Exhaust Pipe - Rear Section

Replacement of the rear exhaust section from the intermediate pipe connection to the rear muffler and tailpipes on a 2017 Maserati Levante 3.0L V6 Twin Turbo.

Warnings

Tools required

Parts

• Rear exhaust section assembly × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust hanger bushings (if deteriorated) × 3 — Use OEM specification

Preparation

1. Park vehicle on level ground and allow exhaust system to cool completely (minimum 2 hours after operation).
2. Raise vehicle on lift or secure on jack stands at all four corners, ensuring adequate working clearance underneath.
3. Visually inspect exhaust system for damage and identify all mounting points and hangers.
4. Spray all flange bolts, hanger bolts, and heat shield fasteners with penetrating oil and allow to soak for 15-30 minutes.
5. Have fire extinguisher accessible in case penetrating oil ignites from residual heat.

Procedure

1. 1

   Remove heat shields
   Locate and remove any heat shields covering the rear exhaust section connection point. These are typically secured with 10mm bolts. Remove bolts completely and set heat shields aside for reinstallation.
   Torque spec

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

   Support rear exhaust section
   Position a transmission jack or suitable support under the rear muffler assembly. Raise jack until it just contacts the exhaust but does not lift the vehicle. This will support the weight during disassembly and prevent sudden dropping.
   ⚠The rear section weighs approximately 40-50 lbs and will drop suddenly when disconnected if not properly supported.
3. 3

   Disconnect rear exhaust hangers
   Locate the rubber exhaust hangers supporting the rear section (typically 2-3 hangers). Use an exhaust hanger removal tool or spray with soapy water and carefully pry the hangers off their mounting studs with a flat blade screwdriver. Work the rubber isolator side-to-side while pulling to avoid tearing. Inspect hangers for cracks or deterioration.
   ℹ️Replace any rubber hangers that show cracking, hardening, or deterioration to prevent future rattles and misalignment.
4. 4

   Remove flange bolts at connection point
   Locate the flange connection between the intermediate pipe and rear section (typically just forward of the rear axle). Using a 13mm or 17mm socket (verify size on your specific vehicle), remove the flange bolts connecting the two sections. There are typically 2-4 bolts in a circular pattern around the flange. Keep the old gasket for reference if ordering parts separately.
   ⚠If bolts are severely corroded and begin to strip or break, use a bolt extractor set or cut with angle grinder as last resort.
   Torque spec

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

   Separate flange connection
   Once bolts are removed, the flange may be stuck due to carbon buildup and corrosion. Gently pry the flanges apart using a pry bar or exhaust spreader tool. Work around the circumference evenly to avoid bending the flanges. The sections should separate with moderate effort.
   ℹ️Do not use excessive force on flanges as they can be bent, requiring replacement of expensive components.
6. 6

   Remove rear exhaust section
   With hangers disconnected and flange separated, carefully lower the transmission jack while guiding the rear section down and out from under the vehicle. Maneuver past the rear suspension components and differential. Remove section from under vehicle and set aside.
   ⚠Exhaust tips extend significantly and can catch on suspension or underbody components. Move slowly and check clearances.
7. 7

   Clean flange mating surface
   Use a wire brush to thoroughly clean the flange surface on the intermediate pipe where the new rear section will connect. Remove all old gasket material, carbon deposits, and rust. The surface should be clean and smooth to ensure proper sealing with the new gasket.
   ℹ️A clean flange surface is critical to prevent exhaust leaks. Take time to clean thoroughly.
8. 8

   Inspect and prepare mounting points
   Inspect all exhaust hanger mounting studs on the vehicle underbody for damage or excessive rust. Clean threads with wire brush. Check that rubber hanger isolators on new exhaust section are in good condition. If reusing old hangers, ensure they are not cracked or deteriorated.
9. 9

   Position new rear exhaust section
   With assistance or using transmission jack, lift new rear exhaust section into position under vehicle. Align the flange with the intermediate pipe connection point first, then maneuver rear muffler and tips to approximate final position. Install new flange gasket between the flanges.
   ℹ️Do not fully tighten any fasteners until all hangers are connected and section is properly aligned.
10. 10

    Install flange bolts loosely
    Apply anti-seize compound to the threads of the flange bolts as specified. Insert bolts through flange and gasket, threading them into the opposite flange. Tighten bolts by hand or only snug with wrench. Leave loose enough that the exhaust can still move for alignment.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
11. 11

    Connect exhaust hangers
    Attach each rubber hanger to its corresponding mounting stud on the underbody. Use soapy water as lubricant if needed. Ensure each hanger is fully seated onto its stud. The exhaust should hang naturally with slight tension on the hangers.
12. 12

    Align exhaust system
    Check alignment of entire rear section. Exhaust tips should be centered in rear fascia openings with equal spacing. Section should have adequate clearance from suspension, differential, fuel tank, and underbody (minimum 10-15mm). Adjust position by loosening flange and repositioning hangers as needed.
    ⚠Inadequate clearance can result in rattles, heat damage to nearby components, or exhaust contact during suspension travel.
13. 13

    Torque flange bolts to specification
    Once alignment is correct, torque the flange bolts to 50 Nm (37 lb-ft) in a cross-pattern sequence to ensure even clamping force on the gasket. Verify anti-seize was applied during installation.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
14. 14

    Reinstall heat shields
    Reposition any heat shields that were removed and secure with original bolts. Torque heat shield bolts to 10 Nm (7 lb-ft). Ensure shields do not contact exhaust pipes or create potential rattle points.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
15. 15

    Final inspection
    Perform final visual inspection of all connections, hangers, and clearances. Verify all fasteners are tight and no tools or parts were left in work area. Check that exhaust tips are properly aligned and positioned in rear fascia cutouts.

Reassembly

1. Ensure all flange bolts are torqued to specification with anti-seize applied.
2. Verify all rubber hangers are properly seated and not twisted or under excessive tension.
3. Confirm adequate clearance exists between exhaust and all surrounding components through full suspension travel.
4. Double-check that heat shields are reinstalled and properly secured.

Verification

• Start engine and listen for exhaust leaks at the flange connection. A leak will produce a ticking or hissing sound that increases with engine speed.
• With engine at operating temperature, perform visual inspection underneath vehicle for any signs of exhaust smoke or soot indicating leaks.
• Test drive vehicle and listen for any rattles, buzzes, or contact noises from exhaust system during acceleration, deceleration, and over bumps.
• Verify exhaust tips remain centered in fascia openings and do not contact bodywork during driving.
• After initial test drive (10-15 minutes), re-inspect flange bolts for proper torque and check for any exhaust leaks that may have developed after heat cycling.

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