Download Print this page

Ferrari California Workshop Manual

Ferrari California Workshop Manual

Hide thumbs Also See for California:

Owner's manual (249 pages)

page of 1727

/ 1727
Bookmarks

Advertisement

Quick Links

Download this manual

Welcome to The California Workshop Manual at Ferrari

Publication Date: 31/12/2018

Disclaimer

Whilst every effort has been made to ensure the accuracy of this Workshop Manual, the

:

manufacturer（Ferrari) shall not in any circumstances be held responsible for any inaccuracy or the consequences

thereof. The manufacturer(Ferrari) reserves the right to vary specifications without notice in accordance with its

policy of continual product improvement.

Download workshop Manual as PDF

Advertisement

Need help?

Need help?

Do you have a question about the California and is the answer not in the manual?

Questions and answers

Summary of Contents for Ferrari California

Page 1 Whilst every effort has been made to ensure the accuracy of this Workshop Manual, the manufacturer（Ferrari) shall not in any circumstances be held responsible for any inaccuracy or the consequences thereof. The manufacturer(Ferrari) reserves the right to vary specifications without notice in accordance with its policy of continual product improvement.
Page 2 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.
Page 3 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.
Page 4 01.03 Symbols The safety symbols illustrated below are used to draw the attention of the operator to injury hazards, to indicate operations which may entail a risk of damage to the vehicle, or to provide useful information for a specific operation. IMPORTANT Failure to observe the instructions in this note may be dangerous and result in serious injury to the operator and/or to persons in the vicinity.
Page 5 01.04 Glossary Nitrogen Carbon Monoxide Carbon Dioxide Nitrogen Oxide 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 Anti Blockier System...
Page 6 Automatic Vehicle Holding Supplementary function of the electric parking brake (EPB):releases the brake shoes and brake pads at different times. The result is optimised brake release behaviour, assisting the driver. Controller Area Network Communication line between ECUs. Control Stability Traction Stability and traction control Dual Clutch Transmission Dual clutch transmission.
Page 7 Ferrari Brake Prefill 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.
Page 8 Vehicle Dynamic Control Vehicle dynamics control using the brake system and engine torque. 4 Wheel Drive 4 wheel drive system.
Page 9 Manual user 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.
Page 10 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.
Page 11 Using tools and spare parts 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.
Page 12 "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.
Page 13 02.05 Tightening torques 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.
Page 14 03.01 Personal protection When performing regular maintenance or repairs on the vehicle, the operator must take all precautions necessary to prevent injury and wear the appropriate personal protective equipment. The personal protective equipment used must comply with applicable safety legislation and must be in excellent condition.
Page 15 Wear safety eyewear when working underneath the vehicle and when handling liquids that are harmful for the eyes. Ear plugs Use safety ear plugs when working with the engine running.
Page 16 03.02 Hazards Exhaust system and engine Danger Precautions As the vehicle is used, the components of the Always wear insulating gloves when handling these exhaust system and the engine itself reach very components, or wait as long as necessary for the high temperatures and remain hot long after the components to cool.
Page 17 03.03 Dangerous emissions Exhaust gas Danger Precautions The engine must be kept running for certain Never run the engine in a closed space; preferably maintenance procedures. Exhaust gases contain work outdoors or use exhaust extraction systems. carbon monoxide, a highly toxic gas which may even cause death in the event of prolonged inhalation.
Page 18 04.01 Label location Label location A - Assembly number label B - Punched chassis number C - Punched engine type and number D - Chassis number E - Gearbox type and number plate F - Tyre pressure monitoring system identifier label G - Antifreeze label H - Expansion tank opening instructions label I - Fuel label...
Page 19 Z - Tyre type and pressure label...
Page 20 04.02 Assembly number Assembly number A - Assembly number label...
Page 21 04.03 Chassis number Chassis number B - Punched chassis number...
Page 22 04.04 Engine type and number Engine type and number C - Punched engine type and number...
Page 23 04.05 Chassis number Chassis number D - Chassis number...
Page 24 04.06 Gearbox type and number Gearbox type and number E - Gearbox type and number plate...
Page 25 04.07 Vehicle identification Vehicle identification K - VIN label (Vehicle Identification Number)
Page 26 04.08 Tyres Tyres F - Tyre pressure monitoring system identifier label Z - Tyre type and pressure label...
Page 27 04.09 Antifreeze and expansion tank opening instructions Antifreeze and expansion tank opening instructions G - Antifreeze label H - Expansion tank opening instructions label...
Page 28 04.10 Fuel Fuel I - Fuel label...
Page 29 04.11 Paintwork Paintwork L - Paintwork label...
Page 30 04.12 Emissions control Emissions control M - Emissions control data label...
Page 31 04.13 Airbag Airbag N - 'Do not install child seat on passenger seat' label...
Page 32 04.14 Airbag Airbag O - Airbag maintenance label...
Page 33 04.15 Airbag Airbag P - Airbag warning label...
Page 34 04.16 Luggage placement in luggage compartment Luggage placement in luggage compartment R - Label with instructions for placing luggage in luggage compartment...
Page 35 04.17 Luggage placement in luggage compartment Luggage placement in luggage compartment S - Labels with instructions for placing luggage in luggage compartment...
Page 36 04.18 Engine oil, gear oil and hydraulic clutch system fluid Engine oil, gear oil and hydraulic clutch system fluid T - Engine oil, gear oil and hydraulic clutch system fluid type label...
Page 37 04.19 Engine oil level check and radiator with antifreeze Engine oil level check and radiator with antifreeze U - Engine oil level check label V - Radiator with antifreeze label...
Page 38 04.20 Safety standard compliance and mercury warning label Safety standard compliance and mercury warning label X - Mercury warning label Y - Safety standard compliance label...
Page 39 04.21 Stop&Start system warning label (optional) Stop&Start system warning label (optional) W - Stop&Start system warning labels (optional)
Page 40 05.01 Performance and consumption Performance 0 to 62 mph Top speed DCT gearbox 3.9 sec > 193 mph Mechanical gearbox 4.2 sec > 193 mph Consumption (for vehicles with DCT gearbox) Urban cycle 13 mpg Extraurban cycle 19 mpg Combined cycle 15 mpg...
Page 41 05.02 Dimensions and weight Dimensions and weights Wheelbase 105.12 in. Max. length 179.6 in. Max. width 75.15 in. Max. height 52.04 in. Front overhang 37.4 in. Rear overhang 37 in. Front track 64.17 in. Rear track 63.18 in. Kerb weight (DCT) 3925 lb.
Page 42 A1.01 Fluid properties 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 50 % Glass cleaner 2 phial...
Page 43 Fluids and lubricants table Model - Fluids and lubricants table [Download]...
Page 44 Scheduled maintenance Model - Pre-Delivery Inspection - PDI [Download] - Scheduled maintenance plan - Annual [Download] - Scheduled maintenance plan - 20,000 km (12,500 miles) [Download] - Scheduled maintenance plan - 40,000 km (25,000 miles) [Download] - Scheduled maintenance plan - 60,000 km (37,500 miles) [Download] - Scheduled maintenance plan - 80,000 km (50,000 miles) [Download]...
Page 45 A3.01 Checking engine oil level and changing engine oil and engine lubrication system filters Checking engine oil level (APPLICABLE UP TO ENGINE No.153878) When checking the engine oil level, the vehicle must be on a level surface and the engine must be warm.
Page 46 Clean the dipstick (A). Insert the dipstick (A) fully. Remove the dipstick (A). Check that the engine oil level is between the MIN and MAX limits indicated on the dipstick (A). The gap between the MIN and MAX limits corresponds to approximately 1.5 litres of oil.
Page 47 Start the engine. Wait for the engine oil temperature to reach 90 °C. Leave the engine running at idle speed (720 rpm) for 2 minutes. IMPORTANT! Only check the engine oil level with the ENGINE OFF. Switch off the engine. Open the engine compartment lid.
Page 48 Check that the engine oil level is between the MIN and MAX limits indicated on the dipstick (A). The gap between the MIN and MAX limits corresponds to approximately 1.5 litres of oil. If the level is too low, identify the cause of excessive oil consumption before proceeding.
Page 49 Undo the cap (A). Wait for the engine oil to drain completely. Replacing the engine oil filter Tightening torque Class Oil filter gaiter Screw 10 Nm Engine oil filter Oil filter cartridge 30 Nm The oil filter must be replaced at every oil change. The engine oil filter is located on the right-hand side of the engine.
Page 50 10 Nm Before refitting the new filter, clean the mating surface on the lower crankcase shell. Use filter cartridges recommended by Ferrari only and check that the rubber seal of the filter cartridge fits perfectly into the seat, with the round part visible, and that there are no cuts and/or cracks.
Page 51 Clean the plug (A) thoroughly with a suitable degreaser that does not leave residue. Tighten the plug (A), replacing the relative seal. Tightening torque Class Magnetic cap M22x1.5 60 Nm Undo and remove the cap (B). Fill the engine lubrication system using only new oil of the type specified in the fluids and lubricants table.
Page 52 Clean the plug (A) thoroughly with a suitable degreaser that does not leave residue. Tighten the plug (A), replacing the relative seal. Tightening torque Class Magnetic cap M22x1.5 60 Nm Undo and remove the cap (B). Fill the engine lubrication system using only new oil of the type specified in the fluids and lubricants table.
Page 53 A3.02 Inspecting oil level and replacing Shell Transaxle 75W-90 GL5 gear oil Check level of Shell Transaxle 75W-90 GL5 gear oil (ONLY for vehicles WITHOUT single oil heat exchanger) Tightening torque Class Gear oil drain/filler plug - GL differential Plug 25 Nm The following procedures must be carried out exactly as described to ensure that the hydraulics are proper lubricated and function correctly.
Page 54 If the level is too low, identify the cause of excessive oil consumption. If topping up is necessary, proceed as follows. Using the pump 8174) element 01 (with the short spout), aspirate the specified oil from a newly opened container. Using the pump 8174) element 01 and a container for collecting excess oil, top up via...
Page 55 With the introduction of the new system of gearbox oil with single oil heat exchanger it becomes necessary to adapt the pump 8174) element 01 (with short spout) in order to perform the operation, proceeding as follows. Fit a piece of flexible hose (3), of suitable diameter and measuring 350 mm in length, on the spout (2), and fasten with the indicated screw collar Part No.
Page 56 Replace and tighten the threaded plug (1). Tightening torque Class Plug 25 Nm Refit the rear flat undertray diffuser ( E3.12). 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 57 ONLY for vehicles WITHOUT single oil heat exchanger To disconnect the gear oil pipes, turn the safety ring nut (14) to align the notch on the ring nut with the pin (13). Push the safety ring nut (14) towards the pin (13) to release the pipes.
Page 58 Connect the unions (5) for the gear oil pipes and fasten the clamp (4) to the bodyshell. Fasten the mounting bracket (3) for the gear oil pipes, by tightening the screws indicated with relevant washers. Tightening torque Class Screw 20 Nm Replace the plugs (1) and (2), fitting and tightening the new components.
Page 59 exchanger) Tightening torque Class Gear oil drain/filler plug - GL differential Plug 25 Nm With the introduction of the new system of gearbox oil with single oil heat exchanger it becomes necessary to adapt the pump 8174) element 01 (with short spout) in order to perform the operation, proceeding as follows.
Page 60 Check the Shell Transaxle 75W-90 GL5 gear oil level ( A3.02). Check that there is no leakage from the drain plugs. Checking the gear oil level with mechanical gearbox Tightening torque Class Fastening oil level inspection cap for mechanical Plug 49 Nm gearbox The following instructions must be carried out precisely to ensure correct lubrication of the gears.
Page 61 The oil level MUST be checked within 10 minutes of switching off the engine. 5) Undo the threaded plug (A) on the left hand side of the gearbox, and check the level: the level must reach the edge of the hole from which the plug was removed, on the limit of overflowing.
Page 62 Fit and fasten the mounting bracket (3), tightening the indicated screws. Fit the shield (1) and fasten the EPB cable (2) by tightening the indicated screws. Refit the rear flat undertray section ( E3.12). Draining the gear oil system for mechanical gearbox The gear oil must be changed at the intervals specified in the MAINTENANCE SCHEDULE.
Page 63 To disconnect the gear oil pipes, turn the safety ring nut (14) to align the notch on the ring nut with the pin (13). Push the safety ring nut (14) towards the pin (13) to release the pipes. ALWAYS dispose of liquids correctly in accordance with applicable legislation.
Page 64 Clean the seat of the filter on the gearbox to remove any contaminants. Fit a new O-ring on the oil filter (6), lubricating with the specified gearbox oil. Fit the oil filter (6) in its seat, after lubricating the seat with the specified oil. Tighten the fastener screws.
Page 65 Clean the plug (1) thoroughly with a suitable degreaser that does not leave residue and replace the seal. Tighten the plug (1). Tightening torque Class Plug 49 Nm Remove the plug (7) for the gearbox speed sensor seat, located at the top left of the gearbox housing, undoing the indicated screw and retrieving the relative seal.
Page 66 A3.03 Checking Shell DCT F-3 hydraulic clutch system fluid level Checking Shell DCT F-3 hydraulic clutch system fluid level Tightening torque Class ATF clutch oil drain/filler plug Plug 25 Nm The following procedures must be carried out exactly as described to ensure that the hydraulics are proper lubricated and function correctly.
Page 67 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.
Page 68 A3.04 Checking the windscreen and headlight washer fluid level Checking the windscreen and headlight washer fluid level The filler neck (1 )for the window and headlight washer fluid tank is accessible by lifting the engine compartment lid. Refill the tank until fluid is visible from the filler neck.
Page 69 A3.05 Checking brake system fluid level Checking brake fluid reservoir level The brake fluid tank is located on the left-hand side of the engine compartment, underneath the windscreen bulkhead. On versions with mechanical gearbox, the brake fluid tank is shared with the clutch system.
Page 70 A3.06 Checking the power steering system fluid level Checking the power steering system fluid level FROM Assembly No. 98002, a different power steering fluid is prescribed. The power steering fluid specified FROM Assembly No. 98002 must be used following installation of the components of the RETROFIT KIT Part No.
Page 71 Screw the cap (A) back on tightly.
Page 72 A3.07 Checking coolant level and topping up Checking the cooling system fluid level CAUTION The fluid in the engine coolant system may be very hot. Hot engine coolant may cause severe burns. ALWAYS WAIT FOR THE SYSTEM TO COOL BEFORE STARTING ANY WORK. Remove the engine compartment cosmetic shields ( E3.13).
Page 73 After loosening or removal, the Caillau Visa hose clamps must be replaced with Mikalor worm drive hose clamps, following the instructions given in Technical Information 2054 of December 2012. Remove the front flat undertray section ( E3.12). Working from under the vehicle, on the right- hand side of the radiator, loosen the clamps (1) fastening the delivery and return pipes (2).
Page 74 01) Detach the bleed pipe (1), on the right-hand side of the radiator, removing the indicated clamp and keeping the pipe at the height of the header tank union. The photo aside was taken with the secondary air pump removed to illustrate the procedure more clearly.
Page 75 04) Unscrew the indicated left hand cylinder head bleed plug, located on the front cover. 05) Unscrew the filler cap (4) on the expansion tank. A new coolant has been introduced FROM Assembly No. 87849. Carefully check which type of coolant has been used in the vehicle before topping up or filling the system.
Page 76 08) Gradually introduce coolant via the expansion tank filler orifice, until fluid escapes from the bleed orifices on the cylinder heads. 09) Tighten the right hand bleed plug indicated, after replacing the relative seal. Tightening torque Class M12x1.25x12 plug 30 Nm 10) Tighten the left hand bleed plug indicated, after replacing the relative seal.
Page 77 13) Complete filling up to the MAX level indicated on the expansion tank. Dynamic filling (engine on) (ONLY for vehicles WITHOUT Single oil heat exchanger) After loosening or removal, the Caillau Visa hose clamps must be replaced with Mikalor worm drive hose clamps, following the instructions given in Technical Information 2054 of December 2012.
Page 78 28) Tighten the filler cap (4) completely onto the expansion tank. Refit the front wheelhouses ( E3.05). Refit the engine compartment cosmetic shields ( E3.13).
Page 79 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 behind the right hand rear wheel bay. Remove the rear wheelhouses ( E3.05).
Page 80 Undo the screw (7) fastening the pipe connecting the filter to the chassis. Open the clamp (8) and release the pipe (6) connecting to the OBD pump filter. Working via the aperture in the wheel bay, disconnect the quick coupling (15) from the active carbon filter (A).
Page 81 Detach the pipe (9) connecting the filter to the diagnostic pump, removing the clamp (18). A double-lock safety clip is fitted on the pipe (14) connecting the filter to the fuel vapour separator (16). To disconnect the "double-lock" quick-coupling, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
Page 82 Disconnect the remaining pipes (17) connected to the carbon filter. A "double-lock" safety clip is fitted on the lower pipe connected to the active carbon filter. 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".
Page 83 Check the state of the protective foam rubber pads (13) applied to the active carbon filter mounting bracket; replace if necessary. Fit the active carbon filter (A) on the relative mounting bracket as originally installed and fasten with the retainer bracket (12), tightening the screw (11).
Page 84 Apply the new adhesive foam rubber (14) onto the active carbon filter, as shown in the photo aside. Fit the active carbon filter, complete with bracket and filter for the OBD pump, into its seat, via the aperture at the rear of the vehicle. Fasten the front of the active carbon filter by tightening the screw (10).
Page 85 Connect the pipe (9) connecting the filter to the diagnostic pump and fasten the clamp (18). Working via the aperture in the wheel bay, connect the quick coupling (15) to the active carbon filter (A). Fasten the rear of the active carbon filter by tightening the screw (6).
Page 86 Hand tighten the screw (7) fastening the pipe connecting the filter to the chassis. Fasten the pipe (6) to the OBD pump filter as originally mounted, closing the clamp (8). Fit the active carbon filter cover (1) and fasten by tightening the screws (2).
Page 87 A3.09 Replacing the oxygen sensor Replacing the front left oxygen sensor Tightening torque Class Oxygen sensor - catalytic converter Oxygen sensor 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.
Page 88 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. Whenever a sensor is replaced, the self-acquired parameters must be deleted from the ECU memory. Located at the rear of the left catalytic converter.
Page 89 Undo the rear oxygen sensor (B) from the catalytic converter and replace. Fit the rear oxygen sensor (B) onto the catalytic converter and tighten it. Tightening torque Class Oxygen sensor 50 Nm Attach the cable to the clamp (3). Attach the cable to the clamp (2). Fit a new plastic clamp in the position indicated.
Page 90 Tightening torque Class Oxygen sensor - catalytic converter Oxygen sensor 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. Whenever a sensor is replaced, the self-acquired parameters must be deleted from the ECU memory.
Page 91 Whenever a sensor is replaced, the self-acquired parameters must be deleted from the ECU memory. Located at the rear of the right catalytic converter. Disconnect the battery ( F2.01). Remove the central flat undertray section ( E3.12). Remove the front wheelhouses ( E3.05).
Page 92 Attach the cable to the clamp (2). Connect the connector (1). Refit the front wheelhouses ( E3.05). Refit the central flat undertray section ( E3.12). Connect the battery ( F2.01).
Page 93 A3.10 Replacing the engine air filters Replacing the engine air filters To ensure maximum engine performance it is essential that the air filters are in perfect condition. NEVER wash or clean a removed air filter and reuse. Always replace with a new component. Replace the air filter cartridges at the intervals indicated in the Maintenance Schedule.
Page 94 NEVER wash or clean a removed air filter and reuse. Always replace with a new component. Remove and replace the air filter cartridge (A). When installing the new air filter cartridge (A), lightly lubricate the mating surfaces with the air box. The following components must ONLY be replaced in the event of evident damage.
Page 95 A3.11 Replacing the air conditioning and heating system filter Replacing the air conditioning and heating system filter A dirty filter impedes the flow of external air into the vehicle, compromising the functions of the air conditioning and heating system. The air conditioning and heating system filter must be changed regularly. The air conditioning and heating system filter is located inside the passenger compartment, on the right-hand side of the heater/evaporator.
Page 96 Fit the new A/C system filter (A). Install the filter in the correct direction, using the arrow indicating the direction of air flow (AIR-FLOW) as reference. Fit the cover (2). Move the bracket (1) in the direction indicated by the arrow. Refit the passenger side underdashboard trim panel ( E4.02).
Page 97 A3.12 Checking tension and replacing auxiliary utilities belts Checking the water pump drive belt tension Check the belt tension when the engine is cool. Remove the central flat undertray section ( E3.12). Start the engine and run at idle speed for a few seconds. Switch off the engine.
Page 98 (Place )the frequency probe of the tension meter 1 (95978151) at the mid point of the lower section of the belt, but without touching the belt itself. Tap the belt with a suitable tool near the tension probe (1) and check that the value displayed by the meter is 155 ±...
Page 99 When fitting the new belt tensioner, ensure that the locator pin (4) is correctly inserted in the relative seat on the front engine cover. Fit the belt tensioner (3) and fasten by tightening the screw (2). Tightening torque Class Screw 25 Nm Refit the A.C.
Page 100 Undo the nuts (2), removing the power steering system pipe mounting brackets (1) from the steering box, moving the pipes out of the way so that they do not hinder the subsequent operations. Turn the crankshaft with the specific wrench, then, using a thin, sharp tool applied on the water pump side, prise the water pump drive belt (A) out of the relevant recess.
Page 101 Fit the water pump drive belt (A) over the torsion damper. Turn the crankshaft, as during removal, and use a sharp tool to fit the NEW water pump drive belt (A) onto the pump. Ensure that the belt sits correctly in the relevant groove.
Page 102 Work from underneath the vehicle. With a fixed wrench applied onto the tensioner roller fastener screw (1), turn the mobile tensioner counterclockwise to loosen the belt (B) and enable its removal, first from the pulley on the A.C. compressor, then from the other pulleys.
Page 103 A3.13 Checking and replacing spark plugs Removing the spark plugs Disconnect the battery ( F2.01). Remove the ignition coils ( F3.17). Using a universal articulated wrench, undo and remove the spark plugs (2). Refitting the spark plugs Tightening torque Class Fastening spark plug NGK spark plug 11 Nm...
Page 104 Connect the battery ( F2.01).
Page 105 A3.14 Checking Blow-by system pipes and connections Checking Blow-by system pipes and connections Remove the engine compartment cosmetic shields ( E3.13). Check the state of the pipes (1) and the tightness of the relative clamps near the vapour separator and the intake manifold. Check the connections.
Page 106 A3.15 Checking cooling system pipes and connections Checking cooling system pipes and connections Remove the engine compartment cosmetic shields ( E3.13). Remove the right hand lateral cosmetic shield. 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.
Page 107 A3.16 Checking injection and ignition system pipes and connections Checking injection and ignition system pipes and connections Remove the lateral flat undertray sections ( E3.12). 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.
Page 108 A3.17 Checking exhaust system connections Checking exhaust system connections Remove the central flat undertray section ( E3.12). Remove the rear flat undertray section ( E3.12). Check the state of the system components, the connections between the manifolds and the catalytic converters, the connections between the catalytic converters and the central silencer and the connections between the central silencer and the rear silencers, then check all fastener elements.
Page 109 A3.18 Checking exhaust emissions Exhaust gas analysis TEST DRIVE (details of procedure): Preferably test drive the vehicle after it has been left unused overnight. The difference between the engine temperature and ambient temperature on starting must be between 3°C and 37.5°C, and the fuel level must be between 15% and 85%.
Page 110 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.
Page 111 Always replace the CCM brake discs on both sides of 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 always be performed after replacing the brake discs or the brake pads.
Page 112 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.
Page 113 Regardless of the overall state of wear, the disc must be replaced if it shows signs of damage around the edge. Any unauthorised mechanical work on the holes in the surface of the disc may damage the brake disc itself. If necessary, clean the holes in the disc brake and the friction surface of the rotor with a pressure cleaner.
Page 114 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”...
Page 115 (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. Bedding-in CCM brake 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.
Page 116 A3.20 Checking service brake/parking brake function Checking service/parking brake operation and control play 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). Check electric parking brake operation and the state of the parking brake cables.
Page 117 A3.21 Checking suspension components 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.
Page 118 Vehicle Setup Parameter Check Form Model - Vehicle Setup Parameter Check Form [Download]...
Page 119 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.
Page 120 A3.24 Checking and recharging battery Checking battery state of charge Use a digital multimeter to measure the battery state of charge. Clean the battery poles and clamps adequately. Connect the terminals of the digital multimeter to the battery poles. Read the battery voltage value from the display of the digital multimeter. If the battery voltage measured is greater than 12.70 V, the state of charge is 100%.
Page 121 Charge cycle duration: min. 12 hours, max. 24 hours. 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.
Page 122 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: located on the right-hand side of the luggage compartment, under the cover hatch (A). CAUTION Ensure that all lids and doors are closed correctly.
Page 123 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.
Page 124 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.
Page 125 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 126 A3.25 Checking alternator absorption and recharging function Checking alternator absorption and recharging function Remove the engine compartment cosmetic shields ( E3.13). Remove the left hand lateral cosmetic shield. Remove the battery connection cover. Disconnect the alternator positive cable (1) from the battery and connect a suitably calibrated digital multimeter such as (Beckman T11 OB) between the cable and the battery.
Page 127 A3.26 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.
Page 128 A3.27 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.
Page 129 A3.28 Inspecting the air conditioning and heating system Inspecting the air conditioning and heating system Remove the central flat undertray section ( E3.12). Remove the front wheelhouses ( E3.05). Remove the rear section of the right hand wheel bay. Remove the engine compartment cosmetic shields ( E3.13).
Page 130 A3.29 Inspecting the brake system Inspecting the brake system Remove the wheels ( D2.01). Remove all. Remove the engine compartment cosmetic shields ( E3.13). Remove the left hand lateral cosmetic 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.
Page 131 A3.30 Tightening bolts, unions and clamps 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.
Page 132 A3.31 Checking and lubricating hinges and adjusters Checking and lubricating hinges and adjusters Check that the hinges of the doors, of the engine compartment lid and of luggage compartment are correctly secured, exhibit no free play and operate quietly. Check that the door locks and the locking mechanisms of the engine compartment lid and luggage compartment function correctly.
Page 133 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.
Page 134 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®.
Page 135 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.
Page 136 A3.33 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.
Page 137 A3.34 Lubricating windscreen cross member seal and Front and Rear RHT Roof shell seals Lubricating windscreen cross member seal and Front and Rear RHT Roof shell seals Lubricate the windscreen cross member seal and Front and Rear RHT Roof shell seals as the intervals specified in the MAINTENANCE SCHEDULE.
Page 138 Bring the RHT electrically into the Spider position, completing the opening cycle. Apply DuPont Lubricants Krytox® 205 GPL Standard Grade Grease grease on the surface of the windscreen cross member seal (C) in contact with the Front Roof shell.
Page 139 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.
Page 140 A3.36 Replacing the transparent film on Tonneau Cover Replacing the transparent film on Tonneau Cover This procedure is necessary only in the event of evident wear or damage (the following photo shows wear on the LH side of the Tonneau Cover as an example) noted exclusively during normal scheduled maintenance.
Page 141 Specific tools and materials needed for the procedure: This film must be applied with a semi-soft rubber or silicone spatula with no sharp corners, measuring no larger than the dimensions given in the image aside. Purchase this spatula locally. The white arrows indicate the rounded sides. New microfibre cloths.
Page 142 Clean the Tonneau Cover thoroughly, using ISOPROPYL alcohol only, to remove any glue residue. Remove any glue residue, using only new microfibre cloths. As you progressively remove the backing from the film, spray water based detergent onto the entire adhesive side of the film.
Page 143 Check again that there is no dust or lint on the Tonneau Cover, then apply the film. Slide the film into place by hand to ensure that the edges are also correctly aligned. Align the film correctly along the entire rear edge of the Tonneau Cover.
Page 144 The definitive application of the film must be carried out exclusively with the specific spatula, using lateral movements (see photo aside) to prevent stretching the film. Then, as described above, working with due caution and performing lateral movements with the spatula, ensure that the film adheres completely to the paintwork, pressing onto the film with the necessary force to expel the detergent without leaving any air bubbles,...
Page 145 A3.37 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". Click "Diagnostics" Select "SET SERVICE"...
Page 146 A3.38 Cylinder compression test Cylinder compression test Connect the DEIS tester to the diagnostic socket ( F2.10). Perform the cycle "160 NCM Compression mode management" with the DEIS diagnostic tester after disabling engine firing. Remove the spark plugs ( A3.13). Remove all.
Page 147 B1.01 Technical specifications 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) control with hydraulic chain tensioners. Four overhead composite camshafts (two per cylinder bank) and four valves per cylinder with self- adjusting hydraulic tappets.
Page 148 B1.02 Specific tooling and equipment Tool (AM 107064) mounting for crankcase on AV 2621 trolley. Trolley 95977565 (AS 107565) removing the engine / gearbox / subframe assembly. Tool 95977566 (AS 107566) for removing the oil sump. Wrench USAGD156 (95971560) for tightening oil filter.
Page 149 Tensiometer (95978151) Seem DIAPAZ. Trolley 95972621 (AV 2621) for overhauling engine-gearbox assemblies Sheet 95973608 (AV 3608) for protecting intake orifices in heads.
Page 150 Torque wrench 95978172 (AV 8172) (Replaces torque wrench USAG 815F) Wrench 95978175 (AV 8175) tightening fuel pump filter retainer ring. Wrench 95978176 (AV 8176) tightening fuel level sensor.
Page 151 Exhaust tailpipe extensions 95978177 (AV 8177) for connection to exhaust fume extractor. Pins 95978350 (AV 8350) aligning engine mounting bushes with front removable subframe. Pins 95978351 (AV 8351) alignment for installation of front/rear removable subframes.
Page 152 B1.03 Tightening torques Tightening torque Class Fastening belt tensioner to crankcase Screw 25 Nm Fastening ancillary belt pulley to front cover Screw 49 Nm Fastening idler pulley to front cover Screw 25 Nm Cap - front cover M20x11 tapered plug 22 Nm Cap - front cover M14x1.5x13 tapered...
Page 153 Tightening torque Class cylinder head cover Fastening engine mounting struts Screw 45 Nm Fastening heads to crankcase Nut (pretightening) 60 Nm Products to use: MOLYKOTE BR2 Nut (with 90° angle) Fastening camshaft caps and cam tower caps Screw (pretightening) 5 Nm Screw (with 30°...
Page 154 Tightening torque Class Fastening oil dipstick tube to cylinder head Screw 10 Nm Fastening oil sump shield to lower crankcase shell Screw 10 Nm Fastening for coolant delivery pipe to block Screw 8 Nm Products to use: AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK Fastening ground cable onto cylinder head cover Screw 10 Nm...
Page 155 Tightening torque Class Fastening electric fan to cowl 9 Nm Fastening cooling system bracket to cowl Screw 24 Nm Fastening cooling system to chassis Screw 24 Nm Fastening coolant system mounting bracket to Screw 24 Nm clutch oil radiator Fastening cooling system pipe couplings to 9 Nm chassis Fastening water pump to front cover...
Page 156 Tightening torque Class Mounting bracket - exhaust extensions 22 Nm Oxygen sensor - catalytic converter Oxygen sensor 50 Nm Catalytic converter - exhaust manifold 25 Nm Nut (pretightening) 15 Nm Catalytic converter clamp - mounting bracket 25 Nm Mounting bracket - silencer 25 Nm Centre silencer - catalytic converter Torx clamp...
Page 157 B2.01 Removing the complete engine Removing the complete engine CAUTION During the following operations, the VEHICLE MUST ONLY BE LIFTED WITH THE ANTI-TIPPING SAFETY RETAINERS INSTALLED. After loosening or removal, the Caillau Visa hose clamps must be replaced with Mikalor worm drive hose clamps, following the instructions given in Technical Information 2054 of December 2012.
Page 158 Loosen the screw collar (3). Disconnect the pipe (4) from the power steering fluid tank. Undo the screw (5). Disconnect the unions for the pipes (6) from the compressor. Loosen the screw collar (7). Disconnect the pipe (8) from the water pump. Loosen the collar (9).
Page 159 Loosen the screw collar (11). Disconnect the delivery pipe (12) from the pressure switch/thermostat. Remove the battery connection cover. Undo the nut (14). Disconnect the positive cable (13). Undo the screw (15) fastening the steering column to the steering box and separate the components.
Page 160 Loosen the screw collar (16). Disconnect the pipe (17) from the secondary air pump. NEW solution Detach the quick release connector indicated. Disconnect the pipe (17) from the secondary air pump. Remove the indicated collar. Disconnect hose union (18) from the evaporative emissions control system solenoid valve.
Page 161 Remove the collar (21). Disconnect the pipe (22) from the expansion tank. ONLY for vehicles WITHOUT single oil heat exchanger Release the indicated clips. Loosen the screw collar (23). Disconnect the coolant pipe (24). ONLY for vehicles WITH single oil heat exchanger UP TO Assembly No.
Page 162 ONLY for vehicles WITH Single Oil Heat Exchanger FROM Assembly No. 91553 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Detach the quick release connector indicated and disconnect the coolant pipe (24) from the rigid pipe (44).
Page 163 Note the position of the pipes (38), to prevent accidentally swapping them during refitting. Disconnect the pipes (38). Release and open the indicated clip. Undo the indicated fasteners. Remove the passenger compartment air duct (27) from the engine compartment. CAUTION Fuel is highly flammable.
Page 164 Disconnect the water pipe (31) leading to the recirculation pump from the pipe (30). Remove the clamps indicated fastening the right hand injection cable (32) at the top. Disconnect the connector (33) from the front oxygen sensor. Disconnect the connector (34) from the rear oxygen sensor.
Page 165 Disconnect the ground cable (39) from the chassis by undoing the relative fastener screw indicated. Release the right hand injection cable (32), removing the indicated clamps. Disconnect the connectors (40). Disconnect the connectors (41). Pull the right hand injection cable (32) upwards out of its seat and place on top of the intake manifold so that it does not hinder the following operations.
Page 166 Disconnect the front engine-chassis ground cable (76) from the engine by undoing the screw (75). ONLY for vehicles WITHOUT single oil heat exchanger Remove the mounting bracket (43) for the hydraulic clutch system oil pipes, by undoing the screws (44). Remove the clamps (45) and (46), by undoing the screws (47).
Page 167 Remove the clamps indicated fastening the left hand injection cable (42) at the top. ONLY for vehicles WITHOUT single oil heat exchanger Undo the screw (52) on the clamp retaining the hydraulic clutch system oil pipes (53). ONLY for vehicles WITHOUT single oil heat exchanger Detach the hydraulic clutch system oil delivery and return unions (54).
Page 168 Lift the hydraulic clutch system oil pipes to allow access to the fasteners for the left hand injection cable (42). Remove the clamps indicated fastening the left hand injection cable (42). Detach the safety fasteners (87). Disconnect the connectors (88) from the LH Motronic ECU (89).
Page 169 Disconnect the connectors (58) of the injection cable (42). Detach the injection cable (42) from the chassis by releasing the indicated clips. Pull the left hand injection cable (42) upwards out of its seat and place on top of the intake manifold so that it does not hinder the following operations.
Page 170 FROM Assembly No. 85739 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the indicated screws fastening the reinforcement tube (90) to the front removable subframe (69). Install the tool 107566) on the top end of a long ram hydraulic jack.
Page 171 The trolley 107565) is necessary for the removal of the engine complete with removable subframe. The trolley consists of a swivelling platform (63) with two handles (64) for locking axial position, six alignment pins (65) with relative swivelling and extensible mounts, a pedal (66) for lifting the platform, and a handle (67) for lowering the platform.
Page 172 CAUTION Always ensure that the pins of the support trolley are inserted correctly in the respective holes on the removable subframe. Using a suitable wrench, raise each alignment pin (70) of the trolley 107565), and insert fully into the respective hole on the front removable subframe.
Page 173 A mobile hydraulic jack or bridge crane with a minimum load capacity of 300 Kg, and two 2.5 m long safety belts are necessary to detach the engine assembly from the respective removable subframe. Position the lift hook over the engine. CAUTION To ensure safety, the straps must be located securely on the engine assembly, taking care not to crush any cables or pipes.
Page 174 On both sides, remove the heat shield (79), detaching the indicated clips. On both sides, remove the rubber lined bracket (80), undoing the indicated nut. UP TO Assembly No. 95407, on both sides, undo the screw (81). FROM Assembly No. 95408, on both sides, undo the nut (81).
Page 175 Right hand bush UP TO Assembly No. 103178, remove the bush heat shield (1), detaching the two clips. Remove the bracket (2), undoing the relative fastener nut indicated. Remove the retainer bracket from the bush. UP TO Assembly No. 95407, undo the screw (3) fastening the engine mounting strut to the respective bush.
Page 176 Refit the front element in both wheel bays. Refit the central flat undertray section ( E3.12). Preparing engine for transport Whenever an engine must be shipped to Ferrari, it must be delivered in the exact configuration described as follows. Therefore, before shipping the engine to the factory:...
Page 177 Remove the dumper flywheel and store for subsequent reassembly. Remove the starter motor and the relative heat shield and store for subsequent reassembly. The motorised throttle bodies and air flow meters must be installed on the intake manifold with the respective intake orifices plugged.
Page 178 The intake manifold must be adequately protected. The injection wiring harness must be gathered and fastened together with cable ties and secured to the engine. Plug the water inlet/outlet orifices. Cap the inlets and outlets of the AC system unions. Cap the inlets and outlets of the power steering system pipes.
Page 179 Remove the fuel delivery pipe leading to the GDI pumps and store for subsequent reassembly. The unions and pipes on the cylinder head covers and on the intake manifold must be plugged. The brake servo vacuum pipe must be installed on the engine and plugged.
Page 180 Plug the ports of the exhaust manifolds. Remove the connector pipes and the secondary air valves, capping the respective orifices, and store for subsequent reassembly. Remove the soundproofing covers on the GDI pumps and store for subsequent reassembly.
Page 181 Remove the water pipe leading from the RH cylinder head and store for subsequent reassembly, and cap the orifices on the head.
Page 182 B2.02 Refitting the complete engine Installing the RETROFIT KIT FOR ENGINES WITH DUAL HEAT EXCHANGER, Part No. 270157 Tightening torque Class Fastening the seal flange Screw (Part No. 231617) 8 Nm The kit consists of the following components: 2 x TCEI M6x18 screws Part No. 231617; Toroid O-ring Part No.
Page 183 Unscrew and retrieve the union (C) from the old engine. Tighten the union (C) onto the new engine to a depth of 7 (+0 / -2) mm. Connect the pipe (D) to the union (C). Tighten the hose clamp (1). Installing the RETROFIT KIT FOR ENGINES WITH SINGLE HEAT EXCHANGER, Part No.
Page 184 Undo the screws indicated. During the removal of the old engine, the pipe (B) must be disconnected from the pipe (C), by undoing the indicated screw. Loosen the hose clamp (1). Open the rubber lined clip (2) by undoing the indicated screw.
Page 185 Align the lower hole on the pipe bracket (D) with the respective hole on the chassis. Holding the pipe bracket (D) in the correct installation position, mark the positions on the chassis of the upper holes indicated. Loosen the hose clamp (1). Open the rubber lined clip (2) by undoing the indicated screw.
Page 186 Fit and connect the pipe (D). Tighten the hose clamp (1). Close the rubber lined clip (2) by tightening the indicated screw. Tightening torque Class Screw 8 Nm Tighten the indicated screws supplied in the kit. During installation of the new engine, the pipe (A) must be connected to the pipe (D).
Page 187 Tightening torque Class transmission tunnel casting Fastening front removable subframe to Screw 110 Nm transmission tunnel side member endpiece Fastening front removable subframe to side Screw 110 Nm member head casting Fastening reinforcement tube - front removable Screw 24 Nm subframe Articulated shaft - transmission housing shaft Screw with control angle...
Page 188 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) On both sides, loosen the screws (82) fastening the engine mounting bushes to the front removable subframe. Provisionally fasten the retainer bracket to the gearbox mounting bush (85), hand-tightening one of the two screws (77).
Page 189 UP TO Assembly No. 95407, on both sides, tighten the screws (81) fastening the engine mounting strut to the engine mounting bush. Tightening torque Class Screw 103 Nm FROM Assembly No. 95408, on both sides, tighten the nuts (81) fastening the engine mounting strut to the engine mounting bush.
Page 190 Turn the bracket (85) installed previously, bringing it over the transmission housing bushing bracket (86) and aligning with the hole on the front removable subframe. Tighten the nut (78). Tightening torque Class 103 Nm Tighten the screws (77). Tightening torque Class Screw 40 Nm...
Page 191 Definitively tighten the relative screws (82). Tightening torque Class Screw 50 Nm Definitively tighten the relative screws (82). Tightening torque Class Screw 50 Nm Tighten the pins 8351) into the M12 holes for fastening the subframe to the vehicle chassis.
Page 192 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the pins 8350) into the M10 holes for fastening the subframe to the vehicle chassis. Move the lift trolley 107565), complete with front removable subframe, under the front of the vehicle, with the trolley operating handle facing toward the front of the vehicle.
Page 193 Pre-tighten all the screws fastening the front removable subframe Tightening torque Class Screw (pretightening) 20 Nm Tighten the front screws (71). Tightening torque Class Screw 110 Nm Tighten the centre screw pairs (74). Tightening torque Class Screw 34 Nm Tighten the centre screws (73). Tightening torque Class Screw...
Page 194 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Partially tighten then fully tighten all the indicated screws fastening the front removable subframe (69) in the following sequence. The screws are not all the same length. Before applying the screws, refer to the notes made during removal to ascertain which screws correspond to which positions.
Page 195 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) CAUTION Check that all screws are correctly fastened before removing the trolley supporting the removable subframe. Slowly lower the trolley lift platform 107565) with the relative lowering handle. Place a hydraulic jack fitted with the tool 107566) under the engine oil sump.
Page 196 Fit the transmission shaft, performing the tests and checks described as follows. On the rear of the transmission shaft is a white marking indicating the point of maximum imbalance. This mark must be positioned at approximately 180° relevant to the marking on the transmission housing (point of maximum flywheel imbalance).
Page 197 Fit and secure the left hand injection cable (42), fastening the indicated clips. Connect the connectors (58). Connect the connector (55) of the front oxygen sensor. Connect the connector (56) of the rear oxygen sensor. Secure the oxygen sensor connector cables by tightening the fastener screws for the indicated brackets Connect the ground cable (57) by tightening the...
Page 198 Fit and secure the left hand injection cable (42), tightening the fastener screws for the indicated brackets. ONLY for vehicles WITHOUT single oil heat exchanger Observe the procedure described as follows to connect the clutch hydraulic system oil pipe unions correctly: ensure that the notch on the safety ring nut (50) is aligned with the pin (51);...
Page 199 ONLY for vehicles WITHOUT single oil heat exchanger Fasten the hydraulic clutch system oil pipes (53), by tightening the screw (52) on the retainer clamp. Fit and secure the left hand injection cable (42), tightening the fastener screws for the indicated brackets.
Page 200 Connect the ground cable (76), tightening the screw (75). Tightening torque Class Screw 25 Nm Fit the right hand injection cable (32). Connect the connectors (41). Secure the right hand injection cable (32), tightening the fastener screws for the indicated brackets. Connect the connectors (40).
Page 201 Connect the ground cable (39), tightening the respective fastener screw. Connect the connectors (36) to the right hand Motronic ECU (37). Fasten the safety fasteners (35). Connect the connector (33) of the front oxygen sensor. Connect the connector (34) of the rear oxygen sensor.
Page 202 Fit and secure the right hand injection cable (32), tightening the fastener screws for the indicated brackets. Connect the water pipe (31) to the pipe (30). Install the engine compartment air duct (27) in its seat in the engine compartment from above and fasten by hand tightening the fasteners indicated.
Page 203 Connect the pipes (38) to the solenoid valve and to the accumulator tank using the markings made during removal as reference. Fasten the pipes (38) with the indicated bracket. Connect the vacuum pipe (26) to the block on the intake manifold. Fit and tighten the collar (25).
Page 204 ONLY for vehicles WITH single oil heat exchanger UP TO Assembly No. 91552 Apply AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK on the thread of the specified screw. Replace the O-ring then connect the engine coolant delivery pipe (24) to the block (44). Fasten the pipe (24), fitting the retainer fork (23) and tightening the indicated screw.
Page 205 Connect the pipe (22) to the expansion tank, fitting and tightening a new collar (21). Connect the hose union (19) to the pipe (20). Connect the hose union (18) to the evaporative emissions control system solenoid valve, fitting and tightening the collar indicated. Connect the pipe (17) to the secondary air pump.
Page 206 NEW solution Connect the pipe (17) to the secondary air pump, fastening the indicated quick release connector. Connect the steering column to the steering box. Tighten the screw (15). Tightening torque Class Special screw 30 Nm Connect the positive cable (13) for connecting to the alternator to the battery terminals, hand tightening the nut (14).
Page 207 Connect the delivery pipe (12) to the pressure switch/thermostat. Tighten the hose clamp (11). Tightening torque Class Screw collar 4 Nm Connect the pipe (10) to the front of the water pump. Tighten the screw collar (9). Tightening torque Class Screw collar 4 Nm Connect the pipe (8) to the rear of the water...
Page 208 Connect the pipe (4) to the power steering fluid reservoir. Tighten the hose clamp (3). Tightening torque Class Screw collar 4 Nm Fit the mounting brackets for the power steering system pipes (1) in the relative seats on the steering box bushes. Tighten the nuts (2).
Page 209 B2.03 Engine overhaul - Disassembly Preparations for engine overhaul The following procedures must be performed in a suitable, clean area, wearing professional disposable nitrile powder free gloves. Frequently check the condition of the gloves used and replace if torn of excessively soiled. After removing each component, note the positions of screws, brackets, braids, sheaths and clamps to facilitate subsequent reassembly and ensure that all components are refitted correctly.
Page 210 Left hand side only _ Only for vehicles WITHOUT SINGLE OIL HEAT EXCHANGER Release the AC pipe (1), removing the indicated clamps. Move the AC pipe (1) aside so that it does not hinder the subsequent operations. Right hand side only Disconnect the connector (9).
Page 211 Left hand side only Undo the indicated screw fastening the pipe (15). Disconnect the connectors (6). Release the pipe (5) by undoing the indicated screw. Move the pipe (5) as far outward as possible, taking care not to bend it. The pipe (5) remains fastened to the exhaust manifold.
Page 212 Right-hand side Release the ground cable (8) by undoing the indicated screw. Move the injection cable (7) away from the cylinder head cover, detaching in the positions indicated by the red arrows. Left-hand side Undo all the screws indicated. Retrieve the clamp (14) complete with cable. Take care not to damage or scratch the cylinder head cover.
Page 213 Remove the compressor ( F5.03). Remove the power steering pump ( D5.03). Disconnect the pipe (1), removing the indicated collar. Disconnect the pipe (2). Disconnect the pipe (1), removing the indicated collar. Disconnect the pipe (2). Disconnect the connector (3). Release and open the indicated clips.
Page 214 Loosen the screws (5). Undo the screws (6). Undo the indicated screw. Remove the belt tensioner (A). Undo the indicated screw. Remove the torsion damper (B).
Page 215 Remove the bracket (C), undoing the respective screw indicated. Remove the bracket (D), undoing the respective screws indicated. Undo the screws indicated. Remove the cover (E). Note the respective positions of the indicated screws. The screws indicated are not all of the same length.
Page 216 Disconnect the connector (1). Adequately support the weight of the sump (A). Note that there may be engine oil residue in the sump. Undo the screws indicated. Remove the sump (A). Retrieve the gasket (2) and replace. Removing the timing chains Remove the front engine cover ( B2.03).
Page 217 Left hand cylinder bank, UP TO engine No. 166072 Undo the screws indicated. Remove the fixed shoe (A). Left hand cylinder bank Immobilise the camshafts with the reaction tool. Undo the tensioner (B). Remove the mobile shoe (C), undoing the respective screw indicated.
Page 218 Right hand cylinder bank Immobilise the camshafts with the reaction tool. Undo the tensioner (B). Remove the mobile shoe (C), undoing the respective screw indicated. Remove the intake variable valve timing adjuster (D), undoing the respective screw indicated and retrieving the respective diamond-coated washer.
Page 219 Remove the indicated Seeger ring from the engine oil pump drive gear. Ease off and remove the engine oil pump drive gear (O), complete with chain (P). Simultaneously, ease off and remove the gear (Q) from the drive gear spindle, and remove the gear (R) from the crankshaft, complete with chain (S).
Page 220 Replace the variable timing adjuster control solenoid valves ( F3.16). Remove the variable timing adjuster solenoid valves Undo the screws indicated. Remove the cap (A). Undo the screws indicated. Remove the cam tower caps (B). Undo the screws indicated. Remove the cap (C). Remove the camshafts from the cylinder heads.
Page 221 Remove the intake manifold ( B4.04). Remove the right hand exhaust manifold ( B7.02). Remove the left hand exhaust manifold ( B7.02). Remove the GDI injection rail pipes ( F3.19). Remove the alternator ( F2.04). Remove the spark plugs ( A3.13).
Page 222 Remove the tappets (A). Undo the indicated nuts, retrieving the respective washers. Remove the cylinder head, easing the head off the respective stud bolts. Remove the gasket (B). Removing the lower crankcase shell Remove the starter motor ( F2.05). Remove the timing chains ( B2.03).
Page 223 Remove the indicated Seeger ring. Pull out and remove the engine oil dipstick extension (A). Undo the screws indicated. Remove the gaiter (B). Unscrew and remove the engine oil filter (C). On both sides of the engine, remove the struts (D), undoing the indicated screws.
Page 224 Undo the screws indicated. Retrieve the brackets (E). Undo the screws indicated. Undo the screws indicated.
Page 225 Undo the indicated nuts, retrieving the respective washers. Easing carefully off the stud bolts, remove the lower crankcase shell (F), complete with the half bearings and bearing shims for the crankshaft. FROM Engine No. 153879 Remove the four blow-by valves (G), undoing the respective screws indicated.
Page 226 Remove the crankshaft (B). Remove the half bearings (1) from the connecting rod caps. Remove the half bearings (2) from the connecting rods.
Page 227 Remove the bearing shims (3) from the crankcase. Remove the half bearings (4) from the crankcase. Remove the bearing shims (5) from the lower crankcase shell.
Page 228 Remove the half bearings (6) from the lower crankcase shell. Removing and disassembling piston-connecting rod assemblies Remove the crankshaft ( B2.03). Remove the cylinder heads ( B2.03). Number the pistons (A) and the respective positions, starting from the timing side of the right hand cylinder bank and proceeding in clockwise order.
Page 229 Detach and remove the indicated ring. Push out and remove the piston pin (D). Separate the piston (A) from the connecting rod shank (C). Remove the piston rings (E) from the respective seats on the piston (A). Remove the oil scraper ring (F) from the respective seat on the piston (A).
Page 230 B2.04 Engine overhaul - Inspections Main characteristics of cylinder sleeves Min. coaxiality 0.03 mm Nominal diameter 94 mm±0.008 (DN) Max. ovalisation at D3 0.015 mm Max. ovalisation at D2 0.015 mm Max. ovalisation at D1 0.02 mm Visual inspection of piston wear The following procedures must be performed in a suitable, clean area, wearing professional disposable nitrile powder free gloves.
Page 231 Measure the main journals and the crankpins with a micrometer. The dimensions measured must comply with the specified values. Using the dimensions measured, refer to the following tables to select the correct crankshaft half bearings and connecting rod half bearings. Main journal half bearing selection table CLASS A...
Page 232 Table for selecting Lead Free crankpin half-bearings (FROM Engine No. 172991) CLASS X CLASS Y connecti connecti ng rod ng rod (47.129 (47.136 47.135) 47.142) CLASS X BLUE cranksh (43.630 43.637) CLASS Y BLUE BLACK cranksh (43.621 43.629)
Page 233 B2.05 Engine overhaul - Rebuild Reassembling and refitting the piston-connecting rod assemblies Check piston wear visually ( B2.04). Fit the oil scraper ring (F) in the respective seat on the piston (A). Orienting correctly, fit the piston rings (E) in the respective seats on the piston (A).
Page 234 Apply SHELL Helix Ultra SAE 5W-40 to the piston rings, taking care not to turn the rings out of position. Apply SHELL Helix Ultra SAE 5W-40 to the inner surfaces of the cylinder sleeves. Before installing the cylinder sleeves, check that the pistons are oriented with the intake side facing upwards and the exhaust side facing downwards, as illustrated.
Page 235 Using a specific piston installation tool, fit the pistons (A), complete with connecting rods, in the respective cylinder sleeves. Refit the crankshaft ( B2.05). Refit the cylinder heads ( B2.05). Refitting the crankshaft Tightening torque Class +1.5 Fastening connecting rods Screw (1st pre- -1.5 Products to use: SHELL Helix Ultra SAE 5W-40...
Page 236 Apply MOLYKOTE BR2 grease to surface of the bearing shim (5) in contact with the lower crankcase shell. Fit the bearing shims (5) in the respective seats on the lower crankcase shell. Fit the half bearings (4) in the respective seats on the crankcase.
Page 237 Fit the half bearings (2) in the respective seats on the connecting rods. Lubricate the half bearings (2) with engine oil SHELL Helix Ultra SAE 5W-40. Fit the half bearings (1) in the respective seats on the connecting rod caps. Lubricate the half bearings (1) with engine oil SHELL Helix Ultra SAE 5W-40.
Page 238 Replace all connecting rod fastener screws that have been subjected to operating temperature. After fitting, the new connecting rod fastener screws may be removed and refitted once only. A connecting rod must be replaced if, after two consecutive tightening sequences, the control torque and/or extension values are no longer within specified tolerances.
Page 239 Tightening torque Class Fastening lower crankcase shell baffles Screw 3 Nm Products to use: Loctite 242 Fastening lower crankcase shell to crankcase Nut (pretightening) 10 Nm Products to use: SHELL Helix Ultra SAE 5W-40 Nut (applying angle of 61.5 145°± 1°) +19.5 Nut (applying angle of -19.5...
Page 240 The nuts fastening the lower crankcase shell must be tightened within 2 minutes of mating the crankcase with the lower crankcase shell. Installing the stud bolts carefully, fit the lower crankcase shell (F), complete with the half bearings and bearing shims for the crankshaft. Fit the washers, with the knurled side in contact with the lower crankcase shell.
Page 241 Tighten the screws indicated. Tightening torque Class Screw 10 Nm Tighten the screws indicated. Tightening torque Class Screw 10 Nm Fit the brackets (E). Tighten the screws indicated. Tightening torque Class Screw 10 Nm Using a dial gauge, check that the endfloat of the crankshaft is between 0.12 and 0.24 mm.
Page 242 On both sides of the engine, fit the struts (D) and tighten the indicated screws. Tightening torque Class Screw 45 Nm Replace the engine oil filter (C), tightening the new component correctly. Fit the gaiter (B). Tighten the screws indicated. Tightening torque Class Screw...
Page 243 Tightening torque Class Fastening heads to crankcase Nut (pretightening) 60 Nm Products to use: MOLYKOTE BR2 Nut (with 90° angle) Replace the gasket (B), fitting the new component correctly. Apply CAF 4 in the indicated points on the top and bottom sides of the gasket. Fit the cylinder head on the respective stud bolts.
Page 244 Pre-tighten the indicated nuts in the sequence given Tightening torque Class Nut (pretightening) 60 Nm Definitively tighten the indicated nuts in the sequence given. Tightening torque Class Nut (with 90° angle) Apply SHELL Helix Ultra SAE 5W-40 to the tappets (A) and fit the tappets. Left hand head Tighten the indicated screws, fitting the respective brackets.
Page 245 Right hand cylinder head, UP TO engine No. 156350 Tighten the indicated screw, fitting the respective bracket. Right hand cylinder head, FROM Engine No. 156351 Tighten the indicated screw, fitting the respective bracket. Refit the camshafts ( B2.05). Refit the spark plugs ( A3.13).
Page 246 Replace the seal rings (1) on the shafts. Check the stamped code on each shaft before installing in the cylinder head. Fit the shafts in the respective seats in the cylinder head. Apply SHELL Helix Ultra SAE 5W-40 oil to the indicated shaft collars.
Page 247 Fit the cap (C). Hand-tighten the indicated screws. Checking the stamped number, fit the caps (B) in the respective positions. Hand-tighten the indicated screws. Replace the gasket (2).
Page 248 Fit the cap (A). Hand-tighten the indicated screws. Pretighten the indicated screws in the sequence given. Tightening torque Class Screw (pretightening) 5 Nm Definitively tighten the indicated screws in the sequence given. Tightening torque Class Screw (with 30° angle) 10 Nm Replace the variable timing adjuster control solenoid valves ( F3.16).
Page 249 Check that the three bearings (T) are installed in the correct position. Simultaneously, fit the gear (Q) on the drive gear spindle, and fit the gear (R) on the crankshaft, complete with chain (S). Fit the engine oil pump drive gear (O), complete with chain (P).
Page 250 Fit the indicated Seeger ring on the engine oil pump drive gear. Fit and fasten the fixed shoe (N), tightening the respective screws indicated. Tightening torque Class Screw 10 Nm Fit and fasten the fixed shoe (M), tightening the respective screws indicated. Tightening torque Class Screw...
Page 251 Fit and fasten the fixed shoe (L), tightening the respective screws indicated. Tightening torque Class Screw 10 Nm Fit and fasten the mobile shoe (I), tightening the respective screws indicated. Tightening torque Class Screw 10 Nm Fit and fasten the shoulder bush (H) tightening the respective screw indicated.
Page 252 Right hand cylinder bank Immobilise the camshafts with the reaction tool. Fit and fasten the fixed shoe (G), tightening the respective screws indicated. Tightening torque Class Screw 10 Nm Fit and fasten the intake variable valve timing adjuster (E), complete with chain (F), fitting the respective diamond-coated washer and hand-tightening the respective screw indicated.
Page 253 Left hand cylinder bank Immobilise the camshafts with the reaction tool. Fit and fasten the fixed shoe (G), tightening the respective screws indicated. Tightening torque Class Screw 10 Nm Fit and fasten the intake variable valve timing adjuster (E), complete with chain (F), fitting the respective diamond-coated washer and hand-tightening the respective screw indicated.
Page 254 Timing adjustment Tightening torque Class Fastening timing adjusters on camshafts Screw (pretightening) 50 Nm Products to use: SHELL Helix Ultra SAE 5W-40 Screw (with 70° angle) 100 ÷ 140 Nm Remove the complete engine ( B2.01). Remove the front engine cover ( B2.03).
Page 255 Install a dial gauge (A) complete with adapter in the spark plug orifice of cylinder 1. While reading the dial gauge (A), turn the crankshaft to bring cylinder 1 to TDC in the power stroke. Install a dial gauge (B), complete with mount, on one of the intake valves of cylinder 1, keeping the probe of the dial gauge as perpendicular as possible with the upper surface of the...
Page 256 While reading the dial gauge (A), turn the crankshaft to bring cylinder 1 to TDC in the power stroke. Install a dial gauge (B), complete with mount, on one of the exhaust valves of cylinder 1, keeping the probe of the dial gauge as perpendicular as possible with the upper surface of the bucket tappet.
Page 257 Check that the reference markings indicated on the camshafts are aligned with the reference markings indicated on the front caps. Repeat the timing adjustment procedure described above for the other cylinder bank. Turn the crankshaft by a few revolutions and measure the timing values again. Remove the dial gauges.
Page 258 Thoroughly clean the sump mating surface. Fit the sump (A) in its relative seat. Hand tighten the screws indicated. Check that the gasket is positioned correctly. Tighten the screws indicated. Tightening torque Class Screw 10 Nm Connect the connector (1). Connect the battery ( F2.01).
Page 259 Replace the gasket (11). Replace the gasket (10). Undo the screws indicated. Remove the tensioner (F), complete with mount.
Page 260 Replace the gasket (9). Fit the tensioner (F), complete with mount. Hand tighten the screws indicated. Clean the bush seat thoroughly.
Page 261 Clean the bush seat thoroughly. Remove the seals (8) and replace. Thoroughly clean the mating surfaces between the crankcase and the front cover. Apply paste CAF 4 in the positions indicated.
Page 262 Fit new seals (8) . Carefully fit and fasten the front cover. Tighten the indicated screws in the respective positions. Replace the gasket (7).
Page 263 Fit the cover (E). Tighten the screws indicated. Tightening torque Class Screw 10 Nm Fit the bracket (D), tightening the respective screws indicated. Fit the bracket (C), tightening the respective screw indicated. Definitively tighten the front cover fastener screws in the sequence indicated. Tightening torque Class Screw...
Page 264 Fit and install the torsion damper (B) fully into its seat. Immobilise the crankshaft. Apply Loctite 242 to the thread of the indicated screw. Tighten the indicated screw, fitting the respective washer. Tightening torque Class Screw 450 Nm Fit the tensioner (A). Tighten the indicated screw.
Page 265 Fit the secondary air system pipe assembly (4). Close and fasten the indicated clips. Connect the connector (3). Connect the pipe (2). Connect the pipe (1) fitting and tightening the new collar as indicated. Connect the pipe (2). Connect the pipe (1) fitting and tightening the new collar as indicated.
Page 266 Refitting the cylinder head covers Tightening torque Class Fastening the cylinder head covers Screw (pretightening) 5 Nm Screw 11 Nm Fastening ground cable onto cylinder head cover Screw 10 Nm Fastening engine oil dipstick Screw 10 Nm Some of the following photos show the engine on the workbench to illustrate the operation more clearly. Replace the cylinder head cover gasket (15).
Page 267 Remove any residual sealant paste from the mating surface with the cylinder head. Apply CAF 4 in the positions indicated in the photo aside. Left-hand side Take care not to damage or scratch the cylinder head cover. Fit the cylinder head cover (12) in its relative seat. Fit the clamp( 14) complete with cable.
Page 268 Right-hand side Take care not to damage or scratch the cylinder head cover. Fit the cylinder head cover (11) in its relative seat. Apply and hand tighten all screws indicated. Right-hand side Pre-tighten the indicated screws in the sequence given in the photo aside. Tightening torque Class Screw (pretightening)
Page 269 Right-hand side Fasten the injection cable (7) to the cylinder head cover, securing in the positions indicated by the red arrows. Fasten the ground cable (8) by tightening the indicated screw. Tightening torque Class Screw 10 Nm Left hand side only Fasten the pipe (15) by tightening the indicated screw.
Page 270 Right hand side only Fasten the engine oil dipstick (10) by tightening the indicated screw. Tightening torque Class Screw 10 Nm Right hand side only Connect the connector (9). Left hand side only _ Only for vehicles WITHOUT SINGLE OIL HEAT EXCHANGER Secure the AC pipe (1), fastening the indicated clamps.
Page 271 B3.01 Engine fuel system layout Fuel system layout A - Fuel tank B - Fuel pump C - High pressure pumps D - Fuel rail E - Low pressure pipes F - High pressure pipes G - Fuel level sensors H - Fuel pump filter...
Page 272 B3.02 Fuel tank Removing the fuel tank 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.
Page 273 CAUTION Before performing the next operation, cover the relevant part of the engine with rags so that any leaking fuel will be absorbed and will not come into contact with the engine or any other unit. In case of contact with fuel, dry the affected area immediately.
Page 274 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.
Page 275 Undo the screws indicated. Remove the indicated ring nuts. Remove the heat shield (B). Support the weight of the tank adequately Undo the screws indicated. Remove bracket (C).
Page 276 Undo the screws indicated. Remove bracket (C). Undo the screws indicated. Remove the bracket (D). Undo the screws indicated. Remove the bracket (D).
Page 277 Remove the fuel tank (E). FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the indicated nuts and screw. Remove the inspection cover (A).
Page 278 CAUTION Before performing the next operation, cover the relevant part of the engine with rags so that any leaking fuel will be absorbed and will not come into contact with the engine or any other unit. In case of contact with fuel, dry the affected area immediately.
Page 279 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.
Page 280 Undo the screws indicated. Undo the indicated nut. Undo the indicated screw. Remove the bracket (B). Undo the indicated screw. Remove the bracket (B).
Page 281 Remove the indicated ring nuts. Remove the heat shield (C). Support the weight of the tank adequately Undo the screws indicated. Remove the bracket (D). Undo the screws indicated. Remove the bracket (D).
Page 282 Undo the screws indicated. Remove the bracket (E). Undo the screws indicated. Remove the bracket (E). Remove the fuel tank (F). Refitting the fuel tank...
Page 283 Tightening torque Class Lower bracket on fuel tank - chassis Screw 20 Nm Heat shield - fuel tank Screw 9 Nm Inspection hatch cover - tank closure 3.5 Nm CAUTION Take every necessary precaution, since fuel residues may remain in the tank and in the pipes, even after the operations described.
Page 284 Fit the bracket (D). Hand tighten the screws indicated. Fit the bracket (D). Hand tighten the screws indicated. Position bracket (C). Hand tighten the screws indicated.
Page 285 Position bracket (C). Hand tighten the screws indicated. Tighten the screws fastening the fuel tank mounting brackets. Tightening torque Class Screw 20 Nm Fit the heat shield (B). Fasten the indicated retainer ring nuts.
Page 286 Tighten the screws indicated. Tightening torque Class Screw 9 Nm Connect the connector (9). Connect the connector (8).
Page 287 Connect the pipe (7), fastening the indicated union. Connect the ground cable (6) by tightening the indicated screw. Connect the connector (5). Fit and fasten the covers (4). Connect the pipe (3), fastening the indicated union. Connect the pipe (2), fastening the indicated union.
Page 288 Fit the inspection cover (A). Tighten the indicated nuts and screw. Tightening torque Class 3.5 Nm FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Check the condition of the tank and the relative components.
Page 289 Fit the bracket (E). Hand tighten the screws indicated. Fit the bracket (E). Hand tighten the screws indicated. Fit the bracket (D). Hand tighten the screws indicated.
Page 290 Fit the bracket (D). Hand tighten the screws indicated. Tighten the screws fastening the fuel tank mounting brackets. Tightening torque Class Screw 20 Nm Fit the heat shield (C). Fasten the indicated retainer ring nuts.
Page 291 Fit the bracket (B). Hand tighten the indicated screw. Fit the bracket (B). Hand tighten the indicated screw. Tighten the screws indicated. Tightening torque Class Screw 9 Nm Tighten the indicated nut.
Page 292 Connect the connector (9). Connect the connector (8). Connect the pipe (7), fastening the indicated union. Connect the ground cable (6) by tightening the indicated screw. Connect the connector (5).
Page 293 Fit and fasten the covers (4). Connect the pipe (3), fastening the indicated union. Connect the pipe (2), fastening the indicated union. Connect the pipe (1), fastening the indicated union. Fit the inspection cover (A). Tighten the indicated nuts and screw. Tightening torque Class 3.5 Nm...
Page 294 For vehicles in "2 seat" configuration. Connect the battery ( F2.01). Connect the DEIS tester to the diagnostic socket ( F2.10). Perform the "NCM Short trip sequence: leak detection monitoring" cycle.
Page 295 B3.03 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 behind the right hand rear wheel bay. Remove the rear wheelhouses ( E3.05). Remove the right one. Remove the rear bumper ( E3.04).
Page 296 Undo the screw (7) fastening the pipe connecting the filter to the chassis. Open the clamp (8) and release the pipe (6) connecting to the OBD pump filter. Working via the aperture in the wheel bay, disconnect the quick coupling (15) from the active carbon filter (A).
Page 297 Detach the pipe (9) connecting the filter to the diagnostic pump, removing the clamp (18). A double-lock safety clip is fitted on the pipe (14) connecting the filter to the fuel vapour separator (16). To disconnect the "double-lock" quick-coupling, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
Page 298 Disconnect the remaining pipes (17) connected to the carbon filter. A "double-lock" safety clip is fitted on the lower pipe connected to the active carbon filter. 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".
Page 299 Check the state of the protective foam rubber pads (13) applied to the active carbon filter mounting bracket; replace if necessary. Fit the active carbon filter (A) on the relative mounting bracket as originally installed and fasten with the retainer bracket (12), tightening the screw (11).
Page 300 Apply the new adhesive foam rubber (14) onto the active carbon filter, as shown in the photo aside. Fit the active carbon filter, complete with bracket and filter for the OBD pump, into its seat, via the aperture at the rear of the vehicle. Fasten the front of the active carbon filter by tightening the screw (10).
Page 301 Connect the pipe (9) connecting the filter to the diagnostic pump and fasten the clamp (18). Working via the aperture in the wheel bay, connect the quick coupling (15) to the active carbon filter (A). Fasten the rear of the active carbon filter by tightening the screw (6).
Page 302 Hand tighten the screw (7) fastening the pipe connecting the filter to the chassis. Fasten the pipe (6) to the OBD pump filter as originally mounted, closing the clamp (8). Fit the active carbon filter cover (1) and fasten by tightening the screws (2).
Page 303 B3.04 Fuel pump assembly Removing the fuel pump filter 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.
Page 304 Disconnect the connector (3). Disconnect 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.
Page 305 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.
Page 306 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.
Page 307 Connect the connector (9). Connect the pipes (7) and (8), fastening the respective unions. Install the new fuel pump filter (A). Check that the indicated tab on the fuel pump filter (A) is fitted correctly in its respective seat. Fit a NEW fastener ring (6). Fit the tool 8175) on the fastener ring (6).
Page 308 Fit the safety clip (10) into its seat on the fuel pump filter ring nut, ensuring that it is securely fastened. Connect the pipe (5), fastening the respective union. Connect the ground cable (4), fitting the seal washer and tightening the indicated screw. Connect the connector (3).
Page 309 ALWAYS replace the O-ring (11), cleaning the respective seat thoroughly. Connect the connector (9). Connect the pipes (7) and (8), fastening the respective unions. Install the new fuel pump filter (A). Check that the indicated tab on the fuel pump filter (A) is fitted correctly in its respective seat.
Page 310 Check that the mating surfaces of the fastener ring (6) are clean. Orienting correctly, fit the fastener ring (6) and tighten the indicated fastener screws. Tightening torque Class Screw 5 Nm Connect the pipe (5), fastening the indicated union. Connect the ground cable (4), tightening the indicated nut.
Page 311 CAUTION Take every necessary precaution, since fuel residues may remain in the tank and in the pipes, even after the operations described. Located inside the fuel tank, on the right-hand side under the fuel pump filter. Disconnect the battery ( F2.01).
Page 312 Fit the fuel pump (A) in the relative seat on the fuel tank floor, taking care not to bend or twist the pump pipes, and matching the groove on the pump with the protrusion indicated in the metal pump housing (2). Fit the lock mechanism (1) in the relative seat indicated on the fuel pump (A).
Page 313 B3.05 Fuel level sensor Replacing the fuel level sensors Tightening torque Class Fastening the fuel level sensors Screw 5 Nm 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.
Page 314 Disconnect the connector (3). Prise off and remove the safety clip (4). Fit the tool 8176) on the fuel level sensor (A). Using the tool 8176), turn the fuel level sensor (A) counterclockwise to bring the retainer clips into the indicated position. Whenever the fuel level sensor is removed, ALWAYS REPLACE WITH A NEW SENSOR, fitting a new O-ring.
Page 315 Fit the tool 8176) on the fuel level sensor (A). Using the tool 8176), turn the fuel level sensor (A) clockwise to bring the retainer clips into the indicated position. Fit the safety clip (4), ensuring that it is securely fastened.
Page 316 Prise out the cable grommet (1). Prise out the plug (2). Disconnect the connector (3). Remove the fastener ring (4), undoing the indicated screws. Note the orientation of the fuel level sensor (A). Remove the fuel level sensor (A) and replace. ALWAYS replace the O-ring, cleaning the respective seat thoroughly.
Page 317 For vehicles in "2+2 seat" configuration. Refit the rear seats ( E4.01). For vehicles in "2 seat" configuration. Connect the battery ( F2.01). Fill the fuel tank. Connect the DEIS tester to the diagnostic socket ( F2.10). Perform the "NCM Short trip sequence: leak detection monitoring" cycle.
Page 318 B3.06 Fuel vapour separator Replacing the fuel vapour separator Tightening torque Class Fastening fuel vapour separator 9 Nm Located in the upper section of the rear right wheel bay, in front of the diagnostic pump. Remove the rear wheelhouses ( E3.05).
Page 319 B3.07 Draining the engine fuel system Draining the fuel system 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 metres in length, with a maximum diameter of 10 mm, to the aspirator pump.
Page 320 B4.01 Engine air intake system layout A - Air filter boxes B - Air flow meters C - Air flow meters D - Throttle bodies E - Intake manifold...
Page 321 B4.02 Engine air duct Removing the engine air duct The duct is located behind the front bumper and feeds air to the radiator assembly. Disconnect the battery ( F2.01). Remove the engine compartment cosmetic shields ( E3.13). Remove the lateral cosmetic shields and the front cosmetic shield. Remove the front flat undertray section ( E3.12).
Page 322 Cut the clamps indicated fastening the headlight washer pipes (G) to the lower reinforcement cross member (A). Remove the lower reinforcement cross member (A), by undoing the screws indicated. On the left-hand side, undo the front screws (3) and the upper screw (4) fastening the upper reinforcement cross member (B) to the vehicle chassis.
Page 323 On the right-hand side, undo the front screws (3) and the upper screw (4) fastening the upper reinforcement cross member (B) to the engine subframe. Detach the engine compartment lid lock connector (6) and detach the clip fastening the connector to the lock mounting cross member (D).
Page 324 Detach the clips indicated fastening the engine compartment lid emergency release cable (12) leading from the passenger compartment to the lock mounting cross member (D). Also detach the clip indicated with the red arrow fastening the engine compartment lid release cable.
Page 325 On the left-hand side, undo the screw (9) fastening the cross member mounting rib to the engine subframe. Repeat the procedure on the opposite side. On the right-hand side, undo the upper screw (10) fastening the rib to the lock mounting cross member (D).
Page 326 Remove the complete impact beam (13) on the right-hand side, undoing the four screws indicated. Remove and retrieve the complete impact beam (13), undoing the four screws indicated on the left-hand side. Undo the screws (11) fastening the air duct (F) to the water radiator.
Page 327 Undo the centre screw (11) fastening the air duct to the water radiator. On the left-hand side, undo the two screws (11) fastening the air duct (F) to the water radiator. On the bottom side, undo the two screws (11) fastening the air duct (F) to the water radiator.
Page 328 Tightening torque Class Fastening bottom side of duct to water radiator Screw 4 Nm Fastening left-hand side of duct to water radiator Screw 4 Nm Fastening duct to water radiator Screw 4 Nm Fastening impact beam Screw 7.5 Nm Fastening engine subframe cross member Screw 30 Nm mounting rib...
Page 329 Tighten the centre screw (11) fastening the air duct to the water radiator. Tightening torque Class Screw 4 Nm Tighten the screws (11) fastening the air duct (F) to the water radiator. Tightening torque Class Screw 4 Nm Fit and fasten the complete impact beam (13) on the right-hand side, tightening the four screws indicated.
Page 330 Fit and fasten the complete impact beam (13) tightening the four screws indicated on the left-hand side. Tightening torque Class Screw 7.5 Nm Fit the lock mounting cross member (D) in the engine compartment. On the left-hand side, hand tighten the upper screw (10) fastening the rib to the lock mounting cross member (D).
Page 331 On the left-hand side, hand tighten the screw (9) fastening the cross member mounting rib to the engine subframe. Repeat the procedure on the opposite side. Tightening torque Class Screw 30 Nm On the left-hand side, tighten the screws (8) fastening the lock mounting cross member (D) to the engine subframe.
Page 332 Fasten the engine compartment lid emergency release cable (12) leading from the passenger compartment to the lock mounting cross member (D) with the indicated clips. Also fix the clip indicated with the red arrow fastening the engine compartment lid release cable.
Page 333 On the left-hand side, tighten the front screws (3) and the upper screw (4) fastening the upper reinforcement cross member (B) to the engine subframe. Tightening torque Class Screw 20 Nm Screw 24 Nm On the right-hand side, tighten the front screws (3) and the upper screw (4) fastening the upper reinforcement cross member (B) to the vehicle chassis.
Page 334 Fit the new clamps fastening the headlight washer pipes (G) to the lower reinforcement cross member (A) in the positions indicated. Fit the air filter cartridge (A). Repeat the procedure for the other air filter. Fit the air box cover (2) and hand tighten the six screws indicated.
Page 335 B4.03 Engine air filters Replacing the engine air filters To ensure maximum engine performance it is essential that the air filters are in perfect condition. NEVER wash or clean a removed air filter and reuse. Always replace with a new component. Replace the air filter cartridges at the intervals indicated in the Maintenance Schedule.
Page 336 NEVER wash or clean a removed air filter and reuse. Always replace with a new component. Remove and replace the air filter cartridge (A). When installing the new air filter cartridge (A), lightly lubricate the mating surfaces with the air box. The following components must ONLY be replaced in the event of evident damage.
Page 337 B4.04 Engine intake manifold Removing the intake manifold Disconnect the battery ( F2.01). Remove the engine compartment cosmetic shields ( E3.13). Remove the internal engine compartment cross brace ( E2.04). Remove the air flow meters (1), complete with relative bellows, removing the clamps (2). Remove the motorised throttle body ( F3.10).
Page 338 Detach the union (1) from the intake manifold. Remove the clamp (2) and release the vacuum pipe (5) from the block. Open the four clamps indicated fastening the pipe (3) and detach the union (4) from the left hand cylinder head cover. Detach the union (4) from the right hand cylinder head cover and retrieve the pipe (3) from the engine compartment.
Page 339 Plug the two unions on the cylinder head covers, as shown in the photo, to keep foreign objects out. Detach the unions (17) of the Blow-by pipe (18) from the front of the intake manifold. Detach the pipe (19) from the relative union on the front of the intake manifold.
Page 340 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. On the left hand bank, undo the eight screws with washers fastening the intake manifold (A) to the cylinder head.
Page 341 Open the two clamps (6) on the rear of the intake manifold and release the low pressure fuel line (7). Remove the intake manifold completely from the engine compartment. Remove the two gaskets (8) from the cylinder heads. Cover the intake duct orifices to prevent foreign bodies from entering. Seal the air inlet ports on the cylinder heads by fitting tool 3608) to keep foreign objects out of the ducts.
Page 342 Clean the mating surfaces on the intake manifold and the cylinder heads thoroughly, and install the two new gaskets (8). Fasten the low pressure fuel line (7) onto the rear of the previously removed intake manifold, closing the plastic clip (6). Take particular care when fitting the intake manifold.
Page 343 Fasten the intake manifold (A) on the right hand cylinder bank, by tightening the eight screws with relative washers. Note that the photo was taken with all components not involved in the procedure removed to illustrate the operation more clearly. Tightening torque Class Screw...
Page 344 Remove the protective cover installed during removal. Fit the pipe (3) and connect the union (4) onto the right hand cylinder head cover. Connect the union (4) onto the left hand cylinder head cover and fasten the pipe (3), closing the four clamps indicated.
Page 345 Fit the air flow meters (1), complete with bellows, in their seats and fasten with clamps (2). Refit the internal engine compartment cross brace ( E2.04). Refit the engine compartment cosmetic shields ( E3.13). Connect the battery ( F2.01).
Page 346 B5.01 Engine lubrication system layout Engine lubrication system layout A - Engine oil sump B - Engine oil pump C - Engine oil filter D - Water/engine oil heat exchanger...
Page 347 B5.02 Engine oil pump Removing the engine oil pump The following photos show the engine removed from the vehicle to illustrate the procedure more clearly. Remove the sump ( B2.03). UP TO Engine No. 153878 Remove the oil sump shield (1) by undoing the indicated screws.
Page 348 FROM Engine No. 153879 Undo the indicated screws and detach the fuel pump (A), complete with drive shaft (2), pulling towards the rear of the vehicle. Refitting the engine oil pump Tightening torque Class Fastening oil pump to lower crankcase shell Screw 25 Nm Fastening oil pump pickup tube to lower...
Page 349 Ensure that the Seeger ring (4) is installed correctly on the timing end of the drive shaft (2). Fit the oil pump (A) on the lower crankcase shell, installing the drive shaft in the relative seat on the drive gear. UP TO Engine No.
Page 350 FROM Engine No. 153879 Tighten the screws, indicated by the black arrows, fastening the oil pump body (A). Tightening torque Class Screw 25 Nm Tighten the screws, indicated by the red arrows, fastening the oil pick-up pipe. Tightening torque Class Screw 10 Nm UP TO Engine No.
Page 351 B5.03 Water-engine oil heat exchanger Removing the engine oil-water heat exchanger 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.
Page 352 Remove the water vent pipe (8), undoing the indicated union. Open the clamps indicated. Remove the connectors (5) from the mounting bracket. Mark the positions of the connectors on the bracket. Move the knock sensor cables out of the way so that they do not hinder the subsequent operations.
Page 353 Retrieve and replace the gasket (6). Refitting the engine oil-water heat exchanger Tightening torque Class Fastening engine oil-water heat exchanger onto Screw 10 Nm crankcase Fastening water vent pipe onto engine oil-water Union 10 Nm heat exchanger Thoroughly clean the mating faces on the crankcase in contact with the gasket (6).
Page 354 Thoroughly clean the mating surface of the oil- water heat exchanger (A) in contact with the gasket. Fit the oil-water heat exchanger (A) in the relative housing. Fit the bracket (7). Fit and snug the indicated screws, using the marks made during removal as reference as the screws are not all of equal length.
Page 355 Lay the engine services cable (4) as originally fitted on the heat exchanger. Fasten the engine services cable (4) to the heat exchanger by closing the indicated clamps. Place the injection cables on top of the heat exchanger as originally fitted. Connect the connector (1).
Page 356 B5.04 Blow-by system Blow-by system A - Oil vapour separator B - Pipe leading from separator to intake manifold C - Breather pipe connecting cylinder heads...
Page 357 B5.05 Draining and filling the engine lubrication system 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 central flat undertray section ( E3.12).
Page 358 Undo and remove the cap (B). Fill the engine lubrication system using only new oil of the type specified in the fluids and lubricants table. Gradually add new oil of the specified type via the filler neck. Due to inevitable pooling within the lubrication system, the actual quantity of oil added may vary from vehicle to vehicle.
Page 359 Undo and remove the cap (B). Fill the engine lubrication system using only new oil of the type specified in the fluids and lubricants table. Gradually add approximately 9.5 litres of new engine oil of the specified type. Due to inevitable pooling within the lubrication system, the actual quantity of oil added may vary from vehicle to vehicle.
Page 360 Remove the outer cap from the bottle. Remove the engine oil dipstick Insert one end of the pipe in the engine oil dipstick tube to immerse it in oil being sampled. Insert approximately the same length of tube as the length of the engine oil dipstick. Connect the bottle to the end of the tube.
Page 361 B6.01 Engine cooling system layout Cooling system layout A - Expansion tank (Nourice) B - Water radiator C - Pressure switch/thermostat D - Water pump E - Recirculation pump F - TGK valves...
Page 362 B6.02 Engine coolant tank Removing the expansion tank The expansion tank is located on the right-hand side of the engine compartment, next to the battery. Remove the engine compartment cosmetic shields ( E3.13). Remove the right hand lateral cosmetic shield. Remove the secondary air pump ( F3.15).
Page 363 Release the expansion tank breather pipe (5) from the clip (6) and the rubber-lined bracket (7). Remove the expansion tank, complete with breather pipe, from the engine compartment. Refitting the expansion tank Tightening torque Class Fastening screw collar Screw 4 Nm Fastening expansion tank to relevant mounting Screw 8 Nm...
Page 364 Fitting the respective washer (3), tighten the screw (2) fastening the expansion tank (A). Tightening torque Class Screw 8 Nm Connect the pipes (1), tightening the respective collars. Fasten the breather pipe (5) with the clip (6) and the rubber-lined bracket (7). Refit the secondary air pump ( F3.15).
Page 365 B6.03 Engine coolant pump Removing the water pump The pump is located on the right hand side of the engine block and is driven by the belt. Remove the water pump drive belt ( A3.12). Drain the cooling system ( A3.07).
Page 366 Replace the gasket (2) before refitting the pump. Fit the water pump (A) in its seat on the engine. Fasten the water pump (A), by tightening the six screws (1). Tightening torque Class Screw 11 Nm Refit the water pump drive belt ( A3.12).
Page 367 B6.04 Engine coolant pressure switch/thermostat Removing the pressure switch/thermostat After loosening or removal, the Caillau Visa hose clamps must be replaced with Mikalor worm drive hose clamps, following the instructions given in Technical Information 2054 of December 2012. The switch is located at the front of the engine. Drain the cooling system ( A3.07).
Page 368 When refitting, replace the gasket between the cover and the pressure switch/thermostat (A) after applying a film of grease SEGO on the new gasket. Fit the pressure switch/thermostat (A) on the cover and tighten the three screws (2). Tightening torque Class Screw 11 Nm...
Page 369 B6.05 Engine coolant radiator Removing the water radiator The water radiator is located on the radiator assembly, behind the front bumper. Disconnect the battery ( F2.01). Remove the engine air duct ( B4.02). Drain the power steering system ( D5.07). Drain the cooling system ( A3.07).
Page 370 Open the plastic clamps (4) on the power steering system pipes. ONLY for vehicles WITHOUT single oil heat exchanger Remove the rear flat undertray section ( E3.12). ONLY for vehicles WITHOUT single oil heat exchanger Remove the mounting bracket (6) for the hydraulic clutch system oil pipes, by undoing the screws (7).
Page 371 Remove the front wheelhouses ( E3.05). Remove the right one. Detach the radiator assembly connector (14), by undoing the nut (15), and detach the earth cable (16). Undo the screws (20) fastening the A.C. pipes (21) to the condenser. Undo the nut (22) retaining the A.C. pipes (21) and move the pipes up so that they will not hinder the subsequent operations.
Page 372 Undo the screw (17) on the clamp retaining the power steering fluid rigid pipes (19). Undo the nuts (18) fastening the rigid pipes to the power steering fluid radiator. Detach the rigid pipes (19) from the power steering fluid radiator, and move the pipes up so that they will not hinder the subsequent operations.
Page 373 Hold up the radiator assembly adequately. On the right-hand side, undo the screw (27) fastening the radiator assembly to the engine compartment chassis. On the left-hand side, undo the screw (28) fastening the radiator assembly to the engine compartment chassis. Remove the radiator assembly from the engine subframe.
Page 374 ONLY for vehicles WITHOUT single oil heat exchanger Remove the clutch hydraulic system oil radiator ( C3.02). Refitting the water radiator Tightening torque Class Fastening cowl to coolant radiator Screw 5 Nm Fastening cooling system to chassis Screw 24 Nm Fastening cooling system bracket to cowl Screw 24 Nm...
Page 375 On the left-hand side, tighten the screw (28) fastening the radiator assembly to the engine subframe. Tightening torque Class Screw 24 Nm On the right-hand side, tighten the screw (27) fastening the radiator assembly to the engine subframe. Tightening torque Class Screw 24 Nm...
Page 376 Connect the pipe (25) onto the water radiator and fasten with a new clamp. Fit the rigid pipes (19) in their respective seats on the power steering fluid radiator, after replacing the relative seals. Tighten the nuts (18) fastening the rigid pipes (19 )to the power steering fluid radiator.
Page 377 After replacing the relative seals, tighten the screws (20) fastening the AC pipes (21) to the condenser. Tightening torque Class Screw 9 Nm Connect the radiator assembly connector (14) and hand tighten the nut (15), fastening the ground cable (16). Refit the front wheelhouses ( E3.05).
Page 378 ONLY for vehicles WITHOUT single oil heat exchanger Connect the delivery and return unions (11) and fasten to the mounting bracket (10). Fasten the clutch hydraulic system oil pipes, by fitting the clamps (8) and (12) and tightening the screws (9). Fasten the mounting bracket for the clutch hydraulic system oil pipes (6), tightening the screws (7).
Page 379 Connect the connector for the temperature sensor (1) on the water radiator. Fill the cooling system ( A3.07). Charge the air conditioning system. ( F5.11). Fill the power steering system ( D5.07). Connect the battery ( F2.01). ONLY for vehicles WITHOUT single oil heat exchanger. Inspect the hydraulic clutch system oil level Shell DCT F-3 ( A3.03).
Page 380 B6.06 Radiator cooler electric fans Replacing the electric fans Tightening torque Class Fastening cowl to coolant radiator Screw 5 Nm Fastening cooling system bracket to cowl Screw 24 Nm The fans are located behind the radiator assembly and fitted on the duct. Disconnect the battery ( F2.01).
Page 381 Undo the screws indicated. Disconnect the connectors (1). Undo the screws indicated. Remove the electric fan assembly and replace. Fit the new electric fan assembly. Tighten the screws indicated. Tightening torque Class Screw 5 Nm Connect the connectors (1). Tighten the screws indicated. Tightening torque Class Screw...
Page 382 Tighten the indicated screw. Tightening torque Class Screw 24 Nm Tighten the screws indicated. Tightening torque Class Screw 5 Nm Refit the front flat undertray section ( E3.12). Refit the secondary air pump ( F3.15). Connect the battery ( F2.01).
Page 383 B6.07 Draining and filling the engine cooling system Draining the cooling system CAUTION The fluid in the engine coolant system may be very hot. Hot engine coolant may cause severe burns. ALWAYS WAIT FOR THE SYSTEM TO COOL BEFORE STARTING ANY WORK. After loosening or removal, the Caillau Visa hose clamps must be replaced with Mikalor worm drive hose clamps, following the instructions given in Technical Information 2054 of December 2012.
Page 384 Tightening torque Class Water-oil pipes - gear oil heat exchanger Pipe union 50 Nm Remove the engine compartment cosmetic shields ( E3.13). Remove the front wheelhouses ( E3.05). Remove the rear right hand element. 01) Detach the bleed pipe (1), on the right-hand side of the radiator, removing the indicated clamp and keeping the pipe at the height of the header tank union.
Page 385 03) Unscrew the indicated right hand cylinder head bleed plug, located on the front cover. 04) Unscrew the indicated left hand cylinder head bleed plug, located on the front cover. 05) Unscrew the filler cap (4) on the expansion tank. A new coolant has been introduced FROM Assembly No.
Page 386 07) Reconnect the radiator bleed pipe (1), fastening with the indicated clamp. 08) Gradually introduce coolant via the expansion tank filler orifice, until fluid escapes from the bleed orifices on the cylinder heads. 09) Tighten the right hand bleed plug indicated, after replacing the relative seal.
Page 387 11) Gradually introduce coolant via the expansion tank filler orifice, until fluid escapes from the delivery pipe (3) leading to the heat exchanger. 12) Fasten the delivery pipe (3) leading to the heat exchanger by tightening the union (2), after replacing the relative seals. Tightening torque Class Pipe union...
Page 388 14) Start the engine and run at idle speed for approximately 1 minute. 15) Bring the engine speed to 2000 rpm for approximately 15 seconds, then allow the engine to return to idle speed. 16) If necessary, top up to the MIN level indicated on the expansion tank. 17) Warm the engine up by running at 2000 rpm until the thermostat valve opens/cooling fans activate (water temperature approx.
Page 389 Remove the rear flat undertray diffuser ( E3.12). 01) Detach the bleed pipe (1), on the right-hand side of the radiator, removing the indicated clamp and keeping the pipe at the height of the header tank union. The photo aside was taken with the secondary air pump removed to illustrate the procedure more clearly.
Page 390 04) Unscrew the indicated left hand cylinder head bleed plug, located on the front cover. 05) Unscrew the filler cap (4) on the expansion tank. Use Shell GLYCOSHELL LONGLIFE (at 50% dilution) as prescribed. 06) Gradually introduce coolant via the expansion tank filler orifice, until fluid escapes from the open bleed orifice on the radiator.
Page 391 08) Gradually introduce coolant via the expansion tank filler orifice, until fluid escapes from the bleed orifices on the cylinder heads. 09) Tighten the right hand bleed plug indicated, after replacing the relative seal. Tightening torque Class M12x1.25x12 plug 30 Nm 10) Tighten the left hand bleed plug indicated, after replacing the relative seal.
Page 392 13) Complete filling up to the MAX level indicated on the expansion tank. Dynamic filling (engine on) (ONLY for vehicles WITH Single oil heat exchanger) 14) Start the engine and run at idle speed for approximately 1 minute. 15) Bring the engine speed to 2000 rpm for approximately 15 seconds, then allow the engine to return to idle speed.
Page 393 29) Tighten the filler cap (4) completely onto the expansion tank. Refit the rear flat undertray diffuser ( E3.12). Refit the engine compartment cosmetic shields ( E3.13).
Page 394 B7.01 Exhaust system layout A - Exhaust manifolds B - Catalytic converters C - Centre silencer D - Exhaust extensions E - Silencers Checking exhaust system alignment The following procedure is necessary whenever any work on the components of the exhaust system is performed. Remove the rear flat undertray diffuser ( E3.12).
Page 395 Check that a 3 mm shim can be inserted between the surface of the vibration damper (1) and the base of the head of the rear pin of the silencer. The protrusion of the pins indicated must be ≥ 3 mm. Perform the procedure on both sides of the vehicle.
Page 396 example in the photo illustrate s how visually identify an Z axis alignme nt error (NOT between the two catalytic converte rs, with vertical differenc exceedi ng 6 If the measurements comply within the values indicated Check the tension of the exhaust system vibration dampers ( B7.01).
Page 397 If the measurements comply within the values indicated Refit the rear wheelhouses ( E3.05). Refit the rear sections of the rear wheelhouses. Refit the central flat undertray section ( E3.12). Refit the rear flat undertray section ( E3.12). Refit the rear flat undertray diffuser ( E3.12).
Page 398 Never reuse exhaust system clamps that have been subjected to operating temperature. Always replace with new components. New clamps may only be removed and refitted for adjustment purposes during initial installation. Refit the centre silencer ( B7.04). Replace all clamps that have been loosened, and hand-tighten the respective screws and nuts. Check that the front edges of the central silencer (A) are aligned with the markings indicated on the catalytic converters (B).
Page 399 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit two shims in the indicated positions so that the exhaust extensions (C) are 31 mm from the removable rear subframe. FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit two shims in the indicated positions so that the exhaust extensions (C) are 37 mm from the removable rear subframe.
Page 400 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit the cross member (D) and hand-tighten the indicated nuts. Only in the event of misalignment of the catalytic converters along the "Z" axis Tighten the indicated nuts fastening the catalytic converters (B).
Page 401 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the indicated nuts fastening the central silencer to the catalytic converter (B). Tightening torque Class Torx clamp 54.2 Nm Ensure that the retainer keys on the central silencer (A) are inserted correctly in the relative seats on the exhaust extensions (C).
Page 402 On both exhaust silencers, tighten the spherical clamp by tightening the indicated screw. Tightening torque Class Spherical clamp 35 Nm Check the alignment of the exhaust system ( B7.01). If the measurements comply with the values indicated UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit both vibration dampers (3) on the central silencer and tighten the indicated nuts.
Page 403 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Loosen the indicated fastener nuts between the catalytic converters (B) and the central compensator. FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Loosen the indicated fastener nuts between the catalytic converters (B) and the central compensator.
Page 404 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the indicated nuts fastening the central silencer to the catalytic converter (B). Tightening torque Class Torx clamp 54.2 Nm FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the indicated nuts fastening the central silencer to the catalytic converter (B).
Page 405 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification), if the measurements comply with the values indicated Fit both vibration dampers (3) on the central silencer and tighten the indicated nuts. Tightening torque Class 25 Nm Check the tension of the exhaust system vibration...
Page 406 Exhaust extension vibration dampers Undo the indicated nut. Loosen the indicated screws. Lift the mounting bracket (C) to relieve the tension on the dampers and allow adjustment to the distance indicated. Tighten the screws indicated. Tightening torque Class Screw 8 Nm Tighten the indicated nut.
Page 407 B7.02 Exhaust manifolds Removing the right hand exhaust manifold Remove the front wheelhouses ( E3.05). Remove the right one. Remove the front removable subframe ( E2.02). Remove the catalytic converters ( B7.03). Remove the right hand catalytic converter. Undo the two screws (2) fastening the right hand secondary air valve (1) to the cylinder head cover.
Page 408 Undo the two screws (4) fastening the secondary air pipe flange to the exhaust manifold. Move the secondary air pipe away from the exhaust manifold so that it does not hinder the subsequent operations. Undo the eight nuts (5) fastening the right hand exhaust manifold (A) to the cylinder heads.
Page 409 Tightening torque Class Exhaust manifold - cylinder head 25 Nm Check that the gasket mating surfaces on the head and manifold are completely flat. If necessary, remove any encrustation or gasket residue. Replace the gasket (8). The gasket must be replaced each time it is removed.
Page 410 Replace the seal on the secondary air pipe flange and fit on the right hand exhaust manifold. Hand tighten the two screws (4). Fit the secondary air valve (1) in its seat and fasten by hand tightening the two screws (2). Fix the secondary air pipe to the right hand cylinder head cover with the clamp and fastener screw (3).
Page 411 Remove the left hand catalytic converter. Remove the front wheelhouses ( E3.05). Remove the left one. Undo the screw (1) fastening the steering column (2) to the steering box, and move out of the way so that it does not hinder the subsequent operations.
Page 412 Undo the two screws (6) fastening the secondary air pipe flange to the exhaust manifold. Move the secondary air pipe away from the exhaust manifold so that it does not hinder the subsequent operations. Undo the eight nuts (7) fastening the left hand exhaust manifold (B) to the cylinder heads.
Page 413 Tightening torque Class Exhaust manifold - cylinder head 25 Nm Check that the gasket mating surfaces on the head and manifold are completely flat. If necessary, remove any encrustation or gasket residue. Replace the gasket (8). The gasket must be replaced each time it is removed.
Page 414 Replace the seal on the secondary air pipe flange and fit on the left hand exhaust manifold. Hand tighten the two screws (6). Fit the secondary air valve (3) in its seat and fasten by hand tightening the two screws (4). Fix the secondary air pipe to the left hand cylinder head cover with the clamp and fastener screw (5).
Page 415 B7.03 Catalytic converters Removing the catalytic converters The following procedure refers to the removal of the left hand catalytic converter; the procedure for removing the right hand catalytic converter is the same. Disconnect the battery ( F2.01). Remove the central flat undertray section ( E3.12).
Page 416 Undo the nut (3) fastening the clamp to the catalytic converter. Remove the catalytic converter from its seat and unscrew the rear oxygen sensor (4). Retrieve the metal gasket (5). Refitting the catalytic converters Tightening torque Class...
Page 417 Tightening torque Class Oxygen sensor - catalytic converter Oxygen sensor 50 Nm Catalytic converter clamp - mounting bracket 25 Nm Catalytic converter - exhaust manifold 25 Nm Nut (pretightening) 15 Nm Replace the metal gasket (5). The metal gasket (5) must be replaced each time it is removed.
Page 418 Fit the catalytic converter (B) in the relative seat, then replace and fasten the clamp by tightening the nut (3). Tightening torque Class 25 Nm Pre-tighten the nuts (2). Tightening torque Class Nut (pretightening) 15 Nm Tighten the nuts (2). Tightening torque Class 25 Nm...
Page 419 Tighten the front oxygen sensor (1) onto the catalytic converter. Tightening torque Class Oxygen sensor 50 Nm Refit the centre silencer ( B7.04). Refit the front removable subframe ( E2.02). Remove the central flat undertray section ( E3.12). Connect the battery ( F2.01).
Page 420 B7.04 Centre silencer Removing the centre silencer Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature. Always replace with new components. Only new exhaust system clamps and gaskets may be removed and refitted for adjustment purposes during initial installation.
Page 421 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the nuts indicated. Remove the connector cross member (Z). Always replace the spherical exhaust system clamps with new components after loosening. On both sides of the vehicle, loosen the spherical clamp (3), undoing the indicated screw.
Page 422 Loosen the two Torx clamps (4) fastening the centre silencer (C) to the exhaust extensions (D). Loosen the nuts indicated fastening the bushings (1) to the mounting bracket. Pulling toward the rear of the vehicle, remove the exhaust extensions (D), complete with bushings (1), from the mounting bracket.
Page 423 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Loosen the Torx clamp (6). UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the nuts (5) fastening the damper (7) to the centre silencer.
Page 424 Tightening torque Class Exhaust extension mounting bracket - chassis Screw 25 Nm Exhaust extension mounting bushings - mounting 10 Nm bracket Centre silencer - catalytic converter Torx clamp 54.2 Nm Damper - central silencer 25 Nm Exhaust extension - centre silencer Torx clamp 54.2 Nm Exhaust extension - silencer...
Page 425 Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature. Always replace with new components. Only new exhaust system clamps and gaskets may be removed and refitted for adjustment purposes during initial installation. Fit new Torx clamps on the front of the exhaust extensions and the front of the central silencer. Working from under the vehicle, fit the centre silencer in the relative seat, fitting onto the catalytic converters.
Page 426 Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature. Always replace with new components. Only new exhaust system clamps and gaskets may be removed and refitted for adjustment purposes during initial installation. Align the exhaust extensions (D) correctly with the silencers (E) and install a new spherical clamp (3).
Page 427 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the Torx clamp (6). Tightening torque Class Torx clamp 54.2 Nm Fit the damper (7) on the centre silencer and fasten by tightening the nuts (5). Tightening torque Class 25 Nm...
Page 428 Tighten the spherical clamp (3) fastening the exhaust extension (D) to the silencer (E). Tightening torque Class Spherical clamp 35 Nm Fasten the front heat shields (65) and (66), by tightening the screws indicated. Tightening torque Class Screw 8 Nm Fit the connector cross member (Z).
Page 429 For vehicles with single oil heat exchanger Fit the connector cross member (Z). Tighten the screws indicated. Tightening torque Class Screw 25 Nm FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit the connector cross member (Z). Tighten the nuts indicated.
Page 430 B7.05 Exhaust extensions Removing the exhaust extensions Located between the central silencer and the exhaust tailpipes (silencers). Remove the DCT gearbox ( C2.02). Remove the two exhaust extensions (A) from the rear removable subframe. Refitting the exhaust extensions Fit the exhaust extensions (A) in their seats on the rear removable subframe.
Page 431 B7.06 Silencers Removing the silencer FROM Assembly No. 87136, new silencers were introduced to replace the previous units, with specific rubber pipes for the bypass valves. ONLY for vehicles UP TO Assembly No. 87135, even if it is necessary to replace one silencer only, both silencers must be replaced, together with the relative pipes for the bypass valves, with the NEW components.
Page 432 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the nuts indicated. Loosen the clamp (1) by undoing the indicated screw. Mark the position of the rear bracket (A) on the silencer (B). Support the weight of the silencer (B) adequately.
Page 433 Tightening torque Class Fastening silencer bracket 25 Nm Exhaust extension - silencer Spherical clamp 35 Nm Fastening silencer connector cross member Screw 25 Nm 25 Nm FROM Assembly No. 87136, new silencers were introduced to replace the previous units, with specific rubber pipes for the bypass valves.
Page 434 Support the weight of the silencer (B). Fit the rear bracket (A), aligning the reference markings. Fit the plate (2). Tighten the nuts indicated. Tightening torque Class 25 Nm Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature.
Page 435 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature. Always replace with new components. Only new exhaust system clamps and gaskets may be removed and refitted for adjustment purposes during initial installation.
Page 436 C1.01 Technical specifications DCT gearbox 7 forward gears + reverse, electrohydraulic dual clutch system, controlled automatically or in semi-automatic mode from the steering wheel shift paddles. DCT gearbox gear ratios Transmission 3.397 2.185 1.626 1.286 1.028 0.839 0.719 2.791 gear ratios Bevel gear 4.444 pair/differential...
Page 437 C1.02 Specific tooling and equipment Hook 95977564 (AS 107564) for lifting the gearbox. Trolley 95977565 (AS 107565) removing the engine / gearbox / subframe assembly. Torque wrench 95978172 (AV 8172) (Replaces torque wrench USAG 815F)
Page 438 Pump 95978174 (AV 8174) topping up gearbox and clutch oil. Pins 95978351 (AV 8351) alignment for installation of front/rear removable subframes.
Page 439 C1.03 Tightening torques Tightening torque Class Starter motor - transmission housing Screw 25 Nm Nut fastening transmission housing - engine Nut (pretightening) 20 Nm 60 Nm Bushing - transmission housing Screw 49 Nm Articulated shaft - transmission housing shaft Screw with control angle 60 Nm of 90°...
Page 440 Tightening torque Class ATF and GL oil pipe mounting bracket Screw 20 Nm ATF and GL oil pipe retainer bracket - relevant 8 Nm mounting bracket Clamps - ATF pipes on water radiator 9 Nm Gear oil heat exchanger mounting bracket - Screw 20 Nm chassis...
Page 441 Tightening torque Class sensor seat Fastening axle shaft heat shield Screw 9 Nm Fastening gearbox strut heat shield Screw 9 Nm...
Page 442 C2.01 Gear oil system layout Layout for vehicles WITHOUT single oil heat exchanger A - DCT gearbox (gear oil tank and gear oil pump) B - Gear oil pipes C - Water/gear oil heat exchanger Layout for vehicles WITH single oil heat exchanger...
Page 443 A - DCT gearbox (gear oil tank and gear oil pump) B - Gear oil pipes C - Water/gear oil/clutch hydraulic system oil single oil heat exchanger...
Page 444 C2.02 Removing the complete DCT gearbox Removing the DCT gearbox CAUTION During the following operations, the VEHICLE MUST ONLY BE LIFTED WITH THE ANTI-TIPPING SAFETY RETAINERS INSTALLED. Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature. Always replace with new components.
Page 445 Undo the screws indicated. Remove the connector cross member (Z). For vehicles with single oil heat exchanger Undo the screws indicated. Remove the connector cross member (Z). FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the nuts indicated.
Page 446 Always replace the spherical exhaust system clamps with new components after loosening. On both sides of the vehicle, loosen the spherical clamp (3), undoing the indicated screw. On both sides of the vehicle, separate the exhaust extension (D) from the silencer (E). ONLY for vehicles WITHOUT single oil heat exchanger Remove the bracket (6), undoing the screws (7)
Page 447 ONLY for vehicles WITHOUT single oil heat exchanger Remove the brackets (15) from the bracket (6), undoing the indicated fasteners. Move the hydraulic clutch system oil pipes out of the way so that they do not hinder the subsequent operations. ONLY for vehicles WITHOUT single oil heat exchanger Remove the mounting bracket (16) for the gear...
Page 448 ONLY for vehicles WITHOUT single oil heat exchanger To disconnect the gear oil pipes, turn the safety ring nut (14) to align the notch on the ring nut with the pin (13). Push the safety ring (14) towards the pin (13) to release the pipes.
Page 449 ONLY for vehicles WITH Single Oil Heat Exchanger FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Remove the bracket (7), undoing the indicated screws. Detach the pipes (6). Place a container under the screw collars (11) for collecting the coolant.
Page 450 Loosen the nuts indicated fastening the bushings (1) to the mounting bracket. Pulling toward the rear of the vehicle, remove the exhaust extensions (D), complete with bushings (1), from the mounting bracket. Undo the two screws (2) and the nut (10), then remove the bracket.
Page 451 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Detach the end (27) of the right hand EPB Bowden cable from the EPB linkage bracket (28). Take care not to damage the EPB linkage bracket (28).
Page 452 Disconnect the connector (37). Undo the screws (38). FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Disconnect the connector (37). Undo the screws (38). Disconnect the ground cable (39), undoing the nut (40). Remove the indicated cable ties.
Page 453 Undo the screws (46) fastening the brake calliper (45) to the hub carrier. Perform the procedure on both sides of the vehicle. Leaving the brake calliper (45) connected to the system, set it down taking care not to tauten the cables and oil pipes. Perform the procedure on both sides of the vehicle.
Page 454 Make two reference markings (X) and (Y) on the chassis and subframe to facilitate correct reassembly of the rear removable subframe. Perform the procedure on both sides of the vehicle. Undo the screws (51) fastening the rear removable subframe (A). FROM Assembly No.
Page 455 The trolley 107565) is necessary for the removal of the rear removable subframe complete with gearbox. 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 relative swivelling and removable mounts;...
Page 456 Undo the screws (57) fastening the rear removable subframe. Perform the procedure on both sides of the vehicle. FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the screws (57) fastening the rear removable subframe.
Page 457 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the screws (58) fastening the rear removable subframe (A). Undo the screws (59) fastening the rear removable subframe (A). Undo the screws (65) fastening the rear removable subframe (A).
Page 458 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the screw (62) fastening the ground braid (63). Operate the lowering handle of the trolley to lower the rear removable subframe by approximately 100 mm. FROM Assembly No.
Page 459 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Remove the EPB parking brake Bowden cable (35) from the rear removable subframe. Operate the lowering handle of the trolley to lower the rear removable subframe completely. Remove the two front heat shields located above the exhaust extensions.
Page 460 ONLY for vehicles WITHOUT single oil heat exchanger Remove the clamps indicated retaining the GL pipes (69). Detach the GL pipes (69) from the gearbox, removing the O-rings from the relevant unions. Plug the oil inlet and outlet orifices immediately. ONLY for vehicles WITHOUT single oil heat exchanger Clean the area surrounding the ATF pipe...
Page 461 ONLY for vehicles WITH single oil heat exchanger Clean the area surrounding the ATF pipe fastening points thoroughly with a suitable degreaser that does not leave residue. Undo the screw (73) and remove the fork (74). Place absorbent paper under the unions to catch any oil spillage.
Page 462 ONLY for vehicles WITH single oil heat exchanger Detach the coolant return pipe (14), undoing the indicated nuts. Retrieve the shim (15). ONLY for vehicles WITH single oil heat exchanger Detach and remove the coolant return pipe (14), undoing the indicated fasteners. ONLY for vehicles WITH Single Oil Heat Exchanger FROM Assembly No.
Page 463 ONLY for vehicles WITH Single Oil Heat Exchanger FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Detach the coolant delivery pipe (12) and the coolant return pipe (14), undoing the indicated nuts. ONLY for vehicles WITH Single Oil Heat Exchanger FROM Assembly No.
Page 464 Undo the six screws (75) fastening the axle shaft to the differential flange, recovering the three spacers (76). Perform the procedure on both sides of the vehicle. Undo the nut (79) and remove the pin (80) fastening the toe-in adjustment tie-rod from the hub carrier, recovering the relevant washers.
Page 465 Undo the two nuts (91) from the front bushings, recovering the relevant washers and retainer washers. Undo the two nuts (85) from the rear bushings, recovering the relevant washers and stop caps. Undo and remove the two pins (88), by recovering the shims (86) and the washers (87).
Page 466 Tighten the eye bolts in the relative holes on the gearbox and fit tool 107564). Connect to a mobile hydraulic jack, lift the gearbox from the rear removable subframe and set down in a safe place. Removing heat shields and DCT gearbox struts With the gearbox on the workbench and supported correctly, remove the heat shields and the relevant mounting struts as follows.
Page 467 Undo the three screws indicated and remove the heat shield (4) from the left hand axle shaft. Front left hand strut Undo the four screws indicated and remove the front left hand strut (A). Front right hand strut Undo the four screws indicated and remove the front right hand strut (B).
Page 468 Rear left hand strut Undo the four screws indicated, recover the bracket (1) and remove the rear left hand strut (C). Rear right hand strut and relevant heat shield Remove the heat shield (2), undoing the three screws indicated (red arrows). Undo the three screws indicated (black arrows) and remove the rear right hand strut (D).
Page 469 C2.03 Refitting the complete DCT gearbox Refitting the heat shields and the DCT gearbox struts Tightening torque Class Fastening gearbox strut heat shield Screw 9 Nm Rear mounting strut - gearbox Screw 25 Nm Products to use: AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK Front mounting strut - gearbox Screw...
Page 470 Fit the rear left hand strut (C) in the relative seat, install the bracket (1) and, after applying AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK on the entire thread of the screws indicated, tighten the screws in the sequence shown in the photo aside.
Page 471 Heat shield on left hand axle shaft Fit the heat shield (4) in the relative seat on the left hand axle shaft and fasten by tightening the three screws indicated. Tightening torque Class Screw 9 Nm Heat shield on right hand axle shaft Fit the heat shield (3) in the relative seat on the right hand axle shaft and fasten by tightening the three screws indicated.
Page 472 Tightening torque Class Products to use: SEGO Park Lock release cables - mounting brackets on 8 Nm gearbox and chassis Fastening axle shaft to differential flange Screw 78 Nm Ground braid - rear removable subframe Screw 18 Nm GL and ATF oil pipe retainer fork Screw 20 Nm Retainer clamps - GL and ATF oil pipes...
Page 473 Tightening torque Class Fastening silencer connector cross member Screw 25 Nm 25 Nm Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature. Always replace with new components. Only new exhaust system clamps and gaskets may be removed and refitted for adjustment purposes during initial installation.
Page 474 Working from underneath, apply and hand tighten the eight screws indicated fastening the gearbox to the rear removable subframe. Tighten the pins (88) fastening the rear bushings to the rear removable subframe. Tightening torque Class 200 Nm Working from underneath, tighten the eight screws indicated fastening the gearbox to the rear removable subframe.
Page 475 Apply and pre-tighten the nuts (85) onto the rear gearbox mounting fastener pins, installing the relative retainer washers and washers. Tightening torque Class Nut (pretightening) 9 Nm Apply and pre-tighten the nuts (91) fastening the front bushings to the gearbox, installing the relative washers and retainer washers.
Page 476 Tighten the nuts (91). Tightening torque Class 70 Nm Apply grease between the bracket on the gearbox pin and the fastener bracket.
Page 477 UP TO Assembly No. 85744 Fit the gearbox lock releaser (83), complete with Bowden cables, on the relevant gearbox lock release pin. Apply grease SEGO to the ends of the screw threads (84). Tighten the screws (84) fastening the gearbox lock releaser (83).
Page 478 Tighten the six screws (75) fastening the axle shaft to the differential flange, after fitting the three shims (76). Repeat the three previous operations for the left hand rear suspension. Tightening torque Class Screw 78 Nm Tighten the screw (89) fastening the gearbox- rear removable subframe ground braid (90).
Page 479 ONLY for vehicles WITHOUT single oil heat exchanger Clean the area surrounding the GL pipe fastening points thoroughly with a suitable degreaser that does not leave residue. Place absorbent paper under the plugs to collect any oil spillage. Remove the plugs installed previously. Remove the GL delivery and return pipes and, after replacing and lubricating the O-rings, insert them in suitable seats.
Page 480 ONLY for vehicles WITH single oil heat exchanger Fasten the coolant return pipe (14) tightening the nuts indicated on the clamps, after fitting the shim (15), as shown in the photo. Tightening torque Class Nut / Screw 8 Nm ONLY for vehicles WITH single oil heat exchanger Fit the coolant delivery pipe (12) in the relevant seat on the gearbox.
Page 481 ONLY for vehicles WITH Single Oil Heat Exchanger FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fasten the coolant delivery pipe (12) and the coolant return pipe (14), tightening the indicated nuts. Tightening torque Class Nut / Screw...
Page 482 ONLY for vehicles WITH single oil heat exchanger Fit the shim (18). Fasten the ATF pipes (72) to the gearbox, tightening the indicated nuts. Tightening torque Class Nut / Screw 8 Nm ONLY for vehicles WITH single oil heat exchanger Clean the area surrounding the GL fluid pipe fastening points thoroughly with a suitable degreaser that does not leave residue.
Page 483 Fit and fasten the two lower heat shields (67) and (68) onto the rear removable gearbox subframe, by tightening the screws indicated. Tightening torque Class 9 Nm Fit the two front heat shields on the exhaust extensions as originally installed. Apply an even layer (93) approximately 15 mm wide of HOLTS FIREGUM sealant paste onto the mating surfaces of both of the rear...
Page 484 Place the trolley 107565), complete with rear removable subframe, under the vehicle and with the trolley operating handle facing towards the rear of the vehicle. Operate the lift pedal to lift the rear removable subframe to approximately 300 mm from the vehicle chassis.
Page 485 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Operate the lift pedal to lift the rear removable subframe sufficiently to permit connection of the ground braid (63). Connect the ground braid (63), tightening the screw (62).
Page 486 Operate the lift pedal to lift the rear removable subframe completely, aligning the references (X) and (Y). Fit the transmission shaft flange onto the respective gearbox flange. Undo the alignment pins. Hand-tighten all the fastener screws for the rear removable subframe. Pre-tighten all the screws fastening the rear removable subframe.
Page 487 Definitively tighten the upper rear screw (57). Perform the procedure on both sides of the vehicle. Tightening torque Class Screw 110 Nm Tighten the front screws (58). Tightening torque Class Screw 65 Nm Definitively tighten the outer central screws (59). Tightening torque Class Screw...
Page 488 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the screws (65) definitively, tightening the front screw first and then the rear screw. Perform the procedure on both sides of the vehicle. Tightening torque Class Screw...
Page 489 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the screws (59) definitively, tightening the front screw first and then the rear screw. Perform the procedure on both sides of the vehicle. Tightening torque Class Screw...
Page 490 Check that the one or two machined conical recesses on the gearbox flange are approximately 180° from the white dot on the rear of the transmission shaft. If there are two machined conical recesses on the gearbox flange, use the centre point between the two recesses as a reference point.
Page 491 Fit the brake calliper (45) in its seat on the hub carrier and fasten by tightening the screws (46). Repeat the procedure for the right hand brake calliper. Tightening torque Class Screw 100 Nm Working on the left hand rear suspension, fasten the clamp on the parking brake cable (43), by hand tightening the relevant nut.
Page 492 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Pre-tighten then definitively tighten the screws (38). Tightening torque Class Screw (pretightening) 20 Nm Screw 110 Nm Connect the connector (37). Perform the operations on both sides of the vehicle.
Page 493 Fit the EPB Bowden cable (35) on the relevant heat shield on the gearbox. Tighten the two screws indicated (36) fastening the EPB Bowden cable (35) to the heat shield on the gearbox. Tightening torque Class Screw 6 Nm Fit the heat shield (34 )protecting the EPB Bowden cable (35) in the relevant seat.
Page 494 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit the clip (92) on the EPB linkage bracket as originally installed. UP TO Assembly No. 85744 Fit the emergency gearbox lock releaser cables, leading towards the passenger compartment, onto the retainer bracket (25), and fasten the cables by fitting the Seeger rings (24).
Page 495 Fit the exhaust extensions (D) correctly onto the centre silencer (C), matching up the welds indicated and aligning at the rear with the silencers. Tighten the Torx clamps (4) fastening the centre silencer (C) to the exhaust extensions (D). Tightening torque Class Torx clamp 54.2 Nm...
Page 496 ONLY for vehicles WITHOUT single oil heat exchanger Connect the unions (21) for the gear oil fastening the pipe retainer clamp (20) to the bodyshell. ONLY for vehicles WITHOUT single oil heat exchanger Fasten the two pipe retainer brackets (19) to the mounting bracket (16), by tightening the fasteners indicated.
Page 497 ONLY for vehicles WITHOUT single oil heat exchanger Connect the clutch hydraulic oil system pipe unions. Follow the instructions given below to ensure proper connection: ensure that the notch on the safety ring nut (14) is aligned with the pin (13); connect the male union and turn the safety ring nut (14) so that it is no longer aligned with the pin (13);...
Page 498 ONLY for vehicles WITH single oil heat exchanger Remove the caps previously placed on the coolant pipe ends. Connect the coolant pipes (10), tightening the collars (11). Tightening torque Class Screw collar 4 Nm Fasten the pipe retainer bracket (9) to the mounting bracket (8) by tightening the screw indicated by the red arrow.
Page 499 ONLY for vehicles WITH single oil heat exchanger Using the photo aside as reference, check that the EPB electric parking brake cable is located correctly relevant to the coolant pipe mounting bracket. ONLY for vehicles WITH Single Oil Heat Exchanger FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Remove the caps previously placed on the...
Page 500 Align the exhaust extension (D) with the silencer (E). Never reuse exhaust system clamps and gaskets that have been subjected to operating temperature. Always replace with new components. Only new exhaust system clamps and gaskets may be removed and refitted for adjustment purposes during initial installation.
Page 501 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit the connector cross member (Z). Tighten the nuts indicated. Tightening torque Class 25 Nm Check the alignment of the exhaust system ( B7.01). Refit the rear wheelhouses ( E3.05).
Page 502 C2.04 DCT gearbox water/gear oil heat exchanger (for vehicles WITHOUT single oil heat exchanger) Removing the gear oil heat exchanger The following system was installed UP TO Assembly No. 90608, and has been replaced by the new single oil heat exchanger system. Located behind the front right wheelhouse.
Page 503 To disconnect the gear oil pipes, turn the safety ring nut (14) to align the notch on the ring nut with the pin (13). Push the safety ring nut (14) towards the pin (13) to release the pipes. ALWAYS dispose of liquids correctly in accordance with applicable legislation.
Page 504 Refitting the gear oil heat exchanger Tightening torque Class Gear oil heat exchanger mounting bracket - 9 Nm relevant mounting bracket Water-oil pipes - gear oil heat exchanger Pipe union 50 Nm ATF and GL oil pipe mounting bracket Screw 20 Nm Clean the pipe unions, pipes and inlets on the heat exchanger thoroughly with a suitable degreaser that does not leave residue.
Page 505 Working from the front right wheel bay, fit the gear oil heat exchanger (A) in the relative mounting bracket and fasten by tightening the four nuts indicated. Tightening torque Class 9 Nm Fasten the front gear oil pipe to the mounting bracket, fitting the clamp (8).
Page 506 Clean the unions to be connected thoroughly with a suitable degreaser that does not leave residue. Connect the gear oil pipe unions. Follow the instructions given below to ensure proper connection: ensure that the notch on the safety ring nut (14) is aligned with the pin (13);...
Page 507 C2.05 DCT gearbox water/gear oil/clutch hydraulic system oil single oil heat exchanger (for vehicles WITH single oil heat exchanger) Removing the water/gear oil/clutch hydraulic system oil single oil heat exchanger CAUTION ALWAYS PERFORM THE OPERATIONS WITH COLD ENGINE AND EXHAUSTS. FROM Ass.ly No.
Page 508 Take care not to contaminate the systems. Clean the unions on the single oil heat exchanger and the surrounding areas with a suitable degreaser that does not leave residue. Place a container under the clamp indicated by the red arrow. Detach the coolant return pipe (2) from the single oil heat exchanger (A) by loosening the clamp indicated by the red arrow.
Page 509 Undo the indicated single oil heat exchanger fastening nuts (A) to the relevant mounting subframe. Move the pipes to one side as much as possible and pull backwards the single oil heat exchanger (A) from the stud bolts. Refitting the water/gear oil/clutch hydraulic system oil single oil heat exchanger Tightening torque Class Fastening single oil heat exchanger to mounting...
Page 510 Remove the plugs placed previously. Insert the gear oil pipes (4) in the relative seats on the single oil heat exchanger, after replacing and lubricating the relative O-rings. Apply AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK on the thread of the screws indicated.
Page 511 Remove the plugs placed previously. Fit the coolant delivery pipe (1) on the single oil heat exchanger (A) and fasten by tightening the indicated clamp. Tightening torque Class Screw collar 4 Nm Refit the rear bumper ( E3.04). Fill the cooling system ( A3.07).
Page 512 FROM Assembly No. 94889 Undo the screws indicated. Remove the single oil heat exchanger mounting subframe (A). Refitting the single oil heat exchanger mounting subframe Tightening torque Class Fastening single oil heat exchanger mounting 25 Nm subframe Screw 25 Nm Screw 8 Nm Fastening single oil heat exchanger mounting...
Page 513 FROM Assembly No. 94889 Fit the single oil heat exchanger mounting subframe (A). Tighten the screws indicated. Tightening torque Class Screw 40 Nm Refit the water/gear oil/clutch hydraulic system oil single oil heat exchanger ( C2.05).
Page 514 C2.06 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 515 ONLY for vehicles WITHOUT single oil heat exchanger To disconnect the gear oil pipes, turn the safety ring nut (14) to align the notch on the ring nut with the pin (13). Push the safety ring nut (14) towards the pin (13) to release the pipes.
Page 516 Connect the unions (5) for the gear oil pipes and fasten the clamp (4) to the bodyshell. Fasten the mounting bracket (3) for the gear oil pipes, by tightening the screws indicated with relevant washers. Tightening torque Class Screw 20 Nm Replace the plugs (1) and (2), fitting and tightening the new components.
Page 517 exchanger) Tightening torque Class Gear oil drain/filler plug - GL differential Plug 25 Nm With the introduction of the new system of gearbox oil with single oil heat exchanger it becomes necessary to adapt the pump 8174) element 01 (with short spout) in order to perform the operation, proceeding as follows.
Page 518 Check the Shell Transaxle 75W-90 GL5 gear oil level ( A3.02). Check that there is no leakage from the drain plugs.
Page 519 C3.01 DCT gearbox clutch hydraulic oil system layout Layout for vehicles WITHOUT single oil heat exchanger A - DCT gearbox (clutch oil tank and clutch oil pump) B - Clutch oil pipes C - Clutch oil radiator Layout for vehicles WITH single oil heat exchanger...
Page 520 A - DCT gearbox (clutch oil tank and clutch oil pump) B - Clutch oil pipes C - Clutch oil radiator...
Page 521 C3.02 DCT gearbox clutch hydraulic oil system radiator (for vehicles WITHOUT single oil heat exchanger) Removing the clutch hydraulic system oil radiator The following system was installed UP TO Assembly No. 90608, and has been replaced by the new single oil heat exchanger system.
Page 522 Remove the clamps (1) retaining the clutch hydraulic system oil pipes. Undo the unions (2) for the clutch hydraulic system oil pipes on the relative radiator (A). Liquid remaining in the system may leak: use absorbent paper and other appropriate means to protect the surrounding components.
Page 523 Fit the clutch hydraulic system oil radiator (A) in its seat on the radiator assembly. Tighten the lower nuts (4) fastening the clutch hydraulic system oil radiator (A) to the radiator assembly. Tightening torque Class 24 Nm Tighten the upper screw (3) fastening the clutch hydraulic system oil radiator (A) to the radiator assembly.
Page 524 Connect the clutch hydraulic oil system pipe unions. Follow the instructions given below to ensure proper connection: ensure that the notch on the safety ring nut (12) is aligned with the pin (13); connect the male union and turn the safety ring nut (12) so that it is no longer aligned with the pin (13);...
Page 525 C3.03 Draining clutch hydraulic system and filling with Shell DCT F-3 fluid Draining Shell DCT F-3 hydraulic clutch system oil 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.
Page 526 Filling with Shell DCT F-3 hydraulic clutch system oil Tightening torque Class ATF and GL oil pipe mounting bracket Screw 20 Nm ATF clutch oil drain/filler plug Plug 25 Nm ONLY for vehicles WITHOUT single oil heat exchanger Clean the unions to be connected thoroughly with a suitable degreaser that does not leave residue.
Page 527 Replace the plug (1), fitting and tightening the new component. Tightening torque Class Plug 25 Nm Undo the threaded plug (7), 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.
Page 528 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 relevant to the amount indicated for filling the tank when empty;...
Page 529 C4.01 Axle shafts 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 identical. Only for vehicles with DCT gearbox. Disable the EPB electric parking brake Autohold function ( D3.07).
Page 530 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).
Page 531 Tightening torque Class Fastening upper arm - rear hub carrier 90 Nm Fastening toe-in tie-rod - rear hub carrier 80 Nm Fastening axle shaft to differential flange Screw 78 Nm Fastening axle shaft to hub carrier 275 Nm When refitting the same axle shaft, remove any residue of AREXONS SYSTEM 56A01 - HIGH STRENGTH RETAINING COMPOUND.
Page 532 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 Class 90 Nm 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...
Page 533 Press on the two indicated fastener tabs and fit the right hand EPB Bowden cable sheath (9) into the relative mounting bracket. Attach the end (8) of the right hand EPB Bowden cable (9) to the EPB linkage bracket. Refit the clip (7) in the relative seat on the EPB linkage bracket.
Page 534 C4.02 Transmission shaft Removing the transmission shaft It connects the transmission housing with the gearbox. Remove the centre silencer ( B7.04). Unscrew the heat shield (1), by undoing the screws (2). Ease the heat shield (1) off the transmission shaft, shifting toward the front; bend slightly if necessary.
Page 535 Undo the six screws (5) fastening the transmission shaft (A) to the gearbox. Remove all the screws and retrieve the three shims (6). Use a sharp tool to separate the transmission shaft flange from the transmission housing, then ease the transmission shaft out (A) toward the front.
Page 536 Check that the flange surfaces on the transmission housing and gearbox are clean. When fitting the transmission shaft, the arrow on the shaft must point forward. On the rear of the transmission shaft is a white marking indicating the point of maximum imbalance.
Page 537 Fit the three shims (6), then snug and subsequently fully tighten the six screws (5) fastening the transmission shaft (A) to the transmission housing shaft. Proceed in a crossed pattern when both snugging and tightening the screws to torque. Tighten the screws to the definitive torque with a control angle of 90°.
Page 538 C4.03 Transmission housing Removing the transmission housing UP TO Engine No. 167394, in the event of transmission housing replacement, follow the indications given in Technical Information No. 1916 of May 2011. Disconnect the battery ( F2.01). Remove the transmission shaft ( C4.02).
Page 539 Undo the indicated nuts fastening the transmission housing (A) to the engine. When removing the transmission housing from the engine, do NOT apply leverage in the sump. With a suitable tool (11), apply leverage to the tool 107566) to separate the transmission housing from the engine, detaching from the respective stud bolts.
Page 540 Make a yellow marking on the crankcase indicating the precise position of the white maximum imbalance marking on the flywheel. Thoroughly clean and degrease the transmission housing shaft. Apply a layer of ROLOIL Copper Grease - copper based grease for high temperatures over the last 2 cm of the transmission housing shaft to completely fill the splining grooves and cover the bevelled...
Page 541 Take particular care not to bend the pipes and/or strain the cables excessively when tilting the engine assembly. Support the transmission housing (A) at the end of the relative shaft to allow some degree of rotation when inserting the shaft into the splined hub of the flywheel.
Page 542 Make a yellow marking on the transmission shaft flange indicating the precise position of the yellow marking made previously on the crankcase. The position of the marking shown in the photo aside is indicative only. Undo the screw (10) of the tool 107566) to position the engine assembly correctly.
Page 543 C4.04 Flywheel Removing the flywheel Remove the transmission housing ( C4.03). Immobilise the crankshaft. Undo the indicated screws in a cross pattern. Note that while the starter motor has been removed in the photo aside, its removal is not necessary. Remove the flywheel (A).
Page 544 FROM Engine No. 181233 Apply a sufficient layer of ROLOIL Copper Grease - copper based grease for high temperatures on the splining and on the O- rings to fill the teeth grooves completely. Immobilise the crankshaft. Fit the flywheel (A). Hand tighten the screws indicated.
Page 545 D1.01 Technical specifications Wheels Front Wheel rim size Light alloy 8 " J x 19 " Light alloy 8 " J x 19 " optional Light alloy 8 " J x 20 " optional Spare wheel 4.5 " J x 20 " Tyre size 245/40 ZR19 Pirelli P Zero 245/40 ZR19 Bridgestone optional...
Page 546 Front Rear Bridgestone ZR 20 32 psi 32 psi Bridgestone RE 050 35 psi 32 psi (Run Flat) Pirelli Winter 35 psi 32 psi Sottozero Vredestein (Spare 61 psi 61 psi wheel) Brake system CCM discs Front: 390 mm x 34 mm Rear: 360 mm x 32 mm Callipers Front: 6 pistons...
Page 547 D1.02 Specific tooling and equipment Support 95973206 (AV 3206) for complete hub. Torque wrench 95978172 (AV 8172) (Replaces torque wrench USAG 815F)
Page 548 D1.03 Tightening torques Tightening torque Class Wheel sensors for checking tyre pressure Sensor 4 Nm Valve fastening for tubeless cover Valve 4 Nm Wheels Pretightening of stud bolt 25 ÷ 45 Nm Stud bolt 100 Nm Fastening cylindrical bushing to EPB ECU Screw 9 Nm Fastening EPB ECU...
Page 549 Tightening torque Class Front brake calliper - stub axle Screw 100 Nm Rigid brake fluid pipe union - front calliper Union 15.5 Nm Centre pin - front brake pads Screw 27 ÷ 33 Nm Fastening brake pedal endstop 12 Nm Fastening the lower front arm to the hub carrier Nut (pretightening) 90 Nm...
Page 550 Tightening torque Class Fastening pipe and cable mounting bracket to Screw 9 ÷ 12 Nm hub carrier Products to use: AREXONS 242 Fastening brake disc shield bracket Screw 9 ÷ 12 Nm Products to use: AREXONS 242 Fastening connector to shock absorber strut 40 Nm Fastening steering wheel hub - upper steering 50 Nm...
Page 551 Tightening torque Class Fastening power steering system pipe mounting 9 Nm brackets - bushings on steering box Fastening mounting bracket for rigid pipe leading Screw 4 Nm from pump to steering box - engine...
Page 552 D2.01 Complete wheel Removing the wheels CAUTION Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0 (Key- OFF). 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"...
Page 553 Refitting the wheels Tightening torque Class Wheels Pretightening of stud bolt 25 ÷ 45 Nm Stud bolt 100 Nm CAUTION Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0 (Key- OFF). 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"...
Page 554 D2.02 Tyres and rims Checking the state of the tyres 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.
Page 555 Tyre grades All passenger car tires must conform to Federal Safety requirements, in addition to these grades. DOT rating Tread wear Traction Temperature Pirelli P Zero 220 (Front) – 160 (Rear) 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.
Page 556 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.
Page 557 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.
Page 558 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.
Page 559 Position the tyre bead on the tool (4) using the lever (5). Remove the lever. 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.
Page 560 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.
Page 561 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).
Page 562 Release the wheel from the clamps (2) on the table. Refit the core of the valve (A). 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.
Page 563 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.
Page 564 D2.03 Tyre pressure monitoring system (optional) TPMS system layout A - Sensors B - Trigger C - Digital antenna D - Electronic control unit Sensors Fastened to the rims, inside the tyres. The sensors measure the temperature and pressure within the tyre. The sensors transmit data to the digital antenna as an RF signal (433.92 MHz / 315 MHz).
Page 565 The antenna receives data from the sensors, decodes the data and transmits them to the electronic control unit. The antenna transmits data via cable to the electronic control unit as a digital signal. Electronic control unit Fastened in the passenger side, on the driver side, under the inspection hatch cover. The electronic control unit processes the data received from the digital antenna and conveys them to the instrument panel.
Page 566 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 failure signal, the TFT display displays the specific message “Check tyre pressure”...
Page 567 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” in area B2 of the screen together with the vehicle symbol in area B1 indicating tyre pressures.
Page 568 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.
Page 569 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".
Page 570 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" in area B2 of the screen, with the vehicle symbol in area B1 indicating tyre pressures.
Page 571 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 50 mph" in area B2 of the screen, with the vehicle symbol in area B1 indicating tyre pressures.
Page 572 TYRES screen: the screen may be recalled by pressing the DISP button, enabling the driver to identify punctured tyres at any time. When the system cannot recognise which wheel is generating the failure signal, as the respective values cannot be displayed by the TYRES screen, the screen is not recallable by the driver.
Page 573 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”...
Page 574 To prevent the inflation valve from turning, insert the rod (1), included in the kit, in the hole on the sensor side. 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.
Page 575 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.
Page 576 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.
Page 577 Refit the tyre pressure sensors ( D2.03). Refit the tyre ( D2.02). Inflate the tyre to a pressure greater than 0.6 bar (8.7 psi) and keep inflated at this pressure for a few minutes. This causes the sensor to activate. Inflate the tyre to the specified pressure.
Page 578 Remove the front wheelhouses ( E3.05). Detach the connector (1) and undo the two nuts indicated then remove and replace the trigger (A). Fit the trigger (A) in its seat, with the connector facing downwards, and fasten by tightening the two nuts indicated. Tightening torque Class 4 Nm...
Page 579 D3.01 System layout Braking system layout A - Brake fluid tank B - Master brake cylinder C - Servo brake D - ABS/ASR electrohydraulic unit E - Front brake fluid pipes F - Rear brake fluid pipes G - Brake callipers H - Brake pads I - Brake discs...
Page 580 D3.02 Brake fluid tank Removing the brake fluid tank Hydraulic brake fluid is corrosive. Contact with brake fluid may cause severe injury or damage to painted parts of the vehicle. In the event of skin contact with fluid, wash the respective part of the body immediately with plenty of water.
Page 581 Apply thread lock compound to the thread of the screw (2). Hydraulic brake fluid is corrosive. Contact with brake fluid may cause severe injury or damage to painted parts of the vehicle. In the event of skin contact with fluid, wash the respective part of the body immediately with plenty of water.
Page 582 D3.03 Brake discs Removing the brake discs Remove the wheels ( D2.01). Remove the rear brake callipers ( D3.05). DO NOT disconnect the calliper fluid pipe and take particular care not to damage the pipe when handling the calliper. Remove the front brake calliper ( D3.05).
Page 583 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. Apply and tighten the fastener screws (3). Tightening torque Class Screw 15.5 Nm Apply and tighten the wheel locator pin (2). Tightening torque Class 15.5 Nm...
Page 584 DO NOT use a drill to remove stubborn material from the holes. DO NOT countersink the holes. DO NOT grind the discs. DO NOT widen the holes with a drill. Remove any material from the cross-drilled ventilation holes in the disc with a metal pin or a screwdriver no larger than 5 mm in diameter.
Page 585 D3.04 Brake pads Removing the front brake pads Disconnect the battery ( F2.01). Remove the wheels ( D2.01). Remove the front wheels. Disconnect connector (1) of brake pad wear sensor, and detach it from the relevant mounting bracket. Detach brake pad wear sensor cable from cable grommet (2).
Page 586 Install the brake pads (A). Install the pin (7). Tighten the screw (6). Tightening torque Class Screw 27 ÷ 33 Nm Install the pin (5), tapping with a suitable punch and mallet. Fit the spring (4). Install the pin (3), tapping with a suitable punch and mallet.
Page 587 Disconnect the connector (1) for the brake pad wear sensor. Remove the clamp (2). Open the clamp (3) to release the pad wear sensor cable. 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.
Page 588 Close the clamp (3) to fasten the pad wear sensor cable. Fit a new clamp (2). Connect the connector (1) for the brake pad wear sensor. Refit the wheels ( D2.01). Connect the battery ( F2.01). Only in the case of replacing the pads. Bed-in the CCM brake pads ( A3.19).
Page 589 D3.05 Brake callipers Removing the front brake calliper Hydraulic brake fluid is corrosive. Contact with brake fluid may cause severe injury or damage to painted parts of the vehicle. In the event of skin contact with fluid, wash the respective part of the body immediately with plenty of water.
Page 590 Check that the calliper mating surfaces with the stub axle are clean, fit the brake calliper (A) to the disc and tighten the two screws (2). Tightening torque Class Screw 100 Nm Fit the rigid pipe on the brake calliper, tightening the union (1).
Page 591 Tightening torque Class Rear brake calliper - hub carrier Screw 100 Nm Hose - rear brake calliper Union 21.5 Nm 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 Class Screw...
Page 592 D3.06 ABS electrohydraulic unit Removing the electrohydraulic ABS/ASR unit The unit is located in the engine compartment, to the left of the battery, and consists of a hydraulic component and an ECU. Remove the battery ( F2.01). Remove the engine compartment cosmetic shields ( E3.13).
Page 593 Open the pipe clamp indicated and release the pipes from the relative clips. Hydraulic brake fluid is corrosive. Contact with brake fluid may cause severe injury or damage to painted parts of the vehicle. In the event of skin contact with fluid, wash the respective part of the body immediately with plenty of water.
Page 594 Tightening torque Class ABS/ASR ECU - mounting bracket Screw 18 Nm Fastening brake pipe union or connection M10 union 16 Nm Brake pipe union or connection M12 Union 16 Nm Check the state of the three mounting bushings (7) for the electrohydraulic ABS/ASR unit and replace if necessary.
Page 595 Connect the connector (3) on the ECU, pushing down the safety clip (4). Hydraulic brake fluid is corrosive. Contact with brake fluid may cause severe injury or damage to painted parts of the vehicle. In the event of skin contact with fluid, wash the respective part of the body immediately with plenty of water.
Page 596 Fit and fasten the cover (8) on the ABS/ASR electrohydraulic unit, pressing the two clips indicated. Refit the battery ( F2.01). Fill and bleed the brake system ( D3.10). Refit the front flat undertray section ( E3.12). Refit the engine compartment cosmetic shields ( E3.13).
Page 597 Remove the indicated cable grommets for the ABS sensor cable (A) from the mounting bracket. Undo the screw (3) and remove the front wheel ABS sensor (A) from the suspension. Refitting the front wheel ABS sensor Check that the ABS sensor and the tone wheel on the hub carrier are clean. Fit the front wheel ABS sensor (A) in the relative seat on the hub carrier and fasten by tightening the screw (3).
Page 598 Fit the indicated cable grommets for the ABS sensor cable (A) onto the mounting bracket. Slide connector (2) of ABS sensor cable above brake pad wear sensor and connect it. Attach cable grommet (1) of ABS sensor cable to the relevant mounting bracket. Connect brake pad wear sensor cable to the cable grommet (1).
Page 599 Remove the indicated cable grommets for the ABS sensor cable (A) from the mounting bracket. Undo the screw (3) and remove the rear wheel ABS sensor (A) from the suspension. Refitting the rear wheel ABS sensor Check that the ABS sensor and the tone wheel on the hub carrier are clean. Fit the front wheel ABS sensor (A) in the relative seat on the hub carrier and fasten by tightening the screw (3).
Page 600 Fit the indicated cable grommets for the ABS sensor cable (A) onto the mounting brackets. Connect the connector (1) for the ABS sensor cable (A) and fit the cable grommets (2) in the mounting bracket on the chassis. Fit the three new clamps in the positions indicated fastening the ABS sensor cable (A) to the ground cable and to the brake pad wear sensor cable.
Page 601 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.
Page 602 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. Press the AUTO PARK button (B). Wait for the specific message "PARK OFF"...
Page 603 Emergency EPB electric parking brake release procedure CAUTION The vehicle may move with no warning when the electric parking brake is mechanically released! The vehicle is only held in position by the Park Lock, if engaged. If the electric parking brake cannot be released due to a flat battery or an electrical system failure, carry out the following emergency procedure.
Page 604 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Insert the articulated wrench (B) in the relative hole on the left of the tool kit. Turn the articulated wrench (B) clockwise to completely release the grip of the parking brake shoes on the rear discs.
Page 605 Use a suitable screwdriver to prise the clip (1) off the EPB linkage bracket. Detach the end (2) of the right hand EPB Bowden cable (B) from the EPB linkage bracket (A) Press on the two indicated fastener tabs and remove the right hand EPB Bowden cable sheath (B) from the relevant mounting bracket.
Page 606 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.
Page 607 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 (2) of the right hand EPB Bowden cable (B) onto the EPB linkage bracket (A). Refit the clip (1) onto the EPB linkage bracket.
Page 608 Rear left hand wheel brake shoes Move the EPB equaliser (C) to the left. Detach the end (3) of the left hand EPB Bowden cable (D) from the EPB equaliser (C). Press on the two indicated fastener tabs and remove the left hand EPB Bowden cable sheath (D) from the relevant mounting bracket.
Page 609 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 Class Fastening EPB Bowden cable - rear hub carrier Screw 8 Nm Fastening brake pad sensor ground cable 6 Nm Fit the linkage (13) correctly and install the brake shoes (E) in the...
Page 610 Attach the eyebolt (6) on the right hand EPB Bowden cable (B) to the fork (7) inside the hub carrier. Tighten the indicated screw fastening the right hand EPB Bowden cable sheath (B) onto the rear right hand hub carrier. Tightening torque Class Screw...
Page 611 Calibrate the EPB electric parking brake ( D3.07). Refit the rear flat undertray section ( E3.12). Refit the wheels ( D2.01). Calibrating the EPB electric parking brake If at Key-ON, the NPB parking brake mode identifies a fault, indicated on the instrument panel and on the TFT display by the specific warning lamps, and with error C155A on the NPB (EPB calibration error) and error C1313 on the NFR (parking brake error), using the DEIS tester, calibrate the EPB system and cancel any errors in the...
Page 612 Rotate the rear CCM brake disc to align one of the two holes (A) with the toothed ring (B) for adjusting the Bowden cable. Insert a suitably sized screwdriver (C) through the hole in the rear disc. Using the screwdriver, turned the toothed ring anticlockwise (D) to tighten the parking brake shows on the inner part of the disc and lock the disc.
Page 613 During this cycle , keep the ignition switch turned to II (KEY ON) with the engine off, then press F12 "Continu e". If the calibration is successful, a green symbol is displayed. Press F2 "Abort" (DO NOT press F12 "Continu e").
Page 614 D3.08 Brake servo - Pump Removing the brake servo Remove the engine compartment cosmetic shields ( E3.13). Remove the left hand cosmetic underwindscreen shield. Remove the brake fluid tank ( D3.02). Remove the windscreen wiper linkage ( E3.09). Remove the driver side underdashboard trim panel ( E4.02).
Page 615 Detach the brake servo linkage from the pedal by releasing the clips (3). Working from under the dashboard on the driver side, undo the four nuts indicated fastening the brake servo to the pedal board (4). Note that the photo aside was taken with the dashboard removed to illustrate the operation more clearly.
Page 616 Tightening torque Class Fastening brake servo - pedal board 20 Nm Brake fluid pipes - master brake cylinder Union 16 Nm Assess the condition of the firewall gaskets (5); replace if necessary. Place the brake servo (A), complete with pump, in the engine compartment, install the two firewall gaskets correctly (5), with the relative shim (6), and fit in the relative seat on the...
Page 617 Fit the two unions (1) in the relative seats on the master brake cylinder and tighten. Tightening torque Class Union 16 Nm Connect the vacuum pipe (2) to the brake servo (A). Fasten the rigid brake fluid pipes by closing the three fastener clips indicated.
Page 618 D3.09 Pedal board Removing the pedal board Disconnect the battery ( F2.01). Remove the dashboard ( E4.02). Disconnect the connector (1) from the brake pedal stop light switch (C). Detach the servo brake linkage from the pedal by releasing the clips (2). Remove the retainer clip (3), remove the pin (4) then remove the brake pedal (B).
Page 619 Fit the pedal board in the relative seat in the passenger compartment and fasten by tightening the six fasteners indicated (four nuts fastening the pedal board to the servo brake and two screws fastening the pedal board to the firewall) in the sequence indicated in the photo aside.
Page 620 The brake pedal (A) is pivoted on the pedal board mounting by a pin (B), fastened at each end by the clips (C). The brake servo linkage is connected to the brake pedal via a snap fit coupling within the retainers (E).
Page 621 D3.10 Filling and bleeding the brake system Filling and bleeding the brake system Tightening torque Class Bleed union - brake calliper Union 17 ÷ 20 Nm Remove the wheels ( D2.01). Remove the engine compartment cosmetic shields ( E3.13). Remove the left hand cosmetic underwindscreen shield. Fill the tank, considering that during bleeding, the fluid level in the tank must never drop below the MIN level indicated on the tank.
Page 622 After the procedure, there must be no sponginess in the pedal and the braking action must be progressive, starting immediately after a short free play. Refit the engine compartment cosmetic shields ( E3.13). Refit the wheels ( D2.01).
Page 623 CCM Brake Disc Wear Form Model All Models - CCM Brake Disc Wear Form [Download]...
Page 624 D4.01 Complete suspension Removing the entire 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.
Page 625 For magnetorheological shock absorbers only (optional) Disconnect the connector (3) from the shock absorber. Detach and disconnect the connector (4) for the ABS sensor. Detach and disconnect the connector (5) for the brake pad wear sensor. Detach the cable grommet (6) from the relevant mounting bracket.
Page 626 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 relevant mounting bracket. FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Detach and disconnect the connector (5) for the...
Page 627 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Detach and disconnect the connector (4) for the ABS sensor. Detach the cable grommet (6) from the relevant mounting bracket. 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.
Page 628 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 arm fastener nuts in the order given for the previous operation.
Page 629 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Support the weight of the suspension adequately. DO NOT use lubricants or electric/pneumatic drivers. Undo the indicated 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...
Page 630 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 arm fastener nuts in the order given for the previous operation.
Page 631 Tightening torque Class Fastening brake pipe union or connection M10 union 16 Nm Fastening front stabiliser bar - spherical tie-rod 50 Nm Fastening steering box spherical tie-rod to hub Nut (pretightening) 40 Nm carrier 40 Nm The following procedure is for refitting of right hand front suspension. The procedure for refitting the left hand front suspension is the same.
Page 632 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.
Page 633 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the indicated screws fastening the shock absorber (D) to the chassis. Tightening torque Class Screw (pretightening) 20 Nm Screw 110 Nm Fit the shims (8) in the relative seats, pushing down completely onto the threaded rods and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs.
Page 634 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. Connect the ground cable, tightening the indicated nut (7).
Page 635 Attach the cable grommet (6) onto the relative mounting bracket. Slide connector (5) of brake pad wear sensor under ABS sensor cable, connect it, and attach it to the relative mounting bracket. Connect connector (4) of ABS sensor, and attach it to the relative mounting bracket.
Page 636 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Connect the ground cable (7), tightening the indicated nut. Tightening torque Class 6 Nm Connect and fasten the connector (5) for the brake pad wear sensor. For magnetorheological shock absorbers only (optional) Connect the connector (3) to the shock absorber.
Page 637 Connect the right steering box tie-rod (A) to the stub axle. Fit the relative washer and tighten the nut (1) fastening the steering box tie rod (A) to the stub axle. Pretighten the nut (1). FROM Assembly No. 98482, there is a recess on the ball stud to facilitate tightening the nut (1).
Page 638 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.
Page 639 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) 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.
Page 640 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Disconnect the connector (14) from the shock absorber (B). Magnetorheological shock absorbers (optional) only. Support the weight of the complete suspension adequately. Undo the indicated screws fastening the shock absorber (B) to the chassis.
Page 641 (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 tie-rod fastener nuts, completely...
Page 642 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 arm fastener nuts in the order given for the previous operation.
Page 643 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 arm fastener nuts in the order given for the previous operation.
Page 644 Refitting the entire rear suspension Tightening torque Class Fastening lower arm to chassis Nut (pretightening) 25 Nm 60 Nm Fastening upper arm to chassis Nut (pretightening) 25 Nm 60 Nm Fastening rear stabiliser bar - spherical tie-rod 50 Nm Fastening toe-in tie-rod to chassis Nut (pretightening) 25 Nm 60 Nm...
Page 645 Fit the shims (16) in the relative seats, pushing down completely onto the threaded rods and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs. UP TO Assembly No. 98014, fork type spacers (16) are used. FROM Assembly No.
Page 646 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).
Page 647 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 indicated fastening the stabiliser bar (D) to the spherical tie-rod.
Page 648 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 relevant nuts and eyebolts fastening the lower arm.
Page 649 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the indicated screws fastening the shock absorber (B) to the chassis. Tightening torque Class Screw (pretightening) 20 Nm Screw 110 Nm Connect the connector (14) to the shock absorber (B).
Page 650 Tighten the indicated screw fastening the EPB Bowden cable sheath (8). Tightening torque Class Screw 8 Nm Tighten the nut (7) fastening the ground cable onto the bracket on the EPB Bowden cable sheath (8). Tightening torque Class 6 Nm Attach the cable grommet (6) to the relative bracket on the EPB Bowden cable sheath (8).
Page 651 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Insert the brake fluid hose (11) into the relevant mounting bracket. Tighten the brake fluid hose union (10). Tightening torque Class M12 Union 16 Nm Refit the clip (9) fastening the union for the brake fluid hose (11) onto the relevant mounting bracket.
Page 652 D4.02 Suspension arms Removing the front suspension upper arm 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. For magnetorheological shock absorbers only (optional).
Page 653 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the indicated screws fastening the shock absorber (A) to the chassis. 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.
Page 654 (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...
Page 655 Tightening torque Class Fastening the upper front arm to the hub carrier Nut (pretightening) 52 Nm 52 Nm Fastening upper arm to chassis Nut (pretightening) 25 Nm 60 Nm Fastening shock absorber to chassis Screw (pretightening) 10 Nm Screw 30 Nm Fastening shock absorbers to chassis (FROM Screw (pretightening) 20 Nm...
Page 656 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 nuts indicated fastening the upper arm (B) in the following order: (a), (b), (c), (d).
Page 657 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 indicated screws fastening the shock absorber (A) to the chassis.
Page 658 For magnetorheological shock absorbers only (optional) Connect the connector (1) to the shock absorber. Refit the wheels ( D2.01). For magnetorheological shock absorbers only (optional). Connect the battery ( F2.01). For magnetorheological shock absorbers only (optional). Refit the engine compartment cosmetic shields ( E3.13).
Page 659 (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...
Page 660 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 the front suspension lower arm Tightening torque Class Fastening the lower front arm to the hub carrier...
Page 661 Fit the lower front suspension arm (A) in its relevant seat. Apply the nut (4), after fitting the relevant washer, and pretighten. Tightening torque Class Nut (pretightening) 90 Nm Loosen the nut (4) and then tighten. Tightening torque Class 63 Nm Fit the pin (3) fastening the shock absorber to the lower arm and, after fitting the relevant washer, tighten the nut (2).
Page 662 Fit the shims (5) in the relative 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.
Page 663 Refit the wheels ( D2.01). Check the vehicle set-up ( D4.07). Removing the rear suspension upper arm 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).
Page 664 (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...
Page 665 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 Class 90 Nm...
Page 666 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. Refit the wheels ( D2.01).
Page 667 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. Detach the tie-rod (1) for the NRRPS motion sensor from the lower arm (A).
Page 668 (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...
Page 669 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 the rear suspension lower arm Tightening torque Class Fastening spherical tie-rod - lower arm...
Page 670 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 Class Spherical tie-rod 50 Nm Fit the four shims (7) in the relative seats, pushing down completely onto the stud bolts and ensuring that they are perfectly perpendicular to the horizontal axis of the flanblocs.
Page 671 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.
Page 672 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 Class 80 Nm Press the rubber plug (D) by hand into its relevant seat at the rear of the lower arm.
Page 673 D4.03 Hub carriers Removing the front suspension stub axle The front stub axle or hub carrier is supplied as a spare part complete with wheel bearing. Remove the front brake calliper ( D3.05). Remove the brake discs ( D3.03). Remove the front one. Support the weight of the suspension adequately.
Page 674 Undo the nut (10) fastening the upper front arm (11) to the stub axle, retrieving the relative washer. Detach the upper front arm (11) from the stub axle. Undo the nut (12) fastening the lower front arm (13) to the stub axle, retrieving the relative washer.
Page 675 Tightening torque Class Fastening pipe and cable mounting bracket to Screw 9 ÷ 12 Nm hub carrier Products to use: AREXONS 242 Fastening brake disc shield bracket Screw 9 ÷ 12 Nm Products to use: AREXONS 242 Fastening the lower front arm to the hub carrier Nut (pretightening) 90 Nm 63 Nm...
Page 676 Clean the ball joint pin and the relative seat on the arm (13) to remove any grease residue. Fit the stub axle on the arms. Apply the nut (12) fastening the lower arm (13) to the stub axle, after installing the relative washer, and pre-tighten.
Page 677 Connect the right steering box tie-rod (9 B) to the stub axle. Fit the relative washer and tighten the nut (8) fastening the steering box tie rod (9) to the stub axle. Pretighten the nut (8). FROM Assembly No. 98482, there is a recess on the ball stud to facilitate tightening the nut (9).
Page 678 The following procedure is for removing the right hand rear hub carrier. The procedure for removing the left hand rear hub carrier is the same. 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).
Page 679 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). Preventing the screw (5) fastening the upper arm (C) to the hub carrier from turning, undo the nut (6).
Page 680 Tightening torque Class Fastening axle shaft to hub carrier 275 Nm Fastening brake disc shield bracket Screw 9 ÷ 12 Nm Products to use: AREXONS 242 Fastening toe-in tie-rod - rear hub carrier 80 Nm Fastening rear anti-rotation link Screw 85 Nm Fastening lower rear arm to rear hub carrier 205 Nm...
Page 681 Fit the hub carrier (E), fitting the axle shaft into the relative seat on the wheel bearing. Tighten the nut (8). Tightening torque Class 275 Nm Use a suitable punch and mallet to caulk (7) the ring nut (8). Fit the brake disc shield (D) on the hub carrier (E).
Page 682 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 Class 80 Nm Whenever the nut and/or the screw fastening the lower rear suspension arm is or are...
Page 683 D4.04 Shock absorbers The vehicle may be equipped with fixed setting shock absorbers (2) or variable setting magnetorheological shock absorbers (1) (optional), already present on the 599 GTB Fiorano. The end of travel of the compression stroke is damped by a rubber bushing fitted coaxially with the stem; the end of travel of the rebound stroke is damped by a rubber bushing installed inside the shock absorber.
Page 684 Remove lateral cosmetic shields. For magnetorheological shock absorbers only (optional). Disconnect the battery ( F2.01). Remove the wheels ( D2.01). For magnetorheological shock absorbers only (optional) Disconnect the connector (1). Undo the indicated screws fastening the shock absorber (A) to the chassis. FROM Assembly No.
Page 685 (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...
Page 686 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.
Page 687 Tightening torque Class Fastening shock absorber to lower arm 80 Nm Fastening upper arm to chassis Nut (pretightening) 25 Nm 60 Nm Fastening shock absorber to chassis Screw (pretightening) 10 Nm Screw 30 Nm Fastening shock absorbers to chassis (FROM Screw (pretightening) 20 Nm Assembly No.
Page 688 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 nuts indicated fastening the upper arm (B) in the following order: (a), (b), (c), (d).
Page 689 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 indicated screws fastening the shock absorber (A) to the chassis.
Page 690 For magnetorheological shock absorbers only (optional) Connect the connector (1). For magnetorheological shock absorbers only (optional). Connect the battery ( F2.01). For magnetorheological shock absorbers only (optional). Refit the engine compartment cosmetic shields ( E3.13). Refit the lateral cosmetic shields. Refit the wheels ( D2.01).
Page 691 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Disconnect the connector (1). Magnetorheological shock absorbers (optional) only. Undo the indicated screws fastening the shock absorber (A) to the chassis. Detach and remove the rubber plug (C) from the front of the lower arm.
Page 692 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 absorbers Tightening torque Class...
Page 693 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. Tighten the indicated screws fastening the shock absorber (A) to the chassis.
Page 694 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the screws indicated fastening the shock absorber (A) to the chassis. Tightening torque Class Screw (pretightening) 20 Nm Screw 110 Nm Connect the connector (1). Magnetorheological shock absorbers (optional) only.
Page 695 Immobilise the shock absorber. 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 (1) by just enough to decompress the spring. Compress the spring (A) with a suitable press. Undo the nut (1) completely, retrieving the relative washer (2).
Page 696 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 (D) in contact with the spring (A).
Page 697 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 (D) in contact with the spring (A).
Page 698 Loosen the ring nut (A) using a standard pin wrench. Tighten or loosen the spring retainer cap (B) to obtain the length (L). The length (L) from the spring retainer to the lower fulcrum axis must be adjusted in relation to the type of spring fitted and the type of shock absorber on which the spring is installed.
Page 699 Variable setting front shock absorber length, FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Yellow 288 mm White 285 mm Variable setting front shock absorber length, FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification), for vehicles with Special Handling pack...
Page 700 D4.05 Stabiliser bars - Tie-rods Removing the front stabiliser bar Refit the wheels ( D2.01). Remove the front wheels. UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Remove the steering box ( D5.04).
Page 701 Lift the front stabiliser bar (A), complete with bushings (3), from its seat on the engine subframe and remove. Note the respective positions and orientation of the bushes and the bar, then remove the bushes from the stabiliser bar. FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Loosen the nut (1) fastening the stabiliser bar (A) to the tie-rod.
Page 702 Undo the screws indicated. Remove the bracket (B) from the respective rubber bush (C). Remove the bracket (D) retaining the bush (C). Undo the screws indicated. Remove the bracket (B) from bush (C). Remove the bracket (D) retaining the bush (C). Remove the stabiliser bar complete with bushes.
Page 703 Apply a uniform layer of grease DuPont Lubricants Krytox® 205 GPL Standard Grade Grease on the surfaces of shoulder bushings in contact with the rubber bushes. Apply 1 ml of grease MOLYKOTE PG21 uniformly over the entire inner surfaces of the rubber bushes.
Page 704 On the left hand front suspension, tighten the nut (2) fastening the stabiliser bar (A) to the tie- rod. Tightening torque Class 50 Nm On the right hand front suspension, tighten the nut (3) fastening the stabiliser bar (A) to the tie-rod.
Page 705 Apply 1 ml of grease DuPont Lubricants Krytox® 205 GPL Standard Grade Grease uniformly on the inner surfaces of the rubber bushes. Pressing into place by hand, fit the rubber bushes on the stabiliser bar in the same position and orientation noted during disassembly.
Page 706 Turning with the arrow pointing towards the interior of the vehicle, fit the bracket (D) retaining the bush (C). Using a cloth moistened with heptane, thoroughly clean and degrease the outer surface of the rubber bush (C) and the inner surface of the bracket (B).
Page 707 Removing the rear stabiliser bar Located behind the gearbox. Remove the rear flat undertray diffuser ( E3.12). Remove the wheels ( D2.01). Remove both rear ones. Remove the rear wheelhouses ( E3.05). Remove both rear elements. ONLY for vehicles WITH single oil heat exchanger. Remove the rear bumper ( E3.04).
Page 708 Undo the nuts (4) fastening the bushing bracket (5) to the rear stabiliser bar (A). Repeat the procedure on the left hand suspension. ONLY for vehicles WITHOUT single oil heat exchanger Note the respective orientation and positions of the rubber bushes and bar. Remove the rear stabiliser bar from the vehicle, easing it out through the gap between the exhaust extensions and the silencers.
Page 709 Apply a uniform layer of grease DuPont Lubricants Krytox® 205 GPL Standard Grade Grease on the surfaces of shoulder bushings in contact with the rubber bushes. Apply 1 ml of grease MOLYKOTE PG21 evenly to the entire inner surface of the bushings in contact with the stabiliser bar.
Page 710 Tighten the nut (3) fastening the rear stabiliser bar (A) to the left hand suspension tie-rod. Repeat the procedure on the left hand suspension. Tightening torque Class 50 Nm ONLY for vehicles WITHOUT single oil heat exchanger Always replace the spherical exhaust system clamps with new components after loosening.
Page 711 Replacing front stabiliser bar tie-rods Tightening torque Class Fastening spherical tie-rod - lower arm Spherical tie-rod 50 Nm Fastening front stabiliser bar - spherical tie-rod 50 Nm Undo the nut (1). Undo the pin (2). Remove the spherical tie-rod (A) and replace it. Fit the new spherical tie-rod (A).
Page 712 Replacing rear stabiliser bar tie-rods Tightening torque Class Fastening spherical tie-rod - lower arm Spherical tie-rod 50 Nm Fastening front stabiliser bar - spherical tie-rod 50 Nm Undo the nut (1). Undo the pin (2). Remove the spherical tie-rod (A) and replace it. Fit the new tie-rod (A).
Page 713 D4.06 Shock absorber set-up adjustment system (optional) General The vehicle may be requested with the SCM (magnetorheological suspension control) electronically controlled shock absorber damping system. The semi-active (reactive/adaptive) system responds in real time to the road and driving conditions using input signals generated by the NRRPS motion sensors which read the movements of the chassis and wheels.
Page 714 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. This phenomenon makes it possible to create "virtual valves"; 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.
Page 715 Replacing the front NRRPS motion sensors Tightening torque Class Fastening motion sensor mounting bracket - Screw 5 Nm 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. Disconnect the battery ( F2.01).
Page 716 Disconnect the battery ( F2.01). Remove the wheels ( D2.01). Remove the right hand rear wheel. Disconnect the connector (1). Detach the tie-rod (2) from the lower arm. Undo the two screws indicated fastening the mounting bracket for the right hand rear NRRPS motion sensor (A).
Page 717 D4.07 Vehicle set-up Checking vehicle set-up Check tightness of wheel fasteners. Check that the tyre pressure is correct. Check that the steering box functions correctly. Check that the suspension components function correctly. Place the vehicle on a wheel alignment lift, filled with all fluids as necessary and with the electric parking brake engaged.
Page 718 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 - Check that the lower suspension arms are in the correct position.
Page 719 After checking, if the toe-in is not within the prescribed values, proceed as follows: ensure that the steering box is in the straight ahead 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.
Page 720 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.
Page 721 D5.01 System layout Steering system layout A - Power steering fluid tank B - Power steering fluid pump C - Steering box D - Power steering fluid radiator E - Steering column F - Steering wheel...
Page 722 D5.02 Power steering tank Removing the power steering tank 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.
Page 723 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 Assembly No. 98001, in the event of replacing the power steering fluid reservoir and the pipe leading from the power steering fluid reservoir to the power steering pump, the components of RETROFIT KIT Part No.
Page 724 D5.03 Power steering pump Removing the power steering pump 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.
Page 725 FROM ENGINE Serial Nr. 149487 The power steering pump heat shield has been replaced by a heat resistant covering wound directly around the pump itself and fastened with clips. Remove the engine compartment cosmetic shields ( E3.13). Remove the left hand lateral cosmetic shield. Working from above, undo the screw (4) fastening the mounting bracket for the rigid pipe leading from power steering pump to the...
Page 726 Remove the power steering pump (A) from the engine to afford access to the pipes fastened to the pump itself. Mark the position of the pipe. After marking the position of the pipe to facilitate correct refitting, undo the pipe union (7) and detach the pipe (8), retrieving the relative seals.
Page 727 Connect the pipe (10) onto the relative union on the power steering pump assembly (A) and fasten by tightening the clamp (9). Tightening torque Class Screw collar 4 Nm Fit the pipe (8), positioning correctly using the markings made during removal as reference, replace the seals and tighten the pipe union (7).
Page 728 Fasten the power steering pump assembly (A), by tightening the screws in the following sequence: (11) - (12). Tightening torque Class Screw 25 Nm Fasten the power steering pump assembly (A), by tightening the rear screw (13). Tightening torque Class Screw 25 Nm Fasten the A.C.
Page 729 UP TO ENGINE Serial Nr. 149486 Apply and tighten the screw (1) by tightening the power steering pump heat shield (3) to the engine. Tightening torque Class Screw 10 Nm UP TO ENGINE Serial Nr. 149486 Tighten the screw (19) fastening the arch bracket to the heat shield.
Page 730 Connect the steering column (23) to the steering box (22), by tightening the screw (24) fastening the universal joint (25). Tightening torque Class Special screw 30 Nm Fit the mounting bracket for the rigid pipe leading from the power steering pump to the steering box and fasten by tightening the screw (4).
Page 731 D5.04 Steering box Removing the steering box Disconnect the battery ( F2.01). Remove the wheels ( D2.01). Remove the front wheels. Remove the central flat undertray section ( E3.12). Drain the power steering system ( D5.07). If applicable, remove the brake air deflector (F) from the steering box tie-rod (G), detaching the fastener clip (5).
Page 732 Loosen the screw (3) fastening the joint (E). Disconnect the steering column (D) from the steering box (A). Unscrew the pipe union (5). Disconnect the pipe (6), retrieving the relative seals. Disconnect the connector (2). Undo the indicated nuts fastening the steering box (A) to the chassis.
Page 733 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the indicated nuts fastening the steering box (A) to the chassis. Undo the indicated nuts fastening the steering box (A) to the chassis. Remove the bracket (4).
Page 734 Tightening torque Class Fastening steering box to chassis Screw (pretightening) 25 Nm Screw 60 Nm Fastening cardan transmission hub - steering box Special screw 30 Nm shaft Fastening union connecting steering box - power Pipe union 35 Nm steering fluid radiator Fastening steering box spherical tie-rod to hub Nut (pretightening) 40 Nm...
Page 735 Fit the plate (4). Tighten the indicated nuts fastening the steering box (A) to the chassis. FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the indicated nuts fastening the steering box (A) to the chassis. Pre-tighten then definitively tighten the nuts fastening the steering box in an X pattern.
Page 736 Connect the connector (2). After replacing the seals, fit the pipe (6) leading from the radiator to the steering box in its relative seat and tighten the pipe union (5). Tightening torque Class Pipe union 35 Nm Connect the tie-rod (B) to the stub axle (C). Pretighten the nut (1).
Page 737 If applicable, fit the right hand brake air deflector (F) onto the steering box tie-rod (G), fastening the fastener clip (5). Perform the procedure on both sides of the vehicle. Refit the wheels ( D2.01). Refit the front ones. Connect the battery ( F2.01).
Page 738 D5.05 Oil radiator Removing the power steering fluid radiator Fit onto the radiator assembly, behind the front bumper. Remove the engine compartment cosmetic shields ( E3.13). Remove the front bumper ( E3.03). Drain the power steering system ( D5.07). Remove the rigid power steering fluid pipes (2) from the retainer clip (1).
Page 739 When refitting the same power steering fluid radiator, clean the radiator core thoroughly with compressed air before reinstalling. Replace the seals on the rigid pipes (2) before connecting to the radiator. Fit the power steering fluid radiator (A) on the relative mounting brackets and fasten by tightening the screws (4).
Page 740 D5.06 Steering column Removing the steering column Take particular care not to damage the structure, the plastic fasteners and the leather trim Disconnect the battery ( F2.01). Remove the central flat undertray section ( E3.12). Remove the steering wheel ( E5.09).
Page 741 On the left side, undo the two lower fastener screws on the steering column (A). On the right side, undo the two lower fastener screws on the steering column (A). Disconnect the connectors (2) and (3).
Page 742 Disconnect the connector (4). Disconnect the connector (5). Remove the two clips (6) fastening the foam rubber. From the passenger compartment, ease out the steering column (A) in order to remove the foam rubber (6).
Page 743 Undo the two screws (7) fastening the gaiter. From the passenger compartment, remove the steering column (A) from the vehicle. Refitting the steering column Tightening torque Class Steering column gaiter - firewall 9 Nm Fastening lower steering column - dashboard Screw 25 Nm cross member...
Page 744 Fit the foam rubber (6). Fit the two clips (6) fastening the foam rubber. From the passenger compartment, fit the steering column (A) in its seat by moving it forwards. Connect the connector (5). Connect the connector (4).
Page 745 Connect the connectors (2) and (3). On the right side, tighten the two lower screws fastening the steering column (A). Tightening torque Class Screw 25 Nm On the left side, tighten the two lower fastener screws on the steering column (A). Tightening torque Class Screw...
Page 746 Tighten the two upper screws fastening the steering column (A) to the dashboard. Note that it is not necessary to remove the lower left dashboard trim panel as shown in the photo. Tightening torque Class Screw 8 Nm Connect the steering column (A) to the steering box (B), by tightening the screw (1) fastening the universal joint (C).
Page 747 D5.07 Emptying and filling the system Draining the power steering system Remove the central flat undertray section ( E3.12). Undo the nuts (2), removing the power steering system pipe mounting brackets (3) from the steering box, moving the pipes out of the way so that they do not hinder the subsequent operations.
Page 748 Filling the power steering system Tightening torque Class Fastening union connecting pump pipe - steering Threaded union 35 Nm FROM Assembly No. 98002, a different power steering fluid is prescribed. The power steering fluid specified FROM Assembly No. 98002 must be used following installation of the components of the RETROFIT KIT Part No.
Page 749 Connect a suitable additional pipe to the power steering fluid reservoir return pipe. 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.
Page 750 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.
Page 751 E1.01 Tightening torques Tightening torque Class Fastening internal engine compartment cross Screw 34 Nm brace - chassis Fastening rear removable subframe to rear Screw 110 Nm suspension mounting casting Fastening rear removable subframe to extruded Screw 65 Nm rear diagonal joint Fastening rear removable subframe to rear Screw 100 Nm...
Page 752 Tightening torque Class Fastening windscreen washer/headlight washer Screw / Nut 7.5 Nm fluid tank Fastening flat undertray Screw 8 Nm Fastening glove compartment Screw 8.5 Nm Fastening steering column trim panel Screw 5 Nm Fastening underwindscreen cosmetic shields Screw 4.5 Nm Fastening wheelhouse Screw 2.5 Nm...
Page 753 Tightening torque Class Fastening passenger side airbag mounting Screw 8.5 Nm bracket - dashboard subframe Fastening lower central dashboard trim panel Screw 8.5 Nm Fastening lateral fastener between dashboard Screw 40 Nm and lateral mounting brackets Screw (pretightening) 25 Nm Fastening upper fastener between dashboard Screw 8.5 Nm...
Page 754 Tightening torque Class Hydraulic pump - left hand Tonneau Cover M6x22 screws 9 Nm kinematics Roof ECU - mounting bracket M10x20 screws 5 Nm Tonneau Cover - Tonneau Cover kinematics M8x50 screw 24 Nm Front Roof shell striker plates - windscreen cross M8x25 screw 20 Nm member...
Page 755 E1.02 Specific tooling and equipment Hook 95977567 (AS 107567) installing the RHT. Bar 95977568 (AS 107568) support for RHT kinematics L=1100. Tool 95977569 (AS 107569) support for hydraulic pump.
Page 756 Bar 95977570 (AS 107570) support for RHT kinematics L=806. Trolley 95977571 (AS 107571) support for complete RHT. Torque wrench 95978172 (AV 8172) (Replaces torque wrench USAG 815F)
Page 757 Riveter Battery Tool 95978173 (AV 8173) (see repair manual for aluminium bodyshell). Rod 95978178 (AV 8178) for RHT kinematics. Separator tool 95978179 (AV 8179) adjusting the Rear Roof shell striker plates...
Page 758 Template 95978180 (AV 8180) locating Rear Roof shell striker plates Feeler gauge 95978181 (AV 8181) checking Rear Roof shell striker plates Template 95978182 (AV 8182) checking Rear Roof shell striker plates...
Page 759 Safety retainers 95978183 (AV 8183) vehicle anti-tipping retention. Fastening brackets for safety retainers 95978184 (AV 8184) raised vehicle anti-tipping retention for runway type car lifts. Pins 95978350 (AV 8350) aligning engine mounting bushes with front removable subframe. Template kit (A7082600 - A7082600/TIN - A456) (see repair manual for aluminium bodyshell).
Page 760 E2.01 General Features of the chassis For the first time in a Ferrari, 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;...
Page 761 Chassis component overview A - Complete front subchassis B - Front removable subframe C - Internal engine compartment cross brace (boomerang) D - Rear removable subframe...
Page 762 E2.02 Front removable subframe Removing the front removable subframe Remove the internal engine compartment cross brace ( E2.04). Remove the central flat undertray section ( E3.12). When installing the strap for lifting the engine, take care not to crush or bend any of the cables and pipes of the different systems.
Page 763 Protect the windscreen area adequately with a cover (5). Connect the ends of the safety strap (1) to the hook on the lift bar (OMCN art. 275 A). When tautening the strap, take care not to bend or crush any cables or pipes. Turn the handle (6) connected to the lifting hook and tauten the safety strap (1).
Page 764 FROM Assembly No. 85739 Undo the screws indicated. Remove the reinforcement tube (20) from the front removable subframe (A). Support the weight of the front removable subframe adequately. Undo the screws (9). Undo the nut (10). Undo the screws (11) fastening the engine bushes to the front removable subframe (A).
Page 765 After loosening the final screws fastening the front removable subframe, ensure that the engine does not move and is held securely in place by the safety strap and the hydraulic jack. Undo the screws (15). Undo the screws (16). Undo the screws (17). Turn the bracket (19) to separate it from the hook (20) on the transmission housing bushing.
Page 766 Undo the screws indicated. Remove the bracket (7). Undo the indicated nut. Support the weight of the front removable subframe adequately. Undo the screws indicated. Remove the front removable subframe. Retrieve the engine bush spacers from the front removable subframe. Refitting the front removable subframe Tightening torque Class...
Page 767 Tightening torque Class suspension mounting casting Fastening engine mounting bush to front Screw 50 Nm removable subframe Fastening front removable subframe to 103 Nm transmission housing bushing Fastening front removable subframe to Screw 110 Nm transmission tunnel side member endpiece Fastening reinforcement tube - front removable Screw 24 Nm...
Page 768 Tighten some of the screws indicated. The screws are not all the same length. Before applying the screws, refer to the notes made during removal to ascertain which screws correspond to which positions. Undo the alignment pins 8350). Tighten the screws (17). Tightening torque Class Screw...
Page 769 Tighten the screws (11). Tightening torque Class Screw 50 Nm Tighten the nut (10). Tightening torque Class 103 Nm Tighten the screws (9). Tightening torque Class Screw 110 Nm FROM Assembly No. 85739 Fit the reinforcement tube (20) on the front removable subframe (A).
Page 770 Hand tighten the screw (18). FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit the engine mounting bush spacers in the respective seats on the front removable subframe. Fit the front removable subframe, supporting its weight adequately. Tighten some of the screws indicated.
Page 771 Tighten the indicated nut. Tightening torque Class 103 Nm Fit the bracket (7). Tighten the respective screws indicated. Tightening torque Class Screw 25 Nm Tighten the screws indicated. Tightening torque Class Screw 50 Nm After tightening all the fasteners of the front removable subframe, remove the hydraulic jack complete with tool 107566).
Page 772 Turn the handle (6) connected to the cross member lifting hook (OMCN art. 275 A) counterclockwise, and slacken the safety strap (1). Detach the ends of the safety strap (1) from the hook on the lift bar. Remove the lift bar (OMCN art. 275 A). Remove the safety strap (1).
Page 773 E2.03 Rear removable subframe Removing the rear removable subframe Remove the DCT gearbox ( C2.02). Remove the complete rear suspension ( D4.01). Remove both. Remove the exhaust extensions ( B7.05). Remove the rear removable subframe from the lift trolley 107565). Refitting the rear removable subframe Place the rear removable subframe on the lift trolley 107565), supporting the weight of the subframe...
Page 774 E2.04 Internal engine compartment cross brace Removing the internal engine compartment cross brace Remove the engine compartment cosmetic shields ( E3.13). Remove the lateral underwindscreen cosmetic shields. Remove the windscreen wiper linkage ( E3.09). UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Open the clips (1) and detach the pipes from the...
Page 775 Undo the screws (3) fastening the diagonal brace (A). Undo the screws (4) fastening the diagonal brace (A). Undo the screws (5) fastening the diagonal brace (A).
Page 776 Detach the indicated clip fastening the pipe (6). Protect the windscreen. Remove the diagonal brace (A), taking care not to bend or damage the rigid brake fluid pipes. Refitting the internal engine compartment cross brace Tightening torque Class Fastening internal engine compartment cross Screw 34 Nm brace - chassis...
Page 777 Fit the diagonal brace (A) in the relative seat, taking care not to bend or damage the rigid fluid pipes. Connect the indicated clip fastening the pipe (6). Fasten the diagonal brace (A), tightening the screws (5). Tightening torque Class Screw 34 Nm Loosen the screws (5) by half a turn and tighten...
Page 778 Tighten the screws (4) fastening the diagonal brace (A). Tightening torque Class Screw 34 Nm Loosen the screws (4) by half a turn and tighten again. Tightening torque Class Screw 34 Nm Tighten the screws (3) fastening the diagonal brace (A). Tightening torque Class Screw...
Page 779 UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fasten the brake fluid pipes in the relative supports and close the clips (1). Refit the windscreen wiper linkage ( E3.09). Refit the engine compartment cosmetic shields ( E3.13).
Page 780 E3.01 Engine compartment lid Removing the engine compartment lid If the engine compartment lid is to be reused, mark the positions of the hinges on the lid itself to facilitate adjustment upon reassembly. Detach the windscreen washer pipe (1) from the engine compartment lid (A), releasing the two retainer clips (2).
Page 781 Check that the lid closes properly and that it is equidistant on all sides of the vehicle bodyshell and perfectly flush in height at the front, at point (6). If the height is incorrect, adjust the swivel spacers (7) at the front of the engine compartment lid, turning them to adjust the height to the correct position.
Page 782 E3.02 Luggage compartment lid Removing the luggage compartment lid Before removing any fastener clamps and/or clips in the electronic system and/or hydraulic system, note the number and position of the components to ensure that they are refitted correctly during reassembly. Remove the luggage compartment trim panels ( E4.07).
Page 783 NEW SOLUTION Undo the screws indicated by the black arrows. Remove the clip indicated by the red arrow. Detach the cables from the clip (17). Remove the tape (16). On the right-hand side of the luggage compartment, disconnect the connectors (3) and (4) and undo the screw (1) fastening the ground cable (2).
Page 784 Detach the two hooks (15) (one per side) fastening the luggage compartment lid to the Tonneau Cover kinematics then open the luggage compartment lid completely. CAUTION Danger of accident! At least two operators are required to manually move the components of the RHT roof, working slowly and in a coordinated fashion.
Page 785 Adequately support the weight of luggage compartment lid. This operation requires at least two operators. Remove the clamp (7) fastening the cable grommet. Prise the cable grommet (8) out of the luggage compartment lid and pull out the light connector disconnected previously. Mark the position of the hinge on the luggage compartment lid to facilitate subsequent reassembly...
Page 786 Tightening torque Class Fastening hinges - luggage compartment lid Screw 20 Nm Fastening hinges - Tonneau Cover Screw 20 Nm Fastening luggage compartment lid striker plate Screw 20 Nm Before removing any fastener clamps and/or clips in the electronic system and/or hydraulic system, note the number and position of the components to ensure that they are refitted correctly during reassembly.
Page 787 Adequately support the weight of luggage compartment lid. This operation requires at least two operators. Fit the connector with cable into the hole on the luggage compartment lid. Fasten the cable grommet (8) onto the luggage compartment lid with the clamp (7). Tighten, applying the shims removed during disassembly, the two screws (9) fastening the hinge to the luggage compartment lid.
Page 788 On the right-hand side of the luggage compartment, connect the connectors (3) and (4) and hand tighten the screw (1) fastening the ground cable (2). Fasten the cables with a new retainer clamp (5). OLD SOLUTION Fasten the cables leading from the luggage compartment lid to the right hand Tonneau Cover kinematics as originally installed, fitting the gutter (13).
Page 789 NEW SOLUTION Tighten the screws indicated by the black arrows. Fit the clip indicated by the red arrow. Fasten the cables to the clip (17). Fit the strip (16) as originally fitted. Detach the two hooks (15) (one per side) fastening the luggage compartment lid to the Tonneau Cover kinematics then lock the luggage compartment lid in its original...
Page 790 With the lid closed, also check the height relative to the bodywork. If necessary, adjust the height with the shims (13). Once adjustment is complete, tighten the screws (9). Tightening torque Class Screw 20 Nm Tighten the screws (12). Tightening torque Class Screw 20 Nm...
Page 791 If the Tonneau Cover has been removed Once adjustment is complete, tighten the screws (14). Tightening torque Class Screw 20 Nm Check that the sill protector striker area is clear of any foreign objects preventing the flap from moving correctly If necessary, move the RHT electrically into the Coupé...
Page 792 Turn the ignition key clockwise and hold in this position to start the Spider to Coupé RHT roof cycle. When the cycle has almost ended - specifically, when the luggage compartment lid is approximately 50 ± 10 mm from completely closed - return the key to the vertical position, interrupting the RHT roof cycle.
Page 793 E3.03 Front bumper Removing the front bumper Remove the front flat undertray section ( E3.12). Remove the front wheelhouses ( E3.05). Remove the front element only of both front wheelhouses. Undo the two lower screws indicated fastening the front bumper (A). On the right side, undo the three lateral screws indicated fastening the front bumper (A).
Page 794 On the left side, undo the three lateral screws indicated fastening the front bumper (A). Remove the upper seal (1). Undo the seven upper screws indicated fastening the bumper (A) and remove the bumper from the vehicle.
Page 795 The vibration damper (2) on the vehicle chassis may now be replaced; the element is secured by two metal brackets. The vibration damper (3) glued to the front bumper may also be replaced. Refitting the front bumper Tightening torque Class Fastening front bumper Screw 7.5 Nm...
Page 796 Fit the bumper (A) on the vehicle, fitting the two lateral air intakes. Hand tighten the upper centre screw fastening the front bumper (A). On both sides of the vehicle, hand tighten the lateral centre screw fastening the front bumper (A). Check on both sides that the panel gap between the front bumper (A) and the front fender (B) is 1 mm (-0/+1).
Page 797 On the left side, tighten the three lateral screws fastening the front bumper (A). Tightening torque Class Screw 7.5 Nm On the right side, tighten the three lateral screws fastening the front bumper (A). Tightening torque Class Screw 7.5 Nm Tighten the two lower screws fastening the front bumper (A).
Page 798 E3.04 Rear bumper Removing the rear bumper Disconnect the battery ( F2.01). Remove the rear flat undertray diffuser ( E3.12). Remove the rear wheelhouses ( E3.05). Remove the rear section only of both rear wheelhouses. Remove the luggage compartment trim panels ( E4.07).
Page 799 Remove the three plugs indicated from their respective holes. Undo the three lower screws indicated fastening the rear bumper (A). Remove the cover (1) from the rear bumper (A), prising out with an appropriate tool. Undo the four centre screws indicated fastening the rear bumper (A).
Page 800 On the left-hand side, undo the lateral screw (2) fastening the rear bumper (A). On the right-hand side, undo the lateral screw (2) fastening the rear bumper (A). Remove the rear bumper from the vehicle. For vehicles with parking camera Undo the screws indicated.
Page 801 Tightening torque Class Fastening lateral mounting brackets for rear 4.5 Nm bumper Fastening lateral fastener for rear bumper Screw 7 Nm Fastening rear bumper Screw 7.5 Nm Connect the parking sensor connectors. For vehicles with parking camera Connect and fasten the cable (3). Hand tighten the screws indicated.
Page 802 On both sides, loosen the three nuts indicated fastening the respective lateral mounting brackets (C) for the rear bumper and adjust to obtain the correct panel alignment. On both sides, tighten the three nuts indicated fastening the respective lateral mounting brackets (C) for the rear bumper.
Page 803 On the left-hand side, tighten the lateral screw (2) fastening the rear bumper (A). Tightening torque Class Screw 7 Nm Tighten the four centre screws indicated fastening the rear bumper (A). Tightening torque Class Screw 7.5 Nm Refit the cover (1), pressing onto the rear bumper (A).
Page 804 Refit the three plugs indicated, pressing into the respective holes. On the right-hand side, tighten the two upper screws indicated fastening the rear bumper (A). Tightening torque Class Screw 7.5 Nm On the left-hand side, tighten the two upper screws indicated fastening the rear bumper (A).
Page 805 E3.05 Wheelhouse Removing the front wheelhouses These consist of two elements which may be removed independently of one another. Where they overlap, the two elements are both fastened by the same screw. Remove the wheels ( D2.01). Front element Remove the five fasteners (1): undo the three screws and prise out the two plastic inserts.
Page 806 Rear element Fit the rear element (B) inserting the underwindscreen shield water drain pipe into the relative hole. Fit it below the front element if it was removed alone. Fasten the rear element (B) with the six fasteners (2): tighten three screws and insert three plastic inserts.
Page 807 Rear element Remove the ten fasteners (1): undo nine screws and prise out the plastic insert. Remove the rear element (A). Front element Remove the seven fasteners (2): undo the three screws and prise out the four plastic inserts. Remove the front element (B). Refitting the rear wheelhouses Tightening torque Class...
Page 808 Front element Fit the front element (B). Fasten the front element (B) with the seven fasteners (2): tighten three screws and insert four plastic inserts. Tightening torque Class Screw 2.5 Nm Rear element Fit the rear element (A). Fasten the rear element (A) with the ten fasteners (1): tighten nine screws and insert a plastic insert.
Page 809 E3.06 Windscreen Removing the windscreen seal Detach the left hand part of the windscreen seal (A) from the relative seat on the left hand windscreen pillar. Detach the right hand part of the windscreen seal (A) from the relative seat on the right hand windscreen pillar.
Page 810 Undo the indicated screw fastening the windscreen seal (A) to the right hand windscreen pillar. Detach and remove the upper part of the windscreen seal from the relative seat on the windscreen cross member. Refitting the windscreen seal Tightening torque Class Fastening windscreen seal Screw...
Page 811 Tighten the indicated screw fastening the windscreen seal (A) to the left hand windscreen pillar. Tightening torque Class Screw 8 Nm Refit the roof trim panels ( E4.04). Fit the right hand part of the windscreen seal (A) in the relative seat on the right hand windscreen pillar.
Page 812 In the event of scratches or other windscreen damage, refer to the above diagram to define the zone in which the damage is located. Visibility zone A (blue line) Visibility zone B (green line) Note that the measurements in the previous image are with reference to the 458 Italia and 458 Spider. Replacing the windscreen Protect all painted bodywork parts and the cabin to prevent damage when using cutting equipment and when installing the new windscreen.
Page 813 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.
Page 814 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). If present, remove the sealant applied between the external windscreen pillar trim panels and the windscreen, then degrease with heptane to remove all adhesive or dust residue.
Page 815 Fasten the locator tab (1) to the bodyshell, pressing the relative pin downwards, then fit the adjustable spacer (2). Set the glass panel carefully on a stable surface so that it is not scratched or damaged. Degrease the perimeter of the glass with DOW BETACLEAN 3300 P/N 81636500 and leave to dry. Apply DOW BETAPRIME 5500 Green cap to the entire perimeter of the glass between the two dotted lines in the figure and leave the...
Page 816 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 around the entire perimeter of the windscreen. Apply a few strips of adhesive fabric tape SYROM 90, starting from the windscreen and fixing to the pillar and roof.
Page 817 Once the sealant has been applied, the area must look as shown in the photo aside. Wait at least 4 hours before refitting the removed components. Refit the windscreen seal ( E3.06).
Page 818 E3.07 Quarterlights Removing the complete quarterlight The following procedure is for removing the left hand quarterlight. The procedure for removing the right hand quarterlight is identical. Move the RHT roof into the Spider position. Remove the rear seats ( E4.01). Remove the foam rubber complete with mounting bracket (1), undoing the two screws indicated, then remove the bracket from the...
Page 819 Remove the filler foam rubber (5) and then the rubber cap (6) on the recess for the quarterlight preload adjuster dowel. Keep the quarterlight preload adjuster dowel (8) immobilised and loosen the fastener nut (7). Unscrew the rubber support (9), lift the internal window scraper seal (12), undo the screw (10) and lift the complete quarterlight (A) from the bodyshell.
Page 820 Detach the connector (11) and remove the complete quarterlight (A) from the vehicle. Refitting the complete quarterlight Tightening torque Class Fastening quarterlight assembly - bodyshell / Screw 9.5 Nm adjusting distance between quarterlight and door window Quarterlight preload adjustment 9 Nm The following procedure is for refitting the left hand quarterlight.
Page 821 Place the complete quarterlight (A) in the passenger compartment and connect the connector (11). Fit the complete quarterlight (A) in the relative seat and prepare for adjustment by moving as far back as possible. Tighten the two screws (10), fitting the rubber support (9) and internal window scraper seal (12) as originally installed.
Page 822 Tightening torque Class Fastening quarterlight assembly - bodyshell / Screw 9.5 Nm adjusting distance between quarterlight and door window Quarterlight rotation adjustment 9.5 Nm Quarterlight/door window alignment adjustment Screw 9.5 Nm Quarterlight preload adjustment 9 Nm Fastening front seat belt guide bracket Screw 24 Nm Remove the passenger compartment trim panels (...
Page 823 Should it be necessary to adjust the quarterlight, remove the filler foam rubber (15) and then the rubber cap (16) on the recess for the quarterlight preload adjuster dowel. To adjust correctly, the internal window scraper seal (14) for the quarterlight must be removed. IT IS IMPORTANT however that all adjustment checks are carried out with the seal (14) installed.
Page 824 Press the relative button to lower the quarterlight to approximately 10 mm from its upper travel limit on the Rear Roof shell seal. Once in this position, check that the quarterlight preload is correct. Check that the step between the Rear Roof shell pillar and the quarterlight is 8.5 ±...
Page 825 If the value measured is incorrect, adjust as follows. Loosen the screws (3). Manually move the quarterlight assembly into the correct position. Once adjustment is complete, tighten the two screws (3). Tightening torque Class Screw 9.5 Nm Check the distance between the quarterlight and the door window again.
Page 826 If the value measured is incorrect, adjust as follows. Loosen the screw (4) by a few thread turns. Holding the adjuster dowel (10) still to prevent it from turning, loosen the nut (9) by a few thread turns. Manually move the quarterlight into the correct position.
Page 827 Bring the RHT into Spider configuration and raise the door window and relative quarterlight. Check that the adjacent corners of the door window and the quarterlight are aligned correctly as shown in the photo aside when in Spider configuration. If the windows are not correctly aligned, proceed as follows: Remove the door panel ( E3.08).
Page 828 If removed previously, refit the rubber cap (16) in the recess for the quarterlight preload adjuster dowel and the filler foam rubber (15), after shaping by hand as required, as originally fitted. If removed previously, refit the foam rubber (19), gluing into place as originally fitted.
Page 829 Replacing the quarterlight glass Tightening torque Class Fastening quarterlight glass - lift mechanism Screw 6.5 Nm Products to use: AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK Remove the complete quarterlight ( E3.07). Set the complete quarterlight down in a safe place. Mark the position of the glass being replaced to ensure that the new component is correctly adjusted.
Page 830 Remove the three bushings (2); cut the sealant if necessary. Remove the sealant, remove the quarterlight glass (A) and replace. Remove the three bushings (3); Remove all traces of sealant from the quarterlight mechanism fastenings. Fit the three bushings (3) in the relative seats. Fit the quarterlight glass (A) on the mechanism, using the markings made during removal as reference.
Page 831 Fit the three bushings (2) in the relative holes on the quarterlight glass (A). Fit the three washers (1). Apply AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK to the threads of the fastener screws. Keeping the washers and bushings correctly aligned, snug the three indicated screws fastening the quarterlight glass (A), following the procedure indicated in the photo aside.
Page 832 Tightening torque Class Fastening quarterlight window scraper seal Screw 2.5 Nm The following procedure is for replacing the left hand quarterlight window scraper seal. The procedure for replacing the right hand quarterlight window scraper seal is identical. Remove the complete quarterlight ( E3.07).
Page 833 Detach the rear section of the window scraper seal (A). Remove the window scraper seal (A) from the relative seat and replace. Fit the new window scraper seal (A) in the relative seat, fitting onto the rear lip and fastening the rubber peg into the relative square hole in the bodyshell.
Page 834 E3.08 Doors Removing the complete door The following procedure is for removing the left hand door. The procedure for removing the right hand door is identical. Disconnect the battery ( F2.01). Disconnect the connector (1). Undo the screw (2) fastening the tie-rod. Undo the two screws (3) fastening the door to the hinges.
Page 835 Fit the complete door (A) on the hinges. Tighten the two screws (3) fastening the door to the hinges. Tightening torque Class Screw 18 Nm Tighten the screw (2) fastening the tie-rod. Tightening torque Class Screw 30 Nm Connect the connector (1). Connect the battery ( F2.01).
Page 836 Open the door. Loosen the two screws indicated fastening the striker plate (A) to the bodyshell. Adjust the striker plate (A) into the correct position. Check that the door opens and closes without sticking. Tighten the two screws fastening the door striker plate (A) to 80% of the rated tightening torque.
Page 837 Disconnect the battery ( F2.01). Using a suitable tool, prise out the centre door panel trim (A) from its seat. Using a suitable tool, prise out and remove the loudspeaker grille (B) from its seat. Turn the air vent ring nut (C) counterclockwise and remove from its seat.
Page 838 Disconnect the two connectors (2) from the door node. Disconnect the connector (3) from the side airbag. Disconnect the connector (4) from the puddle light unit.
Page 839 For the left hand panel only Disconnect the connector (5) from the external mirror control. Detach the cable (6) from the internal door release handle, then release from the indicated retainers. Remove the door panel from the vehicle. Refitting the door panel Tightening torque Class Fastening door panel...
Page 840 Fit the cable (6) in the indicated retainers. Attach the cable (6) to the internal door release handle. For the left hand panel only Connect the connector (5) to the external mirror control. Connect the connector (4) to the puddle light unit.
Page 841 Connect the connector (3) to the side airbag. Connect the two connectors (2) to the door node. Connect the connector (1) to the tweeter.
Page 842 Fit the door panel (D) on the door, attaching the upper part and pressing towards the door. Tighten the thirteen screws indicated fastening the door panel (D). Tightening torque Class Screw 8 Nm Fit the air vent ring nut (C) in the relative seat and turn clockwise.
Page 843 Remove the internal handle (B) from the relative seat, separating the upper part from the door panel and the lower part from the door release lever (C). Remove the door release lever (C) from the relative seat, pulling upward. Remove the plate (D) from the relative seat. Undo the four screws indicated fastening the door release handle mounting bracket (A) to the door panel.
Page 844 Fit the plate (D) in the relative seat. Fit the door release lever (C) in the relative seat, pressing downward. Check that the lever (C) is parallel with the door panel and moves without impediment. Fit the internal handle (B) in the relative seat, fitting the upper part on the door panel and the lower part on the door release lever (C).
Page 845 Remove the door panel ( E3.08). DO NOT disconnect the door panel connectors. Detach the lower part of the internal door window scraper seal (A), removing the relative fastener pegs from the door subframe. Undo the upper screw (1) fastening the internal door window scraper seal (A).
Page 846 The procedure for refitting the internal scraper seal for the left hand door window is the same. Fit the internal window scraper seal (A) in the relative seat on the door subframe and insert the upper part. Tighten the upper screw (1) fastening the internal door window scraper seal (A).
Page 847 Remove the waterproof membranes (A) from the respective seats. Undo the screw (1) fastening the door window to the rear power window mechanism guide. Undo the screw (2) fastening the door window to the front power window mechanism guide. Carefully remove the door window from the relative seat, removing via the upper slit in the door subframe.
Page 848 Set the door window (B) down on a soft surface. Remove the pad (C) from the door window (B). Refitting the door window Tightening torque Class Fastening door window Screw 9.5 Nm Fit the pad (C) in the relative seat on the door window (B).
Page 849 Tighten the screw (2) fastening the door window to the front guide. Tightening torque Class Screw 9.5 Nm Tighten the screw (1) fastening the door window to the rear guide. Tightening torque Class Screw 9.5 Nm Check and adjust the door window ( E3.08).
Page 850 Tightening torque Class Fastening door window Screw 9.5 Nm Fastening lower fastener between power window 9.5 Nm unit guides - door Distance from quarterlight glass With the door closed, press the power window button and check that the window rolls smoothly and stops in the correct position.
Page 851 Press the relative button to lower the power window and allow access to the relative fasteners. Slightly loosen the two screws (2) fastening the door window to the mounting brackets. Manually correct the position of the door window. Once adjustment is complete, tighten the two screws (2).
Page 852 Remove both waterproof liner sheets (1). Press the relative button to lower the power window and allow access to the relative fasteners. Loosen the two screws (2) fastening the door window to the relative mounting brackets. Manually correct the position of the door window. Once adjustment is complete, tighten the screws (2).
Page 853 Working from underneath the door, remove the two plugs (7). Working from underneath the door, loosen the two lower nuts (8) fastening the power window unit guides. Adjust the power window unit guides to bring them into the correct position (keeping as close as possible to the upper 11 mm margin).
Page 854 If removed previously, refit both waterproof membranes (1). Refit the door panel ( E3.08). If removed previously. Replacing the external door window scraper seal Tightening torque Class Fastening external window scraper seal - door Screw 4 Nm The following procedure is for replacing the external scraper seal for the left hand door window. The procedure for replacing the external scraper seal for the right hand door window is the same.
Page 855 Carefully detach and remove the external window scraper seal (A) from the relative seat, starting from the rear end. Replace the external window scraper seal (A). Fit and insert the external window scraper seal (A) in the relative seat, starting from the front end.
Page 856 Detach and remove the strip of protective foam (1) from the door subframe. Undo the two lower nuts indicated fastening the front guide (A) and the rear guide (B). Undo the two upper screws indicated fastening the front guide (A) and the rear guide (B). Detach the clip (2) from the door subframe.
Page 857 Disconnect the connector (4) from the power window unit microswitch. The connector (4) is fastened to the interior of the door frame. Carefully remove the power window unit from the relative seat, removing first the rear guide and then the motor and the front guide from the relative recess.
Page 858 Tighten the three nuts indicated fastening the power window motor (C) to the door subframe. Tightening torque Class 9.5 Nm Connect the connector (3) to the power window motor (C). Attach the clip (2) to the door subframe. Tighten the two upper screws indicated fastening the rear guide (B) and the front guide (A).
Page 859 Apply grease Z2 PROTECTION to the lower (5) and upper pulleys of the rear power window unit guide (B). Apply grease Z2 PROTECTION to the lower (6) and upper pulleys of the front power window unit guide (A). Refit the door window ( E3.08).
Page 860 Undo the screw (1) fastening the external body (A) of the external door handle to the inner body. Remove the external body (A) of the external door handle from the relative seat. Refitting the external body of the external door handle Tightening torque Class Fastening external body of external door handle...
Page 861 Push the seal (B) for the external body (A) of the external door handle into the relative seat. Replacing the internal body of the external door handle Tightening torque Class Fastening internal body of external door handle 5 Nm Lift the door window completely with the relative control. Disconnect the battery ( F2.01).
Page 862 Disconnect the connector (1). Detach the clip (2) from the internal body (A) of the external door handle. Undo the four nuts indicated fastening the internal body (A) of the external door handle. Remove the internal body (A) of the external door handle from the respective seat on the door subframe, retrieving the relative shim (3).
Page 863 Tightening torque Class Fastening door lock Screw 9.5 Nm Lift the door window completely with the relative control. Disconnect the battery ( F2.01). Remove the door panel ( E3.08). Disconnect the connector (1) from the door lock (A). On driver side door lock only Detach the pin (2) from the door lock (A).
Page 864 Detach the Bowden cable (B) from the door lock (A). NEW SOLUTION Cut the indicated cable ties retaining the Bowden cable (3) and the electric cable of the power window motor (4). Undo the three screws indicated fastening the door lock (A) to the door subframe. Remove the door lock (A) from the relative seat in the door subframe and replace.
Page 865 NEW SOLUTION Fit new cable ties as indicated to fasten the Bowden cable (3) and the electric cable of the power window motor (4). Ensure that the Bowden cable (3) is taut. Attach the Bowden cable (B) to the door lock (A). If necessary, apply grease Z2 PROTECTION to the Bowden cable spring (B).
Page 866 Connect the connector (1) to the door lock (A). Refit the door panel ( E3.08). Connect the battery ( F2.01). Replacing the door latch Tightening torque Class Fastening door latch 5.5 Nm Our Spare Parts Service Dept. supplies a complete lock kit, therefore, when replacing the door lock control block, all the locks on the vehicle must be replaced.
Page 867 Undo the two nuts indicated fastening the latch (A) to the door subframe. Remove the latch (A) from the relative seat on the door subframe, detaching the pin (2) from the door lock (B), and replace. Fit the new latch (A) in the relative seat on the door subframe, attaching the pin (2) to the door lock (B).
Page 868 E3.09 Windscreen wiper Replacing the windscreen wiper blades Lift the lever (1) fastening the windscreen wiper blade. Remove the wiper blade (A), pressing in the direction indicated to release it from the windscreen wiper arm (B). Lift the windscreen wiper arm (B) slightly to facilitate removal of the windscreen wiper blade.
Page 869 Undo the nuts (2) fastening the windscreen wiper arms to the linkage. Remove the arms (A). Refitting the windscreen wiper arms Tightening torque Class Fastening windscreen wiper arms 35 Nm Refit the arms (A) on the drive spindles, keeping the wiper blades in their original positions relative to the windscreen.
Page 870 Fit the caps (1). Removing the windscreen wiper linkage The linkage is located on the left-hand side of the engine compartment, under the left hand underwindscreen shield. Disconnect the battery ( F2.01). Remove the engine compartment cosmetic shields ( E3.13). Remove the left hand cosmetic underwindscreen shield.
Page 871 Position the windscreen wiper linkage (A), complete with motor, into its seat. Tighten the three screws indicated fastening the linkage to the chassis. Tightening torque Class Screw 8 Nm Connect the connector (1). Refit the engine compartment cosmetic shields ( E3.13).
Page 872 E3.10 Windscreen washer and headlight washer Windscreen washer system layout A - Windscreen washer/headlight washer fluid tank B - Windscreen washer pump C - Windscreen washer pipes D - Windscreen washer spray nozzles E - Check valve The windscreen washer system consists of a fluid tank (A), which is shared with the headlight washer system, an electric pump (B) and two spray nozzles (D).
Page 873 A - Windscreen washer/headlight washer fluid tank B - Headlight washer pump C - Headlight washer pipes D - Headlight washer spray nozzles The headlight washer system consists of a fluid tank (A), which is shared with the windscreen washer system, an electric pump (B), a timer and two telescopic spray nozzles (D).
Page 874 In the event of fluid leakage from the windscreen washer fluid reservoir, before starting any work, check the marking on the bottom of the windscreen washer fluid reservoir itself with the following procedure: From the wheelhouse, after removing the rear element of the wheel bay, take a photograph of the marking on the bottom of the windscreen washer fluid reservoir...
Page 875 Undo the five fasteners (screws and nuts) indicated fastening the windscreen washer/headlight washer pump (A) to the chassis. Detach the filler neck (B) from the tank. Remove the windscreen washer/headlight washer pump from the wheel bay, disconnecting the connector (3) from the fluid level sensor, then remove the filler neck.
Page 876 Working from the front left wheel bay, fit the windscreen washer/headlight washer fluid tank and the filler neck in the relative seat, connecting the connector (3) to the fluid level sensor. Connect the filler neck (B) to the tank (A). Tighten the five fasteners indicated (screws/nuts) fastening the windscreen washer/headlight washer fluid tank (A).
Page 877 Remove the windscreen washer/headlight washer fluid sensor (A), complete with seal, from the relative seat and replace. Fit the new windscreen washer/headlight washer fluid sensor (A), complete with new seal, in the relative seat, pressing until it clicks audibly into place. Refit the windscreen washer/headlight washer fluid tank ( E3.10).
Page 878 Remove the headlight washer pump (A) from the relative seat and replace. Fit the new headlight washer pump (A) in the relative seat, pushing until it snaps audibly into place. Refit the windscreen washer/headlight washer fluid tank ( E3.10).
Page 879 E3.11 Door perimeter trim panels Removing the kickplate The following procedure is for removing the left hand kickplate. The procedure for removing the right hand kickplate is identical. Detach the door bay perimeter seal strip (A). Using a suitable tool, detach and remove the kickplate (B).
Page 880 Ensure that the surface of the seat for the kickplate (B) is clean. If necessary, clean with a degreasing product. Fit the kickplate (B) correctly in the relative seat, pressing over the entire outer surface to fix evenly. Refit the door bay perimeter seal strip (A). Removing the door sill trim panel The following procedure is for removing the right hand door sill trim panel.
Page 881 Undo the four upper screws indicated fastening the door sill trim panel (A). Undo the rear screw fastening the door sill trim panel (A). Undo the indicated screw fastening the rear element of the flat undertray (B) and the door sill trim panel (A) to the bodyshell.
Page 882 Undo the two lower screws indicated fastening the door sill trim panel (A). Remove the door sill trim panel (A) from the relative seat. Refitting the door sill trim panel Tightening torque Class Fastening flat undertray Screw 8 Nm Fastening front and rear door sill trim panel Screw 2.6 Nm fasteners...
Page 883 Tighten the indicated screw fastening the rear element of the flat undertray (B) and the door sill trim panel (A) to the bodyshell. Note that the wheelhouse and relative wheel are shown in the image aside. These components must be removed. Tightening torque Class Screw...
Page 884 Tighten the three front screws indicated fastening the door sill trim panel (A). Tightening torque Class Screw 2.6 Nm Refit the lateral flat undertray sections ( E3.12). Refit the front wheelhouses ( E3.05). Refit the rear wheelhouses ( E3.05). Refit the kickplate ( E3.11).
Page 885 Detach the front end of the quarterlight window scraper seal (C). Detach the rear end of the door seal (B). Very carefully, completely detach and remove the door seal (B) from the relative seat. Refitting the door seal The following procedure is for refitting the left hand door seal. The procedure for refitting the right hand door seal is identical.
Page 886 E3.12 Flat undertray sections and vehicle lifting Lifting the vehicle CAUTION Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0 (Key- OFF). 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"...
Page 887 Lifting the vehicle with anti-tipping safety retainers CAUTION Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0 (Key- OFF). 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"...
Page 888 Fit the spacers (1) for preventing the vehicle lift arms from coming into contact with the sill trim panel during manoeuvring in the holes previously used for the rubber blocks. The spacers (1) are supplied in different sizes. Fit the sleeves (2) on the shims (1). Fit the washers (3) on the sleeves (2).
Page 889 Turn the positioning levers (7) until the eccentric pin head (4) retracts into the correct position to allow the insertion of the anti-tipping safety retainers into the relative fastener slots. Completely tighten the screws (9) fastening the positioning levers (7). Lower the vehicle lift arms, without allowing the screws (9) fastening the positioning levers (7) to come into contact with the floor, as this...
Page 890 Move the car lift arms manually to align the anti- tipping safety retainers with the relative fastener slots on the car, to ensure correct engagement when lifting. If the arms of the vehicle lift come into contact with the sill trim panels, add spacers as described previously.
Page 891 Removing the engine Detach and remove the plugs (C) from the front fastener slots. Removing the gearbox Detach and remove the plugs (B) from the rear fastener slots. Remove the runway safety extensions (D) from the relative seats.
Page 892 Fit the upper plates (1) of the brackets 8184) fastening the anti-tipping safety retainers 8183) onto the safety extensions on the car lift runways. The anti-tipping safety retainers must be as close as possible to the vehicle lift runway safety extensions, as shown in the image aside.
Page 893 Working carefully and ensuring that the anti- tipping safety retainers are correctly aligned with the respective fastener slots on the vehicle, raise the vehicle lift runways until the anti-tipping safety retainers engage in the respective fastener slots. Lift the vehicle slightly off the ground and check that it is stable.
Page 894 Removing the engine Fit and apply the plugs (C) in the front fastener slots. Removing the gearbox Fit and apply the plugs (B) in the rear fastener slots. Undo and remove the screws (9) fastening the positioning levers (7) onto the bushings (6). Holding the positioning levers to prevent them from turning (7), undo the nuts (8).
Page 895 Refit the pads (A) on the relative arms on the car lift. Runway type vehicle lift Lower the vehicle lift runways until the car is the desired height from the ground. Loosen the screws (3) fastening the positioning levers (6). Tighten the positioning levers (6).
Page 896 Fit the runway safety extensions (B) in the relative seats. Removing the gearbox Fit and apply the plugs (B) in the rear fastener slots. Removing the engine Fit and apply the plugs (C) in the front fastener slots.
Page 897 Lower the vehicle lift runways completely. Remove the rubber blocks (A). Removing the central flat undertray section Undo the screws indicated. Remove the central flat undertray section. FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the screws indicated.
Page 898 Tightening torque Class Fastening flat undertray Screw 8 Nm Fit the front flat undertray section, inserting the oil drain pipe (1) in the respective hole. Tighten the screws indicated. Tightening torque Class Screw 8 Nm FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Fit the front flat undertray section, inserting the...
Page 899 Undo the screws indicated. Remove the rear flat undertray section, prising it out of the two lateral sections. Refitting the rear flat undertray section Tightening torque Class Fastening flat undertray Screw 8 Nm Fit the rear section of the flat undertray, pushing it under the lateral sections and inserting the fuel filler tray drain pipe indicated into the relative hole.
Page 900 Tighten the indicated screws, fitting the respective washers. Tightening torque Class Screw 8 Nm Refit the rear flat undertray diffuser ( E3.12). Removing the front flat undertray section Remove the central flat undertray section ( E3.12). Undo the screws indicated. Remove the front flat undertray section.
Page 901 Fit the front flat undertray diffuser, inserting the coolant breather pipe and the power steering fluid breather pipe in the respective wire guide holes. Tighten the screws indicated. Tightening torque Class Screw 8 Nm Refit the central flat undertray section ( E3.12).
Page 902 Tightening torque Class Fastening flat undertray Screw 8 Nm Fit the rear flat undertray diffuser. Tighten the screws indicated. Tightening torque Class Screw 8 Nm Removing the lateral flat undertray sections Undo the indicated screws, retrieving the respective washers. Remove the left hand lateral element of the front flat undertray section.
Page 903 Undo the indicated screws, retrieving the respective washers. Remove the right hand lateral element of the front flat undertray section. Refitting the lateral flat undertray sections Tightening torque Class Fastening flat undertray Screw 8 Nm Fit the left hand lateral element of the flat undertray section.
Page 904 Fit the right hand lateral element of the flat undertray, inserting the pipe (1) in the relative hole. Tighten the indicated screws, fitting the respective washers. Tightening torque Class Screw 8 Nm...
Page 905 E3.13 Engine compartment guards Engine compartment cosmetic shields A - Right hand lateral cosmetic shield B - Left hand lateral cosmetic shield C - Front cosmetic shield D - Right hand underwindscreen cosmetic shield E - Left hand underwindscreen cosmetic shield Removing engine compartment cosmetic shields CAUTION Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0 (Key-...
Page 906 Undo the five screws indicated and remove the left hand central cosmetic shield (B), after detaching it from the seal (3). Undo the five screws indicated and remove the right hand central cosmetic shield (A), after detaching it from the seal (2). Front cosmetic shield Undo the two front screws on the cosmetic shields on the fenders to facilitate the removal...
Page 907 Remove lateral cosmetic shields Prise out the relative portion of the seal (1). Undo the eight screws and the two inserts fastening the right underwindscreen shield (F). Detach the shield from the windscreen, pull out toward the front of the vehicle and disconnect the drainage pipe (2).
Page 908 Fit the left hand central cosmetic shield (B), install the seal (3) then fasten the shield by hand tightening the five screws indicated. Fit the right hand central cosmetic shield (A), install the seal (2) then fasten the shield by hand tightening the five screws indicated.
Page 909 Lubricate the contact surfaces between the windscreen and the left hand underwindscreen shield (G) with soapy water. Connect the water drainage pipe (3) to the left hand underwindscreen shield (G), tightening the relative screw collar. Fit the left hand underwindscreen shield (G), pressing manually along the windscreen to snap into place.
Page 910 E3.14 Fuel filler neck and fuel filler flap Removing the fuel filler neck CAUTION Fuel is highly flammable. NEVER WORK ON A HOT ENGINE. The filler neck is located in the rear right hand wheel bay. Remove the rear wheelhouses ( E3.05).
Page 911 Fit the fuel filler neck (A) in its seat in the right hand wheel bay, after fitting the relative seal between the neck and the seat (7). Fit the ground cable (6) on the front stud bolt and tighten the nuts (5) fastening the fuel filler neck (A) to the bodyshell.
Page 912 Undo and remove the cap (A). Undo the screws indicated. Remove the actuator (B). Detach the cable (2) from the actuator (B). Undo the indicated screw. Detach and remove the recess (C), easing out from the actuator side first. Disconnect the fuel drain pipe. Replace the recess (C).
Page 913 Fasten the cable (2) to the actuator (B). Fit the actuator (B). Tighten the screws indicated. Tightening torque Class Screw 2.6 Nm Tighten the cap (A). Connect the connector (1). Refit the rear wheelhouses ( E3.05). Connect the battery ( F2.01).
Page 914 Open the fuel filler flap (A) with the relative button and undo the three screws indicated. Replace the fuel filler flap (A) and fasten by tightening the three screws indicated. Close the fuel filler flap (A) and check that it is flush with the bodywork.
Page 915 E3.15 Tow hook Tow hook CAUTION Always comply with road safety legislation when towing the vehicle. Do not connect toe lines to suspension arms, suspension components or wheels. Connect only to the specific tow hook, after fitting the toe hook in its relative mounting. Remember that the power steering and brake servo do not function with the engine off.
Page 916 E4.01 Seats Removing the front seats To facilitate removal and refitting, preferably open the retractable hard top completely. Disconnect the battery ( F2.01). Move the seat all the way forwards. Tip the backrest forwards. Remove the two rear seat rail end caps (4), pressing on the clip indicated.
Page 917 Undo the two front fastener screws on the seat (A). Lift the seat and disconnect the connectors (1) and (2) of the controls. On the driver side seat are two connectors, while on the passenger side seat there is only one. Remove the seat from the vehicle.
Page 918 Fit the seat in the vehicle. Connect the connectors (1) and (2) of the controls and lower the seat. On the driver side seat are two connectors, while on the passenger side seat there is only one. Move the seat all the way back (A). Tighten the two front fastener screws on the seat (A).
Page 919 Move the seat all the way forwards (A). Tip the backrest (A) forwards. Tighten the two rear fastener screws on the seat (A). Tightening torque Class Screw 42 Nm Fit and fasten the two rear seat rail end caps (4), pressing on the clip indicated.
Page 920 Release the rear seat backrests (A) by pulling the relative levers (1) in the luggage compartment. Push the rear seat backrests (A) forwards to fold. Undo the six screws indicated fastening the rear seat backrests (A). Remove the rear seat backrests (A) from the vehicle, pulling toward the front of the vehicle.
Page 921 Undo the four screws indicated fastening the backrest (A). Remove the rear bench backrest (A) from the vehicle, pulling forwards. Refitting the rear backrest Tightening torque Class Fastening rear seat backrests Screw 12 Nm Take particular care not to damage the structure, the plastic fasteners and the leather trim To facilitate removal and refitting, preferably open the retractable hard top completely.
Page 922 Fit the backrest (A) in the relative seat. Tighten the four screws indicated fastening the rear bench backrest (A). Tightening torque Class Screw 12 Nm Lift the backrest and fasten to the relative latches. Removing the rear seats Take particular care not to damage the structure, the plastic fasteners and the leather trim The rear seats are installed in the 2+2 Version only.
Page 923 Undo the indicated nut fastening the branch (B) of the left hand rear seat belt. Remove the branch (B) of the left hand rear seat belt from its relative seat. Prise out and remove the cover (A) for the branch of the right hand rear seat belt from its relative seat.
Page 924 Undo the right hand lateral screw fastening the rear seats (C). Undo the left hand lateral screw fastening the rear seats (C). UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Remove the rear seat cushions, which are held in place with Velcro.
Page 925 Undo the two central screws indicated fastening the rear seats (C). Note that the photo shows the vehicle with the luggage compartment trim panels removed. However, removal of these components is not necessary. UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Press the lower parts of the rear seats (C) at the...
Page 926 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Undo the indicated nuts on the rear seats (C). Remove the rear seats from the passenger compartment. Refitting the rear seats Tightening torque Class Fastening rear seats - bodyshell Screw 5 Nm...
Page 927 Tighten the two central screws indicated fastening the rear seats (C). Note that the photo shows the vehicle with the luggage compartment trim panels removed. However, removal of these components is not necessary. Tightening torque Class Screw 7 Nm UP TO Assembly No. 103178 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) If applicable, tighten the nut indicated fastening...
Page 928 FROM Assembly No. 103179 (consult the Spare Parts Catalogue to identify vehicles not affected by modification) Tighten the indicated nuts on the rear seats (C). Tightening torque Class 7 Nm Fit the rear seat cushions, which are held in place with Velcro. Tighten the left hand lateral screw fastening the rear seats (C).
Page 929 Fit the branch (B) of the right hand rear seat belt in its relative seat. Tighten the indicated nut fastening the branch (B) of the right hand rear seat belt. Tightening torque Class 40 Nm Pressing manually, refit the cover (A) for the branch of the right hand rear seat belt in its relative seat.
Page 930 Pressing manually, refit the cover (A) for the branch of the left hand rear seat belt in its relative seat. Refit the passenger compartment trim panels ( E4.04). Refit the lower lateral trim panels. Refit the rear backrest ( E4.01). Removing the luggage bench Take particular care not to damage the structure, the plastic fasteners and the leather trim The luggage bench is installed in the 2 seat Version only.
Page 931 Undo the left hand lateral screw fastening the bench (C). Undo the two centre screws indicated fastening the bench (C). Note that the photo shows the vehicle with the luggage compartment trim panels removed. However, removal of these components is not necessary.
Page 932 Tightening torque Class Fastening rear bench - bodyshell Screw 5 Nm Fit the bench (C) in the relative seat, inserting the luggage retainer straps through the slots. Press the lower parts of the rear seats (C) at the points corresponding to the fasteners on the bodyshell to fasten into the respective retainers.
Page 933 Tighten the right hand lateral screw fastening the bench (C). Tightening torque Class Screw 5 Nm Fasten the two luggage retainer straps (A). Refit the passenger compartment trim panels ( E4.04). Refit the lower lateral trim panels. Refit the rear backrest ( E4.01).
Page 934 E4.02 Dashboard Removing the steering column trim panel The panel is mounted on the steering column and consists of two elements (a lower element and an upper element). Disconnect the battery ( F2.01). Undo the three screws indicated fastening the lower element (1) of the steering column trim panel.
Page 935 On the left hand side, undo the two fastener screws for the upper element (3) of the steering column trim panel. On the right hand side, undo the two fastener screws for the upper element (3) of the steering column trim panel. Remove the upper element (3) of the steering column trim panel.
Page 936 Fit the upper element (3) of the steering column trim panel and hand tighten the two fastener screws indicated on the right hand side. On the left hand side, apply and hand tighten the two fastener screws for the upper element (3) of the steering column trim panel.
Page 937 Tighten the three screws indicated fastening the lower element (1) of the steering column trim panel. Tightening torque Class Screw 5 Nm Connect the battery ( F2.01). Removing the driver side underdashboard trim panel Disconnect the battery ( F2.01). Undo the screw fastening the left-hand side of the left hand under-dashboard trim panel (A).
Page 938 Disconnect the connector (1) from the left hand footwell light Remove the left hand underdashboard trim panel (A) from the relative seat. Refitting the driver side underdashboard trim panel Tightening torque Class Fastening the dashboard trim panels Screw 2.6 Nm Fit the left hand underdashboard trim panel (A) in the relative seat.
Page 939 Tighten the screw indicated fastening the right- hand side of the left hand under-dashboard trim panel (A). Tightening torque Class Screw 2.6 Nm Tighten the screw indicated fastening the left- hand side of the left hand under-dashboard trim panel (A). Tightening torque Class Screw...
Page 940 Undo the screw fastening the right-hand side of the right hand under-dashboard trim panel (A). Disconnect the connector (1) from the right hand footwell light. Remove the right hand underdashboard trim panel (A) from the relative seat. Refitting the passenger side underdashboard trim panel Tightening torque Class Fastening the dashboard trim panels...
Page 941 Fit the right hand underdashboard trim panel (A) in the relative seat. Connect the connector (1) to the right hand footwell light. Tighten the screw indicated fastening the right- hand side of the right hand under-dashboard trim panel (A). Tightening torque Class Screw 2.6 Nm...
Page 942 Disconnect the battery ( F2.01). Remove the steering column trim panel ( E4.02). On the left-hand side, undo the screw indicated fastening the instrument panel (B) to the dashboard. On the right-hand side, undo the screw indicated fastening the instrument panel (B) to the dashboard.
Page 943 Undo the two screws indicated fastening the binnacle (A) to dashboard. Remove the binnacle (A), complete with instrument panel (B), from the dashboard. Disconnect the connectors (2) and (3) from the instrument panel. Refitting the binnacle Tightening torque Class Fastening the dashboard trim panels Screw 2.6 Nm Take particular care not to damage the structure, the plastic fasteners and the leather trim...
Page 944 Connect the connectors (2) and (3) to the instrument panel. Fit the binnacle (A), complete with instrument panel (B), in the respective seat on the dashboard. Tighten the two screws indicated fastening the binnacle (A) to dashboard. Tightening torque Class Screw 2.6 Nm Fit the central moulding (1) on the binnacle (A)
Page 945 On the right-hand side, tighten the screw indicated fastening the instrument panel (B) to the dashboard. Tightening torque Class Screw 2.6 Nm On the left-hand side, tighten the screw indicated fastening the instrument panel (B) to the dashboard. Tightening torque Class Screw 2.6 Nm...
Page 946 Undo the two screws indicated fastening the cover panel (A). Remove the cover panel (A) from the dashboard. Detach the two clips fastening the leather flap (1). Fold the leather flap (1) down. On the left-hand side, undo the upper screw (2) fastening the lower left hand trim panel.
Page 947 On the right-hand side, undo the upper screw (3) fastening the lower left hand trim panel. Detach and remove the left hand lateral cover (G) from the dashboard. Undo the lateral screw (4) fastening the lower left hand trim panel (B).
Page 948 Undo the two lower screws fastening the lower left hand trim panel (B). Detach the upper part of the lower left hand trim panel (B) and disconnect the connector (5) from the parking brake control button panel. Remove the lower left hand trim panel (B) from the dashboard.
Page 949 Connect the connector (5) to the parking brake control button panel. Fit the lower left hand trim panel (B) in the respective seat on the dashboard. Tighten the two lower screws fastening the lower left hand trim panel (B). Tightening torque Class Screw 2.6 Nm...
Page 950 Fit the left hand lateral cover (G) in its respective seat on the dashboard and fasten by pressing manually until it snaps audibly into place. On the right-hand side, tighten the upper screw (3) fastening the lower left hand trim panel. Tightening torque Class Screw...
Page 951 Fasten the leather flap (1), attaching the two indicated fastener clips. Fit the cover panel (A) in its seat on the dashboard, pushing upwards. Tighten the two screws indicated fastening the cover panel (A). Tightening torque Class Screw 2.6 Nm Refit the steering column trim panel ( E4.02).
Page 952 Attach the photo showing the state of the function “Glove box Key" to the claim. Claims with no photo confirming that the “Glove box Key” function is enabled will be rejected. Removing the complete glove compartment in dashboard Take particular care not to damage the structure, the plastic fasteners and the leather trim The compartment is located on the right-hand side of the dashboard.
Page 953 On the right-hand side, detach and remove the lateral dashboard fastener (1). Remove the lower right dashboard trim panel (2), by undoing the two fastener screws. On the right-hand side, undo the two screws fastening the compartment bin (B). Detach the damper (3) from the door (A).
Page 954 Undo the two central screws fastening the compartment bin (B). Remove the glove compartment (B) from the dashboard. Disconnect the connector (4) from the glove compartment light bulb mounting. If necessary, prise the light bulb mounting out of its seat to replace the glove compartment light bulb.
Page 955 For vehicles with iPod connection Detach and remove the cable grommet (C). Remove the iPod cable from the glove compartment. Remove the complete glove compartment. Refitting the complete glove compartment onto the dashboard Tightening torque Class Fastening glove compartment Screw 8.5 Nm Take particular care not to damage the structure, the plastic fasteners and the leather trim Fit the complete glove compartment.
Page 956 Connect the connector (5) to the glove compartment light switch. Connect the connector (4) to the glove compartment light bulb mounting. Fit the glove compartment into its seat on the dashboard, centring the two reference holes on the left side of the seat. Tighten the two central screws fastening the compartment bin (B).
Page 957 Attach the damper (3) to the door (A). On the right side, tighten the two screws fastening the compartment bin (B). Tightening torque Class Screw 8.5 Nm Fit the lower right dashboard trim panel (2) and fasten by hand tightening the two screws. On the right side, fit and fasten the lateral dashboard fastener (1).
Page 958 On the left side, tighten the two screws fastening the compartment bin (B). Tightening torque Class Screw 8.5 Nm Tighten the three central screws fastening the compartment bin (B). Tightening torque Class Screw 8.5 Nm Check that the hatch (A) is correctly fastened and that it functions properly.
Page 959 Prise out and remove the button (1), disconnecting the relevant connector. Undo the central screw (2) fastening the lower central trim panel. On the right-hand side, undo the lower lateral screw (3) fastening the lower central trim panel (D).
Page 960 On the left-hand side, undo the lower lateral screw (4) fastening the lower central trim panel (D). On the left-hand side, undo the upper lateral screw (5) fastening the lower central trim panel (D). Disconnect the connector (6) for the passenger compartment temperature sensor.
Page 961 Check the state of the passenger compartment internal temperature sensor. Connect the connector (6) for the passenger compartment temperature sensor. Fit the lower central trim panel (D) in the relative seat on the dashboard. On the left-hand side, tighten the upper lateral screw (5) fastening the lower central trim panel (D).
Page 962 Tighten the central screw (2) fastening the lower central trim panel. Tightening torque Class Screw 2.6 Nm Install and fix the button (1), connecting the relevant connector. Refit the complete glove compartment onto the dashboard ( E4.02). Refit the lower left hand dashboard trim ( E4.02).
Page 963 Undo the two screws indicated fastening the left hand trim panel (E). Detach the left hand trim panel (E) from the dashboard. Disconnect the connector (1) from the TFT display control button panel. Disconnect the connector (2) from the external light switch.
Page 964 Tightening torque Class Fastening the dashboard trim panels Screw 2.6 Nm Take particular care not to damage the structure, the plastic fasteners and the leather trim Pick up the left hand trim panel (E). Connect the connector (2) to the external light switch.
Page 965 Refit the lower left hand dashboard trim ( E4.02). Connect the battery ( F2.01). Removing the right hand dashboard trim panel Take particular care not to damage the structure, the plastic fasteners and the leather trim The trim panel is located on the right-hand side of the dashboard. Disconnect the battery ( F2.01).
Page 966 Undo the three central screws (3) fastening the right hand trim panel (F). Undo the lateral screw (4) fastening the right hand trim panel (F). Remove the right hand trim panel (F) from the dashboard. Refitting the right hand dashboard trim panel Tightening torque Class Fastening the dashboard trim panels...
Page 967 Tighten the two lateral screws (2) fastening the right hand trim panel (F). Tightening torque Class Screw 2.6 Nm On the inner right-hand side, tighten the lateral screw (1) fastening the right hand trim panel (F). Tightening torque Class Screw 2.6 Nm Refit the lower central dashboard trim panel ( E4.02).
Page 968 Disconnect the connector (1). Undo the two indicated screws fastening the engine compartment lid release lever (2) and remove the lever, leaving it connected to the cable. Disconnect the connectors (3), (4), (5) and (6). Undo the lower right hand screw (7) fastening the dashboard.
Page 969 Undo the screw indicated fastening the lower right hand mounting bracket for the dashboard (A) to the bodyshell. Undo the two nuts indicated fastening the lower right hand mounting bracket (9) for the dashboard (A) to the centre console and remove the bracket.
Page 970 Undo the lower left hand screw (13) fastening the dashboard (A). Lift the passenger side mat to reveal the ADR ECU and disconnect the two indicated connectors for the GPS antenna and the GSM antenna. Undo the nuts indicated. Undo the screw (14). Disconnect the unions (15) and (16) for the A.C.
Page 971 Open the clamps (17) and (18). Move the pipe (20) away from the pipes (21). Disconnect the cooling system pipes (21). FROM Assembly No. 88561 Open the indicated clamp. Prise out and remove the two defroster grilles (22) from the upper dashboard trim panel.
Page 972 Undo the two screws indicated fastening the upper left hand part of the dashboard (A). Undo the two screws indicated fastening the upper right hand part of the dashboard (A). Undo the two screws indicated fastening the dashboard (A) to the right hand mounting bracket.
Page 973 Undo the two screws indicated fastening the dashboard (A) to the left hand mounting bracket. Firmly grip the dashboard (A) and remove from the vehicle. Refitting the dashboard Tightening torque Class Fastening lateral fastener between dashboard Screw 40 Nm and lateral mounting brackets Screw (pretightening) 25 Nm Fastening upper fastener between dashboard...
Page 974 Take particular care not to damage the structure, the plastic fasteners and the leather trim To facilitate removal and refitting, preferably open the retractable hard top completely. Take particular care NOT TO crush the electrical cables and wiring harnesses. Firmly grip the dashboard (A) and install in the vehicle.
Page 975 Pre-tighten the two screws indicated, fastening the dashboard (A) to the left hand mounting bracket, in a cross pattern. Tightening torque Class Screw (pretightening) 25 Nm Tighten the two screws indicated fastening the dashboard (A) to the right hand mounting bracket.
Page 976 Fit the two defroster grilles (22) in their respective seats and press until they snap audibly into place. Connect the cooling system pipes (21). Move the pipe (20) toward the pipes (21). Close the clamps (17) and (18). FROM Assembly No. 88561 Fit and tighten the indicated clamp.
Page 977 Connect the unions (15) and (16) for the A.C. system pipes. Hand tighten the screw (14). Tighten the nuts indicated. Tightening torque Class 10 Nm Lift the passenger side mat to reveal the ADR ECU and connect the two indicated connectors for the GPS antenna and the GSM antenna.
Page 978 Fit the bracket (12) linking the dashboard to the centre console in the respective seat. Tighten the four screws indicated fastening the bracket (12) linking the dashboard to the centre console. Tightening torque Class Screw 8.5 Nm Fit the lower left hand mounting bracket (11) for the dashboard (A) in its respective seat.
Page 979 Connect the connector (10) to the airbag ECU. Fit the lower right hand mounting bracket (9) for the dashboard (A) in its respective seat and tighten the two lower fastener nuts and the two upper fastener screws. Tighten the two screws indicated fastening the lower right hand mounting bracket (9) for the dashboard (A) to the dashboard subframe.
Page 980 On the left-hand side, hand tighten the lower screw (7) fastening the dashboard. Connect the connectors (3), (4), (5) and (6). Fit the engine compartment lid release lever (2) in its respective seat and tighten the two fastener screws indicated. Tightening torque Class Screw...
Page 981 Undo the screw (1) fastening the rear right hand part of the upper dashboard trim panel (A). Undo the three screws (2) fastening the rear centre part of the upper dashboard trim panel (A). Undo the screw (3) fastening the rear left hand part of the upper dashboard trim panel (A).
Page 982 Undo the screw (5) fastening the front right hand part of the upper dashboard trim panel (A). Undo the two screws (6) fastening the front centre part of the upper dashboard trim panel (A). On the right-hand side of the steering column, undo the screw (7) fastening the upper dashboard trim panel (A).
Page 983 On the left-hand side of the steering column, undo the screw (8) fastening the upper dashboard trim panel (A). Undo the screw (9) fastening the front left hand part of the upper dashboard trim panel (A). Very carefully, detach the upper dashboard trim panel (A) from the dashboard subframe.
Page 984 Tightening torque Class Fastening the dashboard trim panels Screw 2.6 Nm Fastening the upper dashboard trim panel Screw 6 Nm Fastening passenger side airbag mounting Screw 8.5 Nm bracket - dashboard subframe Take particular care not to damage the structure, the plastic fasteners and the leather trim Place the upper dashboard trim panel in the vehicle.
Page 985 On the left-hand side of the steering column, tighten the screw (8) fastening the upper dashboard trim panel (A). Tightening torque Class Screw 2.6 Nm On the right-hand side of the steering column, tighten the screw (7) fastening the upper dashboard trim panel (A).
Page 986 Tighten the screw (5) fastening the front right hand part of the upper dashboard trim panel (A). Tightening torque Class Screw 2.6 Nm Tighten the two screws (4) fastening the passenger airbag mounting bracket to the dashboard subframe. Tightening torque Class Screw 8.5 Nm...
Page 987 Tighten the screw (1) fastening the rear right hand part of the upper dashboard trim panel (A). Tightening torque Class Screw 2.6 Nm Refit the dashboard ( E4.02). Connect the battery ( F2.01).
Page 988 E4.03 Centre console Removing the armrest Take particular care not to damage the structure, the plastic fasteners and the leather trim Located on the centre console trim panel. Undo the four screws indicated fastening the internal armrest (B) trim (A). Remove the internal armrest (B) trim (A).
Page 989 Fit the armrest (B) in its seat. Tighten the two screws indicated fastening the armrest (B) to the respective mounting hinge (C). Fit the inner armrest (B) trim (A) in the respective seat. Tighten the four screws indicated fastening the internal armrest (B) trim (A).
Page 990 Fit the glove compartment (A) in the relative seat. Tighten the four screws indicated fastening the glove compartment (A). Removing the centre console control panel Located at the front of the centre console trim panel. Disconnect the battery ( F2.01). Remove the glove compartment on the centre console trim panel ( E4.03).
Page 991 Undo the two screws indicated fastening the control panel (A) to the centre console trim panel. Remove control panel (A) from the respective seat on the centre console trim panel, easing out toward the rear of the vehicle. Refitting the centre console control panel Tightening torque Class Fastening centre console control panel - centre...
Page 992 Connect the connectors (1), (2) and (3). Refit covers and mats ( E4.05). Refit the centre tunnel console mats. Refit the glove compartment on the centre console trim panel ( E4.03). Connect the battery ( F2.01). Removing the console trim panel Take particular care not to damage the structure, the plastic fasteners and the leather trim The trim panel is located in the centre of the passenger compartment.
Page 993 Undo the two nuts fastening the central section of the console trim panel (A). On the right hand side of the console trim panel (A), undo the front fastener screw (1). On the left hand side of the console trim panel (A), undo the front fastener screw (2).
Page 994 Fit the front of the console trim panel and insert the rear in the relevant seat. On the left hand side of the console trim panel (A), hand tighten the front fastener screw (2). On the right hand side of the console trim panel (A), hand tighten the front fastener screw (1).
Page 995 Hand tighten the two screws fastening the rear section of the console trim panel (A). Refit the armrest ( E4.03). Refit the centre console control panel ( E4.03). Refit the A.C. control panel ( F2.11). Connect the battery ( F2.01).
Page 996 E4.04 Passenger compartment and roof trim panels A - Windscreen cross member trim panel B - Right hand windscreen pillar trim panel C - Left hand windscreen pillar trim panel D - Passenger side sun visor E - Driver side sun visor F - Right hand upper lateral trim panel G - Right hand flap H - Centre trim panel...
Page 997 Driver side Undo the two screws indicated fastening the sun visor (A). Remove the sun visor (A). Passenger side Undo the two screws indicated fastening the sun visor (A). Remove the sun visor (A). Internal windscreen pillar trim panels Left Using a suitable tool, detach the top part of the internal windscreen pillar trim panel (A) first and then the lower part from the relative seat.
Page 998 Right Using a suitable tool, detach the top part of the internal windscreen pillar trim panel (A) first and then the lower part from the relative seat. Remove the internal windscreen pillar trim panel (A) from the vehicle. Windscreen cross member trim panel Bring the RHT electrically into the Spider position, completing the opening cycle.
Page 999 On the right-hand side, undo the screw (1) fastening the fixing plate (A). Remove the fixing plate (A) from the relative seat. On the left-hand side, undo the screw (2) fastening the windscreen cross member trim panel (B). On the right-hand side, undo the screw (2) fastening the windscreen cross member trim panel (B).
Page 1000 Detach the windscreen cross member trim panel (B) from the relative seat, pulling toward the rear of the vehicle. Remove the windscreen cross member trim panel (B) from the vehicle. Refitting the roof trim panels Tightening torque Class Fastening windscreen cross member trim panel Screw 2 Nm Fastening retractable hard top striker plate fixing...