door ASTON MARTIN DB7 1997 Owner's Manual

Electrics
Airbag System E:m3^2?
Disposal of Live Airbags
Modu
les
removed/renewed by Aston Martin dealers
are to be deployed using the following procedure.
WARNING: Never use a customer's vehicle to
deploy airbags.
Equipment Required:
Link harness

'Slave'
battery
Safety goggles to BS 2092 grade 2 or equivalent
Rubber gloves to PrEN 374 class 2 or equivalent
Ear protectors
Particulate respirator to EN 149 grade FFP 25
Deployment cage
Note: If you do not
have access
to a deployment
cage,

please
contact Aston Martin
Lagonda
Limited
Technical

Support Department for advice.
Procedure
This procedure must be performed outdoors, away
from other personnel.
Remove any loose debris from around the airbag
and ensure that no flammable liquids are present.
Assemble the disposal cabinet and fit the airbag as
shown in figure 1 in line with the following
procedures:
a) Remove the mesh guard from the rig frame.
b) Attach the guard to the frame by bolting the
hinges to the frame.
c) Ensure the relevant plate is fitted and rotate into

position.

d) Fit and secure the airbag module onto the plate.
e) Clamp the plate down using the two toggle
clamps.
f) Close the mesh guard.
Note: The harness connected between the driver's
airbag and
the
connector
has
one red
feed
wire and one
grey/orange return wire. The harness connected between
the
passenger's
airbag and the connector
has
one blue/
orange feed wire and one pink/black return wire.
Connect the 10 metre {33ft) link harness to the

airbag.

Ensure that no personnel are in the vicinity of the
cabinet.
5. Move 10 metres (33ft) and connect the link harness
crocodile clips to the 'slave' battery; the airbag will
deploy immediately.
6. Allow the unit to cool for at least 20 minutes.
7. Open the mesh guard and remove the deployed
airbag module.
Note: Should the
design
of your deployment
cage
differ
from that described above, please contact the cage
manufacturer for advice on mounting the airbag.
8. Seal the deployed module into a plastic bag ready
for disposal.
9. In the event of any problems or queries, contact
Aston Martin Lagonda Limited -Technical Services
Department.
Disposal of Deployed Airbags
Deployed airbags are to be disposed of as special
waste and disposal must comply with local
environmental requirements. If
in
any doubt, contact
the local authority for disposal instructions.
Note; The storage, transportation, disposal and/or
recycling of airbag module components must be
performed in accordance with all applicable federal,

state
and local regulations including, but not limited to,

those
governing building and fire
codes,
environmental
protection, occupational health and safety and
transportation.
Modules removed and deployed by Aston Martin
Dealers are to be returned to Aston Martin Lagonda
Limited for disposal following prior consultation.
6-74 September 1996

Electrics
Airbag System ^^?

7.8.02.6

Renew
Passenger's Airbag Module
Read and adhere to all warnings and safety
procedures quoted at the start of this section when
working on airbag modules.
Disconnect the battery and wait for at least one
minute before proceeding with the airbag removal.
Note:
The
vehicle battery
must
be disconnected within
12
seconds
of switchingoff
the
ignition
to
avoid the alarm
siren sounding.
2. Open the passenger airbag deployment door.
3. Release four nuts and remove the airbag module.

4.
Disconnect the airbag harness multi-plug.
5. Connect and fit the new module and secure with
four nuts.
6. Refit the airbag deployment door.
Note:
The vehicle
clock and
the
window control unit will
need
resetting
after completion of
this
procedure.
7. Reconnect the battery. Switch on the ignition and
check that the airbag warning
I
ight comes on when
the ignition is switched on and extinguishes after
approximately six seconds indicating satisfactory
completion of the airbag system self tests.
6.1.23.1/6.2.10.1 Airbag
Crash
Sensors
Renew
Read and adhere to all warnings and safety
procedures quoted at the start of this section when
working on the airbag system.

1.
Disconnect the battery and wait for at least one
minute before working on the airbag system.
Note: The vehicle
battery
must be disconnected within
12
seconds
of switchingoff
the
ignition
to
avoid thealarm
siren sounding.

4.

5.
Raisethevehicleon a rampand remove the relevant
front roadwheel and wheel arch liner.
Disconnect the sensor connector and feed the
protected loom forward through the body aperture.
Open the bonnet and release two bolts securing the
crash sensor to the body.
Fit and secure the new sensor and feed the sensor
loom back through the body aperture.
Reconnect the sensor. Refit the wheel arch liner
and the roadwheel.
Note:
The vehicle
clock and
the
window control unit will
need
resetting
after completion of
this
procedure.
Reconnect the battery, switch on the ignition and
check that the airbag warning
I
ight comes on when
the ignition is switched on and extinguishes after
approximately six seconds indicating satisfactory
completion of the airbag system self tests.
6-76 September 1996

^7
Electrics
Airbag System

6.4.21.2
Airbag 'Safing' Sensor Renew
Read and adhere to all warnings and safety
procedures quoted at the start of this section when
working on the airbag system.

1.
Disconnect the battery and wait for at least one
minute before working on the airbag system.
Note:
The
vehicle battery must be disconnected within
12 secondsofswitchingoffthe ignition to avoid the alarm
siren sounding.
^h
Note: RH drive shown,
the safing sensor is
always
on
the drivers side
of the car
2. Open the drivers door and remove the lower 'A'
post
trim.

3. Release two screws retaining the airbag safing
sensor.

4.
Disconnect and remove the airbag safing sensor.
5. Connectand securethe replacement sensor. Replace
the 'A' post
trim.

Note:
The
vehicle clock and
the
window control unit will
need
resetting
after completion of
this
procedure.
6. Reconnect the battery, switch on the ignition and
check that the airbag warning
I
ight comes on when
the ignition is switched on and extinguishes after
approximately six seconds indicating satisfactory
completion of the airbag system self tests.

6.4.21.1

Renew
Airbag Diagnostic Module

1.

2.

3.

4.

6.
7.
Read and adhere to all warnings and safety
procedures quoted at the start of this section when
working on the airbag system.
Disconnect the battery and wait for at least one
minute before working on the airbag system.
Note: The vehicle battery must
be
disconnected within
l2secondsofswitchingofftheignitiontoavoidthealarm

siren
sounding.
Disarm the airbags (6.4.21.4).
Remove the facia assembly.
Note: RH drive shown,
diagnostic module always on

passengers
side of
the
car
Disconnect the airbag control module (Fig 1-1).
Release the module from the top of the airbag
carrier assembly and remove the module.
Refit and secure the replacement airbag control
module and connect the harness connector.
Refit the facia assembly.
Rearm the airbags (6.4.21.4).
Note:
The
vehicle clock and
the
window control unit will
need
resetting
after completion of this procedure.
September 1996 6-77

Electrics
Airbag System ^2?

6.4.21.4
Airbag Disarming/Arming
Procedures
WARNINGS AND CAUTIONS:
WARNINGS:
Disarm the airbags by disconnecting the battery
ground (black)
lead,
waiting one minute and then
removing the airbag modules before servicing of
any airbag or steering column component.
After disconnecting the battery ground
lead,
allow
a minimum of one minute delay for the back-up
power supply to discharge before servicing the
airbag system.
The system components are non-serviceable, if
faults are
suspected,
change components for new
items
only.

Failure to observe the above procedures may
result in accidental deployment of the airbags.
Always wear safety
glasses
when working on airbag
equipped vehicles.
Personnel carrying an airbag module must ensure
that the module and trim cover are pointing away
from the
body.
When positioning on a bench or
work surface, ensure that the airbag module and
trim cover face upwards to limit motion on
accidental deployment.
Always wear
gloves
when handling deployed airbag
modules. Deposits of sodium hydroxide may be
presenton the module surface. If sodium hydroxide
contacts any area of the skin, wash the affected
area immediately with mild soap and
water.

Dispose of the deployed airbag using the correct
procedures referred to in this section.
Cautions:
When scrapping vehicles,
ensure
that the
airbags
have
been deployed (see
Scrapping Vehicles
with Live
Airbags).

If a component
has been
renewed and the fault
does
not

clear,
refit the original item and repeat the diagnostic
procedure.
After
servicing,
repeatthe diagnostic
procedures
to ensure
correct
system
operation.

Renew
the airbag module if the surrounding trim
panels

are
damaged.
Do not attempt to repaint trim covers as
paint may
damage
cover material.
Disarming the Airbags
3.
4.
WARNING: Carry out the following disarming
procedure before attempting any work on the
vehicles electrical
systems.

Note: The battery ground (black) lead must be
disconnected within 12 seconds of switching off the
ignition to avoid the alarm siren sounding.
Disconnect the battery ground
lead.
Allow a
minimum of one minute delay for the back-up
power supply to discharge.
Remove the drivers side airbag module and replace
it with an airbag simulatorfrom the simulator kit (Pt

No.
43.27028).
Remove the passengers airbag module and replace
it with an airbag simulator from the simulator kit.
Reconnect the battery ground.
Rearming the Airbags
WARNING: Carry out the following procedure to
rearm and check the airbags after completing all
work on the vehicles electrical
systems.

Note: The vehicle battery
must be
disconnected within
12
seconds
of switching off
the
ignition
to
avoid the alarm
siren sounding.
^. Disconnect the battery ground
lead.
Allow a
minimum of one minute delay for the back-up
power supply to discharge.

2.
Removethedriverssideairbagsimulatorand replace
it with the drivers airbag module. Secure the airbag
module with the two captive torx screws.
3. Remove the passengers side airbag simulator and
replace it with the passenger side airbag module.
Secure the module with four nuts and washers.
Close the passenger side airbag door.

4.
Reconnect the battery ground.
5. Switch on the ignition and check for correct
indications from the SRS/AIRBAG warning light.
TheSRS/AIRBAC lamp should come on after
a
brief
delay and remain on for approximately six seconds
during the airbag system self check. The lamp will
extinguish upon satisfactory completion of the self
check, or will flash a diagnostic code if an airbag
system fault is detected. Continuous illumination of
the warning lamp may indicate a seatbelt
pretensioner fault
Note:
Reset the
clock and window
ECUs
on completion.
6-80 September 1996

Electrics
Seat Control Module Removal/Replacement 97.5 MY 'O "3^2?
Switch on the ignition and checi< that the airbag
warning lamp comes on when the ignition is
switched on and extinguishes after approximately
six seconds indicating satisfactory completion of
the pretensioner and airbag system self
tests.

Fit
the front
seat
retaining screws ensuring
a
1.2mm
gap between the screw heads
and
the
slides.
Power
the seat forward and refit the rear screws.
Caution:
Centralise the
rear
fixing holes
with the
body weld
nuts
prior to
inserting the
bolts.

Torque the rear screws to 25 Nm. Power the seat
backwards. Torque the front screws to 25 Nm.
Motor the seat through its full range of movement
to ensure correct
operation.

6.6.08
Seat Control Module 97.5 MY
Removal
WARNING -
Seat
belt
Pretensioners
(if
fitted):

To avoid the possibility
of
personal injury caused

by accidental deployment of the seat belt

pretensioner,
disconnect
the
vehicle battery and

wait at
least
10
minutes
for all
voltages
to fully

discharge
before
working
near the
pretensioner

system.
This covers
the
possibility
of
the
normal
capacitor
discharge circuits
being
inoperative and
failing to discharge the detonator capacitor when
instructed
to
do
so.

1.
Lower the door window and open the relevant
door. Disconnect
the
battery ground cableand wait
for 10 minutes if
a
pretensioner
is
fitted.
Otherwise,
proceed immediately to step 2.
(ei-SMiECu
Figure!.
Seat ECU Removal

2. Loosen two nuts securing the seat ECU. Slide the
ECU to the left and remove it from the front of the
seat.
3. Disconnect two connectors from the ECU.
Replacement

1.
Reconnect the two control module connectors. Fit

the seat control
moduleand
tighten
thetwo securing

nuts.

3. Reconnect the battery ground and test for correct
operation of the seat controls.
6-128 April 1997

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

•=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

Body and Trim
Rear Quarter Glass Adjustment "^^
9.1.01.2
-
Rear Quarter Glass Adjustment
The rear quarter glass can be adjusted in three
planes, Lateral, Up and Down, and Front to Rear.
During initial assembly, assuming that the door is
correctly gapped and profiled, the door glass is set
to the upper 'A' post seal and the front frame
seal.

The rear quarter glass is then set to the door glass.
Both glass tops should be accurately aligned and
there should be a minimum 2mm gap between the
glasses. Any minor adjustments are then made
using the following procedures.
Lateral Adjustment
Remove the rear quarter trim panel. Remove the
adjuster stud locknuts and special washers (Fig 7-

A).
Using a 5mm box spanner, rotate the adjuster
screw clockwise to move the glass inboard or
anti­

clockwise to move the glass outboard (Fig 7-B).
Refit the special washers, refit and tighten the
locknuts. Refit the rear quarter trim panel.
Front to Rear Adjustment
Remove the rear quarter trim panel. Loosen the
three adjuster stud locknuts. Adjust the glass front
to rear
as
required (Fig 7-C). Re-tighten the locknuts.
Check and readjust as required. Refit the rear
quarter trim panel.
Up and Down Adjustment
Remove the rear quarter trim panel. Slacken off the
lockbolt (Fig 7-D) two ro three turns. Adjust the
vertical position of the glass
as
required. Re-tighten
the lockbolt. Rechecktheglass position and readjust
as required. Refit the rear quarter trim panel.
Figure 7. Rear Quarter Class Adjustments
7-14 May 1996

^^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