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Santana
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PS-10
Santana PS-10 User Manual
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BUMPERS, FRONT HOOD AND FRONTAL 2-5
REMOV
AL AND INST
ALLA
TION 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).
1
54
56
Table of Contents
Section 0B 0B Maintenance and Lubrication
6
Propeller Shafts
4
Table of Contents
6
Maintenance and Lubrication
6
Maintenance Schedule
7
Maintenance under Normal Driving Conditions
7
Accesory Driving Belt (Item 1.1)
7
Maintenance Service
9
Engine Oil and Filter (Item 1.3)
10
Engine Oil Change
10
Injectors Gauging (Item 1.4) (ONLY MECHANICAL INJECTION)
13
Engine Coolant (Item 1.5)
13
Water Radiator (Item 1.6)
16
Intercooler (Item1.7)
16
Air Filter (Item 1.8)
16
Exhaust System (Item 1.9)
17
Visual Control (Item 1.10)
17
Fuel System (Item 2)
18
Fuel Lines and Connections (Item 2.3)
18
Fuel Tank (Item 2.4)
18
Transmission (Item 3)
20
Gear-Box Oil (Item 3.1)
20
Transfer Box Oil (Item 3.2)
21
Oil Level
21
Differential Groups Oil (Item 3.3)
22
Clutch Liquid (Item 3.5)
24
Clutch Pedal (Item 3.6)
25
Visual Control and Running (Item 3.7)
26
Brakes, Steering, Suspension and Wheels (Item 4)
27
Performance Inspection
28
Steering Mechanical System (Item 4.4)
29
Servo-Steering Hydraulic Oil Filter (Item 4.6)
30
Dampers, Silent-Blocks and Springs (Item 4.8)
31
Servo-Steering Hydraulic Oil (Item 4.7)
31
Tyres (Item 4.9)
32
Wheels and Wheel Nuts (Item 4.10)
33
Final Inspection
36
Recommended Fluids and Lubricants
38
1A Heater and Ventilation
39
General Description
40
Heater Control Operation
41
Diagnosis
43
On Vehicle Service
44
Ventilator and Diffuser Unit
44
Control Cable Adjustment
46
Heater Unit
48
Inside Ventilation
49
Bumpers, Front Hood and Frontal
51
Front Bumper
52
Rear Bumper
53
Front Hood
54
Removal and Installation of Front Hood
55
Frontal
57
Steering Gear Box and Linkage
75
General Description
77
Tie Rods
80
Removal and Installation
81
Power Steering Pump
83
On Vehicle Service
84
Steering Wheel Inspection
84
Power Steering Fluid Leakage Inspection
85
Power Steering Hydraulic Oil Filter Substitution
85
Hydraulic Pressure Inspection
87
Tightening Torque
89
Steering Wheel, Column and Lower Shaft
91
General Description
92
On Vehicle Service
93
Steering Wheel
93
Steering Wheel Repositioning
94
Ignition Switch and Steering Lock
96
Steering Lower Shaft
98
Data and Assembly Allerances
102
Tightening Torque Specifications
102
Front Suspension
103
General Description
104
On Vehicle Service
105
Springs Bush and Body
108
Front Suspension Inspection
109
Data and Assembly Tolerances
110
Tightening Torque Specifications
110
Rear Suspension
111
General Description
112
On Vehicle Service
113
Leaf Springs and Chassis Bumpers
114
Springs Bumpers
114
Rear Suspension Inspection
115
Assembly Data and Tolerances
116
Wheels and Tires
117
General Description
118
Tires
118
Replacement Tires
118
Maintenance and Minor Adjustments
119
Wheels Maintenance
119
On Vehicle Service
120
Metric Lug Nutsand Wheels Studs
120
Wheels Removal and Installation
120
Wheels Balancing
122
Section 6L
125
Front Drive Shaft
126
General Description
127
Vehicle Service
128
Removal and Installation Steering Pivot Assembly
128
Removal and Installation Differential Group Assembly
130
Removal and Installation Front Drive Shaft Assembly
131
Friction Pads Substitution
134
Front Shaft Housing Substitution
136
Steering Pivot and Wheel Hub Assembly
137
General Description
137
Tightening Torque Specifications
147
Recommended Products
148
Special Tool
148
Rear Drive Shaft
150
General Description
151
On Vehicle Service
152
Flange Oil-Seal of the Differential Group Substitution
156
Rear Shaft Housing Substitution
158
Assembly Data and Tolerances
161
Tightening Torque Specifications
161
Recommended Service Materials
162
Special Tool
162
Front and Rear Propeller Shafts
164
General Description
165
Front Propeller Shaft
166
Removal, Revision and Installation
166
Rear Propeller Shaft
170
Removal, Revision and Installation
170
Assembly Data and Tolerances
171
Recommended Service Materials
171
Tightening Torque Specifications
171
Brakes
172
General Description
174
Master Cylinder Assembly
176
Vacuum Pump
177
Brake Booster Assembly
178
Diagnostics
180
Road Testing Brakes
180
On-Vehicle Service
183
Brake Pedal Free Height Adjustment
183
Master Cylinder Inspection
184
Brake Fluid Substitution and Circuit Purging
188
Master Cylinder Purging
190
Vacuum Circuit Checking
191
Parking Brake Lever and Cable Substitution
194
Lever Substitution
194
Cable Substitution
194
General Data
211
Engine Identification
211
Engine Repair
212
General Characteristics
224
Symbol Chart
234
CHARACTERISTICS and SERVICING of BELT TENSIONS CHECKER (FREQUENCY METER Ref. 00000A01484)
235
On Vehicle Service
237
Belts Substitution
237
Water Pump Substitution
241
Removal and Installation of Injectors (Mechanical Injection Engine)
243
(Mechanical Injection Engine)
243
Mechanical Injection Engine
244
(Common Rail Engine)
247
Mechanical Injection Engine
250
(Common Rail Engine)
253
Bearing of Gearbox Primary Axle Removal
257
Crankshaft Oil-Seals Substitution
258
Crankshaft Rear Oil-Seal Substitution
258
Crankshaft Front Oil-Seal Substitution
258
Camshaft Front Oil-Seal Substitution
259
Valves Play
260
Removal and Installation of Starting Motor
272
Removal and Installation of Turbocharger
273
Removal and Repair of Gearbox and Oil Pump
284
Removal and Installation of Engine on Vehicle
288
Removal and Installation of Engine
288
Checks and Controls
294
Left Side
300
Lower Part
300
Cooling System
372
Water Pump
377
Revision
377
Thermostat
378
Characteristics
378
Thermostat Substitution
378
Water Radiator
379
Removal
379
External Cleaning of Water Radiator
381
Engine Fuel and Emission Control System
383
Emission Control System
383
General Description
385
Fuel System (Mechanical Injection Engine) (Mechanical Injection Engine) (Mechanical Injection Engine)
389
(Mechanical Injection Engine)
390
Bleeding Air of Fuel System
390
Fuel Filter
390
Water and Residue Cleaning from Fuel Filter
391
Fuel Filter Replacing
391
Fuel Tank
392
Fuel Tank Pressure Control Valve
393
Fuel Level Gauge
394
Thermostarter
395
Thermostarter Electro-Valve
395
Thermostarter Spark Plug
395
Thermostarter Inspection
396
High Press. Injection Pump and Injectors Fuel
397
High Pressure Fuel Pump Removal
397
Injectors and Injection Pipes
397
Injectors Adjustment
399
Automatic Device for the Advance Injection for Cold Starting (KSB)
400
High Pressure Electronic Injection System (Common Rail
401
Generalities
401
Common Rail Electronic Injection System Components
402
Electronic Control System
403
System Fuctions
404
General Description
407
Prefilter
409
Electric Feed Pump
410
Main Filter
411
Specifications
411
High Pressure Pump
412
Pressure Regulator Valve
413
Hydraulic Accumulator (Rail)
414
High Pressure Pipes
415
Electro-Injectors
416
Electric/Electronic Components
419
Fuel Pressure Sensor
423
Engine Speed Sensor
423
Fuel Temperature Sensor
424
Coolant Temperature Sensor
424
Control Unit
424
Intake Manifold Air Temperature and Pressure Sensor
425
Accelerator Pedal Stroke Sensor
426
Clutch Pedal Position Sensor
426
Brake Pedal Position Sensor
426
Atmospheric Pressure Sensor
426
Actuators
427
Blink - Code
427
Air Intake System
429
Precaution in Cleaning and Repairing Air Intake System
429
During Repair
429
On-Vehicle Service
430
Air Filter
430
Residues Bleeding
430
Filter Element
430
Intercooler
432
Turbocharger
433
Removal and Installation
433
Pressure Limiting Valve Control and Regulation
434
Replacement
435
Temperature Sensors Location (Mechanical Injection Engines) (Mechanical Injection Engines)
436
(Mechanical Injection Engines) Engine Speed Sensor (Mechanical Injection Engines) (Mechanical Injection Engines)
437
Assembly Tolerances and Data
438
Exhaust Manifold
442
Tigthening Torque Specifications
438
Lubrication System
443
General Description
444
Lubrication Circuit
444
Oil Vapours Recycling Circuit
445
Oil Pump
446
Heat Exchanger
446
Oil Pan
446
Manual Transmission
449
Manual Transmission 7A-1
451
Clutch
490
General Description
491
Diagnosis
492
On-Vehicle Service
493
Clutch Pedal Height
493
Thrust Block Replacement
497
Pressure Plate and Clutch Disc
499
Main Clutch Cylinder
501
Auxiliary Clutch Cylinder
503
Required Service Materials
504
Torque
504
Assembly Data and Tolerances
504
Transfer
506
General Description
507
Diagnosis
510
On Vehicle Service
511
Rear Seal Replacement
511
4WD Switch Replacement
513
Transmission Installation
514
Speedometer Gear Box Repair
517
Speedometer Cable Replacement
521
Transfer Box
522
Torque
535
Special Tools
541
Installation Data and Tolerance
541
Body Electrical System
560
Body Service
564
Door Glass
565
Window Regulator
567
Lock Assy
568
Back Door
570
Door Lock
572
Roof
574
Windscreen
575
Side
581
Rear Body
582
Seats
584
Front Seats
584
Central Seats
585
Back Seats
586
Seat Belts
588
Coatings and Silencers
589
Coatings
589
Silencers
589
Anticorrosion Treatment
590
Metallic Spare Pieces Finishing
592
Frame
593
4
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Santana PS-10 Specifications
General
Brand
Santana
Model
PS-10
Category
Automobile
Language
English
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