Long Block Replacement

Complete replacement of the 3.0L V6 Twin Turbo long block assembly, including removal of the original engine and installation of a new long block with transfer of external components.

Warnings

Tools required

Parts

• Complete long block assembly × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Engine coolant thermostat with gasket × 1 — Use OEM specification
• Water pump gasket × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gasket set × 2 — Use OEM specification
• Valve cover gasket set × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine mount bolts × 8 — Use OEM specification
• Coolant hose clamps × 12 — OEM style hose clamps
• Anti-seize compound × 1 — Nickel-based high-temp
• RTV gasket maker × 1 — OEM approved silicone

Fluids

• Selenia Racing 10W-60 — 5.5 qt
• Maserati OAT Coolant — 10 qt
• ZF Lifeguard 8 — 1 qt
• DOT 4 Racing Brake Fluid — 0.5 qt

Preparation

1. Position vehicle on level ground with adequate overhead clearance for engine removal (minimum 8 feet)
2. Disconnect negative battery terminal and wait 10 minutes for airbag system capacitors to discharge
3. Remove engine cover and upper decorative trim panels
4. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls, then crank for 5 seconds
5. Drain engine coolant completely from radiator drain and engine block drain plugs into appropriate container
6. Drain engine oil and remove oil filter, install drain plug with new crush washer
7. Remove front wheels and raise vehicle on lift to working height
8. Remove underbody panels and splash shields for access to subframe and exhaust
9. Label and photograph all vacuum lines, electrical connectors, and hose routing before disconnection

Procedure

1. 1

   Remove intake and fuel system components
   Disconnect throttle body electrical connector and remove air intake ducting from both turbochargers. Disconnect fuel supply and return lines using appropriate disconnect tools, have shop towels ready for residual fuel. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached, securing it aside. Disconnect PCV hoses and brake booster vacuum line. Remove intake manifold mounting bolts in reverse of tightening sequence and lift intake manifold clear, noting gasket condition.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
2. 2

   Disconnect exhaust system and turbochargers
   From underneath vehicle, disconnect exhaust system at the connection point behind catalytic converters, supporting exhaust weight with jack stand. Remove heat shields around turbochargers. Disconnect oxygen sensor connectors (4 total). Remove turbocharger oil feed and return lines, capping all openings immediately to prevent contamination. Disconnect turbocharger wastegate vacuum lines and position control solenoids. Mark turbocharger clocking orientation before removal for reinstallation reference.
   ⚠Exhaust manifold studs are prone to breaking on this engine. Apply penetrating oil 24 hours before removal if possible. Have replacement studs available.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
3. 3

   Remove valve covers and engine accessories
   Remove ignition coil packs and set aside with connectors attached. Disconnect both camshaft position sensor connectors and crankshaft position sensor. Remove valve cover bolts in reverse sequence and carefully lift valve covers, noting condition of gaskets. Remove alternator mounting bolts and disconnect electrical connections, secure alternator aside. Remove AC compressor mounting bolts but leave refrigerant lines attached, support compressor with wire away from work area. Remove power steering pump (if equipped) or delete bracket. Remove engine oil dipstick tube.
   Torque spec

   Cover Bolts18 Nm (13 lb-ft)

   Mounting Bolts50 Nm (37 lb-ft)
4. 4

   Disconnect coolant system and accessories
   Disconnect upper and lower radiator hoses at engine connections. Remove thermostat housing and note thermostat orientation. Disconnect heater hoses at firewall connections. Remove coolant crossover pipe if equipped. Disconnect coolant temperature sensor connectors and remove sensors if they will be reused. Remove water pump if not included with long block, noting bolt lengths and positions. Remove accessory drive belts by releasing tensioners.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
5. 5

   Remove timing cover and verify timing marks
   Remove crankshaft pulley bolt using holder tool (this is a high-torque fastener). Remove harmonic balancer using appropriate puller. Remove timing cover bolts in sequence, noting different bolt lengths. Carefully separate timing cover from block, tapping gently if needed. Before removing timing components, rotate engine to TDC on cylinder 1 and verify all timing marks align with factory positions. Take detailed photos of timing chain routing, tensioner positions, and cam sprocket alignment. This documentation is critical for new engine assembly verification.
   ⚠️Verify and document exact timing chain routing and all timing marks before proceeding. This information is essential for new long block installation.
   Torque spec

   Cover Bolts18 Nm (13 lb-ft)
6. 6

   Separate transmission from engine
   Support transmission securely with transmission jack positioned at center of gravity. Remove transmission bellhousing inspection cover. Mark flexplate-to-torque converter orientation with paint marker. Remove torque converter to flexplate bolts by rotating crankshaft to access each bolt. Remove all transmission-to-engine bellhousing bolts, noting different lengths and positions. Carefully slide transmission rearward approximately 2 inches to disengage input shaft from clutch/flexplate, then lower transmission slightly and secure on jack. Verify torque converter remains with transmission.
   ⚠The transmission weighs approximately 180 lbs and must be properly supported throughout separation and reinstallation to prevent damage.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
7. 7

   Disconnect engine mounts and electrical connections
   Disconnect all remaining engine electrical connectors including main engine harness connector at ECU connection point (usually near firewall), knock sensors, oil pressure sensor, and all temperature sensors. Remove ground strap connections from engine block to chassis (typically 3 locations). Support engine weight with engine hoist attached to factory lifting eyes or appropriate lifting brackets. Remove left and right engine mount through-bolts. Remove rear engine support bracket bolts. Slightly raise engine to verify all connections are disconnected.
   Torque spec

   Mounting Bolts50 Nm (37 lb-ft)

   Electrical Connector Bolts7 Nm (5 lb-ft)
8. 8

   Extract engine from vehicle
   Perform final visual inspection to verify all hoses, wires, and mechanical connections are disconnected. Check that nothing will interfere with engine removal path. Slowly lift engine with hoist while guiding it forward and upward, using leveling attachment to maintain proper angle. The engine will need to be tilted slightly nose-up to clear the firewall and subframe. Once clear of engine bay, lower onto engine stand or suitable work surface. Immediately inspect removed engine for failure cause to prevent repeat failure with new long block.
   ⚠The complete engine assembly weighs approximately 450 lbs. Ensure hoist capacity is adequate and all lifting points are secure before raising.
9. 9

   Transfer external components to new long block
   Systematically transfer all external components from old engine to new long block: exhaust manifolds with new gaskets, turbochargers (verify no shaft play or damage), oil cooler, coolant crossover passages, all sensors with new O-rings, thermostat housing with new gasket, water pump if not included, starter motor, all mounting brackets, and oil filter housing. Apply anti-seize to exhaust manifold studs before installation. Clean all gasket mating surfaces on transferred components with gasket scraper and solvent, ensuring no residue remains. Install new front crankshaft seal and rear main seal on new long block if not pre-installed. Verify oil pan is properly sealed and install oil pan with new gasket if removed.
   ℹ️This is the critical point to inspect all transferred components for wear or damage. Replace any questionable parts now to avoid removing the new engine later.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Oil Pan Bolts12 Nm (9 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)

   Mounting Bolts50 Nm (37 lb-ft)
10. 10

    Verify new long block timing and preparation
    Before installation, verify the new long block timing marks are correctly positioned at TDC cylinder 1. Install timing cover with new gasket, ensuring proper sealant application per factory specification. Torque timing cover bolts in proper sequence. Install harmonic balancer and crankshaft pulley, torquing to specification. Install valve covers with new gaskets, torquing in proper sequence from center outward. Pre-fill new oil filter with fresh oil and install. Apply clean engine oil to rear main seal lip. Attach engine hoist to lifting points and verify balance before lifting.
    ⚠️Triple-check timing mark alignment before sealing timing cover. Incorrect timing will destroy the engine on first start.
    Torque spec

    Cover Bolts18 Nm (13 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
11. 11

    Install new long block into vehicle
    Carefully lower new engine into engine bay using hoist with leveling attachment, reversing the removal angle (nose-up initially). Guide engine slowly while monitoring clearance to firewall, subframe, and surrounding components. Align engine with transmission bellhousing while lowering into final position. Once aligned, guide engine onto motor mounts. Install engine mount through-bolts and rear support bracket, torquing to specification. Remove hoist only after verifying all mounts are secure.
    Torque spec

    Mounting Bolts50 Nm (37 lb-ft)
12. 12

    Reconnect transmission to engine
    Verify torque converter is fully seated in transmission (should be recessed approximately 1/2 inch from bellhousing face). Apply small amount of high-temp grease to input shaft splines. Raise transmission with transmission jack and carefully align with engine bellhousing dowel pins. Slowly slide transmission forward, ensuring input shaft engages properly without binding. If resistance is felt, do not force - lower and realign. Install transmission-to-engine bolts with appropriate thread sealant, torquing in star pattern to specification. Rotate crankshaft to access torque converter bolt holes and install converter-to-flexplate bolts, torquing in sequence. Install bellhousing inspection cover.
    ⚠Never use transmission-to-engine bolts to pull transmission into place. This indicates misalignment and will damage components.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
13. 13

    Reconnect all electrical and sensor connections
    Reconnect main engine harness connector at ECU connection point. Working systematically, reconnect all engine sensors: crankshaft position sensor, both camshaft position sensors, knock sensors (both banks), oil pressure sensor, coolant temperature sensors, oxygen sensors (all 4), intake air temperature sensor, MAP sensor, throttle position sensor. Reconnect ignition coil connectors and fuel injector harness. Install all ground straps to proper locations on engine block. Verify each connection clicks securely and inspect for damaged pins or corroded contacts. Reference photos taken during disassembly.
    Torque spec

    Electrical Connector Bolts7 Nm (5 lb-ft)

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

    Install intake manifold and fuel system
    Install new intake manifold gaskets on cylinder heads, ensuring proper orientation and alignment with coolant passages. Carefully lower intake manifold into position, verifying gaskets remain properly seated. Install intake manifold bolts and torque in proper sequence from center outward. Install fuel rail with injectors, ensuring O-rings are properly lubricated with clean engine oil and seated. Connect fuel supply and return lines, ensuring proper engagement of quick-connect fittings. Install throttle body with new gasket. Reconnect PCV system hoses and brake booster vacuum line. Install air intake ducting to turbochargers with new clamps.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Gasket Bolts21 Nm (16 lb-ft)
15. 15

    Install accessories and exhaust connections
    Install AC compressor to mounting bracket and torque bolts to specification. Install alternator and connect all electrical connections, torquing mounting bolts. Install accessory drive belts with proper routing and tension. From underneath vehicle, reconnect exhaust system at catalytic converter connection points with new gaskets and hardware. Install heat shields around turbochargers. Reconnect all oxygen sensor connectors. Install underbody panels and splash shields.
    Torque spec

    Mounting Bolts50 Nm (37 lb-ft)
16. 16

    Fill fluids and perform initial system checks
    Fill engine with 5.5 quarts of Selenia Racing 10W-60 engine oil. Install new oil filter. Fill cooling system with 10 quarts of Maserati OAT coolant mixture (50/50 with distilled water), using vacuum fill method if available to eliminate air pockets. Check transmission fluid level and top off with ZF Lifeguard 8 if needed (approximately 1 quart lost during separation). Verify power steering reservoir level (electric system, no fluid required). Double-check all hose clamps are tight and all drain plugs are installed. Verify oil drain plug is torqued with new crush washer.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)
17. 17

    Perform pre-start inspection and initial start
    Reconnect negative battery terminal. Perform complete visual inspection of entire engine bay, verifying no tools, rags, or parts remain. Check that all electrical connectors are secured. Turn ignition to ON position without starting and verify no warning lights indicate unexpected issues. Using scan tool, clear any stored fault codes from battery disconnection. Prime fuel system by cycling ignition on/off 3 times, listening for fuel pump operation. Disable ignition and crank engine for 10 seconds to build oil pressure before first start. Re-enable ignition and start engine, immediately monitoring for proper oil pressure (should register within 2-3 seconds). Allow engine to idle and monitor for leaks, unusual noises, or warning lights.
    ⚠If oil pressure does not register within 5 seconds of starting, shut down immediately and investigate. Running without oil pressure will destroy the new engine.

Reassembly

1. Torque all fasteners to exact specifications using calibrated torque wrench, following proper sequences for cylinder heads, main bearings, and other critical components
2. Replace all torque-to-yield (TTY) bolts including cylinder head bolts, main bearing cap bolts, connecting rod bolts, and flywheel bolts if removed
3. Apply anti-seize compound to all exhaust fasteners before installation to prevent future seizure
4. Use only new gaskets and seals throughout reassembly - never reuse gaskets even if they appear undamaged
5. Install all engine covers and trim panels removed during disassembly, ensuring proper fit and engagement
6. Install front wheels and torque lug nuts to specification after lowering vehicle

Verification

• Start engine and verify oil pressure reaches normal range (40-60 PSI at idle warm) within 3 seconds
• Allow engine to reach operating temperature while monitoring coolant temperature gauge for normal operation (195-220°F)
• Check for any fluid leaks around oil pan, valve covers, timing cover, intake manifold, and all coolant connections
• Verify no exhaust leaks at manifold or turbocharger connections by listening and visual inspection
• Use scan tool to verify all engine sensors are reporting proper values and no fault codes are present
• Check transmission engagement in all gears and verify smooth shifting operation
• Perform test drive at varying speeds and loads, monitoring engine performance, boost pressure, and temperature
• After test drive, re-inspect all fluid levels and top off as needed, checking again for any new leaks
• Verify engine idles smoothly at proper RPM (approximately 650-750 RPM warm) with all accessories operating
• Re-torque cylinder head bolts and intake manifold bolts after first heat cycle (after engine cools completely)
• Change engine oil and filter after first 500 miles of operation to remove any break-in debris

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