Long Block Replacement

Complete replacement of the 6.0L V12 long block assembly, including removal of all ancillary components, engine extraction, installation of replacement long block, and reinstallation of all systems.

Warnings

Tools required

Parts

• Complete long block assembly (6.0L V12) × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Coolant × 1 — OAT 50/50 pre-mixed
• Engine oil (5W-30) × 1 — Aston Martin approved specification
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Intake manifold gaskets × 2 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Water pump gasket/O-rings × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Engine mount bolts × 1 — Use OEM specification
• Transmission-to-engine bolts × 1 — Use OEM specification
• Spark plugs × 12 — Use OEM specification
• Anti-seize compound × 1 — High-temperature nickel-based
• Thread locking compound (medium strength) × 1 — Loctite 243 or equivalent
• RTV silicone gasket maker × 1 — High-temperature
• Various hose clamps × 1 — Assorted sizes

Fluids

• engine_oil — 10.5 qt
• coolant — 10.5 qt
• transmission_auto — 1 qt
• power_steering — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect battery negative terminal, then positive terminal. Remove battery from vehicle.
3. Drain engine coolant completely from radiator drain valve and engine block drain plugs into appropriate containers.
4. Drain engine oil and remove oil filter.
5. Remove engine cover panels and undertray.
6. Document all electrical connector positions, vacuum line routing, and coolant hose connections with photos.
7. Recover AC refrigerant using certified recovery equipment.
8. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls, then crank for 5 seconds.
9. Ensure adequate workspace around vehicle for engine removal. Clear at least 6 feet in front of vehicle for engine hoist.
10. Gather all tools, parts, and fluids before beginning disassembly.

Procedure

1. 1

   Remove hood and front body components
   Mark hood hinge positions with paint pen or tape for alignment during reinstallation. With assistance, remove hood mounting bolts and lift hood from vehicle. Remove front grille assembly, front bumper cover, and radiator support upper trim panels to provide access to radiator and AC condenser. Store all fasteners in labeled containers.
2. 2

   Remove cooling system components
   Disconnect upper and lower radiator hoses from engine. Remove radiator fan shroud assembly by disconnecting electrical connectors and removing mounting fasteners. Remove cooling fans as an assembly. Disconnect any transmission/transaxle cooler lines at the radiator if routed to the front cooling package (verify routing for this vehicle, as the Touchtronic transaxle is rear-mounted). Remove radiator mounting brackets and lift radiator from vehicle. Remove AC condenser mounting fasteners and carefully reposition condenser forward without disconnecting refrigerant lines (lines were previously evacuated). Secure condenser to prevent damage. Note: Disconnect any transaxle cooler lines routed to the radiator if present (DB9 uses a rear-mounted transaxle; verify cooler routing against factory service data).
3. 3

   Disconnect fuel system
   Disconnect fuel supply line (and return line if equipped) at engine bay connections using appropriate line wrenches or quick-disconnect tools as applicable. Have shop towels ready to catch residual fuel. Cap or plug all open fuel lines to prevent contamination. Remove fuel rail covers and disconnect injector harness connectors. Label each connector position for proper reinstallation.
4. 4

   Remove intake system and throttle body
   Remove engine air intake duct and air filter housing assembly. Disconnect mass airflow sensor connector. Remove throttle body by disconnecting throttle cable/linkage and electrical connections. Remove throttle body mounting fasteners and lift throttle body from intake manifold. Disconnect vacuum lines from intake manifold, brake booster, and EVAP system. Label all vacuum connections.
5. 5

   Disconnect engine electrical systems
   Disconnect main engine harness connectors at firewall. Disconnect alternator electrical connections and mounting fasteners, then remove alternator. Disconnect starter motor electrical connections and mounting fasteners, then remove starter. Disconnect all remaining sensor connectors including: camshaft position sensors, crankshaft position sensor, knock sensors, oil pressure sensor, coolant temperature sensors, and oxygen sensors. Label each connector. Remove spark plug wire/coil assemblies from all 12 cylinders.
6. 6

   Remove accessory drive components
   Remove serpentine belt by releasing tensioner. Remove power steering pump mounting fasteners and reposition pump aside without disconnecting hydraulic lines. Remove AC compressor mounting fasteners and secure compressor aside without disconnecting refrigerant lines. Remove alternator bracket if still attached. Remove any remaining accessory brackets from front of engine.
7. 7

   Disconnect exhaust system
   Raise vehicle on lift or support safely on jack stands. Spray exhaust manifold fasteners with penetrating oil and allow to soak. Disconnect oxygen sensor connectors. Remove exhaust system mounting hardware at catalytic converters or exhaust manifolds. Lower exhaust system away from engine or remove front exhaust pipes completely if clearance requires. Support exhaust system with wire or straps to prevent damage.
8. 8

   Disconnect transmission from engine
   Disconnect the engine from the torque tube at the rear of the engine. Mark the clutch/flexplate-to-driveplate position. Remove the torque tube-to-engine mounting fasteners (access via the bellhousing area between engine and torque tube). Note bolt lengths and positions as they vary. Disconnect any clutch/transaxle hydraulic and electrical connections at the engine interface. Support the torque tube independently as the engine is separated.ect transmission electrical harness connectors. Disconnect shift linkage from transmission. Note: If the vehicle uses the rear transaxle/torque tube configuration, disconnect the torque tube from the engine flange rather than removing torque converter and bellhousing bolts; consult factory procedure for the specific driveline configuration before separating. Note: The DB9 uses a rear-mounted transaxle connected to the engine via a torque tube. Separate the engine from the torque tube at the engine-to-torque-tube coupling per factory procedure, rather than removing a conventional bellhousing/torque converter. Support the torque tube/transaxle appropriately, mark the clutch/flexplate coupling position, remove the engine-to-torque-tube fasteners (note lengths and positions), and disconnect any associated electrical connectors. Consult factory service data for the exact separation procedure.
   Torque spec

   Transmission-to-Engine Bolts45 Nm (33 lb-ft)
9. 9

   Remove engine mounts and prepare for extraction
   Attach engine hoist with load leveler to factory lifting points on engine. Apply slight tension to hoist to support engine weight. Remove engine mount-to-chassis fasteners on both sides. Remove engine mount-to-engine bracket fasteners. Check clearance around entire engine bay to ensure all connections have been disconnected (fuel lines, coolant hoses, electrical connectors, vacuum lines, ground straps). Verify transmission is fully separated and supported independently.
10. 10

    Extract engine from vehicle
    With assistant monitoring clearances, slowly raise engine while angling forward. Adjust load leveler to keep engine approximately level as it clears transmission input shaft. Continue lifting and tilting engine forward to clear firewall and suspension components. Once engine is clear of fender wells, raise fully and roll hoist forward to move engine away from vehicle. Lower engine onto engine stand or sturdy work surface. Secure engine to prevent tipping.
11. 11

    Transfer components from old long block to replacement
    Remove the following components from the old engine for transfer to replacement long block: valve covers, intake manifolds, exhaust manifolds, fuel rails and injectors, water pump, thermostat housing, oil pan (if not included with new long block), timing covers, all sensors (camshaft position, crankshaft position, knock sensors, oil pressure, coolant temperature), oil filter housing, motor mounts and brackets, accessory mounting brackets, flywheel/driveplate (per driveline configuration), rear main seal housing, dipstick tube, oil cooler adapter. Inspect each component for wear or damage and replace as necessary. Clean all gasket surfaces thoroughly with appropriate gasket remover and scotch-brite pads. Do not use abrasive tools on aluminum surfaces. Note: motor mounts and brackets, accessory mounting brackets, flywheel/drive flange (per driveline configuration), rear main seal housing, dipstick tube, oil cooler adapter
12. 12

    Install components onto replacement long block
    Install rear main seal and housing with new gasket/seal using RTV where specified. Install flywheel/flexplate with new TTY bolts, tightening in the factory-specified sequence and torque/angle values (verify against Aston Martin service data). Install oil pan with new gasket. Install timing covers with new gaskets in proper sequence. Install water pump with new gasket/O-rings. Install thermostat housing with new gasket. Install all sensors per factory specification; apply anti-seize to sensor threads only where specifically called out by Aston Martin service data (many sensors such as oxygen sensors are pre-coated and should not receive additional anti-seize). Install exhaust manifolds with new gaskets and anti-seize on studs/nuts, following the factory-specified tightening sequence. Install intake manifolds with new gaskets in proper sequence. Install valve covers with new gaskets. Install fuel rails and injectors with new O-rings. Install motor mount brackets. Install oil filter housing. Install all accessory mounting brackets. Verify all fasteners are torqued to specification.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Oil Pan Bolt12 Nm (9 lb-ft)

    Timing Cover Bolts - 8mm25 Nm (18 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolt10 Nm (7 lb-ft)

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

    Verify timing alignment on replacement long block
    Remove timing cover inspection plugs. Rotate crankshaft to TDC position for cylinder 1. Install crankshaft locking tool to verify crankshaft is at TDC. Install camshaft alignment tools in both cylinder banks to verify camshaft timing. If timing is not aligned, consult factory service procedures for timing chain installation and tensioning. Once timing is verified, remove alignment tools and reinstall inspection plugs with new O-rings or gaskets.
14. 14

    Install replacement long block into vehicle
    Attach engine hoist to lifting points on replacement engine. Carefully lift engine and position above engine bay. With assistant guiding, slowly lower engine into bay while angling to clear firewall and align with transmission. Adjust load leveler as needed to maintain clearance. Guide engine onto engine mounts while aligning the engine output coupling with the torque tube per factory procedure. This step requires patience and multiple adjustments for proper alignment.
15. 15

    Secure engine mounts and connect transmission
    Install engine mount-to-engine bracket fasteners and torque to specification. Install engine mount-to-chassis fasteners and torque to specification. Remove slight tension from hoist but leave attached for safety. Guide the torque tube forward to mate with the engine. Install all torque tube-to-engine mounting bolts in correct positions and torque to specification. Install the clutch/driveplate fasteners, aligning marks made during removal. Install bellhousing inspection cover. Remove transmission jack. Remove engine hoist. Note: If equipped with the torque tube/rear transaxle, reconnect the torque tube to the engine flange and torque fasteners to specification per factory procedure; otherwise follow conventional bellhousing procedure as applicable. Note: Mate the engine to the torque tube and install the engine-to-torque-tube coupling fasteners in correct positions, torquing to specification and aligning marks made during removal. Reinstall any coupling access/inspection cover per factory procedure.
    Torque spec

    Transmission-to-Engine Bolts45 Nm (33 lb-ft)
16. 16

    Reconnect exhaust system
    Position exhaust system to engine and install new exhaust manifold gaskets if replacing at manifold connections. Install exhaust fasteners and torque to specification. Reconnect oxygen sensor electrical connectors. Verify exhaust hangers are properly seated and system has adequate clearance from chassis, driveshaft, and suspension components.
17. 17

    Install accessory components
    Install AC compressor to mounting bracket and torque fasteners to specification. Install power steering pump to mounting bracket and torque fasteners to specification. Install alternator to mounting bracket and torque fasteners to specification. Install starter motor and torque fasteners to specification. Install serpentine belt routing around all pulleys and verify proper engagement. Install belt tensioner.
18. 18

    Reconnect engine electrical systems
    Reconnect all electrical connections using labels and photos from disassembly: main engine harness at firewall, alternator connections, starter connections, all sensor connectors (camshaft position, crankshaft position, knock sensors, oil pressure, coolant temperature, oxygen sensors). Install spark plugs and torque to factory specification (do not apply anti-seize unless specified by Aston Martin). Install the individual coil-on-plug units to all 12 cylinders in their correct positions. Verify all ground straps are reconnected. Note: Install spark plugs and torque to specification (do not use anti-seize unless specifically called out by Aston Martin service data, as most modern plugs are pre-coated). Note: Install the individual coil-on-plug units to all 12 cylinders, ensuring each coil connector is seated at its correct cylinder position.
19. 19

    Reconnect intake and throttle systems
    Install throttle body to intake manifold with new gasket and torque fasteners to specification. Reconnect throttle cable/linkage and electrical connections. Reconnect all vacuum lines to intake manifold, brake booster, and EVAP system using labels from removal. Install air filter housing and intake duct. Reconnect mass airflow sensor connector.
    Torque spec

    Intake Manifold Bolt10 Nm (7 lb-ft)
20. 20

    Reconnect fuel system
    Reconnect fuel injector harness connectors to all injectors. Install fuel rail covers. Reconnect fuel supply and return lines at engine bay connections using new O-rings if applicable. Tighten line connections with appropriate line wrenches to specification. Remove caps/plugs from fuel lines.
21. 21

    Install cooling system components
    Reposition AC condenser to original position and install mounting fasteners. Install radiator into mounting position and install radiator brackets. Reconnect transmission cooler lines if applicable. Install cooling fan assembly and shroud. Reconnect fan electrical connectors. Install upper and lower radiator hoses with new clamps. Reconnect all coolant hoses to engine (heater hoses, bypass hoses, etc.). Install new coolant drain plugs with new sealing washers.
22. 22

    Reinstall front body components and hood
    Install radiator support upper trim panels. Install front bumper cover and grille assembly with all mounting fasteners. With assistance, position hood onto hinges aligning with marks made during removal. Install hood mounting bolts and adjust for proper fit and alignment. Install all engine bay covers and undertray.
23. 23

    Fill fluids and perform pre-start checks
    Install new oil filter. Install oil drain plug with new crush washer and torque to specification. Fill engine with approximately 11 quarts (10.5 liters) of 5W-30 engine oil through oil filler cap, verifying final level with the dipstick per factory specification (verify exact capacity against Aston Martin service data). Fill cooling system with OAT 50/50 coolant mixture to factory-specified capacity (verify exact volume against service data), then bleed air per factory procedure. Fill power steering reservoir with the Aston Martin approved power steering fluid per factory specification. No transaxle fluid loss is expected during engine removal since the transaxle is rear-mounted; verify transaxle fluid level only if the torque tube coupling was opened. Reinstall battery and connect positive terminal, then negative terminal. Perform final visual inspection of entire engine bay verifying all connections are secure, no tools are left in engine bay, and no fluid leaks are visible. Note: Fill engine with the Aston Martin approved engine oil grade and quantity per factory specification through the oil filler cap, verifying final level with the dipstick. Note: Fill cooling system with the factory-specified coolant capacity of OAT 50/50 coolant mixture (verify exact volume against Aston Martin service data). Note: Fill engine with approximately 12 quarts of Aston Martin approved 5W-30 engine oil through oil filler cap, verifying final level against factory specification. Note: Fill cooling system with the factory-specified coolant capacity (verify against factory service data) of OAT 50/50 coolant mixture. Note: Fill engine with the factory-specified oil capacity (approximately 11 quarts / 10.5 liters — verify against factory service data) of Aston Martin approved 5W-30 engine oil through oil filler cap.
    Torque spec

    Oil Drain Plug25 Nm (18 lb-ft)
24. 24

    Initial startup and system checks
    Turn ignition to ON position without starting engine. Check for fuel leaks at all connections. Check for coolant leaks at all connections. Turn ignition to START and crank engine. Engine should start within 5-10 seconds. If engine does not start, verify fuel pressure, ignition system operation, and timing alignment. Once running, monitor for unusual noises, vibrations, or warning lights. Verify oil pressure immediately via the gauge or warning lamp (confirm which is fitted on this vehicle); shut down immediately if low oil pressure is indicated. Allow engine to idle and warm to operating temperature while monitoring for leaks. Check coolant level and top off as needed after air purges from system. Bleed cooling system per factory procedure. Note: Confirm oil pressure is within the factory-specified range immediately after startup (verify the DB9 V12 warm-idle oil pressure spec against factory service data).
25. 25

    Evacuate and recharge AC system
    Using certified AC service equipment, evacuate AC system to verify integrity (should hold vacuum for 30 minutes minimum). If vacuum test passes, recharge AC system with the refrigerant type and charge quantity specified on the vehicle's AC service label and factory specification. Verify AC compressor engages and system operates correctly. Note: If vacuum test passes, recharge AC system with the refrigerant type (verify R-134a against the underhood AC service label) to the vehicle-specific charge weight listed on the label or factory specification.
26. 26

    Road test and final adjustments
    Perform road test to verify engine performance, transmission operation, and cooling system function. Monitor engine temperature, oil pressure, and all warning lights. Test under various load conditions including acceleration, cruise, and deceleration. Return to shop and recheck all fluid levels. Inspect engine bay for any fluid leaks, unusual odors, or loose components. Check exhaust system for leaks. Verify no warning lights are illuminated.

Reassembly

1. Reassembly is covered in the installation steps above, mirroring the removal process in reverse order.
2. Use all new gaskets, seals, and O-rings during reassembly.
3. Replace all TTY (torque-to-yield) bolts including main bearing cap bolts, connecting rod bolts, cylinder head bolts, and flywheel bolts if removed.
4. Apply anti-seize compound to exhaust manifold studs/nuts and spark plug threads.
5. Follow all torque specifications exactly and use angle tightening procedures where specified.
6. Tighten all multi-bolt components (valve covers, intake manifolds, oil pan, timing covers, cylinder heads, main bearing caps) in proper sequence from center outward.
7. Verify timing alignment before final reassembly using factory timing tools.
8. Route all wiring harnesses and hoses away from hot exhaust components and moving parts.
9. Double-check that all electrical connectors are fully seated and locked.

Verification

• Engine starts promptly and runs smoothly at idle without unusual noises or vibrations.
• Oil pressure gauge shows normal pressure immediately after startup (typically 40-60 psi at idle when warm).
• No warning lights illuminated on instrument cluster.
• Engine reaches normal operating temperature without overheating.
• No fluid leaks visible from engine oil, coolant, power steering, transmission, or fuel systems.
• AC system operates correctly and blows cold air.
• Exhaust system has no leaks (visual and audible inspection).
• All electrical systems function correctly (lights, gauges, accessories).
• Road test confirms smooth acceleration, proper transmission shifting, and stable engine operation under load.
• Cooling fans cycle on and off automatically as engine temperature varies.
• Fuel system maintains proper pressure with no leaks.
• After road test, recheck all fluid levels and verify no new leaks have developed.

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