1997 ASTON MARTIN DB7 wheel

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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

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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

ES^^^?

Electrics
Headlamp Unit / Headlamp Alignment
6.1.01 Headlamp Unit
Procedure

1.
Remove the front apron undertray and remove the
complete nose assembly.

2.
Release the headlamp plug from the body clip and
disconnect the
plug.

Figure 7. Headlamp Removal
3. Remove
1
bolt from the front headlamp mounting.

4.
Remove the main beam lamp access cover and
loosen the rear headlamp mounting bolt.
5. Lift off the headlamp assembly.
5. On refitting the headlamp assembly, carry out the
headlamp alignment procedure.
6.1.02 Headlamp Alignment
Data
Main Beam Alignment 1.5° down
Dipped Beam Alignment 1.5° down
Tools
Headlamp Alignment Gauge
Procedure

1.
Lift the bonnet and remove the main beam access
cover from the headlamp unit.

2.
Usingthe large hex adjusters, align theouter dipped
beamsto thecorrect pattern in
a
headlampalignment
gauge
Figure 1. Headlamp Alignment
3. Using the small hex adjusters, set the inner main
beam al ignments
so
that the bright spot
is
central ised
and 1.5° down inthealignmentgauge. If necessary,
fine tune the adjustment to suit average vehicle
loading and driver requirements.
Dipped Beam Conversion - UK-Europe-UK

1.
Access the dipped beam lamps through the panels
in the wheel arch liners.

2.
Cut the tie strap securing the rubber gaiter and pull
back the gaiter.
3. Slacken 3 screws securing the lamp backplate
(Figure 2) and rotate the plate to the right for U
K
or
to the left for Europe to the limit of the bolt slots.

1
.For European (RH) Use
(Beam Pattern _/)
2.For UK (LH) Use
(Beam Pattern ^^)
Figure 2. Dipped BeamConversion UK-Europe
4. Tighten the three screws, replace the gaiter and
secure it with a new tie strap.
May 1996 6-3

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
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

^7
Electrics
Component Index Sheet 1-97 MY
Component
Name
ABS ECU
ABS Wheel Speed Sensor - Front RH
ABS Wheel Speed Sensor - Front LH
ABS Wheel Speed Sensor - Rear RH
ABS Wheel Speed Sensor - Rear LH
Airbag Crash Sensor RH
Airbag Crash Sensor LH
Airbag Diagnostic Monitor
Airbag (Drivers)
Airbag (Passengers)
Airbag Safing Sensor LHD
Air Conditioning Compressor Clutch
Air Conditioning Control
Air Conditioning Trinary Switch
Air Conditioning Unit
Air Pump
Air Temperature Sensor (IAT1)
Air Temperature Sensor (IAT2)
Alarm LED Inverter
Alarm Sounder
Alternator (Generator)
Ambient Temperature Sensor
Barometric Pressure Sensor
Blower Fan LH
Blower Fan RH
Bonnet Switch
Boot Lamp LH
Boot Lamp RH
Boot Lock Actuator
Brake Fluid Level Sensor
Camshaft Sensor (CMP)
Capacitor (Generator)
Catalyst Overtemperature/Speed Warning Module
CD Autochanger
Central Locking Unit '
Cigar Lighter
Column Switchgear Assembly
Coolant Low Level Sensor
Coolant Temperature Sensor (ECT)
Coolant Temperature Sensor - Temp Gauge
Courtesy Light
Crankshaft Position Sensor (CKP)
Cruise Control Clutch Switch (RHD)
Cruise Control Disable and Stop Lamp Switch
Cruise Control On/Off Switch
Cruise Control Servo Unit
Cruise Control Set Switch
Diagnostic Socket - Lower
Diagnostic Socket - Upper
Door Closed Microswitch (Drivers)
Door Closed Microswitch (Passengers)
Door Lock Motor (Drivers)
Door Lock Motor (Passengers)
Door Lock Switch (Drivers)
Component
Location
(Figure No.-ltem No.)
1-5
1-3
1-3
8-1
8-1
2-3
2-3
4-2
9-6
9-1
2-6
9-4
9-2
9-5
9-2
9-3
3-7
3-11
7-8
2-4
3-12
1-1
8-6
10-10
10-4
2-2
10-8
10-6
10-7
16-3
3-2
1-2
4-8
5-5
6-10
6-5
10-5
10-3
3-4
3-3
10-9
3-1
10-2
1-4
6-6
2-8
6-7
11-3
11-3
7-6
7-6
11-6
11-9
11-5
Circuit
Reference
(Sheet No.-Coordinates)
20-A1
20-D2
20-D3
20-B6
20-C6
3-D1
1-C3
11-C6
9-A3
11-C4
12-B4
3-C1
3-D3
3-D1
11-CI
1-C2
5-C1
5-B3
14-B6
1-B2
5-A6
1-A2
4-A4
8-A3
12-C3
1-C5
15-A4
16-D3
16-C6
20-B3
5-C1
5-A5
11-C3 Japan Only
10-B3 Rear of Radio
12-D4
13-A3
9-A2
3-A3
5-B1
5-C1
9-B1
5-A2
3-C5
9-A3
13-A5
2-A6
13-B5
10-A6
10-A5
21-A2
22-A2
21-B1
22-Bl
21-A2
September 1996 6-43

Electrics
Airbag System
Airbag (Supplementary Restraint System)
Repair Procedures
Description
Two airbaes are fitted to the 97 model year DB7.
The drivers airbag is located in the centre of the
steering wheel (Fig 1-1), the passenger airbag is
located behind the fascia panel (Fig 1-2).
Figure!. Airbag Locations
The following procedures and safety precautions
must be adhered to while handling, installing and
testing airbag modules. Failure to observe these
precautions could cause the airbag to inadvertently
deploy with the risk of personal injury.
The procedures and precautionary guidelines
conform to the 'Handling and storage - The
Explosives Act 1875 & 1923' and to the 'Health and
Safety at Work Act - 1974' or local guidelines as
appropriate.
Safety Precautions and Warnings
Handling Undeployed Airbags
The electrically actuated airbag module contains
sodium azide and sodium nitrate which are
poisonous and extremely flammable substances.
Their contact with
acid,
water or heavy metals may
produce harmful, irritant gases or combustible
compounds.
The airbag module is non-serviceable and must not
be dismantled, punctured, incinerated or welded.
WARNING: Do not attempt any repairs or
electrical measurements on the airbag module.
Never measure the resistance of the airbag module,
as this may cause the airbag to deploy. Suspect
modules must be returned to Aston Martin Lagonda

Limited,
or their importer for replacement.
Tampering or mishandling can result in personal
injury.
Keep away from heat, sparks and open flames. Do
not store at temperatures exceeding 93°C (200°F).
Keep away from electrical equipment as electrical
contact may cause ignition.
Do not drop or impact the airbag module. Always
position the module 'cover-up'.
Ensure that the module connector is protected to
prevent damage. Never carry the airbag module by
the wires or connector.
Store modules in a secure lockable cabinet.
Never position material over the undeployed
module which could be projected and cause injury
in the event of inadvertent deployment.
Do not wrap arms around the module when carrying
and always carry the module with the cover and
vents facing away from the body to avoid personal
injury in the event of inadvertent deployment.
The chemical propellant mixture deploying the
airbag is a solid and therefore inhalation exposure
is unlikely even if the module is ruptured without
deployment.
As far as practical, avoid skin contact
with,
or
ingestion of, the materials present after combustion.
Exposure to high concentrations of propellant
mixture may cause headache, nausea, blurred

vision,
faintness, cyanosis, lowering of blood
pressure, tachycardia and shortness of breath.
WARNING: Sodium azide has been listed as an
'Extraordinary Hazardous Substance or
Carcinogen' by the state of
Massachusetts,
USA.
Sodium azide has been listed on the
'Right
to Know
Hazardous Substance
List'
by the state of New
Jersey and is also regarded as a 'Special Health
Hazard Substance' by the state. The propellant
mixture is sensitive to premature ignition by
electrical sources if not properly protected and
isolated.
September 1996 6-69