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 test, presents bendings, breakings and lack of perpendicularity, replace it. MAIN DATA FOR CONTROL DF VALVES SPRINGS SPRING EXTERNAL...
Page 334 ENGINE REPAIR 6A-123 INSTALLATION AND ADJUSTMENTS OF CYLINDER HEAD NOTE: Clean cylinder head and components .thoroughly before starting installation Rear cover installation 1) In case of having removed rear cover (1), install it with a new gasket (2) and apply specified tightening torque to the fixing elements.
Page 335 6A-124 ENGINE REPAIR 3) Measure valves and thickness overhanging injectors. Values obtained must be within specified values (see table herewith). Valves head thickness NOTE: If any value exceeds the limit, replace faulty piece. 1,2 ÷ 1,5 1,0 ÷ 1,3 Overhanging injectors 2,230 ÷...
Page 336 ENGINE REPAIR 6A-125 Rocker arms installation 1) Lubricate rocker arms housings. 2) Assemble plungers (12) in the same order they were dismantled and keeping, initially, the same adjusting plates (13). Camshaft and front oil-seal installation Camshaft installation 1) Lubricate the rolling area of supports and covers of camshaft in cylinder head.
Page 337 6A-126 ENGINE REPAIR Oil-seal installation 5) Using tool (G) ref. 790968 and special tool (F) ref. 790969, put a new oil-seal (17) with its protection ring over cover enclosing oil-seal (18). 6) Apply a coat of recommended sealant ref. 790962 on the support surface of cover (18);...
Page 338 ENGINE REPAIR 6A-127 ASSEMBLY AND ADJUSTMENTS OF ENGINE Assembly and adjustments of cylinders block 1) Fix upper cylinders block (1) to rotating work bench ref. 790990 using flanges ref. 790989. 2) Install oil injectors (2) with new braking plates and screws.Tighten screws to the specified tightening torque and brake them with plates.
Page 339 6A-128 ENGINE REPAIR • Install the lower half bearings of main bearing (7), (half bearings without greasing hole) on lower block (5) and gaskets (6). • Install lower block on upper block doing the coincidence of reference marks (8). • Fix lower and upper blocks with screws (9). Apply to them the specified tightening torque going through the two steps decribed herein: Tightening torque for screws fixing lower block:...
Page 340 ENGINE REPAIR 6A-129 • Remove lower block and check width of calibrated wire (10) in the area most crushed. To do this, use engraved scale in the wrappings of calibrated wire. • The measure arrived at must be within specified values. Otherwise substitute the half bearings in question and repeat measurement again starting from the beguining.
Page 341 6A-130 ENGINE REPAIR 8) With the crankshaft pulley (15) temporarily installated, measure distance (Y) as follows: • Measure distance (Y,) between external face of cylinders block (13) and external face of pulley (15). Measure must be within the range 107,17 ÷ 108,53 mm. NOTE: Measure (Y ) must be taken with crankshaft subject to...
Page 342 ENGINE REPAIR 6A-131 Piston rings installation 11) Using clamping tool (C), install piston rings to as indicated in figure at the left. CENT . INF. Piston and connecting rod assembly installation on cylinders NOTE: Install each assembly constituted by the piston, connecting rod and connecting roo bearings, in the same cylinder they were located before removal.
Page 343 6A-132 ENGINE REPAIR • That number in connecting rod agrees with number in cover. • That end gaps of each piston ring are 120° out of phase from other two per ring. • That upper engraved part (23) of each piston is oriented towards engine flywheel or that piston half open lip (22) found at the piston side is oriented towards oil injectors.
Page 344 ENGINE REPAIR 6A-133 • Install bearing caps (26) with bearings, lubricate the screws with oil ref. 790964 and tighten them in two steps to the specified tightening torque. Tightening torque for screws at connecting rods covers: • 1 step; with torque wrench: 5 Kg-m (50 Nm) •...
Page 345 6A-134 ENGINE REPAIR NOTE: • *The height determining the thickness of gaskets is referred to the maximum pistons overhanging once the four pistons have been measured • To do the measurements in the pistons place them in T.D.C. position using a dial gauge. •...
Page 346 ENGINE REPAIR 6A-135 Example: - If displacement is by defect (for instance, 0.2 mm before the zero) turn crankshaft in the opposite direction by half of the measured value, 0.1 mm, before the zero. - - If the displacement is by excess (for instance, 0,2 mm after the cero), rotate crankshaft by ~¼...
Page 347 6A-136 ENGINE REPAIR Lower part 25) Install oil strainer (33), oil pan gasket (34) and oil pan. Apply specified tightening torques. Tightening torques: • Oil strainer screws: 2,5 Kg-m (25 Nm) • Oil pan screws: 1,8 Kg-m (18 Nm) • Principal oil gallery cap M18: 4 Kg-m (40 Nm) For the left side 26) Install assembly of the auxiliary organs group (35) and the...
Page 348 ENGINE REPAIR 6A-137 4) Turn camshaft till ensuring that the cylinder number 1 valves (40) are completely closed. 5) Install cylinder head (39) on cylinders block and select the fixing bolts (38). CAUTION: Before using again the screws of the cylinder head, measure their diameter on the thread with a micrometer.
Page 349 6A-138 ENGINE REPAIR Cylinder head cover installation 9) Fill the cavities (44) between rear cover (45) and cylinder head with impermealising putty ref. 790963. 10) Install a new gasket (43) on cylinderhead cover (42). 11) Apply impermeabilising putty ref. 790963 ( ~10 gr) at cover angles.
Page 350 ENGINE REPAIR 6A-139 7) Install timing belt tensioner (56) without tightening nut (57). 8) Introduce between cylinder (52) and linkage (55) an appropriate spanner (M) to null the pressure of the linkage on tensioner. Timing synchronization and timing belt installation 9) Check that number 1 piston is in T.D.C.
Page 351 6A-140 ENGINE REPAIR 12) Install timing belt (63) ensuring that it fits perfectly in pulleys and that is well tensioned on the fixed side (belt going through the crankshaft pulley, auxiliary organs group pulley, tensioner and camshaft pulley). 13) Install lower timing cover (64) and tighten bolts (62) to the specified tightening torque.
Page 352 ENGINE REPAIR 6A-141 Injection pump installation and setting injectors (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) Installation injecting pump 1) Align mark (60) of the camshaft and (61) of the cylinder head cover. Be sure of the alignment between hole (66) of pulley (62) of the auxiliary organs group and hole of the block using tool ref.
Page 353 6A-142 ENGINE REPAIR 4) Take away cap located in the locking screw of the injection pump and fit adapter (O) ref. 790966. Be sure that the probe of the adapter make contact with the distributor piston of the pump. 5) Install dial gauge (P) on the adapter (O) and fix it in such a way that the needle undertakes a preadvance of about 3 6) Turn slowly crankshaft in opposite direction to rotation till the dial gauge (P) indicates B.T.C.
Page 354 ENGINE REPAIR 6A-143 Upper timing cover, crankshaft pulley and electromagnetic gasket installation Upper timing cover installation 1) Install upper timing cover (75) and apply to the screws the specified tightening torque. Tightening torque for upper timing cover: 0,75 Kg-m (75 Nm) Crankshaft installation 2) Install the crankshaft pulley (15) with the supplement which was dismantled or calculated in 6A-129, «Control of...
Page 355 6A-144 ENGINE REPAIR 8) With thickness calliper (R), measure the distance between the mobile plate of the bushing and the pulley. It must be in correspondence with the specified value. Play between mobile plate of bushing and pulley: 0,25 ÷ 0,45 mm 9) Install camshaft speed sensor (116) and its bracked.
Page 356 ENGINE REPAIR 6A-145 External components installation on the work bench Intake manifold and air inlet box 1) Put new gasket on cylinder head, install intake manifold (86) and fix it with nuts (85) tightened to the specified torque. Tightening torque for intake manifold nuts: 2,5 kg-m (25 Nm) 2) Install pressure tube (91) of the L.D.A device and tighten union nut (90) to the specified tightening torque...
Page 357 6A-146 ENGINE REPAIR 6) Install generator (98), front support (99) and belt (100) (see 6A-59). Engine speed sensor installation and adjust (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) (mechanical injection engine) 7) Install engine speed sensor (123), adjust clearance at specified valve using gauge (D) and tighten locknut (124) to specified torque.
Page 358 ENGINE REPAIR 6A-147 External components installation out of the work bench 1) Using a lifter in engine, separate it from work brench ref. 790990 and take off clamps ref. 790989. 2) By the right hand side, install: • Install turbocharger, exhaust manifold and thermal screen (104) (see 6A-62).
Page 359 6A-148 ENGINE REPAIR TIGHTENING TORQUE SPECIFICATION TORQUE OBSERV. ELEMENT Kg-m Cylinder head bolts First step; pretightening with torque wrench 6 ± 0,5 60 ± 5 Second step; pretightening with torque wrench 6 ± 0,5 60 ± 5 180° ± 10° Third step;...
Page 360 ENGINE REPAIR 6A-149 TORQUE ELEMENT OBSERV. Kg-m Upper soundproofed cover nuts Fuel injectors return pipes union nuts bolts Injection pumper high pressure pump striated hub nut Injection pump or high pressure pump nuts Inlet and fuel return union nut LDA pressure pipe union nut bolt Main shaft bearing plate bolts 1,8 ÷...
Page 361 6A-150 ENGINE REPAIR TORQUE ELEMENT OBSERV. Kg-m Exhaust manifold antivibration bracket bolts Oil draining union nut to turbocharger connecting bolts Turbocharger oil draining adapter to block conneciting bolts Power steering pump outlet union nut bolt 3 ÷ 4 30 ÷ 40 Power steering pump inlet union nut bolt 3 ÷...
Page 362 ENGINE REPAIR 6A-151 TORQUE ELEMENT OBSERV. Kg-m Gear box to engine connecting nuts 4 ÷ 6 40 ÷ 60 Gear box to engine connecting bolts 4 ÷ 6 40 ÷ 60 Silent-blocks to engine mounting connecting nuts Engine mounting bolts M12 7,4 ÷...
Page 363 6A-152 ENGINE REPAIR TORQUE ELEMENT OBSERV. Kg-m Hydraulic accumulator (Rail) nuts Hydraulic accumulator (Rail) soundproof cover nuts High pressure fuel pump to separator connecting nuts Fuel pressure sensor on hydraulic accumulator (Rail) Flow limiters on hydraulic accumulator (Rail) Pressure limiter valve on hydraulic accumulator (Rail) SYMBOLS Apply sealant 790961 ❋...
Page 364 ENGINE REPAIR 6A-153 REQUIRED SERVICE MATERIALS PRODUCT TYPE REF. Water pump screws, auxiliary group screws , organs group, adaptor oil filter 790961 Threads sealant andtemperature water conical transmissor. Camshaft front oil-seal cover, cylinder head rear cover concavities, auxiliary Connections sealant 790962 organs group rear cover.
Page 365 6A-154 ENGINE REPAIR SPECIAL TOOS CLASS OBSERV. REF. GENERAL SPECIF. DENOMINATION 00000A01484 Tension measuring equipment Auxiliary organs group pulley and engine flywheel 790965 positioner. Dial gauge holder tool for overhauling injection pump 790966 Dial gauge 0 ÷ 5 mm 790967 Front oil seal installer (Use with handler 790969) 790968...
Page 366 ENGINE REPAIR 6A-155 CLASS OBSERV. REF. GENERAL SPECIF. DENOMINATION 790969 Handler for tappet Spanne for rotating camshaft 790970 (cylinder head removed) Springs pusher substitute valve 790971 regulating plates Tool for removal, installation and applying the tightening 790972 torque at oil filter Auxiliary organs group 790973 repairing support...
Page 367 6A-156 ENGINE REPAIR CLASS OBSERV. REF. GENERAL SPECIF. DENOMINATION Tool set to check resistence 790974 to rotation of drive axle oil pump. Engine handling device for 790975 removal and installation. Locking tool for engine 790976 flywheel to apply tightening torques. Special spanner (13 mm) for 790977 removal and installation of...
Page 368 ENGINE REPAIR 6A-157 CLASS OBSERV. REF. GENERAL SPECIF. DENOMINATION Bridle for coupling cylinder head in orientable support 790979 (to be used together with 790890). Orientable support to repair cylinder head 790980 (To be used together with tool 790979) Compressing tool to press the springs for removal and 790981 installation of the valves.
Page 369 6A-158 ENGINE REPAIR CLASS OBSERV. REF. GENERAL SPECIF. DENOMINATION Valve guide scraper. 790984 Seat reboring and replacing 790985 tool set. Cilinder head injector seats 790986 cleaning milling bit. 790987 Oil seal installer. Valve spings resistance 790988 checker.
Page 370 ENGINE REPAIR 6A-159 CLASS OBSERV. REF. GENERAL SPECIF. DENOMINATION Engine coupling to work 790989 bench brid les (use together with 790990) Engine repairing bench (use together with 790989) 790990 Injection pump gub remover. 790991 790992 Injection pump positioner. 791037 Fuel injection pipes remo- 790993 ver.
Page 371 6A-160 ENGINE REPAIR CLASS OBSERV. REF. GENERAL SPECIF. DENOMINATION Compression gauge. 790994 Tool set for angular tightening 790995 with 1/2¨ and 3/4¨ couplings. SIMBOLS AND ABBREVIATIONS Only rotative pump mechical injection engine. Only Common Rail Engine. Recommended. Necessary.
Page 372: Cooling System
COOLING SYSTEM 6B-1 SECTION 6B COOLING SYSTEM CONTENT GENERAL DESCRIPTION ............................ 6B- 2 ON VEHICLE SERVICE ............................6B- 4 - Electromagnetic pulley .......................... 6B- 4 • Characteristic ..........................6B- 4 • Electromagnetic gasket substitution ....................6B- 4 - Water pump ............................6B- 6 •...
Page 373 6B-2 COOLING SYSTEM GENERAL DESCRIPTION General description The refrigeration system of engine is of forced circulation type and is constituted by the following elements: • A reservoir tank whose cap incorporates two valves, one for emptying or flushing and another one for filling. •...
Page 374 COOLING SYSTEM 6B-3 CALEFACTOR DIAGRAM OF THE COOLING CIRCUIT C O O L A N T C I R C U L A T I O N 1 Reservoir tank. B E T W E E N THERMOSTAT AND 2 Degasifying hoses. PUMP WITH THEIR THERMOSTAT CLOSED 3 Thermostat box...
Page 375 6B-4 COOLING SYSTEM ON VEHICLE SERVICE ELECTROMAGNETIC PULLEY Characterstics • Torque at 1000 r/min at 20°C: 2.3 Kgm (23 Nm). • Torque which can be transmitted at 20°C with moderate pressure on the clutch: 4.3 Kgm(43 Nm). • Tension: 12 volt. •...
Page 376 COOLING SYSTEM 6B-5 Installation 1) Install new electromagnetic gasket (10) and fix it with nuts tightened at the specified tightening torque. Tightening torque nuts of the electromagnetic gasket : 0.75 Kg-m (7.5 Nm) 2) Install end washer (11), cotter (12) and pulley (8). 3) Applying some pressure to the pulley measure height (Y).Height must be in accordance with the specified value.
Page 377: Water Pump
6B-6 COOLING SYSTEM WATER PUMP Characteristics The generator-driving belt activates the centrifugal type water pump. In its axle it incorporates the hub for coupling of fan. It is constituted by the following elements : • Housing (1). • Fixing nut of bearing (2). •...
Page 378: Thermostat
COOLING SYSTEM 6B-7 THERMOSTAT Characteristics The thermostat (1) is by-pass type and is located in box (4) at the front part and does not need any type of regulation. If doubt about its properly running, replace it. Above box (4) of the thermostat are located the thermometric transmitter/ switch and the coolant temperature sensor.
Page 379: Water Radiator
6B-8 COOLING SYSTEM WATER RADIATOR Removal, installation or substitution of radiator Removal 1) Place the vehicle in a pit or hydraulic lifter and prepare a container to pour the coolant of circuit. 2) Remove coolant of circuit as follows: • Open fully the heating tap. •...
Page 380 COOLING SYSTEM 6B-9 4) If the water radiator is going to be replaced , remove the following elements: • Air radiator (11) (intercooler), fixed with four screws (17). • Metal pipe of interconnection (16) and hose (18). • The piece for channeling the air (20) fixed with four screws (21). •...
Page 381: External Cleaning Of Water Radiator
6B-10 COOLING SYSTEM External cleaning of water radiator External cleaning of water radiator (12) should be carried out using pressurised water, compressed air and a brush no damaging the cooling panel. Do not use pointed implements which could damage the cooling panel.
Page 382 COOLING SYSTEM 6B-11 TIGHTENING TORQUE SPECIFICATIONS TORQUE ELEMENT OBS. Kg-m First Step.Pretightening Selfbraking nut for fan hub to water pump with dynamometric key axle. Threading leftwards Second step: Angular 110° ± 10° Tightening Nuts fixing electromagnetic gasket to water pump 0,75 Screws of the connection water pump to block Nuts adapter inlet hoses to water pump...
Page 383: Emission Control System
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-1 SECTION 6C ENGINE FUEL AND EMISSION CONTROL SYSTEM CONTENT GENERAL DESCRIPTION ............................6C-3 - Fuel system (Mechanical injection engine) (Mechanical injection engine) ................6C-3 (Mechanical injection engine) (Mechanical injection engine) (Mechanical injection engine) - Fuel system (Common rail engine) (Common rail engine) ....................
Page 384 6C-2 ENGINE FUEL AND EMISSION CONTROL SYSTEM • Fuel temperature sensor ......................... 6C-42 • Coolant temperature sensor ......................6C-42 • Intake manifold air temperature and pressure sensor ..............6C-43 • Accelerator pedal stroke sensor ..................... 6C-44 • Clutch pedal position sensor ......................6C-44 •...
Page 385: General Description
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-3 GENERAL DESCRIPTION FUEL SYSTEM (MECHANICAL INJECTION) (MECHANICAL INJECTION) (MECHANICAL INJECTION) (MECHANICAL INJECTION) (MECHANICAL INJECTION) The fuel circuit for vehicles with mechanical injection engines is made up of the following components: • A fuel tank •...
Page 386 6C-4 ENGINE FUEL AND EMISSION CONTROL SYSTEM FUEL SYSTEM (common rail ENGINE) (common rail ENGINE) (common rail ENGINE) (common rail ENGINE) (common rail ENGINE) The fuel system for vehicles with common rail engines is made up of the following elements: •...
Page 387 ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-5 AIR INTAKE SYSTEM The air intake system is made up of the following components: • A dry air filter composed of a filter element to be replaced periodically. • A turbocharger which uses the exhaust gases to move a high revolution turbine to send compressed air to the cylinders.
Page 388 6C-6 ENGINE FUEL AND EMISSION CONTROL SYSTEM ENGINE EMISSIONS MECHANICAL COMMON RAIL INJECTION TYPE 8140.43C ID/TCA 8140.43S EMISSION VALUE - CO (Carbon monoxide) < 4,0 g/KWh Exhaust gases - NO (Nitrogen monoxide) < 7,0 g/KWh Conform to the Euro2 normative on gas - HC (non combusted hydrocarbons) <...
Page 389: Fuel System (Mechanical Injection Engine) (Mechanical Injection Engine) (Mechanical Injection Engine)
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-7 FUEL SYSTEM CLEANING TIPS AND CAUTIONS DURING REPAIR CAUTION: The entry of foreign bodies, dust particles, dirt, water, etc. in the fuel system produces irreparable damage to the fuel injection equipment. To avoid this, suitably cover the open conducts during removal. Cleaning and warnings before repairing Before carrying out any intervention on the fuel system, respect the following to the letter: •...
Page 390: (Mechanical Injection Engine)
6C-8 ENGINE FUEL AND EMISSION CONTROL SYSTEM ON-VEHICLE SERVICE FUEL FILTER CAUTION: • Disconnect the battery before carrying out any intervention of the fuel filter. • Place the vehicle in a ventilated work place, away from heat and flames. • Before intervining on the fuel system, remenber «CLEANING TIPS AND CAUTIONS DURING REPAIR»...
Page 391: Water And Residue Cleaning From Fuel Filter
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-9 Water and residue cleaning from fuel filter (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) • Open bleeder (3) and close when the fuel comes out clean of residue or water.
Page 392: Fuel Tank
6C-10 ENGINE FUEL AND EMISSION CONTROL SYSTEM FUEL TANK CAUTION: • Disconnect the battery before carrying out any inter- vention on fuel tank. • Place the vehicle in a ventilated work place, away from heat or flames • Before carrying out any intervention on fuel system, remember «CLEANING TIPS AND CAUTIONS DURING REPAIR»...
Page 393: Fuel Tank Pressure Control Valve
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-11 Fuel tank pressure control valve Removal 1) From below, remove screw (9) which fixes the valve (11) to the filler (10). 2) Disconnect pipe (12) and remove valve with its pipes. Inspection ATMOSPHERE 1) Blowing strongly from the tank side (14, black), the air should come out the other end;...
Page 394: Fuel Level Gauge
6C-12 ENGINE FUEL AND EMISSION CONTROL SYSTEM Fuel level gauge Removal 1) Prepare a recipient to receive the fuel remaining in tank and pipes. 2) Remove fuel tand (see 6C-10). 3) Remove fuel level gauge (8). NOTE: Drain fuel in tank into a suitable recipientand check for any distiness.
Page 395: Thermostarter
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-13 THERMOSTARTER CAUTION: • Disconnect the battery before carrying out any inter- vention on fuel tank • Place the vehicle in a ventilated work place, away from heat or flames. • Before carrying out any intervention on the fuel system, remember CLEANING TIPS AND CAUTIONS DURING REPAIR (see 6C-7) Thermostarter electro-valve...
Page 396: Thermostarter Inspection
6C-14 ENGINE FUEL AND EMISSION CONTROL SYSTEM Thermostarter inspection 1) Start engine, loosen outlet screw (2) and check that the fuel comes out; if this is not the case, there is an obstruction in pipe (10); check and replace if necessary. 2) With the coolant, fuel or air temperature below 0ºC, check that there is tension in the coupler (4) and in thermostarter spark plug electro-valve (1) when starting the engine.
Page 397: High Press. Injection Pump And Injectors Fuel
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-15 HIGH PRESSURE INJECTION PUMP AND INJECTORS FUEL (mechanical inyection engine) (mechanical inyection engine) (mechanical inyection engine) (mechanical inyection engine) (mechanical inyection engine) CAUCION: • Before carrying out the removal of the hing pressure injection pump or fuel injectors, remember CLEANING TIPS AN CAUTIONS DURING REPAIR (see 6C-7).
Page 398 6C-16 ENGINE FUEL AND EMISSION CONTROL SYSTEM Bench test values for rotary pumps Injection pump: VE4/12F1800R824 P.N. BOSCH: 0460 424 177 Regulator: ALL REGIMES. Engine: 8140.43C.3941 Starting up phase Number 1 piston to P.M.S. and injection pump pumping element in injection phase at 1,10 ±...
Page 399: Injectors Adjustment
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-17 7- Regime r/min: 600 10.- TRANSFER PRESSURE COURSE Overfeed pressure hPa: 1200 Overfeed pressure hPa: 1200 Flow for 1000 deliveries 60,5 ± 4,0 1- Regime r/min: 900 ( ± 6,0) Transfer pump 8- Régimen r/min: 550 pressure bar:...
Page 400: Automatic Device For The Advance Injection For Cold Starting (Ksb)
6C-18 ENGINE FUEL AND EMISSION CONTROL SYSTEM Automatic device for the advance Once the engine is started, the current produced by the generator (terminal D+) feeds the thermic bulb (1) resistance. The heat injection for cold starting (KSB) produced heats the wax bulb which dilates, causing the movement of the rod and cable (3), gradually shifting the lever Description (2) to position (b).
Page 401: High Pressure Electronic Injection System (Common Rail
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-19 HIGH PRESSURE ELECTRONIC INJECTION SYSTEM (COMMON RAIL COMMON RAIL COMMON RAIL COMMON RAIL COMMON RAIL MS 6.3) WARNING: Due to the high pressure reached by the fuel (1350 bar) it is dangerous to handle the high pressure pipe outlets when the engine is running or there is pressure in the hydraulic accumulator (Rail).
Page 402: Common Rail Electronic Injection System Components
6C-20 ENGINE FUEL AND EMISSION CONTROL SYSTEM Common Rail electronic injection system components 12 13 16 17 COMMON RAIL ELECTRONIC INJECTION SYSTEM COMPONENTS 16.-Fuel heater 1.- Engine speed sensor 17.-Fuel temperature sensor 2.- Battery 18.-Electric feed pump 3.- Thermostarter spark plug 19.-Fuel prefilter 4.- Thermostarter electro-valve 20.-Fuel tank...
Page 403: Electronic Control System
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-21 Electronic control system The electronic and electric components involved in the electronic control carried out by the control unit, either sending information to or receiving orders from this, are the following: 1. Electric fuel pump 2.
Page 404: System Fuctions
6C-22 ENGINE FUEL AND EMISSION CONTROL SYSTEM SYSTEM FUCTIONS Exhaust fumes control With rapid acceleration and according to signals received and engine revs, the control unit calculates the amount of Self-diagnosis - BLINK CODE fuel to inject via: The control unit system of self-diagnosis checks the signals -the pressure regulator.
Page 405 ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-23 Control and anticipation of main and pilot injection The advance injection electronic control According to the signals coming from the different sensors, The advance (instant of delivery start, expressed in degrees) including the absolute pressure built-in sensor, the control can be different from one injection to another, and from one unit determines, using an internal program, the point of cylinder to another, and is calculated, similar to the flow,...
Page 406 6C-24 ENGINE FUEL AND EMISSION CONTROL SYSTEM Cold starting Cut-off If one of the three sensors (water, fuel or air) register a This is the interruption of the fuel supply during the temperature below 0ºC, a pre-post heating is activated. deceleration of the vehicle (accelerator pedal not pressed When the ignition key is in 2nd position, the pre-heating down).
Page 407: General Description
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-25 GENERAL DESCRIPTION An electronic control unit, in which the control and power units for the electro-injector piloting are integrated, is A piston pump supplies the fuel at a regular pressure prepared for the control of the entire injection system. equivalent to that of the injection (up to 1350 bar).
Page 408 • Before any intervention on the engine, carry out the engine /vehicle diagnosis with the corresponding equipment and print the results • The replacement of the MS6.3 control board must be authorised by SANTANA MOTOR. • The following components must be replaced as they are irreparable: fuel flow limiter, pressure limiter valve, fuel pressure sensor, hydraulic accumulator, supply pump, complete high pressure pump, pressure regulation valve and electro-injectors.
Page 409: Prefilter
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-27 FUEL DELIVERY SUSTEM 14 13 The hydraulic installation is mainly composed of: - Tank (10) - Prefilter (9) - Electric feed pump (8) - Main filter (7) - High pressure pump (6) - Hydraulic accumulator (Rail) (4) - Electro-injectors (3) - Supply, return and high pressure pipes The fuel supply system is divided into two circuits: low pressure...
Page 410: Electric Feed Pump
6C-28 ENGINE FUEL AND EMISSION CONTROL SYSTEM Electric feed pump Generalities Rotary pump with integrated by-pass, fitted in the aspiration line on the rear left side of the read body. The fuel electro-pump is roller volumetric, with brush motor and stimulation by permanent magnets.
Page 411: Main Filter
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-29 Main filter Generalities The main fuel filter is formed by a bracket (1) and a filter element (3); between the two is placed the fuel heater (2). It has an clogged filter sensor (5), a fuel temperature sensor and fuel heater control (6) and a water-in-fuel sensor (4).
Page 412: High Pressure Pump
6C-30 ENGINE FUEL AND EMISSION CONTROL SYSTEM High pressure pump General description It is a three-piston radialjet (total cylinder capacity 0.7 cc) It is attached to the group of auxiliary organs without needing to be phased and is controlled by the timing belt. Each pumping group is composed of: - a piston (5) driven by a cam (11) in tune with the pump shaft (6) - an admission valve (3)
Page 413: Pressure Regulator Valve
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-31 piston deactivator Generalities The 3 piston deactivator device is made up of and electro-valve (1) which, using a shaft (2), keeps open the admission valve (3) during the delivery stage to the 3 piston.
Page 414: Hydraulic Accumulator (Rail)
6C-32 ENGINE FUEL AND EMISSION CONTROL SYSTEM Hydraulic Accumulator (Rail) Generalities The hydraulic accumulator is fitted in the cylinder head beside the electro-injectors. With its volume of approximately 29 cm it smoothes out the fuel pressure oscillations due to: - the working of the high pressure pump - the opening of the electro-injectors The flow limiters (2) are fitted to the top part of the hydraulic accumulator (1).
Page 415: High Pressure Pipes
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-33 Pressure Limiting Valve Generalities The pressure limiting valve comes into action when the fuel pressure in the hydraulic accumulator (Rail) is greater than 1550 bar. This increase in pressure is due to a fault in the pressure regulating valve of the pump.
Page 416: Electro-Injectors
6C-34 ENGINE FUEL AND EMISSION CONTROL SYSTEM ELECTRO-INJECTORS Generalities The electro-injectors are made to receive a supply at high pressure (up to 1350 bar) and a recycling of atmospheric pressure, necessary for the operation of the pilot valve. The temperature of the recycled diesel can reach high temperatures (120ºC).
Page 417 ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-35 Experimental measurements The map can be measured: - on the injector work bench - in the engine on the bench In both cases an injection pressure is established and the injectors are tested (if done on the bench, more than one injector can be measured at the same time) with and electrical control of duration (ET) and of fixed frequency (NG).
Page 418 6C-36 ENGINE FUEL AND EMISSION CONTROL SYSTEM On-vehicle service For removal, intallation and replacement, see 6A-36. The electro-valve is NC type. Terminals between the electro-injector and the control unit: Pin A12/A40 - injector cylinder Pin A10/A43 - ” ” Pin A23/A42 - ”...
Page 419: Electric/Electronic Components
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-37 ELECTRIC/ELECTRONIC COMPONENTS Electronic control unit MS 6.3 The electronic control unit is a "flash EPROM" - i.e. it is reprogrammable from the exterior without having to intervene on the hardware. The injection control board has the absolute pressure sensor integrated to improve the management of the injection system.
Page 420 6C-38 ENGINE FUEL AND EMISSION CONTROL SYSTEM CONNECTION DIAGRAM FROM CONTROL BOARD TO ENGINE COMPONENTS (CONNECTOR "A")
Page 421 ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-39 CONTROL UNIT CONNECTORS APPLICATION (CONNECTOR "B" FOR VEHICLE COMPONENTS) FUNCTION Accelerator pedal position sensor signal Speedometer signal (Pin B13) Positive for air-conditioning compressor K line for diagnosis connector (Pin 2) Positive for main relay Positive for main relay Thermostarter electro-valve ground Battery direct ground...
Page 422 6C-40 ENGINE FUEL AND EMISSION CONTROL SYSTEM CONNECTIONS DIAGRAM FROM CONTROL UNIT TO VEHICLE COMPONENTS (CONNECTOR "B")
Page 423: Fuel Pressure Sensor
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-41 Fuel Pressure Sensor This is fitted in the centre of the hydraulic accumulator (Rail) (1): its function consists in supplying the control unit with feedback in order to: - regulate the injection pressure - regulate the injection duration •...
Page 424: Fuel Temperature Sensor
6C-42 ENGINE FUEL AND EMISSION CONTROL SYSTEM Camshaft speed and stage sensor This is an inductive sensor and is placed on the rear part of the camshaft pulled (1). It generates signals obtained from lines of magnetic flow which close via the pulled moulding. The signal generated by this sensor is used by the control unit as a redundant sensor to measure the different engine regimes.
Page 425: Intake Manifold Air Temperature And Pressure Sensor
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-43 Intake manifold air temperature and pressure sensor This device is made up of a temperature sensor and a pressure one (1). It’s placed on intake manifold, and measuresover feeding air pressure and temperature. Both values, dire used by the control unit to measure the air flow introduced in cilinders and therefore the fuel ammount sent to injectors.
Page 426: Accelerator Pedal Stroke Sensor
6C-44 ENGINE FUEL AND EMISSION CONTROL SYSTEM Accelerator Pedal Stroke Sensor This sensor supplies the control unit with a tension value proportional to pedal working angle and thus determining the fuel delivery: It is a potentiometer with an NO minimum switch incorporated. •...
Page 427: Actuators
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-45 Actuators The injection system includes three categories of actuators linked to the electronic control unit: A) Electro-injectors (see corresponding chapter) B) Regulators requiring a PWM (Pulse Width Modulation) con- trol: • Fuel pressure •...
Page 428 6C-46 ENGINE FUEL AND EMISSION CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE TABLE Blink - Code Warning Light Defect Vehicle speed Multiple switch state Cruise Control (if fitted) flashing Accelerator pedal Clutch switch Brake switch Brake/accelerator plausibilty Diagnosis warning light Air-conditioning (if fitter) flashing Coolant temperature sensor Air temp.
Page 429: Air Intake System
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-47 AIR INTAKE SYSTEM PRECAUTION IN CLEANING AND REPAIRING AIR INTAKE SYSTEM CAUTION: The entry of foreign bodies, dust particles, dirt, water, etc. in the fuel system produces irreparable damage to the fuel injection equipment. To avoid this, suitably cover the open conducts during removal. Before repair Before any intervention on the air intake system, strictly respect the following: •...
Page 430: On-Vehicle Service
6C-48 ENGINE FUEL AND EMISSION CONTROL SYSTEM ON-VEHICLE SERVICE AIR FILTER CAUTION: • Place the vehicle in a suitable work place, free from dust and air currents which may carry particles. • Before carrying out any intervention on the system,re- member PRECAUTION IN CLEANING AND REPAIRING AIR INTAKE (see 6C-47) Residues bleeding...
Page 431 ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-49 Cleaning or replacement 5) Open the clips (7), separate cover (9) from case (6) and remove the filter element (8). 6) Thoroughly clean the cases (6) and (9) and make sure that the bleeder valve (1) is not obstructed. NOTE: The air filter assembly cases must always be cleaned when the filter element is cleaned or replaced.
Page 432: Intercooler
6C-50 ENGINE FUEL AND EMISSION CONTROL SYSTEM INTERCOOLER CAUTION: • Place the vehicle in a suitable work place, free from dust and air currents which may carry particles. • Before carrying out any intervention on the system, remember PRECAUTION IN CLEANING AND REPAIRING AIR INTAKE (see 6C-47) Removal 1) Disconnect the battery.
Page 433: Turbocharger
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-51 TURBOCHARGER Checks before intervention • Once an abnormal functioning of the air intake system has been confirmed, it is advisable to check the good state and efficiency of the watertight joints and the hose joints in the air filter and intercooler before carrying out the checks on the turbocompressor.
Page 434: Pressure Limiting Valve Control And Regulation
6C-52 ENGINE FUEL AND EMISSION CONTROL SYSTEM Pressure limiting valve control and regulation 1) Plug the exhaust gas and oil lubrication inlets and outlets. 2) Thoroughly clean the external part of the turbocharger using an anti-rust fluid. 3) Disconnect pipe (2) from its join to pressure regulating valve (1) and attach in its place the test pipe (A) ref.
Page 435: Replacement
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-53 Replacement (Mitsubishi turbocharger) (Mitsubishi turbocharger) Valve removal 1) Remove clip (10), separate rod (8) from the butterfly valve lever (9), remove screws (11) and remove limiting valve assembly. Valve installation 1) Assemble in reverse order to dismantling, adjusting the valve lift as indicated in 6C-52.
Page 436: Temperature Sensors Location (Mechanical Injection Engines) (Mechanical Injection Engines)
6C-54 ENGINE FUEL AND EMISSION CONTROL SYSTEM TEMPERATURE SENSORS LOCATION (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) 1.- KSB supply sensor (injection pump) 2.- Engine water temperature termistor (instrument table) 3.- Engine water temperature sensor (thermostarter) 4.- Engine water temperature switch (control light) 5.- Engine water temperature switch (electromagnetic fan joint)
Page 437: (Mechanical Injection Engines) Engine Speed Sensor (Mechanical Injection Engines) (Mechanical Injection Engines)
ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-55 ENGINE SPEED SENSOR (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) (mechanical injection engines) Installation NOTE: The installation of the engine speed sensor can be carried out in two ways; with the gearbox removed from the vehicle or fitted in the vehicle.
Page 438: Tigthening Torque Specifications
6C-56 ENGINE FUEL AND EMISSION CONTROL SYSTEM TIGTHENING TORQUE SPECIFICATIONS TORQUE OBSERV. ELEMENT Kg-m Fuel Filter 1,8 ÷ 2,8 18 ÷ 28 Joining screws - fuel tank to frame 4 ÷ 6 40 ÷ 60 Screws - fuel pipes thermostarter electro-valve Set nuts - thermostarter electro-valve Fuel pipe outlet - thermostarter spark plug Fitting - thermostarter spark plug...
Page 439 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENT GENERAL DESCRIPTION ............................ 6K- 2 MAINTEINANCE ..............................6K- 3 ON-VEHICLE SERVICE ............................6K- 4 Exhaust manifold ..........................6K- 4 Exhaust pipes, sound muffler and catalyser ..................6K- 4...
Page 440 6K-2 EXHAUST SYSTEM GENERAL DESCRIPTION NOTE: Depending on specifications, this model could be or could not be provided with catalyser. The exhaust system consists of exhaust manifold, turbocharger, exhaust gases elbow, exhaust pipe n° 1, another n° 2 which can hold the catalyser (if required) or a primary silent muffler, and an exhaust pipe n°...
Page 441 EXHAUST SYSTEM 6K-3 MAINTENANCE WARNING: To avoid charger of being borned, do not touch exhaust system when sustem is hot. Any service on exhaust system should be pwerfomed when system is cool. While maintaining periodically or when lifting the vehicle for other servicing, check the exhaust system as follows: •...
Page 442: Exhaust Manifold
6K-4 EXHAUST SYSTEM ON-VEHICLE SERVICE WARNING: To avoid charger of being borned, do not touch exhaust system when sustem is hot. Any service on exhaust system should be pwerfomed when system is cool. NOTE: After removal, install using always new gasket and sealing rings.
Page 443: Lubrication System
LUBRICATION SYSTEM 6L-1 SECTION 6L LUBRICATION SYSTEM CONTENT GENERAL DESCRIPTION ............................. 6L- 2 Lubrication circuit ............................. 6L- 2 Oil vapours recycling circuit ........................6L- 3 ON-VEHICLE SERVICE ............................6L- 4 Oil pump ............................6L- 4 Filter and oil substitution ........................6L- 4 Heat exchanger..........................
Page 444: General Description
6L-2 LUBRICATION SYSTEM GENERAL DESCRIPTION LUBRICATION CIRCUIT Overview The engine lubrication is of type forced circulation and is brought about by the following elements: • A gears oil pump incorporated in the auxiliary organs group and a pressure regulating valve incorporated to the auxiliary organs group rear cover.
Page 445: Oil Vapours Recycling Circuit
LUBRICATION SYSTEM 6L-3 OIL VAPOURS RECYCLING CIRCUIT The engine ventilation and oil vapours recycling circuit is constituted by the following components: • A ramp located in the upper part of oil pan of the auxiliary organs group. Oil vapours from the oil pan are collected while running and are sent to the oil condenser.
Page 446: Oil Pump
6L-4 LUBRICATION SYSTEM REPAIRS ON THE VEHICLE Oil pan The oil pump is integrated in the auxiliary organs group. To repair oil pump and pressure regulating valve see 6A-70 «GEARS BOX OF AUXILIARY ORGANS GROUP AND OIL PUMP REPAIRS». WORKING PRESSURES •...
Page 447 TRANSMISSION 7-1 SECTION 7 TRANSMISSION CONTENTS GEARBOX ................................. 7A CLUTCH ..................................7C TRANSFER BOX ............................... 7D FRONT AND REAR DIFFERENTIAL .......................... 7E...
Page 449: Manual Transmission
MANUAL TRANSMISSION 7A-1 SECTION 7A MANUAL TRANSMISSION CONTENTS GENERAL DESCRIPTION ............................. 7A- 1 DIAGNOSIS ................................7A- 5 ON-VEHICLE SERVICE ............................7A- 6 Gear and transfer shift lever .......................... 7A- 6 Dismounting and remounting of transmision assy and transfer box assy ............7A- 8 GENERAL REPAIR OF TRANSMISSION ......................
Page 450 7A-2 MANUAL TRANSMISSION GENERAL DESCRIPTION The transmission LT-85 has five forward speeds, completely synchronised and one reverse. The synchronised ones are friction cones and ball retainers. The synchronised couplings are grooved by electro-erosion, type POCKETS, to help avoid slipping out of spedd in the hardest of working conditions.
Page 451: Manual Transmission 7A-1
MANUAL TRANSMISSION 7A-3 1. Bearing. 43. Reverse idle gear assy. 2. Snap ring. 44. Main shaft reverse gear. 3. Main pinion. 45. Bearing. 4. Shim. 46. Stopper washer. 5. Snap ring. 47. Snap ring. 6. Bearing. 48. 5 speed fork bracket. 7.
Page 452 7A-4 MANUAL TRANSMISSION 1. Input shaft bearing retainer. 16. Bolt. 31. Spring pin. 2. Oil seal. 17. Oil seal. 32. Boot. 3. Clutch housing. 18. Gear shift case plate. 33. Gear shift control lever assy. 4. Inspection cover. 19. Screw. 34.
Page 453 MANUAL TRANSMISSION 7A-5 DIAGNOSIS Condition Possible cause Correction • Fork shaft worn out Replace. • Selector fork or coupling worn out Replace. • Positioning spring worn or damaged Replace. Excesive slip • Intake bearing shaft worn out Replace. • Coupling or gear bevelled teeth worn Replace the coupling and the gear.
Page 454 7A-6 MANUAL TRANSMISSION ON-VEHICLE SERVICE GEAR LEVER AND TRANSFER Dismantling Removal gear lever 1) Take off screws front carpet to access to tunnel cover (1) and remove them. Move bot (2) and the tunnel cover upwards. 3) Remove boot clamp (3). 4) Press case cover (4) and turn it left;...
Page 455 MANUAL TRANSMISSION 7A-7 5) If you replace the spring pins (11), apply grease to the surface before installing them in the gear lever box. 6) Fit the low speed selection spring pin in the gear box and tighten the positioning screw while pushing the spring pin. Install the guide pin for reverse speed in the box and fit the positioning ball firmly on the spring pin groove.
Page 456 7A-8 MANUAL TRANSMISSION DISASSEMBLING AND ASSEMBLING OF TRANSMISSION AND TRANSFER UNIT Disassembling NOTE: When repairing the transmission or transfer unit, you have to fit new oil seals. However, if the oil level continues to lower in the transmission, replace the forward seal and the 5th gear seal.
Page 457 MANUAL TRANSMISSION 7A-9 4) Before removing propeller shaft, mark the flange (A) in order to assemble them in the same position. 5) Remove the fixing elements (5&6) from constant velocity joint (3) and (4); remove forward and rear propeller shaft. 6) Disconnect forward section (first section) of the exhaust pipe from the turbo-compressor gas outlet elbow joint.
Page 458 7A-10 MANUAL TRANSMISSION 8) Disconnect the auxiliary cylinder clutch pipe and cover the ports to lose the lower quantity of liquid. 9) Disconnect parking brake conditioning rod removing the spring pin. NOTE: If you don't have any tool or an hydraulic table to remove the assembly, remove and separate the transfer box and then the gear box.
Page 459 MANUAL TRANSMISSION 7A-11 Assembly Fit the transmission assembly and the transfer box in reverse order to dismantling, noting the specified torque for the complementary tasks as well as the observations. • Apply a recommended grease film to main shaft end and grooving.
Page 460 7A-12 MANUAL TRANSMISSION GENERAL REPAIR OF GEAR BOX SEPARATION AND JOINING OF GEAR BOX AND TRANSFER BOX Separation 1) Extract gear box and transfer box assembly from the vehicle (see 7A-8). 2) Remove the gear box joining screws (1) and transfer box and separate both assemblies.
Page 461 MANUAL TRANSMISSION 7A-13 REPAIR OF THE GEAR BOX 1) Remove gear box and transfer box assembly from the vehicle (see 7A-8). 2) Separate the gear box and transfer box (see 7A-12). Dismantling 5th gear housing removal 1) Unscrew the 5th gear fixing screw and remove the housing. Removal gear box top cover 2) Remove outlet screw with its washers and separate the breather pipe.
Page 462 7A-14 MANUAL TRANSMISSION 5) Remove spring (5) which keeps reverse gear contact in position. 6) Use a punch (A) to tap the elastic bolt that fixes the reverse gear selector head (9) from its shaft, until it is free. NOTE: If repairing selector heads or shafts, the bolts must be extracted sufficiently to free the selector head, being careful that it does not fall into the gear box.
Page 463 MANUAL TRANSMISSION 7A-15 10) Use punch (A) to tap the elastic bolt which fixes the 5th gear selector head (10) until it is free. 11) Take out the selector shaft (11) and remove the selector head (10). 12) Remove screw (12) which fixes the 3rd and 4th gear selector fork from its selector shaft.
Page 464 7A-16 MANUAL TRANSMISSION 16) Use the punch (A) to tap the elastic bolt which fixes the 1st and 2nd selector head (16) to its selector shaft until it is free. 17) Take out the selector shaft (17), the selector head and the reverse gear crosspiece.
Page 465 MANUAL TRANSMISSION 7A-17 Removal 5th gear and synchro 23) Remove snap ring (24) from the rear part of the main shaft. 24) Remove shim (25), seal closing bush (26) and the inner closing "O" ring (27). 25) Remove 5th gear synchro assembly (29) and the synchro cone (28).
Page 466 7A-18 MANUAL TRANSMISSION 28) Remove fixing elements which join retaining plate (36) to the housing. 29) Remove the retaining plate. Reverse speed gear intermediate control lever removal. 30) Unscrew the lever pivoting screw (37) and remove the lever and runner. Removal clutch case and clutch release front cover.
Page 467 MANUAL TRANSMISSION 7A-19 35) Remove fixing elements which join front cover (42) to gear box housing. 36) Remove front cover (42), supplementary washers (43) and fixed set front bearing. Removal gear box casing 37) Remove fixing elements which join the two halves of the gear box housing.
Page 468 7A-20 MANUAL TRANSMISSION 40) Remove the shaft (48) from the reverse speed moveable geari, using tool (B) ref. 262772 41) If reverse gear intermediate lever (51) has not been removed and it needs to be, remove it together with the soft runner; it is not necessary to remove the pivoting screw (52) 42) Remove reverse gear (49) and its fitting washer.
Page 469 MANUAL TRANSMISSION 7A-21 47) Remove: • 3rd and 4th gear synchro (57). • Synchro hub (58). • 3rd gear (59). • Spacer (60). • Needle roller bearing (61). By the rear 48) Remove clip (62) and fitting washer. 49) Using a universal extractor (C) remove bearing (63) as shown. 50) Remove: •...
Page 470 7A-22 MANUAL TRANSMISSION 51) Remove 1st and 2nd gear synchro (68) and synchro (69) 52) Remove 2nd gear (70) as well as needle roller bearing (71) and spacer (72). Removal primary shaft 53) Remove clip (73). 54) Remove fitting washer (74). 55) Remove bearing (75) using an extractor (C).
Page 471 MANUAL TRANSMISSION 7A-23 Checking 3rd and 4th gear synchros (dissasembling) 1) 1) Make two aligning marks (79), one on the inner nucleus (80), the other on the external spool (81). Aligning the marks will assure correct coupling. 2) Provisionally, place the synchro cone (82) on one of the sides of the synchro assembly (83).
Page 472 7A-24 MANUAL TRANSMISSION 3rd gear 9) Install the 3rd gear (59) on the main shaft with its needle roller bearing and separator bush. 10) Attach the 3rd and 4th gear synchro nucleus (83) and measure the separation between the two using calibrated gauges (D).
Page 473 MANUAL TRANSMISSION 7A-25 Assembly NOTE: • Before assembly clean each part and apply gear box oil to all sliding bush and gear surfaces. • Clean the case joining faces before assembly and apply the recommended sealing flex before joining. 3rd and 4th gear synchro (assembly) 1) Place exterior spool (81) on the nucleus (80) aligning the marks (79) made during dismantling.
Page 474 7A-26 MANUAL TRANSMISSION 7) Install 3rd and 4th gear with the (polished) friction surface towards 3rd gear and synchro cone to facing 3rd gear. 8) Fit fitting washer (56) and clip (55). 9) Measure the longitudinal play using calibrated gauges, adjusting to the indicated measurement by means of washers (56).
Page 475 MANUAL TRANSMISSION 7A-27 12) Fit 1st gear (64) and bearing bush (65), needle roller bearing (66) and separator bush (67) assembly. 13) Sink rear bearing and fit fitting washer and clip (62). 14) Using calibrated gauges (D), measure the play between bearing and fitting washer, this must correspond to the specified value, if not adjust the fitting washer to this end.
Page 476 7A-28 MANUAL TRANSMISSION Reverse gear moveable gearing 18) Place reverse gear (49) in a vice. 19) Remove clip (92) and washer (99). 20) Remove needle roller bearing (93). NOTE: Check bearings and gears state. 21) Lubricate the bearings, fit the washer (99) and fix the assembly with a clip (92).
Page 477 MANUAL TRANSMISSION 7A-29 Gearbox 31) Fit fixed gear set to the half-casing. 32) Install 4th gear synchro cone (53) on the synchro and fit needle roller bearing (54) to primary shaft (47). 33) Join primary shaft to main shaft. 34) Place this assembly (primary and main shaft) in the half- casing.
Page 478 7A-30 MANUAL TRANSMISSION 41) Fit 5th gear drive gearing (35) with the bevelled part facing inwards. 42) Fix gearing with its nut (34), tightening it to the specified torque. Torque for fixed gear set nut: 20 Kg-m (200 Nm) 43) Once tightened, block it by turning the bolt to points (C) aligning it to the shaft grooves.
Page 479 MANUAL TRANSMISSION 7A-31 49) Check 5th gear synchro longitudinal play, measuring between washer (25) and bush (26) with calibrated gauges (D), this play must be within the established limits. Longitudinal play: 0,00 ÷ 0,08 mm NOTE: • The play is corrected by the washer (25) •...
Page 480 7A-32 MANUAL TRANSMISSION 54) Using a punch, fit the front bearing ring of the fixed gear set. 55) Measure the depth of the ring with respect to casing plane and select the supplementary washers (43) to cover the housing space (A), leaving no play. 56) Fix washers in position using grease.
Page 481 MANUAL TRANSMISSION 7A-33 Gear forks, shafts and selector heads 63) Onto the synchros, fit 3rd and 4th gear and 1st and 2nd gear selector forks (18 & 19) and the reverse crosspiece connected to the intermediate control lever. 64) Fit the gear selector shaft locking bolts leaving them in the indicated position with the help of tool (D) ref.
Page 482 7A-34 MANUAL TRANSMISSION 67) Fit 3rd&4th gear selector shaft (14). 68) Install selector head (13) to the above and fix with an spring pin. 69) Fit 5th gear selector shaft (11). 70) Install selector head (10) to the above. 71) Fix shaft and head with a spring pin. 72) Fit reverse gear selector shaft (8).
Page 483 MANUAL TRANSMISSION 7A-35 76) Fit reverse gear selector head retaining spring (5) so that the open loop, which is hooks onto the shaft, is facing the exterior of the gear box. 77) Align 5th gear selector shaft orifice (11) with the fork. 78) Fit bolt and fix with a flat washer and a vane pin.
Page 484 7A-36 MANUAL TRANSMISSION 83) Check the longitudinal play of the 3rd&4th (18) and 1st&2nd (19) selector forks. 84) Place both selectors in the centre of the play and tighten the setscrews to the specified torque. 85) Move reverse gear crosspiece (7) towards the front of the gear box and tighten in this position.
Page 485 MANUAL TRANSMISSION 7A-37 94) Fit a new seal (102) to 5th gear casing so that the part opposite to the closing lip lies flush with the projection (103), using tool ref. 494688-2. 95) Apply recommended sealant to the join face between the 5th gear casing and the gear box.
Page 486 7A-38 MANUAL TRANSMISSION TIGHTENING TORQUE SPECIFICATIONS TORQUE ELEMENT Kg-m Screw - gear lever guide Setscrew - gear lever plate 4WD switch Reverse gear screws 2,8 ÷ 3,5 28 ÷ 35 Nuts - transmission 35 ÷ 40 3,5 ÷ 4 Setscrew - speedometer case to transfer box Setscrews - shoe-holder plate 2 ÷...
Page 487 MANUAL TRANSMISSION 7A-39 ASSEMBLY DATA AND TOLERANCES DENOMINATION DATA SERVICE LIMIT STD PLAY Longitudinal play - 3rd, 2nd, 1st & 5th gear 0,190 mm 0,075 - 0,125 mm 0,00 - 0,08 mm Longitudinal play - 3rd & 4th gear synchro Play between rear bearing and limiting screw 0,00 - 0,08 mm 0,00 - 0,08 mm...
Page 488 7A-40 MANUAL TRANSMISSION SPECIAL TOOL REF. 494722 REF. 194635 REF. 262772 CENTERING TOOL BALL FITTER EXTRACTOR REF. 493764-1 REF. 494989-2 REF. 494989-3 FITTER CLIP FITTING GUIDE CLIP FITTER REF. 494688-1 SEAL FITTING GUIDE...
Page 490 CLUTCH 7C-1 SECTION 7C CLUTCH CONTENTS GENERAL DESCRIPTION ............................ 7C- 2 DIAGNOSIS ................................7C- 3 ON-VEHICLE SERVICE ............................7C- 4 Clutch Pedal height ............................. 7C- 4 Draining the clutch circuit ..........................7C- 5 Main clutch cylinder replacement ........................ 7C- 6 Auxiliary clutch cylinder replacement ......................
Page 491: General Description
7C-2 CLUTCH GENERAL DESCRIPTION The clutch is a diaphragm-spring clutch of a dry single. The diaphragm-spring is of a tapering-finger type, which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward. The disc, carrying four torsional coil springs, is positioned on the transmission input shaft with an involute spline fit.
Page 492: Diagnosis
CLUTCH 7C-3 DIAGNOSIS Condition Possible cause Correction Slipping 1. Oil disc facing Replace. 2. Worn disc facing Replace. 3. Weakened disc spring Replace. 4. Warped pressure plate or flywheel Replace. 5. Improper clutch pedal free travel Adjust and replace clutch, facings if needed.
Page 493: On-Vehicle Service
7C-4 CLUTCH ON-VEHICLE SERVICE CLUTCH PEDAL HEIGHT AND FREE TRAVEL 1) Adjust height (A) using screw (1). (A) Pedal height: 140 mm 2) Adjust free travel using nuts (2). (B) Play between piston and rod: 1,5 mm (C) Free pedal play: 15 ÷ 20 mm 3) Once the adjustments have been made, note the observations and torque.
Page 494 CLUTCH 7C-5 CLUTCH CIRCUIT DRAIN NOTE: During the operation, fill the tank with liquid so as to avoid air entering the system. Only use recommended hydraulic liquid. 1) Attach a piece of flexible and transparent piping (1) to slave cylinder bleeder screw (2). 2) Place the free end of the piping in a glass container (3) in order to collect the clutch fluid.
Page 495 7C-6 CLUTCH REPLACEMENT OF THE MAIN CLUTCH CYLINDER Removal 1) Release liquid inlet and outlet pipes. 2) Remove pedal support setscrews from dashboard. 3) Remove support (1) with pedal and cylinder. 4) Clean assembly on a workbench and removing the cylinder fixing elements from the support and pedal.
Page 496 CLUTCH 7C-7 REPLACEMENT OF AUXILIARY CLUTCH CYLINDER Removal 1) Remove liquid through the cylinder valve. 2) Disconnect inlet pipe (1) and bleeder plug (2). 3) Remove auxiliary cylinder (3). Instalation 1) Install the auxiliary clutch cylinder in reverse order to dismantling, noting the observations and indicated torque.
Page 497: Thrust Block Replacement
7C-8 CLUTCH THRUST BLOCK REPLACEMENT Removal 1) Remove gearbox assembly from engine (see 7A-8). 2) Remove plastic clip (1) and take out thrust block (2). NOTE: The coupling and bearing form one single assembly and therefore should be replaced if any anomalies are found.
Page 498 CLUTCH 7C-9 CLUTCH LIQUID REPLACEMENT 1) Place a flexible, transparent tube (1) with one end (2) attached to the bleeder and the other in a glass measuring cylinder. 2) Open the bleeder and pump until a great deal of air comes out of the bleeder.
Page 499: Pressure Plate And Clutch Disc
7C-10 CLUTCH CLUTCH ASSEMBLY REPAIR AND INSPECTION PRESSURE PLATE AND CLUTCH DISC Removal 1) Remove gearbox assembly (see 7A-8). 2) Remove screws (1), take out pressure plate (2) and clutch disc (3). Servicing 1) Check that pressure plate (2) has no cracks, scratches or wear and tear on the disc contact surface.
Page 500 CLUTCH 7C-11 Instalation 1) Fit the clutch assembly in reverse order to dismantling, aligning the coupling marks between the pressure plate and the flywheel. 2) Centre clutch disc (3) using a dismounted main shaft (A). 3) Tighten pressure plate (2) setscrews (1) slowly and crosswise until reaching the specified torque.
Page 501: Main Clutch Cylinder
7C-12 CLUTCH MAIN CLUTCH CYLINDER Removal 1) Remove main clutch cylinder (see 7C-6). 2) On a workbench, clean the assembly and dismantle the cylinder fixing elements from the support and pedal. Removal cylinder 3) Remove ring (1) and take out control rod and fixing washer (2) 4) Remove by using compressed air via the inlet the cylinder assembly, removal spring and packing gland NOTE:...
Page 502 CLUTCH 7C-13 Check 1) Clean all the elements with the specified fluid and leave to dry without using compressed air. 2) Check that the cylinder has no scratched or decay caused by rust. Change if necessary. 3) If the cylinder is in perfect condition, change the elements which are not.
Page 503: Auxiliary Clutch Cylinder
7C-14 CLUTCH AUXILIARY CLUTCH CYLINDER Removal 1) Remove auxiliary clutch cylinder (see 7C-7). Removal cylinder 2) Remove dust guards (1) and take out: • Rotor (2) • Casing (3) • Spring (4) NOTE: Do not remain in front of the rotor if removing using compressed air.
Page 504: Required Service Materials
CLUTCH 7C-15 TORQUE TORQUE ELEMENT Kg-m Setscrews - pressure plate 2,75 ÷ 3,75 27,5 ÷ 37,5 Fixing nuts - main cylinder control rod 2 ÷ 2,5 20 ÷ 25 22 ÷ 25 Fixing nuts - auxiliary cylinder 2,2 ÷ 2,5 ASSEMBLY DATA AND TOLERANCES SERVICE LIMIT DENOMINATION...
Page 506 TRANSFER BOX 7D-1 SECTION 7D TRANSFER CONTENTS GENERAL DESCRIPTION ............................ 7D- 2 DIAGNOSIS ................................7D- 5 ON VEHICLE SERVICE ............................7D- 6 Rear seal replacement ..........................7D- 6 4WD Switch replacement ..........................7D- 8 Parking brake assembly (to transmission) repair ..................7D- 9 Speedometer gear box repair ........................
Page 507: General Description
7D-2 TRANSFER BOX GENERAL DESCRIPTION The transfer box provides two speed relations - "high" and "low". The change between these two speeds, although not synchronised, is by constant contact gears with movable collet which allows selection from both ranges. The transfer box offers the possibility of using rear axle traction in "high", double traction in "high" and double traction in "low".
Page 508 TRANSFER BOX 7D-3 10 6 1 Input shaft bearing. 28 Output high gear. 2 Shim. 29 Bush. 3 Input gear. 30 Bearing. 4 Counter gear. 31 Main shaft nut. 5 Intermediate shaft assembly. 32 Snap ring. 6 Plug. 33 Rear output shaft bearing. 7 Washer.
Page 509 7D-4 TRANSFER BOX 1 Transfer case. 8 Input shaft gear case. 2 Plug. 9 Cover. 3 Front output case. 10 "O" ring. 4 Filler cap. 11 Lock plate. 5 Drain plug. 12 Tachometer case. 6 Lower gasket cover. 13 4WD switch assembly. 7 Side cover.
Page 510: Diagnosis
TRANSFER BOX 7D-5 DIAGNOSIS State Possible cause Correction • Worn shift fork shaft Replace • Worn shift fork Replace Gear slips before • Weak or damaged locating springs Replace engaging • Worn bearings on input shaft or counter shaft Replace •...
Page 511: On Vehicle Service
7D-6 TRANSFER BOX ON VEHICLE SERVICE CAUTION: Disconnect battery before any intervention on the vehicle, this will avoid any possible accidental short circuits. REAR SEAL REPLACEMENT Removal 1) Drain transfer box oil by removing duccin plug (1). 2) Clean oil off the plug thread. 3) Apply recommended sealant to thread and mount the plug to the specified torque.
Page 512 TRANSFER BOX 7D-7 6) Remove brake drum(6) together with control clamp by unscrewing the screw (7) and removing the washer. NOTE: Before removing the brake drum, release the handbrake or, if necessary, loosen the tensing screw. 7) Remove oil collector (8). 8) Take off rear oil seal(9).
Page 513: 4Wd Switch Replacement
7D-8 TRANSFER BOX 4WD SWITCH REPLACEMENT Removal 1) Disconnect 4WD back up light cable (1) and the switch (2) found in the front cover of the transfer box. NOTE: To disconnect the cable (1), press the fixing clip (3) and move outwards. 2) Dismount 4WD switch (2).
Page 514: Transmission Installation
TRANSFER BOX 7D-9 REPAIRING PARKING BRAKE (TO THE TRANSMISSION INSTALLATION) Removal 1) Disconnect the rear propeller shaft and brake drum (see 7D-6) 2) Release the parkingbrake and disconnect the drive rod (A) from the connecting rod. NOTE: To repair the components of the handbrake, it is not necessary to dismount the shoe-holder plates.
Page 515 7D-10 TRANSFER BOX Repair 1) Remove clip which holds rear the pistons (8) in the expansion mechanism. 2) Remove • Pistons (8). • Rollers (9). • Wedge (10). 3) Check all the components and replace the complete mechanism if there is wear and tear. 4) Unscrew screws (11) and remove: •...
Page 516 TRANSFER BOX 7D-11 Installation 1) Fit all the components in reverse order to removal. 2) Once the shoes are fitted, turn screws (11) of the regulating mechanism. 3) Connect drive rod. 4) Fit brake drum (see 7D-6). 5) Applying screw (13), bring shoes into line, making sure that drum remains free.
Page 517: Speedometer Gear Box Repair
7D-12 TRANSFER BOX SPEEDOMETER GEAR BOX REPAIR Removal 1) Disconnect speedometer cable (see 7D-16). 2) Take out shoe-holder plate (2) retention screws. 3) Remove shoe-holder plate. 4) Take out bush (3) and pinion (4). 5) Remove bush (3): • Control gear (4). •...
Page 518 TRANSFER BOX 7D-13 8) Remove: • The bearing (9). • The worm gear (10). • Bush (11). 9) Dismount the bush oil collector and remove seal (12) from the exterior part. 10) Take off clip (13) which fixes the bearing support. 11) Dismount rear outlet support bearing (14), making use of soft stick (A).
Page 519 7D-14 TRANSFER BOX Installation 1) Install ball bearing which supports the rear bearing and fix with clip. 2) Fix a new seal at the bottom, leaving the closing lip towards the outside. 3) Fix oil collector bush. 4) Fix worm (10) and bush (11) into the lower output bearing. 5) Install bearing in the speedometer casing.
Page 520 TRANSFER BOX 7D-15 REMOVAL AND INSTALLATION OF TRANSFER BOX ASSEMBLY Removal 1) Drain oil from the transfer box (see 7D-6). 2) Remove the intermediate (2nd segment) segment of the exhaust pipe. 3) Disconnect: • Transmission clamps. • Speedometer cable (see 7D-16). •...
Page 521: Speedometer Cable Replacement
7D-16 TRANSFER BOX SPEEDOMETER CABLE REPLACEMENT 1) Disconnect speedometer cable (1) from speedometer gear box. 2) Remove steering wheel outer cover (2). 3) Remove dashboard cover. 4) Remove screws (4) and dashboard (5). 5) Disconnect speedometer cable from dashboard. 6) Replace speedometer cable with a new one and replace the components in reverse order to the removal.
Page 522: Transfer Box
TRANSFER BOX 7D-17 GENERAL REPAIR OF THE TRANSFER BOX TRANSFER BOX REMOVAL, SERVICE AND INSTALLATION Removal 1) Remove transfer box installation from vehicle (see 7D-15). 2) Remove brake drum (see 7D-6). 3) Unscrewing nuts (2) and remove the plate with shoes. 4) Take out screws and remove lower cover.
Page 523 7D-18 TRANSFER BOX 7) Remove intermediate triple gear assembly (9) and separate: • Friction and assembly washers (10). • Cog bearing (11). • Supplementary bush (12). 8) Remove "O" ring (13) which is found in intermediate shaft front hole and which stops the oil escape from this zone. 9) Take out screws (17) and washers (18) and remove cover (14).
Page 524 TRANSFER BOX 7D-19 12) Dismount outside ring (20) from the rear bearing using a copper rod (A). 13) Remove assembly washer (21). 14) Remove drive gear (23) two bearings (22) using a bearing extractor (B). 15) Unscrew setscrews (24), remove separator (25) from transfer box and lever box housing.
Page 525 7D-20 TRANSFER BOX 18) Unscrew screws (28) which fix front wheel traction assembly (29) and remove it. 19) Take out plug (30), remove spring (31) and ball (32) which act as locks in the "high/low" selector shaft. 20) Remove main shaft (33) from transfer box, along with the "high/low"...
Page 526 TRANSFER BOX 7D-21 22) Remove output ring (38) from main shaft rear bearing, using a copper rod (C). 23) To repair the speedometer gear box, (see 7D-12). 24) Take off the brake for the extreme rear nut which forms the unit of main shaft gears and remove the aforesaid nut.
Page 527 7D-22 TRANSFER BOX 27) Take out cog bearing (40) from the shaft front inner side (39), using a bearing extractor. 28) Take out screws (47) which fix side cover (48) and remove it. 29) Remove hexagonal-headed plug (51), take out spring (52) and locking ball (53) from double traction shaft.
Page 528 TRANSFER BOX 7D-23 33) Remove stud hook (60) from the interior part of the double traction casing. 34) Remove the screw which fixes the flange to the output bearing. 35) Remove output bearing (62) and separator (63) using a plastic mallet.
Page 529 7D-24 TRANSFER BOX 38) Remove support bearing (67) using a soft rod (C), knocking from inside to out (as shown). 39) Remove exterior ring from the conical bearing of the main shaft frontal support bearing; from outside to in using the rod (C) and remove the assembly washers.
Page 530 TRANSFER BOX 7D-25 Installation 1) Fit cog bearing (40) in main transfer shaft (39) front part. This serves as support for the front outlet bearing. 2) Lubricate low speed gears interior (46) and place it in the main transfer shaft (39). 3) Place high/low interior nucleus (45) and moveable collet (44) in the main shaft.
Page 531 7D-26 TRANSFER BOX 7) Brake previously fitted nut (70) locking the nut rib in the shaft groove. 8) Fit main shaft front bearing, placing it deeply in its housing. 9) Sink exterior ring (38) into the main shaft rear bearing, leaving it flush with box face.
Page 532 TRANSFER BOX 7D-27 12) Completely sink the exterior ring of the main shaft front bearing into the double traction casing. Use a soft rod (C). NOTE: Make sure that the assembly washers - which should be between the box (65) and the ring - have not risen. This is due to the fact that, as yet, the thickness is unknown, but which will be determined shortly.
Page 533 7D-28 TRANSFER BOX 20) Remove front traction casing (65) once again and dismount front bearing ring (68). 21) Place the assembly washer (69), calculated before, in the casing (65). 22) Sink ring (68) once more into the casing. 23) Take out main shaft installation (39) and speedometer ca- sing (37) both of which had been previously placed to carry out the axial adjustment of the main shaft.
Page 534 TRANSFER BOX 7D-29 27) Lubricate the sealing lips and fit: • Bearing. • Clamp (61). • Felt washer. • Metallic washer. • Fixing nut , tightening to the specified torque. Torque for assembly screw for front bearing clamp: 14,6 ÷ 17,9 Kg-m (146 ÷ 179 Nm) 28) Fit, on the front outlet bearing (62), the forward traction stud hook (60), positioning the lowered part towards the main transfer shaft.
Page 535: Torque
7D-30 TRANSFER BOX 34) Install fixing ball (53) and spring (52). 35) Fit recommended sealing plug (51) making sure it is flush with the casing. 36) Apply recommended sealing to the side cover face (48) and fix with screws (47) to the specified torque, applying the recommended sealant to the nuts.
Page 536 TRANSFER BOX 7D-31 41) Fit double traction assembly box (29), applying the sealant recommended to the joint face, and fix with screws (28) to the specified torque. Torque for double traction setscrews: 2,2 ÷ 2,8 Kg-m (22 ÷ 28 Nm) 42) Put high/low selector shaft in the high position.
Page 537 7D-32 TRANSFER BOX 45) Fit conical bearings (22) of drive gear (23). 46) Fit drive gear bearing exterior rings to the transfer box ca- sing and to the support cover to the rear of the gears. NOTE: Do not fit the assembly washer between the rear cover and the exterior ring of the bearing at the moment.
Page 538 TRANSFER BOX 7D-33 52) Lubricate assembly formed by the gears, bearings and shaft. 53) Apply a layer of grease to both axial washers (10) and place them in their position in the casing with the bevelling towards the inside (towards the gears). 54) Situate the gear, bearing and supplement assembly so that the bearing cage face the centre: WARNING:...
Page 539 7D-34 TRANSFER BOX 60) Fit brake drum and clamp assembly, fixing it with screws to the specified torque. Torque for brake drum and clamp setscrews: 11,75 Kg-m (117,5 Nm) 61) Fit transfer box lower cover (4), applying the recommended sealant to the joint face of the casing and fix with screws (3) to the specified torque.
Page 540 TRANSFER BOX 7D-35 TORQUE TORQUE ELEMENT Kg-m Retaining screw - main shaft gear assembly 6 ÷ 8 60 ÷ 80 Setscrews - speedometer casing 4 ÷ 5 40 ÷ 50 Setscrews - double traction casing 22 ÷ 28 2,2 ÷ 2,8 146 ÷...
Page 541: Special Tools
7D-36 TRANSFER BOX INSTALLATION DATA AND TOLERANCE DENOMINATION DATA Longitudinal play - main shaft gears 0,05 ÷ 0,15 Play - triple intermediate gear 0,00 ÷ 0,40 Applicable thickness to obtain pre-tingten for the main shaft 0,025 ÷ 0,076 bearings Applicable thickness to obtain pre-tingten for the transfer drive 0,025 ÷...
Page 542 DIFFERENTIALS 7E-1 SECCION 7E FRONT AND REAR DIFFERENTIAL SYSTEM CONTENTS GENERAL DESCRIPTION ............................ 7E- 2 DIAGNOSTIC ............................... 7E- 5 GENERAL REPAIR OF THE DIFERENTIALS ...................... 7E- 6 Front differential repair ..........................7E- 6 Rear differential repair ..........................7E-15 TIGHTENING TORQUE SPECIFICATION ......................7E-17 DATA AND ASSEMBLY TOLERANCES ........................
Page 543 7E- 2 DIFFERENTIALS GENERAL DESCRIPTION The differentials use conical pinions and gears of the hypoid type being installed in the front and rear axle screwed to the sump of each axle. Dimensionally, the front differential and the rear are different , their components therefore not being exchangeable, although the gear ratio (engaging pinion and crown ) is the same for both.
Page 544 DIFFERENTIALS 7E-3 FRONT DIFFERENTIAL 1. Ensemble flange and dust cover. 11. Differential box ball bearing . 2. Dust cover. 12. Ensemble sump-differential group . 3. Crenellated nut . 13. Adjusting nut . 4. Cotter pin. 14. Ensemble plate fixing of adjusting nut. 5.
Page 545 7E- 4 DIFFERENTIALS REAR DIFFERENTIAL 1. Ensemble flange and dust cover. 11. Ensemble sump - differential group . 2. Dust cover . 12. Adjusting nut . 3. Self braking nut. 13. Supplement for adjusting pinion height. 4. Cotter pin. 14. Supplement for adjusting preloading rollers pinion. 5.
Page 546 DIFFERENTIALS 7E-5 DIAGNOSTIC Symptom Probable Reason Action to take Gear Lubricant spoiled or mixed with water. Replace. noises Lubricant unsuitable or insufficient. Replace or refill. Bad clearance between teeth crown and pinion Adjust if necessary. Contacts between teeth inadequate between pinion and crown Adjust or replace.
Page 547 7E- 6 DIFFERENTIALS GENERAL REPAIR OF THE DIFFERENTIALS REPAIR OF THE FRONT DIFFERENTIAL Disassembly 1) Extract the front differential group (see 4A-5). NOTE: It is essential to identify with marks those pieces which work together as well as the assembly position. 2) Install the differential group on a work bench support.
Page 548 DIFFERENTIALS 7E-7 6) Dismantle: • Oil seal (7) from the flange. • Bushing of supplement (8). • The rear journal (9), (tail) of engaging pinion. 7) Extract: • The ensemble engaging pinion and front journal (10) (head). • Washers (11) which adjust the preloading of the pinion journals.
Page 549 7E- 8 DIFFERENTIALS 11) Dismantle trail (17) of the rear roller (tail) of the engaging pinion and trail (18) of front roller (head). 12) Dismantle trail (18) of head roller and withdraw washer (19) which adjust the height of the engaging pinion. NOTE: Keep washer thickness (19) to assemble them later (as approximate measure).
Page 550 DIFFERENTIALS 7E-9 Revision 1) Examine all the components in case they show wear above normal. 2) All the rolling components must be adjusted by pressure except the rear one of the engaging pinion (tail), which must be by sliding adjustment. 3) Check there are no shavings in the teeth and that the housings, spherical as well as flat ones have no scratches, or wear.
Page 551 7E- 10 DIFFERENTIALS 4) Assemble head roller (16) of pinion , using a press and appropriate tools. 5) Place the ensemble engaging pinion (10) and its roller, over the sump, placing in between the adjusting washers (11). NOTE: Total thickness of adjusting washers (11) must be, initially the same as the one dismantled.
Page 552 DIFFERENTIALS 7E-11 8) Check the resistance to turning pulling progressively with the dynamometer. Such resistance should be within the specified order. Otherwise, increase the thickness of supplements (11) to decrease the resistance or reduce thickness to increase resistance. Resistance to turning of the engaging pinion (without oil seal): 13 ÷...
Page 553 7E- 12 DIFFERENTIALS 11) Apply a recommended grease coating on the lip closing of oil seal (7). 12) Assemble oil seal on sump with the lip closing towards the inside. 13) Install now: • The engaging pinion (10) with the washers controlling the preloading.
Page 554 DIFFERENTIALS 7E-13 22) Before continuing with the assembly check the alabeo of the crown with gauge (E) as indicated . It should not be above the specified limit. Maximum alabeo of the crown: 0.10 mm 23) If reading is above the specified value it could be this is due to the crown itself.
Page 555 7E- 14 DIFFERENTIALS 29) Apply the specified tightening torque to the screws fixing the lids of the rolling elements of the differential box. Tightening torque screws fixing rolling element lids : 8 ÷ 8.5 Kg-m (80 ÷ 85 Nm) 30) Assemble the brake ensemble (2), formed by the elastic pin and the fixing plate.
Page 556 DIFFERENTIALS 7E-15 REAR DIFFERENTIAL REPAIR Dismantling 1) Extract the rear differential group (see 4B-3). NOTE: It is essential to identify with marks those pieces which are going to work together as well as the assembly position. 2) Proceed to dismantle the rear differential group in the same manner you did for the front differential group, (see7E-6), taking into account the following remarks: •...
Page 557 7E- 16 DIFFERENTIALS Revision 1) Revise all the rear differential components in the same way you did in the front differential (see7E-6). Assembly 1) Carry out the assembly of the rear differential reversing the dismantling order, and take into account the specified tightening torque and those specified in the complementary task.
Page 558 DIFFERENTIALS 7E-17 TIGHTENING TORQUE SPECIFICATION TORQUE ELEMENT Kg-m Front Differential 117.5 11.75 Nut fixing flange attack pinion Rear Differential 14 ÷ 20 140 ÷ 200 Front Differential 55 ÷ 65 5.5 ÷ 6.5 Screws fixing crown Rear Differential 120 ÷ 140 12 ÷...
Page 559 7E- 18 DIFFERENTIALS SPECIAL TOOL FRONT REAR REF. 193349 REF. 262761 REF. 262757 REF. 262757 CALLIPER ADJUSTING ENGAGING TRAIL EXTRACTOR TRAIL ASSEMBLY PINION REF. 530105 SPECIAL KEY...
Page 560: Body Electrical System
BODY ELECTRICAL SYSTEM 8- SECTION 8 BODY ELECTRICAL SYSTEM CONTENT GENERAL DESCRIPTION ............................8- 1 Wiring ................................8- 1 OVERALL WIRING SCHEMES ..........................8- 2 GENERAL DESCRIPTION The electrical components of this vehicle are designed to work at 12 volts from electric battery system and the negative terminal as ground or earth.
Page 561 8-2 BODY ELECTRICAL SYSTEM OVERALL WIRING SCHEMES RIGHT FENDER (Main Wiring) LEFT FENDER (Main Wiring) 1. Battery 8. Thermo starter relay 2. Head-light regulator 9. Relays 3. Head-light 10. Fuse box 4. Horn 11. Wind-screen wiper tank 5. Turn and side lights 12.
Page 562 BODY ELECTRICAL SYSTEM 8- FRONT (Main wiring) 1. Wiper motor 2. Floor wiring 3. Instrument panel wiring 4. Negative terminal (ground on gear box) 5. To engine wiring 6. Main wiring 7. Starting motor ENGINE COMPARTMENT (Engine wiring) 1. To main wiring 2.
Page 563 8-4 BODY ELECTRICAL SYSTEM INSTRUMENT PANEL (Instrument panel wiring) 1. Fuses 2. To main wiring 3. To electrical control 4. To combination panel 5. To brake light switch 6. To starting motor switch assy 7. To preformed A/C wiring (optional) 8.
Page 564 BODY SERVICE 9-1 SECTION 9 BODY SERVICE CONTENT FRONT AND REAR DOORS ........................... 9- 2 Door glass ..............................9- 2 Window regulator ............................9- 4 Lock assy ..............................9- 5 Door assy ..............................9- 6 BACK DOOR ................................9- 7 Door glass and lateral windows ........................
Page 565: Door Glass
9-2 BODY SERVICE FRONTAL AND LATERAL DOORS DOOR GLASS Removal Trim removal 1) Removes: • Door regulator handle (1). • Handle case (2). • Pull handle (3). • Inside lock knob (4). • Trim screws (5). 2) Remove interior plastic part from door. Glass removal 3) Remove screws fixing regulator support plate and fixing guide to mechanism.
Page 566 BODY SERVICE 9-3 • Put glass in the lower guide as shown in the figure. • If you do not manage lifting or lowering the glass easily, it could be that the glass is inclined towards the door frame. A = B •...
Page 567: Window Regulator
9-4 BODY SERVICE WINDOW REGULATOR Removal 1) Remove regulator supporting plate and screws fixing the regulator to the guide (see 9-2). 2) Withdraw the door regulator. Inspection 1) Check sliding pieces greasing and regulator rotation. 2) Check for damages and wear in sliding cylinder and cable. NOTE: If you notice any faulty component, replace it.
Page 568: Lock Assy
BODY SERVICE 9-5 LOCK ASSY Removal 1) Remove door trim (see 9-2). 2) Remove control rod (1) for door opening from its connection to lock assembly (2). 3) Remove rod (3) of interior secure system from its connection to lock assembly (2), acting on fixing clip. 4) Remove screws (4) for fixing lock assembly and extract it.
Page 569 9-6 BODY SERVICE DOOR INSTALATION Removal 1) Remove fixing screw (1) of limiter (2) to the body. 2) Hold door using a jack and fitting a piece of wood between door and jack. 3) Remove screws (3) fixing hinges to door and withdraw door. Instalation NOTE: When replacing the door you should apply a wax...
Page 570: Back Door
BODY SERVICE 9-7 BACK DOOR DOOR GLASS AND LATERAL WINDOW Removal 1) Clean around the internal and external sides of glass. 2) Remove spare wheel. 3) Stick band at the body, around the glass, to avoid possible damages when extracting and assembling the glass. 4) Disconnect defrosting electrical heating pad.
Page 571 9-8 BODY SERVICE 2) Apply soapy water to the glass border, and put it on the weather strip and assembly the strip lip progressively onto the glass using an appropriate punch. 3) Once the weather strip lip has been assembled on glass, press firmly glass onto the weather strip.
Page 572: Door Lock
BODY SERVICE 9-9 DOOR LOCK Removal 1) Remove holding handle (1). 2) Remove door trim (2). 3) Remove door opening control lever from its connection to lock assembly. 4) Remove screws fixing lock assembly and extract it. Instalation 1) Reverse removal procedure, noting: •...
Page 573 9-10 BODY SERVICE DOOR ASSY Removal 1) Remove fastening pin (1) fixing the door retention (2). 2) Hold door using a jack and fitting a piece of wood between door and jack. 3) Remove screws (3) fixing hinges to door and withdraw door. Instalation NOTE: When replacing door you should apply a wax layer...
Page 574: Roof
BODY SERVICE 9-11 ROOF Removal 1) Remove the followings pieces: • rear-view mirror. • holding handles. • sunvisors. • Implements and trim located under the roof. 2) Remove screws fixing the roof. 3) Remove roof. Instalation Instalation Reverse removal procedure, noting: •...
Page 575: Windscreen
9-12 BODY SERVICE WINDSCREEN Removal 1) Remove windscreen arms (1). 2) Remove screws fixing windscreen to roof. 3) Remove internal fixing screws (2). 4) Remove covers (3) from plates fixing windscreen (4). 5) Remove plate fixing screws (5) and winscreen.
Page 576 BODY SERVICE 9-13 Instalation 1) Reverse removal procedure, noting: • Apply recommended adhesive to windscreen plates. 2) Inspect impermeability, throwing water with a hosepipe over the windscreen. NOTE: Do not use highly pressurized water, neither pressurized air nor infrared radiation for drying. 3) If water is letting in, dry windscreen and fill the entrance region with adhesive.
Page 577 9-14 BODY SERVICE WINDSCREEN Removal 1) Clean glass inside and outside and around it. 2) Remove windscreen wiper arms. 3) To avoid damages, stick a band at body, around the windscreen. 4) Remove internal mirror and internal fittings. 5) With an appropriate punch, open a hole through the adhesive and let in a steel wire ill through it.
Page 578 BODY SERVICE 9-15 8) If you are using again the windscreen glass, take away the old moulding and the adhesive, paying attention no to damage the surface covered with primer. Instalation CAUTION: This procedure describes the glass substitution using a component of urethane adhesive combined with a primer.
Page 579 9-16 BODY SERVICE 5) Clean the glass surfaces to be glued in the body with a clean rag and if you use cleaning solvent let it dry for more than ten minutes. 6) Install new moulding in glass. 7) Apply enough primer in the entire glass surface to be glued to the body.
Page 580 BODY SERVICE 9-17 CAUTION: To finish the installation note the following: • If door is closed suddenly before the adhesive has stuck completely the glass could be loosened or coming out. Consequently, if you open of close the door before the adhesive has settled, be carefull.
Page 581: Side
9-18 BODY SERVICE SIDES Removal 1) Remove the corresponding rear side seat. 2) Remove trim and internal fittings from the corresponding side. 3) Remove vehicle roof (see 9-11). 4) Remove the corresponding seat belt (see 9-25). 5) Remove nuts (1) fixing side (2) to rear body (3). NOTE: For the right hand side, dismantle screws (4) fixing back door upper hinge (5) to side.
Page 582: Rear Body
BODY SERVICE 9-19 REAR BODY Removal 1) Remove back door (see 9-10). 2) Remove vehicle side (see 9-18). 3) Remove back seats (see 9-23). 4) Remove central seats (see 9-22). 5) Remove rear body trim and safety belts (see 9-25). 6) Remove screws (1) fixing rear body (2) to the vehicle floor.
Page 583 9-20 BODY SERVICE 2) Inspect impermeability throwing water with a hose pipe by the external side of the rear body. NOTE: Do not use highly pressurized water, neither pressurized air nor infrared radiation for drying. 3) If there are water inlets, wipe the loading box and fill the water entrance point with adhesive.
Page 584: Seats
BODY SERVICE 9-21 SEATS FRONT SEATS Removal 1) Remove screws (1) fixing front seat (2) to seat support (3). Instalation 1) Assemble front seat reversing the dismantling order.
Page 585: Central Seats
9-22 BODY SERVICE CENTRAL SEATS Removal 1) Remove butterfly nuts fixing seat to rear body. 2) Remove screws fixing seat lower legs to rear body and remove the seat. Instalation 1) Assemble central seats reversing the dismantling order.
Page 586: Back Seats
BODY SERVICE 9-23 BACK SEATS Removal 1) Remove lower screws (1) fixing back seat to rear body. 2) Remove upper screws fixing back seat back to side of rear body and remove the seat. Instalation 1) Assemble back seats reversing the dismantling order.
Page 587 9-24 BODY SERVICE SEAT BELTS SEAT BELTS SERVICING Before doing the service or replacing seat belts, note the following remarks: • Belts must be in normal position with respect to the retractor and/or buckle. • Keep away belts from sharp objects or others damaging them.
Page 588: Seat Belts
BODY SERVICE 9-25 Removal NOTE: When replacing safety belt, change both the fixing buckle and the belt retractor, with emergency blockage. This must be done to be sure both the buckle and the small tongue close properly. If pieces were changed individually, if could happen that they do not assemble properly.
Page 589: Coatings And Silencers
9-26 BODY SERVICE COATINGS AND SILENCERS COATINGS Removal 1) Remove screws and/or clips fixing the corresponding coating and withdraw it. Instalation 1) Install coating fixing it with screws and/or clips. SILENCERS Removal 1) Remove the corresponding sound proofing plate, dismantling the fixtures previously.
Page 590: Anticorrosion Treatment
BODY SERVICE 9-27 ANTICORROSION TREATMENT Steel sheets have been previously treated for corrosion. To get a higher resistance to corrosion inside and/or outside these are galvanized both sides. Because of greater protection against corrosion some procedures are applied such as those described below: 1) Steel sheets have an electro cathodic priming to provide greater resistance to corrosion.
Page 591 9-28 BODY SERVICE Anticorrosion wax is a penetrating compound applied to the metal- metal contact surfaces (door insides and main lateral frame) where other coating material can not be used. Hence, when choosing an anticorrosion wax it must be of the penetrating type. When a vinyl protecting layer is applied, it must be done carefully in order to avoid that the sealant comes in the motor, damper ensemble and rotating pieces.
Page 592: Metallic Spare Pieces Finishing
BODY SERVICE 9-29 METALLIC SPARE PIECES FINISHING Metallic spare pieces (or ensembles) are covered with electrodeposited primer. To get good paint adhesion, the following procedure is recommended). 1) Use wax or solvent degreaser to clean the piece. 2) Use damp or dry sandpaper (n° 400) to polish slightly the sheet.
Page 593: Frame
9-30 BODY SERVICE FRAME Each individual component of the framework has not only an effect on the vehicle stiffness and but also in wheels alignment (convergence, camber angle, castor angle). Consequently, it is essential to carry out thorough surveys of the framework, doing if necessary weldings related to its correction or substitution.
Page 594 BODY SERVICE 9-31 FRAME MAIN DIMENSIONS...
Page 595 9-32 BODY SERVICE FRAME MAIN DIMENSIONS...
Page 596 BODY SERVICE 9-33 REQUIRED SERVICE MATERIAL PRODUCT TYPE REF. Windscreen glass BETASEAL 1752 791009 Door panel ADHESIVE XK21233 Doors SEALANT 17550 Doors PUTTY 13991...
Page 597 TECHNICAL DATA 10-1 SECTION 10 TECHNICAL DATA CONTENTS ENGINE ................................. 10- 2 GEAR AND TRANSFER BOX ..........................10- 3 DIMENSIONS AND PHYSICAL CONDITIONS ....................... 10- 4 WEIGHTS ................................10- 4...
Page 598 10-2 TECHNICAL DATA ENGINE MECHANICAL COMMON TYPE INJECTION RAIL 4 in line Number of cylinders and configuration Diesel 4 strokes Cycle Overfeeding intercooler Supply Direct Injection 94,4 x 100 Bore and stroke 2.800 Piston displacement 18,5 : 1 Compression ratio 20 ±...
Page 599 TECHNICAL DATA 10-3 GEAR AND TRANSFER BOX Hand operation TYPE gear 3,647 gear 2,179 Gear box ratios gear 1,435 gear 1,000 gear 0,795 High 1,192 Transfer box ratios 3,319 3,909 Transmission ratio, differential groups, 43:11...
Page 600 10-4 TECHNICAL DATA DIMENSIONS AND PHYSICAL CONDITION Overall length (mm) 4.675 Overall width (mm) 1.750 Overall height (mm) 2.000 2.786 Wheel base (mm) 1.486 Front and rear tract width (mm) Turning radius Ground clearence (mm) 50º Entry angle 30º Exit angle Lateral angle 40º...
Page 601 ELECTRICAL DIAGRAMS...
Page 602 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-2 POWER SUPPLY DIAGRAM...
Page 603 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-3...
Page 604 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-4...
Page 605 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-5...
Page 606 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-6...
Page 607 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-7...
Page 608 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-8...
Page 609 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-9...
Page 610 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-10...
Page 611 ONLY COMMON RAIL ELECTRICAL DIAGRAMS-11...
Page 612 ONLY MECHANICAL INJECTION ELECTRICAL DIAGRAMS-12 POWER SUPPLY DIAGRAM...
Page 613 ONLY MECHANICAL INJECTION ELECTRICAL DIAGRAMS-13 GLOW PLUG RELAY DIAGRAM...
Page 614 ONLY MECHANICAL INJECTION ELECTRICAL DIAGRAMS-14...
Page 615 ONLY MECHANICAL INJECTION ELECTRICAL DIAGRAMS-15 COMBINATION METER DIAGRAM...
Page 616 ONLY MECHANICAL INJECTION ELECTRICAL DIAGRAMS-16 COOLING SYSTEM...
Page 617 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-17 HEADLAMP LEVELING SYSTEM DIAGRAM...
Page 618 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-18 REVERSE LAMP DIAGRAM...
Page 619 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-19 RADIO & REAR WINDOW DEFOGGER...
Page 620 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-20 REAR DEMISTER & STOP LAMP DIAGRAM...
Page 621 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-21 HORN DIAGRAM...
Page 622 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-22 TURN SIGNAL & HAZARD LAMP DIAGRAM...
Page 623 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-23 LAMPS DIAGRAM...
Page 624 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-24 WASHER-WIPER DIAGRAM...
Page 625 GENERAL DIAGRAMS ELECTRICAL DIAGRAMS-25 CHARGING SYSTEM DIAGRAM...
Page 626 Prepared by SANTANA MOTOR S.A. After-Sales Service Department Ed. October 2002 Printed in Spain Printed: October 2002...

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