Maserati - Ghibli M157 - Service Manual - 2014 - 2015

Maserati Technical Bulletin Date: January 15, 2019 Bulletin No. – MAS001749 – MTB 19‐02 Fuel Delivery Line Replacement ‐ US Safety Recall Campaign ‐ #378 Supersedes: N/A Model: Quattroporte (M156) and Ghibli (M157) Model Years: 2014 and 2015 Subject: Vehicle Safety Recall Campaign #378 – Fuel Delivery Line Replacement MASERATI SAFETY RECALL BULLETIN PERFORM THE PROCEDURE OUTLINED IN THIS TECHNICAL BULLETIN ON ALL AFFECTED NEW VEHICLES BEFORE CUSTOMER DELIVERY OR FOR VEHICLES ALREADY SOLD AND DELIVERED THE NEXT TIME THE VEHICLE IS IN THE SHOP FOR MAINTENANCE OR REPAIRS. Maserati dealers must ensure recalls are completed after having been notified by Maserati North America, Inc. (MNA) that a safety-related defect or noncompliance exists in any motor vehicle or item of replacement equipment in the dealer’s possession at the time of notification. In MNA's case, this notification would typically be made by the issuance of a recall notification in the form of a Technical Bulletin. Under the National Traffic and Motor Vehicle Safety Act of 1966, as amended, if a recall campaign is announced by MNA, dealers must ensure that all recalls on new vehicles and new items of replacement equipment are completed BEFORE delivery to the consumer. This means that dealers may not legally deliver new motor vehicles or new items of replacement equipment to consumers with an open recall. The Safety Act also prohibits dealers from selling or leasing the motor vehicle or item of replacement equipment, unless and until the open recall has been completed BEFORE delivery. This also pertains to vehicles in the Certified Pre-Owned program, and to items of replacement equipment. Finally, MNA dealers should not sell or use parts that have been recalled by MNA. Please follow the specific instructions provided by MNA on the return or disposition of any parts. © 2019 Maserati North America, Inc. AfterSales www.maseratiusa.com All rights reserved. Reproduction or translation in whole or in part is not permitted without authorization from the publisher. Printed in USA Description of Vehicle Safety Recall #378 Maserati S.p.A. and MNA have determined that the above described vehicles were manufactured with plastic fuel lines (Num. 9 in Fig.1) that may have been damaged by foreign particles present during fuel line production and assembly by the supplier that may have scratched the inside of the fuel line eventually leading to a fuel leak. Leaking fuel may, in certain circumstances and in the presence of an ignition source, lead to a fire. A fire can result in increased risk of occupant injury and injury to persons outside the vehicle. Fig.1 Which Vehicles Are Affected Please refer to ModisCS+ for the affected vehicles. Vehicle Remedy Information 1. Check that the vehicle is included in this Recall Campaign, and that this repair has not been previously performed. 2. Install the new fuel delivery line kit as shown below. 3. The recall procedure is now complete. Recall #378 - Fuel Delivery Line Replacement 2 This repair procedure will be performed free of charge to the customer. Parts Needed For The Recall For this Recall Campaign, the fuel delivery line kit (3 lines and clamps) must be ordered from the Maserati Parts Department. NOTE: P/N: 673007367 is blocked. You must submit a PHD with the VIN when ordering. The original 1 piece fuel delivery line will now be replaced by the above kits which contain 3 lines. The engine connection line (1), the body line (2), and the fuel tank connection line (3). OPERATING PROCEDURES FOR V6 NOTE: Perform this repair when the engine is cold. NOTE: It is recommended that the fuel level be less than a half tank for this repair. 1. Drive the vehicle on the lift. 2. Disconnect the battery (Section 8.20.001 – 02 of the Workshop Manual). 3. Use the fuel fill funnel located in the trunk to vent any fuel tank pressure by inserting it into the filler neck. 4. Remove the rear seat cushion (Section 9.42.006 – 02 of the Workshop Manual). 5. Remove the windshield water containment bay as shown below and in Section 9.15.016 – 02 of the Workshop Manual. Recall #378 - Fuel Delivery Line Replacement 3 a. Remove the wiper arms and the engine cover panels. b. Using a Teflon wedge, remove the l/s and r/s windshield trim. (Fig.2) Fig.2 c. Remove the l/s and r/s inspection covers. (Fig.3) Fig.3 Fig.4 d. Remove the exterior lower windshield trim. (Fig.4) e. Remove the nuts holding the water containment tray. (Fig.5) Fig.5 Fig.6 f. Remove the bolts on the engine compartment front cross member. (Fig.6) Recall #378 - Fuel Delivery Line Replacement 4 g. Remove the bolt between wiper linkage and the front cross member. (Fig.7) Fig.7 Fig.8 h. Unsnap the wire harness support clip and move the front cross member to the side. (Fig.8) 6. a. Remove the 4 screws and then the l/s fuel pump inspection cover (Fig.9). Fig.9 Fig.10 b. Release the safety (2) and unsnap the quick release fuel delivery line (3) as shown in Fig.10. NOTE: Use an absorbent cloth to wipe off any residual fuel when disconnecting the delivery line from the pump as shown in Fig.11. Fig.11 Recall #378 - Fuel Delivery Line Replacement 5 7. In the engine compartment, remove the engine cover, release the safety and disconnect the fuel delivery line, then unclip the fastening clamp. (1 in Fig.12) Fig.12 8. Unclip the delivery line from the 2 fastening clamps. (Fig.13) Fig.13 9. Remove the screw on the heat shield between the engine and the r/s dome. (Fig.14) Fig.14 Recall #378 - Fuel Delivery Line Replacement 6 10. Pull the heat shield back and then unclip the fuel delivery line from the securing clamp. (Fig.15) Fig.15 11. Only on the Ghibli AWD, remove the 3 bolts and the metal plate behind the r/s cylinder head. (Fig.16) Fig.16 12. Release the safety and unhook the quick release on the fuel delivery line located behind the r/s cylinder head. (Fig.17) Fig.17 Recall #378 - Fuel Delivery Line Replacement 7 13. Replace the old fuel delivery line on the engine with the new fuel delivery line from the kit as shown in Fig.18. Fig.18 14. Remove the l/s and r/s central underbody panels as shown in sections 9.14.043 – 00 and 9.14.044 – 00 of the Workshop Manual. 15. Position a hydraulic lift with a brace to support the fuel tank as shown in Fig.19 Fig.19 16. Remove the bolts on the fuel tank support straps. (Fig.20) Fig.20 Recall #378 - Fuel Delivery Line Replacement 8 17. Lower the fuel tank just enough to unsnap the fuel delivery line from the 4 clamps located between the fuel tank and the chassis. (Fig.21) Fig.21 18. On the TPMS sensor, unlock the safety tab and disconnect the wire connector, then release the harness fastener. (1 in Fig.22) Fig.22 Fig.23 19. Unclip the fuel delivery line from the 3 fastening clamps. (Fig.23) 20. Remove the heat shield screws and the fasteners (1) then remove the 2 heat shields as shown in Fig.24 and Fig.25. Fig.24 Recall #378 - Fuel Delivery Line Replacement 9 Fig.25 21. Unclip the fuel delivery line from the clamps located between the engine and the r/s dome. (Fig.26) Fig.26 Fig.27 22. Unclip the fuel delivery line from the lower 2 clamps. (1 in Fig.27) 23. Cut the old fuel delivery line (Fig.28) to facilitate the next several steps. Fig.28 Recall #378 - Fuel Delivery Line Replacement 10 24. With snap ring pliers, loosen the clamps and remove the remaining sections of the fuel delivery line. (Fig.29) Fig.29 25. Install the new fuel lines following the removal procedures in reverse order. 26. Secure the new engine line into the engine compartment clamps. (Fig.30) Fig.30 Fig.31 27. Attach the new body delivery line to the engine delivery line and snap the lock closed. (Fig.31) Fig.32 Fig.33 28. Attach the new tank delivery line to the fuel pump. (3 in Fig.32) 29. Snap the new delivery line into the securing clamps. (2 in Fig.33) Recall #378 - Fuel Delivery Line Replacement 11 30. Attach the new tank delivery line (3) to the new body delivery line (2) and snap the lock closed. (Fig.34) Fig.34 Fig.35 31. Snap the new tank delivery line into the securing clamps above the fuel tank. (Fig.35) 32. Tighten the fuel tank strap bolts to 35Nm. (Fig.36) and remove the lift. Fig.36 33. With the new fuel delivery lines installed and secured, perform the following function test of the system before re-installing the rear seat cushion and the windshield water containment bay. a. Cycle the ignition to the run position and leave on for 30 seconds, during these 30 seconds inspect the connections and tubing for any signs of fuel leakage. b. Repeat the ignition cycle one additional time prior to cranking engine. Verify that there are no leaks in the system. 34. Re-install the remaining components. Recall #378 - Fuel Delivery Line Replacement 12 OPERATING PROCEDURES FOR V8 NOTE: Perform this repair when the engine is cold. NOTE: It is recommended that the fuel level be less than a half tank for this repair. 1. Drive the vehicle on the lift. 2. Disconnect the battery (Section 8.20.001 – 02 of the Workshop Manual). NOTE: Use the fuel fill funnel located in the trunk to vent any fuel tank pressure by inserting it into the filler neck. 3. Remove the rear seat cushion as shown in Section 9.42.006 – 02 of the Workshop Manual. 4. Remove the 4 screws and then the l/s fuel pump inspection cover. (Fig.1) - On a dual pump system, remove the r/s inspection cover also. Fig.1 Fig.2 5. Release the safety (2) and unsnap the quick release on the fuel delivery line (3) as shown in Fig.2. NOTE: Use an absorbent cloth to wipe off any residual fuel when disconnecting the delivery line from the pump as shown in Fig.3. Fig.3 Fig.4 6. In the engine compartment, remove the engine cover then release the engine fuel delivery line from the securing clamps. (Fig.4) Recall #378 - Fuel Delivery Line Replacement 13 Fig.5 Fig.6 7. Disconnect the engine fuel delivery line from the body fuel delivery line with pinch pliers (e.g. Mac Tools P11LRGLA, 11” pliers) as shown in Fig. 5. 8. Remove the engine fuel delivery line. (Fig.6) 9. Remove the l/s and r/s central underbody panels as shown in sections 9.14.043 – 00 and 9.14.044 – 00 of the Workshop Manual. 10. Position a hydraulic lift with a brace to support the fuel tank as shown in Fig.7. Fig.7 Fig.8 11. Remove the bolts on the fuel tank support straps. (Fig.8) 12. Lower the fuel tank just enough to unclip the fuel delivery line from the 4 clamps located between the fuel tank and the chassis. (Fig.9 and Fig.10) Fig.9 Fig.10 Recall #378 - Fuel Delivery Line Replacement 14 13. On the TPMS sensor, unlock the safety tab and disconnect the wire connector, then release the harness fastener (1 in Fig.11). Fig.11 Fig.12 14. Unclip the fuel delivery line from the 3 fastening clamps. (Fig.12) 15. Remove the heat shield screws and the fasteners (1) then remove the 2 heat shields as shown in Fig.13 and Fig.14. Fig.13 Fig.14 Recall #378 - Fuel Delivery Line Replacement 15 16. Unclip the fuel delivery line from the clamps located between the engine and the r/s dome. (Fig.15) Fig.15 Fig.16 17. Unclip the fuel delivery line from the lower 2 clamps. (1 in Fig.16) 18. Cut the old fuel delivery line (Fig.17) to facilitate the next several steps. Fig.17 19. With snap ring pliers, loosen the clamps and remove the remaining sections of the fuel delivery line. (Fig.18) Fig.18 Recall #378 - Fuel Delivery Line Replacement 16 20. Install the new engine delivery line (Fig.19) into the engine compartment clamps. (Fig.20) Fig.19 Fig.20 21. Attach the new body delivery line (2) to the engine delivery line (1) and snap the lock closed. (Fig.21) Fig.21 Fig.22 22. Attach the new tank delivery line to the fuel pump. (3 in Fig.22) 23. Snap the new delivery line into the securing clamps. (2 in Fig.23) Fig.23 Fig.24 24. Attach the new tank delivery line (3) to the new body delivery line (2) and snap the Recall #378 - Fuel Delivery Line Replacement 17 lock closed. (Fig.24) 25. Snap the new tank delivery line into the securing clamps above the fuel tank. (Fig.25) Fig.25 Fig.26 26. Tighten the fuel tank strap bolts to 35Nm. (Fig.26) and remove the lift. 27. With the new fuel delivery lines installed and secured, perform the following function test of the system before re-installing the rear seat cushion. a) Cycle the ignition to the run position and leave on for 30 seconds, during these 30 seconds inspect the connections and tubing for any signs of fuel leakage. b) Repeat the ignition cycle one additional time prior to cranking engine. Verify that there are no leaks in the system. 28. Re-install the remaining components. NOTE: Dispose of the old fuel line according to all Local and Federal Environmental Guidelines. Warranty Information        Campaign Number Warranty Code Defect Code Component code Labor Operation for V6 engine vehicles Labor Operation for V8 engine vehicles Component Part Number 378 24 063 1.43.109 1.43.109.9 (2.25h) 1.43.109.8 (1.7h) See parts section Recall #378 - Fuel Delivery Line Replacement 18