Ferrari 458 Workshop Manual
Ferrari 458 delivers an unparalleled driving experience, blending exhilarating performance with cutting-edge technology. Its aerodynamic design and advanced suspension system provide exceptional handling and stability, while the powerful engine unleashes raw power for an unforgettable ride. Whether navigating city streets or pushing limits on the track, Ferrari 458 empowers you with precision and control like never before.
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1.1 Ferrari quality standards
When manufacturing a Ferrari vehicle, the primary goal is “to achieve optimum product quality”. Consequently Ferrari defines a number of quality standards. These quality standards apply both to production and especially to customer service.
In the event of accident repairs, crash safety must be an absolute priority. To maintain optimum crash safety, all structural work must be done correctly as indicated.
The repair work may only be carried out by Ferrari-trained and certified skilled personnel.
Only genuine parts should be used when carrying out the repair. They have been tested by Ferrari and are compatible for use with aluminium.
Follow the procedures exactly as given in the repair manual.
Any deviations from the procedures are permitted only after consultation with and approval by Ferrari.
Using non-approved repair methods may compromise the crash performance of the vehicle. This may ultimately lead to a non-foreseeable safety and product liability risk.
Only Ferrari-approved tools may be used to carry out accident repairs.
It is essential that corrosion prevention measures are performed during and after the repair.
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1.2 The bodywork concept of the Ferrari F458 Italia
In addition to extruded members, aluminium parts and sheet metal elements, the Ferrari F458 Italia also features new joint reinforcements for the space frame structure; together, they form the bodywork structure.
These ultra-high strength steel reinforcements (A) , installed in the two A -pillars, offer occupants greater safety in critical situations.
The ultra-strong extruded sections of the A -pillars are concealed below the steel reinforcements. The sections are joined to the extruded members of the sill (B) by die-cast node joints.
The sill (B) of the Ferrari F458 Italia is oversized, as on a cabriolet type vehicle. This means that the Ferrari F458 Italia makes no compromises where crash safety is concerned.
B
A
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1.3 General safety instructions
Explanation of safety instructions
Danger!
“Danger” indicates imminent hazards that may result in death or serious injury.
Warning!
“Warning” indicates potential hazards that may result in death or serious injury.
Caution!
“Caution” indicates potential hazards that may result in slight injury.
This symbol also indicates hazards to property.
NOTE!
“Note” indicates important information.
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1.3 General safety instructions
When carrying out any of the procedures described in this repair manual, please observe all national accident safety regulations.
1.3.1 Lifting vehicles
Danger!
Risk of death from the vehicle toppling or slipping off the vehicle lift.
• Align vehicle centrally between the vehicle lift columns.
• Raise the vehicle only at the specific locating points.
• Ensure the lifting pads are seated correctly, lifting the vehicle slowly while monitoring the vehicle visually.
• Before removing any components and significantly shifting the centre of gravity of the vehicle, ensure that the vehicle itself is securely fastened to the vehicle.
1.3.2 Handling body and assembly components with sharp edges
Caution!
Risk of injury from sharp-edged burrs on body and accessories.
• Always wear protective gloves when working in the vicinity of sharp-edged body and assembly components.
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1.3 General safety instructions
1.3.3 Working in presence of aluminium dust
Warning!
Risk of explosion from high concentrations of aluminium dust. Risk of injury from breathing in fine particulate.
• When carrying out any work that creates fine particles of dust, wear a fine dust mask, safety goggles and protective gloves.
• Any grinding work must be carried out with explosionprotected air extraction systems; do not blow off dust deposits with compressed air.
• Clean the work area and the extraction system regularly.
• To prevent a dust explosion, all extraction systems must be earthed and suitable powder extinguishers must be provided.
• Any vehicle parts in the repair area which may be damaged by dust should be removed from the area or covered with fire-resistant covers.
1.3.4 Handling batteries
Warning!
Risk of explosion and fire from flying sparks during grinding and welding work. Risk of damage to vehicle components and other vehicles from flying sparks.
• Before carrying out any welding work, always remove both battery terminal clamps and cover the battery terminals.
• Remove the vehicle battery before carrying out any work that may produce sparks in the vicinity of the battery itself.
• Disconnect the battery earth strap when carrying out any vehicle body repair work and when working on the airbag system.
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1.3 General safety instructions
1.3.5 Grinding and welding
Warning!
Risk of explosion and fire when welding in the vicinity of highly flammable substances. Irritation of the respiratory tract caused by toxic gases produced during welding. Risk of injury from the extremely bright arc and welding splashes when welding. Risk of injury as a result of inadvertent activation of pyrotechnic safety components.
Risk of explosion and fire from flying sparks during grinding and welding work. Risk of damage to vehicle components and other vehicles from flying sparks.
• Use the specific visor when welding.
• Partition off workstations with spark protection curtains.
• A fire extinguisher must always be accessible in the immediate vicinity of the welding area.
• Remove or cover any vehicle parts located in the repair area.
• Always carry out grinding and welding work with an extraction system.
• Clean the air extraction system at regular intervals.
• Never carry out welding and grinding work at the same time in the same room.
• When welding, wear suitable, non-flammable protective clothing and gloves.
• When carrying out grinding and welding work around the fuel tank or fuel-carrying parts, ensure that these parts do not heat up. If in doubt, remove such parts.
• Cover the grinding and welding area with fire-resistant covers.
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1.3 General safety instructions
1.3.6 Removing sealants
Danger!
Risk of death from inhaling toxic vapours. Risk of burns in the event of direct skin contact with hydrochloric acid.
• Hydrochloric acid is produced when PVC sealant is heated to over 180 °C.
• PVC sealant must only be removed with a rotary wire brush or by heating to max. 180 °C with a hot air gun and removing with a spatula.
• Always wear a dust mask and protective goggles when removing sealant with a rotary brush.
• Always ensure there is sufficient air extraction and fresh air ventilation.
1.3.7 Handling chemicals
Caution!
Handling chemicals may cause allergic skin and respiratory tract reactions.
• Always ensure that there is sufficient air extraction and ventilation, and extract any vapours released by adhesives.
• Prevent chemicals from coming into direct contact with the eyes and skin.
• Wear protective gloves, protective goggles and, where necessary, an apron.
• Immediately change out of work clothes that are soiled with adhesive or solvent.
• At the end of the job, wash your hands and apply protective cream.
• Always keep a bottle of eye wash ready for use.
• Only store adhesive products in the safety cupboard and keep them away from naked flames and other sources of ignition.
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1.3 General safety instructions
1.3.8 Working with the air conditioning system
Warning!
Risk of injury from the charged air conditioning system exploding during welding work.
Do not weld, solder or work with a hot air gun in the vicinity of the components of a charged air conditioning system. Similarly, do not perform any welding work on a vehicle if the work will cause parts of the air conditioning system to heat up.
When carrying out a paint repair, object temperatures in the drying oven or preheating zone must not exceed 80 °C as the overpressure caused by heating process may cause the system to explode.
1.3.9 Handling the airbag system
Caution!
Risk of injury from activation of airbag units if earth strap is not disconnected.
Disconnect the battery earth strap when carrying out any vehicle body repair work and when working on the airbag system.
Wash hands thoroughly after touching airbag units that have been fired.
1.3.10 Working with tools
Warning!
Risk of injury. All tools pose potential hazards to health and life. Always observe the safety instructions and warnings of the tool manufacturers.
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1.4 Important information
1.4.1 Assessing the extent of the damage
In the case of accidents involving substantial areas of the vehicle, examine the following components carefully to prevent any damage to vehicle or suspension parts from going undiscovered:
• Check tyres and wheel rims for damage.
• Check that the steering tie-rod, steering linkages and steering system are working correctly. Also check for external damage and cracks.
• Check all chassis components, such shock absorbers, suspension and steering joints, links, axles, anti-roll bars and their fasteners, for external damage or cracks.
• Check brake system components such as brake discs, brake pads, brake callipers, hydraulic lines and hydraulic hoses and their respective fastenings for external damage, stretching or leaks.
• Check engine, gearbox, axle and exhaust system mounts for damage.
• Before returning the vehicle to the customer following a repair, test drive the vehicle carefully to ensure that it is roadworthy.
1.4.2 Instructions for body repairs
• Repair work on the Ferrari F458 Italia must only be carried out by repair personnel who have been trained, tested and
certified by the Ferrari Customer Service department.
• Use only Ferrari-approved tools, spare parts and consumables for repair and maintenance work.
• If, in the course of the repair work, special cases arise that are not envisaged by the repair instructions, contact the
Ferrari Technical Customer service to establish how to proceed further.
• All the main repair operations possible for the Ferrari
F458 Italia are described in this repair manual. Combined instructions may be used to differentiate between different repair procedures. Only the right or left hand components are illustrated in the description of a repair.
• To ensure that the original crash safety of the vehicle is maintained after a body repair, always used the same chassis joint points.
• Cuts that may affect the crash safety of the body, and thereby the safety and roadworthiness of the vehicle, must always be approved by Ferrari.
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1.4 Important information
1.4.3 Original joint points
• The original joint points are all the weld joints made during manufacture of the vehicle.
• To ensure crash safety, these joints must be rewelded in the original positions after a body repair.
• Any methods and procedures that deviate from the original assembly are described in the Ferrari F458 Italia bodywork repair manual.
1.4.4 Cuts
• Cuts must only be made as described by the instructions given in the Ferrari F458 Italia bodywork repair manual!
• Load-bearing components must only be parted at the original joint.
• Cuts may only be made in the outer skin, as described by the repair instructions given in this manual.
1.4.5 Sanding
NOTE!
When grinding weld seams, ensure that the thickness of the outer panels is maintained or is only slightly reduced.
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1.5 Key to symbols
1.5.1 Welding
SG tack weld
SG plug weld
SG continuous weld
SG staggered continuous weld
Spot weld
(SG = shield gas welding)
1.5.2 Riveting
Solid and self-piercing rivet with countersunk head
Blind rivet with countersunk head
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1.5 Key to symbols
1.5.3 Milling off, drilling out or piercing spot welds
Mill off spot weld
Drill out or pierce
1.5.4 Gluing and sealing
Bicomponent sealant mastic
Area to be sealed with mastic
1.5.5 Cavity preservation
1.5.5 Screw symbol
1.5.5 Cutting and grinding points for weld seams
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1.6 Clearances
3
2
1
4
1: Roof/Windscreen
Clearance = 4.0 mm ±1.0 mm
Offset = -2.0 mm -1.0 mm +1.5 mm
2: Roof/Windscreen
Clearance = 4.0 mm ±2.0 mm
Offset = variable
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3: Side window/Roof
Clearance = /
Offset = -8.5 mm ±1.5 mm
4: Roof/Fender
Clearance = Minimum point 3.0 mm (variable) ±1.5 mm
Offset = /
1.6 Clearances
7
5: Lid/Bumper
Clearance = 3.5 mm ±0.5 mm
Offset = -1.0 mm ±1.0 mm
6: Fender/Bumper grille
Clearance = 0.0 mm +0.5 mm
Offset = 0.0 mm ±0.5 mm
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6
8
7: Headlight/Fender
Clearance = 3.0 mm ±1.0 mm
Offset = +0.7 mm ±0.7 mm
8: Headlight/Bumper
Clearance = 3.0 mm ±1.0 mm
Offset = variable
5
1.6 Clearances
12
11
10
9: Bumper/Headlight/Grille
Clearance = 3.0 mm ±1.0 mm
Offset = /
10: Headlight/Lid
Clearance = 3.5 mm ±0.5 mm
Offset = -1.4 mm ±1.0 mm
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11: Fender/Lid
Clearance = 3.5 mm ±0.5 mm
Offset = 0.7 mm +0.7 mm -1.0 mm
12: Roof seal/Front window surround
Clearance = 5.5 mm ±1.5 mm
Offset = /
1.6 Clearances
14
16
13: Fender/Sill trim panel
Clearance = 4.0 mm ±0.7 mm
Offset = -0.5 mm ±0.5 mm
14: Door panel/Fender
Clearance = 3.5 mm ±0.5 mm
Offset = -0.5 mm +0.5 mm
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13 15
15: Side door/Sill trim panel
Clearance = 4.0 mm ±1.5 mm
Offset = 0.0 mm ±1.0 mm
16: Moulding/Door window
Clearance = /
Offset = -8.5 mm ±1.5 mm
1.6 Clearances
17
19
17: Roof/Moulding
Clearance = /
Offset = -1.0 mm ±1.0 mm
18: Door panel/Flank
Clearance = 3.5 mm ±0.5 mm
Offset = 0.75 mm +0.0 mm -0.75 mm
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18 20
19: Quarterlight/Door window
Clearance = 6.3 mm ±2.0 mm
Offset = Var. -0.8/-0.7 mm ±1.0 mm
20: Quarterlight seal/Door window scraper seal
Clearance = 2.5 mm ±0.5 mm
Offset = 0.0 mm ±1.0 mm
1.6 Clearances
21 22 23
21: Air intake surround/Roof
Clearance = 3.5 mm ±0.5 mm
Offset = -1.0 mm ±1.0 mm
22: Rear window/Air intake surround
Clearance = 3.0 mm ±1.0 mm
Offset = -0.0 mm ±1.0 mm
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23: Roof/Rear window
Clearance = 4.5 mm +1.0 mm
Offset = -1.0 mm +0.0 mm
24: Rear window/Engine compartment lid
Clearance = 4.0 mm ±1.0 mm
Offset = -2.0 mm +2.0 mm -1.0 mm
24
1.6 Clearances
27
25: Engine compartment lid/Rear bumper
Clearance = 4.0 mm ±1.0 mm
Offset = 0.0 mm ±1.0 mm
26: Taillight/Exterior flank
Clearance = 3.0 mm ±1.0 mm
Offset = /
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28
27: Taillight/Rear bumper
Clearance = Var. from 2.7 mm to 3.8 mm +1.0 mm
Offset = /
28: Air intake grilles/Rear bumper
Clearance = 0.0 mm +0.5 mm
Offset = /
25
1.6 Clearances
29
32
29: Lower air intake/Rear bumper
Clearance = 1.0 mm +0.5 mm
Offset = /
30: Lower air intake/Diffuser
Clearance = 2.0 mm ±0.7 mm
Offset = 0.0 mm ±0.5 mm
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30 31
31: Lower air intake/Diffuser
Clearance = 2.0 mm +1.0 mm
Offset = /
32: Air intake surround/Exterior flank
Clearance = 4.0 mm ±1.5 mm
Offset = /
1.6 Clearances
33
34
33: Rear window/Exterior flank
Clearance = 4.0 mm ±1.5 mm
Offset = /
34: Engine compartment lid/Rear bumper
Clearance = 4.0 mm ±1.5 mm
Offset = Var. from -4.2 mm to -0.0 mm ±1.5 mm
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35
35: Exterior flank/Rear bumper
Clearance = 0.0 mm ±0.5 mm
Offset = 0.0 mm ±0.5 mm
1.7 Car Bench vehicle bench
To mount the vehicle on the straightening bench, proceed in accordance with the assembly plan provided by the manufacturer of the straightening tool.
A special set of straightening tools has been developed for repairing the Ferrari F458 Italia. To ensure precise fit and dimensional accuracy, it is generally advised to use the set of straightening tools when carrying out all work on the vehicle structure:
• Before separating individual parts from the body assembly.
• When aligning and tack welding new components.
• When welding in new components.
• During the cooling phase after welding.
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1.7 Car Bench vehicle bench
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1.7 Car Bench vehicle bench
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1.7 Car Bench vehicle bench
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1.7 Car Bench vehicle bench
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1.7 Car Bench vehicle bench
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1.7 Car Bench vehicle bench
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1.7 Car Bench vehicle bench
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1.7 Car Bench vehicle bench
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Expanded foam parts are used to reduce interior noise and prevent condensation and exhaust gases from entering the passenger compartment. In the production process, the cavities in certain areas of the bodywork are compartmentalised by using expanded foam components and applying heat to the bodywork.
During vehicle production, strips of sealant, in various widths and thicknesses, are inserted into the box section cavities.
These expanded foam parts are optimally moulded to the shape of the box section cavities by heating the bodywork to approx.
180 °C. This separates the individual box section cavities.
However, as the bodywork may not be heated to this extent during a repair, different procedures have been established for different cases:
Bicomponent expanded foam sealant
The cavities are filled with a bicomponent foam sealant. The foam sealant must form a closed-cell seal. The closed-cell seal prevents moisture from penetrating the area concerned.
Foam sealant is applied via existing holes. Only areas that were foamed-in-situ at the manufacturing plant may be refilled during a repair.
Single component permanently elastic adhesive mastic
This material is applied in very narrow repair areas, and in the outer skin area in particular. For example, on the Ferrari F458
Italia, this is used to hermetically seal the underdoor panel.
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1.9 Workstation for bodywork repairs
A specially equipped workstation is necessary for carrying out repairs on the aluminium bodywork of the Ferrari F458
Italia. If the workstation is not situated in its own dedicated, enclosed space, adjacent workstations used for conventional steel vehicles must be screened off with a sliding protective curtain.
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1.10 Workshop equipment for aluminium repairs
A specific set of tools must be used for work on aluminium bodies. When carrying out surface finishing work (grinding), never use grinding discs that have previously been used on steel panels. When carrying out surface finishing work (planing, beating), never use tools that have previously been used on steel panels.
Caution!
Never use a tool on aluminium vehicles that has previously been used for steel panels.
The following tools are generally required for carrying out work on vehicle bodies:
• Set of straightening tools - Ferrari F458 Italia
• Portal gauge
• Portal gauge accessory - F458 Italia
• MIG welding equipment
• TIG welding equipment
• Welding fumes extraction system
• Welding spot milling cutter
• Aluminium panel beating system
• Oxyacetylene welding equipment
• Riveting tongs for self-piercing rivets
• Riveting tongs for blind rivets
• Pneumatic riveting tongs for blind rivets
• Electric body saw/long stroke
• Pneumatic body saw/short stroke
• Saw blades (coarse tooth)
• Hot air fan
• Angle grinder
• Cutting disc
• Grinding discs
• Hole-punching pliers (hand-operated and pneumatic)
• Joggling tool (hand-operated and pneumatic)
• Spray gun for sealing
• Gun for applying underbody protection
• Gun for applying cavity wax
• Counterhold tool
• Universal dolly
• Plastic wedges
• Plastic drift
• Paintbrushes
• Stainless steel wire brush
• Single component adhesive gun (hand-operated)
• Bicomponent adhesive gun (pneumatic)
• Clamping pliers
• Oscillating cutter
• Stud welding equipment
• Oscillating cutter
• Temperature indicator strips or temperature indicator crayons
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1.10 Workshop equipment for aluminium repairs
Special tools
A new template and punch kit (p/n 95978256) is used for repairs in the wheelhouse area. These tongs enable the removal and replacement of rivet joints at the flange connecting the two halves of the wheel housing.
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1.11 Aluminium
Aluminium is obtained from bauxite and is the second most commonly used metal today after steel. Magnesium and silicon are the main alloying components used in high-quality aluminium alloys. These alloys form the basis of the extruded sections, die-cast node joints and panels in aluminium.
1.11.1 Contact corrosion
When aluminium is in contact with oxygen in the air, a passivating oxide layer is formed on its surface that protects the material underneath from environmental factors. Consequently, an unpainted aluminium component will not normally corrode.
However, if aluminium comes into contact with another metal that is higher in the electromotive series than itself and an electrolyte is present at this point, contact corrosion will occur.
Electromotive series:
• Zinc (Zn)
• Chromium (Cr)
• Iron (Fe)
• Tin (Sn)
• Lead (Pb)
• Aluminium (Al)
Since aluminium is usually lower in the electromotive series and is the more common metal, it will decompose.
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1.11 Aluminium
1.11.2 Corrosion protection
To prevent contact corrosion, only surface-coated fastener elements - bolts, nuts, washers, blind rivets, self-piercing rivets, etc. - are used in the manufacture of the vehicle. These components are tested for their compatibility with aluminium.
New fastener elements must always be used when carrying out repairs. Screws may not be used as the friction generated during tightening reduces the thickness of the coating. Grinding work on steel components (blind rivets, self-piercing rivets, bolts) is not permitted.
1.11.3 Screw connections
Caution!
Bolts must not be reused. Friction produced during tightening reduces the thickness of the coating.
Mechanical components and bodywork elements are fastened to parts of the body with rivets (with blind rivets and self-piercing rivets), screws applied to threaded rivets and screws applied to threads cut directly into the aluminium. To prevent damage to the threads, please observe the maximum torque values.
The dust produced by grinding contains minute steel particles which would damage the aluminium.
The following work is required after an accident repair:
• Painting, from primer right through to glaze
• Post-treatment (sealing) of edges; material used:
1-component polyurethane-based permanently-elastic body sealing compound and 1-component polymer-based permanently-elastic body sealing compound
• Corrosion protection treatment for the underbody
• Post-treatment of cavities with cavity protection agents.
1.11.4 Lightweight construction
To reduce vehicle weight, the entire(*) vehicle body has been manufactured from aluminium components. The specific weight of aluminium is just 2.70 kg/dm 3 , whereas that of steel is 7.85 kg/dm 3 . As a result, a considerably higher strength compared with a unitary construction steel body can be achieved.
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1.11 Aluminium
1.11.5 Space-Frame assembly
The entire bodywork of the Ferrari F458 Italia is constructed on a Space Frame structure.
The areas highlighted in purple are made from an aeronautical grade aluminium alloy. Extruded sections and cast parts are all welded in the area of the join. Replacement parts have been specifically designed for use with prefabricated assemblies.
All welding work carried out on the Space Frame assembly must be done in conjunction with a straightening system. The components to be replaced must be mounted on a straightening jig.
Essentially, this construction consists of:
• extruded sections
• die-cast joints (cast parts)
• gussets (reinforcements)
• (*) The reinforcements in the A pillars are made from ultrahigh strength steel sheet (see chapter 1.12 “Ultra-high strength steel reinforcements”)
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1.11 Aluminium
1.11.6 Extruded sections
Caution!
Deformed extruded sections must not be repaired either cold or by applying heat.
Damaged extruded sections must be replaced.
The body-in-white structure consists of extruded sections with differing cross sections and stiffness characteristics - and die-cast joints (cast parts). Extruded sections have excellent strength characteristics and superior torsional stiffness. The extruded sections used in the vehicle are compartmentalised by one or two cavities. Due to the properties of the material, straightening work on extruded sections is not possible or permitted.
1.11.7 Die-cast joints
Caution!
For safety reasons, die-cast node joints (castings) may not be repaired and must be replaced!
Welding of cracks is not permitted.
The die-cast joints (castings) constitute the key areas of the
Space Frame construction. They constitute the entire welded joint area for all extruded sections.
The die-cast joints are also used as mounts for the axle components and the engine and transmission assembly.
1.11.8 Gussets (reinforcement panels)
The vehicle is fitted with gussets (reinforcement panels) in different thicknesses. The gussets are mainly attached to the space frame by means of welded or riveted joints.
Screw connections are used in a limited number of areas.
The gussets essentially help to strengthen and increase the torsional stiffness of the space frame construction.
1.11.9 Recycling
NOTE!
Scrap aluminium parts must be detached immediately and disposed of separately.
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1.12 Ultra-high strength steel reinforcements
To reinforce the windscreen frame for increased occupant protection and body stiffness, reinforcements made from ultrahigh strength steel are installed in both A-pillars (A) of the
Ferrari.
The cover panel of the A-pillar is made from aluminium.
The joints between aluminium body components and steel components must meet extremely high requisites in terms of strength and corrosion resistance. On the Ferrari F458 Italia, these requirements have been met by joining the components using non-thermal procedures and coated self-piercing rivets.
Self-piercing riveting is a proven joining technology for joining aluminium parts with other aluminium parts and for joining steel and aluminium parts. Any heat subsequently applied to these reinforcements - for example when cutting or welding
- results in considerable loss of strength, which in turn has a drastic effect on the vehicle's crash safety. Therefore, in the event of repair, these reinforcements must not straightened using either cold or hot techniques. The complete part must be replaced in all cases.
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A
1.13 Consumable materials
Only the consumable materials listed must be used when carrying out any of the body repairs described in this manual.
All materials must be approved by the vehicle manufacturer.
Name
Bicomponent cartridge gun for structural adhesive (end-cured)
Bicomponent structural adhesive (end-cured)
Adhesive cleaner
Manufacturer
3M Scotch-Weld
3M Scotch-Weld
3M Scotch-Weld
Mixing tube for structural adhesive
Silicate abrasive paper
Aluminium filler with curing agent
Crack testing material:
Cleaner
Wieländer + Schill
Wieländer + Schill
Wieländer + Schill
Wieländer + Schill
Penetrating dye
Developer
Bicomponent filler foam/ expanding foam
Single component body adhesive sealing compound
Henkel/Teroson
Henkel/Teroson
Product number
EPX 37/50
DP 490
08984
838115
667212
542050
Specification
Contains: petroleum distillates, hylol, ethyl benzene
Contains silicate
Polyester based aluminium filler with aluminium powder
311051
311050
311052
Teroson 9100 1K PUR Permanently-elastic polyurethanebased adhesive sealing compound, may be painted over with all paints
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1.13 Consumable materials
Name
Butyl tape
Single component primer
Cleaner (for painted areas)
Silicone remover
Manufacturer
Henkel/Teroson
Henkel/Teroson
Henkel/Teroson
Henkel/Teroson
Product number Specification
Permanently-elastic sealant,
8 mm
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1.14 Preparing and cleaning areas for welding
Often, for the sake of convenience or due to a shortage of time, joint areas are not adequately prepared and cleaned correctly, in spite of the fact that these preliminary procedures are vital for a perfect, high quality weld.
The quality of a weld seam may be compromised so severely as a result of inadequate preparation that it may even need to be removed for safety and the weld repeated. The time saved in terms of preparation is not even remotely comparable to the amount of time wasted in having to redo a weld.
The following procedures are necessary:
• The weld points on all parts of the bodywork must be ground
(removing the paint).
• Before welding, remove the layer of oxide with a stainless steel wire brush.
• Before welding, clean the welding area with a degreasing detergent or acetone.
NOTE!
Failure to clean weld areas adequately may severely compromise the strength of the weld itself by promoting the development of porosity.
Caution!
Before welding, fit all attached parts (lights, radiator grille, engine compartment lid etc.)!
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1.15 Repair methods
1.15.1 Panel beating
NOTE!
Only use aluminium tools for all panel beating work.
The risk of stretching the material is greater with aluminium than with steel. As a result, aluminium panels should preferably be pressed rather than beaten. Panel beating procedures in which the aluminium panel is placed directly between the counterhold tool and the body hammer, should be kept to a minimum. Contrary to standard practice with steel panels, panel beating work on aluminium panels should begin in the centre of the dent. When panel beating, do not use sharpedged or hard tools such as steel hammers.
When performing finishing operations, operate the counterhold tool loosely. Excessive force applied during finishing actions may cause the material to stretch. To avoid this, use a counterhold tool made from hardwood.
1.15.2 Shrinking
Elongation of the material may be rectified by shrinking, which involves the application of heat. Shrinking is done with a neutral flame. The shrinking operation involves heating the area to be shrunk then locally cooling it immediately. As a result of the rapid temperature change, the aluminium panel shrinks at the area concerned and resumes its original shape.
The surrounding colder material confines the heated area and stretches less.
During subsequent cooling, the heated, buckled aluminium panel shrinks. As a general rule, the repair area must be heated and cooled quickly when carrying out shrinking procedures.
1.15.3 Monitoring temperature
Caution!
Outer skin body components may be heated for straightening and panel beating work provided the temperature is monitored constantly. Never exceed temperature indicator pencils or strips or temperature reading instruments.
Panel beating may be facilitated by applying targeted heat.
When heating aluminium, the material must not be allowed to tarnish. Consequently, the temperature has to be determined by means of temperature indicator strips. The different areas on the temperature indicator strip change colour once predetermined temperatures are exceeded.
Procedure:
1. Thoroughly clean and confine the area to be heated
2. Temperature indicator strips must be applied at a distance of approximately 25 mm from the area to be heated
3. Apply the temperature indicator strips spaced at regular intervals
4. Heat the material while simultaneously monitoring the temperature.
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1.15 Repair methods
1.15.4 Cutting
Caution!
Only perform cuts in accordance with the instructions in this repair manual. Before carrying out any cutting work, the paint and sealant must be removed from the area of the cut. When making the cuts, protect adjacent parts, such as castings, from damage.
Before performing any cutting operations, the structural characteristics of the area in question, such as inner joining flanges, reinforcement panels, etc., must be examined carefully.
In general, and around die-cast joints in particular, start rough cuts with a body saw. This facilitates access for other cutting tools and ensures the necessary visibility of the individual cutting areas.
• Only make cuts with the body saw or panel shears.
• The tooth pitch for aluminium saw blades is coarser than that for steel panels.
1.15.5 Joggling
Joggling is a particularly suitable method for creating a backing for welding aluminium panels. This should be carried out using mechanical or pneumatic joggling tools. Before making a cut, allow 22 mm for an overlap. To allow filler to be applied subsequently to the repair area, create a 45° bevel on the upper panel and deburr.
1.15.6 Same-material weld backing
The same material as the material being welded is used during the repair as a weld backing. This is required when welding aluminium panel sections where a butt-to-butt weld is not possible. The thin material would otherwise burn through very quickly under the effect of the heat. Offcuts from the new or old part may be used for this backing material. Same-material backing should also be used on beaded panel edges.
In the case of small cross sections or large panel edges, cut the material and create a 45° bevel on both panels. The panel edges must be spaced by a 3 to 4 mm gap.
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1.15 Repair methods
1.15.7 Straightening
Aluminium behaves differently from steel when it is being straightened. The risk of stretching the material is considerably greater with aluminium. Aluminium panels should preferably be pressed rather than beaten. Because of the particularly high strength of the aluminium extruded sections and aluminium castings, straightening cannot be carried out on any part of the Space Frame structure. Any damaged parts must be replaced.
The scope of the repair is ascertained by superimposing the measurement points of adjacent components on the straightening bench. Straightening work to correct the dimensions of normal structural panels (e.g. bulkhead, side panel/rear closure panel, spare wheel well/rear cross-member, etc.) is possible to a limited degree.
1.15.8 Riveting
Riveting consists in the formation of a non-detachable joint by plastic deformation of the rivet itself.
Self-piercing riveting
Self-piercing riveting is one of the most important joining techniques used on the bodywork of the Ferrari F458 Italia.
This technique is used to join aluminium body components together and to join aluminium with steel body components.
One example of where this method is used are the ultra-high strength steel reinforcements which are joined to the aluminium cover plate of the A pillar.
The self-piercing rivet is made from steel and has a special coating. In repairs, the original self-piercing rivets are replaced with solid rivets. The self-piercing rivet joint is removed by pressing it out with the riveting tongs. When doing so, observe the following precautions:
ಶ If required, make cuts first
ಶ Adjust the riveting tool to the thickness of the material
ಶ Insert the tip of the punch into the stamped area of the panel
ಶ Pull out the self-piercing rivet with the riveting tool, taking care not to tilt the riveting tool as you do so
NOTE!
Self-piercing rivets must not be drilled or ground out.
Ensure that the riveting tool is adjusted to the thickness of the material before carrying out any job. If the flange is not accessible with the riveting tool, cut the damaged part out roughly.
If the self-piercing rivet is not accessible with the riveting tool, the aluminium may be drilled out around the rivet using a welding spot milling cutter with a sprung tip.
Sparks produced when grinding are an indication of remnants of rivets in the material. Remove these remnants and change the grinding disc.
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1.15 Repair methods
Pressing out the self-piercing rivet leaves a hole in the inner panel. The self-piercing rivet remains on the outer panel.
A gap is created between the head of the self-piercing rivet and the outer panel. If so, detach the damaged part with a flat chisel and remove.
Carefully remove any rivet residues with a flat chisel.
Gently align the flange on the undamaged panel with the riveting tong, using two flat inserts.
Adapt and fasten the part to be repaired, and insert solid or blind rivets in accordance with the repair manual.
Remove all rivets that fall into the vehicle during the repair.
Magnets may be used to remove them.
Blind rivet joints
NOTE!
Factory-installed structural blind rivets must only be replaced with structural rivets, even in the case of repair. Use only blind rivets that have been approved by Ferrari. These blind rivets are coated and prevent contact corrosion. The operating pressure for the pneumatic riveting tongs must be 8 bar. Before starting the riveting procedure, ensure that the parts to be joined and the rivet head are on top of one another and that there is no gap between them.
Blind rivet joints are critical to the strength and torsional stiffness of the bodywork.
Two types of blind rivet have been approved for repairs on the
Ferrari F458 Italia:
• High-strength structural blind rivets are used for work on structural components.
• Textron blind rivets are used to replace factory-installed selfpiercing rivet joints in places that are difficult to access.
Threaded rivets
NOTE!
Use only the threaded rivets that have been approved by the manufacturer (with special coating). Threaded rivets must never be ground or drilled out. The metal swarf produced will cause contact corrosion.
Threaded rivets are generally pre-installed in with replacement parts and assemblies. The repair may necessitate the removal of some of these inserts. Damaged threaded rivets may also be replaced individually. The threaded rivets must also be completely removed from cavities.
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1.15 Repair methods
1.15.9 Welding aluminium
Metal inert gas (MIG) welding is the most commonly used method for carrying out repair welds on aluminium. It is used to create joints between castings and extruded sections and between panel sections. In this method, the arc burns between the component to be welded and the melting wire electrode.
The latter serves as the filler material and transfers the energy required to melt the metal. Argon is used as the shielding gas.
1 mm diameter AlSi 12 wire is used as the filler wire. Before welding, remove any underbody protective treatment, sealants and paint from the parts and then remove the oxide layer with a stainless steel brush.
To prevent the formation of cracks, always continue weld seams around the corners of extruded sections.
Caution!
All welds must be carried out with the parts fixed in the jig to prevent the parts themselves from moving during welding, which would compromise the results of the repair.
Only remove the jigs after checking that the weld areas have cooled.
1.15.10 Checking weld seams and die-cast node joints
Caution!
Before using any penetrating agents, cleaners and developers, it is essential that all the safety precautions indicated by the respective manufacturers are taken.
All three diagnostic agents are highly flammable.
When assessing damage to die-cast joints and the quality of repairs to welded joints, crack-testing is necessary.
The dye penetration method is suitable for carrying out crack tests on surfaces. In this case all faults originating in the surface are highlighted by a contrasting colour. Red or yellowish-green fluorescent dyes are usually used as the penetrating agent.
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1.15 Repair methods
Do not brush the area to be examined before carrying out a crack test as this will fill up the cracks!
Procedure:
1. Expose the damaged area and clean the surface.
2. Apply the penetrating agent with an aerosol spray can. The penetrating agent will permeate into the apertures in the surface by capillary action. Allow the penetration agent to take effect - observe the correct length of time.
3. Use a detergent to completely remove any excess penetrating agent that has not permeated into the damaged surface.
4. Spray on developer and allow it to act. The damaged area becomes visible.
Check the areas for cracks. If a component reveals any cracks, it must be replaced.
If a weld seam contains cracks, it must be reworked. All cracks must be ground out and re-welded. In this case, the crack test will have to be repeated.
In general, however, only faults in the material surface or communicating directly with the surface are detectable.
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1.15 Repair methods
1.15.11 Welding defects
Cracks
The most common types of cracks in aluminium are cracks caused by heat and/or solidification; the risk of crack formation increases with increasing solidification.
Cracking in welds is primarily influenced by the composition of alloys being welded. There is a risk of crack formation with
AlMgSi type aluminium alloys and with AlMg and AlMgMn alloys with an Mg and/or Si content lower than 2.5%. As a result, these alloys may only be welded using welding additives made from alloys with a higher Mg and/or Si content, as these additive wires increase the residual melt content in the weld pool.
In addition to the use of inappropriate additive materials, other cause for cracks include excessively shallow craters, excessively short tack welds or incorrect welding sequences, resulting in high shrinking stress in the event of sheet overheating or tension.
Subsequent processes performed on the welds may also cause the formation of cracks.
For instance, cracks will form around weld beads in the event of using excessively high weld currents or inappropriate electrode wires (Fig. A) .
Cracks in the end crater are usually caused by inappropriate finishing treatments (Fig. B) .
A
B
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1.15 Repair methods
To repair a crack, the weld bead must be ground along the full length of the crack to twice the depth of the crack itself before repeating the weld (Fig. C) . After welding, crack testing must be repeated.
Cracks in the outer skin are repaired by drilling a 2 mm diameter hole at each end of the crack to prevent it from spreading.
Then both the crack and the holes are welded (Fig. D) .
C
Crack
Approximately double the length of the crack
D
Hole
Hole
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1.15 Repair methods
Pores
Pores within the weld bead constitute the most frequently encountered defect. Pore formation reduces with increasing solidification intervals.
Pores are formed by the inclusion of gas bubbles in the event of excessively rapid cooling. This is caused by the greater solubility of hydrogen in liquid aluminium (20 times higher than in the solid state). Condensation therefore poses a particular hazard, as moisture causes a layer of hydroxide to form, which has a high hydrogen content.
Other possible causes of pore formation are:
• unstable electric arc (due to irregular current, irregular movement of the wire electrode or incorrect weld settings),
• incorrect placement of welding torch,
• insufficient inert gas quantity,
• air infiltration,
• nozzles that are too small or obstructed by metal splashes,
• contaminants in the weld bead area (grease, oil, paint, dirt).
Penetration notches (Fig. E) are formed in the event of using excessive weld currents or in the event of incorrect placement of the welding torch.
Protruding weld beads
Protruding weld beads are formed in the event of using excessively low weld currents or in the case of excessively slow weld speeds (Fig. F) .
E
F
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1.15 Repair methods
Inclusions
The most frequent types of inclusions are oxides. These form when small fragments of oxide film fall into the weld pool, as the oxide layer was not removed prior to welding.
As these fragments are in general very fine and uniformly distributed, they have no discernible influence on the strength of the weld bead.
This, however, is not the case in the event of insufficient shielding gas coverage or air infiltration. In these cases, larger oxide inclusions may be formed, resulting in significant notching due to material separation.
End craters
A crater forms at the end of each weld bead, which must be filled (Fig. G) .
To do this, do not turn the welding torch off at the end if the weld bead. The melting welding wire fills the crater (Fig. H) .
Alternatively, turn the welding torch on and off repeatedly until the crate has been filled.
G
H
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1.15 Repair methods
Melting
The weld may melt in the event of excessive weld currents or inadequate edge preparation (Fig. I) .
Application error ('I' shaped bead)
Application errors occur when the filling material runs into the gap and when a weld is applied on top of another newly applied bead that has not yet solidified.
The root must be perfectly welded. Slightly bevelling the inner side of the sheet flanges improves the influx of the root.
Application errors consist of material separation cracks with a high penetration effect, which compromise the strength of the weld itself.
Soot deposits
In event of an excessively small torch angle or incorrect welding torch movements (such as when welding forward), significant soot deposits may be formed in certain conditions (Fig. J) .
Other causes of this phenomenon may be an insufficient quantity of inert gas or inadequate cleaning of the welding flanges.
When working with magnesium based aluminium alloys, small soot deposits are practically unavoidable.
I
J
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1.15 Repair methods
Cold spots
Cold spots may occur at the start and end of the bead, which compromise the strength of the joint due to poor penetration.
As a result, approximately 5 mm should be added to the start and finish of the bead when determining the length of the bead itself.
Effects of Welding Heat on AlMgMn Base Material
The thermally altered area is weakened as a result of crystallisation. Should this occur, there is no way of increasing the strength of the altered area.
Effects of Welding Heat on AlMgSi Base Material.
The thermally altered area is weakened by coarse segregation with mixed hypersaturated crystals (in the case of a cold hardened initial state) and/or by increased segregation with no correlation (in the case of hot hardened initial state).
The only way to substantially increase strength is to temper the material again - in other terms by solubilizing, sudden cooling and natural cooling. However, this process is not possible on bodywork in a workshop.
In both types of alloy, the thermally altered area is the weakest part of the joint.
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1.15 Repair methods
1.15.12 Structural adhesive bonding
Bonded joints are also used in certain areas to supplement the self-piercing or blind rivet joints and resistance spot welds.
This increases the strength of the joint.
1.15.13 Sealing
NOTE!
Before carrying out any cutting work, the paint and sealant must be removed from the area of the cut.
Remove sealant with a rotary wire brush.
After carrying out repair work, all seals must be reapplied as per the original assembly.
To prevent leaks and wind noise, the body is sealed in the factory.
During and after work on the vehicle body, maintain the factory-applied corrosion protection or reapply if necessary. If repair work is required on a vehicle body, the following must be observed.
If, after straightening work, hairline cracks appear near the sealing seams in the area of the outer panels or body joint areas, these must be carefully reworked. Hairline cracks in the sealing seam, or sealing seams that have not been properly made during the repair usually result in water infiltrating into the passenger compartment.
Sealing seams that have not been done correctly or that are missing may also cause wind noise.
Even the tiniest gap in the seal can result in substantial water infiltration.
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2.1 Replacing the fender
Preliminary ಶ Remove connected parts (bumper, headlight, gravel guard). procedures
Replacement parts • Fender (A)
Material necessary • 7 x M6 screws
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A
2.1 Replacing the fender
Repair sequence Removing the old part
1. Use a 10 mm wrench to remove the 2 fastener screws joining the fender and the flank of the vehicle.
2. Use a 10 mm wrench to remove the 4 fastener screws joining the fender and fender mounting.
2
1
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2.1 Replacing the fender
3. Use a 10 mm wrench to remove the fastener screw joining the fender and the front sill pillar.
Fitting the new part 4. Fit the fender, aligning with the holes on the fender mounting and on the vehicle flank.
3
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2.1 Replacing the fender
Fitting the new part
5. Fasten the fender to the fender mounting with 4 M6 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph (1.11.3 Screw connections) .
5
6. Fasten the fender to the front sill pillar with 1 M6 screw.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
6
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2.1 Replacing the fender
7. Fasten the fender to the vehicle flank with 2 M6 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
7
ಶ Refit connected parts (bumper, headlight, gravel guard).
ಶ Check the clearance dimensions, rework if necessary.
Remove the fender for subsequent painting.
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2.2 Replacing the fender mounting assembly
Preliminary procedures
ಶ Remove connected parts (bumper, headlight, hinges, lid)
ಶ Remove the fender (see chapter 2.1)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Front fender mounting (A)
• Reinforcement base (B)
Material necessary • 7 structural rivets (Ø 6.4)
• 4 self-piercing rivets (Ø 3.9)
• Bicomponent sealant mastic
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A
B
2.2 Replacing the fender mounting assembly
Repair features
Warning!
Work with the utmost caution when welding to avoid igniting any components in the vicinity.
Repair sequence Removing the old part
1. Sand the weld points between the fender mounting and the front trellis.
1
1
1
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2.2 Replacing the fender mounting assembly
2. Remove the beads of bicomponent sealant mastic near the three fastener rivets joining the mounting base and the upper diagonal brace.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
2
3. Remove the 3 structural rivets joining the reinforcement base and the upper diagonal brace.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
3
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2.2 Replacing the fender mounting assembly
4. Remove the 4 self-piercing rivets joining the fender mounting and the lower reinforcement base.
• 2 on outer side of vehicle.
• 2 on inner side of vehicle.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
4
5. Remove the 4 structural rivets joining the fender mounting and the lower reinforcement base.
• 2 on outer side of vehicle.
• 2 on inner side of vehicle.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
5
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4
2.2 Replacing the fender mounting assembly
6. Retrieve the protective foam.
6
7. Remove the lower mounting base and sand the welding points for joining the fender mounting and the upper diagonal brace.
NOTE!
Do not remove any other material from the upper diagonal brace.
7
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2.2 Replacing the fender mounting assembly
Fitting the new part 8. Sand the new part.
8
9. Fit the outer tower, then mount the fender mounting in the jig (B - C) .
ಶ Prepare the weld area (see chapter 1.14) .
B
C
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2.2 Replacing the fender mounting assembly
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
10. Weld the fender mounting to the front lateral trellis at the original weld points.
10
10
11. Weld the fender mounting to the upper diagonal brace at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
10
11
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2.2 Replacing the fender mounting assembly
12. Fasten the reinforcement base to the upper diagonal brace with 3 structural rivets.
13
13. Fasten the reinforcement base to the fender mounting with 4 self-piercing rivets.
• 2 on outer side of vehicle.
• 2 on inner side of vehicle.
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
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2.2 Replacing the fender mounting assembly
14. Fasten the reinforcement base to the fender mounting with 4 structural rivets.
• 2 on outer side of vehicle.
• 2 on inner side of vehicle.
15
15. Refit the protective foam.
15
15
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2.2 Replacing the fender mounting assembly
16. Seal the three structural rivets joining the reinforcement base and the upper diagonal brace with bicomponent mastic.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
16
17. Refit the fender (see chapter 2.1) .
ಶ Check that the part is correctly aligned.
ಶ Refit the door and lid.
ಶ Check the clearance dimensions, rework if necessary. Remove the fender, door and lid for subsequent painting.
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2.3 Replacing the front lateral trellis
Preliminary procedures
ಶ Remove connected parts (headlight, gravel guard, radiator, radiator mounting).
ಶ Remove the fender ( see chapter 2.1
).
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Front lateral trellis (A)
• Upper outer radiator mounting bracket (B)
• Front link tube (C)
Material necessary -
C B
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A
2.3 Replacing the front lateral trellis
Repair sequence
Removing the old part
1. Sand the weld points between the front trellis and the front spar.
NOTE!
Do not remove any other material from the front spars.
1
2. Sand the weld points joining the upper outer radiator mounting bracket.
NOTE!
Do not remove any other material from the front cross-member.
2
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2
1
2.3 Replacing the front lateral trellis
3. Sand the weld points on the internal side of the car between the trellis and the cross-member.
NOTE!
Do not remove any other material from the front cross-member.
3
4. Sand the weld points between the trellis and the shock tower.
NOTE!
Do not remove any other material from the shock tower.
Caution!
Check that there are no cracks in the shock tower.
In the event of damage, the part must be replaced (see chapter 2.6) .
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2.3 Replacing the front lateral trellis
5. Sand the weld points between the trellis and the fender mounting.
6. Sand the weld points between the front link tube, the front lateral trellis and the front cross-member.
5
5
6
6
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2.3 Replacing the front lateral trellis
Fitting the new part
7. Mount the front trellis in the jig.
NOTE!
The procedure described above must be performed with the assistance of another worker.
ಶ Prepare the weld area (see chapter 1.14) .
Fitting the new part
NOTE!
Before fitting the new part, read chapter (1.15
Repair methods) thoroughly.
8. Weld the front trellis to the cross-member at the original weld points on the internal side of the vehicle.
8
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2.3 Replacing the front lateral trellis
9. Mount the bracket (A) in the jig and weld at the original weld points to both the front trellis and the cross-member.
9
A
9
10. Weld the front trellis to the front spar at the original weld points.
Caution!
When welding the front lateral trellis, there is a risk of the spar (A) buckling as a result of the heat.
To prevent this, the trellis must only be welded with the front cross-member mounted in the jig
( see chapter 2.4
).
10
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A
10
2.3 Replacing the front lateral trellis
11. Fit and then weld the link tube (B) to the front crossmember and to the front lateral trellis at the original weld points.
B
11
11
12. Weld the front trellis to the shock tower at the original weld points.
12
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2.3 Replacing the front lateral trellis
13. Weld the front trellis to the fender mounting at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
14. Refit the fender ( see chapter 2.1
).
ಶ Refit the door and lid.
ಶ Check the clearance dimensions, rework if necessary.
NOTE!
Refit connected parts after tacking the trellis into position.
Then weld the trellis only after checking clearances.
Remove the fender, door and lid for subsequent painting.
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13
2.4 Replacing the front cross-member
Preliminary procedures
ಶ Remove connected parts (bumper, headlights, radiator, tub).
ಶ Remove the fender ( see chapter 2.1
).
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Front cross-member (A) .
• Upper outer radiator mounting bracket (B) .
Material necessary • 12 structural rivets (Ø 6.4)
• 18 x M8 screws
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A
B
2.4 Replacing the front cross-member
Repair sequence Removing the old part
1. Use a 13 mm wrench to remove the 12 screws located on the internal side of the car in correspondence with the bumper mounting brackets.
2. Use a 13 mm wrench to remove the 6 screws in correspondence with the tow hook mounting.
2 2 2
2
1
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2.4 Replacing the front cross-member
3. Sand the weld points between the front crossmember and the front spars.
NOTE!
Do not remove any other material from the front spars.
3
3
4. Remove the 12 structural rivets (6 per side) connecting the front cross-member and the front spars.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
4
3
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2.4 Replacing the front cross-member
5. Grind and clean the welds on the front spars.
Caution!
Work with the utmost caution, taking care not to damage the front spars.
5
5
Fitting the new part 6. Mount the front cross-member in the jig.
NOTE!
Check that the cross-member is perfectly horizontal.
ಶ Prepare the weld area ( see chapter 1.14
).
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2.4 Replacing the front cross-member
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
7. Fit 4 structural rivets (2 per side) to fix the front cross-member in position.
NOTE!
Check that the cross-member is flush with the front spars on both sides.
8. Then fit the remaining 8 rivets (4 per side) in correspondence with the holes in the front crossmember.
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8
2.4 Replacing the front cross-member
9. Weld the front cross-member to the spars (external/ internal lateral and upper/lower) at the original weld points.
9
9
9
10. Fit the front lateral trellis ( see chapter 2.3
).
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2.4 Replacing the front cross-member
11.
Weld the two upper outer radiator mounting brackets to the cross-member and to the front lateral trellis at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
11
12. Fasten the bumper mounting brackets to the front cross-member with 12 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
11
12
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2.4 Replacing the front cross-member
13. Fasten the tow hook bracket to the front crossmember with 6 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
14. Refit the RH/LH front trellises ( see chapter 2.3
).
15. Refit the fender ( see chapter 2.1
)
ಶ Refit the bumper and lid.
ಶ Check the clearance dimensions, rework if necessary.
Remove the fender, bumper and lid for subsequent painting.
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13 13 13
13
2.5 Replacing the front spar
Preliminary ಶ Remove connected parts (bumper, headlights, lid, radiator, tub) procedures
ಶ Remove the fender ( see chapter 2.1
)
ಶ Remove the front trellis ( see chapter 2.3
)
ಶ Remove the front cross-member ( see chapter 2.4
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts •
•
Front spar (A)
Reinforcement mounting (B)
Material necessary • 10 structural rivets (Ø 4.8)
(5 for RH spar/5 for LH spar)
• 2/4 x M8 screws
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A B
2.5 Replacing the front spar
Repair sequence Removing the old part
1. Use a 13 mm wrench to remove the screws, located on the internal side of the car, fastening the rear luggage tub bracket.
2. Cut the front spar.
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2
1
2.5 Replacing the front spar
3. Remove the 5 structural fastener rivets joining the front spar and the reinforcement mounting.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
4. Sand the lower weld points between the front spar and the reinforcement mounting.
NOTE!
Do not remove any other material from the front spars.
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3
4
2.5 Replacing the front spar
5. Sand the weld points between the reinforcement mounting and the shock tower.
Remove the reinforcement mounting.
NOTE!
Do not remove any other material from the front spars.
Caution!
Check that there are no cracks in the shock tower.
If any cracks are found, the part must be replaced ( see chapter 2.6
).
6. Grind all the welds between the front spar and the shock tower.
Caution!
When grinding the welds, take care not to damage the casting joints.
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5
6
2.5 Replacing the front spar
Fitting the new part 7. Rest the front spar in the relative recess on the shock tower.
NOTE!
Check that the front spar is perfectly horizontal.
ಶ Prepare the weld area ( see chapter 1.14
).
8. Check that the height of the top surface of the spar at both the inner and outer vehicle points is exactly
689.5 mm.
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2.5 Replacing the front spar
9. Mount the front cross-member (A) in the jig, ensuring that it is fitted correctly onto the two spars (B) .
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
10. Tack the front spar to the shock tower.
A
B
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2.5 Replacing the front spar
11. Check that the front cross-member (A) is fitted correctly, removing from the front spars (B) .
Caution!
Perform all the welds described as follows with the part still in the jig.
Remove the jig only once the weld areas are cool.
12. Remount the front cross-member in the jig then weld the spar to the shock tower at the original weld points.
ಶ Apply new corrosion inhibitor to the weld beads at the lower area of the spar.
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A
B
12
2.5 Replacing the front spar
13. Weld the reinforcement mounting to the shock tower at the original weld points.
14 . Fasten the reinforcement mounting to the spar with
5 structural rivets.
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14
13
2.5 Replacing the front spar
15. Weld the front spar to the reinforcement mounting at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
16. Fasten the rear luggage tub bracket with 2 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
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16
2.5 Replacing the front spar
17. Using the front cross-member as a template for drilling, drill the specified holes in the spar and then fasten the spar to the cross-member with 6 structural rivets (Ø 6.4).
18. Refit the front cross-member ( see chapter 2.4
).
19. Refit the front trellis ( see chapter 2.3
).
20. Refit the fender mounting ( see chapter 2.2
).
ಶ Refit the fender, bumper and lid.
ಶ Check the clearance dimensions, rework if necessary.
Remove the fender, bumper and lid for subsequent painting.
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2.6 Replacing the wheel bay cover plate
Preliminary ಶ Remove connected parts (dashboard, interior) procedures
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Wheel bay cover plate (A)
Material necessary • 11 structural rivets (Ø 4.8)
• Bicomponent sealant mastic
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A
2.6 Replacing the wheel bay cover plate
Repair sequence Removing the old part
1. Remove the internal and external beads of sealant mastic around the wheel bay cover plate.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses. 1
1
1
2. Remove the 4 structural rivets from the upper part of the wheel bay cover plate.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
2 2
1
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2.6 Replacing the wheel bay cover plate
3. Remove the 7 structural rivets from the lower part of the wheel bay cover plate.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
3
3
4. Sand the internal weld seams around the wheel bay cover plate.
4
4 4
4
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2.6 Replacing the wheel bay cover plate
Fitting the new part 5. Fit the wheel bay cover plate in correspondence with the rivet holes on the upper diagonal brace and on the torque box.
ಶ Prepare the weld area ( see chapter 1.14
).
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
6. Fasten the wheel bay cover plate in position with 11 structural rivets (Ø 4.8).
6
6
6
6
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5
2.6 Replacing the wheel bay cover plate
7. Perform all the welds connecting the wheel bay cover plate to the connected parts.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 7
7
7
8. Apply new beads of sealant mastic in all areas where it was removed previously.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
ಶ Refit connected parts.
8
8
8
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7
8
2.7 Replacing the shock tower
Preliminary procedures
ಶ Remove connected parts (complete interior, dashboard, front lid and hinges, tub)
ಶ Remove the fender ( see chapter 2.1
)
ಶ Remove the fender mounting ( see chapter 2.2
)
ಶ Remove the front lateral trellis ( see chapter 2.3
)
ಶ Remove the front cross-member ( see chapter 2.4
)
ಶ Remove the front spar ( see chapter 2.5
)
ಶ Remove the roof skin ( see chapter 3.3
)
ಶ Remove the wheel bay cover plate ( see chapter 2.6
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Shock tower (A)
• Wheel bay cover plate (B)
• Underwindscreen covering (C)
(p/n 81302100 RH / p/n 81406900 LH)
Material necessary • 6/8 x M8 screws
• 2 self-piercing rivets (Ø 4.8)
• 3x2 self-piercing rivets (Ø 6.4)
• 11 structural rivets (Ø 6.4)
• Bicomponent sealant mastic
A
B
C
Copyright © 2010
2.7 Replacing the shock tower
Repair sequence Removing the old part
1. Remove the 4 M8 perforating screws fastening the casting link cross-member.
2. Remove the 2/4 M8 screws fastening the lower front suspension cross-member.
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1
2
2.7 Replacing the shock tower
3. Remove the internal and external beads of sealant mastic on the lateral portion of the front firewall.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
4. Remove the beads of sealant mastic on the 3 structural rivets connecting the torque box with the shock tower.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
Copyright © 2010
3
4
2.7 Replacing the shock tower
5. Remove the beads of sealant mastic on the weld points in the underbody between the shock tower and the semi-floorpan.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
Removing the 6. Remove the beads of sealant mastic around the underwindscreen underwindscreen covering. covering
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
6
5
6
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2.7 Replacing the shock tower
7. Sand the beads of joining weld between the underwindscreen covering, the upper diagonal brace and the A-pillar flange.
NOTE!
Do not remove any other material from the upper diagonal brace.
7
7
8. Use the AVDEL FPM-35 gun to remove the 2 self-piercing fastener rivets (Ø 4.8) joining the underwindscreen covering and the vehicle flank.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
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2.7 Replacing the shock tower
9. Cut the shock tower in multiple points to allow access for the removal of the welds on the cross-members and reinforcements.
Caution!
When making separating cuts, take the utmost care not to damage the casting joints.
Check the location of any internal crossmember reinforcement on the new part in order to cut correctly.
9
9
10. Sand the internal lateral weld points connecting the shock tower and the front firewall.
9
10
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9
2.7 Replacing the shock tower
11. Sand the internal lower weld points connecting the shock tower and the front cross-member.
Caution!
Check carefully to ensure that there is no evident buckling in the floorpan and in the reinforcements connected to the centre tunnel.
12. Sand the external lateral weld points connecting the shock tower and the front firewall.
11
12
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2.7 Replacing the shock tower
13. Remove the 3x2 structural rivets connecting the windscreen valence and the shock tower.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
14. Sand the weld points at the ends of the windscreen valence connecting the part with the shock towers.
NOTE!
Do not remove any other material from the upper diagonal brace.
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13
2.7 Replacing the shock tower
15. Remove the structural rivets (1 upper rivet and 3 lateral rivets on inner side) fastening the upper diagonal brace to the shock tower.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
16. Grind the joint welds between the upper diagonal brace and the shock tower.
NOTE!
Do not remove any other material from the upper diagonal brace.
16
15
15
16
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2.7 Replacing the shock tower
17. Gradually grind the joint welds between the upper diagonal brace connected to the tunnel and the shock tower.
NOTE!
Do not remove any other material from the upper diagonal brace connected to the tunnel.
18. Remove the 5 structural rivets (3 lateral rivets and 2 lower rivets) fastening the torque box to the shock tower.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
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18
17
2.7 Replacing the shock tower
19. Gradually grind the joint welds between the torque box and the shock tower, taking care not to damage the parts themselves.
NOTE!
Do not remove any other material from the torque box.
20. Remove the 2 structural rivets on the lower surface of the lower front suspension cross-member.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
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19
20
2.7 Replacing the shock tower
21. Gradually grind the joint welds between the lower front suspension cross-member and the shock tower.
NOTE!
Do not remove any other material from the lower front suspension cross-member.
Fitting the new part 22. Mount the shock tower in the jig and tack.
ಶ Prepare the weld area ( see chapter 1.14
).
21
21
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2.7 Replacing the shock tower
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
23. Fasten the shock tower to the torque box with 5 structural rivets.
24. Fasten the shock tower to the upper diagonal brace with 4 structural rivets.
23
23
24
24
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2.7 Replacing the shock tower
25. Fasten the shock tower to the windscreen valence with 3 structural rivets.
25
25
26. Fasten the lower front suspension cross-member to the shock tower with 2 structural rivets.
26
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2.7 Replacing the shock tower
Caution!
Perform all the welds described as follows with the part still in the jig.
Remove the jig only once the weld areas are cool.
27. Weld the shock tower to the torque box and to the front cross-member at the original weld points in the underbody.
28. Weld the shock tower to the upper diagonal brace at the original weld points.
27
28 28
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2.7 Replacing the shock tower
29. Weld the shock tower to the front cross-member at the original weld points in the passenger compartment interior.
30. Weld the shock tower to windscreen valence at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area.
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29
30
2.7 Replacing the shock tower
31. Weld the upper diagonal brace connected to the tunnel to the shock tower at the original weld points.
32. Weld the lower front suspension cross-member to the shock tower at the original weld points.
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31
32
2.7 Replacing the shock tower
33. Weld the shock tower to the front firewall at the original weld points (passenger compartment interior/exterior).
33
34. Fit the wheel bay cover plate ( see chapter 2.6
).
33
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2.7 Replacing the shock tower
35. Fasten the lower front suspension cross-member with 2/4 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
36. Fasten the casting link cross-member to the shock tower with 4 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
35
36
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2.7 Replacing the shock tower
Fitting the 37. Use the AVDEL FPM-35 gun to apply the 2 selfunderwindscreen covering piercing fastener rivets (Ø 4.8) connecting the underwindscreen covering to the vehicle flank.
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
38. Weld the underwindscreen covering to the upper diagonal brace and to the A-pillar flange at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
38
38
37
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2.7 Replacing the shock tower
39. Reapply the beads of mastic removed previously from the underwindscreen covering.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
39
40. Reapply all the beads of mastic sealant removed previously.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
40
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39
40
40
2.7 Replacing the shock tower
41. Refit the roof skin ( see chapter 3.3
)
42. Refit the front spar ( see chapter 2.5
)
43. Refit the front cross-member ( see chapter 2.4
)
44. Refit the front lateral trellis ( see chapter 2.3
)
45. Refit the fender mounting ( see chapter 2.2
)
46. Refit the fender ( see chapter 2.1
)
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
2.8 Replacing the front end module
Preliminary procedures
ಶ Remove connected parts (complete interior, dashboard)
ಶ Remove the fender ( see chapter 2.1
)
ಶ Remove the fender mounting ( see chapter 2.2
)
ಶ Remove the front lateral trellis ( see chapter 2.3
)
ಶ Remove the roof skin ( see chapter 3.3
)
ಶ Remove the windscreen support rib ( see chapter 3.4
)
ಶ Remove the wheel bay cover plate ( see chapter 2.6
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts •
•
Front end module (A)
Front firewall (B)
•
•
• Lower diagonal braces (C)
• Upper diagonal braces (D)
Underwindscreen covering
Wheel bay cover plate (F)
(E)
• Bumper mounting bracket (G)
• Casting link cross-member (H)
Material necessary • 4 x M8 screws
• 2 self-piercing rivets (Ø 4.8)
• 9 structural rivets (Ø 6.4)
• Bicomponent sealant mastic
Copyright © 2010
E
G
A B
D
C
F
H
2.8 Replacing the front end module
Repair sequence Removing the old part
1. Remove the shock towers ( see chapter 2.7
).
2. Cut the 3 lower diagonal braces near the welds on the centre tunnel and on the lower front suspension cross-member.
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2
2.8 Replacing the front end module
3. Cut the 2 upper diagonal braces near the welds on the centre tunnel.
3
4. Grind the welds between the diagonal braces and the centre tunnel.
Caution!
Carefully check that the centre tunnel is free of cracks.
Caution!
Take the utmost care not to damage the casting joints on the centre tunnel.
4
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2.8 Replacing the front end module
5. Remove the beads of mastic on the front firewall
(lower area/lateral portions).
Danger!
Danger of poisoning due to fume inhalation!
Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
6. Cut the front firewall, following the floorpan/centre tunnel weld line.
Caution!
When cutting the front firewall, take the utmost care not to damage the casting joints on the centre tunnel.
5
6
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2.8 Replacing the front end module
7. Grind the welds between the firewall, floorpan and centre tunnel.
Caution!
Take the utmost care not to damage the casting joints on the centre tunnel.
Caution!
Carefully check that there is no evident buckling on the reinforcements connected to the centre tunnel.
Fitting the new part 8. Mount the front end module in the jig
( see the jigs used for the shock tower - chapter
2.7
).
Warning!
This operation must be carried out with the assistance of another worker, as there is a risk of crushing in the event of the front module falling.
ಶ Prepare the weld area ( see chapter 1.14
).
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7
2.8 Replacing the front end module
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
9. Tack the two shock towers to the upper diagonal brace and to the torque box ( see chapter 2.7
).
9
9
9
Caution!
Perform all the welds described as follows with the part still in the jig.
Remove the jig only once the weld areas are cool.
10. Tack and then weld the three lower diagonal braces to the centre tunnel and to the lower front suspension cross-member at the original weld points.
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2.8 Replacing the front end module
11. Tack and then weld the two upper diagonal braces to the centre tunnel and to the two shock towers at the original weld points.
11
12. Weld and rivet the two shock towers at the original weld points ( see chapter 2.7
).
12
12
12
12
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2.8 Replacing the front end module
13. Fit the front firewall in the relative recess, holding it against the windscreen valence cross-member (A) .
14. Weld the front firewall to the two shock towers
(passenger compartment interior/exterior) at the original weld points.
14
A
13
14
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2.8 Replacing the front end module
15. Weld the front firewall to the front cross-member and to the centre tunnel at the original weld points.
16. Weld the front firewall to the windscreen valence cross-member (passenger compartment interior/ exterior) at to the original weld points.
15
16
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2.8 Replacing the front end module
17. Fasten the casting link cross-member to the shock towers with 4 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
18. Fit the underwindscreen covering ( see chapter 2.7
Replacing the shock tower - step 37 ).
19. Fit the wheel bay cover plate ( see chapter 2.6
).
19
36
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2.8 Replacing the front end module
20. Reapply beads of sealant mastic in the entire portion adjacent to the front firewall (interior/exterior of passenger compartment).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
21. Reapply the beads of sealant mastic in the underbody area ( see chapter 2.7
).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
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20
2.8 Replacing the front end module
22. Refit the windscreen support rib ( see chapter 3.4
)
23. Refit the roof skin ( see chapter 3.3
)
24. Refit the front lateral trellis ( see chapter 2.3
)
25. Refit the fender mounting ( see chapter 2.2
)
26. Refit the fender ( see chapter 2.1
)
ಶ Refit connected parts.
ಶ Check clearances and rectify if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
3.1 Replacing the roof skin
Preliminary procedures
ಶ Remove the connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and relative hinges).
ಶ Remove the fender ( see chapter 2.1
).
ಶ Remove the fender mounting ( see chapter 2.2
).
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Roof skin (A)
Material necessary • 8 x M6 screws
• 32 self-piercing rivets (Ø 4.8x7.5 p/n 81126900)
• 25 self-piercing rivets (Ø 3.9x7.0)
• 4 self-piercing rivets (Ø 3.9x5.5)
• Bicomponent sealant mastic
• Expanded foam
Copyright © 2010
A
3.1 Replacing the roof skin
Repair sequence Removing the old part
1. Remove the beads of mastic in the windscreen adhesive bonding area.
Danger!
Danger of poisoning due to fume inhalation!
Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
1
2. Sand the sections of weld in correspondence with windscreen valence cross-member (passenger compartment interior/exterior).
Caution!
Take care not to damage the casting joints on the shock towers.
1
1
2
2
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1
3.1 Replacing the roof skin
3. Sand the weld points on the A-pillars.
Caution!
Take the utmost care not to damage the casting joints on the front sill pillar.
3
4. Sand the weld points on the C-pillars.
Caution!
Take the utmost care not to damage the casting joints on the rear sill pillar.
4
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3
3.1 Replacing the roof skin
5. Remove all the rivets in the lower windscreen area.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
6. Remove all the rivets in the upper windscreen area.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
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6
5
3.1 Replacing the roof skin
7. Using the 50 mm C-frame, remove all the rivets from the lateral windscreen frame areas.
NOTE!
High strength self-piercing rivets are used for the high strength steel reinforcements of the Apillars.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
8. Remove all the fastener rivets joining the roof skin and the vehicle flank in the upper door area.
NOTE!
High strength self-piercing rivets are used for the high strength steel reinforcements of the Apillars.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
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7 7
8
3.1 Replacing the roof skin
9. Use a 10 mm wrench to remove the 4x2 M6 screws from the rear connector fin joining the upper skin and the vehicle flank.
9
10. Remove all the rivets on the rear connector fin joining the upper skin and the vehicle flank.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Copyright © 2010
10
10
3.1 Replacing the roof skin
11. Remove the beads of mastic from the lower part of the rain gutter.
Danger!
Danger of poisoning due to fume inhalation!
Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
12. Sand the weld points in the lower part of the rain gutter.
11
12
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3.1 Replacing the roof skin
13. Remove the spots of mastic from the rear part of the upper skin.
Danger!
Danger of poisoning due to fume inhalation!
Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
14. Remove the roof skin, detaching the spots of foam on the skin itself in the positions indicated.
13
14
14
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3.1 Replacing the roof skin
Fitting the new part
NOTE!
Before fitting the new part, reapply all the spots of foam removed previously.
• Roof skin/underwindscreen rib joint
• Upper reinforcement cross-members
15. Fit the new part, using the recesses in the windscreen valence cross-member as reference.
ಶ Prepare the weld area ( see chapter 1.14
).
15
16. Tack the edges of the roof skin to keep it in the correct position.
NOTE!
Check the diagonal braces in the windscreen frame.
16
16
15
16
16
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3.1 Replacing the roof skin
17. Refit the connected parts (door, fender, lid).
ಶ Check clearances and rectify if necessary.
Remove the connected parts.
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
Copyright © 2010
3.1 Replacing the roof skin
18. Fasten the front of the roof skin to the underwindscreen rib using 10 self-piercing rivets (Ø 3.9x7.0).
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
19. Fasten the roof skin externally to the vehicle flanks using 10x2 self-piercing rivets (Ø 4.8x7.5 p/n
81126900).
Caution!
The high-strength steel vehicle flank reinforcements in area (A) must only be fastened with high-strength self-piercing rivets.
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
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18
A
19
3.1 Replacing the roof skin
20. Fasten the roof skin internally to the A-pillars using
6x2 self-piercing rivets (Ø 4.8x7.5 p/n 81126900).
Caution!
The high strength A-pillar reinforcements in area
(A) must only be fastened with high strength structural rivets.
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
A
21. Fasten the upper part of the roof skin to the upper reinforcement cross-member using 11 self-piercing rivets (Ø 3.9x7).
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
20 20
21
A
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3.1 Replacing the roof skin
22. Fasten the roof skin to the vehicle flank in correspondence with the C-pillars using 4x2 M6 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
22
23. Use the Avdel FPM-35 gun to apply 2x2 selfpiercing rivets (Ø 3.9x5.5) fastening the roof skin to the vehicle flank in correspondence with the screws applied previously.
24. Fasten the roof skin to the vehicle flank in correspondence with the rear connector fin using
2x2 self-piercing rivets (Ø 3.9x7).
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
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23
24
3.1 Replacing the roof skin
25. Weld the roof skin to the underwindscreen rib at to the original weld points (passenger compartment interior/exterior).
26. Weld the roof skin to the A-pillars at the original weld points.
26
25
25
26
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3.1 Replacing the roof skin
27. Weld the roof skin to the C-pillars at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
27
28. Reapply the beads of mastic removed previously from the windscreen adhesive bonding area.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
28
28
29
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28
3.1 Replacing the roof skin
29. Reapply all the spots of mastic removed previously
(rear rain gutter area/interior of C-pillars).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
29
30. Refit the fender mounting ( see chapter 2.2
).
31. Refit the fender ( see chapter 2.1
).
ಶ Refit connected parts.
ಶ Check clearances and rectify if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
29
3.2 Replacing the windscreen support rib and the windscreen valence cross-member
Preliminary ಶ Remove the connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and procedures relative hinges).
ಶ Remove the fender ( see chapter 2.1
).
ಶ Remove the roof skin ( see chapter 3.1
).
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Windscreen reinforcement support rib (A)
• Windscreen valence cross-member (B)
Material necessary • 3x2 rivets (Ø 6.4)
• Bicomponent sealant mastic
Copyright © 2010
A
B
3.2 Replacing the windscreen support rib and the windscreen valence cross-member
Repair sequence Removing the old part
1. Remove the beads of mastic from the lower part of the underwindscreen rib and the mastic joining the rib itself to the windscreen valence cross-member.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
1
2. Sand the internal sections of weld joining the windscreen valence cross-member with the front firewall.
NOTE!
Do not remove any other material from the front firewall.
2
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3.2 Replacing the windscreen support rib and the windscreen valence cross-member
3. Sand the exterior sections of weld joining to the underwindscreen rib.
NOTE!
Do not remove any other material from the front firewall.
3
4. Sand the sections of weld joining the underwindscreen rib and the windscreen valence cross-member.
4
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3.2 Replacing the windscreen support rib and the windscreen valence cross-member
5. Sand the sections of weld joining the underwindscreen rib and the underwindscreen covering.
6. Remove the 3x2 structural rivets at the ends of the windscreen valence cross-member fastening the part to the two front shock towers.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Copyright © 2010
6
5
6
3.2 Replacing the windscreen support rib and the windscreen valence cross-member
7. Sand the weld beads joining the windscreen valence cross-member and the two front shock towers.
NOTE!
Do not remove any other material from the two shock towers.
7
Fitting the new part 8. Fit the windscreen valence cross-member in the relative seats on the shock towers.
ಶ Prepare the weld area ( see chapter 1.14
).
8
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3.2 Replacing the windscreen support rib and the windscreen valence cross-member
9. Fit the underwindscreen rib against the windscreen valence cross-member.
10. Tack the underwindscreen rib to both the windscreen valence cross-member and the underwindscreen covering.
10
10
10
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
11. Fasten the windscreen valence cross-member to the shock towers using 3x2 structural rivets (Ø 6.4).
11
11
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3.2 Replacing the windscreen support rib and the windscreen valence cross-member
12. Weld the windscreen valence cross-member to the two front shock towers at the original weld points.
12
13. Weld the underwindscreen rib to the underwindscreen covering at the original weld points.
13
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3.2 Replacing the windscreen support rib and the windscreen valence cross-member
14. Weld the underwindscreen rib to the front firewall at the original weld points.
14
15. Weld the windscreen valence cross-member to the front firewall at the original weld points.
15
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3.2 Replacing the windscreen support rib and the windscreen valence cross-member
16. Weld the windscreen valence cross-member to the underwindscreen rib at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
16
17. Reapply the beads of mastic sealant removed previously.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
Copyright © 2010
17
3.2 Replacing the windscreen support rib and the windscreen valence cross-member
18. Refit the roof skin ( see chapter 3.1
).
19. Refit the fender ( see chapter 2.1
).
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
3.3 Replacing the complete vehicle flank
Preliminary procedures
ಶ Remove the connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and relative hinges)
ಶ Remove the fender ( see chapter 2.1
)
ಶ Remove the fender mounting ( see chapter 2.2
)
ಶ Remove the roof skin ( see chapter 3.1
)
ಶ Remove the rear spoiler ( see chapter 4.1
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Complete vehicle flank (A)
• Rear diagonal brace (B)
Material necessary • 5 x M8 screws
• 1 x M6 nut
• 38 self-piercing rivets (Ø 4.8x7.5)
• 38 self-piercing rivets (Ø 3.9x7.0)
• 5 self-piercing rivets (Ø 3.9x7.0 p/n 81126700)
• Bicomponent sealant mastic
• Expanded foam
Copyright © 2010
B
A
3.3 Replacing the complete vehicle flank
Repair sequence Removing the old part
1. Using the AVDEL gun with the 45 mm C frame, remove the rivets from the front pillar.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
1
2. Using the AVDEL gun with the 45 mm C frame, remove the rivets from the door surround (lower area) in correspondence with the sill.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Copyright © 2010
2
1
1
1
3.3 Replacing the complete vehicle flank
3. Using the AVDEL gun with the 45 mm C frame, remove the rivets in correspondence with the lower rear bumper reinforcement and the lateral crash reinforcement.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
3
4. Sand the underdoor weld points on the sill tubular element and on the A-pillar flange.
Caution!
Check that the front sill pillar casting joints are free from cracks or buckling.
If any damage is noted, replace the sill ( see chapter 3.5
).
Caution!
Take care not to damage the sill tubular element.
4
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4
3.3 Replacing the complete vehicle flank
5. Remove the beads of mastic and foam from the upper flank connector cross-members.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
5
6. Sand the weld points on the upper flank connector cross-members.
Caution!
Take care not to damage the upper flank connector cross-members.
6
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5
6
3.3 Replacing the complete vehicle flank
7. Using the AVDEL gun with the 100 mm C frame, remove the rivets from the upper cross-members.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
7
8. Remove the internal and external beads of mastic in the area surrounding the air intake and the rear screen
(interior/exterior of passenger compartment).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
8
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7
7
8
3.3 Replacing the complete vehicle flank
9. Use a 10 mm wrench to remove the M6 nut fastening the vehicle flank to the rear screen bulkhead substructure.
10. Sand the welds joining the vehicle flank with the rear screen bulkhead substructure.
NOTE!
Take care not to remove any other material from the rear screen bulkhead substructure.
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10
9
3.3 Replacing the complete vehicle flank
11. Sand the four weld spots joining the vehicle flank and the rear screen bulkhead .
11
12. Remove the beads of sealant mastic in correspondence with the front sill pillar.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
12
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11
3.3 Replacing the complete vehicle flank
13. Sand the weld beads joining the vehicle flank with the upper casting of the front sill pillar.
Caution!
Take the utmost care not to damage the diecast joints.
Check that the front sill pillar die-cast joints are free from cracks.
If any damage is noted, replace the sill ( see chapter 3.5
).
13
14. Use a 13 mm wrench to remove the 2 M8 screws from the front pillar (interior of vehicle).
NOTE!
When removing the screws, take the utmost care not to let them fall into the front door pillar.
14
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3.3 Replacing the complete vehicle flank
15. Remove the 4 self-piercing rivets in the inner area of the rear lid in correspondence with the two brackets fastened to the rear trellis.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
16. Remove the rear diagonal brace, sanding the weld points at the ends.
Caution!
Check that the rear sill pillar casting joints are free from cracks or buckling.
If any damage is noted, replace the sill ( see chapter 3.5
).
NOTE!
Do not remove any other material from the rear sill pillar and from the casting for the rear shock tower.
Copyright © 2010
16
15 15
16
3.3 Replacing the complete vehicle flank
17. Remove the 2 fastener rivets joining the vehicle flank and the rear flank connector cross-member.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
18. Remove the beads of sealant mastic in correspondence with the rear sill pillar and the rear screen bulkhead (rear lid area).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
Copyright © 2010
17
18
3.3 Replacing the complete vehicle flank
19. Sand any joint weld beads between the vehicle flank and the upper casting of the rear sill pillar (rear lid area).
Caution!
Take the utmost care not to damage the diecast joints.
Check that the rear sill pillar die-cast joints are free from cracks.
If any damage is noted, replace the sill ( see chapter 3.5
).
20. Using the AVDEL FPM-35 gun, remove the 5 selfpiercing rivets joining the vehicle flank with the rear trellis.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
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20
19
3.3 Replacing the complete vehicle flank
21. Remove the 4 self-piercing rivets joining the vehicle flank with the lateral reinforcement.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
22. Use a 13 mm wrench to remove the 3 M8 fastener screws joining the vehicle flank and the rear sill pillar.
NOTE!
When removing the screws, take the utmost care not to let them fall into the front door pillar.
21
22
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3.3 Replacing the complete vehicle flank
23. Remove the beads of sealant mastic in correspondence with the rear sill pillar (interior of passenger compartment).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
24. Sand the joint weld beads between the vehicle flank and the upper casting of the rear sill pillar (interior of passenger compartment).
Caution!
Take the utmost care not to damage the diecast joints.
Check that the rear sill pillar die-cast joints are free from cracks.
If any damage is noted, replace the sill ( see chapter 3.5
).
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23
24
3.3 Replacing the complete vehicle flank
25. Check that the front fender mounting bracket is not damaged.
If necessary, adjust the gap from the sill wall to the exterior of the bracket to the correct value of
115 mm.
26. Check that the rear fender mounting bracket is not damaged.
If necessary, adjust the gap from the vertical wall of the pillar reinforcement to the correct value of
115 mm.
115 mm
115 mm
Copyright © 2010
3.3 Replacing the complete vehicle flank
Fitting the new part 27. Fit the vehicle flank in its seat.
Warning!
This operation must be carried out with the assistance of another worker, as the size of the vehicle flank makes is difficult to position correctly.
ಶ Prepare the weld area ( see chapter 1.14
).
28. Fit the 2 M8 screws onto the front pillar.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
28
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3.3 Replacing the complete vehicle flank
29. Fit the 3 M8 screws onto the rear pillar.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
30. Fit the external tower and the relative jigs to ensure that the vehicle flank is positioned correctly.
ಶ
ಶ
Fit the rear spoiler and fasten in position.
Check the clearance dimensions, rework if necessary.
Remove the rear spoiler.
NOTE!
Check that the vehicle flank is correctly fitted onto the upper reinforcement cross-members.
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29
3.3 Replacing the complete vehicle flank
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
31. Tighten the 5 M8 screws applied previously.
31
31
32. Fasten the vehicle flank to the rear screen bulkhead substructure with an M6 nut.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
32
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3.3 Replacing the complete vehicle flank
33. Using the AVDEL FPM-35 gun, fasten the vehicle flank to the front and rear trellises with 5 self-piercing rivets (Ø 3.9x7.0 p/n 81126700).
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
34. Fasten the vehicle flank to the rear flank connector cross-member with 2 self-piercing rivets
(Ø 3.9x7.0).
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
33
34
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3.3 Replacing the complete vehicle flank
35. Fasten the vehicle flank to the lateral reinforcement with 4 self-piercing rivets (Ø 3.9x7.0).
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
36. Fasten the vehicle flank to the A-pillar with 22 selfpiercing rivets (Ø 4.8x7.5).
Caution!
The high strength A-pillar reinforcements must only be fastened with high strength structural rivets.
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
36
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35
36
36
36
3.3 Replacing the complete vehicle flank
37. Fasten the vehicle flank to the kickplate (lower part of door surround) with 22 self-piercing rivets
(Ø 3.9x7.0).
Caution!
The high strength A-pillar reinforcements must only be fastened with high strength structural rivets.
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
38. Fasten the flank to the lower rear fender reinforcement with 6 self-piercing rivets (Ø 3.9x7.0)
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
38
37
Copyright © 2010
3.3 Replacing the complete vehicle flank
NOTE!
Check that the vehicle flank is correctly fitted onto the upper reinforcement cross-members.
39.
Using the AVDEL gun with the 100 mm C-frame, fasten the vehicle flank to the upper reinforcement crossmembers with 8x2 self-piercing rivets (Ø 4.8x7.5).
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
Rivet the passenger compartment interior side first and then the passenger compartment exterior side.
Caution!
Perform all the welds described as follows with the part still in the jig.
Remove the jig only once the weld areas are cool.
40. Weld the vehicle flank to the sill tubular element and to the A-pillar flange at the original weld points.
39
40
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40
39
39
3.3 Replacing the complete vehicle flank
41. Weld the vehicle flank to the upper casting of the front sill pillar at the original weld points.
41
42. Insert the 4 self-piercing rivets (Ø 3.9x7.0) in the inner area of the rear lid in correspondence with the two brackets fastened to the rear trellis.
NOTE!
Insert the new self-piercing rivets next to the old rivet holes.
42 42
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3.3 Replacing the complete vehicle flank
43. Weld the vehicle flank to the upper casting of the rear sill pillar at the original weld points (rear lid area).
44. Fasten the rear diagonal brace by welding the ends at the original weld points.
44
43
44
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3.3 Replacing the complete vehicle flank
45. Weld the vehicle flank to the upper casting of the rear sill pillar at the original weld points (passenger compartment interior).
46. Weld the vehicle flank to the upper reinforcement cross-members at the original weld points.
46
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45
46
3.3 Replacing the complete vehicle flank
47. Weld the vehicle flank to the rear screen bulkhead with 4 spot welds.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
47
48. Reapply the beads of sealant mastic in the area surrounding the air intake and the rear screen
(interior/exterior of passenger compartment).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
48
Copyright © 2010
47
48
3.3 Replacing the complete vehicle flank
49. Reapply the beads of sealant mastic in correspondence with the upper casting of the rear sill pillar (interior/exterior of passenger compartment).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
49
50. Reapply the beads of sealant mastic in correspondence with the upper casting of the front sill pillar.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
50
Copyright © 2010
49
3.3 Replacing the complete vehicle flank
51. Reapply the beads of sealant mastic on the upper reinforcement cross-members.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
51
52. Refit the roof skin ( see chapter 3.1
)
53. Refit the rear spoiler ( see chapter 4.1
)
54. Refit the fender mounting ( see chapter 2.2
)
55. Refit the fender ( see chapter 2.1
)
ಶ Refit connected parts.
ಶ Check clearances and rectify if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
51
3.4 Replacing the lateral crash reinforcement
Preliminary procedures
ಶ
ಶ
ಶ
ಶ
ಶ
ಶ
Remove connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and relative hinges)
Remove the fender ( see chapter 2.1
)
Remove the fender mounting ( see chapter 2.2
)
Remove the roof skin ( see chapter 3.1
)
Remove the complete vehicle flank ( see chapter 3.3
)
Place the vehicle on the vehicle bench.
Replacement parts •
•
Complete vehicle flank (A)
Lateral crash reinforcement (B)
Material necessary • 5 x M8 screws.
B
A
Copyright © 2010
3.4 Replacing the lateral crash reinforcement
Repair sequence Removing the old part
1. Use a 13 mm wrench to remove the 5 M8 fastener screws joining the lateral crash reinforcement, the rear sill pillar and the extruded elements (A) .
NOTE!
When removing the screws, take the utmost care not to let them fall into the rear door pillar.
1
A
Fitting the new part 2. Fit the rear tower and mount the lateral crash reinforcement in the jig.
1
1
Copyright © 2010
3.4 Replacing the lateral crash reinforcement
Fitting the new part 3. Fasten the lateral crash reinforcement to the rear sill pillar and to the extruded elements (A) with 5 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
3
A
4. Refit the vehicle flank ( see chapter 3.3
).
NOTE!
Carry out final adjustment of the lateral crash reinforcement only after refitting the vehicle flank.
3
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3
3.4 Replacing the lateral crash reinforcement
5. Refit the roof skin ( see chapter 3.1
).
6. Refit the fender mounting ( see chapter 2.2
).
7. Refit the fender ( see chapter 2.1
).
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
3.5 Replacing the sill
Preliminary procedures
Replacement parts
ಶ Remove connected parts (interior trim, windows, lateral seals, front lid and relative hinges, rear lid and relative hinges, doors)
ಶ Remove the rear end module ( see F458 Italia workshop manual)
ಶ Remove the fender ( see chapter 2.1
)
ಶ Remove the fender mounting ( see chapter 2.2
)
ಶ Remove the rear spoiler ( see chapter 4.1
)
ಶ Remove the roof skin ( see chapter 3.1
)
ಶ Remove the underwindscreen covering ( see chapter 2.6 Replacing the shock tower )
ಶ Remove the complete vehicle flank ( see chapter 3.3
)
ಶ Remove the lateral crash reinforcement ( see chapter 3.4
)
ಶ Remove the rear firewall and mountings ( see chapter 3.6
)
ಶ Place the vehicle on the vehicle bench.
• Sill (A)
E
• A-pillar flange (B)
• Wheel bay cover plate (C)
• Torque box (only if necessary) (D)
• Upper diagonal brace (only if necessary) (E)
• Front covering (F)
C
F G
• Rear covering (G)
• Internal pillar bracing (H)
• External pillar bracing (I)
• Front flank mounting bracket (J)
• Lateral firewall mounting (K)
D B
A H
Copyright © 2010
K
J
I
3.5 Replacing the sill
Material necessary • 9 structural rivets (Ø 4.8x9.0)
• 31 structural rivets (Ø 6.4x19.2)
Repair sequence Removing the old part
1. Remove the wheel bay cover plate ( see chapter 2.7
).
1
Copyright © 2010
3.5 Replacing the sill
2.
Cut the sill near the weld beads joining to the torque box, the upper diagonal brace, the fuel tank cross- member and the semi-floorpan.
Caution!
Work with the utmost caution to prevent damaging the internal diagonal braces connected to the centre tunnel, the upper diagonal brace and the torque box.
3.
Remove the structural fastener rivets joining the sill and the semi-floorpan.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
2
2
2
2
2
3 3
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3.5 Replacing the sill
4.
Sand the joint weld beads between the sill, the semifloorpan and the diagonal braces connecting to the centre tunnel.
NOTE!
Do not remove any other material from the diagonal braces connecting to the centre tunnel.
4 4
5.
Remove the beads of sealant mastic in correspondence with the 3 structural fastener rivets joining the front sill pillar and the torque box.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
Copyright © 2010
5
3.5 Replacing the sill
6. Remove the 6 structural fastener rivets joining the front sill pillar and the torque box (interior/exterior of passenger compartment).
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
6
7. Sand the joint weld beads between the front sill pillar and the torque box.
NOTE!
Do not remove any other material from the torque box.
7
6
7
Copyright © 2010
3.5 Replacing the sill
8.
Sand the joint weld beads between the sill and the reinforcement (A) .
NOTE!
Do not remove any other material from the torque box/centre tunnel reinforcement and from the torque box.
A
8
9.
Remove the beads of sealant mastic in correspondence with the weld beads in the underbody between the sill, the torque box and the reinforcement (A) .
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
Copyright © 2010
A
9
3.5 Replacing the sill
10.
Sand the joint weld beads in the underbody between the sill, the torque box and the reinforcement (A) .
NOTE!
Do not remove any other material from the reinforcement (A) and from the torque box.
11.
Sand the internal and external joint weld beads between the sill and the upper diagonal brace.
NOTE!
Do not remove any other material from the upper diagonal brace.
11
Copyright © 2010
A
10
11
3.5 Replacing the sill
12.
Remove the structural fastener rivets joining the sill and the internal B-pillar bracing.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
13.
Sand the joint spot welds between the sill and the internal B-pillar bracing.
NOTE!
Do not remove any other material from the sill connector cross-member.
Copyright © 2010
12
13
3.5 Replacing the sill
14.
Gradually sand the joint weld beads between the sill connector cross-member and the sill itself.
NOTE!
Do not remove any other material from the sill connector cross-member.
NOTE!
The facilitate the operation described above, remove the external bracing.
15.
Gradually sand the joint weld beads between the fuel tank cross-member and the upper sill casting.
NOTE!
Do not remove any other material from the fuel tank cross-member.
Copyright © 2010
14
15
15
3.5 Replacing the sill
16.
Remove the 8 structural fastener rivets (Ø 6.4x19.2) in the underbody joining the sill, the lower extruded element (C) and the sill connector cross-member.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
C
16
16 16
16
17.
Sand the joint weld beads in the underbody between the sill, the lower extruded element (C) and the sill connector cross-member.
Caution!
Work with the utmost caution to prevent damaging the lower extruded element (C) .
NOTE!
Do not remove any other material from the sill connector cross-member.
C
17
17 17
17
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3.5 Replacing the sill
18.
Sand the remaining weld beads in the underbody to facilitate removal of the sill.
Fitting the new part 19.
Fit the external tower, the mount the sill in the jig.
ಶ Prepare the weld area ( see chapter 1.14
).
18
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3.5 Replacing the sill
NOTE!
Check that the two castings of the A-pillar are fitted correctly into the torque box and the upper diagonal brace.
Check that the semi-floorpan is fitted correctly.
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
20.
Tack the sill to the torque box and to the upper diagonal brace.
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20
20
20
3.5 Replacing the sill
21.
Tack the sill to the sill connector cross-member and to the fuel tank cross-member (vehicle interior/ exterior).
Caution!
This operation must only be performed with the two cross-members mounted in the jig.
NOTE!
Check that the upper casting of the B-pillar is fitted correctly into the fuel tank cross-member.
22.
Tack the sill to the internal diagonal braces connecting to the centre tunnel.
NOTE!
Check again that the semi-floorpan is fitted correctly.
21
21
21
22 22
21
21
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3.5 Replacing the sill
23. Weld the front sill pillar to the torque box at the original weld points (interior/exterior of passenger compartment).
23
24. Fasten the front sill pillar and the torque box (interior/ exterior of passenger compartment) with 6 structural rivets (Ø 6.4x19.2).
24
24
23
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3.5 Replacing the sill
25.
Weld the sill to the torque box and to the reinforcement
(A) at the original weld points in the underbody.
26.
Weld the rear sill pillar to the fuel tank cross-member at the original weld points.
A
25
26
26
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3.5 Replacing the sill
27. Weld the sill to the upper diagonal brace at the original interior and exterior weld points.
27
28. Weld the sill to the reinforcement (A) at the original weld points.
A
28
27
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3.5 Replacing the sill
29.
Weld the sill tubular element to the semi-floorpan and to the diagonal braces connecting to the centre tunnel at the original weld points.
29 29
30.
Fasten the semi-floorpan to the sill tubular element, starting at the bottom and working upward, with
9 structural rivets (Ø 4.8x9.0).
NOTE!
When reinstalling the electrical system, apply a protective pad to prevent contact between the cables and any protruding rivets.
Copyright © 2010
30 30
3.5 Replacing the sill
31.
Weld the sill to the sill connector cross-member
(vehicle interior/exterior) at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area.
Caution!
Remove the jigs retaining the sill only after the welds have cooled.
32.
Mount the lower extruded element (C) in the jig.
31
C
31
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3.5 Replacing the sill
33.
Weld the lower extruded element (C) to the sill and to the sill connector cross-member at the original weld points.
34.
Fasten the lower extruded element (C) to the sill and to the sill connector cross-member with 8 structural rivets (Ø 6.4x19.2).
C
33
33 33
33
C
34
34 34
34
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3.5 Replacing the sill
35.
Fit the external bracing and weld to the sill.
ಶ Reapply corrosion inhibitor to the new weld beads.
36.
Fit the internal bracing and weld to the sill.
35
36
Copyright © 2010
3.5 Replacing the sill
37.
Fasten the internal and external bracing to the sill with 17 structural rivets (Ø 6.4x19.2).
38.
Fit the front covering, with the two holes (D) on the covering itself aligned with the two threaded holes in the front sill pillar.
37
37
37
D
Copyright © 2010
3.5 Replacing the sill
39. Weld the front covering to the sill in correspondence with the holes in the covering itself.
ಶ Reapply corrosion inhibitor to the weld beads between the two bracings. 39
39
40. Fit the rear covering, bringing it up against the rear sill pillar.
NOTE!
Check that the rear covering is flush with the front covering fitted previously.
Copyright © 2010
3.5 Replacing the sill
41. Weld the rear covering to the sill in correspondence with the holes in the covering itself.
42. Fit the front flank mounting bracket as shown in the diagram aside.
129.5 mm
41
41
32 mm
11 mm
26 mm
Copyright © 2010
3.5 Replacing the sill
43.
Weld the front flank mounting bracket to the sill and to the external bracing.
44.
Fit the A-pillar flange against the front sill pillar, with the notch in the flange over the lower sill pillar weld.
43
Copyright © 2010
3.5 Replacing the sill
45.
Weld the A-pillar flange to the sill and to the extruded hinge mounts (E) on the sill.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
45
46.
Reapply the beads of mastic sealant removed previously.
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
Copyright © 2010
46
E
46
3.5 Replacing the sill
47. Refit the wheel bay cover plate ( see chapter 2.7
)
48. Refit the subframe connector extruded element ( see chapter 3.8
)
49. Refit the rear shock tower casting ( see chapter 3.9
)
50. Refit the rear firewall and mountings ( see chapter 3.6
)
51. Refit the front/rear lateral trellises ( see chapter 3.10
)
52. Refit the lateral crash reinforcement ( see chapter 3.4
)
53. Refit the complete vehicle flank ( see chapter 3.3
)
54. Refit the rear spoiler ( see chapter 4.1
)
55. Refit the roof skin ( see chapter 3.1
)
56. Refit the underwindscreen covering ( see chapter 2.6 Replacing the shock tower )
57. Refit the rear end module ( see F458 Italia workshop manual)
58. Refit the fender mounting ( see chapter 2.2
)
59. Refit the fender ( see chapter 2.1
)
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
3.6 Replacing the rear firewall and mountings
Preliminary procedures
ಶ Remove connected parts (interior trim, windows, lateral seals, rear lid and relative hinges, doors)
ಶ Remove the rear end module ( see F458 Italia workshop manual)
ಶ Place the vehicle on the vehicle bench.
Replacement parts
• Rear firewall (A)
• RH lateral firewall mounting (B)
• LH lateral firewall mounting (C)
Material necessary • 16 x M6 screws
• 36 structural rivets (Ø 4.8x10.0)
• 6 threaded M6x21.5 rivets
Copyright © 2010
B
A
C
3.6 Replacing the rear firewall and mountings
Repair sequence Removing the old part
1. Remove the beads of mastic sealant on the upper portion of the rear firewall (passenger compartment interior).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
2. Remove the beads of sealant mastic on the perimeter of the rear firewall (engine area).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
2
1
1
2
Copyright © 2010
3.6 Replacing the rear firewall and mountings
3. Use a hex headed wrench (Ø 4.0) to remove the 16
M6 fastener screws joining the firewall and the rear bulkhead.
3
3
3
4. Remove the threaded fastener rivets (M6x21.5) joining the rear firewall and the fuel tank crossmember.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
4
3
Copyright © 2010
3.6 Replacing the rear firewall and mountings
5. Remove the structural rivets fastening the rear firewall (engine area).
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
5
6. Remove the structural fastener rivets joining the firewall, the fuel tank cross-member and the sill connector cross-member.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
6
Copyright © 2010
6
5
6
3.6 Replacing the rear firewall and mountings
7. Remove the structural fastener rivets joining the firewall and the relative mountings.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
7
8. Sand the joint weld beads between the RH and LH firewall mountings and the rear sill pillars.
Caution!
Check that the rear sill pillar casting joints are free from cracks or buckling.
If any damage is noted, replace the sill ( see chapter 3.5
).
8
8
Copyright © 2010
7
3.6 Replacing the rear firewall and mountings
Fitting the new part 9. Fit the RH and LH firewall mountings up against the sill tubular elements and tack in position.
ಶ Prepare the weld area ( see chapter 1.14
).
9
9
10. Fit the rear firewall in the seat, bringing it up against the relative mountings.
NOTE!
Fit the rear firewall from the passenger compartment interior side to facilitate installation of the new part.
Copyright © 2010
3.6 Replacing the rear firewall and mountings
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
11. Fasten the firewall to the sill connector crossmember with 16 structural rivets (Ø 4.8x10.0).
12. Fasten the back of the firewall (engine area) with 10 structural rivets (Ø 4.8x10.0).
11
12 12
Copyright © 2010
3.6 Replacing the rear firewall and mountings
13. Weld the RH and LH firewall mountings to the rear sill pillars at the original weld points.
13
13
14. Fasten the firewall to the relative RH and LH mountings with 2 structural rivets (Ø 4.8x10.0).
14
Copyright © 2010
14
3.6 Replacing the rear firewall and mountings
15. Fasten the firewall to the fuel tank cross-member with 8 structural rivets (Ø 4.8x10.0).
15
16. Fasten the firewall to the centre of the fuel tank cross-member with 6 threaded rivets (M6x21.5).
16
15
Copyright © 2010
3.6 Replacing the rear firewall and mountings
17. Fasten the rear bulkhead to the firewall with 16 M6 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
ಶ Reapply corrosion inhibitor to the welds on the RH and LH firewall mountings and apply a coat of primer to the repair areas.
17
18. Reapply the beads of mastic sealant on the upper portion of the rear firewall (passenger compartment interior).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
17
17
18
18
Copyright © 2010
17
3.6 Replacing the rear firewall and mountings
19. Reapply the beads of sealant mastic on the perimeter of the rear firewall (engine area).
Danger!
Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Wear breathing protection, protective gloves and safety glasses.
19
19
20. Refit the rear end module ( see F458 Italia workshop manual)
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
3.7 Replacing the fuel tank cross-member
Preliminary procedures
ಶ Remove connected parts (interior trim, rear screen, lateral seals, rear lid and relative hinges)
ಶ Remove the rear end module ( see F458 Italia workshop manual )
ಶ Remove the rear firewall ( see chapter 3.6
)
ಶ Remove the lateral firewall mountings ( see chapter 3.6
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Fuel tank cross-member (A)
• Rear screen bulkhead substructure (B)
• Rear firewall (C)
• Lateral firewall mountings (D)
Material necessary • 16 x M8 screws
A
B
D
C
Copyright © 2010
D
3.7 Replacing the fuel tank cross-member
Repair sequence Removing the old part
1. Use a 13 mm wrench to remove the 8 screws fastening the mountings (A) to the fuel tank crossmember.
A
1
1
2. Use a 13 mm wrench to remove the 8 screws fastening the internal tubular elements.
2 2
Copyright © 2010
3.7 Replacing the fuel tank cross-member
3. Cut the fuel tank cross-member near the die-cast joints on the rear sill pillars.
Caution!
Take the utmost care not to damage the diecast joints.
Check that the rear sill pillar die-cast joints are free from cracks.
If any damage is noted, replace the sill ( see chapter 3.5
).
4. Gradually grind the weld beads between the fuel tank cross-member and the casting joints on the rear sill pillars.
Caution!
Take the utmost care not to damage the diecast joints.
4
4
4
3
Copyright © 2010
3.7 Replacing the fuel tank cross-member
Fitting the new part 5. Mount the fuel tank cross-member in the jig.
ಶ Prepare the weld area ( see chapter 1.14
).
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
6. Tack the fuel tank cross-member to the casting joints on the rear sill pillars.
NOTE!
Check that the fuel tank cross-member is perfectly horizontal.
Copyright © 2010
6
3.7 Replacing the fuel tank cross-member
7. Weld the fuel tank cross-member to the casting joints on the rear sill pillars.
Caution!
Remove the jig retaining the fuel tank crossmember only after the welds have cooled.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
8. Fasten the mountings (A) to the fuel tank crossmember with 8 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
A
7
7
7
8
8
Copyright © 2010
3.7 Replacing the fuel tank cross-member
9. Fasten the internal tubular elements removed previously with 8 M8 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
9
10. Refit the lateral firewall mountings ( see chapter 3.6
).
11. Refit the rear firewall ( see chapter 3.6
).
12. Refit the rear end module ( F458 Italia workshop manual ).
ಶ Refit connected parts.
ಶ Check clearances and rectify if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
9
3.8 Replacing the subframe connector extruded section
Preliminary procedures
ಶ Remove connected parts (complete interior, rear lid and relative hinges, lights, bumper and rear grilles)
ಶ Remove the rear end module ( see F458 Italia workshop manual )
ಶ Remove the rear spoiler ( see chapter 4.1
)
ಶ Remove the roof skin ( see chapter 3.1
)
ಶ Remove the complete vehicle flank ( see chapter 3.3
)
ಶ Remove the lateral crash reinforcement ( see chapter 3.4
)
ಶ Remove the front/rear lateral trellises ( see chapter 3.10
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Subframe connector extruded element (A)
• Lateral crash reinforcement tubular element (B)
• Rear mounting bracket for rear flank (C)
• Rear pillar reinforcement (D)
• Suspension casting reinforcement (E)
Material necessary -
LH
C
D
B
RH
E
A
B
D
Copyright © 2010
E
C
A
3.8 Replacing the subframe connector extruded section
Repair sequence Removing the old part
1. Cut the lateral crash reinforcement tubular element, the rear pillar reinforcement and the suspension casting reinforcement in the area next to the weld beads.
Caution!
Take the utmost care not to damage the casting joints on the rear sill pillar.
1
1
2. Grind the joint weld beads between the lateral crash reinforcement tubular element, the rear pillar reinforcement and the suspension casting reinforcement.
NOTE!
Do not remove any other material from the rear sill pillar (D) and the upper external diagonal brace (E) .
2
2
D
E
Copyright © 2010
1
2
3.8 Replacing the subframe connector extruded section
Fitting the new part 3. Mount the subframe connector extruded element in the jig.
ಶ Prepare the weld area ( see chapter 1.14
).
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
4. Fit the lateral crash reinforcement tubular element in the relative seat on the sill and tack.
Copyright © 2010
4
3.8 Replacing the subframe connector extruded section
5. Fit the rear pillar reinforcement in the relative seats on the lateral crash reinforcement tubular element and the subframe connector extruded element and tack.
5
5
5
6. Check that the part is correctly positioned then weld the lateral crash reinforcement tubular element to the sill and to the subframe connector extruded element at the original weld points.
6
Copyright © 2010
6
3.8 Replacing the subframe connector extruded section
7. Weld the rear pillar reinforcement to the sill and to the lateral crash reinforcement at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area. 7
7
7
7
7
8. Fit the suspension casting reinforcement in the seat between the two extruded elements fitted previously.
Tack the suspension casting reinforcement at the ends.
8
8
8
Copyright © 2010
3.8 Replacing the subframe connector extruded section
9. Weld the suspension casting reinforcement to the subframe connector extruded element and to the upper external diagonal brace at the original weld points.
Caution!
Remove the jig retaining the subframe connector extruded element only after the welds have cooled.
ಶ Apply new corrosion inhibitor to the entire repair area.
9
10. Fit the external tower then mount the flank mounting bracket (A) in the jig.
NOTE!
Check that the distance between the outer edge of the bracket (A) and the sill wall is 115 mm.
9
A
115 mm
Copyright © 2010
3.8 Replacing the subframe connector extruded section
11. Weld the rear bracket (A) to the subframe connector extruded element and to the two extruded elements fitted previously.
A
11
11
12. Refit the front/rear lateral trellises ( see chapter 3.10
)
13. Refit the lateral crash reinforcement ( see chapter 3.4
)
14 . Refit the complete vehicle flank ( see chapter 3.3
)
15. Refit the rear spoiler ( see chapter 4.1
)
16. Refit the roof skin ( see chapter 3.1
)
17. Refit the rear end module ( see F458 Italia workshop manual )
Copyright © 2010
3.8 Replacing the subframe connector extruded section
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
3.9 Replacing casting for rear shock tower
Preliminary ಶ Remove connected parts (complete interior, rear lid and relative hinges, lights, bumper and rear grilles) procedures
ಶ Remove the rear end module ( see F458 Italia workshop manual )
ಶ Remove the rear spoiler ( see chapter 4.1
)
ಶ Remove the roof skin ( see chapter 3.1
)
ಶ Remove the complete vehicle flank ( see chapter 3.3
)
ಶ Remove the front/rear lateral trellises ( see chapter 3.10
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts •
•
Casting for rear shock tower (A)
Front/rear lateral trellises (B)
• Upper external diagonal brace (C)
Material necessary •
•
4 x M8 screws
2 structural rivets (Ø 6.4)
A
C
B
Copyright © 2010
3.9 Replacing casting for rear shock tower
Repair sequence Removing the old part
1. Cut the upper external diagonal brace near the weld beads with the die-cast sill joint.
Caution!
When making separating cuts, take the utmost care not to damage the casting joints.
Check the location of any internal crossmember reinforcement on the new part in order to cut correctly.
2. Remove the 2 structural fastener rivets joining the upper external diagonal brace and the die-cast sill joint.
NOTE!
Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
2
1
Copyright © 2010
3.9 Replacing casting for rear shock tower
3. Sand the sections of joint weld between the upper external diagonal brace and the suspension casting reinforcement.
NOTE!
Do not remove any other material from the upper external diagonal brace.
3
4. Use a 13 mm wrench to remove the 4 M8 screws fastening the internal tubular element.
4
Copyright © 2010
4
3.9 Replacing casting for rear shock tower
5. Grind the joint weld beads between the upper external diagonal brace and the die-cast sill joint.
Caution!
Take the utmost care not to damage the diecast sill joint.
If the event of damage, the sill must be replaced
( see chapter 3.5
).
5
6. Grind all the weld beads sanded previously.
5
Copyright © 2010
3.9 Replacing casting for rear shock tower
Fitting the new part 7. Mount the casting for the rear shock tower in the jig.
ಶ Prepare the weld area ( see chapter 1.14
).
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
8. Fasten the casting for the rear shock tower to the shock tower itself with 3 M12 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
8
Copyright © 2010
8
3.9 Replacing casting for rear shock tower
9. Fit the upper external diagonal brace against the relative seat on the die-cast rear sill pillar joint and tack in position.
Check that the upper external diagonal brace is correctly positioned. 9
10. Fasten the upper external diagonal brace to the diecast sill joint with 2 structural rivets (Ø 6.4x19.2).
10
Copyright © 2010
3.9 Replacing casting for rear shock tower
11. Weld the upper external diagonal brace to the diecast sill joint at the original weld points.
11 11
12. Weld the upper external diagonal brace to the casting for the rear shock tower at the original weld points.
Caution!
Remove the jig retaining the casting for the rear shock tower only after the welds have cooled.
12
Copyright © 2010
3.9 Replacing casting for rear shock tower
13. Refit the front/rear lateral trellises ( see chapter 3.10
)
14. Refit the complete vehicle flank ( see chapter 3.3
)
15. Refit the rear spoiler ( see chapter 4.1
)
16. Refit the roof skin ( see chapter 3.1
)
17. Refit the rear end module ( see F458 Italia workshop manual)
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
3.10 Replacing the rear lateral trellis
Preliminary procedures
ಶ Remove connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and relative hinges)
ಶ Remove the roof skin ( see chapter 3.3
)
ಶ Remove the complete vehicle flank ( see chapter 3.5
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Rear lateral trellis (A)
• Angle piece for flank mounting bracket (B)
• Central substructure mounting bracket (C)
• Central substructure mounting bracket (D)
Material necessary • 1 x M8 screw
• 2 x M6 screws
Copyright © 2010
C
A
A
D
B
3.10 Replacing the rear lateral trellis
Repair sequence Removing the old part
NOTE!
The following procedures may be performed both with the rear end module installed or removed.
1. Sand the weld points on the rear trellis.
NOTE!
Do not remove any other material from the rear trellis.
2. Sand the weld points between the connecting brackets and the rear trellis.
NOTE!
Do not remove any other material from the connecting brackets.
1
Copyright © 2010
2
3.10 Replacing the rear lateral trellis
NOTE!
When working with the rear subframe module installed, remove the M8 screw (A) and the 2
M6 screws (B) fastening the lateral trellis to the rear subframe.
3. Sand the weld points between the connecting brackets and the rear pillar reinforcement.
NOTE!
Do not remove any other material from the connecting brackets.
3
Copyright © 2010
A
B
3.10 Replacing the rear lateral trellis
Fitting the new part 4. Mount the lateral trellis in the jig.
ಶ Prepare the weld area ( see chapter 1.14
)
5. Fit the trellis connector in the relative seats on the rear pillar reinforcement.
5
Copyright © 2010
3.10 Replacing the rear lateral trellis
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
6. Weld the lateral trellis at all the original weld points.
7. Position the bracket (C) (p/n 81649700 RH / p/n
81649800 LH) 90 mm from the edge of the extruded section (D) .
C
D
6
90 mm
Copyright © 2010
3.10 Replacing the rear lateral trellis
8. Fasten the bracket (C) to the extruded section (D) with four 15 mm lengths of weld.
8
C
D
9. Fit the rear bracket (E) (p/n 81583200 RH p/n 81583300 LH), centring with the seat on the bushing (F) .
E
F
Copyright © 2010
3.10 Replacing the rear lateral trellis
10. Fasten the rear bracket (E) to the extruded section
(D) with four 20 mm lengths of weld.
11. Mount the bracket (G) (p/n 81952000) in the jig.
NOTE!
When working with the rear subframe module installed on the vehicle, use the module itself as a template for correctly fitting the bracket (G) .
Copyright © 2010
10
D
E
G
3.10 Replacing the rear lateral trellis
12. Fasten the bracket (G) to the front trellis with two
30 mm lengths of weld and two 10 mm lengths of weld.
13.
Fit the bracket (H) (p/n 81582600 RH / p/n 81582700
LH) on the rear trellis, holding the bracket with the inner side flush and at a distance of 5 mm from the front end of the extruded section (I) .
5 mm
12
H I
G
Copyright © 2010
3.10 Replacing the rear lateral trellis
14. Fasten the bracket (H) to the extruded section (I) with four 15 mm lengths of weld.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
H
I
14
NOTE!
When working with the rear subframe module installed, fasten the lateral trellis to the rear subframe with 1 M8 screw (A) and 2 M6 screws (B) .
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
A
Copyright © 2010
B
3.10 Replacing the rear lateral trellis
15. Refit the complete vehicle flank ( see chapter 3.5
).
16. Refit the roof skin ( see chapter 3.3
).
ಶ Refit connected parts.
ಶ Check clearances and rectify if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
4.1 Replacing the rear spoiler
Preliminary procedures
ಶ Remove connected parts (rear bumper, taillights, grilles and, if necessary, rear lid)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Rear spoiler (A)
• Rear bumper mounting cross-member (B)
Material necessary • 2 M6x18 screws
• 5 M6 nuts
Copyright © 2010
B
A
4.1 Replacing the rear spoiler
Repair sequence Removing the old part
1.
Sand the joint weld beads between the rear spoiler and the vehicle flanks.
NOTE!
Do not remove any other material from the vehicle flanks.
1
2.
Use a 10 mm wrench to remove the 2 M6x18 fastener screws joining the spoiler and the rear bumper mounting cross-member.
2
1
Copyright © 2010
4.1 Replacing the rear spoiler
3.
Use a 10 mm wrench to remove the 5 M6 fastener nuts joining the spoiler, the rear bumper mounting cross-member and the mounting bracket.
3 3 3
4.
Clean any welding and filler residue.
4
4
Copyright © 2010
4.1 Replacing the rear spoiler
Fitting the new part 5.
Fit the spoiler in correspondence with the holes in the rear bumper mounting cross-member and the vehicle flanks.
ಶ Prepare the weld area ( see chapter 1.14
).
5
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
6.
Fasten the spoiler to the rear bumper mounting cross-member with the 2 M6x18 screws.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
6
Copyright © 2010
4.1 Replacing the rear spoiler
7.
Apply and tighten the 5 M8 nuts removed previously.
Caution!
Do not reuse the nuts removed previously.
See paragraph ( 1.11.3 Screw connections ).
7 7 7
ಶ Refit connected parts.
ಶ Check clearances on the rear lid and rectify if necessary.
Remove the connected parts for subsequent painting.
Copyright © 2010
4.1 Replacing the rear spoiler
8.
Weld the rear spoiler to the vehicle flanks at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
8
8
Copyright © 2010
4.2 Replacing the rear bumper mounting cross-member
Preliminary ಶ Remove connected parts (bumper, taillights, grilles) procedures
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Rear bumper mounting cross-member (A)
Material necessary -
Copyright © 2010
A
4.2 Replacing the rear bumper mounting cross-member
Repair sequence Removing the old part
1. Roughly cut out the rear cross-member.
1 1
2. Sand the joint weld beads between the crossmember and the rear spars.
NOTE!
Do not remove any other material from the rear spars.
2
Copyright © 2010
4.2 Replacing the rear bumper mounting cross-member
3. Grind the welds on the rear spars.
Caution!
Check that the rear spars are undamaged.
In the event of damage, the spars must be replaced (see chapter 4.3) .
3
Fitting the new part 4. Mount the rear cross-member in the jig.
NOTE!
Check that the cross-member is flush with the rear spars.
ಶ Prepare the weld area ( see chapter 1.14
).
4
Copyright © 2010
4.2 Replacing the rear bumper mounting cross-member
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
5. Tack and then weld the rear cross-member to the spars.
Caution!
Remove the jig only once the weld areas are cool.
5
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
ಶ Refit the connected parts (taillights, grilles, rear bumper).
ಶ Check clearances on the rear lid and rectify if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
4.3 Replacing the rear spar
Preliminary ಶ Remove connected parts (bumper, taillights, grilles) procedures
ಶ Remove the rear upper trellis ( see chapter 4.4
)
ಶ Remove the flank mounting bracket ( see chapter 4.5
)
ಶ Remove the rear cross-member ( see chapter 4.2
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • RH rear spar (A)
• LH rear spar (B)
Material necessary -
Copyright © 2010
A B
4.3 Replacing the rear spar
Repair sequence Removing the old part
1. Roughly cut out the rear spar.
1
2. Sand the joint weld beads between the spar and the rear shock tower.
Caution!
Take care not to damage the die-cast joints.
2
Copyright © 2010
4.3 Replacing the rear spar
3. Grind the welds on the rear shock tower.
Caution!
Check that there are no cracks in the rear shock tower.
In the event of damage, the entire rear end module must be replaced.
3
3
3
Fitting the new part 4. Mount the rear spar in the jig, bringing it against the relative seat on the shock tower.
NOTE!
Check that the spar is perfectly horizontal.
ಶ Prepare the weld area ( see chapter 1.14
).
Copyright © 2010
4
4.3 Replacing the rear spar
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
5. Tack and then weld the rear spar to the shock tower.
Caution!
Remove the jig only once the weld areas are cool.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
6. Refit the rear cross-member ( see chapter 4.2
)
7. Refit the upper rear trellis ( see chapter 4.4
)
8. Refit the flank mounting bracket ( see chapter 4.5
)
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove the connected parts for subsequent painting.
5
5
5
Copyright © 2010
4.4 Replacing the rear upper trellis
Preliminary ಶ Remove connected parts (bumper, taillights, grilles) procedures
ಶ Remove the rear spoiler ( see chapter 4.1
)
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Rear upper trellis (A)
• 2 rear upper trellis support bases (B)
• 2 rear upper trellis connector brackets
Material necessary -
Copyright © 2010
B A B
4.4 Replacing the rear upper trellis
Repair sequence Removing the old part
1. Cut the 2 support bases near the rear spars.
2. Cut the two connector brackets near the weld beads on the rear bumper mounting brackets.
1
2
Copyright © 2010
4.4 Replacing the rear upper trellis
3. Grind all the welds in the vicinity of the cuts made previously.
NOTE!
Do not remove any other material from the rear spars.
Fitting the new part 4. Mount the rear upper trellis in the jig.
ಶ Prepare the weld area ( see chapter 1.14
).
3
Copyright © 2010
4.4 Replacing the rear upper trellis
5. Fit the rear spoiler, the rear bumper, the grilles and the taillights.
ಶ Check clearances and rectify if necessary.
Remove the rear spoiler, the rear bumper, the grilles and the taillights.
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
6. Tack the 2 support bases to the rear spars.
Copyright © 2010
6
4.4 Replacing the rear upper trellis
7. Tack the rear upper trellis to the two support bases.
8. Tack the two rear upper trellis connecting brackets (A) .
7
8
8
A
Copyright © 2010
4.4 Replacing the rear upper trellis
9. Weld the support bases to the spars at the original weld points.
10. Weld the rear upper trellis to the support bases.
9
10
Copyright © 2010
4.4 Replacing the rear upper trellis
11. Weld the connector brackets (A) joining the rear upper trellis and the rear bumper mounting brackets at the original welds.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 11
11
A
12. Refit the rear spoiler ( see chapter 4.1
).
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
4.5 Replacing the flank mounting bracket
Preliminary ಶ Remove connected parts (bumper, rear grilles) procedures
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Flank mounting bracket (A)
• Rear upper trellis connector bracket
Material necessary • 3 x M6 screws
Copyright © 2010
A
4.5 Replacing the flank mounting bracket
Repair sequence Removing the old part
1. Remove the 3 M6 fastener screws joining the flank mounting bracket, the rear lateral trellis and the rear spar.
1
2. Sand the joint weld points between the connector bracket, the rear upper trellis and the rear spar.
NOTE!
Do not remove any other material from the rear spars.
Copyright © 2010
2 2
2
4.5 Replacing the flank mounting bracket
3. Sand the joint weld beads between the flank mounting bracket and the rear spar.
NOTE!
Do not remove any other material from the rear spars.
3
3
3
4. Grind all the welds sanded previously.
NOTE!
Do not remove any other material from the rear spar.
Copyright © 2010
4.5 Replacing the flank mounting bracket
Fitting the new part
NOTE!
Before carrying out the following operation, mount the rear lateral trellis in the jig and ensure that it is correctly positioned.
If the trellis appears particularly damaged, replace the trellis itself ( see chapter 3.7
).
5. Fit the flank mounting bracket, using the two holes in the rear lateral trellis as reference.
ಶ Prepare the weld area ( see chapter 1.14
).
5
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
6. Fasten the M6 screw in the hole on the rear spar.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
Copyright © 2010
6
4.5 Replacing the flank mounting bracket
7. Fasten the 2 M6 screws in the two holes in the rear lateral spar.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
8. Tack the flank mounting bracket to the rear spar.
8
8
8
7
Copyright © 2010
4.5 Replacing the flank mounting bracket
9. Fit the connector bracket (A) and tack in position.
ಶ Check that the assembly is correctly positioned and adjust if necessary.
9
9
10. Weld the flank mounting bracket to the rear spar at the original weld points.
Caution!
When welding the flank mounting bracket, there is a risk of the spar (B) buckling as a result of the heat.
To prevent this, the bracket must only be welded with the rear cross-member mounted in the jig
( see chapter 4.2
).
B
10
10
10
Copyright © 2010
A
4.5 Replacing the flank mounting bracket
11. Weld the flank mounting bracket to the rear upper trellis at the original weld points.
11
12. Weld the connector bracket (A) at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
12
12
A
Copyright © 2010
4.5 Replacing the flank mounting bracket
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
Copyright © 2010
4.6 Replacing the upper trellis mounting bracket
Preliminary ಶ Remove connected parts (rear lid) procedures
ಶ Place the vehicle on the vehicle bench.
Replacement parts • Upper trellis mounting bracket (A)
Material necessary • 1 x M8 screw
Copyright © 2010
A
4.6 Replacing the upper trellis mounting bracket
Repair sequence Removing the old part
1. Remove the M8 fastener screw joining the bracket
(A) and the extruded element (B) .
B
A
2. Sand the weld beads between the trellis mounting bracket and the respective support base on the rear shock tower.
Caution!
Take care not to damage the rear shock tower.
3. Grind the sanded weld points.
2
Copyright © 2010
2
1
4.6 Replacing the upper trellis mounting bracket
Fitting the new part 4. Mount the upper trellis mounting bracket in the jig, centring with the bushing (A) .
ಶ Prepare the weld area ( see chapter 1.14
).
A
Fitting the new part
NOTE!
Before fitting the new part, read chapter ( 1.15
Repair methods ) thoroughly.
5. Fasten the bracket (A) to the extruded element (B) with the M8 screw.
Caution!
Do not reuse the screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
B
A
Copyright © 2010
5
4.6 Replacing the upper trellis mounting bracket
6. Weld the upper trellis mounting bracket to the respective support base at the original weld points.
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
6
ಶ Refit connected parts.
ಶ Check the clearance dimensions, rework if necessary.
Remove connected parts for subsequent painting.
6
Copyright © 2010
4.7 Finishing the rear end module
Preliminary procedures
ಶ Place the rear end module on the vehicle bench using the specific jigs.
Replacement parts • Rear upper trellis (A)
• 2 rear upper trellis support bases (B)
• RH and LH flank mounting brackets (C)
• RH and LH upper trellis mounting brackets (D)
Material necessary • 1x2 M6 screws
D
C
B
A
Copyright © 2010
4.7 Finishing the rear end module
Fitting the new part Flank mounting brackets
1. Mount the flank mounting brackets in the jig ( see chapter 4.5.5
).
2. Fasten the flank mounting brackets to the rear spars with 1x2 M6 screws.
Caution!
Do not reuse screws removed previously.
See paragraph ( 1.11.3 Screw connections ).
Copyright © 2010
1
4.7 Finishing the rear end module
NOTE!
Check that the flank mounting brackets are flush with the spars.
3. Weld the flank mounting brackets to the rear spars.
2
2
Fitting the new part Rear upper trellis
4. Mount the rear upper trellis in the jig ( see chapter 4.4.4
).
2
Copyright © 2010
4.7 Finishing the rear end module
5. Weld the 2 support bases to the rear spars using the weld points on the original part as reference.
3
3
6. Weld the rear upper trellis to the two support bases.
NOTE!
Check that the trellis is perfectly horizontal.
4
4
Copyright © 2010
4.7 Finishing the rear end module
7. Weld the connector brackets (A) between the rear upper trellis and the flank mounting brackets.
Fitting the new part Upper trellis mounting brackets
8. Mount the upper trellis mounting brackets in the jig
( see chapter 4.6.4
).
Copyright © 2010
5
5
4.7 Finishing the rear end module
9. Fit the upper trellis mountings onto the respective support bases by interference, as shown in the figure.
10. Weld the upper trellis mounting brackets to the respective support bases on both the internal and external sides of the bases.
7 7
6
Copyright © 2010
4.7 Finishing the rear end module
ಶ Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
Copyright © 2010
1 Standard times for front body shell
Activity
2.1 Replacing the wings
2.2 Replacing the fender mounting
2.3 Replacing the front lateral trellis
2.4 Replacing the front cross-member
2.5 Replacing the front spar
2.6 Replacing the wheel bay cover plate
2.7 Replacing the shock tower
2.8 Replacing the front end module
Standard times in hours
0.6 hours
3.5 hours
3.9 hours
4.8 hours
4.9 hours
2.4 hours
13.8 hours
32 hours
Copyright © 2010
Activity
3.1 Replacing the roof skin
3.2 Replacing the underwindscreen rib and the windscreen valence cross-member
3.3 Replacing the complete vehicle side
3.4 Replacing the lateral crash reinforcement
3.5 Replacing the sill
3.6 Replacing the rear firewall and mountings
3.7 Replacing the fuel tank cross-member
3.8 Replacing the subframe connector extruded section
3.9 Replacing casting for rear shock tower
3.10 Replacing the rear lateral trellis
Standard times in hours
8.2 hours
5.1 hours
24.2 hours
0.7 hours
46.5 hours
4.9 hours
6.7 hours
7.5 hours
5.5 hours
2.2 hours
Copyright © 2010
3 Standard times for rear body shell
Activity
4.1 Replacing the rear spoiler
4.2 Replacing the rear cross-member
4.3 Replacing the rear spar
4.4 Replacing the rear upper trellis
4.5 Replacing the flank mounting bracket
4.6 Replacing the upper trellis mounting bracket
4.7 Finishing the rear end module
4.8 Replacing the rear subframe
Standard times in hours
2.8 hours
3.9 hours
4.1 hours
3.2 hours
1.5 hours
0.8 hours
5.2 hours see F458 Italia workshop manual
Copyright © 2010
Star sdt - Specific equipment Page 1 of 70
Foto Code Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
900027010
AV 3537
AV 3604
AV 3606
Adapter
(900027010) for tool AV
26300.
Adaptor
95973537
(AV 3537) valve seat guide installer punch.
Adaptor
95973604
(AV 3604) for angular engine timing reference tool.
Adaptor
95973606
(AV 3606) for trolley
(900026230) for transporting and handling enginegearbox assembly.
X
X
X
599
GTO
612
Scaglietti
612
Sessanta
X
AV 6156
ALZF
04702
Blocks
95976156
(AV 6156) for adjusting the exhaust system.
Bore gauge
(ALZF
04702) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment Page 2 of 70 for checking big end diameter.
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Star sdt - Specific equipment
Foto
Page 3 of 70
Code
AV 3350
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
61
Sess
Bushing (AV
3350) for upper pump assembly fastener screws.
ALZF 09206
TLDF006108
Calibre (ALZF
09206)
92 mm diameter for cylinder sleeves.
Calibre
(TLDF006108) for checking valve guide wear.
X
AV 2714
Extractor
95972714_1
(AV 2714) front crankcase cover.
X X X
AV 2734
AV 3335
Extractor
95972734 (AV
2734) oil seal for valve.
False cylinder sleeve (AV
3335) for fitting pistons into crankcase.
X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 4 of 70
Code
CS 107155
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessant
Feeler gauge
(CS 107155) for measuring axial connecting rod endfloat.
AM 105784
Goniometer
95975784_2
(AM 105784) for setting engine timing
TLDF02060
Go/no-go gauge
95972060
(TLDF02060) for small end.
X
900026300
Handle
(900026300) punches.
AV 3430
AV 2944
Index
95973430
(AV 3430) timing reference marker.
Insertion tool
95972944
(AV 2944) for fitting seal ring onto valve guide.
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 5 of 70
Code Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
95971243
Pressure gauge
( 95971243)
900026550
Punch
(900026550) for installing crankshaft bearing, clutch side.
900026590
900027000
900027050
Punch
(900026590) for mounting oil seal on front crankcase cover.
Punch
(900027000) for mounting cylinder head alignment dowel.
Punch
(900027050) for mounting pump assembly
Corteco seal ring on lower crankcase shell.
900027060
Punch
(900027060) for mounting
Corteco seal ring on
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment Page 6 of 70 flywheel side of crankshaft.
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Star sdt - Specific equipment
Foto
Page 7 of 70
Code
AS
102178
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
Punch
95972178
(AS
102178) for installing valve guides, Ø 7 mm
599
GTO
612
Scaglietti
612
Sessanta
X X
AV 2692
AV 3435
Punch
95972692
(AV 2692) for extracting valve guide.
Screw
95973435
(AV 3435) goniometer connector hub (AM
105784).
AV 3002
AV 3608
900027020
Screwdriver
95973002
(AV 3002) for installing piston pin rings.
Sheet
95973608
(AV 3608) for protecting intake orifices in heads.
Special wrench
(900027020) for installing variable valve timing adjuster on camshaft.
X
X
X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 8 of 70
Code
AV 3135
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
Supports
95973135 (AV
3135) for checking camshaft
(concentricity).
X
599
GTO
612
Scaglietti
612
Sessanta
X X
95978151
Tensiometer
(95978151)
Seem
DIAPAZ.
AM
107064
AM
107080
AV 3311
AV 3333
Tool (AM
107064) mounting for crankcase on
AV 2621 trolley.
Tool (AM
107080) for supporting head.
Tool (AV
3311) for fitting gear/drive chain assembly.
Tool (AV
3333) for mounting cable grommet clips for variable valve timing adjuster solenoid valve.
X X X X X X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 9 of 70
Code
AV 3843
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessant
Tool (AV
3843) for immobilising camshafts, with 30 mm diam. hexagonal head.
1870736000
Tool
(1870736000) for removing fuel pump ring nut.
X X X X X
900026610
Tool
(900026610) cylinder sleeve extractor.
900026970
900027030
900027040
Tool
(900026970) for cleaning head conduits.
Tool
(900027030) for fitting pump drive shaft.
Tool
(900027040) for fitting pump unit bearing.
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 10 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
737
CS
102916
AV
2926
AV
2955
AV
3122
AV
3603
Tool
95972926
(AV 2926) for extracting valve guides.
Tool
95972955
(AV 2955) for checking the connecting rod.
Tool
95973122
(AV 3122) for immobilising crankshaft
Tool
95970737
(AV 737) dial gauge for measuring piston TDC.
Tool
95972916
(CS 102916) cylinder sleeve projection measurement dial gauge.
Tool
95973603
(AV 3603) for immobilising camshafts
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 11 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3605
AV
3607
AV
3838
AV
3844
AV
3845
Tool
95973605
(AV 3605) for centring and installing check valve on right and left hand cylinder banks.
Tool
95973607
(AV 3607) for immobilising crankshaft for damper installation
(with engine in vehicle)
Tool
95973838
(AV 3838) for manually checking variable valve timing adjuster.
Tool
95973844
(AV 3844) for fitting right hand float valve.
Tool
95973845
(AV 3845) for fitting left hand float valve.
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
CS
104488
Tool
95974488
(CS 104488) dial gauge for measuring piston
T.D.C.
Page 12 of 70 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 13 of 70
Code
AM
107231
AV 3602
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
Tool
95977231
(AM
107231) for installing cylinder sleeves.
X
599
GTO
612
Scaglietti
612
Sessanta
Tools
95973602
(AV 3602) for installing water-oil pump.
X X X
F9x12/17
Torque wrench end fitting
(F9x12/17)
95973305
Torque wrench
FACOM
S.405DA
(95973305)
AV 8172
900026230
Torque wrench
95978172
(AV 8172)
(Replaces torque wrench
USAG
815F)
Trolley
(900026230) for transporting and handling enginegearbox assemblies
X X X
X
X X
X
X
X
X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Star sdt - Specific equipment
Foto
Page 15 of 70
Code
AV 2621
AV 6038
95971560
900026990
AV 3614
AV 3617
Wrench
USAGD156
(95971560) for tightening oil filter.
Wrench
(900026990) for variable valve timing adjuster control valve oil filter.
Base
95973614
(AV 3614) for assembling double gearing and bearings on secondary shaft.
Bearing pusher
95973617
(AV 3617)
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
Trolley
95972621
(AV 2621) for overhauling enginegearbox assemblies
Wrench
(AV 6038) for detaching delivery pipe from pump to steering box.
X X
599
GTO
612
Scaglietti
612
Sessanta
X X X
X X X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment Page 16 of 70 for removing tapered roller bearing on cover side.
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Star sdt - Specific equipment
Foto
Page 17 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3251
AV
2714
AV
3045
AV
3272
AV
3244
AV
3837
Centring screws
95973251
(AV 3251) for shaft-rod cluster with forks.
Extractor
95972714
(AV 2714) for the differential flange.
Extractor
95973045
(AV 3045) for the differential flange.
Extractor
95973272
(AV 3272) for 3rd - 4th gear synchroniser on main shaft.
Flange
95973244
(AV 3244) gearbox housing seal for measuring rolling torque.
Insert
95973837
(AV 3837)
Facom
D.27.
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Foto
Page 18 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3831
AV
3536
AV
3612
AV
3048
AV
3075
Pin
95973831
(AV 3831) centring pin for bevel gear pair crown installation.
Plate
95973536
(AV 3536) for pressure seal test.
Pliers
95973612
(AV 3612) for crown pinion clearance gauge
(used in conjunction with AV-
3266).
Polygonal wrench
95973048
(AV 3048) hydraulic clutch control stud bolt.
Punch
95973075
(AV 3075) for driving flexible pin onto the bearing mounting bushing https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
3079
Punch
95973079
(AV 3079) for centring the complete thrust bearing.
Page 19 of 70
X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
Foto
Page 20 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3268
AV
3270
AV
8066
AV
3611
AV
3248
AV
8073
Support
95973248
(AV 3248) for gearbox housing.
Templates
95978073
(AV 8073) for locating the Power
Unit pipes and actuator
Ring nut
(AV 8066) for removing oil tank cap with
F1 kit.
Stud bolt
95973611
(AV 3611) union for die-casting gearbox element.
Punch
95973268
(AV 3268) for fitting the retainer washer (Ø
14 mm).
Punch
95973270
(AV 3270) for fitting the retainer washer (Ø
25 mm).
X X X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
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Page 21 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3375
Tool (AV
3375) for replacing upper rubber bushing on gearbox housing.
AV
8065
Tool (AV
8065) for topping up oil with
F1 kit.
X X X X X
AV
3070
Tool
95973070
(AV 3070) disengaging the clutch.
AV
3080
AV
3218
AV
3219
Tool
95973080
(AV 3080) for thrust bearing centring.
Tool
95973218
(AV 3218) for removing the roller race.
Tool
95973219
(AV 3219) for replacing upper rubber bushing on gearbox housing (4 components).
X X
X
X X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
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CodeDescription
AV
3234
Tool 95973234 (AV
3234) for replacing lower bushing on gearbox housing (8 components)
AV
3243
Tool 95973243 (AV
3243) for fitting assembled gearbox shafts (5 components).
AV
3252
Tool 95973252 (AV
3252) for disassembling/assembling the main shaft (4 components).
AV
3255
Tool 95973255 (AV
3255) for assembling double gearing and bearings on secondary shaft (4 components).
AV
3257
Tool 95973257 (AV
3257) kickback tool for tightening secondary shaft ring nut.
CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
ScagliettiSe
AV
3258
Tool 95973258 (AV
3258) for installing clutch shaft ball bearing.
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Star sdt - Specific equipment
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Page 23 of 70
CodeDescription
AV
3259
Tool 95973259
(AV 3259) for fitting roller bearing outer ring.
AV
3260
Tool 95973260
(AV 3260) for extracting/inserting gearbox housing bearing (2 components).
CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3261
Tool 95973261
(AV 3261) for fitting clutch shaft bearing.
AV
3262
AV
3263
Tool 95973262
(AV 3262) for fitting the spacer and the 1st and 2nd gear synchroniser body.
Tool 95973263
(AV 3263) for assembling various components on secondary shaft.
AV
3264
Tool 95973264
(AV 3264) for fitting the ball bearing onto the primary shaft.
X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3265
Tool
95973265
(AV 3265) for fitting bearing and bushing on the intermediate plate (4 components).
AV
3266
Tool
95973266
(AV 3266) for checking pinion play.
X X X
AV
3267
Tool
95973267
(AV 3267) for installing ball bushing.
AV
3271
AV
3273
AV
3275
Tool
95973271
(AV 3271) for locating the gear shift control lever on the rod.
Tool
95973273
(AV 3273) for extracting shaft-rod cluster with forks.
Tool
95973275
(AV 3275) for fitting the external ball bearing ring
(2 components).
X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description
AV
3276
AV
3277
AV
3278
AV
3613
Tool 95973276
(AV 3276) for fitting the bearing onto differential shaft with flange (2 components).
Tool 95973277
(AV 3277) for fitting bearing onto differential half
-shaft with flange on lefthand side.
Tool 95973278
(AV 3278) for fitting the tapered differential bearings (2 components).
Tool 95973613
(AV 3613) for checking bush between bevel gear pair pinion and bearing seat.
California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
X
X
X
X
X
X
AV
3615
Tool 95973615
(AV 3615) for removing/fitting hook.
AV
3616
Tool 95973616
(AV 3616) for removing tapered roller bearing on cover side.
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Code Description California FF
AV
3832
AV
3833
AV
3834
AV
3835
AV
3836
AV
3846
Tool
95973834
(AV 3834) for fitting tapered roller bearing on cover side.
Tool
95973835
(AV 3835) support tool for fitting
Tool
95973832
(AV 3832) for fitting oil circuit seal.
Tool
95973833
(AV 3833) for fitting outer roller bearing tapered ring on cover.
bearing.
Tool
95973836
(AV 3836) adapter tool for piston
Corteco seal ring.
Tool
95973846
(AV 3846) for flushing E-
DIFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment hydraulic system.
Page 28 of 70 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Page 29 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
AM
106121
CS
106524
AV
3283
AV
3245
AV
3246
Union
95973283
(AV 3283) to keep the air under pressure.
Wrench
95973245
(AV 3245) for fastening the main shaft ring nut and check ring nut.
Wrench
95973246
(AV 3246) for fastening the main shaft shoulder ring nut.
Tool
95976121
(AM
106121) for fitting
1st and 2nd gear synchroniser sleeve.
Tool
95976524
(CS
106524) for checking gap between pinion and the bearing seat.
X
X
599
GTO
612
Scaglietti
612
Sessanta
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
3247
Wrench
95973247
(AV 3247) for secondary shaft bearing retainer ring nut.
Page 30 of 70 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description
AS
10723
-07
Plug (AS 10723
-07) for supporting upper arm for ball joint removal.
California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3427-
14
Plug (AV 3427-
14) lower leverage surface for ball joint removal.
AV
3206
Support
95973206 (AV
3206) for complete hub.
X X X X X X X X
AV
1651
Tool 95971651
(AV 1651) for removing lever ball joint.
AV
3189
Tool 95973189
(AV 3189) for removing
Flanbloc and ball joint.
AV
3217
Tool 95973217
(AV 3217) for fitting/removing lower shock absorber
Silentblock.
X
X
X X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description
AV
3281
Tool 95973281
(AV 3281) leverage surface for installing
Flanbloc.
California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
X X X X X
AV
3282
Tool 95973282
(AV 3282) for fitting and removing
Flanbloc.
AV
3304
Tool 95973304
(AV 3304) for removing/fitting shock absorber bushing.
X X X X X
AV
3307
Frame
95973307 (AV
3307) for supporting hard top.
AV
5736
Frame
95975736 (AV
5736) for lifting hard top.
Tool kit
95972004 () for replacing hard top rear screen.
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Code
AV 8072
AV 8170
AS 4736
ALZF
08902
TLDF00754
AM
105165/20
Boring bar
95974736
(AS 4736) for cylinder bank, Ø
66.675 mm.
Calibre
(ALZF
08902)
89 mm diameter for cylinder sleeves.
Calibre
(TLDF00754) for valve guides, Ø 7 mm
Complete goniometer
95975165
(AM
105165/20) for setting engine timing
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessant
Tool
95978072
(AV 8072) for aligning the cosmetic tailpipe tips with the exhaust tailpipes
Shim
95978170
(AV 8170) for locating the engine compartment lid window.
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code
CS 7148
AM
105165/21
AV 2627
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessant
Dial gauge mounting
95977148
(CS 7148) for measuring valve seat wear.
X X
Index
95970208
(AM
105165/21) for engine timing.
X X
Insertion tool
95972627
(AV 2627) for rear crankshaft seal ring
X X
AV 240
Lapper
95970240
(AV 240) cylinder bank.
TLDF02068
Plug gauge
95970206
(TLDF02068) for checking small end bushing.
AV 2945
Protection
95972945
(AV 2945) for installing valve oil seal.
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
865
AV
2727
AV
2740
AV
3011
AV
3052
“Corteco” seal ring.
Punch
95972740
(AV 2740) for installing check valve.
Punch
95973011
(AV 3011) for installing engine cover seal ring, clutch side.
Punch
95970866
(AV 865) for connecting rod bushing.
Punch
95972727
(AV 2727) for installing front crankcase cover
Punch
95973052
(AV 3052) for fitting camshaft pulleys.
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
3106
Punch
95973106
(AV 3106) for fitting front timing cover bearing.
Page 36 of 70
X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
US
4720
Reamer
95974720
(US 4720) camshaft seat
X X
AV
3345
Shim
95973345
(AV 3345) punch AV
102178.
AV
2905
AS
104994
AV
3287
AV
2607
Support
95972905
(AV 2905) for polygonal wrench.
Support
95974994
(AS
104994) for crankcase on trolley
AV 2621.
Tool (AV
3287) for securing crankshaft onto AS
104994 mounting.
Tool
95972607
(AV 2607) for installing camshaft drive bearing.
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
2697
AV
2881
AV
3546-
01
AM
105774
USAG
815F
AV
815
Tool
95975774
(AM
105774) for installing cylinder sleeves.
Torque wrench
(USAG
815F)
(Replaced by torque wrench AV
8172)
Wrench
95970815_1
(AV 815) for timing system drive pulley ring nuts.
Tool
95972697
(AV 2697) for installing cylinder sleeves.
Tool
95972882
(AV 2881) for installing valve oil seal.
Tool
95973546
(AV 3546-
01) for dumper anti-rotation in vehicle.
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Page 40 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
2906
Wrench
95972906
(AV 2906) polygonal.
X X
AV
3400
Wrench
95973400
(AV 3400) for engine oil filter.
AV
3300
Adaptor
95973300
(AV 3300) for tool
AM106628.
AV
3415
AM
106226
AM
106227 gearbox housing onto rear housing.
Jig
95976227
(AM
106227) for fitting front gearbox housing
Base
95973415
(AV 3415) for removing the bearing race from the pinion.
Jig
95976226
(AM
106226) for fitting central
X
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment onto the central housing.
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
2679
AS
102881
AV
2640
AV
2644
AV
2647 aligning clutch plate.
Punch
95972640
(AV 2640) for fitting the bearing onto the secondary shaft.
Punch
95972644
(AV 2644)
Pin
95972679
(AV 2679) for locating the 3rd,
4th, 5th,
6th gearbox rods.
Pin
95972881
(AS
102881) for for the primary shaft bearing.
Punch
95972647
(AV 2647) for fitting the bearing onto the primary shaft.
X
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
2649/1
Punch
95972649
(AV
2649/1) for fitting bushings
Page 43 of 70
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Page 44 of 70
Code
AV 2655
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessant
AV 2649/2
Punch
95972649
(AV 2649/2) for fitting bushings
Punch
95972655
(AV 2655) for the primary shaft bearing.
X
X
X
X
X
X
AV 3297
Punch
95973297
(AV 3297) for bushing extraction.
AM 106629
Punch
95976629
(AM 106629) for fitting seat ring on front cover.
X
X
X
X
X
X
ALZF08501
Shim
95970152
(ALZF08501) for tool
AV3415.
AV 3413
Shim
95973413
(AV 3413) for AV3275 tool.
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Page 45 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3414
Shim
95973414
(AV 3414) bearing location for tool AV
2622.
X X X
AV
3418
Shim
95973418
(AV 3418) for tool AV
3275.
AS
107312
AV
2572
AV
2573
AV
2617
Support
95977312_1
(AS
107312) for fitting gearbox housing onto AV
2621 trolley.
Tool
95972572
(AV 2572) for locating the 1st, 2nd and reverse gear fork.
Tool
95972573
(AV 2573) for locating the 3rd, 4th,
5th, 6th gear fork.
Tool
95972617
(AV 2617) for fitting external bearing track onto
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment gearbox housing.
Page 46 of 70 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
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Page 47 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
2622
AV
2629
AV
2630
AV
2646
AV
2907 housing.
Tool
95972630
(AV 2630) for fitting the bearing onto the rear gearbox housing.
Tool
95972646
(AV 2646) for fitting
Tool
95972622
(AV 2622) for fitting the bearing onto the pinion.
Tool
95972629
(AV 2629) for fitting the bearing onto the central gearbox the outer roller bearing seat.
Tool
95972907
(AV 2907) for fitting the outer roller bearing seat.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
3411
Tool
95973411
(AV 3411) spacer for tool
AV2622.
Page 48 of 70
X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3418
Tool
95973418
(AV 3418) for fitting the case.
AV
3419
AV
3458
AM
105898
AM
106122
Tool
95975898
(AM
105898) for pinion retention.
Tool
95976122
(AM
106122) for fitting
3rd, 4th, 5th,
6th and reverse gear synchroniser.
Tool
95973419
(AV 3419) for centring the side cover lever.
Tool
95973458
(AV 3458) for centring shaft clearance between the universal joint and the actuator.
AM
106628
Tool
95976628
(AM
106628) for fitting crown wheel
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment onto differential.
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AM
106636
Tool
95976636
(AM
106636) for supporting the differential.
AV
2054
AV
2631
AV
2632
AV
2633
Wrench
95972054
(AV 2054) for clutch shaft ring nut.
Wrench
95972631
(AV 2631) for the primary shaft ring nut, differential side.
Wrench
95972632
(AV 2632) for clutch shaft ring nut.
Wrench
95972633
(AV 2633) for the secondary shaft ring nut on engine side and the primary shaft ring nut on differential side.
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
3412
Wrench
95973412
(AV 3412) for the intermediate ring nut on secondary shaft (3 components).
X
Page 52 of 70
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Page 53 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AM
105177
Wrench
95975177
(AM
105177) for fastening the primary shaft ring nut on the engine side.
X X X
AV
3427-
13
Tool (AV
3427-13) for fitting
Flanbloc.
AV
5225-2
AM
107310
AM
107311
Tool (AV
5225-2) leverage surface for extracting
Flanbloc.
Tool
95977310
(AM
107310) leverage surface for installing
Flanbloc.
Tool
95977311
(AM
107311) leverage surface for extracting
Flanbloc and ball joint.
AV
3980
Adapter (AV
3980) support for valve seat wear
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment measurement dial gauge.
Page 54 of 70 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Page 55 of 70
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
8171
AS
107233
AV
8169
Belt tensioner
(AV 8171) setting the alternator belt tension.
Boring bar
95977233
(AS
107233) cylinder bank.
Engine bushing installation template
(AV 8169) for checking alignment of rubber engine bushings.
X
X
X
X
X
X
X
AV
3979
AV
3432
AV
3981
Hook (AV
3979) for hoisting engine.
Hook
95973432
(AV 3432) for hoisting engine.
Kit (AV
3981) pressfitting water pipes on engine.
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
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Page 56 of 70
Code
AV 3982
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
Kit (AV
3982) press-fitting oil pipes on engine.
X
AV 3429
Lapper
95973429
(AV 3429) cylinder bank.
AV 3433
Lever
95973433
(AV 3433) for fitting timing chain
900027260
900027270
Punch
(900027260) for mounting 6 mm diameter centring dowel.
Punch
(900027270) for mounting 13 mm diameter centring dowel.
US 19000
Reamer (US
19000) hand reamer for ø26 mm camshaft seats
X
X
X
X
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AV
3978
AV
3984
AV
3985
Tool (AV
3978) for timing reference
Tool (AV
3984) for aligning cylinder sleeves
(used together with tool
AM
107231).
Tool (AV
3985) for checking variable valve timing adjuster.
Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AV
3983
Shield (AV
3983) intake header cover.
X X X
AM
107256
Tool (AM
107256) for installing half cones.
AV
3374
Tool (AV
3374) for installing oil seal on valve.
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description
900027360
Tool (900027360) for immobilising crankshaft for removing/refitting dumper.
CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
6
Sess
X X X
AV 2885
Tool 95972885
(AV 2885) for fitting oil sump bearing.
AV 3434
AM
107232
AV 3390
AV 8076
Tool 95973434
(AV 3434) for fitting O-rings on crankcase and lower crankcase shell fastener stud bolts.
Tool 95977232
(AM 107232) mounting for crankcase on AV
2621 trolley.
Wrench (AV
3390) for installing oil filters for timing adjusters.
Templates
95978076 (AV
8076) locating F1 gearbox kit pipes.
X
X
X
X
X
X X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Foto
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Code Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
900026250
Tool
(900026250) for complete clutch mount.
AV 3218
AV 8168
AV 3994
AV 8177
Tools
95973218
(AV 3218) for fitting the seal ring (3 components).
354 mm template
(AV 8168) for setting correct distance between chassis and gearbox
(mechanical gearbox).
Tool (AV
3994) for adjusting engine compartment lid striker plate retainer bracket.
Exhaust tailpipe extensions
95978177
(AV 8177) for connection to exhaust fume extractor.
X
X
X
X
X
X
X
X
X
X X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment Page 61 of 70
AS
107566
Tool
95977566
(AS 107566) for removing the oil sump.
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AS
107565
AV
8175
AV
8176
AS
107564
AV
8174
AS
107568
Wrench
95978176
(AV 8176) tightening fuel level sensor.
Hook
95977564
(AS
107564) for lifting the gearbox.
Pump
95978174
(AV 8174) topping up gearbox and clutch oil.
Trolley
95977565
(AS
107565) removing the engine / gearbox / subframe assembly.
Wrench
95978175
(AV 8175) tightening fuel pump filter retainer ring.
Bar
95977568
(AS
107568) support for
RHT
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment kinematics
L=1100.
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AS
107570
AV
8184
AV
8181
AS
107567
AV
8173
Hook
95977567
(AS
107567) installing the RHT.
Riveter
Battery
Tool
95978173
(AV 8173)
(see repair manual for aluminium bodyshell).
vehicle antitipping retention for runway type car lifts.
Feeler gauge
95978181
(AV 8181) checking
Rear Roof shell striker plates
Bar
95977570
(AS
107570) support for
RHT kinematics
L=806.
Fastener brackets for safety retainers
95978184
(AV 8184) raised
X
X
X
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
8178
Rod
95978178
(AV 8178) for RHT kinematics.
X
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Code
AV 8183
AV 8179
A7082600 -
A7082600/TIN
- A456
Description CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
Safety retainers
95978183 (AV
8183) vehicle antitipping retention.
Separator tool
95978179 (AV
8179) adjusting the
Rear Roof shell striker plates
Template kit
(A7082600 -
A7082600/TIN
- A456)
(see repair manual for aluminium bodyshell).
X
X
X
X X
599
GTO
612
Scaglietti
6
Ses
AV 8180
AV 8182
Template
95978180 (AV
8180) locating Rear
Roof shell striker plates
Template
95978182 (AV
8182) checking Rear
Roof shell striker plates
X
X
AS 107569
Tool 95977569
(AS 107569) support for hydraulic pump.
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Code Description California FF
SA
APERTA
458
Italia
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta
AS
107571
AV
8252
AV
8254
AV
8253
AV
8250
Trolley
95977571 (AS
107571) support for complete
RHT.
Brackets for fastening to engine and clutch housing shims
95978252 (AV
8252) for hoisting engine.
Engine retainer bracket for gearbox removal
95978254 (AV
8254) removing the gearbox.
Pins for lifting enginegearbox assembly
95978253 (AV
8253) for lifting engine/gearbox assembly off rear subframe after removal of subframe from vehicle.
Tailpipe cowl for exhaust fume extraction
95978250 (AV
8250) for use exclusively together with one of the
X
X
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Star sdt - Specific equipment
AV
8257 extension elements AV
8177 for connection to an exhaust gas extraction system.
Template
95978257 (AV
8257) fitting flexible exhaust pipe.
Page 68 of 70
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Code Description
AS
107572
AV
8251
AS
107573
AV
8255
Trolley 95977572
(AS 107572) to be used together with trolley AS
107565 for removing/refitting gearbox from and into vehicle.
Mounting bracket for vehicle safety retainers for lifting 95978251
(AV 8251) lifting vehicle on vehicle lift.
Safety extensions
95977513 (AS
107573) for trolley AS
107565 for removing/refitting rear subframe.
Spacers
95978255 (AV
8255) for trolley AS
107565 for removing/refitting rear subframe.
CaliforniaFF
SA
APERTA
458
Italia
599
GTB
Fiorano
X
X
X
X
599
GTO
612
Scaglietti
612
Sessanta
AV
8260
Eye bolts (AV
8260) for hoisting engine.
AV
8259
Brackets
95978259 (AV
8259) compressing fuel pump springs
X
X
X https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
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Foto Code Description California FF
SA
APERTA
458
Italia
A7082900 -
A7082900/T
- A456
Template kit
(A7082900
-
A7082900/T
- A456)
(see repair manual for aluminium bodyshell).
X
599
GTB
Fiorano
599
GTO
612
Scaglietti
612
Sessanta https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=as 8/4/2011
Consultation Page 1 of 1
Print Exit
01.01 Consultation
Consulting the manual
The manual is divided into sections, with each section identified by a different letter.
Each section is divided into chapters, identified by the letter indicating the relative section followed by a sequential number.
Each chapter is, in turn, divided into paragraphs, identified by the letter indicating the relative section, the chapter number and a sequential number, separated from the former by a point.
This format is used for all references to chapters or paragraphs in other sections.
The chapter or paragraph containing the notes relative to a certain topic may be identified by consulting the table of contents at the beginning of each section.
To illustrate the topic more clearly, the text is supplemented by illustrations in which the elements described are highlighted and/or identified with numerical references.
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Updates Page 1 of 1
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01.02 Updates
Updates
The manual will be updated periodically to reflect modifications made to the vehicle and the production of new versions.
ALWAYS read the Technical Notes as they may introduce more recently updated regulations and methods than those in this manual. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_010...
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Symbols Page 1 of 1
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01.03 Symbols
The safety symbols given below are used to warn the operator of personal safety hazards and operational conditions which may cause damage to the vehicle, and to provide useful information concerning the operation being performed.
CAUTION
Failure to observe the instructions given in this note may result in serious injury to the operator and/or to persons in the immediate vicinity.
IMPORTANT
Failure to observe the instructions given in this note may damage the vehicle and its components irreparably.
ENVIRONMENTAL PROTECTION
This symbol indicates recommendations for the protection of the environment.
NOTES
This general note provides operators with useful information concerning the operation being performed.
REFERENCE
Reference to a section or chapter dealing with the operation being performed. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_010...
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Glossary Page 1 of 3
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01.04 Glossary
N
2
Nitrogen
CO
Carbon Monoxide
CO
2
Carbon Dioxide
NO x
Nitrogen Oxide
HC
Hydrocarbons
Standard
Indicates reference value
Service limit
Indicates the limit value beyond which a part or coupling must be serviced to bring it back within the prescribed tolerance range
Right hand and/or left hand
The terms right hand and/or left hand indicate the right hand and/or left-hand side of the vehicle with respect to the front of the vehicle
ABS
Antilock Braking System ( A nti B lokier S ystem)
CST
( T raction S tability C )ontrol https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_010...
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Glossary Page 2 of 3
A.C.
( A ir C onditioning)
ASR
Wheelspin control during acceleration ( A ntriebs S chlupf R egelung)
CAN
Communication line between ECUs ( C ontroller A rea N etwork)
PTC
Positive temperature coefficient, resistance increases as temperature increases ( P ositive T emperature
C oefficient)
NTC
Negative temperature coefficient, resistance decreases as temperature increases ( N egative T emperature
C oefficient)
E-DIFF
( E lectronic D ifferential)
EBD
( E lectronic B rake force D istribution)
ECU
( E lectronic C ontrol U nit)
MSR
Engine braking torque control ( M otor S chleppmoment R egelung)
NO
Normally open (in reference to valves)
NC
Normally closed (in reference to valves)
RHT
( R etractable H ard T op) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_010...
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Glossary Page 3 of 3
EPB
( E lectric P arking B rake)
LC
( L aunch C ontrol)
AVH
( A utomatic V ehicle H olding)
DCT
( D ual C lutch T ransmission)
TPMS
( T yre P ressure M onitoring S ystem)
FBP
A system that eliminates the gap between the brake pads and discs by applying slight pressure to the brake system as soon as the accelerator pedal is released when imminent braking is expected. ( F errari B rake
P refill)
VDC
Vehicle dynamics control using the brake system and engine torque
PTU
( P ower T ransfer U nit) system
4WD
( 4 W heel D rive) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_010...
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Manual user Page 1 of 1
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Manual user
This publication was produced by the FERRARI Technical Service Department as an informative support tool to assist the operator in performing work on FERRARI cars.
This manual is intended for expert operators with sufficient knowledge and skill to carry out all maintenance and repair operations for FERRARI cars correctly and safely.
Carrying out the aforementioned operations without the necessary knowledge and skills will cause damage to the vehicle and may expose the operator and the user of the vehicle to danger.
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Operating procedures Page 1 of 1
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Operating procedures
The operator must observe the instructions and warnings given in the manual precisely and must not implement inappropriate methods or tools, as this may constitute a risk to personal safety and compromise the reliability of the vehicle.
In addition to the guided diagnostic system, that can be implemented using the FERRARI DEIS tester, each section of the manual contains diagnostic procedures to identify malfunctions of the different components in the vehicle.
Evaluating the impressions of the user is of vital importance, formulating appropriate questions to clearly identify the symptoms of the problem.
Once the cause has been identified, plan the job by consulting the relative informative notes concerning the tools necessary, the reference data for servicing and disassembly and reassembly procedures given in the manual.
Following the methods described in this manual precisely for each job ensures the safety of the user and the quality of the vehicle. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_020...
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Using tools and spare parts Page 1 of 1
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Using tools and original spare parts
FERRARI supplies workshops authorised to repair its vehicles with specific tools to ensure that repair work is carried out correctly and safely.
Carrying out any work without using specific FERRARI tools, or using alternative tools, may cause damage to relative component and/or system, voiding the warranty.
Always use original FERRARI spare parts, consulting the relative spare parts catalogue.
In addition to voiding the warranty, using non original components may damage the vehicle and expose the user to danger. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_020...
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Warranty Page 1 of 1
Print Exit
02.04 Warranty
FERRARI guarantees its vehicles for 3 years from the date of delivery.
The warranty may be extended if required. For details, see the specific documents "Power brochure" and "Power warranty handbook". For more information, contact the Ferrari Technical Service Department.
Carrying out any work without using specific FERRARI tools, or using alternative tools, may cause damage to relative component and/or system, voiding the warranty. Always use original FERRARI spare parts, consulting the relative spare parts catalogue. In addition to voiding the warranty, using non original components may damage the vehicle and expose the user to danger.
During this period, the appropriate form must be filled out and the S.T. Schedule, which indicates the time specified by FERRARI for the operation, must be consulted for any work on the vehicle. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_020...
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Tightening torques Page 1 of 1
Print Exit
For the fastening of main vehicle components, Ferrari has defined three tolerance classes relative to the rated torque value: The tolerance class is shown in the summary paragraphs concerning tightening torques, at the beginning of each section and/or at the beginning of each paragraph.
Class
A ±5
B ±10
C ±20 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_020...
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Safety at work Page 1 of 1
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03.01 Safety at work
Prevention measures and protection devices
When carrying out particularly hazardous or difficult service or repair operations, the service staff must take all precautions to prevent personal injury or damage to the vehicle.
Always wear protective gloves when working on sharp or hot parts, or when handling dangerous parts. In the latter case, we recommend protecting the eyes with appropriate safety goggles.
Prevent sparks or open flames when working on the fuel system as fuel and fuel vapours are highly flammable.
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Hazards Page 1 of 2
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03.02 Hazards
Danger
The engine must be kept running for certain maintenance procedures. Exhaust gases contain carbon monoxide, a highly toxic gas which may even cause death in the event of prolonged inhalation.
Exhaust gas
Precautions
Never run the engine in a closed space; preferably work outdoors or use exhaust extraction systems.
The emissions control devices installed were necessary in order for the vehicle to obtain type approval allowing the vehicle to be driven legally on public roads in compliance with emissions and noise legislation. Removing or tampering with these devices is prohibited by law.
Never puncture the exhaust silencers or remove any of their internal elements. Never use the vehicle with any of these devices removed.
Each of these devices bears a marking or label indicating the type approval number obtained.
Never replace any of the original devices with devices without type approval. These devices must also be kept in proper working order, carrying out all the procedures indicated in the maintenance schedule.
Petrol
Danger
The petrol contained in the fuel tank and the entire fuel system is highly flammable and, in certain conditions, potentially explosive.
Precautions
Smoking, sparks and naked flame must not be allowed in the work area or the immediate vicinity.
Keep out of reach of children!
Always work in a well ventilated area.
Never dispose of petrol into the environment!
Used oil
Danger Precautions
Prolonged skin contact with used oil may cause severe skin disease.
Keep out of reach of children!
To prevent risks, always wear protective gloves and/or wash any areas that have come into contact with used oil thoroughly with soap and water.
Never dispose of used oil into the environment!
Hydraulic fluid
Danger
The fluid contained in the brake, clutch and power steering systems is corrosive to plastic, rubber and paintwork and is extremely harmful in the event of contact with the eyes and skin.
Precautions
In the event of contact, wash the affected area with plenty of running water.
To prevent risks, always wear protective eyewear and gloves.
Keep out of reach of children!
Never dispose of used hydraulic fluid into the environment! https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_030...
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Hazards Page 2 of 2
Coolant
Danger Precautions
The cooling circuit contains fluid at high temperature and pressure: contact with hot coolant may cause severe burns. Coolant may cause irritation in the event of skin contact and is poisonous if swallowed.
Keep out of reach of children!
Never dispose of coolant into the environment! https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_030...
8/1/2011
Dangerous emissions
Print Exit
Page 1 of 1
Exhaust system and engine
Danger
As the vehicle is used, the components of the exhaust system and the engine itself reach very high temperatures and remain hot long after the engine is switched off.
Precautions
Always wear insulating gloves when handling these components, or wait as long as necessary for the components to cool.
Battery
Danger
The battery also contains sulphuric acid as an electrolyte, which may cause irritation in the event of skin contact.
Precautions
As the battery is charged, gases are released which are potentially explosive in the event of contact with sparks or naked flame.
Always charge the battery in a well ventilated area.
Always wear appropriate protective garments and a face mask when handling electrolyte.
After the vehicle is stopped with a warm engine, the electric cooling system fans may activate without warning.
Danger
Electric cooling fans
Precautions
Use particular caution when working near these components. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_030...
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Identification and type approval labels
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Identification and type approval labels
Page 1 of 2
A - 'Do not install child seat on passenger seat' label
B - Mercury warning label
C - Safety standard compliance label
D - VIN label (Vehicle Identification Number)
E - Airbag maintenance label
F - Passenger airbag warning label
G - Unleaded fuel label
H - Radiator with antifreeze label
I - Emissions control data label
L - Punched engine type and number
M - Assembly number label
N - Engine and gearbox oil identification label
O - Gearbox type and number plate
P - Tyre type and pressure label https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_040...
8/1/2011
Identification and type approval labels
Q - TPMS system installed warning label
R - Chassis number plate
S - Original paintwork label
Page 2 of 2 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_040...
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'Do not install child seat on passenger seat' warning
Print Exit
04.02 'Do not install child seat on passenger seat' warning
'Do not install child seat on passenger seat' warning
Page 1 of 1
A - 'Do not install child seat on passenger seat' warning https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_040...
8/1/2011
Mercury content warning
Print Exit
Mercury content warning
B - Mercury content warning
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Safety standard compliance
Print Exit
04.04 Safety standard compliance
Safety standard compliance
C - Safety standard compliance
Page 1 of 2 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_040...
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V.I.N. (Vehicle Identification Number)
Print Exit
04.05 V.I.N. (Vehicle Identification Number)
V.I.N. (Vehicle Identification Number)
Page 1 of 1
D - V.I.N. (Vehicle Identification Number) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_040...
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Airbag maintenance
Print Exit
Airbag maintenance
E - Airbag maintenance
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Passenger airbag warning
Print Exit
Passenger airbag warning
F - Passenger airbag warning
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Unleaded fuel
Print Exit
Unleaded fuel
G - Unleaded fuel
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_040...
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Radiator containing antifreeze
Print Exit
04.09 Radiator containing antifreeze
Radiator containing antifreeze
H - Radiator containing antifreeze
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_040...
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Emissions control system specifications
Print Exit
Emissions control system specifications
I - Emissions control system specifications
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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Engine type and number
Print Exit
04.11 Engine type and number
Engine type and number
L - Engine type and number
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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Assembly number
Print Exit
Assembly number
M - Assembly number
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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Engine and gearbox oil identification
Print Exit
04.13 Engine and gearbox oil identification
Engine and gearbox oil identification
Page 1 of 1
N - Engine and gearbox oil identification https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
8/1/2011
Gearbox type and number
Print Exit
04.14 Gearbox type and number
Gearbox type and number
O - Gearbox type and number plate
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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Tyre type and pressure
Print Exit
Tyre type and pressure
P - Tyre type and pressure
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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TPMS system installed warning
Print Exit
TPMS system installed warning
Q - TPMS system installed warning
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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Chassis number
Print Exit
Chassis number
R - Chassis number
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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Original paint
Print Exit
Original paint
S - Original paint
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_041...
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Performance and consumption Page 1 of 1
Print Exit
05.01 Performance and consumption
Performance
DCT gearbox
0 to 62 mph
< 3.4 sec
1.312 ft from standing start
11.3 sec
Top speed
> 202 mph
Fuel consumption (estimated figures based on tests conducted with vehicles equipped with frequently requested options. Figures for 2008 models and later are calculated using EPA methods. The effective consumption for this vehicle may vary depending on driving style, the state of the vehicle, optional accessories fitted and the road and weather conditions in which the test is conducted)
Urban cycle
Extraurban cycle
Combined cycle
12 mpg
18 mpg
14 mpg https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_050...
8/1/2011
Dimensions and weights
Print Exit
05.02 Dimensions and weights
Dimensions and weights
Page 1 of 1
Max. length
Max. width
Max. height
178.23 in.
76.26 in.
47.76 in.
Front overhang
Rear overhang
Front track
Rear track
43.58 in.
30.31 in.
65.83 in.
63.23 in.
Kerb weight (DCT) 3384 lbs (with most favourable combination of options fitted) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_050...
8/1/2011
Fluid properties
Print Exit
Cooling circuit (1)
Protective fluid with antifreeze action for monoethylene glycol-based cooling systems. 50 %
Water 50 %
Windscreen washer/headlight washer system
Mixture of water and denatured isopropyl alcohol
Glass cleaner
50 %
2 phial
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A10...
8/1/2011
Fluids and lubricants table Page 1 of 1
Print Exit
A1.02 Fluids and lubricants table
Parts to be refilled
Engine (1) (2) (3)
Product Quantity
10.57 qts.
PENNZOIL ULTRA™ SAE 5W-40
Gearbox and differential
A.C. system - Compressor
Windscreen washer/headlight washer fluid tank
SHELL TRANSAXLE 75W-90 GL5 / SHELL SPIRAX
S5 ATE 75W-90
4.12 qts.
Clutch system and hydraulic controls
Brake system
Fuel tank - Reserve
A.C. system - Refrigerant
AC system - Refrigerant
(FROM Ass.ly No. 90177)
SHELL DCT-F3
95 RON unleaded fuel.
DELPHI RL 488 "R 134 A"
DELPHI RL 488 "R 134 A"
8.45 qts.
Cooling circuit (1)
SHELL DONAX UB BRAKE FLUID DOT4 Ultra /
SHELL BRAKE and CLUTCH DOT4 Ultra
SHELL DONAX TX / SHELL SPIRAX S4 ATF HDX
1.58 qts.
SHELL GLYCOSHELL LONGLIFE CONC (diluted by
50%)
17.44 qts.
1.69 qts. Hydraulic power steering system (1)
Hydraulic power steering system (FROM Ass.ly No.
98002) (1)
PENTOSIN CHF 11S
"Front Lift" hydraulic system (1)
Fuel tank
SHELL DONAX TX / SHELL SPIRAX S4 ATF HDX
95 RON unleaded fuel.
1.69 qts.
1.06 qts.
22.72 US Gallon
3.69 US Gallon
1.47 ± 0.07 lbs.
1.38 ± 0.07 lbs.
PAG ISO 46
Mixture of water and glass cleaner
10.07 cu.in.
1.32 US Gallon
Certain products in the fluids and lubricants table are indicated with the names used both prior to and after the change in nomenclature of Shell fluid products.
The technical characteristics of the products themselves, however, have remained unchanged.
(1) Empty.
(2) Between MIN and MAX 2.11 qts.
.
(3) Oil consumption 1.06 - 2.11 qts/600 miles . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A10...
8/1/2011
Pre-Delivery Inspection - PDI form Page 1 of 3
Print Exit
Pre-Delivery Inspection - PDI form
Model
458 Italia
Chassis number:
Job order n°:
Notes:
Description of inspection / operation:
1. - Battery connection and vehicle parameters reset.
2. - Check Park Lock device.
3. - Reset Park Lock device.
4. - Battery charge level; charge, if necessary.
5. - Disable “Logistic Mode” function (if enabled)
6. - Print out of parameters and errors for NCM ECUs, etc.
7. - Delete ECU errors.
8. - Test keys, etc.
9. - Day-time lights.
10. - Low beam lights.
11. - Check the vehicle front lift (if present).
12. - High beam lights.
13. - Stop lights.
14. - Turn indicators.
15. - Door lights, cabin light and luggage compartment light.
16. - Door, dashboard and glove compartment lights.
17. - Horn.
18. - Power windows .
19. - Windscreen wipers and headlight washer.
20. - Seats / Electric seats.
21. - Electric parking brake (EPB); manual/auto.
22. - HI-FI system / Navigation system (see point 33).
Page 01 of 03
Updated on
March 2010
Dossier creation date:
Performed
OK
Performed
NOT OK
R.O.L. N°
(if NOT OK) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Pre-Delivery Inspection - PDI form Page 2 of 3
Pre-Delivery Inspection - PDI form
Model
458 Italia
23. - Coolant level.
24. - Power steering fluid level.
25. - Braking system fluid level.
26. - Windscreen washer/headlight washer fluid level.
27. - Tyre pressure / calibrated pressure on TPMS.
28. - Tightening of wheel stud bolts.
29. - * Air conditioning and heating system (static test).
30. - * Electric rear-view mirrors.
31. - * RH or LH rear-view mirror – reverse gear engagement
32. - * Parking sensors.
33. - Navigation system: Set route.
34. - Test drive (20 min.).
35. - Air conditioning and heating system (dynamic test).
36. - Engine oil level (warm engine – at idle speed).
37. - Print out of parameters and errors for NCM ECUs, etc.
38. - Verify VIN from NCM parameters
39. - Delete ECU errors.
40. - Enter the warranty start date.
41. - Disconnect and reconnect the battery.
42. - Perform “CAR OUT” procedures
43. - Print Extended Identification
44. - Remove complete aerodynamic flap.
45. - Water and/or oil leaks in vehicle underbody.
46. - Engine compartment lines.
47. - Engine compartment wiring.
48. - Underbody lines.
49. - Exhaust line.
(
*
) With engine running.
Page 02 of 03
Updated on
March 2010
Performed
OK
Performed
NOT OK
R.O.L. N°
(if NOT OK) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
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Pre-Delivery Inspection - PDI form Page 3 of 3
Pre-Delivery Inspection - PDI form
Model
Page 03 of 03
Updated on
458 Italia
50. - Visual inspection of fuel tanks.
51. – Visual inspection: Suspension units, etc.
52. -Visual inspection of Earth: car/engine and gearbox-chassis.
53. - Condition of brake pads and discs (DO NOT remove wheels).
54. - Condition of tyres and wheel rims.
55. - Refit flat undertray and the engine compartment panels.
56. - Door and lid locks.
57. - Emergency opening of engine compartment lid and fuel tank flap.
58. - Condition of vehicle's leather upholstery.
59. - Condition of vehicle paintwork.
60. - Clean interior and wash car.
61. - Provided with vehicle: Labels, toolkits, etc.
Task performed by (Dealer):
Performed
OK
Technical Manager:
Name
(block letters)
Company stamp
Surname
Vehicle delivery date:
Full signature
March 2010
Performed
NOT OK
R.O.L. N°
(if NOT OK)
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8/1/2011
Scheduled Maintenance File Page 1 of 4
Print Exit
Scheduled Maintenance File
Model
458 Italia
Chassis number: Dossier creation date:
Job order No.:
Notes:
O
Mileage in
Km:
Yearly Maintenance
Description of procedure
A
Vehicle reception - preparation
B Indicator light check
C
External visual brake inspection (pads and discs); replace if necessary
Performed
OK
D EPB electric parking brake function check
E
Lifting the vehicle
F Internal visual brake wear inspection
G
Removing the rear bumper diffuser
H
Removing the rear flat undertray section
I Checking the gear oil level
L Checking the hydraulic clutch system fluid level
N Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
NOT
OK
O1
P
Q
R
R1
Replacing the ancillary drive belt (every 37,500 miles/2 years - replace more frequently if the vehicle is used in severe operating conditions)
Preparations necessary and draining engine oil via plug at base of oil tank (replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts
(perform while draining engine oil)
Checking tightness of engine and gearbox mounting strut fasteners
Page 1 of 2
Updated on
February 2011
Notes https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
S
Setting the vehicle on the ground
T
Replacing the engine oil filter
T1 Filling with engine oil
U Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
U1
Replacing brake fluid (every 2 years - replace more frequently if the vehicle is used in severe operating conditions)
V
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes
Page 2 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
Description of procedure
V1
Z4
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Z Replacing the pollen filter
Z3 Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years) a Start the vehicle to check engine oil level a1 Checking tyre pressure a2 Checking wheel tightness a3 Checking the A.C. system a4
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield a5
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions) a6 Checking function of headlights and horn a7
Checking windscreen wiper, windscreen washer and headlight washer system function a8
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids b
Lifting the vehicle c Visual inspection for leaks c1 Checking radiators for fouling; clean if necessary d
Refitting the rear flat undertray section d1
Refitting the rear bumper diffuser f
Setting the vehicle on the ground g Service counter reset g1 DEIS Diagnosis h Road test (vehicle test) i Car wash and cleaning interiors (optional)
L Treating interior trim in leather (if necessary)
Performed
OK
NOT
OK
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer):
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
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8/1/2011
Scheduled Maintenance File
Vehicle delivery date:
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8/1/2011
Scheduled Maintenance File Page 1 of 4
Print Exit
Scheduled Maintenance File
Model
458 Italia
Chassis number:
Job order No.:
Notes:
Dossier creation date:
Mileage in
Km:
20,000 Km (12,500 Miles)
Description of procedure
A
Vehicle reception - preparation
B Indicator light check
C
External visual brake inspection (pads and discs); replace if necessary
Performed
OK
NOT
OK
D EPB electric parking brake function check
E
Lifting the vehicle
F Internal visual brake wear inspection
G
Removing the rear bumper diffuser
H
Removing the rear flat undertray section
I Checking the gear oil level
L Checking the hydraulic clutch system fluid level
N Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
O
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
P
Q
Preparations necessary and draining engine oil via plug at base of oil tank (replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
R
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts
(perform while draining engine oil)
R1
Checking tightness of engine and gearbox mounting strut fasteners
S
Setting the vehicle on the ground
T
Replacing the engine oil filter
T1 Filling with engine oil
U Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
Page 1 of 2
Updated on
February 2011
Notes https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
V
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes
Page 2 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
Description of procedure
Performed
OK
V1
Z4
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Z Replacing the pollen filter
Z3 Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years) a Start the vehicle to check engine oil level a1 Checking tyre pressure a2 Checking wheel tightness a3 Checking the A.C. system a4
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield a5
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions) a6 Checking function of headlights and horn a7
Checking windscreen wiper, windscreen washer and headlight washer system function a8
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids b
Lifting the vehicle c Visual inspection for leaks c1 Checking radiators for fouling; clean if necessary d
Refitting the rear flat undertray section d1
Refitting the rear bumper diffuser f
Setting the vehicle on the ground g Service counter reset g1 DEIS Diagnosis h Road test (vehicle test) i Car wash and cleaning interiors (optional)
L Treating interior trim in leather (if necessary)
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer):
NOT
OK
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
Page 3 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
Vehicle delivery date:
Page 4 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File Page 1 of 4
Print Exit
Scheduled Maintenance File
Model
458 Italia
Chassis number:
Job order No.:
Notes:
Dossier creation date:
Mileage in
Km:
40,000 Km (25,000 Miles)
Description of procedure
Performed
OK
A
Vehicle reception - preparation
B Indicator light check
C
External visual brake inspection (pads and discs); replace if necessary
NOT
OK
D EPB electric parking brake function check
E
Lifting the vehicle
F Internal visual brake wear inspection
G
Removing the rear bumper diffuser
H
Removing the rear flat undertray section
I Checking the gear oil level
L Checking the hydraulic clutch system fluid level
N Preparations necessary and draining engine oil via plugs in crankcase
(replace more frequently if the vehicle is used in severe operating conditions)
O
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
P
Q
Preparations necessary and draining engine oil via plug at base of oil tank (replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
R
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts
(perform while draining engine oil)
R1
Checking tightness of engine and gearbox mounting strut fasteners
S
Setting the vehicle on the ground
T
Replacing the engine oil filter
T1 Filling with engine oil
U Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
Page 1 of 2
Updated on
February 2011
Notes https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
V
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes
Page 2 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
Description of procedure
V1
Z4
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Z Replacing the pollen filter
Z3 Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years) a Start the vehicle to check engine oil level a1 Checking tyre pressure a2 Checking wheel tightness a3 Checking the A.C. system a4
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield a5
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions) a6 Checking function of headlights and horn a7
Checking windscreen wiper, windscreen washer and headlight washer system function a8
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids b
Lifting the vehicle c Visual inspection for leaks c1 Checking radiators for fouling; clean if necessary d
Refitting the rear flat undertray section d1
Refitting the rear bumper diffuser f
Setting the vehicle on the ground g Service counter reset g1 DEIS Diagnosis h Road test (vehicle test) i Car wash and cleaning interiors (optional)
L Treating interior trim in leather (if necessary)
Performed
OK
NOT
OK
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer):
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
Page 3 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File
Vehicle delivery date:
Page 4 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A20...
8/1/2011
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
Scheduled Maintenance File
Model
Chassis number:
Job order No.:
Notes:
D
I
L
G
H
E
F
N
A
B
C
O
Dossier creation date:
Mileage in
Km:
60,000 Km (37,500 Miles)
Description of procedure
Vehicle reception - preparation
Indicator light check
External visual brake inspection (pads and discs); replace if necessary
Performed
OK o o
EPB electric parking brake function check o
Lifting the vehicle
Internal visual brake wear inspection
Removing the rear bumper diffuser
Removing the rear flat undertray section
Checking the gear oil level
Checking the hydraulic clutch system fluid level
Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
o
o o
o o
o
o o
o
NOT
OK
o o
R1
S
T
T1
U
V
O1
P
Q
R
Replacing ancillary drive belts (every 37,500 miles/2 years - replace more frequently if vehicle is used in severe operating conditions)
Preparations necessary and draining engine oil via plug at base of oil tank
(replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts (perform while draining engine oil)
Checking tightness of engine and gearbox mounting strut fasteners
Setting the vehicle on the ground
Replacing the engine oil filter
Filling with engine oil
Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes o
o o o o o
o
o
o o o o o
o
Page 1 of 2
Updated on
February 2011
Notes
1 of 2 8/5/2011 11:02 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
V1 a8 b c c1 i h g g1
L d d1 f a5 a6 a7
Z
Z1
Z3
Z4 a a1 a2 a3 a4
Description of procedure
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Replacing the pollen filter
Replacing spark plugs (replace more frequently if the vehicle is used in severe operating conditions)
Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years)
Start the vehicle to check engine oil level
Checking tyre pressure
Checking wheel tightness
Checking the A.C. system
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions)
Checking function of headlights and horn
Checking windscreen wiper, windscreen washer and headlight washer system function
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids
Lifting the vehicle
Visual inspection for leaks
Checking radiators for fouling; clean if necessary
Performed
OK o o o o o o o
o o o o o
o o o o
Refitting the rear flat undertray section
Refitting the rear bumper diffuser
Setting the vehicle on the ground
Service counter reset
DEIS Diagnosis
Road test (vehicle test)
Car wash and cleaning interiors (optional)
Treating interior trim in leather (if necessary) o o o
o o
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer): o
NOT
OK o o o o o
o o o o
o o o o o o o
o o o o o o
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
Vehicle delivery date:
2 of 2 8/5/2011 11:02 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
Scheduled Maintenance File
Model
R1
R2
S
T
T1
U
Chassis number:
Job order No.:
Notes:
D
I
L
G
H
E
F
N
A
B
C
O
P
Q
R
V
Dossier creation date:
Mileage in
Km:
80,000 Km (50,000 Miles)
Description of procedure
Vehicle reception - preparation
Indicator light check
External visual brake inspection (pads and discs); replace if necessary
Performed
OK
o
NOT
OK o o o
EPB electric parking brake function check o o
Lifting the vehicle
Internal visual brake wear inspection
Removing the rear bumper diffuser
Removing the rear flat undertray section
Checking the gear oil level
Checking the hydraulic clutch system fluid level
Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
o
o o o
o
o o
o
Preparations necessary and draining engine oil via plug at base of oil tank (replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts (perform while draining engine oil)
Checking tightness of engine and gearbox mounting strut fasteners
Cleaning, repairing or replacing pipes and hoses in emissions control system
Setting the vehicle on the ground
Replacing the engine oil filter
Filling with engine oil
Removing right hand underwindscreen shield cover to allow access to brake
fluid reservoir
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes
o o o o
o
o o
o o o o o o
o
Page 1 of 2
Updated on
February 2011
Notes
1 of 2 8/5/2011 11:01 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Description of procedure
V1
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) a5 a6 a7 a a1 a2 a3
V2
Z3
Z4 a4
Adjusting, cleaning, repairing or replacing ignition cables
Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years)
Start the vehicle to check engine oil level
Checking tyre pressure
Checking wheel tightness
Checking the A.C. system
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions)
Checking function of headlights and horn
Checking windscreen wiper, windscreen washer and headlight washer system function
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids
Lifting the vehicle
Visual inspection for leaks a8 b c c1 Checking radiators for fouling; clean if necessary i h g1 g2
L g f d d1
Refitting the rear flat undertray section
Refitting the rear bumper diffuser
Setting the vehicle on the ground
Service counter reset
DEIS Diagnosis
Adjusting idle speed
Road test (vehicle test)
Car wash and cleaning interiors (optional)
Treating interior trim in leather (if necessary)
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer):
Performed
OK o o o o o o
o
o o o o o o o o o o o
o o o o
NOT
OK o o o o
o o o o o o o o o
o o o o o
o o o o
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
Vehicle delivery date:
2 of 2 8/5/2011 11:01 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
Scheduled Maintenance File
Model
Chassis number:
Job order No.:
Notes:
D
I1
L
G
H
E
F
A
B
C
M2
N
O
P
Q
R
R1
S
T
T1
U
V
Dossier creation date:
Mileage in
Km:
100,000 Km (62,500 Miles)
Description of procedure
Vehicle reception - preparation
Indicator light check
External visual inspection of brakes (pads and discs), replace if necessary
EPB electric parking brake function check
Lifting the vehicle
Internal visual brake wear inspection
Removing the rear bumper diffuser
Removing the rear flat undertray section
Replacing gear oil
Checking the hydraulic clutch system fluid level
Changing power steering fluid
(change more frequently if vehicle is used in severe operating conditions)
Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
Preparations necessary and draining engine oil via plug at base of oil tank (replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts (perform while draining engine oil)
Checking tightness of engine and gearbox mounting strut fasteners
Setting the vehicle on the ground
Replacing the engine oil filter
Filling with engine oil
Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes
Performed
OK
o o o
o
o o o
o
o
o
o o o o o o o
o
o
o
o o o
o
o o
NOT
OK
o o
Page 1 of 2
Updated on
February 2011
Notes
1 of 2 8/5/2011 11:18 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Description of procedure
V1
Z
Z3
Z4
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Replacing the pollen filter
Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years)
Start the vehicle to check engine oil level a a5 a6 a7 a1 a2 a3 a4 a8 b c c1
Checking tyre pressure
Checking wheel tightness
Checking the A.C. system
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions)
Checking function of headlights and horn
Checking windscreen wiper, windscreen washer and headlight washer system function
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids
Lifting the vehicle
Visual inspection for leaks
Checking radiators for fouling; clean if necessary d d1 f g g1 h i
L
Refitting the rear flat undertray section
Refitting the rear bumper diffuser
Setting the vehicle on the ground
Service counter reset
DEIS Diagnosis
Road test (vehicle test)
Car wash and cleaning interiors (optional)
Treating interior trim in leather (if necessary)
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer):
Performed
OK o o o o o o
o o o o
o o o
o o o o o o o o
NOT
OK o o
o o o o o o o
o o o o o o o o o
o o o
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
Vehicle delivery date:
2 of 2 8/5/2011 11:18 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
Scheduled Maintenance File
Model
Chassis number:
Job order No.:
Notes:
D
I
L
G
H
E
F
N
A
B
C
O
Dossier creation date:
Mileage in
Km:
120,000 Km (75,000 Miles)
Description of procedure
Vehicle reception - preparation
Indicator light check
External visual brake inspection (pads and discs); replace if necessary
Performed
OK
o
NOT
OK o o o
EPB electric parking brake function check o o
Lifting the vehicle
Internal visual brake wear inspection
Removing the rear bumper diffuser
Removing the rear flat undertray section
Checking the gear oil level
Checking the hydraulic clutch system fluid level
Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
o
o o
o
o
o o
o
R1
R3
S
T
T1
U
V
O1
P
Q
R
Replacing ancillary drive belts (every 37,500 miles/2 years - replace more frequently if vehicle is used in severe operating conditions)
Preparations necessary and draining engine oil via plug at base of oil tank
(replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts (perform while draining engine oil)
Checking tightness of engine and gearbox mounting strut fasteners
Replacing oxygen sensors
(perform at 80,000 miles)
Setting the vehicle on the ground
Replacing the engine oil filter
Filling with engine oil
Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes o
o o o o o o
o
o
o o o o o o
o
Page 1 of 2
Updated on
February 2011
Notes
1 of 2 8/5/2011 11:19 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Description of procedure
V1
Z
Z1
Z3
Z4
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Replacing the pollen filter
Replacing spark plugs (replace more frequently if the vehicle is used in severe operating conditions)
Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years) a5 a6 a a1 a2 a3 a4 a7
Start the vehicle to check engine oil level
Checking tyre pressure
Checking wheel tightness
Checking the A.C. system
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions)
Checking function of headlights and horn
Checking windscreen wiper, windscreen washer and headlight washer system function
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids
Lifting the vehicle
Visual inspection for leaks
Checking radiators for fouling; clean if necessary a8 b c c1 i h g g1
L d d1 f
Refitting the rear flat undertray section
Refitting the rear bumper diffuser
Setting the vehicle on the ground
Service counter reset
DEIS Diagnosis
Road test (vehicle test)
Car wash and cleaning interiors (optional)
Treating interior trim in leather (if necessary)
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer):
Performed
OK o o o o o o o o o o
o o o o
o o o o o o
o o
NOT
OK o o o o
o o o o o o o o o
o o o o
o o o o o
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
Vehicle delivery date:
2 of 2 8/5/2011 11:19 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
Scheduled Maintenance File
Model
R1
R3
S
T
T1
U
Chassis number:
Job order No.:
Notes:
D
I
L
G
H
E
F
N
A
B
C
O
P
Q
R
V
Dossier creation date:
Mileage in
Km:
140,000 Km (87,500 Miles)
Description of procedure
Vehicle reception - preparation
Indicator light check
External visual brake inspection (pads and discs); replace if necessary
Performed
OK o o
EPB electric parking brake function check o
Lifting the vehicle
Internal visual brake wear inspection
Removing the rear bumper diffuser
Removing the rear flat undertray section
Checking the gear oil level
Checking the hydraulic clutch system fluid level
Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
o
o o
o
NOT
OK
o o o
o o
o o
Preparations necessary and draining engine oil via plug at base of oil tank (replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts (perform while draining engine oil)
Checking tightness of engine and gearbox mounting strut fasteners
Replacing oxygen sensors
(perform at 80,000 miles)
Setting the vehicle on the ground
Replacing the engine oil filter
Filling with engine oil
Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes
o o o o
o
o o
o o o o o o
o
Page 1 of 2
Updated on
February 2011
Notes
1 of 2 8/5/2011 11:20 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
a8 b c c1 i h
L g f d d1 g1
V1 a5 a6 a7 a a1 a2 a3
Z
Z3
Z4 a4
Description of procedure
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Replacing the pollen filter
Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years)
Start the vehicle to check engine oil level
Checking tyre pressure
Checking wheel tightness
Checking the A.C. system
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions)
Checking function of headlights and horn
Checking windscreen wiper, windscreen washer and headlight washer system function
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids
Lifting the vehicle
Visual inspection for leaks
Checking radiators for fouling; clean if necessary
Performed
OK o o
o o o o o o o o o o o
o
Refitting the rear flat undertray section
Refitting the rear bumper diffuser
Setting the vehicle on the ground
Service counter reset
DEIS Diagnosis
Road test (vehicle test)
Car wash and cleaning interiors (optional)
Treating interior trim in leather (if necessary) o
o o o o o
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer): o
NOT
OK o o o o
o o o o o o
o o o o o o o
o o o o
Technical Manager:
Name: Surname:
(block letters)
Page 2 of 2
Notes
(block letters)
Stamp with company trading name
Full signature
Vehicle delivery date:
2 of 2 8/5/2011 11:20 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
Scheduled Maintenance File
Model
R1
R2
R4
S
T
T1
U
Chassis number:
Job order No.:
Notes:
D
I
L
G
H
E
F
N
A
B
C
O
P
Q
R
V
Dossier creation date:
Mileage in
Km:
160,000 Km (100,000 Miles)
Description of procedure
Vehicle reception - preparation
Indicator light check
External visual brake inspection (pads and discs); replace if necessary
Performed
OK
o
NOT
OK o o o
EPB electric parking brake function check o o
Lifting the vehicle
Internal visual brake wear inspection
Removing the rear bumper diffuser
Removing the rear flat undertray section
Checking the gear oil level
Checking the hydraulic clutch system fluid level
Preparations necessary and draining engine oil via plugs in crankcase
(perform more frequently if vehicle is used in severe operating conditions)
Visual inspection for leaks and checking ancillary drive belt (perform while draining the engine oil)
o
o o
o
o
o o
o
Preparations necessary and draining engine oil via plug at base of oil tank (replace more frequently if the vehicle is used in severe operating conditions)
Checking front and rear suspension components (perform while draining the engine oil)
Visual inspection of differential-gearbox assembly, fasteners and bushings and the condition of the exhausts (perform while draining engine oil)
Checking tightness of engine and gearbox mounting strut fasteners
Cleaning, repairing or replacing pipes and hoses in emissions control system
Replacing catalytic converters
Setting the vehicle on the ground
Replacing the engine oil filter
Filling with engine oil
Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir
Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels
Visual inspection of pipes
o o o o o
o
o o
o o o o o o o
o
Page 1 of 3
Updated on
February 2011
Notes
1 of 3 8/5/2011 11:20 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
a8 b c c1 d d1 f a5 a6 a7
V1
V6
Z3
Z4 a a1 a2 a3 a4
V2
V3
V4
V5
Description of procedure
Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended)
Adjusting, cleaning, repairing or replacing ignition cables
Adjusting, cleaning, repairing or replacing air injection system components
Replacing fuel injectors
Adjusting, cleaning, repairing or replacing engine control
ECU and relative sensors (excluding oxygen sensors) and actuators
Adjusting, cleaning, repairing or replacing evaporative and fuel filler emissions canister
Replacing the airbag (every 15 years)
Replacing seat belts and pretensioners (every
15 years)
Start the vehicle to check engine oil level
Checking tyre pressure
Checking wheel tightness
Checking the A.C. system
Visual inspection of oil and fluid tightness and of areas subject to fretting (pipes and hoses)
Refitting cover on right hand underwindscreen shield
Final checks (open/close doors, check fuel filler cap and check seat and seat belt functions)
Checking function of headlights and horn
Checking windscreen wiper, windscreen washer and headlight washer system function
Checking and lubricating controls, adjustment mechanisms in general, hinges, doors and lids
Lifting the vehicle
Visual inspection for leaks
Checking radiators for fouling; clean if necessary
Refitting the rear flat undertray section
Refitting the rear bumper diffuser
Setting the vehicle on the ground
Performed
OK o o o o o o o o o o
o o
o o o o o o o
NOT
OK o o o o o o o o o
o o
o o o o o
o o o
Page 2 of 3
Notes
2 of 3 8/5/2011 11:20 AM
Scheduled Maintenance File https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Description of procedure i
L g g1 g2 h
Service counter reset
DEIS Diagnosis
Adjusting idle speed
Road test (vehicle test)
Car wash and cleaning interiors (optional)
Treating interior trim in leather (if necessary)
Check for the existence of open campaigns on the ModisCS system and record the service in the service entry
Procedure carried out by (Dealer):
Performed
OK o o o o o o o
NOT
OK o o o o o o o
Technical Manager:
Name: Surname:
(block letters)
Page 3 of 3
Notes
(block letters)
Stamp with company trading name
Full signature
Vehicle delivery date:
3 of 3 8/5/2011 11:20 AM
Checking engine oil level and changing engine oil and engine lubrication s... https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
A3.01
Checking engine oil level and changing engine oil and engine lubrication system filters
Checking the engine oil level
Always check the engine oil level with a warm engine.
The oil level must be checked with the vehicle standing on a level surface and with the engine idling.
The symbol shown aside is displayed on the left hand TFT display together with the message "Check engine oil level" to indicate that the engine oil level must be checked.
Proceed as follows:
1. Warm the engine to an engine oil temperature of 90 °C .
2. Run the engine at idle speed.
3. Wait 2 minutes , then open the engine compartment lid and undo the engine oil tank cap (1) .
4. Wipe the dipstick on the cap (1) .
5. Place the cap (1) on the tank filler pipe with the cap spring (A) in its seat, as shown in the image aside.
If the oil level is too low, identify the cause for excessive oil consumption before refilling.
The space between the MIN and MAX notches corresponds to approximately 2 litres of oil.
6. Remove the cap and check that the level is between the MIN and MAX notches on the dipstick.
DO NOT add oils with different specifications that the oil already in the engine.
7. Top up with the specified oil if necessary, taking care not to exceed the MAX level indicated on the dipstick.
1 of 5 8/5/2011 11:21 AM
Checking engine oil level and changing engine oil and engine lubrication s... https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
8. Screw the cap (1) back on tightly.
After topping up, the "Low oil level" symbol shown aside may remain active on the left hand TFT display for a prolonged period of time. This occurs to allow the system to perform all the checks necessary. This is completely normal.
9. After adding or replacing oil, check the oil level again using the procedure described above.
Draining the engine lubrication system
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Remove the rear flat undertray section ( E3.12
).
Undo the two drain plugs (1) on the crankcase and the plug (2) under the engine oil tank.
Drain the oil completely.
2 of 5
Replacing the engine oil filter
Tightening torque
Engine oil filter Engine oil filter cartridge
Nm
25 +0
-5
Nm
Replace damaged parts or parts that have been dropped, even if there is no visual damage.
Class
A
The engine oil filter is mounted on the engine oil heat exchanger, located behind the intake manifold, and is accessible by simply lifting the engine compartment lid.
The oil filter must be replaced at every oil change.
8/5/2011 11:21 AM
Checking engine oil level and changing engine oil and engine lubrication s... https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Drain the engine lubrication system ( A3.01
).
Remove the engine oil filter (A) with a 32 mm socket wrench fitted in the relative seat, an extension (USAG 236
1/2" L = 250mm) and a reversible ratchet.
Turning counterclockwise (as indicated by the arrow), unscrew the complete engine oil filter (A) .
Protect the surrounding area with absorbent cloths.
Remove the complete filter (A) via the space between the engine oil tank and the intake manifold.
3 of 5
On the workbench, detach the filter element (A1) from the cover (A2) , releasing the retainer tabs.
There are plastic tabs at the top of the filter element which fasten to the cover.
Dispose of the filter element (A1) correctly in accordance with applicable recycling procedures.
Remove the gasket (1) from the cover (A2) , taking particular care not to damage the seal recess.
Replace damaged parts or parts that have been dropped, even if there is no visual damage.
Select a new gasket (1) from the spare parts kit and install on the cover (A2) , taking particular care not to damage the gasket itself and the relative seal recess.
Ensure that the gasket (1) is installed correctly and is not twisted.
Replace damaged parts or parts that have been dropped, even if there is no visual damage.
DO NOT assemble the filter element if the drain pipe O-ring is missing.
Select a new filter element (A1) from the spare parts kit and check that the drain pipe O-ring (2) is installed correctly
DO NOT fit the filter element directly onto the casting without fastening to the cover first.
Fit the new filter element (A1) onto the cover (A2) , ensuring that the plastic retainer tabs click audibly into place.
When installing the filter element, take particular care not to bend or damage the plastic retainer tabs.
If the filter element does not fix correctly to the cover, check that the By-pass valve is still correctly installed in the cover. If the valve has accidentally detached, replace the cover with a new component. Do not attempt to repair the By-pass valve, as this may severely compromise filtration.
Check that the filter element (A1) is securely fastened to the cover (A2) .
Lubricate the outer edge of the gasket (1) with new engine oil.
8/5/2011 11:21 AM
Checking engine oil level and changing engine oil and engine lubrication s... https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Fit the complete engine oil filter (A) correctly in the relative seat on the engine, taking care not to damage the filter during assembly.
Fasten the engine oil filter (A) with a 32 mm socket wrench fitted in the relative seat, an extension (USAG 236
1/2" L = 250mm) and a reversible ratchet.
4 of 5 8/5/2011 11:21 AM
Inspecting oil level and replacing Shell Transaxle 75W-90 GL5 gear oil https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
Print Exit
A3.02
Inspecting oil level and replacing Shell Transaxle 75W-90 GL5 gear oil
Checking the Shell Transaxle 75W-90 GL5 gear oil level
Tightening torque
Fastening gearbox oil filler/drain plug and clutch hydraulic fluid filler/drain plug
Plug
Nm
25 Nm
Class
B
The following procedures must be carried out exactly as described to ensure that the hydraulics are proper lubricated and function correctly.
To check the gear oil level correctly, carry out the following procedures precisely as described.
Remove the rear diffuser ( E3.12
).
Before carrying out any work concerning the transmission oil level, ensure that: the vehicle is perfectly levelled on the car lift; reverse gear is engaged, the brake pedal is depressed and the engine is running at idle speed; engine coolant temperature is 40 - 50 °C .
CAUTION
HOT OIL may be released: use adequate protection.
Undo the threaded plug (1) located on the rear surface of the transmission, and check the level: the fluid must reach the edge of the hole from which the plug was removed, on the limit of overflowing.
If the level is too low, identify the possible causes for excessive consumption before refilling.
If topping up is necessary, proceed as follows.
Using the pump ( AV 8174 ) with attachment 01 (with the short spout), aspirate the specified oil from a newly opened container.
Using the pump ( AV 8174 ) with attachment 01 and a container for collecting excess oil, top up via the level pipe until excess oil overflows from the orifice of the cap remove previously.
Let the oil fluid completely until the flow stops.
Tighten the threaded plug (1) .
Tightening torque
Plug
Nm
25 Nm
Class
B
Refit the rear diffuser ( E3.12
).
Draining the Shell Transaxle 75W-90 GL5 gear oil
1 of 2 8/5/2011 11:21 AM
Inspecting oil level and replacing Shell Transaxle 75W-90 GL5 gear oil https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=li...
The gear oil must be changed at the intervals specified in the MAINTENANCE SCHEDULE.
Remove the rear flat undertray section ( E3.12
).
Place a container under the plugs indicated in the figure to collect the oil.
Undo the plugs (1) and (2) at the bottom of the gearbox housing.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Drain the oil completely.
Filling the system with Shell Transaxle 75W-90 GL5 gear oil
Tightening torque
Fastening gearbox oil filler/drain plug and clutch hydraulic fluid filler/drain plug
Plug
Nm
25 Nm
Class
B
Clean the plugs (1) and (2) thoroughly with a suitable degreaser that does not leave residue, and replace the seals.
Tighten the plugs (1) and (2) .
Tightening torque
Plug
Nm
25 Nm
Class
B
Undo the threaded inspection/filler plug (3) located on the rear surface of the transmission.
2 of 2
Using the pump ( AV 8174 ) with attachment 01 (with the short spout), aspirate the specified oil from a newly opened container.
Using the pump ( AV 8174 ) element 01 and a container for collecting excess oil, fill with 3.9 litres of oil via the inspection/filler orifice.
Fill with half of the quantity indicated, wait a few minutes for the fluid to settle, then gradually finish filling, until oil overflows from the check/filler hole.
The quantity of oil required may vary slightly relative to the amount indicated for filling the tank when empty; this is due to unavoidable pooling within the system. Fill gradually.
Check the Shell Transaxle 75W-90 GL5 gear oil level (
Check that there is no leakage from the drain plugs.
A3.02
).
8/5/2011 11:21 AM
Checking Shell DCT F-3 hydraulic clutch system fluid level
Print Exit
A3.03 Checking Shell DCT F-3 hydraulic clutch system fluid level
Checking Shell DCT F-3 hydraulic clutch system fluid level
Page 1 of 2
Tightening torque
Fastening gearbox oil filler/drain plug and clutch hydraulic fluid filler/drain plug
Nm Class
The following procedures must be carried out exactly as described to ensure that the hydraulics are proper lubricated and function correctly.
To check the hydraulic clutch system fluid level correctly, carry out the following procedures precisely as described.
Remove the rear flat undertray section ( E3.12
).
Before carrying out any work concerning the oil level in the hydraulic clutch system, ensure that: the vehicle is perfectly levelled on the car lift; reverse gear is engaged, the brake pedal is depressed and the engine is running at idle speed; engine coolant temperature is 40 - 50 °C .
CAUTION
HOT OIL may be released: use adequate protection.
Undo the threaded plug (1) , located on the left on the bottom of the differential housing.
This hole is connected to a level pipe.
When the threaded plug is unscrewed, fluid pooling within the level pipe may drain out. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Checking Shell DCT F-3 hydraulic clutch system fluid level Page 2 of 2
Check the fluid level with the level pipe (2) : the fluid must reach the upper edge of the pipe, on the limit of overflowing.
If the level is too low, identify the possible causes for excessive consumption before refilling.
If the level is too low (oil not overflowing), top up as follows.
Using the pump ( AV 8174 ) with attachment 02 (with the long spout), aspirate the specified oil from a newly opened container.
Using the pump ( AV 8174 ) with attachment 02 and a container for collecting excess oil, top up via the level pipe until excess oil overflows.
Let the oil fluid completely until the flow stops.
Check that the hydraulic fluid temperature does not exceed 80 °C during operation.
Tighten the threaded plug (1) .
Tightening torque Nm Class
Refit the rear flat undertray section ( E3.12
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Checking the windscreen and headlight washer fluid level Page 1 of 1
Print Exit
A3.04 Checking the windscreen and headlight washer fluid level
Checking the windscreen and headlight washer fluid level
The windscreen/headlight washer fluid reservoir cap is located underneath the luggage compartment lid.
Open the cap (A) on the windscreen/headlight washer fluid filler pipe.
Check that the level of the windscreen/headlight washer fluid level is visible in the filler neck.
If the level of the windscreen/headlight washer fluid level is not visible in the filler neck, top up with the specified fluid until the level is visible in the filler neck.
Close the cap (A) .
A level sensor mounted on the reservoir detects when the windscreen/headlight washer fluid level is too low and causes the relative warning light on the control panel to light.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Checking brake system fluid level
Print Exit
Checking brake fluid reservoir level
Page 1 of 3
The brake fluid reservoir is located at the centre of the luggage compartment, underneath the right hand underwindscreen shield.
Open and close the cover VERY CAREFULLY, as the fastener tabs are particularly fragile.
Remove the cover (A) from the right hand underwindscreen shield to access the brake fluid reservoir cap, prising off at the position indicated by the arrow.
Undo the cap (B) from the brake fluid reservoir. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Checking brake system fluid level Page 2 of 3
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
Check that the brake fluid level in the reservoir is near the MAX limit.
Levels approaching the MIN limit may be indicative of excessive brake fluid consumption.
If the level is near the MIN limit, top the system up with brake fluid as follows.
Always use fresh oil of the recommended type and in the quantity indicated, taken from sealed containers.
The circuit is filled with synthetic oil.
Using mineral oil may cause irreparable damage to the rubber seals in the system.
Fill the brake fluid reservoir to the MAX level.
Tighten the cap (B) firmly onto the brake fluid reservoir.
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Checking brake system fluid level Page 3 of 3
Open and close the cover VERY CAREFULLY, as the fastener tabs are particularly fragile.
Fit the cover (A) onto the right hand underwindscreen shield, inserting the rear tabs in the respective seats first and then the front tabs.
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8/5/2011
Checking the power steering system fluid level
Print Exit
A3.06 Checking the power steering system fluid level
Checking the power steering system fluid level
Page 1 of 2
FROM Ass.ly No. 98002, a different power steering fluid is prescribed.
Before topping up or filling, always check which type of fluid should be used, as mixing the two different types of power steering fluid will damage the power steering system itself.
The power steering fluid level must be checked with the system warm, after driving for at least 15 Km.
If checked cold, the level may appear to be excessively low even with the correct amount of fluid in the system.
At the intervals specified in the MAINTENANCE SCHEDULE, check the level of liquid in the power steering system.
Undo and open the cap (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
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Checking the power steering system fluid level Page 2 of 2
Use the dipstick on the cap (A) to check that the power steering fluid level is between the MIN and MAX levels.
There are MIN and MAX levels indicated on both sides of the dipstick. Use the levels on the side indicating the temperature 90°C .
Always use fresh oil of the recommended type and in the quantity indicated, taken from sealed containers.
The circuit is filled with synthetic oil.
Using mineral oil may cause irreparable damage to the rubber seals in the system.
If the level is near the MIN level, top up with power steering fluid to reach the MAX level.
Levels approaching the MIN limit may be indicative of excessive power steering fluid consumption.
Close and tighten the cap (A) securely. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Checking coolant level and topping up Page 1 of 3
Print Exit
Checking the cooling system fluid level
CAUTION
The fluid contained in the cooling system reaches extremely high temperatures and pressure.
ALWAYS WORK WHEN THE ENGINE IS COLD.
Check that the coolant level is always as indicated by the dotted line in the figure aside.
If not, unscrew the cap (A) and top up to the correct level with the specified fluid.
Fully tighten the filler cap (A) onto the expansion tank.
Filling the cooling system
CAUTION
The fluid contained in the cooling system reaches extremely high temperatures and pressure.
ALWAYS WORK WHEN THE ENGINE IS COLD.
Check that all the connection sleeve clamps are tight.
Static filling (engine off)
Remove the engine compartment cosmetic shields ( E3.13
).
Remove right hand engine compartment shield.
01) Do not disconnect bleed pipes on expansion tank. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
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Checking coolant level and topping up Page 2 of 3
02) Undo expansion tank plug (1) and slowly pour coolant, alternating this operation with repeated pauses of a few seconds so as to allow the bleeding of the air present inside system.
03) Pay attention to the passage of coolant inside vent pipe (2) from engine to expansion tank to confirm the first filling of engine cooling circuit.
04) Complete filling until reaching the point where fluid inside expansion tank is at 60 mm from filler plug top (1) ( MAX level ), corresponding to about
2 litres of coolant inside expansion tank.
Dynamic filling (engine on)
05) Screw plug (1) onto expansion tank. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
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Checking coolant level and topping up Page 3 of 3
06) Check that heater circuit is off.
07) Start engine at idle speed and wait for 5 minutes .
08) Keep engine running at idle speed , check level and, if necessary, top up until MAX level.
09) Take and keep engine at 2000 rpm for 30 seconds .
10) Take and keep engine at idle speed for 30 seconds .
11) Take and keep engine at 2000 rpm for 30 seconds .
12) Take and keep engine at idle speed for 30 seconds .
13) Take and keep engine at 2000 rpm for 30 seconds .
14) Take and keep engine at idle speed for 2 minutes (or until radiators electric fans are enabled).
15) Keep engine running at idle speed , check level and, if necessary, top up until MAX level.
16) Take and keep engine at 2000 rpm for 1 minute .
17) Take and keep engine at idle speed for 30 seconds .
18) Open heater circuit selecting the max. temperature of air conditioning system for both “zones”.
19) Take and keep engine at 3000 rpm for 1 minute .
20) Take and keep engine at idle speed for 2 minutes .
21) Keep engine running at idle speed , check level and, if necessary, top up until MAX level.
22) Take and keep engine at 3000 rpm for 1 minute .
23) Take and keep engine at idle speed for 1 minute .
24) Take and keep engine at 3000 rpm for 1 minute .
25) Take and keep engine at idle speed for 1 minute .
26) Close heater circuit.
27) Turn engine off.
28) Allow engine to cool until water temperature is 40 - 45 °C ( 1h and 30'- 2 hours ) with expansion tank plug open.
29) If necessary, top up until reaching the point where fluid level in header tank is 60 mm from filler plug top (1) ( MAX level ).
Tighten the cap (1) .
Refit the engine compartment cosmetic shields ( E3.13
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the active carbon filter Page 1 of 5
Print Exit
A3.08 Replacing the active carbon filter
Removing the active carbon filter
Replace the active carbon filter at the intervals specified in the MAINTENANCE SCHEDULE. The filter is located in front of the left hand rear wheel bay.
Disconnect the battery ( F2.01
).
Remove the rear flat undertray section ( E3.12
).
Remove the rear wheelhouses ( E3.05
).
Remove the rear left hand wheelhouse.
Only for vehicles with TPMS tyre pressure monitoring system (optional)
Remove the bracket (1) , complete with trigger, undoing the screws indicated and without disconnecting the trigger from the system.
Remove pipe (7) from the indicated mounting rib. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the active carbon filter Page 2 of 5
On pipes (2) there are two "double lock" safety clips.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of quick coupling, and detach pipes (2) from the active carbon filter (A) .
Disconnect the connector (4) .
Undo the screw indicated fastening the active carbon filter mounting bracket (A) .
Working from underneath, undo the two screws indicated fastening the active carbon filter mounting bracket (A) .
Remove the active carbon filter (A) from the wheel bay.
Remove the active carbon filter (A) completely from the wheel bay, complete with mounting bracket, diagnostic pump filter and diagnostic pump.
On the work bench, detach the active carbon filter from the relative mounting bracket.
Refitting the active carbon filter https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the active carbon filter Page 3 of 5
Tightening torque
Fastening active carbon filter mounting bracket to chassis
Nm Class
Fit the active carbon filter on the relative mounting bracket as originally installed.
Fit the active carbon filter (A) complete with bracket in the wheel bay.
Fit the active carbon filter (A) , complete with bracket, in the relative seat and tighten the two screws indicated.
Tightening torque Nm Class
Tighten the screw indicated fastening the active carbon filter mounting bracket (A) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
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Replacing the active carbon filter Page 4 of 5
After connecting the quick connector pipes (2) correctly onto active carbon filter (A) , with due caution and pressing on both sides of the "double-lock" clips indicated, push the clips into their seats until they click audibly into place and the pipes are secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
Connect the connector (4) .
Secure pipe (7) inside the indicated mounting rib.
Only for vehicles with TPMS tyre pressure monitoring system (optional)
Fasten the bracket (1) , complete with trigger, onto the chassis, tightening the screws indicated.
Refit the rear wheelhouses ( E3.05
).
Refit the rear left hand wheelhouse.
Refit the rear flat undertray section ( E3.12
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the active carbon filter
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Perform the " Fuel tank tightness test " cycle.
Page 5 of 5 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the oxygen sensors
Print Exit
A3.09 Replacing the oxygen sensors
Replacing the front oxygen sensors
Page 1 of 8
Tightening torque
Oxygen sensors Oxygen sensor
Nm
50 Nm
Do not clean or apply grease on the oxygen sensor thread.
Do not use solvents or thread locking products as they may impede correct sensor operation.
The oxygen sensor thread is pre-lubricated by the manufacturer with a specific product.
Class
B
Whenever a sensor is replaced, the self-acquired parameters must be deleted from the ECU memory.
The front oxygen sensors are mounted on the exhaust manifolds.
Disconnect the battery ( F2.01
).
Front left hand oxygen sensor
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the left hand engine compartment shield.
Remove the rear wheelhouses ( E3.05
).
Remove the rear left hand wheelhouse. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the oxygen sensors Page 2 of 8
Disconnect the connector (1) .
Detach the indicated clamp fastening the cable.
Unscrew and remove the front left hand oxygen sensor (A) from the left hand exhaust manifold and replace.
Tighten the front left hand oxygen sensor (A) onto the left hand exhaust manifold.
Tightening torque
Oxygen sensor
Nm
50 Nm
Class
B
Attach the indicated clamp fastening the cable.
Connect the connector (1) .
Refit the rear wheelhouses ( E3.05
).
Refit the engine compartment cosmetic shields ( E3.13
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the oxygen sensors
Front right hand oxygen sensor
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the right hand engine compartment shield.
Remove the rear wheelhouses ( E3.05
).
Remove the rear right hand wheelhouse.
Disconnect the connector (1) .
Page 3 of 8
Unscrew and remove the front right hand oxygen sensor (A) from the right hand exhaust manifold and replace.
Tighten the front right hand oxygen sensor (A) onto the right hand exhaust manifold.
Tightening torque
Oxygen sensor
Nm
50 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the oxygen sensors
Connect the connector (1) .
Page 4 of 8
Refit the rear wheelhouses ( E3.05
).
Refit the engine compartment cosmetic shields ( E3.13
).
Reconnect the battery ( F2.01
).
Replacing the rear oxygen sensors
Tightening torque
Oxygen sensors Oxygen sensor
Nm
50 Nm
Do not clean or apply grease on the oxygen sensor thread.
Do not use solvents or thread locking products as they may impede correct sensor operation.
The oxygen sensor thread is pre-lubricated by the manufacturer with a specific product.
Class
B
Whenever a sensor is replaced, the self-acquired parameters must be deleted from the ECU memory.
The rear oxygen sensors are mounted onto the rear of the catalytic converters.
Disconnect the battery ( F2.01
).
Rear left hand oxygen sensor
Remove the rear diffuser ( E3.12
).
Remove the rear wheelhouses ( E3.05
).
Remove the rear left hand wheelhouse. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the oxygen sensors Page 5 of 8
Disconnect the connector (1) , detaching from the relative mounting bracket.
Undo the relative fastener screw to open the clamp with sheath (2) fastening the rear left hand oxygen sensor cable.
Unscrew and remove the rear left hand oxygen sensor (A) from the left hand catalytic converter and replace.
Tighten the rear left hand oxygen sensor (A) onto the left hand catalytic converter.
Tightening torque
Oxygen sensor
Nm
50 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
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Replacing the oxygen sensors Page 6 of 8
Tighten the relative fastener screw to close the clamp with sheath (2) fastening the rear left hand oxygen sensor cable.
Connect the connector (1) , attaching onto the relative mounting bracket.
Refit the rear wheelhouses ( E3.05
).
Refit the rear diffuser ( E3.12
).
Rear right hand oxygen sensor
Remove the rear diffuser ( E3.12
).
Remove the rear wheelhouses ( E3.05
).
Remove the rear right hand wheelhouse. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the oxygen sensors Page 7 of 8
Disconnect the connector (1) , detaching from the relative mounting bracket.
Undo the relative fastener screw to open the clamp with sheath (2) fastening the rear right hand oxygen sensor cable.
Unscrew and remove the rear right hand oxygen sensor (A) from the right hand catalytic converter and replace.
Tighten the rear right hand oxygen sensor (A) onto the right hand catalytic converter.
Tightening torque
Oxygen sensor
Nm
50 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the oxygen sensors Page 8 of 8
Tighten the relative fastener screw to close the clamp with sheath (2) fastening the rear right hand oxygen sensor cable.
Connect the connector (1) , attaching onto the relative mounting bracket.
Refit the rear wheelhouses ( E3.05
).
Refit the rear diffuser ( E3.12
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A30...
8/5/2011
Replacing the engine air filter
Print Exit
A3.10 Replacing the engine air filter
Replacing the air filter
Page 1 of 2
Place a few strips of adhesive tape to protect the bodywork on the areas shown in the photo aside.
Undo the screws indicated fastening the air filter box cover (A) to the air filter box.
WARNING: take care not to damage the bodywork during air filter box cover handling.
Prise out and move the air filter box cover (A) out of its seat.
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8/5/2011
Replacing the engine air filter Page 2 of 2
Remove the air filter (B) from the relevant seat and replace.
Fit the new air filter (B) in the relevant seat.
WARNING: take care not to damage the bodywork during air filter box cover handling.
Fit the air filter box cover (A) in its relevant seat.
Tighten the screws indicated fastening the air filter box cover (A) to the air filter box.
Remove the adhesive tape fitted previously. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Replacing the air conditioning and heating system filter Page 1 of 1
Print Exit
A3.11 Replacing the air conditioning and heating system filter
Replacing the pollen filter
The pollen filter is located under the luggage compartment lid, on the right hand underwindscreen shield.
Gently detach and remove the seal (A) from the relative seat.
Remove the pollen filter (B) from the relative seat and replace.
Fit the new pollen filter (B) in the relative seat.
Fit and affix the seal (A) in the relative seat.
If necessary, apply new double sided adhesive tape underneath the seal (A) to fix into the relative seat. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking tension and replacement of auxiliary utilities belts
Print Exit
A3.12 Checking tension and replacement of auxiliary utilities belts
Checking the tension of the ancillary belt
Page 1 of 3
Tightening torque
Fastening complete tensioner Screw
Remove the rear flat undertray section ( E3.12
).
Nm
25 Nm
Class
B
Crank the engine by a few revolutions then apply the frequency probe (A) of the belt tension measurement instrument ( 95978151 ) at the mid point of the lower section of belt, avoiding contact with the belt.
Tap the belt near the probe with a screwdriver and check that the value indicated by the instrument is 156 ± 10 Hz .
If the tension measured is less than the prescribed value, replace the complete belt tensioner as follows.
Remove the belt as illustrated previously.
Undo the screw (3) and remove the complete tensioner (2) .
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Checking tension and replacement of auxiliary utilities belts Page 2 of 3
When fitting the new belt tensioner, ensure that the locator pin (B) is correctly inserted in the relative seat on the front engine cover.
Fit the tensioner (2) and fasten by tightening the screw (3) .
Tightening torque Nm Class
Repeat the ancillary drive belt tension setting procedure described previously.
Refit the rear flat undertray section ( E3.12
).
Removing the ancillary belt
The engine ancillary drive belt must be replaced at the intervals specified in the MAINTENANCE SCHEDULE.
Remove the rear flat undertray section ( E3.12
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking tension and replacement of auxiliary utilities belts Page 3 of 3
Work from underneath the vehicle.
With a 15 mm (1) fixed wrench applied to the tensioner pulley fastener screw (2) , rotate the mobile tensioner counterclockwise to loosen the belt and enable its removal, first from the pulley on the A.C. compressor, then from the other pulleys.
Remove the worn belt (A) .
Refitting the ancillary belt
In order not to damage the belt, do not fold it with sharp corners and do not let it come into contact with oil or fuel.
Working by hand only and using no tools, fit the belt
(A) as originally installed onto the relative pulleys and tensioners.
Check the tension of the ancillary belt ( A3.12
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking and replacing spark plugs Page 1 of 2
Print Exit
A3.13 Checking and replacing spark plugs
Removing the spark plugs
Disconnect the battery ( F2.01
).
Remove the ignition coils ( F3.02
).
Using a universal articulated wrench, undo and remove the spark plugs (A) .
Refitting the spark plugs
Tightening torque
Fastening spark plug Spark plug
Nm
11 Nm
Class
A
Before refitting the spark plugs, check that they are in good condition and replace if necessary.
Check that the spark plug electrode gap is between 0.6 and 0.7 mm. Oil the threaded part of the spark plug with very little oil. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking and replacing spark plugs Page 2 of 2
When refitting the original spark plugs, clean them with compressed air to remove any dirt.
Fit the spark plugs (A) in the relevant holes in the cylinder head.
Use an articulated wrench to hand tighten the spark plugs until the gasket sits up against the support seat.
Loosen slightly.
Use a torque wrench to tighten the spark plugs.
Tightening torque
Spark plug
Nm
11 Nm
Class
A
Refit the ignition coils ( F3.02
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking Blow-by system pipes and connections
Print Exit
A3.14 Checking Blow-by system pipes and connections
Checking Blow-by system pipes and connections
Page 1 of 1
Check the state of the pipes (1) , (2) , (3) and the tightness of the relative clamps, around the oil tank and intake ducts.
Check the connections. Replace the relative pipe and/or clamp if any leakage or sweating is noted.
Check the state of the pipes (4) and the tightness of the relative unions on both cylinder heads.
Replace the relative pipe and/or clamp if any leaks are noted.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking cooling system pipes and connections Page 1 of 1
Print Exit
A3.15 Checking cooling system pipes and connections
Checking cooling system pipes and connections
Remove the rear flat undertray section ( E3.12
).
Remove the central flat undertray section ( E3.12
).
Remove the front flat undertray section ( E3.12
).
Check that the pipes and pipe unions on the water pump, the radiator and the expansion tank are undamaged.
Replace any worn pipe unions or loose clamps. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking injection and ignition system pipes and connections
Print Exit
A3.16 Checking injection and ignition system pipes and connections
Checking injection and ignition system pipes and connections
Page 1 of 1
Remove the engine compartment cosmetic shields ( E3.13
).
Check the state of the connection pipes between the fuel tank and the high pressure pump, and of the fuel rail on the intake manifold.
In the event of leakage, replace the pipe and check the system.
Remove the rear wheelhouses ( E3.05
).
Check the state of the cables and connectors for the Motronic ECUs and the coils. If the outer casing or the connector locks are damaged, replace the cable.
In the event of malfunction, check the spark plugs. Replace the spark plugs at the intervals indicated in the
MAINTENANCE SCHEDULE. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking exhaust system connections Page 1 of 1
Print Exit
A3.17 Checking exhaust system connections
Checking exhaust system connections
Remove the rear diffuser ( E3.12
).
Remove the rear flat undertray section ( E3.12
).
Refit the rear wheelhouses ( E3.05
).
Remove the engine compartment cosmetic shields ( E3.13
).
Check the state of the system components, the connections between the manifolds and the catalytic converters, and the connections between the catalytic converters and the silencers, then check the fasteners. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking exhaust emissions Page 1 of 1
Print Exit
A3.18 Checking exhaust emissions
Checking exhaust emissions
Remove the engine compartment cosmetic shields ( E3.13
).
Check CO, HC and NOx levels by connecting the tester to the unions on the connector pipes for the exhaust manifold, after removing the two nuts (1) .
After completing the procedure, tighten the two nuts
(1) .
Refit the engine compartment cosmetic shields ( E3.13
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking service brakes for wear Page 1 of 6
Print Exit
A3.19 Checking service brakes for wear
Checking service brakes for wear
At the intervals indicated in the Maintenance Schedule, check the state of wear of the brake pads and discs.
Remove the wheels ( D2.01
).
Remove all.
The front brake pads are fitted with a wear indicator connected to the brake failure warning light on the instrument panel. Should this warning light illuminate, check the thickness of the pads and the state of the braking surfaces on the discs.
In the event of excessive wear, even of just one pad, replace all the pads on the axle.
Checking and inspecting the brake discs
The brake discs must be perfectly clean, free of any oil, grease or rust, and must not be excessively scored.
In the event of poor braking performance not attributable to the state of the brake pads and callipers, carry out a series of dimensional checks on the discs.
Using a dial gauge, measure the planarity with the disc fitted on the wheel hub.
Using a micrometer, measure the parallelism between the contact surfaces and the pads at different points on the braking surface.
Using the special tool, check the roughness of the pad contact surface.
The rear discs differ from the front discs in that they have two additional holes to enable access to the brake shoe adjustment pin without removing the disc.
They also have a large friction surface on the inner side for the parking brake.
Checking CCM brake disc wear
This operation includes: visually inspecting for alterations in the brake disc friction surface; checking the minimum brake disc thickness (maximum permitted wear 0.5 mm ); checking the brake disc edges for damage (damage caused by improper use).
The brake discs must be replaced if: there are significant alterations in the friction surface; the brake discs are worn beyond the minimum required thickness (material abraded).
Normally, both forms of brake disc wear occur simultaneously. Only rarely, following prolonged stress on the race track with large temperature variations on the friction surface, surface alteration may become so pronounced as to necessitate earlier replacement of the brake discs.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking service brakes for wear Page 2 of 6
The front and rear CCM brake discs must always be replaced in pairs (both discs on the same axle).
Front and rear CCM disc wear is calculated by the instrument panel operating software, which uses an algorithm to determine when to switch on the relative indicator to warn the driver.
The bedding in procedure must be carried out after replacing discs or the pads alone.
Disc replacement is necessary when the wear limit is reached, as indicated by the relative warning on the
TFT display, or if visual inspection reveals any surface damage.
Visual inspection of the disc friction surface
The alterations in the friction surface are caused by the material oxidising as a result of extremely high thermal stress. The high temperatures reached by the brake discs, especially in race track conditions, cause the material to oxidise progressively.
Surface alteration is detrimental to braking comfort, reduces brake disc resistance and increases pad wear, requiring the replacement of components earlier than scheduled.
Understanding the signs of brake disc wear and consequent operations necessary:
The figure aside shows the friction surface after normal brake usage in road conditions; disc replacement is not necessary in this case.
The figure aside shows the friction surface after a long journey, with only one intense brake application; here too, disc replacement is not necessary.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking service brakes for wear Page 3 of 6
The figure aside shows the friction surface after an appropriate mileage or following maximum stress in track conditions; disc replacement is necessary in this case.
The figure aside shows the friction surface after an appropriate mileage or following maximum stress in track conditions; disc replacement is necessary in this case.
Checking minimum disc thickness
The minimum thickness of cross-drilled discs must always be measured at the base of the inner or outer friction surface track. Use a suitable micrometrical screw or a brake disc template.
Maximum permissible wear is 0.5 mm
Checking disc edges for damage https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
8/5/2011
Checking service brakes for wear Page 4 of 6
Regardless of the overall state of wear, discs with damage around the edge must be replaced.
Unauthorised work to the holes drilled in the brake disc surface may damage the disc.
If necessary, clean the holes drilled in the brake discs and the friction surface with a high pressure cleaner.
Never carry out mechanical work on the disc holes.
CAUTION
When using pressure cleaners to clean discs, use adequate face protection.
When assessing damage to the disc edges, apply the following criteria: maximum permissible width/depth 2 mm ; maximum permissible length (10 mm) ; no more than 3 damaged areas are permissible.
Check CCM brake pad wear
After severe race track use, visually inspect the appearance of the pads as well as checking for wear. If a marked white coloration is noted around the edges of the pads, extending almost as far as the metal backing plate, the pads must be replaced to ensure optimum braking performance.
CCM brake disc wear
As the discs wear, their mass reduces. This is due to two simultaneous effects - a thermal effect, which burns the carbon fibres, and a mechanical abrasion effect between the disc and pad.
The instrument panel operating software uses an algorithm to calculate, in relation to effective vehicle usage
(e.g.: deceleration caused by braking), separate wear indices for the front P(a) and rear P(p) carbon brake discs, expressed as a percentage (%) of wear. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
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Checking service brakes for wear Page 5 of 6
These indices are periodically compared against a threshold value (100%) . Upon reaching this threshold, an amber warning signal (possible danger of disc failure) is shown on the TFT display, warning the user that disc replacement is necessary.
The user is warned of this condition by the appearance of the message: “CCM brake discs worn” on the display, together with the specific amber symbol. At the end of the display cycle, or when the MODE button is pressed (with “Escape” function), the symbol is reduced to icon form.
An RLI for “Number of brake disc replacements” is also generated, identifying the number of times that the discs have been replaced.
Once the brake discs have been replaced, the wear index may be reset on the instrument panel.
The wear index on the instrument panel may only be reset once the discs have been replaced, after the index has exceeded 100%.
To maintain a record of the latest brake wear index reset, three values are stored in the statistics memory for the front and rear brakes, which are updated upon reset (with the possibility of storing the last seven resets):
Number of brake disc changes counter: --------- (dimensionless number)
Kilometres at first disc brake change: --------- Km
Wear percentage at first disc brake change: --------- %
At each service, submit the following data (printing out the parameters from the instrument panel): vehicle serial number; vehicle mileage (“Odometer” parameter);
“Disc Wear Index” value.
There are essentially 5 different scenarios possible:
1 - Replacing all carbon discs due to vehicle usage;
2 - Replacing one carbon disc (or two discs on same axle) due to failure;
3 - Replacing a working instrument panel (dialogue with diagnostic instrument possible);
4 - Replacing of a malfunctioning instrument panel (dialogue with diagnostic instrument not possible);
5 - Replacing the carbon discs before reaching wear threshold (“Disc Wear Index” parameter < 100%).
1 - Replacing the carbon discs due to vehicle usage
In this situation, the amber warning signal on the TFT display is lit.
Use the diagnostic instrument to verify from the instrument panel that the disc wear index has exceeded
100%.
Replace the carbon discs.
Reset the carbon disc wear index on the instrument panel with the diagnostic instrument.
2 - Replacing one carbon disc (or two discs on same axle) due to failure
In this situation, only one disc (or two discs on the same axle) are replaced, without modifying the parameters https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
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Checking service brakes for wear Page 6 of 6 on the instrument panel.
In other terms, the “Disc Wear Index” parameter is left at the value for the discs not being replaced (partially worn).
3 - Replacing a working instrument panel (dialogue with diagnostic instrument possible)
Order a spare instrument panel, specifying: vehicle serial number; mileage indicated on old instrument panel (“Odometer” parameter readable with diagnostic instrument);
“Disc Wear Index” parameter value (readable with diagnostic instrument).
Upon approval from SAT (which will verify the data supplied by the dealership), the Spare Parts Department will confirm the order and supply a spare instrument panel (with the estimated values from the replaced unit).
4 - Replacing a malfunctioning instrument panel (dialogue with diagnostic instrument not possible)
Order a spare instrument panel, specifying: the serial number of the vehicle; estimated vehicle mileage.
SAT will verify the estimated vehicle mileage.
Using a table correlating vehicle usage time with increase in disc wear % compiled by the engineering division,
SAT will determine the % disc wear value to be entered in the new instrument panel in relation to the mileage recorded at the last service.
Upon approval from SAT (which will verify the data supplied by the dealership), the Spare Parts Department will confirm the order and supply a spare instrument panel (with the estimated values from the replaced unit).
5 - Replacing the carbon discs before reaching wear threshold (“Disc Wear Index” parameter < 100%)
This is a non-standard procedure and may only be performed by authorised personnel. Contact the Ferrari SAT service. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A31...
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Checking service/parking brake operation and control play
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A3.20 Checking service/parking brake operation and control play
Checking service brake/parking brake function
Check the brake pedal travel and STOP light switch function.
Road test the vehicle to check braking performance.
Remove the rear flat undertray section ( E3.12
).
Remove the rear bumper ( E3.04
).
Check electric parking brake operation and the state of the parking brake cables.
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking suspension components Page 1 of 1
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Checking suspension components
Road test the vehicle to check shock absorber performance and to check for suspension noise.
Remove the wheels ( D2.01
).
Remove all.
Check tightness of suspension components.
Check that all protective gaiters are in good order and that the ball joints on the stub axle and on the rear hub holder have sufficient play.
Check that the silentblock bushings at the arm and shock absorber mounting points on the chassis have sufficient play.
Check that the arms are not deformed and exhibit no signs of failure.
Check the state of the upper rebound stop bushes on the shock absorbers.
Check front and rear stabiliser bar alignment and the state of the rubber mounts and tie rod ball joints. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking vehicle set-up Page 1 of 1
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A3.22 Checking vehicle set-up
Checking vehicle set-up
The following operations must be performed beforehand to ensure that vehicle set-up parameters are checked correctly
Check that the tyre pressure is correct.
Check the steering and transmission system components.
Ensure that there is no backlash between the ball tie-rod of the steering box and the stub axle, and between the ball tie-rod and the rear hub holder.
Check the state of the protective gaiters on the steering box tie-rods, on the toe-in tie-rod and on the axle shaft tie-rods.
For optimum vehicle performance, the set-up procedure must be performed accurately.
Check that all suspension components are in proper working order.
Check the set-up data.
Vehicle set-up procedure
Important: for proper use see ( D4.07
)
For optimum vehicle performance, the set-up procedure must be performed accurately. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking proper installation and function of seats and seat belts Page 1 of 1
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A3.23 Checking proper installation and function of seats and seat belts
Checking proper installation and function of seats and seat belts
With the seat adjustment controls, check that the electrical seats move through their entire adjustment travel without impediment.
Check that the seat guides are securely fastened to the floor mounts.
Lubricate the guide connections and sliding surfaces with waterproof lithium grease.
Check that the seat belt anchor screws are properly tightened. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 1 of 9
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A3.24 Checking and recharging battery
Checking battery charge level
If you are in doubt about your battery or it if shows signs of inefficiency, check its charge level.
Disconnect the battery ( F2.01
).
For the purposes of such a check, the battery must be at room temperature (between 15 and 25 °C ) and must have been resting for at least 6 hours, i.e. it must not have been connected to any devices, even if these absorb only a few milliamperes.
Then proceed as follows:
Remove the battery ( F2.01
).
Remove the passenger footrest.
Detach the positive terminal (A) from the battery.
Connect the terminals of an appropriately calibrated digital multimeter (Beckman T11 OB) (M) to the battery poles.
Read the voltage value displayed by the multimeter to two decimal points. If the battery is insufficiently charged, with a voltage of less than 12.55, either recharge or replace, depending on the voltage measured.
Once the battery has been recharged, make sure it maintains the same charge over time by carrying out a test under full-load conditions.
To carry out the test, use a battery tester with a current range of 200 to 300 amperes .
Test the battery in the following way: connect the battery tester to the battery terminals; measure the battery temperature; set the battery tester to a discharge current equal to 75% of the value indicated on the battery identification plate (DC); apply load for 15 second s and measure the voltage while still under load; compare the voltage measured (with open circuit) against the limits given in the following table. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 2 of 9
Charging level (Volt)
Higher than 12.70
Between 12.45 and
12.70
Between 12.36 and
12.45
Lower than 12.36
Percentage charge
100
75 ÷ 100
50 ÷ 75
0 ÷ 50
Check the tester setting regularly.
If the voltage measured under full-load conditions is lower than the voltage indicated in the table, the battery must be considered faulty and must be replaced .
The battery charging level can be considered sufficient if it is higher than 75 ÷ 80% ; the multimeter display must show voltage levels which are not lower than 12.50÷12.55 Volts.
Recharge the battery ( A3.24
).
Perform the procedure if the voltage measured is less than the limit value specified.
You are reminded that, once the battery has been recharged, the voltage of the poles is not a faithful indication of the charging levels because of the electrolyte stratification inside the battery. This phenomenon occurs when the electrolyte has not yet mixed evenly; however, this condition is obviously achieved when the battery is in use.
Checking and recharging battery
A Ferrari battery charger or a "stabilised" battery charger is necessary for this procedure.
Disconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 3 of 9
Check that the terminals and terminal clamps are thoroughly clean and securely fastened.
Visually inspect the outer casing of the battery for cracks.
Remove the battery ( F2.01
).
On models fitted with the special socket for the Ferrari battery charger, this socket can be used to start the vehicle when the battery is flat. If the vehicle does not have the special socket, an auxiliary battery and/or a stabilised battery charger must be connected to the terminal poles on the vehicle’s battery, without using the battery master switch.
If the vehicle is not used for extended periods, remove the battery from the vehicle and recharge at least once every 3 months.
If you intend to the leave battery connected to the electrical system, to keep certain connected devices operating (car radio channel memory, alarm system, etc.), recharge at least once a month.
In case of doubt or if any signs of reduced battery performance are noted, check battery charge and/or check the current absorption of the vehicle electrical system.
CAUTION
The battery must be charged in a well ventilated place away from sources of heat and/or naked flame.
Recharge the battery ( A3.24
).
Refit the battery ( F2.01
).
Check the breather pipe for kinks or obstructions which could raise the internal battery pressure and damage the battery.
Apply water-repellent lubricant to the electrical system terminal clamps and reconnect the clamps to the battery terminals.
Tighten the terminal screws securely.
Reconnect the battery ( F2.01
).
Recharging the battery
CAUTION
The batteries contain sulphuric acid (corrosive) and, in certain conditions, release explosive gas, especially during charging; take the precautionary measures prescribed by the instructions and by Law Decree
626/94 – sections 40 and 46, requiring the use of personal protection devices (gloves, goggles etc.) when working with batteries.
Do not smoke near the battery and keep all sources of flames and sparks away from the battery.
Keep your face out of the area directly above the battery during installation and removal.
To safeguard the electrical components fitted in the vehicle, always use a battery charger with a max. constant voltage of 14.4 ÷ 15V and a charge current limiting device, and disconnect the battery from the vehicle electrical system before recharging.
Lead acid batteries do not produce gas during recharging, but the voltage values must be observed to prevent potential swellings and explosions of the accumulator.
Remove the battery ( F2.01
).
Clean the battery terminals thoroughly with a brush or other suitable tool.
Measure the battery voltage with a digital multimeter. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 4 of 9
The maximum time necessary for the battery to start accepting a measurable charge current, in relation to voltage measured, is as follows.
Charging times and procedure
Standard
Voltage (Volt)
14.4 to 15 max.
Quick 14.4 to 15 max.
From completely flat, battery with voltage of 10 to 9
V
14.4 to 15 max.
Current (A) max. 6 to 12 (10 to
20% battery capacity)
18 to 30 (30 to 50% battery capacity)
1 ÷ 2
Time (hours)
12 ÷ 24
4 ÷ 6
12 to 24 (then perform “normal” charge)
Ensure the internal temperature of the battery never exceeds 45°C during recharging. If this occurs, stop recharging for a few hours, then resume and complete the procedure.
At the end of the recharge cycle, battery voltage must be at least 14.4 – 15.0 V .
If this voltage is NOT reached (even if the battery was charged at constant current) indicates a general deterioration in the state of the battery. In this case, replacing the battery is recommended even if the vehicle will start.
Prolonged periods with the battery not in use (more than 2 weeks with the battery master switch ON) may cause faults at the next recharge cycle. The voltage may reach the value of 14.4 – 15.0 V specified previously, but the current in the battery may drop rapidly and the battery may fail to maintain charge for the correct period.
Assessing charge level
Check the battery charge level ( A3.24
).
Recharging interval
In the event of the vehicle not in use with the battery connected
The battery must be recharged at certain intervals in the event of prolonged periods with the battery not in use.
Follow the recharge intervals given in the following table, in relation to the current absorption of the electrical system.
Absorption (mA) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 5 of 9
< 40
40 to 60
60 to 80
80 to 100
Interval (days)
25
20
15
10
In the event of periods with the vehicle not in use and with the battery disconnected or removed for storage
With the battery removed for storage or with the vehicle kept with the battery disconnected, recharge intervals must not exceed 3 months .
The battery must be stored or the vehicle must be kept in a dry place with a constant temperature of approximately 25°C .
Avoid temperatures above 30°C , as self-discharging phenomena increase with increasing ambient temperature.
Other precautions
Charge the battery with a standard battery charger if battery charge level drops below 75% .
When using battery chargers with automatic disconnection, ensure that the voltage regulator is set to start charging when battery voltage drops below 12.55 - 12.60 V . In case of doubt, have the voltage regulator set correctly by the vendor of the battery charger.
If the battery remains in a discharged state for a prolonged period, the battery may be permanently damaged and may no longer be chargeable. The severity of the damage caused depends on how long and at what temperature the battery remained in this state.
Battery conditioner
Ferrari vehicles are equipped with a battery conditioner representing the state of the art in battery care.
Using the battery conditioner contributes to prolonging battery life.
The device is stored in a pocket in the car cover bag, which is located in the luggage compartment.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 6 of 9
A quick connector socket is installed in a protected and concealed location in the vehicle for connecting the device.
The previous image shows the location of the socket for connecting the battery conditioner: under the dashboard on the passenger side.
CAUTION
Ensure that all lids and doors are closed correctly.
Place the battery conditioner in an easily visible location, away from heat sources and out of the reach of children.
If the vehicle is not to be used for periods longer than a week, the battery conditioner should be connected to the vehicle to keep the battery in perfect working order.
Instructions for use: active mode and passive mode
Connect the battery conditioner first to the vehicle socket and then to the mains socket: this activates the “Active” mode, and the battery conditioner may safely be left connected to the vehicle for months.
Place the device outside the vehicle, taking care not to pinch the connector cable and/or damage the seals when closing the passenger side door. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 7 of 9
CAUTION
Ensure that all lids and doors are closed correctly.
Place the battery conditioner in an easily visible location, away from heat sources and out of the reach of children.
Battery conditioning may be interrupted at any time by simply disconnecting the power cable from the mains socket.
Always disconnect the mains socket before disconnecting the battery conditioner from the vehicle socket.
Engine start is inhibited as long as the battery conditioner is connected to the vehicle socket (even if the battery conditioner is disconnected from mains power).
1 - Error warning light
2 - Active mode indicator light: mode indicator
3 - Battery conditioning function indicator light: battery conditioning in process
Indicator light (1) lights continuously: to indicate a malfunction of the vehicle electrical system or battery.
Indicator light (2) lights continuously: battery conditioner in “Active” mode. In this mode, the battery is charged to the optimum level from a lower level.
Indicator light (3) lights continuously: battery is completely charged and battery conditioner is in “Passive” mode.
In this mode, the device maintains battery charge at an optimum level.
Indicator lights (2) and (3) flashing in alternation: if the lights flash several times a second, the battery is probably sulphatated; if the alternating flashing continues for more than 60 minutes , the battery must be replaced; if the lights flash at intervals of a few minutes, the self-discharge percentage of the battery is high and battery replacement may be necessary.
If no lights are lit, one of the following cases may be possible: the battery conditioner cables may be disconnected; the battery may be incorrectly connected to the vehicle electrical system; https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery Page 8 of 9 the battery may be defective; the battery voltage may be insufficient or there may be no power at the mains socket.
After checking the battery conditioner connections (to the mains and to the vehicle socket) and checking for mains voltage, if lights (2) and (3) indicating the “Active” or “Passive” mode do not illuminate within a few seconds of connecting the battery conditioner, contact the Ferrari Technical Service Department to have the vehicle electrical system checked.
Recharging cycle
A - Desulphating
B - Ground
C - Absorption
D - Impulse
Precautions and warnings
Ensure that the cables are not pinched and do not come into contact with hot surfaces or sharp edges.
Never cover the battery conditioner.
Ensure that the mains socket is not exposed to water.
Never recharge a frozen battery.
Never recharge a damaged battery.
Connections to mains electricity must comply with national law concerning high voltages.
Always check the battery conditioner cables before use: there must be no cracks in the cables or the outer insulation.
Never use a battery conditioner with damaged cables.
Store and use the battery conditioner out of the reach of children; never let children play with the battery https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking and recharging battery conditioner.
Overheating protection
The battery conditioner is equipped with protection against overheating.
Output power is reduced in the event of increased ambient temperature.
Maintenance
The battery conditioner is maintenance-free.
Do not disassemble the battery conditioner.
The battery conditioner casing may be cleaned with a moistened soft cloth or with neutral detergent.
Always disconnect the battery conditioner from the mains before cleaning.
Page 9 of 9 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Checking the state of the chassis and box elements Page 1 of 1
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A3.25 Checking the state of the chassis and box elements
Checking the state of the chassis and box elements
The vehicle chassis elements, box sections and outer components are made of aluminium: all repairs and/or replacements of chassis parts or bodywork components must be performed by skilled personnel using suitable tooling and equipment.
Check that the chassis structures, box elements and outer skins are in perfect condition. Repair if any deformation or failure is noted.
Check tightness of chassis fittings. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
8/5/2011
Checking wheels and tyres Page 1 of 1
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A3.26 Checking wheels and tyres
Checking wheels and tyres
CAUTION
Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration.
Remove the wheels from the vehicle, then check the state of the wheel rims and tyres.
Check that the tyre pressure matches the value specified
Check the location and fastening of the balancer weights on the inside of the wheel rims.
In case of excessive tyre wear, check the wheel alignment data and perform static and dynamic wheel balancing https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Inspecting the air conditioning and heating system Page 1 of 1
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A3.27 Inspecting the air conditioning and heating system
Inspecting the air conditioning and heating system
Remove the front flat undertray section ( E3.12
).
Remove the central flat undertray section ( E3.12
).
Remove the rear flat undertray section ( E3.12
).
Remove the luggage compartment tub ( E4.07
).
Check the unions on the pipes leading to the condenser, the dehydrator filter, the evaporator and compressor for gas leakage.
Check that there is no gas leakage from the system hoses.
Check that there is no refrigerant leakage from the recirculation pump and the evaporator. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
8/5/2011
Inspecting the brake system Page 1 of 1
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A3.28 Inspecting the brake system
Inspecting the brake system
Remove the wheels ( D2.01
).
Remove all.
Remove the underwindscreen shields ( E4.07
).
Remove the right hand underwindscreen shield.
Check the connection pipes leading to the callipers and to the unions on the rigid lines.
Check that there is no leakage near the brake master cylinder unions or on the electrohydraulic unit.
Check that the unions are properly tightened.
Check that the instrument panel warning lights function correctly.
If any leakage is found, replace the defective unions or pipes.
Fill and bleed the brake system ( D3.10
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
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Tightening bolts, unions and clamps Page 1 of 1
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Tightening bolts, unions and clamps
At the intervals given in the Maintenance Schedule, check the tightness of the major mechanical fittings.
Refer to the tightening torque tables given at the beginning of each section.
Also check that all hydraulic hose fittings and clamps are correctly tightened.
Replace only with the clamp types specified. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A32...
8/5/2011
Checking and lubricating hinges and adjusters
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A3.30 Checking and lubricating hinges and adjusters
Checking and lubricating hinges and adjusters
Page 1 of 1
Check that the door hinges and the engine and luggage compartment lid hinges are correctly fastened and that they open and close without free play or noise.
Check that the door locks and the engine and luggage compartment lid release mechanisms function correctly.
Check the state of the engine compartment lid release cable and of the fuel filler flap, luggage compartment lid and engine compartment lid emergency release cables.
Check that the luggage and engine compartment lid gas struts function correctly.
Lubricate all surfaces subject to friction with waterproof lithium grease. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A33...
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Treating interior trim in leather - Alcantara Page 1 of 4
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A3.31 Treating interior trim in leather - Alcantara
Treating interior leather upholstery
Proper and regular treatment (at least once a year) will preserve the natural qualities and softness of Ferrari leather trim.
For this precise purpose, a range of specific leather care products (Cleaner and Cream), developed and tested by Ferrari, is also available. These products may be ordered through the Ferrari Spare Parts
Department, either individually or as part of the "Care Kit", which includes a complete set of car cleaning products.
For the instructions on how to use the products contained in the "Care Kit", see the "User's Manual,
Carrozzeria Scaglietti Programme" and the instructions included with the Kit.
Never use acidic detergents, turpentine, liquid stain removers, petrol, solvents or domestic cleaning products to clean leather as these will damage the natural material.
Treating interior trim in Alcantara
Alcantara® is the registered trade mark of a new generation material produced exclusively by Alcantara S.p.A.
Both elegant and practical, Alcantara® combines softness, sophistication, rich colours and outstanding resilience with remarkably easy maintenance.
The material is ideally suited to innovative and exclusive applications in interior decor, automotive interiors, fashion clothing and fashion accessories.
Regular care
Avoid rubbing with too much force and do not use equipment with vapour.
Regular cleaning is recommended to maintain the beauty of Alcantara® over time.
Daily cleaning
Simply dust Alcantara® with a soft brush or dry cloth, or clean with a vacuum cleaner. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A33...
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Weekly cleaning
Avoid the use of rags/blotting paper because they could leave ink on the material.
After dusting Alcantara®, wipe with a slightly moistened white cotton cloth.
Yearly cleaning
With removable upholstery, machine wash using the following procedure (general guidelines for washing).
With non-removable upholstery, use specific products for cleaning Alcantara®.
If no specific products are available, dust the material thoroughly.
Be very careful not to wet Alcantara® in depth.
Moisten a soft cloth or sponge with water, squeeze out thoroughly and wipe all surfaces in Alcantara®.
Wipe again with a cloth moistened with clean water and leave to dry completely (overnight).
Once dry, brush delicately with a soft bristled brush to restore the nap.
General guidelines for washing
If removable upholstery needs to be cleaned completely due to large stains, observe the washing instructions given aside precisely: https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A33...
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In case of dry-cleaning do not use trichloroethylene and avoid direct contact with equipment that uses steam.
Alcantara® must not be treated with chlorine-based bleaches.
Never use a centrifuge.
With removable upholstery, Alcantara® may be safely machine washed at approximately 30°C, using a neutral detergent.
If Velcro is applied to the upholstery hems, protect the Velcro with counter-velcro before washing to prevent damage to the upholstery.
After washing, allow the upholstery to air-dry and brush gently with a soft-bristled brush.
The bottom of the iron must be at a temperature lower than 110°C.
If necessary, Alcantara® may be ironed, placing a white cloth between the iron and the material.
Spray extraction cleaning machines may only be used at low temperatures.
For non-removable upholstery, follow the procedure give for yearly cleaning.
General guidelines for stain removal
With localised stains, if no specific products for cleaning Alcantara® are available, immediately wipe off
( within 30 minutes ) and minimise the stain, working from the edge of the stain toward the middle to stop it from spreading.
Before wiping off the stain, remove the spilt substance from the upholstery: use a spoon or plastic spatula for dense substances (yoghurt, jam etc.), use unprinted absorbent paper or a sponge with liquids.
Do not pour the product being used for cleaning directly on Alcantara®.
Avoid rubbing to keep the stain from spreading or penetrating in depth.
Use a moistened and thoroughly squeezed white cloth or sponge to remove stains.
When using a sponge, rinse in clean water and squeeze thoroughly between applications. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A33...
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Water-soluble stains
Preferably use specific products for cleaning Alcantara®.
If no specific products are available, use water, lemon juice or pure ethyl alcohol (spirits), depending on the case.
Fruit juice, jam, jelly, ketchup: use lukewarm water; rinse by patting with clean water.
Blood, egg: use cold water; do not use hot water as it coagulates proteins; rinse by patting with clean water.
Liqueur, wine, beer, cola and tea: use lukewarm water; if a coloured stain remains, use lemon juice then rinse well.
Copying pencil, cocoa, chocolate, custard or chocolate confectionary, ice cream, mustard: use lukewarm water; rinse by patting with clean water.
Vinegar, hair gel, tomato sauce, sweet coffee: use lemon juice, then wipe with lukewarm water; rinse by patting with clean water.
Non-water-soluble stains
Preferably use specific products for cleaning Alcantara®.
If no specific products are available, use water, lemon juice or pure ethyl alcohol (spirits), depending on the case.
Lipstick, foundation, mascara, eye shadow, perfume, shoe polish, oil and grease in general, grass stains and marker pen (including indelible markers): pat with ethyl alcohol then pat with water and rinse.
With difficult to remove grass and marker pen stains, especially if light in colour, clean as soon as possible before the stain dries excessively.
Chewing gum and wax: fill a plastic bag with ice; when the substance has hardened, break it off in pieces, then treat with ethyl alcohol.
Stubborn stains
Repeat the treatments described several times.
Often, even non-water-soluble stains require treatment with water after initial cleaning. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A33...
8/5/2011
Checking radiators for fouling Page 1 of 1
Print Exit
A3.32 Checking radiators for fouling
Checking radiators for fouling
Detritus from the road may enter the vehicle front air intake and foul the radiators; over time, this may compromise the functionality of the cooling systems so that they are no longer capable of providing sufficient cooling.
It is therefore VITAL that the radiator cores are checked for fouling at each scheduled service and cleaned, if necessary, using the following procedure.
Check the radiator cores for fouling.
In the event of fouling, clean with a pressurised water jet or equivalent method.
Check for any dirt accumulated between the water radiator and the AC condenser.
Remove the front bumper ONLY in the event of very heavy fouling.
ONLY in the event of very stubborn dirt, which may be possible with particularly high mileage vehicles, remove the radiator assembly and remove the dirt by blowing air from the rear of the radiators.
Checking the condition of the radiators
Periodically check the condition of the radiator core. Clean the radiator fins, removing any leaves, insects or other matter that could obstruct air flow and lead to overheating of the fluid. Straighten any bending present while being careful not to cause breakage of the radiator core.
Replace the radiator if it proves to be in poor condition.
Periodically check the state of the pipe couplings. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A33...
8/5/2011
Cleaning and maintaining matt paints (if applicable)
Print Exit
A3.33 Cleaning and maintaining matt paints (if applicable)
Cleaning and maintaining matt paints (optional)
NEVER polish the paintwork with any product.
Page 1 of 1
DO NOT lean on the vehicle, especially if wearing garments with buttons, belts, rings, necklaces etc., as you may cause irreparable damage to the bodywork.
For information on the correct products to be used, contact the Ferrari Service Network.
Proper care by the owner is essential for keeping vehicles with matt paintwork (optional) in pristine condition.
The following is a list of the most important precautions necessary:
Wash the vehicle exclusively with Steam cleaner , and rinse with demineralised water only.
The vehicle must only be dried with an automatic blower or with compressed air. The vehicle may ONLY be hand dried using a clean Yellow 3M microfibre cloth (Ferrari p/n 571.400.022) moistened with demineralised water and using Glass cleaning solution in areas with remaining limescale residue. Keep the cloth in a specific clean container.
To remove grease stains, use a clean Yellow 3M microfibre cloth (Ferrari p/n 571.400.022) moistened in
R107/S solvent (heptane) . Use a new cloth only, or a cloth that has never been used with demineralised water or Glass cleaning solution .
Do not wash the vehicle in direct sunlight or when the bodywork is still hot.
Never apply adhesive stickers to the bodywork.
Cracks or exposed areas of underlying bodywork caused by stones, scratches, parking damage etc. must be repaired immediately by the Ferrari Service Network.
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8/5/2011
Service counter reset
Print Exit
A3.34 Service counter reset
Service counter reset
Connect the DEIS tester to the diagnostic socket.
Switch on the DEIS tester.
Click the DEIS button.
Select " NQS - Instrument panel ".
Page 1 of 1
Click " Diagnostics "
Select " SET SERVICE " https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_A33...
8/5/2011
Technical specifications Page 1 of 1
Print Exit
Engine specifications
The engine is a naturally aspirated V8 with a 180° crank. variable valve timing with continuous high pressure timing adjuster mechanism on all camshafts; timing chains (one per cylinder bank) with hydraulic chain tensioners; four overhead composite camshafts (two per cylinder bank) and four valves per cylinder with self-adjusting hydraulic tappets; chain driven water pump (integrated in front timing cover) and oil pump; oil-water heat exchanger incorporated in crankcase, between the two cylinder banks; the following components are mounted on the engine: the air conditioner compressor, the power steering pump and the alternator, all of which driven by the crankshaft via a belt; the engine is cooled by a circuit containing an antifreeze mixture.
Main engine specifications
Type F136FB
Number of cylinders 90° V8
Cylinder bore
Piston stroke
3.7 in.
3.2 in.
Total displacement 4499 cm³
Compression ratio
Max. engine speed
(at rev limiter)
12.5 : 1
9200 rpm
Maximum power (Dir.
1999/99/EC)
558 hp
Corresponding rpm 9000 rpm
Maximum torque (Dir.
1999/99/EC)
398.23 ft. lb.
Corresponding rpm 6000 rpm
Specific tooling and equipment
Print Exit
B1.02 Specific tooling and equipment
Page 1 of 5
Tensiometer (95978151)
Seem DIAPAZ.
Hook 95973432 (AV 3432) for hoisting engine.
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8/5/2011
Specific tooling and equipment
Hook (AV 3979) for hoisting engine.
Torque wrench 95978172 (AV 8172)
(Replaces torque wrench USAG 815F)
Page 2 of 5
Wrench 95978175 (AV 8175) tightening fuel pump filter retainer ring.
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8/5/2011
Specific tooling and equipment
Wrench 95978176 (AV 8176) tightening fuel level sensor.
Page 3 of 5
Tailpipe cowl for exhaust fume extraction 95978250
(AV 8250) for use exclusively together with one of the extension elements AV 8177 for connection to an exhaust gas extraction system.
Brackets for fastening to engine and clutch housing shims 95978252 (AV 8252) for hoisting engine.
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8/5/2011
Specific tooling and equipment Page 4 of 5
Pins for lifting engine-gearbox assembly 95978253
(AV 8253) for lifting engine/gearbox assembly off rear subframe after removal of subframe from vehicle.
Engine retainer bracket for gearbox removal
95978254 (AV 8254) removing the gearbox.
Template 95978257 (AV 8257) fitting flexible exhaust pipe. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B10...
8/5/2011
Specific tooling and equipment
Hook 95977564 (AS 107564) for lifting the gearbox.
Page 5 of 5 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B10...
8/5/2011
Tightening torques
Print Exit
Page 1 of 2
Tightening torque
Fastening complete tensioner
Fastening spark plug
Fastening engine mounting bush - chassis
Fastening engine strut - engine mounting bush
Screw
Spark plug
Screw
Screw
Fastening heat shield - engine mounting bush
Fastening ground cable - engine
Fastening front pipe retainer pillory block - bodyshell
Fastening the cylinder heads
Screw
Screw
Fastening heat shield - removable subframe Screw
Fastening U-bracket - removable subframe
Fastening fuel vapour separator mounting bracket removable subframe
Screw
Screw (pretightening)
Fastening active carbon filter mounting bracket to chassis
Fastening fuel tank retainer belts
Fastening heat shield
Nut
Screw
Fastening belts to chassis
Fastening expansion tank to chassis
Fastening water radiators
Fastening upper radiator air ducts
Fastening front brake air ducts
Fastening electric fans to water radiators
Fastening underbody mounting brackets for cooling system rigid pipes
Fastening water pump
Fastening brackets for complete underbody pipe set
Fastening hose union to thermostat
Engine oil filter
Magnetic oil drain plugs
Oil pump - crankcase
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screws (FROM Ass.ly
No. 90802)
Screw collar
Engine oil filter cartridge
M22x1.5 plug
Screw
Nm
25 Nm
11 Nm
50 Nm
15 Nm
9 Nm
18 Nm
9 Nm
5 Nm
5 Nm
20 Nm
9 Nm
40 Nm
8 Nm
25 Nm
6 Nm
5 Nm
5 Nm
10 ÷ 12 Nm
6 Nm
4 Nm
+0
25 Nm
60 Nm
25 Nm
Class
B
A
B
B
B
B
B
B
B
B
B
B
B
B
C
C
B
A
B
B
A
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B10...
8/5/2011
Tightening torques Page 2 of 2
Tightening torque
Fastening engine oil tank to gearbox
Fastening engine oil recovery and pick-up pipe
Fastening oil pump bush retainer bracket
Fastening oil-water heat exchanger
Fastening solenoid valve mounting bracket to engine air filter box
Fastening engine air filter box
Fastening hose unions to engine air filter box
Fastening engine air ducts
Fastening hose unions to engine air ducts
Fastening intake manifold to cylinder heads
Fastening catalytic converters to silencers
Screw
Screw
Screw
Screw
Nut
Screw collar
Screw
Screw collar
Screw
Clamp (pretightening)
Clamp
Fastening catalytic converter mounting brackets to chassis
Fastening catalytic converters to exhaust manifolds Clamp
Fastening exhaust manifolds to cylinder heads Nut
Fastening A.C. compressor heat shield Screw
Nm
10 Nm
10 Nm
10 Nm
10 Nm
9 Nm
4 Nm
6 Nm
4 Nm
10 Nm
25 Nm
13 Nm
25 Nm
9 Nm
Class
B
B
B
B
B
C
B
C
B
B
0
B
B
C https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B10...
8/5/2011
Removing the complete engine
Print Exit
B2.01 Removing the complete engine
Removing the complete engine
Page 1 of 26
CAUTION
For safety reasons, the VEHICLE MAY ONLY BE LIFTED WITH THE ANTI-TIPPING SAFETY RETAINERS
INSTALLED.
Disconnect the battery ( F2.01
).
Remove the engine compartment lid ( E3.01
).
Lift the vehicle using anti-tipping safety retainers ( E3.12
).
Drain the cooling system ( B6.07
).
Drain the power steering system ( D5.08
).
Discharge the air conditioning system ( F5.12
).
UP TO Ass.ly No. 90801. Remove the engine inspection hatch ( E4.06
).
Remove the expansion tank ( B6.02
).
Remove the exhaust manifold ( B7.02
).
Remove both exhaust manifolds.
Remove the engine air ducts ( B4.02
).
Remove the complete gearbox ( C2.02
).
Remove the indicated clamp and separate the respective pneumatic actuator system pipes (1) .
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Removing the complete engine Page 2 of 26
Disconnect the pipe (46) leading from the secondary air pump, removing the indicated clamp.
Open the indicated clamps and remove the secondary air pipe (2) , complete with valves, from the engine compartment.
Remove the cover (92) .
Disconnect the low pressure pipe (3) from the fuel pump filter.
Disconnect the pipes (4) from the right hand fuel pipe.
There are two "double-lock" safety clips fitted onto the union.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick couplings and remove the pipes (4) .
Open the indicated clamp fastening the pipes (4) to the bodyshell.
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Removing the complete engine Page 3 of 26
FROM Ass.ly No. 90802
Open the indicated clamp on the low pressure pipe
(3) .
Remove the cover (91) .
Disconnect the low pressure pipe (5) from the fuel pump filter.
Disconnect the pipe (4) from the left hand fuel tank.
A "double-lock" safety clip is fitted on the union.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick coupling and remove the pipe (4) .
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Removing the complete engine Page 4 of 26
FROM Ass.ly No. 90802
Open the indicated clamp on the low pressure pipe
(5) .
Remove the right hand front heat shield (48) , undoing the indicated screws.
Remove the right hand rear heat shield (47) , undoing the screws indicated by the red arrows.
Follow the same procedure to remove the front and rear heat shields on the left-hand side of the engine.
UP TO Ass.ly No. 90801
Undo the screw indicated fastening the power steering pump shield (6) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
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Removing the complete engine Page 5 of 26
UP TO Ass.ly No. 90801
Undo the screw indicated and remove the power steering pump shield (6) .
UP TO Ass.ly No. 90801
Undo the union (7) on the power steering pump.
Place a container under the clamp (14) .
Loosen the clamp (14) and disconnect the pipe (15) leading from the expansion tank.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
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Removing the complete engine Page 6 of 26
UP TO Ass.ly No. 90801
Remove the clamp (20) on the pipe retainer pillory block, undoing the screws indicated.
UP TO Ass.ly No. 90801
Disconnect the power steering system pipe (8) , removing the indicated clamp.
Disconnect the quick connector (9) of the brake servo vacuum pipe (19) .
Place a container under the clamp (10) .
Loosen the clamp (10) and disconnect the pipe (11) from the front timing cover.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely.
Place a container under the clamp (12) .
Loosen the clamp (12) and disconnect the pipe (13) from the pressure switch/thermostat.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely.
Detach the brake servo vacuum pipe (19) from the pillory block.
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Removing the complete engine Page 7 of 26
UP TO Ass.ly No. 90801
Loosen the clamp (16) and disconnect the pipe (17) from the front timing cover.
FROM Ass.ly No. 90802
Remove the indicated clamp and disconnect the power steering system pipe (8) .
Disconnect the quick connector (7) on the power steering system pipe.
FROM Ass.ly No. 90802
Open the indicated clamp.
Disconnect the quick connector (16) on the water pipe leading to the recirculation pump.
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Removing the complete engine Page 8 of 26
FROM Ass.ly No. 90802
Disconnect the quick connector (9) of the brake servo vacuum pipe.
Place a container under the clamp (10) .
Loosen the clamp (10) and disconnect the pipe (11) from the front timing cover.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely.
Place a container under the clamp (12) .
Loosen the clamp (12) and disconnect the pipe (13) from the pressure switch/thermostat.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely.
FROM Ass.ly No. 91654
Remove the clamp indicated by the red arrow.
Disconnect the pipe (93) from the rigid pipe.
Release the pipe (93) by detaching from the clamp indicated by the black arrow. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
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Removing the complete engine Page 9 of 26
Disconnect the evaporative emissions control system solenoid valve pipe (18) from the left hand plenum, removing the indicated clamp.
Lift the cover (21) of the junction box and undo the indicated nut fastening the cable (45) .
Detach the clamps retaining the cable (45) to the chassis.
Release the right hand injection cable (23) , cutting the indicated cable ties and detaching the indicated clamps fastened to the chassis.
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Removing the complete engine Page 10 of 26
Release the right hand injection cable (23) , cutting the indicated cable ties and detaching the indicated clamps fastened to the chassis.
Disconnect the connector (24) from the right hand
Motronic ECU, and disconnect the connector
(25) from the engine compartment cable junction.
Release the right hand injection cable (22) leading to the ELDOR ECU, removing the indicated clamps.
Disconnect the connectors (26) from the ELDOR
ECU.
Disconnect the front right hand oxygen sensor connector (27) and remove the indicated clip.
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Removing the complete engine Page 11 of 26
Pull out the right hand injection cable (22) and place on top of the intake manifold.
Release the left hand injection cable (28) , removing the indicated clamps.
Disconnect the front left hand oxygen sensor connector (29) and remove the indicated clip.
Undo the screws indicated fastening the fuel vapour separator mounting bracket (30) to the chassis.
Release the left hand injection cable (28) , removing the indicated clamps, and disconnect the connector (31) from the engine compartment cable junction.
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Removing the complete engine Page 12 of 26
Disconnect the connector (32) from the left hand
Motronic ECU.
Pull out the left hand injection cable (28) and place on top of the intake manifold.
Remove the right hand removable subframe (33) from the chassis, undoing the screws indicated.
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Removing the complete engine Page 13 of 26
Remove the U-bracket (35) , undoing the two screws indicated.
Undo the two screws indicated fastening the heat shield (36) .
Undo the fours screws indicated fastening the left hand removable subframe (34) to the chassis.
Remove the indicated clamp fastening the secondary air pipe (46) and retrieve the pipe.
From underneath, undo the two screws indicated fastening the secondary air pump mounting bracket to the left hand removable subframe (34) .
Remove the left hand removable subframe (34) from the chassis.
Undo the screw indicated fastening the ground cable (38) onto the engine and release the cable from the indicated fastener clamp on the starter motor shield.
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Removing the complete engine Page 14 of 26
Remove the heat shields (37) from above the engine mounting bushes on both sides, undoing the screws indicated.
Fit the bracket ( AV 8252 ) onto the stud bolts of cylinder No. 7 on the left hand cylinder bank.
Fit the bracket ( AV 8252 ) onto the stud bolts of cylinder No. 2 on the right hand cylinder bank.
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Removing the complete engine Page 15 of 26
Tighten the three shims, elements 01 of the tool
( AV 8252 ) , onto the stud bolts of the crankcase.
Fit the hook ( AV 3432 ) onto the stud bolts of the shims installed previously, and fasten by tightening the three nuts indicated.
Provisionally fit a block (F) , as shown in the photo aside, to prevent the engine from tipping when the tool ( AV 8254 ) is removed (as described as follows).
Remove the tool ( AV 8254 ) from the underside of the vehicle, undoing the two screws indicated, to allow more room for the engine removal procedure.
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Removing the complete engine Page 16 of 26
Using a mobile hydraulic hoist with a minimum load capacity of 300 Kg , position the lift hook over the engine.
Use a suitable strap (39) to fasten the hook
( AV 3979 ) to the hoist.
Using two suitably sized straps (41) and carabiners, connect the hook ( AV 3979 ) to the brackets
( AV 8252 ) fastened previously to the exhaust stud bolts.
Using a suitably sized strap (42) and carabiners, connect the lift tool ( AV 3432 ) mounted previously onto the crankcase stud bolts to the hydraulic hoist.
Tauten the hoist straps with the mobile hydraulic hoist.
Remove the block (F) fitted previously.
On both sides, undo the screws (42) fastening the engine strut to the engine mounting bush, retrieving the relative washer.
Lift the engine by a few millimetres, ensuring that the strap tension is uniform and that the engine itself lifts evenly.
On the right-hand side only (as shown in the photo aside), undo the screws indicated and remove the engine mounting bush (43) , to allow enough room for the engine to be lifted past the oil pump.
Retrieve the retainer bracket (44) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
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Removing the complete engine Page 17 of 26
When removing the engine, work with due
CAUTION to prevent any of the engine's components - and the engine oil pump, the variable timing adjuster control solenoid valves and the mounting brackets for the secondary air pipes mounted on the cylinder heads in particular - from colliding with the chassis.
Lift the engine from the engine compartment and set down securely in a safe place.
Removing the engine-gearbox assembly
The following procedure is only possible with the rear removable subframe already removed from the vehicle.
Remove the rear subframe ( E2.02
).
Remove the air flow meter ( F3.07
).
Remove both.
Remove the engine air filter box ( B4.03
).
Remove the catalytic converter ( B7.03
).
Remove both.
Remove the silencers ( B7.04
).
Remove the axle shaft ( C4.01
).
Remove both axle shafts from the gearbox flanges.
Remove the shield (1) , undoing the 2 nuts and 2 screws indicated.
Undo the screws indicated fastening the heat shield
(2) .
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Removing the complete engine Page 18 of 26
Remove the heat shield (2) , undoing the screw indicated.
FROM Ass.ly No. 92290
Remove the heat shield (2) , undoing the screw indicated.
Clean the area surrounding the fastener point for the clutch hydraulic system oil pipes thoroughly using a suitable degreaser that does not leave residue.
Place a container for collecting the clutch hydraulic system oil under the pipes.
Undo the screw indicated fastening the fork (3) on the clutch hydraulic system oil pipes.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Disconnect the clutch hydraulic system oil pipes (4) from the gearbox and plug immediately.
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Removing the complete engine Page 19 of 26
Undo the screws indicated fastening the retainers on the pillory blocks holding the clutch hydraulic system oil pipes (4) and the gear oil pipes (6) .
Clean the area surrounding the gear oil pipe fastener point thoroughly with a suitable degreaser that does not leave residue.
Place a container for collecting the gear oil under the pipes.
Undo the screw indicated fastening the fork (5) on the gear oil pipes.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Disconnect the gear oil pipes (6) from the gearbox and plug immediately.
Release the oil pipes from the mounting bracket (7) and remove the bracket from the gearbox.
Move the oil pipes of both systems aside carefully, taking care not to twist or damage them, so that they do not hinder the removal of the gearbox.
Remove the clamp fastening the gearbox wiring harness, undoing the screw indicated, and disconnect the three connectors (8) .
Move the gearbox wiring harness out of the way so that it does not hinder the removal of the gearbox.
Remove the indicated clamp and separate the respective pneumatic actuator system pipes (10) .
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Removing the complete engine Page 20 of 26
Remove the indicated clamps fastening the pipes to the rear subframe.
Undo the screw indicated fastening the ground cable (38) onto the engine and release the cable from the indicated fastener clamp on the starter motor shield.
Release the drain pipe (23) from the rubber lined bracket by undoing the indicated screw.
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Removing the complete engine Page 21 of 26
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Release the drain pipe (23) from the rubber lined bracket by undoing the indicated screw.
Release the drain pipe (23) from the rubber lined brackets by undoing the indicated screws.
Move the pipes out of the way so that they do not hinder the subsequent operations.
Unscrew the indicated screws fastening the lower gearbox mounting cross-member (9) .
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Removing the complete engine Page 22 of 26
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Unscrew the indicated screws fastening the lower gearbox mounting cross-member (9) .
Unscrew the indicated screws and remove the lower gearbox mounting cross-member (9) .
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Unscrew the indicated screws and remove the lower gearbox mounting cross-member (9) .
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Removing the complete engine Page 23 of 26
Remove the right hand front heat shield (11) , undoing the indicated screws.
Remove the right hand rear heat shield (12) , undoing the screws indicated by the red arrows.
Follow the same procedure to remove the front and rear heat shields on the left-hand side of the engine.
Remove the heat shields (37) from above the engine mounting bushes on both sides, undoing the screws indicated.
Tighten the eyebolts (elements 27 ) of the hook
( AV 3432 ) into the specific seats (13) at the front of the engine.
Note that the heat shield is still fitted in the photo aside. The heat shield must be removed. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
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Removing the complete engine Page 24 of 26
Screw the hoisting pins ( AV 8253 ) into the vertical holes in the engine-gearbox connector tie-rods
(14) .
FROM Ass.ly No. 92290
Remove the two eyebolts (19) from the tool
( AS 107564 ) .
FROM Ass.ly No. 92290
Screw the two eyebolts (19) , removed previously from the tool, into the relative holes on the gearbox.
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Removing the complete engine Page 25 of 26
The engine-gearbox assembly must be lifted from the rear subframe: this operation requires the use of a mobile hydraulic hoist or a bridge crane with a minimum load capacity of 300 Kg , element 31 of the hoisting hook ( AV 3432 )
(which is also used for the Enzo) and the crossbeam ( AV 3979 ) .
Connect the hook ( AV 3432 ) to the hoist hook of the bridge crane, aligning so that the crossbeam
( AV 3979 ) faces towards the rear of the subframe.
Connect the fixed length bars (17) to the hook
( AV 3432 ) and connect the variable length tierods (18) to the crossbeam ( AV 3979 ) .
Position the hoist over the engine-gearbox assembly and connect the bars (17) to the eyebolts (elements 27 ) of the hook ( AV 3432 ) .
Connect the tie-rods (18) to the pins ( AV 8253 ) .
Raise the hook to place the bars and tie-rods under tension.
FROM Ass.ly No. 92290
The engine-gearbox assembly must be lifted from the rear subframe: this operation requires the use of a mobile hydraulic hoist or a bridge crane with a minimum load capacity of 300 Kg , element 31 of the hoisting hook ( AV 3432 )
(which is also used for the Enzo) and the crossbeam ( AV 3979 ) .
Connect the hook ( AV 3432 ) to the hoist hook of the bridge crane, aligning so that the crossbeam
( AV 3979 ) faces towards the rear of the subframe.
Connect the fixed length bars (17) to the hook
( AV 3432 ) and connect the variable length tierods (18) to the crossbeam ( AV 3979 ) .
Position the hoist over the engine-gearbox assembly and connect the bars (17) to the eyebolts (element 27 ) of the hook ( AV 3432 ) .
Hook the tie rods (18) onto the eyebolts (19) .
Raise the hook to place the bars and tie-rods under tension.
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8/5/2011
Removing the complete engine Page 26 of 26
On both sides, undo the screws (42) fastening the engine strut to the engine mounting bush, retrieving the relative washer.
Undo the nut (21) retrieving the washer.
Remove the pin (22) fastening the bushing mounting (15) to the rear subframe, retrieving the washer.
Lift the engine-gearbox assembly by a few millimetres, ensuring that the bar tension is uniform and that the assembly itself lifts evenly.
Slowly lift the engine-gearbox assembly from the rear subframe, watching carefully for any electrical connections that may still be connected and taking care not to damage any other components.
Remove the engine-gearbox assembly from the rear subframe and set down in a stable position in a safe place.
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8/5/2011
Refitting the complete engine
Print Exit
Refitting the complete engine
Page 1 of 30
Tightening torque
Fastening engine strut - engine mounting bush Screw
Nm
15 Nm
Class
B
Fastening engine mounting bush - chassis
Fastening heat shield - engine mounting bush
Fastening ground cable - engine
Fastening removable subframe to chassis
Fastening heat shield - removable subframe
Fastening U-bracket - removable subframe
Screw
Screw
Screw
Screw
Screw
Screw
Fastening fuel vapour separator mounting bracket removable subframe
Fastening engine services cable to terminal block Nut
Fastening front pipe retainer pillory block - bodyshell
Fastening rigid pipe to power steering pump Union
50 Nm
9 Nm
18 Nm
24 Nm
9 Nm
5 Nm
15 Nm
B
B
B
B
B
B
B
37 Nm B
On the right-hand side only, fit the engine mounting bushing (43) , the retainer bracket (44) and hand tighten the three indicated screws.
On the left-hand side only, undo the three screws indicated fastening the retainer bracket (44) and the engine mounting bush (43) to the rear subframe.
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8/5/2011
Refitting the complete engine Page 2 of 30
Fit the bracket ( AV 8252 ) onto the stud bolts of cylinder No. 7 on the left hand cylinder bank.
Fit the bracket ( AV 8252 ) onto the stud bolts of cylinder No. 2 on the right hand cylinder bank.
Tighten the three shims, elements 01 of the tool
( AV 8252 ) , onto the stud bolts of the crankcase.
Fit the hook ( AV 3432 ) onto the stud bolts of the shims installed previously, and fasten by tightening the three nuts indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 3 of 30
Using a mobile hydraulic hoist with a minimum load capacity of 300 Kg , position the lift hook over the engine.
Use a suitable strap (39) to fasten the hook
( AV 3979 ) to the hoist.
Using two suitably sized straps (41) and carabiners, connect the hook ( AV 3979 ) to the brackets
( AV 8252 ) fastened previously to the exhaust stud bolts.
Using a suitably sized strap (42) and carabiners, connect the lift tool ( AV 3432 ) mounted previously onto the stud bolts to the hydraulic hoist.
Lift the engine, ensuring that the strap tension is uniform and that the engine itself lifts evenly.
When installing the engine, work with due
CAUTION to prevent any of the engine's components - and the engine oil pump, the variable timing adjuster control solenoid valves and the mounting brackets for the secondary air pipes mounted on the cylinder heads in particular - from colliding with the chassis.
Lift the engine and place in its relative seat on the engine mounting bushes, but without allowing the bushes to take up the weight of the engine.
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8/5/2011
Refitting the complete engine Page 4 of 30
Fit the engine on the engine mounting bushes, aligning the bushes correctly.
On both sides, fit and pretighten the screws (42) fastening the engine strut to the engine mounting bush after installing the relevant washer.
Tightening torque Nm Class
Fasten the engine mounting bushings (43) and the retainer brackets (44) tightening the indicated screws.
Tightening torque Nm Class
Tighten the two screws (42) fastening the engine strut to the engine mounting bushing.
Tightening torque Nm Class
Provisionally fit a block (F) , as shown in the photo aside, to prevent the engine from tipping when the hoisting tools are removed (as described as follows).
Remove all the engine hoisting tools installed previously. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 5 of 30
Working underneath the vehicle, install the tool
( AV 8254 ) onto the chassis, tightening the two screws indicated, to support the weight of the engine and prevent it from tipping.
Remove the block (F) fitted previously.
Use a feeler gauge to check that the gap between the retainer bracket (44) and the engine mounting bush (43) , along the "X" axis, is between 1.2 mm and 2.8 mm .
Use a feeler gauge to check that the gap between the retainer bracket (44) and the engine mounting bush (43) , along the "Z axis, is between 1.2 mm and 2.8 mm . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 6 of 30
Fit and fasten the heat shields (37) over the engine mounting bushes on both sides, tightening the screws indicated.
Tightening torque Nm Class
Tighten the screw indicated on the ground cable
(38) onto the engine and secure the cable to the indicated fastener clamp on the starter motor shield.
Tightening torque Nm Class
Fit the left hand removable subframe (34) in the relative seat on the chassis.
From underneath, tighten the two screws indicated fastening the secondary air pump mounting bracket to the left hand removable subframe (34) .
Fit the secondary air pipe (46) onto the pump inlet and fasten by fitting a new clamp as indicated.
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8/5/2011
Refitting the complete engine Page 7 of 30
Tighten the fours screws indicated fastening the left hand removable subframe (34) to the chassis.
Tightening torque Nm Class
Tighten the two screws indicated fastening the heat shield (36) .
Tightening torque Nm Class
Fit and fasten the U-bracket (35) , tightening the two screws indicated.
Tightening torque Nm Class
Fit and fasten the right hand removable subframe
(33) in the relative seat on the chassis, tightening the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 8 of 30
Lay out the left hand injection cable as originally fitted on the chassis.
Connect the connector (32) to the left hand
Motronic ECU.
Fasten the left hand injection cable (28) , fitting the indicated clamps, and connect the connector
(31) to the engine compartment cable junction.
Tighten the screws indicated fastening the fuel vapour separator mounting bracket (30) to the chassis.
Tightening torque Nm Class
Connect the front left hand oxygen sensor connector (29) and fit the indicated clip.
Fasten the left hand injection cable (28) , fitting the indicated clamps.
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8/5/2011
Refitting the complete engine Page 9 of 30
Lay out the right hand injection cable as originally fitted on the chassis.
Connect the front right hand oxygen sensor connector (27) and fit the indicated clip.
Connect the connectors (26) to the ELDOR ECU.
Fasten the right hand injection cable (22) leading to the ELDOR ECU, fitting the indicated clamps.
Connect the connector (24) to the right hand
Motronic ECU, and fasten the connector (25) to the engine compartment cable junction.
Fasten the right hand injection cable (23) , fitting the indicated clamps.
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8/5/2011
Refitting the complete engine Page 10 of 30
Fasten the right hand injection cable (23) , fitting the indicated clamps.
Lift the cover (21) of the junction box and tighten the indicated nut fastening the cable (45) .
Tightening torque Nm Class
Fit the cable retainer clamps (45) as originally installed on the chassis.
Connect the evaporative emissions control system solenoid valve pipe (18) to the left hand plenum, fitting a new clamp as indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 11 of 30
UP TO Ass.ly No. 90801
Connect the pipe (17) to the front timing cover and fasten by tightening the clamp (16) .
UP TO Ass.ly No. 90801
Fasten the brake servo vacuum pipe (19) in the relative seat on the pillory block.
Connect the pipe (13) to the pressure switch/thermostat and fasten by tightening the clamp (12) .
Connect the pipe (11) to the front timing cover and fasten by tightening the clamp (10) .
Connect the quick connector (9) of the brake servo vacuum pipe (19) .
Connect the power steering system pipe (8) and fasten by tightening the indicated clamp.
UP TO Ass.ly No. 90801
Fit and fasten the bracket (20) onto the pipe retainer pillory block, tightening the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 12 of 30
Connect the pipe (15) leading from the expansion tank and fasten by tightening the clamp (14) .
UP TO Ass.ly No. 90801
Tighten the union (7) on the power steering pump
Tightening torque Nm Class
UP TO Ass.ly No. 90801
Fit the power steering pump shield (6) and fasten by tightening the screw indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 13 of 30
FROM Ass.ly No. 90802
Connect the pipe (13) to the pressure switch/thermostat and fasten by tightening the clamp (12) .
Connect the pipe (11) to the front timing cover and fasten by tightening the clamp (10) .
Connect the quick connector (9) of the brake servo vacuum pipe.
FROM Ass.ly No. 90802
Connect the quick connector (16) on the water pipe leading to the recirculation pump.
Close the indicated clamp.
FROM Ass.ly No. 90802
Connect the quick connector (7) on the power steering system pipe.
Connect the power steering system pipe (8) and fasten by tightening the indicated clamp.
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8/5/2011
Refitting the complete engine Page 14 of 30
FROM Ass.ly No. 91654
Connect the pipe (93) to the rigid pipe.
Fit and tighten a new clamp as indicated by the red arrow.
Secure the pipe (93) by fastening to the clamp indicated by the black arrow.
Fit the right hand rear heat shield (47) in the relevant seat and fasten by tightening the screws indicated by red arrows.
Fit the right hand front heat shield (48) in the relevant seat and fasten by tightening the indicated screws.
Follow the same procedure to fit the front and rear heat shields on the left-hand side of the engine.
UP TO Ass.ly No. 90801
Tighten the screw indicated fastening the power steering pump shield (6) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 15 of 30
Connect the low pressure pipe (5) to the fuel pump filter.
After connecting the quick connector pipe (4) correctly to the left hand fuel tank, with due caution and pressing on both sides of the "double-lock" clip indicated, push the clip into its seat until it clicks audibly into place and the pipe is secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
FROM Ass.ly No. 90802
Fasten the low pressure pipe (5) by closing the indicated clamp.
Fit the cover (91) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 16 of 30
Connect the low pressure pipe (3) to the fuel pump filter.
Fasten the pipes (4) to the engine with the indicated clamp.
After connecting the quick connector pipes (4) correctly to the right hand fuel tank, with due caution and pressing on both sides of the "double-lock" clips indicated, push the clips into their seats until they click audibly into place and the pipes are secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
FROM Ass.ly No. 90802
Fasten the low pressure pipe (3) by closing the indicated clamp.
Fit the cover (92) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 17 of 30
Connect the pipe (46) leading from the secondary air pump to the relative pipe (2) , fitting the indicated clamp.
Close the indicated clamps fastening the secondary air pipe (2) , complete with valves.
Connect the pneumatic actuator system pipes (1) and fasten with a new clamp as indicated.
Refit the complete gearbox ( C2.03
).
Refit the engine air ducts ( B4.02
).
Refit the exhaust manifold ( B7.02
).
Refit the expansion tank ( B6.02
).
UP TO Ass.ly No. 90801. Refit the engine inspection hatch ( E4.06
).
Charge the air conditioning system. ( F5.12
).
Fill the power steering system ( D5.08
).
Fill the cooling system ( A3.07
).
Lower the vehicle using anti-tipping safety retainers ( E3.12
).
Refit the engine compartment lid ( E3.01
).
Reconnect the battery ( F2.01
).
Refitting the engine-gearbox assembly
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 18 of 30
Tightening torque
Fastening engine strut - engine mounting bush Screw
Fastening engine mounting bush - chassis
Fastening gearbox mounting bushing to rear subframe
Fastening heat shield - engine mounting bush
Fastening lower gearbox mounting cross member to chassis
Fastening ground cable - engine
Fastening retainer fork on GL and ATF oil pipes on gearbox
Screw
Screw
Screw
Nm
15 Nm
50 Nm
9 Nm
18 Nm
Class
B
B
B
B
On both sides, undo the three screws indicated fastening the retainer bracket (44) and the engine mounting bush (43) to the rear subframe.
Tighten the eyebolts (elements 27 ) of the hook
( AV 3432 ) into the specific seats (13) at the front of the engine.
Note that the heat shield is fitted in the photo aside. The heat shield must be mounted later on. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 19 of 30
Screw the hoisting pins ( AV 8253 ) into the vertical holes in the engine-gearbox connector tie-rods
(14) .
FROM Ass.ly No. 92290
Remove the two eyebolts (19) from the tool
( AS 107564 ) .
FROM Ass.ly No. 92290
Screw the two eyebolts (19) , removed previously from the tool, into the relative holes on the gearbox.
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8/5/2011
Refitting the complete engine Page 20 of 30
The engine-gearbox assembly must be lifted and positioned in its relevant seat on the rear subframe: this operation requires the use of a mobile hydraulic hoist or a bridge crane with a minimum load capacity of 300 Kg , element 31 of the hoisting hook ( AV 3432 ) (which is also used for the Enzo) and the crossbeam ( AV 3979 ) .
Connect the hook ( AV 3432 ) to the hoist hook of the bridge crane, aligning so that the crossbeam
( AV 3979 ) faces towards the rear of the subframe.
Connect the fixed length bars (17) to the hook
( AV 3432 ) and connect the variable length tierods (18) to the crossbeam ( AV 3979 ) .
Position the hoist over the engine-gearbox assembly and connect the bars (17) to the eyebolts (elements 27 ) of the hook ( AV 3432 ) .
Connect the tie-rods (18) to the pins ( AV 8253 ) .
Raise the hook to place the bars and tie-rods under tension.
FROM Ass.ly No. 92290
The engine-gearbox assembly must be lifted from the rear subframe: this operation requires the use of a mobile hydraulic hoist or a bridge crane with a minimum load capacity of 300 Kg , element 31 of the hoisting hook ( AV 3432 )
(which is also used for the Enzo) and the crossbeam ( AV 3979 ) .
Connect the hook ( AV 3432 ) to the hoist hook of the bridge crane, aligning so that the crossbeam
( AV 3979 ) faces towards the rear of the subframe.
Connect the fixed length bars (17) to the hook
( AV 3432 ) and connect the variable length tierods (18) to the crossbeam ( AV 3979 ) .
Position the hoist over the engine-gearbox assembly and connect the bars (17) to the eyebolts (elements 27 ) of the hook ( AV 3432 ) .
Hook the tie rods (18) onto the eyebolts (19) .
Raise the hook to place the bars and tie-rods under tension.
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8/5/2011
Refitting the complete engine Page 21 of 30
Lift the engine-gearbox assembly by a few millimetres, ensuring that the bar tension is uniform and that the assembly itself lifts evenly.
Lift the engine-gearbox assembly and set down in the relevant seats on the rear subframe, taking care to avoid collisions with any other components.
Fit the pin (22) fastening the bushing mounting (15) to the rear subframe, after fitting the washer.
Hand tighten the nut (21) after fitting the washer. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 22 of 30
Lower the engine-gearbox assembly, locating the engine struts on the bushings.
On both sides, hand-tighten the screws (42) fastening the engine strut to the engine mounting bush, after installing the relevant washer.
On both sides pretighten the screws (42) fastening the engine strut to the engine mounting bushing.
Tightening torque Nm Class
Fasten the engine mounting bushing (43) and the retainer bracket (44) , tightening the three screws indicated.
Tightening torque Nm Class
On both sides tighten the screws (42) fastening the engine strut to the engine mounting bushing.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine
Remove all the hoisting tools fitted previously.
Page 23 of 30
Pretighten the nut (21) .
Tightening torque
Tighten the nut (21) .
Tightening torque
Nm Class
Nm Class
Use a feeler gauge to check that the gap between the retainer bracket (44) and the engine mounting bush (43) , along the "X" axis, is between 1.2 mm and 2.8 mm .
Use a feeler gauge to check that the gap between the retainer bracket (44) and the engine mounting bush (43) , along the "Z axis, is between 1.2 mm and 2.8 mm .
Fit and fasten the heat shields (37) over the engine mounting bushes on both sides, tightening the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 24 of 30
Fit the right hand rear heat shield (12) in the relevant seat and fasten by tightening the screws indicated by red arrows.
Fit the right hand front heat shield (11) in the relevant seat and fasten by tightening the indicated screws.
Follow the same procedure to fit the front and rear heat shields on the left-hand side of the engine.
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Fit the lower gearbox mounting cross-member (9) in its seat and hand-tighten the indicated screws.
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Fit the lower gearbox mounting cross-member (9) in its seat and hand-tighten the indicated screws.
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8/5/2011
Refitting the complete engine Page 25 of 30
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Hand-tighten the indicated screws fastening the lower gearbox mounting cross-member (9) .
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Hand-tighten the indicated screws fastening the lower gearbox mounting cross-member (9) .
Tighten the indicated screws fastening the lower gearbox mounting cross member (9) , following the sequence shown in the photo.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Refitting the complete engine Page 26 of 30
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Tighten the indicated screws fastening the lower gearbox mounting cross member (9) , following the sequence shown in the photo.
Tightening torque Nm Class
Fasten the drain pipe (23) inside the rubber lined brackets tightening the indicated screws.
Fasten the drain pipe (23) inside the rubber lined bracket tightening the indicated screw.
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8/5/2011
Refitting the complete engine Page 27 of 30
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Fasten the drain pipe (23) inside the rubber lined bracket tightening the indicated screw.
Tighten the screw indicated on the ground cable
(38) onto the engine and secure the cable to the indicated fastener clamp on the starter motor shield.
Tightening torque Nm Class
Fit the indicated clamps fastening the pipes to the rear subframe in the original positions.
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8/5/2011
Refitting the complete engine Page 28 of 30
Connect the pneumatic actuator system pipes (10) and fasten by tightening the indicated clamp.
Fasten the gearbox wiring harness to the chassis, fitting the clamp and tightening the screw indicated, then connect the three connectors (8) .
Fit the mounting bracket (7) on the gearbox stud bolts and fasten the oil pipes of both systems onto the relevant pillory blocks.
Clean the area surrounding the gear oil pipe fastener point thoroughly with a suitable degreaser that does not leave residue.
Remove the plugs fitted previously on the oil pipes.
Replace the O-rings on the gear oil pipes (6) and fit into the relevant seats.
Fit the fork (5) on the gear oil pipes and fasten to the gearbox by tightening the screw indicated.
Tightening torque Nm Class
Tighten the screws indicated fastening the retainers on the pillory blocks holding the clutch hydraulic system oil pipes (4) and the gear oil pipes (6) .
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8/5/2011
Refitting the complete engine Page 29 of 30
Clean the area surrounding the fastener point for the clutch hydraulic system oil pipes thoroughly using a suitable degreaser that does not leave residue.
Remove the plugs fitted previously on the oil pipes.
Replace the O-rings on the clutch hydraulic system oil pipes (4) and fit into the relevant seats.
Fit the fork (3) on the clutch hydraulic system oil pipes and fasten to the gearbox by tightening the screw indicated.
Tightening torque Nm Class
Fit and fasten the heat shield (2) , tightening the screw indicated.
FROM Ass.ly No. 92290
Fit and fasten the heat shield (2) , tightening the screw indicated.
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8/5/2011
Refitting the complete engine Page 30 of 30
Tighten the screws indicated fastening the heat shield (2) .
Fit and fasten the shield (1) , tightening the 2 nuts and 2 screws indicated.
Refit the axle shaft ( C4.01
).
Refit both.
Refit the silencers ( B7.04
).
Refit the catalytic converter ( B7.03
).
Refit both.
Refit the engine air filter box ( B4.03
).
Refit the air flow meter ( F3.07
).
Refit both.
Refit the rear subframe ( E2.02
).
Check the Shell Transaxle 75W-90 GL5 gear oil level ( A3.02
).
Inspect the hydraulic clutch system oil level Shell DCT F-3 ( A3.03
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Disassembly
Print Exit
Removing the cylinder head covers
Remove the complete engine ( B2.01
).
Remove the ignition coils ( F3.02
).
Right hand cover
Disconnect the connectors (1) .
Page 1 of 6
Release the clip (2) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Disassembly Page 2 of 6
Disconnect the ground cable (3) by undoing the indicated screw.
Disconnect the connector (4) .
Detach the pipe (5) by loosening the indicated clamp.
Disconnect the connector (6) .
Open the clip (7) and release the relative pipes.
DAL Ass.ly No. 91654, open the clip (8) and release relative pipe.
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8/5/2011
Engine overhaul - Disassembly
Undo the screws indicated.
Remove the cover (A) .
Page 3 of 6
Undo the screws indicated.
Remove the cover carefully.
Left hand cover
Disconnect the connectors (1) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Disassembly
Release the clip (2) .
Page 4 of 6
Disconnect the ground cable (3) by undoing the indicated screw.
Disconnect the connector (4) .
Detach the pipe (5) by loosening the indicated clamp.
Disconnect the connector (6) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Disassembly Page 5 of 6
Open the clip (7) and release the relative pipes.
Open the clip (8) and release the relative pipes.
Undo the screws indicated.
Remove the cover (A) .
Undo the screws indicated.
Remove the cover carefully.
Removing the front timing cover (with engine in vehicle) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Disassembly
In preparation
Page 6 of 6 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Inspections
Print Exit
B2.04 Engine overhaul - Inspections
In preparation
In preparation
Page 1 of 1 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Rebuild
Print Exit
Refitting the front timing cover (with engine in vehicle)
In preparation
Refitting the cylinder head covers
Page 1 of 7
Tightening torque
Fastening the cylinder heads
Soundproofing cover - high pressure pump
Right hand cover
Screw (pretightening)
Screw
Nm
5 Nm
10 Nm
Class
B
B
Clean the cover mating surface thoroughly.
Apply a suitable quantity of paste CAF 4 in the indicated positions.
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8/5/2011
Engine overhaul - Rebuild Page 2 of 7
Replace the gasket (9) .
Replace the gaskets (10) .
Lubricate the gaskets (11) with soapy water.
Fit the cover carefully, tacking the indicated screws.
Pretighten the indicated screws in the sequence given.
Tightening torque
Screw (pretightening)
Nm
5 Nm
Class
B
Tighten the indicated screws in the sequence given.
Tightening torque
Fit the cover (A) .
Hand tighten the screws indicated.
Nm Class
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Rebuild Page 3 of 7
FROM Ass.ly No. 91654, position the respective pipe correctly and close the clip (8) .
Position the respective pipes correctly and close the clip (7) .
Connect the connector (6) .
Connect the pipe (5) , tightening the indicated clamp.
Connect the connector (4) .
Connect the ground cable (3) by tightening the indicated screw.
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8/5/2011
Engine overhaul - Rebuild
Attach the clip (2) .
Page 4 of 7
Connect the connectors (1) .
Left hand cover
Clean the cover mating surface thoroughly.
Apply a suitable quantity of paste CAF 4 in the indicated positions.
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8/5/2011
Engine overhaul - Rebuild Page 5 of 7
Replace the gasket (9) .
Replace the gaskets (10) .
Lubricate the gaskets (11) with soapy water.
Fit the cover carefully, tacking the indicated screws.
Pretighten the indicated screws in the sequence given.
Tightening torque
Screw (pretightening)
Nm
5 Nm
Class
B
Tighten the indicated screws in the sequence given.
Tightening torque
Fit the cover (A) .
Hand tighten the screws indicated.
Nm Class
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine overhaul - Rebuild Page 6 of 7
Position the respective pipes correctly and close the clip (8) .
Position the respective pipes correctly and close the clip (7) .
Connect the connector (6) .
Connect the pipe (5) , tightening the indicated clamp.
Connect the connector (4) .
Connect the ground cable (3) by tightening the indicated screw.
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8/5/2011
Engine overhaul - Rebuild
Attach the clip (2) .
Page 7 of 7
Connect the connectors (1) .
Refit the ignition coils ( F3.02
).
Refit the complete engine ( B2.02
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B20...
8/5/2011
Engine fuel system layout
Print Exit
Fuel system layout
Page 1 of 1
A - Fuel tanks
B - Fuel pumps
C - High pressure pumps
D - Fuel rail
E - Low pressure pipes
F - High pressure pipes
G - Fuel level sensor
H - Fuel pump filters https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank
Print Exit
Removing left hand fuel tank
Page 1 of 12
Disconnect the battery ( F2.01
).
Drain the fuel system ( B3.06
).
Remove the rear subframe ( E2.02
).
Remove the secondary air pump ( F3.12
).
Remove the passenger compartment trim panels ( E4.04
).
Remove the lower left hand lateral passenger compartment trim panel.
In the passenger compartment, push inwards the cable grommet (1) .
Remove from the housing and take out the cap (2) .
Disconnect the connector (3) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 2 of 12
Disconnect the connector (4) .
Undo the screw indicated by the red arrow on the ground cable (5) .
Disconnect the pipe (6) .
A "double-lock" safety clip is fitted on the union.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick coupling and remove the pipe (6) .
Undo the indicated fasteners.
Remove the lower heat shield (7) .
Undo the screws indicated.
Remove the upper heat shield (8) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 3 of 12
Hold properly the left hand fuel tank (A) .
Undo the nuts indicated.
UP TO Ass.ly No. 89228, retrieve the shims (9) .
Remove the belts (10) from the relative seats.
Remove the left hand fuel tank (A) .
Refitting left hand fuel tank
Tightening torque
Fastening fuel tank retainer belts
Fastening heat shield
Nut
Screw
Nm
20 Nm
9 Nm
Class
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 4 of 12
Check the state of the pads; replace if necessary.
Apply a layer of grease TUTELA MR3 on the pads, if necessary.
Fit the left hand fuel tank (A) .
Hold properly the left hand fuel tank (A) .
Lay out the straps (10) in the relative guides on the left hand fuel tank (A) .
UP TO Ass.ly No. 89228, fit the shims (9) .
Fit the belt eyebolts on the tie-rods.
Tighten the nuts indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 5 of 12
Fit the upper heat shield (8) .
Hand tighten the screws indicated.
Tightening torque Nm Class
Fit the lower heat shield (7) .
Tighten the indicated fasteners.
Tightening torque Nm Class
After connecting the quick connector pipe (6) correctly to the fuel tank, with due caution and pressing on both sides of the "double-lock" clip indicated, push the clip into its seat until it clicks audibly into place and the pipe is secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
Connect the connector (4) .
Hand tighten the screw indicated by the red arrow on the ground cable (5) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 6 of 12
In the passenger compartment, connect the connector (3) .
Fasten the cap (2) in the relative housing.
Fasten the cable grommet (1) on the cap (2) .
Refit the passenger compartment trim panels ( E4.04
).
Refit the secondary air pump ( F3.12
).
Refit the rear subframe ( E2.02
).
Add fuel to the tanks.
Reconnect the battery ( F2.01
).
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Perform the " Fuel tank tightness test " cycle.
Removing the right hand fuel tank
Disconnect the battery ( F2.01
).
Drain the fuel system ( B3.06
).
Remove the rear subframe ( E2.02
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 7 of 12
Disconnect the connector (4) .
Undo the screw indicated by the red arrow on the ground cable (5) .
Disconnect the pipes (6) .
There are two "double-lock" safety clips fitted onto the unions.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick couplings and remove the pipes (6) .
Detach the indicated clamps.
Move the pipes (1) aside so that they do not hinder the subsequent operations.
Undo the indicated fasteners.
Remove the lower heat shield (2) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank
Undo the screws indicated.
Remove the upper heat shield (7) .
Page 8 of 12
Disconnect the pipe (8) .
A "double-lock" safety clip is fitted on the union.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick coupling and remove the pipe (8) .
Remove the indicated clamp and disconnect the pipe (9) .
Support the weight of the right hand fuel tank (A) adequately.
Undo the nuts indicated.
UP TO Ass.ly No. 89228, retrieve the shims (10) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 9 of 12
Remove the belts (11) from the relative seats.
Remove the right hand fuel tank (A) .
Refitting the right hand fuel tank
Tightening torque
Fastening fuel tank retainer belts
Fastening heat shield
Nut
Screw
Nm
20 Nm
9 Nm
Class
B
B
Check the state of the pads; replace if necessary.
Apply a layer of grease TUTELA MR3 on the pads, if necessary.
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8/5/2011
Fuel tank Page 10 of 12
Fit the right hand fuel tank (A) .
Support the weight of the right hand fuel tank (A) adequately.
Lay out the straps (11) in the relative guides on the right hand fuel tank (A) .
UP TO Ass.ly No. 89228, fit the shims (10) .
Fit the belt eyebolts on the tie-rods.
Tighten the nuts indicated.
Tightening torque Nm Class
After connecting the quick connector pipe (8) correctly to the fuel tank, with due caution and pressing on both sides of the "double-lock" clip indicated, push the clip into its seat until it clicks audibly into place and the pipe is secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
Connect the pipe (9) and fasten with a new clamp as indicated.
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8/5/2011
Fuel tank Page 11 of 12
Fit the upper heat shield (7) .
Hand tighten the screws indicated.
Tightening torque Nm Class
Fit the lower heat shield (2) .
Tighten the indicated fasteners.
Tightening torque Nm Class
Fit the pipes (1) on the heat shields.
Fasten the indicated clamps on the heat shields. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel tank Page 12 of 12
After connecting the quick connector pipes (6) correctly to the fuel tank, with due caution and pressing on both sides of the "double-lock" clips indicated, push the clips into their seats until they click audibly into place and the pipes are secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
Connect the connector (4) .
Hand tighten the screw indicated by the red arrow on the ground cable (5) .
Refit the rear subframe ( E2.02
).
Add fuel to the tanks.
Reconnect the battery ( F2.01
).
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Perform the " Fuel tank tightness test " cycle. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel pump assembly
Print Exit
Copyright Ferrari S.p.A. - P.IVA 00159560366
Removing the fuel pump filter
Page 1 of 9
CAUTION
FUEL IS HIGHLY FLAMMABLE.
NEVER WORK ON A HOT ENGINE.
TO PREVENT FIRE RISKS AND FUEL LEAKAGE, WORK ONLY ON A COLD ENGINE WITH AN EMPTY
FUEL TANK.
CAUTION
Take every necessary precaution, since fuel residues may remain in the tank and in the pipes, even after the operations described.
Protect the engine components adequately to allow access to the interior of the fuel tanks and work without damaging the engine.
The fuel pump filters are fitted on the respective fuel tanks, at the front of the engine compartment.
The following procedure is for removing the left hand fuel pump. Where applicable, differences in the procedure for the right hand fuel pump are given.
Disconnect the battery ( F2.01
).
Drain the fuel system ( B3.06
).
Remove the engine compartment lid ( E3.01
).
Remove the engine compartment cosmetic shields ( E3.13
).
Right-hand side
Disconnect the connectors (2) and release from the bracket (12) .
Undo the screws indicated.
Remove the bracket (12) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel pump assembly
Remove the cover (1) .
Page 2 of 9
Disconnect the connector (3) .
Remove the ground cable (4) , undoing the indicated screw and retrieving the lock washer.
CAUTION
When connecting a fuel system pipe, bear in mind that the line may be pressurised. Proceed therefore with caution and keep away any type of flame as there is a risk of fuel spraying onto the operator.
Always plug the disconnected fuel pipes to prevent residual fuel from leaking.
Disconnect the fuel pipe (5) from the fuel pump filter.
FROM Ass.ly No. 90802 , detach the clip indicated by the red arrow.
Using a suitable tool, prise off and remove the safety clip (10) from its seat on the fuel pump filter ring nut.
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8/5/2011
Fuel pump assembly Page 3 of 9
Fit the tool ( AV 8175 ) in the relative seat on the fuel pump filter ring nut (6) .
Turn the fuel pump filter ring nut (6) counterclockwise to bring the lock pin (shown in the box in the photo) into the position indicated.
Remove the tool and remove the fuel pump filter ring nut (6) .
CAUTION
When connecting a fuel system pipe, bear in mind that the line may be pressurised. Proceed therefore with caution and keep away any type of flame as there is a risk of fuel spraying onto the operator.
Always plug the disconnected fuel pipes to prevent residual fuel from leaking.
Remove the fuel pump filter (A) from the relative seat and disconnect the unions (7) and (8) .
Disconnect the connectors (9) and remove the fuel pump filter (A) .
Refitting the fuel pump filter
The following procedure is for refitting the left hand fuel pump. Where applicable, differences in the procedure https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel pump assembly Page 4 of 9 for the right hand fuel pump are given.
Before refitting, thoroughly clean all the parts removed and dry with compressed air.
ALWAYS REPLACE the ring nut and relative Oring whenever the fuel pump is removed.
ALWAYS replace the O-ring (11) .
Connect the connectors (9) on the fuel pump filter
(A) .
Connect the unions (7) and (8) and fit the fuel pump filter (A) in the relative housing. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel pump assembly Page 5 of 9
To ensure that the filter is installed correctly, the tab on the fuel pump filter (A) must match up with the respective seat on the fuel tank, as shown in the photo aside.
ALWAYS REPLACE the ring nut and relative Oring whenever the fuel pump is removed.
ALWAYS replace fuel pump filter ring nut (6) with a new ring nut by fitting it in the relative seat.
Fit the tool ( AV 8175 ) in the relative seat on the fuel pump filter ring nut (6) .
Turn the fuel pump filter ring nut (6) clockwise to bring the lock pin (shown in the box in the photo) into the position indicated.
Remove the tool and check that the fuel pump filter ring nut (6) is locked in place.
Fit the safety clip (10) into its seat on the fuel pump filter ring nut, ensuring that it is securely fastened.
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8/5/2011
Fuel pump assembly Page 6 of 9
Connect the fuel pipe (5) onto the fuel pump filter.
Fasten the ground cable (4) , fitting the lock washer and tightening the indicated screw.
Connect the connector (3) .
FROM Ass.ly No. 90802 , fasten the clip indicated by the red arrow.
Fit the cover (1) in the relative seat.
Right-hand side
Fasten the bracket (12) , tightening the indicated screws.
Connect the connectors (2) and fasten to the bracket (12) .
Refit the engine compartment cosmetic shields ( E3.13
).
Refit the engine compartment lid ( E3.01
).
Reconnect the battery ( F2.01
).
Fill the fuel tank.
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel pump assembly
Perform the " Fuel tank tightness test " cycle.
Replacing the fuel pump
Page 7 of 9
CAUTION
FUEL IS HIGHLY FLAMMABLE.
NEVER WORK ON A HOT ENGINE.
TO PREVENT FIRE RISKS AND FUEL LEAKAGE, WORK ONLY ON A COLD ENGINE WITH AN EMPTY
FUEL TANK.
CAUTION
Take every necessary precaution, since fuel residues may remain in the tank and in the pipes, even after the operations described.
Protect the engine components adequately to allow access to the interior of the fuel tanks and work without damaging the engine.
ALWAYS REPLACE the ring nut and relative O-ring whenever the fuel pump is removed.
There are two fuel pumps, installed inside the fuel tanks at the front of the engine compartment.
The following procedure is for the replacement of the left hand fuel pump which, unlike the right hand pump, also incorporates the fuel level sensor.
Disconnect the battery ( F2.01
).
Remove the fuel pump filter ( B3.03
).
Lift the retainer (1) .
Turn the fuel pump (A) counterclockwise to align the pins of the retainer (2) with the indicated recesses.
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8/5/2011
Fuel pump assembly Page 8 of 9
Open the indicated clamp.
Remove the fuel pump (A) from the fuel tank floor.
Remove the fuel pump (A) from the tank and replace.
In the case of the left hand fuel pump, take care not to bend the fuel level sensor rod.
Place the new fuel pump (A) in the tank.
In the case of the left hand fuel pump, take care not to bend the fuel level sensor rod.
Turn the fuel pump (A) clockwise to align the pins of the retainer (2) with the indicated recesses.
Check that the fuel pump (A) engages correctly with the lip (3) on the fuel tank floor.
Lower the retainer (1) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel pump assembly Page 9 of 9
Fasten the fuel pump pipes (A) by closing the indicated clamp.
Refit the fuel pump filter ( B3.03
).
Reconnect the battery ( F2.01
).
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Perform the " Fuel tank tightness test " cycle. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel level sensor
Print Exit
B3.04 Fuel level sensor
Replacing the fuel level sensor
Page 1 of 4
CAUTION
FUEL IS HIGHLY FLAMMABLE.
NEVER WORK ON A HOT ENGINE.
TO PREVENT FIRE RISKS AND FUEL LEAKAGE, WORK ONLY ON A COLD ENGINE WITH AN EMPTY
FUEL TANK.
CAUTION
Take every necessary precaution, since fuel residues may remain in the tank and in the pipes, even after the operations described.
Whenever the fuel level sensor is removed, ALWAYS REPLACE WITH A NEW SENSOR, fitting a new Oring.
The fuel level sensor is mounted on the left hand fuel tank and is accessible from the passenger compartment.
Disconnect the battery ( F2.01
).
Drain the fuel system ( B3.06
).
Remove the passenger compartment trim panels ( E4.04
).
Remove the lower lateral trim panels.
Remove the cap (1) from the fuel level sensor housing.
Push the rubber cable grommet (2) inwards, then remove the cap (1) .
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8/5/2011
Fuel level sensor Page 2 of 4
Disconnect the connector (3) and, using a suitable tool, prise off and remove the safety clip (4) from the fuel level sensor (A) .
Fit the tool ( AV 8176 ) in the relative seat on the fuel level sensor (A) .
Turn the fuel level sensor (A) counterclockwise to bring the retainer clips (shown in the box in the photo) into the position indicated.
Remove the fuel level sensor (A) from its seat and replace.
Whenever the fuel level sensor is removed,
ALWAYS REPLACE WITH A NEW
SENSOR, fitting a new O-ring.
ALWAYS replace the O-ring (5) .
Fit the new fuel level sensor (A) in the relative seat on the tank, aligning the indicated tooth and recess.
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8/5/2011
Fuel level sensor Page 3 of 4
Fit the tool ( AV 8176 ) in the relative seat on the fuel level sensor (A) .
Turn the fuel level sensor (A) clockwise to bring the retainer clips (shown in the box in the photo) into the position indicated.
Fit the safety clip (4) in the relative seat, ensuring that they are correctly oriented, then connect the connector (3) on the fuel level sensor (A) .
Fit and fasten the cap (1) onto the fuel level sensor seat.
Pull the rubber cable grommet (2) outwards, then fit correctly on the cap (1) .
Refit the passenger compartment trim panels ( E4.04
).
Reconnect the battery ( F2.01
).
Fill the fuel tank.
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel level sensor
Perform the " Fuel tank tightness test " cycle.
Page 4 of 4 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel vapour separator
Print Exit
B3.05 Fuel vapour separator
Removing the fuel vapour separator
Page 1 of 3
Remove the engine compartment cosmetic shields ( E3.13
).
Release pipes (1) opening the indicated clamps, and disconnect them from right hand fuel tank
(2) .
There are two "double-lock" safety clips (9) fitted onto the unions.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick couplings and disconnect pipes (1) .
Disconnect the pipe (3) for the fuel vapour separator (A) from the left hand fuel tank (4) .
Disconnect pipe (1) from the left hand fuel tank (4) .
There are two "double-lock" safety clips fitted onto the unions.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick couplings and disconnect pipes (1) and (3) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel vapour separator
FROM Ass.ly No. 93334
Open the indicated studs.
Open the shielding (B) .
Page 2 of 3
Refitting the fuel vapour separator
Remove the indicated clamps fastening the pipe (7) and disconnect the pipe from the active carbon filter.
A "double-lock" safety clip (8) is fitted on the union.
To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
The difference between the safety clip "clicked" and "unclicked" position is only a few millimetres.
Then press on both sides of the quick coupling and remove the pipe (7) .
Undo the screws (10) fastening the fuel vapour separator (A) to the relative mounting bracket.
Remove the fuel vapour separator (A) , complete with pipes, from the engine compartment.
Fit the fuel vapour separator (A) in the relative seat and fasten to the mounting bracket by tightening the screws (10) .
After connecting the quick connector pipe (7) correctly to the active carbon filter, with due caution and pressing on both sides of the "double-lock" clip (8) indicated, push the clip into its seat until it clicks audibly into place and the pipe is fastened securely.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
Fasten the pipe (7) with the indicated clamps. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Fuel vapour separator
FROM Ass.ly No. 93334
Close the shielding (B) .
Fasten the indicated studs.
Page 3 of 3
After connecting the quick connector pipes (1) and
(3) of fuel vapours separator (A) correctly to left hand fuel tank (4) , with due caution and pressing on both sides of the "double-lock" clips indicated, push the clips into their seats until they click audibly into place and the pipes are secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
After connecting the quick connector pipes (1) correctly to the right hand fuel tank (2) , with due caution and pressing on both sides of the "double-lock" clips indicated (9) , push the clips into their seats until they click audibly into place and the pipes are secured correctly.
The difference between the safety clip "unclicked" and "clicked" position is only a few millimetres.
Secure pipes (1) closing the indicated clamps.
Refit the engine compartment cosmetic shields ( E3.13
).
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Perform the " Fuel tank tightness test " cycle. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B30...
8/5/2011
Draining the engine fuel system
Print Exit
B3.06 Draining the engine fuel system
Draining the fuel system
Page 1 of 1
CAUTION
Fuel is highly flammable.
NEVER WORK ON A HOT ENGINE.
This procedure requires the use of an aspirator pump compliant with EEC standards .
Connect a suitable pipe at least 2.5 metres in length, with a maximum diameter of 10 mm , to the aspirator pump.
Only use the funnel included in the vehicle tool kit, which is designed to release the Capless automatic sealing system.
Select the funnel (A) from the vehicle tool kit and insert in the relative seat in the filler neck.
The funnel releases the capless automatic filler neck closure system.
CAUTION
Collect the fuel in a suitable container.
Feed the pipe into the filler neck until it reaches the right hand fuel tank, then aspirate all the fuel out of the tank.
The two tanks are connected by a pipe at the bottom, so the fuel level will drop in both tanks simultaneously.
Check the quantity of fuel remaining in the tanks from the instrument panel. If necessary, repeat the previous procedure to aspirate as much of the fuel as possible out of the tanks.
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8/5/2011
Air intake system layout
Print Exit
B4.01 Air intake system layout
Page 1 of 1
A - Air ducts
B - Air filter box
C - Air flow meters
D - Throttle bodies
E - Intake manifold https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air ducts
Print Exit
Removing the engine air ducts
The following procedure is for removing the left hand duct.
The procedure for removing the right hand duct is identical.
Page 1 of 2
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the relevant engine compartment shield only.
Loosen the screw collar (1) fastening the duct (A) to the hose union (B) .
Disconnect the hose union (B) from the duct (A) .
Undo the screw (2) fastening the duct (A) .
Undo the screw (3) fastening the duct (A) .
Disconnect the duct (A) from the duct (C) , easing out toward the rear of the vehicle.
Remove the duct from the relevant seat. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air ducts
Refitting the engine air ducts
Page 2 of 2
Tightening torque
Fastening engine air ducts
Fastening hose unions to engine air ducts
Screw
Screw collar
The following procedure is for refitting the left hand duct.
The procedure for refitting the right hand duct is identical.
Fit the duct in the relative seat.
Nm
6 Nm
4 Nm
Class
B
C
Connect the duct (A) to the duct (C) , installing towards the front of the vehicle.
Tighten the screw (3) fastening the duct (A) .
Tightening torque Nm Class
Tighten the screw (2) fastening the duct (A) .
Tightening torque Nm Class
Connect the hose union (B) to the duct (A) .
Tighten the screw collar (1) fastening the duct (A) to the hose union (B) .
Tightening torque
Screw collar
Refit the engine compartment cosmetic shields ( E3.13
).
Nm
4 Nm
Class
C https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air filter box
Print Exit
Replacing the air filter
Page 1 of 6
Place a few strips of adhesive tape to protect the bodywork on the areas shown in the photo aside.
Undo the screws indicated fastening the air filter box cover (A) to the air filter box.
WARNING: take care not to damage the bodywork during air filter box cover handling.
Prise out and move the air filter box cover (A) out of its seat.
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8/5/2011
Air filter box Page 2 of 6
Remove the air filter (B) from the relevant seat and replace.
Fit the new air filter (B) in the relevant seat.
WARNING: take care not to damage the bodywork during air filter box cover handling.
Fit the air filter box cover (A) in its relevant seat.
Tighten the screws indicated fastening the air filter box cover (A) to the air filter box.
Remove the adhesive tape fitted previously.
Removing the engine air filter box
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the rear bumper ( E3.04
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air filter box Page 3 of 6
Undo the indicated nuts fastening the air flow meters (A) to the air filter box cover (B) .
Undo the screws indicated fastening the air filter box cover (B) .
Remove the air filter box cover (B) from the relative seat, disconnecting from the air flow meters (A) and retrieving the O-rings.
Loosen the indicated screw collar fastening the left hand lateral hose union (C) to the air filter box
(D) .
Disconnect the left hand lateral hose union (C) from the air filter box (D) .
Undo the nuts (1) fastening the air filter box (D) .
Undo the indicated screws fastening the left hand bracket (E) to the engine compartment lid mounting.
Remove the left hand bracket (E) from the relevant seat.
Loosen the indicated screw collar fastening the right hand lateral hose union (C) to the air filter box
(D) .
Disconnect the right hand lateral hose union (C) from the air filter box (D) .
Undo the nuts (1) fastening the air filter box (D) .
Undo the indicated screws fastening the right hand bracket (E) to the engine compartment lid mounting.
Remove the right hand bracket (E) from the relevant seat.
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8/5/2011
Air filter box Page 4 of 6
Undo the indicated screws fastening the bracket (F) to the back of the air filter box (D) .
Remove the bracket (F) from the relevant seat.
Working with due caution, remove the air filter box from the relevant seat.
Refitting the engine air filter box
Tightening torque
Fastening solenoid valve mounting bracket to engine air filter box
Fastening engine air filter box
Fastening hose unions to engine air filter box
Nut
Screw collar
Working with due caution, fit the air filter box in the relative seat.
Nm
9 Nm
4 Nm
Class
B
C
Fit the bracket (F) in the relative seat.
Tighten the indicated screws fastening the bracket
(F) to the back of the air filter box (D) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air filter box Page 5 of 6
Fit the right hand bracket (E) in the relative seat.
Tighten the indicated screws fastening the right hand bracket (E) to the engine compartment lid mounting.
Tighten the nuts (1) fastening the air filter box (D) .
Tightening torque Nm Class
Connect the right hand lateral hose union (C) to the air filter box (D) .
Tighten the indicated screw collar fastening the right hand lateral hose union (C) to the air filter box
(D) .
Tightening torque
Screw collar
Nm
4 Nm
Class
C
Fit the left hand bracket (E) in the relative seat.
Tighten the indicated screws fastening the left hand bracket (E) to the engine compartment lid mounting.
Tighten the nuts (1) fastening the air filter box (D) .
Tightening torque Nm Class
Connect the left hand lateral hose union (C) to the air filter box (D) .
Tighten the indicated screw collar fastening the left hand lateral hose union (C) to the air filter box
(D) .
Tightening torque
Screw collar
Nm
4 Nm
Class
C https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air filter box Page 6 of 6
Fit the air filter box cover (B) in the relative seat, refitting the O-rings and connecting the cover to the air flow meters (A) .
Tighten the screws indicated fastening the air filter box cover (B) .
Tighten the indicated nuts fastening the air flow meters (A) to the air filter box cover (B) .
Refit the rear bumper ( E3.04
).
Refit the engine compartment cosmetic shields ( E3.13
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air intake manifold
Print Exit
Removing the intake manifold
Page 1 of 18
Disconnect the battery ( F2.01
).
Remove the indicated clamp and disconnect the respective pneumatic actuator system pipes (2) .
Remove the clamps (1) and detach the motorised throttle bodies from the plenums.
Disconnect the quick connector (26) from the left hand bellow.
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8/5/2011
Air intake manifold Page 2 of 18
Right-hand side
Disconnect the pipe (6) from the rigid pipe, removing the indicated clamp.
Remove the vacuum pipe (7) from the plenum, undoing the indicated screw.
FROM Ass.ly No. 91654 _ Right hand side
Remove the clamp indicated.
Disconnect the pipe (32) from the tank.
Release the pipes (6) and (32) , removing the clamp
(33) .
FROM Ass.ly No. 90802 _ Right hand side
Open the indicated clamp. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air intake manifold Page 3 of 18
Right-hand side
Disconnect the pipes (4) and (5) from the plenum, removing the indicated clamps.
Right-hand side
Detach the connector (8) from the mounting bracket.
Right-hand side
Remove the wiring harness retainer bracket (9) , undoing the indicated screws. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air intake manifold Page 4 of 18
Right-hand side
Remove the wiring harness retainer brackets (10) and (11) , undoing the indicated screws.
Right-hand side
Remove the wiring harness retainer bracket (12) , undoing the indicated screw.
Left-hand side
Disconnect the pipes (13) and (14) from the plenum, removing the indicated clamps.
Remove the wiring harness retainer bracket (15) , undoing the indicated screw. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air intake manifold Page 5 of 18
Left-hand side
Detach the connector (16) from the mounting bracket.
Remove the wiring harness retainer bracket (17) , undoing the indicated screws.
Left-hand side
Remove the wiring harness retainer brackets (18) and (19) , undoing the indicated screws.
Disconnect the quick connector (20) of the brake servo vacuum pipe.
Open the indicated clamps fastening the pipes to the intake manifold.
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8/5/2011
Air intake manifold
FROM Ass.ly No. 90802 _ Left hand side
Open the clamps indicated.
Page 6 of 18
Open the indicated clamp fastening the pipes to the intake manifold.
Right-hand side
Undo the indicated upper screw fastening the three plastic clamps to the intake manifold.
Undo the lower screw indicated fastening the injection cable retainer bracket to the intake manifold.
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8/5/2011
Air intake manifold Page 7 of 18
Left-hand side
Undo the indicated upper screw fastening the two plastic clamps to the intake manifold.
Undo the lower screw indicated fastening the injection cable retainer bracket to the intake manifold.
Left-hand side
Move the left hand injection cable (23) aside as far as possible to allow access to the intake manifold fasteners.
Before lifting the intake manifold, check that all the nuts and washers removed have been retrieved so that they cannot fall into the intake ducts.
Undo the eight indicated screws fastening the intake manifold (A) to the cylinder head.
Right-hand side
Move the right hand injection cable (22) aside as far as possible to allow access to the intake manifold fasteners.
Before lifting the intake manifold, check that all the nuts and washers removed have been retrieved so that they cannot fall into the intake ducts.
Undo the eight indicated screws fastening the intake manifold (A) to the cylinder head.
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8/5/2011
Air intake manifold Page 8 of 18
Left-hand side
Tilt the intake manifold slightly to the left in order to be able to remove the indicated clip fastening the power steering fluid pipes (24) .
Left-hand side
Keeping the intake manifold tilted, remove the indicated clip fastening the power steering fluid pipes (24) .
Left-hand side
Disconnect the connector (30) at the front of the intake manifold.
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8/5/2011
Air intake manifold Page 9 of 18
Right-hand side
Disconnect the connector (31) at the front of the intake manifold.
With the assistance of another worker, lift the intake manifold off the engine.
Remove the two gaskets (29) from the cylinder heads.
Cover the intake duct orifices to prevent foreign bodies from entering.
Close off the intake ports in the cylinder heads to prevent foreign objects from entering the ducts.
Refitting the intake manifold
Tightening torque
Fastening intake manifold to cylinder heads Screw
Nm
10 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air intake manifold Page 10 of 18
Fit two new seals (29) in the relative seats on the cylinder heads.
With the assistance of another worker, fit the intake manifold in the relative seat on the engine.
Right-hand side
Connect the connector (31) at the front of the intake manifold.
Left-hand side
Connect the connector (30) at the front of the intake manifold.
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8/5/2011
Air intake manifold Page 11 of 18
Left-hand side
Tilt the intake manifold slightly to the left in order to be able to fix the indicated clip, fastening the power steering fluid pipes (24) , onto the metal bracket.
Left-hand side
Keeping the intake manifold tilted, fix the indicated clip, fastening the power steering fluid pipes
(24) , onto the metal bracket.
Right-hand side
Move the right hand injection cable (22) aside as far as possible in order to be able to tighten the intake manifold fasteners.
Take particular care when fitting the intake manifold. Locating the manifold incorrectly may deform and compromise the tightness of the gaskets, causing the "Engine diagnostic system (EOBD)" warning light to illuminate.
Tighten the eight indicated screws fastening the intake manifold (A) to the cylinder head.
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8/5/2011
Air intake manifold Page 12 of 18
Left-hand side
Move the left hand injection cable (23) aside as far as possible in order to be able to tighten the intake manifold fasteners.
Take particular care when fitting the intake manifold. Locating the manifold incorrectly may deform and compromise the tightness of the gaskets, causing the "Engine diagnostic system (EOBD)" warning light to illuminate.
Tighten the eight indicated screws fastening the intake manifold (A) to the cylinder head.
Tighten the indicated screws in the order given.
Tightening torque Nm Class
Left-hand side
Loosen the lower screw indicated fastening the injection cable retainer bracket to the intake manifold.
Tighten the indicated upper screw fastening the two plastic clamps to the intake manifold.
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8/5/2011
Air intake manifold Page 13 of 18
Right-hand side
Loosen the lower screw indicated fastening the injection cable retainer bracket to the intake manifold.
Tighten the indicated upper screw fastening the three plastic clamps to the intake manifold.
Close the indicated clamp fastening the pipes to the intake manifold.
Close the indicated clamps fastening the pipes to the intake manifold.
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8/5/2011
Air intake manifold Page 14 of 18
Left-hand side
Connect the quick connector (20) of the brake servo vacuum pipe.
Fasten the wiring harness retainer brackets (18) and (19) , tightening the indicated screws.
FROM Ass.ly No. 90802 _ Left hand side
Close the indicated clamps.
Left-hand side
Fasten the wiring harness retainer bracket (17) , tightening the indicated screws.
Fit and fasten the connector (16) on the mounting bracket.
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8/5/2011
Air intake manifold Page 15 of 18
Left-hand side
Fasten the wiring harness retainer bracket (15) , tightening the indicated screw.
Connect and fasten the pipes (13) and (14) to the plenum, using new clamps as indicated.
Right-hand side
Fasten the wiring harness retainer bracket (12) , tightening the indicated screw.
Right-hand side
Fasten the wiring harness retainer brackets (10) and (11) , tightening the indicated screws.
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8/5/2011
Air intake manifold Page 16 of 18
Right-hand side
Fasten the wiring harness retainer bracket (9) , tightening the indicated screws.
Right-hand side
Fit and fasten the connector (8) on the mounting bracket.
Right-hand side
Connect and fasten the pipes (4) and (5) to the plenum, using new clamps as indicated.
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8/5/2011
Air intake manifold Page 17 of 18
Right-hand side
Connect and fasten the pipe (6) to the rigid pipe, using a new clamp as indicated.
Fasten the vacuum pipe (7) to the plenum, tightening the indicated screw.
FROM Ass.ly No. 91654 _ Right hand side
Connect the pipe (32) to the tank.
Tighten a new clamp as indicated.
Fasten the pipes (6) and (32) , fitting the clamp (33) .
FROM Ass.ly No. 90802 _ Right hand side
Close the indicated clamp. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Air intake manifold Page 18 of 18
Connect and fasten the motorised throttle bodies to the plenums with new clamps (1) .
Connect the quick coupling (26) to the left hand bellow.
Connect the pneumatic actuator system pipes (2) and fasten with a new clamp as indicated.
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B40...
8/5/2011
Engine lubrication system layout
Print Exit
Engine lubrication system layout
Page 1 of 1
A - Engine oil tank
B - Engine oil pump
C - Water/engine oil heat exchanger
D - Engine oil filter https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil pump
Print Exit
B5.02 Engine pump
Removing the oil pump
Page 1 of 8
The oil pump is mounted on the lower right hand side of the engine.
Drain the engine lubrication system ( A3.01
).
Undo the indicated screw on the fork (1) retaining the pipe (2) on the oil pump (A) .
Detach the pipe (2) and move out of the way, so that it does not hinder the subsequent operations.
Undo the four screws indicated fastening the lower housing (3) onto the engine oil tank.
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8/5/2011
Engine oil pump Page 2 of 8
UP TO Engine No. 158940
Remove the Seeger ring (4) and push the bushing
(5) down to detach from the orifice on the crankcase.
FROM Engine No. 158941
Undo the indicated screws and remove the bracket
(4) .
Push the bush (5) downwards out of the relative seat on the crankcase.
Undo the six indicated screws fastening the oil pump (A) to the crankcase. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil pump Page 3 of 8
Supporting the weight of the pump and applying leverage with a suitably protected tool (6) , move the oil pump (A) perpendicularly backwards, in order to detach the union bushing (7) from the crankcase.
Remove the oil pump (A) , complete with lower housing, from the engine.
If necessary, detach the oil pump (A) from the flange (8) on the workbench, undoing the indicated screw and retrieving the retainer fork
(9) .
Remove the flange (8) from the pump (A) .
Refitting the oil pump https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil pump Page 4 of 8
Tightening torque
Fastening engine oil recovery and pick-up pipe
Oil pump - crankcase
Fastening oil pump bush retainer bracket
Screw
Screw
Screw
Before refitting the oil pump, replace all the gaskets as follows.
Nm
10 Nm
25 Nm
10 Nm
Class
B
B
B
Remove the mesh filter (14) from the relative seat on the lower housing of the engine oil tank and blow with compressed air to remove any contamination or dirt; replace if necessary.
Then refit in the relative seat.
Replace and lubricate the gasket (15) on the lower engine oil tank housing. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil pump Page 5 of 8
Replace and lubricate the gasket (10) on the oil pump.
The tab at the centre of the gasket (10) must face downward and fasten onto the edge of the relative seat.
Replace the two O-rings (11) on the union bushings.
Replace and lubricate the two O-rings (12) on the hose leading from the engine oil tank.
If removed previously, replace and lubricate the two
O-rings (13) on the flange (8) .
Fit the flange (8) in the relative seat on the pump
(A) .
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8/5/2011
Engine oil pump Page 6 of 8
Fasten the flange (8) onto the oil pump (A) , fitting the retainer fork (9) and tightening the screw indicated.
Tightening torque Nm Class
If the hexagonal bar was removed, during reassembly, ensure that the white paint marking on the bar itself is turned towards the timing side.
Place the pipe leading from the engine oil tank in a position to facilitate subsequent connection to the pump.
Lubricate the seats of the connector bushings between the crankcase and the lower crankcase shell with SEGO grease.
Fit the oil pump (A) in the relative seat, taking particular care not to pinch the mesh gasket, and fit the union bushing (7) perpendicularly onto the crankcase.
Loosely fit the six indicated screws fastening the oil pump (A) to the crankcase. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil pump Page 7 of 8
Tighten the six screws indicated fastening the oil pump (A) onto the crankcase, in the sequence illustrated in the photo aside.
Tightening torque Nm Class
UP TO Engine No. 158940
Push the bushing (5) upward to insert fully in the crankcase, then fit the Seeger ring (4) in the relative seat.
When fitting the bushing (5) , push against the loose Seeger ring (4) so as not to damage the lip of bushing.
FROM Engine No. 158941
Push the bush (5) upwards against the crankcase.
Fit the bracket (4) , fastening the bush (5) .
Fasten the bracket (4) , tightening the indicated screws.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil pump Page 8 of 8
Fit the pipe (2) in the relative seat on the oil pump
(A) .
Fit the fork (1) retaining the pipe (2) in its relative seat and fasten the assembly by tightening the indicated screw.
Tightening torque Nm Class
Tighten the four screws indicated fastening the lower housing (3) onto the engine oil tank.
Fill the engine lubrication system ( A3.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil tank
Print Exit
B5.03 Engine tank
Removing the engine oil tank
Page 1 of 8
Remove the air flow meter ( F3.07
).
Remove both air flow meters.
Remove the motorised throttle body ( F3.08
).
Remove both motorised throttle bodies.
Drain the engine lubrication system ( A3.01
).
Remove the catalytic converter ( B7.03
).
Remove the right hand catalytic converter only.
Remove the power steering tank ( D5.02
).
Remove the power steering fluid reservoir without disconnecting from the system and move aside so that it does not hinder the removal of the engine oil tank.
Undo the screws indicated fastening the valve (1) located at the rear of the engine oil tank (A) .
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8/5/2011
Engine oil tank Page 2 of 8
Open the indicated clamps to detach the power steering fluid pipes (4) and the secondary air pipe (5) .
Disconnect the pipe (3) from the engine oil tank (A) .
Disconnect the pipes (6) and (7) from the right hand intake manifold, removing the relative clamps and opening the indicated clamp. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil tank Page 3 of 8
UP TO Ass.ly No. 92289
Remove the right hand tie-rod (8) , undoing the screws (9) and (10) .
Undo the screw indicated on the fork (12) retaining the pipe (11) on the oil pump (13) .
Detach the pipe (11) .
Undo the screws indicated fastening the engine oil tank (A) to the flange on the oil pump.
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8/5/2011
Engine oil tank Page 4 of 8
Undo the indicated rear screws fastening the engine oil tank (A) to the gearbox.
Undo the front left hand screw fastening the engine oil tank (A) to the gearbox.
Undo the front right hand screw fastening the engine oil tank (A) to the gearbox.
Remove the engine oil tank from the engine compartment, lifting out from above.
Refitting the engine oil tank https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil tank Page 5 of 8
Tightening torque
Fastening engine oil tank to gearbox
Fastening engine oil recovery and pick-up pipe
Fastening Tie-rod to gearbox
Fastening tie-rod to cylinder heads
Screw
Screw
Screw
Screw
Nm
10 Nm
10 Nm
88 Nm
24 Nm
Class
B
B
A
A
Replace the two O-rings (14) on the hose and the Oring (15) on the engine oil tank, lubricating the new rings.
Fit the engine oil tank (A) in the relative seat on the gearbox from above and fasten at the rear by tightening the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil tank Page 6 of 8
Tighten the front right hand screw fastening the engine oil tank (A) to the gearbox.
Tightening torque Nm Class
Tighten the front left hand screw fastening the engine oil tank (A) to the gearbox.
Tightening torque Nm Class
Take care not to pinch or crush the O-ring.
Tighten the indicated screws fastening the engine oil tank (A) to the flange on the oil pump.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil tank Page 7 of 8
Fit the pipe (11) in the relative seat on the oil pump
(13) .
Fit the fork (12) retaining the pipe (11) in its relative seat and fasten the assembly by tightening the indicated screw.
Tightening torque Nm Class
UP TO Ass.ly No. 92289
Fit the right hand tie-rod (8) and fasten by tightening the screws (9) and (10) .
Tightening torque Nm Class
Connect the pipes (6) and (7) onto the right hand intake manifold, fitting new clamps and closing the indicated clamp onto the pipe. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine oil tank Page 8 of 8
Connect the pipes (2) and (3) to the engine oil tank
(A) , fitting a new clamp.
Close the indicated clamps fastening the power steering fluid pipes (4) and the secondary air pipe (5) .
Fit the valve (1) in the relative seat on the rear of the engine oil tank (A) and fasten by tightening the screws indicated.
Refit the power steering tank ( D5.02
).
Refit the catalytic converter ( B7.03
).
Refit the motorised throttle body ( F3.08
).
Refit the air flow meter ( F3.07
).
Fill the engine lubrication system ( A3.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Water-engine oil heat exchanger
Print Exit
B5.04 Water-engine oil heat exchanger
Removing the engine oil-water heat exchanger
Page 1 of 5
There may be residual engine oil inside the heat exchanger.
Clean/dry any pooling oil/water.
Take particular care not to contaminate the two systems.
The following photos show the engine removed from the vehicle to illustrate the procedure more clearly.
However, the following procedure is also possible with the engine still installed in the vehicle.
Disconnect the battery ( F2.01
).
Drain the cooling system ( B6.07
).
Remove the intake manifold ( B4.04
).
Remove the complete rail ( F3.15
).
Remove the complete fuel rail mounting.
Remove the alternator ( F2.04
).
Disconnect the connectors (5) and (6) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Water-engine oil heat exchanger Page 2 of 5
Undo the screws indicated by the black arrows.
Retrieve the bracket (1) .
Undo the stud bolts (2) fastening the clamps (3) .
Undo the screws indicated by the red arrows to release the clamps (3) .
Move the injection cable (4) away from over the heat exchanger so that it does not hinder the subsequent operations.
Move the engine services cable (7) out of the way so that it does not hinder the subsequent operations.
Remove the water vent pipe (8) , undoing the indicated union.
Undo all the screws indicated.
Mark the position of the screws, as they are not all of the same length.
There may be residual engine oil inside the heat exchanger.
Clean/dry any pooling oil/water.
Take particular care not to contaminate the two systems.
Lift the oil-water heat exchanger (A) out of the relative housing.
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8/5/2011
Water-engine oil heat exchanger Page 3 of 5
Remove the gasket (9) from the heat exchanger (A) and replace.
Remove the adhesive gasket (10) from the heat exchanger (A) and replace.
Refitting the engine oil-water heat exchanger
Tightening torque
Fastening oil-water heat exchanger Screw
Nm
10 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Water-engine oil heat exchanger Page 4 of 5
Thoroughly clean the mating faces on the crankcase in contact with the gasket (9) .
Thoroughly clean the mating faces on the heat exchanger (A) in contact with the gasket (9) .
Fit a new gasket (9) .
Thoroughly clean the mating faces on the heat exchanger (A) in contact with the adhesive gasket (10) .
Fit a new adhesive gasket (10) .
Fit the oil-water heat exchanger (A) in the relative housing.
Fit and snug the indicated screws, using the marks made during removal as reference as the screws are not all of equal length.
Tighten the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Water-engine oil heat exchanger Page 5 of 5
Fit and fasten the water vent pipe (8) , tightening the indicated union.
Lay the engine services cable (7) as originally fitted on the heat exchanger.
Refit the alternator ( F2.04
).
Refit the complete rail ( F3.15
).
Refit the intake manifold ( B4.04
).
Reconnect the battery ( F2.01
).
Fill the cooling system ( A3.07
).
Fill the engine lubrication system ( A3.01
).
Fill to the correct level.
Place the injection cables (4) on top of the heat exchanger as originally fitted.
Fit and fasten the clamps (3) , tightening the screws indicated by the red arrows.
Fit and fasten the clamps (3) , tightening the stud bolts (2) .
Fit the bracket (1) and fasten to the stud bolts (2) by tightening the screws indicated by the black arrows.
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8/5/2011
Blow-by system
Print Exit
Page 1 of 1
The oil vapour and gas recirculation system is a closed circuit.
In the event of engine malfunction causing an anomalous increase in oil pressure, oil vapour from the heads is ducted via the pipes (A) to the vapour separator (B) .
In the vapour separator (B) , a portion of the vapour condenses and drains into the oil tank below, whereas the remaining gases are aspirated by the vacuum generated by the engine and ducted via the pipes (C) to the bellows (D) ahead of the throttle bodies and into the intake plenums.
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8/5/2011
Draining and filling the engine lubrication system
Print Exit
B5.06 Draining and filling the engine lubrication system
Draining the engine lubrication system
Page 1 of 3
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Remove the rear flat undertray section ( E3.12
).
Undo the two drain plugs (1) on the crankcase and the plug (2) under the engine oil tank.
Drain the oil completely.
Filling the engine lubrication system https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Draining and filling the engine lubrication system Page 2 of 3
Tightening torque
Magnetic oil drain plugs M22x1.5 plug
Nm
60 Nm
Class
B
Clean the oil drain plugs (1) and (2) thoroughly with a suitable degreaser that does not leave residue.
Always replace the seals with new seals.
Tighten the plugs (1) onto the crankcase.
Tightening torque
M22x1.5 plug
Nm
60 Nm
Class
B
Fully tighten the cap (2) onto the engine oil tank.
Unscrew the engine oil filler cap (B) and remove it. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Draining and filling the engine lubrication system Page 3 of 3
Fill the system with the prescribed type and quantity of oil (see "A1.02 _ Fluids and lubricants table").
The quantity of oil required may vary slightly relative to the amount indicated for filling the tank when empty; this is due to unavoidable pooling within the system.
Fully tighten the engine oil filler cap (B) .
Check that there are no oil leaks from the draining plugs and the filter cartridge.
Refit the rear flat undertray section ( E3.12
).
Check the engine oil level ( A3.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B50...
8/5/2011
Engine cooling system layout
Print Exit
Page 1 of 1
A - Expansion tank
B - Water pump
C - Radiators https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Expansion tank
Print Exit
Page 1 of 2
Removing the expansion tank
Disconnect the battery ( F2.01
).
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the right hand engine compartment shield.
Remove the engine air ducts ( B4.02
).
Remove the right hand air duct.
Drain the coolant from the tank by aspirating it from the filler neck.
Disconnect the oxygen sensor connector (1) and remove the relative clips from the chassis.
Undo the cap (2) .
Remove the clamps (3) then disconnect the relative pipes.
Remove the clamp indicated by the red arrow, located on the front of the expansion tank (A) .
Undo the screws indicated and remove the expansion tank (A) from the chassis.
Refitting the expansion tank
Tightening torque
Fastening expansion tank to chassis Screw
Nm
8 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Expansion tank Page 2 of 2
Fit the expansion tank (A) in the relative seat and fasten by tightening the screws indicated.
Tightening torque Nm Class
Fasten the clamp indicated by the red arrow, located on the front of the expansion tank (A) .
Connect the pipes and fasten with new clamps (3) .
FROM Ass.ly No. 94037 when connecting the delivery pipe to the pump from the expansion tank (A) , the reference slot must be aligned correctly to prevent blockage.
Tighten the cap (2) .
Connect the oxygen sensor connector (1) and fasten to the chassis as originally mounted with the relative clips.
Refit the engine air ducts ( B4.02
).
Refit the engine compartment cosmetic shields ( E3.13
).
Reconnect the battery ( F2.01
).
Fill the cooling system ( A3.07
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water pump
Print Exit
Removing the water pump
The water pump is integrated in the front timing cover.
Drain the engine lubrication system ( A3.01
).
Drain the cooling system ( B6.07
).
Remove the from timing cover ( B2.03
).
Page 1 of 2
Undo the two screws indicated and remove the water pump (A) from its seat in the front timing cover.
Refitting the water pump
Tightening torque
Fastening water pump Screw
Nm
10 ÷ 12 Nm
Class
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water pump Page 2 of 2
On the workbench, replace and lubricate the two Orings (1) on the pump, taking particular care not to damage the rings or the seal recesses.
Ensure that the two O-rings (1) are installed correctly and are NOT twisted.
Fill the engine lubrication system ( A3.01
).
Fill the cooling system ( A3.07
).
Refit the from timing cover ( B2.05
).
Fit the water pump (A) in the relative seat on the front timing cover, taking care not to pinch the Orings.
Prefit the pump, bringing the mating surfaces into contact and aligning the fastener holes, then tighten the two screws indicated.
Tightening torque
Screw
Nm
10 ÷ 12 Nm
Class
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Pressure switch/thermostat
Print Exit
Replacing the pressure switch/thermostat
Page 1 of 1
Tightening torque
Fastening hose union to thermostat Screw collar
Drain the cooling system ( B6.07
).
Remove the engine inspection hatch ( E4.06
).
Nm
4 Nm
Class
B
Loosen the clamp (1) and detach the pipe (2) from the pressure switch/thermostat (A) .
Undo the screws indicated, remove the pressure switch/thermostat (A) and replace.
Refit the engine inspection hatch (
Fill the cooling system ( A3.07
).
E4.06
).
Fit the pressure switch/thermostat (A) in the relative seat and fasten by tightening the screws indicated.
Fit the pipe (2) , positioning the notch correctly, and fasten by tightening screw collar (1) .
Tightening torque
Screw collar
Nm
4 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators
Print Exit
Removing the water radiators
Drain the cooling system ( B6.07
).
If only one radiator needs to be removed, drain that radiator only.
Left hand radiator
Remove the condenser ( F5.04
).
Page 1 of 12
Undo the indicated screw fastening the front brake air duct (A) .
Remove the front brake air duct (A) from the relative seat.
Undo the indicated screws fastening the upper radiator air duct (B) .
Remove the upper radiator air duct (B) from the relative seat.
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8/5/2011
Water radiators
Disconnect the connector (1) .
Page 2 of 12
Disconnect the connectors (2) .
Loosen the clamp (3) fastening the pipe union (C) to the water radiator (D) .
Disconnect the pipe union (C) from the water radiator (D) .
Place a suitably sized container under the pipe union (C) to collect any coolant leakage.
Plug the water radiator (D) with a suitably sized plug.
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8/5/2011
Water radiators Page 3 of 12
Undo the indicated front screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Supporting the weight of the water radiator (D) , undo the indicated rear screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Supporting the weight of the water radiator (D) , undo the indicated lateral screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Remove the water radiator from the relative seat. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators
Right hand radiator
Page 4 of 12
Remove the radiator/power steering fluid coil ( D5.05
).
Remove the water radiator without disconnecting the power steering system pipes.
Undo the indicated screw fastening the front brake air duct (A) .
Remove the front brake air duct (A) from the relative seat.
Undo the indicated screws fastening the upper radiator air duct (B) .
Remove the upper radiator air duct (B) from the relative seat.
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8/5/2011
Water radiators
Disconnect the connector (1) .
Page 5 of 12
Disconnect the connectors (2) .
Loosen the clamp (3) fastening the pipe union (C) to the water radiator (D) .
Disconnect the pipe union (C) from the water radiator (D) .
Place a suitably sized container under the pipe union (C) to collect any coolant leakage.
Plug the water radiator (D) with a suitably sized plug.
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8/5/2011
Water radiators Page 6 of 12
Undo the indicated front screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Supporting the weight of the water radiator (D) , undo the indicated rear screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Supporting the weight of the water radiator (D) , undo the indicated lateral screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Remove the water radiator from the relative seat. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators
Refitting the water radiators
Page 7 of 12
Tightening torque
Fastening water radiators
Fastening upper radiator air ducts
Fastening front brake air ducts
Check the radiators for fouling ( A3.32
).
Left hand radiator
Screw
Screw
Screw
Fit the water radiator in the relative seat.
Nm
25 Nm
6 Nm
5 Nm
Class
B
C
C
Supporting the weight of the water radiator (D) , fit the relevant washer and mounting, and tighten the indicated lateral screw fastening the water radiator (D) .
Tightening torque Nm Class
Supporting the weight of the water radiator (D) , fit the relevant washer and mounting, and tighten the indicated rear screw fastening the water radiator (D) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators Page 8 of 12
Fit the relevant washer and mounting and tighten the indicated front screw fastening the water radiator (D) .
Tightening torque Nm Class
Remove the plug from the water radiator (D) .
Connect the pipe union (C) to the water radiator (D) .
Tighten the clamp (3) fastening the pipe union (C) to the water radiator (D) .
Connect the connectors (2) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators
Connect the connector (1) .
Page 9 of 12
Fit the upper radiator air duct (B) in the relative seat.
Tighten the indicated screws fastening the upper radiator air duct (B) .
Tightening torque Nm Class
Fit the front brake air duct (A) in the relative seat.
Tighten the indicated screw fastening the front brake air duct (A) .
Tightening torque Nm Class
Refit the condenser ( F5.04
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators
Right hand radiator
Fit the water radiator in the relative seat.
Page 10 of 12
Supporting the weight of the water radiator (D) , fit the relevant washer and mounting, and tighten the indicated lateral screw fastening the water radiator (D) .
Tightening torque Nm Class
Supporting the weight of the water radiator (D) , fit the relevant washer and mounting, and tighten the indicated rear screw fastening the water radiator (D) .
Tightening torque Nm Class
Fit the relevant washer and mounting and tighten the indicated front screw fastening the water radiator (D) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators Page 11 of 12
Remove the plug from the water radiator (D) .
Connect the pipe union (C) to the water radiator (D) .
Tighten the clamp (3) fastening the pipe union (C) to the water radiator (D) .
Connect the connectors (2) .
Connect the connector (1) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Water radiators
Refit the radiator/power steering fluid coil ( D5.05
).
Fill the cooling system ( A3.07
).
Page 12 of 12
Fit the upper radiator air duct (B) in the relative seat.
Tighten the indicated screws fastening the upper radiator air duct (B) .
Tightening torque Nm Class
Fit the front brake air duct (A) in the relative seat.
Tighten the indicated screw fastening the front brake air duct (A) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Electric fans
Print Exit
Page 1 of 2
Removing the electric fans
Remove the water radiators ( B6.05
).
Only remove the water radiator on which the relative electric fan is mounted.
Undo the four screws indicated fastening the electric fan (A) to the water radiator.
Remove the electric fan (A) from the relative seat.
Refitting the electric fans
Tightening torque
Fastening electric fans to water radiators Screw
Nm
5 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Electric fans
Refit the water radiators ( B6.05
).
Page 2 of 2
Fit the electric fan (A) in the relative seat.
Tighten the four screws indicated fastening the electric fan (A) to the water radiator.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Draining and filling the engine cooling system
Print Exit
B6.07 Draining and filling the engine cooling system
Draining the cooling system
Page 1 of 5
CAUTION
ALWAYS WORK WHEN THE ENGINE IS COLD.
The fluid contained in the cooling system reaches extremely high temperatures; take the necessary precautions to prevent burns.
Disconnect the battery ( F2.01
).
Remove the front flat undertray section ( E3.12
).
UP TO Ass.ly No. 90801 _ Right hand side
Loosen the clamps (1) fastening the connector pipe
(2) onto the rigid pipes.
Undo the screw indicated fastening the rigid pipe.
FROM Ass.ly No. 90802 _ Right hand side
Loosen the clamps (1) fastening the connector pipe
(2) onto the rigid pipes.
Detach the pipe (6) from the clip indicated by the red arrow.
Undo the screw indicated fastening the rigid pipe. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Draining and filling the engine cooling system Page 2 of 5
UP TO Ass.ly No. 90801 _ Left hand side
Disconnect the temperature sensor connector (3) .
Undo the screw indicated fastening the rigid pipe
Loosen the clamps (4) fastening the connector pipe
(5) onto the rigid pipes.
FROM Ass.ly No. 90802 _ Left hand side
Disconnect the temperature sensor connector (3) .
Undo the screw indicated fastening the rigid pipe
Loosen the clamps (4) fastening the connector pipe
(5) onto the rigid pipes.
Use a suitable container to collect the fluid.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Disconnect the rubber connector pipes one by one from the rear rigid pipe and allow the coolant to drain completely.
Filling the cooling system https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Draining and filling the engine cooling system Page 3 of 5
CAUTION
The fluid contained in the cooling system reaches extremely high temperatures and pressure.
ALWAYS WORK WHEN THE ENGINE IS COLD.
Check that all the connection sleeve clamps are tight.
Static filling (engine off)
Remove the engine compartment cosmetic shields ( E3.13
).
Remove right hand engine compartment shield.
01) Do not disconnect bleed pipes on expansion tank.
02) Undo expansion tank plug (1) and slowly pour coolant, alternating this operation with repeated pauses of a few seconds so as to allow the bleeding of the air present inside system.
03) Pay attention to the passage of coolant inside vent pipe (2) from engine to expansion tank to confirm the first filling of engine cooling circuit.
04) Complete filling until reaching the point where fluid inside expansion tank is at 60 mm from filler plug top (1) ( MAX level ), corresponding to about
2 litres of coolant inside expansion tank.
Dynamic filling (engine on) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Draining and filling the engine cooling system
05) Screw plug (1) onto expansion tank.
Page 4 of 5
06) Check that heater circuit is off.
07) Start engine at idle speed and wait for 5 minutes .
08) Keep engine running at idle speed , check level and, if necessary, top up until MAX level.
09) Take and keep engine at 2000 rpm for 30 seconds .
10) Take and keep engine at idle speed for 30 seconds .
11) Take and keep engine at 2000 rpm for 30 seconds .
12) Take and keep engine at idle speed for 30 seconds .
13) Take and keep engine at 2000 rpm for 30 seconds .
14) Take and keep engine at idle speed for 2 minutes (or until radiators electric fans are enabled).
15) Keep engine running at idle speed , check level and, if necessary, top up until MAX level.
16) Take and keep engine at 2000 rpm for 1 minute .
17) Take and keep engine at idle speed for 30 seconds .
18) Open heater circuit selecting the max. temperature of air conditioning system for both “zones”.
19) Take and keep engine at 3000 rpm for 1 minute .
20) Take and keep engine at idle speed for 2 minutes .
21) Keep engine running at idle speed , check level and, if necessary, top up until MAX level.
22) Take and keep engine at 3000 rpm for 1 minute .
23) Take and keep engine at idle speed for 1 minute .
24) Take and keep engine at 3000 rpm for 1 minute .
25) Take and keep engine at idle speed for 1 minute .
26) Close heater circuit.
27) Turn engine off.
28) Allow engine to cool until water temperature is 40 - 45 °C ( 1h and 30'- 2 hours ) with expansion tank plug open. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Draining and filling the engine cooling system Page 5 of 5
29) If necessary, top up until reaching the point where fluid level in header tank is 60 mm from filler plug top (1) ( MAX level ).
Tighten the cap (1) .
Refit the engine compartment cosmetic shields ( E3.13
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B60...
8/5/2011
Exhaust system layout
Print Exit
Page 1 of 1
A - Manifolds
B - Catalytic converters
C - Silencers
D - Silencer joint https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Exhaust manifold
Print Exit
Removing the exhaust manifold
Page 1 of 9
The following process is for removing the left hand exhaust manifold.
The differences in the procedure for removing the right hand exhaust manifold will be indicated in the instructions.
Remove the engine compartment cosmetic shields ( E3.13
).
Remove lateral cosmetic shields.
Remove the rear flat undertray section ( E3.12
).
Applicable for left hand exhaust manifold only. Remove the compressor ( F5.03
).
Do not disconnect from the system and fasten to the chassis with clamps.
Remove the rear wheelhouses ( E3.05
).
Remove the rear left hand wheelhouse.
Unscrew and remove the oxygen sensor (1) from the exhaust manifold (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Exhaust manifold Page 2 of 9
Working from above, undo the two indicated screws fastening the heat shield (4) .
Working from the wheel bay, undo the indicated screw.
Remove the heat shield (4) via the wheel bay.
If necessary, the heat shield (4) may be bent slightly to facilitate the operation.
Left hand exhaust manifold
Fit the template ( AV 8257 ) on the flexible part of the exhaust manifold, as shown in the photo aside.
Fasten the lug (11) onto the relative hook to secure the template ( AV 8257 ) .
Loosen the clamp (2) between the catalytic converter and the exhaust manifold.
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8/5/2011
Exhaust manifold Page 3 of 9
Right hand exhaust manifold
Fit the template ( AV 8257 ) on the flexible part of the exhaust manifold, as shown in the photo aside.
Fasten the lug (11) onto the relative hook to secure the template ( AV 8257 ) .
Loosen the clamp (2) between the catalytic converter and the exhaust manifold.
Remove the template ( AV 8257 ) from the exhaust manifold.
Undo the screws indicated fastening the secondary air pipe (3) to the exhaust manifold.
Undo the screws indicated fastening the secondary air pipe (3) to the relative valve. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Exhaust manifold Page 4 of 9
Remove the secondary air pipe and retrieve the relative seals (5) on the exhaust manifold and valve.
Applicable for left hand exhaust manifold only
Undo the indicated screw and retrieve the heat shield (6) protecting the compressor.
Undo the eight nuts (7) fastening the exhaust manifold (A) to the cylinder head.
Remove the exhaust manifold (A) via the wheel bay.
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8/5/2011
Exhaust manifold Page 5 of 9
Retrieve the gasket (8) from the exhaust manifold.
Refitting the exhaust manifold
Tightening torque
Fastening exhaust manifolds to cylinder heads
Fastening A.C. compressor heat shield
Oxygen sensors
Nut
Screw
Oxygen sensor
Nm
25 Nm
9 Nm
50 Nm
Class
B
C
B
Check that the gasket mating surfaces on the head and the manifold are perfectly flat; if necessary, remove any encrustation or gasket residue.
Preferably replace the gasket each time it is removed.
Lubricate the head stud bolts with copper based grease COPASLIP for high temperatures.
Fit a new exhaust manifold gasket (8) on the relative stud bolts.
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8/5/2011
Exhaust manifold Page 6 of 9
Fit and fasten the exhaust manifold (A) to the cylinder head, hand-tightening the eight nuts (7) .
Tighten the eight nuts in the sequence indicated in the figure aside.
Tightening torque Nm Class
Applicable for left hand exhaust manifold only
Fit and fasten the compressor heat shield (6) , tightening the screw indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Exhaust manifold Page 7 of 9
Fit new gaskets (5) on the exhaust manifold and valve.
Fit the secondary air pipe (3) in the relative seat and fasten to the valve/mounting bracket by tightening the two screws indicated.
Hand tighten the screws indicated fastening the secondary air pipe (3) to the exhaust manifold.
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8/5/2011
Exhaust manifold Page 8 of 9
Applicable for right hand exhaust manifold ONLY
Working from the wheel bay, fit the heat shield (4) .
Hand tighten the indicated screw.
If necessary, bend the heat shield (4) back into the original shape.
Applicable for right hand exhaust manifold ONLY
Working from above, tighten the two indicated screws fastening the heat shield (4) .
Fit the clamp (2) fastening onto the catalytic converter and partially tighten by tightening the relative nut.
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8/5/2011
Exhaust manifold Page 9 of 9
Fit and tighten the oxygen sensor (1) on the exhaust manifold (A) .
Tightening torque
Oxygen sensor
Nm
50 Nm
Class
B
Applicable for left hand exhaust manifold only. Refit the compressor ( F5.03
).
Adjust the exhaust system ( B7.04
).
Refit the rear wheelhouses ( E3.05
).
Refit the rear flat undertray section ( E3.12
).
Refit the engine compartment cosmetic shields ( E3.13
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Catalytic converter
Print Exit
Removing the catalytic converter
Page 1 of 7
The following procedure is for removing the left hand catalytic converter.
The procedure for removing the right hand catalytic converter is identical.
Remove the rear diffuser ( E3.12
).
Remove the rear wheelhouses ( E3.05
).
Remove the rear left hand wheelhouse.
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the left hand engine compartment shield.
Unscrew and remove the oxygen sensor (1) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Catalytic converter Page 2 of 7
Apply AREXONS SVITOL TECHNIK SILIKON
SPRAY to the joint between the catalytic converter and the silencer, leaving the product to act for a few minutes.
Loosen the Torx clamp (2) fastening the catalytic converter (A) to the silencer (3) .
If present, remove shield (9) by loosening the indicated screws.
Remove the clamp (4) .
Disconnect the two quick connectors indicated from the bellow (5) .
Undo the two nuts indicated fastening the air flow meter to the air box (6) .
Move the air flow meter - motorised throttle body assembly to one side, without disconnecting from the electrical system. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Catalytic converter Page 3 of 7
Undo the two screws indicated fastening the catalytic converter mounting bracket (7) .
For left hand catalytic converter ONLY
Working from above, undo the two indicated screws fastening the heat shield (10) .
For left hand catalytic converter ONLY
Working from the wheel bay, undo the indicated screw.
Remove the heat shield (10) via the wheel bay.
If necessary, the heat shield (10) may be bent slightly to facilitate the operation. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Catalytic converter Page 4 of 7
Left hand catalytic converter
Fit the template ( AV 8257 ) on the flexible part of the exhaust manifold, as shown in the photo aside.
Fasten the lug (11) onto the relative hook to secure the template ( AV 8257 ) .
Loosen the clamp (8) between the catalytic converter (A) and the exhaust manifold.
Right hand catalytic converter
Fit the template ( AV 8257 ) on the flexible part of the exhaust manifold, as shown in the photo aside.
Fasten the lug (11) onto the relative hook to secure the template ( AV 8257 ) .
Loosen the clamp (8) between the catalytic converter (A) and the exhaust manifold.
Remove the template ( AV 8257 ) from the exhaust manifold.
Detach the catalytic converter (A) from the silencer and remove upwards as shown in the photo aside.
Refitting the catalytic converter https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Catalytic converter Page 5 of 7
Tightening torque
Fastening catalytic converter mounting brackets to chassis
Oxygen sensors Oxygen sensor
Nm
50 Nm
Class
B
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Fit the catalytic converter (A) in the relative seat from above, as shown in the photo aside.
Fit the catalytic converter (A) on the silencer.
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Align the catalytic converter (A) with the exhaust manifold and partially tighten the clamp (8) by tightening the relative nut. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Catalytic converter Page 6 of 7
Fasten the catalytic converter mounting bracket (7) to the chassis, tightening the screws indicated.
Tightening torque Nm Class
Fit the air flow meter - motorised throttle body assembly in the relative seat.
Tighten the two nuts indicated fastening the air flow meter to the air box (6) .
Fasten a new clamp (4) .
Connect the two quick connectors indicated to the bellow (5) .
If present, position shield (9) .
Hand tighten the screws indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Catalytic converter Page 7 of 7
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Partially tighten the clamp (2) fastening the catalytic converter (A) to the silencer (3) , by tightening the relative nut.
Fit and tighten the oxygen sensor (1) .
Tightening torque
Oxygen sensor
Nm
50 Nm
Class
B
Adjust the exhaust system ( B7.04
).
Refit the engine compartment cosmetic shields ( E3.13
).
Refit the rear wheelhouses ( E3.05
).
Refit the rear diffuser ( E3.12
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers
Print Exit
B7.04 Silencers
Removing the silencers
Remove the rear bumper ( E3.04
).
Right hand silencer
Page 1 of 20
Disconnect the pipe (1) from the By-pass valve of the silencer.
Loosen the clamps (2) fastening the central exhaust pipe (A) to the silencers (B) , undoing the relative nuts indicated.
Disconnect and remove the central exhaust pipe (A) from the silencers (B) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 2 of 20
Undo the indicated nut fastening the lateral mounting bushing for the silencer.
Support the weight of the silencer adequately.
Undo the indicated nuts fastening the mounting bushings for the silencer (B) .
Loosen the clamp (3) fastening the silencer (B) to the catalytic converter (C) , loosening the relative nut.
Disconnect the silencer (B) from the catalytic converter (C) , and remove from the relative seat.
Left hand silencer https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 3 of 20
Disconnect the pipe (1) from the By-pass valve of the silencer.
Loosen the clamps (2) fastening the central exhaust pipe (A) to the silencers (B) , undoing the relative nuts indicated.
Disconnect and remove the central exhaust pipe (A) from the silencers (B) .
Undo the indicated nut fastening the lateral mounting bushing for the silencer. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 4 of 20
Support the weight of the silencer adequately.
Undo the indicated nuts fastening the mounting bushings for the silencer (B) .
Loosen the clamp (3) fastening the silencer (B) to the catalytic converter (C) , loosening the relative nut.
Disconnect the silencer (B) from the catalytic converter (C) , and remove from the relative seat.
Refitting the silencers
Right hand silencer https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 5 of 20
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Fit the right hand silencer (B) in the relative seat and connect to the right hand catalytic converter
(C) .
Partially tighten the clamp (3) fastening the right hand silencer (B) to the right hand catalytic converter (C) , tightening the relative nut.
Support the weight of the silencer adequately.
Partially tighten the indicated nuts fastening the rear mounting bushings for the right hand silencer (B) .
Partially tighten the indicated nut fastening the lateral mounting bushing for the right hand silencer.
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8/5/2011
Silencers Page 6 of 20
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Connect the central exhaust pipe (A) to the silencers (B) .
Partially tighten the clamps (2) fastening the central exhaust pipe (A) to the silencers (B) , tightening the relative nuts indicated.
Connect the pipe (1) to the By-pass valve of the right hand silencer.
Left hand silencer
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Fit the left hand silencer (B) in the relative seat and connect to the left hand catalytic converter (C) .
Partially tighten the clamp (3) fastening the left hand silencer (B) to the left hand catalytic converter
(C) , tightening the relative nut. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 7 of 20
Support the weight of the silencer adequately.
Partially tighten the indicated nuts fastening the rear mounting bushings for the left hand silencer (B) .
Partially tighten the indicated nut fastening the lateral mounting bushing for the left hand silencer.
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Connect the central exhaust pipe (A) to the silencers (B) .
Partially tighten the clamps (2) fastening the central exhaust pipe (A) to the silencers (B) , tightening the relative nuts indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 8 of 20
Connect the pipe (1) to the By-pass valve of the left hand silencer.
Adjust the exhaust system ( B7.04
).
Adjusting the exhaust system
Tightening torque
Fastening catalytic converters to exhaust manifolds Clamp
Fastening centre exhaust pipe to silencers Clamp (pretightening)
Clamp
Fastening catalytic converters to silencers Clamp (pretightening)
Clamp
Fastening catalytic converter mounting brackets to chassis
Fastening catalytic converters to mounting bushings
Fastening silencers to mounting bushings
Screw / Nut
Nut
Nm
+6.5
+6.5
13 Nm
25 Nm
54.2 Nm
25 Nm
54.2 Nm
25 Nm
Class
B
B
0
B
0
B
13 Nm B
The exhaust system must be adjusted each time a component of the exhaust system is removed and reinstalled.
NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components.
Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the lateral cosmetic shields only.
Remove the rear wheelhouses ( E3.05
).
Remove the rear bumper ( E3.04
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 9 of 20
If present, remove shield (1) by loosening the indicated screws.
If present, remove shield (1) by loosening the indicated screws.
Loosen the indicated nut. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers
Loosen the indicated nuts.
Page 10 of 20
Loosen the indicated nut.
Loosen the indicated nuts. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers
Loosen the indicated screws.
Page 11 of 20
Loosen the indicated screws.
Loosen the indicated clamp. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers
Loosen the indicated clamp.
Page 12 of 20
Loosen the indicated clamps. for the left hand cylinder bank exhaust ONLY
Working from above, undo the two indicated screws fastening the heat shield (10) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 13 of 20 for the left hand cylinder bank exhaust ONLY
Working from the wheel bay, undo the indicated screw.
Remove the heat shield (10) via the wheel bay.
If necessary, the heat shield (10) may be bent slightly to facilitate the operation.
Fit the template ( AV 8257 ) on the flexible part of the exhaust manifold, as shown in the photo aside.
Fasten the lug (11) onto the relative hook to secure the template ( AV 8257 ) .
Loosen the clamp (8) between the catalytic converter and the exhaust manifold.
Remove the template ( AV 8257 ) .
Fit the template ( AV 8257 ) on the flexible part of the exhaust manifold, as shown in the photo aside.
Fasten the lug (11) onto the relative hook to secure the template ( AV 8257 ) .
Loosen the clamp (8) between the catalytic converter and the exhaust manifold.
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8/5/2011
Silencers Page 14 of 20
Check that the central exhaust pipe (A) is spaced equally between the two silencer exhaust pipes
(B) and that it is parallel with the ground.
If not, adjust as necessary to meet the conditions described above.
With the template ( AV 8257 ) still fixed to the flexible exhaust manifold pipe, tighten the clamp (8) .
Tightening torque
Remove the template ( AV 8257 ) .
Nm Class
Fit the template ( AV 8257 ) on the flexible part of the exhaust manifold, as shown in the photo aside.
Fasten the lug (11) onto the relative hook to secure the template ( AV 8257 ) .
Tighten the clamp (8) between the catalytic converter and the exhaust manifold.
Tightening torque Nm Class
Remove the template ( AV 8257 ) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 15 of 20
Pre-tighten the indicated clamps.
Tightening torque
Clamp (pretightening)
Nm
25 Nm
Class
B
Pre-tighten the indicated clamp.
Tightening torque
Clamp (pretightening)
Nm
25 Nm
Class
B
Pre-tighten the indicated clamp.
Tightening torque
Clamp (pretightening)
Nm
25 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 16 of 20
Tighten the screws indicated.
Fasten the catalytic converter mounting bracket first and then fasten the catalytic converter to the relative bushings.
Tightening torque
Screw / Nut
Nm
25 Nm
Class
B
Tighten the screws indicated.
Fasten the catalytic converter mounting bracket first and then fasten the catalytic converter to the relative bushings.
Tightening torque
Screw / Nut
Nm
25 Nm
Class
B
Tighten the nuts indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 17 of 20
Tighten the indicated nut.
Tightening torque Nm Class
Tighten the nuts indicated.
Tightening torque Nm Class
Tighten the indicated nut.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 18 of 20
Tighten the indicated clamp.
Tightening torque
Clamp
Nm
+6.5
54.2 Nm
Class
0
Tighten the indicated clamp.
Tightening torque
Clamp
Nm
+6.5
54.2 Nm
Class
0
Tighten the indicated clamps.
Tightening torque
Clamp
Nm
+6.5
54.2 Nm
Class
0 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers Page 19 of 20 for the left hand cylinder bank exhaust ONLY
Working from the wheel bay, fit the heat shield (10) .
Hand tighten the indicated screw.
If necessary, bend the heat shield (10) back into the original shape.
for the left hand cylinder bank exhaust ONLY
Working from above, tighten the two indicated screws fastening the heat shield (10) .
If present, position shield (1) .
Hand tighten the screws indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Silencers
If present, position shield (1) .
Hand tighten the screws indicated.
Page 20 of 20
Refit the rear bumper ( E3.04
).
Refit the rear wheelhouses ( E3.05
).
Refit the engine compartment cosmetic shields ( E3.13
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_B70...
8/5/2011
Technical specifications
Print Exit
Page 1 of 2
Gear ratios
Transmission gear ratios
Bevel gear pair/differential ratio
1st 2nd 3rd 4th 5th 6th 7th R
3.077 2.185 1.626 1.286 1.028 0.839 0.693 2.791
5.143
General
New dual clutch gearbox with 7 forward speeds + reverse and F1 shift paddles, chosen to offer the driving pleasure of a sequential gearbox together with the comfort of an automatic gearbox.
Electrohydraulic actuation.
Triple cone synchronisers on all gear ratios to ensure the sporty performance typical of a sequential gearbox.
The system has two different wet clutches, each one of which mated to a different primary shaft. One clutch https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C10...
8/5/2011
Technical specifications Page 2 of 2 drives the even gears, the other drives the odd gears.
While one primary shaft transmits torque to 1st gear, 2nd gear is already engaged on the other primary shaft.
Gear shifting is achieved by opening one clutch while simultaneously closing the other. The results of this are shift times close to zero (sportiness), seamless torque delivery (performance) and shifts as smooth as an automatic transmission (comfort).
Control panel on centre console for selecting reverse gear, Automatic gearbox mode and the Launch Control function.
Clutch
Designed to work as a torsional vibration damper (DMF).
Two wet multi-plate clutches with integrated centrifugal force actuation.
Mounting for the dual clutch in the clutch housing.
Hydraulically actuated clutch.
Gear shift system
Hydraulically actuated gearbox
Design of gear selection lever and fork
Mechanically locked torqueless (even or odd) gears.
Hydraulic system
Includes clutch management.
Includes shift actuator unit.
Additional lubricant pump for gearbox and differential.
E-LSD actuation.
Maximum temperature in hydraulic system is 120°C.
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8/5/2011
Specific tooling and equipment
Print Exit
C1.02 Specific tooling and equipment
Page 1 of 3
Trolley 95977565 (AS 107565) removing the engine / gearbox / subframe assembly.
Trolley 95977572 (AS 107572) to be used together with trolley AS 107565 for removing/refitting gearbox from and into vehicle.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C10...
8/5/2011
Specific tooling and equipment
Torque wrench 95978172 (AV 8172)
(Replaces torque wrench USAG 815F)
Page 2 of 3
Hook 95977564 (AS 107564) for lifting the gearbox.
Pump 95978174 (AV 8174) topping up gearbox and clutch oil. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C10...
8/5/2011
Specific tooling and equipment Page 3 of 3
Engine retainer bracket for gearbox removal
95978254 (AV 8254) removing the gearbox.
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8/5/2011
Tightening torques
Print Exit
Page 1 of 1
Tightening torque
Fastening gearbox oil filler/drain plug and clutch hydraulic fluid filler/drain plug
Fastening Tie-rod to gearbox
Fastening tie-rod to cylinder heads
Fastening starter motor to gearbox
Fastening gearbox to engine
Fastening engine mounting bush to gearbox
Fastening retainer fork on GL and ATF oil pipes on gearbox
Fastening axle shaft to wheel hub
Fastening gearbox mounting bushing to rear subframe
Screw
Screw
Screw
Nut
Screw
Nut
Fastening gear oil and clutch oil pipes to radiators Union
Fastening gear oil and clutch oil radiator to chassis Nut
Fastening flywheel to crankshaft Pretightening torque for screw
Fastening electric fan to clutch hydraulic system oil radiator
Fastening gearbox gear oil pipe shield bracket Nut
Nm
88 Nm
24 Nm
25 Nm
60 Nm
100 Nm
275 Nm
35 Nm
9 Nm
45 Nm
24 Nm
Class
A
A
A
A
A
A
B
B
0
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C10...
8/5/2011
Gear oil system layout
Print Exit
C2.01 Gear system layout
Gear oil system layout
Page 1 of 1
A - DCT gearbox (gear oil tank and gear oil pump)
B - Gear oil pipes
C - Water/gear oil radiator https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Removing the complete DCT gearbox
Print Exit
Removing the complete gearbox
Page 1 of 13
CAUTION
For safety reasons, the VEHICLE MAY ONLY BE LIFTED WITH THE ANTI-TIPPING SAFETY RETAINERS
INSTALLED.
Remove the rear diffuser ( E3.12
).
Remove the rear flat undertray section ( E3.12
).
Lift the vehicle using anti-tipping safety retainers ( E3.12
).
Remove the engine oil tank ( B5.03
).
Remove the engine air filter box ( B4.03
).
Remove the rear bumper ( E3.04
).
Remove the silencers ( B7.04
).
Remove the axle shaft ( C4.01
).
Remove both axle shafts from the gearbox flanges.
To remove the rear subframe complete with gearbox and engine, use the trolley ( AS 107565 ) .
The trolley consists of a turntable platform (53) , which can be locked in position with the two handles (54) ; of six locator pins (52) , with relevant swivelling and removable mounts; of a pedal (55) for lifting the platform, and a handle
(56) for lowering the platform. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Removing the complete DCT gearbox Page 2 of 13
Before starting the following procedure, the trolley
( AS 107565 ) must be configured correctly for removing the gearbox on this vehicle.
Undo the indicated screws fastening the telescoping arm (17) to the relevant mounting (18) on all the arms on the trolley ( AS 107565 ) .
Extend all the telescoping arms (17) from the mountings (18) .
Numbers (from 1 to 6 ) are stamped on each of the arms and the respective mountings, which must be matched to ensure correct reassembly.
Position the mountings (18) on the trolley
( AS 107565 ) as shown in the photo aside.
Place the trolley ( AS 107572 ) on the mountings of the trolley ( AS 107565 ) , orienting with the pairs of holes indicated by the red arrows towards the rear of the vehicle, as shown in the photo aside.
Fasten the trolley ( AS 107572 ) onto the mountings, in as centred a position as possible, tightening the four screws indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Removing the complete DCT gearbox Page 3 of 13
Release the drain pipe (23) from the rubber lined bracket by undoing the indicated screw.
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Release the drain pipe (23) from the rubber lined bracket by undoing the indicated screw.
Release the drain pipe (23) from the rubber lined brackets by undoing the indicated screws.
Move the pipes out of the way so that they do not hinder the subsequent operations. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Removing the complete DCT gearbox Page 4 of 13
Remove the shield (1) , undoing the indicated nuts.
Undo the screws indicated fastening the heat shield
(2) .
Remove the heat shield (2) , undoing the screw indicated.
FROM Ass.ly No. 92290
Remove the heat shield (2) , undoing the screw indicated.
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8/5/2011
Removing the complete DCT gearbox Page 5 of 13
Clean the area surrounding the fastener point for the clutch hydraulic system oil pipes thoroughly using a suitable degreaser that does not leave residue.
Place a container for collecting the clutch hydraulic system oil under the pipes.
Undo the screw indicated fastening the fork (3) on the clutch hydraulic system oil pipes.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Disconnect the clutch hydraulic system oil pipes (4) from the gearbox and plug immediately.
Undo the screws indicated fastening the retainers on the pillory blocks holding the clutch hydraulic system oil pipes (4) and the gear oil pipes (6) .
Clean the area surrounding the gear oil pipe fastener point thoroughly with a suitable degreaser that does not leave residue.
Place a container for collecting the gear oil under the pipes.
Undo the screw indicated fastening the fork (5) on the gear oil pipes.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Disconnect the gear oil pipes (6) from the gearbox and plug immediately.
Release the oil pipes from the mounting bracket (7) and remove the bracket from the gearbox.
Move the oil pipes of both systems aside carefully, taking care not to twist or damage them, so that they do not hinder the removal of the gearbox.
Remove the clamp fastening the gearbox wiring harness, undoing the screw indicated, and disconnect the three connectors (8) .
Move the gearbox wiring harness out of the way so that it does not hinder the removal of the gearbox.
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8/5/2011
Removing the complete DCT gearbox Page 6 of 13
Fit the tool ( AV 8254 ) onto the rear subframe to support the weight of the engine and prevent it from tipping when the gearbox is removed.
Fit the tool in the relevant seat and fasten by tightening the two screws indicated; loosen the nut (C) and tighten the pin (D) to bring the bushing (E) into contact with the lower crankcase shell.
After fitting the bushing (E) correctly, tighten the nut
(C) .
Screw the four adjuster pins of the tool ( AS 107572 ) into the relevant holes and adjust each one to the same position.
The shorter adjuster pins must be installed in the front holes.
The longer adjuster pins must be installed in the rear holes.
Insert the support spacer (element 05 ) of tool
( AS 107572 ) between the lower gearbox mounting cross member (9) and the gearbox (A) .
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8/5/2011
Removing the complete DCT gearbox Page 7 of 13
UP TO Ass.ly No. 92289
Remove the left hand tie-rod (12) , undoing the screws (10) and (11) .
Fit a hydraulic jack under the gearbox and lift it slightly, placing it under tension, in order to facilitate the removal of the pin (22) .
Undo the nut (21) retrieving the washer.
Remove the pin (22) fastening the bushing mounting (15) to the rear subframe, retrieving the washer.
Lower the hydraulic jack until the gearbox rests on the support spacer (element 05 ) of the tool
( AS 107572 ) , previously fit.
Undo the three upper nuts (14) fastening the gearbox (A) to the engine (B) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Removing the complete DCT gearbox Page 8 of 13
Position the trolley ( AS 107565 ) under the vehicle and lift the platform to approximately 10 mm from the adjuster pins.
Loosen the nut (19) then unscrew the pin (20) of tool ( AS 107572 ) , until the pin comes into contact with the trolley ( AS 107572 ) .
Repeat this procedure for all the adjuster pins.
From underneath, tighten the indicated screws fastening the four adjuster pins onto the trolley
( AS 107572 ) .
Ensure that the lower and upper parts of the pin are correctly fastened to the gearbox and trolley
( AS 107572 ) respectively, then tighten the nut
(19) .
Repeat this procedure for all the adjuster pins.
Use the pedal on the trolley ( AS 107565 ) to lift the gearbox of a few millimetres in order to support its weight.
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Removing the complete DCT gearbox Page 9 of 13
Undo the four lower nuts (14) fastening the gearbox
(A) to the engine (B) .
Undo the screws indicated fastening the starter motor (13) to the gearbox.
Unscrew the indicated screws fastening the lower gearbox mounting cross-member (9) .
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Removing the complete DCT gearbox Page 10 of 13
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Unscrew the indicated screws fastening the lower gearbox mounting cross-member (9) .
Unscrew the indicated screws and remove the lower gearbox mounting cross-member (9) .
Also recover the support spacer (element 05 ) of tool
( AS 107572 ) .
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Unscrew the indicated screws and remove the lower gearbox mounting cross-member (9) .
Also recover the support spacer (element 05 ) of tool
( AS 107572 ) .
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Removing the complete DCT gearbox Page 11 of 13
Loosen the two trolley platform locking handles
( AS 107565 ) and move the trolley ( AS 107572 ) to ease the gearbox (A) off the engine stud bolts.
After easing out the gearbox (A) , lock the two trolley platform lock handles ( AS 107565 ) .
Replace gearbox mounting bushing ( C2.02
).
Remove the component only.
Tighten the eye bolts in the relative holes on the gearbox and fit tool ( AS 107564 ) .
Connect to a mobile hydraulic jack, lift the gearbox from the trolley and set down in a safe place.
Replacing gearbox mounting bushing
Tightening torque
Fastening gearbox mounting bush cover
Remove the complete gearbox ( C2.02
).
Screw
Nm
30 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
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Removing the complete DCT gearbox Page 12 of 13
Undo the screws indicated and remove the cover
(1) .
Remove the gearbox mounting bushing (A) from the cover (1) and replace it.
Fit a new gearbox mounting bushing (A) inserting the indicated pin inside the relative seat on the cover (1) .
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Removing the complete DCT gearbox Page 13 of 13
Fasten the cover (1) tightening the indicated screws, and following the sequence shown in the photo.
Tightening torque Nm Class
Refit the complete gearbox ( C2.03
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Refitting the complete DCT gearbox
Print Exit
Refitting the complete gearbox
Page 1 of 11
Tightening torque
Fastening lower gearbox mounting cross member to chassis
Fastening gearbox to engine
Fastening starter motor to gearbox
Fastening gearbox mounting bushing to rear subframe
Fastening Tie-rod to gearbox
Fastening tie-rod to cylinder heads
Fastening retainer fork on GL and ATF oil pipes on gearbox
Fastening gearbox gear oil pipe shield bracket
Nut
Screw
Screw
Screw
Nut
Nm
60 Nm
25 Nm
88 Nm
24 Nm
Class
A
A
A
A
24 Nm B
Tighten the eye bolts in the relative holes on the gearbox and fit tool ( AS 107564 ) .
Connect to a mobile hydraulic jack and lift the gearbox, locating in the relative seat on the trolley ( AS 107572 ) .
Replace gearbox mounting bushing ( C2.02
).
Refit the component only. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
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Refitting the complete DCT gearbox Page 2 of 11
Apply a layer of copper grease Copper Grease
ROLOIL on the splined shaft of the gearbox.
Supporting the weight of the gearbox adequately with the lift trolley ( AS 107565 ) and the trolley
( AS 107572 ) , position the complete gearbox (A) under the engine compartment, aligned with the engine stud bolts.
Loosen the two trolley platform locking handles
( AS 107565 ) and move the trolley ( AS 107572 ) to fit the gearbox (A) onto the engine stud bolts.
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Fit the lower gearbox mounting cross-member (9) in its seat and hand-tighten the indicated screws.
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Refitting the complete DCT gearbox Page 3 of 11
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Fit the lower gearbox mounting cross-member (9) in its seat and hand-tighten the indicated screws.
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Hand-tighten the indicated screws fastening the lower gearbox mounting cross-member (9) .
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Apply AREXONS SYSTEM 52A43 - MEDIUM
STRENGTH THREAD LOCK on the thread of the screws indicated.
Hand-tighten the indicated screws fastening the lower gearbox mounting cross-member (9) .
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Refitting the complete DCT gearbox Page 4 of 11
Tighten the indicated screws fastening the lower gearbox mounting cross member (9) , following the sequence shown in the photo.
Tightening torque Nm Class
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Tighten the indicated screws fastening the lower gearbox mounting cross member (9) , following the sequence shown in the photo.
Tightening torque Nm Class
Insert the support spacer (element 05 ) of tool
( AS 107572 ) between the lower gearbox mounting cross member (9) and the gearbox (A) .
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Refitting the complete DCT gearbox Page 5 of 11
Fit and tighten the four lower nuts (14) fastening the complete gearbox (A) to the engine (B) .
Tightening torque Nm Class
Tighten the screws indicated fastening the starter motor (13) to the gearbox.
Tightening torque Nm Class
From underneath, remove the indicated screws fastening the four adjuster pins onto the trolley
( AS 107572 ) .
Slowly lower the trolly ( AS 107572 ) by a few centimetres, allowing the gearbox to rest on the support spacer (element 05 ) of tool ( AS 107572 ) .
Remove all the lifting tools ( AS 107572 ) and ( AS 107565 ) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
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Refitting the complete DCT gearbox Page 6 of 11
Fit a hydraulic jack under the gearbox and lift it slightly, placing it under tension, in order to facilitate the fitting of the pin (22) .
Fit the pin (22) fastening the bushing mounting (15) to the rear subframe, after fitting the washer.
Hand tighten the nut (21) after fitting the washer.
Fit and tighten the three upper nuts (14) fastening the complete gearbox (A) to the engine (B) .
Tightening torque Nm Class
Pretighten the nut (21) .
Tightening torque
Tighten the nut (21) .
Tightening torque
Nm Class
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
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Refitting the complete DCT gearbox Page 7 of 11
UP TO Ass.ly No. 92289
Fit the left hand tie-rod (12) and fasten by tightening the screws (10) e (11) .
Tightening torque Nm Class
Loosen the nut (C) , then unscrew the pin (D) by a few turns.
Supporting the weight of the tool ( AV 8254 ) , undo the two screws indicated then remove the tool from under the vehicle.
Fasten the gearbox wiring harness to the chassis, fitting the clamp and tightening the screw indicated, then connect the three connectors (8) .
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Refitting the complete DCT gearbox Page 8 of 11
Fit the mounting bracket (7) on the gearbox stud bolts and fasten the oil pipes of both systems onto the relevant pillory blocks.
Clean the area surrounding the gear oil pipe fastener point thoroughly with a suitable degreaser that does not leave residue.
Remove the plugs fitted previously on the oil pipes.
Replace the O-rings on the gear oil pipes (6) and fit into the relevant seats.
Fit the fork (5) on the gear oil pipes and fasten to the gearbox by tightening the screw indicated.
Tightening torque Nm Class
Tighten the screws indicated fastening the retainers on the pillory blocks holding the clutch hydraulic system oil pipes (4) and the gear oil pipes (6) .
Clean the area surrounding the fastener point for the clutch hydraulic system oil pipes thoroughly using a suitable degreaser that does not leave residue.
Remove the plugs fitted previously on the oil pipes.
Replace the O-rings on the clutch hydraulic system oil pipes (4) and fit into the relevant seats.
Fit the fork (3) on the clutch hydraulic system oil pipes and fasten to the gearbox by tightening the screw indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
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Refitting the complete DCT gearbox Page 9 of 11
Fit and fasten the heat shield (2) , tightening the screw indicated.
FROM Ass.ly No. 92290
Fit and fasten the heat shield (2) , tightening the screw indicated.
Tighten the screws indicated fastening the heat shield (2) .
Fit and fasten the bracket (1) , tightening the indicated nuts.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
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Refitting the complete DCT gearbox Page 10 of 11
Fasten the drain pipe (23) inside the rubber lined brackets tightening the indicated screws.
Fasten the drain pipe (23) inside the rubber lined bracket tightening the indicated screw.
FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification)
Fasten the drain pipe (23) inside the rubber lined bracket tightening the indicated screw.
Refit the axle shaft ( C4.01
).
Refit the silencers ( B7.04
).
Refit the rear bumper ( E3.04
).
Refit the engine air filter box ( B4.03
).
Refit the engine oil tank ( B5.03
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Refitting the complete DCT gearbox
Inspect the hydraulic clutch system oil level Shell DCT F-3 ( A3.03
).
Check the Shell Transaxle 75W-90 GL5 gear oil level ( A3.02
).
Lower the vehicle using anti-tipping safety retainers ( E3.12
).
Refit the rear flat undertray section ( E3.12
).
Refit the rear diffuser ( E3.12
).
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8/5/2011
Gear oil radiator
Print Exit
C2.04 Gear radiator
Removing gear oil radiator
Page 1 of 4
The gear oil radiator is located on the rear right-hand side of the vehicle, in front of the rear bumper.
Remove the rear bumper ( E3.04
).
Remove the duct (1) by undoing the indicated fasteners.
The internal nut is in common with the radiator fastening to the chassis.
Clean the inlet area of the unions (2) on the radiator with a suitable degreaser that does not leave residues.
Place a container under the unions to collect any oil spillage.
Mark the position of the unions (2) on the radiator to avoid inverting them during the reassembly operations.
Undo the unions (2) on the gear oil radiator (A) .
Place immediately suitable plugs on radiator and pipe inlets.
Clean any spilt fluid. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Gear oil radiator Page 2 of 4
Undo the indicated nuts and remove the gear oil radiator (A) from the vehicle.
If necessary, separate the duct (3) from the gear oil radiator, undoing the indicated screws.
Refitting gear oil radiator
Tightening torque
Fastening gear oil and clutch oil radiator to chassis Nut
Fastening gear oil and clutch oil pipes to radiators Union
Fastening rear radiator air duct Screw / Nut
Nm
9 Nm
35 Nm
9 Nm
Class
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Gear oil radiator Page 3 of 4
Check the state of the foam rubber pads (4) ; replace with new components if necessary.
If removed, fit the duct (3) on the gear oil radiator, tightening the indicated screws.
Fit the gear oil radiator (A) in the relative seat in the vehicle and fasten by tightening the indicated nuts.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Gear oil radiator Page 4 of 4
Clean the inlet area of the unions (2) on the radiator with a suitable degreaser that does not leave residues.
Remove the plugs positioned previously.
Tighten the unions (2) on the gear oil radiator (A) , using the markings made during removal as reference.
Tightening torque Nm Class
Clean any spilt fluid.
Fit and fasten the duct (1) by tightening the indicated fasteners.
The internal nut is in common with the radiator fastening to the chassis.
Tightening torque
Screw / Nut
Nm
9 Nm
Class
B
Check the Shell Transaxle 75W-90 GL5 gear oil level ( A3.02
).
Operation to be carried out in the event of oil spillage.
Refit the rear bumper ( E3.04
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Draining and filling with Shell Transaxle 75W-90 GL5 gear oil
Print Exit
C2.05 Draining and filling with Shell Transaxle 75W-90 GL5 gear oil
Draining the Shell Transaxle 75W-90 GL5 gear oil
The gear oil must be changed at the intervals specified in the MAINTENANCE SCHEDULE.
Remove the rear flat undertray section ( E3.12
).
Page 1 of 2
Place a container under the plugs indicated in the figure to collect the oil.
Undo the plugs (1) and (2) at the bottom of the gearbox housing.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Drain the oil completely.
Filling the system with Shell Transaxle 75W-90 GL5 gear oil
Tightening torque
Fastening gearbox oil filler/drain plug and clutch hydraulic fluid filler/drain plug
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
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Draining and filling with Shell Transaxle 75W-90 GL5 gear oil Page 2 of 2
Clean the plugs (1) and (2) thoroughly with a suitable degreaser that does not leave residue, and replace the seals.
Tighten the plugs (1) and (2) .
Tightening torque Nm Class
Undo the threaded inspection/filler plug (3) located on the rear surface of the transmission.
Using the pump ( AV 8174 ) with attachment 01 (with the short spout), aspirate the specified oil from a newly opened container.
Using the pump ( AV 8174 ) element 01 and a container for collecting excess oil, fill with 3.9 litres of oil via the inspection/filler orifice.
Fill with half of the quantity indicated, wait a few minutes for the fluid to settle, then gradually finish filling, until oil overflows from the check/filler hole.
The quantity of oil required may vary slightly relative to the amount indicated for filling the tank when empty; this is due to unavoidable pooling within the system. Fill gradually.
Check the Shell Transaxle 75W-90 GL5 gear oil level ( A3.02
).
Check that there is no leakage from the drain plugs. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C20...
8/5/2011
Hydraulic clutch oil system layout
Print Exit
Hydraulic clutch oil system layout
Page 1 of 1
A - DCT gearbox (clutch oil tank and clutch oil pump)
B - Clutch oil pipes
C - Clutch oil radiator https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Hydraulic clutch oil system radiator
Print Exit
Removing the clutch hydraulic system oil radiator
Page 1 of 5
The clutch hydraulic system oil radiator is located on the rear left-hand side of the vehicle, in front of the rear bumper.
Remove the rear bumper ( E3.04
).
Remove the duct (1) by undoing the indicated fasteners.
The internal nut is in common with the radiator fastening to the chassis.
Clean the inlet area of the unions (2) on the radiator with a suitable degreaser that does not leave residues.
Place a container under the unions to collect any oil spillage.
Mark the position of the unions (2) on the radiator to avoid inverting them during the reassembly operations.
Undo the unions (2) on the clutch hydraulic system oil radiator (A) .
Place immediately suitable plugs on radiator and pipe inlets.
Clean any spilt fluid. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Hydraulic clutch oil system radiator Page 2 of 5
Undo the indicated nuts and remove the clutch hydraulic system oil radiator (A) from the vehicle.
Detach the connector (5) of the electric fan.
If necessary, separate the duct (3) from the clutch hydraulic system oil radiator, undoing the indicated screws.
Refitting the clutch hydraulic system oil radiator
Tightening torque
Fastening gear oil and clutch oil radiator to chassis Nut
Fastening gear oil and clutch oil pipes to radiators Union
Fastening rear radiator air duct Screw / Nut
Nm
9 Nm
35 Nm
9 Nm
Class
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Hydraulic clutch oil system radiator Page 3 of 5
Check the state of the foam rubber pads (4) ; replace with new components if necessary.
If removed, fit the duct (3) on the clutch hydraulic system oil radiator, tightening the indicated screws.
Fit the clutch hydraulic system oil radiator (A) in the relative seat in the vehicle and fasten by tightening the indicated nuts.
Tightening torque Nm Class
Connect the connector (5) of the electric fan. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Hydraulic clutch oil system radiator Page 4 of 5
Clean the inlet area of the unions (2) on the radiator with a suitable degreaser that does not leave residues.
Remove the plugs positioned previously.
Tighten the unions (2) on the clutch hydraulic system oil radiator (A) , using the markings made during removal as reference.
Tightening torque Nm Class
Clean any spilt fluid.
Fit and fasten the duct (1) by tightening the indicated fasteners.
The internal nut is in common with the radiator fastening to the chassis.
Tightening torque
Screw / Nut
Nm
9 Nm
Class
B
Inspect the hydraulic clutch system oil level Shell DCT F-3 ( A3.03
).
Operation to be carried out in the event of oil spillage.
Refit the rear bumper ( E3.04
).
Replacing the clutch hydraulic system oil radiator electric fan
Tightening torque
Fastening electric fan to clutch hydraulic system oil radiator
Disconnect the battery ( F2.01
).
Remove the rear bumper ( E3.04
).
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Hydraulic clutch oil system radiator Page 5 of 5
Disconnect the connector (1) .
Undo the nuts indicated.
Remove the electric fan (A) and replace.
Fit the new electric fan (A) on the radiator.
Tighten the nuts indicated.
Tightening torque
Connect the connector (1) .
Nm Class
Refit the rear bumper ( E3.04
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Draining and filling with Shell DCT F-3 hydraulic clutch system oil
Print Exit
C3.03 Draining and filling with Shell DCT F-3 hydraulic clutch system oil
Draining Shell DCT F-3 hydraulic clutch system oil
Page 1 of 3
Remove the rear flat undertray section ( E3.12
).
Place a container under the plug indicated in the figure to collect the oil.
Undo the plug (1) located at the bottom of the gearbox housing.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Drain the oil completely.
Filling with Shell DCT F-3 hydraulic clutch system oil
Tightening torque
Fastening gearbox oil filler/drain plug and clutch hydraulic fluid filler/drain plug
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Draining and filling with Shell DCT F-3 hydraulic clutch system oil Page 2 of 3
Clean the plug (1) thoroughly with a suitable degreaser that does not leave residue and replace the seal.
Tighten the plug (1) .
Tightening torque Nm Class
Undo the threaded inspection plug (2) , located on the left on the bottom of the differential housing.
There is a small pipe above the threaded plug for filling and checking the level of the system.
Using the pump ( AV 8174 ) with attachment 02 (with the long spout), aspirate the specified oil from a newly opened container.
Using the pump ( AV 8174 ) together with element 02 and a container for collecting excess oil, fill with
8.0 litres of oil via the dipstick pipe.
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8/5/2011
Draining and filling with Shell DCT F-3 hydraulic clutch system oil Page 3 of 3
Fill with half of the quantity indicated, wait a few minutes for the oil to settle, then gradually finish filling, until oil overflows from the level pipe (8) .
The quantity of oil required may vary slightly relative to the amount indicated for filling the tank when empty; this is due to unavoidable pooling within the system. Fill gradually.
Inspect the hydraulic clutch system oil level Shell DCT F-3 ( A3.03
).
Check that there is no leakage from the drain plug. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C30...
8/5/2011
Axle shafts Page 1 of 6
Print Exit
Removing the axle shaft
The following procedure is for the removal of the right hand axle shaft.
The procedure for removing the left hand axle shaft is similar.
Disable the EPB electric parking brake Autohold function ( D3.07
).
Remove the rear flat undertray section ( E3.12
).
Remove the wheels ( D2.01
).
Remove the rear bumper ( E3.04
).
Use a punch and mallet to remove the caulking (1) from the ring nut (2) .
Undo the ring nut (2) fastening the axle shaft to the hub carrier bearing.
Undo the six screws (3) fastening the axle shaft (A) to the differential flange, recovering the three shims (4) .
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8/5/2011
Axle shafts Page 2 of 6
Undo the nut (5) , removing the relevant pin fastening the toe-in tie-rod (B) to the hub carrier
(C) .
Support the weight of the rear suspension adequately and undo the nut (6) , removing the relevant pin fastening the upper arm (D) to the hub carrier (C) .
Use a suitable screwdriver to prise the clip (7) off the EPB linkage bracket.
Detach the end (8) of the left hand EPB Bowden cable (9) from the EPB linkage bracket.
Move the EPB equaliser (7) to the right.
Detach the end (8) of the right hand EPB Bowden cable (9) from the EPB equaliser (7) .
Press on the two indicated fastener tabs and remove the right hand EPB Bowden cable sheath (9) from the relative mounting bracket.
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8/5/2011
Axle shafts Page 3 of 6
Left hand axle shaft
Press on the two indicated fastener tabs and remove the left hand EPB Bowden cable sheath
(9) from the relative mounting bracket.
Tilt the hub carrier outward to detach the axle shaft from the differential flange.
If necessary, cut the cable retainer clamps to slacken any tension preventing the hub carrier from tilting.
Use a suitable punch and mallet to extract the axle shaft from the hub carrier bearing, then remove the axle shaft from the vehicle.
Refitting the axle shaft
Tightening torque
Fastening upper arm to hub carrier
Fastening toe-in tie-rod to hub carrier
Fastening axle shaft to differential flange
Fastening axle shaft to wheel hub
Nut
Nut
Screw
Nut
Nm
90 Nm
80 Nm
78 Nm
275 Nm
Class
A
A
A
A
When refitting the same axle shaft, remove any residue of AREXONS SYSTEM 56A01 - HIGH STRENGTH
RETAINING COMPOUND .
Remove any residue of AREXONS SYSTEM 56A01 - HIGH STRENGTH RETAINING COMPOUND from the hub carrier bearing.
Check that the surface of the differential flange is completely clean. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C40...
8/5/2011
Axle shafts Page 4 of 6
Apply three even and regularly spaced circular beads of AREXONS SYSTEM 56A01 - HIGH
STRENGTH RETAINING COMPOUND .
Fit the axle shaft in the hub carrier bearing.
Tilt the hub carrier inward to bring the axle shaft and the differential flange together.
Fit new cable retainer clamps if the previous clamps were cut.
Support the weight of the rear suspension adequately, pretighten the nut (6) with a tightening angle of 80°, and then fully tighten, fitting the relative pin fastening the upper arm (D) to the hub carrier (C) .
Tightening torque Nm Class
Pretighten the nut (5) with a tightening angle of 70°, then fully tighten, fitting the relative pin fastening the toe-in tie-rod (B) to the hub carrier (C) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C40...
8/5/2011
Axle shafts Page 5 of 6
Tighten the six screws (3) fastening the axle shaft
(A) to the differential flange, fitting the three shims (4) .
Tightening torque Nm Class
Tighten the ring nut (2) fastening the axle shaft to the hub carrier bearing.
Tightening torque Nm
Loosen the ring nut (2) and retighten.
Class
Tightening torque Nm Class
Use a punch and mallet to caulk (1) the ring nut (2) .
Press on the two indicated fastener tabs and fit the right hand EPB Bowden cable sheath (9) in the relative mounting bracket.
Move the EPB equaliser (7) to the left. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C40...
8/5/2011
Axle shafts Page 6 of 6
Left hand axle shaft
Press on the two indicated fastener tabs and fit the left hand EPB Bowden cable sheath (9) into the relative mounting bracket.
Attach the end (8) of the left hand EPB Bowden cable (9) to the EPB linkage bracket.
Refit the clip (7) in the relative seat on the EPB linkage bracket.
Refit the rear flat undertray section ( E3.12
).
Refit the rear bumper ( E3.04
).
Refit the wheels ( D2.01
).
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Carry out the EPB Calibration procedure. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C40...
8/5/2011
Flywheel Page 1 of 2
Print Exit
C4.02 Flywheel
Removing the flywheel
Located inside the transmission housing and connected to the crankshaft.
Remove the complete gearbox ( C2.02
).
Immobilise the crankshaft.
Undo the eight screws indicated fastening the engine flywheel (A) .
Undo the screws in a crossed pattern, by undoing one screw first and then the opposite screw.
Note that while the starter motor has been removed in the photo aside, its removal is not necessary.
Remove the engine flywheel (A) from under the vehicle.
Refitting the flywheel
Tightening torque
Fastening flywheel to crankshaft Pretightening torque for screw
Nm
45 Nm
Class
0 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C40...
8/5/2011
Flywheel
Refit the complete gearbox ( C2.03
).
Page 2 of 2
Fit the engine flywheel (A) in its seat, aligning the crankshaft bearing and matching up the fastener holes.
The flywheel can only be installed one way, as one of the eight holes is not centred, as on the crankshaft.
Apply all eight fastener screws by hand.
Pretighten the four screws indicated (red markings) in the following order: 1-2-3-4 .
Tightening torque
Pretightening torque for screw
Nm
45 Nm
Class
Tighten the screws definitively in the following order: 5-6-7-8 then 1-2-3-4 .
0
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_C40...
8/5/2011
Technical specifications
Print Exit
Brake system
390 mm x 36 mm carbon-ceramic front disc with 4-piston aluminium calliper
350 mm x 32 mm carbon-ceramic rear disc with 4-piston aluminium calliper
148 T4300 pads (front)
77 S600 pads (rear)
Page 1 of 3
Electric parking brake (EPB)
Can be inserted and removed using a control on the dashboard.
Differentiated release of callipers/pads at vehicle start (AVH function). This guarantees optimum release dynamics.
Automatic activation at engine cut-off (AUTOHOLD function) with the option to disable automatic activation using the AUTOPARK button incorporated into the EPB control.
Stability and Traction Control (CST)
The CST consists of two primary systems:
VDC : vehicle dynamics control through the brake system and engine torque;
F1-Trac : traction control, which functions by modulating engine torque in relation to maximum road grip.
CST also consists of a number of secondary systems, such as ABS, EBD etc., which are active at all times.
F1-Trac is quicker and more precise than a conventional traction control system and delays and minimises the engine torque corrections necessary to maintain the desired trajectory.
The system is self-adaptive and calculates the maximum grip available by constantly monitoring the relative speeds of the wheels.
F1-Trac correlates real data against a vehicle dynamics model stored in the control system and optimises the behaviour of the vehicle by controlling engine torque delivery.
F1-Trac is not active with the Manettino turned to "CST off".
Suspension
New double-wishbone front suspension, including a hollow torsion bar to reduce roll, leading to a subsequent increase in driving comfort.
New rear Multilink suspension. The Multilink layout means that the suspension has greater flexibility lengthwise
(for greater comfort) while maintaining the same transversal rigidity values as a conventional layout (the same handling). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D10...
8/5/2011
Technical specifications Page 2 of 3
The Multilink suspension layout offers a greater capacity to absorb bumps together with lower levels of noise and vibration, optimum transversal rigidity and comfort.
Magnetorheological shock absorbers, already available on 599 GTB Fiorano and California.
Front
Wheel rim size
Light alloy 8.5 " J x 20 "
Spare wheel 4.5 " J x 20 "
Tyre size
235/35 ZR20 Pirelli P Zero
235/35 ZR20 Bridgestone Potenza
235/35 ZR20 Michelin Pilot Sport, interchangeable individually or in pairs with Michelin Pilot Super Sport (only in size indicated for 458 Italia)
235/35 ZR20 Michelin Pilot Super Sport
235/35 ZR20 Bridgestone Potenza Run Flat optional Run Flat
Winter 235/35 ZR20 Pirelli Winter Sottozero optional
Spare wheel 145/60 ZR20 Vredestein optional
Rear
Wheel rim size
Light alloy 10.5 " J x 20 "
Spare wheel 4.5 " J x 20 "
Tyre size
295/35 ZR20 Pirelli P Zero
295/35 ZR20 Bridgestone Potenza
295/35 ZR20 Michelin Pilot Sport 2, interchangeable individually or in pairs with Michelin Pilot Super Sport (only in size indicated for 458 Italia)
295/35 ZR20 Michelin Pilot Super Sport
295/35 ZR20 Bridgestone Potenza Run Flat optional Run Flat
Winter 285/35 ZR20 Pirelli Winter Sottozero optional
Spare wheel 145/60 ZR20 Vredestein optional
Inflation pressure (cold)
Pirelli P Zero
Front
30.46 psi
Bridgestone Potenza 33.36 psi
Michelin Pilot Sport 30.46 psi
Rear
29 psi
33.36 psi
29 psi https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D10...
8/5/2011
Technical specifications
Bridgestone Potenza
(Run Flat)
Pirelli Winter
Sottozero
Vredestein (Spare wheel)
Front
33.36 psi
30.46 psi
60.92 psi
Rear
36.26 psi
29 psi
60.92 psi
Page 3 of 3 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D10...
8/5/2011
Specific tooling and equipment
Print Exit
D1.02 Specific tooling and equipment
Support 95973206 (AV 3206) for complete hub.
Page 1 of 1
Torque wrench 95978172 (AV 8172)
(Replaces torque wrench USAG 815F) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D10...
8/5/2011
Tightening torques
Print Exit
Page 1 of 3
Tightening torque
Fastening rigid pipe to power steering pump
Fastening power steering pump to engine
Fastening cover to power steering pump
Union
Screw
Screw
Fastening power steering fluid pipes to reservoir Screw collar
Fastening steering wheel to steering column Nut
Fastening steering column to steering box
Fastening steering box to chassis
Screw
Nut (pretightening)
Fastening steering box tie-rod to front hub carrier Nut
Fastening power steering pipe unions to power steering fluid radiator
Fastening underbody union with power steering fluid delivery pipe
Fastening underbody union with power steering fluid return pipe
Fastening delivery and return pipes on steering box
M14 pipe union
M16 pipe union
Fastening upper fastener for steering column to dashboard
Fastening lower fastener for steering column to dashboard
Fastening rear stabiliser bar to chassis
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Fastening rear stabiliser bar to tie-rod
Fastening upper arm to hub carrier
Fastening toe-in tie-rod to hub carrier
Fastening axle shaft to differential flange
Fastening upper arm to chassis
Nut
Nut
Nut
Screw
Nut (pretightening)
Fastening shock absorber to chassis
Fastening lower arm to chassis
Fastening brake pad sensor ground cable
Fastening front stabiliser bar to tie-rod
Fastening steering box tie-rod to hub carrier
Screw
Nut (pretightening)
Nut
Nut
Nut
Nm
37 Nm
25 Nm
10 Nm
4 Nm
50 Nm
30 Nm
25 Nm
40 Nm
35 Nm
38 Nm
B
B
50 Nm
90 Nm
80 Nm
78 Nm
9 Nm
110 Nm
9 Nm
6 Nm
50 Nm
40 Nm
A
A
B
B
B
B
A
A
A
A
Class
B
B
B
B
B
B
B
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D10...
8/5/2011
Tightening torques Page 2 of 3
Tightening torque
Fastening shock absorber to lower arm
Fastening shock absorber to chassis
Fastening upper arm to chassis
Fastening toe-in tie-rod to chassis
Screw
Screw
Nut (pretightening)
Nut (pretightening)
Nm
80 Nm
110 Nm
9 Nm
9 Nm
Class
A
A
B
B
Fastening lower arm to chassis
Fastening tyre inflation valve
Fastening tyre pressure sensor
Fastening front stabiliser bar to chassis
Fastening NRRPS motion sensor mounting bracket to chassis
Fastening trigger to mounting bracket
Fastening lower arm to hub carrier
Nut (pretightening)
Nut
Screw
Screw
9 Nm
4 Nm
4 Nm
30 Nm
B
A
A
B
Bushing and shock absorber retainer washer
Connector - shock absorber strut
Fastening bleed union
Fastening brake fluid reservoir
Fastening bleed unions - brake callipers
Fastening brake pipe union or connection
Fastening brake disc - bearing
Screw
Nut (pretightening)
Fastening upper arm to hub carrier
Spherical tie-rod - lower arm
Fastening lower arm to hub carrier
Shock absorber ring nut
Fastening pipe and cable mounting bracket to hub carrier
Products to use: AREXONS 242
Brake disc shield bracket
Products to use: AREXONS 242
Fastening anti-rotation link to hub carrier
Fastening vehicle lift system unions
Fastening mounting bracket for "Front Lift" system electric pump
Fastening vehicle lift system fluid reservoir
Fastening pipe from reservoir onto "Front Lift" system electric pump
Nut
Spherical tie-rod
Nut
Ring nut
Screw
Screw
Screw
Union
Screw
Nut
Nut
Union
Nut
Union
M10 union
Screw
9 Nm
90 Nm
52 Nm
50 Nm
205 Nm
65 Nm
9 ÷ 12 Nm
9 ÷ 12 Nm
85 Nm
16 Nm
4 Nm
40 Nm
40 Nm
10 Nm
9 Nm
17 ÷ 20 Nm
16 Nm
15.5 Nm
B
A
B
B
A
B
B
B
A
B
B
A
A
B
B
0
B
B
Fastening brake fluid underbody pipe unions
Fastening brake fluid pipe on the electrohydraulic
ABS/ASR unit
Union 16 Nm B
Fastening EPB Bowden cable - rear hub carrier B
M10 - M12 union 16 Nm B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D10...
8/5/2011
Tightening torques Page 3 of 3
Tightening torque
Fastening electrohydraulic ABS/ASR unit mounting bracket to chassis
Fastening electrohydraulic ABS/ASR unit to mounting bracket
Fastening air duct on heater/evaporator unit inside luggage compartment
Fastening brake servo - pedal board
Fastening pedal board to firewall
Nut
Screw
Fastening brake calliper to hub carrier Screw
Fastening rigid brake fluid pipe to front brake calliper
Fastening brake fluid hose to rear brake calliper Union
Fastening oil pipe unions to brake pump Union
Fastening central pin on front brake pads
Wheels
Fastening lower radiator air ducts
Screw
Pretightening of stud bolt
Stud bolt
Screw
Nm
20 Nm
20 Nm
21.5 Nm
16 Nm
27 ÷ 33 Nm
25 ÷ 45 Nm
100 Nm
5 Nm
Class
B
B
A
B
0
0
A
C https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D10...
8/5/2011
Complete wheel
Print Exit
Removing the wheels
Page 1 of 3
CAUTION
Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0.
Before performing any maintenance procedures requiring the ignition key to be in position II on vehicles with the Stop&Start system, deactivate the Stop&Start system with the relative button, ensuring that the specific icon and the message "Stop&Start OFF" are shown on the TFT display, and that the LED on the on/off button itself is off.
Failure to do so may result in serious injury to persons working on the vehicle and in the vicinity of the vehicle in the event of the engine unexpectedly starting.
Use tools very carefully in order to prevent damaging the painted surfaces of the wheel rim.
Tyres that have been fitted for over 3 years must be checked to verify they are still suitable for use.
CAUTION
Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration.
Loosen the five stud bolts (1) .
Lift the vehicle.
Remove the complete wheel.
Checking the wheels
CAUTION
Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Complete wheel Page 2 of 3
Check the state of wear of the tyre and the state of the wheel rim.
When replacing a tyre or rim, the wheel must be statically and dynamically balanced.
Check that the mating surfaces on the rim and brake disc are perfectly clean.
Replace any stud bolts with damage to the thread or cone.
Clean the stud bolts thoroughly before refitting.
Never lubricate the contact surfaces between the stud bolt and rim and between the rim and the brake disc.
Do not clean the wheel cones with solvents or aggressive products as they may remove the anti-seizing coating.
Refitting the wheels
Tightening torque
Wheels Pretightening of stud bolt
Stud bolt
Nm
25 ÷ 45 Nm
100 Nm
Class
0
A
CAUTION
Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0.
Before performing any maintenance procedures requiring the ignition key to be in position II on vehicles with the Stop&Start system, deactivate the Stop&Start system with the relative button, ensuring that the specific icon and the message "Stop&Start OFF" are shown on the TFT display, and that the LED on the on/off button itself is off.
Failure to do so may result in serious injury to persons working on the vehicle and in the vicinity of the vehicle in the event of the engine unexpectedly starting.
Use tools very carefully in order to prevent damaging the painted surfaces of the wheel rim.
Tyres that have been fitted for over 3 years must be checked to verify they are still suitable for use.
CAUTION
Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Complete wheel Page 3 of 3
Fit the complete wheel, inserting the locator pin in the seat on the wheel rim.
Hand tighten the stud bolt opposite the locator pin first, then the others.
Pretighten the stud bolts in a crossed pattern.
Tightening torque
Pretightening of stud bolt
Nm
25 ÷ 45 Nm
Class
0
Lower the vehicle and tighten the stud bolts (1) definitively
Tightening torque
Stud bolt
Nm
100 Nm
Class
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyres and rims
Print Exit
Checking the state of the tyres
Page 1 of 11
Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration.
Check the state of the tyres during the scheduled maintenance.
CAUTION
Pressure increases with increasing tyre temperature. Never reduce the tyre pressure if measured when the tyres are hot.
Tyre overheating due to underinflation may seriously compromise handling and tyre integrity.
Do not inflate the tyres to a pressure other than the specified value, as this would render the tyre pressure monitoring system useless.
After replacing one or more tyres, always calibrate the tyre pressure monitoring system by pressing the button on the passenger compartment dome light panel.
Check the inflation pressure: pressure must be measured with cold tyres and must match the values specified.
CAUTION
Always inspect any tyre damage very carefully to assess severity: damage may greatly reduce tyre life and cause accidents.
Check the tyres to ensure that there are no signs of damage such as abrasion, cuts, cracks, bubbles etc.
Violent knocks against kerbs, holes or other obstacles and driving on poor road surfaces for extended periods may cause tyre damage. This damage may not always be visible. Any foreign objects penetrating the tyre in these conditions may cause structural damage that is only identifiable after removing the tyre from the wheel.
CAUTION
If the same tyres have been fitted on the vehicle for over 3 years, check frequently and carefully for signs of deterioration.
Do not monitor the pressure of a damaged tyre.
Tyres will deteriorate even if the vehicle is used rarely or kept stationary. Cracks in the rubber on the tread and sidewalls, at times accompanied by blisters, are an indication of tyre deterioration. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyres and rims Page 2 of 11
CAUTION
Never fit a tyre with tread depth under the specified limit, even if only in a single localised area.
Check the tread depth: the minimum permissible value is 1.7 mm . This depth is identified by the tyre wear indicators.
Check the wear over the entire tread; in the event of uneven tread wear, perform static and dynamic wheel balancing.
Note that in order to mount conventional tyres on a vehicle that has been fitted with Run Flat tyres, the instrument panel must be reprogrammed as the TFT display will display a warning message.
Replace any tyres that have been punctured and/or been inflated with the tyre inflation bottle included with vehicle toolkit. For safety reasons, we do not recommend attempting to repair punctured tyres.
Tyre grades
All passenger car tires must conform to Federal Safety requirements, in addition to these grades.
DOT rating
Pirelli P Zero
Tread wear
220 (Front) – 160
(Rear)
Traction
AA
Temperature
A
Tread wear
The tread wear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course.
For example, a tire graded 150 would wear one and one-half (1 1/2) times as well on the government course as a tire graded 100.
The relative performance of tires depends upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in driving habits, service practices and differences in road characteristics and climate.
Traction
The traction grades, from highest to lowest, are “AA”, “A”, “B” and “C” . Those grades represent the tyre's ability to stop on wet pavement as measured under controlled conditions on specified government test surfaces of asphalt and concrete. A tire marked "C" has poor traction performance.
The traction rating given to a tyre is based on straight line braking tests and does not take other factors such as acceleration, steering angle, aquaplaning or traction peaks into account. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyres and rims Page 3 of 11
Temperature
The temperature grades are "A" (the highest), "B" , and "C" , representing the tyre's resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. Grade "C" corresponds to a minimum level of resistance to which all tyres for cars carrying passengers must comply, according to what is established by the Federal Standard no. 109 on vehicle safety (Federal Motor Safety Standard). Grades “B” and “A” , measured for tyres on a laboratory test wheel, indicate higher performance levels than those required by law.
The temperature rating is with reference to a correctly inflated, correctly loaded tyre. Excessive speed, insufficient inflation, overloading or combinations thereof may cause heat production and possible tyre failure.
Preparation for tyre removal
The tyre pressure monitoring sensor is installed on the wheel rims, near the inflation valve.
Removing the tyre without using the correct tools and taking the necessary precautions may damage the sensor. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyres and rims Page 4 of 11
To avoid this problem, we are showing the entire procedure for removal and refitting of the tyres from the wheel rim, using a CORGHI tool, model Artiglio A2019 RC (shown in the photo) or Artiglio A2020 TI , recommended by Ferrari.
To prevent damage to the wheel rim, all parts of the tool that may come into contact with the rim are rubber coated.
Only use rubberised tools.
Wear gloves and protective eyewear.
Removing the tyre
Ensure that tyres are not kept in stock for more than 4 years. Tyres may be kept in stock for a maximum of 4 years, provided that they are kept out of direct sunlight, protected from the weather and humidity and stored in low oxygen conditions. If necessary, the Ferrari Service Network will verify whether old tyres are suitable for use. In all cases, tyres mounted on a vehicle for over 3 years must be inspected by an authorised Ferrari Service Centre.
Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration.
When removing and refitting tyres, DO NOT use tyre levers which could damage the rim and compromise its protective layer. Use levers coated in protective material.
The photos shown here were taken using a rim from the 575M Maranello.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyres and rims Page 5 of 11
To more clearly identify the correct mounting positions for the tools relative to the wheel, the vertical column of the tyre demounting machine is used as the starting point (12 o'clock).
Undo the core of the valve (A) to completely deflate the tyre.
Place the wheel on the machine table and break the bead on both the inner and outer sides.
Lubricate the bead (1) with the lubricant spray provided.
Place the wheel on the self-centring clamp and use the bead breaker to ensure that the wheel is gripped correctly by the clamps (2) on the table.
If the machine is not equipped with a bead breaker, clamp the wheel from the inside.
Clamp the wheel. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyres and rims Page 6 of 11
Observe the correct positions for bead breaking shown as follows.
Position the inflation valve (A) at 12 o'clock .
Position the bead breaker disc (3) .
Push the bead into the rim channel using the bead breaker disc while simultaneously turning the tyre counterclockwise, until the inflation valve (A) is at 3 o'clock .
Lubricate the bead while turning.
To facilitate tyre removal, if necessary, insert a bead breaker lever at 180° relative to the sensor.
If the bead is not completely broken, repeat this stage in a clockwise direction, moving the inflation valve from 3 o'clock to 12 o'clock .
Perform this stage repeatedly, clockwise and anticlockwise, until the bead is completely broken.
Fit tool (4) : after clamping, the tool automatically moves upwards and outwards.
Position the inflation valve (A) at 11 o'clock .
Mount the lever (5) on tool (4) , using the bead breaker disc to facilitate the operation if necessary.
Remove the bead breaker disc.
Position the tyre bead on the tool (4) using the lever
(5) .
Remove the lever. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyres and rims Page 7 of 11
Ensure that the entire edge of the bead is outside the rim and completely visible. If this is not the case, the bead may be damaged.
If the bead does not slide easily into the groove, lubricate the contact area.
Turn the wheel clockwise.
Position the inflation valve (A) at 12 o'clock .
Fit the lever (5) on the tool (4) .
Lift the tyre.
Take care not to damage the sensor when inserting the tyre lever (5).
Position the lower bead of the tyre on the tool (4) , using the lever (5) .
Turn the wheel clockwise.
Remove the rim from the machine and put carefully in a safe place.
If the tyre is not to be refitted immediately, refit the valve core and cap.
Remove the tyre pressure sensor ( D2.03
).
Proceed as follows if removal is necessary.
Checking wheel rims https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyres and rims Page 8 of 11
When carrying out regular maintenance or replacing tyres, check the state of the wheel rims.
Visually inspect the external and internal wheel rim surfaces; if cracks or deep gouges are noted, replace the wheel.
In the case of scratching, minor dents or superficial scuffs, repaint the affected area or, if necessary, the entire rim. Use the standard procedure for repainting an alloy wheel, applying a coat of silver based paint then, once the coat had dried to a matte finish, applying a layer of clear coat. Dry the wheel in the oven to polymerise the layers of paint applied.
Cover the valve mounting and the hub badge when repainting, as the additional thickness of the paint may impede correct assembly and compromise the effectiveness of the corrosion treatment applied.
Take particular care around the mating surface with the brake disc; this area is only coated with a single layer of cataphoresis film.
This treatment has a limited lifespan as the film is gradually eroded by fretting between the surfaces. This area cannot be repainted and a rim with a deteriorated film must be replaced.
Before refitting, always check that the mating surfaces between the wheel and the brake disc are perfectly clean.
Using inappropriate tools for removing and refitting the tyre may damage the wheel rim and compromise the protective layer.
Balance the wheel without the tyre but with the pressure sensor and valve installed: if, after removing the balancer weights, the values for static balance exceed 36 (including vertical bouncing and wobble), the rim must be replaced.
Refitting the tyre
Ensure that tyres are not kept in stock for more than 4 years. Tyres may be kept in stock for a maximum of 4 years, provided that they are kept out of direct sunlight, protected from the weather and humidity and stored in low oxygen conditions. If necessary, the Ferrari Service Network will verify whether old tyres are suitable for use. In all cases, tyres mounted on a vehicle for over 3 years must be inspected by an authorised Ferrari Service Centre.
Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration.
When removing and refitting tyres, DO NOT use tyre levers which could damage the rim and compromise its protective layer. Use levers coated in protective material.
Refit the tyre pressure sensor ( D2.03
).
Proceed as follows if the component has already been removed. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyres and rims Page 9 of 11
After installing the pressure sensor (A) , mount the clean rim on the self-centring clamp, ensuring that the wheel is gripped correctly by the clamps
(2) on the table.
Lubricate the wheel.
Pick up the tyre and ensure that the direction of rotation is correct.
Lubricate both beads.
Fit the inflation valve (A) at 6 o'clock .
Place the tyre on the rim and tip the tool arm (4) forwards.
Fit the lower bead under the right hand part of the tool (4) .
Turn the wheel clockwise.
Mount the bead on the rim, applying constant pressure.
Turn the wheel, bringing the inflation valve (A) to 12 o'clock .
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Tyres and rims Page 10 of 11
The bead breaker disc must never reach the valve-sensor assembly position.
Fit the inflation valve (A) at 4-5 o'clock .
Place the tyre on the rim, matching the lighter parts of the rim, marked with an embossed letter "G" , with the yellow dots on the tyre.
Insert the lever (5) at 2-3 o'clock , using the bead breaker disc (3) to push the bead in.
If available, use tyre pliers instead of the lever (5) , with the appropriate adapter fitted.
If necessary, insert a second set of tyre pliers, with the correct adapter fitted.
Turn the wheel clockwise until the upper bead is completely mounted.
If used, remove the tyre lever with the bead breaker disc.
Release the wheel from the clamps (2) on the table.
Refit the core of the valve (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyres and rims Page 11 of 11
To ensure that the bead is mounted correctly, inflate the tyre immediately, while the beads are still lubricated.
The tyre must be inflated to activate the tyre pressure monitoring system sensor. Inflate the tyre to a pressure greater than 0.6 bar and keep inflated at this pressure for a few minutes .
If the maximum permissible inflation pressure of
(3.2 bar / 44 psi) is not sufficient to seat the beads, lubricate again.
Balance the wheels ( D2.02
).
Wheel balancing
Only use self-adhesive counterweights. In addition to damaging the wheel rim, other types of counterweights can interfere with parts of the suspension or detach while driving.
Do not touch the adhesive surface of the counterweight before applying to the rim and never reuse counterweights or use weights with no protective paper, as these may detach while driving.
After replacing a tyre, wheel rim, or both, the wheel must be statically and dynamically balanced using a balancing machine and suitable counterweights.
Manufacturers identify the heaviest part of the wheel rim and the tyre with a reference mark. When mounting the tyre onto the rim, always set these reference marks opposite each other to minimise the amount of counterweights necessary for balancing.
The counterweights must be applied in position (A) on the inner edge of the wheel rim, in position
(B) , or in both positions if necessary.
Thoroughly clean the wheel rim surface onto which the counterweight will be applied with heptane.
Remove the protective backing and affix the counterweight onto the wheel rim, pressing evenly to ensure that it adheres perfectly.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyre pressure monitoring system
Print Exit
D2.03 Tyre pressure monitoring system
TPMS system layout
Page 1 of 20
A - Sensors
B - Trigger
C - Antenna
D - Electronic control unit
Operating the TPMS tyre pressure and temperature monitoring system
The system must be calibrated from the relative menu option on the left hand TFT display after replacing or inflating any of the tyres.
The TPMS system may be calibrated from the specific Menu option on the left hand TFT display.
The sensors fixed to the interior of the wheel rims, next to the inflation valve, detect the pressure and temperature of the tyres. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 2 of 20
These sensors transmit a signal received by the triggers fixed to the bodyshell behind the gravel guard, which are in turn connected to the ECU.
The ECU processes the data received from the triggers and transmits the processed data to the instrument panel.
The data transmitted to ECU activates the respective indications on the left hand TFT display.
Visualisation on TFT display
TYRES screen : use the relative controls on the left hand TFT display to access the informative screen displaying the pressure and temperature values for each tyre.
- Insufficient pressure of one or more tyres
With any currently active screen, when the instrument panel receives the signal from the electronic control unit indicating that the pressure of one or more tyres is below the warning threshold, but the system cannot recognise which wheel is generating the fault signal, the TFT display displays the specific message “ Check tyre pressure ” without the vehicle symbol.
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Tyre pressure monitoring system Page 3 of 20
With any currently active screen, when the instrument panel receives the signal from the electronic control unit indicating that the pressure of a tyre is below the warning threshold, the TFT display displays the specific message “ Check tyre pressure ” together with the vehicle symbol indicating tyre pressures.
The background of the box indicating the pressure and relative unit of measurement for the faulty tyre turns amber.
With any currently active screen, when the instrument panel receives the signal from the electronic control unit indicating that the pressure of more than one tyre is below the warning threshold, the TFT display displays the specific message “ Check tyre pressure ” together with the vehicle symbol indicating tyre pressures.
The background of the box indicating the pressure and relative unit of measurement for the faulty tyre turns amber.
The display cycle is 20 seconds, after which time the specific screen disappears.
At key-off, no information is displayed but the function continues to monitor tyre pressure while the vehicle is parked.
If the fault persists at the subsequent key-on, the specific screen is shown again on the display. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 4 of 20
TYRES screen : the driver may recall the screen by using the controls on the left hand TFT display, enabling identification of tyres with insufficient pressure at any time. When the system cannot recognise which wheel is generating the fault signal, as the respective values cannot be displayed by the TYRES screen, the screen is not recallable by the driver.
- TPMS not calibrated
When the TPMS system has not been calibrated or a tyre has been replaced, the TFT display displays the specific message " TPMS not calibrated " together with the message " Execute calibration ".
The vehicle symbol is not displayed. Therefore, if the fault occurs while the TYRES screen is active, the default screen is shown automatically.
Simultaneously, the specific indicator light starts flashing and continues to flash for a maximum period of 90 seconds (determined by NTP), after which the indicator light remains lit continuously until the system is calibrated.
The system may be calibrated via the specific option in the menu, in key-on state with the engine off.
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Tyre pressure monitoring system Page 5 of 20
Upon selection of the menu option and subsequent successful calibration, the TFT display displays the specific message " Calibration activated " for 5 seconds.
In “Calibration activated” state, the TYRES screen is recallable, but the pressure and temperature values are replaced by dashes.
- TPMS failure
In the event of a fault in the circuit and/or wiring harness leading to the ECU, or in the event of a TPMS ECU fault, or in the event of no signal reception from one or more sensors due to fault, breakage or flat battery, the TFT display displays the specific message " TPMS failure ".
The vehicle symbol is not displayed. Therefore, if the fault occurs while the TYRES screen is active, the default screen is shown automatically.
Simultaneously, the specific indicator light starts flashing and continues to flash for a maximum period of 90 seconds (determined by NTP), after which the indicator light remains lit continuously until normal operating conditions are restored.
The TYRES screen is not recallable by the driver.
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Tyre pressure monitoring system
- Punctured tyre
Page 6 of 20
When the instrument panel receives the signal from the electronic control unit indicating that the pressure of one or more normal tyres is below the alarm threshold, but the system cannot recognise which wheel is generating the fault signal, the TFT display displays the specific message “ Low tyre pressure ” together with the message " Do not proceed ", without the vehicle symbol.
If the vehicle is driven for more than 100 Km (62 mi) in “punctured tyre” state, the specific screen is displayed.
When the instrument panel receives the signal from the electronic control unit indicating that the pressure of one or more normal tyres is below the alarm threshold, the TFT display displays the specific message “ Low tyre pressure ” together with the message " Do not proceed " and the vehicle symbol indicating tyre pressures.
If the vehicle is driven for more than 100 Km (62 mi) in “punctured tyre” state, the specific screen is displayed.
The background of the box indicating the pressure and relative unit of measurement for the faulty tyre turns amber. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 7 of 20
When the instrument panel receives the signal from the electronic control unit indicating that the pressure of one or more RUN FLAT tyres is below the alarm threshold, but the system cannot recognise which wheel is generating the fault signal, the TFT display displays the specific message “ Low tyre pressure ” together with the message " Max speed 80 Km/h " without the vehicle symbol.
The system warns the driver and displays the specific screen if the vehicle speed exceeds 80 Km/h (50 mph) while in “punctured tyre” state.
When the instrument panel receives the signal from the electronic control unit indicating that the pressure of one or more RUN FLAT tyres is below the alarm threshold, the TFT display displays the specific message “ Low tyre pressure ” together with the message " Max speed 80 Km/h " and the vehicle symbol indicating tyre pressures.
The system warns the driver and displays the specific screen if the vehicle speed exceeds 80 Km/h (50 mph) while in “punctured tyre” state.
The instrument panel also calculates (but does not display) the remaining range in Km (or mi) and repeats the warning after 50 Km (31 mi).
In the event of a puncture to another tyre, the instrument calculates (but does not display) the updated remaining range in Km (mi), in relation to the distance driven since the previous puncture event.
After the display cycle for the screen is complete, the screen disappears, but the relative indicator light remains lit continuously.
Pressing the “Escape” function key during the display of faults with priority 0 (standard type tyre puncture) or priority 1/ 2 (RUN FLAT tyre puncture, with speed limit not exceeded and with tyres still in usable condition) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyre pressure monitoring system cancels the screen while leaving the relative warning light lit.
Page 8 of 20
TYRES screen : the screen may be recalled using the controls on the left hand TFT display, enabling the driver to identify punctured tyres at any time. When the system cannot recognise which wheel is generating the fault signal, as the respective values cannot be displayed by the TYRES screen, the screen is not recallable by the driver.
- TPMS temporarily inactive https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 9 of 20
In the event of antenna reception disturbance caused by an RF source transmitting in the same frequency range as the sensors, or in the event of sensor overheat, or during calibration, or if the ECU does not recognise the sensor identifiers, the TFT display displays the specific message " TPMS temporarily inactive ".
Simultaneously, the specific indicator light starts flashing and continues to flash for a maximum period of 90 seconds (determined by NTP), after which the indicator light remains lit continuously until normal operating conditions are restored.
Subsequently (or if the “Escape” function key is pressed during the display cycle), the screen disappears but the warning light remains lit.
The TYRES screen is not recallable by the driver.
- "TPMS inactive"
When the system has been disabled via the diagnostic tester, the TFT display displays the specific message " TPMS inactive ".
Simultaneously, the specific indicator light starts flashing and continues to flash for a maximum period of 90 seconds (determined by NTP), after which the indicator light remains lit continuously until normal operating conditions are restored.
Subsequently (or if the “Escape” function key is pressed during the display cycle), the screen disappears but the warning light remains lit. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyre pressure monitoring system
The TYRES screen is not recallable by the driver.
Page 10 of 20
Tyre pressure sensor
The sensors are mounted to the wheel rim and secured by the inflation valve.
The sensor must be correctly fixed to the valve for the system to function.
ALWAYS replace with new components when REMOVING the TPMS sensor, complete with valve, from the rim.
Replace the entire sensor-valve assembly even if only one of the components is damaged.
Detaching the tyre from the rim without due caution may cause irreparable damage to the sensor.
Removing the tyre pressure sensor
ALWAYS replace with new components when REMOVING the TPMS sensor, complete with valve, from the rim.
The sealant liquid contained in puncture repair aerosols may damage the sensor. Always replace the sensor if a tyre has been repaired with a puncture repair aerosol.
Replace the entire sensor-valve assembly even if only one of the components is damaged.
Remove the tyre ( D2.02
).
To prevent the inflation valve from turning, insert the rod (1) , included in the kit, in the hole on the sensor side.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 11 of 20
Undo the nut (2) from the inflation valve, retrieving the insulator washer (3) .
Remove the sensor (6) with valve (4) from the wheel rim and replace.
Refitting the tyre pressure sensor
Tightening torque
Fastening tyre inflation valve
Fastening tyre pressure sensor
Nut
Screw
Nm
4 Nm
4 Nm
Class
A
A
When replacing the tyre pressure sensors, carry out the new ECU sensor acquisition procedure with the
DEIS tester.
Always finish all the components in the batch opened previously before starting a new sensor batch, as the sensors are equipped with a battery with a limited lifespan.
Once the sensor has been activated, the internal battery has a lifespan of approximately 10 years.
ALWAYS replace with new components when REMOVING the TPMS sensor, complete with valve, from the rim.
The sealant liquid contained in puncture repair aerosols may damage the sensor. Always replace the sensor if a tyre has been repaired with a puncture repair aerosol.
Replace the entire sensor-valve assembly even if only one of the components is damaged. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 12 of 20
The sensor must not be treated with detergents, solvents or other harsh products.
Do not clean with compressed air or pressurised liquids (e.g. pulivapor).
Take particular care not to tear the surface of the filter interface (A) on the inner side of the sensor. Always replace the sensor if the interface surface is dirty or torn.
Store all the components of the sensor-valve assembly in a clean, dry place.
Select a new TPMS valve-sensor assembly.
Clean the sensor mating area on the wheel rim.
Check that the sensor frequency matches the system frequency: 433 MHz for the STANDARD version, white label on sensor; 315 MHz for the JAPAN version, blue label on sensor.
Fit the self-locking screw (5) in the hole on the sensor and tighten the valve (4) by two or three turns.
Fit the valve (4) with sensor (6) already assembled, in the hole on the wheel rim.
Ensure that the insulating washer is fitted onto the outside of the rim and is perpendicular to the valve.
Fit the insulating washer (3) and tighten the nut (2) fully.
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Tyre pressure monitoring system Page 13 of 20
Use a rod to ensure that the hole on the valve is kept outside the rim.
Fit the rod (1) in the radial hole of the valve and tighten the nut (2) .
ALWAYS use a torque wrench, using only certified and calibrated tools to ensure that the correct tightening torque is achieved.
Tightening torque Nm Class
Remove the rod (1) .
For the sensor to function correctly, there must be contact between the rim and the mounting points of the sensor itself. The system may not function correctly if the sensor is not installed exactly as instructed.
Push the sensor gently onto the rim to ensure contact between the rim and the mating surface of the sensor itself.
Tighten the self-locking screw (5) .
ALWAYS use a torque wrench, using only certified and calibrated tools to ensure that the correct tightening torque is achieved.
Tightening torque
Refit the tyre ( D2.02
).
Replacing front triggers
Tightening torque
Fastening trigger to mounting bracket
Disconnect the battery ( F2.01
).
Remove the front wheelhouses ( E3.05
).
Screw
Nm Class
Nm
9 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 14 of 20
Remove the rear element of the wheelhouse only.
Disconnect the connector (1) .
Undo the indicated screws fastening the trigger (A) to the relevant mounting bracket.
Remove the trigger (A) from the relevant mounting bracket and replace.
Fit the new trigger (A) correctly on the relevant mounting bracket.
Tighten the indicated screws fastening the trigger
(A) to the relevant mounting bracket.
Tightening torque
Connect the connector (1) .
Nm Class
Refit the front wheelhouses ( E3.05
).
Reconnect the battery ( F2.01
).
Replacing rear triggers
Tightening torque
Fastening trigger to mounting bracket
Disconnect the battery ( F2.01
).
Right hand rear trigger
Screw
Nm
9 Nm
Class
B
Remove the rear wheelhouses ( E3.05
).
Remove the rear element of the wheelhouse only. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 15 of 20
Disconnect the connector (1) .
Undo the indicated screws fastening the trigger (A) to the relevant mounting bracket.
Remove the trigger (A) from the relevant mounting bracket and replace.
Fit the new trigger (A) correctly on the relevant mounting bracket.
Tighten the indicated screws fastening the trigger
(A) to the relevant mounting bracket.
Refit the rear wheelhouses ( E3.05
).
Left hand rear trigger
Remove the rear wheelhouses ( E3.05
).
Remove the front element of the wheelhouse only.
Tightening torque
Connect the connector (1) .
Nm Class
Disconnect the connector (1) .
Undo the indicated screws fastening the trigger (A) to the relevant mounting bracket.
Remove the trigger (A) from the relevant mounting bracket and replace.
Fit the new trigger (A) correctly on the relevant mounting bracket.
Tighten the indicated screws fastening the trigger
(A) to the relevant mounting bracket.
Refit the rear wheelhouses ( E3.05
).
Reconnect the battery ( F2.01
).
Replacing the antenna (UP TO Ass.ly No. 91363)
Tightening torque
Connect the connector (1) .
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 16 of 20
Located under the vehicle, covered by the centre flat undertray section.
Disconnect the battery ( F2.01
).
Remove the central flat undertray section ( E3.12
).
Disconnect the connector (1) .
Undo the indicated screws; then remove and replace the antenna (A) .
Fit the antenna (A) in the relative seat.
Hand tighten the screws indicated.
Connect the connector (1) .
Refit the central flat undertray section ( E3.12
).
Reconnect the battery ( F2.01
).
Replacing the antenna (FROM Ass.ly No. 91364)
Tightening torque
Fastening underbody union with pipe leading from
AC compressor
Fastening brackets for complete underbody pipe set
Union
Union (FROM Ass.ly No.
90802)
Union (FROM Ass.ly No.
90802)
Screws (FROM Ass.ly
No. 90802)
Located under the vehicle, behind the underbody pipes.
Disconnect the battery ( F2.01
).
Remove the central flat undertray section ( E3.12
).
Remove the rear flat undertray section ( E3.12
).
Drain the cooling system ( B6.07
).
Discharge the air conditioning system ( F5.12
).
Nm
16 Nm
20 Nm
26 Nm
6 Nm
Class
B
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 17 of 20
Undo the union (1) .
Open the indicated clamp on the pipe (2) .
Loosen the clamp (5) .
Disconnect the pipe (4) from the rigid pipe (3) .
Cut the clamp indicated by the red arrow.
Undo the indicated screws and remove the bracket
(6) .
Remove the lower part of the pillory block (7) .
Undo the union (8) .
Undo the indicated screws and remove the bracket
(9) .
Remove the lower part of the pillory block (10) .
Undo the indicated screws and remove the lower parts of the pillory blocks (11) with relative brackets.
Remove the AC system pipe (2) .
Remove the engine cooling system pipe (3) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 18 of 20
Disconnect the connector (12) .
Undo the indicated screws; then remove and replace the antenna (A) .
Fit the antenna (A) in the relative seat.
Hand tighten the screws indicated.
Connect the connector (12) .
Fit the AC system pipe (2) .
Fit the engine cooling system pipe (3) .
Fit the lower parts of the pillory blocks (11) with the relative brackets and fasten temporarily by tightening the indicated screws. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
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Tyre pressure monitoring system Page 19 of 20
Tighten the union (1) .
Tightening torque
Union (FROM Ass.ly No.
90802)
Nm
26 Nm
Class
Close the indicated clamp on the pipe (2) .
Connect the pipe (4) to the rigid pipe (3) .
Tighten the clamp (5) .
Fit the lower part of the pillory block (7) .
Fit the bracket (6) and fasten by tightening the indicated screws.
B
Tightening torque
Screws (FROM Ass.ly No.
90802)
Nm
6 Nm
Class
Fit a new clamp as indicated by the red arrow.
B
Tighten the union (8) .
Tightening torque
Union (FROM Ass.ly No.
90802)
Nm
20 Nm
Class
B
Fit the lower part of the pillory block (10) .
Fit the bracket (9) and tighten the indicated screws.
Tightening torque
Screws (FROM Ass.ly No.
90802)
Nm
6 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Tyre pressure monitoring system
Fill the cooling system ( A3.07
).
Charge the air conditioning system. ( F5.12
).
Refit the rear flat undertray section ( E3.12
).
Refit the central flat undertray section ( E3.12
).
Reconnect the battery ( F2.01
).
Page 20 of 20
Fasten the brackets and the pillory blocks (11) onto the pipes (2) and (3) , tightening the indicated screws.
Tightening torque
Screws (FROM Ass.ly No.
90802)
Nm
6 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D20...
8/5/2011
Brake system layout
Print Exit
Brake system layout
Page 1 of 1
A - Brake fluid tank
B - Master brake cylinder
C - Brake servo
D - ABS/ASR electrohydraulic unit
E - Brake callipers
F - Brake pads
G - Brake discs
H - Yaw sensor https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake fluid tank
Print Exit
Removing the brake fluid tank
Page 1 of 3
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
The brake fluid reservoir is located at the centre of the luggage compartment, underneath the right hand underwindscreen shield.
Disconnect the battery ( F2.01
).
Remove the luggage compartment tub ( E4.07
).
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Empty the brake fluid reservoir completely, aspirating the fluid.
Disconnect the brake fluid level sensor connector
(1) .
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
Loosen the relative metal fastener clamps and disconnect the two pipes (2) from the brake fluid reservoir, plugging adequately. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
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Brake fluid tank Page 2 of 3
Undo the two nuts indicated fastening the brake fluid reservoir (A) to the chassis.
Remove the brake fluid reservoir (A) from the relative seat.
Refitting the brake fluid tank
Tightening torque
Fastening brake fluid reservoir Nut
Nm
9 Nm
Class
B
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
Fit the brake fluid reservoir (A) in the relative seat.
Tighten the nuts indicated fastening the brake fluid reservoir (A) to the chassis.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake fluid tank
Reconnect the battery ( F2.01
).
Fill and bleed the brake system ( D3.10
).
Refit the luggage compartment tub ( E4.07
).
Page 3 of 3
Remove the relative caps, connect the two pipes (2) to the brake fluid reservoir (A) and tighten the relative metal fastener clamps.
Connect the brake fluid level sensor connector (1) to the brake fluid reservoir (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake discs Page 1 of 2
Print Exit
Removing the brake discs
Remove the wheels ( D2.01
).
Remove the rear brake callipers ( D3.05
).
Applicable only for removing the rear discs. DO NOT disconnect the calliper fluid pipe and take particular care not to damage the pipe when handling the calliper.
Remove the front brake callipers ( D3.05
).
Applicable only for removing the front discs.
Undo the wheel locator pin (1) .
Undo the screw (2) fastening the disc.
Remove the disc, easing it off the wheel bearing.
Refitting the brake discs
Tightening torque
Fastening brake disc - bearing Screw
Nm
15.5 Nm
Class
B
Check that the disc is in proper working condition and inspect the disc contact surface, even if new.
If any dirt, stains or greasy/oily patches are noted on the disc surface, clean thoroughly with a regular solvent, degreaser and/or soap and water. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
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Brake discs Page 2 of 2
Fit the disc on the wheel bearing.
To centre the disc on the wheel bearing, hand tighten the wheel fastener stud bolts into their seats.
Tighten the screw (2) fastening the disc.
Tightening torque
Tighten the wheel locator pin (1) .
Nm Class
Tightening torque Nm Class
Remove the stud bolts fitted previously for aligning the disc.
Refit the front brake callipers ( D3.05
).
Refit the rear brake callipers ( D3.05
).
Fill and bleed the brake system ( D3.10
).
Carry out this operation only if the oil pipe unions have been disconnected.
Refit the wheels ( D2.01
).
Only in the case of replacing the discs. Bed in the CCM pads ( D3.04
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake pads
Print Exit
Removing the front brake pads
Disconnect the battery ( F2.01
).
Remove the wheels ( D2.01
).
Remove the front wheels only.
Page 1 of 5
Disconnect connector (1) of brake pad wear sensor, and detach it from the relative mounting bracket.
Remove the indicated cable ties.
Remove the indicated cable tie.
Remove the upper pin (2) from the relative seat, tapping into place with a suitable mallet and punch.
Remove the spring (3) from the relative seat.
Remove the lower pin (4) from the relative seat, tapping into place with a suitable mallet and punch.
Undo the screw (5) .
Remove the pin (6) .
Remove the brake pads (A) from the relative seats.
Refitting the front brake pads https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake pads Page 2 of 5
Tightening torque
Fastening central pin on front brake pads Screw
Further separate the calliper pistons with the tool (FACOM DF.6).
Nm
27 ÷ 33 Nm
Class
Fit the brake pads (A) in the relative seats.
Install the pin (6) .
Tighten the screw (5) .
0
Tightening torque
Screw
Nm Class
27 ÷ 33 Nm 0
Fit the lower pin (4) in the relative seat, tapping into place with a suitable mallet and punch.
Fit the spring (3) in the relative seat.
Fit the upper pin (2) in the relative seat, tapping into place with a suitable mallet and punch.
Sliding pad wear sensor cable inside rigid brake fluid pipe connected to brake calliper, tighten a new cable tie in the indicated point.
Sliding it under ABS sensor cable, connect pad wear sensor connector (1) , and secure it to the relative mounting bracket, so as it is pointing toward rear side.
Apply new cable ties in the positions indicated.
Refit the wheels ( D2.01
).
Reconnect the battery ( F2.01
).
In case of replacement only. Bed in the CCM pads ( D3.04
).
Removing the rear brake pads
Disconnect the battery ( F2.01
).
Remove the wheels ( D2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake pads
Remove the rear wheels.
Page 3 of 5
Disconnect the connector (1) for the brake pad wear sensor.
Cut the indicated clamps and remove the brake pad wear sensor cable from the retainers (2) .
Remove the pin (4) , tapping with a suitable punch and mallet.
Remove the spring (5) .
Remove the pin (6) , tapping with a suitable punch and mallet.
Remove the brake pads (A) .
Refitting the rear brake pads
Further separate the calliper pistons with the tool (FACOM DF.6). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake pads Page 4 of 5
Fit the pads (A) .
Install the pin (6) , tapping with a suitable punch and mallet.
Fit the spring (5) .
Install the pin (4) , tapping with a suitable punch and mallet.
Fit new clamps as indicated to fasten the brake pad wear sensor cable and fit the cable in the retainers (2) .
Connect the connector (1) for the brake pad wear sensor.
Refit the wheels ( D2.01
).
Reconnect the battery ( F2.01
).
In case of replacement only. Bed in the CCM pads ( D3.04
).
Bedding in CCM pads
The following procedure is applicable for both CCM1 and CCM2 brake systems and must be performed EACH
TIME the CCM brake pads and/or CCM brake discs are replaced.
For vehicles intended for ROAD use https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake pads Page 5 of 5
Brake 16 times from 80 Km/h to 20 Km/h with constant pressure on the brake pedal and without activating the ABS system.
Leave the brake system to cool for approximately 120 seconds .
Brake 16 times from 120 Km/h to 20 Km/h with constant pressure on the brake pedal and without activating the ABS system.
Leave the system to cool for 180 seconds .
The ABS system must be triggered during the last set of braking runs.
Brake AT LEAST 5 times from 120 Km/h to 0 Km/h (vehicle completely stopped), causing the ABS system to activate.
Allow the brake system to cool completely before using the vehicle again after the bedding-in procedure to ensure maximum braking efficacy.
As soon as you notice an increase in brake pedal travel, stop the car and wait for the brake system to cool completely.
For vehicles intended for TRACK use
Brake 16 times from 80 Km/h to 20 Km/h with constant pressure on the brake pedal and without activating the ABS system.
Leave the brake system to cool for approximately 120 seconds .
Brake 16 times from 120 Km/h to 20 Km/h with constant pressure on the brake pedal and without activating the ABS system.
Leave the system to cool for 180 seconds .
The ABS system must be triggered during the last set of braking runs.
Brake AT LEAST 5 times from 160 Km/h to 0 Km/h (vehicle completely stopped), causing the ABS system to activate.
Allow the brake system to cool completely before using the vehicle again after the bedding-in procedure to ensure maximum braking efficacy.
As soon as you notice an increase in brake pedal travel, stop the car and wait for the brake system to cool completely. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake callipers
Print Exit
Page 1 of 3
Removing the front brake callipers
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
Remove the wheels ( D2.01
).
Remove the front brake pads ( D3.04
).
Undo the union (1) for the rigid pipe on the calliper.
Undo the two screws (2) fastening the front brake calliper (A) .
Remove the front brake calliper (A) from the front suspension.
Refitting the front brake callipers
Tightening torque
Fastening brake calliper to hub carrier Screw
Fastening rigid brake fluid pipe to front brake calliper
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake callipers Page 2 of 3
Check that the calliper mating surfaces with the stub axle are clean, fit the brake calliper (A) to the disc and hand tighten the two screws (2) .
Tightening torque Nm Class
Fit the rigid pipe on the brake calliper, tightening the union (1) .
Tightening torque Nm Class
Refit the front brake pads ( D3.04
).
Fill and bleed the brake system ( D3.10
).
Refit the wheels ( D2.01
).
Removing the rear brake callipers
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
Remove the wheels ( D2.01
).
Remove the rear brake pads ( D3.04
).
Undo the union (1) for the flexible hose on the calliper.
Undo the two screws (2) fastening the calliper (A) .
Remove the calliper from the rear suspension.
Refitting the rear brake callipers https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake callipers Page 3 of 3
Tightening torque
Fastening brake calliper to hub carrier Screw
Fastening brake fluid hose to rear brake calliper Union
Nm Class
21.5 Nm A
Check that the calliper mating surfaces with the stub axle are clean, fit the calliper (A) to the disc and tighten the two screws (2) .
Tightening torque Nm Class
Fit the flexible hose onto the calliper and tighten the union (1) .
Tightening torque Nm Class
Refit the rear brake pads ( D3.04
).
Fill and bleed the brake system ( D3.10
).
Refit the wheels ( D2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
ABS/ASR electrohydraulic unit
Print Exit
Replacing the ABS/ASR electrohydraulic unit
Page 1 of 4
Tightening torque
Fastening electrohydraulic ABS/ASR unit to mounting bracket
Fastening electrohydraulic ABS/ASR unit mounting bracket to chassis
Fastening brake fluid pipe on the electrohydraulic
ABS/ASR unit
Fastening air duct on heater/evaporator unit inside luggage compartment
M10 - M12 union
Nm
16 Nm
The electrohydraulic ABS/ASR unit is located inside the luggage compartment to the right of the heater/evaporator unit.
Disconnect the battery ( F2.01
).
Remove the luggage compartment tub ( E4.07
).
Class
B
Remove the air duct (1) , undoing the screws indicated.
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8/5/2011
ABS/ASR electrohydraulic unit Page 2 of 4
Detach the brake fluid pipes, removing the indicated clips.
Detach the brake fluid pipes, removing the indicated clips.
Disconnect the connector (2) .
Take note of the pipes' position on the electrohydraulic ABS/ASR unit (3) so as to refit them correctly afterwards.
Undo all the unions indicated by the red arrows from the electrohydraulic ABS/ASR unit and place suitable plugs on the inlets.
Undo the indicated screws fastening the electrohydraulic ABS/ASR unit mounting bracket
(3) .
Move the brake fluid pipes to one side, taking particular care not to bend or twist them, then remove the electrohydraulic ABS/ASR unit (3) complete with mounting bracket. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
ABS/ASR electrohydraulic unit Page 3 of 4
On the workbench separate the electrohydraulic
ABS/ASR unit (3) from the relevant mounting bracket, undoing the indicated screws.
Check the state of the mounting bushings; replace if necessary.
Refit the electrohydraulic ABS/ASR unit (3) on the relevant mounting bracket, tightening the indicated screws.
Tightening torque Nm Class
Move the brake fluid pipes to one side, taking particular care not to bend or twist them, then fit the electrohydraulic ABS/ASR unit (3) complete with mounting bracket in the relevant seat.
Tighten the indicated screws fastening the electrohydraulic ABS/ASR unit mounting bracket
(3) .
Tightening torque Nm Class
Remove the plugs positioned previously.
Fit and hand tighten the unions indicated by the red arrows on the electrohydraulic ABS/ASR unit, using the markings made during removal as reference.
Tighten the unions indicated by the red arrows on the electrohydraulic ABS/ASR unit.
Tightening torque
M10 - M12 union
Connect the connector (2) .
Nm
16 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
ABS/ASR electrohydraulic unit Page 4 of 4
Fasten the brake fluid pipes by placing the indicated clips.
Fasten the brake fluid pipes by placing the indicated clips.
Fit and fasten the air duct (1) by tightening the screws indicated.
Tightening torque Nm Class
Refit the luggage compartment tub ( E4.07
).
Reconnect the battery ( F2.01
).
Always perform a complete operating cycle after replacing the electrohydraulic ABS/ASR unit. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 1 of 17
Print Exit
D3.07 EPB electric parking brake
the parking brake is engaged and released with the specific control on the dashboard, to the left of the steering wheel; the brake is actuated by an electric motor; the brake engages automatically when the engine is switched off (Autohold function); it may be used as an emergency brake with the vehicle in motion. In this case, the system applies the brakes to all four wheels for as long as the button is kept pressed, dialoguing with the ESP stability control system, which prevents wheel lockup; ensures optimised brake release dynamics for hill starts with the Automatic Vehicle Holding (AVH) function: when certain conditions are met, the system keeps the vehicle braked by releasing the brake shoes and callipers at different times, allowing the driver enough time to move the foot from the brake to the accelerator without the vehicle rolling backwards.
EPB parking brake system layout https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake
A - ECU
B - Equaliser bracket
C - Bowden cables
D - Shoes
Disabling the EPB electric parking brake Autohold function
Page 2 of 17
The EPB electric parking brake is engaged automatically at each Key-off, as the Autohold function is always enabled by default.
The following procedure disables the Autohold function to impede automatic engagement of the EPB electric parking brake at Key-off: no maintenance is possible on the components of the EPB system while the EPB electric parking brake is engaged, as a result, this procedure is necessary before carrying out any work involving the components of the EPB electric parking brake.
The Autohold function will resume normal operation at the next Key-on, and the EPB electric parking brake will therefore be automatically engaged at the next Key-off.
Open the driver side door.
Depress and hold the brake pedal.
Turn the ignition key to II (Key-ON).
Pull the EPB electric parking brake control lever (A) .
Wait until the respective indicator light on the instrument panel extinguishes. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake
Press the AUTO PARK button (B) .
Page 3 of 17
Wait for the specific message "PARK OFF" to appear on the TFT display.
Turn the ignition key to 0 (Key-OFF).
Emergency EPB electric parking brake release procedure
CAUTION
When the electric parking brake is deactivated manually, the vehicle may move unexpectedly!
The vehicle is held in position only by the Park Lock safety device, if engaged.
To hold the vehicle, the Park Lock safety system must be engaged: ensure that the letter "P" is shown on the gearbox display.
If the electric parking brake cannot be released due to a flat battery or a failure of the electrical system controlling the function and the vehicle must be moved, carry out the following emergency release procedure.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 4 of 17
Remove the articulated wrench, p/n 261346 , for releasing the electric parking brake, from the tool bag.
Fit the articulated wrench, p/n 261346 , into the relative hole underneath the slotted cap (1) on the right hand rear wheelhouse, and turn clockwise to loosen the parking brake cables completely and release the grip of the shoes on the rear discs.
The wrench must be turned approximately 50 times to completely release the parking brake; the brake will begin to release after approximately 20 turns.
After manually releasing the electric parking brake, at the subsequent Key-on, the EPB node registers a "fault" and the symbol shown aside is displayed on the left hand TFT display, together with the message "Parking Brake system revision. Go to dealer”.
CAUTION
For safety reasons, it is IMPERATIVE that the following indications are followed correctly.
The parking brake will return to normal functionality, however, the vehicle must still be taken to a Ferrari service centre to calibrate the system and delete any errors from the failure memory. The system must be calibrated for safety reasons.
Removing the EPB electric parking brake shoes
The following procedure is for removing the rear right hand wheel brake shoes.
With the exception of the specific steps indicated, the procedure for removing the rear left hand wheel brake shoes is the same. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 5 of 17
Disable the EPB electric parking brake Autohold function ( D3.07
).
Remove the wheels ( D2.01
).
Remove the rear ones.
Remove the brake discs ( D3.03
).
Remove the rear ones.
Remove the rear bumper ( E3.04
).
Use a suitable screwdriver to prise the clip (1) off the EPB linkage bracket (A) .
Detach the end (2) of the left hand EPB Bowden cable (D) from the EPB linkage bracket (A) .
Press on the two indicated fastener tabs and remove the left hand EPB Bowden cable sheath
(D) from the relevant mounting bracket.
For the rear right hand brake shoes only
Move the EPB equaliser (C) to the right.
Remove the safety pin (14) .
Detach the end (3) of the right hand EPB Bowden cable (B) from the EPB equaliser (C) .
Press on the two indicated fastener tabs and remove the right hand EPB Bowden cable sheath (B) from the relevant mounting bracket.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 6 of 17
Detach the cable grommet (4) from the bracket on the right hand EPB Bowden cable sheath (B) .
Undo the nut (5) fastening the ground cable onto the bracket on the right hand EPB Bowden cable sheath (B) .
Undo the indicated screw fastening the right hand
EPB Bowden cable sheath (B) onto the rear right hand hub carrier.
Detach the eyebolt (6) on the right hand EPB
Bowden cable (B) from the fork (7) inside the hub carrier.
Release the spring (8) and recover the adjuster pin
(9) .
Do not disassemble the adjuster pin or alter its setting to ensure that the shoes are refitted in their original positions.
Remove the upper spring (10) by pushing towards the brake shoes and then turning.
Remove the lower spring (11) by pushing towards the brake shoes and then turning. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 7 of 17
Release the spring (12) and remove the brake shoes (E) , taking care not to shift the linkage pins (13) .
Refitting the EPB electric parking brake shoes
Tightening torque Nm Class
Fastening EPB Bowden cable - rear hub carrier B
Fastening brake pad sensor ground cable Nut 6 Nm B
Fit the linkage (13) correctly and install the brake shoes (E) in the respective seats, with the spring
(12) already attached to one of the shoes.
Using suitable pliers, attach the spring (12) to the other shoe (E) .
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 8 of 17
Fit the lower spring (11) in the respective seat, pushing towards the brake shoes and then turning the spring.
Fit the upper spring (10) in the respective seat, pushing towards the brake shoes and then turning the spring.
Fit the adjuster pin (9) in its seat.
Attach the spring (8) to both brake shoes.
Check that there is a sufficient gap between the outer surfaces of the shoes to install the brake disc without scuffing.
If the gap is insufficient, to adjust the gap between the outer surfaces of the shoes and allow installation of the brake disc without friction, turn the toothed sleeve on the adjuster pin (9) using a suitable screwdriver.
Attach the eyebolt (6) on the right hand EPB
Bowden cable (B) to the fork (7) inside the hub carrier.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 9 of 17
Tighten the indicated screw fastening the right hand
EPB Bowden cable sheath (B) onto the rear right hand hub carrier.
Tightening torque Nm Class
Tighten the nut (5) fastening the ground cable onto the bracket on the right hand EPB Bowden cable sheath (B) .
Tightening torque Nm Class
Attach the cable grommet (4) to the bracket on the right hand EPB Bowden cable sheath (B) .
For the right hand parking brake cable only
Press on the two indicated fastener tabs and fit the right hand EPB Bowden cable sheath (B) into the relative mounting bracket.
Attach the end (3) of the right hand EPB Bowden cable (B) to the EPB equaliser (C) .
Fit the safety pin (14) .
Move the EPB equaliser (C) to the left. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 10 of 17
Press on the two indicated fastener tabs and fit the left hand EPB Bowden cable sheath (D) into the relevant mounting bracket.
Attach the end (2) of the left hand EPB Bowden cable (D) to the EPB linkage bracket (A) .
Refit the clip (1) in the relevant seat on the EPB linkage bracket (A) .
Refit the brake discs ( D3.03
).
Check that the disc rotates freely without impediment. If not, adjust the adjuster pin to achieve the optimum position.
Adjustment is also possible with the disc installed, inserting a screwdriver through the holes (F) .
Turn the adjuster pin to separate the brake shoes until a slight resistance is felt; then turn the toothed sleeve by one turn in the opposite direction to close them slightly.
Adjust the EPB electric parking brake ( D3.07
).
Refit the rear bumper ( E3.04
).
Refit the wheels ( D2.01
).
Replacing the EPB electric parking brake Bowden cables
Tightening torque Nm Class
Fastening EPB Bowden cable - rear hub carrier B
Fastening brake pad sensor ground cable Nut 6 Nm B
Disable the EPB electric parking brake Autohold function ( D3.07
).
Remove the rear bumper ( E3.04
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake
Left hand EPB Bowden cable
Page 11 of 17
Use a suitable screwdriver to prise the clip (1) off the EPB linkage bracket (A) .
Detach the end (2) of the left hand EPB Bowden cable (D) from the EPB linkage bracket (A) .
Press on the two indicated fastener tabs and remove the left hand EPB Bowden cable sheath
(D) from the relative mounting bracket.
Remove the indicated clamp retaining the left hand
EPB Bowden cable (D) .
Remove the indicated clamp retaining the left hand
EPB Bowden cable (D) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 12 of 17
Detach the cable grommet (4) from the bracket.
Undo the nut (6) fastening the ground cable.
Undo the indicated screw fastening the left hand
EPB Bowden cable sheath (D) onto the hub carrier.
Detach the eyebolt (8) on the left hand EPB
Bowden cable (D) from the fork (9) inside the hub carrier.
Remove the left hand EPB Bowden cable (D) from the respective seat and replace.
Fit the new left hand EPB Bowden cable (D) in the respective sheath.
Fasten the eyebolt (8) on the left hand EPB Bowden cable (D) onto the fork (9) inside the hub carrier.
Tighten the indicated screw fastening the left hand
EPB Bowden cable sheath (D) onto the hub carrier.
Tightening torque Nm Class
Tighten the nut (6) fastening the ground cable to the bracket.
Tightening torque Nm Class
Attach the cable grommet (4) onto the bracket. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 13 of 17
Fasten the indicated clamp retaining the left hand
EPB Bowden cable (D) .
Fasten the indicated clamp retaining the left hand
EPB Bowden cable (D) .
Press on the two indicated fastener tabs and fit the left hand EPB Bowden cable sheath (D) into the relative mounting bracket.
Attach the end (2) of the left hand EPB Bowden cable (D) to the EPB linkage bracket (A) .
Refit the clip (1) onto the EPB linkage bracket.
Right hand EPB Bowden cable https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 14 of 17
Remove the safety pin (14) .
Detach the end (3) of the right hand EPB Bowden cable (B) from the EPB equaliser (C) .
Press on the two indicated fastener tabs and remove the right hand EPB Bowden cable sheath (B) from the relative mounting bracket.
Undo the indicated screw.
Unscrew the stud bolt (17) retaining the right hand
EPB Bowden cable (B) .
Remove the indicated clamp retaining the right hand EPB Bowden cable (B) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 15 of 17
Detach the cable grommet (4) from the bracket.
Undo the nut (6) fastening the ground cable.
Undo the indicated screw fastening the right hand
EPB Bowden cable sheath (B) onto the hub carrier.
Detach the eyebolt (8) on the right hand EPB
Bowden cable (B) from the fork (9) inside the hub carrier.
Remove the right hand EPB Bowden cable (B) from the respective seat and replace.
Fit the new right hand EPB Bowden cable (B) in the respective sheath.
Attach the eyebolt (8) on the right hand EPB
Bowden cable (B) to the fork (9) inside the hub carrier.
Tighten the indicated screw fastening the right hand
EPB Bowden cable sheath (B) onto the hub carrier.
Tightening torque Nm Class
Tighten the nut (6) fastening the ground cable to the bracket.
Tightening torque Nm Class
Attach the cable grommet (4) onto the bracket. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 16 of 17
Fasten the indicated clamp retaining the right hand
EPB Bowden cable (B) .
Fasten the right hand EPB Bowden cable (B) by tightening the stud bolt (17) .
Tighten the indicated screw fastening the EPB control unit Bowden cable.
Press on the two indicated fastener tabs and fit the right hand EPB Bowden cable sheath (B) into the relative mounting bracket.
Attach the end (3) of the right hand EPB Bowden cable (B) to the EPB equaliser (C) .
Fit the safety pin (14) .
Refit the rear bumper ( E3.04
).
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Carry out the EPB Calibration procedure. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
EPB electric parking brake Page 17 of 17
Adjusting the EPB electric parking brake
After replacing the EPB brake shoes, the parking brake must be adjusted correctly with the following procedure.
Insert a suitably sized screwdriver into the slot (A) on the rear disc.
Using the screwdriver inserted previously, turn the sleeve (B) to lock the disc.
Turn the sleeve (B) in the opposite direction until the disc turns freely.
Turn the ignition key to "II" .
Engage the EPB electric parking brake by pulling the electric parking brake control lever (1) .
Check that the rear discs are locked in this state.
Disengage the EPB electric parking brake by pulling the electric parking brake control lever (1) again.
Check that the rear discs turn freely in this state.
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Carry out the procedure for Calibrating the EPB and Bedding in the EPB . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake servo - Pump
Print Exit
D3.08 Brake servo - Pump
Removing the brake servo
Page 1 of 4
Remove the windscreen wiper linkage ( E3.09
).
Remove the antitheft system siren ( F4.01
).
Open the indicated retainer on the pipes (1) .
Undo the screws indicated.
Move the complete TGK valves (2) aside as far as possible, without disconnecting the pipes from the system.
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8/5/2011
Brake servo - Pump Page 2 of 4
Some brake fluid may leak when detaching the unions from the master brake cylinder; ensure that the oil does not come into contact with surrounding parts.
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
Unscrew the unions (2) on the brake pump.
Move the pipes (1) as far away as possible from the brake pump, taking care not to bend or twist them, so that they do not hinder the subsequent operations.
Detach the vacuum pipe (4) from the brake servo
(A) .
Remove the indicated clamps and disconnect the pipes (3) .
Working from underneath the driver side of the dashboard, detach the brake servo linkage (6) , removing the retainer clip (5) .
Undo the four indicated nuts fastening the brake servo (A) to the pedal board.
Remove the brake servo (A) , complete with pump, from the luggage compartment.
Refit the retainer clip (5) in its relative seat on the brake servo (A) .
Refitting the brake servo
Tightening torque
Fastening brake servo - pedal board Nut
Fastening oil pipe unions to brake pump Union
Fastening TGK valve mounting bracket to chassis Screw
Nm
20 Nm
16 Nm
8 Nm
Class
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake servo - Pump Page 3 of 4
Ensure that the retainer clip (5) is installed correctly on the brake servo.
Working from the luggage compartment, fit the brake servo (A) , complete with pump, in the relative seat on the firewall.
Working from underneath the driver side of the dashboard, align the linkage (6) in the relative seat on the brake servo (A) .
Tighten the four nuts indicated in a cross pattern.
Tightening torque Nm Class
Depress the brake pedal fully to engage the linkage
(6) onto the brake servo (A) .
Release the brake pedal and ensure that it is effectively attached to the linkage.
The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water.
Brake fluid may also damage paintwork.
Fit the unions (2) for the pipes (1) in the respective seats on the pump and tighten.
Tightening torque Nm Class
Connect the vacuum pipe (4) to the brake servo (A) .
Connect the pipes (3) to the brake pump and fasten with the indicated clamps. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Brake servo - Pump Page 4 of 4
Fit the complete TGK valves (2) in the relative seat.
Hand tighten the screws indicated.
Tightening torque Nm Class
Fasten the rigid pipes (1) by closing the indicated clamp.
Refit the antitheft system siren ( F4.01
).
Refit the windscreen wiper linkage ( E3.09
).
Fill and bleed the brake system ( D3.10
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Pedal board
Print Exit
Removing the pedal board
Disconnect the battery ( F2.01
).
Remove the complete dashboard ( E4.02
).
Page 1 of 5
Working from underneath the driver side of the dashboard, detach the brake servo linkage (6) , removing the retainer clip (5) .
Undo the four indicated nuts fastening the brake servo (A) to the pedal board.
Refit the retainer clip (5) in its relative seat on the brake servo (A) .
Disconnect the connector (10) from the brake pedal stop light switch.
Undo the indicated upper screw.
Remove the pedal board (B) .
Refitting the pedal board https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Pedal board Page 2 of 5
Tightening torque
Fastening brake servo - pedal board
Fastening pedal board to firewall
Nut
Screw
Nm
20 Nm
20 Nm
Class
B
B
Fit the pedal board (B) in the relative seat in the passenger compartment, hand-tightening all the indicated fasteners.
Tighten the five indicated fasteners (four nuts fastening to the brake servo and one screw fastening to the firewall) in the sequence given in the image aside.
Tightening torque Nm Class
Connect the connector (1) to the brake pedal stop light switch.
Ensure that the retainer clip (5) is fitted correctly on the brake servo (A) .
Depress the brake pedal fully to engage the linkage
(6) onto the brake servo.
Release the brake pedal and ensure that it is effectively attached to the linkage.
Refit the complete dashboard ( E4.02
).
Reconnect the battery ( F2.01
).
Replacing the brake pedal switch
Tightening torque
Fastening AC unit air ducts Screw
Nm
8 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Pedal board Page 3 of 5
Tightening torque Nm Class
In some of the following photographs, the dashboard has been removed from the passenger compartment to illustrate the procedure more clearly.
Disconnect the battery ( F2.01
).
Remove the mats ( E4.05
).
Remove the driver side underdashboard mat.
Undo the screws indicated.
Remove the air duct (1) .
Disconnect the connector (2) .
Keep the brake pedal depressed.
Turn the switch (A) clockwise then ease out of its relative mounting on the pedal board.
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8/5/2011
Pedal board Page 4 of 5
Extend the pin (3) on the new switch completely.
New switches are supplied with the pin in an intermediate position and not fully extended.
Keep the brake pedal depressed.
Fit the new switch (A) fully into the relative seat.
Note that the mounting shown in the photo aside is an example only and is not the specific part for the vehicle.
Turn the switch (A) counterclockwise by approximately 90° until the retainer tang locks into place.
Note that the mounting shown in the photo aside is an example only and is not the specific part for the vehicle.
Ensure that it is securely fastened. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Pedal board Page 5 of 5
Place a 1 mm thick shim (4) between the brake pedal (5) and the pin on the switch (A) .
Release the brake pedal so that it presses against the pin on the switch, allowing the pin to selfadjust.
Remove the shim (4) .
Connect the connector (2) .
Fit the air duct (1) .
Tighten the screws indicated.
Tightening torque Nm Class
Refit the mats ( E4.05
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D30...
8/5/2011
Filling and bleeding the brake system
Print Exit
D3.10 Filling and bleeding the brake system
Filling and bleeding the brake system
Page 1 of 3
Tightening torque
Fastening bleed unions - brake callipers
Remove the wheels ( D2.01
).
Union
Nm
17 ÷ 20 Nm
Class
0
Open and close the cover VERY CAREFULLY, as the fastener tabs are particularly fragile.
Remove the cover (A) from the right hand underwindscreen shield to access the brake fluid reservoir cap, prising off at the position indicated by the arrow.
Undo the cap (B) from the brake fluid reservoir. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D31...
8/5/2011
Filling and bleeding the brake system Page 2 of 3
Always use fresh oil of the recommended type and in the quantity indicated, taken from sealed containers.
The circuit is filled with synthetic oil.
Using mineral oil may cause irreparable damage to the rubber seals in the system.
Fill the reservoir, bearing in mind that the level in the reservoir must never drop below the MIN limit when bleeding the brake system.
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
"Electronic" brake system bleeding must be performed on one calliper at a time using the DEIS diagnostic tester. Use the specific function, following the relative instructions.
Detach the relative protective caps and undo the bleed unions (2) on the brake calliper (C) .
Connect a suitable transparent pipe to the bleed unions (2) .
Immerse the end of the pipes in a container filled with brake fluid.
Control the pulse sequence with the DEIS diagnostic tester and depress the brake pedal to pressurise the circuit until all the air is bled from the circuit.
Disconnect the transparent pipe from the bleed unions (2) .
Tighten the bleed unions (2) and fit the relative protective caps.
Tightening torque
Union
Nm Class
17 ÷ 20 Nm 0 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D31...
8/5/2011
Filling and bleeding the brake system Page 3 of 3
Always use fresh oil of the recommended type and in the quantity indicated, taken from sealed containers.
The circuit is filled with synthetic oil.
Using mineral oil may cause irreparable damage to the rubber seals in the system.
Fill the brake fluid reservoir to the MAX level.
Tighten the cap (B) firmly onto the brake fluid reservoir.
Open and close the cover VERY CAREFULLY, as the fastener tabs are particularly fragile.
Fit the cover (A) onto the right hand underwindscreen shield, inserting the rear tabs in the respective seats first and then the front tabs.
After the procedure, there must be no sponginess notable in the brake pedal and the braking action must be progressive, starting immediately after a short free play.
Refit the wheels ( D2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D31...
8/5/2011
Complete suspension
Print Exit
Page 1 of 25
Removing complete front suspension
The following procedure is for the removal of the right hand front suspension.
The procedure for removing the left hand front suspension is the same.
Note that in some of the following images the vehicle is shown with the wheelhouse and the front flat undertray section removed. However, removal of these components is not necessary.
Remove the luggage compartment cosmetic shields ( E4.07
).
Disconnect the battery ( F2.01
).
Remove the wheels ( D2.01
).
Undo the nut (1) fastening the steering box tie-rod
(A) to the hub carrier.
Undo the nut (2) fastening the stabiliser bar (B) to the spherical tie-rod.
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8/5/2011
Complete suspension Page 2 of 25
Disconnect the connector (3) from the shock absorber.
Disconnect connector (4) of ABS sensor, and detach it from the relevant mounting bracket.
Disconnect connector (5) of brake pad wear sensor, and detach it from the relevant mounting bracket.
Detach the cable grommet (6) from the relevant mounting bracket.
Disconnect ground cable from the indicated clip.
Undo the nut (7) fastening the ground cable. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 3 of 25
Undo the brake fluid hose union (10) .
Remove the clip (11) fastening the union (12) for the brake fluid hose onto the relative mounting bracket.
Remove the union (12) for the brake fluid hose from the relative mounting bracket.
Only for vehicles with "Front Lift" system
Undo the lift system fluid hose union (13) .
Remove the clip (14) fastening the union (15) for the lift system fluid hose onto the relative mounting bracket.
Remove the union (15) for the lift system fluid hose from the relative mounting bracket.
Using a delible yellow marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the lower arm. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 4 of 25
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the four nuts fastening the lower arm (C) , retrieving the four shims (8) , in the following order: (a) , (b) , (c) , (d) .
Check that the yellow reference markings are correctly aligned: the marking on the threaded rods and the marking on the Flanbloc eyebolts must be aligned.
Only the nut must turn, the threaded rod must remain in its original position.
If the markings on the threaded rods and eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk.
If the markings on the threaded rods and eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the four arm fastener nuts in the order given for the previous operation.
Check again that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
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8/5/2011
Complete suspension Page 5 of 25
Support the weight of the suspension adequately.
DO NOT use lubricants or electric/pneumatic drivers.
Undo the two screws fastening the shock absorber
(D) to the chassis.
Using a delible yellow marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Detach the tie-rod (9) for the NRRPS motion sensor from the upper arm (E) .
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the four nuts indicated fastening the upper arm (E) in the following order: (a) , (b) , (c) ,
(d) .
Move the shock absorber aside to facilitate the operation. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 6 of 25
Check that the yellow reference markings are correctly aligned: the marking on the threaded rods and the marking on the Flanbloc eyebolts must be aligned.
If the markings on the threaded rods and eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk.
If the markings on the threaded rods and eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the four arm fastener nuts in the order given for the previous operation.
Move the shock absorber aside to facilitate the operation.
Check again that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
Remove the complete suspension from its seat, retrieving the four washers of upper lever stud bolts.
Refitting complete front suspension
Tightening torque
Fastening upper arm to chassis
Fastening shock absorber to chassis
Fastening lower arm to chassis
Fastening brake pad sensor ground cable
Fastening vehicle lift system unions
Nut (pretightening)
Screw
Nut (pretightening)
Nut
Union
Nm
9 Nm
110 Nm
9 Nm
6 Nm
16 Nm
Class
A
A
A
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 7 of 25
Tightening torque
Fastening brake pipe union or connection
Fastening front stabiliser bar to tie-rod
Fastening steering box tie-rod to hub carrier
M10 union
Nut
Nut
The following procedure is for refitting of right hand front suspension.
Nm
16 Nm
50 Nm
40 Nm
Class
B
B
B
The procedure for refitting the left hand front suspension is the same.
Note that in some of the following images the vehicle is shown with the wheelhouse and the front flat undertray section removed. However, removal of these components is not necessary.
Position the four washers onto upper arm stud bolts, and position the complete suspension inside its seat, supporting its weight adequately.
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the four nuts indicated fastening the upper arm (E) in the following tightening order: (a) , (b) ,
(c) , (d) .
Move the shock absorber aside to facilitate the operation.
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
A
Attach the tie-rod (9) for the NRRPS motion sensor to the upper arm (E) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 8 of 25
Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Tighten the two screws indicated fastening the shock absorber (D) to the chassis.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 9 of 25
Fit the four shims (8) in the relevant seats, pushing down completely onto the threaded rods and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs.
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the four nuts indicated fastening the lower arm (C) in the following tightening order: (a) , (b) ,
(c) , (d) .
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
A
Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
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8/5/2011
Complete suspension Page 10 of 25
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the lower arm.
Tighten the nut (7) fastening the ground cable.
Tightening torque Nm Class
Only for vehicles with "Front Lift" system
Fit the union (15) for the lift system fluid hose onto the relative mounting bracket.
Refit the clip (14) fastening the union (15) for the lift system fluid hose onto the relative mounting bracket.
Tighten the lift system fluid hose union (13) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 11 of 25
Fit the union (12) for the brake fluid hose onto the relevant mounting bracket.
Refit the clip (11) fastening the union (12) for the brake fluid hose onto the relative mounting bracket.
Tighten the brake fluid hose union (10) .
Tightening torque
M10 union
Nm
16 Nm
Class
B
Attach the cable grommet (6) onto the relative mounting bracket.
Connect pad wear sensor connector (5) , and attach it to the relevant mounting bracket so as it is pointing back.
Slide connector (4) of ABS sensor above brake pad wear sensor cable, connect it, and attach it to the relative mounting bracket.
Check that the indicated clip is positioned at 50 - 60 mm from cable grommet (6) .
Connect ground cable to the indicated clip.
Connect the connector (3) to the shock absorber. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 12 of 25
Tighten the nut (2) fastening the stabiliser bar (B) .
Tightening torque Nm Class
Pre-tighten the nut (1) fastening the steering box tierod (A) .
Tightening torque Nm
Loosen the nut (1) then tighten again.
Class
Tightening torque
Refit the wheels ( D2.01
).
Reconnect the battery ( F2.01
).
Refit the luggage compartment cosmetic shields ( E4.07
).
Fill and bleed the brake system ( D3.10
).
Only for vehicles with "Front Lift" system. Fill and bleed the "Front Lift" system ( D4.08
).
Perform the vehicle set-up procedure ( A3.22
).
Removing complete rear suspension
The following procedure is for removing the right hand rear suspension.
The process for removing the left hand rear suspension is identical.
Disable the EPB electric parking brake Autohold function ( D3.07
).
Disconnect the battery ( F2.01
).
Remove the rear flat undertray section ( E3.12
).
Remove the rear wheelhouses ( E3.05
).
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 13 of 25
Remove the rear element of the rear wheelhouse.
Detach the tie-rod (1) for the NRRPS motion sensor from the lower arm.
Disconnect the connector (2) for the brake pad wear sensor.
Disconnect the connector (3) for the ABS sensor.
Detach the cable grommet (4) from the relevant mounting bracket.
Cut the cable tie (5) for retaining cables.
Detach the cable grommet (6) from the relevant bracket on the EPB Bowden cable sheath (8) .
Undo the nut (7) fastening the ground cable onto the bracket on the EPB Bowden cable sheath (8) .
Undo the indicated screw fastening the EPB
Bowden cable sheath (8) onto the hub carrier.
Detach the eyebolt on the EPB Bowden cable from the relevant fork inside the hub carrier.
Remove and retrieve the clip (9) fastening the union for the brake fluid hose (11) onto the relevant mounting bracket.
Undo the brake fluid hose union (10) .
Extract the brake fluid hose (11) from the relevant mounting bracket.
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8/5/2011
Complete suspension Page 14 of 25
Undo the six screws (12) fastening the axle shaft
(A) to the differential flange and retrieve the three spacers (13) .
Disconnect the connector (14) from the shock absorber (B) .
Support the weight of the complete suspension adequately.
Undo the two screws indicated fastening the shock absorber (B) to the chassis.
Using a delible yellow marker pen or paint, make reference markings on the threaded bolts and relative nuts and the eyebolts fastening the toein tie-rod.
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8/5/2011
Complete suspension Page 15 of 25
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the two nuts indicated fastening the toe-in tie-rod (C) to the chassis.
Check that the yellow reference markings are correctly aligned: the marking on the threaded rods and the marking on the eyebolts must be aligned.
Only the nut must turn, the threaded rod must remain in its original position.
If the markings on the threaded rods and eyebolts are not correctly aligned after loosening the toein tie rod fastener nuts (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help
Desk.
If the markings on the threaded rods and eyebolts are correctly aligned after loosening the toe-in tierod fastener nuts, completely undo and remove the two toe-in tie-rod fastener nuts in the order given for the previous operation.
Check again that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the eyebolts must be aligned.
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8/5/2011
Complete suspension Page 16 of 25
Using a delible yellow marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Undo the nut indicated fastening the stabiliser bar
(D) to the spherical tie-rod.
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the two nuts indicated fastening the upper arm (E) to the chassis. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 17 of 25
Check that the yellow reference markings are correctly aligned: the marking on the threaded rods and the marking on the Flanbloc eyebolts must be aligned.
If the markings on the threaded rods and Flanbloc eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help
Desk.
If the markings on the threaded rods and Flanbloc eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the two arm fastener nuts in the order given for the previous operation.
Check again that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
Using a delible yellow marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the lower arm. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 18 of 25
Detach the tie-rod (15) for the NRRPS motion sensor from the lower arm (F) .
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the four nuts indicated fastening the lower arm (F) to the chassis, retrieving the four shims (16) , in the following order: (a) , (b) , (c) , (d) .
Check that the yellow reference markings are correctly aligned: the marking on the threaded rods and the marking on the Flanbloc eyebolts must be aligned.
Only the nut must turn, the threaded rod must remain in its original position.
If the markings on the threaded rods and Flanbloc eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help
Desk.
If the markings on the threaded rods and Flanbloc eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the four arm fastener nuts in the order given for the previous operation.
Check again that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
Remove the complete rear suspension from the vehicle, retrieving the two washers of upper lever stud bolts. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension
Refitting complete rear suspension
Page 19 of 25
Tightening torque
Fastening lower arm to chassis
Fastening upper arm to chassis
Fastening rear stabiliser bar to tie-rod
Fastening toe-in tie-rod to chassis
Nut (pretightening)
Nut (pretightening)
Nut
Nut (pretightening)
Nm
9 Nm
9 Nm
50 Nm
9 Nm
Class
B
B
B
B
Fastening shock absorber to chassis
Fastening axle shaft to differential flange
Screw
Screw
110 Nm
78 Nm
A
A
Fastening brake pipe union or connection M10 union 16 Nm B
Fastening EPB Bowden cable - rear hub carrier B
Fastening brake pad sensor ground cable Nut 6 Nm B
The following procedure is for refitting the right hand rear suspension.
The process for refitting the left hand rear suspension is identical.
Position the two washers onto upper lever stud bolts, and then position the rear suspension inside the relative seat, supporting its weight adequately.
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8/5/2011
Complete suspension Page 20 of 25
Fit the four shims (16) in the relevant seats, pushing down completely onto the threaded rods and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs.
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the four nuts indicated fastening the lower arm (F) to the chassis in the following tightening order: (a) , (b) , (c) , (d) .
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B
Attach the tie-rod (15) for the NRRPS motion sensor onto the lower arm (F) .
Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
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8/5/2011
Complete suspension Page 21 of 25
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the lower arm.
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the two nuts indicated fastening the upper arm (E) to the chassis.
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B
Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned.
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8/5/2011
Complete suspension Page 22 of 25
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Tighten the nut indicated fastening the stabiliser bar
(D) to the spherical tie-rod.
Tightening torque Nm Class
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the two nuts indicated fastening the toe-in tie-rod (C) to the chassis.
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 23 of 25
Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the eyebolts must be aligned.
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the threaded rods and the relative nuts and eyebolts fastening the toe-in tierod.
Tighten the two screws indicated fastening the shock absorber (B) to the chassis.
Tighten in a crossed pattern.
Tightening torque Nm Class
Connect the connector (14) to the shock absorber
(B) .
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 24 of 25
Refit the three spacers (13) and tighten the six screws (12) fastening the axle shaft (A) to the differential flange.
Tightening torque Nm Class
Insert the brake fluid hose (11) into the relevant mounting bracket.
Tighten the brake fluid hose union (10) .
Tightening torque
M10 union
Nm
16 Nm
Class
B
Refit the clip (9) fastening the union for the brake fluid hose (11) onto the relevant mounting bracket.
Attach the eyebolt on the EPB Bowden cable to the relevant fork inside the hub carrier. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Complete suspension Page 25 of 25
Tighten the indicated screw fastening the EPB
Bowden cable sheath (8) .
Tightening torque Nm Class
Tighten the nut (7) fastening the ground cable onto the bracket on the EPB Bowden cable sheath (8) .
Tightening torque Nm Class
Attach the cable grommet (6) to the relative bracket on the EPB Bowden cable sheath (8) .
Fit a new cable tie (5) for retaining cables.
Attach the cable grommet (4) onto the relative mounting bracket.
Connect the connector (2) for the brake pad wear sensor.
Connect the connector (3) for the ABS sensor.
Attach the tie-rod (1) for the NRRPS motion sensor onto the lower arm.
Refit the rear wheelhouses ( E3.05
).
Refit the rear flat undertray section ( E3.12
).
Reconnect the battery ( F2.01
).
Fill and bleed the brake system ( D3.10
).
Perform the vehicle set-up procedure ( A3.22
).
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Carry out the EPB Calibration procedure. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms
Print Exit
Removing front suspension upper arms
The replacement arm is supplied complete with Flanbloc and ball joint.
The following procedure is for removing the right hand front suspension upper arm.
The procedure for removing the left hand front suspension upper arm is the same.
Page 1 of 24
Remove the luggage compartment cosmetic shields ( E4.07
).
Disconnect the battery ( F2.01
).
Remove the wheels ( D2.01
).
Disconnect the connector (1) from the shock absorber.
Support the weight of the suspension adequately.
DO NOT use lubricants or electric/pneumatic drivers.
Undo the two screws fastening the shock absorber
(A) to the chassis.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 2 of 24
Using a delible yellow marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Detach the tie-rod for the NRRPS motion sensor (2) from the upper arm (B) .
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the four nuts indicated fastening the upper arm (B) in the following order: (a) , (b) , (c) ,
(d) .
Move the shock absorber aside to facilitate the operation.
Check that the yellow reference markings are correctly aligned: the marking on the stud bolts and the marking on the Flanbloc eyebolts must be aligned.
If the markings on the stud bolts and eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one stud bolt), a
ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk.
If the markings on the stud bolts and eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the four arm fastener nuts in the order given for the previous operation.
Move the shock absorber aside to facilitate the operation. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 3 of 24
Check again that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Undo the nut (3) fastening the upper arm (B) to the hub carrier (C) , retrieving the relevant washer.
Remove upper lever (B) of front suspension from the relative seat, retrieving the four washers from the relative stud bolts.
Refitting front suspension upper arms
Tightening torque
Fastening upper arm to hub carrier
Fastening upper arm to chassis
Nut
Nut (pretightening)
Nm
52 Nm
9 Nm
Fastening shock absorber to chassis Screw
The replacement arm is supplied complete with Flanbloc and ball joint.
The following procedure is for refitting the right hand front suspension upper arm.
The procedure for refitting the left hand front suspension upper arm is the same.
Clean any traces of grease from the ball stud.
110 Nm
Class
B
B
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 4 of 24
Position the four washers onto the relative stud bolts and upper lever (B) of front suspension into the relative seats.
Hand tighten the nut (3) , fitting the relevant washer, fastening the upper arm (B) to the hub carrier
(C) and pretighten.
Tightening torque Nm
Loosen the nut (3) and then tighten.
Class
Tightening torque Nm Class
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the four nuts indicated fastening the upper arm (B) in the following tightening order: (a) , (b) ,
(c) , (d) .
Move the shock absorber aside to facilitate the operation.
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B
Attach the tie-rod for the NRRPS motion sensor (2) to the upper arm (B) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 5 of 24
Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Tighten the two screws indicated fastening the shock absorber (A) to the chassis.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 6 of 24
Connect the connector (1) to the shock absorber.
Refit the wheels ( D2.01
).
Reconnect the battery ( F2.01
).
Refit the luggage compartment cosmetic shields ( E4.07
).
Perform the vehicle set-up procedure ( A3.22
).
Removing front suspension lower arms
The replacement arm is supplied complete with Flanbloc and ball joint.
The following procedure is for removing the lower front right hand suspension arm.
The procedure for removing the lower front right hand suspension arm is the same.
Note that in some of the following images the vehicle is shown with the wheelhouse and the front flat undertray section removed. However, removal of these components is not necessary.
Remove the wheels ( D2.01
).
Support the weight of the front suspension adequately.
Undo the spherical tie-rod pin (1)
Undo the nut (2) and remove the pin (3) , retrieving the relevant washer.
Undo the nut (4) fastening the lower arm (A) to the hub carrier, retrieving the relevant washer.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 7 of 24
Using a delible yellow marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the lower arm.
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the four nuts fastening the lower arm (A) , retrieving the four shims (5) , in the following order: (a) , (b) , (c) , (d) .
Check that the yellow reference markings are correctly aligned: the marking on the stud bolts and the marking on the Flanbloc eyebolts must be aligned.
Only the nut must turn, the stud bolt must remain in its original position.
If the markings on the stud bolts and eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one stud bolt), a
ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk.
If the markings on the stud bolts and eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the four arm fastener nuts in the order given for the previous operation.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 8 of 24
Check again that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Remove the lower front suspension arm from its relevant seat.
Refitting front suspension lower arms
Tightening torque
Fastening lower arm to hub carrier
Fastening shock absorber to lower arm
Spherical tie-rod - lower arm
Fastening lower arm to chassis
Nut (pretightening)
Screw
Spherical tie-rod
Nut (pretightening)
Support the weight of the front suspension adequately.
Clean the ball joint pin and the relevant seat on the arm to remove any grease residue.
Nm
90 Nm
80 Nm
50 Nm
9 Nm
Class
A
A
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 9 of 24
Fit the lower front suspension arm (A) in its relevant seat.
Apply the nut (4) , after fitting the relevant washer, and pretighten.
Tightening torque
Nut (pretightening)
Nm
90 Nm
Loosen the nut (4) and then tighten.
Class
A
Tightening torque Nm Class
Fit the pin (3) fastening the shock absorber to the lower arm and, after fitting the relevant washer, tighten the nut (2) .
Tightening torque Nm Class
Fasten the spherical tie-rod to the lower arm (A) , tightening the pin (1) .
Tightening torque
Spherical tie-rod
Nm
50 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 10 of 24
Fit the four shims (5) in the relevant seats, pushing down completely onto the stud bolts and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs.
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the four nuts indicated fastening the lower arm (A) in the following tightening order: (a) , (b) ,
(c) , (d) .
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B
Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 11 of 24
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the stud bolts and relevant nuts and the eyebolts of the Flanblocs fastening the lower arm.
Refit the wheels ( D2.01
).
Perform the vehicle set-up procedure ( A3.22
).
Removing rear suspension upper arms
The replacement arm is supplied complete with Flanbloc.
The following procedure is for removing the right hand rear suspension upper arm.
The procedure for removing the left hand rear suspension upper arm is the same.
Remove the wheels ( D2.01
).
Using a delible yellow marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 12 of 24
Holding the pin (1) still, undo the nut (2) and retrieve the relevant washers.
Remove the pin (1) from the relevant seat.
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the two nuts indicated fastening the upper arm (A) to the chassis.
Check that the yellow reference markings are correctly aligned: the marking on the stud bolts and the marking on the Flanbloc eyebolts must be aligned.
If the markings on the stud bolts and Flanbloc eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one stud bolt), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk.
If the markings on the stud bolts and Flanbloc eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the two arm fastener nuts in the order given for the previous operation.
Move the shock absorber aside to facilitate the operation.
Check again that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Remove upper arm of rear suspension from the relative seat, retrieving the two washers from the relative stud bolts. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms
Refitting rear suspension upper arms
Page 13 of 24
Tightening torque
Fastening upper arm to hub carrier
Fastening upper arm to chassis
Nut
Nut (pretightening)
Nm
90 Nm
9 Nm
Class
A
B
The replacement arm is supplied complete with Flanbloc.
The following procedure is for refitting the right hand rear suspension upper arm.
The procedure for refitting the left hand rear suspension upper arm is the same.
Position the two washers onto the relative stud bolts and the upper arm (A) of rear suspension into the relative seat.
Fit the pin (1) in the relevant seat.
Holding the pin (1) still, fit the relevant washers and pretighten then tighten the nut (2) .
Tightening torque Nm Class
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the two nuts indicated fastening the upper arm (A) to the chassis.
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 14 of 24
Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Refit the wheels ( D2.01
).
Perform the vehicle set-up procedure ( A3.22
).
Removing the rear suspension lower arm
The replacement arm is supplied complete with Flanbloc.
The following procedure is for removing the right hand rear suspension lower arm.
The procedure for removing the left hand rear suspension lower arm is the same.
Remove the wheels ( D2.01
).
Remove the rear flat undertray section ( E3.12
).
Support the weight of the rear suspension adequately. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 15 of 24
Detach and remove the rubber plug (C) from the front of the lower arm.
Detach and remove the rubber plug (D) from the rear of the lower arm.
Holding the pin (5) fastening the shock absorber to the lower arm still, undo the nut (6) and retrieve the relevant washer.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 16 of 24
Detach the tie-rod (1) for the NRRPS motion sensor from the lower arm (A) .
Magnetorheological shock absorbers (optional) only.
Undo the nut (2) and remove the screw (3) , retrieving the relevant washer.
Using a delible yellow marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the lower arm.
Undo the tie-rod ball stud (4) on the lower arm.
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the four nuts indicated fastening the lower arm (A) to the chassis, retrieving the four shims (7) , in the following order: (a) , (b) , (c) , (d) .
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 17 of 24
Check that the yellow reference markings are correctly aligned: the marking on the stud bolts and the marking on the Flanbloc eyebolts must be aligned.
Only the nut must turn, the stud bolt must remain in its original position.
If the markings on the stud bolts and Flanbloc eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one stud bolt), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk.
If the markings on the stud bolts and Flanbloc eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the four arm fastener nuts in the order given for the previous operation.
Check again that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Remove the lower rear suspension arm from its relevant seat.
Refitting rear suspension lower arms
Tightening torque
Spherical tie-rod - lower arm
Fastening lower arm to chassis
Spherical tie-rod
Nut (pretightening)
Fastening lower arm to hub carrier
Fastening shock absorber to lower arm
Nut
Screw
The replacement arm is supplied complete with Flanbloc.
Nm
50 Nm
9 Nm
205 Nm
80 Nm
Class
B
B
A
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 18 of 24
The following procedure is for refitting the right hand rear suspension lower arm.
The procedure for refitting the left hand rear suspension lower arm is the same.
Support the weight of the rear suspension adequately.
Fit the rear suspension lower arm (A) in its relevant seat.
Tighten the tie-rod ball stud (4) on the lower rear arm.
Tightening torque
Spherical tie-rod
Nm
50 Nm
Class
B
Fit the four shims (7) in the relevant seats, pushing down completely onto the stud bolts and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs.
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the four nuts indicated fastening the lower arm (A) to the chassis in the following tightening order: (a) , (b) , (c) , (d) .
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 19 of 24
Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the lower arm.
Align the lower arm with the link and the hub carrier then fit the screw (3) in the relevant holes.
Fit the relative washer and tighten the nut (2) fastening the screw (3) .
Tightening torque Nm Class
Attach the tie-rod (1) for the NRRPS motion sensor onto the lower arm (A) .
Magnetorheological shock absorbers (optional) only. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 20 of 24
Fit the pin (5) in the relevant seat.
Holding the pin (5) still, fit the relevant washer and tighten the nut (6) fastening the shock absorber to the lower arm.
Tightening torque Nm Class
Press the rubber plug (D) by hand into its relevant seat at the rear of the lower arm.
Press the rubber plug (C) by hand into its relevant seat at the front of the lower arm.
Refit the wheels ( D2.01
).
Perform the vehicle set-up procedure ( A3.22
).
Removing the toe-in tie-rods https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 21 of 24
Remove the wheels ( D2.01
).
Using a delible yellow marker pen or paint, make reference markings on the threaded bolts and relative nuts and the eyebolts fastening the toein tie-rod.
Holding the pin (1) still, undo the nut (2) and retrieve the relevant washers.
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the two nuts indicated fastening the toe-in tie-rod (A) to the chassis. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms
Remove the toe-in tie-rod from the relative seat.
Refitting the toe-in tie-rods
Page 22 of 24
Check that the yellow reference markings are correctly aligned: the marking on the threaded rods and the marking on the eyebolts must be aligned.
Only the nut must turn, the threaded rod must remain in its original position.
If the markings on the threaded rods and eyebolts are not correctly aligned after loosening the toein tie rod fastener nuts (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help
Desk.
If the markings on the threaded rods and eyebolts are correctly aligned after loosening the toe-in tierod fastener nuts, completely undo and remove the two toe-in tie-rod fastener nuts.
Check again that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the eyebolts must be aligned.
Tightening torque
Fastening toe-in tie-rod to hub carrier
Fastening toe-in tie-rod to chassis
Nut
Nut (pretightening)
Nm
80 Nm
9 Nm
Class
A
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 23 of 24
Fit the relative washers and tighten the nut (2) , holding the pin (1) still to prevent it from turning.
Tightening torque Nm Class
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the two nuts indicated fastening the toe-in tie-rod (A) to the chassis.
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
B
Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the eyebolts must be aligned.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension arms Page 24 of 24
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the threaded rods and the relative nuts and eyebolts fastening the toe-in tierod.
Refit the wheels ( D2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers
Print Exit
Removing the front hub carriers
Remove the front brake callipers ( D3.05
).
Remove the brake discs ( D3.03
).
Remove the front disc.
Page 1 of 11
Remove the indicated cable ties.
Disconnect ground cable from the indicated clip.
Release and disconnect connector (1) .
Detach the cable grommet (2) .
Undo the nut (3) .
Detach the cable grommets (4) .
Remove the clip (5) .
Undo the union (6) .
Detach the pipe (7) from the clip (8) .
Support the weight of the suspension adequately. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 2 of 11
Undo the nut (9) , retrieving the relative washer.
Detach the hub carrier (A) from the steering box tierod (B) .
Undo the nut (10) , retrieving the relative washer.
Detach the hub carrier (A) from the upper arm (C) .
Undo the nut (11) , retrieving the relative washer.
Detach the hub carrier (A) from the lower arm (D) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers
Remove the hub carrier (A) .
Undo the screws (12) .
Remove the bracket (13) .
Undo the screws (14) .
Remove the brake disc shield (15) .
Page 3 of 11
Refitting the front hub carriers
Tightening torque
Brake disc shield bracket
Products to use: AREXONS 242
Fastening pipe and cable mounting bracket to hub carrier
Products to use: AREXONS 242
Fastening lower arm to hub carrier
Screw
Screw
Nut (pretightening)
Fastening upper arm to hub carrier
Fastening steering box tie-rod to hub carrier
Fastening brake pipe union or connection
Fastening brake pad sensor ground cable
Nut
Nut
M10 union
Nut
Nm
9 ÷ 12 Nm
9 ÷ 12 Nm
90 Nm
52 Nm
40 Nm
16 Nm
6 Nm
Class
B
B
A
B
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 4 of 11
Fit the brake disc shield (15) .
Tighten the screws (14) .
Tightening torque
Screw
Fit the bracket (13) .
Tighten the screws (12) .
Nm Class
9 ÷ 12 Nm B
Support the weight of the suspension adequately.
Tightening torque
Screw
Fit the hub carrier (A) .
Nm
9 ÷ 12 Nm
Class
B
Attach the hub carrier (A) to the lower arm (D) .
Clean the ball joint head and the relative seat thoroughly.
Fit the relative washer and pre-tighten the nut (11) .
Tightening torque
Nut (pretightening)
Loosen and tighten the nut (11) .
Nm
90 Nm
Class
A
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 5 of 11
Attach the hub carrier (A) to the upper arm (C) .
Clean the ball joint head and the relative seat thoroughly.
Fit the relative washer and pre-tighten the nut (10) .
Tightening torque
Loosen and tighten the nut (10) .
Nm Class
Tightening torque Nm Class
Attach the hub carrier (A) to the steering box tie-rod
(B) .
Clean the ball joint head and the relative seat thoroughly.
Fit the relative washer and pre-tighten the nut (9) .
Tightening torque
Loosen and tighten the nut (9) .
Nm Class
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 6 of 11
Attach the pipe (7) to the clip (8) .
Tighten the union (6) .
Tightening torque
M10 union
Fit the clip (5) .
Attach the cable grommets (4) .
Tighten the nut (3) .
Nm
16 Nm
Class
B
Tightening torque Nm Class
Attach the cable grommet (2) .
Sliding it onto brake pad wear sensor, connect and attach connector (1) .
Apply new cable ties in the positions indicated.
Check that the indicated clip is positioned at 50 - 60 mm from cable grommet (2) .
Connect ground cable to the indicated clip.
Refit the brake discs ( D3.03
).
Refit the front disc.
Refit the front brake callipers ( D3.05
).
Removing the rear hub carriers
Remove the rear brake callipers ( D3.05
).
Remove the brake discs ( D3.03
).
Remove the rear brake disc.
Remove the EPB electric parking brake shoes ( D3.07
).
Support the weight of the suspension adequately. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 7 of 11
Preventing the screw (1) fastening the lower arm
(A) to the hub carrier from turning, undo the nut
(2) .
Remove the screw (1) from the relative seat and retrieve the relative washers.
Preventing the screw (3) fastening the toe-in tie-rod
(B) to the hub carrier from turning, undo the nut
(4) .
Remove the screw (3) from the relative seat and retrieve the relative washers.
Undo the screw (9) fastening the link (F) to the hub carrier (E) .
Remove the link (F) from the hub carrier (E) and retrieve the compensator ring (10) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 8 of 11
Preventing the screw (5) fastening the upper arm
(C) to the hub carrier from turning, undo the nut
(6) .
Remove the screw (5) from the relative seat and retrieve the relative washers.
Undo the three screws indicated fastening the brake disc shield (D) to the hub carrier (E) .
Remove the brake disc shield (D) from the hub carrier (E) .
Use a suitable punch and mallet to remove the caulking (7) from the ring nut (8) .
Undo the ring nut (8) .
Remove the hub carrier (E) , detaching from the axle shaft.
Refitting the rear hub carriers
Tightening torque
Fastening axle shaft to wheel hub
Brake disc shield bracket
Products to use: AREXONS 242
Fastening upper arm to hub carrier
Fastening anti-rotation link to hub carrier
Fastening toe-in tie-rod to hub carrier
Fastening lower arm to hub carrier
Nut
Screw
Nut
Screw
Nut
Nut
Nm
275 Nm
9 ÷ 12 Nm
90 Nm
85 Nm
80 Nm
205 Nm
Class
A
B
A
A
A
A
When refitting the same hub carrier, remove any residue of AREXONS SYSTEM 56A01 - HIGH STRENGTH
RETAINING COMPOUND .
Remove any residue of AREXONS SYSTEM 56A01 - HIGH STRENGTH RETAINING COMPOUND from the axle shaft. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 9 of 11
Apply three even and regularly spaced circular beads of AREXONS SYSTEM 56A01 - HIGH
STRENGTH RETAINING COMPOUND .
Support the weight of the suspension adequately.
Fit the hub carrier (E) , fitting the axle shaft into the relative seat on the wheel bearing.
Tighten the nut (8) .
Tightening torque Nm Class
Use a suitable punch and mallet to caulk (7) the ring nut (8) .
Fit the brake disc shield (D) on the hub carrier (E) .
Tighten the three screws indicated fastening the brake disc shield (D) to the hub carrier (E) .
Tightening torque
Screw
Nm Class
9 ÷ 12 Nm B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers Page 10 of 11
Fit the screw (5) in the relative seat after installing the relative washer.
Fit the relative washer and, preventing the screw (5) fastening the upper arm (C) to the hub carrier from turning, tighten the nut (6) .
Tightening torque Nm Class
Fit the link (F) and the compensator ring (10) in the relative seat on the hub carrier (E) .
Apply an even layer of grease Z2 PROTECTION to the inner surface of the compensator ring (10) in contact with the screw head (9) .
Fasten the link (F) to the hub carrier (E) , fitting and tightening the screw (9) .
Tightening torque Nm Class
Fit the screw (3) in the relative seat after installing the relative washer.
Fit the relative washer and, preventing the screw (3) fastening the toe-in tie-rod (B) to the hub carrier from turning, tighten the nut (4) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Hub carriers
Refit the EPB electric parking brake shoes ( D3.07
).
Refit the brake discs ( D3.03
).
Refit the rear brake callipers ( D3.05
).
Page 11 of 11
Fit the screw (1) in the relative seat after installing the relative washer.
Fit the relative washer and, preventing the screw (1) fastening the lower arm (A) to the hub carrier from turning, tighten the nut (2) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers
Print Exit
Removing the front shock absorber
Page 1 of 16
The following procedure is for removing the right hand front shock absorber.
The procedure for removing the left hand front shock absorber is the same.
Remove the luggage compartment cosmetic shields ( E4.07
).
Disconnect the battery ( F2.01
).
Remove the wheels ( D2.01
).
Disconnect the connector (1) from the shock absorber.
Undo the two screws indicated fastening the shock absorber (A) to the chassis. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 2 of 16
Using a delible yellow marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Detach the tie-rod for the NRRPS motion sensor (2) from the upper arm (B) .
DO NOT use lubricants or electric/pneumatic drivers.
Partially loosen the four nuts indicated fastening the upper arm (B) in the following order: (a) , (b) , (c) ,
(d) .
Move the shock absorber aside to facilitate the operation.
For vehicles with "Front Lift" system
Undo the lift system fluid hose union (5) .
Remove the clip (6) fastening the union (7) for the lift system fluid hose onto the relative mounting bracket.
Remove the union (7) for the lift system fluid hose from the relative mounting bracket.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 3 of 16
Check that the yellow reference markings are correctly aligned: the marking on the stud bolts and the marking on the Flanbloc eyebolts must be aligned.
If the markings on the stud bolts and eyebolts are not correctly aligned after loosening the arm fastener nuts (even if only on one stud bolt), a
ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk.
If the markings on the stud bolts and eyebolts are correctly aligned after loosening the arm fastener nuts, completely undo and remove the four arm fastener nuts in the order given for the previous operation.
Move the shock absorber aside to facilitate the operation.
Check again that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Holding the pin (3) fastening the shock absorber to the lower arm still, undo the nut (4) and retrieve the relative washer.
Support the weight of the shock absorber (A) and remove the pin (3) from the relative seat.
Remove upper arm from the relative stud bolts, retrieving the four washers, and slightly turn it toward the front of the vehicle.
Remove the shock absorber from the relative seat. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers
Refitting the front shock absorber
Page 4 of 16
Tightening torque
Fastening shock absorber to lower arm
Fastening vehicle lift system unions
Fastening upper arm to chassis
Screw
Union
Nut (pretightening)
Nm
80 Nm
16 Nm
9 Nm
Class
A
B
A
Fastening shock absorber to chassis Screw
The following procedure is for refitting the right hand front shock absorber.
110 Nm A
The procedure for refitting the left hand front shock absorber is the same.
Fit the shock absorber in the relevant seat.
Position the four washers and upper arm, turning it toward the rear of the vehicle, onto the relative stud bolts.
Support the weight of the shock absorber (A) and fit the pin (3) into the relevant seat.
Holding the pin (3) fastening the shock absorber to the lower arm still, fit the relevant washer and tighten the nut (4) .
Tightening torque Nm Class
For vehicles with "Front Lift" system
Fit the union (7) for the lift system fluid hose onto the relative mounting bracket.
Refit the clip (6) fastening the union (7) for the lift system fluid hose onto the relative mounting bracket.
Tighten the lift system fluid hose union (5) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 5 of 16
Clean the mating surfaces with a degreasing product (heptane).
DO NOT use lubricants or electric/pneumatic drivers.
ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed.
Replacement is NOT necessary if the nuts are loosened only.
Tighten the four nuts indicated fastening the upper arm (B) in the following tightening order: (a) , (b) ,
(c) , (d) .
Move the shock absorber aside to facilitate the operation.
Tightening torque
Nut (pretightening)
Nm
9 Nm
Class
A
Attach the tie-rod for the NRRPS motion sensor (2) to the upper arm (B) .
Tighten the two screws indicated fastening the shock absorber (A) to the chassis.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 6 of 16
Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned.
Remove the yellow reference markings made during removal.
Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Connect the connector (1) to the shock absorber.
Reconnect the battery ( F2.01
).
Refit the luggage compartment cosmetic shields ( E4.07
).
Refit the wheels ( D2.01
).
For vehicles with "Front Lift" system. Fill and bleed the "Front Lift" system ( D4.08
).
Perform the vehicle set-up procedure ( A3.22
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers
Removing the rear shock absorber
Page 7 of 16
The following procedure is for removing the right hand rear shock absorber.
The procedure for removing the left hand rear shock absorber is identical.
Remove the wheels ( D2.01
).
Disconnect the battery ( F2.01
).
Disconnect the connector (1) from the shock absorber (A) .
Undo the two screws indicated fastening the shock absorber (A) to the chassis.
Detach and remove the rubber plug (C) from the front of the lower arm. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 8 of 16
Detach and remove the rubber plug (D) from the rear of the lower arm.
Holding the pin (5) fastening the shock absorber to the lower arm still, undo the nut (6) and retrieve the relevant washer.
Support the weight of the shock absorber (A) and remove the pin (5) from the relevant seat.
Remove the rear shock absorber from the relevant seat.
Refitting the rear shock absorber
Tightening torque
Fastening shock absorber to lower arm
Fastening shock absorber to chassis
Screw
Screw
The following procedure is for refitting the right hand rear shock absorber.
The procedure for refitting the left hand rear shock absorber is identical.
Fit the rear shock absorber in the relevant seat.
Nm
80 Nm
110 Nm
Class
A
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 9 of 16
Fit the pin (5) in the relevant seat.
Holding the pin (5) still, fit the relevant washer and tighten the nut (6) fastening the shock absorber to the lower arm.
Tightening torque Nm Class
Press the rubber plug (D) by hand into its relevant seat at the rear of the lower arm.
Press the rubber plug (C) by hand into its relevant seat at the front of the lower arm. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 10 of 16
Tighten the two screws indicated fastening the shock absorber (A) to the chassis.
Tightening torque Nm Class
Connect the connector (1) to the shock absorber
(A) .
Reconnect the battery ( F2.01
).
Refit the wheels ( D2.01
).
Perform the vehicle set-up procedure ( A3.22
).
Replacing the shock absorber elements
Tightening torque
Bushing and shock absorber retainer washer
Connector - shock absorber strut
Nut
Nut
Nm
40 Nm
40 Nm
To replace a component of the front shock absorber. Remove the front shock absorber ( D4.04
).
To replace a component of the rear shock absorber. Remove the rear shock absorber ( D4.04
).
Disassembling the magnetorheological variable-damping shock absorber
Class
A
A https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 11 of 16
Detach and remove the connector (1) .
Immobilise the shock absorber.
Undo the nut (2) .
CAUTION
The following procedure for removing the nut must be observed precisely in order to compress and remove the spring safely.
Partially loosen the nut (3) by just enough to decompress the spring.
Compress the spring (A) with a suitable press.
Undo the nut (3) completely.
Retrieve the washer (4) .
Slowly release the spring (A) .
Remove the upper stop cap (B) , complete with hyperblock.
Remove the bushing (5) .
Remove the upper spring shim (C) .
Remove the spring (A) .
Remove the plug (D) .
Remove the lower spring shim (E) .
Disassembling the magnetorheological variable-damping shock absorber on a vehicle with "Front Lift" system (optional, applicable for front shock absorbers only) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 12 of 16
Detach and remove the connector (1) .
Immobilise the shock absorber.
Undo the nut (2) .
CAUTION
The following procedure for removing the nut must be observed precisely in order to compress and remove the spring safely.
Partially loosen the nut (3) by just enough to decompress the spring.
Compress the spring (A) with a suitable press.
Undo the nut (3) completely.
Retrieve the washer (4) .
Slowly release the spring (A) .
Remove the upper stop cap (B) , complete with hyperblock.
Remove the bushing (5) .
Remove the upper spring shim (C) .
Remove the spring (A) .
Remove the plug (D) .
Remove the lower spring shim (E) .
Remove the actuator (F) .
Remove the shim ring (G) .
Reassembling the magnetorheological variable-damping shock absorber https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 13 of 16
Apply grease Z2 PROTECTION to the surface of the lower shim (E) in contact with the spring (A) .
Fit the lower shim (E) on the shock absorber.
Fit the plug (D) .
Fit the spring (A) .
Apply grease Z2 PROTECTION to the surface of the upper shim (C) in contact with the spring (A) .
Fit the upper shim (C) on the shock absorber.
Fit the bushing (5) .
Fit the upper stop cap (B) , complete with hyperblock.
Compress the spring (A) with a suitable press.
Fit the washer (4) .
CAUTION
Do not release the spring until the nut is fastened to the shock absorber strut.
Apply thread lock compound AREXONS SYSTEM
52A43 - MEDIUM STRENGTH THREAD LOCK to the thread of the nut (3) and tighten.
Tightening torque
Tighten the nut (2) .
Nm Class
Tightening torque
Fit and connect the connector (1) .
Slowly release the spring (A) .
Nm Class
Reassembling the magnetorheological variable-damping shock absorber on a vehicle with "Front Lift" system (optional, applicable for front shock absorbers only) https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers
Adjust the shock absorber length ( D4.04
).
Refit the rear shock absorber ( D4.04
).
Refit the front shock absorber ( D4.04
).
Page 14 of 16
Fit the shim ring (G) .
Apply grease Z2 PROTECTION to the surfaces of the shock absorber and shim ring (G) in contact with the actuator (F) .
Fit the actuator (F) .
With the shock absorber oriented as it would be in the vehicle, the actuator bleed valve (F) must be turned by 37° ± 1° toward the exterior of the vehicle.
Fit the lower shim (E) .
Apply grease Z2 PROTECTION to the surface of the lower shim (E) in contact with the spring (A) .
Fit the plug (D) .
Fit the spring (A) .
Apply grease Z2 PROTECTION to the surface of the upper shim (C) in contact with the spring (A) .
Fit the upper shim (C) .
Fit the bushing (5) .
Fit the upper stop cap (B) , complete with hyperblock.
Compress the spring (A) with a suitable press.
Fit the washer (4) .
CAUTION
Do not release the spring until the nut is fastened to the shock absorber strut.
Apply thread lock compound AREXONS SYSTEM
52A43 - MEDIUM STRENGTH THREAD LOCK to the thread of the nut (3) and tighten.
Tightening torque
Tighten the nut (2) .
Nm Class
Tightening torque
Fit and connect the connector (1) .
Slowly release the spring (A) .
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers Page 15 of 16
Adjusting the shock absorber length
The distance (L) from the disc to the lower fulcrum axis must be adjusted in accordance with the spring fitted and the type of shock absorber on which it is fitted. Two different spring sizes are available with different control load tolerances, identifiable by the different colours stamped on a coil turn.
Length of front variable setting shock absorber
Length of front variable setting shock absorber
Length of rear variable setting shock absorber
Length of rear variable setting shock absorber
Length of front variable setting shock absorber with lift
Length of front variable setting shock absorber with lift https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Shock absorbers
Tightening torque
Shock absorber ring nut
Page 16 of 16
Ring nut
Nm
65 Nm
Class
B
Using a standard pin wrench, loosen the ring nut
(A) fastening the stop cap.
Hand tighten or loosen the spring retainer stop cap
(B) to obtain the distance (L) .
Hold the stop cap in this position and tighten the ring nut (A) .
Tightening torque
Ring nut
Nm
65 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods
Print Exit
D4.05 Stabiliser bars - Tie-rods
Removing the rear stabiliser bar
Page 1 of 10
Remove the rear wheelhouses ( E3.05
).
Remove the rear elements of the rear wheelhouses only.
Remove the engine air filter box ( B4.03
).
Undo the nut (1) fastening the stabiliser bar (A) to the left hand suspension tie-rod, retrieving the retainer plate.
Undo the screws indicated fastening the rear stabiliser bar (A) to the chassis.
Undo the nut (2) fastening the stabiliser bar (A) to the right hand suspension tie-rod, retrieving the retainer plate.
Undo the screws indicated fastening the rear stabiliser bar (A) to the chassis.
Remove the rear stabiliser bar, complete with bushings, from the vehicle, removing via the wheelhouse.
Refitting the rear stabiliser bar https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 2 of 10
Tightening torque
Fastening rear stabiliser bar to chassis
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Fastening rear stabiliser bar to tie-rod
Nm Class
Nut 50 Nm B
Apply 1 ml of DuPont Lubricants Krytox® 205
GPL Standard Grade Grease grease in a uniform film over the entire inner surface and on the lateral surfaces (contact surfaces only) of the bushings.
Apply a uniform film of DuPont Lubricants
Krytox® 205 GPL Standard Grade Grease grease to the outer diameter of the bar and the shoulders of the bushings.
Fit the bushings in the relative seats on the stabiliser bar, ensuring that the bushings are oriented correctly (see notches on bushings).
Fit the rear stabiliser bar (A) in the relative seat on the chassis, with the notch (3) nearest to the outer edge on the bushing is facing upward.
Fit the retainer plate on the bushing and tighten the indicated screws.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 3 of 10
Fit the retainer plate on the bushing and fasten the rear stabiliser bar (A) , tightening the screws indicated.
Tightening torque Nm Class
Fasten the rear stabiliser bar (A) to the tie-rod, tightening the nut (2) .
Tightening torque Nm Class
Fasten the rear stabiliser bar (A) to the tie-rod, tightening the nut (1) .
Tightening torque Nm Class
Refit the engine air filter box ( B4.03
).
Refit the rear wheelhouses ( E3.05
).
Replacing rear spherical tie-rods https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 4 of 10
Tightening torque
Spherical tie-rod - lower arm
Fastening rear stabiliser bar to tie-rod
Spherical tie-rod
Nut
Remove the rear wheelhouses ( E3.05
).
Remove the rear element of the rear wheelhouse.
Nm
50 Nm
50 Nm
Class
B
B
Undo the nut (1) , retrieving the relevant washer.
Undo the ball stud (2) , retrieving the relevant washer.
Remove the spherical tie-rod (A) and replace it.
Fit the new spherical tie-rod (A) in the correct direction.
Tighten the ball stud (2) fitting the relevant washer.
Tightening torque
Spherical tie-rod
Nm
50 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 5 of 10
Tighten the nut (1) fitting the relevant washer.
Tightening torque Nm Class
Refit the rear wheelhouses ( E3.05
).
Removing the front stabiliser bar
Remove the wheels ( D2.01
).
Remove the front wheels.
Undo the nut (1) fastening the stabiliser bar (A) to the spherical tie-rod (2) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 6 of 10
Undo the nut (3) fastening the stabiliser bar (A) to the spherical tie-rod (4) .
Undo the indicated screws fastening the stabiliser bar (A) to the chassis, retrieving the retainer bracket (5) .
Undo the indicated screws fastening the stabiliser bar (A) to the chassis, retrieving the retainer bracket (5) .
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 7 of 10
Remove the stabiliser bar (A) from the chassis, easing out from one side.
Refitting the front stabiliser bar
Tightening torque
Fastening front stabiliser bar to chassis
Fastening rear stabiliser bar to tie-rod
Screw
Nut
Nm
30 Nm
50 Nm
Class
B
B
Apply 1 ml of DuPont Lubricants Krytox® 205
GPL Standard Grade Grease grease in a uniform film over the entire inner surface and on the lateral surfaces (contact surfaces only) of the bushings.
Apply a uniform film of DuPont Lubricants
Krytox® 205 GPL Standard Grade Grease grease to the outer diameter of the bar and the shoulders of the bushings.
Fit the bushings in the relative seats on the stabiliser bar, ensuring that the bushings are oriented correctly (see notches on bushings).
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 8 of 10
Fit the stabiliser bar (A) in the relative seat on the chassis, with the notch (6) nearest to the outer edge on the bushing facing forward.
Fit the retainer bracket (5) on the bushing and tighten the indicated screws.
Tightening torque Nm Class
Fit the retainer bracket (5) on the bushing and fasten the stabiliser bar (A) , tightening the screws indicated.
Tightening torque Nm Class
Fit and tighten the nut (3) fastening the stabiliser bar (A) to the spherical tie-rod (4) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods Page 9 of 10
Fit and tighten the nut (1) fastening the stabiliser bar (A) to the spherical tie-rod (2) .
Tightening torque Nm Class
Refit the wheels ( D2.01
).
Replacing front spherical tie-rods
Tightening torque
Spherical tie-rod - lower arm
Fastening front stabiliser bar to tie-rod
Remove the wheels ( D2.01
).
Spherical tie-rod
Nut
Nm
50 Nm
50 Nm
Class
B
B
Undo the nut (1) , retrieving the relevant washer.
Undo the ball stud (2) , retrieving the relevant washer.
Remove the spherical tie-rod (A) and replace it.
Fit the new spherical tie-rod (A) in the correct direction.
Tighten the ball stud (2) fitting the relevant washer.
Tightening torque
Spherical tie-rod
Nm
50 Nm
Class
Tighten the nut (1) fitting the relevant washer.
B
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Stabiliser bars - Tie-rods
Refit the wheels ( D2.01
).
Page 10 of 10 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension damping control system
Print Exit
Page 1 of 5
System function
This vehicle is equipped with the latest generation MagneRide™ magnetorheologically controlled suspension, a system that continuously and automatically controls suspension damping developed by Delphi and honed by
Ferrari.
By processing data received from the vehicle dynamics sensors measuring the movements of the bodyshell, the
ECU determines the road surface conditions and instantaneously adapts the response of the suspension accordingly, by varying the control current for each shock absorber.
These sensors allow the ECU to calculate vehicle speed, vertical and lateral acceleration, steering angle and instantaneous brake system pressure, and therefore control suspension damping in relation to these parameters.
Damping at each wheel is adjusted by a magnetorheological fluid which changes in density in relation to a magnetic field applied to the suspension.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension damping control system Page 2 of 5
The magnetorheological (MR) fluid is an oil containing a suspension of spherical ferromagnetic particles measuring a few microns in diameter.
Using an electric current to apply a magnetic field to the oil, the viscosity of the oil may be varied.
By varying the magnetic field applied to the MR fluid flowing in a duct, its pressure and flow rate characteristics may be adjusted in real time without the use of any external mechanical moving parts or actuators.
As well as ensuring the perfect balance between handling and comfort at all times, through specific calibrations selectable from the Manettino driving mode selector, this system can also shift the bias slightly towards one or the other of these two aspects.
Three different calibration levels are used on this vehicle:
Level 1 (COMFORT): a slightly softer calibration optimised to absorb bumps better and to offer improved grip in wet conditions (“Low Grip” Manettino setting).
Level 2 (SPORT): a slightly stiffer calibration optimised for sports and high speed use (in medium to high grip conditions) without drastically compromising comfort (SPORT and ESC OFF Manettino settings).
Level 3 (RACE): an even stiffer calibration optimised for track use (RACE, CT OFF and CST OFF Manettino settings).
System layout https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension damping control system Page 3 of 5
The system consists of:
4 NRRPS (Non-Contacting Ratiometer Rotational Position Sensor) sensors installed on the suspension of each wheel, in which the fixed part of the potentiometer is mounted on the chassis (sprung mass) while the rotating part of the potentiometer moves together with the suspension. The sensors transmit a linear signal to the NCS ECU proportional to the angle of movement.
NCS ECU, installed under the hatch cover in the passenger side footrest mat which, in relation to the signals received from the four NRRPS sensors, the data provided by the ECUs connected to the NCS and the
Manettino setting, controls the damping function of the shock absorbers.
4 magnetorheological shock absorbers , with one for each wheel suspension, controlled by the NCS ECU in relation to the signals received by the latter.
Replacing the front NRRPS motion sensors
Tightening torque
Fastening NRRPS motion sensor mounting bracket to chassis
The following procedure is for replacing the right hand front motion sensor.
The procedure for replacing the left hand front motion sensor is identical.
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension damping control system
Disconnect the battery ( F2.01
).
Remove the wheels ( D2.01
).
Remove the relative front wheel only.
Page 4 of 5
Refit the wheels ( D2.01
).
Reconnect the battery ( F2.01
).
Replacing the rear NRRPS motion sensors
Disconnect the connector (1) .
Detach the tie-rod (2) from the upper arm.
Undo the two indicated screws fastening the front motion sensor mounting bracket (A) .
Remove the front NRRPS motion sensor (A) , complete with relative mounting bracket, and replace.
Fit the new front NRRPS motion sensor (A) in its seat, complete with relative mounting bracket.
Tighten the two indicated screws fastening the front
NRRPS motion sensor mounting bracket (A) .
Tightening torque Nm
Fasten the tie-rod (2) to the upper arm.
Connect the connector (1) .
Class
Tightening torque
Fastening NRRPS motion sensor mounting bracket to chassis
The following procedure is for replacing the right hand rear NRRPS motion sensor.
The procedure for replacing the left hand rear NRRPS motion sensor is identical.
Disconnect the battery ( F2.01
).
Remove the wheels ( D2.01
).
Remove the relative rear wheel only.
Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Suspension damping control system Page 5 of 5
Disconnect the connector (1) .
Detach the tie-rod (2) from the lower arm.
Undo the two indicated screws fastening the rear
NRRPS motion sensor mounting bracket (A) .
Remove the rear NRRPS motion sensor (A) , complete with relative mounting bracket, and replace.
Fit the new rear NRRPS motion sensor (A) in its seat, complete with relative mounting bracket.
Tighten the two indicated screws fastening the rear
NRRPS motion sensor mounting bracket (A) .
Tightening torque Nm
Fasten the tie-rod (2) to the lower arm.
Connect the connector (1) .
Class
Refit the wheels ( D2.01
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Vehicle set-up
Print Exit
D4.07 Vehicle set-up
Checks and preparation of vehicle
Check the following before inspecting the set-up:
Wheel fastening;
Tyre pressure;
Clearance between pinion and rack in steering system;
Clearance between ball studs and steering tie-rods;
State of the shock absorbers;
Clearance between hub carriers and ball joints.
Page 1 of 4
Set the vehicle on a flat surface and "filled with the correct quantities of fluids" with a full tank of fuel and the electric parking brake activated.
Toe-in is measured over a diameter of 495 mm .
The following set-up data is relative to the car WITHOUT SAND BAGS.
Front set-up data
Adjusted vehicle height
Wheel camber
139.4±5 mm
-0.73° ± 0.2°
Caster 4.6°±0.4°
Rear set-up data
Adjusted vehicle height
Wheel camber
165.8±5 mm
-1.31° ± 0.2°
Toe-in
Total On wheel https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Vehicle set-up
Front
Rear
Height check
Total
-2 ± 0.5 mm
3 ± 0.5 mm
On wheel
-1 ± 0.25 mm
1.5 ± 0.25 mm
Page 2 of 4
With the vehicle arranged as specified above, the correct height of the vehicle measured between the ground and the front section of the chassis, measured in relation to the point (A) (external surface of the hole), must correspond to the specified set-up values.
With the vehicle arranged as specified above, the correct height of the vehicle measured between the ground and the rear section of the chassis, measured in relation to the point (B) (internal surface of the hole), must correspond to the specified set-up values.
Front suspension
- Wheel camber - https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Vehicle set-up Page 3 of 4
Check that the lower suspension arms are in the correct position.
After checking, if the camber angle is not within the prescribed values, loosen the nuts (1) and fit new shims
(2) to obtain a camber angle between the prescribed values, proceeding as described in chapter D4.02
.
- Toe-in -
After checking, if the toe-in is not within the prescribed values, proceed as follows:
Make sure that the steering box is in central position and that the steering wheel is perfectly horizontal. To assess this condition, use a mounting fitted with a spirit level. In this position, the two lateral tie-rods must be equal in length. If they are not equal, adjust them.
Loosen the nuts (3) and turn the lateral tie-rods (4) , adjusting both tie-rods by the same amount, to obtain a toe-in value within the prescribed values.
Tighten the nuts (3) to a torque of 60 Nm, class A .
Rear suspension
- Wheel camber - https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Vehicle set-up Page 4 of 4
Check that the lower suspension arms are in the correct position.
After checking, if the camber angle is not within the prescribed values, loosen the nuts (5) and fit new shims
(6) to obtain a camber angle between the prescribed values, proceeding as described in chapter D4.02
.
- Toe-in -
After checking, if the toe-in is not within the prescribed values, proceed as follows:
Loosen the nuts (7) and turn the tie-rods (8) , adjusting both tie-rods by the same amount, to obtain a toe-in value within the prescribed values.
Tighten the nuts (7) to a torque of 60 Nm, class A . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional)
Print Exit
D4.08 “Front Lift” ramp clearing front suspension lift (optional)
System layout
Page 1 of 10
A - Tank
B - Electric pump
C - Union block
Operating the "Front Lift" system
CAUTION
The system is not designed to remain active with the engine switched off while the vehicle is parked.
If the vehicle is switched off with the lift function active, the vehicle lowers after 15 seconds.
Do not use the front lift to park the vehicle on obstacles (e.g. kerbs) as the front of the vehicle may come into contact with the obstacle and be damaged when the lift function deactivates. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional) Page 2 of 10
The “Front Lift” system uses the front shock absorbers to raise the front of the vehicle by approximately 40 mm , to allow access to garages or steep ramps without damaging the vehicle.
The “Front Lift” system may be activated with the engine on and at speeds not greater than 40 Km/h by pressing the relative button on the centre console.
At speeds above 40 Km/h, the "Front Lift" system is disabled. If already active, the system deactivates automatically when the vehicle speed exceeds 40 Km/h.
In the event of engine malfunction, the “Front Lift” system may still be activated by pressing and holding the relative button for 10 seconds .
While the “Front Lift” system is raising the front of the vehicle, the specific indicator flashes and the TFT display displays the vehicle symbol with a white arrow pointing upward, together with the specific message "Front
Lift moving" .
While the system is active, the TFT display shows the vehicle symbol with a white arrow pointing upward together with the specific message "Front Lift ON" .
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8/5/2011
“Front Lift” ramp clearing front suspension lift (optional) Page 3 of 10
If the ignition switch is turned to 0 while the system is active, the TFT display displays the vehicle symbol with a white arrow pointing upward with the specific message "Front Lift ON" , together with the message "Set
Front Lift to OFF" .
While the “Front Lift” system is lowering the front of the vehicle, the specific indicator flashes and the TFT display displays the vehicle symbol with a white arrow pointing downward, together with the specific message "Front Lift moving" . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional) Page 4 of 10
If the system is inhibited, the TFT display shows the vehicle symbol with a red arrow pointing upward together with the specific message "Front Lift inhibited" .
Removing the "Front Lift" system electric pump
The electric pump is located in front of the rear right hand wheel bay.
Disconnect the battery ( F2.01
).
Remove the rear flat undertray section ( E3.12
).
Remove the door sill trim panel ( E3.11
).
Remove the right hand sill trim.
Detach the connectors (4) and (5) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional)
Disconnect the union (3) .
Page 5 of 10
Refitting the "Front Lift" system electric pump
Undo the union (1) on the pipe (2) .
Place a container under the pipe (2) .
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely.
Retrieve the seals on the union (1) .
Undo the screws indicated.
Remove the electric pump (A) from the relative seat.
Tightening torque
Fastening mounting bracket for "Front Lift" system electric pump
Fastening pipe from reservoir onto "Front Lift" system electric pump
Fastening vehicle lift system unions Union
Nm Class
16 Nm B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional) Page 6 of 10
Check that state of the adhesive pad applied to the electric pump (A) and replace if necessary.
Fit the electric pump (A) in the relative seat.
Hand tighten the screws indicated.
Tightening torque Nm
Replace the seals on the union (1) .
Tighten the union (1) on the pipe (2) .
Class
Nm Class Tightening torque
Tighten the union (3) .
Tightening torque Nm Class
Connect the connectors (4) and (5) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional)
Reconnect the battery ( F2.01
).
Fill and bleed the "Front Lift" system ( D4.08
).
Refit the door sill trim panel ( E3.11
).
Refit the rear flat undertray section ( E3.12
).
Removing the "Front Lift" system reservoir
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the right hand cosmetic shield.
Aspirate all the fluid from the reservoir with a syringe.
Remove the clamp indicated.
Disconnect the pipe (1) .
Undo the screws indicated.
Remove the reservoir (A) .
Page 7 of 10
Refitting the "Front Lift" system reservoir
Tightening torque
Fastening vehicle lift system fluid reservoir Screw
Nm
4 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional)
Fit the reservoir (A) .
Hand tighten the screws indicated.
Page 8 of 10
Tightening torque
Connect pipe (1) .
Tighten a new clamp as indicated.
Nm Class
Fill and bleed the "Front Lift" system ( D4.08
).
Refit the engine compartment cosmetic shields ( E3.13
).
Filling and bleeding the "Front Lift" system
Tightening torque
Fastening bleed union Union
Nm
10 Nm
The vehicle must be on a level, horizontal surface.
Connect the vehicle to a battery conditioner or keep the engine running during the procedure.
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the right hand cosmetic shield.
Class
B
Undo the cap (1) .
Fill the reservoir (A) , bearing in mind that the level in the reservoir must never drop below the MIN limit when bleeding the system. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional) Page 9 of 10
Turn the ignition switch on.
Wait at least 10 seconds .
Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10
).
Start the "NSV bleeding" cycle, using the DEIS diagnostic tester and following the relative instructions.
Wait at least 5 seconds .
Remove the protector cap on both shock absorbers and loosen the indicated bleed unions.
Connect suitable lengths of transparent pipe to the bleed unions on both shock absorbers.
Immerse the end of the pipes in a container filled with the hydraulic fluid specified for use in the system.
Wait for the "NSV bleeding" cycle to complete.
Disconnect the lengths of transparent pipe from the bleed unions on both shock absorbers.
Tighten the indicated bleed unions and refit the protector caps on both shock absorbers.
Tightening torque
Check the fluid level in the "Front Lift" hydraulic system ( D4.08
).
Refit the engine compartment cosmetic shields ( E3.13
).
Refit the right hand cosmetic shield.
Checking the fluid level in the "Front Lift" hydraulic system
Nm Class
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the right hand cosmetic shield. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
“Front Lift” ramp clearing front suspension lift (optional) Page 10 of 10
Check that the fluid level in the reservoir (A) is near the MAX limit.
If the level is near the MIN limit, top the system up with fluid as follows.
Undo the cap (1) .
Fill the brake fluid reservoir to the MAX level.
Screw the cap (1) back on tightly.
Refit the engine compartment cosmetic shields ( E3.13
).
Refit the right hand cosmetic shield. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D40...
8/5/2011
Steering system layout
Print Exit
D5.01 Steering system layout
Steering system layout
Page 1 of 1
A - Power steering fluid tank
B - Power steering fluid pump
C - Steering box
D - Power steering fluid radiator
E - Steering column
F - Steering wheel https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering tank
Print Exit
D5.02 Power steering tank
Removing the power steering tank
Page 1 of 3
CAUTION
The oil contained in the hydraulic steering system is harmful to the eyes and skin and may also damage the vehicle bodywork.
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
For vehicles UP TO Ass.ly No. 98001 when replacing the power steering fluid reservoir, the pipe from the power steering fluid reservoir to the power steering pump and the pipe from the underbody to the power steering fluid reservoir, the components of either RETROFIT KIT Part No. 280917, or of RETROFIT KIT Part No.
279662, must be used, referring to the indications given in the Spare Parts Catalogue.
The components of RETROFIT KIT Part No. 280917 and RETROFIT KIT Part No. 279662 are solely compatible with the power steering fluid prescribed FROM Ass.ly No. 98002.
Empty the tank, aspirating and collecting the fluid with a suitable syringe.
Remove the shield (3) by undoing the screws indicated.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering tank Page 2 of 3
Disconnect the breather pipe from the cap (1) .
Undo the fastener screws indicated and lift the power steering reservoir (A) .
Disconnect the two pipes (2) from the power steering tank (A) , loosening the relative clamps.
Remove the power steering tank (A) .
Refitting the power steering tank
Tightening torque
Fastening power steering fluid pipes to reservoir Screw collar
Nm
4 Nm
Class
B
CAUTION
The oil contained in the hydraulic steering system is harmful to the eyes and skin and may also damage the vehicle bodywork.
For vehicles UP TO Ass.ly No. 98001 when replacing the power steering fluid reservoir, the pipe from the power steering fluid reservoir to the power steering pump and the pipe from the underbody to the power steering fluid reservoir, the components of either RETROFIT KIT Part No. 280917, or of RETROFIT KIT Part No.
279662, must be used, referring to the indications given in the Spare Parts Catalogue.
The components of RETROFIT KIT Part No. 280917 and RETROFIT KIT Part No. 279662 are solely compatible with the power steering fluid prescribed FROM Ass.ly No. 98002.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering tank Page 3 of 3
Connect the two pipes (2) to the power steering tank (A) by tightening the relative clamps.
Tightening torque
Screw collar
Screw collar
Nm
4 Nm
4 Nm
Class
B
B
Fit the power steering tank (A) onto its mounting bracket.
Tighten the screws indicated fastening the power steering reservoir (A) .
Connect the vent pipe (1) to the power steering reservoir cap (A) .
Fit the shield (3) and fasten by tightening the screws indicated.
Fit the vent pipe (1) in the relative seat on the shield
(3) .
Fill the power steering system ( D5.08
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering pump
Print Exit
D5.03 Power steering pump
Removing the power steering pump
Page 1 of 7
The majority of cases of NOISY power steering pump operation are caused by contaminated fluid in the system; therefore, attempt to rectify the failure before replacing the power steering pump, replacing the power steering fluid tank ALWAYS. Fit the new tank correctly, ensuring that the tank cap and breather are exactly as specified in the respective vehicle layout to prevent infiltration, which will contaminate the power steering fluid. Then fill the power steering system with fluid and bleed and perform another pump function test. Only replace the power steering pump if the problem persists.
(Ref: Technical Information No. 1695 _ December 2008)
Located on the left-hand side of the engine, above the compressor.
Remove the rear wheelhouses ( E3.05
).
Remove the rear left hand wheelhouse.
Remove the compressor ( F5.03
).
Drain the power steering system ( D5.08
).
Remove the engine inspection hatch ( E4.06
).
Remove the heat shield (1) on the compressor, undoing the screw indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering pump Page 2 of 7
Undo the screw indicated fastening the heat shield to the power steering pump (2) .
Remove the heat shield on the power steering pump (2) , undoing the screw indicated.
Undo the rear screw indicated fastening the power steering pump (A) to the engine. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering pump Page 3 of 7
Remove the cover (3) by undoing the screws indicated.
Undo the two front screws indicated fastening the power steering pump (A) to the engine.
Retrieve the pipe guard.
Holding the power steering pump (A) , undo the union (4) on the rigid pipe and remove the clamp
(5) on the hose.
Remove the power steering pump (A) .
Refitting the power steering pump https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering pump Page 4 of 7
Tightening torque
Fastening rigid pipe to power steering pump
Fastening A.C. compressor heat shield
Fastening power steering pump to engine
Fastening cover to power steering pump
Union
Screw
Screw
Screw
Nm
37 Nm
9 Nm
25 Nm
10 Nm
Class
B
C
B
B
The majority of cases of NOISY power steering pump operation are caused by contaminated fluid in the system; therefore, attempt to rectify the failure before replacing the power steering pump, replacing the power steering fluid tank ALWAYS. Fit the new tank correctly, ensuring that the tank cap and breather are exactly as specified in the respective vehicle layout to prevent infiltration, which will contaminate the power steering fluid. Then fill the power steering system with fluid and bleed and perform another pump function test. Only replace the power steering pump if the problem persists.
(Ref: Technical Information No. 1695 _ December 2008)
Holding the power steering pump assembly (A) , connect and fasten the hose, applying and tightening a new clamp (5) , and tighten the rigid pipe union (4) .
Tightening torque Nm Class
Fit the power steering pump assembly (A) , with the relative mountings, in its seat on the engine.
Fit the pipe guard.
Hand tighten the front screws (11) and (12) fastening the power steering pump assembly
(A) , installing the relative washers. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering pump Page 5 of 7
Hand tighten the indicated rear screw (13) fastening the power steering pump (A) to the engine.
Fit the cover (3) onto the power steering pump and fasten by hand tightening the screws (8) .
Fit the heat shield on the power steering pump (2) and fasten by tightening the screw indicated.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering pump Page 6 of 7
Tighten the screw indicated fastening the heat shield to the power steering pump (2) .
Fit and fasten the heat shield on the compressor
(1) , tightening the screw indicated.
Tightening torque Nm Class
Refit the compressor ( F5.03
).
Carry out the procedure for installing the compressor, hand tightening the fastener screws only.
Tighten the front screws fastening the power steering pump in the following sequence: (11) -
(12) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Power steering pump Page 7 of 7
Tighten the indicated rear screw (13) fastening the power steering pump (A) to the engine.
Tightening torque Nm Class
Refit the compressor ( F5.03
).
Tighten the screws fastening the AC compressor.
Tighten the screws indicated fastening the cover (3) .
Tightening torque Nm Class
Refit the ancillary belt ( A3.12
).
Reconnect the battery ( F2.01
).
Refit the rear wheelhouses ( E3.05
).
Refit the rear flat undertray section ( E3.12
).
Fill the power steering system ( D5.08
).
Charge the air conditioning system. ( F5.12
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box Page 1 of 8
Print Exit
Removing the steering box
Disconnect the battery ( F2.01
).
Remove the luggage compartment tub ( E4.07
).
Remove the front flat undertray section ( E3.12
).
Remove the wheels ( D2.01
).
Remove the front wheels.
Remove the front stabiliser bar ( D4.05
).
Drain the power steering system ( D5.08
).
Disconnect the connector (1) from the steering box
(A) .
Undo the nut (2) fastening the left hand tie-rod (B) to the left hand hub carrier (C) .
Disconnect the left hand tie-rod (B) from the left hand hub carrier (C) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box Page 2 of 8
Undo the nut (2) fastening the right hand tie-rod (B) to the right hand hub carrier (C) .
Disconnect the right hand tie-rod (B) from the right hand hub carrier (C) .
Undo the screw (3) fastening the universal joint (D) linking the steering column (E) with the steering box.
On the left-hand side, undo the two screws indicated fastening the steering box (A) to the chassis.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box Page 3 of 8
On the right-hand side, undo the two screws indicated fastening the steering box (A) to the chassis.
Retrieve the mounting (4) and the relative shim (5) .
Remove the clamp (6) retaining the steering box cables (A) .
Undo the two screws indicated fastening the recirculation pump mounting bracket (F) .
Move the recirculation pump (F) , complete with mounting bracket, out of its seat to facilitate the removal of the steering box (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box Page 4 of 8
Rotating clockwise by just enough to allow its removal from the front left hand wheel bay, remove the steering box (A) from the relative seat.
Refitting the steering box
Tightening torque
Fastening retainer bracket on recirculation pump Screw
Fastening steering box to chassis Nut (pretightening)
Nm
9 Nm
25 Nm
Class
B
B
Fastening steering column to steering box Screw
Fastening steering box tie-rod to front hub carrier Nut
30 Nm
40 Nm
B
A
Rotating by just enough to allow to pass through the front left hand wheel bay, fit the steering box (A) in the relative seat.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box Page 5 of 8
Fit the water recirculation pump (F) , complete with mounting bracket, in the relative seat, after installing the steering box (A) correctly.
Tighten the two screws indicated fastening the recirculation pump mounting bracket (F) .
Tightening torque Nm Class
Refit the cable retainer clamp (6) on the steering box (A) .
Fit the mounting (4) and the relative shim (5) on the steering box (A) .
On the right hand side, tighten the indicated screws fastening the steering box (A) to the chassis.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box Page 6 of 8
On the left hand side, tighten the indicated screws fastening the steering box (A) to the chassis.
Pre-tighten and definitively tighten the steering box fastener screws in a cross pattern.
Tightening torque
Nut (pretightening)
Nm
25 Nm
Class
B
Tighten the screw (3) fastening the universal joint
(D) linking the steering column (E) with the steering box.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box Page 7 of 8
Connect the right hand tie-rod (B) to the right hand hub carrier (C) .
Pre-tighten, loosen and then definitively tighten the nut (2) fastening the right hand tie-rod (B) to the right hand hub carrier (C) .
Tightening torque Nm Class
Connect the left hand tie-rod (B) to the left hand hub carrier (C) .
Pre-tighten, loosen and then definitively tighten the nut (2) fastening the left hand tie-rod (B) to the left hand hub carrier (C) .
Tightening torque Nm Class
Connect the connector (1) to the steering box (A) .
Refit the front stabiliser bar ( D4.05
).
Refit the wheels ( D2.01
).
Refit the front wheels.
Refit the front flat undertray section ( E3.12
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering box
Refit the luggage compartment tub ( E4.07
).
Reconnect the battery ( F2.01
).
Fill the power steering system ( D5.08
).
Page 8 of 8 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Radiator/power steering fluid coil
Print Exit
D5.05 Radiator/power steering fluid coil
Removing the radiator/power steering fluid coil
Drain the power steering system ( D5.08
).
Remove the luggage compartment tub ( E4.07
).
Remove the front bumper ( E3.03
).
FROM Ass.ly No. 92003
Undo the indicated screw.
Page 1 of 6
Undo the indicated inner screws fastening the lower radiator air duct (A) to the water radiator.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Radiator/power steering fluid coil
Remove the indicated rivets.
Page 2 of 6
New solution
Undo the screws indicated.
The indicated screws replace the previous rivets.
Undo the indicated outer screws fastening the lower radiator air duct (A) to the water radiator.
Remove the lower radiator air duct (A) from the relative seat, easing out towards the front of the vehicle.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Radiator/power steering fluid coil Page 3 of 6
Disconnect the unions (1) from the power steering fluid radiator (B) , undoing the relative fastener nuts indicated.
Remove the power steering fluid radiator (B) from the relative seat.
FROM Ass.ly No. 94435
Detach the pipes (1) removing the indicated clamps.
FROM Ass.ly No. 94435
Undo the screws indicated.
Remove the coil (B) .
Refitting the radiator/power steering fluid coil https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Radiator/power steering fluid coil Page 4 of 6
Tightening torque
Fastening power steering pipe unions to power steering fluid radiator
Fastening the power steering fluid coil
Fastening lower radiator air ducts
Check the radiators for fouling ( A3.32
).
Screw
Screw
Nm
5 Nm
5 Nm
Class
C
C
Fit the power steering fluid radiator (B) in the relative seat.
Connect the unions (1) to the power steering fluid radiator (B) , tightening the relative fastener nuts indicated.
Tightening torque Nm Class
FROM Ass.ly No. 94435
Fit the coil (B) .
Tighten the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Radiator/power steering fluid coil Page 5 of 6
FROM Ass.ly No. 94435
Connect the pipes (1) , fastening the new clamps as indicated.
Fit the lower radiator air duct (A) in the relative seat, installing from the front of the vehicle.
Tighten the indicated outer screws fastening the lower radiator air duct (A) to the water radiator.
Tightening torque Nm Class
Fit new rivets in the indicated positions. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Radiator/power steering fluid coil Page 6 of 6
New solution
Tighten the screws indicated.
The indicated screws replace the previous rivets.
Tightening torque Nm Class
Tighten the indicated inner screws fastening the lower radiator air duct (A) to the water radiator.
Tightening torque Nm Class
FROM Ass.ly No. 92003
Tighten the indicated screw.
Tightening torque Nm Class
Refit the front bumper ( E3.03
).
Refit the luggage compartment tub ( E4.07
).
Fill the power steering system ( D5.08
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering wheel
Print Exit
Removing the steering wheel
Disconnect the battery ( F2.01
).
Remove the driver side airbag module ( F4.02
).
Remove the cover (1) .
Page 1 of 3
Disconnect the connector (2) .
Undo the fastener nut, (3) , retrieve the washer and remove the steering wheel. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering wheel Page 2 of 3
Fasten the clock spring connector (B) with a clamp
(4) .
Refitting the steering wheel
Tightening torque
Fastening steering wheel to steering column Nut
Nm
50 Nm
Class
B
Remove the clamp (4) to release the clock spring connector (B) .
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering wheel Page 3 of 3
Fit the steering wheel in its seat, by tightening the fastener nut (3) after having fitted the relative washer.
Tightening torque
Connect the connector (2) .
Nm Class
Position the cover (1) and press down fully.
Refit the driver side airbag module ( F4.02
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering column
Print Exit
Removing the steering column
Disconnect the battery ( F2.01
).
Remove the steering wheel ( D5.06
).
Remove the steering column trim panel ( E4.02
).
Remove the dashboard trim panels ( E4.02
).
Remove the lower left hand trim.
Remove the instrument panel ( E5.02
).
Open the clamp (1) .
Disconnect the connectors (2) .
Page 1 of 6
Detach the connectors (3) and (4) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering column
Disconnect the connectors (5) .
Disconnect the connectors (6) .
Page 2 of 6
Mark the position of the steering column with respect to the steering box shaft.
Undo the indicated screw.
Remove the steering column (A) from the steering box.
Undo the lower screws indicated fastening the steering column (A) .
Undo also the two screws on the right hand side of the steering column. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering column Page 3 of 6
Undo the indicated upper screws and remove the steering column (A) from the dashboard.
Refitting the steering column
Tightening torque
Fastening lower fastener for steering column to dashboard
Fastening upper fastener for steering column to dashboard
Fastening steering column to steering box
Nm Class
Screw 30 Nm B
Fit the steering column (A) in the relative seat on the dashboard.
Hand tighten the lower screws indicated fastening the steering column (A) .
Hand tighten also the two screws on the right hand side of the steering column. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering column Page 4 of 6
Hand tighten the upper screws indicated fastening the steering column (A) .
Tighten the lower screws indicated fastening the steering column (A) .
Tighten also the two screws on the right hand side of the steering column.
Tightening torque Nm Class
Tighten the upper screws indicated fastening the steering column (A) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering column Page 5 of 6
Using the markings made during removal as reference, fit the steering column (A) on the steering box.
Tighten the indicated screw.
Tightening torque Nm Class
Connect the connectors (5) .
Connect the connectors (6) .
Connect the connectors (3) and (4) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Steering column Page 6 of 6
Connect the connectors (2) .
Close the clamp (1) securing the cables as originally installed.
Refit the instrument panel ( E5.02
).
Refit the dashboard trim panels ( E4.02
).
Refit the lower left hand trim.
Refit the steering column trim panel ( E4.02
).
Refit the steering wheel ( D5.06
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Emptying and filling the power steering system
Print Exit
D5.08 Emptying and filling the power steering system
Draining the power steering system
Page 1 of 5
Remove the front flat undertray section ( E3.12
).
Remove the left hand element of the front flat undertray section.
Unscrew and open the power steering fluid reservoir cap (A) .
Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Cover the connector adequately.
Loosen the unions (1) and (2) .
Drain the oil completely.
Filling the power steering system https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Emptying and filling the power steering system Page 2 of 5
Tightening torque
Fastening delivery and return pipes on steering box
M14 pipe union
M16 pipe union
Nm
35 Nm
38 Nm
Class
B
B
FROM Ass.ly No. 98002, a different power steering fluid is prescribed.
Before topping up or filling, always check which type of fluid should be used, as mixing the two different types of power steering fluid will damage the power steering system itself.
The power steering system is self-bleeding.
Replace the respective seal and tighten the union
(1) .
Tightening torque
M14 pipe union
Nm
35 Nm
Class
B
Replace the respective seal and tighten the union
(2) .
Tightening torque
M16 pipe union
Nm
38 Nm
Class
B
Remove the power steering tank ( D5.02
).
Clean the interior of the power steering fluid reservoir thoroughly using a small quantity of new power steering fluid of the specified type.
Allow the power steering fluid used to clean the power steering fluid reservoir to drain completely into a suitable container.
Use a suitable syringe to aspirate any residue of the power steering fluid used for cleaning from the power steering fluid reservoir. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Emptying and filling the power steering system Page 3 of 5
Refit the power steering tank ( D5.02
).
Connect a suitable additional pipe to the power steering fluid reservoir return pipe (B)
Place the other end of the pipe into a container for collecting the power steering fluid.
CAUTION
The oil contained in the hydraulic steering system is harmful to the eyes and skin and may also damage the vehicle bodywork.
Adequately protect the areas surrounding the power steering tank pipes (B) and (C) .
DO NOT apply any more turning force to the steering wheel once full lock is reached.
Steer fully to the left and right a few times until power steering fluid starts to flow from the tank return pipe (B) .
Connect a suitable funnel to the power steering fluid reservoir delivery pipe (C) .
Place an 80 micron mesh filter in the funnel.
Pour new power steering fluid into the funnel while simultaneously steering to the left and right a few times until at least 3 litres of power steering fluid has been collected from the power steering fluid reservoir return pipe (A) .
Do not let the funnel empty during this procedure.
Disconnect and remove the funnel from the power steering fluid reservoir delivery pipe (C) .
Disconnect and remove the additional pipe from the power steering fluid reservoir return pipe (B) .
Undo and open the cap (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Emptying and filling the power steering system Page 4 of 5
Always use fresh oil of the recommended type and in the quantity indicated, taken from sealed containers.
The circuit is filled with synthetic oil.
Using mineral oil may cause irreparable damage to the rubber seals in the system.
DO NOT apply any more turning force to the steering wheel once full lock is reached.
Fill the power steering fluid reservoir to the MAX limit on the cap dipstick (A) while simultaneously steering fully to the right and left repeatedly until the power steering fluid level stabilises and the fluid contains no bubbles.
There are MIN and MAX levels indicated on both sides of the dipstick. Use the levels on the side indicating the temperature 20°C .
Start and stop the engine twice repeatedly.
Check that the fluid level is stable and that the fluid is not emulsified with air.
If the power steering fluid level drops, top the power steering fluid reservoir up to the MAX limit on the cap dipstick (A) while simultaneously steering fully to the right and left repeatedly until the power steering fluid level stabilises and the fluid contains no bubbles.
There are MIN and MAX levels indicated on both sides of the dipstick. Use the levels on the side indicating the temperature 20°C .
Lift the vehicle with a vehicle lift so that the wheels are not in contact with the ground.
Start the engine and run at idle speed for 1 minute .
DO NOT apply any more turning force to the steering wheel once full lock is reached.
Check the power steering system fluid level ( A3.06
).
Simultaneously, steer fully 10 times.
Lower the vehicle to bring the wheels into contact with the ground.
Wait for the engine coolant temperature to reach 90°C .
DO NOT apply any more turning force to the steering wheel once full lock is reached.
Check the power steering system fluid level ( A3.06
).
Simultaneously, steer fully 10 times.
Repeat this procedure another three times.
Check the power steering system fluid level ( A3.06
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Emptying and filling the power steering system
Refit the front flat undertray section ( E3.12
).
Page 5 of 5 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_D50...
8/5/2011
Tightening torques
Print Exit
Page 1 of 3
Tightening torque
Fastening wheelhouse
Fastening luggage compartment tub
Fastening underwindscreen shields
Fastening flat undertray elements
Fastening luggage compartment shields
Screw
Screw
Screw
Screw
Screw
Fastening lower gearbox mounting cross member to chassis
Fastening removable subframe to chassis
Fastening seat
Fastening F1 shift paddles
Fastening steering angle sensor mounting to steering column
Fastening cabin light
Fastening DCT gearbox control panel
Fastening the NIT
Fastening the woofer
Fastening radio amplifier
Fastening amplifier
Fastening steering column trim panel
Fastening rear subframe in rear suspension mounting casting area
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Pretightening torque for screw
Fastening for lateral front part of rear subframe Pretightening torque for screw
Fastening for lateral engine strut mounting point extrusion of rear subframe.
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Fastening sill connector cross member area of rear subframe (on bushing)
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Fastening for rear subframe in rear part of rear suspension mounting casting
Fastening rear subframe in rear radiator area Screw
Nm
3 Nm
8 Nm
4.5 Nm
8.5 Nm
4.5 Nm
9 Nm
24 Nm
40 Nm
4 Nm
3 Nm
3 Nm
5 Nm
3.5 Nm
7 Nm
6 Nm
5 Nm
15 Nm
15 Nm
Class
C
C
B
B
B
C
B
C
B
B
B
B
B
B
B
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E10...
8/5/2011
Tightening torques Page 2 of 3
Tightening torque
Fastening for shield plate for fuel tank connector pipe
Fastening mounting bracket for fuel tank connector pipe
Fastening ground cable to rear subframe
Fastening ground cable to rear subframe
Fastening rear radiator air duct
Fastening bumper
Screw
Screw
Screw / Nut
Screw
Fastening engine compartment cosmetic shields Screw
Fastening passenger compartment trim panels Screw
Fastening roof trim panels Screw
Fastening centre console trim panel
Fastening fuel filler neck
Fastening glove compartment to dashboard
Fastening central bracket
Fastening diagnostic socket mounting bracket
Fastening fuse box mounting bracket
Lateral fastening for dashboard from luggage compartment
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Lateral fastening for dashboard from luggage compartment
Central fastening dashboard from luggage compartment
Lateral fastening dashboard from passenger compartment
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Central fastening dashboard from passenger compartment
Fastening engine inspection hatch
Fastening doors
Fastening door panel
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Fastening seat belts
Fastening quarterlight
Screw
Screw
Fastening windscreen and headlight washer fluid Screw
Nm Class
9 Nm
18 Nm
9 Nm
7.5 Nm
4.5 Nm
7 Nm
7 Nm
8.5 Nm
5 Nm
4 Nm
8 Nm
3 Nm
5 Nm
C
C
B
C
B
B
B
B
B
B
B
C
C
9 Nm
18 Nm
4 Nm
40 Nm
5 Nm
5 Nm
C
B
B
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E10...
8/5/2011
Tightening torques Page 3 of 3
Tightening torque reservoir
Fastening fuel filler flap
Fastening actuator striker plate to fuel filler flap
Fastening fuel filler flap actuator
Fastening external rear view mirror
Nut
Nut
Screw
Nut
Fastening engine compartment lid lock shield
Fastening engine compartment lid lock
Fastening engine compartment lid lock striker plate Screw
Fastening luggage compartment lid lock Screw
Fastening luggage compartment lid lock striker plate
Screw
Screw
Fastening gas strut to glove compartment door
Fastening glove compartment liner
Fastening under rear screen cosmetic shield
Fastening structural connector plate
Fastening driver side seat height adjustment mechanism
Fastening engine buffer cross member
Nut
Screw
Screw
Screw
Fastening door striker plates
Fastening internal door window scraper seal
Fastening door window
Fastening external door window scraper seal
Fastening the door triangle trim
Fastening passenger side footrest mat
Fastening the dashboard trim panels
M8x20 screw
M6x14 screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Fastening underdashboard mats Screw
Fastening engine compartment lid grilles
Fastening sill trim
Screw
Screw
Fastening window lifter mechanism Nut
Fastening engine compartment lid release handle Screw
Fastening armrest bracket Nut
Fastening internal body of external door handle Nut
Fastening external body of external door handle Screw
Fastening door lock
Fastening driver side door latch
Screw
Nut
Fastening breather duct and cover Screw
Fastening the fuel filler neck ground lug terminal Nut
Fastening instrument panel binnacle Screw
Class
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
C
B
B
B
B
B
B
C
B
B
C
B
B
B
B
B
A
B
B
Nm
4 Nm
5 Nm
5 Nm
9.5 Nm
4.1 Nm
9 Nm
8 Nm
8 Nm
7 Nm
4 Nm
4.1 Nm
8 Nm
20 Nm
8 Nm
23 Nm
2 Nm
9.5 Nm
4 Nm
9.5 Nm
9 Nm
5 Nm
5 Nm
8 Nm
4.5 Nm
9.5 Nm
5 Nm
9 Nm
2 Nm
3.5 Nm
9.5 Nm
2 Nm
5 Nm
5 Nm
4 Nm https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E10...
8/5/2011
Specific tooling and equipment
Print Exit
E1.02 Specific tooling and equipment
Page 1 of 3
Trolley 95977565 (AS 107565) removing the engine / gearbox / subframe assembly.
Safety extensions 95977513 (AS 107573) for trolley AS 107565 for removing/refitting rear subframe.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E10...
8/5/2011
Specific tooling and equipment
Safety retainers 95978183 (AV 8183) vehicle anti-tipping retention.
Page 2 of 3
Fastener brackets for safety retainers 95978184
(AV 8184) raised vehicle anti-tipping retention for runway type car lifts.
Mounting bracket for vehicle safety retainers for lifting 95978251 (AV 8251) lifting vehicle on vehicle lift. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E10...
8/5/2011
Specific tooling and equipment Page 3 of 3
Spacers 95978255 (AV 8255) for trolley AS 107565 for removing/refitting rear subframe.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E10...
8/5/2011
General Page 1 of 1
Print Exit
E2.01 General
Features of the chassis
As already seen on the California, a "Space-frame" architecture has been adopted for the aluminium chassis, meaning less weight, for improved performance and safety, and greater torsional stiffness, for superior dynamic qualities.
Using a modular chassis also introduces the following advantages: greater service efficiency and shorter service times; easier maintenance from a Client perspective; reduced replacement times for damaged parts; reduced running costs. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
8/5/2011
Rear removable engine-gearbox assembly mounting subframe
Print Exit
Removing the rear subframe
Page 1 of 58
CAUTION
For safety reasons, the VEHICLE MAY ONLY BE LIFTED WITH THE ANTI-TIPPING SAFETY RETAINERS
INSTALLED.
Disconnect the battery ( F2.01
).
Lift the vehicle using anti-tipping safety retainers ( E3.12
).
Remove the rear flat undertray section ( E3.12
).
Remove the central flat undertray section ( E3.12
).
Remove the rear wheelhouses ( E3.05
).
Remove the rear bumper ( E3.04
).
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the engine air ducts ( B4.02
).
Drain the cooling system ( B6.07
).
Discharge the air conditioning system ( F5.12
).
Drain the power steering system ( D5.08
).
Drain the fuel system ( B3.06
).
Remove the expansion tank ( B6.02
).
Remove the engine compartment lid lock ( E5.11
).
FROM Ass.ly No. 90802. Remove the luggage compartment tub ( E4.07
).
To remove the rear subframe complete with gearbox and engine, use the trolley ( AS 107565 ) .
The trolley consists of a turntable platform (53) , which can be locked in position with the two handles (54) ; of six locator pins (52) , with relevant swivelling and removable mounts; of a pedal (55) for lifting the platform, and a handle
(56) for lowering the platform. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
8/5/2011
Rear removable engine-gearbox assembly mounting subframe Page 2 of 58
Before starting the following procedure, the trolley
( AS 107565 ) must be configured correctly for removing the rear subframe on this vehicle.
Undo the indicated screws fastening the handle (A) to the mountings on the trolley ( AS 107565 ) .
Fit the safety extensions ( AS 107573 ) , as shown in the figure aside, and fasten to the trolley
( AS 107565 ) , tightening the screws and nuts indicated by the red arrows after installing the relevant washers.
Fasten the handle (A) to the safety extensions
( AS 107573 ) , tightening the screws removed and retrieved during the previous step.
Check that the cable and handle for lowering the platform are positioned correctly and function correctly.
Disconnect the three gearbox wiring harness connectors (5) and remove from the relevant mounting bracket.
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
8/5/2011
Rear removable engine-gearbox assembly mounting subframe Page 3 of 58
Detach the gearbox wiring harness (6) from the chassis, detaching the indicated clip.
Place the gearbox wiring harness (6) on the air filter box, taking care not to damage the box, so that it does not hinder the subsequent operations.
Separate the cables (7) of the engine compartment lid lock, undoing the lock grub screw and retrieving the cable clamp (8) .
If present, remove shield (81) by loosening the indicated screws.
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If present, remove shield (82) by loosening the indicated screws.
Detach the cable (7) for emergency release of the engine compartment lid lock, removing the indicated clamps.
Detach the cable (9) for the fuel filler flap emergency release, by loosening the nut indicated by the red arrow.
Remove the cover (92) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Disconnect the low pressure pipe (1) from the fuel pump filter.
FROM Ass.ly No. 90802
Release the low pressure pipe (1) by opening the indicated clamp.
Remove the cover (91) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Disconnect the low pressure pipe (2) from the fuel pump filter.
Remove the indicated clamps and disconnect the pipes (3) from the respective evaporative emissions control system solenoid valves.
FROM Ass.ly No. 90802
Release the low pressure pipe (2) by opening the indicated clamp.
Left-hand side
Remove the indicated clamp and remove the evaporative emissions control system solenoid valve connector pipe (3) from the engine compartment.
Remove the indicated clamp and disconnect the secondary air system connector pipe (4) .
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Right-hand side
Remove the indicated clamp and remove the evaporative emissions control system solenoid valve connector pipe (3) from the engine compartment.
Lift the cover (21) of the junction box and undo the indicated nut fastening the cable (45) .
Detach the clamps retaining the cable (45) to the chassis.
Release the right hand injection cable (23) , cutting the indicated cable ties and detaching the indicated clamps fastened to the chassis.
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Release the right hand injection cable (23) , cutting the indicated cable ties and detaching the indicated clamps fastened to the chassis.
Disconnect the connector (24) from the right hand
Motronic ECU, and disconnect the connector
(25) from the engine compartment cable junction.
Release the right hand injection cable (22) leading to the ELDOR ECU, removing the indicated clamps.
Disconnect the connectors (26) from the ELDOR
ECU.
Disconnect the front right hand oxygen sensor connector (27) and remove the indicated clips.
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Pull out the right hand injection cable (22) and place on top of the intake manifold.
Release the left hand injection cable (28) , removing the indicated clamps.
Disconnect the front left hand oxygen sensor connector (29) and remove the indicated clips.
Undo the screws indicated fastening the fuel vapour separator mounting bracket (30) to the chassis.
Release the left hand injection cable (28) , removing the indicated clamps, and disconnect the connector (31) from the engine compartment cable junction.
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Disconnect the connector (32) from the left hand
Motronic ECU.
Pull out the left hand injection cable (28) and place on top of the intake manifold.
Remove the left hand air duct (10) , undoing the indicated screws, then ease out towards the rear.
Disconnect the solenoid valve connector (11) on the radiator.
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Remove the right hand air duct (12) , undoing the indicated screws, then ease out towards the rear.
Disconnect the two connectors (13) on the solenoid valves and release the relevant cables from the retainer clips on the rear subframe.
Disconnect the third stop light connector (14) and release the relevant cable from the indicated clamps.
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On the left hand rear suspension, undo the indicated nut fastening the ground cable (15) and cut the cable tie indicated by the red arrow.
Remove the indicated clamps and disconnect the connector (16) .
Disconnect the connector (18) on the shock absorber and release the cable (17) , removing the indicated clamps. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Undo the screw (19) fastening the ground cables to the chassis and remove the indicated clamps.
Disconnect the connectors (66) and remove the indicated clamps.
Disconnect the shock absorber connector (64) and release the cable (65) , removing the indicated clamps.
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Disconnect the connector (61) on the EPB ECU.
Undo the screw (63) fastening the ground cable to the chassis.
Undo the screw (62) fastening the ground cables to the chassis.
Release the wiring harnesses, removing the indicated clamps.
On the right hand rear suspension, undo the indicated nut fastening the ground cable (60) and cut the cable tie indicated by the red arrow.
Disconnect the right hand rear oxygen sensor connector (59) and release the relevant wiring harness, cutting the indicated clamps.
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Disconnect the left hand rear oxygen sensor connector (58) and release the relevant wiring harness, cutting the indicated clamp.
Remove the mounting bracket (57) , undoing the indicated screw.
FROM Ass.ly No. 90802 _ rear of vehicle
Open the indicated clamp.
Remove the mounting bracket (57) , undoing the indicated screw.
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Remove the two shield brackets (67) from the rear subframe, undoing the indicated screws.
CAUTION
Fuel is highly flammable.
NEVER WORK ON A HOT ENGINE.
CAUTION
Take every necessary precaution, since fuel residues may remain in the tank and in the pipes, even after the operations described.
Place a container under the quick couplings (69) , as there may be some residual fuel in the tanks and in the connector pipe (68) .
Mark the position of the tank connector pipe (68) with respect to the connectors so as to reassemble it correctly.
Disconnect the quick couplings (69) on the tank connector pipe (68) , disconnecting one end first and then the other.
Place plugs on the tank inlets.
UP TO Ass.ly No. 90801
Remove the bracket (70) on the pipe retainer pillory block (72) , undoing the screws indicated by the red arrows.
Place a container under the clamps (71) .
Loosen the indicated clamps then detach the coolant pipes (71) from the rigid pipes and the pipe retainer pillory block.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely.
Remove the clamp (73) and disconnect the vent pipe leading from the radiator to the header tank.
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UP TO Ass.ly No. 90801
Remove the indicated clamps fastening the pipes.
UP TO Ass.ly No. 90801
Undo the screws indicated.
Remove the structural connector plate (90) .
UP TO Ass.ly No. 90801
Undo the indicated screws fastening the mounting brackets to the bodyshell and tilt the rear part of the pipes (80) downwards. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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UP TO Ass.ly No. 90801
The pipe connections are protected by a section of sheath fastened with a clamp. Cut the clamp and move the section of sheath in order to disconnect the pipes.
Both open ends must be adequately plugged immediately after disconnecting pipes.
Undo the AC unions (78) and the power steering system unions (77) .
Disconnect the brake servo vacuum system quick coupling (76) .
Remove the clamp (75) and disconnect the water pipe leading to the recirculation pump.
Undo the unions (74) for the brake fluid pipes leading to the rear callipers.
FROM Ass.ly No. 90802 _ rear of vehicle
Both open ends must be adequately plugged immediately after disconnecting pipes.
Open the clamps indicated.
Release the pipes from the relative clamps.
Remove the clamp (94) on the power steering system pipe.
Disconnect the quick coupling (93) on the AC pipe.
Disconnect the quick coupling (77) on the power steering system pipe.
Undo the union (78) on the AC pipe.
FROM Ass.ly No. 90802 _ rear of vehicle
Undo the union (74) on the brake fluid pipe leading to the rear calliper.
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FROM Ass.ly No. 90802 _ rear of vehicle
Place a container under the clamps (71) .
Loosen the indicated clamps (71) and disconnect the water pipes.
Pour the fluid drained from the system into a container and seal it. DO NOT DISPOSE OF
USED FLUID IN THE ENVIRONMENT.
Allow all the fluid to drain completely.
Disconnect the brake servo vacuum system quick coupling (76) .
Remove the clamp (73) and disconnect the vent pipe leading from the radiator to the header tank.
Detach the brake fluid pipe from the indicated clip.
Undo the union (74) on the brake fluid pipe leading to the rear calliper.
FROM Ass.ly No. 90802 _ vehicle rear end _ for vehicles with front lifter ONLY
Undo the union (1A) .
FROM Ass.ly No. 90802 _ rear of vehicle
Open the indicated clamp.
Disconnect the quick coupling (75) on the water pipe leading to the recirculation pump.
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FROM Ass.ly No. 90802 _ front of vehicle
Remove the clamp (75) and disconnect the pipe.
FROM Ass.ly No. 90802 _ front of vehicle
Undo the screws indicated.
Disconnect the connector (95) .
Remove the clamp (73) and disconnect the vent pipe leading from the radiator to the header tank.
Undo the unions (74) for the brake fluid pipes leading to the rear callipers.
Remove the clamp (96) and disconnect the relative pipe.
Undo the union (78) on the AC pipe.
FROM Ass.ly No. 90802 _ front of vehicle
Loosen the indicated clamp (71) and disconnect the water pipe.
Loosen the clamp (94) and disconnect the power steering system pipe. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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FROM Ass.ly No. 90802 _ front of vehicle
Loosen the indicated clamp (71) and disconnect the water pipe.
FROM Ass.ly No. 90802 _ front of vehicle
Undo the union (93) on the AC pipe.
Remove the clamp indicated.
Disconnect the brake servo vacuum system quick coupling (76) .
Disconnect the quick coupling (77) on the power steering system pipe.
FROM Ass.ly No. 93357 _ front of vehicle
Undo the union (93) on the AC pipe.
Remove the clamp indicated.
Disconnect the brake servo vacuum system quick coupling (76) .
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FROM Ass.ly No. 93357 _ front of vehicle
Undo the pipe union (98) and disconnect the respective pipe.
FROM Ass.ly No. 90802 _ vehicle front end _ for vehicles with front lifter ONLY
Undo the union (2A) .
Release the pipe from the indicated clip.
FROM Ass.ly No. 90802 _ front of vehicle
Undo the screws indicated.
Remove the complete underbody pipe set (97) from underneath the vehicle. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Undo the indicated screws fastening the rear subframe, located on the inner side of the two rear radiators.
Right-hand side
Undo the indicated screws fastening the rear subframe in the rear radiator area.
Left-hand side
Undo the indicated screws fastening the rear subframe in the rear radiator area.
Make reference markings at the rear subframe fastener points to facilitate reassembly. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Right-hand side
From the wheel bay undo the screw indicated fastening the rear subframe, located in the rear of the rear suspension mounting casting.
Left-hand side
From the wheel bay undo the screw indicated fastening the rear subframe, located in the rear of the rear suspension mounting casting.
Right-hand side
Undo the upper screw indicated fastening the rear subframe located in the rear suspension mounting casting area. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Left-hand side
Undo the upper screw indicated fastening the rear subframe located in the rear suspension mounting casting area.
Open the clamp indicated by the red arrow and pull the engine compartment lid lock cable (7) outwards.
From underneath the vehicle, undo the four indicated screws fastening the rear subframe in the sill connector cross member area.
Tighten the spacer ( AV 8255 ) into the relevant hole on the left-hand side of the chassis, as shown in the photo aside. This spacer will serve as a front mounting point for the corresponding pin on the trolley ( AS 107565 ) .
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Tighten the spacer ( AV 8255 ) into the relevant hole on the right-hand side of the chassis, as shown in the photo aside. This spacer will serve as a front mounting point for the corresponding pin on the trolley ( AS 107565 ) .
CAUTION
To ensure safety, the following procedure for placing the support trolley in position must be carried out exactly as described.
Position the trolley ( AS 107565 ) with the control handle facing toward the rear; lift the platform so that the locator pins are approximately 20 mm from the respective holes in the chassis, as shown in the photo.
Lock the turntable platform by using the relevant handles.
CAUTION
ALWAYS ensure that the tool pins are correctly located in the respective holes in the chassis.
Using a hex headed wrench, tighten the locator pins of the trolley ( AS 107565 ) until they are flush with the respective holes on the rear subframe and on the front part of the latter, as shown in the photo, with the spacers ( AV 8255 ) installed previously.
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Right-hand side
Undo the indicated screws fastening the rear subframe in the rear suspension mounting casting area.
Left-hand side
Undo the indicated screws fastening the rear subframe in the rear suspension mounting casting area.
Right-hand side
Undo the indicated screws fastening the rear subframe at the lateral engine strut mounting point extrusion.
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Left-hand side
Undo the indicated screws fastening the rear subframe at the lateral engine strut mounting point extrusion.
Right-hand side
Undo the indicated screws fastening the rear subframe in the lateral front area.
Left-hand side
Undo the indicated screws fastening the rear subframe in the lateral front area. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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The rear subframe (79) is now disconnected from the bodyshell and is supported by the trolley
( AS 107565 ) .
Slowly lower the trolley ( AS 107565 ) , ensuring that there are no cables or pipes still connected and taking care not to scrape against any other components.
If the vehicle is lifted with a runway type vehicle lift, lower the subframe for approximately 150 -
200 mm , then move backwards to avoid contact with the runways.
Lower completely, move away from underneath the vehicle and set the complete rear subframe down in a safe place.
Refitting the rear subframe
Tightening torque
Fastening rear subframe in rear suspension mounting casting area
Pretightening torque for screw
Fastening for lateral front part of rear subframe Pretightening torque for screw
Fastening for lateral engine strut mounting point extrusion of rear subframe.
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Fastening sill connector cross member area of rear subframe (on bushing)
Products to use: AREXONS SYSTEM 52A43 -
MEDIUM STRENGTH THREAD LOCK
Fastening for rear subframe in rear part of rear suspension mounting casting
Fastening rear subframe in rear radiator area
Fastening brake fluid underbody pipe unions
Fastening underbody union with pipe leading from
AC compressor
Screw
Union
Union
Union (FROM Ass.ly No.
90802)
Union (FROM Ass.ly No.
90802)
Fastening underbody union with pipe leading to
AC compressor
Union (FROM Ass.ly No.
90802)
Fastening underbody union with power steering Union
Nm
15 Nm
15 Nm
9 Nm
16 Nm
16 Nm
20 Nm
26 Nm
26 Nm
40 Nm
Class
B
B
C
B
B
B
B
B
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Tightening torque fluid delivery pipe
Fastening underbody union with power steering fluid return pipe
Fastening underbody mounting brackets for cooling system rigid pipes
Fastening front pipe retainer pillory block - bodyshell
Fastening structural connector plate
Fastening brackets for complete underbody pipe set
Fastening delivery and return pipes on steering box
Screw
Screws (FROM Ass.ly
No. 90802)
M14 pipe union
M16 pipe union
Union Fastening vehicle lift system unions
Fastening for shield plate for fuel tank connector pipe
Fastening mounting bracket for fuel tank connector pipe
Fastening brake pad sensor ground cable
Fastening ground cable to rear subframe
Fastening ground cable to rear subframe
Nut
Screw
Screw
Fastening rear radiator air duct
Fastening fuel vapour separator mounting bracket removable subframe
Screw / Nut
Nm
8 Nm
6 Nm
35 Nm
38 Nm
16 Nm
6 Nm
18 Nm
9 Nm
9 Nm
Class
B
B
B
B
B
B
C
C
B
Clean the seats for the fasteners and the fasteners themselves, both on the rear subframe and on the vehicle chassis, to remove any dirt or adhesive residue.
Position the rear subframe (79) , supported by the trolley ( AS 107565 ) , under the rear of the vehicle.
Lift slowly the trolley ( AS 107565 ) making sure that pipes or cables do not touch or interfere.
When using a runway type vehicle lift, lift the subframe to approximately 150 - 200 mm from its seat, insert the subframe horizontally and then lift, to prevent contact with the runways.
Lift the rear subframe completely and fit in the relevant seat, using the markings made on the subframe and chassis during removal as reference.
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Right-hand side
Fit and pre-tighten the indicated screws fastening the rear subframe in the rear suspension mounting casting area.
Tightening torque
Pretightening torque for screw
Nm
15 Nm
Class
B
Left-hand side
Fit and pre-tighten the indicated screws fastening the rear subframe in the rear suspension mounting casting area.
Tightening torque
Pretightening torque for screw
Nm
15 Nm
Class
B
Right-hand side
Fit and pre-tighten the indicated screws fastening the rear subframe in the lateral front area.
Tightening torque
Pretightening torque for screw
Nm
15 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Left-hand side
Fit and pre-tighten the indicated screws fastening the rear subframe in the lateral front area.
Tightening torque
Pretightening torque for screw
Nm
15 Nm
Class
B
Right-hand side
Apply a small quantity of AREXONS SYSTEM
52A43 - MEDIUM STRENGTH THREAD LOCK to the screw threads.
Hand tighten the indicated screws fastening the rear subframe at the lateral engine strut mounting point extrusion.
Left-hand side
Apply a small quantity of AREXONS SYSTEM
52A43 - MEDIUM STRENGTH THREAD LOCK to the screw threads.
Hand tighten the indicated screws fastening the rear subframe at the lateral engine strut mounting point extrusion.
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Right-hand side
Tighten the indicated screws fastening the rear subframe in the lateral front area.
Tightening torque Nm Class
Left-hand side
Tighten the indicated screws fastening the rear subframe in the lateral front area.
Tightening torque Nm Class
Right-hand side
Tighten the indicated screws fastening the rear subframe at the lateral engine strut mounting point extrusion.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Left-hand side
Tighten the indicated screws fastening the rear subframe at the lateral engine strut mounting point extrusion.
Tightening torque Nm Class
CAUTION
Before removing the lift trolley, ensure that the screws are all correctly fastened.
Using the relevant lowering handle, slowly lower the trolley and remove from underneath the vehicle.
Right-hand side
Tighten the indicated screws fastening the rear subframe in the rear suspension mounting casting area.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Left-hand side
Tighten the indicated screws fastening the rear subframe in the rear suspension mounting casting area.
Tightening torque Nm Class
Apply a small quantity of AREXONS SYSTEM
52A43 - MEDIUM STRENGTH THREAD LOCK to the screw threads.
From underneath the vehicle, fit and tighten the four indicated screws fastening the rear subframe in the sill connector cross member area.
Tightening torque Nm Class
Right-hand side
Tighten the upper screw indicated fastening the rear subframe in the rear suspension mounting casting area.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Left-hand side
Tighten the upper screw indicated fastening the rear subframe in the rear suspension mounting casting area.
Tightening torque Nm Class
Fit the cable (7) for releasing the engine compartment lid from the passenger compartment in its original position and fasten by closing the clamp indicated by the red arrow.
Right-hand side
From the wheel bay tighten the screw indicated fastening the rear subframe, located in the rear of the rear suspension mounting casting.
Tightening torque Nm Class
Left-hand side
From the wheel bay tighten the screw indicated fastening the rear subframe, located in the rear of the rear suspension mounting casting.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Right-hand side
Tighten the indicated screws fastening the rear subframe in the rear radiator area.
Tightening torque Nm Class
Left-hand side
Tighten the indicated screws fastening the rear subframe in the rear radiator area.
Tightening torque Nm Class
Tighten the indicated screws fastening the rear subframe, located on the inner side of the two rear radiators.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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On both side of the rear subframe, undo and remove the spacers ( AV 8255 ) .
UP TO Ass.ly No. 90801
Once connected, the pipe connections must be protected with a section of sheath fastened with a new plastic clamp.
Remove the plastic plugs fitted previously on the ends of the pipes.
Tighten the unions (74) for the brake fluid pipes leading to the rear callipers.
Tightening torque Nm Class
Connect the water pipe leading to the recirculation pump and fasten by tightening the clamp (75) .
Connect the brake servo vacuum system quickcoupling (76) .
Tighten the AC unions (78) and the power steering system unions (77) .
Tightening torque
Union
Nm
16 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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UP TO Ass.ly No. 90801
Fasten the pipe mounting brackets (80) , tightening the indicated screws.
Tightening torque Nm Class
UP TO Ass.ly No. 90801
Connect the vent pipe leading from the radiator to the header tank and fasten by tightening the clamp (73) .
Fit the coolant pipes (71) in the relative seats on the pipe retainer pillory block (72) .
Connect the coolant pipes (71) onto the ends of the rigid pipes and tighten the indicated clamps.
Fasten the bracket (70) on the pipe retainer pillory block (72) , tightening the screws indicated by the red arrows.
Tightening torque Nm Class
UP TO Ass.ly No. 90801
Fit the structural connector plate (90) .
Tighten the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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UP TO Ass.ly No. 90801
Fasten the clamps retaining the pipes as originally fitted.
FROM Ass.ly No. 90802 _ front of vehicle
Fit the complete underbody pipe set (97) .
Tighten the screws indicated.
Tightening torque
Screws (FROM Ass.ly No.
90802)
Nm
6 Nm
Class
B
FROM Ass.ly No. 90802 _ front of vehicle
Remove the plastic plugs fitted previously on the ends of the pipes.
Tighten the union (93) on the AC pipe.
Tightening torque
Union (FROM Ass.ly No.
90802)
Nm
26 Nm
Class
B
Connect the brake servo vacuum system quickcoupling (76) .
Connect the quick coupling (77) on the power steering system pipe.
Fit the indicated clamp. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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FROM Ass.ly No. 93357 _ front of vehicle
Remove the plastic plugs fitted previously on the ends of the pipes.
Tighten the union (93) on the AC pipe.
Tightening torque
Union (FROM Ass.ly No.
90802)
Nm
26 Nm
Class
B
Connect the brake servo vacuum system quickcoupling (76) .
Fit the indicated clamp.
FROM Ass.ly No. 93357 _ front of vehicle
Replace the relative seals and tighten the pipe union (98) , connecting the respective pipe.
Tightening torque
M14 pipe union
Nm
35 Nm
Class
B
FROM Ass.ly No. 90802 _ front of vehicle
Connect the water pipe and fasten by tightening the clamp (71) .
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Rear removable engine-gearbox assembly mounting subframe Page 42 of 58
FROM Ass.ly No. 90802 _ front of vehicle
Connect the water pipe and fasten by tightening the clamp (71) .
Connect the power steering system pipe and fasten by tightening the clamp (94) .
FROM Ass.ly No. 90802 _ front of vehicle
Hand tighten the screws indicated.
Connect the connector (95) .
Connect the vent pipe leading from the radiator to the header tank and fasten by tightening the clamp (73) .
Tighten the unions (74) for the brake fluid pipes leading to the rear callipers.
Tightening torque Nm Class
Connect the water pipe to the rigid pipe and fasten by tightening the clamp (96) .
Tighten the union (78) on the AC pipe.
Tightening torque
Union (FROM Ass.ly No.
90802)
Nm
20 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 43 of 58
FROM Ass.ly No. 90802 _ front of vehicle
Connect the pipe and fasten with a new clamp (75) .
FROM Ass.ly No. 90802 _ vehicle front end _ for vehicles with front lifter ONLY
Tighten the union (2A) .
Tightening torque Nm
Fasten the pipe to the indicated clip.
Class
FROM Ass.ly No. 90802 _ rear of vehicle
Connect the quick coupling (75) on the water pipe leading to the recirculation pump.
Close the indicated clamp. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 44 of 58
FROM Ass.ly No. 90802 _ rear of vehicle
Tighten the union (74) on the brake fluid pipe leading to the rear calliper.
Tightening torque Nm Class
Fasten the brake fluid pipe to the indicated clip.
Connect the vent pipe leading from the radiator to the header tank with a new clamp (73) .
Connect the water pipes and fasten by tightening the clamps (71) .
Connect the brake servo vacuum system quickcoupling (76) .
FROM Ass.ly No. 90802 _ rear of vehicle
Tighten the union (74) on the brake fluid pipe leading to the rear calliper.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 45 of 58
FROM Ass.ly No. 90802 _ rear of vehicle
Tighten the union (78) on the AC pipe.
Tightening torque
Union (FROM Ass.ly No.
90802)
Nm
26 Nm
Class
B
Connect the quick coupling (93) on the AC pipe.
Connect the power steering system pipe and fasten by tightening the clamp (94) .
Connect the quick coupling (77) on the power steering system pipe.
Fasten the pipes to the relative clamps.
Close the indicated clamps.
FROM Ass.ly No. 90802 _ vehicle rear end _ for vehicles with front lifter ONLY
Tighten the union (1A) .
Tightening torque Nm Class
Remove the plugs on the tank inlets.
Direct the tank connector pipe (68) toward the connectors, following the notes taken during the disassembly operations.
Connect the quick-couplings (69) on the tank connector pipe (68) , connecting one end first and then the other.
Fasten the two shield brackets (67) onto the rear subframe, tightening the indicated screws.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 46 of 58
Fasten the mounting bracket (57) , tightening the indicated screw.
Tightening torque Nm Class
FROM Ass.ly No. 90802 _ rear of vehicle
Fasten the mounting bracket (57) , tightening the indicated screw.
Tightening torque Nm
Close the clamp indicated by the red arrow.
Class
Connect the left hand rear oxygen sensor connector
(58) and fasten the relevant wiring harness with a new clamp as indicated. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 47 of 58
Connect the right hand rear oxygen sensor connector (59) and fasten the relevant wiring harness with new clamps as indicated.
On the right hand rear suspension, tighten the indicated nut fastening the ground cable (60) and fit a new cable tie, as indicated by the red arrow.
Tightening torque Nm Class
Connect the connector (61) on the EPB ECU.
Tighten the screw (63) fastening the ground cable to the chassis.
Tightening torque Nm Class
Tighten the screw (62) fastening the ground cables to the chassis.
Tightening torque Nm
Secure the wiring harnesses, fastening the indicated clamps.
Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 48 of 58
Connect the shock absorber connector (64) and secure the cable (65) , fastening the indicated clamps.
Connect the connectors (66) and fasten the indicated clamps.
Tighten the screw (19) fastening the ground cables to the chassis and fasten the indicated clamps.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 49 of 58
Connect the shock absorber connector (18) and secure the cable (17) , fastening the indicated clamps.
Fasten the indicated clamps and connect the connectors (16) .
On the left hand rear suspension, tighten the indicated nut fastening the ground cable (15) and fit a new clamp, as indicated by the red arrow.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 50 of 58
Connect the third stop light connector (14) and secure the relevant cable, fastening the indicated clamps.
Connect the two connectors (13) on the solenoid valves and fasten the relevant cables with the retainer clips on the rear subframe.
Fasten the right hand air duct (12) , tightening the indicated screws.
Tightening torque
Screw / Nut
Nm
9 Nm
Class
B https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 51 of 58
Fasten the left hand air duct (10) , tightening the indicated screws.
Tightening torque
Screw / Nut
Nm
9 Nm
Class
B
Connect the solenoid valve connector (11) on the radiator.
Lay out the left hand injection cable as originally fitted on the chassis.
Connect the connector (32) to the left hand
Motronic ECU.
Fasten the left hand injection cable (28) , fitting the indicated clamps, and connect the connector
(31) to the engine compartment cable junction.
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Rear removable engine-gearbox assembly mounting subframe Page 52 of 58
Tighten the screws indicated fastening the fuel vapour separator mounting bracket (30) to the chassis.
Tightening torque Nm Class
Connect the front left hand oxygen sensor connector (29) and fit the indicated clips.
Fasten the left hand injection cable (28) , fitting the indicated clamps.
Lay out the right hand injection cable as originally fitted on the chassis.
Connect the front right hand oxygen sensor connector (27) and fit the indicated clips.
Connect the connectors (26) to the ELDOR ECU.
Fasten the right hand injection cable (22) leading to the ELDOR ECU, fitting the indicated clamps.
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Rear removable engine-gearbox assembly mounting subframe Page 53 of 58
Connect the connector (24) to the right hand
Motronic ECU, and fasten the connector (25) to the engine compartment cable junction.
Fasten the right hand injection cable (23) , fitting the indicated clamps.
Fasten the right hand injection cable (23) , fitting the indicated clamps.
Lift the cover (21) of the junction box and tighten the indicated nut fastening the cable (45) .
Fit the cable retainer clamps (45) as originally installed on the chassis. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 54 of 58
Right-hand side
Fit the pipe (3) leading to the evaporative emissions control solenoid valve onto the relative union, tightening a new clamp as indicated.
Left-hand side
Fit the pipe (3) leading to the evaporative emissions control solenoid valve onto the relative union, tightening a new clamp as indicated.
Connect the pipe (4) connecting to the secondary air pump and fasten by tightening a new clamp as indicated.
Connect the low pressure pipe (2) to the fuel pump filter.
Connect the pipes (3) onto the evaporative emissions control system solenoid valves and fasten by tightening new clamps as indicated.
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Rear removable engine-gearbox assembly mounting subframe Page 55 of 58
FROM Ass.ly No. 90802
Fasten the low pressure pipe (2) by closing the indicated clamp.
Fit the cover (91) .
Connect the low pressure pipe (1) to the fuel pump filter.
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Rear removable engine-gearbox assembly mounting subframe Page 56 of 58
FROM Ass.ly No. 90802
Fasten the low pressure pipe (1) by closing the indicated clamp.
Fit the cover (92) .
Secure the emergency engine compartment lid release cable (7) , fastening the indicated clamps.
Fasten the fuel filler flap emergency release cable
(9) to the relative bracket, tightening the nut indicated by the red arrow. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
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Rear removable engine-gearbox assembly mounting subframe Page 57 of 58
Fit the right hand engine compartment lid lock cable
(7) and feed through relevant hole on the black mounting.
Secure the cables (7) of the engine compartment lid lock, by fitting the cable clamp (8) then fasten it by tightening the indicated lock grub screw.
Secure the gearbox wiring harness (6) to the chassis, fastening the indicated clip.
Connect the three gearbox wiring harness connectors (5) and fasten to the relevant mounting bracket.
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Rear removable engine-gearbox assembly mounting subframe Page 58 of 58
If present, fit and fasten the shield (81) , tightening the indicated screws.
If present, fit and fasten the shield (82) , tightening the indicated screws.
FROM Ass.ly No. 90802. Refit the luggage compartment tub ( E4.07
).
Refit the engine compartment lid lock ( E5.11
).
Refit the expansion tank ( B6.02
).
Refit the engine air ducts ( B4.02
).
Refit the rear bumper ( E3.04
).
Refit the central flat undertray section ( E3.12
).
Refit the rear flat undertray section ( E3.12
).
Reconnect the battery ( F2.01
).
Add fuel to the tanks.
Fill the cooling system ( A3.07
).
Fill the power steering system ( D5.08
).
Charge the air conditioning system. ( F5.12
).
Fill and bleed the brake system ( D3.10
).
Refit the engine compartment cosmetic shields ( E3.13
).
Lower the vehicle using anti-tipping safety retainers ( E3.12
).
Perform the vehicle set-up procedure ( A3.22
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E20...
8/5/2011
Engine compartment lid
Print Exit
E3.01 Engine compartment lid
Removing the engine compartment lid
Page 1 of 11
Disconnect the battery ( F2.01
).
Remove the engine compartment cosmetic shields ( E3.13
).
Remove the right hand engine compartment shield.
Detach the connector (1) of the engine compartment lid window defroster.
Release from the relevant seat the clamp indicated fastening the connector cable (1) .
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Detaching the relevant fastener clip, disconnect the upper end of the right hand gas strut (A) , supporting the engine compartment lid (B) , from the relevant ball stud. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
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Engine compartment lid Page 2 of 11
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Detaching the relevant fastener clip, disconnect the upper end of the left hand gas strut (A) , supporting the engine compartment lid (B) , from the relevant ball stud.
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Undo the two indicated screws fastening the engine compartment lid (B) to the right hand hinge (C) .
Recover the shim (D) .
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Undo the two screws indicated fastening the engine compartment lid (B) to the left hand hinge (C) .
Recover the shim (D) .
Remove the engine compartment lid from the relevant seat.
Refitting the engine compartment lid https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
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Engine compartment lid Page 3 of 11
Fit the engine compartment lid in the relevant seat.
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Fit the shim (D) in the relevant seat.
Tighten the two screws indicated fastening the engine compartment lid (B) to the left hand hinge
(C) .
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Fit the shim (D) in the relevant seat.
Tighten the two screws indicated fastening the engine compartment lid (B) to the right hand hinge (C) .
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Installing the relevant fastener clip, fasten the upper end of the left hand gas strut (A) , supporting the engine compartment lid (B) , onto the relevant ball stud.
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Engine compartment lid Page 4 of 11
CAUTION
Adequately support the weight of the engine compartment lid.
This operation requires at least two operators.
Installing the relevant fastener clip, fasten the upper end of the right hand gas strut (A) , supporting the engine compartment lid (B) , onto the relevant ball stud.
Fasten the clamp indicated fastening the connector cable (1) in the relevant seat.
Connect the connector (1) of the engine compartment lid window defroster.
Check that the engine compartment lid (A) opens and closes correctly.
If the lid does not open and/or close correctly, adjust the engine compartment lid (A) by adjusting the fastener hinges.
Check that the entire perimeter of the engine compartment lid (A) sits flush with the adjacent bodywork.
If the lid does not sit flush with the adjacent bodywork, adjust the engine compartment lid
(A) by adjusting the fastener hinges.
Refit the engine compartment cosmetic shields ( E3.13
).
Refit the right hand engine compartment shield.
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Engine compartment lid
Removing the engine compartment lid grilles
Page 5 of 11
Undo the screws indicated.
Remove the grille (A) , retrieving any shims from the relative mounting brackets.
Note the positions and quantities of any shims fitted
Refitting the engine compartment lid grilles
Tightening torque
Fastening engine compartment lid grilles Screw
Nm
8 Nm
Class
C
Fit the grille (A) , installing any shims necessary on the relative mounting brackets.
Fit any shims necessary in the correct quantities and positions noted during removal.
Tighten the screws indicated.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
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Engine compartment lid Page 6 of 11
Check that the grille (A) is correctly aligned with the window and the bodywork.
If the alignment is not correct, undo the indicated screws and add or remove the shims (1) between the grille (A) and mounting bracket (B) .
Add or remove only where necessary.
Replacing the engine compartment lid window
Protect all painted bodywork parts and the cabin to prevent damage when using cutting equipment and when installing the new windscreen.
Remove the engine compartment lid grilles ( E3.01
).
Remove the engine compartment cosmetic shields ( E3.13
).
Cover the engine compartment with protective material. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
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Engine compartment lid Page 7 of 11
The following tools are required to remove the engine compartment lid glass:
One (Excalibur pneumatic cutter with ESM - 519 short blade) (A) .
For cutting the sealant in the more easily accessible locations and for removing excess sealant on the bodyshell.
One (Excalibur 6 pneumatic cutter with Equaliser
Pat. 4955124 long blade) (B) .
For cutting the sealant in deeper, less accessible locations.
A thin metal plate (0.5 mm thick) (C) .
To facilitate cutting and protect the bodywork from the cutter blade.
A face mask (D) .
To protect the operator's airways from airborne fragments of material.
Safety eyewear is also recommended to protect the eyes from flying splinters.
Disconnect the connector (3) .
Remove the indicated clip. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
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Engine compartment lid Page 8 of 11
Before cutting, always place the metal in front of the pneumatic cutter blade, with the edge of the plate resting against the bodywork to protect the bodywork against the blade.
Ensure that there are no obstructions for the metal plate, as it must be moved together with the pneumatic cutter while cutting.
To cut the sealant along the bottom edge, place the cutter blade (C) between the bodyshell and the glass.
Using specific pneumatic cutter tools, cut the sealant around the entire perimeter of the engine compartment lid window, working from inside the engine compartment inner.
Using suction cup handles, remove the engine compartment lid window from its seat.
This operation must be carried out with the assistance of another operator.
Apply strips of adhesive tape on the bodywork, along the lower mating edge of the engine compartment lid window.
Take care not to damage the bodywork;
Remove residual sealant with the (Excalibur pneumatic cutter with ESM - 519 short blade) (A) .
Clean the engine compartment lid window mating surface thoroughly with compressed air, then degrease with heptane to remove all traces of adhesive or dust.
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8/5/2011
Engine compartment lid Page 9 of 11
Before preparing the glass for installation, check there are no imperfections or scratches on the surface or around the perimeter.
Set the new glass panel carefully on a stable surface so that it is not scratched or damaged.
Fix the defroster cable to the glass with a strip of adhesive tape, as shown in the photo aside.
Degrease the perimeter of the glass with
BETACLEAN 3300 cod. 81636500 and leave to dry.
Check the expiry date of the PRIMER to ensure that it is suitable for use.
Shake the can well, continuing for 30 seconds after the ball bearings inside the can itself can be heard to move.
Protect newly applied primer from draughts during work breaks. Never exceed the drying time of 8 hours.
Apply BETAPRIMER 5500, green cap, code
81636600 to the entire perimeter of the glass between the two dotted lines shown in the photo aside and leave the product to dry for at least 5 minutes .
Degrease the mating surface of the glass on the bodyshell with BETACLEAN 3350, black cap, code 81636700 and WypAll X60 _ Kimberly-
Clark high absorbency cloth .
Check the expiry date of the PRIMER to ensure that it is suitable for use.
Shake the can well, continuing for 30 seconds after the ball bearings inside the can itself can be heard to move.
Protect newly applied primer from draughts during work breaks. Never exceed the drying time of 8 hours.
Apply BETAPRIMER 5404 Red cap code
62864900 to the mating surface between the glass and the bodyshell as indicated by the two dotted lines, and leave the product to dry for at least 10 minutes.
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Engine compartment lid Page 10 of 11
Apply adhesive primer in a uniform, uninterrupted bead.
Using an extrusion gun fitted with a triangular section nozzle, apply a continuous bead (4) of
BETASEAL 1703 code 64954900 over the primer applied previously, starting from the mid point of the bottom edge.
At the bottom and top edges of the glass, the sealant must be applied inside the seals.
The end of the bead must overlap the beginning by approximately 20-30 mm .
Check that there are no bubbles or interruptions in the bead; if necessary, correct with additional sealant.
The fitting of the windscreen on the bodyshell must take place with no possibility of delay within 5 minutes from the application of the adhesive tape.
Hold the engine compartment lid glass parallel to the mating surface and fit onto the bodyshell.
Press along the entire perimeter of the engine compartment lid window.
Check that the gap, along the whole length of the indicated sections, between bodyshell and engine compartment glass corresponds to the values shown in the photo aside. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Engine compartment lid Page 11 of 11
Apply a few strips (2) of adhesive fabric tape
SYROM 90 , stretching out from the engine compartment lid window to the vehicle roof.
Wait at least 3 hours , remove the adhesive tape and remove any sealant residue from the perimeter of the engine compartment lid window with heptane.
Connect the connector (3) .
Fasten the indicated clip.
Refit the engine compartment cosmetic shields ( E3.13
).
Refit the engine compartment lid grilles ( E3.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Luggage compartment lid
Print Exit
E3.02 Luggage compartment lid
Removing the luggage compartment lid
Page 1 of 2
When the same luggage compartment lid is to be reused, mark the positions of the hinges on the lid itself to facilitate adjustment.
Detach the pipe grommet (1) from the relative hole.
Pull out the pipe (2) from the relative hole until the check valve is reached, then detach the pipe from the valve.
CAUTION
Adequately support the weight of luggage compartment lid.
This operation requires at least two operators.
Detaching the relative fastener clip, disconnect the left hand gas strut (B) , supporting the luggage compartment lid (A) , from the relative ball stud.
Undo the two indicated nuts fastening the luggage compartment lid (A) to the left hand hinge (C) .
Retrieve the relative washers, if present.
CAUTION
Adequately support the weight of luggage compartment lid.
This operation requires at least two operators.
Detaching the relative fastener clip, disconnect the right hand gas strut (B) , supporting the luggage compartment lid (A) , from the relative ball stud.
Undo the two indicated nuts fastening the luggage compartment lid (A) to the right hand hinge (C) .
Retrieve the relative washers, if present.
Remove the luggage compartment lid from the relative seat.
Refitting the luggage compartment lid https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Luggage compartment lid Page 2 of 2
When refitting the same luggage compartment lid removed previously, fit the lid onto the relative hinges on the markings made during removal to facilitate subsequent adjustment.
CAUTION
Adequately support the weight of luggage compartment lid.
This operation requires at least two operators.
Tighten the two indicated nuts fastening the luggage compartment (A) to the right hand hinge
(C) , after fitting the relative washers, if present.
Installing the relative fastener clip, fasten the right hand gas strut (B) , supporting the luggage compartment lid (A) , onto the relative ball stud.
CAUTION
Adequately support the weight of luggage compartment lid.
This operation requires at least two operators.
Tighten the two indicated nuts fastening the luggage compartment (A) to the left hand hinge
(C) , after fitting the relative washers, if present.
Installing the relative fastener clip, fasten the left hand gas strut (B) , supporting the luggage compartment lid (A) , onto the relative ball stud.
Connect the pipe (2) to the relative check valve, then insert the valve together with the pipe in the relative hole.
Fit the pipe grommet (1) in the relative hole.
Check that the luggage compartment lid (A) opens and closes correctly.
If the lid does not open and/or close correctly, adjust the luggage compartment lid (A) by adjusting the fastener hinges.
Check that the entire perimeter of the luggage compartment lid (A) sits flush with the adjacent bodywork.
If the lid does not sit flush with the adjacent bodywork, adjust the luggage compartment lid
(A) by adjusting the fastener hinges. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Front bumper
Print Exit
Removing the front bumper
Disconnect the battery ( F2.01
).
Remove the luggage compartment tub ( E4.07
).
Remove the front wheelhouses ( E3.05
).
Undo the indicated screw.
Remove front brakes air duct (A) .
Page 1 of 8
Undo the indicated screw.
Remove front brakes air duct (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Front bumper
Undo the screws indicated.
Page 2 of 8
Undo the indicated nuts, retrieving screws and washers.
Undo the indicated nuts, retrieving screws and washers.
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8/5/2011
Front bumper
Loosen the indicated clip.
Disconnect the pipe (1) .
Page 3 of 8
For vehicles featuring front parking sensors only
Disconnect the connector (2) .
Disconnect the connector (3) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Front bumper
Disconnect the connector (4) .
Page 4 of 8
Undo the screws indicated.
Remove the front bumper (B) .
Refitting the front bumper
Tightening torque
Fastening bumper Screw
Nm
7.5 Nm
Class
C https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Front bumper Page 5 of 8
Position front bumper (A) .
Tighten the screws indicated.
Tightening torque Nm Class
Connect the connector (4) .
Connect the connector (3) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Front bumper Page 6 of 8
For vehicles featuring front parking sensors only
Connect the connector (2) .
Loosen the indicated clip.
Connect pipe (1) .
Tighten the indicated nuts, with screws and washers.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Front bumper Page 7 of 8
Tighten the indicated nuts, with screws and washers.
Tightening torque Nm Class
Tighten the screws indicated.
Tightening torque Nm Class
Position front brakes air duct (A) .
Tighten the indicated screw.
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Front bumper Page 8 of 8
Position front brakes air duct (A) .
Tighten the indicated screw.
Tightening torque Nm Class
Refit the front wheelhouses ( E3.05
).
Refit the luggage compartment tub ( E4.07
).
Reconnect the battery ( F2.01
).
Replacing the front impact absorber
Remove the front bumper ( E3.03
).
Undo the screws indicated.
Remove the impact absorber (A) and replace.
Fit the impact absorber (A) .
Hand tighten the screws indicated.
Refit the front bumper ( E3.03
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper
Print Exit
Removing the rear bumper
Disconnect the battery ( F2.01
).
Remove the rear diffuser ( E3.12
).
Remove the rear wheelhouses ( E3.05
).
Remove the rear elements of the rear wheelhouses only.
Release and disconnect connector (1) .
Page 1 of 8
Only for vehicles with parking camera
Remove the clamp indicated.
Disconnect the connector (2) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper Page 2 of 8
Undo the indicated lower right hand screw fastening the rear bumper (A) .
Undo the indicated lower left hand screw fastening the rear bumper (A) .
Undo the indicated lateral right hand screws fastening the rear bumper (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper Page 3 of 8
Undo the indicated lateral left hand screws fastening the rear bumper (A) .
Undo the indicated upper right hand screw fastening the rear bumper (A) .
Undo the indicated upper left hand screw fastening the rear bumper (A) .
Remove the rear bumper from the relative seat, detaching the relative centre fastener clips.
Refitting the rear bumper https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper Page 4 of 8
Tightening torque
Fastening bumper Screw
Nm
7.5 Nm
Class
C
Fit the rear bumper in the relevant seat, installing the relevant centre fastener clips.
Tighten the upper left hand screw indicated fastening the rear bumper (A) .
Tightening torque Nm Class
Tighten the indicated upper right hand screw fastening the rear bumper (A) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper Page 5 of 8
Tighten the indicated lateral left hand screws fastening the rear bumper (A) .
Tightening torque Nm Class
Tighten the indicated lateral right hand screws fastening the rear bumper (A) .
Tightening torque Nm Class
Tighten the indicated lower left hand screw fastening the rear bumper (A) .
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper Page 6 of 8
Tighten the indicated lower right hand screw fastening the rear bumper (A) .
Tightening torque Nm Class
Only for vehicles with parking camera
Connect the connector (2) .
Lay the cable correctly and apply a new cable tie in the indicated position.
Connect the connector (1) .
Refit the rear wheelhouses ( E3.05
).
Refit the rear diffuser ( E3.12
).
Reconnect the battery ( F2.01
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper
Replacing the rear impact absorbers
Remove the rear bumper ( E3.04
).
Centre impact absorber
Page 7 of 8
Undo the screws indicated.
Remove the impact absorber (A) and replace.
Fit the impact absorber (A) .
Tighten the screws indicated.
Lateral impact absorbers
Left
Undo the indicated screw.
Remove the impact absorber (A) and replace.
Fit the new impact absorber (A) .
Tighten the indicated screw. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Rear bumper Page 8 of 8
Right
Undo the indicated screw.
Remove the impact absorber (A) and replace.
Fit the new impact absorber (A) .
Tighten the indicated screw.
Refit the rear bumper ( E3.04
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse Page 1 of 8
Print Exit
E3.05 Wheelhouse
Removing the front wheelhouses
The complete wheelhouse consists of two elements which may be removed independently.
If it is necessary to remove both elements of the front wheelhouse, remove the front element first and then the rear one, as the front element overlaps the rear element.
The following procedure is for removing the left hand front wheelhouse.
The procedure for removing the right hand front wheelhouse is the same.
Remove the wheels ( D2.01
).
Remove the front wheels only.
Front element
Undo the screws indicated fastening the front element (A) of the front wheelhouse.
Remove the front element (A) of the front wheelhouse from the relative seat.
Rear element https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse Page 2 of 8
Undo the screws indicated fastening the rear element (B) of the front wheelhouse.
Remove the rear element (B) of the front wheelhouse from the relative seat.
Refitting the front wheelhouses
Tightening torque
Fastening wheelhouse Screw
Nm
3 Nm
Class
C
If it is necessary to refit both elements of the front wheelhouse, refit the rear element first and then the front one, as the front element overlaps the rear element.
The following procedure is for refitting the left hand front wheelhouse.
The procedure for refitting the right hand front wheelhouse is the same.
Rear element https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse
Front element
Page 3 of 8
Fit the rear element (B) of the front wheelhouse in the relative seat.
If the front element is already fitted, as the rear element was removed individually, fit the rear element (B) underneath the front element.
Tighten the screws indicated fastening the rear element (B) of the front wheelhouse.
Tightening torque Nm Class
Fit the front element (A) of the front wheelhouse in the relative seat.
Tighten the screws indicated fastening the front element (A) of the front wheelhouse.
Tightening torque Nm Class
Refit the wheels ( D2.01
).
Removing the rear wheelhouses
The rear wheelhouse consists of two elements which may be removed independently.
If it is necessary to remove both elements of the rear wheelhouse, remove the rear element first and then the front one, as the rear element overlaps the front element.
Remove the wheels ( D2.01
).
Remove the rear wheels only. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse
Rear element
Page 4 of 8
Undo the screws indicated fastening the rear element (A) of the rear wheelhouse
Remove the rear element (A) of the rear wheelhouse from the relative seat.
Front element
For the front left hand element only
Undo the screws indicated.
Remove the cover (A) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse
For the front left hand element only
Undo the indicated screw.
Carefully remove the breather duct (B) .
Page 5 of 8
For the front left hand element only
Remove the clamp (1) .
Disconnect and detach the breather pipe (C) from the breather duct (B) .
Remove the breather duct (B) .
Undo the screws indicated fastening the front element (B) of the rear wheelhouse
Remove the front element (B) of the rear wheelhouse from the relative seat.
Refitting the rear wheelhouses https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse Page 6 of 8
Tightening torque
Fastening wheelhouse
Fastening breather duct and cover
Screw
Screw
Nm
3 Nm
5 Nm
Class
C
A
If it is necessary to refit both elements of the rear wheelhouse, refit the front element first and then the rear one, as the rear element overlaps the front element.
Front element
Check conformity of the heat shield fitted on the inner side of the front section of the rear wheelhouse.
If the heat shield is damaged and/or not securely fastened, replace the front section of the rear wheelhouse.
Fit the front element (B) of the rear wheelhouse in the relative seat.
If the rear element is already fitted, as the front element was removed individually, fit the front element (B) underneath the rear element.
Tighten the screws indicated fastening the front element (B) of the rear wheelhouse
Tightening torque Nm Class
For the front left hand section only
Fit a new clamp (1) on the breather pipe (C) .
Connect and fasten the breather pipe (C) to the breather duct (B) , fitting correctly in the relative bracket
Tighten the new clamp (1) . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse
Rear element
Page 7 of 8
For the front left hand section only
Carefully fit the breather duct (B) .
Tighten the indicated screw.
Tightening torque Nm Class
For the front left hand section only
Fit the cover (A) .
Hand tighten the screws indicated.
Tightening torque Nm Class
Fit the rear element (A) of the rear wheelhouse in the relative seat.
Tighten the screws indicated fastening the rear element (A) of the rear wheelhouse
Tightening torque Nm Class https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Wheelhouse
Refit the wheels ( D2.01
).
Page 8 of 8 https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Windscreen
Print Exit
E3.06 Windscreen
Replacing the windscreen
Page 1 of 4
Protect all painted bodywork parts and the cabin to prevent damage when using cutting equipment and when installing the new windscreen.
Remove the underwindscreen shields ( E4.07
).
Remove the roof trim panels ( E4.04
).
Remove the trim from the windscreen cross member and A pillars.
Remove the interior rear view mirror ( E5.09
).
Remove the rain/twilight sensor ( F2.12
).
Cover the dashboard, centre console, mats and front seats with protective material.
The following tools are required to remove the windscreen glass:
One (Excalibur pneumatic cutter with ESM - 519 short blade) (A) .
For cutting the sealant in the more easily accessible locations and for removing excess sealant on the bodyshell.
One (Excalibur 6 pneumatic cutter with Equaliser
Pat. 4955124 long blade) (B) .
For cutting the sealant in deeper, less accessible locations.
A thin metal plate (0.5 mm thick) (C) .
To facilitate cutting and protect the bodywork from the cutter blade.
A face mask (D) .
To protect the operator's airways from airborne fragments of material.
Safety eyewear is also recommended to protect the eyes from flying splinters. https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Windscreen Page 2 of 4
Before cutting, always place the metal in front of the pneumatic cutter blade, with the edge of the plate resting against the bodywork to protect the bodywork against the blade.
Ensure that there are no obstructions for the metal plate, as it must be moved together with the pneumatic cutter while cutting.
To cut the sealant along the right and left-hand sides, place the metal plate (C) between the bodyshell and the glass panel seal.
Use specific pneumatic cutters to cut the sealant around the entire perimeter of the windscreen from inside the passenger compartment.
Using suction cup handles, remove the windscreen from its seat.
This operation must be carried out with the assistance of another operator.
Apply strips of adhesive tape to the bodywork, around the perimeter of the windscreen seat.
Take care not to damage the bodywork;
Remove residual sealant with the (Excalibur pneumatic cutter with ESM - 519 short blade) (A) .
Clean the windscreen mating surface thoroughly with compressed air, then degrease with heptane to remove all traces of adhesive or dust.
Degrease the perimeter on the bodyshell with BETACLEAN 3350, black cap, code 81636700 and WypAll
X60 _ Kimberly-Clark high absorbency cloth .
https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Windscreen Page 3 of 4
If necessary, replace the two alignment blocks (1) , fitting the new parts in the original positions.
Before preparing the glass for installation, check there are no imperfections or scratches on the surface or around the perimeter.
Set the glass panel carefully on a stable surface so that it is not scratched or damaged.
Degrease the perimeter of the glass with BETACLEAN 3300 cod. 81636500 and leave to dry.
Check the expiry date of the PRIMER to ensure that it is suitable for use.
Shake the can well, continuing for 30 seconds after the ball bearings inside the can itself can be heard to move.
Protect newly applied primer from draughts during work breaks. Never exceed the drying time of 8 hours.
Apply BETAPRIMER 5500, green cap, code
81636600 to the entire perimeter of the glass between the two dotted lines in the figure and leave the product to dry for at least 5 minutes .
The inner dotted line at the top and side of the glass overlaps the solid screen-printed area by approximately 10 mm . https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Windscreen Page 4 of 4
Apply adhesive primer in a uniform, uninterrupted bead.
Using an extrusion gun fitted with a triangular section nozzle, apply a continuous bead (3) of
BETASEAL 1812 code 67306000 , starting from the mid point of the bottom side.
The end of the bead must overlap the beginning by approximately 20-30 mm .
Check that there are no bubbles or interruptions in the bead; if necessary, correct with additional sealant.
The fitting of the windscreen on the bodyshell must take place with no possibility of delay within 5 minutes from the application of the adhesive tape.
Hold the windscreen parallel to the mating surface and fit onto the bodyshell.
Press along the entire perimeter of the windscreen and bring the lower edge against the alignment blocks fitted previously.
Check that the gaps between the A pillars and the windscreen are uniform.
Apply a few strips of adhesive fabric tape SYROM 90 , starting from the windscreen and fixing to the pillar and roof.
Wait at least 3 hours , remove the adhesive tape and remove any sealant residue from the perimeter of the windscreen with heptane.
Refit the rain/twilight sensor ( F2.12
).
Refit the interior rear view mirror ( E5.09
).
Refit the roof trim panels ( E4.04
).
Refit the underwindscreen shields ( E4.07
). https://modiscs.ferrari.it/KnowledgeOnline/index.php?action=mo&link=link::SM_SM_E30...
8/5/2011
Q