Muffler

This procedure covers the removal and replacement of the rear muffler assembly on a 2017 Maserati Levante 3.0L V6 Twin Turbo RWD, including disconnection of exhaust hangers and clamps.

Warnings

Tools required

Parts

• Muffler assembly × 1 — Use OEM specification or direct-fit aftermarket
• Exhaust gasket set (if equipped at muffler connection) × 1 — Use OEM specification
• Rubber exhaust hangers (if deteriorated) × 4 — Use OEM specification

Preparation

1. Ensure the vehicle has been sitting for at least 2 hours with the engine off to allow exhaust system to cool completely
2. Raise the vehicle on a lift or securely support on jack stands at all four corners to provide adequate working clearance
3. Spray all exhaust clamp bolts and hanger bracket bolts with penetrating oil and allow 15-20 minutes to soak
4. Locate the active exhaust valve electrical connectors on the muffler assembly (driver and passenger side valves)
5. Inspect the exhaust system for any damaged or deteriorated rubber hangers that should be replaced during this service

Procedure

1. 1

   Disconnect active exhaust valve connectors
   Locate the electrical connectors for the active exhaust valves on both sides of the muffler assembly. Press the locking tab and disconnect each connector. Secure the wiring harnesses away from the work area to prevent damage during muffler removal.
2. 2

   Remove rear exhaust hanger brackets
   Locate the two rear hanger brackets that support the muffler to the vehicle underbody. Using a 17mm socket, remove the bolts securing each hanger bracket to the chassis. There are typically two bolts per bracket. Support the rear of the muffler with one hand or have an assistant hold it to prevent it from dropping.
   Torque spec

   Hanger Bracket Bolts25 Nm (18 lb-ft)
3. 3

   Disconnect rubber exhaust hangers
   Locate the rubber isolator hangers connecting the muffler to the mounting points. Use an exhaust hanger removal tool or carefully pry the rubber hangers off the mounting studs with a pry bar. Work carefully to avoid tearing the rubber if you plan to reuse the hangers. There are typically four hanger points on this system.
4. 4

   Loosen muffler inlet clamps
   Locate the band clamps or V-band clamps connecting the muffler assembly to the mid-pipe/resonator section. Using a 19mm socket, loosen the clamp bolts completely but do not remove them yet. If the vehicle has dual clamps (one per side), loosen both. Ensure the muffler is still supported.
   ⚠The muffler will become free once clamps are removed. Ensure it is properly supported to prevent injury or damage.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
5. 5

   Remove muffler assembly
   With the clamps fully loosened, carefully slide the muffler rearward off the inlet pipes. The muffler assembly is heavy (approximately 40-50 lbs), so use proper lifting technique or have an assistant help. Lower the muffler carefully and remove it from under the vehicle. Inspect the inlet pipes for damage or excessive corrosion.
6. 6

   Clean and inspect mounting points
   Use a wire brush to clean the inlet pipe connection points where the muffler attaches. Remove any rust, carbon buildup, or old gasket material. Inspect the rubber hanger mounting points on the chassis for damage. Check the condition of all rubber hangers and replace if cracked, torn, or excessively worn.
7. 7

   Prepare new muffler for installation
   Unpack the new muffler assembly and verify it matches the original configuration including active exhaust valve provisions. If provided, install new gaskets on the inlet connections. Apply a thin coat of anti-seize compound to the inlet pipe areas (but not on gasket surfaces). Connect the exhaust valve electrical connectors to verify proper fit before installation.
8. 8

   Install new muffler assembly
   Lift the new muffler into position under the vehicle, aligning the inlet connections with the mid-pipes. Slide the muffler forward onto the inlet pipes, ensuring proper engagement. The fit should be snug but not forced. Align the rubber hanger mounting points with the chassis studs.
9. 9

   Install and tighten muffler clamps
   Position the band clamps over the muffler inlet joints, ensuring they are centered on the connection. Hand-thread the clamp bolts, then tighten them in an alternating pattern if dual clamps are present. Torque the clamp bolts to specification using a torque wrench. Verify the muffler is properly seated and aligned before final tightening.
   Torque spec

   Muffler Clamps55 Nm (41 lb-ft)
10. 10

    Reconnect exhaust hangers
    Install new rubber hangers if the originals were damaged, or reuse the existing hangers if in good condition. Use a rubber mallet or exhaust hanger tool to press each hanger onto its corresponding mounting stud. Ensure all four hanger points are fully engaged. The muffler should hang evenly with minimal stress on any single point.
11. 11

    Reinstall hanger brackets
    Position the rear hanger brackets back onto their chassis mounting points. Install the bracket bolts and hand-tighten initially. Verify the muffler alignment and positioning, ensuring adequate clearance from the rear fascia, diffuser, and underbody components. Once aligned, torque the hanger bracket bolts to specification.
    Torque spec

    Hanger Bracket Bolts25 Nm (18 lb-ft)
12. 12

    Reconnect active exhaust valve connectors
    Route the electrical connectors to the active exhaust valves on both sides of the muffler. Press each connector firmly onto its valve until you hear a positive click, indicating the locking tab is engaged. Ensure wiring is secured and routed away from hot exhaust components and moving parts.

Reassembly

1. Verify all electrical connections to the active exhaust valves are secure and properly locked
2. Check that all exhaust clamps and hanger bracket bolts have been torqued to specification
3. Ensure the muffler has proper clearance from the rear bumper, diffuser, and heat shields with no contact points
4. Verify all rubber hangers are properly seated and the exhaust system hangs evenly without excessive stress

Verification

• Lower the vehicle and start the engine. Listen for any exhaust leaks at the muffler connection points (hissing or ticking sounds indicate a leak)
• With the engine running, access the vehicle's infotainment system and verify no exhaust valve fault codes are present
• Test the active exhaust system by switching between Comfort and Sport modes (if equipped) and verify the exhaust note changes appropriately
• Perform a visual inspection from the rear of the vehicle to ensure the exhaust tips are centered and aligned properly in the rear fascia cutouts
• Take a short test drive and listen for any rattles, vibrations, or abnormal exhaust sounds under acceleration and deceleration
• After the test drive, re-inspect all connection points while the exhaust is warm to verify no leaks have developed

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