engine ASTON MARTIN DB7 1997 Workshop 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 3 of 421
^?
Introduction
#
••t
*<;'..
Introduction '-^;^'^<-~'
^--"^^zfjj^^T^""
Workshop Manual Sections
The
DB7
Workshop Manual
is
divided .jnto,9seGtipnsE.a&foli
1 Engine
2.
Fuel,
Emission Control
and
Exhaust
3. Transmission
4.
Suspension
and
Steering
5. Brakes, Wheels
and
Tyres
6. Electrics
7. Chassis
and
Body
8.
Air
Conditioning
9. Aston Martin Diagnostic System
Procedure Numbering
The workshop manual procedures
are
numbered using
the
parts list numbers
as a key. The
first
two
digits
oi a
workshop manual procedure number
are
also
the
parts list number
(e.g.
1.5.01
Sump Removal relates
to PL 1.5 Oil
Pump
and
Sump). Thus when carrying
out a
procedure,
you can
quickly locate
the
relevant parts illustration
and
spare parts list.
To avoid excessive repetition, each procedure will
be
fully detailed once
in its
appropriate place
in the
manual.
In
any other location where this procedure
is
required,
it
will
be
referenced only
by its
title
and its
procedure number.
Special Tools
Where special service tools
are
required
to
perform
an
operation,
the
tool number
is
recorded
at the
point
of use
within
the
procedure.
An
index
and
illustrated list
is
provided
in
this section
for the
purpose
of
identifying special
tools.
References
References
to the
left, right, front
or
rear
of
the vehicle
or of
a component
are
always made as
if
sitting
in the
drivers
seat facing forward.
Any
such references
to
assemblies removed from
the
vehicle
are to the
normal orientation
of
the assembly when fitted
in the
vehicle.
Repairs
and
Replacements
Where replacement parts
are
required,
it is
essential that only genuine Aston Martin parts
are
used. Your attention
is drawn
to the
following points concerning repairs
and the
fitting
of
genuine Aston Martin parts
and
accessories:
• Safety features embodied
in the
vehicle
may be
impaired
if
other than genuine Aston Martin parts
are
fitted.
In certain territories, legislation prohibits
the
fitting
of
parts which
are not
produced
to the
manufacturers
specification.
• Adhere
to
torque wrench settings given
in
this manual.
• Locking devices, where specified, must
be
fitted.
If the
efficiency
of a
locking device
is
impaired during
removal,
it
must
be
renewed.
•
The
vehicle warranty
may be
invalidated
by the
fitting
of
other than genuine Aston Martin parts.
April
1997 Hi
Page 5 of 421
//—-^
^^^^5~^
' -^ ^ Introduction
Safety Precautions
Safety Precautions (continued)
Electrical Equipment
1.
Ensure that electrical equipment is in safe working order before use.
2.
Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly
earthed.
3. Ensure that electrical equipment is protected by a fuse of the correct current rating.
4.
Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine
or when working beneath the vehicle.
Exhaust Fumes
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.
Fire Precautions
1.
Ensure that a suitable form of fire extinguisher is conveniently located near the work area.
2.
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.
4.
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
vapours.
6. All personnel should be aware of the fire drill procedures and precautions.
Jacking and Lifting
1.
The recommended procedures for lifting, jacking and towing are included latefin this seetion-and must be
strictly observed to ensure personal safety.
2.
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.
4.
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
1.
Do not leave tools, equipment, spilt oil, etc. around or on the work area.
2.
Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or
equipment.
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.
4.
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
skin,
leading to
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:
1.
Avoid prolonged and repeated contact with oils, particularly used engine oil.
2.
Wear protective clothing, including impervious gloves where practicable.
3. Do not put oily rags in pockets.
4.
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
skin.
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
fuel,
gas oil, thinners or solvents for washing
skin.
10.
If skin disorders develop, obtain medical advice.
11.
Where practicable, degrease components prior to handling.
12.
Where there is a risk of eye contact, eye protection should be worn, in addition, an eyewash facility should
be provided.
Environmental Protection
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
fitted;
in case of doubt,
contact the Local Authority for advice on disposal facilities.
vi April 1997
Page 14 of 421
Electrics
Starter Motor / Steering Wheel - Removal Procedures ^n:M3^^2?
6.3.02 Starter Motor
Procedure
1.
Disconnect the battery.
2.
Remove the inlet air trunkins
Figure 1. Starter Motor Mountings
3. Disconnect the starter solenoid connector and the
starter motor power lead at the solenoid.
4.
Remove the top starter motor securing bolt.
Note:
The
top bolt is from tlie
engine
side on auto
cars
and from ttie gearbox side on manual cars.
5. Raise the car on a hoist and whilst supporting the
motor, remove the lower starter motor securing
bolt.
6. Lift the motor from the bell housing and remove it
from the vehicle by positioning it vertically and
lowering it down in front of the oil filter.
6.5.01 Steering
Wheel and Horn
Switches
Procedure
1.
Remove the steering wheel centre pad.
Figure 1. Steering Wheel and Horn
2. Mark the position of the steering wheel relative to
the steering column to ensure correct replacement.
3. Removethesteeringwheelsecuringnutand remove
the steering wheel.
6.5.02 Column Switches
Procedure
1.
Remove the steering wheel.
2.
Remove three screws and the column switch cover.
1^
Figure 1. Column Mounted Switches
3. Cut the tywraps securing the switch loom to the
steering column. Disconnect the loom plugs.
4.
Release 4 screws and
1
ift the switch assembly off the
steering column.
6-6 May 1996
Page 27 of 421
Electrics
Electrical Component Location Index - Up to 97 MY
Component Name
ABS ECU
Air Con Compressor Clutch
Air Con Fan Motor - LH
Air Con Fan Motor - RH
Air Conditioning Trinary Switch
Air Conditioning Unit
Air Pump
Air Temperature Sensor
Alarm Override Switch
Alarm Siren
Alternator
Ambient Temperature Sensor
Barometric Pressure Sensor
Boot Lamp
Boot Lamp
Boot Lock Actuator
Boot Release Switch
Brake Accumulator Pump
Bulb Fail Unit - Front Side Lights
Camshaft Sensor
Central Locking Unit
Cigar Lighter
Column Switchgear
Crankshaft Position Sensor
Cruise Control Brake Switch
Cruise Control Clutch Switch (LHD)
Cruise Control ECU
Cruise Control On/Off Switch
Cruise Control Pump
Cruise Control Set Switch
Cruise Control Inhibit Switch
Diagnostic Socket - Transmission
Dimmer Module
Door Lock Actuator
Door Mirror- LHD
Door Mirror- RHD
Door Mirror Switch LH
Door Mirror Switch RH
Door Speaker -LH
Door Speaker - RH
EDIS Coil Pack
EDIS Amplifier Module
Engine Diagnostic Socket
Engine ECU
Exhaust Temperature/Speed Warning
Fan Fuses
Fan Motor 1
Fan Motor 2
Fan Run-on Switch
Flasher Module
Fog Lamp - RH Front
Fog Lamp - LH Front
Location
Reference
15-1
3-20
8-2
8-6
10-6
8-3
8-4
3-13
1-8
11-7
3-2
1-12
11-1
5-2
5-2
13-8
2-10
7-4/8
4-6
3-10
9-4
8-1
13-3
3-3
11-8
12-9
6-3
12-7
1-2
12-8
10-8
10-7
4-16
12-12
2-4
2-8
2-3
2-9
6-4
6-9
3-1
1-10
10-5
7-3
4-3
1-21
7-6
7-7
7-5
4-13
14-10
14-9
Wiring Diag.
Reference
28-A1
5-D2
8-A5
13-C4
5-D3
11-82
1-C2
5-C3
1-C5
1-B3
5-D3
1-A2
4-A4
24-A5
24-C4
27-A5
l-i-C3
28-84
9-C2
6-C3
8-D1
19-D3
12-C5
5-D2
12-85
2-D4
20-A2
20-C3
2-A3
20-D3
21-D3
12-A4
13-A4
17/18-B1
17-A3
17-A5
17-D5
18-D5
17-C5
18-C5
5-D5
6-B2
6-D4
6-C5
11-C5
3-A3
3-A2
3-B2
5-A2
13-C2
1-A1
1-C1
Rep.
Op. Notes
Reference
5.1.11.1
8.1.07.3
8.2.09.1
8.2.08.1
8.1.11.1
8.2.01.1
2.3.01.2
2.2.06.1
6.1.06.1
6.2.03.1
6.3.01.1
8.2.07.1
3.3.08.2
6.9.04.1
6.9.04.1
6.9.06.1
6.5.09.1
5.1.08.1
6.4.01.1
2.5.06.1
6.7.03.1
6.5.10.1
6.5.02.1
2.5.06.3
6.4.02.1
6.1.08.1 Manual only
6.6.09.1
6.5.07.1
6.1.09.2
6.5.07.2
3.3.08.6
6.4.03.1
6.4.04.1
6.7.10.1
6.7.08.1
6.8.01.1
6.7.08.2
6.8.01.2
6.7.09.1
6.8.02.1
6.2.05.1
6.2.05.3
6.4.05.1
6.4.06.1
6.4.07.1 Multi-functio
6.2.06.1
1.7.17.1
1.7.17.2
1.7.16.4
6.4.08.1
6.1.04.1
6.1.04.2
May 1996 6-19
Page 30 of 421
Electrics
Electrical Component Location Index - Up to 97 MY
Component Name
Seat Belt Switch
Seat ECU - Driver
Seat ECU - Passenger
Seat Heater - Cushion Element
Seat Heater - Squab Element
Seat Heater Control Module
Seat Motor Potentiometer
Seat Pressure Pad
Seat Switch Pack - Driver
Seat Switch Pack - Passenger
Security System Aerial
Security System ECU
Side Marker Lamp - LH Front
Side Marker Lamp - RH Front
Speaker - Rear LH
Speaker - Rear RH
Speed Control Dump Valve
Start Inhibit Switch
Starter Motor Solenoid
Stop Lamp Fail
Stop Lamp/Cruise Disable Switch
Thermal Breaker - Window Lift
Throttle Potentiometer
Water Temp Sensor - Engine ECU
Water Temp Sensor - Temp Gauge
Wheel Speed Sensor - Front RH
Wheel Speed Sensor - Front LH
Wheel Speed Sensor - Rear RH
Wheel Speed Sensor - Rear LH
Window ECU - LH
Window ECU - RH
Window Switch - RH
Window Switch LH
Wiper Logic Module
Wiper Motor
Window Lift Motor
Location
Reference
13-2
6-2
6-2
12-5
12-4
6-3
9-7
12-6
6-8
6-8
2-12
15-2
5-5
5-5
6-10
6-10
1-4
10-9
3-14
15-10
11-8
4-7
3-15
3-5
3-4
13-4
13-4
13-1
13-1
12-11
12-11
2-5
2-5
4-5
1-1
12-10
Wiring Diag.
Reference
22-A3
16-A1
15-A1
22-A2
15/16-A4
22-A5
22-C2
22-D3
16-B1
15-B1
24-C2
26-B6
1-C2
1-A3
24-B2
24-C2
2-A2
21-C3
3-C2
25-A3
12-C5
9-C3
5-A3
5-C2
5-C2
29-C3
28-D4
28-D3
28-D2
17-D3
18-D3
19-A2
19-D2
9-A3
8-C3
Rep.
Op.
Reference
6.6.16.1
6.6.17.1
6.6.17.2
6.6.18.1
6.6.18.2
6.6.18.3
6.6.19.1
6.6.20.1
6.6.21.1
6.6.21.1
6.6.22.1
6.6.22.3
6.1.18.1
6.1.18.1
6.6.23.1
6.6.23.1
6.1.19.1
6.1.20.1
6.3.02.2
6.9.15.1
6.4.02.1
6.1.21.1
2.5.02.2
6.3.07.1
8.2.12.1
5.1.12.1
5.1.12.1
5.2.01.1
5.2.01.1
6.1.22.1
6.1.22.1
6.5.03.1
6.5.03.1
6.2.01.1
6.1.21.3
Notes
6-22 May 1996
Page 47 of 421
#
ABS ECU Gearbox ECU Window ECU Central Locking ECU Engine Management ECU
Lamp Fail ECU
EDIS Amp
Security ECU Window ECU Seat ECU'S Air Conditioning ECU
Figure 17
o
o 3 •a o 3 n 3 O n Si 5 3
ere
3
c
•o
o
-<
n
Page 49 of 421
Electrics
Loom Location Diagrams - Up to 97 MY
Fig 5.
1.
Harness Sill
2.
Harness Console
3. Harness Fuse Box
Fig 6.
1.
Harness Engine
2.
Earth Engine Body
3. Harness Foward Right
4.
Rearward Harness
5. Harness Headlamp Link
Fig 7.
1.
Harness Seat
May 1996 6-41
Page 57 of 421
NO COLOUR
159 K 160 0
PIN 1 2 3 4 5 6 7 S 9 10 M 12 13 14
AREA
B6 06
SERIAL COMMS CONNECTOR NO COLOUR 161 RP 162 RG 163 BK 164 B I6S RK
PIN 1 ? 5 4 5 6
AREA B9 B5 Dl B4-27 Dl
NO COLOUR PIN 166 BU 1 16? GP 2
les
wu
3
im B2-25 B6 B3-26
PERFORMANCE
ENGINE HARNESS
NO COLOUF 150 SP 157 B 152 GU 235
BU
154 WU 153 UK 155 W 156 YG 247
CN
l>IN 1 ? 3 4 5 6 7 e 9 10 II 12 1?
AREA B6 B4-27 B6 B2-25 B3-26 A2 66 C5 B6 GEARBOX LINK HARNESS
SHEET 7 AREA At
NO COLOUI 169 S 170 BS
171 NR
172 0
165 'RK 173 GB
174 KB
175 PY 176 KU 15} en
PIN 1 2 3 4 5 6 7 8 9 10 II 12 13 14 15
-If,.,
AREA C5 66
C6
03
A3 86
B5
B6 B6 »?
BULKHEAD HARNESS
SHEET II AREA D4
NO COLOUF 177 OW I7S OR 172 WR 179 OP ISO OB 181 OS 182 OK 183 ON 184 OU 185 OY 186 BU 187 R 188 U 189 6 190 N
PIN 1 ?. 3 4 5 6 7 8 9 10 II 1? 11 14 15 16 17 16 19 .29
AREA B6 B5 Dl B5 Be B5 B5 B5 B5 86 62-25 C6 C6 A6 B6
NO COLOUI 191 B 192 8 193 BU 194 WU
170 BS
181 OS 174 KB
PIN CI a C3 C4 C5 ce C7 C8 C9 CIO Cll CI2 CI3 CI4 CIS C16
AREA B4-27 84-27 B2-25 B3-26
Dl
D3 Dl
HO COLOUI
189 G 190 H 155 W
150 SP 152 GU
159 K 185 OY 167 GP
180 OB
PIN 01 02 03 04 D5 D6 07 1)8 09 010 on 012 013 014 015 piB
Ah'tA
03 D3 CI
CI CI
Al D3 A4
D3
NO COLOUR 161 RP 162 RG 162 OK 183 ON 184 OU 179 OP 178 OR
156 YG 169 S 171 NR
PIN Al A2 A3 A4 A5 A6 A7 A8 A9 AlO All m
AREA A3 A3 D3 03 03 Dl D3
CI Dl V
m COLOUR
247
GN
175 PY 177 OW 173 6B 176 KU
160 0 187 R mv
PIN Bl B? R3 B4 B5 B6 B7 B8 R9 BIO Rll tH
AREA
CI Dl 03 01 01
Al D3 ja
Wiring Diagram
Model - Aston Martin DB7 Coupe
Harness Title - Auto Gearbox
Drawing Part No. - B37-81299
Revision - 0 Sheet 4 of 29 - Up to 97 MY
Page 61 of 421
NO COLOUR 152 GU 154 m 195 DIN I9e UIN 197 RN 198 GN 199 U 200
K
201 8 204 YN 205 YR 206
YO
20TN8 209
OK
210 OU 213 GW 215 GO 216 RG 219 GT 222 OS 223
OG
AREA Dl Dl B2 B2 CI-37 02 C5 C5 Bl B2 B2 B2 02 02 C6 C5 B5 B6 86 02 C6
NO COLOUR 221 KB 225 OY 229
GB
231 GP 232
R
233 8 234 u 235
BU
237
GN
265
WR
301 YB 319 BRD 320
KB
322
KB
AREA ci-3e C6 86 85 B6 B5 BS Dl C5 02 85 A2-54 CI-36 CI-36
NO COLOUR PIN 130 BG I 241 B ?
TRTT C4
_B!
IJEJ
NO COLOUR PIN
ABET
292
RIN
I 86 293
UIN
2 C5 294 W 3 A3-5I
NO COLOUR PIN
ARET
286
KB
A5-50 PURGE VALVE I I tio tOLOuD M mk
SPL
52-
SPL
53-
SPL
54.
HEATED
WASHER
JET
1^
I oooooooooooo gl
NO COLOUR 284
RO
g85B
AREA 81-33 t?-}9
NO COLOUR AREA 238 8 CI-35 239 e CI-34
NO 151 201
COLOUR
6 8
240 B
241 8
AREA
Dl Al 82 42
EARTH!
POINT
r
:ARTHL
'oiNTr
WIPER MOTOR
NO
C6LOUR
357
BLG
358
BR
35SWLG
359
0
24GB
PIN AREA Al
04
A2
D4
Bl
04 82
CI
04
C2 C3-39
NO COLOUf 295 RIN 296 UIN 297 RIN 298 UIN 196
UIN
195
RIN
299
W
300 KB 240
8
204 YH 206 YO 205 VR
t>IN
1 2 5 4 4 6 1 8 9 10 II \i
AREA
C5 C6 86 85 Al Al
A2-54 01-38
81 Al Al Al
NO COLOUR PIN
ABES"
282
RO
I 81-33 iBie 2 Ozil HEATED WASHER JET
SPL 47 SPL 48
LJ-^
a LAMBDA A
NO COLOUR PIN 274 RIN 1 275
W
2 276
RG
3 277
NS
4
AREA 85 B4-49 06 i^-JS
NO COLOUR
FIX
278 UIN
1
279 W
2
280 RY
3
281
NS 4
AREA
C5 84-49 06 84-48
NO COLOUR PIN AREA 271 RIN I C6 272 UIN 2 C6
g"*
^ C3-46
NO COLOUR
PIN
127
UN 1
128
KB 2
129
UR 3
130
BG 4
AREA
C5 D2 C5 A2
NO COLOUH 150
SP
151
8
235 BU 152
GU
154
WU
153
UK
155
W
156
YG
247 RN
PIN 1 2 S 4 5 6 r 8
9 10 II 12 15
AREA
C6 81
Al Al C6 C5 86
CI-37
.a. ^^^^^^^
'^ GEARBOX
SHEET
4
AREA
A2
NO coLour
248
NS
249
LGO
209
OK
250
WS
222 OS 207 NB 251 RN 252
WY
253 UC 15 RO 136 UB 198 GN 255
G
256KB 257
KB
128 KB 258
KB
259
OR
260 0 261 NR 262 BLG 263
WR
SHEET 8 AREA A2
PIN 1 2 3 4 5 6 7 8 9 10 11 1? 13 14 15 16 17 18 19 20 ?l ?? 23 24
AREA B4-46 86
Al 85 81 Al CI-37 C5 CG 81-33 C6 Al C5 CI-38 A5-50 04 CI-36 06 D6 C5 B6 Al
11111 PL 41 1 SPL 43 I SPL SPL 45 SPL 44
NO COLOUF 266
KB
267
R
268 B
269
N
270 G
PIN
1 ? 3 4 5 6 7 8
9
AREA CI-38
C5
85
86
C5
NO CDLOUf 268
B
274
RIN
233
8
301
YB
302 W
305 W 298 UIN
304 8
250
WS
215
GO
231
GP
127
UN
129
UR
255 G 305 8 306 8 507 B 308 B 267
R
270
G
278
UIN
309 W 234 U
200
K
199
U
293 urn 2SI
NR
295 RIN 252 WY 510
B
155
W
213
GW
257
GN
289
K
291
U
311
W
PIN
1 2
3
4 5 6 7 8 9 10
11
12 15 14 15 16
17 18 19 20 21 2? 25 24 25 26 27 28 29 30
31 3? 55 54
35 36 37 58 39 40 41 42 43 44 45 46 47 48 49 50 51 52
AREA
04
85 Al
Al
C4-44
C4-40
82
CI-34
02 81 Al C4 C4 01
CI-35 CI-35 CI-55 CI-35
04 04 85
C4-42
Al
Al
Al A5 02 82 D2
81-34
01
Al Al
A5 A5
C4-41
NO COLOUR
PIN
269 N
252 R
216
RG
249 LCD 292
RIN
156
YC
297 RIN 262 BLG
219
GY
229 GB
136
UB
287
W
271
RIN
512
KB
210
OU
155
UK
296 UIN 272
UIN
515
B
255
UG
150
SP
280 RY 276 RG 259 OR 260
0
225 OG 225
OY
53 54 55 56 57 58 59
60
61 62
63 64
65 66 67 68
69 70 71 72 73 74 75 76 77 78 79 80 81 82 85 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104
iSR 04
Al
81
C2 AJ
01 82 02
81 Al
02
A4 C3 0-3$
Al
01 82 C5 BI-34 02
01
B5 65 02 02 Bl Al
SHEET
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AREA
C3 ^
NO COLOUF 344 B 356 WLG 357 BLC 358 BR 359 0
TOT 1 2 3 4
I
AREA C3-39
CI CI CI CI
"^7 Wiring Diagram
Model - Aston Martin DB7 Coupe
Harness Title - Engine 2
PartNo.-B37-81301
Revision - 0 Sheet 6 of 29 - Up to 97 MY