Fuel Pump Module

Replace the fuel pump module in a 2009 Aston Martin DB9, requiring fuel tank access via rear seat and trunk floor panel removal, fuel system depressurization, and careful handling of high-pressure fuel connections.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Use OEM Aston Martin specification
• Fuel pump lock ring O-ring seal × 1 — Use OEM specification
• Fuel line O-rings (various sizes) × 1 — Use OEM specification, typically 2-4 required
• Tank access cover gasket/seal × 1 — Use OEM specification if reusable seal is damaged

Preparation

1. Park vehicle on level surface in well-ventilated area, preferably outdoors or in shop with exhaust ventilation.
2. Place Class B fire extinguisher within immediate reach of work area.
3. Ensure fuel tank is less than 1/2 full. If necessary, siphon or drive vehicle to reduce fuel level (safer working conditions and less spillage).
4. Locate radio security code from owner's manual or Aston Martin dealer before battery disconnect.
5. Gather all tools and replacement parts before beginning. Verify new fuel pump module matches OEM specifications.
6. Prepare catch container (minimum 1 gallon capacity) and absorbent shop towels for fuel spillage.
7. Allow engine to cool completely if vehicle was recently driven (minimum 2 hours).
8. Remove any items from trunk and rear seat area.

Procedure

1. 1

   Disconnect Battery and Depressurize Fuel System
   Open hood and disconnect negative battery terminal using appropriate wrench. Secure cable away from terminal. Locate the fuel pump fuse or relay per the vehicle's fuse diagram (verify exact location and rating against OEM documentation). Remove the fuel pump fuse or relay. Attempt to start the engine with the fuel pump disabled; it should start briefly then stall or fail to start as residual pressure is consumed. Do not crank excessively. Verify depressurization using a fuel pressure gauge per the method below. Verify zero pressure using fuel pressure gauge attached to Schrader valve on fuel rail if accessible. Leave battery disconnected for entire procedure. Note: Locate the fuel pump fuse/relay (verify exact location and rating against the 2009 DB9 wiring diagram — it may be in the cabin or trunk fuse box rather than the engine bay). Remove the fuel pump fuse or relay. Attempt to start engine; it should crank but not start, or start briefly then stall. Note: Locate the fuel pump fuse or relay (refer to the vehicle's fuse diagram for the correct location and rating, which must be verified against Aston Martin documentation). Remove the fuel pump fuse or relay to disable the pump.
   ⚠️Cranking engine with fuel pump disabled will depressurize system but some residual pressure remains. Always use fuel pressure gauge to verify zero pressure before opening fuel lines.
2. 2

   Remove Rear Seat Cushion
   Verify the fuel pump access method for the 2009 DB9 against factory service documentation before proceeding, as the access point (rear seat area vs. trunk/boot floor vs. tank drop) must be confirmed. If rear-seat access is confirmed, enter the rear compartment, locate the rear seat cushion, release its retainers per the service manual, and remove the cushion to a clean area. Note: Determine the correct fuel pump access location for this vehicle (verify whether access is via the rear seat area or trunk floor per Aston Martin service documentation). If access is via the rear seat, remove the rear seat cushion per the manufacturer's retention method before proceeding.
3. 3

   Remove Rear Seat Backrest
   Identify Torx fasteners securing seat back lower mounts to body structure. Remove the backrest lower mounting fasteners (verify exact count and driver size against 2009 DB9 service documentation) at the left and right mounting points. Lift seat back upward to disengage upper clips or hinges, then remove seat back from vehicle. Inspect area for fuel tank access panel location under carpet. Note: Identify the fasteners securing the seat back lower mounts to the body structure (count and drive type to be verified against Aston Martin documentation). Remove the lower mounting fasteners using the appropriate driver.
4. 4

   Remove Carpet and Locate Access Panel
   Peel back or fold trunk-side carpet in rear seat area to expose metal floor pan. Locate the fuel pump access panel (verify its presence, location, and dimensions against 2009 DB9 service documentation), secured by fasteners around its perimeter. Use shop vacuum to remove any debris around access panel before proceeding. Note: Locate the fuel pump access panel (size, shape, and fastener type to be verified against Aston Martin documentation) secured by fasteners around its perimeter.
   ℹ️Carpet may be multi-piece or have specific fold lines. Do not force or tear carpet; it should fold back naturally to reveal access panel.
5. 5

   Remove Fuel Pump Access Cover
   Remove the access panel perimeter screws (verify exact count and driver size against 2009 DB9 service documentation). Keep fasteners organized in magnetic tray. Carefully lift access panel to reveal fuel pump module top and electrical connections. Observe seal or gasket condition around panel edge for reuse assessment. Note: Remove the fasteners securing the access panel perimeter (count and drive type to be verified against Aston Martin documentation).
   Torque spec

   Access Cover Screws5 Nm (4 lb-ft)
6. 6

   Disconnect Electrical Connector and Fuel Lines
   Identify main electrical connector on top of fuel pump module. Depress locking tab and pull connector straight up to disconnect. Locate fuel supply and return lines connected to pump module top. Using appropriate quick-disconnect tools, depress release collar on each fuel line fitting while pulling line away from pump. Have shop towels ready to catch residual fuel spillage from the disconnected lines. Verify all electrical and fuel connections are fully disconnected before proceeding.
   ⚠️Residual fuel under slight pressure may spray when lines are disconnected. Keep face and ignition sources away from connection points. Wear safety glasses.
7. 7

   Remove Fuel Pump Lock Ring
   Inspect fuel pump lock ring (large threaded ring securing pump module to tank). Clean debris from ring and tank flange using non-sparking brush. Position fuel pump lock ring tool onto the lock ring tabs. Verify the retention type (threaded vs. bayonet/cam-lock) and correct release direction against 2009 DB9 service documentation, then rotate the lock ring in the specified direction using a ratchet or breaker bar. Initial breakaway requires significant force. Once loosened, continue rotating until lock ring is fully unthreaded. Remove lock ring and set aside. Note O-ring seal position on tank flange or pump module base. Note: Rotate the lock ring in the loosening direction (verify thread/retention type and direction against Aston Martin documentation—it may be a threaded ring, bayonet, or cam-lock) using the lock ring tool.
   ⚠Lock ring may be very tight from years of corrosion and fuel deposits. Use proper tool to avoid damaging ring tabs. If ring tool slips, clean ring and tool surfaces before retrying.
8. 8

   Extract Fuel Pump Module from Tank
   Carefully lift fuel pump module straight up out of fuel tank opening. The module includes fuel level sender float arm that must clear tank opening at an angle. Tilt module slightly as needed to navigate float arm through opening without bending. Fuel will drain from pump reservoir and module base—have catch container positioned below. Once module is clear, hold over catch container to drain residual fuel. Place used module in spill-proof container for disposal or core return. Inspect tank opening for debris, corrosion, or damage. Note: Significant fuel may drain from the module reservoir during removal. Ensure the catch container has adequate capacity and absorbent materials are ready.
   ⚠Fuel level sender float arm is fragile and easily bent. Support module weight evenly during extraction and avoid forcing if resistance is felt.
   ⚠️Significant fuel will drain from module during removal. Expect 500-1000ml spillage. Ensure catch container has adequate capacity and absorbent materials are ready.
9. 9

   Clean Tank Flange and Inspect Seal Surfaces
   With tank opening exposed, use clean shop towels to wipe tank flange sealing surface. Remove old O-ring seal from flange groove using seal pick. Inspect flange for corrosion, gouges, or damage that could prevent proper seal. Use non-sparking wire brush if needed to clean corrosion (avoid creating sparks). Vacuum any debris from visible tank interior near opening using shop vacuum—do not allow debris to fall into tank. Verify tank flange is clean, dry, and smooth.
   ⚠️Tank interior contains fuel vapors. Do not insert tools or create sparks near opening. Use only non-sparking tools and vacuum with proper grounding.
10. 10

    Prepare and Install New Fuel Pump Module
    Unpack new fuel pump module and verify it matches original configuration (float arm position, electrical connector type, fuel line ports). Install new O-ring seal into groove on tank flange, ensuring seal is fully seated and not twisted. Lubricate O-ring lightly with clean gasoline or petroleum jelly. Carefully lower new pump module into tank opening at angle to clear float arm through opening. Align module orientation so fuel line ports and electrical connector face correct direction (match original position). Press module down until base seats against tank flange O-ring. Verify module sits flush and evenly on flange.
    ⚠Ensure float arm does not bind or contact tank walls during installation. Module must rotate freely to correct orientation without forcing.
11. 11

    Install and Torque Lock Ring
    Position fuel pump lock ring over module top, aligning threads with tank flange threads. Hand-thread lock ring clockwise until snug against module. Install lock ring tool and torque the lock ring to the manufacturer-specified value (obtain the exact torque spec from 2009 DB9 service documentation and use a torque wrench of appropriate range). Verify module is secure and does not rotate. Inspect O-ring seal by looking for even compression around flange perimeter—seal should be visible as slight bulge, confirming proper seating. Note: Install the lock ring tool and torque the lock ring to the Aston Martin specified value using an appropriate torque wrench (verify the spec and required torque range against documentation).
    Torque spec

    Fuel Pump Lock Ring45 Nm (33 lb-ft)
12. 12

    Reconnect Fuel Lines with New O-Rings
    Install new O-rings onto fuel line quick-disconnect fittings. Lubricate O-rings lightly with clean gasoline. Push each fuel line firmly onto corresponding pump module port until click or detent is felt, indicating full engagement. Gently pull on each line to verify secure connection—line should not pull free. Visually confirm locking collar is fully engaged on each fitting.
    ⚠Quick-disconnect fittings must click or lock audibly. If fitting does not lock, remove, inspect for debris or damaged O-ring, and retry.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
13. 13

    Reconnect Electrical Connector
    Align main electrical connector with pump module connector and press firmly until locking tab engages with audible click. Verify connector is fully seated and locked by attempting gentle pull—connector should not separate. Route wiring to avoid pinching when access cover is reinstalled.
14. 14

    Reinstall Access Cover and Interior Components
    Inspect access cover gasket/seal. If damaged or compressed, replace with new gasket. Position access cover over opening, aligning screw holes. Install cover screws and torque in cross-pattern to specification to ensure even seal compression. Fold carpet back into original position, smoothing to eliminate wrinkles. Reinstall rear seat backrest by engaging upper clips/hinges and securing lower Torx fasteners. Reinstall rear seat cushion by positioning rear edge behind seat back, then pressing front edge down firmly to engage retaining clips.
    Torque spec

    Access Cover Screws5 Nm (4 lb-ft)
15. 15

    Restore Power and Prime Fuel System
    Reinstall the fuel pump fuse or relay in its correct location (as identified in step 1). Reconnect negative battery terminal and tighten securely. Turn ignition key to 'ON' position without starting engine. Fuel pump should run for 2-3 seconds to prime system. Cycle ignition OFF then ON three more times, allowing pump to run each cycle. This pressurizes fuel system. Check all fuel line connections at tank for leaks—look and feel for wetness. If no leaks observed, start engine. Engine may crank longer than normal on first start as system fills. Once running, inspect all connections again under full operating pressure. Check for fuel odor in passenger compartment. Note: With engine running, verify fuel pressure at the fuel rail (if gauge still attached) reads within the manufacturer-specified operating range (confirm the exact spec from 2009 DB9 service documentation). Note: With engine running, verify fuel pressure at fuel rail (if gauge still attached) reads within the Aston Martin specified operating range (confirm exact spec against OEM service data).
    ⚠️First pressurization is critical leak check point. Any fuel weeping or spraying indicates improper connection. Immediately turn off ignition and disconnect battery if leak is observed.

Reassembly

1. Reassembly is covered in procedure steps as removal and installation are integrated.
2. Verify all Torx fasteners for seat mounts and access cover are tightened to specification.
3. Confirm carpet is properly repositioned without wrinkles that could interfere with seat installation.
4. Test rear seat cushion and backrest for secure engagement—no loose movement should be present.

Verification

• With engine running, verify fuel pressure at fuel rail (if gauge still attached) reads 55-65 psi—within normal operating range.
• Check for fuel leaks at all tank connections while engine is running and fuel system is under full pressure. Look for wetness and smell for fuel odor.
• Verify fuel gauge reads correctly on instrument cluster and responds to changes as fuel is consumed.
• Test drive vehicle to confirm normal engine performance, no hesitation, stumbling, or fuel starvation symptoms.
• After test drive, recheck all fuel connections at tank access panel for any signs of seepage or leaks.
• Confirm no fuel odor is present in passenger compartment or trunk area after several hours.
• Monitor for check engine light or fuel system fault codes using OBD-II scanner if available.

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