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Ferrari Challenge Stradale Workshop Manual – PDF DOWNLOAD
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Ferrari Challenge Stradale Workshop Manual – PDF DOWNLOAD
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Ferrari Challenge Stradale Workshop Manual – PDF DOWNLOAD
FERRARI CHALLENGE STRADALE WORKSHOP MANUAL......................................................... 0 0 GENERAL INFORMATION.......................................................................... 2 01 ORGANISATION OF THE MANUAL.............................................................. 2 01.01 CONSULTING THE MANUAL............................................................ 2 01.02 UPDATING - PRINT................................................................. 3 01.03 SYMBOLS.......................................................................... 4 01.04 ABBREVIATIONS AND SPECIAL TERMS.................................................. 5 02 GENERAL INFORMATION..................................................................... 6 02.01 USER OF THE MANUAL............................................................... 6 02.02 SERVICE PROCEDURES............................................................... 7 02.03 USE OF ORIGINAL TOOLS AND SPARE PARTS............................................ 8 02.04 GUARANTEE REPAIRS................................................................ 9 02.05 TIGHTENING TORQUES............................................................... 10 03 SAFETY.................................................................................. 11 03.01 PREVENTION MEASURES AND PROTECTION DEVICES....................................... 11 03.02 DANGEROUS PARTS.................................................................. 12 03.03 DANGEROUS PRODUCTS AND EMISSIONS................................................. 13 04 CAR SPECIFICATIONS...................................................................... 14 04.01 IDENTIFICATION DATA.............................................................. 14 04.02 HOMOLOGATION PLATES.............................................................. 15 04.03 INSTRUCTION PLATES............................................................... 18 04.04 CHILD AIRBAG-SAFETY SYSTEM PLATES................................................ 20 05 SPECIFICATIONS.......................................................................... 23 05.01 PERFORMANCE AND CONSUMPTION...................................................... 23 05.02 DIMENSIONS AND WEIGHTS........................................................... 24 A REFILLING AND MAINTENANCE.................................................................... 25 A1 REFILLING............................................................................... 25 A1.01 CHARACTERISTICS OF THE FLUIDS USED............................................... 25 A1.02 REFILL SERVICING TABLESERVICING TABLE............................................ 26 A2 PROGRAMMED MAINTENANCE PLAN............................................................. 27 A2.01 PROGRAMMED MAINTENANCE PLAN...................................................... 27 A3 MAINTENANCE PROCEDURES.................................................................. 32 A3.01 CHECKING, CHANGING OR REPLACING ENGINE OIL AND FILTERS........................... 32 A3.02 CHECKING AND CHANGING GEARBOX-DIFFERENTIAL OIL................................... 37 A3.03 REPLACING AND CHECKING TIMING SYSTEM BELT TENSION................................ 40 A3.04 CHECKING TENSION AND REPLACING AUXILIARY MEMBER BELTS............................ 51 A3.05 CHECKING AND AND REPLACING SPARK PLUGS........................................... 57 A3.06 CHECKING THE WINDOW-WASHER FLUID LEVEL........................................... 59 A3.07 CHECKING THE THE BLOW-BY SYSTEM PIPES AND CONNECTIONS............................ 60 A3.08 CHECKING THE THE COOLING SYSTEM PIPES AND CONNECTIONS............................ 61 A3.09 CHECKING THE INJECTION AND IGNITION SYSTEM PIPES AND CONNECTIONS................. 62 A3.10 REPLACING THE ACTIVATED CARBON FILTER............................................ 63 A3.11 CHECKING THE OIL LEVEL ON THE F1 GEARBOX......................................... 64 A3.12 REPLACING THE OXYGEN SENSOR...................................................... 65 A3.13 REPLACING THE AIR FILTERS........................................................ 68 A3.14 REPLACING THE THE AIR TEMPERATURE CONTROL SYSTEM FILTER.......................... 70 A3.15 CHECKING EXHAUST EXHAUST SYSTEM CONNECTIONS...................................... 71 A3.16 CHECKING EMISSION LEVELS......................................................... 72 A3.17 TIGHTENING OF NUTS, UNIONS AND CLAMPS............................................ 73 A3.18 CHECKING THE BRAKE SYSTEM FLUID LEVELS........................................... 74 A3.19 CHECKING THE HYDRAULIC STEERING FLUID LEVEL...................................... 77 A3.20 INSPECTING THE THE BRAKING SYSTEM................................................ 78 A3.21 CHECKING THE THE SERVICE BRAKES AND REPLACING PADS............................... 79 A3.22 CHECKING OPERATION OF THE SERVICE PARKING BRAKES AND CONTROL CLEARANCE........... 86 A3.23 CHECKING THE THE SUSPENSION PARTS................................................ 87 A3.24 CHECKING CAR ALIGNMENT........................................................... 88 A3.25 INSPECTING THE AIR TEMPERATURE CONTROL SYSTEM.................................... 89 A3.26 LUBRICATING AND CHECKING HINGES REGISTERS........................................ 90 A3.27 CHECKING THE FASTENING AND OPERATION OF SEATS AND BELTS.......................... 91 A3.28 CHECKING AND RECHARGING THE BATTERY.............................................. 92 A3.29 CHECKING ABSORPTION AND RE-CHARGING THE ALTERNATOR............................... 95 A3.30 CHECKING THE STATE OF THE BOX-TYPE COMPONENTS AND THE CHASSIS.................... 96 A3.31 CHECKING WHEELS AND TIRES........................................................ 97 A3.32 AIRBAG REPLACEMENT............................................................... 98 A3.33 LEATHER INTERIOR TREATMENT....................................................... 99 B ENGINE....................................................................................... 100 B1 INTRODUCTION............................................................................ 100 B1.01 TECHNICAL FEATURES............................................................... 100 B1.02 SPECIFIC EQUIPMENTEQUIPMENT...................................................... 101 B1.03 TIGHTENING TORQUES............................................................... 104 B2 REMOVING COMPLETE ENGINE ASSEMBLY....................................................... 106 B2.01 DISASSEMBLY...................................................................... 106 B2.02 RE-ASSEMBLY...................................................................... 113 B3 COMPONENTS.............................................................................. 117 B3.01 TIMING SYSTEM DRIVING BELTS...................................................... 117 B3.02 CAMSHAFTS-TIMING VARIATORS-PULLEYS............................................... 120 B3.03 CYLINDER HEADS................................................................... 152 B3.04 OIL SUMP......................................................................... 177 B3.05 OIL PUMP......................................................................... 183 B3.06 PISTONS AND CONNECTING RODS...................................................... 194 B3.07 CRANKCASE COVERS AND SUPPORTS.................................................... 213 B3.08 CRANKSHAFT....................................................................... 228 B3.09 CRANKASE AND CYLINDER LINERS..................................................... 236 B3.10 PRESSURE-TIGHTNESS TEST.......................................................... 249 B4 LUBRICATION SYSTEM...................................................................... 250 B4.01 SYSTEM OUTLINE................................................................... 250 B4.02 OIL FILTER....................................................................... 255 B4.03 OIL TANK......................................................................... 256 B4.04 OIL RADIATOR..................................................................... 259 B4.05 OIL AND GAS VAPOUR RECIRCULATION................................................. 262 B5 COOLING SYSTEM.......................................................................... 264 B5.01 SYSTEM OUTLINE................................................................... 264 B5.02 WATER PUMP....................................................................... 266 B5.03 THERMOSTATIC VALVE............................................................... 272 B5.04 WATER RADIATORS.................................................................. 276 B5.05 EXPANSION TANK................................................................... 285 B5.06 OIL-WATER HEAT EXCHANGER......................................................... 286 B5.07 FILLING THE SYSTEM............................................................... 287 B6 FUEL SUPPLY SYSTEM...................................................................... 289 B6.01 FUEL SUPPLY SYSTEM OUTLINE....................................................... 289 B6.02 FUEL VAPOUR EMISSION OUTLINE..................................................... 290 B6.03 FUEL PUMP UNIT................................................................... 293 B6.04 FUEL LEVEL INDICATOR............................................................. 297 B6.05 PRESSURE REGULATOR............................................................... 298 B6.06 ROLL-OVER SHUT-OFF VALVE......................................................... 299 B6.07 FUEL TANK........................................................................ 300 B6.08 MOTOR-DRIVEN THROTTLE BODY....................................................... 306 B6.09 CHECKING THEFUEL SUPPLY SYSTEM PRESSURE SEAL..................................... 308 B7 AIR INTAKE AND EXHAUST SYSTEM........................................................... 309 B7.01 AIR INTAKE SYSTEM OUTLINE........................................................ 309 B7.02 INTAKE MANIFOLD.................................................................. 311 B7.03 AIR INTAKE....................................................................... 317 B7.04 OUTLINE OF THE PNEUMATIC ACTUATING SYSTEM........................................ 319 B7.05 EXHAUST SYSTEM OUTLINE........................................................... 321 B7.06 CATALYTIC CONVERTER.............................................................. 323 B7.07 SILENCER......................................................................... 327 B7.08 EXHAUST MANIFOLD................................................................. 331 C INJECTION-IGNITION........................................................................... 336 C1 SPECIFICATIONS.......................................................................... 336 C1.01 SPECIFICATIONS................................................................... 336 C1.02 SYSTEM DESCRIPTION............................................................... 337 C2 SENSORS................................................................................. 336 C2.01 TIMING SENSOR.................................................................... 338 C2.02 ANGULAR VELOCITY SENSOR.......................................................... 340 C2.03 AIR FLOW METER................................................................... 342 C2.04 COOLANT TEMPERATURE SENSOR....................................................... 343 C2.05 THROTTLE POTENTIOMETER........................................................... 345 C2.06 OXYGEN SENSORS (LAMBDA SENSOR)................................................... 346 C2.07 DETONATION SENSOR................................................................ 348 C2.08 ACCELERATOR PEDAL POSITION SENSOR................................................ 350 C2.09 TANK PRESSURE SENSOR AND VAPOUR INTERCEPTION VALVE............................... 352 C3 ACTUATORS............................................................................... 355 C3.01 FUEL PUMP........................................................................ 355 C3.02 ELECTRO-INJECTORS................................................................ 357 C3.03 COIL............................................................................. 360 C3.04 TIMING VARIATOR CONTROL SOLENOID VALVE........................................... 362 C3.05 EXHAUST BY-PASS SOLENOID VALVE................................................... 363 C3.06 PNEUMATIC ACTUATION SYSTEM SOLENOID VALVES....................................... 365 C3.07 ANTI-EVAPORATION SOLENOID VALVE.................................................. 368 C3.08 SECONDARY AIR PUMP (US version).................................................. 370 C4 PROCEDURES.............................................................................. 372 C4.01 REPLACING THE MOTRONIC ECU....................................................... 372 D CLUTCH - GEARBOX - DIFFERENTIAL.............................................................. 374 D1 GENERAL SPECIFICATIONS.................................................................. 374 D1.01 TECHNICAL FEATURES............................................................... 374 D1.02 SPECIFIC TOOLING................................................................. 378 D1.03 TIGHTENING TORQUES............................................................... 380 D2 DETACHING THE ENTIRE GEARBOX- DIFFERENTIAL UNIT......................................... 382 D2.01 DISMANTLING...................................................................... 382 D2.02 RE-ASSEMBLY...................................................................... 388 D3 CLUTCH.................................................................................. 394 D3.01 REPLACING THE COMPONENTS......................................................... 394 D3.02 SYSTEM BLEEDING.................................................................. 405 D3.03 CLUTCH CONTROL HYDRAULIC SYSTEM.................................................. 406 D4 GEARBOX................................................................................. 407 D4.01 REPLACING THE EXTERNAL COMPONENTS................................................ 407 D4.02 DETACHING RE-FITTING THE GEARBOX SUPPORT MOVABLE FRAME........................... 418 D4.03 GEARBOX OVERHAUL................................................................. 424 D5 DIFFERENTIAL - AXLE SHAFTS.............................................................. 486 D5.01 COMPONENT REPLACEMENT............................................................ 486 D5.02 AXLE SHAFT....................................................................... 503 D6 ELECTRONICALLY-CONTROLLED GEARBOX....................................................... 506 D6.01 INTRODUCTION..................................................................... 506 D6.02 GENERAL FEATURES................................................................. 507 D6.03 REPLACING THE THE ELECTRONIC CONTROL UNIT (TCU).................................. 508 D6.04 OPERATION........................................................................ 509 D6.05 HYDRAULIC SYSTEM................................................................. 510 D6.06 POWER UNIT....................................................................... 513 D6.07 ACTUATORS........................................................................ 517 D6.08 MEASURING SENSORS AND SIGNAL SWITCHES............................................ 523 D6.09 SIGNALS AND CONTROLS............................................................. 529 D6.10 CENTRING THE GEAR SHIFTING-SELECTION ACTUATOR LEVER (FINGER)..................... 531 E STEERING..................................................................................... 534 E1 GENERAL INFORMATION..................................................................... 534 E1.01 TECHNICAL FEATURES............................................................... 534 E1.02 HYDRAULIC SYSTEM OUTLINE......................................................... 535 E1.03 TIGHTENING TORQUES............................................................... 537 E2 COMPONENTS.............................................................................. 538 E2.01 HYDRAULIC STEERING PUMP.......................................................... 538 E2.02 STEERING BOX..................................................................... 544 E2.03 HYDRAULIC STEERING TANK.......................................................... 550 E2.04 COOLING COIL..................................................................... 551 E2.05 STEERING COLUMN.................................................................. 552 E3 PROCEDURES.............................................................................. 560 E3.01 FILLING OF THE HYDRAULIC STEERING PUMP........................................... 560 E3.02 SYSTEM FILLING AND DRAINING...................................................... 561 F SUSPENSION SYSTEMS AND WHEELS................................................................ 563 F1 TECHNICAL FEATURE....................................................................... 563 F1.01 TECHNICAL FEATURES............................................................... 562 F1.02 TIGHTENING TORQUES............................................................... 563 F1.03 SPECIFIC EQUIPMENT............................................................... 564 F2 COMPONENTS.............................................................................. 565 F2.01 HUB-HOLDER-STUB AXLE............................................................. 565 F2.02 WHEEL BEARINGS................................................................... 567 F2.03 SUSPENSION ARMS AND TIE-RODS..................................................... 568 F2.04 FLAMBLOCK - BALL JOINTS.......................................................... 577 F2.05 SHOCK ABSORBERS.................................................................. 586 F2.06 STABILIZER BARS.................................................................. 596 F2.07 WHEEL RIMS....................................................................... 600 F2.08 TYRES............................................................................ 601 F3 PROCEDURES.............................................................................. 603 F3.01 DETACHING THE ENTIRE FRONT SUSPENSION............................................ 603 F3.02 DETACHING THE ENTIRE REAR SUSPENSION............................................. 607 F3.03 REPLACING THE FRONT WHEEL BEARING................................................ 612 F3.04 REPLACING THE REAR WHEEL BEARING................................................. 616 F3.05 CHECK AND ADJUSTMENT OF WHEEL ALIGNMENT.......................................... 620 F3.06 WHEEL REPLACEMENT................................................................ 622 F3.07 WHEEL BALANCING.................................................................. 623 F4 VARIABLE-SETTING SHOCK ABSORBER ADJUSTMENT SYSTEM....................................... 624 F4.01 SYSTEM........................................................................... 624 F4.02 SYSTEM COMPONENTS................................................................ 625 G BRAKING SYSTEM............................................................................... 629 G1 GENERAL INFORMATION..................................................................... 629 G1.01 TECHNICAL SPECIFICATIONS......................................................... 629 G1.02 SYSTEM OUTLINE................................................................... 630 G1.03 TIGHTENING TORQUES............................................................... 631 G2 COMPONENTS.............................................................................. 632 G2.01 SERVO BRAKE PUMP................................................................. 632 G2.02 BRAKE FLUID TANK................................................................. 634 G2.03 PEDAL BOARD...................................................................... 636 G2.04 BRAKE CALIPERS................................................................... 640 G2.05 BRAKE DISCS...................................................................... 641 G2.06 HAND BRAKE....................................................................... 643 G2.07 ABS ASR ELECTRO-HYDRAULIC UNIT................................................... 646 G3 PROCEDURES.............................................................................. 650 G3.01 REPLACING THE SERVICE BRAKE CALIPERS............................................. 650 G3.02 FILLING AND DRAINING OF THE BRAKE SYSTEM......................................... 654 G3.03 REPLACING THE HAND BRAKE PADS.................................................... 656 G3.04 REPLACING THE HAND BRAKE CALIPER................................................. 658 G3.05 HAND BRAKE ADJUSTMENT............................................................ 660 G3.06 ADJUSTING THE BRAKE PEDAL AND BRAKE SWITCH POSITION.............................. 661 H INSTRUMENTS AND CONTROLS..................................................................... 667 H1 INSTRUMENTS............................................................................. 667 H1.01 INSTRUMENT PANEL................................................................. 667 H1.02 WARNING LIGHTS................................................................... 673 H1.03 MULTI-FUNCTION DISPLAY........................................................... 678 H1.04 BUTTONS FOR ADJUSTING FUNCTIONS AND INSTRUMENTS.................................. 683 H2 CONTROLS................................................................................ 686 H2.01 LOCATION IN THE CAR.............................................................. 686 H2.02 IGNITION SWITCH.................................................................. 688 H2.03 SWITCHES PUSH-BUTTONS............................................................ 690 H2.04 DOOR CONTROLS.................................................................... 696 H2.05 POWER WINDOWS.................................................................... 699 H2.06 STEERING WHEEL................................................................... 703 H2.07 STEERING WHEEL LEVERS............................................................ 706 H2.08 REAR VIEW AND WING MIRRORS....................................................... 712 H2.09 INTERNAL LIGHTING AND CLOCK...................................................... 714 H2.10 HAND BRAKE LEVER................................................................. 716 H2.11 GEARSHIFT LEVER.................................................................. 720 H2.12 ACCELERATOR CONTROL.............................................................. 721 H2.13 OPENING DEVICES FOR THE ENGINE LUGGAGE COMPARTMENT LIDS AND FOR THE FUEL TANK.... 724 H2.14 SEAT CONTROL..................................................................... 737 H2.15 STEREO SYSTEM.................................................................... 739 H3 SAFETY SYSTEMS.......................................................................... 745 H3.01 ALARM SYSTEM..................................................................... 745 H3.02 AIRBAG........................................................................... 751 H3.03 SEATBELTS........................................................................ 761 H3.04 INERTIA SWITCH................................................................... 773 H3.05 EXTINGUISHER (Optional).......................................................... 775 I AIR CONDITIONING............................................................................. 776 I1 SYSTEM.................................................................................. 776 I1.01 SYSTEM OUTLINE................................................................... 776 I1.02 CONTROLS......................................................................... 778 I1.03 TIGHTENING TORQUES............................................................... 784 I2 COMPONENTS.............................................................................. 785 I2.01 COMPRESSOR....................................................................... 785 I2.02 CONDENSER........................................................................ 791 I2.03 DEHYDRATOR FILTER................................................................ 792 I2.04 PRESSURE SWITCH.................................................................. 794 I2.05 EXPANSION VALVE.................................................................. 798 I2.06 HEATER EVAPORATOR................................................................ 801 I2.07 PROPORTIONAL VALVE (TGK)......................................................... 808 I2.08 RECIRCULATION PUMP............................................................... 810 I2.09 SENSORS.......................................................................... 811 I2.10 ELECTRONIC CLIMATE CONTROL UNIT.................................................. 814 I3 SYSTEM MAINTENANCE PROCEDURES........................................................... 815 I3.01 SYSTEM DRAINING.................................................................. 815 I3.02 SYSTEM FILLING................................................................... 817 L ELECTRICAL SYSTEM............................................................................ 818 L1 GENERAL INFORMATION..................................................................... 818 L1.01 SPECIFICATIONS................................................................... 818 L1.02 KEY-OPERATED CIRCUITS............................................................ 819 L1.03 LIGHTS........................................................................... 820 L1.04 TIGHTENING TORQUES............................................................... 821 L2 COMPONENTS.............................................................................. 822 L2.01 BATTERY.......................................................................... 822 L2.02 MASTER BATTERY SWITCH............................................................ 823 L2.03 GENERATOR........................................................................ 825 L2.04 STARTER MOTOR.................................................................... 829 L2.05 WINDSCREEN WIPER MOTOR........................................................... 832 L2.06 HEAD LIGHTS...................................................................... 836 L2.07 REAR LIGHTS...................................................................... 843 L2.08 SIDE INDICATORS.................................................................. 846 L2.09 ECUS............................................................................. 847 L2.10 FUSES AND RELAYS BOXES........................................................... 848 L2.11 HORN............................................................................. 862 L2.12 DIAGNOSIS TESTER PLUG-IN......................................................... 863 L3 OPERATIONS AND CHECKS................................................................... 862 L3.01 CHECKING THE ELECTRICAL SYSTEM ABSORPTION........................................ 864 L3.02 CHECKING THE BATTERY CHARGE LEVEL................................................ 865 L3.03 RECHARGING THE BATTERY........................................................... 867 L3.04 HEADLIGHT AIMING................................................................. 870 M BODYWORK PARTS............................................................................... 872 M1 GENERAL INFORMATION..................................................................... 872 M1.01 TIGHTENING TORQUES............................................................... 872 M2 OUTSIDE PARTS........................................................................... 874 M2.01 ENGINE COMPARTMENT LID........................................................... 874 M2.02 LUGGAGE COMPARTMENT LID.......................................................... 885 M2.03 FRONT BUMPER..................................................................... 888 M2.04 REAR BUMPER...................................................................... 892 M2.05 WHEELHOUSE....................................................................... 896 M2.06 WINDSCREEN....................................................................... 898 M2.07 WINDSCREEN WIPERS................................................................ 905 M2.08 WINDSCREEN WASHER................................................................ 906 M2.09 REAR WINDOW...................................................................... 909 M2.10 QUARTER WINDOWS.................................................................. 912 M2.11 DOORS............................................................................ 917 M2.12 UNDERFLOOR PARTS................................................................. 937 M2.13 ENGINE COMPARTMENT GUARDS........................................................ 944 M2.14 HEADLIGHT WASHERS (Optional)..................................................... 946 M2.15 REAR LIGHT SUPPORT COVERING...................................................... 950 M2.16 FUEL TANK FILLER NECK............................................................ 954 M2.17 FUEL TANK CAP FLAP............................................................... 956 M2.18 DOOR RING STRIPS AND COVERING.................................................... 959 M2.19 FIXED LEXAN WINDOW WITH SLIDING UNIT (optional).................................. 965 M3 INTERNAL COMPONENTS..................................................................... 950 M3.01 DASHBOARD........................................................................ 987 M3.02 TUNNEL........................................................................... 996 M3.03 SEATS............................................................................1000 M3.04 PASSENGER COMPARTMENT AND ROOF LINING............................................1003 M3.05 ENGINE INSPECTION LID............................................................1014 M3.06 LUGGAGE COMPARTMENT LINING.......................................................1016 M4 PAINTING................................................................................1019 M4.01 RE-PAINTING CYCLES AT THE WORKSHOP...............................................1019 M4.02 TOUCH-UP TECHNOLOGIES............................................................1021 M4.03 PREPARATION AND PAINTING OF BUMPERS WITH SMC TECHNIQUE...........................1023 M4.04 PAINTING.........................................................................1024 M4.05 APPLYING THE TRICOLOUR ADHESIVE STRIP............................................1026