Maserati GRANTURISMO MC Service Manual Download Page 2

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MASERATI GRANTURISMO MC TROFEO/GT4

SERVICE MANUAL

Ver 1.0 2/16

Index

1. Contacts

2. Introduction

3. Maintenance Check List

4. Fluids and Lubricants

5. Dimensions and Weight

6. Engine

6.2 Maintenance Procedures (engine)

p10

7. Transmission

p15

7.2 Clutch

p18

7.3 Maintenance Procedures (gearbox)

p19

8. Brakes

p33

9. Setup

p38

11. Suspensions

p61

12. Wheels

p73

13. Cockpit

p74

14. Fuel System

p82

15. Electric System

p87

16. GT4 Upgrade kit 2016

p97

17. Specific Maintenance Tools

p97

Summary of Contents for GRANTURISMO MC

Page 1: ...M MA AS SE ER RA AT TI I G GR RA AN NT TU UR RI IS SM MO O M MC C SERVICE MANUAL...

Page 2: ...d Lubricants p7 5 Dimensions and Weight p8 6 Engine p9 6 2 Maintenance Procedures engine p10 7 Transmission p15 7 2 Clutch p18 7 3 Maintenance Procedures gearbox p19 8 Brakes p33 9 Setup p38 11 Suspen...

Page 3: ...880 E mail roberto bozzi maserati com 1 3 Spare parts Name Alberto Ballarini Address Viale Ciro Menotti 322 41121 Modena MO ITALY Telephone 39 059 866 3170 Mobile 39 366 904 3688 E mail alberto ballar...

Page 4: ...cified service interval If the replacement frequency is not specified the part need to be replaced in case of defective abnormal wear found at the scheduled check Description Check Interval Notes Reco...

Page 5: ...5000 km Rear 2000 km Replace in case of excess of freeplay Rear toe rod 500 km Check if loose the stud on the hub carrier In case the stud is loose replace with new bushing and new stud In case of ex...

Page 6: ...ions 10000 km Brake disk bell Check at every discs replacement 5000 km Replace nuts at every disc replacement Cooling systems Water radiator 10000 km Gearbox oil radiator 10000 km Fuel Tank Refuelling...

Page 7: ...uid Shell Glycoshell BS 6580 AFNOR NFR 15 601 ASTM D 3306 5000 km check level every 2000 km Engine Lubricant Shell Helix Ultra Racing 10w60 SAE 10W 60 API SJ CF 5000 km check level every 500 km Brake...

Page 8: ...ang rear Homol Form 10 mm 1064 Front track Homol Form 15 mm 1680 Rear track Homol Form 15 mm 1630 5 2 Weight The weight of the car as supplied may vary due to manufacturing tolerances The average mini...

Page 9: ...ed water with pH 6 0 20 glycol quantity approx 12 5 liters from a completely empty car and engine Max level mark on water tank o Thermostat 86 C available for cold or night events Lubricating system o...

Page 10: ...t follow the 6 2 2 Oil level check procedure 2 Be sure that the engine has got enough water and that there s fuel in the tank 3 Connect a jump battery 4 Turn on the car MAIN switch 5 Wait 2 sec 6 Turn...

Page 11: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 11 Ver 1 0 2 16 o Remove and clean the flexible stick o Introduce the flexible stick into the hollow cylinder...

Page 12: ...level check hose Make sure to introduce slowly the flexible stick especially when the hollow cylinder is close to check hose o Remove the flexible stick an keep it in the flat position in order to ma...

Page 13: ...iary belt only check o The procedure should be done only with the engine stopped and completely cool Engine Water temperature TAir environment o Tension measuring by vibration control Hz in the point...

Page 14: ...fixed but if the hole tolerance of the screw block is moved you can have a good result of the setting details in the picture below o Repeat the procedure after an engine belt replacement Water pump b...

Page 15: ...e following table Gear Input shaft Output shaft Gear Ratio Z1 Z2 Z1 Z2 1st 14 45 14 45 0 311 2nd 20 41 20 41 0 488 3rd 23 33 23 33 0 697 4th 31 34 31 34 0 912 5th 31 28 31 28 1 107 6th 37 28 37 28 1 3...

Page 16: ...14 45 14 45 14 45 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 20 50 80 110 140 170 200 230 260 290 Speed km h RPM GT4 Trofeo 1 1 1 1 11 46 11 46 Final Drive Bevel Gear 31 28 31 28 37 28 37...

Page 17: ...pictures Unscrew and remove the cap Check that the oil level reaches the inspection hole with the car on a flat surface If needed oil can be added through the same hole until reaching the level Oil ca...

Page 18: ...rk on the flywheel 1 maximum flywheel unbalance position opposite to the sign 2 maximum clutch unbalance position shown on the clutch Position the centring shaft 900026250 on the clutch Remove the com...

Page 19: ...2 7 3 3 to complete the clutch bleeding and the self setting gearbox procedures 7 3 Gearbox Procedures 7 3 1 First gearbox start up procedure Follow this procedure before the start of the track activi...

Page 20: ...procedure every time the clutch is replaced or the high pressure quick connect of the clutch actuator system is disconnected first picture below o Lift up the car minimum 50 cm from the ground in orde...

Page 21: ...16 o Open the power unit cap tank and refill the tank of oil o Connect to the OBD connector the Diagnosis tool o Turn ON the car MAIN switch o Turn ON the ignition switch o Launch on the PC the Waycon...

Page 22: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 22 Ver 1 0 2 16 o Click on the green button o Click on the 1 Grey Button Esecuzione diagnosi...

Page 23: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 23 Ver 1 0 2 16 o Click on Start Button o Click on Start Button...

Page 24: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 24 Ver 1 0 2 16 o Select the line Spurgo attuatore frizione and click Start button...

Page 25: ...the procedure o Click OK button when the pump will start running the mechanic has to open the nipple to allow the air bleeding and then close the nipple when the actuator pump is still running See the...

Page 26: ...f setting gearbox procedure Follow this procedure every time you replace the clutch the gearbox or the gearbox TCU o Connect the Diagnosis tool to the OBD connector o Turn ON the car MAIN switch o Tur...

Page 27: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 27 Ver 1 0 2 16 o Click on the green button o Click on the 1 Grey Button Esecuzione diagnosi...

Page 28: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 28 Ver 1 0 2 16 o Click the Start Button o Click the Start Button again...

Page 29: ...he procedure will take 4 to 8 minutes If the procedure time is over 12 14 minutes it need to be aborted and repeated again It may happen to repeat the 1 2 4 Air bleed procedure on the clutch actuator...

Page 30: ...2 16 o Select AUTOAPPRENDIMENTO or SELF LEARNING eng version and click on Start o Click Ok After 2 sec the gearbox engages all gears automatically It s recommended to slightly move back and forth the...

Page 31: ...4 SERVICE MANUAL 31 Ver 1 0 2 16 The third part of the self setting will be AUTOAPPRENDIMENTO CAMBIATA VELOCE or FAST SHIFT SELF LEARNING eng version o Select AUTOAPPRENDIMENTO CAMBIATA VELOCE or FAST...

Page 32: ...ick Ok After 2 sec the gearbox starts to engage all gears automatically o At the end of this procedure Turn OFF the ignition switch Turn OFF the car MAIN switch Wait minimum 20 sec Turn ON the car MAI...

Page 33: ...torques of bleeding nipples Cold brakes 12 16 Nm Hot brakes 8 10 Nm Tightening torque of the brake line fitting to caliper with copper seal is 23 26 Nm Tightening torque of calipers to the hub carrier...

Page 34: ...rt Number Thickness Recommended wear min thk Front 259260 B24 25 170 25 mm 15 mm 10 mm Rear 259261 B24 20 170 20 mm 10 mm 10 mm NOTE New Brake pads fitting When installing the new front brake pads smo...

Page 35: ...50 bar front 40 bar rear easy adjustable by looking at the pressure values displayed on the right side of the dashboard when pushing on the brake pedal 8 4 1 Master cylinders Standard equipment FRONT...

Page 36: ...e fluid tanks are installed in the engine compartment The heat protection shield shown in the picture is recommended 8 4 3 Balance Bar The balance bar should be adjusted following the attached drawing...

Page 37: ...are when released but it has to be under load 8 4 4 Balance knob The balance knob is located on the central console as shown in the picture The brake balance can be modified by turning the knob as fol...

Page 38: ...me equal to 236 mm spring platform Rear mm measured on the circolar profile fixing point rear subframe equal to 150 mm spring platform Total Dist Ballast Differential Brembo RB170 Engine RPM Limit Gea...

Page 39: ...may be checked by mean of a standard electronic setup bench for road cars It is recommended not to modify it unless extreme deviation 2 from the nominal is found Adjustment could only be done by chan...

Page 40: ...head and the stem is fully out and 180 being the position where it is fully in The camber angle values are theoretical values but because of the manufacturing tolerances the actual values may differ u...

Page 41: ...TI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 41 Ver 1 0 2 16 Position Angle Camber decimal Front Rear 0 4 25 3 75 45 4 0 3 5 60 3 9 3 4 75 3 7 3 2 90 3 50 3 105 3 3 2 8 120 3 1 2 6 135 3 0 2 5 180 2 75...

Page 42: ...pin axle and it is adjusted on the hub side only The thread pitch is 1 5 mm thus one turn means 1 5 mm change in length Screwing in the thread shortening the link entails a positive change toe in The...

Page 43: ...ecification without the 25 mm spacers on the wheel hub Positive wheel travel bump 9 3 1 Toe vs Wheel Travel Positive Toe In 3 50 3 00 2 50 2 00 1 50 1 00 0 50 0 00 35 30 25 20 15 10 5 0 5 10 15 20 25...

Page 44: ...Positive Toe Out 4 50 4 00 3 50 3 00 2 50 2 00 1 50 1 00 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 Camber Wheel Travel mm Camber vs Wheel Travel Front 4 00 3 50 3 00 2 50 2 00 1 50 1 00 0 50 40 35...

Page 45: ...50 5 00 5 50 6 00 6 50 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 Caster Wheel Travel mm Caster vs Wheel Travel Front 9 3 4 King Pin vs Wheel Travel 13 50 14 00 14 50 15 00 15 50 16 00 16 50 17 00...

Page 46: ...2 805 6 806 0 806 4 806 8 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 Half track mm Wheel Travel mm Half track vs Wheel Travel Front 788 0 788 2 788 4 788 6 788 8 789 0 789 2 789 4 789 6 789 8 790 0...

Page 47: ...80 1 370 1 360 1 350 1 340 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 Wheel Spring Ratio Wheel Travel mm Wheel Spring Ratio vs Wheel Travel Front 1 180 1 175 1 170 1 165 1 160 1 155 1 150 1 145 1 140 1...

Page 48: ...VICE MANUAL 48 Ver 1 0 2 16 9 3 7 Wheel ARB Ratio vs Wheel Travel 3 250 3 300 3 350 3 400 3 450 3 500 3 550 3 600 3 650 3 700 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 Wheel ARB Ratio Wheel Travel mm...

Page 49: ...80 0 70 0 60 0 50 0 40 0 30 0 20 0 10 0 0 0 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 Roll Centre Height Wheel Travel mm Roll Centre Height vs Wheel Travel Front 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0...

Page 50: ...50 5 55 5 60 5 65 5 70 5 75 5 80 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 Antidive Wheel Travel mm Antidive kinematic vs Wheel Travel Front 7 10 7 05 7 00 6 95 6 90 6 85 6 80 6 75 40 35 30 25 20...

Page 51: ...0 45 40 45 60 45 80 46 00 46 20 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 Antidive Wheel Travel mm Antidive dynamic vs Wheel Travel Front 23 20 23 40 23 60 23 80 24 00 24 20 24 40 40 35 30 25 20 15...

Page 52: ...80 5 75 5 70 5 65 5 60 5 55 5 50 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 Antisquat Wheel Travel mm Antisquat kinematic vs Wheel Travel Rear 63 50 64 00 64 50 65 00 65 50 66 00 66 50 67 00 67 5...

Page 53: ...5 51 60 00 2 36 260 1484 00 56 896 2 24 14820 3330 00 1 39 3 06 120 60 320 120 4 75 60 00 2 36 320 1826 59 50 038 1 97 16000 3595 65 1 35 2 98 120 60 360 120 4 75 60 00 2 36 360 2054 92 48 006 1 89 17...

Page 54: ...load Length Position mm turns MAX Empty MAX Vuoto 140 60 260 123 25 124 16 125 06 331 1 17 0 11 5 511 52 513 33 113 8 116 2 120 60 320 106 39 107 13 107 86 115 0 512 4 348 1 15 6 10 5 511 69 513 16 1...

Page 55: ...dard spec Refer to 2016 GT4 Homologation sheet for optional adjustable shocks Maserati GranTurismo MC Trofeo Front MAS2 0 100 300 1450 3920 4475 0 140 345 1475 1810 2025 4885 2215 3000 2500 2000 1500...

Page 56: ...Ver 1 0 2 16 Maserati GranTurismo MC Trofeo Rear MAS3 0 85 255 1260 3245 3705 0 130 310 1255 1630 1865 4070 2075 2500 2000 1500 1000 500 0 500 1000 1500 2000 2500 3000 3500 4000 4500 0 0 13 0 26 0 39...

Page 57: ...55 15 390 20 810 25 4000 measurement of characteristic without consideration of hysteresis average value bumper guided on piston rod diameter 15 mm during measurement outer diameter of bumper not guid...

Page 58: ...to the bump stop the car is running with the following packers Front 15 mm totally 12 3 see the picture below Rear 10 mm see the picture below It s recommended to have all packers installed in order...

Page 59: ...e anti roll bar is available Maserati P N 239268 It is a 26 outside diameter 17 6 inside diameter hollow bar 9 6 2 Rear Anti Roll Bar The standard Trofeo spec rear antiroll bar is 25 x 1 5 mm The 2016...

Page 60: ...equipped with a hydraulic power assisted steering rack The power assistance is electronically controlled speed dependent The control characteristic cannot be modified but the electro valve may be dis...

Page 61: ...to Subframe R 240876 203795 M14x1 5 A 120 116 156 Upper Arm to Subframe Tab 10312 1 59779 34 203795 M14x1 5 A 120 116 156 Steering Link to Hub Carrier 102742 M10x1 2 5 A 40 39 52 Steering Link Lock N...

Page 62: ...6 Lower Arm to Subframe R 240874 203795 M14x1 5 A 120 116 156 Upper Arm to Subframe Tab 10312 1 55413 34 102825 M12x1 2 5 A 98 95 127 Toe Link to Subframe Tab 10357 03 1 63240 34 203657 M10x1 2 5 A 63...

Page 63: ...11 2 1 Front Suspension The bushings of the suspension arms should be assembled as in the photos below Remember to apply grease driveshaft or ball bearing grease between the bushing and the inner ste...

Page 64: ...w Assemble the nuts with medium strength blue thread locker Tighten with the specified torque Check that the suspension assembly moves freely by hand Pull the lower arm towards the rear and locate the...

Page 65: ...reely by hand Pull the lower arm towards the front and locate the contact point Apply spacers as needed to fill the clearance on the other side of the joint Insert spacers on the other joint on both s...

Page 66: ...pered coupling of the arm in the bushing on the hub carrier Fit a socket wrench in the hexagonal seat on the arm threaded pin Holding the threaded pin still tighten the adjustment nut to a torque of 6...

Page 67: ...socket wrench in the hexagonal seat on the arm threaded pin Holding the threaded pin still tighten the adjustment nut a to a torque of 63 Nm Fully unscrew the adjustment nut and fit a new arm fastenin...

Page 68: ...Rear Hub Carrier Install the rear tie rod on the rear hub carrier following the scheme below Fit the upper arm in its seat on the hub carrier Fit the washer and screw on an adjustment nut to be used...

Page 69: ...djustment nut and fit a new arm fastening nut on the threaded pin Tighten the fastening nut to a torque of 63 Nm Fit the lower arm in its seat on the hub carrier Fit the washer and screw on an adjustm...

Page 70: ...readed pin Tighten the fastening nut to a torque of 63 Nm 11 3 3 Wheel spacers The car is equipped with wheel spacers to increase the track with the same thickness 25mm but with a different tolerance...

Page 71: ...g on the lower front subframe To avoid the replacement of the entire subframe install a specific plate on both sides as shown below The installation of the metal plate requires the replacement of the...

Page 72: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 72 Ver 1 0 2 16...

Page 73: ...ront 20092 Michelin 31 71 13 Rear Pirelli 305 660 11 Front 20873 Pirelli 325 705 13 Rear 21943 Notes 1 Estimated data 2 Measured data Measurements between 300 and 800kg of vertical load and between 50...

Page 74: ...0 2 16 13 Cockpit 13 1 Steering wheel commands Label Function of the control switch Label Function of the control switch 1 gear down shift paddle 4 gear up shift paddle 2 flash button 5 pit limiter bu...

Page 75: ...g fan not working 3 rain light switch 9 lights switch 4 direction indicator 10 windscreen heater defroster 5 main breaker switch 11 Brake cooling fan not working 6 fuel consumption reset button 12 fir...

Page 76: ...Ver 1 0 2 16 13 3 Dashboard The Car is equipped with a high brightness TFT dashboard When turning on the IGNITION switch the Maserati Logo remains few seconds on the screen before changing to the sta...

Page 77: ...wo blue leds blink see n 9 on the upper led lights NOTE the pit limiter can be activated in any gear BUT it works ONLY in 2nd gear 8 PEDAL Throttle pedal Warning to help for the optimal pedal during t...

Page 78: ...RISMO MC TROFEO GT4 SERVICE MANUAL 78 Ver 1 0 2 16 To reset the best lap time e g when moving to a different circuit simply press the lower right button on the dashboard Press the Right Button to rese...

Page 79: ...3 1 Alarm screen warning lights If the dashboard screen turns in one of the following mode slow down the car immediately drive it in the closest safe area and switch off the engine The small display...

Page 80: ...EFT BLINKER light Function left blinker status indication Mode blinks when the left blinker is activated 5 RAIN LIGHT light Function rain light status indication Mode ON when the rain light is activat...

Page 81: ...able also while moving 1 Turn the IGNITION SWITCH to OFF down by using the red safety lock 2 Turn the MAIN BATTERY SWITCH to OFF down 3 Wait 5 seconds 4 Turn the MAIN BATTERY SWITCH to ON up 5 Wait 5...

Page 82: ...the luggage compartment It is a FIA Standard FT3 1999 Homologated SFT 41076 rubber bladder protected by a carbon composite rigid crushable structure The nominal capacity is 107 3 liters The actual cap...

Page 83: ...uel tank No fuel nourice and no transfer pumps are present When performing any maintenance operations on the fuel pumps be extremely careful to avoid any damage to the o ring located under the ring ca...

Page 84: ...eset the fuel consumption meter by pressing the console button for 2 s 14 5 Empting At the end of a session it is always recommended to pump out all the fuel from the car and weigh it to cross check t...

Page 85: ...cedure below The evening before the first track session fill the tank with 50 kg of fuel and leave it through the night Before the first track session pump out all the fuel and fill with the fuel quan...

Page 86: ...MC TROFEO GT4 SERVICE MANUAL 86 Ver 1 0 2 16 14 6 Quick Refuelling optional system A quick refuelling system is available as optional part suitable for endurance racing The system is applicable on th...

Page 87: ...p R Fuse 30 A Gearbox ECU Power Fuse 10 A Radiator Fan L Fuse 30 A Fuel Pump L Fuse 30 A Lo Beam Head Lights Relay 30 A Fuel Pump R Relay 30 A Engine Main Relay 30 A Radiator Fan L Relay 30 A Lights M...

Page 88: ...n this way the main breaker switch and the emergency breaker switch will be able to kill the engine if still running See scheme below The connection shown below must be avoided because it would not al...

Page 89: ...RATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 89 Ver 1 0 2 16 The main breaker relay includes a diode If connected in reverse polarity the diode will blow The right connection is shown in the photos b...

Page 90: ...or p n 188171 Nr 1 CAN Accelerometer Gyro p n 206070 Nr 2 Analogic Pressure Sensors p n 272832 Nr 1 wire for CAN sensors p n 277492 Nr 1 wire for Analogic sensors p n 277493 Nr 1 Voltage regulator for...

Page 91: ...RVICE MANUAL 91 Ver 1 0 2 16 CANbox I O connector Need to connect it To CANbox To Vehicle loom CAN connector Accelerometer and Gyro connector Accelerometer Gyro OUT CANbox connection to Vehicle loom I...

Page 92: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 92 Ver 1 0 2 16 Idrostop new BLS Brake Light Switch for N A signal Location for Front Connection sensor and voltage regulators...

Page 93: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 93 Ver 1 0 2 16 Rear Connection pressure sensor Front Connection sensor and voltage regulators...

Page 94: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 94 Ver 1 0 2 16 Rear Connection pressure sensor...

Page 95: ...SERVICE MANUAL 95 15 4 CAN connector It is possible to connect a CAN data logger by using directly the free connectors on the vehicle Vehicle connector 40 way plastic join connector Pin 3A CAN_High wh...

Page 96: ...ilitary join connector Maserati Ethernet Data Cable w o CAN connection p n 232816 Connector X301 Cod Souriau 851 06R 10 6 P 50 66 Pin A Ethernet TX Positive Pin B Ethernet TX Negative Pin C Ethernet R...

Page 97: ...980144958 Wing pylons Replace with new part TBA Air restrictor Add the 64 4mm flange and spacer The drawings and instruction to modify the affected parts are provided with the 2016 GT4 upgrade availab...

Page 98: ...MASERATI GRANTURISMO MC TROFEO GT4 SERVICE MANUAL 98...

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