Maserati QP 2006 - 2007 Workshop Manual
Maserati QP 2006 - 2007 Workshop Manual
Maserati QP 2006 - 2007 Workshop Manual
GENERAL INFORMATION
Safety
Prevention measures and protection devices
Dangerous parts
Dangerous products and emissions
TECHNICAL DATA
Dimensions and weights
Dimensions
Weights
Engine
Engine
Transmission
Gearbox
Clutch
Differential
Brakes
Service and handbrake
Parking brake
Suspensions
Suspensions
Steering
Steering
Wheels
Wheels
Initial fluid supplies
Initial fluid supplies chart
ENGINE
Tightening torques
Tightening torques
Toolkit
Toolkit
Replacing the engine
Removing-refitting the engine
Circuit filling and level checks
Right-hand side engine mount
Elastic dowel block on the right-hand side of the engine
Left-hand side engine mount
Elastic dowel block on the left-hand side of the engine
Cooling and lubrication system
Radiators
Oil filter
Air filter
Water/engine oil pump
GENERAL INFORMATION
Exhaust system
Tailpipes
Catalytic converter
Central silencer
Exhaust extension pipe
Fuel supply and ignition system
Electro-injectors
Battery
Starter motor
Fuel tank
Motor-driven pump pan assembly
Anti-evaporation system
Replacing the accelerator pedal
Spark plugs
Ignition coils
Alternator
Engine auxiliary devices' control belt
Intake manifold
Exhaust manifold
Throttle body
Air flow meter
Cylinder compression test
Engine overhaul
Engine removing
Fitting and timing the engine
Dimensional checks
Secondary air system
Secondary air pump
Vacuum tank
Pneumatic actuator control solenoid valve
Union between pump and pipeline for air distribution to valves
Secondary air pneumatic actuator valves
GEARBOX COMPONENTS
Tightening torques
Tightening torques
Toolkit
Toolkit
Clutch
Removing-refitting the clutch
Bleeding the clutch
Clutch thrust bearing
Adjusting the clutch sensor magnet
GENERAL INFORMATION
Engine flywheel
Clutch shaft support bearing
Crankshaft oil seal on the flywheel side
Replacing the gearbox
Removing-refitting the gearbox
Electronically controlled gearbox controls
Replacing the electronically-controlled gearbox control unit (TCU)
Power unit
Establishing the electronically-controlled gearbox oil tank level
Kiss point (PIS) ajdustment procedure
Checking and topping-up the oil level in the gearbox housing
Gearbox oil cooling radiator
Clutch pressure sensor
DEIS adjustment procedure
Accelerometer self-calibration procedure
Acceleration sensor
Power unit actuator bleeding
Power unit oil pump
Power unit oil tank
Axle shafts - differential
Axle shafts
Transmission shaft
Removing-refitting the transmission shaft
BRAKES
Tightening torques
Tightening torques
Front brakes
Front brake pads
Front brake caliper
Front brake disk
Bleeding the air from the front brakes
Front A.B.S. sensors
Rear brakes
Rear brake pads
Rear brake calipers
Rear brake disc
Bleeding the air in the rear brake fluid circuit
A.B.S. sensors for rear wheels
Parking brakes
Cables and tie-rods
Brake shoes
Handbrake cable adjustment
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATION
CAPITOLO
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To release tight-fitting parts, strike them gently using an aluminium or, if the parts are made of iron, lead
hammer; Use a wooden or resin mallet for light alloy parts.
During the removal, check that the parts that must be marked for reference purposes duly show the
reference marks.
When refitting, lubricate the parts, where necessary, to prevent engagements or seizures in the initial
operation stages.
When refitting, it is fundamental that the tightening torques and adjustment data are complied with.
For each refitting operation replace the seals, oil seals, elastic washers, safety plates, self-locking nuts
and any parts found to be damaged.
During the operations, when the components are disconnected from the system, close the disconnected
unions with suitable water/air-tight stoppers to prevent dampness and impurities from entering the system.
All the system components are specifically designed for the use of R134a and are NOT
INTERCHANGEABLE with those from earlier vehicles using Freon R12.
The drainage/recovery station is specific for the R134a fluid.
The antifreeze oil is also specific for the compressor lubrication system and is not the same as the oil used
with systems running on Freon R12.
CAUTION
In the event of towing or positioning on the roller stand, remember that the vehicle is endowed
with an automatic door locking function when speeds exceed 20 km/h, which is activated/
deactivated via the IT node.
Once the doors are locked, you must operate the internal release button or the external latch with
the key to open them. There is no other way of opening them.
Therefore, in the event that a vehicle is used with no-one on board, it is necessary to check in the
vehicle settings menu that the autoclose function on exceeding 20km/h is deactivated or,
alternatively, leave a window open or keep a second key outside the vehicle.
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DANGEROUS PARTS
Exhaust system and engine
Using the car, the exhaust system components and the engine itself reach very high temperatures and
remain hot for a long time after the engine is turned off.
Always use insulated gloves to handle these components or wait as long as necessary to let them cool
down.
Battery
The battery charging procedure generates gases that can become explosive in contact with sparks or
flames.
Always charge the battery in a well-ventilated area.
Furthermore, the battery contains sulfuric acid in the form of electrolyte, which can cause irritation if it
comes in touch with the skin.
Always wear suitable protective clothing and a mask when handling the electrolyte.
Electric cooling fans
When the vehicle is stopped and the engine is still warm, the electric fans for the cooling system may start
up suddenly. Be very careful when working near these parts.
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steering systems is very dangerous if it comes into contact with eyes or skin.
In the event of contact, thoroughly rinse the body area involved with running water. To avoid all risks,
always wear goggles and protective gloves.
Keep out of reach of children!
Do not dispose of used fluid in the evironment!
Coolant
The fluid contained in the cooling system reaches high temperatures and is under pressure: any
accidental contact with it can cause severe burns.
Furthermore, the coolant can cause irritation to the skin and is poisonous swallowed.
Keep out of reach of children!
Do not dispose of coolants in the environment!
cooling system
CAUTION
The high temperature and the pressure of the mixture contained in the circuit can cause severe
burns. Always work with the engine cool and taking utmost care.
CAUTION
Do not place hands or clothing near the electric fan as the latter could start up automatically and
cause serious injury to the operator.
Filling the system
CAUTION
Perform this procedure only when the engine is cool.
If you have to work with the engine warm, take all necessary measures to prevent burns caused by
contact with overheated or pressurised fluid that may drain or leak from the system
CAUTION
The fuel contained in the tanks and in the fuel system is highly flammable. Carry out the operation
when the engine is cool and the tanks are empty, or contain little fuel, to avoid fire risks.
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Do not smoke or produce sparks or naked flames near the workplace or in the immediate vicinity.
Electro-injectors
CAUTION
If it is necessary to disconnect any of the fuel supply system's pipelines, remember that they may
be pressurised: this could cause fuel to be sprayed towards the operator. Take special care when
carrying out this operation and keep any naked flames clear of the work area.
DIFFERENTIAL-GEARBOX HYDRAULIC SYSTEM
CAUTION
In case of damage to pipes (e.g. after an accident) through which foreign matters may enter into
the circuit, the Power Unit, the actuator and the respective pipes must be replaced.
CAUTION
The hydraulic system contains high pressure oil.
steering system
Hydraulic steering pump
CAUTION
The oil contained in the system can cause injury to eyes and skin and may damage the car's
painted parts.
BRAKE SYSTEM
Component replacement
CAUTION
The fluid used in the braking and clutch system can cause injury to eyes and skin; in case of
contact, rinse the body part involved with abundant running water. In addition, the fluid may
damage the car's painted parts.
AIR BAG MODULES
CAPITOLO
CAUTION
NEVER expose the Airbag modules to temperatures over 150 C (300 F), since the high
temperature, and not the current, is the factor which triggers bursting.
CAUTION
Before carrying out any intervention or replacing a system component, check that the ignition key
is turned to the STOP position and disconnect the battery
When welding operations have to be performed on the car, the ECU must be disconnected as well.
CAUTION
The driver's and passenger's Airbag modules must be replaced every ten years after their
installation (see C/E plate), even if the car has never been involved in collisions.
No restraining systems for children can be installed on the passenger seat.
Where the legislation in force provides it, children under twelve cannot travel on the front seats.
In the event of a crash with consequent activation of Airbag modules, dispose of the exploded
modules as harmful waste, in accordance with the legislation in force in the related country.
CAUTION
After disconnecting the battery, wait at least one minute before disconnecting the pre-tensioners.
Operations on the components
CAUTION
Do not use a percussion screwer.
AIR CONDITIONING AND HEATING SYSTEM
System draining
CAUTION
Do not drain the coolant near naked flames as this could produce a toxic gas (phosgene).
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CAUTION
Do not use naked flames to locate coolant leaks as this produces a toxic gas.
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dimensions
Wheelbase
Front overhang
Rear overhang
Length
Height
Width
Front axle
Rear axle
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3064 mm
856 mm
1132 mm
5052 mm
1438 mm
1895 mm
1587 mm
1595 mm
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weights
Tank capacity
Low fuel
Kerb weight (with fuel, tools and accessories)
Full load weight (5 persons and kg in the luggage compartment)
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90 liters
18 litres
1970 kg
2345 kg
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ENGINE
General
Type code
Cycle
Cylinder number and position
Number of valves per cylinder
Piston bore and stroke
Total displacement
Compression ratio
Maximum output (EEC)
Corresponding rpm
Maximum torque (EEC)
Corresponding rpm
Injection
Type
Ignition
Static ignition
Firing sequence
Ignition coil (up to engine part number 102268)
Ignition coil (from engine part number 102269)
Spark plugs
Alternator
Battery
M139
Eight
8-90 V
4
92x79,8 mm
3
4244 cm
11,058 0,2:1
295 kw 400 CV
7250 r.p.m.
442 Nm 45 kgm
4750 r.p.m.
Bosch Motronic ME7
1-8-6-2-7-3-4-5
Bosch ZS-K-1X1E
Bosch ELDOR
NGK PMR8A
alternatively, NGK PMR8B
Denso 12V - 150 A
FIAM 12V 100Ah - 850A
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Speed, RPM
Torque, Nm
Power, kw
1009
1501
2000
2506
3003
4000
4501
5001
5501
6000
6500
7003
7513
301.8
328.5
355.2
365.7
390.6
401.1
430.7
440.2
436.4
429.7
414.4
405.8
367.6
31.5
50.9
73.4
94.7
121.2
165.8
200.3
227.5
248.0
266.4
278.3
293.6
285.3
The engine is an 8-cylinder, 90 V aspirated engine with a displacement of 4243.8 cm 3, 92 mm bore, 79.8 mm
stroke, which generates a max. power of 400 HP (294.9 kW) at 7250 RPM.
The maximum torque rate that can be obtained is 444.5 Nm (45 Kgm) at 4750 RPM.
This performance is achieved through some technical solutions such as:
variable timing system with stepless timing variator on the intake camshafts;
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gearbox
Data valid up to serial number 21586
Differential bevel gear pair ratio EUROPE 41/11 = 3,727
Differential bevel gear pair ratio USA
46/11 = 4,182
Gearbox ratios
1 st
2 nd
3 rd
4 th
5 th
6 th
R
46/14 = 3,286
41/19 = 2,158
37/23 = 1,609
33/26 = 1,269
30/29 = 1,034
28/33 = 0,848
46/14 = 3,286
Gearbox ratios
1 st
2 nd
3 rd
4 th
5 th
6 th
R
46/14 = 3,286
41/19 = 2,158
37/23 = 1,609
33/26 = 1,269
30/29 = 1,034
29/33 = 0,878
46/14 = 3,286
Gearbox ratios
1 st
2 nd
3 rd
4 th
5 th
45/14 = 3,21
41/20 = 2,05
33/23 = 1,43
34/31 = 1,10
28/31 = 0,90
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6 th
R
28/37 = 0,76
46/14 = 3,29
3,16
13,74
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clutch
Type
Gasket outside diameter
Dry double-plate clutch with flexible single ramp coupling and with
double series of tangs to retain the intermediate pressure plate and
for rising control.
215 mm
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differential
Differential type
Reduction crown wheel and pinion
Gear ratio for EUROPE and from assembly no.
21587, also valid for the USA
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Service brake
Type
The brake system is equipped with a large brake servo (8"+9") and consists of 4 self-ventilating discs
with 4-piston fixed calipers, an electronic braking distributor (E.B.D.) incorporated into the A.B.S. system
A.S.R., which also performs the anti-skid functions during traction and can be selected from the driver's
seat in the following conditions:
dry;
wet;
cut-out.
The A.B.S./A.S.R. and E.B.D. functions are integrated within the E.S.P. stability check system (M.S.P.)
which operates separately for each brake on the 4 wheels and for the engine control.
Service brakes
Front discs
Outer diameter
330 mm
Effective radius
136.7 mm
32 mm
Total thickness
Rear discs up to serial number 27859
316 mm
Outer diameter
Effective radius
158 mm
28 mm
Total thickness
Rear discs from serial number 27860
330 mm
Outer diameter
Effective radius
- mm
Total thickness
28 mm
Front Brake Calipers
40 mm
44 mm
Output
Rear brake calipers up to serial number 27859
Small piston diameter:
2 facing each other
44 mm
32/36 mm
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Integrated system Bosch VDC 5.7, with ECU joined onto the hydraulic modulator; version for crossed
brake circuit, rear traction. Braking distributor valve function obtained with specific routine software in the
control program.
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Parking brake
type
control
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Suspensions
articulated quadrilateral, with arms and hub carrier in
forged aluminium
shock absorbers
BILSTEIN type, gas operated, with aluminium body
helical
springs
articulated quadrilateral, with arms and hub carrier in
Rear suspensions
forged aluminium
shock absorbers
BILSTEIN type, gas operated, with aluminium body
springs
helical
Electronically controlled system which enables the user to
choose two different setting levels for the shock
Adjustable damping suspensions (optional)
absorbers, according to the roadbed conditions, speed
and driving comfort
Front suspensions
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Steering
TYPE
MIN. STEERING DIAMETER
STEERING COLUMN
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WHEELS
RIMS AND TIRES
Rim size
Tire size
only on SPORT GT
Front (OPT snow tyre)
Rear (OPT snow tyre)
Front (OPT)
Rear (OPT)
Spare wheel (optional)
8.5J x 18 ET52
8.5J x 19
8.5J x 20
10.5J x 18 ET50,5
10.5J x 19
10.5J x 20
8.5J x 18 Winter
10.5J x 18 Winter
8.5J x 19
10.5J x 19
6" J x 17"
245/45ZR 18
245/40ZR 19
245/35ZR 20
285/40ZR 18
285/35ZR 19
285/30ZR 20
245/45VR 18
285/40VR 18
245/40ZR 19
285/35ZR 19
185/60 R17
Rim size
Tire size
Front
8.5J x 18
8.5J x 19
10.5J x 18
10.5J x 19
245/45ZR 18
245/40ZR 19
285/40ZR 18
285/35ZR 19
Front
only on SPORT GT
Rear
Rear
Pressures
2,2 bar
2,2 bar
2,2 bar
2,2 bar
2,2 bar
2,0 bar
Pressures
2,2 bar
2,2 bar
2,2 bar
2,2 bar
CAUTION
The maximum speed that can be reached with winter tires is indicated by the tire manufacturer. In any
case, always comply with the regulations in force in the Country where the car is circulating.
Only use winter tires of the prescribed dimensions and brand.
IMPORTANT
Notwithstanding the prescribed sizes, it is essential that tires of the same brand and type are fitted to all
the wheels in order to ensure safe driving.
IMPORTANT
Do not use air chambers on Tubeless tires.
Tyre size:
SNOW CHAINS
285/40ZR 18
IMPORTANT
The maximum radial protrusion permitted beyond the tyre profile is 9 mm.
The snow chains must be fitted only on the rear tyres
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Brand/Type
Konig/Super Magic
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PRODUCT
QUANTITY
9.5 + 1 litres
Engine (foreign markets)
Gearbox and transmission oil
Tecsint SL 5W-40
Oil specifications: SAE 75W/90 above API GL4GL5C API MT1-PG2 specifications.
2.7 litres
10W.
CHF 11S
0.33 litres
Compressor oil
SP10
Brakes
PLUS / ECOPERMANENT.
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1100 cc
125 cc
13 litres
TIGHTENING TORQUES
Part
Nominal torque
450 Nm
91 Nm
10 Nm
23 Nm
30 Nm
3 Nm
49 Nm
40 Nm
49 Nm
10 Nm
25 Nm
25 Nm
10 Nm
3 Nm
Part
LOCTITE 242
engine oil on
gasket
LOCTITE 242
49 Nm
Nominal torque
25 Nm
10 Nm
60 Nm
45 Nm
Products
30 Nm
Products
10 Nm
50 Nm
120 Nm
14 Nm
30 Nm
22 Nm
27 Nm
32 Nm
10 Nm
Lambda sensors
50 Nm
16 Nm
15 Nm
20 Nm
Spark plug
10 Nm
54 Nm
8 Nm
15 Nm
Timing variators
200 Nm
15 Nm
25 Nm
25 Nm
25 Nm
6 Nm
10 Nm
60 Nm
Spark plug
lubricant
with spinner max
400 rpm
LOCTITE 242
Part
15 Nm
Nominal torque
50 Nm
12 Nm
10 Nm
25 Nm
10 Nm
10 Nm
25 Nm
10 Nm
10 Nm
10 Nm
75 Nm
78 Nm
18 Nm
50 Nm
7 Nm
10 Nm
10 Nm
25 Nm
22 Nm
LOCTITE 242
Products
8 Nm
75 Nm
LOCTITE 242
60 Nm
16 Nm
25 Nm
10 Nm
10 Nm
LOCTITE 242
6 Nm
LOCTITE 242
25 Nm
17 Nm
LOCTITE 242
5 Nm
LOCTITE 242
7 Nm
LOCTITE 242
10 Nm
LOCTITE 242
32 Nm
40 Nm
ATTREZZATURA MOTORE
Toolkit
Specific tooling
Description
Code
900026390
900026520
900026970
900026980
900026990
900027000
900027010
900027260
900027270
900027020
900027030
900027040
900027050
900026590
900027150
900026610
900026560
900027060
900026550
Description
Code
ATTREZZATURA MOTORE
900026310
Punch grip
900026300
Extracting tool
95972714
900026400
CAPITOLO
Rotate the plastic fastening screws on the engine compartment fuse box cover by 90, then remove
the cover.
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Undo the two fastening screws on the engine compartment fuse box.
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Undo the three fastening screws and remove the engine compartment fuse box mount.
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Disconnect the two pipes for draining the water from the service pan.
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For vehicles that have the AQS sensor fitted on the shield, proceed as follows.
Detach the electrical connection.
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Undo the screws fastening the connected devices' pan underneath the windscreen.
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Undo the screws fastening the left-hand pan for the connected devices underneath the windscreen
and remove the pan.
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Drain the air conditioning system using the specific tool connected to the system's valves.
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Undo the four fastening screws on the metal guard, then remove it.
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Undo the three fastening screws, detach the electric connection, then remove the bass box.
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Move the floor panel as far back as possible and undo the two screws and the two nuts on bracket
for the engine control node compartment .
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Loosen the fastening screw and rotate the fastening clamp on the engine control node.
CAPITOLO
Disconnect the two electric connections and remove the engine control node.
CAPITOLO
Unscrew the nut and disconnect the earth cable from the bodywork, then detach the two electric
connections.
CAPITOLO
Cut the plastic clamps and separate the engine wiring from the passenger compartment wiring.
Detach the electric connection.
CAPITOLO
Detach the two electric connections secured to the mudguard and the electric connection on the
fuel vapour solenoid valve.
CAPITOLO
Undo the fastening screws on the clamps fastening the engine wiring.
CAPITOLO
Working from inside the engine compartment and from the passenger compartment, pass the
engine wiring out through the hole on the passenger compartment/engine compartment partition panel,
arranging it so it does not hinder subsequent operations.
N.B.
Slide the wiring out carefully so that it does not damage the electric connections and to prevent
the wiring itself being cut by the sharp parts of the sheet.
CAPITOLO
Undo the fastening screws on the reinforcement bracket and remove it (both sides).
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Undo the screws fastening the shock absorbers to the bodywork and detach the electric
connections on the ABS sensors and on the acceleration sensors.
CAPITOLO
Detach the electric connection on the brake pad wear sensor (this sensor is only found on the lefthand side of the vehicle)
CAPITOLO
Remove the lower screw fastening the shock absorbers on both sides.
CAPITOLO
Detach the electric connection on the headlight adjustment potentiometer, on both sides of the
vehicle.
CAPITOLO
Unscrew the nut fastening the cable for the headlights adjustment potentiometer, working on both
sides of the vehicle.
CAPITOLO
Undo the screw fastening the earth cable on the front right- and left-hand brake calipers
CAPITOLO
Undo the two screws fastening the brake caliper to the pillar, then move it sideways, securing it
with suitable means to ensure the weight of the caliper does not weigh down the oil line.
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Unscrew the upper fastening screw and loosen the lower fastening screw on the windscreen
washer fluid tank.
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Detach the electric connection on the air flow meter and release the two clips from the air filter
housing.
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Release the clips fastening the cover to the air filter housing.
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Undo the screw fastening the air filter housing to the domes' bar.
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Open the clamp and remove the union joining the intake manifold and air flow meter.
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Disconnect the three oil vapour lines to the engine oil tank.
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Disconnect the ignition coil connections and undo the fastening screws on the connector fastening
brackets.
Operation to be carried out for vehicles up to assembly no.24274, engine part number 102269.
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Detach the electric connection on the additional air pump, then undo the fastening screws on the
dome bar bracket.
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Undo the fastening screws on the dual tone horns and release the wiring from the clamps fastening
them to the bodywork.
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Detach the electric connection and remove the dual tone horns.
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Disconnect the two quick couplings on the fuel lines, then disconnect the water line from the pump.
CAPITOLO
Disconnect the anti-evaporation system line from the intake manifold and release it from the plastic
fastening clamps.
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Disconnect the water line running to the heating unit at the point shown.
CAPITOLO
Undo the fastening screw and disconnect the air conditioning system line from the dehydrator filter.
CAPITOLO
Disconnect the air conditioning system line from the expansion valve.
CAPITOLO
Undo the screw fastening the hydraulic steering oil tank to the relative mounting bracket.
Operation to be carried out for vehicles up to assembly no.24274.
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Undo the screw that secures the hydraulic steering tank to the relative support bracket and release
the bracket from the coupling.
Operation to be carried out for vehicles from assembly no. 24275.
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Detach the electric connection and undo the screw fastening the steering column and the steering
box.
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Unscrew and remove the complete union, unscrewing it from the rigid line.
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Disconnect the two connectors for the suspension sensors, taking care to lift the safety tang.
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Unscrew the nut fastening the starter motor cable retaining clamp to the right-hand cylinder head
cover.
CAPITOLO
Lift the hoist and detach the electric connections on the electric fans.
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Unscrew the two unions and disconnect the two engine oil lines from the tank.
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Detach the electric connection for the solenoid valve controlling the secondary air system
pneumatic actuator.
CAPITOLO
Undo the screws fastening the engine oil tank to the chassis.
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Undo the rear screws fastening the engine frame to the bodywork.
CAPITOLO
Position a suitable supporting tool beneath the engine frame, to allow the engine to be removed.
CAPITOLO
CAPITOLO
Using the tool, lower the engine-frame assembly taking care not to damage the wiring, the electric
connections, the steering column and any interfering parts fitted in the vehicle.
CAPITOLO
Lift the vehicle and remove the engine, complete with frame.
CAPITOLO
Unscrew the retaining clamp, disconnect the hydraulic steering oil inlet pipe on the pump, then
drain the hydraulic steering oil system.
CAPITOLO
Release the hydraulic steering oil delivery pipe from the clamp.
CAPITOLO
Unscrew the hydraulic steering oil delivery pipe to detach it from the pump.
CAPITOLO
Unscrew the clamp, then disconnect the engine coolant delivery pipe from the pump.
CAPITOLO
Unscrew the fastening clamp, then disconnect the engine coolant pipe.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Unscrew the two nuts fastening the engine to the mount (one per side).
CAPITOLO
CAPITOLO
CAPITOLO
Connect the air conditioning system pipe and tighten the fastening nut.
N.B.
Replace the rubber gaskets on the two lines.
Connect the rubber unions to the secondary air system rigid lines.
Connect the engine coolant recirculation line.
Connect the two engine coolant lines to the pump.
Tighten the union joining the power steering box delivery line to the pump to a torque of 35 Nm.
CAPITOLO
CAPITOLO
Position the engine - frame assembly beneath the vehicle, lower the hoist, check the frame is
aligned with the respective holes, then lift the tool and move the frame so that it is touching the
bodywork.
CAPITOLO
Tighten the screws fastening the frame to the bodywork to a torque of 123 Nm.
N.B.
Replace the screws fastening the frame to the bodywork with new screws.
CAPITOLO
Remove the engine supporting tool and tighten the rear screws fastening the frame to the vehicle
bodywork to a torque of 123 Nm
N.B.
Replace the screws fastening the frame to the bodywork with new screws.
CAPITOLO
CAPITOLO
Tighten the screws fastening the engine oil tank to the frame to a torque of 25 Nm.
CAPITOLO
Attach the electric connection on the secondary air system pneumatic actuator control solenoid and
fasten the relative electric wiring to the frame.
Tighten the unions on the two oil lines on the engine oil tank.
Attach the two electric engine fans electric connectors.
Tighten the nut fastening the starter motor cable retaining clamp to the right-hand cylinder head
cover.
Tighten the upper fastening nuts on the engine radiator to a torque of 24 Nm.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Connect the air conditioning system line from the dehydrator filter.
Connect the water line to the heater unit.
CAPITOLO
Connect the anti-evaporation system line to the intake manifold and fasten it with plastic clamps.
Connect the two quick couplings on the fuel lines, then connect the water line to the pump.
Fit the dual tone horns and attach the electric connection.
Tighten the fastening screws on the dual tone horns.
Fit the radiator air duct and tighten all the fastening screws.
Fit the front grille.
Fit the dome bar in its seat inside the engine compartment and tighten the fastening screws to a
torque of 49 Nm.
CAPITOLO
Attach the electric connection on the additional air pump, and fasten it to the dome bar with the
fastening screws on the bracket.
Attach the connections on the ignition coils and tighten the fastening screws on the brackets
fastening the connectors.
Connect the three oil vapour lines to the engine oil tank.
Screw up the fastening screw on the engine coolant tank.
Fit the intake manifold and air flow meter joining sleeve.
CAPITOLO
Fit the air filter housing and tighten the fastening screw to the dome bar.
CAPITOLO
Fit the new air filter and the relative cover on the filter housing and fasten it with the relative clips.
CAPITOLO
CAPITOLO
Fit the air flow meter and fasten it using a new clamp.
CAPITOLO
Detach the electric connection on the air flow meter and release the two clips from the air filter
housing.
CAPITOLO
CAPITOLO
Position the brake calipers on the disk and tighten the screws fastening the front brake calipers to
the front pillar to a torque of 145Nm.
CAPITOLO
Connect the earth cable from the front right- and left-hand brake calipers.
Attach the electric connection on the headlight adjustment potentiometer, on both sides of the
vehicle.
Tighten the bolt fastening the shock absorber to the lower wishbone (lever) to a torque of 78 Nm.
CAPITOLO
Attach the electric connection on the brake pad wear sensor (this sensor is only found on the lefthand side of the vehicle)
Tighten the screws that fasten the shock absorber to the dome and attach the ABS and
acceleration sensors electric connectors.
- 33.6 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and
17235 in the right-hand drive versions
- 25 Nm for EUROPE vehicles from assembly no.18535 in the left-hand drive version and 17236 in
the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
Working from the engine compartment towards the passenger compartment, bring the engine
wiring through to the passenger compartment.
N.B.
Fit the wiring carefully, taking care not to damage the electric connections or cut the wiring on the
sharp parts of the sheet.
CAPITOLO
CAPITOLO
Pull the wiring so it is laid out correctly and connect the earth cable, then attach the two electric
connections.
CAPITOLO
Attach the electric connection located in the engine control node area and fasten the cable with the
relative clamps.
CAPITOLO
CAPITOLO
Fit the engine node protective bracket and tighten the two screws and the two fastening nuts.
CAPITOLO
Attach the two electric connections fastened to the mudguard and the electric connection on the
fuel vapour solenoid valve.
CAPITOLO
Fit the Bass Box proceeding as outlined for its removal but in reverse order.
Fit the service pan and the windscreen wiper motor assembly, proceeding as outlined for their
removal but in reverse order.
Connect the equipment used to fill the R134a fluid and run a vacuum cycle to remove all R134a
residues or air that has entered. Upon completion of the vacuum cycle, proceed by filling the air
conditioning system.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
Front wheels
Rear wheels
CAPITOLO
The level check must be performed with the vehicle on a flat surface and the engine warm and
CAPITOLO
idling. The oil level must be between the MIN and MAX notches on the dipstick . The gap between
MIN and MAX corresponds to about 1 litre of oil.
important
Do not top up with oil whose specifications differ from 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. You are advised to contact the Maserati Service Network for oil and filter changes
since they have the right facilities for disposing of the used oils and filters, ensuring respect for
the environment and observance of the regulations in force.
If the engine oil level is close to or actually below the MIN reference mark, add oil through the filler
cap until the MAX reference mark is reached. The oil level should never exceed the MAX reference
point.
The fluid level must be checked when the engine is cold, and it must fall between the MIN and MAX
references marked on the pan. If the level is low, slowly pour the prescribed fluid through the filler neck
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CAPITOLO
on the pan until the level is close to the MAX reference point.
The operation for filling the engine's water circuit must be carried out by partially unscrewing the
two water outlet caps on the heads. These caps are located in the front section of the engine to permit
breathing of any air contained in the top part of the engine during the filling stage.
CAPITOLO
CAPITOLO
CAPITOLO
The system is self-draining. 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 lines which run to the steering box are disconnected
CAPITOLO
IMPORTANT
The brake fluid is hygroscopic (i.e. it absorbs humidity). For this reason, if the car is used mainly
in areas with a high rate of atmospheric humidity, the fluid should be changed more frequently
than indicated in the Service Time Schedule.
IMPORTANT
Do not let the brake fluid, which is highly corrosive, come into contact with the paintwork. If this
does occur, wash the paintwork immediately with water.
The symbol on the container identifies the synthetic type of brake fluid, distinguishing it from the
mineral type. Using mineral fluids damages the special rubber linings of the brake system beyond
repair.
CAPITOLO
Connecting the equipment used to carry out procedures on the air-conditioning system coolant.
The system lines have two unions, one for the high and one for the low pressure, which are used for
coolant-related operations such as:
coolant absorption;
system drainage and dehydration;
finding leakages in the circuit;
filling the oil for the vacuum pump;
filling the system with coolant (R134a);
Version
Quantity
USA
EUROPE
1100 g +/- 25
1100 g +/- 25
The operations outlined above can be carried out with different types of equipment, which can have
different operating procedures; because of this, you should refer to the Owners Manual for the machinery
CAPITOLO
CAPITOLO
Rotate the plastic fastening screws on the engine compartment fuse box cover by 90, then remove
the cover.
CAPITOLO
Undo the two fastening screws on the engine compartment fuse box.
CAPITOLO
Undo the three fastening screws and remove the engine compartment fuse box mount.
CAPITOLO
Undo the bracket screw (1) and the rigid line screws (2).
CAPITOLO
Undo the remaining retaining screw for the pneumatic valve bracket.
CAPITOLO
CAPITOLO
Undo the retaining screws of the engine oil filter heat shield.
CAPITOLO
Undo the screws that secure the rigid engine oil line from the pump.
CAPITOLO
CAPITOLO
Undo the remaining two upper screws and remove the heat shield of the engine oil filter.
CAPITOLO
- The operation described below is applicable to all the EUROPE vehicles manufactured up to
serial number 24274.
Undo the screws securing the catalytic converter to the exhaust manifold.
CAPITOLO
- The operation described below is applicable to all the EUROPE vehicles manufactured up to
serial number 24274.
Unscrew the nuts fastening the exhaust manifold to the cylinder head.
Remove the RH exhaust manifold by slipping it off the stud bolts.
CAPITOLO
- The operation described below is applicable to all the EUROPE vehicles manufactured up to
serial number 24274.
View of the flange which attaches the exhaust manifold to the cylinder head.
CAPITOLO
- The operation described below is applicable to all the USA - CND vehicles and all the EUROPE
vehicles manufactured starting from serial number 24275.
Remove the right-hand side exhaust manifold.
Exhaust manifold
- The subsequent operations are applicable to all vehicles.
Unscrew the nut that secures the RH engine mount to the relevant dowel block.
CAPITOLO
Place a hydraulic supporting and lifting device (1) under the engine so as to work in safety.
CAPITOLO
Undo the screws that secure the RH engine mount to the crankcase.
CAPITOLO
The retaining screws (1) are easily accessible, while the retaining screw (2) needs to be accessed
with a special wrench.
CAPITOLO
CAPITOLO
Refitting
CAPITOLO
Remove the hydraulic supporting and lifting device (1) positioned previously from under the engine.
CAPITOLO
Fit the new gasket, fit the exhaust manifold complete and tighten the fastening nuts to a torque of
25 Nm.
CAPITOLO
- The operation described below is applicable to all the EUROPE vehicles manufactured up to
serial number 24274.
Tighten the screws fastening the exhaust manifold to the catalytic converter to a torque of 25 Nm.
CAPITOLO
- The operation described below is applicable to all the USA - CND vehicles and all the EUROPE
vehicles manufactured starting from serial number 24275.
Remove the right-hand side exhaust manifold.
Exhaust manifold
- The subsequent operations are applicable to all vehicles.
Fit the engine oil filter heat shield and tighten the upper retaining screws.
CAPITOLO
CAPITOLO
Tighten the screws that secure the rigid engine oil line from the pump.
CAPITOLO
Tighten the retaining screws of the engine oil filter heat shield.
CAPITOLO
CAPITOLO
After connecting the batterys negative terminal, the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
Fit the engine floor guard.
Engine floor guard
CAPITOLO
Rotate the plastic fastening screws on the engine compartment fuse box cover by 90, then remove
the cover.
CAPITOLO
Undo the two fastening screws on the engine compartment fuse box.
CAPITOLO
Undo the three fastening screws and remove the engine compartment fuse box mount.
CAPITOLO
Undo the screw that fastens the steering column to the steering box.
CAPITOLO
Remove the eight retaining screws for the wheelhouse and then remove it (both sides of the
vehicle).
CAPITOLO
Undo the fastening screws on the reinforcement bracket and remove it (both sides).
CAPITOLO
Undo the three screws that secure the oil tank to the vehicle frame.
CAPITOLO
Undo the lower screw that secures the windscreen washer-headlight washer fluid tank to the front
frame.
CAPITOLO
Undo the two screws that secure the radiator to the front frame (Figs.1 and 2).
CAPITOLO
CAPITOLO
CAPITOLO
Detach the electric connection on the air flow meter and release the two clips from the air filter
housing.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Disconnect the electrical connector, undo the screws on the clamps fastening the Oxygen sensor
wiring (1), then remove the upper RH Oxygen sensor (2).
CAPITOLO
For versions equipped with a heat guard, undo the screw (1) and the nut (2) and remove rubber
bushing heat guard (3) .
CAPITOLO
Unscrew the two nuts that fasten the right-hand and left-hand rubber bushings to the frame.
CAPITOLO
Position two hydraulic support devices, the first (1) underneath the frame and the second (2)
underneath the engine. The first one will be used to slowly lower the frame in order to access the
rubber bushings. The second one will be used to slowly lift the engine/gearbox assembly so that the
rubber bushing stud bolt can be slipped off the relative rigid mounts.
CAPITOLO
Undo the rear screws that fasten the engine frame to the bodywork.
CAPITOLO
Undo the screws that fasten the tank wiring to the bodywork.
CAPITOLO
Undo the screws that fasten the tank wiring to the bodywork.
CAPITOLO
Loosen the front screw that secures the engine frame to the bodywork.
CAPITOLO
Working on the two hydraulic support devices previously positioned, slowly lower the engine frame
and lift the engine until the threaded pin (1) of the rubber bushing is released from the rigid mount (2).
CAPITOLO
CAPITOLO
CAPITOLO
Refitting
Check that the component is in perfect working order and replace it if necessary.
Fit the rubber bushing and tighten the two nuts that secure the rubber bushing to the engine frame
to a torque of 50 Nm.
CAPITOLO
When refitting the rubber bushing, be careful with its orientation on the frame.
Fit the rubber bushing in such a way that the pin (1) can be coupled to the hole (2) on the engine
mount.
CAPITOLO
After fitting the new rubber bushings, it is recommended to clean the contact surface between the
engine frame and the bodywork, in order to prevent infiltration of foreign bodies which may affect
proper positioning.
Working on the hydraulic support devices, lift the engine frame and screw in the screws that secure
the frame to the bodywork without tightening them.
Remove the hydraulic support device of the engine/gearbox assembly.
Tighten all the screws that secure the frame to the bodywork to a torque of 123 Nm .
N.B.
Replace the screws that fasten the frame to the bodywork with new screws.
CAPITOLO
CAPITOLO
Connect the electrical connector, screw in the screws for clamps that fasten the oxygen sensor
wiring (1), then tighten the upper right-hand oxygen sensor (2) to a torque of 50 Nm.
CAPITOLO
Connect the electrical connector (1),, screw in the screws for the oxygen sensor, then tighten the
upper left-hand oxygen sensor (2) to a torque of 50 Nm.
CAPITOLO
CAPITOLO
CAPITOLO
Fit the two metal protection shields of the oil radiator and the windscreen washer tank on both sides.
Fit the wheelhouse guards (both sides of the vehicle).
Tighten the screw that fastens the steering column and steering box to a torque of 25 Nm.
CAPITOLO
Fully tighten the three fastening screws on the engine compartment fuse box.
CAPITOLO
Fully tighten the two fastening screws on the engine compartment fuse box.
CAPITOLO
Fit the fuse box cover and rotate the plastic screws by 90.
CAPITOLO
CAPITOLO
CAPITOLO
Open the clamp and free the hydraulic steering system line.
CAPITOLO
CAPITOLO
Place a hydraulic supporting and lifting device (1) under the engine so as to work in safety.
CAPITOLO
Undo the screws that secure the RH engine mount to the crankcase.
CAPITOLO
All the retaining screws are easily accessible and a there is no need to use any special wrench.
CAPITOLO
CAPITOLO
Refitting
Check that the component is intact.
Fit the engine mount in its seat and tighten the retaining screws on the crankcase to a torque of 45
Nm.
Tighten the nut fastening the mount to the dowel block to a torque of 120 Nm.
CAPITOLO
Remove the hydraulic supporting and lifting device (1) positioned previously from under the engine.
CAPITOLO
CAPITOLO
Tighten the screws fastening the exhaust manifold to the catalytic converter to a torque of 25 Nm.
CAPITOLO
CAPITOLO
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CAPITOLO
RADIATORS
Removing the radiators
Unscrew the fastening on the buzzers, detach the electrical connections and then remove the
buzzers.
CAPITOLO
Bleed the air conditioning system using the specific tool connected to the system's valves.
CAPITOLO
Undo the screw fastening the air conditioning system pipe to the dehydrator filter.
CAPITOLO
CAPITOLO
Undo the screw fastening the air conditioning system pipe to the cooling coil.
CAPITOLO
Detach the two cooling system fan connectors and the fan speed adjustment sensor.
CAPITOLO
Disengage the pipe connecting the expansion tank and the radiator.
CAPITOLO
CAPITOLO
CAPITOLO
Loosen the clamp fastening the upper sleeve then disengage it.
CAPITOLO
Loosen the clamp fastening the lower sleeve, then disengage it.
CAPITOLO
Loosen the clamp fastening the hydraulic steering pipes, then disengage them, making sure you
recover the liquid.
CAPITOLO
Undo the two lower radiator fastening screws then remove them by sliding them out from the
bottom.
CAPITOLO
Fit the radiator- electric fan-condenser assembly and tighten the lower fastening screws.
Connect the two hydraulic steering oil connection lines with the cooling system coil.
Connect the lower and upper unions to the radiator.
Tighten the upper fastening nuts on the radiator to a torque of 24 Nm.
CAPITOLO
Fit the engine coolant tank and tighten the fastening screw, then connect the pipe between the
tank and the radiator
Connect the two cooling system fan connectors and the fan speed adjustment sensor.
Screw up the screw fastening the air conditioning system line to the cooling coil.
Screw up the screw fastening the air conditioning system line to the dehydrator filter.
Connect the equipment used to fill the R134a fluid and run a vacuum cycle to remove all R134a
residues or air that has entered. Upon completion of the vacuum cycle, proceed by filling the air
conditioning system.
CAPITOLO
Open the engine coolant tank cap and pour in the fluid until it reaches the MAX notch marked on
the tank.
Working from inside the vehicle, set the maximum temperature (+32C) for the air conditioning/
heating system manually, from both the driver's and passenger control panels.
N.B.
This operation allows the engine coolant to flow in and out the heating/air conditioning system.
CAPITOLO
Wait until the electric fans start up at least once (engine temperature approximately 90C) and the
air that comes out the vents in the passenger compartment is warm.
During this stage, the level of the coolant contained in the tank could drop below the MIN notch,
so top it up and keep it level with the MAX notch.
If you are unable to release all the air in the system, open the two breather caps positioned on the
two cylinder heads (figure below).
CAPITOLO
CAPITOLO
Check that the engine coolant is level with the MAX notch.
Pour a suitable amount of oil into the hydraulic steering oil tank, until it reaches the MAX notch
marked on the tank cap dipstick.
The system is self-draining. Draining is carried out by turning the steering wheel as far as
possible to the left, then to the right, doing this several times with the engine running and the vehicle
stationary.
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
OIL FILTER
Detaching the oil filter
Remove the cap and drain out the engine lubrication system oil.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
AIR FILTER
Removing-refitting the air filter
CAPITOLO
Undo the screw fastening the air filter housing to the domes' bar.
CAPITOLO
Remove the retaining clamp and release the two clips, then remove the air flow meter.
CAPITOLO
After releasing the five locking clips, detach the cover from the housing.
CAPITOLO
CAPITOLO
N.B.
Before refitting the new air filter, clean the relative housing carefully.
When refitting, follow the above procedures in reverse order
CAPITOLO
Undo the three retaining screws and detach the rigid union of the water pump line.
CAPITOLO
Undo the screws that secure the water/oil pump to the engine crankcase and remove it.
CAPITOLO
Use the specific tool 900027150 to undo the upper retaining screws.
CAPITOLO
Refitting
Check the oil-water pump to verify that there are no leakages from the draining holes.
Check the groove on the oil/water pump shaft for wear.
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 M8x25 small headed screws to secure the unit to the crankcase, the two M8x65
screws to secure the pumps to the lower part of the crankcase and the three M8x25 screws to secure
the pump to the crankcase, and at the same time remove the three plates AV3602.
CAPITOLO
Tighten the pump retaining screws to a torque of 25 Nm, using tool 900027150 for the upper
retaining screws.
CAPITOLO
Connect the rigid union of the water pump line tightening the three retaining screws.
N.B.
Always replace the gasket
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
TAILPIPE
Removing the tailpipe
Undo the two screws on the crossmember fastening the tailpipes and remove it. Then unscrew
the clamp connecting the exhaust extension and the tailpipe.
CAPITOLO
Unscrew the two fastening screws on the rear tailpipe support then remove it, taking care not to
damage the rear bumper.
CAPITOLO
Fit the exhaust tailpipes onto the exhaust extension pipes and screw on, without tightening them,
all the screws and nuts fastening the mounts to the bodywork.
Tighten the screws and the nuts fastening the mounts to the bodywork to a torque of 24 Nm.
CAPITOLO
Tighten the fastening nut on the clamp securing the tailpipe to the exhaust extension pipes to a
torque of 54 Nm.
CAPITOLO
CAPITOLO
Catalytic converter
Removing the catalytic converter for the EUROPE version up to serial number 24274
IMPORTANT
After the procedure described below, we will describe the procedure for removing the catalytic
converters of the USA - CANADA version and the EUROPE version from serial number 24275.
Release the front Lambda sensor wiring from the five clamps, then remove the front Lambda
sensor.
CAPITOLO
N.B.
When unscrewing the Lambda sensors, make sure the cables do not get damaged by twisting.
CAPITOLO
Unscrew the two screws fastening the pipe to the central bracket
CAPITOLO
Undo the three screws linking the exhaust manifold to the catalytic converter.
Retrieve the gasket below.
CAPITOLO
Unscrew the clamp connecting the catalytic converters and the central silencer.
CAPITOLO
N.B.
Follow the same procedure for the remaining catalytic converter.
CAPITOLO
Refitting the catalytic converter for the EUROPE version up to serial number 24274
Fit the catalytic converter removed into its seat on the central silencer and screw it in without
tightening the fastening screws on the exhaust manifold flange.
N.B.
Visually inspect that the gasket located underneath the flange joining the catalytic converter and
the exhaust manifold is intact and if signs of wear are found, replace it.
N.B.
The conductive gaskets must never be fitted more than once. The second time the component is
fitted, they must be replaced
Tighten the fastening nuts on the clamps securing the catalytic converter to the central silencers
to a torque of 54 Nm.
CAPITOLO
Tighten the screws fastening the exhaust manifold to the catalytic converter to a torque of 25 Nm.
CAPITOLO
Tighten the fastening screws on the central catalytic converter holder bracket to a torque of 25
Nm.
CAPITOLO
Fit the front and rear Lambda sensors, then tighten them to a torque of 50 Nm.
Fasten the front Lambda sensor wiring to the engine mounting frame correctly.
CAPITOLO
Fit the bodywork reinforcement bracket and tighten the fastening screws to torque.
CAPITOLO
Removing the catalytic converter for all the USA CANADA versions and the EUROPE version
from serial number 24275
IMPORTANT
The exhaust pipe of the USA CANADA vehicles has remained unchanged, while the EUROPE
vehicles from serial number 24275 are equipped with the same exhaust pipe as the versions for the
American/Canadian markets.
USA - CANADA VERSION
CAPITOLO
Rotate the plastic fastening screws on the engine compartment fuse box cover by 90, then
remove the cover.
CAPITOLO
Undo the two fastening screws on the engine compartment fuse box.
CAPITOLO
Undo the three fastening screws and remove the engine compartment fuse box mount.
CAPITOLO
CAPITOLO
Disconnect the electrical connector (1), undo the screws on the clamps (2) fastening the Lambda
sensor wiring, then remove the lower LH Lambda sensor (3).
CAPITOLO
Disconnect the electrical connector (1), undo the screws on the clamps (2) fastening the Lambda
sensor wiring, then remove the lower RH Lambda sensor (3).
CAPITOLO
Disconnect the electrical connector (1), undo the screws on the clamps fastening the Lambda
sensor wiring, then remove the upper LH Lambda sensor (2).
CAPITOLO
Disconnect the electrical connector, undo the screws on the clamps fastening the Lambda sensor
wiring (1), then remove the upper RH Lambda sensor (2).
CAPITOLO
Unscrew and remove the oil filter (1), then unscrew the fastening screws and remove the engine
oil filter heat shield (2).
N.B
Place a container under the oil filter to collect the engine oil that is discharged. Carefully clean any
surrounding components hit by the discharged engine oil.
CAPITOLO
Working on the RH catalytic converter, prepare the wrench required to access the fastening.
View of the fastening nuts on the RH catalytic converter.
CAPITOLO
To unscrew the nut (1 see previous figure), use a 3/8 ratchet wrench, connecting a 250 mm long
extension, a 3/8 universal joint and 3/8 bush with diam.
13 mm to it.
Working from the lower side of the vehicle, unscrew the nut (1 see previous figure) fastening the
exhaust manifold catalytic converter coupling.
CAPITOLO
To loosen the nut (2 see previous figure), use a 3/8 ratchet wrench, with a 3/8 bush.
To unscrew the nut (2 see previous figure),completely use a ratchet wrench, with bush.
Working from the lower side of the vehicle, unscrew the nut (2 see previous figure) fastening the
exhaust manifold catalytic converter coupling.
CAPITOLO
To loosen the nut (3) use a 3/8 ratchet wrench, two 250 mm long extensions, a straight 120 mm
long extension and a 120 mm long 8 jointed extension with a 3/8 bush with diam. 13 mm.
Working from the lower side of the vehicle, unscrew the nut (3 see previous figure) fastening the
exhaust manifold catalytic converter coupling.
CAPITOLO
View of the points at which the RH catalytic converter is fixed to the LH exhaust manifold.
CAPITOLO
To unscrew the nuts (4) and (5) use a 3/8 ratchet wrench, two 250 mm long extensions and a 120
mm long 8 jointed extension with a 3/8 bush with diam. 13 mm.
Working from the upper side of the vehicle, unscrew the fastening nuts (4) and (5) on the exhaust
manifold catalytic converter coupling.
CAPITOLO
Using 13 mm wrench, unscrew the nut (6) fastening the LH catalytic converter coupling to the
relative manifold.
CAPITOLO
Undo the screws fastening the catalytic converters onto the central mount.
CAPITOLO
Remove the two catalytic converters from the lower part of the vehicle.
CAPITOLO
Refitting the catalytic converter for all the USA CANADA versions and the EUROPE version from
serial number 24275
Fit the two catalytic converters into their seats on the exhaust manifolds.
Fit the screws fastening the catalytic converters onto the central mount, then tighten to a torque of
25 Nm.
CAPITOLO
Using the same wrenches as instructed for the removal, screw in the fastening nuts (1), (2), (3),
(4), (5) and (6) those fastening the catalytic converters to the relative manifolds, remembering to
tighten them to a torque of 25 Nm..
CAPITOLO
CAPITOLO
Tighten the new oil filter(1) manually, then fit the engine oil filter heat shield (2).
CAPITOLO
Fit the four Lambda sensors into their seats on the catalytic converters, tightening them to a
torque of 50 Nm, then wire up the electrical connections and fasten the wiring with the relative clamps.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Carry out the refitting procedure for the two exhaust extension pipes.
Exhaust extension pipe
Top up the oil in the engine oil tank (using the prescribed oil) to the MAX level on the dipstick.
CAPITOLO
CENTRAL silencer
Removing the central silencer for the EUROPE version up to serial number 24274
IMPORTANT
After the procedure described below, we will describe the procedure for removing the central
silencer of the USA - CANADA version and the EUROPE version from serial number 24275.
Unscrew the two clamps connecting the exhaust extension pipes and the central silencer, then
remove it.
Refitting the central silencer for the EUROPE version up to serial number 24274
Fit the central silencer on the catalytic converter and tighten the fastening nuts on the clamps securing the
silencers to the exhaust extension pipes to a torque of 54 Nm
CAPITOLO
Removing the central silencer for all the USA CANADA versions and the EUROPE version from
serial number 24275
IMPORTANT
The exhaust pipe of the USA CANADA vehicles has remained unchanged, while the EUROPE vehicles
from serial number 24275 are equipped with the same exhaust pipe as the versions for the American/
Canadian markets.
Unscrew the two linking clamps between the central silencer and the catalytic converters, then
remove the central silencer.
CAPITOLO
Refitting the central silencer for all the USA CANADA versions and the EUROPE version from
serial number 24275
Fit the central silencer on the catalytic converter and tighten the fastening nuts on the clamps to a
torque of 54 Nm.
CAPITOLO
CAPITOLO
Before removing the guard for the exhaust extension pipes, undo the fastening screws (five for
the left-hand shield, two for the right-hand shield), then unscrew the clamp connecting the exhaust
extension and the tailpipes.
Unscrew the two fastening screws on the support, then extract the line.
CAPITOLO
Refitting the exhaust extension pipe for the EUROPE version up to serial number 24274
Fit the extension for the exhaust line into the rear silencers and tighten the screws fastening the
mounts to the bodywork.
Tighten the nut securing the tailpipe fastening clamp to the exhaust extension pipes to a torque of
54 Nm.
CAPITOLO
Tighten the screws fastening the mounts to the bodywork to a torque of 24 Nm.
CAPITOLO
Removing the exhaust extension pipe for all the USA CANADA versions and the EUROPE
version from serial number 24275
IMPORTANT
The exhaust pipe of the USA CANADA vehicles has remained unchanged, while the EUROPE
vehicles from serial number 24275 are equipped with the same exhaust pipe as the versions for the
American/Canadian markets.
Undo the fastening screws and remove the heat guard on the left-hand exhaust line.
CAPITOLO
Undo the fastening screws and remove the heat guard on the right-hand exhaust line.
CAPITOLO
Unscrew the nuts fastening the mount for the right-hand exhaust extension to the bodywork.
Carry out the same operation for the left-hand exhaust extension by undoing the screws fastening
the extension pipe to the bodywork.
CAPITOLO
Unscrew the two nuts fastening the metal clamps joining the exhaust tailpipes and central
silencers.
CAPITOLO
CAPITOLO
Refitting the exhaust extension pipe for all the USA CANADA versions and the EUROPE version
from serial number 24275
Fit the exhaust tailpipes on the central silencers and tighten the fastening nuts on the fastening
clamps to a torque of 54 Nm
CAPITOLO
Tighten the screws fastening the mounts to the bodywork to a torque of 24 Nm.
CAPITOLO
CAPITOLO
ELECTRO-INJECTORS
Removing the electro-injectors
CAPITOLO
Undo the two fastening screws on the engine compartment fuse box.
CAPITOLO
Unscrew the three fastening screws, and remove the engine compartment fuse box mount.
CAPITOLO
Open the fastening clamps on the anti-evaporation / engine oil and fuel vapor recirculation system
piping.
CAPITOLO
Release the rigid fuel pipe from the two fastening clips.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Undo the screws fastening the connected devices' pan underneath the windscreen.
CAPITOLO
Undo the screws fastening the left-hand connected devices' pan underneath the windscreen and
remove the pan.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
With the fuel manifold on the bench, remove the clip and separate the electro-injector from the fuel
manifold.
CAPITOLO
CAPITOLO
Unscrew the two fastening nuts on the bracket and remove it, opening the other two clamps
fastening the brake servo vacuum line (not shown).
CAPITOLO
Unscrew the two fastening nuts on the fuel connector and detach the electro-injectors electrical
connections.
CAPITOLO
CAPITOLO
With the fuel manifold on the bench, remove the clip and separate the electro-injector from the fuel
manifold.
CAPITOLO
CAPITOLO
Fit the bracket in the seat, connect the vacuum line to the two clamps (not shown) located near the
shield, fully tighten the fastening nuts and secure the vacuum line with the last remaining clamp.
CAPITOLO
Tighten the fuel line union to a torque of 30 Nm, and restrain the fuel line with the specific clip.
CAPITOLO
CAPITOLO
CAPITOLO
Fit the connected devices' pan underneath the windscreen and tighten the left-hand fastening
screws fully.
CAPITOLO
Tighten the screws fastening the right-hand connected devices' pan underneath the windscreen
fully.
CAPITOLO
CAPITOLO
Fit the brake oil tank and fully tighten the fastening screws.
CAPITOLO
CAPITOLO
Tighten the fuel line union on the injectors manifold to a torque of 30 Nm.
CAPITOLO
Restrain the rigid fuel pipe with the two fastening clamps.
CAPITOLO
Restrain the anti-evaporation / engine oil and fuel vapour recirculation system piping using the
clamps indicated.
CAPITOLO
Fully tighten the three fastening screws on the engine compartment fuse box.
CAPITOLO
Fully tighten the two fastening screws on the engine compartment fuse box.
CAPITOLO
Fit the fuse box cover and rotate the plastic screws by 90.
CAPITOLO
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
Refer to the section:
Component self-learning in the event of battery disconnection
CAPITOLO
BATTERY
Disconnecting-reconnecting the battery
Remove the five fastening screws on the rear covering panel, then remove it.
CAPITOLO
After removing the spare wheel housing cover, unscrew the covering panel's six fastening screws
and remove it.
CAPITOLO
Remove the right-hand cover, releasing the upper fastening button first.
CAPITOLO
CAPITOLO
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
CAPITOLO
STARTER MOTOR
Removing the starter motor
Lift the rubber guard and unscrew the nut fastening the starter motor power supply cable, then
detach the electrical connection.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Fit the starter motor and tighten the three fastening screws to a torque of 24 Nm.
CAPITOLO
Tighten the two screws fastening the reinforcing bracket to the gearbox to a torque of 7.4 Nm.
CAPITOLO
CAPITOLO
FUEL TANK
Removing the fuel tank
Undo the screws and the fastening nuts and remove the protective guard for the fuel tank.
Detach the quick coupling for the recirculation system from the fuel tank.
CAPITOLO
CAPITOLO
CAPITOLO
Open the flap, undo and remove the fuel filler neck cap from its seat.
CAPITOLO
CAPITOLO
CAPITOLO
Undo the screw, disconnect the earth cable, then remove the fuel filler pipe.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Connect the flexible section of the fuel filler pipe to the fuel tank.
Tighten the four fastening screws on the filler neck to a torque of no more than 1.3 Nm.
CAPITOLO
Fit the fuel filler neck cap and close the flap..
Tighten the screw fastening the tank wiring to the bodywork.
Attach the fuel tank wirings electrical connection.
Connect the quick coupling for the recirculation system to the fuel tank.
Fit the fuel tanks protective guard and tighten the nuts and the fastening screws to a torque of 7.4
Nm.
CAPITOLO
Carry out all the refitting operations for all the luggage compartment trim panels.
Luggage compartment trim panels
Disconnect the battery's negative terminal.
After connecting the negative battery terminal, the following self-learning operations must be
carried out to ensure certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
Using the specific tool 900026390, undo the locknut and remove the motor-driven pump pan.
N.B.
Carry out the same procedure for the remaining motor-driven pump.
CAPITOLO
CAPITOLO
CAPITOLO
ANTI-EVAPORATION SYSTEM
Component removal
Below is an explanation of the removal and refitting operations for the anti-evaporation
system components which require the removal of the fuel tank; The following procedure
outlines the component removal and refitting operations (specific for the USA-CANADA
MARKET) which do not require the removal of the fuel tank.
N.B.
The operations described below apply to tanks equipped with a double fuel pump as well as tanks
equipped with a single fuel pump.
Fuel tank
To remove the ventilation valves, proceed as follows.
Disconnect the quick coupling on the ventilation valve line.
Rotate the ventilation valve anticlockwise by 90 degrees and remove it from the tank.
CAPITOLO
To remove the multi-function valve found on the tank, disconnect the pipe (1) and rotate in the
direction shown on the valve (Ref. 3, Fig.2) then remove the valve (2) from the tank.
CAPITOLO
CAPITOLO
Disconnect the quick coupling on the line connecting the tank with the decanter and unscrew the
two nuts fastening the active carbon filter brackets.
Release the fastening brackets from the stops on the upper section of the fuel tank.
CAPITOLO
CAPITOLO
CAPITOLO
Component fitting
To fit the fluid decanter, proceed as follows.
Fit the decanter, placing the earth cable on the fastening shown, and tighten the three fastening
screws.
Connect the three anti-evaporation system pipes.
CAPITOLO
CAPITOLO
Tighten the brackets fastening nuts to a torque of 8.5 Nm and connect the quick coupling on the
line leading to the decanter.
CAPITOLO
CAPITOLO
Rotate clockwise by 90 degrees and secure the ventilation valve to the tank.
CAPITOLO
Connect the quick coupling for the ventilation valve line to the decanter.
CAPITOLO
To fit the multi-function valve (1) on the tank, rotate in the direction shown on the valve (Ref.3-Fig.
2) and connect the pipe (2).
CAPITOLO
CAPITOLO
Undo the screws and the fastening nuts and remove the protective guard for the fuel tank.
CAPITOLO
Detach the connection (1), disconnect the piping from the quick coupling (2), disconnect the piping
(3), undo the fastening screws (4) and remove the diagnosis pump.
CAPITOLO
Undo the screws and the fastening nuts and remove the protective guard for the fuel tank.
CAPITOLO
Lift the anti-evaporation system filter, disengaging the lower rubber couplings (1) from the
bodywork, then remove the pump-filter assembly (2).
CAPITOLO
With the assembly on the bench, disconnect the piping (1)from the filter, open the clamp (2) and
remove the diagnosis pump filter (3).
CAPITOLO
To ensure the best possible system operation, the diagnosis pump filter must be replaced every
50,000 km.
CAPITOLO
CAPITOLO
Detach the electrical connection on the accelerator pedal potentiometer, then remove the
accelerator pedal.
CAPITOLO
CAPITOLO
SPARK PLUGS
Removing the spark plugs
Disconnect the battery's negative terminal.
Remove the trim panels.
CAPITOLO
Undo the two fastening screws on the engine compartment fuse box.
CAPITOLO
Unscrew the three fastening screws, and remove the engine compartment fuse box mount.
CAPITOLO
CAPITOLO
CAPITOLO
Undo the screws fastening the connected devices' pan underneath the windscreen.
CAPITOLO
Undo the screws fastening the left-hand connected devices' pan underneath the windscreen and
remove the pan.
CAPITOLO
Undo the fastening screws and remove the electric wiring cover (operation to be carried out on both
cylinder heads)
CAPITOLO
- The operation described below applies to vehicles equipped with engine part number 102268.
Undo the fastening screws on all the ignition coils for the left-hand and right-hand cylinder heads
CAPITOLO
- The operation described below applies to vehicles equipped with engine part number 102268.
Remove the ignition coils.
CAPITOLO
- The operation described below applies to vehicles equipped with engine part number 102269.
Using a small screwdriver, push the yellow catch (1) in the direction of the arrow, then push on the
black tab (2) and detach the connector from the coil (3).
CAPITOLO
- The operation described below applies to vehicles equipped with engine part number 102269.
Remove all the ignition coils from the right-hand and left-hand bank.
CAPITOLO
CAPITOLO
CAPITOLO
Using a specific wrench and a torque wrench, tighten all the spark plugs to a torque of 10 Nm.
CAPITOLO
- The operation described below applies to vehicles equipped with engine part number 102268.
Fit all the ignition coils and tighten the fastening screws to a torque of 10 Nm.
CAPITOLO
- The operation described below applies to vehicles equipped with engine part number 102269.
Fit all the ignition coils of the right-hand and left-hand bank and connect the electrical connectors.
CAPITOLO
CAPITOLO
Fit the connected devices' pan underneath the windscreen and tighten the left-hand fastening
screws fully.
CAPITOLO
Tighten the screws fastening the right-hand connected devices' pan underneath the windscreen
fully.
CAPITOLO
CAPITOLO
Tighten the two fastening screws on the brake fluid tank fully
CAPITOLO
Fit the engine compartment fuse box mount and tighten the three fastening screws fully.
CAPITOLO
Fit the engine compartment fuse box mount and tighten the three fastening screws fully.
CAPITOLO
Fit the fuse box cover and rotate the plastic screws by 90.
CAPITOLO
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
IGNITION COILS
Removing the ignition coils for engine part number up to 102268.
- The operation described below applies to all vehicles manufactured up to engine part number 102268;
the coil removal/refitting procedure for engines with a later part number will be described subsequently.
Disconnect the battery's negative terminal.
Remove the trim panels.
CAPITOLO
Undo the two fastening screws on the engine compartment fuse box.
CAPITOLO
Unscrew the three fastening screws, and remove the engine compartment fuse box mount.
CAPITOLO
Loosen the clamp screw and remove the water drainage pipe from the trim panel underneath the
windscreen.
CAPITOLO
Undo the fastening screws on all the right-hand cylinder heads ignition coils, remove them from the
spark plugs seats, and undo the fastening screws on the electrical wiring cover and remove it.
CAPITOLO
Undo the two screws and the fastening nut on the wiring brackets.
CAPITOLO
Detach the four electrical connectors and remove the ignition coils located on the right-hand
cylinder head.
CAPITOLO
CAPITOLO
Undo the fastening screws and remove the electrical wiring cover.
CAPITOLO
Undo the fastening screws on all the left-hand cylinder heads ignition coils, and remove them from
the spark plugs seats.
CAPITOLO
CAPITOLO
Undo the fastening screw on the wiring bracket, disconnect the four electrical connectors and
remove the ignition coils located on the left-hand cylinder head.
CAPITOLO
CAPITOLO
Attach the four electrical connectors and tighten the fastening screw on the wiring bracket fully.
CAPITOLO
CAPITOLO
Fit the electrical wiring cover, apply Loctite 242 to the screws and tighten them to a torque of 7 Nm.
CAPITOLO
Tighten the two fastening screws on the brake fluid tank fully.
CAPITOLO
CAPITOLO
Fit the coils, tighten the fastening screws to a torque of 10 Nm; fit the electric wiring cover, apply
Loctite 242 to the screws and tighten them to a torque of 7 Nm.
CAPITOLO
Tighten the two fastening screws and the fastening nut on the wiring bracket fully.
CAPITOLO
Fit the water drainage pipe from the trim panel underneath the windscreen and secure it by
tightening the relative clamp.
CAPITOLO
Fit the engine compartment fuse box mount and tighten the three fastening screws fully.
CAPITOLO
Fit the engine compartment fuse box mount and tighten the fastening screws fully.
CAPITOLO
Fit the fuse box cover and rotate the plastic fastening screws by 90.
CAPITOLO
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
Using a small screwdriver, push the yellow catch (1) in the direction of the arrow, then push on the
black tab (2) and detach the connector from the coil (3) .
CAPITOLO
CAPITOLO
IMPORTANT
For the illustration, the 4th cylinder coil was chosen as it is the most complicated. This is due to
the little space available and to the pipes that interfere with the operation. Because of these
difficulties, the trim panel must be removed. To remove the other ignition coils no additional
components have to be removed.
CAPITOLO
CAPITOLO
ALTERNATOR
Removing the alternator
Place the vehicle on the hoist.
Remove the electro-injectors from the engine.
Removing-refitting the electro-injectors
Remove the belt controlling the engine auxiliary devices.
Removing-refitting the engine auxiliary devices control belt
Disconnect the blow-by system line from the right and left-hand cylinder heads.
Disconnect the anti-evaporation system line from the intake manifold and the coolant recirculation
line.
CAPITOLO
By means of the tear-clamp, separate the throttle body from the intake manifold.
CAPITOLO
Undo the screws fastening the intake manifold to the right-hand cylinder head.
CAPITOLO
Undo the screws fastening the intake manifold to the left-hand cylinder head.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Unscrew the fastening nut and disconnect the power supply cable, then disconnect the electrical
connection.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Loosen the fastening nuts on the bracket, and then loosen the left-hand threaded adjusting pin on
the alternator.
CAPITOLO
Rotate the alternator until it is released from its seat, taking care not to damage the engine
coolant's recirculation pipeline and the blow-by pipe, then remove the alternator.
CAPITOLO
CAPITOLO
Check the hole on the alternator and the relative centring pin are aligned, then apply Loctite 242 to
the nut threads and tighten them to a torque of 10 Nm.
Apply Loctite 242 to the thread on the centring pin and tighten it so that it is flush with the bracket.
CAPITOLO
CAPITOLO
CAPITOLO
Connect the power supply cable and secure it with the fastening nut, then attach the electrical
connection.
Position the power supply cable protection guard.
CAPITOLO
Check the gaskets on the intake manifold lines are intact. As a rule, they should be replaced every
time the manifold is removed.
CAPITOLO
Fit the intake manifold and connect the vacuum and recirculation pipes.
Tighten all the fastening screws on the intake manifold to a torque of 10 Nm.
CAPITOLO
When refitting, follow the remaining procedures in reverse order to those outlined for the removal.
Fit the belt controlling the engine auxiliary devices.
Removing-refitting the engine auxiliary devices control belt
Carry out the refitting operation for the electro-injectors.
Removing-refitting the electro-injectors
Remove the car from the hoist.
CAPITOLO
Detach the electrical connection on the air flow meter and release the two clips from the air filter
housing.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Release the clips fastening the cover to the air filter housing.
CAPITOLO
CAPITOLO
Undo the screw fastening the air filter housing to the dome bar.
CAPITOLO
CAPITOLO
Unscrew the two upper nuts on the guard for the engine auxiliary devices control belt.
CAPITOLO
Lift the hoist and unscrew the two lower nuts on the guard for the engine auxiliary devices control
belt .
CAPITOLO
Lower the hoist and remove the guard for the engine auxiliary devices control belt.
CAPITOLO
Using a wrench, rotate the automatic tensioning device clockwise and remove the engine auxiliary
devices control belt.
CAPITOLO
CAPITOLO
N.B.
The tensioning device is automatic and, by means of a preloaded spring, it is capable of
tensioning the belt correctly during its fitting and of automatically recovering the slack created
during standard operation. No tension check is therefore necessary.
CAUTION
Do not let the belt come into contact with oil or solvents that could alter the elasticity of its rubber
material, with a consequent reduction in grip potential. Also check that there are no cracks or cuts
on the belt and, if any are found, replace the belt.
When refitting, follow the remaining procedures in reverse order and, in addition, clean the air
flow meter and the filter housing thoroughly to prevent the infiltration of impurities which could
impair the operation of the air flow meter's sensor.
CAPITOLO
INTAKE MANIFOLD
Removing the intake manifold
Place the vehicle on the hoist.
Remove the electro-injectors from the engine.
Removing-refitting the electro-injectors
Disconnect the blow-by system line from the right and left-hand cylinder heads.
Disconnect the anti-evaporation system line from the intake manifold and the coolant recirculation
line.
CAPITOLO
By means of the tear-clamp, separate the throttle body from the intake manifold.
CAPITOLO
Undo the screws fastening the intake manifold to the right-hand cylinder head.
CAPITOLO
Undo the screws fastening the intake manifold to the left-hand cylinder head.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Fit the intake manifold and connect the vacuum and recirculation pipes.
Tighten all the fastening screws on the intake manifold to a torque of 10 Nm.
CAPITOLO
When refitting, follow the remaining procedures in reverse order to those outlined for the removal.
Refit the electro-injectors.
Removing-refitting the electro-injectors
Remove the vehicle from the hoist.
CAPITOLO
EXHAUST MANIFOLDS
Removing the exhaust manifolds for the EUROPE version up to serial number 24274
IMPORTANT
After the procedure described below, we will describe the procedure for removing the exhaust
manifolds of the USA - CANADA version and the EUROPE version from serial number 24275.
Remove the floor guard beneath the engine.
Engine floor guard
Remove the exhaust tailpipes.
Removing-refitting the tailpipe
Unscrew the two rear Lambda sensors on the catalytic converters and release the cables from the
central fastening bracket.
Undo the wiring fastening screws, then unscrew the Lambda sensor from the left-hand catalytic
converter.
CAPITOLO
Undo the wiring fastening screws, then unscrew the Lambda sensor from the right-hand catalytic
converter.
CAPITOLO
CAPITOLO
Unscrew the six screws fastening the catalytic converter to the relative manifolds.
CAPITOLO
Position a hydraulic support beneath the catalytic converter/ central exhaust silencer assembly,
lower it slowly, then remove the catalytic converters together with the central exhaust silencers.
Retrieve the catalytic converter conductive gaskets.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Unscrew and remove the complete union, unscrewing it from the rigid line.
CAPITOLO
Lift the hoist and undo the fastening screws, then remove the starter motor's metal guard.
CAPITOLO
Undo the screw fastening the steering column to the box, then separate them.
CAPITOLO
Unscrew the nuts fastening the exhaust manifold to the cylinder head.
CAPITOLO
View of the points at which the exhaust manifold is fastened to the cylinder head.
CAPITOLO
Release the manifold from the stud bolts and remove it, taking care not to damage the secondary
air systems pneumatic valve.
Retrieve the exhaust manifold gasket.
CAPITOLO
N.B.
This procedure also applies to the other exhaust manifold, provided that you remember to remove
the engine compartment fuse box and relative mount before working on the manifold.
Refitting the exhaust manifolds for the EUROPE version up to serial number 24274
Fit the new gasket, fit the exhaust manifold complete with the pneumatic valve and tighten the
fastening nuts to a torque of 25 Nm.
CAPITOLO
Tighten the screw fastening the steering column and steering box to a torque of 25 Nm.
CAPITOLO
Fit the metal guard on the starter motor and tighten the three fastening screws.
Tighten the whole union on the rigid line.
Tighten the screws fastening the pneumatic valve mounting bracket to the cylinder head.
Connect the air vacuum pipe to the valve and to the rigid line.
Fit the trim guards.
Using a hydraulic support positioned underneath the catalytic converter/central exhaust silencer
assembly, position the catalytic converters in their seat together with the central exhaust silencers.
N.B.
Visually inspect that the gasket located underneath the flange joining the catalytic converter and
the exhaust manifold is intact and if signs of wear are found, replace it.
N.B.
The conductive gaskets must never be fitted more than once. The second time the component is
fitted, they must be replaced
CAPITOLO
Tighten the screws fastening the exhaust manifold to the catalytic converter to a torque of 25 Nm.
CAPITOLO
CAPITOLO
Fit all the Lambda sensors, then tighten them to a torque of 50 Nm.
Suitably secure the front Lambda sensor wiring to the engine frame.
CAPITOLO
CAPITOLO
Undo the screw fastening the steering column to the box, then separate them.
CAPITOLO
Working from the top, for the RH manifold, using a ratchet connected to an USAG 236 3/8 TS type
extension with a length of 75mm or a BETA 910 AN/75 extension, unscrew the two fastening nuts
indicated.
Using the same wrenches, lift the hoist and unscrew the same fastening nuts on the LH manifold.
CAPITOLO
Keeping the hoist lifted, unscrew the remaining nuts fastening the exhaust manifolds to the heads,
then remove them.
Retrieve the exhaust manifold gaskets.
CAPITOLO
Refitting the exhaust manifolds for all the USA CANADA versions and the EUROPE version from
serial number 24275
Fit the new exhaust gaskets onto the stud bolts on the cylinder heads.
Fit the two exhaust manifolds and tighten the fastening nuts accessible from lower part of the
vehicle.
CAPITOLO
Lower the hoist and tighten the two nuts accessible from the top of the RH exhaust manifold.
N.B
The fastening nuts on the exhaust manifolds must be tightened to a torque of 25 Nm.
CAPITOLO
Tighten the screw fastening the steering column and steering box to a torque of 25 Nm.
CAPITOLO
Fit the union (1), and tighten the two screws (2) on the rigid secondary air piping coupling flange.
CAPITOLO
CAPITOLO
THROTTLE BODY
The motor-driven throttle body is installed between the air flow meter and the intake manifold of the
engine.
This device incorporates a throttle valve, a DC motor and the throttle RPM sensor (potentiometer).
1 - Throttle
2 - Potentiometers
3 - Electric motor
4 - Gearing
In the event of throttle failure, the engine reverts to a recovery condition, i.e. it runds at a maximum speed
of 1500 RPM.
Removing/refitting the throttle body
Remove the air flow meter.
Air flow meter
CAPITOLO
Working on the tear-clamps that secure the throttle body to the intake manifold and to the front
sleeve,
CAPITOLO
disconnect the electrical connector from the throttle body and remove it.
CAPITOLO
IMPORTANT
Do not place the device on anything that may cause vibration.
After replacing the motor-driven throttle body, you must run a self-learning cycle.
The self-learning procedure is necessary if the throttle body is replaced, if accidentally switching off
the vehicle with the key in the ON position, and if the battery is disconnected.
If the vehicle is accidentally turned off with the key in the ON position , the next time the
engine is started, the engine ECU automatically runs the self-learning procedure, therefore, restart the
engine and let it idle for at least 15 seconds.
If the battery is disconnected , set the ignition switch to ON (KEY ON) and wait at least 15 sec.
After running the self-learning procedure for the "throttle position", run the VVT self-learning procedure;
where necessary, start the engine and let it idle for about 15 seconds.
Refit the parts removed for the procedure.
CAPITOLO
1 - Electrical connector
2 - External body hot-film sensor
3 External body
4 - Protection grille
5 - Metal mesh
If the air flow meter malfunctions and provides data that are incorrect data or recognised as not plausible
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CAPITOLO
by the ECU, the recovery procedure is activated. This analyses the signal coming from the potentiometer
on the throttle body in order to determine opening of the throttle valve and, as a result, the amount of air
aspirated by the engine. In this case, the adjustment is not as fine as obtained with the air flow meter, but
it is in any case sufficient to keep the vehicle in proper working order, preventing it from stopping.
Removing/refitting the air flow meter
Detach the electric connector on the air flow meter and release the two clips from the air filter
housing.
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Open the luggage compartment lid, remove the battery protection cover and remove the two relays
(1) of the fuel pump.
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Position the instrument (1) in the seat of the spark plug of cylinder 1. Choose a plunger of suitable
length.
CAPITOLO
CAPITOLO
Connect the plunger (1) to the instrument (2) for measuring and reading the cylinder compression
data.
CAPITOLO
With the help of a second operator, start the vehicle. Read the compression data of cylinder 1 read
on the instrument. Turn the ignition key to OFF and stop the engine.
The x-axis shows the compression in bar and the y-axis the number of cylinders involved in the test.
Check that the value measured falls within the specified values; if the values are incorrect, repeat
the test and then identify the failure.
CAPITOLO
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ENGINE REMOVING
Position the engine, without the clutch, onto the support stand AV2023 , fixing it with the support
tool 900026310.
Open the two fastening clamps (1) of the vapour recirculation line.
Remove the clamp (1) and disconnect the vapour recirculation line from the tappet cover of the
right-hand cylinder bank.
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Remove the clamp (1) and disconnect the vapour recirculation line from the tappet cover of the lefthand cylinder bank.
Remove the complete line from the engine.
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Unscrew the nut (1) and remove the flexible hose (2) complete with fastening clamp. Unscrew the
nut (3) and remove the line support bracket (4).
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Unscrew the nuts (1), detach the electrical connectors of the electro-injectors (2) and remove the
fuel manifold complete with electro-injectors (3).
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Fit the tools AV3332, securing them with two nuts to avoid allowing foreign bodies to enter the
cylinders.
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Detach the ignition coil connectors, check that all wires are identified in order to position them
correctly during the reassembly stage.
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After having detached the solenoid valve connection in the timing variator, move the coil wiring and
the injector wiring.
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Remove the retaining clamps, detach the connection on the water temperature sensors and move
the wiring on the clutch side.
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Detach the connections on the detonation sensors, the timing sensors and the revolution sensor on
the supporting bracket.
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CAUTION
Check that the sensors on each wire correspond, consulting the electric system manual if
necessary.
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Undo the retaining screws and remove the engine mounting brackets.
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Loosen the poliV belt by turning the tensioner and, holding the tensioner back, slide the belt off the
pulleys and remove it.
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Undo the screws fastening the air conditioning system compressor and then remove it.
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Remove the 6 mm screw from the hydraulic steering pump using the holes on the pulley.
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Open the clamps on the heads' water outputs and remove the entire connecting pipe.
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Take the bearing out of the clutch shaft support using the extracting tool 95972714.
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Remove the torsion damper Once the fastening screw has been removed, the damper can be
taken out by hand.
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Remove the fixing bracket for the pipe which runs from the exchanger to the oil tank.
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Remove the pipe running from the exchanger to the oil tank, unscrewing the 36 mm nut.
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Undo the two screws fastening the alternator and remove it by moving it upwards.
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Extract the retaining seeger ring from the timing variator's wire guide.
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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).
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To remove the tappet covers, the stud bolt supporting the wiring and the fourteen perimetral socket
head screws must be unfastened.
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Lift the cover, taking care to slide out the solenoid valve wire on the timing variator.
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Remove the two fastening screws from the left-hand bank belt tensioner.
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N.B.
Keep the gasket located between the upper edge of the housing and the left-hand belt tensioner.
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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).
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Undo the screws on the pump's toothed control wheel and remove it along with the chain.
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Undo the screws which fix the oil-water pump to the crankcase.
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Move the oil-water pump backwards by hitting it lightly with a rubber hammer, and then remove it.
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After removing the pump, check through the three inspection holes that there are no leakages or
spills.
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Remove the tensioners from the timing chains (Figure 1 and 2).
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Remove the exhaust camshaft screw, countering the rotation with a wrench inserted into the
special hexagon machined on the shaft.
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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.
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Proceed with removing the chains, sliding the toothed wheels off the exhaust camshafts (Figure 1).
N.B.
Keep the centring dowel (Figure 2).
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Remove the tranmission axle's mechanical tensioner and the fixed shoe.
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Take the seeger ring and the relative shim off the transmission axle.
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Slide out the toothed wheels, paying attention to the roller cages on the transmission axle.
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Remove the union pipes leading from the oil accumulator to the heads.
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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.
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N.B.
In this last stage, be sure to recover the timing variator tabs.
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If necessary, remove the continuous timing variator using tool 900027020, provided for this
purpose.
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Using a magnet, take the valve buckets out of their seats, checking their reference numbers.
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Proceed with the removal of the sub-crankcase by unfastening the perimetral screws.
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Move the sub-crankcase away by hitting it lightly with a hammer and then remove it completely.
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Fit the tool AM105786 onto the crankshaft and rotate the shaft in order to gain access the
connecting rod bolts easily.
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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.
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Remove the crankshaft and the bearings (Figure 1) taking care not to drop the crankshaft's central
support shimmings (Figure 2).
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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 0.0010.05 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.
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Heat the bare crankcase in an oven for about 60 minutes to a temperature of 40-50C, and cool
down the cylinder liners to a temperature of -15 to -20C 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.
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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.
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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.
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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.
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If the centring dowels (1) for the 6 heat exchanger on the crankcase are damaged or have been
removed, you must use tool 900026300 together with tool 900027010.
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Install the sealing gasket (1) between the heat exchanger and the crankcase and position the heat
exchanger.
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Fit the air bleeding union for the water cooling circuit and tighten it to a torque of 15Nm.
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Fit the accumulator mount and tighten it with the exchanger to a torque of 10 Nm.
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Fit the four anti-detonation sensors and tighten them to a torque of 20 Nm.
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Fit the oil pressure sensor taking care not to damage the rpm sensor cable and tighten it to a
torque of 40 Nm.
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After having applied a thin layer of Loctite 242 on the oil nozzles, install and tighten them to a
torque of 3 Nm.
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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).
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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.
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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.
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Lubricate the piston skirt and the cylinder liner with engine oil.
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Fit the half-bearings into their seats on the connecting rod and the cap.
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UNIT OF MEASURE mm
SEAT YIELD= 0.008
CRANKPIN
CRANKPIN
47.129 47.135
CLASS X
47.136 47.142
CLASS Y
CRANKSHAFT
CRANKPIN
43.630 43.637
CLASS X
CRANKSHAFT
CRANKPIN
43.621 43.629
CLASS X
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
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firmly in.
IMPORTANT
When fitting the piston, take care that the piston offset is set as in Figures 2, 3 and 4.
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Position all the pistons at the top dead centre before proceeding with the installation of the
crankshaft, so as to avoid interference.
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CRANKCASE SEAT
66.675 66.681
CLASS A
66.682 66.688
CLASS B
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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.
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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 5510 Nm.
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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.
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Insert the upper central mounting shims, following the correct installation direction by turning the
rounded part facing outwards.
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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.
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Put the silicon sealing compound Loctite 518 along the perimeter of the engine crankcase.
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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.
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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.
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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.
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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.
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Insert the oil seal for the crankshaft into its seat on the clutch side, using the specific tool.
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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.
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If the head centring bushings have been damaged or removed, you must refit them using punch
900026300 equipped with tool 900027000.
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Position the head gaskets, making sure that they are intact.
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It is advisable to apply a small amount of silicone CAF4 on the ends of the head gaskets, on the
timing side.
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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.
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Grease the threading of the crankcase stud bolts and the resting surfaces of the head fastening
nuts.
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Loosely fit the nuts with the relative washers, suitably greased with MOLYCOTE 1000.
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Turn a further 90 so as to obtain a torque of 8010 Nm; if the desired torque is not obtained, the
operation must be repeated.
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Position the intake camshaft on the head, fitting the timing variator tab and positioning the oil pump
timing variators in their seats.
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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).
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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.
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Position the two 7x1.78 O-rings for the timing variator bushing. Perform this operation on both
engine heads
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Fasten the oil pump timing variators tightening the four Allen screws on the left-hand head and on
the relative cap.
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Fit the timing variator solenoid valve, lubricate the mount and tighten the retaining screw to a torque
of 10 Nm.
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Fit the grommet for the timing control transmission mount into its seat.
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Fit the timing control transmission mount, tightening the fastening screws with Loctite 242 to a
torque of 6 Nm.
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If the pump assembly shaft bearing has been removed, refit it following the procedure described.
Position the bearing centring template 900027040.
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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.
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Using tool 900027030, fit the pump drive shaft into place.
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Check the condition of the oil-water pump verifying that there is no leakage from the draining holes.
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Check the wear condition of the groove on the oil/water pump shaft.
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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.
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Arrange tool 900027050 on the pump drive shaft to fit the oil seal.
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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.
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Subsequently fit the balancing ring and the see ger ring which retains the bearing on the timing side.
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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 M8X25 small headed screws to secure the assembly to the crankcase, the two
M8X65 screws to secure the pumps to the lower part of the crankcase, and the three M8X25 screws to
secure the pump to the crankcase, and at the same time remove the three plates AV3602.
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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.
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IMPORTANT:
The tightening torques for the chain runners are 10 Nm for the 6mm screws and 25 Nm for the
8mm screws.
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Fit the transmission chain - toothed wheel unit onto the shaft using tool AV3311.
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Install the fixed runner and fit the shoulder, the balancing ring, the elastic pin and the Seeger ring.
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Position the auxiliary pump chain on the toothed wheel for oil-water pump control and engage it
with the crankshaft toothed wheel.
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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.
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Install the pump axle mechanical tensioner, tightening the fastening screws to the prescribed
torque.
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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.
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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.
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Position the crankshaft so that the small wrench is at 45, in order to prevent damaging the valves.
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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).
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Fit the centesimal dial gauge with its holder CS104488, screwing it into the spark plug hole of the
first cylinder.
Position the goniometer and turn the crankshaft until reaching the TDC
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Position the camshaft drive chain on the right-hand cylinder bank. Position the chain on the
innermost gear of the crankshaft.
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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.
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Fit the gearwheel for the exhaust camshaft. Position the centring dowel into the first free hole
available, after coupling the gearwheel onto the camshaft.
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Check that the pointer of the dial gauge fitted on the holder CS104488 always indicates the TDC
position.
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Fit the hydraulic chain tensioner and use a torque wrench to tighten to a torque of 70 Nm.
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Screw down by hand, without tightening, the two retaining screws for the exhaust camshaft
gearwheels.
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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
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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
0.590.08 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.
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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.
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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.
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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.
Exhaust data summary.
Beginning before BDC 15 1
End
0 1
Fit the upper runner and tighten the retaining screws to a torque of 10 Nm
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With the aid of short stud bolts, position the gaskets on the crankcase.
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Fit tool 900026590 onto the crankshaft, in such a way that the oil seal will not be damaged when
the cover is installed.
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Fit the belt tensioner paying particular attention to the position of the reference pin, and tighten to a
torque of 25Nm.
Smontaggio motore
Smontaggio motore
Position the torsion damper on the shaft and tighten the fastening screw with Loctite 242 to a
torque of 450 Nm.
Smontaggio motore
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).
Smontaggio motore
Smontaggio motore
Secure the air-conditioning system compressor by tightening the screws to a torque of 25 Nm.
Smontaggio motore
Smontaggio motore
Fit the alternator by tightening screw A to a torque of 49Nm and screw B to a torque of 59 Nm.
Smontaggio motore
Smontaggio motore
Fit the engine mounting brackets and tighten the retaining screws to a torque of 53 Nm.
Smontaggio motore
Install the starter motor, tightening the fastening screws to a torque of 14 Nm.
Smontaggio motore
Fit the spark plugs after having lubricated the threading with Champion 2612 grease.
Smontaggio motore
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.
Smontaggio motore
Working from the middle outwards, tighten the closing screws to a torque of 10 Nm.
Smontaggio motore
Fit the Seeger ring for the cable guide of the timing variator valve using tool AV3333.
Smontaggio motore
Fit the ignition coils (Figure 1) and tighten the retaining screws to a torque of 10 Nm (Figure 2 ).
Smontaggio motore
Smontaggio motore
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.
Smontaggio motore
Install the tubes which run from the accumulators to the timing variator solenoid valves.
Smontaggio motore
Fit the tube which runs from the exchanger to the tank. Fit the fastening nut onto the exchanger
and secure the retaining bracket.
Smontaggio motore
Complete the procedure by tightening the nut on the exchanger to a torque of 75 Nm.
Smontaggio motore
Secure the service wire onto the alternator and tighten it to a torque of 10 Nm.
Smontaggio motore
Using a clamp, secure the injection cable onto the right-hand head.
Smontaggio motore
Using a clamp, secure the wiring leading to the head coils and the wiring leading to the injectors
and the fuse box.
Smontaggio motore
Smontaggio motore
Secure the earth terminal onto the crankcase, tightening the fastening screw to a torque of 25 Nm.
Smontaggio motore
Smontaggio motore
Smontaggio motore
Secure the wire which leads to the A/C compressor and to the starter motor.
Smontaggio motore
Remove the tools AV3332 protecting the intake ducts and position the gasket on the manifolds.
Smontaggio motore
Position some pins (1) in the holes on the ends of the intake ducts for reference and centring of the
intake manifold.
Smontaggio motore
Smontaggio motore
Smontaggio motore
Smontaggio motore
Smontaggio motore
Smontaggio motore
Smontaggio motore
Fit the line support bracket (1) and connect the flexible hose (2) complete with fastening clamp;
screw on the nut (3).
Tighten the nut (4) of the line support bracket.
Smontaggio motore
Connect the vapour recirculation line (1) to the tappet cover of the left-hand cylinder bank.
Smontaggio motore
Connect the vapour recirculation line (1) to the tappet cover of the right-hand cylinder bank.
Smontaggio motore
Lock the two fastening clamps (1) of the vapour recirculation line.
Smontaggio motore
Smontaggio motore
Important
Once the engine assembly procedure is complete, check that the wiring is correctly positioned,
consulting the electric system manual if necessary.
DIMENSIONAL CHECKS
Checking the camshaft dimensions
Check that the main bearing journals and the cams do not show scoring or excessive wear.
The dimensions measured must fall within the indicated values (Figure 1 e 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.
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.
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.
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.
To measure the diameter of the connecting rod small end, reset the bore meter on the indicated tool
(diameter 20 mm).
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
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.
Measure the diameter of the cylinder liner taking three measurements at the reference heights, then rotate
the liber by 90 and repeat the procedure.
Check that the main bearing journals do not show scoring or excessive wear.
Using a tube-brush, check that the oil passages are not clogged.
n.b.
To check the coaxial factor of the main bearing journals a checking plane is required.
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).
The coaxial factor error detected must be lower than the indicated value.
0.032 0.068 mm
Interference between the valve seat and the housing on the head
Intake.
Draining
0,080 0,140 mm
0,080 0,140 mm
0,030 0,060 mm
0,035 0,065 mm
0.100 mm T.B.D.
Max. shift between valve stem and contact surface with bucket
Intake and draining
0.025 mm
0,025 0,057 mm
0,100 mm
To ensure the best working conditions, position the cylinder heads on the tool 900026520
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.
If the head surface needs to be corrected, always comply with the value given in the figure.
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.
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
Using a 10 mm miller, with a 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.
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.
After this procedure, dry bore the guides using a reamer (3) diameter 6 H7 mm, fitted in the speacial handoperated 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.
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 190C 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.
Lock the centering stem in the guide (4), by means of the tightening screw (5).
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
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..
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.
There are two methods for checking the seat machining:
- application of a "Prussian Blue" layer;
- check of the hydraulic seal with "Vacutest".
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.).
Fit the rectangular punch (D), supplied with the equipment, to plug the intake duct. Fit a round-shaped punch
to plug the exhaust duct
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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.
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.
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.
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.
CAPITOLO
Detach the electrical connection on the air flow meter and release the two clips from the air filter
housing.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Release the clips fastening the cover to the air filter housing.
CAPITOLO
CAPITOLO
Undo the screw fastening the air filter housing to the domes' bar.
CAPITOLO
CAPITOLO
CAPITOLO
Lift the hoist and undo the lower fastening screw on the air pump support bracket.
CAPITOLO
View of the part removed, showing the correct position of the lower fastening screw, accessible
with the vehicle lifted and working from underneath the vehicle itself.
CAPITOLO
Lower the hoist and undo the upper fastening screw on the air pump support bracket.
CAPITOLO
Detach the electrical power supply connection and remove the supplementary air pump.
CAPITOLO
With the component on the bench, undo the screws fastening the pump to the bracket and detach
them.
CAPITOLO
When refitting, follow the above procedures in reverse order and, in addition, clean the air flow
meter and the filter housing thoroughly to prevent the infiltration of impurities which could impair
the operation of the air flow meter sensor.
CAPITOLO
VACUUM TANK
Removing-refitting the vacuum tank
Place the vehicle on the hoist.
Remove the floor guard beneath the engine
Removing-refitting the engine floor guard
Remove the trim guards.
Detach the electrical connection on the air flow meter and release the two clips from the air filter
housing.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Release the clips fastening the cover to the air filter housing.
CAPITOLO
CAPITOLO
Undo the screw fastening the air filter housing to the domes' bar.
CAPITOLO
CAPITOLO
Lift the hoist and unscrew the nut fastening the two oil pipes bracket.
CAPITOLO
CAPITOLO
Lower the hoist and loosen the upper fastening nut on the vacuum tank.
CAPITOLO
Disconnect the two vacuum lines and remove the vacuum tank.
CAPITOLO
When refitting, follow the above procedures in reverse order and, in addition, clean the air flow
meter and the filter housing thoroughly to prevent the infiltration of impurities which could impair
the operation of the air flow meter sensor.
CAPITOLO
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CAPITOLO
Detach the electrical connection on the air flow meter and release the two clips from the air filter
housing.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Release the clips fastening the cover to the air filter housing.
CAPITOLO
CAPITOLO
Undo the screw fastening the air filter housing to the domes' bar.
CAPITOLO
CAPITOLO
CAPITOLO
Disconnect the sleeve from the pipeline, open the clamps and remove it.
CAPITOLO
When refitting, follow the above procedures in reverse order and, in addition, clean the air flow
meter and the filter housing thoroughly to prevent the infiltration of impurities which could impair
the operation of the air flow meter sensor.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Lift the hoist and, working from beneath the vehicle, undo the two screws fastening the valve to the
air pipeline.
CAPITOLO
Remove the secondary air pneumatic actuator valve complete with the gasket and support bracket.
CAPITOLO
N.B.
This procedure can also be applied to the other pneumatic actuator valve, provided that you
remove the fuse box in the engine compartment and the relative support before working on the
valve.
When refitting, follow the above procedures in reverse order
DESCRIZIONE
Tightening torques
DESCRIPTION
TORQUE
130 Nm
50 Nm
24 Nm
7,4 Nm
34 Nm
34 Nm
70 Nm
24 Nm
32 Nm
24 Nm
24 Nm
24 Nm
7.4 Nm
7.4 Nm
70 Nm
24 Nm
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PRODUCT
CHAPTER
TOOLKIT
Specific Equipment
Description
Code
900026250
900027300
900027330
900027370
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CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Undo the front fastening screw on the transmission shaft heat guard.
CAPITOLO
Undo the rear fastening screws on the transmission shaft heat guard.
CAPITOLO
Unscrew the nuts fastening the clutch oil line to the transmission shaft.
CAPITOLO
Undo the two screws fastening the clutch oil line to the relative housing.
N.B
This operation must only be carried out on vehicles fitted with a lateral bleeding clutch housing.
CAPITOLO
N.B
These operations must only be carried out on versions fitted with a SOFAST 3 gearbox
Detach the clutch pressure sensors electrical connection.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Position tool 900027300, in order to support the transmission shaft during the removal of the
transmission shaft - clutch housing assembly, and remove the rear mount placed there previously
during the gearbox removal operation.
CAPITOLO
CAPITOLO
CAPITOLO
Rotate the engine flywheel manually, bringing the mark on the flywheel (1) (maximum flywheel
unbalance position) level with the mark on the clutch on the opposite side (2) (maximum clutch
unbalance position).
CAPITOLO
CAPITOLO
CAPITOLO
Fit the clutch assembly in its seat on the flywheel using the clutch centring tool 900026250.
IMPORTANT
If refitting a clutch unit which has been previously removed from the car, follow the markings
made during its 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.
CAPITOLO
Tighten the nine screws securing the clutch to a torque of 18Nm, in a crosswise sequence.
CAPITOLO
Apply a layer of water-repellent grease to the grooved profile of the thrust bearing and to the
centring two dowels on the clutch housing.
CAPITOLO
Using tool 900027300, fit the transmission shaft - clutch housing assembly in its seat on the engine.
CAPITOLO
CAPITOLO
Remove the lifting device placed under the engine earlier and position it beneath the rear end of
the rear transmission.
Remove tool 900027300 from beneath the transmission shaft.
Tighten the nuts fastening the clutch oil line to the transmission shaft, then tighten the fastening
screws on the heat guard.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
This operation must only be carried out on versions fitted with the SOFAST 3 gearbox
If the clutch unit is replaced, the self-calibration procedure for the DEIS parameters must be
performed
DEIS parameter self-calibration
CAPITOLO
This operation requires the use of the special SD3 tester 95970312.
N.B.
This operation must only be carried out on vehicles fitted with a lateral bleeding clutch housing.
Slacken off the bleed union (1) on the LH side of the clutch housing and connect a small pipe to
drain and collect any excess oil which leaks during bleeding into a suitable pan.
N.B.
This operation must only be carried out on vehicles fitted with lower or central bleeding clutch
housings.
The bleeding cap (1) located in the central and lower section of the clutch housing must be
loosened and a small pipe fitted thereto, in order to allow the excess oil drained out to be collected in a
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CAPITOLO
suitable pan
N.B.
These operations are valid for all clutch housing versions
The system has a second bleeder (2) located in proximity of the quick-coupling block for the clutch
pipe.
CAPITOLO
CAPITOLO
N.B
This operation must only be carried out on vehicles fitted with lower or central bleeding clutch
housings with a new thrust bearing.
CAPITOLO
4
3
2
1
N.B
The procedure below illustrates how to remove one of the two thrust bearings, however the same
procedure applies to both types.
CAPITOLO
With the thrust bearing unit on bench, unscrew the four fastening screws.
CAPITOLO
CAPITOLO
Detach the steering column from the thrust bearing; keep the two springs and pins.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Refit the lower element and tighten the two fastening screws to torque.
CAPITOLO
N.B
This operation must only be carried out on vehicles fitted with a lateral bleeding clutch housing.
Insert the thrust bearing unit (1) into the clutch housing
Tighten the five fastening screws (2) on the thrust bearing unit to torque.
Tighten the upper union (3) on the thrust bearing block to torque.
Tighten the lower union (4) on the thrust bearing block to torque.
CAPITOLO
N.B
This operation must only be carried out on vehicles fitted with lower or central bleeding clutch
housings with a new thrust bearing.
Insert the thrust bearing unit (1) into the clutch housing
Tighten the five fastening screws on the thrust bearing unit to torque.
Position the electrical cables correctly and fasten them with a new clamp (2).
Tighten the upper union (3) on the thrust bearing block to torque.
Tighten the lower union (4) on the thrust bearing block to torque.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
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).
CAPITOLO
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.
CAPITOLO
N.B.
For all the fastenings use Loctite medium thread brake.
CAPITOLO
CAPITOLO
Engine flywheel
Removing the engine flywheel
Remove the clutch assembly.
Removing/refitting the clutch
Using a suitable tool to lock the crankshaft rotation, undo the retaining screws (1) of the engine
flywheel.
Remove the engine flywheel from its seat
CAPITOLO
The flywheel can only be fitted in one position, since one of the 8 holes is not on the same axis as
the others. It is positioned slightly backward with respect to the other holes. Mark the different hole on
the flywheel and on the spacer.
CAPITOLO
Using a suitable tool to lock the crankshaft rotation, first loosely fit and then tighten the retaining
screws (1) of the engine flywheel to a torque of 91 Nm.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
As a spare part, you must use an oil seal of the same dimensions and characteristics.
Clean off any impurities in the oil seal seat.
Using the introducer 900027060, fit the new oil seal in its seat on the cover.
CAPITOLO
CAMBIO ELETTROATTUATO
Undo the fastening screws and remove the heat guard on the left-hand exhaust line.
Undo the fastening screws and remove the heat guard on the right-hand exhaust line.
CAMBIO ELETTROATTUATO
Unscrew the nuts fastening the mount for the right-hand exhaust extension to the bodywork.
Carry out the same operation for the left-hand exhaust extension by undoing the screws fastening
the extension pipe to the bodywork.
CAMBIO ELETTROATTUATO
Unscrew the two nuts fastening the metal clamps joining the exhaust tailpipes and central
silencers.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Undo the nut and the check nut used to fasten and adjust the handbrake cable.
CAMBIO ELETTROATTUATO
Remove the plastic retaining clamp from its seat on the handbrake clamp, then release the
handbrake cable from the bracket.
N.B.
Make sure you do not break the plastic clamp
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Remove the plastic handbrake cable retaining clamps from their seat.
N.B.
Make sure you do not break the plastic clamps
CAMBIO ELETTROATTUATO
Unscrew the nut, remove the bracket and take the handbrake cables out the mount.
CAMBIO ELETTROATTUATO
Undo the lower fastening screws and remove the bodywork reinforcement bracket.
CAMBIO ELETTROATTUATO
Undo the fastening screws and remove the bodywork reinforcement bracket located between the
transmission shaft and the central silencers.
CAMBIO ELETTROATTUATO
Undo the screws fastening the right- and left-hand axle shafts to the gearbox.
CAMBIO ELETTROATTUATO
Undo the fastening screw on the electronically-controlled gearbox oil line bracket.
CAMBIO ELETTROATTUATO
Disconnect the quick coupling connecting the oil delivery line to the clutch.
CAMBIO ELETTROATTUATO
Unscrew the two fastening nuts and remove the plastic guard fastened to the lower lever.
CAMBIO ELETTROATTUATO
Position a hydraulic lifting device under the gearbox supporting cross member, fitted with a
suitable tool for the gearbox cross member to rest on.
N.B.
Keep the gearbox aligned with the rear transmission by fitting suitable shims under the gearbox
housing.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Lower the gearbox unit until the left-hand handbrake cable can be accessed and released from
the fastening bracket.
CAMBIO ELETTROATTUATO
Unscrew the fastening nut and release the right-hand handbrake cable from the gearbox.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Working from the transmission shaft -gearbox coupling area, separate the gearbox unit from the
transmission shaft.
CAMBIO ELETTROATTUATO
Slowly lower the hydraulic device and remove the gearbox from its seat on the vehicle.
N.B.
During the gearbox removal operation, take care to ensure the oil radiator is not damaged.
CAMBIO ELETTROATTUATO
Unscrew the nuts fastening the two gearbox mounts to the relative rubber bushings and separate
the gearbox from the lower cross member.
CAMBIO ELETTROATTUATO
With the gearbox on the bench, check the level of the oil in the tank, then visually inspect that the
components are intact and the main fastenings are tightened to the correct torque.
Position the gearbox on the supporting cross member and tighten the nuts fastening the rubber
bushings to the gearbox mounts to a torque of 130 Nm.
CAMBIO ELETTROATTUATO
Position the gearbox and cross member assembly on the hydraulic lifting device complete with
the tool to support the gearbox, then fit the gearbox in the relative compartment on the vehicle.
Connect the gearbox to the transmission shaft and tighten the fastening nuts to a torque of 70 Nm.
CAMBIO ELETTROATTUATO
Tighten the nut fastening the right-hand handbrake cable to the gearbox.
Fasten the handbrake cable in the relative seat on the left-hand side of the gearbox.
Position a hydraulic lifting device under the gearbox supporting cross member, fitted with a
suitable tool for the gearbox cross member to rest on.
N.B.
Keep the gearbox aligned with the rear transmission by fitting suitable shims under the gearbox
housing.
CAMBIO ELETTROATTUATO
Lift the gearbox and position it in its seat, then tighten the fastening screws on the gearbox
supporting cross member to torque.
CAMBIO ELETTROATTUATO
Remove the hydraulic lifting device fitted with the tool used for removing and refitting the gearbox.
Fit the plastic guard fastened to the lower lever and tighten the two fastening nuts.
Connect the oil delivery line to the clutch with the quick coupling.
Tighten the fastening screw on the electronically-controlled gearbox oil line bracket.
Tighten the screws fastening the right- and left-hand axle shafts to the gearbox to a torque of
80Nm.
CAMBIO ELETTROATTUATO
Fit the bodywork reinforcement bracket located between the transmission shaft and the central
silencers and tighten the fastening screws to torque.
Fit the bodywork reinforcement bracket located under the central exhaust silencers.
Fit the handbrake cables in their seat on the mount, then tighten the fastening nut on the retaining
bracket.
CAMBIO ELETTROATTUATO
Fit the plastic clamps retaining the handbrake cables in their seat.
N.B.
When fitting, make sure you do not break the plastic clamps and always check that they are fitted
correctly
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Position the handbrake cable in its seat connected to the lever, fit the end into the spacer and
tighten the nut and check nut.
Fit the plastic clamp retaining the handbrake cable in its seat.
N.B.
When fitting, make sure you do not break the plastic clamp and always check that it is fitted
correctly.
CAMBIO ELETTROATTUATO
Fasten the electric connector to the chassis by tightening the fastening screw.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Fit the exhaust tailpipes on the central silencers and tighten the fastening nuts on the fastening
clamps to a torque of 54 Nm
CAMBIO ELETTROATTUATO
Tighten the screws fastening the mounts to the bodywork to a torque of 24 Nm.
CAMBIO ELETTROATTUATO
After connecting the batterys negative terminal, the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
Using the SD3 diagnostics tester, run the self-learning procedure of the gear grid:
CAPITOLO
Unscrew the two nuts fastening the ECU retaining bracket then, holding the ECU, detach the two
electrical connections.
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
N.B
This operation must only be carried out on versions fitted with the SOFAST 3 gearbox
If the NCR ECU needs to be replaced, you must carry out the following procedures: the DEIS
Check Parameter self-calibration, the self-learning for the gears and the accelerometer calibration.
To carry out the DEIS adjustment procedure, you must connect the SD3 diagnosis instrument
(95970312) to the diagnosis socket on the Body Computer.
Wait for the data to load and follow the guided procedure.
CAPITOLO
UPLOAD/DOWNLOAD
DEIS check parameter self-calibration
Self-learning
Accelerometer offset self-calibration
1st gear engagement
st gear engagement 2
Select DEIS check parameter self-calibration and wait for the automatic loading procedure to
finish.
This procedure should take approximately 3 minutes and 30 seconds with a check time of 6
minutes, after which the procedure is considered unsuccessful if not completed.
If the procedure is completed successfully, continue with the gear grid self-calibration (selflearning).
If the DEIS adjustment procedure has ended unsuccessfully, identify the causes and carry out the
following checks:
Check that the clutch bleeding has been carried out correctly.
Continue the gear grid self-calibration by selecting self-learning then wait for the automatic
procedure to finish.
This procedure should take approximately 1 minutes and 30 seconds with a check time of 2
minutes, after which the procedure is considered unsuccessful if not completed..
Select Accelerometer offset self-calibration and wait for the automatic procedure to finish.
This procedure should take approximately 30 seconds with a check time of 40 seconds, after
which the procedure is considered unsuccessful if not completed.
If the procedure has been successfully completed and no further adjustments are required, turn
the ignition key to OFF and wait at least 25 seconds. This is the shortest time required to enable the
ECU to store the parameters learnt.
CAMBIO ELETTROATTUATO
POWER UNIT
Removing-refitting the Power Unit
Disconnect the connector for the gearbox rpm sensor and for the potentiometer.
Unscrew the three nuts fastening the electric system and the screw fastening the earths.
CAMBIO ELETTROATTUATO
Unscrew the two nuts fastening the clutch control pipe's coupling valve block.
CAMBIO ELETTROATTUATO
Undo the screw fastening the mounting bracket for the exhaust tailpipes' bushings and remove it.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Undo the upper fastening screw on the power unit mounting bracket, on the left-hand side of the
gearbox.
CAMBIO ELETTROATTUATO
Undo the lower fastening screw on the power unit support bracket, on the left-hand side of the
gearbox.
CAMBIO ELETTROATTUATO
Undo the three fastening screws on the power unit mounting bracket, that are located on the rear
of the gearbox, and the nut fastening the electric system retaining clamp.
CAMBIO ELETTROATTUATO
Undo the fastening screw on the power unit mounting bracket, on the right-hand side of the
gearbox.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Clean the contact surface between the actuator and the gearbox housing carefully.
CAMBIO ELETTROATTUATO
N.B.
During the refitting stage, apply CAF 4 sealant to the area between the gearbox and the actuator.
When refitting, follow the above procedures in reverse order
CAPITOLO
Using a syringe, top up the oil in the electronically-controlled gearbox oil tank.
CAPITOLO
Drain out the oil from the tank using the specific tool 900027330, making sure the remaining oil
level is between the MIN and MAX notches on the tool.
CAPITOLO
CAPITOLO
Access the 4-way connector for the C-CAN line located in the suspension control node compartment and
detach it.
CAPITOLO
Plug the SD3 (95970312) into the EOBD diagnosis connector (1).
Attach the C-CAN connector (2a) to the SD3 cable bundle (95979568) (2b).
Attach the C-CAN connector (2c) to the SD3 cable bundle (95979568) (2d).
CAPITOLO
CAUTION
For the KISS-POINT value to be reliable and useful for clutch testing, this should be measured in the
normal clutch operating conditions ([80100]C). To allow the clutch to reach these temperature
conditions, i.e. a stabilised and uniform thermal state, you must perform the following manoeuvres on the
road:
- Warm up the engine by driving normally (without using the clutch) for 5 minutes.
- Perform 4 pick-up manoeuvres by fully depressing the pedal. The pick-up manoeuvre is complete when
synchronisation between the engine and the input shaft has been reached (the clutch will be completely
closed at about 5000 rpm).
- Wait a few seconds between one pick-up and the other.
- Wait for the clutch to reach its operating temperature by driving normally for 5 minutes (ideally at 4000
rpm), avoiding further pick-ups or gearshifts as far as possible. In case of frequent pick-up manoeuvres,
extend the cooling time (15 min.).
Turn on the SD3 tester and, from the list of diagnostic programs, select INDIVIDUAL ECU DIAGNOSIS, the
manufacturer MASERATI and the vehicle model M139.
CAPITOLO
For vehicles manufactured from serial number 18822 up to serial number 21925, select KISS POINT NCR
2.0 SOFAST III.
For vehicles manufactured from serial number 21926, select KISS POINT NCR 2.0 SOFAST III. it+.
The user is guided through the subsequent stages by the diagnostic system chosen.
Select KISS POINT ENVIRONMENT and enter the vehicle serial number.
CAPITOLO
The system will display a warning message for the user, advising him/her of the vehicle conditions required
to run the calibration procedure correctly.
N.B.
If a high clutch temperature is signalled, let the clutch cool down even further, possibly while driving or in
N, letting the engine run.
If the vehicle meets the conditions which permit the procedure to continue, press "ENTER".
Shift the gear to neutral, rotate 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 current touch point (PIS) position (in red)
and the two references curves (in black) indicating the tolerance range within which the touch point curve must
be located.
For vehicles up to serial number 21925, a graph made up of three curves is displayed, where the central
curve is the current position of the CSC.
For vehicles from serial number 21926, a graph made up of three curves is displayed, where the central
CAPITOLO
At the end of each data acquisition and processing sequence, the following parameters will be displayed:
Number of pick-ups
Touch point (PIS) value (bit,mm)
POINT SCATTERING value
(1-2, 2-2)
(Min 6.00 120 bit, MAX 160 bit) and the value in millimetres
(Min 0 bit, MAX 10 bit)
Example 327
Example 327
CAPITOLO
End the cycle by answering the question on whether the clutch is new or has been replaced.
CAPITOLO
CAPITOLO
If the oil level is below the hole, top it up using suitable equipment, until it reaches the lower edge of
the filling hole.
CAPITOLO
Once topped up, clean the filling hole and replace the sealing gasket.
Tighten the filling cap.
Fit the bracket and screw up the fastening nuts.
Tighten the nuts fastening the mount to the bodywork to a torque of 24 Nm.
CAPITOLO
If the gearbox oil needs to be changed, the oil draining cap shown in the figure must be unscrewed.
CAPITOLO
CAPITOLO
Unscrew the two nuts fastening the oil radiator to the mounting bracket and remove it.
CAPITOLO
Fit the oil radiator in its seat on the bracket and tighten the two fastening nuts.
Connect the two delivery and return lines and tighten the two unions to a torque of 34 Nm.
important
The gaskets on the two oil line fastening unions must always be replaced.
CAPITOLO
CAPITOLO
Disconnect the electrical connector (1) using the specific tool 900027370, then unscrew and
remove the clutch pressure sensor (2).
CAPITOLO
When the component has been fitted, bleed the hydraulic clutch system.
Bleeding the clutch
CAPITOLO
UPLOAD/DOWNLOAD
DEIS check parameter self-calibration
Self-learning
Accelerometer offset self-calibration
st gear engagement 1
st gear engagement 2
Select DEIS Check Parameter Self-Calibration then wait for the automatic procedure to finish.
This procedure should take approximately 3 minutes and 30 seconds with a check time of 6
minutes, after which the procedure is considered unsuccessful if not completed.
If the procedure has been successfully completed and no further adjustments are required, turn the
ignition key to OFF and wait at least 25 seconds. This is the shortest time required to enable the ECU
to store the parameters learnt.
If the DEIS adjustment procedure has ended unsuccessfully, identify the causes and carry out the
following checks:
-
Check that the clutch bleeding has been carried out correctly
Check that the clutch control solenoid valve is operating properly.
Repeat the DEIS Check Parameter Self-Calibration procedure
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CAPITOLO
UPLOAD/DOWNLOAD
DEIS check parameter self-calibration
Self-learning
Accelerometer offset self-calibration
st gear engagement 1
st gear engagement 2
Select Accelerometer offset self-calibration then wait for the automatic procedure to finish.
This procedure should take approximately 30 seconds with a check time of 40 seconds, after which
the procedure is considered unsuccessful if not completed.
If the procedure has been successfully completed and no further adjustments are required, turn the
ignition key to OFF and wait at least 25 seconds. This is the shortest time required to enable the
ECU to store the parameters learnt.
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CAPITOLO
ACCELERATION SENSOR
Removingrefitting the acceleration sensor
This component is fitted on vehicles up to serial number 24274; for vehicles from serial number
24275 its functions have been integrated in the yaw sensor.
Component specific to the electronically-controlled gearbox with Sofast 3 type management
Remove the central tunnel
Central tunnel
Detach the electrical connection (1), unscrew the fastening nuts (2) and remove the acceleration
sensor (3).
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CAPITOLO
CAPITOLO
Run the self-learning procedure for the engagement and selection thresholds by selecting the
GEARBOX SELF-LEARNING function from the DIAGNOSTICS menu.
CAPITOLO
Move the pipes and undo the retaining screw (1) for the power unit oil tank.
Remove the fastening bracket (2) and move the oil tank away from the working area.
CAPITOLO
Unscrew the union (1) and disconnect the oil pipe (2).
CAPITOLO
Unscrew the fastening nuts (1), remove the tank support bracket (2), undo the three stud bolt
screws (3) and remove the power unit oil pump (4).
CAPITOLO
CAPITOLO
Detach the electrical connector (1), unscrew the nut (2) and open the electric cable fastening clamp
(3).
Release the electric cable (4) of the level sensor from the clamp (5).
CAPITOLO
Move the pipes and undo the retaining screw (1) for the power unit oil tank.
Remove the fastening bracket (2).
Disconnect the two pipes (3) and remove the power unit oil tank.
CAPITOLO
CAPITOLO
Axle shafts
Removing the axle shafts
Remove the wheel concerned.
Replacing the wheels
Remove the rear shock absorber concerned
Rear shock absorbers
Unscrew the nut fastening the stabiliser bar connecting rod, on the right- and left-hand side of the
vehicle.
CAPITOLO
CAPITOLO
Remove the flattened part from the nut fastening the wheel hub to the axle shaft and loosen the
said nut.
CAPITOLO
Position the specific tool to remove the axle shaft from the hub carrier.
Screw it onto the threaded pin of the tool and proceed with removal of the axle shaft.
CAPITOLO
Undo the nut fastening the upper lever to the hub carrier.
CAPITOLO
Using the extracting tool shown, draw the levers tapered pin out the hub carrier.
CAPITOLO
Unscrew the nut and, using an extracting tool, separate the tapered head of the toe-in tie-rod from
the hub carrier.
CAPITOLO
Undo the screws that secure the constant speed universal joint to the flange, then remove the axle
shaft from the vehicle.
CAPITOLO
CAPITOLO
Connect the toe-in tie-rod to the hub carrier and tighten the fastening nut to torque.
- 80 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 45 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
Tighten the nut fastening the lever to the pillar (hub carrier) to a torque of 52 Nm.
CAPITOLO
Complete the procedure by carrying out all the refitting operations for the rear brake disc concerned.
Rear brake disc
Tighten the nut fastening the wheel hub to the axle shaft to a torque of 275 Nm
CAPITOLO
CAPITOLO
Fit the stabiliser bar and tighten the fastening nuts to a torque of 24 Nm.
CAPITOLO
Tighten the nuts fastening the small connecting rods to the stabiliser bar to a torque of 50 Nm.
CAPITOLO
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Undo the wiring fastening screws, then unscrew the Lambda sensor from the left-hand catalytic
converter.
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Undo the wiring fastening screws, then unscrew the Lambda sensor from the right-hand catalytic
converter.
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Unscrew the fastening nuts on the central catalytic converter mount.
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Unscrew the six screws fastening the catalytic converter to the relative manifolds.
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Position a hydraulic support beneath the catalytic converter/ central exhaust silencer assembly, lower it
slowly, then remove the catalytic converters together with the central exhaust silencers.
Retrieve the catalytic converter conductive gaskets.
CAPITOLO
Operation valid for ALL THE USA-CANADA versions and for the EUROPE version from serial
number 24276.
Remove the two exhaust extensions.
Exhaust extension pipe
Remove the central exhaust silencer.
Exhaust silencer
Remove the floor guard beneath the engine.
Engine floor guard
Remove the catalytic converters.
Catalytic converters
CAPITOLO
Undo the rear fastening screws on the transmission shaft heat guard.
CAPITOLO
Unscrew the nuts fastening the clutch oil line to the transmission shaft.
CAPITOLO
Unscrew the nuts fastening the transmission shaft to the clutch housing.
CAPITOLO
Position tool 900027300 to support the transmission shaft during its removal and remove the rear
mount placed there previously during the removal of the gearbox.
Slide the transmission shaft out the clutch housing, then remove it.
CAPITOLO
CAPITOLO
Tighten the nuts fastening the transmission shaft to the clutch housing to a torque of 70 Nm.
CAPITOLO
Tighten the nuts fastening the clutch oil line to the transmission shaft, then tighten the fastening
screws on the heat guard.
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Using a hydraulic support positioned underneath the catalytic converter/central exhaust silencer
assembly, position the catalytic converters in their seat together with the central exhaust silencers.
N.B.
Visually inspect that the gasket located underneath the flange joining the catalytic converter and
the exhaust manifold is intact and if signs of wear are found, replace it.
N.B.
The conductive gaskets must never be fitted more than once. The second time the component is
fitted, they must be replaced
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Tighten the screws fastening the exhaust manifold to the catalytic converter to a torque of 25 Nm.
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
CAPITOLO
Operation valid for ALL THE VEHICLES/MARKETS except USA-CANADA and for the EUROPE
version from serial number 24275.
Fit all the Lambda sensors, then tighten them to a torque of 50 Nm.
Suitably secure the front Lambda sensor wiring to the engine frame.
CAPITOLO
Operation valid for ALL THE USA-CANADA versions and for the EUROPE version from serial
number 24276.
Refit the catalytic converters.
Catalytic converters
Refit the engine floor guard.
Engine floor guard
Refit the central exhaust silencer.
Exhaust silencer
Refit the two exhaust extension pipes.
Exhaust extension pipe
OPERATIONS VALID FOR ALL VERSIONS
Proceed by refitting the gearbox.
Removing-refitting the gearbox
Proceed by refitting the exhaust tailpipes.
Removing-refitting the tailpipe
CAPITOLO
tightening torques
Description
Torque
Product
Front brake
Front brake caliper screws
145 Nm
24 Nm
15,5 Nm
60 Nm
Rear brake
Brake caliper retaining screws (up to serial number 27859) 60 Nm
Brake caliper retaining screws (from serial number 27860) 125 Nm
Screws for fastening the rear caliper bracket to the hub
carrier (from serial number 27860)
Rear brake disk screws
65 Nm
15 Nm
7,4 Nm
60 Nm
15 Nm
7,4 Nm
4,4 Nm
Description
14 Nm
Torque
Handbrake
Nut and counternut for cable anchorage
15 Nm
25 Nm
Product
CAPITOLO
Pedal box
Nut for fastening pedal board to fireproof bulkhead 24 Nm
Nut for fastening brake servo
24 Nm
CAPITOLO
CAPITOLO
Insert a punch in the lower hole in the calipers and press until the brake pad retaining pin slides out
of its seat.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Undo the two screws fastening the brake calipers to the pillar, then move them sideways, securing
it with suitable means to ensure the weight of the calipers does not weigh down the oil line.
CAPITOLO
Unscrew the two brake disk fastening screws and remove the disk.
CAPITOLO
Fit the brake disk and tighten the two fastening screws to a torque of 15.5Nm.
CAPITOLO
Position the brake calipers on the disk and tighten the front brake calipers hub carrier screws to a
torque of 145Nm.
CAPITOLO
Fasten the electrical wiring and the oil line to the bracket on the upper wishbone.
CAPITOLO
Fit the relative wheel (carry out the refitting operations only).
Replacing the wheels
CAPITOLO
Check that the oil tank of the tool contains the quantity of oil recommended by the manufacturer. If
the quantity is not sufficient, add the required amount, remembering to ALWAYS release any residual
pressure inside the tool.
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CAPITOLO
Connect the system pressurisation tool to the brake fluid pan. Position the brake fluid recovery tank
provided with the tool next to the pan.
CAPITOLO
Inject pressurised air until the pressure gauge (1) indicates 2 bar. Adjust the overall tool pressure
with the knob (2).
CAPITOLO
When the pressure has been adjusted, turn the tool lever to the indicated position.
With the lever in this position the oil circuit is under pressure; turning it 90 anticlockwise, the
pressure is released from the system.
CAPITOLO
Connect the SD3 diagnostic tester and start the DIAGNOSTIC procedure.
CAPITOLO
CAPITOLO
CAPITOLO
For vehicles up to serial number 24274, select NFR BOSCH BRAKING NODE
For vehicles from serial number 24275, select NFR BOSCH ESP 8 BRAKING NODE
CAPITOLO
CAPITOLO
Follow the SD3 guided procedure, which will prompt you to start opening the caliper bleeders and
to collect the oil in a suitable container, in the sequence described below.
For vehicles up to serial number 24274, the sequence is as follows:
- Internal bleeding of the right-hand rear caliper
- External bleeding of the right-hand rear caliper
- Internal bleeding of the left-hand rear caliper
- External bleeding of the left-hand rear caliper
- Internal bleeding of the right-hand front caliper
- External bleeding of the right-hand front caliper
- Internal bleeding of the left-hand front caliper
- External bleeding of the left-hand front caliper
CAPITOLO
CAPITOLO
Carefully and completely run the bleeding cycle until the end-of-cycle screen appears on the SD3
tester.
Check that the brake pedal travel is correct.
If the pedal travel is incorrect, repeat the bleeding cycle.
Briefly road test the vehicle to check proper functioning of the braking system.
N.B.
Do not re-use the old brake fluid. Refill with new brake fluid.
CAPITOLO
Undo the lower fastening screws on the wheel bay dust-protection shield.
Unscrew the six fastening screws, and remove the five snap-fit buttons, then remove the wheel bay dustprotection shield.
CAPITOLO
Detach the ABS rpm sensors electrical connection and release the wiring from its fastening on the
bodywork.
CAPITOLO
Release the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
CAPITOLO
Remove the front wheel hub, complete with bearing and ABS rpm sensor.
CAPITOLO
CAPITOLO
Using the same punch, insert it in the upper hole on the calipers and press until the brake pad
retaining pin slides out of its seat
CAPITOLO
Remove the two upper and lower pins, in addition to the retaining clips on the brake pads.
CAPITOLO
CAPITOLO
Detach the electrical connector for the rear brake pad wear sensor.
CAPITOLO
Unscrew the nut that fastens the wear sensor cable clamp.
CAPITOLO
Insert a punch in the upper hole on the calipers and press until the brake pad retaining pin slides
out of its seat
CAPITOLO
Using the same punch, insert it in the upper hole on the calipers and press until the brake pad
retaining pin slides out of its seat
Remove the two upper and lower pins, in addition to the retaining clips on the brake linings.
CAPITOLO
CAPITOLO
CAPITOLO
Release the brake oil hose from the snap-fastener located on the chassis.
CAPITOLO
Undo the two fastening screws on the brake calipers and remove it.
CAPITOLO
CAPITOLO
Tighten the union between the brake oil hose and the rigid section of the line to a torque of 18.5
Nm
CAPITOLO
CAPITOLO
Detach the electrical connector (2) for the wear sensor positioned on the rear brake pad.
CAPITOLO
Unscrew the nut that fastens the wear sensor cable clamp.
CAPITOLO
Undo the two screws that secure the brake caliper to the support bracket and remove it from its
seat.
CAPITOLO
If necessary, undo the two retaining screws (1) and remove the brake caliper mounting bracket (2).
CAPITOLO
CAPITOLO
Move the small piston on the caliper away manually to facilitate fitting the calipers.
Position the brake calipers on the disc and tighten the brake caliper fastening screws to a torque of
125Nm.
CAPITOLO
Tighten the union of the brake fluid flexible hose (1) for the caliper.
Attach the electrical connector (2) of the wear sensor positioned on the rear brake pad.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Fit the relative wheel (carry out the refitting operations only).
Replacing the wheels
CAPITOLO
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CAPITOLO
Remove the device used to hook the handbrake cable to the brake shoes.
CAPITOLO
Remove the central pin (not shown) and detach the handbrake cable from the transmission device.
CAPITOLO
CAPITOLO
CAPITOLO
Position the tool that you need to remove the wheel hub from the axle shaft. Tightening the screw
on the tool, remove the wheel hub from the axle shaft.
CAPITOLO
Move the axle shaft backwards and undo the screw fastening the retaining clamp for the ABS
sensor wiring.
CAUTION:
During this operation, take care not to damage the ABS sensor cable.
CAPITOLO
Remove the rear wheel hub together with the ABS sensor for the rear wheels.
CAPITOLO
CAPITOLO
CAPITOLO
Complete the procedure by carrying out all the refitting operations for the brake shoe concerned.
Brake shoes
Complete the procedure by carrying out all the refitting operations for the brake disc concerned.
Rear brake disc
Fit the rear shock absorber concerned.
Rear shock absorbers
Tighten the nut fastening the wheel hub to the axle shaft to a torque of 275 Nm
CAPITOLO
CAPITOLO
CAPITOLO
Undo the fastening screws and remove the heat guard on the left-hand exhaust line.
Undo the fastening screws and remove the heat guard on the right-hand exhaust line.
CAPITOLO
Unscrew the nuts fastening the mount for the right-hand exhaust extension to the bodywork.
Carry out the same operation for the left-hand exhaust extension by undoing the screws fastening
the extension pipe to the bodywork.
CAPITOLO
Unscrew the two nuts fastening the metal clamps joining the exhaust tailpipes and central silencers.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Undo the nut and the check nut used to fasten and adjust the handbrake cable.
CAPITOLO
Remove the plastic retaining clamp from its seat on the handbrake clamp, then release the
handbrake cable from the bracket.
N.B.
Make sure you do not break the plastic clamp
CAPITOLO
CAPITOLO
Remove the plastic handbrake cable retaining clamps from their seat.
N.B.
Make sure you do not break the plastic clamps
CAPITOLO
Unscrew the nut, remove the bracket and take the handbrake cables out the mount.
CAPITOLO
Undo the fastening screws and remove the bodywork reinforcement bracket located between the
transmission shaft and the central silencers.
CAPITOLO
Undo the lower fastening screws and remove the bodywork reinforcement bracket.
CAPITOLO
Undo the screws fastening the right- and left-hand axle shafts to the gearbox.
CAPITOLO
Undo the fastening screw on the electronically-controlled gearbox oil line bracket.
CAPITOLO
Disconnect the quick coupling connecting the oil delivery line to the clutch.
CAPITOLO
Unscrew the two fastening nuts and remove the plastic guard fastened to the lower lever.
CAPITOLO
Position a hydraulic lifting device under the gearbox supporting cross member, fitted with a suitable
tool for the gearbox cross member to rest on.
N.B.
Keep the gearbox aligned with the rear transmission by fitting suitable shims under the gearbox
housing.
CAPITOLO
CAPITOLO
Lower the gearbox unit until the left-hand handbrake cable can be accessed and released from the
fastening bracket.
CAPITOLO
Unscrew the fastening nut and release the right-hand handbrake cable from the gearbox.
CAPITOLO
Release the handbrake cables from the shoes and remove the said cables.
CAPITOLO
CAPITOLO
Remove the hydraulic lifting device fitted with the tool used for removing and refitting the gearbox.
Fit the plastic guard fastened to the lower lever and tighten the two fastening nuts.
Connect the oil delivery line to the clutch with the quick coupling.
Tighten the fastening screw on the electronically-controlled gearbox oil line bracket.
Tighten the screws fastening the right- and left-hand axle shafts to the gearbox to a torque of 80Nm.
CAPITOLO
Fit the bodywork reinforcement bracket located between the transmission shaft and the central
silencers and tighten the fastening screws to torque.
Fit the bodywork reinforcement bracket located under the central exhaust silencers.
Fit the handbrake cables in their seat on the mount, then tighten the fastening nut on the retaining
bracket.
CAPITOLO
Fit the plastic clamps retaining the handbrake cables in their seat.
N.B.
When fitting, make sure you do not break the plastic clamps and always check they are fitted
correctly.
CAPITOLO
CAPITOLO
Position the handbrake cable in its seat connected to the lever, fit the end into the spacer and
tighten the nut and check nut.
Fit the plastic clamp retaining the handbrake cable in its seat.
N.B.
When fitting, make sure you do not break the plastic clamp and always check that it is fitted
correctly.
CAPITOLO
Fasten the electric connector to the chassis by tightening the fastening screw.
CAPITOLO
CAPITOLO
Fit the exhaust tailpipes on the central silencers and tighten the fastening nuts on the fastening
clamps to a torque of 54 Nm.
CAPITOLO
Tighten the screws fastening the door limiting device to the bodywork to a torque of 24 Nm.
CAPITOLO
CAPITOLO
BRAKE SHOES
Removing-refitting the brake shoes
Remove the wheel concerned.
Replacing the wheels
Remove the relative rear wheel brake disc.
Rear brake disc
Rotate and remove the two lateral springs on the shoes.
CAPITOLO
Grip the the lower part of the shoes to open them, and remove the backlash adjustment device.
CAPITOLO
Remove the upper return spring and release the two shoes from the handbrake cable transmission,
then remove the two shoes.
CAPITOLO
Check that the springs, the backlash adjustment device and the shoes are intact and in good
working order. If any of the components are damaged, replace them.
CAPITOLO
CAPITOLO
Make sure that when the handbrake lever is in the resting position, the rear wheels can rotate freely.
Check that the handbrakes braking action begins soon as you hear the mechanism's first click.
Once the adjustment is complete, check that the lever does not require more than four or five
recesses in the toothed section to engage.
http://127.0.0.1:8000/M396_B_E/dt/mo/e/e5_03.htm10/21/2008 8:13:34 PM
CAPITOLO
Detach the electrical connection on the air flow meter and release the two clips from the air filter
housing.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Release the clips fastening the cover to the air filter housing.
CAPITOLO
CAPITOLO
Undo the screw fastening the air filter housing to the domes' bar.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Unscrew the pipeline unions on the front and rear calipers and the unions for the rigid pipelines
coming from the brake master cylinder.
CAPITOLO
CAPITOLO
CAPITOLO
Refitting the A.B.S. electro-hydraulic control unit ASR - EBD ESP valid for vehicles up to
assembly no. 24274
CAPITOLO
CAPITOLO
To refit the remaining components, proceed as outlined for the removal but reversing the order of
the operations.
Bleed the air system to remove any air that may have entered the lines or the A.B.S. control unit.
Bleeding the front brakes
Bleeding the rear brakes
Top the brake system oil up to the correct level.
Circuit filling and level checks
After connecting the negative battery terminal, the following self-learning cycles must be run out to
ensure certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
Removing the A.B.S. electro-hydraulic control unit - A.S.R. - EBD ESP valid for vehicles from
assembly no. 24275
CAPITOLO
From vehicle assembly no. 24275, a new type of ABS equipped with Bosch ESP 8.0 system has
been fitted; the dimensions and weight have been reduced by about 25% with respect to the previous
ABS.
The operating principles of the sub-functions are the same as those of the previous ABS ESP
5.7. The exploded diagram below shows the components making up the new ABS - ESP 8.0.
CAPITOLO
1.
2.
3.
4.
5.
Pump motor
Valve block
Pressure sensor
Hydraulic valves
Electronic control unit
Disconnect the battery's negative terminal.
Remove the trim panels.
CAPITOLO
Remove right-hand cold air intake pipe from the filter box.
CAPITOLO
CAPITOLO
Using a specific USAG 256N wrench or similar, unscrew the unions of the rigid pipes (1) on the
front and rear calipers and the unions of the rigid pipes (2) leading from the brake pump.
Plug the pipes and holes on the ABS to prevent infiltration of air and impurities.
CAPITOLO
CAPITOLO
Remove the ABS electro-hydraulic ECU complete with support bracket and place it on a bench.
CAPITOLO
Unscrew the two retaining nuts (1) and lift the ABS electro-hydraulic ECU off the support bracket,
removing it from the centring pin (2).
CAPITOLO
Refitting the ABS electro-hydraulic control unit ASR EBD ESP valid for vehicles from
assembly no. 24275
Fit the ABS electro-hydraulic ECU on the bracket, centring the pin in the hole on the bracket.
Screw down the unit retaining nuts on the support bracket.
Fit the ABS and bracket assembly and tighten the bracket retaining nuts to a torque of 7.4 Nm.
Screw down the unions of the brake pipes leading from the pump and the brake calipers, then
tighten them to a torque of 14 Nm.
Detach the electrical connector of the ABS electro-hydraulic control unit. ASR - EBD ESP
CAPITOLO
Bleed the air system to remove any air that may have entered the lines or the ABS control unit.
Bleeding the front brakes
Bleeding the rear brakes
If replacing the ABS, use the SD3 diagnostic tester to delete the errors from the ABS ECU.
Subsequently, access the PARAMETERS environment, display the parameters that the ECU has selflearned, print them and keep them in the vehicle logbook.
Disconnect the SD3 tester.
After connecting the batterys negative terminal, the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
To refit the remaining components, proceed as outlined for the removal but reversing the order of
the operations.
CAPITOLO
CAPITOLO
CAPITOLO
Detach the electrical connection and remove the brake oil tank.
CAPITOLO
Unscrew the two unions and disconnect the two brake pipelines from the brake master cylinder
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Working from the engine compartment, remove the brake master cylinder and brake servo
assembly.
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Attach the electrical connection for the low brake oil level warning light .
Screw up the screws fastening the brake oil tank.
CAPITOLO
Connect the two oil delivery pipes (coming from the tank) to the brake master cylinder.
CAPITOLO
CAPITOLO
Bleed the air system to remove any air that may have entered the lines or the A.B.S. control unit.
Bleeding the front brakes
Bleeding the air in the rear brake fluid circuit
Top the brake system oil up to the correct level.
Circuit filling and level checks
CAPITOLO
Undo the lower screws fastening the steering column to the air conditioning/heating unit support
frame, then lower the steering column.
CAPITOLO
Remove the fastening clip on the brake pedal pin, then remove the brake pedal switch from its seat
on the mount.
CAPITOLO
N.B.
For photographic reasons, the operation was photographed on the bench.
CAPITOLO
Disconnect the brake servo push rod from the bushing on the brake pedal, then remove the pedal.
N.B.
For photographic reasons, the operation was photographed on the bench.
CAPITOLO
Unscrew the two upper and lower nuts fastening the brake servo to the pedal board mount.
CAPITOLO
Unscrew the fastening nuts and remove the pedal board mount.
CAPITOLO
Fit the pedal board mount and tighten the fastening nuts to a torque of 24 Nm.
Tighten the four nuts on the brake master cylinder and brake servo assembly to a torque of 24 Nm.
CAPITOLO
Fit the accelerator pedal and connect the brake servo push rod from the bushing on the brake
pedal.
Check that the plastic components (colour: black and white) which fasten the brake servo push rod
are intact. As a rule, these should be replaced every time the pedal is removed.
N.B.
For photographic reasons, the operation was photographed on the bench.
CAPITOLO
Insert the pedal fastening pin fully down, pushing from the clip side to secure the pedal on the
pedal board mount.
N.B.
For photographic reasons, the operation was photographed on the bench.
CAPITOLO
Fasten the pin by inserting the brake pedal fastening clip, then fit the brake pedal switch from the
seat on the mount.
CAPITOLO
Tighten the screws with M8 threading to a torque of 24 Nm and the screw with M6 threading to a
torque of 7.4 Nm to fasten the steering column to the dashboard mounting crossmember.
CAPITOLO
CAPITOLO
BRAKE PEDAL
Removing the brake pedal
Remove the driver's side glove compartment.
Driver's side glove compartment
Remove the Body computer node.
Body Computer Node
Remove the CD player compartment
CD player compartment
Undo the two screws and the fastening nut, then remove the bracket.
CAPITOLO
CAPITOLO
Disconnect the brake servo push rod from the bushing on the brake pedal, then remove the pedal.
CAPITOLO
CAPITOLO
tightening torques
Tightening torques valid for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and
17235 in the right-hand drive versions.
Description
Torque
Front suspensions
Nut for fastening lower lever to hub carrier
63 Nm
52 Nm
59 Nm
75 Nm
98 Nm
98 Nm
78 Nm
33,6 Nm
31 Nm
50 Nm
8 Nm
4,4 Nm
Product
CAPITOLO
78 Nm
50 Nm
80 Nm
52 Nm
Description
Torque
59 Nm
75 Nm
196 Nm
275 Nm
98 Nm
98 Nm
80 Nm
78 Nm
78 Nm
80 Nm
33,6 Nm
24 Nm
50 Nm
4,4 Nm
Product
CAPITOLO
123 Nm
Rear chassis
Screws fastening rear chassis
123 Nm
Wheels
Pre-tightening to
130 Nm,
loosening and
tightening to 98
Nm
Tightening torques valid for EUROPE vehicles from assembly 18535 in the left-hand drive version and
17236 in the right-hand drive versions; In addition, for all the USA - CND versions
Description
Torque
Front suspensions
- pre-tightening to
90 Nm
- complete
untightening
- tightening to 63
Nm
52 Nm
59 Nm
40 Nm
120 Nm
120 Nm
120 Nm
Product
CAPITOLO
120 Nm
25 Nm
40 Nm
50 Nm
40 Nm
7,4 Nm
78 Nm
50 Nm
45 Nm
52 Nm
Description
Torque
59 Nm
40 Nm
78 Nm
275 Nm
120 Nm
120 Nm
63 Nm
Product
CAPITOLO
98 Nm
98 Nm
80 Nm
25 Nm
35 Nm
retightening to 30
Nm + 120 Nm
63 Nm
24 Nm
50 Nm
40 Nm
7,4 Nm
123 Nm
Rear chassis
Screws fastening rear chassis
123 Nm
Description
Torque
Wheels
Pre-tightening to
130 Nm,
loosening and
tightening to 98
Nm
Product
CAPITOLO
CAPITOLO
Undo the lower fastening screws on the wheel bay dust-protection guard.
CAPITOLO
Unscrew the six fastening screws, and remove the five snap-studs, then remove the wheel bay
dust-protection guard.
CAPITOLO
Release the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Unscrew the bolts that fasten the upper fastening wishbone (lever) to the bodywork.
CAPITOLO
Remove the spacers and the washers, remembering to note down the number of spacers removed
and their positions.
CAPITOLO
Unscrew the nuts that fasten the front wheels vertical acceleration sensor.
CAPITOLO
Undo the screws that fasten the shock absorber to the dome.
CAPITOLO
Unscrew the bolt that fastens the shock absorber to the lower wishbone (lever)
CAPITOLO
CAPITOLO
CAPITOLO
Check that the lower part of the shock absorber is firmly coupled to the seat of the tool.
CAPITOLO
Also check that the electric cable of the shock absorber is properly positioned and that it does not
interfere with or be damaged during spring compression.
CAPITOLO
Activate the pneumatic press by operating the lever in the direction of the arrow and compress the
shock absorber until you are able to access the retaining nut.
CAPITOLO
Unscrew the retaining nut (1) and retrieve the washer (2).
CAPITOLO
Remove the top mount (1) complete with upper bushing (2).
CAPITOLO
Remove the upper rubber spacer (1), then remove the spring (2).
CAPITOLO
CAPITOLO
Place the shock absorber on a suitable surface and use a drift to remove the lower joint, which
must be replaced with a new one during re-assembly.
CAPITOLO
CAPITOLO
For vehicles up to assembly no. 25042, i.e. with shock absorbers equipped with adjustable ring nut,
proceed as illustrated.
Unscrew the spring positioner ring nut (1) and its locknut (2) and extract them from the shock
absorber.
CAPITOLO
From assembly no. 25043, shock absorbers equipped with a fixed spring stop are fitted.
On these components, the ring nut for adjusting the spring preload has been replaced with a
washer (1) that is incorporated in the shock absorber stem and it is therefore no longer adjustable.
This solution has been adopted to eliminate the possibility of incorrect spring adjustments which
alter the vehicle height and so compromise vehicle safety.
The old solution of the shock absorber with adjustable ring nut is interchangeable with the new
solution with fixed washer, however, it is important that shock absorbers of the same type are fitted on
the same axle.
The colour of the front axle springs does not need to be the same as that of the rear axle (yellow
springs can be fitted on the front axle and red springs on the rear axle or vice versa).
CAPITOLO
CAPITOLO
For vehicles up to assembly no. 25042, i.e. with shock absorbers equipped with adjustable
ring nut, proceed as illustrated.
Fit the positioner ring nut (1) and, depending on the spring, adjust the distance A from the hub
centre to the value given in the table below.
CAPITOLO
A (mm)
Front
366.5 1.5
368.5 1.5
Red
Yellow
Figures valid for vehicles manufactured from October 2004 up to assembly no. 21586
A (mm)
Front
366.5 1.5
369.5 1.5
Spring colour
Spring colour
Red
Yellow
A (mm)
Front
384 0.5
387 0.5
Spring colour
Red
Yellow
CAPITOLO
For vehicles up to assembly no. 25042, i.e. with shock absorbers equipped with adjustable ring nut,
proceed as illustrated.
Tighten the locknut to a torque of 59Nm.
Check that the spring is in perfect condition and that its dimensions comply with the indicated
values.
For vehicles up to assembly no. 21586.
Front spring
Front
Free spring height
Static length with min. load of 5869
N and max. 6050 N
Static length with min. load of 6050
N and max. 6232 N
Wire diameter
Spring colour
Values
All colours
Yellow
355.2 mm
192 mm
Red
192 mm
All colours
12.75 mm
For vehicles from assembly no. 21587, regardless of whether they are fitted on shock absorbers
with adjustable ring nut or with fixed calibration.
Front spring
Spring colour
Values
CAPITOLO
Front
Free spring height
Static length with min. load of 624639 kg
Static length with min. load of 635650 kg
Wire diameter
All colours
Yellow
365 mm
187 mm
Red
187 mm
All colours
12.75 mm
Fit the spring (1) and then the upper rubber spacer (2)
CAPITOLO
Fit the top mount (1) complete with upper bushing (2).
CAPITOLO
Position the complete shock absorber in the seat of the pneumatic press as described above, then
compress the spring.
Position the washer (1) and fully screw down the nut (2), then tighten it to a torque of:
- 75 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 40 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
CAPITOLO
Tighten the bolt that fastens the shock absorber to the lower wishbone (lever) to a torque of 78 Nm.
CAPITOLO
Tighten the fastening nuts on the front wheels' vertical acceleration sensor to a torque of 8 Nm.
CAPITOLO
Fit the upper front lever in its seat, inserting the fastening screws, fit the shims removed during
disassembly between the silent blocks and the frame structure, then tighten the bolts to a torque of :
- 78 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 120 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
Secure the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Fit the wheel bay dust-protection guard and tighten the six fastening screws fully, then fasten the
five snap-studs.
CAPITOLO
Fully screw down the lower fastening screws on the wheel bay dust-protection guard.
CAPITOLO
CAPITOLO
CAPITOLO
Fit the relative wheel, carrying out the refitting operations only.
Replacing the wheels
After connecting the batterys negative terminal, the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
Undo the three screws that secure the shock absorber to the body.
CAPITOLO
Undo the screw that fasten the shock absorber to the hub carrier.
CAPITOLO
Tilt and remove the rear shock absorber complete with the spring.
CAPITOLO
CAPITOLO
CAPITOLO
Check that the lower part of the shock absorber is firmly coupled to the seat of the tool.
CAPITOLO
Also check that the electric cable of the shock absorber is properly positioned and that it does not
interfere with or be damaged during spring compression.
CAPITOLO
Activate the pneumatic press by operating the lever in the direction of the arrow and compress the
shock absorber until you are able to access the retaining nut.
CAPITOLO
Unscrew the retaining nut (1) and retrieve the washer (2) .
CAPITOLO
Remove the top mount (1) complete with upper bushing (2) .
CAPITOLO
Remove the upper rubber spacer (1) , then remove the spring (2) .
CAPITOLO
CAPITOLO
CAPITOLO
Fit the positioner ring nut (1) and, depending on the spring, adjust the distance A from the hub
centre to the value given in the table below.
CAPITOLO
A (mm)
Rear
163 1.5
166 1.5
Red
Yellow
A (mm)
Front
279.5 0.5
282.5 0.5
Spring colour
Spring colour
Red
Yellow
CAPITOLO
Check that the spring is in proper working order and that its dimensions comply with the indicated
values.
For vehicles up to assembly no. 21586.
Rear spring
Rear
Free spring height
Static length with min. load of 5378
N and max. 5518 N
Static length with min. load of 5278
N and max. 5418 N
Wire diameter
Spring colour
Values
All colours
Yellow
342 mm
192 mm
Red
192 mm
All colours
13.25 mm
For vehicles from assembly no. 21587, regardless of whether they are fitted on shock absorbers
with adjustable ring nut or with fixed calibration.
Rear spring
Spring colour
Rear
Free spring height
All colours
Static length with a load of 571-585 Yellow
kg
Values
333 mm
193 mm
CAPITOLO
Fit the spring (1) and then the upper rubber spacer (2)
193 mm
12.75 mm
CAPITOLO
Fit the top mount (1) complete with upper bushing (2) .
CAPITOLO
Position the complete shock absorber in the seat of the pneumatic press as described above, then
compress the spring.
Position the washer (1) and fully screw down the nut (2), then tighten it to a torque of:
- 75 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 40 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and
17236 in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
CAPITOLO
Tighten the three screws that secure the shock absorber to the body to torque.
- 33.6 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and
17235 in the right-hand drive versions
- 25 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
CAPITOLO
CAPITOLO
Unscrew the six fastening screws, and remove the five snap-fit buttons, then remove the wheel bay
dust-protection shield.
CAPITOLO
Release the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Unscrew the bolts fastening the upper fastening wishbone (lever) to the bodywork.
CAPITOLO
Remove the spacers and the washers, remembering to note down the number of spacers removed
and their positions.
CAPITOLO
Unscrew the nut fastening the lever to the pillar (hub carrier).
CAPITOLO
Using the extracting tool shown in the figure, extract the levers tapered pin from the pillar (hub
carrier).
CAPITOLO
CAPITOLO
CAPITOLO
Tighten the nut fastening the lever to the pillar (hub carrier) to a torque of 52 Nm.
CAPITOLO
Secure the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Fit the wheel bay dust-protection shield and tighten the six fastening screws fully, then fasten the
five snap-fit buttons.
CAPITOLO
Tighten the lower fastening screws on the wheel bay dust-protection shield fully.
CAPITOLO
Fit the relative wheel, carrying out the refitting operations only.
Replacing the wheels
N.B.
We recommend you check the wheel alignment data by carrying out the operations outlined in the
specific paragraph
Wheel alignment - Front wheels
CAPITOLO
Unscrew the six fastening screws, and remove the five snap-fit buttons, then remove the wheel bay
dust-protection shield.
CAPITOLO
Release the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Unscrew the fastening bolts on the lower fastening wishbone (lever). Remove the spacers and the
washers, remembering to note down the number of spacers removed and their positions.
CAPITOLO
Unscrew the nut fastening the lever to the pillar (hub carrier).
CAPITOLO
Using the extracting tool shown in the figure, extract the levers tapered pin from the pillar (hub
carrier).
CAPITOLO
Unscrew the bolt fastening the shock absorber to the lower wishbone (lever)
CAPITOLO
CAPITOLO
Using the extracting tool, disconnect the steering tie-rods tapered head from the pillar.
CAPITOLO
N.B.
Place a hydraulic supporting device under the lower wishbone (lever) to ensure it does not reach
its stroke limit during removal as this could impair the operation of the suspension.
Unscrew the fastening nut on the stabilizer bars articulated joint and remove the lower wishbone
(lever).
CAPITOLO
CAPITOLO
Tighten the nut that fastens the lever to the pillar (hub carrier) to torque.
- 63 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- pretighten to 90 Nm, loosen the nut and tighten to 63 Nm; for EUROPE vehicles from assembly
18535 in the left-hand drive version and 17236 in the right-hand drive versions; in addition, for all the USA
CND versions.
CAPITOLO
Tighten the nut that fastens the stabilizer bar's joint to the lower lever to a torque of 50 Nm
CAPITOLO
Tighten the fastening nut on the steering tie-rods tapered head to a torque of 40 Nm
CAPITOLO
Tighten the bolt fastening the shock absorber to the lower wishbone (lever) to a torque of 78 Nm
CAPITOLO
Secure the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Fit the wheel bay dust-protection shield and tighten the six fastening screws fully, then fasten the
five snap-fit buttons.
CAPITOLO
Tighten the lower fastening screws on the wheel bay dust-protection shield fully.
CAPITOLO
Fit the relative wheel, carrying out the refitting operations only.
Replacing the wheels
N.B.
We recommend you check the wheel alignment data by carrying out the operations outlined in the
specific paragraph
Wheel alignment - Front wheels
CAPITOLO
Remove the spacers and the washers, remembering to note down the number of spacers removed
and their positions.
CAPITOLO
CAPITOLO
Using the extracting tool shown, extract the levers tapered pin from the hub carrier.
CAPITOLO
CAPITOLO
CAPITOLO
Tighten the nut fastening the lever to the pillar (hub carrier) to a torque of 52 Nm.
CAPITOLO
Fit the relative wheel, carrying out the refitting operations only.
Replacing the wheels
N.B.
We recommend you check the wheel alignment data by carrying out the operations outlined in the
specific chapter
Wheel alignment - Front wheels
Wheel alignment - Rear wheels
CAPITOLO
CAPITOLO
CAPITOLO
Unscrew the nut and separate the head of the headlight adjustment potentiometer from the lower
lever.
CAPITOLO
Unscrew the nut and, using an extracting tool, separate the tapered head of the toe-in tie-rod from
the hub carrier.
CAPITOLO
Release the electric cable on the wheel revolution sensor from the fastenings on the lower lever.
CAPITOLO
N.B.
Place a hydraulic support device underneath the hub carrier to ensure the entire suspension does
not reach its stroke limit during removal, as this could impair the operation of the suspension.
Unscrew the nut fastening the rear lever to the hub carrier.
CAPITOLO
Rotate the hub carrier in order to fit the extracting tool, then detach the tapered head of the lever
from its seat on the hub carrier.
CAPITOLO
Undo the bolt fastening the lever to the rear chassis and remove the spacers and the washers,
remembering to note down the number of spacers removed and their positions.
CAPITOLO
For vehicles manufactured up to serial number 13199/ chassis n. 14332, proceed as follows.
Undo the remaining bolt fastening the lever to the rear chassis, remove the spacers and the
washers, remembering to note down the number of spacers removed and their positions, then remove
the lower rear lever.
CAPITOLO
For vehicles manufactured up to serial number 13199/ chassis n. 14333, the front fastening on the
lever has been altered, therefore proceed as follows to remove it.
Undo the left-hand threaded nut (1) by unscrewing it anticlockwise, then slide the pin out the rear
section (see direction of the arrow).
Remove the spacers and the washers, remembering to note down the number of spacers removed,
then remove the rear lower lever.
CAPITOLO
CAPITOLO
For vehicles manufactured up to serial number 13199/ chassis n. 14332, proceed as follows.
Tighten the remaining bolt to a torque of 98 Nm.
CAPITOLO
For vehicles manufactured up to serial number 13199/ chassis n. 14333, the front fastening on the
lever has been altered, therefore, proceed as follows for fitting the pin and for tightening it.
IMPORTANT
The pin removed earlier cannot be refitted. Always replace all the components with new parts.
Fit the new pin with the hexagonal head facing the rear of the vehicle, insert the shims removed
earlier, then fit the front cap nut (1).
Tighten the fastening nut (1) to a torque of 35 Nm exerting a counterforce on the hexagonal pin
head (2).
Screw up the fastening without tightening it (3) exerting a counterforce on the hexagonal pin head
(2).
CAPITOLO
CAPITOLO
There are no differences in the refitting stages outlined below, and therefore the steps described
are applicable to all the models manufactured.
Tighten the nut fastening the lever to the hub carrier to a torque of 52 Nm.
CAPITOLO
Position the electric cable on the wheel revolution sensor, fastening it on the lower lever.
Connect the toe-in tie-rod to the hub carrier and tighten the fastening nut to torque.
- 80 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 45 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
Screw the nut on the head of the headlight adjustment potentiometer onto the lower lever.
Fit the stabiliser bar and tighten the fastening nuts to a torque of 24 Nm.
CAPITOLO
Tighten the nuts fastening the small connecting rods to the stabiliser bar to a torque of 50 Nm.
CAPITOLO
CAPITOLO
Unscrew the six fastening screws, and remove the five snap-fastening buttons, then remove the
wheel bay dust-protection guard.
CAPITOLO
Detach the ABS rpm sensors electrical connection and release the wiring from its fastening on the
bodywork.
CAPITOLO
Release the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
CAPITOLO
Using the extracting tool, disconnect the steering tie-rods tapered head from the pillar.
CAPITOLO
Unscrew the nut fastening the lever to the pillar (hub carrier).
CAPITOLO
Unscrew the nuts fastening the front wheels vertical acceleration sensor.
CAPITOLO
Using the extracting tool shown in the figure, extract the levers tapered pin from the pillar (hub
carrier).
CAPITOLO
Unscrew the bolt fastening the shock absorber to the lower wishbone (lever)
CAPITOLO
CAPITOLO
Remove the front wheel hub, complete with bearing and ABS rpm sensor.
CAPITOLO
N.B.
Place a hydraulic supporting device under the lower wishbone (lever) to ensure it does not reach
its stroke limit during removal, as this could impair the operation of the suspension.
Unscrew the nut fastening the lever to the pillar (hub carrier).
CAPITOLO
Using the extracting tool shown in the figure, extract the levers tapered pin from the pillar (hub
carrier).
CAPITOLO
Remove the front pillar (hub carrier) from the front suspension.
CAPITOLO
CAPITOLO
Fit the front wheel hub complete with bearing and ABS rpm sensor, and tighten the fastening
screws to torque.
CAPITOLO
Tighten the bolt fastening the shock absorber to the lower wishbone (lever) to a torque of 78 Nm
CAPITOLO
Fit the fastening nuts for the front wheels vertical acceleration sensor in their seats and tighten
them to a torque of 8 Nm.
CAPITOLO
Tighten the nut that fastens the lever to the pillar (hub carrier) to torque.
- 63 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and
17235 in the right-hand drive versions
- pretighten to 90 Nm , loosen the nut and tighten to 63 Nm ; for EUROPE vehicles from assembly
18535 in the left-hand drive version and 17236 in the right-hand drive versions; in addition, for all the USA
CND versions.
CAPITOLO
Tighten the fastening nut on the steering tie-rods tapered head to a torque of 40 Nm
CAPITOLO
Secure the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Fit the wheel bay dust-protection guard and tighten the six fastening screws fully, then fasten the
five snap-fit buttons.
CAPITOLO
Tighten the lower fastening screws on the wheel bay dust-protection guard fully.
CAPITOLO
Fit the relative wheel, carrying out the refitting operations only.
Replacing the wheels
N.B.
We recommend you check the wheel alignment data by carrying out the operations outlined in the
specific chapter
Wheel alignment - Front wheels
Wheel alignment - Rear wheels
CAPITOLO
Undo the nut fastening the upper lever to the hub carrier.
CAPITOLO
Using the extracting tool shown, remove the levers tapered pin from the hub carrier.
CAPITOLO
Position the tool to remove the axle shaft from the wheel hub. Screwing down the tool screw,
remove the axle shaft from its seat on the hub.
CAPITOLO
Unscrew the nut and, using an extracting tool, separate the tapered head of the toe-in tie-rod from
the hub carrier.
CAPITOLO
Release the electric cable of the wheel rpm sensor from the fastenings on the lower lever.
CAPITOLO
CAPITOLO
Remove the device used to hatch the handbrake cable to the brake shoes.
CAPITOLO
Remove the central pin (not shown) and detach the handbrake cable from the transmission device.
CAPITOLO
Undo the nut that fastens the tie-rod on the stabiliser bar to the hub carrier
Using the same extractor tool as used earlier for the other heads, extract the tapered head on the
stabiliser bar tie-rod from the hub carrier.
CAPITOLO
N.B.
Place a hydraulic supporting device underneath the lower lever to ensure it does not reach its
stroke limit during removal of the hub carrier, as this could impair the operation of the suspension.
Undo the nut that fastens the lower lever to the hub carrier.
CAPITOLO
Rotate the hub carrier in order to fit the extracting tool, then detach the tapered head of the lower
lever from its seat on the hub carrier.
CAPITOLO
Remove the hub carrier/wheel bearing assembly (ABS sensor) and separate the two components
working as described below.
Undo the fastening screw on the ABS sensor electric cable and unscrew the four screws that fasten
the sensor to the hub carrier.
Separate the sensor from the hub carrier.
CAPITOLO
CAPITOLO
IMPORTANT
The components of the rear suspension must be tightened with the vehicle under static load, i.e.:
all fluids up to top level (including fuel) plus 75+75 kg on the front seats.
Fit the hub carrier in its seat, insert the lower levers tapered head and tighten the fastening nut to a
torque of 52 Nm.
CAPITOLO
Fit the handbrake cable hatching device into its seat on the brake shoes.
Attach the electrical connection on the ABS rpm sensor.
Position the electric cable on the wheel rpm sensor in the fastenings on the lower lever.
Tighten the nut fastening the stabiliser bar tie-rod to a torque of 50 Nm.
CAPITOLO
Connect the toe-in tie-rod to the hub carrier and tighten the fastening nut to torque.
- 80 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 45 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
N.B.
After performing the above operating step, remove the hydraulic supporting device positioned
there earlier.
CAPITOLO
Tighten the nut fastening the lever to the pillar (hub carrier) to a torque of 52 Nm.
CAPITOLO
Tighten the nut fastening the wheel hub to the axle shaft to a torque of 275 Nm
CAPITOLO
CAPITOLO
Complete the procedure by performing all the refitting operations for the wheel concerned.
Replacing the wheels
N.B.
We recommend you check the wheel alignment data by carrying out the operations outlined in the
specific chapter
Wheel alignment - Front wheels
Wheel alignment - Rear wheels
CAPITOLO
TOE-IN TIE-ROD
Removing the toe-in tie-rod
Remove the wheel concerned.
Replacing the wheels
Remove the rear shock absorber concerned
Rear shock absorbers
Undo the fastening nut and, using an extractor tool, remove the tapered head on the toe-in tie-rod
from the hub carrier.
Undo the fastening bolt and remove the toe-in adjustment tie-rod.
CAPITOLO
Connect the toe-in tie-rod to the hub carrier and tighten the fastening nut to torque.
- 80 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 45 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
Tighten the bolt that fastens the toe-in adjustment tie-rod to torque.
- 80 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 63 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAPITOLO
CAPITOLO
FRONT WHEELS
Use wheel alignment equipment to measure the vehicle geometry,
which must fall within the following ranges.
Important
Under static load: all fluids up to top level (including fuel) plus 75+75 kg on the front seats.
Tyres
Wheel rims
Camber
Toe-in
Caster
Height
Height 2
Track
Weight
Steering angle
Front
245/45 R18
245/40ZR 19
245/35 ZR20
8.5 x 18 ET52
8.5J X 19
8.5" J X 20"
-030 +/- 010
-2.0 +/- 0.4mm
+348 +/- 020
173+10/-5mm
392+10/-5mm
1587mm
983 kg
Int. 34.0/ext.40.8
Rear
285/40 R18
285/35ZR 19
285/30 ZR20
10.5 X 18 ET50.5
10.5J X 19
10.5" J X 20"
-130 +/- 010
+4.0 +/- 0.4mm
159+10/-5mm
394+10/-5mm
1569.6mm
1136 kg
Ref. figure
3-4
1-2
11
5-6
12-13
7-8
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
Turn the hexagon positioned on the steering wheel tie-rod clockwise or anticlockwise until reaching
the toe-in value indicated in the table. Then tighten the loosened parts to the specified torque.
CAPITOLO
If the value measured by the instrument does not fall within the specified values, adjust the front
wheel camber.
With the vehicle in "static load" conditions, i.e. full of fluids (including fuel) plus 75+75 kg on the
front seats, proceed with adjustment as described below.
Adjust the camber value of the front wheels by acting on the two cams on the tips of the coupling
between the lever and the front frame.
Turn the cams until the instrument measures the value indicated in the table.
During adjustment check that the cams are facing in the same direction.
Then tighten the loosened parts to the specified torque.
CAPITOLO
After adjusting the front camber, proceed with adjusting the toe-in operating as described above.
If the value measured by the instrument does not fall within the specified values, adjust the front
wheel caster.
With the vehicle in "static load" conditions, i.e. full of fluids (including fuel) plus 75+75 kg on the
front seats, proceed with adjustment as described below.
Loosen the fittings that fasten the lever to the frame and act on the shims. If you need to move a shim
from the lever point (1) to the lever point (2), the shims on the other lever point must be moved in the
same way, i.e. moving them from position (3) to position (4) by an equal distance.
Then tighten the loosened parts to the specified torque.
CAPITOLO
After adjusting the front caster value, you must adjust the camber and then the toe-in, operating as
described above.
CAPITOLO
REAR WHEELS
Use wheel alignment equipment to measure the vehicle geometry,
which must fall within the following ranges.
Important
Under static load: all fluids up to top level (including fuel) plus 75+75 kg on the front seats.
Tyres
Wheel rims
Camber
Toe-in
Caster
Height
Height 2
Track
Weight
Steering angle
Front
245/45 R18
245/40ZR 19
245/35 ZR20
8.5 x 18 ET52
8.5J X 19
8.5" J X 20"
-030 +/- 010
-2.0 +/- 0.4mm
+348 +/- 020
173+10/-5mm
392+10/-5mm
1587mm
983 kg
Int. 34.0/ext.40.8
Rear
285/40 R18
285/35ZR 19
285/30 ZR20
10.5 X 18 ET50.5
10.5J X 19
10.5" J X 20"
-130 +/- 010
+4.0 +/- 0.4mm
159+10/-5mm
394+10/-5mm
1569.6mm
1136 kg
Ref. figure
3-4
1-2
11
5-6
12-13
7-8
CAPITOLO
CAPITOLO
CAPITOLO
If the value measured by the instrument does not fall within the specified values, adjust the rear wheel toe-in.
With the vehicle in "static load" conditions, i.e. full of fluids (including fuel) plus 75+75 kg on the front seats,
proceed with adjustment as described below.
Loosen the retaining nut for the rear toe-in tie-rod.
CAPITOLO
Turn the hexagon positioned on the tie-rod clockwise or anticlockwise until reaching the toe-in value
indicated in the table. Then tighten the loosened parts to the specified torque.
CAPITOLO
CAPITOLO
Turn the cams until the instrument measures the value indicated in the table.
During adjustment check that the cams are facing in the same direction.
Then tighten the loosened parts to the specified torque.
CAPITOLO
After adjusting the rear camber value, you must adjust the rear toe-in operating as described above.
CAMBIO ELETTROATTUATO
FRONT chassis
Removing the engine from the front chassis
Unscrew the unions and disconnect the oil lines from the steering box.
Open the clip and release the hydraulic steering oil line.
CAMBIO ELETTROATTUATO
Undo the screws fastening the dehydrator filter bracket to the chassis.
CAMBIO ELETTROATTUATO
Unscrew the lower radiator screws and remove the radiator/dehydrator filter and engine coolant
tank assembly from the chassis.
CAMBIO ELETTROATTUATO
Undo the lower fastening screw on the secondary air system pump, undo the solenoid valve
fastening screw and detach the relative electric connection.
CAMBIO ELETTROATTUATO
Unscrew the fastening nut on the secondary air system vacuum tank.
CAMBIO ELETTROATTUATO
Unscrew the upper fastening screw on the vacuum tank, unscrew the fastening screw on the
pump and remove the secondary air system pump and vacuum tank assembly.
CAMBIO ELETTROATTUATO
Remove the shock absorbers from their seats on the relative suspensions.
CAMBIO ELETTROATTUATO
Unscrew the fastening bolts on the upper levers, unscrew the fastening nut and, using an
extracting tool, separate the tapered head of the steering tie-rod from the hub carrier.
CAMBIO ELETTROATTUATO
Unscrew the fastening bolts on the lower lever, unscrew the fastening nut on the stabiliser bar
head and remove the front left-hand suspension assembly.
CAMBIO ELETTROATTUATO
Undo the screws fastening the steering box to the chassis on the right-hand side, undo the
screws fastening the stabiliser bar to the chassis on the right-hand side.
CAMBIO ELETTROATTUATO
Undo the screws fastening the steering box to the chassis on the left-hand side, undo the screws
fastening the stabiliser bar to the chassis on the left-hand side.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Position the front chassis on the bench or on the supporting tool used for the removal of the
engine.
Fit the steering box and stabilizer bar assembly in its seat on the frame and tighten the screws that fasten
the hydraulic steering box to the frame to a torque of 40 Nm.
Tighten the screws that fasten the stabilizer bar to the frame to a torque of:
- 31 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 40 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CNDversions.
CAMBIO ELETTROATTUATO
Fit the front suspension assembly and tighten the nut fastening the small connecting rod to the
stabiliser bar to a torque of 50 Nm.
Fit the shims removed during disassembly, then tighten the bolts on the lower lever to a torque of:
- 98 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 120 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAMBIO ELETTROATTUATO
Tighten the fastening nut on the steering tie-rods tapered head to a torque of 40 Nm
Fit the shims removed during disassembly, then tighten the bolts on the upper lever to a torque of:
- 78 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and
17235 in the right-hand drive versions
- 120 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and
17236 in the right-hand drive versions in addition, for all the USA CND versions.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Fit the secondary air system pump and vacuum tank assembly and screw up the fastening
screws on the pump and on the vacuum tank.
Screw up the fastening screw on the solenoid valve and attach the relative electric connection.
Fit the radiator/dehydrator filter and engine coolant tank assembly in its seat on the chassis.
Screw up the two screws fastening the dehydrator filter bracket to the chassis.
Connect the oil lines from the steering box and tighten the two unions to a torque of 35 Nm.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
REAR CHASSIS
Removing the rear chassis
Loosen the screws fastening the shock absorber to the body (on both sides).
After positioning a hydraulic lift below the suspension assembly, undo the screw fastening the
shock absorber to the suspension assembly (on both sides).
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
N.B.
When refitting, position the shimming ring in its seat before inserting the shock absorber fastening
screw.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Undo the two fastening screws on the brake caliper, on both sides.
CAMBIO ELETTROATTUATO
Reposition the cross member removed earlier in its seat, together with the gearbox unit, and
loosely fit two fastening screws per side.
CAMBIO ELETTROATTUATO
Undo the fastening screws on the rear chassis on the right-hand side to the bodywork.
CAMBIO ELETTROATTUATO
Undo the fastening screws on the rear chassis on the left-hand side to the bodywork, lower the
hydraulic lift and remove the rear chassis - rear suspension assembly.
CAMBIO ELETTROATTUATO
Fit the rear chassis assembly, complete with the suspensions, on the tool.
Using the hydraulic lift, bring the rear chassis in position with the fastening holes on the four
rubber bushings.
Loosely fit the fastening screws and before proceeding to tighten them, check that the bevel edge
of the metal discs on the rear rubber bushings is facing the stabiliser bar area, as shown in the figure
below.
CAMBIO ELETTROATTUATO
Tighten the screws fastening the door limiting device to the bodywork to a torque of 123 Nm.
CAMBIO ELETTROATTUATO
Lower the hydraulic lift and remove the tool from the lift.
Undo the screws fitted loosely earlier and remove the cross member supporting the gearbox.
Tighten the fastening screws on the brake calipers to a torque of 145 Nm.
CAMBIO ELETTROATTUATO
CAMBIO ELETTROATTUATO
Attach the ABS cable connection from both sides of the vehicle.
CAMBIO ELETTROATTUATO
Fit the washer and the shimming ring and tighten the screw that fastens the shock absorber to the
suspension assembly (on both sides) to torque.
- 196 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and 17235
in the right-hand drive versions
- 98 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and 17236
in the right-hand drive versions in addition, for all the USA CND versions.
CAMBIO ELETTROATTUATO
Tighten the screws that fasten the shock absorber to the bodywork to torque.
- 33.6 Nm for EUROPE vehicles up to assembly no. 18534 in the left-hand drive version and
17235 in the right-hand drive versions
- 25 Nm for EUROPE vehicles from assembly no. 18535 in the left-hand drive version and
17236 in the right-hand drive versions in addition, for all the USA CNDversions.
CAMBIO ELETTROATTUATO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices acknowledge the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
Detach the electrical connector, undo the two fastening nuts and remove the rear vertical
acceleration sensor.
CAPITOLO
CAPITOLO
Undo the lower fastening screws on the wheel bay dust-protection shield.
Unscrew the six fastening screws, and remove the five snap-fit buttons, then remove the wheel bay
dust-protection shield.
CAPITOLO
Detach the sensors electrical connection and release the wiring from the fastening on the
bodywork.
CAPITOLO
Release the electrical wiring from the fastening on the upper wishbone.
CAPITOLO
Unscrew the fastening nuts on the front wheels vertical acceleration sensor, then remove it.
CAPITOLO
Tighten the fastening nuts on the front wheels vertical acceleration sensor to a torque of 8 Nm.
CAPITOLO
Secure the electrical wiring and the oil line from the fastening on the upper wishbone.
CAPITOLO
Attach the sensors electric connection and fasten the wiring to the bodywork.
CAPITOLO
Fit the wheel bay dust-protection shield and tighten the six fastening screws fully, then fasten the
five snap-fit buttons.
CAPITOLO
Tighten the lower fastening screws on the wheel bay dust-protection shield fully.
CAPITOLO
Fit the relative wheel, carrying out the refitting operations only.
Replacing the wheels
CAPITOLO
To remove the vertical acceleration sensor located on the right-hand side of the engine
compartment, proceed as follows.
Rotate the plastic screws fastening the engine compartment fuse box cover by 90, then remove
the cover.
CAPITOLO
Undo the two fastening screws on the engine compartment fuse box.
CAPITOLO
Unscrew the three fastening screws, and remove the engine compartment fuse box mount.
CAPITOLO
Detach the electrical connector, undo the two fastening nuts and remove the vertical acceleration
sensor from the right-hand side of the engine.
CAPITOLO
To remove the vertical acceleration sensor located on the left-hand side of the engine
compartment, proceed as follows.
After removing the engine compartment trim panels, detach the electrical connector, undo the two
fastening nuts and remove the vertical acceleration sensor from the left-hand side of the engine.
CAPITOLO
CAPITOLO
From vehicle serial number 24275 the lateral acceleration and yaw sensor also incorporates the
functions previously performed by the vehicle acceleration and inclination sensor, found under the
centre console.
Only for vehicles equipped with this new yaw sensor (serial number 24275), if you remove, refit or
replace the component, you must run the accelerometer self-calibration procedure using the SD3
diagnostic tester.
Accelerometer self-calibration procedure
When refitting, follow the above procedures in reverse order
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CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
CAPITOLO
IMPORTANT
When fitting, work crosswise and tighten the screws to a torque of 130 Nm, loosen the stud bolts
and retighten them to a torque of 98 Nm.
For vehicles equipped with pressure sensors (optional component), in the event that the system is
not calibrated (further to the replacement of a tyre) the system must be calibrated by pressing the
specific button on the front ceiling light fixture for over 4 seconds (but no longer than 10 seconds).
The system calibration requires 20 minutes at the most, when the vehicle is moving.
The driver will be advised of completion of the calibration on the instrument panel (Calibration
begun).
If you intend to leave the vehicle unused for a lengthy period, we recommend you increase the
tyre inflation pressure to 3.2 bar, to prevent them flattening.
Before using the vehicle, inflate the tyres to the pressure levels recommended by the
manufacturers (2.2 bar front and rear).
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CAPITOLO
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CAPITOLO
IMPORTANT
Even if only one of the components is damaged, the sensor-valve assembly must be replaced.
Before carrying out any interventions on the rim or on the tyre, you must always check whether the wheel
is equipped with a sensor.
Detaching the tyre from the rim without taking the necessary care could irreparably damage the sensor.
IMPORTANT
CAPITOLO
The sensor should not be treated with detergents, solvents or any other harsh products.
Do not use pressurised air or fluids (eg. pulivapor) to clean it.
Take special care not to tear the surface which interfaces with the filter (1) on the sensor's lower surface.
Always replace the sensor if this surface is dirty or torn.
The sealant liquid contained in the anti-puncture spray bottles can damage the sensor. Always replace the
sensor on a wheel which has been repaired in this way.
All of the sensor-valve assembly components must be stored in a clean, dry place.
Clean the area where the sensor makes contact with the wheel rim.
IMPORTANT
Before beginning a new batch of sensors, always use up the components in the old batch as the sensors
have a battery with a limited life-span.
The battery charge range is approximately 80 months. When the battery charge is running low, a warning
light of the tyre pressure monitoring system will come on to indicate a malfunction.
Connect the SD3 tester to check that the malfunction is due to a flat battery.
The pressure sensors have two different operating frequencies, which depend on their distribution markets:
- 433 MHz
- 315 MHz
Dark grey
Light grey
CAPITOLO
Fit the self-locking screw (1) into the sensor hole and tighten the valve (2) giving it two or three turns.
Fit the valve (1) complete with the sensor, into the hole on the wheel rim.
Fit the insulating washer (2) and tighten the nut (3) until it is flush.
CAPITOLO
Fit the rod (1) into the radial hole on the valve and tighten the nut to a torque of 4 Nm.
Remove the rod (1).
CAPITOLO
Press the sensor gently against the rim so that the sensors resting points come into contact with the rim.
Tighten the self-locking screw fully (1) to a torque of 4 Nm.
CAPITOLO
IMPORTANT
For proper operation, there must be contact between the rim and the sensor's resting points. If positioned
differently, the system may not function correctly.
Calibration button
The system calibration button (1) is located on the ceiling light holding the motion sensors, therefore it
cannot be replaced alone, the entire ceiling light must be replaced.
CAPITOLO
CAPITOLO
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CAPITOLO
tightening torques
Description
Torque
25 Nm
4.4 Nm
50 Nm
40 Nm
40 Nm
30 Nm
35 Nm
40 Nm
40 Nm
40 Nm
40 Nm
40 Nm
20 Nm
40 Nm
Product
CAPITOLO
Description
Torque
7.4 Nm
24 Nm
7.4 Nm
4.1 Nm
7.4 Nm
2.6 Nm
2.6 Nm
Product
CAPITOLO
TOOLKIT
Specific Equipment
Description
Code
900027310
900027450
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TITOLO PARAGRAFO
After an acciden
A. VEHICLE TO BE SERVICED DEPLOYED AIRBAG TO BE REPLACED
After an accident, if the car can still be repaired, the following components are to be replaced:
- the deployed airbag module;
- the pretensioners and the belts;
- the electronic control unit only if the collision caused deployment of both pretensioners and airbag,
since data transferred automatically to the Crash memory cannot be cleared. This also causes the
warning lamp on the dashboard to stay on per-manently;
- if only the pretensioners were operated during the crash, control unit replacement is not required
but the error must be cleared from the memory after replacing the pretensioners to keep the crash
memory clear;
- the specific airbag system should be replaced if damaged or faulty cables are found, either through
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TITOLO PARAGRAFO
TITOLO PARAGRAFO
When servicing is completed, thoroughly wash hands with neutral soap. If the eyes or skin have been
exposed to residual pow-der, rinse immediately under running water.
Servicing of front seats of vehicles fitted with airbags is strictly forbidden unless the system is made
inoperative by disconnecting the two battery cables and waiting for 10 minutes.
The metal components of an airbag that has just deployed are very hot. Avoid touching these components
until they have cooled down.
A. NEVER handle the airbag module holding it from cables or the connector on the bottom.
B. Never apply electric current to the airbag, except as specified by installation and servicing
procedures.
C. Airbag modules cannot be serviced. All faulty airbags should be sent back to Maserati.
D. Do not heat the Airbag module for example by welding, hammering, drilling or mechanical
machining operations, etc.
Storage of spares is allowed only with components in their original packing and their temporary
storage is subjected to the same procedure as an undeployed Airbag module removed from the car, i.
e. using a suitable key-locked metal cabinet (shock resistant and provided with grids to allow natural
ventilation inside).
The cabinet shall be provided with suitable warning stickers (DANGER EXPLOSIVES DO NOT USE
NAKED FLAME AC-CESS PERMITTED TO AUTHORISED PERSONNEL ONLY).
Airbags may only be transported in the boot in special containers. Transporting airbags in the
passenger compartment is forbid-den.
If the electric system is serviced, or an anti-theft system or car radio is installed on a vehicle fitted
with airbag, disconnect both terminals (+) and (-) from the battery and insulate them carefully. If the
inflating devices are to be removed, in addition to discon-necting the battery, wait at least 10 minutes
before starting any servicing operation.
Rules of safety for the handling seat belt assembly with electronic pretensioner
Pretensioners are explosive charges and must therefore be handled and stored with care to
prevent any damage or injury (Fig. 143).
Under normal conditions, the pretensioner is triggered only by the electronic control during
collision. A small amount of gas is developed during deployment which mainly contains non-toxic
nitrogen.
The following rules must be STRICTLY complied with for operator safety, to prevent damage to the seat
belt assembly and to meet the laws in force applying to explosives (5th class, group A). Before servicing
the vehicle, disconnect the battery terminals and ISOLATE THEM ACCURATELY; wait 10 minutes before
disconnecting the pretensioner connectors.
A.
B.
C.
D.
TITOLO PARAGRAFO
Be careful to prevent the assembly from falling and avoid any shock.
N.B.
If a pretensioner has fallen from a height exceeding 1 m, it must not be used and is to be returned
to the sup-plier.
In the event of temporary removal for servicing, place them in a locked metal cabinet suitable for
containing explosive charges.
Do not approach the assembly with naked flames, liquids, solvents or lubricants and do not expose
it to temperatures exceeding 110C. With temperatures above 180C the gas generator may self-ignite.
To handle a deployed device, use protective gloves and gog-gles.
Before handling the assembly, ALWAYS let at least 30 minutes elapse before touching it.
Carefully wash hands with soap and water after handling the device.
TITOLO PARAGRAFO
n.b.
In the event of exceptional weather conditions (floods, sea storms, etc.) if water and mud reach
such a level as to affect the device components, it must be replaced.
The pretensioner does not require any servicing and must never be lubricated. Any alteration to its
origi-nal conditions will invalidate its efficiency.
Work on the body
Do not expose the area surrounding the pretensioner (60 70 cm radius) to heavy shocks (e.g.
hammering); if necessary, remove the complete pretensioner assembly.
- If repairs are carried out on different areas than those men-tioned above, just disconnect the battery
terminals and wait for about 10 minutes.
- For painting operations, use radiant lamps in the area sur-rounding the pretensioner; remove the
pretensioner/re-tractor assembly in the case of welding or brazing.
TITOLO PARAGRAFO
TITOLO PARAGRAFO
In the case of collision only from the rear, the airbag is not operated as the vehicle occupants are pushed
backwards and not for-wards towards the steering wheel. Conversely if the vehicle is pushed from behind
against any obstacle, the airbag can deploy only if the second collision is sufficiently violent.
2. Side collision
The airbag is not operated in the case of a side collision. If the vehicle was travelling forwards, the
deceleration rate might cause airbag deployment. However, the system has been designed to be deployed
in the case of front collision, within a deviation angle of +30 to the direction of travel.
3. The Airbag does not deploy unless a collision occurs
Heavy and stringent tests, very often producing heavy damage to the suspensions and body as a
consequence of the stress trans-mitted from uneven or bumpy roads do not result in airbag deployment.
Therefore, the airbag is not deployed during braking, on narrow bends or on uneven and bumpy roads.
4. Persons wearing glasses
In the event of deployment, the airbag impact is designed to be directed towards the head and chest of
passengers, therefore part of the impact could reach the glasses worn by the passenger. However any
possible injury will be consistently less critical than injuries resulting from impact of the head and chest
against the steering wheel or windscreen. For further protection, the Airbag is suitably shaped and hinged
along the break line and it is tightly retrained to prevent fragments or other materials causing injury to
persons.
5. Airbag without belt fastened (with or without pretensioners)
The airbag is an additional restraint device designed to operate in conjunction with safety belts. Therefore,
max. efficiency of the system is achieved with the safety belt fastened. In the case of head-on collision, the
passengers head and chest are protected against the steering wheel, dashboard and windscreen; if the
seat belts are not fastened, serious injuries might result to the knees, legs and wrists.
6. After deployment the airbag is hot
The cushion itself is not hot, while the components inside the module remain hot for a short time.
These components are accessible and can, therefore, cause burns.
7. Fire on a vehicle fitted with Airbag
The airbag is designed to deploy automatically if, in case of fire, vehicle temperature exceeds 150C.
Under this condition the airbag might deploy without exploding or breaking the gas container (or sodium
azide). All the most effective means may be used to extinguish, water included.
8. Crashed car and airbag not deployed
If the airbag did not deploy during the crash, it can no longer explode as the sensors that send the signals
to the control unit are designed to respond only in the case of the heavy stresses developed during a
crash, therefore it is impossible or highly unlikely that these signals can be sent with the vehicle stationary.
To deactivate the airbag, disconnect the battery cables and wait approx. 10 minutes to cut out the backup
TITOLO PARAGRAFO
CAPITOLO
CAUTION
Follow the instructions and the relative safety regulations for removal and storage of the airbag
modules.
Safety regulations for the airbag modules
Undo the screws fastening the lower steering column covering to the upper steering column covering.
Open the retaining tongues, then remove the lower section of the steering column covering.
CAUTION
Take care not to damage or break the retaining clamps.
CAPITOLO
Position the specific tool 900027310 into the holes (1) found on the rear side of the steering wheel.
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CAPITOLO
The tool will exert its action on the two clips (one per side) fastening the Airbag module's pins,
therefore using the tip of the tool, press the clips towards the central area of the steering wheel, until
both pins on the Airbag module are released.
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The tip of the tool works in the clip's area (1). By pressing it downwards (see arrow), you will also
lower the central area automatically (2), so allowing the Airbag fastening pin to be released. Follow the
same procedure for the other fastening clip.
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Remove the airbag module from its seat on the steering wheel and detach the electrical
connections.
Remove the airbag module and handle it with care, respecting the safety regulations.
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Attach the electric connections and fit the Airbag module into its seat on the steering wheel, by
inserting the fastening pins (1) into the two reference holes (2) and verifying that the clips have
properly locked in place (See figure 2).
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Fit the lower section of the steering column covering panel, taking care not to damage the plastic
retaining fins.
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Screw up the screws fastening the lower section of the steering column covering panel to the
upper section of the steering column covering panel.
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
Detach the electrical connection, undo the two fastening screws and remove the passenger
airbag module.
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
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SIDE AIRBAG
Removing - refitting the side airbag
Remove the front seat concerned from the vehicle.
Front seats
Remove the guards from the front seat.
Front seat guards
Remove the upholstery from the seatback on the front seat
Seatback upholstery (front seat)
Detach the electrical connection, undo the fastening nut and remove the side airbag module from
the chassis.
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Undo the fastening nuts, detach the electrical connections and remove the Airbag Node (NAB).
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Open the retaining tongues, then remove the lower section of the steering column covering.
CAUTION
Take care not to damage or break the retaining clamps.
CAPITOLO
Position the specific tool 900027310 into the holes (1) found on the rear side of the steering wheel.
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The tool will exert its action on the two clips (one per side) fastening the Airbag module's pins,
therefore using the tip of the tool, press the clips towards the central area of the steering wheel, until
both pins on the Airbag module are released.
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The tip of the tool works in the clip's area (1). By pressing it downwards (see arrow), you will also
lower the central area automatically (2), so allowing the Airbag fastening pin to be released. Follow the
same procedure for the other fastening clip.
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Remove the airbag module from its seat on the steering wheel and detach the electrical
connections.
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IMPORTANT
Take special care not to damage the trim panels at the removal stage.
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Undo the fastening screw, then remove the upper part of the rear pillar covering panel from its seat.
CAPITOLO
Undo the fastening screw and remove the rear pillar covering panel.
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Move the lower guard and detach the passenger's airbag connector.
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Move the seats backwards and detach the two sidebag's electrical connectors.
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The following screen page will then appear "ATTACH THE CONNECTOR THAT KEEPS LINE 1
OF THE PASSENGER'S AIRBAG SHORT-CIRCUITED". The part number of the fake connector is
900027450. This can be ordered from Maserati's Spare Parts Department.
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Wait until the following screen pages prompt you to remove the fake connector 900027450 and to
attach passenger's airbag connector.
Attach the passenger's airbag connector.
Wait until the following screen pages prompt you to attach the LH and RH headbag connectors.
Subsequently the screen page prompting you to attach the sidebag connectors will be displayed.
Connect the sidebag connectors.
The diagnostic tester will then perform a check of the switches for the front and rear seat belts.
Buckle the seat belts in the following order:
- Front seat, driver's side
- Rear left-hand seat
- Central seat
- Rear seat, passenger's side
- Front seat, passenger's side
CAPITOLO
The diagnostic tester then prompts the user if the passenger airbag manual deactivation device is
fitted.
For USA CDN versions, reply "NO" and continue with the cycle.
For EU versions reply "YES" and continue with the cycle.
For EU versions, perform the requested operations to check that the manual airbag deactivation
device is properly functioning.
The diagnostic tester will then prompt you to check that the airbag warning light on the instrument
panel is off.
When the cycle progress log is displayed, print the document.
Keep the printed document in a safe place.
Refit all the components previously removed to access the airbag system connectors.
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Unscrew the nut fastening the seat belt to the seat belts height adjustment device.
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Remove the fastening clip and slide the pin out of its seat.
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Move the air inlet duct slightly to allow access to the screw, then unscrew the lower fastening screw
on the seat belt.
CAPITOLO
Detach the pre-tensioners electrical connection, then remove the seat belt and pre-tensioner set.
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Position the pre-tensioner and seat belt in the seat on the pillar.
Tighten the screw fastening the pre-tensioner to the pillar to a torque of 40 Nm
CAPITOLO
Tighten the nut fastening the seat belt to the seat belts height adjustment device to a torque of 40
Nm
CAPITOLO
N.B.
Check the fastening clip is intact; if the clip is damaged or warped, replace it with a new one
Place the seat belt against the pillar, fit the pin in its seat and, using the fastening clip, restrain the
seat belt retaining clip.
CAPITOLO
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
http://127.0.0.1:8000/M396_B_E/dt/mo/g/g3_08.htm10/21/2008 8:16:17 PM
CAPITOLO
Move the seat as far forwards as possible, free the rear door bay strip partially and remove the
lower section of the snap-fit central pillar covering panel.
N.B.
Check the five retaining pins on the pillar covering panel are intact and replace any damaged ones
using the specific tool
CAPITOLO
Unscrew the fastening screw and detach the electrical connection, then remove the side impact
sensor.
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Unscrew the nut fastening the seat belt to the seat belts height adjustment device.
Undo the two fastening screws and remove the front seat belt height adjustment device.
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Tighten the nut fastening the seat belt to its height adjustment device to a torque of 40 Nm
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CAPITOLO
CAUTION
Follow the instructions and respective safety regulations for removal and storage of the airbag
modules.
Safety regulations for the airbag modules
Remove the roof trim panel.
Removing-refitting the roof trim panels
Working with care, lever the pin fastening the Windowbag to the bodywork out of its seat.
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Undo the screw fastening the pretensioner to the bodywork (proceed in the same way for the lefthand pretensioner).
Undo the screw fastening the rear seatbelt to the floor, then remove the rear seatbelt and
pretensioner assembly (proceed in the same way for the left-hand pretensioner).
CAPITOLO
N.B.
The procedure outlined above is also applicable to the central seatbelt with the only exception that
the central seatbelt is not fitted with a pretensioner, only a winder, therefore there is no electric
connection.
Undo the fastening screw and remove the hooking section of the rear seatbelts.
CAPITOLO
Tighten the fastening screw on the hooking section of the rear seatbelts to a torque of 40 Nm.
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Tighten the screw fastening the winder or the pretensioner on the rear seatbelts to the bodywork to
a torque of 40 Nm.
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Tighten the lower screw fastening the seatbelts to the floor to a torque of 40Nm.
CAPITOLO
Attach the electrical connection on the rear right- and left-hand pretensioners.
01
01
The ECU processes the signals received from the weight sensors (pressure). Based on the pressure values received,
the ECU is capable of detecting the total weight on the passenger seat.
If the weight is less than or equal to 25 kg, the ECU detects that a child seat may be fitted on the passenger seat, and
the front airbag is therefore deactivated.
If the weight is between 25 kg and 40 kg, the ECU, based on the pressure read by the weight sensors and the type of
impact detected by the pre-contact sensors, decides whether or not to activate the front passenger airbag.
If the weight is more than 40 kg, the ECU detects the presence of an adult and activates the front passenger airbag.
The weight sensors continuously communicate the pressure status detected to the relative ECU, so helping ensure
immediate adjustment of the airbag status depending on the weight variation.
The layout of the components in the weight sensor assembly must NEVER be modified.
MASERATI does not authorize replacement of the components installed as individual parts.
In the event of a faulty component, all the components need to be replaced together.
The weight sensors are safety components and should therefore be treated as such. Carefully read the warnings listed in
the specific chapter.
01
01
Remove the passenger-side mat from the passenger compartment in order to access the screws that fasten the weight
sensor frame.
Undo the front retaining screws and retrieve the two screws and all the washers, taking care to mark their position so
that they can be refitted in the same place.
01
Unscrew the rear fastening nut and retrieve the nut and all the washers, taking care to mark their position so that they
can be refitted in the same place.
Undo the rear retaining screw and retrieve the screw and all the washers, taking care to mark their position so that
01
Detach the electrical connectors for the weight sensor wiring, then remove the entire assembly (this will be supplied as
a single spare part).
01
01
Position the double concave washer (1) and screw down the fastening nut (2) using your hands only.
Position the washers and the fastening screw, of the same type, in the same quantity and following the same
sequence noted during removal, and screw down the rear fastening screw.
01
Position the washers and the fastening screw, of the same type, in the same quantity and following the same
sequence noted during removal, and screw down the rear fastening screw.
01
Place the passenger compartment mat on the weight sensor, positioning it correctly so that it does not interfere with or
affect the weight sensors or the seat.
01
Position a metal guard on the weight sensor assembly, so as to protect it while refitting the other components
previously removed.
01
01
When the weight sensors have been replaced or removed and refitted, the calibration cycle
with the SD3 tester must be performed in order to test proper functioning of the sensors.
Using SD3 Net connected to the SD3 tester, run the PERSONAL COMPUTER
DIAGNOSTIC SOFTWARE RUNNING procedure.
Follow the on-screen instructions and fill in the vehicle data sheet.
The sensor calibration cycle will be interrupted to allow you to move the seat (as indicated on
the screen) for the first data acquisition session.
Position the seat as requested by the system, also fastening the seat belt.
01
Follow the guided procedure, during which the tester will perform a test on the system,
displaying any errors detected.
The program performs a test of all the system components and initialises the ECU if
necessary.
A screen page will then appear and you will be prompted to position a weight of 25 kg on the
front passenger seat for the first acquisition of the data, that will be read and sent to the ECU by
the weight sensors.
01
The data acquired, the occupant class (based on the weight on the seat) and the values
acquired by the four sensors with a maximum tolerance of 1 kg will be then displayed.
01
OCCUPANT CLASS: Type of occupant detected based on the weight on the seat.
TOTAL WEIGHT:
Total weight detected (in this case 25 kg)
The data shown in the boxes relating to the sensors are not significant, since the procedure has been
executed with the vehicle without the 25 kg weight.
Continue the procedure performing the various operations requested by the program.
Change the seat position to perform the second test on the weight sensors, again with 25 kg
positioned on the seat.
Check that the data acquired is correct and within the tolerance range.
Check that the AIRBAG warning light is on and press YES, then continue with the procedure.
01
Change the seat position to perform the third test on the weight sensors, again with 25 kg
positioned on the seat.
Check that the data acquired is correct and within the tolerance range.
Check that the AIRBAG warning light is on and press YES , then continue with the procedure.
Change the seat position to perform the fourth test on the weight sensors, again with 25 kg
positioned on the seat.
Change the seat position to perform the fourth test on the weight sensors, again with 25 kg
positioned on the seat.
Check that the data acquired is correct and within the tolerance range.
Check that the AIRBAG warning light is on and press YES , then continue with the procedure.
The diagnostic cycles on the sensors with 25 kg weight have now been completed. If the data
shown in the tables is correct and therefore the procedure has not been interrupted, the program
then performs the same steps requesting a weight of 40 kg.
01
Follow the guided procedure moving the seat when requested by the program and in the
order illustrated for the tests with 25 kg weight.
At the end of the cycle, whatever the outcome, print the listing with the summary of the data
acquired and keep it in the vehicle logbook.
If the cycle was not completed successfully, check what caused the incorrect procedure.
In addition to the active diagnosis with SD3, it is important to visually inspect that no objects
interfere with the weight sensors.
It is important to check that there are no objects under the seat which may affect the test.
Also check that, as a result of normal wear, the passenger mat has not moved from its
original position. This would cause it to interfere with the side of the seat, creating friction and
hence affecting the test values.
01
TITOLO PARAGRAFO
TITOLO PARAGRAFO
disable or enable passenger airbag deployment if a child heavier than a typical one-year old infant is
seated on the front passenger seat;
deactivate the passenger-side airbag if the nobody is traveling in the front passenger seat or if an object is
placed on top of it (object weight under 75 lbs - 34 kg).
The status of the passenger airbag will be indicated by the warning light PASSENGER AIRBAG OFF (F)
on the roof panel:
- when passenger airbag deployment is disabled, the warning light PASSENGER AIRBAG OFF will be
illuminated;
- when passenger airbag deployment is enabled, the warning light PASSENGER AIRBAG OFF will NOT
be illuminated.
WARNING
Adults should not ride in the front passenger seat if the PASSENGER AIRBAG OFF light is
illuminated.
WARNING
The extra weight applied to the seat during child seat installation might delay correct occupant
classification if the ignition key is in position MAR (ON) when the child seat is being mounted.
After key MAR (ON) the Occupant Classification System will continuously try to classify every object or
person on the front passenger seat in one of two categories: Infant (for which passenger airbag
deployment is dangerous and must be disabled) or Adult (for which passenger airbag deployment is
beneficial and must be provided). Occupants or objects lighter than a typical one-year old child sitting on a
child seat (including an empty seat) will be classified as infant. Occupants or objects heavier than a small
adult will be classified as adult.
If the Occupant Classification System identifies the front passenger as an infant, the passenger airbag
deployment will be disabled and the warning light PASSENGER AIRBAG OFF on the roof panel will be
illuminated.
If the Occupant Classification System identifies the front passenger as an adult, passenger airbag
deployment will be enabled and the warning light PASSENGER AIRBAG OFF will not be illuminated.
WARNING
The system does not disable the front passenger seat belt pretensioner (also known as emergency
tensioning device).
When the key is turned to be MAR (ON) position, the system will require a few seconds to identify the
passenger on the front seat. As long as the system is in the process of classifying the occupant, the
default setting will be infant, to avoid the risk of injuring an infant during this time.
If the Occupant Classification System identifies a change in the classification of the front passenger after
the vehicle is started (for example, if the driver stops without turning off the engine to allow a front
passenger to come in or get out), the system will update the passenger airbag status and the
PASSENGER AIRBAG OFF warning light status accordingly.
Please note that the system will take some time to update the front passenger classification when the
passenger status changes.
If the Occupant Classification System recognizes an internal error, it will signal the airbag control unit that
TITOLO PARAGRAFO
there may be a malfunction, and the control unit will attempt to:
- illuminate the airbag red warning light on the instrument cluster;
- disable the passenger airbag deployment to avoid the risk of injuring an infant, lacking a certain occupant
classification;
- illuminate the PASSENGER AIRBAG OFF warning light on the roof panel.
WARNING
When a passenger is sitting in the front seat:
- always check that no objects are stuck underneath the seat;
- always check that no objects are loose on the floor, either in front, or behind the seat;
- check that no objects contacts the seat;
- instruct the rear occupants not to lean on the front passenger seat, and not to push with their legs
against it;
- make sure the PASSENGER AIRBAG OFF light status is appropriate for the type of occupant (ON for a
child in a rearward-facing child seat, OFF for an adult, either ON or OFF for a child properly secured in a
forward- facing child restraint system).
CAPITOLO
STEERING WHEEL
Removing-refitting the steering wheel
Disconnect the battery's negative terminal.
Position the steering wheel so that the wheels are as parallel to the vehicles longitudinal axis as
possible.
Safety regulations for the airbag modules
CAUTION
Follow the instructions and respective safety regulations for removal and storage of the airbag
modules.
Remove the drivers side airbag module.
Drivers side airbag module
Unscrew the nut fastening the steering wheel to the steering column.
CAPITOLO
Remove the steering wheel taking care to slide it out without damaging the electric wiring.
CAPITOLO
When refitting, follow the above procedures in reverse order taking care to tighten the steering
wheel fastening nut to a torque of 50 Nm
After connecting the batterys negative terminal the following self-learning operations must be
carried out to ensure that certain connected devices recognize the system again:
Refer to section:
Component self-learning in the event of battery disconnection
CAPITOLO
Steering column
Removing the steering column
Detach the electrical connection on the air flow meter and release the two clips from the air filter
housing.
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Release the clips fastening the cover to the air filter housing.
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Undo the screw fastening the air filter housing to the domes' bar.
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Undo the screws fastening the connected devices' pan underneath the windscreen.
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Undo the screws fastening the left-hand pan for the connected devices underneath the windscreen
and remove the pan.
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Undo the screw fastening the steering column to the steering rack.
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Unscrew the nuts fastening the steering column flange to the engine compartment/ passenger
compartment partition panel.
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Undo the screws fastening the steering column to the dashboard mounting crossmember.
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Undo the screws fastening the steering column to the dashboard mounting crossmember and
remove the steering column complete with flange and rubber bushing.
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Tighten the screw fastening the steering column to the steering rack to a torque of 25 Nm
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Using suction equipment, drain the oil from the hydraulic steering fluid tank located in the engine
compartment.
Unscrew the fastening nut on the steering tie-rods tapered head.
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Using the extractor tool, remove the steering tie-rods tapered head from the pillar.
CAPITOLO
Undo the fastening screw and detach the steering column from the steering rack.
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Undo the screws fastening the stabiliser bar to the chassis. Repeat the operation on the opposite
side.
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Undo the nut fastening the small connecting rod to the stabiliser bar. Repeat the operation on the
opposite side.
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Remove the two air intake pipes, disconnecting them from the air inlet and the filter housing.
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Release the springs fastening the air filter housing and remove it.
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Undo the unions and disconnect the two oil lines from the hydraulic steering system, then detach
the electrical connection from the hydraulic steering rack.
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Remove the hydraulic steering rack from the vehicles left-hand wheel bay, taking care not to
damage nearby components.
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Clean the area where the oil lines engage with the hydraulic steering rack carefully, in order to
remove any residual oil.
Tighten the unions to a 35 Nm torque and attach the electrical connection from the hydraulic
steering rack.
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Fit the air filter and relative rack cover, proceeding as described earlier for its removal but in
reverse order.
Tighten the nut fastening the small connecting rod to the stabiliser bar to a torque of 50 Nm.
Repeat the operation on the opposite side.
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Tighten the screws fastening the stabiliser bar to the chassis to a torque of 31 Nm Repeat the
operation on the opposite side.
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Tighten the fastening nut on the steering tie-rods tapered head to a torque of 40 Nm
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N.B.
After detaching them from the tank, plug the two oil lines.
N.B.
Hydraulic steering fluid tank fitted on vehicles up to serial number 24274
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N.B.
Hydraulic steering fluid tank fitted on vehicles from serial number 24275
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Unscrew the union fastening the oil line to the power steering rack and salvage the oil that leaks
out.
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Disconnect the delivery line leading from the tank to the pump.
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Unscrew the union leading from the pump for the delivery line to the power steering rack.
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Lift the hoist and undo the lower fastening screw on the power steering pump.
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Lower the hoist and undo the fastening screw on the automatic belt tensioning device, then
remove the latter.
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Rotate the pulley so that the screw underneath it is accessible, then unscrew it.
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Fit the power steering pump and tighten all the fastening screws to a torque of 25 Nm .
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Tighten the union on the delivery line leading from the power steering rack to the pump to a 35
Nm torque.
CAPITOLO
CAPITOLO
Tighten the fastening screw on the automatic belt tensioning device to a torque of 25 Nm
CAPITOLO
Clean the area where the oil line engages with the hydraulic steering rack carefully, in order to
remove any residual oil.
CAPITOLO
For filling and draining the hydraulic steering oil circuit, see the chapter "Circuit filling and level
checks".
Circuit filling and level checks
CAPITOLO
Fluid check
Hydraulic steering oil circuit
For filling and draining the hydraulic steering oil circuit, see the chapter headed "Circuit filling and level
check".
Circuit filling and level checks
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CAPITOLO
Before carrying out the drainage/recovery operation on the air conditioning/ heating system, take
the safety and prevention measures described in the relative chapter.
Prevention measures and protection devices
Connect the drainage/recovery/refilling equipment to the two unions on the two high and low
pressure air conditioning system lines, then drain the system.
CAPITOLO
Undo the fastening screw on the two lines leading to the air conditioner compressor.
CAPITOLO
Detach the electrical connection on the electromagnetic joint, unscrew the four fastening screws
and remove the air conditioner compressor.
CAPITOLO
Fit the air conditioner compressor and tighten the four fastening screws to a torque of 25 Nm.
Attach the electrical connection on the electromagnetic joint.
CAPITOLO
Connect the two lines to the air conditioner compressor and tighten the fastening screw.
CAPITOLO
CAPITOLO
CAPITOLO
Heater-evaporator unit
Removing the heater-evaporator unit
Before carrying out the drainage/recovery operation on the air conditioning/ heating system, take
the safety and prevention measures described in the relative chapter.
Prevention measures and protection devices
Connect the drainage/recovery/refilling equipment to the two unions on the two high and low
pressure air conditioning system lines, then drain the system.
CAPITOLO
CAPITOLO
Undo the two right- and left-hand screws fastening the mounting frame to the bodywork.
CAPITOLO
Undo the screws fastening the dashboard mounting frame to the floor.
CAPITOLO
Undo the two screws (left-hand side) fastening the dashboard mounting frame to the bodywork.
CAPITOLO
Undo the screw (right-hand side) fastening the dashboard mounting frame to the bodywork.
CAPITOLO
Undo the screws and the nut fastening the dashboard mounting frame to the left-hand bodywork.
CAPITOLO
Undo the screws fastening the mounting frame to the bodywork and to the heater-air conditioning
unit.
CAPITOLO
CAPITOLO
Pull the dashboard mounting frame out of its seat partially and unscrew the fastening nuts on the
dashboard wiring.
CAPITOLO
CAPITOLO
Undo the fastening screws on the air conditioning and heating system node (NCL).
N.B.
Do not detach the electric connections on the air conditioning and heating system node
CAPITOLO
Pull the dashboard mounting frame out of its seat as far as possible, without damaging the wiring
connected to it.
CAPITOLO
CAPITOLO
Unscrew the fastening nuts and screw and remove the two windscreen wipers.
CAPITOLO
Undo the outer edge screws fastening the connected devices' pan cover and remove it. .
CAPITOLO
CAPITOLO
Undo the two upper fastening screws on the windscreen wiper unit.
CAPITOLO
Undo the two lower fastening screws on the windscreen wiper unit, then remove it.
CAPITOLO
CAPITOLO
CAPITOLO
Undo the screws fastening the connected devices' pan underneath the windscreen.
CAPITOLO
Undo the screws fastening the left-hand pan for the connected devices underneath the windscreen
and remove the pan.
CAPITOLO
Undo the fastening screws and disconnect the two high and low pressure lines on the air
conditioning/ heating system from the expansion valve.
CAPITOLO
Disconnect the engine coolant lines from the heater/air conditioning unit.
CAPITOLO
CAPITOLO
Unscrew the three fastening nuts on the flange for the heater unit lines.
CAPITOLO
CAPITOLO
Unscrew the fastening nuts on the flange for the air conditioning/heating unit lines.
CAPITOLO
Pull the air conditioning/heating unit out of its seat partially and disconnect the wiring joint on the air
conditioning/heating system
CAPITOLO
With the help of a second operator, remove the air conditioning/heating system from the passenger
compartment.
CAPITOLO
CAPITOLO
CAPITOLO
Lift and tilt the floor trim panel and the soundproofing material on the floor area.
CAPITOLO
Undo the fastening screws (one per side, one of which is not shown), detach the electric
connections and remove the Air conditioning/heating system ECU.
CAPITOLO
CAPITOLO
ANTI-POLLEN FILTER
Removing-refitting the anti-pollen filter
Remove the cover and the filter, sliding them both downwards.
CAPITOLO
CAPITOLO
Tightening torques
Description
Torque
15
15
10
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11
15
Product
CAPITOLO
CAPITOLO
02 FRONT LH EARTH
15 REAR PASSENGER COMPARTMENT EARTH ON PARCEL SHELF
18 FRONT LH EARTH
CAPITOLO
03 F1 GEARBOX EARTH B
11 EARTH AND F1 GEARBOX
14 RH LUGGAGE COMPARTMENT EARTH
20 F1 GEARBOX EARTH
CAPITOLO
CAPITOLO
07 ABS EARTH
06 AIRBAG EARTH ON PASSENGER COMPARTMENT CABLE
10 FRONT RH ENGINE COMPARTMENT EARTH
CAPITOLO
CAPITOLO
CAPITOLO
Detach the electrical connections and remove the motion sensors mount.
CAPITOLO
CAPITOLO
Loosen the two fastening nuts and take the siren out of the supporting bracket.
CAPITOLO
Detach the electrical connection and remove the alarm system siren.
CAPITOLO
CAPITOLO
CAPITOLO
Undo the screw (1) and remove the battery mount (2).
CAPITOLO
CAPITOLO
CAPITOLO
N.B.
The programming stage cannot be considered complete until the data have been stored; Any keys
not included in this procedure will not be useable.
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CAPITOLO
SUNROOF:
Sunroof closed and key ON
Rotate the selector switch fully to the maximum tilting position (B3 position in the previous figure,
the part of the selector switch with three notches)
press the selector switch and, keeping it pressed, wait for the sunroof to lock mechanically
release the selector switch
within 5 sec. press the selector switch again and keep it pressed
after a few seconds the sunroof will start an automatic cycle (keep the selector switch pressed)
at the end of the movement, the initialization is complete
release the selector switch
CAPITOLO
When the NIT is switched on, the NIT code must be entered:
Using the knob on the right, enter the four-digit code which will enable you to unlock the
navigator.
Switch on IT Node
Before turning the ignition switch to the OFF position (KEY-OFF), wait for the clock to switch
to the time set via the IT node.
CAPITOLO
Set the information that you wish to be displayed on the instrument panel as well:
Rotate the dial on the right to select the VEHICLE SETUP option
Rotate the dial on the right to select the INSTRUMENT PANEL INFORMATION option
Select (ticked boxes) all three sets of information to be repeated on the instrument panel
(AUDIO, NAVI and TELEPHONE)
Travelstore function:
Press the Radio button
Rotate the dial on the right to select the SCANS./TS third option
Press the dial on the right at length (ENTER) until you hear a tone (beep).
Wait until the memorisation of the stations is complete.
CAPITOLO
Insert the navigation CD (remember that: if a Navigation CD has never been inserted in the
NIT, a screen will appear on which the flash memory data will be loaded. Wait for the data loading
to be completed (this will take a few seconds), then press the NAV button
Select ROUTE OPTIONS and confirm quickest route by pressing the encoder dial on the
right (coloured dot).
Select SCREEN MODE and confirm autom. direct. indic. by pressing the encoder dial on
the right (coloured dot)
Select MAP VIEW and confirm TRAVELLING DIRECTION by pressing the encoder dial on
the right (coloured dot).
Select MAP TYPE and confirm CAR POSITION by pressing the encoder dial on the right
(coloured dot).
CAPITOLO
Unscrew the lower fastening nuts (1) on the bracket, unscrew the upper fastening nuts (not visible,
indicated with an arrow), then undo the electrical wiring fastening screw (2).
CAPITOLO
Remove the ECUs - aerials assembly, pulling the electrical wiring out through the hole on the
bodywork and taking care not to damage it.
CAPITOLO
When refitting, follow the above procedures in reverse order remembering to refit the GPS and
GSM aerials and the buzzer in their original position (as marked) and fasten them with doublesided adhesive tape. Check the double-sided adhesive tape holds perfectly and that the
components are fastened properly.
Disconnecting reconnecting the satellite tracking system wiring
Remove the ECUs - aerials assembly, as described earlier.
Remove the adhesive tape and release the DCU/aerials control unit wiring from the GSM module
cable.
CAPITOLO
CAPITOLO
CAPITOLO
Release the two fuse boxes and the electrical connector from the bracket.
CAPITOLO
Undo the four screws and remove the rear DCU module cover.
CAPITOLO
Detach the GSM aerial connector (1) and the GPS aerial connector (2).
CAPITOLO
Detach the GSM aerial connector (1) and the GPS aerial connector (2).
CAPITOLO
Peel off the adhesive tape and detach the connection beneath it, then remove the wiring complete
with the aerials and buzzer.
CAPITOLO
CAPITOLO
CAPITOLO
Undo the four screws and remove the rear DCU module cover.
CAPITOLO
Detach the USB connector (1) on the GSM module from the DCU module.
CAPITOLO
Peel off the adhesive tape and detach the connection beneath it.
CAPITOLO
Undo the screws fastening it to the bracket and remove the GSM module.
CAPITOLO
CAPITOLO
Undo the four screws and remove the rear DCU module cover.
CAPITOLO
CAPITOLO
Release the fastening clips and remove the DCU module from the bracket.
CAPITOLO
CAPITOLO
Open the protective cap and replace the fuse with one with the same specifications.
CAPITOLO
CAPITOLO
For the USA CANADA version, remove the NBC guard, proceeding as follows.
Unscrew the lower fastenings on the Body Computer Node guard.
Extract the pins (1) from the holes fitted with rubber antifriction bushings (2), and remove the Body
Computer Node guard (3).
CAPITOLO
CAPITOLO
Rotate the body computer node, detach the electrical connections on the rear section and remove
the part.
CAPITOLO
If necessary, separate the body computer node (1) from the dashboard node (2).
CAPITOLO
CAPITOLO
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CAPITOLO
Move the front seat on the drivers side as far back as possible
Disconnect the battery's negative terminal.
Remove the protective cover on the suspension control node compartment.
Undo the fastening screw, detach the electric connection and move the suspension control node
out the compartment.
CAPITOLO
CAPITOLO
Pull out the bracket, unscrew the fastening nuts, detach the electric connection and remove the
headlight set-up ECU (CAF).
CAPITOLO
CAPITOLO
Move the front seat on the drivers side as far back as possible
Disconnect the battery's negative terminal.
Remove the protective cover on the suspension control node compartment.
Undo the fastening screw, detach the electric connection and remove the suspension control node
from the relative compartment.
CAPITOLO
CAPITOLO
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CAPITOLO
Undo the fastening screw on the bracket, detach the two electric connections and remove the
engine control node from the relative compartment.
CAPITOLO
CAPITOLO
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CAPITOLO
Fit the steering angle node and complete the operation by refitting all the components previously
removed.
Proceed with calibrating the steering angle sensor.
Connect the SD3 tester to the diagnostic socket.
Position the wheels perfectly straight and lock the steering wheel in this position.
From the SD3 tester, select SERIAL DIAGNOSTICS and then INDIVIDUAL ECU DIAGNOSTICS.
Select the manufacturer and the vehicle model and then the node concerned.
Select ACTIVE DIAGNOSTIC ENVIRONMENT and then launch the calibration procedure.
Drive a distance of 10 metres in a straight line. When the message that calibration has been
performed correctly appears on the SD3 tester, stop the vehicle and remove the SD3.
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CAPITOLO
Unscrew the fastening nuts on the ECU and digital stereo system amplifier holder bracket.
Unscrew the nut, disconnect the electrical connections, then remove the parking sensor node
(NSP).
CAPITOLO
CAPITOLO
Lever the lower part of the weather strip out the drivers door bay.
Remove the screw covering plug on the engine lid opening lever.
CAPITOLO
CAPITOLO
Pull the lever out of the threaded pin without disconnecting the opening cable.
CAPITOLO
CAPITOLO
When removing the corner trim panel from the door, take care not to damage the plastic fastening
pins on the trim panel itself.
CAPITOLO
Undo the two fastening screws and remove the footrest covering.
CAPITOLO
Unscrew the three fastening screws and extract the ECUs' mounting bracket .
CAPITOLO
Unscrew the nuts, detach the electric connection and remove the power steering ECU (CSG).
CAPITOLO
CAPITOLO
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CAPITOLO
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CAPITOLO
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CAPITOLO
Remove the front seat concerned from the vehicle and the relative guards from the front seat.
Front seats
Disconnect the pneumatic lines from the couplings on the massage and ventilation ECU.
CAPITOLO
CAPITOLO
CAPITOLO
Undo the two fastening screws and remove the driver position node (NAG) and the pneumatic
control unit complete with its bracket.
CAPITOLO
With the assembly on the bench, separate the driver position node (NAG) from the bracket and
from the massage function pneumatic control unit.
CAPITOLO
CAPITOLO
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CAPITOLO
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CAPITOLO
CAPITOLO
Lift and tilt the floor trim panel and the soundproofing material on the floor area.
CAPITOLO
Undo the fastening screw, detach the electrical connections and remove the internal roof node NIM
from the seat.
CAPITOLO
CAPITOLO
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CAPITOLO
Lift the internal rear-view mirror until it is released from the joint glued to the windscreen, then
remove it.
CAPITOLO
Detach the electrical connection, open the fastening clips and remove the rain/ twilight sensor ECU.
CAPITOLO
CAPITOLO
Lever the lower part of the weather strip out the drivers door bay.
Remove the screw covering plug on the engine lid opening lever.
CAPITOLO
CAPITOLO
Pull the lever out of the threaded pin without disconnecting the opening cable.
CAPITOLO
CAPITOLO
When removing the corner trim panel from the door, take care not to damage the plastic fastening
pins on the trim panel itself.
CAPITOLO
Undo the two fastening screws and remove the footrest covering.
CAPITOLO
Unscrew the three fastening screws and extract the ECUs' mounting bracket .
CAPITOLO
Unscrew the nuts, detach the electric connection and remove the windscreen wiper control unit
(CTC)
CAPITOLO
CAPITOLO
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CAPITOLO
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CAPITOLO
TV Node (NTV)
Removing - refitting the TV node (NTV)
Remove the upper trim panel in the luggage compartment
Luggage compartment trim panels
Disconnect the electrical connections on the TV node.
Unscrew the fastening nuts and lower the robotised gearbox node without disconnecting the
electrical connections.
CAPITOLO
Unscrew the fastening nuts on the bracket and remove the bracket and TV node assembly.
CAPITOLO
CAPITOLO
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CAPITOLO
Move the front seat on the drivers side as far back as possible
Disconnect the negative terminal of the battery.
Remove the protective cover on the suspension control node compartment.
Undo the fastening screw, detach the electric connection and move the suspension control node
out the compartment.
CAPITOLO
CAPITOLO
Take out the bracket, unscrew the fastening nuts, detach the electrical connection and remove the
tyre pressure node (NTP).
CAPITOLO
CAPITOLO
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CAPITOLO
Tightening torques
Description
Torque
6.0
28
32
7.4
7.4
7.4
15
32
32
7.4
15
7.4
7.4
24
24
7.4
24
24
7.4
Product
CAPITOLO
11
Armrest fastening
7.4
24
24
24
25
25
7.4
2.6
7.4
40
7.4
7.4
7.4
45
25
24
70
24
7.4
24
7.4
25
CAPITOLO
24
CAPITOLO
TOOLKIT
Specific Equipment
Description
Luggage compartment lock set adjustment wrench
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Code
900027320