Coolant Bypass Pipe

Replace the coolant bypass pipe on a 2017 Maserati Levante 3.0L V6 Twin Turbo, including coolant draining, pipe removal, installation, and system refill with air bleeding.

Warnings

Tools required

Parts

• Coolant bypass pipe × 1 — Use OEM Maserati part
• Bypass pipe O-rings/gaskets × 1 — Usually included with pipe assembly
• Hose clamps (if damaged) × 2 — OEM spring-type clamps
• Coolant drain plug washer × 1 — Use OEM specification

Fluids

• Maserati OAT Coolant — 10 qt

Preparation

1. Ensure engine is completely cold (minimum 2 hours after last operation)
2. Raise vehicle on lift or support securely on jack stands at all four corners
3. Remove engine undertray and splash shields for access to coolant drain
4. Disconnect negative battery terminal to prevent cooling fan activation
5. Place drain pan beneath radiator drain location
6. Remove upper engine cover by unclipping fasteners

Procedure

1. 1

   Drain cooling system
   Slowly release pressure from system by carefully loosening coolant reservoir cap 1/4 turn, then wait for any residual pressure to escape. Remove cap completely. Locate coolant drain plug on driver side lower radiator tank. Place drain pan underneath and remove drain plug with new washer ready for installation. Allow coolant to drain completely (approximately 8-10 quarts). Once drained, reinstall drain plug with new washer.
   Torque spec

   Coolant Drain Plug15 Nm (11 lb-ft)
2. 2

   Remove air intake components
   Disconnect mass airflow sensor electrical connector. Loosen hose clamps securing intake tubes to throttle bodies. Remove air intake tubes and air filter housing assembly to gain access to front of engine. Set components aside in clean area. Disconnect any vacuum lines or breather hoses attached to intake system and label for reassembly.
3. 3

   Access coolant bypass pipe
   Locate the coolant bypass pipe on the front of the engine between the cylinder banks, typically running from the water pump housing to the thermostat housing area. The pipe may be partially obscured by wiring harnesses and coolant hoses. Carefully move any wiring harnesses aside and secure with zip ties to maintain access. Take photos for reference during reassembly.
   ℹ️The bypass pipe location varies slightly based on production date. Verify exact routing before attempting removal.
4. 4

   Disconnect coolant hoses from bypass pipe
   Using hose clamp pliers, compress and slide spring-type hose clamps away from bypass pipe connections. If clamps are crimped factory style, carefully cut them off and note that new screw-type clamps will be needed. Gently twist coolant hoses while pulling to release them from bypass pipe nipples. Be prepared for residual coolant spillage. Inspect hose ends for cracks or damage.
   ⚠Coolant hoses may be adhered to pipe nipples. Do not use excessive force as this may damage hose or connected components.
5. 5

   Remove bypass pipe mounting hardware
   Locate mounting bolts securing bypass pipe to engine block or housing. These are typically 10mm or 13mm head bolts. On this V6 twin turbo configuration, there are usually 2-3 mounting points. Remove bolts and any brackets or supports attached to the pipe. Keep hardware organized for reinstallation.
   Torque spec

   Housing Bolts14 Nm (11 lb-ft)
6. 6

   Extract coolant bypass pipe
   Carefully maneuver the bypass pipe out of position. The pipe typically has multiple bends and may require rotation or angling to clear surrounding components including turbocharger heat shields, engine wiring, and coolant passages. Work slowly to avoid contact with turbocharger components. Once clear, remove pipe from engine bay and inspect mounting surfaces.
   ⚠Be extremely careful not to strike or damage turbocharger oil lines or coolant lines during pipe removal. These lines are expensive and difficult to replace.
7. 7

   Clean mating surfaces and inspect
   Thoroughly clean all mating surfaces where bypass pipe connects using razor blade scraper. Remove all old gasket material, O-ring remnants, and any corrosion or deposits. Clean surfaces should be smooth and free of debris. Inspect mounting bosses for cracks or damage. Check threaded holes for damage and clean with appropriate thread chaser if needed. Verify new bypass pipe matches old pipe configuration exactly.
   ℹ️Any debris left on mating surfaces can cause coolant leaks. Take time to ensure surfaces are completely clean and dry.
8. 8

   Install new bypass pipe O-rings and gaskets
   Install all new O-rings and gaskets onto the new bypass pipe. Lubricate O-rings lightly with fresh coolant or approved O-ring lubricant to ease installation and prevent tearing. Ensure O-rings are seated properly in their grooves and are not twisted. Verify gaskets are oriented correctly per manufacturer instructions included with pipe.
9. 9

   Position and secure new bypass pipe
   Carefully maneuver new bypass pipe into position, reversing the removal path. Ensure pipe is fully seated against all mating surfaces before starting any fasteners. Thread in all mounting bolts by hand to verify proper alignment. Once all bolts are hand-tight and pipe position is verified correct, torque mounting bolts to specification in a crossing pattern to ensure even seating.
   ⚠Do not force bypass pipe into position. If resistance is felt, remove and verify O-rings are properly positioned and passages are aligned.
   Torque spec

   Housing Bolts14 Nm (11 lb-ft)
10. 10

    Reconnect coolant hoses
    Slide coolant hoses onto bypass pipe nipples, ensuring they are pushed on fully until they contact the flange on each nipple. Position new hose clamps (or reuse spring clamps if in good condition) approximately 1/4 inch from end of hose. Tighten screw-type clamps to specified torque. Ensure hoses are routed properly without kinks or sharp bends.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Reinstall air intake system
    Reinstall air filter housing and intake tubes in reverse order of removal. Reconnect all vacuum lines and breather hoses to their original positions using reference photos. Tighten intake tube hose clamps securely. Reconnect mass airflow sensor electrical connector ensuring it clicks into place. Verify all connections are secure and no hoses or wires are pinched.
12. 12

    Refill cooling system
    Locate the cooling system bleed screw on the highest point of the engine (typically on thermostat housing or near upper radiator hose connection). Open bleed screw approximately 2-3 turns. Begin filling cooling system through coolant reservoir with Maserati OAT coolant. Fill slowly to allow air to escape through bleed screw. When solid coolant (no air bubbles) flows from bleed screw, close it to specification. Continue filling reservoir to MAX line. If available, use vacuum fill tool to eliminate air pockets.
    ℹ️This cooling system requires proper air bleeding to prevent overheating. Do not skip bleeding procedure.
    Torque spec

    Bleed Screw7 Nm (5 lb-ft)
13. 13

    Initial system bleeding and warm-up
    Reinstall coolant reservoir cap. Reconnect negative battery terminal. Start engine and allow to idle. Monitor coolant temperature gauge. As engine warms, heater control valve will open and coolant level in reservoir may drop. Add coolant as needed to maintain level between MIN and MAX marks. Run engine until cooling fans cycle on and off at least once (approximately 15-20 minutes). Monitor for leaks around bypass pipe connections.
    ⚠️Monitor engine temperature closely during initial warm-up. If temperature exceeds normal range or warning lights activate, shut down immediately and investigate.
14. 14

    Final bleeding and top-off
    With engine at operating temperature, carefully remove coolant reservoir cap (system will be pressurized - release slowly). Check coolant level and top off to MAX line if needed. With engine running, open bleed screw briefly to purge any remaining air, then close to specification. Shut off engine and allow to cool for 30 minutes. Recheck coolant level and add if necessary. Install engine covers and undertray.
    Torque spec

    Bleed Screw7 Nm (5 lb-ft)

Reassembly

1. Verify all hose clamps are properly tightened and hoses are fully seated on bypass pipe nipples
2. Ensure all wiring harnesses are returned to original positions and secured properly
3. Double-check that no tools or materials were left in engine bay
4. Verify coolant reservoir is filled to MAX line with proper Maserati OAT coolant
5. Reinstall all engine covers, undertray, and splash shields removed during procedure

Verification

• Start engine and verify no coolant leaks from bypass pipe connections or hoses during warm-up cycle
• Confirm engine reaches normal operating temperature (approximately 200°F/93°C) and cooling fans activate properly
• Check for proper heater operation by verifying hot air from HVAC system at idle and during driving
• Monitor coolant level for 24-48 hours after repair and top off if needed as system fully purges air
• Verify no coolant drips under vehicle after overnight parking
• Scan for any stored engine codes related to cooling system using diagnostic tool
• Road test vehicle for at least 20 minutes and verify stable coolant temperature under various load conditions

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle