Ferrari F355 Major Service Procedure – Part 1

Engine Removal Procedure (6-Speed Manual Transmission)

This is the first part of a series outlining the process for a “major” service for the F355. The
vehicle used for the procedure and images is a 1995 F355, Italian market manual
transmission (non-F1). When complete, the series will consist of 5 parts:
1. Engine removal
2. Inspection & Cleaning
3. Service items (accessory drive belts, fluids, spark plugs, Lambda sensors etc.)
4. Camshaft (timing) belt and tensioner bearing replacement
5. Engine installation
All these documents can be accessed at www.ferrarichat.com in the technical Q&A section.
The series will be published in stages as completed.

PLEASE NOTE: Every reasonable effort has been made to ensure the accuracy of the
content of this document. The author declines all responsibility for damages occurring,
howsoever caused from reference to this document. Any work is carried out at the express
risk of the individual. This document is NOT FOR PROFIT, i.e. I have provided this
information free of charge for the Ferrari community to share. This document is not for re-
sale.

General
1. F355 engine removal is relatively straightforward. The main difficulties arise with access
to the hoses and fasteners at the front of the engine compartment where space is tight.
2. The engine is removed from below the vehicle. The engine and transmission weight is
supported on a trolley, while the vehicle body is lifted clear. The engine is wheeled out
from under the body on the trolley.
3. The vehicle body can be raised either with a 2-post ramp or with two good quality floor
jacks. The lifting method must allow good access to the underside of the vehicle.
4. This procedure details the “two-jack” method.
5. Disconnect the battery using the isolator in the luggage compartment before starting
work.
6. Park the car on solid, level ground in a place where you can get good 360º access to the
vehicle.
7. Be prepared for fluid spills when disassembling hoses etc. Keep a supply of oil granules,
wipes and containers to hand.
8. Dispose of all fluids at your local civic amenity site; don’t pour into the soil or down the
drain, as this will eventually work its way into your family’s tap water.

Tools & Equipment

1. A metric hand-tool selection is required including:
- Two sets of spanners and sockets covering 6mm to
24mm A/F are required.
- A range of cross & flat head screwdrivers.
- A very large adjustable spanner and alan-keys.
- Two good quality 3,000kg hydraulic jacks with a lifting
height of approx 500mm.
- 2 drain trays with a capacity minimum of 6 litres and a
height of 200mm max.
- Lead lamp
- 4 good quality 2000Kg axle stands
2. A good quality trolley (steel framed with heavy duty castors is also required. The load
capacity should be at least 750kg and measure approx 620mmx620mm. The height
should be as low as possible (250mm or lower).
3. During dismantle stages be sure to label and carefully store all removed parts and
fasteners to ensure correct and smooth reassembly.

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Before commencing engine removal
1. Remove A/C refrigerant – see below.
2. Let the fuel run down to less than ¼ tank. Remove the fuel filler cap and store safely.
The tank is un-vented and changes in temp etc. will result in fuel leaking from the
feed/return pipes if the filler cap is not removed. If the level of fuel in the tank is too high it
will pour from the feed pipes.
3. Disconnect the battery.

Removal of A/C refrigerant

1. The air-conditioning refrigerant must be removed before work commences. The charge
points are located in the front luggage compartment.
2. Recovery of refrigerant gas must be conducted using the correct equipment. Do not
release the gas into the atmosphere. Complete the steps outlined below with the correct
equipment OR take the vehicle to an A/C specialist.
3. Open the front luggage compartment hood.
4. Unscrew cross-head retaining screws on top of
heater box & remove bezel
5. Remove left and right hand access panel covers,
and brake fluid panel.
6. Unscrew large retaining screws on left and right 4
hand side.
7. Unscrew cross-head retaining screws for retaining
trim.
8. Gently prise off water seal from cowl upper panel.
9. Lift out carpet trim carefully, avoiding kinks and
breaks to the trim.
5
10. Low & High pressure A/C connectors are located to
the right of the heater box.
11. When the refrigerant is recovered be sure to
measure and note the quantities separately of
lubricant oil recovered and refrigerant
recovered – this is important info and
will be explained in full in part 3 of this series.
6

AC System
fill/recovery
connectors 7

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Cooling & Power Steering
1. In the engine compartment remove the side covers. 1
3 hex socket bolts hold the covers on each side.
2. Remove the air filter housings and upper exhaust
heatshields. 2
3. Remove the coolant tank/PAS reservoir trim panel
from the top of the engine (6x10mm nuts).
4. Unscrew & remove the coolant tank cap.
5. From underneath the car drain the coolant from the
radiators. The plugs are at the bottom of the radiators.
6. Prise off the rubber cover and unscrew the drain plug. 5
The drain plug is made of plastic so be very careful not to
damage the plug with the screwdriver. Do this on both
sides of the car and leave to drain.
7. Inspect both drain plugs carefully for cracks or damage.
Make sure you account for both o-ring seals. It is easy for
the seals to drop into the drain tank or get stuck to the
6
radiator.
8. When replacing the drain plug renew the o-rings, they are
cheap. (Ferrari No. 140150), if in doubt, renew the plug also (Ferrari No. 159923).
9. Remove power steering reservoir lid and siphon or pump the power steering fluid out of
reservoir. Try to remove as much fluid as possible to reduce mess & spillage.
10. Unscrew jubilee clips on pipes to/from coolant tank, prise hoses off spigots and remove
tank. There are 2 smaller bore de-gas tubes at the top and 2 larger bore feed/return
tubes underneath the tank.
11. Unscrew jubilee clips for PAS reservoir, prise hoses off spigots and remove reservoir.
There are 2 tubes: feed & return. These are different diameters to ensure correct
orientation/connection.
12. Carefully unclip the throttle cable retaining E-clip. Do not allow the E-clip to ‘ping’ across
the workshop. The retaining bracket and clip is bolted to the thermostat housing.
13. Disengage the throttle cable from the bracket and disengage from throttle linkage. Tuck
the free cable in front of the engine making sure it cannot get tangled as the engine is
removed.
14. Loosen jubilee clips for radiator feed & return pipes. Prise off and remove the hoses.
There are 2 large diameter (40mm) hoses.
15. Loosen jubilee clips for cabin heater feed & return pipes. Prise off and remove the hoses.
There are 2 small diameter (18mm) hoses.

Technique for raising the vehicle with 2 jacks

C
1. Incorrect lifting technique could possibly
lead to damage of the vehicle structure &
bodywork. Caution is required.
2. The 355 has 4 “jack” points under the
vehicle. The illustration shows the location A B
of the jack points (arrows A & B). The
construction of the 355 is such that lifting the entire vehicle and powertrain weight only
from points B simultaneously with the front wheels on the ground puts a high tensile
loading on the roof panel (arrow C) and a high cantilever moment at the relatively weak
point at the base of the B pillar. This is particularly critical on the GTS & Spider versions.
3. Only jack from both points B simultaneously when lifting the body away from the released
engine cradle. When jacking, ensure both doors are closed and the GTS has the roof
panel is in place.
4. When working on the steps other than lifting the body away from the engine ensure the
car is supported by axle stands placed under the main engine frame members adjacent
to the suspension lower wishbones.
5. Always firmly chock both front wheels.

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Wheels, body & trim.
1. Lift the car and position axle stands as described above.
2. Remove both rear wheels. Mark each tyre with crayon to identify LHS/RHS or rotation.
3. In each wheelhouse remove the gravel guards (wheel house lining plates). Each
wheelhouse has 3 separate plates. These are held in place by crosshead screws and
there is also an 8mm nut which holds the air induction tubing in position.
4. As you remove each piece clearly mark where it came from to aid reassembly. Use
masking tape for this purpose and write on the tape.
5. Safely store all screws etc.
6. Remove engine under shield and 10
central under shield. These are held
in place by 8mm nylock nuts and
cross head screws.
7. Remove rear under body venturi
trims, left hand and right hand side.
8. Remove lower exhaust heatshield.
9. Unscrew outer bumper fixing
fasteners, these are 2x13mm nuts
found at the rear of each wheelhouse
left hand and right hand side.
10. Unscrew inner wheelhouse fasteners,
2x17mm nuts. 9
11. Prepare a soft blanket or similar to
rest rear bumper to prevent damage.
12. With an assistant, remove the rear
bumper from the vehicle. Be ready to disconnect the licence plate lamp connector that is
on the left hand side of the bumper. Store the bumper safely, well away from the working
area.

Exhaust & secondary air system 7

1. The entire exhaust system, secondary air
rail and bypass catalyst must be
removed (not the manifolds).
2. Remove joint clamp from catalyst outlet
on both sides of the vehicle. 2x10mm 8
nuts/bolts each side.
3. Unscrew bypass valve securing bolts
taking care to note the orientation of the
spring on the upper bolt, 2x13mm nuts &
bolts. 5
4. Disconnect the vacuum hose to the 3 5
bypass valve, then holding the bypass
valve and spacer ring carefully ease the 2 2
muffler box away from the engine.
Remove the bypass valve and spacer
and store safely.
5. Unscrew silencer to cross bar support bolts, 2x13mm
nuts/bolts each side.
6. Be prepared to support the weight of the muffler, lower to the
ground and remove from below the vehicle.
7. Unscrew bypass catalyst joint clamps. There are 2x13mm
9
nuts/bolts and springs on each side. Carefully note the
orientation of the springs, bolts and washers. Prise bypass cat
away from manifold and remove it from the engine
compartment. Store safely. Carefully remove donut seals and
store, noting which side each sealing ring came from.
8. Unscrew secondary air rail retaining nuts. Disconnect the vaccum hose and air feed hose
in the right hand rear corner.
9. Disconnect silicone connection tubes for air rail to exhaust manifold flow check-valve.
10. Remove secondary air rail from the engine compartment & store safely.

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 Below vehicle
1. Drain motor oil from oil tank and engine. The oil tank has a 22mm plug, while the engine
has a 12mm hex socket.
2. Make sure the transmission is in neutral and Connection point
Shift rod
dismantle the gear shifter linkage at both
ends.

Remove this bolt at gear stick end.

3. Transmission and shift lever ends

have simple pivot bolts that must be
removed.
4. Remove the shifter link rod.

Left hand side wheelhouse connections

1. Dismantle clutch and brake circuit unions at the double
connector block on the main engine cradle spar. USE A
PROPER BRAKE PIPE SPANNER to avoid rounding-
off the fastener.
2. Prevent drips by sealing the pipes by wrapping with a
6
piece of plastic sealed with a strong elastic band.
3. Immediately clean spilt brake fluid and make sure it
does not come into contact with painted surfaces.
4. Unhook the handbrake cable spring and store safely.
5. Unscrew handbrake adjuster nut and locknut,
disengage handbrake cable from the bracket and hand-
start nuts back onto the cable end for safekeeping. 7
6. Disconnect ABS sensor wire. This is a cylindrical
connector at the top of the wheelhouse.
7. Disconnect Petrol vapour recovery hose.
This is a “quick-snap” connector –
squeeze outer ring while pulling apart.
8. Disconnect main A/C feed & return hoses
at the points circled in the picture.
9. Remove both ‘O’ rings and store for later
inspection.

Fuel feed
from filter
Fuel rail return
to tank
10. Disconnect engine fuel feed and return
pipes at the end of the fuel injector rail.
Fuel vapour purge line 11. Be prepared to quickly mop spilt fuel.
(from carbon canister)
12. Apply plastic and elastic bands as per
brake pipes to prevent further spillage.

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Right hand side wheelhouse connections
1. Dismantle brake circuit union at the connector block on the main engine cradle spar.
Prevent drips etc. as per LHS process.
2. Disconnect ABS sensor wire as per LHS process.
3. Place an oil drain tray below the oil radiator prior
to disconnection of oil feed/return pipes.
4. Using a very large adjustable spanner or stilsons
unscrew large pipe-nut on the side connector of
the oil tank (pipe 38 in diagram).
5. Dismantle flange joint on front face of oil tank,
items 50/51 in the diagram.
6. Disconnect pipe nut at the bottom of the oil
radiator and remove the oil pipe. Allow oil to drain
from radiator into the drain pan.
7. Disconnect fuel feed/return pipes as per LHS
process.
8. Unscrew oil tank to body securing bolts (there are
two).

Electrical connections
1. Disconnect electrical connectors as per checklist on
page 8.
2. In addition to the electrical connectors, unscrew and
remove ‘P’ clips for the exhaust thermocouple cables,
Lambda sensors and main 12V power cables.
2

3. Unscrewing the 2x10mm nuts allows

disconnection of the main 12V power
cables.

2.a

2.b

Disconnection of powertrain frame from body structure

1. The powertrain frame is secured by 20 bolts.
2.c
2. These are located as follows:
a. 2 groups of 6 self-aligning bolts at the base of the
cradle, end of each main spar.
b. 2 bolts each side, directly in front of suspension strut.
c. 2 nuts/bolts each side, adjacent to the exhaust catalysts.
3. As a first stage, loosen all frame bolts ¼ turn
only, other than those at 2.b.
4. Place the trolley below the engine and lower
the vehicle so that the weight of the
powertrain is being fully borne by the trolley.
5. Position the 2 jacks under the rear jacking
points.
6. Remove all the cradle bolts. Access to some
of these bolts is very awkward, in particular
those adjacent to the oil tank. Do not get
frustrated or tempted to rush this part of the
job.

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7. Prior to lift-off double and triple check that all hoses, tubes and wires have been
disconnected. Use the checklist, and look for any additional connections that may be
specific to your model.
8. Check that all disconnected items are tied back or tucked well out of harm’s way so they
cannot become tangled when the body is lifted clear.

Lift-off
1. When absolutely sure that all disconnections are complete, lifting of the body can
commence.
2. With an assistant, lift both sides of the car
simultaneously approx 2.5 cm (1”) and stop.
3. Thoroughly check that the cradle is coming free from
the body.
4. Lift the body a further 2.5 cm and re-check that all is
clear, and co connections have been missed.
5. Guide the oil tank pipe union thread past the cradle
spar (circled in picture).
6. Continue to lift the body away from the cradle,
constantly observing and listening for potential touch
conditions.
7. Lift the body until frame corner A (in picture below) is
5 cm higher than the
lateral tube B.
8. Wheel the engine out from
underneath the body,
guiding the valley of the A
engine past frame corner
A.
9. Using this technique it is
not necessary to lift or tilt
the engine on the trolley.
10. Once the engine is fully
clear lower the body and B
support with axle stands.

Next steps
The next instalment in this series will
be posted on www.ferrarichat.com
when complete.

RF128706. March 2005

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 F355 Engine Removal Connection checklist

disconnect

reconnect
Hoses/tubes
1 Radiator feed hose firewall middle
2 Radiator return hose firewall middle
3 Heater feed hose firewall middle
4 Heater return hose firewall middle
5 Coolant de-gas hose firewall middle
6 Fuel vapour vent hose LHS front corner
7 Fuel feed LHS LHS front corner
8 Fuel return LHS LHS front corner
9 Fuel feed RHS RHS front corner
10 Fuel feed RHS RHS front corner
11 Secondary air rail (remove entire tube asy) exhaust manifolds & RHS rear corner
12 vacuum feed to reservoir RHS rear corner
13 Power steering feed firewall LHS
14 Power steering return firewall LHS
15 A/C feed inside LHS wheel arch
16 A/C return inside LHS wheel arch
17 Brake line LHS LHS wheel arch
18 Clutch line LHS LHS wheel arch
19 Brake line RHS RHS wheel arch
20 Oil feed to oil cooler RHS wheel arch
21 Oil return from oil cooler RHS wheel arch

Electrical
22 Main starter and alternator cables (2 cables) RHS middle
23 Suspension actuator LHS LHS wheel arch, upper
24 Suspension actuator RHS RHS wheel arch, upper
25 ABS connection LHS LHS wheel arch, upper
26 ABS connection RHS RHS wheel arch, upper
27 Lambda connector LHS LHS rear corner
28 Lambda connector RHS RHS rear corner
29 Engine loom connectors LHS (2 plugs) LHS rear corner
30 Engine loom connectors RHS (2 plugs) RHS rear corner
31 ECU connector LHS LHS rear corner
32 ECU connector RHS RHS rear corner
33 Aux connector LHS LHS rear corner
34 Thermocouple connector LHS LHS rear corner
35 Thermocouple connector RHS RHS rear corner
36 Ign. Coil connector LHS LHS middle
37 Ign. Coil connector RHS RHS middle
38 Oil sensor connector underneath oil tank

Other
39 Handbrake linkage LHS wheel arch
40 Gearshift rod below vehicle, both ends
41 Throttle cable central, below water tank

Additional model specific items

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