Exhaust Manifold

Remove and replace the exhaust manifold(s) on a 2017 Maserati Levante 3.0L V6 Twin Turbo, including turbocharger access, heat shield removal, and oxygen sensor handling.

Warnings

Tools required

Parts

• Exhaust manifold gasket × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust manifold nuts × 8 — Replace if damaged
• Heat shield × 1 — Inspect and replace if cracked
• Turbocharger gaskets × 1 — Use OEM specification if disturbed

Preparation

1. Ensure engine is completely cold (at least 3 hours after last operation)
2. Disconnect negative battery terminal and wait 10 minutes for system discharge
3. Raise vehicle and secure on jack stands at manufacturer-specified lift points
4. Remove engine undertray and splash shields for access
5. Spray all exhaust fasteners with penetrating oil and allow to soak for 30+ minutes
6. Document or photograph all electrical connector positions and routing

Procedure

1. 1

   Remove heat shields and covers
   Remove the upper engine cover by releasing the mounting clips. Remove the heat shields covering the exhaust manifold using the appropriate socket. These shields protect surrounding components from exhaust heat. Keep track of all mounting hardware as replacement heat shield bolts may be difficult to source.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)

   Cover Bolts18 Nm (13 lb-ft)
2. 2

   Disconnect oxygen sensors
   Locate the oxygen sensor(s) in the exhaust manifold or downstream pipe. Disconnect the electrical connectors by pressing the release tab. Using a 22mm oxygen sensor socket, carefully remove the oxygen sensor(s). If sensors are seized, apply additional penetrating oil and use a breaker bar with caution to avoid breaking the sensor body.
   ⚠Oxygen sensors are fragile. Do not use excessive force or the ceramic element may shatter internally.
   Torque spec

   O2 Sensor50 Nm (37 lb-ft)

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

   Remove turbocharger oil and coolant lines
   Disconnect the turbocharger oil feed line and oil return line from the turbocharger. Have a drain pan ready as residual oil will drain out. Disconnect coolant lines to the turbocharger using appropriate wrenches. Cap or plug all openings immediately to prevent contamination.
   ⚠Do not allow dirt or debris to enter turbocharger oil passages. Contamination will cause immediate turbocharger failure.
   Torque spec

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

   Disconnect exhaust downpipe from manifold
   Working from underneath the vehicle, locate the exhaust flange connection between the manifold/turbocharger and the downpipe. Remove the flange bolts while supporting the exhaust pipe. You may need to remove exhaust hangers to allow sufficient movement. Separate the flange connection and lower the exhaust pipe away from the manifold.
   ⚠Exhaust flange bolts are commonly seized. Apply heat carefully if necessary, avoiding brake lines and wiring.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)

   Hanger Bolts21 Nm (16 lb-ft)
5. 5

   Remove turbocharger mounting hardware
   If the turbocharger must be separated from the manifold for access, remove the turbocharger mounting bolts connecting it to the exhaust manifold. Note that on some configurations, the manifold and turbocharger may be removed as an assembly. Consult service manual diagrams to determine the best approach for your specific bank.
   Torque spec

   Mounting Bolts50 Nm (37 lb-ft)

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Disconnect electrical connectors and sensors
   Disconnect any remaining electrical connectors attached to components on or near the exhaust manifold. This may include temperature sensors, pressure sensors, or additional oxygen sensor wiring. Label each connector for correct reassembly.
   Torque spec

   Electrical Connector Bolts7 Nm (5 lb-ft)

   Mounting Bolts50 Nm (37 lb-ft)
7. 7

   Remove exhaust manifold mounting nuts
   Working from the hottest point (closest to combustion chamber) to the coldest (furthest away), remove the exhaust manifold nuts from the cylinder head studs. Use a systematic pattern to prevent warping. The manifold is secured by 8 nuts on the V6. If a stud breaks, stop immediately and extract the broken stud before proceeding.
   ⚠️Work hot-to-cold when removing manifold nuts to prevent distortion. Do not use impact tools on manifold nuts as this commonly breaks studs.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
8. 8

   Remove exhaust manifold assembly
   Carefully maneuver the exhaust manifold away from the cylinder head. The manifold may be stuck due to carbon buildup. Use a gentle twisting motion and plastic pry bar if needed, taking care not to damage the cylinder head mating surface. Remove the old manifold gasket from the cylinder head.
9. 9

   Clean and inspect mating surfaces
   Use a plastic gasket scraper to carefully remove all old gasket material from the cylinder head mating surface. Do NOT use metal scrapers that can gouge aluminum. Clean the surface with brake cleaner. Inspect the cylinder head surface for warping, cracks, or damage. Check all studs for damage and verify they are tight in the head. Inspect the manifold for cracks, especially around the ports.
   ⚠Even minor scratches on the mating surface can cause exhaust leaks. Work carefully and verify surface is completely clean.
   Torque spec

   Gasket Surface Bolts22 Nm (16 lb-ft)
10. 10

    Install new exhaust manifold gasket and manifold
    Position the new exhaust manifold gasket on the cylinder head studs. The gasket should fit snugly against the head with all ports aligned. Carefully position the exhaust manifold onto the studs and over the gasket. Start all manifold nuts by hand to ensure proper thread engagement before tightening any fasteners.
11. 11

    Torque exhaust manifold nuts to specification
    Apply anti-seize compound to the threads of each manifold nut. Using a torque wrench, tighten the exhaust manifold nuts in the sequence specified in the service manual, working from the center outward. Torque in multiple passes: first to 15 Nm, then to final specification of 30 Nm. Follow the hot-to-cold pattern specified in the service manual.
    ⚠️Critical fastener requiring specific tightening sequence. Improper sequence can warp manifold and cause leaks or cracks.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
12. 12

    Reinstall turbocharger and connections
    If the turbocharger was separated, install new gaskets and reconnect the turbocharger to the exhaust manifold using the mounting bolts and flange bolts. Torque all fasteners to specification with anti-seize applied. Reconnect the turbocharger oil feed line, oil return line, and coolant lines. Ensure all connections are clean and properly seated.
    Torque spec

    Mounting Bolts50 Nm (37 lb-ft)

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Reconnect exhaust downpipe
    Install a new exhaust flange gasket between the manifold/turbocharger outlet and the downpipe. Raise the downpipe into position and start all flange bolts by hand. Apply anti-seize to bolt threads. Torque the exhaust flange bolts to specification following the sequence in the service manual (typically in a cross pattern). Reinstall exhaust hangers.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Hanger Bolts21 Nm (16 lb-ft)
14. 14

    Reinstall oxygen sensors and electrical connections
    Apply anti-seize compound to the oxygen sensor threads (avoid getting anti-seize on the sensor tip). Install the oxygen sensor(s) and torque to specification using the oxygen sensor socket. Reconnect all electrical connectors, ensuring they click into place securely. Reinstall any sensor mounting bolts.
    Torque spec

    O2 Sensor50 Nm (37 lb-ft)

    Mounting Bolts50 Nm (37 lb-ft)

    Electrical Connector Bolts7 Nm (5 lb-ft)
15. 15

    Reinstall heat shields and covers
    Position the heat shields over the exhaust manifold. Install and torque the heat shield bolts according to the service manual sequence to prevent rattling. Reinstall the upper engine cover. Verify all mounting hardware is secure and no tools or parts have been left in the engine bay.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

    Cover Bolts18 Nm (13 lb-ft)

Reassembly

1. Reinstall all engine covers, undertrays, and splash shields removed during preparation
2. Reconnect the negative battery terminal
3. Do not start the engine immediately; perform leak check procedure first

Verification

• Before starting engine, visually inspect all connections and verify no tools remain in engine bay
• Start engine and allow to idle. Listen for exhaust leaks at manifold and flange connections
• Check for oil leaks at turbocharger oil lines and coolant leaks at turbocharger coolant lines
• With engine at operating temperature, inspect all exhaust connections for leaks (visible exhaust smoke or ticking sounds)
• Verify no check engine lights or turbocharger-related fault codes are present
• Test drive vehicle and verify normal turbocharger operation with no unusual noises or loss of power

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