Cylinder Head R&R

Complete removal and reinstallation of both cylinder heads on the 3.0L V6 Twin Turbo engine, including timing chain service, valve train disassembly, and head gasket replacement.

Warnings

Tools required

Parts

• Cylinder head gasket set (both banks) × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — 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 cover gasket × 1 — Use OEM specification
• Timing chain tensioner gaskets × 2 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Camshaft seals (if applicable) × 4 — Use OEM specification
• Anti-seize compound × 1 — Copper-based high temperature
• Engine oil filter × 1 — Use OEM specification
• RTV silicone sealant (OEM approved) × 1 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake. Disconnect negative battery terminal and wait 10 minutes for airbag system discharge.
2. Drain engine oil completely using new crush washer on drain plug. Drain coolant from radiator petcock and engine block drain plugs.
3. Remove engine cover, air intake system, and intercooler piping from both turbochargers.
4. Remove both turbochargers complete with exhaust manifolds (unbolt from cylinder heads but leave oil and coolant lines connected if possible).
5. Disconnect all electrical connectors from cylinder heads, camshaft position sensors, ignition coils, and fuel injectors. Label each connector.
6. Remove intake manifold assembly complete with fuel rail. Cap all fuel lines to prevent contamination.
7. Remove serpentine belt, front engine covers, and accessories as needed to access timing cover.
8. Support engine from above using engine support fixture or carefully with hoist, as engine mounts may need loosening for access.
9. Position drain pans and shop towels to catch residual coolant and oil during disassembly.

Procedure

1. 1

   Remove valve covers
   Remove valve cover bolts in reverse of tightening sequence (outside-to-center pattern). Carefully lift valve covers off cylinder heads. If covers are stuck, gently tap with rubber mallet. Inspect valve train components for wear while exposed. Remove and discard old valve cover gaskets.
   Torque spec

   Cover Bolts18 Nm (13 lb-ft)
2. 2

   Lock crankshaft and camshafts at TDC cylinder 1
   Rotate crankshaft clockwise to bring cylinder 1 to top dead center on compression stroke. Both camshaft timing marks should align with marks on timing cover. Install crankshaft locking pin through special hole in engine block. Install Maserati camshaft locking tools into slots on rear of all four camshafts (both banks). Verify alignment is perfect before proceeding.
   ⚠Do not force camshaft locking tools. If they do not fit smoothly, crankshaft is not at correct position.
3. 3

   Remove timing cover and timing chain components
   Remove timing cover bolts in sequence and carefully remove timing cover. Note location of different length bolts. Remove timing chain tensioners by first compressing them and locking with pin or clip, then unbolt mounting bolts. Remove timing chain guides. Mark timing chain position relative to camshaft and crankshaft sprockets with paint pen before removal. Remove camshaft sprocket bolts while holding each camshaft with wrench on hex section. Remove timing chains from sprockets.
   ⚠Keep timing chains clean and do not allow them to fall into engine valley where they could contact crankshaft.
   Torque spec

   Cover Bolts18 Nm (13 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)
4. 4

   Remove camshaft bearing caps and camshafts
   With camshafts still locked in position, loosen camshaft bearing cap bolts in reverse sequence (outward from center) in multiple passes to gradually release valve spring pressure. Remove bearing caps and mark each with cylinder bank and position number. Carefully lift out all four camshafts (two per head) and place on clean surface. Note position of intake versus exhaust camshafts.
   ⚠Camshaft bearing caps are machined matched sets. Never mix caps between cylinder heads or positions.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

   Camshaft Cap Bolts14 Nm (10 lb-ft)
5. 5

   Remove rocker arms and hydraulic lash adjusters
   Remove rocker arm shaft bolts evenly in sequence. Lift out rocker arm shafts complete with rocker arms. If rocker arms are individual, remove rocker arm bolts and lift each rocker arm off. Remove hydraulic lash adjusters from cylinder head bores. Keep all components organized by cylinder number and intake/exhaust position for reinstallation in original locations.
   ℹ️Store hydraulic lash adjusters upright in clean engine oil to prevent air from entering.
   Torque spec

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)

   Rocker Arm Bolts30 Nm (22 lb-ft)
6. 6

   Disconnect coolant passages and remaining components
   Disconnect thermostat housing and coolant crossover passages between cylinder heads. Remove all remaining sensors including coolant temperature sensors and knock sensors. Unbolt any remaining brackets, ground straps, or hoses still attached to cylinder heads. Verify all electrical connectors, fuel lines, coolant lines, and oil passages are disconnected.
   Torque spec

   Thermostat Housing Bolts15 Nm (11 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)

   Mounting Bolts50 Nm (37 lb-ft)
7. 7

   Remove cylinder head bolts and cylinder heads
   Loosen cylinder head bolts in reverse of tightening sequence (spiral pattern from outside toward center) in multiple passes. Remove all cylinder head bolts and discard (they are TTY and must be replaced). Carefully break cylinder heads free from engine block using plastic pry points (never use pry bar on mating surfaces). Lift cylinder heads straight up off engine block. Place heads on clean padded surface with combustion chambers facing up.
   ⚠Cylinder heads are heavy (approximately 40 lbs each). Use proper lifting technique or have assistant help.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
8. 8

   Inspect and clean cylinder head and block surfaces
   Remove all old gasket material from cylinder head and engine block mating surfaces using plastic scraper. Do not use metal scrapers or abrasive pads that could damage surfaces. Clean surfaces thoroughly with brake cleaner and lint-free shop towels. Inspect cylinder head surfaces for warpage using precision straight edge and feeler gauges. Maximum warpage is typically 0.002 inches (0.05mm) - verify with service manual. Inspect for cracks, especially between valve seats. Check valve seats and guides for wear. If heads are warped or damaged, they must be machined or replaced.
   ⚠Any gouges, scratches, or imperfections on head gasket surfaces will cause compression leaks and head gasket failure.
9. 9

   Inspect cylinder bores and prepare for reassembly
   Inspect cylinder bore walls for scoring, wear, or damage. Clean cylinder bores lightly with clean lint-free towel moistened with engine oil. Inspect pistons and rings while visible. Stuff clean shop towels into cylinder bores to prevent debris from falling in during head installation. Clean all coolant and oil passages in engine block. Inspect head bolt threads in engine block and chase with tap if necessary.
   ℹ️Do not rotate crankshaft with shop towels in cylinders or severe damage will occur.
10. 10

    Install new head gaskets and position cylinder heads
    Remove shop towels from cylinder bores immediately before head installation. Position new cylinder head gaskets on engine block, ensuring correct orientation (usually marked TOP or FRONT). Verify gasket locating dowels are in place and gaskets fit properly around all water and oil passages. Do NOT use any sealant on head gaskets unless specifically required by manufacturer. Carefully lower cylinder heads onto engine block, aligning with dowel pins. Ensure heads seat fully and are properly positioned.
    ⚠Head gaskets are side-specific (left and right). Verify correct gasket orientation before installation.
11. 11

    Install and torque cylinder head bolts
    Install new TTY cylinder head bolts (never reuse old bolts). Lightly oil bolt threads and underside of bolt heads with clean engine oil. Hand-tighten all bolts in sequence starting from center and spiraling outward. Using torque wrench, tighten all bolts to 65 Nm (48 lb-ft) in sequence. Then tighten each bolt an additional angle as specified in service manual (typically 90 degrees, then additional 90 degrees in separate passes). Use torque angle gauge for angle tightening. Verify all bolts have been tightened through complete sequence.
    ⚠️Cylinder head bolt tightening sequence and angle torque are critical. Improper torquing will result in head gasket failure or head damage.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Reinstall rocker arms and hydraulic lash adjusters
    Install hydraulic lash adjusters into their original cylinder head bores (or new ones if replacing). Ensure adjusters are primed with oil and seated fully. Position rocker arms onto valve stems and lash adjusters in correct locations. If using rocker arm shafts, position shafts and rocker arms as assembly. Tighten rocker arm bolts or rocker arm shaft bolts to specification, ensuring camshaft lobe is pointing away from rocker arm (base circle position) during tightening. Verify all rocker arms move freely and are properly seated on valve stems.
    ⚠Tightening rocker arms with cam lobe at peak will damage valves or rocker components.
    Torque spec

    Rocker Arm Bolts30 Nm (22 lb-ft)

    Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
13. 13

    Install camshafts and bearing caps
    Lubricate all camshaft journals, lobes, and bearing surfaces with assembly lube or clean engine oil. Carefully position all four camshafts into cylinder heads in their correct locations (intake vs exhaust, left bank vs right bank). Install camshaft bearing caps in their exact original positions with markings facing up and in correct orientation. Tighten camshaft bearing cap bolts in sequence from center outward in three passes: first pass light snug, second pass to 7 Nm, final pass to 14 Nm (10 lb-ft). Verify camshafts rotate smoothly by hand.
    ⚠️Installing bearing caps in wrong positions or incorrect orientation will cause immediate camshaft seizure and severe engine damage.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

    Camshaft Cap Bolts14 Nm (10 lb-ft)
14. 14

    Install timing chains and components
    Position timing chains onto camshaft sprockets and crankshaft sprockets, aligning painted timing marks made during disassembly (or per factory timing marks). Install camshaft sprockets onto camshafts with chains in place. Hold each camshaft with wrench on hex section and tighten camshaft sprocket bolts to 80 Nm (59 lb-ft). Install timing chain guides and tighten guide bolts to specification. Compress timing chain tensioners and lock with pin, install tensioners and tighten mounting bolts to 25 Nm (18 lb-ft), then carefully release tensioner pins to apply tension. Verify all timing marks align correctly with camshaft locking tools still in place.
    ⚠️Incorrect timing chain installation will cause valve-to-piston contact and catastrophic engine damage upon startup.
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
15. 15

    Remove locking tools and verify timing
    With timing chains installed and tensioned, carefully remove all camshaft locking tools and crankshaft locking pin. Slowly rotate crankshaft two complete revolutions clockwise by hand using socket on crankshaft bolt. Verify engine rotates smoothly with no binding. Bring crankshaft back to TDC cylinder 1 position. Reinstall camshaft locking tools to verify timing marks still align perfectly. If tools do not fit or timing is off, timing chain installation must be corrected before proceeding.
    ⚠If any resistance is felt during crankshaft rotation, stop immediately and verify valve timing and rocker arm installation.
16. 16

    Install timing cover and related components
    Apply thin bead of RTV silicone sealant to timing cover mating surface only where specified in service manual (typically at block-to-head interfaces). Install new timing cover gasket. Position timing cover and install bolts (noting different lengths). Tighten 8mm timing cover bolts to 25 Nm (18 lb-ft) in sequence starting from center and working outward. Install thermostat housing with new gasket and tighten bolts to 15 Nm (11 lb-ft). Reconnect coolant crossover passages between heads.
    Torque spec

    Cover Bolts18 Nm (13 lb-ft)

    Thermostat Housing Bolts15 Nm (11 lb-ft)
17. 17

    Install valve covers and remaining cylinder head components
    Install new valve cover gaskets into valve cover grooves. Apply small dab of RTV at camshaft cap corners if specified. Position valve covers onto cylinder heads and install valve cover bolts. Tighten bolts in sequence from center outward to 10 Nm (7 lb-ft). Reinstall all sensors including camshaft position sensors, coolant temperature sensors, and knock sensors. Tighten sensor bolts to 11 Nm (8 lb-ft). Reconnect all electrical connectors using labels from disassembly.
    Torque spec

    Cover Bolts18 Nm (13 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)

    Mounting Bolts50 Nm (37 lb-ft)

    Electrical Connector Bolts7 Nm (5 lb-ft)
18. 18

    Install intake manifold and exhaust components
    Install new intake manifold gaskets and position intake manifold assembly with fuel rail. Tighten intake manifold bolts to 25 Nm (18 lb-ft) in sequence from center outward. Reconnect fuel lines and all vacuum lines. Install new exhaust manifold gaskets after applying anti-seize compound to threads of exhaust manifold studs. Position exhaust manifolds (or turbochargers with manifolds) and install nuts. Tighten exhaust manifold nuts to 30 Nm (22 lb-ft) working from hottest area (center) toward cooler areas (ends).
    ℹ️Anti-seize on exhaust studs prevents seizing and makes future service easier.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
19. 19

    Reinstall remaining components and fill fluids
    Reinstall turbocharger oil and coolant lines if disconnected. Reinstall intercooler piping and air intake system. Install new oil filter and reinstall oil drain plug with new crush washer torqued to 35 Nm (26 lb-ft). Fill engine with 5.5 quarts Selenia Racing 10W-60 oil. Fill cooling system with 10 quarts Maserati OAT coolant using vacuum fill method if available, or fill slowly while burping air from system. Reinstall engine covers and accessories. Reconnect battery negative terminal.
    ⚠Failure to properly bleed cooling system will cause air pockets leading to overheating.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Double-check that all electrical connectors are properly seated and locked in place
2. Verify all coolant hoses are secured with clamps and no hoses are kinked or misrouted
3. Confirm all vacuum lines are reconnected and fuel system is properly sealed
4. Check that no tools or shop towels were left in engine compartment
5. Verify oil drain plug, oil filter, and all fluid fill caps are installed and tight

Verification

• Prime oil system by cranking engine with fuel pump fuse removed until oil pressure registers on gauge
• Start engine and immediately verify oil pressure is present. Listen for unusual noises indicating timing or valve train problems
• Allow engine to idle and warm up while monitoring for coolant, oil, or fuel leaks around cylinder heads and gaskets
• Check for exhaust leaks at manifold gasket surfaces while engine is running
• Verify coolant level after engine reaches operating temperature and recheck after cooling down completely
• Use Maserati diagnostic software to verify no fault codes are present and all sensor readings are normal
• Verify camshaft timing is correct using diagnostic software cam/crank correlation test
• Road test vehicle under varying loads to confirm proper engine performance and no misfires or detonation
• Recheck all fluid levels after test drive and inspect for any new leaks
• Torque check critical fasteners including cylinder head bolts (if accessible) after initial heat cycle

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