Crankshaft R&R

Complete removal and replacement of the crankshaft on a 2017 Maserati Levante 3.0L V6 Twin Turbo, requiring engine removal, full disassembly, and precision reassembly with TTY fasteners.

Warnings

Tools required

Parts

• Crankshaft × 1 — Use OEM specification
• Main bearing set (upper and lower) × 1 — Use OEM specification - check clearances
• Connecting rod bearings × 1 — Use OEM specification - check clearances
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification - replace all
• Connecting rod bolts (TTY) × 12 — Use OEM specification - replace all
• Cylinder head bolts (TTY) × 20 — Use OEM specification - replace all
• Harmonic balancer bolt (TTY) × 1 — Use OEM specification
• Flywheel or flexplate bolts × 8 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Cylinder head gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Oil pump × 1 — Inspect and replace if worn
• Timing chain kit (chains, guides, tensioners) × 1 — Use OEM specification - replace as assembly
• Water pump × 1 — Recommended replacement
• Thermostat and housing gasket × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine assembly lubricant × 1 — Moly-based assembly lube
• RTV silicone sealant (high-temp) × 1 — OEM or equivalent

Fluids

• Selenia Racing 10W-60 — 5.5 qt
• Maserati OAT Coolant — 10 qt
• ZF Lifeguard 8 — 10 qt

Preparation

1. Position vehicle on level ground with adequate overhead clearance for engine removal
2. Disconnect negative battery cable and remove battery
3. Drain engine oil completely and remove oil filter
4. Drain cooling system completely at block and radiator drain points
5. Remove engine cover and all decorative plastic covers
6. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
7. Raise vehicle on lift and support securely on jack stands
8. Remove front wheels, engine undertray, and lower splash shields
9. Label and photograph all electrical connections, vacuum lines, and hose routing before disconnection
10. Support transmission with transmission jack before removing engine mounts
11. Clear workspace and prepare engine stand for receiving engine

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all electrical connectors including alternator, starter, sensors, and engine harness. Disconnect fuel lines, coolant hoses, vacuum lines, and exhaust manifolds from catalytic converters. Remove accessory drive belt and accessories (alternator, AC compressor - leave lines attached and secure aside, power steering pump if equipped). Disconnect transmission from engine by removing all transmission-to-engine bolts. Remove engine mounts. Attach engine hoist with proper lifting chains to factory lift points. Carefully lift engine from vehicle, ensuring transmission remains supported. Transfer engine to engine stand and secure.
   Torque spec

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

   Mounting Bolts50 Nm (37 lb-ft)
2. 2

   Remove external engine components
   With engine on stand, remove intake manifold, throttle body, fuel rails and injectors. Remove both valve covers. Remove ignition coils and spark plugs. Remove exhaust manifolds if still attached. Remove water pump, thermostat housing, and coolant pipes. Remove alternator bracket and other accessory brackets. Remove oil filter housing and oil cooler lines. Label and remove all sensors including camshaft position sensors, crankshaft position sensor, knock sensors, and oil pressure sensor.
   Torque spec

   Mounting Bolts50 Nm (37 lb-ft)

   Electrical Connector Bolts7 Nm (5 lb-ft)
3. 3

   Remove timing components
   Rotate engine to TDC on cylinder #1. Lock crankshaft using turning tool. Remove harmonic balancer bolt using impact wrench and proper holding tool. Remove harmonic balancer using puller (do not pry). Remove timing cover bolts in reverse of tightening sequence (note different bolt lengths and locations). Remove timing cover carefully. Install timing chain locking tools per manufacturer specification. Remove timing chain tensioners, timing chain guides, and timing chains. Mark camshaft and crankshaft sprocket positions before removal. Remove crankshaft timing sprocket.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts18 Nm (13 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
4. 4

   Remove cylinder heads
   Remove camshaft bearing caps in reverse order of tightening sequence. Remove camshafts and set aside in order. Remove cylinder head bolts in reverse of tightening sequence (start from outside and work inward). Carefully lift cylinder heads from block. Set heads on clean surface. Inspect head gasket surfaces for damage. Clean all gasket material from block deck surface using appropriate gasket scraper. Ensure deck surface is perfectly clean and flat.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
5. 5

   Remove oil pan and pickup
   Remove oil pan bolts in reverse sequence. Carefully separate oil pan from block (may need to tap gently with rubber mallet). Remove oil pan gasket. Remove oil pump pickup tube bolts and remove pickup tube. Inspect pickup screen for debris. Clean all gasket surfaces thoroughly.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
6. 6

   Remove oil pump and front seal housing
   Remove oil pump mounting bolts and remove oil pump assembly. Remove front main seal housing bolts and carefully remove housing. Clean all sealing surfaces. Inspect oil pump for wear; replacement is recommended during crankshaft R&R.
   Torque spec

   Oil Pump Bolts12 Nm (9 lb-ft)

   Front Main Seal Housing12 Nm (9 lb-ft)
7. 7

   Remove flexplate or flywheel
   Lock crankshaft rotation using appropriate holding tool. For automatic transmission, remove flexplate bolts. For manual transmission, remove flywheel bolts. Remove flexplate/flywheel. Inspect for cracks or heat damage. Remove rear main seal housing bolts and carefully remove housing with seal.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)

   Rear Main Seal Housing12 Nm (9 lb-ft)
8. 8

   Remove connecting rods and pistons
   Rotate engine so connecting rod caps are accessible. Mark each connecting rod cap and rod with cylinder number and orientation (use number stamps or marker - CRITICAL for reassembly). Remove connecting rod bolts (these are TTY and must be replaced). Remove rod caps and set aside in order. Push pistons up and out of cylinders from below. Keep pistons with their respective rods. Store piston/rod assemblies in numbered order.
   ⚠Mark connecting rods and caps BEFORE removal. Each rod must return to its original cylinder and orientation. Mixing these will cause immediate engine failure.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
9. 9

   Remove main bearing caps and crankshaft
   Verify all connecting rods are removed and pushed up into bores. Mark each main bearing cap with its position and directional arrow (caps are numbered 1-5, front to rear). Note that main caps have specific orientation. Remove main bearing cap bolts (these are TTY and must be replaced). Using main bearing cap removal tool, carefully remove main bearing caps in sequence. Keep caps in order. Carefully lift crankshaft straight up and out of engine block. Set crankshaft on padded surface. Remove upper main bearing shells from block and lower shells from caps. Keep bearings with their respective positions for inspection.
   ⚠️Main bearing caps MUST be reinstalled in exact original position and orientation. Mark clearly before removal. Improper installation will cause immediate crankshaft failure.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
10. 10

    Inspect and prepare engine block
    Thoroughly clean engine block bearing saddles and main cap mating surfaces. Inspect crankshaft bearing bores for scoring, cracks, or damage. Measure main bearing bore diameters with inside micrometer to verify they are within specification. Clean and inspect oil passages in block using brush and compressed air. Ensure all oil passages are clear and free of debris. Verify block deck surface is flat and within specification using straightedge and feeler gauges.
    ℹ️If bearing bores are damaged or out of specification, block will require line boring or replacement. Do not proceed with damaged bearing bores.
11. 11

    Inspect and measure new crankshaft
    Inspect new crankshaft journals for any shipping damage or defects. Using micrometer, measure all main bearing journals and rod journals at multiple points to verify they are round and within specification (typically 0.0001-0.0003 inch tolerance). Check crankshaft end play surfaces. Install crankshaft in V-blocks and use dial indicator to check runout (should be less than 0.002 inch total). Verify all oil passages in crankshaft are clear. Document all measurements.
    ⚠Do not install crankshaft if journals are out of round, tapered, or show runout beyond specification. This will cause premature bearing failure.
12. 12

    Install main bearings and check clearances
    Install upper main bearing shells in engine block (bearings have locating tabs). Ensure bearings seat fully and tabs engage notches. Apply thin film of assembly lubricant to bearing surfaces. Carefully lower crankshaft into position. Cut Plastigage strips and place on each main journal. Install lower bearing shells in main caps (ensure correct cap position and orientation). Install main caps in correct positions with directional arrows pointing forward. Install NEW main bearing cap bolts finger tight. Torque bolts to 75 Nm in specified sequence (front to rear, alternating side to side), then apply additional angle per specification. Carefully remove caps without rotating crankshaft. Measure Plastigage width to determine bearing clearance. Proper clearance is typically 0.0015-0.0025 inch (0.038-0.064 mm). Record all clearances.
    ⚠️Bearing clearances MUST be within specification. Too tight and bearings will seize. Too loose and bearings will fail from hammering. If clearances are incorrect, diagnose cause before proceeding.
    ℹ️This step is for clearance checking only. Main caps will be removed and reinstalled with proper lubrication in final assembly.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
13. 13

    Final main bearing installation
    Remove main bearing caps. Remove Plastigage residue completely. Liberally coat upper and lower main bearings with engine assembly lubricant. Coat crankshaft journals with assembly lubricant. Install lower bearing shells in main caps. Install main caps in correct order and orientation. Install NEW main bearing cap bolts. Following manufacturer torque sequence (typically front to rear, alternating sides), torque bolts to 75 Nm, then apply the specified angle rotation using torque angle gauge. Verify crankshaft rotates freely by hand after final torque. Check crankshaft endplay using dial indicator (typical spec is 0.002-0.010 inch). If endplay is incorrect, verify thrust bearing (typically journal #3) is properly seated.
    ⚠Use NEW TTY main bearing cap bolts. Follow torque sequence exactly. Torque-to-yield bolts must be torqued in specified sequence plus angle.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
14. 14

    Install connecting rod bearings and pistons
    Install connecting rod bearings in rods and caps (note bearing tang orientation). Check rod bearing clearances using Plastigage method similar to main bearings. Proper rod bearing clearance is typically 0.001-0.002 inch. Lubricate bearings, piston pins, rings, and cylinder walls with assembly lubricant. Stagger piston ring end gaps per specification. Using ring compressor, install piston/rod assemblies into their original cylinders with marked orientation (typically arrow on piston crown faces forward). Guide rod over crankshaft journal carefully. Install rod caps in correct orientation. Install NEW connecting rod bolts. Torque to 45 Nm plus angle per specification. Verify each rod has side clearance on crankshaft journal (typically 0.004-0.012 inch). Verify crankshaft still rotates freely after all rods are installed.
    ⚠️Each piston/rod assembly MUST return to its original cylinder with correct orientation. Rod bearings must be within clearance specification. Use NEW TTY rod bolts.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
15. 15

    Install rear main seal and flexplate/flywheel
    Install new rear main seal in seal housing using appropriate seal driver tool (seal lip faces forward into engine). Apply thin bead of RTV sealant to seal housing mating surface where specified. Install rear main seal housing and torque bolts to 12 Nm in crisscross pattern. Wipe any excess RTV. Inspect flexplate/flywheel for cracks or damage. Install flexplate (automatic) or flywheel (manual) with correct orientation. Install NEW flexplate or flywheel bolts. Lock crankshaft rotation. Torque flexplate bolts to 85 Nm or flywheel bolts to 95 Nm in star pattern.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
16. 16

    Install oil pump and front seal
    Install new or inspected oil pump with new gasket. Ensure oil pump drive engages with crankshaft properly. Torque oil pump bolts to 12 Nm. Install new front crankshaft seal in front seal housing using seal driver (seal lip faces into engine). Apply thin bead of RTV to housing mating surface where specified. Install front seal housing and torque bolts to 12 Nm in crisscross pattern. Install oil pump pickup tube with new O-ring and torque bolts to 12 Nm.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Front Main Seal Housing12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)
17. 17

    Install oil pan
    Clean oil pan and block mating surfaces thoroughly. Install new oil pan gasket or apply RTV sealant per manufacturer specification. Install oil pan and hand-tighten all bolts. Following specified sequence (typically start at center and work outward in spiral pattern), torque oil pan bolts to 12 Nm. Do not overtighten. Allow RTV to cure per product specifications before filling with oil.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
18. 18

    Install cylinder heads
    Ensure block deck surfaces and cylinder head mating surfaces are perfectly clean. Install new cylinder head gaskets with correct orientation (note top side marking and front orientation). Carefully lower cylinder heads onto block. Install NEW cylinder head bolts with light oil on threads and under head. Following manufacturer torque sequence (typically start at center and work outward in spiral), torque cylinder head bolts to 65 Nm, then apply specified angle rotation in multiple steps per service manual. Install camshafts in correct positions with proper timing marks aligned. Install camshaft bearing caps in correct positions and torque per specification.
    ⚠Cylinder head bolts are TTY and must be NEW. Follow torque sequence and angle specifications exactly. Improper torque will cause head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
19. 19

    Install timing components
    Install crankshaft timing sprocket with correct orientation. Verify crankshaft is at TDC for cylinder #1. Install timing chains with alignment marks properly positioned per service manual. Install timing chain guides and torque bolts to 12 Nm. Compress timing chain tensioners and lock with pins. Install tensioners and torque bolts to 25 Nm. Release tensioner pins. Manually rotate crankshaft two complete revolutions and verify timing marks align correctly. Clean timing cover mating surfaces. Apply RTV sealant to specified areas of timing cover. Install new timing cover gasket. Install timing cover and hand-tighten all bolts. Torque 10mm timing cover bolts to 45 Nm and 8mm bolts to 25 Nm in specified sequence.
    ⚠Timing chain alignment is critical. Verify all timing marks align correctly before installing timing cover. Incorrect timing will cause engine damage or failure to start.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts18 Nm (13 lb-ft)
20. 20

    Install harmonic balancer and complete engine assembly
    Ensure crankshaft snout and harmonic balancer bore are clean and dry. Install harmonic balancer using installation tool (do not hammer). Install NEW harmonic balancer bolt. Using impact wrench or torque wrench with holding tool, torque harmonic balancer bolt to 180 Nm plus angle if specified. Install all remaining external components: water pump, thermostat housing, oil filter housing, accessory brackets, exhaust manifolds, intake manifold, fuel rails, ignition coils, spark plugs, valve covers, and all sensors. Reinstall all gaskets and seals as NEW. Apply anti-seize to spark plugs and exhaust studs. Torque all components per specifications.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

    Mounting Bolts50 Nm (37 lb-ft)
21. 21

    Reinstall engine in vehicle
    Ensure transmission mounting surface is clean. Apply small amount of anti-seize to transmission input shaft splines. Using engine hoist, carefully lower engine into vehicle while aligning with transmission. Install transmission-to-engine bolts and torque to 55 Nm. Install engine mounts and torque mounting bolts to 50 Nm. Remove engine hoist. Reconnect all electrical connections, fuel lines, coolant hoses, vacuum lines, and exhaust system. Reinstall accessory drive belt. Install engine undertray and wheels. Lower vehicle.
    Torque spec

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

    Mounting Bolts50 Nm (37 lb-ft)
22. 22

    Fill fluids and prepare for startup
    Install new oil filter. Install oil drain plug with NEW crush washer and torque to 35 Nm. Fill engine with 5.5 quarts of Selenia Racing 10W-60 oil. Fill cooling system with 10 quarts of Maserati OAT coolant. If transmission was serviced, fill with 10 quarts ZF Lifeguard 8 fluid. Reconnect battery. Before starting, remove fuel pump fuse and crank engine for 30 seconds to prime oil system. Check oil pressure gauge shows pressure. Reinstall fuel pump fuse.
    ⚠Do not start engine until oil system is primed and showing oil pressure. Verify no fuel, oil, or coolant leaks before starting.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. All torque-to-yield (TTY) fasteners including main bearing cap bolts, connecting rod bolts, cylinder head bolts, and harmonic balancer bolt MUST be replaced with NEW parts
2. All bearing clearances must be verified with Plastigage or precision measuring tools before final assembly
3. Use liberal amounts of engine assembly lubricant on all bearing surfaces, camshaft lobes, and piston rings during assembly
4. Follow all torque sequences exactly as specified - improper sequence will cause gasket failure or component damage
5. Verify crankshaft rotates freely by hand after each major assembly step
6. Replace all gaskets, seals, and O-rings with new OEM parts
7. Allow RTV sealant to cure for specified time before filling with fluids

Verification

• Verify engine cranks freely by hand before attempting to start (remove spark plugs and turn crankshaft)
• Check that oil pressure registers within 5 seconds of startup (minimum 15 psi at idle)
• Listen for any abnormal noises during initial startup - knocking, ticking, or grinding indicates assembly problem
• Verify no oil, coolant, or fuel leaks after startup
• Allow engine to reach operating temperature and verify cooling system operates normally
• Check for proper engine idle quality and smooth acceleration
• Monitor oil pressure at idle and at 2000 RPM - should be within specification (typically 25-80 psi)
• After first 20 minutes of operation, shut down and recheck all fluid levels
• Perform compression test and leak-down test to verify cylinder sealing
• After 500 miles, perform first oil change and inspect oil filter for metal debris
• Scan for any diagnostic trouble codes and verify all sensor readings are normal
• Road test vehicle and verify smooth operation under all load conditions

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