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Santana PS-10, Service Manual

The Yamaha PS-10, a versatile musical instrument, comes with an Owner's Manual to help users maximize their experience. Easily downloadable for free from manualshive.com, this comprehensive manual provides detailed instructions and insights, enabling users to explore the full potential of their Yamaha PS-10.

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6C-46 ENGINE FUEL AND EMISSION CONTROL SYSTEM

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Warning Light

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Defect

Vehicle speed

Multiple switch state

Cruise Control (if fitted)

Accelerator pedal

Clutch switch

Brake switch

Brake/accelerator plausibilty

Diagnosis warning light

Air-conditioning (if fitter)

Coolant temperature sensor

Air temp. sensor

Fuel temp. sensor

Overfeed pressure sensor

Atmospheric pressure sensor

Electric fuel pump

Fuel heater

Fan (if fitted)

Cylinder 1 rocker (flow limiter)
Cylinder 2 rocker (flow limiter)
Cylinder 3 rocker (flow limiter)
Cylinder 4 rocker (flow limiter)

Battery tension

Thermostarter warning light

Thermostarter (if fitted)

Thermostarter electro-valve (if fitted)

Thermostarter control (if fitted)

Variable Geometry Turbine control (VGT) (if fiteed)

Variable Geometry Turbine actuador (VGT) (if fiteed)

Injector 1 - cylinder 1
Injector 4 - cylinder 2
Injector 2 - cylinder 3
Injector 3 - cylinder 4

Bank 1 (cylinders 1,4)
Bank 2 (cylinders 2,3)

Engine speed sensor

Timing speed sensor

Engine overspeed

PWM signal (if fitted)

BUS «Controller  Area Network» CAN inactive (if fitter)

BUS CAN (if fitter)

CAN message (if fitter)

CAN line (if fitter)

High pressure fuel control

Fuel pressure sensor

Pressure regulator

3

rd

 piston deactivator electro-valve

EGR control (if fitted)

EGR valve (if fitted)

Air flow sensor (if fitted)

Ambient temp. sensor (if fitter)

Control board error

EPROM defect

Electronic Diesel Control (EDC) immobiliser (if fitted)

Main relay

After run test

Engine stop test (ECU)

Sensors supply

Control board error

ECU operating system

DIAGNOSTIC TROUBLE CODE TABLE

Summary of Contents for PS-10

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Page 3: ...te the possibility of danger on the vehicle parts NOTE There special information is given in order to improve the maintenance or to clarify some significant instructions 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 c...

Page 4: ...atest information of the product before publishing SANTANA reserves the rights to make changes whenever it estimates convenient without previous warning ALL RIGHTS RESERVED BY SANTANA MOTOR INDEX MAINTENANCEANDLUBRICATION HEATER AND VENTILATION BUMPERS FRONT HOOD AND FRONTAL STEERING SUSPENSION WHEELS AND TIRES General diagnosis Front end alignment Steering gear box and linkage Steering wheel colu...

Page 5: ......

Page 6: ... 0B 14 Transmission Item 3 0B 15 Gear box oil Item 3 1 0B 15 Transfer box oil Item 3 2 0B 16 Differential groups oil Item 3 3 0B 17 Transmission Shafts Item 3 4 0B 18 Clutch Liquid Item 3 5 0B 19 Clutch pedal Item 3 6 0B 20 Visual Control and running Item 3 7 0B 21 Brakes steering suspension and wheels Item 4 0B 22 Brake Discs and Brake Blocks Item 4 1 0B 22 Brake Liquid Item 4 2 0B 22 Parking bra...

Page 7: ... TRANSMISSION 3 1 Gear Box oil I only after the first 15 000 Km 3 2 Transfer box oil 3 3 Differential groups oil R only after the first 15 000 Km 3 4 Transmission shafts 3 5 Clutch liquid 3 6 Clutch pedal 3 7 Visual control and operation 4 BRAKES SUSPENSION STEERING AND WHEELS 4 1 Brake discs and brake blocks 4 2 Brakes liquid 4 3 Parking brake 4 4 Mechanical steering system 4 6 Servo Steering hyd...

Page 8: ...NTHS ITEM 1 1 Accesory belt I R 15 000 9 000 12 60 000 36 000 48 A CDE G I ITEM 1 2 Timing belt R 60 000 36 000 48 A CDE G I ITEM 1 3 Oil motor and filter R 15 000 9 000 12 BC I ITEM 1 6 1 7 Water radiator and air radiator intercooler I 10 000 6 000 8 C I ITEM 1 8 Air filter 1 I R 2 500 1 500 2 30 000 18 000 24 B I ITEM 1 9 Exhaust system I 15 000 9 000 12 C G I ITEM 2 1 Fuel filter R 10 000 6 000...

Page 9: ...ion for the work been carried out ENGINE Item 1 Accesory belt Item 1 1 Inspection replacement and adjustment Inspection 1 Look for cervices breakings or deformation If any defect is found replace both driving belts 2 Checkifgeneratorandwaterpumpbelts 1 havethespecified tension on item A Generator and water pump belt tension measured with frequency meter ref 00000A01484 140 5 Hz A 1 3 Check if A A ...

Page 10: ...and Filter Item 1 3 Engine oil and oil filter change Engine oil change NOTE This operation must be done with the hot engine and placed level Before draining engine oil check engine for oil leakage 1 Use an adequate container to collect the used oil 2 Disassemble the draining plug 1 and let dripping the used oil about 20 minutes 3 Clean the plug and its lodging within the carter allowing for a new ...

Page 11: ...able use the required SAN TANA MOTOR oil Engine oil amounts Viscosity SAE 10 W 40 Standard API SJ CF Total Amount Drained motor Including filter Without including filters 7 3 litres 7 0 litres 5 9 litres 5 Put the right oil amount for each case start engine while in neutral and check there are not oil losses After a few minutes cut off engine let the oil become still and check with the rod gauge 3...

Page 12: ...area where the filter contacts the coupling CAUTION Be sure that no hair rests no dirt remains in the contact area of the filter with the coupling 4 A 5 4 Unwrap the new filter from its casing apply engine oil in the joints 5 and thread it by hand 5 Using the special spanner A ref 99360091 apply the appropiate torque to the filter Tightening torque for the oil filter 2 5 Kg m 25 Nm 6 Start engine ...

Page 13: ...eplace the cap 2 Check visually there are no leaks the worthiness of the sleeves and the tightness of the braces 3 If you detect mud or dirt within the expansion vase you must clean it as follows Unlock or disconnect Filling cap 1 level gauge 4 radiator degasifier sleeve 5 filling sleeve 6 engine degasifier sleeve 7 and tank 2 fixing nuts 3 Withdraw tank 2 wash it with pressurized water and approp...

Page 14: ... 9 Check the goodness of joint 10 and substitute it if necessary 5 Put back plug 8 and tighten it moderately plastic plug Filling and air purging 1 Prepare the ccolant mixture as stated in the following table Total circuit Capacity Refrigerant Mixture Demineralised water 12 litres 50 50 38 C Freezing Protection Dinagel 9103 Dinamic CAUTION The coolant mixture should be revised in summer and in win...

Page 15: ...ill mouth 11 of the tank If you have had to stop engine switch it on again and keep it about 5 minutes at a rate slightly above the idle over Adjust again the refrigerant level and put on the plug of the spout Speed up the motor till 3 500 rpm to increase fast the temperature of the refrigerant 94 C a 110 C Keep the motor running thus till the air purging of the circuit has been carried out the pu...

Page 16: ...ves union to the air channelling disconnect the four nuts holding the intercooler to the water radiator and remove it without disconnecting the air conduction sleeves Intercooler Item1 7 External Cleaning Do the external cleaning of the intercooler 2 air radiator using the same methods as those used when doing the external cleaning of the water radiator Air Filter Item 1 8 Residues purging cleanin...

Page 17: ...e there are no frictions or rubbings of the exhaust system with other pieces and that the distances are kept right If there are defects prompt action should be taken as soon as possible NOTE Wider information about the exhaust system can be found in section 6K 1 EXHAUST SYSTEM 1 Visual Control Item 1 10 Inspection Check the worthiness of the sleeves and pipes just in case they present damages leak...

Page 18: ...the electrical connector 5 again Fuel Lines and connections Item 2 3 Inspection 1 Check visually the worthiness of the flexible tubings and sleeves from the feeding and back return fuel lines no deformations fissures loses or rubbings should be apparent Substitute or replace if necessary 2 Check visually the worthiness of braces and sleeves connections to rigid pipes and be sure that they are firm...

Page 19: ...Item 2 5 ONL ONL ONL ONL ONLY COMMON R Y COMMON R Y COMMON R Y COMMON R Y COMMON RAIL AIL AIL 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 1 ...

Page 20: ...d up further oil of the recommended type 4 Clean the threadings of the plug and the sump apply the recommended sealant in the threadings of the plug and tighten moderately Oil replacement 1 Prepare an adequate container to pour the oil 2 Unlock level and filling plug 1 and the draining plug 2 Let oil drip and lock again the draining plug 2 with a new joint and tighten it moderately 3 Fill and leve...

Page 21: ...her oil of the recommended type 4 Clean the threadings of the plug and the sump apply the recommended sealant in the threadings of the plug and tighten moderately Oil Replacement 1 Prepare an adequate container to pour the oil 2 Unlock level and filling plug 1 and the draining plug 2 Let oil drip and lock again the draining plug 2 with a new joint and tighten it moderately 3 Fill and level with th...

Page 22: ...pe 4 Clean the threadings of the plug and the sump apply the recommended sealant in the threadings of the plug and tighten moderately Oil Replacement 1 Prepare an adequate container to pour the oil 2 Unlock level and filling cap 1 and the draining plug 2 Let oil drip and lock again the draining plug 2 with a new joint and tighten it moderately 3 Fill and level with the recommended oil NOTE Use sea...

Page 23: ... 10 mm otherwise replace the faulty piece Test the car on the road and feel the running smoothness and the absence of knockings in normal traction and double traction otherwise substitute the faulty piece 2 Check the tightness of the nuts in the union clamp between the propeller shafts and the differential groups and transfer box Tightening torque of the nuts in the union clamp between the propell...

Page 24: ... of the tank 1 otherwise add up till reaching the maximum level MAX CAUTION Use new recommended clutch liquid NOTE If liquid was withdrawn from the circuit leading to the formation of air bubbles you will have to air purge after filling 1 A 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 wel...

Page 25: ... finger till you feel the hardening this is the free travel B NOTE Repeat this motion several times to get familiarized by touch and be sure about the path B 2 If the free travel does not correspond to the specified value adjust it with the nuts 2 free travel B of the clutch pedal 15 20 mm NOTE To know more about the adjustment of the clutch pe dal free travel see 7C 4 CAUTION The clutch pedal fre...

Page 26: ...Check there are no liquid leaks in the clutch hydraulic circuit principal pump or small auxiliary pump 3 Check the worthiness of the dust protectors of levers and transmissions Test 1 Test the running of the clutch gear box and transfer box with the vehicle standing and on the road NOTE If you detect any faults during inspection or in the running test repair or substitute the faulty piece ...

Page 27: ...0 mm 8mm 8 2 mm 20 mm 10 mm 18 mm 9mm 0 15 mm Standard Service Limit 1 2 3 Brake Liquid Punto 4 2 Inspection Liquid level substitution and air purging CAUTION Brakes liquid can damage car enamel If liquid fell on the enamel clean well immediately Inspection 1 Check there are no liquid leaks from the linkages around the tank 1 principal cylinder 2 or from the brake pincers 3 If there are any leaks ...

Page 28: ...t the brakes liquid substitution and the air purging see 5 17 CAUTION Do not use again the spent liquid neither the one coming from air purging Use always new recommended clutch liquid Recommend Brakes Liquid A 1 Parking Brake Item 4 3 Performance Inspection Check the performance of the tensioned parking brake To do it place the vehicle in a pronounced ramp and check that it holds when the lever i...

Page 29: ...ossheads Tie rods joints Fixing of the steering box Fixing of cams and turning pivots NOTE This testing should be carried out by two persons working in coordination while one moves the steering wheel the other check plausible plays in the mechanical components 3 Check the tightness of the screws and nuts of the steering mechanical components including the union the turning pivots of the sump axle ...

Page 30: ...ftwards 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 4 Squeeze again filter drive 4 and turn it rightwards till proper fitting in the tank borders 5 5 Be sure that the oil level is correct see OB 26 Item 4 7 fit cap 1 4 5 45 INSTALLATION 45 4 REMOVAL 3 2 1 ...

Page 31: ...e off filing cap 1 dismount filter 6 measure the mark the oil leaves on the filter and adjust level if necessary 6cm minimum level 7cm maximum level Mount the filter and cap definitely see OB 25 item 4 6 NOTE When engine stops the oil level will increase 1 or 2 cm Recommended hydraulic Oil DEXRON II Dampers silent blocks and springs Item 4 8 Inspection 1 Place the vehicle in the pit or hydraulic l...

Page 32: ...rrect repair or substitute the faults or pieces in bad state detected during the inspection 3 3 4 5 Tyres Item 4 9 Inspection 1 Check the wear of tyres including the spare wheel and adjust the air pressure If air pressure is low wear of the tyre sets on the external part of the tyre band If air pressure is too high wear of the tyre takes place on the central part of the tyre band If air pressure i...

Page 33: ...Item 4 10 Inspection 1 Inspect the wheels to check for dentings deformations or cracks 2 When dismantling a wheel be sure there is no corrosion in the contact area neither in the wheel nuts otherwise suppress it 3 Tighten the nuts to the adequate torque and in the order indicated in the graphic Wheel Nuts Tightening Torque 11 17 kg m 110 170 Nm NOTE Substitute the wheel showing any damages Clear u...

Page 34: ...lding of the rigid tubings of brakes and steering 3 Verify the worthiness of the braking and steering sleeves checking for rubbings cracks or breakings 4 Check there are no rubbings interferences collisions etc between fix and mobile parts of brakes steering and suspension 5 Inspect the linkages and sleeves and tubings junction in case there are liquid or oil leaks NOTE If there are leaks or fault...

Page 35: ...ion and the fixing elements are firmly tightened NOTE Silent blocks are designed to last a life time If one of them gets damaged it could be due to the acciden tal contact with contaminating liquids When a silent block is substituted investigate previously the reason why it got damaged Repair or substitute any anomalous or faulty piece detected during the inspection Optical Equipment Acoustic and ...

Page 36: ...he clutch friction disc is slipping 3 Foot brake While driving check that There are not abnormal noises neither vibrations when braking The applied braking force is evenly distributed between the wheels the vehicle does no show a tendency to modify its trajectory when braking sharply and there is no blockage of any of the wheels 4 Parking brake With the vehicle placed in a steep slope check that t...

Page 37: ...s 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 Seats sliding and reclining systems Windscreen demisting system NOTE Repair the faults found during the checking ...

Page 38: ...omatic 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 TYPE APPLICATION POINT Filling and draining plug of Gear box Transfer box Differential groups Turning Pivots Sump SEALING TB 1215 QUIMILOCK REF API SJ CF SAE 75W 90 API GL 5 API GL 5 50 35 C 791003 7...

Page 39: ...PTION 1A 2 HEATER CONTROL OPERATION 1A 3 DIAGNOSIS 1A 5 ON VEHICLE SERVICE 1A 6 Ventilator and diffuser unit 1A 6 Heatingvalve 1A 7 Heater motor ventilator switch 1A 8 Control cable adjustment 1A 8 Control cables and control levers 1A 9 Heating unit 1A 10 INSIDE VENTILATION 1A 11 1A ...

Page 40: ...tlets for windscreen demisting are located in the upper and sides of the glove compartment 1 Front side air outlet 2 Front center air outlet 3 Side demister outlet 4 Upper demister outlet 5 Fan assy and protector 6 Demister duct 7 Air Flow Ducts 8 Heater assy 9 Protector 10 Heating Control Panel 11 Heating Control Levers Unit 12 Heater valve control cable 13 Ventilator control cable 14 Heater cont...

Page 41: ...n position 1 Ventilation and demisting position 2 Demisting position 3 Control lever B Control lever B has two working positions Air circulation position 4 Fresh air position 5 Control lever C Control lever C is temperature control lever Air temperature can be controlled moving the lever to the chosen temperature Displaced totally to the left maximum hot air Displaced totally to the right maximum ...

Page 42: ...N 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 FORCEDVENTILATION HEATING INTRODUCING OUTSIDE AIR HEATING WITH INSIDE AIR CIRCULATION D ...

Page 43: ...ulty Change resistor switch is ON Fan Motor faulty Change motor Faulty connection or poor grounded Repair as necesary Odd temperature Control cables broken or interconnected Check cables output Air Regulator broken Repair regulator Air flow ducts blocked Repair air ducts Heater Radiator has leaks or blockages Change radiator Heater hoses have leaks or blockages Change sleeves ...

Page 44: ... 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 Instalation 1 Reverse removal procedures 1 3 2 ...

Page 45: ... 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 5 Remove fixing nuts and valve Instalation 1 Reverse removal procedures 2 Refill cooling system with proper coolant referring to Section 0B 8 and check each joint for leakage with motor running 1 4 2 3 ...

Page 46: ...t 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 CONTROL CABLE ADJUSTMENT To adjust any control cable 1 Put the control lever at the OFF position 2 Place the corresponding acting element at the OFF position and fix the cable 1 ...

Page 47: ...move control cables from their unions to Ventilator Protector Heater Valve 5 Remove heating control levers unit 4 NOTE To substitute control cables disconnect from unions and replace by another having the same replacement reference number Instalation 1 Install a new lever unit set if required 2 Install the other component reversing removal procedures noting to tighten to specified torque 3 Proceed...

Page 48: ...e box NOTE Remove required components to extract the glove box to avoid damaging them Heater Removal 8 Disconnect drive cable front heater unit 7 9 Drain the radiator disconnect water hoses from heater unit and cover up them 10 Remove fixing nuts 8 and bolt 9 from heater 7 11 Remove heater unit 9 7 8 Instalation 1 Install heater unit reversing removal procedure noting to tighten to specified torqu...

Page 49: ... 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 ...

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Page 51: ...ly fender 2 8 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 Do not use substitutes neither pieces of inferior quality While assembling take care of ensuring that retention of t...

Page 52: ...2 2BUMPERS FRONTHOODANDFRONTAL FRONT BUMPER 1 Front Bumper 2 Inspection cover 3 Side thermo conformed pad 4 Center thermo conformed pad 2 1 4 3 ...

Page 53: ...BUMPERS FRONTHOODANDFRONTAL2 3 REAR BUMPER 1 Rear bumper 2 Side pad 3 Center pad 2 3 3 1 2 ...

Page 54: ...2 4BUMPERS FRONTHOODANDFRONTAL FRONT HOOD 1 Hood 2 Hinges 3 Lock cable 4 Lock assembly 5 Cushion 6 Stay 2 5 4 6 3 1 ...

Page 55: ...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 1 ...

Page 56: ...ust 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 Hood lock adjustment Loose lock hood assembly screws 3 of the bonnet closing unit adjust anchoring correctly and tighten screws 3 1 2 3 ...

Page 57: ...BUMPERS FRONTHOODANDFRONTAL2 7 FRONTAL 1 Front Grille 2 Fender 3 Register Cover 4 Front Frame 3 4 2 1 ...

Page 58: ...ts regulator 5 Remove components found at the interior of the fender accordingly supports tanks etc 6 Remove other fender fixing elements and withdraw them 7 Remove fender fixing screws to dashboard and front frame 8 Withdraw the fender Installation 1 Install fender and all its components reversing dismantling steps NOTE Apply a final tightening once all fixing screws have been fixed in place ...

Page 59: ...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 3E WHEELS AND TIRES 3F 3 ...

Page 60: ...ENERAL 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 GENERALDIAGNOSIS3 2 1 3 2 ...

Page 61: ...lacement tyre Inflation of tyres Strut damper assembly or coil spring Replacement tyre Check front end alignment Checkandadjustrearwheelalignment Repair front brakes Tighten or replace suspension parts Change silent blocks Abnormal or excessive tyre wear Broken or sagging springs Tyre out of balance Disturbed front rear end alignment Faulty strut shock absorber Overloaded Vehicle Not rotating tyre...

Page 62: ... Wheel nuts loosened Broken or damaged wheel ball bearings Broken springs Silent blocks wear Loosened suspension or steering components Tighten wheel nuts and revise Replacement wheel ball bearings Replacement springs Replacement silent blocks Tighten and check Steering noises bumping or lashing Loosened screws and nuts Broken or damaged wheel ball bearings Worn or broken silent blocks Not enough ...

Page 63: ... silent blocks Very soft suspension Faulty shock absorber Replacement shock absorber Limiting hit frequently Overloading Faulty shock absorber Incorrect broken or weakened springs Check loading Replacement damper Replacement springs Body bends or oscillates when turning Faulty shock absorber or bushings Broken or weakened springs Overloading Spring silent blocks or body give up or broken Replaceme...

Page 64: ...r exists across the tread of any tyre 3 Front tyre wear is unequal between the left and right 4 Rear tyre wear is unequal between the left and right A wheels alignment check is necessary if following conditions are noted 1 Front tyre wear is unequal between the left and right 2 Wear is uneven across the tread of any front tyre 3 Front tyre treads have saffed appearance with feather adhes on one si...

Page 65: ...le con be quickly diagnosed by using Tire Problem Detec tor TPD and following the equiptment manufacture s recommendations If TPD is not available an alternative method of substituting known good tire wheel assemblies con be used as follows although it takes a longer time 1 Ride vehicle to determine wheter the front or rear waddles 2 Install tires and wheels that are known to be good on similar ve...

Page 66: ... lateral forces while driving straight If one side of the tyre has a diameter slightly greater than another the tyre has a tendency to pull sideward This produces a lateral force which might induce dragging of the vehicle The following procedure is used to check the front alignment precision in what concerns tyres dragging 1 A part of the diagnostic procedure differs of the rotating patterns gener...

Page 67: ...ION LEAD CORRECTED IF ROUGHNESS RESULTS REPLACE TYRES LEAD REVERSE DIRECTION INSTALL A KNOWN GOOD TYRE ON ONE FRONT SIDE LEAD CORRECTED REPLACE TYRE LEAD REMAINS INSTALL A KNOW GOOD TYRE INPLACE OF OTHER FRONT TYRE LEAD REMAINS KNOW GOOD TYRES ARE NOT GOOD Lead diagnosis PUT TYRES IN ORIGINAL POSITION AND CHECK ALIGNMENT 3 2 8GENERALDIAGNOSIS LEAD CORRECTED REPLACE TYRE ...

Page 68: ... Measuring tyre and or wheel runout will uneover only part of the problem An three causes known as loaded radial runout must be checked by using a tyre problem detector TPD If TPD in unavailable alternative method of substituting known good tyre and wheel assemblies on the problem vehicle can be used although it takes a longer time SUSPENSION MOVEMENT Loaded runout SMOOTH ROAD Causedby Tyre out of...

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Page 70: ...ding 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 3A 3 Preliminary checks prior to adjusting alignment 3A 3 Toe setting 3A 4 Checking alignment camber caster and kingpin inclination 3A 5 Turning radius 3A 5 3A ...

Page 71: ...e replaced Toe setting Toe is the turning in or out of the front wheels consists in steering the front wheels inwards convergence or outwards divergence Excesive toe in or toe out could accelerate tire wear Amount of toe can be obtained by substracting A from B as shown in above figure and therefore is given in mm Camber Camber is the tilting of the front wheels from thevertical as viewed from the...

Page 72: ...tness of alignment readings and alignment adjustments 1 Check all tires for proper inflaction pressures and approximately the same tread wear 2 Check for llose of ball joints Check tie rod ends if excessive looseness is noted it must be corrected before adjusting 3 Check for run out of wheels and tires 4 Check vehicle trim heights if out of limits and a correction is tobe made it must be made befo...

Page 73: ...r nuts 1 which fix tie rod ends 2 to the tie rod 3 connecting the wheels 7 Turn the tie rod 3 upwards to open the wheel front parts and downwards to close them correcting thus simultaneously lengths B and C Repeat this operation until the toe reaches a value between the maximum and minimum limits Minimum Maximum Toe value 8 Once adjusted tighten nuts 1 9 Move the vehicle to and fro a few meters wh...

Page 74: ...moved up and down a few times before inspection ALIGNMENT SERVICE DATA Camber 1º 30 Caster 3º Kingpin inclination 7º TURNING RADIUS If the tie rod 1 or its tie rod end have been substituted check if the steering wheel rotation is the same for both moving sides left and right Then check the turning radius using gauge 2 Turning radius 7 3 m NOTE When the tie rod 1 is substituted be respectful with t...

Page 75: ... end ball joints 3B 4 Tie rods 3B 6 SERVOSTEERING BOX 3B 7 Dismantling and assembly 3B 7 SERVOSTEERING PUMP 3B 9 Removal and installation 3B 9 ON VEHICLE SERVICE 3B 10 Steering wheel inspection 3B 10 Steering force inspection 3B 10 Power steering fluid leakage inspection 3B 11 Power steering hydraulic oil filter substitution 3B 11 Inspection power steering fluid level 3B 11 Air bleeding and steeri...

Page 76: ...ubstitution I n t e r m i t t e n t Stiffness of the servo steering Distribution valve dirty Faulty operation of the pressure pump Not enough oil Oil dirty Authorized dealer revision Authorized dealer revision Refill Change oil Oil Leaks Faulty retention rings or assembly deficiencies Authorized dealer revision Stiff Servo steering Faulty operation of the pressure pump Authorized dealer revision T...

Page 77: ... 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 1 Power steering pump 2 Steering gear box 3 Oil tank 1 Power steering gear box 2 Control valve section 3 Power steering pump 4 Oil tank 1 3 2 1 2 3 4 ...

Page 78: ...in drag rod end ball joint 6 Withdraw tie 7 Before separating in drag rod end ball joints from the rods annotate the distance x between centres of in drag rod end ball joints Such length must be kept when assembling the new in drag rod end ball joints 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 ro...

Page 79: ...dify distance x between in drag rod end ball joints centres acting on rod 4 Once the steering wheel positioning is correct tighten nuts 5 to the specified torque and check that steering wheel rotates in the same proportion to the right and to the left Tightening torque for nuts fixing positioning rod 7 8Kg m 70 80Nm 2 Squeeze the internal spring of the floating axle of in drag rod endball joint us...

Page 80: ...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 3 Check convergence of wheels and carry out the appropriate adjustments see 3A 4 ...

Page 81: ...t front wheel see 3F 4 4 Disconnect steering lower shaft 7 from its connection to the steering gear box 6 5 Disconnect from steering gear box the pressure hose 1 and the return hose 2 beforehand place under it an appropriate container to drip the liquid at the hydraulic circuit 6 Remove power steering liquid tank 3 7 Take away clamp 4 of the tank 8 Remove the generator see 6A 52 CAUTION Protect wi...

Page 82: ...ank 3 4Kg m 30 40Nm Nutsfixingjointstocams 4Kg m 40Nm 6 Install steering lower shaft and fix its nut to the specified torque Tightening torque nut connecting shaft to the power steering gear box axle 2 3Kg m 20 30Nm 7 Install left front wheel lower the vehicle and follow the sequence show in the figure to tighten fixing nuts to the specified torque Tightening torque for nuts fixing wheels 11 17 Kg...

Page 83: ... CAUTION Protect with appropriate caps the air water and hydraulic circuit ducts as they are open during the dismantling Intake of foreign bodies trough these ducts could seriously damage the corresponding component 4 2 3 1 5 Installation NOTE Clean carefully the areas around the couplings of the pump linkages and fittings with the group of auxiliary devices Assemble new O ring brake washers and p...

Page 84: ...Check for looseness or rattling of the steering wheel by moving it in the axle direction and sideways POWER STEERING FORCE INSPECTION 1 Put the vehicle on a levelled place and the steering wheel in the straightforward direction 2 Check if tyres pressure is correct 3 Start engine and leave it running till power steering oil reach 50 to 60 C temperature If it is necessary turn steering wheel both si...

Page 85: ...Inspect visually if there are any leaks in the hydraulic pump the liquid tank hose connections or power steering gear box CAUTION Do not keep the steering wheel turned at the maximum position for more than 10 seconds POWER STEERING HYDRAULIC OIL FILTER SUBSTITUTION 1 To substitute hydraulic oil filter see 0B 25 INSPECTION STEERING FLUID LEVEL 1 To adjust hydraulic oil level see 0B 26 ...

Page 86: ...Connect the oil return hose to the tank and fill again till the specified level see 0B 26 NOTE Always use new fresh recommend hydraulic oil 6 Start the engine and turn the steering wheel several times fully in both directions till and add oil till the specified level CAUTION Do not keep the steering wheel turned at the maximum position for more than 10 seconds NOTE Uncompleted air purging will ent...

Page 87: ...e of its course let the engine to idle speed and check that the hydraulic pressure corresponds to the specified one Back pressure than 10 Kg cm2 6 If higher than the indicated value check for possible blockages in the control valve or in pipes Relief pressure check Checking at pump 7 Increase engine speed till about 1500 rpm 8 Close slowly the manometer valve while reading with it the pressure inc...

Page 88: ...ic pump have been successful check worthiness of the power steering gear box as explained below 11 Open completely the manometer valve and increase the engine speed till about 1500 rpm 12 Turn fully the steering wheel leftwards and rightwards The maximum pressure should be the stated value Maximum pressure 60 80 Kg cm2 13 If the reading is lower probably there is a failure in the mechanism of the ...

Page 89: ...r box fixing screw Fixing screw from steering lower shaft to the steering gear box Hydraulic Oil inlet connector to pump Pressurized oil outlet connector to pump 40 70 80 110 170 ELEMENT TORQUE Kg m Nm Hydraulic pump fixing nuts 3 5 Pressure inlet connector to power steering gear box Return oil connector to the tank 35 DENOMINATION DATA Steering wheel play 10 30 mm Power steering handling force 5 ...

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Page 91: ...ing reassembling the specified torques must be strictly applied to be sure of the correct clamping of the different parts To diagnostic failures on the different components which could bring about anomalous behaviours of the general steering system see carefully CHART OF GENERAL DIAGNOSTICS 3 2 2 CONTENT GENERAL DESCRIPTION 3C 2 ON VEHICLE SERVICE 3C 3 Steering wheel 3C 3 Steering wheel reposition...

Page 92: ...ques 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 1 Steering wheel 2 Steering wheel cover 3 Steering column assembly 4 Steering lower shaft 5 Steering ...

Page 93: ...eering wheel is going to be dismantled and put back again 4 Remove steering wheel using an appropriate extractor Installation 1 Install steering wheel over the column aligning the coincidental marks A which you did when dismantling 2 Tighten not 2 from steering column to the specified torque Tightening torque for the fixing nut of the steering wheel 2 5 4 Kg m 25 40 Nm 3 Install steering wheel cov...

Page 94: ... 2 With wheels straightened as indicated above dismantle the steering wheel and adjust it in the correct position without tightening nut 2 completely 3 Run straightforward the vehicle for a short distance to confirm the correct positioning of the steering wheel If the trial is satisfactory tighten fixing nut 2 to the tightening torque below specified and assemble cover 1 If during the trial you ob...

Page 95: ...move upper cover 1 and lower cover 2 of the steering 4 Disconnect the lights switch and wind screen wiper switch couplers 3 5 Remove combination switch unit 4 and the wind wiper switch set 5 Installation 1 To assembly combination switch invert the dismantling sequences noting the tightening torques and the specified observations in the complementary tasks 3 1 2 4 5 ...

Page 96: ...ove 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 5 Turn ignition switch to position 1ª to disengage the steering lock assembly and remove the ignition key assembly 3 3 3 1 2 ...

Page 97: ...it in this form the steering lock assembly is activated 4 Align hub of the steering lock assembly and turn the steering shaft to check it get properly engaged 5 Fix the ignition switch to assembly 3 using slave screw 2 tightening it to the specified torque Tightening torque of slave screw 1 3 1 5 Kg m 13 15 Nm 6 Connect coupler 1 to the instrument panel wiring connector 7 Assemble the other compon...

Page 98: ...seembly see 3C 6 4 Remove upper cover 1 fixing steering lower shaft 2 to the body Installation 1 Revise worthiness of dust cover 7 and closing joint 8 to dashboard and replacing it if worn out etc 5 Remove bolts 3 fixing steering column 2 to lower support 4 6 Remove nut 5 connecting steering column 2 and steering lower shaft 6 Take them away 7 Remove steering lower shaft from the engine compartmen...

Page 99: ... and original connecting screw 5 4 Fix the steering column in its lower end tightening to the specified torque Tightening torque for screws fixing the lower end of the steering column 1 8 2 8 Kg m 18 28 Nm 2 1 6 5 A 5 Install upper fixing support 1 of steering lower shaft to the body and fix it with the appropriate screws tightened to the specified torque Tightening torque of upper fixing screws o...

Page 100: ... Remove steering lower shaft Installation 1 Fit steering lower shaft 3 till the bottom of the box till 2 Connect steering lower shaft 3 in the threaded end of the steering column 3 Install screw joining lower shaft to the steering box tightening to the specified torque Tightening torque of the screw joining lower shaft to the box 2 3 Kg m 20 30 Nm 4 Install bolt 1 joining lower shaft to steering c...

Page 101: ...e 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 If it is found to be shorter substitute the steering lower shaft for a new one Lower limited length 345 mm 2 Verify steering column and check for damages or deformations in the assembly 345 mm ...

Page 102: ...the steering lower shaft Screws fixing lower shaft to the steering box Slave screw fixing the steering lock assembly ELEMENT TORQUE Kg m Nm 2 5 4 25 40 CONCEPT DATA Lower length limit of the lower shaft 345 mm 2 3 20 30 2 3 20 30 1 3 1 5 13 15 Upper screw fixing steering column to the body Lower screw fixing steering column to the body 1 8 2 8 18 28 1 8 2 8 18 28 ...

Page 103: ...se replacement part of lesser quality Or substitute design during the reassembling keep strictly to the specified torques to ensure the correct hold up of the different parts Never attempt to heat quench or straighten any front suspension part Replace it a new part or damage to the part may result CONTENT GENERAL DESCRIPTION 3D 2 ON VEHICLE SERVICE 3D 3 Front leaf springs and shock absorbers 3D 3 ...

Page 104: ...PENSION 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 GENERAL DESCRIPTION 10 3 8 9 2 1 6 4 7 5 ...

Page 105: ...e front part of the vehicle and lift it till front wheel is loose 6 Remove nuts 8 from U bolt 9 and withdraw fixing spring seat 10 1 2 4 3 4 2 5 6 7 6 7 8 10 9 7 Remove bolts counter nuts 11 which ensure the bolts tightening on shackle plates 12 8 Bring down the vehicle till the wheels rest on the ground and springs lose contact with axle 9 Loose screws 11 connecting twin plates to shackle and rem...

Page 106: ... 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 14 13 14 13 12 11 ...

Page 107: ...U bolts 7 Kg m 70 Nm 16 Bring down the vehicle till wheels rest on the ground and take away the hydraulic lifting device 17 Tighten to specified torque bolts and nuts fixing spring front and back ends Tightening torque for bolts and nuts 9 5 Kg m 95 Nm Dampers installation 18 Fix the upper of shock absorber 3 with silent blocks 4 and top washes 2 install nut 1 without tightening 15 16 19 Fix the l...

Page 108: ...ydraulic 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 SPRING BUMBPER 1 If it is necessary to substitute some spring bumper remove fixing screws 1 and withdraw top 2 Check that tops are not unstuck cracked deformed etc otherwise change ensemble for another new one 3 Install spring bu...

Page 109: ...r hardness is different in each part of the course being higher in the extending course 6 Check that leaf spring free height is as the specified one Front leaf spring free height 120 mm 7 If leaf spring free height is lower than this value check if leaf spring is sound and there are no breakings neither wear If it is sound then try to get back the right value sending it to a qualified centre other...

Page 110: ...SPENSION TIGHTENING TORQUE SPECIFICATIONS DATA AND ASSEMBLY TOLERANCES Bolts and bolt nuts 9 5 Nuts of U bolts 7 95 70 ELEMENTS TORQUE Kg m Nm CONCEPT DATA Front leaf spring free height semi elliptic spring 120 mm ...

Page 111: ...re 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 Do not use replacement part of lesser quality or susbstitute design Torque values must be used as specified during reassembly to assure proper re...

Page 112: ...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 9 3 7 8 2 6 4 5 1 ...

Page 113: ...unter nut 5 fixing shock absorber 3 to rear shaft housing remove washers 6 and rubber 7 4 Remove shock absorber 3 Leaf springs removal 5 Remove leaf springs as same front leaf springs see 3D 3 Components check 6 Check if the removed components are in good condition and do not show wear or breakage If found defective replace Leaf spring installation 7 Reverse removal procedures noting tighten to sp...

Page 114: ...ame 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 absorber to rear shaft housing and tighten to specified torque Tightening torque for nut fixing the shock absorber 4 6 Kg m 40 60 Nm 3 6 7 5 6 10 Install bumpers 4 on 11 Fix sh...

Page 115: ...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 Darts free 190 ...

Page 116: ...ARSUSPENSION TIGHTENING TORQUE ESPECIFICATIONS ASSEMBLY DATA AND TOLERANCES Shock absorber lower fixing nuts 4 6 40 60 ELEMENT TORQUE Kg m Nm CONCEPT DATA Leaf spring free height semi elliptical spring 190 mm ...

Page 117: ...arts 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 Do not use a replacement part of lesser quality or substitute design Torque valves must bu used as spedified during reassemply to assure proper retention of al parts There is to be no w...

Page 118: ...vehicle ground clearance and tire or snow chain clearence to the body and chassis NOTE Do not mix different tupes of tires on the same vehicle such as radial bras belted tires except in emergencies because vehicle handling may be sectously affected and may result in loss of control It is recommended that new tires be installed in pairs on the same axle If necessary to replace only one tire it shou...

Page 119: ...rmal for tire pressure increase when the tires become hot during driving Do not bleed or reduce tire pressure after driving Bleeding reduces the Cold Inflation Pressure Higher than recommended pressure can cause 1 Hard ride 2 Tire bruising or carcass damage 3 Rapid tread wear at center of tire Lower than recommended pressure can cause 1 Tire squeal on turns 2 Hard steering 3 Rapid end uneven wear ...

Page 120: ...wheel lug nuts because the wheel life time could be shortened and induced damages in the components Installation 1 Reverse removal procedures and tighten nuts to specified torque follow the tightening order shown in figure to avoid bending of wheels or brake discs Tightening torque of wheel fixing nuts 11 17 Kg m 110 117Nm NOTE Before installing wheels remove eventual corrosion at the assembly sur...

Page 121: ...en to repair tires These instructions can be obtained from each tire manufaturer Installation 1 Install the wheel see 3F 4 noting the specified tightening torques and the tightening order NOTE The seats of the tyres on the rim must be adequately cleaned with a wire brush or rough steel wool to remove lubricant rubber remainders and rust Before install or removing a tyre adequate lubrication should...

Page 122: ... Dynamic balancing is the uniform distribution of on each side of the while center line in such a way that tires turnings does not imply lateral movement tendency Dynamically unbalanced wheels could lead to shimmy NOTE If any type of wheels unbalance is observed bring the vehicle to a specialized centre ADDCOUNTERBALANCES INTHESEPLACES COUNTERBALANCES CORRECTIVES L COFSCREW STAINSDARK VAGABONDAGE ...

Page 123: ...WHEELS AND TIRES 3F 7 TIGHTENING TORQUE SPECIFICATIONS Wheel nuts 11 17 110 170 ELEMENT TORQUE Kg m Nm ...

Page 124: ......

Page 125: ...FRONTANDREARPROPELLERSHAFT4 1 SECTION 4 FRONT AND REAR PROPELLER SHAFTS CONTENT FRONT DRIVE SHAFT 4A REAR DRIVE SHAFT 4B FRONT AND REAR PROPELLER SHAFT 4C 4 ...

Page 126: ...ads substitution 4A 9 Hemispheres oil seals substitution 4A 10 Front shaft housing substitution 4A 11 STEERING PIVOT AND WHEEL HUB ASSEMBLY 4A 12 General description 4A 12 Removal revision and installation of steering pivot and wheel hub assembly 4A 13 TIGHTENING TORQUE SPECIFICATIONS 4A 22 ASSEMBLY DATA TOLERANCES 4A 22 RECOMMENDEDPRODUCTS 4A 23 SPECIAL TOOL 4A 23 NOTE To diagnose failures of the...

Page 127: ...him inner 21 Speandle bearing 22 Outer spindle bearing 23 Oil seal 24 Retainer 25 Wheel center cap 26 Spindle nut 27 Washer 28 Washer GENERAL DESCRIPTION 3 2 11 1 9 4 8 6 12 4 13 7 5 10 15 14 18 17 25 23 26 16 24 19 28 22 21 20 27 1 King pin assembly 2 Oil seal 3 Oil seal 4 King pin bearing 5 Pitnan arm assembly 6 Steering knucle 7 O ring 8 Steering knucle 9 King pin shim ...

Page 128: ...t be kept away adequately do not allow it to be hanging from the brake sleeve 4 Remove fixing elements 3 of tie rod end joint 4 and disconnect it from its connection to the lower rotation axle cam To do this use tool A ref 600590 5 Remove fixing elements 5 connecting flange 6 of the hemisphere and flange 7 of the axle housing 6 Remove steering pivot assembly 8 formed by the rotation axles rotation...

Page 129: ...isphere flange Fixing elements 5 connecting bridles tightening torque 3 5 4 25 Kg m 35 42 5 Nm NOTE Install new self braking nuts in the flange unions Tighten to the specified tightening torque nut fixing tie rod end joint and block it with pins Nuts fixing ball and socket joints tightening torque 4 Kg m 40 Nm Apply recommended sealant to nuts fixing brake caliper and tighten them to the specified...

Page 130: ...erential group 1 2 3 Installation 1 Apply recommended sealant to coupling face of the differential group 3 with the front axle housing 2 Assemble the group and fix it using nuts 2 to the specified tightening torque NOTE Install new self braking nuts Tightening torque for nuts fixing group 3 5 4 25 Kg m 35 42 5 Nm 3 Install front transmission shaft and fix it using its screws and screws 5 to the sp...

Page 131: ...e shock absorber nuts 3 from connection to spring plates and disconnect shock absorber 5 Loose wheel nuts lift front part of the vehicle leaving both wheels suspended and the vehicle firmly anchored 6 Remove both front wheels 7 Remove screws 4 fixing brake caliper 5 and take it away together with the sleeve NOTE Do not press brake lever till putting back again the brake caliper While doing this ta...

Page 132: ...lling from the front part and moving it with its own wheels 6 5 7 Installation 1 To carry out front drive shaft assembly install reverse removal procedures noting followings remarks and tightening torques NOTE With leaf springs under tension move shaft housing to put in coincidence the screw head and its lodging within the axle housing Tighten nuts from bolts and bolts when the vehicle is fully re...

Page 133: ... 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 Tightening torque Screws nuts fixing transmission shaft 2 8 3 5 Kg m 28 35 Nm Nut fixing engaging pinion flange 11 75 Kg m 117 5 Nm 1 ...

Page 134: ...upport 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 110 117Nm 1 2 3 1 4 2 5 3 ...

Page 135: ...draw oil seal extension case and the oil seal 3 Install a new oil seal previously applying oil to the enclosing lip 4 Fix oil seal to extension case 2 tightening screws to the specified tightening torque Tightening torque for screws fixing oil seal plate of the hemisphere oil seal 0 8 1 1 Kg m 8 11 Nm 5 Install steering pivot assembly see 4A 3 1 2 ...

Page 136: ...bolts 1 and withdraw housing 2 3 Installation 1 Install a new housing and fix it with U bolts tightening nuts to the specified tightening torque Tightening torque for U bolts nuts 7Kg m 70 Nm 2 Install new oil seals 3 on the housing and apply grease into the enclosing lips 3 Continue install the differential group and steering pivots as indicated in complementary task 1 2 ...

Page 137: ... rotation axles upper and lower From the lower pivot goes the drive cam to which the connecting rod between wheels and the steering rod drive lower pivot of the right side front wheel are connected NOTE The repair can be done with the steering pivot ensemble fitted over the axle or taking it away previously as an independent ensemble in order to repair it 1 Steering pivot and wheel hub assembly 2 ...

Page 138: ...d screw it to support ref 192170 Removal 1 Remove or disconnect the following components the o adequate wheel Caliper Tie rod end see 4A 3 2 Dismantle hub cap 1 Hub and flange removal 3 Remove oil seal circlip 2 from rotating shaft and shim 3 4 Remove fixing screws 4 from the drive shaft flange 5 and take it away 5 Straighten wings of catching washer 7 6 Remove bushing nut and counter nut 6 using ...

Page 139: ...s 12 fixing the oil seal to extension case 13 take away extension case and oil seal 14 10 Straighten screw blocking plates 15 remove screws and withdraw upper rotation axle 16 with the adjustment plates the upper bearing will remain lodged into the hemisphere 14 13 12 16 15 11 Take away housing 17 lodging rotation axles joined to the rotation axle lower arm 19 and bearing 18 17 18 19 10 ...

Page 140: ...ion case 13 and oil seal 14 Taking apart revising and putting back again the pivot components and hub 1 Revise and substitute if necessary the followings hub components Oil seal 24 replace it each time a general repair is carried out Bearing and internal 23 and external 22 bearing seats replace them if they show pittings or wear If this is not so keep them in the original position Wheel fixing thr...

Page 141: ...r rotation axle 16 bearing 18 and bearing seats Substitute when wear pittings knocks or deformations are observed 4 If deemed necessary to substitute conical bearings of the hemisphere substitute the external bearing seats 30 using the appropriate soft material puller 5 Substitute oil seal 35 with the closing lip towards the hemisphere NOTE If you notice lack of pressure while installating bearing...

Page 142: ...pply a layer of the recommended sealant 3 Continue installation reverse removal procedures noting details and to specified tightening torques Hemisphere and rotation axle housing installation Before installating hemisphere 21 apply recommended grease to closing lip of the housing flange oil seal and to the hemisphere Put correctly oil seal 14 of the hemisphere and oil seal extension case 13 Instal...

Page 143: ...oduce housing 17 into hemisphere 21 install upper rotation axle 16 using plates of the original thickness and fix rotation axle using screws 15 to the specified tightening torque Tightening torque for screws fixing upper rotation axle 7 Kg m 70 Nm Rotation resistance check Using dial gauge A check that the rotation resistance or bearings preloading correspond to the specified value otherwise incre...

Page 144: ...d hubing centred using recommended grease Apply grease to constant velocity grease of drive shaft 11 install it on shaft and install the flange 10 with the cotter pin holder 36 upwards fix flange with screws 37 to the specified tightening torque Tightening torque for screws fixing flange 3 5 4 25 Kg m 35 42 5 Nm 37 10 36 11 17 Fit a hub 9 fixing it with cotter pin 8 and adjusting nut 6 fully tight...

Page 145: ...ed tightening torque using key C ref 161950 Tightening torque for counter nut fixing bushing 12 14 Kg m 120 140 Nm NOTE Once applied the final tightening torque to counter nut 38 check again the longitudinal play which must remain at the value 0 05 0 10 mm Ensure that coupling surfaces between flange and hub are clean Apply a coat of the recommended sealant in the coupling surface of the dragging ...

Page 146: ... hub and place dial gauge with the measuring tip touching the drive shaft end Measure the longitudinal play of the shaft axle which must be in agreement with the specified value otherwise substitute longitudinal adjusting washer 3 Longitudinal play of the half axle 0 12 0 25 mm Install hub cap with a new O ring Continue installation tie rod end brake caliper support brake caliper and wheels see 4A...

Page 147: ... the hemisphere Screws fixing the flange Hub counter nut Screws fixing lower and upper rotation axles 7 Screws Nuts fixing assy flange steering pivot or hemisphere Nut fixing engaging pinion flange 70 11 17 110 170 Screws fixing brake caliper support 6 5 7 5 65 75 9 5 7 95 70 3 5 4 25 35 42 5 0 8 1 1 8 11 3 5 4 25 35 42 5 12 14 120 140 3 5 4 25 35 42 5 ASSEMBLY DATA AND TOLERANCES CONCEPT DATA Res...

Page 148: ...LL AND SOCKETJOINTS EXTRACTOR REF 161950 WHEEL HUB KEY REF 192170 ROTATION AXLE HOLDER FOR BENCH REF PRODUCT TYPE POINT OF APPLICATION AGUILA 95 RECOMMENDED PRODUCTS Coupling faces Screw threadings TB 1215 LOCTITE573 Bearings and oil seals 790997 790998 790999 ...

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Page 150: ...p substitution 4B 7 Friction pads substitution 4B 8 Removal revision and installation of the wheel hub 4B 8 Rear shaft housing substitution 4B 9 TIGHTENING TORQUE SPECIFICATIONS 4B 12 ASSEMBLY DATA AND TOLERANCES 4B 12 RECOMMENDED SERVICE MATERIALS 4B 13 SPECIAL TOOL 4B 13 NOTE To diagnose failures of the different components leading to abnormal behaviour of the general steering system read carefu...

Page 151: ...sher catch 7 Driving flange 8 O ring 9 Circlip 10 Hub internal bearing 11 Hub external bearing 12 Oil seal 13 Rear shaft housing 14 Group fixing studs 15 Oil filling plug 16 Oil emptying plug 17 Rear shaft 18 Hub cap GENERAL DESCRIPTION 18 8 9 7 1 2 11 5 6 10 12 3 4 17 14 13 15 16 ...

Page 152: ...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 Install emptying plug applying recommended sealant in the thread 7 Remove nuts 6 and withdraw differential group 7 1 2 5 3 7 6 4 4 Remove rear propeller shaft see 4C 7 5 Remove screws 4 fixing driving flange 3 6 Remove at both sides as an assembly flange...

Page 153: ...l procedures noting the following steps Apply recommended sealant to the surfaces where driving flanges to hub and differential group to shaft housing meet Install new blocking washer and new self braking nuts Apply the specified tightening torques indicated in the complementary task Tightening torques Nuts fixing differential group 3 5 4 25 Kg m 35 42 5 Nm Screws fixing dragging flange 3 5 4 25 K...

Page 154: ...lanetary gear remove the rear shaft piece stuck inside as follows Remove the hub and flange assembly according to the broken rear shaft side see 4B 8 3 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 g...

Page 155: ...oting the followings steps Clean and wipe out residues from the contact surfaces between driving flange and hub and apply a layer of recommended sealant Install new blocking washers and new O rings to the hub cap Apply specified tightening torques and those indicated in the complementary tasks Tightening torque for screws fixing dragging flanges 3 5 4 25 Kg m 35 42 5 Nm ...

Page 156: ... shows excessive wear in the oil seal closing area replace it 2 Lubricate lip of the new oil seal with recommended grease 3 Install oil seal 2 with the lip towards the interior of the group and the back part levelled with the housing face 6 4 Continue installation reversing removal procedures applying the specified tightening torques Tightening torques Nut 4 fixing flange 14 20 Kg m 140 200 N m Fi...

Page 157: ...fixing driving flange 1 2 Remove as an assembly flange 1 and rear shaft 3 3 Remove according wheel and ensure that the vehicle is perfectly wedged 4 Carry out remove revision and installation of hub following the same procedure indicated for the front hub see 4A 13 NOTE Take care of applying the recommended sealant in the contacting surfaces of flange and driving flange Apply the specified tighten...

Page 158: ...ng the task 4 Strangle brake sleeve 1 using a Girling calipers A ref 191661 NOTE Strangling of the brake sleeve A is made to avoid the total loss of brake liquid when brake clamps are dismantled and consequently to have to carry out a complete purging of the circuit 1 5 6 5 Disconnect both shock absorber 5 from its connection to the axle housing 6 Disconnect the rigid pipes 6 from its connection t...

Page 159: ...aces of the differential group driving flange hub flange clamp and flange support of the flange housing for spindle apply while install a layer of recommended sealant Apply specified tightening torques and those indicated in the complementary tasks 12 9 11 8 Disconnect T connection 8 and support 7 used for the connection of the compensating braking spring and push apart adequately all the disconne...

Page 160: ...n 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 Nuts fixing lower part of shock absorber 4 6 Kg m 40 60 N m Screws fixing brake caliper support 6 5 7 5 Kg m 65 75 Nm Screws fixing driving flange 3 5 4 25 Kg m 35 42 5 Nm Nuts fixing wheel 11 17 Kg m 110 170Nm 1 A ...

Page 161: ... Fixing elements of the propeller shaft 2 8 3 5 Nuts fixing spring u bolt 28 35 Nut fixing engaging pinion group flange Screws fixing driving flange Nut fixing shock absorber to housing 11 17 110 170 Screws fixing caliper support 6 5 7 5 65 75 7 70 3 5 4 25 35 42 5 14 20 140 200 3 5 4 25 35 42 5 ASSEMBLY DATA AND TOLERANCES CONCEPT DATA Longitudinal hub play 0 05 0 10 mm 4 6 40 60 ...

Page 162: ...ARDRIVESHAFT4B 13 SPECIAL TOOL REF 191661 GIRLINGCLAMP REF 161950 WHEEL HUB KEY REF PRODUCT TYPE APLICATION POINT TB 1215 RECOMMENDED SERVICE MATERIAL Coupling faces Screw thread LOCTITE573 790997 790998 ...

Page 163: ......

Page 164: ...S 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 4C 8 ASSEMBLY DATA AND TOLERANCES 4C 8 RECOMMENDED SERVICE MATERIALS 4C 8 4C ...

Page 165: ...afts 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 Cup 5 Gasket 6 Oil filter 7 Rear propeller shaft 8 Constant relocity 2 3 6 5 4 1 8 7 ...

Page 166: ...in a vice at a bench 2 Fit a dial gauge with its measuring tip on the axle grooves and move rotate the axle to find out the play between grooves Maximum play between grooves 0 10 mm NOTE If play between grooves is above the indicated maximum value change the whole propeller shaft Flange revision 3 Displace flange 3 to check longitudinally to detect possible radial play of the bearings or their lod...

Page 167: ...en change the whole propeller shaft Removal and repair 7 Before disconnecting axle from its connection to grooved shaft check the alignment mark you did If necessary make new alignment marks for installation to keep the original balancing 8 Unscrew the basket 1 and take away grooved shaft 2 from grooving axle 9 Dismantle circlip 4 fixing crosshead bearings 4 1 2 4 ...

Page 168: ...han previous ones been thus able to separate flange from the crosshead 16 Place needles in the bearings paths and apply a small amount of grease to keep them in place 17 Once the needles have been placed fill bearings till half with recommended grease 18 Install bearing on its lodging at the fork 19 Mount a new crosshead in the bearing and introduce it till the top 20 Install opposite bearing in s...

Page 169: ...d towards transfer box 2 Align the flanges marks which you did while removing and make coincident the four flange holes to mount fixing screws 7 Install new self braking nuts 8 tightening to the specified tightening torque Tightening torque for screws fixing flanges 2 8 3 5 Kg m 28 35 Nm 3 Tighten screws 9 fixing constant celocity joint to the specified tightening torque Tightening torque for nuts...

Page 170: ...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 Installation 1 Install rear propeller shaft as is done with the front propeller shaft see 4C 6 Tightening torque for nuts fixing propeller shaft 2 8 3 5 Kg m 28 35 Nm NOTE Install new self braking nuts ...

Page 171: ... propeller shafts TIGHTENING TORQUE SPECIFICATIONS Kg m Nm 2 8 3 5 28 35 CONCEPT DATA ASSEMBLY DATA AND TOLERANCES RECOMMENDED SERVICE MATERIALS Maximum play between shaft grooves and axle 0 10 mm REF PRODUCT TYPE APPLICATION POINT Crosshead bearing AGUILA 95 790999 ...

Page 172: ...5 3 Brake calliper assembly 5 4 Master cylinder assembly 5 5 Brake boostar depressor assembly Vacuum pump 5 6 Brake boostar assembly 5 7 LSPV assembly 5 8 DIAGNOSTICS 5 9 Road testing brakes 5 9 Brake fuel leaks 5 9 Substandard or contaminated brake fluid 5 9 Brakes diagnostis table 5 10 ON VEHICLE SERVICE 5 12 Brake pedal free height adjustment 5 12 Stop light switch adjusment 5 13 Pedal path rev...

Page 173: ...y substitution 5 25 Caliper assembly repair 5 26 Brake discs substitution 5 29 MASTER CYLINDER SUBSTITUTION 5 31 BRAKE BOOSTER INSPECTION 5 32 Vacuum brake substitution 5 32 Brake booster substitution 5 32 REMOVAL ISTALLATION AND ADJUSTMENT OF LSPV 5 33 TIGHTENING TORQUE SPECIFICATIONS 5 35 ASSEMBLY DATA AND TOLERANCES 5 35 REQUIRED SERVICE MATERIALS 5 36 ...

Page 174: ...ne 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 In this braking system brake disc are used at front and rear The parking brake system is mechanical It applies the braking force to the rear properller shaft through a drum type brake found in the outlet of trans...

Page 175: ... as damage to rubber components may result If any component is removed or line disconnected bleed the brake system Replacement pads in axle sets only The torque values specified are for dry unlubricated fasteners How the brake caliper works There are two types of caliper brakes in this vehicle the front one with two pistons and the rear one with a single piston They have one cylinder per piston th...

Page 176: ...this master cylinder Lubricate rubber parts with clean fresh brake fluid to ease assembly Do not use lubricated shop air on brake parts as demage to rebber components may result If any hidralulic component is removed or brake line disconnected bleed the brake system The torque values specified are for dry unlubricated fasteners Brake master cylinder running When the brake pedal is pressed the prim...

Page 177: ... 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 pedal is pressed control valve C closes the communication between the two chambers A and B and allows entrance of external air to chamber B This way all the generated vacuum pressure by the vacuum pump system gets into chamber A at the master cylinder side leading to the displacement towards this side of membrane D and pushing rod E which drives the brake master cylinder pistons helping thus...

Page 179: ...te Since the sensor spring is attracted by a relatively strong force the applied force to the pistons is greater and the hydraulic characteristic curve lies higher than formerly as seen in the figure below 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 hydrauli...

Page 180: ...g is necessary Fill reservoir with specified brake fluid SUBSTANDARD OR CONTAMINATED BRAKE FLUID Improper brake fluid mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components in the hydraulic system to deteriorate If primary piston cups are swollen then rubber parts have deteriorated This deterioration may also be evidenced by swollen wheel cylinder piston cups ...

Page 181: ...en LSPV connecting spring Faulty spring connectors Find out the location of the leaks and repair Clean or substitute Find out the reason and repair Repair or substitute Purge the system Revise or adjust Substitute Substitute Uneven tyres pressure Wheel alignment inadequately adjusted Unequal tyres in same axle Damaged pipes or brake hoses Faulty running of the brake calliper assembly Loosened susp...

Page 182: ...ing elements Substitute or tighten fixing elements Master cylinder pistons do not return back correctly Damaged or strangled pipes or hoses Wheel cylinder or brake caliper piston sticking Repair master cylinder Lookfordamagedsleevesor tubes and replace for new sleeves and or new steel tubes Repair as required Damaged or loose wheel bearing Excessive disc lateral run out Parallelism not within spec...

Page 183: ...erubbercapofbrakepedalsupportanddisconnect fork 5 from connection to pedal 6 Withdraw lung 4 dismantling nuts 6 fixing to pedal support 7 Check distance B of the fork length which must be within the specified values Fork adjustment length B 147 5 0 5 mm 8 Adjust length acting on the fork counter nut and fix position with counter nut 9 Reverse lung and master cylinder precedures noting the specifie...

Page 184: ...oring as shown in the figure Play A of the pedal in braking position 71 mm 4 If play is less than specification there could be two reasons Air is present in the brake system conductions and if this is so then purge the circuit see 5 17 There is maladjustment in brake pedal height If this is so adjust acting on the brake booster lung fork see 5 12 MASTER CYLINDER INSPECTION 1 Check for cracked mast...

Page 185: ...e readings in two points located at the border and at the centre of the brake disc with a dial gauge fixed to housing and with its measuring tip touching the disc Limit on brake disc deflection 0 15 mm NOTE When measuring check for looseness at wheel bearing 6 Install wheel see 3F 4 PAD INSPECTION 1 Inspect periodically thickness of pads according to 0B MAINTENANCE AND LUBRICACION 0B 21 and every ...

Page 186: ...heck 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 2 Adjust parking brake cable acting on the drum fork 2 and fixing it with the counter nut 1 Adjustment At the drum 1 Bring up brake drum shoes to the transmission till they friction with the brake drum acting on the tensioning screw 1 Then unscrew one tur...

Page 187: ... the vehicle 5 Lift partly the front carpet to accede to the parking brake cable tensioning mechanism located in the parking brake lever 6 Loose or tighten tensioning nut from parking brake cable to achieve the indicated maximum efficiency Parking brake maximum efficiency Point 7 of the ratchet 7 Install all components reversing removal procedures ...

Page 188: ...the other end introduced in an empty container 2 Press a few times the brake pedal and keeping it pressed loose purging screw 2 3 Keep pressed brake pedal till circuit lose pressure Circuit purging 1 Fill tank 3 with new brake fluid and keep it half full while purging 4 Fill tank 3 with new recommended fluid and keep it half full substitution of the fluid is carried out 5 Remove fluid through whee...

Page 189: ...bubbles disappear from hydraulic pipes 6 When bubbles stop coming press the brake pedal and keep it pressed tighten moderately purging screw 2 7 Assemble purging protection cap 4 8 Install pressure in the circuit and check for leaks 9 Carry out purging task in the rest of the wheels 10 Fill again the tank with new recommended fluid till the specified maximum level MAX NOTE Do no use again the repl...

Page 190: ...e brake pedal 4 Block hole with a finger and release gradually the brake pedal keeping it closed for about five seconds before pressing again the brake pedal 5 Repeat the former procedure till fluid comes out through the hole 6 Repeat again the procedure three times at least and connect pipe 2 7 Disconnect pipes 3 and 4 from the secondary side of front wheel 2 1 8 With holes blocked with the finge...

Page 191: ...leaks through the vacuum sleeve 2 Eventual blockage of depressor exit 1 or breakdown in it Eventual leaks in the brake booster 3 Eventual leaks in the vacuum tank 4 Locating leaks and breakdowns 4 Connect a vacuum meter to vacuum pump and carry out checking as explained in task 3 4 1 2 3 A 5 If it is no correct the depressor is faulty If it is right then do as follows Connect vacuum sleeve 2 to de...

Page 192: ...right the tank is faulty otherwise the sleeve is faulty 8 One the faulty component has been substituted check again the circuit if the reading is not right the brake booster is faulty too NOTE In practice to carry out a brake booster checking press slightly brake pedal till finding initial resistance engine off Keeping brake pedal in this position start engine and check that with the same pressure...

Page 193: ...touch painted surface immediately wipe fluid from paint and clean painted surface 4 Install new pipes or hose noting the following points Place correctly clips or braces Be sure that the hose is nor twisted neither trapped Be sure that the hose is no contact other parts which could lead to damaging rubbings Check hose and pipes under steering maximum rotation condition right and left If there are ...

Page 194: ... parking brake activating switch 3 Take away counter nut of the parking brake cable 4 Remove parking brake lever fixing screws 5 Remove pin and remove pin fixing cable to lever 6 Substitute lever for a new one 7 Install the other components reversing removal procedures 8 Once lever is fitted proceed to adjust the parking brake see 5 15 2 From lower part take away the retention clip and remove pin ...

Page 195: ... forcing hose 4 Substitute pads 3 by new ones 5 Install caliper 1 in support 2 and tighten screws to specified tightening torque Tightening torque for screws fixing clamp 3 1 3 5 Kg m 31 35 Nm 6 Install wheel and fit tightening nuts 7 Bring down the vehicle and tighten wheel fixing nuts to specified tightening in the sequence order shown in the figure Tightening torque for wheel nuts 11 17 Kg m 11...

Page 196: ... extract it 5 Substitute brake pads if necessary 6 Install a new brake caliper and fix it with screws to specified tightening torque Tightening torque for screws fixing brake clamp 3 1 3 5 Kg m 31 35 Nm 7 Install brake hose fixing it at the specified tightening torque and withdraw the strangulation Girling clamp Tightening torque for fixing brake sleeve to the brake clamp 2 2 5 Kg m 20 25 Nm 8 Onc...

Page 197: ...ushion 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 3 Remove dust cover 4 Remove oil seals 1 from pistons using a thin blade like a thickness gauge and paying attention no to damage the cylinders 1 ...

Page 198: ... pads could be caused by a faulty return of a piston In such a case change oil seals 7 Verify worthiness of cylinders and pistons in case they show wears scratches corrosion etc Substitute them if necessary 8 Ensure that the purge hose is not blocked NOTE To wash metallic parts use a solution of hot water and neutral detergent Cilindro RETEN Cilindro RETEN Pistón Pistón A B Cilindro sin presión Ci...

Page 199: ...on the pistons ensuring they stay positioned correctly as shown in the figure 12 Install piston with their corresponding cylinders and fix the dust cover clip in the cylinder internal channelling 13 Introduce thoroughly pistons and ensuring that the dust cover clip is lodged in the piston channelling Installation 14 Reverse removal procedures noting the specified tightening torques in the compleme...

Page 200: ...ke hose 4 3 A 1 3 Install a dial gauge fixing it to the axle housing and with measuring tip resting at about two millimetres approximately form the outer edge of the disc 4 Left brake disc rotate and check there is no a deflection higher than indicated Brake disc maximum deflection 0 15 mm 5 If deviation is higher proceed to mechanically rectify the brake disk without exceeding the service limit 6...

Page 201: ...in the brake disc replace it Brake disc thickness Front Rear 20 mm 10 mm 18 mm 9mm Standard Service limit Intallation 1 Align marks A you did under task 9 and fix the brake disc to hub tightening screws to specified tightening torque Tightening torque for nuts fixing brake disc 3 5 Kg m 35 Nm 2 Proceed to install hub and to its adjustment see 4A 13 3 Install support 2 of the brake caliper and cali...

Page 202: ... painted surfaces 2 Remove nuts fixing cylinder and take it away 3 Clean coupling area and fit a new master cylinder tightening the nuts to specified tightening torque Tightening torque for nuts fixing master cylinder 1 1 6 Kg m 10 16 Nm 4 Proceed to Install reversing removal procedure carry out the master cylinder purging see 5 19 5 Connect brake tubs 2 tighten linkages to the specified tightenin...

Page 203: ... 5 4 Withdraw lung 3 remove nuts 6 fixing to brake pedal support 5 Substitute brake booster lung by a new one Installation 1 On the new lung 3 adjust distance B by using fork 5 and fix the fork with their locknut This distance must agree with the one of the removed lung Fork adjusting distance B 147 5 0 05 mm 2 Continue installation reversing removal procedures the specified tightening torques Tig...

Page 204: ...port 4 5 Withdraw the LSPV assembly 1 spring 3 and its support 4 6 Disconnect spring 3 from the LSPV lever CAUTION Do not loose nor tighten any screws or nuts from the LSPV assembly indicated in the figure LSPV assembly must not be disassembled replace with new one if defective Installation 1 Install LSPV reversing removal procedures noting the following remarks and tightening torques Apply recomm...

Page 205: ...djust length L turning eccentrically head of screw 5 tighten afterwards nut 6 to specified tightening torque Tightening torque for nut fixing adjustment 1 8 2 8 Kg m 18 28 N m NOTE Check to make sure that LSPV body and brake pipes are free form fluid leakage Replace defective parts if any 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...

Page 206: ... assembly to framework 10 16 11 13 10 15 ELEMENT TORQUE Kg m Nm Screws fixing LSPV support spring 1 8 2 8 Screws fixing brake disc to hub LSPV valve purger 18 28 11 17 3 1 3 5 2 2 5 1 8 2 8 3 5 1 1 3 110 170 31 35 20 25 18 28 35 10 13 Linkages fixing brake pipes to LSPV 1 4 1 8 Nut fixing LSPV adjustment Linkages fixing brake pipes to master cylinder 14 18 1 8 2 8 1 4 1 8 18 28 14 18 Brake pedal h...

Page 207: ...5 36 BRAKES REF PRODUCT TYPE APPLICATION POINT REQUIRED SERVICE MATERIALS LSPV valve spring connection Grease AGUILA 95 Brake circuit 790999 791002 Líquid DOT 4 ...

Page 208: ...ENGINE6 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 6 ...

Page 209: ......

Page 210: ...SECTION 6 2 ENGINE GENERAL INFORMATION CONTENT GENERALDATA 6 2 2 Repair instructions and care 6 2 2 Engine identification 6 2 2 GENERALINFORMATIONABOUTTHEENGINE6 2 1 6 2 ...

Page 211: ...emove the engine parts place them in order in such a way that they can be put them back again easily when install In common rail engine high pressure pipes should be replaced after dismantling Flow limitler and the pressure limiter valve wich are installated on Rail can stand 5 fitting after wich it is necessary to replace them The following components do not accept repairing must be remove the as...

Page 212: ...on engine mechanical injection engine mechanical injection engine mechanical injection engine mechanical injection engine 6A 39 Removal and installation of flywheel Common rail engine Common rail engine Common rail engine Common rail engine Common rail engine 6A 42 Flywheel revision and ring gear substitution 6A 45 Bearing of gearbox primary axle removal 6A 46 Crankshaft oil seals substitution 6A ...

Page 213: ...mechanical rectifying 6A 120 Mechanical rectifying injectors seats 6A 121 Valves springs check 6A 121 Installation and adjustments of cylinder head 6A 123 Rear head installation 6A 123 Vvalves assembly installation 6A 123 Injector protruding valves head thickness and valveS impermeability control 6A 123 Valves installation 6A 125 Camshaft and front oil seal installation 6A 125 Check and adjustment...

Page 214: ...DOES NOT START Efficient terminals from battery Clean check tighten battery terminals nuts Efficient battery Efficient starting motor Checks as described at the SERVICE MANUAL under Electric System Checks as described at the SERVICE MANUAL under Electric System Efficient thermo start All right injection pump setting Correct substitute Check injection pump setting see 6A 33 YES 1 Normal running of ...

Page 215: ... supply circuit included tank Compression right Efficient fuel filters Check engine or keep to interventions over worn pieces Substitute Automatic advance exchanger and STOP device sound Control leaks and substitute faulty pieces Next NO NO NO NO NO NO ENGINE OVERHEATS EXCESSIVELY 2 ª Correct refrigeration fluid level Check possible leaks and keep level right Efficient water pump timing belt and f...

Page 216: ...ully and check for fluid leaks if necessary substitute Air filter and circuit pipes are efficient Correctsettingoftheinjectionpump Clean or substitute faulty pieces Check setting of the injection pump see 6A 33 Cylinder head gasket is efficient Substitute NO NO NO NO NO NO Fan is efficient Substitute NO Next YES YES YES YES YES YES ...

Page 217: ...nt thermostat Check and repair if necessary Substitute Efficient injection pump Efficient injectors Substitute Correct setting of the injection pump Checkinjectionpumpsetting see6A 33 NO NO NO NO NO NO Injection pump correctly adjusted Check and adjust injection pump at work bench NO Check running and adjust them correctly Next YES YES YES YES YES YES ...

Page 218: ...ute assembly Check NO NO NO ENGINE LETS OUT BLACK FUMES OR DARK GREY 4 ª Efficient air filter Substitute Efficient thermo start Automaticadvanceexchangeractcorrectly Check and substitute Check and substitute if necessary Efficient injectors Correctsettingoftheinjectionpump Check running NO NO NO NO NO Check setting of the injection pump See 6A 33 YES YES YES YES YES YES ...

Page 219: ...lean tank and substitute fuel filters NO NO NO NO ENGINE LETS OUT GREY FUMES WHITISH 5 ª Thermostart normal working Substitute Efficient injectors Correct setting of the injection pump Check running and adjustments as prescribed Check injection pump setting see 6A 33 Correct coolant fluid level Probable coolant fluid entrance to the combustion chamber substitute cylinder head gasket or revise engi...

Page 220: ...ngs covers and engine flywheel oil pressure Connecting rods knockings Pistons knockings Check play and oval shaping of the journal of connecting rod screws fixing connecting rods cover connecting rods aligning Substitute pieces or check Check play between pistons cylinders borings integrity of elastic piston rings play ofjournal bolts of pistons Substitute pieces or replace Cylinder head knockings...

Page 221: ... Fill tank and purge as described in section 0B MAINTENANCE AND LUBRICACION Efficient fuel filters Efficient fuel supply circuit Substitute Check circuit and carry out purging Ticking over normal Injection pump flow normal Adjust Injectionpumpdrivescorrect Substitute damaged pieces NO NO NO NO NO NO Check flow in the work bench Next YES YES YES YES YES YES YES ...

Page 222: ...uate viscosity Pressure regulating valve works all right Efficient oil pump and entrance pipes Check and if necessary substitute Efficient ball bearings of main bearing and connectingrod Substitute ball bearings and if necessary rectify crankshaft NO NO NO NO Check and if necessary substitute EXCESSIVE FUEL COMSUPTION 11 ª Efficienttankandfuelpipes Correct leaks and substitute damaged pieces NO Ef...

Page 223: ...orrect Check running and adjust Injection pump adjustment correct Efficient L D A device Check and adjust at work bench Correct setting of the injection pump Check injection pump setting see 6A 33 NO NO NO NO Adjust L D A device YES YES YES ...

Page 224: ... T D C pressure bar T D C minimum allowed pressure bar 18 5 3600 1800 20 2 6 16 E Exhaust A Admission Maximum rpm regime of engine without loading r p m 4200 50 Pressure value is read starting the engine using an auxiliary starting electric motor with oil at temperature between 40 and 50 C and pump set up in stop ID Direct Injection TCA Intercooler over supplying GENERAL CHARACTERISTICS MECHANICAL...

Page 225: ...ection mm Sprayer type BOSCH Injection Sequency injection pump engine Working pressure injectors During the control operations for values under 200 bar calibrate injectors at 230 8 bar 8º 37º 48º 8º 0 5 0 05 0 5 0 05 0 5 0 05 0 5 0 05 Rotative timing VER 6C All regimes K S B electro mechanical 1 10 0 05 SACLESS DSLA 134 P 604 A B C D 1 3 4 2 240 12 X X MECHANICAL INJECTION 8140 43C 3 COMMON RAIL 8...

Page 226: ...Thermostat Beginning opening Maximum opening OIL REFURBISHING Total Capacity 1st filling litres Capacity for periodical replacement oil pan litres oil pan filter litres MITSUBISHI TF0 HM 13 T 6 1 29 0 019 1 45 0 039 At pressure through gears pump valve limiting the pressure oil filter for double filtrering 0 8 3 5 Through centrifugal pump thermostat fan with electromagnetic clutch radiator heat ex...

Page 227: ...Fumes According to Normatives on limits of the exhaust fumes Limits fixed by Normatives CEE 72 306 and R 24 03 Maximum power grades opacimeter Bosch BSU 2 0 1 5 Maximum torque grades opacimeter Bosch BSU 2 5 2 5 Full load at 1000 r p m grades opacimeter Bosch BSU 3 5 3 5 AcousticEmissions Máximum acoustic level LPA of engines in standard configuration Measured according to ISO standard 3475 microp...

Page 228: ... Internal diameter Ø 2 Piston cylinder liners Diameter of pistons Ø 1 Position pistons block X Gudgeon pins Ø 3 Housing gudgeon pins 97 39 97 45 97 47 97 50 167 00 167 30 0 02 0 11 0 005 max 94 402 94 432 MONDIAL PISTON AND KS 10 94 306 94 320 32 003 32 009 0 082 0 126 0 4 0 40 0 80 31 990 31 996 0 003 0 015 Diameter to achieve in block for installation of liners provided for spare parts Size prov...

Page 229: ...g rod Ø 2 connecting rod supplied as spare parts Ø1 Bush diametre of connecting rod foot external Ø 4 internal Ø 3 Half ball bearings of connecting rod supplied as spare parts Bush of connecting rod foot housing Piston bush bolt Half ball bearings of connecting rod MONDIAL PISTON AND KS 2 200 2 230 2 050 2 070 2 540 2 560 2 068 2 097 1 970 1 995 2 470 2 490 0 103 0 162 0 055 0 100 0 050 0 090 0 4 ...

Page 230: ...ngs journal of main bearings Half ball bearings journal of main bearings Half ball bearings of main bearings Half ball bearings of connecting rod Journal of axial main bearings X1 Axial support of main bearing X2 Axial half ball bearings X3 Axial Support of crankshaft X3 0 09 80 182 80 208 86 182 86 208 56 515 56 538 2 165 2 174 1 875 1 884 84 588 84 614 90 588 90 614 0 032 0 102 0 035 0 083 0 254...

Page 231: ...at Ø 1 Ø 1 Ø 1 Linkage of valves and corresponding guide Ø ext of valves seats inclinat seats valves regard to cylinder head Ø 2 Ø 2 X X X a Ø 2 12 950 12 985 8 023 8 038 13 012 13 025 0 027 0 075 0 05 0 10 0 20 7 985 8 000 60º 15 7 30 7 985 8 000 45º 30 7 30 0 023 0 053 42 125 42 175 37 380 37 415 42 245 42 260 60º 5 37 495 37 510 45º 5 a a 1 2 1 5 1 0 1 3 Sinking Ø1 MECHANICAL INJECTION 8140 43C...

Page 232: ...6 4 1 H 1 Kg 30 1 5 H 2 X Coming out of injectors X Seats for connecting rods bush normal Ø oversized Ø Journal of camshaft support normal Ø oversized Ø Between seats and journal of support Housing of plungers in normal cylinder head Ø normal 0 070 0 135 0 080 0 130 52 38 5 28 5 45 5 33 5 23 5 2 230 2 690 33 985 34 015 34 185 34 215 33 934 33 950 34 134 34 150 0 035 0 081 44 000 44 025 MECHANICAL ...

Page 233: ... 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 4 ID TCA ...

Page 234: ... Higher than Undersize Less than Selection Classes Oversizes Temperature 0 ºC Cold Winter OF FORM Circularity Cylindricality Parallelism Perpendicularity Concentricity or coaxiality Circled Oscillations Total Oscillation OFORIENTATION OF LOCATION OF OSCILLATION CLASS ATRRIBUTED TO THE CHARACTERISTICS OF THE PRODUCT GRAPHIC SYMBOL TOLERANCES CHARACTERISTICS GRAPHIC SYMBOL CRITICAL IMPORTANT SECONDA...

Page 235: ... strictly procedures described for this frequency meter CHARACTERISTICS Instrument outline Belt frequency is measured using this checker The measure unit is the Hertz Hz Reading head A is constituted by two sensors a and b allowing the measurement of vibrations induced at the belt One of sensors takes the reading while the other located outside the measuring field is used as a reference see explan...

Page 236: ...eads of sensors a or b can be used industictly but remember that the other reference sensor must be out of measuring field NOTE Measure can be carried out either in face 1 or face 2 of belt 4 Take reading inducing vibrations on belt with one of your fingers as shown in figure The reading is correct when you hear a bip NOTE The two sensors must not be simultaneously in front of the belt during the ...

Page 237: ...an 3 withdraw it and air conduct 2 2 1 3 4 5 6 Loose screws or nuts 7 8 and 11 by one turn to free generator and tensor support 10 7 Untaught belt 6 loosening regulating screw 9 and take it away Installation 1 Put new belt 6 ensuring the correct path and coupling at pulleys 2 Taut slightly belt using screw 9 put back again previously loosened screws and nuts turn once the crankshaft and check for ...

Page 238: ...13 14 15 16 17 B Installation 1 Install the new belt 16 ensuring the correct coupling in the pulleys 2 Tension slightly the belt rotating the compressor towards outside get tighter screws and nuts previously loosened turn crankshaft by one turn and check the coupling of belt 3 Apply the specified tension to the belt and measure on point B centre of stretch using frequency meter ref 00000A01484 Fre...

Page 239: ...e position fit tool ref 790965 in hole 25 of organs group driving gear 24 in such a way that it fit in the hole of block located in front of gear hole 25 NOTE If the three control points are correct the engine is ready to take a new belt If one of them is not properly aligned this mean that the belt is too tight or badly placed You should ensure of coincidence in the three control points before in...

Page 240: ...ar 24 and flywheel 21 using tools C ref 790965 NOTE If these conditions are not fulfilled do a new setting of the timing belt 4 Install timing lower cover 26 tighten screws to the specified tightening torque Tightening torque of timing lower cover screw 0 75 Kg m 7 5 Nm Timing belt tension checking 5 Apply torque of 2 8 3 0 Kg m to crankshaft 34 in the rotating direction to put belt slightly tensi...

Page 241: ...electro magnetic pulley 8 remove nut 10 clockwise and remove hub 11 NOTE Nut 10 fixing hub threads left wise 10 Remove electromagnetic pulley 8 blocking washer 7 and washer 6 11 Removescrews 9 andwithdrawelectro magneticgasket 5 12 Move downwards circlip 18 and disconnect tube 19 from water pump moving it towards thermostat box 17 NOTE If you install Air Conditioner AA remove nut from compressor d...

Page 242: ...sor 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 0 75 Kg m 7 5 Nm Nuts at tube adapter at water pump inlet 2 5 Kg m 25 Nm Nuts sound proofing upper cover...

Page 243: ... Remove linkages 7 and withdraw fuel remaining pipe 8 6 Remove screws 5 remove fixing braces 4 and withdraw injectors 6 CAUTION Plug with appropriate caps the conductions which have been opened Entrance of some alien body in this conductions could seriously damage the injection system 2 3 4 5 8 7 6 Installation 1 Reverse removal procedures applying the specified tightening torque Tightening torque...

Page 244: ...fuel supply and return pipes Accelerator cable 5 Fuel injection rigid pipes 10 use recommended special key ref 790993 5 Turn crankshaft till mark A of camshaft gear is aligned with mark B of plungers lit In this position fit tool ref 790965 in hole 13 of the driving gear 12 and in hole at block placed in front of 13 it this is not possible turn the crankshaft two complete turn till aligning slowly...

Page 245: ...o extract hub Tightening torque for nut 17 of injecting pump grooved hub 8 Kg m 80 Nm Align marks to be found in the housing sump and in the auxiliary organs group housing if you are fitting the same pump Install nuts 18 fixing injecting pump without tighten too much 2 Inactivate K S B device 9 supplying tension from the vehicle during the setting up of pump NOTE The K S B device is inactivated wh...

Page 246: ...t to the right value Once this has been achieved tighten nuts fixing injecting pump applying the specified tightening torque To tighten lower nut use key ref 790997 Distributor piston of injecting pump course 1 10 0 05 mm Tightening torque for nuts fixing injecting pump 2 5 Kg m 25 Nm 7 Stop providing current to K S B device 8 Remove dial gauge D and adaptation tool C Install cap of pump closing s...

Page 247: ...ing any removal perfecty clean all components to remove or disconnect and its enviroment Removal 1 Disconnect negative cable at battery 2 Remove thermo starting valve fuel feed hose 1 3 Remove upper 2 and side 3 sound proof covers 4 Disconnect injectors couplers Injectors removal 5 Press clips 4 towards arrow direction and disconnect return pipe 6 form injectors and multiple connector 7 6 Remove h...

Page 248: ...llation 1 Install high pressure fue pump 25 and tighten nuts at spedified torque Tightening torque high pressure fuel pump nuts 2 5 kg m 25 Nm NOTE When replacing high pressure fuel pump coupling hub use the out rotation tool 99365143 to loosen the hub fitting nut To remove hub use tool 790991 2 Install hydraulic accumulator Rail 23 and tighten nuts at spedified torque Tightening torque hydraulic ...

Page 249: ...20 Nm NOTE If any repair is required on injectors high pressure pipes replace it as assembly 6 Install rail soundproof cover 15 and multiple connector 21 fixed by union nut 22 at valve 26 Tighten at specified torque Tightening torques Rail soundproof cover nuts 1 8 kg m 18 Nm Return multiple connector union nuts 2 7 kg m 27 Nm 7 Install pump return pipe 16 8 Connect return pipe 6 to multiple conne...

Page 250: ...on at the same time you press tool C Stop rotating the crankshaft when you notice that the tool fit in the milling of flywheel 2 When this is done check that marks A and B are perfectly aligned otherwise there is some belt stretching a bad fit ting of belt or an out phasing in the flywheel fitting 4 Unlock cap at the injection pump register fill adapter tool D ref 790966 and the dial gauge E NOTE ...

Page 251: ...chronising tool C remove flywheel 2 NOTE If oil leaks through the back oil seal from crankshaft are detected replace it see 6A 47 Installation 1 Align mark A of camshaft gear and mark B at lit Ensure that the dial gauge remain reading zero 2 Install flywheel placing its screws without tightening and centre flywheel using tool C ref 790965 in this position dial gauge in zero block flywheel from tur...

Page 252: ...6 and tighten them to the specified tightening torque Tightening torque for screws on plate for bearing support 1 8 2 8 Kg m 18 28 Nm 4 Install the r p m Sensor 8 adjusting it asspecifiedin6C 55 FUEL SUPPLY SYSTEM AND EXHAUST CONTROL 5 Withdraw tool blocking the flywheel and centring tool Dismantle adapter tool D and compactor E Assemble cover on register of injection pump tightening it moderately...

Page 253: ...rs 3 Remove generator and front bracket see 6A 59 4 Remove timing front upper cover 2 5 Remove Gear box assembly see a 7A 9 Pressure plate assembly and clutch disc see 7C 10 6 Lock flywheel rotation remove bolts 4 from input shaft bearing plate 3 of gear box and remove plate 7 Remove bolts 6 flywheel rotation lock tool and remove flywheel 5 NOTE If you see any oil leakage from crankshaft rear oil ...

Page 254: ...to align mark A on camshaft timing belt pulley With mark B on plungers cover Then insert special tool 790965 into camshaft hole 8 on driving gear 7 and into block hole placed in front of 8 if it is not possible slowly rotate crankshaft two complete turns until align marks A and B Without moving the crankshaft insert special tool C 790965 into flywheel cover synchronization hole rotate flywheel as ...

Page 255: ... with installation noting to tighten at specified torque 7 Check sensor clearance 9 To adjust it act on bolts 10 and bracket 11 Clearance between sensor and flywheel face 0 8 1 5 mm 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 3 4 9 10 11 ...

Page 256: ...e for scratches or ridges it any replace flywheel 2 Installation 1 Clean gear ring contact surface 2 Heat new gear ring 1 to about 150 ºC for 15 20 WARNING Protect hands using gloves during gear ring installation 3 Install gear ring on flywheel facing inner beveled diameter towards inside and fit ring to the end of flywheel 4 Go on with installation reversing removal procedure noting to tighten to...

Page 257: ...move screws 2 and remove bearing support plate 1 Bearing replacement 4 Substitute bearing 3 using a hydraulic press A and an appropriate extractor B Installation 1 Proceed to install reversing removal procedures apply specified tightening torque and those indicated in complementary tasks Tightening torque for screws of bearing support plate 1 8 2 8 Kg m 18 28 Nm 3 A B 3 A B DISMANTLING ASSEMBLY 1 ...

Page 258: ...ghtening torque and withdraw the wedge 2 Tightening torque for screws 3 from rear cover oil seal 2 5 Kg m 25 Nm 4 Continue installation reversing the removal procedures and applying the tightening torque specified in the complementary tasks Crankshaft front oil seal substitution Removal 1 Remove timing belt see 6A 28 2 Remove screws 8 and withdraw assembly cover oil seal 6 Installation 1 In Points...

Page 259: ...ver oil seal assembly 3 on cylinder head fix screws 5 to the specified tightening torque and withdraw oil seal guiding wedge Tightening torque for screws on cover oil seal assembly 0 75 Kg m 7 5 Nm 5 Continue installation reversing removal procedures apply specified tightening torque to screws of camshaft driving gear and those indicated in the complementary tasks Tightening torque screws of camsh...

Page 260: ... the two valves of each cylinder proceeding from cylinder to cylinder 1 Use the appropriate tool on the crankshaft pulley screw to be able to turn it NOTE If the cylinder head us removed apply tool A ref 790970 on flange of camshaft driving gear to be able to turn it 2 Turn camshaft using the crankshaft engine on the vehicle or directly using on the camshaft tool A cylinder head dismantled till ac...

Page 261: ...ust be closed as explained in task 2nd of the Check With cylinder head assembled the nose of cylinder admission connecting rod being adjusted must stay approximately upwards Under these conditions the piston is about 10 13 mm of the T D C avoiding thus valves hitting the piston in the tasks heredown described FRONT LOCATION OF VALVES IN THE CYLINDER HEAD E EXHAUST A ADMISSION EA EA EA EA 1 2 3 4 1...

Page 262: ...the valves play measured under Checking select a new regulating plate to adjust the valves play to the specified value Valves play admission and exhaust 0 5 0 05 mm NOTE The plates for adjustment of valves play are supplied by the Spare Pieces Department the following thickness 3 25 3 30 3 35 3 40 3 45 3 50 3 55 3 60 3 65 3 70 3 72 3 75 3 77 3 80 3 82 3 85 3 87 3 90 3 92 3 95 3 97 4 00 4 05 4 10 4...

Page 263: ...or 9 and position adjust the clearence to the specified measure with nuts 10 and support 11 common rail engine common rail engine common rail engine common rail engine common rail engine NOTE When install maintain the parallelism betwen sensor and inside surface of pulley Clearence between sensor and camshaft pulley 0 8 1 5 mm 11 Install upper soundproof cover with its nuts tighten moderaty Tighte...

Page 264: ...l injection engine engine engine engine engine Thermometric switch K S B power supply 11 Union nut and pressure pipe 6 of L D A device Clamp and fuel return hose 7 6 Disconnect or remove all engines all engines all engines all engines all engines Oil filler bracket nut 4 Heat exchanger water return hose 9 and pipe bolt 5 Oil condenser bolt 10 and oil condenser 12 Oil steam recirculation hose brack...

Page 265: ...e inlet 25 to turbocharger from connection to thermocompressor and to cylinders block Turbocharger oil draining pipes 32 fromturbochargerand from cylinders block Thermal screen 28 Antisquake to exhaust manifold screw connection 30 Nuts 23 connectiing exhaust manifold 24 to cylinder head 8 Remove assemblyexhaustmanifoldandturbocharger 26 NOTE If cylinder head is going to be repaired or replaced rem...

Page 266: ...6A 93 and 6A 116 1 Proceed to installation reversing removal and keeping in mind the following remarks Verify that piston n 1 is in T D C of compressure period sincronizingpositionofflywheel 44 withtool C ref 790965 as shown and hole 48 of crankshaft driving pinion 47 looking downwards Verify that faces of coupling contact of cylinder head and cylinders block are clean Select appropriated thicknes...

Page 267: ...d put screws and tighten them to the specified tightening torque as specified follow the prescribed order indicated in the drawing Tightening torque for screws of cylinder head 1st phase pretighten 6 0 5 Kg m 60 5 Nm 2nd phase recheck torque of 6 0 5 Kg m 60 5 Nm 3rd phase angular tightening 180º 10º ALTO TIGHTENING SEQUENTIAL ORDER 1 2 3 7 15 17 5 8 13 18 21 11 10 20 22 14 12 6 4 9 16 19 A B 35 I...

Page 268: ...or and inside surface of pulley Clearance between sensor and camshaft pulley 0 8 1 5 mm Install news Rubber gasket Connection tube circlips of thermostate box and water pump Not reusable clamps Autoblocking washer Components danger High pressure of fuel pipes common rail engine common rail engine common rail engine common rail engine common rail engine 2 Continue installation reverse removal proce...

Page 269: ... of metallic fastening belts to exhaust manifold 3 5 Kg m 35 Nm Screws connecting linkages of turbocharger oil draining tube 2 5 Kg m 25 Nm Nut fixing support the spout of oil filler 1 8 Kg m 18 Nm L D A high pressure racord 1Kg m 10 Nm mechanical injection engine mechanical injection engine mechanical injection engine mechanical injection engine mechanical injection engine ...

Page 270: ...support 5 should be removed when the required tasks warrant the need of remove the timing upper cover A 6 If there is play or abnormal noises on rotation of roller 8 replace it Installation 1 Reverse removal procedures apply the specified tightening torques and those specified in the complementary tasks Tightening torque for screw 7 of front support 5 Kg m 50 Nm 2 For installation of driving belt ...

Page 271: ...ing belt 5 see 6A 27 6 Remove screws 2 and 4 and withdraw air conditioning compressor 3 Installation 1 Reverse removal procedures apply the specified tightening torques and those specified in the complementary tasks 2 Tighten moderately linkages of gas compressor inlet and outlet pipes 3 For installation of compressor belt as well as for applying the tightening torques to the screws fixing compres...

Page 272: ...isconnect 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 Tightening torque for nuts 1 of starting motor 4 1 Kg m 41 Nm 2 1 ...

Page 273: ...oil draining from connection to it and to cylinders block Thermal screen 3 Screws 11 of connection exhaust coll to cylinder head Screw 12 connecting takeaway of metallic fastening belts to exhaust manifold 1 2 5 Remove assembly exhaust manifold 10 and turbocharger 5 Withdraw gaskets closing between manifold and cylinder head 6 Remove nuts 15 fixing exhaust manifold to turbocharger take apart both ...

Page 274: ...urbocompressor and colector 2 5 Kg m 25 Nm Continue assembly applying specified tightening torques CAUTION Before fitting greasing tube charge turbocompressor with engine oil Tightening torques Nuts of exhaust collector 2 5 Kg m 25 Nm Linkages at compressor oil inlet tube 2 5 Kg m 25 Nm Oil pressure interruptor switch 4 Kg m 40 Nm Oil pressure interruptor switch 8 Kg m 80 Nm Screws of connection e...

Page 275: ... hydraulic circuits holes while they keep appearing during dismantling because the entry of alien bodies in the conductions could seriously damage the component in question Assembly NOTE Clean carefully touching contact areas of pumps linkages and lodgings in auxiliary organs group 1 Proceed to assemble reversing the dismantling order paying attention to the following tasks Assemble the new imperm...

Page 276: ...h dragging gasket 5 and impermeability gasket Assembly 1 Clean the coupling contact areas between the vacuum pump and the auxiliary organs group Fit a new impermeabilizing gasket on the pump lodging and place vacuum pump with dragging gasket 2 Assemble fixing screws and tighten them to the specified tightening torque Tightening torque for screws fixing vacuum pump M8 1 8 Kg m 18 Nm M6 1 2 Kg m 12 ...

Page 277: ...A 59 2 Desmonte la bomba inyectora refiérase a 6A 36 motor motor motor motor motor de inyeccion mecanica de inyeccion mecanica de inyeccion mecanica de inyeccion mecanica de inyeccion mecanica 3 Desmonte la bomba de alta presión de combustible refiéra se a 6A 36 motor common rail motor common rail motor common rail motor common rail motor common rail 4 Dismantle driving belt of the timing see 6A 2...

Page 278: ... belts to heat exchanger 2 5 Kg m 25 Nm Continue assembly reversing the previously applied dismantling order apply the specified tightening torques and those specified in the complementary tasks Tightening torques Linkage sleeve of oil outlet 3 3 4 Kg m 30 40 Nm Linkage oil inlet tube 4 3 4 Kg m 30 40 Nm NOTE Ensure that synchronization between connecting rodshaft and crankshaft is still the adequ...

Page 279: ...ype SAE 30 Oil inlet temperature 115 C Oil flow 30 l min Water inlet temperature 85 C Water flow 20 l min Deliveries Heat quantity exchanged 4 5 Kw Oil pressure depression 0 85 bar Openingpressuresafetyvalve 0 82 1 03 bar Assembly 1 Clean carefully coupling contact areas of the heat exchanger in support 5 and oil tubings 2 Fit the new thermal gaskets 6 on heat exchanger 3 Then fix heat exchanger t...

Page 280: ... a double filtering effect special device 1 Lubrify with engine oil oil seals 3 and ensure that they are perfectly tight in the lodgings of filter 2 Screw filter by hand till being sure oil seals 3 contact with closing surface in support 3 Using key A ref 790972 apply to filter specified tightening torque Tightening torque for the oil filter 2 5 Kg m 25 Nm 2 1 A 3 NOTA Para el cambio de aceite del...

Page 281: ... on support A ref 790973 and fix ensemble in a work bench 5 2 With tool B ref 790972 dismantle oil filter 1 3 Dismantle screw 2 and withdraw heat exchanger 3 with its own gaskets 4 Dismantle the linking adaptor 6 holding oil filter support 7 and 8 of the heat exchanger 5 Dismantle vacuum pump 9 with dragging adaptor 10 and impermeabilizing gasket 6 Dismantle back cover and oil pressure regulating ...

Page 282: ... broken cracked or loose 11 Check resistance and length of valve spring 19 according to specifications given in the drawing 12 Install valve spring and cap applying to it specified tightening torque Tightening torque for cap 18 of valve 6 5 kg m 65 Nm Removal and revision of gears 13 With ruler B and thickness calliper C check play between upper plane 21 of gears and upper plane of support of cove...

Page 283: ...il 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 22 23 24 D 25 26 ...

Page 284: ...ce done control height between upper plane of gear 25 and external plane of gear 27 end of axle 26 Height between external plane of gear 25 and 27 88 0 2 mm 2 Check torque of resistance to rotation between gear 25 and axle 26 of oil pump as follows Fit tool E ref 790974 to avoid turnings at the gear 25 Draw two reference signals F aligned on gear 25 and on axle 26 Apply specified tightening torque...

Page 285: ...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 Tightening torque for screws front cover 2 3 Kg m 23 Nm 7 Apply a coat of recommended sealant J 790962 over the face of coupling of rear cover 11 24 I 28 23 29 23 28 30 J 11 ...

Page 286: ... Nm M6 1 2 Kg m 12 Nm 11 9 12 10 Fit driving gear 14 fix it with screws 13 and apply specified tightening torque Tightening torque for screws fixing driving gear 10 Kg m 100 Nm 11 Install hydraulic pump 15 with new gasket and tighten screws to the specified tightening torque Tightening torque for screws fixing hydraulic pump 3 5 Kg m 35 Nm 13 14 15 12 Fit support of oil filter 7 and of heat exchan...

Page 287: ...t them in the lodgings of filter Fit the filter and tighten it to the specified tightening torque CAUTION Screw filter by hand till ensuring the correct contact of oil seals 31 with coupling contact surface in the support Afterwards tighten to the specified torque Tightening torque of oil filter 2 5 Kg m 25 Nm NOTE For installation of the auxiliary organs group on engine see 6A 66 GAUGING DATA Gau...

Page 288: ...fferent circuits 2 Disconnect battery 3 Remove bonnet of engine 4 Open and put away cap 1 for the filling of refrigerating circuit 5 Loose completely emptying cap 8 of water radiator and remove coolant from the circuit 6 Disconnect or remove Conector 2 of coolant lever sensor 3 Degasifier hoses 6 with its support to engine Hose by pass of filling 7 Screws 4 fixing expanding vase 5 and withdraw tan...

Page 289: ...ature Switch 15 Sensor of coolant temperature in radiator 16 Electromagnetic Pulley 17 Starting motor 20 Electrostop 22 K S B 23 Rev sensor of engine 24 Disconnect accelerator cable 18 from the injecting pump and from support to engine Disconnect fuel tubes 19 and 21 NOTE In vehicles with air conditioning disconnect wire of evaporator and electromagnetic pulley connector of compressor 24 23 22 21 ...

Page 290: ...r of oil low level 42 Fuel filter leads 43 Battery 44 Control board lead 45 Wiring instrument panel connector 46 NOTE Rest electrics leads of wiring engine will be disconnect for components after separated the engine Disconnect fuel return pipes 47 and 48 Disconnect admission pipe of high pressure pump 49 9 10 44 45 47 48 49 42 43 44 46 common rail engine common rail engine common rail engine comm...

Page 291: ...g CAUTION Plug adequately conducts and hoses having been exposed to air while remove Otherwise entry of alien bodies could lead to very serious damages in turbocharger or in water pump 10 Remove screws 30 and nuts 29 Remove in assembly water radiator and air radiator 28 moving them upwards and then towards the front NOTE In vehicles with air conditioning remove gas from the circuit disconnect the ...

Page 292: ... pump putting previously a container under the pump to pour oil from the tank Hose 38 sending oil to the steering box Vacuum pipe 12 Remove upper and lower nuts 40 from the silentblocks 39 of front seatings left and right CAUTION Cap adequately conductions opened to air as the entry of foreign bodies in these conductions could cause very serious damages in the servo steering pump in the air condit...

Page 293: ... the gear box upwards and downwards 16 Ensure there are no pieces connected to the motor interfering in its extraction 17 Lift engine and gear box using devices A and B till reaching heights as those later involved in your hand work Displace engine forwards till separating it from the primary shaft of speeds box and extract it CAUTION Be cautions when lifting engine avoidng catches that damage the...

Page 294: ...gine engine engine 2 Execute the following tasks Refill an level engine with engine oil see 0B 5 point 1 3 Fille purge and level of refrigerant circuit see 0B 8 point 1 5 Fuel supply system purge see 6C 8 To fill and level servosteering hydraulic circuit servosteering hydraulic circuit purge see 0B 27 point 4 7 Servosteering hydraulic circuit purge see 3B 12 3 If vehicle fit air conditioning pleni...

Page 295: ...hose of vapours recycling 1 hose for discharge to the atmosphere of excess vapours 3 oil vapours condenser 4 and oil recycling hose 5 1 4 2 5 6 9 8 7 CAUTION Cap adequately air and gas inlets and outlets of turbocharger as well as the oil ducts The entry of alien bodies in the conductions will very seriously damage the turbo charger 3 Fit to engine flange or bridle ref 790989 and fix the ensem ble...

Page 296: ...ction mechanical injection mechanical injection mechanical injection mechanical injection engine engine engine engine engine Upper soundproof cover common rail engine common rail engine common rail engine common rail engine common rail engine 3 4 7 6 5 Generator and front support 3 see 6A 59 1 2 Air Conditioning Compressor 4 see 6A 60 Fixing screw 6 linking screw 5 and assembly water inlet pipe 7 ...

Page 297: ...chanical injection engines In mechanical injection engines In mechanical injection engines In mechanical injection engines Remove the injectors set 18 see 6A 32 and the pipes for excess fuel 19 and 20 Mark the mounting position A of injection pump remove the fixing nuts 16 and withdraw injection pump 17 NOTE The lower nut near the block is loosened with special key ref 790977 In common rail engine...

Page 298: ...e of later over the tensioning roller 28 remove nut 29 withdraw lower cover 32 and remove the timing belt 30 NOTE The screws of gear 31 should be only loosened if a repair of auxiliary organs group gear box of is wished 22 21 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...

Page 299: ...thdraw gasket D 44 45 46 43 42 41 48 47 49 50 51 52 53 54 Cylinders block removal Front part 1 Prepair a metal sheet D in order to use it as a tool to prevent electromagnetic pulley from turning 44 Fix the sheet as shown dismantle nut 45 and remove fan hub 46 NOTE The nut 45 fixing hub threads leftwards 2 Remove Pulley 52 elastic opening ring 47 and rear end washer 49 Fixing nuts 50 and remove the...

Page 300: ...oil pan 58 with gasket 5 Remove the oil sucker 60 Pistons and connecting rods 6 Place engine vertically as shown and dismantle the tool preventing flywheel from turning 7 Loose nuts of connecting rods covers by pairs n 1 4 and n 2 3 using appropriate key C If the covers and pistons to remove are n 1 and 4 place these pistons in T D C while for n 2 and 3 place pistons in L D C 8 Remove screws and c...

Page 301: ...heel rotation using tool B ref 790976 and remove plate support of ball bearings 63 63 B 64 65 B 66 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: ...evice 15 Straighten the braking sheets that put in place the screws 71 of oil injectors 73 remove screws and withdraw injectors 16 Remove the half ball bearings of block 72 located in the upper and in the lower block NOTE If the half ball bearings of block 72 are going to be used again store them in such a way that the original mounting positions keep identified 67 68 69 70 71 72 73 ...

Page 303: ...zero the comparator corresponds with the nominal measurement of the cylinders diameter If you do not have this kind of caliper use a micrometer for setting to zero the comparator The micrometer must be adjusted to specified measurement Micrometer measurement for adjusting to zero the comparator 94 402 mm 2 Carry out three measurements at three different heights of the cylinder as shown and at two ...

Page 304: ...nal Ø of pistons oversized by 0 4 mm 94 706 94 720 mm Nominal play between piston and cylinder 0 082 0 126 mm CAUTION After doing an oversizing mechanical rectifying of cylinders or cylinders lined up remove mechanization caps and clean thoroughly the block with cleaning fluid compressed air and cylindical sweeping brushes U U U U U Surface coupling measurement with cylinder head 3 Dismantle the f...

Page 305: ...n internal dimensions measuring calliper check that diameter of ball bearings housings at the block adjusts to specified size Diameter of the ball bearings lodgings at the block Lodgings nº 1 2 3 4 84 588 84 614 mm Lodging nº 5 90 588 90 614 mm CAUTION If the diameter of any housing is higher than specified substitute cylinders block A B A Timing side B Side flying motor 7 8 3 4 2 1 6 5 10 9 Cylin...

Page 306: ... The mean diameter D1 med must be specified and calculated as follows D1med NOTE The values between brackets are the heights to which measurements from the upper face of block have to be performed Mean diameter D1 med of mechanized cylinders to be lined 97 390 97 450 mm The difference between the maximum and minimum diameter D máx y D mín must be below the specified value Maximum difference D máx ...

Page 307: ...sary pressure is like 130 Kg while at the end it must be around 500 Kg Be sure of perfect support of lined borders over the mechanized tip 8 of cylinder The liner must not overhang more than 0 005 mm of milling plane X Y Z X Dm Y Ø external shirt Z Ø internal shirt 97 390 97 450 97 470 97 500 92 700 92 900 94 402 94 432 Bench mark to obtain in the diameter of shirts after the automated one final P...

Page 308: ... µm Ra 0 3 0 6 µm W1 2 µm Surface porosities allowed with milled cylinder ZONE B1 Greatest mechanical effort zone of the contact piston rings body intermitent n 2 porousities allowed máx 0 5x0 5 100 ZONE B2 Surface affected by piston rings rubbings no adjoining n 2 porousities máx 1 x0 8 100 CAUTION After carrying out oversize mechanizing or cylinders block sheating dismantle mechanization caps an...

Page 309: ...connecting rods or main bearings signs of gripping knockings scratches or excessive wear it will be necessary to carry out an oversize mechanical rectifying 1 2 3 4 Crankshaft measurement of the 1 Using a micrometer 1 proceed to measure the journal of connecting rods 2 and main bearing 4 to determine the diameter to be reduced NOTE It is necessary to annotate the results of measurements in a table...

Page 310: ... to both of them 1 Carry out mechanical rectifying of connecting rod and main bearing journal to the data sketched in the drawings PRIN CIPALDATA ABOUTJOURNAL and CRANKSHAFTPRIN CIPAL TOLERANCES For cilindrado follow the rules described next It forces of compressure 1st main bearing journal 925 25 Kg 2nd 3rd 4th and 5th main bearing journal 1850 50 Kg 1st y 4th connecting rod journal 1850 50 Kg 2n...

Page 311: ... 10 C 0 10 C 2 5 2 0 5 2 5 R 1 6 1 7 C 0 2 0 7 TIMING SIDE CRANPIN OF MAIN BEARING INTERMEDIATE JOURNAL OF THE MAIN BEARING CONNECTING ROD JOURNAL FLYWHEEL SIDE JOURNAL OF THE MAIN BEARING PRINCIPAL DATA ON MAIN BEARING AND CONNECTING RODS JOURNAL CRANKSHAFT PRINCIPAL TOLERANCES 0 04 A B 0 04 A B 0 05 A B 0 005 0 01 AB 0 006 0 007 0 10 C 0 005 0 05 C 0 03 AB 0 03 AB 0 007 0 03 AB 0 06 AB 0 007 0 0...

Page 312: ...ng of seatings and thoroughly clean the crankshaft using appropriate fluid cylindrical sweeping brushes and air pressure Install caps 4 block them adequately and carry out an impermeabilizing test submiting crankshaft to specified internal pressure Pressure to control caps impermeability of crankshaft 1 5 bar 2 3 5 max 0 35 mm max 0 35 mm 0 125 4 OF FORM Circularity Cylindricality Parallelism Perp...

Page 313: ...tor B as shown and remove drive gear 1 Installation 1 Clean area of gear contact coupling on crankshaft Ensure the correct installation of the positioning elastic ring and its soundness 2 Heat new gear 1 in such a way that the difference of temperature with the crankshaft 200 C 3 Put facing correctly gear drive 1 with elastic ring and press putting it fully in CAUTION Once fixed and cooled it shou...

Page 314: ...ing 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 7 A 2 3 3 Take apart piston from connecting rod extracting elastic ring 2 and connecting bolt 3 NOTE Mark cylinder number on all pis...

Page 315: ...097 1 970 1 995 2 470 2 490 2 200 2 230 2 050 2 070 2 540 2 560 Ø 31 994 Ø 32 000 Ø 32 003 Ø 32 009 Ø 94 306 Ø 94 320 10 2 068 2 097 1 970 1 995 2 470 2 490 2 200 2 230 2 050 2 070 2 540 2 560 Ø 31 994 Ø 32 000 Ø 32 003 Ø 32 009 Ø 94 308 Ø 94 320 10 PRINCIPAL DATA PISTONS KS BOLTS AND PISTON RINGS Height measured over the diameter of 91 4 mm PRINCIPAL DATA PISTONS MONDIAL PISTON BOLTS AND PISTON R...

Page 316: ...andard Oversized X 10 mm 10 mm Ø1 94 306 94 320m m 94 706 94 720 m m B Ø1 X 3 Once known the diameter of pistons and corresponding cylinder see 6A 84 the play between piston and cylinder This play must correspond with specifications Play between piston and cylinder 0 082 0 126 mm 4 Play between piston and cylinder can be measured using thickness calliper C as shown in the figure Verificación del m...

Page 317: ... Play between bolt and seating at the piston 0 007 0 019 mm D F 12 2º 3 11 E Checking the play between piston rings and piston slits or grooves 7 Using a micrometre E measurethepistonringsthickness To consult sizes see 6A 104 2nd and 3rd piston rings 8 Using a thickness calliper F and piston rings 2nd and 3rd placed in the piston slits or grooves check play as shown in the figure Play should be as...

Page 318: ...rd piston ring 0 30 0 55 mm Connecting rods check CAUTION Weight reduction of connecting rods by chipping out material is strongly no recommended 1 Concerning connecting rods noting the following remarks A same number engraved in body and cover mean good matching between both In cover a letter engraved o or x means the diameter of head chosed for installation while produced in the car factory In s...

Page 319: ...er Internal diameter for rod foot connecting bush 32 010 32 020 mm 4 Check that play between connecting rod foot bush and bolt of piston keeps to specified value Play between connecting foot bush and gudgeon pin of piston 0 014 0 03 mm Connecting installation rod on the verifying tool verifying torsion and flexion 5 Install connecting rod to be checked 7 on tool G ref 790978 as follows Place conne...

Page 320: ...torsion of connecting rod 0 08 mm H G 4 B A 7 G 2 Flexion verifying 7 Check flexion of connecting rod on Points C and D of the piston pin G 4 as follows Place connecting rod 7 in vertical position Place measuring tip on Point C of piston pin G 4 Passing by Point C move connecting rod to rear and front Put comparator to zero at the highest height detected Displaceconnectingrod 7 andmandril G 2 tota...

Page 321: ...the meaning of marks engraved at the pistons head 14 Engine type class of piston and purveyor 15 Number code for optical reading of engine and selection of classes 16 Spatial direction of assembly of piston on connecting rod and cylinder NOTE All pistons must have the same weight 14 15 16 3 mm 3 6 mm 2 Fit piston 1 to connecting rod 7 in such a way that the reference of assembly 16 and the numbers...

Page 322: ... with screw G 3 Lean connecting rod 7 on bar G 1 With the measuring tip of dial gauge H feel on Point A of piston 1 Apply a predisplacement of 0 5 mm and put comparator to zero Displace mandril G 2 with piston and connecting rod assembly in such a way that measuring tip touch now in point B of piston The difference between Point A and B must not be above specified Maximum allowed value for out of ...

Page 323: ... camshaft supports do not show scratches or symptoms of gripping If there is evidence of any of such defects substitute camshaft Check that supports surfaces in cylinder head do not show scratches or symptoms of gripping If any of the stated defects is observed proceed to rectify the diameter of oversized replacement supports which means you have to replace camshaft by an oversized spare If in ord...

Page 324: ...ied values Radial play supports of camshaft 0 035 0 081 mm NOTE If play is no within specified values substitute the adequate pieces 33 934 33 950 34 134 34 150 33 985 34 015 34 185 34 215 MEASURES SUPPORTS DIAMETER OF CAMSHAFT IN CYLINDER HEAD AND IN CAMSHAFT Standard diameter Oversized diameter 0 2 mm A 4 2 If it is necessary substitute caps at the ends of camshaft use a cylindrical pushing bit ...

Page 325: ... 43 970 44 000 44 025 MEASURES OF THE DIAMETER OF THE VALVES PLUNGERS AND THEIR LODGINGS IN CYLINDER HEAD 4 With the connecting camshaft placed as described above check that wear of admission and exhaust cam does not exceed the specified value Intake cam height 9 5 mm Exhaust cam height 10 5 mm NOTE If run out or cam war valve does not adjust to specified values substitute camshaft Check NOTE Chec...

Page 326: ...excessive install oversized rocker arms after scraping housings 5 A Valves removal 1 Install tool B ref 790981 as shown 2 Compress springs 8 and 9 in such a way that you can extract the valve cotter 6 Stop putting pressure on the springs Take away tool B take away upper spring retainer 7 springs 8 and 9 and the spring seat 10 3 Repeat task in all the valves 11 turn upside down cylinder head take a...

Page 327: ... calliper I measure flatness of support surface 13 of cylinder head If when measuring you notice some lack of flatness proceed to rectify the support surface noting the following steps Data on surface flattening Maximum thickness of chipped material while carrying out surface flattening 0 4 mm Minimum thickness of cylinder head after work 149 6 0 1 mm NOTE If in order to achieve surface flattening...

Page 328: ...gauge K on magnetic base as shown in the figure feeling with its measuring tip head of valve 15 and check radial play which must be within the specified range Valves radial play 0 023 0 053 mm NOTE If radial play exceeds specified value substitute the valves guides 5 With dial gauge placed as above described check for valves run out turning them around Run out should not be above specified value O...

Page 329: ...of regrinded and measure the valve width this measure must correspond width specified range see figure herewith NOTE If width is higher than specified substitute corresponding valves seatings x Witdh of the valves 1 2 1 5 1 1 3 x x EXHAUST ADMISSION MAIN DATA OF VALVES SEATS 0 5 0 2 45º 2º 0 2 MAX 0 8 0 25 7 0 1 R 2 MAX Ø 34 8 0 2 45º 1º R 0 8 MAX 20º 1º º 30º 1º R 0 8 MAX Ø 38 2 0 3 30º 1º R 5 0 ...

Page 330: ... Install chilled guide 16 using the tapping L ref 790982 and using the limiting tool M ref 790983 L L M 16 EXHAUST ADMISSION 93 0 3 15 0 1 4 Ream valve guide bore with reamer N ref 790984 NOTE Valves guides ream must be done always you fit new guides to guarantee specified internal diameter Internal diameter of valves guides 8 023 8 038 mm N 3 Once the valve guides had been fitted check position a...

Page 331: ...n not to damage the cylinder head For doing this respectthe following dimensions External Ø exhaust valve 37 80 37 415 mm External Ø admission seating valve 42 125 42 175 mm Height of seating 7 mm O 17 Valves seats installation 2 Clean carefully seatings and be sure of correct performance Housing in cylinder for valve seating Ø1 Ø1 Ø1 42 125 42 175 mm 37 380 37 415 mm 3 Install new valve seats as ...

Page 332: ...grinding Keep identified the valves for later installation according to realised matchings O EXHAUST ADMISSION MAIN DATA OF VALVES SEATINGS Injectors seats reboring 1 With milling element P ref 790986 clean injectors seats to scrape any crusts P P Check valves springs 1 Measure stresses of springs using tester Q ref 790988 or similar Q 0 5 0 2 45º 2º 0 2 MAX 0 8 0 25 7 0 1 R 2 MAX Ø 34 8 0 2 45º 1...

Page 333: ...ring does not pass the stress checking test presents bendings breakings and lack of perpendicularity replace it SPRING EXTERNAL INTERNAL SPRING Height mm H 52 H1 38 5 H2 28 5 Under a charge of Height mm H 45 5 H1 33 5 H2 23 5 kg Free P1 43 8 2 5 P1 16 4 1 P2 77 4 4 P2 30 1 5 H H1 H2 P1 P2 MAIN DATA FOR CONTROL DF VALVES SPRINGS ...

Page 334: ...il seals 1 2 3 Install valves 10 in respective positions and the rest of components as explained Valve spring seat 9 Assembly external spring 7 and internal 8 springs Valve spring retainer 6 Compress springs with tool B install valve cotter 5 and decompress springs ensuring that the cotter 5 are perfectly lodged in the channeling of the valve and in the upper fixture 6 NOTE Repeat the same procedu...

Page 335: ...alue exceeds the limit replace faulty piece X Valves head thickness 1 2 1 5 1 0 1 3 X Overhanging injectors X 2 230 2 690 Valves impermeability 4 With tools D and E check valves impermeability NOTE If there are signs of any leaks check if they are through the valves or through the injector seating or casing rectify again faulty seating or casing D E X X ...

Page 336: ...he rolling area of supports and covers of camshaft in cylinder head 2 Install camshaft with hub 14 towards the front part and put in place the five covers 15 with the numbering oriented as seen in the drawing 14 15 3 Install nuts 16 tightening them gradually and uniformly till managing to get support in cylinder head of all the covers 15 4 Apply to nuts 16 specified tightening torque Tightening to...

Page 337: ...sealant ref 790962 on the support surface of cover 18 lubricate the end 19 of camshaft install cover enclosing oil seal porta oil seal in cylinder head and apply specified tightening torque to fixing nuts 20 Tightening torque for the nuts of cover enclosing oil seal 0 75 Kg m 7 5 Nm F G 17 18 18 19 20 Check and adjustment of the valves play NOTE Check valves play and adjust as described in 6A 49 V...

Page 338: ...uired install the old ones respecting the former order and position before removal 3 Install the half bearings 3 on upper block half ball bearings with greasing hole NOTE Oversized ball bearings for main bearing are supplied with diameter reduced in 0 254 and 0 508 mm Play between bearings and journals measuring 4 Once journals and bearings are clean install crankshaft 4 on upper block Measure pla...

Page 339: ...wer 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 1st Step with dynamometric key A 5 0 5 Kg m 50 5 Nm 2nd Step angular tightening 90 5 following the sequence described herewith A 9 7 3 2 6 8 4 1 5 10 9 A B SCHEME OF THE TIGHTENING SEQUENCE FOR FIXING SCREWS OF LOWER BLOCK A Ti...

Page 340: ...kshaft axial play 6 With dial gauge B placed as formerly described measuring tip touching flange 11 of crankshaft check that axial play of the crankshaft is within the tolerance range Axial play of crankshaft 0 060 0 310 mm NOTE If axial play exceeds the tolerated range substitute half ball bearings of the support n 5 If half ball bearings of the support n 5 have been replaced check again play of ...

Page 341: ...ar and front oil seals 9 Install crankshaft cover and rear oil seal assembly 16 and front 17 too see 6A 47 NOTE The assembly guide or supporting rim 18 should not be removed till the oil seals are coupled to the crankshaft Flywheel installation NOTE If it is deemed necessary to substitute toothed crown 20 of flywheel see 6A 45 10 Fit dust protecting plate located between block and flywheel install...

Page 342: ...y 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 12 Lubricate generously pistons piston rings and cylinders 13 Using piston ring compressor D install piston and connecting rod assembly into corresponding cylinder hose noting the following remarks D ...

Page 343: ...2 PISTONHALFOPENLIP ORIENTEDTOWARDOILINJECTOR 23 UPPER ENGRAVED PART OF THE PISTON ORIENTED TOWARDS THE ENGINE FLYWHEEL 24 AUXILIARY ORGANS GROUP 25 NUMBERS ENGRAVING AREA IN CONNECTING ROD Main bearing clearance 14 To measure clearance between bearings and main journal do as follows Clean carefully main journals and bearing taking away oil residues Put the main journals to be tested in the L D C ...

Page 344: ...8 ones lubricate connecting rods bearings lubricate screws threads with oil ref 790964 install caps and tighten screws to specified tightening torque CAUTION The screws from caps will have to be always new when doing final installation NOTE Measure clearance between bearings and main journals in the four journals 16 Control using your hands that the connecting rods move axially in journals after f...

Page 345: ...ronized with the pistons because its connection with crankshaft is no prepared to be in a unique position There is a small play between the flywheel and its screws accordingly before tightening the screws of the engine flywheel you will have to locate its position as described now 20 To carry out the flywheel synchronization do as follows Ensure the screws fixing the engine flywheel are loose and ...

Page 346: ...I of the flywheel housing It must penetrate in the milled mark of theflywheel Otherwise without moving the crankshaft turn flywheel the amount allowed by its play with the screws 21 till tool H enters in the milled mark 22 Tighten moderatelly the screws 21 and withdraw synchronising tool H 23 Lock flywheel from turning by doing the appropriate manipulations and apply final tightening of engine fly...

Page 347: ... 1 and number 4 in position T D C This position is always guaranteed using tool H ref 790965 introducing it in the milling mark of the flywheel NOTE This position for number 1 and number 4 pistons is necessary to synchronize timing 2 Check Cleaning of the las surfaces of the cylinder head and cylinders block coupling Lubrication of the cylinders and absence of alien bodies inside them Thickness of...

Page 348: ... cylinder head and tighten them a little 7 Install camshaft timing bolt pulley 41 with screws lightly tightened Finalt tightening should be done with timing belt on 38 39 40 41 TIGHTENING ORDER 1 2 3 7 15 17 5 8 13 18 21 11 10 20 22 14 12 6 4 9 16 19 L 8 Apply specified tightening torque to cylinder head bolts in three steps and following the order specified herewith Tightening torque for cylinder...

Page 349: ...8 Nm 4 Install tubes adapter at the water pump inlet Apply to nuts the specified tightening torque Tightening torque for the inlet tubes of the water pump screws 2 5 Kg m 25 Nm 5 Introduce reaction cylinder 52 into water pump housing 6 Install protection 53 and fixed tensor 54 of the timing belt Tighten screws to the specified tightening torque Tightening torque for fixed tensor nuts 2 5 Kg m 25 N...

Page 350: ...is oriented downwards 10 Align perfectly mark 60 on camshaft pulley 41 with signal 61 on cylinder head cover 42 This alignment guarantees that the valves of number 1cylinder are closed and synchronized with number 1piston T D C 11 Make sure this alignment using special tool N ref 790965 this synchronization is essential for further tests and for injection pump synchronization in engines with mecha...

Page 351: ...n tool H in milled slot of the engine flywheel Then check coincidence of the control points for synchronization see operating steps 10 and 11 NOTE If the above mentioned conditions are no fulfilled ca rry out a new trial fitting of the timing belt 62 63 55 M 64 N 56 Timing belt tension inspection 16 Unlock engine flywheel tool H and the driving gear of the auxiliary organs group tool N 17 Apply to...

Page 352: ...ning of the bushing during removal or installation 68 To extract bushing use tool ref 790991 2 Install injection pump in housing of the auxiliary organs group as follows Put into coincidence channel 69 of the driving shaft with guiding tooth 70 of the bushing 67 and install the pump Align the marks done during removal on the sump of the injection pump and on the sump of the auxiliary organs group ...

Page 353: ...tion pump must have had undertaken a course of 1 10 0 05 mm read in dial gauge P If the course is different turn the body of the injection pump in its coverers till achieving the specified value Do not change this position during the tightening of the fixing nuts of the injection pump Course of the distributor piston of the injection pump 1 10 0 05 mm 8 Apply specified tightening torque to fixing ...

Page 354: ...p pulley and fan bushing 4 Install electromagnetic gasket 77 and tighten nuts 76 to the specified tightening torque Tightening torque nuts of the electromagnetic gasket 0 75 Kg m 7 5 Nm 5 Install washers 79 blocking washer 80 and pulley 78 6 Pressing on pulley 78 measure height Y it must be in correspondece with specified value Height Y front of the block to front of the pulley 88 9 90 1 mm 7 Inst...

Page 355: ... vaue acting on screws 120 and bracket 121 common rail engine common rail engine common rail engine common rail engine common rail engine Clearance between sensor and flywheel 0 8 1 5 mm NOTE Keep paralellism between sensor and flywheel inte rior side Use a dial gauge to adjust clearance 11 Install soundproof upper cover 84 and tighten nuts to specified torque mechanical injection engine mechanica...

Page 356: ...ake 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 mechanical injection engine mechanical injection engine mechanical injection engine mechanical injection engine mechanical injection engine 3 Install fuel supply...

Page 357: ... pressure plate 102 see 7C 10 99 100 102 103 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 Clearance between sensor and flywheel 0 7 1...

Page 358: ...urbocharger oil draining adapter to block bolt 4 Kg m 40 Nm Oil inlet to turbocharger tube 105 il pressure transmissor 101 and cap 106 if available Apply specified tightening torques Tightening torques Oil inlet to turbocharger union nut 2 5 Kg m 25 Nm Oil pressure tranmissor 4 Kg m 40 Nm Oil pressure transmisor adapter and pipe fixing 8 Kg m 80 Nm 3 By the left side install Oil vapours condenser ...

Page 359: ...ing nut thread leftwards First step pretightening with torque wrench Second step angular tightening 4 0 40 Generator belt tensioner bolt 4 5 45 110 10 Generator front bracket bolts 5 50 Air con compressor to belt tensioner connecting nut 4 5 45 Air con compressor to belt tensioner connecting nut 3 5 35 Air con compressor bracket to block connecting bolt or nut 4 5 45 Air con compressor to bracket ...

Page 360: ...mshaft front bearing cap bolts 0 75 Camshaft driving gear bolts 2 5 Cylinder head cover bolts 1 0 Intake and exhaust manifold nuts 2 5 Timing belt tensioner bracket bolt 2 5 Thermostat box screws 1 8 Thermostate box cover nuts 1 8 10 18 28 25 7 5 7 5 25 10 25 25 18 18 Inlet oil pipe to turbocharger union nut 2 5 Oil pressure switch 4 0 25 40 Termo starter valve fuel inlet union nut bolt 1 8 Oil fi...

Page 361: ...cketblotsM12 6 0 Antivibration to heat exchanger bracket connecting bolt 2 5 Heat exchanger antivibration to bracket connecting nuts 2 5 Heat exchanger bolt 8 0 Block water pipes bolts 4 0 Oil filter fixing 2 5 Oil pressure regulation valve plug 6 5 Main oil gallery plug M18 4 0 Resistence to rotation between drived and driving gear of auxiliary organs group 6 4 35 18 80 25 60 25 25 80 40 25 65 40...

Page 362: ... plug 2 5 Oil filter adapter and bracket 8 0 Engine flywheel housing bolts 7 10 Air inlet box to intake manifold connecting bolts 1 8 Thermo starter sparkplug nuts 3 5 Thermo starter sparkplug pipe union nut 2 2 Thermo starter valve pipe union nut 1 8 25 18 25 80 70 100 18 35 22 18 Water temperature transmissor conical to thermostat box 3 0 30 High pressure fuel pump outlet pipe union nut 2 0 Hydr...

Page 363: ...separator connecting nuts 2 5 Fuelpressuresensoronhydraulicaccumulator Rail 3 5 Flow limiters on hydraulic accumulator Rail 4 5 Pressure limiter valve on hydraulic accumulator Rail 4 5 25 18 25 35 45 45 ELEMENT TORQUE OBSERV Kg m Nm SYMBOLS Apply sealant 790961 Only rotative pump mechanical injection engines Only Common Rail engines ...

Page 364: ...ansgroup adaptoroilfilter andtemperature water conical transmissor Camshaftfrontoil sealcover cylinder head rear cover concavities auxiliary organs group rear cover Cylinder head cover gasket corners Connecting rods screws Threads sealant Connections sealant Gaskets sealant putty Oil 790961 790962 790963 790964 ...

Page 365: ...PECIF 00000A01484 Tension measuring equipment Auxiliary organs group pulley and engine flywheel positioner Dial gauge holder tool for overhauling injection pump Dial gauge 0 5 mm X R N R N X X X Front oil seal installer Use with handler 790969 X 790965 790966 790967 790968 ...

Page 366: ...moved Springs pusher to substitute valve set regulating plates Tool for removal installation and applying the tightening torque at oil filter X X X X OBSERV REF CLASS DENOMINATION GENERAL SPECIF R N R N Auxiliary organs group repairing support X 790969 790970 790971 790972 790973 ...

Page 367: ...evice for removal and installation Locking tool for engine flywheel to apply tightening torques Specialspanner 13mm for removal and installation of injection pump lower nut X X X X OBSERV REF CLASS DENOMINATION GENERAL SPECIF R N R N Connectingrodsasignments tester X 790974 790975 790976 790977 790978 ...

Page 368: ...ylinder head To be used together with tool 790979 Compressing tool to press the springs for removal and installation of the valves Valve removal and installation use together wit 790983 X X X X OBSERV REF CLASS DENOMINATION GENERAL SPECIF R N R N Valve guide limiter installer use together with 790082 X 790979 790980 790981 790982 790983 ...

Page 369: ...er Seat reboring and replacing tool set Cilinder head injector seats cleaning milling bit Oil seal installer X X X X OBSERV REF CLASS DENOMINATION GENERAL SPECIF R N R N Valve spings resistance checker X 790984 790985 790986 790987 790988 ...

Page 370: ...e together with 790990 Engine repairing bench use together with 790989 Injection pump hub positioner Fuel injection pipes remo ver Injectionpumpgubremover X X X X X OBSERV REF CLASS DENOMINATION GENERAL SPECIF R N R N 790989 790990 790991 790992 790993 791037 X ...

Page 371: ...lsetforangulartightening with 1 2 and3 4 couplings X X SIMBOLS AND ABBREVIATIONS OBSERV REF CLASS DENOMINATION GENERAL SPECIF R N R N Only rotative pump mechical injection engine Recommended Necessary R N 790994 790995 Only Common Rail Engine ...

Page 372: ...tic 6B 4 Electromagnetic gasket substitution 6B 4 Water pump 6B 6 Characteristics 6B 6 Water pump substitution 6B 6 Revision 6B 6 Thermostat 6B 7 Characteristics 6B 7 Thermostat substitution 6B 7 Water radiator 6B 8 Removal 6B 8 External cleaning of water radiator 6B 10 TIGHTENING TORQUE SPECIFICATION 6B 11 REQUIRED SERVICE MATERIAL 6B 11 6B ...

Page 373: ...ng liquid Running With a temperature of coolant below 79 C 2 C the water pump moves around the coolant from the engine and the heating system refrigerating the cylinders block and cylinder head thermostat closed With a normal temperature of coolant thermostat open the thermostat coolant heated by engine to radiator In this situation the water pump moves all of system coolant The pressure of circui...

Page 374: ...CLOSED COOLANT CIRCULATION WITH THERMOSTAT CLOSED COOLANT CIRCULATION WITH THERMOSTAT OPEN A A B C B DIAGRAM OF THE COOLING CIRCUIT 1 Reservoir tank 2 Degasifying hoses 3 Thermostat box 4 Inlet hose to radiator 5 Outlet hose of the radiator 6 Water Radiator 7 By pass hose of engine filling and heater outlet 8 Inlet hose to heater 9 Heat exchanger ...

Page 375: ...OMAGNETIC 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 Required power 24 W MECHANICAL INJECTION ENGINE When the temperature of coolant reaches 94 C 2 C the thermometric switch located in the radiator allows operation of electromagnetic gasket 1 which it magnetization attra...

Page 376: ...o nut the specified tightening torque in two steps Tightening torque nut fixing hub of fan threading leftwards First step with dynamometric key 4 Kg m 40 Nm Second step angular tightening 110 10 NOTE The selfbraking nut fixing hub of fan must be replaced each time it is removed This nut threads leftwards 9 8 10 11 12 Y 5 With thickness gauge A measure distance between mobile plate of hub and pulle...

Page 377: ...ring 3 Oil seal 4 Rotor 5 NOTE The water pump does not allow repairs If anomalies are detected while running replace it Water pump substitution To replace the water pump see 6A 30 1 2 3 4 5 1 2 B 1 2 A Revision 1 With thickness gauge B measure distance A between rotor 1 and internal wall 2 It must be in accordance with the stated value Play A between rotor and internal wall 0 56 1 08 mm 2 Check th...

Page 378: ... B Course at 97 ºC 7 mm Course at 110 ºC 10 5 mm The 7 mm course is reached in less than 60 seconds Water losses with thermostat closed and valve closed 2 l h Thermostat substitution Removal 1 Remove coolant of circuit see 0B 9 2 Disconnect inlet hose to radiator connection to cover 3 of thermostat 3 Removal screws 2 remove cover 3 and replace thermostat 1 Installation 1 For intallation reverse re...

Page 379: ...ould get burnings 3 Remove water radiator and air intercooler assembly as follows Disconnectofwaterradiator 12 degasifyinghose 9 upper 6 and lower 7 hoses Disconnect air inlet hose 3 to intercooler 11 connection to metal tube and air outlet 10 of intercooler CAUTION Protect with appropriate plugs the parts which have remained open hoses connectors inlets and outlets of the intercooler This precaut...

Page 380: ... 16 and hose 18 Thepieceforchannelingtheair 20 fixedwithfourscrews 21 The termometric switch 22 The fixing silent blocks 19 Installation 1 Install over new radiator elements removed in task 4th 2 Continue installation reversing removal procedures 3 Fill the cooling circuit see 0B 9 Filling start engine and check there are no leaks 16 17 18 19 20 21 22 11 6 7 8 9 10 11 12 13 14 15 ...

Page 381: ...g the cooling panel Do not use pointed implements which could damage the cooling panel If it is necessary to take away the intercooler 11 disconnect the rigid interconnection pipe of its connection to the air channelling part remove the four screws fixing the intercooler to the water radiator and take away the intercooler without disconnecting the hoses of air conduction 11 12 ...

Page 382: ...s 4 First Step Pretightening with dynamometric key 110 10 Second step Angular Tightening 0 75 Nuts adapter inlet hoses to water pump Screws of the connection water pump to block Nuts fixing electromagnetic gasket to water pump Screws fixing thermostat box 40 7 5 ELEMENT TORQUE Kg m Nm Nuts fixing thermostat cover 3 Screws connecting fan to hub Conical water temperature transmitter to thermostat bo...

Page 383: ...13 Thermostarter inspection 6C 14 HIGH PRESS INJECTION PUMP AND INJECTORS FUEL onl onl onl onl only mechanical injection engines y mechanical injection engines y mechanical injection engines y mechanical injection engines y mechanical injection engines 6C 15 High pressure fuel pump removal 6C 15 Injectors and injection pipes 6C 15 Bench test values for rotary pump 6C 16 Injectors adjustment 6C 17 ...

Page 384: ...s bleeding 6C 48 Filter element 6C 48 Intercooler 6C 50 Interccoler removal and installation 6C 50 Interccoler exterior cleaning 6C 50 Turbocharger 6C 51 Checking before intervention 6C 51 Removal and installation 6C 51 Pressure limiting valve control and regulation 6C 52 Replacement 6C 53 TEMPERATURE SENSORS LOCATION MECHANICAL INJECTION ENGINES MECHANICAL INJECTION ENGINES MECHANICAL INJECTION E...

Page 385: ...ifold Four mechanical injectors An electro valve which controls the rate of fuel to the spark plug at starting when the coolant or fuel temperature is below 0ºC A thermostarter spark pug attached at the intake manifold which carries out pre post heating when the ignition is on and the coolant temperature is below 0ºC 5 4 3 2 12 6 7 8 9 10 1 11 FUEL SYSTEM DIAGRAM MECHANICAL INJECTION ENGINES 1 Fue...

Page 386: ...w limitation valves one pressure limitation valve and a pressure sensor Four fuel electro injectors An electro valve which controls the rate of fuel to the thermo starter in the pre post heating of air admitted when the coolant temperature air admitted or fuel is below 0ºC A thermostarter spark pug attached at the intake manifold which carries out pre post heating when the ignition is on and the c...

Page 387: ...tion is to lower the temperature of the air leaving the turbocharger before entering the cylinders An intake manifold which distributes the air sent from the turbocharger to the cylinders Attached to the intake ma nifold is a pipe to show the pressure generated within the turbocharger to the LDA device mechanical injection engines 9 3 2 1 7 8 AIRINTAKESYSTEMDIAGRAM 1 Air filter 2 Air inlet pipe to...

Page 388: ... to normative on exhaust fumes limit Limits fixed by normative CEE 72 306 and R 24 03 Maximum power Bosch BSU opacimeter degrees 2 0 1 5 Maximum torque Bosch BSU opacimeter degrees 2 5 2 5 Full load at 1000 rpm Bosch BSU opacimeter degrees 3 5 3 5 Acoustic emissions Mean maximum acoustic level Lpa of standard configuration engines Measured according to ISO std 3474 microphones placed 1m from engin...

Page 389: ...ft Clean your hands before and during the intervention If protective gloves are to be worn these must be made of latex Cleaning and warnings during repair When a circuit is opened plug the open conducts correctly Any fuel circuit element that is removed must be stored in an hermetic plastic bag after having been plugged Once a circuit is open brushes cleaning products compressed air or traditional...

Page 390: ...ilter element is replaced and when air has got into the system 1 Open the bleeder 2 and pump using push button 1 several times until fuel comes out free from air In this situation close the bleeder 2 NOTE If the engine has stopped due to lack of fuel loosen the outlets from the injection pipes and turn the starter motor until the entire system is drained Tighten the pipe outlets after the drainage...

Page 391: ...1 Remove the filter element 5 using a special filter key 2 Install a new filter with the joint 4 correctly positioned and tighten to the specified way mechanical injection engines mechanical injection engines mechanical injection engines mechanical injection engines mechanical injection engines Fuel filter torque 1 8 2 8 Kg m 18 28 Nm Bleed air as previously indicated Start engine and check there ...

Page 392: ...l gauge 8 6 Prepare a device to support the tank 1 from the outside remove the six screws 4 and remove the tank Installation 1 If the tank is to be replaced pour the fuel into a suitable recipient and transfer the complements to the new tank NOTE If the removed hoses show any signs of deformity or decay replace them If the tank is to be re used pour the fuel into a suitable recipient and check for...

Page 393: ...black the air should come out the other end if this is not the case the valve needs to be replaced 2 Blowing normally from the atmosphere side 13 orange the air should easily come out the other side if this is not the case or if it is necessary to blow hard the valve 11 should be replaced 14 13 11 TANK ATMOSPHERE Installation 1 Install in reverse order to the dismantling noting the position of the...

Page 394: ...uge 8 NOTE Drain fuel in tank into a suitable recipientand check for any distiness If there s any thoroughly clean the tank Inspection 1 Check inner float moving presence of dirt and electrical response on instrument papel If any problem is detected replace 8 8 Installation 1 Reverseremovalprocedure notingtightentospecifiedtorque Fuel level gauge screws tightening torque 0 5 Kg m 5 Nm ...

Page 395: ...rter spark plug 3 Take out the screws 5 and remove the electro valve 3 Installation 1 Reverse removal procedure fit new joints and tighten to the specific torque Torque Electro valve inlet screws 2 and 6 1 8 Kg m 18 Nm Electro valve setscrews for 1 8 Kg m 18 Nm Thermostarter spark plug Removal 1 Disconnect coupler 1 2 Disconnect outlet 8 remove gauge screw 6 and remove interconnecting pipe 9 3 Rem...

Page 396: ...uel or air temperature below 0ºC loosen the outlet 8 try to start the engine and check the fuel comes out if this is not the case the electro valve is broken or the interconnecting pipe 9 is obstructed 9 8 10 1 2 3 4 Thermostarter spark plug inspection 5 Carry out the initial installation for the spark plug as follows remove interconnecting pipe 9 and spark plug 7 plug housing 11 on intake manifol...

Page 397: ... hing pressure injection pump or fuel injectors remember CLEANING TIPS AN CAUTIONS DURING REPAIR see 6C 7 Place the vehicle in a ventilated word away from heat or flames High pressure fuel pump removal For removal intallation or replacement of the high pressure fuel pump refer to 6A 33 Injectors and injection pipes For removal installation or replacement of injectors and injection pipes refer to 6...

Page 398: ...TS MUST ONLY BE USED AS CONTROL VALUES 1 INJECTION START Prelifting from P M I mm 0 0 02 2 VARIABLE CHANGE PLAY ADVANCE Regime r min 900 Overfeed pressure hPa 1200 Regulating values bar 1 2 0 1 3 TRANSFER PUMP PRESSURE Regime r min 900 Overfeed pressure hPa 1200 Regulating values bar 5 9 0 3 4 FULL LOAD FLOW WITH OVERFEED PRESSURE Regime r min 1100 Overfeed pressure hPa 1200 Flow for 1000 delverie...

Page 399: ... hPa 1200 Flow for 1000 deliveries cm3 57 5 0 5 cm3 3 5 7 Regime r min 600 Overfeed pressure hPa 1200 Flow for 1000 deliveries cm3 60 5 4 0 cm3 6 0 8 Régimen r min 550 Overfeed pressure hPa 0 Flow for 1000 deliveries cm3 28 5 0 5 cm3 3 5 13 NO FLOW STOP 1 Electric Regime r min 350 Flow for 1000 deliveries cm3 1 5 1 5 Voltage volt 0 14 MINIMUN REGIME FLOW 1 Regime r min 350 Flow for 1000 deliveries...

Page 400: ...espect to its normal position which in turn causes the changer 6 producing an increase in the advance respect to the static advance of the assembly Once the engine is started the current produced by the generator terminal D feeds the thermic bulb 1 resistance The heat produced heats the wax bulb which dilates causing the movement of the rod and cable 3 gradually shifting the lever 2 to position b ...

Page 401: ...to 6000 rpm acting capacity Injection pressure control before and during the injection Fuel consumption reduction Emissions reduction The main functions of the system are essentially the following Fuel temperature control Engine coolant temperature control Quantity of injected fuel control Minimum regime control Fuel when pedal is released cut off control Cylinder balance at minimum rocker control...

Page 402: ...ure pump 13 3rd pinston deactivator valve 14 Fuel pressure regulator 15 Fuel filter 16 Fuel heater 17 Fuel temperature sensor 18 Electric feed pump 19 Fuel prefilter 20 Fuel tank 21 Electronic control unit 22 Multiple connector 5 way 23 Hydraulic accumulator Rail fuel pressure limiter 24 Accelerator stroke sensor 25 Clutch pedal sensor 26 Brake pedal sensor 27 Thermostarter warning light 28 Speedo...

Page 403: ...r 11 Coolant temperature sensor 12 Fuel temperature sensor 13 Air temperature sensor 14 Camshaft position sensor 15 Crankshaft position sensor 16 Speedometer 18 Battery 20 Fuel pressure regulator electro valve 21 Electro injectors 22 Thermostarter spark plug 23 Thermostarter panel warning light Thecontrolunitcontrolstheamountoffuelinjected regulatingthein linepressureandthedurationoftheinjection T...

Page 404: ... of engine rotation at constant regime during increase of revs From sensor signals the control unit determines the amount of fuel to inject via the pressure regulator electro injector opening time Exhaust fumes control With rapid acceleration and according to signals received and engine revs the control unit calculates the amount of fuel to inject via the pressure regulator varies injection time M...

Page 405: ...niences are known the control unit has been programmed to avoid them De rating In the event of engine overheating the injection is modified reducing the flow proportionately to the temperature reached by the refrigerant fluid Rev egulation from variable geometry turbocharger turbine if fitted The turbine speed is continually regulated and can be corrected by acting on the variable geometry The adv...

Page 406: ... used for a new engine start see run up This data consists mainly of calibration of some components memory of breakdowns The procedure lasts some several seconds normally from 2 7 depending on the amount of data to be saved and then the ECU signals main relay to disconnect the battery CAUTION It is very important that this procedure is not interrupted eg stopping the engine by disconnecting from t...

Page 407: ...ensors connected to the control board can deter mine the state of the engine and the injection system at every moment as well as the demand for power by the driver Moreover the system can control an operator for the EGR and for the turbocompressor with waste gate or a variable geometry turbocompressor HIGHPRESSUREELECTRONICINJECTIONSYSTEMFUNCTIONALDIAGRAM 1 3rd pinston deastintor valve 2 Crankshaf...

Page 408: ...r the electro valve In the event of interventions on the high pressure pipe the injector hexagonal side must be held with a key Before any intervention on the pipes check that the injector is held in place on the cylinder head When dismantling fitting the injector excess connector the retaining spring must not be removed from its place pushing the spring towards the engine and exercising a vertica...

Page 409: ...miter valve mouth where 5 way multiple connector is fitted has a 2 5 mm calibrated orifice whose function is to maintain a pressure of 0 5 bar on the thermostarter The circuit does not need air bleeding Prefilter Generalities This is a small translucent filter 9 placed in the aspiration line of the electric feed pump between this and the tank It must be replaced when impurities become visible or c...

Page 410: ...the pump stopped the second a pressure valve which communicates the delivery with aspiration when pressures superior to 5 bar occur Characteristics Delivery pressure 2 5 bar Flow 155 l h Supply 13 5 V 5A Reel resistance at 20ºC 28 5 Ohm On vehicle service 1 To remove and fit the electric pump disconnect the battery the pump electrical couplers and the fuel inlet outlet pipes 2 Loosen the clamp whi...

Page 411: ...ontrol 6 and a water in fuel sensor 4 The control unit prepares the amount of fuel to be injected into the cylinders according to the fuel temperature Specifications Filter grade 5 micras Internal working pressure 0 6 bar On vehicle service To carry out interventions on the fuel filter see 6C 8 1 2 3 4 5 6 MAIN FILTER 1 Bracket 2 Fuel heater 3 Filter element 4 Water in fuel sensor 5 Clogged filter...

Page 412: ...deactivator valve Characterístics Type with radial pumps Number of pumps 3 Total cylinder capacity 0 7 cm3 Volumetric output 80 at 1000 bar from 500 to 3000 pump r min Operating pressure up to 1350 bar Power absorbed 3 2 kW at 1000 bar and 3000 pump r min Maximum speed 3000 r min Supply Pressurised diesel at 0 5 bar with minimum flow equivalent to 0 5 l min plus the flow ab sorbed by the high pres...

Page 413: ...d by the electronic control unit this valve regulates the fuel pressure to the electro injectors The pressure regulator is mainly composed of a spherical stopper 2 a valve 1 drive shaft 3 a preload spring 6 a reel 5 Once the solenoid is not stimulated the delivery pressure depends on the preload of the spring 6 The modulation of the pressure is obtained by exciting in PWM Pulse Width Modulation th...

Page 414: ... a film of oil and fit new joints including the pressure sensor 4 1 2 3 6 5 4 Flow limiter Generalities The flow limiters guarantee the engine working engine protecting it from the risk of the engine catching fire in the event of fuel loss internal electro injector spray blocked open external pipe and high pressure pipes to the electro injectors outlets weak or damaged In normal working conditions...

Page 415: ...on 10 the fuel is discharged into the low pressure circuit excess On vehicle service For removal installation or replacement see 6A 36 9 10 Pressure limiting valve 9 Spring 10 Piston High Pressure Pipes The high pressure pipes are made of steel and have an exterior diameter of 6mm and an interior diameter of 2 4mm Replace any pipe which has been removal Strictly respect the outlet torque and the a...

Page 416: ...tart of injection The reel 4 is stimulated and raises the stopper 6 The fuel from the control volume 9 flows to the return collector 10 causing a decrease in pressure in the control area 7 At the same time the in line pressure through the supply conduct 12 exercises in the chambre 8 a force Fa Fc raising the spigot 2 with consequent introduction of fuel to the cylinders End of injection The reel 4...

Page 417: ...ump pressure restricters injectors must be replaced in the circuit after the meter until the measurement remains unaltered The injected amount for each injector for each cycle is 6 10 8 1 1 60 1 eNG C Q n c Where Qc amount injected in mm2 cycle cylinder Cn hourly consumption in kg h NG regime r min d fuel density in kg dm3 ddiesel 0 835 kg dm3 while 2 t c N N e with Nc number of cylinder Nt number...

Page 418: ... 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 1st Pin A10 A43 2nd Pin A23 A42 3rd Pin A24 A41 4th ...

Page 419: ...ressure sensor Camshaft speed and phase sensor signal Fuel pressure sensor ground Positive for fuel pump telerruptor command Telerruptor ground Positive fuel pressure regulator electro valve 2nd cylinder electro injector ground 1st cylinder electro injector ground Positive fuel pressure sensor Positive fuel temperature sensor signal Ground for intake manifold air temperature and pressure sensor Gr...

Page 420: ...6C 38ENGINEFUELANDEMISSIONCONTROLSYSTEM CONNECTION DIAGRAM FROM CONTROL BOARD TO ENGINE COMPONENTS CONNECTOR A ...

Page 421: ...ccelerator pedal minimum analogue switch ground Speedometer signal ground Pin B5 Engine speed signal Pin B2 L line for diagnosis connector Pin 1 Thermostarter control lamp ground pre post heating Pin B6 Positive for main relay Blink code pulse ground EDC Pin B17 Battery direct ground Positive for brake pedal switch Accelerator pedal position sensor ground Phase signal for diagnosis connector Pin 2...

Page 422: ...6C 40ENGINEFUELANDEMISSIONCONTROLSYSTEM CONNECTIONS DIAGRAM FROM CONTROL UNIT TO VEHICLE COMPONENTS CONNECTOR B ...

Page 423: ...olt supply Engine Speed Sensor This is an inductive sensor and is placed on the flywheel 1 rear face It generates signals obtained from the lines of magnetic flow which close through the moulded orifices on the flywheel itself Number of orifices 58 The control unit uses this signal to measure the engine rotation speedfordeterminateangularpositionandtodrivetherevcounter If this signal is lacking th...

Page 424: ...pump cannot be guaranteed the control unit using the values received determines fuel the density and volume Correcting the delivery and limiting the engine per formance It is a NTC sensor and its resistance values in function of temperature are as follows Terminals between fuel temperature sensor and control unit Pin A15 A30 Temperature Resistance 40 ºC 20 ºC 0 ºC 20 ºC 40 ºC 60 ºC 80 ºC 100 ºC 12...

Page 425: ...roduced in cilinders and therefore the fuel ammount sent to injectors Resistance valves in fuction of temperature Temperatura Resistencia Voltage valves in fuction of pressure See enclosed figure Terminals between control unit and intake manifold air temperature and pressure sensor Central unit Sensor Pin A 19 Pin 1 ground Pin A 2 Pin 2 temp signal Pin A 3 Pin 3 5V supply Pin A 34 Pin 4 ressure si...

Page 426: ... the engine is ingager free pedal During desengaging pressed pedal in order to change gear the control unit does not receive the signal and therefore deactivates cruise control if fitted Brake Pedal Position Sensor There are two sensors fitted to brake pedal support With brake pedal free a positive signal is sent to control unit which uses it to determine if the brake is being used when the brake ...

Page 427: ...determines the duty cycle which is normally represented as a percentage of the total period for example if the duration of the two active and inactive states is equal the duty cycle will be 50 For reasons of diagnosis the duty cycle is limited between 1 and 99 the control resolution is equal to 0 005 1 20000 of the period The duration of the period is chosen noting control response dynamic charact...

Page 428: ...ater Fan if fitted Cylinder 1 rocker flow limiter Cylinder 2 rocker flow limiter Cylinder 3 rocker flow limiter Cylinder 4 rocker flow limiter Battery tension Thermostarter warning light Thermostarter if fitted Thermostarter electro valve if fitted Thermostarter control if fitted Variable Geometry Turbine control VGT if fiteed Variable Geometry Turbine actuador VGT if fiteed Injector 1 cylinder 1 ...

Page 429: ...loves are used they must be latex Prepare the suitable protection elements plugs and hermetic plastic bags During repair when a conduct is opened suitably plug it immediately any element of the system that is removed must be placed in a hermetic plastic bag after having been plugged once a conduct is open the use of brushes cleaning products compressed air or traditional cloths is strictly prohibi...

Page 430: ... humidity changes to the filter element should be made more frequently see maintenance programme Independently of the filter changes frequently bleed the residues accumulated in the filter case To do this push aside the rubber valve 1 1 PUSH Filter element Removal 1 Disconnect the battery 2 Disconnect and remove the elastic belts 5 which fix air filter assembly 3 3 Disconnect the turbocompressor a...

Page 431: ... that there are no deformities or obstructions produced by other elements that are not strictly speaking dust if this is not the case replace the filter element Eliminate the accumulated dust in the filter using compressed air blowing from the interior to the exterior as shown Installation 1 Filter element and its cases in reverse order to dismantling align the two cases using the positioning hing...

Page 432: ...setscrews 2 and remove intercooler 1 CAUTION Avoid hitting or scraping the intercooler so as not to damage the refrigeration panel Intallation 1 Install in reverse order to dismantling Check for good state of the air conduct hoses and firmly tighten the fixing clamps If any defects are found in the hoses or the clamps look worn replace Intercooler exterior cleaning Intercooler exterior 1 cleaning ...

Page 433: ...es are not obstructed deformed bent double or worn out If the turbocharger damage has been caused by lack of lubrication check that oil conduct pipes are not obstructed deformed or flattened Replace if any doubts exist to their correct working OVERFEED SYSTEM DIAGRAM Exhaust gases Aspired admission air Pressurised admission air hot Pressurised admission air cold CAUTION Place the vehicle in a suit...

Page 434: ... maintained throughout the test if not replace the valve Pressure for minimum lift of rod valve Pink Blue Mechanical inject Common Rail Turbo KKK Turbo Mitsubishi 1 29 0 019 bar 1 21 0 02 bar Pressure for maximum lift of rod valve Pink Blue Mechanical inject Common Rail Turbo KKK 1 3 0 002 bar 1 3 0 02 bar Turbo Mitsubishi 1 45 0 04 bar 1 45 0 04 bar Minimum lift for limiting rod valve Pink Blue M...

Page 435: ... 1 12 3 13 1 5 4 14 Valve installation Install the valve in reverse order to dismantling and regulate in the following way Thread nut 4 on valve rod 5 to the end Fit lever 14 to rod valve Introduce compressed air into the valve at the correct pressure and in this situation turn nut 3 until the butterfly valve is positioned snugly in its housing Unscrew nut 4 until it comes into contact with lever ...

Page 436: ...ical 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 1 2 3 4 5 ...

Page 437: ...on casing 2 until it touches the flywheel motor 3 2 Loosen sensor 1 and measure with calibrated gauges D the air gap between the sensor end and engine flywheel This should be adjusted to the specified measurement Air gap between sensor and flywheel 0 7 1 5 mm 3 Tighten the counter nut 4 to the specified torque Torque for sensor counter nut 4 kg m 40 Nm With gearbox fitted 1 Install sensor 1 on eng...

Page 438: ...ter spark plug 2 2 22 Fitting thermostarter spark plug 3 5 35 Set screws level gauge 0 5 5 TORQUE Kg m Nm SPECIAL TOOL OBSERV REF CLASS DENOMINATION GENERAL SPECIF Turbocharger pressure limiting valve tester X R N R N 790996 Counter nut rpm sensor 4 40 ASSEMBLY TOLERANCES AND DATA DENOMINATION DATA Engine speed sensor air gap mechanical injection engine 0 7 1 5 mm Engine speed sensor air gap commo...

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 6K ...

Page 440: ... elements The catalyser if provided is a device for the control of emissions incorporated in the exhaust system to reduce the amount of contaminating hydrocarbons HC and carbon monoxide CO present in the exhaust gases SKETCH OF THE EXHAUST TUBE 1 Elements of connection gases exhaust elbow to turbo charger 2 Elements of connection pipe n 1 with gases exhaust elbow 3 Elements of connection pipe n 2 ...

Page 441: ...y are located out of place Check if there are leaks significant knockings loose connections or damages If you detect loose fixing elements tighten them moderately Check the areas near the exhaust system to see if there are damaged pieces or badly placed welds or opened unions or other defects which could allow the inletting of exhaust fumes inside the vehicle Ensure there are no rubbings of the ex...

Page 442: ...old see 6A 62 REMOVAL AND INSTALLATION OF TURBOCHARGER Before installation clean the coupling contact surfaces and check the soundness of these ones If there are cracks or deformations replace manifold Exhaust pipes sound muffler and catalyser CAUTION When the system comes provided with catalyser in pipe n 2 the pipe should not be knocked neither submitted to vibrations While installation tighten ...

Page 443: ...L 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 6L 4 6L ...

Page 444: ...oil filter arriving later to the different organs in motion of engine to be lubricated through conduits and pipes When the lubrication cycle is accomplished oil returns to the oil pan by gravity In case the oil filter is blocked or the heat exchanger is blocked any of both would be excluded of lubrication circuit through its safety valve avoiding thus that the engine becomes without lubrication SK...

Page 445: ...n oil condenser receiving the vapours coming from the ramp condensing them and sending them again to the oil pan At the same time the eventual exceeding vapours which can not be condensed are vented to the atmosphere through a pipe located in the upper part SKETCH OF OIL VAPOURS RECYCLING CIRCUIT 1 Ramp for collecting oil vapours and oil spout 2 Pipe sending oil vapours to condenser 3 Oil vapours ...

Page 446: ... l Heat exchanger For the removal installation or substitution of heat exchanger see 6A 68 Checking 1 Let in pressurized air at 1 bar in the heat exchanger 4 and check there are no leaks neither communications between the water circuit 6 and the oil circuit 5 2 Check that the coupling contact faces 7 are not scratched or deformed NOTE If you detect any anomalies in the heat exchanger replace it Te...

Page 447: ...TRANSMISSION 7 1 SECTION 7 TRANSMISSION CONTENTS GEARBOX 7A CLUTCH 7C TRANSFER BOX 7D FRONT AND REAR DIFFERENTIAL 7E 7 ...

Page 448: ......

Page 449: ...RAL REPAIR OF TRANSMISSION 7A 12 Disassembling and assembling of the transmission and transfer box 7A 12 Repairing the transmision 7A 13 TIGHTENING TORQUE SPECIFICATIONS 7A 38 DATA AND ASSEMBLY TOLERANCE 7A 39 REQUIRED SERVICE MATERIALS 7A 39 SPECIAL TOOLS 7A 40 7A NOTE The unions between cases or covers can be carried out by product sealant or by gasket During the assembly apply in each case reco...

Page 450: ...speeds are permanent and of helicoidal construction The reverse gear is straight The relations of transmission for each speed have been established so that they are in a series of steps allowing the optimum use of engine FIRST GEAR RATIO 29 21 29 21 FIRST SPEED RATIO 1 380 1 380 SELECTED SPEED REV 1ª 2ª 3ª 4ª 5ª GEAR RATIO 36 13 37 14 30 19 26 25 19 33 SECONDARY RELATIONS SPEED RATIO 2 768 2 643 1...

Page 451: ... Reverse idle gear assy 44 Main shaft reverse gear 45 Bearing 46 Stopper washer 47 Snap ring 48 5th speed fork bracket 49 Bracket retainer 50 Bolt 51 Plain washer 52 5th speed gear shift fork 53 Pin 54 Snap ring 55 5th speed fork roller 56 Low speed shaft 57 Hight speed fork shaft 58 5th gear shift shaft 59 Reverse gear shift shaft 60 Low speed shaft yoke 61 High speed shaft yoke 62 5th gear yoke ...

Page 452: ...Gear shift case upper plate 14 Selector head finger 15 Gear shift arm 16 Bolt 17 Oil seal 18 Gear shift case plate 19 Screw 20 Control lever knob 21 Gear shift lever boot 22 Flange 23 Bolt 24 Washer 25 Oil seal 26 Bolt 27 Outer spring 28 Pin 29 Inner spring 30 Gear control lever bush 31 Spring pin 32 Boot 33 Gear shift control lever assy 34 Spring pin 1 2 5 3 4 9 8 11 10 6 7 20 21 22 33 16 24 23 3...

Page 453: ... Replace Difficulty to get Synchronized spring worn or broken Replace out gear Gear shift shaft or fork out of distorted Replace Inadequate clutch pedal play Adjust Broken or distorted clutch disc Replace Damaged clutch pressure plate Replace clutch cover Synchronized ring worn Replace Coupling or gear bevelled tooth worn Replace the coupling and the gear Distorted gear shift shaft Replace Incorre...

Page 454: ...carpet to access cover screws 5 7 Move the boots 6 7 and flange 8 upwards 8 Remove the three cover screws 9 from lever case 9 Extract the transfer shift lever assembly and boot 5 6 7 8 9 10 Inspection 1 Check if there is erosion on the friction zones lever supports and cases Correct and replace them if necessary 2 Check the boots for breakages and replace if necessary 3 Check the state of screws a...

Page 455: ...ll each guide pin make sure that the flat surface 12 of the pin point faces upwards towards the gear lever 5 If you replace the spring pins 11 apply grease to the surface before installing them in the gear lever box Assembly 1 Apply recommended grease to the lever seating zone 2 Install the boot fitting new belts and tightening firmly 3 Fit the rest of the components in reverse order to dismantlin...

Page 456: ...e transfer gear lever assembly see On lift 3 If the transmission is going to be removed Draintransmissionoil removingtheplug 1 andfromtransfer box removing plug 2 Clean oil from plug thread and housings apply the recommended sealant assemble the plugs and tighten them to the specified torque Torque for plug 1 4 5 Kg m 45 Nm Torque for plug 2 2 3 Kg m 23 Nm 1 2 7A 6 Under hood 2 Disconnect negative...

Page 457: ...t 6 Disconnect forward section first section of the exhaust pipe from the turbo compressor gas outlet elbow joint WARNING Never work on the exhaust system when it is hot A 4 6 3 5 7 4 Before removing propeller shaft mark the flange A in order to assemble them in the same position 7 Disconnect the speedometer cable 7 and ground cable ...

Page 458: ...ssion holding plate 13 Detach plates with the corresponding silentblocks 14 Place a holding system for engine 15 Disconnect reverse speed and double traction couplers disconnect the electric branch of the rolled flange and the small breather hoses placed on the rear of engine 16 Remove screws which join engine and transmission and transfer box assembly 17 Detach the transmission and transfer box a...

Page 459: ...smission silentblock holding plates are in good condition if not replace them with new ones Torque for gear box holding plates 7 10 Kg m 70 100 Nm Torque for silentblock fixing screws 7 10 Kg m 70 100 Nm Fix wiring with rolled clamps and connect the electric couplers Torque for propeller shafts flange fixing nuts 2 8 3 5 Kg m 28 35 Nm Torque for propeller shafts constant velocity joint fixing scre...

Page 460: ... flex to the coupling face 2 of the transfer box and gear box case respecting the oil bleeding slot B 4 Align the grooving of the rear main shaft to the grooved entry gear of the transfer box This alignment will be made using tool A 5 Connect the transfer box assembly to gear box assembly and fix both with screws 1 to the specified torque Torque for joining screw 5 Kg m 50 Nm 6 Remove tool A and a...

Page 461: ...gear selector forks 4 Remove springs 4 which press on the centralising balls of the selector shafts Use the tool ref 194635 to extract the balls 4 Removal gear box top cover 2 Remove outlet screw with its washers and separate the breather pipe 3 Remove axis 1 lever housing 2 and cover 3 from gear box upper Dismantling 5th gear housing removal 1 Unscrew the 5th gear fixing screw and remove the hous...

Page 462: ...ads or shafts the bolts must be extracted sufficiently to free the selector head being careful that it does not fall into the gear box A 9 7 Remove screw 6 that fixes reverse gear crosspiece 7 NOTE The three bolts of the selector shafts can be extracted at the end of the operation 8 Extract rear gear selector shaft 8 and selector head 9 7 8 6 9 Remove vane pin and spring pin which fix 5th gear sel...

Page 463: ...ead 10 10 11 A 12 Remove screw 12 which fixes the 3rd and 4th gear selector fork from its selector shaft 12 13 Use the punch A to tap the elastic bolt which fixes the 3rd and 4th gear selector head 13 until it is free 14 Take out the selector shaft 14 and remove the selector head 13 13 A 14 15 Remove screw 15 which fixes the 1st and 2nd gear selector fork from its selector shaft 15 ...

Page 464: ...he 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 casing 22 Remove the selector fork assembly 23 and the support 22 ...

Page 465: ...ove the nut which holds in place the 5th gear drive gear constant contact select two speeds at the same time this blocks the gears 30 31 32 33 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 27 Remove the nut 34 having already removed its brake and take out the drive gear 35 34 35 ...

Page 466: ...l lever removal 30 Unscrew the lever pivoting screw 37 and remove the lever and runner 37 Removal clutch case and clutch release front cover 31 Remove screw and washer 38 32 Remove retaining clip 39 33 Remove control lever 40 with the pushing bush 41 and remove lever support pivot 38 39 40 41 34 Remove fixing elements which join the clutch case to the gear box housing ...

Page 467: ...oval gear box casing 37 Remove fixing elements which join the two halves of the gear box housing 38 Separate both halves using a plastic headed hammer CAUTION To crack open the two half casings hit the ribs using a plastic hammer 39 Once two halves are separated take out the fixed gear set 45 and the main shaft assembly 46 together with the primary shaft 47 45 46 47 42 44 43 42 ...

Page 468: ...soft runner it is not necessary to remove the pivoting screw 52 48 B 51 52 42 Remove reverse gear 49 and its fitting washer 49 50 Removal main shaft 43 Separate primary shaft 47 from main shaft 46 without misplacing synchro cone 53 or needle roller bearing 54 44 Remove synchro cone 53 which will be loose and needle roller bearing 54 54 53 47 46 By the front 45 Remove clip 55 46 Remove fitting wash...

Page 469: ...ub 58 3rd gear 59 Spacer 60 Needle roller bearing 61 59 60 61 58 57 By the rear 48 Remove clip 62 and fitting washer 62 49 Using a universal extractor C remove bearing 63 as shown 63 C 50 Remove 1st gear 64 Bearing bush 65 Needle roller bearing 66 Spacer bush 67 65 66 67 64 ...

Page 470: ...roller bearing 71 and spacer 72 70 71 72 Removal primary shaft 53 Remove clip 73 54 Remove fitting washer 74 55 Remove bearing 75 using an extractor C 74 73 C 75 Counter shaft assembly 56 Remove rear bearing 76 and front bearing 78 assembly 57 Using an universal extractor C remove the inner ring 77 from both bearings C 77 76 78 ...

Page 471: ...the cone 82 83 NOTE The 1st and 2nd gears and the 5th gear synchros are dismantled in the same way Inspection 4 Clean all the parts with petrol and blow them with compressed air 5 Check the state of the synchro cones for flatness and wear and tear Make sure the springs show no signs of wear deformation or breakage 6 Check that the synchro spool cog teeth are in perfect condition 7 Check all the ge...

Page 472: ...5 0 125 mm 1st gear 12 Assemble bearing bush 65 needle roller bearing supplementary bush and first gear 64 13 Place this assembly on the 1st and 2nd gear synchro nucleus 68 in its working position 14 Use calibrated gauges D to measure the horizontal play for the 1st gear Service limit 0 190 mm STD play 0 075 0 125 mm 68 65 D 64 D 84 85 86 87 5th gear 15 Install fitting washer 84 needle roller bear...

Page 473: ...ace this assembly on tool E ref 493764 1 and position brake blocks 88 using springs 89 NOTE Fit the brake blocks with the arched part facing out 3 Place balls 90 in front of springs 89 4 Press down on each ball until they are inside blocks 88 5 Push blocks down so that the balls are trapped between spool 81 and springs 89 Fit synchro cones and check the synchro working and verifying smooth movemen...

Page 474: ...ing washer 56 and clip 55 9 Measure the longitudinal play using calibrated gauges adjusting to the indicated measurement by means of washers 56 Longitudinal play 0 00 0 08 mm Rear part 10 Fit 2nd gear 70 needle roller bearing 71 and separator bush 72 71 70 72 11 Fit 1st and 2nd gear synchro 68 and the synchro cones 69 with crown facing the front part 68 69 ...

Page 475: ...correspond to the specified value if not adjust the fitting washer to this end Longitudinal play 0 00 0 08 mm 66 62 D Primary shaft 15 Fit a 1 9 mm fitting washer 60 This washer adjusts 4th gear synchro cone play 60 D 73 74 75 16 Install bearing 75 fitting washer 74 and clip 73 17 Using calibrated gauges D measure the play between bearing and fitting washer 74 this must correspond to the specified...

Page 476: ...t with the indented crown facing the front part of the half casing 24 Fit fitting washer 50 to the gears 25 Tap the shaft using a plastic hammer until it is completely housed in its slot 94 in the half casing as shown 26 Fit reverse selector lever 51 with its runner 95 27 Check that the runner fits perfectly in the gear channel 28 Apply the recommended sealant to screw thread 52 making sure that i...

Page 477: ... remain free 36 Apply a thin coat of recommended sealant to one of the joining faces of the half casing 53 54 47 37 Fit the other half casing tightening the screws to the specified torque Torque for half casing screws 1 8 2 4 Kg m 18 24 Nm 38 Fit retaining plate 36 39 Apply recommended sealant to the Allen screws and fix the retaining cover with its four screws tightened to the specified torque To...

Page 478: ...es 34 35 C 44 Fix to the rear part of the main shaft Fixing washer 33 Needle roller bearing 32 Spacer 31 5th gear driven gear 30 NOTE Apply oil to the bearing and the geari 30 31 32 33 45 Fit 5th gear synchro 28 and its synchro cone 29 28 29 46 Fit O ring 27 and main shaft closing bush 26 so that bush slot 96 fits 5th gear synchro pin 97 47 Fit washer 25 to control 5th gear synchro play 48 Split c...

Page 479: ...ip D 25 26 50 Fit guide tool F ref 494989 2 to main shaft 51 Place a new clip 24 around this tool and push it into its housing using tool G ref 494989 3 F G 24 52 Fit 5th gear selector fork 23 with its support 22 and fix with screws to 21 the specified torque Torque for 5th gear fork support screws 1 5 2 Kg m 15 20 Nm NOTE Make sure that the runners 98 are housed in the synchro grooves 98 22 21 23...

Page 480: ...face 42 and the housing and fix with screws to the specified torque Torqueforfrontcoverfixingscrews 2 Kg m 20 Nm 59 Fix the clutch casing applying recommended sealant to the joining surface and fix with screws to the specified torque Torque for clutch casing fixing screws 4 6 Kg m 40 60 Nm 60 Fit lever support pivot 40 tightening the screws to the specified torque Torque for pivot fixing screws 1 ...

Page 481: ...e indicated position with the help of tool D ref 194635 1 Between 3rd 4th gear selector shaft and 5th gear 2 Between 1st 2nd gear selector shaft and 3rd 4th gear 3 Between reverse selector shaft and 1st and 2nd gear 3 2 1 D CAUTION The spring pins must be fitted new with the groove positioned to the front od rear of the gear box 65 Fit 1st 2nd gear selector shaft 17 66 Install selector head 16 to ...

Page 482: ...ove and fix with an spring pin 13 14 69 Fit 5th gear selector shaft 11 70 Install selector head 10 to the above 71 Fix shaft and head with a spring pin 10 11 72 Fit reverse gear selector shaft 8 73 Install selector head 9 to the above 74 Fix shaft and head with a spring pin 75 Fit the locking bolt 9 8 ...

Page 483: ...s 6 which fix the forks to the selector shafts without tightening 80 Place the four balls and four springs 4 in their housing these fix the position of the selector shafts 81 Fit reverse gear switch 100 tighten to normal tension and check that the reverse gear is not blocked 4 6 100 Regulating the forks 82 With all gears in neutral fix the position of the selector shafts by fitting a plate and sep...

Page 484: ...ck that the reverse gear pinion does not rub against the 1st gear fixed gear set 87 If there is rubbing loosen the crosspiece screw and move the crosspiece far enough back so as to correct the defect 88 Remove plate 101 and the separators 89 Apply recommended sealant in the face of support of the superior cover 3 90 Fit lever housing 2 next to superior cover 3 and axis 1 91 Fit the lodging of the ...

Page 485: ...screw 104 and tighten until it comes into contact with the selector shaft and then loosen by one complete turn NOTE Before fitting the screw 104 apply recommended sealant to its thread 104 99 Join the gear box to the transfer box see 7A 12 100 Fit this assembly to the vehicle see 7A 8 94 Fit a new seal 102 to 5th gear casing so that the part opposite to the closing lip lies flush with the projecti...

Page 486: ...35 35 40 20 25 23 40 60 Setscrews gear box support plates 7 10 Bolts silentblocks to holding plates 7 10 Setscrews constant velocity to transfer box clamp Set screws transfer box to gear box Joining screw gear box half casings 70 100 70 100 Setscrew retaining plate 2 5 Setscrew 5th gear drive gear Setscrew 5th gear selector fork support 25 3 4 5 1 8 2 4 20 1 5 2 30 40 50 18 24 200 15 20 Setscrew g...

Page 487: ... 08 mm 0 00 0 08 mm RECOMMENDED PRODUCTS REF PRODUCT TYPE APPLICATION 790997 Joining surfaces casings and covers LOCTITE573 Setscrews Bleeder and feeder plugs Axial washers and seal closing lips TB 1215 TB 1215 QUIMILOCK AGUILA 95 Play between rear bearing and limiting screw Play between primary bearing and limiting screw Longitudinal play 5th gear synchro Parking brake maximum efficiency Point 7 ...

Page 488: ...ANUAL TRANSMISSION REF 494722 CENTERINGTOOL REF 194635 BALL FITTER REF 262772 EXTRACTOR REF 493764 1 FITTER REF 494989 2 CLIP FITTING GUIDE REF 494989 3 CLIPFITTER REF 494688 1 SEAL FITTING GUIDE SPECIAL TOOL ...

Page 489: ......

Page 490: ...clutch cylinder replacement 7C 6 Auxiliary clutch cylinder replacement 7C 7 Thrust block replacement 7C 8 Clutch fluid replacement 7C 9 REPAIR AND INSPECTION OF THE CLUTCH ASSEMBLY 7C 10 Pressure plate and clutch disc 7C 10 Main clutch cylinder 7C 12 Auxiliary clutch cylinder 7C 14 TORQUE 7C 15 ASSEMBLY DATA AND TOLERANCES 7C 15 REQUIRED SERVICE MATERIALS 7C 15 7C ...

Page 491: ...between when the clutch release bearing is held back This is the engaged condition of the clutch Depressing the clutch pedal causes the release bearing to advance and pushes on the tips of the tapered fingers of the diaphragm spring pulls the pressure plate away from the flywheel Thereby interrupting the flow of drive from flywheel through clutch disc to transmission input shaft 1 Clutch assembly ...

Page 492: ... like disc facings Replace vibration 2 Disc facings dirty with oil Replace 3 Wobbly clutch disc or poor facing contact Replace 4 Weakened torsion springs in clutch disc Replace 5 Clutch disc rivets loose Replace disc 6 Distorted flywheel or pressure plate surfaces Replace clutch cover or flywheel 7 Weakened or loosened engine silentblock nut or bolt Retighten or replace mounting Noisy clutch 1 Bro...

Page 493: ...w 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 Oncetheadjustmentshavebeenmade notetheobservations and torque Torque for rod setscrews 2 2 5 Kg m 20 50 Nm NOTE To clean and dry the parts use fluff free cloths 2 B C A 1 ...

Page 494: ...ss container 3 in order to collect the clutch fluid Make sure the end is always submerged during the bleeding 3 Loosen the bleeder screw 2 4 Push the clutch pedal slowly pausing briefly when the pe dal is up 5 Stop pumping when the liquid comes out without air 6 Keep the piping end submerged and tighten bleeder screw 2 at the same time as pushing the pedal down 7 Adjust clutch fluid level to the t...

Page 495: ...ort 1 with pedal and cylinder 4 Clean assembly on a workbench and removing the cylinder fixing elements from the support and pedal Instalation 1 To install the main clutch cylinder reverse the order of dismantling noting the indicated torque and the clutch pe dal height adjustment see 7C 4 Torque for main cylinder control rod fixing nuts 2 2 5 Kg m 20 25 Nm 1 ...

Page 496: ...ve 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 Bleed the circuit see 7C 5 Torque for auxiliary cylinder setscrews 2 2 2 5 Kg m 22 25 Nm 1 3 2 ...

Page 497: ... 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 Instalation 1 Install in reverse order to dismantling noting the indicated observation and the specified torque Lubricate the turret in which the thrust block moves 2 1 ...

Page 498: ...leeder 3 Stop pumping and fill tank 5 to maximum Max using new recommended fluid 4 Start pedalling again until the tank is empty 5 Check that fluid in the cylinder is approximately double that of the circuit total This guarantees that the old fluid has been successfully flushed out NOTE Never use the old fluid not even in bleeding operations 6 Carry out the final bleeding see 7C 5 and adjust the f...

Page 499: ...s deformations and wear on the thrust block with the diaphragm contact zone Wear limit for the thrust block and diaphragm spring contact zone 0 50 mm 3 Change the pressure plate that shows any of the above or goes beyond the service limit Wear limit for the disc contact surface 0 25 mm 4 Check clutch disc 3 for breakages burns and grease glazed etc 5 Check the facings and grooving for warping and ...

Page 500: ...aft A 3 Tighten pressure plate 2 setscrews 1 slowly and crosswise until reaching the specified torque Torque for pressure plate setscrews 2 75 3 75 Kg m 27 5 37 5 Nm 4 Apply a film of graphite grease to the gearbox main shaft end and fit the gearbox and transfer box assembly see 7A 8 NOTE Fit the clutch disc in its correct position so that it allows friction with the flywheel and pressure plate 3 ...

Page 501: ...he 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 Do not remain in front of the rotor while removing it by compressed air 5 Lift pin 5 separate recovery assembly 6 from rotor 7 and remove casing 8 3 6 2 1 4 7 8 5 ...

Page 502: ...n 2 Fit the assembly A recovery spring and valve in the indicated position Seal valve 9 Rod valve 10 Valve 3 Spring 11 Housing retention spring 12 3 Clean cylinder and the rest of the elements with a dry cloth 4 Apply a film of fluid specified for use in the circuit to the cylinder interior and housing 5 Fit the rotor to the recovery spring and valve assembly and then continue the assembly in reve...

Page 503: ...housing surfaces for scratches corrosion or warping 3 Replace old parts for new ones when necessary 4 Replace the casing for a new one Instalation Instalation cylinder 1 Install housing 3 on rotor 2 with the rim of greater diameter facing the interior of the cylinder 2 Clean cylinder and the rest of the elements with a dry cloth 3 Apply a film of fluid specified for use in the circuit to the casin...

Page 504: ... control rod 2 2 5 Fixing nuts auxiliary cylinder 2 2 2 5 27 5 37 5 20 25 22 25 ELEMENT TORQUE Kg m Nm Contact surface wear pressure plate Contact zone wear diaphragm and thrust block Clutch disc facing wear Clutch disc warping Clutch pedal height Clutch pedal free travel REF PRODUCT TYPE APPLICATION POINT Clutch hydraulic circuit DOT 4 DENOMINATION Play between rod and main clutch pump 1 5 mm 791...

Page 505: ......

Page 506: ...g of the transfer box assembly 7D 15 Speedometer cable replacement 7D 16 GENERAL REPAIR OF TRANSFER BOX 7D 17 Removal service and installation of transfer box 7D 17 TORQUE 7D 35 INSTALLATION DATA AND TOLERANCE 7D 36 REQUIRED SERVICE MATERIALS 7D 36 SPECIAL TOOLS 7D 36 7D NOTE The unions between crankcases or covers they can be carried out by product sealant or for meetings of union During the asse...

Page 507: ...on in high double traction in high and double traction in low The transfer box is extended along its right side to allow the joining of the speedometer casing the brake to transmission and the box for forward axle traction The table of ratios which basically equips the transfer box is the following SELECTED RATIO HIGH LOW 41 26 41 26 40 19 31 41 TOTAL REDUCTION 3 319 1 192 NOTE Ratios marked corre...

Page 508: ...ow sleeve 28 Output high gear 29 Bush 30 Bearing 31 Main shaft nut 32 Snap ring 33 Rear output shaft bearing 34 Oil seal 35 Universal joint flange 36 Bolt 37 Stud bolt 38 Bolt 39 O ring 40 Washer 41 Flange washer 42 Autobraking nut 43 Oil manifold 44 Rear output shaft 45 Worm gear speedometer 46 Worm gear spacer 47 Worn gear case 48 O ring 49 Shaft and pinion speedometer 50 Oil seal 51 Lock plate ...

Page 509: ... Plug 3 Front output case 4 Filler cap 5 Drain plug 6 Lower gasket cover 7 Side cover 8 Input shaft gear case 9 Cover 10 O ring 11 Lock plate 12 Tachometer case 13 4WD switch assembly 14 4WD switch nut 12 1 11 2 9 8 4 10 6 5 3 13 14 7 ...

Page 510: ...leeve and gears Replace sleeve andgears Shift fork shaft or shift fork deformed Replace Lubrication inadequate or insufficient Replenish Worn chamfered tooth on sleeve and gears Replace sleeve or gear Distorted shift shaft Replace Lubrication inadequate or insufficient Replenish Damaged or worn bearing s Replace Damaged or worn gears Replace Worm damaged Replace Gear slips before engaging Gears do...

Page 511: ...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 Plug torque when empty 2 3 Kg m 23 Nm 1 4 Unscrew nutss 4 which fix the propeller shaft clamp 5 Adjust the transmission brake until it blocks using the parkingbrake 5 NOTE If drum does not block use the transmission brake tensing screw 4 5 ...

Page 512: ...l collector 8 3 Fit the rest of the components in reverse order to the removal noting the following points and torque Apply grease to the seal closing lip Torque for the fixing of brake drum and control clamp 11 75 Kg m 117 5 Nm Torque for fixing nuts of constant velocity transmission clamp 2 8 3 5 Kg m 28 35 Nm 6 Remove brake drum 6 together with control clamp by unscrewing the screw 7 and removi...

Page 513: ...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 Installation 1 Fit the 4WD switch and tighten to the specified torque Torque for 4WD switch 2 Kg m 20 Nm 2 Connect the double traction back up light cable 1 to the 4WD switch 1 2 3 ...

Page 514: ...epair the components of the handbrake it is not necessary to dismount the shoe holder plates 1 2 3 4 5 Remove dust guard 5 6 Take out fixing plates 6 7 Remove expansion assembly 7 5 6 7 3 Extend springs 4 to disconnect shoes 1 from their coupling to the extending mechanism and the regulating mechanism NOTE To extend the springs and disconnect the shoes use a GIRLING lever set reference number 1916...

Page 515: ... wear and tear 6 Grease all the components of the two mechanisms and refit in inverse order to removal 7 Fit the shoe adjustment mechanism leaving screws 11 loose 8 Turn screw 13 until pistons extension 12 occurs 9 Check wear on the shoes 10 Clean shoes in volatile liquid trichlorine eliminating dirt and possible oil stains 11 Check that height between the lining rivets and friction zone is more t...

Page 516: ... 6 5 Applying screw 13 bring shoes into line making sure that drum remains free 6 Regulate parkingbrake driving rod using as reference the lever ratchets see 5 22 Maximum efficiency of parkingbrake Point 7 of the ratchet 7 Fit rear propeller tightening the flange screws of the constant velocity to the specified torque Toque for screws of constant velocity propeller clamp 2 8 3 5 Kg m 28 35 Nm 13 ...

Page 517: ...e 7D 16 2 Take out shoe holder plate 2 retention screws 3 Remove shoe holder plate 4 Take out bush 3 and pinion 4 6 Take out speedometer casing retention screws 7 from transfer box 7 Remove speedometer casing 8 2 1 3 4 6 3 4 5 7 8 5 Remove bush 3 Control gear 4 Interior oil seal 5 O ring 6 ...

Page 518: ...rom 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 ...

Page 519: ...ng 5 applying grease to both 7 Grease the gear shaft 4 attach to bush and fix the assembly in its speedometer casing housing 15 8 Apply recommended sealant to the attachment face between the speedometer casing and the transfer box 9 Fix the speedometer casing 8 to the transfer box tightening the screws to the specified torque Torque for speedometer casing screws 4 5 Kgm 40 50 Nm 10 Fix the rest of...

Page 520: ...Speedometer cable see 7D 16 Parkingbrake drive rod see 7D 9 4 Remove transfer lever see 7D 6 5 Disconnect 4WD switch cable see 7D 8 6 Separate transfer box from gear box see 7A 13 Installation 1 Join the gear box to the transfer box noting the torque specific to each task see 7A 12 2 Connect the 4WD switch cable 3 Fit the rest of the components in reverse order to the removal noting the torque spe...

Page 521: ...rom speedometer gear box 1 2 Remove steering wheel outer cover 2 3 Remove dashboard cover 4 Remove screws 4 and dashboard 5 3 2 5 Disconnect speedometer cable from dashboard 6 Replace speedometer cable with a new one and replace the components in reverse order to the removal 4 5 1 5 ...

Page 522: ...sfer 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 7 2 1 3 4 5 6 6 Remove shaft 7 together with its O ring 8 pressing its front part 7 8 5 Remove screw and plate which hold intermediate triple gear shaft 7 ...

Page 523: ...shers 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 10 Unscrew conical screws 15 and remove Supporting plate Drive gear 23 and conical bearings 22 10 11 9 10 11 12 13 18 17 16 15 14 23 22 ...

Page 524: ...ly 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 25 A 20 21 22 B 23 24 16 Put the high low selector in the high position 17 Loosen screw 26 which fixes the yoke selector and remove it 27 26 ...

Page 525: ...nscrew 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 28 29 30 31 32 30 33 34 35 20 Remove main shaft 33 from transfer box along with the high low selector shaft 34 and selector pin ...

Page 526: ... Take off the brake for the extreme rear nut which forms the unit of main shaft gears and remove the aforesaid nut 25 Remove front and rear bearing 41 from the main shaft use a press and conical bearing extractor 41 D 26 Remove main shaft 39 High gear bush 42 High gear 43 Moveable sleeve 44 Sleeve interior nucleus 45 Low gear 46 42 43 44 45 46 39 ...

Page 527: ...ction selector yoke 58 32 Remove Double traction selector shaft 59 Spring 55 Rod 56 Double traction yoke 58 54 55 56 55 56 59 58 57 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 51 52 53 47 48 27 Take out cog bearing 40 from the shaft front inner side 39 using a bearing extractor 40 3...

Page 528: ...Remove the screw which fixes the flange to the output bearing 60 61 35 Remove output bearing 62 and separator 63 using a plastic mallet 36 Remove seals 64 from the outside part of double traction casing 65 37 Remove clip 66 which fixes the support bearing of the front output bearing 62 63 64 65 66 ...

Page 529: ...ngs 4 Check the state of the transfer gear cog teeth Look for possible wear and tear in the gear bearings 5 Look for wear and tear of all the components in the front traction box as well as for possible deformations of springs rods and bearings 6 Check the state of wear and tear in the high low shaft and in zones of contact of the selector rod 38 Remove support bearing 67 using a soft rod C knocki...

Page 530: ...e assembly using calibrated gauges F this play must be within the specific measurements Longitudinal play 0 05 0 15 mm NOTE The longitudinal play of the main shaft gears is determined by the their own mechanism F 5 Install the rear bearing 41 of the main shaft placing it deep in its housing and fit the retaining nut for the installation tightening it to the specified torque Torque for retaining nu...

Page 531: ...ar bearing while the main shaft is being fitted 36 37 11 Place provisionally main transfer shaft assembly 39 in its housing in transfer box 39 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 38 70 ...

Page 532: ...r the low gears and move the entire main shaft assembly upwards until it rests perfectly on its front bearing 17 Determine the movement of the main shaft shown on the meter Repeat the operation several times to do this 18 Once the measure has been obtained add to it the thickness of the pre tingten specified for the main shaft bearings Applicable thickness of pre tingten 0 025 0 076 mm 19 The sum ...

Page 533: ...ed 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 65 68 69 39 24 Fit the ball bearings to the double traction casing this supports the front bearing and fix it with its clip 25 Fit the two oil seals the first with its clos...

Page 534: ...ont outlet bearing 62 the forward traction stud hook 60 positioning the lowered part towards the main transfer shaft 61 60 62 29 Join control rod 56 to the forward traction stud hook 60 30 Compress spring 55 and place it the rod socket 31 Fit selector shaft 59 so that the lowered part is facing forwards and upwards 32 Fix selector yoke 58 to the selector shaft using the pegs 58 59 56 55 33 On each...

Page 535: ...ll 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 Torque for side cover screws 1 5 2 Kg m 15 20 Nm 37 Fit speedometer box 37 applying the recommended sealant to the joint face and fix with screws ...

Page 536: ...action setscrews 2 2 2 8 Kg m 22 28 Nm 42 Put high low selector shaft in the high position 43 Fit selector yoke 27 and fix using locking bolt 26 28 29 26 27 NOTE Make sure that the yokes face one another perfectly 44 Apply the recommended sealant to separator joint face 25 and fix with screws to the specified torque Torque for separator setscrews 2 2 2 8 Kg m 22 28 Nm 25 24 ...

Page 537: ...gten thickness place it in the ring in the rear cover and carry out the final assembly 51 Fit one new O ring 13 in the assembly groove of the intermediate gear shaft and another in the groove of the shaft itself NOTE Apply a layer of grease to both O rings 23 16 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...

Page 538: ...ause injury to the hands 55 Install triple intermediate gear 9 and fix it with its shaft 7 56 Check the axial gear play this must be within the stipulated measurement Axial play 0 00 0 40 mm 57 If the average play is not within the indicated limits replace the axial washers 10 NOTE Make sure that the axial washers are not displaced during the assembly of the intermediate gear assembly 10 11 10 11 ...

Page 539: ...the components in reverse order to the removal noting the specified torque for each task H 3 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 Torque for the lo...

Page 540: ...gear 60 80 40 50 22 28 ELEMENT TORQUE Kg m Nm Setscrews lower cover 1 5 2 Setscrews rear cover 4WD switch 15 20 14 6 19 7 2 2 2 8 1 5 2 2 2 2 8 4 5 2 146 197 22 28 15 20 22 28 40 50 20 Fixing nuts and screws of constant velocity 2 8 3 5 Fixing nuts shoe holder plate 2 2 5 Oil bleeder screw transfer box Setscrews transfer box support Fixing nuts transfer box silentblock support Fixing nuts brake dr...

Page 541: ... Applicable thickness to obtain pre tingten for the main shaft bearings 0 025 0 076 Applicable thickness to obtain pre tingten for the transfer drive gears Parkingbrake maximum efficiency 0 025 0 076 Point 7 on the ratchet REF PRODUCT TYPE APPLICATION POINT Join surfaces casings and covers Setscrews TB 1215 LOCTITE573 TB 1215 QUIMILOCK Filling and oil bleeder screws Axial washers and closing lip s...

Page 542: ...TS 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 7E 17 REQUIRED SERVICE MATERIAL 7E 17 SPECIAL TOOL 7E 18 7E ...

Page 543: ... fundamental as the traction force is concentrated in them Consequently authorised main dealer pieces should be used Tightening torques should be applied as specified repair data and specifications followed and recommended products used only either in repairs or in every day running use The procedures applied when repairing the front differential as explained herein are also valid for the rear dif...

Page 544: ...ial box 11 Differential box ball bearing 12 Ensemble sump differential group 13 Adjusting nut 14 Ensemble plate fixing of adjusting nut 15 Oil seal engaging pinion 16 Washer 17 Supplement for adjusting pinion height 18 Supplement for adjusting preloading rolling pinions 19 Ball bearing pinion head 20 Ball bearing pinion tail FRONT DIFFERENTIAL 11 10 11 8 7 7 9 12 19 17 14 13 18 20 15 2 1 16 4 5 6 ...

Page 545: ...l box 11 Ensemble sump differential group 12 Adjusting nut 13 Supplement for adjusting pinion height 14 Supplement for adjusting preloading rollers pinion 15 Ball bearing differential box 16 Oil seal 17 Ball bearing pinion head 18 Ball bearing pinion tail 19 Ensemble fixing plate for adjusting nuts 20 Rolling washer satellite pinion REAR DIFFERENTIAL 15 10 15 8 20 7 9 11 17 13 19 12 14 18 16 2 1 5...

Page 546: ...ontacts between teeth inadequate between pinion and crown Adjust or replace Looseness of fixing crown bolts Replace or tighten again Planetary or spider gears damaged Replace Ball bearing Constant noise Spoilt Lubricant or mixed with water Replace noises Constant noise Inadequate or insufficient lubricant Replace or add on Noises descending by inertia Damaged Conical pinion ball Replace bearing s ...

Page 547: ...ther as well as the assembly position 2 Install the differential group on a work bench support 3 Mark the position of the lids 1 extract the brake ensem ble 2 and dismantle The lids 1 The nuts 3 The differential ensemble 4 paying attention to keep in the right position the external traisls 4 Dismantle cotter pin 5 from nut fixing the flange 5 Hold flange 6 using tool A dismantle nut and extract fl...

Page 548: ...ers 11 which adjust the preloading of the pinion journals NOTE Keep the washer thickness 11 to assemble them later as an approximate measure 9 11 10 8 7 8 Dismantle screws 12 fixing crown 13 to the differential box 14 and separate the crown 9 Dismantle rollers 15 from differential box and pair them with their respective trails 10 Dismantle roller 16 of the engaging pinion head 12 13 14 15 16 ...

Page 549: ...nd withdraw washer 19 which adjust the height of the engaging pinion NOTE Keep washer thickness 19 to assemble them later as approximate measure 13 Dismantle circlip 20 and extract axle 14 Dismantle the two planet wheels 22 and the two satellite wheels 23 NOTE Keep satellite and planetary wheels in pairs with their housings and washers 19 18 22 23 20 21 23 20 22 21 ...

Page 550: ...he correcting measure to be done engraved on the engaging pinion 1 Write down the sign engraved in the pinion 6 and the numbers before the sign Numbers and letters before the sign correspond to the indenting for proper pairing which must be the same as the one marked on the crown 2 Install trail 18 of the head roller or journal and the adjusting regulating washers 19 whose thickness must be initia...

Page 551: ...he one dismantled If this thickness was lost assemble initially a thickness of no less than 4 06 mm 6 Assemble Rear rolling element 9 Bushing of supplement 8 Flange 6 The nut 24 with its washer 25 tightened to the specified torque Tightening torque nut fixing flange 11 75 Kg m 117 5 Nm NOTE Lubricate rolling elements before assembling them on the sump Do not assemble oil seal jet 7 Wrap a piece of...

Page 552: ...ing gauges D and proceeds as follows If the pinion is at the zero position 0 add underneath trail 18 of the pinion head a certain amount of washers making up for the distance measured with calliper D If the pinion is marked with the sign supplement trail 18 by as much as the measure resulting from subtracting to the D measure the engraved figure after the sign Example Measure D 0 30 Engraving on t...

Page 553: ...the rolling elements of the differential box paying attention not to exchange trails 17 Assemble the crown on the differential box 18 Apply recommended sealant to the screws fixing the crown to the differential box tightening them to the specified tightening torque Tightening torque for screws fixing the differential ensemble 5 5 6 5 Kg m 55 65 Nm 19 Lubricate rolling elements 15 of the differenti...

Page 554: ...crown and pinion To do this proceed as follows Fit a dial gauge E with the dip stick on a tooth of the crown Loose nut 31 located in front of the crown by two or three threads above the lid Tighten nut 32 located behind the crown till cancelling the play between teeth when measuring with the comparator gauge E 32 31 25 Loose slightly nut 32 26 Tighten nut 31 till displacing the crown backwards and...

Page 555: ...he 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 31 Assemble the differential group reversing the dismantling order and taking account the specified tightening torque in the complemenatry task 2 2 ...

Page 556: ... the front differential group see7E 6 taking into account the following remarks The brake ensemble 2 consists of screw and plate as shown in the figure 2 4 3 6 5 7 9 Dismantle the screws 3 joining the upper half sump 4 and the lower half sump 5 Fix a reference for half sumps 4 and 5 with an aligning mark and separate them Withdraw The two planetary gears 6 The satellite axle 7 The four satellite g...

Page 557: ... Tightening torque Nut fixing flange 14 20 Kg m 140 200 Nm Screws fixing crown 12 14 Kg m 120 140 Nm Screws for rolling element lids 12 14 Kg m 120 140 Nm Screws fixing half sumps of differential box 5 6 Kg m 50 60 Nm Resistance to engaging pinion turning without oil seal 12 3 14 3 Kg m 123 143 Nm Revision 1 Revise all the rear differential components in the same way you did in the front different...

Page 558: ...ithout oil seal Maximum Alabeo of crown Play between crown teeth and engaging pinion Front Diff Rear Diff TIGHTENING TORQUE SPECIFICATION Nut fixing flange attack pinion 11 75 Screws fixing crown 14 20 5 5 6 5 Screws fixing rolling element lid Screws fixing half sumps on reinforced groups 117 5 140 200 55 65 ELEMENT TORQUE Kg m Nm 12 14 8 8 5 12 14 5 6 120 140 80 85 120 140 50 60 Front Differentia...

Page 559: ...7E 18DIFFERENTIALS SPECIAL TOOL REF 262757 TRAILEXTRACTOR REF 530105 SPECIAL KEY REF 193349 CALLIPER ADJUSTING ENGAGING PINION REF 262761 FRONT REAR REF 262757 TRAIL ASSEMBLY ...

Page 560: ...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 WIRING To ease identification of each of the circuit a colour code is used 8 ...

Page 561: ...1 12 11 10 13 2 3 4 9 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 Wind screen wiper pump 6 To floor wiring 13 To lateral turn lights 7 To instrument panel wiring 14 To engine wiring 5 8 7 6 14 ...

Page 562: ...tor 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 2 3 4 5 6 1 To main wiring 2 Thermo starter relay 3 Fuse box 4 Starting motor 5 Generator 6 Switch ...

Page 563: ...ting motor switch assy 7 To preformed A C wiring optional 8 To clock 9 To fan motor INSTRUMENT PANEL Instrument panel wiring 3 2 1 4 5 6 7 8 1 To left rear light 2 To defrosting electric pad 3 To right rear light and license light 4 To courtesy light 5 To main wiring 6 To reverse switch 7 To parking brake switch 8 To 4WD switch FLOOR Floor wiring ...

Page 564: ...s 9 7 Door lock 9 9 Door assy 9 10 ROOF 9 11 WINDSCREEN 9 12 Wind screen glass 9 14 SIDE 9 18 REARBODY 9 19 SEATS 9 21 Front seats 9 21 Central seats 9 22 Back seats 9 23 SEAT BELTS 9 24 Seat belts servicing 9 25 COATINGS AND SILENCERS 9 26 Coatings 9 26 Silencers 9 26 ANTICORROSION TREATMENT 9 27 Metallic spare pieces finishing 9 29 FRAME 9 30 REQUIRED SERVICE MATERIAL 9 33 9 ...

Page 565: ...emoval 3 Remove screws fixing regulator support plate and fixing guide to mechanism 4 Withdraw one of the glass guiding profiles to leave it free 5 Withdraw glass through the lower part and its guiding channel 6 Separate glass from channel Instalation 1 Reverse removal procedure noting To fix glass 6 in the lower guiding channel 7 apply soapy water on the guide and fit the glass using a plastic ha...

Page 566: ...f you do not manage lifting or lowering the glass easily it could be that the glass is inclined towards the door frame Adjust the window run regulator in such a way that dimensions A and B are the same 244 285 A A B B Secure sealing door cover with appropriate adhesive ...

Page 567: ...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 ...

Page 568: ...ing 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 Instalation 1 Reverse removal procedure noting specifications of the complementary task 1 3 2 4 ...

Page 569: ...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 layer inside the new door as anticorrosion treatment see 9 27 1 Reverse removal procedure noting Apply sealant off component in the door internal wedge and put back again the door sealant cover 1 2 3 ...

Page 570: ...ip 1 Instalation NOTE If the weather strip to be fixed has been provided as a roll slice a piece having the glass perimeter plus a 25 mm excess in order to be sure there will be a proper fitting of the glass when installed Do the cutting at right angles with some sort of fretting saw 1 Fit weather strip to the frame border noting to the curved areas coupling and press the weather strip till any le...

Page 571: ...sembled on glass press firmly glass onto the weather strip Instalation of the expanding strip 4 Take a roll of expanding strip 4 cut one end at right angle and start assembly on the weather strip beginning now at the opposite lip to the weather strip joint To assembly expanding strip use tool A ref 262771 5 Once done cut at right angle the expanding strip leaving 6 mm more and pressing till proper...

Page 572: ...im 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 Apply sealant off component in the door internal wedge and put back again the door sealant cover 2 1 ...

Page 573: ...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 inside the new door as anticorrosion treatment see 9 27 1 For assembling door reverse the dismantling order 1 2 3 ...

Page 574: ... fixing the roof 3 Remove roof Instalation Instalation 1 Reverse removal procedure noting Substitute sealing rubbers by new ones Check for impermeability throwing water with a hosepipe and if there is any water letting in check that sealing rubbers are well placed NOTE Do not use highly pressurized water neither pressurized air nor infrared radiation for drying ...

Page 575: ...SCREEN 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 1 2 3 4 5 ...

Page 576: ...ct 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 If water is still coming in Remove windscreen and repeat the assembly ...

Page 577: ...opriate punch open a hole through the adhesive and let in a steel wire ill through it 6 With the steel wire cut the adhesive all around the windscreen NOTE To avoid damages on body use the steel wire as near as possible to the glass 7 Using a knife smoothen the adhesive on the body side in such a way that 1 to 2 mm thickness stay all around NOTE Before using your knife clean it with alcohol or sim...

Page 578: ...tly before carrying out the work you should read with care the instructions given by the manufacturer of the adhesive to be used and keep strictly to each one of the stated cautions 1 Using a clearing solvent clean all around the windscreen where the glass is going to fix and let it dry for more than ten minutes 2 To determine the installing position of the glass in the body put the glass in such ...

Page 579: ... width of the adhesive strip must be 10 12 mm Press glass quickly against the body after applying adhesive Use a rubber suction pad to fix and transport the glass after applying the adhesive 10 Fix using rubber suction pad and place the glass against the body aligning the marks you did and press 11 Inspect for impermeability throwing water with a hose pipe over the windscreen NOTE Do not use highl...

Page 580: ... before the adhesive has settled be carefull If the moulding is no firmly anchored in place fix it with tape till the adhesive has settled Each adhesive has its own settling time Check the manufacturer instruction about the fixing time of the adhesive and take into account the stated cautions till the adhesive is fully settled Do not drive the vehicle till the adhesive has fully settled to allow f...

Page 581: ...rresponding 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 Instalation 1 Reverse removal procedure noting the remarks on the complementary tasks 1 2 3 5 4 ...

Page 582: ...move screws 1 fixing rear body 2 to the vehicle floor 7 Remove screws fixing lower profile to front profile in rear body 8 Remove nuts fixing rear body to frame 1 2 Instalation 1 Reverse removal procedure noting the specifications of the complementary tasks and following remarks Assemble new sound insulating plates if necessary in the new rear body Assemble new sealant rubbers connecting sides to ...

Page 583: ... 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 If water entrance continues inspect sealant gaskets repeat assembly if necessary ...

Page 584: ...BODYSERVICE9 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 1 3 2 ...

Page 585: ...SERVICE CENTRAL SEATS Removal 1 Remove butterfly nuts fixing seat to rear body 2 Removescrewsfixingseatlowerlegstorearbodyandremove the seat Instalation 1 Assemble central seats reversing the dismantling order ...

Page 586: ... 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 1 ...

Page 587: ...ny buckle parts and the belt tensioner Avoid whitening or dye the belt Use only soft soap and tepid water for cleaning When installing the seat belt anchoring bolt do it first by hand to avoid damaging the thread Don t tray to repair the retracting mechanism or its cover Replace faulty pieces by new ones Keep always belts dry and clean If in doubt about the worthiness of any piece replace it Repla...

Page 588: ...emble safety belt unit reversing the dismantling order INSPECTION Seat belts and fixing pieces might affect to important components and systems of the vehicle Consequently they must be carefully inspected and substituted only by original pieces Inspect the followings components Seat belt The strip or belt must be free Retractor Should block the strip when pulling it fast Beside the retractor shoul...

Page 589: ...g 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 Instalation 1 Cut the sound proofing coating plate using as a patron the plate to be substituted 2 Assemble plate and fix it to body ...

Page 590: ...ion when repairing the corresponding surfaces All the metal sheets are covered with metal conditioner and pri mer when they come out from the factory When repairs are done or pieces are replaced all the naked metal surfaces must be cleaned and covered with rust proof primer Do this work before applying the sealer and the anticorrosion was coating Sealants are applied to specific unions of a vehicl...

Page 591: ...our paint at all the part previously coloured 5 Apply anticorrosion compound penetrating wax 6 Apply protecting layer rust proof material When welding or heating lead to burning of the original galvanic protection or the anticorrosive materials in the surface the surfaces of internal sheets and under the bodywork must be cleaned Cleaning of burning residues must be done carefully when the place to...

Page 592: ...p 8 Paints require different drying methods Follow manufacturer instructions indicated in the paint container 9 When applying lacquer fast drying paint layer dry the painted surface and polish with a polishing compound If melamine or acrylic is being used no latter polishing after drying is required 10 If a lacquer coating is used do no apply was on the covered surface till full complete drying ab...

Page 593: ...ently it is essential to carry out thorough surveys of the framework doing if necessary weldings related to its correction or substitution When it is found that the plugging treatment or the anticorrosion one on the framework are damaged it is compulsory to repair immediately followed by an anticorrosion treatment see 9 27 NOTE To check main dimensions of the frame see the annexed sketches ...

Page 594: ...BODYSERVICE9 31 FRAME MAIN DIMENSIONS ...

Page 595: ...9 32BODYSERVICE FRAME MAIN DIMENSIONS ...

Page 596: ...BODYSERVICE9 33 REF PRODUCT TYPE USE REQUIRED SERVICE MATERIAL Windscreen glass BETASEAL 1752 791009 Door panel ADHESIVE XK21233 Doors SEALANT 17550 Doors PUTTY 13991 ...

Page 597: ...TECHNICALDATA10 1 SECTION 10 TECHNICAL DATA CONTENTS ENGINE 10 2 GEAR AND TRANSFER BOX 10 3 DIMENSIONS AND PHYSICAL CONDITIONS 10 4 WEIGHTS 10 4 10 ...

Page 598: ...ar 20 2 6 16 kw Maximum power CV r p m 75 5 80 5 102 7 109 5 88 8 95 2 120 8 129 5 Nm Maximum torque kgm r p m 250 25 5 275 5 304 7 28 1 31 1 1 800 Maximum r p m regime engine without loading r p m 4 200 25 4 200 50 Minimum r p m regime engine without loading r p m Working pressure injectors bar 240 12 1 350 electro injector Maximum opening of the thermostat at 110 ºC Oil pressure when the engine ...

Page 599: ...ar box ratios Hand operation GEAR AND TRANSFER BOX TYPE 1st gear 3 647 2nd gear 2 179 3rd gear 1 435 4th gear 1 000 5th gear 0 795 Transfer box ratios High 1 192 Low 3 319 3 909 Transmission ratio differential groups 43 11 ...

Page 600: ... mm Overall height mm Turning radius m Front and rear tract width mm Entry angle Ground clearence mm 40º 45º 500 Fording deepness mm Maximum slope Lateral angle Maximum authorised weight kg Weight in gear order kg Maximum load kg Maximum towing weight A Without auxiliary brake kg B With auxiliary brake kg 5 Doors WEIGHTS TYPE 3 050 2 050 1 000 750 2 040 ...

Page 601: ...ELECTRICAL DIAGRAMS ...

Page 602: ...ELECTRICAL DIAGRAMS 2 ONLY COMMON RAIL POWER SUPPLY DIAGRAM ...

Page 603: ...ELECTRICAL DIAGRAMS 3 ONLY COMMON RAIL ENGINE CONTROL SYSTEM ELECTRONIC FUEL INJECTION CONNECTOR A ...

Page 604: ...ELECTRICAL DIAGRAMS 4 ONLY COMMON RAIL ENGINE CONTROL SYSTEM ELECTRONIC FUEL INJECTION CONNECTOR B ...

Page 605: ...ELECTRICAL DIAGRAMS 5 ONLY COMMON RAIL STARTING HEATER VALVE DIAGRAM ...

Page 606: ...ELECTRICAL DIAGRAMS 6 ONLY COMMON RAIL GLOW PLUG STARTING HEATER RELAY DIAGRAM ...

Page 607: ...ELECTRICAL DIAGRAMS 7 ONLY COMMON RAIL FUEL FILTER SENSORS DIAGRAM ...

Page 608: ...ELECTRICAL DIAGRAMS 8 ONLY COMMON RAIL DOUBLE STOP SWITCH ...

Page 609: ...ELECTRICAL DIAGRAMS 9 ONLY COMMON RAIL FUEL PUMP ...

Page 610: ...ELECTRICAL DIAGRAMS 10 ONLY COMMON RAIL DIAGNOSIS DIAGRAM ...

Page 611: ...ELECTRICAL DIAGRAMS 11 ONLY COMMON RAIL A C DIAGRAM ...

Page 612: ...ELECTRICAL DIAGRAMS 12 ONLY MECHANICAL INJECTION POWER SUPPLY DIAGRAM ...

Page 613: ...ELECTRICAL DIAGRAMS 13 ONLY MECHANICAL INJECTION GLOW PLUG RELAY DIAGRAM ...

Page 614: ...ELECTRICAL DIAGRAMS 14 ONLY MECHANICAL INJECTION INSTRUMENT PANEL ...

Page 615: ...ELECTRICAL DIAGRAMS 15 ONLY MECHANICAL INJECTION COMBINATION METER DIAGRAM ...

Page 616: ...ELECTRICAL DIAGRAMS 16 ONLY MECHANICAL INJECTION COOLING SYSTEM ...

Page 617: ...ELECTRICAL DIAGRAMS 17 GENERAL DIAGRAMS HEADLAMP LEVELING SYSTEM DIAGRAM ...

Page 618: ...ELECTRICAL DIAGRAMS 18 GENERAL DIAGRAMS REVERSE LAMP DIAGRAM ...

Page 619: ...ELECTRICAL DIAGRAMS 19 GENERAL DIAGRAMS RADIO REAR WINDOW DEFOGGER ...

Page 620: ...ELECTRICAL DIAGRAMS 20 GENERAL DIAGRAMS REAR DEMISTER STOP LAMP DIAGRAM ...

Page 621: ...ELECTRICAL DIAGRAMS 21 GENERAL DIAGRAMS HORN DIAGRAM ...

Page 622: ...ELECTRICAL DIAGRAMS 22 GENERAL DIAGRAMS TURN SIGNAL HAZARD LAMP DIAGRAM ...

Page 623: ...ELECTRICAL DIAGRAMS 23 GENERAL DIAGRAMS LAMPS DIAGRAM ...

Page 624: ...ELECTRICAL DIAGRAMS 24 GENERAL DIAGRAMS WASHER WIPER DIAGRAM ...

Page 625: ...ELECTRICAL DIAGRAMS 25 GENERAL DIAGRAMS CHARGING SYSTEM DIAGRAM ...

Page 626: ...Prepared by SANTANA MOTOR S A After Sales Service Department 1st Ed October 2002 Printed in Spain Printed October 2002 ...

Page 627: ......

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