air conditioning ASTON MARTIN DB7 1997 Repair Manual
[x] Cancel search | Manufacturer: ASTON MARTIN, Model Year: 1997, Model line: DB7, Model: ASTON MARTIN DB7 1997Pages: 421, PDF Size: 9.31 MB
Page 328 of 421
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Air Conditioning Repair Procedures
Compressor Removal
8.1.01.1 Compressor Removal/Renewal
Procedure
1.
Open the bonnet and fit a wing cover.
2.
Depressurise the air conditioning system.
3.
6.
7.
8.
9.
Disconnect the low and high pressure hoses from
the rear of the compressor. Plug the hose ends to
prevent the ingress of dirt.
Remove the compressor pivot bolt securing nut.
Carefully separate the muffler from the compressor
and remove and discard the 'O' ring
seal.
Fit a blanking plug to the muffler and a blanking
plate to the compressor, fit and tighten the bolt that
secures blanking plate.
Raise the vehicle to working height on a ramp.
Figure 7.
10.
Slacken the compressor drive belt adjuster rod and
adjuster plate securing nuts and bolts (Fig.
1
-4, 5, 6
and 7)
11.
Slacken adjuster nut (Fig.
1
-10).
12.
Remove the nut and bolt (Fig. 1-4 and 5) from
adjuster plate (Fig. 1-3).
13.
Slacken trunnion nut and bolt (Fig.
1
-9 and 2) and
remove the adjuster rod (Fig. 1-1).
14.
Disconnect the compressor multi-plug.
1
5. Remove the compressor drive belt.
16.
Pivot the compressor away from engine, support
the compressor and remove the top pivot bolt and
lift the compressor clear of the vehicle.
17.
Removethemountingbracketsfromthecompressor.
26.
Lift the compressor up to the engine and fit the top
pivot bolt (Fig.
1
-2) from above.
27.
Attach adjustment rod loosely to the compressor
(Fig.
1
-1) with nut and bolt (Fig.
1
-6 and 7).
28.
Loosely attach adjustment plate (Fig. 1-3) to the
compressor with nut and bolt (Fig.
1
-4 and 5).
29.
Fit bolt (Fig.
1
-2) through trunnion (Fig.
1
-8) and fit
nut (Fig. 1-9) to the bolt.
30.
Fit the drive belt over the pulley, move the
compressor away from the engine to tension the
drive belt and lightly tighten the bolts and nuts.
31.
To obtain the correct tension on the drive belt
tighten adjuster nuts
(Fig.
1
-10). The belt
is
correctly
tensioned when a load of 59- 63.6 kg (130 -140 lb)
applied at the centre deflects the belt 4 mm.
32.
Ensure that all securing bolts and nuts are fully
tightened.
33.
Lowerthe vehicle to the ground.
34.
Remove the blanking plate and the blanking plugs
from the compressor.
36.
Fit new 'O' ring seals to the low and high pressure
hoses and connect them to the compressor. Fit the
retaining plate, fit and tighten the screw.
38.
Charge the air conditioning system.
39.
Remove the wing cover and close the bonnet.
May 1996 8-51
Page 329 of 421
Air Conditioning Repair Procedures
Field Coil Renewal
/
Gasket Kit Renewal ffi^e^'^^
8.1.02.1 Field Coil Renewal 8.1.03.1 Renew Gasket
Kit
Procedure
1.
Open
the
bonnet
and fit a
wing cover.
2.
Depressurise
the air
conditioning system.
3. Remove
the
compressor.
4.
Remove
the
compressor drive clutch.
5. Remove
the
compressor pulley.
6. Slacken
the
field coil wire clamp screw
(Fig.
1) and
release
the
wire from
the
clamp.
10.
Remove
the
field coil retaining snap ring
and
detach
the
field
coil.
Clean
the
mating face
of the
compressor with
a
cloth moistened with
an
approved cleaning
fluid.
Position
the new
field coil
on the
compressor
and
fit
the
retaining snap
ring.
Route
the
wire
to the
compressor
and fit the
wire
clamp, tighten
the
securing screw.
11.
Fit the
compressor pulley.
12.
Fit the
compressor drive clutch.
13.
Fit the
compressor.
14.
Recharge
the air
conditioning system.
15.
Remove
the
wing cover
and
close
the
bonnet.
Data
Torque Figures
Cylinder head bolts 29.83
to 33.9 Nm.
Procedure
1.
Open
the
bonnet
and fit a
wing cover.
2.
Depressurise
the air
conditioning system.
3. Remove
the
compressor.
4.
Position
the
compressor
in a
vice, tighten
the
vice
onto
the
compressor body lugs.
5. Remove the outlet port blanking plate securing bolt
and detach
the
plate.
6. Remove
and
discard
the 'O'
ring seals from
the
outlet port.
7. Remove
the
compressor cylinder head securing
bolts,
detach
the
cylinder head.
8. Detach
the
valve plate from
the
compressor.
9. Remove
the
gaskets from
the
compressor.
10.
Remove
all
traces
of
gasket material from
the
mating surfaces
of the
cylinder head, valve plate
and cylinder block.
Figure
1.
11.
Position
new
gaskets (Fig.
1 -1
and 3) on the
valve
plate
(Fig. 1-2) and
then place
it on the
cylinder
block.
8-52 May
1996
Page 330 of 421
ES3^^
Air Conditioning Repair Procedures
Valve Plate Renewal
Figure
2.
12.
Position the cylinder head (Fig. 2-1) on the cylinder
block (Fig. 2-2), fit and tighten the securing bolts in
the sequence shown in Fig. 3.
8.1.04.1 Valve Plate Renewal
Data
Torque Figures
Cylinder head bolts 29.83 - 33.9 Nm
Procedure
1.
Open the bonnet and fit a wing cover.
2.
Depressurise the air conditioning system.
3. Remove the compressor.
4.
Position the compressor in a vice, tighten the vice
onto the compressor body lugs.
5. Remove the outlet port blanking plate securing bolt
and detach the plate.
6. Remove the 'O' ring seals from the compressor
outlet port.
figure 3.
13.
Fit new 'O' ring seals in the compressor outlet port,
position the outlet port blanking plate and fit and
tighten the securing bolt.
14.
Check and top up compressor oil
15.
Refit the compressor.
16.
Recharge the air conditioning system.
Figure 1.
7. Removethecylinder head securing boltsand detach
the cylinder head (Fig. 1-1) from the cylinder block.
8. Remove valve plate
(Fig.
1
-2) from the compressor.
9. Remove all traces of gasket material from the
mati
ng
surfaces of the cy
I
i nder
head
and compressor.
10.
Apply clean refrigerant oil to the gaskets and then
position them on the valve plate.
May 1996 8-53
Page 331 of 421
Air Conditioning Repair Procedures
Expansion Valve Renewal
ES^'^?
Figure 2.
11.
Position valve plate and gaskets (Fig. 2-1 and 2) on
the compressor and fit the cylinder head.
12.
Tighten the cylinder head securing bolts in the
order shown in Fig. 3.
Figure 3.
13.
Fit new 'O' rings to the outlet port blanking plate,
position the plate on the compressor and fit and
tighten the securing bolt.
14.
Check compressor oil and top up in necessary.
14.
Refit the compressor.
15.
Remove the wing mat and close the bonnet.
8.1.05.1 Expansion Valve Renewal
1.
Depressurise the air conditioning system.
2.
Undo the pipe to expansion valve clamp bolt and
retaining plate and disconnect the pipes (Fig. 1)
Figure 1.
3. Fit blanking plugs to the expansion valve and to the
pipes.
4.
Reposition the pipes to one side.
5. Unscrew the two torx head retaining screws and
remove the expansion valve from the air
conditioning unit (Fig.
1
-1).
6. Remove and discard the 'O' rings.
7. Fitting a new valve is the reversal of the removal
procedure.
8. Ensure new 'O' rings to all union connections are
fitted.
9. Evacuate the system.
10.
Recharge the system.
8-54 May 1996
Page 332 of 421
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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
Page 333 of 421
Air Conditioning Repair Procedures
Air-Conditioning Unit Renew ^^?
10.
Disconnect the pliable trunking from the unit (Fig.
8.2.02.1
EvaporatOr Unit Renewal
1-2). ^
1.
Remove the air conditioning unit assembly.
2.
Remove the heater pipe guide plate securing screws
and remove the guide plate.
3. Remove the screws secu ri ng evaporator sensor and
withdraw the sensor from the evaporator.
4.
Remove the screws securing the solenoid mounting
plate and displace the mounting plates from the
unit.
5. Removetheharnesstocasingearthboltand displace
the harness.
6. Cut and remove the harness to casing securing
ratchet straps and displace the harness from the
casing.
7. Displace the vacuum hose from the casing.
8. Displace and remove the casing securing clips.
9. Splitthecasingandremovetheevaporatorfromthe
unit.
10.
Remove the expansion valve guide securing screws
and remove the plate.
11.
Displace and remove the plate from the evaporator.
12.
Fitting the new evaporator is the reversal of the
removal procedure.
13.
Refill the engine cooling system with coolant.
14.
Recharge the air conditioning system.
Figure 1
11.
Twistandpulloutthefourairconditioningunitstub
pipes (Fig. 1-3)
12.
Remove the screws securing the air conditioning
unit support stays.
13.
Displace the tunnel carpet for access to the lower
fixing bolts and remove the stays.
14.
Disconnect the condensate drain tubes.
15.
Peel off the tape securing the windscreen demist
duct to the distribution box (Fig.
1
-4).
16.
Remove the air conditioning unit to bulkhead
securing nuts.
1
7. Carefully lift out the air conditioning unit complete
with the distribution box.
18.
Remove the distribution box securing screws and
remove the assembly (Fig.
1
-5).
19.
Reverse the removal procedure to refit the air
conditioning unit.
Note:
Ensure new'O'rings
are
fitted toall air conditioning
tiose connections.
8-56 May 1996
Page 334 of 421
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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
Page 335 of 421
Air Conditioning Repair Procedures
Upper/Lower Flap Motor Renew [EB^^^?
8.2.05.1 Upper Flap Motor Assembly
Renew
8.2.06.1 Lower Flap Motor Assembly
Renew
1.
Disconnect the battery earth
lead.
2.
Remove the electronic control module.
3. Disconnect the motor block connector.
4.
Remove the securing screws and motor assembly
(Figl).
Figure
5.
5. Fitting a new motor is the reverse of the removal
procedure.
1.
Disconnect the battery earth
lead.
2.
Remove the right hand side underscuttle casing.
3. Remove the electronic control unit.
4.
Disconnect the block connector.
5. Remove the screws securing the motor to the air
conditioning unit.
6. Displace the'P'clip.
7. Withdraw and remove the motor from the air
conditioning unit.
8. Fitting a new motor is the reversal of the removal
procedure.
8-58 May 1996
Page 336 of 421
'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
Page 337 of 421
Air Conditioning Repair Procedures
Blower Assembly Renewal o^s^-^?
12.
Disconnect the vacuum pipe from the flap actuator
(Fig.
1-4).
13.
Open the re-circulation flap in the base of the
blower assembly and fit a wedge to retain it in the
open position (Fig. 1-5).
14.
Remove the bolts securing the blower assembly
and ease the blower unit from its location (Fig.
1
-6).
15.
Remove the tape securing the ducting to the
assembly and remove the ducting (Fig.
1
-7).
Note: To remove the blower motor
assembly
from the
vehicle,
the
lower flap must be opened to allow the upper
flap to
disengage
from the upper body
aperture.
8.2.10.1 Blower Assembly Driver/
Passenger Side Overhaul
Note:
Blower
assemblies
under warranty must not be
dismantled.
1.
Remove the three selftapping screws
(Fig.
1-1) from
the air intake casing.
Figure 7.
2.
Part the air intake casing (Fig.
1
-2) from the motor
assembly (Fig. 1-2) and disconnect the electrical
connections at the lucar connectors (Fig.
1
-4).
Note: Mark the position of the
various components
with
paint or
a
scriber.
This
facilitates
re-assembly.
3. One lucar connector has a raised projection which
matches the aperture in the motor casing to ensure
that the connections are replaced correctly and that
the rotation of the motor is unaffected.
4.
Remove the bolts securing the motor mounting
bracket to the fan housing (Fig. 1-5).
5. Remove the motor and fan assembly from the fan
housing.
6. Remove the mounting bracket from the motor.
7. Using appropriate Allen key, remove the impellor
fan from the spindle.
Re-assembling
1.
Refit the fan to the motor and secure it to the
spindle.
2.
Refit the mounting bracket tot he motor.
3. Locate the fan and mounting assembly into the fan
housing.
8-60 May 1996