1997 ASTON MARTIN DB7 roof

Electrics
Interior Lamps and Front Seat - Removal Procedures EM^^^
6.6.01 Front Interior Lamps
Procedure

1.
Releasethequarterturnfasteneronthefrontinterior
light assembly and lower the assembly from the
roof liner.
Figure 7. Front Interior Lamp
2. Disconnect the interior lamp plug and remove the
interior lamp assembly.
6.6.02 Rear Interior Lamps
Procedure

1.
Release the rear upper trim panel.

2.
Remove two spire washers and the rear interior
lamp assembly.
6.6.03 Front Seat Removal
Procedure

1.

2.

Motor the front seat forward and remove the rear
securing bolts for the seat rails.
Motor the seat to the rear and remove the front seat
rail securing bolts.
Figure 1. Front Seat Removal
3. Lift the footweil carpet, release the access plate
securing screws and remove the plate to gain
access to the seat control unit.

4.
Cutand remove thetywrapssecuringtheseat loom.
5. Disconnect the seat harness connectors at the
control unit.
6. Remove the seat assembly.
Figure 7. Rear Interior Lamps
3. Disconnect the lamp wiring and remove the lamp
assembly.
6-10 May 1996

NO
COLOUR
5
YS
14
WU
17
GW
51
RO
65
UB
70
YW
71
YB
83
WB
86
BK
90
GR
92
NR
94
RY
95
U
96
UW
97
GY
98
YP
99
YD
109
l.«S
121
WR
131
YR
136
UB
138
RN
163
BK
172
G
174
KB
198
GN
207
NB
209 OK 222
OS
226
BN
248 NS 250
WS
252
WY
253
UG
255
0
258
KB
259
OR
260 0 261
NR
262
BLG
321
PW
322
RU
323
GU
324
Y
325
LG
328
RN
330 YG 331
YU
351
WU
354
W
555
WR

362
RW
368 OS 369 OU 375
BY
377 8G 378 BS 379
BY
380 PG 381
BP
382
WB
383 K 384
WP
385 BU 386 60 387 CW 388 PS

AREA
C2 A5 A5 A5 A5 C4 C4 A5 B5
A5-97 A5-99
B5 B5 B5 B5 C4 04 B9 85 BS B5 B5 85 B5 B5 05 C5 C5 C5 C5 C5 C5
C4-93
C5 C5 C5 02 02 02 C5
A4-94
C5 C5 C5 C5 C5 C5 05 C6 C5 C5
C5 C5 C5
A5-98
05 05
A5-9e
OS 05 05 02 05
A5-I0C
86 B6 B6
NO
COLOUR
401
BY
402 WS 416
LOG
417
LGW
418
LGN
420 LGR 421
LG
422
LGP
423 BS 425
WP
433 P 435 WU 437 LG 438 W 439 W 445 NG 449 WK 451
1.G
455 GP 455 NP 457 NP 459 G 461
P
470 NU 471
BW
472
B
473 B 494 BR 498 P 505
LGO
510
B
522
YR
528
BK
536 B 537 W 551
B
552
B
555
W
565
B
566 NY 586 LGO 604 NB 608 0 616
P
618
B
622
KB
649 P 662 N 663 P 668 WO 687 NY 695 P 699 NU 710
R
712
W
714
WK
717
OU
718
OW

AREA
B6
A4-89
B6 B6 B6 B6 B6 B6 B6 B4 ez B2 B6 Be C4 B6 B6 86 B6 02 C4 D2 B6 B4 A2 A2 «2 C2 C2 02 85 C5 04 06 B6 86 86 86 B6 B6 B6 B6 B6 B6 B6 B6 C6 C6 C6 06 C6 C6 C6
45-96
C6
A4-94
C6
A4-90
-fl—«
SHEET
9
AREA
6

RADIO
SHEET
23
AREA
B2

SHEET
23
AREA
C2

REARWARD
REARWARD

rr
.
94 SPL 95

NO
COLOUi;
471
BW
472
B
475
B
474
YG
475
B
476
BR
477
BW
478
B
479
S
435 WU
435P
480 RK 481
B
48? BP
t>m 1 2 3 4 5 6 7 8 9 10 II 12 13
1*

~im Bl Bl Bl B2 B2 B2 66 Be 02 Al Al Be B2 B?
SPL
90

•N6
«Lot)R
PiN
482
BR
476
BR
483
LGK
484
RIN
485
WS
486
RN
487
GR
474
YC
488
BRD
481
B
475
B
489
UlN

490
R

491
W

1 2 '-^S 4 5 6 7 8 9 10 II 12 13 14 15
IS

AREA
B2 A2 C6 C6
A4-89
C6
A5-97
A2 C6 B2 A2 C6

A5-9e

CS
diQ]

IIDIIl

or

(DID
(DID

IT

r' '
IDDI

D) ID

k
4

1
5

(r

c

IDDl^
ID 01

QIIQ

ID
ffl^
4
8

NO
COLOUR
492
YW
493 KB
5
YS

261
NR
494 BR
495 OR 496 OU
PIN
2 3 4 5 6 7 S 9 10 II 12 IJ
AR^A'
C6 C6
Al
Bl Bl
C6 C6
NO
COLOW
497 SLG 498 P 499 PW 459 G 500 KB 259
OR
501
GB
383 K 455 NP 502
RU
503 BW 504
GW
260
0
505 LGO 506 OW 507 GP 508 OG
509
WK

479 S
175
PY

PIN 1 ? 3 4 5 6 7 8 9 10 11 1? 13 14 15 16 17 18 19 ?0 21 22 23
2<

AREA
C6 Bl
A4-94
Al 06 Bl
A4-92
CI Al ce C6 C6 81 Bl
A4-90
BS A4-91

A4-95

A2
85
SPL
96
SPL
98-

SUNROOF/ACC
NO
COLOUR
PIN
510
B 1
2 457 NP
3
511
WK 4

AREA
81
Al
A4-95

ABS
LOOM
|75
t^LOUtt
^IN
507
GP
512
WY
513
BY
514
RB
515
W
425
WP
516
BLG

1 2 3 4 5 e

I

AlitA
02 C6
A5-98
C6 C6 Al C6
'

(

EC
r
f
f=

IBIDl

(DID

Bjcnc

mm
m m
r

m
ml
7
13
1
14

SHEET
28
AREA
C3
ABS
LOOM
NO
COLOUR
PIN
445 NG 470 KU

AREA
Al

CRUISE CONTROL
NO
COLOUR
PIN
517
LGY 1
518
WY 2
519
GB 3
99
YO 4
98
YP 5
70
YW 6
71
YB 7
520
U
8
521
YU 9
522 YR
10
523
RW
11
524
B
12
525 BK
1?

AREA
C6
64-93 A4-92
Al Al Al Al C6 C6 Bl C6 C6 04

SHEET AREA
I

m
umti
14
WU
17
GW
51
RO
65
UB
83
WK
86
BK
94
RY
95
U
96
UW
97
GY
109
IGB
121
WR
131
YR
136
UB
138
RN
163
BK
172
G
174
KB
175
PY
198
GN
207
NB
209
OK
222
OS
226 BN 248
NS
250
WS
253
UG
255
G
258
KB
262
BLG
322 RU 323
GU
324
Y
325
LG
328
RN
330 YG 331
YU
351
WU
354
W
355
WR

362 RW 368 OS 369 OU 377
BG
378
BS
380 PG 381
BP
382
WB
384
WP

AREA
Al Al Al Al Al Al Al Al Al Al Al Al Bl Bl Bl Bl Bl Bl 02 Bl Bl Bl Bl Bl Bl Bl Bl Bl 61 Bl 81 81 Bl Bl CI CI CI CI CI CI
CI CI CI CI CI a CI CI CI
NO
COLOUR
386 GO 387 BW 388 PS 401
BY
416
LGG
417
LGW
416
LGH
420 LGR 421
LG
422
LGP
423
BS
437 LG 438 W 439 W
449WK
451
LG
453 GP 461
P
477
BW
478
B
480 RK 483 LGK 484 RIN 486 RN 488 BRD 489 UlN 491
R
492
YW
493 KB 495 OR 496 OU 497 SLG 500 KB 502
RU
503 BW 504 GW 512
WY
514
RB
515
W
516
BL6
517
LGY
520
U
521
YU
523
RW
524
B
526
BK
527
BK
536 B 557 W 540 NR

AREA
CI Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Bl A2 A2 B2 B2 B2 82 62 82 82 C2 C2 C2 C2 C2 D2 02 02 D2 85 B5 B5 BS C5 C5 C5 C6 C6 04 04 Bl Bl
A5-99

NO
COLOUR
542 GB 551
B
552
B
554
WY
555
W
563 BU 565
B
566 NY 574
WK
584
GR
586
LGO
587
WY
588 WS 595
BY
600 GB 603 NR 604 NB 608 0 615
BU
616
P
617
PW
618
6
622
KB
630 NR 646 GR 649 P 662 N 663 P 664 WK 668 WO 682
R
687 NY 688 OG 690 OW 695 P 699 NK 705
WK
712
W
716
PW
717
OU

mi
A4-92
61 Bl
B4-93
Bl
A5-10<
Bl Bl
A4-95 A5-97
ei
84-93 A4-89 A5-9S A4-92 A5-99
Bl Bl
A5-I0C
61
A4-94
CI CI
A5-99 A5-97
a CI CI
A4-95
CI
A5-9G
a
A4-9I A4-90
a a
A4-95
CI
A4-94
a

Emm
[D:m^-2? Wiring Diagram
Model
-
Aston Martin
DB7
Coupe
Harness Title
-
Bulkhead
RHD - 3

PartNo.-B37-81305
Revision
- 0
Sheet
10 of 29 - Up to 97 MY

Electrics
Component Index Sheet 2 - 97 MY
Component
Name
Door Lock Switch (Passengers)
Door Mirror - (Drivers)
Door Mirror - (Passengers)
Door Mirror Switch (LHD)
Door Mirror Switch (RHD)
Door Rear Guard Lamp (RH)
Door Rear Guard Lamp (LH)
DPFE Sensor
EDIS Coil Pack
EVR Valve
Exhaust Temperature/Speed Warning
Fan Control Module
Fan Motor 1
Fan Motor 2
Foglamp - RH Front
Foglamp - LH Front
Fuel Filler Flap Solenoid
Fuel Pump 1
Fuel Pump 2
Fuel Tank Pressure Sensor
Fuel Tank Sender Unit
Gear Selector Illumination
Glass Break Sensor
Handbrake Switch
Head/Side Lamp - LH Front
Head/Side Lamp - RH Front
Heated Backlight (Volante)
Heated Backlight (Voiante)
Heated Oxygen Sensor
1
-1
Heated Oxygen Sensor
1
-2
Heated Oxygen Sensor 2-1
Heated Oxygen Sensor 2-2
Heated Washer Jet LH
Heated Washer Jet RH
High Level Stop Lamp
Hood Control Module (Volante Roof)
Hood Motor (Volante Roof)
Horn - LH
Horn - RH
Idle Speed Control Valve (Eng Sub-harness)
Ignition Coil Pack (EDIS)
Ignition Switch
Indicator/Side Lamp - LH Front
Indicator/Side Lamp - RH Front
Inertia Switch
Injector 1
Injector 2
Injector 3
Injector 4
Injector 5
Injector 6
Instrument Pack
Instrument Panel Illumination Control
Instrument Panel Illumination Dimmer Switch
Interior Light - Rear LH
6-44
Component
Location
11-10
n-4
11-11
11-12
11-12
11-7
11-8
3-5
3-9
2-1
1-6
2-7
11-1
11-2
12-3
12-2
12-10
12-7
12-9
12-8
12-6
12-5
7-8
7-5
12-1
12-4
12-11
12-11
2-5
2-5
8-2
8-2
13-3
13-3
13-7
8-4
13-6
1-7
1-7
3-8
3-9
14-5
14-2
14-2
6-9
13-2
13-2
13-2
13-2
13-2
13-2
13-5
7-4
13-8
14-9
fEB^-^?
Circuit
Reference
22-A2
21-A3
22-A5
21-C5
22-C5
21-D2
22-D2
5-C4
5-A5
5-D2
11-C3
3-D2
3-B1
3-C1
1-A1
1-C1
15-A2
16-A5
16-A6
15-C3
16-B4
13-C4
14-C6
14-C5
1-D2
1-A2
15-D3
16-A2
6-D4
14-A6
6-D4
14-A6
5-D3
5-D4
15-82
18-D4
19-B6
1-A3
1-A3
5-C3
5-A5
9-D4
1-C1
1-A1
12-C5
5-B2
5-B2
5-B2
5-B3
5-B4
5-B4

9-A/B5/6

8-C5
9-C4
15-C3
September 1996

Electrics
Component Index Sheet 3 - 97
MY

Component
Name
Interior Light - Rear RH
Key Solenoid
Key-In Warning Switch
Low Coolant Signal Transmitter
Low Level Sensor (Screenwash)
Map Reading Light
Mass Airflow (MAF) Sensor
Multifunction Module
Number Plate Lamp - LH
Number Plate Lamp - RH
Oil Pressure Transducer (EOP)
PATS Module
PATS Transceiver
Performance Mode Switch
Powertrain Control Module (PCM)
Purge Cannister Vent Valve
Radiator Switch
Radio
Radio Aerial
Radio Telephone Connector
Radio Tweeter (LH)
Radio Tweeter (RH)
Rear Lamp - LH
Rear Lamp - RH
Relay - Air Conditioning
Relay - Air Conditioning W.O.T.
Relay - Air Pump
Relay - Auxiliary Load (
Relay - Auxiliary Load (
Relay - Courtesy Lights (
Relay - Clutch (
Relay-Day Time Running (
Relay - Drivers Seat Heater (
Relay - Fan Change-Over (
Relay - Fan Run On
Relay - Front Fog Lamps
Relay - Fuel Pump 1
Relay - Fuel Pump 2
Relay - Gearbox Failure Warning
Relay - Glass Drop
Relay - Hazard Unit
Relay - Headlamp Dipped Beam
Relay- Headlamps
Relay - Heated Front Screen Control
Relay - Heated Rear Window
Relay - Hood Down (Roof Down)
Relay - Hood Up (Roof Up)
Relay - Horn
Relay - indicator Unit (Flasher Unit)
Relay - Left Quarter Light Up
Relay - Left Quarter Light Down
Relay - Load
Relay- Main
Relay - Main Beam
Relay - Passenger Seat Heater
Component
Location
14-6
14-4
14-4
7-13
14-3
10-9
14-1
6-1
14-8
14-7
15-3
4-9
15-4
6-8
4-1
15-7
15-2
5-1
5-4
8-3
5-2
5-2
15-8
15-6
see relay location chart) di II II II
II II II II
II II II II
11 II II II
II II II II
II II II II
II II II II
II II II II
II II II II
11 II II II
II II II II
II II II II
II II It II
II II II II
11 II II II
II II II II
II II II II
II II II II
II II II II
II It II II
II II II II
11 II II II
II II II II
11 II II II
11 II II II
II II II II
II II II II
II II II II
II II II II
II II II II
Circuit
Reference
16-A2
9-D3
9-D3
12-82
3-A2
8-A4
5-D2
12-B5
16-D6
16-C6
5-C4
12-B1
9-C2
4-A2
6-B5
15-B3
5-D1
10-B3
16-C2
16-B5
8-A3
12-C2
15-B6
16-D2
3-A4
3-A5
1-A5
9-D1
12-D1
9-D1
1-B5
1-A6
23-D3
3-C4
3-A3
) 1-B5
) 17-A2
) 17-A4
9-D2
) 12-C1
) 8-C3
2-A2
) 2-B2
) 12-D3
) 8-C4
) 19-A2
) 19-A3
) 1-85
) 8-C3
) 18-A5
) 18-A5
) 12-D1
) 12-D2
) 2-83
) 24-D3
September 1996 6-45

Electrics

Relay Location Index - 97 MY
D^^
Facia Component Panel
- LHD
Passenger
Function
Heated Front Screen Timer Relay
Multi-Function Module
Low Coolant Transmitter Module
Main Relay (Red Stripe)
Auxiliary Load
Auxiliary Load
Fusebox
Heated Front Screen Fuse
Otter Switch (door drop glass)
Side
-
Right
to
Left
Base Colour
Yellow
Black
Black
Red
White
Black
Black
White
Fascia Component Panel
- LHD
Drivers Side
-
Right
to
Left
Function
Gearbox Failure Warning
Ignition Load
Courtesy Lights
Indicator/Flasher Unit
Hazard Warning
Heated Rear Window
Rear
Fog
Light
Dimmer Module
Fusebox
Base Colour
Black
White
Red
Yellow
Green
Blue
Brown
Black
Relay/Module Cover.
Grey
Black
Black
Silver
Blue
Blue
Orange Fuse
Black
Relay/Module Cover.
Pink
Blue
Blue
Black
Black
Blue
Blue
Red
Location
1
2
3
4
5
6
7
8
9
Location
1
2
3
4
5
6
7
8
9

Seat Heater Relays - Beneath the Driver and Passenger Seats
Boot (Trunk) Relays Volante (Front To Rear)

Function
LH Quarter
Up

LH Quarter Down
Hood Down
Hood
Up

RH Quarter Down
Reverse Lights
Fuel Pump
1

Fuel Pump
2

Tilt Sensor
RH Quarter
Up

Stop Lights
Hood Lift Fuse
Fusebox
Hood (Roof) Control Module
Thermal Cut-Outs Quarter Glasses
Base Colour
White
Yellow
Blue
Green
Red
Yellow
Blue
Green
White
Black
Brown
Black
Relay/Module Cover.
Pink
Pink
Pink
Pink
Pink
Blue
Silver (Bosch)
Silver (Bosch)
Pink
Pink
Blue
Green
30A

Black
Location
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Boot (Trunk) Relays Coupe (Front To Rear)
Function
Stop Lights
Reverse Lights
Fuel Pump 1
Fuel Pump 2
Tilt Sensor
Fusebox
Base Colour
Brown
Yellow
Blue
Green
White
6-66

Relay/Module
Blue
Blue
Silver (Bosch)
Silver (Bosch)
Pink
Cover. Location
1
2
3
4
5
6
September
1996

fj

NO COLOUR 636 N 655
N
704
N
7r7 N
AREA e.M S.A6 9.DI 9.04
UPPER SOCKET LOWER SOCKET

BATTERY
STUDt
NO COLOUR 786
N
787
N
788
N

AREA I0.AZ-I5I
8.B6-75
IO.BI-90

BATTERY
STUDt

NO COLOUR
PIN
AREA
760
ON
U
9.C4-85
761 GW W I0.B?-9I

SPL 151
-

^w^

SPL 89 SPL 90
T^

SUNROOF/ACC
NO COLOUR PIN AREA 762 B I
e.B4-67
2 658
NP
3 8.A6 660 WG 4 8.A6

II
[D
fl]

(D
01 ^5 4

ABS LOOM
RED
764
BY
726 RB 645 WR 765 0

AREA
A4/5
ABS
LOOM
BROWN
NO COLOUR
PIN
AREA 656
NG
I 8.A6
766 NO
2
II.A3 3
REARWARD HARNESS NO COLOUR 767 KB
338 OY 769 KB 3
YS
340 OC
771
BR

772 OR 773 OU
PIN 1 2 3 4 5 e
7 8 9 10 II 12 13
AREA I0.B4-I04
I2.BI I2.AI 8.AI 12.81
10.82-96
I0.C2-I00 IO.C3-I02

SHEET
14
AREA
B/CI

-4
«

NO COLOUR
PIN
AREA
774 YW 775 B
776
B
199
K
779 NS

I0.B2-92 I0.B3-IIO II.C4-II9
II.CI I0.B3-ID9
NO COLOUR
344 RIN 822 0 781 8 316 B
346 UIN
348 YU
785
NS

PIN
? 3 4 5 6 7 8 9 10 II 12 13 14 15 16
AREA
I2.A3 I0.D5 I0.B4-II0 I2.A3
I2.A3
I2.A3
10.84-109

'YD 0 0
D D
0
D
a
do DD pan Dap'

SPL 105 SPL 106 SPL 107

16/0 D
0
D
0 0
D
0\'

e/flDDODaODDo\'

SHEET
II
AREA
81
-SPL 97
-SPL 98

-
SPL 99

-
SPL 100

-
SPL 101

-
SPL 102
NO /89 790 791 792 793 794 795 796 797 643 641 798 799 800
COLOUf BW B B YG B BR BW B S
wu
p RK BR B
Pll 1 2 1 4 b 6
/
8 9 10 II 12 13 14
AREA
8.B4-66
8.B3-64
8.B2-63
IOCS I0.C5 I0.C5 I2.C3-14I I2.C2-I37 10.05 8.A4 8.A4 I0.B2-93 I0.C5 I0.C5

ILOGIC
EARTH
'
NO COLOUR AREA
1004 BK I0.B5-I0! 1005 BK I0.B2-95

(f

D
D

•
a
D
•
DOZL
D
D
0
D
0
D
•
D
D
D
DCT D
D
D
a
0
0 13 24

AREA
C/OI
REARWARD HARNESS NO COLOUF 803 SLG 804 PC 805 PW 667 G 1 LC 335 OR 807 GB 808 K 809 YN 621 RU 810 BW 811 GW 336 0 813 LGO 814 OW 815 GP 816 OG 294
R
652
WU
330 LCO 797
S
304
YB

337
RN

PIN 1 ? 3 4 5 6 7 8 9 10 II 12 13 14 15 16 17 18 19 20 21 22 23 24
AREA 11.03
e.B2-6l
8.83-65
8.A6 8.BI I2.AI I0.C2-I0I I2.A5 I2.A5 8.C4 10.62-94 I0.B2-9I
12.
Al
10.82-97 I0.B2-99 II.C2-II5 10,82-98 I2.AI 8.A4 I2.AI I0.B4
12.
Al
I2.AI

c

Q
D
n
n
D
CZ
u
u
D
D
D
0

SC:

D
D
D
D

n
n
3
CZ
u
u
D
D
REARWARD HARNESS NO COLOUf 799
BR
794
BR
724
LGK
736 RIN 327 RIN
823
GR
792 YG 824 SR 800 8 793 8 737 UIN 326 UIN 826
SW
827
R
828
BG

829
RN
374 0 723 LGS 822 0 177 YW
PIN 1 2 3 4 4 5 6 7 8 9 10 II 12 12 13 14 15 16 17 IB 19 20 21 22 23
AREA I0.B4 I0.B4 I2.CI 9.B4 I2.AI

9.C2-79
I0.B4 11.03 I0.B4 I0.D4 9.B4 I2.A1 11.03
9.C4-84
I0.B5-I06

9.C3-80
I0.B5-III I1.B3-I16 I0.A6 10.82-92

Wiring
Diagram

Model
- Aston Martin DB7

Harness
Title - Bulkhead LHD - 3

Part
No. - B37-84635

Revision
- 0
Sheet
10 of 26-97 MY

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
Precautions
Paint
Ensure that there is efficient ventilation at all times. Paint spraying should be confined to spray booths.
Anyone with a history asthma should not be engaged in any process which involves the use of isocyanates.
Any operator working inside a spray booth where isocyanates are present must use air-fed breathing equipment.
Supplied air to the visor should be fed at the recommended pressure and filtered to remove oil, water and fumes.
Operators involved in handling, mixing or spraying should wear protective clothing, gloves and goggles to avoid
skin and eye contact. A Paticle mask or canister typr respirator should be worn when sanding.
Applied heat
When welding, flame cutting or brazing and so on, goggles, a mask or fume extractor and flameproof protective
clothing should be used always.
It is especially important when working with polyurethane compounds to use air-fed breathing equipment.
Ensure that at all times the appropriate fire fighting equipment isavailableand that personnel are trained in its use.
Metal repair
Wear appropriate eye and hand protection when sanding, drilling, cutting, chiselling, flatting or welding. Wear a
face mask or air-fed visor when sanding or flatting either body solder or
fillers.
When a soldering operation has been

completed,
remove swarf from the work area and wash your hands thoroughly.
General Repair Notes
The following precautions should be noted before any work is carried out:
• disconnect the vehicle battery ground
lead,
taking note of the reconnection procedures
• Make sure that you have read and understood the safety related procedures in this section.
Caution:
Electric arc
welding must not
be
used on the
vehicle as the high
voltages produced by
this process
will
cause
irreparable

damage
to the electrical control and
microprocessor
systems.

All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel
removal or replacement.
Welding and Gas Process Special Notes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated

metal.
The flanges of panels, which are to be welded together, must be clean, corrosion free and treated as
appropriate with either weld-through or inter-weld sealer.
The resistance spot welding equ ipment used in vehicle repair does not always produce
a
weld of
equ
ivalent strength
to that produced in manufacturing. This means that a single row of spot welds should be spaced on a pitch of 19-
25 mm, which will usually result in more spot welds than found in the original factory joint.
Use a resistance spot weld cutter to remove resistance spot welds. Where a new joint is to be MIC welded, cut the
old resistance spot welds from the panel that is to be retained; the resulting holes are then used for plug welding.
Suitable holes may be drilled or punched as follows:
• 8.0 mm for sections up to 1.5 mm thickness
• 10.0 mm for thicker sections.
Always refer to the welding equipment manufacturers diagrams and tables for the relevant procedure.
May 1996 7-3