Intake Manifold

This procedure covers the removal and replacement of the intake manifold on a 2017 Maserati Levante 3.0L V6 Twin Turbo engine, including removal of associated components and proper torque sequencing during reinstallation.

Warnings

Tools required

Parts

• Intake manifold gaskets (set of 2) × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• PCV valve grommet × 1 — Use OEM specification
• Fuel injector O-rings (set of 6) × 1 — Use OEM specification
• Vacuum line grommets × 1 — Use OEM specification
• Coolant (for top-off) × 1 — Maserati OAT Coolant

Fluids

• Maserati OAT Coolant — 1 qt

Preparation

1. Ensure engine is completely cool (minimum 2 hours after shutdown)
2. Disconnect negative battery terminal and wait 10 minutes for system power-down
3. Remove engine cover by pulling upward on front edge then sliding forward
4. Place drip pans under vehicle to catch coolant spillage
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
6. Document all electrical connector locations with photos for reassembly reference

Procedure

1. 1

   Drain coolant and remove upper coolant hoses
   Drain coolant from radiator drain plug into appropriate container. Disconnect upper radiator hose and heater hoses connected to intake manifold. Use hose clamp pliers to compress spring clamps and slide back before twisting hoses to break seal. Expect residual coolant drainage from manifold passages.
2. 2

   Disconnect air intake system
   Loosen clamps on air intake tubes leading from air filter box to throttle body. Disconnect mass airflow sensor electrical connector by pressing release tab. Remove entire air intake assembly including resonator box. On twin turbo models, both turbo inlet tubes must be disconnected from throttle body.
3. 3

   Remove throttle body
   Disconnect throttle position sensor and electronic throttle control connectors. Remove four throttle body mounting bolts. Carefully separate throttle body from intake manifold, twisting gently to break gasket seal. Inspect throttle plate for carbon buildup and clean if necessary. Keep throttle body protected from debris.
   ⚠Do not force throttle plate open manually. Electronic throttle actuator is delicate and can be damaged.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect fuel system
   Disconnect fuel supply line from fuel rail using appropriate quick-disconnect tool. Have shop towels ready to catch residual fuel spray. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached away from intake manifold. Cap all fuel openings immediately to prevent contamination. Secure fuel rail assembly to side of engine bay.
   ⚠️Work in well-ventilated area. Have fire extinguisher nearby when working with fuel system.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
5. 5

   Disconnect PCV system and vacuum lines
   Remove PCV valve from valve cover by twisting counterclockwise. Disconnect PCV hose from intake manifold. Label and disconnect all vacuum lines connected to intake manifold including brake booster line, purge valve line, and any vacuum-actuated turbo control lines. Use photos taken during preparation for reference.
   Torque spec

   PCV Valve8 Nm (6 lb-ft)
6. 6

   Disconnect electrical connections
   Disconnect all remaining electrical connectors on intake manifold including MAP sensor, intake air temperature sensor, and any solenoid valves. Press release tabs fully before pulling connectors to avoid damage. Remove any wiring harness clips or brackets attached to intake manifold mounting points.
   Torque spec

   Electrical Connector Bolts7 Nm (5 lb-ft)

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

   Remove intake manifold support brackets
   Locate and remove support brackets connecting intake manifold to engine block. These are typically located on underside of manifold and may require working from underneath vehicle or through wheel well. Remove mounting bolts for all support brackets before attempting to remove manifold.
   Torque spec

   Mounting Bolts50 Nm (37 lb-ft)
8. 8

   Remove intake manifold mounting bolts
   Working from outer bolts toward center, gradually loosen all intake manifold mounting bolts in reverse of tightening sequence. There are typically 12-16 bolts securing manifold to cylinder heads. Loosen each bolt 2-3 turns at a time in sequence to prevent manifold warping. Once all bolts are loose, remove them completely and keep organized.
   ⚠Intake manifold is heavy and awkward to handle. Have helper assist with removal to prevent dropping and damaging manifold or surrounding components.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
9. 9

   Remove intake manifold assembly
   Carefully lift intake manifold straight up and away from cylinder heads. Manifold may be stuck due to gasket seal - use plastic pry tools at gasket surfaces if necessary, never pry against machined aluminum surfaces. Maneuver manifold around turbocharger piping and other obstacles. Place manifold on clean protected surface with ports facing upward.
10. 10

    Clean all gasket surfaces
    Using non-metallic gasket scraper and brass brush, carefully remove all old gasket material from cylinder head mating surfaces and intake manifold mating surfaces. Surfaces must be completely clean with no gasket residue, carbon buildup, or scratches. Clean bolt holes with compressed air to remove debris. Wipe surfaces with brake cleaner on lint-free cloth. Inspect for cracks, warping, or damage.
    ⚠Do not use metallic scrapers or wire wheels on aluminum gasket surfaces as this will cause damage requiring resurfacing.
    Torque spec

    Gasket Surface Bolts22 Nm (16 lb-ft)
11. 11

    Install new gaskets and position intake manifold
    Place new intake manifold gaskets on cylinder heads, ensuring all ports align correctly and gaskets are fully seated. Some gaskets may have alignment pins or tabs. Position intake manifold carefully over gaskets, ensuring no gasket movement. Guide manifold down evenly, checking that all ports align and no vacuum lines or wires are pinched underneath.
12. 12

    Install and torque intake manifold bolts
    Hand-thread all intake manifold bolts to prevent cross-threading. Following factory service manual bolt sequence diagram, tighten bolts from center outward in progressive stages. First pass: snug all bolts hand-tight. Second pass: torque all bolts to 12 Nm (9 lb-ft) in sequence. Final pass: torque all bolts to final specification of 25 Nm (18 lb-ft) in same sequence. Verify all bolts are torqued correctly.
    ⚠Bolt sequence is critical. Improper sequence will cause vacuum leaks and potentially crack the intake manifold.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Reinstall support brackets and fuel system
    Reinstall intake manifold support brackets to engine block and torque mounting bolts to specification. Install new fuel injector O-rings if replacing. Carefully position fuel rail with injectors into intake manifold ports, ensuring all injectors seat fully. Install fuel rail bolts and torque in sequence per service manual to specification. Reconnect fuel supply line until it clicks into place.
    Torque spec

    Mounting Bolts50 Nm (37 lb-ft)

    Fuel Rail Bolts12 Nm (9 lb-ft)
14. 14

    Install throttle body and reconnect systems
    Install new throttle body gasket. Position throttle body on intake manifold and install mounting bolts, torquing to specification in cross pattern. Install PCV valve with new grommet and torque to specification. Reconnect all vacuum lines to correct ports per documentation. Reconnect all electrical connectors including sensors and solenoids. Install air intake system and secure all clamps.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)

    PCV Valve8 Nm (6 lb-ft)

    Mounting Bolts50 Nm (37 lb-ft)

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

    Refill coolant and complete final checks
    Refill cooling system with Maserati OAT coolant to proper level. Reconnect negative battery terminal. Using Maserati diagnostic scanner, perform throttle body relearning procedure per factory specifications. This is mandatory for proper engine operation. Double-check all connections, bolts, and hoses. Start engine and check for vacuum leaks, fuel leaks, and coolant leaks while engine warms up.
    ⚠Throttle body must be relearned using factory diagnostic tool or engine will run poorly with possible fault codes.

Reassembly

1. Torque all fasteners in specified sequences per service manual to prevent vacuum leaks
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Verify fuel line quick-disconnect is fully locked by pulling firmly on line
4. Check coolant level after engine reaches operating temperature and top off if needed
5. Install engine cover by sliding rearward then pressing down until clips engage

Verification

• Start engine and verify smooth idle with no rough running or stalling
• Check for vacuum leaks using carburetor cleaner spray around manifold gasket surfaces while engine idles - RPM change indicates leak
• Verify no fuel odor or visible fuel leaks around fuel rail and supply line
• Check for coolant leaks around hose connections and manifold passages
• Scan for diagnostic trouble codes using Maserati scanner - there should be no codes present
• Test drive vehicle and verify normal throttle response and boost pressure from turbochargers
• Monitor coolant level for next several days and top off as needed after air purges from system

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