Cylinder Head Resurface

This procedure covers removal, resurfacing, and reinstallation of cylinder heads on the 2017 Maserati Levante 3.0L V6 Twin Turbo engine, including timing system disassembly and head gasket replacement.

Warnings

Tools required

Parts

• Cylinder head gasket set × 2 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Camshaft seals × 4 — Use OEM specification
• Spark plugs × 6 — NGK or OEM equivalent
• Anti-seize compound × 1 — Copper-based high temp
• Engine coolant × 1 — Maserati OAT Coolant

Fluids

• Selenia Racing 10W-60 — 5.5 qt
• Maserati OAT Coolant — 10 qt

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 15 minutes for system capacitor discharge
3. Remove engine cover and decorative trim pieces
4. Drain engine coolant completely into appropriate container
5. Drain engine oil and remove oil filter
6. Remove front underbody panels for access to lower engine components
7. Tag and photograph all electrical connectors, vacuum lines, and hose routing before disconnection
8. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls

Procedure

1. 1

   Remove intake and accessory components
   Remove air intake system including air filter housing, intake ducts, and mass airflow sensor. Disconnect throttle body electrical connector and coolant hoses. Remove intake manifold by loosening bolts in reverse sequence (outside to center). Disconnect all injector connectors, ignition coils, and associated wiring harnesses. Remove ignition coils and spark plugs from cylinder heads.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Electrical Connector Bolts7 Nm (5 lb-ft)
2. 2

   Remove valve covers and camshaft components
   Disconnect PCV system and breather hoses from valve covers. Remove valve cover bolts in reverse sequence and carefully lift covers away. Remove variable valve timing solenoids and camshaft position sensors from each cylinder head. Keep all components organized by bank (left/right).
   Torque spec

   Cover Bolts18 Nm (13 lb-ft)

   Mounting Bolts50 Nm (37 lb-ft)
3. 3

   Remove exhaust manifolds
   Disconnect oxygen sensors from exhaust manifolds (both upstream and downstream). Remove heat shields. Working from the center bolts outward (hot-to-cold pattern), remove exhaust manifold nuts. Support turbochargers if they remain attached. Keep fasteners separate for each side.
   ⚠Exhaust studs are prone to breaking. Use penetrating oil 24 hours before removal if possible.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
4. 4

   Lock engine timing and remove timing components
   Rotate engine to TDC cylinder 1 using crankshaft bolt. Install crankshaft locking pin through bellhousing access hole. Install camshaft locking tools on both cylinder heads to secure camshafts in position. Remove timing chain cover bolts and carefully separate cover from engine block. Mark timing chain to sprocket relationship with paint. Remove timing chain tensioners, then chain guides. Carefully remove timing chains from camshaft sprockets while keeping crankshaft locked.
   ⚠️Engine MUST be locked in position before removing timing components. Any movement can result in valve damage upon reassembly.
   Torque spec

   Cover Bolts18 Nm (13 lb-ft)
5. 5

   Support engine and remove cylinder head mounting
   Install engine support fixture across engine bay to support engine weight. Remove engine mount bolts as needed for cylinder head clearance. Disconnect any remaining coolant hoses, temperature sensors, and knock sensors from cylinder heads. Label all sensor locations.
   Torque spec

   Mounting Bolts50 Nm (37 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)
6. 6

   Remove cylinder heads
   Loosen cylinder head bolts in reverse of tightening sequence (outside to center, spiral pattern). Remove bolts completely and set aside for disposal (TTY bolts cannot be reused). Carefully lift cylinder head straight up to avoid damaging gasket surfaces. Use lifting hooks if available. Place cylinder heads on clean padded surface with combustion chambers facing up. Remove and discard old head gaskets.
   ⚠️Cylinder heads are extremely heavy (approximately 40 lbs each). Use proper lifting technique or assistance.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
7. 7

   Inspect and prepare for resurfacing
   Clean all gasket material from cylinder head mating surfaces using plastic scrapers only. Do NOT use metal scrapers that can gouge aluminum surfaces. Use straightedge and feeler gauge to check cylinder head flatness at multiple points. Check diagonally, lengthwise, and crosswise. Flatness must be within 0.002 inches. Measure deck height and record measurements. Transport cylinder heads to machine shop for professional resurfacing. Specify maximum material removal of 0.008 inches total per head.
   ⚠Aluminum cylinder heads are easily damaged. Never use wire wheels or aggressive abrasives on gasket surfaces.
8. 8

   Clean engine block deck surfaces
   Thoroughly clean cylinder block deck surfaces using plastic gasket scrapers. Remove all traces of old gasket material. Stuff clean rags into cylinder bores to prevent debris from entering. Use brake cleaner and lint-free cloths to clean surfaces to bare metal. Remove rags and vacuum out any debris. Check block deck surface flatness with straightedge. Inspect cylinder bores for damage or scoring. Clean all bolt holes using thread chaser or bottoming tap. Blow out holes with compressed air.
   ⚠Any debris left in cylinder bores or bolt holes can cause improper torque or engine damage.
   Torque spec

   Gasket Surface Bolts22 Nm (16 lb-ft)
9. 9

   Install new head gaskets and position cylinder heads
   After cylinder heads return from machine shop, inspect resurfacing quality and cleanliness. Install new head gasket positioning dowels if needed. Place new head gaskets on block deck, ensuring correct orientation (TOP marking faces up). Verify all coolant and oil passages align properly. Carefully lower cylinder heads onto block, using dowel pins for alignment. Do not slide heads on gasket surface.
   ⚠Head gaskets are not interchangeable between left and right banks. Verify correct gasket orientation before installation.
   Torque spec

   Gasket Bolts21 Nm (16 lb-ft)
10. 10

    Install and torque cylinder head bolts
    Install NEW cylinder head bolts finger-tight in all positions. Following the factory tightening sequence (center to outside, spiral pattern), torque all bolts to 65 Nm (48 lb-ft) using calibrated torque wrench. Using torque angle gauge, perform first angle tightening of 90 degrees on all bolts in sequence. Perform second angle tightening of 90 degrees on all bolts in sequence. Perform final angle tightening of 45 degrees on all bolts in sequence. Total angle after initial torque is 225 degrees.
    ⚠️Cylinder head bolt torque sequence and angle tightening MUST be followed exactly. Do not skip or reverse sequence steps.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
11. 11

    Reinstall timing system
    With crankshaft and camshafts still locked in position using special tools, reinstall timing chains onto sprockets, aligning timing marks made during disassembly. Install chain guides and secure with bolts. Install timing chain tensioners but do not activate yet. Verify all timing marks align correctly before removing locking tools. Apply new gasket or sealant to timing chain cover. Install cover and torque bolts to specification in sequence.
    ⚠️Double-check all timing marks before removing locking tools. Incorrect timing will cause immediate engine damage on startup.
    Torque spec

    Cover Bolts18 Nm (13 lb-ft)

    Gasket Bolts21 Nm (16 lb-ft)
12. 12

    Reinstall exhaust manifolds
    Clean exhaust manifold mating surfaces and install new gaskets. Apply copper anti-seize compound to exhaust manifold studs. Position exhaust manifolds and install new nuts finger-tight. Torque exhaust manifold nuts to 30 Nm (22 lb-ft) working from center outward (hot-to-cold pattern). Reconnect oxygen sensors and install heat shields.
    ℹ️Anti-seize compound is critical for future exhaust manifold removal.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
13. 13

    Reinstall camshaft components and valve covers
    Reinstall camshaft position sensors and variable valve timing solenoids to each cylinder head. Install new valve cover gaskets ensuring proper seating in cover grooves. Position valve covers on heads and install bolts finger-tight. Torque valve cover bolts to 10 Nm (7 lb-ft) in proper sequence (center to outside). Reconnect PCV system and breather hoses.
    Torque spec

    Cover Bolts18 Nm (13 lb-ft)

    Mounting Bolts50 Nm (37 lb-ft)
14. 14

    Reinstall intake system and accessories
    Install new intake manifold gaskets. Position intake manifold and install bolts finger-tight. Torque intake manifold bolts to 25 Nm (18 lb-ft) in proper sequence (center to outside). Reconnect all fuel injector connectors, coolant hoses, and vacuum lines per photos taken during disassembly. Install new spark plugs to manufacturer specification. Reinstall ignition coils. Reinstall throttle body and air intake system. Reconnect all electrical connectors and sensors.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Electrical Connector Bolts7 Nm (5 lb-ft)
15. 15

    Refill fluids and perform initial startup
    Reinstall engine mount bolts and remove engine support fixture. Install new oil filter and refill engine with 5.5 quarts Selenia Racing 10W-60 oil. Refill cooling system with 10 quarts Maserati OAT coolant, bleeding air from system at bleeder valves. Reconnect negative battery cable. Perform visual inspection of all connections. Prime fuel system by cycling ignition on/off three times without cranking. Start engine and check immediately for leaks, unusual noises, or warning lights. Allow engine to reach operating temperature while monitoring coolant level and temperature gauge.
    ⚠First startup is critical. Be prepared to shut down immediately if oil pressure does not build within 5 seconds or any abnormal sounds occur.

Reassembly

1. Torque all fasteners to exact specifications using calibrated torque wrench
2. Replace all torque-to-yield (TTY) bolts with new OEM parts
3. Apply anti-seize compound to exhaust manifold studs as specified
4. Ensure all timing marks align correctly before removing camshaft and crankshaft locking tools
5. Use new gaskets for all mating surfaces including head gaskets, valve covers, intake manifold, and exhaust manifolds
6. Follow all tightening sequences from center outward where specified
7. Reinstall all components in reverse order of removal, referencing photos taken during disassembly

Verification

• Verify no coolant, oil, or fuel leaks after initial startup and at operating temperature
• Check that engine idles smoothly without misfires or unusual noises
• Verify proper oil pressure reading on instrument cluster
• Confirm coolant temperature reaches and maintains normal operating range
• Test drive vehicle and verify normal acceleration, no hesitation, and smooth power delivery
• Scan for diagnostic trouble codes using factory scan tool - there should be no stored codes
• Recheck cylinder head bolt torque after 500 miles if specified by manufacturer (consult service manual)
• Monitor coolant and oil levels for first few days of operation to detect any consumption issues
• Verify exhaust system has no leaks at manifold connections

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