Exhaust Tip

Remove and replace the exhaust tip(s) on a 2009 Aston Martin DB9, including proper hanger disconnection and sealing.

Warnings

Tools required

Parts

• Exhaust tip assembly (left or right as needed) × 1 — Use OEM Aston Martin specification or aftermarket equivalent
• Exhaust flange gasket × 1 — Use OEM specification

Preparation

1. Ensure engine and exhaust system are completely cold to the touch
2. Park vehicle on level, solid ground and apply parking brake
3. Place wheel chocks at front wheels
4. Raise rear of vehicle using floor jack at designated rear jacking points near differential
5. Support vehicle securely on jack stands rated for vehicle weight (approximately 1,800 kg)
6. Verify vehicle stability before working underneath
7. Prepare work area with adequate lighting to view exhaust routing

Procedure

1. 1

   Access the exhaust tip assembly
   Position yourself under the rear of the vehicle with clear access to the exhaust outlet area. Identify the exhaust tip you're replacing (left or right side, inner or outer position). The DB9 quad-tip design has two tips per side exiting through the rear valance. Inspect the tip mounting configuration to confirm the flange connection point and any rubber hanger attachments.
2. 2

   Apply penetrating oil to fasteners
   Spray penetrating oil liberally on all visible fasteners at the exhaust tip flange connection. The tip connection method should be confirmed on this specific vehicle—DB9 exhaust tips may attach via a flange, a sleeve clamp, or be integral to the rear muffler/backbox. Inspect to determine the actual fastener type and count before proceeding. Also spray any hanger bracket mounting points if rubber isolators are present. Allow penetrating oil to soak for 10-15 minutes on heavily corroded fasteners. Note: The tip-to-pipe connection may use a band/sleeve clamp or a bolted flange depending on configuration; inspect the actual joint to confirm fastener type and count before proceeding.
3. 3

   Disconnect rubber exhaust hangers (if equipped)
   If the exhaust tip assembly is supported by rubber hanger isolators, use a prying motion to work the rubber grommet off the hanger hook. The hanger typically connects between the tip assembly and the chassis-mounted bracket. Some DB9 configurations may have the hanger further upstream rather than at the tip itself; inspect and disconnect as needed. Apply leverage carefully to avoid tearing the rubber isolator if reusing.
4. 4

   Remove exhaust tip flange bolts
   Using the appropriate driver, remove the flange or clamp fasteners connecting the exhaust tip to the intermediate exhaust pipe. Confirm the exact fastener count and size on this vehicle before removal, as this is unverified for the 2009 DB9. If a bolted flange is present, the bolts may thread into captive nuts on the opposite flange face; confirm the actual joint configuration on this vehicle, as DB9 tips are commonly secured by a band/sleeve clamp rather than a bolted flange. Support the tip assembly with one hand while removing the final fastener to prevent it from dropping. Set hardware aside and inspect condition—replace if threads are damaged or heads are rounded. Note: Using the appropriate Torx driver, remove the flange bolts or clamp hardware connecting the exhaust tip to the intermediate exhaust pipe. Confirm the exact fastener count, type, and Torx/socket size against the factory workshop manual before proceeding, as the DB9 tip mounting may use a clamp band rather than a bolted flange. Note: Confirm the fastener type and size at the tip joint before removal; it may be a band clamp (requiring a socket/nut driver) rather than Torx flange bolts. Remove the fasteners that secure the exhaust tip to the intermediate exhaust pipe.
   Torque spec

   Exhaust Flange Bolt24 Nm (18 lb-ft)
5. 5

   Separate and remove exhaust tip
   Pull the exhaust tip rearward to separate the flange connection. The tip may be stuck due to carbon buildup and heat bonding. Gently twist and pull with steady force to break the seal. Once separated, remove the exhaust tip from the vehicle. Note the orientation and any alignment features on the flange faces for reinstallation.
6. 6

   Clean flange surfaces
   Thoroughly clean both the tip flange and the mating pipe flange using a wire brush or scraper. Remove all carbon deposits, old gasket material, and corrosion to ensure a proper seal. Inspect both flanges for warping or damage—minor surface corrosion is acceptable, but deep pitting or distortion may cause exhaust leaks. Clean the bolt threads and flange bolt holes with a wire brush.
7. 7

   Install new flange gasket
   Position the new exhaust flange gasket onto the intermediate pipe flange. The gasket should fit snugly over the pipe end with bolt holes aligned. Some gaskets have a specific orientation or coating direction—check for manufacturer markings indicating which side faces outward. Ensure the gasket sits flat without wrinkles or gaps.
8. 8

   Install new or replacement exhaust tip
   Align the new exhaust tip flange with the gasket and intermediate pipe flange. Verify the tip is oriented correctly with any logos, cuts, or styling features positioned as desired. Thread both flange bolts in by hand to hold the assembly in position, but do not tighten yet. The tip should hang with minimal gap at the flange connection.
9. 9

   Apply anti-seize and torque flange bolts
   Only apply anti-seize compound to the flange bolt threads if the factory torque specification is a lubricated (wet) value; otherwise install dry. If anti-seize is used, confirm the appropriate wet torque figure in the workshop manual. Using a torque wrench, tighten the fasteners in a cross pattern (alternating between them) to the manufacturer-specified torque. Verify the correct torque spec against Aston Martin documentation, as the value is unconfirmed for this platform. This ensures even clamping force on the gasket and prevents warping. If a bolted flange is present, verify all fasteners reach the same torque setting and feel equally snug; if a band clamp is used, tighten the clamp nut to the specified torque. Note: If the manufacturer torque spec is a dry value, do not apply anti-seize, as it will cause over-clamping. Only apply a thin coating of anti-seize if the torque spec is specified for lubricated threads. Note: Using a torque wrench, tighten the bolts in a cross pattern (alternating between the two bolts) to the manufacturer-specified torque. Verify the exact exhaust flange torque value against the Aston Martin workshop manual before final tightening. Note: If the manufacturer permits, apply a thin coating of high-temperature anti-seize compound to the fastener threads; note that torque values may be specified for dry threads, so adjust accordingly. Note: Using a torque wrench, tighten the fasteners evenly (in a cross pattern if multiple bolts) to the manufacturer-specified torque; verify the exact value in Aston Martin service documentation before final tightening.
   Torque spec

   Exhaust Flange Bolt24 Nm (18 lb-ft)
10. 10

    Reconnect exhaust hangers
    If rubber hanger isolators were disconnected in Step 3, reconnect them now. Work the rubber grommet back onto the chassis-mounted hanger hook using a prying or levering motion. Ensure the hanger is fully seated and the exhaust tip is properly supported without excessive strain on the flange connection. The exhaust should hang with even spacing from the rear valance opening.
11. 11

    Verify tip alignment and clearance
    Visually inspect the installed exhaust tip to confirm it is aligned properly with the rear valance cutout and parallel to adjacent tips. Check for adequate clearance (minimum 10-15mm) between the tip and surrounding bodywork, diffuser elements, or suspension components. Gently push on the tip to verify it has normal flex in the hanger system without binding or contact points.

Reassembly

1. Lower vehicle from jack stands using floor jack
2. Remove jack stands and lower vehicle completely to ground
3. Remove wheel chocks and return tools to storage
4. If replacing multiple tips, repeat procedure for remaining assemblies

Verification

• Start engine and allow to idle—listen for exhaust leaks at the flange connection (hissing or ticking sounds indicate poor seal)
• Visually inspect flange area while engine is running for any escaping exhaust gases (visible vapor or soot streaking)
• Rev engine slightly and confirm no abnormal rattling or contact between tip and bodywork
• Verify exhaust tip alignment from rear view—all tips should appear symmetrical and evenly spaced
• After initial heat cycle, re-check flange bolt torque when cool to ensure gasket has seated and no loosening has occurred

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