Timing Chain Kit

Complete timing chain system replacement on the 2009 Aston Martin DB9 6.0L V12, including chains, tensioners, guides, cam phasers, and front cover seals. This is an extensive procedure requiring engine disassembly and precise cam-crank timing alignment.

Warnings

Tools required

Parts

• Timing chain kit (includes chains, tensioners, guides, sprockets) × 1 — Use OEM specification
• Cam phaser assemblies (if not included in kit) × 4 — Use OEM specification
• Timing cover gasket/seal kit × 1 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Engine coolant (OAT 50/50) × 1 — Use OEM specification
• RTV silicone gasket maker (high-temp) × 1 — Use OEM specification
• Timing cover bolt set (if not reusing) × 1 — Use OEM specification

Fluids

• engine_oil — 10.5 qt
• coolant — 10.5 qt

Preparation

1. Disconnect negative battery cable and isolate from terminal
2. Raise vehicle on lift and support securely on jack stands at manufacturer lift points
3. Remove engine undertray and splash shields
4. Drain engine oil completely and remove oil filter
5. Drain engine coolant from radiator and block drain plugs into suitable container
6. Remove front wheels for access to subframe area
7. Document all electrical connector positions with photos before disconnection
8. Allow engine to cool completely if recently operated (minimum 4 hours)

Procedure

1. 1

   Remove Front Accessory Drive Components
   Remove the serpentine belt by releasing the automatic tensioner. Remove the belt tensioner assembly. Disconnect the alternator electrical connectors and remove the alternator mounting bolts to remove the alternator. Remove the power steering pump mounting bolts and secure the pump aside without disconnecting hydraulic lines. Remove the A/C compressor mounting bolts and secure aside without disconnecting refrigerant lines. Remove the water pump pulley (typically 4 bolts). Tag and disconnect all necessary vacuum lines and electrical connectors from the front of the engine that will interfere with timing cover removal. Note: Install the serpentine belt tensioner and belt according to the factory routing diagram for this vehicle.
2. 2

   Remove Intake System and Valve Covers
   Remove the engine cover (if equipped). Disconnect the air intake system from the throttle bodies. Remove the intake manifold assembly by disconnecting fuel lines (relieve fuel system pressure first), throttle linkages, and all vacuum connections. Remove all ignition coils from the cam/valve covers (verify cover configuration — this V12 uses multiple cam covers across both banks). Disconnect any wiring harnesses attached to the valve covers. Remove the valve cover bolts gradually and evenly in reverse of the factory tightening sequence. Verify the correct sequence against Aston Martin documentation. Carefully lift valve covers and set aside with gaskets (confirm the exact number of cam/valve covers and gaskets — the parts list shows 2 but this V12 may use 4; verify against Aston Martin documentation). Inspect cam lobes and rockers while covers are off; document any wear. Note: Remove all ignition coils (verify exact count against Aston Martin documentation — this V12 is coil-on-plug; confirm whether single or dual plug per cylinder) and set them aside in labeled order. Note: Remove all ignition coils (12 total, 6 per bank) from both valve covers.
3. 3

   Position Engine at TDC and Install Locking Tools
   Rotate the crankshaft clockwise (viewing from front) using a socket on the crankshaft pulley bolt until cylinder 1 is at top dead center (TDC) on the compression stroke. Verify TDC by checking that both intake and exhaust valves on cylinder 1 are closed (rockers loose). Install the crankshaft timing/TDC locking tool per the factory service procedure (confirm exact location and engagement point in the Aston Martin workshop manual before proceeding). The tool should engage the crankshaft only when cylinder 1 is at TDC. Install cam locking tools to lock all four camshafts in position at the factory-designated engagement points (confirm front vs. rear location per the Aston Martin service manual). These tools engage machined slots on the camshafts. Verify that all locking tools are fully seated and secure. Note: Install the crankshaft timing peg tool into the designated hole in the engine block (verify the exact peg location against the factory service tool documentation for this engine). Note: Install the factory cam locking tools to lock all four camshafts in position (verify tool location and engagement method against the Aston Martin/Ford 303-series service tool instructions for this engine). Note: Install the crankshaft timing peg tool into the designated hole in the engine block at the position specified in the factory service tool documentation. The peg should engage the crankshaft at the TDC reference point when properly positioned. Verify tool location against factory documentation before use. Note: Install cam locking tools to lock all four camshafts in position per the factory service tool documentation. Verify the engagement location (front or rear of heads) and tool part numbers against Aston Martin special service tool references before use.
4. 4

   Remove Crankshaft Pulley and Harmonic Balancer
   Install the harmonic balancer holding tool to prevent crankshaft rotation. The DB9 typically uses a multi-pin tool that engages holes in the balancer face. Remove the crankshaft pulley bolt using an impact wrench or breaker bar (turns counterclockwise). This bolt is a high-clamp-load fastener and will require significant force to remove. Once bolt is removed, use a harmonic balancer puller to remove the balancer from the crankshaft snout. Do not pry against the timing cover. Inspect the balancer for rubber deterioration or separation; replace if damaged. Note the orientation of any locating keys or dowels. Note: Remove the crankshaft pulley bolt using an impact wrench or breaker bar (standard right-hand thread, turns counterclockwise to loosen). This bolt is torqued very high and will require significant force; obtain the exact removal/installation torque and any angle stage from the Aston Martin service manual. Note: Remove the crankshaft pulley bolt using an impact wrench or breaker bar (standard right-hand thread, turns counterclockwise to loosen). This bolt is high-torque and will require significant force. Obtain the exact removal/installation torque and any torque-angle specification from Aston Martin factory documentation before reassembly.
5. 5

   Remove Front Timing Cover
   Disconnect any remaining sensors or harnesses attached to the timing cover (typically crankshaft position sensor). Remove the oil pan-to-timing cover bolts from underneath the vehicle (access from below). Remove all timing cover bolts, noting their positions as they are different lengths. The DB9 V12 timing cover is retained by multiple bolts of varying sizes and lengths (verify exact count and sizes against factory documentation). Work in a crossing pattern to avoid warping the cover. Gently pry the timing cover away from the block using plastic pry tools at designated pry points (typically cast bosses). Do not pry against sealing surfaces. Remove the cover and old gasket material. Inspect the cover for cracks, especially around bolt holes. Note: The DB9 V12 timing cover is retained by multiple bolts of varying length and size; confirm the exact count, sizes, and positions against the Aston Martin service manual before removal.
6. 6

   Inspect and Document Timing Chain Alignment
   With the cover removed and cam locks still installed, photograph the timing chain alignment marks for reference. The DB9 V12 uses a primary chain driving intermediate sprockets, with secondary chains driving each bank's camshafts. Verify that all colored links or timing marks align with their corresponding marks on sprockets. The crankshaft sprocket should have a mark aligned with a reference on the block or chain. Each cam sprocket should have its mark aligned with the corresponding chain link (typically a colored or marked link). Document the routing of each chain around guides and tensioners. This is your reference for correct reassembly.
7. 7

   Release and Remove Timing Chain Tensioners
   The DB9 uses hydraulic timing chain tensioners; confirm the exact number and per-bank arrangement against the Aston Martin service manual before ordering replacements. Release tension on each tensioner by carefully compressing the tensioner plunger and installing a retaining pin or clip through the alignment hole to lock it in the retracted position. Remove the tensioner mounting bolts and remove each tensioner. Inspect tensioners for hydraulic fluid leakage, scored plungers, or weak springs. These are not rebuildable and must be replaced if defective. Keep tensioners organized by position for comparison with new units.
   Torque spec

   Tensioner Bolt27 Nm (20 lb-ft)
8. 8

   Remove Timing Chain Guides
   Remove the fixed timing chain guides. These are typically plastic or composite rails bolted to the block or head with 2 bolts each. The DB9 has multiple guides that control chain position and reduce vibration (verify exact count against the timing chain kit contents or factory documentation). Remove the guide bolts and carefully extract each guide. Some guides may be located between chains or in tight spaces requiring careful manipulation. Inspect guides for wear grooves, cracks, or material loss. Any guide showing more than 1mm of wear depth should be replaced. Note the orientation and position of each guide for correct installation. Note: The DB9 has multiple fixed and tensioner guides that control chain position; confirm the exact number and locations against the Aston Martin parts catalog and timing chain kit contents.
   Torque spec

   Guide Bolts10 Nm (7 lb-ft)
9. 9

   Remove Cam Phasers and Camshaft Sprockets
   With cam locking tools still in place, mark each cam phaser and sprocket position relative to its camshaft for reference. Remove the cam phaser/sprocket mounting bolts. Confirm the exact number of variable cam phasers on this specific engine (intake-only vs. intake and exhaust) against the Aston Martin service manual before ordering and removing. These bolts typically thread into the front of the camshaft. Use a hex key or socket on the camshaft hex flat to hold the cam stationary while loosening the phaser bolt. Remove each cam phaser assembly (phaser and sprocket are typically one unit on this engine). If sprockets are separate, remove the camshaft sprocket bolts and remove sprockets. Note that intake and exhaust camshaft sprockets may be different and are not interchangeable. Label each sprocket with its position (LH intake, LH exhaust, RH intake, RH exhaust) for comparison with new parts; verify interchangeability against factory documentation. Note: Remove the cam phaser/sprocket mounting bolts (verify the number and location of variable cam phasers — some configurations phase intake cams only rather than all four camshafts). Note: Remove the camshaft sprocket/gear mounting bolts (4 total, one per camshaft). These bolts thread into the front of each camshaft. IMPORTANT: Resolve the phaser question against factory documentation before ordering parts — the 2009 DB9 6.0L V12 does NOT use variable cam phasers; it uses fixed or vernier-adjustable camshaft sprockets. Remove the 'Cam phaser assemblies' line from the parts list if phasers are confirmed absent.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)

   Camshaft Sprocket Bolts80 Nm (59 lb-ft)
10. 10

    Remove Timing Chains and Crankshaft Sprocket
    Remove the secondary timing chains (one per cylinder bank) by lifting them off their respective cam sprockets and intermediate sprockets. Note the chain routing carefully. Remove the primary timing chain by lifting it off the crankshaft sprocket and intermediate sprockets. Remove any idler sprockets if present by removing their mounting bolts. Remove the crankshaft timing sprocket by pulling it straight off the crankshaft snout. It may require gentle prying with two small pry bars on opposite sides, but should not be forced. If the sprocket is stuck, use a harmonic balancer-style puller. Inspect the crankshaft nose for wear or damage. Inspect all sprockets for wear on teeth; any hooked or worn teeth indicate replacement is needed.
    Torque spec

    Timing Chain Idler Sprocket25 Nm (18 lb-ft)
11. 11

    Clean and Inspect Timing System Mounting Surfaces
    Thoroughly clean all timing chain mounting surfaces on the block, heads, and timing cover. Remove all old gasket material and RTV sealant using a plastic scraper (never metal on aluminum surfaces). Clean the crankshaft nose, cam noses, and all sprocket mounting surfaces with brake cleaner or solvent. Inspect the block and head surfaces for cracks or damage. Verify that all oil passages in the block that supply the cam phasers and tensioners are clear and clean. Use compressed air to blow out passages. Inspect the oil pump (typically visible with timing cover removed) for wear or damage. If oil pump shows wear, now is the time to replace it. Clean the timing cover interior thoroughly, ensuring no debris remains that could contaminate the new chains.
12. 12

    Install New Crankshaft Sprocket and Verify TDC
    Install the new crankshaft timing sprocket onto the crankshaft nose. Ensure any locating key or dowel is properly aligned. The sprocket should slide on smoothly; if excessive force is required, check for burrs or debris. Verify that the timing mark on the crankshaft sprocket is visible and properly oriented (typically at 12 o'clock position when at TDC). Reinstall the crankshaft timing peg tool to verify the engine is still at TDC. The peg should engage the crankshaft slot fully. If the crankshaft has moved, remove the peg and rotate the crank back to TDC position.
13. 13

    Install New Timing Chain Guides
    Install the new fixed timing chain guides in their original positions. Apply a small amount of clean engine oil to the guide surfaces that will contact the chains. Install guide mounting bolts and torque in the sequence specified in your timing chain kit instructions (if provided). Guides should be snug but not over-torqued as they mount to aluminum. Verify that no guides interfere with chain routing paths and that all guides are flush against their mounting surfaces.
    Torque spec

    Guide Bolts10 Nm (7 lb-ft)
14. 14

    Install Primary Timing Chain
    Route the new primary timing chain around the crankshaft sprocket, ensuring the colored or marked link aligns with the timing mark on the crankshaft sprocket (typically at 12 o'clock). Route the chain around any intermediate sprockets or idler sprockets according to your documented routing from disassembly. If equipped with idler sprockets, install them now with mounting bolts torqued to specification. Verify chain routing matches factory configuration. The chain should have slight slack at this point since tensioners are not yet installed.
    Torque spec

    Timing Chain Idler Sprocket25 Nm (18 lb-ft)
15. 15

    Install Secondary Timing Chains
    Route each secondary timing chain (one per bank) around its respective intermediate sprocket. Ensure colored or marked links align with any timing marks on intermediate sprockets. Allow chains to hang in position ready for cam sprocket installation. Verify chain routing around guide slots and that chains are not twisted. The chains will have significant slack until cam sprockets and tensioners are installed.
16. 16

    Install New Cam Phasers and Camshaft Sprockets
    With cam locking tools still installed, position the first camshaft sprocket onto its camshaft, aligning the chain colored/marked link with the timing mark on the sprocket. Ensure the phaser mounts flush against the camshaft face. Install the cam phaser bolt finger-tight. Use a hex key or wrench on the camshaft hex flat to hold the cam stationary. Apply medium-strength threadlocker to the phaser bolt threads as specified. Torque the phaser bolt to specification. Repeat for all four cam phasers, ensuring each phaser is labeled correctly for its position (intake vs. exhaust, left vs. right). Double-check that all timing marks align with their respective colored chain links before tightening bolts. Verify that the cam locking tools remain fully engaged after tightening each phaser.
    Torque spec

    Cam Phaser Bolt65 Nm (48 lb-ft)

    Camshaft Sprocket Bolts80 Nm (59 lb-ft)
17. 17

    Prepare and Install Timing Chain Tensioners
    Prepare each new timing chain tensioner by compressing the plunger and installing the retaining pin or clip to lock it in the retracted position. Some tensioners come pre-compressed with a pin installed. Lubricate the tensioner plunger and body with clean engine oil. Install each tensioner into its mounting position with the tensioner bolt, torque to specification. Install all tensioners but do not release the retaining pins yet. Verify that each tensioner is oriented correctly and seats fully against its mounting surface. The tensioner plunger should face the chain and guide it will tension.
    Torque spec

    Tensioner Bolt27 Nm (20 lb-ft)
18. 18

    Release Tensioners and Verify Chain Tension
    Release each timing chain tensioner by carefully removing the retaining pin or clip. The tensioner plunger should extend smoothly and apply pressure to the chain guide. If a tensioner does not extend or extends too slowly, it may be defective or have air in the hydraulic system. Gently rotate the crankshaft clockwise approximately 90 degrees by hand (with cam locks still installed if possible, or remove locks if rotation is restricted). This will allow the tensioners to seat properly and take up chain slack. Return the crankshaft to TDC and reinstall the crankshaft timing peg if it was removed. Verify all timing marks still align correctly after rotation. Check chain tension by pressing on the chain between sprockets; it should have minimal slack (approximately 5-10mm deflection) but should not be over-tensioned.
19. 19

    Install New Front Crankshaft Seal and Prepare Timing Cover
    Remove the old crankshaft front seal from the timing cover using a seal puller or pick. Clean the seal bore in the timing cover thoroughly. Lubricate the new crankshaft seal with clean engine oil. Install the new seal into the timing cover using a seal driver or appropriate socket that contacts only the outer edge of the seal. Drive the seal in until it is flush with the timing cover surface or to the depth specified (do not over-drive). Clean all timing cover gasket surfaces again with brake cleaner. Install a new timing cover gasket onto the block, or prepare to apply RTV sealant per factory specification. Some DB9 engines use a formed gasket, others use RTV only. If using RTV, apply a continuous 3-4mm bead around the timing cover mating surface, with extra beads around bolt holes and oil passages as specified.
20. 20

    Install Timing Cover
    Carefully position the timing cover onto the engine block, ensuring the crankshaft seal slides over the crankshaft nose without damage. Guide the cover into position, aligning all bolt holes. Install timing cover bolts finger-tight, ensuring correct bolt lengths in each position. Torque timing cover bolts in the specified sequence (typically start at center and work outward in a crossing pattern). Torque 6mm bolts first, then 8mm bolts, then 10mm bolts, each to their respective specification. Install the oil pan-to-timing cover bolts from underneath and torque to specification. Do not over-torque small fasteners. Reconnect the crankshaft position sensor and any other sensors to the timing cover. Verify no wiring is pinched.
    Torque spec

    Timing Cover Bolt22 Nm (16 lb-ft)
21. 21

    Install Harmonic Balancer and Crankshaft Pulley
    Lubricate the crankshaft nose and seal lip with clean engine oil. Align the harmonic balancer with the crankshaft key or dowel and slide it onto the crankshaft by hand as far as possible. Use the crankshaft pulley bolt and a large washer to draw the balancer onto the crank, but do not fully torque yet. Install the balancer fully until it seats against the crankshaft timing sprocket or shoulder. Install the harmonic balancer holding tool. Install a new crankshaft pulley bolt (if TTY type, these are typically not reused). Torque the new crankshaft pulley bolt to the OEM specification using the factory torque-plus-angle procedure with a calibrated torque wrench and angle gauge (do not use an impact wrench for final torque). Verify the balancer is fully seated and does not wobble. Note: Install a new crankshaft pulley bolt and torque it to the factory specification using a calibrated torque wrench (confirm the exact torque and any final angle/degree stage from the Aston Martin service manual). Do not use an impact wrench for final torque. Note: Torque the crankshaft pulley bolt to the factory specification (typically a torque value followed by an angle for torque-to-yield bolts) using a calibrated torque wrench. Do not use an impact wrench for final torque. Obtain the exact value and angle from Aston Martin documentation.
    Torque spec

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
22. 22

    Remove Cam Locking Tools and Verify Engine Rotation
    Remove all camshaft locking tools from the cylinder heads (confirm front vs. rear engagement location per the Aston Martin service manual). Remove the crankshaft timing peg from the block. Manually rotate the crankshaft clockwise two complete revolutions using a socket on the crankshaft pulley bolt. The engine should rotate smoothly without binding or unusual resistance. Reinstall the crankshaft timing peg to verify TDC. The peg should engage the crankshaft slot when cylinder 1 returns to TDC. Reinstall the cam locking tools; they should engage properly if cam timing is correct. If locking tools do not engage or the crankshaft peg does not align, timing is incorrect and must be rechecked. Remove timing cover and repeat timing chain installation.
23. 23

    Reinstall Valve Covers
    Clean valve cover gasket surfaces on both cylinder heads. Install new cam/valve cover gaskets onto each cover (verify gasket quantity — this V12 may require four cover gaskets depending on cover configuration), ensuring gasket sealing beads fit properly in their grooves. Apply a small dab of RTV sealant at the cam cap corners where the cap meets the head (typical leak points). Position valve covers onto heads and install valve cover bolts finger-tight. Torque valve cover bolts in sequence (typically start at center and work outward) to specification. Do not over-torque as valve covers are aluminum and can warp. Reconnect any wiring harnesses to the valve covers. Reinstall ignition coils into their original positions and torque mounting bolts to specification.
    Torque spec

    Valve Cover Bolts10 Nm (7 lb-ft)
24. 24

    Reinstall Intake System and Accessory Components
    Reinstall the intake manifold assembly using new gaskets. Torque intake manifold bolts in the specified sequence. Reconnect all fuel lines, throttle linkages, vacuum connections, and electrical connectors to the intake system. Reinstall the air intake system to the throttle bodies. Reinstall the water pump pulley and torque bolts to specification. Reinstall the A/C compressor and power steering pump to their mounting brackets with bolts torqued to specification. Reconnect alternator mounting and electrical connections. Install the serpentine belt tensioner and belt according to the accessory drive routing diagram (refer to your disassembly photos or the Aston Martin service manual for correct routing).
25. 25

    Refill Fluids and Final Checks
    Install a new oil drain plug crush washer and reinstall the drain plug, torque to specification. Install a new oil filter, pre-filling it with fresh engine oil and lubricating the gasket. Refill engine with the OEM-specified quantity (verify exact capacity against factory specification — the 6.0L V12 holds approximately 12 quarts with filter) of the Aston Martin-specified engine oil (verify grade against factory specification; this engine typically requires a 5W-40 or 5W-50 synthetic, NOT 5W-30). Refill cooling system with the Aston Martin-specified coolant mixture to the OEM total capacity (verify exact coolant type and system capacity against factory specification). Bleed cooling system by running engine with heater on until thermostat opens and air is purged. Reinstall front wheels and torque lug nuts to specification. Reinstall engine undertray and splash shields. Reconnect negative battery cable. Perform final visual inspection of all connections, hoses, and fasteners. Note: Refill the cooling system with the factory-specified coolant (confirm type and exact total capacity for the 2009 DB9 6.0L V12 from the Aston Martin service manual). Note: Refill the engine with the factory-specified oil grade and quantity for the 2009 DB9 6.0L V12 (confirm exact capacity and viscosity from the Aston Martin owner's/service manual before filling). Note: Refill engine with the factory-specified oil grade and quantity for the 6.0L V12 (verify exact capacity and viscosity against the Aston Martin service manual before filling). Note: Refill cooling system with the factory-specified coolant type and 50/50 mixture (verify exact coolant specification and total system capacity against the Aston Martin service manual).
    Torque spec

    Oil Drain Plug25 Nm (18 lb-ft)
26. 26

    Initial Start and Break-In
    Before starting, disconnect the fuel pump fuse or relay and crank the engine in short bursts to prime the oiling system and build oil pressure before first start-up. Reinstall fuel pump fuse. Start the engine and immediately verify oil pressure on the gauge. Listen for any unusual noises from the timing chain area. If any rattling, knocking, or abnormal sounds are heard, shut down immediately and investigate. Allow engine to idle for 5 minutes while monitoring for leaks around the timing cover, valve covers, and oil filter. Check coolant level and top off if needed. Perform a 20-minute break-in run at varying RPM between 1500-3000, avoiding sustained high load. After break-in, shut down and allow to cool for 30 minutes. Recheck oil level and coolant level; top off as needed. Inspect for any leaks.

Reassembly

1. Reassembly is covered in the procedure steps above, which include installation instructions integrated with removal
2. Always replace crush washers, gaskets, and seals during timing chain service
3. Use threadlocker on cam phaser bolts as specified in the torque spec list
4. Verify cam timing alignment at least twice before final timing cover installation
5. After initial start, allow engine to reach operating temperature and recheck for leaks before returning vehicle to service

Verification

• Engine should idle smoothly without unusual mechanical noise from the timing chain area
• No oil leaks visible around timing cover, valve covers, or front crankshaft seal after test drive
• Oil pressure should be within normal range (typically 25-65 PSI depending on RPM and temperature)
• Engine should accelerate smoothly without hesitation, indicating proper cam phaser operation
• Coolant level should remain stable with no signs of leaks or air in the system
• Scan for any diagnostic trouble codes related to cam position sensors; clear any codes set during the procedure and verify they do not return
• After 500 miles, recheck oil level and inspect timing cover area for any signs of seepage

Related trouble codes on this vehicle

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