Instrument ASTON MARTIN DB7 1997 User Guide

Electrics
Seat Belt Pretensioner ^?
060C Warning Lamp Short Circuit
060C will be logged if the nnonitor current flow
through the SRS/Airbag warning lamp is excessive.
The warning lamp circuit is normally at 12 volts and
is switched to ground by the airbag control module
or by the pretensioner control module when one of
these control modules detects a fault.
If either control module connector is displaced and
the ignition is switched on, the warning lamp will
be illuminated via the ground shorting link between

pins!
and 2 ofthe pretensioner controller connector
or pins 4 and 5 of the airbag controller connector,
both control modules must be checked for the
appropriate DTC to isolate which circuit is at fault.
Procedure

1.
Connect the PDU to the lower diagnostic socket
and access the pretensioner control module. Verify
that an 060C code is logged and note if the fault is
shown as intermittent. Note any other codes in the
DTC log and then clear all codes. Go to step 2.
If fault code 060C is not logged, go to the diagnostics
section of the airbag system.

2.
Check the security of the pretensioner control
module connector.
If the connector is secure, go to step 3.
If the connector isdisplaced,resecu re theconnector.
Clear all logged DTCs and retest the vehicle to
ensure that the problem is resolved.
3. Access the SRS/Airbag warning lamp and check the
lamp resistance.
If the resistance is approximately
120£2,
the lamp is

good.
Refit the lamp and go to step 4.
If the resistance of the lamp is significantly less than
approximately 120^, fit a new lamp and refit the
instrument panel. Clear the logged DTCs from the
pretensioner control module and retest the vehicle
to ensure that the problem is resolved.

4.
If the checks in step 3 are good, the low circuit
resistance must be in the instrument pack or in the
control module. Replace the pretensioner control
module and reconnect all components.
6. Switch on the ignition and then test the vehicle.
If the 060C code is logged again, replace the
instrument pack.
060D Warning lamp open circuit
060D will be logged if the monitor current flow
through the SRS/Airbag warning lamp is below the
normal monitor level.
The warning lampcircuit is normally at 12 voltsand
is switched to ground by the airbag control module
or by the pretensioner control module when one of
these control modules detects a fault.
Procedure
Connect the PDU to the lower diagnostic socket
and access the pretensioner control module. Verify
that an 060D code is logged and note if the fault is
shown as intermittent. Note any other codes in the
DTC log and then clear all codes. Go to step 2.
lffaultcode060D is not
logged,
gotothediagnostics
section of the airbag system.
Switch off the ignition. Access the SRS/Airbag
warning lamp and check the lamp resistance. The
resistance should be approximately 120Q.
If the resistance is 120i2, go to step 3.
If the lamp resistance is significantly lower than

120^2,
replace the lamp. Retest the vehicle to
ensure that the problem is resolved.
Wait 10 minutes after switching off the ignition to
ensure that the pretensioner firing capacitors have
fully discharged.
Disconnect the pretensioner control module and
temporarily cheat the warning lamp shorting link.
Note: The control module harness connector has a
shorting link which short circuits the warning lamp line
(pin 2)to ground
(pin
Dwhen
the
connector
is
displaced.
Carefully insert a suitable non-metallic cheater to remove
the
short
circuit
between
pins
1
and 2 before continuing
with fault
diagnosis.

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i^i
^ ^ ^ 1^1
Insert cheater hare
6-108
September
1996

Electrics
Seat Belt Pretensioner
Check the continuity of
the
line from pretensioner
control module pin 2 to instrument pack green
connector pin 2.
If continuity is approximately
OQ,
go to step 5.
If the line resistance
is
significantly greater
than
OQ,
service the wiring as necessary. Reconnect all
components and test the vehicle to ensure that the
problem is resolved.
Ifthe lamp
and
wiring
checks are
good,
the
fault lies
in the instrument pack or in the control module.
Replace the control module and retest. Ifthe fault
persists, replace the instrument
pack.
Reconnectall
components and test the vehicle to ensure that the
problem is resolved.
Pretensioner Control Module Internal
Faults
The following codes indicate internal faults within the
pretensioner control module.
0209 Safing sensor error
030A Temperature sensor error
0D13 Capacitor voltage error
0D14 Capacitor capacitance
0D09 Energy reserve switch
0D1E Energy shutdown switch
050E Seatbelt pretensioner switch error
0109 Accelerometer function
01OA Acceleration out of range

01 OB
Acceierometer offset
OAOC Analogue voltage error
090A EEPROM not programmed
0909 EEPROM checksum
090C RAM check error
060E Warning lamp driver error
0A09 Communications error
OAOA External watchdog error
OAOB External watchdog time out
020A Safing sensor not closed
If any of the above codes are logged, replace the
pretensioner control module.
September 1996 6-109

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 Panel and Trim Removal 5^7
Body Panel and Trim Removal
The following diagrams show the fixings for all
removeable body and trim panels.
Sheet 1. Front Apron
Sheet 2. Front Undertray
Sheet 3. Wheel Arch Liners
Sheet 4. Side Sills (top fixings)
Sheets. Side Sills (bottom fixings)
Sheet 6. Rear Bumper
Sheet 7. Doors
Sheet 8. Door Liners
Sheet 9. Door Liner (components)
Sheet 10. Steering Wheel
Sheet 11. Column Switches
Sheet 12. Instrument Panel (surround)
Sheet 13. Instrument Panel
Sheet 14. Facia Underscuttles
Sheet 15. Glove Box
Sheet 16. Facia Mountings (1)
Sheet
1
7. Facia Mountings (2)
Sheet 18. Console Instruments
Sheet 19. Radio
Sheet 20. Front Seats
Sheet
21.
Ashtray
Sheet 22. Centre Console
Sheet 23. Seat ECU Covers
Sheet 24. Rear Console
Sheet 25. Rear Seats and C Post Trim
Sheet 26. Quarter Panels, B Post Panels, Parcel Shelf
Sheet 27. Headlining
7-6 May 1996

Body
and
Trim
Sheet
12

Instrument
Panel
(Surround)

^2?
Air Conditioning Repair Procedures
Hose - Compressor to Evaporator/Air-Con Unit Renew
8.1.06.1 Hose-Compressor
to
Evaporator
Renewal
Procedure

1.
Open the bonnet and fit a wing cover.

2.
Depressurise the air conditioning systenn.
3. Remove the hose to evaporator valve clamping

plate,
disconnect the hose from the valve, remove
and discard the 'O' ring
seal.

4.
Fit a blanking plug to the evaporator valve. Release
the evaporator hose securing clips.
5. Remove the compressor outlet port retaining bolt.
6. Disconnect the hose from the compressor, discard
the hose complete with 'O' ring seals.
7. Connect the hose to the evaporator valve and
tighten clamp onto the hose.
8. Route the hose to the compressor, fit a new 'O' ring
seal and connect it to the compressor.
9. Position the outlet port retaining plate on the
compressor, fit and tighten the securing bolt.

10.
Refit the hose to the clips.

11.
Charge the air conditioning system.

12.
Remove the wing cover and close the bonnet.
8.2.01.1 Air Conditioning Unit Renewal

1.
Disconnect the battery earth
lead.

2.
Drain the engine coolant into a suitable container.
3. Depressurise the air conditioning system.

4.
Disconnect the high and low pressure hoses and
expansion valve from the air conditioning unit (see
expansion valve renewal).
5. Slacken the coolant hose to the heater matrix pipe
securing clips and disconnect the hoses from the
matrix. (This will require the removal of the air
intake hose for access.)
6. Remove the following items from inside the car:
front seats
underscuttle panels/knee bolsters
glove box assembly
facia trim (walnut trim)
radio and ashtray
centre console switch panel assembly
instrument panel and surround trim
steering wheel and column
facia assembly complete
hoses - distribution box to door vents
facia support frame
Details and drawings of the above operations can
be found in the electrical and trim sections.
Disconnect the vacuum hoses from the blower
motors, water valve and reservoir.
Un-clip the electrical harness from the air
conditioningunit, release theelectrical connections
and reposition the harness to allow removal of the
unit.
Displace and remove the footwell ventilator ducts
and hoses (Fig. 1-1).
May 1996 8-55

^?
Air Conditioning Repair Procedures
upper/Lower Servo Feedback Potentiometer Renew

8.2.03.1
Upper Servo Feedback
Potentiometer Renewal

8.2.04.1
Lower Servo Feedback
Potentiometer Renew

1.
Disconnect the battery earth
lead.

2.
(On left hand cars) Remove the instrument paci<
and surround
trim.

2.
(On right hand cars) Remove the glove box
assembly.
3.
Remove the
securing screws
and
the potentiometer
assembly. Disconnect the electrical connector.

4.
Fitting a new potentiometer is the reverse of the
removal procedure.

1.
Disconnect the battery earth
lead.

2.
Un-clip and remove the left hand underscuttle

casing.

Figure 1.
3. Disconnect the electrical block connector
(Fig.
1).

4.
Remove the securing screw and the potentiometer
assembly.
5. Fitting a new potentiometer is the reversal of the
removal procedure.
May 1996 8-57

'nzm^=2?
Air Conditioning Repair Procedures
Blower Motor Renewal
8.2.07.1 Ambient Temperature Sensor
Renew

?\gure
1.
The ambient temperature sensor is located in the
left hand side of the air plenum chamber under the
lower windshield panel (Fig. 1-1).
Procedure

1.
Disconnect the battery earth
lead.

2.
(On left hand cars) Remove the steering wheel
(mark the position on the column shaft for re­
assembly), instrument pack and surround
trim.

2.
(On right hand cars) Removethegloveboxlidand
liner.
3. Disconnect the hose from the distribution box to
the side vent outlet. Reposition the hose for access.

4.
Disconnect the sensor block connector.
The sensor has locating clips and is a push fit into
the plenum chamber.
5. Lever the sensor free.
8.2.08.1 Blower Motor Driver Side
Renewal
8.2.09.1 Blower Motor Passenger Side
Renewal

1.
Move seat
fu 1
ly rearward.

2.
Disconnect vehicle battery ground
lead.

3. Remove the under scuttle/knee pad bolster.

4.
Remove the lower brace bar/facia assembly
underscuttle knee pad.
Driver Side Only
5. Removetheinstrumentpack, bonnetreieasehandle
mounting bracket and steering column..
6. Disconnect the air hose from the facia side air
outlet.
Passenger Side Only
7. Remove the glove box lid and liner.
Both
8. Remove the nuts securing the component panel

(Fig.
1-1).
Figure 1.
9. Ease the component panel clear for access to the
blower assembly mounting bolts.

10.
Disconnect the pliable trunking from the stub pipes
on either side of the air conditioning unit
(Fig.
1
-3).

11.
Disconnect the blower motor electrical harness at
the block connector.
May 1996 8-59

Air Conditioning Repair Procedures
Water Temperature Switch/Heater Matrix Renew •=2?
8.2.12.1 Water Temperature Switch
Renewal

1.
Disconnect the battery earth
lead.

2.
Un-clip and remove the left hand underscuttle

casing.

Figure.
3. Note and disconnect the feed wires from the switch

(Fig.
1-1).

4.
Displace and remove the switch from the water

pipe.

5. Fitting a new switch is the reversal of the removal
procedure.
8.2.13.1 Heater Matrix Renewal

1.
Disconnect the battery earth
lead.

2.
Remove the left hand underscuttle panel.
3. (On right hand cars) Remove the glove box
assembly.
3. (On left hand cars) Remove the instrument pack
and surround
trim,
steering column and mounting
bracket.

4.
Drain the coolant into a suitable container.
5. Remove the matrix cover panel securing screws.
6. Removethe rear
panel,
displacethefront panel and
foam seal for access.
7. Place rag in position.
8. Remove screws securing the feed pipe and
disconnect the pipe from the matrix.
9. Remove and discard the gasket.

10.
Remove the screws securing the feed pipe and
disconnect the pipe from the matrix.

11.
Remove and discard the gasket.

12.
Disconnectthewatertemperatureswitchfeedwires.

13.
Remove the foam pad from the pipes.

14.
Remove the front panel from the unit.

15.
Undo the heater hose matrix pipe hose clips and
disconnect the hoses from the pipes.

16.
Reposition the pipes from the matrix.

1
7. Remove the matrix from the air conditioning unit.

18.
Fitting a new matrix is the reversal of the removal
procedure.

19.
Ensure that new gaskets are fitted.
8-62 May 1996

^>
Air Conditioning Repair Procedures
Electronic Control Module/Vacuum Solenoid Renewal
8.2.14.1 Electronic Control Module
Renew
8.3.01.1 Vacuum System Solenoid
Renewal

1.
Disconnect the battery earth
lead.

2.
Remove the right hand underscuttle casing.
3. (On left hand cars) Removethe glove box assembly.
3. (On right hand cars) Remove the instrument pack
and surround
trim.

4.
Disconnect the earth wire and three block
connectors from the control module (Fig.
1
-2).
5. Remove the securing screws and module from the
air conditioning unit (Fig. 1-1).
Fitting a new module
is
the reversal of the removal
procedure.
The flaps in the cabin air distribution vents and the
water valve in the pipe line from the engine coolant
system to the heater matrix are all operated by
vacuumactuators.The vacuumfor these issupplied
by four solenoids mounted in a manifold pack
located behind the front left hand footwell outlet.
Failureof a solenoid will require replacement of the
manifold pack.
Procedure

1.
Disconnect the battery earth
lead.

2.
Remove the following:
• glove box and lid
• facia trim (walnut strip)
• radio and ashtray
• centre console switch assembly
• left hand underscuttle casing/knee bolster
Detai
Is
ofthe above operations can be found in the
trim and the electrical sections.

2.
Remove thefixings joining the centre console to the

facia.
This allows the front of the console to be
repositioned for access.
3. Disconnect the ducting from the left hand footwell
outlet.

4.
Remove the two plastic fixings that secure the
slotted footwel
I
outlet and
si
ide the outlet out ofthe
unit.
7. Cut the tie strap holding the vacuum lines and
electrical harness to the underside of the air
conditioning unit.
8. Remove the screws that secure the manifold pack
to the underside of the air conditioning unit and
slide out the plate complete with the manifold
pack.

10.
To fit a new manifold pack reverse the steps for the

removal.

May 1996 8-63