2009-2015 Ferrari 458 Italia Service & Repair Manual

Start Model Spare Parts S.T. Sched ul e Worksh op Manual Body Repair Manual Graphic Na vig a tion Electri cal Syst em Troubl esh ooting Language To start the consultabon, please select one of the secbons of the left menu. -----------------------------------

1.1 Ferrari quality standards When manufacturing a Ferrari vehicle, the primary goal is “to achieve optimum product quality”. Consequently Ferrari deﬁnes a number of quality standards. These quality standards apply both to production and especially to customer service. In the event of accident repairs, crash safety must be an absolute priority. To maintain optimum crash safety, all structural work must be done correctly as indicated. The repair work may only be carried out by Ferrari-trained and certiﬁed skilled personnel. Only genuine parts should be used when carrying out the repair. They have been tested by Ferrari and are compatible for use with aluminium. Follow the procedures exactly as given in the repair manual. Any deviations from the procedures are permitted only after consultation with and approval by Ferrari. Using non-approved repair methods may compromise the crash performance of the vehicle. This may ultimately lead to a non-foreseeable safety and product liability risk. Only Ferrari-approved tools may be used to carry out accident repairs. It is essential that corrosion prevention measures are performed during and after the repair. Copyright © 2010

1.2 The bodywork concept of the Ferrari F458 Italia In addition to extruded members, aluminium parts and sheet metal elements, the Ferrari F458 Italia also features new joint reinforcements for the space frame structure; together, they form the bodywork structure. These ultra-high strength steel reinforcements (A), installed in the two A-pillars, offer occupants greater safety in critical situations. A The ultra-strong extruded sections of the A-pillars are concealed below the steel reinforcements. The sections are joined to the extruded members of the sill (B) by die-cast node joints. The sill (B) of the Ferrari F458 Italia is oversized, as on a B cabriolet type vehicle. This means that the Ferrari F458 Italia makes no compromises where crash safety is concerned. Copyright © 2010

1.3 General safety instructions Explanation of safety instructions Danger! “Danger” indicates imminent hazards that may result in death or serious injury. Warning! “Warning” indicates potential hazards that may result in death or serious injury. Caution! “Caution” indicates potential hazards that may result in slight injury. This symbol also indicates hazards to property. NOTE! “Note” indicates important information. Copyright © 2010

1.3 General safety instructions When carrying out any of the procedures described in this 1.3.2 Handling body and assembly components with sharp repair manual, please observe all national accident safety edges regulations. 1.3.1 Lifting vehicles Caution! Risk of injury from sharp-edged burrs on body and accessories. Danger! Risk of death from the vehicle toppling or slipping off the vehicle lift. • Align vehicle centrally between the vehicle lift columns. • Raise the vehicle only at the speciﬁc locating points. • Ensure the lifting pads are seated correctly, lifting the vehicle slowly while monitoring the vehicle visually. • Before removing any components and signiﬁcantly shifting the centre of gravity of the vehicle, ensure that the vehicle itself is securely fastened to the vehicle. Copyright © 2010 • Always wear protective gloves when working in the vicinity of sharp-edged body and assembly components.

1.3 General safety instructions 1.3.3 Working in presence of aluminium dust Warning! Risk of explosion from high concentrations of aluminium dust. Risk of injury from breathing in fine particulate. • When carrying out any work that creates fine particles of dust, wear a fine dust mask, safety goggles and protective gloves. • Any grinding work must be carried out with explosion- protected air extraction systems; do not blow off dust deposits with compressed air. • Clean the work area and the extraction system regularly. • To prevent a dust explosion, all extraction systems must be earthed and suitable powder extinguishers must be provided. • Any vehicle parts in the repair area which may be damaged by dust should be removed from the area or covered with fire-resistant covers. Copyright © 2010 1.3.4 Handling batteries Warning! Risk of explosion and fire from flying sparks during grinding and welding work. Risk of damage to vehicle components and other vehicles from flying sparks. • Before carrying out any welding work, always remove both battery terminal clamps and cover the battery terminals. • Remove the vehicle battery before carrying out any work that may produce sparks in the vicinity of the battery itself. • Disconnect the battery earth strap when carrying out any vehicle body repair work and when working on the airbag system.

1.3 General safety instructions 1.3.5 Grinding and welding • When welding, wear suitable, non-flammable protective clothing and gloves. Warning! Risk of explosion and fire when welding in the vicinity of highly flammable substances. Irritation of the respiratory tract caused by toxic gases produced during welding. Risk of injury from the extremely bright arc and welding splashes when welding. Risk of injury as a result of inadvertent activation of pyrotechnic safety components. Risk of explosion and fire from flying sparks during grinding and welding work. Risk of damage to vehicle components and other vehicles from flying sparks. • When carrying out grinding and welding work around the fuel tank or fuel-carrying parts, ensure that these parts do not heat up. If in doubt, remove such parts. • Cover the grinding and welding area with fire-resistant covers. • Use the specific visor when welding. • Partition off workstations with spark protection curtains. • A fire extinguisher must always be accessible in the immediate vicinity of the welding area. • Remove or cover any vehicle parts located in the repair area. • Always carry out grinding and welding work with an extraction system. • Clean the air extraction system at regular intervals. • Never carry out welding and grinding work at the same time in the same room. Copyright © 2010

1.3 General safety instructions 1.3.6 Removing sealants Danger! Risk of death from inhaling toxic vapours. Risk of burns in the event of direct skin contact with hydrochloric acid. • Hydrochloric acid is produced when PVC sealant is heated to over 180 °C. • PVC sealant must only be removed with a rotary wire brush or by heating to max. 180 °C with a hot air gun and removing with a spatula. • Always wear a dust mask and protective goggles when removing sealant with a rotary brush. • Always ensure there is sufficient air extraction and fresh air ventilation. Copyright © 2010 1.3.7 Handling chemicals Caution! Handling chemicals may cause allergic skin and respiratory tract reactions. • Always ensure that there is sufficient air extraction and ventilation, and extract any vapours released by adhesives. • Prevent chemicals from coming into direct contact with the eyes and skin. • Wear protective gloves, protective goggles and, where necessary, an apron. • Immediately change out of work clothes that are soiled with adhesive or solvent. • At the end of the job, wash your hands and apply protective cream. • Always keep a bottle of eye wash ready for use. • Only store adhesive products in the safety cupboard and keep them away from naked flames and other sources of ignition.

1.3 General safety instructions 1.3.8 Working with the air conditioning system Warning! Risk of injury from the charged air conditioning system exploding during welding work. Do not weld, solder or work with a hot air gun in the vicinity of the components of a charged air conditioning system. Similarly, do not perform any welding work on a vehicle if the work will cause parts of the air conditioning system to heat up. When carrying out a paint repair, object temperatures in the drying oven or preheating zone must not exceed 80 °C as the overpressure caused by heating process may cause the system to explode. Copyright © 2010 1.3.9 Handling the airbag system Caution! Risk of injury from activation of airbag units if earth strap is not disconnected. Disconnect the battery earth strap when carrying out any vehicle body repair work and when working on the airbag system. Wash hands thoroughly after touching airbag units that have been ﬁred. 1.3.10 Working with tools Warning! Risk of injury. All tools pose potential hazards to health and life. Always observe the safety instructions and warnings of the tool manufacturers.

1.4 Important information 1.4.1 Assessing the extent of the damage 1.4.2 Instructions for body repairs In the case of accidents involving substantial areas of the vehicle, examine the following components carefully to prevent any damage to vehicle or suspension parts from going undiscovered: • Check tyres and wheel rims for damage. • Check that the steering tie-rod, steering linkages and steering system are working correctly. Also check for external damage and cracks. • Check all chassis components, such shock absorbers, suspension and steering joints, links, axles, anti-roll bars and their fasteners, for external damage or cracks. • Check brake system components such as brake discs, brake pads, brake callipers, hydraulic lines and hydraulic hoses and their respective fastenings for external damage, stretching or leaks. • Check engine, gearbox, axle and exhaust system mounts for damage. • Before returning the vehicle to the customer following a repair, test drive the vehicle carefully to ensure that it is roadworthy. • Repair work on the Ferrari F458 Italia must only be carried out by repair personnel who have been trained, tested and certiﬁed by the Ferrari Customer Service department. • Use only Ferrari-approved tools, spare parts and consumables for repair and maintenance work. • If, in the course of the repair work, special cases arise that are not envisaged by the repair instructions, contact the Ferrari Technical Customer service to establish how to proceed further. • All the main repair operations possible for the Ferrari F458 Italia are described in this repair manual. Combined instructions may be used to differentiate between different repair procedures. Only the right or left hand components are illustrated in the description of a repair. • To ensure that the original crash safety of the vehicle is maintained after a body repair, always used the same chassis joint points. • Cuts that may affect the crash safety of the body, and thereby the safety and roadworthiness of the vehicle, must always be approved by Ferrari. Copyright © 2010

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2009-2015 Ferrari 458 Italia Service & Repair Manual

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