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

Towing on a flat truck
This is the better method to choose in order to
guarantee greater safety.
•PULL THE HAND BRAKE ALL THE WAY.
•TIE THE VEHICLE TO THE MEANS OF
TRANSPORT WITH SUITABLE CABLES. DO
NOT APPLY EXCESSIVE FORCE ON THE
HOOKSWHICHAREONTHEVEHICLEBODY-
WORK OR YOU RISK DAMAGING THE BODY-
WORK.
Towing with wheels lifted.
Use a towing carriage to tow the vehicle, leaving
either front or rear wheels on the ground.
CHECK THAT THERE ARE NO PERSONS IN THE VEHICLE
BEING TOWED.
•MAKE SURE TO FASTEN THE FRONT AND
REAR WHEELS TO THE TOWING CARRIAGE.
•NEVER TOW THE VEHICLE USING HAR-
NESSES. FAILURE TO OBSERVE THIS PRE-
CAUTION MAY CAUSE SERIOUS DAMAGE
TO THE VEHICLE BODYWORK.
Emergency tow
This procedure can be used if the vehicle has manual transmission or if the road surfaces are firm and
even. In this case, strictly observe the safety measures indicated below
•THE DRIVER OF THE VEHICLE TO BE TOWED SHALL ALWAYS TAKE INTO ACCOUNT
THAT BRAKING REQUIRES GREATER FORCE THAN NORMAL, SINCE THE POWER
BRAKE REMAINS INACTIVE ONCE THE ENGINE IS SHUT OFF.
•NEVER HAUL THE VEHICLE AT A SPEED OVER 30 KM/H. SET THE IGNITION SWITCH
OF THE VEHICLE TO BE HAULED TO «ACC» DURING HAULAGE OPERATIONS. NEV-
ERREMOVETHEKEYOR SETTHE IGNITIONSWITCH TO«LOCK» DURINGHAULAGE
OPERATIONS. FAILURE TO OBSERVE THIS PRECAUTION MAY CAUSE LOSS OF
CONTROL OVER THE VEHICLE AND CAUSE ACCIDENTS.
•NEVER HAUL THE VEHICLE IN THIS WAY UNLESS THE WHEELS, AXLE, STEERING,
AND BRAKES ARE IN GOOD CONDITION.
WARNING
•NEVER HAUL A VEHICLE WITH AUTOMATIC TRANSMISSION IN THIS WAY. ALWAYS
USE A TOWING CARRIAGE.
•WHILE PULLING THE HOOK, ALWAYS KEEP IT IN AN UPRIGHT POSITION TO AVOID
DAMAGING IT. NEVER PULL IT SIDEWARDS OR VERTICALLY. ALSO AVOID SUDDEN
MOVEMENTS.
•CONNECT THE TOWING ROPE, CABLE OR SIMILAR ITEMS ONLY TO THE HOOKS ON
THE VEHICLE BODY. IF THE TOWING ROPE, CABLE OR SIMILAR ITEMS ARE CON-
NECTED TO PARTS OTHER THAN THE HOOKS PROVIDED, THIS COULD SERIOUSLY
DAMAGE THESE COMPONENTS.
•CHECK THAT THE HOOKS ARE FIRMLY FIXED TO THE VEHICLE BODY BEFORE
STARTING HAULAGE OPERATIONS.
1. Fix the "Towing eye" to the towing rod, avoid using ropes.
2.The driver must be inside the hauled vehicle.
3. Release the hand brake and take the gearshift lever to neutral.
4.Formodelswithfourwheeldrive(4WD)movethecentraldifferentiallockingswitchtothefreeposition.
N.B.
PORTER 1.3 16V General guidelines
N GEN - 11

•IF THE ENGINE DOES NOT START, CHECK THAT THE CENTRAL DIFFERENTIAL
LOCKING DEVICE IS FREE, LIFTING ONE OF THE WHEELS AND CHECKING THAT
THESE TURN FREELY. ALSO IF THE DIFFERENTIAL LOCKING CHECKING DEVICE
WARNING 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:
Support the vehicle at the bodywork points indica-
ted in the figure.
(A): Front support Point
Rear part
Support the vehicle under the leaf spring.
(P): Rear support Point
General guidelines PORTER 1.3 16V
N GEN - 12

Support points for jack
Front part
Place the jack on the cross-member of the front
suspension.
Rear part
Place the jack under the differential.
Maintenance guidelines
5. LOCKING TORQUE
For operations which require locking torque check, the relevant value is indicated in bold type. Make
sure to check the relevant locking torque.
3. SPECIAL TOOLS
The code of special tools necessary for individual operations is indicated in bold type.
4. MAINTENANCE PROCEDURE
Themaintenancespecificationsareindicatedinboldtypeorunderlined.Makesuretochecktherelevant
specifications.
DESCRIPTION OF MANUAL USE
1. COMPONENT SKETCH
•The component sketch shown at the beginning of each section describes the nomenclature
and the fitting conditions of each individual component.
•Those parts marked with ( * ) can not be reused. Be careful to replace these parts with new
components during the assembly.
•During the assembly, lubricate the parts marked in the figure.
(Example)
PORTER 1.3 16V General guidelines
N GEN - 13

1. Brake main cylinder unit 2. Reservoir cap 3. Reservoir cap spacer 4. Reservoir diaphragm 5. Float
switch 6. Main cylinder reservoir subassembly 7. Clamp 8. Fixing bolt 9. Gasket 10. Gasket 11. Main
cylinder repair kit *: Non-reusable 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 detailed maintenance procedure, specifications and notes.
- The main point of each item describes the section about maintenance and relevant procedure, with
the aid of illustrations.
General guidelines PORTER 1.3 16V
N GEN - 14

(Example); Brake pipe fitting,
•Temporarily fit the brake pipe on the
wheel cylinder, manually
•Tighten the brake pipe on the wheel
cylinder, using the special tool «A».
Specific tooling
09751-36011-000 tool description
- The inspection comprises only the checking operations. Therefore, if malfunctions are detected, it is
necessary to replace the defective parts with new ones.
Circuit check
Electric fault repair
DIAGNOSIS CONNECTOR (DLC Data Link
Connector).
TheElectronic Control Unit ofthevehicle complies
with the ISO protocol 14230 (Euro-OBD). Regard-
ing the position, the configuration of the connector
andtheterminalpre-installation,theDLCcomplies
with the ISO 15031-3 (SAEJ1962) and ISO 14230
standards.
The OBD II serial data line (K line) is used for the
OBD II general scanning device or for the specific
diagnostic tester, to communicate with the elec-
tronic control unit.
PORTER 1.3 16V General guidelines
N GEN - 15

OBD DIAGNOSIS CONNECTOR TERMINALS:
A = OBD (DLC) Diagnosis connector
1. (+B) Battery positive (Voltage always detec-
ted: 9 ÷ 14V)
2. ECU-T
3. EFI-T
4. (REV) Engine rpm signal
5. (-) Chassis ground (Resistance < 10 Ω, al-
ways detected ).
6. (- ECU) Electronic control unit ground
7. (K line) OBD serial data line (generation of
pulses on the line during transmission.
GENERAL INSTRUCTIONS FOR MAINTE-
NANCE OPERATIONS ON THE CABLE HAR-
NESS
1.Do not pullor press connectorsduringthe trans-
port or fitting 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 sure that the flaps of the fixing clip
are properly inserted into the chassis hole.
- Make sure that the fixing clip does not come out
of its hole by pulling it gradually in the arrow direc-
tion.
- If there are metal clamps welded to the chassis,
make sure to fit the cable harness so that it does
not make contact with the welded metal surface or
withsharpedgestopreventpossiblemalfunctions.
(A) Correct
(B) Incorrect
General guidelines PORTER 1.3 16V
N GEN - 16

-Inthecaseofguidesorreferences whichindicate
the fastening clamp position, make sure that it is
placed inside the guides. As regards fixing with
references, make sure that the clamp is fastened
with a maximum error of ± 10 mm.
C= Guide for clamp
D= The fastening clamp shall be inserted between two points.
- Terminals and connectors
E= Reference for fixing position F= Fixing shall be carried out with a tolerance of ± 10 mm with respect
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 at the end of the stroke.
Fixing with screws
- When the locking torque is specified, strictly fol-
low the specifications.
- Make sure that the protruding section is not on
the fixing surface.
- After fixing, pull the terminal gradually to make
sure that it is not loose.
- While carrying out other operations, make sure
not to accidentally disconnect connectors.
A = Correct B = Incorrect (terminal bent)
PORTER 1.3 16V General guidelines
N GEN - 17

Using resin clamps
When using resin clamps, do not use pliers or sim-
ilar tools, as improper use could damage or cut
them.
CABLE HARNESS
- THE DIMENSION AND CAPACITY OF EACH CABLE ARE SPECIFIC TO GUARANTEE THE
PROPER OPERATION OF THE ELECTRICAL SYSTEM.
- THEREFORE, DO NOT POWER OTHER POSSIBLE ACCESSORIES USING THE EXISTING CA-
BLE HARNESS. FAILURE TO OBSERVE THIS PRECAUTION MAY CAUSE A SYSTEM MALFUNC-
TION AND ALSO FIRE HAZARD.
Disconnection of connectors with safety lock
- Press the locking lever, as shown in the figure,
then pull the connector. Do not pull the cable har-
ness, otherwise the terminals could come out of
their seats.
The locking connector can be the following types
ofconnector: apush-pieceopening, tractionopen-
ing, spring closing, one-way closing mechanism
and so on.
Once the type of locking has been identified, open
the lock. Disconnect the connector holding it.
- NEVER PULL THE CABLE HARNESS WHILE DISCON-
NECTING.
- MAKE SURE TO TAKE OUT THE CONNECTOR IN AN UP-
RIGHT POSITION SO AS NOT TO DAMAGE THE TERMI-
NAL.
2. Connection.
Connectthe male connectortothe female connector.Makesure that thelockis completely disengaged.
3. Terminal removal.
Terminal with bayonet lock
Insert a small screwdriver (B) inside the connector
opening between the terminal and the locking lev-
er. Lever on the locking lever (A) and take out the
terminal.
General guidelines PORTER 1.3 16V
N GEN - 18

Disconnection of terminal with metal lock
-Press the indicated leverinthe figure with asmall
screwdriver, then pull the terminal to remove it
from the connector.
4. Terminal insertion.
Terminal with box locking:
Insert the terminal in the protruding section of the connector, until the lock is completely engaged. Pull
the cable harness gradually to make sure that the lock is properly fitted.
Terminal with metal lock:
Insert the terminal in the connector, until the lock is properly engaged. Pull the cable harness gradually
to make sure that the lock is properly fitted.
DO NOT DISCONNECT A CONNECTOR WITH SAFETY LOCK, IF NOT STRICTLY NECESSARY.
BATTERY MAINTENANCE INSTRUCTIONS.
Before any intervention 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.
•AFTER RECONNECTING THE GROUND LEAD TO THE BATTERY NEGATIVE (-) POLE,
RESTORE ANY ACCESSORIES ON THE VEHICLE (CLOCK, RADIO, etc...)
In case it is necessary to interrupt the battery power supply to carry out repairs or maintenance; first
disconnect the negative (-) ground lead from the battery and then the positive (+) lead.
To avoid damaging the battery, loosen the nut and remove the terminal pushing it up, without turning
it or forcing it with a lever.
N.B.
•USE A SPECIFIC EXTRACTOR (AVAILABLE ON THE MARKET), TO REMOVE THE
NEGATIVE (-) AND POSITIVE (+) LEADS FROM THE BATTERY POLES, SHOULD
THERE BE ANY DIFFICULTIES IN REMOVAL.
Clean the battery poles and lead terminals with a cloth.
PORTER 1.3 16V General guidelines
N GEN - 19

Before connecting the ground lead 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 guidelines PORTER 1.3 16V
N GEN - 20