Bumper Reinforcement - Front

This procedure covers removal and installation of the front bumper reinforcement bar on a 2009 Aston Martin DB9, requiring removal of the front bumper cover and access to crash structure mounting points.

Warnings

Tools required

Parts

• Front bumper reinforcement bar × 1 — Use OEM specification
• Bumper cover mounting clips (if damaged) × 1 — Use OEM specification
• Reinforcement bar mounting hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake.
2. Place wheel chocks behind rear wheels.
3. Allow engine and exhaust system to cool completely if vehicle has been driven.
4. Disconnect negative battery terminal to prevent accidental airbag deployment (if working near sensor zones).
5. Raise front of vehicle using floor jack and support securely on jack stands at manufacturer-recommended lift points.
6. Remove both front wheels to improve access to bumper cover mounting points and wheel arch liners.

Procedure

1. 1

   Remove front wheel arch liners
   Working in each front wheel well, locate and remove the Torx fasteners securing the wheel arch liner to the bumper cover and body. There are typically multiple fasteners along the rear edge of the liner and along the bumper interface. Carefully pull the liner away from the bumper cover to expose the side mounting points of the bumper. The liners may be partially attached with push-clips; use trim removal tools to release these without breaking the clips.
2. 2

   Remove front bumper cover lower fasteners
   From underneath the vehicle, locate the Torx or E-Torx fasteners securing the lower edge of the bumper cover to the subframe and undertray. Remove these fasteners completely. Note the location of any alignment dowels or guide pins for reinstallation. Check behind the bumper cover for any wiring harnesses connected to fog lights or parking sensors and prepare to disconnect these.
   Torque spec

   Bumper Cover Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect bumper electrical connections
   Locate the wiring harness connectors for fog lights, daytime running lights, and parking sensors (if equipped). Press the release tabs and disconnect each connector. Route the wiring harnesses clear of the bumper cover to prevent snagging during removal. Use masking tape to secure loose harnesses to the body temporarily.
4. 4

   Remove bumper cover upper and side fasteners
   Open the hood and locate the Torx fasteners securing the top edge of the bumper cover to the radiator support and fender brackets. Remove these fasteners. Working from the wheel arch openings, remove the Torx fasteners securing each side of the bumper cover to the fender and body structure. There are typically 3-4 fasteners per side along the vertical edge.
   Torque spec

   Bumper Cover Bolts10 Nm (7 lb-ft)
5. 5

   Remove front bumper cover
   With all fasteners removed and electrical connections disconnected, carefully pull the bumper cover forward and away from the vehicle. The cover may have alignment pins that require slight upward or downward movement to disengage. Have an assistant support the opposite end to prevent the cover from flexing or dropping. Place the bumper cover on a clean, padded surface to prevent scratching.
6. 6

   Access front bumper reinforcement bar
   With the bumper cover removed, the aluminum front bumper reinforcement bar is now visible. This bar spans horizontally across the front of the vehicle and is mounted to the front frame rails or crash box assemblies on each side. Inspect the bar and mounting points for any signs of damage, corrosion, or previous repair.
7. 7

   Disconnect any auxiliary components
   Check if any auxiliary components are mounted to the reinforcement bar, such as cooling duct brackets or sensor mounts. Disconnect any electrical connections and remove any fasteners securing these components to the reinforcement bar. These components may need to be transferred to the new reinforcement bar.
8. 8

   Mark reinforcement bar alignment
   Before removing the reinforcement bar, use masking tape or a marker to indicate the current position of the bar relative to the mounting brackets on each side. This will help ensure proper alignment during reinstallation and maintain correct bumper-to-body gaps.
9. 9

   Remove bumper reinforcement bar mounting fasteners
   Locate the mounting bolts securing each end of the reinforcement bar to the frame rails or crash box assemblies. These are typically large Torx or E-Torx bolts; verify the exact count and location of the reinforcement bar mounting bolts per Aston Martin OEM documentation before removal. Support the reinforcement bar with one hand or have an assistant hold it while removing the fasteners. Remove all mounting bolts completely. Note: These are typically large Torx or E-Torx bolts; the exact count and location of the reinforcement bar mounting bolts per side MUST be confirmed against Aston Martin OEM workshop documentation before removal — do not assume a count. Note: These are typically large Torx or E-Torx bolts; the exact count per side must be confirmed against Aston Martin service documentation (the DB9 crash-box/reinforcement mounting bolt count is not verified here).
   Torque spec

   Body Panel Bolts25 Nm (18 lb-ft)
10. 10

    Remove front bumper reinforcement bar
    With all mounting fasteners removed, carefully lift the reinforcement bar away from the vehicle. The bar is heavy and may have locating pins or slots that require specific movement to disengage. Place the removed bar in a safe location. Inspect the mounting surfaces on the frame rails for any damage, corrosion, or misalignment that should be addressed before installing the new bar.
11. 11

    Prepare new bumper reinforcement bar
    Unpack the new reinforcement bar and inspect it for shipping damage. Transfer any auxiliary components, brackets, or sensors from the old bar to the new bar if they are not damaged and are reusable. Ensure all mounting surfaces on the new bar are clean and free of protective coatings that might interfere with proper torquing.
12. 12

    Install new bumper reinforcement bar
    Position the new reinforcement bar onto the mounting points on the frame rails or crash boxes, aligning it with the marks made during removal. Ensure any locating pins or alignment features are properly seated. Start all mounting bolts by hand to ensure proper thread engagement before tightening. Have an assistant support the bar during this process to maintain alignment.
    Torque spec

    Body Panel Bolts25 Nm (18 lb-ft)
13. 13

    Torque reinforcement bar mounting fasteners
    Using a torque wrench, tighten the reinforcement bar mounting bolts to specification in a cross-pattern sequence (alternating from left to right side) to ensure even seating. Torque all fasteners to the OEM-specified value for the reinforcement bar mounting bolts (verify in Aston Martin workshop documentation — do NOT assume 25 Nm, as these structural crash-box fasteners typically require a significantly higher torque). Verify that the bar is seated flush against all mounting surfaces and that alignment marks match the original position. Note: Torque all fasteners to the Aston Martin specified value (verify in the workshop manual before final tightening). Note: Using a torque wrench, tighten the reinforcement bar mounting bolts to specification in a cross-pattern sequence (alternating from left to right side) to ensure even seating. Torque all fasteners to the Aston Martin OEM-specified value for the front reinforcement bar mounting bolts (verify in service documentation — do NOT assume a generic value, as these are structural crash-bar fasteners typically torqued well above 25 Nm). Verify that the bar is seated flush against all mounting surfaces and that alignment marks match the original position.
    Torque spec

    Body Panel Bolts25 Nm (18 lb-ft)
14. 14

    Reinstall auxiliary components
    Reconnect and secure any auxiliary components that were removed from the reinforcement bar, such as sensor mounts or cooling duct brackets. Note: the 2009 DB9 uses fixed cooling ducts, not active grille shutters. Reconnect all electrical connections and verify they are fully seated and locked.
15. 15

    Reinstall front bumper cover
    With an assistant, carefully position the bumper cover onto the vehicle, aligning the mounting points and any locating pins with their corresponding holes in the body and fender structures. Ensure the cover is properly seated before installing fasteners. Start with the upper fasteners at the radiator support, then install the side fasteners from the wheel arch areas, and finally install the lower fasteners from underneath. Torque all bumper cover fasteners to the OEM-specified value per Aston Martin workshop documentation (small cover fasteners are typically low torque, approximately 8-10 Nm, but verify). Note: Torque all bumper cover fasteners to the Aston Martin specified value (verify in the workshop manual before final tightening). Note: Torque all bumper cover fasteners to the Aston Martin OEM-specified values (approximately 10 Nm / 7 lb-ft for small trim fasteners is typical, but verify in service documentation).
    Torque spec

    Bumper Cover Bolts10 Nm (7 lb-ft)
16. 16

    Reconnect bumper electrical connections
    Reconnect all wiring harness connectors for fog lights, daytime running lights, and parking sensors. Ensure each connector clicks into place and is fully seated. Remove any masking tape used to secure harnesses during removal.
17. 17

    Reinstall wheel arch liners
    Position each wheel arch liner back into place, ensuring it fits properly behind the bumper cover edge. Install all Torx fasteners and push-clips to secure the liner. Verify that the liner does not interfere with suspension or steering components.
18. 18

    Reinstall wheels and lower vehicle
    Reinstall both front wheels and torque lug nuts to manufacturer specification. Lower the vehicle from jack stands and perform a final torque check on all lug nuts with the vehicle on the ground. Reconnect the negative battery terminal if it was disconnected.

Reassembly

1. Reinstall components in reverse order of removal, ensuring all electrical connections are secure and properly routed.
2. Verify all bumper cover fasteners are torqued to specification to prevent rattles and ensure proper alignment.
3. Check bumper-to-body panel gaps on both sides and at the hood line to ensure proper alignment before final tightening.
4. If parking sensors were disconnected, verify proper operation after reconnecting the battery.

Verification

• Visually inspect bumper cover alignment and panel gaps around entire perimeter of bumper.
• Test operation of fog lights, daytime running lights, and parking sensors (if equipped) to ensure all electrical connections are functioning.
• Gently push on the center and edges of the bumper cover to verify it is securely fastened with no excessive movement.
• Road test vehicle at low speed and verify no rattles or unusual noises from the front bumper area.
• Re-check torque on all reinforcement bar mounting bolts after first 50 miles of driving.

More procedures for this vehicle