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Santana PS-10 Service Manual

Santana PS-10 Manual Online:

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Santana PS-10 User Manual
Santana PS-10 User Guide
Santana PS-10 Online Manual

Text of Santana PS-10 User Guide:

  • Santana PS-10, 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. A 16 17 18) Remove the selector forks for 3rd and 4th gears (18) and 1st and 2nd gears (19). 18 19 19) Remove the plug so as to access the selector shaft bolts through the passage. 20) Using tool (D) ref.194635, remove the selector shaft bolts (20) D 21) Remove the fixing elements (21) which link the support (22) to the box

  • Santana PS-10, 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. • To adjust tension of compressor driving belt, (see 6A- 27). 2) Apply specified tightening torque and those specified in the complementary tasks. Tightening torques: • Nut (10) for hub (threads left wise) Pre tightening: 4 Kg-m (40 Nm) Angular tightening: 110º ± 10º • Screw (20) fixing water pump: 5 Kg-m (50 Nm) • Nuts (9) fixing electro magnetic gasket:

  • Santana PS-10, ENGINE REPAIR 6A-103 CHECKING AND FORMING ASSEMBLIES OF PISTONS, PISTON RINGS AND CONNECTING RODS Disassembly assembly piston and connecting rod 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 8.- Half ball bearings 9.- Head cover connecting rod cover 10.- Screws fixing head cover 1) Check there are no signs of grippings, scratches, cracks or excessive play on pistons ; otherwise, replace them. 1 2 3 4 5 6 10 9 8

  • 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. Tightening torque for nuts fixing “U“ bolts: 7 Kg m (70 Nm) 16) Bring

  • Santana PS-10, ENGINE FUEL AND EMISSION CONTROL SYSTEM 6C-27 FUEL DELIVERY SUSTEM 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 and high pressure. Forming part of the low pressure circuit are: flexible pipes, rigid pipes fixed to the frame, the prefilter, the feed electro-pump, the main filter, the thermostarter electro-valve and the thermostarter spark plug. Part of the excess fuel in the high press

  • Santana PS-10, 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. Instalation 1) Reverse removal procedure ,noting specifications at the complementary tasks.

  • Santana PS-10, 6A-22 ENGINE REPAIR Concept Ø Plungers in normal cylinder head Ø normal Adjusting plate Between plungers and lodgings H Height of cams: H H BELTS TENSION Driving Belt Alternator and Water Pump Tension Driving Belt Air Conditioning Compressor Tension Timing Belt Tension 43,950 ÷ 43,970 0,035 ÷ 0,081 From 3.25 till 4.45 mm In progression of 0.05 9,5 10,5 140 ± 50 Hz 160 ± 10 Hz Belt in HSN (High Strength Nitrile), with Frecuency metre, must be 88 - 112 Hz MECHANICAL INJECTION 8140.43C.3 COMMON RAIL 8140.43S.4ID/TCA

  • Santana PS-10, MAINTENANCE AND LUBRICATION 0B-33 RECOMMENDED FLUIDS AND LUBRICANTS ANTIFREEZE REFRIGERANT BRAKES LIQUID GEAR BOX OIL TRANSFER BOX OIL ENGINE OIL DIFFERENTIAL GROUPS OIL CLUTCH LIQUID SERVOSTEERING HYDRAULIC OIL GREASES FOR TRANSMISSIONS DINAGEL-9103 (DINAMIC) DOT-4 SAE 75W-90 SAE 10W-40 HIPOID GEAR SAE 80W-90 API GL-5 DOT-4 Automatic transmission Fluid DEXRON-II AGUILA 95 / BRUGAROLAS TIHGTENING TORQUES ELEMENT REMARK Engine oil pan draining plug 3 ÷ 4 30 ÷ 40 Oil filter 2,5 25 TORQUE Kg-m Nm REQUIRED SURVICE MATERIAL REF. PRODUCT TYPEAPPLICATION POINT Filling and draining plug of: • Gear box • Transfer box • Differential

  • 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. Chassis and silent-block bodywork supports

  • ENGINE REPAIR 6A-15 Concept OVERFEEDING Turbo charger type: marked with colour Radial play turbo charger axle Axial play turbo charger axle Minimum course opening of the valve pressure restricter mm Maximum course opening of the valve pressure restricter mm Minimum course pressure bar Máximum course pressure bar LUBRICATION Oil pressure with engine hot: Engine ticki

  • Santana PS-10, 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. Tightening torque for screws fixing clamp: 3.1 ÷ 3.5 Kg-m (31 ÷ 35 Nm) 5) Install wheel and tighten nuts to the specified tightening torque following the sequence order shown in the figure. Tightening torque for wheel nuts: 11÷17Kg-m (11

  • Santana PS-10, 6A-156 ENGINE REPAIR Tool set to check resistence to rotation of drive axle oil pump. Engine handling device for removal and installation. Locking tool for engine flywheel to apply tightening torques. Special spanner (13 mm) for removal and installation of injection pump lower nut. X X X X OBSERV. REF. CLASS DENOMINATIONGENERAL SPECIF. R NR N Connecting rods asignments tester. X 790974 790975 790976 790977 790978 ■

  • 6A-158 ENGINE REPAIR Valve guide scraper. Seat reboring and replacing tool set. Cilinder head injector seats cleaning milling bit. Oil seal installer. X X X X OBSERV. REF. CLASS DENOMINATIONGENERAL SPECIF. R NR N Valve spings resistance checker. X 790984 790985 790986 790987 790988

  • Santana PS-10, TRANSFER BOX 7D-13 8) Remove: • The bearing (9). • The worm gear (10). • Bush (11). 9 10 11 12 13 14 A 9) Dismount the bush oil collector and remove seal (12) from the exterior part. 10) Take off clip (13) which fixes the bearing support. Check 1) Service all the components of the speedometer casing and check for wear and tear and possible deformations. 2) Examine the state of the outlet bearing grooves, worm gear and speedometer gears. 11) Dismount rear outlet support bearing (14), making use of soft stick (A).

  • Santana PS-10, 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 Remove and check of rocker arms Removal 1) Remove rocker arm and adjusting plates (5) and place them identifying installation order. 5 43,950 ÷ 43,970 44,000 ÷ 44,025 MEASURES OF THE DIAMETER OF THE VALVES PLUNGERS AND THEIR LODGINGS IN CYLINDER HEAD 4) With t

  • Santana PS-10, 5-32 BRAKES 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 master cylinder (1) to lung and withdraw the master cylinder assembly and the tank. 2) Disconnect vacuum pipe (2) from connection to lung (3). 3) Remove rubber caps (4) from the brake pedal support and disconnect fork (5). 4) Withdraw lung (3) remove nuts (6) fixing to brake pedal support. 5) Substitute brake booster lung by a new one. Installati

  • Santana PS-10, 3E-4 REAR SUSPENSION LEAF SPRINGS AND CHASSIS BUMPERS 1) Check and substitute, if necessary, leaf springs bumpers and body of rear suspension as same as the front suspension (see 3D-6). SPRINGS BUMPERS 1) Check and substitute, if necessary, the rear suspension spring as same as the front suspension (see 3D-6). 2 4 3 4 2 1 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 abso

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