Magna TF Head gasket kit and timing belt replacement - engine in place.

Personal reference photos. Some operations may be out of order. Attempting to leave engine installed. One engine mount (of the three) will need to be removed as it keeps the timing belt captive.

I destroyed the allen key socket of two of the 10mm head bolts in the rear head of the Magna V-motor. Twice the work...maximum pain. There's no way I'm getting these out. They're long settled in, 190nM tension by spec (That's ~200kg at a 1 meter leverage on a torque point...that's HUGE) and it broke me trying to remove the other ones with relatively short breaker bars on a regular 10mm toy allen key. They need premium tool engagement which I didn't have on the two that failed... I should have simply cut the ends off the key I had, and put it into a regular 10mm socket with a 3/8 or 1/2 drive and proper breaker bar.

I need to grind the heads of these head-bolts off. Free handing will result in a random accident. I can't mount the head in a mill because it's still attached to the car!! I've used the other head which I was able to remove as an easy-access template to make a drilling jig.

I can bolt this jig down with the valve rocker arm securing bolts, and drop a milling bit into the hole. A regular hand drill attached will do the work.

A second hole is placed for the other head bolt position that I wrecked. Flipping the jig over allowed me to reuse the mounting holes. Hopefully I can grind my way through these high tensile bolts.

I modified a 20mm 4tooth endmill so I could use it in a regular ~12.5mm drill chuck.

Add mustard to all lubrication points...

Getting there.

Both bolt heads ground off. Engine head pulled off. Bolt shanks still bolted to the block. With no tension on them I was able to wind them out with my fingers.

Magna TF V6 3L head removal without pulling the engine out...contrary to instructions in the workshop manual... Gizmology FTW.

Spot the culprit buring oil. (exhaust manifold)

Spot the nasty oil leaking exhaust.

Manifold tipped up to see the bottom. Blargh look at that char buildup protruding out of the exhaust port at the top!! Likewise you can see the dark gritty dead oil around the head/block ports that were leaking into the combustion chamber. New head gasket gonna make things all betterer...

Terrible shot, but you can see the ground through the bay here where the timing belt would normally be...notice an engine mount removed... Secondary mission accomplished, remove timing belt without removing the engine from the car as the workshop manual instructions would have had you do. Pro gaming.