PIAGGIO PORTER 1.3 16V 2008 Manuals

PIAGGIO PORTER 1.3 16V 2008 Manuals

Manuals and User Guides for PIAGGIO PORTER 1.3 16V 2008. We have 1 PIAGGIO PORTER 1.3 16V 2008 manual available for free PDF download: Service Manual

PIAGGIO PORTER 1.3 16V 2008 Service Manual

PIAGGIO PORTER 1.3 16V 2008 Service Manual (893 pages)

Brand: PIAGGIO | Category: Automobile | Size: 35 MB

Table of Contents

Index of Topics
5
General Guidelines
7
General Recommendations for Safety
8
Recommendations and Important Notes
8
General Guidelines
9
General Information
9
Safety Guidelines
10
Emergency Tow
11
Towing on a Flat Truck
11
Towing with Wheels Lifted
11
Front Support Point
12
Lifting Points
12
Rear Support Point
12
Description of Manual Use
13
Maintenance Guidelines
13
Support Points for Jack
13
Maintenance Procedure
14
Circuit Check
15
DLC Data Link Connector
15
Electric Fault Repair
15
General Instructions for Maintenance Operations on the Cable Harness
16
OBD Dignosis Connector Terminals
16
Fixing with Screws
17
Terminals and Connectors
17
Cable Harness
18
Disconnection of Connectors with Safety Lock
18
Using Resin Clamps
18
Disconnection of Terminal with Metal Lock
19
Terminal Insertion
19
Characteristics
21
Chassis Identification
22
Engine Identification
22
Engine Number and Type
22
Manufacturer Label
22
Pick-Up Model Bodywork Colour Codes
23
Van Model Bodywork Colour Code
23
Vehicle Model Code
23
Kinematic Chain Specifications
24
Impianto Elettrico
25
Dimensions
26
Table of Contents
27
Tightening Torques
27
Cylinder-Piston Oversizes
29
Vehicle Overhaul Data
29
Crankshaft - Rod Head
30
Piston - Pin
30
Piston Ring Oversizes
30
Camshaft
31
Tappets
31
Valve Clearance
31
Valve Guide - Valve Stem
31
Valve Spring
31
Crankshaft Pulley
32
Cylinder Head
32
- Special Tools
  33
- Injection System Tool
  34
- Tooling
  34
- Engine Tool
  35
- Clutch Tool
  36
- Transmission Tool
  36
- Differential Tool
  37
- Brake Tool
  38
- Front Suspension Tool
  38
- Rear Suspension Tool
  39
- Steering Tool
  40
- Maintenance
  42
- Scheduled Maintenance Chart
  43
- Air Filter
  44
- Engine Assembly
  44
- Suggested Products Chart
  44
- Engine Oil Level Check
  45
- Engine Oil Replacement
  45
- Oil Quality Check
  45
- Engine Oil Change and Filter Replacement
  46
- Gear-Box Oil Replacement
  46
- Gearbox Oil Change
  46
- Leaks
  46
- Differential Oil Change
  47
- Differential Oil Replacement
  47
- Oil Leak
  47
- Coolant Change
  48
- Coolant Replacement
  48
- Cable Check
  50
- Spark Plug
  50
- Spark Plug Check
  50
- Headlight Alignment Check
  51
- Light Beam Direction Adjustment
  51
- Settings and Adjustments
  51
- Emission Control System
  53
- Component Layout
  54
- Catalytic Converter
  55
- Fuel Vapour Control System
  56
- Control System Diagram
  57
- Engine off
  57
- Engine Operation with the Accelerator Pedal Pushed
  57
- Blow-By Ventilation Pipe
  58
- Fuel Closing Device During Deceleration
  58
- Fuel Vapour Control Device
  59
- Emission Control Device
  62
- CO/HC Concentration Check
  63
- Exhaust Emission Control System
  63
- Troubleshooting
  65
- Engine
  66
- Clutch
  67
- Brakes
  68
- Gearbox
  68
- Suspensions and Steering
  69
- Electrical System
  71
- Battery-Chassis Ground
  72
- Ground Points
  72
- Main Ground
  73
- Rear Services System Ground
  73
- Services System Ground
  73
- Additional Ground
  74
- Electric Circuit Diagram
  74
- Injection System - Engine Ground
  74
- Electric Diagrams
  78
- Ignition
  78
- Starting and Recharging
  79
- Air Conditioning Electrical System Diagram
  81
- Colour Table
  83
- Fuse Box
  83
- Fuses
  83
- Instructions to Replace Fuses and Fuse Holders
  83
- Remote Controls
  84
- Air Conditioning Remote Controls
  85
- Electrical Controls
  85
- Multifunction Switch Lever
  85
- Ignition Key Switch
  86
- Rear Windscreen Wiper and Spray Nozzle Switch
  88
- Wiper Switch
  88
- Handbrake Switch
  89
- Headlamp Light Beam Adjustment Switch
  89
- Heated Rear Window Switch
  89
- Front Fog Light
  90
- Windscreen Wiper Mechanism
  91
- Windscreen Wiper Remote Control
  92
- Rear Wiper Mechanism
  94
- Start-Up System
  95
- Starter Motor
  95
- Inspection with Starter Motor Fitted
  96
- Bench Tests
  98
- Thrust Test
  98
- Checking Performance Without Load Applied
  99
- Pinion Engagement Upholding Test
  99
- Pinion Return Check
  99
- Starter Motor Removal
  100
- Commutator Check
  103
- Commutator Continuity Check
  103
- Rotor Insulation Check
  103
- Brush Check
  105
- Field Winding Check
  105
- Brush Holder Check
  106
- Brush Replacement Procedure
  106
- Coupling Check
  106
- Magnetic Field Check
  107
- Starter Motor Coupling Check
  107
- Bearing Check
  108
- Alternator
  111
- Recharge System
  111
- Rotor Check
  117
- Brush and Brush Holder
  118
- Stator
  118
- Brush Replacement
  119
- Rectifier Check
  120
- Rear Bearing Check
  121
- Rear Bearing Replacement
  121
- Front Bearing Check
  122
- Front Bearing Replacement
  122
- Refitting
  123
- Generator Shaft Fixing
  125
  - Central Locking with Remote Control System Description
    126
  - Power Lock
    126
  - Electromechanical Actuators
    127
  - Remote Control
    127
  - Technical Characteristics of the System
    127
  - New Remote Control Detection
    129
  - Remote Control
    131
  - System Maintenance
    131
  - Alarm System and Central Locking
    132
  - Electrical Contacts for Sliding Doors
    132
  - System Protection Fuse
    132
  - Operation Description
    133
  - Garage Function
    135
  - LED Warning
    135
  - Alarm and Central Locking
    136
  - Electrical Connections
    136
  - Ultrasound Module Connection and Positioning
    137
  - Super-High Frequency Module Connection and Positioning
    138
  - Super-High Frequency Sensor Adjustment
    139
  - Programmable Functions
    140
  - Anti-Hijack Function
    143
  - New Control Device Detection
    145
  - New Pin-Code Programming
    146
  - Emergency Unlocking through Pin-Code
    147
  - Device Battery Replacement
    148
  - Magnetic Contact
    148
  - Infrared Sensor
    149
  - Radio Control
    149
  - Light Layout and Specifications
    150
  - Replacing Light Bulbs
    150
  - Bulb Position and Characteristics
    151
  - Replacing the Headlight Bulbs
    152
  - Front Indicators
    154
  - Replacing the Front Turn Signal Light Bulbs
    154
  - Replacing the Taillight Bulbs
    154
  - Cab Rear Light
    155
  - Rear Turn Indicators/Stop Lights
    155
  - Replacing the Courtesy Lamp
    155
  - Replacing the License Plate Light Bulb
    155
  - Fog Light Headlamp Replacement
    156
  - Fog Light Headlamps
    156
  - Indicators - Warning Lights
    157
  - Rear Fog Light
    157
  - Reverse Gear Light
    157
  - Instrument Panel
    158
  - Speedometer
    158
  - Fuel Gauge
    160
  - Fuel Level Probe
    161
  - Unit Check
    161
  - Fuel Gauge and Temperature Gauge
    162
  - Water Temperature Gauge
    162
  - Ignition Check
    163
  - Electrode Gap
    164
  - Battery Voltage
    165
  - Electrical Power Supply
    165
  - Ignition Cable
    165
  - Camshaft Sensor
    166
  - Ignition Timing
    167
  - Electronic Injection Control Unit
    168
  - Control Unit Output Characteristics
    169
  - Fan Check
    170
  - Fan Switch Check
    170
  - Internal/External Air Control Cable
    171
  - Main Fitting Operations
    171
  - Temperature Adjustment Cable
    171
  - Flow Regulation Cable
    172
  - Heating System and Ventilation
    172
  - Cooling Circuit
    174
  - Cooling Electric Fan Check
    174
  - Engine Injection Cable Harness
    175
  - Ignition Coil
    176
  - Battery Negative Cable Harness
    178
  - Engine - Chassis Ground Cable Harness
    179
  - Battery Positive Cable Harness
    180
  - Bodywork-Engine Ground Transmission Cable Harness
    183
  - Cab Roof Cable Harness
    184
  - Positions of Cables in the Connectors
    184
  - Roof Light Cable Harness
    185
  - Tail Door Cable Harness No.1
    186
  - Engine Cable Harness
    187
  - Rear Chassis Cable Harness
    188
  - Instrument Panel Cables
    190
  - Right Hand Drive Instrument Panel
    190
  - Left Hand Instrument Panel
    199
  - Right Hand Drive Van
    207
  - Left Hand Drive Van
    214
  - Tipper
    222
  - E.G.R. Circuit Intake Duct
    225
  - Engine Mechanism
    225
  - Engine Type 2
    225
  - Inlet Manifold Removal
    225
  - Inlet Manifold - Fuel Delivery Pipe
    227
    
    EGR Valve - EGR Pipe
    228
    
    Exhaust Manifold Removal
    230
    
    Exhaust Pipe
    230
    
    Manifold Check
    230
    
    Exhaust Manifold Fitting
    231
    
    Alternator Drive Belt
    232
    
    Tension Adjustment
    232
  - Cylinder Head - Exhaust Manifold
    232
    
    Driving Belt Test
    233
    
    Crown Gear Replacement
    234
    
    Flywheel Test
    234
    
    Crankshaft Pinion Fitting
    235
    
    Crankshaft Pulley Flange Fitting
    235
    
    Crankshaft Pulley Test
    235
    
    Driving Pulley
    235
- Crankshaft - Crankshaft Belt Pulley
  235
  - Initial Operations
    236
  - Timing Belt and Gears
    236
  - Timing Belt Replacement
    236
  - Timing Belt Removal
    237
  - Belt Tensioner
    240
  - Belt Tensioner Pulley Check
    240
  - Crankshaft Pulley and Flange Test
    240
  - Timing Belt Tensioner Spring Check
    240
  - Crankshaft Pulley Removal
    241
  - Crankshaft Pulley Fitting
    242
  - Refitting Pulley on Crankshaft
    242
Crankshaft - Timing System Pulley Screw
242
- Camshaft Pulley Removal
  243
- Removal - Refitting Timing Pulley
  243
- Camshaft Pulley Fitting
  244
- Tension Spring Connection
  244
- Timing Belt Fitting
  244
- Timing System Belt Tensioner
  246
  - Timing Belt Cover Screw
    247
    
    Valve Timing - Belt Tensioning
    247
    
    Crankshaft Pulley - Transmission Screws
    248
    
    Oil Pump Removal
    248
    
    Timing Side Oil Sealing Ring Replacement
    252
  - Cover - Oil Pump
    253
    
    Cylinder Head Assembly
    254
    
    Cylinder Head Unit
    254
    
    Alternator Removal
    256
    
    Removal of the Engine Wire from the Cylinder Head
    256
    
    Head Removal
    257
    
    Cylinder Head Cover Inspection
    260
    
    EGR Valve Check
    260
    
    Pressure Relief Valve
    260
    
    Tappet Cover Gasket
    260
    
    Valve Clearance Adjustment
    261
    
    Rocking Lever and Pin Check
    262
    
    Tappet Pin
    262
    
    Rocking Lever Identification
    263
    
    Camshaft Check
    264
    
    Camshaft Inspections
    264
    
    Spacer and Crinkle Washer Check
    264
    
    Cylinder Head - M 8 Camshaft
    266
    
    Camshaft Axial Clearance Test
    267
    
    Head Removal - Cylinders
    268
    
    Gasket Residue Removal
    269
    
    Head Cleaning and Check
    269
    
    Combustion Chamber Cleaning
    270
    
    Levelness Tolerance
    270
    
    Head Cracking Check
    271
    
    Valve Check and Rectification
    271
    
    Valve Guide Bushing Cleaning
    271
    
    Checking Clearance between the Valve Guide and the Valve Stem
    273
    
    Valve Spring Check
    274
    
    Valve Guide Replacement
    275
    
    Valve Guides and Seats
    275
    
    Inlet Valve Guide
    276
    
    Specific Tooling
    276
    
    Checking and Cleaning the Valve Seats
    277
    
    Valve Seat Rectification
    278
    
    Fitting New Valves
    280
    
    Valve Manual Grinding
    280
    
    Head Fitting
    281
    
    Fitting the Valve Spring Seats on the Head
    282
    
    Valve Fitting
    283
    
    Valve Sealing Ring Fitting
    283
    
    Fitting the Valve Springs, Caps and Cotters
    284
    
    Cylinder Head - Water Temperature Sensor 24.5 ÷
    285
    
    Camshaft and Rocking Lever Pin Fitting
    286
    
    Cylinder Head - Cylinder Block
    286
    
    Final Operations
    288
  - Oil Pump Fitting
    253
- Cylinder Head - Cylinder Head Cover
  288
  - Base - Pistons - Cylinders
    289
  - Block Removal
    290
  - Operations on Components
    290
  - Cylinder Block Removal
    291
  - Oil Sump Removal
    295
  - Piston Removal
    296
  - Remove the Flywheel
    297
  - Oil Sump Test
    298
  - Piston - Removal and Inspection
    298
  - Piston and Connecting Rod Test
    298
  - Removing the Oil Sump
    298
  - Piston and Connecting Rod Removal
    299
  - Piston Inspection
    300
  - Piston Ring Clearance
    301
  - Piston Ring Opening
    302
  - Piston Ring Rated Thickness
    302
  - Piston Ring Removal
    302
  - Piston Rings - Inspection
    302
  - Piston and Connecting Rod Fitting
    303
  - Piston Refitting
    303
  - Connecting Rod Check
    304
  - Pin-Connecting Rod Forced Coupling Check
    304
  - Clearance Measurement between Connecting Rod Bushings and Crankshaft
    305
  - Connecting Rod Clearance Measurement
    305
- Connecting Rod - Connecting Rod Cap
  307
  - Connecting Rod Head Types
    308
  - Connecting Rod Replacement
    309
  - Cylinder Block Test
    310
  - Cylinders
    310
  - Cylinder Reaming
    311
  - Cylinder Scale Removal
    311
  - Cylinder Block Replacement
    312
  - Crankcase Bearings
    314
  - Oil Sealing Rear Gasket Replacement
    314
  - Check the Axial Clearance of the Crankshaft
    315
  - Checking Coupling Clearance of the Main Bushing
    315
  - Crankshaft
    315
  - Cylinder Block - Main Bearing Cap
    317
    
    Main Bushing Category Selection
    318
    
    Crankshaft Replacement
    319
    
    Connecting Rod Pin Category
    320
    
    Main Journal Categories
    320
    
    Connecting Rod Bushing Categories
    321
    
    Connecting Rod Head Categories
    321
    
    Water Pump Fitting
    321
    
    Cylinder Block - Water Pump
    322
    
    Oil Filter Fitting
    322
    
    Pressure Switch Fitting
    323
    
    Spring Connection to the Timing Belt Tensioner
    323
    
    Water Filler Fitting
    323
    
    Fitting the Clutch Disc and Driven Plate
    324
    
    Flywheel Fitting
    324
    
    Water Pipe Fitting
    324
    
    Cylinder Block Fitting
    326
    
    Fitting the Flange Supporting the Flywheel Side Sealing Ring
    326
    
    Rear Plate Fitting
    327
    
    Crankshaft Fitting
    328
    
    Arrangement to Fit the Head on the Engine
    329
    
    Fitting the Timing Pinion Fixing Screw
    332
    
    Fitting the Thermostat in the Cylinder Block
    336
    
    Oil Suction System Fitting
    336
    
    Oil Sump - Cylinder Block
    336
    
    Oil Sump Fitting
    336
    
    Checking and Adjusting the Ignition Timing
    337
    
    Compression Check
    338
    
    Idle Speed Check and Adjustment
    339
    
    Clutch Bell and Diaphragm Spring
    343
    
    Clutch Disc
    344
    
    Clutch Lever Stop
    344
    
    Spring
    344
    
    Thrust Bearing
    345
    
    Thrust Bearing Hub Stop
    345
    
    Clutch Cable
    346
    
    Clutch Pedal Adjustment
    347
    
    Free and Residual Travel of the Pedal
    348
    
    Lubrication System
    348
    
    Oil Pressure Check
    349
    
    Oil Pump
    349
- Connecting Rod Bearing Thickness Selection
  307
- Oil Pressure Switch - Cylinder Block
  350
  - Measuring Pump Housing Clearance, Upper Part and Side Clearance
    352
  - Wear Check
    353
  - Oil Pump - Cylinder Block
    355
    
    Oil Filter - Cylinder Block
    356
    
    Checks
    357
    
    Oil Cartridge
    358
    
    Oil Pressure Warning Light
    359
    
    Coolant Pump
    360
    
    Cooling System
    360
    
    Oil Pump - Oil Pressure Switch
    360
    
    Fuel Filter
    361
    
    Fuel Filter Replacement
    361
    
    Injection Fuel System
    361
    
    Water Pump Pulley Test
    361
    
    Conceptual Diagram
    362
    
    Cooling System Diagram
    362
    
    Fuel Filter Fixing Nut
    362
    
    Radiator Cap Check
    363
    
    Radiator Cleaning
    363
    
    Cooling Circuit Check for Possible Water Leaks
    364
    
    Thermostat Inspection
    365
    
    Thermostat Removal
    365
    
    Thermostatic Valve
    365
    
    Cover - Thermostat 5.9 ÷
    366
    
    Thermostat Fitting
    366
    
    Radiator Removal
    367
    
    Radiator Fitting
    369
    
    Coolant Temperature Sensor
    370
    
    Radiator Thermoswitch Inspection
    370
    
    Radiator Thermoswitch Removal
    370
    
    Radiator Thermoswitch Specifications
    370
    
    Radiator Thermoswitch Fitting
    371
    
    Water Pump Removal
    372
    
    Inspecting Parts Relating to the Water Pump
    373
    
    Water Pump Sealing Test
    374
    
    Injection System
    377
    
    General Safety Measures
    378
    
    Injection System Circuit Check
    379
    
    Instructions for the Mobile Communication System
    379
    
    Using the Engine Checking System
    381
    
    DLC Connector Key
    384
    
    Component Location
    385
    
    Injection System Basic Diagram
    386
    
    ECU-Draco Connector Layout
    387
    
    Draco-Denso ECU Interface Diagram
    388
    
    EFI-Draco ECU Interface Diagram
    388
    
    Safety Measures to Repair the Supply System
    397
    
    Clip Position
    398
    
    Fuel Pipe
    398
    
    Pipe Insertion Length
    398
    
    Suction Pipe
    398
    
    Bleeding Pipe
    399
    
    Fuel Leak Check
    400
    
    European on Board Diagnostic System of Vehicles
    401
    
    ISO Diagnosis Code Key
    402
    
    Data Link Connector
    404
    
    Checking, Storing and Clearing the Failure Code/Frozen Image Data
    406
    
    Malfunction Phenomenon Reproduction Confirmation
    406
    
    Question Form
    406
    
    Counterchecking, Storing and Clearing Failure Code/Frozen Image Data
    407
    
    Visual Check
    407
    
    Connector/Cables
    408
    
    Final Confirmation Test
    408
    
    Malfunction Reproduction Simulation Test
    408
    
    Vibration
    408
    
    Another
    409
    
    Cold/Hot
    409
    
    Parts, Sensors
    409
    
    Water Application
    409
    
    Checking Diagram Common Options
    410
    
    Checking Wires and Connectors
    410
    
    Continuity Check
    411
    
    Resistance Check
    411
    
    Short Circuit
    411
    
    Visual Inspection and Contact Pressure Check
    412
    
    Check the Malfunction
    413
    
    Checking and Replacing the Electronic Control Unit
    413
    
    Failure Code Diagram Specifications
    414
    
    Specified Codes of the ISO/SAE Standards
    414
    
    Daihatsu Motor Corporation Codes
    418
    
    Failure-Free Function
    419
    
    Failure-Free Specifications
    419
    
    Matrix Table for Troubleshooting
    420
    
    Start-Up Problems
    420
    
    Engine Does Not Hold Idling
    421
    
    Engine Irregular Performance
    421
    
    Diagnostic Failure Code Check
    422
    
    Diagnostic Failure Code Clearing
    422
    
    Engine Poor at Full Power
    422
    
    Signs of Knocking
    422
    
    Failure Code Check Using the Diagnostic Tester
    423
    
    Warning Light Check
    423
    
    The Diagnostic Tester DS-21 Is Not Used
    425
    
    Using the Diagnostic Tester DS-21/OBD II General Scanning Device
    425
    
    Diagram of Basic Operations to Check the Engine
    426
    
    Ignition Timing Check
    427
    
    Engine Idle Speed Check
    428
    
    Fuel Pressure Check
    428
    
    Fuel Injector Operation Confirmation
    430
    
    Spark Check
    430
    
    Scanning Device Data
    431
    
    Service of the Electronic Control Unit and Relevant Circuits
    433
    
    Wiring Diagram - Inlet Manifold Absolute Pressure Circuit
    436
    
    Absolute Pressure in the Inlet Manifold
    438
    
    Checking Procedure
    438
    
    Circuit Description
    438
    
    Diagnostic Failure Code Detection Conditions
    438
    
    Ground Node
    444
    
    IAT Sensor Circuit Description
    445
    
    Using Diagnostic Tester DS-21/Digitek/Obd II General Scanning Device
    446
    
    Diagnosis with Multimeter and Interface Wiring
    449
    
    Does the Value Measured Match that One Specified?
    450
    
    Does the Value Measured Match the One Specified?
    450
    
    Is the Voltage Measured 5.0 V?
    450
    
    Using the Tester DS-21 or OBD II General Scanning Device
    451
    
    Functional Check
    467
    
    Using the Diagnostic Tester DS-21 or OBD II General Scanning Device
    482
    
    Confirming the Driving Configuration
    486
    
    Signal Control
    492
    
    Using the Diagnostic Tester DS-21
    500
    
    Without Using the Diagnostic Tester DS-21
    503
    
    Ignition Switch
    533
    
    Intake Air Temperature Sensor
    539
    
    Vacuum Switchover Valve for Bleeding Fuel Evaporative Emissions
    540
    
    Throttle Valve Sensor
    541
    
    Vacuum Switchover Valve for Increasing Idle Speed
    541
    
    Engine Coolant Temperature Sensor
    542
    
    VSV EGR - Vacuum Switchover Valve for EGR
    542
    
    Fuel Pump
    543
    
    Main Relay and Fuel Pump Relay
    543
    
    Front and Rear Oxygen Sensors with Heater
    544
    
    Ignition Unit
    544
    
    Terminal Resistance Values
    544
    
    Gear-Box
    545
    
    For Removing and Fitting the Conical Spring Washer
    546
    
    Gearbox and Cover
    548
    
    Components
    549
    
    Sub-Gear
    549
    
    Clutch Cover
    550
    
    Recommendations before Removal
    557
    
    Repairs to be Carried out on the Vehicle
    557
    
    Remove the Gearbox Cover
    559
    
    Removing the Gear Control Fork
    559
    
    Removing the Gearbox
    559
    
    Inspection
    560
    
    Main and Transmission Shafts
    560
    
    Removing the Input and the Secondary Shaft
    560
    
    Spring Specifications
    560
    
    Forks and Heads of the Gear
    561
    
    Gear Clutch Control
    561
    
    "S" Type Oil Seal Replacement
    562
    
    Reverse Transmission Gear
    562
    
    Bimetallic Bushing
    563
    
    Replacement of Gearshift Lever and Gear Components
    563
    
    Inlet Shaft
    564
    
    3Rd and 5Th Gear
    567
    
    Fitting
    571
    
    Main Shaft
    574
    
    Transmission Shaft
    577
    
    Secondary Shaft Components
    578
    
    Replacing the Conical Spring Washer
    583
    
    Secondary Shaft - Inspection before Removal
    586
    
    Gear Fork Shafts
    588
    
    Fitting the Gear Control Fork and the Relevant Shaft
    589
    
    Fitting the Gear Assembly on the Vehicle
    592
    
    Differential
    594
    
    Differential Removal
    596
    
    Operations before Removal
    597
    
    Bearings
    600
    
    Control Pinion and Crown Gear
    600
    
    Differential Housing
    600
    
    Side Pinion Gear and Pinion
    600
    
    Coupling Flange
    601
    
    Adjustment Procedure
    602
    
    Adjusting Control Pinion Protrusion
    603
    
    Available Shim Washers
    604
    
    Bearing Preloading Measurement
    605
    
    Differential Housing Fitting
    605
    
    Adjusting Crown Gear Clearance and Bearing Preloading
    606
    
    Crown Gear
    606
    
    Checking/Adjusting Teeth Contact Surface between Crown Gear and Pinion
    608
    
    Cover Refitting
    609
    
    Braking System
    610
    
    Brake Pedal
    611
    
    Brake Pipe
    611
    
    Empty Travel
    611
    
    Inspection and Repair
    612
    
    Pedal Travel Adjustment
    614
    
    Adjusting the Reserve Travel of the Brake Pedal
    615
    
    Brake Fluid Reservoir
    615
    
    Pedal Height Adjustment
    615
    
    Specified Values
    615
    
    Brake Booster Inspection Procedure
    618
    
    Power Brake Hermetic Seal Check
    618
    
    Power Brake Multimeter Connection
    619
    
    Power Brake Operation Check
    619
    
    Power Brake Simple Check
    619
    
    Checking the Power Brake Hermetic Seal with Loaded/Unloaded Vehicle
    620
    
    Power Brake Operation Failure Check
    620
  - Air Bleeding
    621
  - Brake System
    621
    
    Filling with Brake Fluid
    621
    
    Brake Fluid Leakage Check
    622
    
    Front Disc Brake Pad
    622
    
    Front Disc Brake
    624
    
    Front Disc Brake Calliper
    625
    
    Disc Thickness and Irregular Wear
    627
    
    Pad Thickness and Irregular
    627
    
    Operation Following Installation
    629
    
    Rear Brake
    629
    
    Brake Drum Wear
    631
    
    Wear of Friction Material
    631
    
    Parking Brake Lever
    634
- Valve Timing - Belt Refitting
  244
- Handbrake
  637
Parking Brake Cable
637
- Operation before Removal
  638
- Fitting (Pickup Model)
  639
- Brake Controller Lspv
  641
- LSPV (Brake Calibrator)
  641
- Operation after Fitting
  641
- Performance Diagram
  644
- Pickup
  645
- Van
  645
- Component
  647
- LSPV Brake Calibrator
  648
- Lspv Assembly
  651
LSPV Brake Calibrator - Bracket
652
- Clearance Check
  655
- Inspection on Vehicle
  655
- Noise Check
  655
- Steering Column
  659
- Steering Arm
  660
- Universal Joint Arm
  661
- Steering Box Assembly
  666
- Strut Bracket Body
  666
  - Control
    670
  - Assembly Procedure of the Rack and the Steering Pinion
    675
  - Steering Pinion Preloading
    676
Rack Guide Protection Lock Nut - Steering Rack Housing
676
- Steering Column
  677
- Key Switch Cylinder Removal
  678
- Tie-Rods
  681
- Arm Head
  682
- Checking after Fitting the Arm Heads
  683
- Toe-In
  683
- Front Wheel Alignment Check
  684
- Steering Angles
  684
- Pick up Front Wheel Alignment
  685
- Steering Wheel Clearance
  685
- Van Front Wheel Alignment
  685
- Toe-In Adjustment
  687
- Toe-In Measurement
  687
- Wheel Alignment
  687
- Suspensions
  689
- Axle and Front Suspension
  690
- Front
  690
- Shock-Absorbers Removal
  691
- Steering Articulation Fitting
  692
- Spring Removal
  694
- Front Arms Removal
  695
- Shock Absorber Operation Check
  695
- Suspension Lower Arm
  695
- Twisting and Breaking
  698
- Front Hubs Removal
  699
- Castle Nut - Front Axle Hub 177.0 ÷
  701
- Front Axle Bearing Installation
  702
- Front Axle Bearing Replacement
  702
- Preliminary Checks before the Wheel Alignment Check
  703
- Turning Radius Gauge Setting
  705
- Checking the Camber, Caster and Kingpin Angles
  706
- External Side Wheel Steering Angle Check
  706
- Wheel Steering Angle Correction
  706
- Axle and Rear Suspension
  710
- Wheel Hub
  710
Brake Pipe Joint - Brake Cylinder
715
- U-Bolt - Leaf Spring Buffer
  718
Spring Support Pin - Leaf Spring Assembly
719
Rear Shock Absorber - Chassis (Upper Part)
721
- Noise
  722
- Shock Absorbers
  722
- Tipper Version
  724
- Electric Diagram - Tipper
  727
- Tipper Removal
  728
- Tipper Refit
  729
- Hydraulic Jack Fitting
  731
- Hydraulic Jack Removal
  731
- Removal of Pump Parts
  732
- Removing Valve Body from the Electric Motor
  733
- Valve Body Removal
  733
- Valve Body Fitting
  734
- Assembly of Pump Parts
  735
- Fitting the Valve Body to the Electric Motor
  735
- Hydraulic Pump and Electric Motor Fitting
  736
- Pressure Relief Valve Check and Calibration
  737
- Chassis
  739
- Windscreen
  740
- Side Windows
  742
- Rear Window Upholstery Panel
  744
- Tools and Other Equipment
  744
- Doors
  745
- Door Alignment Adjustment
  752
- Prescribed Alignment Sizes
  752
- Sliding Door Frame
  753
- Sliding Door Upholstery Panel
  753
- Upholstery Panel Removal
  755
- Upper Roller Removal
  763
- Central Hinge Removal
  764
- Lower Roller Removal
  764
- Central Hinge Fitting
  766
- Lower Roller Fitting
  766
- Adjustment in Longitudinal Direction
  767
- Height Adjustment
  767
- Sliding Door
  767
- Adjustment of Height Difference
  768
- Adjustment Tolerance
  768
- Rear Door Upholstery Panel
  770
- Door Panel
  772
- Adjustment in Longitudinal Direction of the Upper Section
  773
- Front Bumper
  773
- Catalytic Converter Replacement
  774
- Replacing the Exhaust
  774
- Exhaust Pipe - Catalytic Converter
  775
Instrument Panel Support - Chassis
783
- Refitting Air Vents/Loudspeakers/Cigarette Lighter
  786
- Starting Operations
  787
- Van Front Seat
  789
- Check-Up of Inclination Angle until Clicking Sound of Belt Is Heard
  790
- Fitting the Front Seat Internal Bolt
  791
- Safety Belt at Three Anchor Points with Winder
  791
- Safety Belts
  791
- Fuel Tank Cap
  794
- Pre-Delivery
  795
- Closing and Hinge Operation
  797
- General Inspection
  797
- Vehicle External Appearance
  797
- Vehicle General Check
  797
- Internal
  798
- Vehicle Cleaning
  798
- User Manual
  799
- Wheel Guard-Central Cover Fitting
  799
- Loosening the Hub Clamps
  800
- Nut Tightening
  800
- Preliminary Inspections
  800
- Tyre Pressure
  800
- Adjusting Devices
  801
- Cigarette Lighter
  801
- Seatbelt
  801
- Horn Functioning
  802
- Horn Operation
  802
- Windshield Washer Orientation Adjustment
  802
- Wipers Operation
  802
- External Lights
  803
- Headlamp Orientation
  803
- Headlight Adjustment
  803
- Windscreen Wiper and Washer Operation
  803
- Chassis Inspection
  804
- Checks to be Carried out under the Body
  804
- Warning Lights
  804
- Door Lock Adjustment
  805
- Door Stop Plate - Chassis
  805
  - Battery Connections
    806
  - Bellow Joint
    806
  - Engine Housing Inspection
    806
  - Ignition Timing
    806
  - Sleeve Connections and Fluid Pipes
    806
  - Coolant in the Expansion Tank
    808
  - Window Cleaning Liquid
    808
  - Windshield Washer Fluid in the Reserve Tank
    808
  - Engine Idle
    809
  - Idle Speed Adjustment
    809
  - Rpm Indicator Connection
    809
  - Brake Fluid
    810
  - Brake Pedal Adjustment
    810
  - Engine Oil
    810
  - Service and Parking Brake Operation
    810
  - Road Test
    811
  - Steering Wheel
    811
  - Test Drive
    811
  - Steering - Wheel Hub Joint - Dust Guard
    812
  - Time-Sheet
    814
  - Camshaft and Timing Belt
    815
  - Drive Shaft
    816
  - Propeller Shaft
    817
  - Leaf Spring and Shock Absorbers
    819
  - Suspension Leaf Spring
    819
  - Battery
    820
  - H.T. Coil
    821
  - HV Coil and Spark Plugs
    821
  - Cable Harnesses
    822
  - Front Chassis
    824
  - Bodywork
    825
  - Rear Chassis
    825
  - Wheel Rim
    826
  - Brake Cylinder
    827
  - Horn
    827
  - Clutch Assembly
    828
  - Clutch Unit
    828
  - Engine Unit
    829
  - Ducts
    830
  - Oil Sump
    831
    
    Rear Differential
    832
    
    Brake Discs
    834
- Fluid Leaks
  805
Leakages
805
Brake Disc
836
- Position Light
  837
- Sidelight
  837
- Headlamps
  838
- Oil Filter
  840
  - Parking Brake
    841
  - Brake Shoes and Drum
    842
  - Drum Shoes
    842
  - Front Grid
    842
  - Front Grille
    843
  - Fuel Injection
    844
  - Inside Parts
    845
  - Interiors
    845
  - Switches and Regulators
    846
  - Window Sprayer
    847
  - Gear Stick
    848
  - Windscreen Washers
    848
  - Gearshift Lever
    849
  - Single-Block
    850
  - Rear Floor Panel
    852
  - Dashboard
    854
  - Bumper
    856
  - Clutch Pedal
    858
  - Column/ Steering/ Steering Housing/ Joints
    860
  - Piston and Connecting Rod
    860
  - Water Pump and Thermostat
    861
  - Fuel Pump
    862
  - Brake Fluid Pump
    863
  - Rear Van Door
    865
  - Tail Door
    865
  - Rear-View Mirror Sun Shade
    866
  - Radiator and Water Pipes
    867
  - Radio
    868
  - Heating
    869
  - Front Seat
    870
  - Rear Van Seat
    871
Lights
838
Rear Axle Shaft
872
- Cam Sensor
  873
- Fuel Tank and Pipes
  874
- Front Suspensions and Front Axle
  876
- Rear End-Gate
  877
- Tailboard
  877
- Spare Wheel Mounting Bracket
  878
- Spare Wheel Support
  878
- Labels
  879
- Plates
  879
- Windscreen Wiper
  880
- Rear Van Wiper
  881
- Head
  882
- Accelerator Transmision
  883
- Throttle Cable
  883
- Brake Hoses
  884
- Brake Pipes and Calibrator
  884
- Valves
  885
- Van Side Window
  886
- Windows
  886
- Door Glass and Profile
  887
- Frameless Side Window
  887
- Side Glass
  887
- Steering
  889
- Index
  891

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