Replacement of the intermediate exhaust pipe on the 2017 Maserati Levante 3.0L V6 Twin Turbo, connecting the catalytic converters to the rear exhaust section.

Warnings

Tools required

Parts

• Intermediate pipe assembly × 1 — Use OEM specification
• Exhaust flange gaskets (front connection) × 2 — Use OEM specification
• Exhaust flange gaskets (rear connection) × 2 — Use OEM specification
• Exhaust flange bolts/nuts × 8 — Replace if corroded

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Raise vehicle on lift or secure on jack stands at proper lift points
3. Spray all exhaust flange bolts, O2 sensor connections, and hanger bolts with penetrating oil
4. Allow vehicle to sit for 30 minutes for penetrating oil to work
5. Inspect intermediate pipe routing and identify all connection points before removal

Procedure

1. 1

   Disconnect oxygen sensors
   Locate the downstream oxygen sensors on the intermediate pipe. Disconnect the electrical connectors by pressing the release tabs and pulling connectors apart. Using an oxygen sensor socket or 22mm wrench, carefully unthread the O2 sensors from the intermediate pipe bungs. Rotate counterclockwise and remove sensors completely. Inspect sensor threads and replace if damaged.
2. 2

   Remove heat shields
   Identify heat shields covering the intermediate pipe sections. Remove heat shield mounting bolts using a 13mm socket. There are typically 4-6 bolts securing shields to the underbody. Set heat shields aside for reinstallation. Inspect shields for damage or excessive corrosion.
   Torque spec

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

   Disconnect front flange connection
   Locate the front flange connection where the intermediate pipe connects to the catalytic converter outlets. Using a 17mm socket, remove the flange bolts (typically 4 bolts total, 2 per side). Support the intermediate pipe with one hand while removing the final bolts. Separate the flanges and remove old gaskets. Inspect flange surfaces for damage or warping.
   ⚠Intermediate pipe may shift or drop when front connection is separated. Ensure adequate support.
4. 4

   Remove exhaust hangers
   Locate the rubber exhaust hangers supporting the intermediate pipe (typically 2-3 hangers along the pipe length). Using a pry bar or exhaust hanger tool, carefully pry the hanger loops off the mounting brackets. Work methodically from front to rear. If hangers are severely degraded, cut them and replace with new hangers during reassembly.
5. 5

   Disconnect rear flange connection
   Move to the rear connection where the intermediate pipe connects to the rear muffler section. Remove the rear flange bolts using a 17mm socket (typically 4 bolts). Support the rear of the intermediate pipe while removing final fasteners. Once all bolts are removed, carefully lower and slide the intermediate pipe rearward to clear the front connection, then remove from vehicle.
   ⚠Intermediate pipe is heavy and awkward to maneuver. Use assistance or exhaust jack to prevent dropping.
6. 6

   Clean flange surfaces
   Using a wire brush and gasket scraper, thoroughly clean both the front and rear flange surfaces on the vehicle. Remove all old gasket material, carbon deposits, and corrosion. Ensure flange surfaces are flat and smooth. Inspect flange bolt holes for damage or stripped threads. Clean oxygen sensor bungs with wire brush if reusing sensors.
7. 7

   Prepare new intermediate pipe
   Unpack the new intermediate pipe and verify all oxygen sensor bungs are present and undamaged. Install new exhaust flange gaskets on both front and rear flanges of the new pipe. Apply a thin coat of anti-seize compound to O2 sensor threads, being careful not to contaminate sensor tips or let anti-seize enter sensor openings.
8. 8

   Install new intermediate pipe
   Lift the new intermediate pipe into position, aligning the front flange first with the catalytic converter outlets. Slide pipe forward to engage front connection, then align rear flange with muffler section. Do not fully tighten any fasteners yet. Install all front and rear flange bolts hand-tight to hold pipe in position. Verify gaskets are properly seated at all connections.
9. 9

   Install exhaust hangers
   Working from front to rear, install the intermediate pipe loops into the rubber exhaust hangers on their mounting brackets. Use a pry bar or lubricate hangers with soapy water to ease installation. Ensure all hanger connections are fully seated and pipe is properly supported along its length.
10. 10

    Torque flange connections
    Apply anti-seize compound to flange bolt threads. Starting with the front flange connection, torque the exhaust flange bolts in a cross-pattern to specification. Move to the rear flange and torque those bolts in the same manner. Verify all bolts are tightened and pipe flanges are seated flush against mating surfaces with no gaps.
    Torque spec

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

    Install oxygen sensors
    Thread oxygen sensors into the bungs on the new intermediate pipe by hand first, ensuring threads engage properly. Apply anti-seize compound was already applied to threads in step 7. Using an oxygen sensor socket, torque sensors to specification. Reconnect electrical connectors to both sensors, ensuring they click securely into place.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
12. 12

    Reinstall heat shields
    Position heat shields back over the intermediate pipe sections. Install and torque heat shield mounting bolts to specification using a 13mm socket. Ensure shields do not contact exhaust pipe directly and have proper clearance for thermal expansion.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Verify all exhaust connections are properly torqued and gaskets are seated
2. Ensure oxygen sensor wiring is routed away from hot exhaust components and secured with factory clips
3. Check that exhaust hangers are fully engaged and pipe has proper clearance from underbody components
4. Verify no tools or parts were left in the work area

Verification

• Start engine and allow to reach operating temperature while monitoring for exhaust leaks at flange connections
• Listen for unusual exhaust noises, rattles, or leaks during idle and light acceleration
• Visually inspect all connections for smoke or soot indicating leaks
• Use OBD-II scanner to verify oxygen sensors are reading properly and no fault codes are present
• Test drive vehicle and verify normal exhaust sound and no vibration from exhaust system
• After test drive, re-inspect all connections for any signs of leakage or loosening

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