ASTON MARTIN DB7 1997 Workshop Manual
Page 1 of 421
(Issue II -Volume 2)
Page 2 of 421
ASTON MARTIN LAGONDA LIMITED
Tickford Street, NeAfwrt Pagneii, Buci
Whilst every effort has been made to ensure the accuracy of particulars contained in this Workshop Manual, neither the
Manufacturers nor the Dealer, by whom this Manual is supplied, shall in any circumstances be held responsible for any
inaccuracy or the consequences thereof.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form,
elei:tronic, mechanical, photocopying, recording or other means without prior writien permission from Aston Martin Lagonda
The manufacturers reserve the right to vary specifications without notice in accordance with their policy of continual product
Produced by the Technical Publications Department
ASTON MARTIN LACONDA LIMITED
Issue II - 5/96 Part No. - 43-83658
Page 3 of 421
Workshop Manual Sections
5. Brakes, Wheels
9. Aston Martin Diagnostic System
The workshop manual procedures
parts list numbers
as a key. The
workshop manual procedure number
parts list number
Sump Removal relates
to PL 1.5 Oil
Sump). Thus when carrying
relevant parts illustration
spare parts list.
To avoid excessive repetition, each procedure will
fully detailed once
any other location where this procedure
Where special service tools
left, right, front
always made as
seat facing forward.
assemblies removed from
are to the
the assembly when fitted
Where replacement parts
essential that only genuine Aston Martin parts
used. Your attention
following points concerning repairs
genuine Aston Martin parts
• Safety features embodied
other than genuine Aston Martin parts
In certain territories, legislation prohibits
torque wrench settings given
• Locking devices, where specified, must
other than genuine Aston Martin parts.
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Safety Precautions L —^ ^^—^
Safety Precautions "
All service workshops are a source of potential danger and repair work should only be performed by technically
trained staff following the procedures in this manual. A safety conscious approach to the performance of all service
procedures must be observed at all times. Statutory requirements governing all aspects of health and safety at work
including directives for the proper use of materials and equipment must be implemented.
The following contains a list of particular safety precautions which should be observed; it is not intended to be
Air Conditioning System
Do not disconnect any air conditioning refrigerant system pipes unless trained and instructed to do
used can cause blindness if allowed to contact your eyes.
Chemical Handling and Storage
Chemicalsusedintheservicingofmotorvehiclesincludeacids,adhesives, antifreeze, brake fluids, coolants, grease,
paint, resin and solvents. Exposure to certain chemicals through direct contact or inhalation can be
Potential hazards may also be present through the incorrect use, storage and handling of chemicals causing a fire
risk. The following precautions should be observed.
Strictly adhere to handling and safety information found on containers and labels.
Do not store chemicals in unlabelled or incorrectly labelled containers.
3. Containers used for storing chemicals should not be left
there is a risk of
or evaporation of fumes
which may be inflammable or toxic.
Do not mix chemicals unless instructed to do so following manufacturers guidelines.
5. Do not inhale chemical materials to determine identity, they may be toxic.
6. Do not use petrol, kerosene, diesel
gas oil, thinners or solvents for washing
7. Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages.
8. Chemicals based on solvents such as paint should not be sprayed in a confined space; work areas used for
such operations should be well ventilated and fume extraction equipment should be utilised.
9. Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.
WARNING: Fume extraction equipment must be in operation when
spirit, SBP3, methylene chloride, perchlorethylene.
WARNING: Do not smoke in the vicinity of volatile de-greasing agents.
Avoid splashing the
eyes and clothing.
Clean chemicals from the skin and clothing as soon as possible after soiling.
Wear protective clothing such as goggles, non porous gloves and apron when hand
ing battery acid and other
corrosive and toxic substances.
iv April 1997
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' -^ ^ Introduction
Safety Precautions (continued)
Ensure that electrical equipment is in safe working order before use.
Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly
3. Ensure that electrical equipment is protected by a fuse of the correct current rating.
Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine
or when working beneath the vehicle.
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.
Ensure that a suitable form of fire extinguisher is conveniently located near the work area.
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.
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
6. All personnel should be aware of the fire drill procedures and precautions.
Jacking and Lifting
The recommended procedures for lifting, jacking and towing are included latefin this seetion-and must be
strictly observed to ensure personal safety.
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.
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
Do not leave tools, equipment, spilt oil, etc. around or on the work area.
Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or
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.
Use the recommended service tool where instructed to do so.
April 1997 v
Page 6 of 421
Introduction //—">) ^nir>^ ' ^ 1
Safety Precautions L 1 .^—y^
Safety Precautions (continued)
Used Engine Oil
Prolonged and repeated contart with mineral oil will result in the removal of natural fats from the
dryness, irritation and dermatitis. In addition, used engineoii contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and washing facilities should be provided.
Health protection precautions:
Avoid prolonged and repeated contact with oils, particularly used engine oil.
Wear protective clothing, including impervious gloves where practicable.
3. Do not put oily rags in pockets.
Avoid contaminating clothes with oil.
5. Overalls must be cleaned regularly. Discard unwashable clothes and oil impregnated footwear.
6. First aid treatment should be obtained immediately for open cuts or wounds.
7. Use barrier creams, apply before each work period to help the removal of oil from the
8. Wash with soap and water to ensure all oil is removed. Preparations containing lanolin replace the natural
skin oils which have been removed.
9. Do not use petrol, kerosene, diesel
gas oil, thinners or solvents for washing
If skin disorders develop, obtain medical advice.
Where practicable, degrease components prior to handling.
Where there is a risk of eye contact, eye protection should be worn, in addition, an eyewash facility should
It is illegal to pour used oil on the ground, down sewers or drains, or into water courses. The burning of used engine
oil in small space heaters or boilers is not recommended unless emission control equipment is
in case of doubt,
contact the Local Authority for advice on disposal facilities.
vi April 1997
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Page 8 of 421
Page 9 of 421
Front Indicator/Parking Lamp Unit
Front Fog Lamp Assembly
Side Repeater Lamps
Windscreen Wiper Motor
Steering Wheel and Horn Switches
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
April 1997 6-1
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Electrical Component Location and Wiring Information - Up to 97 MY
Component Index 6-19
Component Location Diagrams 6-23
Electronic Control Unit Location Diagram 6-38
Relay Panel, Fusebox and Earth Point Location Diagram 6-39
Loom Location Diagrams 6-40
Wiring Diagrams and Splice Lists 6-42
Electrical Component Location and Wiring Information - 97 MY
Component Index 6-43
Component Location Diagrams 6-47
Relay Location Diagrams 6-64
Wiring Diagrams and Splice Lists 6-68
Airbag System - Repair and Diagnostic Procedures 6-69
Seat Belt Pretensioner System - Repair and Diagnostic Procedures 6-101
Security System (Restricted Circulation) 6-111
PATS System (Restricted Circulation) 6-121
97.5 Model Year
6.6.03 Seat Removal (97.5 MY)
6.6.08 Seat Control Module (97.5 MY)
6-2 April! 997