roof rack ASTON MARTIN DB7 1997 Workshop Manual

Body and Trim
Roof Removal/Replacement [D::M^=2?
9.0.02.1 - Roof Removal/Replacement

1.

2.

3.

4.

5.
6.
7.
8.
Move the front seats fully forward for access.
Remove the rear seat squab and cushion. Remove
the rear quarter trim panel.
Release the roof side curtain clips.
Release the rear window support bracket securing
bolts (Fig 1-2).
Remove the side curtain clips (2 per side).
Release the side curtain rods and move the curtains

aside.

Disconnect the heated rear window connector.
Release the rear window support bracket from the
body.
Figure 1. Rear Window Support Bracket
9. Release the roof catches.

10.
Select Manual on the roof motor control switch.
Lower the roof to the midway position. Select
Electric on the roof motor control switch - the roof
will remain in a raised position.

11.
Raise the trim and remove the cable securing nuts.

12.
Release the roof outer finisher securing screws and
remove the finisher.

13.
Release the cable and roof material from the body

channel.

cqD
Figure 2. Ram Mountings

14.
Select the Manual position on the roof motor control

switch.
Fold the roof and remove the ram to roof
securing pins.

15.
Remove the six roof to body securing bolts.

16.
Remove the roof assembly.
Refitting

1.
Fit the roof into position on the vehicle, aligned
with the fixing holes.

2.
Refit the six roof to body securing bolts.
3. Locate the rams to the pivot.

4.
Select Manual on the roof motor control switch.
Place the roof in the partially open position to
al
ign
the ram fixing holes. Fit but do not tighten the
securing bolts.
5. Fit the pivot pins and securing clips.
6. Finally tighten all bolts.
7. Position the rear window support bracket, fit and
tighten the securing bolts.
8. Fully raise the roof. Select Electric on the roof motor
control switch.
Figure 2. Cable Securing Nuts
7-10 May 1996

^=2?
Body and Trim
Roof Hydraulic Control System
9. Position the rear edge of the roof to the body.

10.
Position the rear cable to the roof lower edge.
Position the loops on the cable (approximately 17in
equi-spaced apart). Position the cable to the
mou nti ng
brackets,
fit but do not tighten the
secu
ring

nuts.

Figure 3. Cable, Roof Channel and Body Channel

11.
Align the rear edge of the roof material to the body
and commence tightening the cable nuts evenly.
Stop frequently and check that the cable and roof
channel
are
correctly bedding into the body channel.
Continue tightening and checking until the roof is
fully seated in the body channel.

12.
Fit and secure the roof finishers.

13.
Reconnect the heated rear window connector.

14.
Position the roof inner curtain. Fit clips to the
curtain rods. Fit and tighten the securing screws.

15.
Refit all trim and check the roof mechanism for
correct operation and fitting.
9.0.02.3 - Roof Hydraulic
Control
System
Procedure

1.
Move the front seats forward for access.
Fully lower the roof.
2.

3.

4.

6.
Remove the rear seat squab and cushion. Remove
the rear quarter trim panels.
Remove both the cylinder pivot pins. Release the
ram cylinder assemblies (take care not to kink the
pipes).
Remove the screws from the hydraulicpipegrommet
in the rear of the roof stowage
well.
Remove the
grommet.
Release the pipe securing clips.
Figure 2. Ram Mountings
7. Open the boot and remove the boot floor trim

panel.
Remove the pump mounting plate securing

bolts.

8. Release and remove the pump cover.
9. Disconnect the pump multi-plug.

10.
Releasethe pump mounting rubbers from the plate.

11.
Feed both ram cylinders into the boot through the
aperture in the roof well rear
wall.

12.
Remove the complete hydraulic system from the
boot.
Note: Check that the reservoir fluid level is correct.
Always bleed the hydraulic
system
before topping up.
Refitting is the reverse of the removal procedure.
On completion of the refitting, check the roof

operation.

May 1996 7-11

•=2?

Body and Trim
Rear Quarter Window Renewal
9.1.01.1 -
Rear
Quarter Window Renewal
Procedure

1.
Move the front seat forward to gain access.

2.
Switch on the ignition, release the roof locking
latches and lower the roof to approximately the
midway position. Switch off the ignition.
3. Remove the rear seat squab and cushion. Remove
the rear quarter trim panel.

4.
Remove the roof cylinder support bracket securing

bolts.

5. Support the roof, removethecylindertoroofsecuring
bolt. Remove the cylinder bracket.
6. Disconnectthecylinderfromthepivotand carefully
lower the roof.
7. Remove the window motor cover. Disconnect the
window motor feed wires.
Reassembly
Reassembly is the reverse of the removal procedure.
On reconnection of the motor, check the window
height as follows:

1.
Switch on the ignition and raise the rear quarter
windows.

2.
Check that the top of the glass is exactly level with
the top edge of the fully raised door window.
3. Check for
a
complete vertical seal between the rear
quarter window and the door window.

4.
If the rear window alignment is not correct, adjust
it using the procedure in the Wind Noise and
Sealing section.
5. Switch off the ignition and complete the reassembly.
6. Switch on the ignition, raise the roof and recheck
for complete sealing at the rear window top edge.
Figure 1. Window Motor Mountings
8. Release and remove the window motor finisher,
feeding the wires through the grommet.
9. Remove the window motor mounting bracket
securing bolts.

10.
Remove the motor assembly, disengaging it from
the glass.

11.
Remove the window carrier securing nuts and
special washers

12.
Remove the window
adjusters,
d isplace and remove
the window carrier.
May 1996 7-13

^^7
Body and Trim
Rear Quarter Window Lift Motor
9.1.01.4 - Rear Quarter Window Lift
Motor - Left Hand
Procedure

1.
Move the front seat forward to gain access.

2.
Switch on the ignition, release the roof locking
latches and lower the roof. Switch off the ignition.
Remove the rear seat squab and cushion. Remove
the rear quarter trim panel.
Disconnect the window motor feed wires.
Figure 1. LH Window Lift Motor Removal
5. Release and remove the window motor finisher,
feeding the wires through the grommet.
6. Remove the window motor mounting bracket
securing bolts.
7. Remove the motor assembly, disengaging it from
the glass.
8. Remove the motor to carrier securing bolts and
remove the motor.
Reassembly
Reassembly is the reverse of the removal procedure.
On reconnection of the motor, check the window
height as follows:

1.

2.

Switch on the ignition and raise the rear quarter
windows.
Check that the top of the glass is exactly level with
the top edge of the fully raised door window.
Check for
a
complete vertical seal between the rear
quarter window and the door window.
Figure 1. Rear Quarter Window Alignment

4.
If the rear window alignment is not correct, adjust
it using the procedure in the Wind Noise and
Sealing section.
5. Switch off the ignition and complete the reassembly.
6. Switch on the ignition, raise and latch the roof,
recheck for complete sealing at the rear window
top edge.
May 1996 7-15

Body and Trim
Rear Quarter Window Lift Motor '^^
9.1.01.5 - Rear Quarter Window Lift
Motor - Right Hand
Procedure

1.
Move the front seat forward to gain access.

2.
Switch on the ignition, release the roof locking
latches and lower the roof. Switch off the ignition.
3. Remove the rear seat squab and cushion. Remove
the rear quarter trim panel.

4.
Disconnect the window motor feed wires.
Figure 1. LH Window Lift Motor Removal
5. Release and remove the window motor finisher,
feeding the wires through the grommet.
6. Remove the window motor mounting bracket
securing bolts.
7. Remove the motor assembly, disengaging it from
the glass.
8. Remove the motor to carrier securing bolts and
remove the motor.
Reassembly
Reassembly is the reverse of the removal procedure.
On reconnection of the motor, check the window
height as follows:

1.
Switch on the ignition and raise the rear quarter
windows.

2.
Check that the top of the glass is exactly level with
the top edge of the fully raised door window.
3. Check for a complete vertical seal between the rear
quarter window and the door window.
A
Figure 2. Rear Quarter Window Alignment
4. If the rear window alignment is not correct, adjust
it using the procedure in the Wind Noise and
Sealing section.
5. Switch offthe ignition and complete the reassembly.
6. Switch on the ignition, raise and latch the roof,
recheck for complete sealing at the rear window
top edge.
7-16 May 1996