Freeze Plug - Single

Replace a single freeze plug on the 2009 Aston Martin DB9 6.0L V12 engine, requiring partial engine access and coolant system draining.

Warnings

Tools required

Parts

• Freeze plug (cup type) × 1 — Use OEM specification - size depends on location
• Engine coolant (OAT 50/50 premix) × 1 — Use OEM specification
• Freeze plug sealant (high-temp anaerobic) × 1 — Permatex 51817 or equivalent
• Oil filter × 1 — Use OEM specification if draining oil
• Engine oil 5W-30 × 1 — Use OEM specification if draining oil

Fluids

• coolant — 10.5 qt
• engine_oil — 10.5 qt

Preparation

1. Verify freeze plug location and accessibility. Front bank plugs typically accessible from wheel well; rear bank plugs may require subframe lowering or engine tilting.
2. Allow engine to cool completely (minimum 4 hours after last operation).
3. Disconnect battery negative terminal and isolate cable.
4. Raise vehicle on lift or secure on jack stands at all four corners at working height.
5. Remove engine undertray panels (Torx fasteners, typically T30).
6. Place coolant drain pan under engine and open coolant drain at radiator and engine block drain plug.
7. Relieve residual cooling system pressure by slowly opening expansion tank cap once system is cool.
8. Photograph all connectors, hose routing, and component positions for reassembly reference.

Procedure

1. 1

   Drain cooling system
   Open radiator drain valve at lower radiator tank. Remove engine block coolant drain plug(s) if equipped, or disconnect lower coolant hose to drain the block per OEM procedure (location and fastener size per OEM documentation). Allow system to drain completely into collection pan. If freeze plug location is low on block and oil contamination is evident, drain engine oil as well to prevent dilution. Note: Remove engine block coolant drain plug(s) (location and fastener size per OEM specification for the AM11 V12 block). Allow system to drain completely into collection pan. Note: If equipped, remove engine block coolant drain plug (location and size per OEM documentation).
2. 2

   Remove wheel and inner fender liner for access
   Remove the wheel on the side corresponding to the freeze plug location. Remove inner fender liner by extracting Torx fasteners (typically T25 and T30) and press-fit clips. Work liner free from wheel arch to expose engine bay access. On driver side, this provides access to front bank plugs; passenger side accesses rear bank front-most plugs.
3. 3

   Remove obstructing components
   Based on freeze plug location, remove components blocking access. Common obstructions: alternator (E-Torx bolts and electrical connectors), power steering reservoir and lines, coolant pipes and hoses, engine harness brackets, and accessory drive components. Label all connectors and hardware by location. For rear bank access, you may need to disconnect engine mounts and tilt engine using support fixture - see step 4 if required. Note: Use a freeze plug sealant/retaining compound per manufacturer specification (verify exact part number) Note: Side-to-bank access mapping must be verified against OEM documentation for the specific freeze plug location before proceeding. Note: Verify correct Permatex product against manufacturer documentation for core/freeze plug retention Note: High-temp anaerobic freeze plug/core plug retaining compound (verify exact manufacturer part number against product documentation)
4. 4

   Support and tilt engine if necessary
   If freeze plug is inaccessible without engine movement (typical for rear bank lower plugs), install engine support fixture across engine bay or attach hoist to engine lift points. Remove engine mount fasteners on the side requiring access (count, fastener type/size, and torque per OEM specification — verify before proceeding). Carefully raise or tilt engine 2-3 inches to create clearance. Do not exceed 5-degree tilt angle to avoid stressing attached hoses and wiring. Note: Remove engine mount fasteners on the side requiring access (quantity, drive type, and torque per OEM specification — verify before proceeding). Carefully raise or tilt engine only as far as needed to create clearance, avoiding stress on attached hoses and wiring; follow OEM-specified maximum tilt limits. Note: Remove engine mount fasteners on the side requiring access (count, drive type, and size per OEM documentation). Note: Engine mount fastener drive type, size, and torque per OEM specification — verify against factory documentation before reinstalling
5. 5

   Clean freeze plug area
   Use wire brush to clean area around failed freeze plug, removing any corrosion, scale, or debris. Inspect surrounding plugs for seepage or corrosion indicating imminent failure. Clean the block surface around the plug thoroughly so the new plug seats properly.
6. 6

   Remove failed freeze plug
   Using a freeze plug removal tool or a punch and hammer, carefully drive one edge of the plug inward to rotate it in the bore. Once tilted, grip the plug edge with locking pliers and extract from bore. Alternatively, drill a small pilot hole in the center of the plug and use a slide hammer with screw attachment. Take care not to damage the bore surface during removal.
7. 7

   Prepare freeze plug bore
   Thoroughly clean the freeze plug bore using a razor scraper and wire brush. Remove all old sealant, corrosion, and scale until bare metal is exposed. Inspect bore for damage, cracks, or excessive corrosion. The bore must be smooth and round for proper plug seating. Wipe clean with lint-free cloth and allow to dry completely.
8. 8

   Install new freeze plug
   Apply a thin, continuous bead of freeze plug sealant (high-temp anaerobic type) around the outer edge of the new freeze plug. Position plug squarely in bore with the closed (domed) face outward and the open cup edge toward the block interior, per the installation convention for cup-type core plugs. Using a freeze plug installation driver of appropriate size, drive plug into bore evenly. Tap around the perimeter progressively to ensure even seating. The plug should seat to the depth specified in OEM documentation (typically flush to slightly recessed); verify exact installation depth against factory specification. Verify plug is not cocked or unevenly seated.
   Torque spec

   Freeze Plug20 Nm (15 lb-ft)
9. 9

   Allow sealant to cure
   Allow sealant to cure per manufacturer specifications, typically 1 hour minimum before filling with coolant. Verify plug is secure and properly seated. Wipe away any excess sealant that extruded during installation.
10. 10

    Reinstall engine mounts and lower engine
    If engine was tilted or raised, carefully lower engine back onto mounts. Install and torque engine mount fasteners per OEM specification. Remove engine support fixture or hoist. Verify all engine movement clearances are restored.
11. 11

    Reinstall obstructing components
    Reinstall all components removed for access in reverse order of removal. Reconnect all electrical connectors, ensuring positive engagement. Install coolant hoses and secure with clamps. Torque all fasteners to OEM specifications. Verify no hoses or wiring are pinched or stretched.
12. 12

    Reinstall fender liner and wheel
    Position inner fender liner and secure with all Torx fasteners and press-fit clips. Verify liner is properly seated and does not interfere with wheel rotation. Reinstall wheel and torque wheel bolts to OEM specification (verify exact value against factory documentation before use). Note: Reinstall wheel and torque wheel bolts to OEM specification (verify exact torque for 2009 DB9 against factory documentation before use). Note: Reinstall wheel and torque lug bolts to OEM specification (verify exact value in manufacturer documentation).
13. 13

    Refill cooling system
    Close all coolant drains. Reinstall engine block drain plug with sealing washer if equipped, or reconnect lower coolant hose and secure clamp per OEM procedure. Fill cooling system with OAT 50/50 premix coolant through expansion tank. Fill to cold-fill level marking. Use vacuum fill procedure if available to eliminate air pockets in this V12 configuration. If vacuum filling not available, proceed to bleeding process in verification steps.
14. 14

    Refill engine oil if drained
    If engine oil was drained due to low freeze plug location, install new oil filter and refill with the OEM-specified quantity of Aston Martin-approved synthetic engine oil (5W-40/5W-50 per OEM specification). Verify exact grade and capacity against factory documentation before filling. Verify oil level on dipstick after filling. Note: If engine oil was drained due to low freeze plug location, install new oil filter and refill with engine oil of the grade and quantity specified by Aston Martin for the 6.0L V12 (verify exact capacity and viscosity per OEM specification). Note: If engine oil was drained due to low freeze plug location, install new oil filter and refill with the OEM-specified quantity and grade of engine oil (verify capacity and viscosity in manufacturer documentation). Note: Engine oil (Aston Martin-approved synthetic, 5W-40/5W-50 per OEM specification)
15. 15

    Reinstall undertray and reconnect battery
    Install all engine undertray panels and secure with Torx fasteners. Reconnect battery negative terminal. Ensure all tools and materials are removed from engine bay and under vehicle.

Reassembly

1. Verify all fasteners are torqued to specification and no components were left disconnected.
2. Double-check all coolant hose connections for security before starting engine.
3. Ensure inner fender liner is properly secured and will not contact rotating components.

Verification

• With expansion tank cap removed, start engine and allow to idle. Monitor coolant level and add as air purges from system.
• Run engine until cooling fans cycle on, indicating thermostat has opened. Continue adding coolant as level drops.
• Rev engine to 2500 RPM briefly several times to help purge air from system.
• Inspect freeze plug installation for any coolant seepage while engine is at operating temperature.
• Allow engine to cool and recheck coolant level at expansion tank cold-fill mark. Top off as necessary.
• Perform second cold inspection after overnight cooling to verify no seepage from freeze plug or disturbed connections.
• Test drive vehicle and verify normal operating temperature. Recheck coolant level after test drive.
• Inspect undertray area for any coolant drips 24 hours after repair.

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