PIAGGIO PORTER 1.3 16V 2008 Service Manual

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MANUALE STAZIONE DI SERVIZIO

633530 (IT) - 531 (EN) - 532 (Fr) - 533 (DE) - 534 (ES)

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

PORTER 1.3 16V

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Summary of Contents for PIAGGIO PORTER 1.3 16V 2008

Page 1 MANUALE STAZIONE DI SERVIZIO 633530 (IT) - 531 (EN) - 532 (Fr) - 533 (DE) - 534 (ES) - 535 (PT) - 536 (NL) - 537 (EL) PORTER 1.3 16V...
Page 2 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.
Page 3 SERVIZIO PORTER 1.3 16V Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.
Page 5 INDEX OF TOPICS N GEN ENERAL GUIDELINES HARACTERISTICS PECIAL TOOLS AINTENANCE CO EM MISSION ONTROLO YSTEM TROUBL ROUBLESHOOTING LECTRICAL SYSTEM NGINE NIECTION YSTEM IFFERENTIAL RAKING SYSTEM RANSMISSION SHAFT TEERING COLUMN USPENSIONS IPPER VERSION HASSIS DELIVERY...
Page 6 SHEET...
Page 7 INDEX OF TOPICS N GEN ENERAL GUIDELINES...
Page 8 PORTER 1.3 16V General guidelines 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. •...
Page 9: General Guidelines
PORTER 1.3 16V General guidelines Specification Desc./Quantity are classified as SD, SE, SF, etc. ; while those for diesel en- gines are classified as CC, CD, etc. A/Y Assembly A group of components or an assembled component which in- cludes more than two single parts or subassembly parts. ATDC: after Top Dead Centre (ATDC) BTDC:...
Page 10: Safety Guidelines
PORTER 1.3 16V General guidelines 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.
Page 11 PORTER 1.3 16V General guidelines Towing on a flat truck This is the better method to choose in order to guarantee greater safety. • PULL THE HAND BRAKE ALL THE WAY. • TIE THE VEHICLE TO THE MEANS OF TRANSPORT WITH SUITABLE CABLES. DO NOT APPLY EXCESSIVE FORCE ON THE HOOKS WHICH ARE ON THE VEHICLE BODY- WORK OR YOU RISK DAMAGING THE BODY-...
Page 12 PORTER 1.3 16V General guidelines • IF THE ENGINE DOES NOT START, CHECK THAT THE CENTRAL DIFFERENTIAL LOCKING DEVICE IS FREE, LIFTING ONE OF THE WHEELS AND CHECKING THAT THESE TURN FREELY. ALSO IF THE DIFFERENTIAL LOCKING CHECKING DEVICE WARNING LIGHT INDICATES THAT IT IS FREE, IT IS POSSIBLE THAT IT IS NOT COM- PLETELY FREE.
Page 13: Maintenance Guidelines
PORTER 1.3 16V General guidelines 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.
Page 14 PORTER 1.3 16V General guidelines 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.
Page 15 PORTER 1.3 16V General guidelines (Example); Brake pipe fitting, • Temporarily fit the brake pipe on the wheel cylinder, manually • Tighten the brake pipe on the wheel cylinder, using the special tool «A». Specific tooling 09751-36011-000 tool description - The inspection comprises only the checking operations. Therefore, if malfunctions are detected, it is necessary to replace the defective parts with new ones.
Page 16 PORTER 1.3 16V General guidelines 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 ).
Page 17 PORTER 1.3 16V General guidelines - 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 ±...
Page 18 PORTER 1.3 16V General guidelines Using resin clamps When using resin clamps, do not use pliers or sim- ilar tools, as improper use could damage or cut them. CABLE HARNESS - THE DIMENSION AND CAPACITY OF EACH CABLE ARE SPECIFIC TO GUARANTEE THE PROPER OPERATION OF THE ELECTRICAL SYSTEM.
Page 19 PORTER 1.3 16V General guidelines 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.
Page 20 PORTER 1.3 16V General guidelines 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.
Page 21 INDEX OF TOPICS HARACTERISTICS...
Page 22 PORTER 1.3 16V Characteristics 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.
Page 23 PORTER 1.3 16V Characteristics 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...
Page 24 PORTER 1.3 16V Characteristics CLUTCH Specification Desc./Quantity Engine - transmission mechanism Engine - clutch - transmission Type Dry single disc RANSMISSION Specification Desc./Quantity Forward gear Continue drive gear Reverse gear With sliding gears First gear Ratio 3.769 Second gear Ratio 2.045 Third gear Ratio 1.376...
Page 25: Impianto Elettrico
PORTER 1.3 16V Characteristics PASSENGER PROTECTION DEVICE Specification Desc./Quantity Front safety belt 3 points, with ELR GLASS Specification Desc./Quantity Front windshield glass Laminated Front windshield glass 5.3 mm thickness MOTORE Specification Desc./Quantity Tipo HC - ES E/G a benzina, raffreddamento ad acqua 4 cicli N.
Page 26 PORTER 1.3 16V Characteristics Pick-Up CH - 26...
Page 27: Table Of Contents
PORTER 1.3 16V Characteristics Tightening torques ENGINE Name Torque in Nm Cylinder head - Water outlet joint 15÷22 Cylinder head - Water temperature sensor 24.5 ÷ 34.3 Water pipe - Radiator electric fan thermal switch 20÷30 Cylinder block - Water pump 15 ÷...
Page 28: Table Of Contents
PORTER 1.3 16V Characteristics BODYWORK Name Torque in Nm Muffler front pipe - Exhaust joint 39.2 ÷ 53.9 Instrument panel support - Chassis 18 ÷ 28 Rear seat safety belt - Chassis (external) 28.4 ÷ 53.0 Rear seat safety belt - Chassis (internal) 28.4 ÷...
Page 29 PORTER 1.3 16V Characteristics PROPELLER SHAFT AND DIFFERENTIAL Name Torque in Nm Differential flange - Propeller shaft 39÷54 Differential 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÷54 Filler cap - Differential cover...
Page 30 PORTER 1.3 16V Characteristics Piston ring oversizes OPENING CLEARANCE AFTER USE - PISTON RINGS Specification Desc./Quantity Piston ring max. clearance «1» (mm) Piston ring max. clearance «2» (mm) Max. clearance between piston ring «3» and oil scraper (mm) STANDARD OPENING - PISTON RINGS Specification Desc./Quantity Piston ring «1»...
Page 31: Valve Clearance
PORTER 1.3 16V Characteristics Valve guide - Valve stem VALVES Specification Desc./Quantity Valve stem diameter (mm): Intake valve: 6.6 -0.020-0.040 Valve stem diameter (mm): Outlet valve: 6.6 -0.025-0.045 Valve length: (mm) Intake valve: 112.8 Valve length: (mm) Outlet valve: 114.5 Valve base thickness: (mm) Intake valve: 0.8 Valve base thickness: (mm)
Page 32: Cylinder Head
PORTER 1.3 16V Characteristics Specification Desc./Quantity Intake cam standard height (mm) 33.435 ÷ 33.634 Intake cam minimum height (mm) 33.2 Outlet cam standard height (mm) 33.17 ÷ 33.37 Outlet cam minimum height (mm) 33.0 Testata motore - montaggio e serraggio INLET - EXHAUST MANIFOLD Specification Desc./Quantity...
Page 33 INDEX OF TOPICS PECIAL TOOLS...
Page 34 PORTER 1.3 16V Special tools Tooling INJECTION SYSTEM TOOL Stores code Description 020680Y Srumento diagnosi - Navigator 020682Y Cablaggio interfaccia EOBD - Navigator 020460Y Diagnostic tester 020463Y ECU-EFI interface cable harness to check the injection system electrical val- ues. 020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester 020469Y...
Page 35 PORTER 1.3 16V Special tools Stores code Description 020492Y 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 TOOL Stores code Description 020180y Engine support 020387Y Tool to remove or replace the valve guide bushing...
Page 36 PORTER 1.3 16V Special tools Stores code Description 020401Y Clutch guide tool (clutch fitting) 020398Y Punch (sealing ring fitting) 020388Y Box-spanner for spark plugs (Spark plug removal and refit) 020382Y Tool to remove the valve cotters TRANSMISSION TOOL Stores code Description 020206y Bearing extractor...
Page 37 PORTER 1.3 16V Special tools DIFFERENTIAL TOOL Stores 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...
Page 38 PORTER 1.3 16V Special tools Stores code Description 020211y Flange oil seal extractor 020206y Bearing extractor BRAKE TOOL Stores code Description 020221y Brake drum stop device 020222y Front hub and drum extractor FRONT SUSPENSION TOOL Stores code Description 020224y Connecting rod bushing extractor and changer 020235y Front spiral spring compressor...
Page 39 PORTER 1.3 16V Special tools Stores code Description 020188y Axial hub support and driving pinion tool series - Front axle bearing and differential pinion 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 TOOL Stores code...
Page 40 PORTER 1.3 16V Special tools Stores code Description 020201y Gear bearing fitting punch 0.20222y Front hub and drum extractor 0.20200y Oil seal extractor STEERING TOOL Stores 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-...
Page 41 PORTER 1.3 16V Special tools Stores code Description 0.20230y Tool to replace the differential control pin- ion bearing 020231Y Tie rod head extractor ST - 41...
Page 42 INDEX OF TOPICS AINTENANCE...
Page 43: Scheduled Maintenance Chart
PORTER 1.3 16V Maintenance Scheduled maintenance chart SCHEDULED MAINTENANCE TABLE I: 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 Safety clamps Engine oil *...
Page 44 PORTER 1.3 16V Maintenance Suggested products chart PRODOTTI CONSIGLIATI Product Description Specifications AGIP ROTRA MP 80W-90 Oil with specifications SAE 80W-90, API Gearbox oil GL-5 AGIP BRAKE FLUID DOT4 Brake fluid FMVSS DOT 4 AGIP GREASE PV 2 Multipurpose grease NLGI 2 specifications;...
Page 45: Engine Oil Replacement
PORTER 1.3 16V Maintenance 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»...
Page 46 PORTER 1.3 16V Maintenance 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.
Page 47 PORTER 1.3 16V Maintenance 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.
Page 48: Coolant Replacement
PORTER 1.3 16V Maintenance 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.
Page 49 PORTER 1.3 16V Maintenance 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.
Page 50: Spark Plug
PORTER 1.3 16V Maintenance 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.
Page 51 PORTER 1.3 16V Maintenance 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;...
Page 52 PORTER 1.3 16V Maintenance 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".
Page 53 INDEX OF TOPICS CO EM MISSION ONTROLO YSTEM...
Page 54 PORTER 1.3 16V Emission Controlo System 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.
Page 55 PORTER 1.3 16V Emission Controlo System 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.
Page 56 PORTER 1.3 16V Emission Controlo System 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.
Page 57 PORTER 1.3 16V Emission Controlo System 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.
Page 58 PORTER 1.3 16V Emission Controlo System 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.
Page 59 PORTER 1.3 16V Emission Controlo System 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.
Page 60 PORTER 1.3 16V Emission Controlo System 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.
Page 61 PORTER 1.3 16V Emission Controlo System 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 THEIR ORIGINAL POSITION.
Page 62 PORTER 1.3 16V Emission Controlo System 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.
Page 63 PORTER 1.3 16V Emission Controlo System N.B. CHECK THAT NO EXHAUST FUMES LEAK THROUGH THE OXYGEN SENSOR (LAMBDA PROBE) 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.
Page 64 PORTER 1.3 16V Emission Controlo System - 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 IDLE COMPLY WITH THE REGULATIONS IN FORCE.
Page 65 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 66 PORTER 1.3 16V Troubleshooting Engine Starting difficulties DIFFICULT STARTING Possible Cause Operation Pipes clogged Check/replace damaged parts Fuel filter clogged Replace Air in the fuel feed circuit Bleed and check seals Faulty fuel supply pump Replace Flat battery Check/Replace Unstable battery connections Check and restore contacts Faulty key switch Replace...
Page 67 PORTER 1.3 16V Troubleshooting Possible Cause Operation Leak from injection-pump unit Check and replace damaged components Cylinder-head gasket damaged Replace Excessive oil consumption EXCESSIVE OIL CONSUMPTION Possible Cause Operation High oil level Restore the level Low idle Adjust correctly Piston rings worn or seized Check and replace damaged components Worn or scored cylinders Check and replace damaged components...
Page 68 PORTER 1.3 16V Troubleshooting Possible Cause Operation Oil or grease on disc friction surfaces Check and clean Clutch does not disengage and drags CLUTCH DOES NOT DISENGAGE AND DRAGS Possible Cause Operation Deformed clutch disc Check/replace damaged components External controls seized Check the control unit components, adjust correctly and re- place damaged components Controls not properly adjusted...
Page 69 PORTER 1.3 16V Troubleshooting Brakes overheat SHOE SLIPPAGE ON THE DRUMS Possible Cause Operation Insufficient clearance between shoes and drums Self-adjusting device locked Shoe return spring weak or damaged Replace Pump pistons or cylinders locked Check the unit Drums and shoes worn or scored Overhaul Locked brakes BRAKES BLOCKED...
Page 70 PORTER 1.3 16V Troubleshooting Possible Cause Operation Rear 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 CHASSIS Possible Cause Operation Silent blocks fixing engine to chassis not properly locked or Lock or replace damaged Difficult riding...
Page 71 INDEX OF TOPICS LECTRICAL SYSTEM...
Page 72 PORTER 1.3 16V Electrical system Ground points PUNTI DI MASSA BATTERY-CHASSIS GROUND ES - 72...
Page 73 PORTER 1.3 16V Electrical system 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) ES - 73...
Page 74 PORTER 1.3 16V Electrical system 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...
Page 75 PORTER 1.3 16V Electrical system 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.
Page 76 PORTER 1.3 16V Electrical system 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.
Page 77 PORTER 1.3 16V Electrical system 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.
Page 78 PORTER 1.3 16V Electrical system 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...
Page 79 PORTER 1.3 16V Electrical system 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.
Page 80 PORTER 1.3 16V Electrical system 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...
Page 81 PORTER 1.3 16V Electrical system 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...
Page 82 PORTER 1.3 16V Electrical system 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.
Page 83 PORTER 1.3 16V Electrical system OLOUR TABLE ITALIAN FRENCH ENGLISH GERMAN SPANISH GREEK Πορτοκαλόχρους Arancio Orange Orange Orange Naranjado Γαλανόσ Azzurro D'azur Light Blue Hellblau Azul Λευκόσ Bianco Blanc White Weiss Blanco Κυανόσ Bleu Blue Blau Turqui Κίτρινοσ Giallo Jaune Yellow Gelb Amarillo...
Page 84 PORTER 1.3 16V Electrical system 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.
Page 85 PORTER 1.3 16V Electrical system 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...
Page 86 PORTER 1.3 16V Electrical system 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.
Page 87 PORTER 1.3 16V Electrical system 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...
Page 88: Wiper Switch
PORTER 1.3 16V Electrical system 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.
Page 89 PORTER 1.3 16V Electrical system 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.
Page 90 PORTER 1.3 16V Electrical system 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...
Page 91 PORTER 1.3 16V Electrical system 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.
Page 92 PORTER 1.3 16V Electrical system 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 ES - 92...
Page 93 PORTER 1.3 16V Electrical system 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.
Page 94 PORTER 1.3 16V Electrical system 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.
Page 95: Starter Motor
PORTER 1.3 16V Electrical system 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.
Page 96 PORTER 1.3 16V Electrical system 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.
Page 97 PORTER 1.3 16V Electrical system 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.
Page 98 PORTER 1.3 16V Electrical system 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 tests Starter motor checks - EACH ONE OF THE FOLLOWING TESTS MUST BE PER- FORMED FOR NOT LONGER THAN 3-5 SECONDS.
Page 99 PORTER 1.3 16V Electrical system • 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.
Page 100 PORTER 1.3 16V Electrical system 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...
Page 101 PORTER 1.3 16V Electrical system 5. Using a thickness gauge, measure the rotor shaft thrust clearance at the point between the lock washer and the external cover. Characteristic Clearance: 0.05 - 0.60 mm KEY: 1. Washer 2. Cover 3. Clearance 6.
Page 102 PORTER 1.3 16V Electrical system 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.
Page 103 PORTER 1.3 16V Electrical system 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.
Page 104 PORTER 1.3 16V Electrical system 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. Characteristic Eccentricity limit.
Page 105 PORTER 1.3 16V Electrical system 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.
Page 106 PORTER 1.3 16V Electrical system 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.
Page 107 PORTER 1.3 16V Electrical system 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.
Page 108 PORTER 1.3 16V Electrical system 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.
Page 109 PORTER 1.3 16V Electrical system 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. Characteristic Clearance limit : 0.2 mm Montaggio Assembly...
Page 110 PORTER 1.3 16V Electrical system 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 SLIDING SECTIONS OF THE ROTOR SHAFT AND THE ENGAGING LEVER.
Page 111 PORTER 1.3 16V Electrical system 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.
Page 112 PORTER 1.3 16V Electrical system 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 •...
Page 113 PORTER 1.3 16V Electrical system - 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.
Page 114 PORTER 1.3 16V Electrical system 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.
Page 115 PORTER 1.3 16V Electrical system 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.
Page 116 PORTER 1.3 16V Electrical system 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...
Page 117 PORTER 1.3 16V Electrical system 8.Remove the rotor. Verifiche e controlli 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. Characteristic Standard resistance: 2.9 ±...
Page 118 PORTER 1.3 16V Electrical system 2. with a gauge, measure the commutator outside diameter. If the commutator outside diameter is shorter than the minimum value requested, replace the rotor. Characteristic Standard diameter 14.4 mm Minimum diameter 14 mm Stator Stator check - (for circuit opening). With an ohmmeter, check if there is continuity be- tween the stator coil terminals.
Page 119 PORTER 1.3 16V Electrical system 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 PAINT FROM THE WELDING SURFACE BEFORE CARRYING OUT THE OPERATION.
Page 120 PORTER 1.3 16V Electrical system 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.
Page 121 PORTER 1.3 16V Electrical system 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.
Page 122 PORTER 1.3 16V Electrical system 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.
Page 123 PORTER 1.3 16V Electrical system 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.
Page 124 PORTER 1.3 16V Electrical system • 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.
Page 125: Generator Shaft Fixing
PORTER 1.3 16V Electrical system 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 8.
Page 126 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.
Page 127: Remote Control
PORTER 1.3 16V Electrical system TECHNICAL CHARACTERISTICS OF THE SYSTEM Specification Desc./Quantity Rated supply voltage: 12 Volts Supply voltage range: 11-18 volt Electric current requirement at 13.5 V: 4 mA Locking relay maximum capacity: 30 Amp Turn indicator relay maximum capacity: 8 Amp Module output maximum capacity: 50 mA...
Page 128 PORTER 1.3 16V Electrical system 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.
Page 129 PORTER 1.3 16V Electrical system 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.
Page 130 PORTER 1.3 16V Electrical system 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.
Page 131 PORTER 1.3 16V Electrical system • 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.
Page 132 PORTER 1.3 16V Electrical system 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. CAUTION TO PLACE THE NEW BATTERIES INSIDE THE REMOTE CONTROL, REFER TO THE FIGURE.
Page 133 PORTER 1.3 16V Electrical system IN ORDER TO CARRY OUT THE DIFFERENT FITTING PROCEDURES PROPERLY, CAREFULLY CHECK ALL THE ELECTRICAL CONNECTIONS REQUIRED, PAYING SPECIAL ATTENTION TO BASIC CONNECTIONS: • DEVICE POWER SUPPLY (POSITIVE AND GROUND). • LIVE POSITIVE (+15/54) • DOOR SWITCH.
Page 134 PORTER 1.3 16V Electrical system • 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. •...
Page 135 PORTER 1.3 16V Electrical system 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.
Page 136 PORTER 1.3 16V Electrical system 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.
Page 137 PORTER 1.3 16V Electrical system • 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. •...
Page 138 PORTER 1.3 16V Electrical system • 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;...
Page 139 PORTER 1.3 16V Electrical system installing sensor 7059 under the cab panelling, and therefore it is completely out of sight. THE SENSOR MUST BE ALWAYS FIXED AT A CENTRAL POSITION WITH RESPECT TO THE VEHICLE AXIS, WITH THE SIDE SHOWING THE WORDS AND THE ADJUST- MENT TRIMMER FACING THE VEHICLE INTERNAL SPACE.
Page 140 PORTER 1.3 16V Electrical system • 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".
Page 141 PORTER 1.3 16V Electrical system CAUTION BEFORE 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.
Page 142 PORTER 1.3 16V Electrical system 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).
Page 143 PORTER 1.3 16V Electrical system 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...
Page 144 PORTER 1.3 16V Electrical system 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.
Page 145 PORTER 1.3 16V Electrical system • 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 DETECTION CAUTION IT IS NECESSARY THAT THE ELECTRICAL CONNECTIONS REQUIRED ARE CARRIED OUT (DOOR SWITCH, BONNET SWITCH AND LIVE POSITIVE) SO THAT THE OPERATION HAS A POSITIVE OUTCOME.
Page 146 PORTER 1.3 16V Electrical system IT IS NECESSARY THAT THE ELECTRICAL CONNECTIONS REQUIRED ARE CARRIED OUT (DOOR SWITCH, BONNET SWITCH AND LIVE POSITIVE) SO THAT THE OPERATION HAS A POSITIVE 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).
Page 147 PORTER 1.3 16V Electrical system • 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. •...
Page 148 PORTER 1.3 16V Electrical system • 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.
Page 149 PORTER 1.3 16V Electrical system • 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.
Page 150: Replacing Light Bulbs
PORTER 1.3 16V Electrical system 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.
Page 151 PORTER 1.3 16V Electrical system BULB POSITION AND CHARACTERISTICS 1. Headlamp and clearance lamp 2. Front and side hazard turn indicators/indicator 3. Fog light headlamp CARATTERISTICHE DELLE LAMPADE Specification Desc./Quantity Faro 55 - 60 W Lampeggiatori anteriore e laterale 21 W Faro fendinebbia anteriore 55 W Luce di ingombro...
Page 152: Replacing The Headlight Bulbs
PORTER 1.3 16V Electrical system 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...
Page 153 PORTER 1.3 16V Electrical system 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.
Page 154: Replacing The Taillight Bulbs
PORTER 1.3 16V Electrical system 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.
Page 155 PORTER 1.3 16V Electrical system 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- Replacing the license plate light bulb License plate lights 1.
Page 156 PORTER 1.3 16V Electrical system 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.
Page 157 PORTER 1.3 16V Electrical system Luce retromarcia Reverse gear light 1. Undo the screw to remove the light unit. 2. Turn the bulb anticlockwise by pressing it slight- Faro fendinebbia posteriore Rear fog light 1. Undo the two screws to remove the light unit. 2.
Page 158 PORTER 1.3 16V Electrical system 5. Speedometer Components INSTRUMENT PANEL ES - 158...
Page 159 PORTER 1.3 16V Electrical system 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.
Page 160 PORTER 1.3 16V Electrical system 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.
Page 161 PORTER 1.3 16V Electrical system 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.
Page 162 PORTER 1.3 16V Electrical system Fuel gauge and temperature gauge KEY: 1. Battery 2. Fuel gauge 3. Gauge 4. Water temperature 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.
Page 163 PORTER 1.3 16V Electrical system 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 () 26.0 26.0 Controllo impianto di accensione Ignition check Spark plug 1.
Page 164 PORTER 1.3 16V Electrical system 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.
Page 165 PORTER 1.3 16V Electrical system 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 Cylinder head 15 ÷...
Page 166 PORTER 1.3 16V Electrical system Camshaft sensor 1. Disconnect the camshaft sensor connector. 2. Measure the resistance between the connector terminals. Characteristic Specified 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.
Page 167 PORTER 1.3 16V Electrical system 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...
Page 168 PORTER 1.3 16V Electrical system 5. Jump terminals T and E of the connector using the following specific tool. Specific tooling Integrated 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.
Page 169 PORTER 1.3 16V Electrical system 2. Connection of the specific tool. • Disconnect the ground lead from the battery negative (-) pole. N.B. - THE ELECTRONIC INJECTION UNIT CAN BE CHECKED BY MEASURING THE RESISTANCE OR VOLTAGE ON THE PROBES OF HE SPECIAL TOOL. CAUTION - BEFORE DISCONNECTING THE GROUND LEAD CHECK IF THE FAILURE CODES ARE STORED.
Page 170 PORTER 1.3 16V Electrical system Unit Terminal Condition Standard voltage or Solutions resistance 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-...
Page 171 PORTER 1.3 16V Electrical system 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.
Page 172 PORTER 1.3 16V Electrical system 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.
Page 173 PORTER 1.3 16V Electrical system Removal 1. Disconnect the battery negative (-) terminal. 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.
Page 174: Cooling Circuit
PORTER 1.3 16V Electrical system 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.
Page 175 PORTER 1.3 16V Electrical system 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.
Page 176 PORTER 1.3 16V Electrical system 18. Ignition coil 2 From Position Terminal Terminal Position Instrument panel cable har- Low oil pressure switch ness (Instrument panel, oil pressure warning light) Handbrake switch engaged To the instrument panel cable harness (Instrument panel, handbrake warning light en- gaged) Connection to N5-N13...
Page 177 PORTER 1.3 16V Electrical system From Injector No. 4 (+) 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...
Page 178 PORTER 1.3 16V Electrical system Battery negative cable harness (Pickup/Tipper) 1. Battery 2. Chassis Cable harness unit 1. Engine cable harness ES - 178...
Page 179 PORTER 1.3 16V Electrical system 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.
Page 180 PORTER 1.3 16V Electrical system Battery positive cable harness (Tipper) 1. Battery 2. To the vehicle cable harness Battery positive cable harness (Pickup) ES - 180...
Page 181 PORTER 1.3 16V Electrical system 1. Battery 2. To the vehicle cable harness Battery positive cable harness (Porter Van) 1 Battery 2 To the vehicle cable harness ES - 181...
Page 182 PORTER 1.3 16V Electrical system Battery negative cable harness (Porter Van) 1 Battery 2 Chassis Bodywork-engine ground transmission cable harness (Pickup) ES - 182...
Page 183 PORTER 1.3 16V Electrical system 1. Transmission (gear crankcase) 2. Body Bodywork-engine ground transmission cable harness (van) 1. Transmission (gear crankcase) 2. Body 3. Foldable clamp ES - 183...
Page 184 PORTER 1.3 16V Electrical system 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 VIEWS From Position Terminal Terminal Position Light fuse (L) Courtesy light (+) Courtesy light (DOOR) Courtesy light switch (+)
Page 185 PORTER 1.3 16V Electrical system Roof light cable harness (Van) 1. To the chassis cable harness 2. Light fitting POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEW From Position Terminal Terminal Position Roof light Light switch (tail door) (+) Light fuse (L) Roof light (+) ES - 185...
Page 186 PORTER 1.3 16V Electrical system Tail door cable harness No.1 (Van) 1. To the chassis cable harness 2. Heated rear window defroster 3. License plate light From Position Terminal Terminal Position Light switch License plate light (+) License plate light (+) License plate light (+) Heated rear window defroster Heated rear window defroster...
Page 187 PORTER 1.3 16V Electrical system 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 VIEW From Position...
Page 188 PORTER 1.3 16V Electrical system 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.
Page 189 PORTER 1.3 16V Electrical system From Connection to E1-E5 Left stop light Right turn indicator light switch F1 Rear right turn indicator light Left turn indicator light switch Rear left turn indicator light Roof light (L) Tail door courtesy light switch Reverse gear light switch Reverse gear light (+) Chassis ground...
Page 190 PORTER 1.3 16V Electrical system 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...
Page 191 PORTER 1.3 16V Electrical system 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...
Page 192 PORTER 1.3 16V Electrical system 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 Posizione Terminale Terminale...
Page 193 PORTER 1.3 16V Electrical system Collegamento a A11 -A23 Resistenza (R3) Resistenza (R4) Interruttore orientamento proiettori Resistenza (R3) Interruttore orientamento proiettori Resistenza (R3) Interruttore orientamento proiettori Luce posizione anteriore (des- Luce posizione anteriore (sin- tra) istra) Collegamento a B1-B2 Luce posizione posteriore destra (B) Collegamento a ~ B3 Luce posizione posteriore sin-...
Page 194 PORTER 1.3 16V Electrical system Fanale luci posteriori (Luce Interrutore luci stop (-) stop destra (+)) Fanale luci posteriori (Luce Fanale luci posteriori (Luce stop destra (+)) stop sinistro) Commutatore lampeggiatori Lampeggiatore anteriore/lat- (destri) erale destro Commutatore lampeggiatori Lampeggiatore anteriore/lat- (sinistri) erale sinistro Collegamento a F1-F9...
Page 195 PORTER 1.3 16V Electrical system Commutatore lampeggiatori Motorino Tergicristallo (+2) (Tergicristallo (+2)) Collegamento a 11-12 Motorino Lavacristallo (+) J/B C (Relè tergicristallo lnt.:S) I16 Motorino Tergicristallo (S) Collegamento a K5-K6 Collegamento a K36-K14 J/B C (Fusibile riscaldatore Motorino riscaldamento (+) (L)) Interruttore ventola riscalda- Motorino riscaldamento (-)
Page 196 PORTER 1.3 16V Electrical system R/B (Relè principale (L)) R/B (Relè pompa carburante (+B)) R/B (Relè principale (+S)) R/B (Relè pompa carburante (+S)) Fusibile EFI n° 1 L41A R/B (Relè principale (+B)) Fusibile EFI n° 2 R/B (Relè principale (+S)) Collegamento a L17 ~ L21 EFI ECU (A/T) Collegamento a-X152...
Page 197 PORTER 1.3 16V Electrical system EFI ECU velocità (SPD) Quadro strumenti (Tachimetro sensore velocità) R/B (Relè pompa carburante (- X257 EFI ECU (FC) Controllo diagnostico (VF) EFI ECU (VF) Collegamento a L41A-L41 EFI ECU (BAT) EFI ECU (DSW2) X152 Diodo (IN) Collegamento a K12-K13 X219 EFI ECU (BLW)
Page 198 PORTER 1.3 16V Electrical system Massa telaio anteriore sinistra Z12 Autoradio (-) Collegamento a -Z5 Luce targa destra (-) Collegamento a -Z5 Luce retromarcia Collegamento a -Z5 Luce targa sinistra (-) Collegamento a Z1 -Z2 Pompa carburante (Massa) Collegamento a Z1-Z2 R/B (Relè...
Page 199 PORTER 1.3 16V Electrical system INSTRUMENT PANEL CABLES 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.
Page 200 PORTER 1.3 16V Electrical system 19. J/B A connection 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 .
Page 201 PORTER 1.3 16V Electrical system 57. Diagnostic check 58. Windscreen wiper motor 59. Diagnostic check 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 Position Terminal Terminal Position Right headlight (HI)
Page 202 PORTER 1.3 16V Electrical system From Front position light (right) Front position light (left) Connection to B1-B2 Rear right position light (B) Connection to B18-B3 Rear left position light (B) Connection to B1-B2 Turn indicator switch (lighting (-)) Rear fog light switch (L) Rear fog light (+) Fog light switch Fog light relay...
Page 203 PORTER 1.3 16V Electrical system From Instrument panel (brake oil Low brake oil level switch level warning lights) Reverse gear light switch (-) Reverse gear light (+) Fuel level transmitter (+) Instrument panel (fuel gauge) Oil pressure switch (+) Instrument panel (oil pressure warning light) Instrument panel (Coolant Coolant temperature sensor...
Page 204 PORTER 1.3 16V Electrical system From Connection to K5-K6 Reverse gear light switch (+) Connection to K5-K6 Instrument panel (+B) Connection to K12-K13 Diode (output) Radiator motor relay Radiator fan motor (+) Radiator fan relay (-) Coolant temperature sensor (LO) Connection to L2-L16 Alternator (IG) FUSE ENGINE 20A...
Page 205 PORTER 1.3 16V Electrical system From R/B (Fuel pump relay (L)) Fuel pump (+B) EFI ECU - diagnosis (W) Diagnosis instrument panel (Diagnosis) EFI ECU - speed (SPD) Speed sensor instrument pan- el (Speedometer) R/B (Fuel pump relay (-S)) X257 EFI ECU (FC) Instrument panel (VF) EFI ECU (VF)
Page 206 PORTER 1.3 16V Electrical system From Connection to -Z5 Reverse gear light Connection to -Z5 Left license plate light (-) Connection to Z1 -Z2 Fuel pump (Ground) Connection to Z1 -72 R/B (Main relay (-S)) Connection to Z1 -Z2 Rear fog light switch (-) Connection to -Z5 Rear fog light (-) Connection to Z1 -Z2...
Page 207 PORTER 1.3 16V Electrical system INSTRUMENT PANEL CABLES RIGHT HAND DRIVE VAN: 1. To the courtesy light cable harness 2. left headlight adjustment actuator 3. front left /side turn indicator 4. front left fog light 5. left headlight 6. Front left chassis ground 7.
Page 208 PORTER 1.3 16V Electrical system 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 26.
Page 209 PORTER 1.3 16V Electrical system From Position Terminal Terminal Position Right headlight (HI) Left headlight (HI) Right headlight (LO) Left headlight (LO) Connection to A1-A2 Turn indicator switch (Switch- ing (HU) Connection to A3-A4 Turn indicator switch (Switch- ing (HL) Connection to A1-A2 Instrument panel (High beam warning light)
Page 210 PORTER 1.3 16V Electrical system From Connection to B1-B2 Rear fog light switch Fog light relay Right fog light Turn indicator switch (fog Rear fog light switch (B) lights) Connection to B1-B2 Instrument panel (lighting) Connection to B1-B2 Right license plate light (B) Connection to B1-B2 Heater switch (Lighting) Courtesy light (-)
Page 211 PORTER 1.3 16V Electrical system From Turn indicator switch (Wind- Windscreen wiper motor (+1) screen wiper (+1)) Windshield washer motor (-) Turn indicator switch (Wind- shield washer) Turn indicator switch (Wind- Windscreen wiper motor (+2) screen wiper (+)) Connection to I1-I2 Windshield washer motor (+) Rear window wiper switch Rear window washer motor (-)
Page 212 PORTER 1.3 16V Electrical system From Connection to Z32-Z8 Radiator fan relay Connection to L33-L40 Injector No. 4 (+) R/B (Main relay (L)) R/B (Fuel pump relay (+B)) R/B (Main relay (+S)) R/B (Fuel pump relay (+S)) EFI fuse No. 1 L41A R/B (Main relay (+B)) EFI fuse No.
Page 213 PORTER 1.3 16V Electrical system From Connection to K12-K13 X219 EFI ECU (BLW) Connection to L33-L40 X251 EFI ECU (+B1) Connection to L33-L40 X252 EFI ECU (+B2) Instrument panel (T) X266 EFI ECU (T) EFI ECU (SIO) X268 X269 Diagnostic check (SIO) EFI ECU (REV) X242 X271...
Page 214 PORTER 1.3 16V Electrical system From Connection to Z1 -Z2 Instrument panel Connection to Z5 Rear right lights (-) INSTRUMENT PANEL CABLES LEFT HAND DRIVE VAN: 1. main relay box and fuel pump 2. brake fluid level switch 3. courtesy light switch 4.
Page 215 PORTER 1.3 16V Electrical system 15. rear fog light switch 16. stop light switch 17. J/B A connection 18. Fog light fuse 19. J/B A connection 20. flashing light switch 21. J/B B connection 22. front fog light relay 23. windshield washer motor 24.
Page 216 PORTER 1.3 16V Electrical system 53. windscreen wiper motor 54. Diagnostic check 55. instrument panel 56. key switch ble class=editor height="60%" width="70%" border=1> From Position Terminal Terminal Position Right headlight (HI) Left headlight (HI) Right headlight (LO) Left headlight (LO) Connection to A1-A2 Turn indicator switch (Switch- ing (HU))
Page 217 PORTER 1.3 16V Electrical system From Connection to B1-B2 Rear right position light (B) Connection to B1-B2 Turn indicator switch (lighting (-)) Rear fog light switch (L) Rear fog light (+) Fog light switch Fog light relay Fuse (fog light) Fog light relay Connection to B1-B2 Rear fog light switch...
Page 218 PORTER 1.3 16V Electrical system From Instrument panel (cooling tem- Coolant temperature sensor perature gauge) Instrument panel (Low fuel Fuel level sensor (reserve) warning light) Connection to B1-B2 Sounding mechanism (Lights Sounding mechanism (Lights Diode (input) Diode (output) Courtesy light switch (+) Connection to B19-B22 Diode (input) (Rear fog light switch)
Page 219 PORTER 1.3 16V Electrical system From J/B C (Heating fuse (L)) Heating switch (B) Connection to K5-K6 Reverse gear light switch (+) Connection to K5-K6 Instrument panel (+B) Connection to K12-K13 Diode (output) Radiator motor relay Radiator fan motor (+) Radiator fan relay Coolant temperature sensor Connection to L2-L16...
Page 220 PORTER 1.3 16V Electrical system From Car radio (Loudspeaker (-)) Loudspeaker (-) R/B (Fuel pump relay (L)) Fuel pump (+B) EFI ECU - diagnosis (W) Diagnosis instrument panel (Diagnosis) EFI ECU - speed (SPD) Speed sensor instrument pan- el (Speedometer) R/B (Fuel pump relay (-S)) X257 EFI ECU (FC)
Page 221 PORTER 1.3 16V Electrical system From Front left chassis ground Car radio (-) Connection to Z32-Z8 Rear chassis ground Connection to Z1 -Z2 Fuel pump (Ground) Connection to Z1 -Z2 R/B (Main relay (-S)) Connection to Z1 -Z2 Rear fog light switch (-) Connection to Z1 -Z2 Right headlight adjustment ac- tuator...
Page 222 PORTER 1.3 16V Electrical system INSTRUMENT PANEL CABLES 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.
Page 223 PORTER 1.3 16V Electrical system 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.
Page 224 INDEX OF TOPICS NGINE...
Page 225 PORTER 1.3 16V Engine 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.
Page 226 PORTER 1.3 16V Engine 4. Take out the nut fixing the delivery pipe, then remove the delivery pipe. CAUTION LEAVE THE INJECTOR ON THE INLET MANIFOLD SIDE. BE CAREFUL NOT TO LET THE INJECTORS FALL. PLACE A CLOTH OR A SIMILAR OBJECT UNDER THE INJECTOR BECAUSE FUEL MAY COME OUT.
Page 227: Inlet Manifold - Fuel Delivery Pipe
PORTER 1.3 16V Engine 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.
Page 228: Egr Valve - Egr Pipe
PORTER 1.3 16V Engine 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.
Page 229 PORTER 1.3 16V Engine 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...
Page 230: Exhaust Pipe
PORTER 1.3 16V Engine 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. Characteristic Maximum deformation limit: 0.1 mm If the deformation exceeds the maximum value, replace the exhaust manifold No.1.
Page 231 PORTER 1.3 16V Engine 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.
Page 232: Cylinder Head - Exhaust Manifold
PORTER 1.3 16V Engine Cylinder head - Exhaust manifold 35 ÷ 53 haust manifold for oxygen sensor 29.4 ÷ 39.2 Nm Exhaust 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.
Page 233 PORTER 1.3 16V Engine 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.
Page 234 PORTER 1.3 16V Engine 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.
Page 235: Crankshaft - Crankshaft Belt Pulley
PORTER 1.3 16V Engine 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.
Page 236 PORTER 1.3 16V Engine Timing belt and gears KEY: 1. Alternator-water pump belt 2. Water pump pulley 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.
Page 237 PORTER 1.3 16V Engine 4. Remove the crankshaft pulley. SET THE GEARSHIFT LEVER TO THE FOURTH GEAR, SO AS 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.
Page 238 PORTER 1.3 16V Engine 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.
Page 239 PORTER 1.3 16V Engine 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.
Page 240: Belt Tensioner
PORTER 1.3 16V Engine 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.
Page 241 PORTER 1.3 16V Engine 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.
Page 242: Crankshaft - Timing System Pulley Screw
PORTER 1.3 16V Engine 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.
Page 243 PORTER 1.3 16V Engine Removal - Refitting timing pulley Camshaft pulley removal 1. Remove the timing belt. 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.
Page 244 PORTER 1.3 16V Engine 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.
Page 245 PORTER 1.3 16V Engine 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.
Page 246: Timing System Belt Tensioner
PORTER 1.3 16V Engine 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.
Page 247: Timing Belt Cover Screw
PORTER 1.3 16V Engine 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. Characteristic Belt deflection: 5 mm with a 8 ÷...
Page 248: Crankshaft Pulley - Transmission Screws
PORTER 1.3 16V Engine 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.
Page 249 PORTER 1.3 16V Engine 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 THE SPRING HOLDER, TO AVOID THAT THE SPRING JUMPS OUT.
Page 250 PORTER 1.3 16V Engine • 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.
Page 251 PORTER 1.3 16V Engine • 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.
Page 252 PORTER 1.3 16V Engine • 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. Characteristic Axial clearance: 0.035 - 0.085 mm 8.
Page 253: Cover - Oil Pump
PORTER 1.3 16V Engine 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. DRY THEM WITH COMPRESSED AIR.
Page 254: Cylinder Head Assembly
PORTER 1.3 16V Engine 6. Insert a new sealing ring in the right position with the following special tool. - BE CAREFUL NOT TO DAMAGE THE OIL PUMP DURING FITTING. - MAKE SURE THAT THE SEALING RING IS NOT PLACED DIAGONALLY.
Page 255 PORTER 1.3 16V Engine 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.
Page 256 PORTER 1.3 16V Engine 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 •...
Page 257 PORTER 1.3 16V Engine Drain the coolant and detach water pipes. Detach the delivery and reverse fuel pipe. CAUTION • THE PRESSURE INSIDE THE FUEL DUCT IS APPROX. 284 KPA HIGHER THAN THE AT- MOSPHERIC PRESSURE. • THEREFORE, REMOVE THE PIPES GRADU- ALLY TO AVOID FUEL SPRAYING.
Page 258 PORTER 1.3 16V Engine 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.
Page 259 PORTER 1.3 16V Engine 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 MAY CAUSE THE BREAKING OR DEFORMATION OF THE CYL- INDER HEAD, AND ALSO ENGINE SEIZURE.
Page 260: Pressure Relief Valve
PORTER 1.3 16V Engine 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.
Page 261 PORTER 1.3 16V Engine 2. Fit a new spark plug sealing ring with the special tool recommended. N.B. - MAKE SURE THAT THE SEALING RING IS ADEQUATELY POSITIONED. - USE A SUITABLE WOODEN PIECE TO AVOID DAMAGING THE CYLINDER HEAD COVER. - BE CAREFUL NOT TO DAMAGE THE SEALING RING PROTRUDING PART.
Page 262 PORTER 1.3 16V Engine 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.
Page 263 PORTER 1.3 16V Engine 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.
Page 264 PORTER 1.3 16V Engine Spacer and crinkle washer check 1. Measure the spacer unloaded width with a gauge. Characteristic Minimum 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.
Page 265 PORTER 1.3 16V Engine 2. Cam lobe height check Measure, with a micrometer, the cam lobe height. Characteristic Rated 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:...
Page 266: Cylinder Head - M 8 Camshaft
PORTER 1.3 16V Engine 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 IDENTIFICATION NUMBER. • THE INTAKE ROCKING LEVER PIN CAN BE IDENTIFIED BY THE SPARK PLUG JACKET MILLING.
Page 267 PORTER 1.3 16V Engine 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 IDENTIFICATION NUMBER.
Page 268 PORTER 1.3 16V Engine 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 tooling 020382Y Tool to remove the valve cotters 4.
Page 269 PORTER 1.3 16V Engine 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.
Page 270 PORTER 1.3 16V Engine LEVELNESS TOLERANCE Specification Desc./Quantity Block side: 0.10 mm Inlet 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 GASKET CONTACT SURFACES.
Page 271 PORTER 1.3 16V Engine 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.
Page 272 PORTER 1.3 16V Engine 3. Rectify the valve only as much as to obtain an even surface contacting the valve seat. MAKE SURE THAT VALVES ARE MACHINED WITH THE CORRECT ANGLE. Characteristic Valve rectification angle: 45.5° 4. Visually check if the valve stem end has traces of abnormal wear.
Page 273 PORTER 1.3 16V Engine 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.
Page 274 PORTER 1.3 16V Engine 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. Characteristic Valve spring maximum out of square <...
Page 275 PORTER 1.3 16V Engine If the minimum unloaded length value and/or the minimum tension value is below the minimum limit, replace the valve spring. Reference: Characteristic Valve spring unloaded length (marked in PINK) 45.2 ± 0.5 mm Valve spring unloaded length (marked in OR- ANGE) 47.4 mm 3.
Page 276 PORTER 1.3 16V Engine 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.
Page 277 PORTER 1.3 16V Engine 4. Clearance check Make sure that clearance complies with specifica- tion values. Characteristic Inlet: 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.
Page 278 PORTER 1.3 16V Engine 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.
Page 279 PORTER 1.3 16V Engine 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 •...
Page 280 PORTER 1.3 16V Engine 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.
Page 281 PORTER 1.3 16V Engine - CLEAN CAREFULLY ALL THE PARTS TO BE FITTED . - BEFORE FITTING THE DIFFERENT PARTS, APPLY A LAYER OF ENGINE OIL ONTO ALL THE SLIDING 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...
Page 282 PORTER 1.3 16V Engine 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.
Page 283 PORTER 1.3 16V Engine 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 THAT IT DOES NOT BEND. - DO NOT REUSE ANY RING THAT WAS PREVIOUSLY BENT OR FITTED INCORRECTLY.
Page 284 PORTER 1.3 16V Engine 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 tooling...
Page 285: Cylinder Head - Water Temperature Sensor 24.5 ÷
PORTER 1.3 16V Engine 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.
Page 286: Cylinder Head - Cylinder Block
PORTER 1.3 16V Engine 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 TO TIGHTEN THE SCREWS, CAN CAUSE CRACKS AND DIS- TORTIONS ON THE HEAD, LEADING ALSO TO THE EN- GINE SEIZURE.
Page 287 PORTER 1.3 16V Engine 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 THREADED HOLES WHERE SCREWS FOR SUPPORTS ARE FITTED.
Page 288: Cylinder Head - Cylinder Head Cover
PORTER 1.3 16V Engine 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.
Page 289 PORTER 1.3 16V Engine E.G.R. circuit intake duct Exhaust 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.
Page 290 PORTER 1.3 16V Engine 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.
Page 291 PORTER 1.3 16V Engine 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.
Page 292 PORTER 1.3 16V Engine 3. Remove the crankshaft pulley. - IF THE CRANKSHAFT PULLEY CAN NOT BE TAKEN OUT MANUALLY, FIT THE FOLLOWING SPECIAL TOOL: Specific tooling 020380Y TIMING PINION EXTRACTOR 4. Remove the crankshaft pulley flange. EN - 292...
Page 293 PORTER 1.3 16V Engine 5. Remove the tensioner and relevant spring. 6. Remove the water pump. 7. Remove the water pump gasket. Cylinder block removal - Phase 2 1. Remove the alternator support bracket, the en- gine right support with the guide for the oil dipstick. 2.
Page 294 PORTER 1.3 16V Engine 4. Remove the pressure plate and clutch disc. N.B. - AVOID THE FLYWHEEL ROTATION, USING THE FOL- LOWING SPECIAL TOOL: Specific tooling 020184Y FLYWHEEL LOCKING TOOL 5. Check the flywheel eccentricity. N.B. - IF THE FLYWHEEL ECCENTRICITY DOES NOT COMPLY WITH THE SPECIFICATION REQUIREMENTS, REPLACE THE FLYWHEEL.
Page 295 PORTER 1.3 16V Engine 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 tooling 020403Y FLYWHEEL LOCK WRENCH 3.
Page 296 PORTER 1.3 16V Engine 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.
Page 297 PORTER 1.3 16V Engine 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 CONNECTING RODS, SO THAT THE SINGLE FITTING POSITIONS ARE EASILY IDENTIFIED.
Page 298 PORTER 1.3 16V Engine 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.
Page 299 PORTER 1.3 16V Engine 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. Characteristic Specification values 19.002 - 19.005 mm...
Page 300 PORTER 1.3 16V Engine 2. Fit the special tool in pin hole. Take out the pin with a hydraulic press. - DISASSEMBLE THE SPECIAL TOOL AND USE ONLY THE CYLINDRICAL PART. Piston inspection 1. Piston cleaning • Remove the piston rings. •...
Page 301 PORTER 1.3 16V Engine 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.
Page 302 PORTER 1.3 16V Engine PISTON RING RATED THICKNESS Specification Desc./Quantity Piston ring No. 1 1.17-1.19 Piston ring No. 2 1.47- 1.49 PISTON RING OPENING Specification Desc./Quantity Piston ring No. 1 ("T" reference mark) 0.27-0.37 mm Piston ring No. 1 ("N" reference mark) 0.27-0.40 mm Piston ring No.
Page 303 PORTER 1.3 16V Engine 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 tooling 020385Y SUPPORT FOR PISTONS 020386Y TOOL TO FIT/REMOVE THE PISTON FROM THE CONNECTING ROD 2.
Page 304 PORTER 1.3 16V Engine 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.
Page 305 PORTER 1.3 16V Engine 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.
Page 306 PORTER 1.3 16V Engine 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.
Page 307: Connecting Rod - Connecting Rod Cap
PORTER 1.3 16V Engine 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.
Page 308 PORTER 1.3 16V Engine 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.
Page 309 PORTER 1.3 16V Engine 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 PROTECTIVE GOGGLES. 2. Measure the diameter of each connecting rod pin in four directions, distanced 90°...
Page 310 PORTER 1.3 16V Engine 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.
Page 311 PORTER 1.3 16V Engine measured value is considered to be the cylinder diameter. Characteristic Cylinder 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.
Page 312 PORTER 1.3 16V Engine 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.
Page 313 PORTER 1.3 16V Engine 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.
Page 314 PORTER 1.3 16V Engine • Select a piston that has the same type of cylinder coupling E. N.B. - THE COUPLING TYPE «E» IS INDICATED ON THE PISTON CROWN. Crankcase bearings Oil sealing rear gasket replacement 1. Rear sealing ring removal. Remove the sealing ring from the flange, using a punch.
Page 315 PORTER 1.3 16V Engine 2.Timing side sealing ring fitting Insert a new sealing ring using the following spe- cial tool. THE SPECIAL TOOL IS DESIGNED CARRY OUT REMOVAL AND REFIT DIRECTLY ON THE VEHICLE. Specific tooling 020384Y TOOL FOR TIMING SIDE CRANK- SHAFT OIL SEAL Crankshaft Check the axial clearance of the crankshaft.
Page 316 PORTER 1.3 16V Engine 2. With the fixing screws remove the main bearing with the bushing. - KEEP THE LOWER BUSHING COUPLED WITH THE MAIN BEARING. 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.
Page 317: Cylinder Block - Main Bearing Cap
PORTER 1.3 16V Engine 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. Characteristic Eccentricity limit allowed: 0.06 mm 8. Place the crankshaft in the cylinder block. 9.
Page 318 PORTER 1.3 16V Engine 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.
Page 319 PORTER 1.3 16V Engine 5 = Main bearing category 4 = Main bearing category 3= Main bearing category 2 = Main bearing category 1 = 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...
Page 320 PORTER 1.3 16V Engine • 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 3 = categories of the main journal No.3 2 = categories of the main journal No.2 1 = categories of the main journal No.1 (TIMING SIDE) •...
Page 321 PORTER 1.3 16V Engine 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.
Page 322: Cylinder Block - Water Pump
PORTER 1.3 16V Engine 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 THE THREADED SECTION FROM THE CYLINDER BLOCK SIDE. Recommended products Three Bond 1377B Adhesive sealing com- pound Locking torques (N*m)
Page 323 PORTER 1.3 16V Engine 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 WITH SEALANT. THEREFORE, WHEN THE PRESSURE SWITCH IS REPLACED WITH A NEW ONE, FIRST, REMOVE THE COATING COMPLETELY SINCE THE PRODUCT LOOSES ITS CHARACTERISTICS WITH TIME.
Page 324 PORTER 1.3 16V Engine 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.
Page 325 PORTER 1.3 16V Engine - WHEN REMOVING GREASE, CLEAN ANY TRACES OF OIL FROM THE THREADED AREA WITH A CLOTH SOAKED IN ALCOHOL. - DO NOT ALLOW THAT RESIN OR RUBBER PARTS MAKE CONTACT WITH ALCOHOL, ESPE- CIALLY THE SEALING RING. •...
Page 326 PORTER 1.3 16V Engine 5. Measure the flywheel eccentricity using the dial gauge. - REPLACE THE FLYWHEEL IF ECCENTRICITY EXCEEDS THE LIMIT ALLOWED. Characteristic Maximum limit allowed 0.1 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.
Page 327 PORTER 1.3 16V Engine 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 fitting N.B.
Page 328 PORTER 1.3 16V Engine Crankshaft fitting 1. Fit the main bushings on the block and on sup- ports. N.B. - DO NOT TOUCH THE FRONT AND LOWER SURFACES OF BUSHINGS. MAKE SURE THAT BUSHINGS ARE PER- FECTLY FITTED. 2. Lubricate the seat of each bushing with engine oil.
Page 329 PORTER 1.3 16V Engine 5. Apply oil onto the crankshaft main journal. - AVOID THAT THE OIL FLOWS IN THE THREADS FOR THE MAIN BEARING SCREWS. 6. Fit the main bearing with the reference arrow facing towards the oil pump and following the nu- merical sequence.
Page 330 PORTER 1.3 16V Engine 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.
Page 331 PORTER 1.3 16V Engine 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.
Page 332 PORTER 1.3 16V Engine 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 USING THE SPECIAL TOOL BELOW. Specific tooling 020184Y FLYWHEEL LOCKING TOOL Locking torques (N*m) Crankshaft - Crankshaft belt pulley 88÷98...
Page 333 PORTER 1.3 16V Engine 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 BE EASILY TURNED.
Page 334 PORTER 1.3 16V Engine 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.
Page 335 PORTER 1.3 16V Engine 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.
Page 336: Oil Sump - Cylinder Block
PORTER 1.3 16V Engine 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 TO AVOID THE FORMATION OF EXCESSIVE RESIDUES IN- SIDE THE ENGINE.
Page 337 PORTER 1.3 16V Engine 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 tooling 020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester 2.
Page 338 PORTER 1.3 16V Engine COMPRESSION CHECK IF 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.
Page 339 PORTER 1.3 16V Engine 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.
Page 340 PORTER 1.3 16V Engine 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.
Page 341 PORTER 1.3 16V Engine 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...
Page 342 PORTER 1.3 16V Engine 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.
Page 343 PORTER 1.3 16V Engine 5. With a thickness gauge and using the special tool, check the diaphragm spring, to detect possi- ble height deviations. Specific tooling 020197y Instrument to measure the height of the clutch diaphragm spring Characteristic Height deviation Limit: 0.7 mm 6.
Page 344 PORTER 1.3 16V Engine Clutch lever stop Check for wear or damage. Spring Check for wear or damage. Clutch lever Check for wear or damage. Clutch disc 1. Check the clutch disc for signs of wear. Rivet depth Characteristic Limit 0.3 mm 2.
Page 345 PORTER 1.3 16V Engine 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.
Page 346 PORTER 1.3 16V Engine 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...
Page 347 PORTER 1.3 16V Engine 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.
Page 348: Lubrication System
PORTER 1.3 16V Engine 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. Characteristic Nut 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.
Page 349 PORTER 1.3 16V Engine 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.
Page 350: Oil Pressure Switch - Cylinder Block
PORTER 1.3 16V Engine 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 THE OIL PRESSURE SWITCH.
Page 351 PORTER 1.3 16V Engine 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.
Page 352 PORTER 1.3 16V Engine 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.
Page 353 PORTER 1.3 16V Engine 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 EXCEEDS THE PRESCRIBED VALUE. Characteristic Clearance 0.16 - 0.24 4.
Page 354 PORTER 1.3 16V Engine 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.
Page 355: Oil Pump - Cylinder Block
PORTER 1.3 16V Engine 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.
Page 356: Oil Filter - Cylinder Block
PORTER 1.3 16V Engine 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 TWO POINTS: ONE ON THE OIL PUMP SIDE AND THE OTHER ON THE FLYWHEEL SIDE.
Page 357 PORTER 1.3 16V Engine 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.
Page 358 PORTER 1.3 16V Engine 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 EXCEEDS THE PRESCRIBED VALUE. Characteristic Clearance 0.16 - 0.24 4.
Page 359 PORTER 1.3 16V Engine 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.
Page 360: Oil Pump - Oil Pressure Switch
PORTER 1.3 16V Engine 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.
Page 361 PORTER 1.3 16V Engine 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.
Page 362: Fuel Filter Fixing Nut
PORTER 1.3 16V Engine 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. - NEVER REUSE AN OLD GASKET. FAILURE TO OBSERVE THIS SAFETY MEASURE CAN CAUSE FIRE AFTER FUEL LEAKAGE.
Page 363 PORTER 1.3 16V Engine Verifiche e controlli 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 THE RADIATOR FINS.
Page 364 PORTER 1.3 16V Engine 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.
Page 365 PORTER 1.3 16V Engine Thermostatic valve Thermostat removal 1. Disconnect the battery negative (-) terminal. 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 INTO THE ALTERNATOR.
Page 366: Cover - Thermostat 5.9 ÷
PORTER 1.3 16V Engine 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.
Page 367 PORTER 1.3 16V Engine 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 1.
Page 368 PORTER 1.3 16V Engine • 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.
Page 369 PORTER 1.3 16V Engine 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.
Page 370 PORTER 1.3 16V Engine Coolant temperature sensor Radiator thermoswitch removal 1. Disconnect the battery negative (-) terminal. 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.
Page 371 PORTER 1.3 16V Engine 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.
Page 372 PORTER 1.3 16V Engine 4. Connect the battery negative (-) terminal. 5. Start up the engine and check any water leaks. Water pump Water pump removal 1. Disconnect the battery negative (-) terminal. 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.
Page 373 PORTER 1.3 16V Engine 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.
Page 374 PORTER 1.3 16V Engine 5. Cylinder block *: Non-reusable parts 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.
Page 375 PORTER 1.3 16V Engine 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.
Page 376 PORTER 1.3 16V Engine 6. Fill with coolant. 7. Fit the lower crankcase. 8. Connect the battery negative (-) terminal. EN - 376...
Page 377 INDEX OF TOPICS NIECTION YSTEM...
Page 378 PORTER 1.3 16V Iniection System 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.
Page 379 PORTER 1.3 16V Iniection System 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.
Page 380 PORTER 1.3 16V Iniection System 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.
Page 381 PORTER 1.3 16V Iniection System 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.
Page 382 PORTER 1.3 16V Iniection System 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.
Page 383 PORTER 1.3 16V Iniection System - THE NUMBER OF THE SPECIAL TOOL CONNECTOR TERMINAL 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 BEFORE DISCONNECTING THE BATTERY CABLE TO AVOID THAT IT IS CLEARED WHEN THE CABLE IS DISCONNECTED.
Page 384 PORTER 1.3 16V Iniection System DLC CONNECTOR KEY Specification Desc./Quantity Battery powered ECU - T EFI - T REV - Engine revs signal OBD II serial data line (ISO 14230 K line) Present during transmission ECU ground 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.
Page 385 PORTER 1.3 16V Iniection System 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.
Page 386 PORTER 1.3 16V Iniection System 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.
Page 387 PORTER 1.3 16V Iniection System ECU-DRACO CONNECTOR LAYOUT IS - 387...
Page 388 PORTER 1.3 16V Iniection System 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...
Page 389 PORTER 1.3 16V Iniection System * 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 terminali...
Page 390 PORTER 1.3 16V Iniection System CONNECTOR A ( CONNECTED TO THE ENGINE ELECTRICAL SYSTEM Specification Desc./Quantity 21 (N1+) 22 (N2+) Cam angle sensor (+) 23 (E1) Sensor unit ground 24 (#40) Injector (cylinder No.4) 25 (#30) Injector (cylinder No.3) 26 (#20) Injector (cylinder No.2) 27 (#10) Injector (cylinder No.1)
Page 391 PORTER 1.3 16V Iniection System CONNECTOR B ( CONNECTED TO THE ENGINE ELECTRICAL SYSTEM Specification Desc./Quantity 14 (ICMB) Ignition unit (with ionic current measurement) 15 (PIM) Pressure sensor signal 16 (VC) Throttle valve sensor power supply 17 (E2) Sensor ground 18 (FCCP) 19 (VFP) 20 (OXH1)
Page 392 PORTER 1.3 16V Iniection System CONNECTOR C ( CONNECTED TO THE VEHICLE ELECTRICAL SYSTEM Specification Desc./Quantity 8 (SI01) Diagnostic tester 9 (T) Test terminal 10 (DEF) Anti-fog system switch 11 (A/T) Radiator fan relay 12 (MGC) 13 (FAN1) 37 (SPD) Vehicle speed sensor 38 (ACSW) 39 (BLW)
Page 393 PORTER 1.3 16V Iniection System CONNECTOR D ( CONNECTED TO THE VEHICLE ELECTRICAL SYSTEM Specification Desc./Quantity 1 (BAT) Memory protection power supply 2 (FC1) 3 (W) Malfunction indicator light 4 (ATTX) b (SI02) 6 (TRRQ) Headlight switch 7 (+B1) Fuel supply 29 (E21) Rear oxygen sensor ground 30 (FC2)
Page 394 PORTER 1.3 16V Iniection System DRACO CONNECTOR - 14 Specification Desc./Quantity 70 (SEL1) 37 (SPD) Vehicle speed sensor 6 (TRRQ) Headlight switch 36 (+B2) Fuel supply 31 (REV) Engine revs signal (rpm) 29 (E21) Rear oxygen sensor ground 1 (BAT) Memory protection power supply 9 (T) Test terminal...
Page 395 PORTER 1.3 16V Iniection System DRACO CONNECTOR - 16 Specification Desc./Quantity 75 (OX1) Front oxygen sensor 15 (PIM) Pressure sensor signal 14 (ICMB) Ignition unit (with ionic current measurement) 73 (OX3) Rear oxygen sensor 40 (STP) Stop light switch 39 (BLW) Heater fan switch 45 (THW) Engine coolant temperature sensor...
Page 396 PORTER 1.3 16V Iniection System DRACO CONNECTOR - 22 Specification Desc./Quantity 27 (#10) Injector (Cyl. 1) 58 (IG3) Injection signal (Cyl. 3) 59 (IG2) Injection signal (Cyl. 2) 60 (IG1) Injection signal (Cyl. 1) 57 (IG4) Injection signal (Cyl. 4) 82 (GND) Ground lead (-) 52 (N2-)
Page 397 PORTER 1.3 16V Iniection System DRACO PROGRAM. CONNECTOR Specification Desc./Quantity 82 (GND) Ground lead (-) 2d (TX) Signal transmission 3d (RX) Signal reception 4d (V dc-Ref) (+ 5 V) Power supply with reference direct current volt- Misure di sicurezza per la diagnosi SAFETY MEASURES TO REPAIR THE SUPPLY SYSTEM 1.
Page 398 PORTER 1.3 16V Iniection System 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.
Page 399 PORTER 1.3 16V Iniection System Bleeding pipe Pipe insertion length 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.
Page 400 PORTER 1.3 16V Iniection System 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.
Page 401 PORTER 1.3 16V Iniection System 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.
Page 402 PORTER 1.3 16V Iniection System Diagnostic failure code: P0120 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.
Page 403 PORTER 1.3 16V Iniection System 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.
Page 404 PORTER 1.3 16V Iniection System - 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.
Page 405 PORTER 1.3 16V Iniection System Specific tooling 020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester 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.
Page 406 PORTER 1.3 16V Iniection System 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.
Page 407 PORTER 1.3 16V Iniection System 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.
Page 408 PORTER 1.3 16V Iniection System 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.
Page 409 PORTER 1.3 16V Iniection System • 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.
Page 410 PORTER 1.3 16V Iniection System 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.
Page 411 PORTER 1.3 16V Iniection System 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.
Page 412 PORTER 1.3 16V Iniection System 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.
Page 413 PORTER 1.3 16V Iniection System CAUSED BY A BAD CONTACT BETWEEN THE MALE AND THE 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.
Page 414 PORTER 1.3 16V Iniection System Characteristic Resistance: 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. Diagnostic failure code: P0105 Failure detected:Manifold absolute pressure/ barometric pressure circuit malfunction Affected area...
Page 415 PORTER 1.3 16V Iniection System - Engine electronic control unit Diagnostic failure code: P0130 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 Diagnostic failure code: P0135 Failure detected:Oxygen sensor circuit slow response (bank 1, sensor 1)
Page 416 PORTER 1.3 16V Iniection System - Injector locking or leakage - Interrupted or short-circuited wire in the oxygen sensor circuit. - Oxygen sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Gas leak in the exhaust system - Vacuum switching valve for vapour bleeding - Engine electronic control unit Diagnostic failure code: P0172...
Page 417 PORTER 1.3 16V Iniection System - Cylinder 2 - Cylinder 3 - Cylinder 4 Affected area: - Ignition system - Injector - Fuel pressure - Compression pressure - Adjustment valve clearance of valves - Ionic current sensor Diagnostic failure code: P0314 Failure detected: Single cylinder irregular ignition (cylinder not specified) (EU standards) Affected area: - Engine coolant temperature sensor...
Page 418 PORTER 1.3 16V Iniection System Failure detected: Vehicle speed sensor failure Affected area: - Interrupted or short-circuited wire in the vehicle speed sensor circuit. - Instrument panel - Vehicle speed sensor - Engine electronic control unit DAIHATSU MOTOR CORPORATION CODES Diagnostic failure code: P1105 Failure detected: Barometric pressure sensor circuit failure Affected area:...
Page 419 PORTER 1.3 16V Iniection System Diagnostic failure code: P1667 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 - Engine electronic control unit FAILURE-FREE FUNCTION If one of the following codes are detected, the electronic control unit enters the failure-free mode allowing...
Page 420 PORTER 1.3 16V Iniection System Failure detected:When an abnormal situation is detected in the signal sent by the rear oxygen sensor Failure-free operation: - 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.
Page 421 PORTER 1.3 16V Iniection System Malfunction phenomenon Probable affected area • Difficult start-up (summer) Fuel pump checking circuit • Injector circuit • Ignition coil circuit (with ignition spark plug) • Spark plug • Vacuum switching valve circuit to increase idle speed Engine does not hold idling Malfunction phenomenon Probable affected area...
Page 422 PORTER 1.3 16V Iniection System Malfunction phenomenon Probable affected area • PVC line • No output Fuel pump checking circuit • Injector circuit • Fuel filter - Fuel circuit pipes Engine poor at full power Malfunction phenomenon Probable affected area •...
Page 423 PORTER 1.3 16V Iniection System 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.
Page 424 PORTER 1.3 16V Iniection System 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.
Page 425 PORTER 1.3 16V Iniection System 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.
Page 426 PORTER 1.3 16V Iniection System - 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.
Page 427 PORTER 1.3 16V Iniection System 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.
Page 428 PORTER 1.3 16V Iniection System 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.
Page 429 PORTER 1.3 16V Iniection System - 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.
Page 430 PORTER 1.3 16V Iniection System 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.
Page 431 PORTER 1.3 16V Iniection System • 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 THE MEASUREMENT AS SOON AS POSSIBLE. Characteristic Limit value: 1030 kPa (10.5 kgf-cm²) Specified value:...
Page 432 PORTER 1.3 16V Iniection System Diagnostic tester display Signal Vehicle conditions Reference values under abbrevia standard conditions tion FUEL SUPPLY SYSTEM (Fuel FSYS Minimum speed after warming up 02 (closed cycle) supply system status) CALCULATED LOAD (calculated LOAD Minimum speed without load after warming 4.0-5.0% load value) 2500 rpm without load after warming up...
Page 433 PORTER 1.3 16V Iniection System Diagnostic tester display Signal Vehicle conditions Reference values under abbrevia standard conditions tion OXYGEN SENSOR S1 (heated 02,FP Minimum speed after warming up -5-5% oxygen sensor 1) 02,FV 0.05-0.95 V OXYGEN SENSOR S2 (heated 02,RP With the engine running at 2000 rpm, for 3 12.5-87.5% oxygen sensor 2)
Page 434 PORTER 1.3 16V Iniection System OR AN OHMMETER TO THE ELECTRONIC CONTROL UNIT WHEN 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.
Page 435 PORTER 1.3 16V Iniection System System to be checked Terminals Measurement conditions Reference values Rear O2 sensor 73 (0X3)-17 (E2) After keeping the vehicle speed at 0.05-0.95 V 3000 rpm for four minutes Ignition system (ionic current 14 (ICMB)- 43 (IE) While the engine is running at idle Wave shape produc- sensor)
Page 436 PORTER 1.3 16V Iniection System System to be checked Terminals Measurement conditions Reference values With the heater fan switch set to Battery voltage "OFF" Radiator fan control system 11 (A/T) - 23 (E1) With the water temperature switch 1 V or less set to "ON"...
Page 437 PORTER 1.3 16V Iniection System 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...
Page 438 PORTER 1.3 16V Iniection System 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.
Page 439 PORTER 1.3 16V Iniection System 020618Y Cable harness for connecting the OBD 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.
Page 440 PORTER 1.3 16V Iniection System • 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.
Page 441 PORTER 1.3 16V Iniection System 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.
Page 442 PORTER 1.3 16V Iniection System • 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...
Page 443 PORTER 1.3 16V Iniection System 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 •...
Page 444 PORTER 1.3 16V Iniection System 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.
Page 445 PORTER 1.3 16V Iniection System 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.
Page 446 PORTER 1.3 16V Iniection System 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...
Page 447 PORTER 1.3 16V Iniection System Specific tooling Integrated in the 020618Y Lift for diagnosis 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. Specific tooling 020463Y ECU-EFI interface cable harness to check the injection system electrical values.
Page 448 PORTER 1.3 16V Iniection System 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).
Page 449 PORTER 1.3 16V Iniection System 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.
Page 450 PORTER 1.3 16V Iniection System 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.
Page 451 PORTER 1.3 16V Iniection System 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.
Page 452 PORTER 1.3 16V Iniection System 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.
Page 453 PORTER 1.3 16V Iniection System 5. 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 140° C or higher?: If SO: the wire between the ECT sensor and the electronic control unit is interrupted.
Page 454 PORTER 1.3 16V Iniection System Checking short circuits in the cable harness or in- side the electronic control unit EFI ECU or DRA- 1. Set the tester main switch and then the ignition switch to OFF. 2. Disconnect the engine coolant temperature sen- sor connector (ECT).
Page 455 PORTER 1.3 16V Iniection System 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).
Page 456 PORTER 1.3 16V Iniection System 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...
Page 457 PORTER 1.3 16V Iniection System 1. Cable harness side 2. Engine coolant temperature sensor 3. To the instrument panel (indicate the engine temperature) 4. BNDR 5. EFI ECU control unit Model EURO 4 KEY: 1. Cable harness side 2. Engine coolant temperature sensor 3.To the instrument panel (indicate the engine temperature) 4.BNDR 5.
Page 458 PORTER 1.3 16V Iniection System 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.
Page 459 PORTER 1.3 16V Iniection System Failure code Diagnostic failure code detection Affected area Conditions P0116 When the engine is started, the coolant tem- - Engine coolant temperature sensor perature is -7.5°C or higher, and lower than 40° - Cooling system C.
Page 460 PORTER 1.3 16V Iniection System Malfunzionamento circuito interruttore sensore posizione pedale farfalla KEY: 1. Cable harness side 2. Throttle valve sensor A. comp. open B. comp. closed 3. BNDR 4. EFI ECU control unit Model EURO 4 1. Cable harness side 2.
Page 461 PORTER 1.3 16V Iniection System 3. BNDR 4. EFI ECU control unit 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.
Page 462 PORTER 1.3 16V Iniection System Throttle valve opening affected area position Completely closed Completely open 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.
Page 463 PORTER 1.3 16V Iniection System If the voltage matches the specified value proceed with step 5, otherwise with step 3. 3. Throttle valve sensor check • Set the ignition switch to OFF. • Measure resistance between the respective connector terminals A. Terminal Condition Standard value...
Page 464 PORTER 1.3 16V Iniection System Throttle status Specified value 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).
Page 465 PORTER 1.3 16V Iniection System cable harness connectors coming from the DRACO control unit). • With the ignition switch set to ON, 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 Completely open 3.5 - 5.0 V...
Page 466 PORTER 1.3 16V Iniection System 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. P0130 - Malfunzionamento circuito sensore ossigeno (sensore 1) KEY: 1.
Page 467 PORTER 1.3 16V Iniection System 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).
Page 468 PORTER 1.3 16V Iniection System 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.
Page 469 PORTER 1.3 16V Iniection System If other diagnostic failure codes are detected be- sides P0130, proceed with the relevant diagnostic failure code diagram, otherwise jump to step 2. 2.Checking the cable harness between the oxygen sensor and the electronic control unit. •...
Page 470 PORTER 1.3 16V Iniection System 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.
Page 471 PORTER 1.3 16V Iniection System If the diagnostic failure code P0130 is detected again, check or replace the engine electronic control unit. 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.
Page 472 PORTER 1.3 16V Iniection System 13. 15A EFI fuse No. 1 14. 15A EFI fuse No. 2 15. EFI ECU control unit Circuit description Refer to the diagnostic failure code P0130 (Oxygen sensor circuit malfunction (Bank 1 sensor 1) Failure code Diagnostic failure code detection Affected area Conditions...
Page 473 PORTER 1.3 16V Iniection System 75 of the special tool. Repair and replace the cable harness or the connector, if necessary. 3. Checking the oxygen sensor output voltage while running at idle. • Connect the oxygen sensor and connectors of the special tool, respectively. •...
Page 474 PORTER 1.3 16V Iniection System • Disconnect the oxygen sensor connec- tor with the ignition switch set to OFF. • Connect a voltmeter to the oxygen sen- 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.
Page 475 PORTER 1.3 16V Iniection System 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 14.
Page 476 PORTER 1.3 16V Iniection System 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.
Page 477 PORTER 1.3 16V Iniection System 11. Front O2 sensor heating 12. Front O2 sensor 13. 15A EFI fuse No. 1 14. 15A EFI fuse No. 2 15. EFI ECU control unit Refer to the diagnostic failure code P0130 (oxygen sensor circuit malfunction (bank 1 sensor 1) Failure code Diagnostic failure code detection Affected area...
Page 478 PORTER 1.3 16V Iniection System 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. •...
Page 479 PORTER 1.3 16V Iniection System • 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. Specific tooling 020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester •...
Page 480 PORTER 1.3 16V Iniection System P0171 - Sistema troppo povero / P0172 - Sistema troppo ricco (taglio combustibile) KEY: 1. Ignition switch. 2. 60A fuse F/L 3. 15A EFI fuse No. 1 4. 15A EFI fuse No. 2 5. Main relay 6.
Page 481 PORTER 1.3 16V Iniection System 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.
Page 482 PORTER 1.3 16V Iniection System • - 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 OFF AFTER CARRYING OUT STEPS FROM 2 TO 4, THEN REPEAT THESE STEPS. <?xml:namespace prefix = or ns = "urn:schemas-microsoft-com:office:office"...
Page 483 PORTER 1.3 16V Iniection System 8. Gas leakage check in the exhaust system Check there are no gas leaks, repair and replace, if necessary. 9.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).
Page 484 PORTER 1.3 16V Iniection System • 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.
Page 485 PORTER 1.3 16V Iniection System • 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.
Page 486 PORTER 1.3 16V Iniection System Failure code Description P0302 Irregular ignition detected - cylinder 2 P0303 Irregular ignition detected - cylinder 3 P0304 Irregular ignition detected - cylinder 4 Confirming the driving configuration 1. Connect the diagnostic tester DS-21 or OBD II general scanning device with the ignition switch set to OFF.
Page 487 PORTER 1.3 16V Iniection System KEY: 1. Ignition switch 2. 60A fuse F/L 3. 15A EFI fuse No. 1 4. 15A EFI fuse No. 2 5. Main relay 6. Fuel pump relay 7. Battery 8. Fuel pump 9. EFI ECU control unit 10.
Page 488 PORTER 1.3 16V Iniection System 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.
Page 489 PORTER 1.3 16V Iniection System 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. • If the vehicle is brought to the workshop without the irregular ignition check, this can be confirmed by reproducing the frozen image data conditions.
Page 490 PORTER 1.3 16V Iniection System 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 THOSE RECOMMENDED. 3. Checking the output signal of the cylinder injector electronic control unit with irregular ignition •...
Page 491 PORTER 1.3 16V Iniection System 5. Check the cable harness between the injec- tor and the electronic control unit • Disconnect the special tool connectors from the fuel injection electronic control unit (with the ignition switch set to OFF). • Refer to sect.
Page 492 PORTER 1.3 16V Iniection System 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...
Page 493 PORTER 1.3 16V Iniection System 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 ONE DETECTED WITH THE ENGINE AT IDLE.
Page 494 PORTER 1.3 16V Iniection System 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-...
Page 495 PORTER 1.3 16V Iniection System 4. Starter motor 5. EFI ECU control unit 6. Cam angle sensor (sensor n+1) 7. Cable harness side connector Circuit description Cam angle sensor (NE signal) comprises a single rotor and a pickup coil. The NE signal rotor is equipped with "4+1"...
Page 496 PORTER 1.3 16V Iniection System 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 9. Rear O2 sensor heating 10. Rear O2 sensor 11. Front O2 sensor heating 12.
Page 497 PORTER 1.3 16V Iniection System - STRICTLY OBSERVE THE TESTING CONDITIONS TO DETECT THE MALFUNCTION. - IF THERE IS NO DIAGNOSTIC TESTER DS-21 AVAILABLE, SET THE IGNITION SWITCH TO OFF AFTER CARRYING OUT STEPS FROM 2 TO 4, THEN REPEAT THESE STEPS. <?xml:namespace prefix = or ns = "urn:schemas-microsoft-com:office:office"...
Page 498 PORTER 1.3 16V Iniection System P0443 - Malfunzionamento circuito Valvola di controllo spurgo_Sistema di controllo delle emissioni evaporative KEY: 1. Ignition switch 2. 60A fuse F/L 3. 15A EFI fuse No. 1 4. 15A EFI fuse No. 2 5. Main relay 6.
Page 499 PORTER 1.3 16V Iniection System KEY: 1. Throttle body 2. ECU 3. VSV for EVAP 4. Atmosphere 5. Combustion chamber 6. Active carbon filter 7. Fuel tank Failure code Diagnostic failure code detection Affected area Conditions P0443 If there are interrupted or short-circuited wires - Interrupted or short-circuited wires in the va- in the vapour vacuum switching valve circuit, pour vacuum switching valve circuit...
Page 500 PORTER 1.3 16V Iniection System Using the diagnostic tester DS-21 1. Checking the operation of the vapour bleed- ing control system • With the ignition switch set to OFF, connect the diagnostic tester DS-21 to the Data Link Connector through the special tool.
Page 501 PORTER 1.3 16V Iniection System • 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.
Page 502 PORTER 1.3 16V Iniection System 4. Check the cable harness between the elec- tronic control unit and the vacuum switching valve for bleeding • With the ignition switch set to OFF, connect the special tool (sub-wiring harness). Do not connect the connec- tor to the electronic control unit.
Page 503 PORTER 1.3 16V Iniection System Characteristic specified 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). •...
Page 504 PORTER 1.3 16V Iniection System 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.
Page 505 PORTER 1.3 16V Iniection System P0500 - Malfunzionamento Sensore velocità veicolo KEY: 1. EFI ECU control unit 2. Instrument panel 3. Speedometer cable 4. Vehicle speed sensor 5. Cable harness side Circuit description The sensor fitted inside the instrument panel has a magnet that is turned by the speedometer cable.
Page 506 PORTER 1.3 16V Iniection System Failure code Diagnostic failure code detection Affected area Conditions P0500 The speed sensor does not transmit any signal - Instrument panel to the electronic control unit for a certain period - Interrupted and short-circuited wires in the after the fuel supply is cut during the deceler- vehicle speed sensor circuit ation phase.
Page 507 PORTER 1.3 16V Iniection System 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...
Page 508 PORTER 1.3 16V Iniection System • 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.
Page 509 PORTER 1.3 16V Iniection System 6. Fuel pump relay 7. Battery 8. Fuel pump 9. Ignition spark plug unit wire on the cable harness side (Electronic Control Unit side) 10. EFI ECU control unit 11. Ignition spark plug unit wire on the cable harness side (ignition coil side) 12.
Page 510 PORTER 1.3 16V Iniection System 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.
Page 511 PORTER 1.3 16V Iniection System • 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. Characteristic Specified value battery voltage If failures are detected during checks proceed with step 5.
Page 512 PORTER 1.3 16V Iniection System • With the ignition switch set to OFF, reset. • Set the special tool (sub-wiring harness). Specific tooling 020463Y ECU-EFI interface cable harness to check the injection system electrical values. • Warm up the engine (only when the engine can be started).
Page 513 PORTER 1.3 16V Iniection System • 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.
Page 514 PORTER 1.3 16V Iniection System 10. Checking the cable harness between the ignition unit and ignition coil Check there are no interrupted or short-circuited wires in the cable harness and connector. • Set the ignition switch to OFF. • Disconnect coils and the side connec- tor of the ignition coil of the ignition unit.
Page 515 PORTER 1.3 16V Iniection System 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 •...
Page 516 PORTER 1.3 16V Iniection System KEY: 1. Ignition switch 2. 60A fuse F/L 3. Battery 4. Starter motor 5. EFI ECU control unit 6. Ignition switch wire on the cable harness side 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.
Page 517 PORTER 1.3 16V Iniection System 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.
Page 518 PORTER 1.3 16V Iniection System Connector X99 - on the sensor side - Connector on the 16 VC electronic control unit side. Model EURO 4 • Set the tester main switch and the ig- nition switch to OFF. • connect the special tool to the cable harness connectors coming from the DRACO control unit on the EFI ECU side.
Page 519 PORTER 1.3 16V Iniection System KEY: 1. Ignition switch 2. Throttle valve sensor wire on the cable harness side 3. EFI ECU control unit 4. 60A fuse F/L 5. Battery 6. Throttle valve sensor Model EURO 4 IS - 519...
Page 520 PORTER 1.3 16V Iniection System KEY: 1. Ignition switch 2. Throttle valve sensor wire on the cable harness side 3. EFI ECU control unit 4. 60A fuse F/L 5. Battery 6. Throttle valve sensor 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.
Page 521 PORTER 1.3 16V Iniection System 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 BY CHECKING 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...
Page 522 PORTER 1.3 16V Iniection System P1560 - Malfunzionamento circuito alimentazione ausiliaria unità di controllo elettronica KEY: 1. Ignition switch 2. 60A fuse F/L 3. 15A EFI fuse No. 1 4. 15A EFI fuse No. 2 5. Main relay 6. Fuel pump relay 7.
Page 523 PORTER 1.3 16V Iniection System Failure code Diagnostic failure code detection Affected area Conditions P1560 Interrupted wire in the auxiliary power supply - Interrupted wire in the auxiliary power supply circuit circuit - Engine electronic control unit IF THE CODE P1560 IS DISPLAYED , THE ELECTRONIC CONTROL UNIT DOES NOT STORE ANOTHER CODE.
Page 524 PORTER 1.3 16V Iniection System 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 •...
Page 525 PORTER 1.3 16V Iniection System - 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.
Page 526 PORTER 1.3 16V Iniection System • With the ignition switch set to ON, measure voltage between the cable harness side con- nector XÀF of the valve and the body ground. Characteristic specified value: battery voltage. If it does not match the specified value, check the cable harness and the connector between the vac- uum switching valve for EGR and the main relay, and that there are no interrupted or short-circuited...
Page 527 PORTER 1.3 16V Iniection System Characteristic specified 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.
Page 528 PORTER 1.3 16V Iniection System 4. 15A EFI fuse No. 2 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 12. EFI ECU control unit Circuit description In order to reduce NOx emissions, the anti-pollu- tion system with exhaust gas recirculation (EGR)
Page 529 PORTER 1.3 16V Iniection System 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.
Page 530 PORTER 1.3 16V Iniection System KEY: 1. Ignition switch 2. 60A fuse F/L 3. 15A EFI fuse No. 1 4. 15A EFI fuse No. 2 5. Main relay 6. Fuel pump relay 7. Battery 8. Fuel pump 9. EFI ECU control unit 10.
Page 531 PORTER 1.3 16V Iniection System 1. Checking the electronic control unit power supply voltage • 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). •...
Page 532 PORTER 1.3 16V Iniection System 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.
Page 533 PORTER 1.3 16V Iniection System 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. Replace the fuse, if necessary, otherwise check and replace the electronic control unit.
Page 534 PORTER 1.3 16V Iniection System 11. Fuel pump relay 12. Data Link Connector (DTC ) Checking procedure 1. Functional check of the fuel pump • With the ignition switch set to OFF, connect the diagnostic tester DS-21 to the Data Link Connector through the special tool.
Page 535 PORTER 1.3 16V Iniection System • Measure voltage between the connector 30 W/0 IMB of the special tool and the chassis ground. Characteristic specified value: 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.
Page 536 PORTER 1.3 16V Iniection System Malfunzionamento sistema valvola di commutazione VSV KEY: 1. Ignition switch 2. 60A fuse F/L 3. 15A EFI fuse No. 1 4. 15A EFI fuse No. 2 5. Main relay 6. Fuel pump relay 7. Battery 8.
Page 537 PORTER 1.3 16V Iniection System 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.
Page 538 PORTER 1.3 16V Iniection System • 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. Characteristic specified value: battery voltage.
Page 539 PORTER 1.3 16V Iniection System • Check there are no interrupted or short-circuited wires in the cable har- ness and connector. Vacuum switching valve connector XAB - terminal 56 VSV2. Repair and replace the cable harness or the connector, if necessary. 5.
Page 540 PORTER 1.3 16V Iniection System Referen values Temper- ature (° Resist- 28.6 16.2 2.45 0.33 0.18 ance (kOhm) (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.
Page 541 PORTER 1.3 16V Iniection System (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.
Page 542 PORTER 1.3 16V Iniection System (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.
Page 543 PORTER 1.3 16V Iniection System 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.
Page 544 PORTER 1.3 16V Iniection System from 74 to 117 Ohm Front and rear oxygen sensors with heater (For EU specifications only) 1. Measure resistance between terminals (+B) and (HT). Characteristic Specified 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.
Page 545 INDEX OF TOPICS...
Page 546 PORTER 1.3 16V Gear-box 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. •...
Page 547 PORTER 1.3 16V Gear-box 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.
Page 548 PORTER 1.3 16V Gear-box 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.
Page 549 PORTER 1.3 16V Gear-box 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.
Page 550: Clutch Cover
PORTER 1.3 16V Gear-box 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.
Page 551 PORTER 1.3 16V Gear-box 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.
Page 552 PORTER 1.3 16V Gear-box 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.
Page 553 PORTER 1.3 16V Gear-box 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.
Page 554 PORTER 1.3 16V Gear-box 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.
Page 555 PORTER 1.3 16V Gear-box 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.
Page 556 PORTER 1.3 16V Gear-box 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.
Page 557 PORTER 1.3 16V Gear-box 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 ±...
Page 558 PORTER 1.3 16V Gear-box 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 REVERSE GEAR LIGHT SWITCH: 3.
Page 559 PORTER 1.3 16V Gear-box 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.
Page 560 PORTER 1.3 16V Gear-box 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 AND THE CONTACT WIDTH BETWEEN THE GEAR CONTROL...
Page 561 PORTER 1.3 16V Gear-box Specification Desc./Quantity Fitting load (N) for reverse gear limit pin 28.93 N Fitting 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.
Page 562 PORTER 1.3 16V Gear-box 2. Measure the width of the contact sections be- tween the heads of the gear and the gear internal lever. Characteristic Heads of the gear Specified value: 12.1 +0.1 mm +0 mm Gear internal lever: Specified value: 12 -0.02 mm -0.12 mm Reverse transmission gear 1.
Page 563 PORTER 1.3 16V Gear-box 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.
Page 564 PORTER 1.3 16V Gear-box Inlet shaft COMPONENTS * Non-reusable parts 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.
Page 565 PORTER 1.3 16V Gear-box 19. Synchronisation ring No. 1 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.
Page 566 PORTER 1.3 16V Gear-box Components 9, and 17 are identical and are used in different positions. Then, a total of 6 pieces is used simultaneously. Thickness: 4.6 - 4.8 mm Thickness: 7.19 - 7.25 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.
Page 567 PORTER 1.3 16V Gear-box Spring washer to be selected according to thickness. 19. Synchronisation ring No. 1 Components 6, 14 and 19 are identical and are used in different positions. Refer to components 6 and 14 20. Needle bearing (open) This needle bearing is placed between the input shaft and the main shaft.
Page 568 PORTER 1.3 16V Gear-box 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 •...
Page 569 PORTER 1.3 16V Gear-box 10. Remove the needle bearing (open). - NEVER EXPAND OPENING (B) OF THE BEARING WITH A VALUE EXCEEDING THE INPUT SHAFT DIAMETER + 5 MM, UPON FITTING AND REMOVAL. 11. Remove the circlip of the shaft. 12.
Page 570 PORTER 1.3 16V Gear-box 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 THE TABLE SHOULD BE EMPLOYED, THAT WOULD CAUSE ABNORMAL NOISE.
Page 571 PORTER 1.3 16V Gear-box 7. Measure the thickness and the inside diameter of the third and the fifth gear Characteristic 3rd gear A Specified value: 37.0 +0.25 mm +0 mm 5th gear B Specified value: 37.0 +0.25 mm +0 mm 3rd gear C Specified value: 37.95 ±...
Page 572 PORTER 1.3 16V Gear-box - MAKE SURE TO ALIGN THE MISSING TEETH SECTIONS, WHICH ARE IN THREE DIFFERENT POSITIONS, WHEN FITTING THE HUB AND SLEEVE. - THE SAME HUB SLEEVE IS USED FOR THE THIRD AND THE FOURTH GEAR; NEVERTHELESS, THE HUB OF THE THIRD AND THE FOURTH GEAR DIFFERS DUE TO ITS SHAPE.
Page 573 PORTER 1.3 16V Gear-box P/N 90045-20266 (No colour) Thickness: 1.94 mm P/N 90045-20267 (Brown) Thickness: 1.90 mm P/N 90045-20268 (Blue) Thickness: 1.86 mm P/N 90045-20269 (No colour) Thickness: 1.82 mm P/N 90045-20270 (Brown) Thickness: 2.10 mm * THE SPRING WASHERS INDICATED IN THE TABLE ABOVE ARE EQUAL TO THOSE USED WHEN THE SECONDARY SHAFT HUB IS FITTED.
Page 574 PORTER 1.3 16V Gear-box P/N 90045-20272 (Brown) Thickness: 2.02 mm P/N 90045-20273 (Blue) Thickness: 1.98 mm P/N 90045-20274 (No colour) Thickness: 1.94 mm P/N 90045-20275 (Brown) Thickness: 1.90 mm P/N 90045-20276 (Blue) Thickness: 1.86 mm P/N 90045-20277 (No colour) Thickness: 1.82 mm P/N 90045-20278 (Brown) Thickness: 1.78 mm - MAKE SURE THAT THE GASKET OF THE RADIAL BALL BEARING IS FACING THE FRONT PART.
Page 575 PORTER 1.3 16V Gear-box 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: Specific tooling 020206Y Extractor Inspection 1. Check clearance between the synchronisation ring and the gear conical section.
Page 576 PORTER 1.3 16V Gear-box 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 PRESS ON THE INTERNAL ROTATION SEAT.
Page 577 PORTER 1.3 16V Gear-box 93.00 mm Outside diameter 35.00 mm Inside diameter 25.00 mm Transmission shaft Components * Non-reusable parts 1. Circlip * 2. Radial ball bearing 3. Thrust washer of the 1st gear 4. Circlip * 5. 1st sub-gear 6.
Page 578 PORTER 1.3 16V Gear-box 19. Transmission gear 20. Radial ball bearing 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;...
Page 579 PORTER 1.3 16V Gear-box 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.
Page 580 PORTER 1.3 16V Gear-box 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.
Page 581 PORTER 1.3 16V Gear-box 7. Remove the following components: • Synchroniser hub assembly No. 1 • Synchronisation ring No. 3 • 2nd gear with sub-gear - THE COMPONENTS DESCRIBED ABOVE, CAN BE RE- MOVED BY SLIGHTLY PRESSING ON THE SECONDARY SHAFT, WHILE THE 2nd GEAR (SUB-GEAR SURFACE) IS SUPPORTED BY MEANS OF THE TOOL INDICATED ABOVE.
Page 582 PORTER 1.3 16V Gear-box 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.
Page 583 PORTER 1.3 16V Gear-box 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.
Page 584 PORTER 1.3 16V Gear-box 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.
Page 585 PORTER 1.3 16V Gear-box P/N 90045-20266 (No colour) Thickness: 1.94 mm P/N 90045-20267 (Brown) Thickness: 1.90 mm P/N 90045-20268 (Blue) Thickness: 1.86 mm P/N 90045-20269 (No colour) Thickness: 1.82 mm P/N 90045-20270 (Brown) Thickness: 2.10 mm 11. Fit the needle bearing. Apply engine oil onto the external ring of this bearing.
Page 586 PORTER 1.3 16V Gear-box P/N 90045-20285 (No colour) Thickness: 1.82 mm P/N 90045-20286 (Brown) Thickness: 1.78 mm 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 Specification value: 10 -0.1 mm -0.3 mm...
Page 587 PORTER 1.3 16V Gear-box 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.
Page 588 PORTER 1.3 16V Gear-box 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...
Page 589 PORTER 1.3 16V Gear-box 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.
Page 590 PORTER 1.3 16V Gear-box 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.
Page 591 PORTER 1.3 16V Gear-box 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 products Three Bond® 1216 Specific sealant Characteristic Nozzle inside diameter: 0.9 mm...
Page 592 PORTER 1.3 16V Gear-box 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.
Page 593 PORTER 1.3 16V Gear-box 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 TO FIT THE GEAR ASSEMBLY ON THE VEHICLE. ONLY FEW POINTS HAVE BEEN MODIFIED RE- GARDING THE PREVIOUS PROCEDURE.
Page 594 INDEX OF TOPICS IFFERENTIAL...
Page 595 PORTER 1.3 16V Differential 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.
Page 596 PORTER 1.3 16V Differential Differential removal Removal Remove the parts in numerical order, as shown in the figure. 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.
Page 597 PORTER 1.3 16V Differential 18.Spacer 19. Differential housing 20. Tap roller bearing 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.
Page 598 PORTER 1.3 16V Differential Inspections before removal Check the following values: 1. Crown gear clearance Characteristic Specified value: 0.10 - 0.20 mm 2. Crown gear eccentricity Characteristic Limit allowed 0.10 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 tooling 020335y Magnetic support for dial gauge...
Page 599 PORTER 1.3 16V Differential 2. Remove the oil seal, with the following special tool: Specific tooling 020211y Flange oil seal extractor 3. Remove the bearing, with the following special tool: - BE EXTREMELY CAREFUL WITH THE PINION WHICH, AT THE MOMENT OF BEING DETACHED FROM THE BEAR- ING, IT CAN JUMP OUT FROM THE SEAT.
Page 600 PORTER 1.3 16V Differential 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.
Page 601 PORTER 1.3 16V Differential Differential housing 1. Bearing coupling sections 2. Coupling sections of the bearing rolling external seat 3. Gasket seat 4. Coupling surface 5. Differential housing Coupling flange 1. Oil seal contact section 2. Grooved section Montaggio Fitting Fit the parts in numerical order, as shown in the figure.
Page 602 PORTER 1.3 16V Differential 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 15. Tap roller bearing 16. Tap roller bearing 17.
Page 603 PORTER 1.3 16V Differential Characteristic Specified value: 102.5 - 141.7 Nm 4. Adjusting crown gear clearance and differential clearance in axial direction Characteristic Specified value: 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...
Page 604 PORTER 1.3 16V Differential 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. 1.
Page 605 PORTER 1.3 16V Differential 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.
Page 606 PORTER 1.3 16V Differential Crown gear - CLEAN THE COUPLING SURFACES OF THE CROWN GEAR AND HOUSING. MAKE SURE THAT MARKS PUNCHED, IN THE REMOVAL SEAT, 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.
Page 607 PORTER 1.3 16V Differential 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 propeller shaft 60 - 74 Nm...
Page 608 PORTER 1.3 16V Differential 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.
Page 609 PORTER 1.3 16V Differential 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 products AGIP ROTRA LSX 75W-90 Differential SAE 75W-90, API GL-5 Characteristic Capacity 1.1 l...
Page 610 INDEX OF TOPICS RAKING SYSTEM...
Page 611 PORTER 1.3 16V Braking system 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.
Page 612: Inspection And Repair
PORTER 1.3 16V Braking system 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.
Page 613 PORTER 1.3 16V Braking system 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...
Page 614 PORTER 1.3 16V Braking system 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.
Page 615: Brake Fluid Reservoir
PORTER 1.3 16V Braking system 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.
Page 616 PORTER 1.3 16V Braking system 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.
Page 617 PORTER 1.3 16V Braking system 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.
Page 618 PORTER 1.3 16V Braking system Remove the parts, following the numerical order shown in the figure. 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.
Page 619 PORTER 1.3 16V Braking system THE INTERVALS BETWEEN THE FIRST AND SECOND TIME THE PEDAL IS PUSHED AS THE SECOND 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.
Page 620 PORTER 1.3 16V Braking system 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.
Page 621: Brake System
PORTER 1.3 16V Braking system Brake system Filling with brake fluid IF THE BRAKE FLUID COMES INTO CONTACT WITH THE PAINTED 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-...
Page 622 PORTER 1.3 16V Braking system • 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.
Page 623 PORTER 1.3 16V Braking system Verifica - Check that the brake disc is not damaged, that there are no signs of wear, scores and irregular wear. Characteristic Specified thickness: 16.0 mm Admissible limit: 15.0 mm - Check that the brake disc pad is not damaged or excessively worn.
Page 624: Front Disc Brake
PORTER 1.3 16V Braking system KEY: 1. Pad unit and thickness 2. Pad pin 3. Clip 4. Disc brake calliper unit 5. Screw *: Non-reusable parts Locking torques (N*m) Disc brake calliper assembly for disc brake dust guard 49 ÷ 59 N.B.
Page 625 PORTER 1.3 16V Braking system 1. Disconnect the hose. 2. Remove the castle nut with the special tool A. Specific tooling 020221y Brake drum stop device 3. Remove the hub and the disc, with the special tool B. Specific tooling 020222y Front hub and drum extractor Front disc brake calliper Removal...
Page 626 PORTER 1.3 16V Braking system KEY: 1. Spring 2. Pad pin 3. Pad unit and thickness 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.
Page 627 PORTER 1.3 16V Braking system Inspection Check the pads and brake discs. Always replace parts indicated with *. PAD THICKNESS AND IRREGULAR WEAR: Specification Desc./Quantity Specified thickness: 9 mm Limit: 1 mm DISC THICKNESS AND IRREGULAR WEAR: Specification Desc./Quantity Specified thickness: 16 mm Limit: 5 mm...
Page 628 PORTER 1.3 16V Braking system 3. Secondary bushing 4. Main bushing 5. Piston sealing ring 6. Piston cover 7 Piston 8. Retention ring 9. Pad unit and thickness 10. Pad pin 11. Spring *: Non-reusable parts Installation Installation Fit the parts, following the numerical order illustrated. KEY: 1.
Page 629: Rear Brake
PORTER 1.3 16V Braking system 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.
Page 630 PORTER 1.3 16V Braking system 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.
Page 631 PORTER 1.3 16V Braking system WEAR OF FRICTION MATERIAL Specification Desc./Quantity Friction material thickness: 4.0 mm Maximum limit allowed: BRAKE DRUM WEAR Specification Desc./Quantity Drum diameter: 200 mm Maximum 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.
Page 632 PORTER 1.3 16V Braking system 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.
Page 633 PORTER 1.3 16V Braking system 21. Rear brake shoe No. 1 22. Spring 23. Spring 24. Spring 25. Shoe fixing pin 26. Shoe retaining spring 27. Brake drum *: Non-reusable parts 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.
Page 634: Parking Brake Lever
PORTER 1.3 16V Braking system 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 products Three Bond N.1212 silicone sealant KEY: 1.
Page 635 PORTER 1.3 16V Braking system Removal Remove the parts, following the numerical order shown in the figure. KEY: 1. Gearshift lever knob 2. Screw 3. Central tunnel 4. Switch cable 5. Nut 6. Nut 7. Screw 8. Parking brake cable 9.
Page 636 PORTER 1.3 16V Braking system KEY: 1. Parking brake lever unit 2. Screw 3. Parking brake cable 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.
Page 637: Parking Brake Cable
PORTER 1.3 16V Braking system Handbrake Reserve travel Apply 196 N (20 kgf) of force, slowly pull the hand- brake lever upwards and count the notches. Characteristic Number of notches: 6 ÷ 10 Parking brake cable Removal Operation before removal(pickup model) •...
Page 638 PORTER 1.3 16V Braking system 3. Clip 4. Clip 5. Clip 6. Parking brake cable unit 7. Parking brake cable unit 8. Clip 9. Nut 10. Parking brake lever unit 11. Nut 12. Clip 13. Parking brake with brake control cable unit Operation before removal (van model) •...
Page 639 PORTER 1.3 16V Braking system KEY: 1. Parking brake cable left guide 2. Parking brake cable left guide 3. Clip 4. Clip 5. Clip 6. Clip 7. Parking brake cable 8. Parking brake cable 9. Clip 10. Nut 11. Parking brake lever 12.
Page 640 PORTER 1.3 16V Braking system KEY: 1. Parking brake with brake control cable unit 2. Clip 3. Nut 4. Parking brake lever unit 5. Nut 6. Clip 7. Parking brake cable unit 8. Parking brake cable unit 9. Clip 10. Clip 11.
Page 641 PORTER 1.3 16V Braking system KEY: 1. Parking brake control cable 2. Clip 3. Nut 4. Parking brake lever 5. Nut 6. Clip 7. Parking brake cable 8. Parking brake cable 9. Clip 10. Clip 11. Clip 12. Parking brake cable left guide 13.
Page 642 PORTER 1.3 16V Braking system 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...
Page 643 PORTER 1.3 16V Braking system 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...
Page 644 PORTER 1.3 16V Braking system 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.
Page 645 PORTER 1.3 16V Braking system 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.
Page 646 PORTER 1.3 16V Braking system 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".
Page 647 PORTER 1.3 16V Braking system Adjustment 1. 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: Characteristic Pressure deviation in MPa (kqf/cm2) =...
Page 648 PORTER 1.3 16V Braking system 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.
Page 649 PORTER 1.3 16V Braking system 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...
Page 650 PORTER 1.3 16V Braking system 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.
Page 651: Lspv Assembly
PORTER 1.3 16V Braking system Lspv assembly 1. Fit the new guide bushing, with the special tool. Specific tooling 020196Y Clutch guiding tool 2. Assemble the following parts on the bar: • Spring stop • Spring • Valve adjustment lever •...
Page 652: Lspv Brake Calibrator - Bracket
PORTER 1.3 16V Braking system 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 Brake 15 ÷ 22 calibrator - Brake pipe 13 ÷...
Page 653 PORTER 1.3 16V Braking system 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 IS ASSEMBLED TO THE BRACKET, ON THE AXLE SIDE.
Page 654 INDEX OF TOPICS RANSMISSION SHAFT...
Page 655 PORTER 1.3 16V Transmission shaft 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.
Page 656 PORTER 1.3 16V Transmission shaft 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 JOINT FLANGE. - FIT A SUITABLE PLUG TO PREVENT OIL LEAKS. KEY: A= Reference marks B= Plug...
Page 657 PORTER 1.3 16V Transmission shaft 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.
Page 658 PORTER 1.3 16V Transmission shaft 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.
Page 659 INDEX OF TOPICS TEERING COLUMN...
Page 660 PORTER 1.3 16V Steering column 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 tooling 020196Y Clutch guiding tool 0.20228y Rear conical tool to replace the dif-...
Page 661 PORTER 1.3 16V Steering column KEY: 1. Bushing 2. Steering arm 3. Bolt 4. Elastic washer 5. Nut *: Non-reusable parts To fit the bushing, use the series of special tools with a press, as indicated. Specific tooling 020196Y Clutch guiding tool 0.20228y Rear conical tool to replace the differential control pinion bearing Universal joint arm Components...
Page 662 PORTER 1.3 16V Steering column 7. Control arm on the stub axle 8. Dust guard 9. Gasket 10. Roller bearing 11. Bushing assembly *: Non-reusable parts Removal/Disassembly 1. Turn the steering wheel. Remove the nut. Afterwards, take out the arm. 2.
Page 663 PORTER 1.3 16V Steering column 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.
Page 664 PORTER 1.3 16V Steering column 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 tooling 020229Y Tools for needle bearing and sealing rings replacement...
Page 665 PORTER 1.3 16V Steering column MAKE SURE TO INSERT THE BUSHING ASSEMBLY IN THE CORRECT DIRECTION. Characteristic Prescribed 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.
Page 666: Strut Bracket Body
PORTER 1.3 16V Steering column 6. Assemble the stub axle control arm with a new lock nut. ONCE THE FITTING HAS BEEN COMPLETED, TURN THE ARM CLOCKWISE AND ANTICLOCKWISE AND MAKE SURE THAT IT COMES INTO CONTACT WITH THE RELE- VANT LIMIT SWITCH.
Page 667 PORTER 1.3 16V Steering column Gruppo cremagliera Remove the parts following the numerical order. 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.
Page 668 PORTER 1.3 16V Steering column 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.
Page 669 PORTER 1.3 16V Steering column 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.
Page 670 PORTER 1.3 16V Steering column 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.
Page 671 PORTER 1.3 16V Steering column 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.
Page 672 PORTER 1.3 16V Steering column 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.
Page 673 PORTER 1.3 16V Steering column 21. Spring cap 22. Hexagonal ring nut *: Non-reusable parts 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. •...
Page 674 PORTER 1.3 16V Steering column 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 •...
Page 675 PORTER 1.3 16V Steering column 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.
Page 676: Rack Guide Protection Lock Nut - Steering Rack Housing
PORTER 1.3 16V Steering column 4. Tighten bellows «A». 5. Position the rack end following the perspective indicated in the figure. 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.
Page 677: Steering Column
PORTER 1.3 16V Steering column 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.
Page 678 PORTER 1.3 16V Steering column 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- Remove the parts following the numerical order.
Page 679 PORTER 1.3 16V Steering column Installation Fit the parts following the numerical order. KEY: 1. Ring 2. Washer 3.Universal joint 4. Steering column 5. Bolt 6. Steering joint cover 7. Light switch lever unit 8. Guide column protection 9. Steering wheel Installation 1.
Page 680 PORTER 1.3 16V Steering column 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.
Page 681 PORTER 1.3 16V Steering column 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.
Page 682 PORTER 1.3 16V Steering column 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.
Page 683 PORTER 1.3 16V Steering column 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.
Page 684 PORTER 1.3 16V Steering column 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 OF THE RIGHT SIDE CABLE AND THE LEFT SIDE CABLE ARE IDENTICAL.
Page 685 PORTER 1.3 16V Steering column PICK UP FRONT WHEEL ALIGNMENT Specification Desc./Quantity Tie rod 1° 23' +40'-50' Caster angle 3°13' ± 1° Steering angle 1°49' ± 1° VAN FRONT WHEEL ALIGNMENT Specification Desc./Quantity Camber angle 1° +40'-50' Caster angle 3°02' ± 1° Kingpin inclination angle 11°25' ±...
Page 686 PORTER 1.3 16V Steering column 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 BOX OR THE JOINTS ARE WORN, OR THE SUPPORTING BRACKET HAS BEEN LOOSENED.
Page 687: Wheel Alignment
PORTER 1.3 16V Steering column 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 VEHICLE BACKWARDS.
Page 688 PORTER 1.3 16V Steering column SC - 688...
Page 689 INDEX OF TOPICS USPENSIONS...
Page 690 PORTER 1.3 16V Suspensions 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 4.
Page 691 PORTER 1.3 16V Suspensions 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 tooling 020235y Front spiral spring compressor 3. Fit the spring seat upper cap B and the bushing - APPLY 0.5 GR OR MORE MT GREASE ON THE UPPER SURFACE OF BUSHING A.
Page 692 PORTER 1.3 16V Suspensions 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 Installation Fit the suspension support. (Use new nuts) Locking torques (N*m) Front suspension support for chassis 35 - 44 Nm Steering articulation fitting...
Page 693 PORTER 1.3 16V Suspensions 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.
Page 694 PORTER 1.3 16V Suspensions 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.
Page 695 PORTER 1.3 16V Suspensions 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...
Page 696 PORTER 1.3 16V Suspensions 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.
Page 697 PORTER 1.3 16V Suspensions 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. 3. Removal of the suspension lower arm assem- bly. •...
Page 698 PORTER 1.3 16V Suspensions 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.
Page 699 PORTER 1.3 16V Suspensions Front hubs removal 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. 5. Disc assembly removal • Remove the cotter pin •...
Page 700 PORTER 1.3 16V Suspensions 7. Remove the disc brake dust guard 8. Remove the tie rod head, using the following tool: Specific tooling 020231Y Tie rod head extractor 9. Remove the articulation of the steering by un- screwing bolts A and B Installation 1.
Page 701: Castle Nut - Front Axle Hub 177.0 ÷
PORTER 1.3 16V Suspensions 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.
Page 702 PORTER 1.3 16V Suspensions 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.
Page 703 PORTER 1.3 16V Suspensions • Place the external radial ball bearing using the following tool: N.B. - MAKE SURE THAT THE BEARING IS IN CONTACT WITH THE STOP SECTION OF THE STEERING ARTICULATION. Specific tooling 020188y Axial hub support and driving pinion tool series - Front axle bearing and differential pinion replacement kit •...
Page 704 PORTER 1.3 16V Suspensions 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. •...
Page 705 PORTER 1.3 16V Suspensions 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.
Page 706 PORTER 1.3 16V Suspensions - REMOVE THE STOP LIGHT FUSE SO THAT IT DOES NOT REMAIN 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 Characteristic External side B...
Page 707 PORTER 1.3 16V Suspensions 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 •...
Page 708 PORTER 1.3 16V Suspensions • 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 A TAPE ON THE RIMS MATCHING THE INSERTION POINTS OF THE COMPENSATOR PINS. •...
Page 709 PORTER 1.3 16V Suspensions • 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 GAUGE CASTER SET SCREW.
Page 710 PORTER 1.3 16V Suspensions • 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.
Page 711 PORTER 1.3 16V Suspensions 8. Oil seal * Non-reusable parts 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.
Page 712 PORTER 1.3 16V Suspensions 10. Remove the oil seal, using the special tool: Specific tooling 020200Y Extractor 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. •...
Page 713 PORTER 1.3 16V Suspensions Check Check the following parts: 1. Rear axle shafts, especially: A Wear, damage or eccentricity B Oil seal contact section C Grooved profile Characteristic Limit allowed: Flange: 0.05 mm Axle shaft: 0.80 mm 2. Bearing A worn or damaged 3.
Page 714 PORTER 1.3 16V Suspensions 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. Specific tooling 020225y Buffer to fit the rear bridge bearing Quickly fit the bearing sealing ring on the shaft, using a press together with the special tool.
Page 715: Brake Pipe Joint - Brake Cylinder
PORTER 1.3 16V Suspensions 5. Fit the rear axle shaft together with the shoe holding plate, using the following special tool. Specific tooling 020226y Rear axle shaft extractor 6. Fasten the shoe holding plate with four nuts. Locking torques (N*m) Shoe holding plate - Rear axle shaft housing 63.7 ÷...
Page 716 PORTER 1.3 16V Suspensions 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).
Page 717 PORTER 1.3 16V Suspensions 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.
Page 718: U-Bolt - Leaf Spring Buffer
PORTER 1.3 16V Suspensions 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.
Page 719: Spring Support Pin - Leaf Spring Assembly
PORTER 1.3 16V Suspensions 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 •...
Page 720 PORTER 1.3 16V Suspensions COMPONENTS 1. Hexagon nut 2. Spring washer 3. Shock absorber buffer washer 4. Hexagon nut 5. Spring washer 6. Shock absorber buffer washer 7. Shock absorber 8. Shock absorber buffer washer 9. Shock absorber buffer washer 10.
Page 721: Rear Shock Absorber - Chassis (Upper Part)
PORTER 1.3 16V Suspensions 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.
Page 722 PORTER 1.3 16V Suspensions 2. Lower the vehicle. - MAKE SURE THAT THE HEXAGON NUTS HAVE BEEN PROPERLY FITTED, SINCE UPPER SECTION AND LOWER SECTION 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.
Page 723 PORTER 1.3 16V Suspensions Push the rear part of the vehicle with downward force in order to check the damping capacity of the shock absorbers. SS - 723...
Page 724 INDEX OF TOPICS IPPER VERSION...
Page 725 PORTER 1.3 16V Tipper version 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.
Page 726 PORTER 1.3 16V Tipper version 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 VR - 726...
Page 727 PORTER 1.3 16V Tipper version 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.
Page 728 PORTER 1.3 16V Tipper version 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.
Page 729 PORTER 1.3 16V Tipper version 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, IT COULD BE EXTREMELY HAZARDOUS FOR THE OPERA- TOR.
Page 730 PORTER 1.3 16V Tipper version 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...
Page 731 PORTER 1.3 16V Tipper version 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.
Page 732 PORTER 1.3 16V Tipper version 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.
Page 733 PORTER 1.3 16V Tipper version 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.
Page 734 PORTER 1.3 16V Tipper version 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 shown in the figure. Finally, remove the valve body by acting on the nut indicated in the figure.
Page 735 PORTER 1.3 16V Tipper version 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.
Page 736 PORTER 1.3 16V Tipper version 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.
Page 737 PORTER 1.3 16V Tipper version 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.
Page 738 PORTER 1.3 16V Tipper version A 130 BAR PRESSURE IS SUITABLE TO LIFT A WEIGHT OF 750 KG WEIGHT AS SPECIFIED BY VEHICLE CHAR- ACTERISTICS. THE VEHICLE MUST NEVER LIFT A WEIGHT EXCEEDING THE PRESCRIBED VALUE. SUCH AN ACTION COULD IRRETRIEVABLY DAMAGE THE LIFTING SYSTEM.
Page 739 INDEX OF TOPICS HASSIS...
Page 740 PORTER 1.3 16V Chassis 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.
Page 741 PORTER 1.3 16V Chassis 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.
Page 742: Side Windows
PORTER 1.3 16V Chassis 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...
Page 743 PORTER 1.3 16V Chassis 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.
Page 744: Rear Window
PORTER 1.3 16V Chassis 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...
Page 745 PORTER 1.3 16V Chassis 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.
Page 746 PORTER 1.3 16V Chassis 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.
Page 747 PORTER 1.3 16V Chassis 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.
Page 748 PORTER 1.3 16V Chassis 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.
Page 749 PORTER 1.3 16V Chassis 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 2. Fit the lock block with the relevant retainer 3.
Page 750 PORTER 1.3 16V Chassis 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.
Page 751 PORTER 1.3 16V Chassis 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. THIS WILL FACILITATE REMOVAL. - ONCE REMOVAL IS FINISHED, TURN THE GASKET TOOTHED SECTION BACK INTO THE ORIGINAL POSI- TION.
Page 752 PORTER 1.3 16V Chassis 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:...
Page 753 PORTER 1.3 16V Chassis 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.
Page 754 PORTER 1.3 16V Chassis 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 Removal 1.
Page 755 PORTER 1.3 16V Chassis 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 TOOLS AND OTHER EQUIPMENT Butyl tape To prevent water infiltration MP grease To lubricate Water with soap...
Page 756 PORTER 1.3 16V Chassis 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.
Page 757 PORTER 1.3 16V Chassis 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.
Page 758 PORTER 1.3 16V Chassis 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.
Page 759 PORTER 1.3 16V Chassis 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.
Page 760 PORTER 1.3 16V Chassis - 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 THE GLASS TO IDENTIFY THE CORRECT REFITTING POSI- TION OF THE GROOVE.
Page 761 PORTER 1.3 16V Chassis - 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.
Page 762 PORTER 1.3 16V Chassis 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 THE COVER APPLICATION PART.
Page 763 PORTER 1.3 16V Chassis 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.
Page 764 PORTER 1.3 16V Chassis Lower roller removal 1. Hold the sliding door with a jack, interposing a 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.
Page 765 PORTER 1.3 16V Chassis 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 UPPER ROLLER AND THE CENTRAL HINGE FROM THE GUIDE, STARTING FROM THE REAR (REMOVAL SECTION) 6.
Page 766 PORTER 1.3 16V Chassis 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.
Page 767 PORTER 1.3 16V Chassis Regolazioni Sliding door Prescribed alignment sizes 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 ±...
Page 768 PORTER 1.3 16V Chassis 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. Characteristic Adjustment tolerance ~ ± 2 mm 2. The adjustment is carried out after loosening the screw fixing the lock striker plate.
Page 769 PORTER 1.3 16V Chassis 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 AND FITTING.
Page 770: Rear Door Panel
PORTER 1.3 16V Chassis 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.
Page 771 PORTER 1.3 16V Chassis Serratura e maniglie 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.
Page 772 PORTER 1.3 16V Chassis Installation 1. Apply MP grease onto each of the sliding sec- 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.
Page 773: Front Bumper
PORTER 1.3 16V Chassis 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 support side surface and the door side surface does not exceed 4.6 - 8.6 mm.
Page 774 PORTER 1.3 16V Chassis 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.
Page 775: Exhaust Pipe - Catalytic Converter
PORTER 1.3 16V Chassis 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 ÷...
Page 776 PORTER 1.3 16V Chassis 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.
Page 777 PORTER 1.3 16V Chassis 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.
Page 778 PORTER 1.3 16V Chassis Refitting 1. Place hooks A on pins B 2. Tilt the panel and fix pins C in clips D Front panel components CH - 778...
Page 779 PORTER 1.3 16V Chassis 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.
Page 780 PORTER 1.3 16V Chassis 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.
Page 781 PORTER 1.3 16V Chassis 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.
Page 782 PORTER 1.3 16V Chassis 4. Remove the reinforcing bracket from the body by taking out the eight bolts. CH - 782...
Page 783: Instrument Panel Support - Chassis
PORTER 1.3 16V Chassis 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.
Page 784 PORTER 1.3 16V Chassis 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.
Page 785 PORTER 1.3 16V Chassis 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: •...
Page 786 PORTER 1.3 16V Chassis 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.
Page 787 PORTER 1.3 16V Chassis 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...
Page 788 PORTER 1.3 16V Chassis 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...
Page 789 PORTER 1.3 16V Chassis Van front seat KEY: 1. Front seat inclination adjustment 2. Seat back for front seat 3. Seat back upholstery 4. Bushing 5. Gasket 6. Engine inspection cover 7. Cushion upholstery 8. Central mat 9. Internal guides 10.
Page 790 PORTER 1.3 16V Chassis KEY: 1. Screw 2. Seat back fastener 3. Seat back fastener subassembly for rear seat 4. Ring 5. Seat back upholstery 6. Seat back cushion 7. Screw 8. Cushion 9. Ring 10. Cushion upholstery 11. Rear seat cushion Check Check-up of inclination angle until the clicking sound of the belt with winder is heard...
Page 791 PORTER 1.3 16V Chassis 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.
Page 792 PORTER 1.3 16V Chassis 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.
Page 793 PORTER 1.3 16V Chassis KEY: 1. Cable harness (for fuel transmitter gauge) 2. Cable harness (for fuel pump) 3. Clamp & pipe (for fuel inlet) 4. Clamp & pipe (for breathing) 5. Clip & pipe (for fuel main) 6. Clip & pipe (for fuel return) 7.
Page 794 PORTER 1.3 16V Chassis 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.
Page 795 INDEX OF TOPICS DELIVERY...
Page 797 PORTER 1.3 16V Pre-delivery 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.
Page 798 PORTER 1.3 16V Pre-delivery - 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.
Page 799 PORTER 1.3 16V Pre-delivery 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-...
Page 800: Tyre Pressure
PORTER 1.3 16V Pre-delivery 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.
Page 801: Cigarette Lighter
PORTER 1.3 16V Pre-delivery 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.
Page 802 PORTER 1.3 16V Pre-delivery 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).
Page 803: External Lights
PORTER 1.3 16V Pre-delivery 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.
Page 804: Warning Lights
PORTER 1.3 16V Pre-delivery 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.
Page 805: Door Stop Plate - Chassis
PORTER 1.3 16V Pre-delivery 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...
Page 806: Ignition Timing
PORTER 1.3 16V Pre-delivery 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.
Page 807 PORTER 1.3 16V Pre-delivery 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 Specific tooling 020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester Integrated in the 020618Y Lift for diagnosis 4.
Page 808 PORTER 1.3 16V Pre-delivery 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.
Page 809 PORTER 1.3 16V Pre-delivery 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 FUEL INJECTION.
Page 810: Engine Oil
PORTER 1.3 16V Pre-delivery 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.
Page 811: Road Test
PORTER 1.3 16V Pre-delivery 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.
Page 812 PORTER 1.3 16V Pre-delivery 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.
Page 813 INDEX OF TOPICS...
Page 814 SHEET...
Page 815 PORTER 1.3 16V Time-sheet This section has the operation number for various repair procedures. USED ABBREVIATIONS RS right side LS Left side Camshaft CAMSHAFT AND TIMING BELT Code Action Duration 140011 CAMSHAFT REPLACEMENT 140021 CAMSHAFT TIMING SYSTEM PUL- LEY REPLACEMENT 140031 CRANKSHAFT TIMING SYSTEM BELT PULLEY REPLACEMENT...
Page 816: Drive Shaft
PORTER 1.3 16V Time-sheet Crankshaft CRANKSHAFT Code Action Duration 131011 CRANKSHAFT AND/OR BUSHING REPLACEMENT 131051 FLYWHEEL REPLACEMENT 131101 CRANKSHAFT PULLEY REPLACE- MENT Drive shaft TS - 816...
Page 817 PORTER 1.3 16V Time-sheet PROPELLER SHAFT Code Action Duration 370011 PROPELLER SHAFT - REPLACE- MENT Alternator TS - 817...
Page 818 PORTER 1.3 16V Time-sheet ALTERNATOR Code Action Duration 271011 ALTERNATOR - REPLACEMENT 270112 ALTERNATOR - SERVICE 271151 ALTERNATOR PULLEY TS - 818...
Page 819 PORTER 1.3 16V Time-sheet Suspension leaf spring LEAF SPRING AND SHOCK ABSORBERS Code Action Duration 481011 LEAF SPRING (ONE SIDE) - RE- PLACEMENT 481012 LEAF SPRING (ONE SIDE) - SERV- 481021 LEAF SPRING (BOTH SIDES) - RE- PLACEMENT 481022 LEAF SPRING (BOTH SIDES) - SERVICE 481201 LEAF SPRING SUPPORTS AND/...
Page 820 PORTER 1.3 16V Time-sheet Battery BATTERY Code Action Duration 190011 BATTERY - REPLACEMENT 190101 BATTERY CABLE (TO STARTER MOTOR) - REPLACEMENT 190151 BATTERY CABLE (TO GROUND) - REPLACEMENT TS - 820...
Page 821 PORTER 1.3 16V Time-sheet H.T. Coil HV COIL AND SPARK PLUGS Code Action Duration 191011 HV COIL AND/OR EXTENSIONS - REPLACEMENT 191101 SPARK PLUGS - REPLACEMENT 191201 SPARK PLUG HV CABLES (WITH RESISTANCE) - REPLACEMENT TS - 821...
Page 822 PORTER 1.3 16V Time-sheet Cable harnesses CABLE HARNESSES Code Action Duration 820011 CAB INTERNAL CABLE HARNESS - REPLACEMENT 820021 ENGINE CABLE HARNESS - RE- PLACEMENT 820031 ENGINE CABLE HARNESS No. 2 - REPLACEMENT 820101 CHASSIS CABLE HARNESS RE- PLACEMENT 820151 TAIL DOOR CABLE HARNESS - REPLACEMENT 820301...
Page 823 PORTER 1.3 16V Time-sheet Gear-box TS - 823...
Page 824 PORTER 1.3 16V Time-sheet GEARBOX Code Action Duration 331011 COMPLETE GEAR REPLACE- MENT 331011 COMPLETE GEAR REPLACE- MENT 331012 COMPLETE GEAR SERVICE 331031 OUTPUT SHAFT REPLACEMENT 331041 MAIN SHAFT - REPLACEMENT 331101 SYNCHRONISER RING REPLACE- MENT 331121 5TH SPEED GEAR 331141 TRANSMISSION SHAFT BEARING AND/OR TRANSMISSION SHAFT...
Page 825 PORTER 1.3 16V Time-sheet BODYWORK (FRONT SIDE) Code Action Duration 531101 FRONT MUDFLAPS (ONE SIDE) - REPLACEMENT 531201 FRONT SIDE PANEL GASKET (ONE SIDE) - REPLACEMENT 531301 FRONT SIDE PANEL (ONE SIDE) - REPLACEMENT Rear chassis BODYWORK (REAR SIDE) Code Action Duration 612011...
Page 826 PORTER 1.3 16V Time-sheet Wheel rim WHEEL RIM Code Action Duration 430101 WHEEL RIM (1 WHEEL) - RE- PLACEMENT 430111 WHEEL RIM (2 WHEEL) - RE- PLACEMENT 430121 WHEEL RIM - ADDITIONAL TIME: WHEEL ADJUSTMENT - 12 MI- NUTES/WHEEL (THREE WHEELS) - REPLACEMENT 430131 WHEEL RIM - ADDITIONAL TIME:...
Page 827 PORTER 1.3 16V Time-sheet Brake cylinder BRAKE CYLINDER Code Action Duration 471051 REAR BRAKE CYLINDER- ONE SIDE - REPLACEMENT 471551 REAR SHOE DISC - ONE SIDE - REPLACEMENT Horn TS - 827...
Page 828: Clutch Unit
PORTER 1.3 16V Time-sheet HORN Code Action Duration 862051 HORN REPLACEMENT Clutch assembly CLUTCH UNIT Code Action Duration 311011 CLUTCH ASSEMBLY AND/OR CLUTCH DISC REPLACEMENT 311251 PRESSURE PLATE BEARING RE- PLACEMENT 311611 CLUTCH LEVER AND/OR FORK REPLACEMENT TS - 828...
Page 829: Engine Unit
PORTER 1.3 16V Time-sheet Engine assembly ENGINE UNIT Code Action Duration 120011 ENGINE ASSEMBLY - REPLACE- MENT 120012 COMPLETE ENGINE - SERVICE 120051 ENGINE, PARTIAL (BLOCK WITH SUMP AND HEAD) - REPLACE- MENT 120101 BLOCK, PARTS (BLOCK WITH PIS- TONS AND SHAFT) - REPLACE- MENT TS - 829...
Page 830 PORTER 1.3 16V Time-sheet Ducts DUCTS Code Action Duration 170011 INTAKE DUCT AND/OR GASKET REPLACEMENT 170021 EXHAUST DUCT AND/OR GASKET REPLACEMENT 170101 EXHAUST PIPE GASKET RE- PLACEMENT 170211 MUFFLER, DUCT No. 1 - RE- PLACEMENT 170171 MUFFLER REPLACEMENT, DUCT N°2 TS - 830...
Page 831: Oil Sump
PORTER 1.3 16V Time-sheet Oil sump OIL SUMP Code Action Duration 112011 OIL SUMP, OIL AND/OR GASKET REPLACEMENT TS - 831...
Page 832 PORTER 1.3 16V Time-sheet Rear differential TS - 832...
Page 833 PORTER 1.3 16V Time-sheet REAR DIFFERENTIAL Code Action Duration 410011 DIFFERENTIAL HOUSING AND REAR AXLE - REPLACEMENT 410061 BLEEDING (OF THE REAR AXLE) - REPLACEMENT 410101 DIFFERENTIAL HOUSING - RE- PLACEMENT 410102 DIFFERENTIAL HOUSING - SERV- 410151 PINION AND CROWN REPLACE- MENT 410221 DIFFERENTIAL PINION BEARINGS...
Page 834 PORTER 1.3 16V Time-sheet Brake discs TS - 834...
Page 835 PORTER 1.3 16V Time-sheet TS - 835...
Page 836: Brake Disc
PORTER 1.3 16V Time-sheet BRAKE DISC Code Action Duration 473011 FRONT BRAKE DISC REPLACE- MENT (ONE SIDE) 473021 FRONT BRAKE DISC REPLACE- MENT (TWO SIDES) 473101 DISC BRAKE CALLIPER ASSEM- BLY (ONE SIDE) - REPLACEMENT 473111 DISC BRAKE CALLIPER ASSEM- BLY (BOTH SIDES) - REPLACE- MENT 473301...
Page 837 PORTER 1.3 16V Time-sheet Sidelight POSITION LIGHT Code Action Duration 811011 TAILLIGHT ASSEMBLY (ONE SIDE) - REPLACEMENT 811031 TAILLIGHT BULB AND/OR GLASS - ONE SIDE - REPLACEMENT TS - 837...
Page 838 PORTER 1.3 16V Time-sheet Code Action Duration 811201 LICENSE PLATE HOLDER LIGHT REPLACEMENT 811211 LICENSE PLATE LIGHT GLASS REPLACEMENT 811401 REVERSE LIGHT AND/OR BULB REPLACEMENT 811501 REAR FOG LIGHT REPLACEMENT Lights HEADLAMPS Code Action Duration 810011 FRONT HEADLAMP REPLACE- MENT 810201 FRONT TURN INDICATOR AS- SEMBLY - ONE SIDE - REPLACE-...
Page 839 PORTER 1.3 16V Time-sheet Air filter AIR FILTER Code Action Duration 171021 AIR FILTER ASSEMBLY - RE- PLACEMENT 171051 FILTERING ELEMENT REPLACE- MENT 171101 AIR FILTER FITTING REPLACE- MENT TS - 839...
Page 840: Oil Filter
PORTER 1.3 16V Time-sheet Fuel filter FUEL FILTER Code Action Duration 236021 Fuel filter - replacement Oil filter OIL FILTER Code Action Duration 151011 OIL FILTER AND/OR GASKET - RE- PLACEMENT TS - 840...
Page 841: Parking Brake
PORTER 1.3 16V Time-sheet Parking brake PARKING BRAKE Code Action Duration 465021 PARKING BRAKE CONTROL LEV- ER - REPLACEMENT 465721 PARKING BRAKE FRONT CABLE REPLACEMENT 465731 PARKING BRAKE REAR CABLE REPLACEMENT TS - 841...
Page 842 PORTER 1.3 16V Time-sheet Drum shoes BRAKE SHOES AND DRUM Code Action Duration 472031 REAR BRAKE SHOE REPLACE- MENT (ONE WHEEL) 472041 REAR BRAKE SHOE REPLACE- MENT (TWO WHEELS) 472131 REAR BRAKE DRUM REPLACE- MENT - ONE WHEEL 472141 REAR BRAKE DRUM REPLACE- MENT - TWO WHEELS 472231 REAR SHOE RETURN SPRING (1...
Page 843: Front Grille
PORTER 1.3 16V Time-sheet FRONT GRILLE Code Action Duration 751011 FRONT COWL REPLACEMENT 751031 HEADLAMP HOUSING - ONE SIDE - REPLACEMENT Instrument panel INSTRUMENT PANEL Code Action Duration 830011 INSTRUMENT PANEL - REPLACE- MENT 830101 GAUGES - REPLACEMENT 830121 ODOMETER - REPLACEMENT 830141 PRINTED CIRCUIT - REPLACE- MENT...
Page 844 PORTER 1.3 16V Time-sheet Fuel injection FUEL INJECTION Code Action Duration 223011 THROTTLE BODY OR GASKET - REPLACEMENT 223101 FUEL INJECTOR - REPLACEMENT 223201 INJECTOR SUPPLY MANIFOLD - REPLACEMENT 223301 FUEL PRESSURE REGULATOR - REPLACEMENT TS - 844...
Page 845 PORTER 1.3 16V Time-sheet Interiors INSIDE PARTS Code Action Duration 743011 CAB ROOF INTERNAL PROTEC- TION - REPLACEMENT 743021 CAB ROOF INTERNAL PROTEC- TION - REPLACEMENT 743511 FRONT FLOOR CARPET - RE- PLACEMENT 743651 CONSOLE REPLACEMENT 743751 REAR FLOOR CARPET - RE- PLACEMENT TS - 845...
Page 846 PORTER 1.3 16V Time-sheet Adjusting devices SWITCHES AND REGULATORS Code Action Duration 832011 FUEL GAUGE INDICATOR RE- PLACEMENT 832031 MINIMUM OIL PRESSURE INDICA- TOR - REPLACEMENT 832101 STOP SWITCH - REPLACEMENT 832111 REVERSE GEAR BULB SWITCH - REPLACEMENT TS - 846...
Page 847 PORTER 1.3 16V Time-sheet Code Action Duration 832251 ENGINE CHECKING COMPUTER - REPLACEMENT 832301 LIGHT SWITCH REPLACEMENT 832431 WINDSCREEN WIPER RELAY - REPLACEMENT 832311 TURN INDICATOR BLINKER RE- PLACEMENT 832341 VOLTAGE REGULATOR RE- PLACEMENT 832351 COURTESY LIGHT SWITCH RE- PLACEMENT 832361 REAR GLASS DEFROSTER SWITCH - REPLACEMENT...
Page 848: Windscreen Washers
PORTER 1.3 16V Time-sheet WINDSCREEN WASHERS Code Action Duration 851051 GLASS WASHING PUMP AND MO- TOR REPLACEMENT 851061 SPRINKLER - REPLAC. 851081 REPLACEMENT OF THE PIPE CONNECTING THE PUMP TO THE OPENING 851091 RESERVOIR AND WASHING PUMP REPLACEMENT Gear stick TS - 848...
Page 849: Gearshift Lever
PORTER 1.3 16V Time-sheet GEARSHIFT LEVER Code Action Duration 332301 GEAR CONTROL TRANSMISSION REPLACEMENT 332401 GEAR SHIFT LEVER REPLACE- MENT 332501 GEAR SHIFT LEVER KNOB RE- PLACEMENT TS - 849...
Page 850 PORTER 1.3 16V Time-sheet Single-block BLOCK Code Action Duration 111011 BLOCK/CYLINDER REPLACE- MENT 111151 SEALING RING REPLACEMENT (FRONT SIDE CRANKSHAFT) 111201 Sealing and/or retaining ring, engine rear side ring - Replacement 111251 ELASTIC SUPPORT REPLACE- MENT TS - 850...
Page 851 PORTER 1.3 16V Time-sheet Starter motor TS - 851...
Page 852 PORTER 1.3 16V Time-sheet STARTER MOTOR Code Action Duration 280011 STARTER MOTOR - REPLACE- MENT 280112 MOTOR - SERVICE 280211 REMOTE CONTROL - REPLACE- MENT Rear floor panel REAR FLOORING PANEL Code Action Duration 613011 ENGINE SERVICE COMPART- MENT COVER REPLACEMENT 613051 BATTERY HOUSING COVER - RE- PLACEMENT...
Page 853 PORTER 1.3 16V Time-sheet Door panel DOOR PANEL Code Action Duration 670051 FRONT DOOR PANEL (ONE SIDE) - REPLACEMENT 670061 SIDE DOOR PANEL (ONE SIDE) - REPLACEMENT 670201 FRONT DOOR UPPER/LOWER HINGE (ONE SIDE) - REPLACE- MENT 670301 FRONT DOOR LINING - ONE SIDE - REPLACEMENT 670311 SIDE DOOR UPHOLSTERY (ONE...
Page 854 PORTER 1.3 16V Time-sheet Code Action Duration 670801 SIDE DOOR GUIDE - REPLACE- MENT Dashboard TS - 854...
Page 855 PORTER 1.3 16V Time-sheet INSTRUMENT PANEL Code Action Duration 550011 INSTRUMENT PANEL REPLACE- MENT 550101 INSTRUMENT PANEL FINISHING - REPLACEMENT 550131 INSTRUMENT PANEL CENTRAL FINISHING - REPLACEMENT 550201 GLOVEBOX REPLACEMENT 550211 GLOVEBOX OPEN/CLOSE LEVER REPLACEMENT 550301 ASHTRAY REPLACEMENT 550311 VENTILATED AIR PASSAGE RE- PLACEMENT - ONE SIDE TS - 855...
Page 856 PORTER 1.3 16V Time-sheet Bumper BUMPERS Code Action Duration 520011 FRONT BUMPER REPLACEMENT 520021 REAR BUMPER REPLACEMENT TS - 856...
Page 857 PORTER 1.3 16V Time-sheet Brake pedal BRAKE PEDAL Code Action Duration 467011 BRAKE PEDAL REPLACEMENT 467101 PEDAL PROTECTION - REPLACE- MENT TS - 857...
Page 858: Clutch Pedal
PORTER 1.3 16V Time-sheet Clutch pedal CLUTCH PEDAL Code Action Duration 313101 PEDAL PROTECTION - REPLACE- MENT 313201 CLUTCH TRANSMISSION RE- PLACEMENT TS - 858...
Page 859 PORTER 1.3 16V Time-sheet Steering column TS - 859...
Page 860: Piston And Connecting Rod
PORTER 1.3 16V Time-sheet COLUMN / STEERING / STEERING HOUSING / JOINTS Code Action Duration 442101 ARM REPLACEMENT - ONE SIDE 442111 ARM REPLACEMENT - TWO SIDES 442201 REPLACEMENT OF THE ARTICU- LATED ARM WITH BAR:ONE SIDE 442301 UNIVERSAL JOINT REPLACE- MENT 442401 STEERING HOUSING REPLACE-...
Page 861 PORTER 1.3 16V Time-sheet Water pump WATER PUMP AND THERMOSTAT Code Action Duration 161011 WATER PUMP AND/OR GASKET REPLACEMENT 161051 WATER PUMP PULLEY - RE- PLACEMENT 161101 THERMOST. AND/OR GASKET, WATER. OUTL. FITT. REPLACE- MENT TS - 861...
Page 862: Fuel Pump
PORTER 1.3 16V Time-sheet Fuel pump FUEL PUMP Code Action Duration 234011 FUEL PUMP AND/ OR GASKET - REPLACEMENT 234012 FUEL PUMP AND/ OR GASKET - SERVICE TS - 862...
Page 863 PORTER 1.3 16V Time-sheet Brake fluid pump BRAKE PUMP Code Action Duration 461021 TANK AND/OR TANK PIPE RE- PLACEMENT 463011 POWER BRAKE PUMP ASSEMBLY REPLACEMENT TS - 863...
Page 864 PORTER 1.3 16V Time-sheet Oil pump OIL PUMP Code Action Duration 150011 OIL PUMP AND/OR O-RING RE- PLACEMENT 150012 OIL PUMP AND/OR O-RING SERV- 150051 OIL INTAKE ASSEMBLY OR GAS- KET - REPLACEMENT 150251 OIL PRESSURE SAFETY VALVE REPLACEMENT TS - 864...
Page 865 PORTER 1.3 16V Time-sheet Rear van door TAIL DOOR ( VAN ) Code Action Duration 642151 TAIL DOOR GLASS AND/OR GAS- KET - REPLACEMENT 642321 TAIL DOOR HINGE - TWO SIDES - REPLACEMENT 642361 TAIL DOOR LOCK ASSEMBLY - REPLACEMENT 642391 CYLINDER KIT / REAR DOOR LOCK KEY - REPLACEMENT...
Page 866 PORTER 1.3 16V Time-sheet Rear-view mirror sun shade SUN VISOR AND REAR-VIEW MIRROR Code Action Duration 752011 EXTERNAL REAR-VIEW MIRROR - ONE SIDE - REPLACEMENT 752021 INTERNAL REAR-VIEW MIRROR WITH CEILING LIGHT REPLACE- MENT. 752101 SUN VISOR REPLACEMENT 752151 SUPPORT HANDLE REPLACE- MENT - ONE SIDE TS - 866...
Page 867 PORTER 1.3 16V Time-sheet Radiator RADIATOR AND WATER PIPES Code Action Duration 160011 RADIATOR REPLACEMENT 160021 TANK, EXPANSION TANK, RADIA- TOR REPLACEMENT 160031 PRESSURISED CAP ON RADIA- TOR REPLACEMENT 160101 RADIATOR INLET PIPE REPLACE- MENT 160111 RADIATOR OUTLET PIPE RE- PLACEMENT 160151 ENGINE OUTLET RADIATOR...
Page 868 PORTER 1.3 16V Time-sheet Radio RADIO Code Action Duration 860021 RADIO AND PARTS RELATED TO FITTING - REPLACEMENT 860031 RADIO - REPLACEMENT 860051 LOUDSPEAKER - REPLACEMENT 860101 AERIAL WITH RELEVANT SUP- PORT - REPLACEMENT TS - 868...
Page 869 PORTER 1.3 16V Time-sheet Heating HEATING Code Action Duration 870031 HEATING REPLACEMENT 870271 DEFROSTER PIPE REPLACE- MENT - TWO SIDES 870311 DEFROSTER NOZZLE REPLACE- MENT - TWO SIDES 870401 REPLACEMENT OF THE HEATING CONTROL AND THE TRANSMIS- SION 870771 RADIATOR ASSEMBLY REPLACE- MENT 870781 FAN REPLACEMENT, HEATING...
Page 870 PORTER 1.3 16V Time-sheet Front seat FRONT SEAT Code Action Duration 711011 FRONT SEAT CUSHION RE- PLACEMENT - ONE SIDE 711021 SEAT BACK FOR FRONT SEAT REPLACEMENT - ONE SIDE 711061 FRONT SEAT HEADREST RE- PLACEMENT - ONE SIDE 711101 FRONT SEAT INTERNAL TRACK - ONE SIDE - REPLACEMENT TS - 870...
Page 871 PORTER 1.3 16V Time-sheet Code Action Duration 711151 SEAT BACK CLOSING FOR FRONT SEAT - ONE SIDE - RE- PLACEMENT 711201 FRONT SEAT CUSHION COVER (ONE SIDE) - REPLACEMENT 711251 SEAT BACK COVER FOR FRONT SEAT (ONE SIDE) - REPLACE- MENT 711301 FRONT SAFETY BELT HOOK-ONE...
Page 872: Rear Axle Shaft
PORTER 1.3 16V Time-sheet Rear half-shaft REAR AXLE SHAFT Code Action Duration 421051 REAR AXLE SHAFT (ONE SIDE) - REPLACEMENT 421101 REAR AXLE SHAFT RADIAL BEAR- ING (ONE SIDE) - REPLACEMENT 421201 REAR AXLE SHAFT RADIAL BEAR- ING (BOTH SIDES) - REPLACE- MENT 421301 SEALING RING («T»...
Page 873 PORTER 1.3 16V Time-sheet Cam sensor CAM SENSORS Code Action Duration 192501 CAM SENSOR ASSEMBLY - RE- PLACEMENT 192531 CAM SENSOR SUPPORT- RE- PLACEMENT 192561 SIGNAL GENERATOR - REPLACE- MENT TS - 873...
Page 874: Fuel Tank
PORTER 1.3 16V Time-sheet Fuel tank FUEL TANK AND PIPES ( VAN ) Code Action Duration 237011 FUEL TANK - REPLACEMENT 237051 FUEL TANK CAP REPLACEMENT 237701 REACTION VALVE - REPLACE- MENT 237811 ACTIVATED CARBON FILTER - REPLACEMENT TS - 874...
Page 875 PORTER 1.3 16V Time-sheet FUEL TANK AND PIPES (PICK-UP) Code Action Duration 237011 FUEL TANK - REPLACEMENT 237051 FUEL TANK CAP REPLACEMENT 237701 REACTION VALVE - REPLACE- MENT 237811 ACTIVATED CARBON FILTER - REPLACEMENT TS - 875...
Page 876 PORTER 1.3 16V Time-sheet Front suspensions FRONT SUSPENSIONS AND FRONT AXLE Code Action Duration 431011 LOWER SUSPENSION ARM - ONE SIDE - REPLACEMENT 431051 LOWER SUSPENSION ARM - BOTH SIDES - REPLACEMENT 431101 FRONT SHOCK ABSORBER SPRING REPLACEMENT - ONE SIDE 431111 FRONT SHOCK ABSORBER...
Page 877 PORTER 1.3 16V Time-sheet Rear end-gate TAILBOARD Code Action Duration 611011 TAILBOARD REPLACEMENT 611101 TAILBOARD HOOK REPLACE- MENT TS - 877...
Page 878 PORTER 1.3 16V Time-sheet Spare wheel mounting bracket SPARE WHEEL SUPPORT Code Action Duration 511201 SPARE WHEEL SUPPORT - RE- PLACEMENT TS - 878...
Page 879 PORTER 1.3 16V Time-sheet Plates LABELS Code Action Duration 750011 PLATE REPLACEMENT - SINGLE PIECE TS - 879...
Page 880: Windscreen Wiper
PORTER 1.3 16V Time-sheet Wiper WINDSCREEN WIPER Code Action Duration 850051 REPLACEMENT OF THE FRONT WINDSCREEN WIPER ARM AND/ OR BLADE 850161 FRONT WINDSCREEN WIPER MO- TOR REPLACEMENT 850171 FRONT WINDSCREEN WIPER AR- TICULATION REPLACEMENT TS - 880...
Page 881 PORTER 1.3 16V Time-sheet Rear van wiper REAR WINDSCREEN WIPER AND REAR WINDOW WASHER ( VAN ) Code Action Duration 852011 WINDSCREEN WIPER ARM AND/ OR BLADE - REPLACEMENT 852051 MOTOR AND REAR WINDSCREEN WIPER SUPPORT - REPLACE- MENT 852101 REAR WINDOW WASHER SPRAY- ER - REPLACEMENT TS - 881...
Page 882 PORTER 1.3 16V Time-sheet Head HEAD Code Action Duration 110011 HEAD/CYLINDER - REPLAC. 110051 GASKET/HEAD REPLACEMENT 110101 REPLACEMENT OF COVER OR HEAD AND/OR HEAD GASKET/ COVER 110201 OIL SEAL RING (CAMSHAFT) RE- PLACEMENT 110131 OIL FILLER CAP - REPLACEMENT TS - 882...
Page 883 PORTER 1.3 16V Time-sheet Throttle cable ACCELERATOR TRANSMISSION Code Action Duration 552031 ACCELERATOR TRANSMISSION REPLACEMENT TS - 883...
Page 884: Brake Hoses
PORTER 1.3 16V Time-sheet Brake hoses BRAKE PIPES AND CALIBRATOR Code Action Duration 464011 FRONT HOSE REPLACEMENT 464051 REAR BRAKE HOSE REPLACE- MENT 464751 POWER BRAKE REGULATOR AS- SEMBLY REPLACEMENT TS - 884...
Page 885 PORTER 1.3 16V Time-sheet Valves VALVES Code Action Duration 141011 VALVE, VALVE GUIDE REPLACE- MENT 141031 SPRING, CAP PLATE AND/OR COTTERS AND/OR SEAL. RING REPLAC. 141101 PIN, ROCKING LEVER REPLACE- MENT TS - 885...
Page 886 PORTER 1.3 16V Time-sheet Windows WINDOWS Code Action Duration 554011 WINDSHIELD AND GASKET RE- PLACEMENT 554051 REAR GLASS AND/OR GASKET REPLACEMENT Van side window TS - 886...
Page 887 PORTER 1.3 16V Time-sheet SIDE GLASS ( VAN ) Code Action Duration 645011 SIDE GLASS STRIP (ONE SIDE) - REPLACEMENT 645021 SIDE GLASS AND/OR PROFILE - REPLACEMENT Frameless side window DOOR GLASS AND PROFILE Code Action Duration 671011 FRONT DOOR GLASS REPLACE- MENT - ONE SIDE 671021 SIDE DOOR GLASS (ONE SIDE) -...
Page 888 PORTER 1.3 16V Time-sheet Code Action Duration 671251 FRONT DOOR INTERNAL PLATE REPLACEMENT: ONE SIDE 561261 SIDE DOOR INTERNAL PLATE (ONE SIDE) - REPLACEMENT 671271 FRONT DOOR EXTERNAL GLASS EDGE: ONE SIDE 671281 SIDE DOOR EXTERNAL GLASS EDGE (ONE SIDE) - REPLACE- MENT 671351 FRONT DOOR GASKET REPLACE-...
Page 889 PORTER 1.3 16V Time-sheet Steering TEERING WHEEL Code Action Duration 441071 HORN CONTACT RING REPLACE- MENT TS - 889...
Page 890 PORTER 1.3 16V Time-sheet Code Action Duration 441101 STEERING WHEEL REPLACE- MENT 441121 HORN CONTACT SQUARE PLATE REPLACEMENT 441151 HORN BUTTON REPLACEMENT TS - 890...
Page 891 Battery: 820 Belt: 232, 236, 240, 244, 247 Bodywork: Brakes: 68, 69 Bulbs: 150, 152, 154 Chassis: 70, 740, 804, 824, 825 Checks: 357 Cleaning: 808 Clearance: Control: 561, 664, 670, 682 Coolant: 48, 67, 360, 370, 808 Differential: 47, 595, 596, 832 Doors: 745 Engine: 44, 45, 66, 70, 225, 806, 809, 810, 829 Filter: 44, 126, 361, 839, 840...
Page 892 Oil: 45–47, 66, 67, 248, 298, 349, 358, 810, 831, 840, 864 Pressure: 66, 260, 800 Products: 44 Remote control: Safety: 10 Seats: 275, 277 Shock Absorbers: Spark plugs: Specifications: Switch: 88 System: 54, 72, 348, 360, 361, 378, 611, 621 Tank: 874 Van: 865, 871, 881, 886 Vehicle: 29, 655...

PIAGGIO PORTER 1.3 16V 2008 Service Manual

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