2003-2008 Piaggio Porter 1.3 16V OEM Service & Repair Manual

MANUALE STAZIONE DI SERVIZIO 633530 (IT) - 531 (EN) - 532 (Fr) - 533 (DE) - 534 (ES) - 535 (PT) - 536 (NL) - 537 (EL) PORTER 1.3 16V

MANUALE STAZIONE DI SERVIZIO PORTER 1.3 16V COPYRIGHT © Copyright 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 Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) ITALY www.piaggio.com

MANUALE STAZIONE DI SERVIZIO PORTER 1.3 16V Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale 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 to carry out for preventing damages to the vehicle. Refers to specific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment. Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS GENERAL GUIDELINES N GEN CHARACTERISTICS CH SPECIAL TOOLS 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 STEERING COLUMN SC SUSPENSIONS SS TIPPER VERSION VR CHASSIS CH PRE-DELIVERY PD

TIME-SHEET TS

INDEX OF TOPICS GENERAL GUIDELINES N GEN

RECOMMENDATIONS AND IMPORTANT NOTES Each symbol has a specific meaning, as shown below. • WARNING:- This symbol indicates risks to the health of the operator or persons nearby, if the procedures described are not carried out properly. • WARNING:- This symbol indicates that the component on which the operator is working could be damaged, if the procedures described are not carried out properly. • NB: - Additional instructions related to the procedure in progress are provided in this section, so that the operation can be performed in an efficient way. GENERAL RECOMMENDATIONS FOR SAFETY: 1. - Always wear protective goggles and suitable clothing. 2. - Always use a safety support to work under the vehicle. 3. - Check that the ignition switch is always set to "OFF", unless otherwise specified in the procedure. 4. - Pull the hand brake before starting to work on the vehicle. 5. - Let the engine run only in well ventilated places to avoid risks related to carbon monoxide. 6. - Stand well away from moving parts during the engine operation, especially from fans 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. 9. - To avoid possible injuries, remove rings, watches, jewellery and loose clothes before starting to work on the vehicle. 10.- Keep hands and other objects away from the electric fan blades of the radiator ! 11.- The cooling electric fan is fitted on the radiator and can be started at any time due to the increase in coolant temperature or if the air conditioner switch is set to ON, for vehicles equipped with air conditioner. It is important to check that the cooling electric fan motor is disconnected from the cable harness before starting work. The units of measurement used in this manual are indicated as IS UNITS (International System of Units). Example:24.5 ÷ 34.3 Nm The abbreviations indicated in this manual are listed in the following table. • (B) - Bolt • (S) - Screw • (N) - Nut • (W) - Washer • (T) - Tightening torque ABBREVIATIONS Specification Desc./Quantity A/C: Air conditioner API: American Petroleum Institute which assesses and classifies the properties of the different oil types. Oils for petrol engines General guidelines PORTER 1.3 16V N GEN - 8

Specification Desc./Quantity are classified as SD, SE, SF, etc. ; while those for diesel engines are classified as CC, CD, etc. A/Y Assembly A group of components or an assembled component which includes more than two single parts or subassembly parts. ATDC: after Top Dead Centre (ATDC) BTDC: before Top Dead Centre (BTDC) DLC: Data Link Connector. DLI: Distribution less ignition DTC: Diagnostic Trouble Code indicates a code for injection system failures. ECU: Electronic Control Unit - Electronic unit. EFI: Electronic Fuel Injection ESA: Electronic Spark Advance ETR: Electronic Tuning Radio - Radio with variable frequency, the value varies according to voltage or current applied. EX: Exhaust pipe / Muffler. F/L: Fuse GND: Bodywork ground HC: Hydrocarbon IGN: Injection system ignition IN: Inlet ISO: International Standards Organisation. LED: Low Emission Diode LH: Left Handed LHD Left hand drive vehicle MIL: Malfunction Indicator Light / Self-diagnosis warning light MP: Multi Purpose Multipurpose, indicates that it has more than one application. M/T: Manual / Transmission NO: Nitric oxide O/S: Over Size Oversize means that upon fitting, there is excessive clearance due to extended use or due to frequent removal/ refitting operations. If the piece to be fitted (e.g. piston) is replaced with a part with larger dimensions, the other part to be coupled can be still used. "Oversized" parts are those which have larger dimensions with respect to standard parts. PCV: Positive Crankcase Ventilation RH: Right handed RHD: Right hand drive vehicle S/A: Subassembly A subassembly is a component which includes more than two single parts which are welded or fixed with stud bolts one to the other, constituting a single component. SAE: Society of Automotive Engineers - Standardisation body for the automotive industry. Lubricating oils are classified with a SAE number. These identifying numbers are set by the Society of Automotive Engineers of the United States of America. The larger the SAE number, the thicker the oil is. SST: Special Service Tool Special tool: tool designed for a specific purpose. STD: Standard - when making reference to vehicle parts, "standard" indicates those parts which are installed by the manufacturer and have standard dimensions. T: Torque This refers to the tightening torque TDC: Top Dead Centre (TDC) U/S: Under/ Size Undersize - as with "oversized" parts, if the mechanical part (e.g. bushing and bearing) is replaced with a part having a smaller diameter, the other coupled part can be reused. "Un- dersized" parts are those parts with smaller dimensions with respect to standard parts. VSV: Vacuum Switching Valve Vacuum Switching Valve W: With With 4WD: Four-Wheel Drive: vehicle with 4 driving wheels. General information This section comprises general information about the manual use and the vehicle, besides important notes relevant to safety. PORTER 1.3 16V General guidelines N GEN - 9

Safety guidelines Important notes about safety Suitable maintenance and repair procedures are essential for safety, vehicle reliability purposes, as well as for the personnel in charge of maintenance operations. The operations described in this manual provide general information on technical procedures recom- mended by the manufacturer necessary to guarantee product reliability. Maintenance operations comprise various types of procedures. Technical procedures, tools and parts necessary for each operation can also be significantly different from each other. The manual does not describe all technical procedures, operations, parts, tools and instructions necessary for performing maintenance operations. Therefore, anyone who consults the manual should first and foremost have suitable technical knowledge and professional skills and assumes responsibility for choosing the procedures to be followed, tools and parts required for proper vehicle maintenance. This person shall bear full responsibility for actions related to their personal safety. For this reason, operators should not carry out any operation if they are not able to make a responsible selection of techniques and/or if they are not able to understand the content of this manual, 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 FIRE HAZARD. TO PREVENT THIS PROBLEM, STRICTLY OBSERVE THE FOLLOWING PRECAUTIONS, ALSO EXPLAINING THEM TO YOUR CUSTOMERS. PRECAUTIONS RELATED TO THE CATALYTIC CONVERTER 1. Only use unleaded petrol. 2. Do not let the engine idle for long periods. Do not let the engine idle longer than 20 minutes. WARNING CHECK AND REPAIR THE VEHICLE IMMEDIATELY IF IDLE SPEED IS UNSTABLE OR IF THE SYSTEM FAILS. FAILURE TO OBSERVE THESE SPECIFICATIONS MAY CAUSE A FIRE. 3. Follow the procedure below to carry out the spark test of the spark plug. Carry out the test only if strictly necessary and as quickly as possible. Interrupt fuel supply before carrying out this test. 4. Do not run the engine if the fuel tank is almost empty. Failure to observe this precaution can cause an ignition failure. Besides, an excessive load on the catalytic converter could occur, and it can even get damaged. 5. Do not dispose of the old catalytic converter together with components contaminated with petrol or oil. VEHICLE HAULAGE AND TOW To haul or tow a vehicle in case of emergency, strictly follow the instructions below. NEVER HAUL THE VEHICLE USING HARNESSES. FAILURE TO OBSERVE THIS MEASURE MAY SERIOUSLY DAMAGE THE VEHICLE BODYWORK. General guidelines PORTER 1.3 16V N GEN - 10

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2003-2008 Piaggio Porter 1.3 16V OEM Service & Repair Manual

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