exhaust

Flex Pipe

for 2017 Maserati Levante 3.0L V6 Twin Turbo · RWD

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

Difficulty

Moderate

Time

2.2 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.

Replace the exhaust flex pipe on a 2017 Maserati Levante 3.0L V6 Twin Turbo to restore exhaust flexibility and eliminate leaks or rattles caused by a damaged flex section.

Warnings

⚠️Allow exhaust system to cool completely before beginning work. Exhaust components can remain dangerously hot for hours after engine operation.

⚠Exhaust fasteners are prone to corrosion and seizure. Apply penetrating oil 24 hours before beginning work if possible.

⚠The flex pipe is located near oxygen sensors and wiring. Avoid damage to sensor connectors and wiring harnesses during removal.

ℹ️This vehicle may have two flex pipes (one per bank). Verify which flex pipe requires replacement before ordering parts.

Tools required

Floor jack and jack standsEssential

Metric socket set (10mm-19mm)Essential

Torque wrench (10-60 Nm range)Essential

Oxygen sensor socket (22mm or 7/8")Essential

Penetrating oilEssential

Wire brush

Anti-seize compoundEssential

Exhaust hanger removal tool

Reciprocating saw or exhaust pipe cutter

Copper anti-seize pasteEssential

Parts

Exhaust flex pipe assembly × 1 — Use OEM specification
Exhaust flange gasket × 2 — Use OEM specification
Exhaust clamps (if applicable) × 2 — Use OEM specification
Oxygen sensor (if damaged) × 1 — Use OEM specification

Preparation

Ensure exhaust system is completely cool to the touch
Park vehicle on level ground and engage parking brake
Raise vehicle using floor jack and support securely on jack stands at manufacturer-specified lift points
Spray all exhaust fasteners, flange bolts, and clamps with penetrating oil and allow to soak for 15-30 minutes
Locate the flex pipe section between the turbocharger downpipe and catalytic converter assembly
Disconnect negative battery terminal if working near oxygen sensor wiring

Procedure

1
Remove heat shields
Remove any heat shields covering the flex pipe area by removing the heat shield bolts. The shields may be attached to the undercarriage or exhaust system. Set shields aside for reinstallation.
Torque spec
Heat Shield Bolts14 Nm (10 lb-ft)
2
Disconnect oxygen sensor
Locate the oxygen sensor upstream or downstream of the flex pipe. Disconnect the electrical connector by pressing the release tab. If removing the sensor, use a 22mm oxygen sensor socket and turn counterclockwise. Inspect sensor threads and replace if damaged.
⚠Oxygen sensors are fragile. Do not use excessive force or impact tools which can damage the internal element.
Torque spec
O2 Sensor50 Nm (37 lb-ft)
3
Support exhaust system
Place a jack or exhaust support stand under the catalytic converter or mid-pipe section to support the weight of the exhaust once the flex pipe is disconnected. This prevents damage to hangers and other components.
⚠Failure to support the exhaust can result in component damage or injury from falling exhaust sections.
4
Remove upstream flange connection
Remove the flange bolts or nuts connecting the flex pipe to the turbocharger downpipe or front exhaust section. There are typically 2-3 bolts per flange. Remove the old gasket and clean the flange surface with a wire brush.
Torque spec
Flange Bolts45 Nm (33 lb-ft)
5
Disconnect exhaust hangers
Locate rubber exhaust hangers supporting the flex pipe section. Use an exhaust hanger removal tool or spray with soapy water and pry the rubber mounts off their studs. Note the hanger positions for reassembly.
Torque spec
Hanger Bolts22 Nm (16 lb-ft)
6
Remove downstream connection
Depending on flex pipe design, either remove flange bolts at the downstream connection or loosen exhaust clamps. If the flex pipe is welded, use a reciprocating saw or pipe cutter to cut the pipe at the appropriate locations. Ensure cuts are straight for proper new pipe fitment.
Torque spec
Flange Bolts45 Nm (33 lb-ft)
Exhaust Clamps55 Nm (41 lb-ft)
7
Remove flex pipe assembly
Carefully maneuver the flex pipe assembly down and out from the vehicle. The flex pipe may be restricted by crossmembers or other undercarriage components. Rotate and angle as needed to clear obstacles.
8
Prepare mounting surfaces
Thoroughly clean all flange mating surfaces with a wire brush to remove carbon deposits, old gasket material, and rust. Inspect flanges for warping or damage. Clean oxygen sensor bung threads with a thread chaser if reusing existing sensor.
9
Install new flex pipe
Position the new flex pipe assembly into place, aligning the upstream flange first. Install new exhaust gaskets on both flange connections. Loosely install flange bolts finger-tight to allow for alignment adjustment. Ensure the flex section has proper clearance from chassis components and heat shields.
10
Secure downstream connection
Align and secure the downstream connection using new flange bolts and gasket or exhaust clamps as applicable. Leave fasteners loose enough to allow final alignment adjustments.
Torque spec
Flange Bolts45 Nm (33 lb-ft)
Exhaust Clamps55 Nm (41 lb-ft)
11
Reconnect exhaust hangers
Reinstall rubber exhaust hangers onto their mounting studs. Spray with soapy water to ease installation. Ensure the exhaust system hangs properly with adequate clearance from chassis, driveshaft, and suspension components.
12
Torque all fasteners
Working from upstream to downstream, torque all flange bolts to specification in a criss-cross pattern. Then torque exhaust clamps if applicable. Ensure all connections are secure and properly sealed. Remove exhaust support jack.
Torque spec
Flange Bolts45 Nm (33 lb-ft)
Exhaust Clamps55 Nm (41 lb-ft)
13
Install oxygen sensor
Apply a thin coat of copper anti-seize compound to the oxygen sensor threads (avoid getting anti-seize on the sensor tip). Thread the sensor into the bung by hand, then torque to specification using the oxygen sensor socket. Reconnect the electrical connector until it clicks.
⚠Do not over-torque oxygen sensors as this can damage the sensor housing or exhaust bung threads.
Torque spec
O2 Sensor50 Nm (37 lb-ft)
14
Reinstall heat shields
Reinstall all heat shields in their original positions and torque heat shield bolts to specification. Ensure heat shields do not contact the exhaust pipe and have proper clearance.
Torque spec
Heat Shield Bolts14 Nm (10 lb-ft)

Reassembly

Reconnect negative battery terminal if disconnected
Lower vehicle from jack stands
Perform final visual inspection of all connections and ensure no tools or parts were left in the work area

Verification

Start the engine and allow it to idle. Listen for exhaust leaks at the flex pipe connections (hissing or ticking sounds indicate a leak)
Check for proper exhaust system alignment and ensure no components are contacting the chassis or suspension
Verify oxygen sensor electrical connector is properly seated and no warning lights are illuminated on the dashboard
Rev engine to 2500-3000 RPM and listen for abnormal exhaust noises or rattles
After a short test drive, re-inspect all fasteners and connections for any signs of loosening or leakage

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