Santana PS-10 User Manual

CONTENTSGENERALHEATER AND VENTILATIONBUMPER, ENGINE HOOD AND FRONTALSTEERING, SUSPENSION AND WHEELSPROPELLER SHAFTBRAKE SYSTEMENGINE AND ITS SYSTEMSTR

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VENGINE 6A-056A-05. CYLINDER HEAD3 6A0511 LOCK PLUG SUBSTITUTIO

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCYLINDER HEAD 6A-05Cylinder head 1CYLINDER HEAD 6A-05Cylinder head gasket 2Lock pl

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V96A0522VALVE SEAT RECTIFICATION (ONE)(SEPARATED VALVE)INCLUDES

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCYLINDER HEAD 6A-05Cylinder head 1CYLINDER HEAD 6A-05Cylinder head gasket 2Lock pl

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V10 6A0530 DESCALING AND RECTIFICATION NEXT VALVE(SEPARATED VAL

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-06. CRANKSHAFTENGINE 6A-061 6A0601 D / M FRONT CRANKSHAFT S

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VENGINE 6A-066A-06. CRANKSHAFT4 6A0611 CLEARANCE CONTROL BETWEE

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V5 6A0618 CONNECTING ROD CRANKPINS DIAMETER MEASURE(FOUR)(SEPAR

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VENGINE 6A-076A-07. PISTONS AND CONNECTING RODS106A0708D / M CO

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V11 6A0714 DIAMETER MEASURE INSIDE CONNECTING ROD BEAR(ONE)(SEP

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V136A0724PISTON RINGS SUBSTITUTION (FOUR PISTONS)INCLUDES:- Ext

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V15 6A0803 0.2D / M EXTREME SUPPORT BEARING PLATE OF PRIMARYGE

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCRANKSHAFT 6A-06Front catch cover 1PISTONS AND CONNECTING RODS 6A-07Rear catch cov

GENERAL CONTENTS PAG1. HOW TO READ THIS MANUAL ... 22. HOW TO USE THIS MA

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V216A0814 5.0D / M DUSTGUARD PLATE OF FLYWHEEL COVERING(SEPARAT

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCAMSHAFT AND TIMING 6A-09Camshaft 1CAMSHAFT AND TIMING 6A-09Cam 2Front seal cover

6 ENGINE AND ITS SYSTEMS ENGINE 6A-09POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V1 6A0901 D / M CAMSHAFTINCLUDES:- Control and mea

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCAMSHAFT AND TIMING 6A-09Camshaft 1CAMSHAFT AND TIMING 6A-09Cam 2Front seal cover

6 ENGINE AND ITS SYSTEMS ENGINE 6A-09POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6 6A0913 D / M PLUNGERS AND CONTROL(SEPARATED ENG

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCAMSHAFT AND TIMING 6A-09Camshaft 1CAMSHAFT AND TIMING 6A-09Cam 2Front seal cover

6 ENGINE AND ITS SYSTEMS ENGINE 6A-09POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V12 6A0927 ENGINE BEARING TIMING REVISION(SEPARATE

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSAUXILIARY ORGANS GROUP 6A-10Bracket housing assembly 1FRONT ENGINE MOUNTING 6A-11F

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VENGINE 6A-101 6A1001 D / M BRACKET HOUSING ASSEMBLYINCLUDES:-

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSAUXILIARY ORGANS GROUP 6A-10Bracket housing assembly 1FRONT ENGINE MOUNTING 6A-11F

1. HOW TO READ THIS MANUAL6 ENGINE AND ITS SYSTEMS6A-06-07-08 ENGINESection numberIndicates section number and the product it refers to (consult index

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VENGINE 6A-10-116 6A1101 FRONT CUSHION SUBSTITUTION (ONE) 0.85

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSFUEL INJECTION 6A-12Injection assembly 1FUEL INJECTION 6A-12Injection pump bush 2L

6 ENGINE AND ITS SYSTEMS ENGINE 6A-12POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V16A1201D / M AND TARE INJECTION PUMP (*)INCLUDES:

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSFUEL INJECTION 6A-12Injection assembly 1FUEL INJECTION 6A-12Injection pump bush 2L

6 ENGINE AND ITS SYSTEMS ENGINE 6A-12POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-12. FUEL INJECTION4 6A1216 ELECTRICAL PEAR DEV

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSFUEL INJECTION 6A-12Injection assembly 1FUEL INJECTION 6A-12Injection pump bush 2L

6 ENGINE AND ITS SYSTEMS ENGINE 6A-12POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-12. FUEL INJECTION(*) INCLUDES AIR DRAIN11 6A1

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSFUEL INJECTION 6A-12Injection assembly 1FUEL INJECTION 6A-12Injection pump bush 2L

6 ENGINE AND ITS SYSTEMS ENGINE 6A-12POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-12. FUEL INJECTION18 6A1246 D / M HIGH PRESSUR

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSFUEL INJECTION 6A-12Injection assembly 1FUEL INJECTION 6A-12Injection pump bush 2L

1 3 5 51 52 9 7 2 48 516A 06 18Section codeComponent assembly codeCorrelative operation number 52 51 52 6A 06 00Section codeComponents assem

6 ENGINE AND ITS SYSTEMS ENGINE 6A-12POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A1200 OTHER*20 6A1249 D / M HIGH PRESSURE HYDRAU

ENGINE COOLING... 6BWATER PUMP, THERMOSTAT AND HEAT EXCHAN

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSWATER PUMP, THERMOSTAT AND HEATEXCHANGER TUBING6B-01 VENTILATOR AND CONTROL BELTS

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6B-01. WATER PUMP, THERMOSTAT AND HEAT EXCHANGER

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSWATER PUMP, THERMOSTAT AND HEATEXCHANGER TUBING6B-01 VENTILATOR AND CONTROL BELTS

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6B-02. VENTILATOR AND CONTROL BELTS13 6B0207 D / M COOLING FAN

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSWATER RADIATOR ANDDEGASING BOX6B-03WATER HOSE6B-04Radiator assembly 1Water radiato

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V 6B-03. WATER RADIATOR AND DEGASING BOX1 6B0301 D / M WATER RA

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSWATER RADIATOR ANDDEGASING BOX6B-03WATER HOSE6B-04Radiator assembly 1Water radiato

Symbols " " " - "- When the symbol appears " " in the repair time column, it means there is no established tim

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6B-04. WATER HOSES8 6B0402 VISUAL LOSS CONTROL IN COOLING CIRC

FEEDING AND EMISSION CONTROL ... 6CFUEL FEEDING ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMS6C-01 FEEDING AND EMISSION CONTROLFUEL FEEDING 6C-01Fuel tank 1FUEL FEEDING 6C-01F

POSBASICOPERATIONCODE6 ENGINE AND ITS SYSTEMSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6C-01. FUEL FEEDINGFEEDING AND EMISSION CONTROL 6C-011 6C0101

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMS6C-01 FEEDING AND EMISSION CONTROLFUEL FEEDING 6C-01Fuel tank 1FUEL FEEDING 6C-01F

POSBASICOPERATIONCODE6 ENGINE AND ITS SYSTEMSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6C-01. FUEL FEEDINGFEEDING AND EMISSION CONTROL 6C-018 6C0116

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMS6C-01 FEEDING AND EMISSION CONTROLFUEL FEEDING 6C-01Fuel tank 1FUEL FEEDING 6C-01F

POSBASICOPERATIONCODE6 ENGINE AND ITS SYSTEMSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6C-01. FUEL FEEDINGFEEDING AND EMISSION CONTROL 6C-01(*) INCLU

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMS6C-02 FEEDING AND EMISSION CONTROLAIR OVERFEEDING 6C-02Air cleaner assembly 1AIR O

2. HOW TO USE THIS MANUALWhen you have done a repair, substitution, adjustment, etc..., consult this manual to apply correct operation codeand repair

POSBASICOPERATIONCODE6 ENGINE AND ITS SYSTEMSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VFEEDING AND EMISSION CONTROL 6C-026C-02. AIR OVERFEEDING1 6C0

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMS6C-02 FEEDING AND EMISSION CONTROLAIR OVERFEEDING 6C-02Air cleaner assembly 1AIR O

POSBASICOPERATIONCODE6 ENGINE AND ITS SYSTEMSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VFEEDING AND EMISSION CONTROL 6C-026C-02. AIR OVERFEEDING13 6C0

COMPONENTS POS COMPONENTS POS COMPONENTES POS6 ENGINE AND ITS SYSTEMS6C-03 FEEDING AND EMISION CONTROLSENSORS, THERMISTORS AND ENGINECONTROL SWITCHES6

POSBASICOPERATIONCODE6 ENGINE AND ITS SYSTEMSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6C-03. SENSORS, THERMISTORS AND ENGINE CONTROL SWI

COMPONENTS POS COMPONENTS POS COMPONENTES POS6 ENGINE AND ITS SYSTEMS6C-03 FEEDING AND EMISION CONTROLSENSORS, THERMISTORS AND ENGINECONTROL SWITCHES6

POSBASICOPERATIONCODE6 ENGINE AND ITS SYSTEMSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6C0300 OTHER*13 6C0314 D / M PRE-HEATING RESISTOR(*) 0.3 0.3 0

ENGINE ELECTRICAL SYSTEM... 6GGENERATOR AND BATTERY ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSGENERATOR AND BATTERY 6G-01 STARTING MOTOR 6G-02Generator assembly 1Rectifier brid

BasicOperation:D/M CRANKSHAFT PULLEYComplementaryOperation:Additional time:ADDITIONAL TIME WITH AIR CONDITIONEROperation code: 6A0622 AOperati

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6G-01. GENERATOR AND BATTERY1 6G0101 D / M GENERATOR 0.6ENGINE

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSGENERATOR AND BATTERY 6G-01 STARTING MOTOR 6G-02Generator assembly 1Rectifier brid

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6G-01. GENERATOR AND BATTERYENGINE ELECTRICAL SYSTEM 6G-013 6G

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSGENERATOR AND BATTERY 6G-01 STARTING MOTOR 6G-02Generator assembly 1Rectifier brid

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6G-02. STARTING MOTORENGINE ELECTRICAL SYSTEM 6G-0213 6G0201 D

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSGENERATOR AND BATTERY 6G-01 STARTING MOTOR 6G-02Generator assembly 1Rectifier brid

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6G-03. THERMO-STARTING AND E.C.M. CONTROL UNITENGINE ELECTRICA

ENGINE EXHAUST SYSTEM ... 6KEXHAUST MANIFOLD...

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSEXHAUST MANIFOLD 6K-01Protection 1MUFFLER 6K-02Retainer 2Exhaust manifold 3Exhaust

Example 3: (When the OTHER "00" has to be used)Model code: AL01 (mechanical injection)Basic operation: CRANKSHAFT PULLEY ALIGNMENT CHECKStep

6 ENGINE AND ITS SYTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6K-01. EXHAUST MANIFOLD6K-02. MUFFLERENGINE EXHAUST SYSTEM 6K-0

ENGINE LUBRICATION ... 6LOIL PUMP ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSOIL PUMP 6L-01Oil pump gear 1OIL FILTER AND COOLER 6L-02Oil pump valve 2Suction st

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6L-01. OIL PUMP6L-02. OIL FILTER AND COOLERENGINE LUBRICATION

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSOIL PUMP 6L-01Oil pump gear 1OIL FILTER AND COOLER 6L-02Oil pump valve 2Suction st

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6L-02. OIL FILTER AND COOLERENGINE LUBRICATION 6L-026 6L0208 D

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSOIL PUMP 6L-01Oil pump gear 1OIL FILTER AND COOLER 6L-02Oil pump valve 2Suction st

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V16 6L0305 D / M OIL RETURN PIPE ASSEMBLY OFTURBOCHARGER0.46L-0

3. CONDITION FOR ESTABLISHING FLAT RATE TIMESDefinition of flat rate timeThe flat rate time in this manual refer to the time required to perform warr

TRANSMISSION ... 7GEAR BOX ...

.

GEAR BOX ... 7ATRANSMISSION CASE ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONTRANSMISSION CASE 7A-01Gear box and transfer assembly 1Gear box 2Input shaft bearing retaine

7 TRANSMISSIONPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V7A-01. TRANSMISSION CASE7A-02. INTERNAL ORGANS1 7A0101 D-M OR SUBSTITUTI

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONTRANSMISSION CASE 7A-01Gear box and transfer assembly 1Gear box 2Input shaft bearing retaine

7 TRANSMISSIONPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V7A-02. INTERNAL ORGANS7A-03. GEAR SHIFTING CONTROLGEAR BOX 7A-02-0320 7A

CLUTCH ... 7CHYDRAULIC COMPONENTS .

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONHYDRAULIC COMPONENTS 7C-01Master cylinder 1MECHANICAL COMPONENTS 7C-02Tank assembly 2Plug 38

HEATER AND VENTILATION ... 1AHEATING CONTROL ...

7 TRANSMISSIONPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V7C-01. HYDRAULIC COMPONENTS7C-02. MECHANICAL COMPONENTSCLUTCH 7C-01-021

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONHYDRAULIC COMPONENTS 7C-01Master cylinder 1MECHANICAL COMPONENTS 7C-02Tank assembly 2Plug 38

7 TRANSMISSIONPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VOTHER7C0200*7C0207 CLUTCH RELEASE BEARING SUBSTITUTION 4.5137C-02. MECHA

TRANSFER... 7DTRANSFER CASE ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONTRANSFER CASE 7C-01Transfer assembly 1INTERNAL ORGANS 7D-02Transfer case 2Front output case

7 TRANSMISIONPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMESAL01 AL02 AL03 AS02 AS03C/V7D-01. TRANSFER CASE7D-02. INTERNAL ORGANSTRANSFER 7D-01-021 7

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONTRANSFER CASE 7C-01Transfer assembly 1INTERNAL ORGANS 7D-02Transfer case 2Front output case

7 TRANSMISIONPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMESAL01 AL02 AL03 AS02 AS03C/V7D-02. INTERNAL ORGANS7D-03. TRANSFER SELECTOR LEVERTRANSFER

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONTRANSFER CASE 7C-01Transfer assembly 1INTERNAL ORGANS 7D-02Transfer case 2Front output case

COMPONENTS POS COMPONENTS POS COMPONENTS POSHEATING CONTROL 1A-01Heating control panel 1Heating control lever assembly 2Heater switch 3Control assembl

7 TRANSMISIONPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMESAL01 AL02 AL03 AS02 AS03C/V25 7D0307 SHIFT CONTROL LEVER ASSEMBLY REPAIR 0.87D0300 OTHER*

FRONT AND REAR DIFFERENTIAL ... 7EFRONT DIFFERENTIAL GEAR ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS7 TRANSMISSIONFRONT DIFFERENTIAL GEAR 7E-01Front differential assembly 1REAR DIFFERENTIAL GEAR 7E-02Pinion

7 TRANSMISSION FRONT AND REAR DIFFERENTIAL 7E-01-02POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V1 7E0101 FRONT DIFFERENTIAL ASSEMBL

BODY ELECTRICAL SYSTEM ... 08WIRING AND RELAYS...

COMPONENTS POS COMPONENTS POS COMPONENTS POSWIRING AND RELAYS 08-01Wiring main harness 1SWITCHES 08-02Instrument panel harness 2Wiring floor harness 3

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V08-01. WIRING AND RELAYS08-02. SWITCHES1 080101 WIRING MAIN HARNESS SUBSTITUTION 2.02

COMPONENTS POS COMPONENTS POS COMPONENTS POSWIRING AND RELAYS 08-01Wiring main harness 1SWITCHES 08-02Instrument panel harness 2Wiring floor harness 3

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V1A-01. HEATING CONTROL1A-02. HEATER AND VENTILATOR1 1A0101 HEATING CONTROL PANEL SUBST

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V08-02. SWITCHES08-03. INDICATORSBODY ELECTRICAL SYSTEM 08-02-0315 080205 REAR DEFFOGER

COMPONENTS POS COMPONENTS POS COMPONENTS POSHEADLAMP 08-04Headlamp assembly 1OTHER LAMPS 08-05Side lamp assembly 2Bulb 3678Front turn lamp assemblyFro

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V08-04. HEADLAMP08-05. OTHER LAMPS1 080401 HEADLAMP ASSEMBLY SUBSTITUTION (ONE)INCLUDES

COMPONENTS POS COMPONENTS POS COMPONENTS POSHEADLAMP 08-04Headlamp assembly 1OTHER LAMPS 08-05Side lamp assembly 2Bulb 3678Front turn lamp assemblyFro

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V14 080510 ROOM LAMP ASSEMBLY SUBSTITUTION 0.315 080511 ROOM LAMP LENS AND BULB SUBSTIT

BODY AND FRAME... 09BODY PANELS ...

COMPONENTS POS COMPONENTS POS COMPONENTS POSBODY PANELS 09-01Gear shift case and floor panel 1ROOF AND MOLDINGS 09-02Dash panel assembly 2Frnot window

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-01. BODY PANELS09-02. ROOF AND MOLDINGS1 090101 GEAR SHIFT CASE AND FLOOR PANEL SUB

COMPONENTS POS COMPONENTS POS COMPONENTS POSBODY PANELS 09-01Gear shift case and floor panel 1ROOF AND MOLDINGS 09-02Dash panel assembly 2Frnot window

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V15 090207 D / M ROOF AND SIDE REAR BODY ASSEMBLYADDITIONAL TIME FOR SLIDING GLASS ON S

COMPONENTS POS COMPONENTS POS COMPONENTS POSDOORS AND LOCKS 09-03Front door assembly 1DOORS AND LOCKS 09-03Rear side door assembly 2Rear door assembly

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-03. DOORS AND LOCKSBODY AND FRAME 09-031 090301 FRONT DOOR ASSEMBLY SUBSTITUTION (O

COMPONENTS POS COMPONENTS POS COMPONENTS POSTRIMS AND DOOR REGULATOR 09-04Front door trim 1WINDOW GLASS 09-05Center door trim 2Rear door trim 309-04-0

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-04. TRIMS AND DOOR REGULATOR09-05. WINDOW GLASSBODY AND FRAME 09-04-051 090401 FRON

COMPONENTS POS COMPONENTS POS COMPONENTS POSTRIMS AND DOOR REGULATOR 09-04Front door trim 1WINDOW GLASS 09-05Center door trim 2Rear door trim 309-04-0

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V090500 OTHER*17 090512 FIXED SIDE REAR DOOR GLASS GUIDE SUBSTITUTION(ONE GUIDE)0.217 0

COMPONENTS POS COMPONENTS POSSEATS AND SEAT BELTS 09-06Front seat 1INNER GARNISHES 09-07Center seat 2Side rear seat 309-06-07 BODY AND FRAMEFront belt

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-06. SEATS AND SEAT BELTS09-07. INNER GARNISHESBODY AND FRAME 09-06-071 090601 FRONT

COMPONENTS POS COMPONENTS POSSEATS AND SEAT BELTS 09-06Front seat 1INNER GARNISHES 09-07Center seat 2Side rear seat 309-06-07 BODY AND FRAMEFront belt

BUMPER, GRILLE AND ENGINE HOOD ... 02BUMPER ...

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-07. INNER GARNISHESBODY AND FRAME 09-0720 090712 BACK DOOR SCUFF SUBSTITUTION (ONE)

COMPONENTS POS COMPONENTS POSRUBBERS ANDWEATHERSTRIP PROFILES09-08Roof weatherstrip 109-08Upper side roof rubber 2Side rear roof rubber 309-08 BODY AN

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V1 090801 ROOF WEATHERSTRIP SUBSTITUTION(SEPARATED WINDSHIELD, OP.090104)0.209-08. RUBB

COMPONENTS POS COMPONENTS POSRUBBERS ANDWEATHERSTRIP PROFILES09-08Roof weatherstrip 109-08Upper side roof rubber 2Side rear roof rubber 309-08 BODY AN

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-08. RUBBER AND WEATHERSTRIP PROFILESBODY AND FRAME 09-0817 090817 HOOD LACTH RELEAS

COMPONENTS POS COMPONENTS POSCHASSIS FRAME ASSEMBLY 09-09Frame assembly 1CHASSIS FRAME ASSEMBLY 09-091st crossmember 2Engine rear bracket 309-09 BODY

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-09. CHASSIS FRAME ASSEMBLYBODY AND FRAME 09-091 090901 BODY TO CHASSIS SEPARATION A

COMPONENTS POS COMPONENTS POSCHASSIS FRAME ASSEMBLY 09-09Frame assembly 1CHASSIS FRAME ASSEMBLY 09-091st crossmember 2Engine rear bracket 309-09 BODY

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V09-09. CHASSIS FRAME ASSEMBLYBODY AND FRAME 09-0917 090918 CROSSMEMBER 6TH REINFORCEME

COMPONENTS POS COMPONENTS POS COMPONENTS POSBUMPER 02-01Front bumper 1Cover outer bumper 2Cover center bumper 3ENGINE HOOD 02-02Hood hinge 8Opener dri

Prepared bySANTANA MOTOR S.A.After-Sales Service Department1st Ed. October 2002Printed in SpainPrinted: October 2002

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V02-01. BUMPERS02-02. ENGINE HOOD02-03. GRILLE1 020101 FRONT BUMPER ASSEMBLY SUBSTITUTI

COMPONENTS POS COMPONENTS POS COMPONENTS POSBUMPER 02-01Front bumper 1Cover outer bumper 2Cover center bumper 3ENGINE HOOD 02-02Hood hinge 8Opener dri

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V02-03. GRILLE15 020307 FRONT FRAME WELDERING ASSEMBLY SUBSTITUTION 1.317 020309 R/H HE

SECTION CODE INDEXCODESSEC. ASS.CODESSEC. ASS.HEATER AND VENTILATIONHeating controlHeater and ventilator1A1A-011A-02BUMPER, ENGINE HOOD AND FRONTALBu

STEERING, SUSPENSION AND WHEELS ... 3STEERING ...

.

STEERING ... 3BTIE ROD AND RODS ...

COMPONENTS POS COMPONENTS POS COMPONENTS POSTIE ROD AND RODS 3B.01Control rod 1Union rod 2Tie rod 3POWER-STEERING SYSTEM 3B.02Filter 5Intake pipe 63B-

3 STEERING, SUSPENSION AND WHEELSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V3B-01. TIE ROD AND RODS3B-02. POWER-STEERING SYSTEM1

COMPONENTS POS COMPONENTS POS COMPONENTS POSTIE ROD AND RODS 3B.01Control rod 1Union rod 2Tie rod 3POWER-STEERING SYSTEM 3B.02Filter 5Intake pipe 63B-

3 STEERING, SUSPENSION AND WHEELSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VPITMAN ARM SUBSTITUTIONINCLUDES:- Turning radius meas

STEERING WHEEL ... 3CSTEERING WHEEL AND COLUMNS ...

3 STEERING, SUSPENSION AND WHEELSCOMPONENTS POS COMPONENTS POS COMPONENTS POSSTEERING WHEEL AND COLUMNS 3C.01Steering wheel 1Upper and lower cover 2St

FOREWORDThis Flat Rate Manual contains the operations and times assigned to repair SANTANA vehicles related in model code listin GENERAL section. The

POSBASICOPERATIONCODE3 STEERING, SUSPENSION AND WHEELSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V3C-01. STEERING WHEEL AND COLUMNS1 3C0101 STEERING WH

FRONT SUSPENSION ... 3DFRONT SPRINGS ...

3 STEERING, SUSPENSION AND WHEELSCOMPONENTS POS COMPONENTS POS COMPONENTS POSFRONT SPRINGS 3D.01Front spring 1Bush 2Spring bumper 3FRONT SHOCK ABSORBE

3 STEERING, SUSPENSION AND WHEELSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V3D-01. FRONT SPRINGS3D-02. FRONT SHOCK ABSORBER1 3D01

REAR SUSPENSION... 3EREAR SPRINGS ...

3 STEERING, SUSPENSION AND WHEELSCOMPONENTS POS COMPONENTS POS COMPONENTS POSREAR SPRINGS 3E.01Rear spring 1Bush 2Rear stopper 3REAR SHOCK ABSORBER 3E

3 STEERING, SUSPENSION AND WHEELSPOSBASICOPERATIONCODEMODEL CODE ANDREPAIR TIMEAL01 AL02 AL03C/V3E-01. REAR SPRINGS3E-02. REAR SHOCK ABSORBER1 3E0101

1A-01-02 02-01-02-03 3B-01-023C-01 3D-01-02 3E-01-023F-01 4A-01-02-03 4B-01-02ILLUSTRATION INDEX

WHEELS ... 3FWHEEL AND TYRES ...

3 STEERING, SUSPENSION AND WHEELSCOMPONENTS POS COMPONENTS POS COMPONENTS POSWHEEL AND TYRES 3F.01Wheel 1Tyre 2Wheel 33F-01 WHEELS

3 STEERING, SUSPENSION AND WHEELSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V3F-01. WHEEL AND TYRES1 3F0101 WHEEL SUBSTITUTION (ON

PROPELLER SHAFT ... 4FRONT DRIVE SHAFT ...

.

FRONT DRIVE SHAFT ... 4AFRONT SHAFT ASSEMBLY ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS4 PROPELLER SHAFTSFRONT SHAFT ASSEMBLY 4A-01Front axle assembly 1Front axle housing 2King pin assembly 3FR

4 PROPELLER SHAFTSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V4A-01. FRONT SHAFT ASSEMBLY4A-02. FRONT WHEEL HUB ASSEMBLY1 4A0101 D

COMPONENTS POS COMPONENTS POS COMPONENTS POS4 PROPELLER SHAFTSFRONT SHAFT ASSEMBLY 4A-01Front axle assembly 1Front axle housing 2King pin assembly 3FR

4C-016A-01-026A-03-046A-056A-06-07-086A-096A-10-1105-01 05-02

4 PROPELLER SHAFTSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V4A-02. FRONT WHEEL HUB ASSEMBLY4A-03. KING PIN ASSEMBLYFRONT DRIVE S

COMPONENTS POS COMPONENTS POS COMPONENTS POS4 PROPELLER SHAFTSFRONT SHAFT ASSEMBLY 4A-01Front axle assembly 1Front axle housing 2King pin assembly 3FR

4 PROPELLER SHAFTSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V4A-03. KING PIN ASSEMBLY18 4A0314 LEFT PITMAN ARM SUBSTITUTION (*)

REAR DRIVE SHAFT ... 4BREAR SHAFT ASSEMBLY...

COMPONENTS POS COMPONENTS POS COMPONENTS POS4 PROPELLER SHAFTSREAR SHAFT ASSEMBLY 4B-01Rear shaft assembly 1Rear shaft housing 2King pin 3REAR WHEEL H

4 PROPELLER SHAFTSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V4B-01. REAR SHAFT ASSEMBLY4B-02. REAR WHEEL HUB ASSEMBLY2 4B0102 REA

PROPELLER SHAFTS ... 4CPROPELLER SHAFT ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS4 PROPELLER SHAFTSPROPELLER SHAFT 4C-01Propeller front shaft 1Propeller rear shaft 24C-01 PROPELLER SHAFTS

6A-126B-01-026C-016C-026C-036G-01-02-036K-01-02 6L-01-02-036B-03-04

POSBASICOPERATIONCODE4 PROPELLER SHAFTSMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V4C-01. PROPELLER SHAFT1 4C0101 PROPELLER FRONT SHAFT SUBSTITUTION 0.

BRAKE SYSTEM ... 05PARKING BRAKE & DISC BRAKE COMPO

COMPONENTS POS COMPONENTS POS COMPONENTS POSPARKING BRAKE & DISC BRAKECOMPONENTS05-01Transmission brake 1Switch transmission brake 2Parking brake

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V05-01. PARKING BRAKE & DISC BRAKE COMPONENTS1 050101 TRANSMISSION BRAKE MEASURE 0.

COMPONENTS POS COMPONENTS POS COMPONENTS POSPARKING BRAKE & DISC BRAKECOMPONENTS05-01Transmission brake 1Switch transmission brake 2Parking brake

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V05-01. PARKING BRAKE & DISC BRAKE COMPONENTS18 050121 REAR BRAKE ASSEMBLY SUBSTITU

COMPONENTS POS COMPONENTS POS COMPONENTS POSHYDRAULIC CIRCUIT & SERVOBRAKE05-02Brake pedal bracket 1Pedal assembly and bracket 2Brake master cylin

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VBRAKE SYSTEM 05-0205-02. HYDRAULIC CIRCUIT & SERVOBRAKE1 050201 BRAKE PEDAL BRACKE

COMPONENTS POS COMPONENTS POS COMPONENTS POSHYDRAULIC CIRCUIT & SERVOBRAKE05-02Brake pedal bracket 1Pedal assembly and bracket 2Brake master cylin

7A-01-02-037C-01-027C-01-02-037E-01-0208-01-02-0308-04-0509-01-0209-0309-04-05

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VBRAKE SYSTEM 05-0205-02. HYDRAULIC CIRCUIT & SERVOBRAKE(*) INCLUDES FILLING, DRAIN

COMPONENTS POS COMPONENTS POS COMPONENTS POSHYDRAULIC CIRCUIT & SERVOBRAKE05-02Brake pedal bracket 1Pedal assembly and bracket 2Brake master cylin

POSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V050237 MASTER CYLINDER TO FIVE WAY VALVE PIPESUBSTITUTION AFTER ANOTHER INTERVENTION I

ENGINE AND ITS SYSTEMS ... 6ENGINE ASSEMBLY ...

.

ENGINE ASSEMBLY ... 6ASTRIPPED ENGINE ...

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSSTRIPPED ENGINE 6A-01Stripped engine 1COMPLETE ENGINE 6A-02Complete engine 26A-01-

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-01. STRIPPED ENGINE6A-02. COMPLETE ENGINE16A0101D / M STRIP

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSSTRIPPED ENGINE 6A-01Stripped engine 1COMPLETE ENGINE 6A-02Complete engine 26A-01-

09-06-0709-0809-09

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-02. COMPLETE ENGINE2 6A0203 REMOVAL,CLEAN,VERIFICATION, MEA

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSSTRIPPED ENGINE 6A-01Stripped engine 1COMPLETE ENGINE 6A-02Complete engine 26A-01-

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V2 6A0205 GENERAL ENGINE REPARATION(SEPARATED ENGINE)INCLUDES:-

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCYLINDER BLOCK 6A-03Upper block 1OIL PAN 6A-04Lock plug 2Lower block 3Engine flat

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-03. CYLINDER BLOCK6A-04. OIL PANENGINE 6A-03-041 6A0301 PLA

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCYLINDER BLOCK 6A-03Upper block 1OIL PAN 6A-04Lock plug 2Lower block 3Engine flat

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/VENGINE 6A-046A-04. OIL PAN9 6A0405 OIL FLAT GASKET SUBSTITUTIO

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCYLINDER HEAD 6A-05Cylinder head 1CYLINDER HEAD 6A-05Cylinder head gasket 2Lock pl

6 ENGINE AND ITS SYSTEMSPOSBASICOPERATIONCODEMODEL CODES ANDREPAIR TIMEAL01 AL02 AL03C/V6A-05. HEAD CYLINDERENGINE 6A-051 6A0503 D / M CYLINDER HEAD(S

COMPONENTS POS COMPONENTS POS COMPONENTS POS6 ENGINE AND ITS SYSTEMSCYLINDER HEAD 6A-05Cylinder head 1CYLINDER HEAD 6A-05Cylinder head gasket 2Lock pl