Aston Martin DB7 User Manual

Aston Martin DB7

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Workshop Manual

(Issue II -Volume 2)

Table of Contents

Procedure Numbering3
Repairs and Replacements3
Special Tools3
Safety Precautions4
Air Conditioning System4
Chemical Handling and Storage4
Fire Precautions5
Jacking and Lifting5
Exhaust Fumes5
Electrical Equipment5
Used Engine Oil6
Health Protection Precautions6
Environmental Protection6
Contents7
Table of Contents9
Headlamp Unit11
Dipped Beam Conversion11
Headlamp Alignment11
Front Indicator/Parking Lamp Unit12
Front Fog Lamp Assembly12
Side Repeater Lamps12
Windscreen Wiper Motor13
Alternator13
Starter Motor14
Steering Wheel and Horn Switches14
Column Switches14
Ignition Switch15
Instrument Panel15
Air Conditioning and Switch Panel16
Radio16
Cruise Control, Window and Gearshift Switches17
Seat Control Switch Panels17
Front Interior Lamps18
Rear Interior Lamps18
Front Seat Removal18
Front Seat Runner Assembly19
Front Seat Rail Motor19
Lumbar Support Motor20
Seat Recline Motor20
Seat Control Unit20
Door Edge Lamps20
- Door Mounted Components21
- Central Locking System21
Rear Lamp Cluster21
Door Central Locking Motors21
- Electric Windows22
- Fault Analysis Procedure22
Door Window Motor22
Door Mirror Assembly23
Transmission Control Module - Renew (TCM)24
Barometric Pressure Sensor - Renew25
- Component Index26
- Component Location on the Vehicle26
- Component Location on the Wiring Diagrams26
- Electrical Component Location and Wiring Information26
- Relay Locations129
- Airbag (Supplementary Restraint System)185
- Handling Undeployed Airbags185
- Safety Precautions and Warnings185
- Emergency First Aid Procedures186
- Fire Hazard Information186
- Handling Undeployed Damaged Modules186
- Safety Procedures186
- Driver and Passenger Airbag Modules187
- Eye Protection187
- Handling and Storage Precautions187
- Protective Clothing187
- Scrapping Vehicles with Live Airbags188
- Spillage and Leakage188
- Scrapping Vehicles with Deployed Air Bags189
- Disposal of Deployed Airbags190
- Disposal of Live Airbags190
- Driver's Airbag Module Renew191
- Airbag Crash Sensors Renew192
- Passenger's Airbag Module Renew192
- Airbag 'Safing' Sensor Renew193
- Airbag Diagnostic Module Renew193
- Airbag Diagnostic Module194
- Airbag Modules194
- Airbag System Diagnostics194
- Wiring Harness194
- Airbag System Wiring Diagram195
- Airbag Disarming/Arming Procedures196
- Airbag Diagnostic Module Fault Codes197
- Airbag Diagnostic Module Connector198
- No Airbag Warning Lamp199
- Continuous Airbag Warning Lamp200
- Airbag D M Fault Code 12201
- Airbag DM Fault Code 13202
- Airbag DM Fault Code 14203
- Airbag DM Fault Code 21203
- Airbag D M Fault Code 22204
- Airbag D M Fault Code 23205
- Airbag DM Fault Code 24206
- Airbag DM Fault Code 32207
- Airbag DM Fault Code 33208
- Airbag DM Fault Code 34209
- Airbag DM Fault Code 35210
- Airbag DM Fault Code 41211
- Airbag DM Fault Code 42211
- Airbag DM Fault Code 44212
- Airbag DM Fault Code 45213
- Airbag D M Fault Code 51214
- Airbag DM Fault Code 52215
- Airbag DM Fault Code 53215
- Airbag D M Fault Code 99216
- The Seat Belt Pretensioner System (Where Fitted)217
- Assembly/Removal/Service Instructions218
- System Fault Strategy218
- Pretensioner Assembly Renew219
- Pretensioner Control Module - Renew219
- Seat Belt Pretensioner Circuits220
- Diagnostic Trouble Codes221
- Pretensioner Squib Leak to Battery Positive221
- Seat Beit Pretensioner Diagnostics221
- Pretensioner Squib Leakto Ground222
- Pretensioner Squib High Resistance223
- Pretensioner Squib Low Resistance223
- Warning Lamp Open Circuit224
- Warning Lamp Short Circuit224
- Pretensioner Control Module Internal Faults225
- Seat Removal 97.5 MY227
- Seat Control Module 97.5 MY228
- Applied Heat230
- Body Repair230
- Paint230
- Potential Risks230
- General Repair Notes231
- Welding and Gas Process Special Notes231
- RTM Body Parts233
- Body Panel and Trim Removal234
- Front Apron235
- Front Undertray236
- Wheel Arch Liners237
- Side Sills238
- Rear Bumper240
- Doors241
- Door Liners242
- Steering Wheel244
- Facia Mountings251
- Console Instruments252
- Front Seats254
- Ashtray255
- Centre Console256
- ECU Covers257
- Rear Console258
- Rear Seats259
- Roof and Rear Quarter Light Control262
- Volante Roof262
- Roof Component Location263
- Roof Control System264
- Roof Removal/Replacement265
- Roof Hydrailic Control System266
- Bleed the Right Hand Ram and Pump267
- Bleeding the Roof Hydraulic System267
- Left Hand Ram Bleeding267
- Rear Quarter Window Renewal268
  - Window Motor Mountings268
  - Front to Rear Adjustment269
  - Lateral Adjustment269
- Rear Quarter Glass Adjustment269
  - Up and down Adjustment269
  - LH Window Lift Motor Removal270
  - Rear Quarter Window Lift Motor - LH/RH270
  - Rear Quarter Window Lift Motor - Right Hand271
  - 'A' Post/Header Sealing and Lock Adjustment272
- Roof Sealing and Wind Noise272
- Roof Seals - Adjustment273
- Cheater Plate Seals - Adjust/Renew274
- Door Glass Adjustment275
  - Cleaning of Alcantara Trimmed Roof Lining and Interior Components276
  - Spot Removal Chart276
- General Description282
- Specifications282
- Climate Control System283
- Special Servicing Tools and Equipment284
- System Description284
- General285
- Handling Lubricating Oil285
- Handling Refrigerant285
- System Maintenance285
- Working Practices285
- Temperature Distribution System286
- Face Level Temperature Differential287
- Fan Speed Control (Mode Switch)287
- Temperature Rotary Control287
- Air Conditioning Function Switch288
- Refrigeration Cycle288
- Charge Recovery (System Depressurisation)289
- General System Procedures289
- Leak Test289
- System Protection289
- Adding Compressor Lubricating Oil290
- Evacuating the System290
- Adding Refrigerant291
- First Aid291
- Functional Check292
  - Insufficient Cooing294
  - No Cooling294
- System Trouble Shooting 8-1294
  - Insufficient Heating295
  - Intermittent Cooling295
  - Noisy System295
- Electronic Control Module (ECM)296
- Input-Output Voltage Signals297
- Face Level Differential Controller298
- In Car Controls298
- Temperature Demand Switch298
- Air Conditioning Function Switch299
- Fan Speed Control Switch (Mode Switch)300
- Temperature Sensors300
- Ambient Temperature Sensor301
- Evaporator Sensor301
- Motorised In-Car Aspirated Sensor301
- Water Temperature Switch302
- Blower Motors303
- Lower Feedback Potentiometer303
- Potentiometers303
- Lower Servo Motor304
- Servo Motors304
  - Upper Feedback Potentiometer304
  - Upper Servo Motor304
- Vacuum System305
- Pressure-Temperature Graphs306
- Fault Finding307
- System Fault Diagnosis307
- Blower Motor Test310
- Open Water Temperature Switch Needs310
- Short Water Temperature Switch Leads310
- Refrigeration311
- Compressor Clutch Control312
- Condenser312
- Trinary Switch312
- Evaporator313
- Expansion Valve313
- Receiver-Drier313
- Sanden Compressor SD7H15314
  - High Side Pressure Gauge315
  - Low Side Pressure Gauge315
- Manifold Gauge Set315
- Connecting the Manifold Gauge Set316
- Stabilising the System316
- System Checking with the Manifold Gauge Set316
- Leak Test317
- Purging the Test Hoses317
- Manifold Gauge Set Check Procedures318
- Pressure Temperature Relationship318
- Refrigerant Slightly Low318
- Test Conditions318
- Air in the System319
- Refrigerant Excessively Low319
- Compressor Malfunction320
- Condenser Malfunction or System Overcharge320
- Moisture in the System321
- A Large Amount of Air in the System322
- Expansion Valve Malfunction322
- Expansion Valve Malfunction323
- Restriction in the High Pressure Side323
- Air Conditioning Procedures324
- Depressurising324
- Recovering Refrigerant324
- Torque Levels for the Hose Connections324
- Evacuating and Recycling the Refrigerant325
- Recovery Procedure325
- Compressor Oil Check326
- Recharging the System326
- Compressor Removal/Renewal328
- Field Coil Renewal329
- Renew Gasket Kit329
- Valve Plate Renewal330
- Expansion Valve Renewal331
- Air Conditioning Unit Renewal332
- Hose-Compressor to Evaporator Renewal332
- Evaporator Unit Renewal333
- Lower Servo Feedback Potentiometer Renew334
- Upper Servo Feedback Potentiometer Renewal334
- Lower Flap Motor Assembly Renew335
- Upper Flap Motor Assembly Renew335
- Ambient Temperature Sensor Renew336
- Blower Motor Driver Side Renewal336
- Blower Motor Passenger Side Renewal336
- Blower Assembly Driver/Passenger Side Overhaul337
- Blower Motor High Speed Relay Renewal338
- Heater Matrix Renewal339
- Water Temperature Switch Renewal339
- Electronic Control Module Renew340
- Vacuum System Solenoid Renewal340
  - Air Conditioning Diagnostics342
  - Cable Connections to the A/CCM342
  - The Air Conditioning System Diagnostics342
  - Air Conditioning Signal Monitoring343
- Installation Instructions353
- Radio Interference Statements353
- The Aston Martin Diagnostic System353
  - Component Identification355
  - Controls355
  - Diagnostic System Cables355
  - Electronics Module355
- Diagnostic System Cables356
- Base Station Installation359
  - Wall Mounting359
  - Bench Mounting360
  - Electronic Module Installation360
  - Powering-Up the Base Station361
  - Installing the CD - ROM (Early Systems)362
  - Installing the CD - ROM (Later Systems)362
  - Removing the CD-ROM (Early Systems)363
  - Removing the CD-ROM (Later Systems)363
  - Powering-Up the PDU364
  - Battery Charging365
  - Using the PDU on the Vehicle365
  - Vehicle Battery Adaptor365
  - Vehicle Interface Adaptor365
  - Care of the Equipment366
  - Finishing the Test366
  - PDU Self-Test367
- Problem Solving367
- Parts Ordering371
- Service Centres372
  - Battery Changing Procedure373
  - Battery Testing373
  - Changing the Battery Pack373
  - Servicing and Maintenance373
  - Changing the Dust Filter374
  - Support Arm Adjustment374
  - VIA Carrying Case374
  - New CD-ROM Releases375
- Technical Specifications375
- Statement of Calibration376
- The Aston Martin Lagonda Diagnostic System376
  - The Aston Martin Lagonda Diagnostic System378
  - PDU Functions379
  - PDU Power379
  - Software for 95 and 97 Model Year Vehicles380
  - Software Loading and Selection380
  - Vehicle Area381
  - Vehicle Features381
  - Cable Setup - 95 MY382
  - Cable Setup - 97 MY382
- Diagnostic Sockets - 97 MY382
- Establishing Communications383
- PDU Use383
- System Menu Selections383
- Diagnostic Trouble Codes (Dtcs)384
- Engine Diagnostics - 97 MY384
  - KOEO Test384
  - KOER Test384
  - OBD II Readiness Test Monitor - 97 MY385
  - Throttle Position Sensor Track Test - 97 MY385
  - Electromechanical Outputs386
  - Low and High Speed Fans386
  - Output State Control - 97 MY386
  - Engine Datalogger387
  - Engine Setup - 95 MY389
  - Throttle Sensor Adjustment - 95 MY389
  - Idle Fuelling Trim - 95 MY390
  - Gearshift Timing391
  - TCM-PCM Communication391
- Transmission Diagnostics391
  - Warm-Up391
  - DIGS Number of Dtcs Logged392
  - FMA Actual Force Motor Current392
  - HOT Hot Mode392
  - Transmission Datalogger392
  - TCCS Torque Convertor Clutch Solenoid393
  - TCS Torque Convertor Slip393
  - TISSA Turbine Input Shaft Speed393
  - Transmission Diagnostic Trouble Codes393
  - ABS Diagnostic Trouble Codes394
  - Anti-Lock Braking Diagnostics394
- Climate Control Diagnostics394
  - ABS Datalogger395
  - Brake Switch395
  - Number of Dtcs Logged395
- Passive Anti-Theft (PATS) Diagnostics395
- Airbag System Diagnostics396
- Airbag Diagnostic Trouble Code Monitor397
- Seat Belt Pretensioner Diagnostics398
  - System Connections398
  - Seatbelt Pretensioner Diagnostic Trouble Codes399
  - Connecting to the PDU400
- Print Facility400
  - Printer Configuration400
  - RS232 Protocol400
- Digital Multimeter401
  - Print Screen401
  - Print Trace401
  - Printer Use401
  - DMM Measurement Selection402
  - Measurement Source Selection402
  - Module Pin Selection (Air-Con Only)402
  - Display Freezing403
  - System Exit403
- Diagnostic Trouble Codes404
  - Clear All Trouble Codes405
  - Clear Selected Trouble Codes405
- Datalogger406
  - Parallel Communication406
  - Serial Communication406
  - Using the Datalogger406
  - Datalogger Waveform Screen407
  - Main Menu407
  - Parameter Customisation407
  - Datalogger Timing411
  - Datalogger Specific Icons412
  - Pre-Trigger and Post-Trigger412
  - Record Icon412
  - Waveform Display412
  - Horizontal Scale413
  - Re-Scale Vertical Icon413
  - Split Cursor Icon413
  - Waveform Display Number413
- Datalogger Example414
  - Parameter Customisation - Final Setup416
  - The Trigger Set-Up Screen416
  - Wheel Speed Sensor Display416
  - New User Training417
- OBD II Scan Tool417
- Training417
  - Accessing Freeze Frame Data418
  - The Asterisk Icon420
  - User Self Test420
- System Setup421

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Aston Martin DB7 Specifications

General

Brand	Aston Martin
Model	DB7
Category	Automobile
Language	English

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