engine

Intercooler

for 2017 Maserati Levante 3.0L V6 Twin Turbo · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Advanced

Time

3.7 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

Replacement of the air-to-air intercooler assembly on the 2017 Maserati Levante 3.0L V6 Twin Turbo, including removal of front fascia components and charge air piping.

Warnings

⚠️Allow engine to cool completely before beginning work. Coolant system operates under pressure and can cause severe burns.

⚠The intercooler is located behind the front bumper and requires removal of multiple fascia components. Take care not to damage clips and mounting points.

⚠Do not over-torque charge pipe clamps as this can damage the intercooler inlet/outlet tubes.

ℹ️Some residual coolant may be present in charge air pipes if engine has been recently operated. Have drain pan ready.

Tools required

10mm socket and ratchetEssential

13mm socket and ratchetEssential

T25 Torx bitEssential

T30 Torx bitEssential

Torque wrench (5-60 Nm range)Essential

Trim panel removal toolsEssential

Jack and jack standsEssential

Drain pan

Hose clamp pliersEssential

Shop light or headlamp

Parts

Intercooler assembly × 1 — Use OEM specification
Charge pipe clamps (if damaged) × 4 — Use OEM specification
Intercooler mounting hardware kit × 1 — Use OEM specification
Coolant (for top-off) × 1 — Maserati OAT Coolant

Fluids

Maserati OAT Coolant — 0.5 qt

Preparation

Ensure engine is completely cool to the touch (minimum 2 hours after operation)
Disconnect negative battery terminal and wait 10 minutes for system capacitor discharge
Raise vehicle on jack stands to working height and secure properly
Remove engine undertray panels to access lower mounting points
Photograph charge pipe routing and electrical connector positions for reassembly reference

Procedure

1
Remove front fascia lower section
Remove T25 Torx screws securing the lower front fascia. Starting from the center, carefully release the retaining clips using trim tools. Work outward toward the wheel wells. Remove the lower grille panel to expose the intercooler assembly.
2
Disconnect charge air temperature sensor
Locate the charge air temperature sensor on the intercooler outlet pipe. Press the locking tab and disconnect the electrical connector. Remove the sensor mounting bolt and carefully extract the sensor from the charge pipe.
⚠Do not damage the sensor element. This is a critical component for boost control and engine management.
Torque spec
Sensor Bolts11 Nm (8 lb-ft)
3
Remove inlet charge pipe
Loosen the charge pipe clamps at the turbocharger outlet and intercooler inlet connections. Carefully twist and pull the charge pipe to break any seal formed by compressed air system. Remove the pipe completely and set aside.
Torque spec
Charge Pipe Clamps4 Nm (3 lb-ft)
4
Remove outlet charge pipe
Loosen the charge pipe clamps at the intercooler outlet and throttle body inlet connections. Carefully remove the outlet charge pipe, taking care not to damage the throttle body connection. Inspect pipe interior for oil accumulation which may indicate turbocharger seal issues.
Torque spec
Charge Pipe Clamps4 Nm (3 lb-ft)
5
Disconnect auxiliary electrical connections
Identify any additional electrical connectors or wiring harness brackets attached to the intercooler or mounting frame. Remove the electrical connector bolts and carefully move wiring harnesses clear of the work area.
Torque spec
Electrical Connector Bolts7 Nm (5 lb-ft)
6
Remove intercooler side mounting bolts
Access the intercooler mounting bolts from both sides of the assembly. Remove the left and right intercooler mounting bolts securing the unit to the support brackets. Support the intercooler weight with one hand while removing final fasteners.
Torque spec
Intercooler Mounting Bolts15 Nm (11 lb-ft)
7
Remove intercooler lower mounting hardware
From beneath the vehicle, locate and remove the lower mounting bolts securing the intercooler assembly to the crash bar structure. These are typically larger fasteners requiring 13mm socket.
Torque spec
Intercooler Mounting Bolts15 Nm (11 lb-ft)
8
Extract intercooler assembly
Carefully lower the intercooler assembly downward and forward, navigating around any remaining brackets or crash structure. The assembly is heavier than it appears due to aluminum construction. Inspect mounting points and crash bar for damage.
9
Prepare new intercooler and clean mating surfaces
Inspect all mating surfaces on the mounting brackets for corrosion or damage. Clean all gasket surfaces thoroughly using appropriate cleaner. Verify new intercooler includes all necessary gaskets and seals. Transfer charge air temperature sensor to new intercooler if not pre-installed.
ℹ️Ensure all mating surfaces are clean and dry before installing new intercooler to prevent boost leaks.
Torque spec
Gasket Surface Bolts22 Nm (16 lb-ft)
10
Install new intercooler assembly
Position new intercooler into mounting location, navigating carefully around crash structure. Align lower mounting points first, then position upper mounts. Hand-thread all mounting bolts before final tightening to ensure proper alignment.
11
Torque lower mounting bolts
Install and torque the lower mounting bolts to specification in a cross-pattern to ensure even loading on the intercooler mounting frame.
Torque spec
Intercooler Mounting Bolts15 Nm (11 lb-ft)
12
Torque side mounting bolts
Install and torque the left and right intercooler mounting bolts to specification. Verify intercooler is properly seated in all mounting locations.
Torque spec
Intercooler Mounting Bolts15 Nm (11 lb-ft)
13
Reconnect charge air piping
Install outlet charge pipe first, connecting to throttle body and intercooler outlet. Install new clamps or reuse existing if in good condition. Torque clamps to specification. Then install inlet charge pipe from turbocharger to intercooler inlet, ensuring proper alignment to prevent stress on connections.
⚠Ensure charge pipes are fully seated before tightening clamps. Improper seating will cause boost leaks and check engine lights.
Torque spec
Charge Pipe Clamps4 Nm (3 lb-ft)
14
Install charge air temperature sensor and reconnect electrical
Install charge air temperature sensor into outlet pipe using new O-ring if provided. Torque sensor mounting bolt to specification. Reconnect electrical connector ensuring positive lock engagement. Reinstall any wiring harness brackets removed earlier.
Torque spec
Sensor Bolts11 Nm (8 lb-ft)
Electrical Connector Bolts7 Nm (5 lb-ft)
15
Reinstall front fascia components
Reinstall lower grille panel and front fascia lower section. Ensure all clips are properly engaged and fascia is aligned correctly. Install T25 Torx screws and verify panel gaps are even. Reinstall engine undertray panels.

Reassembly

Reconnect negative battery terminal
Verify all tools and parts have been removed from engine bay
Check coolant level and top off with Maserati OAT coolant if necessary
Double-check all charge pipe clamps are tight and properly torqued

Verification

Start engine and allow to idle, listening for any unusual hissing sounds that indicate boost leaks
Monitor charge air temperature sensor reading using diagnostic scan tool to verify proper operation
Perform gentle test drive and verify full boost pressure is achieved under moderate acceleration
Inspect all connections for leaks after test drive while engine is at operating temperature
Check for any diagnostic trouble codes related to boost pressure or charge air temperature
Verify front fascia is properly aligned and all clips are secure

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