Lifter - Single

Replace a single hydraulic valve lifter on the 2009 Aston Martin DB9 6.0L V12 engine, requiring removal of valve covers, intake manifold, and rocker assemblies to access the lifter bore.

Warnings

Tools required

Parts

• Hydraulic valve lifter × 1 — Use OEM Aston Martin specification
• Valve cover gasket set (bank-specific) × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Engine oil × 1 — 5W-30 synthetic
• Rocker arm shaft seals (if damaged) × 2 — Use OEM specification
• Coolant hose O-rings (if disturbed) × 4 — Use OEM specification

Fluids

• engine_oil — 10.5 qt
• coolant — 2 qt

Preparation

1. Verify which cylinder and bank requires lifter replacement. This procedure covers general access; right bank requires additional steering reservoir relocation.
2. Ensure engine is completely cold (minimum 4 hours after last operation) to prevent coolant system burns.
3. Disconnect negative battery terminal and wait 10 minutes for airbag system capacitor discharge.
4. Remove engine cover by releasing quick-release fasteners at four corners.
5. Drain engine oil completely into appropriate container. Remove oil filter.
6. Relieve fuel system pressure: remove fuel pump fuse, start engine and allow to stall, crank for 5 seconds.
7. Document all vacuum line routing, electrical connectors, and coolant hose positions with photographs.
8. Support vehicle on stable jack stands if working on lower bank components. Ensure adequate overhead clearance for intake manifold removal.
9. Position engine hoist or support beam above engine bay for upper intake manifold handling (component weighs approximately 35 lbs).

Procedure

1. 1

   Remove Intake Plenum and Upper Intake Assembly
   Remove engine acoustic cover completely. Disconnect throttle body electrical connector and carefully release locking tab. Disconnect the brake booster vacuum line from the intake plenum (note its connection type and any retaining clip or bracket fastener, which must be released before removal). Remove air intake duct from throttle body by loosening hose clamps. Disconnect all vacuum lines from intake plenum, noting that most use quick-release fittings requiring rotation while pulling. Remove plenum mounting bolts (locate bolts around perimeter and center support brackets). Carefully lift plenum away from engine, tilting rear upward first to clear fuel rail components. Set aside on padded surface.
   ⚠Do not force plenum removal. Several hidden vacuum fittings may still be connected underneath. Verify all connections are free before lifting.
2. 2

   Remove Lower Intake Manifold
   Disconnect fuel supply and return lines at fuel rail using appropriate line disconnect tools. Cap all open fuel connections immediately. Disconnect fuel injector electrical connectors for the affected bank (connectors have sliding locks requiring tab depression). Disconnect coolant crossover hoses at manifold connection points if accessing rear cylinders. Remove intake manifold mounting bolts working from outside toward center. Note bolt length variations and positions for reassembly. Carefully lift intake manifold section from engine, ensuring no wiring harnesses are trapped underneath. Inspect manifold gaskets and mating surfaces.
   ⚠Residual fuel will drain from fuel rail. Have absorbent materials ready and ensure adequate ventilation.
   Torque spec

   Intake Manifold Bolt25 Nm (18 lb-ft)
3. 3

   Remove Valve Cover for Affected Bank
   Disconnect any ignition coil connectors mounted to valve cover if present. Remove ignition coils by removing mounting bolts and pulling straight upward with slight rotation. Disconnect PCV hose and any breather hoses from valve cover. Remove valve cover perimeter bolts in reverse order of tightening sequence (outside to inside pattern). Gently tap valve cover with rubber mallet at designated lift points if gasket is adhered. Lift valve cover straight up to avoid damaging gasket surfaces. Set aside and inspect gasket for reuse suitability (recommend replacement).
   ℹ️Valve cover gaskets on this engine are multi-piece assemblies with integrated spark plug tube seals. Order complete gasket set for affected bank.
   Torque spec

   Valve Cover Bolts10 Nm (7 lb-ft)
4. 4

   Establish and Lock Engine Timing
   Rotate crankshaft clockwise (viewed from front) using breaker bar on crankshaft pulley bolt until cylinder #1 is at TDC compression stroke. Verify timing mark on crankshaft pulley aligns with timing pointer on front cover. Install crankshaft timing pin through front cover access hole into crankshaft timing hole. Install the factory Aston Martin camshaft locking/alignment tools onto the camshafts through the designated access points (verify correct tool part numbers against current Aston Martin service tool documentation for this engine). Verify both tools fully engage and camshafts cannot rotate. Mark camshaft positions relative to cylinder head with paint pen as additional verification. Note: Install the factory Aston Martin camshaft locking/alignment tools onto the camshafts as specified in the factory workshop manual. Verify tool part numbers against current Aston Martin service documentation before proceeding. Note: Install the Aston Martin factory camshaft locking/timing tools (verify correct tool numbers against official AMDS/workshop manual) onto the camshafts through the designated access points. Note: Camshaft locking/alignment tools (verify exact Aston Martin service tool part numbers against official AMDS/workshop manual documentation for the AM11 6.0L V12)
   ⚠️Do NOT proceed without camshaft locking tools properly installed and verified. Camshaft movement will result in valve timing loss and catastrophic engine damage on startup.
5. 5

   Remove Rocker Arm Assembly for Affected Cylinder
   Identify the tappet for the cylinder requiring replacement and determine which camshaft (intake or exhaust) overlies it. Rotate the engine (while maintaining the ability to re-lock timing) until that cam lobe is on its base circle over the affected tappet. With camshaft timing locked, progressively loosen the camshaft bearing cap bolts for the affected camshaft evenly, following the factory loosening sequence, to relieve valve-spring load gradually. Remove the bearing caps (noting their numbered positions and orientation) and carefully lift the camshaft out. Access the direct-acting bucket tappet in its head bore.m assembly straight up. Note rocker arm orientation and position (mark with paint pen if removing multiple assemblies). Inspect rocker arm contact surfaces for wear or scoring. Set assembly on clean workspace with pushrods still in contact if not removing pushrods.
   ⚠Rocker arm shafts are under light spring pressure. Remove bolts evenly to prevent shaft bending or sudden release.
   Torque spec

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
6. 6

   Remove Pushrod and Access Lifter Bore
   With the camshaft removed, lift the bucket tappet straight up and out of its bore in the cylinder head. If equipped, remove and note the valve-adjustment shim location (early/revised engines may differ). Mark the tappet position and orientation so original bores can be matched if multiple are removed. The tappet may be tight; gentle rotation while lifting helps release it. Place the removed tappet in a marked container for failure analysis. Clean the tappet bore thoroughly with a clean lint-free cloth. seal. If lifter is severely stuck, use appropriate threaded lifter extraction tool. Once removed, place lifter in marked container if inspecting for failure analysis. Clean lifter bore thoroughly with clean lint-free cloth and compressed air.
   ℹ️Inspect removed lifter for scoring, collapsed piston, or contamination. This information helps diagnose root cause and prevent future failures.
7. 7

   Inspect Lifter Bore and Camshaft Lobe
   Using clean solvent and lint-free cloths, thoroughly clean the lifter bore. Inspect bore walls for scoring, galling, or excessive wear using flashlight and inspection mirror. Minor surface marks are acceptable; deep scoring requires cylinder head machining. Using compressed air, blow out any debris from oil passages in lifter valley. Inspect corresponding camshaft lobe for wear, pitting, or scoring. Measure lobe height with micrometer if available and compare to service specifications. Check lifter bore oil supply hole is clear and unobstructed. If bore or lobe damage is found, consult professional machinist for head/camshaft serviceability assessment.
   ⚠A failed lifter often indicates contaminated oil, improper break-in, or camshaft lobe wear. Address root cause before installing new lifter to prevent repeat failure.
8. 8

   Prepare and Install New Lifter
   Remove new lifter from packaging. Pre-prime lifter by submerging in clean engine oil and working plunger up and down until no air bubbles emerge (this may take 30-50 cycles). Coat lifter exterior with assembly lube or clean engine oil. Coat lifter bore with clean engine oil. Carefully insert new lifter into bore, ensuring it slides freely without binding. Rotate lifter while inserting to distribute oil. Press lifter down until it seats fully in bore. Verify lifter moves up and down smoothly in bore with light pressure (indicating proper oil cushion). Apply fresh engine oil to lifter top contact surface.
   ℹ️Improperly primed lifters will cause valve train noise and premature wear. Ensure lifter plunger is fully collapsed and oil-filled before installation.
9. 9

   Reinstall Pushrod and Verify Preload
   Coat the new bucket tappet with clean engine oil and install it fully into its head bore, confirming it slides freely. Reinstall any adjustment shim in its original location if applicable. Lubricate the camshaft journals and lobes with assembly lube, lay the camshaft back into position confirming its timing reference, and ensure the cam lobe over the serviced tappet is on its base circle before loading the valve springs.ocker arm cup (verify by feel and visual inspection). Check that cam lobe is still pointing away from rocker arm (on base circle) before installing shaft bolts.
   ⚠Pushrod must be fully seated in both lifter and rocker cup. Partial seating will cause immediate failure on startup.
10. 10

    Install and Torque Rocker Arm Assembly
    Install the camshaft bearing cap bolts finger-tight with caps in their correct numbered positions and orientation. Confirm the serviced cam lobe is on its base circle. Tighten the camshaft bearing cap bolts progressively and evenly in the factory-specified sequence, in multiple passes, to the factory-specified torque, so the camshaft is drawn down squarely against valve-spring pressure. Use torque wrench to bring all bolts to the factory-specified rocker arm shaft bolt torque in the final pass (verify exact value against Aston Martin service data before tightening). Manually rotate crankshaft two complete revolutions slowly (with timing tools removed temporarily, then reinstalled) to verify smooth operation and proper valve train geometry. Observe rocker arm movement through full cycle to confirm no binding or interference. Recheck rocker shaft bolt torque after rotation. Note: Torque camshaft cap / valvetrain fasteners to the factory-specified value and sequence from the Aston Martin workshop manual (verify against official documentation before tightening).
    ⚠️Cam lobe MUST be on base circle (pointing away) during tightening. Tightening with lobe under load will damage valve train components.
    Torque spec

    Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
11. 11

    Verify Valve Lash and Timing
    With the camshaft reinstalled and bearing caps torqued, do NOT attempt a feeler-gauge lash check. This engine uses hydraulic bucket tappets with automatic zero-lash adjustment; verify instead that the tappet is fully primed and seated and that there is no free play with the lobe on its base circle. Verify the tappet is properly primed and seated rather than measuring lash with a feeler gauge. If lash is excessive, verify lifter is properly primed and seated. Reconfirm engine timing: verify crankshaft timing pin is still engaged, camshaft locking tools are secure, and timing marks remain aligned. Remove camshaft locking tools only after verifying all components are secure. Rotate engine by hand through two complete revolutions, feeling for smooth resistance and listening for unusual sounds. Note: This engine uses hydraulic lifters with a self-adjusting zero-lash design; no feeler-gauge lash measurement is required. Verify proper lifter preload by confirming the lifter is fully primed and seated and that the valve train has no free play when the lifter is on the base circle. Note: This engine uses hydraulic bucket tappets with a self-adjusting zero-lash design; no valve lash measurement is required. Verify tappets are properly primed and seated under the camshaft lobes.
    ⚠️Do not start engine if timing cannot be positively verified or if valve train binding is felt during manual rotation.
12. 12

    Reinstall Valve Cover
    Clean valve cover and cylinder head mating surfaces thoroughly with plastic scraper and solvent. Remove all old gasket material without scratching aluminum surfaces. Install new valve cover gasket, ensuring all locating tabs are properly seated in valve cover grooves. Apply small dab of RTV sealant at camshaft cap/cylinder head junctions only if specified by factory procedure. Position valve cover over cylinder head, aligning all bolt holes and ensuring no wiring harnesses are trapped. Install valve cover bolts finger-tight. Torque valve cover bolts to the factory-specified value in the factory-specified sequence per the Aston Martin workshop manual (verify value and pattern before tightening). Do not overtighten as this will distort cover and cause leaks. Note: Torque valve cover bolts to the factory-specified value in the sequence specified by Aston Martin service data (verify both torque value and tightening pattern before tightening). Note: Torque cam cover bolts in the factory-specified sequence to the manufacturer-specified value (verify against official workshop manual).
    ℹ️Valve cover bolt sequence is critical for proper gasket sealing. Follow factory pattern precisely to prevent oil leaks.
    Torque spec

    Valve Cover Bolts10 Nm (7 lb-ft)
13. 13

    Reinstall Intake Manifold and Plenum
    Install new intake manifold gaskets onto cylinder head surfaces, ensuring proper orientation and alignment with coolant and oil passages. Position intake manifold section onto engine, guiding carefully to avoid gasket displacement. Install intake manifold bolts finger-tight, verifying correct bolt lengths in each position. Torque intake manifold bolts to the factory-specified value in sequence from center outward (verify exact torque against Aston Martin service data before tightening). Reconnect fuel injector electrical connectors with positive click. Reconnect coolant crossover hoses if removed, using new O-rings. Reconnect fuel supply and return lines, ensuring proper engagement of quick-connect fittings. Position intake plenum onto manifold, reconnecting all vacuum lines to marked positions. Install plenum mounting bolts and torque evenly. Reconnect throttle body connector and brake booster vacuum line. Note: Torque intake manifold bolts to the factory-specified value in the factory-specified sequence per the Aston Martin workshop manual (verify value and pattern before tightening). Note: Torque intake manifold bolts to the manufacturer-specified value in the factory-specified sequence (verify against official workshop manual).
    ⚠Verify all fuel connections are fully seated before pressurizing fuel system. Improperly connected fuel lines will cause dangerous fuel leaks.
    Torque spec

    Intake Manifold Bolt25 Nm (18 lb-ft)
14. 14

    Refill Fluids and Prepare for Startup
    Install new oil filter, lubricating gasket with clean oil before installation. Hand-tighten filter until gasket contacts, then an additional 3/4 turn. Refill engine with the factory-specified quantity of the Aston Martin-approved synthetic engine oil (verify exact capacity and oil grade against the owner's manual / service data before filling). Top off coolant system to proper level if coolant was disturbed, using the Aston Martin-approved coolant at the specified mixture ratio (verify coolant specification and fill capacity against service data). Reconnect battery negative terminal. Turn ignition to ON position (without starting) to pressurize fuel system. Inspect all fuel connections for leaks. Cycle ignition off and on three times to fully prime fuel system. Check for any fluid leaks around valve cover, intake manifold, and fuel connections. Verify all tools have been removed from engine bay and all electrical connectors are secured. Note: Refill engine with the factory-specified quantity and grade of synthetic engine oil per the Aston Martin service documentation for this engine (verify exact capacity and viscosity before filling). Note: Top off coolant system to proper level if coolant was drained, using the coolant type and mixture specified by Aston Martin for this vehicle. Note: Top off coolant system to proper level if coolant was drained, using the Aston Martin-specified coolant type and concentration (verify against workshop manual). Note: Refill engine with the factory-specified quantity of Aston Martin-approved synthetic engine oil (verify grade and exact capacity against the 2009 DB9 owner/workshop manual).
    ⚠Do not start engine if any fuel leaks are observed. Repair all leaks before proceeding.
15. 15

    Initial Startup and Break-In
    With vehicle in Park/Neutral and parking brake engaged, start engine. Engine should start normally; initial valve train noise for 3-5 seconds is normal as lifter fully pumps up. Observe oil pressure gauge; pressure should register within 5 seconds. Allow engine to idle for 2-3 minutes while monitoring for unusual noises, vibrations, or leaks. Increase engine speed gradually to 2000 RPM for 30 seconds, then return to idle. Listen carefully for valve train noise, ticking, or knocking. Shut off engine and recheck oil level; add if needed. Inspect for any new fluid leaks around all recently disturbed components. Test drive vehicle gently for 10-15 miles, avoiding high RPM or heavy load. Recheck oil level and inspect for leaks after test drive.
    ⚠️If unusual valve train noise persists beyond initial startup, or if knocking/grinding sounds are heard, shut down immediately and investigate. Do not continue operation.
    ℹ️New lifter may exhibit minimal noise for first 15-20 minutes of operation as it fully seats and oil passages clear. Persistent noise beyond this indicates installation problem.

Reassembly

1. Installation follows removal in reverse order with these critical exceptions: all gaskets must be replaced, all fasteners must be torqued to specification in proper sequence, and engine timing must be verified before and after reassembly.
2. Apply assembly lube to all valve train contact surfaces including rocker arm tips, pushrod ends, and lifter contact faces.
3. Use new O-rings on all coolant and fuel connections disturbed during procedure.
4. When reinstalling intake plenum, ensure all vacuum lines are routed exactly as documented during removal to prevent idle quality issues.
5. After initial startup and test drive, recheck valve cover and intake manifold for leaks after engine reaches full operating temperature and cools.

Verification

• Start engine and verify smooth idle with no valve train noise after initial 5-second pump-up period.
• Check oil pressure registers normal range (40-60 PSI at idle when warm).
• Verify no oil leaks from valve cover, no fuel leaks from intake manifold or fuel rail connections.
• Test drive vehicle through full RPM range; valve train should remain quiet without ticking or tapping noises.
• Recheck engine oil level after test drive; hydraulic lifter replacement should not affect oil consumption or level.
• Scan for diagnostic trouble codes; no misfires or timing-related codes should be present.
• Verify smooth throttle response and normal engine performance across all operating conditions.

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