workshop manual - porter 1.3 16v - workshop

MANUALE STAZIONE DI SERVIZIO633530 (IT) - 531 (EN) - 532 (Fr) - 533 (DE) - 534 (ES)

- 535 (PT) - 536 (NL) - 537 (EL)

PORTER 1.3 16V

MANUALESTAZIONE 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

http://www.piaggio.com/

MANUALE STAZIONE DISERVIZIO

PORTER 1.3 16V

Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalleofficine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questapubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base deiprincipi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioniimportanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verrannocomunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavorocompletamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è perquesto che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e ilcatalogo 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 tospecific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures tocarry out for preventing damages to the vehicle. Refers to specific procedures to carry out for preventingdamages 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 personalinjury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage 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

ABBREVIATIONSSpecification Desc./Quantity

A/C: Air conditionerAPI: 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./Quantityare 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 ignitionDTC: Diagnostic Trouble Code indicates a code for injection system

failures.ECU: Electronic Control Unit - Electronic unit.EFI: Electronic Fuel InjectionESA: Electronic Spark AdvanceETR: 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 groundHC: HydrocarbonIGN: Injection system ignitionIN: Inlet

ISO: International Standards Organisation.LED: Low Emission DiodeLH: Left HandedLHD Left hand drive vehicleMIL: Malfunction Indicator Light / Self-diagnosis warning light

MP: Multi Purpose Multipurpose, indicates that it has more than one application.M/T: Manual / TransmissionNO: Nitric oxide

O/S: Over Size Oversize means that upon fitting, there is excessive clearancedue to extended use or due to frequent removal/ refitting oper-ations. If the piece to be fitted (e.g. piston) is replaced with apart 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 VentilationRH: Right handed

RHD: Right hand drive vehicleS/A: Subassembly A subassembly is a component which includes more than two

single parts which are welded or fixed with stud bolts one to theother, constituting a single component.

SAE: Society of Automotive Engineers - Standardisation body for theautomotive industry. Lubricating oils are classified with a SAEnumber. These identifying numbers are set by the Society ofAutomotive 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 asmaller 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 With4WD: 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 CATALYTICCONVERTER CAN CAUSE OVERHEATING, RESULTING IN FIRE HAZARD. TO PREVENT THISPROBLEM, STRICTLY OBSERVE THE FOLLOWING PRECAUTIONS, ALSO EXPLAINING THEMTO 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 THESYSTEM 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 MAYSERIOUSLY DAMAGE THE VEHICLE BODYWORK.


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. DONOT APPLY EXCESSIVE FORCE ON THEHOOKS WHICH ARE ON THE VEHICLE BODY-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 VEHICLEBEING TOWED.

• MAKE SURE TO FASTEN THE FRONT ANDREAR WHEELS TO THE TOWING CARRIAGE.

• NEVER TOW THE VEHICLE USING HAR-NESSES. FAILURE TO OBSERVE THIS PRE-CAUTION MAY CAUSE SERIOUS DAMAGETO 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 ACCOUNTTHAT BRAKING REQUIRES GREATER FORCE THAN NORMAL, SINCE THE POWERBRAKE REMAINS INACTIVE ONCE THE ENGINE IS SHUT OFF.

• NEVER HAUL THE VEHICLE AT A SPEED OVER 30 KM/H. SET THE IGNITION SWITCHOF THE VEHICLE TO BE HAULED TO «ACC» DURING HAULAGE OPERATIONS. NEV-ER REMOVE THE KEY OR SET THE IGNITION SWITCH TO «LOCK» DURING HAULAGEOPERATIONS. FAILURE TO OBSERVE THIS PRECAUTION MAY CAUSE LOSS OFCONTROL 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 SUDDENMOVEMENTS.

• CONNECT THE TOWING ROPE, CABLE OR SIMILAR ITEMS ONLY TO THE HOOKS ONTHE VEHICLE BODY. IF THE TOWING ROPE, CABLE OR SIMILAR ITEMS ARE CON-NECTED TO PARTS OTHER THAN THE HOOKS PROVIDED, THIS COULD SERIOUSLYDAMAGE THESE COMPONENTS.

• CHECK THAT THE HOOKS ARE FIRMLY FIXED TO THE VEHICLE BODY BEFORESTARTING 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. For models with four wheel drive (4WD) move the central differential locking switch to the free position.N.B.


N GEN - 11

• IF THE ENGINE DOES NOT START, CHECK THAT THE CENTRAL DIFFERENTIALLOCKING DEVICE IS FREE, LIFTING ONE OF THE WHEELS AND CHECKING THATTHESE TURN FREELY. ALSO IF THE DIFFERENTIAL LOCKING CHECKING DEVICEWARNING 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


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

The maintenance specifications are indicated in bold type or underlined. Make sure to check the relevant

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)


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.


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 tooling09751-36011-000 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).

The Electronic Control Unit of the vehicle complies

with the ISO protocol 14230 (Euro-OBD). Regard-

ing the position, the configuration of the connector

and the terminal pre-installation, the DLC complies

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.


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 pull or press connectors during the 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

with sharp edges to prevent possible malfunctions.

(A) Correct

(B) Incorrect


N GEN - 16

- In the case of guides or references which indicate

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)


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 THEPROPER 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

of connector: a push-piece opening, traction open-

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.

Connect the male connector to the female connector. Make sure that the lock is 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.


N GEN - 18

Disconnection of terminal with metal lock

- Press the indicated lever in the figure with a small

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 THENEGATIVE (-) AND POSITIVE (+) LEADS FROM THE BATTERY POLES, SHOULDTHERE BE ANY DIFFICULTIES IN REMOVAL.

Clean the battery poles and lead terminals with a cloth.


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.


N GEN - 20

INDEX OF TOPICS

CHARACTERISTICS CH

Identification

Chassis Identification

(1) Manufacturer's label.

(2) Chassis identification number

Manufacturer label:

A - Type-approval number B - Vehicle Identifica-

tion Number C - Technically permissible maximum

total weight D - Vehicle plus trailer 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 Identification:

(3) Engine identification number

(4) Type of engine

Engine number and type

- The engine number is stamped on the cylinder block.

- the engine type is indicated by the letters stamped on the cylinder block

Characteristics PORTER 1.3 16V

CH - 22

VEHICLE CODE BODYWORK

S85LP-TRME Standard loading deck (Pick ) Long

loading deck (Big deck),

S85LP-TRME Tilting loading deck (Tipper)

S85LV-ZBRME Van (Blind Van)

S85LV-ZNDME 4-seat glass van (Glass van)

S85LV-TRMCE Chassis

VEHICLE MODEL CODE

The code of the vehicle model is assigned according to the following specifications:

E: EFI specifications (Electronic Fuel Injection) HC-ES E/G

M: 5-gear manual mechanical transmission

R : Standard D : De luxe

ZB : VAN ZN : GLASS VAN T : TIPPER PICK UP

V : VAN P : PICK-UP

L: LEFT GUIDE R : RIGHT GUIDE

S85: HIJET model

CODICE ABBIGLIAMENTO VANSpecification Desc./Quantity

LV Pelle cloruro di vinileLV YR: Semi tessutoS2 Grigio

CODICE ABBIGLIAMENTO PICK-UPSpecification Desc./Quantity

LU Pelle di cloruro di vinileLU YZ: Semi tessutoS2 Grigio

VAN MODEL BODYWORK COLOUR CODESpecification Desc./Quantity

W10 WhiteB24 BlueR16 REDG15 Metallic greenS13 Metallic dark greyA01 Dark blue

PICK-UP MODEL BODYWORK COLOUR CODESSpecification Desc./Quantity

W10 WhiteB24 BlueR16 REDA01 Dark blue

Characteristics

KINEMATIC CHAIN SPECIFICATIONS

PORTER 1.3 16V Characteristics

CH - 23

CLUTCHSpecification Desc./Quantity

Engine - transmission mechanism Engine - clutch - transmissionType Dry single disc

TRANSMISSIONSpecification Desc./QuantityForward gear Continue drive gearReverse gear With sliding gears

First gear Ratio 3.769Second gear Ratio 2.045

Third gear Ratio 1.376Fourth gear Ratio 1.000 (-)Fifth gear Ratio 0.838

Reverse gear Ratio 4.128Reducer ratio 1.23 (27/22)

DIFFERENTIAL UNITSpecification Desc./QuantityBevel gear pair Crown / Pinion

Gear ratio 4.444 (40/9)

WHEEL ADJUSTMENTSpecification Desc./Quantity

Toe-in 2.0 +1.5 / -1.0 mmCamber 1°23' + 40' / - 50' (Deck)

1°00' + 40' / - 50' (Van)Caster angle 3°13' ± 1° (Deck)

3°02' ± 1° (Van)Kingpin inclination angle 10°49' ± 1° (Deck)

11°25' ± 1° (Van)Rear axle Semi-floating

STEERINGSpecification Desc./Quantity

Wheel outside diameter (mm) 370Steering wheel turns 4.1

Steering Housing gear Pinion and rackInternal steering angle (°) 36.0External steering angle (°) 34.8

BRAKESpecification Desc./QuantityFront brake disc brakeRear brake drum brake

Main brake cylinder (mm) Inside diameter 19.05Front wheel brake cylinder (mm) Inside diameter 51.10

Rear brake cylinder (mm) Inside diameter ø 17.46Parking brake Mechanical functioning acting on the rear wheels.

SUSPENSIONSpecification Desc./Quantity

Front suspension Independent, McPherson type, with suspension arms andstruts fitted on silent-block.

Rear suspension Rigid semifloating axle.Front shock absorber spring Helicoidal typeRear shock absorber spring semi-elliptical leaf spring

Shock absorber Telescopic double-acting


CH - 24

PASSENGER PROTECTION DEVICESpecification Desc./Quantity

Front safety belt 3 points, with ELR

GLASSSpecification Desc./Quantity

Front windshield glass LaminatedFront windshield glass 5.3 mm thickness

MOTORESpecification Desc./Quantity

Tipo HC - ES E/G a benzina, raffreddamento ad acqua 4 cicliN. cilindri e posizione 4 cilindri allineati, montati longitudinalmente

Meccanismo della distribuzione trasmissione a cinghia, SOHCAlesaggio x corsa (cm) 76,0x71,4

Cilindrata (cm3) 1295Potenza massima (kW/giri) 48,0/4800Coppia massima (Nm/giri) 99/2800

Messa in fase dell'accensione (°) BTDC 3 ± 2Sistema di accensione ESA (Anticipo Accensione Elettronica)Ordine d'accensione 1-3-4-2

Candela NGK BKUR6EKDENSO K20PTR-S

Velocità al minimo (giri/min) 900 ± 50Registrazione delle valvole (°) Aspirazione Aperta: 1° prima del P.M.S.

Chiusa: 39° dopo il P.M.I.Registrazione delle valvole (°) Scarico Aperta: 42 prima 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 ± 0,05Sistema di lubrificazione lubrificazione forzata

Pompa dell'olio tipo a trocoideCapacità olio motore Complessiva: 4,2 lCapacità olio motore Al cambio dell'olio: 3,5 lCapacità olio motore Al cambio dell'olio e del filtro dell'olio: 3,7 l

Raffreddamento ad acqua, del tipo a elettromotoreTipo di radiatore Alette e TubiCoolant circuit 5,7 (l) heater circuit and expansion tank included.

Pompa dell'acqua centrifuga, azionata da cinghia trapezoidaleTermostato a cera (84°C)

Pompa del combustibile ElettromotoreFiltro del combustibile Carta da filtro

CAPACITÀSpecification Desc./Quantity

Serbatoio del carburante Capacità (Pick Up): 35 lSerbatoio del carburante Capacità (Van): 33 l

IMPIANTO ELETTRICOSpecification Desc./Quantity

1 Alternatore trifase a corrente alternata del tipo a commutazione2 Potenza sviluppata (V-A) alternatore 12-503 Regolatore di tensione IC Regolatore4 Potenza (V-kw) motorino avviamento 12-0,8

Van


CH - 25

Pick-Up


CH - 26

Tightening torques

ENGINEName Torque in Nm

Cylinder head - Water outlet joint 15÷22Cylinder head - Water temperature sensor 24.5 ÷ 34.3

Water pipe - Radiator electric fan thermal switch 20÷30Cylinder block - Water pump 15 ÷ 22

Cylinder block - Water inlet joint 6 ÷ 9Catalytic converter - Muffler 39 ÷ 54

Exhaust pipe - Catalytic converter 42 ÷ 56Exhaust manifold - Front exhaust pipe 42÷620X1 Oxygen sensor - Exhaust manifold 29.4 ÷ 39.20X2 Oxygen sensor - Exhaust manifold 29.4 ÷ 39.2

Oxygen sensor - Exhaust manifold 29÷39Cylinder head - Exhaust manifold 35 ÷ 53

Cylinder head - Inlet manifold 15 ÷ 22Inlet manifold - Fuel delivery pipe 6÷11

Inlet manifold - EGR pipe 15÷22Inlet manifold - EGR valve 15÷22

EGR valve - EGR pipe 47÷71Inlet manifold - Throttle body 15÷22

Fuel tank - Canister bleed valve bracket 3.9 ÷ 6.9Camshaft sensor - Cylinder head 15÷22

Oil sump - Cylinder block 7÷12Oil filter - Cylinder block 15÷22

Oil pump - Cylinder block 6÷9Cover - Oil pump 8÷13

Oil pressure switch - Cylinder block 12÷20Oil sump - Cylinder block 7÷12

Oil pump body - Oil pump cover 8÷13Oil pump - Oil pressure switch 12÷20

Intake pipe for oil in sump - Oil sump 15 - 22Cylinder block - Oil pump 6÷9

Clutch cover 15÷22Connecting rod - Connecting rod cap 34÷44

Engine shaft - Camshaft control belt pulley 15÷22Crankshaft - Crankshaft belt pulley 88÷98

Crankshaft - Flywheel 78÷98Cylinder block - Rear bottom plate 10÷15Cylinder block - Generator bracket 34÷49

Cylinder block - Transmission 49÷69Cylinder block - Rear oil seal ring 6÷9Cylinder block - Main bearing cap 44 ÷ 54

Cylinder head - Cylinder block 59÷67Cylinder head - M 8 Camshaft 13÷17

Cylinder head - M 10 Camshaft 29÷36Cylinder head - Cylinder head cover 9 ÷ 13

Cylinder head - Spark plug 15 ÷ 22Valve adjustment lock nut 17 ÷ 22

Timing system pulley screws 15÷22Crankshaft - timing system pulley screw 88 ÷ 98

Timing system belt tensioner 29÷44Crankshaft pulley - transmission screws 20÷29

Timing belt cover screw 2÷4Cylinder head cover - Ignition coil 6÷11

Generator fixing screws - M8 18÷22Generator fixing screws - M10 28÷32

Fuel filter fixing nut 34 ÷ 43Cover - Thermostat 5.9 ÷ 8.8

Radiator - Water thermal switch 24.5 ± 5Generator shaft fixing nut: 110

Generator - Pulley 80


CH - 27

BODYWORKName Torque in Nm

Muffler front pipe - Exhaust joint 39.2 ÷ 53.9Instrument panel support - Chassis 18 ÷ 28

Rear seat safety belt - Chassis (external) 28.4 ÷ 53.0Rear seat safety belt - Chassis (internal) 28.4 ÷ 53.0Front seat safety belt - Chassis (inside) 28.4 ÷ 53.0

Radiator protection bar - Chassis 28.4 ÷ 53.0Front seat - Seat slide tracks 14.7 ÷ 23.5

Adjustable seat back regulator - Front seat 22.6 ÷ 44.1Engine compartment cap - Chassis 9.8 ÷ 15.7

Front seat back - Front seat 18.6 ÷ 30.4Tail door support - Tail door 17.7 ÷ 23.5Door stop plate - Chassis 20 - 30

BRAKE SYSTEMName Torque in Nm

LSPV brake calibrator - Rear axle 10 ÷ 16LSPV brake calibrator - Bracket 15 ÷ 22Parking brake cable - Chassis 4.0 ÷ 6.8

Disc brake dust guard - Wheel hub articulation 39.3 ÷ 53.9Front hub or drum - Front axle shaft or front axle 176.6 ÷ 215.7

Disc brake calliper - Disc brake dust guard 49 ÷ 59Brake disc dust guard - Wheel hub joint 39.3 ÷ 53.9

Power brake - Pedal assembly plate 17.7 ÷ 21.5Brake calibrator - Brake pipe 13 ÷ 18

Brake pipe - Wheel brake cylinder 12.8 ÷ 17.6Wheel cylinder - Bleed cap 6.9 ÷ 9.8

Supporting plate - Wheel cylinder 9.9 ÷ 12.7Main cylinder - Pedal bracket 29.5 ÷ 44.1

Brake pipe joint - Brake cylinder 10 ÷ 12

STEERING AND SUSPENSIONSName Torque in Nm

Tie rod head - Articulated arm 39 ÷ 54Tie rod head - Tie rod head lock nut 34.3 ÷ 53.9

Central arm - Tie rod head 39.3 ÷ 53.9Central arm - Front suspension cross-member 111.7 ÷ 137.3

Longitudinal rod end - Longitudinal rod 68.6 ÷ 88.2Rack guide protection lock nut - Steering rack housing 34 ÷ 44

Steering rack - Steering rack No. 1 49.0 ÷ 68.6Steering rack housing - Body 53.9 ÷ 68.6

Flexible coupling - Steering pinion flange 9.8 ÷ 15.7Flexible coupling - Intermediate shaft 9.8 ÷ 15.7

Universal joint 19.6 ÷ 29.4Flywheel - Steering shaft 29.4 ÷ 39.2Nut - Leaf spring shackle 29.4 ÷ 49.0U-bolt - Leaf spring buffer 44 ÷ 54

Spring support pin - Leaf spring assembly. 88 ÷ 108Rear axle shaft housing - Rear shock absorber (lower part) 34.3 ÷ 53.9

Rear shock absorber - Chassis (upper part) 34 ÷ 54Shoe holding plate - Rear axle shaft housing 63.7 ÷ 70.4Shock absorber - Front suspension support 49.0 ÷ 69

Steering joint - Front shock absorber 78.5 ÷ 98Brake dust guard - Steering joint 39.2 ÷ 53.9

Tie rod head - Steering joint 39.2 ÷ 53.9Suspension lower arm - Steering joint 73.5 ÷ 93

Strut bracket body 39 ÷ 54Cross-member - Suspension lower arm 78.5 ÷ 98.0Strut bracket - Suspension lower arm 69 ÷ 88

Castle nut - Front axle hub 177.0 ÷ 216.0Wheel rim nuts - Wheel hub 88 ÷ 118

Rack spring cap 7


CH - 28

PROPELLER SHAFT AND DIFFERENTIALName Torque in Nm

Differential flange - Propeller shaft 39÷54Differential 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÷54Filler cap - Differential cover 39.2 - 49.00

Differential cover - Differential housing 8.5 ± 2Differential housing - Crown gear 66.5 - 73.5

* Value to be determined according to pinion bearing preloading.

GEAR RETAINERSName Torque in Nm

Propeller shaft - Rear differential flange 39÷54Clutch lower cover - Gearbox 4÷7

Direct connection bolt - Transmission 49÷69Engine rear bracket - Gearbox 29÷44Rear bearing lock - Gearbox 15÷22

Gear control fork shaft screw - Clutch housing 19÷30Reverse lever - Gearbox 15÷22

Inlet shaft bearing locking plate - Clutch housing 15 ÷ 22Gearbox - Oil filler cap 29 ÷ 49

Gearbox - Cover 29 ÷ 44Clutch housing - Gearbox 15 ÷ 22

Rpm indicator locking plate - Gearbox cover 7 ÷ 10Reverse limiting shaft screw - Gearbox 19 ÷ 22

Gearbox cover - Gearbox 15 ÷ 22Reverse limiting pin lock - Gearbox 29 ÷ 49

Lock nut - Main shaft 177÷216Reverse transmission gear shaft screw - Gearbox 19 ÷ 31

Rear engine support bracket - Chassis 49 ÷ 69

CLUTCH RETAINERSName Torque in Nm

Brake pedal - Brake pedal support 15÷22Clutch cover - Flywheel 15÷22

Vehicle overhaul data

Cylinder-piston oversizes

CYLINDER CLOCKSpecification Desc./Quantity

Cylinder - standard diameter (mm) 76.000 ÷ 76.030Cylinder diameter - 1st oversize (mm) 76.250 ÷ 76.280

Finishing angle of the liner 35° ± 5°Roughness 1 - 4Z

PISTONSpecification Desc./Quantity

Standard diameter piston (mm) 75.965 ÷ 75.9951st oversize diameter piston (mm) 76.215-76.245

Cylinder - Piston standard clearance (mm) 0.025 ÷ 0.045Maximum clearance between Cylinder - Piston (mm) 0.11

Clearance between piston and pin (mm) 0.005 - 0.011


CH - 29

Piston ring oversizes

OPENING CLEARANCE AFTER USE - PISTON RINGSSpecification Desc./Quantity

Piston ring max. clearance «1» (mm) 0.7Piston ring max. clearance «2» (mm) 0.8

Max. clearance between piston ring «3» and oil scraper (mm) 1.0

STANDARD OPENING - PISTON RINGSSpecification Desc./Quantity

Piston ring «1» (mm) 0.27 ÷ 0.37 with reference letter «T»Piston ring «1» (mm) 0.27 - 0.40 with reference letter «N»Piston ring «2» (mm) 0.45 - 0.55

Oil scraper ring «3» (mm) 0.20 - 0.60 (mm) - type «A»Oil scraper ring «3» (mm) 0.15 - 0.60 (mm) - type «B»

THICKNESS - PISTON RINGSSpecification Desc./Quantity

Compression piston ring «1» (mm) 1.17 ÷ 1.19Compression piston ring «2» (mm) 1.47 ÷ 1.49

Piston ring max. clearance «C» (mm) 0.12

Piston - Pin

PINSpecification Desc./Quantity

Pin outside diameter (mm) 18.994-18.997Pin coupling interference - Rod small end (mm) 0.015 ÷ 0.044

Crankshaft - Rod head

CRANKSHAFTSpecification Desc./Quantity

Connecting rod pin bearing diameter (mm) 49.976 - 45.000Main journal bearing diameter (mm) 49.976 - 50.000

Connecting rod pin standard coupling clearance (mm) 0.020 - 0.044Main journal standard coupling clearance (mm) 0.024 - 0.042

Connecting rod pin maximum coupling clearance (mm) 0.050Main journal maximum coupling clearance (mm) 0.050

Standard axial clearance (mm) 0.02 - 0.20Maximum axial clearance (mm) 0.30

Maximum eccentricity clearance (mm) 0.06

CONNECTING RODSpecification Desc./Quantity

Rod small end standard diameters (mm) 18.953-18.979Connecting rod head standard diameters (mm) 48 000 - 48.024

Connecting rod head axial clearance (mm) standard 0.15-0.40Connecting rod head axial clearance (mm) Maximum limit. 0.45

Maximum off-line (mm) 0.05Maximum torsion (mm) 0.05


CH - 30

Valve guide - Valve stem

VALVESSpecification Desc./Quantity

Valve stem diameter (mm): Intake valve: 6.6 -0.020-0.040Valve stem diameter (mm): Outlet valve: 6.6 -0.025-0.045

Valve length: (mm) Intake valve: 112.8Valve length: (mm) Outlet valve: 114.5

Valve base thickness: (mm) Intake valve: 0.8Valve base thickness: (mm) Outlet valve: 1.0

Stem - guide coupling clearance (mm) Intake valve: Standard 0.020 - 0.055Stem - guide coupling clearance (mm) Maximum limit: 0.080Stem - guide coupling clearance (mm) Outlet valve: Standard 0.025 - 0.060Stem - guide coupling clearance (mm) Maximum limit: 0.090

Valve seat angle (°) 45.5°

Tappets

VALVE CLEARANCESpecification Desc./Quantity

Intake valve clearance (mm) 0.25 ± 0.05 [hot engine]Outlet valve clearance (mm) 0.33 ± 0.05 [hot engine]

Distribution timing Intake - Open - 1° before TDCDistribution timing Intake - Closed - 39° after BDCDistribution timing Outlet - Open - 42° before TDCDistribution timing Outlet - Closed - 2° after BDC

ROCKING LEVERS AND PINSSpecification Desc./Quantity

Rocking lever hole diameter (mm) 19.500-19.521Rocking lever pin outside diameter (mm) 19.468 ÷ 19.488Rocking lever standard clearance (mm) 0.015 ÷ 0.053

Maximum limit (mm): 0.08Unloaded width (mm) 22.00

Valve spring

VALVE SPRINGSSpecification Desc./Quantity

Valve spring unloaded length (marked in ORANGE) 47.4 mmValve spring unloaded length (marked in PINK) 45.2 ± 0.5 mm

Valve spring minimum unloaded length (marked in ORANGE) 46.1 mmValve spring minimum unloaded length (marked in PINK) 43.9 mm

Valve spring preloading (marked in ORANGE) 208.9 N to 38.0 mm (Standard fitting height)Valve spring preloading (marked in PINK) 244.9 N to 38.0 mm (Standard fitting height)

Obliquity maximum limit (mm) 1.6

Camshaft

CAMSHAFTSpecification Desc./Quantity

Camshaft maximum eccentricity 0.03 mmCamshaft bearing coupling clearance (mm) 0.035 ÷ 0.076

Camshaft bearing maximum coupling clearance (mm) 0.17Camshaft axial clearance (mm) 0.1 ÷ 0.25

Camshaft maximum axial clearance (mm) 0.45


CH - 31

Specification Desc./QuantityIntake cam standard height (mm) 33.435 ÷ 33.634Intake cam minimum height (mm) 33.2Outlet cam standard height (mm) 33.17 ÷ 33.37Outlet cam minimum height (mm) 33.0

Testata motore - montaggio e serraggio

INLET - EXHAUST MANIFOLDSpecification Desc./Quantity

Unevenness (mm) 0.1

CYLINDER HEADSpecification Desc./Quantity

Cylinder block side unevenness (mm): 0.10Inlet manifold side unevenness (mm): 0.10

Exhaust manifold side unevenness (mm): 0.10Inlet valve seat angle (mm) 30° ÷ 45° ÷ 70°

Exhaust valve seat angle (mm) 20° ÷ 45° ÷ 70°

TIMING SYSTEM SHAFT PULLEYSpecification Desc./Quantity

Timing system shaft pulley diameter (mm) 119.94Timing shaft pulley wear limit 119.8

CRANKSHAFT PULLEYSpecification Desc./Quantity

Crankshaft pulley diameter (mm) 59.37Crankshaft pulley wear limit (mm) 59.3


CH - 32

INDEX OF TOPICS

SPECIAL TOOLS ST

Tooling

INJECTION SYSTEM TOOLStores code Description

020680Y Srumento diagnosi - Navigator

020682Y Cablaggio interfaccia EOBD - Navigator

020460Y Diagnostic tester

020463Y ECU-EFI interface cable harness tocheck the injection system electrical val-

ues.

020618Y Cable harness for connecting the OBDConnector and the Diagnostic Tester

020469Y Reprogramming kit for Diagnostic tester

Special tools PORTER 1.3 16V

ST - 34

Stores code Description020492Y CD Software Porter 1300 16V

020331Y Digital multimeter

020274Y Checking tool kit

020400Y Fuel pressure checking kit

020275Y Cable harness to check fuel injection

ENGINE TOOLStores code Description

020180y Engine support

020387Y Tool to remove or replace the valve guidebushing

PORTER 1.3 16V Special tools

ST - 35

Stores code Description020401Y Clutch guide tool (clutch fitting)

020398Y Punch (sealing ring fitting)

020388Y Box-spanner for spark plugs (Spark plugremoval and refit)

020382Y Tool to remove the valve cotters

TRANSMISSION TOOLStores code Description

020206y Bearing extractor

CLUTCH TOOLStores code Description

020195y Tool kit to align the diaphragm spring

020196y Clutch guiding tool

020197y Instrument to measure the height of theclutch diaphragm spring


ST - 36

DIFFERENTIAL TOOLStores code Description

020293y 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 locking tool


ST - 37

Stores code Description020211y Flange oil seal extractor

020206y Bearing extractor

BRAKE TOOLStores code Description

020221y Brake drum stop device

020222y Front hub and drum extractor

FRONT SUSPENSION TOOLStores code Description

020224y Connecting rod bushing extractor andchanger

020235y Front spiral spring compressor

020231Y Tie rod head extractor


ST - 38

Stores code Description020188y Axial hub support and driving pinion tool

series - Front axle bearing and differentialpinion replacement kit

020222y Front hub and drum extractor

020221y Brake drum stop device

020223y Extractor and changer for front suspen-sion arm bushing

REAR SUSPENSION TOOLStores code Description

020227y Rear wheel bearing extractor

020226y Rear axle shaft extractor

020225y Buffer to fit the rear bridge bearing


ST - 39

Stores code Description020201y Gear bearing fitting punch

0.20222y Front hub and drum extractor

0.20200y Oil seal extractor

STEERING TOOLStores code Description

020177y Pinion bearing replacement kit

020196y Clutch guiding tool

0.20228y Rear conical tool to replace the differen-tial control pinion bearing

0.20229y Roller bearing extractor and tool to re-place the oil seal


ST - 40

Stores code Description0.20230y Tool to replace the differential control pin-

ion bearing

020231Y Tie rod head extractor


ST - 41

INDEX OF TOPICS

MAINTENANCE MA

Scheduled maintenance chart

SCHEDULED MAINTENANCE TABLEI: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY; C : CLEAN; R : REPLACE; A : ADJUST;L : LUBRICATE* Check level every 5,000 km ** Replace every 2 years

km x 1,000 10 20 30 40 50 60 70 80 90 100 110 120Safety clamps I I I I I I I I I I I IEngine oil * R R R R R R R R R R R RGearbox Oil R R RDifferential Oil R R ROil filter R R R R R R R R R R R RAir filter C C C R C C C R C C C RFuel filter R RCoolant level ** I I I I I I I I I I I IBrake fluid level ** I I I I I I I I I I I IGenerator belt I I I I R ITiming belt RIdle speed - Enginetiming

I I I I I I

Ignition spark plug I I I I I IValve clearance I I IAccelerator control I I I I I IClutch control I I I I I IFuel hoses I I IOil vapour recoverypipe (blow by)

I I I

Suspensions I I ISteering wheel I I I I I IBrake pedal and park-ing brake lever

I I I I I I

Parking brake cable I I I I I IBrake flexible hoses I I I I I IBrake drum - Brakegasket

I I I

Brake disc - Brakepads

I I I

Radiator - Cooling sys-tem hoses

I I I I

Transmission (lubrica-tion)

L L L L L L

Electrical system andbattery

I I I I I I I I I I I I

Headlight aiming A A A A A ATyre pressure andwear

I I I I I I I I I I I I

Test drive I I I I I I I I I I I IOPERATION TIMES 115' 240' 115' 265' 115' 240' 115' 265' 115' 240' 115' 265'

EVERY 2 YEARSSpecification Desc./Quantity

Brake fluid ReplacementCoolant Replacement

EVERY 4 YEARSSpecification Desc./QuantityServo brake Operation

PORTER 1.3 16V Maintenance

MA - 43

Suggested products chart

PRODOTTI CONSIGLIATIProduct Description Specifications

AGIP ROTRA MP 80W-90 Oil with specifications SAE 80W-90, APIGL-5

Gearbox oil

AGIP BRAKE FLUID DOT4 Brake fluid FMVSS DOT 4AGIP GREASE PV 2 Multipurpose grease NLGI 2 specifications; ISO-LXBIB2

AGIP ARNICA 46 Oil for hydraulic tilting system pump Oil for hydraulic systems in compliancewith ISO VG 46, DIN 51524 HVLP

AGIP SUPERDIESEL MULTIGRADE15W-40

Engine oil SAE 15W-40, API CF-4/SG

AGIP SINT EVOLUTION Olio motore (indicato per climi freddi) SAE 5W-40, API SL, ACEA A3

Engine assemblyN.B.

• ADJUSTMENTS OR SERVICES DESCRIBED IN THIS SECTION ARE CARRIED OUT ASA GENERAL RULE WHEN THE ENGINE IS HOT.

• A "HOT ENGINE" MEANS THAT CONDITION IN WHICH THE COOLING FAN HAS BEENACTIVATED AT LEAST ONCE.

• CHECK THAT ALL THE ACCESSORY SWITCHES ARE SET TO OFF.• THE GEARSHIFT LEVER SHALL BE IN NEUTRAL.• PULL THE HANDBRAKE ALL THE WAY.• POSITION THE STEERING WHEEL SO THAT THE WHEELS ARE PERFECTLY

ALIGNED.• CHECK THAT THOSE PARTS REMOVED FOR ADJUSTMENTS OR CHECKS ARE RE-

FITTED.

Air filter

1. Remove the filtering element from the air filter

housing.

2. Visually inspect the filtering element and check

that it is not too dirty, damaged or oily. If necessa-

ry, replace the filtering element.

3.Blow compressed air over the entire lower sec-

tion A of the filtering element. Then, do the same

with the upper section B.

4.Refit the filtering element into the filter housing.

Close the housing.

Maintenance PORTER 1.3 16V

MA - 44

Engine oil replacement

Engine oil level check

Check that the engine oil level is between the

«L» and «F» marks on the dipstick to check oil

level.

If the oil level is below the reference mark «L», top

up with recommended oil until the reference mark

«F» is reached. Make sure that there are no leaks.• USE SPECIFIC OIL OR OIL WITH A HIGHER

COEFFICIENT OF VISCOSITY.• THE QUANTITY OF OIL BETWEEN THE "L"

AND "F" REFERENCE MARKS IS EQUIVA-LENT TO APPROX. ONE LITRE.

CharacteristicEngine oil capacity at «MAX» level3.5 l ("F" level)

Engine oil capacity at «MIN» level2.5 l ("L" level)

Engine oil capacity (engine sump + filter)3.7 l

Total engine oil capacity4.2 l

Oil quality check

Check that the engine oil is not deteriorated, dis-

coloured or diluted, and that there is no water

infiltration.N.B.

• PARK THE VEHICLE ON A LEVEL SURFACE.


MA - 45

Engine oil change and filter replacement

1. Shut off the engine after warming it up for a few

minutes; remove the protection cover;

2. Remove the oil drainage plug and empty the

engine sump;

3. Remove the oil filter with a suitable wrench;

4. Check and clean the filter fitting surface.

5. Apply engine oil on the sealing ring of the new

filter before fitting it.

6. Finger screw the oil filter until the sealing ring

makes contact with the filter fitting surface.

7. Tighten the oil filter 3/4 of a turn with a filter

wrench

8. Clean the oil drainage plug. Fit the plug and

place a new gasket in between.- REMOVE GASKET WASTE OFF THE OIL SUMP USING ASUITABLE SCRAPER.

9. Pour oil in the engine until the maximum level in

the oil dipstick is reached.

10. Start the engine and check that there are no

leaks.

11. Stop the engine.

12. Check the level again and top up, if necessary.

Leaks

Check that there are no oil leaks from the gasket.

Gear-box oil replacementSostituzione olio cambio

Gearbox oil change

1. Remove the drainage plug and the filler cap.

Drain the gearbox oil.

2. Refit the drainage plug and place a new gasket in between.

3. Top up with recommended oil until it starts to come out through the fill opening.

Recommended productsAGIP ROTRA MP 80W-90 Transmission oil


MA - 46

SAE 80W-90, API GL-5

4. Refit the filler cap and place a new gasket in between.

Locking torques (N*m)Gearbox cover for filler cap 30 ÷ 49

Oil leaks

Check the gearbox for oil leaks.

Check the gearbox oil level.

1. Remove the filler cap.

2. The gearbox oil level must reach the level in-

spection hole or should be below 5 mm.

Differential oil 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 until it starts to come out through the fill opening.

Recommended productsAGIP ROTRA MP 80W-90 Differential oil

SAE 80W-90, API GL-5

4. Refit the filler cap and place a new gasket in between.

Locking torques (N*m)Differential oil cap 39 ÷ 59 Nm

Oil leak

Check that the differential does not leak oil.


MA - 47

Coolant replacement

Check

Check that the coolant level is between the MINI-

MUM and the MAXIMUM reference notches in the

auxiliary reservoir. If the coolant level almost rea-

ches the minimum or is below the MINIMUM level,

add coolant until the MAXIMUM level is reached.• NEVER REMOVE THE RADIATOR CAP WHILE

THE ENGINE STILL HOT. FAILURE TO OB-SERVE THIS SAFETY MEASURE MAY CAUSEBURNS.

N.B.• IF THERE IS NO COOLANT IN THE AUXILIARY

RESERVOIR OR IF THE FLUID LEVEL IS TOOLOW, CHECK THERE ARE NO WATER LEAKSUSING THE APPROPRIATE TESTER.

• THE COOLANT SHOULD HAVE A SUITABLEANTIFREEZE DEGREE.

N.B.• USE A TOP QUALITY ETHYLENE GLYCOL

BASED ANTIFREEZE SOLUTION.N.B.

• THE QUANTITY INDICATED ABOVE IN-CLUDES THE LITRES FOR THE EXPANSIONTANK.

CharacteristicCoolant reservoir capacity:5.7 litres

Coolant change

NEVER OPEN THE RADIATOR CAP AND/OR THE DRAINAGE PLUG WHEN THE ENGINE IS STILLHOT.

A. Take the heater control lever to "hot".

B. Remove the radiator cap 3.

C. To drain the coolant, remove the drainage plugs

located on the radiator lower reservoir and the ra-

diator pipe.

D. Remove plug 2 on the engine side and plug 1

of the heater bleed pipe on the upper part of the

engine.

E. Insert a pipe in the radiator fill opening. Clean

the radiator internal side. During this operation

keep the engine at idle speed.

F. Shut off the engine. Refit and close the drainage

plugs.


MA - 48

G. Pour coolant in the radiator. When the coolant

starts coming out through hole 2 located on the

engine side and through the heater bleed pipe,

close both openings.

H. Pour coolant until the fluid comes out through

the radiator fill opening.

I. Close the radiator cap 3 completely.

L. Clean the expansion tank internal side. Fill up

with coolant.

M. Start the engine and 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 low, add coolant. Tight-

en plug 2 again.DURING THIS PHASE, NEVER OPEN THE RADIATOR CAP3 SO THAT COOLANT DOES NOT COME OUT THROUGHCAP 2.

KEY:

1. Radiator cap

2. Radiator cap

3. Radiator cap

4. Radiator

5. Engine

P. Check the coolant level in the expansion tank.

Add water until the maximum level is reached. Re-

fit the expansion tank cap.


MA - 49

Leaks

A. Fill up the radiator with coolant. Connect the

tester to the radiator cap.

B. Warm up the engine.

C. Apply a 117 kPa pressure to the cooling system

by means of the tester connected to the radiator

cap.

D. Make sure there are no leaks.

Spark plug

Cable check

1. Disconnect the ignition coil connector. After-

wards, remove the ignition coil by taking out the

fixing nuts.

2. 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 other

damage.

Spark plug check

1. Remove the spark plugs.

2. Spark plug visual inspection.

Visually inspect the spark plug by checking wheth-

er the electrodes are worn and that the thread or

the insulator is damaged. If necessary, replace the

spark plug.

3. Electrode gap inspection.

Measure the electrode gap with the appropriate

thickness gauge.


MA - 50

If the gap between the electrodes of a used spark

plug does not match the specified values, replace

the spark plug with a new one.

If the gap between the electrodes of a new spark

plug does not match the specified values, adjust

the distance by bending the earth electrode base;

pay attention not to touch the central electrode.

CANDELE CONSIGLIATESpecification Desc./Quantity

DENSO K20PTR-S Distanza elettrodi mm: 0,9 ÷ 1,0NGK BKUR6EK 0,9 ÷ 1,0

Settings and Adjustments

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 adjust if necessary.

- Make sure that the following components are

properly fitted: spare wheel, jack, toolkit bag.

- Check level, and if necessary, top-up: engine oil;

gearbox oil; windshield fluid, etc.

- Move the vehicle in different directions so its

weight is proportionally distributed so that the ve-

hicle can take a correct position.

- Cause the engine to run at 1500 rpm or more

during headlamp adjustment.

- Set the headlamp switch to "0".


MA - 51

1. Set a screen three meters away from the head-

lamps.

2. Measure 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 headlamp axes must be 1020 mm.


MA - 52

INDEX OF TOPICS

EMISSION CONTROLO SYSTEM CO EM

Emission check: this section of the manual describes operations and precautions to be followed to check

emissions.

EMISSION CONTROL SYSTEM

Crankcase gas recirculation: A system by means of which the gas generated in the crankcase re-

enters the inlet manifold, instead of being released to the atmosphere, in order to be burned inside the

combustion chamber.

Three-way catalytic converter: A device by means of which hydrocarbons (HC) and carbon monoxide

(CO) contained in exhaust fumes are oxidised, and Nitric oxides (NOx) are deoxidised by the monolithic

catalytic converter, thus minimising HC, CO and NOx emissions that are released into the atmosphere.

Closed-loop control system (EFI) (Electronic Fuel Injection): The closed-loop control system guar-

antees a suitable air-fuel ratio for the engine. It also guarantees optimum quantity of oxygen contained

in the exhaust fumes so as to obtain a high degree of purification of the three-way catalytic converter.

Electronic ignition timing control ESA (Electronic Spark Advance): 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 to engine conditions.

Fuel closing in deceleration (Cut-off): Device that interrupts fuel supply during the deceleration phase

in order to reduce HC and CO emissions. System by means of which Nitric oxide (NOx) emissions are

minimised, thus allowing recirculation of exhaust fumes present in optimum quantity in the inlet manifold

according to engine conditions.

Fuel vapour emission check: System by means of which hydrocarbons (HC) released by the fuel tank

are absorbed by an activated carbon filter (CANISTER), thus preventing the emission of hydrocarbons

(HC) into the atmosphere.

HC: Hydrocarbons

CO: Carbon monoxide

NOx: Nitric oxides

Disposizione componentiCOMPONENT LAYOUT

1. Activated carbon filter

2. Vacuum switching valve for bleeding

3. Oil filler cap

4. Atmospheric opening

5. Activated carbon filter

6. VSV (vacuum switching valve) for EGR (exhaust gases recirculation)

7. EGR vacuum modulator

8. EGR (exhaust gases recirculation) valve

9. Throttle body

10. Bleed opening

Emission Controlo System PORTER 1.3 16V

CO EM - 54

11. EGR (valve ) opening

12. To the fuel tank

13. To the fuel tank

14. Atmospheric opening

A = Crankcase gas recirculation system

B = Fuel vapour control system

Catalizzatore

Catalytic converter

A cylindrical three-way catalytic 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 simultane-

ously in a single unit. When the exhaust emissions

are purified by the three-way catalytic converter,

the purification characteristics mainly depend on

PORTER 1.3 16V Emission Controlo System

CO EM - 55

the engine air-fuel ratio. That is to say, when the

air-fuel ratio is lean, the quantity of oxygen after

combustion increases. Oxidation becomes active

while reduction becomes inactive . Instead, when

the air-fuel ratio is rich, oxidation becomes inactive

while reduction becomes active. It is therefore nec-

essary to keep the air-fuel ratio constantly within

the limits of the stoichiometric air-fuel ratio. This

can be obtained with the Electronic Control Unit,

according to the signals by the oxygen sensors,

both front and rear.

Cr = Low - Purification ratio (%) - High

Mr = Rich - Air-fuel ratio - 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 evaporated from the fuel feed circuit are reduced. During

operation, vapours that form in the fuel tank enter the activated carbon filter. Carbon absorbs fuel va-

pours, keeping them in the filter. When the throttle valve is opened during engine operation, the manifold

vacuum acts on the activated carbon filter. In this way, the fuel vapours captured, together with clean

air, are carried into the throttle body to be burned. In the figure, the full arrows show the clean air path

whereas the dotted arrows show the fuel vapours path.


CO EM - 56

CONTROL SYSTEM DIAGRAM

A. Electronic control unit of the electronic fuel injection

B. Vacuum switching valve - evaporation

C. Air filter

D.Throttle body

E. Filter

F. Activated carbon filter

G. bleed checking valve - evaporation

H. Carburettor chamber

Engine off

High tank pressure: Hydrocarbon emissions are absorbed by the activated carbon filter (only valve 2

open)

Average tank pressure: The activated carbon filter captures hydrocarbon emissions (All valves closed)

Low tank pressure:

The 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 operation with the accelerator pedal pushed

High tank pressure: Hydrocarbon emissions absorbed by the activated carbon filter are sucked in by

the engine (only valve 2 open)

Average tank pressure: Hydrocarbon emissions absorbed by the activated carbon filter are sucked in

by the engine (only valve 2 open)

Low tank pressure: Hydrocarbon emissions absorbed by the activated carbon filter are sucked in by

the engine (only valve 2 open)


CO EM - 57

Blow-by ventilation pipe (crankcase vapour re-

covery)

Check that there are no signs of wear or strangling

on the pipe and that it is properly connected.

Fuel closing device during deceleration

The fuel closing device stops fuel supply during deceleration in order to reduce hydrocarbon and CO

emissions, also avoiding catalytic converter overheating.

For HC-ES engines, this device is checked by the program set for the Electronic Control Unit of the

Electronic Fuel Injection.

It is checked when the throttle valve 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-fuel mixture control system

The closed-loop control system guarantees a suitable air-fuel ratio in the engine. Besides, it guarantees

an optimum quantity of oxygen in the exhaust fumes so as to obtain a high degree of purification of the

three-way catalytic converter.

A = Injector

B = Combustion chamber

C = Front oxygen sensor

D = Three-way catalytic converter

E = Rear oxygen sensor

F = Elect. control unit of the elect. fuel injection

G = Engine coolant temperature sensor


CO EM - 58

H = Pressure sensor

I = Intake air temperature sensor

Fuel vapour control device

1. Visual inspection of fuel vapour ducts and

connections.

Check pipes and connections for any leaks, see if

they are entangled or damaged.

2. Visual inspection of the fuel tank.

Check the fuel tank for possible deformations,

cracks or petrol leaks. Replace the fuel tank, if

necessary.- MAKE SURE THAT NEITHER THE ACTIVATED CARBONFILTER FITTING IS REDUCED NOR THE FUEL TANK CAPDAMAGED

3. Fuel tank cap check

Check that the fuel tank cap and the gasket are not

damaged or deformed.

4. Activated carbon filter check

A. Detach the pipe bracket from the activated car-

bon filter.

B. Detach the rubber pipes from the activated car-

bon filter.

C. Remove the activated carbon filter from the ve-

hicle by pulling the filter housing upwards.- BEFORE DETACHING THE RUBBER PIPES, APPLY A LA-BEL ON EACH PIPE SO AS TO REFIT THEM IN THEIRORIGINAL POSITION.


CO EM - 59

D. Visually check the activated carbon filter hous-

ing for breaking or damage. Replace the activated

carbon filter if it is damaged.

E. Check that no air leaks through the activated

carbon filter. Check leaks by injecting compressed

air at 29.4 kPa (0.3 kgf/cm2) into the pipe on the

fuel tank side B with the pipes on bleed side A and

atmosphere side C closed. In case of air leaks, re-

place the activated carbon filter with a new one.

F. Check that there is no reduction in the activated

carbon filter.

a) Check for air continuity in the pipe on the at-

mosphere side C by blowing air into the pipe on

the fuel tank side B with the pipe 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 using the

MityVac device.

If there is no air continuity, replace the activated

carbon filter with a new one.

G. Activated carbon filter cleaning.

Clean the activated carbon filter by blowing com-

pressed air at 294 kPa (3.0 kg/cm2) inside the pipe

on the fuel tank side B with the pipes bleed side of

filter A closed.

H. Fit the activated carbon filter on the vehicle.

I. Reconnect the rubber pipes and refit the new

pipe bracket.- DO NOT TRY TO WASH THE ACTIVATED CARBON FIL-TER.- THE ACTIVATED CARBON MUST NOT COME OUT DUR-ING THE TEST. SHOULD THIS OCCUR, REPLACE THEACTIVATED CARBON FILTER.


CO EM - 60

5. Vapour bleed control valve inspection

A. Disconnect the rubber pipes from the vapour

bleed control valve.- BEFORE DETACHING THE RUBBER PIPES, APPLY A LA-BEL ON EACH PIPE SO AS TO REFIT THEM IN THEIRORIGINAL POSITION.

B. Remove the vapour bleed control valve from the

fuel tank by undoing the relevant fixing bolts.

C. Visually inspect the vapour bleed control valve

for cracks or damage.

If damage of any kind is found, replace the valve

with 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 side,

with the pipe on the activated carbon filter side and

pipes on the atmosphere side closed.

In case of air leaks, replace the valve with a new

one.

E. Check the vapour bleed control valve for reduc-

tions.

a) Check that there is no air continuity in the pipe

on the atmosphere side by blowing air inside the

pipe on the fuel tank side, with the pipe on the ac-

tivated carbon filter side closed.


CO EM - 61

b) Check that there is air continuity in the pipe on

the activated carbon filter side by blowing air into

the pipe on the fuel tank side.

c) Check there is air continuity by applying a neg-

ative pressure to the pipe on the activated carbon

filter side using the MityVac device.

In cases in which there is no air continuity, replace

the valve with a new one.

F. Fit the valve on the upper side of the fuel tank.

I. Reconnect 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 again, if necessary.• AFTER TIGHTENING THE NUTS, CHECK

THAT NO EXHAUST FUMES LEAK THROUGHTHE CATALYTIC CONVERTER FLANGE.

• IF EXHAUST FUME LEAKS ARE DETECTED,REPLACE THE GASKET.

Check that the exhaust pipe attachment is not

loose.

Locking torques (N*m)Catalytic converter fixing nuts 39 ÷ 54

Check that the oxygen sensor (lambda probe) is not loose.

Tighten it, if necessary.


CO EM - 62

N.B.

CHECK THAT NO EXHAUST FUMES LEAK THROUGH THE OXYGEN SENSOR (LAMBDAPROBE) ATTACHMENT.

Locking torques (N*m)Exhaust manifold for oxygen sensor 29.4 ÷ 39.2 Nm

4. Check the oxygen sensor (lambda probe) cable

for signs of cracks or other kinds of damage. If

necessary, replace the oxygen (lambda probe)

sensor with a new one.

5. Check that the oxygen sensor (lambda probe)

connector is properly connected and fixed. Other-

wise, connect and fix the connector properly.

Exhaust emission control system

Fuel vapour emission control device

1. Visual inspection of the connections and the

fuel vapours 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 necessary.N.B.CHECK THAT THE ACTIVATED CARBON FILTER PIPE ISNOT OBSTRUCTED AND THAT THE FILLER CAP HAS NODEFECTS.

CO check

CO/HC concentration check

Arrangements before the CO/HC concentration check.

- Pull the handbrake all the way.

- Check and adjust ignition timing

- Check and adjust idle speed.

- Warm up the engine.

- Take all the accessory switches to OFF.

- Fit the filtering element.

- Connect all the pipes and the low-pressure pipe.

- Check that there are no air leaks in the intake system.

- Check that there are no gas leaks in the exhaust system.


CO EM - 63

- Take the gearshift lever to neutral.

- Position the steering wheel so that the wheels are perfectly straight.

- Prepare the CO/HC meter according to the manufacturer's instructions.

THIS CHECK IS NECESSARY TO DETERMINE IF HC/CO EMISSIONS WITH THE ENGINE AT IDLECOMPLY WITH THE REGULATIONS IN FORCE.

Measure HC/CO emissions by inserting one probe of the meter in the exhaust pipe. Wait for at least

one minute before measuring so that concentrations stabilise. Finish the measurement within three

minutes. If HC/CO concentrations do not comply with the regulations in force, consult the following table

to determine 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. Incorrect valve clearance

3. Exhaust valves with leaks

4. Cylinder with leaks

High Low Irregular idle speed (Fluctua-

tions in reading HC )

1. Lean mixture causing irregular ignition

High High Irregular idle speed (Black

smoke in exhaust pipe)

1. Air filter clogged

2. Defective electronic fuel injection system

- Pressure regulator defective

- Reverse fuel pipe clogged.

- Water temperature sensor defective.

- Air temperature sensor defective.

- Gas position sensor defective.

- Pressure sensor defective.

- Electronic Control Unit defective.

- Oxygen sensor (lambda probe) defective.


CO EM - 64

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Engine

Starting difficulties

DIFFICULT STARTINGPossible Cause OperationPipes clogged Check/replace damaged parts

Fuel filter clogged ReplaceAir in the fuel feed circuit Bleed and check sealsFaulty fuel supply pump Replace

Flat battery Check/ReplaceUnstable battery connections Check and restore contacts

Faulty key switch ReplaceFaulty starter motor Replace damaged parts

Air filter clogged ReplaceInjection advanced Check advance

Black smoke from exhaust

BLACK EXHAUST SMOKEPossible Cause Operation

Incorrect injection pump calibration CheckAir filter clogged ReplaceInjection delayed Check injection advance

White smoke from exhaust

WHITE EXHAUST SMOKEPossible Cause Operation

High oil level Restore the levelPiston rings worn or seized Check/replaceWorn or scored cylinders Check and grind if possible

Worn valve guides Check/Replace

Low oil pressure

LOW OIL PRESSUREPossible Cause Operation

Pressure adjustment by-pass blocked Check/ReplaceWorn oil pump Check/Replace

Air to the oil intake pipe Check/ReplaceFaulty pressure switch Check/ReplaceOil intake pipe clogged Check/Replace

Main bushings/connecting rod worn Check the crankshaft and when possible, recondition it

Increase of oil level

OIL LEVEL INCREASEPossible Cause Operation

Fuel feed injection-pump faulty Replace

Troubleshooting PORTER 1.3 16V

TROUBL - 66

Possible Cause OperationLeak from injection-pump unit Check and replace damaged components

Cylinder-head gasket damaged Replace

Excessive oil consumption

EXCESSIVE OIL CONSUMPTIONPossible Cause Operation

High oil level Restore the levelLow idle Adjust correctly

Piston rings worn or seized Check and replace damaged componentsWorn or scored cylinders Check and replace damaged components

Worn valve guides Check and replace damaged components

Oil and fuel leakage from exhaust

OIL AND FUEL LEAK AT EXHAUSTPossible Cause Operation

Prolonged running at idle Accelerate several times with engine in neutralLow idle Adjust correctly

Piston rings worn or seized Check and replace damaged componentsWorn or scored cylinders Check and replace damaged components

Worn valve guides Check and replace damaged components

Coolant overheats

COOLANT OVERHEATPossible Cause Operation

Piston rings worn or seized Check and replace damaged componentsCylinder-head gasket damaged Replace and check the cooling circuit

Air in the cooling circuit BleedCoolant leaks from the system Check/replace damaged components

Cooling fan damaged Replace

Clutch

Clutch slipping

CLUTCH SLIPSPossible Cause Operation

Discs, pressure plates and flywheel wear Check/replace damaged componentsBelleville spring stretched or damaged Check/replace damaged componentsOil or grease on disc friction material Check and clean

Clutch gripping

ROUGH CLUTCHPossible Cause Operation

External controls hardened Check the control unit components, adjust correctly and re-place damaged components

Deformed clutch disc Check/replace damaged components

PORTER 1.3 16V Troubleshooting

TROUBL - 67

Possible Cause OperationOil or grease on disc friction surfaces Check and clean

Clutch does not disengage and drags

CLUTCH DOES NOT DISENGAGE AND DRAGSPossible Cause Operation

Deformed clutch disc Check/replace damaged componentsExternal controls seized Check the control unit components, adjust correctly and re-

place damaged componentsControls not properly adjusted Adjust

Noisy clutch at engagement and/or disengagement

NOISY CLUTCH WHEN ENGAGING AND/OR DISENGAGINGPossible Cause Operation

Clutch disc with damaged anti-vibration buffer springs Check/replace damaged components

Gearbox

Gears disengage abruptly or are difficult to engage

SPONTANEOUS DISENGAGEMENT AND DIFFICULT ENGAGEMENTPossible Cause Operation

Levers and gear tie rods incorrectly adjusted AdjustControl rod retaining springs fault Replace the springs

Synchroniser coupling teeth or coupling sleeve teeth fault Check/replace damaged componentsIncomplete coupling travel Check the components of the selection and gear engaging unit,

replace damaged components

Gears difficult to engage

DIFFICULT COUPLINGPossible Cause Operation

Levers and gear tie rods incorrectly adjusted AdjustSynchronisers or coupling sleeves fault Check/replace damaged components

Sliding problems in internal controls: rods, forks and sleeves Check/replace damaged componentsHardening and/or seizing of levers and tie rod gears Check the unit components, adjust correctly and replace dam-

aged componentsCentral clutch hardening Check/replace damaged components

Noisy gears

GEARSHIFT NOISEPossible Cause Operation

Worn or faulty internal component Check/replace damaged components

Brakes


TROUBL - 68

Brakes overheat

SHOE SLIPPAGE ON THE DRUMSPossible Cause Operation

Insufficient clearance between shoes and drums Self-adjusting device lockedShoe return spring weak or damaged Replace

Pump pistons or cylinders locked Check the unitDrums and shoes worn or scored Overhaul

Locked brakes

BRAKES BLOCKEDPossible Cause Operation

Shoe return springs stretched ReplaceRubber gaskets swollen or seized Check the system, replace all the rubber parts and the fluid,

bleed air from the system: use the recommended oilRusty plungers Replace

Incorrect position of brake pedal stop Adjust

Brake pedal elastic response

BRAKE PEDAL FLEXIBLE MOVEMENTPossible Cause OperationAir in the system Bleed the system

Hoses that swell under pressure due to wear Replace or bleed the systemAir leak in the pump due to poor tightness of rubber rings Replace the rings

Brake pedal too soft

BRAKE PEDAL SINKS TOO MUCHPossible Cause Operation

Tank cap breather hole blocked causes vacuum in the pumpfor air to pass through the gasket

Clean the tank cap and bleed the system

Fluid leak from fittings, cylinders and hoses Check and replace damaged components

Suspensions and steering

Noisy suspension

FRONT SUSPENSION NOISEPossible Cause Operation

Wheel axle bearings worn or with excessive clearance ReplaceNo grease in the wheel hub chamber Remove, grease or replace the bearingsInefficient or leaking shock absorbers Replace

Worn ball joints ReplaceWorn steering box Replace

REAR SUSPENSION NOISEPossible Cause Operation

Wheel axle bearings worn or with excessive clearance ReplaceNo grease in the wheel hub chamber Remove, grease or replace the bearings

PORTER 1.3 16V Troubleshooting

TROUBL - 69

Possible Cause OperationRear suspension spring buffers damaged Replace

Swinging arm to chassis attachment silent blocks damaged Replace

Vibration sent from engine to chassis

VIBRATIONS TRANSMITTED FROM ENGINE TO CHASSISPossible Cause Operation

Silent blocks fixing engine to chassis not properly locked ordamaged

Lock or replace

Difficult riding

DRIVING PROBLEMSPossible Cause Operation

The vehicle «pulls» to one side Check any steering arm alterations and then check toe-inSteering hardening or knocking Check the steering assembly components (column-housing

joints, steering, etc.)Inefficient or leaking shock absorbers Replace

Incorrect tyre pressure Restore the correct pressure


TROUBL - 70

INDEX OF TOPICS

ELECTRICAL SYSTEM ES

Ground pointsPUNTI DI MASSA

BATTERY-CHASSIS GROUND

Electrical system PORTER 1.3 16V

ES - 72

SERVICES SYSTEM GROUND (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 Electrical system

ES - 73

ADDITIONAL GROUND (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


ES - 74

2. Starter

3. F/L principale 60A

4. Interruttore avviamento

5. Alternatore 50A

6. Altoparlante

7. Radio

8. Accendisigari

9. Comando tergicristallo

10. Comando tergilunotto (modello van)

11. Teleruttore tergicristallo

12. Pompa tergicristallo

13. Motore spazzole tergicristallo

14. Fusibile ACC 15A

15. Fusibile

16. Pompa tergilunotto

17. Motore spazzole tergilunotto

18. Teleruttore elettroventola

19. Fusibile motore 20A

20. Elettroventola

21. Termointerruttore

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. Luce fendinebbia posteriore

28. Attuatore regolazione proiettore sinistro

29. Attuatore regolazione proiettore destro

30. Interruttore luci anabbaglianti

31. Diode

32. Luci abbagliante/anabbagliante

33. Luci fendinebbia

34. Teleruttore luci fendinebbia anteriori

35. Interruttore luci fendinebbia anteriori

36. Spia luci abbaglianti

37. Fusibile lampade 20A

38. Fusibile H/L Left 10A

39. Fusibile H/L Rigth 10A


ES - 75

40. Fusibile fendinebbia 20A

41. Interruttore luci di posizione

42. Luci di posizione

43. Illuminazione comandi riscaldamento

44. Luce di posizione anteriore

45. luce di posizione anteriore

46. Illuminazione quadro strumenti

47. Luci targa

48. Luce di cortesia posteriore (per van)

49. Luce di cortesia

50. Interruttore su portellone posteriore per luce di cortesia

51. Interruttore Luce di cortesia anteriore

52. Buzzer

53. Fusibile clacson/lampeggiatori 15A

54. Fusibile Lunotto termico 10A

55. Interruttore 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 lampeggiatori

64. Indicatori di direzione anteriori e posteriori destri

65. Indicatori di direzione anteriori e posteriori sinistri

66. spia indicatori di direzione

67. Sensore livello carburante

68. Quadro strumenti

A. Spia diagnostica

B. Spia ricarica batteria

C. Spia Pressione olio

D. Spia freno di stazionamento

E. Spia liquido freni

F. Indicatore temperatura

G. Indicatore livello carburante

H. Spia riserva carburante

69. Interruttore liquido freni


ES - 76

70. Interruttore freno a mano inserito

71. Interruttore pressione olio

72. Luce retromarcia

73. Interruttore luce retromarcia

74. Fusibile riscaldamento

75. Fusibile starter

76. Centralina elettronica (EFI ECU)

77. Interruttore per elettroriscaldatore

78. Resistenza elettroriscaldatore

79. Motorino elettroriscaldatore

80. Centralina elettronica (controllo diagnostico)

81. Sensore temperatura aria

82. Sensore temperatura liquido raffreddamento

83. Rivelatore velocità veicolo

84. Sensore quantità aria

85. Sensore pressione

86. Resistore (EFI)

87. Sensore riscaldatore posteriore

88. Sensore riscaldatore anteriore

89. Sensore angolo di rotazione

90. Cablaggio candele

91. Spinotto 1

92. Spinotto 2

93. Spinotto 3

94. Spinotto 4

95. Bobina accensione

96. Teleruttore Principale

97. E/G J/CA

98. Fusibile EFI1 15A

99. Fusibile EFI2 15A

100. Motore F/P

101. Teleruttore F/P

102. Iniettori

103. IDOL UP VSV

104. PURGE VSV

105. EGR VSV


ES - 77

Electric diagrams

Ignition

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


ES - 78

10. Throttle valve sensor

11. Data Link Connector (DLC)

12. Engine coolant temperature sensor

13. Vehicle speed sensor

14. Pressure sensor

15. Cam angle sensor

Ignition 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 Motor fuse

5. 20A Heating fuse

6. Battery recharge warning light

7. Voltage regulator with integrated circuit

8. Alternator


ES - 79

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


ES - 80

Aria Condizionata

AIR CONDITIONING ELECTRICAL 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.


ES - 81

7. 7-way connector (male).

8. 20A Fuse.

9. Fuse-box.

10.Resistor.

11.Cab electric fan.

12.Terminal from ground to eyelet (-31).

13.Switch relay - Cab electric fan control (1st speed).

14.5-way connector (connects evaporator control to electric fan control).

15.Evaporator assembly.

16.Air Conditioning A/C switch.

17.Bulb.

18.De-icer thermostat.

19.2-way connector (connects engine electrical system to vehicle electrical system).

20.Terminal from ground to eyelet (-31).

21.Switch relay - Electric fan control.

22.30A Fuse

23.Switch relay - Electric fan control.

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 Thermostatic sensor normally closed (control to release compressor electromagnetic coupling

with water temperature >117°C).

31.Compressor electromagnetic coupling

32.A/C system protection pressure switch.

33.3-way connector.

34.Generator.

35.Engine.

36.Depression fitting.

37.Solenoid valve of accelerated idle control (VSV MIN ).

38.2-way connector.

39.Breather pipe.

40.Depression fitting.

41.Electric fan operation logic.

(*) NB: The sketched parts represent components of the original electrical system.


ES - 82

COLOUR TABLEITALIAN FRENCH ENGLISH GERMAN SPANISH GREEK

Arancio Orange Orange Orange Naranjado ΠορτοκαλόχρουςAzzurro D'azur Light Blue Hellblau Azul ΓαλανόσBianco Blanc White Weiss Blanco ΛευκόσBlu Bleu Blue Blau Turqui ΚυανόσGiallo Jaune Yellow Gelb Amarillo ΚίτρινοσGrigio Gris Grey Grau Gris ΓκρίMarrone Marron Brown Braun Marrón ΓκρίNero Noir Black Schwarz Negro ΜαύροςRosa Rose Pink Rosa Rosa ΓαρύφαλλοRosso Rouge Red Rot Rojo ΕρυθρόσVerde Vert Green Grün Verde ΧλωρόσViola Violet Violet Violett Violado Βιολετής

Fuses

Fuse box

Fitting position: The fuse 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 the fuse to blow and/or the fuse holder to burn.

2. Repair the malfunction, and fit a new fuse and/or fuse holder, use only an identical one and with the

same capacity.

3. Before removing or fitting fuses into the fuse holder, make sure that the key switch is set to OFF.

4. Use small pliers to remove or fit fuses.

FUSE BOX

(A) Main fuse box

(B) Auxiliary fuses

(C) Windscreen wiper activation position.

(D) Flashing turn indicators activation position.


ES - 83

Teleruttori

REMOTE CONTROLS:

1. Fuel pump remote control 2. Control unit

main remote control 3. 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 (optional

equipment)

8. Radiator electric fan remote control


ES - 84

AIR CONDITIONING REMOTE CONTROLS

13 - Cab electric fan control remote control (first

speed). 20 - Ground with eyelet terminal. 21 -

Electric fan control switch remote control 22 - 30A

Fuse 25 - Compressor electromagnetic coupling

control 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 properly.

2. Disconnect the multifunction switch lever connector. Make sure there is continuity between the rel-

evant terminals according to the continuity tables shown in the following diagram.


ES - 85

KEY:

1.Windscreen wiper switch

2. Windshield spray nozzle switch with automatic return system

3. Hazard indicator switch

4. Turn indicators switch with automatic return system

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 spray nozzle switch with automatic return system

Key-switch

Ignition key switch

1. Remove the ignition key switch cylinder unit.


ES - 86

2. Make sure that battery voltage is applied to terminal «B» regardless the ignition key switch 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 = Cable colour

Continuity table

C = Position

D = Terminal


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Wiper switch

Rear windscreen wiper and spray nozzle

switch

TERMINALS:

0= Windshield washer spray WASH2

1= Windscreen wiper first position

2= Windshield washer spray WASH1

TERMINALS:

1= From the spray nozzle motor

2= To ground

3= To ground

4= From 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. Disconnect the stop light switch.

2. Make sure there is continuity between terminals

when the brake pedal is pushed.

3. Make sure there is no continuity between termi-

nals when the brake pedal is not pushed.


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Interruttore freno stazionamento

Handbrake switch

1. Take out the handbrake connector and perform

continuity checks between the terminal and the

body ground.

2. Make sure there is continuity between terminals

when the handbrake lever is pulled.

3. Make sure there is no continuity between termi-

nals when the handbrake lever 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 defroster

2= Ground

3= Switch

C= Bulb

Continuity table

A= Switch

B= Terminal

Interruttore regolazione proiettori

Headlamp light beam adjustment switch

1. Remove the switch for headlamp light beam adjustment.

2. Check continuity between the terminals, as indicated in the following table.


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Continuity table

A= Switch

B= Terminal

3= Ground

Interruttore luci 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 table

A= Switch

B= Terminal


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Windscreen wiper mechanism

Check

1. Low speed operation check.

Connect terminal 3 to the battery positive (+) ter-

minal; terminal 1 to the battery negative (-) termi-

nal. Then, connect terminal 2 to terminal 5. Make

sure that the windscreen wiper operates at low

speed.

2. High speed operation 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 speed.

3. End of operation check.

After checking operation at high and low speeds,

connect terminal 2 to terminal 4, or connect termi-

nal 2 to terminal 5.

Make sure that the windscreen wiper works and

stops at the automatic stop position.


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KEY:

1. Arm and blade

2. Connection unit

3. Motor

4. Windscreen wiper

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 4: There is no continuity


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1. Connect terminal 4 to the battery positive (+)

terminal.

2. Connect terminal 1 to the battery negative (-)

terminal.

3. Make sure that a noise (a click) is heard indi-

cating functioning. The relay is set to ON.

4. Connect terminal 3 to terminal 1. Then (about a

second later), connect terminal 3 to terminal 4. The

relay is set to OFF.

5. After about four seconds a noise indicating func-

tioning must be heard (intermittent operation).

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 the figure.

4. Fit the instrument panel.

CharacteristicDriver-side arm length441 mm

Passenger-side arm length416.5 mm

Driver-side blade length400 mm

Passenger-side blade length380 mm

Removal

1. Remove the windscreen wiper and the blade arm.

2. Remove the instrument panel.

3. Remove the hexagon nut.

4. Remove the windscreen wiper motor with the connection unit.

Components


ES - 93

KEY:

1. Arm and blade

2. 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


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Diagram

Fitting

1. Fit the rear window wiper motor.

2. Run the motor until it reaches the automatic stop

position.

3. Align the blade with the lower line of the rear

defroster. Tighten the nut.

Removal

1. Remove the rear window wiper and the blade holder arm.

2. Remove the connection cover and the hexagon nut.

3. Remove the washer and the 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 B to the battery positive (+)

terminal. Make sure that rear window wiper is

working.

4. In the operation conditions described above,

disconnect terminal S from the battery negative (-)

terminal. Make sure that the rear window wiper

stops at the automatic stop position.

Starter motor

Start-up system


ES - 95

This section of the manual describes the start-up system and provides information to check for its correct

operation.

Removal and fitting operations are also described.

Starter motor maintenance instructions

1. Pay attention when locking the starter motor terminal or the battery terminal properly; if the connection

is not correct, there is serious risk of overheating due to a strong passage of current upon starting the

vehicle.

2. Before removing the starter motor, disconnect the battery negative (-) terminal. Then, disconnect

terminals (+B, ST) from the motor. Since battery voltage is always applied to terminal +B of the starter

motor, carefully 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 relevant locking torque.

Any incorrect refit can result in early wear of pinion teeth or flywheel crown, or even cracking of the

crankcase.

Inspection with starter motor fitted

1. Take the gearshift lever to neutral. Pull the

handbrake lever.

2. Disconnect the ignition coil connector so that the

motor does not start.

3. Turn the ignition switch to ST. Check that the

motor starts running.

4. If the motor does not turn, check if the battery is

damaged or discharged. Perform the cable har-

ness continuity test.

5. If despite the above checks, the starter motor

does not start, remove the motor and check it.


ES - 96

Componenti

KEY:

1. Starter motor assembly

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


ES - 97

17. Support cap

18. Remote control

Rimozione dal veicolo

Removal

1. Disconnect the starter motor cables.

2. Remove the starter motor from the clutch cover.

Bench testsStarter motor 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

• Disconnect the remote control cable.

• Connect the battery negative (-) termi-

nal to the starter motor body and to the

remote control terminal.


ES - 98

• Connect the positive (+) terminal to the

ST terminal. Make sure that the pinion

advances. If this does not occur, re-

place the remote control.

2. Pinion engagement upholding test

After having performed the test described above,

detach the remote control negative terminal. Make

sure that the guide pinion remains advanced.

If this does not occur, replace the remote control.

3. Pinion return check

After 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 performance without load applied

Connect the battery to the starter motor by inter-

posing an ammeter as shown in the figure.

Make sure that the motor rotates regularly while

the pinion advances. Measure the current as in the

figure:- CONNECT THE CABLE TO THE REMOTE CONTROL, BE-FORE PERFORMING THE TEST.

CharacteristicPrescribed current:less than 50 A at 11 V


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Starter motor removal

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.


ES - 100

5. Using a thickness gauge, measure the rotor

shaft thrust clearance at the point between the lock

washer and the external cover.

CharacteristicClearance:0.05 - 0.60 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 the springs and remove

the brushes from the relevant brush holder.PAY ATTENTION NOT TO SCORE THE COMMUTATORWHEN REMOVING IT.


ES - 101

9. Remove the engaging lever from the rotor.

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.


ES - 102

14. Remove the coupling.

Verifiche e controlli

Rotor check

Rotor insulation check

Make sure that there is no continuity between the

commutator and the rotor coil: use an ohmmeter.

If there is continuity, replace the remote control.

Commutator 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.

Commutator check

1. Check for possible burning on each contact sur-

face of the commutator segments with the brush-

es. If surfaces are dirty or burnt, rectify with

abrasive paper (No. 400) or with a lathe.


ES - 103

2. Commutator eccentricity check

Hold the rotor by both sides on two V-shaped sup-

ports. Check the commutator eccentricity with a

dial gauge.

If the eccentricity exceeds the limits allowed, po-

sition the commutator on a lathe.

CharacteristicEccentricity limit.0.05 mm

3. Commutator diameter measurement

Measure the commutator diameter with a micro-

meter or a sliding gauge.

If the commutator diameter is shorter than the di-

ameter minimum, replace the rotor.

CharacteristicStandard diameter28 mm

Minimum diameter27 mm

4. Groove depth check. Measure the depth of in-

sulator grooves between the commutator seg-

ments

If the depth of insulator grooves is less than the

limit value, replace the commutator.

CharacteristicMinimum depth:0.2 mm

KEY:

A= Grooves

B= Groove correction

C= Incorrect groove depth

D= Correct

E= Segment


ES - 104

Field winding check

1. Field winding continuity check. With an ohm-

meter, check the continuity between windings B

and C D.

In case there is no continuity, replace the brush

unit and/or windings. Field winding check.

2. Field winding short circuit 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 the brush length, with a sliding gauge.

Brush replacement

If the length is shorter than the minimum value re-

quired, replace the brushes.

CharacteristicStandard length A:16 mm

Minimum length B:10.5 mm


ES - 105

Brush holder check

Brush holder insulation check

With an ohmmeter, measure the resistance be-

tween the positive and negative terminals of brush

holder A.

Brush holder replacement

If the resistance value is lower, replace the brush

holder.

CharacteristicInsulation resistance:100 M or more

Coupling check

Checking the pinion gear tooth and grooves.

Check for possible damage to the pinion gear tooth

and grooves. If 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 point A shown in the figure.

KEY:

A= Cutting point

2. With a file or a similar tool, remove the welding

traces, in order to obtain the correct terminal sizes.

Prescribed sizes:- PAY ATTENTION TO REMOVE THE MATERIAL AS INDI-CATED IN THE SIDE FIGURE, SINCE THE PART TO BEREMOVED IS VERY REDUCED AND IT IS EASY TO SCORETHE FIELD WINDING.

CharacteristicThickness:1.3 - 1.5 mm

Width:5 mm


ES - 106

KEY:

A= Cutting point

B= Brush

C= Section to be removed

D= Coil side end

3. Position the brush flat end on the braid side to

be welded (copper braid). Press with pliers both

side ends.

4. Weld the connection section. Rectify the section

with a file or similar tool, so that the section com-

plies with sizes, as indicated in the right figure.- MAKE SURE THE BRAID POSITION IS CORRECT. - WHENWELDING IS PERFORMED, HEAT THE PART TO BE WEL-DED. PAY ATTENTION THAT THE WELDING IS NOT ONTHE BRAID SIDE.- MAKE SURE THAT THE WELDING ADEQUATELY FLOWSINSIDE THE PLATE.- MAKE SURE THAT THERE ARE NO WELDING DEPOSITSIN THE FIELD WINDING.

Starter motor coupling check

Hold the coupling and rotate the pinion clockwise.

Make sure that it turns properly. Rotate the pinion

anticlockwise. Make sure that the pinion does not

turn. If this is not met, replace the starter motor

clutch.

Magnetic field check

1. Remote control

Cause the plunger to re-enter by pressing it with

your fingers. Releasing the plunger, make sure

that it returns immediately to its original position. If

this does not occur, replace the remote control.


ES - 107

2. Return coil check

With an ohmmeter, make sure that there is con-

tinuity between the ST and C terminals. If this does

not occur, replace the remote control.

3. Seal 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. Measure the inside diameters of the bushings,

transmission seat and the cover.

2. Measure the rotor bearing outside diameter.


ES - 108

3. Determine clearance by extracting the rotor

bearing outside diameter from the bushing inside

diameter.

If clearance exceeds the limit, replace the bushing.

The punch has a 15 mm outside diameter.

CharacteristicClearance limit :0.2 mm

Montaggio

Assembly

1. Fit the coupling on the rotor shaft.

2. Fit the collar on the rotor shaft.- TO LUBRICATE BUSHINGS, USE GREASE FOR HIGHTEMPERATURES.

3.Fit the circlip on the rotor shaft.


ES - 109

4. Give it a few taps with a screwdriver so that the

collar is fitted on the circlip.

5. Fit the engaging lever and the rotor in the trans-

mission seat.- APPLY HIGH TEMPERATURE GREASE ON THE SLIDINGSECTIONS OF THE ROTOR SHAFT AND THE ENGAGINGLEVER.

6. Fit the stator.

7. Fit the brush holder on the rotor shaft.

8. Keeping the springs lifted with pliers, refit the 4

brushes on the relevant support.

9. Fix the commutator cover to the stator coil as-

sembly with the two through bolts.


ES - 110

10. Fit the rubber ring, brake spring and the safety

plate in the respective order on the rotor shaft

11. Position and fix the rear cover with the two

screws.

12.Refit the remote control in the relevant housing,

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

Installation

Once removal and fitting operations are finished, perform function controls and, afterwards, fit the starter

motor on the vehicle.

Alternator

Recharge system


ES - 111

This section of the manual provides information to check the correct operation of the recharge system.

Removal and fitting operations are also described.

Before performing checks on the vehicle,

check the following:

• Battery electrolyte density

• Battery terminal fitting and check

• V-belt tension

• Fuse

• Cable harness

• Abnormal noises emitted by 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 system

- Car radio

- Defroster

- Cab internal lights, etc.

2. Gradually increase engine revs up to 2500 rpm.

Then, measure voltage and current.N.B.- IMMEDIATELY AFTER THE ENGINE IS STARTED, THECURRENT EXCEEDS 10 AMPERE. THIS IS CONSIDEREDNORMAL.

CharacteristicCurrent:not exceeding 10 A

Voltage:14.2-14.8 V


ES - 112

- If the voltage detected was lower than that speci-

fied, earth the "F" terminal as indicated in the side

figure. Then start the engine. If voltage increases,

replace the regulator. If instead, voltage shall re-

main below that specified, it is necessary to check

alternator.

Test of delivered power with electric charge

applied.

1. 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 COMPLETELY CHARGED, IT ISPOSSIBLE THAT THE CURRENT IS BELOW TO THAT DE-SCRIBED ABOVE: THIS IS CONSIDERED NORMAL. NOW,INCREASE THE ELECTRIC CHARGE, FOR EXAMPLE, AC-TIVATING THE REAR DEFROSTER. THEN CHECK IF THEDELIVERED CURRENT INCREASES OR NOT.

CharacteristicSpecified value:20 A or more


ES - 113

Componenti

KEY:

1.Alternator assembly

2. Pulley fixing nut

3. Alternator 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. Brushes

16. Spring

17. Brush holder


ES - 114

18. Rear cover

Rimozione dal veicolo

Removal

1. Disconnect the battery negative (-) terminal.

2. Remove the terminal clamps (+) B, IG and L of

the alternator.

3. 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 removal

• Remove the nut and the insulator.

• Undo the three screws.

• Remove the rear cover.

4.Remove the brush holder.


ES - 115

5. Remove the regulator unit.

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.


ES - 116

8.Remove the rotor.


Check

Rotor

Rotor check - (for circuit opening).

Using an ohmmeter, check resistance between

the commutator rings.

If this does not result, replace the remote control.

CharacteristicStandard resistance:2.9 ± 0.2 Ω

Rotor check - (for ground).

Make sure there is no continuity between the com-

mutator rings and the rotor casing.

If there is, replace the rotor.

Commutator check.

1. Check the commutator surface for irregularities

(e.g. wear, burning etc.); then replace the rotor.


ES - 117

2. with a gauge, measure the commutator outside

diameter.

If the commutator outside diameter is shorter than

the minimum value requested, replace the rotor.

CharacteristicStandard diameter14.4 mm

Minimum diameter14 mm

Stator

Stator check - (for circuit opening).

With an ohmmeter, check if there is continuity be-

tween the stator coil terminals. If there is no con-

tinuity, replace the stator assembly.

CharacteristicSpecified resistance:around 0.2 Ω

Stator check - (for short circuit).

Using an ohmmeter, check if there is any condition

present that could cause a short circuit between

the coil cables and the casing cables. If there is

continuity, replace the stator.

Brush and brush holder

Brush protrusion length check.

With a gauge, measure the brush protrusion

length.

If the length measured is shorter than the minimum

length specified, replace the brushes.

CharacteristicStandard length:10.5 mm

Minimum length:1.5 mm


ES - 118

Brush replacement (if necessary).

1. With a welder, take the pre-existent welding to

the melting point, so as to remove the brushes and

the springs from the relevant support.N.B.- IT IS NECESSARY TO REMOVE THE COAT OF PAINTFROM THE WELDING SURFACE BEFORE CARRYING OUTTHE OPERATION.- USE A WELDER WITH A POWER OF ABOUT 40 W FORTHIS OPERATION.

2. With the spring placed in the relevant housing,

fit the braid in the brush holder.N.B.- REMOVE THE WELDING MATERIAL FROM THE BRUSHHOLDER 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 specified

length.N.B.- TO FACILITATE THE WELDING OPERATION: INSERTTHE WIRE IN THE BRUSH HOLDER AND POSITION THEPART EXPOSED ACCORDING TO THE SPECIFICATION.BEND THE FRONT PART OF THE WIRE ON WHICH THEWELDING MATERIAL IS APPLIED, THEN WELD THE WIRETO THE BRUSH HOLDER.

CharacteristicStandard length:10.5 mm

4. Make sure that the brush moves freely in the

brush holder.


ES - 119

5. Cut possible wire surplus material and spread

insulating varnish.

Rectifier check - (positive + side).

1. Using an ohmmeter, connect a probe to the rec-

tifier positive terminal; Alternatively, connect the

other probe to each one of the other rectifier 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

rectifier support.

Rectifier check - (negative - side).

1. With an ohmmeter, connect one of the two ohm-

meter probes to each rectifier negative terminal

and connect the other probe to each rectifier pos-

itive terminal.


ES - 120

2. Repeat the same operation described above re-

versing test polarity.

3. Make sure there is continuity only in one of the

two tests. If continuity is detected in both tests, the

rectifier support should be replaced.

Rear bearing check.

Make sure that 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.N.B.- PAY SPECIAL ATTENTION NOT TO DAMAGE THE RO-TOR DURING THE OPERATION.

2. With a hydraulic press, refit the bearing with the

relevant spacer.

3. Using an adequate section of tube, fit a new

bearing cover.


ES - 121

Front bearing check.

Make sure that the bearing turns freely. Otherwise,

replace the 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, place the new bearing in the rel-

evant housing.


ES - 122

4. Refit the plate with the 4 screws.

Refitting

Assembly

1. Fit the rotor in the relevant housing.

2. Refitting the rectifier housing cover.

Fit the rectifier housing cover by using two bolts

and nuts.- PAY ATTENTION NOT TO DAMAGE THE STATOR CA-BLES DURING REFITTING.- IF FITTING TURNS OUT DIFFICULT, SLIGHTLY PRESS BYTAPPING WITH A PLASTIC HAMMER.

3. Refitting the rectifier support, regulator and the

brush holder.

• Fix the rectifier support to the cover,

with the stator coil wires passing

through the rectifier support holes.


ES - 123

• Wind up the coil wires around the rec-

tifier fixing screws.

• 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 with the 2 screws.


ES - 124

6. Rear cover refit.

• fix the rear cover with the three screws.

• Position the insulating terminal and

lock it with the relevant nut.

7. Fixing the pulley to 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 torques (N*m)Generator shaft fixing nut: 110

9. Remove the specific tools.

10. Make sure that the rotor turns freely.


ES - 125

Installazione sul veicolo

Installation

1. Temporarily fit the alternator to the engine with

two fixing bolts.

2. Fit the alternator belt.

3. Regulate the belt bending so that, by applying a

pressure equivalent to 98 N (10 kg-f), at the central

point between the water pump pulley and the al-

ternator pulley, this results as follows

4. Fix cable B (+) and the alternator connector.

5. Reconnect the ground lead terminal to the bat-

tery negative (-) terminal.N.B.- A NEW BELT IS A BELT WHICH HAS BEEN USED LESSTHAN 5 MINUTES.

CharacteristicBending:New belt: 5.0-7.0 mmBelt used: 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 (central locking). The central locking, can be activated in two different modes:

- Manual - Radio-controlled

The activation of the central locking via remote control is signalled by a differentiated switch-on of the

turn indicators. For central locking of locks, the Piaggio device 612697 is equipped with a remote control

working via radio with a frequency type-approved to operate at 433.92 Mhz. A safety device integrated

to the system blocks central locking activation with the remote control while the vehicle is moving.


ES - 126

TECHNICAL CHARACTERISTICS OF THE SYSTEMSpecification Desc./Quantity

Rated supply voltage: 12 VoltsSupply voltage range: 11-18 volt

Electric current requirement at 13.5 V: 4 mALocking relay maximum capacity: 30 Amp

Turn indicator relay maximum capacity: 8 AmpModule output maximum capacity: 50 mA

REMOTE CONTROLSpecification Desc./Quantity

Transmission frequency: (TUV AUSTRIA type-approved frequency): 433.92 MhzFree field capacity: 20 m

ELECTROMECHANICAL ACTUATORS:Specification Desc./Quantity

Rated supply voltage: 12 VoltsSupply voltage range: 11-15 Volts

Electric current requirement at 13.5 V while blocked: 5 Amp

Schemi elettrici e di principio

KEY:

1. Door locking control unit


ES - 127

2. Remote control

3 Turn indicators

4. Front right actuator

5. Electrical contacts for 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 positiveN.B.

IN DIESEL ENGINE VEHICLES, THE LIVE DEVICE CONNECTION WIRE IS BLACK.


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Settaggio dei parametri e manutensione

NEW REMOTE CONTROL DETECTION

The central locking system, to work by means of

remote control, must learn the transmission code.

When the vehicle is purchased, the system is pro-

vided with a remote control already working. If the

customer wants a second remote control or looses

the original one, it is necessary to perform a new

transmission code detection procedure. To per-

form this operation correctly, strictly follow the in-

structions indicated below.

New remote control detection procedure:

• Open the glove-box cover.

• Remove 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 glove-

box.

• Remove the door-locking control unit from its

seat so as to be able to reach the cable harness

to which it is connected.

• Identify in the cable harness, a white wire with a

free end.

• Remove the insulating cap from the free end of

the wire.

• Connect the white wire A to the red/white wire

connected to the door locking control unit.

• the vehicle turn indicators flash four times indi-

cating that the detection procedure has started.

• From this time on, the procedure is differentiated

according to the vehicle engine.


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Procedure

• Start the engine.

• The turn indicator bulbs remain stead-

ily on.

• Stop the 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 the con-

trol unit from the white/red wire.


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• The turn indicator bulbs flash one time

indicating that the procedure has fin-

ished.

• Refit the insulating cap on the white

wire.

Final operations:

• Once the insulating cap on the white

wire is refitted, reinstall the door lock-

ing control unit in its original seat.

• Refit the glove-box in its original seat

and fix it with the corresponding

screws.

SYSTEM MAINTENANCE

In order to maintain the central locking system, it is necessary to adopt some simple tactics, listed below:

REMOTE CONTROL:

Recommendations of use:

The system remote control does not require par-

ticular tactics for its working. As every electronic

device, avoid exposing it to violent shocks, 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 replacement:

For its operation, the remote control uses alkaline

batteries. Batteries are subject to a gradual loss of

their charge with the regular use of the remote

control. The more the remote control is used the

faster the batteries will be discharged. To prevent

failures of the central locking operated by remote

control, the latter has inside a device that indicates

the battery charge status. When using the remote

control regularly, press the control switch and the

green transmission LED turns on to remain stead-

ily on. In case the battery charge status should

decrease below the standard level in order to guar-


ES - 131

antee the control proper operation, by pressing the

control switch, the green transmission LED turns

on flashing, warning the user that it is necessary a

battery replacement.CAUTIONTO PLACE THE NEW BATTERIES INSIDE THE REMOTECONTROL, REFER TO THE FIGURE. BATTERIES TO BEUSED ARE TYPE CR1616. THE USE OF DIFFERENT BAT-TERIES FROM THOSE RECOMMENDED COULD CAUSEIRREPARABLE DAMAGE TO THE REMOTE CONTROL. DONOT DISPOSE OF DISCHARGED BATTERIES IN THE EN-VIRONMENT, USE THE APPROPRIATE CONTAINERS.

CharacteristicBattery type:CR1616

ELECTRICAL CONTACTS FOR SLIDING

DOORS:

Contact maintenance:

The contacts of sliding doors allow the central

locking system 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 PROTECTION FUSE:

Fuse replacement:

If the system stops working in manual mode as

well as in the radio operated mode, check if the

system protection fuse A is in proper conditions.

For this check, it is necessary to remove the fuse

box board, located under the instrument panel

close to the pedal assembly, removing the two fix-

ing screws.

Modello GEMINI

ALARM SYSTEM AND CENTRAL LOCKING

GEMINI 7563 MODEL

Introduction

The unit 7563 is a module operated by radio comprising a self-powered alarm control unit and an

external sound unit, that can be used on vehicles without original radio control and a 12V battery.


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IN ORDER TO CARRY OUT THE DIFFERENT FITTING PROCEDURES PROPERLY, CAREFULLYCHECK ALL THE ELECTRICAL CONNECTIONS REQUIRED, PAYING SPECIAL ATTENTION TOBASIC CONNECTIONS:

• DEVICE POWER SUPPLY (POSITIVE AND GROUND).• LIVE POSITIVE (+15/54)• DOOR SWITCH.• BONNET OR TRUNK SWITCH.

Functions

• Alarm system activation/deactivation through rolling code radio remote controls (random

rolling code).

• Passive activation function (programmable).

• Visual signalling (blinker).

• Sound alarms (programmable).

• Perimetric protection.

• Volumetric protection (excludible during the activation phase).

• Central locking, electric windows and roof (for vehicles equipped with "Pack-comfort" sys-

tem).

• Engine electrical locking.

• Current absorption sensor (programmable).

• Alarm memory by means of visual signalling/sound alarms.

• "PANIC" or "CAR-FINDER" function.

• Emergency deactivation of the system 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 but not self-powered.

GEMINI 7562.01: Similar to 7562 without electronic key.

GEMINI 7561: Similar to 7562.01 without engine block and control for additional or self-powered siren.

OPERATION DESCRIPTION

1. Alarm total activation

Press key No. 1 (stippled) of the radio control or insert the electronic key in the appropriate hole.

A sound alarm by the siren and a visual signal by the turn indicators confirm the operation.

The alarm has a pre-activation "neutral period" which lasts 45". During the first 25" of this period, the

sensors can be excluded as described in the relevant section.

2. Activation without siren sound

This function allows users to activate the alarm system without the siren sound in case of a car break-

in is attempted.

To exclude the siren, follow the instructions given below:


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• Turn the ignition key to "ON"; the status LED comes on for 0.5 seconds.

• During this period, press key No. 2 of the radio control.

• Leave the vehicle and press key No.1 of the radio control.

• The alarm is activated with light and sound signals, as previously described, which are not

activated in case of a break-in attempt.THE SIREN SOUND EXCLUSION IS LINKED TO EACH SINGLE ACTIVATION CYCLE. WE REC-OMMEND THIS FUNCTION TO BE APPLIED WHEN NEAR HOSPITALS.3. Activation without sensors and comfort control

This function allows userS to activate the alarm system without external sensors and comfort control.

The exclusion concerns any wire sensor connected to the alarm system (ultrasounds, super-high fre-

quency, impact).

Besides, if volumetric sensors via radio are installed via radio (section 7709), the following procedure

also includes such sensors.

Press key No. 1 of the radio control and, during the first 25" of the activation neutral period, press key

No. 2 of the radio control.

Following such operation, the turn indicators flash once and the sensors are subsequently excluded.N.B.THE PROCEDURE DESCRIBED ABOVE IS LINKED TO EACH SINGLE ACTIVATION CYCLE.4. Alarm activated

Once 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 break-in attempt is signalled when the alarm with light/sound alarms is deactivated (see the relevant

section).

5. Alarm, neutral period and alarm cycles

As previously described, break-in attempts are signalled by the system with light/sound alarms.

Once the alarm cause is over, before another possible warning, there is a "neutral period" of 5 seconds,

useful to deactivate the system using a pin-code.

The alarm causes have a limit of 5 cycles, lasting 30 seconds each, for each entry and each activation

cycle.

The only alarm causes which are unlimited are the starting attempts (live positive, +15/54) and the cable

cut.THE ALARM CYCLE CAN BE INTERRUPTED, WITHOUT DEACTIVATING THE SYSTEM, BYPRESSING KEY No. 2 OF THE RADIO CONTROL.6. Alarm deactivation

Press key No. 1 of the radio control and insert the electronic key in the appropriate hole. The turn

indicators flash three times and the siren sounds three times to signal deactivation.

If an alarm condition is detected, the turn indicators flash five times and the siren sounds five times. For

causes and related warnings, see the relevant section.

7. Emergency deactivation with pin-code


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This function allows users to deactivate the device if the radio controls do not work or are lost.

The PIN-CODE provided comprises four numbers between 1 and 9. These digits, with 1-1-1-1 as the

factory default code, are the same in all the alarms of 7563 series and similar. For safety reasons,

change the code, by personalising it with a code chosen by the user.

For the new pin-code program specifications follow the indications contained in the relevant section

(page 12).

8. Alarm memory

If the turn indicators flash five times and the siren sounds five times when the alarm is deactivated,

thanks to the LED memory, the cause which has generated the last alarm condition can be identified.

To do so, turn the starter key to "ON" and watch the status LED, which starts flashing, indicating the

last cause of alarm. The visual signal will be repeated for 5 times and can be interrupted simply by

turning the starter key to "OFF".

The possible alarm warnings are indicated in the following diagram.

LED WARNINGSpecification Desc./Quantity

*O* Absorption sensor (5 cycles)**O** Start-up tried (+15/54) (infinite cycles)

***O*** Door switch (5 cycles)****O**** Cable cut (infinite cycles)

*****O***** External wire sensor bonnet/trunk switch (5 cycles)******O****** Magnetic contact via radio (5 cycles)

*******O******* Infrared sensor via radio (5 cycles)*= ON - 1 secondO= OFF - 2 seconds

Garage function.

This function is useful if it is necessary to deactivate the alarm, for example, due to maintenance, without

intervening on the programming performed.

In fact, this function deactivates the alarm completely without activating the anti-distraction function and

passive function.

To do so, follow the short procedure described below:

• With the alarm deactivated, turn the ignition key to "ON".

• The LED turns on for a short time (0.5 ").

• During that period, insert the electronic key in the appropriate hole.

• The LED turns off, indicating the alarm deactivation.

• To restore the regular functions, activate the alarm with the radio control.


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ALARM AND CENTRAL LOCKING

1. Emergency key

2. Super-high frequency module

3. Alarm positive activated

4. To the central locking

5. To the door and case switches

6. To the bonnet switch

7. To the turn indicators

8. To the switch

9. To the engine block device (Only for models 7563 and 7562)

10. Additional 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 with catalytic converter, carry out the engine locking on the fuel pump.

• Connect the power supply positive of the system 7563 to vehicle battery positive pole or to

its shunt.

• Connect the power supply negative of the system 7563 to the vehicle metal frame.


ES - 136

• Always connect the GREEN/BROWN wire of the module to the vehicle door switches.

• Always connect the GREEN wire of the module to the vehicle bonnet switch.

• Always carry out the electrical connections, then any programming of the module.

• For central locking connections refer to the diagrams shown in the following pages.

The table shown below refers to the alarm cable harness wiring diagram on the next page.

Before carrying out all the electrical connections, detach the battery negative pole and reconnect it only

when the fitting has finished.

IN THE ALARM CABLE HARNESS, THERE ARE 2 TWO-WAY CONNECTORS FOR THE CON-NECTION OF THE ELECTRONIC KEY HOLE AND RELEVANT LED. THE 4-WAY CONNECTOR ISUSED FOR THE ULTRASOUND OR SUPER-HIGH FREQUENCY MODULE CONNECTION.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 the 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 ultrasound

module.

Fit the WHITE connector matching the word RX on

the ultrasound module.

Fit the RED connector matching the word TX on

the ultrasound module.

Install the ultrasound sensor transducers at the

highest point of the internal posts of the front wind-

shield, far from the air conditioner ventilation.

KEY:

1. Red connector

2. Ultrasound module

3. White connector

4. Transmission

5. Reception

Ultrasound sensor adjustment

In case you do not wish to activate the diagnosis,

proceed as described below:

• With the alarm deactivated, lower the

vehicle front glass about 20 cm.


ES - 137

• Adjust the trimmer located on the ul-

trasound module.

• Activate the alarm and wait for the end

of neutral activation time with doors,

bonnet and trunk closed.

• Introduce a foreign matter in the vehi-

cle cab and shake it; The LED inserted

in module 5123 turns on (in addition to

the siren sound) to signal the matter

detection.

• If sensitivity is not correct, adjust the

trimmer again and repeat operations

from the start.

• If the adjustment carried out is correct,

position the module 5123 definitively.

Super-high frequency module connection and

positioning

Connection is simple since, the connector corre-

sponding to that present in the 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 principle of re-

flection of the high-frequency electromagnetic

waves by conductive objects (metals, human

body, etc.).

Measuring the magnitude of these reflections al-

lows detecting any foreign object moving within the

electromagnetic field, thus causing an alarm sta-

tus.

The characteristics of sensor 7059 render it unaf-

fected by air fluctuations (for example: wind, tur-

bulence, thermal variations, etc.), therefore it is

particularly suitable to be fitted on cabriolet vehi-

cles or vehicles with sunroof.

Permeability to electromagnetic waves of non-

conductive materials (plastic, fabrics, etc.) permits


ES - 138

installing sensor 7059 under the cab panelling,

and therefore it is completely out of sight.THE SENSOR MUST BE ALWAYS FIXED AT A CENTRALPOSITION WITH RESPECT TO THE VEHICLE AXIS, WITHTHE SIDE SHOWING THE WORDS AND THE ADJUST-MENT TRIMMER FACING THE VEHICLE INTERNALSPACE.

KEY:

1. Sensitivity adjustment

2. Alarm indicator LED

Super-high frequency sensor adjustment

In case you do not wish to activate the diagnosis, proceed as described below:

• Adjust the trimmer to a maximum sensitivity position (turning it clockwise to maximum).

• Activate the alarm and wait for the end of neutral activation time with doors, bonnet, trunk

and windows of the vehicle closed.

• Move the hands close to the vehicle windows (side windows, windshield and rear window)

checking that the sensor 7059 does not detect anything.

• If alarm conditions are detected, it is necessary to reduce the sensor sensitivity. Turn the

adjustment trimmer anticlockwise, then repeat the test as indicated above.

• If sensor operations are not detected, deactivate the alarm 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 introduction of the foreign body in the cab, adjustment

has been carried out correctly.

Diagnosis

ACTIVATING THE DIAGNOSIS PROCEDURE THE ALARM RETURNS TO THE INITIAL STATUS,AS PROGRAMMED BY GEMINI. THEREFORE, CARRY OUT A POSSIBLE DIAGNOSIS TEST BE-FORE PROGRAMMING OR CHANGING THE PIN-CODE (SEE THE USER MANUAL). TRANSMIT-TERS, ELECTRONIC KEYS, TAG CARDS, MAGNETIC CONTACTS AND INFRARED SENSORSPREVIOUSLY STORED ARE NOT DELETED.

For a correct check of connections, sensors or control peripherals, turn off any TAG cards near the

vehicle on which the test is being carried out.

In fact, the TAG periodic transmission could distort the different tests.

To activate the procedure, follow the instructions given below:

• Remove the alarm power supply.

• Press and hold the LED status key or short-circuit the RED and BLACK cables of the two-

way connector to connect the LED.

• Power the alarm.

• Once the alarm is powered, the 4 sound alarms and 4 turn indicator flashes, indicate that

"diagnosis" has started.


ES - 139

• By opening one door of the vehicle, the siren is activated for all the time during which the

door is open, while by opening and closing the door again the siren is activated for a period

of about 2".

• In both cases, once the siren sound alarm has finished , there is a turn indicator flashing

and a sound signal.

• By activating any other device, at each alarm reception, or in case of signals coming from

electrical connections (e.g. bonnet switch) there is a turn indicator flashing and a sound

signal.

• Release the status LED switch or remove the short-circuit carried out previously.

The alarm indicates the end of the diagnosis procedure with a sound alarm and a turn indicator flashing.

Control for self-powered siren/pager

The alarm control unit has the command to use an additional siren with the Yellow-Black wire (there is

no negative lead during the alarm activation). In case it is desired to reverse the command (there is a

negative lead during the alarm activation) follow the operations described below:

• With the alarm not powered, turn the starter key to "ON".

• Power the control unit.

• Take the starter key back to "OFF".TO REVERSE THE COMMAND AGAIN, IT IS NECESSARY TO REPEAT THE OPERATIONS PRE-VIOUSLY DESCRIBED. CHECK THERE IS A NEGATIVE LEAD DURING THE ALARM ACTIVATIONTO CONNECT THE PAGER.

Programmable functions

1. Sound alarms

This function allows the user to exclude all the sound alarms permanently. For programming see the

relevant paragraph.

2. Panic alarm or car-finder

The PANIC ALARM function allows the user to activate the visual signalling/sound alarms intentionally,

simply by pressing key No. 2 of the radio control independently of the alarm status.

The alarm warning lasts for about 30", and it is possible to stop such warning by pressing key No. 2 of

the radio control again.

During the alarm warning, the status LED remains steadily on.

If during the programming phase the PANIC function is disabled, the "CAR FINDER" is activated.

This function allows, only with the ALARM ACTIVATED, to obtain a short visual signalling/sound alarm

by pressing key No. 2 of the radio control. Such function is useful in case it is necessary to trace the

vehicle inside a car park, without causing useless alarm conditions.

The visual signalling/sound alarm comprises a siren grave tonality and simultaneous turn indicator

flashing.SOUND ALARM EMISSION IS SUBJECT TO THE ENABLING OF ALARMS DURING THE PRO-GRAMMING PHASE OF ACCESSORY FUNCTIONS.3. Current absorption sensor


ES - 140

CAUTIONBEFORE ENABLING THE ABSORPTION SENSOR, CHECK REGULATIONS IN FORCE REGARD-ING (NOISE POLLUTION).By enabling the absorption sensor, there is an alarm warning at each minimum voltage variation inside

the electric circuit of the vehicle (e.g. bulb lighting).

4. Anti-distraction activation and door lock closing

This function determines the reactivation of the system if, after deactivating it, doors do not open within

a period of 35 seconds.

The function prevents leaving the vehicle unprotected if, after activating the protection system, key No.

1 of the radio control is pressed unintentionally, deactivating in this way the system.

The automatic activation is signalled by standard visual signalling/sound alarms (a turn indicator flashing

and a sound alarm) .

Activating the anti-distraction function comprises the activation of the central lock closing control.THE FUNCTION IS CANCELLED WHEN OPENING A DOOR AFTER DEACTIVATION. THE CLOS-ING OF LOCKS OF THE VEHICLE IN RUNNING ORDER IS AUTOMATICALLY ACTIVATED TO-GETHER WITH THE FUNCTION PREVIOUSLY DESCRIBED.After closing all the doors of the vehicle, turn the ignition key to "ON"; the vehicle locks are locked after

20".

Turn the key to "OFF" to open the vehicle locks automatically.

To avoid activating this function unintentionally, the system continuously monitors the panel key 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. Passive activation

The passive activation allows the alarm system to activate autonomously after 45" from the time the

vehicle is shut off.

To activate this function, after its programming, turn the ignition key to "OFF".

The alarm signals the activation of the passive function by means of the turn indicator flashing for a

long time, the status LED flashing two times and two sound alarms.

When a door of the vehicle is opened during the activation of the passive function, the activation time

count is reset, which is signalled by the LED which turns on and remains steadily on; the 45" count

continues when the door previously open is closed again.

6. Locking time

The alarm has an original locking time set to 0.5". If the vehicle requires a locking time of 6", change

such time in the programming phase.IF THE COMFORT FUNCTION IS ACTIVATED, LEAVE THE LOCKING TIME SET TO 0.5". IN FACT,BY LEAVING A LOCKING TIME OF 6" ENABLED, THE WINDOWS OF THE VEHICLE OPEN WHENTHE ALARM IS DEACTIVATED.7. Comfort control

The comfort control automatically sets the closing of the vehicle windows when the alarm is activated.

In fact, the moment in which the function is activated, each time the alarm is activated, a 25" locking

control is also set on motors/control units which control the vehicle window rise.


ES - 141

8. Central locking opening double pulse

By enabling this function, a double control pulse on the opening of locks is obtained, each lasting 0.5"

when the system is deactivated.

This allows unlocking the central locking on the vehicle having differentiated modes of opening doors

(first pulse to open the driver side door, second pulse to open the other doors).

The function is active only if the opening/closing time is set to 0.5 seconds, while setting the opening/

closing time to 6" automatically removes the double pulse.

System programming

The 7563 has a "basic configuration"; that is, a programming set by Gemini during manufacture, which

can be modified according to needs.

During programming phases, press key No.1 (stippled) of this control radio to enable functions, press

key No. 2 (plain) to disable them.PAY 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 starter key to "ON".

• The status LED turns on for 0.5 seconds. during that time, press both radio control keys at

the same time.

• The confirmation that programming has started is signalled by two sound alarms, a high-

pitched one and a grave tone one, besides the LED which turns on and remains on.

• Refer to the table below to enable/disable functions, bearing in mind that, each time a radio

control key is pressed, the module moves on to the following function.

Sound alarms

Status: enabled

Key 1: enables

Key 2: disabled

Panic alarm or ''car-finder''

Status: panic alarm enabled

Key 1: enables panic alarm

Key 2: ''car finder'' enabled

Current absorption

Status: disabled

Key 1: enables

Key 2: disables

Anti-distraction, lock automatic closing

Status: disabled

Key 1: enables

Key 2: disables


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Passive activation

Status: disabled

Key 1: enables

Key 2: disables

Locking time selection

Status: 0.5'' selected

Key 1: enables 6''

Key 2: enables 0.5''

25 second control for comfort locking

Status: disabled

Key 1: enables

Key 2: disables

Double pulse during opening

Status: disabled

Key 1: enables

Key 2: disables

BY TURNING THE KEY TO "OFF" AT ANY MOMENT OF THE PROGRAMMING PROCEDURE,PROGRAMMING IS FINISHED, LEAVING THE SUBSEQUENT FUNCTIONS UNCHANGED.

• ONCE THE LAST FUNCTION IS PROGRAMMED, THE SYSTEM INDICATES THAT THEPROCEDURE HAS FINISHED WITH TWO GRAVE TONE SOUND ALARMS AND ONEHIGH-PITCHED SOUND ALARM, PLUS THE FACT THAT THE LED COMES OFF.

• TURN THE IGNITION KEY TO "OFF".

ANTI-HIJACK FUNCTION

For safety reasons and so that the anti-hijack function can intervene with the vehicle running,

keep the TAG card separately from the radio control (generally paired with the vehicle ignition

key).

THE ANTI-HIJACK FUNCTION ACTIVATION MEANS ONLY THE RADIO CODE PROGRAMMED ISRECEIVED AND SENT BETWEEN THE TAG AND THE MODULE 7563 BUT NOT THAT THE VE-HICLE IS IMMOBILISED.

The module 7563 is equipped with an anti-hijack function, able to immobilise the vehicle in case of

assault and theft damaging the owner. The operation principle is based on the use of an automatic

transmitter, named TAG, which communicates with 7563 module through a radio code signal. When

the signal is not received by the TAG anymore, the module is activated, locking the vehicle as described

in the following chapters.CAUTION

CONNECT THE BROWN/GREEN CABLE TO THE DOOR SWITCH SO THAT THE ANTI-HIJACKFUNCTION OPERATES CORRECTLY.

1. ignition device

Press the TAG button for at least 3 seconds; the LED remains steadily on for all the time the key is

being pressed and held. During regular operation, a short flashing of the status LED of 3 seconds signals


ES - 143

the TAG "ON" status. The identification code is periodically sent to the device fitted on the vehicle and

when the system receives it, a short flashing of the status LED signals the reception.

2. Device turnoff

Press the TAG button until the LED turns on and remains steadily on. After three short warning flashes,

the device turns off.

3. Vehicle start-up

Start the vehicle (ignition key set to "ON"). Il 7563 waits for two minutes a TAG transmission; if a trans-

mission is detected the anti-hijack function is activated. Otherwise (if the TAG does not come on and

therefore there is no transmission to the module 7563), the anti-hijack function does not activate. This

automatic procedure allows the safe use of the vehicle if the user does not carry the TAG, or the device

does not work due to a failure or due to exhausted batteries.

4. Assault with the vehicle running and vehicle theft

FOR CORRECT OPERATION, IT IS ASSUMED THAT THE VEHICLE HAS BEEN TAKEN AWAYFROM THE USER WHO CARRIES THE TAG.

Once the door is open and walking away from the TAG, the module looses the radio contact with it,

after 16 seconds once the door is open, the vehicle prepares for pre-immobilisation mode. The LED

alarm system turns on and remains steadily on to signal this status. In this situation note that, for safety

reasons, the vehicle running 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. Fitting with tachometric signal connection

The vehicle immobilisation is activated (with the engine on) at speed close to 0 Km/h. It is signalled by

the flashing of turn indicators (lasting about 3 hours).

THIS FUNCTION INCLUDES THE 7563 CONNECTION TO THE SENSOR GEMINI 7667.

6. Fitting without tachometric signal connection

The vehicle immobilisation is activated when the engine is shut off; It is not possible to start it again

without following the unlocking procedures described below. The immobilisation is signalled by the

flashing of turn indicators (lasting about 3 hours).

7. System unlocking with tag

To deactivate the system, the user must approach the vehicle with the TAG on. The module, receiving

a transmission again, deactivates the anti-hijack function and interrupts the flashing of turn indicators.

8. System unlocking with tag

This procedure is useful in case of an improper activation of the ant highjack function (e.g. failure or

TAG battery discharged with the anti-hijack function activated and vehicle running). The procedure to

deactivate the immobilisation function and allow the user to use the vehicle again is the following:

• Press the status LED switch or insert the electronic key in the hole after at least 2 minutes

the anti-hijack warning has started. !


ES - 144

• Within 2 seconds after the LED switch has been pushed, press key 2 and then key 1 of the

system radio control.

NEW CONTROL DEVICE DETECTIONCAUTION

IT IS NECESSARY THAT THE ELECTRICAL CONNECTIONS REQUIRED ARE CARRIED OUT(DOOR SWITCH, BONNET SWITCH AND LIVE POSITIVE) SO THAT THE OPERATION HAS APOSITIVE OUTCOME.

The alarm can store a maximum number of 12 control devices, such as radio controls, electronic keys,

TAG cards, magnetic contacts or infrared sensors (the latter not as control but as protection devices).

The procedure to carry out this operation is described below.

• With the alarm deactivated, open and keep both the bonnet and the driver side door open.

THE "ON-OFF" OPERATIONS ARE CARRIED OUT WITHIN A MAXIMUM TIME OF FOUR SEC-ONDS. IF THESE STEPS ARE NOT FOLLOWED, THE DATA STORAGE PROCEDURE OF NEWDEVICES IS CANCELLED.

• Turn the vehicle ignition key "ON".

• Turn the vehicle ignition key "OFF".

• Take the ignition key back to "ON" three times (ignition key "ON" and "OFF") and, as de-

scribed above, within a period of four seconds.

• The fourth time the key is switched to "ON", leave the key in that 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-pitched one and a grave tone one.

DO NOT CHANGE THE BONNET POSITION SINCE, INSTEAD OF STORING NEW DEVICES,THOSE DEVICES PRESENT IN THE ALARM MEMORY ARE DELETED, AS DESCRIBED IN THEFOLLOWING PARAGRAPH.

• The alarm is now on hold, ready to receive the device code.

• Press key No. 1 of the radio control, insert the electronic key in the appropriate hole, press

the TAG card key, activate the magnetic contact (bring contact and magnet together and

then separate them) or activate the infrared sensor (see instructions annexed to the sensor

section), according to the device to be stored.

• In all the four cases, the alarm signals the detection of a new device by the flashing of the

status LED and a high-pitched tonality sound alarm.

• Repeat the same operation to store other devices.


• Turn indicators flash and the siren sounds with a grave tonality to signal the end of the

procedure.

TO STORE THE THIRTEENTH DEVICE, THE FIRST DEVICE ENTERED IN LOCATION ONE OFTHE ALARM MEMORY IS DELETED.

CONTROL DEVICE DELETIONCAUTION


ES - 145

IT IS NECESSARY THAT THE ELECTRICAL CONNECTIONS REQUIRED ARE CARRIED OUT(DOOR SWITCH, BONNET SWITCH AND LIVE POSITIVE) SO THAT THE OPERATION HAS APOSITIVE OUTCOME.

Control devices can be deleted from the alarm, such as radio controls, electronic keys, TAG cards,

magnetic contacts or infrared sensors (the latter as protection devices).

The procedure to carry out this operation is described below.

• With the alarm deactivated, open and keep both the bonnet and the driver side door open.CAUTION

THE "ON-OFF" OPERATIONS ARE CARRIED OUT WITHIN A MAXIMUM TIME OF FOUR SEC-ONDS. IF THESE STEPS ARE NOT FOLLOWED, THE PROCEDURE TO DELETE DEVICES THATARE IN THE MEMORY IS CANCELLED.

• Turn the vehicle ignition key "ON".


• Take the ignition key back to "ON" three times (ignition key "ON" and "OFF") and, as de-

scribed above within a period of four seconds.

• The fourth time the ignition key is switched to "ON", leave it in that position.

• The alarm signals the annulment of the control devices, magnetic contacts or infrared sen-

sors 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 four seconds, the radio devices are completely

deleted.

IF THE VEHICLE BONNET IS CLOSED FOR LESS THAN FOUR SECONDS THE DELETION OFRADIO DEVICES CAN NOT BE OBTAINED .

• Deletion is signalled by the turning off of the status LED, a long flashing of turn indicators

and a sound alarm with grave tonality.


PROGRAMMED FUNCTIONS ARE NOT MODIFIED BY DELETING CONTROL DEVICES.

NEW PIN-CODE PROGRAMMING

Find below the procedure to personalise the PIN-CODE which, as previously described, is useful to

personalise the coded at the customer's will. In the example shown you want to enter a code with the

digits 5-4-6-7.

• When the system is deactivated, open and keep the vehicle driver side door open.

• Turn the ignition key to "ON".

• The status LED turns on for 0.5 seconds. during that time, press both radio control keys at

the same time.

• Following this operation, there are two sound alarms, a high-pitched one and a grave tone

one.

• Close again the driver side door previously opened.


ES - 146

• Press both keys of the radio control at the same time. The status LED turns off.

• Turn the ignition key to "OFF".

• The LED remains on for about 4 seconds to start the first series of flashes afterwards.

• Once the LED has flashed for five times (corresponding to No. 5, first 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".

• The LED remains off for about 4 seconds to start a new series of flashes afterwards.

• Once the LED has flashed four times (corresponding to No. 4, second PIN-CODE digit),

press the status LED switch or turn the ignition key to "ON" for at least one second.



• Once the LED has flashed for six times (corresponding to No. 6, third PIN-CODE digit), press

the status LED switch or turn the ignition key to "ON" for at least one second.



• Once the LED has flashed seven times (corresponding 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.


• Two sound alarms with grave tonality and one with high-pitch tonality signal that the proce-

dure has finished.CAUTION

DURING THE PIN-CODE PROGRAMMING PHASE, IF THE NUMBER OF FLASHES EXCEED 9,THAT PHASE IS CANCELLED AND THE ALARM STOPS THE PROCEDURE.

EMERGENCY UNLOCKING THROUGH PIN-CODE

The alarm emergency unlocking procedure through the PIN-CODE is described below. The original

PIN-CODE is set by Gemini, and consists of four digits 1-1-1-1. In the example shown, the alarm is

unlocked with the same digits shown in the CODE-PIN programming example ( 5-4-6-7).

• To trigger an alarm status.

• Let the alarm sound for a standard period (about 30 seconds) and wait for the "neutral period

between the two alarm warnings".

During this period the LED remains on for about 5 seconds; turn the vehicle ignition key to "ON".

DO NOT LET THE IGNITION KEY REMAIN IN "ON" FOR MORE THAN 3" OR THE SITUATION ISINTERPRETED BY THE ALARM AS A THEFT ATTEMPT.

The LED turns off indicating that the "emergency unlocking procedure" has started.

• Turn the vehicle ignition key to "OFF".

• After about 4 seconds, the first sequence of 9 flashes has started.


ES - 147

• Once the LED has flashed for five times (corresponding to No. 5, first 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.

• The LED remains off for about 4 seconds to start afterwards a new series of 9 flashes.

• Once the LED has flashed for four times (corresponding to No. 4, second 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.


• Once the LED has flashed for six times (corresponding to No. 6, third 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.


• Once the LED has flashed 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 exact, the unlocking procedure is signalled by the alarm and visual signalling/

sound alarms.

Vice versa, if digits entered are incorrect, a new alarm status is triggered.

In this case, repeat the procedure described above from the start.

DEVICE BATTERY REPLACEMENT

The use of different batteries from those recom-

mended could cause irreparable damage to the

remote control. Do not dispose of discharged bat-

teries in the environment, use the appropriate con-

tainers.

1 Magnetic contact

The intensity of the light given out by the LED in-

dicates the magnetic contact operation battery

charge status:

• Intermittent or low intensity LED light,

battery discharged.

• Permanent or high intensity LED light,

battery discharged.

To replace batteries, follow the instructions given

below:

• With the alarm activated, open the

magnetic contact cover.


ES - 148

• Take out exhausted batteries and re-

place them with new ones, paying at-

tention to observe polarity.

• Refit the magnetic contact cover.USE ONLY CR1616 TYPE BATTERIES

Open the TAG plastic using the crack located near

the slot by levering with a screwdriver. Take out

the circuit and slide off the discharged battery; fit

the charged battery holding the positive pole fac-

ing upwards. Refit the whole unit being careful that

it closes properly and effectively.USE ONLY CR2032 TYPE BATTERIES FOR A LONGERLIFE OF THE BATTERY TURN THE DEVICE OFF DURINGTHE PERIODS OF INACTIVITY.

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 and the green warn-

ing LED turns on to remain steadily on. In case the

radio control battery charge status should de-

crease below the standard level in order to guar-

antee proper operation, by pressing the system

activation/deactivation switch, the green warning

LED turns on flashing, warning the user that it is

necessary a battery replacement.USE ONLY CR1616 TYPE BATTERIES

3. Infrared sensor

When the battery voltage decreases below 5.5V, before reaching the minimum charge level for oper-

ation, the sensor signals such condition.


ES - 149

In fact, there is a visual signalling (LED) and a sound alarm (buzzer) which lasts one second following

each movement detection.

To replace the battery follow the instructions below:

• Deactivate the alarm system.

• Remove the sensor cover by slightly pressing on its upper and lower sides.

• Remove the battery from its seat and separate it from the connector.

• Replace the battery and close the cover removed previously again.

USE ONLY 9 VOLT TYPE BATTERIES.

Warranty conditions

Any manufacturing faults appearing on this appliance are guaranteed for a period of 24 months from

the installation date indicated in this guarantee slip, complying with directive 1999/44/EC with the im-

plementation of Legislative Decree No. 24 dated 02/02/2002.

Therefore, please fill in the entire warranty certificate included 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 filled in or the attached sales document is missing.

The warranty is exclusively valid at Gemini Technologies S.p.A. authorised centres

The manufacturer is not responsible for any faults or failures of the appliance or the vehicle electrical

system due to a bad installation, tampering or improper use.

The alarm has a theft deterrent function.

THE INSTALLATION CERTIFICATE AND THE RELEVANT PRODUCT WARRANTY IS AUTOMAT-ICALLY INVALIDATED BY ANY TYPE OF MODIFICATION OR ADDITION NOT EXPRESSLYINDICATED IN THE INSTALLER'S MANUAL, OR AUTHORISED BEFOREHAND BY GEMINI TECH-NOLOGIES S.P.A.

Replacing light bulbs

LIGHT LAYOUT AND SPECIFICATIONS

1. Rear fog light

2. License plate light

3. Reverse light

4. Stop light and rear position

5. Rear hazard turn indicator


ES - 150

BULB POSITION AND CHARACTERISTICS

1. Headlamp and clearance lamp

2. Front and side hazard turn indicators/indicator

3. Fog light headlamp

CARATTERISTICHE DELLE LAMPADESpecification Desc./Quantity

Faro 55 - 60 WLampeggiatori anteriore e laterale 21 W

Faro fendinebbia anteriore 55 WLuce di ingombro 5 W

SPECIFICHE DELLE LUCISpecification Desc./Quantity

Fari 60/55 W (Alogeno)Luci di ingombro 5 W

Lampeggiatori anteriori 21 WLampeggiatori posteriori 21 W

Luce per retromarcia 21 WLuci targa 5 W

Faro fendinebbia posteriore 21 WLuce dell'abitacolo 5 W

Luce posteriore dell'abitacolo 5 WFari fendinebbia anteriori 55 W

Luce stop e posizione posteriore 21/5 W


ES - 151

Replacing the 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.


ES - 152

3. Remove the turn indicator locking spring.

4. Remove the turn indicator unit from the vehicle

inside.

5. Disconnect the connector and remove the turn

indicator.

6. Undo 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 headlamp from the clip located at

the bottom. To refit the headlamp unit, carry out

the same operations but in reverse order.


ES - 153

Replacing the front turn signal light bulbs

Front indicators

Removal/fitting

1. Remove the turn indicator 1 from its seat.

2. Disconnect the bulb holder.

3. Remove bulb 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 unit.

2. Remove the bulb holder by turning it anticlock-

wise.

3. Remove the bulb by turning anticlockwise,

pressing it slightly.


ES - 154

Rear turn indicators/Stop lights

For the Pickup model

1. Take out the two screws to remove the light unit.

2. Turn the bulb anticlockwise by pressing it slight-

ly.

Replacing 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


2. Take out the bulb by pulling it.

Cab lights

1. Remove the lenses by gently levering them.

2. Extract the bulb.


ES - 155

Fari fendinebbia

Fog light headlamps

Removal/fitting

1. Operating from the front compartment of the

bumper disconnect bulb holder 1 with the bulb and

remove it from the fog light headlamp support 2.

2. Remove bulb 3 from bulb holder 1.

To refit the fog light 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 the four fixing screws 3 of the fog light

headlamp 4 on support 5.

3. Remove the fog light headlamp 4 with the bulb

holder and bulb.

To refit the fog light headlamp, carry out the same

operations but in reverse order.


ES - 156

Luce retromarcia

Reverse gear light

1. Undo the screw to remove the light unit.


ly.

Faro fendinebbia posteriore

Rear fog light



ly.

Indicators - Warning lights

Gruppo strumenti

KEY:

1. Odometer

2 Warning light panel

3.Fuel gauge

4. Water temperature gauge


ES - 157

5. Speedometer

Components

INSTRUMENT PANEL


ES - 158

KEY:

1. Battery

2. F/L main fuse

3. F/C main fuse

4.Main switch

5. 20A Horn

6. Windscreen wiper

7.Hazard 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 heater

17. Water temperature

18.Fuel gauge

19. Charge

20. Brake


ES - 159

21. Engine check bulb

22. Engine check bulb

23. Low fuel warning light

24. Beam

25. To the alternator (L)

26. 20A bulb

Fuel gauge

Check

Disconnect the fuel probe connector A placed at

the upper part of the fuel tank. Carry out the fol-

lowing checks 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 warning light turns on; after a few

seconds, the warning light must start flashing.

4. The fuel gauge must move up gradually.

KEY:

1. Battery

2. Link fuse

3. IG switch

4. Fuel gauge

5. Check warning light

6. Fuse


ES - 160

Fuel gauge

Unit check

1. Remove the combined instrument panel.

2. Measure the resistance value between termi-

nals B7 and B2.

3. Connect the multiple pole connector to the

"combination meter".

4.Turn the key switch to ON.

5. Make sure that battery voltage is applied be-

tween terminal A4 and the body ground.

6. Make sure 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 between the terminal and the body to the positions listed below.

Float A position: Resistance 5-10 Ohm Reference dimensions 95.5 ± 3 mm

Float B position: Resistance 30-38 Ohm Reference dimensions 95.5 ± 3 mm

Float C position: Resistance 87-102 Ohm Reference dimensions 230 ± 3 mm


ES - 161

Fuel gauge and temperature gauge

KEY:

1. Battery

2. Fuel gauge

3. Gauge


5. Gauge

6. Fuel level probe

7. Water temperature probe

Water temperature gauge

1. Disconnect the connector from the water tem-

perature 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 flashing.

4. The temperature gauge must start to move up

gradually.

KEY:

1. Link fuse

2. Battery

3. Fuse

4. Switch


6. Check warning light 3.4W

Water temperature probe

Check


ES - 162

1. Remove the probe from the cylinder head.

2. Measure the resistance value between the terminal and ground at the following temperatures:

Temperature (°C) Resistance value ()

50 26.0

115 26.0

Controllo impianto di accensione

Ignition check

Spark plug

1. Connect the stroboscopic light terminal 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 following checks.

Remove the fuel pump relay from the relay hous-

ing.

4. Disconnect the ignition coil connector.

5. Remove the ignition coil and the spark plug.

6. Connect a spark plug and a connector to the

ignition coil.- TESTER DS. 21. CAN BE USED


ES - 163

7. Check ignition sparks while the letting the en-

gine run with the starter motor.

8. Remove the spark plug.- IF THERE ARE NO SPARKS, CHECK FOR POWER SUP-PLY. - BEFORE CARRYING OUT THIS OPERATION,CHECK FOR FUEL LEAKS INSIDE THE ENGINE COM-PARTMENT. CLEAN THE FUEL LEAK, IF NECESSARY.WORK IN A WELL VENTILATED AREA PAYING ATTEN-TION THAT THERE ARE NO VOLATILE LIQUIDS, GAS,ETC. NEARBY.

9. Spark plug cleaning.N.B.- REMOVE ANY OIL TRACES WITH PETROL BEFORECLEANING THE SPARK PLUG WITH THE APPROPRIATECLEANING DEVICE.- IF THERE IS HUMID CARBON ON THE ELECTRODE, DRYTHE ELECTRODE AND CLEAN IT WITH THE APPROPRI-ATE CLEANING DEVICE.AIR PRESSURE:IT MUST NOT EXCEED 588 KPA. DURATION: LESS THAN20 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 distance between the electrodes.

Measure the distance between the electrodes with

a thickness gauge.IF NECESSARY, REPLACE THE SPARK PLUG.N.B.- IF THE DISTANCE BETWEEN THE ELECTRODES DOESNOT COMPLY TO THE SPECIFIED VALUES, ADJUSTBENDING THE EARTH ELECTRODE BASE PAYING AT-TENTION NOT TO TOUCH THE FACE.- THE FOUR SPARK PLUGS MUST BE AT THE SAME HEATRATING AND BELONGING TO THE SAME BRAND.

CharacteristicElectrode gap0.9 - 1.0 mm

12. Checking spark plug insulation resistance to a

value higher than 20 MΩ- IF THE INSULATION RESISTANCE IS BELOW THE SPECI-FIED VALUE, REPLACE THE SPARK PLUG.


ES - 164

13. Fit the spark plugs. Tighten to the prescribed

torque.

14. Fit the ignition coil on the cylinder head cover.

15. Connect the ignition coil connector.

Locking torques (N*m)Cylinder head - Spark plug 15 ÷ 22 Cylinder headcover - Ignition coil 6÷11

Electrical power supply


2. Measure voltage between terminals 3 +B on the

wire connector side and with the ignition switch set

to ON.- IF VOLTAGE DOES NOT COMPLY WITH THE SPECIFIEDVALUE, CHECK THE FUSE AND THE CABLE HARNESS.

CharacteristicSpecified 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 when the

engine is started with the starter motor.N.B.IN THESE CONDITIONS, THE BULB MUST START FLASH-ING. OTHERWISE, CHECK THE SENSOR OUTPUT TERMI-NAL OF THE CAMSHAFT SENSOR.

Ignition cable


2. Remove the ignition coil by taking out the fixing

nuts.

3. Disconnect the spacer and the cable from the

spark plug.N.B.- REMOVE THE IGNITION CABLE FROM THE SPARKPLUGS AND FROM THE IGNITION COIL HOLDING THERUBBER SHEATH.


ES - 165

Camshaft sensor

1. Disconnect the camshaft sensor connector.

2. Measure the resistance between the connector

terminals.

CharacteristicSpecified value:230 ± 25 ohm (a 20°C)

3. Check that the waveform (see the signal shown

in the graphic) is shown on the oscilloscope dis-

play when the engine is started with the starter

motor.- THE WAVEFORMS AS THOSE SHOWN IN THE FIGUREARE OBTAINED BY MEASURING THE VOLTAGETHROUGH THE CONNECTOR TERMINALS DURING THEENGINE START-UP WITH AN APPROPRIATE OSCILLO-SCOPE, IF THE 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 signal generator.

7. In all the four points check that the air gap be-

tween the signal generator and signal rotor is

equal to the specified value.- IF THE AIR GAP DOES NOT COMPLY WITH THE SPECI-FICATIONS, ADJUST IT.

CharacteristicSpecified air gap:0.2 - 0.4 mm

8. Air gap adjustment.

• Loosen the signal generator fixing

screws.

• Adjust the air gap between the signal

generator and the signal rotor to the

prescribed value.

• Tighten the signal generator fixing

screws.


ES - 166

9. Fit the camshaft sensor cover.

10. Fit the camshaft sensor on the head, and tight-

en the fixing bolt.

11. Check the ignition timing and adjust it if nec-

essary.

Locking torques (N*m)Camshaft sensor - Cylinder head 15÷22

Accensione

Ignition timing

1. Set the ignition switch to OFF and connect the

following specific tool to the DLC A (Data Link

Connector) located at the lower part of the instru-

ment panel.

2. Connect a rpm indicator to the REV terminal,

using the following specific tool.

Specific tooling020618Y Cable harness for connecting theOBD Connector and the Diagnostic Tester

09991-87402-000 Rpm indicator pulse pickupwire (Engine speed measurement)

3. Heat the engine.

4. Connect the stroboscopic light clamp to the ig-

nition coil of cylinder No.1 or No.4.

KEY:

A= Probe

B= Ignition coilUSE A STROBOSCOPIC LIGHT WITH INDUCTIONCLAMPS CALIBRATED AS PER THE HV COIL PRIMARYSIGNAL.


ES - 167

5. Jump terminals T and E of the connector using

the following specific tool.

Specific toolingIntegrated in the 020618Y Lift for diagnosis

6. With a stroboscopic light, check that the ignition

timing reference on the flywheel matches the rear

plate reference.- IGNITION TIMING SHOULD BE CHECKED OR ADJUSTEDUSUALLY AFTER THE ENGINE IS FULLY HEATED.

CharacteristicIgnition timing:Before Top Dead Centre 3 ± 2°/minimum

7. If the ignition timing reference is not aligned with

the indicator, adjust the ignition timing by turning

the camshaft sensor- TURN THE CAMSHAFT SENSOR CLOCKWISE TO AD-VANCE TIMING.

Locking torques (N*m)Camshaft sensor - Cylinder head 15÷22

ECU - Centralina elettronica

Electronic injection control unit

1. Check if the diagnostic system indicates the fail-

ure codes.


ES - 168

2. Connection of the specific tool.

• Disconnect the ground lead from the

battery negative (-) pole.N.B.- THE ELECTRONIC INJECTION UNIT CAN BE CHECKEDBY MEASURING THE RESISTANCE OR VOLTAGE ON THEPROBES OF HE SPECIAL TOOL.CAUTION- BEFORE DISCONNECTING THE GROUND LEAD CHECKIF THE FAILURE CODES ARE STORED. CUT OFF POWERSUPPLY AND DATA STORAGE IS CANCELLED.

• Disconnect the cable harness connec-

tor from electronic injection control unit

connectors on located on the upper

side of the glove-box.

• Connect the specific tool between ca-

ble harness connectors and control

unit connectors.

• Reconnect the ground lead from the

battery negative (-) pole.CAUTION- BEFORE DISCONNECTING OR RECONNECTING THEELECTRONIC INJECTION ECU CONNECTORS, DISCON-NECT THE GROUND LEAD FROM THE BATTERY NEGA-TIVE (-) POLE WITH THE IGNITION SWITCH AND ALL THEACCESSORY SWITCHES SET TO "OFF".- WHILE FITTING A NEW BATTERY, PAY ATTENTION NOTTO INVERT POLARITY. AN INVERTED CONNECTION OFPOLES COULD DAMAGE THE CONTROL UNIT.- BEFORE USING THE SPECIAL TOOL, CHECK WHETHERITS TERMINALS ARE SHORT CIRCUITED OR OPEN CIR-CUIT.

3. Voltage or resistance measurement.

• Measure the voltage or resistance be-

tween each terminal.

• Check that the measured voltage or re-

sistance comply with specifications.N.B.- BESIDES, IF THE CHECK DESCRIBED ABOVE DETER-MINES THAT THE CONTROL UNIT SHOULD BE RE-PLACED, MAKE SURE THAT THE CONTROL UNIT FAIL-URE IS NOT DUE TO EXTERNAL FACTORS. AFTER-WARDS, REPLACE THE CONTROL UNIT.- VOLTAGE MEASURED WITH ALL CONNECTORS CON-NECTED.

Control unit output characteristics

Control unit voltage or resistance standard values are indicated in the table.


ES - 169

Unit Terminal Condition Standard voltage or

resistance

Solutions

Fuel supply 2 - 62 Always Battery voltage Check the fuse

11-62 43-62 Ignition switch set to "ON" Battery voltage Check the main relay

Earthing unit 20 52 62 Always Less or equal to 1 Check the cable har-

ness ground

Camshaft sen-

sor

21 -53 Run the engine with the starter

motor

0.1 - 0.3 V (AC scale) Check the camshaft

sensor and the cable

harness

Ignition coil

control

62-29 62-64 Ignition switch set to "ON" Less or equal to 3 V Check the control unit

Once the inspection has finished:

1. Disconnect the ground lead terminal to the 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 unit.

4. Reconnect the ground lead terminal to the battery negative (-) pole.

- IF THE VOLTAGE OR RESISTANCE MEASURED DOES NOT COMPLY WITH SPECIFICATIONS,CHECK THE CABLE HARNESS.- IF THE PROBLEM IS NOT SOLVED BY REPAIRING THE CABLE HARNESS OR THE COMPO-NENTS, REPLACE THE ELECTRONIC INJECTION CONTROL UNIT.

Riscaldamento e ventilazione

Fan check

Fan check. Measure the resistance value between

following terminals.

Specified value:

1 - 3: ~ 2 Ohm

1 - 2: ~ 3 Ohm

Fan switch check

Make sure there is continuity between the respec-

tive terminals as indicated in the table.


ES - 170

Continuity table

A= Switch

B= Terminal

1= High

2= Average

3= Low

Main fitting operations

Temperature adjustment cable

Set the heater control temperature adjusting 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 control cable

Set the heater control internal/external lever to In-

sert and lock the cable.

KEY:

C= Cold

D= Recirculation


ES - 171

Flow regulation cable

Take the heater control flow regulation lever to

"VENT". Insert and lock the cable.

E= VENT

Check after fitting

Make sure that the air quantity and flow direction match 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 ventilation

COMPONENTS:

1. Defroster

2. Connector, etc.

3. Headlamp frame

4. Bumpers

5. Radiator

6. Cable for temperature check

7. Heater pipe

8. Heater unit


ES - 172

Removal


2. With the heating system adjustment lever set to

"hot", drain the water from the radiator (about 500

cm³).

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 the front panel gasket (Van and Com-

bined models).


ES - 173

Cooling Circuit

Cooling electric fan check

1. Turn the switch key to «ON». Make sure that the

electric fan does not start turning when the liquid

temperature is below 92° C. Should this occur,

check the electric fan thermoswitch, and 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

connected to the connector terminals for the ther-

moswitch. If the fan does not turn, check the fan

motor assembly, fuse and remote control.

4. Connect the connector to the radiator thermos-

witch.


ES - 174

Installazione impianto elettrico

Engine injection cable harness

1. Engine ground

2. Oxygen sensor

3. Cam sensor

4. Water temperature sensor

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 pressure switch

15. EFI ECU (26 pin)

16 .To the instrument panel cable harness

17. Ignition coil


ES - 175

18. Ignition coil 2

From A

Position Terminal Terminal Position

Instrument panel cable har-

ness (Instrument panel, oil

pressure warning light)

H5 H6 Low oil pressure switch

Handbrake switch engaged

(+)

G7 G9 To the instrument panel cable

harness (Instrument panel,

handbrake warning light en-

gaged)

Connection to N5-N13 - N75 Ignition coil 2 (IG+)

Ignition coil 2 (-) N77 N56 EFI ECU (IG2)

Ignition coil 1 (IG +) N5 N31 To the instrument panel cable

harness (J/B fuse) B

Ignition coil 1 (-) N7 N27 EFI ECU(IG1)

Cam sensor (NE-) N47 N48 EFI ECU (N-)

Cam sensor (NE+) N8 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 (E2) X35 X34 Intake air temperature sensor

(-)

Connection to X38-X46 - X40 Throttle sensor (VC)

EFI ECU (VC) X38 X46 Pressure sensor (VC)

EFI ECU (PIM) X43 X45 Pressure sensor (PIM)

Connection to Z48-Z49 (near

X44)

- X44 Pressure sensor E1

Connection to X97-X100 - X50 Injector No. 1 (+)

EFI ECU (#10) X56 X51 Injector No. 1 (-)


Connection to X96-X98 - X53 Injector No. 2 (-)


Connection to X56-X51 - X55 Injector No. 3 (-)

EFI ECU (#20) X96 X98 Injector No. 4 (-)


ES - 176

From A

Injector No. 4 (+) X9 X100 To the instrument panel cable

harness (EFI (L) main relay)

EFI ECU (VSV1) X138 X254 (Fast idle) VSV1 (-)

EFI ECU (PSW) X203 X263 Accelerator sensor (PSW)

Connection to X97-X100 - X253 (Fast idle) VSV1 (+)

Connection to Z76-Z66 - Z221 Ignition coil 2 (E)

Connection to Z76-Z66 - Z220 Ignition coil 1 (E)

EFI ECU (E01) Z47 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

Connection to Z76-Z66 - Z218 Ignition coil 2

Water temperature sensor H10 H20 To the instrument panel cable

harness and water tempera-

ture gauge


Connection to Z76-Z66 - Z216 Ignition coil 1

Connection to Z48-Z49 - Z190 Lambda probe sensor (-)


ES - 177

Battery negative cable harness (Pickup/Tipper)

1. Battery

2. Chassis

Cable harness unit

1. Engine cable harness


ES - 178

2. Instrument panel cable harness (Pick/Van/Tipper)

3. Van chassis cable harness

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 cable harness

1 Head cover

2. Chassis


ES - 179

Battery positive cable harness (Tipper)

1. Battery

2. To the vehicle cable harness

Battery positive cable harness (Pickup)


ES - 180

1. Battery

2. To the vehicle cable harness

Battery positive cable harness (Porter Van)

1 Battery

2 To the vehicle cable harness


ES - 181

Battery negative cable harness (Porter Van)

1 Battery

2 Chassis

Bodywork-engine ground transmission cable harness (Pickup)


ES - 182

1. Transmission (gear crankcase)

2. Body

Bodywork-engine ground transmission cable harness (van)

1. Transmission (gear crankcase)

2. Body

3. Foldable clamp


ES - 183

Cab roof cable harness (mirror courtesy light)

1. To the instrument panel cable harness

2. Internal lighting

POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEWSFrom A


Light fuse (L) C2 C1 Courtesy light (+)

Courtesy light (DOOR) D1 D2 Courtesy light switch (+)


ES - 184

Roof light cable harness (Van)

1. To the chassis cable harness

2. Light fitting

POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEWFrom A


Roof light D1 D2 Light switch (tail door) (+)

Light fuse (L) C3 C4 Roof light (+)


ES - 185

Tail door cable harness No.1 (Van)

1. To the chassis cable harness

2. Heated rear window defroster


From A


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

(+)

Chassis ground Z1 Z7 License plate light (-)

License plate light (-) Z7 Z8 License plate light (-)


ES - 186

Engine cable harness

1. Starter motor

2. Reverse gear light switch

3. To the battery positive cable harness

4. Alternator

5. To the instrument panel cable harness (fuses)

6. To the instrument panel cable harness

POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEWFrom A


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 Starter motor (ST)

Bulb switch

reverse gear (-)

G3 G1 Reverse gear bulb

(+)

J/B-Fuse box (Heating fuse) G4 G2 Reverse gear bulb

switch (+)

J/B-Fuse box (Engine fuse) 021 019 Alternator (IG)

Instrument panel (charge bulb) 023 020 Alternator (L)


ES - 187

Rear chassis cable harness (Porter Van)

1.Rear left lights

2.To the tail door (rear window wiper)

3. To the roof (roof light)

4. Rear left fog light

5.To the instrument panel cable harness

6. Chassis earthing

7. Reverse gear light

8.Rear right fog light

9.To the tail door cable harness (license plate and heated rear window)

10.Tail door courtesy light switch

11.Rear right lights

From A


Rear right fog light (+) B6 B7 Rear fog light switch (L)

Light switch B5 B4 License plate light (+)

Light switch B18 B3 Right position light

Connection to B6-B7 - B8 Rear left fog light (+)

Connection to B18-B3 - B2 Left position light

Light fuse (L) C3 C4 Roof light (+B)

Stop light switch E1 E5 Right stop light


ES - 188

From A

Connection to E1-E5 - E6 Left stop light

Right turn indicator light switch F1 F7 Rear right turn indicator light

Left turn indicator light switch F2 F9 Rear left turn indicator light

Roof light (L) D1 D2 Tail door courtesy light switch

(+)

Reverse gear light switch G1 G7 Reverse gear light (+)

Chassis ground Z1 Z8 Chassis 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 rear window

Rear window wiper (L) I1 I14 Rear window wiper (+)

Rear window wiper switch I12 I13 Rear window wiper (-)

Connection to Z1-Z8 - Z6 Reverse gear light (-)

Connection to Z1-Z8 - Z7 License plate light (-)

Connection to Z1-Z8 - Z9 Rear left fog light (-)

Connection to Z1-Z8 - Z10 Rear right fog light (-)


ES - 189

Cruscotto

INSTRUMENT PANEL CABLES

RIGHT HAND DRIVE INSTRUMENT PANEL:

1 Diode

2 To the injection cable harness

3 EFI fuses No. 1 - No. 2

4 EFI ECU

5 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 adjustment actuator

13 Horn

14 Left fog light

15 windshield washer motor

16 Front left /side turn indicator


ES - 190

17 coolant temperature sensor

18 radiator fan relay

19 main fuse

20 to the engine cable harness

21 to the engine cable harness

22 J/B C connection

23 Fog light fuse

24 J/B A connection

25 electric heater motor

26 stop light switch

27 loudspeaker

28 windscreen wiper motor

29 key switch

30 headlight adjustment switch

31 heating resistance component

32 flashing 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 chassis ground

43 rear fog light

44 rear right light

45 reverse gear light

46 left license plate light

47 right license plate light

48 rear left light

49 front right /side turn indicator

50 right fog light

51 right headlight adjustment actuator

52 right headlight

53 front right position light

54 front right chassis ground


ES - 191

55 fog light switch

56 rear fog light switch

57 main relay box and fuel pump

58 brake fluid level switch

59 courtesy light switch

POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEWS

Da A

Posizione Terminale Terminale Posizione

Proiettore destro (HI) A1 A2 Proiettore sinistro (HI)

Proiettore destro (LO) A3 A4 Proiettore sinistro (LO)

Collegamento a A1-A2 A5 Commutatore lampeggiatori

(Commutazione (HU))

Collegamento a A3-A4 A6 Commutatore lampeggiatori

(Commutazione (HL))

Collegamento a A1-A2 A7 Quadro strumenti (Spia abba-

glianti)

Fusibile proiettore sinistro (B) A21 A8 J/B 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 proiettore sinistro (L)

Collegamento a A22-A14 A12 Luce di cortesia (B)

Fusibile proiettore destro (B) A22 A14 J/B C - Scatola fusibili (Fusibile

luci: L)

Collegamento a A3-A4 A15 Diodo (uscita)

Collegamento a A1 -A2 A16 Diodo (uscita)

Interruttore luci ind. direzione

(emergenza)

A19 A39 Quadro strumenti (Spia emer-

genza)

Collegamento a A9-A24 A54 Orientamento proiettore des-

tro (+)

Collegamento a A11-A23 A61 Orientamento proiettore sinis-

tro (+)

Orientamento proiettore des-

tro (0)

A56 A63 Orientamento proiettore sinis-

tro (0)

Collegamento a A56-A63 A69 Resistenza (R4)


ES - 192

Da A

Collegamento a A11 -A23 A70 Resistenza (R3)

Resistenza (R4) A71 A75 Interruttore orientamento

proiettori


proiettori


proiettori

Luce posizione anteriore (des-

tra)

B1 B2 Luce posizione anteriore (sin-

istra)

Collegamento a B1-B2 B3 Luce posizione posteriore

destra (B)

Collegamento a ~ B3 B4 Luce posizione posteriore sin-

istra (B)

Collegamento a B1-B2 B5 Commutatore lampeggiatori

(Illuminazione (-))

Interruttore retronebbia (L) B7 B15 Luci retronebbia (+)

Interruttore fendinebbia B21 B16 Relè luci fendinebbia

Fusibile (fendinebbia) B17 B18 Relè luci fendinebbia

Collegamento a B1-B2 B20 Interruttore luci fendinebbia

Relè fendinebbia B19 B22 Luce fendinebbia destro

Collegamento a B21-B22 B23 Luce fendinebbia sinistra

Interruttore lampeggiatori

(Fendinebbia)

C1 C20 Interruttore retronebbia (B)

Collegamento a B1-B2 C2 Quadro strumenti (illumina-

zione)

Collegamento a B1-B2 C3 Luce targa destra (B)

Collegamento a B1-B2 C4 Interruttore riscaldatore (Illu-

minazione)

Collegamento a C3 C7 Luce targa sinistra (+)

Luce di cortesia (-) D1 D2 Interruttore luce di cortesia (+)

Fusibile clacson J/B C (L) -

Scatola fusibili

E1 E7 Interruttore luci stop (+)

Clacson (+) E2 E7 Interruttore luci stop (+)

Clacson (-) E3 E4 Interruttore lampeggiatori

(Clacson (+))


ES - 193

Da A

Fanale luci posteriori (Luce

stop destra (+))

E5 E6 Interrutore luci stop (-)

Fanale luci posteriori (Luce

stop destra (+))

E5 E8 Fanale luci posteriori (Luce

stop sinistro)

Commutatore lampeggiatori

(destri)

F1 F9 Lampeggiatore anteriore/lat-

erale destro


(sinistri)

F3 F10 Lampeggiatore anteriore/lat-

erale sinistro

Collegamento a F1-F9 F5 Quadro strumenti (spia lamp-

eggiatori)

Collegamento a F3-F10 F6 Quadro strumenti (spia lamp-

eggiatori)

Collegamento a F1-F9 F7 Lampeggiatore posteriore

destro

Collegamento a F3-F10 F8 Lampeggiatore posteriore sin-

istro

Interruttore freno a mano 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 (+)

Trasmettitore livello carbur-

ante (+)

H2 H3 Quadro strumenti (Indicatore

livello carburante)

Interruttore pressione olio (+) H4 H5 Quadro strumenti (Spia press-

ione olio)

Quadro strumenti (Indicatore

temperatura liquido refriger-

ante)

H6 H7 Sensore temperatura liquido

refrigerante (+)

Quadro strumenti (Spia riser-

va carburante)

H8 H9 Sensore livello carburante (ris-

erva)

J/B C (Fusibile tergicristallo) I1 I2 Motorino Tergicristallo (+)


(Tergicristallo (+1))

I3 I4 Motorino Tergicristallo (+1)

Motorino lavacristallo (-) I5 I6 Commutatore lampeggiatori

(Lavacristallo)


ES - 194

Da A


(Tergicristallo (+2))

I7 I8 Motorino Tergicristallo (+2)

Collegamento a 11-12 I9 Motorino Lavacristallo (+)

J/B C (Relè tergicristallo lnt.:S) I16 I17 Motorino Tergicristallo (S)

Collegamento a K5-K6 Collegamento a K36-K14

J/B C (Fusibile riscaldatore

(L))

K5 K6 Motorino riscaldamento (+)

Interruttore ventola riscalda-

mento (HI)

K7 K8 Motorino riscaldamento (-)

Motore ventola riscaldamento

(-)

K8 K9 Resistenza riscaldamento (HI)


mento (ME)

K10 K11 Resistenza riscaldamento

(ME)


mento (LO)

K12 K13 Resistenza riscaldamento

(LO)

J/B C (Fusibile 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)

Relè motore radiatore L26 L1 Motore ventola radiatore (+)

Collegamento a B19-B22 B24 Diodo (entrata) (interruttore

retronebbia)

Collegamento a A22-A14 B25 Diodo (uscita) (interruttore ret-

ronebbia)

Relè ventola radiatore (L) L17 L21 Sensore temperatura liquido

refrigerante (LO)

Collegamento a L2-L16 L11 Alternatore (IG)

Fuse engine 20A L2 L16 Relè ventola radiatore (B)

Collegamento a Z32-Z8 L10 Motore ventola radiatore

Collegamento a N1 ~ N2 L25 Relè ventola radiatore (+)

Collegamento a Z32-Z8 L22 Termo sensore ventola radia-

tore (-)

Collegamento a L33-L40 L31 Iniettore n° 4 (+)


ES - 195

Da A

R/B (Relè principale (L)) L33 L40 R/B (Relè pompa carburante

(+B))

R/B (Relè principale (+S)) L42 L39 R/B (Relè pompa carburante

(+S))

Fusibile EFI n° 1 L41A L41 R/B (Relè principale (+B))

Fusibile EFI n° 2 L48 L42 R/B (Relè principale (+S))

Collegamento a L17 ~ L21 L46 EFI ECU (A/T)

Collegamento a-X152 L50 Diodo (IN)

Fusible principale (B) M1 M2 Principale F/L

Commutatore chiave (ST) M3 M4 Motorino d'avviamento (ST)

Fusibile principale (L) N1 N2 J/B A (Commutatore a chiave

B))

Collegamento a N1-N2 N3 Commutatore a chiave (B)

Commutatore chiave (IG) N7 N15 J/B A (Commutatore a chiave

IG)

Collegamento 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 Controllo diagnostico (IG2)

Collegamento a N1-N2 N39 Fusibile (Fendinebbia)

Collegamento a N1-N2 01 Alternatore (B)

Quadro strumenti (Spia carica

batteria)

03 04 Alternatore (L)

J/B C (Fusibile ACC(L)) R1 R2 Accendisigari (+)

Collegamento a R1-R2 R4 Autoradio (+)

Commutatore a chiave (ACC) R6 R7 J/B A (Commutatore a chiave

(ACC))

Autoradio (Altoparlante (+)) R13 R15 Altoparlante (+)

Autoradio (Altoparlante (-)) R14 R16 Altoparlante (-)

R/B (Relè pompa carburante

(L))

U7 U12 Pompa carburante (+B)

EFI ECU diagnostica (W) X2 T4 Quadro strumenti (Diagnosti-

ca)


ES - 196

Da A

EFI ECU velocità (SPD) X4 H38 Quadro strumenti (Tachimetro

sensore velocità)

R/B (Relè pompa carburante (-

S))

X8 X257 EFI ECU (FC)

Controllo diagnostico (VF) X20 X21 EFI ECU (VF)

Collegamento a L41A-L41 X23 EFI ECU (BAT)

EFI ECU (DSW2) X18 X152 Diodo (IN)

Collegamento a K12-K13 X219 EFI ECU (BLW)

Collegamento a L33-L40 X251 EFIECU(+B1)

Collegamento a L33-L40 X252 EFIECU(+B2)

Controllo diagnostico (T) X57 X266 EFI ECU (T)

EFI ECU (SIO) X268 X269 Controllo diagnostico (SIO)

EFI ECU (REV) X242 X271 Controllo diagnostico (REV)

Massa telaio anteriore destra Z1 Z2 Massa telaio anteriore sinistro

Collegamento a Z1-Z2 Z3 Quadro strumenti (Massa)

Collegamento a Z1-Z2 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)

Collegamento a Z1 -Z2 Z10 Lampeggiatore anteriore/lat-

erale destro (-)

Collegamento a Z32-Z8 Z11 Lampeggiatore anteriore/lat-

erale sinistro (-)

Collegamento a Z1-Z2 Z13 Interruttore insufficiente livello

olio freni (-)

Collegamento a Z32-Z8 Z17 Luce posizione anteriore sin-

istra (-)

Collegamento a Z1 -Z2 Z18 Luce posizione anteriore des-

tra (-)

Collegamento a Z1-Z2 Z19 Interruttore fendinebbia

Collegamento a Z1 -Z2 Z20 Fendinebbia destro

Collegamento a Z1-Z2 Z21 Fendinebbia sinistro

Collegamento a Z1-Z2 Z22 Relè fendinebbia

Collegamento a -Z5 Z23 Fanale luci posteriori sinistro

Collegamento a Z1-Z2 Z26 Accendisigari (-)


ES - 197

Da A

Massa telaio anteriore sinistra Z12 Z27 Autoradio (-)

Collegamento a -Z5 Z33 Luce targa destra (-)

Collegamento a -Z5 Z34 Luce retromarcia

Collegamento a -Z5 Z37 Luce targa sinistra (-)

Collegamento a Z1 -Z2 Z84 Pompa carburante (Massa)

Collegamento a Z1-Z2 Z85 R/B (Relè principale (-S))

Collegamento a Z1 -Z2 ZA5 Interruttore retronebbia (-)

Collegamento a -Z5 ZA8 Luce retronebbia

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 Interruttore orientamento

proiettori

Resistenza (R1) ZB4 ZC3 Interruttore orientamento

proiettori

Collegamento a Z1 -Z2 ZB7 Tergicristallo (-)

Collegamento a Z1 -Z2 ZC1 Quadro strumenti

Collegamento a Z1-Z2 ZC2 Quadro strumenti

Collegamento a Z1-Z2 ZC4 EFI ECU ventola radiatore

Collegamento a -Z5 Z35 Fanale luci posteriori destro (-)


ES - 198


LEFT HAND DRIVE INSTRUMENT PANEL:

1. Main relay locking and fuel pump relay

2. Brake fluid level switch

3. Courtesy light switch

4. Buzzer

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

13. Rear fog light switch

14. Fog light switch

15. Loudspeaker

16. Stop light switch

17. J/B A connection

18. Fog light fuse


ES - 199


20. Flashing light switch

21. J/B B connection

22. Headlight fuses

23. Fog light relay

24. Windshield washer motor

25. Coolant temperature sensor

26. Radiator electric fan relay

27. Main fuse

28 . to the engine cable harness


30. Fuel pump

31. Fuel and low fuel gauge

32. Chassis earthing

33. Rear left lights

34. Rear fog light



37. Rear right lights

38. Diode

39. Diode

40. Radiator cooling electric fan

41. To the injection cable harness


43. 12V Acc. socket / Cigarette lighter

44. Radio

45. Radio

46. Front right /side turn indicator

47. Electric heater fan switch

48. Right fog light

49. Right headlight

50. Right headlight adjustment actuator

51. Front right position light

52. Front right chassis ground

53. To the courtesy light cable harness

54. Electric fan motor

55. Heater resistance

56. EFI fuse No. 1 - EFI fuse No. 2


ES - 200

57. Diagnostic check

58. Windscreen wiper motor


60. Instrument panel

61. Key switch

POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEWS

ble class=editor height="60%" width="70%" border=1>

From A


Right headlight (HI) A1 A2 Left headlight (HI)

Right headlight (LO) A3 A4 Left headlight (LO)

Connection to A1-A2 A5 Turn indicator switch (Switch-

ing (HU))


ing (HL))

Connection to A1-A2 A7 Instrument panel (High beam

warning light)

Left headlight fuse (B) A21 A8 J/B C (Light fuse: L)

Right headlight (+B) A9 A24 Right headlight fuse (B)


warning light)

Left headlight (+B) A11 A23 Left headlight fuse (L)

Connection to A22-A14 A12 Courtesy light (B)

Right headlamp (B) A22 A14 J/B C (Light fuse: L)

Connection to A3-A4 A15 Diode (output)


Turn indicator switch (emer-

gency)

A19 A39 Instrument panel (emergency

warning light)

Connection to A9-A24 A54 Right headlight aiming (+)

Connection to A11 -A23 A61 Left headlight aiming (0)

Right headlamp aiming (0) A56 A63 Left headlight aiming (0)

Connection to A56-A63 A69 Resistance (R4)

Connection to A11 -A23 A70 Resistance (R3)

Resistance (R4) A71 A75 Headlight aiming switch




ES - 201

From A

Front position light (right) B1 B2 Front position light (left)

Connection to B1-B2 B3 Rear right position light (B)

Connection to B18-B3 B4 Rear left position light (B)

Connection to B1-B2 B5 Turn indicator switch (lighting

(-))

Rear fog light switch (L) B7 B15 Rear fog light (+)

Fog light switch B21 B16 Fog light relay

Fuse (fog light) B17 B18 Fog light relay

Connection to B1-B2 B20 Rear fog light switch

Fog light relay B19 B22 Right fog light

Connection to B22-B19 B23 Left fog light

Turn indicator switch (Fog

lights)

C1 C20 Rear fog light switch (B)

Connection to B1-B2 C2 Instrument panel (lighting)

Connection to B1-B2 C3 Right license plate light (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 switch (+)

Horn (-) E3 E4 Turn indicator switch (Horn

(+))

Rear lights (Right stop light

(+))

E5 E6 Stop light switch (-)


(+))

E5 E8 Rear lights. (Left stop light)

Right turn indicator switch F1 F9 Front right /side turn indicator

Left turn indicator switch F3 F10 Front 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 turn indicator

Connection to F3-F10 F8 Rear left turn indicator

Handbrake switch G1 G5 Instrument panel (handbrake

warning light)


ES - 202

From A

Instrument panel (brake oil

level warning lights)

G2 G3 Low brake oil level switch

Reverse gear light switch (-) G6 G7 Reverse gear light (+)

Fuel level transmitter (+) H2 H3 Instrument panel (fuel gauge)

Oil pressure switch (+) H4 H5 Instrument panel (oil pressure

warning light)

Instrument panel (Coolant

temp. gauge)

H6 H7 Coolant temperature sensor

(+)

Instrument panel (Low fuel

warning light)

H8 H9 Fuel level sensor (reserve)

Connection to B1-B2 H50 Sounding mechanism (lights

on)

Sounding mechanism (lights

on)

H51 H52 Diode (input)

Diode (output) H53 D2 Courtesy light switch (+)

Connection to B19-B22 B24 Diode (input) (Rear fog light

switch)

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)

Windshield washer motor (-) I5 I6 Turn indicator switch (Wind-

shield washer)


screen wiper (+2))


Connection to I1-I2 I9 Windshield washer motor (+)

J/B A (Int. windscreen wiper

relay: S)

I16 I17 Windscreen wiper (S)

Connection to K5-K6 Connection to K36-K14

J/B A (Heater fuse (L)) K5 K6 Heating motor (+)

Heating fan switch (HI) K7 K8 Heating motor (-)

Heating fan motor (-) K8 K9 Heating resistance (HI)

Heating fan switch (ME) K10 K11 Heating resistance (ME)

Heating fan switch (LO) K12 K13 Heating resistance (LO)

J/B A (Heater fuse (L)) K36 K14 Heating switch (B)


ES - 203

From A

Connection to K5-K6 K17 Reverse gear light switch (+)

Connection to K5-K6 K18 Instrument panel (+B)

Connection to K12-K13 KA1 Diode (output)

Radiator motor relay L26 L1 Radiator fan motor (+)

Radiator fan relay (-) L17 L21 Coolant temperature sensor

(LO)

Connection to L2-L16 L11 Alternator (IG)

FUSE ENGINE 20A L2 L16 Radiator fan relay (B)

Connection to Z32-Z8 L10 Radiator fan motor

Connection to N1-N2 L25 Radiator fan relay (+)

Connection to Z32-Z8 L22 Radiator fan thermal sensor

Connection to L33-L40 L31 Injector No. 4 (+)

R/B (Main relay (L)) L33 L40 R/B (Fuel pump relay (+B))

R/B (Main relay (+S)) L42 L39 R/B (Fuel pump relay (+S))

EFI fuse No. 1 L41A L41 R/B (Main 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 N2 J/B A (Key switch (B))

Connection to N1-N2 N3 Key switch (B)

Key switch (IG) N7 N15 J/B A (Key switch IG)

Connection to L2-L16 N8 Ignition

Connection to N7-N15 N16 J/B A (Key switch (IG1 ))

EFI F/L N35 N46 EFI fuse No. 1

Key switch (IG2) N30 N37 EFI fuse No. 2

Connection to L48-L42 N38 Diagnosis check (IG2)

Connection to N1-N2 O1 Alternator (B)

Instrument panel (Battery

charge warning light)

O3 O4 Alternator (L)

J/B B (ACC fuse (L)) R1 R2 Cigarette lighter (+)

Connection to R1-R2 R4 Car radio (+)

Key switch (ACC) R6 R7 J/B A (Key switch (ACC))

Car radio (Loudspeaker (+)) R13 R15 Loudspeaker (+)

Car radio (Loudspeaker (-)) R14 R16 Loudspeaker (-)


ES - 204

From A

R/B (Fuel pump relay (L)) U7 U12 Fuel pump (+B)

EFI ECU - diagnosis (W) X2 T4 Diagnosis instrument panel

(Diagnosis)

EFI ECU - speed (SPD) X4 H38 Speed sensor instrument pan-

el (Speedometer)

R/B (Fuel pump relay (-S)) X8 X257 EFI ECU (FC)

Instrument panel (VF) X20 X21 EFI ECU (VF)

Connection to L41A-L41 X23 EFI ECU (BAT)

EFI ECU (DSW2) X18 X152 Diode (IN)

Connection to K12-K13 X219 EFI ECU (BLW)

Connection to L33-L40 X251 EFI ECU (+B1)


Diagnostic check (T) X57 X266 EFI ECU (T)

EFI ECU (SIO) X268 X269 Diagnostic check (SIO)

EFI ECU (REV) X242 X271 Diagnostic check (REV)

Front right chassis 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 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 to Z1 -Z2 Z10 Front right side turn indicator

(-)

Connection to Z32-Z8 Z11 Front left side turn indicator (-)

Connection to Z1 -Z2 Z13 Low brake oil level switch (-)

Connection to Z32-Z8 Z17 Front left position light (-)

Connection to Z1 -Z2 Z18 Front right position light (-)

Connection to Z1 -Z2 Z19 Fog light switch

Connection to Z1 -Z2 Z20 Right fog light

Connection to Z1 -Z2 Z21 Left fog light

Connection to Z1 -Z2 Z22 Fog light relay

Connection to -Z5 Z23 Rear left lights

Connection to -Z5 Z35 Rear right lights

Connection to Z1 -Z2 Z26 Cigarette lighter (-)

Front left chassis ground Z12 Z27 Car radio (-)

Connection to -Z5 Z33 Right license plate light (-)


ES - 205

From A

Connection to -Z5 Z34 Reverse gear light

Connection to -Z5 Z37 Left license plate light (-)

Connection to Z1 -Z2 Z84 Fuel pump (Ground)

Connection to Z1 -72 Z85 R/B (Main relay (-S))

Connection to Z1 -Z2 ZA5 Rear fog light switch (-)

Connection to -Z5 ZA8 Rear fog light (-)

Connection to Z1 -Z2 ZB1 Right headlight 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 aiming switch

Connection to Z1 -Z2 ZB7 Windscreen wiper motor (-)

Connection to Z1 -Z2 ZC1 Diagnostic check


Connection to Z1 -Z2 ZC4 EFI ECU - fan

Connection to N1-N2 N39 Fog light fuse

Cablaggio cruscotto (Furgone-guida a destra)


ES - 206


RIGHT HAND DRIVE VAN:


2. left headlight adjustment actuator

3. front left /side turn indicator

4. front left fog light

5. left headlight


7. Diode

8. Diode


10. EFI ECU



13. radiator cooling electric fan

14. windshield washer motor

15. rear window washer motor

16. temperature sensor

17. radiator fan relay

18. main fuse


ES - 207

19. to the engine cable harness

20. to the engine cable harness

21. to the chassis cable harness

22. fuel pump

23. fuel and low fuel gauge

24. stop light switch

25. electric heater motor


27. Fog light fuse

28. J/B C connection

29. front fog light relay

30. headlight fuses


32. flashing light switch

33. key switch

34. loudspeaker

35. cigarette lighter

36. radio

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 light

44. front right /side turn indicator

45. right headlight

46. front right position light

47. front right chassis ground

48. courtesy light switch

49. brake fluid level switch

50. main relay box and fuel pump

51. rear defroster switch

52.rear window wiper switch

53. rear fog light switch

54. fog light switch



ES - 208

From A





ing (HU)


ing (HL)


warning light)

Left headlight fuse (B) A21 A8 J/B C Fuse box (Light fuse: L)

Right headlight (+B) A9 A24 Right headlight fuse (B)


warning light+)

Left headlight (+B) A11 A23 Left headlight fuse (L)


Connection to A22-A14 A13 Ceiling light (B)

Right headlight fuse (B) A22 A14 J/B C Fuse box (Light fuse: L)



Turn ind. switch (emergency) A19 A39 Instrument panel (Emergency

warning light)


Connection to A11 -A23 A61 Left headlight aiming (+)

Right headlight aiming (0) A56 A63 Left headlight aiming (0)









(-))


fog light switch B21 B16 Fog light relay



ES - 209

From A



Turn indicator switch (fog

lights)




Connection to B1-B2 C4 Heater switch (Lighting)


J/B C horn fuse (L) - Fuse box E1 E7 Stop light switch (+)


Horn (-) E3 E4 Turn indicator switch (Horn

(+))


(+))


Turn indicator switch (right) F1 F9 Front right /side turn indicator

Turn indicator switch (left) F3 F10 Front left /side turn indicator

Connection to F1-F9 F5 Instrument panel (Turn indica-

tor warning light)


tor warning light)



Handbrake switch G1 G5 Instrument panel (handbrake

warning light)

Instrument panel (Brake oil

level warning light)



Fuel level transmitter (+) H2 H3 Instrument panel (Fuel gauge)

Oil pressure switch (+) H4 H5 Instrument panel (Oil pressure

warning light)

Instrument panel (Coolant

temp. gauge)


(+)


warning light)


J/B C (Windscreen wiper fuse) I1 I2 Windscreen wiper motor (+)


ES - 210

From A


screen wiper (+1))



shield washer)


screen wiper (+))



Rear window wiper switch

(rear window washer)

I10 I11 Rear window washer motor (-)

Rear window wiper switch (+) I12 I13 Rear window wiper motor (-)

Connection to -19 I14 Rear window wiper motor (+)

Connection to -19 I15 Rear window washer motor (+)

J/B C (Int. windscreen wiper

relay: S)



J/B C (Defroster fuse (L)) K1 K2 Defroster switch (+)

Defroster switch (-) K3 K4 Defroster (+)

J/B (Heater fuse (L)) K5 K6 Heating motor (+)

Heating fan switch (H1) K7 K8 Heating motor (-)




J/B C (Heating fuse (L)) K36 K14 Heating switch (B)



Connection to K12-K13 KA1 Diode (output) (rear fog light

switch)


Radiator fan relay (L) L17 L21 Coolant temperature sensor

(LO)


Fuse engine 20A L2 L16 Radiator fan relay (B)

Connection to Z32-Z8 L10 Radiator fan motor (-)

Engine cooling motor (-) L28 L19 Engine cooling motor relay (+)

Front right chassis ground Z1A L20 Engine cooling motor relay (-)

No.1 - No.2 connection L25 Radiator fan relay (+)


ES - 211

From A

Connection to Z32-Z8 L22 Radiator fan relay




EFI fuse No. 1 L41A L41 R/B (Main relay (+B))


Connection to L17-L21 L46 EFI ECU (AT)


Main fuse (B) M1 M2 F/L Main fuse


Main fuse (L) N1 N2 J/B A (Key switch (B))


Key switch (IG) N7 N15 J/B A (Key switch IG)


Connection to N7-N15 N16 J/B A (Key switch (IG1 ))

EFI F/L N35 N45 EFI fuse No. I


Connection to L48-L42 N38 Diagnostic check (IG2)

Connection to N1-N2 N39 Fuse (Fog light)





J/B A (ACC fuse (L)) R1 R2 Cigarette lighter (+)






EFI ECU - diagnosis (W) X2 T4 Instrument panel (Diagnosis)

EFI ECU - speed (SPD) X4 H38 Instrument panel (Speed sen-

sor speedometer)


Diagnostic check (VF) X20 X21 EFI ECU (VF)

Connection to L41A-L41 X23 IEFI ECU (BAT)

F/B (Fuel pump relay (L)) X124 IEFI ECU (BAT)

EFI ECU (H/L) X18 X152 Diode (IN)


ES - 212

From A




Instrument panel (T) X57 X266 EFI ECU (T)

EFI ECU (SIO) X268 X269 Diagnostic check (SIO)



Connection to Z1 -72 Z3 Instrument panel (Ground)





Connection to Z1 -Z2 Z10 Front right /side turn indicator

(-)

Connection to Z32-Z8 Z11 Front left/side turn indicator (-)


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 -Z5 Z33 Right license plate light (-)



Connection to Z1 -Z2 Z85 R/B (Main relay (-S))



tuator (-)


tuator (-)

Connection to ZB1-ZB2 ZB3 Resistance (R1)


Resistance (R1) ZB4 ZC3 Headlight aiming switch

Connection to Z1 -Z2 ZB7 Windscreen wiper (-)

Connection to Z1 -Z2 ZC1 Instrument panel


ES - 213

From A

Connection to Z1 -Z2 ZC2 Instrument panel

Connection to Z5 Z35 Rear right lights (-)


LEFT HAND DRIVE VAN:

1. main relay box and fuel pump

2. brake fluid level switch

3. courtesy light switch

4. sound alarm (buzzer)

5. left headlight adjustment actuator



8. left headlight

9. Horn

10. left fog light

11. Front left /side turn indicator

12. headlight adjustment switch

13. fog light switch

14. rear window wiper


ES - 214

15. rear fog light switch

16. stop light switch


18. Fog light fuse


20. flashing light switch


22. front fog light relay

23. windshield washer motor

24. rear window wiper motor

25. coolant temperature sensor

26. radiator fan relay

27. main fuse



30. fuel and low fuel gauge

31. fuel pump

32. to the chassis cable harness

33. Diode

34. Diode

35. radiator electric fan motor


37. ECU control unit

38. cigarette lighter

39. radio

40. radio

41. front right /side turn indicator

42. electric heater fan switch

43. right fog light

44. right headlight

45. right headlight adjustment actuator

46. front right position light

47. front right chassis ground


49. electric heater motor

50. resistance component (heating)

51 EFI fuses No. 1 - No. 2



ES - 215

53. windscreen wiper motor


55. instrument panel

56. key switch


From A





ing (HU))


ing (HL))


warning light)

Left headlight fuse (B) A21 A8 J/B C (Light fuse: L)

Right headlight (+B) A9 A24 Right Headlight fuse (B)


warning light+1 )

Left headlight (+B) A11 A23 Left headlamp fuse (L)



Right Headlight fuse (B) A22 A14 J/B C (Light fuse: L)



Turn indicator switch (emer-

gency)

A19 A39 Instrument panel (Emergency

warning light)


Connection to A11 -A23 A61 Left headlight aiming (+)

Right headlamp aiming (0) A56 A63 Left headlight aiming (0)








ES - 216

From A



(-))


Fog light switch B21 B16 Fog light relay




Connection to B19-B22 B23 Left fog light

Turn indicator switch (Fog

lights)




Connection to B1-B2 C4 Heater switch (lighting)


J/B C horn fuse (L) E1 E7 Stop light switch (+)


Horn (-) E3 E4 Turn indicator switch (Horn +))


(+))


Right turn indicator switch F1 F9 Front right /side turn indicator

Left turn indicator switch F3 F10 Front left /side turn indicator

Connection to F1-F9 F5 Instrument panel light (Turn in-

dicator warning light)


tor warning light)



Handbrake switch G1 G5 Instrument panel (Handbrake

warning light)

Instrument panel (Brake oil

level warning light)



Fuel level transmitter H2 H3 Instrument panel (fuel gauge)

Oil pressure switch (+) H4 H5 Instrument panel (Oil pressure

warning light)


ES - 217

From A

Instrument panel (cooling tem-

perature gauge)


(+)


warning light)


Connection to B1-B2 H50 Sounding mechanism (Lights

on)

Sounding mechanism (Lights

on)

H51 H52 Diode (input)

Diode (output) H53 D2 Courtesy light switch (+)

Connection to B19-B22 B24 Diode (input) (Rear fog light

switch)

Connection to A22-A14 B25 Diode (output) (Rear fog light

switch)

J/B C (Windscreen wiper fuse) I1 I2 Windscreen wiper motor (+)


screen wiper (+1))



shield washer)


screen wiper (+2))



Rear window wiper switch

(rear window washer)

I10 I11 Rear window washer motor (-)

Rear window wiper switch (+) I12 I13 Rear window washer motor (+)

Connection to -I9 I14 Rear window wiper motor (-)

Connection to -I9 I15 Rear window wiper motor (+)

J/B C (Int. windscreen wiper

relay: S)



J/B C (defroster fuse (L)) K1 K2 Defroster switch

Defroster switch (-) K3 K4 Defroster (+)

J/B C (Heater fuse (L)) K5 K6 Heating motor (+)

Heating fan switch (H]) K7 K8 Heating motor (-)





ES - 218

From A

J/B C (Heating fuse (L)) K36 K14 Heating switch (B)



Connection to K12-K13 KA1 Diode (output)


Radiator fan relay L17 L21 Coolant temperature sensor


FUSE ENGINE 20A L2 L16 Radiator fan motor (B)

Connection to Z32-Z8 L10 Radiator fan relay (L)

No.1 - No.2 connection L25 Radiator fan thermal sensor

(+)

Connection to Z32-Z8 L22 Radiator fan relay (-)




EFI fuse No. 1 L41A L41 R/B (Main relay (+E))


Connection to L17-L21 L46 EFI ECU (A/T)


Main fuse (B) M1 M2 F/1 Main fuse


Main fuse (L) N1 N2 J/B A (Key switch (E))


Key switch (IG) N7 N15 J/B (Key switch IG)


Connection to N7-N 15 N16 J/B A (Key switch (IG1 ))

EFI F/L N35 N45 EFI fuse No. 1


Connection to L48-L42 N38 Diagnostic check (IG2)





J/B C (ACC fuse (L)) R1 R2 Cigarette lighter





ES - 219

From A



EFI ECU - diagnosis (W) X2 T4 Diagnosis instrument panel

(Diagnosis)

EFI ECU - speed (SPD) X4 H38 Speed sensor instrument pan-

el (Speedometer)


Instrument panel (VF) X20 X21 EFI ECU (VF)

Connection to L41A-L41 X23 EFI ECU (BAT)

Connection to K3-K4 X124 EFI ECU (DEF)

EFI ECU (H/L) X18 X152 Diode (IN)




Diagnostic check (T) X57 X266 EFI ECU (T)

EFI ECU (S10) X268 X269 Diagnostic check (SIO)



Connection to Z1 -Z2 Z3 Instrument panel (Ground)




Connection to Z1 -Z2 Z11 Front right side turn indicator

(-)

Connection to Z32-Z8 Z12 Front left side turn indicator (-)


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 Z1 -Z2 Z19 Fog light switch

Connection to Z1 -Z2 Z20 Right fog light

Connection to Z1-Z2 Z21 Left fog light

Connection to Z1 -Z2 Z22 Fog light relay

Connection to Z1 -Z2 Z26 Cigarette lighter (-)


ES - 220

From A




Connection to Z1 -Z2 Z85 R/B (Main relay (-S))



tuator


tuator

Connection to Z1 -Z2 ZB3 Resistance (R1)



Connection to Z1 -Z2 ZB7 Windscreen wiper motor (-)



Connection to No.1 - No.2 N39 Fog light fuse

Cablaggio cruscotto (Tipper-guida sinistra)


ES - 221


TIPPER:

1. Main relay block

2. Brake fluid level switch

3. Courtesy light switch

4. Sound alarm (buzzer)

5. Headlight adjustment switch

6. Tipper warning light

7. Fog light switch

8. Tipper ascent/descent switch

9. Blinker

10. Rear fog light switch



13. Left headlight

14. Left headlight adjustment 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


23. Fog light fuse

24. J/B C connection

25. Fog light relay

26. Front headlight fuse Left (10A)


28. Flashing light switch

29. Front windscreen wiper motor

30. OBD diagnostic check

31. Radiator cooling electric fan

32. Sound alarm (tipper)

33. Windshield washer electric pump motor

34. Radiator electric fan thermoswitch

35. Radiator fan relay

36. Main fuse (60A)


ES - 222

37. to the engine compartment main cable harness

38. to the injection cable harness

39. Limit switch (tipper descent)

40. Tipper pump solenoid valve

41. Rear oxygen probe

42. Tipper electric pump relay

42 B. To the battery positive (+) cable harness

43. Fuel pump

44. Fuel level sensor

45. Rear right lights


47. Chassis ground

48. Right license plate light

49. Left license plate light

50. Rear fog light

51. Rear left lights

52. Diode

53. Diode


55. EFI ECU

56. EFI fuse No.1 - EFI fuse No. 2

57. 12V Acc. socket / Cigarette lighter

58. Car radio

59. Heater electric fan switch

60. Right headlight adjustment actuator

61. Right fog light

62. Front right/side turn indicator

63. Right headlight

64. Front right position light

65. Front right chassis ground



ES - 223

INDEX OF TOPICS

ENGINE EN

Engine type 2

Engine mechanism

E.G.R. circuit intake duct

Inlet manifold removal

THE INLET MANIFOLD CAN BE REMOVED TO-

GETHER WITH 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 modulator.

3. Remove the bolts and fixing nuts on the throttle body and gasket.

KEY:

A= Throttle body

B= Gasket

PORTER 1.3 16V Engine

EN - 225

4. Take out the nut fixing the delivery pipe, then

remove the delivery pipe.CAUTIONLEAVE THE INJECTOR ON THE INLET MANIFOLD SIDE.BE CAREFUL NOT TO LET THE INJECTORS FALL. PLACEA CLOTH OR A SIMILAR OBJECT UNDER THE INJECTORBECAUSE FUEL MAY COME OUT.

5. Remove bolts and nuts fixing the inlet manifold

by undoing them evenly in two or three stages,

according to the sequence indicated 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

- DO NOT INTERFERE WITH OTHER PARTS.

3. Place bolts and nuts fixing the inlet manifold.

• By-Pass pipe

• Oil pressure switch terminal

4. Tighten bolts and nuts fixing the inlet manifold

evenly to the prescribed torque, in two or three

stages, according to the sequence indicated in the

figure on the right.

Locking torques (N*m)Cylinder head - Inlet manifold 15 ÷ 22

Engine PORTER 1.3 16V

EN - 226

5. Fit the inlet manifold supports and tighten the

fixing bolts.

6. Fit the engine wire ground lead to the inlet mani-

fold.

7. Connect the fuel inlet and reverse 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 the inlet manifold.

12. Fit the delivery pipe.

13. Tighten the fixing nuts.

Locking torques (N*m)Inlet manifold - Fuel delivery pipe 6÷11


EN - 227

14. Fit the throttle body interposing a new gasket.

15. Tighten the bolts and fixing nuts.

Locking torques (N*m)Inlet manifold - Throttle body 15÷22

Inlet manifold fitting -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 pipe 47÷71

18. Fit the EGR pipe in the inlet manifold interpos-

ing a new gasket.

Locking torques (N*m)Inlet manifold - EGR pipe 15÷22


EN - 228

19. Connect the fittings to the respective pipes.

20. Engine cable installation

• Connect the engine wire connector to

the parts listed below:

- Ignition coils

- Injectors

- Pressure sensor

- Throttle position sensor

- Intake air temperature sensor

- VSV (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 of Exhaust Fumes)

- Ground cables

- Handbrake switch

- Oil pressure switch

• Fit the terminals on each bracket.

21. Fit the toothed belt.

22. Fit the alternator.

23. Add coolant.

24. Adjust valve clearance with temperature.


EN - 229

Exhaust pipe

Manifold check

1. Check for any deformation of the head-cylinder connection surface with the exhaust manifold, using

a ruler with rectilinear edge and a thickness gauge.

CharacteristicMaximum 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.

CharacteristicMaximum deformation limit:0.1 mm

Exhaust manifold removal

1. Remove the front exhaust pipe from the exhaust

manifold.

2. Remove the oxygen sensor from the exhaust

manifold.


EN - 230

3. Loosen bolts and nuts fixing the exhaust mani-

fold evenly in two or three stages, according to the

sequence indicated in the figure on the right.

4. Remove the exhaust manifold from the cylinder

head avoiding any interference with other parts.

Exhaust manifold fitting

1. Fit the new exhaust manifold gasket.

2. Fit the exhaust manifold on the cylinder head.N.B.- PAY ATTENTION NOT TO INTERFERE WITH OTHERPARTS.

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 the oxygen sensor on the exhaust manifold.

5. Connect the front exhaust pipe to the exhaust

manifold, interposing a new gasket.

6. Tighten the bolt fixing the front exhaust pipe to

the prescribed torque.- DO NOT REUSE OLD GASKETS. - BE EXTREMELY CARE-FUL TO AVOID DAMAGING THE CABLE HARNESS DUR-ING FITTING OPERATIONS.

Locking torques (N*m)


EN - 231

Cylinder head - Exhaust manifold 35 ÷ 53 Ex-haust manifold for oxygen sensor 29.4 ÷ 39.2 NmExhaust manifold - Front exhaust pipe 42÷62

Alternator drive belt

Tension adjustment

1. Screw the adjustment bolt until the driving belt

bending reaches the indicated value. Check by

pressing the belt central part between the water

pump pulley and the alternator pulley, applying a

force equivalent 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 force equivalent to 98 N at the indicated point.

CharacteristicNew belt:

3.5 ÷ 5.5 mm

Belt bending specified value:

with the application of a force equivalent to 98 N

at the indicated point.

CharacteristicUsed belt:4.5 ÷ 6.5 mm

2. Tighten the alternator locking screws.

Locking torques (N*m)Generator fixing screws - M8 18÷22 Generator fixing screws - M10 28÷32


EN - 232

Driving belt test

1. Visual inspection of the driving belt.

Visually check the belt for any traces of separation

of the upper or lower part of the belt from the ad-

hesive rubber, belt core separations from the

sides, belt core ravelling, adhesive rubber weft

ravelling, cracks or separations of ribs, tearing or

cracking in the belt internal ribs. Replace the driv-

ing belt, if necessary.

2. Driving belt tension test. Measure the driving

belt deflection (bending) when a 98 N (10 Kgf)

force is applied at the middle point of the belt, be-

tween the alternator pulley and the water pump

pulley.

CharacteristicRated deflection of the New Belt (with a 10 kgforce applied at the indicated point):3.5 - 5.5 mm

Rated deflection of the Used Belt (with a 10 kgforce applied at the indicated point):4.5 - 6.5 mm

KEY:

A = Water pump pulley

B = Alternator pulley

Adjust driving belt tension, if necessary.

• A "NEW BELT" IS A BELT THAT HAS BEEN USED FOR LESS THAN FIVE MINUTES ONA RUNNING ENGINE.

• A "USED BELT" IS A BELT THAT HAS BEEN USED FOR MORE THAN FIVE MINUTESON A RUNNING ENGINE.

• AFTER FITTING A NEW BELT, LET THE ENGINE RUN FOR AT LEAST FIVE MINUTESAND THEN CHECK TENSION AGAIN.


EN - 233

Flywheel

Flywheel test

1. Visually inspect the flywheel to detect any

cracks, wear or other damage.

2. Visually inspect the crown gear to detect any

worn areas, cracks or other damage. Replace the

crown gear, if necessary.

Crown gear replacement

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 torch, heat the crown gear evenly, until

due to its own weight, it adapts to the flywheel.N.B.- DO NOT FORCE THE CROWN GEAR.- DO NOT COOL THE CROWN GEAR QUICKLY BY USINGWATER.

4. Let the crown gear gradually cool down.


EN - 234

Driving pulley

Crankshaft pulley test

1. Visually check the crankshaft pulley

• Check for deformations, wear or

cracks on the crankshaft pulley attach-

ment seat.

• Check for any deformations or wear on

the belt contact surface. Replace the

crankshaft pulley, if necessary.

Crankshaft pulley flange 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 screw

Fit the timing pinion fixing screw Tighten the screw

to the specified torque.- AVOID THE ROTATION OF THE CRANKSHAFT BY USINGTHE SPECIAL TOOL BELOW.

Specific tooling020184Y FLYWHEEL LOCKING TOOL

Locking torques (N*m)Crankshaft - Crankshaft belt pulley 88÷98


EN - 235

Timing belt and gears

KEY:

1. Alternator-water pump belt


3. Pulley-crankshaft 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 pump belt.

3. Remove the water pump pulley, undoing the fix-

ing screws.


EN - 236

4. Remove the crankshaft pulley.SET THE GEARSHIFT LEVER TO THE FOURTH GEAR, SOAS TO AVOID THE ROTATION OF THE CRANKSHAFT.

5. Disconnect the minimum oil pressure switch

connector and remove the screws locking the elec-

tronic cable supporting brackets.

6. Remove 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 ARROWON THE BELT INDICATING THE BELT ROTA-TION DIRECTION.

WARNING• DO NOT ATTEMPT TO REMOVE THE TIMING

BELT WITH A SCREWDRIVER, OR ANYTHINGSIMILAR, DURING REMOVAL OR FITTING.

• PREVENT THAT THE BENT COMES INTOCONTACT WITH OIL OR WATER.

• DO NOT BEND, TWIST OR TURN THE BELTUPSIDE DOWN.


EN - 237

7. Turn the crankshaft until the "F" mark on the

camshaft pulley matches the indicator of the head

- 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 BELTUPSIDE DOWN.

• PREVENT THAT THE BENT COMES INTOCONTACT WITH OIL, WATER OR VAPOURS.


EN - 238

If the belt has defects similar to those shown in the

figures, check the following points and replace the

belt, if necessary.

1. Early breaking

- Check for a proper fitting.

- Check that the timing gear cover gaskets are not

damaged and that they are properly fitted.

2. If the belt teeth 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 only one side of the belt is worn and damaged,

check the crankshaft pulley flange.

5. If belt teeth are worn, check for possible damage

on the cover gasket, or if the gasket has been

properly fitted. Check there are no foreign bodies

on the pulley teeth.


EN - 239

Belt tensioner

Belt tensioner pulley check

If the tensioner is not damaged, check if the rele-

vant bearing has an excessive clearance.• CHECK THAT PULLEYS TURN FREELY

(WITHOUT JAMMING).• CHECK THAT THE BELT CONTACT SUR-

FACE IS NOT DAMAGED.• REPLACE THE BELT TENSIONER PULLEY, IF

NECESSARY.NEVER WASH THE BELT TENSIONER PULLEY

Timing belt tensioner spring check

1. Check the unloaded spring length.

CharacteristicUnloaded length:

not exceeding 46.5 mm

2. Check the spring tension when the spring is

tensioned up to the length corresponding to the

working position.

Smontaggio puleggia sull'albero motore

Crankshaft pulley and flange test

1. Measure the pulley outside diameter, using a gauge.

CharacteristicCrankshaft pulley wear limit (mm)

59.3


EN - 240

If the value measured is lower than the rated value,

replace the pulley.

2. Visually check for possible damage on the pul-

ley. If there is damage, replace the pulley.

3. Carry out a visual inspection of the crankshaft

pulley flange, to check for possible bending, wear

or damage.

If there is damage, replace the flange.

Crankshaft pulley removal


2. Remove the screw locking the crankshaft pulleyLOCK THE CRANKSHAFT WITH THE SPECIAL TOOL FIT-TED INSTEAD THE STARTER MOTOR. DURING A SERV-ICE ON A BENCH, USE THE SPECIAL TOOL.

Specific tooling020397Y FLYWHEEL LOCK WRENCH (ENGINEON VEHICLE)

020184Y FLYWHEEL LOCKING TOOL


EN - 241

3. Remove the crankshaft pulley.IF THERE WAS A DIFFICULTY DURING THE CRANK-SHAFT PULLEY REMOVAL USE THE SPECIAL TOOL.

4. Remove the timing belt pulley flange.

Refitting pulley on crankshaft

Crankshaft pulley fitting

1.Fit the crankshaft pulley flange with the edge

bending facing 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 screw to the prescribed tor-

que.• AVOID CRANKSHAFT ROTATION.• USE THE SPECIAL TOOLS PROVIDED


020397Y FLYWHEEL LOCK WRENCH (ENGINEON VEHICLE)

Locking torques (N*m)Crankshaft - timing system pulley screw 88 ÷ 98


EN - 242

Removal - Refitting timing pulley

Camshaft pulley removal


2. Remove the cylinder head cover.

3. Camshaft pulley removal. Using a special tool,

prevent the camshaft pulley from rotating, then un-

do the three pulley fixing screws. Then, remove the

camshaft pulley.

Specific tooling020172Y TOOL TO LOCK THE TIMING BELTPULLEY

Camshaft pulley check

1. Measure the pulley outside diameter with a

gauge.

CharacteristicTiming shaft pulley wear limit119.8

If the value measured is lower than the specified value, replace the pulley.

2. Visually check that the timing belt pulley is not

damaged. Replace, if necessary.


EN - 243

Camshaft pulley fitting

1. Fit the camshaft pulley on the camshaft, so that

the "F" mark remains visible and matches the po-

sition notch.

2. Fit the screws locking the pulley, avoiding that

the latter rotates, inserting a steel rod inside the

pulley hole or using the special tool.• DO NOT ROTATE THE CAMSHAFT• BE CAREFUL NOT TO DAMAGE THE CYLIN-

DER HEAD CLOSING SURFACE GASKET.• SCREWS AS WELL AS THREADED HOLES

MUST BE DRY DURING TIGHTENING.

Specific tooling020172Y TOOL TO LOCK THE TIMING BELTPULLEY

Locking torques (N*m)Timing system pulley screws 15÷22

Tension spring connection

Connect the tension spring to the timing belt ten-

sioner.

Attach the tension spring ring to the pin.

Fit the belt tensioner and fixing screw.• ATTACH THE SPRING RING FIRMLY ON THE

RELEVANT PIN.• MAKE SURE THAT THE PIN ON THE OIL

PUMP IS FITTED IN THE TENSIONER HOLE.

Valve timing - Belt refitting

Timing belt fitting

1. Temporarily fit the head cover.


EN - 244

2. Place the timing shaft pulley with reference point

B matching the head coupling surface with the

cover.

3. Match reference point C of the crankshaft pulley

with indicator D located in the oil pump casting.

4. Fit the belt so that the two coloured marks match

the respective pulley references.• DO NOT SPILL OIL, WATER ETC. ON THE

TIMING BELT.• DO NOT ATTEMPT TO REMOVE THE BELT

WITH A SCREWDRIVER OR ANYTHING SIMI-LAR.

• WHEN REFITTING A BELT, THERE MUST BE35 TEETH BETWEEN THE CRANKSHAFTPULLEY AND THE CAMSHAFT PULLEY REF-ERENCES.

• WHEN REFITTING A USED BELT, KEEP THESAME ROTATION DIRECTION (SEE DEFLEC-TION APPLIED DURING 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 tensioner locking bolt. Tension the

belt. Temporarily tighten the locking screw.MAKE SURE THAT THERE IS NO CLEARANCE ON THETIGHT SECTION OF THE BELT (THE OPPOSED SIDE TOTHE TENSIONER).

6. Rotate the crankshaft by 3~4 turns in the normal

direction of rotation.

After aligning the belt, continue in the rotation di-

rection until the letter "F" of the pulley is positioned

three teeth before the reference located in the

head cover.NOW, DO NOT TURN THE CRANKSHAFT IN THE OP-POSED DIRECTION.MAKE SURE THAT THE BELT IS NOT BENT IN THE SEC-TION BETWEEN THE CRANKSHAFT PULLEY AND THECAMSHAFT PULLEY.


EN - 245

7. Loosen the tensioner locking screw.

8. Further turn the crankshaft in the regular direc-

tion until reference "F" of the camshaft pulley

matches the indicator (notch) placed on the head

- cylinder cover.• NEVER TURN THE CRANKSHAFT IN THE RE-

VERSE DIRECTION.• NEVER TURN THE CRANKSHAFT BEYOND

THE POINT WHERE REFERENCE "F" OF THECAMSHAFT PULLEY MATCHES THE INDICA-TOR.

• IF THE CRANKSHAFT IS TURNED TO THEREVERSE DIRECTION OR TURNED SO ASTO EXCEED THE POINT DESCRIBED ABOVE,TIGHTEN THE TENSIONER LOCKINGSCREW TEMPORARILY AND REPEAT ALLTHE OPERATIONS FROM POINT (5) ON-WARDS.

9. Tighten the belt tensioner locking screw to the

specified torque value.

Locking torques (N*m)Timing system belt tensioner 29÷44

10. Make sure that the crankshaft pulley as well as

camshaft pulley reference points, match the cor-

responding indicators.

If the reference does not match the indicator, re-

peat the operations from point 2. onwards.

KEY:

A: Reference on head cover

B: Reference on timing pulley


EN - 246

C: Reference on crankshaft pulley

D: Reference on oil pump casting

F: "F" reference mark on timing pulley external side

Valve timing - Belt tensioning

Belt tensioning check

Make sure that deflection is within the specified value.

CharacteristicBelt deflection:

5 mm with a 8 ÷ 16N force applied

If belt tension does not comply with the specified

values, repeat the operations carried out for ten-

sioning.

Fitting the upper and lower cover of the timing

beltWARNINGBE CAREFUL THAT THE SCREWS ARE PROPERLY FIT-TED. THE BLACK SCREW IS PLACED TOGETHER WITHTHE SUPPORT FOR THE CABLE, IN THE CLAMP CLOSERTO THE MINIMUM OIL PRESSURE SWITCH.

Locking torques (N*m)Timing belt cover screw 2÷4

1. Fit the oil pressure switch wire and tighten the

wire clamps.

2. Connect the oil pressure switch connector.


EN - 247

3. Fit the crankshaft pulley with the relevant fixing

bolt. Tighten the bolt to the prescribed torque.N.B.ENGAGE THE 4TH GEAR TO AVOID CRANKSHAFT RO-TATION.

Locking torques (N*m)Crankshaft 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. Remove the oil pump cover.

2. Remove the sealing ring with a punch.N.B.- THE SEALING RING CAN BE REMOVED AND REFITTEDDIRECTLY ON THE VEHICLE WITH THE SPECIAL TOOL.


EN - 248

3. Remove the oil pump rotors.

4. Take out the split pin keeping the spring holder

cap in its seat.- PLACE AN ADEQUATE PROTECTIVE CLOTH ON THESPRING HOLDER, TO AVOID THAT THE SPRING JUMPSOUT.

5. Remove the cap, the spring and piston.- WASH THE PARTS REMOVED USING SOLVENT.

6. Checking each single part

• Check if the valve body is damaged.


EN - 249

• Check if rotors are damaged.

• Check if the valve piston is damaged.

Replace the piston if it is damaged.

Check if the valve seat on the oil pump body is

damaged.

• 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.

CharacteristicUnloaded length value according to specifica-tions:57 mm

• Check if the spring holder is damaged.

Replace the holder if it is damaged.


EN - 250

• Apply engine oil onto the pressure-reg-

ulating valve.

Insert the piston in the oil pump body.

Check if the piston moves regularly.

Replace the oil pump body, if the piston does not

move smoothly and without problems.

7. Pump body-rotor coupling check.

• Apply an oil film onto the rotor coupling

surfaces.

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.

Replace the oil pump if the rotor clearance ex-

ceeds the specified value.

CharacteristicBody clearance:0.20 - 0.28 mm

• Measure clearance between lobes

with a thickness gauge.

Replace rotors if clearance exceeds the specified

value.

CharacteristicLobe clearance:0.16 - 0.24 mm


EN - 251

• Measure the axial clearance of rotors

with the pump body using a ruler with

rectilinear edge and a thickness

gauge.

Replace the oil pump if the axial clearance ex-

ceeds the specified value.

CharacteristicAxial clearance:0.035 - 0.085 mm

8. Check for any 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 removal

Remove the sealing ring from the oil pump, using

a punch.

2) Timing side sealing ring fitting

Insert a new sealing ring using the following spe-

cial tool.

Specific tooling020384Y TOOL FOR TIMING SIDE CRANK-SHAFT OIL SEAL


EN - 252

Refitting

Oil pump fitting

1. Apply oil onto the pressure-regulating valve.

Then, insert the valve piston in the specific oil

pump body seat.

2. Insert the spring and its cap in the oil pump body.- WASH THE PARTS TO BE FITTED USING SOLVENT. DRYTHEM WITH COMPRESSED AIR. - WHEN COMPRESSEDAIR 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 onto rotors. Fit the rotors in the pump

body, so that rotor references are visible from the

outside.

5. Fit the oil pump cover. Tighten the cover to the

specified torque values.

Locking torques (N*m)Cover - Oil pump 8÷13


EN - 253

6. Insert a new sealing ring in the right position with

the following special tool.- BE CAREFUL NOT TO DAMAGE THE OIL PUMP DURINGFITTING.- MAKE SURE THAT THE SEALING RING IS NOT PLACEDDIAGONALLY.


7. Turn rotors by hand. Check that rotors turn free-

ly.

If rotor jamming is detected, carry out a pump

service.N.B.- THE FUNCTIONAL TEST PROCEDURE OF THE OIL PUMPIS DESCRIBED IN THE 'LUBRICATION SYSTEM' SECTION .

Cylinder head assembly

Cylinder head unit

KEY:

1. Cylinder head cover


EN - 254

2. Camshaft

3. Rocking lever for valve

4. Valve guide

5. Cylinder head

6. Oil seal

7. Spark plug

8. Valve

9. Spring seat

10. Valve stem oil seal

11. Valve spring

12. Valve spring cap

13. Valve rocking lever

14. Camshaft toothed belt pulley

15. Spacer

16. Sealing 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 (Recirculation of Exhaust Fumes)

26. EGR vacuum modulator (Recirculation of Exhaust Fumes)

27. Inlet manifold

28. EGR pipe (Recirculation of Exhaust Fumes)

29. EGR pipe gasket (Recirculation of Exhaust Fumes)

A= Front

*: Non-reusable parts


EN - 255

Initial operations

Alternator removal

1. Remove the connector and cable on the alter-

nator rear side.

2. Remove the alternator with belt tension adjust-

ment bar.

Remove the driving belt.

Removal of the engine wire from the cylinder

head

• Disconnect the engine wire connector

from the following parts:

1. Ignition coil

2. Injectors

3. Pressure sensor

4. Throttle sensor

5. Intake air temperature sensor

6. VSV (Vacuum Switching Valve) - idle speed


8. Oxygen sensor

9. Camshaft sensor

10. VSV (Vacuum Switching Valve) - bleeding

11. Ignition system

12- VSV (Vacuum Switching Valve) EGR (Recir-

culation of Exhaust Fumes)

13. Ground lead

14.Oil pressure switch

15. Handbrake switch

• Disconnect the cable terminals.

• Remove the engine wires from the cyl-

inder head.


EN - 256

Drain the coolant and detach water pipes.

Detach the delivery and reverse fuel pipe.CAUTION

• THE PRESSURE INSIDE THE FUEL DUCT ISAPPROX. 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 VTLExhaust pipeE.G.R. circuit intake duct

Head removal

1. Remove the ignition coil unit from the cylinder

head cover.


EN - 257

2.Loosen bolts fixing the cylinder head cover even-

ly in two or three stages, according to the se-

quence indicated in the figure on the right.

3. Remove the oil filling pipe and cylinder head

cover.

4. Remove the camshaft pulley and camshaft sen-

sor.• DO NOT 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 cylinder head rocking levers.

7. Remove the rocking levers, the spacer and crin-

kle washer from the valve rocking lever pin previ-

ously removed.PLACE THE PARTS REMOVED IN ORDER SO AS TO OB-SERVE THE ORIGINAL POSITIONS WHEN REFITTING.


EN - 258

8. Remove the camshaft supports, taking out the

relevant clamps.

Remove the camshaft from the head.

9. Loosen the head screws, operating evenly in

two or three stages, according to the sequence in-

dicated in the figure.FAILURE TO OBSERVE THE INDICATION ABOVE MAYCAUSE THE BREAKING 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 other screws: 155 mm

11. Remove the head from the cylinder block.• REST THE HEAD ON SUITABLE WOODEN

SUPPORTS, TO AVOID DAMAGING THEHEAD GASKET SUPPORTING SURFACE.

• BE CAREFUL NOT TO LOSE THE SEALINGGASKET FITTED BETWEEN THE WATERPUMP AND THE HEAD.


EN - 259

Pressure relief valve

EGR valve check

1. Apply a negative pressure of about 53 kPa (400

mmHg) to the chamber with diaphragm. At this

point, check that the MityVac device pointer is sta-

ble.

2. Close opening B, blow compressed air into

opening A. Check if there is no air continuity.

3. Close opening C 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 B.

4. Close section 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

Cylinder head cover inspection

1. Visually check the la cylinder head cover gasket.

Replace the gasket with a new one, if necessary.

Fit the cylinder head gasket on the cylinder head

cover so that the reference mark is facing towards

the inlet manifold.

2. Check that the spark plug pipe sealing rings are

not damaged. Replace the sealing rings, if neces-

sary.

Spark plug sealing ring replacement.

1. Remove the spark plug sealing rings with the

appropriate extractor.


EN - 260

2. Fit a new spark plug sealing ring with the special

tool recommended.N.B.- MAKE SURE THAT THE SEALING RING IS ADEQUATELYPOSITIONED.- USE A SUITABLE WOODEN PIECE TO AVOID DAMAGINGTHE CYLINDER HEAD COVER.- BE CAREFUL NOT TO DAMAGE THE SEALING RINGPROTRUDING PART.

Specific tooling020274Y Checking tool kit

Valve - tappet play

Valve clearance adjustment

Measure and adjust valve clearance when the pis-

ton of cylinders No.1 and No.4 is at the top dead

centre at the end of compression.AS A RULE, VALVE CLEARANCE IS ADJUSTED WHENTHE ENGINE IS HOT . "HOT ENGINE" MEANS THAT THECOOLING WATER TEMPERATURE IS 75 ÷ 85°C AND THATTHE ENGINE OIL TEMPERATURE IS ABOVE 65°C. NEV-ERTHELESS, ONCE THE ENGINE IS SERVICED, ADJUSTVALVE CLEARANCES WITH COLD ENGINE AND THENADJUST AGAIN WITH HOT ENGINE AFTER WARMING UPTHE ENGINE.

Locking torques (N*m)Lock nut 16.7 ÷ 22.5 Nm

VALVE CLEARANCESSpecification Desc./Quantity

Intake with hot engine 0.25 ± 0.05 mmExhaust hot engine 0.33 ± 0.05 mm

Intake with cold engine 0.18 mmExhaust with cold engine 0.25 mmExhaust with cold engine 0.25 mmExhaust with cold engine 0.25 mm

• With rocking levers for valve of cylinder No.1 free (intake),

adjust the cylinder valves: 1-2

• The piston of cylinder No.1 is at the top dead centre during compression (exhaust),


• With rocking levers for valve of cylinder No.4 free (intake),


• The piston of cylinder No.4 is at the top dead centre during compression (exhaust),

Adjust the cylinder valves: 2-4


EN - 261

Tappet pin

Rocking lever and pin check

1. Visually check the rocking lever to detect any

cracks, seizures or wear. Replace the rocking lev-

er if necessary.

2. If the contact surface between the cam and the

rocking lever is excessively worn, replace the rock-

ing lever.

3. Visually check the pin to detect any cracks, seiz-

ures or wear.

Replace the pin, if necessary.

KEY:

A = Intake

B = Exhaust

4. Pin 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 the coupling posi-

tion with the rocking lever. Measure in

two directions perpendicular to each

other.

• Calculate clearance by deducting the pin diameter from the rocking lever diameter.

MEASURE THE PIN OUTSIDE DIAMETER IN THE COUPLING POSITIONS OF EACH ROCKINGLEVER.

CharacteristicSpecification value clearance:

0.012 - 0.053 mm

Clearance value allowed:

0.08 mm


EN - 262

Reference:

• Rocking lever identification.

• On the intake rocking lever pin, seats

are included so as not to interfere with

the spark plug jacket.

• On the intake side pin, there are

grooves for lubrication close to the

screw holes.

• On the exhaust side pin, the grooves

are located far from the screw holes.

• Pin fitting direction.

The 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 are 4 different types of rocking levers: 2 for

the intake side and 2 for the exhaust side, as

shown in the figure.

- Pin and rocking lever dimensions.

CharacteristicPin outside diameter:19.468 - 19.488 mm

Rocking lever hole diameter:19.500 - 19.521 mm

KEY:

F = Intake

G = Exhaust

H = No.1

I = No.2

L = No.3

M = No.4


EN - 263

Spacer and crinkle washer check

1. Measure the spacer unloaded width with a

gauge.

CharacteristicMinimum unloaded width:22.0 mm

Replace the spacers with an unloaded width lower than the minimum unloaded width value.

2. Visually check the crinkle washers, to assess flattening condition or damage possibilities.

Replace the crinkle washers, if necessary.

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 one turn, paying attention that

the shaft does not move in an axial direction. Read

the dial gauge during rotation.

Calculate the eccentricity; that is, the difference

between the maximum and the minimum reading.

CharacteristicMaximum eccentricity:0.03 mm

If the eccentricity exceeds the maximum value, replace the camshaft.


EN - 264

2. Cam lobe height check

Measure, with a micrometer, the cam lobe height.

CharacteristicRated height of the cam lobe during intake:33.434 - 33.634 mm

Rated height of the cam lobe during exhaust:33.17 - 33.37 mm

Minimum limit during intake:33.2 mm

Minimum limit during exhaust:33.0 mm

3. Checking the surface making contact with the

sealing 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 the groove where the cam angle

sensor is fitted, to verify that there is no damage.

Replace the camshaft, if the sensor groove is dam-

aged.N.B.IF THERE IS DAMAGE, ALSO CHECK THE CAM ANGLESENSOR DRIVE.

N.B.

BEFORE CHECKING, MAKE SURE THAT THE SHAFT IS RECTILINEAR.

1. Fit the camshaft on the head-cylinders.


EN - 265

2. Apply plastigauge onto each camshaft bearing.

3. Fit supports and rocking lever pins.

Tighten to the specified torque.N.B.

• EACH SUPPORT HAS AN IDENTIFICATIONNUMBER.

• THE INTAKE ROCKING LEVER PIN CAN BEIDENTIFIED BY THE SPARK PLUG JACKETMILLING.

• THE ROCKING LEVER PINS MUST BE FITTEDWITH THE BIGGEST CHAMFER FACING TO-WARDS THE TIMING SYSTEM SIDE.

• MAKE SURE THAT THE THREADS OFSCREWS AND HOLES ARE DRY.

Locking torques (N*m)Cylinder head - M 8 Camshaft 13÷17 Cylinderhead - M 10 Camshaft 29÷36

4. Remove the bearing covers and measure clearance.

CharacteristicCamshaft bearing coupling clearance (mm)

0.035 ÷ 0.076 mm

limit accepted: 0.17 mm

If clearance exceeds the allowed limit, replace the

head and camshaft.N.B.ONCE CHECKING HAS FINISHED, REMOVE PLAS-TIGAUGE. WASH THE CAMSHAFT AND SUPPORTS US-ING SOLVENT.


EN - 266

Camshaft axial clearance test

1. Apply engine oil onto the camshaft bearings.

2. Fit the camshaft on the head.

Fit supports and rocking lever pins and lock them

to the specified torque.N.B.

• EACH SUPPORT HAS AN IDENTIFICATIONNUMBER.

• THE INTAKE ROCKING LEVER PIN CAN BEIDENTIFIED BY THE SPARK PLUG JACKETMILLING.

• THE ROCKING LEVER PINS MUST BE FITTEDWITH THE BIGGEST CHAMFER FACING TO-WARDS THE TIMING SYSTEM SIDE.

• MAKE SURE THAT THE THREADS OFSCREWS AND HOLES ARE DRY.

Locking torques (N*m)Cylinder head - M 8 Camshaft 13÷17 Cylinderhead - M 10 Camshaft 29÷36

3. Measure camshaft axial clearance, through a

dial gauge with magnetic base.

Specific tooling020335y Magnetic support for dial gauge

CharacteristicCamshaft axial clearance (mm)specified value: 0.1 ÷ 0.25 mm

limit accepted: 0.45 mm

If axial clearance exceeds the allowed limit, replace the camshaft and head.

CharacteristicSeat width in the head:

4.10 - 4.20 mm

Camshaft collar thickness:

3.95 - 4.00 mm


EN - 267

Head removal/overhaul

Head Removal - Cylinders

1. Remove the water temperature sensor from the

cylinder head.

2. Remove the bracket for engine handling.

3. Remove the cotters and valve spring stop caps,

with the special tool.

Specific tooling020382Y Tool to remove the valve cotters

4. Remove the valve springs.N.B.POSITION THE PARTS REMOVED SO THAT THEIR ORIG-INAL FITTING POSITIONS CAN BE EASILY IDENTIFIED.

5. Remove the valves.N.B.POSITION THE PARTS REMOVED SO THAT THEIR ORIG-INAL FITTING POSITIONS CAN BE EASILY IDENTIFIED.


EN - 268

6. Remove the valve sealing rings

7. Remove the valve spring supporting caps.N.B.POSITION THE PARTS REMOVED SO THAT THEIR ORIG-INAL FITTING POSITIONS CAN BE EASILY IDENTIFIED.

8. Wash the parts removed, except for the electrical and plastic 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 and solvent, clean the head-

cylinders thoroughly.

Check that the head is even

2. With a precision ruler and a thickness gauge, check that the gasket surfaces which contact the block

and manifold are even.


EN - 269

LEVELNESS TOLERANCESpecification Desc./Quantity

Block side: 0.10 mmInlet 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 THE HEAD GASKETCONTACT SURFACES.


EN - 270

Valve guide bushing cleaning

With a brush for guides and solvent, clean all the

valve guides.

Head cracking check

With a penetrating liquid, check if there are any

cracks in the combustion chamber, inlet and ex-

haust ducts and on 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 signs of

overheating or damage. If there are traces of over-

heating or damage, replace valve A. If the un-

evenness of the contact surface can be restored,

rectify the contact surface of the valve seat.


EN - 271

3. Rectify the valve only as much as to obtain an

even surface contacting the valve seat.MAKE SURE THAT VALVES ARE MACHINED WITH THECORRECT ANGLE.

CharacteristicValve rectification angle:45.5°

4. Visually check if the valve stem end has traces

of abnormal wear.

If the valve stem shows abnormal wear, proceed

with 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.

CharacteristicInlet valve rated length:112.8 mm

Exhaust valve rated length:114.5 mm

5. Check the valve head thickness.

If the valve head thickness is shorter than the min-

imum value allowed, replace the valve.

CharacteristicInlet valve minimum thickness allowed:0.8 mm

Exhaust valve minimum thickness allowed:1.0 mm


EN - 272

Checking clearance between the valve guide

and the valve stem

1. Ream the valve guide bushing to remove any

burrs.THIS REAMING MUST BE CARRIED OUT ONLY TO RE-MOVE ANY BURRS.

2. With a plug gauge, measure the valve guide in-

side diameter at six points. Record the values

measured.

3. With a micrometer, 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 diameter -

Valve stem outside diameter =

Coupling clearance

CharacteristicInlet valve Clearance specification values:

0.020 - 0.055 mm

Exhaust valve Clearance specification values:

0.025 - 0.060 mm

Inlet valve allowed limits:

0.080 mm

Exhaust valve allowed limits:

0.090 mm


EN - 273

If clearance values calculated exceed the values

allowed, replace the valve guide and valve.

Valve springs

Valve spring check

1. Check the valve spring obliquity, with a carpen-

ter's square.

CharacteristicValve spring maximum out of square< 1.6 mm

KEY:

B = Lower than 1.6 mm

If the inclination exceeds the maximum limit, replace the valve spring.

2. With the special tool measure the unloaded length and tension of the valve spring.

CharacteristicValve spring minimum unloaded length (marked in PINK)

43.9 mm

Valve spring minimum unloaded length (marked in ORANGE)

46.1 mm

Valve spring preloading (marked in PINK)

244.9 N to 38.0 mm (Standard fitting height)

Valve spring preloading (marked in ORANGE)

208.9 N to 38.0 mm (Standard fitting height)


EN - 274

If the minimum unloaded length value and/or the

minimum tension value is below the minimum limit,

replace the valve spring. Reference:

CharacteristicValve spring unloaded length (marked in PINK)45.2 ± 0.5 mm

Valve spring unloaded length (marked in OR-ANGE)47.4 mm

3. Check that the valve spring supporting surface

is even.

a. Load 49 N to the valve spring.

b. Fit a thickness gauge at point "A", indicated 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 reaches the spiral centre,

replace the spring.

Valve guides and seats

Check

Check that the valve spring cap seats and cap

locks are not cracked or worn. Replace the defec-

tive parts, if necessary.

Valve guide replacement

THE REMOVAL AND FITTING OF THE VALVE GUIDE MUST BE PERFORMED WITH A HEAD-CYLINDER TEMPERATURE EQUIVALENT TO 80°C - 100°C, AFTER HEATING IT GRADUALLY.


EN - 275

Inlet valve guide

If the valve guide is already fitted with a stop ring

A (the original guide does not have a ring), replace

the head.

1. Take out the valve guide by pushing from the

combustion chamber seat with the following spe-

cial tool.BE CAREFUL NOT TO DAMAGE THE HEAD

Specific tooling020387y Punch for valve 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 CAUSE THEVALVE GUIDE BUSHING CRACKING.

• DO NOT FORCE THE VALVE GUIDE EXCES-SIVELY SO AS NOT TO TAKE OUT THE STOPRING.

Specific tooling020387y Punch for valve extraction

3. Ream the valve guide bushing to remove any

burrs.THIS REAMING MUST BE CARRIED OUT ONLY TO RE-MOVE ANY BURRS.


EN - 276

4. Clearance check

Make sure that clearance complies with specifica-

tion values.

CharacteristicInlet:0.020 - 0.055 mm

Outlet:0.025 - 0.060 mm

Valve seats and guides

Checking and cleaning the valve seats

1. Rectify the valve seat, with a mill at 45°. Only

remove the quantity of material useful to clean the

seat.

2. Apply a thin layer of minium onto the valve seat.

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

valve and the sealing is continuous on

the whole circumference. Otherwise,

replace the valve.

• Make sure that contact between the

valve and its seat is continuous on the

whole circumference. Otherwise, re-

work the valve seat.

• Measure the length of the valve seat contact surface.

CharacteristicValve seat contact surface:

1.2 - 1.6 mm


EN - 277

Otherwise, rework the valve seat.

KEY:

B = Contact surface at the centre of the valve

C = Contact surface length

Valve seat rectification

1. Rectification for inlet valve seats

• With a mill at 45°, remove the surface

unevenness of the area making con-

tact with the valve 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 a mill at 70°, work the seat so that,

the length of the surface machined with

the mill at 45°, turns equal to 1.4 mm.

• With the mill at 45°, remove any burrs

which are produced during previous

machining operations with mills at 30°

and 70°.


EN - 278

KEY:

C = Intake

2. Rectification of exhaust valve seats

• With a mill at 45°, remove the surface

roughness of the area making contact

with the valve seat, only as much as to

obtain an even surface.

KEY:

A = Intake


so that the largest diameter of the ma-

chining operation at 45°, is 25 mm.

KEY:

D = Exhaust


so that, the length of the surface ma-

chined with the mill at 45°, turns equal

to 1.4 mm.

• With the mill at 45°, remove any burrs

which are produced during previous

machining operations with mills at 20°

and 70°.


EN - 279

KEY:

E = Exhaust

Valve manual grinding

1. Grind valves and valve seats manually, with a lapping compound.

2. Once grinding has finished, clean the valves and valve seats.N.B.BE CAREFUL NOT TO PUT THE LAPPING COMPOUND IN THE VALVE GUIDES.

Fitting new valves

When the valve seats 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 does not exceed the following maximum limits.

CharacteristicInlet valve maximum limit:2.775 mm

Exhaust valve maximum limit:6.026 mm

If the value is higher than the maximum limit al-

lowed, replace the head.

Montaggio testa

HEAD FITTINGN.B.


EN - 280

- CLEAN CAREFULLY ALL THE PARTS TO BE FITTED .- BEFORE FITTING THE DIFFERENT PARTS, APPLY A LAYER OF ENGINE OIL ONTO ALL THESLIDING OR ROTATION SURFACES.- REPLACE ALL THE GASKETS AND SEALING RINGS.

Head fitting

Initial operations

Using a new head, take into account that the spark plug jackets and coolant outlet union are supplied

separately. Fit these parts following the procedure described below.

1. Wash the head using solvent and dry it with compressed air.

2. Apply a thin layer of special adhesive onto the

jacket surfaces making contact with the head.

Recommended productsThree Bond 1377B Adhesive sealing com-pound-

3. With wooden wedges placed on the upper part

of the spark plug jacket, place the spark plug jacket

in the head so that the distance between the spark

plug tightening surface and the upper end of the

jacket is 139 mm.NOTE:- DO NOT PLACE THE SPARK PLUG JACKET TOO DEEP-LY.- BE CAREFUL NOT TO DAMAGE THE UPPER END OF THESPARK PLUG JACKET.- WHEN INSERTING THE SPARK PLUG JACKET IN THESEAT, MAKE SURE THAT IT IS NOT BENT.


EN - 281

4. Apply a thin layer of sealant onto the outlet union

contact section from the head to the throttle body.

5. Drive the union with a wooden 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, any wood

splinters etc.

Fitting the valve spring seats on the head

Fit the valve spring seats on the head.


EN - 282

Valve sealing ring fitting

1. Apply engine oil onto the sealing ring hole.

2. Fit the sealing ring manually on the valve guide.N.B.- WHEN THE SEALING RING IS FITTED, MAKE SURE THATIT DOES NOT BEND.- DO NOT REUSE ANY RING THAT WAS PREVIOUSLYBENT OR FITTED INCORRECTLY.- DO NOT TOUCH THE SEALING LIP OF THE RING.

3. Turn the sealing ring slowly by hand to see if it

is fitted properly.- NEVER TURN THE SEALING RINGS MORE THAN ONCE,BECAUSE AN EXCESSIVE ROTATION CAN CAUSE SCOR-ING FORMATION ON THE SEALING EDGE.- IF THE SEALING RING CAN NOT TURN FREELY IN ITSSEAT, IT MEANS THAT IT WAS BENT, INSERTED DIAGO-NALLY OR WAS INADEQUATELY FORCED.- DO NOT REUSE ANY RING THAT WAS PREVIOUSLYBENT OR INSERTED INCORRECTLY.

Valve fitting

Apply oil onto the valve stem. Fit the valve in the guide.N.B.

- PAY ATTENTION TO THE FITTING POSITION. DO NOT TAKE THE VALVE OUT ONCE IT HASBEEN FITTED.- IF A VALVE THAT IS ALREADY FITTED MUST BE TAKEN OUT, THE SEALING RING MUST BEREPLACED AGAIN.

Valve identification- THERE IS AN INDICATION AT THE CENTRE OF THEVALVE.

CharacteristicHC-ES engineidentification number (4)


EN - 283

Fitting the valve springs, caps and cotters.

1. Fit the valve spring so that the painted side (side

with a longer pitch) is on the cotter part.

2. Fit the cap on the spring. Fit the cotters while

the spring is compressed with the following special

tool:

Specific tooling020382Y Tool 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 DO NOT JUMP OUT.- DURING THIS OPERATION, PROTECT EYES WITH PRO-TECTIVE GOGGLES.

Head fitting

Next operations

1. Clean and dry the seats threaded on the block.

2. Clean the block upper surface.- DURING THIS OPERATION, PROTECT EYES WITH PRO-TECTIVE GOGGLES.


EN - 284

3. Fit the head gasket A, on the centring dowels

inserted in the block.

4. Take the crankshaft to the top dead centre of

cylinders 1-4.

5. Clean the threaded part of the water tempera-

ture sensor.

6. Wrap sealing tape around the threaded part and

fit the sensor in the head-cylinders.- THE NEW TEMPERATURE SENSOR IS COVERED WITHA SEALANT LAYER.THEREFORE, WHEN A SENSOR IS REPLACED, REMOVETHE SEALANT LAYER BEFORE WRAPPING THE SEAL-ING TAPE. BESIDES, MAKE SURE THAT THE HOLE OFTHE HEAD THREADED SECTION IS CLEAN.- THE ORIGINAL SEALANT IS REMOVED BECAUSE AF-TER BEING STORED FOR A LONG TIME IT HAS LOST ITSCHARACTERISTICS.

Locking torques (N*m)Cylinder head - Water temperature sensor 24.5÷ 34.3

7. Cover each head fixing screw with a thin layer

of engine oil and let it drip.

Fit the head on the block.N.B.- BEFORE FITTING THE HEAD, CHECK THE BLOCK.


EN - 285

8. Tighten the screws evenly in two or three

stages, according to the sequence shown in the

figure.N.B.- FAILURE TO OBSERVE THE SEQUENCE SHOWN TOTIGHTEN THE SCREWS, CAN CAUSE CRACKS AND DIS-TORTIONS ON THE HEAD, LEADING ALSO TO THE EN-GINE SEIZURE.- MAKE SURE THAT ALL THE SCREWS ARE TIGHTENEDEVENLY 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 COMPRESSED AIR IS USED, PROTECT EYESWITH PROTECTIVE GOGGLES.

2. Apply engine oil onto the shaft supports.- BE CAREFUL NOT TO APPLY OIL INTO THE THREADEDHOLES.

3. Fit the camshaft on the head so that the cam-

shaft pulley positioning pin is in the upper part.


EN - 286

4. Apply sealant onto the support No.1 of the cam-

shaft, at the points shown in the figure.

5. Apply oil onto the camshaft support section.N.B.- BE CAREFUL NOT TO APPLY OIL INTO THE THREADEDHOLES WHERE SCREWS FOR SUPPORTS ARE FITTED.

Recommended productsThree Bond 1104 Liquid sealant-

6. Fit the camshaft supports according to the nu-

merical sequence indicated on them.N.B.- BEFORE FITTING THE CAMSHAFT SUPPORTS, CLEANEACH SEALANT TRACE FROM SUPPORT No. 1 OF THECAMSHAFT.

7. Fit the rocking levers and elastic inserts on the

relevant pins.

Lubricate the parts.N.B.- THE INTAKE SIDE PIN CAN BE RECOGNISED BY THEMILLING LOCATED IN CORRESPONDENCE WITH THESPARK PLUG JACKETS.- PINS MUST BE PLACED WITH THE BIG CHAMFER FAC-ING TOWARDS THE TIMING SYSTEM SIDE.

8. Fit the pin with the rocking levers on the cam-

shaft supports.N.B.- FOR AN EASIER FITTING, IT IS RECOMMENDED TOKEEP THE ROCKING LEVERS ORIENTED TOWARDS THETIMING SHAFT UNTIL THE PIN IS IN THE SEAT ON THESUPPORTS.


EN - 287

Head fitting

Final operations

1. Place two spacers between the rocking levers

for inlet valves on the rocking lever pin.

2. Apply engine oil onto the protruding part of the

camshaft T oil seal.

3. Place the oil seal in the right position, with the

special tool recommended.CAUTION- BE CAREFUL NOT TO REST THE OIL SEAL ON THE CAM-SHAFT OIL SEAL ATTACHMENT HOLE.

Specific tooling020381Y PUNCH TO FIT THE CAMSHAFT OILSEAL

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

stages, according to the sequence indicated in the

figure.

Locking torques (N*m)Cylinder head - Cylinder head cover 9 ÷ 13

7. Connect the connector to the engine coolant

temperature sensor.

8. Fit the ignition coil on the cylinder head cover

and tighten it.

Locking torques (N*m)Cylinder head cover - Ignition coil 6÷11

9. Fit the exhaust manifold.

10. Fit the inlet manifold.

Pagina Manuale VTL


EN - 288

E.G.R. circuit intake ductExhaust pipe

Base - pistons - cylinders

BLOCK COMPONENTS

A = Vehicle front side * = Non-reusable parts

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. Main bushings

14. Piston-Pin

15. Piston circlips

16. Connecting rod

17. Connecting rod bushings


EN - 289

18. Oil pump

19. Pipes with pre-filter

20. Rear plate

21. Flange for sealing ring

22. Sealing ring

23. Shoulder rings.

Smontaggio

Block removal

Operations on components

Place the engine on proper engine bench.

Remove the toothed belt

Cylinder head cover removal.

1. Remove the ignition coil 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 in the figure on the right.N.B.- FAILURE TO OBSERVE THE SEQUENCE SHOWN TOTIGHTEN THE SCREWS, CAN CAUSE CRACKS AND DIS-TORTIONS ON THE HEAD, LEADING ALSO TO THE EN-GINE SEIZURE.- MAKE SURE THAT ALL THE SCREWS ARE TIGHTENEDEVENLY TO THE PRESCRIBED TORQUE.


EN - 290

5. Remove the cylinder head bolts.

6. Remove the cylinder head from the cylinder

block.

7. Remove the head gasket.

8. Remove each gasket 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.- AVOID THE CROWN GEAR ROTATION USING THE SPE-CIAL TOOL.



EN - 291

3. Remove the crankshaft pulley.- IF THE CRANKSHAFT PULLEY CAN NOT BE TAKEN OUTMANUALLY, FIT THE FOLLOWING SPECIAL TOOL:

Specific tooling020380Y TIMING PINION EXTRACTOR

4. Remove the crankshaft pulley flange.


EN - 292

5. Remove the tensioner and relevant spring.

6. Remove the water pump.

7. Remove the water pump gasket.


1. Remove the alternator support bracket, the en-

gine right support with the guide for the oil dipstick.

2. Remove the thermostat cover and thermostat.

3. Remove the water hose.


EN - 293

4. Remove the pressure plate and clutch disc.N.B.- AVOID THE FLYWHEEL ROTATION, USING THE FOL-LOWING SPECIAL TOOL:


5. Check the flywheel eccentricity.N.B.- IF THE FLYWHEEL ECCENTRICITY DOES NOT COMPLYWITH THE SPECIFICATION REQUIREMENTS, REPLACETHE FLYWHEEL.- BEFORE REPLACING THE FLYWHEEL, CHECK THELOCKING TORQUE.

CharacteristicLimit value:0.1 mm

6. Loosen the flywheel fixing screws in the se-

quence indicated in the figure. Remove the fly-

wheel.- AVOID THAT THE FLYWHEEL TURNS, WITH THE FOL-LOWING SPECIAL TOOL



Remove the rear plate.


EN - 294

Oil sump removal

1 Loosen the screws and nuts fixing the oil sump,

operating in two or three stages. Take out bolts

and nuts.

2 Separate the oil sump from the cylinder block

with the following special tool:

Specific tooling020403Y FLYWHEEL LOCK WRENCH

3. Remove the two oil sump gaskets.

4. Remove the rear flange with the sealing ring.


EN - 295

5. Remove the oil inlet duct with the four nuts and

spacer.

6. Remove the oil pump.

Piston removal

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 guarantee torque uni-

formity. Remove then the connecting rod cap.


EN - 296

4. Fit the plastic caps on each connecting rod

screw to protect the thread.

5. Take out the piston, with the connecting rod and

upper bushing, from the upper part of the cylinder

block.

- POSITION THE PISTONS REMOVED AND CONNECTINGRODS, SO THAT THE SINGLE FITTING POSITIONS AREEASILY IDENTIFIED.- BE CAREFUL NOT TO DAMAGE THE BUSHINGS.

Remove the flywheel.- LOCK THE CROWN GEAR ROTATION BY MEANS OF THESPECIAL TOOL.



EN - 297

Removing the oil sump

OIL SUMP TEST

Visually check the oil sump to detect possible dam-

age or cracks. Replace the oil sump, if necessary.

Pistone

Piston - Removal and inspection

Piston and connecting rod test

Coupling check between the piston and the pin

Turn the piston around the pin axle. If the move-

ment turns hard, replace the piston and pin.- IF THE PISTON MOVES REGULARLY, WITHOUT 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 measured following the proce-

dure below.

1.Clearance measurement with the piston and

connecting rod assembled: place the connecting

rod between two V blocks resting on a reference

surface. Measure clearance trying to move the

piston, as indicated in the figure.- THIS COUPLING CLEARANCE CAN NOT BE MANUALLYDETECTED.

CharacteristicPiston/pin clearance


EN - 298

0.005 - 0.011 mm

2. Checking piston clearance with the pin after re-

moval:

1. measure the diameter in positions A and B,

shown in the figure. The minimum size found

is the pin seat diameter.

CharacteristicSpecification values19.002 - 19.005 mm

3 Measure the pin diameter in positions A and B,

shown in the figure. The maximum size found is

the pin outside diameter.

The values indicated in the figure are in millime-

tres.

CharacteristicSpecification values18.994 - 18.997

Piston and connecting 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 CONSIDERED A SINGLE KIT. THEREFORE, WHENREMOVING THE PISTON, BE CAREFUL THAT THE PISTONAND PIN ARE NOT MIXED UP WITH OTHERS.- REMOVE THE PISTON ONLY WHEN NECESSARY DUETO MALFUNCTIONS.FAILURE TO OBSERVE THIS RECOMMENDATIONS CANLEAD TO A DISASSEMBLY OF THE CORRECT COUPLINGBETWEEN THE CONNECTING ROD AND THE PIN, CAUS-ING DAMAGE TO THE ENGINE.

Specific tooling020385Y SUPPORT FOR PISTONS

020386Y TOOL TO FIT/REMOVE THE PISTONFROM THE CONNECTING ROD


EN - 299

2. Fit the special tool in pin hole.

Take out the pin with a hydraulic press.- DISASSEMBLE THE SPECIAL TOOL AND USE ONLY THECYLINDRICAL PART.

Piston inspection

1. Piston cleaning

• Remove the piston rings.

• Remove the carbon deposits from the

upper part of the pistons, with a scra-

per.

• Clean the slots for the piston rings with

a portion of the sealing ring.- BE CAREFUL NOT TO SCORE THE SLOTS FOR THE PIS-TON RINGS.

2. Piston check

Visually check the piston to detect any cracks,

damage or seizures. 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 the allowed limit,

the whole kit must be replaced.

CharacteristicPoint H of measurement:15 mm

• Calculate the cylinder piston coupling.

Deduct the piston diameter from the cylinder diameter.

Make sure that clearance between the piston and the cylinder is below 0.045 mm.

If the cylinder piston clearance exceeds the lower limit, carry out the reaming and smoothing operations

of the cylinders, so that the cylinder diameter couples with the oversized piston.


EN - 300

4. Checking coupling clearance between the

piston rings and the piston

Measure the clearances of the piston rings No. 1

and No. 2 on the whole circumference of each slot,

with a thickness gauge.

The maximum value measured is considered to be

the piston ring clearance.

If clearance of the piston ring with the piston ex-

ceeds the limit allowed, measure the piston ring

thickness. Making reference to the following

standard thickness levels. Replace the piston ring

and/or the piston, so that clearance is within the

allowed limits.

CharacteristicPiston - cylinder clearanceSpecification values: 0.025 - 0.045 mm

Admissible limit: 0.11 mm

PISTON RING CLEARANCESpecification Desc./Quantity

Piston ring No. 1 Specification value: 0.03-0.07 mmAdmissible limit: 0.12 mm

Piston ring No. 2 Specification value: 0.02-0.06 mmAdmissible limit: 0.12 mm

Clearance limit allowed 0.12 mm

5. Opening check of the piston ring in the cyl-

inder

• Apply oil onto the cylinder walls.

• Fit the piston ring in the cylinder.

• With the piston, take the piston ring

«B» to 110 mm from the cylinder block

upper surface.

• Measure the piston ring opening, with

thickness gauge, or a feeler gauge.- IN CASE OF REPLACEMENT, REPLACE THE WHOLEPISTON RING KIT.


EN - 301

PISTON RING RATED THICKNESSSpecification Desc./Quantity

Piston ring No. 1 1.17-1.19Piston ring No. 2 1.47- 1.49

PISTON RING OPENINGSpecification Desc./Quantity

Piston ring No. 1 ("T" reference mark) 0.27-0.37 mmPiston ring No. 1 ("N" reference mark) 0.27-0.40 mm

Piston ring No. 1 (clearance limit allowed) 0.12 mmPiston ring No. 2 0.4-0.55

Piston ring No. 2 (clearance limit allowed) 0.8 mmScraper ring (Spring A) 0.2-0.6 mmScraper 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 ring removal

1. Remove the circlips No.1 and No. 2, with an ex-

pander for circlips.

2. Remove the oil scraper rings manually.

3. Remove the oil scraper spring manually.- POSITION THE PISTON RINGS REMOVED FROM THEPISTONS SO THAT ITS FITTING POSITION CAN BE EASI-LY RECOGNISED.- DO NOT EXTEND THE PISTON RING MORE THAN RE-QUIRED PURPOSELESSLY.


EN - 302

Piston refitting

Piston and connecting rod fitting

Use the following special tools to carry out fitting

operations.

1. Fit pin B on the special tool, as shown in the

figure:

A= Milled part

Specific tooling020385Y SUPPORT FOR PISTONS

020386Y TOOL TO FIT/REMOVE THE PISTONFROM THE CONNECTING ROD

2. Fit the piston and connecting rod on 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 FITTEDSO THAT THE PISTON FRONT PART AND THE CONNECT-ING ROD FRONT PART, BOTH HAVING THE IDENTIFICA-TION REFERENCE, ARE IN THE SAME DIRECTION.- THE SPECIAL TOOL MUST BE INSERTED FROM THESIDE THAT IS MILLED.

4. Remove the piston-connecting rod assembly

from the special tool.

Remove the special tool from the pin.


EN - 303

Connecting rod

Connecting rod check

1. Visually check the connecting rod, to find pos-

sible damage or cracks.

2. Resorting to a special tool to align connecting

rods, check if connecting rods are bent A or twis-

ted B.

If the bending and/or torsion level exceeds the

maximum allowed value, replace the connecting

rod.

CharacteristicMaximum bending:0.05 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 connecting rod diameter,

with a dial gauge for holes.

3. Determine the forced coupling deducting the

connecting rod inside diameter value from the pin

outside diameter value.

If the forced coupling does not comply with the

specified values, replace the connecting rod.

CharacteristicForced coupling:0.015 - 0.044 mm (interference)


EN - 304

Connecting rod clearance measurement.

Measure the axial clearance between the connect-

ing rod and the crankshaft, with a thickness gauge.

If clearance exceeds the specified value, replace

the connecting rod or crankshaft, or both, if nec-

essary.

CharacteristicAxial clearanceStandard: 0.15 - 0.4 mm

Maximum: 0.45 mm

Connecting rod head width in the thrust direc-tion21.80 - 21.85 mm

Seat width on the connecting rod pin22.0 - 22.2 mm

Coupling clearance measurement between the

connecting rod bushings and crankshaft

1. Temporarily fit the flywheel.


EN - 305

2. Clean the coupling area between the connecting

rod cap and the connecting rod.

Draw a mark on one side, so that the part can be

properly refitted, also mark the coupling to the cyl-

inder.

3. Turn the crankshaft 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 connecting rod cap.- REPLACE THE CRANKSHAFT, IF THE CONNECTINGROD PIN HAS SEIZURES.

6. Place a "plastigauge" on the connecting rod pin.N.B.- CLEAN ANY OIL TRACES FROM THE CONNECTING RODPIN.


EN - 306

7. Fit the connecting rod, making sure that the

coupling marks are aligned. Tighten the connect-

ing rod nuts, operating in two or three stages to

guarantee that they are tightened evenly to the

specified torque value.- LUBRICATE THE NUTS BEFORE FITTING.

Locking torques (N*m)Connecting rod - Connecting rod cap 34÷44

8. Loosen the connecting rod cap nuts, operating

in two or three stages to guarantee torque uni-

formity. then remove the connecting rod bearing

cap.

9. Measure the "plastigauge" thickness at its max-

imum point.

CharacteristicClearance0.020 ÷ 0.044 mm

If clearance does not comply with the specification value, measure the connecting rod pin diameter and

select a bushing with a suitable thickness, or replace the crankshaft.

10. Remove the "plastigauge" from the connecting rod pin.

11. Measure coupling clearances of the bushings of other connecting rods.

Connecting rod bearing thickness selection.

1. Read the classification number of the connecting rod head diameter.

- REPLACE THE BEARINGS WHEN ALL THE INSPECTIONS ARE FINISHED. THE CONNECTINGROD CAN BE CLASSIFIED IN THREE CATEGORIES: 4, 5, 6.


EN - 307

A = Connecting rod diameter classification

B = Front reference

2. Measure the connecting rod pin diameter.

The measurement must be carried out on 4 points

distanced 90° one from the other, for each con-

necting rod pin, at the points shown in the figure.

The maximum value is considered to be the meas-

urement of the connecting rod pin diameter. Nev-

ertheless, if the variation among the different

diameters measured on the pin exceeds 0.044

mm, replace the crankshaft.

3. Select the connecting rod bushing thickness or replace the crankshaft, according to the results of

points 1 and 2.

The values indicated in the figure are in millimetres.

CONNECTING ROD HEAD TYPESName Description Dimensions Initials Quantity

Category 5 50.000 - 49.995 1Category 5 49.994 - 49.989 2Category 5 49.998 - 49.983 3Category 5 49.982 - 49.976 4Category 5 49.975 or less -Category 6 50.000 - 49.995 2Category 6 49.994 - 49.989 3Category 6 49.998 - 49.983 4Category 6 49.982 - 49.976 5Category 6 49.975 or less -Category 7 50.000 - 49.995 3Category 7 49.994 - 49.989 4Category 7 49.998 - 49.983 5Category 7 49.982 - 49.976 6Category 7 49.975 or less -Category 8 50.000 - 49.995 4Category 8 49.994 - 49.989 5Category 8 49.998 - 49.983 6Category 8 49.982 - 49.976 7Category 8 49.975 or less -


EN - 308

Connecting rod replacement

Wash connecting rods using solvent.

Connecting rod bushing selection

1. Read the category of the connecting rod.- BE CAREFUL TO PROTECT EYES WITH PROTECTIVEGOGGLES.

2. Measure the diameter of each connecting rod

pin in four directions, distanced 90° one from the

other, at the points indicated in the figure.

The values indicated are in millimetres.- THE LARGER VALUE MEASURED DEFINES THE CON-NECTING ROD PIN DIAMETER. NEVERTHELESS, IF THEDIFFERENCE AMONG ALL THE VALUES MEASURED EX-CEEDS 0.044 MM, REPLACE THE CRANKSHAFT.

3. Select the connecting rod bushings according the following table.




EN - 309

Cylinders

Cylinder block test

1. Removing gasket residues.

Remove all gasket residues from the cylinder

block.

2. Cylinder block cleaning

Clean the cylinder block using a soft brush and

solvent.

3. Cylinder block upper surface check.

Check for any deformation of the head gasket con-

tact surface, using a precision scale and a thick-

ness gauge.

If unevenness exceeds the limit allowed, replace

the cylinder block.

CharacteristicMaximum unevenness:0.10 mm

4. Cylinder check

Measure 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 between the

maximum and the minimum value exceeds 0.1

mm, ream and/or grind the cylinder hole.

The grinding angle is 35° ± 5°. Surface roughness

is 1 - 4Z.

Reference:

The table indicated below identifies the cylinder

diameter when oversized pistons are used. Meas-

ure the oversized piston diameter. Continue with

the cylinder finishing according to the piston diam-

eter.

• Measure the diameter of each cylinder

in the position shown in the figure. The


EN - 310

measured value is considered to be the

cylinder diameter.

CharacteristicCylinder diameter (standard)76.000 - 76.030

Cylinder diameter (OS/0.25)76.250 - 76.280

• Cylinder scale removal

If scales are formed in the upper part of the cylin-

der holes, a special reamer is necessary to remove

them.

Cylinder reaming

1. Cylinder diameter measurement

Measure the diameter at a point that is 45 mm

away from the upper surface 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 diameter

by means of a micrometer.N.B.- THE MEASUREMENT MUST BE CARRIED OUT IN COR-RESPONDENCE WITH THE INDICATED POINT H = 15 MM.- CARRY OUT THE MEASUREMENT IN AN ORTHOGONALPOSITION WITH RESPECT TO THE PIN.

• Calculate the cylinder finishing size, as follows:

A: Piston diameter

B: Cylinder piston clearance 0.025 - 0.045 mm

C: Grinding tolerance 0.02 mm

D: Finishing diameter

D = A + B - C


EN - 311

3. Grind the cylinder after the reaming.

• Ream the cylinder, leaving a reaming tolerance of 0.02 mm.

• Grind the cylinder.

Grinding angle: 35° ± 5°

Degree of surface machining: 1 - 4Z

A = Grinding angle

B = Surface machining

Cylinder block replacement

1. Wash the cylinder block using solvent.

2. Insert the shutter on the oil delivery up to a 3.0

± 1.0 mm depth, measured from the upper surface

of the cylinder.N.B.- THE CYLINDER BLOCK IS PROVIDED TOGETHER WITHTHE PISTONS, AS A SINGLE KIT. THEREFORE, BE CARE-FUL THAT EACH PISTON IS FITTED IN THE RELEVANTCYLINDER.N.B.- TO INSERT THE PARALYSER, USE A 10 MM OUTSIDEDIAMETER BUFFER.




EN - 312

3. Crankshaft bearing selection

• Read the category number of the main

bearing.

• Measure the main journal diameter at

the points indicated in the figure.

The measurement 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

1) Read the type of the cylinder coupling.

Key

A = Cylinder type No.1

B = Cylinder type No.2

C = Cylinder type No.3

D = Cylinder type No.4


EN - 313

• Select a piston that has the same type

of cylinder coupling E.N.B.- THE COUPLING TYPE «E» IS INDICATED ON THE PISTONCROWN.

Crankcase bearings

Oil sealing rear gasket replacement

1. Rear sealing ring removal.

Remove the sealing ring from the flange, using a

punch.N.B.- BE CAREFUL NOT TO DAMAGE THE SEAT WHERE THESEALING RING IS 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 OUT THEINSTALLATION ALSO WHEN THE FLANGE IS FITTED ONTHE ENGINE.

Specific tooling020383Y Punch for flywheel fitting

Timing side oil sealing ring replacement

1.Sealing ring removal.

Remove the sealing ring from the oil pump, using

a punch.

- BE CAREFUL NOT TO DAMAGE THE OIL PUMP DURINGFITTING.


EN - 314

2.Timing side sealing ring fitting

Insert a new sealing ring using the following spe-

cial tool.THE SPECIAL TOOL IS DESIGNED CARRY OUT REMOVALAND REFIT DIRECTLY ON THE VEHICLE.


Crankshaft

Check the axial clearance of the crankshaft.

If the axial clearance exceeds the limit allowed,

measure 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 CLEARANCE WITH A DIALGAUGE.

CharacteristicCrankshaft axial clearance0.02 ÷ 0.22 mm

Maximum clearance limit allowed: 0.30 mm

Checking coupling clearance of the main

bushing.

1. Loosen the main bearing screws gradually, op-

erating in two or three stages, according to the

sequence indicated in the figure.

Remove the support screws.


EN - 315

2. With the fixing screws remove the main bearing

with the bushing.- KEEP THE LOWER BUSHING COUPLED WITH THE MAINBEARING. POSITION THE MAIN BEARING, IN GOOD OR-DER.

3. Take out the crankshaft.

- Remove the shoulder rings.

- If main journals or bushings are damaged, re-

place the crankshaft with the bushings or just 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 the

crankshaft. If the main bushings are damaged, re-

place them.WARNING- PROTECT EYES WITH PROTECTIVE GOGGLES DURINGTHE CLEANING OPERATION.

6. Fit the main bushings on the block and on the

main bearings and keep the original position.- DO NOT TOUCH THE METAL SURFACE OF BEARINGS.


EN - 316

7. Hold the two crankshaft ends with two V-shaped

blocks.

Measure the crankshaft eccentricity with a dial

gauge.

If the eccentricity exceeds this limit, replace the

crankshaft.

CharacteristicEccentricity limit allowed:0.06 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 figure.N.B.- THE MAIN BEARINGS HAVE THE ARROWS WHICH INDI-CATE THE TIMING SIDE AND ARE NUMBERED FROM 1 TO5.- NO. 1 IS THE TIMING SIDE.

Locking torques (N*m)Cylinder block - Main bearing cap 44 ÷ 54


EN - 317

11. Remove the main bearings with the bushings.

12. Measure the "plastigauge" thickness at its

maximum point.

If clearance does not comply with the specification

values, measure the diameter of the main journal

area and select the bushings, or replace the crank-

shaft.

13. Remove the "plastigauge" from the main jour-

nals.

CharacteristicClearance0.024 ÷ 0.042 mm

Main bushing category selection.

1. Read the references to recognise the category

of cylinder block main bearings.N.B.- REPLACE THE MAIN BUSHINGS AFTER ALL THE IN-SPECTIONS HAVE BEEN CARRIED OUT.- TO SELECT THE MAIN BUSHINGS AFTER REPLACINGTHE CRANKSHAFT, REFER TO, "CRANKSHAFT RE-PLACEMENT".- THERE ARE FOUR TYPES , IDENTIFIED BY NUMBERS 5,6, 7 AND 8.- REFERENCES ARE AS INDICATED IN THE FIGURE.

2. Measure the crankshaft main journals. The measurement must be carried out on 4 points distanced

90° one from the other, for each crankshaft pin, at the points shown in the figure.

The maximum value is considered to be the measurement of the main journal.

Nevertheless, if the variation among the diameters measured on the pin exceeds 0.026 mm, replace

the crankshaft.

The values indicated in the figure are in millimetres.


EN - 318

5 = Main bearing category


3= Main bearing category



3. Select the main bushings or replace the crankshaft, according to the results of points 1 and 2.

- CONNECTING ROD HEAD TYPES -Name Description Dimensions Initials Quantity


Crankshaft replacement

1. Wash the crankshaft using solvent. Dry it with

compressed air.

2. Crankshaft bushing selection

• Read the category of the main bearing.N.B.- MAKE SURE THAT THE LUBRICATION DUCTS AREFREE.

Main bearing categories

5 = Category of support No.5 (FLYWHEEL SIDE)

4 = Category of support No.4



1 = Category of support No.1 ( TIMING SIDE)


EN - 319

• Read the category of the main journal

on the crankshaft.

Main journal categories

5 = categories of the main journal No.5 (FLYWHEEL SIDE)

4 = categories of the main journal No.4



1 = categories 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 bushing selection

• Read the category of the connecting

rod pin.

Connecting rod pin category

1 = Category of the connecting rod pin No.1 (TIMING SIDE)

2 = Category of the connecting rod pin No.2

3 = Category of the connecting rod pin No.3


EN - 320

4 = Category of the connecting rod pin No.4 (FLYWHEEL SIDE)

• Read the category of the connecting

rod head.

Connecting rod head categories

U =Front reference

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 = Connecting rod

P = Connecting rod categories

Montaggio

Water pump fitting

1. Fit a new water pump gasket on the cylinder

block.


EN - 321

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 THETHREADED SECTION FROM THE CYLINDER BLOCKSIDE.


Locking torques (N*m)Cylinder block - Water pump 15 ÷ 22

Oil filter fitting

1. Apply a reduced quantity of engine oil onto the

oil filter gasket.

2. Screw the oil filter until the gasket makes con-

tact with the oil pump.

3. Then, turn once more the oil filter completely

(360°).


EN - 322

pressure switch fitting

1. Clean the threaded part of the pressure switch.

Wrap a sealing tape around the threaded part.N.B.- THE NEW PRESSURE SWITCHES ARE COATED WITHSEALANT. THEREFORE, WHEN THE PRESSURE SWITCHIS REPLACED WITH A NEW ONE, FIRST, REMOVE THECOATING COMPLETELY SINCE THE PRODUCT LOOSESITS CHARACTERISTICS WITH TIME. ALSO CLEAN THETHREADED HOLES WHERE THE SWITCH 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

Connect the spring to the timing belt tensioner. At-

tach the spring ring on the pin. Fit the belt tensioner

and fit the screw.

Push the tensioner towards the alternator to the

end of the travel position. Temporarily tighten the

tensioner.

Water filler fitting

Fit the water filler.

Locking torques (N*m)Cylinders lock for water inlet 5.9 ÷ 8.8 Nm


EN - 323

Water pipe fitting

Fit the water pipe to the cylinder block to use the

throttle body.

Fit the relevant clamps.

Fitting the clutch disc and driven plate

1. Fit the special tool A in the rear end of the crank-

shaft.

2. Fit the clutch disc.

Specific tooling020196y Clutch guiding tool

3. Fit the clutch cover, aligning the reference pin

of the same cover.

Tighten the fixing bolts to the prescribed torque.

Locking torques (N*m)Clutch cover 15÷22

Flywheel fitting

1. Fit the flywheel on the crankshaft.

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.- MAKE SURE THAT THERE ARE NO TRACES OF ADHESIVE OR FOREIGN MATTER, (DUST),ON SCREWS.- ALSO WHEN USING NEW SCREWS, CARRY OUT THIS OPERATION.

• Check for possible damage to the flywheel screws. Replace each damaged flywheel screw.

- CARRY OUT OPERATIONS OF POINT (1) ALSO WHEN A NEW SCREW IS USED.• Clean the threaded seats of the crankshaft. Remove grease and dry them.

- MAKE SURE THAT THERE ARE NO TRACES OF SEALANT OR FOREIGN MATTER, AS FOREXAMPLE DUST, IN THE FLYWHEEL THREADS.


EN - 324

- WHEN REMOVING GREASE, CLEAN ANY TRACES OF OIL FROM THE THREADED AREA WITHA CLOTH SOAKED IN ALCOHOL.- DO NOT ALLOW THAT RESIN OR RUBBER PARTS MAKE CONTACT WITH ALCOHOL, ESPE-CIALLY THE SEALING RING.

• Clean and remove grease from the flywheel surface.

- WHEN REMOVING GREASE, USE A CLOTH SOAKED IN ALCOHOL.- DO NOT ALLOW THAT RESIN OR RUBBER PARTS MAKE CONTACT WITH ALCOHOL.

• Apply two or three drops of product on-

to the threaded section front end of

each one of the flywheel bolts.- WARNING: APPLY LUBRICANT ONLY TO THE FIRSTSECTION OF THE THREADED SCREW. AN EXCESSIVEAMOUNT OF LUBRICANT COULD REACH THE COUPLINGSURFACES. THIS COULD LOOSEN THE BOLTS.- NEVER USE ANOTHER SEALANT THAN THE RECOM-MENDED.- AVOID THAT THE SEALANT REACHES RESIN OR RUB-BER PARTS.

Recommended productsThree Bond 1324C Sealant-

3. At the same time tighten the bolts fixing the fly-

wheel to the following torque and in the sequence

indicated in the figure.

4. Tighten the bolts fixing the flywheel to the pre-

scribed torque according to the sequence indica-

ted in the figure.- USE THE SPECIFIC TOOL TO PREVENT THE CRANK-SHAFT FROM TURNING WITH RESPECT TO THE CROWNGEAR.CAUTION- WHILE BOLTS ARE TIGHTENED, CHECK THERE IS NOSEALANT ON THE BOLT SEAT SURFACE. IF THE SEAL-ANT SEEPS, REPEAT THE OPERATION FROM POINT 2.


Locking torques (N*m)Flywheel fixing screws 44 ÷ 64 Crankshaft - Fly-wheel 78÷98


EN - 325

5. Measure the flywheel eccentricity using the dial

gauge.- REPLACE THE FLYWHEEL IF ECCENTRICITY EXCEEDSTHE LIMIT ALLOWED.

CharacteristicMaximum limit allowed0.1 mm

Fitting the flange supporting the flywheel side

sealing ring

1. Apply sealant onto the coupling surface with the

cylinder block, as shown in the figure.CAUTION- APPLY THE RIGHT SEALANT QUANTITY IN ORDER TOAVOID THE FORMATION OF EXCESSIVE RESIDUES IN-SIDE THE ENGINE.

Recommended productsThree Bond 1207C SEALANT-

2. Apply engine oil onto the sealing ring internal

surface.

Fit the flange to the cylinder block. Tighten to the


Locking torques (N*m)Cylinder block - Rear oil seal ring 6÷9

Cylinder block fitting

1. Make sure that pins are fitted at the front, rear

and upper positions of the cylinder block, accord-

ing to the indications indicated in the figure.

Make sure that the protrusion of each single pin,

complies with the value specified below.

Specific protrusion value

A: 4 ± 0.5 mm

B: 8 ± 1.0 mm

C. 7 ± 1.0 mm

D: 3 ± 1.0 mm


EN - 326

E: 6.5 ± 1.0 mm

F = Front view

R = Rear view

P = Diagram view

If the pins fitted are not rectilinear or the protrusion value does not comply with the specified value,

replace the pin.

Cylinder block fittingN.B.

- ALL PARTS TO BE REFITTED MUST ALSO BE CLEANED USING SOLVENT (EXCEPT FORSOME PARTS, SUCH AS BEARINGS WITH GREASE SEAL, SEALING GASKETS, DUST GUARDAND ELECTRICAL COMPONENTS).- THEN DRY THEM, USING COMPRESSED AIR.WARNING

- WHEN COMPRESSED AIR IS USED, REMEMBER TO PROTECT EYES WITH PROTECTIVEGOGGLES.

rear plate fitting

Fit the rear plate on the cylinder block with a fixing

screw.

Tighten the screw to the specified torque value.

Locking torques (N*m)Cylinder block for clutch rear plate 15 ÷ 22 Nm

Crankshaft pulley flange fitting

Fit the crankshaft pulley flange so that the input

edge for the belt is positioned towards the oil

pump.


EN - 327

Crankshaft fitting

1. Fit the main bushings on the block and on sup-

ports.N.B.- DO NOT TOUCH THE FRONT AND LOWER SURFACESOF BUSHINGS. MAKE SURE THAT BUSHINGS ARE PER-FECTLY FITTED.

2. Lubricate the seat of each bushing with engine

oil.- DO NOT TOUCH THE FRONT AND LOWER SURFACESOF BUSHINGS. DO NOT APPLY ENGINE OIL ONTO THEMAIN BEARINGS.

3. Fit the crankshaft in the cylinder block.

4. Apply engine oil onto the shoulder rings.

Fit the shim half rings on support No. 3, make sure

that grooves are facing towards the crankshaft.


EN - 328

5. Apply oil onto the crankshaft main journal.- AVOID THAT THE OIL FLOWS IN THE THREADS FOR THEMAIN BEARING SCREWS.

6. Fit the main bearing with the reference arrow

facing towards the oil pump and following the nu-

merical sequence.

7. Apply engine oil, in a reduced quantity, onto the

support screws.

Tighten the screws until the specified 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. Place the cylinder block on a stand for engines.

2. Clean and dry the threaded holes for head

screwsN.B.- MAKE SURE TO WEAR PROTECTIVE GOGGLES EACHTIME AIR COMPRESSED IS USED.

Specific tooling020180y Engine support

020396Y ENGINE SUPPORT ATTACHMENT

3. Align the timing pinion with the oil pump indica-

tor.


EN - 329

4. Place the new head gasket on the cylinder block

positioning reference «A».

5. Turn the timing crankshaft, until the pulley ref-

erence mark «F» is in the highest position.

6. Fit the head from the cylinder block.

7. Apply engine onto the thread of head screws.

8. Fit the screws on the head.

9. Tighten the head screws to rated torque value,

evenly, operating in two or three stages and fol-

lowing the sequence shown in the figure.N.B.- BE CAREFUL NEITHER TO DAMAGE THE HEAD, NORTHE 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 THAT ARE ON THETIMING SIDE, USE THOSE HAVING A 112 MM RATEDLENGTH.

Locking torques (N*m)Cylinder head - Cylinder block 59÷67

10. Head-cylinder cover fitting

• Check for possible damage dependent

on head cover gaskets. Replace the

head cover gasket, if it is damaged.

• Head cover gasket replacement (Only

applicable to cases where this replace-

ment is necessary): remove the gasket

from the head cover and fit the new


EN - 330

gasket so that the identification is loca-

ted on the inlet manifold side.

• Check for possible damage on the

spark plug jacket sealing rings. Re-

place the damaged sealing rings.

• Fit the cylinder head cover on the cyl-

inder head.

• Tighten the bolts fixing the cylinder

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 PIPESEALING RING DURING FITTING.

Locking torques (N*m)Cylinder head - Cylinder head cover 9 ÷ 13

• Fit and tighten the ignition coils on the

cylinder head cover.

11. Fit the toothed belt.

Locking torques (N*m)Cylinder head cover - Ignition coil 6÷11

Crankshaft pinion fitting

Fit the timing belt pinion.


EN - 331

Fitting the timing pinion fixing screw

Fit the timing pinion fixing screw Tighten the screw

to the specified torque.- AVOID THE ROTATION OF THE CRANKSHAFT BY USINGTHE SPECIAL TOOL BELOW.


Locking torques (N*m)Crankshaft - Crankshaft belt pulley 88÷98

Piston and connecting rod fitting

Temporarily fit the flywheel on the crankshaft.N.B.- DO NOT LUBRICATE SCREWS AND THREADED HOLESOF THE FLYWHEEL.

1. Fit the oil scraper spring in the relevant seat.

Make sure that the end is positioned as in the fig-

ure.- DO NOT OPEN THE SPRING MORE THAN NECESSARY.

2. Fit the oil scraper upper ring, so that it fits in the spring edge.

- MAKE SURE THAT THE END OF THE RING IS MOVED 90° TO THE RIGHT WITH RESPECT TOTHE SPRING END.- DO NOT EXTEND THE RING MORE THAN NECESSARY.- MAKE SURE THAT THE OIL SCRAPER RING CAN BE EASILY TURNED.


EN - 332

3. Insert the lower ring, so that it also fits in the

spring.- MAKE SURE THAT THE END OF THE RING IS MOVED 90°TO THE RIGHT WITH RESPECT TO THE SPRING END.- DO NOT EXTEND THE RING MORE THAN NECESSARY.- MAKE SURE THAT THE OIL SCRAPER RING CAN BEEASILY TURNED.

4. Using an expander, fit the sealing ring No. 2 with

the reference mark T or N facing upwards.

5. Position the sealing rings so that the end of 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 THATTHE END OF THE RING IS ALIGNED WITH THE THRUSTDIRECTION. BESIDES, EACH RING MUST BE DEVIATEDAPPROX. 120° /180° FROM THE ADJACENT RING.

6. Fit the bushings on the connecting rods and rel-

evant caps, being careful that the fingers of the

operator do not contact the upper and lower sur-

faces of the bushings.

7. Cut the specific vinyl pipes with a suitable

length. Put the vinyl pipes on each connecting rod

screw.


EN - 333

8. Apply engine oil onto the sealing rings, pins,

connecting rod bushings, to the cylinder walls and

to the connecting rod pins.

9. Compress the sealing rings by means of the

special tool, making sure that the sealing sing ends

do not move during fitting.

10. Push the piston manually into the cylinder. The

arrow must be placed towards the oil pump side.- BE CAREFUL NOT TO DAMAGE THE BUSHINGS OF THECONNECTING ROD DURING FITTING.- BE CAREFUL NOT TO DAMAGE THE CONNECTING RODPINS DURING THE PISTON FITTING.

Specific tooling020328Y LOCK UP RINGS

11. Push the piston manually until the connecting

rod reaches the connecting rod pin.

12. Apply engine oil onto the bushing of each con-

necting rod cap.- DO NOT TOUCH THE FRONT SURFACE OF THE BUSH-INGS.

13. Remove the vinyl pipes, which were put on the

connecting rod screws for protection.

14. Fit the connecting rod caps with the reference

facing towards the oil pump side.- WITH THE CONNECTING ROD CAP PROPERLY FITTED,THE BUSHING CLAMPS ARE ON THE SAME SIDE.


EN - 334

15. Apply a small quantity of engine oil onto the

connecting rod locking nuts. Tighten the nuts to the

specified torque value, operating evenly in two or

three stages.

Locking torques (N*m)Connecting rod - Connecting rod cap 34÷44

16. For each cylinder, carry out the operations de-

scribed from point 1 to point 16.

17. Remove the flywheel.

18. Remove the special tool.


Oil pump fitting

1. Apply adhesive onto the coupling surface of the

oil pump with the cylinder block.

2. Replace the O-ring gasket A of the oil pump with

a new one.


3. Apply engine oil onto the sealing ring internal

surface.

Fit the oil pump to the cylinder block. Tighten to the


Locking torques (N*m)Cylinder block - Oil pump 6÷9


EN - 335

Oil suction system fitting

Fit the oil suction system interposing a new gasket

and spacer.

Lock the nuts.

Locking torques (N*m)Nut locking 15 ÷ 22

Oil sump fitting

1. Apply sealant onto the cylinder block surface.- APPLY THE RIGHT SEALANT QUANTITY IN ORDER TOAVOID THE FORMATION OF EXCESSIVE RESIDUES IN-SIDE THE ENGINE.


2. Position the oil sump gaskets.- MAKE SURE THAT THE FINAL SECTION OF THE OILSUMP 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 and operate in two

or three stages.

Locking torques (N*m)Oil sump - Cylinder block 7÷12

Fitting the thermostat in the cylinder block

Fit the thermostat in the cylinder block so that the

wander plug section A can be placed on the upper

side.- BE CAREFUL TO FIT THE THERMOSTAT WANDER PLUGIN THE RIGHT DIRECTION. FAILURE TO OBSERVE THISSAFETY MEASURE CAN CAUSE OVERHEATING.


EN - 336

Controlli

Checking and adjusting the ignition timing

1. Connect the special tool indicated below to the diagnostic tester connector (DLC) located at the lower

part of the instrument panel.

Specific tooling020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester

2. Prepare the diagnosis instrument DS-21.

3. Select "Actuator - Terminal 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 timing

on the flywheel is aligned with the indicator of the

rear bottom plate.

Ignition timing:

Before top dead centre 3° ± 2°CHECKING AND ADJUSTING THE IGNITION TIMING ISGENERALLY CARRIED OUT WITH THE ENGINE HOT.

6. If the ignition timing reference is not aligned with

the indicator, adjust the timing turning the cam-

shaft sensor.


EN - 337

COMPRESSION CHECKIF AFTER THE ENGINE TUNE IN, A POWER LOSS, EXCES-SIVE OIL OR FUEL CONSUMPTION ARE DETECTED,MEASURE THE CYLINDER COMPRESSION PRESSURE.

1. Heat the engine.

2. Set the ignition switch to OFF.

3. Remove the fuel pump relay from the relevant housing.

4. Remove all the spark plugs from the cylinder head.

5. Fit a cylinder compression gauge in the spark plug hole.

6. Let the engine run and measure the compression value.

• PUSH THE ACCELERATOR PEDAL COMPLETELY DURING THE COMPRESSION VAL-UE MEASUREMENT.

• ALWAYS USE A BATTERY COMPLETELY CHARGED SO AS TO OBTAIN A SPEEDEQUAL 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 cylinders:

147 kPa (1.5 kgf/cm2) at 300 rpm

If the compression of one or more cylinders is low, add a small quantity of engine oil in the cylinder

through the spark plug hole, then measure the cylinder compression again.

- If by adding oil, the compression has improved, probably the piston rings and/or cylinder holes are

worn or damaged.

- If pressure remains low after carrying out this operation, probably the valves stick or are not placed

properly in their seats, or the head gasket sealing is loose.


EN - 338

Idle speed check and adjustment_

Arrangements to be carried out before the idle

speed adjustment.

- Check and adjust ignition timing.

- Set all the accessory switches to OFF.

1. Connect the special tool 1 to the diagnostic test-

er connector 2 under the instrument panel.


2. Prepare the diagnosis instrument DS-21.

3. Warm up the engine. Let the engine run at 2500 rpm for about two minutes.

4. Select the option "Current data indication -

Current data monitoring " from the option list.WHEN THE DIAGNOSIS INSTRUMENT DS-21 IS NOTUSED, CONNECT A RPM INDICATOR TO THE REV. TER-MINAL USING THE SPECIAL TOOL (SST).

Specific tooling09991-87402-000 Rpm indicator pulse pickupwire (Engine speed measurement)

KEY:

1. Special tool

2.Diagnostic tester connector

• A REV CONNECTOR

• B Ground

5. Measure the idle speed. M/T vehicles: 900 ± 50

rpm

If the number of revolutions at idle speed does not

correspond to the specified value, adjust by means

of the idle speed set screw located on the throttle

body using a key C of 4 mm.TO REDUCE THE NUMBER OF REVOLUTIONS, TURN THEIDLE SPEED SET SCREW CLOCKWISE. TO INCREASE,TURN THE IDLE SPEED SET SCREW ANTICLOCKWISE.

Clutch

Clutch


EN - 339

This section of the manual describes how to inspect, remove and fit clutch components.

Clutch

As regards the main manufacturing principles of the gear and clutch for the new Porter 16V, there are

no changes with respect to the current one. The maintainability and duration level has been 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 direct result

of engine output power increase, specifications for the clutch and clutch cover have been modified with

respect to those of the current Porter model.

KEY:

1. Diaphragm spring

2. Clutch disc

3. Lever

4. Bearing

5. Bell

Smontaggio - montaggio

Removal


EN - 340

Remove the parts, following the numerical order shown in the figure 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 shown in the figure below.

Components:


EN - 341

1. Clutch lever stop

2. Thrust bearing

3. Thrust bearing hub stop

4. Clutch lever

5. Spring

6. Clutch disc

7. Pressure plate

A= Apply MP grease

B= Apply EP grease

C= Apply EF grease

Fitting the clutch disc and driven plate

1. Fit the special tool A in the rear end of the crank-

shaft.

2. Fit the clutch disc.

Specific tooling020196y Clutch guiding tool

3. Fit the clutch cover, aligning the reference pin

of the same cover.

Tighten the fixing bolts to the prescribed torque.

Locking torques (N*m)Clutch cover 15÷22

4. Apply grease for long duration onto the grooved

section of the clutch disc B.


EN - 342

5. With a thickness gauge and using the special

tool, check the diaphragm spring, to detect possi-

ble height deviations.

Specific tooling020197y Instrument to measure the height ofthe clutch diaphragm spring

CharacteristicHeight deviationLimit: 0.7 mm

6. If height deviation exceeds the specified limit,

adjust the diaphragm spring with the special tool

C.

Specific tooling020195y 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 contact surface.

8. Fit the vehicle gear unit.

Revisione

Clutch bell and diaphragm spring

Test the following parts. Replace any defective

part.

1. Check the clutch pressure plate and flywheel

contact surface with the clutch disc; checking that

there are no signs of wear or overheating.

2. Check that there are no signs of wear, corrosion

or damage on the lever.


EN - 343

Clutch lever stop

Check for wear or damage.

Spring


Clutch lever


Clutch disc

1. Check the clutch disc for signs of wear. Rivet

depth

CharacteristicLimit0.3 mm

2. Check for possible eccentricity of the clutch disc.

Limit:

CharacteristicLongitudinal eccentricity1.0 mm

side eccentricity:1.0 mm


EN - 344

Thrust bearing

1. Check that the thrust bearing turns freely, with-

out jamming. Turn the thrust bearing while an axial

force is manually applied to the this bearing. Make

sure there are no abnormal 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 or wear.

Thrust bearing hub stop


Pedale frizione

Removal

Remove the parts, following the numerical order shown in the figure.

Components:


EN - 345

1. Cover

2. Clutch cable adjusting nut

3. Clutch cable terminal

4. Clutch pedal shaft

5. Spring

6. Bushing

7. Clutch pedal

8. Clutch pedal protection

Inspection

Check the parts indicated below: replace 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

obtained, owing to an improved protection against

scoring due to possible foreign objects.

Installation

Fit the parts, following the numerical order shown in the figure.


EN - 346

Components:

1. Clutch pedal protection

2. Clutch pedal

3. Bushing

4. Spring

5. Clutch pedal shaft

6. Clutch cable

7. Clutch 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 value,

by means of the external adjusting nut A.

CharacteristicPedal height:137 - 147 mm


EN - 347

Free and residual travel of the pedal

1. Pull the sheath towards the bottom. Then, turn

the adjusting nut until reaching the position shown

in the figure.

CharacteristicNut position:20 mm

2. Position the adjusting nut, gear side, as follows:

Pull the cable with a force of 19.6 - 39.2 N in the

direction indicated by the arrow. At this stage, turn

the set nut until the interval between the adjusting

nut 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 following adjustment values. Pedal

residual travel: 25 - 35 mm Pedal residual travel:

not less than 20 mm (Distance between the point

where the clutch is detached and the stop vertical

line).

Lubrication system

This section of the manual provides information to check the proper operation of the lubrication system.

The removal and fitting operations are described as well.


EN - 348

Oil pump

Oil pump

COMPONENTS

1. Oil pressure switch

2. Oil pump unit

3. Gasket

4. Oil filter

Oil pressure check

1. Remove the engine cover (only for van)

2. Disconnect the oil pressure switch connector.

3. Remove the oil pressure switch.

4. Fit a suitable oil pressure gauge.

5. Oil pressure measurement:

- start up the engine and let it warm up until reach-

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 VALUES, CHECK AND REPAIR THE OIL PUMP.

CharacteristicOil pressure values:At idle speed: 20 kPa or more

At 3000 rpm: 245 - 490 kPa standard

6. Stop the engine.

7. Remove the oil pressure gauge.

8. Clean the threaded part of the oil pressure

switch.

9. Wrap the sealing tape around the threaded part

of the oil pressure switch.


EN - 349

10. Fit the oil pressure switch on the oil pump.

11. Connect the engine cable harness connector

to the oil pressure switch.

12. Start up the engine and check any oil leaks.- USE A LONG HEXAGONAL BOX-SPANNER TO FIT THEOIL PRESSURE SWITCH.- THE NEW OIL PRESSURE SWITCH IS COATED WITHSEALANT.- NEVERTHELESS, WHEN REPLACING THE OIL PRES-SURE SWITCH WITH A NEW ONE, REMOVE THE SEALANTCOMPLETELY BEFORE WRAPPING THE SEALING TAPE .- MAKE SURE TO CLEAN THE OIL PUMP SIDE HOLETHREADS BEFORE FITTING THE OIL PRESSURESWITCH.

Locking torques (N*m)Oil pressure switch - Cylinder block 12÷20

Removal

1. Place the engine unit on a suitable service

stand.

2. Remove the oil filtering element.

3. Remove bolts and nuts fixing the oil sump.

4. Separate the oil sump from the cylinder block.

5. Remove the oil filter undoing the fixing bolts.

6. Remove all the bolts fixing the oil pump unit.

7. Remove the oil pump from the cylinder block.


EN - 350

Removal

1. Remove the oil pump cover.

2. Remove the front oil seal.

3. Remove the oil 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 SPRING RE-TAINING CAP SO THAT IT CAN NOT JUMP OUT.


EN - 351

Checking each part

- Wash the parts to be removed using solvent for

cleaning.

- Check for possible damage to the pump body.

- Check for possible damage to the rotor

- Check for possible damage to the oil pump valve.

- Check for possible damage to the spring retaining

cap.

- Check for possible damage to the compression

spring and measure the relevant unloaded length.

Unloaded length prescribed value: 57 mm

- Apply engine oil onto the pump safety valve. In-

sert the valve in the pump and check for correct

operation.- REPLACE EACH SINGLE DAMAGED PART. - REPLACETHE COMPRESSION SPRING IF DAMAGED OR IN CASEITS UNLOADED LENGTH IS SHORTER THAN THE PRE-SCRIBED VALUE. - REPLACE THE PUMP IF THE VALVE ISNOT WORKING PROPERLY.

Measuring pump housing clearance, upper

part and side clearance.

1. Apply a thin layer of engine oil onto the surface

joining the oil pump assembly rotors and on the

rotor series. Fit the rotor series on the oil pump

assembly so that the drilled mark is visible from the

outside.

2. Rotor clearance - pump housing measurement

With a thickness gauge, measure clearance be-

tween the external rotor and the pump housing.REPLACE THE OIL PUMP IF CLEARANCE EXCEEDS THEPRESCRIBED VALUE.



EN - 352

3. End clearance measurement

With thickness gauge, measure clearance be-

tween the end (tip) of the internal rotor and that one

of the external rotor.REPLACE THE ROTOR SERIES IF CLEARANCE EXCEEDSTHE PRESCRIBED VALUE.

CharacteristicClearance0.16 - 0.24

4. Side clearance measurement

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 THEPRESCRIBED VALUE.

CharacteristicMaximum 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 the valve and insert, af-

terwards, the valve inside the oil pump body.

2. Insert the compression spring and or the spring

retaining cap inside the oil pump body.N.B.- WASH THOSE PARTS TO BE FITTED USING SOLVENTFOR CLEANING. DRY THEM BLOWING COMPRESSEDAIR. - WHEN COMPRESSED AIR IS USED, PROTECT EYESBY WEARING PROTECTIVE GOGGLES. - FIT THE SPRINGRETAINING CAP SO THAT THE PROTRUDING PART ISPLACED ON THE COMPRESSION SPRING SIDE.


EN - 353

3. Insert a new split pin in the lock while it is

stretched with pliers, etc. Separate the end of the

split pin until reaching an anchor shape.

4. Insert a new oil seal if the one being used is

damaged, with a hydraulic press.- BE CAREFUL NOT TO DAMAGE THE OIL PUMP DURINGTHE OIL SEAL REMOVAL AND FITTING.- MAKE SURE THAT THE OIL SEAL IS NOT FITTED IN ANINCLINED POSITION .

5. Apply engine oil onto the rotor series. Fit the ro-

tor series on the pump body so that the two refer-

ence marks are facing outwards.

6. Fit the oil pump cover and tighten it to the pre-

scribed torque.

Locking torques (N*m)Cover - Oil pump 8÷13


EN - 354

7. Turn the rotor by hand. Make sure that the rotor

turns slowly. Otherwise, service the oil pump.

Installation

1. Remove the gasket from the oil pump and from

the cylinder block.

2. Apply sealant onto the fitting surface of the cyl-

inder block oil pump, as indicated in the figure.


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 cylinder block with fixing

boltsCAUTION- BE CAREFUL NOT TO DAMAGE THE CRANKSHAFT OILSEAL DURING THE OIL PUMP FITTING.- BE CAREFUL NOT TO LET THE O-RING FALL DURINGTHE OIL PUMP FITTING.

Locking torques (N*m)Oil pump - Cylinder block 6÷9


EN - 355

6. Fit the oil filter on the cylinder block interposing

a new gasket.

Locking torques (N*m)Oil filter - Cylinder block 15÷22

7. Fix the gaskets of the oil sump to the cylinder

block.N.B.- THE OIL SUMP GASKETS ARE LOCATED IN TWOPOINTS: ONE ON THE OIL PUMP SIDE AND THE OTHERON THE FLYWHEEL SIDE. FIT THE GASKET PROTRUDINGPART IN THE SPECIFIC SECTION OF THE CYLINDERBLOCK.

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 BOTHOIL SUMP GASKET ENDS, SO THAT THE PARTS ONWHICH IT IS APPLIED CAN OVERLAP.

9. Fit the oil sump on the cylinder block with bolts

and fixing nuts.

10. Tighten in the same way, the bolts and nuts

fixing the oil sump to the prescribed torque in two

or three stages.

Locking torques (N*m)Oil sump - Cylinder block 7÷12


EN - 356

Checks

Checking each part

- Wash the parts to be removed using solvent for

cleaning.

- Check for possible damage to the pump body.

- Check for possible damage to the rotor

- Check for possible damage to the oil pump valve.

- Check for possible damage to the spring retaining

cap.

- Check for possible damage to the compression

spring and measure the relevant unloaded length.

Unloaded length prescribed value: 57 mm

- Apply engine oil onto the pump safety valve. In-

sert the valve in the pump and check for correct

operation.- REPLACE EACH SINGLE DAMAGED PART. - REPLACETHE COMPRESSION SPRING IF DAMAGED OR IN CASEITS UNLOADED LENGTH IS SHORTER THAN THE PRE-SCRIBED VALUE. - REPLACE THE PUMP IF THE VALVE ISNOT WORKING PROPERLY.

Measuring pump housing clearance, upper

part and side clearance.

1. Apply a thin layer of engine oil onto the surface

joining the oil pump assembly rotors and on the

rotor series. Fit the rotor series on the oil pump

assembly so that the drilled mark is visible from the

outside.

2. Rotor clearance - pump housing measurement

With a thickness gauge, measure clearance be-

tween the external rotor and the pump housing.REPLACE THE OIL PUMP IF CLEARANCE EXCEEDS THEPRESCRIBED VALUE.



EN - 357

3. End clearance measurement

With thickness gauge, measure clearance be-

tween the end (tip) of the internal rotor and that one

of the external rotor.REPLACE THE ROTOR SERIES IF CLEARANCE EXCEEDSTHE PRESCRIBED VALUE.

CharacteristicClearance0.16 - 0.24

4. Side clearance measurement

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 THEPRESCRIBED VALUE.

CharacteristicMaximum 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.

Oil cartridge

Oil filter fitting

1. Apply a reduced quantity of engine oil onto the

oil filter gasket.


EN - 358

2. Screw the oil filter until the gasket makes con-

tact with the oil pump.

3. Then, turn once more the oil filter completely

(360°).

Sensore pressione olio

Oil pressure warning light

Check if the oil pressure warning light turns on by

turning the ignition switch to ON.- IF THE WARNING LIGHT DOES NOT TURN ON, CHECKTHAT THE BULB IN THE PANEL IS NOT BURNED. (REFERTO THE SECTION "ELECTRICAL SYSTEM COMPONENTS"- IF THE WARNING LIGHT TURNS ON WHEN THE ENGINEIS RUNNING, CARRY OUT THE FOLLOWING CHECKS:(FIRST OF ALL, MAKE SURE THAT THE ENGINE OIL IS ATAN ADEQUATE LEVEL).

pressure switch fitting

1. Clean the threaded part of the pressure switch.

Wrap a sealing tape around the threaded part.N.B.- THE NEW PRESSURE SWITCHES ARE COATED WITHSEALANT. THEREFORE, WHEN THE PRESSURE SWITCHIS REPLACED WITH A NEW ONE, FIRST, REMOVE THECOATING COMPLETELY SINCE THE PRODUCT LOOSESITS CHARACTERISTICS WITH TIME. ALSO CLEAN THETHREADED HOLES WHERE THE SWITCH IS FITTED.


EN - 359

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

Cooling system

Coolant pump

Water pump fitting

1. 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 THETHREADED SECTION FROM THE CYLINDER BLOCKSIDE.




EN - 360

Water pump pulley test

1. Visually check the water pump pulley.

• Check the water pump pulley attach-

ment seat for deformations or worn

areas.

• Check the belt groove for deformations

or worn areas. Replace the water

pump pulley, if necessary.

Injection fuel system

Fuel filter

Fuel filter

Fuel filter replacement- DO NOT OPERATE NEAR NAKED FLAMES. DO NOT WORK NEAR THE OPEN TANK. FAILURETO OBSERVE THIS INDICATIONS CAN CAUSE FIRE.1. Check the ignition switch is placed on OFF.

2. Open the fuel tank cap.

3. Place a collecting container 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 SIMILAROBJECT TO PREVENT ITS ROTATION.- CAREFULLY AVOID FUEL SPLASHES ON THE BODY-WORK OR RUBBER PARTS, ETC., SINCE FUEL LEAKAGEWILL BE PROFUSE.

KEY:

A= Fuel

B= Filter

5. Disconnect the pipe clamp from the fuel filter.

6. Disconnect the fuel pipe from the filter.

7. Remove the pipe clamp and fit a new one.

8. Remove the fuel filter unscrewing both fastening

bolts.

9. Install the new fuel filter screwing both fastening

bolts.

Locking torques (N*m)Cylinders lock for water inlet 5.9 ÷ 8.8 Nm

10. Connect the pipe to the fuel filter, fasten the new clamp in the correct position.


EN - 361

11. Manually tighten the nut on the fuel filter.

12. Tighten the nut to the prescribed torque.

- PREVENT FILTER ROTATION BY HOLDING IT WITH A WRENCH OR SIMILAR TOOL. - NEVERREUSE AN OLD GASKET. FAILURE TO OBSERVE THIS SAFETY MEASURE CAN CAUSE FIREAFTER FUEL LEAKAGE.

Locking torques (N*m)Fuel filter fixing nut 34 ÷ 43

13. Close the fuel tank cap.

14. Remove the collecting container or cloth.

15. Place the ignition switch on ON/OFF for four or five times, every three seconds.

16. After replacement, check that there is no fuel leaks from the fuel filter.

Visually inspect the fuel supply system and the fuel filter checking there are no cracks, leaks, loosen

connections or distortions.

Cooling Circuit

This section of the manual provides 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 forced circulation type of system. In addition, it uses a cooling electric

fan and by-pass cooling system, where there is thermostat equipped by an inlet by-pass valve. The

cooling system comprises the radiator, water pump, thermostat, cylinder head, cylinder block, water

pipe and the relevant fittings.

- FOR COOLING, USE SWEET WATER (DE-IONISED) WHICH DOES NOT CONTAIN MINERALSALTS, CALCIUM, MAGNESIUM ETC. .- IF THE COOLANT SLIGHTLY TOUCHES PARTS OF THE BODYWORK, WASH THOROUGHLY.- NEVER OPEN THE RADIATOR CAP WHEN THE COOLING WATER IS HOT.- THE RADIATOR INSIDE IS UNDER PRESSURE WHEN THE COOLING WATER IS HOT. IF THERADIATOR CAP IS REMOVED, THE COOLING WATER MAY SPLASH OUT, PROBABLY CAUS-ING INJURIES AND BURNS


EN - 362


Radiator cleaning

Using water or vapour jets, remove the residues and the dust from the external radiator.

- WHEN A VAPOUR JET IS USED AT HIGH PRESSURE, BE CAREFUL NOT TO DEFORM THERADIATOR FINS.- IF THE JET PRESSURE IS 2.9 - 4.9 MPA (3-5 BAR), KEEP A DISTANCE EXCEEDING 40 - 50 CMBETWEEN 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 suitable device, (tester for radiator cap

testing) check the sealing valve opening pressure:

59 -103 kpa (0.6-1.0 bar). If this is not so, replace

the radiator cap.N.B.- NEVER OPEN THE RADIATOR CAP WHEN THE ENGINEIS STILL HOT. FAILURE TO OBSERVE THIS PRECAUTIONMAY CAUSE BURNS.


EN - 363

2. Check the radiator cap gasket for possible dam-

age. If this is so, replace the radiator cap.

3. With your fingers lift the cap valve. Check that

the valve operates properly. In case the valve does

not operate properly, replace the radiator cap.

Cooling circuit check for possible water leaks

1. Fill the radiator with coolant and apply the radi-

ator testing device.

2. Warm up the engine.

3. Apply a pressure 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: heating radiator,

block, head and heat exchanger for possible leaks.

Check the pipes for possible deterioration, break-

ing or damage. Replace the defective parts.

5. Remove the radiator testing device from the ra-

diator.

6. Refit the radiator cap- NEVER REMOVE THE RADIATOR CAP OR BLEEDINGCAP WITH THE COOLANT STILL HOT. FAILURE TO OB-SERVE THIS PRECAUTION CAN CAUSE BURNS.


EN - 364

Thermostatic valve

Thermostat removal


2. Drain the coolant.

3. Remove the two sleeves from the thermostat

cover.- NEVER OPEN THE RADIATOR CAP AND/OR THE DRAIN-AGE PLUG WHEN THE FLUID IS HOT. - COVER THE AL-TERNATOR TO AVOID THAT THE COOLANT GETS INTOTHE ALTERNATOR.

4. Remove the 3 thermostat cover screws.

Thermostat inspection

1. Make sure that the thermostat valve is com-

pletely closed at an ambient temperature of 20°C

and that the spring has no clearance. Replace the

thermostat, if the valve is open or if the spring has

clearance.


EN - 365

2. Check the thermostat sealing ring for possible

damage or breaking. Replace the thermostat if the

sealing ring shows signs of damage or breaking.

3. Immerse the thermostat in the water. Warming

up very slowly, check the opening start tempera-

ture.

Replace the thermostat if characteristics do not

comply

CharacteristicValve opening temperature in °C82 - 86°C

Valve lifting8.5 mm or more at 97°C

Thermostat fitting

1. Fit the thermostat with the bleeding pin placed

towards the upper part of the engine.- THE THERMOSTAT MUST BE FITTED WITH THE BLEED-ING PIN UPWARDS. FAILURE TO OBSERVE THIS PRE-CAUTION COULD CAUSE A MALFUNCTION IN THEENGINE OPERATION.

2. Fit the thermostat cover.

Locking torques (N*m)Cover - Thermostat 5.9 ÷ 8.8


EN - 366

3. Filling with coolant.

4. Connect the battery negative (-) terminal.

5. Start the engine and check for possible leaks. If

there are leaks, repair the point at which the leak

is detected.

Radiatore

Radiator removal


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 RADIATOR CAP AND/OR THE DRAINAGE PLUG WHEN THE COOLANT ISHOT.

KEY:

1. Cap for heating air breather pipe.

2. Engine side cap

3. Radiator cap

4. Heating

5. Radiator

6. Engine


EN - 367

• Remove the drainage plug placed near

the radiator inlet sleeve (right housing)

and on the outlet pipe fitting from the

radiator.

• Remove cap 2 on the engine side and

cap 1 for the heating air breather pipe

at the upper part of the engine.

3. Remove the front bumpers.

4. Remove 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-

ator taking out the 4 fixing screws.

8. Remove the radiator, the relevant fan and the

fan protection.

9. Remove the radiator fan and the relevant radi-

ator protection.- BE CAREFUL NOT TO LET THE RADIATOR FALL WHENTHE RADIATOR SUPPORT IS REMOVED.


EN - 368

Radiator fitting

1. Fit the radiator fan and the relevant protection

on the radiator and tighten the fixing nuts.

2. Insert the right and left supports of the radiator

on the radiator.

3. Fit the radiator with the relevant 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. Fit the reinforcement on the vehicle.

7. Fit the front bumpers on the vehicle.


9. Refill with coolant.

10. Fit the front panel gasket on the vehicle.


EN - 369

Coolant temperature sensor

Radiator thermoswitch removal


2. Drain the coolant.

3. Disconnect the radiator thermoswitch connec-

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. Connect an ohmmeter between terminals A and

B of the radiator thermoswitch.

2. Immerse the switch heat measuring section in a

water bath.


EN - 370

3. Heat the water until reaching a temperature of

93°C. Check continuity between terminals A - B of

the radiator thermoswitch. If there is no continuity,

carry out the following checks.

4. Take the water temperature to 97°C. Check

continuity between terminals A and B of the

switch. If there is continuity, replace the switch.


there is no continuity between terminals A - B of

the switch. If there is continuity, carry out the fol-

lowing checks.


there is no continuity between terminals A - B of

the switch. If there is continuity, replace the switch.

Radiator thermoswitch fitting

1. Clean the threaded part of the switch and after-

wards wrap the thread with the adhesive tape.

2. Fit the radiator thermoswitch on the radiator.

Locking torques (N*m)Radiator - Water thermal switch 24.5 ± 5

3. Fill with coolant.


EN - 371


5. Start up the engine and check any water leaks.

Water pump

Water pump removal


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 WHEN THE ENGINE IS HOT.

4. Remove the timing belt

5. Remove the water pump removing the relevant

fixing screws and nuts.


EN - 372

Inspecting parts relating to the water pump

1. Check if the water pump pulley is damaged or

deformed. Replace the water pump if it damaged

or deformed.

2. Check if the pump rotor 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 coupled with the pump

rotor. If damage is detected, replace the cylinder

block.

COMPONENTS:

1. Sealing ring


3. Water pump

4. Gasket


EN - 373

5. Cylinder block


Water pump sealing test

1. Visually check the water pump.

• The mechanical sealing section for wa-

ter leaks.

• The water pump rotating pallet 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 if there is excessive clearance or noise

of the water pump bearing and the pulley attach-

ment section.

Replace the water pump, if necessary.


EN - 374

Water pump fitting

1. With a scraper, remove the gasket residues

from the cylinder block

2. Remove the gasket from the water pump, using

a scraper for gaskets.

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 BOLTS, MAKE SURE THATTHE PUMP ROTATES PROPERLY.


5. Fit the timing belt


EN - 375

6. Fill with coolant.

7. Fit the lower crankcase.



EN - 376

INDEX OF TOPICS

INIECTION SYSTEM IS

This section of the manual comprises information regarding to safety measures and the Injection system

diagnosis.

Precauzioni

GENERAL SAFETY MEASURES

INSTRUCTION FOR MANUAL USE: The manual is drawn up for the areas where a type-approval

certificate is issued according to the approval of EC exhaust emissions. Therefore, the assignment,

reading, clearing of failure codes and checking, repair and confirmation procedures, are different from

the procedures carried out up to now.

And therefore, follow the instructions described below: 1. Using the diagnostic tester or OBD II general

scanning device.

2. Note regarding failure codes: to read or clear the 4 digit failure codes (e.g. P0105) assigned according

to the ISO standards, always use a tester or the device described in point 1. Also use the tester or the

device to turn the warning light off.

- AN OBD II GENERAL SCANNING DEVICE IS A SCANNING DEVICE COMPLYING WITH THEFORMAT ISO14230 (KWP2000).- WHEN USING AN OBD II GENERAL SCANNING DEVICE, NOT ALL THE FAILURE CODES (4DIGIT CODES) CAN BE READ. TAKE INTO ACCOUNT THAT ONLY THE FAILURE CODES INWHICH "ZERO" FOLLOWS LETTER "P" CAN BE READ, FOR EXAMPLE POXXX.- IN THIS MANUAL, THE AREAS WHERE THE TYPE-APPROVAL CERTIFICATION IS ISSUEDACCORDING TO THE APPROVAL OF EC EXHAUST EMISSIONS ARE INDICATED WITH "EUSPECIFICATIONS".

Specific tooling020461Y Diagnostic tester kit DS-21 (ex 09991-87301-000)

INSTRUCTIONS TO USE THE VEHICLE EQUIPPED WITH CATALYTIC CONVERTER

RECOMMENDATIONS: 1. If there is a great quantity of unburned gases in the catalytic converter,

an overheating can be detected with the consequent fire hazard. To prevent this type of incon-

venient strictly follow the instructions and inform the customer properly.

2. With vehicles equipped with catalytic converter use only unleaded petrol.

3. Avoid running the engine at idle speed for a long time. Do not run the engine at idle speed for

a more than 20 minutes.

4. Check and repair the vehicle immediately if the idle speed or idle is unstable or if failures are

detected in the system, failure to observe this safety measure can cause fire hazard.

5. Procedure to test the electric discharge.

• The electric discharge must be carried out only when it is strictly necessary; complete the

test as soon as possible.

• Do not run the engine with no gear engaged during the test.

• Be careful to lock the fuel supply during the test.

Iniection System PORTER 1.3 16V

IS - 378

6. Do not run the engine with the fuel tank almost empty. Failure to observe this safety measure

causes an irregular ignition. Besides, an excessive charge to the catalytic converter could dam-

age it .

7. Avoid riding downhill in neutral with the ignition switch set to OFF. Besides, avoid braking

for a long time.

8. Avoid disposing of the catalytic converter with other parts contaminated with petrol or diesel.WARNING

- CHECK AND REPAIR THE VEHICLE IMMEDIATELY IF THE IDLE IS TOO HIGH OR UNSTABLEOR IF MALFUNCTIONS ARE DETECTED IN THE SYSTEM. FAILURE TO OBSERVE THIS SAFETYMEASURE CAN CAUSE FIRE HAZARD. - IF THERE IS A GREAT QUANTITY OF UNBURNEDGASES IN THE CATALYTIC CONVERTER, AN OVERHEATING CAN BE DETECTED WITH THECONSEQUENT FIRE HAZARD. TO PREVENT THIS TYPE OF PROBLEM, STRICTLY FOLLOW THEINSTRUCTIONS ON THE SUBJECT. IN ADDITION, ALSO EXPLAIN TO THE CUSTOMERS WHICHSAFETY MEASURES MUST BE ADOPTED.

INSTRUCTIONS FOR THE MOBILE COMMUNICATION SYSTEM

In case of vehicles with an engine equipped with a mobile communication system, as two-way wireless

telephones 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 sensors.

2. The aerial wire must be at least at 30 cm from the electronic control unit and from the vehicle electronic

control system sensors. For further information regarding the electronic control unit and the sensors,

refer to the diagram about the component layout in the relevant paragraph.

3. Do not wrap the aerial power supply wires with other wires. Avoid placing the aerial feeder in direction

to other wires, when this is possible.

4. Be careful to adjust the aerial and the power supply wires properly.

5. Never fit a mobile communication system too hard.

INJECTION SYSTEM CIRCUIT CHECK

1. Before connecting or disconnecting the connec-

tors and terminals, place the ignition switch to OFF

or disconnect the battery negative (-) terminal.

Otherwise, there will be an interrupted wire in the

cable harness and the failure-free function will be

activated.

On the other hand, when the battery negative (-)

terminal is disconnected, the diagnosis code is

cleared. Therefore, confirm the diagnosis code be-

forehand, if necessary.

PORTER 1.3 16V Iniection System

IS - 379

2. Avoid pulling the wires to disconnect the con-

nector. Hold the connector properly after releasing

it and pull slightly. To connect the connector, insert

it until the insertion click is not felt.

3. Do not touch the terminal contacts with the

hands.

4. Prevent contact between the two testing probes

applied to the terminal supplied electrically, to

avoid short circuits.

5. When the connector is connected to the elec-

tronic control unit, never place an ohmmeter be-

tween the control unit connector and the sensor or

the 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 (cable harness

side). In case of connectors to which a testing

probe can not be connected on the rear part, such

as waterproof connectors, apply the testing probe

on the connector side, being careful not to bend

the male terminal or to open the female terminal.

7. Use a voltmeter/ohmmeter with internal impe-

dance equal to at least 10 k Ohm/V. If a voltmeter/

ohmmeter with internal impedance below 10 k

Ohm/V is used, failures can be detected or there

can be incorrect measurements.


IS - 380

8. While checking the condition of terminals, verify

that the male terminal is not bent and that the fe-

male terminal is not excessively open. Besides,

check the locking of both terminals, and that there

is no rust, dust, etc.

9. Before measuring voltage on each terminal,

check the battery voltage is at least 11 V. If the

check is performed with a low battery voltage, the

diagnosis could be incorrect.

Connessione Attrezzo Specifico (SST)

USING THE DIAGNOSTIC TESTER or OBD II GENERAL SCANNING DEVICE

- OBSERVE THE FOLLOWING INSTRUCTIONS TO OPERATE IN GREATER SAFETY CONDI-TIONS:- BEFORE USING THE DIAGNOSTIC TESTER or OBD II GENERAL SCANNING DEVICE, READTHE USER MANUAL CAREFULLY.- DURING THE VEHICLE RIDING WITH THE OBD II GENERAL SCANNING DEVICE OR DIAG-NOSTIC TESTER CONNECTED TO THE VEHICLE, PLACE THE CABLES SO THAT THEY DO NOTINTERFERE WITH DRIVING MANOEUVRES (IT MEANS, THE CABLES MUST NOT BE NEARFEET, PEDALS, STEERING AND GEARSHIFT LEVER).- DURING THE TEST RIDING WITH THE OBD II GENERAL SCANNING DEVICE OR DIAGNOSTICTESTER, TWO PERSONS ARE NECESSARY. ONE PERSON DRIVES THE VEHICLE, WHILE THEOTHER ACTIVATES THE ONE OF THE DIAGNOSIS INSTRUMENTS.

USING THE ENGINE CHECKING SYSTEM

1. The electronic control unit, sensors, etc. are

precision components. Be careful not to hit these

parts during fitting and removal operations. Do not

use the parts have been suddenly hit (for example,

if they fell down the floor).

2. If the test is performed on a rainy day or after

the vehicle has been washed, be careful to avoid

water infiltration and not to wet the electronic con-

trol unit, sensors, actuators, etc.

3. Never disconnect the connector from the battery

terminal during the engine operation. When the

connector is disconnected from the battery termi-

nal, an electric discharge could be generated (ap-

prox. 100V), which could damage the electronic

control unit.


IS - 381

4. Do not reverse the battery polarity, when the

connectors are connected. Failure to observe this

safety measure could cause the immediate break-

ing of the battery.

5. Never remove the electronic control unit cover

or the bracket on the electronic control unit side.

Also avoid touching the fixing screws.

6. If an electronic control unit malfunction is detected and the vehicle is repaired with its replacement,

refit the control unit previously removed (that defective) to confirm the original malfunction. At this stage,

it is possible to establish once and for all that the electronic control unit is not working properly.

7. Rpm indicator sensor connection. Connect the rpm indicator sensor to the measurement terminal of

the special tool. WARNING: THIS IS INVALID IF THE RPM INDICATOR SENSOR IS OF THE PICK-

UP TYPE. PREVENT 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. THEREFORE, CHECK IF THE

RPM INDICATOR IS COMPATIBLE WITH THE VEHICLE IGNITION SYSTEM.


KEY:

1. Special tool connector

A. Rpm indicator terminal

GND. Chassis ground

SST. Special tool

DLC. Data link connector on the vehicle 2. SST

SPECIAL TOOL CONNECTION

INTERFACE CABLE HARNESS TO CHECK

THE ELECTRONIC INJECTION SYSTEM

To measure the voltage of the electronic control

unit terminal with its connector connected to the

engine control unit, connect the special tool fol-

lowing the procedure described below:

1. Set the ignition switch to OFF. Or disconnect the

battery from the negative (-) terminal, with the ig-

nition switch set to OFF. Disconnect the battery

ground lead from the negative (-) terminal.


IS - 382

- THE NUMBER OF THE SPECIAL TOOL CONNECTORTERMINAL IS THE SAME THAT THE ELECTRONIC CON-TROL UNIT CONNECTOR NUMBER (SEE TERMINAL LAY-OUT OF THE INJECTION SYSTEM ELECTRONIC CON-TROL UNIT) - STORE THE ERROR CODE BEFOREDISCONNECTING THE BATTERY CABLE TO AVOID THATIT IS CLEARED WHEN THE CABLE IS DISCONNECTED.

2. Disconnect connectors, B, C, D, from the ECU

electronic control unit, placed under the glove-box

on the passenger side.

3. Connect the special tool indicated below be-

tween the cable harness connectors B and con-

nectors of ECU A.

Specific tooling020463Y ECU-EFI interface cable harness tocheck the injection system electrical values.

4. Reconnect the battery ground lead to the negative terminal (-).N.B.

- WHEN THE INJECTION SYSTEM ELECTRONIC CONTROL UNIT CONNECTORS ARE DISCON-NECTED OR CONNECTED, BE CAREFUL THAT THE BATTERY IS DISCONNECTED, WITH THEIGNITION SWITCH AND ALL THE ACCESSORY SWITCHES SET TO OFF.- WHEN FITTING THE NEW BATTERY, BE CAREFUL NOT TO REVERSE POLARITY. FAILURETO OBSERVE THIS SAFETY MEASURE COULD CAUSE A MALFUNCTION OF THE ELECTRONICCONTROL UNIT.- BEFORE USING THE SPECIAL TOOL, CHECK THERE ARE NO SHORT CIRCUITS OR INTER-RUPTED WIRES BETWEEN TERMINALS<.

Data link connector (common destinations)

The vehicle engine electronic control unit adopts the ISO 14230 protocol (Euro-OBD). As regards the

position, shape of the connector and pin layout, the data link connector complies with the standards

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 scanning device or for the diagnostic tester DS-21, to allow communication

with the electronic control unit.


IS - 383

DLC CONNECTOR KEYSpecification Desc./Quantity

16 Battery powered13 ECU - T12 EFI - T9 REV - Engine revs signal7 OBD II serial data line (ISO 14230 K line)

Present during transmission5 ECU ground4 Chassis ground

N.B.

WITH THE CABLE OF THE DIAGNOSTIC TESTER DS-21 CONNECTED TO THE DATA LINK CON-NECTOR BY MEANS OF THE CONTROL UNIT SELF-DIAGNOSIS CONTROL CABLE HARNESS,SET THE IGNITION SWITCH TO ON. IF THE TESTER VOLTAGE INDICATOR DOES NOT TURNON, PERFORM THE FOLLOWING CHECKS AND REPAIR THE PARTS NOT WORKING PROPER-LY.


CONNECT THE TESTER DS-21 TO ANOTHER VEHICLE, SET THE IGNITION SWITCH TO ON:

1. When the voltage indicator of the diagnostic tester DS-21 turns on: Vehicle side operation failure.

Check the data link connector, +B and Ground. - BAT terminal voltage check - Continuity check

between terminals E and Ground.

2. When the voltage indicator of the diagnostic tester DS-21 does not turn on: Operation failure of the

diagnostic tester DS-21

A = voltage indicator (switch section)


IS - 384

Descrizione del sistema

COMPONENT LOCATION (EU SPECIFICATIONS)

1. Data link connector between the ECU and the Diagnostic tester (DLC ). 2. Remote control unit (fuel

pump, main ECU, etc...) 3. Intake air temperature sensor(IAT) 4. Throttle valve position sensor (TPS)

5. Manifold absolute pressure sensor (MAP) 6. EGR valve 7. Fuel pump 8. EGR vacuum modulator

9. Vacuum switching 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 sensor (OX1 lambda probe) 16. Fuel pressure regulator 17. Injector

18. Electronic injection control unit (ECU EFI - DENSO) 18 D. Emission control unit (ECU - DRACO)

19. Vacuum switching valve to increase idle speed(VSV 2) 20. vehicle speed sensor in the instrument

panel 21. Vacuum switching valve for recovery of fuel vapours (VSV )


IS - 385

INJECTION SYSTEM BASIC DIAGRAM (FOR EU SPECIFICATIONS) 1. Data link connector between

the ECU and the Diagnostic tester(EOBD socket) 2. Vehicle speed sensor, integrated in the Instrument

panel. 3. Injection system electronic control unit; with a built-in atmospheric pressure sensor (ECU -

EFI) 3D. Electronic control unit of the emission system. (ECU - DRACO) 4. Front oxygen sensor heater/

front oxygen sensor (OXH1/OX1) 5. Malfunction indicator light (MIL) 6. Ignition coil 7. Fuel pressure

regulator 8. Ignition 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 oxygen sensor (OXH2/OX2) 15. Auxiliary air valve, controlled by the ther-

mostat. 16. Throttle body 17. Activated carbon filter (CANISTER) 18. Fuel tank 19. Vacuum switching

valve of fuel vapours (VSV) 20. Air filter 21. Intake air temperature sensor (IAT) 22. Throttle valve

position sensor (TPS) 23. Manifold absolute pressure sensor (MAP) 24. Vacuum modulator for EGR

25. Vacuum switching valve to increase idle speed (VSV2) 26. Vacuum switching valve for EGR valve

(VSV1)


IS - 386

ECU-DRACO CONNECTOR LAYOUT


IS - 387

DRACO-DENSO ECU interface diagram

EFI - DRACO ECU INTERFACE 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 cable harness


IS - 388

* Connector from front view, opposed side to cable output

** COLOUR TABLE

B = BLACK = NERO G = GREEN= VERDE 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 terminaliDisposizione del morsetto dell'unità di controllo elettronica del sistema di iniezione


IS - 389

CONNECTOR A (CONNECTED TO THE ENGINE ELECTRICAL SYSTEM )Specification Desc./Quantity

1 21 (N1+) -2 22 (N2+) Cam angle sensor (+)3 23 (E1) Sensor unit ground4 24 (#40) Injector (cylinder No.4)5 25 (#30) Injector (cylinder No.3)6 26 (#20) Injector (cylinder No.2)7 27 (#10) Injector (cylinder No.1)8 28 (OCV+) -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 speed15 57 (IG4) Ignition signal (cylinder No.4)16 58 (IG3) Ignition signal (cylinder No.3)17 59 (IG2) Ignition signal (cylinder No.2)18 60 (IG1) Ignition signal (cylinder No.1)19 61 (OCV) -20 79 (PRG) Vacuum switching valve to control bleeding21 80 (V8V1) Vacuum switching valve for EGR22 81 (ALT) -23 82 (E01) Power supply system ground


IS - 390

CONNECTOR B (CONNECTED TO THE ENGINE ELECTRICAL SYSTEM )Specification Desc./Quantity

1 14 (ICMB) Ignition unit (with ionic current measurement)2 15 (PIM) Pressure sensor signal3 16 (VC) Throttle valve sensor power supply4 17 (E2) Sensor ground5 18 (FCCP) -6 19 (VFP) -7 20 (OXH1) Front oxygen sensor heater8 43 (IE) Ionic current sensor ground9 44 (VTH) Throttle valve sensor10 45 (THW) Engine coolant temperature sensor11 46 (VCPM) Pressure sensor power supply12 47 (E2PM) Pressure sensor ground13 48 (ACLK) -14 49 (ACEN) -15 50 (OXH2) Rear oxygen sensor heater16 74 (0X2) -17 75 (0X1) Front oxygen sensor18 76 (THA) Intake air temperature sensor19 77 (ACVR) -20 78 (PST) -


IS - 391

CONNECTOR C (CONNECTED TO THE VEHICLE ELECTRICAL SYSTEM )Specification Desc./Quantity

1 8 (SI01) Diagnostic tester2 9 (T) Test terminal3 10 (DEF) Anti-fog system switch4 11 (A/T) Radiator fan relay5 12 (MGC) -6 13 (FAN1) -7 37 (SPD) Vehicle speed sensor8 38 (ACSW) -9 39 (BLW) Heater fan switch10 40 (STP) Stop light switch11 41 (AUX) Resistance for switching constant value12 42 (FAN2) -13 69 (SEL2) -14 70 (SEL1) -15 /1 (H/L) -16 /2 (ACEV) -17 73 (0X3) Rear oxygen sensor


IS - 392

CONNECTOR D (CONNECTED TO THE VEHICLE ELECTRICAL SYSTEM )Specification Desc./Quantity

1 1 (BAT) Memory protection power supply2 2 (FC1) -3 3 (W) Malfunction indicator light4 4 (ATTX) -5 b (SI02) -6 6 (TRRQ) Headlight switch7 7 (+B1) Fuel supply8 29 (E21) Rear oxygen sensor ground9 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 terminal14 35 (FPOF) -15 36 (+B2) Fuel supply16 62 (VCO) -17 63 (VTHO) -18 64 (IDLO) -19 65 (FCO) -20 66 (TRPR) -21 67 (ACT) -22 68 (STA) Starter motor signal

Model EURO 4


IS - 393

DRACO CONNECTOR - 14 PINSpecification Desc./Quantity

1 70 (SEL1) -2 37 (SPD) Vehicle speed sensor3 6 (TRRQ) Headlight switch4 36 (+B2) Fuel supply5 31 (REV) Engine revs signal (rpm)6 29 (E21) Rear oxygen sensor ground7 1 (BAT) Memory protection power supply8 9 (T) Test terminal9 8 (SI01) Diagnostic tester10 68 (STA) Starter motor signal11 7 (+B1) Fuel supply12 34 (VF) VF monitor terminal13 30 (FC2) Fuel pump relay (without IMB)14 3 (W) Malfunction indicator light


IS - 394


1 75 (OX1) Front oxygen sensor2 15 (PIM) Pressure sensor signal3 14 (ICMB) Ignition unit (with ionic current measurement)4 73 (OX3) Rear oxygen sensor5 40 (STP) Stop light switch6 39 (BLW) Heater fan switch7 45 (THW) Engine coolant temperature sensor8 44 (VTH) Throttle valve sensor9 43 (IE) Ionic current sensor ground10 80 (VSV1) EGR solenoid valve11 41 (AUX) Resistance for constant value interruption12 11 (A/T) Radiator fan relay13 10 (DEF) Defroster switch


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1 27 (#10) Injector (Cyl. 1)2 58 (IG3) Injection signal (Cyl. 3)3 59 (IG2) Injection signal (Cyl. 2)4 60 (IG1) Injection signal (Cyl. 1)5 57 (IG4) Injection signal (Cyl. 4)6 82 (GND) Ground lead (-)7 52 (N2-) Cam angle sensor (-)8 47 (E2PM) Pressure sensor ground9 46 (VCPM) Pressure sensor power supply10 76 (THA) Air intake temperature sensor11 26 (#20) Injector (Cyl. 2)12 25 (#30) Injector (Cyl. 3)13 24 (#40) Injector (Cyl. 4)14 23 (E1) Signs of ground15 56 (VSV2) IDLE-UP solenoid valve16 22 (N2+) Cam angle sensor (+)17 50 (OXH2) Rear oxygen thermal sensor18 79 (PRG) PURGE CONTROL solenoid valve19 20 (OXH1) Front oxygen thermal sensor20 17 (E2) Ground GND21 16 (VC) Throttle position sensor power supply


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4 PIN DRACO PROGRAM. CONNECTORSpecification Desc./Quantity

1 82 (GND) Ground lead (-)2 2d (TX) Signal transmission3 3d (RX) Signal reception4 4d (V dc-Ref) (+ 5 V) Power supply with reference direct current volt-

age

Misure di sicurezza per la diagnosi

SAFETY MEASURES TO REPAIR THE SUPPLY SYSTEM

1. Before carrying out any intervention on the supply system, disconnect the battery negative (-) cable.

2. Do not smoke during the interventions on the supply system. Besides, do not carry out any operation

with open fire.

3. Also with the engine off, the supply duct (between 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 releasing pressure, a small fuel leak can be detected

when pipes are removed. Therefore, before removal, it is recommended to cover with a cloth the part

to be removed to avoid fuel spraying.

4. The connection method of fuel pipes or vapour emission pipes is different depending on the pipe

type. When fuel pipes or vapour emission pipes are refitted, carry out the connections adequately and

lock the pipes referring to the figure on the side. Check there is no twisting or signs of wear after carrying

out the connection.


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Fuel pipe

Pipe insertion length

Insert the pipe so that L1 is at 0 - 2 mm

Clip position.

Fix it so that L2 is at 2 - 5 mm (the clip must not be

placed on the pipe elbow. Besides, it must not ex-

ceed the pipe end).

Suction pipe


Insert the pipe as shown in the figure on the side.

Clip position

The clip end must be at a 2 mm distance from the

pipe end.

KEY:

A= Elbow starting point


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Bleeding pipe


Insert the pipe so that L1 is at 0 - 3 mm

Clip position

Lock the pipe so that L2 is at 2 - 7 mm

LEGEND:

A= Elbow starting point

5. When fitting the union bolt on the fuel filter, use a new gasket and tighten to the prescribed torque.

6. When fitting the injector, fuel pipe, fuel pressure regulator or the pulsation damper, fit a new O-ring

or gasket. Before fitting, wet the O-ring with petrol or silicon oil.

Fuel pressure release

1. Set the gearshift lever to the "N" position.

Pull 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 relay block.

5. Start the engine. Run the engine until running out of fuel.

6. Fit the fuel pump relay. Fit the relay block on the body.CAUTION

- NEVER CARRY OUT THIS INTERVENTION WITH THE ENGINE STILL HOT. FAILURE TO OB-SERVE THIS SAFETY MEASURE COULD DAMAGE THE CATALYTIC CONVERTER.AFTER THE ENGINE IS COLD, RELEASE THE FUEL PRESSURE ACCORDING TO THE PROCE-DURE DESCRIBED BELOW.WARNING

- BE EXTREMELY CAREFUL SO AS NOT TO ENTANGLE THE WIRE WHILE THE RELAY BLOCKIS FITTED.


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7. Fit the upper and lower covers of the steering

column.N.B.- IF THE DIAGNOSTIC TESTER DS - 21 IS USED, SELECT" FUEL PUMP LOCKED" IN THE " ACTUATOR CONTROL"WHILE THE ENGINE IS RUNNING, AND CONTINUE RUN-NING THE ENGINE UNTIL THIS LOCKS.

Fuel leak check

After repairing the supply system, carry out the following checks to verify there are no fuel leaks.

1. Set the ignition switch to ON for three seconds, then put it back to OFF. Repeat the operation three

or four times.

2. Now, check there are no leaks in the supply system.

Troubleshooting safety measures

1. Never disconnect the connector from the electronic control unit, the battery cable, the ground lead

of the electronic control unit from the engine, or the main fuse, before the diagnosis information stored

in the memory of the electronic control unit is confirmed.

2. The diagnosis information stored in the memory of the electronic control unit can be cleared with the

diagnostic tester DS-21 or OBD-II general scanning device in the same way control is. Therefore, before

using the tester, read the relevant user manual so as to understand 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 it is not specified, comply with

the priority indicated below and carry out troubleshooting for each code.

• failure code different from P0171, P0172 (too lean/too rich in the supply system), and P0300,

P0301-P0304, P0314 (irregular ignition).

• P0171, P0172 (too lean/too rich in the supply system).

• P0300, P0301-P0304, P0314 (irregular ignition).

4. Before carrying out checks, read the section "system circuit checking safety measures" carefully.

Carry out the diagnosis being extremely careful where necessary.

Diagnosi del motore

General information

The engine and the engine control system of this vehicle are controlled by the electronic control system.

Besides, the vehicle is also equipped with an on board diagnosis system. If failures are detected in the

input/output systems (sensors, actuators, cable harnesses, connectors, etc.) of the engine control sys-

tem, the electronic control unit stores the relevant failure and informs the rider with the relevant

malfunction indicator light turning on or flashing (MIL, warning light). Besides, the operator is informed


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about the failure by means of the data link connector (diagnosis connector). While engine failures are

identified, it is necessary to have a general idea of the on board diagnostic system as well as a perfect

knowledge of the safety measures to be observed during troubleshooting, and how to use a tester.

Therefore, carry out troubleshooting according to the operation diagram which specifies the correct

procedure to be followed.

European on board diagnostic system of vehi-

cles (EOBD)

The vehicles designed for the European market

are equipped with the following functions, comply-

ing with the standard 1999/102/EC (generally

called EURO-OBD)

1. With the ignition switch set to ON, the warning

light (MIL) turns on. If no operation failure is de-

tected, the warning light turns on, once the engine

is started (check if the bulbs are burnt).

2. If during the engine operation, the electronic control unit detects an operation failure in the 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 (only if an

irregular ignition which can damage the catalytic converter is detected). Therefore, the electronic control

unit stores the area that has an operation failure (failure code ISO 15031-6/SAEJ2012). If the failure is

not detected for three sequential times, the warning light turns on automatically. In any case, the failure

code is stored in the electronic control unit memory.N.B.- THE WARNING LIGHT TURNS ON ONLY IN CASE OF FAILURES AFFECTING VEHICLE EMIS-SIONSfor example:

Diagnostic failure code P0105

Failure detected: Intake air absolute pressure failure / barometric pressure circuit failure

Diagnostic failure code: P0110

Failure detected: Intake air temperature circuit failure


Failure detected: Engine coolant temperature circuit failure


Failure detected: Circuit failure: engine coolant temperature/functional problems


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Failure detected: Throttle valve position sensor Failure (TPS) / pedal position sensor / switch "A"

3. It is possible to read different data sent by the

electronic control unit connecting the OBD II gen-

eral scanning device complying with the format

specified by ISO 14230, or the diagnostic tester

DS-21 to the data link connector of the vehicle.

Troubleshooting can be performed efficiently by

controlling these data (failure code, frozen image

data, current data, oxygen sensor monitor data,

etc.).

4. The failure code is formed by the ISO standard

code (specified by ISO 15031-6) and by designa-

tion code of the manufacturer. The ISO standard

code must be set complying with the ISO stand-

ards. On the other hand, the manufacturer desig-

nation code can be freely set by the manufacturer

within a specified limit.

ISO Diagnosis Code 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. Many failure codes have a detection logic with two interventions, which avoids the incorrect detection

and which starts working only when there has been an operation failure undoubtedly. Nevertheless,

another mode of diagnosis is determined, for which a single final confirmation test is necessary, so that

the mechanic confirms that the operation failure has been completely removed after the repair. This

mode can be activated with the OBD II general scanning device or with the diagnostic tester DS-21. If

the diagnostic tester DS-21 is used, select "continuous monitoring results" of "vehicle communication

in CARB mode".


Failure detected: Oxygen sensor heater circuit failure


Failure detected: Fuel trim system too lean



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Failure detected: Fuel trim system too rich

6. When an operation failure is detected, the en-

gine running conditions at the moment the failure

is detected are stored as frozen image data in the

memory of the electronic control unit .

7. Detection logic with 2 interventions.

When an operation failure is detected for the first

time, such failure is temporarily stored in the mem-

ory of the electronic control unit (first operation). If

this failure is detected again during the second op-

eration, the warning light turns on and the failure

code is determined (second operation). (The igni-

tion switch must be always off between the first

and the second operation).

8. Frozen image data

When an operation failure is detected for the first

time, the engine running conditions at the moment

the failure is detected are stored in the memory.

The engine status and running 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 useful for

troubleshooting and for determining if the vehicle

was running or stopped, if the engine was hot or

not, if the air - fuel ratio was lean or rich, when the

operation failure was detected

9. Frozen image data update

Considering that the electronic control unit can store the frozen image data for each single malfunction,

the data described in point 1 have priority when the data are stored. If the data described in point 1 are

detected when the data described in point 2 are already stored, the data 2 are replaced by data 1.

1: Frozen image data the first time the operation failure is detected between the irregular ignition (P0300-

P0304 e P0314), supply system too lean (P0171) and supply system too rich (P0172).

2: Frozen image data when an operation failure different from the one specified in point 1 is detected.


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- If the operation failure detected afterwards has a

lower priority or the same priority than the previous

one, data are not updated.

10. Clearing the frozen image data. The frozen im-

age data are cleared at the same time the failure

code is cleared. Except for vehicles equipped with

electrically controlled automatic transmission, the

frozen image data can be cleared at the same time

the failure code is cleared selecting the option

"failure code clearing (others)".

Misure di sicurezza per la diagnosi

Data link connector (common destinations)

The vehicle engine electronic control unit adopts

the ISO 14230 protocol (Euro-OBD). As regards

the position, shape of the connector 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 scanning de-

vice or for the diagnostic tester DS-21, to allow

communication with the electronic control unit.

DLC CONNECTOR KEYSpecification Desc./Quantity

16 Battery powered13 ECU - T12 EFI - T9 REV - Engine revs signal7 OBD II serial data line (ISO 14230 K line)

Present during transmission5 ECU ground4 Chassis ground

N.B.

WITH THE CABLE OF THE DIAGNOSTIC TESTER DS-21 CONNECTED TO THE DATA LINK CON-NECTOR BY MEANS OF THE CONTROL UNIT SELF-DIAGNOSIS CONTROL CABLE HARNESS,SET THE IGNITION SWITCH TO ON. IF THE TESTER VOLTAGE INDICATOR DOES NOT TURNON, PERFORM THE FOLLOWING CHECKS AND REPAIR THE PARTS NOT WORKING PROPER-LY.


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A = voltage indicator (switch section)

CONNECT THE TESTER DS-21 TO ANOTHER VEHICLE, SET THE IGNITION SWITCH TO ON:

1. When the voltage indicator of the diagnostic tester DS-21 turns on: Vehicle side operation failure.

Check the data link connector, +B and Ground. - BAT terminal voltage check - Continuity check

between terminals E and Ground.

2. When the voltage indicator of the diagnostic tester DS-21 does not turn on: Operation failure of the

diagnostic tester DS-21

Troubleshooting

The engine control system is equipped with diagnosis functions able to diagnose areas which have

operation failures. Such functions are important for troubleshooting purposes. The operation diagram

in the following page shows the procedure to be followed to identify the failures using the diagnosis

functions mentioned. The operation diagram shows how to use the diagnostic failure code control effi-

ciently. Besides, once all the results are examined, it can be determined if the troubleshooting is carried

out according to the diagnostic failure codes or 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).- IF THE DIAGNOSTIC TESTER DS-21 OR OBD-II GENERAL SCANNING DEVICE IS NOT USED,THE DIAGNOSTIC FAILURE CODE OR THE FROZEN IMAGE DATA CAN NOT BE READ IN THEOPERATION DIAGRAM.Customer information

The cause of the vehicle failure can not be removed, if the malfunction phenomenon is not previously

confirmed. Even if operations are continued for a long indefinite time, the vehicle can not be restored

unless the malfunction phenomenon is confirmed. The information provided by the customer is impor-

tant and it must be obtained even before the malfunction phenomenon confirmation. The information

obtained from the customer is important evidence to reproduce the malfunction phenomenon. Besides,

information provided by the customer can be consulted during troubleshooting. Therefore, instead of

posing general questions, focus attention on what is related to the defect. The following five points

represent the most important questions to be posed to analyse the operation defect. In some cases,

information about defects previously detected and about the past record of repairs, which apparently


IS - 405

have nothing to do with the current defect, could instead turn out useful to repair the defect. It is therefore

important to manage to obtain as much information as possible and bear it in mind as a reference during

the identification of the malfunction phenomenon.

Main points to analyse the defect the customer has complained about

What? Vehicle model, system rules

When? Date, time, event frequency

Where? Road surface conditions

Under which conditions? Running conditions, riding conditions, atmospheric con-

ditions

What happened? How could the customer identify the operation defect?

Question form

If the question form is prepared beforehand, as

shown below, it is possible to pose all the neces-

sary questions. A standard form which can be

modified according to the single characteristics of

the market is shown below.

Question form

Checking, storing and clearing the failure code/frozen image data

Once the failure code is indicated, confirm if that particular defect has been previously detected or if it

is still being detected currently, and confirm how the defect is related to the failure reproduced. To

confirm this, indicate the failure code / frozen image data twice, that is to say, 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 code (including the failure codes which are not identified) referring

to the section "failure code checking procedure". Print or take note of the code and frozen image data

when they are identified. Then, clear them referring to the "failure code clearing" procedure. If the failure

code is not cleared, an incorrect diagnosis could be carried out, reaching the conclusion that the regular

circuit is not working properly, or difficulties could arise during troubleshooting.

Malfunction phenomenon reproduction confirmation

While identifying failures, the operator can not detect the cause of the malfunction unless the phenom-

enon is confirmed. In this regard, it is essential to reproduce the failure phenomenon recreating the

same conditions and environment where the failure was detected, according to the information obtained

from the customer.

In case of phenomena which can not be easily reproduced, recreate the same running conditions oc-

curring when the failure was detected (road surface conditions, atmospheric conditions, riding condi-

tions). To that end, it is very important to try to reproduce the failure constantly, with the aid of external


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factors such as movements (moving the wires and the relay manually), heat (using hot air), and water

(humidity).

Movements, heat or humidity can be the failure causes which are difficult to be reproduced. Therefore,

with the vehicle stopped, the failure reproduction simulation test described below can be performed.

Besides, if it is considered that a component causes the failure and a tester, etc. is connected to that

component so as to confirm the failure phenomenon, it is also possible to assess functionality.

Counterchecking, storing and clearing the failure code/frozen image data

By checking the failure code/frozen image data after having confirmed the malfunction phenomenon

reproduction, it can be determined if the system indicated by the failure code before the reproduction

confirmation works properly or not. Afterwards, proceed with one of the following steps.

1. When a failure code is detected at the moment of checking, and this code is detected after the

malfunction reproduction confirmation, it means that the problem still remains in the diagnosis circuit.

Remove failures according to the codes detected.

2. If no abnormal code is detected, although the failure has been found during the malfunction repro-

duction confirmation, it is probable that a different defect from the one connected to the diagnosis system

is being detected. Remove the failure according to the malfunction phenomenon.

3. If no malfunction is detected during the malfunction reproduction confirmation, and the 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 currently. Check cables

and connectors of the system connected to the failure code detected before the malfunction phenom-

enon reproduction confirmation.

Visual check

Check cables and connectors of the systems indicated at the moment of the initial check of the failure

code, according to the "visual check and contact pressure check" procedure.

Check and repair according to the table of self-diagnosis codes

Before troubleshooting, perform the basic check to identify the possible malfunction causes. For ex-

ample, if by checking the spark, it turns out that there are no problems, it can be inferred that the ignition

system works properly. Besides, the defect causes can be identified also according to the information

obtained from the customerN.B.- IF THE MALFUNCTION CAN NOT BE DETECTED THROUGH THE DIAGNOSIS SYSTEM, AL-THOUGH THERE IS A MALFUNCTION PHENOMENON, IT MEANS THAT SUCH DEFECT IS NOTINCLUDED WITHIN THE DETECTION RANGE OF THE DIAGNOSIS SYSTEM OR THAT THE DE-FECT IS IN A SYSTEM DIFFERENT FROM THOSE CONNECTED TO THE DIAGNOSIS SYSTEM.Checking malfunctions which are detected intermittently

Inspect the parts where the malfunction is detected intermittently, as cable harness and connectors, as

described in the section "Checking malfunctions which are detected intermittently and bad contacts".

During the inspection, focus checks on the circuits connected to the failure code systems indicated at

the moment of the failure code initial check


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Final confirmation test

Confirm that the malfunction phenomenon detec-

ted by the customer has been completely re-

moved. If parts repaired are connected to the code

failure, clear the code one time and perform the

failure code confirmation test. Check that no code

is indicated. Now, to increase the operation effec-

tiveness, make use of the function "continuous

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 test

1. Vibration:

When vibration is considered the main cause

• Connector

Slightly shake the connector vertically or laterally

• Cables

Slightly shake the cables vertically and laterally

The points to be checked are the connector join

points, vibration points and the section in which the

cables pass through the body.


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• Parts, sensors

With the finger, slightly move the part of the sensor

which is considered the cause of the malfunction.

Check if the malfunction is reproduced.N.B.- PAY ATTENTION NOT TO MOVE THE RELAY EXCES-SIVELY, SINCE IT COULD DAMAGE THE REMOTE CON-TROL.

2. Cold/hot:

In case of a part which is considered the cause of

the failure when it is hot and cold. Heat the com-

ponent which is suspected to be the cause of the

failure with a hair dryer or a similar device. Check

if a malfunction is detected.CAUTION- DO NOT EXCEED A TEMPERATURE OF 60°C. (MAXIMUMLIMIT TO AVOID DAMAGING THE COMPONENT).- DO NOT HEAT THE PARTS DIRECTLY IN THE ELEC-TRONIC 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 WET THE ENGINE COMPARTMENT DIRECTLY.THE TEMPERATURE AND HUMIDITY CAN BE CHANGEDBY WETTING THE RADIATOR FRONT PART INDIRECTLY.- NEVER WET THE ELECTRONIC PARTS.- IF CASE OF RAIN INFILTRATION TO THE VEHICLE IN-SIDE, THE WATER COULD PENETRATE INSIDE THEELECTRONIC CONTROL UNIT THROUGH THE CABLES. IFPREVIOUS WATER INFILTRATION ARE DETECTED, BEEXTREMELY CAREFUL.

4. Another:

When it is considered that the malfunction is de-

tected by applying a heavy electric charge.

Activate all the electrical charges, including the

heater fan, lights, anti-fog system rear window,

etc. Check if a malfunction is detected.


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Procedura ricerca guasti

Checking diagram common options

1. For a correct troubleshooting, refer to the checking procedure detailed for each circuit according to

the failure code diagram or the diagram related to malfunction phenomena.

2. If by troubleshooting of all the components, wires and connectors, except for the electronic control

unit, no malfunction is detected, it is probable that the electronic control unit is not working properly.

Therefore, if no defect is detected after the diagnosis, check the electronic control unit and replace it,

if necessary, also if no problem has been found in it. Check if a malfunction phenomenon has been

detected. If there are no malfunction problems, proceed with checks according to the method of the

malfunction reproduction simulation test.

3. Checking procedures on cable harnesses, electrical and electronic components described in this

chapter can be applied to various systems. Checks must be therefore performed according to these

procedures, as described below.

4. To 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 for open circuits or short circuits with a multimeter, referring to the DRACO pin-out table

(EFI ECU side).

Checking wires and connectors

Wire and connector malfunctions are caused by

interrupted or short-circuited wires.

Interrupted wire:

it is caused by detached wires, bad contacts inside

the connector, disconnected connector terminal,

and so on.

- There are bad contacts due to the formation of

oxide on the connector terminal, foreign bodies on

the terminal, or inadequate contact pressure be-

tween the male and female terminals of the con-

nector. Simply disconnect the connector one time,

then connect it again. The contact could be in this

way modified, restoring regular operation. If during

checking no defect is detected in wires and con-

nectors, and if the malfunction stops after finishing

checks, it is probable that the wire or the connector

could be the cause of the problem.N.B.- WIRES ARE RARELY CUT AT THE CENTRE. IN MOST OFTHE CASES, THERE IS AN INTERRUPTED WIRE NEARBY


IS - 410

CONNECTORS. CHECK VERY CAREFULLY THE CONNEC-TORS OF THE SENSOR AND THE ACTUATOR

Short circuit:

this is caused by a short circuit between the cable

harness and the chassis ground, or by a short cir-

cuit inside the switches, etc.- IF A SHORT CIRCUIT IS DETECTED BETWEEN THE CA-BLE HARNESS AND THE CHASSIS GROUND, CHECK IFTHE WIRES ARE ENTANGLED, IF THE WIRE IS RUBBED,IF THE INSULATING PART IS BROKEN ALLOWING A CON-TACT WITH OTHER PARTS, AND IF THE WIRE IS LOCKEDPROPERLY.

Resistance check (short circuit 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 CABLE HARNESS LONGITUDINALLY AS WELL AS HORIZONTALLYDURING THE MEASUREMENT OF RESISTANCE.

CharacteristicResistance:

10 MΩ or more

Continuity check (interrupted wire check)

1. Disconnect the connector on both sides of the

electronic control unit and the sensor

2. Measure resistance between the connector ter-

minals- SLIGHTLY SHAKE THE CABLE HARNESS LONGITUDI-NALLY AS WELL AS HORIZONTALLY DURING THE MEAS-UREMENT OF RESISTANCE.

CharacteristicResistance:10 Ω or less


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In case of waterproof connectors, probes A must

be inserted in the connector on each cable har-

ness side.

- If the waterproof connector is checked without

removing waterproof rubber, be careful not to de-

form the connector terminal during the probe ap-

plication.

Visual inspection and contact pressure check

1. Disconnect the connectors on both sides of the

relevant cable harness.

2. Visually inspect for rust on the connector termi-

nal. Besides, check that there are no foreign bod-

ies.

3. Check that the tightened section A is not loos-

ened or damaged. Besides, 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 the socket. If the socket force is lower

with respect to that one of the other terminals, the

contact could result bad.- IF THERE IS RUST ON THE TERMINAL OR FOREIGNBODIES ARE FILTERED, OR IF THE CONTACT PRESSUREBETWEEN THE MALE AND FEMALE TERMINAL DECREA-SES, DISCONNECT AND CONNECT THE CONNECTORAGAIN SO THAT A MALFUNCTION IS NOT DETECTED. IFCABLE HARNESS AND CONNECTOR CHECK DOES NOTSHOW FAILURES, THE MALFUNCTION CODE IS CON-FIRMED. NOW, IF NO MALFUNCTION PHENOMENON ISREPRODUCED, IT IS PROBABLE THAT DEFECT WAS


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CAUSED BY A BAD CONTACT BETWEEN THE MALE ANDTHE FEMALE TERMINAL.

Check the malfunction which is detected intermittently and false contacts

The relay or solenoid valve can be locked. Most of the operation defects which are detected intermit-

tently are due to interrupted wires caused by bad connections or wrong connections inside the circuit.

Check, following the described procedure.

1. Inspect the connector and the terminal. Check according the options related to interrupted wires in

the section "cable harness and connector check".

2. Visual inspection and check of the contact pressure. Check according to options indicated in point

"Visual Inspection and contact pressure check ".

3. inspect the DRACO control unit, checking continuity between the pin of the vehicle device cable

harness side and those of the EFI ECU interface side, or checking for possible internal short circuits.

As an extra check, it is possible to bypass the DRACO connecting the cable harness of vehicle devices

to EFI ECU control 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 defect is

detected, replace the electronic control unit.

1. Disconnect the electronic control unit connector.

Inspect that there is no bending on ground termi-

nals E1 and E2 on the electronic control unit side

and on the cable harness side. Also check the

contact pressure.

2. Measure the resistance between ground termi-

nals E1 and E2 (cable harness side) and the chas-

sis ground. In addition, measure the voltage

between the power supply terminal (cable harness

side) and the chassis ground.- WHEN THE GROUND CIRCUIT OF THE ELECTRONICCONTROL UNIT IS CHECKED, IT CAN BE THE CASE INWHICH THE TERMINAL CONTACT CONDITIONS CAN BEMODIFIED BY DISCONNECTING AND CONNECTING THENEW CONNECTOR AND RESULTING IN "NO OPERATIONDEFECTS". IF WHILE CHECKING THE GROUND CIRCUITOF THE ELECTRONIC CONTROL UNIT NO MALFUNC-TIONS ARE DETECTED, CONNECT THE NEW ELECTRON-IC UNIT CONNECTOR TO CONFIRM THAT THE THERE ISA MALFUNCTION. NOW, IT CAN BE DETERMINED IF THECONTROL UNIT IS DEFECTIVE.


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CharacteristicResistance:10 Ω . or less

Voltage:battery voltage

Codici diagnotici

Failure code diagram specifications

SPECIFIED CODES OF THE ISO/SAE STANDARDS

For further information related to single codes, refer to the failure code diagram.


Failure detected:Manifold absolute pressure/ barometric pressure circuit malfunction

Affected area

- Interrupted or short-circuited cable in the manifold absolute pressure sensor

- Manifold absolute pressure sensor

- Engine electronic control unit (ECU)


Failure detected:Intake air temperature circuit failure

Affected area

- Interrupted or short-circuited cable in the intake air temperature sensor

- Intake air temperature sensor

- Engine electronic control unit


Failure detected:Engine coolant temperature circuit failure

Affected area

- Interrupted or short-circuited cable in the water temperature sensor circuit




Failure detected: Engine coolant temperature/functional problems

Affected area


- Cooling system


Failure detected:Throttle switch circuit/pedal position sensor/switch "A" failure

Affected area

- Interrupted or short-circuited wire in the throttle position sensor circuit

- Throttle position sensor


IS - 414



Failure detected:Oxygen sensor circuit failure (bank 1, sensor 1)

Affected area

- Air intake system

- Fuel pressure or Injector

- Interrupted or short-circuited cable in the front oxygen sensor Heater circuit (O1).

- Oxygen sensor heater


Failure detected:Oxygen sensor circuit slow response (bank 1, sensor 1)

Affected area

- Air intake system

- Fuel pressure

- Injector injection

- Interrupted or short-circuited cable in the oxygen sensor heater circuit.


- Engine electronic control unit (ECU)


Failure detected:Oxygen sensor heater circuit failure (bank 1, sensor 1)

Affected area

- Interrupted or short-circuited cable in the oxygen sensor circuit heater.




Failure detected:Rear oxygen sensor circuit failure (O2) (bank 1, sensor 2)

Affected area

- Interrupted or short-circuited wire in the rear oxygen sensor circuit heater (O1).

- Rear oxygen sensor (O2)



Failure detected:Oxygen sensor heater circuit failure (bank 1, sensor 2)

Affected area

- As failure code P0135


Failure detected:Fuel trim system too lean (lean air-fuel ratio failure, bank 1)

Affected area

- Air intake (pipe loosened)

- Fuel duct pressure


IS - 415

- Injector locking or leakage

- Interrupted or short-circuited wire in the oxygen sensor circuit.

- Oxygen sensor



- Gas leak in the exhaust system

- Vacuum switching valve for vapour bleeding



Failure detected:Fuel trim system too rich (lean air-fuel ratio failure, bank 1)

Affected area




- Interrupted or short-circuited wire in the oxygen sensor circuit.

- Oxygen sensor




- Vacuum switching valve for vapour bleeding



Failure detected:Random/multiple cylinder irregular ignition

Affected area

- Ignition system

- Injector

- Fuel pressure

- Compression pressure

- Adjustment valve clearance of valves

- Ionic current sensor


- Interrupted or short-circuited wire in the engine wires

- Connector connection



Diagnostic failure code: P0301 P0302 P0303 P0304

Failure detected: Irregular ignition

- Cylinder 1


IS - 416

- Cylinder 2

- Cylinder 3

- Cylinder 4

Affected area:

- Ignition system

- Injector

- Fuel pressure


- Adjustment valve clearance of valves

- Ionic current sensor


Failure detected: Single cylinder irregular ignition (cylinder not specified) (EU standards)

Affected area:


- Interrupted or short-circuited wire in the engine wires





Failure detected: Crankshaft position sensor circuit "A" failure

Affected area:

- Interrupted or short-circuited wire in the cam angle sensor circuit

- Cam angle position sensor

- Rotor signal



Failure detected: Catalytic converter efficiency below the threshold limit

Affected area:

- Three-way catalytic converter

- Interrupted or short-circuited wire in the oxygen sensor circuit (heated).

- Oxygen sensor (heated)


Failure detected: Vapour emission control system - bleeding control valve failure

Affected area:

- Interrupted or short-circuited wire in the vapour vacuum switching valve circuit

- Vacuum switching valve for vapours




IS - 417

Failure detected: Vehicle speed sensor failure

Affected area:

- Interrupted or short-circuited wire in the vehicle speed sensor circuit.

- Instrument panel

- Vehicle speed sensor


DAIHATSU MOTOR CORPORATION CODES


Failure detected: Barometric pressure sensor circuit failure

Affected area:



Failure detected: Ionic system failure

Affected area:

- Interrupted or short-circuited wire in the ionic system circuit.

- Ignition unit

- Ignition coil (all cylinders)

- Spark plug (all cylinders)



Failure detected: Start-up signal circuit failure

Affected area:

- Interrupted wire in the start-up signal circuit



Failure detected: Switch signal circuit failure

Affected area:

- Interrupted or short-circuited wire in the C/A switch circuit

- C/A switch

- Interrupted or short-circuited wire in the throttle valve sensor circuit

- Throttle valve sensor

- Interrupted or short-circuited wire in the neutral starter switch

- Neutral starter switch


Failure detected: Electronic control unit protection power supply circuit failure

Affected area:

- Interrupted wire in the electronic control unit protection power supply circuit



IS - 418


Failure detected: Exhaust gas recirculation system control valve circuit failure

Affected area:

- Interrupted or short-circuited wire in the circuit of the vacuum switching valve for EGR

- Vacuum switching valve for EGR


FAILURE-FREE FUNCTION

If one of the following codes are detected, the electronic control unit enters the failure-free mode allowing

the riding of the vehicle with complete safety. If the failure is indicated regularly, the failure-free com-

mand is deactivated. The diagnosis results remain anyway in the memory. It is therefore necessary to

determine if the failure is still there or not.

FAILURE-FREE SPECIFICATIONS

failure codes-1, failure code No. P0105:

Failure detected:When the signal sent by the inlet manifold pressure sensor indicates there is an

interrupted or short-circuited wire.

Failure-free operation:

- The signal sent by the inlet manifold pressure sensor is set to the value established 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 value.

- The fuel supply is interrupted if the throttle opening angle and the engine speed exceed the respective

set values.


Failure detected: When the signal sent by the intake air temperature sensor indicates there is an

Interrupted or short-circuited wire.


- The signal sent by the intake air sensor is set to a constant value


Failure detected: When the signal sent by the engine coolant temperature sensor is open or closed.


- The signal of the engine coolant temperature sensor turns into a constant value.


Failure detected:When the signal sent by the throttle position sensor indicates there is an Interrupted

or short-circuited wire.


- The signal sent by the throttle position sensor turns into a constant value.



IS - 419

Failure detected:When an abnormal situation is detected in the signal sent by the rear oxygen sensor


- The rear oxygen sensor return is blocked.

- The correction coefficient of the rear oxygen sensor return is set to the value determined by the engine

speed and by pressure.


Failure detected:When the signal sent by the atmospheric pressure sensor indicates there is an In-

terrupted or short-circuited wire.


- The signal sent by the atmospheric pressure sensor is set to a constant value.

Matrix table for troubleshooting

Matrix table for troubleshooting according to the malfunction phenomenon

If no failure code is detected during the check, and if no defect is confirmed during the basic check,

perform troubleshooting 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 starter motor relay

The engine starts normally (difficult start-up) • Fuel pump checking circuit

• Injector circuit

• Ignition coil circuit (with ignition spark plug)

• Spark plug

• Vacuum switching valve circuit to increase idle speed

An initial combustion is not detected • Electronic control unit power supply circuit

• Fuel pump checking circuit



• Spark plug

Even if an initial combustion is detected

This is not complete




Difficult start-up (winter) • Fuel pump checking circuit



• Spark plug



IS - 420


Difficult start-up (summer) • Fuel pump checking circuit



• Spark plug


Engine does not hold idling


Idle speed not in working order • Vacuum switching valve circuit to increase idle speed

Minimum speed too slow • Electronic control unit power supply circuit




Minimum speed too fast • Pipe, etc. detached

• PVC line


Irregular/unstable idle speed • Fuel pump checking circuit


• Fuel duct filter



Oscillation during idle speed operation • Electronic control unit power supply circuit


• Pipe, etc. detached

• PVC line


The engine stops during idle speed operation • Fuel pump checking circuit


• Fuel duct filter


Engine irregular performance


The engine stops when the accelerator pedal

is pushed

• Fuel filter - Fuel circuit pipes

• PVC line

The engine stops when the accelerator pedal

is released



Oscillation while riding • Pipe, etc. detached


IS - 421


• PVC line

No output • Fuel pump checking circuit



Engine poor at full power


Hesitation on acceleration phase • Fuel pump checking circuit



Signs of knocking


Head knocking • Fuel pump checking circuit


Backfire/fire retarding • Injector circuit

• Ignition 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 device is used to clear the failure code (refer to the

relevant user manual for the procedure).

2. The electronic control unit power supply is interrupted allowing to clear the failure code without using

the diagnostic tester or OBD II general scanning device. (Disconnect the battery negative (-) terminal

or detach the injection system fuse).

Controlli

Diagnostic failure code check

Before inspecting, check the warning light following the procedure described below.


IS - 422

Warning light check

1. Check if the warning light turns on with the ig-

nition switch set to ON, but with the engine stop-

ped.

2. Check if the warning light turns off when the en-

gine is started.

If the warning light remains on or flashing, the di-

agnosis system has detected an operation defect.

A failure code has been therefore stored in the

electronic control unit.

If no failure code has been stored in the electronic

control unit, check the warning light circuit.N.B.- IF THE WARNING LIGHT DOES NOT TURN ON, PERFORMTROUBLESHOOTING 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 scanning device.

2. With the ignition switch set to OFF, connect the

diagnostic tester DS-21 or OBD II general scan-

ning device to the data link connector located at

the lower part of the driver side instrument panel.

Now, connect the diagnostic tester DS-21 to the

data link connector interposing the following spe-

cial tool, and connect the OBD II general tester

directly.



IS - 423

3. Set the ignition switch and the tester main switch

to ON.

4. Check the failure code and frozen image data.

Print or take note. (For the operative procedure,

refer to the user manual).

If the OBD II general scanning device is used, only

failure codes determined by ISO/SAE can be read.

However, DMC failure codes can not be read.

(1) As regards the failure check with 2 interven-

tions (failure code detected only once) not identi-

fied, select the option "continuous monitoring

results" from the menu "vehicle communication" of

the CARB mode, and press the "F1 " key. The

possible failure codes detected are properly indi-

cated.

(2) Also in this case, the OBD II general scanning

device indicates only the failure codes specified by

the ISO/SAE 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

disconnect the tester from the special tool.N.B.- IF THE MALFUNCTION PHENOMENA MUST BE REPRO-DUCED WITH THE DIAGNOSTIC TESTER DS-21 OR OBD IIGENERAL SCANNING DEVICE CONNECTED TO THE DA-TA LINK CONNECTOR, THE FUNCTION "CONTINUOUSMONITORING RESULTS" CAN BE USED (IF THE DIAG-NOSTIC TESTER DS-21 IS USED, SELECT THE OPTION"CONTINUOUS MONITORING RESULTS" FROM THEMENU "VEHICLE COMMUNICATION" OF THE CARBMODE). WITH THIS FUNCTION, THE FAILURE CODE CANBE INDICATED WHEN THE MALFUNCTION PHENOMEN-ON IS REPRODUCED. (REQUEST FOR ON BOARD MONI-TORING TEST RESULTS ISO 15031-5, CONTINUOUSMONITORING SYSTEM).

Diagnostic failure code clearing

The failure code and frozen image data can be cleared as follows:


IS - 424

1. The diagnostic tester DS-21 or OBDII general scanning device is used to clear the failure code (refer

to the relevant user manual for the procedure).

2. The electronic control unit power supply is interrupted allowing to clear the failure code without using

the diagnostic tester DS-21 or OBD II general scanning device. (Disconnect the battery negative (-)

terminal or detach the injection system fuse).

Using the diagnostic tester DS-21 or OBD II

general scanning device

1. As in failure code checking, connect the diag-

nostic tester DS-21 to the data link connector in-

terposing the following special tool. Or, connect

the OBD II general scanning device directly.


2. Set the 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-

nication" of the DAIHATSU mode.

4. After clearing the code, set the tester main

switch and the ignition switch to OFF. Disconnect

the special tool from the data link connector and

disconnect the diagnostic tester DS-21 from the

special tool. Or, disconnect the OBD II general

scanning device.

The diagnostic tester DS-21 is not used

When the diagnostic tester DS-21 or OBD II

general scanning device is not used:

Clearing by disconnecting the injection system

fuse. To clear the diagnostic failure codes stored

in the control unit after the malfunction has been

repaired, disconnect the injection system fuse

from the relay block for at least 30 seconds with

the ignition switch set to OFF. With an ambient

temperature of about 20°C


IS - 425

- Warming up cycle

The warming up cycle refers to the riding cycle

which allows to increase water temperature to at

least 22°C above the temperature at the moment

of the engine start-up, reaching at least 70°C.

- Riding cycle

The riding cycle comprises the engine start-up and

stop.N.B.- THE CODE CAN BE CLEARED IN ABOUT 30 SECONDS.IN SOME CASES, HOWEVER, MORE TIME COULD BE RE-QUIRED. BESIDES, THE CODE CAN BE CLEARED BY DIS-CONNECTING THE CIRCUIT, AS WELL AS THE BATTERYPOWER SUPPLY AND FUSE CONNECTION. IF THE BAT-TERY TERMINAL MUST BE DISCONNECTED, TAKE NOTEOF THE RADIO CHANNELS. AFTER FINISHING THE OP-ERATION, SET THE RADIO CHANNELS AGAIN.- IN CASES IN WHICH THE SAME MALFUNCTION IS NOTDETECTED ANYMORE DURING THE COURSE OF THE 40ENGINE WARMING UP CYCLES, THE FAILURE CODE ANDFROZEN IMAGE DATA ARE CLEARED AUTOMATICALLYFROM THE CONTROL UNIT MEMORY (ONLY IN VEHICLESWITH EU SPECIFICATIONS).

Controlli di base del motore

Diagram of basic operations to check the engine

If the electronic control unit does not detect any diagnostic failure code during the malfunction phe-

nomenon test, and during the visual inspection no failure is detected, perform a progressive trouble-

shooting of circuits which are presumably the cause of malfunctions. In many cases, the areas causing

malfunctions can be quickly and efficiently identified by carrying out a basic check of the engine, as

indicated in the following diagram. Therefore, it is very important to carry out these checks to identify

engine failures.

1. Check that battery voltage is equal to 11 V or more, with the engine stopped

Charge or replace the battery, if necessary.

2. Check that the engine runs with the starter motor

3. Check if the engine does not start

• Proceed with step 6, otherwise proceed with step 4.


IS - 426

4. Ignition timing check.

• In case of M/T vehicles, set the gear in

neutral position.

• Set the electric charge switches to

OFF.

• Warm up the engine until the engine

coolant temperature reaches 90°C or a

higher value.

• If the diagnostic tester DS-21 is not

used, connect the T terminal of the

special tool connector to the ground

terminal, with a linking wire. If the di-

agnostic tester DS-21 is used, select

the option "T terminal 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 necessary to de-

tect correct engine timing.

• Check that the flywheel reference mark

is within the parameters of the gauge

with a square hole to check ignition

timing located on the rear bottom plate.

Adjust the ignition timing by turning the cam angle

sensor.


CharacteristicSpecifications:3 ± 2° BTDC (Before Top Dead Centre)


IS - 427

5. Engine idle speed check

1. Connect the tester DS-21 to the Data Link Con-

nector interposing the special tool, or connect the

OBD II general scanning device directly to the Da-

ta Link Connector. Then check idle speed.

2. If the tester DS-21 or OBD II general scanning

device is not used, connect a speedometer to the

REV terminal.

Does the value measured match the specified val-

ues?

Adjust engine idle speed turning the idle adjust-

ment screw located on the throttle body otherwise

continue with troubleshooting according to the

malfunction phenomena.AFTER CHECKING, AVOID THE SHORT CIRCUIT OF THET TERMINAL BY MEANS OF THE "ACTUATOR CONTROL"FUNCTION.


CharacteristicSpecifications850 - 950 rpm.

6. Fuel pressure check (simple control)

• Check that there is enough fuel in the tank.

• If the diagnostic tester DS-21 is not used:

- Remove the fuel pump relay and connect a linking wire, as shown in the figure.



IS - 428

- Fasten the fuel pipe to the main pipe manually.

With the ignition switch set to ON, a fuel pressure

increase must be detected. Otherwise, check the

fuel pump for correct operation.

• If the diagnostic tester DS-21 is used:

- connect the diagnostic tester DS-21 to the Data Link Connector interposing the special tool.


- Fasten the fuel pipe to the main pipe manually,

and set the ignition switch to ON. Afterwards, se-

lect the option "Fuel pump control" between the

single functions so as to activate the fuel pump. A

fuel pressure increase must be detected. Other-

wise, check the fuel pump for correct operation.


IS - 429

7. Spark check

• Remove the fuel pump relay from the

relay block.

• Remove the ignition coils and the spark

plugs (all cylinders 1, 2, 3 and 4).

• Fit the spark plug on the ignition coil.

Connect the ignition coil connector to

the coil.

• Earth the spark plug.

• Run the engine with the starter motor.

Check if the spark plugs produce

sparks. Replace, if necessary.

8. Fuel injector operation confirmation

• Fit the spark plugs, ignition coils and

fuel pump relay. Connect the ignition

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 must be

heard. Otherwise, check the Fuel Injector Circuit.

9. Fuel pressure check

• Warm up the engine.

• With the ignition switch set to OFF, re-

move all the ignition coils and the spark

plugs.

• Temporarily remove the main relay

and the fuel pump relay.

• Fit a compression test gauge in the spark plug hole.

• Push the accelerator pedal completely.

• While the engine is run with the starter motor, measure the compression pressure.


IS - 430

• Repeat the three previous steps to carry out the measurement on all the cylinders.

BE CAREFUL TO USE A BATTERY COMPLETELY CHARGED. BESIDES, CARRY OUT THEMEASUREMENT AS SOON AS POSSIBLE.

CharacteristicLimit value:

1030 kPa

(10.5 kgf-cm²)Specified value:

1373 kPa

(14.0 kgf-cm²)

Perform troubleshooting according to malfunction

phenomena.

Scanning device data (electronic control unit data)

The values indicated below are those obtained under "standard conditions" using the scanning device.

Please refer to these values.

However, there are cases in which the system works regularly even if the value measured differs from

the indicated values. Therefore, do not to pass judgement on the possible malfunction according to

these data under "standard conditions".

• The value of data 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 indicate the reference values defined. Consequently, there are

cases in which malfunctions are detected also when the value measured is within the ref-

erence values.

• As regards less important phenomena, as intermittent failures or irregular idle speed, per-

form a total assessment based on all the data checking options, sampling the data of

vehicles of the same type obtained under the same conditions, and comparing them.

• In the case of the OBD II general scanning device, it is possible to read the data and mark

an asterisk in the following table.

• When the data are checked with the engine running, the gearshift lever must be in a neutral

position, switch A/C must be set to OFF, and all the accessory switches must be set to OFF.


IS - 431

Diagnostic tester display Signal

abbrevia

tion

Vehicle conditions Reference values under

standard conditions

FUEL SUPPLY SYSTEM (Fuel

supply system status)

FSYS Minimum speed after warming up 02 (closed cycle)

CALCULATED LOAD (calculated

load value)

LOAD Minimum speed without load after warming

up

4.0-5.0%

2500 rpm without load after warming up 8.0-9.0%

COOLANT TEMPERATURE (en-

gine coolant temperature)

ECT Cold start ~ Warming up running order The value must increase gradu-

ally

Engine completely warmed up 80-100°C

During the failure-free function (at start-up) 20°C

During the failure-free function (after start-up) 80°C

SHORT CF (short term fuel com-

pensation)

SHRT Minimum speed after warming up -20-+20%

LONG CF (long term fuel com-

pensation)

LONG Minimum speed after warming up -20-+20%

ENGINE SPEED rpm With engine running at a constant speed There must not 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

IGNITION ADVANCE (ignition

timing advance for cylinder No.1)

ITA At idle without load after warming up. With

idle switch set to OFF

5-9° Variations to be carried out

according to running conditions

INTAKE AIR TEMPERATURE IAT With the engine running Variations to be carried out ac-

cording to running conditions °C

MANIFOLD ABSOLUTE PRES-

SURE (Inlet manifold absolute

pressure)

MAP With the ignition switch set to ON (suction

pipe released into the atmosphere) While

running at idle speed (after warming up, with-

out load)

Approx.100 kPa 28-35 kPa

MANIFOLD ABSOLUTE PRES-

SURE (Inlet manifold absolute

pressure)

MAP Standard conditions with the engine at idle 24 - 28 kPa

THROTTLE POSITION (throttle

absolute position)

TP With the accelerator pedal pushed Variations must be carried out ac-

cording to the pedal operation,%


IS - 432

Diagnostic tester display Signal

abbrevia

tion

Vehicle conditions Reference values under

standard conditions

OXYGEN SENSOR S1 (heated

oxygen sensor 1)

02,FP Minimum speed after warming up -5-5%

02,FV 0.05-0.95 V

OXYGEN SENSOR S2 (heated

oxygen sensor 2)

02,RP With the engine running at 2000 rpm, for 3

minutes or more, after warming up

12.5-87.5%

02,RV 0.05-0.95 V

Distance travelled once the MIL

was activated

DWM Without diagnostic failure code 0 Km

Diagnostic tester display Signal code Vehicle conditions Reference values under

standard conditions

BATTERY VOLTAGE BAT With engine running at 5000 rpm (25°C),

bnb,

Approx. 14 V

ELECTRIC CHARGE DSW With the light switch, heating fan, anti-fog

system or radiator fan set to ON

"OFF" -> "ON"

AIR CONDITIONING (if

present)

AC With the 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"

INJECTION PULSE AMPLI-

TUDE (fuel injection pulse am-

plitude)

TAU Cold start ~ warming up running order The value

must decrease gradually

While the engine is running at idle speed

(after warming up, without load)

0.8-2.0 ms

Service of the electronic control unit and rele-

vant circuits

The electronic control unit and relevant circuits can

be serviced by measuring voltage and resistance

of the electronic control unit connector. In order to

identify the cause, measure voltage and resist-

ance of the electronic control unit external path.

Measure voltage and resistance during the system

inspection, according to the procedure described

below.CAUTION- THE ELECTRONIC CONTROL UNIT CAN NOT BE SERV-ICED WITHOUT HELP. NEVER CONNECT A VOLTMETER


IS - 433

OR AN OHMMETER TO THE ELECTRONIC CONTROL UNITWHEN THE CONNECTOR IS NOT CONNECTED TO IT.- WHILE TESTING CONTINUITY OR MEASURING RESIST-ANCE, TURN OFF THE IGNITION SWITCH. AFTERWARDS,DISCONNECT THE ELECTRONIC CONTROL UNIT CON-NECTOR.

KEY:


2. Cable harness

3. Connector

1. Fitting the special tool. First of all, fit the special

tool between the electronic control unit and the ve-

hicle cable harness.

2. Measure voltage between the respective con-

nector terminals of the special tool.

3. Check that the values detected comply with

specifications indicated in the following " STAND-

ARD VOLTAGE" table.

System to be checked Terminals Measurement conditions Reference values

Power supply system 7 (+B1) - 23 (E1) With ignition switch set to "ON" Battery voltage

36 (+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 the engine start-up: The value changes

according the accel-

erator opening angle

Throttle valve sensor 16 (VC )- 17 (E2) With ignition switch set to "ON" 4.5 - 5.5 V

44 (VHT) - 17 (E2) Throttle valve completely closed 0.4 - 0.8 V

Throttle valve completely open 3.2 - 5.0 V

Engine coolant temperature

sensor

45 (THW) - 17 (E2) While warming up the engine (water

temperature: 60-120°)

0.2 - 1.0 V

Intake air temperature sen-

sor

76 (THA) -17 (E2) While warming up the engine 0.1 - 4.8 V

Vehicle speed sensor 37 (SPD)-23 (E1) The driving wheels are slowly turned 0 - 5 V

Cam angle sensor 22 (N2+) - 52 (N2-) While the engine is running at idle

speed

Wave shape produc-

tion

Front O2 sensor 75 (OX1)- 17 (E2) After keeping the vehicle speed at

3000 rpm for four minutes

0.05-0.95 V


IS - 434


Rear O2 sensor 73 (0X3)-17 (E2) After keeping the vehicle speed at

3000 rpm for four minutes

0.05-0.95 V

Ignition system (ionic current

sensor)

14 (ICMB)- 43 (IE) While the engine is running at idle

speed

Wave shape produc-

tion

Injectors 27 (#10) - 23 (E1) With ignition switch set to "ON" Battery voltage

26 (#20) - 23 (E1)

25 (#30) - 23 (E1) During the starter motor activation Impulse production

24 (#40) - 23 (E1)

Ignition 60 (IG1) - 23 (E1) With ignition switch set to "ON" Battery voltage

59 (IG2) - 23 (E1)

58 (IG3) - 23 (E1) During the starter motor activation Impulse production

57 (IG4) - 23 (E1)

Vacuum switching valve -

idle speed increase

56 (VSV2) - 82 (E01) With ignition 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 speed and after it

has been warmed up.

0 - 0.5 V

Fuel pump 30 (FC2) - 23 (E1) With the fuel pump off Battery voltage

While the engine is running at idle

speed (or it is activated with the

starter motor)

2 V or less

VF monitor 34 (VF) - 23 (E1) After keeping the vehicle speed at

3000 rpm for four minutes (terminal

T short-circuited)

0 - 5 V (Impulse)

Headlight 6 (TRRQ) - 23 (E1) With the headlight switch set to "ON" 0-0.5 V

With the headlight switch set to

"OFF"

Battery voltage

Anti-fog system 10 (DEF) - 23 (E1) With the anti-fog system switch set

to "ON"

Battery voltage

With the anti-fog system switch set

to "OFF"

0 - 0.5 V

Fan 39 (BLW) - 23 (E1) With the heater fan switch set to

"ON"

0 - 0.5 V


IS - 435


With the heater fan switch set to

"OFF"

Battery voltage

Radiator fan control system 11 (A/T) - 23 (E1) With the water temperature switch

set to "ON"

1 V or less

With the water temperature switch

set to "OFF"

Battery voltage

Stop light 40 (STP) - 23 (E1) With the stop light switch to set "ON" Battery voltage

With the stop light switch set to

"OFF"

0 - 0.5 V

Vapour bleeding control sys-

tem

79 (PRG) - 23 (E1) Running at idle speed Battery 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 engine is running at idle

speed

Impulse production

EGR system 80 (VSV1) - 23 (E01) While the engine is running at idle

speed

Battery voltage

3000 rpm speed after warming up

the engine

0 - 0.5 V

P105 - Malfunzionamento circuito pressionebarometrica/pressioneassoluta del collettore

WIRING DIAGRAM (MAP) - INLET MANIFOLD ABSOLUTE PRESSURE CIRCUIT (EURO3)

1. ECU EFI control unit 2. Manifold absolute pressure sensor (MAP) 3. Cable harness side view con-

nector


IS - 436

WIRING DIAGRAM (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


IS - 437

CIRCUIT DESCRIPTION

The manifold absolute pressure sensor measures

the inlet manifold pressure as voltage. Since the

manifold absolute pressure sensor does not take

atmospheric pressure as a measurement method,

but measures the absolute pressure inside the in-

let manifold (vacuum corresponds to 0 pressure),

it is not influenced by atmospheric pressure fluc-

tuations caused by altitude and other factors. This

allows the sensor to check the air-fuel ratio at the

suitable level under all conditions.

M.A.P.: Absolute pressure in the air inlet manifoldN.B.

AFTER CONFIRMING THE DIAGNOSTIC FAILURE CODE P0105, USE THE OBD II GENERALSCANNING DEVICE OR DIAGNOSTIC TESTER TO CONFIRM THE MANIFOLD ABSOLUTE PRES-SURE IN "CURRENT DATA".

DIAGNOSTIC FAILURE CODE DETECTION CONDITIONS - P0105Specification Desc./Quantity

P0105 - Open circuit or short circuit in the manifold absolutepressure sensor circuit

- interrupted or short-circuited wire in the manifold absolutepressure sensor cable harness

- manifold absolute pressure sensor- engine electronic control unit

If the electronic control unit detects the diagnostic failure code P0105, the failure-free function which

keeps the ignition timing and the injection volume constant is activated, allowing vehicle riding.

ABSOLUTE PRESSURE IN THE INLET MANIFOLDSpecification Desc./Quantity

0 kPa PIM circuit in short circuit130 kPa - VCPM circuit open or short-circuited - PIM circuit open - E2PM

circuit open

For the Model EURO 4, the circuits described in the table above comprise the cable harnesses before

and after the ECU DRACO control unit and on the DRACO.

CHECKING PROCEDURE - USING THE DIAG-

NOSTIC TESTER OR OBD II GENERAL SCAN-

NING DEVICE.

1. Checking MAP sensor output value

• With the ignition switch set to OFF,

connect the diagnostic tester directly to

the (DTC) Data Link Connector with

the special tool.

Specific tooling


IS - 438

020618Y Cable harness for connecting theOBD Connector and the Diagnostic Tester

• After setting the ignition switch to ON, turn on the tester main switch. Read the inlet manifold

absolute pressure value of the diagnostic tester. If the value measured matches the atmos-

pheric pressure value (about 100 kPa) check the malfunction that is detected intermittently

or the inefficient contacts (see relevant section), otherwise proceed with step 2.

2. Checking MAP sensor power supply voltage

• After setting the ignition switch to OFF also turn off the Diagnostic tester main switch.

• Connect the special 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 tooling020463Y ECU-EFI interface cable harness to check the injection system electrical values.

• Check that voltage between terminals

46 and 47 matches the value specified

with the ignition switch set to ON.

CharacteristicVoltage specified Value:4.5 - 5.5 V

If no voltage is detected, check the power supply

circuit of the electronic control unit, then check or

replace the electronic control unit.

3. MAP sensor check


move the MAP sensor from the throttle

body with the cable harness towards

the electronic control unit.


IS - 439

• Set the ignition switch and then the

tester main switch to ON.

• Apply a negative pressure to the MAP

sensor, with the MityVac device.

• Check the manifold absolute pressure

value according to the following speci-

fications.

Vacuum applied Value displayed on the scanning device

0 kPa About 100 kPa (760 mm Hg)

27 kPa (200 mm Hg) About 73 kPa (560 mm Hg)

67 kPa (500 mm Hg) About 33 kPa (260 mm Hg)

If values measured match those indicated in the

table, check for possible intermittent malfunctions

caused by problems 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 switch and the ig-

nition switch to OFF.

• Disconnect the cable harness from the

MAP sensor. Fit the MAP sensor on the

throttle body.

• Disconnect the special tool connectors

on the electronic control unit side.

Connector X44 on the sensor side - connector 47

on the E2PM electronic control unit side.

Connector X45 on the sensor side - connector 15

on the PIM electronic control unit side.

Connector 46 on the sensor side - connector 46 on

the VCPM electronic control unit side.


IS - 440

Repair or replace the cable harness or connector,

if necessary, otherwise replace the MAP sensor.N.B.APPLY FUEL ONTO THE MAP SENSOR O-RING, THEN IN-SERT IT BEING EXTREMELY CAREFUL.

CHECKING PROCEDURE - WITHOUT USING THE DIAGNOSTIC TESTER OR OBD II GENERAL

SCANNING DEVICE

1. Checking the PIM input signal of the electronic control unit

• Connect the special tool (For the Model EURO 4, connect the special tool between the EFI

ECU control unit and the cable harness connectors coming from the DRACO control unit).


• With the ignition switch set to ON,

measure voltage between terminals 15

and 47 (PIM-E2PM).

Characteristicspecified value3.3 - 4.0V

If the value measured does not match the specified

value, proceed with step 2.

2. Checking the sensor power supply voltage

• Check that voltage between terminals

46 and 47 matches the specified value.

CharacteristicVoltage specified Value:4.5 - 5.5 V

If no voltage is detected, check the power supply

circuit of the electronic control unit, then check or

replace the electronic control unit (for model EU-

RO 4, check cable harnesses and also that the EFI

ECU control unit is downstream as well as up-

stream the DRACO control unit) otherwise pro-

ceed with step 3.

3. MAP sensor check


IS - 441

• Remove the MAP sensor from the

throttle body with the cable harness

connected to the control unit.

• Apply a negative pressure to the MAP

sensor, with the MityVac device.

• Check that voltage between terminals 15 and 47 matches the voltage specified according

to the following conditions:

Vacuum applied Value displayed on the voltmeter

0 kPa 3.3 - 4.0 V

27 kPa (200 mm Hg) 2.6 - 3.1 V

67 kPa (500 mm Hg) 1.1 - 1.4 V

If the value measured matches the values indica-

ted 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 sensor and the electronic control unit.

Model EURO 3

• Set the ignition switch to OFF.


MAP sensor. Fit the MAP sensor on the

throttle body.



• Connector X44 on the sensor side -

connector on the E2PM electronic con-

trol unit side.

Connector X45 on the sensor side - connector on

the PIM electronic control unit side.


IS - 442

Connector X46 on the sensor side - connector on

the VCPM electronic control unit side.

Repair or replace the cable harness or connector,

if necessary, otherwise replace the MAP sensor.

Model EURO 4

Check cable harnesses downstream and up-

stream the ECU DRACO and on the ECU DRACO

itself in the following order

• Test the cable harness in the vehicle

connecting the special tool to the DRA-

CO connectors on the device side.

• Test the cable harness in the EFI ECU

control unit connecting the special tool

to the DRACO connectors 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 the DRACO pro-

ceed as follows:

a) Disconnect the cable harness of the DRACO to

the EFI ECU control unit

b) Connect the special tool between the EFI ECU

connectors and cable harness connectors to the

vehicle devices so as to bypass the DRACO.

c) carry out the check as in Step 3. If failures are

detected, the problem is in the DRACO control unit

which must be replaced, otherwise replace the

sensor.APPLY FUEL ONTO THE MAP SENSOR O-RING, THEN IN-SERT IT BEING EXTREMELY CAREFUL.


IS - 443

P0110 - Malfunzionamento circuito temperatura aria immessa

KEY:1. ECU electronic control 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 sensor

(IAT) 4. Ground node 5. DRACO control unit


IS - 444

IAT SENSOR CIRCUIT DESCRIPTION

The intake air temperature sensor IAT sensor,

measures the air temperature in the intake pipe

between the air filter and the throttle body. The

thermistor inside the sensor changes the resist-

ance value according to the intake air temperature.

The lower the temperature value is, the higher the

thermistor resistance value is and, the higher the

intake air temperature is, the lower the thermistor

resistance value is.

When the IAT sensor resistance value varies ac-

cording to temperature variations, also the THA

terminal potential changes. According to this sig-

nal, the engine electronic control unit (ECU) in-

creases the fuel volume injected improving riding

conditions while operating with the engine cold.

For the Model EURO 4, the circuits in question

comprise the cable harnesses 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 sensor

circuit.

- interrupted or short-circuited cable in the IAT

sensor cable harness

- IAT sensor, intake air temperature

- ECU

Once the diagnostic failure code P0110 is confirmed, use the diagnostic tester to measure the intake

air temperature by:"CURRENT DATA".

Temperature displayed Malfunction

-30° Open circuit

about 130° Short circuit

Checking procedure

• If the diagnostic failure codes P0110 (IAT - Intake air temperature sensor circuit), P0115

(ECT - Engine coolant temperature sensor circuit), and P0120 (TPS - Throttle position sen-

sor) are generated at the same time, the Sensor ground E2 could be open.

• Read the frozen image data using the diagnostic tester. As frozen image data record the

engine conditions at the moment the defect is detected, these data are useful to determine


IS - 445

during the troubleshooting phase, if at the moment 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.

USING THE DIAGNOSTIC TESTER DS-21 OR

DIGITEK OR OBD II GENERAL SCANNING DE-

VICE

Step 1

1. With the ignition switch set to OFF, connect the

Diagnostic tester to the OBD connector, vehicle,

data link, with the special tool.


to ON. Read the intake air temperature value on

the diagnostic tester.

DOES THE VALUE MEASURED MATCH THE

ONE SPECIFIED?(for example, intake air temper-

ature with cold engine about 20°C); If SO: Check

the 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.


Step 2

Checking interrupted cables in the cable harness

or inside the engine electronic control unit ECU (1).

1. Set the tester switch and the ignition switch to

OFF. 2. Disconnect the intake air temperature sen-

sor connector (IAT). 3. Close the contact (through

a conductive wire) between terminals (X33) and

(X34) of the IAT sensor. 4. Set the ignition switch

and the tester switch to ON. Is the value measured

about 130°C?

If SO: Connect the IAT sensor connector connec-

tion if it is the one specified, then replace the IAT

sensor.

If NOT: see Step 3.


IS - 446


Step 3

Checking for interrupted cables in the cable harness or inside the ECU

1. Set the tester switch and the ignition switch to OFF.

2. Connect the special tool for interface sub-wiring harness and refer to the relevant section for use.


3. Disconnect the linking cable from the IAT sensor

connector.

4. Afterwards, connect it between terminals (76)

and (17) of the special tool connector.

5. Set the ignition switch and the tester switch to

ON. Read the air temperature 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): interruption inside ECU. Check

or replace the engine electronic control unit. (see

the relevant section).

If SO (EURO 4) - transfer the 4 interface Sub-wir-

ing harness connectors, from the ECU to the DRA-

CO; - reconnect the DRACO to the ECU through

the original connectors. - jumper PIN 76 and 17

and check the air temperature value Is the tem-

perature value approx. 130°C?

If SO (EURO 4): the IAT sensor connection cable

harness is interrupted. Repair or replace the cable

harness.

If NOT (EURO 4): the DRACO or the cable har-

ness connecting with the ECU is interrupted. Fix

the cable harness or replace the DRACO.


IS - 447

Step 4

Checking short circuits in the cable harness or in-

side the engine electronic control unit ECU or

DRACO (1).

1. Set the tester main switch and the ignition switch

to OFF.

2. Disconnect the intake air temperature sensor

connector (IAT).


to ON. Read the intake air temperature value on

the diagnostic tester; Is the value measured about

- 30°C?

If SO: replace the IAT sensor,

If NOT (EURO 3): proceed with Step 5.

If NOT (EURO 4): Check for short circuits in the

IAT sensor cable harness; 1. Set the ignition

switch and the tester switch to OFF. 2. Disconnect

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 (EURO 4): Check for short circuits in the

DRACO or in the connection cable harness to the

ECU; 1. Set the ignition switch and the tester

switch to OFF. 2. Disconnect connector "B" from

the ECU 3. Switch to ON and read the intake air

temperature

Is the value measured about - 30°C?

If SO (EURO 4): There is a short circuit in the

DRACO or in the connection cable harness to the

ECU. Repair and replace the connection cable

harness or the DRACO.

If NOT (EURO 4): There is a short circuit inside the

ECU. Check and replace the ECU. (see the rele-

vant section EF-36)

Step 5


IS - 448

Checking for short circuits in the cable harness or

inside the ECU (2).

1. Set the tester switch and the ignition switch to

OFF. 2. Disconnect connector "B" of the special

tool from the ECU. 3. Set the ignition switch and

the tester switch to ON. Read the intake air tem-

perature value on the diagnostic tester.

Is the value measured about -30°C?

If SO: repair and replace the cable harness or the

connector.

If NOT: check and replace the ECU. (see the rel-

evant section EF-36)

NOTE: This diagnosis 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 B 3. Cable harness side 4. Special tool (SST)

DIAGNOSIS WITH MULTIMETER AND INTERFACE WIRING.

Step 1

Checking the THA signal entering the ECU.

1. Connect the interface wiring. (See the relevant section "Connection of the special tool, Interface

wiring").

2. With the ignition switch set to ON, measure voltage between connectors (76) and (17) (THA-E2)

according to the following conditions:

Intake air temperature Specified value

20° C 1.8 - 2.9 V

60° C 0.6 - 1.2 V


IS - 449

DOES THE VALUE MEASURED MATCH THAT

ONE SPECIFIED?

If SO (EURO3): Check the malfunction that is de-

tected intermittently or inefficient contacts

If SO (EURO4): Check the signal entering the

DRACO 1. connect the interface wiring between

the DRACO and the vehicle cable harness and re-

store the original connection between the DRACO

and the ECU. 2. Repeat voltage checks as in Step

1.

IS THE VOLTAGE MEASURED 5.0 V ?

There is an interruption in the DRACO or in the

connection cable harness to the ECU. check con-

tinuity between: 11/22 76R< 1 Ohm = no failure

detected 21/22 17R< 1 Ohm = replace DRACO or

cable harness.

DOES THE VALUE MEASURED MATCH THE

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 connections between the DRACO and the

vehicle cable harness. 2. Repeat voltage checks

as in Step 1.

If NOT : proceed with Step 2.

Step 2

Checking the cable harness between the IAT sen-

sor and the ECU electronic control unit.


2. Disconnect the cable harness from the IAT sen-

sor.

3. Disconnect the special tool connectors (inter-

face wiring), ECU side, electronic control unit.

4. Referring to the section "Checking cables and

connectors" and to the "IAT sensor circuit dia-

gram" at the beginning of the chapter, check there

are no interrupted or short-circuited cables in the


IS - 450

cable harness and connector, between the follow-

ing terminals: IAT sensor terminal (X33) - ECU

terminal 76 (THA), IAT sensor terminal (X34) -

ECU terminal 17 (E2),

If the values measured do not match specifications

in the table, replace the cable harness or the con-

nector.

CONTINUITY CHECK

Affected terminals Value measured

76 - X33 < 1 (Ohm)

17 - X34 < 1 (Ohm)

Step 3

IAT sensor check

Check and replace the IAT sensor, if necessary, otherwise check or replace the engine electronic control

unit.

P0115 - Malfunzionamento circuito temperatura liquido raffreddamentomotore

Using the tester DS-21 or OBD II general scanning device

1)

1. With the ignition switch set to OFF, connect the diagnostic tester DS-21 to the Data Link Connector

through the special tool, or connect the OBD II general scanning device directly to the Data Link Con-

nector.



to ON. Read the coolant temperature on the diag-

nostic tester DS-21 or on the OBD II general scan-

ning device.


IS - 451

If the value measured matches the actual water

temperature, check the malfunction that is detec-

ted intermittently or inefficient contacts (see the

relevant section); otherwise, if it is -40°C, proceed

with step 2; if it is 140°C or higher, proceed with

step 4.

2) Checking interrupted cables in the cable

harness or inside the engine electronic control

unit ECU

1. Set the tester main switch and then the ignition

switch to OFF.

2. Disconnect the engine coolant temperature sen-

sor connector (ECT).

3. Connect a linking wire between terminals (X30)

and (X31) of the ECT sensor.


4. Set the ignition switch 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 higher, check the connector connection or the ECT sensor terminal. If it is satis-

factory, replace the ECT sensor, otherwise proceed with step 3.

3)

Checking interrupted cables in the cable harness or inside the engine electronic control unit (2)

1. Set the tester main switch and then the ignition switch to OFF.

2. Set the special tool (sub-wiring harness).


3. Disconnect the linking wire from the ECT sensor

connector.

4. Afterwards, connect the linking wire between

terminals (46) and (7) of the special tool connector.


IS - 452


to ON. Read the engine coolant temperature value

on the diagnostic tester DS-21 or on the OBD II

general scanning device.

Is the value measured equal to 140° C or higher?:

If SO: the wire between the ECT sensor and the

electronic control unit is interrupted. Repair or re-

place the cable harness.

If NOT (EURO 3): check the connector connection

and the electronic control unit terminals. If this is

in order, replace the engine electronic control unit

(see the relevant section).

If NOT (EURO 4): the DRACO or the cable har-

ness connecting with the ECU is interrupted. 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

control unit connecting the special tool

to the DRACO connectors on the con-

trol unit side.

• Check the DRACO works properly: dis-

connect the DRACO cable harness on

the device side of the vehicle, connect

the special tool to the relevant connec-

tors and follow the procedure of Step 3

from the start. If no failures are detec-

ted, the problem is in the DRACO con-

trol unit which must be replaced.

• Test the cable harness in the vehicle

connecting the special tool to the DRA-

CO connectors on the device side.

If all the tests do not work, go back to Step 2.

4)

MODEL EURO 4


IS - 453


side the electronic control unit EFI ECU or DRA-

CO.


switch to OFF.

2. Disconnect the engine coolant temperature sen-

sor connector (ECT).


to ON. Read the coolant temperature value on the

diagnostic tester DS-21 or on the OBD II general

scanning device.

If the value measured is equal to -40°C replace the

ECT sensor, otherwise proceed with step 5.

5)


side the electronic control unit ECU or DRACO

(Model EURO 4)


switch to OFF.

2. Disconnect connector B of the special tool from

the electronic control unit connector.

KEY:


2. Connector B

3. Cable harness side connector

4. Diagnostic socket

3. Set the ignition switch and 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.

Is the value measured equal to -40°C?

If SO (EURO 3): repair or replace the cable harness or the connector otherwise check or replace the

engine electronic control unit (see the relevant section).

If NOT (EURO 4): the DRACO or the connection cable harness with the ECU is interrupted. Fix the

cable harness or replace the DRACO. Check cable harnesses downstream and upstream the DRACO

and on the DRACO itself as specified in Step 3.


IS - 454

Without using the diagnostic tester DS-21 or

OBD II general scanning device

1) Checking the input signal of the THW elec-

tronic control unit

1. Connect the special tool (For the Model EURO

4, connect the special tool between the EFI ECU

control unit and the cable harness connectors

coming from the DRACO control unit).

2. With the ignition switch set to ON, measure volt-

age between connectors (45) and (17) (THW-E2)

according to the following conditions:

Intake air temperature Specified value

20° C 1.8 - 2.9 V

60° C 0.6 - 1.2 V

If the value measured matches the specified value

check the malfunction that is detected intermittent-

ly or due to false contact (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 step 2.

2) Checking the cable harness between the

ECT sensor and the electronic control unit

Model EURO 3


2. Disconnect the cable harness from the ECT

sensor.

3. Disconnect the special tool connectors on the

electronic control unit side.

4. check there are no interrupted or short-circuited

wires in the cable harness and connector.

(X30) connector on the sensor side - connector 45

on the electronic control unit side (THW).

(X31) connector on the sensor side - connector 17

on the electronic control unit side (E2).

Repair and replace the cable harness or the con-

nector, if necessary.


IS - 455

Model EURO 4

Proceed as for the model EURO 3, but checking

cable harnesses downstream as well as upstream

the DRACO control unit and on the DRACO itself.

With the special tool, check for continuity on the

following lines:

(X30) connector on the sensor side - connector

(B10) on the 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 unit - connector

(17) on the electronic control unit side (E2).



3)

Check and replace the ECT sensor, if necessary.

4)

Check and replace the engine electronic control unit.

KEY:


IS - 456

1. Cable harness side


3. To the instrument panel (indicate the engine temperature)

4. BNDR


Model EURO 4

KEY:



3.To the instrument panel (indicate the engine temperature)

4.BNDR


6. DRACO control unit

CIRCUIT DESCRIPTION

The thermistor inside the engine coolant temperature sensor modifies the resistance value according

to the engine coolant temperature. The sensor structure and connection to the electronic control unit is

like the one for the diagnostic failure code P0110 (intake air temperature circuit malfunction).

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-circuited wire in the engine

coolant temperature sensor circuit



For the Model EURO 4, the circuits described in the table above comprise the cable harnesses down-

stream and upstream the DRACO control unit and on the DRACO itself.

AFTER CONFIRMING THE DIAGNOSTIC FAILURE CODE P0115, USE THE OBD II GENERALSCANNING DEVICE OR DIAGNOSTIC TESTER DS-21 TO CONFIRM THE ENGINE COOLANTTEMPERATURE IN THE CURRENT DATA.

Once the diagnostic failure code P0110 is confirmed, use the diagnostic tester to measure the intake

air temperature by:"CURRENT DATA".


IS - 457

Temperature displayed Malfunction

-30° Open circuit

about 130° Short circuit

Checking procedure

If the diagnostic failure codes P0110 (intake air temperature circuit malfunction), P0115 (engine coolant

temperature circuit malfunction), and P0120 (Throttle/pedal position sensor "A" switch malfunction) are

generated at the same time, the Sensor ground E2 could be open. Read the frozen image data using

the diagnostic tester DS-21 or OBD II general scanning device. As 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 vehicle was working or at standstill, if the engine

was hot or not, if the air/fuel ratio was lean or rich etc.

P0116 - Problemi funzionali portata circuito temperatura liquidoraffreddamento motore

KEY:



3. To the instrument panel (indicate the engine temperature)

4. BNDR


Circuit description Refer to Engine Coolant Temperature Circuit Malfunction.


IS - 458


Conditions

Affected area

P0116 When the engine is started, the coolant tem-

perature is -7.5°C or higher, and lower than 40°

C. After about 5 minutes the engine is running,

the coolant temperature sensor value is about

40°C or lower, (measurement logic with two in-

terventions)


- Cooling system

• If the diagnostic failure codes P0115 (engine coolant temperature circuit malfunction) and

P0116 (Functional problems/engine coolant temperature circuit capacity) are generated at

the same time, the engine coolant temperature sensor circuit could be open.

• Read the frozen image data using the diagnostic tester DS-21 or OBD II general scanning

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, the vehicle was working or at standstill, if the engine was hot or not, if

the air/fuel ratio was lean or rich etc.

• To perform troubleshooting in the water temperature sensor system, using only the diag-

nostic tester DS-21 or OBD II general scanning device allows to determine if failure causes

are interrupted, short-circuited wires P0115 or functional problems P0116.

1.

If other codes are generated apart from the diagnostic failure code P0116 go to the diagnostic failure

code operation diagram applicable, otherwise proceed with step 2.

2.

Check efficiency and replace the thermostat, if necessary, if it is efficient, replace the engine coolant

temperature sensor ECT.


IS - 459

Malfunzionamento circuito interruttore sensore posizione pedale farfalla

KEY:



A. comp. open

B. comp. closed

3. BNDR


Model EURO 4

KEY



A. comp. open

B. comp. closed


IS - 460

3. BNDR


5. DRACO control unit

Circuit description

The throttle valve sensor is fitted on the throttle

body and is used to measure the opening angle of

the throttle valve. With the throttle valve complete-

ly closed, a voltage equal to about 0.4-0.8 V is

applied to the VTH terminal of the engine elec-

tronic control unit. The voltage applied to VTH

terminals of the engine electronic control unit in-

creases proportionally to the throttle valve opening

angle, until reaching a value equal to about 3.5-5.0

V when the throttle valve is completely open. The

engine electronic control unit determines the ve-

hicle riding conditions according to the signals

input by the VTH terminal, it is considered as one

of the adopted parameters to 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 the DRA-

CO itself.

KEY:


2. Engine ECU


Conditions

Affected area

P0120 Condition (1) or (2) continues with more than

0.6 seconds:

1. VTH < 0.2 V

2. VTH > 4.8 V

- Interrupted or short-circuited wire in the throt-

tle valve sensor circuit



For the Model EURO 4, the circuits described in the table above comprise the cable harnesses down-

stream and upstream the DRACO control unit and on the DRACO itself.

After confirming the Diagnostic Failure Code P0120, use the diagnostic tester DS-21 or OBD II general

scanning device to confirm the throttle valve opening degree and the closed throttle position switch.


IS - 461

Throttle valve opening

position

affected area

Completely closed Completely open

0% 0% VC line open, interrupted or short-circuited wire in VTH line

About 100% about 100% E2 line open

Using the tester DS-21 or OBD II general scan-

ning device

1. Checking the throttle valve sensor output

value


connect the diagnostic tester DS-21 to

the Data Link Connector through the

special tool, or connect the OBD II gen-

eral scanning device directly to the Da-

ta Link Connector.


• 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:

Completely closed: 0%

Completely open: 100%

If the opening value does not match, check the malfunction that is detected intermittently or due to false

contact (see the relevant section).

2. Checking the power supply voltage on the throttle valve sensor cable harness side

• Set the tester main switch and then the ignition switch to OFF.

• Disconnect the throttle valve sensor connector.

• Measure voltage between the terminals (X99) of the cable harness connector and chassis

ground, with the ignition switch set to ON.

CharacteristicVoltage specified Value:

4.5 - 5.5 V


IS - 462

If the voltage matches the specified value proceed

with step 5, otherwise with step 3.

3. Throttle valve sensor check


• Measure resistance between the respective connector terminals A.

Terminal Condition Standard value

X99 - XT1 - 2.5 - 6.0

XT1 - XT0 Throttle valve completely closed 0.1 - 1.3

XT1 - XT0 Throttle valve completely open 1.7 - 4.2

If no 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 Model

EURO 4, connect the special tool be-

tween the EFI ECU control unit and the

cable harness connectors coming from

the DRACO control unit).


measure voltage between connectors

44 and 17 (VTH-E2) according to the

following conditions.

Throttle status Specified value

Completely closed 0.4 - 0.8 V


IS - 463


Completely open 3.5 - 5.0 V

If the value measured matches the specified value, check or replace the EFI ECU electronic control

unit, otherwise check the cable harness and the connector between the engine electronic control unit

and the throttle valve sensor (VTH line) for interrupted or short-circuited wires (in this case, for the model

EURO 4, possible failures are to be searched for in the cable harnesses downstream and upstream the

DRACO control unit or can derive from an incorrect operation of the DRACO).

5. Checking the power supply voltage on the throttle valve sensor electronic control unit side




• With the ignition switch set to ON, measure voltage between connectors 16 and 17 (VTH-

E2).

CharacteristicVoltage specified Value:

4.5 - 5.5 V


value, check or replace the EFI ECU electronic

control unit, otherwise check the cable harness

and the connector between the engine electronic

control unit and the throttle valve sensor (VC line)

for interrupted or short-circuited wires (in this case,

for the model EURO 4, possible failures are to be

searched for in the cable harnesses downstream

and upstream the DRACO control unit or can de-

rive from an incorrect operation of the DRACO).

If no voltage is detected, check the electronic con-

trol unit power supply circuit.

Without using the diagnostic tester DS-21 or

OBD II general scanning device

1. Checking the input signal of the VTH elec-

tronic control unit

• Connect the special tool (For the Model

EURO 4, connect the special tool be-

tween the EFI ECU control unit and the


IS - 464

cable harness connectors coming from

the DRACO control unit).


measure voltage between connectors

44 and 17 (VTH-E2) according to the

following conditions.


Completely closed 0.4 - 0.8 V

Completely open 3.5 - 5.0 V


value, check the malfunction that is detected in-

termittently or due to false contact (see the rele-

vant section).

2. Throttle valve sensor check


• Disconnect the throttle valve sensor A.

Terminal Condition Standard value

X99 - XT1 - 2.5 - 6.0

XT1 - XT0 Throttle valve completely closed 0.1 - 1.3

XT1 - XT0 Throttle valve completely open 1.7 - 4.2

If no failures are detected during checks replace the throttle valve sensor, otherwise proceed with 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 circuits in question comprise the cable harnesses downstream and up-

stream the DRACO control unit and on the DRACO itself.

If there are no failures, check or replace the EFI ECU control unit.

Checking procedure• If the diagnostic failure codes P0110 (intake air temperature circuit malfunction), P0115

(engine coolant temperature circuit malfunction), and P0120 (Throttle/pedal position sensor

A7 switch malfunction) are generated at the same time, the Sensor ground E2 could be

open.





IS - 465



P0130 - Malfunzionamento 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. Front O2 sensor heating

12. Front O2 sensor

13. 15A EFI fuse No. 1




IS - 466

Circuit description

The front oxygen sensor (bank 1, sensor 1) detects

the concentration of oxygen in the exhaust fumes

according to the magnitude of the electromotive

force generated Vo. When the air-fuel ratio Si

turns richer than the stoichiometric ratio, a greater

electromotive force is applied to the electronic con-

trol unit (about 1 volt). Vice versa, when the ratio

turns leaner than the stoichiometric ratio, a smaller

electromotive force is applied to the electronic con-

trol unit (about O volt). In this way, the electronic

control unit determines if the air-fuel ratio Si is rich

or lean. The injection time is checked according to

this assessment.

KEY:

Si Air-fuel ratio

Vo Increasing voltage


Conditions

Affected area

P0130 If the following conditions (a) and (b) continue

to be detected after a certain period:

a) after 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 more, or at 0.6 V or less while run-

ning at idle speed after the engine has been

warmed up (detection logic with 2 interven-

tions).

- Air intake system

- Fuel pressure


- Open circuit or short circuit in the heated oxy-

gen sensor circuit

- Oxygen sensor heated


By using the diagnostic tester DS-21 or the OBD II general scanning device, confirm that the oxygen

sensor output voltage (bank 1, sensor 1) is equal to 0.1V or less. It is very probable that the oxygen

sensor circuit (bank 1, sensor 1) is open or short-circuited.

Functional check


through the special tool. Set the ignition switch and the tester main switch to ON. Set the tester to

"Continuous monitoring results" of the CARB mode.


IS - 467

2. Start the engine. Warm up the engine for more than five minutes, until the engine cooling water

temperature reaches 90°C or a higher value.

3. Run the engine at a speed of 2500 - 3000 rpm for about three minutes.

4. After one minute the engine is running at idle, press the F1 key on the tester. Check that the diagnostic

failure code P0130 is generated.CAUTION

- Strictly follow the described procedure or the malfunction can not be detected.- If there is no diagnostic tester DS-21 available, set the ignition switch to OFF after carrying out stepsfrom 2 to 4, then repeat steps from 2 to 4.

Checking procedure

Read the frozen image data using the diagnostic

tester DS-21 or OBD II general scanning device.

As frozen 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 working or at standstill, if the engine

was hot or not, if the air/fuel ratio was lean or rich

etc.

1.


IS - 468

If other diagnostic failure codes are detected be-

sides P0130, proceed with the relevant diagnostic

failure code diagram, otherwise jump to step 2.


oxygen sensor and the electronic control unit.

• With the ignition switch set to OFF, set

the special tool (sub-wiring harness).

Disconnect the special tool connectors


• Disconnect the oxygen sensor connec-

tor.

• Check the cable harness and the con-

nector for interrupted or short-circuited

wires. Check if there are interrupted or

short-circuited wires between the 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 output voltage while running at idle.

• Connect the oxygen sensor and connectors of the special tool, respectively.

• Connect the diagnostic tester DS-21 to the Data Link Connector by means of the special

tool.


• Let the engine run at 2500 rpm for

about 90 seconds.

• Set the tester main switch to ON to

read the oxygen sensor output voltage

while running at idle.

If voltage varies repeatedly between a voltage be-

low 0.3V and above 0.6V, jump to step 10.


IS - 469

4. Irregular ignition check

Check if an irregular ignition is detected by moni-

toring the diagnostic failure code and the data list,

troubleshoot the irregular ignition failure, if neces-

sary. (diagnostic failure code P0300, P0301-304).

5. Air intake system check

Check 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 air intake system parts between the

cylinder head and the throttle body. Repair or re-

place the intake system, if necessary.

6.

Check and repair the fuel pump, the fuel pressure

regulator, 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 parts, if nec-

essary.

9.

Checking the oxygen sensor unit output voltage.

• Warm up the engine completely.


tor with the ignition switch set to OFF.

• Connect a voltmeter to the oxygen sen-

sor connector terminal.

• Keep the engine rotation speed at 2000 rpm for 3 minutes.

Now, check that the value indicated on the voltmeter matches the value specified. Specified value:

If the voltmeter indicates an output voltage of 0.2V or more at least once, check or replace the engine

electronic control unit, otherwise replace the oxygen sensor (bank 1, sensor 1).

10.

Repeat the functional check.


IS - 470

11.

If the diagnostic failure code P0130 is detected again, check or replace the engine electronic control

unit.

12.

If the vehicle has run out of fuel before, the diagnostic failure code P0130 is caused 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 relay

4. Fuel pump relay

5. Battery

6. Fuel pump

7. Front part

8. Rear part


10. Rear O2 sensor


12. Front O2 sensor


IS - 471




Circuit description

Refer to the diagnostic failure code P0130 (Oxygen sensor circuit malfunction (Bank 1 sensor 1)


Conditions

Affected area

P0133 The response time so that the oxygen sensor

output voltage changes from rich to lean, or

from lean to rich, exceeds a certain period

while the engine runs at idle speed after it has

been warmed up (detection logic with 2 inter-

ventions)

- Air intake system - Fuel pressure


- Open circuit or short circuit in the heated oxy-

gen sensor circuit

- Oxygen sensor heated


SENSOR 1 REFERS TO THE SENSOR CLOSURE ON THE ENGINE BLOCK.

READ THE FROZEN IMAGE DATA USING THE DIAGNOSTIC TESTER DS-21 OR OBD II GENERALSCANNING DEVICE. AS FROZEN IMAGE DATA RECORD THE ENGINE CONDITIONS AT THEMOMENT THE DEFECT IS DETECTED, THESE DATA ARE USEFUL TO DETERMINE DURING THETROUBLESHOOTING PHASE, IF AT THE MOMENT OF FAILURE CHECKING, THE VEHICLE WASWORKING OR AT STANDSTILL, IF THE ENGINE WAS HOT OR NOT, IF THE AIR/FUEL RATIOWAS LEAN OR RICH ETC.

CHECKING PROCEDURE

1. If other codes are generated besides the code

P0130, proceed with the relevant diagnostic failure

code diagram.


oxygen sensor and the electronic control unit.



Disconnect the special tool connectors



tor.

• Refer to sect. ''Checking wires and

connectors'', check the cable harness

and the connector for interrupted or

short-circuited wires.

Check if there are interrupted or short-circuited ca-

bles between the X28 connector of the oxygen

sensor on the cable harness side and the terminal


IS - 472

75 of the special tool. Repair and replace the cable

harness or the connector, if necessary.




tool.


• Set all the accessory switches to OFF.

Warm up the engine at 2500 rpm, until

the radiator fan completes one turn.

• Set the tester main switch to ON.

Read the oxygen sensor output voltage with the

engine 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.



- 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 air intake system parts between the

cylinder head and the throttle body. Repair or re-

place the intake system, if necessary.

5.

Checking the fuel pressure and repair the fuel

pump, fuel pressure regulator, fuel pipe and filter,

if necessary.

6.

Checking the injector injection. Check for proper

operation and replace the injector, if necessary.

7. Checking the oxygen sensor unit output

voltage



IS - 473




sor connector terminal A

• Keep the engine rotation speed for 3

minutes at 2000 rpm. Now, check if the

value indicated in the voltmeter match-

es the specified value.

If the voltmeter indicates an output voltage of 0.2V or more at 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.

If code P0133 is detected again, check or replace the electronic control unit, otherwise check the mal-

function that is detected intermittently or due to false contact.

P0135 (Sensore1) P0141 (Sensore2) - Malfunzionamento circuitoriscaldatore sensore ossigeno

KEY:

1. Starter switch

2. 60A fuse F/L

3. Main relay


IS - 474

4. Fuel pump relay

5. Battery

6. Fuel pump

7. Front part

8. Rear part


10. Rear O2 sensor


12. Front O2 sensor




Circuit description

Refer to the diagnostic failure code P0130 (Oxygen sensor circuit malfunction (bank 1 sensor 1)


Conditions

Affected area

P0135

P0141

With battery voltage above 7.5 V and heater

terminal voltage of the electronic control unit

above 1.0 V while the heater is on, or below 7.5

V while the heater is off: (detection logic with 2

interventions)

- Interrupted or short-circuited wire in the oxy-

gen sensor heater



READ THE FROZEN IMAGE DATA USING THE DIAGNOSTIC TESTER DS-21 OR OBD II GENERALSCANNING DEVICE. AS FROZEN IMAGE DATA RECORD THE ENGINE CONDITIONS AT THEMOMENT THE DEFECT IS DETECTED, THESE DATA ARE USEFUL TO DETERMINE DURING THETROUBLESHOOTING PHASE, IF AT THE MOMENT OF FAILURE CHECKING, THE VEHICLE WASWORKING OR AT STANDSTILL, IF THE ENGINE WAS HOT OR NOT, IF THE AIR/FUEL RATIOWAS LEAN OR RICH ETC.

1. Checking the electronic control unit output

voltage

• Set the special tool (sub-wiring har-

ness).

• Measure voltage between connectors

20 OXH1, 50 OXH2 and the body

ground according to the following con-

ditions.

Measurement conditions

With ignition switch set to ON After the engine start-up

Front oxygen sensor Battery voltage Below 1V immediately after


IS - 475

Measurement conditions

rear oxygen sensor Battery voltage Below 1V only after about

three minutes

If failures are detected during checks, inspect or replace the electronic control unit.

2. Oxygen sensor check

Check resistance of the front and rear oxygen sensor 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.

P0136 - Malfunzionamento circuito sensore ossigeno (Sensore 2)

KEY:

1. General switch

2. 60A fuse F/L

3. Main relay

4. Fuel pump relay

5. Battery

6. Fuel pump

7. Front part

8. Rear part


10. Rear O2 sensor


IS - 476


12. Front O2 sensor




Refer to the diagnostic failure code P0130 (oxygen sensor circuit malfunction (bank 1 sensor 1)


Conditions

Affected area

P0136 The voltage output of the heated oxygen sen-

sor remains at 0.4V or more, or at 0.5V or less,

when the vehicle is run at 100 km/h or more

after the engine has been warmed up

(detection logic with 2 interventions)

- Interrupted or short-circuited wire in the heat-

ed oxygen sensor circuit.

- Oxygen sensor


SENSOR 2 REFERS TO THE SENSOR THAT IS MORE DETACHED FROM THE ENGINE BLOCK.

Functional check



"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


3. Accelerate the vehicle up to a speed of 50 km/h or more with range 2 in case of vehicles with automatic

transmission; with the 1st - 2nd gear in case of vehicles with manual transmission. Run the vehicle at

this speed for at least 40 seconds.

4. Under these conditions, remove the foot from the accelerator so as to decelerate the vehicle. Run

the engine at idle speed.

5. After one minute the engine is running at idle, press the F1 key on the tester. Check that the diagnostic

failure code P0136 is generated.

- STRICTLY FOLLOW THE DESCRIBED PROCEDURE OR THE MALFUNCTION CAN NOT BE DE-TECTED.- IF THERE IS NO DIAGNOSTIC TESTER DS-21 AVAILABLE, SET THE IGNITION SWITCH TO OFFAFTER CARRYING OUT STEPS FROM 2 TO 5, THEN REPEAT THE PREVIOUS STEPS.- Perform the confirmation test according to the described procedure in sect. Using the OBDII generalscanning device or diagnostic tester DS-21.


IS - 477

Checking procedure

1. If other diagnostic failure codes are detected besides P0136, proceed with the relevant step of the

diagnostic failure code diagram.

2. Checking the cable harness between the oxygen sensor and the electronic control unit.

• With the ignition switch set to OFF, set the special tool (sub-wiring harness). The special

tool connectors on the electronic control unit side must be disconnected.

• Disconnect the oxygen sensor connector.

• Check the cable harness and the connector for interrupted or short-circuited wires.

Check if there 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 the connector, if necessary.READ THE FROZEN IMAGE DATA USING THE DIAGNOS-TIC TESTER DS-21 OR OBD II GENERAL SCANNING DE-VICE. AS FROZEN IMAGE DATA RECORD THE ENGINECONDITIONS AT THE MOMENT THE DEFECT IS DETEC-TED, THESE DATA ARE USEFUL TO DETERMINE DURINGTHE TROUBLESHOOTING PHASE, IF AT THE MOMENT OFFAILURE CHECKING, THE VEHICLE WAS WORKING ORAT STANDSTILL, IF THE ENGINE WAS HOT OR NOT, IFTHE AIR/FUEL RATIO WAS LEAN OR RICH ETC.



IS - 478



tool.


• Warm up the engine.

• Set the tester main switch to ON. Run

the engine at 4000 rpm for three mi-

nutes, pushing accelerator pedal.

• Then, remove the foot from the pedal

and run the engine at idle speed.

• Read the oxygen sensor output volt-

age among previous steps.

Voltage must be 0.4 V or less, and 0.55 V or more,

respectively, at least once. Otherwise, check the

malfunction that is detected intermittently or bad

contacts.


voltage










The voltmeter must indicate an output voltage of

0.2V or more at least once, if below, check or re-

place the engine electronic control unit, otherwise

replace the oxygen sensor (bank 1, sensor 2).

P0141 - Circuito riscaldatore sensore ossigeno secondario

Pagina Manuale VTLP0135 (Sensore1) P0141 (Sensore2) - Malfunzionamento circuito riscaldatore sensore ossigeno


IS - 479

P0171 - Sistema troppo povero / P0172 - Sistema troppo ricco (tagliocombustibile)

KEY:

1. Ignition switch.

2. 60A fuse F/L



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump



11. Front O2 sensor

12. Injector


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 long term fuel trim.

Short term fuel trim is a short term fuel compensation which must occur to keep the air-fuel ratio at the

level of the stoichiometric air-fuel ratio. The signal arriving from the oxygen sensor indicates if the current


IS - 480

air-fuel ratio is rich or lean with respect to the stoichiometric air-fuel ratio. Therefore, if the air-fuel ratio

is rich, the fuel injection decreases. Vice versa, if the air-fuel ratio is lean, the fuel injection increases.

Long term fuel trim is a fuel compensation which is detected in a long term period to offset a constant

drift of short term fuel trim with respect to the central value, caused by the intrinsic characteristics of

the vehicle, due to long term use or a variation of the operative environment.

If the total of the short and long term fuel trim exceeds a certain value, and if it turns rich or lean, the

system turns the warning light MIL on to indicate it as a malfunction.

Diagnostic failure code

No.

Diagnostic failure code detection

conditions

Affected area

P0171 If the following conditions are detected

during the execution of the air-fuel return

after warming up the engine:

- Air-fuel too lean: The total of fuel trim

(total of short term and long term fuel trim)

exceeds the set value




- Interrupted or short-circuited wire in the

oxygen sensor circuit.

- Oxygen sensor malfunction




- Vacuum switching valve for vapour

bleeding


P0172 - Air-fuel too rich: (the total of fuel trim is

lower than the set value). (detection logic

with 2 interventions)

IF THE VEHICLE HAS RUN OUT OF FUEL, THE AIR-FUEL RATIO TURNS LEAN, THEREFORE,THE DIAGNOSTIC FAILURE CODE P0171 IS INDICATED.READ THE FROZEN IMAGE DATA USING THE DIAGNOSTIC TESTER DS-21 OR OBD II GENERALSCANNING DEVICE. AS FROZEN IMAGE DATA RECORD THE ENGINE CONDITIONS AT THEMOMENT THE DEFECT IS DETECTED, THESE DATA ARE USEFUL TO DETERMINE DURING THETROUBLESHOOTING PHASE, IF AT THE MOMENT OF FAILURE CHECKING, THE VEHICLE WASWORKING OR AT STANDSTILL, IF THE ENGINE WAS HOT OR NOT, IF THE AIR/FUEL RATIOWAS LEAN OR RICH ETC.

Functional check

• With the ignition switch set to OFF, connect the diagnostic tester DS-21 to the Data Link

Connector through the special tool. Set the ignition switch and the tester main switch to ON.

Set the tester to "Continuous monitoring results" of the CARB mode.

• Start the engine. Warm up the engine for more than five minutes, until the engine cooling

water temperature reaches 90°C or a higher value.

• Run the vehicle for more than five minutes at a speed of 70 km/h after engaging the 5th gear

or in range D.

• After one minute the engine is running at idle, press the F1 key on the tester. Check if the

diagnostic failure code P0171/0172 is indicated


IS - 481

• .

- STRICTLY FOLLOW THE DESCRIBED PROCEDURE OR THE MALFUNCTION CAN NOT BE DE-TECTED.- IF THERE IS NO DIAGNOSTIC TESTER DS-21 AVAILABLE, SET THE IGNITION SWITCH TO OFFAFTER CARRYING OUT STEPS FROM 2 TO 4, THEN REPEAT THESE STEPS.<?xml:namespace prefix = or ns = "urn:schemas-microsoft-com:office:office" />CARRY OUT THE CONFIRMATION TEST ACCORDING TO THE INSTRUCTIONS INDICATED INTHE SECTION " USING THE OBD II GENERAL SCANNING DEVICE OR DIAGNOSTIC TESTERDS-21 ".

Using the diagnostic tester DS-21 or OBD II general scanning device

If other diagnostic failure codes are detected besides P0172 or P0172 proceed with the relevant diag-

nostic failure code diagram.



• 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 air intake system parts

between the cylinder head and the throttle body. Repair or replace the intake system, if

necessary.

3. Checking the injector injection.

Check for proper operation and replace the injector, if necessary.

4. Checking the vacuum switching valve for vapour bleeding.

Replace the vacuum switching valve for vapour bleeding, if necessary.

5. Checking the engine water temperature sensor operation.

Replace the engine coolant temperature sensor, if necessary.

6. MAP sensor check.

Replace the MAP sensor, if necessary.

7. Fuel pressure check.

Check and repair the fuel pump, the fuel pressure regulator, fuel duct and filter, if necessary.


IS - 482

8. Gas leakage check in the exhaust system

Check there are no gas leaks, repair and replace,

if necessary.


oxygen sensor and the electronic control unit



The special tool connectors on the

electronic control unit side must be dis-

connected.


tor.

• Check the cable harness and the con-

nector for 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 special tool, repair or replace the cable

harness or the connector, if necessary.

10. Checking the oxygen sensor output volt-

age while running at idle

• Connect the oxygen sensor and spe-

cial tool connectors, respectively.

• Connect the diagnostic tester DS-21 to

the Data Link Connector by means of

the special tool.



IS - 483

• Let the engine run at 2500 rpm for

about 90 seconds.

• Set the tester main switch to ON to

read the oxygen sensor output voltage

while running at idle. Specified value: if

voltage varies repeatedly between a

voltage below 0.3V and above 0.6V,

jump to step 12.


voltage










If the voltmeter does not 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 configuration.

13.

If the diagnostic failure code P0171 or P0172 is indicated again, check or replace the engine electronic

control unit.

14.

If the vehicle has run out of fuel before, the diagnostic failure code P0171 is determined by fuel ex-

haustion. Alternatively, check the malfunction that is detected intermittently or due to false contact.

Without using the diagnostic tester DS-21 or OBD II general scanning device

1.

If other diagnostic failure codes are detected besides P0172 or P0172 proceed with the relevant diag-

nostic failure code diagram.




IS - 484

• 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 air intake system parts

between the cylinder head and the throttle body.


Check and repair the fuel pump, fuel duct and filter, if necessary.

4. Injector check

Check for proper operation and replace the injector, if necessary.

5. Checking the engine water temperature sensor operation

Replace the engine coolant temperature sensor, if necessary.

6. MAP sensor check

(see troubleshooting of diagnostic failure code P0105) Replace the MAP sensor, if necessary.

7.

After fitting an oxygen sensor operating properly (bank 1, sensor 1), confirm the driving configuration.

If the diagnostic failure code 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

Pagina Manuale VTLP0171 - Sistema troppo povero / P0172 - Sistema troppo ricco (taglio combustibile)

P0300 - Mancata accensione casuale di più cilindri

Pagina Manuale VTLP0314-P0300-P0301-P0302-P0303-P0304 - Accensione irregolare/monocilindro/cilindro multiplo/cil-indro1/cilindro2/

P0301 - Mancata accensione cilindro 1

Pagina Manuale VTLP0314-P0300-P0301-P0302-P0303-P0304 - Accensione irregolare/monocilindro/cilindro multiplo/cil-indro1/cilindro2/

P0314-P0300-P0301-P0302-P0303-P0304 - Accensione irregolare/monocilindro/cilindro multiplo/cilindro1/cilindro2/

Failure code Description

P0314 Single-cylinder irregular ignition (cylinder not specified)

P0300 Random/multiple cylinder irregular ignition detected

P0301 Irregular ignition detected - cylinder 1


IS - 485





Confirming the driving configuration

1. Connect the diagnostic tester DS-21 or OBD II general scanning device with the ignition switch set

to OFF.

2. Record the diagnostic failure code and the frozen image data with the ignition switch set to ON.

3. Clear the diagnostic failure code.

4. Use the diagnostic tester DS-21 or OBD II general scanning device to set "Continuous monitoring

results" of the CARB mode.

5. Ride the vehicle at a constant speed many times, with load and related parameters indicated by

ENGINE RPM.CALC LOAD in the frozen image data or MISFIRE RPM, MISFIRE LOAD in the data

list. If malfunctions 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,

repeat the simulation process.

TO STORE THE DIAGNOSTIC FAILURE CODE RELATED TO IRREGULAR IGNITION, RUN THEENGINE ACCORDING TO MISFIRE RPM, MISFIRE LOAD VALUES INDICATED IN THE DATA LISTDURING THE TIME INDICATED BELOW.

Engine speed Time

Idle speed 3 minutes 30 seconds or more

1000 rpm 3 minutes or more

2000 rpm 1 minute 30 seconds or more

3000 rpm 1 minute or more

6. Check if there is an irregular ignition by monitoring the diagnostic failure code and the frozen image

data. Then, record the data.

7. Set the ignition switch to OFF after at least 5 seconds.WARNING

CARRY OUT THE CONFIRMATION TEST ACCORDING TO THE INSTRUCTIONS INDICATED INTHE SECT. ''USING THE OBD II GENERAL SCANNING DEVICE OR DIAGNOSTIC TESTER DS-21''


IS - 486

KEY:

1. Ignition switch

2. 60A fuse F/L



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump


10. CABLE HARNESS SIDE FUEL INJECTOR

11. Ignition system

12. Ignition coil

13. 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 input in the Electronic Control Unit. If the voltage value is lower than a certain value,

the Electronic Control Unit considers it an irregular ignition, counting the number of events. When the


IS - 487

number of irregular ignitions reaches or exceeds the digit which indicates that the engine is damaged,

the malfunction warning light MIL turns on. If an irregular ignition is detected and the number of events

is such that under riding conditions an overheating of the catalytic converter can be detected, the mal-

function warning light MIL starts flashing.

Code Code detection conditions Affected area

P0314

P0300

In the course of 400 or 2,000 ignitions, no

firing of random/multiple cylinders has

been detected.

- Ignition system (ignition spark plug unit,

etc.)

- Ion system (ignition spark plug unit, etc.)

- Injector

- Fuel pressure

- Valve clearance

- Valve adjustment

- Pressure sensor


- Interrupted or short-circuited wire in en-

gine cables



- Engine Electronic Control unit

P0301

P0302

P0303

P0304

On 400 engine ignitions, irregular igni-

tions are detected which can cause the

overheating of the catalytic converter (the

malfunction warning light starts to flash)


On 2,000 engine ignitions, irregular igni-

tions are detected which cause a degra-

dation of emissions (detection logic with

2 interventions)

N.B.IF 2 OR MORE CODES RELATED TO A CYLINDER WITH IRREGULAR IGNITION ARE RECORDEDIN SUCCESSION, AS LONG AS RANDOM/MULTIPLE CYLINDER IRREGULAR IGNITION CODESARE NOT RECORDED, IT MEANS THAT THE IRREGULAR IGNITION IS DETECTED AND RE-CORDED AT DIFFERENT TIMES. IF ONE OR MORE CODES COMPRISED WITHIN P0301 ANDP0304 ARE INDICATED, THE CODE P0314 IS CERTAINLY STORED. HOWEVER, THE CODEP0314 IS DISPLAYED ONLY WHEN THE FUNCTION "CONTINUOUS MONITORING RESULTS" OFTHE CARB MODE IS USED.


P0314 Single-cylinder irregular ignition (cylinder not specified)

P0300 Random/multiple cylinder irregular ignition detected





Checking procedure• In case that besides the irregular ignition code other diagnostic failure codes are stored at

the same time, first of all, detect relative failures.





IS - 488



• If the vehicle is brought to the workshop without the irregular ignition check, this can be

confirmed by reproducing the frozen image data conditions. Besides, once the repair is

finished, confirm that conditions for an irregular ignition have not been detected (see con-

firming the driving configuration).

• When the value of SHORT FT or LONG FT in the frozen image data is approx. ±20%, it is

probable that the air-fuel ratio tends to RICH (-20% or less) or LEAN (+20% or more).

• When the COOLANT TEMP value in the frozen image data is lower than 80°C (176°), an

irregular ignition can be detected only during the warm-up phase.

• If the irregular ignition can not be reproduced, this can be due 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 Control Unit of the Fuel Injection, can be considered an irregular

ignition.

1. Engine compartment visual check

• Check the cable harness and connec-

tor connections.

• Check that suction, bleeding, fuel and

other pipes are not disconnected or

broken, repair or replace, if necessary,

then confirm there is no irregular igni-

tion.

2. Check the spark plug and spark of the cyl-

inder with irregular ignition


relay block. Remove the ignition coils

and the spark plugs (cylinders with ir-

regular ignition).

• Fit the spark plug on the ignition coil.

Connect the ignition coil connector to

the coil.


• Now, start the engine and check if the

spark plug releases sparks.

• Otherwise, check according the proce-

dure described for spark plugs.


IS - 489

Replace the spark plug or check the ignition sys-

tem and the ionic system.

(See troubleshooting of Diagnostic Failure Code

P 1300).DO NOT USE SPARK PLUGS DIFFERENT FROM THOSERECOMMENDED.

3. Checking the output signal of the cylinder

injector electronic control unit with irregular

ignition


set


ness).


measure voltage between the injector

connector terminal, in which 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 of the voltage among con-

nectors 27 up to 24 and 82 E01, with the engine at

idle speed.

If failures are detected during checks proceed with

step 6.

4. Checking the defective cylinder injector.


• Disconnect the connector of the defec-

tive cylinder injector.

• Measure resistance between the injec-

tor terminals Specified value: 12.5_

mm at 20°C.

If no failures are detected while checking, replace

the injector.


IS - 490

5. Check the cable harness between the injec-

tor and the electronic control unit


from the fuel injection electronic control

unit (with the ignition switch set to

OFF).

• Refer to sect. ''Checking wires and

connectors'', check the cable harness

and the connector for interrupted or

short-circuited wires.

- X51 injector connector #1 on the cable harness

side. Special tool connector 27






side - special tool connector 24 , repair or replace

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 Diagnostic Failure Code P 1300), repair or replace, if necessary.


Check and repair the fuel pump, the fuel pressure regulator, fuel duct and filter, if necessary.

8. Check the injection injector.

Replace the injector, if necessary.

9. Check the manifold absolute pressure sensor, (See troubleshooting of Diagnostic Failure

Code P0105).

Replace the manifold absolute pressure sensor.

10. Check the engine water temperature sensor, (see troubleshooting of Diagnostic Failure Code

P0116).

Replace the engine coolant temperature sensor, otherwise check the compression pressure, valve

clearance and distribution timing, if necessary.


IS - 491

P0135 - Malfunzionamento circuito sensore posizione albero a camme

Checking procedure

Read the frozen image data using the diagnostic

tester DS-21 or OBD II general scanning device.

As frozen 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 working or at standstill, if the engine

was hot or not, if the air/fuel ratio was lean or rich

etc.

1. Checking the cam angle sensor circuit re-

sistance


ness). Connector A of the tool must

remain disconnected from the Elec-

tronic Control Unit connector B.

2. Set the ignition switch to OFF and measure resistance between terminals of the special tool 22 -

52 (N2 + N2).

Characteristicspecified value

from 205 to 255 Ohm at 20°C

Signal control

Check with an oscilloscope.

a. Connect connector A to the electronic control

unit.

b. Start the engine and run it at idle speed.

c. Connect the positive (+) and negative (-) probe

of an oscilloscope to the special tool connector

terminals from 22 to 23, respectively.


IS - 492

d. If the wave shapes shown in the figure on the

right are detected, the cam angle sensor circuit

operates properly.N.B.THE WAVE SHAPE DETECTED WITH THE VEHICLE RUN-NING BECOMES WIDER WITH RESPECT TO THAT ONEDETECTED WITH THE ENGINE AT IDLE. IF SO, PASS TOSTEP 4.

2. Cam angle sensor check

• Remove the engine service opening cover.

• Disconnect the connector lock and remove the cam angle sensor connector.

• With an ohmmeter, measure resistance between terminals.

Characteristicspecified 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 electronic con-

trol unit and the cam angle sensor

Repair or replace the cable harness or the con-

nector, otherwise check the malfunction that is

detected intermittently or bad contacts.

4. Check the sensor fitting conditions and the

signalling rotor teeth status

Check there are no free spaces, the sensor is no

loosened, teeth are not deformed, there is no rust,

foreign bodies, etc. Tighten the sensor, if neces-

sary or replace the signalling rotor.


IS - 493

5. Check the starter motor signal

• Connect connector A to the electronic

control unit.

• Measure voltage between terminals 68

and 23 of the 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), oth-

erwise check or replace the electronic

control unit.

KEY:

1. AM 60 A

2. Ignition switch

3. Battery


IS - 494

4. Starter motor


6. Cam angle sensor (sensor n+1)


Circuit description

Cam angle sensor (NE signal) comprises a single rotor and a pickup coil. The NE signal rotor is equipped

with "4+1" teeth and fitted on the cylinder head so that the rotor is directly connected to the camshaft.

The NE sensor produces five signals (from which one is used to differentiate 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.


Conditions

Affected area

P0335 No signal sent from the cam angle sensor to

the engine electronic control unit during the ac-

tivation with the starter motor

- Interrupted or short-circuited wire in the cam

angle sensor

- Cam angle sensor

- Signalling rotor

- Starter motor


P0420 - Catalizzatore efficienza inferiore

KEY:


IS - 495

1. General switch

2. 60A fuse F/L

3. Main relay

4. Fuel pump relay

5. Battery

6. Fuel pump

7. Front part

8. Rear part


10. Rear O2 sensor


12. Front O2 sensor




Circuit description

The electronic control unit monitors the concentration of oxygen in the exhaust fumes which passes

through the three-way catalytic converter, with the rear oxygen sensor. If the catalytic converter works

properly, the variable rear oxygen sensor output voltage is slower than the front oxygen sensor output

voltage. However, if the wave shape variation of the front and rear sensor output is equal, it means that

the catalytic converter performance declines.


Conditions

Affected area

P0420 With wave shapes of front as well 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 catalytic converter

- Interrupted or short-circuited wire in the oxy-

gen sensor circuit.

- Oxygen sensor

1. Set the ignition switch set to OFF, and connect the diagnostic tester DS-21 to the Data Link Connector


"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


3. Run the engine at a constant speed of 50 km/h for about five minutes (4th gear, in case of vehicles

with manual transmission; range D, in case of vehicles with automatic transmission).

4. After one minute the engine is running at idle, press the F1 key on the tester. Check that the suitable

diagnostic code PD420 is generated.


IS - 496

- STRICTLY OBSERVE THE TESTING CONDITIONS TO DETECT THE MALFUNCTION.- IF THERE IS NO DIAGNOSTIC TESTER DS-21 AVAILABLE, SET THE IGNITION SWITCH TO OFFAFTER CARRYING OUT STEPS FROM 2 TO 4, THEN REPEAT THESE STEPS.<?xml:namespace prefix = or ns = "urn:schemas-microsoft-com:office:office" />

Checking procedure

Read the frozen image data using the diagnostic tester DS-21 or OBD II general scanning device. As

frozen 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 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 diagram of diagnostic failure.

2. Front oxygen sensor checking

(bench 1, sensor 1).

(See troubleshooting of diagnostic failure code P0130). Repair or replace, if necessary.

3. Rear oxygen sensor checking

(bench 1, sensor 2).

(See troubleshooting of diagnostic failure code P0136). Repair or replace, if necessary.

4. Validate the driving configuration.

5. If the failure code P0420 has not been indicated again, check the failure that is detected with inter-

mittence or due to a bad contact, otherwise replace the three-way catalytic converter.


IS - 497

P0443 - Malfunzionamento circuito Valvola di controllo spurgo_Sistema dicontrollo delle emissioni evaporative

KEY:

1. Ignition switch

2. 60A fuse F/L



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump


10. Injector

11. EFI ECU

Circuit description

When working conditions for vapour emission bleeding are fulfilled, the electronic control unit checks

the operation of the vacuum switching valve for bleeding vapour emissions, introducing them in the

combustion chamber.


IS - 498

KEY:

1. Throttle body

2. ECU

3. VSV for EVAP

4. Atmosphere

5. Combustion chamber

6. Active carbon filter

7. Fuel tank


Conditions

Affected area

P0443 If there are interrupted or short-circuited wires

in the vapour vacuum switching valve circuit,

and with the working conditions of the vapour

emission bleeding system fulfilled: (detection

logic with 2 interventions)

- Interrupted or short-circuited wires in the va-

pour vacuum switching valve circuit

- Vapour vacuum switching valve


Checking procedure






IS - 499

Using the diagnostic tester DS-21

1. Checking the operation of the vapour bleed-

ing control system




special tool.


• Disconnect the pipe that goes from the

active carbon filter to the vacuum

switching valve.

• Set the ignition switch to ON and press

the tester 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, no air

continuity when air is blown into the

pipe. VSV ON, air continuity when air

is blown into the pipe.

KEY:

1. Bleeding side

2. Air blown

3. Atmospheric hole

4. Tank side

2. Checking the bleeding pipe and passage

• "Unlock" the vacuum switching valve to

return the bleeding valve to original

working conditions.

• Start the engine and let it run.

• Disconnect the pipe that goes from the

vacuum switching valve to the inlet

manifold.


IS - 500

• Put a finger on the removed pipe.

Check that a negative pressure is ap-

plied. Specifications: It is necessary to

apply a negative pressure.

• Check there are no leaks, narrowing,

bending on pipes and that they are not

damaged. Clean, repair or replace

connections, if necessary.

KEY:

1. Vapour vacuum switching valve

2. Bleeding pipe

3. Active carbon filter (Canister).

4. Bleeding pipe

5. Throttle body

3. Check the power supply voltage 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.


measure voltage between the cable

harness side connector #7M of the

valve and the body ground.

If there is no response, check the cable harness

and the connector between the vacuum switching

valve for bleeding and the battery, and that there

are no interrupted or short-circuited wires on the

main relay. Repair or replace, according to the

case.

Characteristicspecified value:battery voltage.


IS - 501

4. Check the cable harness between the elec-

tronic control unit and the vacuum switching

valve for bleeding


connect the special tool (sub-wiring

harness). Do not connect the connec-

tor to the electronic control unit.

• Check there are no interrupted or

short-circuited wires in the cable har-

ness and the connector. Connector

#7N on the vacuum switching valve ca-

ble harness side - connector 79, on the

PRG electronic control unit side. Re-

pair and replace the cable harness or

the connector, if necessary.

5. Checking the vacuum switching valve for bleeding

Replace the vacuum switching valve for vapour bleeding, 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 control unit. Connect the pipes previously removed in the

original position.

• With the engine cold and at idle speed, measure voltage between the connector 79 and 82

PRG-E01.

Characteristicspecified value:

battery voltage.

• After warming up the engine (after the

fan starts working at least once), meas-

ure voltage between connectors 79

and 82 PRG-E01 for more than two mi-

nutes, pushing and holding down the

accelerator pedal.

• If failures are detected during checks,

inspect the malfunction that is detected

intermittently or due to false contact,

otherwise check or replace the elec-



IS - 502

Characteristicspecified value:the voltage must shift from 0 to 1 V within two mi-

nutes.

Without using the diagnostic tester DS-21

1. Check the output signal of the electronic control unit

• Set the special tool (sub-wiring harness).

• With the engine cold and at idle speed, measure voltage between connectors 79 and 82

PRG-E01.


battery voltage.

• After warming up the engine (after the fan starts working at least once), measure voltage

between connectors 79 and 82 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 control unit.

Characteristicspecified value:the voltage must shift from 0 to 1 V within two minutes.

2. Check the power supply voltage of the vacuum switching valve for bleeding.


• Disconnect the vacuum switching valve connector.

• With the ignition switch set to ON, measure voltage between the cable harness side con-

nector #7M of the vacuum switching valve and the body ground.


battery voltage.


IS - 503

If it does not match the specified value, check the

cable harness and the connector between the vac-

uum switching valve for bleeding and the battery,

and that there are no interrupted or short-circuited

wires in the main relay. Repair or replace, accord-

ing to the case.



valve for bleeding




tor of the special tool to the electronic

control unit.



ness and the connector. Connector

#7N on the vacuum switching valve ca-

ble harness side - connector 79, on the

PRG electronic control unit side. Re-

pair and replace the cable harness or


4. Checking the vacuum switching valve for bleeding

Replace the vacuum switching valve for bleeding, otherwise check the malfunction detected intermit-

tently or due to false contact.


IS - 504

P0500 - Malfunzionamento Sensore velocità veicolo

KEY:


2. Instrument panel

3. Speedometer cable

4. Vehicle speed sensor


Circuit description

The sensor fitted inside 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 electronic control unit, which de-

termines the vehicle speed according to the fre-

quency of pulse signals.

KEY:

1. Transmission and front-wheel drive

2. Instrument panel

3. ECU


IS - 505


Conditions

Affected area

P0500 The speed sensor does not transmit any signal

to the electronic control unit for a certain period

after the fuel supply is cut during the deceler-

ation phase.


- Instrument panel

- Interrupted and short-circuited wires in the

vehicle speed sensor circuit

- Vehicle speed sensor

- Vehicle electronic control unit

1. Speedometer operation check

• Start the vehicle. If the speedometer does not indicate the correct vehicle speed, check the

speedometer circuit and the instrument panel (including the speedometer gear & meter ca-

ble). If the speedometer indication is normal, it means that the speedometer works regularly.

2. Check the input signal of the speed sensor to the electronic control unit


• Check that voltage between terminals 37 and 17 is within the specified limits when the ve-

hicle is moving with the ignition switch set to ON.


4.5 a 5.5 V per pulse signal.

If it does not match the specified value, check or

replace the engine electronic control unit.

3. Check the speed sensor (reed switch)


• Remove the instrument panel

• Check that there is continuity for four

times on terminals B10 and B11 of the

instrument panel, while the speedom-

eter transmission completes one revo-

lution. Check continuity two times for

each speedometer transmission revo-


IS - 506

lution. If there is no continuity, replace

the speed sensor (instrument panel).

4. Check for interrupted and short-circuited

wires in the cable harness, and in the connec-

tor between the engine control unit and the

vehicle speed sensor

Repair or replace the cable harness or the con-

nector, otherwise check the malfunction that is

detected intermittently or due to false contact.

P1105 - Malfunzionamento circuito sensore pressione barometrica

The electronic control unit is equipped with an atmospheric sensor of the same type of the MAP sensor.

Therefore, the atmospheric sensor wiring diagram is shown in the manual.


Conditions

Affected area

P1105 When the following conditions (1 and 2) are

fulfilled 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


Checking procedure





1. Diagnostic failure code reconfirmation


Connector through the special tool.



IS - 507

• Set the ignition switch and the tester

main switch to ON.

Clear the diagnostic failure code. (To perform this

operation, consult the user manual of the diagnos-

tic tester DS-21).

• Set the tester main switch and 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 check or replace electronic control

unit.

P1300 - Malfunzionamento sistema ione

KEY:

1. Ignition switch

2. 60A fuse F/L



5. Main relay


IS - 508

6. Fuel pump relay

7. Battery

8. Fuel pump

9. Ignition spark plug unit wire on the cable harness side (Electronic Control Unit side)


11. Ignition spark plug unit wire on the cable harness side (ignition coil side)

12. Ignition switch wire on the cable harness side

13. Ignition coil wire on the cable harness side

14. Ignition device

15. Ignition coil

16. Spark plug

17. 20A engine fuse

Circuit description

The system detects any irregular ignitions of the engine through an ionic current which has the same

wave shapes of combustion pressure. Each time an irregular ignition is detected, no ionic current is

generated. Therefore, if input voltage on the Electronic Control Unit side is lower than a certain 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.


Conditions

Affected area

P1300 During engine start-up or operation, no signal

of ionic current is sent to the engine electronic

control unit.

- Interrupted or short-circuited wires inside the

ionic system circuit

- Ignition unit

- Ignition coil (all cylinders)

- Spark plug (all cylinders)


Checking procedure

• Read the frozen image data using the

diagnostic tester DS-21 or OBD II gen-

eral scanning device. As frozen image

data record the engine conditions at

the moment the defect is detected,

these data are useful to determine dur-

ing the troubleshooting phase, if at the

moment of failure checking, the vehicle

was working or at standstill, if the en-


IS - 509

gine was hot or not, if the air/fuel ratio

was lean or rich etc.

• The diagnosis diagram is based on the

assumption that the engine is started

under normal conditions. If the engine

does not start, go to the Matrix table for

troubleshooting according to the mal-

function phenomenon.

• When code P1300 is generated (ionic

system malfunction), the code P0300

(detecting random/multiple cylinder ir-

regular ignition) as well as codes

P0301-P0304 (detecting irregular igni-

tion of cylinders 1 to 4) can be gener-

ated at the same time.

1. Spark check


relay block.

• Remove the ignition coils and the spark

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.


• Start the engine and check the spark

plug sparks.SPARKS WILL BE CHECKED. PAY ATTENTION TO SUR-ROUNDING INFLAMMABLE OBJECTS.CAUTIONNEVER USE SPARK PLUGS DIFFERENT FROM THOSERECOMMENDED.

2. If sparks have been checked in all cylinders proceed with step 5.

• If sparks are not checked in some cylinders, inspect the spark plug of cylinders where there

is no spark.

• Replace the spark plug, if necessary, repeat the spark check.

• If no spark plug detected, go to step 3, otherwise go to step 5.

3. Checking the ignition coil power supply voltage

• With the ignition switch set to OFF, disconnect the ignition coil connector of each cylinder.


IS - 510

• With the ignition switch set to ON, measure voltage between the body ground and each one

of the cable harness side connectors N05, N53, N54 and N83 of all the ignition coils.

CharacteristicSpecified valuebattery voltage

If failures are detected during checks proceed with

step 5.

KEY:


4. Checking the ignition coil power supply volt-

age

Check there are no interrupted or short-circuited

wires in the cable harness, connector and fuse re-

ferring to the checking of wires and connectors.


• 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.

- Between the ignition switch and each connector

NO5 N53 N54 and N83 of all the ignition coils.


nector, if necessary, or replace the fuse, otherwise

replace the ignition switch.

KEY:



5. Checking the ignition signal and the ionic signal

Check that ignition and ionic signals are generated by the Electronic Control Unit and input with an

oscilloscope.


IS - 511

• With the ignition switch set to OFF, reset.



• Warm up the engine (only when the

engine can be started).

• With the engine at idle speed or run-

ning, connect the (-) oscilloscope

probe to terminal 82 of the special tool;

the (+) probe to terminals 60, 59, 58

and 57 of the special tool, respectively.

Check the ignition signal of all cylin-

ders.

Specifications:

The wave shapes of the pulse must be confirmed.

• As done with step 4, connect the (+)

and (-) oscilloscope probes to termi-

nals 14 ICMB and 43 IE of the special

tool, respectively, and check the ionic

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 signals, check or replace

the Electronic Control Unit.

If no sparks are detected, the wave shape of the ignition signal is present, and there is no wave shape

of the ionic signal proceed with step 10.

If sparks are detected and the wave shape of the ignition signal is present, the wave shape of the ionic

signal can be seen. Proceed with step 6.

6. Checking the cable harness between the Electronic Control Unit and the ignition unit.


• Connect the special tool connector of Electronic Control Unit of the Electronic Fuel Injection.

• Disconnect the ignition unit connector on the Electronic Control Unit side.


IS - 512

• Check there are no interrupted or short-circuited wires in the cable harness and connector.

- Terminal 14 of the special tool.

- Input/Output terminal of the ignition unit on the cable harness side, repair or replace the cable harness

or the connector, if necessary.

7. Checking the cable harness between the ig-

nition unit and ignition coil



• Disconnect the side connector of the

ignition coil of the ignition unit C.

• Disconnect 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.



8. Ignition unit check

Replace the ignition unit, if necessary

9. Checking the ignition unit ground circuit

• Measure continuity between engine ground and terminals G1 and G2 on the cable harness

side of the ignition unit E.


signs of continuity.

If failures are detected during checks replace the

ignition coil (all the cylinders), otherwise repair or

replace the cable harness or the connector.


IS - 513


ignition unit and ignition coil




• Disconnect coils and the side connec-

tor of the ignition coil of the ignition unit.

- Terminals N07, N54, N65 and N84 on the cable

harness side of each ignition coil D

- Terminals C1, C2, C3 and C4 on the cable har-

ness side of the ignition unit C. Repair or replace

the cable harness or the connector.


Electronic Control Unit of the Fuel Injection

and the ignition unit.



• Disconnect the connector of the spe-

cial tool from the Electronic Control

Unit of the Fuel Injection.

• Disconnect the ignition unit connector

on the Electronic Control Unit side E.

- Terminals S1, S2, S3, S4 on the cable harness

side and Input/Output of the ignition unit.

- special tool connector terminals 60, 59, 58, 57

and 14, repair or replace the cable harness or the

connector, otherwise go back to step 7.


IS - 514

P1510 - Malfunzionamento circuito segnale avviamento

Checking procedure

The diagnosis diagram is based on the assump-

tion that the engine is started under normal condi-

tions.

1. Checking the input signal of the STA Elec-

tronic Control Unit


ness).

• Measure voltage between connectors

68 and 82 STA-E01 of the special tool

with the following conditions.

Condition Specified value

Engine started with starter motor 6 - 10 V

After the engine start-up: 0V

If the value 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 switch and the Electronic Control Unit

(M/T vehicles)


• Disconnect the ignition switch connec-

tor.


cial tool on the Electronic Control Unit

side.

• M/T vehicles: Connector N30 on the

ignition switch side - connector 68 STA

on the Electronic Control Unit side. Re-

pair or replace the cable harness or the

connector, if necessary, otherwise

check or replace the Engine Electronic

Control Unit side.


IS - 515

KEY:

1. Ignition switch

2. 60A fuse F/L

3. Battery

4. Starter motor



Circuit description

When the engine is started with the starter motor, the intake air flow is slow, that is why there is a lean

combustion vaporisation. A rich mixture is therefore necessary in order to obtain a proper start-up. When

the engine is started with the starter motor, the battery 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-start-up injection check.


Conditions

Affected area

P1510 Interrupted or short-circuited wire in the start-

up signal circuit.


- Interrupted or short-circuited wire in the start-

up signal circuit.


THE CODE P1510 CAN BE DETECTED AFTER START-UPS WITHOUT USING THE STARTERMOTOR.


IS - 516

P1520 - Malfunzionamento circuito segnale interruttore

Using the diagnostic tester DS-21

1. Checking the input signal through the C/A switch of the idle switch to the Electronic Control

Unit

• Set the ignition switch to OFF. Connect the diagnostic tester DS-21 to the Data Link Con-

nector through the special tool.


• Set the ignition switch and the tester main switch to ON. Check the idle switch signals (To

perform this operation, refer to the user manual of the diagnostic 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 sensor and the Electronic Con-

trol Unit

Model EURO 3




ness). Do not connect the connector of

the special tool to the Electronic Con-

trol Unit.



ness and connector.


Connector XT1 on the sensor side - connector on

the 17 E2 electronic control unit side.

Connector XT0 on the sensor side - connector on

the 44 VTH electronic control unit side.


IS - 517

Connector X99 - on the sensor side - Connector

on the 16 VC electronic control unit side.

Model EURO 4



• connect the special tool to the cable

harness connectors coming from the

DRACO control unit on the EFI ECU

side.

• Check the cable harness downstream

and upstream the DRACO control unit

and on the DRACO itself:


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


VTH.

Connector X99 - on the sensor side - DRACO con-

nector B3


VC.

Repair or replace the cable harness, if necessary,

otherwise check the throttle valve sensor and re-

place it, if necessary.

Alternatively, check or replace the EFI ECU control

unit.


IS - 518

KEY:

1. Ignition switch

2. Throttle valve sensor wire on the cable harness side


4. 60A fuse F/L

5. Battery


Model EURO 4


IS - 519

KEY:

1. Ignition switch

2. Throttle valve sensor wire on the cable harness side


4. 60A fuse F/L

5. Battery


7. Draco

Circuit description

This code is used to check the throttle valve signal. With terminal T set to ON, the diagnostic code failure

is generated for cases in which the throttle valve sensor is set differently from idle. However, the failure

code is diagnosed only if terminal T is set to ON. It is not stored.




Conditions

Affected area

P1520 When conditions 1 and 2 described below are

fulfilled:

1. terminal T set to "ON"

2. Idle switch set to "OFF", air conditioner set

to "ON" or neutral starter switch set to "ON"

- Interrupted or short-circuited wire in the throt-

tle valve sensor circuit


- Engine Electronic Control Unit


IS - 520

IF THE IDLE SWITCH TURNS OFF WHILE TERMINAL T IS SET TO ON, IT IS POSSIBLE TO IN-SPECT, IF THE IDL SYSTEM OF THE THROTTLE VALVE SENSOR WORKS PROPERLY BYCHECKING THE DIAGNOSTIC FAILURE CODE GENERATED.

Checking procedure

If the diagnostic failure codes P0110, (intake air temperature circuit malfunction), P0115 (engine coolant

temperature circuit malfunction), and P0120 (Throttle/pedal position sensor switch malfunction A) are

generated at the same time, the Sensor Ground E2 could be open.

1. Check the input signal of the electronic control unit


• With the ignition switch to ON, measure the voltage between connectors 16 , 17 VC and E2,

44 , 17 VTH and E2.


16 , 17 VC and E2: 4.5 - 5.5 V .

44 , 17 VTH and E2: move the throttle lever from the completely closed to the completely open position,voltage must increase proportionally from 0 to 4.8 V.



false contact, otherwise proceed with step 2.

2.Checking the cable harness between the neutral starter switch and the electronic control unit.

As for switch C/A and the throttle valve sensor, go to step 2 of the section: Using the diagnostic tester

DS - 21 Repair or replace the cable harness or the connector, if necessary, otherwise check or replace

the engine electronic control unit.


IS - 521

P1560 - Malfunzionamento circuito alimentazione ausiliaria unità dicontrollo elettronica

KEY:

1. Ignition switch

2. 60A fuse F/L



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump


10. Main relay

11. Fuel pump relay

Circuit description

Battery positive voltage is delivered to the BAT terminal of the engine electronic control unit also when

the ignition switch is turned off to keep failures and self-adaptive parameters relative to the air-fuel ratio

check, etc. stored.


IS - 522


Conditions

Affected area

P1560 Interrupted wire in the auxiliary power supply

circuit

- Interrupted wire in the auxiliary power supply

circuit


IF THE CODE P1560 IS DISPLAYED , THE ELECTRONIC CONTROL UNIT DOES NOT STOREANOTHER CODE.

Checking procedure





1. Checking the auxiliary power supply voltage of the electronic control unit


• With the ignition switch to OFF, measure voltage between the 1 BAT connector and the

chassis ground.


battery voltage

Check the malfunction that is detected intermit-

tently or due to false contact, if necessary.

2. Check the cable harness between the relay

block and the electronic control unit

• With the ignition switch set to OFF, dis-

connect the special tool connector

from the control unit.

• Remove the cable harness from the

battery terminal. Check there are no

interrupted or short-circuited wires in

the cable harness and connector.


IS - 523

Cable harness side connector L41 of R/B - elec-

tronic control unit 1 BAT.

Cable harness side connector L41 of R/B battery

(+) terminal, repair or replace the cable harness or

connector.

3. Checking the electronic fuel injection fuse

No.1

• Remove fuse No.1 from the bulb hold-

er.

• Check continuity of fuse No.1. If it is in

proper conditions, check or replace the

engine electronic control unit.

P1667 - Malfunzionamento circuito valvola controllo sistema ricircolo gasdi scarico

Using the tester DS-21

1. Functional check of the EGR vacuum switch-

ing valve control system




special tool.


• Disconnect the suction pipe that goes

from the EGR vacuum modulator to the

vacuum switching valve and to the vac-

uum switching valve pipe.

• Set the ignition switch and the tester

main switch to ON. Clear the diagnos-

tic failure code. Select the "VSV 1 driv-

ing" from the "Actuator control".

• When switching ON and OFF, check

the operation of the "VSV 1 driving".


IS - 524

- Valve set to OFF: there must be no air continuity

when air is blown into the suction pipe with pipe

A closed. Afterwards, there must be air continuity

when air is blown into the suction pipe with pipe

A open.

- Valve set to ON: there must be air continuity

when air is blown into the suction pipe, and there

must be no air continuity inside the suction pipe.

- If failures are detected during checks, inspect the


false contact, otherwise proceed with step 2.

KEY:

1. EGR vacuum modulator

2. EGR valve

2. Checking the suction pipes

• "Release" 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 switching valve for

EGR to the throttle body.

• Cover the pipe with a finger. Check that

a negative pressure is applied. Speci-

fications: a negative pressure must be

applied.

• Check there are no leaks, rust, narrow-

ing, bending and deformations on the

suction pipe connection. Clean, repair

or replace, if necessary.

KEY:

3. Switching valve

4. Throttle body

5. Suction pipe

3. Checking the power supply voltage of the vacuum switching valve for EGR.

• Set the tester main switch and the ignition switch to OFF.

• Disconnect the vacuum switching valve connector.


IS - 525

• With the ignition switch set to ON, measure voltage between the cable harness side con-

nector XÀF of the valve and the body ground.


battery voltage.



uum switching valve for EGR and the main relay,

and that there are no interrupted or short-circuited

wires in battery. Repair or replace, if necessary.



valve for EGR




tor of the special tool to the electronic

control unit.



ness and connector. Connector XAE

on the valve cable harness side - con-

nector 80 on the VSV1 electronic con-

trol unit side. Repair and replace the

cable harness or the connector, if nec-

essary.

5. Checking the vacuum switching valve for EGR

Replace the vacuum switching valve for EGR, if necessary.

6. Checking the output signal of the electronic control unit

• Connect the connector to the vacuum switching valve for EGR. Connect the connector of

the special tool to the electronic control unit of the electronic fuel injection. Reconnect the

pipes previously removed in the original position.

• With the engine cold and the vehicle running, measure voltage between connectors 80 and

82 of the special tool VSV1-E01.


IS - 526

Characteristicspecified value:battery voltage.

• After warming up the engine (after the cooling fan has started at least once), measure volt-

age between connectors 80 and 82 VSV1 - E01 with the vehicle running at a speed of 60

km/h (4a gear) - max. 4800 rpm.

Characteristicspecified value:the voltage must shift from 0 to 1 V.



false contact, otherwise check or replace the elec-


KEY:

1. Ignition switch

2. 60A fuse F/L



IS - 527


5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump

9. Cable harness side wire

10. Vacuum switching valve (VSV) for ERG

11. Injector


Circuit description

In order to reduce NOx emissions, the anti-pollu-

tion system with exhaust gas recirculation (EGR)

allows the recirculation of an ideal quantity of ex-

haust fumes inside the inlet manifold according to

riding conditions, moderating combustion. The

suction pipe leading to the EGR valve is equipped

with a vacuum switching valve. Therefore, if EGR

working conditions are fulfilled, the electronic 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. Vacuum modulator

2. ECU

3. Switching valve

4. EGR valve

5. Throttle body


Conditions

Affected area

P1667 If there are interrupted or short-circuited wires

in the vacuum switching valve for EGR and

conditions necessary to carry out the recircu-

lation of exhaust fumes have been fulfilled:


- Interrupted or short-circuited wire in the circuit

of the vacuum switching valve for EGR

- Vacuum switching valve for EGR


Checking procedure

NOTE:


IS - 528





Circuito alimentazione unità di controllo elettronica

KEY:

1. Ignition switch

2. 60A fuse F/L



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump


10. Main relay

11. F/P Relay


Model EURO 4


IS - 529

KEY:

1. Ignition switch

2. 60A fuse F/L



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump


10. Main relay

11. F/P Relay


13. Draco

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 the engine electronic control

unit.



Checking procedure


IS - 530

1. Checking the electronic control unit power supply voltage



• With ignition switch set to ON, measure voltage between connectors 7, 36 up to 82 E01.


battery voltage.

If it matches the specified value, check the mal-

function that is detected intermittently or due to

false contact (see the relevant section).

2.Checking the cable harness between the re-

lay block and the electronic control unit.


connect the special tool connector

from the electronic control unit.


battery positive + terminal.



ness and connector (For the model

EURO 4, the circuits in question com-

prise the cable harnesses downstream

and upstream the DRACO control unit

and on the DRACO itself).

Connector L33 of the relay block on the cable har-

ness side and terminal 7 and 36 of the special tool.

Connector L41 of the relay block and battery pos-

itive (+) terminal.




IS - 531

3. Checking the main relay of the electronic

fuel injection

• Disconnect the main relay of electronic

fuel injection from the relay block.

• Check for proper operation and re-

place the main relay of the electronic

fuel injection, if necessary.

KEY:

1. Fuel pump relay

2. Main relay

4. Ignition switch check

• Disconnect the connector from the ignition switch.

• With the ignition 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

switch.

5. Check that there are no interrupted or short-

circuited wires in the cable harness and the

connector among the ignition switch, relay

block and chassis ground



KEY:


4. R/B wire on the cable harness side


IS - 532

6. Checking the electronic fuel injection fuse

No.2

• Disconnect the electronic fuel injection

fuse No.2 from the fuse board.

• Check if there is continuity in 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



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump


10. Main relay


IS - 533

11. Fuel pump relay

12. Data Link Connector (DTC )

Checking procedure

1. Functional check of the fuel pump




special tool.

• After setting the ignition switch to ON,

set the tester main switch to ON. Select

the actuator control.

• With your fingers, press down the fuel

pipe on the main pipeline.

• Activate the fuel pump. If there is no

diagnostic tester DS-21 available, con-

nect a linking wire between terminal 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 of the en-

gine control unit. Check according to failures

identified in the power supply circuit of the

electronic control unit

Repair or replace, if necessary.

3. Checking the fuel pump relay


connect the fuel pump relay A from the

relay block.

• Check the relay and replace it, if nec-

essary.

4. Voltage check on terminal FC2 of the engine electronic control unit


• Set the ignition switch to ON.


IS - 534

• Measure voltage between the connector 30 W/0 IMB of the special tool and the chassis

ground.


battery voltage.

If it does not match the specified value, check

there are no interrupted or short-circuited wires in

the cable harness and the connector between 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 interrupted or short-circuited wires in the cable harness and the connector.

- Relay block - fuel pump.

- Fuel pump - chassis ground.

Repair or replace the cable harness or the connector, if necessary, otherwise check or replace the

electronic control unit.


IS - 535

Malfunzionamento sistema valvola di commutazione VSV

KEY:

1. Ignition switch

2. 60A fuse F/L



5. Main relay

6. Fuel pump relay

7. Battery

8. Fuel pump


10. Cable harness side wire

11. To the cooling fan

12. To the front headlight switch

13. To the heater fan switch

14. To the anti-fog system switch

15. Vacuum switching valve to increase idle speed


IS - 536

Circuit description

The solenoid valve to increase idle speed is loca-

ted on the compensation chamber of the inlet

manifold. The intake air by-passes the throttle

valve through the vacuum switching valve.

In this way, the engine electronic control unit in-

creases idle speed controlling the vacuum switch-

ing valve.

KEY:

1. Throttle body

2. Vacuum switching valve to increase idle speed


Conditions

Affected area

- Interrupted or short-circuited wire in the ISC

valve circuit.

- Interrupted or short-circuited wire in the circuit

of the vacuum switching valve

- Vacuum switching valve


Checking procedure

1. Functional check of the vacuum switching valve to increase idle speed


Connector through the special tool.


• Warm up the engine with all the acces-

sory switches set to OFF.

• Set the main switch of the diagnostic

tester DS-21 to ON.

• With the engine running at idle speed,

select the VSV2 from the Actuator con-

trol. Set the VSV2 to ON.

If there is an increase of engine speed, check the


false contact.

2. Checking the power supply voltage of the vacuum switching valve.

• Set the tester main switch and the ignition switch to OFF.


IS - 537

• Disconnect the connector of vacuum switching valve to increase idle speed.

• Measure voltage between terminals XAC of the cable harness connector and the body

ground with the ignition switch set to ON.


battery voltage.



uum switching valve and the main relay, and that

there are no interrupted or short-circuited wires in

battery.

3. Checking the output 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 to ON.

• Select VSV2 ON from the Actuator

control. Measure voltage between ter-

minals 56 and 82 E01.

CharacteristicSpecified value0-0.5 V

Check and replace the electronic control unit, if

necessary.


vacuum switching valve and the electronic

control unit




cial tool on the Electronic Control Unit

side.


IS - 538



ness and connector.

Vacuum switching valve connector XAB - terminal

56 VSV2. Repair and replace the cable harness or


5. Checking the vacuum switching valve to increase idle speed

Replace the vacuum switching valve to increase idle speed, if necessary.

6. Checking the input signal of the electronic control unit to verify the electric charge


• With the engine running, measure voltage 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 or less

3 Heater fan switch set to ON 0.5 V or less

4 Front headlight switch set to ON 0.5 V or less

5 Cooling fan activated 0.5 V or less

N.B.

DO NOT PERFORM THE MEASUREMENT IF MANY CONDITIONS TAKE PLACE AT THE SAMETIME.

If it does not match the specified value, check and

repair the relative systems, otherwise check the

malfunction that is detected intermittently and bad

contacts.

Controlli generali

(IAT) Intake air temperature sensor

1. Measure resistance between terminals.


IS - 539

Referen

ce

values

Temper-

ature (°

C)

-30 -20 20 80 120

Resist-

ance

(kOhm)

28.6 16.2 2.45 0.33 0.18

(CANISTER VSV) Vacuum switchover valve for

bleeding fuel evaporative emissions.

Check continuity between the outlets.

Specifications: there must not be continuity.

2. Apply voltage to the connector terminals of the

CANISTER VSVvalve and check continuity be-

tween openings.

Specifications: there must be continuity.

3. Measure the resistance value between termi-

nals.

Characteristicspecified value:from 30 to 34 Ohm at 20°C

Spark plug

The spark plug could be too hot. Watch out not to get burned.

1. Check that the spark plug is not dirty or too hot.

2. Check the gap between spark plug electrodes using the proper tool.

CharacteristicElectrode gap = 0.9 / 1.0 mm

3. Check the value of the spark plug internal re-

sistance.

CharacteristicSpecified value:3.0° - 7.5 Ohm


IS - 540

(TPS) Throttle valve sensor

1. Measure resistance between VC and E2.

2. Measure the resistance variation between VTH

and E2.

Specification: the resistance value should in-

crease according to the gas lever degree of open-

ing.

KEY:

A:Throttle valve sensor (PTS)

CharacteristicSpecified value2.5° - 5.0 Ohm

With the throttle lever fully open the resistancevalue must be around3.4° kOhm

With the throttle lever fully closed the resist-ance value must be around0.4° kOhm

(VSV2 MIN) Vacuum switchover valve for in-

creasing idle speed.

1. Check continuity between outlets.

Specifications Value: there must not be continu-

ity.

2. Apply voltage to the connector terminals of the

vacuum switchover valve and check continuity be-

tween openings.

Specifications Value:there must be continuity.

3. Measure the resistance value between the ter-

minals.

CharacteristicSpecified value37 - 44 Ohm at 20°C


IS - 541

(ECT) Engine coolant temperature sensor

1. Measure resistance between terminals.

Circuit diagram - Key

1. Thermistor for electronic fuel injection

2. Thermistor for water temperature gauge

KEY:

T: Temperature

R: Resistance

VSV EGR - Vacuum switchover valve for EGR

1. Check the continuity between openings. Spec-

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 check continuity be-

tween the openings. Specifications: there must be

continuity between openings E and F. There must

not be continuity between openings G andE.

3.Measure the resistance value between the ter-

minals.

CharacteristicSpecified value:30 - 34 Ohm at 20°C


IS - 542

Fuel pump

1. Turn the ignition switch to ON.

2. Short circuit terminals T and E of the Connecting

Connector in Data Transmission using the specific

tool. Check if the relay emits a sound signal indi-

cating it is operating.

3.Turn the ignition switch to OFF.

4. Remove the connector placed on the fuel tank.

Measure resistance between the fuel pump termi-

nals- IT IS STRICTLY FORBIDDEN TO USE NAKED FLAMESWHILE PERFORMING THIS PROCEDURE.


020618Y Cable harness for connecting theOBD Connector and the Diagnostic Tester

CharacteristicSpecified valuefrom 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 attention to the sound sig-

nal and vibration.- CHECK THAT THE RELAY IS VERY HOT DURING THISOPERATION. DO NOT TOUCH IT WITH BARE HANDS.

2. Measure resistance between terminals 1 and

2.

3. Check that there is no continuity, except be-

tween terminals 1 and 2.

4. Apply battery voltage between terminals 1 and

2. Check that there is continuity between terminals

3 and 4.- MEASURE AFTER THE RELAY HAS BEEN SLOWLYLOADING FOR AT LEAST ONE HOUR AT AMBIENT TEM-PERATURE OF 0°C-40°C.

CharacteristicSpecified value


IS - 543

from 74 to 117 Ohm

Front and rear oxygen sensors with heater

(For EU specifications only)

1. Measure resistance between terminals (+B) and (HT).

CharacteristicSpecified 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 VALUESSpecification Desc./Quantity

I/O G1 1.9 - 2.1 kΩS1 G2 3.7 - 4.1 kΩS2 G2 3.7 - 4.1 kΩS3 G2 3.7 - 4.1 kΩS4 G2 3.7 - 4.1 kΩ


IS - 544

INDEX OF TOPICS

GEAR-BOX GE

Gearbox

This section of the manual describes the gear components and shows the removal/fitting operations.

Precautions

Before removing and fitting a new gear, it is necessary to observe the following precautions:

• It is advisable to use the following special tools, so that parts are not damaged.

• The gear removal procedure has been omitted, since the procedure above is the same

applied to the gears used so far.

• It is advisable to carry out removal operations after the checks (as for example: the proper

operation of the gear and excessive clearance, etc.) that can be only lead when the gear is

assembled.

• It is advisable to check the tightening 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 necessary (for example: oil leakage, abnormal noise, etc.).

• As regards those sections which require measurements and accurate surveys, which may

be conducted more easily when the assembly is fitted (as for example: the gear fork as-

sembly and hub, the thrust clearance of each gear, etc.:), it is advisable to conduct those

measurements also during removal.

FOR REMOVING AND FITTING THE CONICAL SPRING WASHERSpecification Desc./Quantity

Total width 75.00 mmTotal width 70.00 mm

Total inside width 65.00 mmHeight 40.00 mm

Thickness 5.00 mm

The figure shows positions related to the special

tool Drw. 020277Y - bracket.

Gear-box PORTER 1.3 16V

GE - 546

Tool to be used from the input shaft and the sec-

ondary shaft side.

D. 80.00

d. 36.00

F. 15.00

L. 200.00

R. 185.00

A. 42.00

The figure shows positions related to the special

tool Drw. 020202y.

Tool to be used from the input shaft and the sec-

ondary shaft side for the synchroniser.

t. 8.00

L. 250.00

W. 75.00

P and D. Make sure that the outside diameter

«D» is 55 mm with a 10 mm thickness interposed

matching section «P».

• «P» is used as a guide, when the

grooved pin of the 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 inserted in the fork from the pro-

peller shaft front end, when the main shaft is

turned.

Diagram

1. The manual gear has five speeds for all the models.

2. The layout of the gear train is changed from the conventional method with primary reduction to that

of output reduction.

3. The mechanism to avoid noise and excessive clearance has been changed from the conventional

method by damped friction to that which uses the sub-gear.

PORTER 1.3 16V Gear-box

GE - 547

A = Gear section

B = Pin and fork section

Gearbox and cover

1. In order to reduce the number of gearbox com-

ponents, the gear system has been altered. At the

same time, in order to decrease the possibility of

oil leaks, the 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 housing has been made

in aluminium die-casting.

In addition, there are special ribs on each housing

which allow to obtain a compact design and a

weight reduction.

KEY

1. Clutch bell

2. Gearbox


GE - 548

3. Selection pin cover

4. Rear cover

Sub-gear

1. Each single sub-gear has one tooth less with

respect to the main gear; in this way, a phase

movement towards the main gear can be obtained.

This makes possible to remove clearance among

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-gear is fitted in secondary shaft speed

I and II

KEY

1.Sub-gear

2. Main gear

3. Main gear

4. Conical spring washer

5. Retaining circlip

6. Sub-gear

ComponentsCambio (parte 1)

COMPONENTS

1. Clutch housing


GE - 549

2. S type oil seal

3. Gear synchronisation plate

4. Spring

5.Reverse gear control lever

6. Plate locking the input shaft bearing

7. Reverse transmission gear

8. Reverse transmission gear thrust washer

9. Reverse transmission gear shaft

10. Pin

11. Hexagonal bolt

12. Gasket

13. Gasket

14. Spring

15. Ball

16. Control fork shaft of the 5th gear and the reverse gear

17. Control head of the 5th gear and the reverse gear

18. Pin

19. Control fork of the 5th gear

20. Control fork shaft of the 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 of the 1st and 2nd gear

26. Oil reception duct

27. Cap with gasket

28. Gearbox

29. Oil drainage plug (magnetised)

* Non-reusable parts

1. Clutch housing

The clutch body is connected to the gearbox by means eight bolts M8 (I =40 mm) and two bolts M8 (I

= 60 mm).

Locking torques (N*m)Clutch cover 15÷22*2. "S" type oil seal

Lubricate the gasket lip with engine oil during fitting. Press slightly on this gasket by means of a 35 mm

pipe.

3. Gear synchronisation plate


GE - 550

Total length = 23.25 - 23.55 mm

Internal part length = 17.7 -17.9 mm

A similar plate is used in other two points.

4. Spring

The tension spring is fitted between parts 5 and 6 of this list.

5. Reverse gear control lever

Make sure that the operation pin moves slightly and freely between the neutral position and the 5th

gear. The control lever of the reverse gear is fitted with three bolts M8 (I = 20 mm)

Locking torques (N*m)Reverse lever - Gearbox 15÷226. Bearing locking plate

The bearing locking plate of the input shaft is fitted with three bolts M8 (l = 20 mm)

7. Reverse transmission gear

Bushing hole diameter D = 20.03 - 20.06 mm. Pay attention to fit it in the proper direction.

8. Reverse transmission 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 shaft is of 2.5 mm or less.

11. Hexagonal bolt

Black bolt, hexagonal head. Extract this bolt only when the gear is removed.

*12. Gasket

*13. Gasket

Locking torques (N*m)Control fork shaft 15 - 22 Nm14. Spring

A similar spring is used in other three different points L = 40 mm . This compression spring is locked

by means of a bolt M10 (I = 19 mm).

Locking torques (N*m)Gear control fork shaft screw - Clutch housing 19÷3015. Ball

A similar spring is used in other three different points, including the reverse gear limit ball.

D = 7.9375 mm

16. Control fork shaft of the 5th gear and the reverse gear

This control fork shaft is the longest among the three shafts.

L = 265 mm


GE - 551

D = 13.0 mm

17. Control head of the 5th gear and the reverse gear

Width of the area making contact with the internal lever: 12.1 -12.2 mm

Width of the area making contact with the reverse gear control arm pin: 15.0-15.043 mm

*18. Pin

A similar pin is used in other six different places.

D = 5 mm

L = 23 mm

19. Control fork of the 5th gear

Thickness of the section of the fin making contact with the hub bushing:

D = 6.7 - 6.9 mm

20. Control fork shaft of the 3rd and 4th gear

This shaft has an intermediate length with respect to the three shafts.

L = 259 mm

D = 13.0 mm

21. Control head of the 3rd and 4th gear

Groove depth corresponding to the section making contact with the internal control: 12.1 12.2 mm

22. Control fork of the 3rd and 4th gear

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

24. Control fork of the 1st and 2nd gear

Thickness of the section of the fin making contact with the hub bushing: 9.7 - 9.9 mm (This fork is longer

than the others).

25. Control head of the 1st and 2nd gear

Groove depth corresponding to the section making contact with the internal control: 12.1 - 12.2 mm

26. Oil reception duct

The duct is located inside the gearbox and it is fixed by means of a bolt M6 (I = 16 mm).

27. Cap with gasket

Remove this cap, only in case of an oil leak (or similar event)

28. Gearbox

The clutch body is linked to the gearbox with 10 bolts.

Locking torques (N*m)Clutch housing for gearbox 15 - 22 Nm Engine fitting rear bracket for gearbox cover 29 ÷ 44 Nm29. Oil drainage plug (magnetised)


GE - 552

This magnet is not locked with any bolt.

Cambio componenti

COMPONENTS

34. Spring

35. Reverse gear limit cam

36. Reverse gear limit shaft

37. Subassembly of the 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 internal lever

50. Gear control shaft subassembly sleeve

51. Pin

52. Gear control shaft subassembly

53. Radial bearing

54. Circlip


GE - 553

55. Lock nut

56. Odometer control gear

57. Radial bearing (rear)

58. Bearing rear locking

59. Oil seal

60. Gasket

61. Filler cap

62. Bimetallic bushing

63. T oil seal

64. Dust guard

65. Housing subassembly

66. Plate locking the odometer sleeve

67. V oil seal

68. Gasket

69. Sleeve assembly of the rpm indicator shaft

70. Gasket

71. Rpm indicator guide gear subassembly

72. T oil seal

73. K Oil seal

74. Oil guide plate

34. Spring

Pay special attention to the fitting direction, which shall be the same to the 35 part.

35. Reverse 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 = 8 mm, L = 7.15 mm.

37. Subassembly of the selection lever

Pay special attention to the lever fitting direction when the components are fitted 41 and 42.

*38. Pin

D = 6 mm, L = 22 mm

Fit this pin in its seat, inserting it from the side without the groove.

39. Gear control shaft cover

The gearbox cover is fitted with four bolts; three bolts M8 (L= 28 mm) and the remaining bolt (olive-

green) always M8 (L=19 mm). Component 40 is interposed between the cover and the gearbox.

*40. Gasket

(No asbestos).


GE - 554

41. Spring

Pay attention to the fitting direction (upside down) of the spring, during fitting.

42. Selection internal lever

Width of the section making contact with the control head: 4.88-14.98 mm

43. Main shaft

This shaft corresponds to the 4th gear.

44. Reverse gear limit pin holder

Locking torques (N*m)Reverse limiting pin lock - Gearbox 29 ÷ 49*45. Gasket

Unloaded length: 24.00 mm

46. Spring

Fitted length: 17.00 mm

47. Ball

A similar ball is used in four different positions, including the gear control fork ball.

48. Gearbox

Refer to "Components (Part 1 )" for the description. Apply liquid sealant onto sections 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 sleeve

Width of the section making contact with the selection internal lever: 15.1 ± 15.2 mm

Fit this sleeve so that the air bleeding section is facing downwards.

*51. Pin

D = 6 mm, L = 24 mm

52. Gear control shaft subassembly

Pay special attention to the lever fitting direction.

53. Radial bearing

Press on the bearing from the side having the gasket facing backwards.

54. Circlip

This circlip can be reused.

*55. Lock nut

Lock nut thickness: 38 mm

Tightening torque: 177 - 216 Nm

56. Odometer control gear

Make sure to fit the lock nut after the tightening operation. Made of nylon.


GE - 555

Pay attention not to deform the gear due to an excessive pressure during fitting. For the fitting procedure,

make reference to the next part 57.

57. Radial bearing

Insert this bearing by pressure, keeping the gasket side facing backwards. Also, pay attention when

pressing the bearing. Carry out the measurement at the moment in which the bearing comes slightly

into contact with the rpm indicator gear. At this point, check that the value measured from the edge of

the main shaft is 93.0 mm.

58. Bearing rear locking

This locking device is fitted with three bolts M8 (I = 20 mm)

Tightening torque 14.7 - 21.6 Nm

59. Oil seal

Made of nylon. (This deflector is also called oil deflector of the 5th gear).

*60. Gasket

61. Filler cap

The cap located at the top, is used either to add oil or to check oil level. (The capacity is of 1.0 ± 1.1

litres when oil is added before it starts to circulate). The cap located at the bottom 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 oil groove.

*63. T oil seal

The gasket inclination, at the time of positioning it in the seat by pressure, shall be of 1° or less. Apply

MP grease onto the lip section.

64. Dust guard

Pay attention to the handling of this deflector, because it can be easily deformed.

65. Housing subassembly

This component is treated as a subassembly on which components 62 and 64 are fitted. The gearbox

cover is fixed with six bolts M10 (I = 35 mm).

From these six bolts, one is locked together with the engine support bracket.

Tightening torque29.4 - 49.0 Nm

66. Plate locking the odometer sleeve

Fit this locking plate with a bolt M6 (I = 16 mm). Tightening torque: 6.9 ÷ 9.8 Nm.

67 V oil seal

68 Gasket

Before replacing this part with a new one, measure beforehand the insertion depth of part 69. Then,

insert the new part by pressure up to the same depth.

69. Sleeve assembly of the rpm indicator shaft


GE - 556

Fit this assembly with part 66 interposed. Components 67 to 71 are generally used as a set.

70. Gasket

71. Rpm indicator guide gear subassembly

Fit this gasket in the external groove of part 69. Made of nylon.

Gear oil

Filling capacity: 1.0 ± 1.1 litres

Place the vehicle on level ground and fill with oil up to the lower edge of cap 61. SAE 75W-90 or 80W-

go API GL-3.

72. T oil seal

During the fitting phase, strictly observe the protrusion size, which shall be of 5 ± 0.3 mm.

73. K Oil seal

The gasket inclination, at the time of positioning it in the seat by pressure, shall be of 1° or less. Apply

MP grease 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 gasket and cover.

3. Oil deflection and bearing locking.

4. Control gear of the rpm indicator, radial bearing and the oil drainage screw.

5. Check that there is continuity between the reverse gear light switch and engagement of the reverse

gear.

Removal

Recommendations before removal

This section has a summary of the gear main components illustrated in the sections:

• Component Gear (Part 1)

• Component Gear (Part 2)

• Input shaft

• Secondary shaft

The description facilitates the removal and fitting operations. For clearer and further details, refer to the

corresponding pages.


GE - 557

Removal

Removing the parts connected to the gear and

to the selection lever

1. Remove the clutch components.

2. Place the gearbox assembly and the clutch

housing in a vertical position so that the gearbox

is under the clutch.- AFTER CHECKING THE CONTINUITY OF THE REVERSEGEAR LIGHT SWITCH:

3. Remove the control shaft cover with the gasket

(bolt C is used as a centring bolt).

4. Remove the compression spring and the ball

locking the reverse gear limit pin with the gasket.

5. Remove the compression spring and the ball by

taking out the reverse gear limit pin locking B with

the gasket.

6. Remove the hexagonal bolt 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 PINFROM THE GEARSHIFT LEVER SHAFT.- THIS HEXAGONAL BOLT IS USEFUL TO LOCK THE RE-VERSE TRANSMISSION GEAR. THEREFORE, TAKE OUTTHIS BOLT BEFORE THE GEAR IS REMOVED.

7. Take out the gearshift lever subassembly and

lift the internal lever, after removing the grooved

pin.

8. Remove the reverse gear limit cam A, the tor-

sion spring B and the reverse gear limit shaft C,

taking out the hexagonal bolt with the gasket.

9. Remove the reverse gear light switch with the

gasket.- DURING THE ASSEMBLY, OBSERVE THE FITTING PO-SITION OF THE REVERSE GEAR LIMIT CAM A BEFOREREMOVAL, MARK THE FITTING POSITION. - DO NOT RE-USE THE GASKET MENTIONED ABOVE.


GE - 558

Remove the gearbox cover

1. Remove the subassembly of the rpm indicator

shaft sleeve.

2. Remove the eight bolts of the gearbox cover,

together with the engine rear support bracket.

3. Slightly hit the ribbed section of the gearbox

cover. Then, take it out towards the operator.- REMOVE THE GEARBOX COVER AND THE MAIN SHAFTONLY AFTER CHECKING FROM THE REAR PART IFTHERE IS AN OIL LEAKAGE, DEFORMATION, ETC., INTHE DUST GUARD.

Removing the gearbox

1. Take out the oil seal from the secondary shaft.

2. Take out the oil drainage plug (magnetised) A.

Remove the residues that are collected on the

magnet.

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 THEREIS CLEARANCE BETWEEN THE INPUT SHAFT AND THEPRIMARY SHAFT.

5. Remove the ten bolts of the gearbox (including

the two nuts which shall be removed from the low-

er side of the clutch box).

6. Slightly hit section C of the gearbox cover. Then,

take it out towards the operator.

Removing the gear control fork

1. Release the traction spring A.

2. Remove the compression spring and the ball,

taking out the hexagonal bolt with gasket B.

3. Remove the grooved pin of the traction spring

and then remove the gear control fork shaft.

4. Take out the reverse transmission gear C, the

thrust washer and reverse gear D.


GE - 559

5. Remove the gear control fork shaft of the 1st

and 2nd gear and, gradually, the gear control fork

shaft of the 3rd and 4th gear, following the proce-

dure described in previous points from 1 to 3.- CHECK THE REVERSE GEAR CONTROL LEVER MOVE-MENTS OF THE REVERSE GEAR CONTROL LEVER ANDTHE CONTACT WIDTH BETWEEN THE GEAR CONTROLFORK AND THE RIBBED SLEEVE.- BEFORE REMOVING THE GEAR CONTROL FORK,PLACE THE RELEVANT GEARS IN NEUTRAL.- DURING PIN REMOVAL, MEASURE THE TRACTIONFORCE OF THE SPRING.

Main and transmission shafts

Removal

Removing the input and the secondary shaft

1. Take 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. Remove the plate locking the input shaft, by

taking out the three bolts.

4. While the input and the secondary shaft are held

with the hands, slide them off upwards.

Inspection

1. Measure the unloaded compression spring length for the gear control fork shafts and for the reverse

gear limit pin

SPRING SPECIFICATIONSSpecification Desc./Quantity

Unloaded length for gear control fork shafts 40 mmFitting load (N) for gear control fork shafts 47.33 NFitting height for gear control fork shafts 30 mm

Unloaded length for reverse gear limit pin 24 mm


GE - 560

Specification Desc./QuantityFitting load (N) for reverse gear limit pin 28.93 NFitting height for reverse gear limit pin 17 mm

2. Visually inspect the balls, to detect possible de-

formations or scoring.

3. Measure the length of the contact section be-

tween the selection internal lever shaft and the

gear fork heads.

CharacteristicSelection internal leverSpecified value: 15-0.002 mm-0.12 mm

Internal lever headsSpecified value: 15-0.02 mm-0.1 mm

Gear clutch control

Removal

Forks and heads of the gear

Inspection

1. Measure the outside diameter of the gear con-

trol fork shafts and the inside diameter of the seats.

CharacteristicSeatSpecified value: 13.0 +0.043 mm +0 mm

ShaftsSpecified value: 13.0 -0.06 mm -0.07 mm


GE - 561

2. Measure the width of the contact sections be-

tween the heads of the gear and the gear internal

lever.

CharacteristicHeads of the gearSpecified value: 12.1 +0.1 mm +0 mm

Gear internal lever:Specified value: 12 -0.02 mm -0.12 mm

Reverse transmission gear

1. Visually check the chamfered section of the re-

verse transmission gear, and check for 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 scoring,

etc.

CharacteristicSpecified value (d)20 + 0.061 mm+0.032 mm

Specified value (D)20.0 + 0 mm+0.013 mm

"S" type oil seal replacement

1. Remove the "S"oil seal.

2. Apply lithium grease onto the edge of the new

oil seal.

3. Fit the new oil seal, using a 26 mm bushing

(outside diameter of 35 mm), and a plastic ham-

mer.


GE - 562

Bimetallic bushing

1. Remove the oil seal.

2. Visually inspect the internal surface of the stam-

ped bimetallic bushing, and check for possible

discolouration or scoring.

3. Measure the inside diameter of the stamped bi-

metallic bushing.

4. Apply lithium grease onto the edge of the new

gasket.

5. Fit the new gasket.N.B.- THE HOLE DIAMETER SHALL MATCH THE SPECIFIEDVALUE. AN EXCESSIVELY LARGE DIAMETER CAUSESOIL LEAKAGE. THE BIMETALLIC BUSHING SHALL BE RE-PLACED TOGETHER WITH THE GEARBOX COVER.

Specific tooling020200Y Extractor

CharacteristicSpecified 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.B.- DO NOT REUSE THE SEALING CAP AND THE OIL SEALPREVIOUSLY REMOVED .

Installation

1. Fit a new sealing cap, as shown in the figure on the right.

2. Fit a new T oil seal, as shown in the figure on the right.

3. Make sure that the protruding part A of the T oil seal complies with the specified value.

4. Check there is electric continuity between the switch and the reverse bulb.N.B.

- IF THE PROTRUDING PART EXCEEDS THE VALUE SPECIFIED ABOVE (OR 5.3 MM), IT CANCAUSE OIL LEAKAGE.


5 ± 0.3 mm


GE - 563

Inlet shaft

COMPONENTS


1. Circlip *

2. Radial ball bearing (front)

3. Input shaft

4. Needle bearing

5. 5th gear

6. Synchronisation 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





18. Circlip *


GE - 564


20. Needle bearing (open)

INPUT SHAFT - COMPONENTS

1. Circlip *

This component is the same as part 18. Spring washer to be selected according to thickness.

2. Radial ball bearing

Fit the bearing so that the side having the gasket is at the front part.

3. Input shaft

Needle bearing rolling section:

D = 31.971 - 31.991 mm, measure at two points.

Needle bearing rear end section:

D = 19.966 - 19.984 mm


Never expand the opening of the bearing with a value exceeding the input shaft diameter + 5 mm, upon

fitting and removal.

The opening of the bearing shall not exceed 37 mm.

5. 5th gear

Hole diameter: 37.00 - 37.025 mm

Width: 27.82 - 27.88 mm

Axial clearance: 0.1 - 0.4 mm


Components 6, 14 and 19 are identical and are used in different positions.

The clearance between the gear and the synchronisation ring is:

0.95 - 1.35 mm


Components 7, and 15 are identical and are used in different positions.

Make sure that the key openings are fitted displaced one from the other.


Hub section thickness: 12.37 -12.43 mm

Sleeves 8, and 16 are identical and are used in different positions.

Nevertheless, pay special attention not to mix sleeves with other components, since the hub and the

sleeve are fitted together as a set.

Fit the hub so that the grooved side for the hub oil is at the front side, precisely from the 5th gear side.

The sleeve, instead, does not have a correct fitting direction that shall be followed. Nevertheless, make

sure to align the missing teeth sections, which are in three different positions, when coupling the hub

and sleeve.



GE - 565


Then, a total of 6 pieces is used simultaneously.

Thickness: 4.6 - 4.8 mm


10. Hub key stop

Fit this stop so that the flat part is located at the front; and the oil grooved side is located at the back.

This component is equal to the component 23 of the secondary shaft.

*11. Circlip

It required to select thickness.

This component is equal to the component 7 of the secondary shaft.

12. Needle bearing

Hole diameter: 37.00 - 37.025 mm

13. 3rd gear

Width: 37.95 - 37.98 mm

Number of gear teeth: 32

Outside diameter: 61 mm




The clearance between the gear and the synchronisation ring is:

0.95 - 1.35 mm





Hub section thickness: 18.52 - 18.58 mm

Fit the hub so that the grooved side for the hub oil is at the front side, precisely from the 3rd gear side.

Make sure to align the missing teeth sections, which are in three different positions, when coupling the

hub and sleeve.

The sleeve, instead, does not have a correct fitting direction that shall be followed.

Gear control fork groove width: 7.05 - 7.12 mm



Then, a total of 6 pieces is used simultaneously.


*18. Circlip

This component is common in position 1


GE - 566

Spring washer to be selected according to thickness.



Refer to components 6 and 14


This needle bearing is placed between the input shaft and the main shaft.

* -1 When circlip 11 is removed, components from 4 to 10 can be removed together.

* -2 When circlip 18 is removed, components from 12 to 17 can be removed together.

Inspections before removal

1. Measure the 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-0.3mmAdmissible limit: 6.6

Hub sleeve Specification value: 7 +0.12 mm -0.2 mmLimit: 7.2

2. Measure and adjust thrust clearance for the 3rd

gear C and the 5th gear D, using a thickness

gauge.- MAKE SURE THAT THE THRUST CLEARANCE IS MEAS-URED AT DIFFERENT POINTS.- IF THE THRUST CLEARANCE MEASUREMENT DOESNOT COMPLY WITH SPECIFICATIONS, REMOVE THE IN-PUT SHAFT ASSEMBLY.

CharacteristicGear CSpecified value: 0.10 - 0.52 mm

Gear DSpecified value: 0.10 - 0.40 mm


GE - 567

Removal

1. With soft shoes, close the input shaft assembly

in a vice so as to avoid damaging the grooved

section.

2. Remove the shaft circlip from the rear part.

• Synchroniser hub assembly No. 2

• Synchronisation ring No. 1

• 3rd gear

3. As a reference during fitting, measure and ad-

just the size of the shaft spring washer just re-

moved.- THE PARTS LISTED BELOW SHALL BE REMOVED, TAK-ING OUT THE INPUT SHAFT BY PRESSING AND HOLDINGTHE SECTION OF THE 3rd GEAR WITH THE SPECIALTOOL.


5. Remove the needle bearing.

6. Remove the circlip of the shaft.

7. As a reference during fitting, measure and ad-

just the size of the shaft spring washer just re-

moved.

8. Remove stop of the gear hub sleeve.



• 5th gear- THE PARTS LISTED BELOW SHALL BE REMOVED, TAK-ING OUT THE INPUT SHAFT BY PRESSING AND HOLDINGTHE SECTION OF THE 5th GEAR WITH THE SPECIALTOOL.



GE - 568

10. Remove the needle bearing (open).- NEVER EXPAND OPENING (B) OF THE BEARING WITH AVALUE EXCEEDING THE INPUT SHAFT DIAMETER + 5MM, UPON FITTING AND REMOVAL.

11. Remove the circlip of the shaft.

12. Measure the thickness and adjust the values obtained from the circlip just removed. These data are

useful as a reference during the fitting phase.

13. Remove the radial bearing from the front side.

Inspection

1. Check clearance between the gear conical sec-

tion and the synchronisation rings.

CharacteristicSpecification value:0.95 -1.35 mm

2. Measure the input shaft outside diameter

matching sections A, B and C, according to the

indications in the figure.

3. Visually inspect sections A, B and C, to highlight

possible scoring or discolouration.

CharacteristicA and BSpecification values: 32-0.0090mm-0.029mm

CSpecification values: 20-0.0016mm-0.034mm


GE - 569

4. Measure the outside diameter of synchroniser

No. 2 of the third gear A and of synchroniser No.

3 of the fifth gear B and the inside diameter of both

hub sleeves.- IF ANY PART WHICH EXCEEDS THE VALUES OF THETABLE SHOULD BE EMPLOYED, THAT WOULD CAUSEABNORMAL NOISE. THEREFORE, MAKE SURE THAT INADDITION TO THE PARTS OUT OF TOLERANCE ALSOTHE 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 - (White)

A and B: 57 58 - 57.64 mm

Hub sleeve 57.67 - 57.77 mm

5. Measure the hub thickness of synchroniser No.

2 C and No. 3 D.

CharacteristicCSpecified value: 18.55 ± 0.03 mm

DSpecified value 12.4 ±0.03 mm

6. Measure the height of the gear hub sleeve stop.

CharacteristicSize A:Specified value:

7.2 + 0.05 mm

7.2 - 0.01 mm


GE - 570

7. Measure the thickness and the inside diameter

of the third and the fifth gear

Characteristic3rd gear ASpecified value: 37.0 +0.25 mm +0 mm

5th gear BSpecified value: 37.0 +0.25 mm +0 mm

3rd gear CSpecified value: 37.95 ± 0.03 mm

5th gear D27.85 ± 0.03 mm

8. Measure the height of the synchronised move-

ment key.

9. Visually inspect the synchroniser movement

key, to highlight possible signs of wear or damage.- THE SIX SYNCHRONISER MOVEMENT KEYS, FITTED ONTHE INPUT SHAFT, ARE EQUAL.

CharacteristicSpecified value5 - 0.2 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 EXPAND OPENING (B) OF THE BEARING WITH AVALUE EXCEEDING THE INPUT SHAFT DIAMETER + 5MM, UPON FITTING AND REMOVAL.

2. Fit the fifth gear and the synchronisation ring to

the input shaft.

3. Fit the synchronised movement key and the rel-

evant elastic key to the hub, as shown in the figure.

- The same hub sleeve is used for the third or

fourth gear.

Nevertheless, the hub of third and fourth gear dif-

fers due to its shape.- MAKE SURE THAT THE KEY OPENINGS ARE FITTEDDISPLACED ONE FROM THE OTHER.


GE - 571

- MAKE SURE TO ALIGN THE MISSING TEETH SECTIONS,WHICH ARE IN THREE DIFFERENT POSITIONS, WHENFITTING THE HUB AND SLEEVE.- THE SAME HUB SLEEVE IS USED FOR THE THIRD ANDTHE FOURTH GEAR; NEVERTHELESS, THE HUB OF THETHIRD AND THE FOURTH GEAR DIFFERS DUE TO ITSSHAPE.

4. Make sure that the grooved area of the protrud-

ing part of the synchroniser hub No. 3 faces to the

front (for example: the fifth gear) and press slightly.- MAKE SURE THAT THE SYNCHRONISER RINGS AREALIGNED WITH THE GROOVES OF THE MOVEMENT KEYS(THREE POINTS), WHILE THE SYNCHRONISER HUB No. 3IS FITTED BY PRESSURE.

5. Fit the stop of the hub sleeve.- MAKE SURE THAT THE GROOVED SECTOR FOR LOCK-ING THE FIFTH MOVEMENT KEY IS FACING THE THIRDGEAR.

6. Selection procedure of the 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 spring washer. Then, fit

the spring washer (selected in this

way) in the input shaft fitting groove.

• Measure clearance, using a thickness

gauge, as shown in the figure.

• Select a shaft spring washer, having clearance near zero or zero which can be identified

easily, as indicated below.

Make sure that clearance between the movement key locking and the shaft spring washer complies

with specified values.

P/N 90045-20263 (No colour) Thickness: 2.06 mm

P/N 90045-20264 (Brown) Thickness: 2.02 mm

P/N 90045-20265 (Blue) Thickness: 1.98 mm


GE - 572






* THE SPRING WASHERS INDICATED IN THE TABLE ABOVE ARE EQUAL TO THOSE USEDWHEN THE SECONDARY SHAFT HUB IS FITTED.

CharacteristicClearance:

Specified value: 0

Value allowed: less than 0.16 mm

7. Fit the needle bearing and lubricate with engine

oil.

8. Fit the third gear and the synchronisation ring.

9. Fit the synchroniser elastic key and movement

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, REFERTO POINT 3. - MAKE SURE THAT THE SYNCHRONISERRINGS ARE ALIGNED WITH THE GROOVES OF THEMOVEMENT KEYS (THREE POINTS), WHILE THE SYN-CHRONISER HUB No. 3 IS FITTED BY PRESSURE.

11. Selection procedure of the new shaft spring

washer

• For the selection procedure of the new

shaft spring washer, refer to the proce-

dure described above in reference with

the following values.

• Make sure that clearance between the

hub and the shaft spring washer com-

plies with the values specified.



GE - 573







P/N 90045-20278 (Brown) Thickness: 1.78 mm- MAKE SURE THAT THE GASKET OF THE RADIAL BALLBEARING IS FACING THE FRONT PART.- DO NOT LET FALL THE SYNCHRONISATION RING ANDTHE HUB SLEEVE, WHILE THE RADIAL BALL BEARING ISBEING FITTED BY PRESSURE.- THE RADIAL BALL BEARING SHALL BE FITTED FIRST.

CharacteristicClearance:Specified value: 0


12. Fit the ball bearing by pressure.

13. Fit the elastic ring of the shaft (component to

be selected) following the same procedure indica-

ted in point 11.- MAKE SURE THAT THE GASKET OF THE RADIAL BALLBEARING IS FACING THE FRONT PART.- DO NOT LET FALL THE SYNCHRONISATION RING ANDTHE HUB SLEEVE, WHILE THE RADIAL BALL BEARING ISBEING FITTED BY PRESSURE.- THE RADIAL BALL BEARING SHALL BE FITTED FIRST.

Main shaft

Removal

1. Remove the radial ball bearing (from the rear

part), with the following special tool:

2. Take out the odometer pinion.

3. To avoid damage, lock the main shaft grooved

section in a vice with soft shoes.


GE - 574

4. Remove the lock nut with a 32 mm wrench.- DO NOT REUSE THE LOCK NUT REMOVED.

5. Remove the radial ball bearing with the following

special tool:


Inspection

1. Check clearance between the 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.

CharacteristicSpecification value:0.95 - 1.35 mm

3. When the external and central part of the radial

ball bearing internal rotation seat is turned with the

fingers, as shown in the figure, the rotation must

be smooth and without jamming.


GE - 575

Fitting

1. Press on radial ball bearing internal rotation

seat.

- Make sure that the locking section (this is the part

which has the sealing gasket) of the radial ball

bearing is facing towards the rear part.THE RADIAL BALL BEARING CAN BE FITTED BY PRES-SURE, USING THE SPECIAL TOOL OR A PIPE TO PRESSON THE INTERNAL ROTATION SEAT.

2. Fit a 32 mm torque wrench in the main shaft.

3. To avoid damage, lock the main shaft grooved

section in a vice with soft shoes.

4. Tighten the lock nut with a torque wrench.

Locking torques (N*m)Lock nut - Main shaft 177÷216

5. Tighten the new lock nut.- AFTER TIGHTENING THE LOCK NUT, PUNCH THE REL-EVANT SAFETY PLATE. FOR A PROPER LOCKING,PUNCH IN A VERTICAL DIRECTION WITH RESPECT TOTHE MAIN SHAFT (SEE THE FIGURE ON THE RIGHT - UP).- THE LOCK NUT CAN BE LOOSENED (SEE THE FIGUREON THE RIGHT - AT THE CENTRE AND AT THE BOTTOM)DUE TO INCORRECT PUNCHING.

6. Fit the odometer pinion.

7. Press on the radial ball bearing internal rotation

seat (to be used at the rear part), with the following

steel tool with pipe shape.N.B.FROM THE MOMENT THAT THE ODOMETER PINION ISMADE OF NYLON, IT CAN BE DEFORMED IF THE RADIALBALL BEARING (TO BE USED AT THE REAR PART) ISDEEPLY THRUST BY PRESSURE MORE THAN SPECIFIED(93.00 mm).THEREFORE, PAY SPECIAL ATTENTION WHILE PRESS-ING ON THE RADIAL BALL BEARING (TO BE USED ATTHE REAR PART). WHEN THE BEARING COMES INTOCONTACT WITH THE ODOMETER PINION, STOP PRESS-ING. NOW, MAKE SURE THERE IS A 93.00 mm DEPTH.FOR THIS OPERATION, IT IS ADVISABLE TO USE THEFOLLOWING TOOL TO FIT BY PRESSURE «A» HAVINGTHE DIMENSIONS DESCRIBED BELOW.

CharacteristicTotal depth


GE - 576

93.00 mm

Outside diameter35.00 mm

Inside diameter25.00 mm

Transmission shaft

Components


1. Circlip *


3. Thrust washer of the 1st gear

4. Circlip *

5. 1st sub-gear

6. Circlip

7. Needle bearing

8. 1st gear






14. Needle bearing

15. 2nd gear

16. Conical spring washer *

17. 2nd sub-gear

18. Shaft spring washer


GE - 577

19. Transmission gear


21. Circlip *

SECONDARY SHAFT COMPONENTS

* 1 Circlip

Type to be selected.

2 Radial ball bearing

Bearing without gasket.

3 Thrust washer of the 1st gear

Thickness = 3.97 - 4.03

Fit the washer so that the protruding part is facing to the front; and the oil grooved part is facing towards

the 1st gear.

Thrust clearance of the 1st gear = 0.1 - 0.52 mm

* 4 Circlip * - 1

5 1st sub - gear

Components 4 and 18 have the same function. Components 4 and 18 are generally considered as

assembled parts.

Components 6 and 16 have the same function.

6 Conical spring washer

This bearing is interchangeable with part 12 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 ring No. 2

The synchronisation ring No. 2 is not interchangeable with part 13. In order to distinguish it from part

13 teeth are eliminated in three different points.

10 Synchroniser elastic key


11 Synchroniser hub assembly No. 1

The hub and sleeve (transmission gear) are fitted at set level.

Real width of the hub: 26.97 - 27.03 mm

Fit the hub assembly so that the side having the wider protruding parts, is facing to the front.

As regards the sleeve (transmission gear), make sure that the gear control fork groove is facing the

front.


GE - 578

Fork groove width: 10.05 - 10.12 mm *-2

12 Synchroniser movement key

Thickness = 5.0 - 5.2 mm, composed by 3 pieces.

13 Synchronisation ring No. 3

Not interchangeable with component 9

14 Needle bearing

This bearing is interchangeable with bearing 4 of the input shaft.

Never expand the opening of the bearing with a value exceeding the input shaft diameter + 5 mm, upon

fitting and removal.

The opening of the bearing shall not exceed 37 mm.

15 2nd gear

Inside diameter: 37.00 - 37.025 mm

Real thickness: 36.27 - 36.33 mm

Clearance regarding the synchronisation ring:

0.95 - 1.35 mm

Limit: 0.9 mm


16 Conical 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

Components 15 and 17 are considered parts assembled together with ring 18.

* 18 Shaft spring washer

Components 4 and 18 are identical.

19 Transmission gear

Outside diameter of the bearing rolling section:

31.971 - 31.991 mm

20 Radial ball bearing

Fit the bearing so that the side having the gasket is facing backwards.

* 21 Circlip

This component is identical to part 11 of the input shaft: Part selected due to thickness.

* - 1 When spring washer 1 is removed, all components up to 8 can be removed together.

* - 2 When spring washer 18 is removed, all components from 10 to 18 can be removed together.


GE - 579

Removal

1. To avoid damage, lock the secondary shaft

grooved section in a vice with soft shoes.

2. Remove the shaft circlip (part indicated in the

figure).

3. Measure the shaft circlip immediately after it has

been removed. Record the values measured.

This measurement will be a reference at the mo-

ment of fitting.

4. Remove the following parts, slightly pressing on

the secondary shaft by means of a specific pipe.

• Radial ball bearing

• Thrust washer of the 1st gear

• 1st gear


• Needle bearing- THE COMPONENTS DESCRIBED ABOVE, CAN BE RE-MOVED BY SLIGHTLY PRESSING ON THE SECONDARYSHAFT, WHILE THE 1ST GEAR IS SUPPORTED BY MEANSOF THE SPECIAL TOOL.


5.Remove the shaft circlip (part indicated in the

figure).

6. Measure the shaft circlip immediately after it has

been removed. Record the values measured.


GE - 580

7. Remove the following components:



• 2nd gear with sub-gear- THE COMPONENTS DESCRIBED ABOVE, CAN BE RE-MOVED BY SLIGHTLY PRESSING ON THE SECONDARYSHAFT, WHILE THE 2nd GEAR (SUB-GEAR SURFACE) ISSUPPORTED BY MEANS OF THE TOOL INDICATEDABOVE.

8. Remove the needle bearing.- NEVER EXPAND OPENING (A) OF THE BEARING WITH AVALUE EXCEEDING THE SECONDARY SHAFT DIAMETER+ 5 MM, UPON FITTING AND REMOVAL. FAILURE TO OB-SERVE THIS CONDITION CAN CAUSE ABNORMAL NOISEOF 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 spring, to highlight possible damage or distor-

tions.

3. Measure the outside diameter of the secondary

shaft, corresponding to sections (A) and (B)

4. Visually check the sections (A) and (B), to high-

light the presence of possible scores and wear.

Characteristic(A)Specified value: 32 - 0 0029 mm- 0.0029;mm

(B)Specified value: 32 - 0 0029 mm- 0.0029;mm

5. Measure the thickness of the thrust washer of

the 1st gear.

CharacteristicSpecification value:4 ± 0.03 mm


GE - 581

6. Measure the outside diameter sizes of the syn-

chroniser hub No. 1 (A) and the inside diameter

(B) of the sleeve.

(Reference information)

The components (A) and (B) are available only as

kits. The synchroniser hub end surface has an

identification mark.

Classification No. 2 - Yellow

(A): 69.78-69.84

(B): 69.871-69.97

Classification No. 1 - No colour

(A): 69.68-69.74

(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 the 1st and the

2nd gear.

CharacteristicSpecification value:27 ± 0.03 mm

1st gear (A)Specified value: 37.0 + 0.025+0 mm

2nd gear (B)Specified value: 37.0 + 0.025+0 mm

9. Measure the thickness of the 1st and the 2nd

gear.

Characteristic1st gear (C)Specified value: 27.34 ± 0.03 mm

2nd gear (D)Specified value: 36.30 ± 0.03 mm


GE - 582

Replacing the conical spring washer

1. Lock the 1st gear, together with a square clamp,

in a vice, as shown in the figure.

2. Remove the conical spring washer and the sub

gear, removing the spring washer of the shaft.

Fitting

- During the fitting phase of the secondary shaft,

lubricate with engine oil and assemble each part.

1. Fit the needle bearing.

2. Apply engine oil onto the external peripheral

area of the roller bearing and fit the 2nd gear into

the secondary shaft.WARNING- NEVER EXPAND OPENING A OF THE BEARING WITH AVALUE EXCEEDING THE SECONDARY SHAFT DIAMETER+ 5 MM, UPON FITTING AND 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.

4. Fit the synchronisation ring No. 3 on the syn-

chroniser No. 1.

5. Fit the synchronised movement key and the

synchronised gear elastic key in the synchroniser

hub assembly No. 1.N.B.- THE EXTERNAL APPEARANCE OF THE SYNCHRONISA-TION RING No. 3 FOR THE 2nd GEAR B IS DIFFERENTFROM THAT ONE OF THE SYNCHRONISATION RING No.2 (FOR THE 1st GEAR A), AS IT IS SHOWN IN THE FIGUREON THE RIGHT.N.B.- MAKE SURE THAT THE KEY OPENINGS ARE FITTEDDISPLACED ONE FROM THE OTHER.- WHEN FITTING THE HUB AND THE HUB SLEEVE, MAKESURE TO ALIGN SECTIONS OF THE THREE TEETH MISS-ING.


GE - 583

6. Before pressing on the synchroniser hub as-

sembly No. 1, make sure that the hub protruding

part A is facing to the front (the hub sleeve has a

groove of the gear control fork).

7. Apply engine oil onto the conical section of the

2nd gear.

8. Apply engine oil onto the grooved section.

9. Align the grooved section. Slightly press the hub

assembly of synchroniser No. 2.N.B.- WHILE SLIGHTLY PRESSING ON THE SYNCHRONISERHUB ASSEMBLY No. 2 IN ORDER TO INSERT IT IN THESECONDARY SHAFT, MAKE SURE THAT THE MOVEMENTKEY FITTED ON THE HUB IS ALIGNED WITH THE GROOVEPROVIDED BY THE SAME KEY, WHICH IS PLACED ONTHE 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 spring washer. Then, fit

the spring washer (selected in this

way) in the secondary shaft fitting

groove.

• Measure clearance, using a thickness

gauge, as shown in the figure.

• Select a shaft spring washer, having

clearance near zero or zero and which

can be identified easily, as indicated

below. Then, proceed to fit it.

• Make sure that clearance complies

with the specified values.







GE - 584






11. Fit the needle bearing. Apply engine oil onto

the external ring of this bearing.

12. Place the synchronisation key No. 2 (the ring

with teeth missing).

13. Fit the 1st gear with the sub-gear fitted.

14. Fit the thrust washer of the 1st gear.WARNING- MAKE USE THAT THE PROTRUDING PART A OF THETHRUST WASHER OF THE 1st GEAR IS FACING TO THEFRONT.

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 selection procedure of a new

shaft spring washer, refer to the proce-

dure described above.

• Make sure that clearance complies

with the specified values.










GE - 585



Secondary shaft - inspection before removal

1. Measure the length of the contact section of the

hub assembly of synchroniser No. 1 (B) and of the

first and second gear control fork (A)

Characteristic(A)Specification value: 10 -0.1 mm -0.3 mm

(A)Admissible limit: 9.6 mm

(B)Specification value: 10 +0.12 mm +0.05 mm

(B)Admissible limit: 10.2 mm

2. Measure and adjust the axial clearance of the 1st gear (C) and of the 2nd gear (D), as shown in the

figure.

- BEFORE STARTING REMOVAL, MAKE SURE OF MEASURING THE AXIAL CLEARANCE ATDIFFERENT POINTS.- IF THE AXIAL CLEARANCE MEASURED EXCEEDS THE SPECIFIED VALUE IN THE TABLEBELOW, REMOVE THE SECONDARY SHAFT.

Characteristic1st gear (C)

Specified value: 0.10 - 0.52 mm

2nd gear (D)

Specified value: 0.10 ± 0.40 mm

Inspection - 2

1. Measure the height of the conical spring washer.

2. Place the new conical spring washer 1, the sub-

gear on the 1st gear.

3. Make sure that the convex side of the conical

spring washer is facing towards the sub-gear, as


CharacteristicSpecification value:2.01 mm

Admissible limit:


GE - 586

1.04 mm

4. Fit the new shaft circlip, pressing on the conical

spring washer, by means of the square clamp.

5. Following the same procedure described above,

replace the conical spring washer of the 2nd sub-

gear.

6. Make sure that the conical spring washer con-

vex side of gear No. 2 (1) is facing towards the sub-

gear side, as shown in the figure.

Fitting

Installation

Initial operations

1. For a simpler fitting of the shaft assemblies in-

side the gearbox, align the teeth 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 ASSEMBLYAND THE INPUT SHAFT ASSEMBLY INSIDE THE GEAR-BOX, MAKE SURE THAT EACH GEAR IS IN NEUTRALPOSITION.

2. While the input and the secondary shaft assem-

blies are held with both hands, fit them inside the

clutch housing.

3. Tighten the plate locking the input shaft bearing

with the three bolts.

4. Place the two pieces of the plates locking the

gear, from the clutch housing part.N.B.- PAY ATTENTION NOT TO DAMAGE THE S TYPE OILSEAL, WHILE THE SHAFTS ARE FITTED.


GE - 587

Locking torques (N*m)Rear bearing lock - Gearbox 15÷22

5. Attach the tension spring to the plate locking the

input shaft bearing.

6. Tighten the reverse gear control lever with three

bolts.

Locking torques (N*m)Reverse lever - Gearbox 15÷22

Checking that the reverse gear control lever

moves freely

1.Checking that the reverse gear control lever

moves freely

• Lift the reverse gear control lever pin

with the fingers.

• Make sure that the reverse gear control

lever pin falls freely due to its weight,

when 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 LOCKINGPIN, WHICH PREVENTS THE TRANSMISSION GEARSHAFT ROTATION FROM THE CLUTCH HOUSING SEC-TION TO THE GROOVED SECTION.- MAKE SURE THAT THE CHAMFERED SIDE OF THEGEAR AND THE THRUST WASHER (NYLON) IS FACINGUPWARDS (OR THE REAR SIDE).

3. The following three shafts of the gear control

fork, are different from each other by length, as

shown in the figure on the right. +

GEAR FORK SHAFTS

Shaft No.. 1: 1st and 2nd - total length: 224.00 mm

Shaft No.. 2: 3rd and 4th - total length: 259.00 mm

Shaft No.. 3: 5th and reverse gear - total length:

265.00 mm


GE - 588

N.B.- PAY ATTENTION NOT TO MAKE MISTAKES DURING FIT-TING OF THESE THREE SHAFTS.

4. The gear control fork and the heads of the gear

are different by their external image, as it is shown

in the figure. Therefore, pay attention not to make

any mistakes while fitting this fork and this gear

head.

Fork No. 1: 1st and 2nd

Fork No. 2: 3rd and 4th

Fork No. 3: 5th and reverse gear- IT IS ADVISABLE TO MAKE A TEMPORARY FITTING(FROM BENCH) OF THE GEAR CONTROL FORK AND REL-EVANT HEADS, THEN CHECK THAT THE COUPLING ANDFITTING DIRECTION ARE CORRECT. THEN PROCEEDWITH THE FITTING.

Fitting the gear control 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

all the gear control forks and heads, so that the

shaft can be easily guided.

2. Fit the gear control fork of the third and the fourth

gear on the hub sleeve and insert the shaft of this

fork.- MAKE SURE THAT THE GEAR IS IN NEUTRAL POSITION.- IN ORDER TO INSERT A SPRING GROOVED PIN WITH-OUT JAMMING, IT IS ADVISABLE TO PREPARE A GUIDEPIN WITH A 4.0 MM OUTSIDE DIAMETER AND A 50.00 MMLENGTH.- CARRY OUT FITTING OPERATIONS AFTER CHECKINGTHE CORRECT FITTING POSITION OF THE GEAR CON-TROL FORK AND HEAD AND THE RELEVANT PROPERPOSITION REGARDING THE GEARS


GE - 589

3. Insert a guide pin, or anything equivalent, at the

rear part of the control fork groove, as a fitting

guide for the spring grooved pin.

4. Fit a new spring grooved pin.

5. Following the steps of points 2 and 3, insert the

head of the third and the fourth gear.

6. Fit the gear control fork of the first and the sec-

ond gear in the hub sleeve and insert the fork shaft

of the first and the second gear.

7. As regards fitting the control fork of the first and

the second gear and the relevant head, refer to the

operations described above.

8. Insert the head of the fifth 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 spring to the reverse gear

control lever.

11. Fit the three balls and relevant compression

springs and tighten the three bolts, after interpos-

ing a new gasket.

12. Fit the primary shaft with the synchronisation

ring and the needle bearing.

Locking torques (N*m)Gear control fork shaft screw - Clutch hous-ing 19÷30

Final operations

1. Clean the contact surface between the clutch

housing and the gearbox, using solvent or a similar

product.- MAKE SURE THAT THE OIL RECEPTION DUCT IS PROP-ERLY FITTED (LOCKED MECHANICALLY) INSIDE THEGEARBOX.


GE - 590

2. Apply the following liquid sealant onto the gear-

box surface, as shown in the figure.

3. Fit the gearbox quickly.

4. Tighten the ten bolts between the gearbox and

the clutch housing.

Recommended productsThree Bond® 1216 Specific sealant.

CharacteristicNozzle inside diameter:0.9 mm

Locking torques (N*m)Gearbox cover - Gearbox 15 ÷ 22

5. After interposing the new gasket, tighten hex-

agonal bolt (A) of the transmission gear shaft of

the reverse gear.

6. Lock the rear bearing stop 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 screw - Gear-box 19 ÷ 31 Rear bearing lock for gearbox 15 ÷ 22Nm

9. Clean the contact surface between the gearbox

and gear cover, using solvent or a similar product.

10. Apply the following liquid sealant onto the re-

bound housing surface, as shown in the figure.- MAKE SURE THAT THE OIL SUCTION PIPE IS FITTED(LOCKED) FIRMLY INSIDE THE GEAR COVER

Recommended productsThree Bond® 1216 Specific sealant.

CharacteristicNozzle inside diameter:0.9 mm


GE - 591

11. Fit the gear cover with the engine rear fitting

bracket quickly. Then, lock it with the eight bolts.

12. Fit the rpm indicator gear assembly.

13. Tighten the plate locking the rpm indicator gear

with the bolt.

14. Fit the clutch components.

Locking torques (N*m)Engine fitting rear bracket for gearbox cover 29÷ 44 Nm Rpm indicator locking plate - Gearboxcover 7 ÷ 10

15. Fit the reverse gear limit cam (A) and the gear-

shift lever (B) as shown in the figure.- MAKE SURE THAT THE LIMIT CAM OF THE REVERSEGEAR IS FITTED PROPERLY. FAILURE TO OBSERVE THISWARNING CAN CAUSE THE REVERSE GEAR DISEN-GAGEMENT.

16. Fit the gear lever sleeve and the gearshift 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 A OFTHE SLEEVE, IS FACING DOWNWARDS.N.B.- MAKE SURE THAT THE GUIDE BOLT «C» IS PLACED ASSHOWN IN THE FIGURE.

Locking torques (N*m)gear selection lever 15 - 22 Nm

18. Fit the ball and the compression spring, and

tighten the reverse gear limit pin locking «B» with

a new gasket by interposing it.

19. Make sure that the selection lever and the

gears move without jamming.

Locking torques (N*m)Reverse limiting pin lock - Gearbox 29 ÷ 49

Fitting the gear assembly on the vehicle

1. While holding the gearbox assembly with a suitable jack, or anything equivalent, fit it to the vehicle

and tighten the connection bolts.


GE - 592

2. Tighten the rear support bracket of the engine to the chassis by means of bolts.

3. Tighten the clutch housing with bolts.

- THE SAME INSTRUCTIONS APPLICABLE TO GEAR INSTALLATION (FITTING) ARE VALID TOFIT THE GEAR ASSEMBLY ON THE VEHICLE. ONLY FEW POINTS HAVE BEEN MODIFIED RE-GARDING THE PREVIOUS PROCEDURE. THEREFORE, ONLY THE MAIN POINTS OF THE PRO-CEDURE ARE INDICATED BELOW.

Locking torques (N*m)Direct connection bolt - Transmission 49÷69 Rear engine support bracket - Chassis 49 ÷ 69Clutch lower cover - Gearbox 4÷7

4. Connect the transmission flange with the differ-

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 becomes as

small as possible).

5. Tighten the four bolts of the propeller shaft.

6. Remove the filler cap with its gasket.

7. Fill with new gearbox oil. (Reference informa-

tion)

8. Fit a new gasket and then tighten the filler cap.

(Quantity of gearbox oil required until it starts to

overflow from the filler cap).

Recommended productsAGIP ROTRA MP 80W-90 Transmission oilSAE 80W-90, API GL-5

CharacteristicGearbox oil capacity:1.0 ± 1.1 l

Locking torques (N*m)Propeller shaft - Rear differential flange 39÷54Gearbox cover for filler cap 30 ÷ 49


GE - 593

INDEX OF TOPICS

DIFFERENTIAL DI

Differential

This section of the manual provides information to check differential correct operation.

Vista in sezione

Main removal operations

(1) Position the axle on the bench.

2) Remove the half-shafts.

(3) Remove the differential cover and the differential housing.

(4) Remove the flange, 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 nut according to preloading.

P = 1.03 -1.42 Mm - measured with the special tool

(3) Caulk the nut.

(4) Refit the differential housing and the relevant cover.

(5) Refit the half-shafts.

- THIS OPERATION INCLUDES REMOVING THE HALF-SHAFTS AND REPLACING THE SPACER.

PORTER 1.3 16V Differential

DI - 595

Differential removal

Removal

Remove the parts in numerical order, as shown in the 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




Differential PORTER 1.3 16V

DI - 596

18.Spacer

19. Differential housing


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

Operations before removal

Position the differential assembly, removed from

the vehicle, on the appropriate work bench.

Specific tooling020180y Engine support

020286y Adaptor for attachment to the enginesupport

Mark the bearing cap and the differential support,

on the right and left side, respectively.MARK THEM USING A PUNCH, TO GUARANTEE A COR-RECT REFITTING


DI - 597

Inspections before removal

Check the following values:

1. Crown gear clearance

CharacteristicSpecified value:0.10 - 0.20 mm

2. Crown gear eccentricity

CharacteristicLimit allowed0.10 mm

3. Pinion bearing preloading

Measured value with the special tool fitted on the

flange tongue with the oil gasket fitted in its seat

Specific tooling020335y Magnetic support for dial gauge

CharacteristicSpecified value:0.1 ÷ 0.2 mm

Main removal operations

1. Remove the hexagon nut, with the following

special tool:- BEFORE UNDOING THE NUT, UNCAULK IT.

Specific tooling020212y Flange locking tool


DI - 598

2. Remove the oil seal, with the following special

tool:

Specific tooling020211y Flange oil seal extractor

3. Remove the bearing, with the following special

tool:- BE EXTREMELY CAREFUL WITH THE PINION WHICH, ATTHE MOMENT OF BEING DETACHED FROM THE BEAR-ING, IT CAN JUMP OUT FROM THE SEAT.

Specific tooling020206y Bearing extractor

4. Remove the external track of the bearing with

the following special tool:

Specific tooling020188y Axial hub support and driving piniontool series - Front axle bearing and differentialpinion replacement kit

5. Remove the bearing, with the following special

tool:

Specific tooling020213Y Bearing extractor

6. Mark parts before removing them from the

crown gear. Mark the crown gear and the differ-

ential housing.


DI - 599

Smontaggio

Inspection

Check each section of the following parts, searching for possible damage, wear or excessive clearance.

Replace all the defective parts.

Control pinion and crown gear

1. Gear teeth

2. Pinion grooved section

3. Bearing seat

Side pinion gear and pinion

1. Gear teeth

2. Side pinion gear hub 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 side pinion gear hub (pin-

ion and crown)

2. Pinion contact section

3. Crown gear attachment section

4. Coupling section, bearing side


Bearings

1. Front bearing

2. Rear bearing

3. Side bearing

Make sure that bearings turn freely without jam-

ming or noise.


DI - 600

Differential housing

1. Bearing coupling sections

2. Coupling sections of the bearing rolling external

seat

3. Gasket seat

4. Coupling surface


Coupling flange

1. Oil seal contact section

2. Grooved section

Montaggio

Fitting

Fit the parts in numerical order, as shown in the figure.

Key

1. Screw

2. Cover

3. Screw


DI - 601

4. Support

5. Spacer


7. Nut

8. Washer

9.Pinion connection flange

10. Oil seal


12. Spacer

13. Spacer

14. Pinion




18.Spacer



21. Screw

22. Crown gear

23. Bevel gear pair support

24. Pin


26. Crown wheels

27. Side pinions

28. Spacer

29. Spacer

30. Plate

31. Gasket

32. Cap

Adjustment procedure

1. Adjusting control pinion protrusion

2. Measuring control pinion bearing preloading

CharacteristicSpecified value:102.5 - 141.7 Nm

(When the oil seal is fitted)

3. Differential housing assembly


DI - 602


102.5 - 141.7 Nm

4. Adjusting crown gear clearance and differential clearance in axial direction


0.1 ÷ 0.2 mm

5. Checking and adjusting the coupling area between the crown gear and the control pinion

6.Checking operations described at points 4 and 5 above

Adjusting control pinion protrusion

1 Fit the following parts, with the following special

tool.

2 Fit the bearing internal rolling fifth wheel in the

differential support.


3 To determine the size of the shim washer to be

interposed between the pinion and the bearing,

position two opposed flanges, as shown in the fig-

ure. Tighten bolt (5) so that bearings can turn

freely.

4 Position the bearing supports on the differential

unit and tighten the bolts two by two.

5 Measure diameter (d) of the bearing seats.

6 Position pin (7) between the bearing seats and

measure size (Y) with a gauge.- BE CAREFUL NOT TO TIGHTEN EXCESSIVELY.

Specific tooling020284y Tool to adjust pinion position


DI - 603

7. Determine the shim washer value with the fol-

lowing formula:

B=Y-3

8. The value of the shim washer to be fitted is ob-

tained calculating the difference of estimated size

B and the size indicated on the pinion head.

Key

1. Size

2. Number of teeth

9 Select the shim washer calculated among all the

available values and fit it by pressure on the pinion

shaft, with the following special tool.

10 Position the shim washer on the control pinion

with the tapered part facing towards the teeth. Fit

the rear bearing by pressure in its seat, with the

following special tool:


Key

1. Shim washer

AVAILABLE SHIM WASHERSSpecification Desc./QuantityP/N 132001 Shim washer: 2.50 mmP/N 132002 Shim washer: 2.60 mmP/N 132003 Shim washer: 2.70 mmP/N 132004 Shim washer: 2.80 mmP/N 132005 Shim washer: 2.90 mmP/N 132006 Shim washer: 3.00 mmP/N 132007 Shim washer: 3.10 mmP/N 132008 Shim washer: 3.20 mmP/N 132009 Shim washer: 3.30 mmP/N 132010 Shim washer: 3.40 mm


DI - 604

Bearing preloading measurement

1. Fit a new spacer 1 on the pinion.

2. Fit the pinion in the relevant seat on the differ-

ential support.

3. Fit the front bearing, the oil seal, the flange, the

gasket and the flat washer.

4. Tighten the nut to obtain the pre-set preloading

value.- APPLY OIL ONTO THE NUT AND TO THE THREADEDPART OF THE CONTROL PINION.- UPON FITTING, TURN THE PINION IN BOTH DIRECTIONSMANY 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 - 14.2 N.

CharacteristicSpecification preloading:1.03 -1.42 Nm

Differential housing fitting

1. Fit the differential housing by following the pro-

cedure indicated below.

Key

1. Differential and side pinion gear

2. Differential and crown wheel


4. Pin

2. When the differential housing is completely assembled, fit the parts listed below:


DI - 605

Crown gear- CLEAN THE COUPLING SURFACES OF THE CROWNGEAR AND HOUSING.MAKE SURE THAT MARKS PUNCHED, IN THE REMOVALSEAT, ARE ALIGNED.

Adjusting crown gear clearance and bearing

preloading

1. Fit the differential housing in the support, posi-

tioning the external fifth wheels of the bearings in

the relevant seats.

2. Position shim washers 1 in the relevant seats,

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-

sponding ones located on the differential support.

4. Check clearance between the pinion and the

crown gear, replace the shim washers so as to ob-

tain a 1.0 mm clearance.

5. Remove the shim washer on the opposed side

of the crown gear and, fit a shim washer with an

oversized value (incremental step of 0.1 mm.) with

an appropriate tool.


DI - 606

6. Remove the tool, refit covers and check clear-

ance between the pinion and the crown gear: 0.1

- 0.2 mm.

7. At the end, tighten the bolts two by two to the

prescribed torque.

Locking torques (N*m)Differential bearing support for propellershaft 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-

viously measured.

The force to exceed the total preloading must be:

(P + 1.6) - (P + 2.4) N

Section view: shim washer position

Key

1. Adjustment shim washer for crown pinion clearance


DI - 607

2. Cover

3. Protection

Checking and adjusting the teeth contact sur-

face between the crown gear and the pinion

1. Apply minium onto both sides of the gear teeth.

Turn the flange to check the teeth contact surface

between the crown gear and the pinion.

NOTE

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/Side contact

Select a flat washer with such a thickness so as to

draw the pinion closer to the crown gear.

Rear contact/Front contact

2. Caulk the nut after checking preloadings and the

pinion-crown gear contact surfaces.


DI - 608

Cover refitting

1. Apply the specified gaskets onto the cover.

2. Refit the cover on the differential housing.

3. Fill the differential with the following oil:

Recommended productsAGIP ROTRA LSX 75W-90 DifferentialSAE 75W-90, API GL-5

CharacteristicCapacity1.1 l

Locking torques (N*m)Rear axle differential cover 6.5 - 10.5 Nm


DI - 609

INDEX OF TOPICS

BRAKING SYSTEM BS

Brake

Brake pedal

Brake pipe

Perform the following checks:

1. Hoses and pipes: damage, wear, cracks

2. Hoses: deformation or swelling

3. Pipes: corrosion or swelling

4. Connections: fluid leaks

5. Pipe clamps: tightening

6. Hoses: excessive bending, twisting or traction

KEY:

1. Cracking

2. Wear

3. Twisting

4. Swelling

Empty travel

Stop the engine 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.

CharacteristicPedal clearance A:2 ÷ 7 mm

Position wedges under the wheels. Place the gear

in neutral. With the engine at idle speed, releasing

the handbrake lever, push the brake pedal with a

force equal to 490 N (50 kgf). Measure distance

B between the point in which the pedal stops and

the bodywork bottom.

CharacteristicTravel B:beyond 85 mm

PORTER 1.3 16V Braking system

BS - 611

Removal

Brake pedal

Removal

Remove the parts, following the numerical 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. Replace those defective parts.

Braking system PORTER 1.3 16V

BS - 612

KEY:

1. Bending and twisting

2. Wear

3. Wear

4. Flattening

5. Wear

Installation

Installation

Fit the parts, following the numerical order illustrated.


BS - 613

KEY:

1. Bushing

2. Bushing

3. Spring

4. Brake control pedal

5. Pedal pin

6. Bracket

7. Screw

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 specified value and that the tail light

works properly.


BS - 614

Pedal height adjustment

1. Remove the fixing pin of the push rod.

2. Disconnect the stop light switch connector.

Loosen the nut 1 and insert the switch so as to

adjust the pedal height according to the specifica-

tion. Then tighten the nut 1.

3. Loosen the nut 2 and align the u-bolt with the

pin hole. Fit the pin.

4. Adjust the pedal travel and tighten the nut 2.

5. Once adjustment is finished, make sure that the

rear stop light works properly.

Adjusting the reserve travel 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 the front panel.

SPECIFIED VALUE: NOT LESS THAN 85 MM

SPECIFIED VALUESSpecification Desc./Quantity

Pedal height in mm 132 - 142Pedal travel in mm 2 - 7

Pedal reserve travel Not less than 85 mm [When the force applied on the pedal is30 kg]

Brake fluid reservoir

Removal

Removal

Remove the parts, following the numerical order

illustrated.FIT AND REMOVE THE MAIN RESERVOIR/CYLINDER AS-SEMBLY FROM THE INSTRUMENT PANEL LOWER SIDE.


BS - 615

KEY:

1. Instrument panel with brake fluid level warning light

2. Heating gate No.1

3. Heating duct No.4

4. Pipe clamp

5. Pipe clamp

6. 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

Installation

Installation

Fit the parts, following the numerical order shown in the figure.


BS - 616

KEY:

1. Brake fluid reservoir float

2. Spacer

3. Reservoir diaphragm

4. Reservoir cap

5. Pipe No.2 of the reservoir

6. Hose

7. Reservoir pipe

8. Pipe 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 REMOVE THE MAIN RESERVOIR/CYLINDER ASSEMBLY FROM THE INSTRUMENTPANEL LOWER SIDE.

servofreno

Removal


BS - 617


KEY:

1. Cotter pin

2. Pin

3. Nut

4. Screw

5. Bracket

6. Pipe clamp

7. Brake pipe fitting nut

8. Screw

9. Screw

10. Brake pump assembly with power brake

11. Nut

12. Main 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 times,

applying force necessary during regular braking. If during the second or third time the brake is pushed,

its position lifts gradually, it means that the power brake works properly.


BS - 618

THE INTERVALS BETWEEN THE FIRST AND SECOND TIME THE PEDAL IS PUSHED AS THESECOND AND THIRD TIME MUST BE OF FIVE SECONDS.

Power brake operation check

With the engine stopped, push the brake pedal for several times, applying the same force each time it

is pushed. Make sure the brake pedal height does not change each time it is pushed. Start the engine

while pushing the brake pedal, the power brake works properly if the brake pedal is slightly moved.

Checking the power brake hermetic seal with loaded vehicle

With the engine on, push the brake pedal. By pushing and holding down the pedal, shut off the engine.

The power brake works properly if the brake pedal height does not vary, for at least 30 seconds.

Power brake simple check

1. Power brake hermetic seal check. After shutting off the engine, push the brake pedal for several

times. The second, third time the pedal is pushed, the brake pedal position must be higher with respect

to the original position.

2. Power brake operation. Start the engine pushing the brake pedal. Slightly move the pedal during

the engine start-up.

3. Checking the power 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 by using a multimeter

4. Power brake multimeter connection.

5. Checking the power brake hermetic seal after the engine is off, vacuum must not vary during 15

seconds.

6. Power brake hermetic seal check. With the vehicle unloaded after the engine is off, the vacuum

drop must remain within 3.3 kPa, during 15 seconds.

7. Power brake operation failure.

• A hydraulic pressure of 3.13 Mpa corresponds to 10 Kg of force applied to the pedal;


8. Power brake operation





Power brake multimeter connection

Connect the power brake multimeter as indicated in the figure. Release air from the power brake mul-

timeter. Then perform the checks indicated below.


BS - 619

KEY:

1. Gauge to measure force applied to the pedal

2. Low pressure gauge

3. Pressure gauge

4. Vacuum pump connection hose

Power brake hermetic seal check

Start the engine. Shut the engine off when the low pressure gauge indicates approx. 500 mmHg. Then,

check the power brake air sealing.

Checking the power brake hermetic seal with loaded/unloaded vehicle

With the engine on, push the brake pedal applying 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 low pressure gauge to zero. Under these conditions, check the ratio between

the force applied on the pedal and hydraulic pressure.

Power brake operation check

With the engine on, set the value of the low pressure gauge to approx. 500 mmHg. In this position, push

the brake pedal. Then, check the ratio between the force applied on the pedal and hydraulic pressure.


BS - 620

Brake system

Filling with brake fluidIF THE BRAKE FLUID COMES INTO CONTACT WITH THEPAINTED SURFACES OF THE VEHICLE, DRY IT IMMEDI-ATELY. THEN WASH THE AREA USING UNLEADED PET-ROL OR A SIMILAR PRODUCT.

KEY:

A = closed

Connection of the plastic pipe to the wheel cyl-

inder bleeding cap

Immerse one plastic pipe end in a brake fluid con-

tainer. Connect the other pipe end to 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 fitted with LSPV (pressure regulator)

follow the points indicated below:

• Two individuals are required for this

operation. Make sure that the brake

fluid reservoir is always full.

• While the first individual loosens the

bleeding cap 1/3 - 1/2 of a turn at a

time, the second individual slightly

pushes the pedal one time and keeps

it pressed.


BS - 621

• Then the first individual locks the

bleeding cap and the second one re-

leases the brake pedal.

• Repeat the operations described in

previous points until there are no more

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, following the numerical order shown in the figure below.

KEY:

1. Screw

2. Disc brake calliper unit

3. Clip

4. Pad pin

5. Pad unit and thickness


BS - 622

Verifica

- Check that the brake disc is not damaged, that

there are no signs of wear, scores and irregular

wear.

CharacteristicSpecified thickness:16.0 mm

Admissible limit:15.0 mm

- Check that the brake disc pad is not damaged or

excessively worn.

CharacteristicSpecified thickness:9 mm

Admissible limit:1 mm

Installation

Installation



BS - 623

KEY:


2. Pad pin

3. Clip


5. Screw


Locking torques (N*m)Disc brake calliper assembly for disc brake dust guard 49 ÷ 59N.B.UPON THE BRAKE CALLIPER FITTING, BE CAREFUL NOTTO PINCH THE PROTECTION COVER OF PISTON A.

Front disc brake

Removal


KEY:

1. Screw

2. Brake calliper unit

3. Cotter pin

4. Castle nut

5. Washer

6. Hub unit and disc

7. Disc brake dust guard


BS - 624

1. Disconnect the hose.

2. Remove the castle nut with the special tool A.

Specific tooling020221y Brake drum stop device

3. Remove the hub and the disc, with the special

tool B.

Specific tooling020222y Front hub and drum extractor

Front disc brake calliper

Removal

Removal



BS - 625

KEY:

1. Spring

2. Pad pin


4. Retention ring

5 Piston

6. Piston cover

7. Piston sealing ring

8. Main 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.DURING THIS OPERATION BE CAREFUL THAT THE PIS-TON DOES NOT COME OUT OF THE SEAT.


BS - 626

InspectionCheck the pads and brake discs. Always replace

parts indicated with *.

PAD THICKNESS AND IRREGULARWEAR:

Specification Desc./QuantitySpecified thickness: 9 mm

Limit: 1 mm

DISC THICKNESS AND IRREGULARWEAR:

Specification Desc./QuantitySpecified thickness: 16 mm

Limit: 5 mm

Refitting

Assembly

Assemble the parts, following the numerical order illustrated.

KEY:

1. Bushing

2. Pin cover


BS - 627

3. Secondary bushing

4. Main bushing

5. Piston sealing ring

6. Piston cover

7 Piston

8. Retention ring


10. Pad pin

11. Spring


Installation

Installation


KEY:


2. Hub unit and disc

3. Washer

4. Castle nut

5. Cotter pin



BS - 628

7. Screw

* non-reusable parts

Operation following installation

1. Disc eccentricity check

• Before checking the disc eccentricity,

make sure that the front wheel bear-

ings are not loose.

• Measure the disc eccentricity from the

outside edge.

CharacteristicLimit:0.15 mm (to 10 mm towards the inside, from the

disc external perimeter).

2. If the disc eccentricity exceeds the limit replace it.

Adjust the brake pedal height.

Rear brake

Removal

KEY:


BS - 629

1. Brake drum

2. Shoe retaining spring

3. Shoe fixing pin

4. Spring

5. Spring

6. Spring

7. Rear brake shoe No. 1

8. Seeger ring

9. Automatic adjustment lever

10. Parking brake shoe strut

11. Seeger ring

12. Washer

13. Automatic adjustment latch

14. Torsion spring

15. Automatic adjustment lever pin

16. Parking brake cable unit


18. Seeger ring

19. Parking brake shoe lever

20. Rear wheel brake cylinder unit

21. Screw

22. Shoe holding plate

23. Wheel cylinder protection cover

24. Wheel brake cylinder piston

25. Cylinder cap

26. Spring

27. Bleeding plug

Inspection

Check the parts, following the numerical order il-

lustrated.

1. Damage and deformation of the shoe.

2. Wear of friction material.


BS - 630

WEAR OF FRICTION MATERIALSpecification Desc./Quantity

Friction material thickness: 4.0 mmMaximum limit allowed: 1.0

BRAKE DRUM WEARSpecification Desc./Quantity

Drum diameter: 200 mmMaximum 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. Thickness

B. Gasket

C. Diameter

D. Drum

Installation

Fit the parts, following the numerical order illustrated


BS - 631

KEY:

1. Bleeding plug

2. Spring

3. Cylinder cap

4. Wheel brake cylinder piston

5. Wheel cylinder protection cover

6. Shoe holding plate subassembly

7. Screw

8. Rear wheel brake cylinder unit

9. Parking brake shoe lever

10. Seeger ring



13. Automatic adjustment lever pin

14. Torsion spring

15. Automatic adjustment latch

16. Washer

17. Seeger ring

18. Parking brake shoe strut

19. Automatic adjustment lever

20. Seeger ring


BS - 632


22. Spring

23. Spring

24. Spring

25. Shoe fixing pin

26. Shoe retaining spring

27. Brake drum


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 AT THE INPUTSIDE IS DIFFERENT FROM THAT ONE ON THE OUTPUTSIDE


BS - 633

2. Apply the recommended product at the end of

the rear axle shaft seat as indicated in the figure

on the right. Then, fit the shoe holding plate on the

rear axle shaft.

Recommended productsThree Bond N.1212 silicone sealant-

KEY:

1. Section view of the silicon sealant

2. Sealant

3. Apply the piston ring onto the internal edge

3. Apply liquid sealant (recommended product)

onto the fitting area E of the wheel cylinder F on

the shoe holding plate, as indicated.

Recommended productsThree Bond 520 sealing compound-

4. Apply liquid sealant (recommended product)

onto the fitting area H of the shoe retaining pin G

on the shoe holding plate, as indicated.

Recommended productsThree Bond 520 sealing compound-

5. Brake adjustment procedure.

• Push the brake pedal four or five times (after bleeding the air).

• Make sure that the automatic adjustment mechanism works properly.

• Adjust the brake pedal height.

• Adjust the working travel of the parking brake lever.

Parking brake lever


BS - 634

Removal


KEY:

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 numerical order shown in the figure below.


BS - 635

KEY:


2. Screw


4. Screw

5. Nut

6. Switch cable

7. Cover

8. Central tunnel

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 BECARRIED OUT WHEN THE CLEARANCE OF THE REARBRAKE SHOE COMPLIES WITH SPECIFICATIONS.


BS - 636

Handbrake

Reserve travel

Apply 196 N (20 kgf) of force, slowly pull the hand-

brake lever upwards and count the notches.

CharacteristicNumber of notches:6 ÷ 10

Parking brake cable

Removal

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 (Pickup)


KEY:

1. Parking brake cable right guide

2. Parking brake cable left guide


BS - 637

3. Clip

4. Clip

5. Clip



8. Clip

9. Nut


11. Nut

12. Clip

13. Parking brake with brake control cable unit

Operation 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.

• Remove the spare wheel support and

the thermal insulator C to protect the

muffler B.

Removal (Van)



BS - 638

KEY:



3. Clip

4. Clip

5. Clip

6. Clip



9. Clip

10. Nut

11. Parking brake lever

12. Nut

13. Clip

14. Parking brake with control cable

Installation

Fitting (pickup model)



BS - 639

KEY:

1. Parking brake with brake control cable unit

2. Clip

3. Nut


5. Nut

6. Clip



9. Clip

10. Clip

11. Clip

12. Clip


14. Parking brake cable right guide

Fitting (pickup model)

Fit the parts, following the numerical order shown in the figure below.


BS - 640

KEY:

1. Parking brake control cable

2. Clip

3. Nut

4. Parking brake lever

5. Nut

6. Clip



9. Clip

10. Clip

11. Clip



Operation after fitting (pickup)

• Adjust the rear brake;

• Adjust the parking brake.

Brake controller lspv

LSPV (brake calibrator)


BS - 641

The LSPV (pressure regulator/ brake calibrator) regulates the hydraulic pressure of the proportional

valve 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 rear main cylinder

Pr = hydraulic pressure of the rear wheel cylinder


BS - 642

Description

KEY:

1. Sealing ring

2. O-ring

3. Cover

4. Cap

5. Retainer

6. Spring

7 Piston

8. Sealing metal gasket

9. O-ring

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 = Small diameter section of the piston

A3 = Small diameter section of the piston


BS - 643

Performance diagram

KEY:

PM = Main cylinder hydraulic pressure

PR = Rear brake hydraulic pressure

W = When the front brake does not work

K = When the SPG sensor is broken

1. PM < PF

The main cylinder pressure PM starts to increase. At this stage, however, there is still clearance between

the main section of the piston A2, and the sealing metal gasket. Therefore, the pressure of the main

cylinder PM is transmitted to 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 balancing. Consequently, the piston comes

into contact with the metal gasket.

PM x A1 = F + S

3. PM > PC

If the main cylinder pressure PM increases beyond the PT pressure, the metal gasket is open and

closed. Consequently, the rear brake pressure increases according to the ratio of the piston sectional

area.

1-[A1 /(A2-A3)]

Pr = Pm [1-(A1 /(A2-A3))] + (S+F)/(A2-A3)

4. When the front brake does not work:


BS - 644

Since no pressure is applied to the intermediate diameter section of piston A3, all force applied to the

piston, that is PM (A3 - A1), F and S, acts so that the piston is thrust into the body . Therefore, a clearance

between the large diameter section of piston A2 and the metal gasket remains. Consequently, the

pressure of the main cylinder PM is transmitted to the rear brake.

PM = PR

5. When no more reaction force F is generated towards the piston:

If the spring or the connection system were broken, the braking system works as valve P.

Inspection2

Inspection

1. Preliminary arrangements before the inspection

• Park the vehicle on a flat surface and pull the parking brake.

• Place weights on the vehicle with an 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 return the vehicle to the

original position and pull the parking brake.

• Connect a gauge to the front calliper and to the left rear wheel cylinder respectively.

• Bleed the air of the gauges.

Check that the LSPV valve is not damaged.

2. Calculation to check front brake pressure:

Calculate pressure at the LSPV turning point according to the weight on the rear axle Wr (kg), with the

following formula:

PICKUPSpecification Desc./Quantity

Rear axle weight: [ 450 kg (MPa): Pc = 21.6 x 10-3 Wr - 6.7Rear axle weight: [ 450 kg (MPa): Pc = 71.6 x 10-3 Wr - 0.21

VANSpecification Desc./Quantity

Rear axle weight: [ 463 kg (MPa): Pc = 9.95 x 10-3 Wr - 2.57Rear axle weight: [ 463 kg (MPa): Pc = 20.2 x 10-3 Wr - 6.7


BS - 645

The value set for checking PF pressure of the front brake must be a higher value than that one obtained

with the following formula: Pressure at the LSPV turning point: Pc + 4.9 MPa.

3. Pressure measurement

Push the brake pedal, so that the front brake pressure can reach the value set in the phase "Calculation

to check front brake pressure". At this stage, read the rear brake pressure.N.B.

• IF DURING THE TEST, ONCE THE FRONT BRAKE PRESSURE IS SET, PRESSURE ISINTERRUPTED ON THE PEDAL, OR THE PEDAL IS RELEASED DURING THE LOWER-ING TRAVEL, REMOVE THE FOOT FROM THE PEDAL COMPLETELY. THEN REPEATTHE OPERATION.

• SET THE REAR BRAKE PRESSURE VALUE ABOUT TWO SECONDS AFTER THEFRONT BRAKE PRESSURE IS SET.

4. Pressure test

1. Calculate the reference pressure PR of the rear brake, according to the pressure (PC) at the LSPV

turning point and the checking hydraulic pressure PF 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 - 0.19

Value allowed for the smaller side (KPa) : Y= 1.60 x 10-3 - 0.14

3. Determine the rear brake reference pressure according to phases 1 and 2. The rear brake hydraulic

reference pressure must be between (PR + y) and (PR + x).

4. The rear brake pressure measured at step 3 is satisfactory if its value matches the one calculated

above phase. Otherwise, adjust the LSPV.

5. Reference

With a person sitting in the vehicle, place a weight to load the rear axle as it is described:

DO NOT EXCEED 10 KG OF DIFFERENCE BETWEEN RIGHT AND LEFT

CharacteristicRear axle weight for Pickup

400 ± 5 kg

Rear axle weight for Van

450 ± 5 kg

At this stage, push the brake pedal so that the front brake pressure can turn into 7.85 MPa.

Make sure that the rear brake pressure complies with specifications.

CharacteristicPickup

2.08 - 2.86 Mpa

Van

1.95 - 2.72 Mpa


BS - 646

Adjustment1. Measurement calculation of the LSVP connection end movement.

The rear brake pressure changes about 0.13 MPa when the LSVP connection end moves 1 mm up-

wards and downwards. Therefore, calculate the required movement measurement, using the following

formula:

CharacteristicPressure deviation in MPa (kqf/cm2) =(Measurement of 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 CONNECTION, MARK THENUT. NEVER SCRATCH OR PUNCH THE SURFACE OFTHE PART.

Locking torques (N*m)LSPV brake calibrator - Rear axle 10 ÷ 16

KEY:

A= the rear brake pressure increases

A= the rear brake pressure decreases

3. Check pressure again. Make sure that LSPV pressure is within the specified field.

Component


BS - 647

LSPV BRAKE CALIBRATOR:

1. Cotter pin

2. LSPV unit (pressure regulator)

3. Pin

4. 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 body.

2. Remove the valve control screw.


BS - 648

3. Remove 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.


BS - 649

4. Remove the following parts:

• Valve adjustment lever

• Washer

• Guide bushing

• Spring

• Spring 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 distortions

4. Flattening

5. Distortions and damage


BS - 650

Lspv assembly

1. Fit the new guide bushing, with the special tool.

Specific tooling020196Y 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 on the control lever

and fit the pin.


BS - 651

5. Fit the cotter pin

Installation

1. Fit the LSPV unit on chassis A.

Afterwards, connect the brake pipe B.

Tighten to the prescribed torque's.

Locking torques (N*m)LSPV brake calibrator - Bracket 15 ÷ 22 Brakecalibrator - Brake pipe 13 ÷ 18

2. Fix the LSPV articulation lever to the valve

bracket through a belt or other similar object.WHILE FIXING, MAKE SURE THAT THE PISTON ENDCOMES INTO CONTACT WITH THE ARTICULATION LEV-ER COMPLETELY.

Arrange the weight on the rear axle as in the table:

DO NOT EXCEED 10 KG OF DIFFERENCE BETWEEN RIGHT AND LEFT

CharacteristicRear axle weight for Pickup

363 ±5 Kg

Rear axle weight for Van

417±5 Kg


BS - 652

4. Slowly move the vehicle 1 meter forwards or

backwards. Pull the parking brake.

5. Fit the LSPV articulation end to the bracket, on

the axle side. Tighten the nut to the prescribed tor-

que.NEVER PUSH THE LSPV END UP AND DOWN WHEN IT ISASSEMBLED TO THE BRACKET, ON THE AXLE SIDE.

Locking torques (N*m)LSPV brake calibrator - Rear axle 10 ÷ 16

6. Remove the belt fixing the LSPV articulation lever.

7. Check pressure. If it does not comply with specifications, adjust it.


BS - 653

INDEX OF TOPICS

TRANSMISSION SHAFT TS

This section of the manual comprises information related to the transmission and to the operations

which can be carried out on it.

Components

KEY:

1. Propeller 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 detected,

replace the propeller shaft or the cross.

Noise check

Check that the propeller shaft is not noisy or dam-

aged.

PORTER 1.3 16V Transmission shaft

TS - 655

Removal

Removal

1. Lift the vehicle and hold it by means of safety

stands.

2. Remove the propeller shaft.- MARK REFERENCES ON THE FORK AND THE JOINTFLANGE.- 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 bearing seat, the sliding

shaft and the cap are not damaged.

CharacteristicBending limit:0.5 mm

Transmission shaft PORTER 1.3 16V

TS - 656

3. Check the flange fork and the sleeve fork.

• Check that contact surface A of the

flange coupled to the differential pinion

is not damaged.

• Check that the sliding surface B of the

oil seal is not damaged or worn.

• Check that the grooved section C is not

damaged or worn.

• Fit the sleeve fork on the propeller shaft

sliding grooved section. Check there 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 no clearance on the

cross in the axial direction E.

• Check that there is no clearance on the

cross in the perpendicular direction D.

• Check that cross rotates regularly.

Installation

Installation

1. Apply oil for gears onto the internal side and on

the external side of the sleeve as indicated in the

figure.

PORTER 1.3 16V Transmission shaft

TS - 657

2. Insert the gear side propeller shaft.

3. Fit the propeller shaft aligning it with the refer-

ence mark A on the differential 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 abnormal noises.

Locking torques (N*m)Universal joint - Rear differential flange 39÷54

Transmission shaft PORTER 1.3 16V

TS - 658

INDEX OF TOPICS

STEERING COLUMN SC

Steering arm

Removal

Removal

Remove the parts following the numerical order.

KEY:

1. Nut

2. Elastic washer

3. Bolt

4. Steering arm

5. Bushing

To take out the bushing, use the following series

of special tools with a press, as indicated.

Specific tooling020196Y Clutch guiding tool

0.20228y Rear conical tool to replace the dif-ferential control pinion bearing

Installation

Installation

Fit the parts following the numerical order.

Steering column PORTER 1.3 16V

SC - 660

KEY:

1. Bushing

2. Steering arm

3. Bolt

4. Elastic washer

5. Nut


To fit the bushing, use the series of special tools with a press, as indicated.

Specific tooling020196Y Clutch guiding tool0.20228y Rear conical tool to replace the differential control pinion bearing

Universal joint arm

Components

KEY:

1. Control arm assembly on the stub axle

2. Cotter pin

3. Nut

4. Tie rods

5. Lock nut

6. Plain washer

PORTER 1.3 16V Steering column

SC - 661

7. Control arm on the stub axle

8. Dust guard

9. Gasket

10. Roller bearing

11. Bushing assembly


Removal/Disassembly

1. Turn the 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 end section, using the

following special tool.

Specific tooling020231Y Extractor for articulated heads


SC - 662

4. Remove the front suspension cross-member.

5. Take out the bushing assembly from the stub

axle control arm.

F: Bushing and washer

6. Take out the roller bearing H, the dust guard 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 tooling0.20229y Roller bearing extractor and tool toreplace the oil seal

020230Y Tools for pinion bearing and differen-tial replacement


SC - 663

Control

Check for possible damage to the bushing assem-

bly and to the bearings.

Installation

1. Fit the bearings with the following special tools

with a press.

First apply lithium based multipurpose grease in

the prescribed quantity inside the bearing.

Specific tooling020229Y Tools for needle bearing and sealingrings replacement


CharacteristicPrescribed depth of the bearing (A):6 ÷ 6.3 mm

2. Fit the new dust guard gaskets using the follow-

ing special tools.

Before fitting, apply grease onto the sliding surfa-

ces of the dust guard gaskets.




SC - 664

MAKE SURE TO INSERT THE BUSHING ASSEMBLY INTHE CORRECT DIRECTION.

CharacteristicPrescribed depth of the dust guard gaskets:0.1 - 0.7 mm

3. Fit the new dust guard gaskets using the follow-

ing special tools.

Before fitting, apply grease onto the sliding surfa-

ces of the dust guard gaskets.



4. Apply lithium based multipurpose grease to sec-

tions A indicated in the figure.

5. Insert the bushing assembly in the stub axle

control arm.MAKE SURE TO INSERT THE BUSHING ASSEMBLY INTHE CORRECT DIRECTION.


SC - 665

6. Assemble the stub axle control arm with a new

lock nut.ONCE THE FITTING HAS BEEN COMPLETED, TURN THEARM CLOCKWISE AND ANTICLOCKWISE AND MAKESURE THAT IT COMES INTO CONTACT WITH THE RELE-VANT LIMIT SWITCH.

Locking torques (N*m)prescribed torque 112 - 137 Nm

7. Fit the front cross-member together with the

control arm assembly.

Locking torques (N*m)Cross-member bracket for suspension arm: 98÷ 118 Nm Cross-member - Suspension lowerarm 78.5 ÷ 98.0

8. Tighten the tie rod head to the prescribed torque

and, afterwards, insert a new locking cotter pin.

Locking torques (N*m)Strut bracket body: 39 ÷ 54 Nm

9. Tighten the unit to the prescribed torque.

Locking torques (N*m)Strut bracket - Suspension lower arm 69 ÷ 88Housing on the cross-member for tie rod: 54 ÷69 Nm

10. Front wheel toe-in adjustment and check.

Steering box assembly


SC - 666

Gruppo cremagliera


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 flange


SC - 667

1. Lift the front part of the vehicle with the jack.

2. Remove the steering housing cover aligning 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 rack bellows

8. Clip and Circlip

9. Nut

10. Bracket

11. Ring


SC - 668

12. Clamp

13. Bellows

14. Steering box cover

15. Gasket

16. Circlip

17. Steering pinion

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 rack guide spring cap with a 17 mm

Allen key.


SC - 669

4. To avoid damaging toothed surfaces, remove

the locking nut acting on the working section with

a 17 mm key. The working section is provided by

the rack end, as shown in the figure.

5. Remove the circlip with pliers to expand circlips.

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. Remove the circlip with pliers to expand circlips.

9. Take out the bearing very gently with a punch,

as shown in the figure.

Control

Check the following parts and replace those which are defective.


SC - 670

KEY:

1. Toothed surfaces worn or damaged

2. Bushing 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 defective.


SC - 671

KEY:

1. Ball bearing

2. Circlip

3. Oil seal

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


SC - 672

21. Spring cap

22. Hexagonal ring nut


Steering box assembly

Fitting

1. Apply EP grease (high resistance) at the points

indicated in the figure in the prescribed quantity.

• Roller bearing section 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 tooling020177y Pinion bearing replacement kit

3. Fill the ball bearing with EP grease in the pre-

scribed quantity.

4. Fit the circlip with pliers to expand circlips.

5. Fit the oil seal with the special tool.

Specific tooling020177y Pinion bearing replacement kit


SC - 673

6. When fitting the oil seal, cover the whole edge

of the oil seal with MP grease.

7. Apply EP grease onto toothed surfaces and on

the rack shaft in the prescribed quantity.

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: 2 - 4 gr.

9. Insert rack G in the relevant seat H in the posi-

tion indicated in the figure.

10. Position the pinion with a punch.


SC - 674

11. Fit the circlip with pliers to expand circlips.

Assembly procedure

Assembly procedure of the rack and the steer-

ing pinion

1. Position 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 plastic cap, protect the threaded section

of the rack so as to avoid damaging it during as-

sembly.


SC - 675

4. Tighten bellows «A».

5. Position the rack end following the perspective


6. Tighten the lock nut with a 17 mm wrench.

7. With the rack in a neutral position, fit the spring

cap to the prescribed torque. Turn the rack approx.

10 - 20 times up to its bedding. 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

8. Fit the hexagon nut with a 39 mm Allen key.

Locking torques (N*m)Rack guide protection lock nut - Steering rackhousing 34 ÷ 44

Steering pinion preloading

Check the steering pinion preloading.

CharacteristicPrescribed value:

0.5 - 1.1 Nm


SC - 676

Installazione complessivo

Fit the parts, following the numerical 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. Guard

Steering column


SC - 677

Removal

Key switch cylinder removal

1. Insert the ignition key and turn it to the "IGN"

position.

2. Acting by means of the upper hole, keep the lock

section in position and take out the key switch cyl-

inder from the guide column upper support brack-

et.


KEY:

1. Steering wheel

2. Guide column protection

3. Light switch lever unit


5. Bolt

6. Steering column

7. Washer

8. Ring

9. Universal joint


SC - 678

Installation


KEY:

1. Ring

2. Washer

3.Universal joint

4. Steering column

5. Bolt


7. Light switch lever unit

8. Guide column protection

9. Steering wheel

Installation

1. Apply MP grease onto the PP points indicated.


SC - 679

2. Position the front wheels in straight line motion

and fit the universal joint in the indicated position.

KEY:

A = Universal joint;

B = Intermediate shaft

3. Fit the guide column so that the milling on the

grooved section is aligned with the fixing bolt hole.

KEY:

C = Specific section;

D = Fixing bolt hole.

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, straighten the

front wheels.

6. Tighten bolts E and F to the prescribed torque.

7. Remove the steering wheel fitted provisionally.

8. Fit the steering wheel so that the groove on the

rear section of the steering wheel is aligned with

the turn indicator switch cam.


SC - 680

9. Apply grease at the indicated point G.

Tie-rods

Removal

Remove the parts, following the numerical order of

the figure 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 the special

tool.

Specific tooling020231Y Extractor for articulated heads


SC - 681

Control

Check the following parts and replace the defec-

tive ones.

1. Breaking and deterioration

2. Damage and bending

3. Breaking and deterioration

Installation

Remove the parts, following the numerical order of

the figure shown below.

1. Dust guard

2. Ring

3. Arm head

4. Dust guard

5. Ring

6. Arm head

7. Tie rods

8. Nut

9. Cotter pin

10. Nut

11. Cotter pin


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 THE CONI-CAL SECTION OR THE THREADED SECTION.

CharacteristicPrescribed quantity of grease3 cm³

Arm head

MAKE SURE THAT THE ARM HEAD WITH ANTICLOCKWISE THREAD IS ON THE CENTRAL ARMSIDE OF THE RIGHT TIE ROD ASSEMBLY AND ON THE ARTICULATION SIDE OF THE LEFT TIEROD ASSEMBLY.


SC - 682

2. The distance between the arms of the head

must correspond to the figure specification. Tight-

en the lock nut temporarily (after performing the

toe-in test, tighten the lock nuts firmly).

CHECKING AFTER FITTING THE ARM HEADS

1. Check toe-in

TOE-INSpecification Desc./Quantity

B-A (one passenger) 2.0 + 1.5 - 1.0B-A (unloaded vehicle) 1.5 + 1.5 - 1.0

Alignment

Toe-in

1. Check the tyre pressure. Position the vehicle on

a car lift. 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 excessive clearance in axial direction

detected on wheels.

3. Make sure that no front suspension mechanism and steering shows excessive clearance.

4. Measure the distance between the marks on the front side of each front wheel. Determine the toe-

in value calculating the difference.




SC - 683

5. If the toe-in value is not within the prescribed

specifications, loosen the lock nuts of the arm

head. Perform adjustment on tie rods C.N.B.ADJUSTMENT SHOULD BE SO THAT THE LENGTH OFTHE RIGHT SIDE CABLE AND THE LEFT SIDE CABLE AREIDENTICAL.

6. Take the turning radius gauge to «0» degrees.

Straighten the wheels and check the steering an-

gle as follows:

a. Turn the steering all the way towards the right

and left respectively.

Read the turning radius gauge scale on the right

and left sides.MAKE SURE THAT WHEELS DO NOT INTERFERE WITHTHE BODY DURING ROTATION.

b. Check the tyre steering angles 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 TIEROD LENGTH BY TWO TURNS TO MAKE SURE THAT THE TOE-IN IS THE SAME .

STEERING ANGLESSpecification Desc./Quantity

Inside: 36°Outside: 34.8°

Tolerance between right and left sides: 3°

Front wheel alignment check

The suspension is of reinforced type, the components have a significant rigidity and the distance be-

tween lower and upper support points is prominent.

The front wheel alignment remains unchanged, unless the vehicle suffers sudden accidents.

However, if the front wheels are misaligned due to an abnormal tyre wear, an incorrect driving or due

to other causes, restore correct alignment.


SC - 684

PICK UP FRONT WHEEL ALIGNMENTSpecification Desc./Quantity

Tie rod 1° 23' +40'-50'Caster angle 3°13' ± 1°

Steering angle 1°49' ± 1°

VAN FRONT WHEEL ALIGNMENTSpecification Desc./QuantityCamber angle 1° +40'-50'Caster angle 3°02' ± 1°

Kingpin inclination angle 11°25' ± 1°


Toe-in with a passenger 2.0 +1.5-1.0Toe-in with unloaded vehicle 1.5 +1.51.0

BEFORE MEASURING THE FRONT WHEEL ALIGNMENT, CHECK THE REGULAR VEHICLEHEIGHT AS IN THE CASE OF TOE-IN MEASUREMENT. BESIDES, MAKE SURE THAT NO PARTOF THE VEHICLE IS LOOSE.

2. Place a turning radius gauge on a flat surface

so as to keep the vehicle levelness. Perform meas-

urement slowly.

3. Before measuring, swing the front and rear part of the vehicle up and down so that front and rear

suspensions settle in their regular condition.

4. Perform the measurement with brakes locked.

Steering wheel

Controlli

Steering wheel clearance

Position the vehicle with the wheels straight.

Check steering wheel clearance "A" turning it

slightly with the fingers.

Specified value: less than 30 mm


SC - 685

Move the steering wheel in axial direction with re-

spect to the guide column. Check if the steering

wheel shows excessive clearance or loosening.N.B.IF THE STEERING WHEEL SHOWS EXCESSIVE CLEAR-ANCE OR LOOSENING,PROBABLY THE STEERING BOXOR THE JOINTS ARE WORN, OR THE SUPPORTINGBRACKET HAS BEEN LOOSENED.

Removal


KEY:

1. Steering wheel padding

2. Nut

3. Washer

4. Steering wheel

5. Screw

6. Horn plate

7. Horn ring

BEFORE REMOVAL, DISCONNECT THE BATTERY TERMINAL CABLE.

Installation


KEY:

1. Horn ring

2. Horn plate

3. Screw

4. Steering wheel

5. Washer


SC - 686

6. Nut

7. Steering wheel padding

Wheel alignment

Toe-in measurement

1. Shake the vehicle manually so as to level its

height.

2. Move the vehicle approx. 5 meters forwards so

that front wheels are not steered.- DURING MEASUREMENT, DO NOT MOVE THE VEHICLEBACKWARDS.

3. Put the gauge pointer at the centre of the front wheel tread.

4. Mark a reference at the centre of the tread of each of the front wheel tyres, on the rear side. Measure

the distance between the two marks (Size A) in the figure.

5. Move the vehicle slowly, pushing it until the wheels are turned 180°.

6. Measure the distance (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 adjustment

1. Loosen the lock nuts of the tie rod heads.

2. Adjust toe-in by turning the tie rod heads.- BE CAREFUL NOT TO KINK THE COVER DURING THEADJUSTMENT.- WHILE ADJUSTING TOE-IN, RIGHT AND LEFT TIE-RODSMUST HAVE THE SAME SIZE.- LENGTH (A) INDICATED IN THE FIGURE ON THE RIGHTMUST BE THE SAME ON THE RIGHT AND LEFT SIDES. (IFTHE LENGTH ON THE LEFT SIDE IS DIFFERENT FROMTHE RIGHT SIDE, THERE IS A DIFFERENCE IN THEWHEEL STEERING ANGLE, BETWEEN THE RIGHT ANDLEFT SIDES).


SC - 687


SC - 688

INDEX OF TOPICS

SUSPENSIONS SS

Front

Axle and front suspension

This section of the manual describes how to inspect, remove and fit the axle and the front suspension.

KEY:

1. Cotter pin

2. Castle nut and flat washer

3. Brake calliper assembly and disc


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 seal

12. T oil seal


14. Collar


16. Wheel shaft

17. Front shock absorber


Suspensions PORTER 1.3 16V

SS - 690

Shock-absorbers removal

Assembly

1. Insert the dust guard and the elastic buffer in the

shock absorber stem.

2. Compress the spring, using the following tool:

Specific tooling020235y Front spiral spring compressor

3. Fit the spring seat upper cap B and the bushing

A.- APPLY 0.5 GR OR MORE MT GREASE ON THE UPPERSURFACE 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 THEPART SEPARATED FROM THE FRONT SUSPENSIONSUPPORT C WITH THAT OF THE SHOCK ABSORBERSTEM D.

6. Lock the front suspension support in a vice.

Tighten the suspension support nut to the shock

absorber stem.

Locking torques (N*m)Shock absorber - Front suspension support49.0 ÷ 69

PORTER 1.3 16V Suspensions

SS - 691

7. Fit the support dust guard.

8. Align the spring end with the concave section of

the upper seat F and lower seat G. Remove tool

H.

Installation

Fit the suspension support. (Use new nuts)

Locking torques (N*m)Front suspension support for chassis 35 - 44 Nm

Steering articulation fitting

1. Fit the steering articulation on 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 the shock ab-

sorber.

5. Bleed the air completely.

6. Move the vehicle, without load, upwards and

downwards, so that the suspension settles.

7. Tighten the following:

Bolt and nut (Shock absorber for steering articu-

lation)

Locking torques (N*m)Steering joint - Front shock absorber 78.5 ÷ 98


SS - 692

COMPONENTS:

1. Support dust guard

2. Self-locking nut

3. Front suspension support

4. Bushing

5. Front spring upper seat

6. Front spring buffer

7. Shock absorber dust guard

8. Spiral spring

9. Front shock absorber

10. Bolt

11. Retention plate



Removal

1. Lift the vehicle with the jack

2. Remove the front wheel.N.B.- MAKE SURE THAT THE JACK IS PLACED CORRECTLY,MATCHING THE LIFTING POINTS.


SS - 693

3. Remove the seat in order to reach the upper

seat of the front shock absorber.

4. Remove the shock absorber pipe fixing bracket.

5. Detach the brake hose from the calliper.

6. Shock absorber removal.

- Remove the fixing nuts.

- Leave the 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.

Specific tooling020235y Front spiral spring compressor

Spring removal

1. Tighten the front suspension support in a vice.

2.Remove the dust guard of the support

3.Loosen the nut.- NEVER HIT THE NUT.


SS - 694

4. Remove the support of the front suspension A.

5.Remove the bushing and the upper seat of the

front spring B.

6.Remove the spiral spring, dust guard and rubber

buffer from the shock absorber.

Check

Check the following parts:

A = Damaged rubber part

B = Endless screw bushing

C = Damage or twisting

D = Wear

E = Twisting and breaking

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 noise.

2. Check for the same conditions with the stem

extended. Check that it returns at a constant speed

from the beginning to the end.

3. If the shock absorber operation fails, replace it.- DISCHARGE ALL THE GAS BEFORE DISPOSING OF THESHOCK ABSORBER.

Front arms removalSuspension lower arm


SS - 695

COMPONENTS:

1. Throttle cable locking bolt

2. Speedometer cable tightening screw

3. Nut and 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 dust guard




SS - 696

Removal



3. Removal of the suspension lower arm assem-

bly.

• Remove the bolt and the fixing nut of

the steering articulation.

• 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 support.

• Remove the suspension lower arm

from the vehicle.

4. Remove the strut support after taking out the

four hexagonal bolts.

Check

Check the components and replace them if nec-

essary

A. Deterioration

B. Torsion and damage


SS - 697

C. Twisting and breaking

Installation

1 Insert the strut buffer on the suspension lower

arm.

2. Temporarily fit the strut support on the body-

work.

3. Fit the strut buffer and the plain washer on the

strut support and temporarily tighten the locking

bolt.

4. Fit the strut support with the four hexagonal-

head bolts.

Locking torques (N*m)Strut bracket body 39 ÷ 54

5. Apply the ball-and-socket joint in the steering

articulation and insert the bolt.

6. Temporarily fit the screw and the lock nut.- MAKE SURE THAT NEITHER GREASE NOR OIL OR ANYOTHER SUBSTANCES COVER THE SCREW AND THE NUTFASTENING THE BALL-AND-SOCKET JOINT.

7. Fit the front wheel.

8. Lower the vehicle. Move the unloaded vehicle

up and down so that the suspension settles. With

the vehicle unloaded (lower arm in horizontal po-

sition). Follow the operations below:

9. Tighten:

- Bolt and nut

- Lock nut

- Bolt and nut

10. Adjustment and check of the front wheel align-

ment.

Locking torques (N*m)Suspension lower arm - Steering joint 73.5 ÷ 93Strut bracket - Suspension lower arm 69 ÷ 88Cross-member - Suspension lower arm 78.5 ÷98.0


SS - 698

Front hubs removal

Removal



5. Disc assembly removal

• Remove the cotter pin

• Remove the castle nut using the fol-

lowing tool:

6. Remove the disc brake assembly using the fol-

lowing tool:


0.20222y Front hub and drum extractor

3. Disconnect the brake hose from the calliper.

4. Remove the calliper assembly by unscrewing

the two bolts.N.B.- COVER THE BRAKE HOSE CONNECTION WITH A CLOTHTO KEEP DUST FROM ENTERING.


SS - 699

7. Remove the disc brake dust guard

8. Remove the tie rod head, using the following

tool:

Specific tooling020231Y 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 shock absorber 78.5 ÷ 98Suspension lower arm - Steering joint 73.5 ÷ 93


SS - 700

2. Fit the tie rod on the articulation.- ALIGN THE CASTLE NUT RECESS WITH THE HOLE.

Locking torques (N*m)Tie rod head - Articulated arm 39 ÷ 54

3. Fit a new cotter pin on the castle nut.

4. Fit the brake disc dust guard.

Locking torques (N*m)Brake disc dust guard - Wheel hub joint 39.3 ÷53.9

5. Fit the hub and the disc assembly, and tighten

the castle nut, using the following tool:- ALIGN THE CASTLE NUT RECESS WITH THE HOLE.


Locking torques (N*m)Castle nut - Front axle hub 177.0 ÷ 216.0

6. Fit a new cotter pin on the castle nut.

7. Install the calliper assembly with two bolts.

8. Connect the brake hose to the calliper.

9. Bleed the air completely.- BE CAREFUL NOT TO DAMAGE THE COVER.

Locking torques (N*m)Disc brake calliper - Disc brake dust guard 49 ÷59


SS - 701

Inspection

Check the following parts. Replace any faulty

parts.

1. Front axle bearing replacement

• With a press, remove the wheel shaft

from the steering articulation.

• Move the collar, as shown in the figure.

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 WITHTHE STOP SECTION OF THE STEERING ARTICULATION.



SS - 702

• Place the external radial ball bearing

using the following tool:N.B.- MAKE SURE THAT THE BEARING IS IN CONTACT WITHTHE STOP SECTION OF THE STEERING ARTICULATION.


• Place the internal and external oil seal,

using the following tool:

Specific tooling020223y Extractor and changer for front sus-pension arm bushing

3. Place the wheel shaft in the articulation

Use the following tool:

Specific tooling020224y Connecting rod bushing extractor andchanger

Verifiche e regolazioni

Preliminary checks before the wheel alignment

check

1. Tyre wear check

2. Correct tyre pressure control

3. Checking bolt tightening of affected parts


SS - 703

4. Checking excessive clearance of the affected

parts.

• Lift the vehicle with the jack. Push and

pull alternatively the lower and upper

part of each tyre. Make sure that these

parts do not have excessive clearance.

• If one of the tyres has an excessive

clearance, check again with the brake

control pedal lowered.

If there is excessive clearance, then the front

wheel bearing is loose.

If 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 cracking.

Attachments and joints

• Check the attachments for correct

tightness and signs of damage.

• Check that the joints are not noisy.

KEY:

1. Spiral spring

2. Shock absorber

3. Connection bar

4. Suspension lower arm

Shock Absorbers

Inspection

Visually inspect all the shock absorbers and check that there are no signs of deterioration and fluid

leaks.


SS - 704

Operation check

Push the rear part of the vehicle with downward force in order to check the damping capacity of the

shock absorbers.

In the case that the wheel bearing is loose, check

the clearance in the axial direction, using the fol-

lowing tool and the micrometer.

Specific tooling020222y Front hub and drum extractor

CharacteristicFront wheel bearingsSpecified value

Maximum limit: Do not exceed 0.05 mm

PICK UP FRONT WHEEL ALIGNMENTSpecification Desc./QuantityCamber angle 1°23' +40'-50'Caster angle 3°13' ± 1°

Kingpin inclination angle 10°49' ± 1°Toe-in 1 passenger: 2.0+1.5-1.0

Unloaded vehicle: 1.5+1.5-1.0Steering angle Inside: 36°+0°-3°

Outside: 34.8°+0°-3°

VAN FRONT WHEEL ALIGNMENTSpecification Desc./QuantityCamber 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+1.5-1.0Steering angle Inside: 36°+0°-3°

Outside: 34.8°+0°-3°

Turning radius gauge setting

• Set the turning radius gauge to point

zero. Lock the indicator.

• Place the vehicle so that the wheel/

flooring surface is aligned with the cen-

tre of the turning radius indicator.- CARRY OUT THE CHECK ON LEVEL GROUND.- IF A PORTABLE TURNING RADIUS GAUGE IS USED,PLACE A PLATE WITH THE SAME THICKNESS AS THATOF THE INDICATOR UNDER THE REAR WHEEL IN ORDERTO KEEP THE VEHICLE LEVEL.- MAKE SURE THAT THE FRONT WHEELS ARE NOTSTEERED.- KEEP THE VEHICLE UNLOADED. MAKE SURE THAT THEBRAKE PEDAL IS ENGAGED, USING A BRAKE PEDALTHRUSTING DEVICE, SO THAT THE VEHICLE DOES NOTMOVE DURING CHECK.


SS - 705

- REMOVE THE STOP LIGHT FUSE SO THAT IT DOES NOTREMAIN ON.

External side wheel steering angle check

1. Measure the wheel steering angle with an internal side turning radius indicator. Specified value:

2. If there is a difference between the right and left side of the wheel steering angle, correct the steering

angle

CharacteristicExternal side B

34.8°+0°-3°

Internal side C

36°+0°-3°

KEY:

A = Front

B = External 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.- BE CAREFUL NOT TO KINK THE CAP DURING THIS OP-ERATION.- MAKE SURE THAT THE TIE RODS ON BOTH LEFT ANDRIGHT SIDE ARE THE SAME SIZE.

Checking the camber, caster and kingpin an-

gles

1. In the case of aluminium wheels, carry out the

measurement by using the CCK (camber, caster,

kingpin inclination) gauge.- THE TOE-IN CHECK (CCK-IN) EQUIPMENT CAN BE USEDALSO ON STEEL WHEELS.


SS - 706

2. Fitting procedure of the equipment to check toe-

in, camber, caster and kingpin.

KEY:

A = CCK pitch 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 on

the zero mechanical line, F turning the

compensator dial.


SS - 707

• Fix the equipment to check toe-in, firm-

ly hooking the four stop pins to the

wheel rims.- TO AVOID SCRATCHING THE WHEEL RIMS, APPLY ATAPE ON THE RIMS MATCHING THE INSERTION POINTSOF THE COMPENSATOR PINS.

• Place the camber, caster and kingpin

gauge on the equipment fitting 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 the caster air

bubble with the zero position.

• Turn the wheel by 180°, so as to invert

the gauge. Align the lines set on the

gauge and on the compensator. Then,

turn the wheel so that the air bubble in

the gauge reaches the central position.


SS - 708

• Set the caster value read from the

gauge. Turn the compensator dial G so

as to align it at the half of the set caster

value.- PAY ATTENTION NOT TO TAMPER WITH THE GAUGECASTER SET SCREW.

• Repeat the operations described at the two previous points. Make sure that the caster gauge

air bubble sets the same value when the wheel is turned by 180 degrees in a regular or

inverted direction.

• Lower the wheel on the turning radius indicator. Manually shake the vehicle upwards and

downwards so as to stabilise suspension.

4. Camber check

• Make sure that the front wheels are not

steered.

• Align the air bubble H with the central

position

• Set the camber value I read from the

gauge

CharacteristicSpecified value:1° +40' - 50'

5. Check the caster and kingpin inclination angle

• Turn the steering wheel to the right, so that the right front wheel reaches the point in which

the steering angle gauge L registers 20 degrees.

• Turn both caster and kingpin set screws so as to align the respective air bubble with the

zero point.

• Turn the steering wheel to the left, so that the right front wheel reaches the point in which

the steering angle gauge L registers 20 degrees.

• Set the values of the caster angle M and of the kingpin read from the gauge.


Caster: Pickup 3°13' ± 1°, Van 3°02' ± 1°

Kingpin inclination angle: Pickup 10°49' ± 1° Van 11°25' ± 1


SS - 709

• Following the right wheel procedure, check also the left wheel. However, the steering wheel

steering 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

4. Internal snap ring

5. Bearing

6.Spacer

7.Shoe holding plate


SS - 710

8. Oil seal


Removal

1. Lift the vehicle with the jack.N.B.- MAKE SURE THAT THE JACK IS PLACED CORRECTLY,MATCHING THE LIFTING POINTS.

2.Drain the differential oil.

3. Remove the rear wheel.

4. Loosen 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 the four nuts fixing the shoe holding

plate.

9. Remove the rear axle shaft with the shoe hold-

ing plate, using the special tool:

Specific tooling020226y Rear axle shaft extractor


SS - 711

10. Remove the oil seal, using the special tool:


11. Rear axle bearing removal

• With 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 the follow-

ing special tool:

Specific tooling020227y Rear wheel bearing extractor


SS - 712

Check

Check the following parts:

1. Rear axle shafts, especially:

A Wear, damage or eccentricity

B Oil seal contact section

C Grooved profile

CharacteristicLimit allowed:Flange: 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 press insert the axle shaft

bearing.

Specific tooling020225y Buffer to fit the rear bridge bearing

KEY:

A Spacer

B Shoe holding plate

C Bearing


SS - 713

Heat a new bearing stop bushing E in an oil bath

at approx. 150°, and with the aid of the special tool,

insert it quickly until it stops against the bearing.


Quickly fit the bearing sealing ring on the shaft,

using a press together with the special tool.- MAKE SURE THERE IS NEITHER GREASE NOR OIL ONTHE REAR AXLE SHAFT AND THE SEALING RING.


2. Apply MP grease on the oil seal edge.

3. Fit the oil seal, using the following special tool.

Specific tooling020201y Gear bearing fitting punch

4. Apply silicone sealant at the housing end of the

rear axle shaft. Apply sealant uniformly, as shown

in the figure, to cover the rear axle shaft coupling

surfaces.N.B.APPLY THE SEALANT WITHOUT INTERRUPTIONS.AFTER APPLYING THE PRODUCT, CARRY OUT THE OP-ERATIONS IMMEDIATELY.

Recommended productsThree Bond N.1212 silicone sealant-

Key

1. Silicone sealant section view

2. Silicone sealant

3. From the base of the bearing, fit an elastic gasket on the internal edge


SS - 714

5. Fit the rear axle shaft together with the shoe

holding plate, using the following special tool.

Specific tooling020226y Rear axle shaft extractor

6. Fasten the shoe holding plate with four nuts.

Locking torques (N*m)Shoe holding plate - Rear axle shaft housing63.7 ÷ 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. Adjust the brake shoe clearance.

12. Restore the oil level in the differential.

13. Fit the wheel.

14. Lower the vehicle.

Locking torques (N*m)Brake pipe joint - Brake cylinder 10 ÷ 12


SS - 715

Balestra

COMPONENTS

1) Nut, 2) Spring washer, 3) U-bolt,4) Rear rubber buffer, 5) Flexible shoe (for vans), 6) Nut, 7) Spring

washer 8) Nut, 9) Spring washer, 10) Rear shackle, 11) Rear shackle, 12) Bushing, 13) Nut, 14) Upper

spring pin, 15) Spring washer, 16) Leaf spring with bushing, 17) Flexible shoe stop, 18) Flexible shoe

(for vans).

Removal


2. Remove the rear wheel.

3. Disconnect the + and - battery leads.

4. Remove the battery housing by undoing the

three bolts/clips and a ground bolt (only for vans).


SS - 716

5. Remove the U-bolt by undoing the four nuts.

6. Remove the rear rubber buffer support and the

flexible shoe of the leaf spring.

7.Remove the 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 spring A and its

lock B from the leaf spring assy (in vans).

11. Remove the leaf spring shackle from the chassis.


SS - 717

Check the following:

1) Damage, 2) Damage or wear, 3) Damage, wear or deterioration,4) Wear 5) Cracking, damage or

flattening, 6) Damage, wear or deterioration, 7) Bending or damage, 8) Damage or wear, 9) Damage,

wear or deterioration.

Installation

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 spring shackle with the

bushings and the nut.

4. Fix the elastic plate and the leaf spring buffer.

5. Fit the U-bolts and tighten the nuts.

Locking torques (N*m)U-bolt - Leaf spring buffer 44 ÷ 54


SS - 718

6. Fit the rear wheel.

7. Lower the vehicle. Move the vehicle rear sus-

pension, upwards and downwards, two or three

times to 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 - Leaf spring assembly. 88 ÷ 108

• Leaf spring shackle support nut.

Shock-absorbers removal


SS - 719

COMPONENTS

1. Hexagon nut

2. Spring washer

3. Shock absorber buffer washer

4. Hexagon nut

5. Spring washer


7. Shock absorber



10. Buffer

11. Buffer


Removal


2. Hold the differential housing with a workshop

jack.

3. Disconnect the battery + and - terminals.

4. Remove the battery container, undoing the

three bolts/clips and 1 ground bolt (only on vans).

5. Remove the rear shock absorber, unscrewing

the hexagon nuts from the bodywork (upper sec-

tion A) and from the axle shaft housing (lower

section B) .

6. Detach the buffers and the buffer washers in the

upper and the lower section.


SS - 720

Check

1. Check the following parts.

A. Damage

B. Distortion, damage causing oil leaks and mal-

function

C. Damage and wear

2. Shock absorber operation check.

• Pushing the piston rod, check that trac-

tion is uniform from the beginning to the

end of the stroke and that there is no

abnormal resistance or noise.

• Push the piston 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-ING OF THE SHOCK ABSORBER.

Installation

1. Fit the rear shock absorber with the buffer washers and buffers and tighten the hexagon nuts.

Upper Section

Locking torques (N*m)Rear shock absorber - Chassis (upper part) 34 ÷ 54Locking torques (N*m)Rear shock absorber for chassis (lower part)34 ÷ 54


SS - 721

2. Lower the vehicle.- MAKE SURE THAT THE HEXAGON NUTS HAVE BEENPROPERLY FITTED, SINCE UPPER SECTION AND LOWERSECTION LENGTHS ARE DIFFERENT.

Verifiche

Noise

Move the wheel upwards and downwards, holding

it up with both hands as shown in the figure.

Check that the wheel 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 attachments by moving the suspension

manually.

KEY:

1. Shock absorber

2. Leaf spring

Shock Absorbers

Inspection

Visually inspect all the shock absorbers and check that there are no signs of deterioration and fluid

leaks.

Operation check


SS - 722

Push the rear part of the vehicle with downward force in order to check the damping capacity of the

shock absorbers.


SS - 723

INDEX OF TOPICS

TIPPER VERSION VR

KEY:

1. Reservoir

2. Hydraulic control unit

3. Cylinder 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

15. Safety prop

PORTER 1.3 16V Tipper version

VR - 725

Circuito idraulico

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 1.3 16V

VR - 726

Schema impianto elettrico ribaltabile

ELECTRIC DIAGRAM - TIPPER:

1. Battery

2. 80A Fuse

3. Electric motor electromagnet

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. Blinker

12. Raised loading deck signal switch

13. Tipper electric pump motor


VR - 727

Smontaggio - Montaggio pianale ribaltabile

Tipper removal

Brake the vehicle.

Lift the tipper via the button located in the cab up

to its maximum height.

Insert the safety rod as in the figure, afterwards,

slightly lower the tipper so that the weight is un-

loaded onto the rod.

Remove the two clamps which connect 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 operation.MAKE SURE THAT THE THRUST PISTON RE-ENTERSCOMPLETELY.

At this stage, the only constraint to removing the

tipper is the two hinges shown in the figure.

With the two spanners, remove the nut and release

the spring. Do not remove the pin during this op-

eration.


VR - 728

Now it is necessary to lower the tipper to continue

removal.

Slightly lift the tipper and release the safety prop,

then lower the loading deck carefully.PERFORM THIS OPERATION VERY CAREFULLY, ITCOULD BE EXTREMELY HAZARDOUS FOR THE OPERA-TOR.

Remove the two screws which act as a pin for the

hinge.

To perform this operation, it is necessary to slightly

lift the loading deck so that the two pins can be

released. Slide off the screw from its seat, and pull

the tailboard unlocking lever.

Now the tipper can 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 and place it on the vehicle with the aid of

the front reference pin as shown in the figure.

Fit the screws with the tailboard locking lever in the

hinges following the removal operations but in re-

verse order. To facilitate this operation it is neces-

sary to slightly move the deck vertically or

horizontally so as to align the deck and the vehicle

chassis holes. Once this operation is finished,

place the relevant nut with washer on the screw

but do not tighten it.


VR - 729

Manually raise the deck to the maximum tilting po-

sition and position the safety prop.

Tighten the hinge bolt to the prescribed torque.

Locking torques (N*m)Hinge bolt 41 - 49 Nm

Hooking the hydraulic jack lift arm to the tipper. To

perform this operation, raise the jack with the suit-

able button placed in the cab and take it up to the

maximum travel range (automatically reached

thanks to the limit switch ascent). Not being con-

nected to the deck, it will be checked that the arm

goes in 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 part of the vehicle. During this operation,

pay attention not to unintentionally press the as-

cent limit switch which would lock the jack ascent.

Insert the two lift arm retainers on the deck and tighten to the prescribed torque.

Locking torques (N*m)Lift arm retainer for tipper 75 - 88 Nm

Remove the safety prop and lower the tipper with

the button placed in the cab. The descent limit is

determined by the activation of a limit switch by

this deck.


VR - 730

Smontaggio - Montaggio martinetto idraulico

Hydraulic jack fitting

For fitting, follow the removal operations but in re-

verse order. Observe the correct tightening torque.

Locking torques (N*m)hydraulic jack retainer for chassis 74 - 88 Nm

Fasten the oil fitting coming from the pump, to the

hydraulic piston, by fitting the 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 the screw fixing the oil fitting to the piston

as shown in the figure, taking the necessary pre-

cautions against oil leakage that will occur.

Remove the bolt fixing the jack assembly to the

vehicle chassis, then remove the whole lifting de-

vice.

Pompa idraulica e motore elettrico


VR - 731

Smontaggio

Hydraulic pump and electric motor removal

Before carrying out this operation, it is necessary

to lift the tipper, position the safety prop, release

the jack from the tipper and take it to the rest po-

sition.

Disconnect the oil fitting pipe on the pump, pay at-

tention to any possible oil leaks.

Disconnect the negative cable (-) from the battery.

Disconnect the pump unit electric motor power

supply cable.

Disconnect the pump unit motor remote control

switch excitation 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

right side. During this operation it is necessary to

hold the pump, as the two screws are indeed the

only connections between the hydraulic pump and

the vehicle chassis.

Smontaggio particolari

Removal of pump parts

Place the pump body in a vice. Undo the screws

locking the two plates which support the oil reser-

voir, remove the clamp and the reservoir also tak-

ing out the O-ring.

Slide off the oil intake pipe taking it out from its

seat.


VR - 732

With a hexagonal spanner remove the four Allen

screws to take out the pump.

Remove the O-ring which guarantees the sealing

between the pump body and the valve body.

Remove the oil filter 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.

Smontaggio valvole

Valve body removal

From the hole uncovered by the oil fitting removal,

it is possible to undo the flow control valve with a

screwdriver.


VR - 733

Remove the plastic protection manually and after-

wards unscrew the pressure relief valve and the

check valve.

Unscrew the solenoid of the solenoid valve to

check the jack descent acting on the knob as


Finally, remove the valve body by acting on the nut


Montaggio valvole

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 seat located in the valve body and tighten to the prescribed torque.

Locking torques (N*m)valve body for valve body 25 - 30 Nm

Fit the solenoid in the seat located in the solenoid

valve and tighten to the prescribed torque.

Locking torques (N*m)Solenoid for valve body 5 - 6 Nm


VR - 734

Successively insert the one-way valve in its seat

and the pressure relief valve, locking it to the pre-

scribed torque.

Locking torques (N*m)One-way valve for valve body 25 - 30 Nm

Insert the flow control valve in its seat and start it

until it has reached the stop. Afterwards, tighten to

the prescribed torque, the appropriate socket head

cap on the head.

Locking torques (N*m)Flow control valve for valve body 20 - 25 Nm

Montaggio corpo valvole dal motore elettrico

Fitting the valve body to the electric motor

For this operation 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 pump parts

Fit the oil filter after cleaning and blowing it with compressed air, and lock it by tightening the three

screws to the prescribed torque.

Locking torques (N*m)hydraulic oil filter 8 NmBefore carrying out the following operation make sure that the contact surfaces between the valve body

and the pump are perfectly smooth and have no dents.

Fit a new O-ring in the specific slot located in the valve body. Before this operation, immerse the O-ring

in oil for about 10 min.


VR - 735

Fit the hydraulic pump and tighten the four Allen screws to the prescribed torque.

Locking torques (N*m)hydraulic pump for valve body 12 Nm

Proceed by inserting the oil intake pipe in the

pump. Fit a new O-ring, then install the reservoir

by first locking it with the two plates, and then with

the clamp.WHILE INSTALLING THE RESERVOIR, IT IS ADVISABLETO LUBRICATE THE O-RING AND THE 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, tightening them

to the correct torque.

Locking torques (N*m)pump assembly for chassis bracket 26 - 39 Nm

Connect the connection sleeve between the pump and the hydraulic piston with the specific copper

gaskets and lock it.

Locking torques (N*m)oil fitting 29 - 39 Nm

Restore all the electric connections following re-

moval operations but in reverse order.


VR - 736

Verifica e taratura della valvola limitatrice di pressione

Pressure relief valve check and calibration

If the loading tipper can not be raised, the cause

may be almost certainly attributed to an operation

failure or an incorrect calibration of the pressure

relief valve.

It is therefore necessary to operate so as to restore

correct operation.

Before adjusting, it is necessary to make some

preparations.

Make sure that the tipper is completely lowered.

Remove the plastic protection of the pressure re-

lief valve.

Fit a pressure gauge which can resist high pres-

sure (full scale about 300 Bar) on the connection

sleeve between the hydraulic piston and the pump.

Remove the maximum ascent limit switch by operating on the specific nut as shown in the figure.

TAKE ALL POSSIBLE PRECAUTIONS WHILE PERFORMING THESE OPERATIONS, CLOSE ALLTHE CONNECTIONS PROPERLY. REMEMBER THAT 200 BAR CATEGORY PRESSURES AREVERY DANGEROUS FOR BOTH USERS AND THE EQUIPMENT BEING USED.

Activate the tilting system.

Once the loading body is completely raised, press

the ascent button for a few seconds . In these con-

ditions the pressure relief valve is automatically

activated. When the valve mentioned before is ac-

tivated, a reading of about 130 Bar pressure shall

be displayed on the pressure gauge.

If the pressure is lower than the 130 Bar specifi-

cation, loosen the nut and with a hexagonal span-

ner operate on the maximum pressure relief valve

set screw as shown in the figure.

By undoing the set screw, the pressure on the

pressure gauge shall decrease. By tightening the

set screw, the pressure on the pressure gauge

shall increase.

Take the pressure to the prescribed value and

tighten the nut to the prescribed torque.


VR - 737

A 130 BAR PRESSURE IS SUITABLE TO LIFT A WEIGHTOF 750 KG WEIGHT AS SPECIFIED BY VEHICLE CHAR-ACTERISTICS.THE VEHICLE MUST NEVER LIFT A WEIGHT EXCEEDINGTHE PRESCRIBED VALUE.SUCH AN ACTION COULD IRRETRIEVABLY DAMAGE THELIFTING SYSTEM.

Locking torques (N*m)pressure regulator set screw 25 - 30 Nm


VR - 738

INDEX OF TOPICS

CHASSIS CH

Windscreen

Preparation

Tools and other equipment:

- Cable to work with (about 5 mm x 6 m): used to fit glass

- Bamboo spatula: used to fit glass

- Rubber hammer: used to fit glass

- Brush, etc.: used to apply water with soap

- Water with soap: used to fit glass easily

COMPONENTS:

1. Front wiper arm and 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 pressing on the edge.

This operation shall be carried out from inside the

cab.

2. Take out the windshield by pressing and, while levering from the inside, lift the upper part of the

sealing gasket from both ends.

Remove the windshield with the sealing gasket.

Chassis PORTER 1.3 16V

CH - 740

AT THIS STAGE, MAKE SURE TO APPLY EQUALLY DISTRIBUTED FORCE ON THE GLASS.ALSO HOLD THE GLASS FROM THE OUTSIDE SO THAT IT DOES NOT COME OUT OF ITS SEAT.

Refitting

Fitting (to be carried out by two individuals)

1. Perform the following preliminary operations:

- Fix the sealing gasket onto the windshield glass.

- Prepare a cable «A» to work with, as shown in

the figure.

- Apply water with soap on the sealing gasket pe-

rimeter «B» so that it slides 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, always from inside the cab, while

a second person, from the outside, slaps their

palms against the windshield surface adjacent to

the gasket so that this gasket is properly fitted in

its seat.

4. To fit the windshield slap the top of it with the

palms of your hands.N.B.NEVER USE GASKETS WHICH ARE DAMAGED, BROKEN,ETC., SINCE THIS COULD CAUSE WATER INFILTRATION.TO FACILITATE FITTING, USE A RUBBER HAMMER.

PORTER 1.3 16V Chassis

CH - 741

5. Front wiper arm and brush. For the fitting posi-

tion, see the figure.

Side windows

Preparation

Tools and other equipment:

- Cable to work with (about 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 fit glass easily

COMPONENTS:

1. Side window protection strip (optional equipment)

2. Side glass and relevant gaskets


CH - 742

Removal

1. With a bamboo spatula (or with a plain slot

screwdriver, etc.) take out the sealing gasket from

the body by pressing on the edge.

This operation shall be carried out from inside the

cab.

2. Take out the glass by pressing and, by levering from the inside lift the upper part of the sealing gasket,

from both ends.

Remove the glass with the gasket.

AT THIS STAGE, MAKE SURE TO APPLY EQUALLY DISTRIBUTED FORCE ON THE GLASS.ALSO HOLD THE GLASS FROM THE OUTSIDE SO THAT IT DOES NOT COME OUT OF ITS SEAT.

Refitting

1. Place the gasket on the 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 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.

4. Pull the wire, always from inside the vehicle,

while a second person, from the outside, slaps

their palms against the glass surface adjacent to

the gasket so that this gasket is properly fitted in

its seat.

5. To fit the windshield slap the top of it with the

palms of your hands.NEVER EMPLOY GASKETS WHICH ARE DAMAGED, BRO-KEN, ETC., SINCE THIS COULD CAUSE WATER INFILTRA-TION.


CH - 743

Rear window

Rear window upholstery panel

TOOLS AND OTHER EQUIPMENT

Butyl tape To prevent water infiltration

MP grease 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 adjustment

COMPONENTS

1. Rear window upholstery panel

Removal/Fitting

REMOVAL

Remove the rear window internal upholstery panel

using the special tool to take out the relevant re-

tainers.

COMPONENTS:

2. Panel

3. Retainer

FITTING

Fit the rear window internal upholstery panel.

Rear window

COMPONENTS:

1. Rear window protection strip

2. Window and sealing gasket


CH - 744

REMOVAL AND FITTING

1. Remove rear window protection 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. Window lifter handle


CH - 745

5. Front door upholstery panel

Removal

1. Remove the screw fixing the door opening han-

dle. Remove the front door inside handle.

2. Remove the inside handle by taking out the two

screws.

3. With a cloth, remove the 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. Place the upholstery panel on the door, then fit

the retainers.

2. Fit the door opening handle by tightening the

relevant screw.

3. Fit the inside handle by tightening the two

screws.


CH - 746

4. Fit the window lifter handle with 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

Smontaggio


CH - 747

COMPONENTS:

1. Opening control tie rod

2. Lock knob

3. Lock block with retainer

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 control

tie rod by undoing the three screws.


CH - 748

4. Remove the lock block by taking out the relevant

retainer.

5. Remove the outside handle by undoing the two

nuts.

Installation

1. Fit the outside handle by screwing the two 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 tie rod.

5. Fit the door locking knob.

6. Fit the door upholstery panel and the relevant components.N.B.

AFTER FITTING, CHECK AND ADJUST THE LOCK.


CH - 749

Dispositivo alzacristallo

COMPONENTS (only Pick-up):

1. External gasket

2. Internal gasket

3. 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.- REMOVE THE BUTYL TAPE SO AS NOT TO DAMAGE THEINSPECTION COVER.


CH - 750

3. Remove the external gasket of the front door

glass.

4. Remove the internal gasket of the front door

glass.

5. Remove the glass side gasket.- LIFT THE EXTERNAL GASKET TOOTHED SECTION. THISWILL FACILITATE REMOVAL.- ONCE REMOVAL IS FINISHED, TURN THE GASKETTOOTHED SECTION BACK INTO THE ORIGINAL POSI-TION.

6. Front door glass removal

- Remove the rear frame and the front frame by

unscrewing the bolts indicated in the figure.

- Remove the two bolts 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 correct limit switch refitting po-

sition.

Installation

1. Front door glass unit fitting.

- Apply the MP grease on each window lifter sliding

section.

- Fit the front door window lifter with the three bolts.

- Insert the front door glass unit and tighten with

two bolts temporarily.

2. Fit the side gasket in its relevant seat.

3. Tighten the two bolts.- MAKE SURE THAT THE GLASS IS CORRECTLY FITTEDIN THE FRONT DOOR.


CH - 751

4. Tighten the rear frame bolt, then tighten the two

front frame bolts.

5. Fit the inspection cover.

6. Fit the door upholstery panel.

7. Fit the door upholstery 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 1.5 mm

Tolerance for each side D Specified value: not ex-

ceeding 2.0 mm

Height difference Specified value: not exceeding ±

1.5 mm


CH - 752

Tolerance between the right and left side A, B, C,

D Specified value: not exceeding 2.0 mm

1. Adjustment in height and towards right/left

Adjust after undoing the two door side hinge bolts.

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 remains closed.

Porte Scorrevoli

Sliding door frame

COMPONENTS:

1. Frame glass guide

2. Glass frame

Sliding door upholstery panel



CH - 753







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 tightening the relevant

bolt.- BEFORE FITTING, APPLY ADHESIVE AT THE REARPART OF THE GLASS GUIDE.

2. Fit the guide.

3. Fit the inspection cover and the door upholstery

with the relevant components.

KEY:

1. Adhesive

2. Guide


CH - 754

Pannelli

Components

1. Door inside handle and relevant circlip

2. Circlip and spacer

3. Window lifter handle

4. Sliding door upholstery panel

Sliding door upholstery panel








Upholstery panel removal

1. Using a cloth, remove the circlip and take out

the door internal handle.

2. Using a cloth, remove the circlip and take out

the window lifter handle and collect the relevant

spacer.


CH - 755

3. With the special tool, remove the upholstery re-

tainers and take out the door upholstery panel.

Installation

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 the glass completely closed.


COMPONENTS:

1. Door locking knob


CH - 756

2. Control unit locking the sliding door

3. Tie rod

4. Outside handle

5. Locking frames

6. Door lock

7. Retention plate

Removal

1. Remove the door upholstery panel and the in-

spection 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.

6. Remove the locking tie rod by disconnecting it

from the outside handle unit.

7. Remove the door lock by taking out the two rel-

evant screws.


CH - 757

INSTALLATION

1. Apply MP grease on each of the sliding sections.

2. Fit the door lock by tightening the two relevant

bolts.

3. Connect the 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. Fit the inspection cover and the door upholstery with the relevant components.

Dispositivo alzacristallo


CH - 758

COMPONENTS:

1. External gasket

2. Internal gasket

3. Side gasket

4.Inspection cover

5. Bolt

6. Sliding door glass

7. Bolt

8. Window lifter unit

9. Lower gasket

10.Glass support groove

11.Frame

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 BUTYL TAPE SO AS NOT TO DAMAGE THEINSPECTION COVER.

6. Loosen the frame unit bolt.

7. Sliding door glass removal.

- Remove the two glass retention bracket bolts A.


CH - 759

- Remove the glass from the outside, starting from

the front/ upper part, with the glass tilted back-

wards.

8. Separate the glass support groove from this

glass.- IMMEDIATELY DRAW A REFERENCE MARK ON THEGLASS TO IDENTIFY THE CORRECT 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 the glass to identify

the correct fitting position of the lower gasket and

the groove.

- Apply water with soap inside the lower gasket.

- To place the gasket and the groove properly, use

a wooden hammer.


CH - 760

- Insert the glass inside the door, starting from 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 external gasket.


CH - 761

7. Fit the inspection cover.

8. Fit the door upholstery panel and the relevant

components.- APPLY THE BUTYL TAPE, WITHOUT EXTENDING IT,ALONG THE INSPECTION COVER GROOVE.- ONCE THE OPERATION IS FINISHED, PRESS ON THECOVER 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 arm support

5. Lower roller arm

6. Pin and lower bearing

7. Roller pin guide and lower roller

8. Cap

9. Screw

10. Upholstery

11. Limit switch

12. Central hinge

13. Pin and central bearing


CH - 762

14. Guide roller pin and central roller

15. Central guide

A = Sliding door hinge upper rollers

B = Sliding door roller

C= Central hinge

Upper roller removal

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 upper roller arm by taking out the

relevant pin, using an Allen wrench.

5. Remove the upper roller arm from the body.


CH - 763

Lower roller removal


wooden wedge as shown in the figure.

2. Remove the lower roller arm by taking out the

two relevant bolts.

3. Remove the guide roller pin and the lower roller

from the lower roller arm, using an Allen wrench.

Central hinge removal


wooden wedge as shown in the figure.N.B.- CARRY OUT THIS OPERATION WITH ANOTHER PERSONTO KEEP THE DOOR IN POSITION.

2. Remove the side upholstery.

3. Remove the central guide upholstery.N.B.- THE UPHOLSTERY IS HELD BACK BY TOOTHED HOOK.THEN MOVE THE UPHOLSTERY IN THE DIRECTION INDI-CATED BY THE ARROW AND, AFTERWARDS, REMOVE ITFROM THE FRONT SECTION OUT OF THE VEHICLE.


CH - 764

4. Remove the limit switch A by undoing the two

relevant bolts.

5. Remove the central hinge by taking out the two

relevant bolts.N.B.- SLIDE THE DOOR AND, THEN REMOVE THE UPPERROLLER AND THE CENTRAL HINGE FROM THE GUIDE,STARTING FROM THE REAR (REMOVAL SECTION)

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 nuts.N.B.

THE NUTS SHALL BE COATED WITH A LAYER OF PAINT.

3. Fit the upper roller arm to the support with the

relevant pin indicated in the figure, using an Allen

wrench.

4. Insert the arm in the track section.

5. Remove the jack.


CH - 765

Lower roller fitting

1. Apply MP grease onto each of the sliding sec-

tions.

2. Fit the guide roller pin and the lower roller on the

lower roller arm, using an Allen wrench.

3. Fit the lower roller arm on the door with the two

relevant bolts.

4. Remove the jack under the door panel.

Central hinge fitting


tions.

2. Fit the guide by tightening the three relevant

nuts.

3. Fit the central hinge by tightening the two rele-

vant bolts.

4. Fit the limit switch by tightening the two relevant

bolts.

5. Fit the central guide upholstery.

6. Remove the jack.


CH - 766

Regolazioni

Sliding door


Distance B, G, H <Specified value: 3.5 - 7.5 mm

Tolerance for each side B, G Specified value: not

exceeding 1.5 mm

Tolerance for each side H Specified value: not ex-

ceeding 2.0 mm

Height difference Specified value: not exceeding ±

1.5 mm

Tolerance between the right and left side B, G, H

Specified value: not exceeding 2.00 mm

Height adjustment

1. Adjust after undoing the two fixing bolts.

Now, move the catch at a distance equal to the

lower roller movement.

CharacteristicAdjustment tolerance~ ± 2 mm

2. Adjust after undoing the two central hinge fixing

bolts.


Adjustment in longitudinal direction

Adjust after undoing the two central hinge fixing

bolts.

If after adjusting the central hinge, the door front

side distance (point G) is excessively narrow, ad-

just by inserting a shim washer in the section fixing

the lower catch.

Characteristic


CH - 767

Adjustment tolerance~ ± 2 mm

Thickness height:1 mm

Adjustment of height difference

1. The adjustment is carried out after loosening the

lower roller fixing bolt.


2. The adjustment is carried out after loosening the

screw fixing the lock striker plate.IF THE DOOR REAR SECTION IS LOWERED OR LIFTED,NEVER TRY TO CORRECT THE TRIM BY OPERATING ONTHE DOOR LOCKING PLATE. ADJUST BY OPERATING ONITS HINGE.


3. Move the lower catch at a distance equal to the

movement.

- Temporarily fit the door by tightening the bolts

fixing the lower catch.

- After opening/closing the door two or three times,

tighten the bolts tightly.


CH - 768

Portellone posteriore

COMPONENTS:

1. Rear shock absorber

2. Nut

3.Door hinge

4. Door

Removal

1. Remove the side 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 ANDFITTING.

2. Remove the nuts from the door hinges.

3. Disconnect the heated rear window device (if

fitted).

4. Remove the door from the body.


CH - 769

Installation

1. Fit the door on the body.

2. Connect the heated rear window device (if fit-

ted).

3. Tighten the door hinge nuts.

4. Fit the side shock absorbers by tightening the

two relevant 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/Fitting

REMOVAL

1. Remove the door upholstery panel using the special tool to take out the relevant retainers.

FITTING

1. Fit the door upholstery panel.


CH - 770


COMPONENTS:

1. Block fixing device

2. Lock block

3. Door lock

4. Retention 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 the retention plate by taking out the two

relevant bolts.


CH - 771

Installation


tions.

2. Fit the retention plate by tightening the two bolts.

3. Fit the lock block by tightening the two relevant

bolts.

4. Fit the lock block using the fixing device.

5. Check and adjust the locking device.

Regolazioni

Door panel


J distance

Prescribed value: 3.6-8.6 mm

K distance


P distance

(Standard)


(Not standard)


Tolerance for each side

Prescribed value: Not exceeding 2.0 mm

Height difference:

Prescribed value: Not exceeding ± 1.5 mm

Tolerance between right and left sides

Prescribed value: Not exceeding 2.0 mm


CH - 772

Adjustment in longitudinal direction of the up-

per section

Adjust after undoing the body side hinge bolts.- When the upper section is adjusted in longitudinal direction,make sure that the distance between the rear window supportside 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 longitudinal direction of the low-

er section and closing adj.

Carry out adjustments by changing the fitting po-

sition of the lock plate.

Front bumper

COMPONENTS:

1. Screws

2. Bumpers


CH - 773

Removal

1. Remove the front panel

2. Loosen the eight screws and detach the front

bumpers from the two upper 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 catalytic converter by undoing the

relevant fixing nut on the main silencer.


CH - 774

3. Install the new catalytic converter and tighten

the relevant fixing nuts using a new gasket.

4. Tighten catalytic converter fixing bolts 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 catalytic converter flanges.

Light unit

COMPONENTS:

1. Clip

2. Headlamp support

3. Front/side turn indicator

4. Headlamp


CH - 775

Removal

1. Remove the front panel

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.


CH - 776

6. Loosen the two fixing screws shown in the fig-

ure.

7. Remove the retention clip from the front panel.

8. Loosen the two screws fixing 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 upper pins from the clips and tilt

panel 1 forward.

2. Release the panel from the lower pins and re-

move it.


CH - 777

Refitting

1. Place hooks A on pins B

2. Tilt the panel and fix pins C in clips D

Front panel components


CH - 778

Instrument panel

COMPONENTS:

1. Panel for combined instrument panel

2. Combined 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 defroster

10. Switches

11. Instrument panel (assembly)


CH - 779

Removal

Starting operations

1. Disconnect the battery negative cable.

2. Remove the steering wheel (steering section

reference).

3. Pull out the panel of the instrument panel.

4. Remove the instrument panel and the warning

lights by taking out the five screws.

5. Disconnect the speedometer cable and electric

connections.

6. Remove the diffuser hand grip by taking out the

relevant 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 panel of the instrument

panel and the glove compartment

1. Press firmly the left end section A as shown in

the figure, operating in the direction indicated by

the arrow. Then, open the section joint B. Fit a

screwdriver wrapped with protective tape in order

to disconnect section B.

2. Insert a screwdriver in section C so as to detach

it.


CH - 780

3. Lift section B so as to detach section D.

(Pay attention not to scratch the instrument panel

with the clip of section C).

4. Detach the fitting of section E.

5. Remove the object-holding drawer/glove-box

compartment 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 inspection cover.

Pay attention so as not to scratch during removal.

2. Remove the brake fluid reservoir by taking out

the two bolts.

3. Remove the instrument panel by taking out the

seven bolts.


CH - 781

4. Remove the reinforcing bracket from the body

by taking out the eight bolts.


CH - 782

Removing air vents/loudspeakers/cigarette

lighter

1. Remove the diffuser assembly by taking out the

five screws.

2. Remove the right and left side air vent clip.

3. Remove the right side air vent.

4. Remove the central and left 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 bracket by

taking out the two screws.

Instrument panel installation

1. Fit the instrument panel on the body and tighten

the seven bolts.

Locking torques (N*m)Instrument panel support - Chassis 18 ÷ 28


CH - 783

2. Fit the brake 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.


CH - 784

6. Fit the object-holding drawer/glove-box com-

partment with the relevant lid using the seven

screws.

7. 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 seat

• Tighten the two screws

10. Fasten the heating adjustment hand grips.


CH - 785

11. Fit the diffuser hand grip with the relevant

screw.

12. Connect the speedometer and electric con-

nections.

13. Fit the instrument panel and the warning lights

with the five screws.

14. Fit instrument panel upholstery frame.

15. Fit the steering wheel (see the "Steering" sec-

tion).

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 the two screws.

3. Fit the right and left side resistors with the four

screws.

4. Fit the central and left air vents with the three

screws.

5. Fit the air vent and, afterwards, place the clip.

6. Fit the diffuser assembly by tightening the five

screws.


CH - 786

Starting operations

Fit the reinforcing bracket on the body and tighten

the eight bolts.

Locking torques (N*m)Instrument panel support - Chassis 18 ÷ 28


CH - 787

Sedili - 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


CH - 788

Van front seat

KEY:

1. Front seat inclination adjustment

2. Seat back for front seat


4. Bushing

5. Gasket

6. Engine inspection cover


8. Central mat

9. Internal guides

10. Front seat cushion


CH - 789

KEY:

1. Screw

2. Seat back fastener

3. Seat back fastener subassembly for rear seat

4. Ring


6. Seat back cushion

7. Screw

8. Cushion

9. Ring


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

position. Make sure that the belt lock is not re-

leased in any direction with an inclination angle of

15 degrees.


CH - 790

2. Make sure that the belt remains locked when the

inclination angle is exceeds the 45 degrees.Never remove the winder.

Fitting the front seat internal bolt

Fit the front seat 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 belt

4. Safety belt attachment

Safety belt at three anchor points with winder

KEY:

1. Bolt

2. Bolt

3. Screw

4. Safety belt

5. Safety belt attachment


CH - 791

Serbatoio carburante

COMPONENTS:

1. Cable harness (fuel pump)

Cable harness (fuel transmitter gauge)

2. Clamp & pipe (for breathing)

3. Clip & pipe (for fuel return)

4. Clip & pipe (for emissions)

5. Clip & pipe (for fuel main)

6. Bolt

7. Fuel tank unit




11. Vapour bleeding checking valve unit

12. Pipe

13. Fuel transmitter gauge unit

14. Fuel pump unit


CH - 792

KEY:

1. Cable harness (for fuel transmitter gauge)

2. Cable harness (for fuel pump)

3. Clamp & pipe (for fuel inlet)


5. Clip & pipe (for fuel main)



8. Bolt



11. Pipe (for emissions)

12. Vapour bleeding checking valve unit

13. Fuel transmitter gauge unit

14. Fuel pump unit

Removal

Remove the parts, as shown in the figure.

Refitting

To refit, follow the operations described above but in reverse order.


CH - 793

Fuel tank cap

Inspection

1. Remove tank cap from the fuel filler.

2. Check that the key can 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 faults are detected, replace the fuel tank cap with a new one.


CH - 794

INDEX OF TOPICS

PRE-DELIVERY PD

General inspection

Vehicle general check

Vehicle external appearance

Check for possible external damage of the vehicle.

- Bodywork paintwork

- Mouldings

- Window panes

- External mirrors

- headlamp glass

- Bumpers

Bodywork panel coupling

Check the correct 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 and close with the key each door.

- Open and close each door with the internal lock.

Van

- Open the tail door with the key to check closing

and hinge operation.

- Close the tail door to check the lock operation.

Pickup

PORTER 1.3 16V Pre-delivery

PD - 797

- Release the locking levers of the side and the

tailboards for checking.

- Open the side and tailboards for checking.

Vehicle cleaning

External

Carry out the following operations:

1. With a low-pressure water jet, soften and rinse

caked dirt.

2. Wash the vehicle with a soft sponge and a mix

of water and car shampoo.

3. Rinse the car shampoo with a low-pressure wa-

ter jet.

4. Use a specific compound for any grease or tar

marks.

5. Thoroughly rinse the vehicle with water.

6. Dry the vehicle 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

9. Adjust mirrors aiming.

Internal

Carry out the following operations:

1. Remove any trace of grease or dirt off the inter-

nal surfaces.

2. Completely remove all plastic covers from

seats, sun screens, instruments panel.

3. Vacuum upholstery and carpets.

4. Vacuum the boot.

5. Remove the protective film from the control pan-

el of the heating system.

6. Remove all the shipping information labels.

7. Clean all glasses and mirrors with a specific

compound.

Pre-delivery PORTER 1.3 16V

PD - 798

8. Check that all the optional parts are correctly

fitted and that they work properly.

User manual

Use and Maintenance Booklet - Warranty

Booklet

Make sure the following elements are in the glove-

box:

- Use and maintenance booklet

- Warranty Booklet

Tools

Check that the vehicle 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: placed inside the left side rear loading com-

partment.

Wheel cover fitting

Wheel guard-central cover fitting

- Fit the central covers and the wheel guards,

slightly hitting, aligning the carved part (of the

wheel guard) with the air valve.


PD - 799

Tyre pressure

tyre pressure

Check inflation pressure.

Adjust inflation pressure of each tyre to the pre-

scribed value. (Tyre pressure is indicated on the

specific label affixed to the vehicle).

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 e ventilazione

Heating system operation - ventilation

Operation check:

- Check controls and make sure that the system

works properly.

Preliminary inspections


PD - 800

Cigarette lighter

Cigarette lighter:

Check if they works properly:

Press the lighter. This will disconnect automatical-

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

Adjustment devices of seat and seat back

locks

Check if they work properly.


PD - 801

Horn operation

Horn functioning

Check if the horn hoots each time that the button

is pressed.

Wipers operation

Windshield washer orientation adjustment

Insert a straight pin in the spray nozzle, 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 window anti-fog device

Check the warning light operation of the device

activated.

Set the anti-fog device switch to "ON".

The relevant warning light turns on.


PD - 802

Windscreen wiper and washer operation

Check:

- The windscreen wipers work easily.

- The windscreen washer fluid sprays at the centre

of the windshield.

External lights

External Lights

Check the operation of the following external

lights:

- Headlamps, high-beam and low-beam lights.

- Left and right turn indicators.

- Tail lights and stop lights.

- License plate 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 repeatedly on the front suspensions.

3. Swing the vehicle sideways repeatedly, then

take the vehicle to its regular position.

4. Clean the headlamp glass, then fit at their front,

the special checking tool and check the correct

orientation.

- Check headlamp orientation.

A = Transversal adjustment

B = Vertical adjustment


PD - 803

Warning lights

Warning lights (instrument panel)

Check the operation of warning lights. (The ignition

switch must be set to "ON").

Parking brake/engaged warning light: It turns

on if the parking brake lever is lifted.

Oil pressure warning light: On.

Battery/charging system warning light: On.

Emergency flashing warning light: It flashes in-

termittently if the emergency indicator switch is

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 the jack and support points for

safety supports

1. Support points for safety supports and dou-

ble upright lift.

The support points are arranged in four positions,

two on the right side and two on the left side.

Place the front part supports under the body strut.

Place the rear part supports on the leaf spring.

Never apply supports to the body.


PD - 804

2. Support points for workshop jack

Front side: apply the jack to the cross-member of

the front suspension.

Rear side: apply the jack to the lower section of the

differential

Leakages

Fluid leaks

Check for possible 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 the door striker square

plate.

2.Place the striker correctly and tap it with a plastic

hammer.

3.Tighten the door screws again:

Locking torques (N*m)Door stop plate - Chassis 20 - 30


PD - 805

Engine housing inspection

Battery connections

Check the following:

- Corrosion or slackness of connections.

- Battery terminals detached due to slackness.

Tighten connections or the terminal, if necessary.

Battery fluid

Check the level:

- Add distilled water up to the upper level if neces-

sary.

- The electrolyte specific weight shall exceed 1.25

at 20°C.

Bellow joint

Sleeve connections and fluid pipes

Check the sleeve and fluid pipe connections.

- Check that there are no signs of leaks in the coolant pipes.

- Check that the hoses and the air inlet duct are properly connected.

Ignition timing

IGNITION TIMING - CHECKING AND ADJUSTMENT

- BEFORE CARRYING OUT THE IGNITION TIMING, CONNECT THE TESTER MULTIMETERPROBE WITH THE DIAGNOSIS CONNECTOR GROUND TERMINAL.- THE ENGINE SHALL NOT EXCEED THE INDICATED SPEED. BESIDES, OPERATE SO THATTHE IGNITION TIMING IS STEADY.

1. Warm up the engine;

2. Connect the rpm indicator terminal to the diagnosis connector.

- AVOID CONTACT BETWEEN THE RPM INDICATOR TERMINAL AND GROUND SO AS NOT TODAMAGE THE ELECTRONIC CONTROL UNIT OF THE ELECTRONIC FUEL INJECTION AND/ORTHE IGNITION COIL.- TAKING INTO ACCOUNT THAT SOME RPM INDICATORS ARE NOT COMPATIBLE WITH THISIGNITION SYSTEM, IT IS RECOMMENDED TO CHECK THE RPM INDICATOR COMPATIBILITYWITH THE SYSTEM BEFORE ITS USE.


PD - 806

A) Rpm indicator terminal

B) Ground terminal

3. Connect the tester multimeter probe with the di-

agnosis connector ground terminal with the spe-

cial tools.

C) Ground

D) Special tool

E) Special tool

F) ECU-T


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 the

ignition timing reference (yellow) on the flywheel is

aligned with indicator (H).

Ignition timing: 3° ± 2° at idle speed; Before top

dead centre (BTDC).

G) Stroboscopic gun flash

H) Reference on the ignition timing inspection hole


PD - 807

6. Ignition timing adjustment

- Loosen the bolt fixing the camshaft sensor.

- Adjust the camshaft sensor position until the fly-

wheel ignition timing reference is aligned with the

indicator.- IF THE CAMSHAFT SENSOR IS TURNED CLOCKWISE,THE IGNITION TIMING IS DELAYED. CONVERSELY, IF THECAMSHAFT SENSOR IS TURNED ANTICLOCKWISE, THEIGNITION TIMING IS ADVANCED.

7. Tighten the bolt fixing the camshaft sensor to the prescribed torque 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 washer fluid in the reserve tank

Check the level:

- The windshield washer fluid level in the reserve

tank must reach the maximum "FULL".

Add windshield washer fluid, if necessary.

Coolant

Coolant in the expansion tank

Check the level (when cold):

- The coolant level in the expansion tank must

reach the maximum "FULL".

Add (in the expansion tank) coolant special for

aluminium engines, if necessary.


PD - 808

Engine idle

Rpm indicator connection

Connect the rpm indicator measurement terminal

to the diagnosis connector.- AVOID CONTACT BETWEEN THE RPM INDICATOR TER-MINAL AND GROUND SO AS NOT TO DAMAGE THE ELEC-TRONIC CONTROL UNIT OF THE ELECTRONIC FUELINJECTION.- TAKING INTO ACCOUNT THAT SOME RPM INDICATORSARE NOT COMPATIBLE WITH THIS IGNITION SYSTEM,CHECK THE RPM INDICATOR COMPATIBILITY BEFOREITS USE.

A) Rpm indicator terminal

B) Ground terminal

Adjust the throttle adjustment valve so that the idle

speed reaches the specified value. Specification:

900 ± 50 rpm.N.B.- DO NOT ADJUST IDLE SPEED WHILE THE VACUUMSWITCHING VALVE IS WORKING. BEFORE ADJUSTINGIDLE SPEED, CHECK THAT THE VACUUM SWITCHINGVALVE 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 radiator

electric fan activation).

- Check that all the accessory switches are set to OFF.

- Check that there is an air filter.

- Check that all the vacuum pipes are connected.

- Check that there are no air leaks in the intake system.

- Check that there are no air leaks in the exhaust system.

- On vehicles with manual transmission, position the gearshift lever in neutral.

- Pull the hand brake.

- Check that the throttle cable is correctly adjusted.

- Check that ignition timing is correctly adjusted.

- Check that the pipe system for engine oil vapour recovery (blow-by), works properly.N.B.

DO NOT ADJUST IDLE SPEED WHILE THE RADIATOR ELECTRIC FAN IS WORKING.


PD - 809

Engine oil

ENGINE OIL

Check the level:

- Check oil level when the engine is hot.

Let the engine run for 2 or 3 minutes, then stop the

engine; add oil until reaching the MAX limit, if nec-

essary.

Recommended productsAGIP SINT EVOLUTION 5W-40 Synthetic mul-tigrade oil for 4-stroke enginesSAE 5W-40, API SL, ACEA A3

Livello 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 parking brake operation_

Operation check:

- The vehicle must brake in straight line.

- Park the vehicle on a slant and operate the park-

ing brake. The vehicle must remain in the same

position.

- Lift the parking brake lever from 6 to 10 notches

when a 20 kg force is applied to the lever.


PD - 810

Road test

Test drive

Engine operation at idle speed and throttle grip

partial opening

At idle speed

Note the idle speed with the engine fully heated.

At throttle grip partial opening

Performance must be regular and without pauses.

Keep speed constant at 40 - 50 km/h.

Engine operation with loaded vehicle and at a

cruising speed

Operation check:

With loaded vehicle

Accelerate up to 3/4 of throttle.

The vehicle must 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 vibration or noises.

The vehicle must operate without any vibration or

abnormal noise of the chassis as well as the body-

work.

Steering wheel

Steering wheel

Check that the steering wheel is in an upright po-

sition (spokes parallel to the cabin floor).

When the vehicle is travelling in a straight line on

a level surface, the steering wheel spokes must be

parallel to the cabin floor.


PD - 811

Steering - Wheel hub joint - Dust guard

Check that there is no interference between 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 strut

2. Suspension arm

3. Steering arm


PD - 812

INDEX OF TOPICS

TIME-SHEET TS

This section has the operation number for various repair procedures.

USED ABBREVIATIONS

RS right side

LS Left side

Camshaft

CAMSHAFT AND TIMING BELTCode Action Duration

1 140011 CAMSHAFT REPLACEMENT2 140021 CAMSHAFT TIMING SYSTEM PUL-

LEY REPLACEMENT3 140031 CRANKSHAFT TIMING SYSTEM

BELT PULLEY REPLACEMENT4 140041 TIMING BELT REPLACEMENT5 140051 BELT TENSIONER REPLACE-

MENT6 140201 UPPER AND/OR LOWER TIMING

BELT COVER - REPLACEMENT

PORTER 1.3 16V Time-sheet

TS - 815

Crankshaft

CRANKSHAFTCode Action Duration

1 131011 CRANKSHAFT AND/OR BUSHINGREPLACEMENT

2 131051 FLYWHEEL REPLACEMENT3 131101 CRANKSHAFT PULLEY REPLACE-

MENT

Drive shaft

Time-sheet PORTER 1.3 16V

TS - 816

PROPELLER SHAFTCode Action Duration

1 370011 PROPELLER SHAFT - REPLACE-MENT

Alternator


TS - 817

ALTERNATORCode Action Duration

1 271011 ALTERNATOR - REPLACEMENT2 270112 ALTERNATOR - SERVICE3 271151 ALTERNATOR PULLEY


TS - 818

Suspension leaf spring

LEAF SPRING AND SHOCK ABSORBERSCode Action Duration

1 481011 LEAF SPRING (ONE SIDE) - RE-PLACEMENT

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-

PLACEMENT6 481301 SHOCK ABSORBER (ONE SIDE) -

REPLACEMENT7 481302 SHOCK ABSORBER (BOTH

SIDES) - REPLACEMENT


TS - 819

Battery

BATTERYCode Action Duration

1 190011 BATTERY - REPLACEMENT2 190101 BATTERY CABLE (TO STARTER

MOTOR) - REPLACEMENT3 190151 BATTERY CABLE (TO GROUND) -

REPLACEMENT


TS - 820

H.T. Coil

HV COIL AND SPARK PLUGSCode Action Duration

1 191011 HV COIL AND/OR EXTENSIONS -REPLACEMENT

2 191101 SPARK PLUGS - REPLACEMENT3 191201 SPARK PLUG HV CABLES (WITH

RESISTANCE) - REPLACEMENT


TS - 821

Cable harnesses

CABLE HARNESSESCode Action Duration

1 820011 CAB INTERNAL CABLE 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 -REPLACEMENT

6 820301 ROOF CABLE HARNESS - RE-PLACEMENT


TS - 822

Gear-box


TS - 823

GEARBOXCode Action Duration

1 331011 COMPLETE GEAR REPLACE-MENT

2 331011 COMPLETE GEAR REPLACE-MENT

3 331012 COMPLETE GEAR SERVICE4 331031 OUTPUT SHAFT REPLACEMENT5 331041 MAIN SHAFT - REPLACEMENT6 331101 SYNCHRONISER RING REPLACE-

MENT7 331121 5TH SPEED GEAR8 331141 TRANSMISSION SHAFT BEARING

AND/OR TRANSMISSION SHAFTREPLACEMENT

9 331151 REVERSER GEAR REPLACE-MENT

10 331161 CLUTCH BELL - REPLACEMENT11 331201 GEAR CRANKCASE REPLACE-

MENT12 331251 REAR COVER REPLACEMENT13 331271 REAR COVER GASKET - RE-

PLACEMENT14 331281 REPLACING "T" SEALING RINGS

AND/OR REAR COVER15 331351 FORK, RODS SERVICE16 331381 ODOMETER CONTROL GEAR RE-

PLACEMENT17 331411 ODOM. SHAFT AND/OR ODOM.

GEAR REPLACEMENT18 331511 ODOMETER TRANSMISSION RE-

PLACEMENT19 331551 GEAR SUPPORT - REPLACEMENT

Front chassis


TS - 824

BODYWORK (FRONT SIDE)Code Action Duration

1 531101 FRONT MUDFLAPS (ONE SIDE) -REPLACEMENT

2 531201 FRONT SIDE PANEL GASKET(ONE 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 - ONE SIDE

3 612031 REAR SIDE BODYWORK RE-PLACEMENT

4 612041 CAB REAR PROTECTION RE-PLACEMENT


TS - 825

Wheel rim

WHEEL RIMCode Action Duration

1 430101 WHEEL RIM (1 WHEEL) - RE-PLACEMENT

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/WHEEL (FOUR WHEELS) -REPLACEMENT

5 430201 WHEEL CAP


TS - 826

Brake cylinder

BRAKE CYLINDERCode Action Duration

1 471051 REAR BRAKE CYLINDER- ONESIDE - REPLACEMENT

2 471551 REAR SHOE DISC - ONE SIDE -REPLACEMENT

Horn


TS - 827

HORNCode Action Duration

1 862051 HORN REPLACEMENT

Clutch assembly

CLUTCH UNITCode Action Duration

1 311011 CLUTCH ASSEMBLY AND/ORCLUTCH DISC REPLACEMENT

2 311251 PRESSURE PLATE BEARING RE-PLACEMENT

3 311611 CLUTCH LEVER AND/OR FORKREPLACEMENT


TS - 828

Engine assembly

ENGINE UNITCode Action Duration

1 120011 ENGINE ASSEMBLY - REPLACE-MENT

2 120012 COMPLETE ENGINE - SERVICE3 120051 ENGINE, PARTIAL (BLOCK WITH

SUMP AND HEAD) - REPLACE-MENT

4 120101 BLOCK, PARTS (BLOCK WITH PIS-TONS AND SHAFT) - REPLACE-

MENT


TS - 829

Ducts

DUCTSCode Action Duration

1 170011 INTAKE DUCT AND/OR GASKETREPLACEMENT

2 170021 EXHAUST DUCT AND/OR GASKETREPLACEMENT

3 170101 EXHAUST PIPE GASKET RE-PLACEMENT

4 170211 MUFFLER, DUCT No. 1 - RE-PLACEMENT

5 170171 MUFFLER REPLACEMENT, DUCTN°2


TS - 830

Oil sump

OIL SUMPCode Action Duration

1 112011 OIL SUMP, OIL AND/OR GASKETREPLACEMENT


TS - 831

Rear differential


TS - 832

REAR DIFFERENTIALCode Action Duration

1 410011 DIFFERENTIAL HOUSING ANDREAR AXLE - REPLACEMENT

2 410061 BLEEDING (OF THE REAR AXLE) -REPLACEMENT

3 410101 DIFFERENTIAL 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 410251 FLANGE AND/OR OIL SEAL AND/OR COLLAPSIBLE SPACERS - RE-

PLACEMENT9 410311 PLANETARY GEARS AND CROWN

WHEELS REPLACEMENT


TS - 833

Brake discs


TS - 834


TS - 835

BRAKE DISCCode Action Duration

1 473011 FRONT BRAKE DISC REPLACE-MENT (ONE SIDE)

2 473021 FRONT BRAKE 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-

MENT5 473301 DISC BRAKE SERVICE KIT (ONE

SIDE) - REPLACEMENT6 473311 DISC BRAKE SERVICE KIT (BOTH

SIDES) - REPLACEMENT


TS - 836

Sidelight

POSITION LIGHTCode Action Duration

1 811011 TAILLIGHT ASSEMBLY (ONESIDE) - REPLACEMENT

2 811031 TAILLIGHT BULB AND/OR GLASS -ONE SIDE - REPLACEMENT


TS - 837

Code Action Duration3 811201 LICENSE PLATE HOLDER LIGHT

REPLACEMENT4 811211 LICENSE PLATE LIGHT GLASS

REPLACEMENT5 811401 REVERSE LIGHT AND/OR BULB

REPLACEMENT6 811501 REAR FOG LIGHT REPLACEMENT

Lights

HEADLAMPSCode Action Duration

1 810011 FRONT HEADLAMP REPLACE-MENT

2 810201 FRONT TURN INDICATOR AS-SEMBLY - ONE SIDE - REPLACE-

MENT3 810271 BULB REPLACEMENT: ONE SIDE


TS - 838

Air filter

AIR FILTERCode Action Duration

1 171021 AIR FILTER ASSEMBLY - RE-PLACEMENT

2 171051 FILTERING ELEMENT REPLACE-MENT

3 171101 AIR FILTER FITTING REPLACE-MENT


TS - 839

Fuel filter

FUEL FILTERCode Action Duration

1 236021 Fuel filter - replacement

Oil filter

OIL FILTERCode Action Duration

1 151011 OIL FILTER AND/OR GASKET - RE-PLACEMENT


TS - 840

Parking brake

PARKING BRAKECode Action Duration

1 465021 PARKING BRAKE CONTROL LEV-ER - REPLACEMENT

2 465721 PARKING BRAKE FRONT CABLEREPLACEMENT

3 465731 PARKING BRAKE REAR CABLEREPLACEMENT


TS - 841

Drum shoes

BRAKE SHOES AND DRUMCode Action Duration

1 472031 REAR BRAKE SHOE REPLACE-MENT (ONE WHEEL)

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 (1WHEEL) - REPLACEMENT

6 472241 REAR SHOE RETURN SPRING -TWO WHEELS - REPLACEMENT

Front grid


TS - 842

FRONT GRILLECode Action Duration

1 751011 FRONT COWL REPLACEMENT2 751031 HEADLAMP HOUSING - ONE SIDE

- REPLACEMENT

Instrument panel

INSTRUMENT PANELCode Action Duration

1 830011 INSTRUMENT PANEL - REPLACE-MENT

2 830101 GAUGES - REPLACEMENT3 830121 ODOMETER - REPLACEMENT4 830141 PRINTED CIRCUIT - REPLACE-

MENT


TS - 843

Fuel injection

FUEL INJECTIONCode Action Duration

1 223011 THROTTLE BODY OR GASKET -REPLACEMENT

2 223101 FUEL INJECTOR - REPLACEMENT3 223201 INJECTOR SUPPLY MANIFOLD -

REPLACEMENT4 223301 FUEL PRESSURE REGULATOR -

REPLACEMENT


TS - 844

Interiors

INSIDE PARTSCode Action Duration

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 REPLACEMENT5 743751 REAR FLOOR CARPET - RE-

PLACEMENT


TS - 845

Adjusting devices

SWITCHES AND REGULATORSCode Action Duration

1 832011 FUEL GAUGE INDICATOR RE-PLACEMENT

2 832031 MINIMUM OIL PRESSURE INDICA-TOR - REPLACEMENT

3 832101 STOP SWITCH - REPLACEMENT4 832111 REVERSE GEAR BULB SWITCH -

REPLACEMENT


TS - 846

Code Action Duration5 832251 ENGINE CHECKING COMPUTER -

REPLACEMENT6 832301 LIGHT SWITCH REPLACEMENT7 832431 WINDSCREEN WIPER RELAY -

REPLACEMENT8 832311 TURN INDICATOR BLINKER RE-

PLACEMENT9 832341 VOLTAGE REGULATOR RE-

PLACEMENT10 832351 COURTESY LIGHT SWITCH RE-

PLACEMENT11 832361 REAR GLASS DEFROSTER

SWITCH - REPLACEMENT12 832371 REAR WINDSHIELD WIPER

SWITCH - REPLACEMENT13 832381 REAR FOG LIGHT SWITCH RE-

PLACEMENT14 832391 KEY SWITCH REPLACEMENT15 832411 LIGHTER REPLACEMENT16 832421 HAND BRAKE SWITCH REPLACE-

MENT17 832441 FAN CONTROL SWITCH RE-

PLACEMENT18 832461 FUEL PUMP RELAY - REPLACE-

MENT19 832471 MAIN RELAY - REPLACEMENT20 832481 PRESSURE SENSOR - REPLACE-

MENT21 832491 FUSE BLOCK REPLACEMENT22 832501 LAMBDA PROBE - REPLACEMENT23 832511 VACUUM RELIEF VALVE SWITCH

- REPLACEMENT24 832541 WATER TEMPERATURE SENSOR

- REPLACEMENT25 832561 WATER TEMPERATURE SENSOR

- REPLACEMENT

Window sprayer


TS - 847

WINDSCREEN WASHERSCode Action Duration

1 851051 GLASS WASHING PUMP AND MO-TOR REPLACEMENT

2 851061 SPRINKLER - REPLAC.3 851081 REPLACEMENT OF THE PIPE

CONNECTING THE PUMP TO THEOPENING

4 851091 RESERVOIR AND WASHINGPUMP REPLACEMENT

Gear stick


TS - 848

GEARSHIFT LEVERCode Action Duration

1 332301 GEAR CONTROL TRANSMISSIONREPLACEMENT

2 332401 GEAR SHIFT LEVER REPLACE-MENT

3 332501 GEAR SHIFT LEVER KNOB RE-PLACEMENT


TS - 849

Single-block

BLOCKCode Action Duration

1 111011 BLOCK/CYLINDER REPLACE-MENT

2 111151 SEALING RING REPLACEMENT(FRONT SIDE CRANKSHAFT)

3 111201 Sealing and/or retaining ring, enginerear side ring - Replacement

4 111251 ELASTIC SUPPORT REPLACE-MENT


TS - 850

Starter motor


TS - 851

STARTER MOTORCode Action Duration

1 280011 STARTER MOTOR - REPLACE-MENT

2 280112 MOTOR - SERVICE3 280211 REMOTE CONTROL - REPLACE-

MENT

Rear floor panel

REAR FLOORING PANELCode Action Duration

1 613011 ENGINE SERVICE COMPART-MENT COVER REPLACEMENT

2 613051 BATTERY HOUSING COVER - RE-PLACEMENT


TS - 852

Door panel

DOOR PANELCode Action Duration

1 670051 FRONT DOOR PANEL (ONE SIDE)- REPLACEMENT

2 670061 SIDE DOOR PANEL (ONE SIDE) -REPLACEMENT

3 670201 FRONT DOOR UPPER/LOWERHINGE (ONE SIDE) - REPLACE-

MENT4 670301 FRONT DOOR LINING - ONE SIDE

- REPLACEMENT5 670311 SIDE DOOR UPHOLSTERY (ONE

SIDE) - REPLACEMENT6 670501 GUIDE FOR FRONT DOOR WIN-

DOW (ONE SIDE)- REPLACEMENT7 670511 GUIDE FOR FRONT DOOR WIN-

DOW (ONE SIDE)- REPLACEMENT8 670601 FRONT DOOR END OF STROKE:

ONE SIDE9 670701 SIDE SLIDING DOOR ARM - RE-

PLACEMENT


TS - 853

Code Action Duration10 670801 SIDE DOOR GUIDE - REPLACE-

MENT

Dashboard


TS - 854

INSTRUMENT PANELCode Action Duration

1 550011 INSTRUMENT PANEL REPLACE-MENT

2 550101 INSTRUMENT PANEL FINISHING -REPLACEMENT

3 550131 INSTRUMENT PANEL CENTRALFINISHING - REPLACEMENT

4 550201 GLOVEBOX REPLACEMENT5 550211 GLOVEBOX OPEN/CLOSE LEVER

REPLACEMENT6 550301 ASHTRAY REPLACEMENT7 550311 VENTILATED AIR PASSAGE RE-

PLACEMENT - ONE SIDE


TS - 855

Bumper

BUMPERSCode Action Duration

1 520011 FRONT BUMPER REPLACEMENT2 520021 REAR BUMPER REPLACEMENT


TS - 856

Brake pedal

BRAKE PEDALCode Action Duration

1 467011 BRAKE PEDAL REPLACEMENT2 467101 PEDAL PROTECTION - REPLACE-

MENT


TS - 857

Clutch pedal

CLUTCH PEDALCode Action Duration

1 313101 PEDAL PROTECTION - REPLACE-MENT

2 313201 CLUTCH TRANSMISSION RE-PLACEMENT


TS - 858

Steering column


TS - 859

COLUMN / STEERING / STEERING HOUSING / JOINTSCode Action Duration

1 442101 ARM REPLACEMENT - ONE SIDE2 442111 ARM REPLACEMENT - TWO

SIDES3 442201 REPLACEMENT OF THE ARTICU-

LATED ARM WITH BAR:ONE SIDE4 442301 UNIVERSAL JOINT REPLACE-

MENT5 442401 STEERING HOUSING REPLACE-

MENT6 442501 STEERING COLUMN REPLACE-

MENT7 442601 LEFT SIDE COVER - REPLACE-

MENT8 442611 RIGHT SIDE COVER - REPLACE-

MENT9 442801 COLUMN PROTECTIONS - RE-

PLACEMENT10 442851 ELASTIC JOINT - REPLACEMENT11 442861 JOINT - REPLACEMENT12 442871 CENTRAL ARM - REPLACEMENT

Piston/connecting rod

PISTON AND CONNECTING RODCode Action Duration

1 132011 PISTONS WITH PIN REPLACE-MENT

2 132021 PISTON RINGS REPLACEMENT3 132051 CONNECTING ROD REPLACE-

MENT4 132061 CONNECTING ROD BUSHING RE-

PLACEMENT


TS - 860

Water pump

WATER PUMP AND THERMOSTATCode Action Duration

1 161011 WATER PUMP AND/OR GASKETREPLACEMENT

2 161051 WATER PUMP PULLEY - RE-PLACEMENT

3 161101 THERMOST. AND/OR GASKET,WATER. OUTL. FITT. REPLACE-

MENT


TS - 861

Fuel pump

FUEL PUMPCode Action Duration

1 234011 FUEL PUMP AND/ OR GASKET -REPLACEMENT

2 234012 FUEL PUMP AND/ OR GASKET -SERVICE


TS - 862

Brake fluid pump

BRAKE PUMPCode Action Duration

1 461021 TANK AND/OR TANK PIPE RE-PLACEMENT

2 463011 POWER BRAKE PUMP ASSEMBLYREPLACEMENT


TS - 863

Oil pump

OIL PUMPCode Action 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 VALVEREPLACEMENT


TS - 864

Rear van door

TAIL DOOR ( VAN )Code Action Duration

1 642151 TAIL DOOR GLASS AND/OR GAS-KET - REPLACEMENT

2 642321 TAIL DOOR HINGE - TWO SIDES -REPLACEMENT

3 642361 TAIL DOOR LOCK ASSEMBLY -REPLACEMENT

4 642391 CYLINDER KIT / REAR DOORLOCK KEY - REPLACEMENT

5 642711 TAIL DOOR PANEL - REPLACE-MENT

6 642771 TAIL DOOR GASKET - REPLACE-MENT

7 642801 TAIL DOOR UPHOLSTERY - RE-PLACEMENT

8 642841 TAIL DOOR SHOCK ABSORBER -REPLACEMENT


TS - 865

Rear-view mirror sun shade

SUN VISOR AND REAR-VIEW MIRRORCode Action Duration

1 752011 EXTERNAL REAR-VIEW MIRROR -ONE SIDE - REPLACEMENT

2 752021 INTERNAL REAR-VIEW MIRRORWITH CEILING LIGHT REPLACE-

MENT.3 752101 SUN VISOR REPLACEMENT4 752151 SUPPORT HANDLE REPLACE-

MENT - ONE SIDE


TS - 866

Radiator

RADIATOR AND WATER PIPESCode Action Duration

1 160011 RADIATOR REPLACEMENT2 160021 TANK, EXPANSION TANK, RADIA-

TOR REPLACEMENT3 160031 PRESSURISED CAP ON RADIA-

TOR REPLACEMENT4 160101 RADIATOR INLET PIPE REPLACE-

MENT5 160111 RADIATOR OUTLET PIPE RE-

PLACEMENT6 160151 ENGINE OUTLET RADIATOR

SLEEVE - REPLACEMENT7 160201 MOTOR, FAN WITH FRAME - RE-

PLACEMENT8 160251 V-BELT REPLACEMENT9 160801 ENGINE SIDE PRESSURISED CAP

- REPLACEMENT


TS - 867

Radio

RADIOCode Action Duration

1 860021 RADIO AND PARTS RELATED TOFITTING - REPLACEMENT

2 860031 RADIO - REPLACEMENT3 860051 LOUDSPEAKER - REPLACEMENT4 860101 AERIAL WITH RELEVANT SUP-

PORT - REPLACEMENT


TS - 868

Heating

HEATINGCode Action Duration

1 870031 HEATING REPLACEMENT2 870271 DEFROSTER PIPE REPLACE-

MENT - TWO SIDES3 870311 DEFROSTER NOZZLE REPLACE-

MENT - TWO SIDES4 870401 REPLACEMENT OF THE HEATING

CONTROL AND THE TRANSMIS-SION

5 870771 RADIATOR ASSEMBLY REPLACE-MENT

6 870781 FAN REPLACEMENT, HEATINGMOTOR

7 870801 RESISTOR REPLACEMENT8 870821 HEATING WATER INLET PIPE RE-

PLACEMENT9 870841 HEATING WATER OUTLET PIPE

REPLACEMENT


TS - 869

Front seat

FRONT SEATCode Action Duration

1 711011 FRONT SEAT CUSHION RE-PLACEMENT - ONE SIDE

2 711021 SEAT BACK FOR FRONT SEATREPLACEMENT - ONE SIDE

3 711061 FRONT SEAT HEADREST RE-PLACEMENT - ONE SIDE

4 711101 FRONT SEAT INTERNAL TRACK -ONE SIDE - REPLACEMENT


TS - 870

Code Action Duration5 711151 SEAT BACK CLOSING FOR

FRONT SEAT - ONE SIDE - RE-PLACEMENT

6 711201 FRONT SEAT CUSHION COVER(ONE SIDE) - REPLACEMENT

7 711251 SEAT BACK COVER FOR FRONTSEAT (ONE SIDE) - REPLACE-

MENT8 711301 FRONT SAFETY BELT HOOK-ONE

SIDE REPLACEMENT9 711351 FRONT SAFETY BELT - ONE SIDE

REPLACEMENT

Rear van seat

REAR SEAT ( VAN )Code Action Duration

1 710051 REAR SEAT CUSHION AND/ORSEAT BACK - REPLACEMENT

2 710101 REAR SEAT CUSHION COVER -REPLACEMENT

3 710151 SEAT BACK COVER FOR REARSEAT - REPLACEMENT


TS - 871

Rear half-shaft

REAR AXLE SHAFTCode Action Duration

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-

MENT4 421301 SEALING RING («T» TYPE) - RE-

PLACEMENT


TS - 872

Cam sensor

CAM SENSORSCode Action Duration

1 192501 CAM SENSOR ASSEMBLY - RE-PLACEMENT

2 192531 CAM SENSOR SUPPORT- RE-PLACEMENT

3 192561 SIGNAL GENERATOR - REPLACE-MENT


TS - 873

Fuel tank

FUEL TANK AND PIPES ( VAN )Code Action Duration

1 237011 FUEL TANK - REPLACEMENT2 237051 FUEL TANK CAP REPLACEMENT3 237701 REACTION VALVE - REPLACE-

MENT4 237811 ACTIVATED CARBON FILTER -

REPLACEMENT


TS - 874

FUEL TANK AND PIPES (PICK-UP)Code Action Duration

1 237011 FUEL TANK - REPLACEMENT2 237051 FUEL TANK CAP REPLACEMENT3 237701 REACTION VALVE - REPLACE-

MENT4 237811 ACTIVATED CARBON FILTER -

REPLACEMENT


TS - 875

Front suspensions

FRONT SUSPENSIONS AND FRONT AXLECode Action Duration

1 431011 LOWER SUSPENSION ARM - ONESIDE - REPLACEMENT

2 431051 LOWER SUSPENSION ARM -BOTH SIDES - REPLACEMENT

3 431101 FRONT SHOCK ABSORBERSPRING REPLACEMENT - ONE

SIDE4 431111 FRONT SHOCK ABSORBER

SPRING REPLACEMENT - BOTHSIDES

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 431251 BAR BUFFER REPLACEMENT -ONE SIDE

9 431321 FRONT WHEEL HUB REPLACE-MENT: ONE SIDE

10 431371 SEALING RING («T» TYPE) AND/OR BEARING (ONE SIDE) - RE-

PLACEMENT11 431381 SEALING RING («T» TYPE) AND/

OR BEARING (BOTH SIDES) - RE-PLACEMENT


TS - 876

Rear end-gate

TAILBOARDCode Action Duration

1 611011 TAILBOARD REPLACEMENT2 611101 TAILBOARD HOOK REPLACE-

MENT


TS - 877

Spare wheel mounting bracket

SPARE WHEEL SUPPORTCode Action Duration

1 511201 SPARE WHEEL SUPPORT - RE-PLACEMENT


TS - 878

Plates

LABELSCode Action Duration

1 750011 PLATE REPLACEMENT - SINGLEPIECE


TS - 879

Wiper

WINDSCREEN WIPERCode Action Duration

1 850051 REPLACEMENT OF THE FRONTWINDSCREEN WIPER ARM AND/

OR BLADE2 850161 FRONT WINDSCREEN WIPER MO-

TOR REPLACEMENT3 850171 FRONT WINDSCREEN WIPER AR-

TICULATION REPLACEMENT


TS - 880

Rear van wiper

REAR WINDSCREEN WIPER AND REAR WINDOW WASHER ( VAN )Code Action Duration

1 852011 WINDSCREEN WIPER ARM AND/OR BLADE - REPLACEMENT

2 852051 MOTOR AND REAR WINDSCREENWIPER SUPPORT - REPLACE-

MENT3 852101 REAR WINDOW WASHER SPRAY-

ER - REPLACEMENT


TS - 881

Head

HEADCode Action Duration

1 110011 HEAD/CYLINDER - REPLAC.2 110051 GASKET/HEAD REPLACEMENT3 110101 REPLACEMENT OF COVER OR

HEAD AND/OR HEAD GASKET/COVER

4 110201 OIL SEAL RING (CAMSHAFT) RE-PLACEMENT

5 110131 OIL FILLER CAP - REPLACEMENT


TS - 882

Throttle cable

ACCELERATOR TRANSMISSIONCode Action Duration

1 552031 ACCELERATOR TRANSMISSIONREPLACEMENT


TS - 883

Brake hoses

BRAKE PIPES AND CALIBRATORCode Action Duration

1 464011 FRONT HOSE REPLACEMENT2 464051 REAR BRAKE HOSE REPLACE-

MENT3 464751 POWER BRAKE REGULATOR AS-

SEMBLY REPLACEMENT


TS - 884

Valves

VALVESCode Action Duration

1 141011 VALVE, VALVE GUIDE REPLACE-MENT

2 141031 SPRING, CAP PLATE AND/ORCOTTERS AND/OR SEAL. RING

REPLAC.3 141101 PIN, ROCKING LEVER REPLACE-

MENT


TS - 885

Windows

WINDOWSCode Action Duration

1 554011 WINDSHIELD AND GASKET RE-PLACEMENT

2 554051 REAR GLASS AND/OR GASKETREPLACEMENT

Van side window


TS - 886

SIDE GLASS ( VAN )Code Action Duration

1 645011 SIDE GLASS STRIP (ONE SIDE) -REPLACEMENT

2 645021 SIDE GLASS AND/OR PROFILE -REPLACEMENT

Frameless side window

DOOR GLASS AND PROFILECode Action Duration

1 671011 FRONT DOOR GLASS REPLACE-MENT - ONE SIDE

2 671021 SIDE DOOR GLASS (ONE SIDE) -REPLACEMENT

3 671051 FRONT DOOR GLASS GUIDE RE-PLACEMENT - ONE SIDE

4 671061 FRONT DOOR GLASS GUIDE(ONE SIDE) - REPLACEMENT


TS - 887

Code Action Duration5 671251 FRONT DOOR INTERNAL PLATE

REPLACEMENT: ONE SIDE6 561261 SIDE DOOR INTERNAL PLATE

(ONE SIDE) - REPLACEMENT7 671271 FRONT DOOR EXTERNAL GLASS

EDGE: ONE SIDE8 671281 SIDE DOOR EXTERNAL GLASS

EDGE (ONE SIDE) - REPLACE-MENT

9 671351 FRONT DOOR GASKET REPLACE-MENT: ONE SIDE

10 671361 SIDE DOOR GASKET (ONE SIDE) -REPLACEMENT


TS - 888

Steering

STEERING WHEELCode Action Duration

1 441071 HORN CONTACT RING REPLACE-MENT


TS - 889

Code Action Duration2 441101 STEERING WHEEL REPLACE-

MENT3 441121 HORN CONTACT SQUARE PLATE

REPLACEMENT4 441151 HORN BUTTON REPLACEMENT


TS - 890

BBattery: 820Belt: 232, 236, 240, 244, 247Bodywork: Brakes: 68, 69Bulbs: 150, 152, 154

CChassis: 70, 740, 804, 824, 825Checks: 357Cleaning: 808Clearance: Control: 561, 664, 670, 682Coolant: 48, 67, 360, 370, 808

DDifferential: 47, 595, 596, 832Doors: 745

EEngine: 44, 45, 66, 70, 225, 806, 809, 810, 829

FFilter: 44, 126, 361, 839, 840Fluid: 615, 863Fuel: 67, 361, 840, 844, 862, 874Fuses: 83

GGearshift:

HHeadlamps: Horn: 802, 827

IIdentification: 22Instrument panel: 779, 843

LLevel: 66Lights: 157, 803, 804, 838

MMaintenance: 13, 43

OOil: 45–47, 66, 67, 248, 298, 349, 358, 810, 831, 840, 864

PPressure: 66, 260, 800Products: 44

RRemote control:

SSafety: 10Seats: 275, 277Shock Absorbers: Spark plugs: Specifications: Switch: 88System: 54, 72, 348, 360, 361, 378, 611, 621

TTank: 874

VVan: 865, 871, 881, 886Vehicle: 29, 655

WWarning: 157, 804Wheel: 685, 687, 710, 799, 811, 826, 878Windows: 742, 886

workshop manual - porter 1.3 16v - workshop

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