Front Pipe

Replacement of the front exhaust pipe (downpipe) connecting the turbocharger outlets to the catalytic converters on the 2017 Maserati Levante 3.0L V6 Twin Turbo RWD.

Warnings

Tools required

Parts

• Front exhaust pipe assembly × 1 — Use OEM specification
• Exhaust flange gaskets (turbo to front pipe) × 2 — Use OEM specification
• Exhaust flange gasket (front pipe to catalytic converter) × 1 — Use OEM specification
• M8 copper exhaust nuts (if corroded) × 6 — Use OEM specification

Preparation

1. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
2. Raise vehicle on lift or secure on jack stands at manufacturer-specified lift points
3. Spray all exhaust fasteners with penetrating oil and allow to soak for 15-30 minutes
4. Disconnect negative battery terminal to prevent O2 sensor fault codes during removal
5. Remove engine undertray/splash shields to access exhaust system

Procedure

1. 1

   Disconnect oxygen sensors
   Locate the upstream oxygen sensors on both banks mounted in the front exhaust pipes. Disconnect the electrical connectors by pressing the release tabs and pulling away from sensors. Using a 22mm oxygen sensor socket, carefully unthread both sensors counterclockwise. If sensors are being reused, inspect threads and apply anti-seize to threads only (avoid getting anti-seize on sensor tip).
   ⚠Never apply anti-seize to the oxygen sensor tip as this will contaminate the sensing element and cause false readings.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
2. 2

   Remove heat shield fasteners
   Locate the heat shields covering portions of the front exhaust pipes. Remove all heat shield mounting bolts using appropriate socket. Some shields may be in multiple sections. Keep fasteners organized for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect front pipe from turbocharger outlets
   Locate the exhaust flange connections where the front pipes connect to both turbocharger outlets. Remove the exhaust flange nuts or bolts securing each connection (typically 3 fasteners per side). Support the front pipe assembly to prevent it from dropping. Separate the flanges and remove old gaskets. Clean mating surfaces thoroughly with wire brush.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)

   Manifold Nuts35 Nm (26 lb-ft)
4. 4

   Disconnect mid-pipe flange connection
   Move to the rear of the front pipe assembly where it connects to the catalytic converters or center exhaust section. Remove the flange bolts securing this connection. You may need to support the downstream exhaust section to prevent strain on rubber hangers.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Release exhaust hangers
   Identify all rubber exhaust hangers supporting the front pipe assembly. Using an exhaust hanger removal tool or prying carefully with a pry bar, release each hanger from its mounting bracket. Note the orientation and position of hangers for reinstallation.
6. 6

   Remove front pipe assembly
   With all connections and hangers released, carefully maneuver the front pipe assembly downward and away from the vehicle. The assembly may need to be rotated or angled to clear chassis components and wiring. Support the weight throughout removal to prevent damage to surrounding components.
7. 7

   Inspect and clean mounting surfaces
   With the front pipe removed, thoroughly inspect all flange mating surfaces on the turbochargers and downstream exhaust. Remove all old gasket material using a wire brush or scraper. Check turbocharger outlet flanges for warping or damage. Inspect exhaust studs for damage and replace any that are stripped or corroded.
   ⚠Do not use aggressive abrasives on turbocharger flanges as these are precision surfaces. Use brass brush only.
8. 8

   Prepare new front pipe assembly
   Install new exhaust flange gaskets onto the new front pipe assembly. Apply anti-seize compound to all exhaust fastener threads. If reusing oxygen sensors, apply fresh anti-seize to sensor threads only (not the tip). Thread sensors into new front pipe hand-tight initially.
9. 9

   Install front pipe assembly
   Position the new front pipe assembly into place, maneuvering carefully to align with turbocharger outlets and downstream exhaust connection. Engage exhaust hangers onto their mounting brackets. Ensure all gaskets are properly positioned at flange connections before installing hardware.
10. 10

    Connect turbocharger flange connections
    Install exhaust flange bolts or nuts at both turbocharger outlet connections. Thread all fasteners hand-tight first to ensure proper alignment. Torque fasteners in a cross-pattern to specified value to ensure even clamping pressure and prevent gasket leaks.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Manifold Nuts35 Nm (26 lb-ft)
11. 11

    Connect mid-pipe flange
    Install new gasket at the connection between front pipe and downstream catalytic converter section. Install flange bolts hand-tight, then torque in cross-pattern to specification. Ensure proper alignment before final torquing.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Torque oxygen sensors
    Using the 22mm oxygen sensor socket and torque wrench, torque both oxygen sensors to specification. Reconnect the electrical connectors to each sensor, ensuring they click securely into place and are routed away from hot exhaust components.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
13. 13

    Reinstall heat shields
    Position all heat shields back into their original locations. Install and torque heat shield mounting bolts to specification. Ensure shields are not contacting any moving parts or rubbing on chassis components.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
14. 14

    Verify exhaust hanger alignment
    Check that all exhaust hangers are properly seated and that the exhaust system hangs with appropriate clearance from chassis components, driveshaft, and suspension parts. Adjust hanger positions if necessary to achieve proper alignment.

Reassembly

1. Reinstall engine undertray and splash shields
2. Reconnect negative battery terminal
3. Double-check all fastener torque values before lowering vehicle
4. Verify no tools or parts were left in engine bay or under vehicle

Verification

• Start engine and allow to idle, listening for exhaust leaks at all flange connections (ticking or hissing sounds indicate leaks)
• With engine at operating temperature, visually inspect all connections for signs of exhaust gas leakage (soot or discoloration)
• Verify no exhaust components are contacting chassis, driveshaft, or suspension during engine idle
• Use scan tool to verify oxygen sensor readings are normal and no fault codes are present
• Test drive vehicle and verify no unusual exhaust noises or vibrations
• After test drive, re-inspect all connections while hot for any signs of leaks or loosening

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