Maserati Coupe Manual PDF
Maserati Coupe Manual PDF
Maserati Coupe Manual PDF
TECHNICAL INFORMATION
Maserati Spyder and Coupé produced from assembly number 11353 (V IN num. 10103)
onwards, feature batteries which contain a transponder for the purpose of providing the
following data:
Date of production
Current (%)
Static voltage (V)
State of the battery (current condition)
Vehicle VIN
With the “MASERATI BATTERY TESTER” (p/n 900026750), you can diagnose the
efficiency of the battery and record the above listed data from the transponder. Included
with the tester is the operating instruction manual. The managing software has to be
downloaded from MODIS (after sales / technical service / download SD2 software /
tools) and it is called “INST9984_10700.exe”.
Transponder
Battery
Antenna
Please, observe the correct position the antenna above the transponder when reading
or writing data.
è Make sure that the pegs that are located on the bottom of the tool (circled in red
below) are properly set into the recesses on the battery housing.
Whenever a battery diagnosis is being performed, be sure the battery is not connected
to any loads.
You are required to make a reading and record the results whenever:
Keep a record of the acquired files and make them available in the event of future
problems or complaints concerning the battery or charging system.
Note: Listed are some recommendations that will help conserve the battery’s power
until the time of delivery to the customer:
è Disconnect the battery whenever the car is not moved for an extended period of
time. (lower windows first)
è Connect an external power supply if, with the engine off, you need to operate
functions that require electrical power, e.g., radio, soft top, air conditioning, seats,
lights, etc.
Rough Cold Start Software
Download
MY 2004
ENDING ASSEMBLY NO. 14592
ENDING CHASSIS NO. 13336
MY 2004 PRODUCTION AS OF 4/15/04 HAS THE NEW SOFTWARE STARTING WITH ASSY NO.
14594 & VIN 13444
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION BULLETIN
Subject: New Software Download for All MY 2003-2004 Spyder & Coupe
models - Service Campaign No. 116
A new software version has been developed to address a rough cold start complaint that
the Spyder and Coupe may experience with the original factory installed Bosch Motronic
ECU software. All MY 2003-2004 Spyder & Coupe Models are affected up to assembly
number 14592 (chassis number 13336).
The Motronic Electronic Control Unit (ECU) part number 180251 is used on all MY 2003 -
2004 Maserati Coupe and Spider, F1 and GT versions. The software in each model is
different. Close attention must be made to the particular model being worked on so the
correct software is installed.
______________________________
Maserati North America, Inc.
Technical Department
The updated software to be downloaded is:
Note: This update is only for vehicles starting with assembly number 10265 up to
assembly number 14592. After assembly 14592 the newer software is already
factory installed.
______________________________
Maserati North America, Inc.
Technical Department
The procedure is as follows:
Ø Download the files from the CD supplied into the P.C. by selecting, “Maintenance”,
then “Update”, then “Load File”.
Ø Update the SD2 by deleting all files currently loaded.
Ø With the SD2 in “Link to PC” mode, select the correct file to download according to the
vehicle being worked on.
Ø Jump the Immobilizer relay with an appropriate jumper wire obtained locally. (Fig.1)
Ø Connect the SD2 in Stand Alone mode to the OBD socket, connector E.
Ø Select “MENU, ECU Programming and follow the listed instructions.
Ø If a warning message “Security Message # 1” or “Security Message # 2” appears, exit
the download and restart the remote loading procedure again.
Ø When the download procedure is completed, verify the correct software is loaded by
selecting the “Information” environment and refer to the software listed above.
Ø Road test and recheck for errors in the ECU.
Figure 1
______________________________
Maserati North America, Inc.
Technical Department
Warranty Submission procedures for ECU:
• Cost Code..........................................................................................................23
• Campaign Number ...........................................................................................116
• Malfunction Code ............................................................................................. 063
• Problem Code................................................................................................... 810001
• Operation Code ................................................................................................ 8100017
• Time ..................................................................................................................0.5 hour
After the download is completed, it is extremely important that every upgraded ECU
is marked with a special sticker as shown below in Fig. 2.
Fig. 2 Fig. 3
You will receive enough stickers to complete 10 vehicles, if additional stickers are
required, please contact the Warranty Department at 201-816-2659.
In addition to the ECU stickers that must be installed, you will also receive a sticker
which must be placed on the engine compartment cover as shown in Fig.3.
Please fill in the sticker with the Dealer code and date of the repair.
______________________________
Maserati North America, Inc.
Technical Department
Description of Repairs: The OBD II system does not set any DTC codes while
experiencing the Rough Cold Start problem. Please notice that this software upgrade
improves it by introducing new parameters during cold starting.
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
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Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
______________________________
Maserati North America, Inc.
Technical Department
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
For your Information, the Quattroporte starting with assembly number 15140 (VIN:
14216) up to and including assembly number 17559 (VIN: 16353) are involved in a
Service Campaign to install a new reverse gear lever. After assembly number 17559
(VIN: 16353) the newer part is already installed from the factory.
The newer lever is being installed to eliminate noises, (i.e., rattles or squeaks) and
cracks that may develop, due to the plastic used in the construction of the “T” handle.
Always check with Modis to ensure the vehicle being worked on is included in the
campaign.
Warranty Information:
TECHNICAL INFORMATION
MODEL: Quattroporte
For your Information, the Quattroporte starting with vin number 14719 up to and including
vin number 17090 are involved in a Service Campaign. This campaign is to inspect and
if necessary, replace a connector union located on the oil pipe between the oil pump
and the oil reservoir (No. 15 below) that may show signs of minor seepage.
Inspection Procedure:
1. Remove the protective shields under the front bumper and the engine
compartment.
2. Read the part number on the collar of the pipe as shown below.
3. If the collar has part number 196233 stamped, the part does not require
replacement. Mark the collar with red paint to show the campaign has been
completed. Reassemble the panels and submit the inspect only procedure on
the warranty claim.
If the collar has part number 211411 stamped, the part must be replaced.
Replacement Procedure:
1. Drain the oil from the reservoir into a clean container so the oil can be reused.
2. Remove the pipe from the reservoir side and drain the residual oil.
3. Remove the pipe from the pump side.
4. Install the new pipe (part number 211411) and seal (part number 109649)
Torque on the reservoir side union is 78 Nm. Torque on the pump side bolts is
10 Nm. Mark the collar with red paint to show the campaign has been
completed.
5. Reinstall all the previously removed components.
6. Refill the oil using the saved oil and top off if necessary.
7. Return all parts as per the warranty return system and indicate the campaign
number on the box of return parts.
Warranty Information:
TECHNICAL INFORMATION
MODEL: Quattroporte
For your Information, the Quattroporte starting with assembly number 15140 (VIN:
14216) up to and including assembly number 18210 (VIN: 17271) are involved in a
Service Campaign to install a snap ring on each of the rear brake caliper hoses. The
snap ring (p/n: 327456313) will help keep a rubber insulator in the correct position to
help prevent rattles and noises that may appear to be coming from the rear trunk area.
Always check Modis to ensure the vehicle being worked on is included in the campaign.
Procedure:
Warranty Information:
TECHNICAL INFORMATION
MODEL: Quattroporte
For your Information, the Quattroporte starting with assembly number 19454 (VIN:
18352) has a newer style roll over valve installed in the fuel tank. This newer style valve
is installed to help prevent rattle type noises that may be emitted from the rear of the car
on rough road surfaces.
Anytime the valve has to be replaced, use part number 217194 which replaces the older
valve part number 192099.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
TECHNICAL INFORMATION
MODEL: GranSport
Below you will find the process to correctly configure the BECKER Infotainment system.
Note: The following operations should be performed with the key OFF and the Becker
Radio ON; Please reference the documentation in the BECKER manual.
¾ Setting the system with the navigation CD. NOTE: It is necessary the setting of
the satellite navigator according to the country where the vehicle is going to be used.
This operation will require a few minutes:
1. Make sure the battery voltage is constant. It is recommended that a battery
charger is connected.
2. Turn the system ON and enter the navigation CD
3. The screen will display a message to confirm the update
4. Select YES the press on OK
5. The system will turn OFF (do not operate on the system at all, wait for a few
minutes)
6. The radio will turn ON automatically and the progress bar will be displayed on
the screen.
7. When the downloading is complete, the system turns OFF automatically.
8. Wait for the front LED to blink, then turn the system ON
9. The operation is now complete.
Information regarding software updates
Each time that a navigation CD of a later version is used, the newer software level of the
CD is automatically downloaded and this will overwrite the older version. This may occur
when delivering the vehicle to the customer and anytime an updated version of the map
is distributed.
It is recommended to load the navigation CD before the car is delivered to the customer.
If the automatic uploading begins and is interrupted in any way before completion, the
system may exhibit an abnormal operation and could cause a delay in delivering the car.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
SUBJECT: 2004 Spyder and Coupe Fuel Delivery Rails – Campaign 141
For your information if the Check Engine light is illuminated due to detection of
engine missfire faults in cylinders 3, 4, 6, and 8 in the ECU, new fuel rails which
contain a dampener to help eliminate pulsations are now being used.
This campaign only affects cars with engine numbers below the following;
• Coupe engine number 93324 (VIN number 18809)
• Spyder engine number 93330 (VIN number 18792)
Engine numbers after those listed above already have the newer rails installed from
the factory.
The part numbers for the fuel rails that contain a dampener are;
• Right side fuel rail: 212697 (replaces 197846)
• Left side fuel rail 212696 (replaces 197845)
TECHNICAL INFORMATION
MODEL: Quattroporte
NOTE: The SD3NET system and the SD3 tester must be updated to diagnostic
software version 8.4M or later. SD3 tester must be updated to SD3 Base
Software 2.28.
NOTE: Verify that the software in the Engine Control Unit is 198428.002. If it is
not, then Campaign 140 must be performed. (Refer to bulletin 200506)
Operating procedure:
8. Once the download window opens: click, save and select a suitable location
9. Once the download is complete, double click either file and extract the file to a
suitable location on your PC
10. Open SD3net on your PC and select updates on the top left hand corner
11. Select personal computer software update
12. On the left hand side of the update screen locate the file you previously
extracted labeled SwDwnSD3
13. Once the program DOWNLOAD TELECARICAMENTI is shown on the right
click select all
14. Click update NOTE: If the screen seems to freeze or the progress bar (in
green) does not move, do not do anything. The system is still updating
and will end briefly.
15. Select EXIT
16. While SD3NET is open on your PC, select updates on the top left hand corner
17. Select tester SD3 software update
18. On the left hand side of the update screen locate the file you previously
extracted labeled INST_SD3 in the SwDwnSD3 folder
19. Once the program DOWNLOAD TELECARICAMENTI is shown on the right
click select all
20. Click TRANSFER NOTE: If the screen seems to freeze or the progress bar
(in green) does not move, do not do anything. The system is still
updating and will end briefly.
21. Select EXIT
This is a general purpose tool that is used for flash programming software in the
ECUs of the M139. Software from this download is loaded on both the PC and the
SD3. The following lines will be added on the menu of the SD3 tester:
8. Once the download window opens: click ,save, and select a suitable location
9. Once the download is complete, double click either file and extract the file to a
suitable location on your PC
5. Once the programs are shown in the new window, select NCR CFC301 and
click CONFIRM (see below)
6. In the new window, select the folder where the previous file MDDD31U21 was
stored and double click the file on the right side of the screen. When the icon
and text appear in the bottom window, click TRANSFER.
TECHNICAL INFORMATION
For your information, if a temporary interruption of the signal from the r / s fuel level
sending unit occurs, the check engine light will be illuminated.
To help prevent this erroneous illumination of the Check Engine light, a new r / s fuel
level sending unit is now being used.
Starting with assembly number 19763 (VIN number 18193) the newer style fuel level
sending unit has been installed by the factory. On any Quattroporte before assembly
number 19763 (VIN number 18193) if the Check Engine light is illuminated due to the
fuel level sending unit, the unit must be replaced.
The newer part, p/n 187572 is the same part number as the original, but the
improvements necessary have been included since January production.
When replacement of the r / s fuel level sending is completed, use the information
below for the Warranty submission.
Component Code…………………………..143001
Labor Operation…………………………….1430010 (3.5h)
Problem Code………………………….……001
Cost Code…………………………………...16
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
For your information, if the instrument cluster displays “Service Due Now” and then
the message “NACK UNKOWN” appears on the SD3 when attempting to reset the
service with the SD3, it could be an internal instrument cluster malfunction. This may
happen when the date in the NIT was not set before the odometer reaches 120
miles. If that is the case, the wrong initial maintenance interval date will be set to 01-
01-2000.
A new software level was installed in the Instrument cluster beginning with VIN
number 19864 to help prevent the “NACK UNKNOWN” from appearing.
Warranty Information:
• Component code 8 50 001
• Labor operation 8 50 001 0 (1.7h)
• Cost code 16
NOTE: It is recommended to check and if necessary set the date and time on all new
vehicles delivered (e.g. on PDI).
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
For your information, new software for the Air Conditioning ECU (NCL Nodo
Climatizzore) is now available on MODIS. All Quattroporte up to and including VIN
num. 20785 (Assembly num. 21975) must be updated with this software.
You must access MODIS to download 8.4N. Please follow the outlined instructions in
Bulletin MNA-20 / N for more information on how to load into PC and SD3.
7. While SD3NET is still open on your PC, select Update on the top left hand
corner.
8. Select Tester SD3 Software Update.
9. On the left hand side of the update screen locate the file you previously
extracted labeled INST_SD3 in the SwDwnSD3 folder.
10. Once the program DOWNLOAD TELECARICAMENTI is shown on the right
click SELCT ALL (reference screen shot below).
11. Click TRANSFER. NOTE: If the screen seems to freeze or the progress bar
(in green) does not move, wait. The system is still updating and will end
briefly.
12. Select EXIT.
The Air Conditioning ECU software can be found in the SD2 download menu under:
1. After-sale
2. Technical Service
3. SD2 Software Download
4. M139_B – QuattroPorte
5. ECU Software
6. NCLSW_M139_1.exe (see caption below)
,
7. Click on the file NCLSW_M139_1.exe and save it in an appropriate location on
the PC.
8. Unzip the file – M139NCL Telecaricamento should then appear.
9. Double-click M139NCL Telecaricamento to extract the file.
10. When prompted, extract files to same directory.
11. There should be two (2) directories now present: M139NCL0703 and
M139OPTNCL0303.
12. Set up the PC and SD3 to Link to PC mode.
13. Start SD3NET.
14. Select PC Diagnosis.
15. Select Personal Computer Diagnostic Software Running.
16. Select DOWNLOAD TELECARICAMENTO, then click Execute.
17. Select NCL, and click Confirm.
18. Go to the directory where the files in Step 11 were saved (see figure on the
next page).
19. Select the folder M139NCL0703, the corresponding file should appear in the
right window.
20. Double click the file until the file is prepared for transfer in the bottom window.
21. Click TRANSFER to load the file into the SD3.
22. Repeat Steps 19 – 21 with the folder M139NCLOPT0303.
23. Although it is possible to transfer both files at the same time, it is better to
transfer one by one.
24. The SD3 is now ready for the software update.
NOTE:
The 2 different softwares correspond to whether the vehicle has Front and Rear
A/C control, or Front Only A/C control. They should be loaded accordingly.
TECHNICAL INFORMATION
This Bulletin Cancels and Replaces Bulletin number 200517 which was sent
on 10-31-2005
MODEL: Quattroporte
8. Insert a plastic tie wrap into the indicated holes (shown in Figure 3) and
secure the seat wiring harness to the frame of the seat. Cut away the extra
length of the tie wrap end (Figures 3 and 4)
Figure 3 Figure 4
9. Lower the seat to the fully down position and make sure that the seat wiring
harness does not exhibit any interference.
10. Affix a red dot in the location shown in Figure 5 to confirm that the repair has
been performed.
11. Remove the extension harness tool (part number 220381) and re-install the
seat.
Figure 5
Necessary material:
Warranty Information:
• Component code 9 41 09
• Labor operation 9 41 009 9 (0.9h)
• Problem code 063
• Cost code 23
• Campaign number 145
VIN Assembly 15690 16842 15785 17124
15368 16654 16527 17538 15786 16944
16339 17514 16530 17530 15787 16929
16640 17619 15574 16688 15789 16996
15330 16514 16271 17699 15790 17099
16762 17780 16318 17460 15791 17026
16250 17445 16319 17480 15792 16979
16251 17491 15819 17181 15794 17399
16649 17607 16553 17880 15796 17101
16764 17956 14719 17387 15802 16951
16780 17853 14854 17512 15803 17142
15335 16549 15018 17192 15804 17316
15353 16708 15139 16727 15806 17006
15551 16622 15210 16711 15811 17155
16638 17767 15216 16524 15839 16971
16333 17676 15225 16502 15994 17211
15346 16583 15231 16488 15996 17227
15361 16656 15232 16627 16000 17219
15684 16785 15233 16559 16001 17119
16767 17912 15370 16490 16002 17163
16768 17830 15374 16522 16005 17617
16773 17974 15379 16692 16007 17415
15327 17239 15380 16528 16008 17395
15816 17175 15382 16566 16009 17186
15196 16536 15385 16540 16011 17126
15341 16585 15386 16570 16012 17303
15347 16776 15387 16601 16024 17201
15349 16599 15391 16644 16149 17117
15692 17014 15397 16676 16151 17203
15762 17007 15707 16765 16152 17283
15778 17001 15713 16757 16160 17443
15965 16931 15714 16763 16285 17207
16112 17197 15715 16867 16288 17237
16272 17653 15724 16851 16289 17662
16313 17459 15725 16849 16293 17419
16636 17583 15727 16890 16296 17376
15359 16673 15728 16789 16297 17483
14629 16813 15729 16859 16342 17505
15698 16907 15730 16856 16344 17532
15704 17033 15731 16925 16345 17647
15782 17078 15732 16941 16347 17517
15783 17128 15733 16863 16348 17547
16146 17261 15734 16903 16349 17502
16147 17350 15738 16998 16352 17604
16278 17568 15739 16900 16353 17559
16279 17490 15741 16667 16355 17553
16281 17778 15742 16686 16356 17753
16544 17668 16021 17087 16536 17595
16547 17666 16309 17402 16539 17773
16550 17645 16372 17804 16623 17671
16806 17751 16373 17693 16646 17570
16809 17806 16560 17718 16653 17651
16812 17836 14348 16882 16660 17739
16816 17794 14998 16888 16664 17757
15581 16741 15350 16694 16790 17943
16668 18049 15362 16650 16791 17984
16089 17060 15543 17115 16925 18065
16120 17827 15546 16612 15334 16519
16256 17451 15548 16669 15577 16663
16771 17790 15554 16743 15680 16865
16246 17441 15560 16632 15682 16773
15201 16492 15565 16749 15696 16896
15202 16494 15569 16747 15780 16919
15203 16498 15573 16684 16630 17722
15674 16783 15958 16678 16139 17425
15695 16911 15964 17891 16140 17465
15768 17071 15968 16964 16323 17695
16087 17153 15969 16923 15587 16770
16138 17273 15971 17135 15673 16745
16645 17609 15981 17105 15351 16589
15743 17081 15982 17161 15038 17095
16822 18047 15983 17091 15039 17131
16823 17901 16114 17549 16378 17692
16824 18058 16115 17431 16777 17872
15578 16725 16118 17340 16316 17584
16124 17313 16125 17279 16268 17591
16141 17567 16131 17299 16269 17461
15235 16509 16267 17378 16315 17384
15754 16821 16320 17536 16329 17544
15759 16945 16321 17450 16337 17625
16019 16976 16531 17602
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
The following table shows the data for the wheel alignment that are specific to all
MY2006 Quattroporte (Assembly number 21926 and later).
FRONT REAR
Toe in -2.0 ± 0.4 mm -4.0 ± 0.4 mm
Make these measurements after verifying the ride height of the reference points (see
below) on the suspension under the following conditions of static load:
TECHNICAL INFORMATION
MODEL: Quattroporte
The latest software release for diagnostic system SD3 (both Tester and PC), 8.4O, is
now available on MODIS. Perform the following procedures:
NOTE: After this procedure, there will be no diagnostic software on the tester.
Therefore, in addition to 8.4O, you must load all porting software previously on
the tester before data deletion (Coupe, Spyder, GranSport).
B. Download the SD3 Tester and PC software from MODIS using the path:
a. Log into MODIS
b. Select After-Sale
c. Select Technical Service
d. Select SD2 Software Download
e. Select M139_B – QuattroPorte
f. Select SD2 Software
g. Select M139_PC_84O.exe, and then select M139_SD3_84O.exe, and
save in an appropriate location on your PC (See Figure 1).
h. Once both files are downloaded, double-click each file in order to
extract it and make it suitable for installation
i. Follow the procedure outlined in the bulletin: MNA – 20 – N – New SD3
Software in order to correctly install the software in the PC and SD3. It
is recommended to install the PC software before installing the SD3
software.
Figure 1
Figure 2
h. Once the file is downloaded, double-click the file in order to extract it
and make it suitable for installation. Select “RUN” when prompted.
i. When the WinRAR program prompt appears, select “Installa” and
indicate the directory where you want the files extracted by selecting
“Sfolglia”(Figure 3). NOTE: The downloaded file will extract into several
folders. Make sure that you know exactly where these extracted folders
are located on your PC.
Figure 3
D. Load the latest Kisspoint 2 and Telecaricamento 7284 into the SD3 tester by
the following procedure:
a. Connect the PC to the SD3 tester in Link-to-PC mode
b. Start the SD3NET program
c. Select Updates in the top menu bar
d. Select Tester SD3 Software Update
e. Select the directory in which you originally saved and extracted the file
in Step B. An icon should appear in the right window (Figure 4).
f. Select SELECT ALL
g. Select TRANSFER
h. After the downloading process takes place, select CONTINUE when the
screen displays OPERATION COMPLETE
i. The software is loaded; exit from SD3NET
Figure 4
E. Load the latest Telecaricamento 7284 into the PC by the following procedure:
a. Start the SD3NET program
b. Select Updates in the top menu bar
c. Select Personal Computer Software Update
d. Select the directory in which you originally saved and extracted the file
in Step B. The text “DOWNLOAD TELECARICAMENTI” should appear
in the right window (See Figure 5).
e. Select SELECT ALL
f. Select UPDATE
g. The download is complete when “Operations completed” is displayed.
h. The software is loaded; exit from SD3NET
Figure 5
F. Important Notes
When performing the Kiss Point 2 procedure, follow the procedure outlined in
bulletin TECH TIPS – Vol 1 Issue 2. However, you must use the following path to
get to the correct software:
a. SERIAL DIAGNOSIS
b. DIAGNOSTICS CYCLE ON INDIVIDUAL ECU
c. TOOLS
d. MASERATI
e. M139
Use KISS POINT NCR 2.0 SOFAST III for MY05 Quattroporte
Use KISS POINT NCR 2.0 SOFAST III MY06 for MY06 Quattroporte
(See Figure 6).
Figure 6
After selecting this software, the SD3 will start the same Kiss Point Procedure
outlined in TECH TIPS – Vol 1 Issue 2.
NOTE: This version of SD3 software adds the following diagnostic software:
• NCR CAMBIO ROBATIZZATO MAGNETI MARELLI SOFAST3+
• NCM CONTROLLO MOTORE BOSCH MOTRONIC MY06
These are to be used with MY2006 Quattroporte ONLY!
TECHNICAL INFORMATION
MODEL: Quattroporte
Maserati Quattroporte with Assembly # 23742 and later are required to have the
“Vehicle Start Date” entered manually in the instrument cluster using the SD3. This
procedure must be included in the PDI process. The date entered will be the date
of delivery to customer and beginning of the warranty period of the vehicle.
Instrument clusters supplied as spare parts have already been programmed with the
software necessary to carry out this process.
NOTE: The instrument cluster must be already loaded with Software Level 2.38. To
verify this, connect the SD3 to the vehicle and follow the path: Serial Diagnosis >
Diagnostic cycle on individual ECU > MASERATI > M139 > NQS QUADRO
STRUMENTI MAGNETTI MARELLI > ECU IDENDIFICATION ENVIRONMENT.
Check the field “SW LEVEL”; it should read 0238.
NOTE: The SD3 must be loaded with Software Level 8.4O. To verify this, turn the
SD3 on and select the VERSIONS menu. The current version of the software is
located in the right side column for all M139 (Quattroporte) control units.
Figure 1 Figure 2
6. After the date is set and verified, select OK to save the date.
7. After OK is selected with the date entered, the SD3 will display a screen
asking if the date is correct (See Fig. 3). Select CONFIRM to permanently
write the date into the cluster. If the date entered is wrong, select CANCEL to
enter another date.
VERY IMPORTANT!: Once the date is entered by selecting CONFIRM, it is
permanently set and can never be modified.
Figure 3 Figure 4
8. Once CONFIRM is selected, the writing process takes a few seconds and
requires the key to be turned OFF and ON, which should be done when
prompted by the SD3.
9. Once the date is written to the cluster, the SD3 will display a confirmation
message (see Fig. 4).
10. Select OK at the confirmation message in Step 9 to return to the programming
menu. The date that was entered is now set in the cluster (see Fig. 5).
11. The date in the instrument cluster is now programmed correctly.
NOTE: If an attempt is made to program the date again, a message will appear
indicating that it is not possible (see Fig. 6).
Figure 5 Figure 6
12. Check that the current TIME and DATE on the Instrument Cluster is correct. If
not, set the current TIME and DATE in the NIT.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
In any event where the clutch housing must be removed (e.g., clutch replacement,
throw out bearing replacement), the part of the harness extension traveling from the
rear trunk wiring harness to the clutch sensor connector must be modified. The
purpose of the modification is to help reduce the potential of the formation of
condensed water on the cable near the connector.
Please perform the following procedure when the clutch housing is replaced:
NOTE: Make sure that key is OFF and vehicle is cold when performing this
procedure
1. Locate the clutch sensor connector on the extension (the connector housing is
denoted as K038 in the technical documentation) of the rear trunk wiring loom
(See Figure 1, red highlight).
2. Bend this extension in order to form a “U”-shape. The gap between the
connector housing of K038 and the bottom of the newly formed “U” must
measure 80mm (see Figure 2).
3. Use electrical tape to adhere both parts of the newly formed “U” so that the
tape is positioned 20mm from the bend (see Figure 2).
4. When performing this modification, make sure not to stress the harness at any
point.
Warranty Information:
Operation Code 8 60 003 1 (0.1h)
Figure 1
Figure 2
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
The repair should be performed on customer vehicles first, then on vehicles in stock.
There are 2 parts to this procedure:
A. Adjustment of the parking brake
B. Driving procedure after adjustment
NOTE: It takes about 40 seconds to drive the complete distance under the conditions
outlined in Step 3. Therefore, it is not necessary to reference the trip odometer to
drive the exact 0.2 miles. A count to 40 seconds while driving is sufficient.
NOTE: It is not required that the road is straight; however, it is important that the road
is NOT sloped. This might cause clutch slippage and reduce the effect of the
procedure.
Figure 2
RECALL CAMPAIGN
INSTRUCTIONS
RECALL CAMPAIGN
QUATTROPORTE
2005 MODEL YEAR
SEPTEMBER 2005
READ , INITIAL Service Manager Parts Manager Service Writer Technician Warranty Clerk
AND PASS ON »
Maserati North America, Inc.
February _, 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
Serial Number: «VIN» «ASSY»
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati
Quattroporte vehicles.
The defect consists of the presence of a non-functioning button with the words
“Passenger Air Bag Off” etched into it and located, along with an LED light, on a
console adjacent to the sun roof. This non-functioning button does not deactivate
the passenger-side air bag. Nor is the LED light an indication that the passenger-
side air bag has been deactivated. The button is non-functional and cannot be
depressed when pushed. Maserati is concerned, however, that drivers and customers
may be misled by this non-functioning button and LED light into thinking that the
passenger-side air bag has been, or can be, deactivated. As a result, infants and small
children might be placed in the front passenger seat. The placement of infants and
small children in the front passenger seat could result in serious injury or death in
the event of a crash in which the passenger-side air bag deploys.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
Maserati North America, Inc.
September _, 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This notice is a follow up to the first notice we sent to you in the month of February. In the
first notice we notified you that Maserati S.p.A., the manufacturer of Maserati automobiles,
had decided that a defect which relates to motor vehicle safety exists in certain 2005 model
year Maserati vehicles.
The defect consists of the presence of a non-functioning button with the words “Passenger Air
Bag Off” etched into it and located, along with an LED light, on a console adjacent to the sun
roof. This non-functioning button does not deactivate the passenger-side air bag. Nor is
the LED light an indication that the passenger-side air bag has been deactivated. The
button is non-functional and cannot be depressed when pushed. Maserati is concerned,
however, that drivers and customers may be misled by this non-functioning button and LED
light into thinking that the passenger-side air bag has been, or can be, deactivated. As a result,
infants and small children might be placed in the front passenger seat. The placement of
infants and small children in the front passenger seat could result in serious injury or death
in the event of a crash in which the passenger-side air bag deploys.
Maserati will provide, at no charge to the customer, a replacement console which does not
contain the non-functioning button with the wording “Passenger Air Bag Off”. Currently, the
new console is available at our MNA parts department. Therefore, we notified the customer to
take his or her vehicle to an authorized Maserati dealer to have the console replaced as soon as
possible.
The operation will be performed free of charge to the vehicle owner, and will require
approximately 1.0 hour to complete.
Best Regards,
Victor Soriano
National Aftersales Operations Manager
Maserati North America, Inc.
Maserati North America, Inc.
February _, 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This notice is sent to you in accordance with the requirements of the “Canada Motor
Vehicle Safety Act”.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati vehicles.
The defect consists of the presence of a non-functioning button with the words
“Passenger Air Bag Off” etched into it and located, along with an LED light, on a console
adjacent to the sun roof. This non-functioning button does not deactivate the
passenger-side air bag. Nor is the LED light an indication that the passenger-side
air bag has been deactivated. The button is non-functional and cannot be depressed
when pushed. Maserati is concerned, however, that drivers and customers may be misled
by this non-functioning button and LED light into thinking that the passenger-side air bag
has been, or can be, deactivated. As a result, infants and small children might be placed
in the front passenger seat. The placement of infants and small children in the front
passenger seat could result in serious injury or death in the event of a crash in which
the passenger-side air bag deploys.
Maserati is sending you this notice to inform you that the non-functioning button with the
words “Passenger Air Bag Off” will not turn off the passenger air bag, and the LED light
is not an indication that the passenger-side air bag has been deactivated. Because the
passenger-side air bag cannot be turned off by any means, you should never place
infants and small children in the front passenger seat of the 2005 Maserati
Quattroporte.
The corrective action for the replacement of the console will be performed free of charge
to you. Details about the repair and the length of time that it will take will be sent to you
in the additional notice.
If the affected vehicle is not repaired free of charge to you and within a reasonable time,
you may submit a written complaint to the Head of Recalls, Road Safety and Motor
Vehicle Regulation, Transport Canada, 2780 Sheffield Road, Ottawa, Ontario KIB 3V9.
You may also telephone Transport Canada at (613) 993-9851.
Canadian regulation requires that any vehicle lessor receiving this recall notice must
forward a copy of this notice to the lessee within ten working days.
If you no longer own this vehicle or your address has changed, please complete the
enclosed prepaid yellow card and return it to Maserati North America, Inc.
We urge you to comply with this notice promptly and we apologize for any
inconvenience this may cause you.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
Maserati North America, Inc.
September _ , 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This second notice is sent to you in accordance with the requirements of the “Canada
Motor Vehicle Safety Act”.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati vehicles.
The defect consists of the presence of a non-functioning button with the words
“Passenger Air Bag Off” etched into it and located, along with an LED light, on a console
adjacent to the sun roof. This non-functioning button does not deactivate the
passenger-side air bag. Nor is the LED light an indication that the passenger-side
air bag has been deactivated. The button is non-functional and cannot be depressed
when pushed. Maserati is concerned, however, that drivers and customers may be misled
by this non-functioning button and LED light into thinking that the passenger-side air bag
has been, or can be, deactivated. As a result, infants and small children might be placed
in the front passenger seat. The placement of infants and small children in the front
passenger seat could result in serious injury or death in the event of a crash in which
the passenger-side air bag deploys.
Maserati will provide, at no charge to you, a replacement console which does not contain
the non-functioning button and LED light. Currently, the new console is available at our
dealers. Therefore, you should take your vehicle to an authorized Maserati dealer to have
the console replaced as soon as possible.
The operation will be performed free of charge to the vehicle owner, and will require
approximately 1 hours to complete.
Maserati also stated in the first notice that the non-functioning button with the words
“Passenger Air Bag Off” will not turn off the passenger air bag, and the LED light is not
an indication that the passenger-side air bag has been deactivated. Because the
passenger-side air bag cannot be turned off by any means, you should never place
infants and small children in the front passenger seat of the 2005 Maserati
Quattroporte.
The Canadian vehicles affected are as follows:
If the affected vehicle is not repaired free of charge to you and within a reasonable time,
you may submit a written complaint to the Head of Recalls, Road Safety and Motor
Vehicle Regulation, Transport Canada, 2780 Sheffield Road, Ottawa, Ontario KIB 3V9.
You may also telephone Transport Canada at (613) 993-9851.
Canadian regulation requires that any vehicle lessor receiving this recall notice must
forward a copy of this notice to the lessee within ten working days.
If you no longer own this vehicle or your address has changed, please complete the
enclosed prepaid yellow card and return it to Maserati North America, Inc.
We urge you to comply with this notice promptly and we apologize for any
inconvenience this may cause you.
Best Regards,
Victor Soriano
National Aftersales Operations Manager
Maserati North America, Inc.
RECALL CAMPAIGN NO. 136
Maserati Quattroporte
“Passenger Air Bag Indicator Light”
RECALL CAMPAIGN OVERVIEW
CONDITION: The defect consists of the presence of a non-functioning button with the
words “Passenger Air Bag Off” etched into it and located, along with an
LED light, on a console adjacent to the sun roof. This non-functioning
button does not deactivate the passenger-side air bag. Nor is the LED
light an indication that the passenger-side air bag has been
deactivated. The button is non-functional and cannot be depressed when
pushed. Maserati is concerned, however, that drivers and customers may
be misled by this non-functioning button and LED light into thinking that
the passenger-side air bag has been, or can be, deactivated. As a result,
infants and small children might be placed in the front passenger seat.
The placement of infants and small children in the front passenger seat
could result in serious injury or death in the event of a crash in which
the passenger-side air bag deploys.
PARTS: The parts required for this repair are identified by the following part numbers:
Note:
Return the removed console to our warranty department following the normal warranty parts
return procedure.
All Canadian Maserati Quattroporte with VIN 14410 (assembly number 15774) up to and
including VIN 17865 (assembly number 18966) are involved in a recall campaign to
remove the passenger air bag indicator light console that is located in the overhead
control panel. The defect consists of the presence of a non-functioning button with the
words “Passenger Air Bag Off” etched into it and located, along with an LED light, on a
console adjacent to the sun roof. This non-functioning button does not deactivate the
passenger-side air bag. Nor is the LED light an indication that the passenger-side
air bag has been deactivated. The button is non-functional and cannot be depressed
when pushed.
The new consoles do not have the words “Passenger Air Bag Off” etched into it.
NOTE:
¾ Carefully read this bulletin to determine the repairs that need to be performed.
¾ Reference the technical documentation in order to properly perform the repair
procedure.
¾ Check via MODIS CS that the vehicle is included in the campaign, and has not
previously undergone corrective action.
¾ Protect areas that could be exposed to damages during repair.
A. Software Download
1. Make sure that the SD3NET system and the SD3 tester are updated to software
version 8.4N or later. If not, please reference bulletin MNA – 20 / N.
2. Follow the path in MODIS
a. After-sale
b. Technical Service
c. SD2 Software Download
d. M139_B – Quattroporte
e. ECU Software
Figure 1
Figure 3
11. The next screen asks you to select the specific software. Go to the folder that
contains the software that was previously downloaded (NM04_18_M139AQ).
When the folder is selected, it should automatically appear in the right window.
12. Double click NM04_18_M139AQ in order to have file appear in the bottom
window, then click TRANSFER. (See Figure 4)
Figure 4
13. The process should take several minutes. When the “Operation Complete”
message appears, select CONTINUE.
14. Select EXIT - Download is complete.
B. Software Update
NOTE: During the downloading process, the instrument cluster screen may display
the messages “Air bag system failure” and “Electrical system failure”. This is
perfectly normal and the messages will disappear when the download procedure is
complete. There is no malfunction.
9. The download process takes approximately 3 minutes to complete, and concludes
with the message “REPROGRAMMING SUCCESSFULLY COMPLETED”.
Press “ENTER”.
10. Turn Key OFF
11. Press ESC until you reach the main menu.
12. The software download for the NIM is now complete.
1. Vehicles with assembly numbers between 15774 and 18966 must have the Proxi
file re-loaded.
2. Proceed with performing a PROXI alignment
3. Select Proxi (F2)
4. When prompted to enter a Proxi file, select Proxilocal.mdb downloaded and
unzipped in Section A, Step 5.
5. Be sure to enter the correct VIN, then carry out the proxi alignment
D. Console Replacement
1. Remove console assembly as per the procedure shown on the workshop manual
(Reference the section labelled “ALARM SYTEM KIT REPLACEMENT”)
Figure 5
2. Remove the interior color-matching bezel from the black electronics housing. NOTE:
Pay attention to the color of screws as they are of different lengths. There are a total
of six (6) screws fastening the main electronic housing (Figure 5). There are three (3)
screws fastening the front pictogram faceplate to the bezel (Figure 6).
Figure 6
3. Remove the electronic components from the bezel, and install the replacement
electronic components (Figure 7).
Figure 7
Parts Bulletin
No. 08 Date: September 23, 2005
Subject: Recall Campaign No. 136 Passenger Air Bag Indicator Light
Please be aware that in accordance with Recall Campaign No. 136, Parts Operations will
begin shipping the necessary parts on September 26, 2005. Each dealer will receive a
shipment of parts equal to approximately 50% of the total allocation of vehicles reported as
units in operation in your area. The following parts will be shipped:
For more information, please refer to the Recall Campaign No. 136 instructions in the
booklet or contact Dealer Services.
08.092305
RECALL CAMPAIGN
INSTRUCTIONS
RECALL CAMPAIGN
QUATTROPORTE
2005 MODEL YEAR
OCTOBER 2004
READ , INITIAL Service Manager Parts Manager Service Writer Technician Warranty Clerk
AND PASS ON »
Maserati North America, Inc.
October, 2004
This notice is sent to you in accordance with the requirements of the Motor Vehicle
Safety Act.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati
Canadian Quattroporte vehicles.
The defect involves the internal wiring harness of the affected door handles, which may
accidentally short circuit, opening the electrical switch of the door, and in certain
situations the door might open without any action from the vehicle occupant. However,
this cannot occur if the vehicle is traveling at a speed in excess of 6 miles per hour (10
kilometer per hour), due to the intervention of the central locking system.
Model year 2005 Canadian Quattroporte with Vehicle Identification Numbers from
ZAMCE39A150014410 to ZAMCE39A750015027, which have a Vehicle Assembly
Number from 15774 to 16038.
The remedy consists of replacing the four outer door handles on the vehicle.
Sincerely,
Enzo Francesconi
REMEDY: The remedy consists of replacing all four affected outer door
handles with the new outer door handles that have the new
routing of the wiring harness.
RECALL CAMPAIGN NO. 128
Maserati Quattroporte
“Outer Door Handles”
RECALL CAMPAIGN OVERVIEW
PARTS: The parts required for this repair are identified by the following part numbers:
Note:
Return the removed outer door handles to our warranty department following the
normal warranty parts return procedure.
Carefully read this document to determine the repair to be performed on all four doors. Do not
forget to check via MODIS CS that the vehicle is flagged for the recall campaign no. 128.
Follow the instructions and protect the door areas that could be exposed to damages during the
repair.
Notice: Since you will be reusing the water shield, do not touch the stripe of glue as it
may reduce its adhesive ability. Replace the water shield with a new one only if it is
necessary.
Do Not Cut
Vapor Barrier.
Only cut the
glue.
• Remove the outer door handles from each door.
Forward
Stud
• Hold button of the handle in to allow better access to the back stud
• Install the new outer door handles supplied by our Part Department to each door
on the vehicle.
• Tighten the outer door handles by applying a torque at the fixing point of the
handles of 3 Ft-Lbs. ( 4.1 Nm).
• Attach the peeled section of the water shield by pressing firmly around the edge to
assure proper adhesion. Replace water shield if necessary.
• Reinstall the door panel, door pull trim, door panel trim and clean the area with a
clean cloth.
• Place one green color-coding label on the inner side of the driver’s door. The label
will be provided by MNA and will help identify the completed vehicles.
• Send the removed outer door handles to our warranty department following the
normal warranty parts return procedure.
Assembly
VIN No.
14410 15774
14645 15782
14723 15968
14724 16008
14725 16051
15027 16038
M138_G: GRANSPORT - 7 - INJECTION DEVICE - IGNITION
Cylinders 8-90°V
Bore 92 mm
Stroke 79,8 mm
FRONT SIDE 1
SIDE 2 REAR
TOP
1.2.1 Specifications
Injection
Ignition
Static ignition
The system uses the following signals coming from external sensors:
• engine rpm and position (with respect to the T.D.C.);
• intake air volume and temperature;
• throttle position and opening speed;
• accelerator pedal position;
• coolant temperature;
• catalytic converter internal temperature;
• mixture ratio;
• knocking detection;
• car speed;
• ignition key to ON;
• battery voltage;
• brake system operation;
• clutch operation;
• turbocompressor activation;
• A/C system activation;
• engine supply cut-out;
• parameters coming from other systems over the CAN line (ABS, ASR, Electronically controlled gear-
box, etc.).
4 5 2 7 12 1
13
3
2 4
6
10
5 3 10
9 11 14
These components, together with the ECU, provide the MOTRONIC ME7.3.2 system with the following
specifications:
• EGAS (Electronic GAS Pedal).
An engine control system in which every situation is interpreted as a torque demand. The main ele-
ment in torque demand is represented by the accelerator pedal.
• OBD II (On Board Detection and Diagnostic system)
A system which detects operational malfunctions inside the engine control system, in order to ensure
compliance with emissions control standards.
• RLFS (Return Less Fuel System)
Fuel supply system preventing fuel return to the tank.
7
6 5
4 3
2
1
1) Air inlet
2) Air filter
3) Air flow meter
4) Conveyor-Resonator
5) Air Flow Meter /Throttle body duct
6) Throttle body
7) Plenum chamber
5 6 1
4 2
1) Fuel tank
2) Electric pumps
3) Delivery pipes/injector rail
4) Injectors
5) Float valves
6) Decanter
5 7 1 2 4 8
6 3
1) Tank
2) Decanter
3) Float valves
4) Active charcoal filter
5) Plenum chamber
6) Piping
7) Solenoid valve
8) Roll-over shut off valves
6 1
7 3
5
8 6
1) Solenoid valve
2) Pneumatic valves
3) Vacuum tank
4) Tank/valve pipe
5) Tank/plenum chamber duct
6) Exhaust manifold pipes
7) Exhaust manifolds
8) Secondary air pump
2 4 4 5 7 8
1 3 2 1 4 6
1) Manifolds
2) Pre-catalytic converters
3) Upstream Lambda sensors
4) Downtream Lambda sensors
5) Catalytic converters
6) Thermocouples
7) Pre-silencers
8) Silencers
MODEL: Quattroporte
With the introduction of the Quattroporte, the procedures listed in this bulletin must
be followed to ensure the best possible service experience for the customers.
Following these procedures will make it possible to monitor and provide immediate
assistance to the servicing dealer and technician.
Procedure:
3. Photos of any aesthetic related anomalies (i.e. leaks of any kind, defects
relating to paint, interior items, glass, etc.) must also be attached to the “Blue
on Line” reports electronically.
4. When repairs are completed, the “Blue on Line” report must be closed within 1
hour with all the above mentioned information (i.e parameters, fault codes,
diagnostic tests of any kind with results) attached to the report, electronically.
TECHNICAL INFORMATION
For your Information, below is a list of Maserati Campaigns that are closed or will be
closing along with the respective closing dates.
TECHNICAL INFORMATION
For your information, if the reverse shift lever “T” handle comes loose, it can be tightened
so that replacement of the complete shifter assembly, part number; 67734326 /
67734327 is no longer necessary.
To tighten the securing screw for the “T” handle, remove the lever assembly and remove
the bottom cover screws. After removing the bottom cover, it is now possible to access
the lever to tighten the securing screw.
Warranty Information;
TECHNICAL INFORMATION
For your information, please note tha t the North America market uses specific software
on SD3 to communicate with the Nodo Cambio Robotizzato (Duoselect transmission).
In the event that any software other than what is listed below is used, some parameters
and acquisitions could be incomplete and/or incorrect.
The correct software for diagnosis and clutch setup is indicated on the SD3 as CFC301
and/or Sofast 3. The marking CFC301 can also can be found on the NCR
Control unit located in the trunk above the battery. In order to access the below listed
software be sure to have version 8.4H or above installed on your PC and in your
SD3tester.
Figure 1 shows the correct diagnosis software that should always be used to diagnose
transmission faults in the Quattroporte:
Figure 1
For clutch setup please be sure to follow the following steps:
1. Load your Quattroporte technical documentation CD (be sure to have all 7
updates installed from Modis)
2. Click on Service Manual
3. Click on Gearbox Components
4. Click on Electronically Controlled Gearbox Controls
5. Click on Kiss point (PIS) adjustment procedure
6. Follow all instructions carefully
Please note that upon booting up SD3 you must enter the diagnosis software Kisspoint
NCR CFC301 as shown in figure 2:
Figure 2
Please note that cable 95979568 is needed to complete the procedure and will be
automatically sent to your dealer.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: ALL
For your Information, attached is the form that will be used to explain why parts are being
returned to a dealer. This form will accompany any parts returned to you that are not
accepted in the warranty system.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
We would like to inform you that the following new diagnostic software releases
for SD3 are now available on Modis.
After this procedure, there will be no diagnostic software on the tester. Therefore, in
addition to 8.4M, you must load all porting software previously on the tester before
data deletion (Coupe, Spyder, GranSport).
9. Click Save and select a suitable location on your PC to save the file
10. Once the download is complete click open on the window or locate the file and
double-click ScaricoSO_228.EXE
11. Type or select a location to extract the file to and click Extract
12. Power up your SD3 tester and select the 2 option from the top Dialogue
Activation with the PC
13. Using your PC now, double-click on the SD3-Net icon on your desktop
14. Click on Maintenance at the top
15. Select Tester Operating System
16. Next locate the file you extracted on your PC
17. Sistema Operativo SD3 2.28 should now be seen on the right column as
shown below:
18. Click update and the PC is now sending the file to the tester
19. When complete turn the tester OFF then back ON
20. When the tester is booted up select the last option on the main menu
Information
21. Check that the tester operating system is 2.28 as shown below:
Now that the Operating System Software2.28 is installed, it is possible to install 8.4M
Diagnostic Software.
8. Once the download window open click save and select a suitable location
9. Once the download is complete double click either file and extract the file to a
suitable location on your PC
10. Repeat with the other file
11. Open SD3net on your PC and select updates on the top left hand corner
12. Select personal computer software update
13. On the left hand side of the update screen locate the file you previously
extracted labeled SwDwnSD3
14. Once the program DOWNLOAD TELECARICAMENTI are shown on the right
click select all
15. Click update NOTE: If the screen seems to freeze or the progress bar (in
green) does not move, do not do anything. The system is still updating
and will briefly end.
16. Select EXIT
17. While SD3NET is open on your PC, select updates on the top left hand corner
18. Select tester SD3 software update
19. On the left hand side of the update screen locate the file you previously
extracted labeled INST_SD3 in the SwDwnSD3 folder
20. Once the program DOWNLOAD TELECARICAMENTI is shown on the right
click select all
21. Click TRANSFER NOTE: If the screen seems to freeze or the progress bar
(in green) does not move, do not do anything. The system is still
updating and will briefly end.
22. Select EXIT
This is a general purpose tool for the flash programming of software of the on-board
ECUs of the M139. Suitable files for different purposes will be issued on MODIS
anytime necessary and the specific Technical information will be provided
accordingly. Software from this download is loaded on both the PC and the SD3. The
following lines will be added on the menu of the SD3 tester:
1. While SD3NET is open on your PC, select updates on the top left hand corner
2. Select tester SD3 software update
3. On the left hand side of the update screen locate the file you previously
extracted labeled KISS_TWO_NCR
4. Once all the ECU’s are shown on the right click select all
5. Click TRANSFER NOTE: If the screen seems to freeze or the progress bar
(in green) does not move, do not do anything. The system is still
updating and will briefly end.
The KISSPOINT II software is ONLY loaded on the SD3. This process and the
interface to the end user have been modified. On the SD3 diagnostic tester, the
KISSPOINT II procedure can be found in the Serial Diagnosis menu under
“Diagnostics Cycle on Individual ECU”. The following are the specific programs used,
with location on SD3 and description:
1. TOOLS / MASERATI / M139 / KISSPOINT NCR 2.0 SOFAST II: DO NOT USE!:
This is software for the M139 EU specifications (European Only)
2. TOOLS / MASERAT/ M139 / KISSPOINT NCR 2.0 SOFAST III: For all model
M139 US specifications using software “SOFAST 3” (They can be identified trough
the hardware version of the gearbox ECU CFC301)
3. TOOLS / MASERATI / M138 / KISSPOINT NCR 2.0 SOFAST II: Spyder and
Coupè MY05, GranSport, Spyder 90th Anniversary; software “SOFAST 2” (They can
be identified trough the hardware version of the gearbox ECU CFC231)
¾ Flash programming in Porting mode for M138 and M139: the current flash
programming mode is placed in the environment MASERATI / M139SWUPDATE
for M139 and MASERATI / M138SWUPDATE for M138. The flash programming
porting for M138 has a high memory occupation therefore it must be downloaded
alone and only when actually necessary.
Listed below are changes to the above mentioned software for SD3Net
OPERATING SYSTEM;
- The new version 2.28 for the SD3 operating system is now included.
- The buttons 8 and 9 (page up/page down) have been added to the
errors/parameters/diagnosis
- The color of the active diagnosis result windows has been modified:
› Green – result OK,
› Red – result KO,
› Light blue – diagnostics cycle ended by the user
- The vehicle serial number is now requested each time the SD3 tester is connected
to a vehicle.
IMPORTANT:
For the “dual brand” workshops, it is essential that the same software release
is installed on the SD3 tester for the individual vehicles (for example, it would
create problems if you installed release 8.4 L for 612 Scaglietti vehicles and
release 8.4 M for Maserati Quattroporte vehicles on the SD3 tester).
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
This Bulletin cancels and replaces Bulletin number MNA-20, dated June 2005.
We would like to inform you that the following new diagnostic software releases
for SD3 are now available on Modis:
After this procedure, there will be no diagnostic software on the tester. Therefore, in
addition to 8.4N, you must load all porting software previously on the tester before
data deletion (Coupe, Spyder, GranSport).
9. Click Save and select a suitable location on your PC to save the file
10. Once the download is complete click open on the window or locate the file and
double-click ScaricoSO_228.EXE
11. Type or select a location to extract the file to and click Extract
12. Power up your SD3 tester and select the 2 option from the top Dialogue
Activation with the PC
13. Using your PC now, double-click on the SD3-Net icon on your desktop
14. Click on Maintenance at the top
15. Select Tester Operating System
16. Next locate the file you extracted on your PC
17. Sistema Operativo SD3 2.28 should now be seen on the right column as
shown below:
18. Click update and the PC is now sending the file to the tester
19. When complete turn the tester OFF then back ON
20. When the tester is booted up select the last option on the main menu
Information
21. Check that the tester operating system is 2.28 as shown below:
Now that the Operating System Software2.28 is installed, it is possible to install 8.4N
Diagnostic Software.
8. Once the download window open click save and select a suitable location
9. Once the download is complete double click either file and extract the file to a
suitable location on your PC
10. Repeat with the other file
11. Open SD3net on your PC and select updates on the top left hand corner
12. Select personal computer software update
13. On the left hand side of the update screen locate the file you previously
extracted labeled SwDwnSD3
14. Once the program DOWNLOAD TELECARICAMENTI are shown on the right
click select all
15. Click update NOTE: If the screen seems to freeze or the progress bar (in
green) does not move, do not do anything. The system is still updating
and will briefly end.
16. Select EXIT
17. While SD3NET is open on your PC, select updates on the top left hand corner
18. Select tester SD3 software update
19. On the left hand side of the update screen locate the file you previously
extracted labeled INST_SD3 in the SwDwnSD3 folder
20. Once the program DOWNLOAD TELECARICAMENTI is shown on the right
click select all
21. Click TRANSFER NOTE: If the screen seems to freeze or the progress bar
(in green) does not move, do not do anything. The system is still
updating and will briefly end.
22. Select EXIT
This is a general purpose tool for the flash programming of software of the on-board
ECUs of the M139. Suitable files for different purposes will be issued on MODIS
anytime necessary and the specific Technical information will be provided
accordingly. Software from this download is loaded on both the PC and the SD3. The
following lines will be added on the menu of the SD3 tester:
1. While SD3NET is open on your PC, select updates on the top left hand corner
2. Select tester SD3 software update
3. On the left hand side of the update screen locate the file you previously
extracted labeled KISS_TWO_NCR
4. Once all the ECU’s are shown on the right click select all
5. Click TRANSFER NOTE: If the screen seems to freeze or the progress bar
(in green) does not move, do not do anything. The system is still
updating and will briefly end.
The KISSPOINT II software is ONLY loaded on the SD3. This process and the
interface to the end user have been modified. On the SD3 diagnostic tester, the
KISSPOINT II procedure can be found in the Serial Diagnosis menu under
“Diagnostics Cycle on Individual ECU”. The following are the specific programs used,
with location on SD3 and description:
1. TOOLS / MASERATI / M139 / KISSPOINT NCR 2.0 SOFAST II: DO NOT USE!:
This is software for the M139 EU specifications (European Only)
2. TOOLS / MASERAT/ M139 / KISSPOINT NCR 2.0 SOFAST III: For all model
M139 US specifications using software “SOFAST 3” (They can be identified trough
the hardware version of the gearbox ECU CFC301)
3. TOOLS / MASERATI / M138 / KISSPOINT NCR 2.0 SOFAST II: Spyder and
Coupè MY05, GranSport, Spyder 90th Anniversary; software “SOFAST 2” (They can
be identified trough the hardware version of the gearbox ECU CFC231)
¾ Flash programming in Porting mode for M138 and M139: the current flash
programming mode is placed in the environment MASERATI / M139SWUPDATE
for M139 and MASERATI / M138SWUPDATE for M138. The flash programming
porting for M138 has a high memory occupation therefore it must be downloaded
alone and only when actually necessary.
Listed below are changes to the above mentioned software for SD3Net
OPERATING SYSTEM;
- The new version 2.28 for the SD3 operating system is now included.
- The buttons 8 and 9 (page up/page down) have been added to the
errors/parameters/diagnosis
- The color of the active diagnosis result windows has been modified:
› Green – result OK,
› Red – result KO,
› Light blue – diagnostics cycle ended by the user
- The vehicle serial number is now requested each time the SD3 tester is connected
to a vehicle.
IMPORTANT:
For the “dual brand” workshops, it is essential that the same software release
is installed on the SD3 tester for the individual vehicles (for example, it would
create problems if you installed release 8.4 L for 612 Scaglietti vehicles and
release 8.4 N for Maserati Quattroporte vehicles on the SD3 tester).
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
Please be informed that the dealer extranet now includes important information for
the after sales departments. The dealer extranet web address is
http://www.dealers.maseratiusa.com.
In order to access this information you must first complete the attached form and fax
it to 201-816-3397. Please print legibly. Once the form is processed, you will receive
a user name and password using the email address you provided on the form.
• Technical Bulletins
• Recall Campaigns
• Technical Tips
• Warranty Bulletins
After-sales Dealer Extranet Sign-up
Last Name:
Title:
Email:
Mobile#:
Fax#:
TECHNICAL INFORMATION
For your information the below mentioned procedures should be carried out when
ever you are programming new keys for the M139 Quattroporte.
Important: Before you begin the procedure, be sure to have all keys on hand.
Any key left out will no longer function. Second, be sure to have the electronic
key code card from the vehicles pouch.
IMPORTANT!
Once complete with the steps on SD3 remove the key from the ignition and
close all the doors (trunk and hood included). Wait 15 min for the vehicle’s
CAN bus to go to sleep as indicated by the CD-changer lights and the NQS
lights going out. Once asleep the remote part of the keys (alarm system) will
now function and the reprogramming will be complete.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
For your information, starting September 1st, to be able to access ModisCs, the
Internet Explorer version required is 6.0.
To see the version currently on your system, while using Internet Explorer, click on
“Help”, then click on “About Internet Explorer”. If the version you are currently
using is not 6.0 or higher, you must go to Microsoft.com and follow the instructions
for loading version 6.0 on your system.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
* Number located at the bottom left corner of the label affixed to Transmission ECU
(see Figure 1).
** Maserati Stability Program
The new units will come blank and must be programmed for each individual car.
ModisCS now has programming software listed for SD2 and SD3 for engine and
transmission control units for all Maserati models.
1. After-sale
2. Technical Service
3. SD2 Software Download
4. (Select car model)
5. ECU Software
Figure 1 M139 Transmission ECU (NCR)
TECHNICAL INFORMATION
MODEL: Quattroporte
The purpose of this document is to clarify the location of the two (2) required files for
Campaign 136 on the Maserati Quattroporte. Please reference the specified steps
outlined in A. Software Download in the section labeled “Software Downloads &
Technical Instructions”
Figure 1
B. The location of NIMSW_M139_1.exe (Figure 2) is found on MODIS using the
path:
a. After-sale
b. Technical Service
c. SD2 Software Download
d. M139_B - QuattroPorte
e. ECU Software
Figure 2
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
To verify the software version, check the value SW VER. It must be 0236.
1. During PDI, the instrument cluster does not require any programming, setup,
or intervention with the SD3.
• The only action that must be performed is to set the TIME and DATE on
the NIT if necessary.
• Make sure that the time and date on the display on the cluster do not show
dashes (e.g. --:-- or --/--/----). This is an indication that they must be set.
NOTE: If the TIME and DATE are not set (--:-- and --/--/---- for the time and
date, respectively, displayed in the cluster) at the instant the mileage reaches
120 miles, the cluster will store the initial date as 01-01-2000. If this happens,
the cluster must then be replaced.
2. The NIT will display the current mileage and date UNTIL the next service. Use
the following key strokes on the NIT to obtain this info: TRIP >> SERVICE
INFO. You will see 2 possible screens:
• If the vehicle has less than 120 miles, the mileage is displayed, but day
information is not available
• Once the vehicle reaches 120 miles, the day countdown will start at 356
days, or 1 year.
• If the Service Information Reset in the SD3 is performed on the cluster
before 120 miles, the SD3 will display “NACK UNKNOWN”. This is normal
operation because the SD3 prevents a reset as service is not due.
3. There are 2 basic problems that may occur with the service interval in the
instrument cluster.
• If the “Service Due Now” indicator is displayed on the instrument cluster
and the NIT during the first 120 miles, the instrument cluster must be
replaced
• If the “Service Due Now” indicator is displayed on the instrument cluster
and the NIT before the first service interval (6000), the instrument cluster
must be replaced
NOTE: When the SD3 is used to reset the service interval in these above
mentioned intervals, it is highly probable that the SD3 will display “NACK
UNKNOWN” – this is NOT normal operation and the cluster must be replaced.
4. When a new cluster is installed, the cluster display might show the message
“System not programmed”. In this case, the following actions must be done:
• Set the TIME and DATE on the NIT
• Perform a Proxi Align (Ricambi M139 on SD3NET in Link-to-PC
mode)
• Perform a Cycle Test on the Cluster
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
MODEL: Quattroporte
There is now available on MODIS new Kiss Point software specifically for Model Year
2006 Quattroporte. This software must be used on all MY06 Quattroportes.
1. Download the Kiss Point software from MODIS using the path:
a. After-sales
b. Technical Service
c. SD2 Software Download
d. STRU_G – Strumenti Generici
e. Other Software
f. Select the file: KISS_TWO_NCRM139M138.exe
Figure 1
g. When prompted save the file in an appropriate location on the PC
(preferably in a directory branching directly from the C: drive)
Figure 2
2. Load the Kiss Point 2 software into the tester by the following procedure:
a. Connect the PC to the SD3 tester in Link-to-PC mode
b. Start the SD3NET program
c. Select Updates in the top menu bar
d. Select Tester SD3 Software Update
e. Select the directory in which you originally saved and extracted the file
in Step 1. An icon should appear in the right window (Fig. 2).
f. Select SELECT ALL
g. Select TRANSFER
h. After the downloading process takes place, select CONTINUE when the
screen displays OPERATION COMPLETE
3. When performing the Kiss Point, follow the procedure outlined in bulletin
TECH TIPS – Vol 1 Issue 2. However, you must use the following path to get
to the correct software:
a. SERIAL DIAGNOSIS
b. DIAGNOSTICS CYCLE ON INDIVIDUAL ECU
c. MASERATI
d. TOOLS
e. M139
After selecting this software, the SD3 will start the same Kiss Point Procedure
outlined in TECH TIPS – Vol 1 Issue 2.
MASERATI NORTH AMERICA, INC.
TECHNICAL SERVICE DEPARTMENT
TECHNICAL INFORMATION
For your information, to help clarify the current software for a particular model we
have created a list for your reference. The list shows all production software for all
models years and model types since 2002.
Please note that this list is subject to change. It is recommended that you check on
Modis to stay current with any updates relating to software and Technical
Documentation updates that may be posted.
1. Maserati
2. After-sale
3. Technical Service
4. SD2 Software Download
5. Select the appropriate vehicle
6. Select ECU software
ME7.11 Engine
Model year Model Cambio Software
Software
Coupe GT 193591.002
MY02 Non- Coupe F1 193592.002 MAC1BF45
sofast Spyder GT 192657.003
Spyder F1 192658.003 MAC1BE45
Coupe GT 193591.002
Boot Sofast +
Coupe F1 200007.000
MAC45F08
MY02 Sofast
Spyder GT 192657.003
Boot Sofast +
Spyder F1 200008.000
MAC45E49
Coupe GT 198861.001
Coupe F1 200004.001 MAC45F08
MY03 Sofast
Spyder GT 198863.001
Spyder F1 200005.001 MAC45F08
Coupe GT 202919.001
Coupe F1 202918.001 MAB56F36
MY04
Spyder GT 202921.001
Spyder F1 202920.001 MAB56F36
Coupe GT 210517.001
Coupe F1 210515.001 MCC44F13
Spyder GT 210518.001
Spyder F1 210516.001 MCC44F13
MY05 Coupe
210520.001 MCC44H12
Gransport
Spyder
214771.000 MCC44H12
Gransport
Quattroporte 198428.002 MDD31U21
Coupe GT 219620.000
Coupe F1 216619.001 MCC47F22
MY06 Coupe
219629.001 MCC49H21
Gransport
Spyder
219629.001 MCC49H21
Gransport
Quattroporte 219314.002 MDED31A60
M139_B: Quattroporte Release 1.0 - 1.40 - AIR INTAKE MANIFOLD AND THROTTLE HOLDER
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This notice is sent to you in accordance with the requirements of the National Traffic and
Motor Vehicle Safety Act.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect which
relates to motor vehicle safety exists in certain 2002 through 2004 model year Maserati
vehicles.
The defect involves two of the four securing bolts in the steering assembly that may not have
had a locking compound applied to the threads prior to installation. As a result of the
omission of the locking compound, the bolts may become loose when the cars are driven
aggressively. Such circumstances could lead to a reduction in vehicle control and possibly, a
crash without prior warning. The vehicles possibly affected are as follows:
Model year 2002 through 2004 Spyder and Coupe with Vehicle Identification Numbers from
ZAMBC38A320005335 to ZAMBC38A340011963, which have a Vehicle Assembly
Number from 6605 to 13190.
The remedy consists of replacing the two affected bolts with new bolts that are coated with a
locking compound.
Since your car is among those that may be affected by the above condition, we ask you to
immediately contact any Authorized Maserati Dealer in order to arrange an inspection of your
automobile and to have the corrective action performed.
The corrective action for the above listed repair will be performed free of charge to you and
will require up to approximately 1 hour to complete. Please plan, however, to leave your
vehicle with the dealership to allow the dealer some flexibility for scheduling your repairs.
By the time you receive this letter, the Authorized Maserati Dealers will have been supplied
with the parts and the instructions to perform the repair. If the Dealer fails or is unable to
make the necessary repairs free of charge within a reasonable time, or if you have any
problem obtaining the needed repair, you should inform the national headquarters of Maserati
North America, Inc. at:
If the affected vehicle is not repaired free of charge to you and within a reasonable time, you
may submit a written complaint to the Administrator, National Highway Traffic Safety
Administration, (NHTSA), 400 Seventh Street, SW, Washington, DC 20590. You may also
telephone the toll free Auto Safety Hotline at 888-327-4236.
You may be eligible to receive reimbursement for the cost you incurred if you already have
obtained a remedy for a problem associated with the defect described in this letter.
However, you still must have this corrective action performed, regardless of any previous
repairs that may have been performed. Information about the reimbursement program for
pre-notification repairs is provided in the enclosure to this letter.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a
copy of this notice to the lessee within ten working days.
If you no longer own this vehicle or your address has changed, please complete the enclosed
prepaid yellow card and return it to Maserati North America, Inc.
We urge you to comply with this notice promptly and we apologize for any inconvenience this
may cause you.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
ENCLOSURE
You may be eligible for reimbursement if you previously incurred out-of-pocket costs for
repairs or replacements of the steering rack bolts covered by this recall campaign number
106.
1. This reimbursement program applies to the vehicles listed below and in the attached letter:
• Model year 2002 through 2004 Spyder and Coupe with Vehicle Identification
Numbers from ZAMBC38A320005335 to ZAMBC38A340011963, which have a
Vehicle Assembly Number from 6605 to 13190.
2. This reimbursement program applies to repairs or replacements of the steering rack bolts.
4. This reimbursement program does not apply to repairs or replacements that were made
within the period during which the original warranty would have provided for a free repair of
the problem addressed by this recall, unless (i) a franchised dealer or authorized
representative of Maserati denied warranty coverage or (ii) the repair made under the
warranty did not remedy the problem. Reimbursement also will not be provided if the pre-
notification remedy was not of the same type as the recall remedy provided herein, did not
address the defect that led to this recall, or was not reasonably necessary to correct the
defect.
5. To obtain reimbursement for pre-notification remedies, you will need to provide a receipt,
which may be an original or copy, identifying the equipment replaced; and, if the pre-
notification remedy was obtained at a time when the vehicle was covered under the original
warranty program, documentation indicating that the manufacturer’s dealer or authorized
facility either refused to remedy the problem addressed by the recall under the warranty or
that the warranty repair did not correct the problem addressed by the recall. In addition, you
will need to submit a written and signed claim for reimbursement that contains the information
required in paragraph 6, below.
6. The claim for reimbursement should include the following information. (a) the name and
address of the claimant; (b) identification of their vehicle’s make, model, model year, and
vehicle identification number; (c) identification of the Maserati Campaign number (Campaign
No. 106) or identification of the recall by reference to NHTSA’s recall number; and (d)
identification of the owner or purchaser of the vehicle at the time that the pre-notification
remedy was obtained.
7. If you have any questions about the reimbursement program or need help in making a
claim for reimbursement, please write or call Maserati North America, Inc., at the following
address and telephone number:
This notice is sent to you in accordance with the requirements of the National Traffic and
Motor Vehicle Safety Act.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect,
which relates to motor vehicle safety exists in certain 2002 through 2004 model year
Maserati vehicles.
The defect involves two of the four securing bolts in the steering assembly that may not
have had a locking compound applied to the threads prior to installation. As a result of
the omission of the locking compound, the bolts may become loose when the cars are
driven aggressively. Such circumstances could lead to a reduction in vehicle control and
possibly a crash. The vehicles possibly affected are as follows:
Model years 2002 through 2004 Spyder and Coupe with Vehicle Identification
Numbers from ZAMBC38A320005335 to ZAMBC38A340011963 which have a
Vehicle Assembly Number from 6605 to 13190.
The remedy consists of replacing the two affected bolts with new bolts that are coated
with a locking compound.
This operation will be performed free of charge to the vehicle owner, and will require up
to approximately 1 hour to complete.
We have accordingly sent notices to all owners of the affected vehicles advising them of
this problem and requesting that they contact any Authorized Maserati Dealer for the
repairs, as per the attached notification letter.
Federal regulation requires that any vehicle lessor receiving this recall notice must
forward a copy of this notice to the lessee within ten working days.
A supply of these parts will be shipped automatically to you based on the number of
vehicles in your servicing area. Any additional quantities must be ordered, as needed,
from our Parts Department.
Upon transmittal of the repair under the normal warranty system, we will of course
reimburse you for the parts and the labor necessary to carry out this campaign.
Obviously, if you have any of the affected vehicles in your stock, you must not sell them
until you have performed the necessary repairs. If you have already sold any vehicles
with the chassis numbers specified in the enclosed instructions and have not yet sent in
the new owner information to MNA, please do so at once so we may notify these
owners.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
RECALL CAMPAIGN NO. 106
Maserati Spyder and Coupe
“Steering Rack Bolts”
RECALL CAMPAIGN OVERVIEW
Model years 2002 through 2004 Spyder and Coupe with Vehicle
Identification Numbers from 5335 to 11963 which have a Vehicle
Assembly Number from 6605 to 13190.
CONDITION: The defect involves two of the four securing bolts in the steering
assembly that may not have had a locking compound applied to the
threads prior to installation. As a result of the omission of the locking
compound, the bolts may become loose when the cars are driven
aggressively. If this condition was to exist while the cus tomer was
driving, it could pose a potential safety risk to the driver as well as
other vehicles and potentially result in damage to the vehicle or
property and possibly crash.
REMEDY: The remedy consists of replacing the two affected bolts with new
bolts that have a locking compound applied.
RECALL CAMPAIGN NO. 106
Maserati Spyder and Coupe
“Steering Rack Bolts”
RECALL CAMPAIGN OVERVIEW
PAGE 2
PARTS : The parts required for this repair are identified by the following part
numbers:
202965 2 Bolts
11190574 2 Tapered Washer
12641021 2 Flat Washer
NOTE: Before starting this procedure, you MUST read these instructions carefully
and completely.
1. Using MODIS, check to be certain that the vehicle has not had the procedure
performed previously.
2. Raise the car on a lift.
3. Remove one of the two bolts on the steering rack where the steering column
attaches. (Picture 1)
4. Check the bolt hole threads with a 10 x 1.25 tap.
5. Clean the bolt hole to ensure there is no debris remaining after using the tap.
6. Install the new bolt and torque to 25 Nm.
7. Remove the second bolt and repeat steps 4, 5 and 6.
8. Perform a final torque of 40 Nm on both bolts.
9. Apply red touch-up paint (obtained locally) to the breather outlet pipe on the L/S
cam cover. (Picture 2) This will be used to identify that the recall has been
completed.
Picture 1 Picture 2
Recall 106 - Steering Bolts
VIN Assembly VIN Assembly VIN Assembly
Number Number Number Number Number Number
RECALL CAMPAIGN
QUATTROPORTE
2005 MODEL YEAR
OCTOBER 2004
READ , INITIAL Service Manager Parts Manager Service Writer Technician Warranty Clerk
AND PASS ON »
Maserati North America, Inc.
October, 2004
This notice is sent to you in accordance with the requirements of the National Traffic and
Motor Vehicle Safety Act.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati
Quattroporte vehicles.
The defect involves the internal wiring harness of the affected door handles, which may
accidentally short circuit, opening the electrical switch of the door, and in certain
situations the door might open without any action from the vehicle occupant. However,
this cannot occur if the vehicle is traveling at a speed in excess of 6 miles per hour (10
kilometer per hour), due to the intervention of the central locking system.
The remedy consists of replacing the four outer door handles on the vehicle.
The operation will be performed free of charge to the vehicle owner, and will require
approximately 4 hours to complete.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
Maserati North America, Inc.
October, 2004
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This notice is sent to you in accordance with the requirements of the National Traffic and
Motor Vehicle Safety Act.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati
Quattroporte vehicles.
The defect involves the internal wiring harness of the affected outer door handles, which
may accidentally short circuit, opening the electrical switch of the door, and in certain
situations the door might open without any action from the vehicle occupant. However,
this cannot occur if the vehicle is traveling at a speed in excess of 6 miles per hour, due to
the intervention of the central locking system.
The remedy consists of replacing the four door handles on the vehicle.
We may have contacted you by telephone concerning this matter. If we did not reach
you, or if you have not yet scheduled an appointment with your Authorized Maserati
dealer to have this matter addressed, we ask you to immediately contact any Authorized
Maserati Dealer in order to arrange an inspection of your automobile and to have the
corrective action performed.
The corrective action for the above listed repair will be performed free of charge to you
and will require up to approximately four hours to complete. Please plan, however, to
leave your vehicle with the dealership to allow the dealer some flexibility for scheduling
your repairs.
By the time you receive this letter, the Authorized Maserati Dealers will have been
supplied with the parts and the instructions to perform the repair. If the Dealer fails or is
unable to make the necessary repairs free of charge within a reasonable time, or if you
have any problem obtaining the needed repair, you should inform the national
headquarters of Maserati North America, Inc. at:
If the affected vehicle is not repaired free of charge to you and within a reasonable time,
you may submit a written complaint to the Administrator, National Highway Traffic
Safety Administration, (NHTSA), 400 Seventh Street, SW, Washington, DC 20590. You
may also telephone the toll free Auto Safety Hotline at 888-327-4236.
You may be eligible to receive reimbursement for the cost you incurred if you already
have obtained a remedy for a problem associated with the defect described in this letter.
However, you still must have this corrective action performed, regardless of any previous
repairs that may have been performed. Information about the reimbursement program for
pre-notification repairs is provided in the enclosure to this letter.
Federal regulation requires that any vehicle lessor receiving this recall notice must
forward a copy of this notice to the lessee within ten working days.
If you no longer own this vehicle or your address has changed, please complete the
enclosed prepaid yellow card and return it to Maserati North America, Inc.
We urge you to comply with this notice promptly and we apologize for any
inconvenience this may cause you.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
ENCLOSURE
You may be eligible for reimbursement if you previously incurred out-of-pocket costs for
repairs or replacements of the outer door handles covered by this recall campaign number
128.
1. This reimbursement program applies to the vehicles listed below and in the attached
letter:
4. This reimbursement program does not apply to repairs or replacements that were made
within the period during which the original warranty would have provided for a free
repair of the problem addressed by this recall, unless (i) a franchised dealer or authorized
representative of Maserati denied warranty coverage or (ii) the repair made under the
warranty did not remedy the problem. Reimbursement also will not be provided if the
pre-notification remedy was not of the same type as the recall remedy provided herein,
did not address the defect that led to this recall, or was not reasonably necessary to
correct the defect.
6. The claim for reimbursement should include the following information. (a) the name
and address of the claimant; (b) identification of their vehicle’s make, model, model year,
and vehicle identification number; (c) identification of the Maserati Campaign number
(Campaign No. 128) or identification of the recall by reference to NHTSA’s recall
number; and (d) identification of the owner or purchaser of the vehicle at the time that the
pre-notification remedy was obtained.
7. If you have any questions about the reimbursement program or need help in making a
claim for reimbursement, please write or call Maserati North America, Inc., at the
following address and telephone number:
REMEDY: The remedy consists of replacing all four affected outer door
handles with the new outer door handles that have the new
routing of the wiring harness.
RECALL CAMPAIGN NO. 128
Maserati Quattroporte
“Outer Door Handles”
RECALL CAMPAIGN OVERVIEW
PARTS: The parts required for this repair are identified by the following part numbers:
Note:
Return the removed outer door handles to our warranty department following the
normal warranty parts return procedure.
Carefully read this document to determine the repair to be performed on all four doors. Do not
forget to check via MODIS CS that the vehicle is flagged for the recall campaign no. 128.
Follow the instructions and protect the door areas that could be exposed to damages during the
repair.
Notice: Since you will be reusing the water shield, do not touch the stripe of glue as it
may reduce its adhesive ability. Replace the water shield with a new one only if it is
necessary.
Do Not Cut
Vapor Barrier.
Only cut the
glue.
• Remove the outer door handles from each door.
Forward
Stud
• Hold button of the handle in to allow better access to the back stud
• Install the new outer door handles supplied by our Part Department to each door
on the vehicle.
• Tighten the outer door handles by applying a torque at the fixing point of the
handles of 3 Ft-Lbs. (4.1 Nm).
• Attach the peeled section of the water shield by pressing firmly around the edge to
assure proper adhesion. Replace water shield if necessary.
• Reinstall the door panel, door pull trim, door panel trim and clean the area with a
clean cloth.
• Place one green color-coding label on the inner side of the driver’s door. The label
will be provided by MNA and will help identify the completed vehicles.
• Send the removed outer door handles to our warranty department following the
normal warranty parts return procedure.
RECALL CAMPAIGN
QUATTROPORTE
2005 MODEL YEAR
SEPTEMBER 2005
READ , INITIAL Service Manager Parts Manager Service Writer Technician Warranty Clerk
AND PASS ON »
Maserati North America, Inc.
February _, 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
Serial Number: «VIN» «ASSY»
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati
Quattroporte vehicles.
The defect consists of the presence of a non-functioning button with the words
“Passenger Air Bag Off” etched into it and located, along with an LED light, on a
console adjacent to the sun roof. This non-functioning button does not deactivate
the passenger-side air bag. Nor is the LED light an indication that the passenger-
side air bag has been deactivated. The button is non-functional and cannot be
depressed when pushed. Maserati is concerned, however, that drivers and customers
may be misled by this non-functioning button and LED light into thinking that the
passenger-side air bag has been, or can be, deactivated. As a result, infants and small
children might be placed in the front passenger seat. The placement of infants and
small children in the front passenger seat could result in serious injury or death in
the event of a crash in which the passenger-side air bag deploys.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
Maserati North America, Inc.
September _, 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This notice is a follow up to the first notice we sent to you in the month of February. In the
first notice we notified you that Maserati S.p.A., the manufacturer of Maserati automobiles,
had decided that a defect which relates to motor vehicle safety exists in certain 2005 model
year Maserati vehicles.
The defect consists of the presence of a non-functioning button with the words “Passenger Air
Bag Off” etched into it and located, along with an LED light, on a console adjacent to the sun
roof. This non-functioning button does not deactivate the passenger-side air bag. Nor is
the LED light an indication that the passenger-side air bag has been deactivated. The
button is non-functional and cannot be depressed when pushed. Maserati is concerned,
however, that drivers and customers may be misled by this non-functioning button and LED
light into thinking that the passenger-side air bag has been, or can be, deactivated. As a result,
infants and small children might be placed in the front passenger seat. The placement of
infants and small children in the front passenger seat could result in serious injury or death
in the event of a crash in which the passenger-side air bag deploys.
Maserati will provide, at no charge to the customer, a replacement console which does not
contain the non-functioning button with the wording “Passenger Air Bag Off”. Currently, the
new console is available at our MNA parts department. Therefore, we notified the customer to
take his or her vehicle to an authorized Maserati dealer to have the console replaced as soon as
possible.
The operation will be performed free of charge to the vehicle owner, and will require
approximately 1.0 hour to complete.
Best Regards,
Victor Soriano
National Aftersales Operations Manager
Maserati North America, Inc.
Maserati North America, Inc.
February _, 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This notice is sent to you in accordance with the requirements of the National Traffic
and Motor Vehicle Safety Act.
Maserati S.p.A., the manufacturer of Maserati automobiles, has decided that a defect
which relates to motor vehicle safety exists in certain 2005 model year Maserati
vehicles.
The defect consists of the presence of a non-functioning button with the words
“Passenger Air Bag Off” etched into it and located, along with an LED light, on a
console adjacent to the sun roof. This non-functioning button does not deactivate
the passenger-side air bag. Nor is the LED light an indication that the passenger-
side air bag has been deactivated. The button is non-functional and cannot be
depressed when pushed. Maserati is concerned, however, that drivers and customers
may be misled by this non-functioning button and LED light into thinking that the
passenger-side air bag has been, or can be, deactivated. As a result, infants and small
children might be placed in the front passenger seat. The placement of infants and
small children in the front passenger seat could result in serious injury or death in
the event of a crash in which the passenger-side air bag deploys.
Maserati is sending you this notice to inform you that the non-functioning button with
the words “Passenger Air Bag Off” will not turn off the passenger air bag, and the LED
light is not an indication that the passenger-side air bag has been deactivated. Because
the passenger-side air bag cannot be turned off by any means, you should never place
infants and small children in the front passenger seat of the 2005 Maserati
Quattroporte.
The corrective action for the replacement of the console will be performed free of
charge to you. Details about the repair and the length of time that it will take will be
sent to you in the additional notice.
If you have any questions, please call Maserati North America at 201-816-2600. If you
believe that Maserati has failed to remedy the defect described in this letter free of
charge to you and within a reasonable time, you may submit a written complaint to the
Administrator, National Highway Traffic Safety Administration, (NHTSA), 400
Seventh Street, SW, Washington, DC 20590. You may also telephone the toll free
Auto Safety Hotline at 888-327-4236.
Federal regulation requires that any vehicle lessor receiving this recall notice must
forward a copy of this notice to the lessee within ten working days.
If you no longer own this vehicle or your address has changed, please complete the
enclosed prepaid yellow card and return it to Maserati North America, Inc.
We urge you to comply with this notice promptly and we apologize for any
inconvenience this may cause you.
Best Regards,
Enzo Francesconi
Vice President of Technical Services
2
Maserati North America, Inc.
September _ , 2005
«FIRST» «LAST»
«ADD1»
«ADD2»
«CITY», «ST» «ZIP»
This second notice is sent to you in accordance with the requirements of the National
Traffic and Motor Vehicle Safety Act.
In the first notice we notified you that Maserati S.p.A., the manufacturer of Maserati
automobiles, has decided that a defect which relates to motor vehicle safety exists in
certain 2005 model year Maserati vehicles.
The defect consists of the presence of a non-functioning button with the words
“Passenger Air Bag Off” etched into it and located, along with an LED light, on a
console adjacent to the sun roof. This non-functioning button does not deactivate
the passenger-side air bag. Nor is the LED light an indication that the passenger-
side air bag has been deactivated. The button is non-functional and cannot be
depressed when pushed. Maserati is concerned, however, that drivers and customers
may be misled by this non-functioning button and LED light into thinking that the
passenger-side air bag has been, or can be, deactivated. As a result, infants and small
children might be placed in the front passenger seat. The placement of infants and
small children in the front passenger seat could result in serious injury or death in
the event of a crash in which the passenger-side air bag deploys.
Maserati will provide, at no charge to you, a replacement console which does not
contain the non-functioning button and LED light. Currently, the new console is
available at our dealers. Therefore, you should take your vehicle to an authorized
Maserati dealer to have the console replaced as soon as possible.
The operation will be performed free of charge to the vehicle owner, and will require
approximately 1 hour to complete.
Maserati also stated in the first notice that the non-functioning button with the words
“Passenger Air Bag Off” will not turn off the passenger air bag, and the LED light is
not an indication that the passenger-side air bag has been deactivated. Because the
passenger-side air bag cannot be turned off by any means, you should never place
infants and small children in the front passenger seat of the 2005 Maserati
Quattroporte.
If you have any questions, please call Maserati North America at 201-816-2600. If you
believe that Maserati has failed to remedy the defect described in this letter free of
charge to you and within a reasonable time, you may submit a written complaint to the
Administrator, National Highway Traffic Safety Administration, (NHTSA), 400
Seventh Street, SW, Washington, DC 20590. You may also telephone the toll free
Auto Safety Hotline at 888-327-4236.
Federal regulation requires that any vehicle lessor receiving this recall notice must
forward a copy of this notice to the lessee within ten working days.
If you no longer own this vehicle or your address has changed, please complete the
enclosed prepaid yellow card and return it to Maserati North America, Inc.
We urge you to comply with this notice promptly and we apologize for any
inconvenience this may cause you.
Best Regards,
Victor Soriano
National Aftersales Operations Manager
Maserati North America, Inc.
2
RECALL CAMPAIGN NO. 136
Maserati Quattroporte
“Passenger Air Bag Indicator Light”
RECALL CAMPAIGN OVERVIEW
CONDITION: The defect consists of the presence of a non-functioning button with the
words “Passenger Air Bag Off” etched into it and located, along with an
LED light, on a console adjacent to the sun roof. This non-functioning
button does not deactivate the passenger-side air bag. Nor is the LED
light an indication that the passenger-side air bag has been
deactivated. The button is non-functional and cannot be depressed when
pushed. Maserati is concerned, however, that drivers and customers may
be misled by this non-functioning button and LED light into thinking that
the passenger-side air bag has been, or can be, deactivated. As a result,
infants and small children might be placed in the front passenger seat.
The placement of infants and small children in the front passenger seat
could result in serious injury or death in the event of a crash in which
the passenger-side air bag deploys.
PARTS: The parts required for this repair are identified by the following part numbers:
Note:
Return the removed console to our warranty department following the normal warranty parts
return procedure.
All Maserati Quattroporte with VIN 14216 (assembly number 15140) up to and including
VIN 18112 (assembly number 19216) are involved in a recall campaign to remove the
passenger air bag indicator light console that is located in the overhead control panel.
The defect consists of the presence of a non-functioning button with the words
“Passenger Air Bag Off” etched into it and located, along with an LED light, on a console
adjacent to the sun roof. This non-functioning button does not deactivate the
passenger-side air bag. Nor is the LED light an indication that the passenger-side
air bag has been deactivated. The button is non-functional and cannot be depressed
when pushed.
The new consoles do not have the words “Passenger Air Bag Off” etched into it.
NOTE:
¾ Carefully read this bulletin to determine the repairs that need to be performed.
¾ Reference the technical documentation in order to properly perform the repair
procedure.
¾ Check via MODIS CS that the vehicle is included in the campaign, and has not
previously undergone corrective action.
¾ Protect areas that could be exposed to damages during repair.
A. Software Download
1. Make sure that the SD3NET system and the SD3 tester are updated to software
version 8.4N or later. If not, please reference bulletin MNA – 20 / N.
2. Follow the path in MODIS
a. After-sale
b. Technical Service
c. SD2 Software Download
d. M139_B – Quattroporte
e. ECU Software
Figure 1
Figure 3
11. The next screen asks you to select the specific software. Go to the folder that
contains the software that was previously downloaded (NM04_18_M139AQ).
When the folder is selected, it should automatically appear in the right window.
12. Double click NM04_18_M139AQ in order to have file appear in the bottom
window, then click TRANSFER. (See Figure 4)
Figure 4
13. The process should take several minutes. When the “Operation Complete”
message appears, select CONTINUE.
14. Select EXIT - Download is complete.
B. Software Update
NOTE: During the downloading process, the instrument cluster screen may display
the messages “Air bag system failure” and “Electrical system failure”. This is
perfectly normal and the messages will disappear when the download procedure is
complete. There is no malfunction.
9. The download process takes approximately 3 minutes to complete, and concludes
with the message “REPROGRAMMING SUCCESSFULLY COMPLETED”.
Press “ENTER”.
10. Turn Key OFF
11. Press ESC until you reach the main menu.
12. The software download for the NIM is now complete.
1. Vehicles with assembly numbers between 15140 and 19126 must have the Proxi
file re-loaded.
2. Proceed with performing a PROXI alignment
3. Select Proxi (F2)
4. When prompted to enter a Proxi file, select Proxilocal.mdb downloaded and
unzipped in Section A, Step 5.
5. Be sure to enter the correct VIN, then carry out the proxi alignment
D. Console Replacement
1. Remove console assembly as per the procedure shown on the workshop manual
(Reference the section labelled “ALARM SYTEM KIT REPLACEMENT”)
Figure 5
2. Remove the interior color-matching bezel from the black electronics housing. NOTE:
Pay attention to the color of screws as they are of different lengths. There are a total
of six (6) screws fastening the main electronic housing (Figure 5). There are three (3)
screws fastening the front pictogram faceplate to the bezel (Figure 6).
Figure 6
3. Remove the electronic components from the bezel, and install the replacement
electronic components (Figure 7).
Figure 7
Parts Bulletin
No. 08 Date: September 23, 2005
Subject: Recall Campaign No. 136 Passenger Air Bag Indicator Light
Please be aware that in accordance with Recall Campaign No. 136, Parts Operations will
begin shipping the necessary parts on September 26, 2005. Each dealer will receive a
shipment of parts equal to approximately 50% of the total allocation of vehicles reported as
units in operation in your area. The following parts will be shipped:
For more information, please refer to the Recall Campaign No. 136 instructions in the
booklet or contact Dealer Services.
08.092305
REMOVING-REFITTING THE ENGINE
• Working from inside the engine compartment, loosen the cap for the hydraulic steering reservoir.
1
• Loosen the oil reservoir cap.
2
• Detach the air filter duct clips and remove it
• Unscrew the oil draining pipe clip next to the air flow meter.
3
• Unscrew the plenum chamber/throttle connector clip.
4
• Release the throttle cabling
5
N.B.
Suitably plug the plenum chamber "intake".
• Working from the underbody, unscrew the four screws and disassemble the front frame (Figure 1).
N.B.
Using a felt-tip pen, mark the relative positions of the two parts of the front frame (Figure 2).
6
• Remove the central exhaust line.
Removing/refitting the central exhaust line
• Drain the cooling system fluid by unscrewing the radiator plug.
7
• Drain the lubrication system oil by unscrewing the duct to the tank.
8
• Disconnect the torsion bar from the body by unscrewing the two screws on each jumper.
9
• Unscrew its eight fastening screws and remove the transmission shaft heat shield.
• Remove the heat shield for the spare wheel housing by unscrewing its six screws.
10
• Release the clutch hydraulic hose from its seven metal clips.
11
• Unscrew the four locknuts securing the catalytic converter support to the clutch housing and remove the
support.
12
• Working from both sides, loosen the four screws securing the rear frame.
13
• Extract the clutch hydraulic duct.
14
• Unscrew the rear frame fastening screws.
• Unscrew the eight nuts connecting the transmission shaft to the clutch housing.
15
• Release the gearbox oil radiator clips.
N.B.
This enables rotating the gearbox unit when it is being moved back.
16
• Unscrew the screws of both engine rubber bushings.
17
• Move the gearbox/transmission shaft assembly back by about 10cm, so that the clutch housing stud bolts
completely disengage from the transmission shaft.
18
• Detach the engine earth cable from the chassis.
19
• Position the tool 900026210 between the engine damper and the front chassis and remove the hydraulic
lift.
• Working from inside the engine compartment, detach the water nourice hoses; The nourice hoses must
also be freed from the clips securing them to the engine compartment.
20
• Unscrew the two screws securing the water nourice to the chassis.
21
• Detach the vacuum tube from the secondary air valve.
22
• Free the oil reservoir from the oil decanter hose and from the oil vapour collector hose.
• Free the oil reservoir from the oil return hose. (Figure 1).
N.B.
Fit a plug to the oil return hose (Figure 2).
23
• Detach the coil connector plates on the RH and LH sides of the engine compartment,
To access the external plate screw, the connector must be temporarily removed (1).
24
• Extract the connector unit from the clip.
25
• Free the secondary air system vacuum tank hose from its clips.
• Disconnect the heating system hose by slackening its clip. (Figure 1).
N.B.
Fit a plug to the heating system delivery sleeve. (Figure 2).
26
• Unscrew the air pump sleeve clip.
27
• Unscrew the secondary air valve sleeve clip
• Extract the pneumatic valve check pipe from the secondary air valve
28
• Unscrew the screws securing the rigid pipe connected to the secondary air system pneumatic valves and
extract the pipe itself.
29
• Unscrew the hydraulic steering system tank/pump duct.
• Unscrew the screw securing the window fluid reservoir support clip to the car body.
30
• Remove the rear gravel guard from the front RH wheelhouse.
31
• Remove the carpet from the passenger foot area.
32
• Disconnect the earth cable.
33
• From inside the engine compartment, extract the wiring.
• Unscrew the engine service wiring screw (1), the power fuse box cable screws (2) and the earth cable (3).
34
N.B.:
For the right-hand drive version, the cable is positioned on the left-hand side of the engine
compartment.
• Unscrew the union connecting the fuel pipes to the injector rails (one per bank).
35
• Fit the engine in a harness so that the belts pass around the exhaust manifolds.
36
• Extract the engine from the car using a hydraulic lift.
N.B.
Guide the engine so as to prevent parts hitting and damaging the bodywork and rest it on the stand
900026230.
• Tighten the four screws securing the engine bushing to the engine underframe to a torque of 50Nm.
• Reconnect the handbrake cable.
Removing-refitting the handbrake and tie-rods
• Fit the central exhaust line.
Removing/refitting the central exhaust line
• Mount the spare wheel housing.
Removing /refitting the spare wheel housing
• Mount the front lid
Removing/refitting the engine compartment lid
37
FILLING THE CIRCUITS AND CHECKING THE LEVELS
• In order to check and top up the levels of the brakes/clutch hydraulic control fluid and the power steering
fluid, remove the left-hand panel B from the engine compartment. To remove the engine compartment
panels, rotate the fixing pins. To refit the panels, position them correctly then screw in the fixing pins
(Figure 1).
(MY2003) In order to check and top up the fluid level of the brake/clutch hydraulic control, you must
unscrew the cap (Figure 2).
1
Engine lubrication circuit
• To check and top up the engine oil and cooling fluid levels, remove the right-hand panel A from the
engine compartment.
CAUTION
With the engine warm, be very careful when working inside the engine compartment: risk of burns!
Remember that, with the engine warm, the electric fan could start to move: risk of injuries!
2
• The level check must be carried out with the car on the flat and the engine warm and idling. The oil level
must be between the MIN and MAX reference points on the dipstick C
The gap between MIN and MAX corresponds to about 1 litre of oil.
IMPORTANT
Do not top up with oil having characteristics other than those of the oil already used in the engine.
CAUTION
The engine oil used and the oil filter replaced contain substances that are dangerous for the
environment. For replacing the oil and the filters you are advised to contact the Maserati Service
Network, where all the necessary equipment is available to dispose of the used oil and filters in
compliance with the regulations in force and in an environment-friendly manner.
3
• If the level is close to or just under the MIN reference point, add oil through the filler neck which is closed
by plug D until the MAX reference point is reached. The oil level should never exceed the MAX reference
point.
4
Engine coolant circuit
CAUTION
When the engine is very hot, do not remove the cap from the pan: risk of burns!
• The fluid level must be checked with the engine cold and must be between the MIN and MAX reference
points which can be seen on the pan. If the level is low, slowly pour the prescribed fluid through the filler
neck on the pan until the level is close to the MAX reference point.
5
• The operation of filling the engine's water circuit is carried out by partially unscrewing the two caps which
let water out from the heads. These are located in the front section of the engine to allow air contained in
the top part of the engine to escape during the filling stage.
A further degassing is carried out via these two caps after the thermostat has been opened (or rather when
the fan starts up), to release any air which may be present in the external engine circuit.
6
Hydraulic steering fluid circuit
IMPORTANT
Make sure that the power steering fluid does not come in touch with the engine hot parts as it is
flammable.
• To get to the pan, remove the left-hand panel from the engine compartment following the instructions in
the "Engine compartment panels" paragraph. With the car on a level ground and the engine cold, check
that the fluid level corresponds with the MAX reference point on the tank cap dipstick. To carry out the
check, unscrew the cap, clean the dipstick, tighten the cap back , remove it again and check the level.
The system is self-draining. The draining is carried out by turning the steering wheel as far as possible to the
left and to the right several times with the engine running and the vehicle stationary. This procedure must be
carried out every time the delivery and return pipes which run to the steering box are disconnected
7
Connection of equipment for operations concerning the air conditioning system refrigerant fluid
There are two fittings on the system pipes, one for high and one for low pressure, which are used for
operations involving the refrigerant, such as:
• refrigerant absorption;
• emptying and drying the system;
• seeking any leaks in the circuit;
• admitting vacuum pump oil;
• charging the system with refrigerant (R134a);
Version Quantity
USA 1100 gr
EUROPA 750 gr
8
The above operations may be carried out with different types of equipment with different operating
procedures;
for more detailed information, use the technical use and maintenance manual relating to the machinery used.
The high (Figure 1) and low (Figure 2) pressure fittings are shown respectively on the car without and with
the connections to the charging equipment.
9
RADIATORS
1
• Drain the air conditioning system using the special tool connected to the system valve.
2
• Unscrew the four lower screws on the cooling system fan duct.
3
• Drain the oil from the reservoir by undoing the relative screw.
• Detach the two cooling system fan connectors and the fan speed sensor.
4
• Remove the two clips on each cable bundle.
5
• Release the clip and detach the radiator water return sleeve.
6
• Detach the air filter duct clips and remove it
• Unscrew the oil draining pipe clip next to the air flow meter.
7
• Unscrew the plenum chamber/throttle connector clip.
8
• Release the throttle cabling
9
N.B.
Suitably plug the plenum chamber "intake".
10
• Unscrew the upper radiator duct screws and remove it.
• Unscrew its clips and disconnect the return hose for the hydraulic steering cooling circuit .
11
• Unscrew its clip and disconnect the delivery hose for the hydraulic steering cooling circuit.
N.B.
Fit the plugs to the radiator ducts.
12
• Unscrew the lower fan unit screws.
13
• Unscrew the screws securing the condenser from the water radiator.
14
OIL FILTER
Working from the underfloor, remove the oil filter using a suitable standard tool (Figure 1 and 2).
AIR FILTER
• Working in the underfloor, undo, starting from the left-hand side of the base, the seven perimetric screws
(Figure 1) and the central screw (Figure 2).
• Remove the front left-hand wheelhouse, undoing the six fastening screws.
• Remove the air filter housing cover, releasing its left-hand side.
• Slide the air filter out of the relative housing.
1
• Working from the underbody, unscrew the four screws and disassemble the front frame (Figure 1).
N.B.
Using a felt-tip pen, mark the relative positions of the two parts of the front frame (Figure 2).
2
• Detach the rear Lambda sensor cables from the clamps and from the restraint on the support.
• Detach the front Lambda sensor cables from the front chassis cross member
• Unscrew the four Lambda sensors from the catalytic converters.
Mark the right-hand or left-hand sensor and the corresponding catalytic converter in order to avoid
reversing their positions during the re-assembly stage.
N.B.
When unscrewing the Lambda sensors, make sure the cables do not get damaged by twisting.
3
• Unscrew the thermocouples.
• Unscrew the four screws connecting the exhaust manifolds to the pre-catalytic converters.
4
• Unscrew the clamp Unscrew the clamp connecting the central exhaust line and the terminals.
• Unscrew the screws securing the central exhaust anti-vibration supports from the gearbox housing.
5
• Position a hydraulic lift under the central silencer
• Disconnect the terminals from the central exhaust line.
6
• Remove the exhaust line.
7
TAILPIPES
N.B.
The headlight adjusting device is only present on the left-hand side.
1
• Remove the rear wheelhouse, undoing the five fastening screws (Figures 1, 2, 3 and 4).
2
3
• Working in the underbody, loosen the fastening clamp between the exhaust extensions and the tailpipe.
• Loosen the connecting clamp between the exhaust extension and the central silencer.
4
• Unscrew the two vibration damper fastening nuts from the gearbox housing.
• Remove the cross member which fastens the exhaust pipe, undoing the two fastening screws on each
extension.
5
• Remove the exhaust extensions from the tailpipe and from the connection with the central silencer.
6
• Working between the heat-shield and the tailpipe, undo the two screws fastening the vibration damper to
the car body (Figures 1 and 2).
7
• Working in the wheel compartment, undo the two screws fastening the vibration damper to the car body
(Figures 1 and 2).
8
Re-attaching the tailpipe
N.B.
Grease the tailpipe and the exhaust extension pipe to make them easier to fit.
9
• Working in the wheel compartment, fix the vibration damper to the car body and tighten the two fastening
screws (Figures 1 and 2).
10
• Secure the other vibration damper by tightening the two fastening screws to the car body (Figures 1 and
2).
11
• Connect the exhaust extension ahead of the central silencer and after the tailpipe.
• Place a soft cloth over the exhaust tailpipes to avoid damaging the bumper while centring the tailpipe.
12
• Refit the cross-member between the exhaust pipes, tightening the two fastening screws on each of the
extensions.
• Using the specific tool, centre the tailpipes with respect to the bumper's seatings.
• Working in the underbody, refit the vibration damper onto the gearbox housing and tighten the two
fastening nuts.
13
• Tighten the clamp which fastens the exhaust extension to the tailpipe.
• Tighten the clamp which fastens the exhaust extension to the central silencer.
14
• Refit the rear wheelhouse, tightening the five fastening screws (Figures 1, 2, 3 and 4).
15
16
• Fix the cable of the headlight adjusting device to the wheel arch liner.
N.B.
The headlight adjusting device is only present on the left-hand side of the car
17
ENGINE REMOVING
• Position the engine, without the clutch, onto the support stand AV2023 , fixing it with the support tool
900026310.
1
• Remove the corrugated tubes from the wire guides.
2
• Detach the oil draining pipes from the heads and remove the connecting pipes.
3
• Unfasten the bolts on the intake manifold.
4
• Remove the gaskets on the intake ducts.
• Fit the tools AV3332, securing them with two nuts to avoid allowing foreign bodies to enter the
cylinders.
5
• Remove the wiring covers.
• Detach the ignition coil connectors, check that all wires are identified in order to position them correctly
during the reassembly stage.
6
• After having detached the solenoid valve connection in the timing variator, move the coil wiring and the
injector wiring.
• Remove the retaining clamps, detach the connection on the water temperature sensors and move the
wiring on the clutch side.
7
• Remove the battery-generator wire.
8
• Detach the connections on the alternator and remove the wiring.
• Detach the connections on the detonation sensors, the timing sensors and the revolution sensor on
the supporting bracket.
CAUTION
Check that the sensors on each wire correspond, consulting the electric system manual if
necessary.
9
• Unscrew the injection wiring's seven retaining clamps.
10
• Take away the engine wiring.
11
• Remove the starter motor.
• Loosen the poliV belt by turning the tensioner and, holding the tensioner back, slide the belt off the
pulleys and remove it.
12
• Undo the screws fastening the air conditioning system compressor and then remove it.
• Remove the 6 mm screw from the hydraulic steering pump using the holes on the pulley.
13
• Unfasten the two 8 mm screws and remove the pump.
• Open the clamps on the heads' water outputs and remove the entire connecting pipe.
14
• Take the bearing out of the clutch shaft support using the extracting tool 95972714.
15
• Remove the torsion damper Once the fastening screw has been removed, the damper can be taken
out by hand.
16
• Remove the belt tensioner, undoing the 8mm fastening screw.
• Remove the fixing bracket for the pipe which runs from the exchanger to the oil tank.
17
• Remove the pipe running from the exchanger to the oil tank, unscrewing the 36 mm nut.
• Undo the two screws fastening the alternator and remove it by moving it upwards.
18
• Remove the ignition coils by unfastening the two retaining screws.
• Extract the retaining seeger ring from the timing variator's wire guide.
19
• Place the connectors for the timing (rh and lh), revolution (rh) and detonation (four) sensors into their
housings on the support bracket.
CAUTION
Check that the sensors on each wire correspond, consulting the electric system manual if
necessary.
N.B.
If necessary, remove the timing sensors (Figure 2).
20
21
• To remove the tappet covers, the stud bolt supporting the wiring and the fourteen perimetral socket
head screws must be unfastened.
• Lift the cover, taking care to slide out the solenoid valve wire on the timing variator.
22
• Remove the two fastening screws from the left-hand bank belt tensioner.
23
• Using a screwdriver, separate the front cover from the engine.
N.B.
Keep the gasket located between the upper edge of the housing and the left-hand belt tensioner.
24
• Keep the upper gasket and remove the cover (Figure 1).
N.B.
The lower gasket remains attached to the cover: remember to keep it for future assembly (Figure
2).
25
• Remove the mechanical tensioner from the oil-water pump chain.
26
• Undo the screws on the pump's toothed control wheel and remove it along with the chain.
• Undo the screws which fix the oil-water pump to the crankcase.
27
• Move the oil-water pump backwards by hitting it lightly with a rubber hammer, and then remove it.
• After removing the pump, check through the three inspection holes that there are no leakages or spills.
28
• Remove the tensioners from the timing chains (Figure 1 and 2).
29
• Remove the upper fixed shoes.
30
• Remove the exhaust camshaft screw, countering the rotation with a wrench inserted into the special
hexagon machined on the shaft.
31
N.B.
If it is necessary to keep the same timing, mark the toothed wheels and the chains(Figure 1 and 2)
at the correct point.
32
• Proceed with removing the chains, sliding the toothed wheels off the exhaust camshafts (Figure 1).
N.B.
Keep the centring dowel (Figure 2).
33
• Remove the timing chain's fixed shoes.
• Remove the tranmission axle's mechanical tensioner and the fixed shoe.
34
• Take the seeger ring and the relative shim off the transmission axle.
• Slide out the toothed wheels, paying attention to the roller cages on the transmission axle.
35
• Remove the transmission axle, paying attention to the grommet.
• Remove the union pipes leading from the oil accumulator to the heads.
36
• Unfasten the retaining nuts on the camshaft caps.
37
• Remove the screws which fasten the timing variator oil pump onto the left-hand bank intake camshaft.
• Remove the caps checking that the reference number is stamped on them.
N.B.
In this last stage, be sure to recover the timing variator tabs.
38
• If necessary, remove the continuous timing variator using tool 900027020, provided for this purpose.
• Using a magnet, take the valve buckets out of their seats, checking their reference numbers.
39
• Unscrew the ten head fastening nuts.
40
• Remove the head gaskets.
41
• Proceed with the removal of the sub-crankcase by unfastening the perimetral screws.
42
• Move the sub-crankcase away by hitting it lightly with a hammer and then remove it completely.
43
• Fit the tool AM105786 onto the crankshaft and rotate the shaft in order to gain access the connecting
rod bolts easily.
• Loosen the connecting rod caps and move them away by hitting them lightly with a hammer. Remove
the bolts by hand and take off the caps.
44
• Remove the crankshaft and the bearings (Figure 1) taking care not to drop the crankshaft's central
support shimmings (Figure 2).
45
• Remove the pistons.
46
• Remove the cylinder liners using the tool 900026610.
47
• Unscrew the four anti-detonation sensors.
48
• Remove the heat exchanger.
49
FITTING AND TIMING THE ENGINE
In order to install the cylinder liners, the crankcase must be heated up in an oven. The crankcase must be
completely bare.
The chokes for the pressurised oil delivered to the heads
have different diameters and are fitted on both cylinder banks. Each choke is fitted on a check valve.
Upon each
overhaul, it is essential to check that this valve is clean and that it works properly. The crankcase is
removed using an extracting tool, while for reassembly it is interference fitted.
Using tool AV3605 (not illustrated) loosely fit the choking dowels.
N.B.
During the reassembly stage, check that the oil choking dowels on the heads are installed
correctly: the dowel with a 5.5mm internal diameter is found on the left-hand bank (Fig. 1), while
that with a 3mm internal diameter is found on the right-hand bank (Fig. 2).
1
2
• After checking the dimensions of the cylinder liners and the respective seats in the upper crankcase,
check that the cylinder liner resting surfaces are perfectly clean, then measure the liner protrusion with
respect to the crankcase as follows:
• Fit the cylinder liner to be installed turned upside down on the crankcase.
• Using the specific tool equipped with dial gauge with DTI plunger CS0102916measure the protrusion
of the cylinder liner from the crankcase, checking that it falls within the 0.001÷0.05 mm value range.
• If necessary, try the various liners in the various seats so as to obtain the correct coupling.
• It is important that the protrusion is uniform for all the cylinder liners on each bank.
• After coupling the various cylinder liners to the respective seats, number them in order to prevent a
coupling error during assembly.
3
• Heat the bare crankcase in an oven for about 60 minutes to a temperature of 40-50°C, and cool down
the cylinder liners to a temperature of -15 to -20°C putting them in a freezer or liquid nitrogen.
• When the specified temperatures for the crankcase and the cylinder liners have been reached, fix the
crankcase on the support tool and proceed with installation as follows.
• Position the O-rings on the cylinder liners and lubricate them with engine oil.
4
• Insert the cylinder liners in the crankcase, carefully respecting the coupling order established when
checking the protrusion, and take care that the two adjoining faces of the upper edge, between the
various cylinder liners, do not interfere with each other.
• To fully bed in the cylinder liner, evenly tap on its perimeter with a rubber hammer.
• The cylinder liners must be fitted within two minutes from taking the crankcase out of the oven.
• Check once again that the total cylinder liner protrusion for each cylinder bank is between 0.01 and
0.05 mm.
5
• If the cylinder liners are not replaced, but the same ones are reinstalled in their seats, always check
the protrusion of the coupling edge with respect to the crankcase, in order to make sure that there are
no faults.
• Make sure that there is no interference between the adjoining faces of the upper edge.
6
• When installing the water/oil heat exchanger, it is advisable to visually inspect the conditions of the
radiator core. Thoroughly clean the part to assure maximum heat dissipation in operating conditions.
• To check that there is no leakage or spillage, before installing the heat exchanger, perform a pressure
test by immersing it in a container of water, plugging one of the two inlets and blasting in air from the
other inlet.
7
• If the centring dowels (1) for the Ø 6 heat exchanger on the crankcase are damaged or have been
removed, you must use tool 900026300 together with tool 900027010.
8
• Always replace the adhesive gasket of the heat exchanger.
9
• Install the sealing gasket (1) between the heat exchanger and the crankcase and position the heat
exchanger.
10
• Fit the air bleeding union for the water cooling circuit and tighten it to a torque of 15Nm.
• Fit the accumulator mount and tighten it with the exchanger to a torque of 10 Nm.
11
• Fit the four anti-detonation sensors and tighten them to a torque of 20 Nm.
12
• Fit the oil accumulator for the variators.
• Fit the oil pressure sensor taking care not to damage the rpm sensor cable and tighten it to a torque of
40 Nm.
13
• After having applied a thin layer of Loctite 242 on the oil nozzles, install and tighten them to a torque of
3 Nm.
• Position the piston sealing segments in the direction shown in Figure (A) with the openings of the first
(1) and the second (2) sealing segment at 180° between them, as shown in Figure (B).
14
• (1) = Upper sealing segment opening
• (2) = Central sealing segment opening
There is no specific fitting direction for the oil scraper ring, nonetheless, take care at the
joint of the internal clip: do not position it near the opening of the
upper and lower rings.
15
• Mount the connecting rod on the piston, taking care that the mark on the lower part of the connecting
rod is positioned on the piston exhaust side.
IMPORTANT
After every removal, replace the pin stop rings. The connecting rod caps match the respective
connecting rods. An identification number is printed on both the connecting rod and the
connecting rod cap.
• Lubricate the piston skirt and the cylinder liner with engine oil.
16
• Fit the half-bearings into their seats on the connecting rod and the cap.
CRANKPIN CRANKPIN
UNIT OF MEASURE mm CONNECTING ROD CONNECTING ROD
SEAT SEAT
47.129 – 47.135 47.136 – 47.142
SEAT YIELD= 0.008
CLASS X CLASS Y
17
• Insert the piston into the dummy cylinder liner, so that the lower part of the skirt comes out slightly
(Figure 1).
• Loosely fit the piston on the cylinder liner, taking care to observe the correct direction, then push it
firmly in.
IMPORTANT
When fitting the piston, take care that the piston offset is set as in Figures 2, 3 and 4.
18
19
• Position all the pistons at the top dead centre before proceeding with the installation of the crankshaft,
so as to avoid interference.
20
• Choose the main bearings according to the instructions on the table.
21
• Fit the crankshaft on its mounts.
• After having thoroughly lubricated the components, fit the connecting rod caps.
N.B.
• Be sure that the two marks on the connecting rod and the connecting rod big end are on the same
side during the assembly procedure.
22
• Apply Molykote 1000 grease on the connecting rod tightening screws.
• After having closed them by hand first, tighten all the screws to a torque of 15 Nm, then use a 60°
tightening angle so as to obtain a torque of 55±10 Nm.
23
N.B.
If the required torque is not attained after having applied the tightening angle, the entire
procedure must be repeated.
IMPORTANT
Every time the connecting rod screws are tightened, use a new set of screws.
• Fit the shims for the lower central crankshaft mount, being careful with the installation direction: the
side with the two lubrication grooves must face the crankshaft shoulder. These shim rings help
defining the axial play of the crankshaft. Different shims are available (standard, 1st allowance, 2nd
allowance) depending on the type of coupling to be achieved.
24
• Insert the upper central mounting shims, following the correct installation direction by turning the
rounded part facing outwards.
• Use the special tool (thickness 20-30) to check that the axial play of the connecting rods falls within
the values 0.20-0.25 mm.
25
• Put the silicon sealing compound Loctite 518 along the perimeter of the engine crankcase.
26
• Prepare the lower part of the engine crankcase by fitting the bearings and the lower central mounting
shims, respecting the fitting direction, i.e. with the rounded part facing outwards.
27
• Lubricate the tie-rods and the relative washers with Molycote 1000 grease, then loosely fit the nuts
onto the stud bolts, checking that the stamped part is facing outwards.
• Tighten the nuts to a pre-load of 30Nm for the inner nuts and 25 Nm for the outer ones.
Finally, tighten the internal ones to a torque of 60 Nm and the external ones to a torque of 55 Nm.
During the procedure check that the shaft turns freely.
28
• Observe the tightening sequence.
• Fit the 6mm screws onto the crankcase perimeter and the small hexagonal fastening nuts for the 2
stud bolts on the clutch side, tightening them to the a torque of 10 Nm.
29
• Insert the oil seal for the crankshaft into its seat on the clutch side, using the specific tool.
• Fit tool AM105786 for crankshaft rotation and check the shaft end float using a dial gauge.
The value must fall between 0.08and 0.18 mm
After completing the check, it is recommended to position piston number 1 at the top dead centre.
30
• If the head centring bushings have been damaged or removed, you must refit them using punch
900026300 equipped with tool 900027000.
• Position the head gaskets, making sure that they are intact.
31
• It is advisable to apply a small amount of silicone CAF4 on the ends of the head gaskets, on the timing
side.
N.B.
Before fitting the engine head, turn the crankshaft in such a way that all the pistons are positioned
below the TDC. To do this, you must rotate the crankshaft until the tab on the crankshaft (timing
side) is positioned as shown in the figure.
32
• Grease the threading of the crankcase stud bolts and the resting surfaces of the head fastening nuts.
33
• Position the heads.
• Loosely fit the nuts with the relative washers, suitably greased with MOLYCOTE 1000.
34
• Apply a pre-load equal to 60Nm.
• Turn a further 90° so as to obtain a torque of 80±10 Nm; if the desired torque is not obtained, the
operation must be repeated.
35
• Observe the tightening sequence.
36
• Lubricate the camshaft mounts on the head.
• Make sure that the grommets are duly fit on the seat of the oil pump timing variators.
37
• Position the intake camshaft on the head, fitting the timing variator tab and positioning the oil pump
timing variators in their seats.
• Position the exhaust camshaft and proceed with fitting the camshaft caps tightening them to a torque
of 9 Nm (the two nuts and the Allen screw of the first cap must be tightened to a torque of 10 Nm).
38
• Position the protection filter (if it was removed) for the variator pressure control valve using tool
900026990. Carry out this operation on both engine heads.
• Position the two 7Øx1.78 O-rings for the timing variator bushing. Perform this operation on both
engine heads
39
• Fasten the oil pump timing variators tightening the four Allen screws on the left-hand head and on the
relative cap.
• Fit the timing variator solenoid valve, lubricate the mount and tighten the retaining screw to a torque of
10 Nm.
40
• Fit the grommet for the timing control transmission mount into its seat.
• Fit the timing control transmission mount, tightening the fastening screws with Loctite 242 to a torque
of 6 Nm.
41
• If the pump assembly shaft bearing has been removed, refit it following the procedure described.
• Position the bearing centring template 900027040.
42
• Insert the punch into the template and bed in the bearing by tapping it with a plastic hammer.
• Subsequently check that the bearing has been fitted correctly.
43
• Using tool 900027030, fit the pump drive shaft into place.
• Check the condition of the oil-water pump verifying that there is no leakage from the draining holes.
44
• Check the wear condition of the groove on the oil/water pump shaft.
45
• Fit the balancing ring (1) and relevant Seeger ring (2) on the drive shaft (pump side).
• Fit the O-ring (3) (Figures 1 and 2) in the drive shaft seat.
46
• Arrange tool 900027050 on the pump drive shaft to fit the oil seal.
47
• Use the special punch to fit the grommet in its seat. Subsequently fit the balancing ring and the see
ger ring which retains the bearing on the timing side.
• Subsequently fit the balancing ring and the see ger ring which retains the bearing on the timing side.
48
• Lubricate the driving joint seat with Molykote 1000 grease.
49
N.B.
Always replace the pump OR.
• Lubricate the pump drive shaft with Molycote 1000 grease.
• Arrange the three O-Ring protection plates of tool AV3602.
• Fit the oil-water pump into its seat by inserting the shaft into the joint.
• Check that there are no signs of peeling of the O-rings in the area where the pumps join the
crankcase. Fit the four M8 small headed screws to secure the assembly to the crankcase, the two M8
screws to secure the pumps to the lower part of the crankcase, and the three M8 screws to secure the
pump to the crankcase, and at the same time remove the three plates AV3602.
50
• Tighten the pump fastening screws to a torque of 25 Nm.
• To fit the screws housed in the upper part of the pump assembly, use tool
900027150.
• Use a torque wrench to tighten to a torque of 25 Nm.
51
IMPORTANT:
The tightening torques for the chain runners are 10 Nm for the 6mm screws and 25 Nm for the
8mm screws.
52
• Fit the transmission chain - toothed wheel unit onto the shaft using tool AV3311.
• Install the fixed runner and fit the shoulder, the balancing ring, the elastic pin and the Seeger ring.
53
• Install the fixed runner for oil-water pump control.
• Position the auxiliary pump chain on the toothed wheel for oil-water pump control and engage it with
the crankshaft toothed wheel.
54
• Fasten the toothed wheel for oil-water pump control onto the oil-water pump driving joint, and tighten
the fastening screws to a torque of 23 Nm.
• Install the pump axle mechanical tensioner, tightening the fastening screws to the prescribed torque.
55
• Fit the elastic pin onto the transmission axle, insert the triple gearing shoulder support and the
balancing ring.
• Fix the assembly with the see ger ring provided.
• Fit the fixed runners and the timing chain tensioners tightening them to the specified torque of 25 Nm.
N.B.
To facilitate subsequent fitting of the camshaft drive chain, it is advisable to keep the two
retaining screws of the RH fixed chain tensioner runner loose.
56
• Position the crankshaft so that the small wrench is at 45°, in order to prevent damaging the valves.
57
• Turn the camshafts of the two cylinder banks in such a way that the references at the ends of the
shafts match the marks on the respective fixing caps. Lock the camshaft rotation.
• Having previously positioned all the pistons below the TDC, there is no risk of interference between
the valves and the pistons during operation of the timing camshafts.
•
N.B.
Depending on the version, the camshafts may be differently machined so as to allow rotation
during timing. The part number identifying the spare part is the same, but there may be a hexagon
on the camshaft for positioning a fixed wrench, or an opening machined to host a wrench, or a
hole to position a cylindrical punch.
IMPORTANT
At this point in the assembly procedure, the engine timing must be checked or restored.
• Move the camshafts to align the reference marks on the heads with those on the shafts themselves
(Figures 1, 2 and 3).
58
59
• Fit the centesimal dial gauge with its holderCS104488, screwing it into the spark plug hole of the first
cylinder.
• Position the goniometer and turn the crankshaft until reaching the TDC
• Position the camshaft drive chain on the right-hand cylinder bank. Position the chain on the innermost
gear of the crankshaft.
60
• When fitting the chain, loosen the screws on the timing variator of the right-hand and left-hand cylinder
bank.
• Position the adjustment slots in the centre of the available adjustment range, so that play can be
recovered during timing adjustment. Tighten at least two retaining screws on the variator.
• After positioning the timing chain on the engine, tighten the two retaining screws of the right-hand fixed
chain tensioning runner to a torque of 25 Nm using a torque wrench.
61
• Fit the gearwheel for the exhaust camshaft. Position the centring dowel into the first free hole
available, after coupling the gearwheel onto the camshaft.
• Check that the pointer of the dial gauge fitted on the holder CS104488 always indicates the TDC
position.
62
• Fit the hydraulic chain tensioner and use a torque wrench to tighten to a torque of 70 Nm.
63
• Repeat the operation for the left-hand cylinder bank.
• When the assembly procedures have been completed, check the TDC position with the dial gauge.
• Screw down by hand, without tightening, the two retaining screws for the exhaust camshaft
gearwheels.
64
• Position the hydraulic chain tensioner together with the gasket on the left-hand cylinder bank using
two screws with washers.
• Use a torque wrench to tighten the two screws to a torque of 10 Nm.
• Use a torque wrench to tighten the tensioner screw to a torque of 40 Nm
65
ADJUSTING THE INTAKE SHAFT TIMING
• Turn the engine anticlockwise and position the first piston at the TDC. Make sure that the dial gauge is
on zero.
• Place a support for the magnetic base of the dial gauge holder on the right-hand engine head.
• position a magnetic base with a long-rod centesimal dial gauge.
• Turn the engine clockwise positioning the intake cam immediately before the opening ramp. In this
condition, the hydraulic tappet is still in the rest position.
• Position the dial gauge plunger above the tappet of an intake valve. The dial gauge rod must be as
perpendicular as possible to the tappet surface.
66
• Reset the dial gauge that measures the movement of the intake tappet.
• Go back to the TDC position and check the dial gauge previously reset. In this position (TDC), the
intake valves of the first cylinder have already started their travel. Therefore, carefully check the
position on the dial gauge positioned on the tappet.
• Turn the crankshaft 15° beyond the TDC. This corresponds to a piston stroke of 1.75 mm beyond the
TDC.
• Check that the tappet downstroke (begun before the TDC) and hence the intake valve upstroke is
0.59±0.08 mm.
• Should the values measured in these conditions be out of tolerance, hold the crankshaft still, loosen
the screws on the timing variator and turn the intake camshaft until obtaining the desired intake valve
upstroke. For this reason, as described earlier, it is advisable to get ready for the timing procedure by
positioning the variator adjustment slots in the centre of the angular adjustment.
• Check the timing again.
• Use a torque wrench to tighten the previously loosened screws that secure the variator to a torque of
15 Nm, after applying Loctite 242.
67
ADJUSTING THE EXHAUST SHAFT TIMING
• Turn the engine clockwise and position the first piston at the TDC with the camshafts balanced
(exhaust closed and intake open). Make sure that the dial gauge is on zero.
• Position the dial gauge plunger on the tappet of an exhaust valve. The dial gauge rod must be as
perpendicular as possible to the tappet surface.
• Reset the dial gauge that measures the movement of the exhaust tappet.
• Turn the crankshaft clockwise until an exhaust valve is closed.
• Check that the closing stroke of the exhaust valve is 1.09±0.08 mm
68
• Should the values measured in these conditions be out of tolerance, hold the crankshaft still, move the
centring dowel anticlockwise or clockwise (depending on whether you wish to delay or advance the
shaft) until obtaining the desired timing value.
• Fit the retaining dowel (1) in the hole immediately after or before the centring dowel, whatever is
easier.
69
• To complete the operation, fix the exhaust camshaft gearwheel.
N.B.
Use engine oil to lubricate the thread and underhead of the retaining screw on the exhaust
camshaft and the toothed ring gear.
• Tighten the retaining nut with sealing washer to a torque of 200 Nm.
• During the procedure, lock the camshaft by working on the handling hexagon in such a way as not to
load the timing belt.
•
• Perform the same procedure for the left-hand cylinder bank, positioning the dial gauge holder in the
seat of the spark plug of cylinder number 8.
N.B.
After adjusting the timing, it is advisable to perform an OIL PRESSURE TEST, introducing
pressurised engine oil through the oil filter union at a pressure of 5-6 bar. In this way, you can
check the lubrication of the camshaft seats, hydraulic chain tensioners, tappets and central
transmission pin.
70
• Fit the upper runner and tighten the retaining screws to a torque of 10 Nm
• With the aid of short stud bolts, position the gaskets on the crankcase.
71
• Lubricate the seats of the cooling circuit grommets.
• Fit tool 900026590 onto the crankshaft, in such a way that the oil seal will not be damaged when the
cover is installed.
72
• Install the front crankcase cover.
73
• Tighten the front cover screws to a torque of 10 Nm.
• Fit the belt tensioner paying particular attention to the position of the reference pin, and tighten to a
torque of 25Nm.
74
• Fit tool 900026560 to lock the crankshaft rotation.
• Position the torsion damper on the shaft and tighten the fastening screw with Loctite 242 to a torque of
450 Nm.
75
• Fit the hydraulic steering pump, tightening the front screw to a torque of 10 Nm (Figure 1) and the rear
screw to a torque of 25 Nm (Figure 2).
76
• Secure the air-conditioning system compressor by tightening the screws to a torque of 25 Nm.
77
• Fit the alternator by tightening screw A to a torque of 49Nm and screw B to a torque of 59 Nm.
78
• Fit the engine mounting brackets using tool 900027160, and tighten the fastening screws to a torque
of 53 Nm.
• Install the starter motor, tightening the fastening screws to a torque of 14 Nm.
79
• Fit the spark plugs after having lubricated the threading with Champion 2612 grease.
• Fit the tappets' cover remembering to arrange the head gaskets and the spark plug tube gaskets
beforehand. Insert the timing variator connector through the specific hole.
80
• Working from the middle outwards, tighten the closing screws to a torque of 10 Nm.
• Fit the Seeger ring for the cable guide of the timing variator valve using tool AV3333.
81
• Fit the ignition coils (Figure 1) and tighten the retaining screws to a torque of 10 Nm (Figure 2 ).
82
• Working from their housings on the support bracket, take out the connectors of the timing sensors (RH
and LH), the rpm sensor (RH) and the detonation sensors (four).
CAUTION
Check that the sensors on each wire match, consulting the electric system manual if necessary.
83
• Install the tubes which run from the accumulators to the timing variator solenoid valves.
• Fit the tube which runs from the exchanger to the tank. Fit the fastening nut onto the exchanger and
secure the retaining bracket.
84
• Complete the procedure by tightening the nut on the exchanger to a torque of 75 Nm.
• Secure the service wire onto the alternator and tighten it to a torque of 10 Nm.
85
• Using a clamp, secure the injection cable onto the right-hand head.
• Using a clamp, secure the wiring leading to the head coils and the wiring leading to the injectors and
the fuse box.
86
• Fit the connector onto the alternator.
• Secure the earth terminal onto the crankcase, tightening the fastening screw to a torque of 25 Nm.
87
• Attach the connectors to the wiring support bracket.
88
• Secure the wire which leads to the A/C compressor and to the starter motor.
• Remove the tools AV3332 protecting the intake ducts and position the gasket on the manifolds.
89
• Position the intake manifold, centring it on the duct's stud bolts.
90
• Using clamps, fix the oil vapour breather lines and head water outlet lines.
• Attach the connector onto the timing variator solenoid valve. Then attach the injector wiring and the
motor driven throttle connector.
91
• Connect the ignition coil wiring harness.
• Fit the wiring covers, securing the screws with Loctite 242 to a torque of 8 Nm.
92
• Using tool 900026550, insert the clutch shaft support bearing.
IMPORTANT
Once the engine assembly procedure is complete, check that the wiring is correctly positioned,
consulting the electric system manual if necessary.
93
94
DIMENSIONAL CHECKS
• Check that the main bearing journals and the cams do not show scoring or excessive wear.
1
• The dimensions measured must fall within the indicated values (Figure 1 e 2)..
2
N.B.
To check the coaxial factor of the main bearing journals, a checking plane is required.
• Place the camshaft on the indicated tool. AV3135.
• Reset the dial gauge on the main bearing journal to be examined and rotate the shaft checking the dial
gauge indication.
• The coaxial factor error detected must be lower than the prescribed value.
3
Piston dimensional check
• Carry out a careful visual check of the skirt checking that there is no scoring or excessive wear.
• Measure the piston diameter taking three measurements at the reference heights.
4
• The dimensions detected must fall within the indicated values.
• In addition, check the pin seat diameter, which must be 20+0.011+0.005 mm, and the pin outer diameter,
which must be 20 – 0.005 mm.
5
IMPORTANT
The pin hole is NOT symmetrical with the piston axis.
The reason for this offset is the need to limit the lateral forces that are perpendicular to the cylinder
liner. The offset follows the rotation direction of the crankshaft and, for this reason, the RH bank
pistons are different from those on the LH cylinder bank.
• After removing the grommets from the piston, carefully inspect them. In the event of scoring, cracks or
signs of abnormal wear, they must be replaced.
IMPORTANT
There is no specific fitting direction for the oil scraper ring, nonetheless, take care at the joint of the
internal clip: do not position it on the upper and lower ring opening.
6
Connecting rods dimensional check
N.B.
All checks of the connecting rods must be carried out with used screws.
• To measure the diameter of the connecting rod big end, reset the bore-meter on tool ALZ F04702.
• Using a torque wrench, tighten the fastenings on the connecting rod big end to torque.
• Check the diameter of the connecting rod big end taking two measurements at a distance of 90°.
7
• The dimensions detected must fall within the indicated values.
• To measure the diameter of the connecting rod small end, reset the bore meter on the indicated tool
(diameter 20 mm).
8
• Check the diameter of the connecting rod small end taking two measurements at a distance of 90°.
• Proceed with a second inspection of the connecting rod small end using the "go-no-go" gauge
TLDF02060
9
• The dimensions detected must fall within the indicated values.
10
N.B.
To balance the connecting rod a checking plane is required.
• The parallelism of the connecting rod axes is checked by means of tool AV2955.
Insert the pins supplied into the connecting rod small end and the connecting rod big end, then check for
any parallelism error with the dial gauge.
11
• The values measured must correspond to those indicated in the drawing.
12
Cylinder liner dimensional check
N.B.
To carry out the dimensional check of the cylinder liners a bore-meter and the relative reference ring
are required.
• Measure the diameter of the cylinder liner taking three measurements at the reference heights, then
rotate the liber by 90° and repeat the procedure.
13
• The dimensions measured must fall within the indicated values.
14
Drive shaft dimensional check
• Check that the main bearing journals do not show scoring or excessive wear.
15
• Using a tube-brush, check that the oil passages are not clogged.
16
• The dimensions detected must fall within the indicated values.
17
• The dimensions detected must fall within the indicated values.
N.B.
To check the coaxial factor of the main bearing journals a checking plane is required.
18
• Reset the dial gauge on the main bearing journal to be checked and rotate the shaft checking the dial
gauge indication (Figura 1 e 2).
19
• The coaxial factor error detected must be lower than the indicated value.
20
Main cylinder head data
Interference between the valve guide and the housing on the head 0.032 ÷ 0.068 mm
Interference between the valve seat and the housing on the head
• Intake. 0,080 ÷ 0,140 mm
• Draining 0,080 ÷ 0,140 mm
Max. shift between valve stem and contact surface with bucket
• Intake and draining 0.025 mm
21
Checking the cylinder heads
N.B.
To ensure the best working conditions, position the cylinder heads on the tool 900026520
22
• Remove the valves, using specific standard pneumatic equipment.
• Clean the heads carefully, removing all traces of scaling from the combustion chambers and the oil and
water lines. For this purpose, it is advisable to inject pressurised petroleum into the oil lines and a
standard descaling liquid into the water lines. Perform these operations with the aid of tool 900026970
(not shown).
• Check the state of the spark plugs' seats.
• Using the bore-meter, check the valve control bucket seats for wear and the camshafts seats.
• On a straightening surface, check if the head and crankcase coupling surfaces are perfectly flat.
23
• If the head surface needs to be corrected, always comply with the value given in the figure.
24
Checking the valve seats and guides
• Following the checks, if replacement of the valve seats is required, they must be removed by milling in
order to prevent damage to the housing on the head.
• Check the dimensions of the grooves and the seats to ensure that the prescribed interference is created
after assembly.
• To insert the new seats, heat the head in a kiln until it reaches a temperature of 190 °C, for six minutes,
then cool down the seats in liquid nitrogen, for about five minutes.
NOTES
The above described operation must be exclusively carried out by a specialized laboratory.
• Insert the seats onto the head using the special punch. Carefully check that the kickback does not cause
the previously installed seats to fall out; if necessary, check that all installed seats are correctly fitted.
• Using gauge TLDF 006108, check the valve guides for wear.
25
• If the gauge inside the guide features an excessive backlash, replace with new guides in order to obtain
the prescribed assembly engagement.
• The guides can be removed following the below procedure
• Using tool AV 2734 extract the seal rings (1) from the valve guides
26
• Using a Ø 10 mm miller, with a Ø 6 mm tapered shank, supplied with tool AV 2926, mill the guide on the
seal ring side for about 25 mm from its end, lubricating the miller to prevent it from breaking and keeping
it aligned with the valve guide.
• Heat the head in a kiln at about 100 °C, for ca. thirty minutes, to ease removal, then position it on two
rubber shims.
• Extract the guide using the punch supplied with tool AV 2926.
27
• To insert the new guides, it is necessary to heat the head at about 100 °C for ca. 1 hour and then cool
down the guides in liquid nitrogen.
• To install the new guide (2) use tool AS 102178 with shim AV 3537.
• Lubricate the guide with "SEGO" grease and push it into its seat, until the shim AV 3537 comes flush with
the head.
28
• After this procedure, dry bore the guides using a reamer (3) diameter 6 H7 mm, fitted in the speacial
hand-operated spindle. Before carrying out the operation, check that the reamer cutting edges are sharp.
• Using gauge TLDF 006108, directed towards side "P", check that the guide is properly bored.
29
If, once the checks have been carried out, the valve seats need to be replaced, remove them by milling in
order to prevent damaging their seat on the head.
• Check the dimensions of the recesses and seats.
• After fitting, it is absolutely essential to have the indicated interference.
• To fit the new seats, heat the head in the oven to a temperature of 190°C for six minutes, and cool down
the seats in liquid nitrogen for approx. five minutes.
N.B.
The above described operation must be carried out by a specialized laboratory only
After having replaced the valve guides, it is necessary to grind the valve seats, thereby obtaining the
prescribed union angle in order to perfectly match the seat-valve support surfaces. For this operation, use
the recommended grinder for valve seats equipped with the relative
• To work on both sides of the head, position it on the special supports, working from the lid side.
• Insert the centering stem into the guide (4), diameter 6 mm, working from the side equipped with
tightening screw.
30
• Lock the centering stem in the guide (4), by means of the tightening screw (5).
31
• The grinder must be fitted with the specific wheel for the valve seat to be machined:
- for the intake valves use a 37 mm diameter wheel;;
- for the exhaust valves use a 33 mm diameter wheel.
NOTES
The wheel outer diameter must be slightly larger than that of the valve.
• Set the diamond point inclination (6) to 45°, with respect to the fixed index on the base.
• Sharpen the wheel swinging the small connecting rod (A) which holds the diamond point and, at the same
time, operate the control knob (B).
IMPORTANT
To prevent the abrasive product from infiltrating into the camshaft central hole, plug the latter and
clean with compressed air
32
• Grease the centering stem and fit the grinder
• Move the wheel so that it skims the valve seat, and lock the screw which positions the knob (7) used to
adjust the cutting depth..
• Start-up the grinder and machine the valve seat, gradually increasing the cutting depth using the knob (7).
• Grind the whole surface (H) of the valve seat, letting the machine work freely for a few seconds. Check
the working depth and the alignment (centering) of the machining with respect to the seat, adjusting the
grinder position if necessary..
33
• Once the machining procedure is completed, lift the wheel operating the knob then remove it from the
centering stem.
• Release the centering stem, working on the lower tightening screw.
• Using tool (C) supplied with the grinder, extract the centering stem (4) from the valve guide.
IMPORTANT
After having ground the seats as described above, it is not necessary to lap the valves before re-
assembly.
34
Check through the application of a "Prussian Blue" layer
• Using a paintbrush, apply a thin and uniform layer of "Prussian Blue" on the whole resting surface of the
valve.
• Insert the valve into its guide, making it "strike" on its seat.
• Then rotate it manually and, after having removed it, check that the "Prussian Blue" layer is evenly
distributed on the whole seat. If this is not the case, grind the seat once again.
35
Check of the hydraulic seal with "Vacutest"”
• Fit all the valves for a duct (intake or exhaust) and, in order to avoid that the cotter grooves - on the valve
stem - damage the inside sealing surface of the grommet, fit the protection cap AV 2944 and lubricate the
coupling with engine oil
36
• Fit the sealing rings on the valve guides to be tested using the fitting tool 900026980 (Maserati part no.)
or AV 2692 (Ferrari part no.).
37
• Fit the rectangular punch (D), supplied with the equipment, to plug the intake duct. Fit a round-shaped
punch to plug the exhaust duct
• Activate the "Vacutest" and check on the pressure gauge that vacuum ranges between 0,94 and 0,86
bar. If the value proves to be lower, check once again applying a "Prussian Blue" layer, in order to verify
which is the seat to be ground once again.
38
Fitting the valves and checking the springs
• During servicing, after a careful examination, check the state of the valves (Figure 1 and 2) and, if
necessary, replace them.
39
• Whenever necessary or, in any case, when fitting new valves, replace the grommets, using the punch AV
2692 to insert them.
• To prevent the cotter grooving on the valve stem damaging the inner surface of the grommet, fit the
protective cap AV 2944 and lubricate the coupling with engine oil.
40
• The figures 3 and 4 show the nominal lengths (L) the spring must have depending on the charge (N)
applied.
• Replace the deformed springs with new ones with a static charge of 30 ÷ 50 N
• Examine the upper and lower washers visually to make sure they are intact.
• Refit the components, using the compression tool employed to remove them.
41
• The outer and inner valve springs must be fitted in a specific direction. A mark indicates the correct fitting
direction: the marked end of both springs must be positioned in contact with the engine head.
• Fit the hydraulic tappets, abundantly lubricating the housings on the head and checking them for wear.
The tappets on the head do not need to be positioned following a specific sequence, however, it is
recommended to refit the hydraulic tappets following the same order in which they were removed.
42
ELECTRO-INJECTORS
Electro-injector detaching-reattaching
N.B.
To remedy any possible fuel leakage during operation, it is advisable to position a cloth beneath the
connection between the fuel line and the electro-injector pipe.
1
• Unscrew the two retaining nuts on the electro-injector pipe cover and remove it.
2
• Unscrew the retaining nuts on the electro-injector pipe. Extract the electro-injector pipe.
• Extract the locking retainer from the electro-injectors and remove the electro-injectors.
3
When fitting, follow the procedures described above in reverse order.
N.B.
1. Prior to insertion of the electro-injectors in the seat, it is advisable to grease the grommet to
facilitate insertion.
2. Align the reference tabs for correct fitting.
4
BATTERY
Battery disconnection-connection
• Open the luggage compartment, unscrew the seven screws and remove the luggage compartment hinge
cover.
1
• With the tool, detach the push fittings on the side panel of the luggage compartment and then remove the
panel.
2
• Disconnect the battery by unscrewing the two retaining nuts.
3
STARTER MOTOR
1
• Detach the lid-open indicator connector.
2
• Remove the clamp on the valve connection pipe.
• Undo the two lower fastening screws on the secondary air valve.
3
• Undo the two screws fastening the secondary air valve support (Figure 1) and slide off the rubber sleeve
(Figure 2) to remove the valve
4
• Remove the diagnosis union found on the secondary air distributor pipe for the exhaust.
• Undo the screw fastening the connector bracket found alongside the air flow meter.
5
• Remove the wiring from the two retaining clamps.
6
• Loosen the clamp to remove the pipe found under the air flow meter.
7
• Loosen the clamp (Figure 1) and release the retaining spring (Figure 2) to remove the air flow meter.
8
• Remove the air flow meter-oil decanter connection pipe from the retaining clamp.
• Unscrew the two nuts fastening the stiff pipe to the engine.
9
• Turn the stiff pipe towards the rear side of the vehicle to facilitate the loosening and removal of the nuts
fastening the exhaust manifolds.
• Working on both sides of the engine, unscrew seven of the eight nuts fastening the manifolds.
N.B.
The last nut fastening the manifolds is positioned towards the passenger compartment and it is
concealed by the manifold itself. It is easier to unscrew it by lifting the vehicle and working from the
underfloor.
10
• Raise the vehicle and unscrew the last nut fastening the exhaust manifolds.
• Unscrew the engine mounting bracket retaining nut from both sides.
11
• Unscrew the blow-by pipe union (Figure 1).
N.B.
Screw on a cap to avoid oil leakages (Figure 2).
12
• Undo the four engine shield fastening screws.
N.B.
Fit a rubber shim between the hydraulic lift and the engine/housing.
13
• Lift the engine just enough to slide out the exhaust manifold from the compressor unit side.
14
• Unscrew the nut for the positive wire to disconnect the starter motor.
15
• Undo the two screws fastening the engine (1) and unscrew the nut fastening the wire (2).
N.B.
If replacement of the starter motor is necessary, unscrew the two nuts (3) to remove the bracket from
the motor.
16
Reattaching the starter motor
• Position the starter motor on the engine and tighten the two screws fastening it to the engine (1) and the
wire retaining nut (2).
N.B.
If replacement of the starter motor is necessary, before fastening the new one on the engine, position
the bracket and tighten the two nuts (3).
• Tighten the three screws fastening the motor to the clutch housing, to the torque of 17 Nm.
17
• Connect the pin.
• Connect the starter motor, tightening the nut on the positive cable.
18
• Lift the engine to a height sufficient to insert the shield and secure it with the four screws.
• Insert the new gaskets on the stud bolts for the exhaust manifolds.
N.B.
The gaskets have a raised side that should face the exhaust pipes when refitting them.
19
• Insert the exhaust manifold from the compressor unit side.
• Position a lever between the engine rubber bushing support and the engine mounting bracket and shift
the engine sideways.
Insert the manifold.
N.B.
This procedure requires the help of another person to insert the manifold.
20
• Insert the manifolds in the housing and tighten the last nut, passenger compartment side.
• Lower the engine, remove the hydraulic lift and tighten the nuts securing the engine.
21
• Tighten the blow-by union.
N.B.
Before fitting the union, remove the cap on the engine.
22
• Lock the stiff pipe to the engine.
• Fasten the air flow meter-oil decanter connection pipe with the clamp.
23
• Refit the air flow meter by tightening the clamp (Figure 1) and lock the retaining spring (Figure 2).
24
• Attach the connector on the air flow meter.
• Refit the pipe found underneath the air flow meter and tighten the clamp.
25
• Refit the secondary air delivery pipe and tighten the clamp.
26
• Fasten the connector support bracket found alongside the air flow meter and tighten the screw.
• Tighten the diagnosis union on the secondary air distributor pipe for the exhaust.
27
• Refit and tighten the two lower screws fastening the secondary air valve on the manifolds.
N.B.
Insert the new gaskets between the secondary air valve and the distributor pipe for the exhaust.
• Screw on the two screws fastening the support to the engine and secure the rubber sleeve with the
clamp.
28
• Connect the small pipe to the secondary air valve.
29
• Refit the side, rear and front coverings and screw the twelve fastening screws.
30
FUEL TANK
CAUTION
1. The fuel contained in the fuel tank and in the entire engine fuel supply system is highly
flammable and under certain conditions, it can also catch fire.
2. Do not smoke, produce sparks or use naked flames near the work site or in the immediate
vicinity.
N.B.
It is advisable to drain the fuel out of the tank using the specific equipment.
• Working on the fuel filler neck, undo the four fastening screws.
1
• Working in the luggage compartment, remove the plugs fastening the internal trim panels.
• Disconnect and remove the connection pin for the tank wiring .
2
• Disconnect the fuel delivery pipes.
3
• (USA Version) Disconnect the diagnosis pump connector.
4
• Unscrew the two active carbon filter retaining nuts and remove the filter.
5
• Remove the tank from the vehicle.
N.B.
Two persons are required for tank removal.
6
Reattaching the tank
N.B.
The earth wire must be positioned under the fastening tab for the filler neck screw, in order to
connect it to the body.
• Glue the sponge strips on the tank, keeping the same arrangement as on the tank being replaced.
7
• Put the tank in the luggage compartment, inserting it from the filler neck side.
N.B.
Two persons are required for tank removal.
• Position the filler neck in its seat on the car body and loosely fit the four fastening screws.
Working in the luggage compartment, position the fuel tank correctly.
8
• Grease the external surfaces of the active carbon filter to facilitate insertion in its housing.
• Fit the active carbon filter in the luggage compartment. Position the support and tighten the two retaining
nuts.
9
• Tighten the two fastening bolts on the fuel tank.
10
• (USA Version) Attach the diagnosis pump connector.
11
• Attach the connection pipes for the active carbon filter.
12
• Tighten the four fastening screws on the filler neck.
• Refit the internal trim panel in the luggage compartment and secure it with the plugs.
13
MOTOR-DRIVEN PUMP PAN ASSEMBLY
1
• Unscrew the ring nut using the tool 900026390 and extract the motor-driven pump unit from the fuel tank.
2
Reattaching the motor-driven pump pan assembly
N.B.
The fuel pump complete with the floater must be positioned on the left-hand fuel tank seat.
• Insert the pump in the tank, aligning the motor-driven pump reference tab (1) with the seat (2) on the tank.
3
• Press the fuel pump down and tighten the ring nut.
Using the pin wrench 900026390 tighten to the torque of 15 Nm.
4
ANTI-EVAPORATION SYSTEM
Component removal
• Working from inside the luggage compartment, remove the caps which fasten its lining.
• Working on the left-hand side of the fuel tank, disconnect the three tubes leading to the active carbon
filter using their victaulic couplings.
1
• Remove the active carbon filter by unscrewing its two fastening nuts.
2
• Detach the tube which connects the diagnosis pump filter using the victaulic coupling positioned next to
the diagnosis pump (USA Version).
• Remove the diagnosis pump, unscrewing the two nuts which fasten the supporting plate.
• Detach the connector (1). Slide out the rubber pipe (2) (USA Version).
3
N.B.
The diagnosis pump filter is positioned underneath the rear left-hand wheelhouse (USA Version).
4
5
• Loosen the clamp which fixes the diagnosis pump filter to the car body (USA Version).
• Remove the diagnosis pump filter by loosening the clamp which fixes it to the diagnosis pump connecting
tube (USA Version).
6
• Remove the liquid decanter located above the fuel tank, detaching the two victaulic couplings (1) from the
float valves and the connecting pipe from the roll-over valve (2).
• Detach the connecting pipe from the Pierburg valve (3) (USA version).
7
Component fitting
• On the liquid decanter, connect the two victaulic couplings (1) to the float valves and the connecting pipe
to the roll-over valve (2).
• Attach the connecting pipe to the Pierburg valve (3) (USA version).
8
• Place the diagnosis pump filter onto the diagnosis pump connection tube and loosely fit the clamp (USA
Version).
• Secure the diagnosis pump filter to the car body by tightening the fastening screw.
Screw on the clamp which fastens the connecting tube to the diagnosis pump (USA Version).
9
• Refit the wheelhouse, fastening the five screws which secure it to the car body (Figure 1, 2, 3 and 4).
Refit the wheel.
10
11
• Fit the rubber tube into its seating (2).
Refit the diagnosis pump onto the support plate by tightening the two fastening nuts.
• Attach the connector (1) (USA Version).
• Insert the tube which connects the diagnosis pump filter, positioned next to the pump (USA Version).
12
N.B.
For easier fitting of the active carbon filter fitting into its housing, grease its outer surface.
• Secure the active carbon filter by tightening the two fastening nuts.
13
• Connect the three tubes to the active carbon filter using the victaulic couplings.
14
ACCELERATOR PEDAL REPLACEMENT
• (MY2003-Cambiocorsa gearbox version) Remove the lower soundproof panel, driver's side, by
unscrewing the two nuts and removing the two fastening caps (Figure 1 and 2).
1
• Use a screwdriver to remove the Seeger ring of the pedal pin.
2
• Unscrew the two fastening screws for the potentiometer.
• Remove the accelerator pedal by pressing it towards the inside of the vehicle.
3
• Unscrew the fastening nut on the potentiometer lever and separate the two components.
4
TIGHTENING TORQUES
Preload of 60 Nm
Screw fastening cylinder head to the crankcase MOLYKOTE BR2
90° = 80±10Nm
Nut "E" for stud bolt Screw fastening the sub-crankcase to the
crankcase
Degrease the
coupling surfaces.
Lubricate the
Camshaft control gearing 200 Nm
screw thread and
underhead with
engine oil
engine oil on
Oil filter cartridge 25 Nm
gasket
Screw fastening piston cooling system multiple union (oil
3 Nm LOCTITE 242
nozzles)
Lambda sensors 50 Nm
Spark plug
Spark plug 10 Nm
lubricant
with spinner max
"Torca" clamp for exhaust system 54 Nm
400 rpm
Specific tooling
Description Code
Tool for fitting exhaust valve cotters on cylinder heads AM-107079 900026970
Special wrench for fitting timing variator on F136 camshaft AV-3305 900027020
Punch for fitting pump unit control shaft on sub-crankcase AV-3324 900027030
Punch for fitting pump unit seal ring on sub-crankcase AV-3325 900027050
Punch for fitting seal ring on front crankcase cover AV-3336 900026590
Special wrench for tightening pump body screws to torque AV-3350 900027150
Spacer for earth wire connection onto engine stud bolts 900026940
1
• Detach the cooling system oil delivery and return unions from the gearbox, by unscrewing the two screws
• Unscrew the six RH and LH axle shaft differential output flange screws
2
• Disconnect the main wiring
3
• Unscrew the seven transmission shaft gearbox nuts
• Remove the rear frame by unscrewing the four screws on each side
4
• Holding it on both sides, push the gear unit towards the rear of the car until it completely detaches from
the transmission shaft
• Rock the gear unit lightly to extract it from the base of the car
5
REPLACING THE ELECTRONICALLY-CONTROLLED GEARBOX CONTROL UNIT (TCU)
• Unscrew the two screws fastening the control unit to the bracket.
1
• Unscrew the two retaining nuts to remove the pin and free the earth wire.
2
POWER UNIT REPLACEMENT
Removal
• Remove the lower and upper brackets, undoing their fastening screws.
Fitting
• Fit the side cover and tighten the screws to 7,4 Nm.
• Fit the lower bracket and the upper bracket.
N.B.
The following procedure shows how to establish the electronically-controlled gearbox's oil tank level
in the vehicle.
N.B
This operation must only be carried out on versions fitted with the SOFAST 2 gearbox
Before proceeding with PIS (or KISS POINT) the clutch has to be bedded in.
• In order to allow minimal bedding-in of the clutch when driving the first kilometres, follow the instructions
below:
− avoid Sport drive
− gear shifts at max 4000 rpm and max 50% accelerator pedal
− avoid violent pick-ups
− avoid prolonged pickups as far as possible (traffic jams, manoeuvres)
− change gears several times while moving
• Keep the vehicle running in idle for 5 minutes in order to calibrate the solenoid valves when hot. With the
vehicle running, engage 1-2-1 in sequence, hold the vehicle in idle with the 1st gear engaged and the
brake pedal pushed for 1 minute. Repeat the sequence three times to allow correct assessment of the
clutch solenoid valve leakage.
• Turn off the engine, checking that the ignition switch is in OFF position
• Unscrew the retaining nut of the lower guard of the instrument panel.
• Partially pull down the lower guard of the instrument panel and access the 4-way connector of the C-CAN
line, then disconnect it.
- If the vehicle has been stationary for over 8 hours, it must be driven for 15 minutes in "Free Drive"
conditions with repeated gear shifts.
- If the vehicle has been stationary for over 30 minutes after the bedding stage, perform the pick-up
manoeuvre 10 times, bringing the engine speed up to 1500 rpm.
- If the car has been stationary for less under 30 minutes after the bedding stage, perform the pick-up
manoeuvre 5 times, bringing the engine speed up to 1500 rpm.
• Switch on the SD3 and select the "NCR KISS-POINT" software option from the diagnostic programmes.
• Select the "KISS POINT ENVIRONMENT" function from the list of M138 software
• The user is guided through the subsequent stages by the diagnostic system chosen.
• Enter the vehicle serial number.
• Use the TAB button to select "CONTINUE" then press "ENTER" to confirm the data entered.
• The system will display a warning message for the user, advising him/her of the vehicle conditions
required to run the calibration procedure correctly.
• If the vehicle meets the conditions which permit the procedure to continue, press "ENTER".
• Shift the gear to neutral, turn the ignition switch to the OFF position, wait approximately 15 seconds, then
start the engine and select "ENTER" on the SD3.
• Select "START PROCEDURE "
• The following screen pages instruct the user to keep the accelerator pedal pressed throughout the entire
data acquisition period.
• The system will carry out 10 clutch opening and closing cycles automatically, with the gearbox in the
neutral position, during which the SD3 will acquire the data needed to calculate the touch point (PIS)
correctly.
• Wait for the data acquisition procedure end message to appear on the display and a tone to be emitted by
the instrument panel node.
• The SD3 will display the "TRANSMITTABILITY" graph, i.e. the torque value depending on the clutch
position (in red) and the two reference curves (in black) indicating the tolerance range within which the
transmittability curve must be positioned.
• The system will automatically check that the transmittability curve read lies within the two tolerance
curves.
• Two results are possible, depending on the outcome of this processing:
- the data is correct and therefore the system will proceed with the next data acquisition stages.
- the data is incorrect and therefore the procedure will be cancelled and an error message will be
displayed with instructions on how to solve the problem.
• At the end of each data acquisition and processing sequence, the following parameters will be displayed:
- Number of pickups
- PIS value (bit,mm)
- POINT DISPERSION value (bits)
• Detach the cooling system oil delivery and return hoses from the gearbox by unscrewing their two screws.
1
• Position the hydraulic lift underneath the gearbox and lift the unit slightly.
• Remove the rear cross member by unscrewing the four fastening screws positioned on each side.
2
• Remove the hydraulic lift and unscrew the seven nuts securing the transmission shaft to the gearbox unit,
leaving one nut screwed on to ensure the transmission shaft does not come off unexpectedly (Figure 1).
N.B.
Use a pipe wrench to remove the upper transmission shaft screw (Figure 2).
3
• Remove the front modular cross member by unscrewing the two screws on each side.
• On both sides, unscrew the two screws securing the front rollbar jumpers.
4
• Lower the front rollbar.
• Remove the clip and unscrew the rear Lambda sensor cable bracket screw.
5
• Unscrew the four Lambda sensors from the catalytic converters.
Mark the RH and LH sensors and the respective catalytic converters to avoid inverting their positions
during re-assembly.
N.B.
When unscrewing the Lamda sensors, make sure the cables do not get damaged by twisting.
6
• Unscrew the four screws securing the pre-catalytic converter flange to the exhaust manifolds.
• Detach the pre-catalytic converter from the exhaust manifolds and extract the seal.
7
• Unscrew the two screws securing the catalytic converter support to the clutch housing and remove the
pre-catalytic converters as well as the catalytic converters from the car.
• Unscrew the six screws securing the steering box heat shield and remove it from the
8
• Position a second hydraulic lift underneath the car so as to align the transmission shaft to the gearbox
unit.
• Unscrew the eighth screw securing the transmission shaft to the gearbox unit
9
• From both sides, push the gearbox to the rear of the car until it completely disengages from the
transmission shaft.
N.B.
The unit must be moved about 10 - 15cm to disengage the transmission shaft.
• Lower the second hydraulic lift and tilt the transmission shaft sufficiently to allow its removal from the
gearbox unit.
10
• Unscrew seven of the nuts securing the transmission shaft to the clutch housing, leaving one nut screwed
on so as to avoid the shaft coming off unexpectedly.
• Position the front hydraulic lift underneath the engine guard and raise it to fit snugly against one of the
securing screws.
11
• Use the hoist to rock the transmission shaft until it tilts to the correct position for removal.
• Unscrew the eighth screw securing the transmission shaft to the clutch housing.
CAUTION
When the transmission shaft is fully disengaged, take care not to allow it to fall out unexpectedly by
tilting it too far.
12
• Remove the transmission shaft from the car (two operators are required for this procedure).
IMPORTANT
Do not tilt the shaft so far as to damage its machined profile, while still allowing easy extraction.
Clutch removal
13
• Remove the seven screws securing the clutch housing to the engine.
• Remove the three screws fastening the starter motor and take out the clutch housing.
14
• Unscrew the six retaining screws (1,3,4,6,7,9) on the clutch pack.
15
• Remove the clutch pack including the car starting wheel.
• Mark the relative position between the clutch, flywheel crown and crankcase.
16
• Unscrew the eight flywheel screws and remove it from the car.
N.B.
Mark the positions of the screws on the flange and the relative position between the plate (1) and the
flywheel(2),
17
RE-ATTACHING THE CLUTCH
Clutch refitting
• Position the plate (1) and the flywheel (2) on the engine, immobilise the flywheel rotation using the special
tool, and screw down the screws to a torque of 91Nm.
N.B.
If re-fitting a flywheel which has previously been removed from the car, position it using the
markings made during removal.
1
• Fit the clutch set with the centring shaft 900026250 and, using the clutch unit removal stage sequence,
loosely fit the three central screws and then the six lateral screws.
IMPORTANT
If re-fitting a clutch unit which has been previously removed from the car, follow the markings made
during removal.
N.B.
The clutch disk is supplied by the manufacturer with the maximum unbalance point marked.
IMPORTANT
If fitting a new clutch disk, its maximum unbalance point must be oriented at 180° with respect to the
maximum unbalance point of the flywheel.
2
• Tighten the nine screws securing the clutch to a torque of 18Nm, in a crosswise sequence.
• Apply waterproof grease onto the grooved profile of the thrust bearing and the two clutch housing
grubscrews.
3
• Position the clutch housing on the engine using a rubber mallet.
• Fit the clip retaining the thrust bearing cabling to the upper stud bolt.
4
• Tighten the seven screws securing the clutch housing to the engine to a torque of 26Nm.
5
• Attach the thrust bearing / clutch housing connector
• Apply waterproof grease to the grooved profile of the transmission shaft and clutch housing.
6
Refitting the transmission shaft
• Key the transmission shaft to the clutch housing (two operators are required for this procedure).
IMPORTANT
Do not tilt the shaft so far as to damage its machined profile, while still allowing easy extraction.
• Use a hoist to align the transmission shaft with the clutch housing, so as to fit the eight transmission shaft
fastening nuts.
CAUTION
When fitting, take care with the angle of the shaft to prevent the latter from coming out
unexpectedly.
7
• Using the hoist, align the transmission shaft with the gearbox.
• Key the transmission shaft to the gearbox and push the gearbox forwards to fit snugly against the shaft.
8
• Tighten the eight nuts securing the transmission shaft to the gearbox to a torque of 70Nm
• Tighten the eight nuts securing the transmission shaft to the clutch housing to a torque of 70Nm.
CAUTION
When fitting, take care with the angle of the shaft to prevent the latter from coming out unexpectedly.
9
• Fit the heat shield to the steering box and tighten its six screws.
• Fit the pre-catalytic converters, and insert the relative seal between the catalytic converter and the
exhaust manifold.
10
• Tighten the four screws securing the precatalytic converter to the exhaust manifold.
• Fit the catalytic converter support to the clutch housing and tighten its two screws.
11
• Screw the four Lambda sensors and the two thermocouples into their seats.
N.B.
Follow the markings on the Lambda sensors made during removal.
12
• Tighten the four nuts securing the rollbar to a torque of 24Nm.
13
• Mount the rear cross member by tightening the eight fastening screws to a torque of 24Nm.
• Mount the adjuster and fit the handbrake cable to the pulley lever.
14
CLUTCH BALANCING
IMPORTANT
Since component 9044, a new clutch has been introduced and the visible differences between the
two components are illustrated in the figure.
1
Clutch balancing procedure "for components up to component 9044"
• Before fitting the new clutch set, use a thickness gauge to check the tolerance between the clutch and the
pan, which should be 0.20-0.30 mm.
Using a felt-tip pen, mark the centring between the clutch and the pan.
N.B.
Remove the clutch housing.
Disassemble the clutch set
2
• Mark the point of maximum unbalance on the unit outer casing (see arrow).
• Mark the reference points “0”-“1”-“2” starting from the point furthest from the maximum unbalance and
working anti-clockwise.
• Install the new pan onto the flywheel, without the clutch, and screw down the nine screws, tightening
them to a torque of 18 Nm.
• Position the clutch set's maximum unbalance point at 180° with respect to the maximum unbalance point
of the flywheel (see arrow).
3
• At point “0” in the side section of the pan, attach a reflective strip of approximately 15 x 40 mm.
• Affix the accelerometer mount 900026950 to the lower right-hand part of the crankcase with glue.
4
• Using a screwdriver, rotate the flywheel so as to position point "0" as shown in the figure.
5
• Pulling the pressure plate backwards, place a spacer 900026930 in the housing between it and the
retainer.
6
• Secure the starter motor by tightening three screws which have to be shorter than those fastening the
housing unit.
7
• Refit the exhaust pipe, the four lambda sensors and the two thermocouples.
• Using the arm of a hoist, position the photoelectric cell 900026950 for measuring the engine revolutions
vertically, at a distance of 350 mm from the reflector, as shown in the figure.
8
• Attach the connector holding bundle to the "SD2 DIAGNOSIS SYSTEM".
• Connect the accelerometer's electric wire to the instrument "EQUALIZER DSE1/DSE2", using the socket
marked "Front accelerometer".
9
• Connect the electric cable of the photoelectric cell which measures the speed to the instrument
"EQUALIZER DSE1/DSE2", using the socket marked "transmission shaft speed sensor".
10
• Prepare the adjustment weights.
• At this point, follow all the steps in the specific SD2 programme.
IMPORTANT:
These procedures must be carried out after balancing the flywheel, following the fitting of new clutch
discs
11
Clutch disc type
Version Code
GT 196021
Cambiocorsa gearbox 196335
• Connect the SD2 tester and select the "M138 Marelli Gearbox" option. In the "Parameters" environment,
read the value for "AUTO-SET CLOSED CLUTCH POSITION". Digit this value in the “DIAGNOSIS”
environment, “CLUTCH CONFIGURATION” option, and store it in the ECU memory. You have thus
correctly configured the parameter “CLOSED CLUTCH POSITION WHEN NEW”.
• Check that the PIS (Touch point) is set at 5.6.
• Keep the vehicle idling in neutral gear for five minutes, in order to set the solenoid valves when cool,
taking care not to perform sharp pick-up manoeuvres during the first movements.
• To allow the clutch to set-in, follow the below instructions at least during the first Kilometres:
- do not drive the car in sport mode
- shift gears at 4000 rpm max and press the pedal only half way down (50%)
- avoid sharp pick-up manoeuvres
- avoid, as much as possible, prolonged pick-ups (in queues, during manoeuvres)
- shift gears several times while driving
• Keep the vehicle idling in neutral gear for five minutes, in order to set the solenoid valves when warm.
With the engine running, engage the 1st-2nd-1st gears in sequence, then keep the vehicle idling with the
first gear engaged and the brake pedal pressed for 1 minute. Repeat the sequence three times in order to
perform a correct evaluation of the clutch solenoid valve leakage.
• Modify the PIS only after having carried out the procedures specified in the first 5 points, following
the below indications:
- if, during UP-shifting, you feel that the rpm tend to “runaway” during the torque discharge phase,
decrease the set value by 0.2 mm max.
- if, during UP-shifting in AUTO mode, with average loads and average rpm, you feel a too strong
“sinking” sensation, increase the set value by 0.2 mm.
• In any case, the PIS values must range between 5.4 and 6.2
• Check the pick-up pressing the pedal down / mid-way, in normal and sport mode, at 1300-1500-1700-
2000 Rpm, and make sure that the clutch closes progressively (two steps max.) performing three
consecutive pick-up manoeuvres maximum and then leaving the clutch cool down.
12
Clutch balancing procedure "for components up to component 9044"
N.B.
Remove the clutch housing.
Disassemble the clutch set
• Mark the point of maximum unbalance on the unit outer casing (see arrow).
• Mark the reference points “0”-“1”-“2” starting from the point furthest from the maximum unbalance and
working anti-clockwise.
13
• Fit the complete clutch block on the flywheel, tightening the nine screws to a torque of 18 Nm.
• Position the clutch set's maximum unbalance point at 180° with respect to the maximum unbalance point
of the flywheel (see arrow).
• At point “0” in the side section of the pan, attach a reflective strip of approximately 15 x 40 mm.
14
• Affix the accelerometer mount 900026950 to the lower right-hand part of the crankcase with glue.
• Using a screwdriver, rotate the flywheel so as to position point "0" as shown in the figure.
15
• Insert the accelerometer 900026950 in the relative mount.
• Pulling the pressure plate backwards, place a spacer 900026930 in the housing between it and the
retainer.
16
• Attach the connector for the clutch position sensor.
• Secure the starter motor by tightening three screws which have to be shorter than those fastening the
housing unit.
17
• Connect the earth wire to the crankcase stud bolt.
• Refit the exhaust pipe, the four lambda sensors and the two thermocouples.
18
• Using the arm of a hoist, position the photoelectric cell 900026950 for measuring the engine revolutions
vertically, at a distance of 350 mm from the reflector, as shown in the figure.
19
• Connect the accelerometer's electric wire to the instrument "EQUALIZER DSE1/DSE2", using the socket
marked "Front accelerometer".
• Connect the electric cable of the photoelectric cell which measures the speed to the instrument
"EQUALIZER DSE1/DSE2", using the socket marked "transmission shaft speed sensor".
20
• Connect the cable marked "RS232" to the instrument "EQUALIZER DSE1/DSE2".
• Connect the cable marked "CAN" to the supplementary terminal of cable "RS232".
• At this point, follow all the steps in the specific SD2 programme.
IMPORTANT:
These procedures must be carried out after balancing the flywheel, following the fitting of new clutch
discs
21
Clutch disc type and software
• Connect the SD2 tester and select the "M138 Marelli Gearbox" option. In the "Parameters" environment,
read the value for "AUTO-SET CLOSED CLUTCH POSITION". Digit this value in the “DIAGNOSIS”
environment, “CLUTCH CONFIGURATION” option, and store it in the ECU memory. You have thus
correctly configured the parameter “CLOSED CLUTCH POSITION WHEN NEW”.
• The value should be 20 ± 2 mm. If the reading falls within13 + 1/2 (13 + 1mm _ 13 - 2 mm), you will need
to modify the clutch sensor magnet fitting.
• Keep the vehicle idling in neutral gear for five minutes, in order to set the solenoid valves when cool,
taking care not to perform sharp pick-up manoeuvres during the first movements.
• To allow the clutch to set-in, follow the below instructions at least during the first Kilometres:
- do not drive the car in sport mode
- shift gears at 4000 rpm max and press the pedal only half way down (50%)
- avoid sharp pick-up manoeuvres
- avoid, as much as possible, prolonged pick-ups (in queues, during manoeuvres)
- shift gears several times while driving
• Keep the vehicle idling in neutral gear for five minutes, in order to set the solenoid valves when warm.
With the engine running, engage the 1st-2nd-1st gears in sequence, then keep the vehicle idling with the
first gear engaged and the brake pedal pressed for 1 minute. Repeat the sequence three times in order to
perform a correct evaluation of the clutch solenoid valve leakage.
• Modify the PIS only after having carried out the procedures specified in the first 5 points, following
the below indications:
- if, during UP-shifting, you feel that the rpm tend to “runaway” during the torque discharge phase,
decrease the set value by 0.2 mm max.
- if, during UP-shifting in AUTO mode, with average loads and average rpm, you feel a too strong
“sinking” sensation, increase the set value by 0.2 mm.
• However, the PIS values must always fall between 4.8 and 5.4
• Check the pick-up pressing the pedal down / mid-way, in normal and sport mode, at 1300-1500-1700-
2000 Rpm, and make sure that the clutch closes progressively (two steps max.) performing three
consecutive pick-up manoeuvres maximum and then leaving the clutch cool down.
22
BLEEDING THE CLUTCH
After replacing the system components, bleed the air from the circuit.
IMPORTANT
1. During the bleeding phase, keep checking the oil level in the tank: Must never fall below the
"MIN" level
2. Never re-use the oil which has leaked from the system
1
To bleed the clutch using the SD2 tester you must:
• connect the diagnostic socket using the data acquisition cable;
• attach connector E, on the data acquisition cable, to the SD2 tester;
• turn the ignition key to ON;
• launch the bleed program.
Once the bleed program is running the two operators, stationed at the tester and the circuit bleed valve
respectively, can complete the procedure:
• the circuit pump runs in pulse mode; it is therefore essential that the bleed valve be opened when the
pump starts running to stop the circuit being overpressurised
• open and close the valve until the flow of oil becomes uniform. The procedure is now complete.
IMPORTANT
1. Before bleeding a hydraulic circuit, top up the tank with specific oil to avoid emptying out and
thereby damaging the circuit itself.
2. At the end of the procedure, check the fluid level again.
2
ADJUSTING THE CLUTCH PEDAL POSITION
• Check the distance of the switch from the clutch pedal: this must be 3 mm.
If this is not so, loosen the check nut, screw or unscrew the sensor until reaching the above mentioned
value, then tighten the check nut.
1
CLUTCH PEDAL REPLACEMENT
• (MY2003-Cambiocorsa gearbox version) Remove the lower soundproof panel, driver's side, by
unscrewing the two nuts and removing the two fastening caps (Figure 1 and 2).
1
• Remove the seeger ring fastening the clutch pump stem from the pedal.
• Slide the clutch pedal from the pin, taking care to keep the two drive half-bushings.
2
• Remove the clutch pedal spring.
• Remove the stop from the pedal board pin and extract it.
3
• Slide the pin towards the inside of the vehicle and remove the clutch pedal.
4
CLUTCH PUMP
• Remove the fastening screws for the engine compartment left-hand shield.
1
• Use a screwdriver to disconnect the gas spring pin from the body.
2
• Reattach the gas strut stem to the pin.
• Unscrew the clutch oil tank cap. Use a syringe to top up the oil level to half-full.
3
• Working from the engine compartment, undo the two screws fastening the clutch cylinder and remove
the clutch pedal switch using a screwdriver.
• Detach the pump from the sealant and pull the clutch pedal towards the rear of the vehicle.
4
• Use pliers to remove the seeger ring fastening the clutch pump stem to the pedal.
• Separate the clutch pedal from the adjusting screw, taking care to keep the two drive half-bushings.
5
• Use a screwdriver to remove the clutch pump union stop and extract the pump.
6
For refitting, follow the above procedures in reverse order
• Working from the passenger compartment, tighten the two clutch pump fastening screws to a torque of
20 Nm and apply sealant MULTI PURPOSE SILICONE SEALANT.
N.B.
On completion of the remounting operation, top up the brake fluid in the tank.
7
CLUTCH THRUST BEARING
1
• Remove the five fastening screws from the thrust bearing unit
2
• Undo the two fastening screws to remove the lower element
• With the thrust bearing unit on bench, unscrew the four fastening screws.
3
• Unscrew the two fastening pins.
• Detach the steering column from the thrust bearing; keep the two springs and pins.
4
Refitting the clutch thrust bearing
5
• Tighten the two fastening screws to a torque of 7,5 Nm.
• Refit the lower element and tighten the two fastening screws to a torque of 1,2 Nm.
6
• Insert the thrust bearing unit into the clutch housing
• Tighten the five fastening screws on the thrust bearing unit to a torque of 7,5 Nm.
7
• Tighten the upper union on the thrust bearing block to a torque of 18 Nm.
• Tighten the lower union on the thrust bearing block to a torque of 18 Nm.
8
ADJUSTING THE CLUTCH SENSOR MAGNET
1
• Undo the stud bolts (4).
• Extract the thrust bearing (5) taking care not to damage the inner grommets.
• Remove the springs (6) and the spacers (7).
2
• Remove the pin (8) from the thrust bearing
• Rotate the magnet mount (9) by 180°.
• Re-insert the pin (8).
3
• Dampen the thrust bearing seals (10) with oil from the gearbox actuator unit.
• Carefully slip the thrust bearing over the sliding flange inserting the springs (11) and the spacers (12).
• Tighten the stud bolts (13) to 7.4 Nm, fitting the washers (14) and the washers (15).
N.B.
For all the fastenings use Loctite medium thread brake.
4
• Fit the mount (16).
• Tighten the screws (17) to 1.2 Nm.
N.B.
For all the fastenings use Loctite medium thread brake.
5
HALF SHAFTS
Removal
• Slacken the six screws fastening the right and left half shafts to the differential output flanges.
• Working from both sides, remove the caulking from the nut fastening the wheel hub to the half shaft.
• Slacken the nut fastening the wheel hub to the half shaft.
• Disconnect the anti-roll bar control rod loosening the fastening nuts.
• Remove the half shaft part from the wheel hub connection (Figure 1) and, with the utmost care, withdraw the
half shaft from the vehicle (Figure 2).
Installation
• Working on both sides, insert a new half shaft in the car, then connect its connection part to the wheel hub.
• Connect the anti-roll bar control rod, tightening the fastening nut.
• Tighten the nut fastening the half shaft to the wheel hub to 275 Nm (with lubricated thread) or 320 Nm (when
dry).
IMPORTANT
The differential crown wheel is supplied as a spare part together with the pinion (bevel gear pair)
these components must always be replaced as a pair.
Differential removal
• Remove the fastening screw for the bearing holder case from the differential compartment.
• Remove the differential from the gearbox housing using tool 95973266.
• To remove the inner roller race for the LH side bearing, use the USAG 454N/3 extracting tool with spacer
washer 900026800, as shown in the figure, and insert the tool arms into the the grooves on the
differential housing.
IMPORTANT
The tapered roller bearings on the differential must always be replaced as a pair. Do not exchange
the components for the two bearings. Do not refit any bearings that have been removed.
• To remove the relative outer race on the LH tapered roller bearing, take out the LH flange shaft and work
on the differential housing.
Removal of the right-hand differential housing cover and flange shafts
Disassembly of the differential housing components
• Lock the diferential using tool 95976628, clamped in a vice, and undo all the screws fastening the crown
wheel.
Take out the differential housing's cover and remove the crown wheel.
IMPORTANT
The crown fastening screws must be replaced after every disassembly procedure.
• To remove the tapered roller bearing inner race, on the RH side, force the roller cage from the inner race.
IMPORTANT
The tapered roller bearings on the differential must always be replaced as a pair. Do not exchange
the components for the two bearings. Do not refit any bearings that have been removed.
• Apply the separator's USAG 472A/3 jaws under the inner race's rim and remove it from the differential
housing using extractor USAG 472N/3 .
• To remove the corresponding outer track on the RH tapered roller bearing, work on the differential
housing side cover.
Removal of the right-hand differential housing cover and flange shafts
Differential reassembly
• After having cleaned the coupling zone on the differential housing, fit the new crown wheel and the
differential housing cover.
Apply LOCTITE 270 on the threading of the new screws and loosely fit them on the differential housing.
Tighten the screws to a preload of 60 Nm working crosswise and using the torque wrench USAG 815 F
(progr. 10) with angle adjustment control, tighten to the yield point.
IMPORTANT
After replacing the crown wheel, check the backlash with the pinion teeth and the differential's roller
bearing preload.
Checking the crown wheel and pinion backlash
Measuring the preload for the differential taper roller bearings
• Fit the inner roller races onto the differential using the base and the punch 95973278 in a vice.
• To install the RH tapered roller bearing outer race, work on the differential housing side cover.
Reassembly of the right-hand differential housing cover and flange shafts
• To install the LH tapered roller bearing outer race, insert the LH flange shaft and work on the differential
housing.
Reassembly of the differential housing components
Reassembly of the right-hand differential housing cover and flange shafts
• Insert the differential-crown wheel set into the differential housing, using the tool 95973266.
• Tighten the thirteenth fastening screw for the bearing holder case to a torque of 30 Nm.
• Clean and degrease the contact surfaces on the cover and differential housing and outline the holes
uniformly and evenly with LOCTITE 510.
Fit the differential housing cover matching the lubrication opening (1) found on the cover with the
differential housing retaining washer (2).
• Position the two cable-guide brackets (3) and tighten the eleven fastening screws on the differential
housing cover to a torque of 30 Nm, proceeding crosswise.
N.B.
The front fastening screw differs in the length of the thread stem. check the figure for proper fitting.
GEARBOX REMOVAL
IMPORTANT
In order to read the gearbox identification number (Figure 1), which is found under the plastic cover
for the gearbox housing (Figure 2), you must remove the adhesive tape (Figure 3), after having
disassembled the mechanical gearbox control with its driving rod (“cambiocorsa” gearbox version)
or the actuator.
1
• Drain the oil in the gearbox from the cap found on the front cover.
2
Removal of the right-hand differential housing cover and flange shafts
• Slide the gearbox housing cover and the flange shaft off of the gearbox, using the extracting tool
95972714 with pins 900026400.
3
• Remove the O-ring from the gearbox housing cover.
4
• Rivet the flange shaft with a rubber hammer and extract it from the differential housing cover.
• Remove the grommet from the gearbox housing cover using a flat screwdriver.
5
• Remove the ball bearing, the adjustment ring and the external tapered roller bearing seat from the flange
shaft using the punch (b) on the tool 900026410, the support tool 95976628 and the press.
IMPORTANT
The ball bearing removed with this procedure must always be replaced.
• Remove the fastening screw for the bearing holder case from the differential compartment.
6
• Remove the differential from the gearbox housing using the tool 95973266.
7
• Slide off the flange shaft, left-hand side, from the gearbox using the extracting tool 95972714 with pins
900026400.
• Remove the grommet from the gearbox housing, using a flat screwdriver.
8
• Remove the Seeger ring from the gearbox housing using two flat screwdrivers simultaneously.
• Remove the left-hand flange shaft support bearing with a USAG 468/2 standard bearing extractor
and accessory 468A/7.
9
Removal of shaft-rods unit with forks
N.B.
Before working on the internal parts of the gearbox, it is advisable to check the housing for any
cracks or deformation, or the presence of lubricant leakage from couplings or from the closure
flanges.
IMPORTANT
If replacement of the gearbox housing is necessary, the thickness of the crown wheel and pinion
spacers should be calculated on the basis of the new dimensions.
• Unscrew the two fastening screws for the lubrication nozzle from the differential compartment.
10
• Remove the lubrication nozzle from the differential compartment and then the O-ring.
• Lock the vertical hooking bracket900026790 on the front gearbox housing cover with two screw nuts.
11
• Sling the gearbox housing and lock it on the vertical mount for the trolley 900026840 using the special
screw nut.
• Remove the vertical hooking bracket 900026790. Unscrew the thirteen perimeter fastening screws on the
front cover and take the latter off of the gearbox housing.
12
• Slide the O-ring off the centering pin and use the USAG 468S11 bushing extractor or a flat screwdriver to
remove the ball bushing.
• Remove the grommet from the front cover using the tool 900026870 and a rubber hammer.
13
• Working from the differential compartment, unscrew the eight fastening screws for the bearing holder
case and remove the sheet protecting the oil passage lines (1).
• Slide off the reverse gear idle gearing (2) with its respective shouldering rings (3). There are two
shouldering rings, one for each side of the idle gearing.
14
• Rivet the two elastic pins off of the rod using a suitable pin-driver.
15
• Shift to neutral. Rivet the main shaft ring nut - front side - and use the tool 900026770 to unscrew it off of
the main shaft.
IMPORTANT
All ring nuts that are removed must be replaced.
16
• Remove the reverse gear fork by sliding it off the control rod.
17
• Position the ends of the USAG 454N/2 extractor arms under the Reverse driven gearing and extract the
latter and the Reverse gear synchronizer together with the lay shaft.
• Slide the Reverse gearing roller cage off the lay shaft.
18
• Unscrew the four fastening screws on the bearing retaining plate.
19
• Slide the driving Reverse gearing and respective O-ring off the lay shaft.
• Unscrew the thirteen screws securing the gearbox housing to the differential housing.
20
• Insert a centering bushing of suitable dimensions on the main shaft, screw the extractor 900026810 tie-
rods into the two holes for the screws removed previously and remove the gearbox housing.
21
• Fit the centering bushing 900026780 onto the lay shaft. Position the USAG 454N/2 extractor arms under
the 1st speed gearing and lift it just enough to release the components placed on the lay shaft between
the track with the bearing rollers and the 1st speed gearing.
• Leave the complete 1st speed gearing assembled on the shaft and remove the track with the bearing
rollers, the spacer and the shouldering fifth wheel.
22
• Position the tool 900026420 plate (a) on the shafts. Insert the tool 900026420 bush (b) on the lay shaft
and lock it with the Seeger ring.
• Insert the specific bushings (c and d) for tool 900026420 on the fork support rods and lock them with their
respective socket head screws.
23
• Position the spacer (f) on the main shaft and lock the ring nut (e) using the specific wrench (g) on tool
900026420.
24
• Position the tool 900026860 under the pinion to release the support bearing coupling and to facilitate
removal.
25
• Remove the complete tool 900026420 from the shaft-rod unit with forks, following the assembly
procedures in reverse order.
• Detach the 5th - 6th speed fork from the lay shaft and the 1st - 2nd and 3rd - 4th gear forks from the
main shaft.
26
Disassembly of the gearbox housing components
• Remove the gearbox housing together with the oil pump, main shaft ball bearing, the external seat for the
tapered roller bearing, the ball bushing for the control rod and the lubrication channel.
• Working from inside the gearbox housing, extract the external track for the roller bearing using the
punch/extractor (a) on the tool 900026460 and then remove the ball bushing using the USAG 468S11
bushing extractor
IMPORTANT
Do not refit any ball bushings that have been removed.
27
• Working from inside the gearbox housing, extract the ball bearing using the punch 900026470. The
bearing is equipped with a stop ring used to obtain a correct positioning.
• Remove the two fastening screw nuts from the channel and remove the latter.
28
• Remove the ball bushing in the gearbox housing - front cover side - using the USAG 468S11 bushing
extractor or a flat screwdriver.
IMPORTANT
Do not refit any ball bushings that have been removed.
• Unscrew the four fastening screws with the rubber washer and remove the gearbox oil pump.
29
Main shaft disassembly
• Lock the base (a) of the tool 900026440 in a vice and insert the main shaft from the front cover side.
• Remove the ring nut and the check nut - differential housing side - from the main shaft using a specific
wrench 900026880.
IMPORTANT
All ring nuts that are removed must be replaced.
30
• Insert a centering bushing of suitable dimensions on the main shaft and, using a USAG 452N/2 extractor
with arms, lift the 3rd - 4th speed synchronizer sliding coupling up by a few millimeters.
• Push the 4th speed gearing downwards and remove the roller bearing, positioning the USAG 452N/2
extractor arms under the internal ring of the bearing.
31
• Slide the support washer and the 4th speed gearing off the main shaft.
• Slide the roller cage for the 4th speed gearing off the main shaft.
32
• Remove the Seeger ring and slide off the sliding coupling, the balls, the dowels and the 3rd - 4th speed
synchronizer springs.
• Position the spacer 900026490 on the main shaft and position the tool 95973272.
33
• Fasten the 95973272 extractor arms in the dowel seats of the 3rd - 4th speed synchronizer hub and
extract it.
• Slide the 3rd - 4th speed synchronizer rings, the 3rd speed gearing and the roller cage off the main
shaft.
34
• Rivet the chamferings in the shouldering ring nut and unscrew it off the main shaft using the 95973246
wrench.
• Slide the 6th speed gearing, the roller cage, the sliding coupling, the balls, the dowels and the 5th - 6th
speed synchronizer springs off the main shaft.
35
• Working from the recess found in the 5th - 6th speed synchronizer hub, use a flat screwdriver to slide
off the spacer and remove the underlying Seeger ring.
• Insert the main shaft on a support cylinder (1), resting the 5th speed gearing on the support flange
900026820. Press the shaft to release and extract the 5th - 6th speed and 5th speed gearing
synchronizer hub and rings.
36
Lay shaft disassembly
N.B.
The double 5th - 6th and 3rd - 4th speed gearings are interference-fit on the lay shaft. The two
tapered roller bearings are positioned between the pinion and gearings with a retainer ring nut and a
spacer which determines the pre-loading of the bearings. The removal of these components from the
shaft is a delicate procedure which should only be performed if the crown wheel and pinion or the
above-mentioned parts are being replaced.
• Fit the lay shaft, pinion side, in the base (a) of the tool 900026450.
37
• Insert the centering bushing 900026780 on the lay shaft and using the USAG 454N/2 extractor with arms,
slide off the spacer, the shouldering fifth wheel and the 1st speed gearing.
• Remove the roller cage for the 1st speed gearing from the lay shaft.
38
• Use the USAG 454N/3 extractor with its arm ends resting on the 2nd speed gearing, after having
inserted the centering bushing 900026780. Slide the internal bushing, the complete 1st - 2nd speed
synchronizer and the 2nd speed gearing off the lay shaft.
• Remove the Seeger ring, the roller cage for the 2nd speed gearing from the lay shaft.
39
• Install the lay shaft on a support cylinder (1), resting the 5th speed gearing on the support flange
900026820. Press the shaft to release and extract the shouldering fifth wheel and the double 5th - 6th
speed gearing.
• With the support flange resting on the 3rd speed gearing, press the shaft to release and extract the
double 3rd - 4th speed gearing.
40
• Block the tool 95973257 support plate in a vice and insert the lay shaft, matching the raised flange
sections with the ring nut notches. To keep the shaft in this position, use the supplied screw and lock it on
the bearing holder case.
• Apply the tool 95973247 on the end of the lay shaft to release the ring nut retaining the bearings. Undo
the screw supplied with the toolkit 95973257 and remove the ring nut from the lay shaft.
IMPORTANT
All ring nuts that are removed must be replaced.
41
• Suitably support the bearing holder case with a support cylinder and, using the press, slide the case, the
front tapered roller bearing and the external track for the rear tapered roller bearing off the lay shaft.
• Using the FACOM U.53J2 bearing extractor, press the lay shaft and slide off the internal track for the
front tapered roller bearing and the middle spacer.
Take out the second taper roller bearing using tool 900026800 and arm extracting tool USAG 454N/3.
42
• Remove the external track for the front tapered roller bearing from the bearing holder case, while
adequately holding the case with a support cylinder 900026450; press with bushing 900026450.
• Remember to keep the spacer for the bearing holder case from the differential housing.
43
• Undo the two fastening screws on the 1st - 2nd and Reverse gear speed control rod bushing and
remove the latter from the differential housing .
• Unscrew the socket head screw and remove the rubber washer and the retaining bushing from the
differential housing.
44
• Extract the external track for the tapered roller bearing with USAg 468/2 extractor and accessory 468A/7
from the differential housing.
• Remove the ball bushing from the differential housing using the USAG 468S11 bushing extractor or a flat
screwdriver.
IMPORTANT
Do not refit any ball bushings that have been removed.
45
• Remove the adjustment ring and the external track for the tapered roller bearing from the differential
compartment, using the expanding hub (a) on tool 9000264600.
46
REFITTING THE DIFFERENTIAL -GEARBOX -
N.B.
1. In order to perform a visual inspection of the components, all metal parts should be washed
thoroughly with a solvent, possibly a biodegradable one, and then blown with compressed
air.
Be especially careful with the internal lubrication lines on the gearbox shafts, the housings
and the cover, as they must be perfectly clean.
2. Ensure that the housings and cover are free of cracks and that the bearing housings are
intact, showing no scoring or grooves. If such defects are found, replace immediately.
3. Ensure that the surfaces and the profile of the gearing teeth show no traces of wear or
spalling. The contact zone should extend over the entire length of the tooth and
and it must be smooth and uniform. Replace all gearings showing these defects.
4. Prior to reassembly of the double gearings, the coupling surfaces must be visually inspected:
there should not be any scoring or deformation.
5. Ensure that the gearings have maintained the prescribed minimum interference with the lay
shaft. If not, replace the components immediately.
6. Check the sides of the sliding couplings and the contact surfaces on the gear-shifting forks
for wear. It is extremely important that the contact surfaces on the fork and the coupling
remain perpendicular with respect to the support rods.
7. Ensure that the shimming surfaces on the idle gearings, the spacers and the shouldering
rings are free of burrs or ripples. In such cases, replace them.
8. Ensure that the claw clutches on the couplings and the idle gearings are free of burrs,
spalling or excessive wear that could impair the clutch.
9. Ensure that the threadings and grooves on the shafts, synchronizer hubs and the Reverse
driving gear are intact.
10. In addition to the closing plugs for the machined holes on the gearbox housing and
differential, tapered-thread plugs are also fitted to close the lubrication lines. In case of
removal, apply LOCTITE 510 on the threading.
11. The oil breather is driven into the gearbox housing until flush. Ensure that it is not blocked by
any foreign matter.
IMPORTANT
Proper positioning and end float of the gearings on the main and lay shafts is determined by the
shouldering rings. The thickness of the latter must be checked each time a component in the set is
replaced. It is possible to keep the same shoulderings only in the case that the new component
presents a deviation equal to or lower than 0.02 mm with respect to the thickness of the replaced
component.
1
Differential housing reassembly
• Insert the differential with the beveled edge facing the differential housing seat and position the external
track of the tapered roller bearing.
• Bring the external track of the tapered roller bearing flush with the differential housing using the tool
900026460 punch (b) and press.
2
• Bring the external track of the tapered roller bearing in the differential housing flush using the punch
95973259.
• Lock the external track for the roller bearing with the retaining bushing, washer and the fastening screw
by applying LOCTITE 242 and tightening it to a torque of 1.4 Nm.
3
• Insert the new ball bushing on the differential housing using the punch 95973267.
• Lock the control rod bushing on the differential housing with two washers and fastening screws.
4
Main shaft reassembly
IMPORTANT
Clean and degrease the main shaft surface and the interior gearing surfaces.
Checking the 3rd - 4th and 5th - 6th speed synchronizer for wear.
• Form a set by centering the middle synchronizer ring with gasket (1) in the external ring (2) and inserting
the internal ring (3) in the middle ring - the couplings must be parallel and uniform.
Rest the set thus formed with the divergent part of the internal ring on a suitable checking plane. Then
while maintaining light pressure on the external ring, measure the distance at diametrically opposite
points.
If it is less than the prescribed distance, replace the synchronizer.
IMPORTANT
Visually inspect the male cone which should not show lapping, excessive ripples or overheated
zones.
5
6
5th - 6th speed synchronizer reassembly
N.B.
Prior to reassembly, lubricate all synchronizer components with gearbox oil and particularly the
rings with gaskets.
• Fit the 5th - 6th speed synchronizer rings on the coupling element for the 5th speed gearing, being
careful as to the positioning of the driving teeth on the internal ring (1) with respect to the external ring (2).
7
• Insert the main shaft, differential housing side, on the base (a) of the tool 900026440.
Using the punch (b) on the tool 900026440 , bring the set formed and the 5th - 6th speed synchronizer
hub flush with the main shaft.
N.B.
The 5th - 6th speed synchronizer hub can be fitted in both directions without distinction.
• Insert the sliding coupling on the 5th - 6th speed synchronizer hub and fit the Seeger ring on the main
shaft.
8
• Insert the 6th speed gearing spacer with the grooved side resting on the 5th - 6th speed synchronizer
hub retaining Seeger ring, using the tubular punch (b) on the tool 900026440.
Push the sliding coupling towards the 5th speed gearing. Put the springs inside the dowels and using a
screwdriver, push them into the seats, inserting the balls as well.
• Fit the 5th - 6th speed synchronizer rings on the coupling element for the 6th speed gearing, being
careful as to the positioning of the driving teeth on the internal ring (3) with respect to the external ring (4).
Insert the set formed onto the main shaft after having first inserted the roller cage.
9
• Apply LOCTITE 242 on the shouldering ring nut threading and using the wrench 95973246, tighten to the
torque of 70 Nm.
• Bend the shouldering ring nut on the two points (see arrows), corresponding to the main shaft notches.
10
3rd - 4th speed synchronizer reassembly
N.B.
Prior to reassembly, lubricate all synchronizer components with gearbox oil and particularly the
rings with gaskets.
• Fit the 3rd - 4th speed synchronizer rings on the 3rd speed gearing coupling element, carefully checking
the positioning of the driving teeth (1) on the internal ring with respect to the external ring (2). Then fit the
set formed on the main shaft after having first inserted the roller cage.
11
• Lock the set formed and the 3rd - 4th speed synchronizer hub onto the tool 95976121 with a screw and
a washer of suitable dimensions.
Insert the sliding coupling onto the synchronizer hub.
N.B.
The 3rd - 4th speed synchronizer hub can be fitted in both directions without distinction.
• Using a screwdriver, put the spring inside the dowel and push it into the seat, inserting the ball as well.
12
• Insert the set formed onto the main shaft using the tubular punch (c) on tool 900026440 and a hammer.
13
• Fit the 3rd - 4th speed synchronizer rings onto the 4th speed gearing coupling element, carefully
checking the positioning of the driving teeth on the internal ring with respect to the external ring. Then put
the set formed on the main shaft after having first inserted the roller cage.
• Insert the support washer on the main shaft with the slotted side facing the gearing.
14
• Bring the internal track for the roller bearing flush with the support washer, using the punch (d) on the tool
900026440 and a hammer.
• Apply LOCTITE 242 on the ring nut and check nut threading and use the wrench 900026880 to tighten
the two ring nuts in sequence to a torque of 100 Nm.
15
Lay shaft reassembly
IMPORTANT
All ring nuts that are removed must be replaced.
Clean and degrease the main shaft surface and the interior gearing surfaces.
• Using the press, drive in the external track of the front tapered roller bearing flush with the bearing holder
case using the base (a) and the punch (d) on the tool 900026450.
16
• With the press, drive in the internal track for the rear tapered roller bearing using the tubular punch (b) on
the tool 900026450.
• Position the outer track for the rear tapered roller bearing, the spacer, the internal track for the front
tapered roller bearing and the bearing holder case. Then using the press and the tubular punch (b) on the
tool 900026450, bring it flush.
17
• Loosely fit the ring nut, pinion side, onto the lay shaft.
• Block the tool 95973257 support plate in a vice and insert the lay shaft, matching the raised flange
sections with the ring nut notches. To keep the shaft in this position, use the supplied screw and lock it on
the bearing holder case.
18
• Fit the tool 95973247 on the end of the lay shaft and tighten the bearing retainer ring nut to the torque of
300 Nm with the FACOM R.250A torque wrench. Undo the screw supplied with the toolkit 95973257 and
remove the lay shaft from the latter.
• Put the two double gearings and the shouldering ring in an oven for at least 2 hours at a temperature of
140°C.
Position the pinion under the press and use the tubular punch (b) on the tool 900026450 to drive in the
first double gearing.
Leave it under load (10000 Kg) for at least 15 minutes and allow the shaft to cool.
19
• Remove the second double gearing from the oven and follow the same procedure described above to
drive it onto the lay shaft, using the tubular punch (c) on the tool 900026450.
• Remove the shouldering ring from the oven, set it on the side with the notches facing the double gearing
and following the same procedure described above, drive it onto the lay shaft, using the tubular punch (c)
on the tool 900026450.
20
• Insert the roller cage for the 2nd speed gearing on the lay shaft and lock it into place with the Seeger ring.
21
Checking the 1st - 2nd speed synchronizer for wear
• Form a set by centering the first middle synchronizer ring with gasket (1) in the external ring (2), inserting
the internal ring (3) in the middle ring and adding the second ring with gasket (4) to the set, ensuring that
the couplings are parallel and uniform.
Rest the set thus formed with the divergent part of the internal ring on a suitable checking plane. Then
while maintaining light pressure on the external ring, measure the distance at diametrically opposite
points.
IMPORTANT
Visually inspect the male cone which should not show lapping, excessive ripples or overheated
zones.
22
• Position the 1st - 2nd speed synchronizer rings on the 2nd speed gearing coupling element and fit the
set formed on the lay shaft.
23
• Insert the complete 1st - 2nd speed synchronizer on the lay shaft and bring it flush with the punch
95973262.
N.B.
After inserting the synchronizer, ensure that the 2nd speed gearing moves freely.
• Insert the 1st speed gearing bushing on the lay shaft with the punch 95973263.
24
• Insert the roller cage for the 1st speed gearing on the lay shaft.
• Position the 1st - 2nd speed synchronizer rings on the 1st speed gearing coupling element and fit the set
formed on the lay shaft.
25
• Fit the shouldering fifth wheel on the lay shaft using punch 95973263.
26
Reassembly of gearbox housing components
IMPORTANT
In the event of retaining washer replacement, use 95973268 (∅ 14 mm), 900026830 (∅ 8mm) punches
to fit them.
• Fit the two centering dowels and the new O-rings on the gearbox housing.
• Insert the external track for the roller bearing on the gearbox housing, front cover side, using the tool
900026480.
27
• Insert the roller box on the gearbox housing, front cover side, using the punch (d) on the tool 900026480.
• Using the punch (c) on the tool 900026480, insert the ball bushing on the gearbox housing, front cover
side.
28
• Insert the ball bushing in the gearing compartment of the gearbox housing, using the punch 95973267.
• Lock the raceway in the gearing compartment with two bolts and their respective washers and apply
LOCTITE 270.
29
• Fasten the positive-displacement pump driven by the auxiliary gearing for reverse gear,on the gearbox
housing, using four fastening screws and rubber washers.
30
Reassembly of shaft-rod unit with forks
• Assemble the shafts and forks with the respective control rods.
• Fit all of the tool components 900026420 on the shaft-rod unit with forks and lock into place.
31
• Position the spacer on the refaced surface of the differential housing.
• Fit the three centering screws (a) for the tool 900026430 on the bearing holder case in diametrically
opposite positions and while lifting the unit slowly with a hoist, insert it into the housing gradually in order
to prevent bumping or interference.
32
• Working from the differential compartment, bring the unit flush using the screw nut (b) supplied with the
tool 900026430 and a socket wrench.
• Unscrew the tool 900026430 removing it from the bearing holder case. Position the sheet (A), apply
LOCTITE 270 on the eight fastening screws and tighten to the torque of 30 Nm proceeding crosswise.
33
• Put the roller bearing on the lay shaft using the tubular punch 95973262.
34
Gearbox housing reassembly
• Clean and degrease the contact surfaces on the gearbox and differential housing and outline the holes
uniformly and evenly with LOCTITE 510.
Lock the thirteen fastening screws on the housings, tightening them to the torque of 30 Nm.
• Working from the differential compartment, check the condition of the O-ring and fit it on the lubrication
nozzle.
35
• Apply LOCTITE 270 on the threading of the two fastening screws for the lubrication nozzle and position
the two respective washers. Tighten to the torque of 10 Nm.
N.B.
The two fastening screws have different thread stem lengths; check the figure for proper fitting.
• Put the ball bearing on the main shaft and bring it flush with the gearbox housing using the punch
900026470.
36
• Position the O-ring on the main shaft and fit the two centering dowels with the respective new O-rings.
• Lock the bearing retaining plate on the gearbox housing with the two hexagonal-head fastening screws,
(B), tightening them to the torque of 30 Nm and the two socket head screws (C) and the retaining plate
for the toothed washers, to the torque of 26 Nm, after applying LOCTITE 270 sealer.
37
• Insert the Reverse driving gear on the main shaft and the roller cage on the lay shaft.
38
Checking the Reverse gear synchronizer for wear
• Center the synchronizer ring (1) on the respective clutch cone. The two cones must be in a position to
mate uniformly and in a parallel manner by means of the relative axial rotation.
Check the distance between the coupling element (2) and the synchronizer ring at several points that are
diametrically opposite each other.
If it is less than the prescribed distance, replace the synchronizer.
IMPORTANT
Visually inspect the male cone which should not show lapping, excessive ripples or overheated
zones.
IMPORTANT
From gearbox no. 2406 on, a new 63 mm diameter RM synchronizer has been fitted (previously 63
mm). Apart from the single components, this change affects the synchronizer, the RM gearing and
the roller retaining washer. New parts cannot be used to replace pre-modification parts. When
replacing even one component only, the complete new RM synchorizer must be fitted as well as the
new RM gearing.
39
40
Reverse gear synchronizer reassembly
IMPORTANT
From gearbox no. 2406 on, a new 63 mm diameter RM synchronizer has been fitted (previously 63
mm). Apart from the single components, this change affects the synchronizer, the RM gearing and
the roller retaining washer. New parts cannot be used to replace pre-modification parts. When
replacing even one component only, the complete new RM synchorizer must be fitted as well as the
new RM gearing.
• Insert the Reverse driven gear on the lay shaft and position the Reverse synchronizer rings on the gear
coupling element.
41
• Insert the synchronizer hub for the Reverse gear synchronizer using punch 95973263, carefully checking
to ensure that the lubrication slots on the element are facing the gear.
N.B.
Match the synchronizer hub recess with the coupling of the synchronizer rings.
42
• Fit the sliding coupling on the Reverse gear synchronizer hub, with the Reverse gear fork fitted.
N.B.
Ensure that the notch on the sliding coupling is facing the recess in the synchronizer hub.
• Fit the rollers on the Reverse gear synchronizer using a flat screwdriver and pushing the sliding coupling
towards the Reverse driven gearing.
43
• Insert the Seeger ring on the lay shaft.
• Put the elastic pins on the Reverse gear fork using a pin-driver, as well as the tool 900026430 to help
center them.
44
• Fit the shouldering ring on the roller box with the protruding part inserted between the gearbox housing
retainers.
45
• Engage the two gears and fasten the ring nut on the main shaft. Apply LOCTITE 242 and using the tool
900026770, tighten to a torque of 100 Nm.
46
Front cover reassembly
Bring the roller box (a) flush with tool 95973267. Insert the grommet on the front cover with the punch
900026760 and slide the new O-ring onto the pin.
• Grease the surface on which the shouldering ring rests, on the front cover, to keep it positioned between
the retainers during cover reassembly.
47
• Clean and degrease the contact surfaces on the gearbox housing and the front cover. Outline the holes
uniformly and evenly with LOCTITE 510.
Lock the thirteen stud bolts and fastening screws on the front cover, tightening them to a torque of 30
Nm, proceeding crosswise (Figure 1).
N.B.
Insert the scraper ring 900026850 guard on the shaft (Figure 2).
48
Reassembly of the differential housing cover and flange shafts
• Bring the ball bearing flush with the differential housing seat using the punch 900026890 and a hammer.
49
• Clean the seat for the new grommet thoroughly and grease it adequately.
Place the grommet with the closed side facing outward and using the base and the punch on the tool
900026410, bring it flush with the differential housing.
IMPORTANT
Lubrication of the grommet is indispensable to ensure its proper functioning.
• Fit the left-hand flange shaft on the differential housing using the punch (a) on the tool 95973276.
50
• Working from the differential compartment, fit the Seeger ring on the differential housing.
• Insert the new ball bearing and center the differential housing cover on the base (a) of the tool 95973275.
51
• Position the spacer on the cover ball bearing, differential housing side, with the side equipped with slots
for the passage of the lubricating oil opposite the bearing.
• Bring the external track for the tapered roller bearing flush with the differential housing cover using the
95973275 toolkit and the press.
52
• Clean the seat for the new grommet thoroughly and grease it adequately.
Place the grommet with the closed side facing outwards and, using the base and the punch on the tool
900026410, bring it flush with the differential housing cover.
IMPORTANT
Lubrication of the grommet is indispensable to ensure its proper functioning.
53
• Fit the Seeger ring on the differential housing cover.
• Check the condition of the O-ring and fit it on the differential housing cover.
54
• Insert the differential- crown wheel set inside the differential housing, using the tool AV3266.
• Tighten the thirteenth fastening screw for the bearing holder case to the torque of 30 Nm.
55
• Clean and degrease the contact surfaces on the cover and differential housing and outline the holes
uniformly and evenly with LOCTITE 510.
Fit the differential housing cover matching the lubrication opening (1) found on the cover with the
differential housing retaining washer (2).
• Position the two cable-guide brackets (3) and tighten the eleven fastening screws on the differential
housing cover to the torque of 30 Nm, proceeding crosswise.
N.B.
The front fastening screw differs in the length of the thread stem. check the figure for proper fitting.
56
Seal test
To check for leaks, a seal test can be performed on the gearbox housing when it is completely assembled.
IMPORTANT
If leaks are present, the external grommets must be replaced and/or the front cover, gearbox housing
and differential housing couplings must be checked.
• Plug all openings leading outside of the gearbox housing and remove the breather valve.
57
• Fit the union 95973283 in the breather valve seat and, using a standard inflation equipment provided with
a precision pressure gauge, let in air up to the pressure of 0.3 bar. A drop in pressure of 20 Pascal in 15
seconds is acceptable.
N.B.
Use a leak detector spray on the gearbox to check for the presence of any leaks.
58
ADJUSTMENTS AND CHECKS
IMPORTANT
For fitting and removing the gearbox components required for the adjustment and check procedures,
follow the operations indicated in the chapters "Gearbox removal" and "Gearbox reassembly".
Gearbox removal
Gearbox reassembly
1
• Check the flatness of the outer track for the upper taper roller bearing (Figure 1 and 2).
2
• Measure the distance W between the side surfaces of the bearings' outer rings (Figure 1,2 and 3).
3
4
• Measure the distance X between the crown rear surface and the side surface of the lower bearing's outer
ring (Figure 1 and 2).
5
• The deviation t from the theoretical distance of 45,10 mm is marked on the differential crown wheel.
• Thus the actual distance G between the crown rear surface and pinion axis is:
6
• To determine the total dimension L of the differential set with bearings and spacers calculate: (Figure 1):
• Where R and V are printed on the differential housing (Figure 2 and 3) and the differential cover (Figure
4 and 5) respectively.
7
8
9
• The spacer thickness S3, on the differential housing side, is calculated as follows (Figure 1):
N.B.
S is punched on the differential housing (Figure 2).
10
• To calculate the spacer S4, on the differential cover side, a bearing preload of 0,07 mm must be taken
into account.
Calculate the thickness as follows:
N.B.
The thickness of the spacers supplied as spare parts may not correspond to the values obtained
through the calculations described: in this case, the spacers must be adjusted to the right size using
a surface grinder.
11
Checking the differential housing rolling torque
N.B.
To check the rolling torque of the differential housing, it is essential that the lay shaft is not installed.
• Fit the differential cover tightening the fastening screws to the torque 30 Nm.
12
• Fit the prescribed tool 95973266 (Figure 1).into the seat for the right hand flange shaft and fit the specific
torque wrench onto the tool hexagon (Figure 2).
• Rotate the differential checking that the torque is as prescribed (Figure 3).
13
Checking the crown wheel and pinion backlash
14
• Position the bearing case spacer (Figure 1) and fit the lay shaft onto the differential housing (Figura 2).
15
• Working from the differential compartment, bring the unit flush using the nut (b) supplied with tool
900026430 and a socket wrench.
• Remove the centering tools and fix the case in its seat using the specific screws to the torque of 30 Nm.
16
• Place the differential in its seating using tool 95973266 (Figure 1) and tighten the differential cover's
fastening screws to a torque of 30 Nm (Figure 2).
17
• Fit the prescribed tool 95973266 into the seat for the right-hand flange shaft.
Lock the fastening tool for the dial gauge 900026900.
• Reset the dial gauge plunger in position with the mark on the tool, which corresponds to the crown outer
diameter.
18
• Rotate the tool (Figure 1).and check that the backlash falls within the prescribed values. (Figure 2).
N.B.
If the backlash measured is not correct, adjust the spacer thickness keeping the preload conditions
for the differential bearings stable.
19
Checking the crown wheel and pinion impression
• Fit the differential cover tightening the fastening screws to the torque of 30 Nm.
20
• Fit the prescribed tool 95973266 into the seat for the right-hand flange shaft.
• Have the differential perform some revolutions in a clockwise and anticlockwise direction.
• Remove the differential cover and extract the differential with the prescribed tool 95973266.
21
• Check that the impression on the crown teeth is three quarters the width of each tooth side, both on the
pulling (Figure 1) and on the releasing side (Figure 2).
N.B.
The distance between the inner edge of the crown wheel tooth and the beginning of the impression
must range from 5 to 8 mm.
22
• If the preceding conditions are not met, the spacers' thickness must be modified according to the logics
displayed , keeping the prescribed backlash and bearing preload conditions.
• Place inner roller track on the checking plane (1) and set the case equipped with outer track on it (2).
23
• Check that the case lies evenly on the resting surface (Figure 1 and 2).
• In this position, reset the dial gauge.
24
• Measure the distance T1 between the bearing holder case surface and the inner ring (Figura 1 e 2).
25
• Verify that the values taken are correct by checking the flatness of the bearing inner ring.
• Place the lay shaft equipped with taper roller bearing on the checking plane.
26
• Check the flatness of the outer ring (Figure 1 and 2).
27
• Measure the distance R1 between the surfaces of the outer and inner bearing rings (Figure 1 and 2).
28
• Considering a bearing preload of 0.03 mm, the thickness S1 of the spacer to be positioned between the
taper roller bearings is:
• Fit the inner ring of the front taper roller bearing using the press equipped with the prescribed tubular
punch 900026450.
29
• Onto the lay shaft place the outer ring of the front taper roller bearing (1), the taper roller bearing spacer
(2) (Figure 1), the bearing holder case (3) and the rear taper roller bearing (4) (Figure 2).
30
• Bring the components flush with the press equipped with the prescribed tubular punch 900026450.
31
• Fix the retaining plate of the prescribed tool 95973257 in a vice and mount the lay shaft aligning the
flange ridges with the notches in the ring nut.
• To keep the shaft in this position, fix the bearing holder case with the screw supplied.
32
• Apply the prescribed tool 95973247 onto the end of the lay shaft and tighten the ring nut to the torque of
300 Nm.
• Remove the lay shaft from the tool. Lock the bearing case in a vice suitably protecting the contact
surfaces.
33
• After having engaged tool 95973247 (Figure 1), rotate the shaft using the prescribed torque wrench
FACOM R.250°A, and check that the rolling torque falls between the prescribed values (Figure 2).
34
Pinion positioning
35
• Considering the deviation marked on the pinion head (Figure 1), calculate the distance P1 between the
taper roller bearing surface plane and the differential axle (Figure 2).
36
• Place the lay shaft on an x block and measure the distance H (Figure 1) between the pinion head surface
(Figure 2) and the resting surface of the bearing case (Figure 3) on the differential housing.
37
• The deviation from the theoretical distance of 75,50 mm must be marked on the pinion head.
38
• Thus the actual distance between the pinion head and differential axis is:
39
• To measure the thickness of the spacer S2 to be inserted between the bearing case and the differential
housing calculate the following: (Figure 1):
N.B.
Z is printed on the differential housing (Figure 2).
40
• Using a bore-meter measure the diameter d of the side cover's seat on the differential housing.
• Fit the lay shaft onto the differential housing, including the spacer for preloading the pinion's taper roller
bearings.
• Reset the dial gauge 900026510 to 2mm on a checking plane, positioning it on the bushing 900026500.
41
• Rest the bushing 900026500 including the dial gauge 900026510 onto the pinion head and read the
deviation M.
• In order to determine the actual positioning of the taper roller bearing in relation to the differential axle,
carry out the following procedure:
42
• In order to obtain the correct positioning of the pinion in relation to the differential axle, this must be:
IMPORTANT
If this does not prove correct, increase or reduce the thickness of the spacer in order to obtain this
condition.
43
Measuring the seeger ring thickness for positioning the Ist and IInd gear synchroniser
• Fit the seeger ring (Figure 1) orientating the bevelled side towards the roller cage (Figure 2).
44
• Fit the first and second speed synchronizer hub using the punch for the prescribed tool 95973262.
45
• Insert the pinion positioning spacer under the bearing case and rest it on the checking plane base.
• Measure the distance between the spacer surface (Figure 1) and the synchronizer hub (Figure 2), the
value must be (Figure 3):
46
N.B.
If the measured value does not correspond to the prescribed one, adjust the seeger ring thickness
until it reaches the reference measurement.
47
Measuring the spacer thickness for IInd gear end float
• With the synchronizer and seeger ring fitted, measure the distance M between the synchronizer hub and
the fifth speed gear using gauged blocks (Figure 1).
N.B.
The blocks must rest on the surface of the synchronizer hub ledge and not on the protrusion of the
seeger ring as this would distort the measurement.
48
• Using a micrometer, measure the thickness N of the second speed gear hub (Figure 1 and 2).
49
• To obtain the thickness of the shouldering ring calculate the following:
• Remove the synchronizer and the seeger ring and heat the lay shaft in a kiln.
N.B.
Put the shouldering ring in the oven at a temperature of 140°G for at least 20 minutes.
• Fit the shoulder onto the shaft with the side with notches turned towards the double gear.
N.B.
Apply a load (10,000 kg) for at least 2 minutes and let the shaft cool down.
50
• Bring the entire unit flush with the punch of the prescribed tool AV3262.
51
• Fit the bushing (1) so that it rests on the first and second speed synchronizer hub and install the seeger
ring in the specific seat (2).
52
• Using the gauged blocks measure the distance O between the bushing edge and the seeger ring (Figure
1 and 2).
• To obtain the thickness of the shouldering fifth wheel, the thickness of the roller bearing inner track and
the prescribed value for the roller bearing P (Figure 1) and float must be deducted from the distance
measured (Figure 3).
53
54
GEARBOX CONTROL ADJUSTMENT
• Present instruction is applicable on cars that feature the gearbox controls p/n 198245 (Spyder GT)
and p/n 198242 (Coupé GT) (from assembly number 10256) onwards
• Hold firmly the gearshift lever in neutral by mean of tool p/n 900026260.
• Check that the axis-to-axis dimension between the ball joints of lever corresponds to 76 ± 0,5 mm.
1
Adjusting the gearshift wire
• Disconnect the cable from bracket (A) and from the ball joint of rocker (B).
• Connect the head of the cable to the bracket.
• Open the linking block (C) and connect the plastic (D) end to the ball joint of the rocker.
• Let the internal spring compensate the freeplay of the cable then close the linking block.
2
Adjusting the gears selection
• Disconnect the cable from bracket (A) and from the ball joint of rocker (B).
• Connect the head of the cable to the bracket.
• Open the linking block and connect (C) the plastic end (D) to the ball joint of the rocker.
• Hang a weight heavy 3.5 – 4.0 kg about to the ball joint of the rocker and let it droop from the spacer
bar (A) of the exhaust, with a wire so that the freeplay of the system will be compensated. Then
close the linking block.
3
TIGHTENING TORQUES
Screw fastening nuts for cover with control rod 8 Nm LOCTITE 270
1
Description Torque Product
2
TOOLKIT
Specific equipment
Wrench for fastening main shaft ring nut and check-nut 1 95973245 AV3245
Wrench for lay shaft bearing retaining ring nut 1 95973247 AV3247
Toolkit for fitting twin gearings and bearings on lay shaft 4 900026450
Torque tool for tightening lay shaft ring nut 1 95973257 AV3257
Tool for fitting 1st - 2nd speed synchroniser hub and spacer 1 92973262 AV3262
1
Description Pieces Code
Extracting tool for 3rd - 4th speed synchroniser on main shaft 1 900026490
Tool for fitting ball bearing outer ring on differential cover 2 95973275 AV3275
Tool for checking distance between pinion and bearing seat 1 900026510
2
Description Pieces Code
3
Standard toolkit
4
MECHANICAL GEARBOX LEVER HOUSING
1
Remove the heat shield by undoing the fastening screws.
• Undo the two front screws fastening the gearbox lever housing.
2
• Undo the rear fastening screw of the gearbox lever housing.
3
• Use a screwdriver to slide out the two gearbox control wires.
4
• Relocate the gearbox lever housing.
5
• Tighten the two front nuts to a torque of 17 Nm.
• Remount the heat shield below the transmission shaft, tightening the fastening screws.
6
• Fit the transmission shaft.
Reattaching the clutch
7
MAIN EARTH LOCATION - M138 COUPÈ
• Figure no. 8: Earth for dashboard wiring and A.C. system cable bundle.
1
Figure no. 1
• BATTERY MASTER SWITCH EARTH (15 Nm).
• Position : Luggage compartment, RH side.
Figure no. 2
• F1 WIRING EARTH (15 Nm).
• Position : Luggage compartment, RH side.
2
Figure no. 3
• STRANDED EARTH WIRE FOR AIR BAG ECU (15 Nm).
• Position: Passenger compartment central tunnel.
• N.B.: The black cable is available only in the RHD version (dashboard cable earth).
Figure no. 4
• LONGITUDINAL WIRING EARTH (15 Nm).
• Position : Luggage compartment, LH side.
3
Figure no. 5
• A.B.S. WIRING EARTH (15 Nm).
• Position: Luggage compartment, LH side.
Figure no. 6
• ENGINE COMPARTMENT WIRING EARTH (15 Nm).
• Position: Engine compartment, RH side.
4
Figure no. 7
• ENGINE EARTH.
• 1- Position : Clutch housing RH side (60 Nm).
• 2- Position : RH side underbody (15 Nm).
Figure no. 8
• DASHBOARD WIRING EARTH, A.C. UNIT CABLE BUNDLE AND POWER WINDOW KEYBOARD (15
Nm).
• Position: Passenger compartment, tunnel RH side.
5
Figure no. 9
• EARTH FOR DASHBOARD WIRING, A.C. SYSTEM AND INJECTION (15 Nm).
• Position: Passenger compartment, RH side on fire protection shield.
Figure no. 10
• LHD DASHBOARD WIRING EARTHS (15 Nm).
• Position: LH side passenger compartment, under dashboard.
6
Figure no. 11
• RHD DASHBOARD WIRING EARTHS (15 Nm).
• Position: RH side passenger compartment, under dashboard.
Figure no. 12
• IGNITION COIL EARTHS (25 Nm).
• Position: Engine compartment rear side, near the oil pressure sensor.
7
Figure no. 13
• EARTHS ON GEARBOX (10 Nm).
• Position: Gearbox LH side.
Figure no. 14
• EARTH FOR F1 GEARBOX ECU WIRING.
• Position: RH side luggage compartment.
8
Figure n° 15
• Earth for IT Node bracket.
• Position: Central tunnel, LH side
9
ALARM SYSTEM KIT REPLACEMENT
• Undo the two fastening screws - located behind the steering wheel - for the half bearings on the steering
column stalk.
• Undo the five screws and remove the steering column cover.
1
• Detach the two alarm system aerial connectors.
2
Hyperfrequency sensors
• Unscrew the four fastening screws to remove the sun visors on both sides.
• Unscrew the five screws fastening the lower trim panel.
3
• Working on the side column, remove the trim panel on both sides of the vehicle, undoing the two
fastening screws.
• Disconnect the hyperfrequency sensors and remove them by undoing the two fastening screws for each
sensor.
4
Alarm system ECU and anti-lift sensor
• Detach the connector for the anti-lift sensor (1) and remove it by undoing the two fastening screws.
• Detach the two connectors of the alarm system (2) and remove it by unscrewing the two fastening
screws.
5
Alarm system siren
• Working in the luggage compartment, remove the spare wheel support shelf.
• Detach the fastening buttons on the left-hand side panel of the luggage compartment and remove the
panel.
6
• Detach the connector on the alarm siren and remove it by unscrewing the fastening screw.
7
CHECK FOR CORRECT ALARM TRIGGER OPERATION
Observe the following procedure for controlling correct operation of the alarm trigger:
1. Check that the vehicle windows are open.
2. Activate the alarm system by remote control.
3. Wait for 10s for the system to stabilize.
4. Put a hand into the cockpit and move it in a horizontal direction along the longitudinal axis of the
cockpit and parallel to the ground; be sure to cover the whole area of the open front window, The
correct indication of an intrusion is signalled by a double flash of the direction indicators.
5. Wait for 10s and repeat the procedure outlined in point 4 on the other side of the vehicle.
6. To check for excessive sensitivity, make a sample test by passing a metallic strip (about 50 cm x 50
cm) around the glassed surface of the vehicle, including the top if the vehicle is a sports car. Pass
the metal strip at a distance corresponding to that at which another vehicle or a pedestrian might
pass, or imagine a tilting garage door closing around the vehicle. The alarm must not emit any signal
in these cases.
These operations must be done within 25s from activation of the alarm system to prevent triggering of the
siren.
At each flash of the headlights, indicating a triggering of the alarm, the 25s timer is reset and a fresh testing
period commences.
The alarm system is completely active after 25s from the last direction indicator flash. The active state is
signalled by a different flashing of the LED on the instrument panel.
IDENTIFICATION OF ALARM MEMORIES FOR THE METASYSTEM M826 ALARM SYSTEM
If alarms have gone off during operation, when the alarm system is deactivated by remote control, the LED
on the instrument panel indicates the alarms as follows:
When more than one alarm goes off, a sequence is activated, with pauses between single alarms of 3s.
The alarm memory is reset by turning the key to ON or when it is activated by remote control.
PROGRAMMING A NEW KEY
To program a new key, the following are needed: the electronic code (grey card), the old keys and obviously
the new keys.
• Connect the SD2 tester in "link to PC" mode, immobilizer ECU, "spare parts" section.
• Follow the steps as advised and in particular:
1. enter the electronic code;
2. run a key-on/key-off cycle with the original keys;
3. the new keys are programmed symply leaving them inserted in the switch, without carrying out a
key-on cycle.
4. to end the procedure, reply "no" when a further key is requested.
DETACHING – REFITTING D-BOX
(MY2004)
1
DETACHING – REFITTING ARMREST UNIT
(MY2004)
1
• Move the front seats as far back as possible.
• Release the passenger compartment floor mat tab (1), so that the lateral fastening screw on the armrest
unit is practicable.
• Undo the lateral fastening screw (2) on the pocket change tray unit
2
• Perform the same operation on the side opposite the armrest unit too.
• Undo the retaining buttons to release the handbrake lever boot (1).
• Remove the armrest unit from the seat following the direction indicated by the arrow.
N.B.: Take care when carrying out the operation not to damage the dashboard trim panel or any of
the other nearby parts.
3
• Detach the electric connections (1), (2), (3), (4) and the aerial connections (5) and (6) on the NIT.
• Detach the electric connections on the electric mirror control unit, and also those on the top
opening/closing control and the cigar lighter/power socket.
• Remove the armrest unit from its seat..
4
DETACHING – REFITTING HANDBRAKE LEVER MY 04
(MY 2004)
1
• Free the cable from the handbrake lever (1).
• Working on the passenger side, unscrew the fastening nut (2) and remove the handbrake lever (3).
2
DETACHING – REFITTING FRONT AERIAL AMPLIFIER MY 04
1
• Detach the electric amplifier connection with the D-BOX (1).
• Detach the aerial amplifier electricity supply connection (2).
Refitting
• Fit the aerial amplifier by following the procedure outlined before in reverse order.
• Before proceeding to refit the front right-hand trim panel, check the aerial amplifier is working correctly,
proceeding as follows:
• Tune the radio in the AM mode.
• If the radio receives the signal, then the amplifier is working correctly.
2
DETACHING – REFITTING REAR AERIAL AMPLIFIER
(MY2004)
Detaching
N.B.: The roof lining must be removed to prevent it becoming misshapen when the amplifier is
removed.
• Detach the electric amplifier connection to the aerial on the heated rear window (1).
• Detach the electric amplifier connection to the D-BOX (2).
• Undo the screw fastening the aerial amplifier (3).
• Remove the aerial amplifier (4) from its seat.
Refitting
• Fit the aerial amplifier by following the procedure outlined before in reverse order.
• Before proceeding to refit the roof lining, make sure the aerial amplifier works correctly, proceeding as
follows:
• Detach the front amplifier.
• Check the radio tunes in normally to the stations selected.
• If the radio is working in the standard fashion, then the aerial amplifier is working correctly.
1
YAW SENSOR
(M.Y. 2003)
The Sensor (1) is part of the ABS/ASR/MSP braking system, which is linked to the ABS 5.7 ECU.
The dashboard wiring has been integrated with a connector (2) which is attached to the yaw sensor, and with
a single earth for the airbag system, that is fixed together with the stranded earth wire (3).Also the
longitudinal cable earth must be connected into the earth bracket (4).
1
The modification on the tunnel acoustic insulation lies in the removal of a piece of soundproofing material, in
the point shown in the figure. This allows the earth bracket to be inserted and the yaw sensor to be secured
on the tunnel, in front of the airbag ECU.
2
FUEL SUPPLY DISTRIBUTION
CAMBIOCORSA ROBOTIZED GEARBOX
ENGINES FUEL ELECTRONIC MANAGEMENT
ELECTRICAL COMPONENTS - DESCRIPTION
A
1 Earth
2 Earth
3 Power supply from main relay
4 Front lambda sensor 2 heater
5 Front lambda sensor 1 heater
6 Rear lambda sensor 2 heater
7 Cylinder 5 coil control 4
8 Cylinder 4 coil control 4
9 -
10 Rear lambda sensor 2 reference earth
11 Rear lambda sensor 2 signal
12 Front lambda sensor 2 reference earth
13 Front lambda sensor 2 signal
14 Front lambda sensor 2 equalizing current
15 Front lambda sensor 2 pumping current
16 Cylinders 3 and 4 detonation sensor
17 -
18 Immobilizer relay
19 Cylinder 5 injector control
20 Cooling fan 1 control input
21 ECU power supply +15 (key)
22 A / C compressor control
23 Power supply from main relay
24 Cylinder 4 injector control
25 Seal control pump
26 Intake air temperature signal
27 Air flow meter reference earth
28 -
29 Air flow meter signal
30 -
31 Cylinders 7 and 8 detonation sensor
32 -
33 Reference earth for accelerator pedal 2 potentiometer
34 Signal for accelerator pedal potentiometer 2
35 Signal for accelerator pedal potentiometer 1
36 Reference earth for accelerator pedal 1 potentiometer
37 Engine speed rate signal for rev. counter
38 Cruise control: acceleration adjustment
39 Closed clutch signal
40 A / C system activation signal
41 -
42 -
43 K diagnosis line
44 Secondary air valve control
45 -
46 Secondary air pump control
47 High speed fan control
48 -
49 -
50 Sensor reference earth
51 Front lambda sensor 1 reference earth
52 Front lambda sensor 1 pumping current
53 Air flow meter power supply
54 -
55 Brake pedal switch signal
56 Stop switch signal
57 Cruise control: deceleration adjustment
58 CAN line (-)
59 -
60 CAN line (+)
61 Cooling fan 2 control input
62 Power supply +30
63 Rear lambda sensor 1 heater
64 Canister purge valve
65 Fuel pump relay (reduced power)
66 Low speed fan control
67 Inertia switch signal
68 Rear lambda sensor 1 reference earth
69 Rear lambda sensor 1 signal
70 Front lambda sensor 1 signal
71 Front lambda sensor 1 equalizing current
72 Stabilized voltage for accelerator pedal potentiometer 2
73 Stabilized voltage for accelerator pedal potentiometer 1
74 -
75 Cruise control restoring
76 Cruise control ON / OFF
77 -
78 -
79 -
80 -
81 -
B
82 Toothed wheel signal (A)
Stabilized voltage for motor driven throttle potentiometers 1 and
83 2
84 Signal for motor driven throttle 2 potentiometer
85 -
86 Bank timing sensor signal
87 Bank timing sensor signal
88 Cylinder 6 injector control
89 Cylinder 2 injector control
90 Toothed wheel signal (B)
91 Reference earth for throttle 1 and 2 potentiometers
92 Signal for motor driven throttle 1 potentiometer
93 Engine temperature signal
94 Cylinder 6 coil control 1
95 Cylinder 2 coil control 1
96 Cylinder 1 injector control
97 Cylinder 8 injector control
98 Power supply 5V for sensors 1 and 2
99 Detonation sensors reference earth
100 -
101 -
102 Cylinder 1 coil control 1
103 Cylinder 8 coil control 1
104 -
105 Seal check valve
106 Cylinders 1 and 2 detonation sensor signal
107 Cylinders 5 and 6 detonation sensor signal
108 Detonation sensors shield
109 -
110 Cylinder 7 coil control 1
111 Cylinder 3 coil control 1
112 Cylinder 7 injector control
113 Cylinder 3 injector control
114 -
115 Bank 1 timing variator control
116 Fuel pump control 2
117 Motor driven throttle control (-)
118 Motor driven throttle control (-)
119 -
120 Bank 2 timing variator control
121 -
Keys
CABLE COLOURS
A light blue
B white
C orange
H grey
L blue
M brown
N black
O nut-brown
R red
S pink
V green
Z violet
ROBOTIZED GEARBOX NODE (NCR-M018)
1 Ground
2 Ground
3 Output: Gear selection solenoid valve, robotized gearbox
4 -
5 -
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
15 -
16 -
17 -
18 -
19 -
20 -
21 -
22 -
23 -
24 -
25 -
26 Gearshift control cluster on steering wheel (up)
27 +30
28 +15
29 Output: Gear selection solenoid valve, robotized gearbox
30 Output: Gear selection solenoid valve, robotized gearbox
31 Input: F1 robotized gearbox pump relay
Output: Gear engagement solenoid valve, robotized
32
gearbox
33 C CAN-L
34 Clutch sensor
35 Clutch sensor
36 -
37 -
38 +Gearbox sensor
39 Gear selection/engagement potentiometer
40 Input: Pressure transducer
41 Input: Reverse gear engagement switch
42 Starter motor activation
43 Output: Clutch solenoid valve
Output: Gear engagement solenoid valve, robotized
44
gearbox
45 C CAN-H
46 Clutch sensor
47 Clutch sensor
48 Engine control node (NCM)
49 K diagnosis line
50 +Gearbox sensor
51 Gear selection/engagement potentiometer
52 -
B
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 -
10 -
11 Cambiocorsa robotized gearbox acceleration sensor
12 Input: Pressure sensor on clutch
13 Ground
14 Ground
15 Gearshift control cluster on steering wheel (stand-by)
16 Gearshift control cluster on steering wheel (down)
17 Input: Stop indicator switch (N.A.)
18 -
19 Input: ASR
20 -
+Cambiocorsa robotized gearbox acceleration sensor;
21
+Gear selection/engagement potentiometer
22 Input: Reverse gear engagement control set
23 -
24 +50
25 Input: "Auto"
26 Input: Front door lock motor (driver's side)
+Pressure transducer;
27
+Pressure sensor on clutch
28 -
Keys
CABLE COLOURS
A light blue
B white
C orange
H grey
L blue
M brown
N black
O nut-brown
R red
S pink
V green
Z violet
LUGGAGE COMPARTMENT ECU (CVB– M019)
A
F41 30A Heated rear window
F42 7,5A External defogging units
F43 20A Fuel pumps
F52 30A Radio amplifier
R14 30A Heated rear window
R15 - Fuel pump 1 speed
R16 - Fuel pump 2 speed
R23 30A Luggage compartment lid opening alarm
B
F16 7,5A Reverse gear
F48 30A Fuel tank flap
F49 25A Luggage compartment lid
F56 15A Power socket
R19 30A Fuel tank flap
R20 30A Luggage compartment lid
R21 20 Reverse gear
Luggage compartment lid and fuel tank flap
R22 -
relay cut out