Exhaust Gasket - Front

Replace the front exhaust gasket between the exhaust manifolds and catalytic converters on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, ensuring proper sealing and preventing exhaust leaks.

Warnings

Tools required

Parts

• Front exhaust gasket (left bank) × 1 — Use OEM specification
• Front exhaust gasket (right bank) × 1 — Use OEM specification
• Exhaust flange bolts/nuts (if corroded) × 4 — M8 or M10 depending on location
• Oxygen sensor (if damaged during removal) × 1 — Use OEM specification

Preparation

1. Ensure engine and exhaust system are completely cold to the touch
2. Park vehicle on level ground and engage parking brake
3. Disconnect negative battery terminal to prevent accidental airbag deployment
4. Raise front of vehicle and secure on jack stands rated for vehicle weight
5. Remove engine undertray/splash shields for access to exhaust components
6. Spray all exhaust flange bolts and oxygen sensor threads with penetrating oil and allow 15-30 minutes soak time
7. Identify which bank (left or right) requires gasket replacement by locating source of exhaust leak

Procedure

1. 1

   Remove heat shields
   Remove the exhaust heat shields covering the front exhaust flanges. These are typically secured with 10mm bolts. Remove all heat shield bolts and carefully extract shields, noting their positions for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect oxygen sensors
   Locate the upstream oxygen sensors on the exhaust pipe just after the manifold connection. Disconnect the electrical connector by pressing the release tab. Using an oxygen sensor socket, carefully unscrew the sensor(s) from the exhaust pipe. Work slowly to avoid breaking the sensor. If sensor is seized, apply additional penetrating oil and allow to soak, then retry.
   ⚠Do not force oxygen sensors if seized. Broken sensors require drilling and retapping the bung.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
3. 3

   Remove exhaust support hangers
   Locate the rubber exhaust hangers supporting the front catalytic converter section. Use a 13mm socket to remove hanger bracket bolts. Support the exhaust pipe with a jack or stand to prevent it from hanging on remaining connections and causing damage.
   Torque spec

   Hanger Bolts22 Nm (16 lb-ft)
4. 4

   Separate exhaust flange connection
   Locate the exhaust flange bolts connecting the manifold outlet to the catalytic converter inlet. These are typically two bolts per side. Use a 15mm socket to remove the flange bolts. If bolts are severely corroded, cut them with a reciprocating saw or grinder and plan to replace. Carefully separate the flange connection and lower the front exhaust section slightly.
   ⚠Exhaust flanges may be seized together. Gently tap with rubber mallet to separate; do not pry aggressively as flanges can crack.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Remove old gasket
   Once the flange is separated, remove and discard the old exhaust gasket. It may be stuck to either the manifold flange or catalytic converter flange. Inspect the gasket for failure pattern (blown section, compression marks) to confirm leak source.
6. 6

   Clean mating surfaces
   Using a plastic or brass gasket scraper, carefully remove all remnants of the old gasket material from both mating surfaces (manifold outlet flange and catalytic converter inlet flange). Do not use steel scrapers that could gouge the sealing surfaces. Follow with a wire brush and brake cleaner to remove all carbon deposits and oil. Both surfaces must be completely clean and flat for proper gasket sealing.
   ℹ️Inspect flange surfaces for warping, cracks, or deep scoring. Damaged flanges will not seal properly even with new gaskets.
7. 7

   Inspect exhaust studs and bolts
   Examine all exhaust studs and bolt threads for damage, corrosion, or stripping. Chase threads with appropriate tap/die if necessary. Replace any damaged fasteners before reassembly. Clean threads with brake cleaner and allow to dry.
8. 8

   Install new gasket
   Position the new front exhaust gasket onto the manifold outlet flange. Ensure the gasket is oriented correctly per manufacturer markings (if present). Most gaskets have a specific top/bottom orientation. The gasket should sit flat without forcing.
   ℹ️Some gaskets have metal reinforcement rings or crush sections that must face specific directions. Verify orientation before installation.
9. 9

   Reconnect exhaust flange
   Carefully align the catalytic converter inlet flange with the manifold outlet flange, sandwiching the new gasket. Support the exhaust section to maintain alignment. Install flange bolts finger-tight initially. Apply anti-seize compound to bolt threads before installation. Once all bolts are started, tighten in a cross-pattern to specified torque.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Reinstall oxygen sensors
    Apply a thin coat of anti-seize compound to the oxygen sensor threads only, keeping compound away from the sensor tip. Thread sensors into exhaust pipe bungs by hand to ensure proper thread engagement. Tighten to specified torque using oxygen sensor socket. Reconnect electrical connectors ensuring they click into place securely.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
11. 11

    Reinstall exhaust hangers
    Reattach exhaust support hangers and rubber mounts. Ensure exhaust system hangs properly with no binding or contact with undercarriage components. Tighten hanger bolts to specified torque.
    Torque spec

    Hanger Bolts22 Nm (16 lb-ft)
12. 12

    Reinstall heat shields
    Reposition exhaust heat shields in their original locations. Ensure shields do not contact exhaust pipes directly and have proper clearance. Install and tighten heat shield bolts to specified torque.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reinstall engine undertray and splash shields
2. Lower vehicle from jack stands
3. Reconnect negative battery terminal
4. If other bank also requires gasket replacement, repeat procedure for opposite side

Verification

• Start engine and allow to reach operating temperature while monitoring for exhaust leaks at the repair location
• Listen for hissing or ticking sounds that indicate exhaust leaks at the flange connection
• Visually inspect the flange area for escaping exhaust gases (may see heat waves or soot deposits forming)
• Check that oxygen sensor readings are normal using OBD-II scanner (if available)
• Verify no exhaust odor in cabin during operation
• Perform a test drive and confirm no exhaust leaks under acceleration or load
• After test drive, re-inspect all connections while engine is hot to ensure gasket has seated properly

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