Santana PS-10 Service Manual

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Page 3 WARNING: This handbook has been prepared for the authorized SANTANA dealers and for the mechanics undertaking the servicing. It could be that mechanics without the adequate experience or without the appropriate tools and equipment could not perform properly the servicing described in this publication.
Page 4: Propeller Shafts
HEATER AND VENTILATION disassembling and assembling of major components and general repairs. BUMPERS, FRONT HOOD AND FRONTAL Apply to: MODEL SANTANA on and after the following body number: STEERING, SUSPENSION, VSFPSW10V00100001~ WHEELS AND TIRES VSFPSW20V00100009~ General diagnosis Front end alignment...
Page 6: Table Of Contents
MAINTENANCE AND LUBRICATION 0B-1 SECTION 0B MAINTENANCE AND LUBRICATION CONTENTS MAINTENANCE SCHEDULE ..........................0B- 2 - Maintenance under normal driving conditions ................... 0B- 2 - Maintenance under severe driving conditions ..................0B- 3 MAINTENANCE SERVICES ..........................0B- 4 - Engine (Item 1) ............................0B- 4 •...
Page 7: Maintenance Schedule
0B-2 MAINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE MAINTENANCE UNDER NORMAL DRIVING CONDITIONS INTERVAL: This table includes services as sscheduled up to 120.000 Km The interval can be fixed either by odometer (72.000 miles) milease Beyond 120.000 Km (72.000 milles) reading or months; whichemer comes first. coming out the same services at the same internals respective.
Page 8 MAINTENANCE AND LUBRICATION 0B-3 MAINTENANCE UNDER SEVERE DRIVING CONDITIONS If the vehicle is driven under the conditions stated under SEVERE DRIVING described below, it is advised to carry out the MAINTENANCE operations on the corresponding parts, according to the particular intervals indicated in the following table.
Page 9: Maintenance Service
0B-4 MAINTENANCE AND LUBRICATION MAINTENANCE SERVICE NOTE: The maintenance service should be done according to order as established in the SCHEDULE UNDER NORMAL DRIVING CONDITION, see OB-2. WARNING: All the inspection Works and changes must be carried out with ENGINE NOT RUNNING and THE BATTERY DISCONECTED (if it is not necessary the electrical tension for the work been carried out).
Page 10: Engine Oil And Filter (Item 1.3)
MAINTENANCE AND LUBRICATION 0B-5 Replacement and adjustment • In order to substitute or adjust the tension the generator and water pump belts, see 6A-26. • In order to substitute or adjust the tension of the A/A compressor belt, see 6A-27. Timing Belts (Item 1.2) To substitute the timing belt see 6A-28.
Page 11 0B-6 MAINTENANCE AND LUBRICATION 4) Fill with the recommended oil through the hole (2) and check oil level using the dipstick (3). Oil type and amount Recommended oil SAE 10 W/40 Viscosity Standard API SJ/CF NOTE: If the recommended oil is not the one adequate to the climate of the country where the vehicle is being utilized (see viscosities table), use the required SAN- TANA MOTOR oil.
Page 12 MAINTENANCE AND LUBRICATION 0B-7 Changing the oil filter 1) Use an appropriate container to dispose the used oil from the filter. 2) Using special spanner (A) ref. 790972, unlock the oil filter (4). 3) With an appropriate clean new brush cleanse the area where the filter contacts the coupling.
Page 13: Injectors Gauging (Item 1.4) (Only Mechanical Injection)
0B-8 MAINTENANCE AND LUBRICATION Injectors gauging (Item 1.4) (ONL (ONL (ONLY MECHANICAL INJECTION) Y MECHANICAL INJECTION) Y MECHANICAL INJECTION) Y MECHANICAL INJECTION) (ONL (ONL Y MECHANICAL INJECTION) Data for injectors gauging SACLESS DSLA BOSCH type sprayer 134 P 604 Gauging controls below 200 bars 230 + 8 bar Running Gauging 240 + 12 bar...
Page 14 MAINTENANCE AND LUBRICATION 0B-9 Substitution Draining 1) Open fully the heating tap (lever (c) displaced totally toward the left, refer at 1A-3). 2) Unlock cap (1) from spout. 3) Release totally the draining plug (8) of the radiator and withdraw all refrigerant from the circuit. 4) Unlock plug (8) squeezing the lever (9).
Page 15 0B-10 MAINTENANCE AND LUBRICATION 2) Proceed to till the circuit till mouth (11) as follow: • Pour the coolant slowly (approximately 8 litres per minute); this will avoid air pouches within the circuit. • Place a screen in front the radiator. This will help to reach fast the optimal working temperature once engine is started (94°C to 110°C).
Page 16: Water Radiator (Item 1.6)
MAINTENANCE AND LUBRICATION 0B-11 Water Radiator (Item 1.6) External Cleaning • External cleaning of the water radiator (1) must be done with pressurized water, compressed air and a brush no harming the refrigerating panel. • Do not use sharp pointed objects which could damage the refrigerating panel.
Page 17: Exhaust System (Item 1.9)
0B-12 MAINTENANCE AND LUBRICATION Exhaust system (Item 1.9) Inspection • Check the worthiness of the elastic supports (1) just in case there were any problems. • Check for any leaks, significant dents, loose couplings or damages. • Check the areas around the exhaust system looking for damaged or badly fitted pieces, weldings or open unions, holes or other defects leading to eventual inlet of gases inside of the vehicle.
Page 18: Fuel System (Item 2)
MAINTENANCE AND LUBRICATION 0B-13 FUEL SYSTEM (Item 2) MECHANICAL INJECTION Fuel filter and air purge (Item 2.1) • MECHANICAL INJECTION MECHANICAL INJECTION MECHANICAL INJECTION MECHANICAL INJECTION MECHANICAL INJECTION To substitute the filter element (1), as well as to air purge with pump (2) through purger (3), see 6C-8 "MANIPULATING THE FUEL FILTER ".
Page 19 0B-14 MAINTENANCE AND LUBRICATION Fuel prefilter (Item 2.5) (ONL (ONL Y COMMON R Y COMMON R AIL) AIL) (ONL (ONL (ONLY COMMON R Y COMMON R Y COMMON RAIL) AIL) AIL) Substitution 1) Untighten clamps at each side of the filter (1) and dismount. 2) Mount the new filter respecting the assembly and filtrating position.
Page 20: Transmission (Item 3)
MAINTENANCE AND LUBRICATION 0B-15 TRANSMISSION (Item 3) Gear Box Oil (Item 3.1) (Levelling and oil changing) Oil levelling 1) Place the vehicle on flat even ground, pit or hydraulic lifter. 2) Check there are no leaks; otherwise act on them. 3) Unlock level and filling plug (1).
Page 21: Transfer Box Oil (Item 3.2)
0B-16 MAINTENANCE AND LUBRICATION Transfer Box Oil (Item 3.2) (Oil level and replacement) Oil Level 1) Place the vehicle on flat even ground, pit or hydraulic lifter. 2) Check there are no leaks; otherwise act on them. 3) Unlock level and filling plug (1). When unlocking, a small oil will come out through the hole, meaning that level is right;...
Page 22: Differential Groups Oil (Item 3.3)
MAINTENANCE AND LUBRICATION 0B-17 Differential Groups Oil (Item 3.3) (Oil level and replacement) Oil Level 1) Place the vehicle on flat even ground, pit or hydraulic lifter. 2) Check there are no leaks; otherwise act on them. 3) Unlock level and filling plug (1). When unlocking, a small quantity of oil will come out through the hole, meaning that level is right;...
Page 23 0B-18 MAINTENANCE AND LUBRICATION Propeller Shafts (Item 3.4) (Inspection and Lubrication) Inspection 1) Check the worthiness of the universal and constant velocity joints of the propeller shafts with the following steps: • With the vehicle placed on the pit or the hydraulic lifter, try fast wheels turnings left and right by hand, as indicated in the figure.
Page 24: Clutch Liquid (Item 3.5)
MAINTENANCE AND LUBRICATION 0B-19 Clutch Liquid (Item 3.5) (Inspection, level, substitution and air purging) CAUTION: The clutch liquid can damage the car enamel. If liquid fell on the enamel, clean well immediately. Inspection 1) Check there are no liquid leaks through linkages, around the main cylinder (2), liquid tank (1) or auxiliary cylinder (3);...
Page 25: Clutch Pedal (Item 3.6)
0B-20 MAINTENANCE AND LUBRICATION Clutch pedal (Item 3.6) (Pedal height and free travel) Pedal height Check the clutch pedal height (A); if different than the specified value adjust with the adjusting screw (1 ). Clutch lever height (A): 140 mm Free travel 1) Check the clear path of the clutch lever (B) as follows: From the lever rest position, press with a finger till you feel the...
Page 26: Visual Control And Running (Item 3.7)
MAINTENANCE AND LUBRICATION 0B-21 Visual control and running (Item 3.7) Inspection 1) Check visually the gear box, transfer box and differential groups for oil leaks through joints and oil seals. 2) Check there are no liquid leaks in the clutch hydraulic circuit, principal pump or small auxiliary pump.
Page 27: Brakes, Steering, Suspension And Wheels (Item 4)
0B-22 MAINTENANCE AND LUBRICATION BRAKES, STEERING, SUSPENSION and WHEELS (Item 4) Brake Discs and Pads (Item 4.1) Inspection NOTE: For brake blocks removal see 4A-9. 1) Check the brake pads for wear and uniformity. 2) Check the brake discs for wear, uniformity and deflection measured with the dial gauge.
Page 28: Performance Inspection
MAINTENANCE AND LUBRICATION 0B-23 Liquid Level 1) Brake liquid level must be on the line (A) (MAX) of the tank (1); otherwise, add up till reaching the maximum level (MAX). CAUTION: Use new recommended brakes liquid. NOTE: If liquid was withdrawn from the circuit leading to the formation of air bubbles, you will have to air purge after filling.
Page 29: Steering Mechanical System (Item 4.4)
0B-24 MAINTENANCE AND LUBRICATION Steering Mechanical System (Item 4.4) Inspection 1) With vehicle standing on the ground, wheels straightened and engine off, check the steering play (A); which must be in accordance with the specified value. Steering play (A): 10 ÷ 30 mm To check play (A), proceed thus: •...
Page 30: Servo-Steering Hydraulic Oil Filter (Item 4.6)
MAINTENANCE AND LUBRICATION 0B-25 Servo steering hydraulic oil filter (Item 4.6) Oil Filter Substitution 1) Unlock tank cap (1). 2) Squeeze filter drive (4), turn it leftwards 45º approximately and extract filter (2). 3) Choose a new filter and put it into the can ensuring that the lower hole fits inside the guiding tube (3).
Page 31: Servo-Steering Hydraulic Oil (Item 4.7)
0B-26 MAINTENANCE AND LUBRICATION Servo steering hydraulic oil (Item 4.7) (Inspection and oil level) Inspection 1) Check there are no leaks around the oil tank, hydraulic pump, steering box and sleeves; otherwise, correct them. MAXIMUM 2) Check the worthiness of sleeves and the components of the MINIMUM servo steering.
Page 32: Tyres (Item 4.9)
MAINTENANCE AND LUBRICATION 0B-27 4) Check the worthiness of the silent blocks (3), springs and framework to see if rubber is deteriorated, deformed or loose from the metallic bushing. 5) Check that the metallic ascending tops (5) have no deformations. 6) Check that the elastic descending tops (4) are sound.
Page 33: Wheels And Wheel Nuts (Item 4.10)
0B-28 MAINTENANCE AND LUBRICATION Maintenance 1) To equilibrate the wear on the tyres, exchange them BEFORE periodically as showed in the schemes. NOTE: • Fitting of new tyres, must be done with equivalent to the original ones. • Check the tyres air pressure when they are cold; the pressure is specified in owners hand book.
Page 34 MAINTENANCE AND LUBRICATION 0B-29 Visual control (Item 4.11) Inspection 1) Verify the worthiness of the dust protector of the ball and socket joints in case they show breakings, cracks, deformations or misplacing. 2) Check the correct path and holding of the rigid tubings of brakes and steering.
Page 35 0B-30 MAINTENANCE AND LUBRICATION CHASSIS, BODYWORK AND ELECTRIC SYSTEM (Item 5) Locks and hinges (Item 5.1) Inspection and lubrication 1) Check the correct operation of door and hood locks, ensuring that the principal and the secondary security locks work properly in each one of them. 2) Lubricate hinges and locks operating them while oiling.
Page 36: Final Inspection
MAINTENANCE AND LUBRICATION 0B-31 FINAL INSPECTION Try the vehicle on the road controlling the following: WARNING: When carrying out road test, select a safe place where no man or no running vehicle is seen so as to prevent any accident. 1) Engine start.
Page 37 0B-32 MAINTENANCE AND LUBRICATION 9) Seat belts. Check the retractors, anchors, safety locks and general estate of the seat belts. 10) Body. With the vehicle parked, check the following points: • Hood locks: principal and security one. • Door locks: principal and security one. •...
Page 38: Recommended Fluids And Lubricants
MAINTENANCE AND LUBRICATION 0B-33 RECOMMENDED FLUIDS AND LUBRICANTS PRODUCT TYPE DENOMINATION REF. 791003 ENGINE OIL API SJ/CF SAE 10W-40 791008 ANTIFREEZE REFRIGERANT DINAGEL-9103 (DINAMIC) -35°C BRAKES LIQUID DOT-4 791002 GEAR BOX OIL SAE 75W-90 API-GL-5 791004 SAE 75W-90 TRANSFER BOX OIL API-GL-5 791004 HIPOID GEAR...
Page 39 HEATER AND VENTILATION 1A-1 SECTION 1A HEATER AND VENTILATION CONTENT GENERAL DESCRIPTION ............................ 1A- 2 HEATER CONTROL OPERATION ......................... 1A- 3 DIAGNOSIS ................................1A- 5 ON VEHICLE SERVICE ............................1A- 6 Ventilator and diffuser unit ........................... 1A- 6 Heating valve ............................... 1A- 7 Heater motor ventilator switch ........................
Page 40: General Description
1A-2 HEATER AND VENTILATION GENERAL DESCRIPTION The heating for hot water type with in and out air flow, is manufactured to provide always permanent and pleasant ventilation, through air outlets on the front panel. The hot air outlet is located on the glove compartment side, and air outlets for windscreen demisting are located in the upper and sides of the glove compartment.
Page 41: Heater Control Operation
HEATER AND VENTILATION 1A-3 HEATER CONTROL OPERATION The correct handling of the heating system control is based on the use and proper handle of four levers. • Control lever A Control lever A has three working positions: • Ventilation position (1) •...
Page 42 1A-4 HEATER AND VENTILATION • Control lever D Control lever D is an air speed selection lever. The fan speed increases when the lever is displaced from left to right. FORCED VENTILATION HEATING INTRODUCING OUTSIDE AIR HEATING WITH INSIDE AIR CIRCULATION...
Page 43: Diagnosis
HEATER AND VENTILATION 1A-5 DIAGNOSIS Condition Possible Cause Reference item Heater fan does • Fan fuse broken Check fuse and for short-circuit not work when the • Heater resistor faulty Change resistor switch is "ON" • Fan Motor faulty Change motor •...
Page 44: On Vehicle Service
1A-6 HEATER AND VENTILATION ON VEHICLE SERVICE VENTILATOR AND DIFUSSOR UNIT Removal 1) Disconnect negative cable at battery. 2) Disconnect connector at ventilator and diffusor unit. 3) Remove air recirculation lever cable bolt (1) front ventilator and diffusor unit. 4) Remove ventilator nuts (2). 5) Extract unit (3).
Page 45 HEATER AND VENTILATION 1A-7 HEATER VALVE Removal 1) Remove bolts (1) from the tank. 2) Remove degassing tank without forcing the water hoses. 3) Disconnect opening and closing drive from valve (2). 4) Disconnect water inlet and outlet hoses (3) and (4) from valve and cover up them.
Page 46: Control Cable Adjustment
1A-8 HEATER AND VENTILATION HEATER BLOWER MOTOR SWITCH Removal 1) Remove heating system control levers (see 1A-9). 2) Remove heater blower motor switch nuts. 3) Remove switch, disconnect connector and check continuity from terminal to terminal. Instalation 1) Install a new switch, if necessary, and the other components reversing removal procedure, noting to tighten to specified torque.
Page 47 HEATER AND VENTILATION 1A-9 CABLES AND CONTROL LEVERS Removal 1) Remove control levers hub caps (1) front levers and withdraw the control panel (2). 2) Remove fixing screws (3) on the glove box where levers unit (4) is located. 3) Remove glove box (see 1A-10). 4) Remove control cables from their unions to: •...
Page 48: Heater Unit
1A-10 HEATER AND VENTILATION HEATER UNIT Removal Removal glove box 1) Remove steering wheel (see 3C-3). 2) Remove combined drives (see 3C-5). 3) Remove ventilator nozzles (1) and clock (2). 4) Remove hub caps (3), control panel (4) and the levers unit screws.
Page 49: Inside Ventilation
HEATER AND VENTILATION 1A-11 INSIDE VENTILATION When air admission control lever is at fresh air position, outside air enters inside the vehicle through the admission grille to be found in the front part of the windscreen, and comes out through the ventilation outlet located in the back side of the vehicle roof.
Page 51 BUMPERS, FRONT HOOD AND FRONTAL 2-1 SECTION 2 BUMPERS, FRONT HOOD AND FRONTAL NOTE: Fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or entail significant repair expenses. In case it was required to replace a piece, it should be one with same replace reference number or equivalent.
Page 52: Front Bumper
2-2 BUMPERS, FRONT HOOD AND FRONTAL FRONT BUMPER 1. Front Bumper. 2. Inspection cover. 3. Side thermo conformed pad. 4. Center thermo conformed pad.
Page 53: Rear Bumper
BUMPERS, FRONT HOOD AND FRONTAL 2-3 REAR BUMPER 1. Rear bumper. 2. Side pad. 3. Center pad.
Page 54: Front Hood
2-4 BUMPERS, FRONT HOOD AND FRONTAL FRONT HOOD 1. Hood. 2. Hinges. 3. Lock cable. 4. Lock assembly. 5. Cushion. 6. Stay.
Page 55: Removal And Installation Of Front Hood
BUMPERS, FRONT HOOD AND FRONTAL 2-5 REMOVAL AND INSTALLATION OF THE FRONT HOOD Removal 1) Remove the four fixing hood screws (1). 2) Withdraw the hood. Installation 1) Install hood reversing the dismantling steps and carry out the adjustment steps required for its correct assembly (see 2-6).
Page 56 2-6 BUMPERS, FRONT HOOD AND FRONTAL FRONT HOOD ADJUSTMENTS Longitudinal and transversal adjustment Loose the four screws (1), adjust lengthwise and transversally the hood and then fix it once adjusted. Vertical adjustment If one of the hod sides is no level with the fender, adjust loosing or tightening hood cushion (2).
Page 57: Frontal
BUMPERS, FRONT HOOD AND FRONTAL 2-7 FRONTAL 1. Front Grille. 2. Fender. 3. Register Cover. 4. Front Frame.
Page 58 2-8 BUMPERS, FRONT HOOD AND FRONTAL FENDER Removal 1) Remove the front bumpers and grille. 2) Disconnect lateral turn signal lamp. 3) Remove head lights from fender pulling till removal. 4) Remove head lights regulator. 5) Remove components found at the interior of the fender accordingly (supports, tanks, etc.).
Page 59 STEERING, SUSPENSION, WHEELS AND TIRES 3-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES CONTENT GENERAL DIAGNOSIS ............................. 3-2 FRONT END ALIGNMENT ............................3A STEERING GEAR BOX AND LINKAGE ........................3B STEERING WHEEL, COLUMN AND LOWER SHAFT ....................3C FRONT SUSPENSION ............................... 3D REAR SUSPENSION ..............................
Page 60 GENERAL DIAGNOSIS 3-2-1 SECTION 3 - 2 GENERAL DIAGNOSIS CONTENT GENERAL DIAGNOSIS TABLE ..........................3-2-2 TYRE DIAGNOSIS ..............................3-2-5 Irregular and/or premature wear ........................3-2-5 Radial tyre waddle ............................3-2-6 Radial tyres lead ............................3-2-7 VIBRATION DIAGNOSIS ............................3-2-9...
Page 61 3-2-2 GENERAL DIAGNOSIS GENERAL DIAGNOSIS TABLE Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Proceed with the following preliminary inspection and correct any defectos which are found.
Page 62 GENERAL DIAGNOSIS 3-2-3 GENERAL DIAGNOSIS TABLE B Condition Possible Cause Task • Drag rod end ball joint hard Replacement drag rod end ball joint. • Disturbed front end alignment Check front alignment. Steering feels • Incorrect adjust steering box system Authorized dealer revision.
Page 63 3-2-4 GENERAL DIAGNOSIS GENERAL DIAGNOSIS TABLE C Condition Possible Cause Task Low or • Broken or weakened springs Replecement springs. uneven • Overloading Check loading. vehicle • Incorrect springs Replecement springs. height • Spring silent-blocks or body give up or broken Replecement silent-blocks.
Page 64 GENERAL DIAGNOSIS 3-2-5 TYRES DIAGNOSIS IRREGULAR AND/OR PREMATURE WEAR Irregular and premature wear can be attributed to different cau- ses. Same of them are: incorrect inflaction pressures, lack of tyres rotation, driving habits and improper alignment. If the following conditions are noted, rotation is necessary: 1.
Page 65 3-2-6 GENERAL DIAGNOSIS RADIAL TYRE WADDLE Waddle is side to side movement at the front and/or rear of the vehicle. It is caused by the steel belt not being straight within the tire. It is most noticeable at a low speed, 10 to 50 km/h. It is possible to locate the faulty tire by road testing the vehicle or “waddles“.
Page 66 GENERAL DIAGNOSIS 3-2-7 RADIAL TYRE LEAD Dragging is the deviation of the vehicle when is driven straight on a levelled road, without any force on the steering wheel. Dragging is usually caused by: 1. Incorrect Alignment. 2. Unequal brakes Adjustment. 3.
Page 67 3-2-8 GENERAL DIAGNOSIS Lead diagnosis INFLATE TYRES TO RECOMMENDED PRESSURE. ROAD TEST VEHICLE ON LEVEL UNCROWNED ROAD IN BOTH DIRECTIONS SWITCH FRONT TYRES SIDE TO SIDE AND ROAD TEST AGAIN LEAD CORRECTED. IF LEADS IN SAME LEAD REVERSE ROUGHNESS RESULTS, DIRECTION.
Page 68 GENERAL DIAGNOSIS 3-2-9 VIBRATION DIAGNOSIS Most of the vibration problems of highway speed are caused to wheel unbalance. If vibration remain after a dynamic balancing, its possible suses are as follows: SUSPENSION MOVEMENT (Loaded runout) 1) Tyre runout. 2) Wheel runout. 3) Tyre stiffness variation.
Page 70 FRONT END ALIGNMENT 3A-1 SECTION 3A FRONT END ALIGNMENT NOTE: To diagnose the failures of the different components leading to abnormal behaviour of the steering general system, refer to "CHARTS OF GENERAL DIAGNOSTICS" (3-2-2). CONTENT GENERAL DESCRIPTION ............................ 3A- 2 FRONT END ALIGNMENT ............................
Page 71 3A-2 FRONT END ALIGNMENT GENERAL DESCRIPTION OF WHEEL CENTER LINE FORWARD Aligment service data (unloaded) Body Toe-in 2 ÷ 4 mm Center 1º 30´ Camber Caster 3º P O S I T I V E Kingpin indication 7º TOE-IN CAMBER ANGLE CAMBER TOP VIEW Front alignment refers to the angular relationships between the front wheels, the front suspension attaching parts and the...
Page 72 FRONT END ALIGNMENT 3A-3 FRONT END ALIGNMENT PRELIMINARY CHECKS PRIOR TO ADJUSTING ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked is the possibility of tire liad due to worn or improperly manufactured tires.
Page 73 3A-4 FRONT END ALIGNMENT TOE ADJUSTMENT Check 1) Place the vehicle on levelled ground and with the front wheels along the vehicle length. 2) Measure the actual length (B) at height (A), with the appropriate meter and signalize on the tyre the measuring points.
Page 74 FRONT END ALIGNMENT 3A-5 CHECKING ALIGNMENT: CMABER, CASTER AND KINGPIN INCLINATION. Should camber or caster be found out of especification upon inspection, locale its cause first. If it is in demaged, loose, bent, dented or worn suspension parts, they should be replaced. If it is in vehicle body, perapir it so as to attain specifications.
Page 75 STEERING GEAR BOX AND LINKAGE 3B-1 SECTION 3B STEERING GEAR BOX AND LINKAGE NOTE: All diagnose failures of the different components which could be responsible of the anomalous behaviour of the steering general system, thoroughly revise " CHART OF GENERAL DIAGNOSTICS " (3-2-2). CONTENT DIAGNOSIS ................................
Page 76 3B-2 STEERING GEAR BOX AND LINKAGE SERVOSTEERING DIAGNOSTICS Condition Possible cause Reference item • Not enough oil Check oil level • Air in the system Check for leaks, purge and fill oil • Pressure pump does not provide enough fluid Authorized dealer revision.
Page 77: General Description
STEERING GEAR BOX AND LINKAGE 3B-3 GENERAL DESCRIPTION Power steering system reduces driver tiredness to rotate the steering wheel, using the hydraulic pressure generated by the power steering pump. The mechanical gear unit, the hydraulic pressure cylinder unit and the control valve unit constitute an integral set, and they are found in the gear box.
Page 78 3B-4 STEERING GEAR BOX AND LINKAGE STEERING RODS AND DRAG JOINTS DRAG ROD AND DRAG ROD END BALL Tie rodend ball joints revision 1) Check for play in drag rod end ball joints, by jerking upwards and downwards on the corresponding rod of in drag rod end ball joint.
Page 79 STEERING GEAR BOX AND LINKAGE 3B-5 Greasing 1) Remove boot with the adjustment springs. 2) Squeeze the internal spring of the floating axle of in drag rod end ball joint, using a press, and fill in with the recommended grease. 3) Assemble the boot again with the adjustment springs.
Page 80: Tie Rods
3B-6 STEERING GEAR BOX AND LINKAGE TIE ROD Removal 1) Remove the tie rod as you do with the drag rod (see 3B-4). 2) Remove in drag rod end ball joints and check them (see 3B-4). Installation 1) Install tie rod end ball joints (see 3B-4). 2) Install tie rod as you do with the drag rod (see 3B-4).
Page 81: Removal And Installation
STEERING GEAR BOX AND LINKAGE 3B-7 POWER STEERING GEAR BOX REMOVAL AND INSTALLATION CAUTION: Before starting removal clean carefully the components to be dismantled and the surroundings. Removal 1) Place the vehicle in an appropriate working place. 2) Place wheels straightened, which is equivalent to have the steering at the middle of its left or right handling.
Page 82 3B-8 STEERING GEAR BOX AND LINKAGE 9) Dismantle nuts (5) and remove the power steering gear box unit (6) Installation 1) Install power steering gear box (6) fixing nuts (5) at the specified torque. Tightening torque for fixing nuts of the power steering gear box: 7 ÷...
Page 83: Power Steering Pump
STEERING GEAR BOX AND LINKAGE 3B-9 POWER STEERING PUMP REMOVAL AND INSTALLATION CAUTION: Before starting dismantling clean carefully the components to be dismantled and the surroundings. Removal 1) Remove water radiator and air radiator (intercooler) (see 6B-8). 2) Remove hydraulic oil inlet connector (3) to the pump and pour the tank content in an appropriate container.
Page 84: On Vehicle Service
3B-10 STEERING GEAR BOX AND LINKAGE ON VEHICLE SERVICE STEERING WHEEL INSPECTION 1) With the engine off, wheels straightened and resting on the ground, make small turns with the steering wheel both sides. Annotate the play or dead path (A) that the steering wheel do before the wheels move.
Page 85: Power Steering Fluid Leakage Inspection
STEERING GEAR BOX AND LINKAGE 3B-11 POWER STEERING FLUID LEAKAGE INSPECTION 1) Start engine and turn completely the steering wheel in both directions to get the maximum hydraulic pressure. 2) Inspect visually if there are any leaks in the hydraulic pump, the liquid tank, hose connections or power steering gear box.
Page 86 3B-12 STEERING GEAR BOX AND LINKAGE PURGING AND SUBSTITUTION OF THE STEERING LIQUID 1) Lift the front part of the vehicle and put an appropriate trestle to keep wheels above ground. 2) Disconnect the oil return hose from tank. 3) Turn steering wheel leftwards and run the engine, a maximum of 10 seconds, to evacuate the oil from pump.
Page 87: Hydraulic Pressure Inspection
STEERING GEAR BOX AND LINKAGE 3B-13 HYDRAULIC PRESSURE INSPECTION 1) Clean carefully the pipe connections to the pump and disconnect the oil outlet hose (pressurized oil hose). 2) Connect the manometer valve set and hoses as shown, between pump outlet and inlet to power steering gear box. 3) Fill the hydraulic oil circuit and purge air (see 3B-12).
Page 88 3B-14 STEERING GEAR BOX AND LINKAGE 10) If the measured value is not within the specified range proceed as follows: • If pressure is higher than 80 Kg/cm it could be due to a fault in the relief valve. Substitute pump. •...
Page 89: Tightening Torque
10 ÷ 30 mm Power steering handling force < 5 Kg Back pressure < 10 Kg/cm Relief pressure 60 ÷ 80 Kg/cm REQUIRED SERVICE MATERIAL SANTANA PRODUCT REF. RECOMMENDED Rod end ball joint inside AGUILA 95 790999 Oil hydraulic DEXRON-II Power steering fluid...
Page 91 STEERING WHEEL, COLUMN AND LOWER SHAFT 3C-1 SECTION 3C STEERING WHEEL, COLUMN AND LOWER SHAFT NOTE: • All fastening pieces of the steering wheel and the column play a fundamental role, as the could affect the performance of the essential systems and components, and/or lead to considerable reparse fees. If any piece requires replacement, it must be substituted by another piece having the same serial replacement number, or equivalent.
Page 92: General Description
The steering column can be easily dismantled or reassembled. To ensure the adequate energy damping, it is important to use only the original SANTANA fixing elements, and tightening up to the specified torques. When dismantling the vehicle steering ensemble, attention must be paid to carefully handling. The eventual sharp hitting at the end of the axle ensemble or the accidental falling of such ensemble could lead to the breaking of the security plastic pins holding the steering column and lower shaft.
Page 93: On Vehicle Service
STEERING WHEEL, COLUMN AND LOWER SHAFT 3C-3 ON VEHICLE SERVICE STEERING WHEEL Removal 1) Disconnect negative battery cable. 2) Removal steering wheel cover (1) and nut (2) from the steering column. 3) Do coincidental marks (A) on the steering wheel and the steering column, to use them as a guide to assembly.
Page 94: Steering Wheel Repositioning
3C-4 STEERING WHEEL, COLUMN AND LOWER SHAFT STEERING WHEEL REPOSITIONING 1) With the wheels straightened, which is equivalent to keep the steering at the centre of possible leftwards and rightwards turning positions, check if the steering wheel stay in the adequate position;...
Page 95 STEERING WHEEL, COLUMN AND LOWER SHAFT 3C-5 COMBINATION SWITCH FOR LIGHTS, WIND-SCREEN WIPERS AND HORN Removal 1) Disconnect the battery. 2) Remove steering wheel (see 3C-3) 3) Remove upper cover (1) and lower cover (2) of the steering. 4) Disconnect the lights switch and wind screen wiper switch couplers (3).
Page 96: Ignition Switch And Steering Lock
3C-6 STEERING WHEEL, COLUMN AND LOWER SHAFT IGNITION SWITCH AND STEERING LOCK ASSEMBLY Removal 1) Remove steering wheel (see 3C-3). 2) Remove combination switch and wind screen wiper (see 3C-5). 3) Disconnect coupler (1) from the instrument panel wiring connector. 4) Remove slave screw (2) fixing the ignition switch assembly (3) to the steering column.
Page 97 STEERING WHEEL, COLUMN AND LOWER SHAFT 3C-7 Installation 1) Position oblong hole of the steering shaft in the center of the steering column hole. 2) Turn ignition key to position (1ª) and set up the ignition switch assembly (3) on the steering column. 3) Turn ignition switch to position (0) and extract it, in this form the steering lock assembly is activated.
Page 98: Steering Lower Shaft
3C-8 STEERING WHEEL, COLUMN AND LOWER SHAFT STEERING LOWER SHAFT Removal 1) Remove steering wheel (see 3C-3). 2) Remove combination switch and wind screen wiper (see 3C-5). 3) Remove the ignition switch assembly and the steering lock aseembly (see 3C-6). 4) Remove upper cover (1) fixing steering lower shaft (2) to the body.
Page 99 STEERING WHEEL, COLUMN AND LOWER SHAFT 3C-9 2) Connect steering column (2) with the lower shaft (6); aligning plane (A) of the threading with the fixing nut. 3) Fix lower shaft to the steering column tightening fixing screw (5) to the specified torque Tightening torque for the screw connecting lower shaft and steering column: 2 ÷...
Page 100 3C-10 STEERING WHEEL, COLUMN AND LOWER SHAFT STEERING LOWER SHAFT Removal 1) Remove screw (1) connecting steering column with steering lower shaft. 2) Remove screw (2) connecting steering lower shaft with the power steering gear box. 3) Remove lower shaft (3) toward the steering box until disconnect it of the threading of the steering column.
Page 101 STEERING WHEEL, COLUMN AND LOWER SHAFT 3C-11 CHECKING SRTEERING COLUMN FOR ACCIDENT DAMAGE CAUTION: Vehicles having been damaged in the body or with impacts in the steering column through an accident, could present damages or misalignments in the steering column. 1) Check that the steering lower shaft keeps its specified length.
Page 102: Tightening Torque Specifications
3C-12 STEERING WHEEL, COLUMN AND LOWER SHAFT TIGHTENING TORQUE SPECIFICATIONS TORQUE ELEMENT Kg-m Steering wheel fixing nut 2,5 ÷ 4 25 ÷ 40 2 ÷ 3 20 ÷ 30 Screw fixing the steering column to the steering lower shaft 2 ÷ 3 20 ÷...
Page 103: Front Suspension
FRONT SUSPENSION 3D-1 SECTION 3D FRONT SUSPENSION NOTE: -All front suspension fagternors play a fundamental role, since they could affect the performance of the systems and vital components, and/or cauld result in major repair expense. If some piece requires replacement, it must be replaced with another one having the same part number, or equivalent.
Page 104: General Description
3D-2 FRONT SUSPENSION GENERAL DESCRIPTION 1. Leaf spring. 2. Spring bush. 3. Spring bumper. 4. Snackle bush. 5. Spring seat. 6. Shackle inner plate. 7. Shackle outer plate. 8. U bolt. 9. Spring plate bracket. 10. Shock absorber.
Page 105: On Vehicle Service
FRONT SUSPENSION 3D-3 ON VEHICLE SERVICE LEAF SPRINGS AND SHOCK ABSORBER Dampers removal 1) Remove nut (1) and washer (2) fixing shock absorber (3). 2) Release silent blocks (4) from shock absorber. 3) Remove from the lower part of shock absorber: •...
Page 106 3D-4 FRONT SUSPENSION 10) Remove nut (13) and screw (14) (front part) and withdraw spring. Components revision 11) Check if remove components are sound and they show no wear neither or breaking; substituting them when necessary. Leaf springs installation 12) Connect leaf spring front part to body using screw (14) and nut (13), and the rear of leaf spring to shackle plates (12) with screw (11), do not fully tighten nuts and bolts.
Page 107 FRONT SUSPENSION 3D-5 13) Lift the vehicle till the axle rests suspended from the springs and centre it till the spring top (15) is perfectly lodged in the axle supporting point (16). 14) Install “U“ bolts (9), spring seats (10) and nuts (8). 15) Tighten nuts (8) to specified torque.
Page 108: Springs Bush And Body
3D-6 FRONT SUSPENSION SPRINGS BUSH AND BODY 1) Remove shock absorber and front leaf springs (see 3D-3). 2) Check silent blocks worthiness or if they have pittings, breakings, deformations, etc. 3) Substitute the bad silentblock using the special hydraulic tool to extract and install the silent blocks. 4) Install the other components reversing the install order and taking into account the specified tightening torques.
Page 109: Front Suspension Inspection
FRONT SUSPENSION 3D-7 FRONT SUSPENSION INSPECTION 1) Remove shock absorbers and front leaf springs (see 3D-3). 2) Place shock absorber (1) in a vice, fixing its lower part. 3) Compress and extend the shock absorber. 4) Check if hardness along each course is constant. 5) If hardness is intermittent or weak, substitute shock absor- ber for a new one.
Page 110: Tightening Torque Specifications
3D-8 FRONT SUSPENSION TIGHTENING TORQUE SPECIFICATIONS TORQUE ELEMENTS Kg-m Bolts and bolt nuts Nuts of “U“ bolts DATA AND ASSEMBLY TOLERANCES CONCEPT DATA Front leaf spring free height (semi elliptic spring) 120 mm...
Page 111: Rear Suspension
REAR SUSPENSION 3E-1 SECTION 3E REAR SUSPENSION NOTE: - All suspension fasteners are an important attaching part in that it could affect the perfomance of vital parts and system, and/or could result in major repair expense. They must be replace with one of the same part number or whith an equivalent part if replacement becomes necessary.
Page 112: General Description
3E-2 REAR SUSPENSION GENERAL DESCRIPTION 1. Leaf spring. 2. Leaf spring silentblock. 3. Spring bumper. 4. Body spring bush. 5. Shackle plate inner. 6. Shackle plate outer. 7. U bolt. 8. Spring support. 9. Shock absorber.
Page 113: On Vehicle Service
REAR SUSPENSION 3E-3 ON VEHICLE SERVICE LEAF SPRINGS AND SHOCK ABSORBERS Shock absorbers removal 1) Remove nut (1) and top washers (2) fixing the shock absor- ber (3) to the upper part. 2) Take away shock absorber (3) and silentblocks (4). 3) Remove nut and counter nut (5) fixing shock absorber (3) to rear shaft housing, remove washers (6) and rubber (7).
Page 114: Leaf Springs And Chassis Bumpers
3E-4 REAR SUSPENSION Shock absorber installation 8) Install shock absorber (3) on right position, install in the lower part the washers (6) and the rubber (7). 9) Install nut and counter nut (5) fixing shock absorber to rear shaft housing and tighten to specified torque. Tightening torque for nut fixing the shock absorber: 4 ÷...
Page 115: Rear Suspension Inspection
REAR SUSPENSION 3E-5 REAR SUSPENSION INSPECTION 1) Inspect rear suspension as same as the front suspension (see 3D-7) noting the free height specified value. Leaf spring free height: 190 mm...
Page 116: Assembly Data And Tolerances
3E-6 REAR SUSPENSION TIGHTENING TORQUE ESPECIFICATIONS TORQUE ELEMENT Kg-m Shock absorber lower fixing nuts 4 ÷ 6 40 ÷ 60 ASSEMBLY DATA AND TOLERANCES DATA CONCEPT Leaf spring free height (semi elliptical spring) 190 mm...
Page 117: Wheels And Tires
WHEELS AND TIRES 3F-1 SECTION 3F WHEELS AND TIRES NOTE: • Wheels tasteners are important atraching parts in that they could affect the performance of vital and/or could result in major repair expense. They must be replaced with one of the same part number or cith an equivalent part of replacement becomes nacessary.
Page 118: General Description
3F-2 WHEELS AND TIRES GENERAL DESCRIPTION TIRES Concerning tires size to be used in this vehicle, see the OWNER´S MANUAL. The tyres are of tubuless type. They are designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflaction pressure.
Page 119: Maintenance And Minor Adjustments
WHEELS AND TIRES 3F-3 MAINTENANCE AND MINOR ADJUSTMENTS WHEELS MAINTENANCE Wheels maintenance Wheel repairs that use welding, heating or prening are not approved. All damaged wheels should be replaced. Tires inflating The pressure recommended has been carefully calculated to get the best performance in what concerns running comfort, stability, steering, tread wear, tires life and resistance to bruises.
Page 120: On Vehicle Service
3F-4 WHEELS AND TIRES ON VEHICLE SERVICE METRIC LUG NUTSAND WHEELS STUDS The vehicle use metric lug nuts and wheels studs M12x1,25. NOTE: Always a wheel is remove, check worthiness of lug nuts and wheels studs; substitute when necessary. WHEELS REMOVAL AND INSTALLATION Removal 1) Loose wheel nuts about 180°...
Page 121 WHEELS AND TIRES 3F-5 TIRES SUBSTITUTION AND REPAIR Removal 1) Remove wheel (see 3F-4). 2) Remove tire from rim. NOTE: To carry out the assembly or dismantling of the tire you must use an appropriate machine, and follow the manufacturer instructions. Do no use hand tools or levers to change the tires, because the tire and the wheel could be damaged.
Page 122: Wheels Balancing
3F-6 WHEELS AND TIRES WHEELS BALANCING ADD COUNTERBALANCES IN THESE PLACES Balancing tipes There are two balancing modes of wheels and tires: static and dynamic. The static balancing, is the equal distribution weight around the wheel. Statically unbalanced wheels lead to bouncing described as COUNTERBALANCES wandering about.
Page 123 WHEELS AND TIRES 3F-7 TIGHTENING TORQUE SPECIFICATIONS TORQUE ELEMENT Kg-m Wheel nuts 110 ÷ 170 11 ÷ 17...
Page 125: Section 6L
FRONT AND REAR PROPELLER SHAFT 4-1 SECTION 4 FRONT AND REAR PROPELLER SHAFTS CONTENT FRONT DRIVE SHAFT .............................. 4A REAR DRIVE SHAFT ..............................4B FRONT AND REAR PROPELLER SHAFT ......................... 4C...
Page 126: Front Drive Shaft
FRONT DRIVE SHAFT 4A-1 SECTION 4A FRONT DRIVE SHAFT NOTE: To diagnose failures of the different components which could lead to abnormal behaviour of the general steering system, read carefully "CHARTS OF GENERAL DIAGNOSTICS" (3-2-2). CONTENT GENERAL DESCRIPTION ............................ 4A- 2 VEHICLE SERVICE ..............................
Page 127: General Description
4A-2 FRONT DRIVE SHAFT GENERAL DESCRIPTION 1. King pin assembly. 16. Spindle bush. 2. Oil-seal. 17. Shaft drive flange. 3. Oil-seal. 18. O ring. 4. King pin bearing. 19. Circlip. 5. Pitnan arm assembly. 20. Shim inner. 6. Steering knucle. 21.
Page 128: Vehicle Service
FRONT DRIVE SHAFT 4A-3 ON VEHICLE SERVICE REMOVAL AND INSTALLATION STEERING PIVOT ASSEMBLY Removal 1) Place vehicle in appropriate ground to do this task. 2) Remove front wheels (see 3F-4). 3) Remove brake caliper (1) of its connection to support (2) and take away together with sleeve.
Page 129 4A-4 FRONT DRIVE SHAFT Installation 1) To carry out install of assemblies, reverse removal procedures, noting remarks and tightening torques: • Inspect the worthiness of the oil-seal and substitute it if damage, wear or deformations are observed. • Ensure that faces of the couplings between the housing flange and hemisphere flange are clean.
Page 130: Removal And Installation Differential Group Assembly
FRONT DRIVE SHAFT 4A-5 REMOVAL AND INSTALLATION DIFFERENTIAL GROUP ASSEMBLY Removal 1) Unlock emptying plug (1) and remove oil from front differential group and assembly plug after applying the recommended sealant on the thread. 2) Remove left and right steering pivot assemblies (see 4A-3). 3) Disconnect front transmission shaft (4) from its connection to differential group.
Page 131: Removal And Installation Front Drive Shaft Assembly
4A-6 FRONT DRIVE SHAFT REMOVAL AND INSTALLATION FRONT DRIVE SHAFT ASSEMBLY Removal 1) Place the vehicle in a pit or an appropriate hydraulic lifter to carry out this task. 2) Disconnect front propeller shaft from its connection to the differential group. 3) Disconnect drive rod (1) from its connection to arm (2).
Page 132 FRONT DRIVE SHAFT 4A-7 8) Remove U-bolt nuts (5) from both sides and withdraw plates (6). 9) Install both front wheels without tightening nuts and bring down the vehicle till the wheels rest on the ground and leaf springs become separated from the axle. 10) Remove U-bolts.
Page 133 4A-8 FRONT DRIVE SHAFT OIL-SEAL OF DIFFERENTIAL GROUP FLANGE SUBSTITUTION 1) Disconnect front proppeler shaft (1) from connection to the differential group. 2) Substitute the oil-seal following the same steps as indicated for the oil-seal of back differential group (see 4B-7). 3) Fill with oil till the correct level and connect proppeler shaft fixing screws and nuts tightening them to the specified tightening torque.
Page 134: Friction Pads Substitution
FRONT DRIVE SHAFT 4A-9 FRICTION PADS SUBSTITUTION 1) Remove wheel from the side you want to substitute the friction pads and firmly wedge the vehicle. 2) Remove caliper (1) from its connection to support (2). 3) Remove friction pads (3) and replace them by new ones. 4) Install caliper (1), tightening fixing screws to the specified tightening torque.
Page 135 4A-10 FRONT DRIVE SHAFT HEMISPHERE OIL-SEALS SUBSTITUTION 1) Remove steering pivot assembly (see 4A-3). 2) Remove screws (1) fixing oil-seal extension case (2), withdraw oil-seal extension case and the oil-seal. 3) Install a new oil-seal previously applying oil to the enclosing lip.
Page 136: Front Shaft Housing Substitution
FRONT DRIVE SHAFT 4A-11 FRONT SHAFT HOUSING SUBSTITUTION Removal 1) Remove left and right steering pivot assemblies (see 4A-3). 2) Remove differential group (see 4A-5). 3) Remove U-bolts (1) and withdraw housing (2). Installation 1) Install a new housing and fix it with U-bolts tightening nuts to the specified tightening torque.
Page 137: Steering Pivot And Wheel Hub Assembly
4A-12 FRONT DRIVE SHAFT STEERING PIVOT AND WHEEL HUB ASSEMBLY GENERAL DESCRIPTION The components, turning pivots, wheel hub, disc and axle shaft joint, form a unique ensemble installed over the hemisphere. The later is screwed to the front axle housing flange. With the exception of the hemisphere, all the components are mobiles (rotary).
Page 138 FRONT DRIVE SHAFT 4A-13 REMOVAL, REVISION AND INSTALLATION OF THE STEERING PIVOT AND WHEEL HUB ASSEMBLY NOTE: If repair is going to be done as a whole ensemble away from the vehicle, remove steering pivot ens- emble (see 4A-3) and screw it to support ref. 192170. Removal 1) Remove or disconnect the following components: the o adequate wheel.
Page 139 4A-14 FRONT DRIVE SHAFT 7) Withdraw wheel hub and disc (9) 8) Remove wheel spindle (10) and after the drive shaft remove (11). Removal hemisphere and housing lodging rotation shaft 9) Remove screws (12) fixing the oil-seal to extension case (13), take away extension case and oil-seal (14).
Page 140 FRONT DRIVE SHAFT 4A-15 12) Open blockages of nuts fixing lower rotation axle and arm, remove nuts (20) and withdraw rotation axle and arm ens- emble (19). NOTE: • Identify the rotation axle conical bearings in order to put them back in the same position. •...
Page 141 4A-16 FRONT DRIVE SHAFT 2) Check in the spindle: • Wear of oil-seal closing ring (27). If necessary replace the flange. • Centering bushing (29); replace it if worn. • Oil-seal (28); replace each time a general repair is carried out.
Page 142 FRONT DRIVE SHAFT 4A-17 6) Revise drive shaft (11) just in case there are pittings, play in the joint or wear in the threadings. If any of these defects is present, substitute the whole drive shaft unit. Installation 1) Install new oil-seals (31) in flanges lodgings (32) of the housing shaft, pointing lip towards the interior of the axle.
Page 143 4A-18 FRONT DRIVE SHAFT • Put new O ring (34) on lower rotation axle (19), install it housing (17) keeping the original plate thickness; apply specified tightening torque to nuts and block properly with new fixing plates. Tightening torque for lower rotation axle fixing nuts: 7 Kg-m (70 Nm) •...
Page 144 FRONT DRIVE SHAFT 4A-19 • Apply recommended grease to the hemisphere oil-seal (14); position it using extension case (13) and fix extension case using screws (12) to the specified tightening torque. Tightening torque for screws fixing plate of the oil- seal: 0.8 ÷...
Page 145 4A-20 FRONT DRIVE SHAFT • Set up dial gauge (B) as shown in the figure: fix support to hub and place dial gauge with the measuring tip touching the adjusting nut (6). • Measure the longitudinal play of the hub which must agree with the specified value;...
Page 146 FRONT DRIVE SHAFT 4A-21 • Fit a screw (D) on the drive shaft end to be able to take it out or to put it in. • Install washer for the longitudinal adjustment (3) and circlip (2). • Setup dial gauge (B) as shown: fix support to hub and place dial gauge with the measuring tip touching the drive shaft end.
Page 147: Tightening Torque Specifications
4A-22 FRONT DRIVE SHAFT TIGHTENING TORQUE SPECIFICATIONS TORQUE ELEMENT Kg-m Screws fixing dragging flange 35 ÷ 42.5 3.5 ÷ 4.25 Nut fixing tie rod end 31 ÷ 35 Screws fixing brake caliper to support 3.1 ÷ 3.5 65 ÷ 75 Screws fixing brake caliper support 6.5 ÷...
Page 148: Recommended Products
FRONT DRIVE SHAFT 4A-23 RECOMMENDED PRODUCTS POINT OF APPLICATION REF. PRODUCT TYPE TB 1215 Coupling faces 790997 Screw threadings LOCTITE 573 790998 Bearings and oil-seals 790999 AGUILA 95 SPECIAL TOOL REF. 600590 REF. 192170 REF. 161950 STEERING BALL-AND-SOCKET JOINTS ROTATION AXLE HOLDER FOR WHEEL HUB KEY EXTRACTOR BENCH...
Page 150 REAR DRIVE SHAFT 4B-1 SECTION 4B REAR DRIVE SHAFT NOTE: To diagnose failures of the different components leading to abnormal behaviour of the general steering system, read carefully "CHARTS OF GENERAL DIAGNOSTICS" (3-2-2). CONTENT GENERAL DESCRIPTION ............................ 4B- 2 ON VEHICLE SERVICE ............................4B- 3 Removal and installation differential group ....................
Page 151: General Description
4B-2 REAR DRIVE SHAFT GENERAL DESCRIPTION 1. Wheel hub. 10. Hub internal bearing. 2. Wheel studs. 11. Hub external bearing. 3. Rear spindle. 12. Oil-seal. 4. Nuts. 13. Rear shaft housing. 5. Washer. 14. Group fixing studs. 6. Washer catch. 15.
Page 152: On Vehicle Service
REAR DRIVE SHAFT 4B-3 ON VEHICLE SERVICE REMOVAL AND INTALLATION DIFFERENTIAL GROUP Removal 1) Place the vehicle in an appropriate working place to carry out this task. 2) Removal oil emptying plug (1) and levelling plug (2) of the rear differential group (2) letting all the oil out. 3) Clean the emptying plug thread as well as the corresponding lodging thread in the housing.
Page 153 4B-4 REAR DRIVE SHAFT Installation 1) Clean carefully the surfaces where driving flanges to hub and differential group to axle housing meet. Wipe away the sealant residues which could have stay adhered. 2) Reverse removal procedures noting the following steps: •...
Page 154 REAR DRIVE SHAFT 4B-5 REAR SHAFTS OR DRIVING FLNAGES SUSBSITUTION Removal of a worn rear shaft NOTE: If replacement of a worn rear shaft but not broken is required you should do as follows. 1) Remove flange hub cap. 2) Remove cir-clip (1) which blocks the rear shaft avoiding getting displaced towards inside.
Page 155 4B-6 REAR DRIVE SHAFT Installation 1) If you were forced to remove the hub and flange assembly, install it as same as 4B-8. 2) Continue the installation reversing removal procedures, noting the followings steps: • Clean and wipe out residues from the contact surfaces between driving flange and hub and apply a layer of recommended sealant.
Page 156: Flange Oil-Seal Of The Differential Group Substitution
REAR DRIVE SHAFT 4B-7 FLANGE OIL-SEAL OF THE DIFFERENTIAL GROUP SUBSTITUTION Removal 1) Remove oil from group. 2) Disconnect front propeller shaft (1) from its connection to the group. 3) Disconnect pin (5), nut and washer (4) and withdraw flange (3).
Page 157 4B-8 REAR DRIVE SHAFT FRICTIONS PADS SUBSTITUTION Frictions pads substitution from the back brakes must be done following the same procedure indicated or the front brakes (see 4A-9). WHEEL HUB REMOVAL, REVISION AND INSTALLATION 1) Remove screws (2) fixing driving flange (1). 2) Remove as an assembly flange (1) and rear shaft (3).
Page 158: Rear Shaft Housing Substitution
REAR DRIVE SHAFT 4B-9 REAR SHAFT HOUSING SUBSTITUTION Removal 1) Place the vehicle in an appropriate working surface to carry out this task. 2) Remove the differential group (see 4B-3). 3) Loose back wheels nuts. Lift the rear part of the vehicle till the wheels do not touch ground, wedge it firmly in this position and remove wheels.
Page 159 4B-10 REAR DRIVE SHAFT 8) Disconnect "T" connection (8) and support (7) used for the connection of the compensating braking spring and push apart adequately all the disconnected pieces. 9) Remove hub, flange, and brake caliper support and protection hubs of both wheels. NOTE: For removing, installation and hub adjustment, proceed as for the front hub (see 4A-13).
Page 160 REAR DRIVE SHAFT 4B-11 • Finally remove strangling Girling clamp (A) from back sleeve (1), purge rear brake circuit (see 5-17) and try brakes on road (see 5-9). Tightening torques: • Screws/nuts fixing flange and brake caliper support flange: 3.5 ÷ 4.25 Kg-m (35 ÷ 42.5 Nm) •...
Page 161: Tightening Torque Specifications
4B-12 REAR DRIVE SHAFT TIGHTENING TORQUE SPECIFICATIONS ELEMENTS Kg-m Screws fixing flange and caliper support 35 ÷ 42.5 3.5 ÷ 4.25 65 ÷ 75 Screws fixing caliper support 6.5 ÷ 7.5 Nuts of the wheels 11 ÷ 17 110 ÷ 170 Nuts fixing differential group 3.5 ÷...
Page 162: Recommended Service Materials
REAR DRIVE SHAFT 4B-13 RECOMMENDED SERVICE MATERIAL APLICATION POINT PRODUCT TYPE REF. Coupling faces 790997 TB 1215 Screw thread LOCTITE 573 790998 SPECIAL TOOL REF: 191661 REF: 161950 GIRLING CLAMP WHEEL HUB KEY...
Page 164 FRONT AND REAR PROPELLER SHAFTS 4C-1 SECTION 4C FRONT AND REAR PROPELLER SHAFTS CONTENT GENERAL DESCRIPTION ............................ 4C- 2 FRONT PROPELLER SHAFT ..........................4C- 3 Removal, revision and installation ........................ 4C- 3 REAR PROPELLER SHAFT ..........................4C- 7 Removal, revision and installation ........................ 4C- 7 TIGHTENING TORQUE SPECIFICATIONS ......................
Page 165: General Description
4C-2 FRONT AND REAR PROPELLER SHAFTS GENERAL DESCRIPTION The propeller shafts are two mechanical elements whose mission is to transmit motion from transfer box to the front and back propulsion axles respectively. 1. Front propeller shaft. 2. Flange. 3. Crosshead. 4.
Page 166: Front Propeller Shaft
FRONT AND REAR PROPELLER SHAFTS 4C-3 Front propeller shaft REMOVAL, REVISION AND INSTALLATION Removal 1) Place the vehicle in a pit or appropriate hydraulic lifter. 2) Before remove propeller shaft, do alignment mark in the connection flanges and the propeller shaft in order to facilitate later installation.
Page 167 4C-4 FRONT AND REAR PROPELLER SHAFTS 5) Replacement shaft showing knockings, bendings, fractures, rustiness, etc. 6) If radial play is observed in the constant velocity joint then change the whole propeller shaft. Removal and repair 7) Before disconnecting axle from its connection to grooved shaft, check the alignment mark you did.
Page 168 FRONT AND REAR PROPELLER SHAFTS 4C-5 10) Using a tube with internal diameter greater than the one of the bearings, and a soft pushing rod with external diameter slightly less than that of the bearings, remove bearing at one of the sides as indicated in the figure. 11) Extracted bearing (5) will be lodged into the tube.
Page 169 4C-6 FRONT AND REAR PROPELLER SHAFTS 22) Apply grease generously on the axle grooving and fit it on the shaft at the same time you do coincide the arrow alignment marks to keep the original balancing. Installation 1) Install propeller shaft with its constant velocity pint oriented towards transfer box.
Page 170: Rear Propeller Shaft
FRONT AND REAR PROPELLER SHAFTS 4C-7 REAR PROPELLER SHAFT REMOVAL, REVISION AND INSTALLATION Removal 1) Do removing of the rear propeller shaft as with the front propeller shaft (see 4C-3). Revision 1) Check grooving and flanges (see 4C-3). 2) Remove and repair flanges crossheads (see 4C-4). 3) Change the shaft if there are knockings, bendings, fractu- res, rustiness, etc.
Page 171: Tightening Torque Specifications
4C-8 FRONT AND REAR PROPELLER SHAFTS TIGHTENING TORQUE SPECIFICATIONS ELEMENT TORQUE Kg-m Screws/Nuts fixing propeller shafts 2,8 ÷ 3,5 28 ÷ 35 ASSEMBLY DATA AND TOLERANCES CONCEPT DATA 0,10 mm Maximum play between shaft grooves and axle RECOMMENDED SERVICE MATERIALS APPLICATION POINT PRODUCT TYPE REF.
Page 172 BRAKES 5-1 SECTION 5 BRAKES NOTE: All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number of with an equivalent part of replacement becomes necessary.
Page 173 5-2 BRAKES BRAKE DISC ASSEMBLY REPAIR AND INSPECTION ................... 5-24 Brake pad substitution ........................... 5-24 Parking brake shoe and brake booster substitution ..................5-25 Caliper assembly substitution ........................5-25 Caliper assembly repair ..........................5-26 Brake discs substitution ..........................5-29 MASTER CYLINDER SUBSTITUTION ........................5-31 BRAKE BOOSTER INSPECTION ..........................
Page 174: General Description
BRAKES 5-3 GENERAL DESCRIPTION Pressing the pedal generates a hydraulic pressure in the master cylinder which pushes pistons. The master cylinder is a unit of a tandem. There are three pipes connected to the master cylinder, which constitute two independent circuits. One connects front brakes (right and left) and the other one connect rear brakes (right and left). There is a load sensing pressure valve (LSPV), placed between the master cylinder and back brakes.
Page 175 5-4 BRAKES BRAKE CALIPER ASSEMBLY The brake caliper is mounted on the brake caliper holder using two fixing screws. The hydraulic force generated when the brake pedal is pressed, is converted into friction by the caliper. The hydraulic force acts uniformly against the piston and internal wall of the caliper to move the piston outwards and sliding the caliper inwards, leading to a friction force acting on the disc.
Page 176: Master Cylinder Assembly
BRAKES 5-5 MASTER CYLINDER ASSEMBLY There are two pistons and three oil-seals (leathers) in each master cylinder. Hydraulic pressure is produced in primary chamber ("a") in the drawing below) and secondary ("b"). The hydraulic pressure generated in primary chamber ("a") acts on the rear wheels brakes (left and right).
Page 177: Vacuum Pump
5-6 BRAKES VACUUM PUMP The vacuum pump is located in the auxiliary organs group. It constitutes with the brake booster a tandem to decrease the physical effort of the driver when braking takes place. Vacuum pressure is generated continuously by the vacuum pump, transmitted to the brake booster which converts it to lineal motion applied to the rod acting on the brake master cylinder piston.
Page 178: Brake Booster Assembly
BRAKES 5-7 BRAKE BOOSTER ASSEMBLY The vacuum pressure acts on chambers "A" and "B" of the brake booster while the brake pedal and control valve "C" stand still. This position allows the communication between both chambers and avoids external air entrance to chamber "B". When the brake pedal is pressed, control valve "C"...
Page 179 5-8 BRAKES BRAKING REGULATING VALVE AS A FUNCTION OF LOADING ASSEMBLY (LSPV) LSPV makes part of the braking circuit which communicates the master cylinder with the rear wheels brakes. It controls the hydraulic pressure applied to the rear wheels brakes as a function of the vehicle loading (loading weight), avoiding thus that rear wheels become blocked too early.
Page 180: Diagnostics
BRAKES 5-9 DIAGNOSTICS ROAD TESTING BRAKES Brakes should be tested on dry, clean, smooth and reasonably level readway which is not crowned. Road test brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if the vehicle stops evenly and effectively. Also drive vehicle to see if it leads to one side or the otherwithout brake application.
Page 181 5-10 BRAKES DIAGNOSIS TABLE Condition Possible cause Correction Not enough • Brake oil leakage Find out the location of the braking force leaks and repair. • Brake from brake lines discs or pads stained with oil Clean or substitute. • Overheated brakes Find out the reason and repair.
Page 182 BRAKES 5-11 Condition Possible cause Correction • Master cylinder pistons do not return back correctly. Repair master cylinder. Dragging brakes • Damaged or strangled pipes or hoses. Look for damaged sleeves or (every light dragg tubes, and replace for new is present all disc sleeves and/or new steel brakes after in...
Page 183: On-Vehicle Service
5-12 BRAKES ON-VEHICLE SERVICE BRAKE PEDAL FREE HEIGHT ADJUSTMENT 1) Check brake pedal free height. 2) If it is not within specification proceed to adjust the lung fork length. Free height "A" of brake pedal: ~ 105 mm Fork length adjustment 3) Remove nuts (2) fixing master cylinder (1) and take away master cylinder assembly and fluid tank.
Page 184: Master Cylinder Inspection
BRAKES 5-13 STOPLIGHT SWITCH ADJUSTMENT 1) Push brake pedal towards you and keep it like that. 2) Adjust switch position in such a way that play between thread end and brake pedal top lies between the specified values. Play (A) of stopping switch: 0.5 ÷ 1 mm 3) Once play has been checked and adjusted tighten counter nut (1) to specified tightening torque.
Page 185 5-14 BRAKES BRAKE DISCS INSPECTION 1) Remove wheel (see 3F-4). 2) Inspect brake disc surface for scratches in wearing parts. NOTE: Scratches on disc surface are normal and disc is not defective unless they are serious deep. 3) If scratches or scratctes all over disc surface, substitute the brake disc (see 5-29).
Page 186 BRAKES 5-15 PARKING BRAKE INSPECTION AND ADJUSTMENT (AT TRANSMISSION) Inspection 1) Pull slowly from parking brake lever and check the maximum efficiency is found at ratchet number 7. Maximum handbrake efficiency: Point 7 of the ratchet 2) Check that both rear wheels are firmly blocked. 3) If ratchet number does not adjust to the specified one, proceed to adjust the parking brake cable.
Page 187 5-16 BRAKES In the lever 3) Remove the right front seat (see 9-27). 4) Remove protecting profiles from front (3) and rear doors (4) of the right side of the vehicle. 5) Lift partly the front carpet to accede to the parking brake cable tensioning mechanism located in the parking brake lever.
Page 188: Brake Fluid Substitution And Circuit Purging
BRAKES 5-17 BRAKE FLUID SUBSTITUTION AND CIRCUIT PURGING CAUTION: Brake fluid is extremely damaging paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. Fluid Substitution 1) Attach a vinyl tube (1) with an end connected to the brake caliper purger (2) (of one of the four wheels) and the other end introduced in an empty container.
Page 189 5-18 BRAKES 2) Attach a vinyl tube (1) with an end connected to the brake caliper purger (2) (of one of the four wheels) and the other end introduced in an appropriate recipient to pour the fluid. 3) Press a few times the brake pedal and keeping it pressed, loose purging screw turning it between one third and a full turn.
Page 190: Master Cylinder Purging
BRAKES 5-19 MASTER CYLINDER PURGING CAUTION: Brake fluid is extremely damaging paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface. 1) Fill brake fluid tank (1) with new recommended fluid and wait at least one minute. 2) Disconnect pipe (2) from primary side (of rear wheels).
Page 191: Vacuum Circuit Checking
5-20 BRAKES VACUUM CIRCUIT CHECKING FRONT Circuit checking ENGINE 1) Do a trial on road and verify that help towards breaking is enough. 2) If help towards breaking is not satisfactory, disconnect sleeve (2) from brake booster (3) connection and fix vacuum meter in series point (A), as seen in the drawing.
Page 192 BRAKES 5-21 6) If the reading is right, depressor (1), vacuum tank (4) and sleeve (2) are sound, and servo brake (3) is faulty; otherwise, if the reading is not right, do as follows: • Disconnect sleeve (2) from tank (4) and plug the sleeve. •...
Page 193 5-22 BRAKES BRAKES PIPES AND HOSES SUBSTITUTION Brake pipes 1) Place vehicle in an appropriate working ground. Fuel pipes 2) Clean dirt and accumulated impurities at the end of the pipes, brake hoses and surrounding. 3) Dismantle pipes or hoses plugging the holes to pour out the minimum possible amount of fluid.
Page 194: Parking Brake Lever And Cable Substitution
BRAKES 5-23 PARKING BRAKE LEVER AND CABLE SUBSTITUTION LEVER SUBSTITUTION 1) Remove lower and central profiles from right door and central side respectively and lift partly the flooring carpet to have access to parking brake lever. 2) Disconnect the electric connector from parking brake activating switch.
Page 195 5-24 BRAKES BRAKE DISC ASSSEMBLY REPAIR AND INSPECTION PADS SUBSTITUTION 1) Loose wheel nuts. 2) Lift the vehicle and remove wheel. 3) Remove brake caliper fixing screws (1) from connection to support (2) and pull them apart without forcing hose. 4) Substitute pads (3) by new ones.
Page 196 BRAKES 5-25 PARKING BRAKE SHOES AND DRUM MECHANISM SUBSTITUTION 1) To carry out substitution of the parking brake shoes and drum assembly, (see 7D-9). BRAKE CALIPER ASSEMBLY SUBSTITUTION 1) Remove wheel. 2) Install a Girling clamp (A) ref. 181661 in the brake hose (1) to strangle brake fluid falling out 3) Remove hose from connection to brake caliper.
Page 197 5-26 BRAKES BRAKE CALIPER ASSEMBLY REPAIR Removal 1) Remove the wheel (see 3F-4). 2) Remove brake caliper (see 5-25). Repair Disassembly 1) Place a rag cushion in front of the pistons to avoid they get damaged. 2) Remove pistons using compressed air at moderate pressure. NOTE: Do not put your hands where pistons could damage them when coming out suddenly.
Page 198 BRAKES 5-27 Revision 5) Verify dust covers in case there are any breakages, cracks or damages, and replace them if necessary. 6) Verify oil-seals in case they show deformations, wear, decomposition, etc... NOTE: Cilindro RETEN Cilindro RETEN Excessive wear on pads could be caused by a faulty return of a piston.
Page 199 5-28 BRAKES Assembly 9) Lubricate cylinders, pistons and oil-seals with new brake fluid. 10) Install the oil-seals in the cylinders, is such a way they are perfectly fitted in the channellings. 11) Place dust covers on the pistons, ensuring they stay positioned correctly, as shown in the figure.
Page 200 BRAKES 5-29 BRAKE DISC SUBSTITUTION Removal 1) Remove wheel (see 3F-4). 2) Disconnect brake caliper (1) from its support, taking it away from hose and remove support (2). NOTE: • Do no act on the brake pedal till the new brake caliper has been fully installated.
Page 201 5-30 BRAKES Revision 1) Verify the brake disc friction surface in case there are too deep scratches. If there are these types of scratches, mechanically rectify the corresponding disc face, without exceeding the service limit. Service Standard limit Front 20 mm 18 mm Brake disc thickness...
Page 202 BRAKES 5-31 MASTER CYLINDER SUBSTITUTION NOTE: The master cylinder does not allow any repairs. If abnormal behaviour or fluid leaks are found then substitute assembly. 1) Disconnect master cylinder from brake three pipes (2) and plug them to avoid fluid leaks. NOTE: Brake fluid is extremely damaging to paint.
Page 203 5-32 BRAKES BRAKE BOOSTER ASSEMBLY INSPECTION BRAKE BOOSTER VACUUM PUMP SUBSTITUTION 1) For removal and intallation of vacuum pump or depressor, (see 6A-65). BRAKE BOOSTER LUNG SUBSTITUTION NOTE: Brake booster lung allows no repair. When anomalous behaviour is detected replace the whole ensemble. Removal 1) Remove brake fluid from tank by using a syringe or similar, disconnect the three brake pipes (2), remove nuts connecting...
Page 204 BRAKES 5-33 REMOVAL, INSTALLATION AND ADJUSTMENT OF LSPV Removal 1) Clean around brake fluid tank cap and remove fluid with a syringe or similar. 2) Place the vehicle in an appropriate working ground. 3) Disconnect brake pipes from LSPV (1). 4) Remove screws (2) fixing LSPV (1) and the support (4).
Page 205 5-34 BRAKES Tightening torques: • Screws fixing valve LSPV: 1,8 ÷ 2,8 Kg-m (18 ÷ 28 N m) • Fixing screws of support: 1,8 ÷ 2,8 Kg-m (18 ÷ 28 N m) • Purger: 1 ÷1,3 Kg-m (10 ÷ 13 Nm) •...
Page 206 BRAKES 5-35 TIGHTENING TORQUE SPECIFICATIONS TORQUE ELEMENT Kg-m Nuts fixing master cylinder 10 ÷ 16 1 ÷ 1.6 Nuts fixing brake booster lung to support 1.1 ÷ 1.3 11 ÷ 13 10 ÷ 15 Counter nut adjusting stop light switch 1 ÷...
Page 207 5-36 BRAKES REQUIRED SERVICE MATERIALS APPLICATION POINT PRODUCT TYPE REF. LSPV valve spring connection Grease AGUILA 95 790999 Brake circuit 791002 Líquid DOT-4...
Page 208 ENGINE 6-1 SECTION 6 ENGINE CONTENT GENERAL INFORMATION ABOUT THE ENGINE ...................... 6-2 ENGINE REPAIR ................................ 6A COOLING SYSTEM ..............................6B FUEL SUPPLY SYSTEM AND EXHAUST CONTROL ....................6C EXHAUST SYSTEM ..............................6K LUBRICATION SYSTEM .............................6L...
Page 210 GENERAL INFORMATION ABOUT THE ENGINE 6-2-1 SECTION 6 - 2 ENGINE GENERAL INFORMATION CONTENT GENERAL DATA ..............................6-2-2 Repair instructions and care .......................... 6-2-2 Engine identification ............................6-2-2...
Page 211: General Data
6-2-2 GENERAL INFORMATION ABOUT THE ENGINE GENERAL DATA REPAIR INSTRUCTIONS AND CARE When repairing engine noting the followings points: • Cylinders injecting sequence 1, 3, 4, 2. Cylinder n° 1 is located at the engine front part, near the engine distribution and cylinder n° 4 in at the rear part of engine, near the flywheel.
Page 212 ENGINE REPAIR 6A-1 SECTION 6A ENGINE REPAIR CONTENT ENGINE DIAGNOSTICS (ONL MECHANICAL INJECTION ENGINE) ) ) ) ) ..........6A- 3 (ONL (ONL (ONL (ONLY Y Y Y Y MECHANICAL INJECTION ENGINE MECHANICAL INJECTION ENGINE MECHANICAL INJECTION ENGINE MECHANICAL INJECTION ENGINE GENERAL CHARACTERISTICS ...........................
Page 213 6A-2 ENGINE REPAIR ENGINE REPAIR ON WORK BENCH ........................6A-84 - Prepare of engine to put it on work bench ..................6A-84 - Engine removal ............................6A-85 • External components removal ......................6A-87 • Timing and cylinder head removal ....................6A-87 •...
Page 214 ENGINE REPAIR 6A-3 ENGINE DIAGNOSIS (ONL (ONL Y MECHANICAL INJECTION ENGINE) Y MECHANICAL INJECTION ENGINE) (ONL (ONLY MECHANICAL INJECTION ENGINE) (ONL Y MECHANICAL INJECTION ENGINE) Y MECHANICAL INJECTION ENGINE) Main running anomalies of engine with mechanical injection pump: 1.- Engine does not start. 7.- Engine subject to abnormal knockings 2.- Engine overheats excessively 8.- Engine stops...
Page 215 6A-4 ENGINE REPAIR Efficient injectors. Control running and adjust them. - NO Absence of air infiltration in the fuel supply Correct infiltration causes and purge. circuit or in the injection pump. - NO Correct infiltration causes and purge. No water in the fuel supply circuit or in the - NO Clean the supply circuit included tank.
Page 216 ENGINE REPAIR 6A-5 Efficient water pump. Check or substitute assembly. - NO Thermostat efficient. Substitute. - NO Wash carefully and check for fluid leaks; if Radiator is efficient. - NO necessary substitute. Clean or substitute faulty pieces. Air filter and circuit pipes are efficient. - NO Correct setting of the injection pump.
Page 217 6A-6 ENGINE REPAIR ENGINE UNDERPOWER Efficient fuel filter. Substitute (see section 0B «MAINTENANCE - NO AND LUBRICATION»). Efficient fuel supply circuit. Check and repair if necessary. - NO Substitute. Efficient thermostat. - NO Substitute. Efficient injection pump. - NO Efficient injectors. Check running and adjust them correctly.
Page 218 ENGINE REPAIR 6A-7 Prescribed compression. Check with compressor meter and repair if - NO necessary. Efficient intake manifold. Repair or substitute assembly. - NO Check. Efficient circuit and L.D.A. device. - NO ENGINE LETS OUT BLACK FUMES OR DARK GREY Efficient air filter.
Page 219 6A-8 ENGINE REPAIR Efficient L.D.A. device. Adjust L.D.A. device. - NO Injection pump correctly adjusted. Check and adjust injection pump at work - NO bench. Check with compressor meter and repair if Prescribed compression. - NO necessary. Clean tank and substitute fuel filters. Good quality Diesel fuel.
Page 220 ENGINE REPAIR 6A-9 Clean tank and substitute fuel filters. Good quality Diesel fuel. - NO ENGINE LETS OUT BLUE FUMES Check: oil vapours vents; cylinders compression. Excessive oil comsuption. - NO If necessary revise cylinder head or engine. ENGINE SUBJECT TO ABNORMAL KNOCKINGS Crankshaft knockings.
Page 221 6A-10 ENGINE REPAIR Check or substitute turbocharger. Turbocharger knockings. - YES Injectors knockings. Check and adjust as prescribed. - YES ENGINE STOPS Fuel in the tank. Fill tank and purge as described in section - NO 0B «MAINTENANCE AND LUBRICACION». Efficient fuel filters.
Page 222 ENGINE REPAIR 6A-11 ENGINE EXCEEDS THE MAXIMUM ALLOWED RPM Speed regulator works all right. Check and if necessary replace worn pieces. - NO EXCESSIVE OR INSUFICIENT OIL PRESSURE Substitute engine oil by another of adequate Oil engine SAE viscosity correct. - NO viscosity.
Page 223 6A-12 ENGINE REPAIR Check running and adjust. Injector adjustment correct. - NO Check and adjust at work bench. Injection pump adjustment correct. - NO Adjust L.D.A. device. Efficient L.D.A. device. - NO Correct setting of the injection pump. Check injection pump setting (see 6A-33). - NO...
Page 224: General Characteristics
ENGINE REPAIR 6A-13 GENERAL CHARACTERISTICS COMMON RAIL MECHANICAL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 Cycle Four strokes Diesel Supply Oversupplied Injection Directly Cylinders number 4 in line Diameter 94,4 Course Total cylinder capacity 2800 Compression ratio 18,5 Maximum power 88,8 ÷ 95,2 75,5 ÷...
Page 225 6A-14 ENGINE REPAIR MECHANICAL COMMON RAIL INJECTION Concept ID/TCA 8140.43S.4 8140.43C.3.. TIMING Beguinning before T.D.C. 8º End after L.D.A. 37º Beguinning before L.D.A. 48º End after T.D.C. 8º For control of fixing phase 0,5 ± 0,05 0,5 ± 0,05 Of running 0,5 ±...
Page 226 ENGINE REPAIR 6A-15 MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 OVERFEEDING With intercooler Turbo charger type: MITSUBISHI TF0 MITSUBISHI TD04 HM 13 T-6 marked with colour blue 0,396 ÷ 0,602 Radial play turbo charger axle 0,034 ÷ 0,106 Axial play turbo charger axle Minimum course opening of the valve pressure restricter Maximum course opening of the valve...
Page 227 6A-16 ENGINE REPAIR MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 EMISSIONS VALUES - CO (Carbon Monoxide) < 4.0 g/KWh Gaseous Emissions - NO (oxides of nitrogen) < 7.0 g/KWh According to "Normative on Gaseous Emissions - HC (hydrocarbon residues < 1.10 g/KWh Euro2"...
Page 228 ENGINE REPAIR 6A-17 ASSEMBLY GENERAL DATA AND TOLERANCES MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 CYLINDERS BLOCK, CRANKSHAFT, PISTONS AND CONNECTING RODS Ø1 Housings of cylinders liners Ø 1 97,39 ÷ 97,45 Cylinders liners External diameter Ø 2 97,47 ÷ 97,50 Length 167,00 ÷...
Page 229 6A-18 ENGINE REPAIR MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 MONDIAL PISTON AND KS Tipe of piston 2,200 ÷ 2,230 X 1* Slits for elastic piston rings 2,050 ÷ 2,070 2,540 ÷ 2,560 * measured over Ø of 91.4 mm S 1* 2,068 ÷...
Page 230 ENGINE REPAIR 6A-19 MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 Measured height Maximum error on parallelism of 0,09 0,07 connecting rods axles Journal of Main bearing Ø 1 nº 1-2-3-4 80,182 ÷ 80,208 Ø2 Ø1 nº 5 86,182 ÷ 86,208 Journal of connecting rod Ø...
Page 231 6A-20 ENGINE REPAIR MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 CYLINDER HEAD Ø1 Valves housing guides in 12,950 ÷ 12,985 cylinder head Ø 1 Ø 2 8,023 ÷ 8,038 Ø 2 Valve guides 13,012 ÷ 13,025 Ø 3 Ø 3 Valve guides and housings in 0,027 ÷...
Page 232 ENGINE REPAIR 6A-21 MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 Between valve seat 0,070 ÷ 0,135 and cylinder head 0,080 ÷ 0,130 Exernal sping of valves height Free spring Under load of : 38,5 Kg 43,8 ± 2,5 28,5 Kg 77,4 ±...
Page 233 6A-22 ENGINE REPAIR MECHANICAL COMMON RAIL INJECTION Concept 8140.43C.3 ID/TCA 8140.43S.4 Plungers in normal cylinder head Ø normal 43,950 ÷ 43,970 Ø Between plungers and lodgings 0,035 ÷ 0,081 From 3.25 till 4.45 mm Adjusting plate In progression of 0.05 Height of cams: 10,5 BELTS TENSION...
Page 234: Symbol Chart
ENGINE REPAIR 6A-23 SYMBOL CHART Surface to be worked Preloading Finishing Number of revolutions Interference Forced installation Thickness Pressure Play > Oversize Intake Higher than ... < Undersize Exhaust Less than... Selection Running Classes Oversizes Temperature < 0 ºC Compressure Ratio Cold Winter TOLERANCES...
Page 235: Characteristics And Servicing Of Belt Tensions Checker (Frequency Meter Ref. 00000A01484)
6A-24 ENGINE REPAIR CHARACTERISTICS AND SERVICING OF BELT TENSIONS CHECKER (FREQUENCY METER ref. 00000A01484) CAUTION: • Tensioning of a belt is an important task as it is related directly to belt life time. • The use of the referred frequency meter is essential to apply the correct tension of belts and avoid excess tension risks, lack of tension, noises and any other problem arising from an uncorrected belt...
Page 236 ENGINE REPAIR 6A-25 CHECKER USE 1) Switch on the checker (press button D) and bring reading head (A) near the belt to be measured. 2) Place reading head at distance (X) from belt. Measuring distance: (X)= 5 a 10 mm 3) Reading heads of sensors (a) or (b) can be used industictly, but remember that the other reference sensor must be out of measuring field.
Page 237: On Vehicle Service
6A-26 ENGINE REPAIR ON-VEHICLE SERVICE BELTS SUBSTITUTION Water pump and generator driving belt substitution Removal 1) Disconnect battery. 2) Disconnect hoses (5) and (1) from interconnecting tube (4). CAUTION: Plug adequately hoses and interconnecting tube to avoid alien bodies entrance while repairing. 3) Dismantle interconnecting tube (4).
Page 238 ENGINE REPAIR 6A-27 4) Tighten to the specified torque screws or nuts (11), (7) and (8) which anchor the generator, the support and tensioning block. Tightening torque's: • Screws or nuts (11) and (7): 5 Kg-m (50 Nm) • Screw (8): 4,5 Kg-m (45 Nm) 5) Continue the installation reverse removal precedures;...
Page 239 6A-28 ENGINE REPAIR Timing substitution Removal 1) Remove: • Generator and frontal support (see 6A-52). • Air Conditioning compressor driving belt (see 6A-27). • Water radiator and air radiator (intercooler) (see 613-8). 2) Disconnect fixings of tubing of thermo starter and the cable assembly (19).
Page 240 ENGINE REPAIR 6A-29 Installation NOTE: • Remember that the three control points must be synchronised as explained under dismantling task (5 In other words, mark (A) from camshaft gear and mark (B) of plungers cover must be aligned; tool (C1) lodged into synchronisation position of gear (24) (holes aligned);...
Page 241: Water Pump Substitution
6A-30 ENGINE REPAIR WATER PUMP SUBSTITUTION Removal 1) Disconnect battery. 2) Remove chiller from circuit (see 0B-9). 3) Remove generator and front support (see 6A-52). 4) Disconnect fixings of pipe from thermo starter and electric wiring (3). Put apart adequately pipe and electric wiring assembly.
Page 242 ENGINE REPAIR 6A-31 NOTE: • Nut (10) fixing hub must be replaced each time removal takes place, and threads left wise. • If Air conditioning is available, place a threaded rod at hole (22) to fix the tensioning support of compressor driving belt.
Page 243: Removal And Installation Of Injectors (Mechanical Injection Engine)
6A-32 ENGINE REPAIR REMOVAL AND INSTALLATION OF INJECTORS (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) CAUTION: Before starting to remove, clean carefully all the components to be removed or disconnect then as well as surroundings.
Page 244: Mechanical Injection Engine
ENGINE REPAIR 6A-33 REMOVAL AND INSTALLATION OF INJECTION PUMP (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) CAUTION: Before starting to remove, clean carefully all the components to be removed or disconnect them as well as surroundings.
Page 245 6A-34 ENGINE REPAIR 6) Remove nuts fixing injecting pump and take it away. NOTE: The lower nut place near the block is removed with key (F) ref. 790997. CAUTION: Plug with appropriate caps the conductions which have been opened. Entry of some alien body in this conductions could seriously damage the injection system.
Page 246 ENGINE REPAIR 6A-35 6) Fit tool (E) ref. 790965 in hole (20) of flywheel housing (21). Turn slowly crankshaft in the same direction of rotate while at the same time you press tool (E). Stop turning when you notice that tool has found the milling mark ( ) of flywheel (19).
Page 247: (Common Rail Engine)
6A-36 ENGINE REPAIR REMOVAL AND INSTALLATION OF ELECTRO- INJECTORS, HYDRAULIC ACCUMULATOR (RAIL) AND HIGH PRESSURE PUMP (Common Rail Engine) (Common Rail Engine) (Common Rail Engine) (Common Rail Engine) (Common Rail Engine) WARNING: Loosening any union nut ofd high pressure pipe whith engine running or while pressure still remains an hydraulic accumulator (Rail), may result in severe injury.
Page 248 ENGINE REPAIR 6A-37 Removal of hydraulic accumulator (Rail) and hing pressure fuel pump assembly 8) Remove high pressure fuel pipe (19); when disconnecting high pressure fuel pump (18), hold outlet union nut (17) to avoid turning. 9) Disconnect return pipes (16), remove union nut (22) and return multiple connector (21).
Page 249 6A-38 ENGINE REPAIR 4) Install injector (8) using clamps (14) and bolts (13), tightenedan specified torque Tightening torque injectors clamps nuts: 4 kg-m (40 Nm) 5) Connect hihg pressure pipes (9) to injectors (8) and hydraulic accumulator (23). Tighten union nuts at specified torque, holding how limiters to avoid rotation.
Page 250: Mechanical Injection Engine
ENGINE REPAIR 6A-39 REMOVAL AND INSTALLATION OF FLYWHEEL (Mechanical injection engine) (Mechanical injection engine) (Mechanical injection engine) (Mechanical injection engine) (Mechanical injection engine) Removal 1) Disconnect battery. 2) Remove soundproofing upper cover (1). 3) Turn crankshaft till putting front to front the mark (A) at camshaft gear with mark (B) of plungers cover.
Page 251 6A-40 ENGINE REPAIR NOTE: Fitting the dial gauge and adjusting to zero are necessary only to verify if the crankshaft moves while the flywheel is replaced. 6) Remove: • Gear box assembly (see 7A-9). • Pressure plate and clutch disc assembly (see 7C-10). 7) Take away connector of r.p.m sensor (8) and remove sensor.
Page 252 ENGINE REPAIR 6A-41 NOTE: • Before using again the screws of engine flywheel, measure with a micrometer the diameter on threading. Never the diameter should be below 10.8 mm; otherwise, replace them. • Because the play between flywheel bolts and their pass holes, the relative position of flywheel from crankshaft must be determined before retighten flywheel permanently.
Page 253: (Common Rail Engine)
6A-42 ENGINE REPAIR FLYWHEEL (COMMON RAIL ENGINE) (COMMON RAIL ENGINE) (COMMON RAIL ENGINE) (COMMON RAIL ENGINE) (COMMON RAIL ENGINE) Removal 1) Disconnect negative cable from battery. 2) Remove upper soundproof cover (1) and yoke that fixes wiring to injectors. 3) Remove generator and front bracket (see 6A-59) 4) Remove timing front upper cover (2).
Page 254 ENGINE REPAIR 6A-43 Installation 1) Installation flywheel; then install flywheel bolts temporarity. NOTE: • Before reinstalling flywheel bolts, measure thread diameter using a micrometer. If any measure is lower than 10,8 mm, replace them. • Because the play between flywheel bolts and their pass holes, the relative position of flywheel from crankshaft must be determined before retighten flywheel permanently.
Page 255 6A-44 ENGINE REPAIR 3) Install bearing plate (3) with bolts (4) and tighten to specified torque. Tightening torque bearing plate bolts: 1,8 ÷ 2,8 kg-m (18 ÷ 28 Nm) 4) Install pressure plate assembly and clutch disc (see 7C-10). 5) Install gear box assembly (see 7A-9). 6) Go on with installation, noting to tighten at specified torque.
Page 256 ENGINE REPAIR 6A-45 FLYWHEEL CHECK AND GEAR RING REPLACEMENT Gear ring check and replacement 1) Remove flywheel (see 6A-39 ó 6A-42) 2) Check clutch disc support face. If any scratch or ridge, repair 3) Inspect surface marked ( ) (common rail engine); for scratches or ridges;...
Page 257: Bearing Of Gearbox Primary Axle Removal
6A-46 ENGINE REPAIR BEARING OF GEARBOX PRIMARY AXLE REMOVAL Removal 1) Remove: • Gear box assembly (see 7A-9). • Pressuring plate and clutch disc assembly (see 7C-10). 2) Block adequately flywheel from turning. 3) Remove screws (2) and remove bearing support plate (1). Bearing replacement 4) Substitute bearing (3) using a hydraulic press (A) and an ASSEMBLY...
Page 258: Crankshaft Oil-Seals Substitution
ENGINE REPAIR 6A-47 CRANKSHAFT OIL-SEALS SUBSTITUTION CAUTION: The front and rear crankshaft oil-seals have a cover or oil-seal support and an oil-seal of "ROTOSTAT" type. These oil-seals have an assembling guide or wedge which should not be taken away till the oil-seal is properly placed on the crankshaft.
Page 259: Camshaft Front Oil-Seal Substitution
6A-48 ENGINE REPAIR CAMSHAFT FRONT OIL-SEAL SUBSTITUTION Removal 1) Remove timing belt (see 6A-28) and plungers cover (see 6A-49 VALVES PLAY). NOTE: Before untensioning the timing belt, loose screws (1) of camshaft driving gear (2). 2) Take away screws (1) and remove driving gear (2). 3) Remove nuts (5) and withdraw cover covering oil-seal (3).
Page 260: Valves Play
ENGINE REPAIR 6A-49 VALVES PLAY MECHANICAL INJECTION ENGINE Checking the valves play Removal or disconnected 1) Disconnect battery 2) Remove upper soundproof cover (1). (mechanical (mechanical (mechanical (mechanical (mechanical injection engine) injection engine) injection engine) injection engine) injection engine) 3) Remove side soundproof cover, upper (1 ) and fixing yoke of electroinjector wire (common rail engine) (common rail engine)
Page 261 6A-50 ENGINE REPAIR Adjustment of valves play OPENING CLOSES CAUTION: 8° The adjustment of valves must be carried out very 8° carefully in order to keep the timing diagram as prescribed;otherwise valves play will be different than specified. In actual fact, excessive play causes noises, retarding OPENING the opening and anticipating the closure of valves.
Page 262 ENGINE REPAIR 6A-51 3) Apply an air jet on millings (4) at plungers with an air gun (5) till lifting the regulating plate (3) to be replaced and take it away using tweezers. 4) Measure thickness of regulating plate thus extracted. NOTE: Regulating plates bear in one the sides their thickness engraved;...
Page 263 6A-52 ENGINE REPAIR Assembly of plungers covers 8) Take away sealant from the cavities located between the back cover (7) and cylinder head (8); fill them with recommended sealant ref. 790962. 9) Fit new gasket (2) in plungers cover (6). Apply in angles indicated ( ) at plungers cover ~10 gr.
Page 264 ENGINE REPAIR 6A-53 CYLINDERHEAD COVER GASKET MECHANICAL INJECTION ENGINE Removal 1) Disconnect negative cable at battery. 2) Remove timing belt (see 6A-28). 3) Remove fuel injectors (1) (see 6A-32, mechanical mechanical mechanical mechanical mechanical injection engine injection engine injection engine injection engine injection engine) 4) Remove fuel injectors (2) and rail (3) (see 6A-36, common...
Page 265 6A-54 ENGINE REPAIR • Air inlet hose (22) to intake manifold. • Electric connection (19) of thermal starter spark plug and electric connection (21) of electrovalve. • Linkage (20) and the fuel inlet pipe to thermal starter electrovalve, • Water inlet hose to heating (18). Turbocharger and exhaust manifold removal.
Page 266 ENGINE REPAIR 6A-55 12) Remove support of fixed belt tensor (40) and protection (41) located underneath . 13) Remove thermostate box (36) with thermistors (37) and (38) and tube (39) connecting with water pump. 14) Remove screws (42) fixing cylinder head (43) and remove the later with its gasket.
Page 267 6A-56 ENGINE REPAIR • Install cylinder head gasket on cylinders block orientig word "ALTO" upwards (towards cylinder head). ALTO NOTE: The arrow indicates the point where the specified thickness of gasket was read. CAUTION: The gasket should be kept properly wrapped till the moment of installation.
Page 268 ENGINE REPAIR 6A-57 • Take away sealant from the cavity located between rear cover (45) and cylinder head (43). Fill them with recommended sealant ref. 790962; put a new gasket (46) on the plungers ensemble cover (35). Apply in angles indicated ( ) at the cover ~10 gr of recommended sealant ref.
Page 269 6A-58 ENGINE REPAIR • Oil pressure interruptor adaptor: 8 Kg-m (80 Nm) • Screw for connecting adaptor to block for turbocharger oil draining tube: 4 Kg-m (40 Nm) • Screw connecting takeaway of metallic fastening belts to exhaust manifold: 3,5 Kg-m (35 Nm) •...
Page 270 ENGINE REPAIR 6A-59 REMOVAL AND INSTALLATION OF GENERATOR AND SUPPORT Removal 1) Disconnect battery. 2) Disconnect generator electrical terminals. 3) Remove driving belt of water pump and generator (see 6A-26). 4) Remove screws (2) and (6) and take away generator (4). Front support removal 5) Remove screws (1) and (7), withdraw front support (5) and tensor (3).
Page 271 6A-60 ENGINE REPAIR REMOVAL AND INSTALLATION OF AIR CONDITIONING COMPRESSOR Removal 1) Remove in the appropriated way gas from the air conditioning circuit. 2) Disconnect battery. 3) Remove driving belt of water pump and generator (see 6A-26). 4) Disconnect compressor inlet and outlet pipes (1). 5) Remove compressor driving belt (5) (see 6A-27).
Page 272: Removal And Installation Of Starting Motor
ENGINE REPAIR 6A-61 REMOVAL AND INSTALLATION OF STARTING MOTOR Removal 1) Disconnect battery. 2) Disconnect electric leads of starting motor. 3) Remove the three screws (1) and withdraw starting mo- tor (2). Installation 1) Reverse removal procedures, apply the specified tightening torques and those specified in the complementary tasks.
Page 273: Removal And Installation Of Turbocharger
6A-62 ENGINE REPAIR REMOVAL AND INSTALLATION OF TURBOCHARGER Removal 1) Disconnect battery. 2) Disconnect support (2) of degasifier hoses; disconnect expansion vase (1) and take away. 3) Disconnect electric connector at the oil pressure interruptor switch. 4) Disconnect or remove: •...
Page 274 ENGINE REPAIR 6A-63 Assembly NOTE: Clean carefully the surfaces of the coupling contacts of the cylinder head, exhaust collector and turbocompressor. 1) Proceed to assemble reversing the dismantling order paying attention to the following tasks: • Assemble new gaskets, washers , gases closing rings and all the pieces showing any kinds of faults •...
Page 275 6A-64 ENGINE REPAIR DISMANTLING AND ASSEMBLY OF THE SERVO STEERING HYDRAULIC PUMP CAUTION: Before starting dismantling clean thoroughly components to be dismantled and around them. Dismantling 1) Dismantle water radiator and air radiator (intercooler) (see 6B-8). 2) Disconnect inlet linkage (3) of hydraulic oil to pump and pour the content of the tank in an adequate container.
Page 276 ENGINE REPAIR 6A-65 DISMANTLING AND ASSEMBLY OF THE VACUUM PUMP (DEPRESSOR) Dismantling 1) Disconnect battery. 2) Disconnect vacuum tube (1). 3) Dismantle screws (3) fixing vacuum pump (2) to body of the auxiliary organs group.(4). 4) Withdraw vacuum pump (2) with dragging gasket (5) and impermeability gasket.
Page 277 6A-66 ENGINE REPAIR DISMANTLING AND ASSEMBLY OF THE AUXILIARY ORGANS GROUP Characteristics Los órganos auxiliares siguientes: bomba hidráulica de servodirección, filtro de aceite, bomba inyectora ó bomba de alta presión de combustible, bomba de aceite, bomba de vacío y el intercambiador de calor, se agrupan en un bloque al que se le denomina «GRUPO DE ORGANOS AUXILIARES».
Page 278 ENGINE REPAIR 6A-67 Assembly 1) Proceed to assembly reversing the dismantling order, paying attention to the following remarks: • Clean thoroughly the contact coupling areas between the auxiliary organs group and cylinders block. • Assemble new oil-seals of the points indicated by an arrow, lubricating previously.
Page 279 6A-68 ENGINE REPAIR DISMANTLING, ASSEMBLY OR REPLACEMENT OF THE HEAT EXCHANGER Dismantling 1) Disconnect battery. 2) Remove refrigerant from the engine (see OB-8). 3) Disconnect water outlet (1) and intlet (2) tubes to heat exchanger (3). 4) Dismantle screw (4) and withdraw heat exchanger (3) with its thermal gaskets.
Page 280 ENGINE REPAIR 6A-69 REPLACEMENT OF THE OIL FILTER Dismantling 1) Dismantle oil filter (1) with key (A) ref. 790972. 2) Clean carefully contact area of oil filter on support (2). Assembly CAUTION: Assemble always original filters . Remember it is a double filtering effect special device.
Page 281 6A-70 ENGINE REPAIR REPAIR OF GEAR BOX, AUXILIARY ORGANS GROUP AND OIL PUMP NOTE: For dismantling and assembly of the auxiliary organs group ensemble, (see 6A-66). Dismantling and repairing gear box and oil pump 1) Assemble the auxiliary organs group (4) on support (A) ref. 790973 and fix ensemble in a work bench (5).
Page 282 ENGINE REPAIR 6A-71 7) Remove the servo steering hydraulic pump (15) with its gasket; remove screws (13) and remove the driving gear (14) of auxiliary organs group. 8) Remove upper cover (12) with gasket. Oil pressure regulating valve revision 9) From rear cover (11), unlock cap (18) and spring (19); remove regulating valve constituted by piston (17) and cylinder (16).
Page 283 6A-72 ENGINE REPAIR 14) Remove axle and driver gear (22) of oil pump. 15) Dismantle front cover (23). 16) Remove axle and driving gear (24). 17) Take away the two parts of oil pump driving gear , gear (25) and axle (26); use a hydraulic press (D). NOTE: This removal must be done only if excessive wear is detected in gears.
Page 284: Removal And Repair Of Gearbox And Oil Pump
ENGINE REPAIR 6A-73 Removal and repair of gear box and oil pump NOTE: Clean thoroughly removed components , left overs from gaskets and sealant. CAUTION: Clean using pressurized air oil flow conductions, linkages, filter support, heat exchanger support and the heat exchanger itself. Installation of gears 1) Install gear (25) and axle (26) of oil pump, using a hydraulic press (D).
Page 285 6A-74 ENGINE REPAIR 4) Install axle and driving or driven gear (24). Covers installation 5) On upper front cover (23), install a new oil-seal (28) using an appropriate pushing and knocking rod (I). 6) Fit new gasket (29) on cover (23), lubricate oil-seal (28) and install cover tightening screws (30) to the specified tightening torque.
Page 286 ENGINE REPAIR 6A-75 8) Install rear cover (11) and upper cover (12) with new impermeabilizing gasket. Tighten screws to the specified tightening torque. Tightening torque: • Screws back cover: 1,8 Kg-m (18 Nm) • Screws upper cover: 1,8 Kg-m (18 Nm) Auxiliary organs installation 9) Install vacuum pump (9) with dragging adaptor and impermeabilizing gasket.
Page 287 6A-76 ENGINE REPAIR 14) Install the thermal gaskets (32) on heat exchanger (4); fixing heat exchanger to support and fix it with screw (3) tightened to the specified tightening torque. Tightening torque for screw (3) fixing heat exchanger: 8 Kg-m (80 Nm) 15) Lubricate with engine oil oil-seals (31) of oil-filter (2) and fit them in the lodgings of filter.Fit the filter and tighten it to the specified tightening torque.
Page 288: Removal And Installation Of Engine On Vehicle
ENGINE REPAIR 6A-77 REMOVAL AND INSTALLATION OF ENGINE ON VEHICLE Removal and installation of engine Removal Place the vehicle in an appropriated pit or hydraulic lifter and prepair containers to pour the fluid of the different circuits. 2) Disconnect battery. 3) Remove bonnet of engine.
Page 289 6A-78 ENGINE REPAIR 7) MECHANICAL INJECTION ENGINES MECHANICAL INJECTION ENGINES MECHANICAL INJECTION ENGINES MECHANICAL INJECTION ENGINES MECHANICAL INJECTION ENGINES Disconnect electric leads from: • Thermo electrovalve starter (9). • Thermostarter spark plug (10). • Generator (11). • Switch of oil pressure device (12). •...
Page 290 ENGINE REPAIR 6A-79 8) en motores common rail en motores common rail en motores common rail en motores common rail en motores common rail Disconnect electric leads from: • Thermostarter electrovalve (9). • Thermostarter spark plug (10). • Indicator of oil low level (42). •...
Page 291 6A-80 ENGINE REPAIR 9) Disconnect or remove the following air or water hoses: • (34) Air inlet to turbocharger. • (31) Blowing of turbocharger. • (25) Fresh air inlet to intake manifold. • (26) Water inlet to radiator. • (27) Water outlet from the radiator. •...
Page 292 ENGINE REPAIR 6A-81 11) Remove or disconnect: • Screws (35) fixing the first stretch of exhaust tube to elbow of turbocharger first strecht. • In vehicles with air conditioning, the hoses (36) of inlet and outlet of compressor. • Delivery hose (37) of servo steering hydraulic pump, putting previously a container under the pump to pour oil from the tank.
Page 293 6A-82 ENGINE REPAIR 13) Connect to engine a lifting tool (A) ref. 790975; connect a hydraulic lifter device and hang the engine as required to extract the silentblocks at front seatings. 14) Lower engine as much as allowed and put a lifting table (B) over the lower part of gear box, in order to share weight between this table and the engine lifting device.
Page 294: Checks And Controls
ENGINE REPAIR 6A-83 Installation Checks and controls 1) Proceed in reversing removal procedures. Apply the 1) Start engine and leave it at a rev. regime slightly over ticking specified tightening torques and noting the following over regime, wait till the coolant comes to a temperature remarks: ensuring the opening of thermostat (94ºC to 110ºC).
Page 295 6A-84 ENGINE REPAIR ENGINE REPAIR ON THE WORK BENCH NOTE: While repairing the engine on the work bench, we will no go deep down into those tasks described in "REPAIRS ON VEHICLE", and basically identical to the ones in "ENGINE REPAIR ON THE WORK BENCH".
Page 296 ENGINE REPAIR 6A-85 REMOVAL ENGINE External components removal 1) Removal the following components: • Pressure plate and disc of clutch (see 7C-10). • Starting motor and flywheel casing (2). • Upper soundproof cover (mechanical injection (mechanical injection (mechanical injection (mechanical injection (mechanical injection engine) engine)
Page 297 6A-86 ENGINE REPAIR • Linkage and pressure pipe (10) of L.D.A. device with pipe fixed clamps (mechanical injection engine (mechanical injection engine (mechanical injection engine (mechanical injection engine). (mechanical injection engine • Linkage and pipe (8) of fuel inlet to electrovalve (9) of thermo starter.
Page 298 ENGINE REPAIR 6A-87 Timing and cylinder head removal 1) Remvoe cramshaft position sensor (77) and its support (common rail engine) (common rail engine) (common rail engine) (common rail engine) (common rail engine) 2) Remove timing upper cover (21) and the plungers cover (22). 3) Block flywheel using tool (B) ref.
Page 299 6A-88 ENGINE REPAIR 6) Remove: • Fixed tensioning roller (38) and internal protection (39). • Thermostat box (33), switches of temperature (34) and (35) and hose (36) of connection with water pump. • Oil filling spout (37) and assembly oil level gauge rod (40). 7) Remove the camshaft driving gear (43).
Page 300: Left Side
ENGINE REPAIR 6A-89 Left side 3) Dismantle screws (56) fixing the auxiliary organs group (55); withdraw generator rear support of (57) and the auxiliary organs group assembly (55). NOTE: • Plug adequately the oil passages of auxiliary organs group. Entrance of alien bodies could damage seriously the assembly.
Page 301 6A-90 ENGINE REPAIR Rear part 9) Block again the flywheel rotation using tool (B) ref. 790976 and remove plate support of ball bearings (63). 10) Remove screws (65) fixing flywheel (64), take away blocking tool (B), remove flywheel and dust preventing plate . 11) Remove assembly cover and rear oil-seal (66).
Page 302 ENGINE REPAIR 6A-91 Crankshaft and lower block 12) Remove screws (67) fixing lower block (68) to upper block (69). 13) Remove lower block (68) with gasket. 14) Remove crankshaft (70) using a lifting device . 15) Straighten the braking sheets that put in place the screws (71) of oil injectors (73);...
Page 303 6A-92 ENGINE REPAIR CYLINDERS BLOCK REPAIR Revision and measurement of cylinders block Revision 1) Clean thoroughly cylinders block and check carefully there are no cracks. 2) Verify caps of mechanization to see they are not oxidized or present lack of impermeability. NOTE: If there are any anomalies substitute whatever is necessary.
Page 304 ENGINE REPAIR 6A-93 • Measurements to carry out the mechanical rectiffying are obtained from the four Ø of set of four new spare pistons oversized in 0.4 mm plus the nominal play between piston and cylinder. • If the measurements obtained concerning amount of wear, oval and conical shaping of cylinders are more than 0.4 mm when comparing against the nominal Ø...
Page 305 6A-94 ENGINE REPAIR Cylinders lining up Beforehand verifyings in the cylinders block 1) Before proceeding to the cylinders block lining, verify diametre of ball bearings lodgings at the block as indicated; if results are inadequate as specified substitute cylinders block. •...
Page 306 ENGINE REPAIR 6A-95 Ø 101,07 ÷ 101,13 0,05 K Ø 97,5 -0,05 0,03 B -0,11 R 0,4÷0,6 0,02 0,05 Longitudinal axis of the motor AUTOMATED OF CYLINDERS to HOUSE SHIRTS 3) Once the four cylinders have been mechanized measure each one using an internal dimensions caliper adjusted to the nominal diameter size of mechanized cylinders.
Page 307 6A-96 ENGINE REPAIR 4) Install the liners over mechanized cylinders using a hydraulic press . Noting to the following steps: • Control values specified in the annexed table. • Do not use grease, oil or other lubricant to get in the sheatings.
Page 308 ENGINE REPAIR 6A-97 Cylinders surface finishing 1) Once the sheatings have been placed or oversize rectified, proceed to final mechanical rectifying according to the stated data and at the accompanying drawing. Ø 1= Standard: 94,402 ÷ 94,432 mm Ø 2= Oversize: 94,802 ÷ 94,832 mm A-B= axle longitudinal and transversal Ø...
Page 309 6A-98 ENGINE REPAIR CRANKSHAFT REPAIR Revision and measurement of crankshaft Revision 1) Clean thoroughly crankshaft and check carefully there are no knockings, scratches, signs of gripping or wear. 2) Verify caps of oil tunnels (3) just in case they show rust or lack of impermeability.
Page 310 ENGINE REPAIR 6A-99 Mechanical rectifying of crankshaft journal NOTE: •The rectified journal will be identified by a letter engraved in arm n° 1 of the crankshaft: For rectified journal of connecting rod: letter (M). For rectified journal of main bearing : letter (B). For rectified journal of connecting rod and main bearing: letter (MB).
Page 311 6A-100 ENGINE REPAIR TIMING SIDE CRANPIN OF MAIN BEARING INTERMEDIATE JOURNAL OF THE MAIN BEARING 1,6 ÷ 1,7 1,6 ÷ 1,7 After the After the compression compression After the compression (1,5 ÷ 2,5) Before the compression (1,5 ÷ 2,5) CONNECTING ROD JOURNAL FLYWHEEL SIDE JOURNAL OF THE MAIN BEARING Max 0,4 R 2 min...
Page 312 ENGINE REPAIR 6A-101 TOLERANCES CHARACTERISTICS, GRAPHIC SYMBOL Circularity OF FORM Cylindricality Parallelism OF ORIENTATION Perpendicularity OF LOCATION Concentricity or coaxiality Circled Oscillations OF OSCILLATION Total Oscillation CLASS ATRRIBUTED TO THE CHARACTERISTICS OF THE PRODUCT GRAPHIC SYMBOL CRITICAL IMPORTANT SECONDARY Symmetry between the main bearing journal and connecting rod journal .
Page 313 6A-102 ENGINE REPAIR Timing driver gear replacement NOTE: If damages or wear in the gear of the timing driver gear are detected, replace it as specified below. Removal 1) Make two notches (A) at each side of gear (1) to be able to get in the gripping jaws of extractor (B).
Page 314 ENGINE REPAIR 6A-103 CHECKING AND FORMING ASSEMBLIES OF PISTONS, PISTON RINGS AND CONNECTING RODS Disassembly assembly piston and connecting The assembly piston and connecting rod consists of : 1.- Piston 2.- Elastic ring 3.- Gudgeon pin 4.- Trapezoidal Piston Ring 5.- Scrapping Piston Ring 6.- Scrapping Piston Ring with spring 7.- Connecting rod...
Page 315 6A-104 ENGINE REPAIR Checking pistons and piston rings 1) Clean thoroughly pistons and piston rings taking off the spent carbon residues. Do not use cleaning tools leading to scratches.Then, do the measurements specified in the table herewith. 2,068 1,970 2,470 2,200 2,050 2,540...
Page 316 ENGINE REPAIR 6A-105 Verifying play between piston and cylinder NOTE: The pistons supplied and sold as spares can be either stan- dard or oversized pistons; coming with piston rings, gudgeon pins and elastic rings. 2) Using a micrometer (B), measure the pistons diameter at height (X).
Page 317 6A-106 ENGINE REPAIR Checking the gudgeon pins of pistons installation 5) Using a micrometer (D), measure diameter of gudgeon pins. To check dimensions, see 6A-96. 6) Lubricate gudgeon pin (3) and seating (11) in piston. Gudgeon pin must be introduced with a slight pressure of fingers and must no come out of its housing by gravity Play between bolt and seating at the piston: 0,007÷...
Page 318 ENGINE REPAIR 6A-107 piston ring (trapezoidal) PISTON 9) Check play between piston ring 1 and piston slit or groove as follows: • Install piston ring in the corresponding piston slit or groove piston. • Fit piston in a cylinder as shown. Piston ring 1 must come 1º...
Page 319 6A-108 ENGINE REPAIR Connecting rod foot bushies 2) Control that connecting rod bush foot is no loose in its housing , that there are no symptoms of gripping, scratches or excessive wear. Replace if necessary . 3) To replace bush use a pushing cylindrical hand tool as required.
Page 320 ENGINE REPAIR 6A-109 Torsion verifying 6) Check torsión of connecting rod on Points (A) and (B) of the piston pin (G-4) as follows: • Contact with measuring tip of dial gauge (H) on Point (A) of piston pin (connecting rod resting in bar G-1). Apply a pre-advance ~ 0,5 mm and adjust comparator to zero.
Page 321 6A-110 ENGINE REPAIR Assembly rearranging piston and connecting NOTE: If pistons are going to be installated again they must be matched with their respective connecting rods and later installated on the same cylinders they connecting rod from. 1) Once selected pistons and connecting rods, proceed to the rearranging of assembly.
Page 322 ENGINE REPAIR 6A-111 Pistons parallelism control 4) After making adequate assemblies of pistons and the connecting rods, check pistons parallelism using tool (G) ref. 790978 proceeding as follows : • Install connecting rod and piston on mandril (G-2) and fíx it with screw (G-3).
Page 323 6A-112 ENGINE REPAIR REMOVAL AND REPAIR OF CYLINDER HEAD Dismantling and check of camshaft Dismantling 1) Install cylinder head on tool ref. 790979 and orientable support ref. 790980. 2) Dismantle front cover (3), liberate gradually nuts of resting covers (1), remove covers and withdraw camshaft (2). CAUTION: To avoid excessive flexions because the pressure coming from the springs of valves, loose nuts of...
Page 324 ENGINE REPAIR 6A-113 33,934 34,134 33,950 34,150 33,985 34,185 34,015 34,215 MEASURES SUPPORTS DIAMETER OF CAMSHAFT IN CYLINDER HEAD AND IN CAMSHAFT * Standard diameter * * Oversized diameter 0.2 mm 1) Measure supports diameter (4) camshaft with a micrometer (A) and of supports in the cylinder head, with installed covers, using a micrometer for interiors.
Page 325 6A-114 ENGINE REPAIR Run out and cam wear 3) Place camshaft on two identical height supports by the ends. Apply a centesimal dial gauge on central support and check that run out is no higher than specified . Camshaft run out limit: 0,04 mm 4) With the connecting camshaft placed as described above, check that wear of admission and exhaust cam does not...
Page 326 ENGINE REPAIR 6A-115 1) Measure rocker arms diameter (5) with micrometer (A) and its housings in cylinder head using a micrometer for internal distances. The difference between both readings gives the installation play between rocker arms and housings, which must be within the specified range.
Page 327 6A-116 ENGINE REPAIR Cylinder head proof control 1) Check cylinder head proof using adequate tools and appropriate gaskets (D), (F), (E) and (G). 2) Introduce hot water at ~ 90° C through (G), at a pressure of 2 ÷ 3 Kg / (cm 3) Check there are no leaks through caps.Otherwise substitute leaking caps applying recommended hydro reacting sealant.
Page 328 ENGINE REPAIR 6A-117 Valves and valves guides check 7,985 8,000 NOTE: 13,012 To carry out measurements on valves and valves guides, 13,025 see table herewith 8,023 8,038 45° 30´ ± 7´ 60° 15´ ± 7´ 40,75 ÷ 41,00 35,80 ÷ 36,00 ADMISSION EXHAUST MAIN MEASURES OF VALVES AND VALVES GUIDES...
Page 329 6A-118 ENGINE REPAIR Seat rebored 6) Rectify , if necessary, valves seats taking as little material as possible. To seats, see values indicated in table herewith. EXHAUST ADMISSION 30º ± 1º 20º ± 1º R 2 MAX R 0,8 MAX R 0,8 MAX Ø...
Page 330 ENGINE REPAIR 6A-119 Valves guides substitution 1) Dismantle the valves guides using tapping (L) ref. 790982. 2) Install the new guides as follows : • Heat cylinder head between 80° ÷ 100 ° C. • Cool valve guide to be fitted with liquid nitrogen •...
Page 331 6A-120 ENGINE REPAIR Valves seatings substitution and rebored Seats removal 1) Using special tool (Q) ref 790985 and grindstone,take away material from seat to be substituted (17) till being able to extract with. CAUTION: While chipping away material from valves seatings check valves seats and during the extraction of the same, take attention not to damage the cylinder head.
Page 332 ENGINE REPAIR 6A-121 Seats reboring 4) Using tool (Q) ref. 790985 or similar and appropriated grindeg, go through the valves seatings according to the values stated under "MAIN DATA OF VALVES SEATINGS". NOTE: • Once the casings or seatings have been rectified couple them with their respective valves doing a fine grinding.
Page 333 6A-122 ENGINE REPAIR 2) Check the springs worthiness of valves at rest and under load. See table of values herewith. NOTE: If some spring does not pass the stress checking

Santana PS-10 Service Manual

Section 0B 0B Maintenance and Lubrication

1A Heater and Ventilation

Bumpers, Front Hood and Frontal

Steering Gear Box and Linkage

Steering Wheel, Column and Lower Shaft

Front Suspension

Rear Suspension

Wheels and Tires

Front Drive Shaft

Rear Drive Shaft

Front and Rear Propeller Shafts

Brakes

Engine Repair

Cooling System

Engine Fuel and Emission Control System

Lubrication System

Manual Transmission

Clutch

Transfer

Body Service

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Summary of Contents for Santana PS-10