Inside Ferrari's Engine Assembly: How the California T and FF Are Built

Marinelo is the only facility in the world that controls the entire engineering and manufacturing process. This engine block, for instance, was cast in the Marinelo aluminum factory and machined in its mechanical machining department. The plant has two engine assembly lines, one for V8s and one for V12s. Here on the V8 line, a technician oils the bores before loading the pistons. An automated quality control system photographs each piston to ensure it's been properly inserted into the correct cylinder bank.

A technician flips the engine block 180° before carefully positioning a register template. This will hold the ends of the con rods apart as he sprays oil on the bearings. Once he's finished the oiling procedure, he can then install the crankshaft. The steel crankshaft is one of the few engine components that isn't forged in the Marinelo foundry, but Ferrari does spend 35 days machining, heat treating, and finishing the component. The technician positions a template that holds the crankshaft in place while he adds the conrod caps. These he positions one by one before torquing them securely in place around the crank.

A team member attaches a specialized device and uses it to rotate the crankshaft, moving the pistons through their bores and ensuring the installation has been successful. With the gasket in position, a technician now installs the cylinder head. As with the rest of the engine, this aluminum component was cast and machined by Ferrari inhouse. The aluminum cam cover with cam shafts already in place is ready for installation. Ferrari uses between 5 and 7 tons of aluminum alloy per day in their foundry. Each casting requires 8 to 12 different sand cores to produce. A technician brings the aluminum timing chain cover to the engine where he aligns and installs it.

He applies a specialized grease to bolt studs to ensure the correct torque is applied when subsequently tightening the retaining nuts. He positions a guide over the cover. This shows the correct order in which insertion and torquing should occur. The order is important to ensure that the gaskets are uniformly sealed and to reduce the risk of overtightening any single bolt. A technician installs the injector rail for the direct injection system. The rail injects highly pressurized gasoline into the combustion chamber of each cylinder.

This leads to increased fuel efficiency and power output. After manually snugging the attachment bolts, he uses a device to tighten them to the specified torque. The pipe he attaches to the fuel rail is capable of handling highly pressurized material. The other end connects to the fuel pump that pressurizes the gasoline. Next, he brings the wiring harness for the eight ignition coils to the engine and begins plugging it in. He clamps it at key attachment points to ensure the wiring doesn't shift out of position.

A technician installs one of the engine's two twin scroll turbochargers. Ferrari added turbos to the California T in 2014 to boost the car's efficiency and power. Turbochargers use the exhaust gas from the engine to spin a turbine, which turns a compressor, driving extra air into the cylinders. The car maker sources these components from the Japanese manufacturer IHI. The catalytic converter, exhaust, and intercooler air intake are all in place.

The innovative exhaust header and other high-tech advances help overcome the turbo lag and slow throttle response that usually accompany these amazing turbocharged engines. The California T drivetrain is a state-of-the-art powerhouse which includes an F1 dualclutch 7-speed gearbox and multi-link rear suspension. Powertrain assembly, which takes 2 and 1/2 hours, is done on a subasssembly line parallel to the general assembly lines. Here, technicians use a hydraulic lift to help them mount the gearbox in a rear transaxle layout, a position which optimizes weight distribution throughout the car. Torque control drivers ensure fasteners are tightened to the correct parameters.

The F1 type gearbox has been modified for performance and efficiency. So, while the 2016 California T can accelerate to 60 mph in under 3.6 seconds. Fuel consumption is down 15% from previous models. A technician now installs the rear hubs with axles and multi-link suspension systems. Unlike older, heavier forms of independent rear suspension systems like swing axle, trailing arm, or McFersonson strut, a multi-link system uses several short links to attach the hub to the subframe. The links are designed to allow the wheel to travel up and down over bumps without altering its tilt or camber angle.

This in turn leads to better traction and handling. With the rear suspension in place, the powertrain sub assembly advances to the next station where it will meet its centerpiece. Technicians use a hoist to bring the engine to the sub assembly. With the help of the hoist, they insert the V8 into the subframe, ensuring it aligns correctly with the openings for the fixing bolts. For 80% of the bolts in the California T, members of the Ferrari assembly team use electronic drivers, which automatically control the torque and angle as they tighten fasteners in place.

A technician installs a hose which will move coolant to and from the gearbox's oil radiator. As assemblies move down the line, team members switch seamlessly from one model to the other. The V8 line alone has produced as many as six different Ferrari models simultaneously. Longer hoses will allow coolant to travel back and forth from the engine to the radiator. A technician installs and clamps them securely in position. The assembly moves forward on the automated track every 19 minutes, allowing ample time for workers at each station to complete their tasks.

This feature is meant to ensure optimal quality. Before installing the torque transfer, a heat shield goes in to protect it from the exhaust pipes. Made of steel, the torque tube is hollow to reduce weight. It transfers torque from the engine to the transaxle. This configuration allows the engine to maintain its position in the midfront of the car for good weight distribution while sending torque to the rear wheels for optimal power. A specialized clamping system holds the tube in place as an automated wrench tightens the fastener.

The Ferrari's exhaust system has two final silencers, one for each of the engine cylinder banks. These silencers ensure a quiet ride around town and at cruising speeds. But while this powertrain is designed for quiet luxury, it's also built for speed. Gun the engine and bypass valves open in the exhaust system. This boosts performance by reducing back pressure and lets the California T sound like an old school Ferrari. Once the sound and heat insulation has been applied, technicians install the harness, which is made up of 1640 yards of wiring and includes 300 connectors. Ferrari builds the California TE's dashboard on a parallel sub assembly line. Upstairs, the in-house upholstery department trims the entire cockpit.

The upholstery team includes 40 highly specialized crafts people. 15 standard leather colors are available together with the range of Alcantara and other materials. A technician installs the steering wheel using a specialized tool to center it. The paddle shifters, now a standard feature on many high-end cars, were invented by Ferrari for its 1989 F1 car. A team member uses a wheeled hoist system to mount one of the front hub assemblies, which includes the double wishbone suspension and the Brembo carbon ceramic brakes.

A handheld automated wrench allows him to fasten bolts in tight places. The completed powertrain travels on an automatic guided vehicle that follows an electromagnetic field embedded in the floor. Reaching the general assembly line, the guidance system positions the powertrain precisely under the waiting California T body. The powertrain rises to meet the descending body and team members attach the subframes to the chassis with a total of 38 bolts.

A technician uses a specialized hydraulic arm to pick up a wheel and bring it to a front hub where he mounts it, installs the lug nuts, and tightens them all simultaneously with a torque controlled device. Customers can opt for partly electric or fully electric seats with multi-memory settings and heating and cooling functions. The seats upholstery can be fully personalized. Ferrari created the first retractable hardtop roof of its kind for the 2008 California T. The lightweight aluminum folding mechanism occupies little space when stored in the rear.

The automated system can retract and store the roof in just 14 seconds. A specialized robot arm reads the position of the windshield and picks it up. The mechanism then cleans the perimeter of the glass and sprays that area with a primer, which quickly dries. The robot then applies a thick bead of high-tech high viscosity polyurethane glue before aligning the glass with its frame and installing it, holding it in place until the glue is stable. On a parallel sub assembly line, technicians mount the window runners and electronics on the all aluminum doors before they go to general assembly. Here, a team member installs the left front door. The leather trim panels are left off to prevent damage.

The prancing horse derives from a similar image on the fuselage of the plane piloted by heroic World War I pilot Francesco Baraka. Baraka's parents suggested Ferrari put the prancing horse on his cars for good luck. The clear division between dash and tunnel and the round air vents are distinctive Ferrari features. It can take 5 days to upholster this interior. In position, the hard top reduces wind noise and drag better than a soft top. But on a warm, sunny day, it's hard to resist the urge to stow it away. The first major component of this car is the 12cylinder engine block. Made of lightweight aluminum. It is the core of the 660 horsepower engine. In the in-house foundry of the factory,

a worker uses a high-pressure blower to remove any remains from casts used to create the essential molds of the aluminum engine cylinder blocks. Using highquality chemicals and sand, the combination is pressed in a gravity-powered mold which produces the cast of the internal intake and exhaust pipes of the cylinder block head. This technology guarantees the best mechanical performance of the individual pieces and is also used in developing engines of prototypes for Formula 1 race cars. The work removes the sand molds to another area to remove any unnecessary pieces. Using a small saw, file, and a sanding sponge, the pieces are removed

to conform to the cast design necessary to create the internal pipes of the block head. The sand molds will also undergo a regeneration process where the sand will be reused to create future molds. The finished sand molds arrive at another workstation where they are assembled. A worker places the bottom components together before using a lifting device to deliver the larger and heavier top section, completing the cylinder block matrix. Once the grouping of molds is aligned, a set of transport spikes from a lifting device usher the grouping to another workstation where the molds are cured in a high temperature kiln called a waiting oven. The molten metal will flow into

all vacant spaces left free by the sand mold. Thousands of aluminum ingots can be found in a storage bay at the Marinelo factory. These blocks are melted at nearly500° F in order to become the engine cylinder blocks. As molten aluminum, the smelted metal is poured through a funnel and injected into sand casts, soon to become one of the most integral parts of the engine. The waiting oven's 1400° temperature is consistent in order to prevent any defects or air bubbles within the block. Once the molten aluminum hardens, the automated clamps from the kiln release the mold, allowing the new aluminum parts to cool before removal from the molds.

An automated lift removes the finished cast and cylinder block from the heated station. A worker extracts the aluminum pieces from the sand mold, which is discarded. Quality control is imperative to the assembly of the engine. At the first workstation, a worker places the cylinder block on a table, inspecting the part with a small flashlight for any cracks or imperfections within the cavities. Very little variation in the mold is tolerated from beginning to end. Up to 8,000 instruments are used to control dimensions throughout the process of building the cylinder block.

The engine cylinder block underos a secondary look in a radiation shielded cabinet of a radiocopic inspection system. This further detects any possible flaws in the cylinder block's construction. After getting the green light from the X-ray inspection, a worker mounts the cylinder block onto a fixture where it travels into a small cabinet for refinement. This CNC device removes any additional and unwanted materials within the block center using high-pressure water and sand grains. As a result of this refining process, the cylinder block looks sleeker than before. The worker removes the holding bolts and the part is ready for the next workstation. At another workt in the metrology room, a worker uses a computerized measuring

tool known as a touch probe to verify the Ferrari FF cylinder blocks tolerance and integrity. Later in the show, we'll see much more of this engine. Ferrari's mechanical workshop is comprised of 15 areas containing workstations with machine tools, offices, and two green areas. It's a space where technology and environmental sustainability coexist. In this particular room, two assembly robots, affectionately nicknamed Romeo and Juliet, install valve set inserts into the cylinder head, an operation known as the thermal interface process.

One robot passes the ring to the other robot which places the ring into the head. The valve sets cool and shrink 40 to 60 microns in liquid nitrogen cooled atus 320° F. When the valves are warmed up to room temperature, which increases its volume by.12 to.15 mm, they clasp tightly into place. This area is known as the 12cylinder assembly line composed of five sections. In the first section, a worker moves the 12cylinder engine block to a table to install the cylinder sleeves. Using a rubber mallet, she hammers the sleeves into place with the assistance of a support fixture, which lifts and releases each sleeve into the block pipes. That action is repeated until she installs the 12 liners. The cylinder liners serve as the inner wall of a

cylinder, forming a sliding surface for the piston rings while retaining the lubricant within. A worker double checks that the sleeves are aligned with the blocks pipes by tapping the ends with a rubber mallet. A worker rotates the engine cylinder block on a lift, oiling the cam bearings before placing the crankshaft into position. Once the crankshaft is in place, the worker installs containment clamps to keep the rotating part in position. He rotates the entire cylinder block in preparation for the installation of the engine's pistons.

The engine pistons are made for maximum efficiency using the same research and development for Ferrari's Formula 1 racing cars. A worker installs each of the 12 pistons by hand and verifies that they are inserted correctly with the assistance of a cylindrical guide. Once finished, this 12cylinder engine, along with its other running components, will allow the car to reach a top speed of over 200 m an hour.

The 12cylinder engine spends roughly 62 minutes at each station. It takes approximately 5 days for assembly. Almost complete, the engine requires the proper electrical wiring and mechanical tubing. A worker meticulously places a web of tubes onto their proper outlets. Once the wires and tubes are connected, he secures them with high strength screws and fasteners. The velocity stack is part of the engine's air intake system, which allows for a smooth and even flow of air at high velocities. The worker adds the stack and bolts it on each side using an air impact wrench. This car's engine

delivers a sensational tone because the intake noise is channeled from filter casings into the cabin, making an unmistakable sound without being loud. The worker uses a motorized assembly shuttle to transport the engine just a few feet away, where the velocity staff will receive its stylish covers. This completes the assembly of the high-end V12 engine. The 6.3 L V12 direct injection 6,262cc engine delivers a power output of 660 horsepower at 8,000 RPM with maximum torque of 504 lb feet at 6,000 RPM.

Built for impressive response and unparalleled performance, this engine is solely made for the FF model. After the assembly, the engine underos a series of driving and emission tests. This section of the assembly line is where workers install mobile parts like doors and trunk lids as well as interior parts. Operation and quality control tests are executed before the body moves to the next line. Prepared and waiting, the hatchback body shell hangs in an overhead carousel bracket before the next assembly phase. The dashboard may seem unfamiliar, but this is a crucial step in installing its switches and dials. In the upholstery department, nearly 75%

of all interior cabin work is done by hand. The car's chassis is about higher cabin comfort, space requirements, and safety standards. Using a space frame design and made from aluminum, the car's chassis is much lighter than any other road car in the automaker's history and with greater torsional rigidity. The interiors are always personalized with options like matching or contrasting stitching, accents like carbon fiber or fabrics with aluminum effect or titanium effect. With the assistance of a lifting device, workers install the dashboard, ensuring that the console parts fit securely. Once the dashboard has been mounted, the steering wheel equipped with the main controls will be added, offering different vehicle dynamics.

A worker inspects the running gear, which includes the engine and drivetrain for installation below the body shell. This car's all-wheel drive system is 50% lighter than the average system with two independent traction systems. The rear wheels provide the power with torque transferred only to the front axle when required. Using a mechanized dolly, the worker moves the running parts below the frame where another worker lowers the carousel bracket and the large components meet halfway. A team of workers merge the running gear consisting of the suspension, steering, and all-wheel drive powertrain with the shooting brake body shell using power tools to lock the parts in place. With the assistance of a lifting device,

a worker places the five-spoke rims and tires on their respective wheel plates, securing them with bolts. Both the front windshield and rear windows receive a high strength adhesive that a robot deposits onto the edges of the glass. Another robot precisely anticipates the car's location and delivers the new windows into their respective positions with calculated pressure and care. After 1 month of assembly, a worker fills gasoline into the tank. With the majority of the vital parts in place, the car requires a few more elements before becoming an extreme twodoor hatchback.

All style and soul aside, this car was built to tackle even the lowest grip terrain, including snow, ice, and dirt. Its modern shooting brake shape and styling cues are to be admired. The chassis engineering delivers supercar dynamics and the prancing horses F1 racing DNA. Tailored to perfection, the leather interior is as stellar as the bold exterior.