Short Block Replacement

Complete removal and replacement of the short block assembly on a 2009 Aston Martin DB9 6.0L V12, including disassembly of top end components, removal of cylinder heads, and installation of new block assembly with all critical bearing and fastener specifications.

Warnings

Tools required

Parts

• Short block assembly (complete with pistons, rings, crankshaft) × 1 — Use OEM specification
• Main bearing set (upper and lower) × 1 — Use OEM specification
• Connecting rod bearing set × 1 — Use OEM specification
• Piston ring set (if not included with short block) × 1 — Use OEM specification
• Cylinder head gasket set (left and right) × 1 — Use OEM specification
• Timing chain kit (chains, guides, tensioners) × 1 — Use OEM specification
• Oil pump assembly × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Coolant pipe O-rings and seals × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Crankshaft pulley bolt (if TTY) × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 1 — Use OEM specification
• Flywheel bolts (if TTY) × 1 — Use OEM specification
• Engine coolant (OAT 50/50 premix) × 1 — Use OEM specification
• Engine oil (5W-30) × 1 — Use OEM specification

Fluids

• engine_oil — 10.5 qt
• coolant — 10.5 qt
• transmission_auto — 9.5 qt
• power_steering — 1.2 qt

Preparation

1. Park vehicle on level ground in well-ventilated workspace with adequate overhead clearance for engine hoist operation.
2. Disconnect battery negative terminal and secure cable away from terminal. Wait minimum 10 minutes for airbag system discharge.
3. Remove engine cover panels and undertray panels to access engine compartment from below.
4. Drain engine coolant completely into appropriate container by opening radiator petcock and removing lower radiator hose.
5. Drain engine oil by removing drain plug and allowing complete drainage (minimum 20 minutes).
6. Relieve fuel system pressure by removing fuel pump fuse, starting engine, and allowing it to run until it stalls.
7. Have air conditioning system refrigerant professionally recovered and evacuated by certified technician.
8. Raise vehicle on lift or support securely on jack stands at all four corners with wheels removed for underside access.
9. Position engine hoist with load leveler in front of vehicle and verify adequate range of motion for engine removal.
10. Prepare clean, organized workspace for component storage with labeled containers for fasteners organized by assembly location.
11. Have new short block assembly inspected and measured for bearing clearances, piston ring gaps, and cylinder bore specifications before beginning disassembly.

Procedure

1. 1

   Remove intake and throttle body assembly
   Disconnect manifold absolute pressure (MAP) sensor connectors and intake air temperature sensors. Release clamps securing intake air ducts to throttle bodies. Remove throttle body connectors (electronic throttle control). Remove intake plenum assembly fasteners (verify exact count and E-Torx size against OEM documentation). Lift plenum assembly clear and disconnect any remaining vacuum lines and PCV connections. Remove lower intake manifold runners by removing their mounting fasteners. Inspect and label all vacuum lines and electrical connectors for reassembly reference.
2. 2

   Disconnect fuel system and fuel rails
   Verify fuel pressure is relieved by wrapping shop towel around fuel rail Schrader valve and depressing valve core. Disconnect fuel supply line from fuel rail using appropriate quick-disconnect tool. Remove fuel rail mounting bolts (typically 4 per bank, E-Torx). Carefully lift fuel rails with injectors attached. Disconnect injector electrical connectors and remove injectors from fuel rails if they remain attached. Cap all fuel lines and rail ports immediately to prevent contamination.
3. 3

   Remove ignition coils and spark plugs
   Disconnect ignition coil electrical connectors on all 12 cylinders. Remove coil mounting fasteners (typically one E-Torx fastener per coil). Pull coils straight out from valve cover. Using spark plug socket with extension, remove all 12 spark plugs. Inspect plug wells for oil accumulation which would indicate valve cover gasket seepage. Store plugs in order for inspection and comparison.
4. 4

   Remove valve covers
   Disconnect any remaining wiring harnesses clipped to valve covers (typically cam position sensors and variable valve timing solenoids). Remove valve cover fasteners (approximately 10-12 E-Torx fasteners per cover arranged around perimeter). Carefully break gasket seal using plastic pry tool at designated pry points (never between mating surfaces). Lift valve covers clear. Remove and discard valve cover gaskets. Inspect camshaft lobes and valve train components for wear or damage.
5. 5

   Disconnect exhaust manifolds
   From underneath vehicle, disconnect exhaust system at collector flanges downstream of catalytic converters. Remove oxygen sensor connectors. Remove exhaust manifold-to-cylinder head fasteners (typically 6-8 fasteners per manifold, may be studs with nuts). Support exhaust system weight with jack or suspension strap to prevent damage to catalytic converters. Lower exhaust assembly clear of engine bay. Remove and discard exhaust manifold gaskets.
6. 6

   Remove accessory drive system
   Release belt tensioner and remove serpentine belt. Remove power steering pump mounting bolts and position pump aside with hoses still attached (do not disconnect lines unless necessary). Remove air conditioning compressor mounting bolts and secure compressor aside with hoses attached. Remove alternator mounting bolts and disconnect electrical connections, then remove alternator. Remove any belt idler pulleys and tensioner assemblies by removing their mounting bolts. These accessories will remain with vehicle, not engine.
7. 7

   Disconnect cooling system components
   Disconnect upper and lower radiator hoses from engine. Disconnect heater hoses from engine block or coolant crossover pipes. Remove coolant bypass hoses. Disconnect coolant temperature sensor connectors. On this engine, remove the water pump assembly by removing its mounting bolts and carefully separating it from timing cover. Remove water pump gasket and O-rings. Remove thermostat housing and thermostat for inspection.
8. 8

   Remove front timing cover
   Remove crankshaft pulley bolt using crankshaft holding tool to prevent rotation. This bolt requires significant torque to remove (typically requires impact gun or long breaker bar). Remove crankshaft pulley/harmonic balancer using appropriate puller tool. Remove timing cover fasteners in reverse of tightening sequence (approximately 18-22 fasteners of varying lengths around perimeter - note locations for reassembly). Carefully separate timing cover from engine block, breaking RTV seal with plastic pry tools. Remove and discard timing cover gasket. Inspect timing cover oil seal for wear.
   Torque spec

   Crankshaft Pulley Bolt120 Nm (89 lb-ft)

   Timing Cover Bolts - 8mm25 Nm (18 lb-ft)
9. 9

   Lock camshaft timing and remove timing chains
   Rotate crankshaft to TDC position for cylinder 1 (crankshaft keyway at 12 o'clock, camshaft timing marks aligned). Install Aston Martin camshaft locking tools into camshaft ends to prevent rotation during chain removal. Mark timing chain relationship to sprockets using paint marker as reference. Release timing chain tensioners by removing tensioner mounting bolts. Remove timing chain guide bolts and guides. Slide timing chains off camshaft and crankshaft sprockets. Remove camshaft sprocket bolts (typically 2-3 bolts per sprocket) and remove sprockets. Remove crankshaft sprocket using appropriate puller if tight on crankshaft snout.
10. 10

    Remove camshafts
    With timing chains removed and camshafts locked, remove camshaft bearing cap bolts in reverse order of tightening sequence (work from outside toward center in multiple passes to prevent bending camshafts). Mark bearing caps with cylinder bank and position before removal. Carefully lift camshafts from cylinder heads, keeping intake and exhaust camshafts identified. Inspect camshaft lobes and journals for scoring or wear. Store camshafts in protective covering to prevent damage.
11. 11

    Remove cylinder heads
    Remove cylinder head bolts in reverse of tightening sequence (typically start from center and work outward in multiple passes). The exact head bolt count per cylinder head (bank) must be verified against OEM documentation before removal. Use appropriate E-Torx socket. Once all head bolts are removed, break head gasket seal using plastic pry tools at designated pry points (never between head and block surfaces). Lift cylinder heads from block using proper lifting technique or assistance - heads are heavy. Place heads on clean, padded surface with combustion chambers facing up. Remove and discard cylinder head gaskets. Inspect head gasket surfaces on block for damage or warping.
12. 12

    Support and disconnect transmission
    Support the torque tube using an appropriate support fixture. The DB9 uses a rear-mounted transaxle connected to the engine via a torque tube — there is no engine-mounted bellhousing. Disconnect starter motor electrical connections and remove starter mounting bolts to remove starter. Separate the engine from the torque tube at the front engine coupling per the Aston Martin DB9 procedure; the transaxle remains at the rear of the vehicle and does not come out with the engine. Secure and support the torque tube/transaxle on the chassis per factory procedure (verify driveline configuration and coupling fasteners against factory service data). Separate the engine from the torque tube/transaxle assembly per the Aston Martin DB9 procedure — this vehicle uses a rear-mounted transaxle connected by a torque tube, so the engine is decoupled from the torque tube rather than from a directly-mounted transmission. Lower transmission on jack and secure on appropriate stand. Note: Note that the DB9 uses a rear-mounted transaxle connected to the engine via a torque tube; disconnect the torque tube and driveline connections per Aston Martin procedure rather than a conventional engine-mounted bellhousing (verify driveline configuration against factory service data). Note: Note: the DB9 uses a rear-mounted transaxle connected via a torque tube; separation involves the torque tube and clutch/driveline connections per the OEM procedure, not a conventional bellhousing split — verify configuration before disconnecting.
    Torque spec

    Transmission-to-Engine Bolts45 Nm (33 lb-ft)
13. 13

    Remove flywheel or flexplate
    Install crankshaft locking tool or use appropriate method to prevent crankshaft rotation. Remove flywheel/flexplate bolts in star pattern (typically 6-8 bolts around perimeter). Carefully remove flywheel or flexplate from crankshaft flange. Inspect pilot bearing or bushing in crankshaft center. Remove rear main seal housing if equipped, or note rear main seal for removal with engine block. Mark flywheel orientation to crankshaft for proper balance during reassembly.
    Torque spec

    Flywheel Bolts45 Nm (33 lb-ft)
14. 14

    Remove engine mounts and prepare for lifting
    Disconnect engine mount bolts connecting engine mounts to engine block (typically 2-3 large bolts per mount, left and right sides). Leave mount brackets attached to chassis. Disconnect any remaining electrical connectors including engine harness main connectors, ground straps, and sensor connections. Attach engine hoist chains or lifting sling to engine lifting eyes (verify factory lifting points on engine block). Adjust load leveler to balance engine weight front-to-rear.
15. 15

    Lift assembled short block from engine bay
    Apply slight upward tension on engine hoist to take weight off mounts. Verify all connections, hoses, and wiring are disconnected. Slowly lift engine while guiding clear of chassis components, especially tight areas near firewall and radiator support. Adjust load leveler angle as needed to maintain clearance. Once clear of engine bay, lower engine onto appropriate engine stand or work surface. Secure engine to stand using an appropriate engine stand adapter bolted to the rear block face / main crankcase mounting bosses per factory service data (this engine has no bellhousing).
16. 16

    Remove oil pan and pickup
    With engine secured on stand, remove oil pan mounting bolts (approximately 20-24 bolts around pan perimeter). Use plastic pry tool to carefully break RTV seal between pan and block. Lower oil pan away from block. Remove oil pickup tube mounting bolts (typically 2-3 bolts securing pickup to block). Remove pickup tube and O-ring seal. Inspect oil pan for debris, metal particles, or sludge accumulation which would indicate internal engine damage.
    Torque spec

    Oil Pan Bolt12 Nm (9 lb-ft)
17. 17

    Remove oil pump
    Remove oil pump mounting bolts (typically 4-6 bolts securing pump to front of block). Carefully pull oil pump assembly straight out from block, disengaging drive gear from crankshaft. Remove oil pump gasket or O-ring seals. Inspect crankshaft oil pump drive gear for wear or damage.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)
18. 18

    Remove pistons and connecting rods
    Rotate crankshaft to position each piston at bottom dead center for access. Mark connecting rods and caps with cylinder number and orientation using permanent marker or stamps before disassembly. Remove connecting rod cap bolts (2 bolts per rod). Remove rod caps keeping them matched with their respective rods. Push piston and rod assemblies up and out through top of cylinder bore. Inspect cylinder bores for scoring, taper, and out-of-round condition. Remove piston rings from pistons if pistons are to be reused. Keep all components organized by cylinder number.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
19. 19

    Remove crankshaft and main bearing caps
    Before removal, check crankshaft endplay using dial indicator (specification typically 0.05-0.25mm). Mark main bearing caps with position number and orientation arrow pointing toward front of engine. Remove main bearing cap bolts in sequence from front to rear. Carefully lift main bearing caps, keeping upper and lower bearing shells matched. Carefully lift crankshaft from block using proper lifting technique - the crankshaft is heavy; use appropriate handling. Inspect crankshaft journals for scoring, out-of-round, or taper using micrometer. Remove upper main bearing shells from block, keeping them identified by position. Note: Carefully lift crankshaft from block using proper lifting technique - the V12 crankshaft is heavy; use assistance and verify weight/handling requirements against factory service data.
    Torque spec

    Main Bearing Cap Bolts43 Nm (32 lb-ft)
20. 20

    Clean and prepare new short block
    Thoroughly clean new short block cylinder bores, deck surface, and all mating surfaces using appropriate solvent and lint-free cloths. Verify all oil gallery plugs are installed and sealed. Check all machined surfaces for damage or imperfections. Oil all cylinder bores with assembly lubricant to prevent corrosion. Verify crankshaft is not installed in short block (if this is bare block) or verify installed crankshaft rotates freely with no binding (if short block includes rotating assembly).
21. 21

    Install main bearings and crankshaft
    Clean all main bearing saddles in block and bearing cap surfaces thoroughly. Install upper main bearing shells into block, ensuring locating tabs engage properly (do not force). Coat bearing surfaces with assembly lubricant or engine oil. Carefully lower crankshaft into block, aligning journals with bearing shells. Install lower main bearing shells into main caps, ensuring proper orientation and tab engagement. Coat bearing surfaces with assembly lubricant. Install main bearing caps in correct positions with orientation arrows pointing forward. Install new TTY main bearing cap bolts finger-tight. Torque main bearing cap bolts in sequence from center outward to the OEM-specified initial torque, then tighten the additional angle per Aston Martin factory specification (verify exact values against factory service data before assembly). Verify crankshaft rotates freely after torquing. Check crankshaft endplay is within specification using dial indicator. Note: Torque main bearing cap bolts to the manufacturer's specified value and sequence — VERIFY against Aston Martin DB9 workshop manual before applying, as this engine uses cross-bolted mains with separate specs for vertical and side bolts. Note: Torque main bearing cap bolts in sequence from center outward to the OEM-specified initial torque, then tighten the additional angle per the factory service manual (values must be verified against Aston Martin OEM specification).
    Torque spec

    Main Bearing Cap Bolts43 Nm (32 lb-ft)
22. 22

    Install pistons and connecting rods
    If reusing pistons, install new piston rings by carefully expanding rings over piston crown, installing lower expander ring first, then oil control rails, then second compression ring, then top compression ring. Verify ring end gaps are staggered 120 degrees apart. Measure piston ring end gaps in cylinder bore (typically 0.30-0.50mm for compression rings). Coat piston skirts and rings with assembly lubricant. Install connecting rod bearing shells into rods and caps with locating tabs engaged. Coat bearing surfaces with assembly lubricant. Compress piston rings using ring compressor sized for the 89mm cylinder bore (verify bore diameter against OEM specification). Insert piston and rod assembly into correct cylinder bore from top, ensuring orientation marks face forward. Guide connecting rod carefully to avoid damaging crankshaft journal. Install connecting rod cap in correct orientation. Install new TTY connecting rod bolts and torque to the manufacturer's specified value and angle — VERIFY against Aston Martin DB9 workshop manual before applying. Repeat for all 12 cylinders. Verify crankshaft rotates freely after all rods are installed. Note: Compress piston rings using ring compressor sized for 89mm bore (verify bore diameter against OEM specification before selecting compressor). Note: Install new TTY connecting rod bolts and torque to the OEM-specified initial torque, then tighten the additional angle per Aston Martin factory specification (verify exact values against factory service data before assembly). Note: Compress piston rings using ring compressor sized for the correct bore diameter (verify OEM bore specification for this engine before selecting tool). Note: Install new TTY connecting rod bolts and torque to the OEM-specified initial value, then tighten the additional angle per the factory service manual (values must be verified against Aston Martin OEM specification).
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
23. 23

    Install oil pump and oil pan
    Install new oil pump gasket or O-rings onto oil pump. Align oil pump drive gear with crankshaft drive and carefully push pump into position on block. Install oil pump mounting bolts and torque to the OEM-specified value in the specified pattern (verify against Aston Martin factory service manual). Install new O-ring on oil pickup tube. Install oil pickup tube into block and pump housing, securing with mounting bolts torqued to 12 Nm (9 lb-ft). Clean oil pan mating surface and block surface thoroughly. Apply thin bead of RTV sealant to block mating surface and oil pan rail. Install new oil pan gasket if used (some applications use RTV only). Position oil pan onto block and install oil pan bolts finger-tight. Torque oil pan bolts to the OEM-specified value in spiral pattern from center outward (verify against Aston Martin DB9 factory service data). Allow RTV to cure per manufacturer specifications before filling with oil. Note: Install oil pump mounting bolts and torque to the OEM-specified value in star pattern (verify against Aston Martin DB9 factory service data). Install new O-ring on oil pickup tube. Install oil pickup tube into block and pump housing, securing with mounting bolts torqued to the OEM-specified value.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pan Bolt12 Nm (9 lb-ft)
24. 24

    Install timing components
    Clean timing cover mating surface on block thoroughly. Install new crankshaft front seal into timing cover using appropriate seal driver. Install crankshaft sprocket onto crankshaft snout, ensuring keyway aligns with crankshaft key. Install timing cover with new gasket, applying thin bead of RTV at block-to-oil pan junction points. Install timing cover bolts and torque to the OEM-specified value(s) in sequence (start at top center and work outward in cross pattern) — verify exact torque and any size-specific values against Aston Martin DB9 factory service data. Install harmonic balancer/crankshaft pulley onto crankshaft, coating keyway with anti-seize compound. Install new crankshaft pulley bolt and torque to the OEM-specified value, then apply the additional torque angle per Aston Martin factory specification (verify exact torque and angle against factory service data). Note: Install new crankshaft pulley bolt and torque to the manufacturer's specified value plus torque-to-angle stage — VERIFY against Aston Martin DB9 workshop manual before applying. Note: Install new crankshaft pulley bolt and torque to the OEM-specified value plus any required angle (verify against Aston Martin factory service manual).
    Torque spec

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

    Crankshaft Pulley Bolt120 Nm (89 lb-ft)
25. 25

    Install cylinder heads with new gaskets
    Clean cylinder head mating surfaces on block and head thoroughly - surfaces must be completely free of old gasket material and oil. Verify deck surface is not warped using straightedge and feeler gauge. Install new cylinder head gaskets onto block, ensuring all alignment dowels engage properly and gaskets are oriented correctly (TOP marking faces up, FRONT marking toward front). Carefully lower cylinder heads onto block, aligning with dowel pins. Install new cylinder head bolts (if TTY) with light coating of engine oil on threads and under bolt heads. Torque cylinder head bolts in proper sequence (typically start from center and work outward in spiral pattern) using multiple progressive steps as specified by manufacturer - typically 3-4 stages with final torque-to-angle specification. Follow the OEM-specified multi-stage cylinder head bolt torque values and final torque angle per Aston Martin factory specification (verify exact stages, sequence, and angle against factory service data before assembly). Repeat for opposite cylinder bank. Note: Torque cylinder head bolts using the manufacturer's exact staged sequence and final torque-to-angle specification — VERIFY against Aston Martin DB9 workshop manual before applying. Note: Follow the exact staged torque values and final angle specified in the Aston Martin factory service manual for this engine (do not use generic values).
26. 26

    Install camshafts and timing chains
    Lubricate camshaft journals and lobes with assembly lubricant. Install camshafts into cylinder heads, ensuring proper intake/exhaust identification. Install camshaft bearing caps in correct positions and orientation. Torque camshaft bearing cap bolts in sequence from center outward in multiple progressive passes to prevent bending camshafts (typically 3-4 steps to final torque of 12-15 Nm). Install camshaft sprockets onto camshaft ends with timing marks aligned to TDC position. Install timing chain guides and secure with bolts. Route timing chains over crankshaft and camshaft sprockets, ensuring all timing marks align with TDC reference marks. Install timing chain tensioners with tensioner pins installed to prevent premature extension. Verify all timing marks are aligned before releasing tensioners. Remove tensioner pins to allow tensioner operation. Manually rotate crankshaft two complete revolutions and verify timing marks return to proper alignment. Install Aston Martin camshaft locking tools to verify timing is correct.
27. 27

    Install water pump and cooling components
    Install new water pump gasket and O-rings onto water pump. Position water pump onto timing cover and install mounting bolts, torquing in star pattern to specification (typically 12-18 Nm). Install thermostat housing with new gasket and thermostat (verify thermostat orientation with jiggle valve at highest point). Connect coolant bypass hoses and engine block coolant passages using new O-rings where applicable. Connect heater hoses to engine.
28. 28

    Install valve covers and ignition components
    Install new valve cover gaskets onto valve covers. Apply small dab of RTV sealant at camshaft cap-to-cylinder head junctions (front and rear). Position valve covers onto cylinder heads and install valve cover bolts finger-tight. Torque valve cover bolts to specification in sequence from center outward (typically 10-12 Nm). Install spark plugs and torque to the OEM-specified value (verify against Aston Martin DB9 factory service data; do not over-torque in the aluminum head). Install ignition coils into spark plug wells and secure with mounting bolts. Connect ignition coil electrical connectors.
29. 29

    Install intake manifold and fuel system
    Install new intake manifold gaskets onto cylinder heads. Position lower intake runners and secure with mounting bolts torqued in sequence from center outward to specification (typically 10-12 Nm). Install upper intake plenum with new gaskets, torquing mounting bolts in sequence from center outward. Connect all vacuum lines and PCV connections. Install fuel injectors into fuel rails with new O-rings. Install fuel rails onto intake manifold and secure with mounting bolts. Connect fuel injector electrical connectors. Connect fuel supply line to fuel rail. Install throttle bodies with new gaskets and connect electronic throttle control connectors. Connect intake air ducts and MAF sensor connections.
30. 30

    Install exhaust manifolds and accessories
    Install new exhaust manifold gaskets onto cylinder heads. Position exhaust manifolds and install mounting fasteners, torquing from center outward in multiple passes to specification (typically 25-30 Nm). Connect exhaust system at collector flanges downstream of catalytic converters. Install oxygen sensors and connect electrical connectors. Install alternator and connect electrical connections, torquing mounting bolts to specification. Install air conditioning compressor and power steering pump, torquing mounting bolts to specification. Install belt tensioner and idler pulleys. Install serpentine belt according to routing diagram.
31. 31

    Install flywheel and prepare for transmission mating
    Install new rear main seal if not already installed in block or seal housing. Clean flywheel and crankshaft flange surfaces thoroughly. Position the crankshaft rear coupling/drive plate per the Aston Martin DB9 torque-tube driveline configuration, aligning balance/orientation marks made during disassembly. Install new fasteners and torque per the OEM-specified value plus any torque-to-angle stage — VERIFY the fastener layout, torque, and angle against the DB9 workshop manual, as this vehicle uses a rear transaxle with torque tube rather than an engine-mounted flywheel/bellhousing. Install starter motor and torque mounting bolts to specification.pecification. Connect starter electrical connections. Note: Install new flywheel bolts and torque in star pattern to the manufacturer's specified value plus any torque-to-angle stage — VERIFY against Aston Martin DB9 workshop manual before applying.
    Torque spec

    Flywheel Bolts45 Nm (33 lb-ft)
32. 32

    Reinstall engine assembly into vehicle
    Attach engine hoist to engine lifting eyes and lift engine from stand. Position engine above engine bay and carefully lower while guiding into position, adjusting load leveler angle to maintain clearance from firewall and radiator support. Align the engine rear coupling with the torque tube front coupling and carefully engage them per the Aston Martin procedure (the transmission is a rear transaxle, not engine-mounted — there is no input shaft or torque converter at the engine). Reconnect the torque tube/transaxle assembly per the Aston Martin transaxle procedure and torque fasteners to the manufacturer's specified values — VERIFY layout and specs against the DB9 workshop manual (this vehicle uses a rear transaxle with torque tube, not a direct bellhousing mount). Remove transmission support jack. Install engine mount bolts connecting engine mounts to engine block, torquing to specification. Connect all engine electrical connectors including main harness connectors, sensor connectors, and ground straps. Note: Couple the engine to the torque tube and torque the connection fasteners to the OEM-specified value per Aston Martin factory procedure (the DB9 uses a rear transaxle; verify configuration and torque against factory service data).
    Torque spec

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

    Reconnect all fluid systems
    Connect upper and lower radiator hoses to engine with new clamps. Connect power steering hoses if disconnected, using new O-rings where applicable. Have air conditioning system refrigerant lines reconnected and system recharged by certified technician. Install new oil filter and fill engine with the OEM-specified engine oil grade and capacity (verify viscosity and quantity against Aston Martin factory specification). Install oil drain plug with new crush washer and torque to the OEM-specified value (verify exact torque against Aston Martin DB9 factory service data before applying, as the aluminum pan is easily over-torqued). Fill cooling system with the OEM-specified quantity and type of coolant premix through the radiator and expansion tank (verify capacity and coolant specification against Aston Martin DB9 documentation). Note: Fill cooling system with OAT 50/50 coolant premix through radiator and expansion tank per OEM capacity specification (verify total system capacity against factory data). Note: Install new oil filter and fill engine with the OEM-specified quantity and grade of engine oil (verify capacity and viscosity against Aston Martin DB9 specification). Note: Install new oil filter and fill engine with the OEM-specified quantity and grade of engine oil (verify viscosity and capacity against Aston Martin service data). Note: Fill cooling system with OAT 50/50 coolant premix (verify OEM total system capacity for this engine) through radiator and expansion tank.
    Torque spec

    Oil Drain Plug25 Nm (18 lb-ft)
34. 34

    Final systems check and preparation for start
    Verify all fasteners are torqued to specification and no tools or parts remain in engine bay. Install engine covers and undertray panels. Reconnect battery negative terminal. Pressurize fuel system by cycling ignition key to ON position 3-4 times without cranking. Check for fuel leaks at all connections. Verify engine oil level on dipstick and adjust if necessary. Verify coolant level in expansion tank. Check power steering fluid level and top off if needed. Verify all electrical connections are secure and properly routed.

Reassembly

1. Reassembly follows removal steps in reverse order with critical attention to proper torque specifications and torque-to-yield bolt replacement.
2. All main bearing cap bolts, connecting rod bolts, and cylinder head bolts (if TTY) must be replaced with new fasteners - these are single-use critical components.
3. Verify camshaft timing alignment using factory locking tools before finalizing timing cover installation.
4. Apply RTV sealant at all block-to-pan junction points when installing timing cover and valve covers.
5. Use new gaskets for all disassembled components including cylinder heads, intake manifolds, exhaust manifolds, valve covers, and coolant passages.
6. Fill all systems with proper fluid types and quantities before initial start: 10.5 qts engine oil (5W-30), 10.5 qts coolant (OAT 50/50).
7. Prime oil system by removing fuel pump fuse and cranking engine for 10-15 seconds intervals until oil pressure registers on gauge before allowing engine to start and run.

Verification

• Before starting engine, verify oil pressure gauge shows zero and warning light illuminates with key ON - this confirms gauge function.
• Prime oil system by cranking engine with fuel pump fuse removed until oil pressure registers on dash gauge (typically 10-15 seconds of cranking in intervals).
• On first start, verify oil pressure reaches minimum 20 PSI within 5 seconds of engine starting. If not, shut down immediately and investigate.
• Allow engine to reach operating temperature while monitoring for coolant leaks, oil leaks, and fuel leaks at all connection points.
• Verify cooling fans cycle on and off properly and engine temperature stabilizes in normal range (typically 85-95°C).
• Check for exhaust leaks at manifold connections while engine is running.
• After initial warm-up and cool-down cycle, recheck coolant level and top off as needed - system will purge air pockets during first heat cycle.
• Road test vehicle under light load conditions for first 50 miles, avoiding sustained high RPM or heavy load while rings seat.
• Perform first oil change at 500 miles to remove break-in contaminants and metal particles.
• After 500-mile break-in period, perform compression test and leak-down test to verify proper ring seal and cylinder sealing.
• Monitor oil consumption during first 1000 miles - some consumption is normal during ring break-in but should stabilize by 1500 miles.

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