SERVICEBULLETINS

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SERVICEBULLETINS
SERVICE BULLETINS
INHALTSVERZEICHNIS
Service Bulletin
Datum
Seite
Klima- und Heizungsdiagramm
01.07.2005
1
Streichung Reparaturset Zylinder
14.10.2004
3
Kupplungsmodifikation
02.06.2003
5
Hintere Carrosserie-Modifikation
05.07.2004
7
Hochdruckeinspritzpumpe
13.07.2004
11
Dachreparatur
05.07.2006
13
Motorhaubenfixierung
16.09.2005
19
Verbindung Getriebe / Schalthebel
26.09.2005
21
Schalthebelmodifikation
28.10.2005
23
Kupplungsmodifikation
14.06.2005
29
Seitentürenverkleidung
18.05.2005
31
Hecktürenstopper
13.07.2004
33
Neues Getriebe (ZF)
09.09.2005
35
Neuer Ölfilter
03.03.2005
37
Neue Teilenummer Rückbank
07.09.2005
39
Lärmdämmung Radkasten
21.05.2004
41
Kardanwellenumbau
27.05.2005
43
Blattfedermodifikation
04.05.2005
47
Schaltermodifikation
23.11.2004
49
Heizungsklappenmodifikation
06.06.2005
51
Scheibenwischermotorabdichtung
28.05.2007
53
SERVICE
REFERENCE NO.
:
PS-011
DATE
:
Jul. 01st, 2005
PAGE
:
1 of 2
SUBJECT
:
PS-10 SERVICE MANUAL A/C & HEATING WIRING DIAGRAM
APPLICABLE MODEL
:
PS-10 (Type 2 – E-III)
V.I.N. OR FRAME NO.
:
REFERENCE OF PARTS CATALOGUE
:
791044-C1I
This Service Bulletin is edited to inform you about a modification in the PS-10 Service
Manual for Front and rear (if equipped) A/C and heating system wiring diagram.
Please update your Service Manual according to the next sheets. Also please provide your
dealers with this information.
MANUAL NAME
PS-10 Service Manual
PART NUMBER
791044-C1I
SANTANA MOTOR, S.A.
CORRESPONDING PAGE
Sec. Electrical Diagrams 26
GENERAL DIAGRAMS
A/C-HEATER REAR & FRONT
ELECTRICAL DIAGRAMS-26
SPARE PARTS
REFERENCE Nº
:
PS-030/ 04-I
DATE
:
14-10-2004
PÁGI NA
:
1 DE 1
SUBJECT
:
CANCELATI ON OF REPAI R SET
AFFECTED MODELS
:
PS-10
V.I .N. OR ENGI NE Nº
:
ALL VEHCI LES
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you that Repair Set (p.n. 194519) is not going to be
supplied as Spare Part any longer, affecting this modification to all PS-10 vehicles.
In Fig. 41, Pos. 30 Ref. 194519 Repair Set , is no longer supplied as Spare Part, being modified to
Pos. 17 Ref. 173275 Auxiliary Cylinder Assy , which includes Pos.30.
FIG.41
CLUTCH
POS. REFERENCE
DESCRIPTION
17
30
AUXILIARY CYLINDER ASSSY
REAPIR SET
173275
194519
Thanks to take note and modify your catalogues accordingly.
Fdo: Juan Morales López
Asesor Técnico
QTY´.
1
1
REMARKS
INCLUDES 194519
MODIFIED TO 173275
SPARE PARTS
REFERENCE Nº
:
PS-013/003-I
DATE
:
02-06-2003
PAGE
:
1/1
SUBJECT
:
CLUTCH ASSY AND DISK
AFFECTED MODELS
:
SANTANA (PS-10)
V.I.N. OR ENGINE NUMBER
:
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about some modifications that have been introduced
in the above mentioned catalogue.
FIG. 41, pos. 1 Ref. PS-110052 CLUTCH ASSY, has been modified by Ref. PS-110075
pos. 2 Ref. PS-110051 CLUTCH DISK, has been modified by Ref. PS-110076.
This modification is not interchangeable separately with the old references.
VINs shown in the column UP TO, must order p.n. PS-110075 and also PS-110076.
FIG.41 CLUTCH
POS.Nº REFERENCE
DESCRIPTION
QTY´.
REMARKS
1-1
PS-110052
CLUTCH ASSY
1
PS-110075+PS-110076
1-2
PS-110075
CLUTCH ASSY
1
FROM VIN (see index)
2-1
PS-110051
DISK, CLUTCH
1
PS-110075+PS-110076
2-2
PS-110076
DISK, CLUTCH
1
FROM VIN (see index)
UP TO VIN
FROM VIN
FROM VSFPSW20V00100001; UP TO VSFPSW20V00100371
FROM VSFPSW20V00100388; UP TO VSFPSW20V00100394
AND ALSO VIN Nº
VSFPSW20V00100377; VSFPSW20V00100381; VSFPSW20V00100383
FROM VSFPSW20V00100372; UP TO VSFPSW20V00100376
FROM VSFPSW20V00100378; UP TO VSFPSW20V00100380
FROM VSFPSW20V00100384; UP TO VSFPSW20V00100387
FROM VSFPSW20V00100395 ONWARDS
AND ALSO VIN Nº
VSFPSW20V00100382;
Kindly take note and modify your catalogues accordingly
Fdo. Fº Javier Machado Baldasano
Asesoramiento Técnico
SPARE PARTS
REFERENCE Nº
:
PS-023/04-I
DATE
:
05-07-2004
PAGE
:
4 PAGES
SUBJECT
:
CROSSMEMBER AND MOULDING SIDE MODIFICATIONS
AFFECTED MODELS
:
SANTANA PS-10
V.I.N. OR ENGINE NUMBER
:
SHOWN IN THIS BULLETIN
CATALOGUE REFERENCE
:
790960-02I
With this Service Bulletin we inform you about the new Crossmembers and Door Moulding Side,
affecting to all PS-10 vehicles from VINs shown in this Bulletin.
In Fig. 88 the following modifications have been introduced:
Pos. 12 changes to:
- Pos. 12-1 fitted according NOTE 1, a new pos. is created:
- Pos. 12-2 fitted according NOTE 2.
Pos. 31-1 is assembled according NOTE 1, and the following positions are created:
Pos. 31-3 fitted according NOTE 2, BOTH FOR TYPE 1
- Pos. 31-2 fitted according NOTE 1,
- Pos. 31-4 fitted according NOTE 2, BOTH FOR TYPE 2
Pos. 35 changes to:
- Pos. 35-1 fitted according NOTE 1, a new pos. is created
- Pos. 35-2 fitted according NOTE 2
FIG.88
REAR BODY
POS.
REFERENCE
DESCRIPTION
12
12-1
12-2
31-1
31-2
31-3
31-4
35
35-1
35-2
PS-901533
PS-901533
PS-902195
PS-901534
PS-901721
PS-902194
PS-902192
PS-901532
PS-901532
PS-902191
CROSSMEMBER ASSY, Nº 2 & Nº 3
CROSSMEMBER ASSY, Nº 2 & Nº 3
CROSSMEMBER ASSY, Nº 2 & Nº 3
CROSSMEMBER ASSY
CROSSMEMBER ASSY
CROSSMEMBER ASSY
CROSSMEMBER ASSY
CROSSMEMBER ASSY, Nº 1
CROSSMEMBER ASSY, Nº 1
CROSSMEMBER ASSY, Nº 1
Rest of positions in this figure are not affected by this modification
QTY´.
1
1
1
1
1
1
1
1
1
1
REMARKS
CHANGES TO 12-1
NOTE 1
NOTE 2
TYPE 1 1 (NOTE 1)
TYPE 2 (NOTE 1)
TYPE 1 (NOTE 2)
TYPE 2 (NOTE 2)
CHANGES TO 35-1
NOTE 1
NOTE 2
SPARE PARTS
REFERENCE Nº
:
PS-023/04-I
DATE
:
05-07-2004
PAGE
:
4 PAGES
FIG.88
In Fig. 101 the following modifications have been introduced:
Pos. 7 changes to:
- Pos. 7-1 fitted according to NOTE 1, pos. 7-2 is created
- Pos. 7-2 fitted according to NOTE 2.
Pos. 8 changes to:
- Pos. 8-1 fitted according to NOTE 1, pos. 8-2 is created
- Pos. 8-2 fitted according to NOTE 2.
FIG.101
GARNISH / SPLASH GUARD
POS.
REFERENCE
DESCRIPTION
7
7-1
7-2
8
8-1
PS-911058
PS-911058
PS-911794
PS-911059
PS-911059
MOULDING SIDE, L/H
MOULDING SIDE, L/H
MOULDING SIDE, L/H
MOULDING SIDE, R/H
MOULDING SIDE, R/H
QTY´.
1
1
1
1
1
REMARKS
CHANGES TO 7-1
NOTE 1
NOTE 2
CHANGES TO 8-1
NOTE 1
SPARE PARTS
8-2
PS-911795
REFERENCE Nº
:
PS-023/04-I
DATE
:
05-07-2004
PAGE
:
4 PAGES
MOULDING SIDE, R/H
1
NOTA 2
Rest of positions in this figure are not affected by this modification
FIG.101
NOTE 1: Vehicles previous to the modifications
TYPE 1 UP TO VIN: ~ VSFPSW10V00100208
UP TO VIN: ~ VSFPSW20V00101243
NOTE 1
TYPE 2 AND ALSO VINs
~ VSFPSW20V00101350, ~ VSFPSW20V00101352
~ VSFPSW20V00101360, ~ VSFPSW20V00101361
NOTE 2: From first vehicle that is affected by this modifications, onwards .
NOTE 2 TYPE 1 FROM VIN: VSFPSW10V00100209 ~
ONWARDS
SPARE PARTS
REFERENCE Nº
:
PS-023/04-I
DATE
:
05-07-2004
PAGE
:
4 PAGES
FROM VIN: VSFPSW20V00101362 ~
ONWARDS
AND ALSO VINs
TYPE 2 FROM ~ VSFPSW20V00101244 UP TO ~ VSFPSW20V00101249
VSFPSW20V00101351~
FROM ~ VSFPSW20V00101353
UP TO ~ VSFPSW20V00101359
Thanks to take note and modify your catalogues accordingly
Fdo: Juan Morales López
Asesor Técnico
SPARE PARTS
SUBJECT
:
AFFECTED MODELS
:
V.I.N. OR ENGINE NUMBER
:
CATALOGUE REFERENCE
:
REFERENCE Nº
:
PS-024/04-I
DATE
:
13-07-2004
Nº PAGES
:
2
DIVISION INTO PARTS OF THE HIGH PRESSURE
INJECTION PUMP
PS-10 TYPE 2
790960-02I
The purpose of this Service Bulletin is to inform you about division into parts of the High Pressure Injection
Pump, in order to supply as spare part the Pressure Regulator, affecting to all PS-10 vehicles (Type 2)
In Fig. 16 you have to add the following modifications:
New pos. added: Pos. 10, Ref. A140031-009
New pos. added: Pos. 11, Ref. A140031-010
New pos. added: Pos. 12, Ref. A140031-011
New pos. added: Pos. 13 Ref. A140031-012
Pos. 10 includes Pos. 11, 12 and 13
Pressure regulator .
engine, plain washer .
joint .
ring .
Spare Parts Catalogue will stay as shown below:
FIG.16
INJECTION PUMP
POS.
REFERENCE
DESCRIPTION
10
11
12
13
A140031-009
A140031-010
A140031-011
A140031-012
PRESSURE REGULATOR
PLAIN WASHER, ENGINE
JOINT
RING
Rest of positions in this Fig. are not affected by this modification.
FIG.16
QTY´.
1
1
1
1
REMARKS
TYPE 2
TYPE 2
TYPE 2
TYPE 2
SPARE PARTS
REFERENCE Nº
:
PS-024/04-I
DATE
:
13-07-2004
Nº PAGES
:
2
Thanks to take note and modify your catalogues accordingly.
Fdo: Juan Morales López
Asesor Técnico
SERVICE
REFERENCE NO.
:
PS-018
DATE
:
July 5th, 2006
PAGE
:
1 of 5
SUBJECT
:
FISSURES IN ROOF. REPAIR PROCEDURE
APPLICABLE MODEL
V.I.N. OR FRAME NO.
:
:
PS-10
REFERENCE OF PARTS CATALOGUE
:
We are issuing this Service Bulletin to inform you about the procedure to recover roofs in PS-10 model in case of
appearing of fissures on the roof border.
1.- APLICATION
Apply to PS-10 Roof PS-901562 / PS-901629
2.- MATERIALS AND TOOLS
-
Trowel Nº33
Chisel
Cúter
Rubber gloves
Putty knife
Sandpaper no. 60
Container for the mix
Polyester resin
Catalyst for the polyester resin
Fibre Mat-375 gr/m•
Acetone
Paint (Polyuretane Ivory Textured)
Catalyst polyuretane for textured
Poyiuretane solvent
SANTANA MOTOR, S.A.
3.- DIAGNOSIS
Fissures in the roof border as in the pictures below.
4.- REPAIR PROCEDURE
1.- Clean up the area affected using a pneumatic saw..
2.- Clean with pressurized air the area affected.
SANTANA MOTOR, S.A.
3.- Prepare the Fibre strips Mat-375 of aprox. 80mm width and a length according to the affected area.
4.- Prepare in a container the amount of resin adequate for the area affected, adding a 2% of catalyst to the quantity of
resin used, and mixing both components.
5.- Apply the resin prepared with the trowel No.33 in both sides of the fibre strip Mat-375.
SANTANA MOTOR, S.A.
6.- Place the fibre strips in the affected areas and assisting of a putty knife introduce the fibre strips inside the groove.
7.- Clean with a cloth impregnated with acetone the remains of resin.
8.- After finishing this operation, you must wait the chemical reaction of the resin 8aprox. 15 minutes depending of the
temperature).
SANTANA MOTOR, S.A.
9.- Press the repaired areas using jacks.
10.- Cut using a cuter the remains of fibre or using a mechanical sander if the fibre has become too tough.
11.- Sand the area affected with sandpaper No. 60 to correct possible defects of undulations.
12.- Paint the areas repaired using the next proportion in volume:
10% catalyst
20% solvent
SANTANA MOTOR, S.A.
SANTANA MOTOR, S.A.
SERVICE
REFERENCE NO.
:
PS-012
DATE
:
Sep. 16th, 2005
PAGE
:
1 of 3
SUBJECT
:
HOOD LOCK FIXATION RECOVERY
APPLICABLE MODEL
:
PS-10
V.I.N. OR FRAME NO.
:
SEE ITEM 3. VIN AFFECTED
REFERENCE OF PARTS CATALOGUE
:
We are editing this Service Bulletin to inform you about the needed of proceed to the
recovery and improvement of the hood lock fixations in the PS-10 vehicles indicated in the
item 3 and according to the procedure described in the item 4 of this communication.
We request you that:
•
•
•
For the vehicles affected that you or your dealers have still in stock, you carry out the
operations described in the item 4 before proceeding to the sale of the vehicle.
For the vehicles affected already sold, proceed to carry out the operations described in
the item 4 during the first visit of the owner to the dealer to be serviced.
The complete range of vehicles affected by this bulletin must be recovered during the
next 6 months after the launching date of this document.
1.- SITUATION.
Recovery and improvement of hood lock fixations. Picture 1.
Pict. 1
2.- CORRECTION
Replacement, tight and checking of hood lock fixations as indicated in item 4.
SANTANA MOTOR, S.A.
3.- VIN AFFECTED.
Vehicles before:
∼ VSFPSW20V00102146
∼ VSFPSW10V00100212
∼ VSFPSL20T00100134
∼ VSFPSL10T00100021
4.- REPAIR PROCEDURE
The area to recover is hood lock fixations. To have visual access we must follow the next
steps:
1.- Raise the hood and secure it with the hood stay rod.
2.- Remove the left hand side of the hood lock. See picture 2 & 3.
Fixation
Pict. 2
Pict. 3
3.- Once removed the fixation bolt, fit a new bolt ref. 01500-06123, apply a retaining
adhesive, fit the washers ref. 08321A31063 and 08322-01063 and tighten it to 1.0
Kgm. Picture 4.
New bolt
Pict. 4
SANTANA MOTOR, S.A.
SPARE PARTS
REFERENCE Nº
:
PS-008/05-3I
DATE
:
26/09/05
PAGE
:
1/2
3ª EDITION
SUBJECT
:
JOINING OF THE ZF GEAR BOX, LEVER
AFFECTED MODELS
:
ALL
V.I.N. OR ENGINE NUMBER
:
VSFPSW20V00101808
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about needed components for the joining of the
Lever in the New Gearbox (Ref. 791129) ZF model.
POSITION
1
1
2
3
4
5
6
7
8
REFERENCE
PS-201092
PS-201093
PS-210189
PS-210183
PS-210177
PS-201087
PS-210180
PS-201091
PS-210186
DESCRIPTION
GEAR LEVER ASSY & GASKET
GEAR LEVER ASSY & GASKET
BOOT, GEAR LEVER HOUSING
GASKET FOR LEVER
GEAR LEVER BRACKET
LINK ASSY
STUD
GASKET, SELECTOR SHAFT
CIRCLIP
REMARKS
LHD
RHD
SPARE PARTS
Fdo: Juan Morales López
Asesor Técnico
REFERENCE Nº
:
PS-008/05-E
DATE
:
26/09/05
PAGE
:
2/2
SERVICE
REFERENCE NO.
:
PS-013
DATE
:
October 28th, 2005
PAGE
:
1 of 4
SUBJECT
:
ZF GEAR BOX LEVER PLAY / LINK BREAKING
APPLICABLE MODEL
:
PS-10
V.I.N. OR FRAME NO.
:
SEE ITEM 2. VIN AFFECTED
REFERENCE OF PARTS CATALOGUE
:
We are editing this Service Bulletin to inform you about the needed of recovery and improvement of Gear Box Lever in the vehicles
equipped with ZF Gear Box indicated in the item 2 of this bulletin, according to the procedure described in the annexe I.
We request you that:
•
•
•
For the vehicles affected that you or your dealers have still in stock, you must carry out the operations described in the annexe I
before proceeding to the sale of the vehicle.
For the vehicles affected already sold, proceed to carry out the operations described in the annexe I during the first visit of the
owner to the dealer to be serviced.
For vehicles already sold that show the problem of excessive vibration / play in the gear box lever or Link Assy breaking, proceed
to repair it according to the procedure described in the annexe I.
1.- SITUATION
It is necessary to replace the next parts of the Gear Box lever Assy:
LINK;
à
PS-201087
GEAR BOX LEVER ASSY
REF.- PS-201092 LHD
PS-201093 RHD
SELECTOR SHAFT BUSH
REF.- PS-201091 + PAD REF PS-210196
FLAT WASHER
REF.- PS-210185
Picture 1
SANTANA-MOTOR, S. A.
2.- VIN AFFECTED.
VSFPSW20V00101526
FROM VSFPSW20V00101808 – TO VSFPSW20V00102330
FROM VSFPSW20V50101944 – TO VSFPSW20V50101993
FROM VSFPSW10V00100209 – TO VSFPSW10V00100262
FROM VSFPSL10T00100001 – TO VSFPSL10T00100026
FROM VSFPSL20T00100066 – TO VSFPSL20T00100158
3.- WARRANTY PROCEDURE
CLAIM CATEGORY:
COMPLAINT CODE:
DEFECT CODE:
BASIC CODE:
HOURS OTHERS CODES:
CAUSAL PART:
ASSOCIATED PARTS:
8
ZC
99
7A0300
1.2
PS-201087
PS-201091
PS-201092
(PS-201093)*
PS-210185
PS-210196
QTTY: 1
QTTY: 1
QTTY: 1
QTTY: 1
QTTY: 1
*For RHD vehicles
SANTANA-MOTOR, S. A.
ANNEXE 1: PROCEDURE OF RECOVERY OF GEAR BOX LEVER ASSY
1
4.1.- Disassembly the lever assy knob. Ref.- PS-210048 / POS. 1.
Picture 1.
Picture1
4.2.- Remove the floor carpet pad POS.2, that cover the gear box
tunnel. Picture 2.
2
Picture 2
4.3.- Remove the Gear Shift Lever Boot, loosening the four fixing bolts of the base plate POS. 3. Picture 3.
Remove the bolts of the plate POS. 4. (picture 3) to have access to the Gear Box lever elements. Picture 4
Picture 4
Picture 3
4
3
4.5.- Remove the lever boots Ref.- PS-210189 / POS. 4, and Ref.29345-60A01 / POS. 5. Picture 5.
5
4
Picture 5
4.6.- Remove the fixing bolts of the lever bracket to the rear
housing. Ref.- BH110071 / POS. 6. Picture 6.
Picture 6
Note.- Torque when fitting: 2 - 2.5 kg.
6
SANTANA MOTOR, S.A.
4.7.- Remove the front fixing shaft Ref.- PS-210187 / POS. 7 to the rear
housing. Picture 7.
Note.- Take care of fitting again the fixing shaft in the same
position.
7
Picture 7
4.8.- Remove the fixing clip that links the bush to the sliding rod (picture 8), taking out the ring POS. 8 and lock pin POS. 9
(pictures 8 and 9).
9
8
Picture 9
Picture 8
4.9.- Replace the next parts:
Picture 10
1/ Gear Box Assy Lever. Ref.- PS-201092 (PS201093)
Extract the lever removing the fixing clip link and
replace it for the new lever. Picture 10.
Picture 11
2/ Selector shaft bush. Ref.- PS-201091
Remove the bush and replace it for a new one as
previously explained, fitting inside the pad ref. PS210196. Picture 11 & 12.
Picture 12
3/ Link Assy. Ref.- PS-201087.
4/ Flat Washer. Ref.- PS-210185.
Fitted in the fixing shaft of the lever assy bracket
to the rear housing. Picture 1.
4.10.- Once replaced these parts, fit the Lever Assy in reverse order to the described above.
SANTANA MOTOR, S.A.
Wir redigieren diesen Dienstbericht, um dich über das erforderliche der
Wiederaufnahme und der Verbesserung des Getriebe-Hebels in den Trägern
zu informieren, die mit dem ZF Getriebe ausgerüstet werden, das im
Einzelteil 2 dieser Nachricht, entsprechend dem Verfahren angezeigt
wird, das im Anhang I. beschrieben wird. Wir verlangen dich das: · Für
die Träger beeinflußte, daß du oder deine Händler noch auf Lager haben,
du muß die Betriebe durchführen, die im Anhang I beschrieben wurden,
bevor es zum Verkauf des Trägers fortfuhr. · Für die Träger beeinflußte
bereits verkauft, fortfahren, die Betriebe durchzuführen, die im Anhang
I während des ersten Besuchs des Inhabers zum instandgehalten zu werden
beschrieben wurden Händler. · Für Träger verkaufte bereits, die das
Problem übermäßiger Erschütterung/Spiel im Getriebehebel oder in der
Verbindung Zus zeigen, die bricht, fortfahren, sie entsprechend dem
Verfahren zu reparieren, das im Anhang I. beschrieben wurde. 1. SITUATION Es ist notwendig, die folgenden Teile der Getriebe-Hebel Zus
zu ersetzen:
4.1. - Zerlegung der Hebelzusdrehknopf. Hinweis. - PS-210048/POSITION 1.
Abbildung 1.
4.2. - Die Fußbodenteppichauflage POS.2, diese Abdeckung entfernen der
Getriebetunnel. Abbildung 2.
4.3. - Die Gangschaltung-Hebel-Aufladung entfernen und die vier
regelnschraubbolzen der Grundplatte Position 3 lösen. Abbildung 3. Die
Schraubbolzen der Platte Position 4 entfernen. (Abbildung 3) Zugang zu den
Getriebe-Hebelelementen haben. Abbildung 4
4.5. - Den Hebelaufladungen Hinweis entfernen. - PS-210189/Position 4 und
Hinweis. - 29345-60A01/Position 5. Abbildung 5.
4.6. - Die regelnschraubbolzen des Hebelhaltewinkels zur Rückseite
entfernen Gehäuse. Hinweis. - BH110071/POSITION 6. Abbildung 6. Anmerkung.
- Drehkraft, bei der Einpassung: 2 - 2.5 Kilogramm. 1 Picture1 2 Abbildung
2 Abbildung 3 Abbildung 4 4 3 5 4 Abbildung 5 6 Abbildung 6 SANTANA MOTOR,
S.A.
4.7. - Den vorderen regelnwelle Hinweis entfernen. - PS-210187/Position 7
zur Rückseite Gehäuse. Abbildung 7. Anmerkung. - Nehmenobacht von die
regelnwelle im selben wieder passen Position.
4.8. - Den regelnclip entfernen, der den Busch mit der gleitenden Stange
(Abbildung 8) verbindet und die Ring Position 8 und Verriegelung Stift
Position 9 herausnimmt (Abbildungen 8 und 9).
4.9. - Die folgenden Teile ersetzen:
1 Getriebe-Zus-Hebel. Hinweis. - PS-201092 (PS- 201093) Den Hebel
extrahieren, der die regelnclipverbindung entfernt und sie für den neuen
Hebel ersetzen. Abbildung 10. 2 Wählwelle Busch. Hinweis. - PS-201091 Den
Busch entfernen und ihn für ein Neues wie ersetzen vorher erklärt, passend
innerhalb des Auflageverweises PS- 210196. Abbildung 11 u. 12. 3 Verbindung
Zus. Hinweis. - PS-201087. Flache Unterlegscheibe 4. Hinweis. - PS-210185.
Gepaßt in die regelnwelle des Hebelzushaltewinkels zum hinteren Gehäuse.
Abbildung 1.
4.10. - Ersetzte einmal diese Teile, passen die Hebel-Zus im Rückauftrag zu
oben beschrieben.
SPARE PARTS
REFERENCE Nº
:
PS-005/05-I
DATE
:
14-06-2005
PAGE
:
1/2
SUBJECT
:
MODIFICATION CLUTCH, SPACER JOINT
AFFECTED MODELS
:
PS-10
V.I.N. OR ENGINE NUMBER
:
FROM VSFPSW20V00101974
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about modification in the Clutch, Spacer Joint in
the above mentioned vehicles.
Interchangeability is affected, and it´s not possible replacement neither of the old part by the New one,
nor in the opposite way.
FIG.75
CLUTCH PEDAL
POS. REFERENCE
DESCRIPTION
QTY´.
19-1
269783
SPACER
1
19-2
PS-110090
SPACER
1
REMARKS
UP TO
VSFPSW20V00101973
FROM
VSFPSW20V00101974
SPARE PARTS
REFERENCE Nº
:
PS-005/05-I
DATE
:
14-06-2005
PAGE
:
2/2
Thanks to take note and modify your catalogues accordingly
Fdo: Juan Morales López
Asesoramiento Técnico
SPARE PARTS
REFERENCE Nº
:
PS-002/05-I
DATE
:
18/05/05
PAGE
:
1/1
SUBJECT
:
MODIFICATION IN THE PANEL ASSY, DASH
AFFECTED MODELS
:
ALL
V.I.N. OR ENGINE Nº
:
VSFPSW20V00101578
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about the modification that have been introduced
in the Panel Assy, Dash
This modification must be included in FIG. 85 of the above mentioned catalogue
Part number PS-901214, has been declared Out of Production, and part number PS-902094 must be
fitted as replacement, ordering also the following parts:
REFERENCE
DESCRIPTION
PS-902206
DOOR, STOPPER ASSY
2
PS-911811
STUD, STOPPER
2
08322-11103
WASHER
2
08321A11088
RING, STOPPER
2
Fdo: Juan Morales
Asesoramiento Técnico
QTY´.
5.- WARRANTY PROCEDURE
CLAIM
SANTANA MOTOR, S.A.
SPARE PARTS
REFERENCE Nº
:
PS-025/04-I
DATE
:
13-07-2004
Nº OF PAGES
:
2
SUBJECT
:
NEW FIG. 103A, DOOR STOPPER
AFFECTED MODELS
:
PS-10
V.I.N. OR ENGINE Nº
:
SHOWN IN THIS BULLETIN
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about the new Rear Door, Stopper, which can be
found in a new FIG. 103A, and affects to all PS-10 vehicles from VIN numbers shown in this Bulletin. This FIG.
will stay in the catalogue as follow:
Pos. 1 Ref. 81851-85C00 Rear Door, Stopper Spring
Pos. 2 Ref. 81852-61A00 Shaft for spring
Pos. 3 Ref. 09159-06076 Nut M6 .
Pos. 4 Ref. PS-902147 Spring Bracket , door in the roof .
Pos. 5 Ref. PS-911746 Spring Bracket, Cap .
Pos. 6 Ref. PS-000065 Fixing Screw, Bracket to roof .
FIG.103A
REAR DOOR STOPPER
POS. REFERENCE
DESCRIPTION
1
2
3
4
5
6
RR DOOR, STOPPER SPRING
SPRING, SHAFT
NUT M6
SPRING BRACKET, DOOR IN THE ROOF
SPRING BRACKET, CAP
FIXING SCREW, BRACKET ROOF
81851-85C00
81852-61A00
09159-06076
PS-902147
PS-911746
PS-000065
FIG.103A
QTY´.
1
2
2
1
1
2
REMARKS
FROM VIN
FROM VIN
FROM VIN
FROM VIN
FROM VIN
FROM VIN
SPARE PARTS
REFERENCE Nº
:
PS-025/04-I
DATE
:
13-07-2004
Nº OF PAGES
:
2
In Fig. 100, Pos. 1 changes to:
- Pos. 1-1 Ref. PS-901629 Panel Assy, Roof and a
- New pos. is created Pos. 1-2 Ref. PS-901562 Panel Assy, Roof ,
FIG.100
ROOF PANEL
POS. REFERENCE
DESCRIPTION
1
1-1
1-2
PANEL ASSY, ROOF
PANEL ASSY, ROOF
PANEL ASSY, ROOF
PS-901629
PS-901629
PS-901562
QTY´.
REMARKS
1
1
1
CHANGES TO POS. 1-1
UP TO VIN
FROM VIN
Rest of positions in this FIG don´t change
Vehicles with VIN nº previous to the modifications.
TYPE 1 UP TO VIN: ~ VSFPSW10V00100208
UP TO VIN: ~ VSFPSW20V00101243
UP TO
TYPE 2 AND ALSO VIN´S
~ VSFPSW20V00101350, ~ VSFPSW20V00101352
~ VSFPSW20V00101360, ~ VSFPSW20V00101361
From the first vehicle affected by these modifications, onwards
FROM
TYPE 1 FROM VIN: VSFPSW10V00100209 ~
ONWARDS
FROM VIN: VSFPSW20V00101362 ~
ONWARDS
.
AND ALSO VINs
TYPE 2 FROM ~ VSFPSW20V00101244 UP TO~ VSFPSW20V00101249
VSFPSW20V00101351~
FROM ~ VSFPSW20V00101353 UP TO ~ VSFPSW20V00101359
Thanks to take note and modify your catalogues accordingly
Fdo: Juan Morales López
Asesor Técnico
SPARE PARTS
REFERENCE Nº
:
PS-008/05-I
DATE
:
09/09/05
PAGE
:
1/2
SUBJECT
:
NEW GEAR BOX
AFFECTED MODELS
:
ALL
V.I.N. OR ENGINE Nº
:
VSFPSW20V00101808
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about disassembly of the New Gear Box ZF (reference
791129)
REFERENCE
FRC3327
FRC3416
FRC5180K2
FRC5255
PS-101026
PS-201050
PS-210190
PS-210200
01500-08253
08321B31083
127607
591988
PS-000120
PS-210171
PS-210175
PS-210176
PS-210182
PS-210379
01500-12353
PS-210174
PS-210188
PS-210404
07130-84CD0
08321A31103
PS-610022
PS-610454
21945-85C30
PS-110049
SH112251
08321-01123
BH110071
PS-201047
DESCRIPTION
CLIP
FORK
PIVOT
PATÍN
CLUTCH CYLINDER ASSY
DISENGAGIN BEARING ASSY
FITTING OUT ROD, CLUTCH
PIVOT, DISENGAGING LEVER
SCREW
SECURITY WASHER
DISENGAGING LEVER, ASSY
STPPAGE LEVER
NUT
CONEXTION SHAFT
CRANKCASE, FRONT OUTLET
CRANKCASE, RR.
OIL STOP PROTECTION
CRANKCASE, FRONT OUTLET
SCREW
UNION CRANKCASE GEAR BOX / TRANSFER
FIXED
UNION CRANKCASE GEAR BOX / TRANSFER
SCREW L=40
WASHER GROWER
SWITCH 4WD/M.A.
SWITCH CABLE, REVERSE GEAR
JOINT
RR ENGINE BRACKET
SCREW
SPRING WASHER
SCREW
LINK ASSY
SPARE PARTS
REFERENCE
PS-201087
PS-210177
PS-210196
PS-210374
PS-210376
PS-210398
PS-210403
08321A31103
PS-210180
PS-210181
PS-210183
PS-210184
PS-210185
PS-210186
PS-210187
PS-210396
PS-210189
PS-210196
PS-210398
PS-210400
Fdo: Juan Morales López
Asesor Técnico
REFERENCE Nº
:
PS-008/05-I
DATE
:
09/09/05
PAGE
:
1/2
DESCRIPTION
LINK ASSY
SUPPORT BASE, GEAR LEVER
SMALL CUSHION, SELECTION SHAFT
BUSH
BUSH SELECTION SHAFT
BUSH SELECTION SHAFT
BUSH
GROWER WASHER
CYLINDRIC STUD
BUSH SELECTOR SHAFT
LEVER BUSH
SECURITY CLIP
PLASTIC WASHER
CIRCLIP
BASIS STUD
GEAR LEVER
DUST COVER ACCOMMODATION
SMALL CUSHION, SELECTION SHAFT
BUSH
GEAR LEVER
SPARE PARTS
REFERENCE Nº
:
PS-032/ 05-I
DATE
:
03-03-2005
PAGE
:
1/ 2
SUBJECT
:
NEW OI L FI LTER
AFECTED MODELS
:
PS-10
V.I .N. OR ENGI NE Nº
:
ALL VEHI CLES
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about the introduction of a New Oil Filter, which is
fitted in all PS-10 vehicles.
FIG.25
OIL PIPING
POS.
REFERENCE
DESCRIPTION
QTY´.
ENGINE Nº
5
A301016-004
OIL FILTER
1
UP TO 3981326
5
A301016-016
OIL FILTER
1
FROM 3981327
6
A301016-005
THREADED UNION
1
UP TO 3981326
6
A301016-018
THREADED UNION
1
FROM 3981327
10
A301016-009
SUPPORT, OIL FILTER
1
UP TO 3981326
10
A301016-017
SUPPORT, OIL FILTER
1
FROM 3981327
SPARE PARTS
REFERENCE Nº
:
PS-032/ 05-I
DATE
:
03-03-2005
PAGE
:
1/ 2
Thanks to take note and modify your catalogues accordingly
Fdo: Juan Morales López
Asesor Técnico
SPARE PARTS
REFERENCE Nº
:
PS-007/05-I
DATE
:
07/09/05
PAGE
:
SUBJECT
:
AFFECTED MODELS
:
ALL
V.I.N. OR ENGINE NUMBER
:
ALL VEHICLES
CATALOGUE REFERENCE
:
790960-02I
1/2
NEW PART NUMBERS
The purpose of this Service Bulletin is to inform you about introduction of new part
numbers.
Part Numbers A901090-007 and A901841-000 (Cushion Subassy) does not include
fixation legs with the bodywork. When you need these two parts the following Ref.
should also be ordered.
The Catalogue will stay as follow:
FIG. 113
CENTER SEAT
POSITION
REFERENCE
DESCRIPTION
QTY`.
13
791141
QUICK FIXATION, CENTER SEAT
3
14
791142
SHAFT HINGE, CENTER SEAT
3
15
791143
FIXATION LEG, CENTER SEAT
3
SPARE PARTS
Fdo: Juan Morales López
Asesor Técnico
REFERENCE Nº
:
PS-007/05-I
DATE
:
07/09/05
PAGE
:
2/2
SPARE PARTS
REFERENCE Nº
:
PS-017/04-I
DATE
:
21-05-2004
PAGE
:
1/1
SUBJECT
:
NEW SOUND PROOF LINING, WHEEL ARCH
AFFECTED MODELS
:
SANTANA PS-10
V.I.N. OR ENGINE Nº
:
VINs shown in this Bulletin
CATALOGUE REFERENCE
:
Sound proof lining, inside wheel arch, R/H
790960-02I
The purpose of this Service Bulletin is to inform you about the New Sound proof lining, wheel arch,
affceting to all PS-10 vehicles from VINs shown in this Bulletin.
In FIG. 117 the following positions are created:
-
Pos. 21 Ref. PS-911197 “Sound proof lining, inside wheel arch, R/H”
Pos. 22 Ref. PS-911198 “Sound proof lining, inside wheel arch, L/H”
Pos. 23 Ref. 03141-06203 “Sheet Threaded Screw”
Pos. 24 Ref. 0341-06123 “Sheet Threaded Screw”,
Pos. 23 and 24 are created for fixation of the Sound Proof Lining to the Bodywork, staying in the
Catalogue as follow:
FIG.117
POS.N
SILENCER
REFERENCIA
21
PS-911197
22
PS-911198
23
24
03141-06203
03141-06123
DENOMINACIÓN
SOUND PROOF LINING, IN WHEEL
ARCH, R/H
SOUND PROOF LINING, IN WHEEL
ARCH, L/H
THREADED SCREW
THREADED SCREW
CANT.
OBSERVACIONES
1
NOT ILLUSTRATED
1
NOT ILLUSTRATED
4
12
NOT ILLUSTRATED
NOT ILLUSTRATED
Vehicles where the above mentioned positions are fitted are:
FROM VIN
~VSFPSW10V00100037 ONWARDS
TYPE 1 AND ALSO VIN
~VSFPSW10V00100026
~VSFPSW20V00100141 ONWARDS
AND ALSO VINs
TYPE 2 FROM ~VSFPSW20V00100002 UP TO ~VSFPSW20V00100008
FROM ~VSFPSW20V00100104 UP TO ~VSFPSW20V00100115
AND ~VSFPSW20V00100100
Thanks to take note nad modify your catalogues accordingly
Fdo: Juan Morales López
Asesor Técnico
SERVICE
REFERENCE NO.
:
PS-010
DATE
:
May 27th, 2005
PAGE
:
1 of 4
Propeller Shaft Recovering
SUBJECT
:
APPLICABLE MODEL
:
PS-10
V.I.N. OR FRAME NO.
:
See section VIN affected
REFERENCE OF PARTS CATALOGUE
:
We are editing this Service Bulletin to inform about the need of proceeding to the recovering of the front
and rear propeller shafts in our model PS-10 to improve the performance of them, since they can reach to
seize due to an insufficient evacuation of heat generated in the front (pos. 13, picture-1) and rear flange
(pos. 54 picture –1).
REAR PROPERLLER SHAFT
JOINT WITH DIFFERENTIAL
FRONT PROPELLER SHAFT
JOINT WITH DIFFERENTIAL
1. POS. 13 FRONT FLANGE. REF.- PS-210001
2. POS. 54 REAR FLANGE. REF.- PS-210179
Picture 1
This modification must be carried out at the fist service of the vehicle at one of your dealers or
workshop authorized services (by maintenance or any other repair).
1
1.- CORRECTION
The action to take will be to drill 3 holes of 2 mm of diameter at 120º in the front and rear flanges as will be
indicated in the section “Repair Procedure”.
3 DRILLED HOLES ø 2 mm AT 120º IN FRONT
AND REAR FLANGES
FRONT
REAR
The period estimated to complete this Service action is 12 months.
2.- VIN AFFECTED.
∼ VSFPSW20V00101807 (Euro III Type 2)
∼ VSFPSW10V00100208 (Euro II Type 1)
∼ VSFPSL20T00100063 (Pick Up Euro III)
2
REPAIR PROCEDURE
Front Flange
1.- Go up the vehicle in a lift, leaving free the 4 wheels
2.- Drill 3 holes of 2 mm of diameter to 120º to the flange of
the front propeller shaft as indicated in the picture and
drawing below.
FRONT
3 holes of 2 mm of diameter to 120º
Front Flange
Section
3
Rear Flange
1.- Go up the vehicle in a lift, leaving free the 4 wheels
2.- Drill 3 holes of 2 mm of diameter to 120º to the flange of
the rear propeller shaft as indicated in the picture and
drawing below.
REAR
3 holes of 2 mm of diameter to 120º
Rear Flange Section
4
SPARE PARTS
REFERENCE Nº
:
PS-001/05-I
DATE
:
04/05/05
Nº OF PAGES
:
2
SUBJECT
:
RR SPRINGS MODIFICATIONS
AFFECTED MODELS
:
ALL MODELS
V.I.N. OR ENGINE Nº
:
FROM VIN Nº VSFPSW20V00101840
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about modifications that have been introduced
regarding RR Springs
This modification must be included in FIG. 68 of the above-mentioned vehicle.
Parts number PS-501021 (supercession of p.n. PS-501016 according to Service Bulletin PS-011/04-I3) has now
been declared Out of Production, and Ref. PS-501024 must be fitted as replacement.
If it s the first time that part number PS-501021 is replaced by Ref. PS-501024, this modification
must be applied to the complete Axle of the vehicle. You should order Ref. 791137 (RR SPRING
ASSY) composed by:
POS.
REFERENCE
DESCRIPTION
QTY´.
1-3
PS-501024
RR PARABOLIC SPRING ASSY, REINFORCED
2
12-3
PS-510027
U-BOLT, RR SPRING
4
14
PS-000009
NUT, U-BOLT
8
18-2
PS-501025
RR SHOCK ABSORBER ASSY
2
We remind that U-Bolt Nuts (Ref. PS-000009) must be replaced each time that they are disassembled.
SPARE PARTS
REFERENCE Nº
:
PS-001/05-I
DATE
:
04/05/05
Nº OF PAGES
:
2
18-2
12-3
1-3
14
Fdo: Juan Morales
Asesor Técnico
SPARE PARTS
REFERENCE Nº
:
PS-031/ 04-I
DATE
:
23-11-2004
Nº OF PAGES
:
1
SUBJECT
:
SWI TCH ASSY MODI FI CATI ON
AFFECTED MODELS
:
SANTANA PS-10
V.I .N. OR ENGI NE Nº
:
ALL VEHI CLES
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you that modifications on the RR, Fog Lamp and RR
Defogger, Switch Assies affect to all vehicles Santana PS-10.
The old part can be interchangeable by the new one, but not in the opposite way.
FIG.56
ELECTRICAL CONTROL
POS. REFERENCE
DESCRIPTION
QTY´.
19.1
37280-80C00
SWITCH ASSY, RR FOG LAMP
1
19.2
37280-60G00
SWITCH ASSY, RR FOG LAMP
1
26.1
37860-50A00
SWITCH ASSY, RR DEFOGGER
1
26.2
37860-70F00
SWITCH ASSY, RR DEFOGGER
1
REMARKS
UP TO
VSFPSW20V00101432
FROM
VSFPSW20V00101433
UP TO
VSFPSW20V00101432
FROM
VSFPSW20V00101433
SPARE PARTS
REFERENCE Nº
:
PS-031/ 04-I
DATE
:
23-11-2004
Nº OF PAGES
:
1
Thanks to take note and modify your catalogues accordingly.
Fdo: Juan Morales López
Asesor Técnico
SPARE PARTS
REFERENCE Nº
:
PS-003/05-I
DATE
:
06/06/05
PAGE
:
1 /2
SUBJECT
:
VALVE HEATER MODIFICATION
AFFACTED MODELS
:
PS-10
V.I.N. OR ENGINE Nº
:
FROM VSFPSW20V00101675
CATALOGUE REFERENCE
:
790960-02I
The purpose of this Service Bulletin is to inform you about modifications
introduced in the above mentioned vehicle.
Part number PS-910705, is fitted up to VIN nº VSFPSW20V00101674 and from
VIN nº VSFPSW20V00101675 it will be replaced by p.n. PS-601055, modifying
the catalogue as follow:
FIG. 38
POS NO.
14-1
14-2
WATER HOSE
REFERENCE
PS-910705
PS-601055
DESCRIPTION
VALVE HEATER
VALVE HEATER
QTY´.
1
1
REMARKS
VSFPSW20V00101674
VSFPSW20V00101675
SPARE PARTS
Fdo: Juan Morales
Asesoramiento Técnico
REFERENCE Nº
:
PS-003/05-I
DATE
:
06/06/05
PAGE
:
1 /2
SERVICE
REFERENCE NO.
:
PS-021
DATE
:
May 28th, 2007
PAGE
:
1 of 2
SUBJECT
:
WINDSCREEN WIPER SEALING
APPLICABLE MODEL
:
PS-10
V.I.N. OR FRAME NO.
:
REFERENCE OF PARTS CATALOGUE
:
PS-610019 / PS-610216
Following to our Service Bulletin PS-004 where we informed about different action taken to prevent
the failure of the windscreen wiper engine caused by the internal rust due to water entry, we have
detected through the analysis of defective parts after the countermeasure date that although the
situation improves, it still exist other points that it is necessary to seal to avoid water entry.
1.- ACTION
Additionally to the measures indicated in our S.B PS-004 that was applied in production after the
chassis no. VSFPSAW2V00101210 and VSFPSW10V00100187, it is necessary to seal also the points
shown below (points 1, 2 and 3) to avoid the failure of windscreen wiper engine.
2
3
1
SANTANA MOTOR, S.A.
The sealing of these three points must be carried out using an adhesive of poly-urethane similar to the
one used of the windscreen (for instance Terostal-8590 of Henkel).
2
1
3
2.- CHASSIS AFFECTED
E-III
ALL
E-II
ALL
SANTANA MOTOR, S.A.
MILITARY
∼ VSFPMW20V0M120504
∼ VSFPML20T0M120357
∼ VSFPML20C0M100009
SERVICE BULLETINS

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