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INSTRUMENT PANEL CABLES

RIGHT HAND DRIVE VAN:

1. To the courtesy light cable harness

2. left headlight adjustment actuator

3. front left /side turn indicator

4. front 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 electric fan

14. windshield washer motor

15. rear window washer motor

16. temperature sensor

17. radiator fan relay

18. main fuse

PORTER 1.3 16V Electrical system

ES - 207

Index of Topics5
General Guidelines7
General Recommendations for Safety8
Recommendations and Important Notes8
General Guidelines9
General Information9
Safety Guidelines10
Emergency Tow11
Towing on a Flat Truck11
Towing with Wheels Lifted11
Front Support Point12
Lifting Points12
Rear Support Point12
Description of Manual Use13
Maintenance Guidelines13
Support Points for Jack13
Maintenance Procedure14
Circuit Check15
DLC Data Link Connector15
Electric Fault Repair15
General Instructions for Maintenance Operations on the Cable Harness16
OBD Dignosis Connector Terminals16
Fixing with Screws17
Terminals and Connectors17
Cable Harness18
Disconnection of Connectors with Safety Lock18
Using Resin Clamps18
Disconnection of Terminal with Metal Lock19
Terminal Insertion19
Characteristics21
Chassis Identification22
Engine Identification22
Engine Number and Type22
Manufacturer Label22
Pick-Up Model Bodywork Colour Codes23
Van Model Bodywork Colour Code23
Vehicle Model Code23
Kinematic Chain Specifications24
Impianto Elettrico25
Dimensions26
Table of Contents27
Tightening Torques27
Cylinder-Piston Oversizes29
Vehicle Overhaul Data29
Crankshaft - Rod Head30
Piston - Pin30
Piston Ring Oversizes30
Camshaft31
Tappets31
Valve Clearance31
Valve Guide - Valve Stem31
Valve Spring31
Crankshaft Pulley32
Cylinder Head32
- Special Tools33
- Injection System Tool34
- Tooling34
- Engine Tool35
- Clutch Tool36
- Transmission Tool36
- Differential Tool37
- Brake Tool38
- Front Suspension Tool38
- Rear Suspension Tool39
- Steering Tool40
- Maintenance42
- Scheduled Maintenance Chart43
- Air Filter44
- Engine Assembly44
- Suggested Products Chart44
- Engine Oil Level Check45
- Engine Oil Replacement45
- Oil Quality Check45
- Engine Oil Change and Filter Replacement46
- Gear-Box Oil Replacement46
- Gearbox Oil Change46
- Leaks46
- Differential Oil Change47
- Differential Oil Replacement47
- Oil Leak47
- Coolant Change48
- Coolant Replacement48
- Cable Check50
- Spark Plug50
- Spark Plug Check50
- Headlight Alignment Check51
- Light Beam Direction Adjustment51
- Settings and Adjustments51
- Emission Control System53
- Component Layout54
- Catalytic Converter55
- Fuel Vapour Control System56
- Control System Diagram57
- Engine off57
- Engine Operation with the Accelerator Pedal Pushed57
- Blow-By Ventilation Pipe58
- Fuel Closing Device During Deceleration58
- Fuel Vapour Control Device59
- Emission Control Device62
- CO/HC Concentration Check63
- Exhaust Emission Control System63
- Troubleshooting65
- Engine66
- Clutch67
- Brakes68
- Gearbox68
- Suspensions and Steering69
- Electrical System71
- Battery-Chassis Ground72
- Ground Points72
- Main Ground73
- Rear Services System Ground73
- Services System Ground73
- Additional Ground74
- Electric Circuit Diagram74
- Injection System - Engine Ground74
- Electric Diagrams78
- Ignition78
- Starting and Recharging79
- Air Conditioning Electrical System Diagram81
- Colour Table83
- Fuse Box83
- Fuses83
- Instructions to Replace Fuses and Fuse Holders83
- Remote Controls84
- Air Conditioning Remote Controls85
- Electrical Controls85
- Multifunction Switch Lever85
- Ignition Key Switch86
- Rear Windscreen Wiper and Spray Nozzle Switch88
- Wiper Switch88
- Handbrake Switch89
- Headlamp Light Beam Adjustment Switch89
- Heated Rear Window Switch89
- Front Fog Light90
- Windscreen Wiper Mechanism91
- Windscreen Wiper Remote Control92
- Rear Wiper Mechanism94
- Start-Up System95
- Starter Motor95
- Inspection with Starter Motor Fitted96
- Bench Tests98
- Thrust Test98
- Checking Performance Without Load Applied99
- Pinion Engagement Upholding Test99
- Pinion Return Check99
- Starter Motor Removal100
- Commutator Check103
- Commutator Continuity Check103
- Rotor Insulation Check103
- Brush Check105
- Field Winding Check105
- Brush Holder Check106
- Brush Replacement Procedure106
- Coupling Check106
- Magnetic Field Check107
- Starter Motor Coupling Check107
- Bearing Check108
- Alternator111
- Recharge System111
- Rotor Check117
- Brush and Brush Holder118
- Stator118
- Brush Replacement119
- Rectifier Check120
- Rear Bearing Check121
- Rear Bearing Replacement121
- Front Bearing Check122
- Front Bearing Replacement122
- Refitting123
- Generator Shaft Fixing125
  - Central Locking with Remote Control System Description126
  - Power Lock126
  - Electromechanical Actuators127
  - Remote Control127
  - Technical Characteristics of the System127
  - New Remote Control Detection129
  - Remote Control131
  - System Maintenance131
  - Alarm System and Central Locking132
  - Electrical Contacts for Sliding Doors132
  - System Protection Fuse132
  - Operation Description133
  - Garage Function135
  - LED Warning135
  - Alarm and Central Locking136
  - Electrical Connections136
  - Ultrasound Module Connection and Positioning137
  - Super-High Frequency Module Connection and Positioning138
  - Super-High Frequency Sensor Adjustment139
  - Programmable Functions140
  - Anti-Hijack Function143
  - New Control Device Detection145
  - New Pin-Code Programming146
  - Emergency Unlocking through Pin-Code147
  - Device Battery Replacement148
  - Magnetic Contact148
  - Infrared Sensor149
  - Radio Control149
  - Light Layout and Specifications150
  - Replacing Light Bulbs150
  - Bulb Position and Characteristics151
  - Replacing the Headlight Bulbs152
  - Front Indicators154
  - Replacing the Front Turn Signal Light Bulbs154
  - Replacing the Taillight Bulbs154
  - Cab Rear Light155
  - Rear Turn Indicators/Stop Lights155
  - Replacing the Courtesy Lamp155
  - Replacing the License Plate Light Bulb155
  - Fog Light Headlamp Replacement156
  - Fog Light Headlamps156
  - Indicators - Warning Lights157
  - Rear Fog Light157
  - Reverse Gear Light157
  - Instrument Panel158
  - Speedometer158
  - Fuel Gauge160
  - Fuel Level Probe161
  - Unit Check161
  - Fuel Gauge and Temperature Gauge162
  - Water Temperature Gauge162
  - Ignition Check163
  - Electrode Gap164
  - Battery Voltage165
  - Electrical Power Supply165
  - Ignition Cable165
  - Camshaft Sensor166
  - Ignition Timing167
  - Electronic Injection Control Unit168
  - Control Unit Output Characteristics169
  - Fan Check170
  - Fan Switch Check170
  - Internal/External Air Control Cable171
  - Main Fitting Operations171
  - Temperature Adjustment Cable171
  - Flow Regulation Cable172
  - Heating System and Ventilation172
  - Cooling Circuit174
  - Cooling Electric Fan Check174
  - Engine Injection Cable Harness175
  - Ignition Coil176
  - Battery Negative Cable Harness178
  - Engine - Chassis Ground Cable Harness179
  - Battery Positive Cable Harness180
  - Bodywork-Engine Ground Transmission Cable Harness183
  - Cab Roof Cable Harness184
  - Positions of Cables in the Connectors184
  - Roof Light Cable Harness185
  - Tail Door Cable Harness No.1186
  - Engine Cable Harness187
  - Rear Chassis Cable Harness188
  - Instrument Panel Cables190
  - Right Hand Drive Instrument Panel190
  - Left Hand Instrument Panel199
  - Right Hand Drive Van207
  - Left Hand Drive Van214
  - Tipper222
  - E.G.R. Circuit Intake Duct225
  - Engine Mechanism225
  - Engine Type 2225
  - Inlet Manifold Removal225
  - Inlet Manifold - Fuel Delivery Pipe227
    - EGR Valve - EGR Pipe228
    - Exhaust Manifold Removal230
    - Exhaust Pipe230
    - Manifold Check230
    - Exhaust Manifold Fitting231
    - Alternator Drive Belt232
    - Tension Adjustment232
  - Cylinder Head - Exhaust Manifold232
    - Driving Belt Test233
    - Crown Gear Replacement234
    - Flywheel Test234
    - Crankshaft Pinion Fitting235
    - Crankshaft Pulley Flange Fitting235
    - Crankshaft Pulley Test235
    - Driving Pulley235
- Crankshaft - Crankshaft Belt Pulley235
  - Initial Operations236
  - Timing Belt and Gears236
  - Timing Belt Replacement236
  - Timing Belt Removal237
  - Belt Tensioner240
  - Belt Tensioner Pulley Check240
  - Crankshaft Pulley and Flange Test240
  - Timing Belt Tensioner Spring Check240
  - Crankshaft Pulley Removal241
  - Crankshaft Pulley Fitting242
  - Refitting Pulley on Crankshaft242
Crankshaft - Timing System Pulley Screw242
- Camshaft Pulley Removal243
- Removal - Refitting Timing Pulley243
- Camshaft Pulley Fitting244
- Tension Spring Connection244
- Timing Belt Fitting244
- Timing System Belt Tensioner246
- Cylinder Head - Cylinder Head Cover288
- Connecting Rod - Connecting Rod Cap307
- Connecting Rod Bearing Thickness Selection307
- Oil Pressure Switch - Cylinder Block350
- Valve Timing - Belt Refitting244
- Handbrake637
Parking Brake Cable637
- Operation before Removal638
- Fitting (Pickup Model)639
- Brake Controller Lspv641
- LSPV (Brake Calibrator)641
- Operation after Fitting641
- Performance Diagram644
- Pickup645
- Van645
- Component647
- LSPV Brake Calibrator648
- Lspv Assembly651
LSPV Brake Calibrator - Bracket652
- Clearance Check655
- Inspection on Vehicle655
- Noise Check655
- Steering Column659
- Steering Arm660
- Universal Joint Arm661
- Steering Box Assembly666
- Strut Bracket Body666
Rack Guide Protection Lock Nut - Steering Rack Housing676
- Steering Column677
- Key Switch Cylinder Removal678
- Tie-Rods681
- Arm Head682
- Checking after Fitting the Arm Heads683
- Toe-In683
- Front Wheel Alignment Check684
- Steering Angles684
- Pick up Front Wheel Alignment685
- Steering Wheel Clearance685
- Van Front Wheel Alignment685
- Toe-In Adjustment687
- Toe-In Measurement687
- Wheel Alignment687
- Suspensions689
- Axle and Front Suspension690
- Front690
- Shock-Absorbers Removal691
- Steering Articulation Fitting692
- Spring Removal694
- Front Arms Removal695
- Shock Absorber Operation Check695
- Suspension Lower Arm695
- Twisting and Breaking698
- Front Hubs Removal699
- Castle Nut - Front Axle Hub 177.0 ÷701
- Front Axle Bearing Installation702
- Front Axle Bearing Replacement702
- Preliminary Checks before the Wheel Alignment Check703
- Turning Radius Gauge Setting705
- Checking the Camber, Caster and Kingpin Angles706
- External Side Wheel Steering Angle Check706
- Wheel Steering Angle Correction706
- Axle and Rear Suspension710
- Wheel Hub710
Brake Pipe Joint - Brake Cylinder715
- U-Bolt - Leaf Spring Buffer718
Spring Support Pin - Leaf Spring Assembly719
Rear Shock Absorber - Chassis (Upper Part)721
- Noise722
- Shock Absorbers722
- Tipper Version724
- Electric Diagram - Tipper727
- Tipper Removal728
- Tipper Refit729
- Hydraulic Jack Fitting731
- Hydraulic Jack Removal731
- Removal of Pump Parts732
- Removing Valve Body from the Electric Motor733
- Valve Body Removal733
- Valve Body Fitting734
- Assembly of Pump Parts735
- Fitting the Valve Body to the Electric Motor735
- Hydraulic Pump and Electric Motor Fitting736
- Pressure Relief Valve Check and Calibration737
- Chassis739
- Windscreen740
- Side Windows742
- Rear Window Upholstery Panel744
- Tools and Other Equipment744
- Doors745
- Door Alignment Adjustment752
- Prescribed Alignment Sizes752
- Sliding Door Frame753
- Sliding Door Upholstery Panel753
- Upholstery Panel Removal755
- Upper Roller Removal763
- Central Hinge Removal764
- Lower Roller Removal764
- Central Hinge Fitting766
- Lower Roller Fitting766
- Adjustment in Longitudinal Direction767
- Height Adjustment767
- Sliding Door767
- Adjustment of Height Difference768
- Adjustment Tolerance768
- Rear Door Upholstery Panel770
- Door Panel772
- Adjustment in Longitudinal Direction of the Upper Section773
- Front Bumper773
- Catalytic Converter Replacement774
- Replacing the Exhaust774
- Exhaust Pipe - Catalytic Converter775
  - Light Unit775
  - Front Panel Components778
  - Removing Upper Panel of Instrument Panel and Glove Compartment780
  - Instrument Panel Removal781
  - Instrument Panel Installation783
  - Removing Air Vents/Loudspeakers/Cigarette Lighter783
Instrument Panel Support - Chassis783
- Refitting Air Vents/Loudspeakers/Cigarette Lighter786
- Starting Operations787
- Van Front Seat789
- Check-Up of Inclination Angle until Clicking Sound of Belt Is Heard790
- Fitting the Front Seat Internal Bolt791
- Safety Belt at Three Anchor Points with Winder791
- Safety Belts791
- Fuel Tank Cap794
- Pre-Delivery795
- Closing and Hinge Operation797
- General Inspection797
- Vehicle External Appearance797
- Vehicle General Check797
- Internal798
- Vehicle Cleaning798
- User Manual799
- Wheel Guard-Central Cover Fitting799
- Loosening the Hub Clamps800
- Nut Tightening800
- Preliminary Inspections800
- Tyre Pressure800
- Adjusting Devices801
- Cigarette Lighter801
- Seatbelt801
- Horn Functioning802
- Horn Operation802
- Windshield Washer Orientation Adjustment802
- Wipers Operation802
- External Lights803
- Headlamp Orientation803
- Headlight Adjustment803
- Windscreen Wiper and Washer Operation803
- Chassis Inspection804
- Checks to be Carried out under the Body804
- Warning Lights804
- Door Lock Adjustment805
- Door Stop Plate - Chassis805
  - Battery Connections806
  - Bellow Joint806
  - Engine Housing Inspection806
  - Ignition Timing806
  - Sleeve Connections and Fluid Pipes806
  - Coolant in the Expansion Tank808
  - Window Cleaning Liquid808
  - Windshield Washer Fluid in the Reserve Tank808
  - Engine Idle809
  - Idle Speed Adjustment809
  - Rpm Indicator Connection809
  - Brake Fluid810
  - Brake Pedal Adjustment810
  - Engine Oil810
  - Service and Parking Brake Operation810
  - Road Test811
  - Steering Wheel811
  - Test Drive811
  - Steering - Wheel Hub Joint - Dust Guard812
  - Time-Sheet814
  - Camshaft and Timing Belt815
  - Drive Shaft816
  - Propeller Shaft817
  - Leaf Spring and Shock Absorbers819
  - Suspension Leaf Spring819
  - Battery820
  - H.T. Coil821
  - HV Coil and Spark Plugs821
  - Cable Harnesses822
  - Front Chassis824
  - Bodywork825
  - Rear Chassis825
  - Wheel Rim826
  - Brake Cylinder827
  - Horn827
  - Clutch Assembly828
  - Clutch Unit828
  - Engine Unit829
  - Ducts830
  - Oil Sump831
    - Rear Differential832
    - Brake Discs834
- Fluid Leaks805
Leakages805
Brake Disc836
- Position Light837
- Sidelight837
- Headlamps838
- Oil Filter840
Lights838
Rear Axle Shaft872
- Cam Sensor873
- Fuel Tank and Pipes874
- Front Suspensions and Front Axle876
- Rear End-Gate877
- Tailboard877
- Spare Wheel Mounting Bracket878
- Spare Wheel Support878
- Labels879
- Plates879
- Windscreen Wiper880
- Rear Van Wiper881
- Head882
- Accelerator Transmision883
- Throttle Cable883
- Brake Hoses884
- Brake Pipes and Calibrator884
- Valves885
- Van Side Window886
- Windows886
- Door Glass and Profile887
- Frameless Side Window887
- Side Glass887
- Steering889
- Index891

Brand	PIAGGIO
Model	PORTER 1.3 16V 2008
Category	Automobile
Language	English

PIAGGIO PORTER 1.3 16V 2008 User Manual

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PIAGGIO PORTER 1.3 16V 2008 Specifications

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