Freeze Plug - Single

Replace a single freeze plug (core plug) on the 2017 Maserati Levante 3.0L V6 Twin Turbo engine, requiring coolant drain, component removal for access, and proper sealing during installation.

Warnings

Tools required

Parts

• Engine freeze plug (core plug) × 1 — Use OEM specification - size varies by location
• Engine coolant × 1 — Maserati OAT Coolant
• Gasket set (as needed for removed components) × 1 — Use OEM specification

Fluids

• Maserati OAT Coolant — 10 qt

Preparation

1. Ensure engine is completely cold (minimum 2 hours after last operation)
2. Position vehicle on level ground with parking brake engaged
3. Disconnect negative battery cable and wait 5 minutes for system discharge
4. Remove engine undertray and splash shields for access
5. Identify exact freeze plug location requiring replacement (front, side, or rear of block)
6. Place coolant drain pan under engine drain plug location
7. Gather all tools and parts before beginning procedure

Procedure

1. 1

   Drain engine coolant system
   Open the coolant drain valve at the bottom of the radiator or remove the lower radiator hose at the engine block. Allow coolant to drain completely into the collection pan. If the failed freeze plug is accessible, you may not need to drain the entire system, but draining ensures no spillage during removal.
2. 2

   Remove components blocking freeze plug access
   Based on freeze plug location, remove necessary components for access. Common obstructions include: engine mount brackets, alternator or AC compressor (if front side), exhaust manifold heat shields, wiring harnesses, coolant hoses, or turbocharger inlet/outlet pipes. Label all electrical connectors and vacuum lines during removal. For side plugs, you may need to remove the starter motor. For rear plugs, transmission bellhousing access may be required.
   ⚠V6 twin turbo engines have limited working space. Take care not to damage fragile vacuum lines, sensors, or wiring harnesses during component removal.
   Torque spec

   Mounting Bolts50 Nm (37 lb-ft)

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

   Clean area around failed freeze plug
   Use wire brush and brake cleaner to thoroughly clean the area around the freeze plug and surrounding engine block surface. Remove all dirt, oil, coolant residue, and corrosion. This prevents contamination from entering the cooling system and ensures proper sealant adhesion.
4. 4

   Remove failed freeze plug
   Using a freeze plug removal tool or slide hammer with adapter, extract the old freeze plug from the engine block. If tools are unavailable, carefully drill a small hole in the center of the plug (avoid drilling into the block), insert a slide hammer or pry bar, and lever the plug out at an angle. Work carefully to avoid damaging the bore in the engine block, as this can cause leak issues with the new plug.
   ⚠Do not use excessive force or sharp tools that could gouge or damage the freeze plug bore in the engine block. Bore damage will prevent proper seal and may require machine shop repair.
5. 5

   Inspect and prepare freeze plug bore
   Thoroughly inspect the freeze plug bore in the engine block for corrosion, pitting, or damage. Use a wire brush or abrasive pad to clean the bore surface until it is smooth and free of rust or debris. The bore must be clean, dry, and smooth for proper plug seating. Check bore diameter to ensure it matches the replacement plug specifications.
6. 6

   Prepare new freeze plug
   Verify the new freeze plug matches the original in diameter and type (cup-type or expansion type). Apply a thin, even bead of high-temperature RTV silicone sealant around the outer edge of the freeze plug as specified in torque specifications. Allow sealant to become slightly tacky per manufacturer instructions (typically 2-5 minutes) before installation.
   ℹ️Use only high-temperature sealant rated for engine coolant contact. Standard RTV may not withstand coolant temperature and chemical exposure.
7. 7

   Install new freeze plug
   Position the new freeze plug squarely in the bore with the convex (domed) side facing outward. Using a freeze plug installation tool or appropriately sized brass drift and hammer, carefully drive the plug into the bore. The plug should seat evenly and be recessed approximately 1-2mm below the block surface (or flush, depending on plug type). Ensure the plug is not cocked or tilted during installation. For expansion-type plugs, tighten the center bolt to the specified torque to expand the plug in the bore.
   Torque spec

   Freeze Plug10 Nm (7 lb-ft)
8. 8

   Verify freeze plug installation
   Visually inspect the installed freeze plug to ensure it is seated evenly around the entire circumference and at the proper depth. Check that sealant has formed a complete seal around the plug edge. Allow sealant to cure per manufacturer recommendations (typically 15-30 minutes minimum, 24 hours for full cure).
9. 9

   Reinstall removed components
   Reinstall all components removed for access in reverse order of removal. Replace any gaskets that were disturbed during disassembly. Clean all gasket mating surfaces with a plastic scraper and brake cleaner before installing new gaskets. Reconnect all electrical connectors, vacuum lines, and coolant hoses. Reference photos taken during disassembly to ensure correct routing.
   ℹ️Torque all fasteners to specification in the proper sequence. Over-tightening can strip aluminum threads in the engine block or crack components.
   Torque spec

   Gasket Surface Bolts22 Nm (16 lb-ft)

   Gasket Bolts21 Nm (16 lb-ft)

   Mounting Bolts50 Nm (37 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)

   Electrical Connector Bolts7 Nm (5 lb-ft)

   Cover Bolts18 Nm (13 lb-ft)
10. 10

    Refill cooling system
    Close all drain valves and ensure all coolant hoses are properly connected. Using Maserati OAT coolant, refill the cooling system through the coolant reservoir or radiator cap (depending on system design). Fill slowly to allow air to escape. Fill to the appropriate level mark on the reservoir. Install radiator cap securely.
11. 11

    Bleed cooling system
    Start the engine and allow it to warm up to operating temperature with the heater set to maximum temperature. Monitor coolant level and add as needed as air purges from the system. The engine cooling fan should cycle on and off, indicating proper thermostat operation. Check for leaks around the new freeze plug and all disturbed connections. Squeeze upper radiator hose to help purge air pockets. Shut off engine and allow to cool, then recheck coolant level and top off as needed.
    ⚠Monitor engine temperature gauge closely during bleeding procedure. If temperature rises above normal or coolant leaks appear, shut down engine immediately.
12. 12

    Final inspection and test
    With engine cool, inspect the freeze plug installation area and all reassembled components for any signs of coolant leakage. Check coolant level in reservoir and top off to proper mark. Reconnect negative battery cable. Clear any diagnostic codes that may have set during battery disconnection. Reinstall engine undertray and splash shields. Test drive vehicle and monitor temperature gauge for normal operation.

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify all coolant hoses are properly clamped with no signs of leakage
3. Double-check that all fasteners have been reinstalled and torqued to specification
4. Confirm coolant level is at the proper mark on the reservoir with engine cold
5. Verify no tools or parts have been left in the engine compartment

Verification

• Start engine and verify no coolant leaks from freeze plug or disturbed connections
• Confirm engine reaches normal operating temperature without overheating
• Check that heater produces hot air, indicating proper coolant circulation
• Inspect freeze plug area after first drive cycle for any seepage or weeping
• Verify coolant level remains stable after several heat cycles
• Monitor for any warning lights or temperature anomalies during test drive

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