Maserati GRANTURISMO MC User manual

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

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
2
Ver 1.0 2/16
Index
1. Contacts p3
2. Introduction p4
3. Maintenance Check List p4
4. Fluids and 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. 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

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
3
Ver 1.0 2/16
1. Contacts
1.1. Manufacturer
Company name:
Maserati S.p.A.
Address:
Viale Ciro Menotti, 322
41121 Modena (MO)
ITALY
1.2. Sales / Marketing
Name:
Roberto Bozzi
Address:
Viale Ciro Menotti, 322
41121 Modena (MO)
ITALY
Telephone:
[phone]
Mobile:
[phone]
E-mail:
[email protected]
1.3. Spare parts
Name:
Alberto Ballarini
Address:
Viale Ciro Menotti, 322
41121 Modena (MO)
ITALY
Telephone:
[phone]
Mobile:
[phone]
E-mail:
[email protected]
1.4. Electronic / Diagnosis support
Company name:
Waycon S.r.l.
Name:
Stefano Moroni
Address:
Via Martinella, 25
41053 Maranello (MO)
ITALY
Telephone:
[phone]
E-mail:
[email protected]
1.5. PR & WEB
Name:
Filippo Ghialamberti
Address:
Viale Ciro Menotti, 322
41121 Modena (MO)
ITALY
E-mail:
[email protected]

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
4
Ver 1.0 2/16
2. Introduction
This manual is intended as a general introduction to some specific maintenance procedure
of the Maserati GranTurismo MC Trofeo race car.
The destination use is for experienced technicians, familiar with the mechanical checks
required by a race car.
3. Maintenance Check List
3.1. Periodic Checks and Life limits
The following components shall be checked and/or replaced within the specified 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
Recommended
replacement
frequency
Notes
Engine
Engine complete rebuild
15000 km
Oil
500 km
Level Check
5000 km
One time per
season
Oil filter
5000 km
One time per
season
Auxiliary belt + pulleys
3000 km
10000 km
Air filter
1000 km
5000 km
Coolant
3000 km
Level Check
2 years
Spark plugs
5000 km
One time per
season
Coils
10000 km
Transmission
Clutch
10000 km
Gearbox
2000 km
Only Oil
Level Check
10000 km
Transaxle
10000 km
Drive Shafts
CV joints
inspection
1000 km

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
5
Ver 1.0 2/16
Description
Check
Interval
Notes
Recommended
replacement
frequency
Notes
Suspension and Steering
Suspension Joints
500 km
CV joints
inspection
Replace in case
of excessive
freeplay
Suspension Arms +Tie
rods
500 km
CV
inspection
Replace in case
of excessive
freeplay
Hub Carriers
1000 km
CV
inspection
Replace in case
of excess of
freeplay
Wheel Hubs and Bearings
+Studs (welded)
500 km
Front 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 excessive
free play
between bushing
and hub carrier
replace both.
Dampers
500 km
CV
inspection
5000 km
Overhauling
service
Power Steering Fluid
5000 km
10000 km
Steering rack
10000 km
Brakes
Front brake master
cylinder
10000 km
Overhauling
service
Rear brake master
cylinder
10000 km
Overhauling
service
Balance bar
2000 km
Clean and
inspection
10000 km
Check often if
the balance bar
is working
properly.
Replace the circ
clip in case the
uniball goes off.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
6
Ver 1.0 2/16
Description
Check
Interval
Notes
Recommended
replacement
frequency
Notes
Calipers
5000 km
(2000 km if
used on
severe
tracks)
Check piston
seals
10000 km
Send to Brembo
for servicing
Flexible brake lines
(caliper-chassis)
5000 km
Visual
inspection of
lines and
connections.
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 hose
500 Km
Check
leakage
Electronics
Wiring harness
End of
Season
Fuel pumps
End of
Season
Fluids
Engine oil
500 Km
Level check
5000 Km
Gearbox oil
1000 Km
Level check
5000 Km
Gearbox F1 unit
1000 Km
Level check
5000 Km
Power steering
1000 Km
Level check
5000 Km
Clean/wash the
full circuit
Coolant
1000 Km
Level check
5000 Km

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
7
Ver 1.0 2/16
4. Fluids & lubricants
Application
Brand
Type
Specifications
Replace interval
Power Steering
Fluid
Shell
Donax TM
GM Allison C-4
ZF TE ML
09/12
5000 km, check level every 1000 km
Engine Coolant
Fluid
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 Fluid
Brembo
LCF 600+
5000 km
Gearbox F1 &
Clutch Fluid
Shell
Donax TX
ATF Dexron III
ZF TE ML 14
5000 km, check level every 1000 km
Gearbox Lubricant
Pakelo
DLS -
Racing
5000 km, check level every 2500 km
Driveshaft Grease
Castrol
Optitemp
HT 1 - LF
Bechem
GKN HTBJ

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
8
Ver 1.0 2/16
5. Dimensions and Weight
5.1. Dimensions
Description Rules Tolerance Design (2016)
Overall length
Homol. Form.
± 5 mm 4991
Overall width
Homol. Form.
± 1 % 2096
Overall body width front wheel centerline
Homol. Form.
± 1 % 1962
Overall body width rear wheel centerline
Homol. Form.
± 1 % 1962
Wheelbase
Homol. Form.
± 10 mm 2942
Overhang front
Homol. Form.
± 10 mm 1038
Overhang 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 minimum weight should not exceed 1410 kg in running order, without fuel
and driver.
The minimum homologated weight depends on the sporting authority of the
championship. The weight should be adjusted by the team by mean of appropriate ballast.
5.3. Ballast
Ballast should be fixed to the specific plate (P/N 082959700) installed in the front
passenger place in the cockpit.
Maximum applicable ballast weight is 100 kg.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
9
Ver 1.0 2/16
6. Engine
6.1. Engine specification
Engine Spec:
oEngine code: M145
oEngine type: V8 90°
oDisplacement: 4692 cc
o4 valves per cylinder.
oWet sump / One Volumetric oil pump.
o1 throttle, drive by wire control.
o8 BOSCH injectors, 8 coils, multi-phased injection & ignition.
Otpimum upshift rpm :
oGear shift at 7200 RPM in all gears.
o7000 rpm, optimum rpm in VI gear continuously.
oRev limiter at 7600 RPM in all gears.
oGear shifting recommended at the first RED light.
Cooling system:
oDemineralised 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.
oThermostat @ 86°C available for cold or night events.
Lubricating system:
oOil type: see Table in 4 Fluids & lubricants.
oMinimum oil level in engine sump: 10 liters
oMaximum oil level in engine sump: 11.5 liters
oTotal oil capacity from empty engine: 14.2 liters to have 11.5 liters in engine wet
sump.
oFor further details see below the oil level check procedure.
Exhaust system:
oOne collector of 4 into 1, double exhaust manifolds - separate tubes - rigid assembly
–rubber mountings on chassis.
Temperatures (T1 = top speed straight line ) given for step 1 engine :
oMax temp. cooling fluid: 96°C in T1, 98°C max during a lap. Optimum 88 ÷ 91°C.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
10
Ver 1.0 2/16
Electronic devices
oEngine ECU: Bosch Motronic ME 7.1.1.
oGearbox ECU: Magneti Marelli CFC 301.
oElectronic gear box shifting control with two manual paddles at the wheel (gear up
by right paddle, gear down by left paddle).
oControl dashboard with already programmed alarms available.
oShift lights in top position directly incorporated into the dashboard case.
6.2. Maintenance procedures
6.2.1. First engine start up procedure
Follow this procedure if you are doing the first start of the day, after an engine or gearbox
change, or after a maintenance work on cooling system or oil system.
1. First 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 on ignition switch
7. Push firmly the Start button until the Engine starts.
8. Pay attention, only after a complete pump out of fuel tank, if you want to run the
engine (after refill of fuel) repeat twice time the procedure at point 6), because at
first time the engine will not run.
6.2.2. Oil level check procedure
In order to have the exact check of the oil level, it’s recommended the use of the specific
tool shown in Picture 1. The procedure is the following:
oCondition of the test:
-Cool engine (15°< Water temperature <35°)
-Wait at least 30 minutes since the switch off of the engine.
-Car fixed and parked on an even surface on his 4 tires.
Picture 1. Hollow cylinder.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
11
Ver 1.0 2/16
oRemove and clean the flexible stick
oIntroduce the flexible stick into the hollow cylinder.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
12
Ver 1.0 2/16
oInsert both components in the oil level check hose. Make sure to introduce slowly the
flexible stick, especially when the hollow cylinder is close to check hose.
oRemove the flexible stick an keep it in the flat position in order to make a visual
check. The nominal oil level recommend by Maserati is 11.0 Liters
See below the reference

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
13
Ver 1.0 2/16
6.2.3. Engine auxiliary belt and water pump belt (check and replacement).
Follow this procedure every time you check or replace the engine auxiliary belt or the
water pump belt.
Engine Auxiliary belt (only check):
oThe procedure should be done only with the engine stopped and completely cool
(Engine Water temperature ≤ TAir environment).
oTension measuring by vibration control (Hz), in the point “A” shown below.
oIn the picture below, a standard vibration measurement tool and a standard
measurement procedure.
oThe measurement must be done always after 2 complete manual crankshaft turns,
in order to keep off residual tension of the rubber material.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
14
Ver 1.0 2/16
oTarget values reported in the table below
Adjust if
Working range
Adjust if
A< 75 (Hz)
78 (Hz)<A<110 (Hz)
A>115 (Hz)
oThe tension should be adjusted only with an accurate setting of the stretcher.
Generally the position is 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)
oRepeat the procedure after an engine belt replacement.
Water pump belt (Only replacement):
oThe belt must be mounted or replaced by two synchronized operations, that is made
by an helping hands during the manual crankshaft turning.
Loose the shown screw and
move the tightening pulley
as shown by red arrows
- Counterclockwise Decrease
- Clockwise Increase

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
15
Ver 1.0 2/16
7. Transmission
7.1. Gearbox
The car is equipped with a 6 gear + reverse gearbox, with electro-hydraulic control.
7.1.1. Transmission Ratios
The transmission ratios are fixed and are shown in the 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
1.321
R
14 / 46
14
46
0.304
Bevel
11 / 46
11
46
0.239
The following diagram shows the speed vs. RPM relationship for the different gears, in two
possible rear tyres configurations: 305/680/18 (old spec 2010, do not consider) and
325/705/18 (current spec, named Trofeo).

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
16
Ver 1.0 2/16
Gear Ratios MC145
4592
5039
5504
5929
6032
4592
5039
5504
5929
6032
68.3
107.0
152.9
200.0
242.9
281.9
70.7
110.8
158.3
207.1
251.5
287.7
37 / 2837 / 2837 / 2837 / 2837 / 2837 / 2837 / 2837 / 2837 / 28
31 / 28
31 / 34
31 / 28
31 / 34
31 / 28
31 / 3431 / 3431 / 3431 / 3431 / 3431 / 34
23 / 3323 / 3323 / 33
20 / 4120 / 4120 / 4120 / 4120 / 41
14 / 4514 / 4514 / 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 / 28
23 / 33
23 / 33
31 / 34
31 / 34
14 / 45
14 / 45
20 / 41
20 / 41
Granturismo MC
Tyre rolling radius (m) 0.338
Limit 6° gear 7000
Limit 1° gear 7200
Limit 2° gear 7200
Limit 3° gear 7200
Limit 4° gear 7200
Limit 5° gear 7200
Tyre rolling radius (m) 0.35
Limit 6° gear 6900
Limit 1° gear 7200
Limit 2° gear 7200
Limit 3° gear 7200
Limit 4° gear 7200
Limit 5° gear 7200
Titoli
Scala_x_17_49
Scala_x_21_52

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
17
Ver 1.0 2/16
7.1.2. Oil level check procedure
The oil level of the gearbox may be checked through the specific inspection hole, shown in
the following 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 can be added also by filling the gearbox catch tank, located in the luggage
compartment, but the time required to actually flow into the gearbox is rather long, since
it is connected to a breather (small hole).

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
18
Ver 1.0 2/16
7.2. Clutch
7.2.1. Clutch Replacement Procedure
To access the clutch, remove the complete clutch housing, together with the torque tube
and the transmission shaft.
Loosen the clutch retaining screws.
Rotate the engine flywheel manually, bringing the mark 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 complete clutch.
Fit the clutch assembly in its seat on the flywheel using the clutch centring tool
900026250 .
If refitting a clutch assembly which has been previously removed from the car, follow the
markings made during removal.
The clutch disk is supplied by the manufacturer with the maximum unbalance point
marked.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
19
Ver 1.0 2/16
If fitting a new clutch disk, its maximum unbalance point must be positioned at 180° with
respect to the maximum unbalance point of the flywheel.
Reinstall the complete housing with the torque tube and the transmission shaft.
IMPORTANT: after the replacement of the clutch, follow the procedures
described at 7.3.1, 7.3.2, 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 activities on the first day or after any
maintenance work on the gearbox or on the gearbox electronic related part.
1) Push the brake pedal, pull the right paddle on the wheel to engage the first gear.
2) Push the brake pedal, pull both paddles simultaneously, to shift into Neutral.
3) Push the brake pedal, push the white button at the bottom left side on the wheel to
engage the reverse gear.

MASERATI GRANTURISMO MC TROFEO/GT4 SERVICE MANUAL
20
Ver 1.0 2/16
7.3.2. Air bleed procedure on the clutch actuator system.
Follow this procedure every time the clutch is replaced or the high pressure quick connect
of the clutch actuator system is disconnected (first picture below).
oLift up the car, (minimum 50 cm from the ground), in order to have enough space to
operate under the chassis.
oInsert a rubber pipe in the bleed connector (nipple) as shown in the picture below.