Radiator

Complete removal and installation of the radiator assembly on a 2009 Aston Martin DB9 6.0L V12, including coolant drainage, upper radiator support removal, and disconnection of all cooling system connections.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Upper radiator hose × 1 — Replace if cracked or swollen
• Lower radiator hose × 1 — Replace if cracked or swollen
• Radiator drain plug O-ring × 1 — Use OEM specification
• Coolant (OAT 50/50 premix) × 1 — Use OEM specification

Fluids

• coolant — 10.5 qt

Preparation

1. Ensure engine is completely cold to the touch (minimum 2 hours after last operation).
2. Disconnect negative battery terminal and secure away from battery post.
3. Raise vehicle on lift or secure on jack stands at appropriate lift points per owner's manual.
4. Remove front undertray panels to access lower radiator area (secured with multiple Torx fasteners).
5. Place large drain pan beneath radiator drain location.
6. Remove engine cover by releasing quick-release fasteners.

Procedure

1. 1

   Drain cooling system
   Locate the coolant drain point at the lower corner of the radiator. If a drain petcock is fitted, slowly open it counterclockwise and allow coolant to drain completely into the drain pan. Open the expansion/header tank cap to relieve pressure and aid drainage. If no petcock is fitted or it is seized or damaged, disconnect the lower radiator hose to drain the system. Note: If equipped, locate the radiator drain petcock at the lower corner of the radiator and slowly open it to allow coolant to drain completely into the drain pan. If no petcock is present, drain the system by disconnecting the lower radiator hose. Verify drain location against factory documentation for the 2009 DB9. Note: Check the lower radiator for a drain petcock or plug. If equipped, slowly open it and allow coolant to drain completely into the drain pan. On many DB9 configurations no petcock is fitted and coolant must be drained by disconnecting the lower radiator hose. Note: Once drained, remove the expansion tank cap to break the vacuum and ensure complete drainage. Note: Coolant drain pan (minimum 14 quart capacity; verify system capacity against factory documentation)
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Remove front grille and upper radiator support access
   Remove the front grille assembly by locating and removing its fasteners (verify exact type, size, and count against Aston Martin service documentation for the 2009 DB9). Carefully pull the grille forward to disengage any retaining clips. Set aside in a protected area. This provides access to the upper radiator mounting points and cooling fan assemblies.
   ⚠Grille assembly includes delicate chrome or painted trim. Handle with care to avoid cosmetic damage.
3. 3

   Disconnect cooling fan electrical connectors
   Locate the electrical connectors for both cooling fans mounted on the radiator shroud. Press the locking tabs and disconnect both fan motor connectors. Verify the number of cooling fan assemblies against factory documentation for the 2009 DB9 before disconnecting; configurations may vary. Secure the wiring harnesses away from the radiator removal path using zip ties or by routing them to the side.
4. 4

   Remove cooling fan assemblies
   Remove the cooling fan shroud assemblies from the radiator. The fan shroud is secured to the radiator with mounting fasteners (verify exact count and type against Aston Martin service documentation for the 2009 DB9 before removal). Remove all fasteners and carefully lift each fan assembly upward and out of the engine bay. The fans are mounted as integrated shroud units that detach from the radiator core.
   ⚠Fan assemblies are bulky and have sharp blade edges. Use care when lifting out of the tight engine bay.
5. 5

   Disconnect upper radiator hose
   Locate the upper radiator hose connection at the top of the radiator. Using hose clamp pliers, squeeze and slide the spring-type hose clamp away from the connection point. Twist the hose gently while pulling to break any seal, then disconnect the hose from the radiator inlet. Cap or plug the hose end to prevent coolant spillage. Note: Locate the upper radiator hose connection at the top of the radiator (verify side against the vehicle, as orientation varies).
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
6. 6

   Disconnect lower radiator hose
   Access the lower radiator hose connection from beneath the vehicle. Using hose clamp pliers, release the spring clamp and slide it away from the connection point on the lower radiator outlet. Twist and pull the hose to disconnect. Additional coolant will drain; ensure drain pan is positioned correctly. Note: release the spring clamp and slide it away from the connection point on the lower radiator outlet (verify side against the vehicle)
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
7. 7

   Disconnect transmission cooler lines
   The 2009 DB9 uses a rear-mounted transaxle with a separate dedicated transmission oil cooler; the engine radiator does NOT have integrated transmission cooler lines. This step does not apply to this vehicle. Confirm against factory documentation, but do not expect to find transmission cooler fittings on the engine radiator. Note that many DB9s use a separate dedicated transmission oil cooler rather than radiator-integrated cooler lines; verify configuration before attempting this step. Be prepared for residual transmission fluid spillage. Cap all open connections immediately to prevent contamination. Note: If the vehicle is equipped with a radiator-integrated transmission cooler, locate the cooler lines and disconnect their fittings using a flare nut wrench. NOTE: The DB9 commonly uses a separate transmission/driveline oil cooler rather than a radiator-integrated cooler; verify whether this step applies to this vehicle before proceeding. Cap all open connections immediately to prevent contamination. Note: Verify whether transmission/transaxle cooler lines are routed to this radiator on the 2009 DB9. The DB9 uses a rear transaxle with a separate cooler, so the engine radiator may have no transmission cooler lines — confirm before attempting to disconnect any fittings.
   ⚠Use a flare nut wrench to prevent rounding of the transmission cooler line fittings. These fittings can be difficult to access and easily damaged.
   Torque spec

   Transmission Cooler Lines25 Nm (18 lb-ft)
8. 8

   Disconnect auxiliary coolant hoses
   Identify and disconnect any auxiliary coolant hoses connected to the radiator. On the DB9, this typically includes a coolant overflow/expansion tank hose connected to the radiator filler neck or side tank. Release the hose clamps and disconnect, routing hoses clear of the radiator removal path.
9. 9

   Remove upper radiator mounting brackets
   Locate the upper radiator mounting brackets that secure the top of the radiator to the radiator support frame. These are typically secured with 2 bolts or fasteners on each side (E-Torx or Torx fasteners). Remove all upper mounting fasteners completely and set aside with their hardware.
   Torque spec

   Radiator Mounting Bolt12 Nm (9 lb-ft)
10. 10

    Remove lower radiator mounting hardware
    From beneath the vehicle, locate the lower radiator mounting points. The radiator typically sits on rubber isolator mounts with retaining brackets or pins. Remove any lower mounting fasteners or release clips that secure the bottom of the radiator to the crossmember. On some configurations, the radiator may simply lift off locating pins once upper fasteners are removed.
    Torque spec

    Radiator Mounting Bolt12 Nm (9 lb-ft)
11. 11

    Remove radiator from vehicle
    With all hoses, lines, and mounting hardware disconnected, carefully lift the radiator assembly straight upward and out of the engine bay. The radiator must be tilted slightly to clear the engine and surrounding components. Guide it carefully past the hood latch mechanism and any remaining obstacles. Have an assistant support the radiator if needed due to its size and weight. Inspect the radiator mounting location for debris or damage once removed.
    ⚠Radiator core fins are extremely delicate. Avoid contact with engine components, frame rails, or tools during removal to prevent damage.
12. 12

    Prepare new radiator for installation
    Compare the new radiator with the old unit to verify correct fitment, mounting points, and connection locations. Transfer any reusable components if necessary (though typically not required with new OEM radiators). Inspect all rubber mounting isolators and replace if worn or damaged. Ensure the drain petcock is closed on the new radiator. Install new O-ring on drain petcock if provided separately.
13. 13

    Install radiator into vehicle
    Carefully lower the new radiator into position in the engine bay, guiding it past all obstacles and aligning it with the mounting points. Ensure the lower radiator mounts engage properly with their locating pins or brackets on the crossmember. Align the upper mounting bracket holes with the radiator support frame.
14. 14

    Install radiator mounting hardware
    Install the upper radiator mounting brackets and secure with their fasteners. Torque the upper mounting bolts to specification. Install any lower mounting fasteners or clips. Verify the radiator is properly seated and secure with no movement.
    Torque spec

    Radiator Mounting Bolt12 Nm (9 lb-ft)
15. 15

    Reconnect all hoses and lines
    Reconnect the lower radiator hose to the radiator outlet, positioning the hose clamp properly and securing it to specification. Reconnect the upper radiator hose to the radiator inlet, ensuring the hose is fully seated before securing the clamp. The DB9 engine radiator has no integrated transmission cooler lines, so no transmission cooler line reconnection is required at the radiator. Omit this action for this vehicle. Reconnect the expansion tank overflow hose and any other auxiliary coolant hoses. Verify all connections are tight and properly positioned.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)

    Transmission Cooler Lines25 Nm (18 lb-ft)
16. 16

    Install cooling fan assemblies
    Position each cooling fan shroud assembly onto the radiator, aligning the mounting points. Install all fan mounting fasteners and tighten securely. Reconnect the electrical connectors to both fan motors, ensuring the locking tabs engage fully.
17. 17

    Install front grille and access panels
    Reinstall the front grille assembly by engaging any locating clips and installing all Torx fasteners. Verify proper alignment and secure fit. Reinstall the front undertray panels from beneath the vehicle.
18. 18

    Refill and bleed cooling system
    Using the Aston Martin factory-specified coolant (verify chemistry — OAT vs HOAT — per owner's manual/service documentation) as a 50/50 premix, slowly fill the cooling system through the radiator filler neck or expansion tank. Fill until coolant reaches the cold fill line on the expansion tank. With the expansion tank cap off, start the engine and allow it to reach operating temperature while monitoring coolant level. Add coolant as needed as air bleeds from the system. Verify against Aston Martin factory documentation whether the 2009 DB9 cooling system has dedicated bleed screws/points and their locations; if equipped, open them briefly to purge air during the fill/bleed procedure. Run the engine until the cooling fans cycle on and off, indicating proper thermostat operation. Once fully bled and at operating temperature, shut off the engine, allow to cool, and top off coolant to the proper level. Install the expansion tank cap securely.
    ⚠Monitor engine temperature closely during bleeding process. Do not allow engine to overheat due to air pockets in the system.

Reassembly

1. Reinstall engine cover using quick-release fasteners.
2. Reconnect negative battery terminal and verify all electrical connections are secure.
3. Check transmission fluid level after reconnecting cooler lines, as some fluid will have been lost during disconnection.
4. Lower vehicle from lift or jack stands.

Verification

• Start engine and allow to reach full operating temperature while monitoring for leaks at all radiator connections, hoses, and transmission cooler lines.
• Verify both cooling fans engage when engine reaches operating temperature.
• Check coolant level in expansion tank after engine cools and top off if necessary.
• Inspect beneath vehicle for any signs of coolant or transmission fluid leaks.
• Test drive vehicle and monitor temperature gauge to ensure normal cooling system operation.
• Recheck all fluid levels after test drive and inspect for leaks once more.

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