Engine R&R

Complete removal and reinstallation of the 6.0L V12 engine from a 2009 Aston Martin DB9, including disconnection of all electrical, fuel, cooling, and exhaust systems, separation from the transaxle, and extraction from the engine bay.

Warnings

Tools required

Parts

• Engine oil drain plug crush washer × 1 — Use OEM specification
• Engine coolant × 3 — OAT 50/50 premix
• Engine oil and filter × 1 — 5W-30 specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Exhaust flange gaskets × 2 — Use OEM specification
• AC O-ring seal kit × 1 — For compressor lines
• Intake manifold gaskets (if disturbed) × 1 — Use OEM specification
• Fuel line O-rings × 1 — Use OEM specification
• Coolant hose clamps (assorted) × 10 — Replace any reused clamps
• Anti-seize compound × 1 — High-temperature nickel-based

Fluids

• engine_oil — 10.5 qt
• coolant — 10.5 qt
• transmission_auto — 9.5 qt
• power_steering — 1.2 qt

Preparation

1. Position vehicle on level ground or lift with sufficient clearance to work underneath.
2. Disconnect negative battery cable, then positive cable. Remove battery from vehicle.
3. Remove engine cover panels and underbody splash shields to access all engine mounting points.
4. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls.
5. Drain engine coolant into appropriate container by opening radiator drain and lower hose.
6. Drain engine oil and remove oil filter.
7. Recover AC refrigerant using certified recovery equipment.
8. Document or photograph all electrical connector locations, vacuum routing, and cable positions before disassembly.

Procedure

1. 1

   Remove front fascia and cooling system components
   Remove front bumper cover by releasing fasteners along bottom edge, wheel well liners, and upper radiator support. Disconnect fog light connectors. Remove radiator grille assembly. Disconnect radiator inlet and outlet hoses at radiator. Remove upper radiator support brackets. Disconnect cooling fan electrical connectors and remove fan assembly. Remove radiator mounting bolts and lift radiator from vehicle. Remove AC condenser if necessary for clearance.
2. 2

   Disconnect fuel system and intake components
   Disconnect fuel supply and return lines at engine bay connections using appropriate disconnect tools. Cap all open fuel lines immediately. Remove engine intake duct from throttle bodies. Disconnect throttle cable(s) and cruise control cable if equipped. Disconnect vacuum lines from intake manifold, brake booster, and fuel pressure regulator. Label all connections. Remove intake plenum cover if present to access fuel rail connections. Disconnect fuel injector harness connectors.
3. 3

   Disconnect AC compressor and power steering pump
   Disconnect AC compressor electrical connector. Remove AC line mounting bolts from compressor and cap all openings immediately to prevent contamination. Remove serpentine belt by releasing tensioner. Unbolt AC compressor and secure it to chassis with mechanic's wire without allowing lines to support its weight. Disconnect power steering pressure and return lines at pump. Remove power steering pump mounting bolts and secure pump aside without stressing hoses.
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Power Steering Pump Bolts25 Nm (18 lb-ft)
4. 4

   Remove alternator and starter motor
   Disconnect alternator electrical connections (main power cable and harness connector). Remove alternator mounting bolts and remove alternator from engine. From underneath vehicle, disconnect starter motor electrical connections (main power cable and trigger wire). Remove starter mounting bolts and extract starter from its mounting at the engine rear.rter motor electrical connections (main power cable and trigger wire). Remove starter mounting bolts and extract starter from the engine.
   Torque spec

   Alternator Mounting Bolts25 Nm (18 lb-ft)

   Starter Mounting Bolt43 Nm (32 lb-ft)
5. 5

   Disconnect exhaust system
   From underneath vehicle, apply penetrating oil to all exhaust fasteners and allow to soak. Remove exhaust manifold-to-catalytic converter flange nuts on both banks. Support exhaust system weight with jack or stand. Remove any exhaust hangers or brackets connecting exhaust to the torque tube housing or chassis. Lower exhaust system enough to clear engine during removal.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
6. 6

   Disconnect engine electrical harnesses
   Disconnect main engine control module (ECM) connectors. Disconnect all sensor connectors including: crankshaft position sensor, camshaft position sensors (bank 1 and bank 2), oxygen sensors (all positions), knock sensors, oil pressure sensor, coolant temperature sensors, and throttle position sensors. Disconnect ignition coil harness connectors for all 12 cylinders. Remove any harness mounting brackets securing engine harness to block. Route harness clear of engine to prevent snagging during removal.
7. 7

   Disconnect cooling system hoses and heater lines
   Disconnect upper and lower radiator hoses at engine. Disconnect heater inlet and outlet hoses at firewall connections. Disconnect coolant overflow/expansion tank hose. Remove any coolant bypass hoses or auxiliary coolant lines. Disconnect oil cooler lines if equipped with external engine oil cooler. Cap or plug all open coolant passages to prevent debris entry.
8. 8

   Separate transmission from engine
   Separate the engine from the torque tube assembly. Support the torque tube appropriately. Remove the engine-to-torque-tube bellhousing/adapter bolts. On manual or Touchtronic (automated single-clutch) cars the clutch assembly remains with the torque tube/transaxle; there is no torque converter or flexplate at the engine. Disconnect any ground straps, then separate the engine from the torque tube input, ensuring the torque tube is fully supported.There is no torque converter or flexplate at the engine on this platform. The engine separates from the torque tube/clutch assembly at the engine rear flange; ensure the torque tube and rear-mounted transaxle remain fully supported as the engine is separated. Note: Note that the Touchtronic transmission is an automated single-clutch manual (no torque converter); handle the clutch/flywheel assembly accordingly. Note: Support the torque tube assembly securely. Disconnect the engine from the torque tube at the engine rear flange. Remove the fasteners securing the clutch/drive plate and torque tube coupling to the rear of the crankshaft. Note the clutch alignment and index the driveshaft coupling if required. Separate the engine from the torque tube so the engine can be lifted without stressing the driveshaft or rear-mounted transaxle, ensuring the torque tube is fully supported. Note: Separate engine from torque tube Note: Support the torque tube securely. Remove the torque tube-to-engine bellhousing/adapter bolts. Disconnect any ground straps between engine and torque tube. Note the coupling alignment between the engine driveplate and the torque tube input. Separate the engine from the torque tube coupling, ensuring the torque tube remains fully supported during and after separation. Note: Engine-to-Torque-Tube Coupling Bolts Note: Engine Rear Flange Bolts
   Torque spec

   Transmission-to-Engine Bolts45 Nm (33 lb-ft)

   Flywheel Bolts95 Nm (70 lb-ft)
9. 9

   Disconnect remaining engine-mounted accessories
   Disconnect any remaining vacuum lines, breather hoses, or evaporative emission lines. Disconnect any chassis ground straps from engine block. Remove any brackets or supports connecting engine accessories to chassis or firewall. Verify all connections between engine and vehicle have been disconnected by visual inspection from all angles.
10. 10

    Attach engine hoist and remove engine mounts
    Attach engine hoist chains to factory lifting points on cylinder heads or use appropriate lifting brackets designed for this engine. Verify the factory lifting point locations for this engine against Aston Martin service documentation before attaching the hoist; use appropriate lifting brackets if dedicated eyes are not present. Adjust chain length to achieve initial balance with engine leveler. Apply slight upward tension to hoist to transfer engine weight from mounts. Remove engine mount-to-frame bolts on both left and right mounts from underneath vehicle. Remove engine mount-to-block bolts on both sides. Inspect that all mount hardware is removed. Note: Attach engine hoist chains to verified OEM lifting points or use appropriate lifting brackets designed for this engine. Confirm lifting point locations against Aston Martin workshop documentation before applying load.
    Torque spec

    Engine Mount-to-Block Bolts49 Nm (36 lb-ft)

    Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
11. 11

    Extract engine from vehicle
    Slowly raise engine while monitoring clearance on all sides. The engine will need to be angled slightly as it lifts to clear the torque tube coupling and subframe structure. Use leveling attachment to adjust angle as needed. Guide engine forward and upward simultaneously, clearing radiator support, fender aprons, and firewall. Have assistant guide engine to prevent contact with body panels. Once engine clears all body components, raise fully and move hoist away from vehicle. Place engine on sturdy engine stand with appropriate V12 mounting adapters.
12. 12

    Inspect and prepare for reinstallation
    With engine removed, inspect engine bay for any damaged components, deteriorated hoses, or fluid leaks that should be addressed. Clean engine mounting surfaces on chassis. Inspect engine mounts for wear, cracking, or fluid saturation and replace if necessary. If engine was removed for repairs, complete all necessary service work. Replace all gaskets that were disturbed during removal including exhaust manifolds. Clean all mating surfaces thoroughly. Install new oil filter and drain plug with new crush washer.

Reassembly

1. Reinstallation is reverse of removal with the following critical points:
2. Ensure transmission input shaft/torque converter alignment is correct before mating engine to transmission. Rotate crankshaft or transmission input to align splines if necessary.
3. Torque all fasteners to specifications in the order listed, using star pattern for multi-bolt flanges.
4. Apply anti-seize compound to exhaust manifold studs before installing nuts.
5. Install new AC O-rings on compressor connections and apply appropriate refrigerant oil before connecting lines.
6. Refill engine with fresh oil and filter before starting.
7. Refill cooling system with 50/50 OAT coolant mix. Bleed cooling system according to manufacturer procedure to prevent air pockets.
8. Recharge AC system to proper refrigerant capacity after verifying system holds vacuum.
9. Double-check all electrical connections are secure and properly seated.
10. Verify transmission fluid level after engine installation and top up if necessary.
11. Check power steering fluid level and top up with CHF 11S as needed.

Verification

• Before starting engine, verify all fluid levels are correct: engine oil, coolant, transmission fluid, power steering fluid, and brake fluid.
• Perform visual inspection of entire engine bay to verify no tools, rags, or fasteners were left in engine compartment.
• Verify all electrical connectors are seated and locked, all vacuum lines are connected, and all ground straps are secured.
• Reconnect battery cables (positive first, then negative).
• Turn ignition to ON position without starting and verify no warning lights indicate system faults. Clear any stored codes if necessary.
• Prime fuel system by cycling ignition on/off several times without cranking.
• Start engine and immediately verify oil pressure builds within 3-5 seconds.
• Check for any fuel, coolant, or oil leaks while engine is running.
• Allow engine to reach operating temperature and verify cooling fans operate correctly.
• Check for exhaust leaks at manifold connections.
• Test drive vehicle to verify normal operation, smooth acceleration, proper transmission engagement, and no abnormal noises or vibrations.
• Recheck all fluid levels after test drive and top up as necessary.
• Verify AC system operates correctly and produces cold air.

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