roof 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 18 of 421
Electrics
Interior Lamps and Front Seat - Removal Procedures EM^^^
6.6.01 Front Interior Lamps
Procedure
1.
Releasethequarterturnfasteneronthefrontinterior
light assembly and lower the assembly from the
roof liner.
Figure 7. Front Interior Lamp
2. Disconnect the interior lamp plug and remove the
interior lamp assembly.
6.6.02 Rear Interior Lamps
Procedure
1.
Release the rear upper trim panel.
2.
Remove two spire washers and the rear interior
lamp assembly.
6.6.03 Front Seat Removal
Procedure
1.
2.
Motor the front seat forward and remove the rear
securing bolts for the seat rails.
Motor the seat to the rear and remove the front seat
rail securing bolts.
Figure 1. Front Seat Removal
3. Lift the footweil carpet, release the access plate
securing screws and remove the plate to gain
access to the seat control unit.
4.
Cutand remove thetywrapssecuringtheseat loom.
5. Disconnect the seat harness connectors at the
control unit.
6. Remove the seat assembly.
Figure 7. Rear Interior Lamps
3. Disconnect the lamp wiring and remove the lamp
assembly.
6-10 May 1996
Page 69 of 421
NO
COLOUR
5
YS
14
WU
17
GW
51
RO
65
UB
70
YW
71
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83
WB
86
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NR
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95
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96
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97
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98
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99
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109
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131
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136
UB
138
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BK
172
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174
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198
GN
207
NB
209 OK 222
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226
BN
248 NS 250
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252
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253
UG
255
0
258
KB
259
OR
260 0 261
NR
262
BLG
321
PW
322
RU
323
GU
324
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325
LG
328
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330 YG 331
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351
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354
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555
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377 8G 378 BS 379
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380 PG 381
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418
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422
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94 SPL 95
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475
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RN
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BRD
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B
475
B
489
UlN
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491
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C6 C6
Al
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NO
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497 SLG 498 P 499 PW 459 G 500 KB 259
OR
501
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383 K 455 NP 502
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ABS
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PIN
445 NG 470 KU
AREA
Al
CRUISE CONTROL
NO
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PIN
517
LGY 1
518
WY 2
519
GB 3
99
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98
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RY
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96
UW
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121
WR
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136
UB
138
RN
163
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172
G
174
KB
175
PY
198
GN
207
NB
209
OK
222
OS
226 BN 248
NS
250
WS
253
UG
255
G
258
KB
262
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322 RU 323
GU
324
Y
325
LG
328
RN
330 YG 331
YU
351
WU
354
W
355
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362 RW 368 OS 369 OU 377
BG
378
BS
380 PG 381
BP
382
WB
384
WP
AREA
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COLOUR
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416
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417
LGW
416
LGH
420 LGR 421
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422
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423
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453 GP 461
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492
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514
RB
515
W
516
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517
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520
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521
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523
RW
524
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526
BK
527
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B
552
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W
563 BU 565
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586
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587
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588 WS 595
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BU
616
P
617
PW
618
6
622
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Emm
[D:m^-2? Wiring Diagram
Model
-
Aston Martin
DB7
Coupe
Harness Title
-
Bulkhead
RHD - 3
PartNo.-B37-81305
Revision
- 0
Sheet
10 of 29 - Up to 97 MY
Page 109 of 421
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
Page 110 of 421
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
Page 131 of 421
Electrics
Relay Location Index - 97 MY
D^^
Facia Component Panel
- LHD
Passenger
Function
Heated Front Screen Timer Relay
Multi-Function Module
Low Coolant Transmitter Module
Main Relay (Red Stripe)
Auxiliary Load
Auxiliary Load
Fusebox
Heated Front Screen Fuse
Otter Switch (door drop glass)
Side
-
Right
to
Left
Base Colour
Yellow
Black
Black
Red
White
Black
Black
White
Fascia Component Panel
- LHD
Drivers Side
-
Right
to
Left
Function
Gearbox Failure Warning
Ignition Load
Courtesy Lights
Indicator/Flasher Unit
Hazard Warning
Heated Rear Window
Rear
Fog
Light
Dimmer Module
Fusebox
Base Colour
Black
White
Red
Yellow
Green
Blue
Brown
Black
Relay/Module Cover.
Grey
Black
Black
Silver
Blue
Blue
Orange Fuse
Black
Relay/Module Cover.
Pink
Blue
Blue
Black
Black
Blue
Blue
Red
Location
1
2
3
4
5
6
7
8
9
Location
1
2
3
4
5
6
7
8
9
Seat Heater Relays - Beneath the Driver and Passenger Seats
Boot (Trunk) Relays Volante (Front To Rear)
Function
LH Quarter
Up
LH Quarter Down
Hood Down
Hood
Up
RH Quarter Down
Reverse Lights
Fuel Pump
1
Fuel Pump
2
Tilt Sensor
RH Quarter
Up
Stop Lights
Hood Lift Fuse
Fusebox
Hood (Roof) Control Module
Thermal Cut-Outs Quarter Glasses
Base Colour
White
Yellow
Blue
Green
Red
Yellow
Blue
Green
White
Black
Brown
Black
Relay/Module Cover.
Pink
Pink
Pink
Pink
Pink
Blue
Silver (Bosch)
Silver (Bosch)
Pink
Pink
Blue
Green
30A
Black
Location
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Boot (Trunk) Relays Coupe (Front To Rear)
Function
Stop Lights
Reverse Lights
Fuel Pump 1
Fuel Pump 2
Tilt Sensor
Fusebox
Base Colour
Brown
Yellow
Blue
Green
White
6-66
Relay/Module
Blue
Blue
Silver (Bosch)
Silver (Bosch)
Pink
Cover. Location
1
2
3
4
5
6
September
1996
Page 152 of 421
fj
NO COLOUR 636 N 655
N
704
N
7r7 N
AREA e.M S.A6 9.DI 9.04
UPPER SOCKET LOWER SOCKET
BATTERY
STUDt
NO COLOUR 786
N
787
N
788
N
AREA I0.AZ-I5I
8.B6-75
IO.BI-90
BATTERY
STUDt
NO COLOUR
PIN
AREA
760
ON
U
9.C4-85
761 GW W I0.B?-9I
SPL 151
-
^w^
SPL 89 SPL 90
T^
SUNROOF/ACC
NO COLOUR PIN AREA 762 B I
e.B4-67
2 658
NP
3 8.A6 660 WG 4 8.A6
II
[D
fl]
(D
01 ^5 4
ABS LOOM
RED
764
BY
726 RB 645 WR 765 0
AREA
A4/5
ABS
LOOM
BROWN
NO COLOUR
PIN
AREA 656
NG
I 8.A6
766 NO
2
II.A3 3
REARWARD HARNESS NO COLOUR 767 KB
338 OY 769 KB 3
YS
340 OC
771
BR
772 OR 773 OU
PIN 1 2 3 4 5 e
7 8 9 10 II 12 13
AREA I0.B4-I04
I2.BI I2.AI 8.AI 12.81
10.82-96
I0.C2-I00 IO.C3-I02
SHEET
14
AREA
B/CI
-4
«
NO COLOUR
PIN
AREA
774 YW 775 B
776
B
199
K
779 NS
I0.B2-92 I0.B3-IIO II.C4-II9
II.CI I0.B3-ID9
NO COLOUR
344 RIN 822 0 781 8 316 B
346 UIN
348 YU
785
NS
PIN
? 3 4 5 6 7 8 9 10 II 12 13 14 15 16
AREA
I2.A3 I0.D5 I0.B4-II0 I2.A3
I2.A3
I2.A3
10.84-109
'YD 0 0
D D
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SPL 105 SPL 106 SPL 107
16/0 D
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D
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SHEET
II
AREA
81
-SPL 97
-SPL 98
-
SPL 99
-
SPL 100
-
SPL 101
-
SPL 102
NO /89 790 791 792 793 794 795 796 797 643 641 798 799 800
COLOUf BW B B YG B BR BW B S
wu
p RK BR B
Pll 1 2 1 4 b 6
/
8 9 10 II 12 13 14
AREA
8.B4-66
8.B3-64
8.B2-63
IOCS I0.C5 I0.C5 I2.C3-14I I2.C2-I37 10.05 8.A4 8.A4 I0.B2-93 I0.C5 I0.C5
ILOGIC
EARTH
'
NO COLOUR AREA
1004 BK I0.B5-I0! 1005 BK I0.B2-95
(f
D
D
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D
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D
D
0
D
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D
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D
D
DCT D
D
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a
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0 13 24
AREA
C/OI
REARWARD HARNESS NO COLOUF 803 SLG 804 PC 805 PW 667 G 1 LC 335 OR 807 GB 808 K 809 YN 621 RU 810 BW 811 GW 336 0 813 LGO 814 OW 815 GP 816 OG 294
R
652
WU
330 LCO 797
S
304
YB
337
RN
PIN 1 ? 3 4 5 6 7 8 9 10 II 12 13 14 15 16 17 18 19 20 21 22 23 24
AREA 11.03
e.B2-6l
8.83-65
8.A6 8.BI I2.AI I0.C2-I0I I2.A5 I2.A5 8.C4 10.62-94 I0.B2-9I
12.
Al
10.82-97 I0.B2-99 II.C2-II5 10,82-98 I2.AI 8.A4 I2.AI I0.B4
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3
CZ
u
u
D
D
REARWARD HARNESS NO COLOUf 799
BR
794
BR
724
LGK
736 RIN 327 RIN
823
GR
792 YG 824 SR 800 8 793 8 737 UIN 326 UIN 826
SW
827
R
828
BG
829
RN
374 0 723 LGS 822 0 177 YW
PIN 1 2 3 4 4 5 6 7 8 9 10 II 12 12 13 14 15 16 17 IB 19 20 21 22 23
AREA I0.B4 I0.B4 I2.CI 9.B4 I2.AI
9.C2-79
I0.B4 11.03 I0.B4 I0.D4 9.B4 I2.A1 11.03
9.C4-84
I0.B5-I06
9.C3-80
I0.B5-III I1.B3-I16 I0.A6 10.82-92
Wiring
Diagram
Model
- Aston Martin DB7
Harness
Title - Bulkhead LHD - 3
Part
No. - B37-84635
Revision
- 0
Sheet
10 of 26-97 MY
Page 229 of 421
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
Page 231 of 421
^"^
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
Page 262 of 421
y/--^^^^3^
'—-p "^ Body and Trim
Roof Description
Volante Roof
Description
The system comprises an electrically driven hydraulic pump and two hydraulic rams for raising and lowering the
roof.
The pump is powered via two heavy duty changeover relays. Two further pairs of changeover relays power
the rear quarter windows (one pair for each window). The roof hydraulic pump is protected by a 30A fuse, the
windows by circuit breakers.
An electronic control module (ECM) is actuated by the roof switch on the centre console. The ECM controls the
operation of
both
the roof
and
rear quarter window circuits
so
that they can only be operated in
a
pre-programmed
manned.
When in operation, the ECM provides signals to the roof and to the rear quarter windows.
When the roof
switch
is moved into the open (Roof Down) position, the roof
and
rear windows move together until
approximately four seconds has elapsed. At this time, the ECM will remove power from the rear window circuits,
leaving the roof motor running. The roof motor will stop after 12 seconds (i.e. a further 8 seconds after the rear
window motors stop).
The signals will be removed from the rear window relay after 4 seconds and from the roof relay after 12 seconds
if the roof switch is held in either position for longer than 12 seconds.
In order to comply with legislation, the following features are built into the system:
If the roof switch is operated in either direction and then released before that operation is complete, the roof and
rear quarter windows will stop immediately. If, whilst the system is in operation, the ignition switch
is
turned to the
off position, the system will immediately stop.
If the roof switch is pressed again after pausing during a roof movement, the timing sequence will be as follows:
1.
If the previous direction is selected, the timing recommences from where it left off and will continue to
completion. If the ignition has been turned off, the timing will start from the beginning of its cycle.
2.
If theoppositedirection
is
selected,
the timing sequence will commence
from the beginning
of the newly selected
direction and continue to completion.
Roof and Rear Quarter Light Control
The following diagrams show the component location and the electrical control for the roof and rear quarter light
systems.
May 1996 7-7
Page 263 of 421
Body and Trim >/—^
^^^^5^
' ^ ^
Roof Components I -^' ^—^ -^-^
Roof Component Location
Roof Switch
Hydraulic Pump
ECM
Roof Up Relay
Roof Down Relay
LH Q Light Up Relay
LH Q Light Down Relay
RH Q Light Up Relay
RH Q Light Down Relay
Fuse and Circuit Breakers
Hydraulic Rams
Heated Rear Window Overide Switch
Figure 7. Roof
System
Component Location
7-8 May 1996