PIAGGIO PORTER 1.3 16V 2008 User 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 Sectionsmarkedwiththis 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:-Additionalinstructionsrelatedtotheprocedure in progress are providedinthis 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. -Checkthat theignitionswitch isalwayssetto"OFF", unlessotherwisespecified intheprocedure.
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.-Thecooling 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 en-
gines are classified as CC, CD, etc.
A/Y Assembly A group of components or an assembled component which in-
cludes 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 oper-
ations. 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 di-
mensions 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: SocietyofAutomotiveEngineers -Standardisation bodyfor 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 op-
eration can also be significantly different from each other.
The manual does not describe all technical procedures, operations, parts, tools and instructions nec-
essary 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