternating waveform is induced
in the sensor by 31 serrations on the forward clutch
housing as it rotates. The waveform frequency and
amplitude is low at low speeds and high at high speeds.
The TCM changes this signal into a digital signal. 1 bit =
1/8 RPM. Range: 0 - 8192 RPM.
TOS+ Transmission Output Speed
The output speed sensor is mounted on the transmission
case and measures the speed of the output shaft. As the
shaft rotates an alternating waveform is induced in the
sensor which varies in frequency and voltage. The wave
form is converted into
a
digital signal by the TCM and used
to control TCC, line pressure, shift timing and torque
management. 1 bit = 1/8 RPM. Range 0-8192 RPM
TRX Transmission Control Switch X
TRY Transmission Control Switch Y
TRZ Transmission Control Switch Z
The transmission range is detected by the pressure switch
manifold (PSM) and input to the
TCM.
The signal consists
of three discrete lines X, Y, Z which transmit a 3 bit binary
code as shown in the table below.
0 = open circuit
1 = short circuit to ground
X Y Z
p
R
N
D
3
2
Error
0
1
0
1
0
0
1
0
0
0
0
1
1
1
0
1
0
0
1
0
1
VS Vehicle Speed
Veh icie speed
is
derived from
a pu Ised
wave form generated
by the speed sensor in the hypoid unit. There are 40 pulses
per shaft rotation and the TCM converts this to vehicle
speed and applies correction for axle ratio and road wheel
diameter. 1 bit -
1
kph. Range 0 - 255kph
Transmission Diagnostic Trouble Codes
The diagnostic trouble codes supported by the CM 4L80-

E
Transmission Control Module are covered indetail inthe
DB7 OBD II Diagnostics Manual.
TOT Transmission Oil Temperature
The transmission temperature sensor signal is used to
control TCC and line
pressure.
It
has a
negative temperature
coefficient so when the temperature is cold its resistance
is high and the TCM sees
a
high voltage. Asthe temperature
warms the volts drop across the sensor decreases and the
signal voltage becomes lower. The TCM converts this
analogue input into a digital signal.
1 bit =
1
°C Range -55°C to +200°C.
9-42 September 1996