Resonator

This procedure covers the removal and replacement of the exhaust resonator on a 2017 Maserati Levante with the 3.0L V6 Twin Turbo engine.

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — Use OEM specification
• Exhaust clamps × 2 — Reuse if not damaged
• Exhaust flange gasket × 2 — Use OEM specification
• Rubber exhaust hangers × 2 — Replace if torn or degraded

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Raise vehicle on lift or securely support on jack stands at all four corners
3. Spray all exhaust clamps, flange bolts, and hanger bolts with penetrating oil and allow 15-20 minutes to soak
4. Inspect exhaust system for damage, excessive corrosion, or previous repairs that may affect procedure
5. Have replacement gaskets and hardware available before starting disassembly

Procedure

1. 1

   Remove heat shields
   Locate and remove any heat shields covering the resonator area. These are typically secured with 10mm or 13mm bolts. Remove all heat shield bolts and set shields aside for reinstallation.
   Torque spec

   Heat Shield Bolts14 Nm (10 lb-ft)
2. 2

   Support exhaust system
   Position an adjustable jack or exhaust support stand under the muffler section behind the resonator to support the weight of the exhaust once disconnected. Adjust height to eliminate tension on the resonator connections.
3. 3

   Disconnect front flange connection
   Locate the flange connection between the front pipe (from catalytic converter) and the resonator inlet. Remove the flange bolts using a 15mm socket. There are typically 2-3 bolts securing this connection. Separate the flange and remove the old gasket.
   Torque spec

   Flange Bolts45 Nm (33 lb-ft)
4. 4

   Loosen rear exhaust clamp
   Locate the band clamp connecting the resonator outlet to the rear muffler section. Loosen the clamp bolt completely using a 13mm socket but do not remove it yet. The clamp should be loose enough to slide along the pipe.
   Torque spec

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

   Remove exhaust hanger mounts
   Identify the rubber exhaust hangers supporting the resonator section. Using an exhaust hanger removal tool or pry bar, carefully unhook the exhaust hangers from their mounting points. Work slowly to avoid tearing the rubber insulators. Note the orientation of hangers for reinstallation.
   Torque spec

   Hanger Bolts22 Nm (16 lb-ft)
6. 6

   Remove resonator assembly
   With all connections loosened and hangers disconnected, carefully maneuver the resonator assembly out from under the vehicle. You may need to slide it rearward slightly to clear the front flange, then drop it down and out. Have an assistant support the weight if necessary.
7. 7

   Clean mating surfaces
   Using a wire brush, thoroughly clean all flange mating surfaces on both the front pipe and rear muffler connections. Remove all old gasket material, carbon deposits, and corrosion. Clean surfaces ensure proper sealing and torque values.
8. 8

   Install new resonator
   Position the new resonator assembly under the vehicle, aligning it with the front flange connection first. Install new flange gaskets at both the front and rear connections. Loosely start all flange bolts but do not tighten yet. Ensure the resonator is properly oriented with adequate clearance from the driveshaft, fuel tank, and body components.
9. 9

   Reconnect exhaust hangers
   Reattach the resonator to the rubber exhaust hangers at their mounting points. Ensure hangers are fully seated and oriented correctly. If rubber hangers show signs of deterioration, replace them now to prevent future exhaust movement or rattles.
10. 10

    Tighten front flange connection
    With the exhaust properly supported and aligned, torque the front flange bolts to specification in a cross-pattern to ensure even gasket compression and prevent warping. Verify the connection is fully seated before final torque.
    Torque spec

    Flange Bolts45 Nm (33 lb-ft)
11. 11

    Tighten rear exhaust clamp
    Position the rear band clamp at the connection between the resonator outlet and muffler inlet, ensuring both pipes are fully engaged with proper overlap. Torque the clamp bolt to specification.
    Torque spec

    Exhaust Clamps55 Nm (41 lb-ft)
12. 12

    Reinstall heat shields
    Reposition all heat shields removed in step 1, ensuring proper clearance from exhaust components. Install and torque all heat shield bolts to specification. Verify shields do not contact exhaust pipes or create rattle points.
    Torque spec

    Heat Shield Bolts14 Nm (10 lb-ft)

Reassembly

1. Remove exhaust support jack and lower vehicle to ground
2. Perform a final visual inspection of all connections to ensure proper alignment and adequate clearance from surrounding components
3. Check that all fasteners have been properly torqued and no tools or parts have been left in the work area

Verification

• Start the engine and listen for any exhaust leaks at the flange connections and clamp areas. A hissing sound indicates a leak that must be addressed
• With engine running, carefully feel around connections for escaping exhaust gases (do not touch hot components)
• Perform a test drive and listen for any rattles, vibrations, or abnormal exhaust sounds
• After test drive, re-inspect all connections and torque values while exhaust is warm (but not hot)
• Verify exhaust system hangs properly with no excessive movement or contact with undercarriage components

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