oil pressure ASTON MARTIN DB7 1997 Workshop Manual

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

[n:m3^y

Component Name
Microwave Sensor
Mode Switch
Multifunction Module
Number Plate Lamp - LH
Number Plate Lamp - RH
Oil Pressure Warning Light Transducer
Output Speed Sensor (Auto)
Park Switch (Auto)
Purge Valve 1
Purge Valve 2
Radio Aerial
Radio Telephone Connector
Radio Tweeter
Radio Tweeter
Radio
Rear & Number Plate Bulb Fail Unit
Rear Fog Lamp LH
Rear Fog Lamp RH
Rear Lamp - LH
Rear Lamp - RH
Recline Motor Potentiometer
Relay - ABS Pump
Relay - Air conditioning clutch
Relay - Air Pump
Relay - Auxiliary Load
Relay - Boot Release
Relay - Courtesy Lights
Relay - Cruise Control On/Off
Relay - Drivers Seat Heater
Relay - Fan 1
Relay - Fan 2
Relay - Fan Run On
Relay - Front Fog Lamps
Relay - Fuel Pump 1
Relay - Fuel Pump 2
Relay - Gearbox Failure Warning
Relay - Headlamp Dipped Beam
Relay - Headlamps
Relay - Heated Rear Window
Relay - Horns
Relay - Ignition Load
Relay - Main
)
Location
Reference
12-1
7-9
4-2
5-3
5-3
3-17
11-12
10-1
10-3
10-4
15-4
15-3
6-7
6-5
6-6
15-11
14-2
14-5
14-1
14-6
9-7
4-8
1-17
4-14
4-4
15-9
4-11
6-1
12-3
1-20
1-19
1-18
1-6
15-7
15-8
4-9
1-5
1-7
4-15
1-16
4-10
4-12
Relays - Drivers/Passengers Seat Heaters 12-3
Relay - Rear Fog Lamps
Relay - Reverse Lamps
Relay - Sidelamps
Relay - Starter Solenoid
Relay - Stop Lamps
Reversing Lamp Switch (Man)
Reversing Light Switch (Auto)
Screen Wash Pump
4-17
15-6
1-9
1-15
15-5
11-3
10-2
1-13
Electrics
Electrical Component Location Index - Up to 97 MY
Wiring Diag.
Reference
24-C2
4-A3
8-C4
27-84
27-B6
5-C5
7-B3
21-B1
5-A4
5-A5
24-D2
25-B2
8-C3
14-C4
10-A2
25-C3
17-D2
18-D2
24-A5
24-C4
22-81
9-C4
3-A3
13-A5
9-D1
26-D3
13-A2
20-B1
16-D3
3-B6
3-B6
3-A5
1-B5
26-A2
26-A3
13-A1
1-B5
1-84
13-A4
3-A4
13-A2
13-A3
15-D3
13-A5
25-A4
1-B4
3-A4
25-A5
7-C5
21-C2
3-D1

Rep.
Op. Notes
Reference

6.6.14.2

6.5.07.4

6.4.12.1
6.9.03.1
6.9.03.1

1.5.08.1

3.4.02.2
Auto only

6.5.13.1
Auto only

6.1.14.1

6.1.14.2

6.9.08.1
6.9.09.1
6.5.17.1
6.5.17.1
6.5.05.1
6.9.10.1
6.7.02.1
6.6.07.1

5.1.15.1

6.2.06.1
6.4.13.1
6.4.14.1
6.9.11.1
6.4.15.1
6.5.18.1
6.6.15.1

1.7.16.3
1.7.16.3

1.7.16.4

6.1.04.3

6.9.12.1
6.9.12.1
6.4.16.1
Auto only

6.1.15.1
6.1.16.1
6.4.17.1
6.2.07.1
6.4.18.1
6.4.19.1

6.6.15.2

6.4.20.1
6.9.13.1
6.1.17.1
6.2.08.1
6.9.14.1
6.2.09.1

6.2.09.2

6.3.06.1

May 1996 6-21

Electrics
Component Index Sheet 2 - 97 MY
Component
Name
Door Lock Switch (Passengers)
Door Mirror - (Drivers)
Door Mirror - (Passengers)
Door Mirror Switch (LHD)
Door Mirror Switch (RHD)
Door Rear Guard Lamp (RH)
Door Rear Guard Lamp (LH)
DPFE Sensor
EDIS Coil Pack
EVR Valve
Exhaust Temperature/Speed Warning
Fan Control Module
Fan Motor 1
Fan Motor 2
Foglamp - RH Front
Foglamp - LH Front
Fuel Filler Flap Solenoid
Fuel Pump 1
Fuel Pump 2
Fuel Tank Pressure Sensor
Fuel Tank Sender Unit
Gear Selector Illumination
Glass Break Sensor
Handbrake Switch
Head/Side Lamp - LH Front
Head/Side Lamp - RH Front
Heated Backlight (Volante)
Heated Backlight (Voiante)
Heated Oxygen Sensor
1
-1
Heated Oxygen Sensor
1
-2
Heated Oxygen Sensor 2-1
Heated Oxygen Sensor 2-2
Heated Washer Jet LH
Heated Washer Jet RH
High Level Stop Lamp
Hood Control Module (Volante Roof)
Hood Motor (Volante Roof)
Horn - LH
Horn - RH
Idle Speed Control Valve (Eng Sub-harness)
Ignition Coil Pack (EDIS)
Ignition Switch
Indicator/Side Lamp - LH Front
Indicator/Side Lamp - RH Front
Inertia Switch
Injector 1
Injector 2
Injector 3
Injector 4
Injector 5
Injector 6
Instrument Pack
Instrument Panel Illumination Control
Instrument Panel Illumination Dimmer Switch
Interior Light - Rear LH
6-44
Component
Location
11-10
n-4
11-11
11-12
11-12
11-7
11-8
3-5
3-9
2-1
1-6
2-7
11-1
11-2
12-3
12-2
12-10
12-7
12-9
12-8
12-6
12-5
7-8
7-5
12-1
12-4
12-11
12-11
2-5
2-5
8-2
8-2
13-3
13-3
13-7
8-4
13-6
1-7
1-7
3-8
3-9
14-5
14-2
14-2
6-9
13-2
13-2
13-2
13-2
13-2
13-2
13-5
7-4
13-8
14-9
fEB^-^?
Circuit
Reference
22-A2
21-A3
22-A5
21-C5
22-C5
21-D2
22-D2
5-C4
5-A5
5-D2
11-C3
3-D2
3-B1
3-C1
1-A1
1-C1
15-A2
16-A5
16-A6
15-C3
16-B4
13-C4
14-C6
14-C5
1-D2
1-A2
15-D3
16-A2
6-D4
14-A6
6-D4
14-A6
5-D3
5-D4
15-82
18-D4
19-B6
1-A3
1-A3
5-C3
5-A5
9-D4
1-C1
1-A1
12-C5
5-B2
5-B2
5-B2
5-B3
5-B4
5-B4

9-A/B5/6

8-C5
9-C4
15-C3
September 1996

Electrics
Component Index Sheet 3 - 97
MY

Component
Name
Interior Light - Rear RH
Key Solenoid
Key-In Warning Switch
Low Coolant Signal Transmitter
Low Level Sensor (Screenwash)
Map Reading Light
Mass Airflow (MAF) Sensor
Multifunction Module
Number Plate Lamp - LH
Number Plate Lamp - RH
Oil Pressure Transducer (EOP)
PATS Module
PATS Transceiver
Performance Mode Switch
Powertrain Control Module (PCM)
Purge Cannister Vent Valve
Radiator Switch
Radio
Radio Aerial
Radio Telephone Connector
Radio Tweeter (LH)
Radio Tweeter (RH)
Rear Lamp - LH
Rear Lamp - RH
Relay - Air Conditioning
Relay - Air Conditioning W.O.T.
Relay - Air Pump
Relay - Auxiliary Load (
Relay - Auxiliary Load (
Relay - Courtesy Lights (
Relay - Clutch (
Relay-Day Time Running (
Relay - Drivers Seat Heater (
Relay - Fan Change-Over (
Relay - Fan Run On
Relay - Front Fog Lamps
Relay - Fuel Pump 1
Relay - Fuel Pump 2
Relay - Gearbox Failure Warning
Relay - Glass Drop
Relay - Hazard Unit
Relay - Headlamp Dipped Beam
Relay- Headlamps
Relay - Heated Front Screen Control
Relay - Heated Rear Window
Relay - Hood Down (Roof Down)
Relay - Hood Up (Roof Up)
Relay - Horn
Relay - indicator Unit (Flasher Unit)
Relay - Left Quarter Light Up
Relay - Left Quarter Light Down
Relay - Load
Relay- Main
Relay - Main Beam
Relay - Passenger Seat Heater
Component
Location
14-6
14-4
14-4
7-13
14-3
10-9
14-1
6-1
14-8
14-7
15-3
4-9
15-4
6-8
4-1
15-7
15-2
5-1
5-4
8-3
5-2
5-2
15-8
15-6
see relay location chart) di II II II
II II II II
II II II II
11 II II II
II II II II
II II II II
II II II II
II II II II
II II II II
11 II II II
II II II II
II II II II
II II It II
II II II II
11 II II II
II II II II
II II II II
II II II II
II II II II
II It II II
II II II II
11 II II II
II II II II
11 II II II
11 II II II
II II II II
II II II II
II II II II
II II II II
II II II II
Circuit
Reference
16-A2
9-D3
9-D3
12-82
3-A2
8-A4
5-D2
12-B5
16-D6
16-C6
5-C4
12-B1
9-C2
4-A2
6-B5
15-B3
5-D1
10-B3
16-C2
16-B5
8-A3
12-C2
15-B6
16-D2
3-A4
3-A5
1-A5
9-D1
12-D1
9-D1
1-B5
1-A6
23-D3
3-C4
3-A3
) 1-B5
) 17-A2
) 17-A4
9-D2
) 12-C1
) 8-C3
2-A2
) 2-B2
) 12-D3
) 8-C4
) 19-A2
) 19-A3
) 1-85
) 8-C3
) 18-A5
) 18-A5
) 12-D1
) 12-D2
) 2-83
) 24-D3
September 1996 6-45

^"^
Body and Trim
Body Repair
Precautions
Paint
Ensure that there is efficient ventilation at all times. Paint spraying should be confined to spray booths.
Anyone with a history asthma should not be engaged in any process which involves the use of isocyanates.
Any operator working inside a spray booth where isocyanates are present must use air-fed breathing equipment.
Supplied air to the visor should be fed at the recommended pressure and filtered to remove oil, water and fumes.
Operators involved in handling, mixing or spraying should wear protective clothing, gloves and goggles to avoid
skin and eye contact. A Paticle mask or canister typr respirator should be worn when sanding.
Applied heat
When welding, flame cutting or brazing and so on, goggles, a mask or fume extractor and flameproof protective
clothing should be used always.
It is especially important when working with polyurethane compounds to use air-fed breathing equipment.
Ensure that at all times the appropriate fire fighting equipment isavailableand that personnel are trained in its use.
Metal repair
Wear appropriate eye and hand protection when sanding, drilling, cutting, chiselling, flatting or welding. Wear a
face mask or air-fed visor when sanding or flatting either body solder or
fillers.
When a soldering operation has been

completed,
remove swarf from the work area and wash your hands thoroughly.
General Repair Notes
The following precautions should be noted before any work is carried out:
• disconnect the vehicle battery ground
lead,
taking note of the reconnection procedures
• Make sure that you have read and understood the safety related procedures in this section.
Caution:
Electric arc
welding must not
be
used on the
vehicle as the high
voltages produced by
this process
will
cause
irreparable

damage
to the electrical control and
microprocessor
systems.

All trim and electrical components in the locality of the repair must be removed or disconnected prior to panel
removal or replacement.
Welding and Gas Process Special Notes
Resistance spot welding, MIG welding and all gas processes may only be carried out on bare, unpainted or unplated

metal.
The flanges of panels, which are to be welded together, must be clean, corrosion free and treated as
appropriate with either weld-through or inter-weld sealer.
The resistance spot welding equ ipment used in vehicle repair does not always produce
a
weld of
equ
ivalent strength
to that produced in manufacturing. This means that a single row of spot welds should be spaced on a pitch of 19-
25 mm, which will usually result in more spot welds than found in the original factory joint.
Use a resistance spot weld cutter to remove resistance spot welds. Where a new joint is to be MIC welded, cut the
old resistance spot welds from the panel that is to be retained; the resulting holes are then used for plug welding.
Suitable holes may be drilled or punched as follows:
• 8.0 mm for sections up to 1.5 mm thickness
• 10.0 mm for thicker sections.
Always refer to the welding equipment manufacturers diagrams and tables for the relevant procedure.
May 1996 7-3

in:!M3^^?
Air Conditioning
Contents
Contents
General Description 8-5
Specifications 8-5
Climate Control System 8-6
System Description 8-7
Special Servicing Tools and Equipment 8-7
Working Practices 8-8
General 8-8
Handling Refrigerant 8-8
Handling Lubricating Oil 8-8
System Maintenance 8-8
Temperature Distribution System 8-9
Fan Speed Control (Mode Switch) 8-10
Face Level Temperature Differential 8-10
Temperature Rotary Control 8-10
Refrigeration Cycle 8-11
System Protection 8-12
General System Procedures 8-12
Leak Test 8-12
Charge Recovery (System Depressurisation) 8-12
Evacuating the System 8-13
Adding Compressor Lubricating Oil 8-13
Adding Refrigerant 8-14
Functional Check 8-15
System Trouble Shooting 8-1 7
Electronic Control Module (ECM) 8-19
In Car Controls 8-21
Temperature Demand Switch 8-21
Face Level Differential Controller 8-21
Air Conditioning Function Switch 8-22
Fan Speed Control Switch (Mode Switch) 8-23
Temperature Sensors 8-23
Evaporator Sensor 8-24
Motorised In-Car Aspirated Sensor 8-24
Water Temperature Switch 8-25
Blower Motors 8-25
Potentiometers 8-26
Servo Motors 8-27
Vacuum System 8-28
Pressure-Temperature Graphs 8-29
May 1996 8-1

Air Conditioning
Contents '=2?
System Fault Diagnosis
Fault Finding
Blower Motor Test
Open Water Temperature Switch Needs
Short Water Temperature Switch Leads
Refrigeration
Compressors
Compressor Clutch Control
Trinary Switch
Condenser
Receiver-Drier
Evaporator
Expansion Valve
Sanden Compressor SD7H15
Manifold Gauge Set
System Checking with the Manifold Gauge Set
Evacuating the Manifold Gauge Set
Connecting the Manifold Gauge Set
Stabilising the System
Purging the Test Hoses
Leak Test
Manifold Gauge Set Check Procedures
Refrigerant Slightly Low.
Refrigerant Excessively Low.
Air In The System.
Compressor Malfunction
Moisture in the System
A Large Amount of Air in the System.
Expansion Valve Malfunction.
Expansion Valve Malfunction
Restriction in the High Pressure Side.
Torque Levels for the Hose Connections
8-30
8-33
8-33
8-33
8-34
8-35
8-35
8-35
8-35
8-36
8-36
8-36
8-37
8-39
8-39
8-39
8-39
8-40
8-40
8-41
8-41
8-42
8-42
8-43
8-44
8-45
8-45
8-46
8-46
8-47
Air Conditioning Procedures
Depressurising
Recovering Refrigerant
Evacuating and Recycling the Refrigerant
Recharging the System
Compressor Oil Check
8-47
8-47
8-48
8-49
8-49
8-2 May 1996

Em^^^?
Air Conditioning
General Description
General Description
Specifications
Refrigerant
Designation
Refrigerant R134A

(HFCUAA)

Compressor
Type
&
model
SD-7H15
Charge weight
1050g±50g
Configuration
7 cylinder
Compressor Lubricants
Designation
Polyalkylene glycol
(PAG)

Standard
for
Recovery, Recharge
and
Recycle Equipment,
System Capacity
120-150
ml

Manufacturer and Type
ICI Klea
or
equivalent

Manufacturer

Sanden
155 cm^
per
revolution
Manufacturer and Type
Sanden SP
20

Feature

Recovery rate
Cleaning capability
Oil separator
Vacuum pump
Filter

Charge

Hoses
Charge pressure
Compressor Belt Tension
Type
Vee belt
Burroughs method
Clavis method
Requirement

0.014-0.062
mVmin.
(1.36 kg in 20
minutes)
15
ppm
moisture; 4000
ppm oil; 330 ppm
non-condensable gases
in air

With hermetic compressor and automatic
oil
return
2 stage
0.07
-0.127 mVmin.
Replaceable with moisture indicator
Selectable charge weight and automatic delivery
Dedicated Refrigerant R134A port connections.
Heating element
to
increase pressure
Condition and range
All figures apply
to a
cold belt.
New belt
578 to 623 N

If tension
is
below
356 N,
reset
at 512 to 534 N

New belt
147 to 153 Hz

If tension
is
below
110 Hz,
reset
at 132 to 138 Hz

Note:
The
tension
is
measured
midway between the
compressor
and crankshaft pulleys. For a new
belt,
rotate engine three
revolutions minimum and then re-check the tension.

May 1996
8-5

Air Conditioning
General Description 5^^?
climate Control System
Features
Refrigerant R134A (Hydro fluorocarbon), non ozone depletory.
PAG (polyalkylene glycol) synthetic compressor lubricating oil.
Dedicated and improved compressor for Refrigerant R134A.
Quick fit and release self sealing charge and discharge ports.
Triple pressure (Trinary) switch to control the compressor (incorporated into the liquid line).
Clamp retained 'O' ring seals at the expansion valve and evaporator.
All aluminium evaporator matrix and pipe work.
Aluminium receiver-dryer (without sight glass) and HFC dedicated desiccant.
Parallel flow extended height condenser.
Single muffler situated in the suction hose.
Improved electrical system connectors.
Improved system control panel.
System Recognition
Identification Features
Aluminium pipes.
Large diameter, quick release charge and recovery ports.
No sight glass.
8-6 May 1996

Air Conditioning
Working Practices O" 15-^?
Working Practices
General
Be aware of, and comply
with,
all health and safety
requirements.
Before beginning any repair or service procedure,
disconnect the vehicle battery ground connection
and protect the vehicle from dirt or damage.
Work in a well ventilated, clean and tidy area.
Recovery and chargeequipment must comply
with,

or exceed the standard detailed in the General
Description.
Handling Refrigerant
Wear eye protection at all times.
Use gloves, keep skin that may come into contact
with refrigerant covered. If the refrigerant comes
into contactwith youreyesorskin wash the affected
area immediatelyw'ith cool water and seek medical
advice, do not attempt to treat yourself.
Avoid inhaling refrigerant vapour, it wil
your respiratory system.
irritate
Never use high pressure compressed air to flush out
a system. Under certain circumstances a
combination of HFC 134A and compressed air in
the presenceofa source ofcombustion (for instance,
welding or brazing equipment), results in an
explosion that releases toxic compounds into the
atmosphere.
The refrigerant and CFC 12 must never come into
contact with each other
as
they form an inseparable
mixture that can only be disposed of by incineration.
Do not vent refrigerant directly into the atmosphere,
always use approved recovery equipment.
Refrigerant is costly but it can be recycled. Clean
the refrigerant, using the recovery equipment and
reuse it.
Carry out LeakTestsonly with an electronic analyser
dedicated to Refrigerant El 34A.
Do not attemptto guess the amount of refrigerant in
a system, always recover it and recharge with the
correct charge weight. Do not depress the charge or
discharge port valves to check for the presence of
refrigerant.
Handling Lubricating Oil
Avoid breathinglubricantmist,itwillcauseirritation
to your respiratory system.
Always decant fresh oil from a sealed container. Do
not leave oil exposed to the atmosphere for any
reason other than to fill or empty a system; PAG oil
is hygroscopic (it absorbs water) and iscontaminated
rapidly by atmospheric moisture.
Following the recovery cycle do not reuse the oil
when it has been separated from the refrigerant;
dispose of the oil safely.
System Maintenance
Do not leave the system open to the atmosphere. If
a unit or part of the system is left open for more than
five minutes, it is advisable to renew the receiver-
dryer. There is not a safe period in which work is to
be carried out. Always plug pipes and units
immediately after disconnection and only remove
plugs when re-connecting.
If replacement parts are supplied without transit
plugs and seals do not use the parts. Return them to
your supplier.
Diagnostic equipment for pressure, mass and
volumeshouidbecalibrated regularly and certified
by a third party organisation.
Use extreme care when handling and securing
aluminium fittings, always use a backing spanner
and take special care when handlingtheevaporator.
Use only the correct or recommended tools for the
job and apply the manufacturer's torque
specifications.
Keep the working area, all components and tools

clean.

8-8 May 1996