Aston Martin DB7 Vantage 1999 - 2003 Workshop Service Manual

Description Aston Martin DB7 Vantage 1999 - 2003 Workshop Service Manual

02.1999 / All Regions / 1 CD / Windows OS, MacOS, Linux / 32 & 64 bit

Aston Martin DB7 Vantage 1999 - 2003 PDF workshop service & repair manual

Language: English

Engine: 6.0L V12 313kW

SERVICE MANUAL CONTENT:

Engine Specification

Component

Block

Cylinder Bore Grade

Main Bearing Bore (without shells)

Crankshaft

Main Bearing Diameter

Main Bearing Clearance

Connecting Rod Bearing Diameter

Connecting Rod Bearing Clearance

Pistons

Piston Diameter Grade

Piston Clearance

Piston Ring Gaps

Ring Gap - Upper Compression Ring

Ring Gap - Lower Compression Ring

Ring Gap - Oil Control Ring Segments

Connecting Rods

Connecting Rod Bearing Diameter (with shells)

Piston Pin Clearance

Side Clearance

Cylinder Heads

Head Volume

Head Face-Roof Button

Valve Seat Width - Inlet

Valve Seat Width - Exhaust

Camshaft Bore

Camshaft Journals

Valves, Guides & Springs

Spring Force at 40mm Spring Height

Valve Guide Internal Diameter

Valve Guide Maximum Runout

Valve Stem Diameter - Inlet

Valve Stem Diameter - Exhaust

Valve Stem Clearance - Inlet

Valve Stem Clearance - Exhaust

Valve Face Maximum Runout

Valve Lash Adjusters

Bore

Outside Diameter

Clearance

Turning Torque

Guideline

A - Crankshaft and rear seal only 6 Nm

B - Crank, rear seal + pistons & rods 16-20 Nm

C - Crank, rear seal, pistons & rods + camshafts & tensioned chains

Crank Sensors

Air Gap

Cam Sensors

Air Gap

Spark Plugs

Type Dual Platinum Fine Wire

Gap

Torque

Fuel, Emission Control and Exhaust

Description

General

Fuel System Schematic Diagrams

Fuel Tank

Fuel Pumps

Evaporative Loss System

On-Board Refuelling Vapour Recovery (US Specification)

Fuel Rails and Injectors

Exhaust System

Engine Management

Fuel System Safety Precautions

Service Procedures

Depressurise the Fuel System

Fuel System - Pressure Test

Throttle Cables

Throttle Body and Adaptor

Inlet Manifold Removal

Air Filters

Mass Air Flow Meter

Fuel Rails and Injectors

Fuel Tank Draining

Fuel Tank Removal

Fuel Pump Removal

Fuel Filter Renewal

Exhaust System

Exhaust Manifolds

Transmission

Transmissions - General Description

Tremec T-56 Manual Gearbox

ZF 5 HP-30 Automatic Gearbox

Specifications

Transmission Components

Transmission Control Module

Auto Transmission

Solenoid/Clutch Application

Output Flange Oil Seal Renew

Torque Converter Removal

Automatic Transmission Fluid Check/Top-Up

Gear Shift Interlock Solenoid Removal

Gear Shift Lever Renew

Gear Selector Cable Assembly

Rotary Switch Removal

Speed Sensor Renew

Oil Pump Shaft Seal Renew

Shift Unit Removal

Regulator/Solenoid Valve Removal

Propeller Shaft Remove

Clutch Assembly Renew

Transmission Fluid Check and Top-up

Master Cylinder Renew

Clutch Hydraulic System Bleed

Manual Transmission - Removal

Propeller Shaft Remove

Oil Cooling Pump Removal

Pinion Shaft Oil Seal Renew

Output Shaft Assembly Renew

Output Shaft Bearing Renew

Hypoid Casing Rear Cover Seal Renew

Speedometer Sensor Adjust

Hypoid Unit Remove

Suspension and Steering

Front Suspension

Front Suspension - Description

Suspension Settings

Suspension Set-up

Ride Height and Suspension Geometry Checks

Upper Balljoint - Renew

Lower Balljoint - Renew

Front Hub Bearing - Renew

Bump Stops - Renew

Rebound Stops - Renew

Upper Wishbone - Renew

Lower Wishbone Renew

Front Suspension Mounting Bush - Renew

Front Suspension Rear Mounting - Renew

Front Shock Absorber - Renew

Front Road Springs - Renew

Front Anti-roll Bar - Renew

Anti-roll Bar Link Arm - Renew

Anti-roll Bar Bushes - Renew

Rear Suspension

Rear Suspension - Description

Hypoid - Description

Rear Suspension Height Check

Check and Adjust the Camber Angle

Rear Spring / Shock Absorber

Radius Arm Bushes Renew

Wishbone / Inner Fulcrum Mounting Bracket - Renew

Rear Suspension Unit Renewal

Rear Suspension Mountings

Anti-roll Bar Renew (Coupe only)

Rear Wheel Toe Adjustment

Drive Shaft Description

Drive Shaft Renew and Overhaul

Steering

Steering - Description

Front Wheel Toe Adjustment

Front Wheel Castor / Camber - Check and Adjust

Track Rod Ball Joint Renew

Upper Steering Column Renw

Power Assisted Steering System Bleed

Power Steering Rack Renew

Steering Rack Bushes Renew

Steering Rack Feed Hose Renew

Steering Rack Return Hoses Renew

Power Steering Rack Gaiter

Power Steering Pump Renew

Power Steering Fluid Cooler Renew (RHD only)

Power Steering Reservoir Renew

Brakes, Wheels and Tyres

Braking System

Brakes - General Description

Anti-lock Braking System / Traction Control System

Braking System Components

Brake Vacuum Booster

Tandem Master Cylinder

Brake Fluid Reservoir

Front Brake Calipers

Rear Brake Calipers

Handbrake

Anti-lock Braking System

ABS Modulator Unit

ABS Control Module

Wheel Speed Sensors

Hydraulic Operation

Non ABS Diagnostics

ABS Control Module Pin Connections

ABS Control Module - Quick Checks

ABS Diagnostics

Service Procedures

Brake Bleeding Procedure

Front Brake Caliper Renew

Front Brake Pads Renew

Front Brake Disc Renew

Fluid Reservoir Renew

Master Cylinder Assembly - Renew

ABS Modulator and Control Module Renew

Rear Brake Disc Renew

Rear Brake Pad Renew

Rear Brake Caliper Renewal

Handbrake Setting Procedure

Handbrake Shoes Renew

Wheels and Tyres

Specifications

General Information

Misalignment and Road Cambers Effects

Tyre and Wheel Balance

Irregular Wear and Tyre Damage

Road Wheel Removal and Refitting

Spare Wheel

Electrics

Service Procedures

Electrical Systems General Description

Procedures for Battery Disconnecton and Reconnection

Headlamp Unit Removal

Headlamp Alignment

Front Indicator/Parking/Fog Lamp Removal

Rear Lamp Cluster Removal

Side Repeater Lamps Removal

Side Marker Lamps - Federal Markets Only Removal

Windscreen Wiper Motor Removal

Alternator Removal

Starter Motor Removal

Column Switches Removal

Ignition Switch Removal

Instrument Panel Removal

Radio Removal

Air Conditioning and Switch Panel Removal

Window, Hood, Transmission Mode and Traction Control Switches

Seat Control Switch Panels Removal

Front Interior Lamps Removal

Rear Interior Lamps Removal

Front Seat Removal

Front Seat Runner Assembly Removal

Front Seat Rail Motor Removal

Lumbar Support Motor Removal

Seat Recline Motor

Seat Control Module

Door Edge Lamps

Supplementary Restraint System (SRS)

Driver Airbag

Passenger Airbag

Front Seat Belt Pretensioners

Occupant Restraint Module

Safety Precautions and Warnings

Emergency First Aid Procedures

Health and Safety

Scrapping Vehicles With Live Airbags

Scrapping Vehicles With Deployed Airbags

Disposal of Live Airbags

Disposal of Deployed Airbags

General Servicing Instructions

Drivers Airbag Module Renew

Passengers Airbag Module Renew

Occupant Restraint Module Renew

Pretensioner Assembly Renew

Airbag System Diagnostics

Airbag Disarming / Arming Procedures

Airbag Diagnostic Fault Codes

The Passive Anti-Theft System (PATS)

Description and Operations

PATS Functional Description

Fault Codes

PDU Procedures

Electrical Component Location and Wiring Information

Fuse and Relay Locations

Fuse Lists

Relay Location

Relay List

Wiring Harness Locations

How to Locate an Electrical Component

Component Location Index

Component Location Diagrams

Circuit Diagrams

Security System - Restricted Circulation

The Security System

RF Transponder Key Learning

Special Features Programming

Security Datalogger

Diagnostic Trouble Codes and Alarm History

Electrical Information from Chassis 300556/400557

Instrument Panel Diagnostics

Fusebox and Relay Chassis Location

Circuit Diagram List

Chassis and Body

Contents

Body Repair

Potential Risks

Precautions

General Repair Notes

Steel Body Parts - Repair, Remove and Replace

RTM Body Parts

Volante Roof

Roof Removal/Replacement

Roof Hydraulic Control System

Bleeding the Roof Hydraulic System

Rear Quarter Window Renewal

Rear Quarter Glass Adjustment

Rear Quarter Window Lift Motor - Left Hand

Rear Quarter Window Lift Motor - Right Hand

Door Glass Adjustment

Roof Sealing and Wind Noise

Cleaning of Alcantara Trimmed Roof Lining and Interior Components

Body Panel and Trim Removal

Coupe Body Panels

Volante Body - Front End

Volante Body - Rear End

Filler Flap

Door Panels

Door Lock and Latch

Bonnet

Front Wings

Boot Lid

Body Fittings

Front Bumper

Rear Bumper - European

Rear Bumper - Federal

Glass

Door Glass

Volante Rear Quarter Glass

Facia and Trim

Coupe Centre Console

Volante Centre Console

Door Casings and Fittings

Volante Seals

Coupe Door Seals

Upper Trim and Roof

Volante Upper Trim and Roof

Volante Roof Lift Pump and Header Trim

Front Seats and Belts

Rear Seats and Belts

Air Conditioning

General Description

Specifications

System Description

Special Servicing Tools and Equipment

Working Practices

General

Handling Refrigerant

Handling Lubricating Oil

System Maintenance

The Air Conditioning System

Temperature Control

Fan Speed / Defrost Switch

Face Level Temperature Differential

Refrigeration Cycle

System Protection

General System Procedures

Leak Test

Charge Recovery (System Depressurisation)

Evacuating the System

Adding Compressor Lubricating Oil

Adding Refrigerant

Functional Check

System Trouble Shooting

Air Conditioning Control Module (ACCM)

In-Car Controls

Temperature Demand Switch

Face Level Differential Controller

Air Conditioning Mode Switch

Fan Speed Control Switch

Temperature Sensors

Ambient Temperature Sensor

Evaporator Sensor

Motorised In-Car Aspirated Sensor

Water Temperature Switch

Blower Motors

Potentiometers

Servo Motors

Vacuum System

Pressure/Temperature Graphs

System Fault Diagnosis

Fault Finding

System Fault Diagnosis

Blower Motor Test

Open Water Temperature Switch Leads

Short Water Temperature Switch Leads

Refrigeration

Compressor

Compressor Clutch Control

Trinary Switch

Condenser

Receiver-Drier

Expansion Valve

Evaporator

Visteon Compressor FS

Manifold Gauge Set

System Checking with 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

Restriction in the High Pressure Side

Air Conditioning Repair Procedures

Recover, Recycle and Recharge the Refrigerant

Recovering Refrigerant

Evacuating and Recycling the Refrigerant

Recharging the System

Torque Levels for the Hose Connections

Compressor Oil Level Check

Compressor Removal/Renewal

Clutch Field Coil Renew

Expansion Valve Renew

Hose-Compressor to Evaporator Renew

Air Conditioning Unit Renew

Evaporator Unit Renew

Upper Feedback Potentiometer Renew

Lower Feedback Potentiometer Renew

Upper Flap Motor Assembly Renew

Lower Flap Motor Assembly Renew

Ambient Temperature Sensor Renew

Blower Motor Driver Side Renew

Blower Motor Passenger Side Renew

Blower Assembly Driver/Passenger Side Overhaul

Blower Motor High Speed Relay Renew

Water Temperature Switch Renew

Heater Matrix Renew

Aston Martin Diagnostic System

Introduction

The Aston Martin Diagnostic System

Diagnostic System Cables

Base Station Installation

Problem Solving

Genrad Service

The Aston Martin Lagonda Diagnostic System User Guide

PDU Power

Software

Engine Diagnostics (DB7 Vantage)

Air Conditioning Diagnostics

Diagnostic Sockets

Establishing Communications

System Menu Selections

Datalogger

Diagnostic Trouble Codes

System Specific Tests

Exit

PDU Use

Engine Diagnostics

Diagnostic Trouble Codes (DTCs)

KOEO and KOER On Demand Self Tests (ODST)

OBD II Readiness Test Monitor

Throttle Position Sensor Track Test

Output State Control

Transmission Diagnostics

Engine and Transmission Datalogger - (PIDs) Parameter Identifications

Diagnostic Trouble Codes

Freeze Frame Data

Climate Control Diagnostics

Anti-Lock Braking Diagnostics

Passive Anti Theft (PATS) Diagnostics

Security System Diagnostics

Airbag / Pretensioner Diagnostics

Airbag Diagnostic Trouble Code Monitor

Print Facility

Aston Martin PDU - PC Software

Self Test Adaptor

Print Screen

Print Trace

Image Capture and Download

Digital Multimeter

Datalogger

Introduction

Serial Communication

Parallel Communication

Using the Datalogger

Datalogger Example

Training

OBD II Scan Tool

Accessing Freeze Frame Data

User Self Test

System Setup