Engine R&R

Complete removal and reinstallation of the 3.0L V6 Twin Turbo engine from a 2017 Maserati Levante RWD, including separation from transmission, disconnection of all engine systems, and engine mount removal.

Warnings

Tools required

Parts

• Engine oil with filter × 1 — Use OEM specification
• Engine coolant × 1 — Maserati OAT Coolant
• Oil drain plug crush washer × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Transmission-to-engine gasket/seal × 1 — Use OEM specification
• Engine mount hardware (if corroded) × 1 — Use OEM specification
• Serpentine belt × 1 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated

Fluids

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

Preparation

1. Install memory saver device, then disconnect negative battery terminal followed by positive terminal
2. Raise vehicle on lift to comfortable working height and ensure secure support
3. Remove engine undertrays and belly panels for access to lower components
4. Remove front bumper cover and upper radiator support trim for forward access clearance
5. Have EPA-certified technician recover all AC refrigerant from system
6. Position fluid catch pans and drain engine coolant from radiator petcock and block drains
7. Drain engine oil completely and remove oil filter
8. Remove front wheels and disconnect front brake line heat shields if obstructing access
9. Photograph all hose routing, electrical connections, and component positions for reinstallation reference
10. Label all electrical connectors with wire labels or tape to ensure correct reconnection

Procedure

1. 1

   Remove intake and engine covers
   Remove engine beauty cover by releasing retaining clips. Remove air intake system including air filter housing, mass airflow sensor, and intake ducting from throttle bodies to air filter. Disconnect intake air temperature sensor. Remove secondary air injection components if equipped. Label and disconnect all vacuum lines from intake manifold and brake booster.
   Torque spec

   Cover Bolts18 Nm (13 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)
2. 2

   Disconnect fuel system and electrical harnesses
   Relieve fuel system pressure by removing fuel pump fuse and cranking engine briefly. Disconnect fuel supply and return lines at engine bay connections using proper fuel line disconnect tools. Disconnect main engine wiring harness connectors at firewall junction points (typically 3-4 large multi-pin connectors). Disconnect alternator wiring, all ignition coil connectors, fuel injector harness, throttle body connectors, and all sensor connectors including oxygen sensors, knock sensors, cam position sensors, and crank position sensor. Remove engine harness grounds from cylinder heads and block.
   ⚠Fuel will spray when disconnecting lines even after pressure relief. Have rags ready to catch fuel.
   Torque spec

   Electrical Connector Bolts7 Nm (5 lb-ft)

   Mounting Bolts50 Nm (37 lb-ft)
3. 3

   Remove cooling system components
   Disconnect upper and lower radiator hoses at engine. Disconnect heater hoses at firewall connections. Remove coolant overflow tank hose. Disconnect transmission oil cooler lines from radiator if integrated. Disconnect cooling fan electrical connectors and remove radiator/fan assembly as complete unit by unbolting from core support. This provides necessary clearance for engine removal. Cap all open coolant passages to prevent debris entry.
   Torque spec

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

   Disconnect AC and accessory drive components
   Disconnect AC compressor electrical connector. Remove serpentine belt by rotating tensioner and sliding belt off pulleys. Unbolt AC compressor from mounting bracket but do NOT disconnect refrigerant lines. Secure compressor to frame with wire or bungee cords, ensuring no tension on refrigerant lines. Disconnect alternator electrical connections and unbolt alternator from mounting bracket. Remove power steering pump from mounting bracket (no lines to disconnect due to electric steering) if obstructing access.
   ⚠️Do not disconnect AC refrigerant lines. Compressor must remain attached to lines and be secured safely out of the way.
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Alternator Mounting Bolts50 Nm (37 lb-ft)

   Power Steering Pump Bolts25 Nm (18 lb-ft)
5. 5

   Disconnect exhaust system
   From underneath vehicle, spray exhaust manifold nuts and studs with penetrating oil. Allow to soak for 15 minutes. Disconnect oxygen sensors from exhaust manifolds (4 sensors total on twin turbo setup). Unbolt exhaust downpipes from turbocharger outlets, working from hot side (cylinder bank closest to manifold) to cold side. Remove exhaust manifold heat shields. Support exhaust system with jack or wire to prevent damage when engine is removed.
   ⚠Exhaust studs are prone to breaking. Work slowly and use penetrating oil liberally. Replacement studs may be needed.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
6. 6

   Separate transmission from engine
   Support transmission with transmission jack positioned securely under transmission pan. Remove starter motor by disconnecting electrical connections and removing mounting bolts. Access bell housing through starter opening to disconnect torque converter bolts (if automatic) by rotating flexplate - mark flexplate position for reassembly. Remove all transmission-to-engine bell housing bolts (typically 6-8 bolts of varying lengths - note locations). Disconnect transmission wiring harness at connectors near bell housing. Carefully slide transmission rearward approximately 2 inches to clear input shaft from engine, maintaining support with transmission jack. Secure transmission on jack and lower slightly to create clearance.
   ⚠Transmission weighs approximately 200 lbs. Ensure transmission jack is properly positioned and secured before unbolting.
   Torque spec

   Mounting Bolts50 Nm (37 lb-ft)

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

   Disconnect remaining engine connections
   Disconnect throttle cable or electronic throttle connections if not already removed. Verify all ground straps are disconnected from engine to chassis. Check for any remaining vacuum lines, breather hoses, or PCV connections. Inspect entire engine perimeter to ensure nothing remains connected to vehicle chassis or components staying with vehicle. Disconnect any remaining sensor connections missed in previous steps.
8. 8

   Attach engine hoist and support engine
   Install engine leveler on engine hoist chain or cable. Attach lifting chains or hooks to designated engine lifting points on cylinder heads or block (typically threaded lifting eyes on front and rear of engine). Adjust engine leveler to achieve balanced load. Take up slack on hoist until chains are taut but engine weight is still on mounts. Verify all attachment points are secure and properly threaded.
   ⚠️Verify lifting capacity of hoist and all attachment hardware before proceeding. Engine must be properly balanced to prevent tipping during removal.
9. 9

   Remove engine mounts
   Raise engine with hoist approximately 1/4 inch to relieve weight from engine mounts. Remove left engine mount by unbolting mount-to-frame bolts first, then mount-to-block bolts. Remove right engine mount using same sequence. Remove rear engine mount/torque mount if present. Inspect mount condition and hardware for corrosion or damage requiring replacement. With all mounts disconnected, verify engine is free to be lifted.
   ⚠Engine will shift when mounts are removed. Ensure hoist is supporting full weight before removing final mount bolts.
   Torque spec

   Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)

   Engine Mount-to-Block Bolts65 Nm (48 lb-ft)
10. 10

    Remove engine from vehicle
    With assistant guiding, slowly raise engine with hoist while monitoring clearances on all sides. Adjust engine angle using leveler to clear firewall, frame rails, and front crossmember. Tilt engine as needed - typically nose-up angle required for clearance. Continue lifting and adjusting until engine clears front subframe. Carefully roll hoist forward to extract engine from engine bay. Watch turbochargers and accessories for contact with body components. Once clear, lower engine onto suitable engine stand or secure work surface. Immediately inspect engine for damage and verify all components that should remain with engine are present.
    ⚠️Maintain constant communication with assistant during extraction. Stop immediately if any binding or contact occurs.
11. 11

    Prepare engine for reinstallation
    If performing engine work, complete all necessary repairs at this stage. For reinstallation preparation: clean all mating surfaces including transmission bell housing mounting face and engine block mating surface. Inspect and replace flywheel/flexplate bolts if they are TTY (torque-to-yield) type - these must be replaced. Install new transmission-to-engine gasket or seal. Apply anti-seize compound to exhaust manifold studs. Verify all sensors, accessories, and components that must be installed before engine installation are in place. Check that all electrical connectors on engine harness are clean and undamaged.
    ℹ️This is the ideal time to replace difficult-to-access components like rear main seal, valve cover gaskets, turbocharger components, or timing components.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

Reassembly

1. Installation is reverse of removal with the following critical points
2. Use new gaskets for all separated joints including exhaust manifolds and transmission bell housing
3. Apply anti-seize compound to exhaust manifold studs working hot-to-cold pattern as specified
4. Tighten flywheel bolts in star pattern if reinstalling or if new bolts required
5. When mating engine to transmission, ensure alignment dowels engage properly and torque converter is fully seated before tightening bell housing bolts
6. Clean all gasket mating surfaces thoroughly before installing new gaskets
7. Torque all fasteners to specified values in the order listed: engine mounts, transmission bolts, accessory brackets, exhaust manifolds
8. Replace serpentine belt with new belt during reassembly
9. Use new oil drain plug crush washer when refilling engine oil
10. Refill all fluids to proper levels: engine oil (5.5 qt Selenia Racing 10W-60), coolant (10.0 qt Maserati OAT Coolant)
11. Reconnect battery positive terminal first, then negative terminal, and remove memory saver
12. Have AC system recharged by EPA-certified technician
13. Reset any stored fault codes using Maserati-compatible scan tool

Verification

• Verify no tools or parts remain in engine bay before starting
• Check that all electrical connectors are fully seated and locked
• Verify all fluid levels are correct: engine oil, coolant, transmission, brake fluid
• Perform visual inspection for any disconnected hoses, wires, or loose components
• With scan tool connected, clear any stored codes from battery disconnection
• Start engine and allow to reach operating temperature while monitoring for leaks at all connection points
• Check for proper oil pressure on instrument cluster immediately after starting
• Monitor coolant temperature to verify proper cooling system operation
• Verify no exhaust leaks at manifold connections
• Check AC compressor operation after system recharge
• Verify alternator charging voltage (13.5-14.5V at idle)
• Test drive vehicle and verify normal operation, smooth acceleration, and proper transmission engagement
• Scan for any new fault codes after test drive and address as necessary
• Recheck all fluid levels after test drive and top off as needed
• Inspect engine bay for any signs of leaks after vehicle has sat overnight

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