Fuel Tank Strap

This procedure covers removal and replacement of the fuel tank retention straps on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including fuel system depressurization and safe tank support.

Warnings

Tools required

Parts

• Fuel tank strap (left) × 1 — Use OEM specification
• Fuel tank strap (right) × 1 — Use OEM specification
• Fuel line O-ring kit × 1 — Use OEM specification
• Fuel tank heat shield fasteners × 1 — Use OEM specification if damaged
• Strap mounting hardware kit × 1 — Use OEM specification if corroded

Preparation

1. Ensure fuel tank is below 1/4 full. If necessary, siphon fuel into approved containers in a well-ventilated area away from ignition sources
2. Park vehicle on level ground and engage parking brake. Place wheel chocks at front wheels
3. Disconnect negative battery terminal and wait 2 minutes for system capacitors to discharge. Consider using a battery memory saver on a separate battery source
4. Remove fuel filler cap to release any tank pressure
5. Locate fuel pump fuse or relay in engine compartment fuse box (refer to fuse diagram on box cover) and remove to disable fuel pump
6. Attempt to start engine and let it run until it stalls to depressurize fuel system. Crank for additional 5 seconds after stalling
7. Raise vehicle on lift or safely support on jack stands at manufacturer-specified lift points. Vehicle must be level and secure
8. Remove rear wheels if additional working clearance is needed
9. Allow exhaust system to cool completely (minimum 1 hour after last operation) before beginning work

Procedure

1. 1

   Access fuel tank area
   Remove rear exhaust heat shields by removing fasteners. Lower exhaust system slightly if needed using exhaust hanger tool or support with jack to provide clearance to fuel tank. Remove any underbody panels or aerodynamic covers that obstruct access to fuel tank straps. On RWD models, the driveshaft does not need removal but note its proximity.
2. 2

   Disconnect fuel tank electrical connections
   Locate the fuel pump module electrical connector on top of the fuel tank (accessible from underneath on Levante). Press release tab and disconnect the main fuel pump/sender connector. Disconnect any additional connections for fuel level sensors or EVAP system components. Label connections if necessary for reassembly.
   ⚠Do not force electrical connectors. Maserati connectors use specific release mechanisms that can break if improperly handled.
3. 3

   Disconnect fuel lines and EVAP lines
   Using appropriate fuel line disconnect tools, disconnect the fuel supply and return lines at the tank connections. Be prepared for residual fuel spillage—position drain pan beneath connections. Disconnect EVAP vapor lines and purge line from tank. Use a fuel line clamp or plugs to seal open fuel lines to prevent contamination and further spillage. Inspect O-rings and plan to replace during reassembly.
   ⚠️Even after depressurization, residual pressure may remain. Place shop towel over connection and release slowly. Keep face and body clear of connection point.
4. 4

   Disconnect fuel filler neck and vent hose
   Locate the fuel filler neck connection at the rear of the tank. Loosen hose clamp and disconnect filler neck hose from tank. Disconnect vent hose from tank using appropriate technique for clamp type installed (typically worm-drive or constant-tension clamp). Allow any residual fuel to drain into catch pan.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
5. 5

   Support fuel tank
   Position hydraulic transmission jack or dedicated fuel tank support stand under the center of the fuel tank. Raise jack until it just contacts tank—do not lift tank yet. Use wide wooden blocks or tank support adapter on jack to distribute load. Secure tank to jack using adjustable straps to prevent shifting during lowering. Ensure jack is stable and centered.
   ⚠️The tank must be properly supported before removing straps. An unsupported or improperly supported tank can fall causing severe injury or death.
6. 6

   Remove fuel tank heat shield
   Remove fasteners securing the fuel tank heat shield (typically located above tank between tank and exhaust). The heat shield must be removed to access the fuel tank strap mounting bolts. Note orientation and position of shield for reinstallation.
7. 7

   Remove fuel tank strap mounting bolts
   Locate the fuel tank strap mounting bolts at each end of both straps (typically two straps running transversely under tank). The mounting bolts attach straps to the vehicle chassis/frame. Using appropriate socket, remove the mounting bolts from both straps. Support straps by hand as final bolt is removed to prevent them from falling. Inspect strap condition for corrosion, cracking, or deformation—replace if any damage is present.
   ⚠As bolts are loosened, tank weight will transfer to jack. Monitor jack stability and tank position continuously.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
8. 8

   Lower and inspect fuel tank
   Carefully lower the hydraulic jack 4-6 inches to provide access to tank top if needed for strap removal. The straps can now be removed from around the tank. Remove old straps completely and inspect tank mounting surfaces for damage, corrosion, or deformation. Inspect tank shield mounting points and rubber isolators. Check tank surface for damage, dents, or corrosion. If tank requires further service, continue lowering with extreme care.
9. 9

   Install new fuel tank straps
   Position new fuel tank straps around the tank in the same orientation as removed straps. Ensure straps sit properly in tank indentations/grooves and are not twisted. Raise tank with hydraulic jack until strap mounting holes align with chassis mounting points. Start all mounting bolts by hand before tightening any. Verify tank is centered and positioned correctly before final tightening.
10. 10

    Torque strap mounting bolts
    Torque fuel tank strap mounting bolts to specification in a cross-pattern (alternate between straps and sides) to ensure even loading. Torque to 28 Nm (21 lb-ft). After initial torque, verify tank position has not shifted and all mounting surfaces are flush. Re-check torque on all bolts.
    ⚠Over-torquing can damage mounting threads in chassis. Under-torquing can allow tank movement and strap failure.
    Torque spec

    Mounting Bolts28 Nm (21 lb-ft)
11. 11

    Reinstall heat shield and reconnect filler neck
    Reinstall fuel tank heat shield using original or new fasteners as needed. Ensure proper positioning between tank and exhaust. Reconnect fuel filler neck hose to tank inlet and secure with hose clamp torqued to 3 Nm (2 lb-ft). Reconnect vent hose and secure with clamp to same specification. Ensure hoses are routed properly without kinks or interference.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
12. 12

    Reconnect fuel and EVAP lines
    Install NEW O-rings on all fuel line fittings—lubricate lightly with clean gasoline or approved lubricant. Connect fuel supply and return lines to tank, ensuring they click or seat fully. Torque fuel line fittings to 25 Nm (18 lb-ft) or 28 Nm (21 lb-ft) depending on specific fitting type (refer to service information for your specific connections). Reconnect EVAP vapor and purge lines ensuring proper routing and secure connection.
    ⚠️Reusing old O-rings can cause fuel leaks under pressure. Always use new O-rings on fuel system connections.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
13. 13

    Reconnect electrical connections
    Reconnect fuel pump module electrical connector ensuring it clicks fully into place. Reconnect any additional sensor or EVAP electrical connections. Verify all connections are secure and properly seated. Remove jack and support from under fuel tank.
14. 14

    Reinstall exhaust components and underbody panels
    Raise exhaust system back to normal position and secure all exhaust hangers. Reinstall exhaust heat shields with fasteners. Reinstall any underbody panels or aerodynamic covers that were removed. If rear wheels were removed, reinstall and torque to specification.
15. 15

    System pressurization and leak check
    Reinstall fuel pump fuse or relay. Reconnect negative battery terminal. Without starting engine, turn ignition to ON position (not START) for 5 seconds, then OFF. Repeat this cycle 3-4 times to allow fuel pump to pressurize system. Carefully inspect all fuel connections, filler neck, and tank area for any signs of fuel leakage using flashlight and mirror. Check for fuel odor. If any leaks are detected, immediately depressurize system and repair before proceeding.
    ⚠️This is the critical leak check. Any fuel leak under pressure presents immediate fire hazard. Do not start engine if any leak is detected.

Reassembly

1. Reinstall fuel filler cap and verify it seals properly
2. Lower vehicle from jack stands or lift
3. Clear all tools and equipment from under and around vehicle
4. Properly dispose of old fuel tank straps and any drained fuel according to local environmental regulations

Verification

• With vehicle running, monitor fuel system for leaks around all connections—check immediately after start and again after 5 minutes of operation
• Check for fuel odor inside vehicle cabin and around fuel filler area
• Verify fuel gauge operates correctly and shows accurate level
• Test drive vehicle and monitor for any unusual odors, sounds from fuel tank area, or fuel gauge irregularities
• After test drive, perform final underneath inspection for any fuel seepage or strap movement
• Monitor vehicle for first 100 miles of operation—recheck all connections if any fuel odor is detected

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