PIAGGIO PORTER 1.3 16V 2008 Service Manual Download Page 29

Page: 29 / 892

PROPELLER SHAFT AND DIFFERENTIAL

Name

Torque in Nm

Differential flange - Propeller shaft

39÷54

Differential bearing support - Differential support

60÷74

Pinion - Differential coupling flange

162 ÷ 199*

Rear axle - Oil filler cap

39÷63

Universal joint - Rear differential flange

39÷54

Filler cap - Differential cover

39.2 - 49.00

Differential cover - Differential housing

8.5 ± 2

Differential housing - Crown gear

66.5 - 73.5

* Value to be determined according to pinion bearing preloading.

GEAR RETAINERS

Name

Torque in Nm

Propeller shaft - Rear differential flange

39÷54

Clutch lower cover - Gearbox

4÷7

Direct connection bolt - Transmission

49÷69

Engine rear bracket - Gearbox

29÷44

Rear bearing lock - Gearbox

15÷22

Gear control fork shaft screw - Clutch housing

19÷30

Reverse lever - Gearbox

15÷22

Inlet shaft bearing locking plate - Clutch housing

15 ÷ 22

Gearbox - Oil filler cap

29 ÷ 49

Gearbox - Cover

29 ÷ 44

Clutch housing - Gearbox

15 ÷ 22

Rpm indicator locking plate - Gearbox cover

7 ÷ 10

Reverse limiting shaft screw - Gearbox

19 ÷ 22

Gearbox cover - Gearbox

15 ÷ 22

Reverse limiting pin lock - Gearbox

29 ÷ 49

Lock nut - Main shaft

177÷216

Reverse transmission gear shaft screw - Gearbox

19 ÷ 31

Rear engine support bracket - Chassis

49 ÷ 69

CLUTCH RETAINERS

Name

Torque in Nm

Brake pedal - Brake pedal support

15÷22

Clutch cover - Flywheel

15÷22

Vehicle overhaul data

Cylinder-piston oversizes

CYLINDER CLOCK

Specification

Desc./Quantity

Cylinder - standard diameter (mm)

76.000 ÷ 76.030

Cylinder diameter - 1st oversize (mm)

76.250 ÷ 76.280

Finishing angle of the liner

35° ± 5°

Roughness

1 - 4Z

PISTON

Specification

Desc./Quantity

Standard diameter piston (mm)

75.965 ÷ 75.995

1st oversize diameter piston (mm)

76.215-76.245

Cylinder - Piston standard clearance (mm)

0.025 ÷ 0.045

Maximum clearance between Cylinder - Piston (mm)

0.11

Clearance between piston and pin (mm)

0.005 - 0.011

PORTER 1.3 16V

Characteristics

CH - 29

Summary of Contents for PORTER 1.3 16V 2008

Page 1: ...MANUALE STAZIONE DI SERVIZIO 633530 IT 531 EN 532 Fr 533 DE 534 ES 535 PT 536 NL 537 EL PORTER 1 3 16V...

Page 2: ...ght 2008 PIAGGIO C S p A Pontedera All rights reserved Reproduction of this publication in whole or in part is strictly prohibited This publication has been edited by After sales PIAGGIO C S p A V le...

Page 3: ...riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures...

Page 4: ......

Page 5: ...S ST MAINTENANCE MA EMISSION CONTROLO SYSTEM CO EM TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ES ENGINE EN INIECTION SYSTEM IS GEAR BOX GE DIFFERENTIAL DI BRAKING SYSTEM BS TRANSMISSION SHAFT TS STEERIN...

Page 6: ...TIME SHEET TS...

Page 7: ...INDEX OF TOPICS GENERAL GUIDELINES N GEN...

Page 8: ...and belts 7 In order to avoid serious burns do not touch hot metal parts such as the radiator exhaust manifold exhaust pipe catalytic converter and muffler 8 Do not smoke during maintenance operations...

Page 9: ...e still used Oversized parts are those which have larger di mensions with respect to standard parts PCV Positive Crankcase Ventilation RH Right handed RHD Right hand drive vehicle S A Subassembly A su...

Page 10: ...anual since this manual has been drawn up to be used by qualified personnel WARNING THE PRESENCE OF A GREAT QUANTITY OF UNBURNED GASES INSIDE THE CATALYTIC CONVERTER CAN CAUSE OVERHEATING RESULTING IN...

Page 11: ...SPEED OVER 30 KM H SET THE IGNITION SWITCH OF THE VEHICLE TO BE HAULED TO ACC DURING HAULAGE OPERATIONS NEV ER REMOVE THE KEY OR SET THE IGNITION SWITCH TO LOCK DURING HAULAGE OPERATIONS FAILURE TO O...

Page 12: ...ING LIGHT INDICATES THAT IT IS FREE IT IS POSSIBLE THAT IT IS NOT COM PLETELY FREE 5 Move the ignition switch to ACC 6 Start haulage operations Lifting points Support point for 4 arm lift Front part S...

Page 13: ...erations is indicated in bold type 4 MAINTENANCE PROCEDURE The maintenance specifications are indicated in bold type or underlined Make sure to check the relevant specifications DESCRIPTION OF MANUAL...

Page 14: ...able parts 2 MAINTENANCE PROCEDURE As a rule the maintenance procedure is described in the following sequence removal inspection fitting and removal inspection assembly The explanation indicates the d...

Page 15: ...new ones Circuit check Electric fault repair DIAGNOSIS CONNECTOR DLC Data Link Connector The Electronic Control Unit of the vehicle complies with the ISO protocol 14230 Euro OBD Regard ing the positi...

Page 16: ...ting of the electrical cable harness To prevent possible malfunctions 2 Do not scratch or cut the cable harness during transport or fitting 3 Cable harness fixing system if there are resin clamps make...

Page 17: ...pect to the reference 4 Terminals and connectors Connector connection Connector with safety lock make sure that the lock is properly inserted Connector without lock insert the connector until it stops...

Page 18: ...nals could come out of their seats The locking connector can be the following types of connector a push piece opening traction open ing spring closing one way closing mechanism and so on Once the type...

Page 19: ...tion on the electrical system disconnect the battery negative terminal N B BEFORE REMOVING THE GROUND LEAD FROM THE BATTERY NEGATIVE POLE REMEMBER TO READ THE DIAGNOSTIC FAILURE CODE IF NECESSARY AFTE...

Page 20: ...to the battery fit the terminal on the battery pole then tighten the terminal nut Do not use a hammer or other tools to fit the terminal in the battery pole Refit the positive terminal cover General g...

Page 21: ...INDEX OF TOPICS CHARACTERISTICS CH...

Page 22: ...r maximum weight E Maximum weight permissible on front axle F Maximum weight permissible on rear axle G Vehicle model H Type of engine NB This option is not available in some models Engine Identificat...

Page 23: ...GLASS VAN T TIPPER PICK UP V VAN P PICK UP L LEFT GUIDE R RIGHT GUIDE S85 HIJET model CODICE ABBIGLIAMENTO VAN Specification Desc Quantity LV Pelle cloruro di vinile LV YR Semi tessuto S2 Grigio CODIC...

Page 24: ...11 25 1 Van Rear axle Semi floating STEERING Specification Desc Quantity Wheel outside diameter mm 370 Steering wheel turns 4 1 Steering Housing gear Pinion and rack Internal steering angle 36 0 Exte...

Page 25: ...a del P M I Chiusa 2 dopo il P M S Gioco valvola di aspirazione a caldo 0 25 0 05 Gioco valvola di scarico a caldo 0 33 0 05 Sistema di lubrificazione lubrificazione forzata Pompa dell olio tipo a tro...

Page 26: ...Pick Up Characteristics PORTER 1 3 16V CH 26...

Page 27: ...ck 7 12 Oil pump body Oil pump cover 8 13 Oil pump Oil pressure switch 12 20 Intake pipe for oil in sump Oil sump 15 22 Cylinder block Oil pump 6 9 Clutch cover 15 22 Connecting rod Connecting rod cap...

Page 28: ...rake pipe joint Brake cylinder 10 12 STEERING AND SUSPENSIONS Name Torque in Nm Tie rod head Articulated arm 39 54 Tie rod head Tie rod head lock nut 34 3 53 9 Central arm Tie rod head 39 3 53 9 Centr...

Page 29: ...g 15 22 Gearbox Oil filler cap 29 49 Gearbox Cover 29 44 Clutch housing Gearbox 15 22 Rpm indicator locking plate Gearbox cover 7 10 Reverse limiting shaft screw Gearbox 19 22 Gearbox cover Gearbox 15...

Page 30: ...ter mm 18 994 18 997 Pin coupling interference Rod small end mm 0 015 0 044 Crankshaft Rod head CRANKSHAFT Specification Desc Quantity Connecting rod pin bearing diameter mm 49 976 45 000 Main journal...

Page 31: ...ution timing Outlet Closed 2 after BDC ROCKING LEVERS AND PINS Specification Desc Quantity Rocking lever hole diameter mm 19 500 19 521 Rocking lever pin outside diameter mm 19 468 19 488 Rocking leve...

Page 32: ...fication Desc Quantity Cylinder block side unevenness mm 0 10 Inlet manifold side unevenness mm 0 10 Exhaust manifold side unevenness mm 0 10 Inlet valve seat angle mm 30 45 70 Exhaust valve seat angl...

Page 33: ...INDEX OF TOPICS SPECIAL TOOLS ST...

Page 34: ...interfaccia EOBD Navigator 020460Y Diagnostic tester 020463Y ECU EFI interface cable harness to check the injection system electrical val ues 020618Y Cable harness for connecting the OBD Connector an...

Page 35: ...al multimeter 020274Y Checking tool kit 020400Y Fuel pressure checking kit 020275Y Cable harness to check fuel injection ENGINE TOOL Stores code Description 020180y Engine support 020387Y Tool to remo...

Page 36: ...removal and refit 020382Y Tool to remove the valve cotters TRANSMISSION TOOL Stores code Description 020206y Bearing extractor CLUTCH TOOL Stores code Description 020195y Tool kit to align the diaphr...

Page 37: ...20293y Expanding tool 020286y Adaptor for attachment to the engine sup port 020284y Tool to adjust pinion position 020177y Pinion bearing replacement kit 020213Y Bearing extractor 020212y Flange locki...

Page 38: ...Stores code Description 020221y Brake drum stop device 020222y Front hub and drum extractor FRONT SUSPENSION TOOL Stores code Description 020224y Connecting rod bushing extractor and changer 020235y F...

Page 39: ...t kit 020222y Front hub and drum extractor 020221y Brake drum stop device 020223y Extractor and changer for front suspen sion arm bushing REAR SUSPENSION TOOL Stores code Description 020227y Rear whee...

Page 40: ...Oil seal extractor STEERING TOOL Stores code Description 020177y Pinion bearing replacement kit 020196y Clutch guiding tool 0 20228y Rear conical tool to replace the differen tial control pinion beari...

Page 41: ...Stores code Description 0 20230y Tool to replace the differential control pin ion bearing 020231Y Tie rod head extractor PORTER 1 3 16V Special tools ST 41...

Page 42: ...INDEX OF TOPICS MAINTENANCE MA...

Page 43: ...Valve clearance I I I Accelerator control I I I I I I Clutch control I I I I I I Fuel hoses I I I Oil vapour recovery pipe blow by I I I Suspensions I I I Steering wheel I I I I I I Brake pedal and p...

Page 44: ...UT AS A GENERAL RULE WHEN THE ENGINE IS HOT A HOT ENGINE MEANS THAT CONDITION IN WHICH THE COOLING FAN HAS BEEN ACTIVATED AT LEAST ONCE CHECK THAT ALL THE ACCESSORY SWITCHES ARE SET TO OFF THE GEARSHI...

Page 45: ...TH A HIGHER COEFFICIENT OF VISCOSITY THE QUANTITY OF OIL BETWEEN THE L AND F REFERENCE MARKS IS EQUIVA LENT TO APPROX ONE LITRE Characteristic Engine oil capacity at MAX level 3 5 l F level Engine oil...

Page 46: ...g Fit the plug and place a new gasket in between REMOVE GASKET WASTE OFF THE OIL SUMP USING A SUITABLE SCRAPER 9 Pour oil in the engine until the maximum level in the oil dipstick is reached 10 Start...

Page 47: ...l replacement Differential oil change 1 Remove the drainage plug and the filler cap Drain the differential oil 2 Refit the drainage plug and place a new gasket in between 3 Top up with recommended oil...

Page 48: ...A TOP QUALITY ETHYLENE GLYCOL BASED ANTIFREEZE SOLUTION N B THE QUANTITY INDICATED ABOVE IN CLUDES THE LITRES FOR THE EXPANSION TANK Characteristic Coolant reservoir capacity 5 7 litres Coolant chang...

Page 49: ...d warm it up to the operating temperature N Make sure there are no leaks O After the fluid temperature decreases remove plug 2 located on the engine side Check the cool ant level If the level is too l...

Page 50: ...Disconnect the spark plug from the cable 3 Carefully remove the spark plug cable from the ignition coil 4 Visually inspect the spark plug cable by check ing if there are signs of wear cracks or any ot...

Page 51: ...stments Headlight alignment check Light beam direction adjustment Before adjusting direction carry out the following operations Make a person sit down at the driving position Check tyre pressure and a...

Page 52: ...easure the headlamp height from the ground H 3 Turn the set screw for headlamp aiming 1 until the limiting line between the dark and bright areas is 36 mm shorter than H Distance A between the headlam...

Page 53: ...INDEX OF TOPICS EMISSION CONTROLO SYSTEM CO EM...

Page 54: ...vance Thanks to the electronic igni tion timing control based on signals sent by the various sensors the computer controlling emissions keeps the ignition timing constant at optimum levels according t...

Page 55: ...atalytic converter having a monolith is assembled under the bodywork be tween the exhaust manifold and the main silencer The three way catalytic converter can treat all three components CO HC and NOx...

Page 56: ...atio Lean A Range to be used 1 Converter 2 ID number 3 Monolithic catalytic converter Sistema di controllo dei vapori carburante Fuel vapour control system With this system hydrocarbon HC emissions ev...

Page 57: ...activated carbon filter captures hydrocarbon emissions All valves closed When the pressure inside the fuel tank dramatically drops the valve opens so that the fuel tank does not get damaged Engine op...

Page 58: ...ve is completely closed and when the engine speed exceeds the set value Besides the initial and return engine speed to stop fuel is preset according to the temperature of the engine cooling water Air...

Page 59: ...R THE ACTIVATED CARBON FILTER FITTING IS REDUCED NOR THE FUEL TANK CAP DAMAGED 3 Fuel tank cap check Check that the fuel tank cap and the gasket are not damaged or deformed 4 Activated carbon filter c...

Page 60: ...on the bleed side A closed If there is no air continuity replace the activated carbon filter with a new one b Check for air continuity by applying a negative pressure to the pipe on the bleed side A...

Page 61: ...a new one D Check that no air leaks through the vapour bleed control valve Make sure that there are no air leaks by injecting compressed air at 29 4 kPa 0 3 kgf cm2 into the pipe on the fuel tank sid...

Page 62: ...nnect the rubber pipes and fit the new bracket Sistema di controllo delle emissioni allo scarico Emission control device 1 Check that the fixing nuts are not loose Tighten the catalytic converter nuts...

Page 63: ...duct Check that ducts and connections are not loose twisted or damaged 2 Visual inspection of the fuel tank Check that there are no deformations cracks or fuel leaks Replace the fuel tank if necessar...

Page 64: ...ine the probable causes HC CO Problem Possible cause High Regular Irregular idle speed 1 Faulty ignition Inaccurate ignition timing Spark plugs dirty short circuited or with incorrect electrode gaps 2...

Page 65: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 66: ...Replace Injection delayed Check injection advance White smoke from exhaust WHITE EXHAUST SMOKE Possible Cause Operation High oil level Restore the level Piston rings worn or seized Check replace Worn...

Page 67: ...eck and replace damaged components Worn valve guides Check and replace damaged components Coolant overheats COOLANT OVERHEAT Possible Cause Operation Piston rings worn or seized Check and replace dama...

Page 68: ...rods incorrectly adjusted Adjust Control rod retaining springs fault Replace the springs Synchroniser coupling teeth or coupling sleeve teeth fault Check replace damaged components Incomplete couplin...

Page 69: ...ar Replace or bleed the system Air leak in the pump due to poor tightness of rubber rings Replace the rings Brake pedal too soft BRAKE PEDAL SINKS TOO MUCH Possible Cause Operation Tank cap breather h...

Page 70: ...xing engine to chassis not properly locked or damaged Lock or replace Difficult riding DRIVING PROBLEMS Possible Cause Operation The vehicle pulls to one side Check any steering arm alterations and th...

Page 71: ...INDEX OF TOPICS ELECTRICAL SYSTEM ES...

Page 72: ...Ground points PUNTI DI MASSA BATTERY CHASSIS GROUND Electrical system PORTER 1 3 16V ES 72...

Page 73: ...ND under the instru ment panel on the Left side SERVICES SYSTEM GROUND under the instru ment panel on the Right side MAIN GROUND Gear cover Chassis REAR SERVICES SYSTEM GROUND PICK PORTER 1 3 16V Elec...

Page 74: ...between the engine and the left longitudinal arm INJECTION SYSTEM ENGINE GROUND cor respond to the ground terminals in the control unit Electric circuit diagram Legenda 1 Batteria Electrical system PO...

Page 75: ...re 22 Interruttore fanali fendinebbia posteriori 23 Teleruttore fanali fendinebbia posteriori 2 24 Teleruttore fanali fendinebbia posteriori 1 25 Comando regolazione proiettori 26 Interruttore luci 27...

Page 76: ...nterruttore lunotto termico 56 Lunotto termico 57 Interruttore luci stop 58 Luci stop 59 Interruttore clacson 60 Clacson 61 Dispositivo lampeggiatori 62 Deviatore lampeggiatori 63 Indicatore quattro l...

Page 77: ...e temperatura aria 82 Sensore temperatura liquido raffreddamento 83 Rivelatore velocit veicolo 84 Sensore quantit aria 85 Sensore pressione 86 Resistore EFI 87 Sensore riscaldatore posteriore 88 Senso...

Page 78: ...gnition IGNITION SYSTEM DIAGRAM 1 Battery 2 F L fuse 3 60A F L main fuse 4 F L IG 1 fuse 5 20A Engine fuse 6 Ignition unit Igniter 7 Coils 8 Ignition spark plugs 9 ECU control unit Electrical system P...

Page 79: ...n system This section of the manual provides information to check the correct operation of the ignition system Starting and recharging START UP AND RECHARGE 1 Main switch IG 2 60A Fuse 3 Battery 4 20A...

Page 80: ...START UP AND RECHARGE 1 F L fuse 2 Fuse 60A 3 Ignition switch 4 Battery 5 Starter motor 6 10A Start up fuse 7 EFI ECU control unit Iniezione Electrical system PORTER 1 3 16V ES 80...

Page 81: ...CTRICAL SYSTEM DIAGRAM 1 Instrument panel 2 A C control micro switch with recirculation lever set to ON 3 Ventilation selector 4 7 way connector female 5 7 way connector male 6 7 way connector female...

Page 82: ...l 24 60A Fuse 25 Switch relay Compressor electromagnetic coupling control 26 7 5A Fuse 27 Water thermostatic sensor 28 3 way connector connects Electrical system to Electric fan 29 Electric fan 30 NC...

Page 83: ...box is located on the left side of the steering wheel either in right or left hand drive vehicles Instructions to replace fuses and fuse holders 1 Before replacing a fuse find the problem that caused...

Page 84: ...Rear fog light remote control 1 4 Rear fog light remote control 2 5 Windscreen wiper intermittence remote con trol 6 Turn indicator intermittence remote con trol 7 Front fog lights remote control opti...

Page 85: ...remote control 26 7 5A Fuse Electrical controls Multifunction switch lever Check 1 Make sure that turn indicators low beam high beam lights hazard indicator and windscreen wiper switches work properl...

Page 86: ...ystem 5 Light switch 6 Low beam light switch KEY 1 Turn indicators switch with automatic return system 2 Light switch 3 Low beam light switch 4 Indicator switch 5 Windscreen wiper switch 6 Windshield...

Page 87: ...tch position 3 Disconnect the connector DIV class cnt_summary title Testo Breve 4000 car 4 Make sure there is continuity among the relevant terminals as indicated in the table below KEY A Terminal B C...

Page 88: ...m the windscreen wiper motor Make sure there is continuity between the relevant terminals as indicated in the following table Continuity table A Switch B Terminal Interruttore luci stop Check 1 Discon...

Page 89: ...ver is released Lunotto termico Heated rear window switch 1 Remove the heated rear window 2 Make sure there is continuity between the respective terminals as indicated in the table below KEY 1 To the...

Page 90: ...i fendinebbia Front fog light 1 Remove the front fog light switch 2 Check continuity between the terminals as in dicated in the following table 1 To the front fog light 2 Ground 3 Switch Continuity ta...

Page 91: ...ation check Connect terminal 3 to the battery positive ter minal terminal 1 to the battery negative termi nal Then connect terminal 2 to terminal 4 Make sure that the windscreen wiper operates at high...

Page 92: ...Windscreen wiper circuit diagram Windscreen wiper remote control Location Fuse block upper part Make sure that there is continuity between Terminals 2 and 3 There is continuity between Terminals 2 and...

Page 93: ...tion Installation 1 Fit the windscreen wiper motor with the connec tion unit 2 Run the motor and take it to the automatic stop position 3 Position the blades in their respective positions as shown in...

Page 94: ...Connection unit 3 Motor 4 Windscreen wiper Rear wiper mechanism KEY 1 Nut 2 Rear window wiper blade and arm 3 Connection cover 4 Hexagon nut 5 Washer 6 Connection gasket 7 Motor unit Electrical system...

Page 95: ...he connection gasket 4 Remove the engine unit Check 1 Connect the rear window wiper motor body to the battery negative terminal 2 Connect terminal S to the battery negative terminal 3 Connect terminal...

Page 96: ...arefully observe the removal sequence to avoid causing a short circuit in the battery which is extremely dangerous 3 When refitting the starter motor make sure to tighten the bolts observing the relev...

Page 97: ...mbly 2 Bushing 3 Transmission seat 4 Engagement lever 5 Retention collar 6 Circlip 7 Coupling 8 Rotor 9 Reed 10 Stator 11 Brush holder 12 Clamp C 13 Bushing 14 Cover 15 Rubber ring 16 Safety plate POR...

Page 98: ...otor checks EACH ONE OF THE FOLLOWING TESTS MUST BE PER FORMED FOR NOT LONGER THAN 3 5 SECONDS IF THIS WARNING IS NOT OBSERVED THE COIL RECEIV ING A LONG LASTING CURRENT CAN BE BLOWN 1 Thrust test Dis...

Page 99: ...performing the pinion maintenance check disconnect the negative of the motor casing Make sure that the pinion is in the relevant housing If this is not met replace the remote control 4 Checking perfo...

Page 100: ...al Removal 1 Disconnect the cable from the remote control 2 Remove the remote control fixing nut 3 Remove the remote control 4 Undo the two screws and then remove the sup port cap Electrical system PO...

Page 101: ...mm KEY 1 Washer 2 Cover 3 Clearance 6 Remove the lock washer the spring and the rubber ring from the cover 7 Remove the cover from the stator removing the through bolts 8 With a pair of pliers lift th...

Page 102: ...or 10 Remove the coil and the rotor 11 Remove the retention collar from the circlip by giving a few taps on the collar with a screwdriver 12 Remove the circlip with a screwdriver 13 Remove the collar...

Page 103: ...mutator continuity check Check the continuity between each segment ad jacent to the commutator with an ohmmeter If there is no continuity among any of the adjacent segments replace the rotor Commutato...

Page 104: ...meter with a micro meter or a sliding gauge If the commutator diameter is shorter than the di ameter minimum replace the rotor Characteristic Standard diameter 28 mm Minimum diameter 27 mm 4 Groove de...

Page 105: ...t test With an ohmme ter make the connection between the brush and the relevant support If there is continuity replace the brush unit and or windings Inspection Brush check Brush length check Measure...

Page 106: ...the tooth is damaged replace the coupling Also check the flywheel crown gear for signs of wear or damage Brush replacement procedure 1 Cut the brush braid copper braid from the ter minal side at poin...

Page 107: ...ON THE BRAID SIDE MAKE SURE THAT THE WELDING ADEQUATELY FLOWS INSIDE THE PLATE MAKE SURE THAT THERE ARE NO WELDING DEPOSITS IN THE FIELD WINDING Starter motor coupling check Hold the coupling and rot...

Page 108: ...al coil check Always using an ohmmeter make sure that there is continuity between the ST terminals and the re mote control body If there is no continuity replace the remote control Bearing check 1 Mea...

Page 109: ...limit replace the bushing The punch has a 15 mm outside diameter Characteristic Clearance limit 0 2 mm Montaggio Assembly 1 Fit the coupling on the rotor shaft 2 Fit the collar on the rotor shaft TO...

Page 110: ...IGH TEMPERATURE GREASE ON THE SLIDING SECTIONS OF THE ROTOR SHAFT AND THE ENGAGING LEVER 6 Fit the stator 7 Fit the brush holder on the rotor shaft 8 Keeping the springs lifted with pliers refit the 4...

Page 111: ...sing while paying attention to hook the remote control to the control lever Finally lock the remote control with the 2 screws 13 Connect the cable to the remote control Installazione sul veicolo Insta...

Page 112: ...y the alter nator with engine running Test of delivered power without electric charge applied 1 Make sure that all the switches are off to avoid applying unnecessary electric charge Headlamps Heating...

Page 113: ...To apply electric charge operate as follows Turn the high beam headlamps on Set the heater fan to the maximum speed to hot 2 With the engine at 2500 rpm check the output current WITH THE BATTERY COMPL...

Page 114: ...pulley 4 Spacer 5 Transmission side cover 6 Stud bolt 7 Bearing 8 Fixing plate 9 Alternator rotor unit 10 Bearing 11 Dust guard 12 Rectifier side cover 13 Rectifier support 14 Regulator unit 15 Brush...

Page 115: ...Undo the alternator fixing bolts 4 Remove the V belt Removal Removal 1 Undo the nut fixing the alternator pulley 2 Remove the spacer N B USE A PNEUMATIC GUN TO PERFORM THIS OPERA TION 3 Rear cover rem...

Page 116: ...t 6 Rectifier support removal Unscrew the fixing screws Straighten the stator cable Remove the rectifier support 7 Loosen the nuts and the bolts and remove the rectifier support housing Electrical sys...

Page 117: ...result replace the remote control Characteristic Standard resistance 2 9 0 2 Rotor check for ground Make sure there is no continuity between the com mutator rings and the rotor casing If there is rep...

Page 118: ...e the stator assembly Characteristic Specified resistance around 0 2 Stator check for short circuit Using an ohmmeter check if there is any condition present that could cause a short circuit between t...

Page 119: ...n the brush holder N B REMOVE THE WELDING MATERIAL FROM THE BRUSH HOLDER SO THAT THE METAL BELOW CAN BE SEEN 3 Weld the brush wire in the brush holder so that the part exposed complies with the specif...

Page 120: ...neg ative terminals 2 Repeat the same operation inverting the 2 ohm meter probes 3 Make sure there is continuity only in one of the two tests If continuity is detected in both tests replace the rectif...

Page 121: ...hat the rear bearing turns freely Otherwise replace the bearing Rear bearing replacement if necessary 1 Remove the rear bearing and relevant dust guard from the rotor using and extractor for bear ings...

Page 122: ...bearing Front bearing replacement if necessary 1 Undo the four screws and remove the fixing plate 2 With a press and using a box spanner remove the bearing and the relevant housing 3 With a press plac...

Page 123: ...two bolts and nuts PAY ATTENTION NOT TO DAMAGE THE STATOR CA BLES DURING REFITTING IF FITTING TURNS OUT DIFFICULT SLIGHTLY PRESS BY TAPPING WITH A PLASTIC HAMMER 3 Refitting the rectifier support regu...

Page 124: ...crews Tighten the 4 screws 4 Fit the regulator with the three fixing screws 5 Refit the brush holder so that the distance be tween the brush support and the regulator is 1 mm Lock the brush holder wit...

Page 125: ...the alternator shaft Use a box wrench and a bushing Beta 720 type Locking torques N m Generator Pulley 80 8 Lock the specific tool C in a vice Tighten the nut by turning the specific tool B Locking to...

Page 126: ...6 0 8 0 mm Power lock Air filter CENTRAL LOCKING WITH REMOTE CONTROL SYSTEM DESCRIPTION The Piaggio system 612697 is an electronic device which allows the simultaneous activation of vehicle door locks...

Page 127: ...Module output maximum capacity 50 mA REMOTE CONTROL Specification Desc Quantity Transmission frequency TUV AUSTRIA type approved frequency 433 92 Mhz Free field capacity 20 m ELECTROMECHANICAL ACTUATO...

Page 128: ...or sliding doors 6 Rear right actuator 7 Rear left actuator 8 Front right actuator 9 Remote controls autodetection 10 Fixed power supply 11 Ignition key 12 Live positive N B IN DIESEL ENGINE VEHICLES...

Page 129: ...ove the screws fixing the glove box The po sition of screws is shown in the following figures Remove glove box extracting it from the instru ment panel Identify the door locking control unit in the gl...

Page 130: ...engine The turn indicator bulbs turn off Press the remote control button to be learnt The turn indicator bulbs flash one time confirming the remote control detec tion Disconnect the white wire A in t...

Page 131: ...s ex tremely high temperatures and immersing it in any type of fluid Remember that on summer days the instrument panel of vehicle can get significantly hot if it is exposed to the sun Battery replacem...

Page 132: ...em to control locks from the doors Check the contact plate status periodically for traces of dirt or oxide To clean these devices use a cloth soaked in alcohol Do not use abrasive ma terial SYSTEM PRO...

Page 133: ...through the pin code Negative control for additional self powered siren and pager Anti hijack function Garage function GEMINI 7563 01 Similar to 7563 without electronic key GEMINI 7562 Similar to 7563...

Page 134: ...the neutral period has finished approx 45 seconds the system is armed or rather ready to detect a break in attempt The LED flashes intermittently to signal that the system is completely armed Any bre...

Page 135: ...urning the starter key to OFF The possible alarm warnings are indicated in the following diagram LED WARNING Specification Desc Quantity O Absorption sensor 5 cycles O Start up tried 15 54 infinite cy...

Page 136: ...al or self powered siren Only for models 7563 and 7562 11 Ground 12 Battery Only for models 7563 and 7562 13 To the tone wheel 14 Aerial 15 Control unit Electrical connections In vehicles equipped wit...

Page 137: ...N N B FOR THE AVAILABLE DIAGRAMS OF EACH SINGLE VEHICLE CONTACT AN AREA DEALER Ultrasound module connection and position ing Connection is simple since the connector corre sponding to that present in...

Page 138: ...he ultrasound module is fitted in the alarm cable harness Join the 4 way connector of the alarm cable har ness to the 4 way connector of the super high frequency The sensor operates based on the princ...

Page 139: ...larm and lower one of the front win dows of the vehicle Activate the alarm again and introduce a foreign matter inside the cab simulating a theft attempt If the alarm intervenes only after the introdu...

Page 140: ...NECESSARY TO REPEAT THE OPERATIONS PRE VIOUSLY DESCRIBED CHECK THERE IS A NEGATIVE LEAD DURING THE ALARM ACTIVATION TO CONNECT THE PAGER Programmable functions 1 Sound alarms This function allows the...

Page 141: ...status and the DOOR SWITCHES input line does not allow lock activation if during the engine start up or within the 20 seconds after start up the DOORS or the TRUNK OF the vehicle are manually opened 5...

Page 142: ...ATTENTION NOT TO CHANGE ANY PROGRAMMING SET DURING FITTING To change programming proceed as described below When the system is deactivated open and keep the vehicle driver side door open Turn the sta...

Page 143: ...control generally paired with the vehicle ignition key THE ANTI HIJACK FUNCTION ACTIVATION MEANS ONLY THE RADIO CODE PROGRAMMED IS RECEIVED AND SENT BETWEEN THE TAG AND THE MODULE 7563 BUT NOT THAT T...

Page 144: ...ng is still not influenced After 1 minute the door is open the module activates the vehicle immobilisation as described in subsequent paragraphs in addition to the siren that sounds for 2 minutes 5 Fi...

Page 145: ...hat position The alarm signals the start of the detection procedure of new control devices magnetic contacts or infrared sensors by means of two long turn indicator flashes and two sound alarms a high...

Page 146: ...rs by means of two turn indicator flashes and two sound alarms a high pitched one and a grave tone one Close the bonnet the status LED remains steadily on Leave the bonnet closed until after about fou...

Page 147: ...onding to No 7 fourth and last PIN CODE digit press the status LED switch or turn the ignition key to ON for at least one second Take the vehicle ignition key back to OFF Two sound alarms with grave t...

Page 148: ...ed for seven times corresponding to No 7 fourth PIN CODE digit turn the ignition key to ON for at least one second then turn it back to OFF or press the status LED switch If the digits entered are exa...

Page 149: ...TY 2 Radio control To prevent remote control operation failures the latter has inside a device that indicates the battery charge status When using the radio control regu larly press the control switch...

Page 150: ...uded in this instruction manual and DO NOT REMOVE the warranty label on the appliance The warranty is invalidated if such label or one of the parts are broken or missing while the certification is fil...

Page 151: ...aro fendinebbia anteriore 55 W Luce di ingombro 5 W SPECIFICHE DELLE LUCI Specification Desc Quantity Fari 60 55 W Alogeno Luci di ingombro 5 W Lampeggiatori anteriori 21 W Lampeggiatori posteriori 21...

Page 152: ...headlight bulbs KEY 1 Clip 2 Headlamp seat 3 Front turn indicators 4 Headlamp Removal Fitting 1 Remove the panel 2 Undo and remove the fixing screw Remove the headlamp cover Electrical system PORTER 1...

Page 153: ...ndo the two screws fixing the headlamp seat to the front panel 7 Remove the headlamp seat from the clip on the front panel 8 Undo the two screws fixing the headlamp to the front panel 9 Remove the hea...

Page 154: ...ulb 2 from bulb holder 3 To refit the turn indicator follow the same operations but in reverse order Replacing the taillight bulbs For Van and Combined models_ 1 Undo the screw to remove the light uni...

Page 155: ...the license plate light bulb License plate lights 1 Undo the two screws to remove the light unit 2 Extract the bulb Replacing the courtesy lamp passenger light Cab rear light 1 Undo the two screws to...

Page 156: ...ight headlamp carry out the same operations but in reverse order Fog light headlamp replacement 1 Operating from the front compartment of the bumper disconnect connector 1 from bulb holder 2 2 Undo th...

Page 157: ...g it slight ly Faro fendinebbia posteriore Rear fog light 1 Undo the two screws to remove the light unit 2 Turn the bulb anticlockwise by pressing it slight ly Indicators Warning lights Gruppo strumen...

Page 158: ...5 Speedometer Components INSTRUMENT PANEL Electrical system PORTER 1 3 16V ES 158...

Page 159: ...rd indicator switch 8 Turn indicator switch 9 Side light switch 10 Turn indicators 11 Left turn indicator light 12 Right turn indicator light 13 Hazard indicator 14 Lighting 15 To the ECU 16 20A heate...

Page 160: ...hecks on the receiving side end 1 Disconnect the connector from the fuel level probe cable harness Earth the probe through a check warning light 2 Turn the ignition key switch to ON 3 The check warnin...

Page 161: ...that a variable voltage between 2 and 7 V is applied between terminal B7 and the body ground Fuel level probe Remove the fuel tank Then remove the fuel level probe Check Measure the resistance value b...

Page 162: ...probe cable harness Earth the gauge through a check warning light Reference about 55 2 Turn the key switch to ON 3 The check warning light turns on After a few seconds the warning light must start fla...

Page 163: ...nal to the ignition coil cable harness KEY A Probe B Ignition coil 2 Check that the stroboscopic light flashes while the engine in being run with the starter motor 3 If it does not flash carry out the...

Page 164: ...ESSURE IT MUST NOT EXCEED 588 KPA DURATION LESS THAN 20 SECONDS 10 Visually inspect the spark plug checking that the electrode is not worn and that the thread or insulator is not damaged 11 Check of d...

Page 165: ...CABLE HARNESS Characteristic Specified value Battery voltage 3 Connect the bulb 12 V 6 W between terminals S1 and GR on the wire connector side of the igni tion system Check that the bulb turns on whe...

Page 166: ...HE SIGNAL GENERATOR WORKS PROPER LY 4 Remove from the head the camshaft sensor by undoing the fixing bolt 5 Remove the camshaft sensor cover 6 Turn the rotor shaft until the signal rotor is facing the...

Page 167: ...the lower part of the instru ment panel 2 Connect a rpm indicator to the REV terminal using the following specific tool Specific tooling 020618Y Cable harness for connecting the OBD Connector and the...

Page 168: ...UALLY AFTER THE ENGINE IS FULLY HEATED Characteristic Ignition timing Before Top Dead Centre 3 2 minimum 7 If the ignition timing reference is not aligned with the indicator adjust the ignition timing...

Page 169: ...ON NECT THE GROUND LEAD FROM THE BATTERY NEGA TIVE POLE WITH THE IGNITION SWITCH AND ALL THE ACCESSORY SWITCHES SET TO OFF WHILE FITTING A NEW BATTERY PAY ATTENTION NOT TO INVERT POLARITY AN INVERTED...

Page 170: ...he battery negative pole 2 Remove the special tool disconnecting the relevant connectors from the control unit and engine cable harness connectors 3 Connect the cable harness connectors to the control...

Page 171: ...ng lever to COLD Besides set the lever on the heater inlet pipe to CLOSED Insert the cable Fit the cable guide lock by inserting it in the bracket grooves KEY A Closed B Open Internal external air con...

Page 172: ...h the control lever position Operations after fitting 1 Fit the unit 2 Supply the system 3 Fit the battery negative terminal 4 Fit the front panel gasket Van and Combined models Heating system and ven...

Page 173: ...ever set to hot drain the water from the radiator about 500 cm Radiator Undo the fixing bolts Take out the radiator down wards with the radiator pipes fitted on the radiator 3 Remove the unit 4 Remove...

Page 174: ...the cable harness for possible short circuits 2 Disconnect the radiator thermoswitch connec tor 3 Check that the radiator fan turns properly with the ignition switch set to ON when the jumper is conne...

Page 175: ...ensor 5 Injector No 4 6 Injector No 3 7 Injector No 2 8 Injector No 1 9 Parking brake switch 10 Throttle position sensor 11 Pressure sensor 12 Air inlet temperature sensor 13 VSV 1 fast idle 14 Oil pr...

Page 176: ...N26 EFI ECU N EFI ECU OX X27 X28 Lambda probe EFI ECU THW X29 X30 Water temperature sensor Water temperature sensor X31 Connection to X35 X34 EFI ECU THA X32 X33 Intake air temperature sensor EFI ECU...

Page 177: ...EFI ECU E01 Z47 Z49 E G ground EFI ECU E1 Z48 Z49 E G ground Connection to X35 X34 Z140 Accelerator sensor E2 Connection to Z48 Z49 Z212 Cam sensor Connection to Z48 Z49 Z213 Lambda probe sensor Conn...

Page 178: ...Battery negative cable harness Pickup Tipper 1 Battery 2 Chassis Cable harness unit 1 Engine cable harness Electrical system PORTER 1 3 16V ES 178...

Page 179: ...4 Courtesy light roof cable harness 5 Van roof light cable harness 6 Tail door cable harness No 1 van 7 Rear window cable harness No 1 van 8 Rear window cable harness No 2 van Engine chassis ground c...

Page 180: ...Battery positive cable harness Tipper 1 Battery 2 To the vehicle cable harness Battery positive cable harness Pickup Electrical system PORTER 1 3 16V ES 180...

Page 181: ...1 Battery 2 To the vehicle cable harness Battery positive cable harness Porter Van 1 Battery 2 To the vehicle cable harness PORTER 1 3 16V Electrical system ES 181...

Page 182: ...Battery negative cable harness Porter Van 1 Battery 2 Chassis Bodywork engine ground transmission cable harness Pickup Electrical system PORTER 1 3 16V ES 182...

Page 183: ...1 Transmission gear crankcase 2 Body Bodywork engine ground transmission cable harness van 1 Transmission gear crankcase 2 Body 3 Foldable clamp PORTER 1 3 16V Electrical system ES 183...

Page 184: ...nel cable harness 2 Internal lighting POSITIONS OF CABLES IN THE CONNECTORS CONNECTOR FRONT SIDE VIEWS From A Position Terminal Terminal Position Light fuse L C2 C1 Courtesy light Courtesy light DOOR...

Page 185: ...cable harness 2 Light fitting POSITIONS OF CABLES IN THE CONNECTORS CONNECTOR FRONT SIDE VIEW From A Position Terminal Terminal Position Roof light D1 D2 Light switch tail door Light fuse L C3 C4 Roof...

Page 186: ...A Position Terminal Terminal Position Light switch B1 B4 License plate light License plate light B4 B5 License plate light Heated rear window defroster switch K1 K4 Heated rear window defroster Chass...

Page 187: ...RONT SIDE VIEW From A Position Terminal Terminal Position F L EFI fuse M10 X4 EFI fuse F L Main fuse X2 N1 Main fuse J B Fuse box ignition switch B 022 018 Alternator B Ignition switch ST M1 M2 Starte...

Page 188: ...ness license plate and heated rear window 10 Tail door courtesy light switch 11 Rear right lights From A Position Terminal Terminal Position Rear right fog light B6 B7 Rear fog light switch L Light sw...

Page 189: ...ground J B Con nection box Connection to Z1 Z8 Z4 Rear right lights E Connection to Z1 Z8 Z5 Rear left lights E Connection to Z1 Z8 Z3 Tail door courtesy light switch Defroster switch K1 K4 Heated re...

Page 190: ...Diode 6 To the courtesy light cable harness 7 Diagnostic check 8 Front left chassis ground 9 Front left position light 10 radiator cooling electric fan motor 11 Left headlight 12 Left headlight adjus...

Page 191: ...g light switch 33 fog light relay 34 J B B connection 35 Headlight fuses 36 instrument panel 37 electric heater fan switch 38 radio 39 cigarette lighter 40 fuel pump 41 fuel and low fuel gauge 42 chas...

Page 192: ...C Scatola fusibili Fusibile luci L Proiettore destro B A9 A24 Fusibile proiettore destro B Collegamento a A22 A14 A10 Quadro strumenti Spia abba glianti Proiettore sinistro B A11 A23 Fusibile proietto...

Page 193: ...B16 Rel luci fendinebbia Fusibile fendinebbia B17 B18 Rel luci fendinebbia Collegamento a B1 B2 B20 Interruttore luci fendinebbia Rel fendinebbia B19 B22 Luce fendinebbia destro Collegamento a B21 B22...

Page 194: ...ano G1 G5 Quadro strumenti Spia freno a mano Quadro strumenti Spia livello olio freni G2 G3 Interruttore insufficiente livello olio freni Interruttore luce retromarcia G6 G7 Luce retromarcia Trasmetti...

Page 195: ...ibile riscaldamento L K36 K14 Interruttore riscaldamento B Collegamento a K5 K6 K17 Interruttore luce retromarcia Collegamento a K5 K6 K18 Quadro strumenti B Collegamento a K12 K13 KA1 Diodo uscita Re...

Page 196: ...llegamento a L2 L16 N8 Accensione Collegamento a N7 N15 N16 J B A Commutatore a chiave IG1 EFI F L N35 N46 Fusibile EFI 1 Commutatore a chiave IG2 N30 N37 Fusibile EFI n 2 Collegamento a L48 L42 N38 C...

Page 197: ...Z4 Interruttore luce cortesia Collegamento a Z32 Z8 Z5 Massa telalo posteriore Collegamento a Z1 Z2 Z7 Interruttore ventola riscalda mento Massa telaio anteriore destra Z32 Z8 J B B Massa Collegament...

Page 198: ...Collegamento a Z1 Z2 ZB1 Attuatore regolazione proiet tore destro Collegamento a Z1 Z2 ZB2 Attuatore regolazione proiet tore sinistro Collegamento a ZB1 ZB2 ZB3 Resistenza R1 Resistenza R1 ZB4 ZB5 Int...

Page 199: ...5 Left headlight adjustment actuator 6 Front left chassis ground 7 Front left position light 8 Left headlight 9 Horn 10 Left fog light 11 Front left side turn indicator 12 Headlight adjustment switch...

Page 200: ...plate light 36 Reverse gear light 37 Rear right lights 38 Diode 39 Diode 40 Radiator cooling electric fan 41 To the injection cable harness 42 EFI ECU control unit 43 12V Acc socket Cigarette lighter...

Page 201: ...Right headlight fuse B Connection to A22 A14 A10 Instrument panel High beam warning light Left headlight B A11 A23 Left headlight fuse L Connection to A22 A14 A12 Courtesy light B Right headlamp B A2...

Page 202: ...B Connection to B1 B2 C4 Heater switch lighting Connection to C3 C7 Left license plate light Courtesy light D1 D2 Courtesy light switch J B C horn fuse L E1 E7 Stop light switch Horn E2 E7 Stop light...

Page 203: ...tch Connection to A22 A14 B25 Diode output Rear fog light switch J B A Windscreen wiper fuse I1 I2 Windscreen wiper motor Turn indicator switch Wind screen wiper 1 I3 I4 Windscreen wiper motor 1 Winds...

Page 204: ...relay B EFI fuse No 2 L48 L42 R B Main relay S Connection to L17 L21 L46 EFI ECU A T Connection to X152 L50 Diode IN Main fuse B M1 M2 F L Main fuse Key switch ST M3 M4 Starter motor ST Main fuse L N1...

Page 205: ...nel Ground Connection to Z1 Z2 Z4 Courtesy light switch Connection to Z32 Z8 Z5 Rear chassis ground Connection to Z1 Z2 Z7 Heating fan switch Front right chassis ground Z32 Z8 J B B Ground Connection...

Page 206: ...adjustment ac tuator Connection to Z1 Z2 ZB2 Left headlight adjustment ac tuator Connection to Z1 Z2 ZB4 ZB3 Resistance R1 Resistance R1 ZB4 ZB5 Headlight aiming switch Resistance R1 ZC3 Headlight aim...

Page 207: ...ont left fog light 5 left headlight 6 Front left chassis ground 7 Diode 8 Diode 9 To the injection cable harness 10 EFI ECU 11 Diagnostic check 12 Front left position light 13 radiator cooling electri...

Page 208: ...37 Electric heater fan switch 38 heating resistance component 39 headlight adjustment switch 40 windscreen wiper motor 41 instrument panel 42 right headlight adjustment actuator 43 front right fog li...

Page 209: ...ight fuse L Connection to A3 A4 A15 Diode output Connection to A1 A2 A16 Diode output Turn ind switch emergency A19 A39 Instrument panel Emergency warning light Connection to A9 A24 A54 Right headligh...

Page 210: ...left side turn indicator Connection to F1 F9 F5 Instrument panel Turn indica tor warning light Connection to F3 F10 F6 Instrument panel Turn indica tor warning light Connection to F1 F9 F7 Rear right...

Page 211: ...oster J B Heater fuse L K5 K6 Heating motor Heating fan switch H1 K7 K8 Heating motor Heating fan motor K8 K9 Heating resistance HI Heating fan switch ME K10 K11 Heating resistance ME Heating fan swit...

Page 212: ...No I Key switch IG2 N30 N37 EFI fuse No 2 Connection to L48 L42 N38 Diagnostic check IG2 Connection to N1 N2 N39 Fuse Fog light Connection to N1 N2 O1 Alternator B Instrument panel Battery charge warn...

Page 213: ...witch Connection to Z1 Z2 Z14 Rear window washer switch Connection to Z1 Z2 Z15 Rear window wiper switch Connection to Z1 Z2 Z16 Defroster switch Connection to Z32 Z8 Z17 Front left position light Con...

Page 214: ...pump 2 brake fluid level switch 3 courtesy light switch 4 sound alarm buzzer 5 left headlight adjustment actuator 6 Front left chassis ground 7 Front left position light 8 left headlight 9 Horn 10 lef...

Page 215: ...gauge 31 fuel pump 32 to the chassis cable harness 33 Diode 34 Diode 35 radiator electric fan motor 36 To the injection cable harness 37 ECU control unit 38 cigarette lighter 39 radio 40 radio 41 fro...

Page 216: ...t headlight B A11 A23 Left headlamp fuse L Connection to A22 A14 A12 Courtesy light B Connection to A22 A14 A13 Courtesy light B Right Headlight fuse B A22 A14 J B C Light fuse L Connection to A3 A4 A...

Page 217: ...Horn E2 E7 Stop light switch Horn E3 E4 Turn indicator switch Horn Rear lights Right stop light E5 E6 Stop light switch Right turn indicator switch F1 F9 Front right side turn indicator Left turn ind...

Page 218: ...ield washer Turn indicator switch Wind screen wiper 2 I7 I8 Windscreen wiper motor 2 Connection to I1 I2 I9 Windshield washer motor Rear window wiper switch rear window washer I10 I11 Rear window wash...

Page 219: ...ump relay S EFI fuse No 1 L41A L41 R B Main relay E EFI fuse No 2 L48 L42 R B Main relay S Connection to L17 L21 L46 EFI ECU A T Connection to X152 L50 Diode IN Main fuse B M1 M2 F 1 Main fuse Key swi...

Page 220: ...ground Z1 Z2 Front left chassis ground Connection to Z1 Z2 Z3 Instrument panel Ground Connection to Z1 Z2 Z4 Courtesy light switch Connection to Z1 Z2 Z7 Heating fan switch Front right chassis ground...

Page 221: ...adjustment ac tuator Connection to Z1 Z2 ZB2 Left headlight adjustment ac tuator Connection to Z1 Z2 ZB3 Resistance R1 Resistance R1 ZB4 ZB4 Headlight aiming switch Resistance R1 ZB4 ZB4 Headlight aim...

Page 222: ...actuator 15 Horn 16 Left fog light 17 Front left side turn indicators 18 Key switch 19 Instrument panel 20 Loudspeaker 21 Stop light switch 22 J B A connection 23 Fog light fuse 24 J B C connection 2...

Page 223: ...ground 48 Right license plate light 49 Left license plate light 50 Rear fog light 51 Rear left lights 52 Diode 53 Diode 54 To the injection cable harness 55 EFI ECU 56 EFI fuse No 1 EFI fuse No 2 57 1...

Page 224: ...INDEX OF TOPICS ENGINE EN...

Page 225: ...THE THROTTLE BODY EGR VALVE EGR MODULATOR AND INJECTORS IF NECESSARY 1 Detach the suction pipe from the throttle body 2 Remove the bolts and fixing nuts on the EGR valve and on the EGR vacuum modulat...

Page 226: ...ed in the figure 6 Remove the inlet manifold 7 Remove the gasket Inlet manifold fitting 1 1 Fit a new inlet manifold gasket to the cylinder head 2 Fit the inlet manifold on the cylinder head CAUTION D...

Page 227: ...fuel pipe 8 Connect the water pipe 9 Connect the blow by pipe suction pipes and throttle cable 10 Fit the injector vibration insulators and delivery pipe thermal insulators 11 Fit the injectors on th...

Page 228: ...itting 2 16 Fit the EGR valve on the inlet manifold inter posing a new gasket Locking torques N m Inlet manifold EGR valve 15 22 17 Fit the EGR pipe on the EGR valve Locking torques N m EGR valve EGR...

Page 229: ...SV Vacuum Switching Valve idle speed Oxygen sensor Camshaft sensor VSV Vacuum Switching Valve bleeding Ignition system Engine coolant temperature sensor VSV Vacuum Switching Valve EGR Recircu lation o...

Page 230: ...ic Maximum deformation limit 0 1 mm If the deformation exceeds the maximum value replace the exhaust manifold No 1 2 Check the contact surface of the inlet manifold with the head Characteristic Maximu...

Page 231: ...B PAY ATTENTION NOT TO INTERFERE WITH OTHER PARTS 3 Place bolts and fixing nuts and tighten them evenly in two or three stages according to the se quence indicated in the figure on the right 4 Fit th...

Page 232: ...alent to 98 N KEY 1 Water pump pulley 2 V belt 3 Shaft pulley 4 Alternator pulley 5 Force application point 6 Straight ruler 7 Bending degree Belt bending specified value With the application of a for...

Page 233: ...ed at the middle point of the belt be tween the alternator pulley and the water pump pulley Characteristic Rated deflection of the New Belt with a 10 kg force applied at the indicated point 3 5 5 5 mm...

Page 234: ...ent 1 Position the flywheel on an adequate wooden block Remove the crown gear by using a punch together with a hammer 2 Position a new crown gear on the flywheel in a horizontal position 3 With a torc...

Page 235: ...fitting Fit the crankshaft pulley flange so that the input edge for the belt is positioned towards the oil pump Crankshaft pinion fitting Fit the timing belt pinion Fitting the timing pinion fixing s...

Page 236: ...t assembly 4 Upper cover 5 Lower cover 6 Tensioner 7 Timing belt Timing belt replacement Initial operations 1 Remove the water pump V belt undoing the al ternator support screws 2 Remove the water pum...

Page 237: ...the timing belt cover removing the three remaining fixing screws Timing belt removal IF THE TIMING BELT IS ALREADY USED WITH A PIECE OF CHALK MARK AN ARROW ON THE BELT INDICATING THE BELT ROTA TION DI...

Page 238: ...cylinder cover 8 Loosen the screw fixing the timing belt tension er Move the tensioner towards the left and lock it temporarily 9 Remove the timing belt DO NOT BEND TWIST OR TURN THE BELT UPSIDE DOWN...

Page 239: ...eth are cracked or damaged check that the camshaft is not jammed 3 If the surface of the belt has clear signs of wear or breaking check if there are notches on one side of the tensioner pulley 4 If on...

Page 240: ...NEVER WASH THE BELT TENSIONER PULLEY Timing belt tensioner spring check 1 Check the unloaded spring length Characteristic Unloaded length not exceeding 46 5 mm 2 Check the spring tension when the spr...

Page 241: ...check for possible bending wear or damage If there is damage replace the flange Crankshaft pulley removal 1 Remove the timing belt 2 Remove the screw locking the crankshaft pulley LOCK THE CRANKSHAFT...

Page 242: ...g towards the oil pump Align the holes with the toothing cavity 2 Fit the pulley on the crankshaft and align it with the key slot 3 Fit the pulley fixing screw on the crankshaft 4 Tighten the fixing s...

Page 243: ...pulley fixing screws Then remove the camshaft pulley Specific tooling 020172Y TOOL TO LOCK THE TIMING BELT PULLEY Camshaft pulley check 1 Measure the pulley outside diameter with a gauge Characteristi...

Page 244: ...EWS AS WELL AS THREADED HOLES MUST BE DRY DURING TIGHTENING Specific tooling 020172Y TOOL TO LOCK THE TIMING BELT PULLEY Locking torques N m Timing system pulley screws 15 22 Tension spring connection...

Page 245: ...G REMOVAL KEY A Reference on head cover B Reference on timing pulley C Reference on crankshaft pulley D Reference on oil pump casting F F reference mark on timing pulley external side 5 Loosen the ten...

Page 246: ...ERSE DIRECTION OR TURNED SO AS TO EXCEED THE POINT DESCRIBED ABOVE TIGHTEN THE TENSIONER LOCKING SCREW TEMPORARILY AND REPEAT ALL THE OPERATIONS FROM POINT 5 ON WARDS 9 Tighten the belt tensioner lock...

Page 247: ...es not comply with the specified values repeat the operations carried out for ten sioning Fitting the upper and lower cover of the timing belt WARNING BE CAREFUL THAT THE SCREWS ARE PROPERLY FIT TED T...

Page 248: ...t pulley transmission screws 20 29 4 Fit the water pump pulley and tighten the rele vant fixing bolts 5 Fit the driving belt 6 Adjust the driving belt tension Oil pump Removal Oil pump removal 1 Remov...

Page 249: ...er cap in its seat PLACE AN ADEQUATE PROTECTIVE CLOTH ON THE SPRING HOLDER TO AVOID THAT THE SPRING JUMPS OUT 5 Remove the cap the spring and piston WASH THE PARTS REMOVED USING SOLVENT 6 Checking eac...

Page 250: ...amaged Check the spring for deformations measure its unloaded length as well Replace the spring if deformations are detected or its unloaded length is below the specified value Characteristic Unloaded...

Page 251: ...aces Fit the rotors on the oil pump body so that the identification points are visible from the outside Measure clearance between the oil pump body and the external rotor with a thickness gauge Replac...

Page 252: ...y worn areas on the pump cover corresponding to the surface coupling with rotors Replace the oil pump cover if signs of wear are detected Timing side oil sealing ring replacement 1 Sealing ring remova...

Page 253: ...EM WITH COMPRESSED AIR WHEN COMPRESSED AIR IS USED PROTECT EYES WITH PROTECTIVE GOG GLES FIT THE SPRING CAP PROPERLY 3 Insert a new split pin in the holder Lock by opening the split pin 4 Apply oil on...

Page 254: ...DIAGONALLY Specific tooling 020384Y TOOL FOR TIMING SIDE CRANK SHAFT OIL SEAL 7 Turn rotors by hand Check that rotors turn free ly If rotor jamming is detected carry out a pump service N B THE FUNCTI...

Page 255: ...ealing ring 17 Gasket 18 Driving belt upper cover 19 Driving belt 20 Driving belt tensioner 21 Camshaft cap 22 Cylinder head gasket 23 Ignition coil assembly 24 Throttle body 25 EGR valve Recirculatio...

Page 256: ...Ignition coil 2 Injectors 3 Pressure sensor 4 Throttle sensor 5 Intake air temperature sensor 6 VSV Vacuum Switching Valve idle speed 7 Engine coolant temperature sensor 8 Oxygen sensor 9 Camshaft se...

Page 257: ...APPROX 284 KPA HIGHER THAN THE AT MOSPHERIC PRESSURE THEREFORE REMOVE THE PIPES GRADU ALLY TO AVOID FUEL SPRAYING Remove the inlet manifold Remove the exhaust manifold Pagina Manuale VTL Exhaust pipe...

Page 258: ...TURN THE CAMSHAFT WITHOUT HELP AVOID DAMAGING THE CYLINDER HEAD COVER GASKET SURFACE 5 Loosen the bolts fixing the valve rocking lever pin 6 Remove the valve rocking lever pin together with the cylind...

Page 259: ...NG OR DEFORMATION OF THE CYL INDER HEAD AND ALSO ENGINE SEIZURE 10 Remove the head fixing screws REFERENCE Screws 1 and 3 are shorter than the others Rated length of 1 and 3 110 mm Rated length of the...

Page 260: ...B and apply a negative pressure of about 14 6 kPa 110 mmHg to the EGR valve using the MityVac device At the same time check if there is air continuity between points A and C Tappet cover gasket Cylind...

Page 261: ...ELESS ONCE THE ENGINE IS SERVICED ADJUST VALVE CLEARANCES WITH COLD ENGINE AND THEN ADJUST AGAIN WITH HOT ENGINE AFTER WARMING UP THE ENGINE Locking torques N m Lock nut 16 7 22 5 Nm VALVE CLEARANCES...

Page 262: ...n and rocking lever coupling With a dial gauge measure the rocking lever inside diameter according to two directions perpendicular to each other With a micrometer measure the pin outside diameter in t...

Page 263: ...pin must be fitted so that the side with the lon ger chamfer is facing towards the timing belt KEY C Intake D Exhaust E Timing belt side F Spark plug jacket seat Rocking lever identification There ar...

Page 264: ...Camshaft inspections Camshaft check 1 Check for camshaft wear Rest both camshaft ends on two V shaped blocks Place a dial gauge at the central point of a cam shaft support section Rotate the shaft by...

Page 265: ...ling ring Check the surface to identify areas which are pos sibly worn Replace the camshaft if there are areas with ex cessive wear 4 Checking the guiding groove of the cam angle sensor Visually check...

Page 266: ...TO WARDS THE TIMING SYSTEM SIDE MAKE SURE THAT THE THREADS OF SCREWS AND HOLES ARE DRY Locking torques N m Cylinder head M 8 Camshaft 13 17 Cylinder head M 10 Camshaft 29 36 4 Remove the bearing cove...

Page 267: ...THE TIMING SYSTEM SIDE MAKE SURE THAT THE THREADS OF SCREWS AND HOLES ARE DRY Locking torques N m Cylinder head M 8 Camshaft 13 17 Cylinder head M 10 Camshaft 29 36 3 Measure camshaft axial clearance...

Page 268: ...alve spring stop caps with the special tool Specific tooling 020382Y Tool to remove the valve cotters 4 Remove the valve springs N B POSITION THE PARTS REMOVED SO THAT THEIR ORIG INAL FITTING POSITION...

Page 269: ...lastic parts Dry them with compressed air Gasket residue removal With a gasket scraper remove each gasket resi due from the head and from manifold surfaces Head cleaning and check 1 With a soft brush...

Page 270: ...0 10 mm Inlet manifold side 0 10 mm Exhaust manifold side 0 10 mm Combustion chamber cleaning With an iron brush remove all the carbon deposits from the combustion chamber BE CAREFUL NOT TO SCRATCH TH...

Page 271: ...the head surface Replace the head if there are cracks Valves Valve check and rectification 1 Visually check if the valve stem has signs of seizure or damage 2 Visually check if the valve head shows s...

Page 272: ...h the relevant rectification This reworking must however be comprised within a 2 mm limit from the rated length value DO NOT OVERHEAT THE VALVE DURING RECTIFICA TION Characteristic Inlet valve rated l...

Page 273: ...rometer measure the valve stem diameter at six points Record the values measured 4 Clearance calculation Calculate clearance of each single valve according to the following formula Guide inside diamet...

Page 274: ...clination exceeds the maximum limit replace the valve spring 2 With the special tool measure the unloaded length and tension of the valve spring Characteristic Valve spring minimum unloaded length mar...

Page 275: ...icated by the arrow in the figure The thickness gauge must measure 0 07 mm thickness and 12 5 mm length Make sure that the thickness gauge does not reach the spiral centre If the thickness gauge reach...

Page 276: ...e extraction 2 Insert a new valve guide bushing until the circlip is not stopped by the cylinder head BE CAREFUL NOT TO CAUSE AN EXCESSIVE IMPACT DURING FITTING FAILURE TO OB SERVE THIS PRECAUTION CAN...

Page 277: ...eat 3 Let the valve fall in its seat by its own weight two or three times KEY A Intake 4 Remove the valve 5 Check the sealing and relevant valve seat as follows Make sure that contact between the valv...

Page 278: ...e seat only as much as to obtain an even surface KEY A Intake With a mill at 30 rework the valve seat so that the largest diameter of the ma chining operation at 45 is 29 0 1 mm KEY B Inlet seat With...

Page 279: ...e With a mill at 20 rework the valve seat so that the largest diameter of the ma chining operation at 45 is 25 mm KEY D Exhaust With a mill at 70 rework the valve seat so that the length of the surfac...

Page 280: ...ts are reworked fit the new valves Measure the distance between the cylinder head attachment surface head cylinder gasket position surface and the upper part of the valve Make sure that this distance...

Page 281: ...ry it with compressed air 2 Apply a thin layer of special adhesive onto the jacket surfaces making contact with the head Recommended products Three Bond 1377B Adhesive sealing com pound 3 With wooden...

Page 282: ...oden wedge and a hammer Place the union so that the pipe is in an orthogonal position with respect to the head sur face 6 Once these operations have finished remove each protruding adhesive residue an...

Page 283: ...CAUSE SCOR ING FORMATION ON THE SEALING EDGE IF THE SEALING RING CAN NOT TURN FREELY IN ITS SEAT IT MEANS THAT IT WAS BENT INSERTED DIAGO NALLY OR WAS INADEQUATELY FORCED DO NOT REUSE ANY RING THAT W...

Page 284: ...to remove the valve cotters 3 After fitting the cotters slightly hit the stem with a hammer to make sure that the valve cotters are fitted firmly WARNING DURING THIS OPERATION BE CAREFUL THAT COT TERS...

Page 285: ...T LAYER THEREFORE WHEN A SENSOR IS REPLACED REMOVE THE SEALANT LAYER BEFORE WRAPPING THE SEAL ING TAPE BESIDES MAKE SURE THAT THE HOLE OF THE HEAD THREADED SECTION IS CLEAN THE ORIGINAL SEALANT IS REM...

Page 286: ...IGHTENED EVENLY TO THE PRESCRIBED TORQUE Locking torques N m Cylinder head Cylinder block 59 67 Camshaft and rocking lever pin fitting 1 Wash and dry holes for screws fixing camshaft supports WHEN COM...

Page 287: ...AFT SUPPORTS CLEAN EACH SEALANT TRACE FROM SUPPORT No 1 OF THE CAMSHAFT 7 Fit the rocking levers and elastic inserts on the relevant pins Lubricate the parts N B THE INTAKE SIDE PIN CAN BE RECOGNISED...

Page 288: ...OIL SEAL 4 Fit the pulley for the camshaft toothed belt 5 Adjust valve clearance and ignition timing 6 Fit the cylinder head cover with gasket A and tighten the fixing bolts evenly in two or three sta...

Page 289: ...1 Timing belt cover No 1 2 Timing belt cover No 2 3 Water pump 4 Water pump gasket 5 Dust guard 6 Oil pump 7 Sealing ring 8 Head gasket 9 Cylinder block 10 Crankshaft 11 Flange 12 Timing pinion 13 Ma...

Page 290: ...oil unit 2 Remove the bolts fixing the cylinder head cover 3 Remove the cylinder head cover 4 Loosen bolts fixing the cylinder head evenly in two or three stages according to the sequence in dicated i...

Page 291: ...ket residue from the head and cylinder block surface with a suitable scraper Cylinder block removal Phase 1 1 Remove the oil pressure switch and oil filter 2 Remove the crankshaft pulley screw N B AVO...

Page 292: ...nkshaft pulley IF THE CRANKSHAFT PULLEY CAN NOT BE TAKEN OUT MANUALLY FIT THE FOLLOWING SPECIAL TOOL Specific tooling 020380Y TIMING PINION EXTRACTOR 4 Remove the crankshaft pulley flange Engine PORTE...

Page 293: ...mp 7 Remove the water pump gasket Cylinder block removal Phase 2 1 Remove the alternator support bracket the en gine right support with the guide for the oil dipstick 2 Remove the thermostat cover and...

Page 294: ...Y WITH THE SPECIFICATION REQUIREMENTS REPLACE THE FLYWHEEL BEFORE REPLACING THE FLYWHEEL CHECK THE LOCKING TORQUE Characteristic Limit value 0 1 mm 6 Loosen the flywheel fixing screws in the se quence...

Page 295: ...two or three stages Take out bolts and nuts 2 Separate the oil sump from the cylinder block with the following special tool Specific tooling 020403Y FLYWHEEL LOCK WRENCH 3 Remove the two oil sump gask...

Page 296: ...al 1 Remove the carbon deposits at the end of cyl inders 2 Turn the crankshaft until the piston reaches the bottom dead centre 3 Loosen the connecting rod cap nuts operating in two or three stages to...

Page 297: ...om the upper part of the cylinder block POSITION THE PISTONS REMOVED AND CONNECTING RODS SO THAT THE SINGLE FITTING POSITIONS ARE EASILY IDENTIFIED BE CAREFUL NOT TO DAMAGE THE BUSHINGS Remove the fly...

Page 298: ...HOUT JAM MING THIS PISTON COUPLING IS CONSIDERED NOR MAL Reference Check clearance between the piston and the pin is as specified Clearance measurement between the piston and the pin Clearance can be...

Page 299: ...ecting rod removal Use the following special tools to carry out removal operations 1 Fit the connecting rod in the special tool as shown in the figure THE PISTON AND PIN AS REGARDS ITS CLEARANCE ARE C...

Page 300: ...izures Replace the piston if neces sary 3 Piston diameter measurement Measure the outside diameter at the point specified and in a perpendicular position to the pin If the piston ring opening exceeds...

Page 301: ...wed limits Characteristic Piston cylinder clearance Specification values 0 025 0 045 mm Admissible limit 0 11 mm PISTON RING CLEARANCE Specification Desc Quantity Piston ring No 1 Specification value...

Page 302: ...it allowed 0 8 mm Scraper ring Spring A 0 2 0 6 mm Scraper ring Spring B 0 15 0 6 mm Scraper ring allowed limit 1 0 mm Oil scraper piston circlip A Shape A B Shape B Piston rings Inspection Piston rin...

Page 303: ...the special tool as shown in the figure Fit the special tool in the piston where the pin is fitted 3 Fit the pin in the connecting rod with a hydraulic press THE PISTON AND CONNECTING ROD MUST BE FITT...

Page 304: ...5 mm Maximum torsion 0 05 mm Pin connecting rod forced coupling check 1 Measure the pin outside diameter which must be coupled with the connecting rod using a mi crometer 2 Measure the inside connecti...

Page 305: ...e the connecting rod or crankshaft or both if nec essary Characteristic Axial clearance Standard 0 15 0 4 mm Maximum 0 45 mm Connecting rod head width in the thrust direc tion 21 80 21 85 mm Seat widt...

Page 306: ...t until the connecting rod cap is on the oil sump part 4 Loosen the nuts of the connecting rod cap even ly operating in two or three stages Then remove the nuts of connecting rod cap 5 Remove the conn...

Page 307: ...easure the plastigauge thickness at its max imum point Characteristic Clearance 0 020 0 044 mm If clearance does not comply with the specification value measure the connecting rod pin diameter and sel...

Page 308: ...ording to the results of points 1 and 2 The values indicated in the figure are in millimetres CONNECTING ROD HEAD TYPES Name Description Dimensions Initials Quantity Category 5 50 000 49 995 1 Categor...

Page 309: ...THE CRANKSHAFT 3 Select the connecting rod bushings according the following table CONNECTING ROD HEAD TYPES Name Description Dimensions Initials Quantity Category 5 50 000 49 995 1 Category 5 49 994...

Page 310: ...asure the diameter of each cylinder at six points a shown in the figure Make sure that the difference between the maxi mum and the minimum diameter of each cylinder is within 0 1 mm If the difference...

Page 311: ...urface of the cylinder in the direction shown in the figure If the measured value exceeds 76 28 mm replace the cylinder block 2 Determining the cylinder finishing diameter Measure the oversized piston...

Page 312: ...RELEVANT CYLINDER N B TO INSERT THE PARALYSER USE A 10 MM OUTSIDE DIAMETER BUFFER CONNECTING ROD HEAD TYPES Name Description Dimensions Initials Quantity Category 5 50 000 49 995 1 Category 5 49 994 4...

Page 313: ...ement must be performed in four di rections for each support point distanced 90 one from the other as indicated in the figure Select the main bushing according to the following table Piston selection...

Page 314: ...S FITTED 2 Rear sealing ring fitting Insert a new ring using in the seat with the follow ing special tool N B BE CAREFUL THAT THE RING IS NOT FITTED DIAGO NALLY THE SPECIAL TOOL IS DESIGNED TO CARRY O...

Page 315: ...sure the thickness of the shim washers with the block If the measured value is below 23 59 mm replace the half rings If the value measured exceeds 23 59 mm replace the crankshaft MEASURE THE AXIAL CLE...

Page 316: ...the bushings 4 Clean the main journals and bushings using sol vent Dry them blowing compressed air 5 Check main journals and bushings for scoring or porosity If the main journals are damaged replace...

Page 317: ...06 mm 8 Place the crankshaft in the cylinder block 9 Apply a plastigauge string onto each crank shaft main journal 10 Fit the main bearings Tighten the screws evenly in the sequence indicated in the f...

Page 318: ...INGS AFTER ALL THE IN SPECTIONS HAVE BEEN CARRIED OUT TO SELECT THE MAIN BUSHINGS AFTER REPLACING THE CRANKSHAFT REFER TO CRANKSHAFT RE PLACEMENT THERE ARE FOUR TYPES IDENTIFIED BY NUMBERS 5 6 7 AND 8...

Page 319: ...49 982 5 Category 6 49 975 or less Category 7 49 995 50 000 3 Category 7 49 989 49 994 4 Category 7 49 983 49 988 5 Category 7 49 976 49 982 6 Category 7 49 975 or less Category 8 49 995 50 000 4 Cate...

Page 320: ...ies of the main journal No 1 TIMING SIDE Set the category of main bushings us ing the table shown below M Crankshaft N Main journal category O Cylinder block N Main bearing category 3 Connecting rod b...

Page 321: ...ence V Connecting rod category Set the category of connecting rod bushings using the table shown be low Connecting rod bushing categories M Crankshaft N Categories of the connecting rod pin O Connecti...

Page 322: ...LINDER BLOCK SIDE Recommended products Three Bond 1377B Adhesive sealing com pound Locking torques N m Cylinder block Water pump 15 22 Oil filter fitting 1 Apply a reduced quantity of engine oil onto...

Page 323: ...ITCH IS FITTED 2 Tighten the oil pressure switch to the specified torque value using a box spanner Locking torques N m Oil pump Oil pressure switch 12 20 Spring connection to the timing belt tensioner...

Page 324: ...aft 2 Application of sealant to the flywheel screws Wash the flywheel screws then remove grease and dry them N B WHEN GREASE IS REMOVED FROM SCREWS CLEAN COMPLETELY EVERY TRACE OF OIL USING SOLVENT MA...

Page 325: ...S THIS COULD LOOSEN THE BOLTS NEVER USE ANOTHER SEALANT THAN THE RECOM MENDED AVOID THAT THE SEALANT REACHES RESIN OR RUB BER PARTS Recommended products Three Bond 1324C Sealant 3 At the same time tig...

Page 326: ...SIDE THE ENGINE Recommended products Three Bond 1207C SEALANT 2 Apply engine oil onto the sealing ring internal surface Fit the flange to the cylinder block Tighten to the specified torque values Lock...

Page 327: ...GASKETS DUST GUARD AND ELECTRICAL COMPONENTS THEN DRY THEM USING COMPRESSED AIR WARNING WHEN COMPRESSED AIR IS USED REMEMBER TO PROTECT EYES WITH PROTECTIVE GOGGLES rear plate fitting Fit the rear pla...

Page 328: ...ITTED 2 Lubricate the seat of each bushing with engine oil DO NOT TOUCH THE FRONT AND LOWER SURFACES OF BUSHINGS DO NOT APPLY ENGINE OIL ONTO THE MAIN BEARINGS 3 Fit the crankshaft in the cylinder blo...

Page 329: ...torque value operating in two or three stages according to the sequence indicated in the figure Locking torques N m Cylinder block Main bearing cap 44 54 Arrangement to fit the head on the engine 1 P...

Page 330: ...NEITHER TO DAMAGE THE HEAD NOR THE SURFACE WHERE SUCH GASKET IS RESTING NEVER TURN SEPARATELY NEITHER THE CRANK SHAFT NOR THE CAMSHAFT BEFORE FITTING THE TIM ING BELT N B AS REGARDS THE TWO SCREWS THA...

Page 331: ...head cover to the prescribed torque according to the sequence indicated in the figure on the right N B BE CAREFUL NOT TO DAMAGE THE SPARK PLUG PIPE SEALING RING DURING FITTING Locking torques N m Cyli...

Page 332: ...y fit the flywheel on the crankshaft N B DO NOT LUBRICATE SCREWS AND THREADED HOLES OF THE FLYWHEEL 1 Fit the oil scraper spring in the relevant seat Make sure that the end is positioned as in the fig...

Page 333: ...each ring reaches the respective points as indicated in the figure IT IS NOT NECESSARY TO STRICTLY FOLLOW THE FIG URE INDICATIONS NEVERTHELESS MAKE SURE THAT THE END OF THE RING IS ALIGNED WITH THE T...

Page 334: ...URING FITTING BE CAREFUL NOT TO DAMAGE THE CONNECTING ROD PINS DURING THE PISTON FITTING Specific tooling 020328Y LOCK UP RINGS 11 Push the piston manually until the connecting rod reaches the connect...

Page 335: ...move the flywheel 18 Remove the special tool Specific tooling 020184Y FLYWHEEL LOCKING TOOL Oil pump fitting 1 Apply adhesive onto the coupling surface of the oil pump with the cylinder block 2 Replac...

Page 336: ...AKE SURE THAT THE FINAL SECTION OF THE OIL SUMP GASKET OVERLAPS AT LEAST 10 MM WITH AD HESIVE 3 Fit the oil sump Tighten the screws and nuts fixing the oil sump to the specified torque value evenly an...

Page 337: ...T Terminal T ON from the option list 4 Connect a probe to the ignition cable harness of cylinder No 4 then start the engine KEY A Probe B Ignition coil 5 Check that the reference of the ignition timi...

Page 338: ...ERY COMPLETELY CHARGED SO AS TO OBTAIN A SPEED EQUAL TO AT LEAST 300 RPM Compression value 1373 kPa 14 kgf cm2 at 300 rpm Minimum pressure 1030 kPa 10 5 kgf cm2 at 300 rpm Reading difference among cyl...

Page 339: ...data monitoring from the option list WHEN THE DIAGNOSIS INSTRUMENT DS 21 IS NOT USED CONNECT A RPM INDICATOR TO THE REV TER MINAL USING THE SPECIAL TOOL SST Specific tooling 09991 87402 000 Rpm indic...

Page 340: ...en kept op erative life and guaranteed up to now while an improvement has been introduced to face engine output power increase due to a change engine capacity increase of the engine to be fitted As a...

Page 341: ...re below Components 1 Spring 2 Thrust bearing hub stop 3 Clutch lever 4 Thrust bearing 5 Lever stop 6 Pressure plate 7 Clutch disc Installation Fit the single parts according to the numerical order sh...

Page 342: ...iven plate 1 Fit the special tool A in the rear end of the crank shaft 2 Fit the clutch disc Specific tooling 020196y Clutch guiding tool 3 Fit the clutch cover aligning the reference pin of the same...

Page 343: ...Tool kit to align the diaphragm spring 7 Fit the clutch lever Apply EP grease onto the thrust bear ing hub and to the lever contact sur face Apply EP grease onto the clutch lever and to relevant cont...

Page 344: ...ver Check for wear or damage Clutch disc 1 Check the clutch disc for signs of wear Rivet depth Characteristic Limit 0 3 mm 2 Check for possible eccentricity of the clutch disc Limit Characteristic Lon...

Page 345: ...normal signs of hardening or obstacles 2 Check the thrust bearing hub for signs of dam age or wear Also check the contact surface of the relevant stop and housing sliding section for signs of damage o...

Page 346: ...ace those defective parts Components A Screw B Spacer C Spring D Pedal lever Clutch cable The clutch cable is the protection sheath type of cable As a consequence an increased liability level is obtai...

Page 347: ...utch cable terminal 8 Clutch cable adjusting nut 9 Cover Clutch pedal adjustment Pedal fitting height Set the distance between the floor and the centre of the pedal upper surface to the specified valu...

Page 348: ...ut and the cable guide ring reaches the value 2 5 4 mm Lock the adjusting nut after aligning the cable guide ring protrusion with the grooves of the nut KEY 1 Front 2 Sheath 3 Nut 4 Ring 3 Check the f...

Page 349: ...ing the operation standard temperature make sure that the oil pressure is within the pre scribed values USE A LONG HEXAGONAL BOX SPANNER FOR REMOV AL IF THE VALUE FOUND IS NOT WITHIN THE PRESCRI BED V...

Page 350: ...SEALANT COMPLETELY BEFORE WRAPPING THE SEALING TAPE MAKE SURE TO CLEAN THE OIL PUMP SIDE HOLE THREADS BEFORE FITTING THE OIL PRESSURE SWITCH Locking torques N m Oil pressure switch Cylinder block 12 2...

Page 351: ...pump rotor series 4 Take out the cotter pin pushing the retaining spring with the pliers 5 Remove the spring retaining cap the compres sion spring and oil pump valve PLACE A SUITABLE CLOTH ETC ON THE...

Page 352: ...DAMAGED PART REPLACE THE COMPRESSION SPRING IF DAMAGED OR IN CASE ITS UNLOADED LENGTH IS SHORTER THAN THE PRE SCRIBED VALUE REPLACE THE PUMP IF THE VALVE IS NOT WORKING PROPERLY Measuring pump housin...

Page 353: ...ALUE Characteristic Maximum clearance allowed 0 04 0 08 mm WEAR CHECK Check if the pump cover rotor series connection surface is worn REPLACE THE OIL PUMP COVER IF WORN Fitting 1 Apply engine oil onto...

Page 354: ...ess BE CAREFUL NOT TO DAMAGE THE OIL PUMP DURING THE OIL SEAL REMOVAL AND FITTING MAKE SURE THAT THE OIL SEAL IS NOT FITTED IN AN INCLINED POSITION 5 Apply engine oil onto the rotor series Fit the ro...

Page 355: ...d in the figure Recommended products Three Bond 1207C SEALANT 3 Apply engine oil onto the oil seal internal sur face 4 Replace the O ring A of the oil pump with a new one 5 Fit the oil pump on the cyl...

Page 356: ...IFIC SECTION OF THE CYLINDER BLOCK 8 Apply the sealant onto the fixing section of the oil sump cylinder block as shown in the figure on the right N B MAKE SURE THAT THE SEALANT IS APPLIED TO BOTH OIL...

Page 357: ...GLE DAMAGED PART REPLACE THE COMPRESSION SPRING IF DAMAGED OR IN CASE ITS UNLOADED LENGTH IS SHORTER THAN THE PRE SCRIBED VALUE REPLACE THE PUMP IF THE VALVE IS NOT WORKING PROPERLY Measuring pump hou...

Page 358: ...nt With a rectified bar section and a thickness gauge measure side clearance between rotors and the oil pump housing REPLACE THE OIL PUMP IF CLEARANCE EXCEEDS THE PRESCRIBED VALUE Characteristic Maxim...

Page 359: ...TEM COMPONENTS IF THE WARNING LIGHT TURNS ON WHEN THE ENGINE IS RUNNING CARRY OUT THE FOLLOWING CHECKS FIRST OF ALL MAKE SURE THAT THE ENGINE OIL IS AT AN ADEQUATE LEVEL pressure switch fitting 1 Clea...

Page 360: ...Fit a new water pump gasket on the cylinder block 2 Fit and tighten the water pump to the specified torque value N B WHEN STUD BOLTS ARE LOOSENED OR REPLACED APPLY THE RECOMMENDED PRODUCT ONTO THE THR...

Page 361: ...r or a cloth under the fuel filter 4 Loosen the fuel filter nut slowly avoiding fuel splashes HOLD THE FUEL FILTER WITH A WRENCH OR SIMILAR OBJECT TO PREVENT ITS ROTATION CAREFULLY AVOID FUEL SPLASHES...

Page 362: ...information to check the proper operation of the cooling system The removal and fitting operations are described as well Conceptual diagram Cooling system diagram The cooling system is a water and fo...

Page 363: ...N THE RADIATOR AND THE NOZZLE WARNING DIRECT THE JET TO A RIGHT ANGLE WITH RESPECT TO THE RADIATOR FAILURE TO OBSERVE THESE RULES CAN CAUSE DEFORMATION OF THE RADIATOR FINS Radiator cap check 1 With a...

Page 364: ...ssure of 88 kPa 0 9 bar to the cool ing system with radiator testing device 4 In case the pressure lowered check pipes the radiator water pump heating for possible leaks If no leaks are detected check...

Page 365: ...GE PLUG WHEN THE FLUID IS HOT COVER THE AL TERNATOR TO AVOID THAT THE COOLANT GETS INTO THE ALTERNATOR 4 Remove the 3 thermostat cover screws Thermostat inspection 1 Make sure that the thermostat valv...

Page 366: ...racteristics do not comply Characteristic Valve opening temperature in C 82 86 C Valve lifting 8 5 mm or more at 97 C Thermostat fitting 1 Fit the thermostat with the bleeding pin placed towards the u...

Page 367: ...diator removal 1 Disconnect the battery negative terminal 2 Drain the coolant as follows Set the heating control lever to hot Remove the front panel gasket Remove the radiator cap NEVER OPEN THE RADIA...

Page 368: ...ove the reinforcement 5 Disconnect the inlet pipe outlet pipe and the water pipe for heating from the radiator 6 Disconnect the radiator fan connector 7 Remove the right and left supports of the radi...

Page 369: ...levant supports on the vehicle and tighten the 4 screws fixing the radiator supports 4 Connect the radiator fan connector 5 Connect the radiator inlet outlet pipe and the water pipe for the heater 6 F...

Page 370: ...nec tor 4 Remove the radiator thermoswitch from the ra diator pipe Radiator thermoswitch inspection Radiator thermoswitch specifications The figure shows the hysteresis cycle of the ther moswitch 1 Co...

Page 371: ...94 C Check there is no continuity between terminals A B of the switch If there is continuity carry out the fol lowing checks 6 Take the water temperature to 85 C Check there is no continuity between t...

Page 372: ...ative terminal 2 Remove the lower crankcase 3 Drain the coolant Open the radiator cap and the drainage plug and let the coolant off in a container NEVER OPEN THE RADIATOR CAP AND OR THE DRAIN AGE PLUG...

Page 373: ...or is damaged or de formed 3 Make sure that water pump rotates properly by hand If it does not rotate properly replace it 4 Check for signs of damage and wear on the cyl inder block surface which is c...

Page 374: ...llet for pos sible corrosion deformations or cracks The water pump attachment surface for scores The attachment seat of the pump pul ley for possible wear Replace the water pump if necessary 2 Check i...

Page 375: ...skets 3 Fit a new gasket on the cylinder block 4 Fit the water pump on the cylinder block Tight en in two or three stages the fixing screws and nuts to the prescribed torque N B AFTER TIGHTENING THE B...

Page 376: ...6 Fill with coolant 7 Fit the lower crankcase 8 Connect the battery negative terminal Engine PORTER 1 3 16V EN 376...

Page 377: ...INDEX OF TOPICS INIECTION SYSTEM IS...

Page 378: ...LLOWS LETTER P CAN BE READ FOR EXAMPLE POXXX IN THIS MANUAL THE AREAS WHERE THE TYPE APPROVAL CERTIFICATION IS ISSUED ACCORDING TO THE APPROVAL OF EC EXHAUST EMISSIONS ARE INDICATED WITH EU SPECIFICAT...

Page 379: ...ephones or mobile phones be careful to follow the safety measures indicated below 1 Fit the aerial as far as possible from the electronic control unit and from the vehicle electronic control system se...

Page 380: ...actuator Failure to observe this safety meas ure can damage the electronic control unit the sensor or the actuator 6 If a testing probe is applied to the connector be careful to place on its rear part...

Page 381: ...DRIVING MANOEUVRES IT MEANS THE CABLES MUST NOT BE NEAR FEET PEDALS STEERING AND GEARSHIFT LEVER DURING THE TEST RIDING WITH THE OBD II GENERAL SCANNING DEVICE OR DIAGNOSTIC TESTER TWO PERSONS ARE NE...

Page 382: ...ENT THE CONTACT OF THE SPEED SENSOR WITH THE GROUND SINCE THE IGNITION SPARK PLUG AND OR IGNITION COIL COULD BE DAMAGED SOME TYPES OF RPM INDICATORS ARE NOT FIT FOR THE VEHICLE IGNITION SYSTEM THEREFO...

Page 383: ...CONTROL UNIT CONNECTORS ARE DISCON NECTED OR CONNECTED BE CAREFUL THAT THE BATTERY IS DISCONNECTED WITH THE IGNITION SWITCH AND ALL THE ACCESSORY SWITCHES SET TO OFF WHEN FITTING THE NEW BATTERY BE CA...

Page 384: ...E FOLLOWING CHECKS AND REPAIR THE PARTS NOT WORKING PROPER LY Specific tooling 020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester CONNECT THE TESTER DS 21 TO ANOTHER VEHI...

Page 385: ...tching valve for EGR valve VSV 1 10 Engine coolant temperature sensor ECT 11 Engine revolution sensor RPM 12 Rear oxygen sensor OX2 lambda probe 13 Ignition unit 14 Ignition coil 15 Front oxygen senso...

Page 386: ...nition unit with ionic current measurement 9 Cam angle position sensor RPM 10 EGR valve 11 Surge tank 12 Injector 1 2 3 4 13 Engine coolant temperature sensor ECT 14 Rear oxygen sensor heater Rear oxy...

Page 387: ...ECU DRACO CONNECTOR LAYOUT PORTER 1 3 16V Iniection System IS 387...

Page 388: ...ACE DIAGRAM 1 Emission control unit DRACO 2 EFI ECU control unit DENSO 3 connector to program the DRACO control unit 4 EFI DRACO connection cable harness 5 To the engine cable harness 6 To the vehicle...

Page 389: ...RDE R RED ROSSO L LIGHT BLUE AZZURRO O ORANGE ARANCIO P PINK ROSA Y YELLOW GIALLO W WHITE BIANCO V VIOLET VIOLA Br BROWN MARRONE Gr GREY GRIGIO Disposizione terminali Disposizione del morsetto dell un...

Page 390: ...9 51 N1 10 52 N2 Cam angle sensor 11 53 KNK 12 54 ISC 13 55 ALTC 14 56 VSV2 Vacuum switching valve to increase idle speed 15 57 IG4 Ignition signal cylinder No 4 16 58 IG3 Ignition signal cylinder No...

Page 391: ...8 FCCP 6 19 VFP 7 20 OXH1 Front oxygen sensor heater 8 43 IE Ionic current sensor ground 9 44 VTH Throttle valve sensor 10 45 THW Engine coolant temperature sensor 11 46 VCPM Pressure sensor power sup...

Page 392: ...F Anti fog system switch 4 11 A T Radiator fan relay 5 12 MGC 6 13 FAN1 7 37 SPD Vehicle speed sensor 8 38 ACSW 9 39 BLW Heater fan switch 10 40 STP Stop light switch 11 41 AUX Resistance for switchin...

Page 393: ...2 6 6 TRRQ Headlight switch 7 7 B1 Fuel supply 8 29 E21 Rear oxygen sensor ground 9 30 FC2 Fuel pump relay without IMB 10 31 REV Engine revs signal rpm 11 32 ATRX 12 33 ATNE 13 34 VF VF monitor termin...

Page 394: ...REV Engine revs signal rpm 6 29 E21 Rear oxygen sensor ground 7 1 BAT Memory protection power supply 8 9 T Test terminal 9 8 SI01 Diagnostic tester 10 68 STA Starter motor signal 11 7 B1 Fuel supply...

Page 395: ...73 OX3 Rear oxygen sensor 5 40 STP Stop light switch 6 39 BLW Heater fan switch 7 45 THW Engine coolant temperature sensor 8 44 VTH Throttle valve sensor 9 43 IE Ionic current sensor ground 10 80 VSV...

Page 396: ...nsor ground 9 46 VCPM Pressure sensor power supply 10 76 THA Air intake temperature sensor 11 26 20 Injector Cyl 2 12 25 30 Injector Cyl 3 13 24 40 Injector Cyl 4 14 23 E1 Signs of ground 15 56 VSV2 I...

Page 397: ...the fuel pump and the fuel delivery pipe is still under pressure Before loosening or removing the pipes release the fuel pressure according to the procedure to release fuel pressure Also after releasi...

Page 398: ...mm the clip must not be placed on the pipe elbow Besides it must not ex ceed the pipe end Suction pipe Pipe insertion length Insert the pipe as shown in the figure on the side Clip position The clip e...

Page 399: ...ll the handbrake and apply locking wedges to the wheels 2 Remove the upper and lower covers of the steering column 3 Remove the relay block with the cable harness 4 Remove fuel pump relay B from the r...

Page 400: ...and the operation perfectly 3 Troubleshooting priority A priority is specified for troubleshooting a certain number of diagnosis codes in the relevant operation diagram act observing such priority If...

Page 401: ...emission control system components which could negatively affect emissions or in propeller control compo nents or a failure is detected in the same control unit the warning light turns on or flashes o...

Page 402: ...e Key 1 B Body C Chassis P Propulsor U Network 2 0 Regulation 1 Maker 3 Vehicle system 4 Diagnostic failure code digits for example 1 2 Fuel and air measurement 3 Ignition system 7 8 Transmission 5 Ma...

Page 403: ...conditions are stor ed when the operation failure is detected supply system calculated load engine coolant tempera ture fuel trim engine speed vehicle speed etc The frozen image data are therefore use...

Page 404: ...ector and pin layout the data link connector complies with the stand ards ISO 15031 3 SAEJ1962 and the format ISO 14230 The OBD II serial data line ISO 14230 K line is used for the OBD II general scan...

Page 405: ...according to the malfunction phenomenon The diag nosis of this system is equipped with a battery protection function which allows to power the diagnosis memory also with the ignition switch set to OFF...

Page 406: ...ay indicate the failure code frozen image data clear the data and confirm the malfunction phenomenon Then indicate the failure code frozen image data once more It is recommended to check the failure c...

Page 407: ...e regular code is indicated when the failure code is checked it is assumed that an abnormal situation as bad contacts of cables and connectors was previously detected but it does no longer exist curre...

Page 408: ...tinuous monitoring results if the diagnostic tester DS 21 is used select the option continuous monitoring results from the CARB mode vehicle communi cation menu Malfunction reproduction simulation tes...

Page 409: ...C CONTROL UNIT 3 Water application If it is suspected that the malfunction is detected during rainy days or in humid conditions Wet the vehicle with water Check if a malfunction is detected N B NEVER...

Page 410: ...test the cable harness between the EFI ECU control unit and the DRACO Emission Control Unit disconnect the latter from the DRACO and from the EFI ECU and connect the SST on the EFI side Then check fo...

Page 411: ...t check 1 Disconnect the connector on both sides 2 Measure the resistance between the relevant connector terminals and the chassis ground Besides check connectors on both sides SLIGHTLY SHAKE THE CABL...

Page 412: ...s check that the termi nal is not disconnected slightly pulling the connec tor wire 4 Prepare this male terminal of the connector ter minal Insert it in the female terminal and slightly pull to check...

Page 413: ...rol unit Checking and replacing the electronic control unit First of all check the ground circuit of the elec tronic control unit If an operation defect is detec ted repair the ground circuit If no de...

Page 414: ...area Interrupted or short circuited cable in the intake air temperature sensor Intake air temperature sensor Engine electronic control unit Diagnostic failure code P0115 Failure detected Engine coola...

Page 415: ...P0135 Failure detected Oxygen sensor heater circuit failure bank 1 sensor 1 Affected area Interrupted or short circuited cable in the oxygen sensor circuit heater Oxygen sensor heater Engine electroni...

Page 416: ...r circuit Oxygen sensor Manifold absolute pressure sensor Engine coolant temperature sensor Gas leak in the exhaust system Vacuum switching valve for vapour bleeding Engine electronic control unit Dia...

Page 417: ...ircuit A failure Affected area Interrupted or short circuited wire in the cam angle sensor circuit Cam angle position sensor Rotor signal Engine electronic control unit Diagnostic failure code P0420 F...

Page 418: ...rol unit Diagnostic failure code P1510 Failure detected Start up signal circuit failure Affected area Interrupted wire in the start up signal circuit Engine electronic control unit Diagnostic failure...

Page 419: ...blished by the throttle opening angle engine speed and ISC opening angle Ignition timing is set to be controlled according to the pressure determined by the engine speed and by the above mentioned val...

Page 420: ...roubleshooting referring to the following table Start up problems Malfunction phenomenon Probable affected area The engine does not start with the starter motor does not start up Starter motor and sta...

Page 421: ...el pump checking circuit Injector circuit Fuel duct filter Ignition coil circuit with ignition spark plug Vacuum switching valve circuit to increase idle speed Oscillation during idle speed operation...

Page 422: ...pump circuit with ignition spark plug Spark plug Diagnostic Failure Code Clearing The failure code and frozen image data can be cleared as follows 1 The diagnostic tester or OBDII general scanning de...

Page 423: ...ON PERFORM TROUBLESHOOTING ON THE INSTRUMENT PANEL Failure code check using the diagnostic tester DS 21 or OBD II general scanning device 1 Prepare the diagnostic tester DS 21 or OBD II general scanni...

Page 424: ...standards DMC failure codes can not be read 5 Once checking has finished set the tester main switch and the ignition switch to OFF Disconnect the special tool from the data link connector then disconn...

Page 425: ...ignition switch and then the tester main switch to ON 3 If the diagnostic tester DS 21 is used clear the failure code by selecting the option Failure code clearing others from the menu Vehicle commu...

Page 426: ...CLEARED AUTOMATICALLY FROM THE CONTROL UNIT MEMORY ONLY IN VEHICLES WITH EU SPECIFICATIONS Controlli di base del motore Diagram of basic operations to check the engine If the electronic control unit...

Page 427: ...nal ON of the ac tuator control so as to short circuit the T terminal If it does not correspond Connect the stroboscopic gun to the ignition coil wire 4 cylinder 4 to acti vate the signal light necess...

Page 428: ...d on the throttle body otherwise continue with troubleshooting according to the malfunction phenomena AFTER CHECKING AVOID THE SHORT CIRCUIT OF THE T TERMINAL BY MEANS OF THE ACTUATOR CONTROL FUNCTION...

Page 429: ...ink Connector interposing the special tool Specific tooling 020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester Fasten the fuel pipe to the main pipe manually and set the...

Page 430: ...nition coil connector With a sound alarm check the opera tion sound of the single injectors while the engine is run with the starter motor or at idle speed The sound of operation of all the injectors...

Page 431: ...ata checking can vary significantly according to a slight difference in meas urement measurement environment and deterioration due to the passing of time and so on It is therefore difficult to indicat...

Page 432: ...ot be substantial dif ferences rpm Minimum speed without load after warming up 850 950 rpm VEHICLE SPEED VS During running measured with a speedome ter There must not be a significant difference Km h...

Page 433: ...air conditioner switch set to ECON or A C OFF ON THROTTLE POSITION SWITCH CLOSED throttle position switch closed IDL When the throttle valve is changed from fully closed to open status OFF ON INJECTI...

Page 434: ...6 B2 23 E1 With ignition switch set to ON 1 BAT 23 E1 At any moment Pressure sensor 46 VCPM 47 E2PM With ignition switch set to ON 4 5 5 5 V 15 PIM 47 E2PM Sensor at ambient pressure 2 2 3 1 V After t...

Page 435: ...switch set to ON Battery voltage With the headlight switch of the anti fog system the heating fan radiator fan thermoswitch and the stop light switch set to ON while the engine is running at idle spee...

Page 436: ...tery voltage Speed 3000 rpm Impulse production engine revs output 3 REV 23 E1 While the engine is running at idle speed Impulse production Communication signal con trol system 8 SIO1 23 E1 While the e...

Page 437: ...MAP INLET MANIFOLD ABSOLUTE PRESSURE CIRCUIT EURO3 4 1 ECU EFI control unit 2 DRACO control unit 3 MAP sensor inlet manifold absolute pressure 4 Cable harness side connector PORTER 1 3 16V Iniection...

Page 438: ...manifold absolute pressure sensor circuit interrupted or short circuited wire in the manifold absolute pressure sensor cable harness manifold absolute pressure sensor engine electronic control unit I...

Page 439: ...pecial tool to the ECU EFI For the Model EURO 4 connect the special tool between the ECU EFI control unit and the cable harness connectors coming from the ECU DRACO control unit Specific tooling 02046...

Page 440: ...ms in the vacuum duct cable harness or connector otherwise proceed with step 4 4 Checking the cable harness between the MAP sensor and the electronic control unit Model EURO 3 Set the tester main swit...

Page 441: ...injection system electrical values With the ignition switch set to ON measure voltage between terminals 15 and 47 PIM E2PM Characteristic specified value 3 3 4 0V If the value measured does not match...

Page 442: ...in the table check for possible intermittent malfunctions caused by problems in the vacuum duct cable harness or connector otherwise pro ceed with step 4 4 Checking the cable harness between the MAP s...

Page 443: ...nnectors on the con trol unit side If there are no short circuits or open circuits on both cable harnesses the malfunction could be caused by the sensor or the DRACO To check for correct operation of...

Page 444: ...ntrol unit 2 Cable harness side connector 3 Intake air temperature sensor IAT 4 Ground node Model EURO 4 KEY 1 ECU electronic control unit 2 Cable harness side connector 3 Intake air temperature senso...

Page 445: ...nesses downstream and upstream the DRACO control unit and on the DRA CO itself Failure code Diagnostic failure code detection Conditions Affected area P0110 Short circuit or open circuit in the IAT se...

Page 446: ...malfunction detected intermittently or ineffi cient contacts see relevant section If NOT Value measured about 30 C proceed with Step 2 Value measured about 130 C pro ceed with Step 4 Specific tooling...

Page 447: ...re value measured by the diagnostic tester Is the value measured about 130 C If SO EURO 3 the IAT sensor connection cable harness is interrupted Repair or replace the cable harness If NOT EURO 3 inter...

Page 448: ...connect connector B from the DRACO 3 Switch to ON and read the intake air temperature Is the value measured about 30 C If SO EURO 4 Repair and replace the IAT sen sor connection cable harness If NOT E...

Page 449: ...is procedure generates fur ther temporary diagnostic failure codes for exam ple P0105 and P0115 which can be cleared from the memory at the end of the diagnosis KEY 1 EFI ECU control unit 2 Connector...

Page 450: ...ONE SPECIFIED If SO EURO4 Check the malfunction that is detected intermittently or insuf ficient contacts If NOT EURO4 1 Connect the interface wiring 020463Y between the ECU and the DRACO and restore...

Page 451: ...ontrol unit P0115 Malfunzionamento circuito temperatura liquido raffreddamento motore Using the tester DS 21 or OBD II general scanning device 1 1 With the ignition switch set to OFF connect the diagn...

Page 452: ...h and then the tester main switch to ON Read the engine coolant temperature value on the diagnostic tester DS 21 or on the OBD II general scanning device If the value measured is equal to 140 C or hig...

Page 453: ...errupted Fix the cable harness or replace the DRACO Check cable harnesses downstream and up stream the DRACO and on the DRACO itself in the following order Test the cable harness in the EFI ECU contro...

Page 454: ...n the ignition switch to OFF 2 Disconnect connector B of the special tool from the electronic control unit connector KEY 1 EFI ECU control unit 2 Connector B 3 Cable harness side connector 4 Diagnosti...

Page 455: ...tact for the model EURO 4 check the cable harnesses and also that the EFI ECU control unit is downstream as well as up stream the DRACO control unit see the relevant paragraph otherwise proceed with s...

Page 456: ...DRACO unit side Connector 2 10 on the DRACO unit connector 45 on the electronic control unit side THW X31 connector on the sensor side connector B4 on the DRACO unit side Connector 3 21 on the DRACO...

Page 457: ...lfunction Failure code Diagnostic failure code detection Conditions Affected area P0115 Interrupted or short circuited wire in the engine coolant temperature sensor circuit Interrupted or short circui...

Page 458: ...frozen image data record the engine conditions at the moment the defect is detected these data are useful to determine during the trouble shooting phase if at the moment of failure checking the vehic...

Page 459: ...device As frozen image data record the engine conditions at the moment the defect is de tected these data are useful to determine during the troubleshooting phase if at the moment of failure checking...

Page 460: ...ione pedale farfalla KEY 1 Cable harness side 2 Throttle valve sensor A comp open B comp closed 3 BNDR 4 EFI ECU control unit Model EURO 4 KEY 1 Cable harness side 2 Throttle valve sensor A comp open...

Page 461: ...correct air fuel ratio power increase and to control fuel closure etc For the Model EURO 4 the circuits in question comprise the cable harnesses downstream and upstream the DRACO control unit and on...

Page 462: ...Tester Set the ignition switch and the tester main switch to ON Read the throttle valve opening value on the diagnostic tester DS 21 or on the OBD II general scanning device Throttle valve opening Com...

Page 463: ...failures are detected during checks replace the throttle valve sensor otherwise proceed with step 4 4 Checking the input signal of the VTH elec tronic control unit Connect the special tool For the Mo...

Page 464: ...DRACO control unit With the ignition switch set to ON measure voltage between connectors 16 and 17 VTH E2 Characteristic Voltage specified Value 4 5 5 5 V If the value measured does not match the spec...

Page 465: ...h step 3 3 Check the cable harness and the connector between the EFI ECU control unit and the throttle valve sensor lines VC VTH E2 for interrupted or short circuited wires For the Model EURO 4 the ci...

Page 466: ...ionamento circuito sensore ossigeno sensore 1 KEY 1 Switch 2 60A fuse F L 3 Main relay 4 Fuel pump relay 5 Battery 6 Fuel pump 7 Front part 8 Rear part 9 Rear O2 sensor heating 10 Rear O2 sensor 11 Fr...

Page 467: ...warming up the engine the signal ar riving from the oxygen sensor remains con stantly in the non rich status without turning rich not even once b The oxygen sensor output voltage remains at 0 3 V or...

Page 468: ...be detected If there is no diagnostic tester DS 21 available set the ignition switch to OFF after carrying out steps from 2 to 4 then repeat steps from 2 to 4 Checking procedure Read the frozen image...

Page 469: ...con nector X28 of the oxygen sensor on the cable harness side and the terminal 75 of the special tool repair or replace the cable harness or the connector if nec essary 3 Checking the oxygen sensor ou...

Page 470: ...gulator fuel duct and filter if necessary 7 Check the injector for correct operation and re place if necessary 8 Check there are no gas leaks in the exhaust sys tem replace or repair the defective par...

Page 471: ...by fuel exhaustion otherwise check the malfunction that is detected intermittently or due to false contact P0133 Risposta lenta circuito sensore ossigeno Sensore 1 KEY 1 Switch 2 60A fuse F L 3 Main...

Page 472: ...EN IMAGE DATA RECORD THE ENGINE CONDITIONS AT THE MOMENT THE DEFECT IS DETECTED THESE DATA ARE USEFUL TO DETERMINE DURING THE TROUBLESHOOTING PHASE IF AT THE MOMENT OF FAILURE CHECKING THE VEHICLE WAS...

Page 473: ...running at idle and the radiator fan stop ped If voltage varies repeatedly between a voltage be low 0 32V and above 0 58V jump to step 8 4 Air intake system check Check the following options Checking...

Page 474: ...least once check or replace the engine electronic control unit otherwise replace the oxygen sensor bank 1 sensor 1 8 Repeat the functional check Refer to the diagnostic failure code diagram P0130 9 I...

Page 475: ...oxy gen sensor heater Oxygen sensor heater Engine electronic control unit READ THE FROZEN IMAGE DATA USING THE DIAGNOSTIC TESTER DS 21 OR OBD II GENERAL SCANNING DEVICE AS FROZEN IMAGE DATA RECORD TH...

Page 476: ...ensor heater replace the oxygen sensor if necessary otherwise check or replace the cable harness or the connector between the main relay and the oxygen sensor and the engine electronic control unit P0...

Page 477: ...to Continuous monitoring results of the CARB mode 2 Start the engine With all the switches set to OFF warm up the engine until the engine coolant temperature reaches 90 C or a higher value 3 Accelerat...

Page 478: ...ere are interrupted or short circuited cables between the connector XJ5 of the oxygen sensor on the cable harness side and the terminal 74 of the special tool Repair and replace the cable harness or t...

Page 479: ...k the malfunction that is detected intermittently or bad contacts 4 Checking the oxygen sensor unit output voltage Warm up the engine completely Disconnect the oxygen sensor connec tor with the igniti...

Page 480: ...O2 sensor 12 Injector 13 EFI ECU control unit Circuit description Fuel trim means the return offset value which compensates the basic injection time There are two modes of fuel trim short term and lon...

Page 481: ...r Gas leak in the exhaust system Vacuum switching valve for vapour bleeding Engine electronic control unit P0172 Air fuel too rich the total of fuel trim is lower than the set value detection logic wi...

Page 482: ...k the following options Checking the engine oil level indicator oil cap and PVC pipe also inspecting that the latter is not disconnected Checking there is no disconnection loosening or cracking in the...

Page 483: ...interrupted or short circuited wires Check if there are interrupted or short circuited wires between the connector X28 of the oxygen sensor on the cable harness side and the terminal 75 of the specia...

Page 484: ...t indicate an output voltage equal to 0 2V or more at least once check or re place the engine electronic control unit otherwise replace the oxygen sensor bank 1 sensor 1 12 Confirm the driving configu...

Page 485: ...de P0171 or P0172 is not indicated replace the oxygen sensor bank 1 sensor 1 previously fitted on the vehicle otherwise check or replace the engine electronic control unit P0172 Carburazione ricca Pag...

Page 486: ...alfunctions are detected code P0314 is displayed press F1 key If there is no diagnostic tester DS 21 available set the ignition switch to OFF after the indication is simulated for the first time Then...

Page 487: ...Spark plugs 14 20A engine 15 Injector Circuit description Irregular ignition The ignition system detects the ionic current according to the fuel pressure The ionic current turns into voltage that is i...

Page 488: ...dation of emissions detection logic with 2 interventions N B IF 2 OR MORE CODES RELATED TO A CYLINDER WITH IRREGULAR IGNITION ARE RECORDED IN SUCCESSION AS LONG AS RANDOM MULTIPLE CYLINDER IRREGULAR I...

Page 489: ...e to riding with low fuel to the inadequate use of fuel dirty spark plug etc An interrupted wire detected at the input line of the ionic signal between the ignition spark plug unit and the Electronic...

Page 490: ...hich the irreg ular ignition is detected connectors 27 up to 24 and the body ground Speci fied value battery voltage Watch the injector wave shape with an oscilloscope reference Check the wave shape o...

Page 491: ...the cable harness or the connector if necessary otherwise check the malfunction that is detected intermittently or that there are no bad contacts 6 Ionic system check see troubleshooting of Diagnosti...

Page 492: ...or rich etc 1 Checking the cam angle sensor circuit re sistance Set the special tool sub wiring har ness Connector A of the tool must remain disconnected from the Elec tronic Control Unit connector B...

Page 493: ...ed value from 205 to 255 Ohm at 20 C Replace the cam angle sensor if necessary 3 Check there are no interrupted or short circuited wires in the cable harness and the connector between the engine elect...

Page 494: ...special tool connector STA E1 during engine start up Specified value battery voltage repair or replace the cable harness or the connector between the engine elec tronic control unit ignition switch ot...

Page 495: ...ferentiate cylinders every two engine revs The electronic control unit measures the crankshaft angle according to the signal N2 and the engine speed with NE signals Failure code Diagnostic failure cod...

Page 496: ...as rear oxy gen sensors which indicate the same frequen cy while running the vehicle at a predetermined speed with the engine revs within a pre set range detection logic with 2 interventions Three way...

Page 497: ...ent of failure checking the vehicle was working or at standstill if the engine was hot or not if the air fuel ratio was lean or rich etc 1 Other codes besides P0420 are indicated consult the relevant...

Page 498: ...No 2 5 Main relay 6 Fuel pump relay 7 Battery 8 Fuel pump 9 Cable harness side 10 Injector 11 EFI ECU Circuit description When working conditions for vapour emission bleeding are fulfilled the electr...

Page 499: ...Interrupted or short circuited wires in the va pour vacuum switching valve circuit Vapour vacuum switching valve Engine electronic control unit Checking procedure Read the frozen image data using the...

Page 500: ...ster main switch Clear the diag nostic failure code Select the VSV Bleeding from the Actuator control When switching ON and OFF check the operation of the vacuum switching valve for bleeding VSV OFF n...

Page 501: ...of the vac uum switching valve for bleeding Set the tester main switch to ON Set the ignition switch to OFF Disconnect the vacuum switching valve connector With the ignition switch set to ON measure v...

Page 502: ...ding if necessary 6 Check the output signal of the electronic control unit Connect the connector to the vacuum switching valve for bleeding Connect the connector of the special tool to the electronic...

Page 503: ...PRG E01 for more than two minutes pushing and holding down the accelerator pedal DIV class cnt_summary title Testo Breve 4000 car If there is no response check or replace the engine electronic contro...

Page 504: ...the special tool sub wiring harness Do not connect the connec tor of the special tool to the electronic control unit Check there are no interrupted or short circuited wires in the cable har ness and...

Page 505: ...the instrument panel has a magnet that is turned by the speedometer cable The reed switch is set to ON and OFF for four times for each speedometer revolution It is therefore transmitted to the electro...

Page 506: ...meter indication is normal it means that the speedometer works regularly 2 Check the input signal of the speed sensor to the electronic control unit Set the special tool sub wiring harness Check that...

Page 507: ...filled for certain period 1 The AD conversion value of the atmospheric sensor is lower than 1 6V 2 The AD conversion value of the atmospheric sensor is equal or higher than 4 7V Engine electronic cont...

Page 508: ...d then the ignition switch to OFF Set the ignition switch and then the tester main switch to ON Check the diagnostic failure code If P1105 is indicated replace the electronic control unit otherwise ch...

Page 509: ...tain value it is assumed that an irregular ignition is detected Considering that the ionic current detected is too weak it is amplified in the ignition unit Failure code Diagnostic failure code detect...

Page 510: ...ark plugs all cylinders 1 2 3 and 4 Fit the spark plug on the ignition coil connect the ignition coil connector to the ignition coil Earth the spark plug Start the engine and check the spark plug spar...

Page 511: ...rs Set the ignition switch to OFF Disconnect the connectors of the igni tion switch and ignition unit on the Elec tronic Control Unit side Between the ignition switch and the ignition unit terminal B1...

Page 512: ...nic signal Specifications All wave shapes must be present as shown in the figure KEY A For a cylinder B For all cylinders If no sparks are detected and there is no wave shape of ignition signals ionic...

Page 513: ...connect the connector of each igni tion coil D Terminal I C on the cable harness side of the ig nition unit Terminals LI L2 L3 L4 on the cable har ness side of each ignition coil Repair and replace th...

Page 514: ...harness or the connector 11 Checking the cable harness between the Electronic Control Unit of the Fuel Injection and the ignition unit Check there are no interrupted or short circuited wires in the c...

Page 515: ...alue measured matches the specified value check the malfunction that is detected intermittent ly and bad contacts otherwise proceed with step 2 2 Checking the cable harnesses between the ignition swit...

Page 516: ...y positive voltage is applied to the terminal STA of the Engine Electronic Control Unit The start up signal is used mainly to increase the fuel injection volume for the start up injection and post sta...

Page 517: ...agnostic tester DS 21 If failures are detected during checks inspect the malfunction that is detected intermittently or due to false contact 2 Check the cable harnesses between the throttle valve sens...

Page 518: ...he DRACO itself Throttle valve sensor Connector XT1 on the sensor side DRACO con nector B4 DRACO connector 3 21 EFI ECU connector 17 E2 Connector XT1 on the sensor side DRACO con nector B4 DRACO conne...

Page 519: ...KEY 1 Ignition switch 2 Throttle valve sensor wire on the cable harness side 3 EFI ECU control unit 4 60A fuse F L 5 Battery 6 Throttle valve sensor Model EURO 4 PORTER 1 3 16V Iniection System IS 519...

Page 520: ...ed only if terminal T is set to ON It is not stored For the Model EURO 4 the circuits in question comprise the cable harnesses downstream and up stream the DRACO control unit and on the DRACO itself F...

Page 521: ...measure the voltage between connectors 16 17 VC and E2 44 17 VTH and E2 Characteristic specified value 16 17 VC and E2 4 5 5 5 V 44 17 VTH and E2 move the throttle lever from the completely closed to...

Page 522: ...pump relay 7 Battery 8 Fuel pump 9 EFI ECU control unit 10 Main relay 11 Fuel pump relay Circuit description Battery positive voltage is delivered to the BAT terminal of the engine electronic control...

Page 523: ...cle was working or at standstill if the engine was hot or not if the air fuel ratio was lean or rich etc 1 Checking the auxiliary power supply voltage of the electronic control unit Set the special to...

Page 524: ...21 1 Functional check of the EGR vacuum switch ing valve control system With the ignition switch set to OFF connect the diagnostic tester DS 21 to the Data Link Connector through the special tool Spec...

Page 525: ...ease the vacuum switching valve so as to set the vacuum switching valve for EGR to the original operating mode Start the engine and let it run Disconnect the suction pipe that goes from the vacuum swi...

Page 526: ...l tool to the electronic control unit Check there are no interrupted or short circuited wires in the cable har ness and connector Connector XAE on the valve cable harness side con nector 80 on the VSV...

Page 527: ...le running at a speed of 60 km h 4a gear max 4800 rpm Characteristic specified value the voltage must shift from 0 to 1 V If failures are detected during checks inspect the malfunction that is detecte...

Page 528: ...con trol unit closes the atmospheric inlet opening of the vacuum switching valve allowing the conduction of vacuum to the EGR valve In this way the recir culation of exhaust fumes is obtained KEY 1 V...

Page 529: ...of failure checking the vehicle was working or at standstill if the engine was hot or not if the air fuel ratio was lean or rich etc Circuito alimentazione unit di controllo elettronica KEY 1 Ignition...

Page 530: ...Circuit description With the ignition switch set to ON apply battery positive voltage to the coil closing the contacts of the electronic fuel injection main relay and powering terminals B1 and B2 of t...

Page 531: ...en the re lay block and the electronic control unit With the ignition switch set to OFF dis connect the special tool connector from the electronic control unit Disconnect the cable harness from the ba...

Page 532: ...n switch disconnected check continuity between the terminals shown below Switch position Continuity terminal No LOCK IGN 4 5 ON 2 3 4 5 START 1 2 3 4 If checks do not correspond replace the ignition s...

Page 533: ...n fuse No 2 Replace the fuse if necessary otherwise check and replace the electronic control unit Circuito controllo pompa carburante IGNITION SWITCH 1 Ignition switch 2 60A fuse F L 3 15A EFI fuse No...

Page 534: ...T of the Data Link Connector and the ground terminal If there is no pressure increase check the mal function that is detected intermittently or due to false contact 2 Checking the power supply circuit...

Page 535: ...the relay block and the electronic control unit 5 Fuel pump check Repair or replace the fuel pump if necessary 6 Checking the cable harness between the relay block and the fuel pump Check there are no...

Page 536: ...I fuse No 2 5 Main relay 6 Fuel pump relay 7 Battery 8 Fuel pump 9 EFI ECU control unit 10 Cable harness side wire 11 To the cooling fan 12 To the front headlight switch 13 To the heater fan switch 14...

Page 537: ...nic control unit Checking procedure 1 Functional check of the vacuum switching valve to increase idle speed With the ignition switch set to OFF connect the diagnostic tester DS 21 to the Data Link Con...

Page 538: ...utput signal of the electronic control unit vacuum switching valve terminal After warming up the engine and after stopping it set the ignition switch and the main switch of the diagnostic tester DS 21...

Page 539: ...tage between terminals 56 and 82 VSV2 and E2 E01 Condition Specified value 1 Until the complete engine warm up after start up with cold en gine 0 5 V or less 2 Anti fog system switch set to ON 0 5 V o...

Page 540: ...y be tween openings Specifications there must be continuity 3 Measure the resistance value between termi nals Characteristic specified value from 30 to 34 Ohm at 20 C Spark plug The spark plug could b...

Page 541: ...st be around 3 4 kOhm With the throttle lever fully closed the resist ance value must be around 0 4 kOhm VSV2 MIN Vacuum switchover valve for in creasing idle speed 1 Check continuity between outlets...

Page 542: ...ec ifications there must be continuity between open ings G and E There must not be continuity between openings E and F 2 Apply voltage to the connector terminals of the vacuum switchover valve and che...

Page 543: ...he OBD Connector and the Diagnostic Tester Characteristic Specified value from 0 2 to 3 0 Ohm Main relay and fuel pump relay 1 Turn the ignition switch to ON Check that the relay is working paying att...

Page 544: ...aracteristic Specified value from 11 7 to 14 5 Ohm at 20 C Ignition unit For EU specifications only 1 Measure resistance between the following con nector terminals TERMINAL RESISTANCE VALUES Specifica...

Page 545: ...INDEX OF TOPICS GEAR BOX GE...

Page 546: ...tening torque when it is detected that the main section bolts are loosened From checking confirmations it is possible to discover which can be the cause of the problem which has rendered the removal n...

Page 547: ...he gear control fork spring is inserted in its seat D 4 00 mm L 50 00 mm Y is used when it is checked by man ually turning the main shaft that the transmission assembly works properly The part Y is in...

Page 548: ...e possible oil leak sections have been reduced 2 In order to improve rigidity the gear transverse section has been changed from the conventional U to the cylindric shape 3 To reduce weight each housin...

Page 549: ...ong the teeth at the moment of meshing with the main gear In addition to this an elastic spring conical placed between the sub gear and the main gear avoids any noise when shifting gears 2 The sub gea...

Page 550: ...3rd and 4th gear 21 Control head of the 3rd and 4th gear 22 Control fork of the 3rd and 4th gear 23 Control fork shaft of the 1st and 2nd gear 24 Control fork of the 1st and 2nd gear 25 Control head o...

Page 551: ...ransmission gear thrust washer Nylon washer 9 Reverse transmission gear shaft D 20 mm This shaft is locked by means of the hexagonal bolt 11 10 Pin Make sure that the part that comes out from the shaf...

Page 552: ...Thickness of the section of the fin making contact with the hub bushing 6 7 6 9 mm 23 Control fork shaft of the 1st and 2nd gear This shaft is the shortest among the three shafts L 224 mm D 13 0 mm 2...

Page 553: ...he selection lever 38 Pin 39 Gear control shaft cover 40 Gasket 41 Spring 42 Selection internal lever 43 Main shaft 44 Reverse gear limit pin holder 45 Gasket 46 Spring 47 Ball 48 Gearbox 49 Gear inte...

Page 554: ...e gear limit cam Pay special attention to the fitting direction during the removal and fitting phases so that the reverse gear limit cam has the proper fitting direction 36 Reverse gear limit shaft D...

Page 555: ...ections coupling with the clutch housing and the housing rebound 49 Gear internal lever Width of the section making contact with the control head 11 88 11 98 mm 50 Gear control shaft subassembly sleev...

Page 556: ...tom is used to drain oil Tightening torque 29 4 49 0 Nm 62 Bimetallic bushing In cases in which only the bushing is replaced pay attention that the contact section has 120 distance with respect to the...

Page 557: ...onto the lip section 74 Oil guide plate This plate is fitted inside the gearbox Tightening torque 6 9 9 8 Nm Repairs to be carried out on the vehicle 1 Sleeve assembly of the rpm indicator gear 2 Box...

Page 558: ...olt A from the reverse transmission gear with the gasket REMOVE THE COVER OF THE GEAR CONTROL SHAFT AS REQUIRED BEFORE REMOVAL TAKE OUT THE GROOVED PIN FROM THE GEARSHIFT LEVER SHAFT THIS HEXAGONAL BO...

Page 559: ...t 3 Remove the bearing lock 4 Detach the spring washer B of the primary shaft radial ball bearing from the rear part REMOVE THE GEARBOX AFTER CHECKING IF THERE IS CLEARANCE BETWEEN THE INPUT SHAFT AND...

Page 560: ...ake out the main shaft assembly with the nee dle bearing and the synchroniser ring N B MAKE SURE THAT EACH GEAR CAN BE PROPERLY 2 Remove the reverse gear control lever remov ing the three bolts 3 Remo...

Page 561: ...rnal lever shaft and the gear fork heads Characteristic Selection internal lever Specified value 15 0 002 mm 0 12 mm Internal lever heads Specified value 15 0 02 mm 0 1 mm Gear clutch control Removal...

Page 562: ...r possible damage 2 Measure the diameter of the reverse transmis sion gear bushing seat 3 Measure the outside diameter of the reverse transmission gear shaft Inspect its surface to check for possible...

Page 563: ...pecified value 30 0 0 021 mm 0 mm Replacement of gearshift lever and gear com ponents Removal 1 Remove the sleeve of the selection lever 2 Remove the sealing cap if necessary 3 Remove the T oil seal N...

Page 564: ...hronisation ring No 1 7 Synchroniser elastic key 8 Synchroniser hub assembly No 3 9 Synchroniser movement key 10 Hub key stop 11 Circlip 12 Needle bearing 13 3rd gear 14 Synchronisation ring No 1 15 S...

Page 565: ...dentical and are used in different positions The clearance between the gear and the synchronisation ring is 0 95 1 35 mm 7 Synchroniser elastic key Components 7 and 15 are identical and are used in di...

Page 566: ...The clearance between the gear and the synchronisation ring is 0 95 1 35 mm 15 Synchroniser elastic key Components 7 and 15 are identical and are used in different positions Make sure that the key op...

Page 567: ...he contact section of the gear control fork and of the hub sleeve for the 3rd gear A and for the 5th gear B 3RD GEAR A AND 5TH GEAR A Specification Desc Quantity Fork Specification value 7 0 1mm 0 3mm...

Page 568: ...HAFT BY PRESSING AND HOLDING THE SECTION OF THE 3rd GEAR WITH THE SPECIAL TOOL Specific tooling 020206Y Extractor 5 Remove the needle bearing 6 Remove the circlip of the shaft 7 As a reference during...

Page 569: ...se 13 Remove the radial bearing from the front side Inspection 1 Check clearance between the gear conical sec tion and the synchronisation rings Characteristic Specification value 0 95 1 35 mm 2 Measu...

Page 570: ...HE OTHER ARE REPLACED Classification No 2 Yellow A and B 57 78 57 84 mm Hub sleeve 57 871 57 97 mm Classification No 1 No colour A and B 57 68 57 74 mm Hub sleeve 57 771 57 87 mm Classification No 3 W...

Page 571: ...2 mm 0 4 mm Fitting Initial operations 1 Fit the needle bearing and apply engine oil N B UPON FITTING APPLY ENGINE OIL ONTO THE COMPO NENTS NEVER REUSE COMPONENTS MARKED WITH AN AS TERISK NEVER EXPAN...

Page 572: ...THAT THE GROOVED SECTOR FOR LOCK ING THE FIFTH MOVEMENT KEY IS FACING THE THIRD GEAR 6 Selection procedure of the new shaft spring washer select the new shaft spring washer which has the same thickne...

Page 573: ...vement key on the synchroniser hub assembly No 2 10 Make sure that the grooved section A of the synchroniser hub assembly No 2 is facing the third gear side FOR THE CORRECT USE OF THE HUB SLEEVE REFER...

Page 574: ...D FIRST Characteristic Clearance Specified value 0 Value allowed less than 0 16 mm 12 Fit the ball bearing by pressure 13 Fit the elastic ring of the shaft component to be selected following the same...

Page 575: ...e synchronisation ring and the gear conical section 2 Visually check the possible worn areas and damage of the gear and the main shaft grooved section Characteristic Specification value 0 95 1 35 mm 3...

Page 576: ...AIN SHAFT SEE THE FIGURE ON THE RIGHT UP THE LOCK NUT CAN BE LOOSENED SEE THE FIGURE ON THE RIGHT AT THE CENTRE AND AT THE BOTTOM DUE TO INCORRECT PUNCHING 6 Fit the odometer pinion 7 Press on the rad...

Page 577: ...er of the 1st gear 4 Circlip 5 1st sub gear 6 Circlip 7 Needle bearing 8 1st gear 9 Synchronisation ring No 2 10 Synchroniser elastic key 11 Synchroniser hub assembly No 1 12 Synchroniser movement key...

Page 578: ...of the input shaft 7 Needle bearing Inside diameter 37 00 37 025 mm 8 1st gear Real thickness 27 31 27 37 mm Clearance regarding the synchronisation ring 0 95 1 35 mm Limit 0 9 mm 9 Synchronisation ri...

Page 579: ...l spring washer Components 6 and 16 have the same function Secure each part of the 2nd gear so that the part of the washer having the larger diameter is facing the sub gear side 17 2nd sub gear Compon...

Page 580: ...lightly pressing on the secondary shaft by means of a specific pipe Radial ball bearing Thrust washer of the 1st gear 1st gear Synchronisation ring No 2 Needle bearing THE COMPONENTS DESCRIBED ABOVE C...

Page 581: ...CONDITION CAN CAUSE ABNORMAL NOISE OF THE GEAR Inspection 1 Measure the height of synchronised gear elastic keys Specification value 5 1 0 1 mm 2 Visually inspect the synchronised gear elastic key spr...

Page 582: ...69 74 B 69771 69 87 Classification No 3 White A 69 58 69 64 B 69 67 69 77 PARTS A AND B SHALL BE REPLACED TOGETHER 7 Measure thickness A of the synchroniser hub No 1 8 Measure the inside diameter of t...

Page 583: ...ND REMOVAL 2 Apply engine oil onto the external peripheral area of the needle bearing and fit the 2nd gear into the secondary shaft 3 Place the synchronisation ring No 3 on the syn chroniser hub No 1...

Page 584: ...SYNCHRONISATION RING 10 Sequence for selection of a new shaft spring washer Select the new shaft spring washer which has the same thickness as that measured at the time of removal or a thinner shaft...

Page 585: ...HRUST WASHER OF THE 1st GEAR IS FACING TO THE FRONT 15 Push with pressure on the radial ball bearing this bearing does not have gaskets 16 Sequence to select a new shaft spring washer For the selectio...

Page 586: ...d of the 2nd gear D as shown in the figure BEFORE STARTING REMOVAL MAKE SURE OF MEASURING THE AXIAL CLEARANCE AT DIFFERENT POINTS IF THE AXIAL CLEARANCE MEASURED EXCEEDS THE SPECIFIED VALUE IN THE TAB...

Page 587: ...of the 1st and 2nd sub gear with those of the input shaft gear Each single sub gear has one tooth less with respect to the main gear N B BEFORE FITTING THE SECONDARY SHAFT ASSEMBLY AND THE INPUT SHAFT...

Page 588: ...released 2 Fit the reverse transmission gear A shaft C and the thrust washer B as shown in the figure DURING THE FITTING PHASE INSTALL THE LOCKING PIN WHICH PREVENTS THE TRANSMISSION GEAR SHAFT ROTATI...

Page 589: ...fork and the relevant shaft Apply engine oil where it is required Carry out op erations according to the procedures provided be low Proceed as follows 1 Insert temporarily a new spring grooved pin in...

Page 590: ...and reverse gear in the gear control fork shaft 9 As regards fitting the control fork of the fifth and reverse gear and relevant heads refer to points 2 and 3 described above 10 Attach the tension sp...

Page 591: ...op device with the three bolts 7 Place the magnetised drainage screw A of the gear and the circlip B 8 Fit the oil deflector inside secondary shaft Locking torques N m Reverse transmission gear shaft...

Page 592: ...earshift lever shaft properly as shown in the figure 17 Tighten the subassembly of the selection lever shaft with the four bolts after fitting a new gasket N B MAKE SURE THAT THE AIR BLEEDING SECTION...

Page 593: ...fer ential flange in a position in which the transmission flange identification mark B comes as near as pos sible to the differential flange identification mark C or in a position in which size A beco...

Page 594: ...INDEX OF TOPICS DIFFERENTIAL DI...

Page 595: ...ange the bevel pinion and the sealing ring 5 Replace the pinion spacer Main fitting operations 1 Fit the bevel pinion a new sealing ring the flange a new O ring a washer and a new nut 2 Tighten the nu...

Page 596: ...figure Key 1 Screw 2 Cover 3 Screw 4 Support 5 Spacer 6 Tap roller bearing 7 Nut 8 Washer 9 Pinion connection flange 10 Oil seal 11 Tap roller bearing 12 Spacer 13 Spacer 14 Pinion 15 Tap roller beari...

Page 597: ...et 32 Cap Operations before removal Position the differential assembly removed from the vehicle on the appropriate work bench Specific tooling 020180y Engine support 020286y Adaptor for attachment to...

Page 598: ...oading Measured value with the special tool fitted on the flange tongue with the oil gasket fitted in its seat Specific tooling 020335y Magnetic support for dial gauge Characteristic Specified value 0...

Page 599: ...ecific tooling 020206y Bearing extractor 4 Remove the external track of the bearing with the following special tool Specific tooling 020188y Axial hub support and driving pinion tool series Front axle...

Page 600: ...b section 3 Side pinion gear toothed section 4 Pin shaft adjustment hole 5 Differential housing of the crown wheel gear 6 Pinion shaft 7 Thrust washer Differential housing 1 Contact section of the sid...

Page 601: ...ing rolling external seat 3 Gasket seat 4 Coupling surface 5 Differential housing Coupling flange 1 Oil seal contact section 2 Grooved section Montaggio Fitting Fit the parts in numerical order as sho...

Page 602: ...al housing 20 Tap roller bearing 21 Screw 22 Crown gear 23 Bevel gear pair support 24 Pin 25 Crown wheel shaft 26 Crown wheels 27 Side pinions 28 Spacer 29 Spacer 30 Plate 31 Gasket 32 Cap Adjustment...

Page 603: ...support Specific tooling 020188y Axial hub support and driving pinion tool series Front axle bearing and differential pinion replacement kit 3 To determine the size of the shim washer to be interposed...

Page 604: ...art facing towards the teeth Fit the rear bearing by pressure in its seat with the following special tool Specific tooling 020188y Axial hub support and driving pinion tool series Front axle bearing a...

Page 605: ...IRECTIONS MANY TIMES TO FACILITATE THE BEDDING OF BEAR INGS 5 Pinion preloading check Value measured with the tool fitted on the flange shank The preloading resistance measured on the bench is 10 3 14...

Page 606: ...in order to remove the bearing clearance and to fix clearance between the pinion and the crown gear 3 Make sure the bearing support marks punched in the removal seat are aligned with the corre spondin...

Page 607: ...al bearing support for propeller shaft 60 74 Nm 8 Check total preloading T of the bearing pinion differential T P 0 16 P 0 24 N m P 1 6 P 2 4 Kgf cm Where P represents the pinion preloading pre viousl...

Page 608: ...E TURN THE FLANGE IN BOTH DIRECTIONS AND CHECK THE CONTACT MARK OF TEETH AT DIFFERENT POINTS Select a flat washer with such a thickness so as to separate the pinion from the crown gear Tip contact Sid...

Page 609: ...on the differential housing 3 Fill the differential with the following oil Recommended products AGIP ROTRA LSX 75W 90 Differential SAE 75W 90 API GL 5 Characteristic Capacity 1 1 l Locking torques N...

Page 610: ...INDEX OF TOPICS BRAKING SYSTEM BS...

Page 611: ...and push the brake pedal at least ten times Measure pedal clearance A starting from the neu tral position up to the point in which there is resist ance Characteristic Pedal clearance A 2 7 mm Positio...

Page 612: ...ical order illustrated KEY 1 Cotter pin 2 Pin 3 Nut 4 Screw 5 Bracket 6 Pin 7 Brake control pedal 8 Spring 9 Bushing 10 Bushing Inspection and repair Inspection and repair Check the following parts Re...

Page 613: ...KEY 1 Bending and twisting 2 Wear 3 Wear 4 Flattening 5 Wear Installation Installation Fit the parts following the numerical order illustrated PORTER 1 3 16V Braking system BS 613...

Page 614: ...8 Nut 9 Pin 10 Cotter pin Adjustment Pedal travel adjustment 1 Loosen the nut 2 and turn the push rod 3 to adjust the pedal travel 2 After adjusting make sure that the pedal height matches the specifi...

Page 615: ...ravel of the brake pedal 1 Run the engine at idle speed 2 With the parking brake lever lowered push the brake pedal exercising 30 kg force Then measure the distance between the brake pedal pushed and...

Page 616: ...Bolt 7 Brake fluid reservoir assembly 8 Pipe clamp 9 Pipe clamp 10 Reservoir pipe 11 Hose 12 Pipe No 2 of the reservoir 13 Reservoir cap 14 Reservoir diaphragm 15 Spacer 16 Brake fluid reservoir float...

Page 617: ...ipe clamp 9 Pipe clamp 10 Brake fluid reservoir assembly 11 Bolt 12 Pipe clamp 13 Pipe clamp 14 Heating duct No 4 15 Heating gate No 1 16 Instrument panel with brake fluid level warning light FIT AND...

Page 618: ...n cylinder assembly 13 Sealing ring Brake booster inspection procedure Power brake hermetic seal check Start the engine Stop it after running it for one or two minutes Push the brake pedal for several...

Page 619: ...brake hermetic seal with the vehicle unloaded After the engine is off the brake pedal height must not change If the power brake does not comply with requirements proceed with Checking the power brake...

Page 620: ...pplying 20 kg force Shut the engine off when the low pres sure gauge indicates approx 500 mmHg Then check the power brake air sealing Power brake operation failure check With the engine off set the lo...

Page 621: ...the wheel cylinder bleeding cap Air bleeding Bleed air following the sequence below 1 Rear left wheel 2 Rear right wheel 3 LSPV pressure regulator 4 Front left wheel 5 Front right wheel In vehicles fi...

Page 622: ...air bubbles in the fluid container Brake fluid leakage check Push the brake pedal and check there are no fluid leaks in all the pipe sections Front disc brake pad Removal Removal Remove the parts foll...

Page 623: ...racteristic Specified thickness 16 0 mm Admissible limit 15 0 mm Check that the brake disc pad is not damaged or excessively worn Characteristic Specified thickness 9 mm Admissible limit 1 mm Installa...

Page 624: ...isc brake dust guard 49 59 N B UPON THE BRAKE CALLIPER FITTING BE CAREFUL NOT TO PINCH THE PROTECTION COVER OF PISTON A Front disc brake Removal Remove the parts following the numerical order illustra...

Page 625: ...ling 020221y Brake drum stop device 3 Remove the hub and the disc with the special tool B Specific tooling 020222y Front hub and drum extractor Front disc brake calliper Removal Removal Remove the par...

Page 626: ...ain bushing 9 Secondary bushing 10 Pin cover 11 Bushing 1 Place a piece of wood between the piston and the calliper body as illustrated in the figure and remove the piston using compressed air N B DUR...

Page 627: ...AR Specification Desc Quantity Specified thickness 9 mm Limit 1 mm DISC THICKNESS AND IRREGULAR WEAR Specification Desc Quantity Specified thickness 16 mm Limit 5 mm Refitting Assembly Assemble the pa...

Page 628: ...g 9 Pad unit and thickness 10 Pad pin 11 Spring Non reusable parts Installation Installation Fit the parts following the numerical order illustrated KEY 1 Disc brake dust guard 2 Hub unit and disc 3 W...

Page 629: ...that the front wheel bear ings are not loose Measure the disc eccentricity from the outside edge Characteristic Limit 0 15 mm to 10 mm towards the inside from the disc external perimeter 2 If the dis...

Page 630: ...adjustment lever pin 16 Parking brake cable unit 17 Rear brake shoe No 2 18 Seeger ring 19 Parking brake shoe lever 20 Rear wheel brake cylinder unit 21 Screw 22 Shoe holding plate 23 Wheel cylinder p...

Page 631: ...ion Desc Quantity Drum diameter 200 mm Maximum limit allowed 201 5 mm Check that the brake drum is not damaged that there are no signs of wear on the internal surface scoring or irregular wear KEY A T...

Page 632: ...ew 8 Rear wheel brake cylinder unit 9 Parking brake shoe lever 10 Seeger ring 11 Rear brake shoe No 2 12 Parking brake cable unit 13 Automatic adjustment lever pin 14 Torsion spring 15 Automatic adjus...

Page 633: ...rake drum Non reusable parts 1 Apply grease for rubber components at the points indicated with A and grease for the brake at the points indicated with B as illustrated THE POSITION OF THE SHOE SUPPORT...

Page 634: ...wheel cylinder F on the shoe holding plate as indicated Recommended products Three Bond 520 sealing compound 4 Apply liquid sealant recommended product onto the fitting area H of the shoe retaining p...

Page 635: ...EY 1 Gearshift lever knob 2 Screw 3 Central tunnel 4 Switch cable 5 Nut 6 Nut 7 Screw 8 Parking brake cable 9 Parking brake lever unit 10 Cover Installation Installation Fit the parts following the nu...

Page 636: ...l 9 Screw 10 Gearshift lever knob Turn set nut A to set the parking brake lever travel when the adjustment has been carried out tighten the lock nut B THE PARKING BRAKE LEVER ADJUSTMENT MUST BE CARRIE...

Page 637: ...Operation before removal pickup model Remove the engine inspection compartment cover Lift the front left seat Remove the rear brake drum Disconnect the parking brake cable from the rear brake Removal...

Page 638: ...before removal van model Remove cover A from the engine in spection compartment Lift the front left seat Remove the rear brake drum Discon nect the cable of the rear brake and the parking brake Remov...

Page 639: ...Clip 5 Clip 6 Clip 7 Parking brake cable 8 Parking brake cable 9 Clip 10 Nut 11 Parking brake lever 12 Nut 13 Clip 14 Parking brake with control cable Installation Fitting pickup model Fit the parts...

Page 640: ...Nut 6 Clip 7 Parking brake cable unit 8 Parking brake cable unit 9 Clip 10 Clip 11 Clip 12 Clip 13 Parking brake cable left guide 14 Parking brake cable right guide Fitting pickup model Fit the parts...

Page 641: ...ing brake cable 8 Parking brake cable 9 Clip 10 Clip 11 Clip 12 Parking brake cable left guide 13 Parking brake cable left guide Operation after fitting pickup Adjust the rear brake Adjust the parking...

Page 642: ...according to the weight applied on the vehicle rear axle KEY 1 Side cross member 2 Rear axle A While operating with light load A While operating with regular load Pm High hydraulic pressure of the re...

Page 643: ...ing Pm Main cylinder hydraulic pressure Pf Front brake hydraulic pressure S Thrust force of the SPG A2 Large diameter section of the piston Pr Rear brake hydraulic pressure F Piston thrust force A1 Sm...

Page 644: ...the rear brake PR PM PR 2 PM Pc When the pressure of the main cylinder PM reaches a PC pressure at the turning point the piston moves towards the right of the figure indicated above due to force balan...

Page 645: ...individual sitting at the driving position load the rear axle with 400 800 kg weights for the Pick up and 450 800 kg weights for the Van Move the vehicle slowly one meter forwards and backwards then r...

Page 646: ...F of the front brake calculated at step 2 PR 0 1 PF 0 9 C 2 Calculate the range allowed of the rear brake pressure according to following formula Value allowed for the larger side MPa X 1 98 x 10 3 Wr...

Page 647: ...the LSPV end deviation mm 0 13 MPa mm 2 Loosen the nut fixing the LSPV connection to the axle side Move the LSPV connection end to the measurement calculated during phase 1 BEFORE MOVING THE LSPV CONN...

Page 648: ...Cotter pin 5 Washer 6 Bushing 7 Bushing control lever 8 Spring 9 Spring stop 10 Valve control rod 11 Screw 12 Bushing 13 Washer Non reusable part Removal 1 Disconnect the brake pipe from the valve bo...

Page 649: ...the screw fixing the valve bracket Removal 1 Remove the cotter pin then lift the pin 2 Remove the LSPV with the bracket NEVER TRY TO REMOVE THE LSPV 3 Remove the cotter pin PORTER 1 3 16V Braking syst...

Page 650: ...stop Valve adjustment bar 5 Remove the guide bushing with a plastic ham mer Inspection Check the following parts Replace those defective parts 1 Worn piston 2 Deteriorated plastic parts 3 Damage and...

Page 651: ...tooling 020196Y Clutch guiding tool 2 Assemble the following parts on the bar Spring stop Spring Valve adjustment lever Guide bushing Washer 3 Fit the new cotter pin 4 Fit the LSPV with the bracket o...

Page 652: ...2 Fix the LSPV articulation lever to the valve bracket through a belt or other similar object WHILE FIXING MAKE SURE THAT THE PISTON END COMES INTO CONTACT WITH THE ARTICULATION LEV ER COMPLETELY Arra...

Page 653: ...ghten the nut to the prescribed tor que NEVER PUSH THE LSPV END UP AND DOWN WHEN IT IS ASSEMBLED TO THE BRACKET ON THE AXLE SIDE Locking torques N m LSPV brake calibrator Rear axle 10 16 6 Remove the...

Page 654: ...INDEX OF TOPICS TRANSMISSION SHAFT TS...

Page 655: ...shaft assembly Inspection on vehicle Clearance check Make sure that the universal joint of the propeller shaft does not show excessive clearance by mov ing it in all directions If any defects are det...

Page 656: ...AND THE JOINT FLANGE FIT A SUITABLE PLUG TO PREVENT OIL LEAKS KEY A Reference marks B Plug Inspection Inspection 1 Check that the propeller shaft is not damaged and bent 2 Check that the cross bearin...

Page 657: ...re is no clearance on the grooved section during the rotation and that the sleeve can slide freely in the axial direction of the grooved section 4 Check universal joint clearance Check that there is n...

Page 658: ...flange 4 Fit the fixing bolts with new washers 5 Tighten the fixing bolts evenly and gradually to the prescribed torque 6 Turn the propeller shaft and check that it is not forced and does not produce...

Page 659: ...INDEX OF TOPICS STEERING COLUMN SC...

Page 660: ...shing To take out the bushing use the following series of special tools with a press as indicated Specific tooling 020196Y Clutch guiding tool 0 20228y Rear conical tool to replace the dif ferential c...

Page 661: ...tools with a press as indicated Specific tooling 020196Y Clutch guiding tool 0 20228y Rear conical tool to replace the differential control pinion bearing Universal joint arm Components KEY 1 Control...

Page 662: ...he steering wheel Remove the nut Afterwards take out the arm 2 Remove the nut on the steering rack side and with the wheels in straight line motion take out the fixing bolt 3 Disconnect the tie rod en...

Page 663: ...rd G and the gasket I in the respective sequence using the special tools with a press Follow the same op eration on both sides N B IF THE BUSHING OR THE WASHER IS DEFECTIVE RE PLACE THEM Specific tool...

Page 664: ...bearing and sealing rings replacement 020230Y Tools for pinion bearing and differen tial replacement Characteristic Prescribed depth of the bearing A 6 6 3 mm 2 Fit the new dust guard gaskets using t...

Page 665: ...the sliding surfa ces of the dust guard gaskets Specific tooling 020229Y Tools for needle bearing and sealing rings replacement 020230Y Tools for pinion bearing and differen tial replacement 4 Apply...

Page 666: ...ly Locking torques N m Cross member bracket for suspension arm 98 118 Nm Cross member Suspension lower arm 78 5 98 0 8 Tighten the tie rod head to the prescribed torque and afterwards insert a new loc...

Page 667: ...wing the numerical order KEY 1 Steering joint cover 2 Bolt 3 Reinforcement bar support 4 Bolt 5 Bolt 6 Steering box 7 Dust guard 8 Bushing 9 Intermediate shaft 10 Elastic coupling 11 Steering box flan...

Page 668: ...the special section A of the plate with the pinion flange Removal Remove the parts following the numerical order KEY 1 Hexagonal ring nut 2 Spring cap 3 Spring 4 Rack guide 5 Ring 6 Clamp 7 Steering...

Page 669: ...18 Rack 19 Dust guard 20 Oil seal 21 Circlip 22 Ball bearing 1 Position the steering guide box in a vice using copper or aluminium jaws 2 Remove the hexagon nut with a 39 mm Allen key 3 Remove the ra...

Page 670: ...ips 6 Move the rack rotating the pinion until the rack teeth are disengaged from those of the pinion 7 Take out the pinion using a punch with a diam eter of approx 12 mm as shown in the figure 8 Remov...

Page 671: ...ing worn or damaged 3 Toothed surfaces worn or damaged 4 Damage crack 5 Wear 6 O ring 7 Deterioration 8 Wear or damage 9 Damage crack Refitting Check the following parts and replace those which are de...

Page 672: ...al 4 Dust guard 5 Rack 6 Steering pinion 7 Circlip 8 Gasket 9 Steering box cover 10 Bellows 11 Clamp 12 Ring 13 Bracket 14 Nut 15 Clip and Circlip 16 Bellows 17 Clamp 18 Ring 19 Rack guide 20 Spring S...

Page 673: ...n A 0 2 0 4 gr Sintered bushing section B 0 2 0 4 gr 2 Fit the ball bearing with the special tool Specific tooling 020177y Pinion bearing replacement kit 3 Fill the ball bearing with EP grease in the...

Page 674: ...antity Prescribed quantity Rack end C minimum quantity Toothed surface D 4 gr Shaft E 1 gr 8 Apply EP grease onto the rack guide F fitting hole in the prescribed quantity Prescribed quantity of grease...

Page 675: ...osition the rack in the relevant seat with the pinion flange as indicated 2 After engaging the rack and the pinion make sure that the pinion and the rack assume the indi cated position 3 With a plasti...

Page 676: ...Loosen the spring cap and take the rack to a neutral position After wards restore the spring cap to a 7 Nm torque with a 17 mm key so as to form an angle of 50 5 Locking torques N m Rack spring cap 7...

Page 677: ...ical order of the figure shown below KEY 1 Steering box flange 2 Elastic coupling 3 Intermediate shaft 4 Bushing 5 Dust guard 6 Steering assembly 7 Bolt 8 Bolt 9 Reinforcement bar support 10 Bolt 11 G...

Page 678: ...section in position and take out the key switch cyl inder from the guide column upper support brack et Remove the parts following the numerical order KEY 1 Steering wheel 2 Guide column protection 3...

Page 679: ...r KEY 1 Ring 2 Washer 3 Universal joint 4 Steering column 5 Bolt 6 Steering joint cover 7 Light switch lever unit 8 Guide column protection 9 Steering wheel Installation 1 Apply MP grease onto the PP...

Page 680: ...ole 4 Tighten bolts E and F temporarily as indicated in the figure then fit the steering wheel provision ally 5 Turn the steering wheel two or three times to wards the right and left afterwards straig...

Page 681: ...igure shown below 1 Cotter pin 2 Nut 3 Cotter pin 4 Nut 5 Tie rods 6 Arm head 7 Dust protection ring 9 Arm head 10 Ring 11 Dust guard 1 Lift the vehicle with a jack 2 Remove the tie rod assembly using...

Page 682: ...9 Cotter pin 10 Nut 11 Cotter pin Non reusable parts 1 Apply the prescribed quantity of lithium based multipurpose grease at the points specified in the figure MAKE SURE THAT THERE IS NO GREASE ON TH...

Page 683: ...Swing front and rear sections of the ve hicle up and down so that the front and rear sus pensions can settle in their regular condition 2 Check for possible signs of wear or eccentricity of tyres or e...

Page 684: ...les when the steering wheel is turned all the way towards the right and left respectively IF THE LEFT TIE ROD LENGTH IS INCREASED BY TWO TURNS DECREASE THE RIGHT TIE ROD LENGTH BY TWO TURNS TO MAKE SU...

Page 685: ...T AS IN THE CASE OF TOE IN MEASUREMENT BESIDES MAKE SURE THAT NO PART OF THE VEHICLE IS LOOSE 2 Place a turning radius gauge on a flat surface so as to keep the vehicle levelness Perform meas urement...

Page 686: ...BOX OR THE JOINTS ARE WORN OR THE SUPPORTING BRACKET HAS BEEN LOOSENED Removal Remove the parts following the numerical order KEY 1 Steering wheel padding 2 Nut 3 Washer 4 Steering wheel 5 Screw 6 Ho...

Page 687: ...istance Size B between the two references marked in the previous phase Perform this measurement from the vehicle front side Calculate the toe in value A B TOE IN Specification Desc Quantity B A one pa...

Page 688: ...Steering column PORTER 1 3 16V SC 688...

Page 689: ...INDEX OF TOPICS SUSPENSIONS SS...

Page 690: ...d flat washer 3 Brake calliper assembly and disc 4 Disc brake dust guard 5 Cotter pin 6 Castle nut 7 Tie rod assembly 8 Nut and bolt 9 Suspension lower arm assembly 10 Steering articulation 11 T oil s...

Page 691: ...OR MORE MT GREASE ON THE UPPER SURFACE OF BUSHING A 4 Fit the front suspension support C 5 Temporarily tighten the nut Use a new nut DURING THE ASSEMBLY REMEMBER TO ALIGN THE PART SEPARATED FROM THE F...

Page 692: ...n the lower support of the shock absorber 2 Fit the new bolts and screws in the relevant seats and tighten them temporarily 3 Connect the brake hose to the calliper 4 Fit the clip locking the pipes on...

Page 693: ...ing buffer 7 Shock absorber dust guard 8 Spiral spring 9 Front shock absorber 10 Bolt 11 Retention plate 12 Steering articulation Non reusable parts Removal 1 Lift the vehicle with the jack 2 Remove t...

Page 694: ...e bolts fitted in their places Remove the three suspension fixing nuts Remove the steering articulation fixing bolts Take out the shock absorber Removal Compress the spring using the following tool Sp...

Page 695: ...g F Flattening G Oil leak Shock absorber operation check 1 While pressing the shock absorber stem check that compression is uniform along the whole travel and that there is no abnormal resistance or n...

Page 696: ...bolt 4 Stud bolt not provided as a spare part 5 Screw 6 Lock nut 7 Hexagonal bolt 8 Suspension lower arm 9 Lock nut 10 Flat washer 11 Strut buffer 12 Strut support 13 Strut buffer 14 Lower ball joint...

Page 697: ...n Remove the suspension lower arm from the steering articulation Remove the suspension lower arm by removing the cross member bolt Remove the suspension lower arm tak ing out the nut from the strut su...

Page 698: ...rarily fit the screw and the lock nut MAKE SURE THAT NEITHER GREASE NOR OIL OR ANY OTHER SUBSTANCES COVER THE SCREW AND THE NUT FASTENING THE BALL AND SOCKET JOINT 7 Fit the front wheel 8 Lower the ve...

Page 699: ...Remove the castle nut using the fol lowing tool 6 Remove the disc brake assembly using the fol lowing tool Specific tooling 020221y Brake drum stop device 0 20222y Front hub and drum extractor 3 Disco...

Page 700: ...ling 020231Y Tie rod head extractor 9 Remove the articulation of the steering by un screwing bolts A and B Installation 1 Install the steering articulation Locking torques N m Steering joint Front sho...

Page 701: ...assembly and tighten the castle nut using the following tool ALIGN THE CASTLE NUT RECESS WITH THE HOLE Specific tooling 020221y Brake drum stop device Locking torques N m Castle nut Front axle hub 17...

Page 702: ...Remove the bearing by pushing the collar 2 Front axle bearing installation Place the internal radial ball bearing using the following tool N B MAKE SURE THAT THE BEARING IS IN CONTACT WITH THE STOP SE...

Page 703: ...it Place the internal and external oil seal using the following tool Specific tooling 020223y Extractor and changer for front sus pension arm bushing 3 Place the wheel shaft in the articulation Use th...

Page 704: ...f there is still excessive clearance then the steer ing articulation or suspension section is loose Spring Inspection visually inspect all the springs and check that there are no signs of damage or cr...

Page 705: ...HEEL ALIGNMENT Specification Desc Quantity Camber angle 1 40 50 Caster angle 3 02 1 Kingpin inclination angle 11 25 1 Toe in 1 passenger 2 0 1 5 1 0 Unloaded vehicle 1 5 1 5 1 0 Steering angle Inside...

Page 706: ...nal side C Internal side Wheel steering angle correction 1 Loosen the lock nuts of the tie rod heads 2 Length a indicated in the figure at the right should be the same between the right and left sides...

Page 707: ...tch compensator B CCK pitch compensator C Zero mechanical line D Fitting plate E Compensator dial Lift the vehicle with the jack Before fitting the CCK gauge on the wheel place the pitch compensator o...

Page 708: ...plate Now align the lines of the gauge and the equipment Turn the wheel so that the air bubble in the gauge reaches the central position In this position turn the gauge caster set screw so as to align...

Page 709: ...air bubble H with the central position Set the camber value I read from the gauge Characteristic Specified value 1 40 50 5 Check the caster and kingpin inclination angle Turn the steering wheel to th...

Page 710: ...ing direction shall be inverted Rear Axle and rear suspension This manual section describes how to check remove and fit the axle and rear suspension Wheel hub COMPONENTS 1 Drum 2 Nut 3 Rear axle shaft...

Page 711: ...n the parking brake set screw 5 Disconnect the brake transmission from the splitter and from the chassis 6 Disconnect the brake hose fitting from the wheel cylinder 7 Remove the brake drum 8 Remove th...

Page 712: ...h a disc grinder grind the stop bushing of the bearing leaving a re maining thickness of about 1 mm Cut the stop bushing A with a chisel B and remove it from the axle shaft Remove the bearing using th...

Page 713: ...0 05 mm Axle shaft 0 80 mm 2 Bearing A worn or damaged 3 Oil seal contact section in the rear bridge hous ing Installation 1 Insert the shoe holding plate with spacer A with the special tool and pres...

Page 714: ...ridge bearing 2 Apply MP grease on the oil seal edge 3 Fit the oil seal using the following special tool Specific tooling 020201y Gear bearing fitting punch 4 Apply silicone sealant at the housing end...

Page 715: ...es N m Shoe holding plate Rear axle shaft housing 63 7 70 4 7 Insert the brake hose fitting nut 8 Fit the hand brake cable end 9 Fit the hand brake cable adjustment nut 10 Bleed the air completely 11...

Page 716: ...ng pin 15 Spring washer 16 Leaf spring with bushing 17 Flexible shoe stop 18 Flexible shoe for vans Removal 1 Lift the vehicle with the jack N B MAKE SURE THAT THE JACK IS PLACED CORRECTLY MATCHING TH...

Page 717: ...e shackle of the leaf spring by undo ing the nuts 8 Remove the leaf spring assy by undoing the flex ible support pin 9 Remove the leaf spring assy from the vehicle 10 Detach the shoe of the leaf sprin...

Page 718: ...lation 1 Fix the leaf spring pad A and its stop B to the leaf spring in vans 2 Temporarily fit the leaf spring on the chassis to gether with the elastic support and the nut 3 Temporarily fit the leaf...

Page 719: ...stabilise suspension 8 With the vehicle unloaded tighten the following sections Elastic pin support side nut Leaf spring subassembly upper and lower section nut Locking torques N m Spring support pin...

Page 720: ...E THAT THE JACK IS PLACED CORRECTLY MATCHING THE LIFTING POINTS 2 Hold the differential housing with a workshop jack 3 Disconnect the battery and terminals 4 Remove the battery container undoing the t...

Page 721: ...rod to the end and un lock it Make sure that it returns at a constant speed from the beginning to the end If the shock absorber operation fails replace it DISCHARGE THE GAS COMPLETELY BEFORE DISPOS IN...

Page 722: ...bearing does not have an excessive clearance Also check for abnormal noises when turning the wheel Inspection Visually inspect the suspension checking for signs of wear and damage Noise check Check a...

Page 723: ...Push the rear part of the vehicle with downward force in order to check the damping capacity of the shock absorbers PORTER 1 3 16V Suspensions SS 723...

Page 724: ...INDEX OF TOPICS TIPPER VERSION VR...

Page 725: ...or jack 4 Tie rods 5 Thrust angle 6 Pins 7 Tilting hinges 8 Counter chassis 9 Cross member 10 Loading deck 11 Tailboard 12 Tailboard closing 13 Limit switch 14 Raised loading deck warning light switch...

Page 726: ...ico KEY 1 Hydraulic piston 2 Hose break valve 3 One way valve 4 Hydraulic pump 5 Electric motor 6 Pressure regulating valve 7 Flow regulating valve 8 Solenoid valve 9 Oil filter Tipper version PORTER...

Page 727: ...net 4 7 5A Fuse 5 A B loading deck ascent descent switch 6 Loading deck maximum ascent limit switch 7 Relay 8 Solenoid valve 9 Raised loading deck horn Buzzer 10 Raised loading deck warning light 11 B...

Page 728: ...nect the tipper to the lifting arm Press and hold down the button for the descent cause the lifting arm to fold by applying force on it so as to simulate the force applied by the tipper during regular...

Page 729: ...be removed by lifting and then resting it on the ground using two supports so that the mudguards do not touch the ground Tipper refit To refit the tipper it is necessary to lift it from the ground an...

Page 730: ...the direction opposite to the desired direc tion vehicle front part In order to solve this prob lem during the ascent firmly hold the part connecting the arm and the deck forcing it towards the rear...

Page 731: ...he two copper gaskets while respecting the tightening torque Locking torques N m oil fitting 29 39 Nm Hydraulic jack removal To carry out this operation first detach the jack from the tipper Remove th...

Page 732: ...cable pin Remove the safety screw and disconnect the con trol pin of the solenoid valve for the jack descent Undo the two screws supporting the hydraulic pump which can be accessed from the vehicle ri...

Page 733: ...taking out the three Allen screws Smontaggio corpo valvole dal motore elettrico Removing valve body from the electric motor Remove the two screws fixing the electric motor to the hydraulic pump Smonta...

Page 734: ...alvole Valve body fitting Before refitting the valve body it is necessary to clean all the ducts thoroughly Wash with mild solvents and afterwards blow with compressed air Place the valve body in its...

Page 735: ...ion proceed with the fitting opera tions but in reverse order and tighten to the pre scribed locking torque Locking torques N m valve body for electric motor 10 12 Nm Montaggio particolari Assembly of...

Page 736: ...TWO FAYING SUR FACES WITH USED OIL TAKEN FROM THE PUMP Montaggio Hydraulic pump and electric motor fitting Place the pump with electric motor on the vehicle chassis bracket fix the two screws tighten...

Page 737: ...SSIBLE PRECAUTIONS WHILE PERFORMING THESE OPERATIONS CLOSE ALL THE CONNECTIONS PROPERLY REMEMBER THAT 200 BAR CATEGORY PRESSURES ARE VERY DANGEROUS FOR BOTH USERS AND THE EQUIPMENT BEING USED Activate...

Page 738: ...AS SPECIFIED BY VEHICLE CHAR ACTERISTICS THE VEHICLE MUST NEVER LIFT A WEIGHT EXCEEDING THE PRESCRIBED VALUE SUCH AN ACTION COULD IRRETRIEVABLY DAMAGE THE LIFTING SYSTEM Locking torques N m pressure r...

Page 739: ...INDEX OF TOPICS CHASSIS CH...

Page 740: ...brush 2 Windshield and sealing gasket Removal Removal to be carried out by two individuals 1 With a bamboo spatula or with a plain slot screwdriver etc take out the sealing gasket from the body by pr...

Page 741: ...des more easily 2 Fit the windshield and the relevant gasket on the frame so that these are properly fitted on their seats Also make sure that the two wire ends hang inside the vehicle 3 Pull the wire...

Page 742: ...bout 5 mm x 6 m used during the glass fitting Bamboo spatula used during the glass fitting Rubber hammer used during the glass fitting Brush etc used to apply water with soap Water with soap used to f...

Page 743: ...e side window glass 2 Prepare a cable A to work with as shown in the figure Apply water with soap on the sealing gasket pe rimeter so that it slides more easily 3 Fit the side glass and the relevant g...

Page 744: ...Paint for touch up For paint touch ups after removal fitting and adjustment COMPONENTS 1 Rear window upholstery panel Removal Fitting REMOVAL Remove the rear window internal upholstery panel using th...

Page 745: ...tion strip 2 Remove the rear window by following the same operations described for windshield removal fitting Doors Pannelli COMPONENTS 1 Door opening handle 2 Inside handle 3 Circlip and spacer 4 Win...

Page 746: ...e lever circlip and take out the window lifter handle and collect the rele vant spacer 4 With the special tool remove the upholstery re tainers and take out the door upholstery panel Installation 1 Pl...

Page 747: ...the spacer and the circlip with the glass completely closed Serratura e maniglie COMPONENTS 1 opening control tie rod 2 Locking knob 3 Lock block with the retainer 4 Outside handle 5 Lock 6 Plate Smon...

Page 748: ...iner 4 Outside handle 5 Lock 6 Plate 1 Remove the front door upholstery panel see the Front Door Panel Upholstery Removal section 2 Remove the locking knob 3 Remove the lock along with the opening con...

Page 749: ...nuts A 2 Fit the lock block with the relevant retainer 3 Fit the lock by screwing the three screws N B APPLY MP GREASE ON EACH OF THE SLIDING SEC TIONS SHOWN IN FIGURE B 4 Fit the door opening control...

Page 750: ...Side gasket 4 Front door glass 5 Window lifter 6 Limit switch 7 Rear frame 8 Rear guide 9 Front frame 10 Front guide Removal 1 Remove the front door upholstery panel 2 Remove the inspection cover REMO...

Page 751: ...olts fixing the front door glass unit Remove the glass from the front door Keeping the glass in vertical position pull it up wards Draw a reference mark on the front side of the glass to identify the...

Page 752: ...panel components Regolazioni Door alignment adjustment FRONT DOOR Prescribed alignment sizes Distance A B C D Specified value 3 5 7 5 mm Tolerance for each side A B C Specified value not exceeding 1...

Page 753: ...ts 2 Adjustment in height and longitudinal direc tion Adjust after undoing the two strut side hinge bolts 3 Door locking plate adjustment Undo the screw Adjust and tighten the plate so that the door r...

Page 754: ...d adjustment Removal 1 Remove the door upholstery panel and the in spection cover 2 Remove the side gasket 3 Remove the glass frame by undoing the relevant bolt Installation 1 Fit the glass frame by t...

Page 755: ...ase To lubricate Water with soap For a better gasket sliding Brush etc To apply the water with soap Wooden hammer To fit the support Paint for touch up For paint touch ups after removal fitting and ad...

Page 756: ...1 Place the upholstery panel on the door then fit the retainers 2 Fit the window lifter handle with the spacer and the circlip see the figure for correct fitting position 3 Fit the inside handle with...

Page 757: ...pection cover 2 Remove the door locking knob 3 Remove the sliding door locking control unit by undoing the two screws 4 Remove the tie rod 5 Remove the outside handle by undoing the two relevant nuts...

Page 758: ...locking tie rod 4 Fit the outside handle by tightening the two rel evant nuts 5 Fit the tie rod 6 Fit the control unit locking the door lock with the two relevant screws 7 Fit the door locking knob 8...

Page 759: ...Removal 1 Remove the door upholstery panel 2 Remove the inspection cover 3 Remove the external gasket of the sliding door glass 4 Remove the internal gasket 5 Remove the side gasket B REMOVE THE BUTY...

Page 760: ...T REFITTING POSI TION OF THE GROOVE KEY A Front part 9 Remove the window lifter unit by undoing the three bolts Installation 1 Fitting the glass support groove lower gasket Draw a reference mark on th...

Page 761: ...rom the lower part with the glass tilted forward 2 Fit the glass on the retention bracket A with the relevant bolts 3 Tighten the frame bolt 4 Fit the side gasket 5 Fit the internal gasket 6 Fit the e...

Page 762: ...OVER APPLICATION PART IF THE INSPECTION COVER SHOWS SIGNS OF DAM AGED ETC THERE MAY BE WATER INFILTRATION Guide e rulli COMPONENTS 1 Sliding door 2 Guide roller pin 3 Upper roller arm 4 Upper roller a...

Page 763: ...emoval 1 Hold the sliding door with a jack interposing a wooden wedge as shown in the figure 2 Remove the door glass gasket 3 Unscrew the two nuts and remove the upper roller arm support 4 Remove the...

Page 764: ...ench Central hinge removal 1 Hold the sliding door with a jack interposing a wooden wedge as shown in the figure N B CARRY OUT THIS OPERATION WITH ANOTHER PERSON TO KEEP THE DOOR IN POSITION 2 Remove...

Page 765: ...6 Remove the guide by taking out the three rele vant nuts Upper roller removal 1 Apply MP grease onto each of the sliding sections 2 Fit the upper roller arm support on the door with the two relevant...

Page 766: ...or with the two relevant bolts 4 Remove the jack under the door panel Central hinge fitting 1 Apply MP grease onto each of the sliding sec tions 2 Fit the guide by tightening the three relevant nuts 3...

Page 767: ...adjustment 1 Adjust after undoing the two fixing bolts Now move the catch at a distance equal to the lower roller movement Characteristic Adjustment tolerance 2 mm 2 Adjust after undoing the two cent...

Page 768: ...fixing the lock striker plate IF THE DOOR REAR SECTION IS LOWERED OR LIFTED NEVER TRY TO CORRECT THE TRIM BY OPERATING ON THE DOOR LOCKING PLATE ADJUST BY OPERATING ON ITS HINGE Characteristic Adjustm...

Page 769: ...shock absorbers by removing the two relevant bolts N B APPLY ADHESIVE TAPE IN ORDER TO AVOID DAMAG ING THE DOOR INSIDE PANEL DURING REMOVAL AND FITTING 2 Remove the nuts from the door hinges 3 Discon...

Page 770: ...evant bolts 5 Align the door with respect to the body Locking torques N m Tail door support Tail door 17 7 23 5 Rear door panel Rear door upholstery panel COMPONENTS 1 Rear upholstery panel Removal Fi...

Page 771: ...ion plate Removal 1 Remove the door upholstery panel 2 Remove the door lock block by taking out the relevant block fixing device 3 Remove the lock block by taking out the two rel evant bolts 4 Remove...

Page 772: ...g device Regolazioni Door panel Prescribed alignment sizes J distance Prescribed value 3 6 8 6 mm K distance Prescribed value 4 6 8 6 mm P distance Standard Prescribed value 5 5 9 5 mm Not standard Pr...

Page 773: ...the rear window support side surface and the door side surface does not exceed 4 6 8 6 mm Considering the adjustment that shall not exceed 2 0 mm loosen the door side hinge bolts Adjustment in longit...

Page 774: ...pper clips Refit For refit follow the previous operations in reverse Replacing the exhaust Catalytic converter replacement 1 Remove the front pipe by undoing the relevant fixing bolts 2 Remove the cat...

Page 775: ...and the front pipe fixing nuts to the prescribed torque using new gaskets Locking torques N m Exhaust pipe Catalytic converter 42 56 5 Start the vehicle and check if there are leaks from the catalyti...

Page 776: ...anel 2 Unscrew the fixing screw Remove the headlamp protection 3 Remove the turn indicator fixing spring 4 Take out the unit from the vehicle 5 Disconnect the connector and remove the turn indicator C...

Page 777: ...the headlamp 9 Remove the retention clip located at the lower part then remove the headlamp Refitting For refit follow the previous operations in reverse Mascherina anteriore Removal 1 Release the upp...

Page 778: ...Refitting 1 Place hooks A on pins B 2 Tilt the panel and fix pins C in clips D Front panel components Chassis PORTER 1 3 16V CH 778...

Page 779: ...ned instrument panel 3 Central panel for instrument panel 4 Glove box lid 5 Glove box 6 Brake oil reservoir housing cover 7 Cap for instrument panel holes 8 Panel upper cover 9 Sleeve No 2 for defrost...

Page 780: ...levant screw 7 Take out the heating adjustment lever 8 Central upholstery panel removal Remove the two screws Remove the clip Take out the panel 9 Remove the heating adjustment unit Removing the upper...

Page 781: ...and the relevant lid by taking out the seven screws Instrument panel removal 1 Lift the cover using a plain slot screwdriver wrapped around with a cloth then remove the brake fluid reservoir inspectio...

Page 782: ...4 Remove the reinforcing bracket from the body by taking out the eight bolts Chassis PORTER 1 3 16V CH 782...

Page 783: ...eft air vents by taking out the three screws 5 Remove the two openings by taking out the four screws 6 Remove the loudspeakers by taking out the two screws 7 Remove the cigarette lighter support brack...

Page 784: ...fluid reservoir with the two bolts 3 Fit brake fluid reservoir inspection lid 4 Fasten the cover in the relevant seat 5 Fit the upper panel of the instrument panel in the relevant seat Chassis PORTER...

Page 785: ...Connect the rear section of the unit 8 Fit the heating adjustment panel with the two screws 9 Central upholstery panel installation Fix the lower section with the clip Place the panel in the relevant...

Page 786: ...n 16 Connect the battery negative terminal Installation Refitting air vents loudspeakers cigarette lighter 1 Fit the cigarette lighter support bracket with the two screws 2 Fit the loudspeakers with t...

Page 787: ...Starting operations Fit the reinforcing bracket on the body and tighten the eight bolts Locking torques N m Instrument panel support Chassis 18 28 PORTER 1 3 16V Chassis CH 787...

Page 788: ...edili Cinture di sicurezza KEY 1 Seat back for front seat 2 Seat back upholstery 3 Gasket 4 Engine inspection cover 5 Central mat 6 Front seat cushion 7 Cushion upholstery Chassis PORTER 1 3 16V CH 78...

Page 789: ...seat inclination adjustment 2 Seat back for front seat 3 Seat back upholstery 4 Bushing 5 Gasket 6 Engine inspection cover 7 Cushion upholstery 8 Central mat 9 Internal guides 10 Front seat cushion PO...

Page 790: ...hion 9 Ring 10 Cushion upholstery 11 Rear seat cushion Check Check up of inclination angle until the clicking sound of the belt with winder is heard 1 Lean slightly the winder from the fitting angular...

Page 791: ...eat internal bolt assembly in the cor rect fitting position as shown in the figure KEY A Left B Right Safety belts FRONT Safety belt at three anchor points without winder KEY 1 Bolt 2 Bolt 3 Safety be...

Page 792: ...hing 3 Clip pipe for fuel return 4 Clip pipe for emissions 5 Clip pipe for fuel main 6 Bolt 7 Fuel tank unit 8 Clamp pipe for breathing 9 Clip pipe for fuel return 10 Clip pipe for emissions 11 Vapour...

Page 793: ...for fuel return 7 Clip pipe for emissions 8 Bolt 9 Clamp pipe for breathing 10 Clip pipe for emissions 11 Pipe for emissions 12 Vapour bleeding checking valve unit 13 Fuel transmitter gauge unit 14 F...

Page 794: ...not be turned and re moved from the fuel tank cap 3 Press the lever to check that the key can not be turned and removed from the fuel tank cap 4 Insert the fuel tank cap in the fuel inlet opening If f...

Page 795: ...INDEX OF TOPICS PRE DELIVERY PD...

Page 796: ......

Page 797: ...alignment and closing of body work panels Doors Van Tail door Sliding door side Pickup Side board Tailboard Closing and hinge operation Check the correct operation and lubricate if nec essary Open an...

Page 798: ...cle wiping from the top to the bottom using a clean shammy cloth or a soft absorbing cloth 7 Check that water does not leak in 8 Remove all the check labels from the vehicle window glasses or mirrors...

Page 799: ...icle has the following compo nents 1 Toolkit bag Wrench for wheel hub nut Wrench for spark plug Screwdriver 2 Inflate repair kit T E K Tire Emergency Kit Pick up placed in between the two seats Van pl...

Page 800: ...e Nut tightening Loosening the hub clamps With a specific wrench check that nuts and bolts of the wheels are not loosened Locking torques N m Wheel rim nuts Wheel hub 88 118 Impianto di riscaldamento...

Page 801: ...atical ly as soon as heated Take out the cigarette lighter and make sure that the element is heated Seatbelt Safety Belts Check if they works properly Fasten and release the buckle Adjusting devices A...

Page 802: ...zle then adjust the position Gauge functions and rear window anti fog de vice Check the operation of the following gauges after engine warm up Fuel gauge Temperature gauge Low fuel warning light Rear...

Page 803: ...late lights Emergency lights Reverse gear light Rear fog guard lights Internal light Headlight adjustment Headlamp orientation Check headlamp orientation 1 Place the vehicle on level ground 2 Act repe...

Page 804: ...s lowered High beam warning light It turns on when the turn indicator lever is pulled backwards Engine control warning light On Chassis inspection Checks to be carried out under the body Brackets for...

Page 805: ...ble fluid leaks from the following components Engine Transmission Differential Fuel pipe fuel tank and drainage plug Fuel internal filler Riscontri porte Door lock adjustment 1 Loosen the screws of th...

Page 806: ...nnected Ignition timing IGNITION TIMING CHECKING AND ADJUSTMENT BEFORE CARRYING OUT THE IGNITION TIMING CONNECT THE TESTER MULTIMETER PROBE WITH THE DIAGNOSIS CONNECTOR GROUND TERMINAL THE ENGINE SHAL...

Page 807: ...e OBD Connector and the Diagnostic Tester Integrated in the 020618Y Lift for diagnosis 4 Remove the inspection hole cap from the upper side of the transmission 5 Check with the stroboscopic gun G that...

Page 808: ...orque and check that the ignition timing is not postponed Locking torques N m Cylinder for spark plug 14 7 21 6 8 Disconnect the cable from the diagnosis connector Window cleaning liquid Windshield wa...

Page 809: ...AT THE VACUUM SWITCHING VALVE IS INACTIVE Idle speed adjustment Preliminary operations for idle speed adjustment Warm up the engine continue warming up the engine for other 10 minutes after the first...

Page 810: ...ivello liquido freni Brake fluid Check the level The fluid level is correct when it reaches MAX mark Fill the reserve tank up to the MAX mark with brake fluid Brake pedal adjustment Service and parkin...

Page 811: ...t accelerate smoothly without any signs of fatigue or hesitation At cruising speed The vehicle must operate smoothly without any hesitation or oscillation Vibration and noises Check for possible vibra...

Page 812: ...tween tyres and other members by turning the steering wheel fully to the right and to the left and the dust guard in addition to the uniform rotation of the joint and steering members 1 Suspension arm...

Page 813: ...INDEX OF TOPICS...

Page 814: ...TIME SHEET TS...

Page 815: ...TIMING BELT Code Action Duration 1 140011 CAMSHAFT REPLACEMENT 2 140021 CAMSHAFT TIMING SYSTEM PUL LEY REPLACEMENT 3 140031 CRANKSHAFT TIMING SYSTEM BELT PULLEY REPLACEMENT 4 140041 TIMING BELT REPLA...

Page 816: ...ankshaft CRANKSHAFT Code Action Duration 1 131011 CRANKSHAFT AND OR BUSHING REPLACEMENT 2 131051 FLYWHEEL REPLACEMENT 3 131101 CRANKSHAFT PULLEY REPLACE MENT Drive shaft Time sheet PORTER 1 3 16V TS 8...

Page 817: ...PROPELLER SHAFT Code Action Duration 1 370011 PROPELLER SHAFT REPLACE MENT Alternator PORTER 1 3 16V Time sheet TS 817...

Page 818: ...ALTERNATOR Code Action Duration 1 271011 ALTERNATOR REPLACEMENT 2 270112 ALTERNATOR SERVICE 3 271151 ALTERNATOR PULLEY Time sheet PORTER 1 3 16V TS 818...

Page 819: ...T 2 481012 LEAF SPRING ONE SIDE SERV ICE 3 481021 LEAF SPRING BOTH SIDES RE PLACEMENT 4 481022 LEAF SPRING BOTH SIDES SERVICE 5 481201 LEAF SPRING SUPPORTS AND OR BUSHING ONE SIDE RE PLACEMENT 6 48130...

Page 820: ...Battery BATTERY Code Action Duration 1 190011 BATTERY REPLACEMENT 2 190101 BATTERY CABLE TO STARTER MOTOR REPLACEMENT 3 190151 BATTERY CABLE TO GROUND REPLACEMENT Time sheet PORTER 1 3 16V TS 820...

Page 821: ...COIL AND SPARK PLUGS Code Action Duration 1 191011 HV COIL AND OR EXTENSIONS REPLACEMENT 2 191101 SPARK PLUGS REPLACEMENT 3 191201 SPARK PLUG HV CABLES WITH RESISTANCE REPLACEMENT PORTER 1 3 16V Time...

Page 822: ...BLE HARNESS REPLACEMENT 2 820021 ENGINE CABLE HARNESS RE PLACEMENT 3 820031 ENGINE CABLE HARNESS No 2 REPLACEMENT 4 820101 CHASSIS CABLE HARNESS RE PLACEMENT 5 820151 TAIL DOOR CABLE HARNESS REPLACEME...

Page 823: ...Gear box PORTER 1 3 16V Time sheet TS 823...

Page 824: ...ISSION SHAFT REPLACEMENT 9 331151 REVERSER GEAR REPLACE MENT 10 331161 CLUTCH BELL REPLACEMENT 11 331201 GEAR CRANKCASE REPLACE MENT 12 331251 REAR COVER REPLACEMENT 13 331271 REAR COVER GASKET RE PLA...

Page 825: ...SIDE REPLACEMENT 3 531301 FRONT SIDE PANEL ONE SIDE REPLACEMENT Rear chassis BODYWORK REAR SIDE Code Action Duration 1 612011 REAR MUDFLAP REPLACEMENT ONE SIDE 2 612021 REAR SIDE PANEL REPLACE MENT ON...

Page 826: ...2 430111 WHEEL RIM 2 WHEEL RE PLACEMENT 3 430121 WHEEL RIM ADDITIONAL TIME WHEEL ADJUSTMENT 12 MI NUTES WHEEL THREE WHEELS REPLACEMENT 4 430131 WHEEL RIM ADDITIONAL TIME WHEEL ADJUSTMENT 12 MI NUTES W...

Page 827: ...Brake cylinder BRAKE CYLINDER Code Action Duration 1 471051 REAR BRAKE CYLINDER ONE SIDE REPLACEMENT 2 471551 REAR SHOE DISC ONE SIDE REPLACEMENT Horn PORTER 1 3 16V Time sheet TS 827...

Page 828: ...REPLACEMENT Clutch assembly CLUTCH UNIT Code Action Duration 1 311011 CLUTCH ASSEMBLY AND OR CLUTCH DISC REPLACEMENT 2 311251 PRESSURE PLATE BEARING RE PLACEMENT 3 311611 CLUTCH LEVER AND OR FORK REPL...

Page 829: ...Duration 1 120011 ENGINE ASSEMBLY REPLACE MENT 2 120012 COMPLETE ENGINE SERVICE 3 120051 ENGINE PARTIAL BLOCK WITH SUMP AND HEAD REPLACE MENT 4 120101 BLOCK PARTS BLOCK WITH PIS TONS AND SHAFT REPLAC...

Page 830: ...1 INTAKE DUCT AND OR GASKET REPLACEMENT 2 170021 EXHAUST DUCT AND OR GASKET REPLACEMENT 3 170101 EXHAUST PIPE GASKET RE PLACEMENT 4 170211 MUFFLER DUCT No 1 RE PLACEMENT 5 170171 MUFFLER REPLACEMENT D...

Page 831: ...Oil sump OIL SUMP Code Action Duration 1 112011 OIL SUMP OIL AND OR GASKET REPLACEMENT PORTER 1 3 16V Time sheet TS 831...

Page 832: ...Rear differential Time sheet PORTER 1 3 16V TS 832...

Page 833: ...ENTIAL HOUSING RE PLACEMENT 4 410102 DIFFERENTIAL HOUSING SERV ICE 5 410151 PINION AND CROWN REPLACE MENT 6 410221 DIFFERENTIAL PINION BEARINGS REPLACEMENT 7 410231 SEALING RING T TYPE RE PLACEMENT 8...

Page 834: ...Brake discs Time sheet PORTER 1 3 16V TS 834...

Page 835: ...PORTER 1 3 16V Time sheet TS 835...

Page 836: ...RAKE DISC REPLACE MENT TWO SIDES 3 473101 DISC BRAKE CALLIPER ASSEM BLY ONE SIDE REPLACEMENT 4 473111 DISC BRAKE CALLIPER ASSEM BLY BOTH SIDES REPLACE MENT 5 473301 DISC BRAKE SERVICE KIT ONE SIDE REP...

Page 837: ...Sidelight POSITION LIGHT Code Action Duration 1 811011 TAILLIGHT ASSEMBLY ONE SIDE REPLACEMENT 2 811031 TAILLIGHT BULB AND OR GLASS ONE SIDE REPLACEMENT PORTER 1 3 16V Time sheet TS 837...

Page 838: ...S REPLACEMENT 5 811401 REVERSE LIGHT AND OR BULB REPLACEMENT 6 811501 REAR FOG LIGHT REPLACEMENT Lights HEADLAMPS Code Action Duration 1 810011 FRONT HEADLAMP REPLACE MENT 2 810201 FRONT TURN INDICATO...

Page 839: ...Air filter AIR FILTER Code Action Duration 1 171021 AIR FILTER ASSEMBLY RE PLACEMENT 2 171051 FILTERING ELEMENT REPLACE MENT 3 171101 AIR FILTER FITTING REPLACE MENT PORTER 1 3 16V Time sheet TS 839...

Page 840: ...Fuel filter FUEL FILTER Code Action Duration 1 236021 Fuel filter replacement Oil filter OIL FILTER Code Action Duration 1 151011 OIL FILTER AND OR GASKET RE PLACEMENT Time sheet PORTER 1 3 16V TS 840...

Page 841: ...e PARKING BRAKE Code Action Duration 1 465021 PARKING BRAKE CONTROL LEV ER REPLACEMENT 2 465721 PARKING BRAKE FRONT CABLE REPLACEMENT 3 465731 PARKING BRAKE REAR CABLE REPLACEMENT PORTER 1 3 16V Time...

Page 842: ...2 472041 REAR BRAKE SHOE REPLACE MENT TWO WHEELS 3 472131 REAR BRAKE DRUM REPLACE MENT ONE WHEEL 4 472141 REAR BRAKE DRUM REPLACE MENT TWO WHEELS 5 472231 REAR SHOE RETURN SPRING 1 WHEEL REPLACEMENT...

Page 843: ...751031 HEADLAMP HOUSING ONE SIDE REPLACEMENT Instrument panel INSTRUMENT PANEL Code Action Duration 1 830011 INSTRUMENT PANEL REPLACE MENT 2 830101 GAUGES REPLACEMENT 3 830121 ODOMETER REPLACEMENT 4 8...

Page 844: ...ON Code Action Duration 1 223011 THROTTLE BODY OR GASKET REPLACEMENT 2 223101 FUEL INJECTOR REPLACEMENT 3 223201 INJECTOR SUPPLY MANIFOLD REPLACEMENT 4 223301 FUEL PRESSURE REGULATOR REPLACEMENT Time...

Page 845: ...1 743011 CAB ROOF INTERNAL PROTEC TION REPLACEMENT 2 743021 CAB ROOF INTERNAL PROTEC TION REPLACEMENT 3 743511 FRONT FLOOR CARPET RE PLACEMENT 4 743651 CONSOLE REPLACEMENT 5 743751 REAR FLOOR CARPET R...

Page 846: ...LATORS Code Action Duration 1 832011 FUEL GAUGE INDICATOR RE PLACEMENT 2 832031 MINIMUM OIL PRESSURE INDICA TOR REPLACEMENT 3 832101 STOP SWITCH REPLACEMENT 4 832111 REVERSE GEAR BULB SWITCH REPLACEME...

Page 847: ...ACEMENT 13 832381 REAR FOG LIGHT SWITCH RE PLACEMENT 14 832391 KEY SWITCH REPLACEMENT 15 832411 LIGHTER REPLACEMENT 16 832421 HAND BRAKE SWITCH REPLACE MENT 17 832441 FAN CONTROL SWITCH RE PLACEMENT 1...

Page 848: ...n 1 851051 GLASS WASHING PUMP AND MO TOR REPLACEMENT 2 851061 SPRINKLER REPLAC 3 851081 REPLACEMENT OF THE PIPE CONNECTING THE PUMP TO THE OPENING 4 851091 RESERVOIR AND WASHING PUMP REPLACEMENT Gear...

Page 849: ...GEARSHIFT LEVER Code Action Duration 1 332301 GEAR CONTROL TRANSMISSION REPLACEMENT 2 332401 GEAR SHIFT LEVER REPLACE MENT 3 332501 GEAR SHIFT LEVER KNOB RE PLACEMENT PORTER 1 3 16V Time sheet TS 849...

Page 850: ...n 1 111011 BLOCK CYLINDER REPLACE MENT 2 111151 SEALING RING REPLACEMENT FRONT SIDE CRANKSHAFT 3 111201 Sealing and or retaining ring engine rear side ring Replacement 4 111251 ELASTIC SUPPORT REPLACE...

Page 851: ...Starter motor PORTER 1 3 16V Time sheet TS 851...

Page 852: ...PLACE MENT 2 280112 MOTOR SERVICE 3 280211 REMOTE CONTROL REPLACE MENT Rear floor panel REAR FLOORING PANEL Code Action Duration 1 613011 ENGINE SERVICE COMPART MENT COVER REPLACEMENT 2 613051 BATTERY...

Page 853: ...R HINGE ONE SIDE REPLACE MENT 4 670301 FRONT DOOR LINING ONE SIDE REPLACEMENT 5 670311 SIDE DOOR UPHOLSTERY ONE SIDE REPLACEMENT 6 670501 GUIDE FOR FRONT DOOR WIN DOW ONE SIDE REPLACEMENT 7 670511 GUI...

Page 854: ...Code Action Duration 10 670801 SIDE DOOR GUIDE REPLACE MENT Dashboard Time sheet PORTER 1 3 16V TS 854...

Page 855: ...NSTRUMENT PANEL FINISHING REPLACEMENT 3 550131 INSTRUMENT PANEL CENTRAL FINISHING REPLACEMENT 4 550201 GLOVEBOX REPLACEMENT 5 550211 GLOVEBOX OPEN CLOSE LEVER REPLACEMENT 6 550301 ASHTRAY REPLACEMENT...

Page 856: ...Bumper BUMPERS Code Action Duration 1 520011 FRONT BUMPER REPLACEMENT 2 520021 REAR BUMPER REPLACEMENT Time sheet PORTER 1 3 16V TS 856...

Page 857: ...Brake pedal BRAKE PEDAL Code Action Duration 1 467011 BRAKE PEDAL REPLACEMENT 2 467101 PEDAL PROTECTION REPLACE MENT PORTER 1 3 16V Time sheet TS 857...

Page 858: ...Clutch pedal CLUTCH PEDAL Code Action Duration 1 313101 PEDAL PROTECTION REPLACE MENT 2 313201 CLUTCH TRANSMISSION RE PLACEMENT Time sheet PORTER 1 3 16V TS 858...

Page 859: ...Steering column PORTER 1 3 16V Time sheet TS 859...

Page 860: ...LUMN REPLACE MENT 7 442601 LEFT SIDE COVER REPLACE MENT 8 442611 RIGHT SIDE COVER REPLACE MENT 9 442801 COLUMN PROTECTIONS RE PLACEMENT 10 442851 ELASTIC JOINT REPLACEMENT 11 442861 JOINT REPLACEMENT...

Page 861: ...MP AND THERMOSTAT Code Action Duration 1 161011 WATER PUMP AND OR GASKET REPLACEMENT 2 161051 WATER PUMP PULLEY RE PLACEMENT 3 161101 THERMOST AND OR GASKET WATER OUTL FITT REPLACE MENT PORTER 1 3 16V...

Page 862: ...Fuel pump FUEL PUMP Code Action Duration 1 234011 FUEL PUMP AND OR GASKET REPLACEMENT 2 234012 FUEL PUMP AND OR GASKET SERVICE Time sheet PORTER 1 3 16V TS 862...

Page 863: ...Brake fluid pump BRAKE PUMP Code Action Duration 1 461021 TANK AND OR TANK PIPE RE PLACEMENT 2 463011 POWER BRAKE PUMP ASSEMBLY REPLACEMENT PORTER 1 3 16V Time sheet TS 863...

Page 864: ...n Duration 1 150011 OIL PUMP AND OR O RING RE PLACEMENT 2 150012 OIL PUMP AND OR O RING SERV ICE 3 150051 OIL INTAKE ASSEMBLY OR GAS KET REPLACEMENT 4 150251 OIL PRESSURE SAFETY VALVE REPLACEMENT Time...

Page 865: ...NGE TWO SIDES REPLACEMENT 3 642361 TAIL DOOR LOCK ASSEMBLY REPLACEMENT 4 642391 CYLINDER KIT REAR DOOR LOCK KEY REPLACEMENT 5 642711 TAIL DOOR PANEL REPLACE MENT 6 642771 TAIL DOOR GASKET REPLACE MENT...

Page 866: ...R Code Action Duration 1 752011 EXTERNAL REAR VIEW MIRROR ONE SIDE REPLACEMENT 2 752021 INTERNAL REAR VIEW MIRROR WITH CEILING LIGHT REPLACE MENT 3 752101 SUN VISOR REPLACEMENT 4 752151 SUPPORT HANDLE...

Page 867: ...160031 PRESSURISED CAP ON RADIA TOR REPLACEMENT 4 160101 RADIATOR INLET PIPE REPLACE MENT 5 160111 RADIATOR OUTLET PIPE RE PLACEMENT 6 160151 ENGINE OUTLET RADIATOR SLEEVE REPLACEMENT 7 160201 MOTOR...

Page 868: ...Action Duration 1 860021 RADIO AND PARTS RELATED TO FITTING REPLACEMENT 2 860031 RADIO REPLACEMENT 3 860051 LOUDSPEAKER REPLACEMENT 4 860101 AERIAL WITH RELEVANT SUP PORT REPLACEMENT Time sheet PORTE...

Page 869: ...NOZZLE REPLACE MENT TWO SIDES 4 870401 REPLACEMENT OF THE HEATING CONTROL AND THE TRANSMIS SION 5 870771 RADIATOR ASSEMBLY REPLACE MENT 6 870781 FAN REPLACEMENT HEATING MOTOR 7 870801 RESISTOR REPLACE...

Page 870: ...711011 FRONT SEAT CUSHION RE PLACEMENT ONE SIDE 2 711021 SEAT BACK FOR FRONT SEAT REPLACEMENT ONE SIDE 3 711061 FRONT SEAT HEADREST RE PLACEMENT ONE SIDE 4 711101 FRONT SEAT INTERNAL TRACK ONE SIDE R...

Page 871: ...FRONT SEAT ONE SIDE REPLACE MENT 8 711301 FRONT SAFETY BELT HOOK ONE SIDE REPLACEMENT 9 711351 FRONT SAFETY BELT ONE SIDE REPLACEMENT Rear van seat REAR SEAT VAN Code Action Duration 1 710051 REAR SE...

Page 872: ...on 1 421051 REAR AXLE SHAFT ONE SIDE REPLACEMENT 2 421101 REAR AXLE SHAFT RADIAL BEAR ING ONE SIDE REPLACEMENT 3 421201 REAR AXLE SHAFT RADIAL BEAR ING BOTH SIDES REPLACE MENT 4 421301 SEALING RING T...

Page 873: ...Cam sensor CAM SENSORS Code Action Duration 1 192501 CAM SENSOR ASSEMBLY RE PLACEMENT 2 192531 CAM SENSOR SUPPORT RE PLACEMENT 3 192561 SIGNAL GENERATOR REPLACE MENT PORTER 1 3 16V Time sheet TS 873...

Page 874: ...K AND PIPES VAN Code Action Duration 1 237011 FUEL TANK REPLACEMENT 2 237051 FUEL TANK CAP REPLACEMENT 3 237701 REACTION VALVE REPLACE MENT 4 237811 ACTIVATED CARBON FILTER REPLACEMENT Time sheet PORT...

Page 875: ...IPES PICK UP Code Action Duration 1 237011 FUEL TANK REPLACEMENT 2 237051 FUEL TANK CAP REPLACEMENT 3 237701 REACTION VALVE REPLACE MENT 4 237811 ACTIVATED CARBON FILTER REPLACEMENT PORTER 1 3 16V Tim...

Page 876: ...SHOCK ABSORBER SPRING REPLACEMENT BOTH SIDES 5 431151 FRONT SHOCK ABSORBER RE PLACEMENT ONE SIDE 6 431161 FRONT SHOCK ABSORBER RE PLACEMENT BOTH SIDES 7 431211 BAR SUPPORT REPLACEMENT ONE SIDE 8 43125...

Page 877: ...Rear end gate TAILBOARD Code Action Duration 1 611011 TAILBOARD REPLACEMENT 2 611101 TAILBOARD HOOK REPLACE MENT PORTER 1 3 16V Time sheet TS 877...

Page 878: ...Spare wheel mounting bracket SPARE WHEEL SUPPORT Code Action Duration 1 511201 SPARE WHEEL SUPPORT RE PLACEMENT Time sheet PORTER 1 3 16V TS 878...

Page 879: ...Plates LABELS Code Action Duration 1 750011 PLATE REPLACEMENT SINGLE PIECE PORTER 1 3 16V Time sheet TS 879...

Page 880: ...Action Duration 1 850051 REPLACEMENT OF THE FRONT WINDSCREEN WIPER ARM AND OR BLADE 2 850161 FRONT WINDSCREEN WIPER MO TOR REPLACEMENT 3 850171 FRONT WINDSCREEN WIPER AR TICULATION REPLACEMENT Time s...

Page 881: ...EAR WINDOW WASHER VAN Code Action Duration 1 852011 WINDSCREEN WIPER ARM AND OR BLADE REPLACEMENT 2 852051 MOTOR AND REAR WINDSCREEN WIPER SUPPORT REPLACE MENT 3 852101 REAR WINDOW WASHER SPRAY ER REP...

Page 882: ...0011 HEAD CYLINDER REPLAC 2 110051 GASKET HEAD REPLACEMENT 3 110101 REPLACEMENT OF COVER OR HEAD AND OR HEAD GASKET COVER 4 110201 OIL SEAL RING CAMSHAFT RE PLACEMENT 5 110131 OIL FILLER CAP REPLACEME...

Page 883: ...Throttle cable ACCELERATOR TRANSMISSION Code Action Duration 1 552031 ACCELERATOR TRANSMISSION REPLACEMENT PORTER 1 3 16V Time sheet TS 883...

Page 884: ...ses BRAKE PIPES AND CALIBRATOR Code Action Duration 1 464011 FRONT HOSE REPLACEMENT 2 464051 REAR BRAKE HOSE REPLACE MENT 3 464751 POWER BRAKE REGULATOR AS SEMBLY REPLACEMENT Time sheet PORTER 1 3 16V...

Page 885: ...VALVES Code Action Duration 1 141011 VALVE VALVE GUIDE REPLACE MENT 2 141031 SPRING CAP PLATE AND OR COTTERS AND OR SEAL RING REPLAC 3 141101 PIN ROCKING LEVER REPLACE MENT PORTER 1 3 16V Time sheet...

Page 886: ...Windows WINDOWS Code Action Duration 1 554011 WINDSHIELD AND GASKET RE PLACEMENT 2 554051 REAR GLASS AND OR GASKET REPLACEMENT Van side window Time sheet PORTER 1 3 16V TS 886...

Page 887: ...LE REPLACEMENT Frameless side window DOOR GLASS AND PROFILE Code Action Duration 1 671011 FRONT DOOR GLASS REPLACE MENT ONE SIDE 2 671021 SIDE DOOR GLASS ONE SIDE REPLACEMENT 3 671051 FRONT DOOR GLASS...

Page 888: ...SIDE DOOR INTERNAL PLATE ONE SIDE REPLACEMENT 7 671271 FRONT DOOR EXTERNAL GLASS EDGE ONE SIDE 8 671281 SIDE DOOR EXTERNAL GLASS EDGE ONE SIDE REPLACE MENT 9 671351 FRONT DOOR GASKET REPLACE MENT ONE...

Page 889: ...Steering STEERING WHEEL Code Action Duration 1 441071 HORN CONTACT RING REPLACE MENT PORTER 1 3 16V Time sheet TS 889...

Page 890: ...Code Action Duration 2 441101 STEERING WHEEL REPLACE MENT 3 441121 HORN CONTACT SQUARE PLATE REPLACEMENT 4 441151 HORN BUTTON REPLACEMENT Time sheet PORTER 1 3 16V TS 890...

Page 891: ...ntrol 561 664 670 682 Coolant 48 67 360 370 808 D Differential 47 595 596 832 Doors 745 E Engine 44 45 66 70 225 806 809 810 829 F Filter 44 126 361 839 840 Fluid 615 863 Fuel 67 361 840 844 862 874 F...

Page 892: ...0 800 Products 44 R Remote control S Safety 10 Seats 275 277 Shock Absorbers Spark plugs Specifications Switch 88 System 54 72 348 360 361 378 611 621 T Tank 874 V Van 865 871 881 886 Vehicle 29 655 W...

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PIAGGIO PORTER 1.3 16V 2008, Service Manual

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