Мануал дайхатсу хайджет s331v

MANUALE STAZIONE DI SERVIZIO

633530 (IT) — 531 (EN) — 532 (Fr) — 533 (DE) — 534 (ES) — 535 (PT) — 536 (NL) — 537 (EL)

MANUALE

STAZIONE DI

SERVIZIO

PORTER 1.3 16V

COPYRIGHT

© Copyright 2008 — PIAGGIO & C. S.p.A. Pontedera.

All rights reserved. Reproduction of this publication in whole or in part is strictly prohibited. This publication has been edited by:

After sales — PIAGGIO & C. S.p.A.

V.le Rinaldo Piaggio, 23 — 56025 PONTEDERA (Pi)

ITALY www.piaggio.com

RECOMMENDATIONS AND IMPORTANT NOTES

Each symbol has a specific meaning, as shown below.

∙WARNING:- This symbol indicates risks to the health of the operator or persons nearby, if the procedures described are not carried out properly.

∙WARNING:- This symbol indicates that the component on which the operator is working could be damaged, if the procedures described are not carried out properly.

∙NB: — Additional instructions related to the procedure in progress are provided in this section, so that the operation can be performed in an efficient way.

GENERAL RECOMMENDATIONS FOR SAFETY:

1.— Always wear protective goggles and suitable clothing.

2.— Always use a safety support to work under the vehicle.

3.— Check that the ignition switch is always set to «OFF», unless otherwise specified in the procedure.

4.— Pull the hand brake before starting to work on the vehicle.

5.— Let the engine run only in well ventilated places to avoid risks related to carbon monoxide.

6.— Stand well away from moving parts during the engine operation, especially from fans and belts.

7.— In order to avoid serious burns, do not touch hot metal parts, such as the radiator, exhaust manifold, exhaust pipe, catalytic converter and muffler.

8.— Do not smoke during maintenance operations.

9.— To avoid possible injuries, remove rings, watches, jewellery and loose clothes before starting to work on the vehicle.

10.- Keep hands and other objects away from the electric fan blades of the radiator !

11.- The cooling electric fan is fitted on the radiator and can be started at any time due to the increase in coolant temperature or if the air conditioner switch is set to ON, for vehicles equipped with air conditioner. It is important to check that the cooling electric fan motor is disconnected from the cable harness before starting work.

The units of measurement used in this manual are indicated as IS UNITS (International System of Units). Example:24.5 ÷ 34.3 Nm

The abbreviations indicated in this manual are listed in the following table.

∙(B) — Bolt

∙(S) — Screw

∙(N) — Nut

∙(W) — Washer

∙(T) — Tightening torque

General information

This section comprises general information about the manual use and the vehicle, besides important notes relevant to safety.

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 recommended by the manufacturer necessary to guarantee product reliability. Maintenance operations comprise various types of procedures. Technical procedures, tools and parts necessary for each operation can also be significantly different from each other.

The manual does not describe all technical procedures, operations, parts, tools and instructions necessary for performing maintenance operations. Therefore, anyone who consults the manual should first and foremost have suitable technical knowledge and professional skills and assumes responsibility for choosing the procedures to be followed, tools and parts required for proper vehicle maintenance. This person shall bear full responsibility for actions related to their personal safety.

For this reason, operators should not carry out any operation if they are not able to make a responsible selection of techniques and/or if they are not able to understand the content of this manual, since this manual has been drawn up to be used by qualified personnel.

WARNING

THE PRESENCE OF A GREAT QUANTITY OF UNBURNED GASES INSIDE THE CATALYTIC CONVERTER CAN CAUSE OVERHEATING, RESULTING IN FIRE HAZARD. TO PREVENT THIS PROBLEM, STRICTLY OBSERVE THE FOLLOWING PRECAUTIONS, ALSO EXPLAINING THEM TO YOUR CUSTOMERS.

PRECAUTIONS RELATED TO THE CATALYTIC CONVERTER

1.Only use unleaded petrol.

2.Do not let the engine idle for long periods. Do not let the engine idle longer than 20 minutes.

WARNING

CHECK AND REPAIR THE VEHICLE IMMEDIATELY IF IDLE SPEED IS UNSTABLE OR IF THE SYSTEM FAILS. FAILURE TO OBSERVE THESE SPECIFICATIONS MAY CAUSE A FIRE.

3.Follow the procedure below to carry out the spark test of the spark plug. Carry out the test only if strictly necessary and as quickly as possible. Interrupt fuel supply before carrying out this test.

4.Do not run the engine if the fuel tank is almost empty.

Failure to observe this precaution can cause an ignition failure. Besides, an excessive load on the catalytic converter could occur, and it can even get damaged.

5. Do not dispose of the old catalytic converter together with components contaminated with petrol or oil.

VEHICLE HAULAGE AND TOW

To haul or tow a vehicle in case of emergency, strictly follow the instructions below.

NEVER HAUL THE VEHICLE USING HARNESSES. FAILURE TO OBSERVE THIS MEASURE MAY SERIOUSLY DAMAGE THE VEHICLE BODYWORK.

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-

WORK.

Towing with wheels lifted.

Use a towing carriage to tow the vehicle, leaving either front or rear wheels on the ground.

CHECK THAT THERE ARE NO PERSONS IN THE VEHICLE

BEING TOWED.

∙MAKE SURE TO FASTEN THE FRONT AND REAR WHEELS TO THE TOWING CARRIAGE.

∙NEVER TOW THE VEHICLE USING HARNESSES. FAILURE TO OBSERVE THIS PRE-

CAUTION MAY CAUSE SERIOUS DAMAGE

TO THE VEHICLE BODYWORK.

Emergency tow

This procedure can be used if the vehicle has manual transmission or if the road surfaces are firm and even. In this case, strictly observe the safety measures indicated below

∙THE DRIVER OF THE VEHICLE TO BE TOWED SHALL ALWAYS TAKE INTO ACCOUNT THAT BRAKING REQUIRES GREATER FORCE THAN NORMAL, SINCE THE POWER BRAKE REMAINS INACTIVE ONCE THE ENGINE IS SHUT OFF.

∙NEVER HAUL THE VEHICLE AT A SPEED OVER 30 KM/H. SET THE IGNITION SWITCH OF THE VEHICLE TO BE HAULED TO «ACC» DURING HAULAGE OPERATIONS. NEVER REMOVE THE KEY OR SET THE IGNITION SWITCH TO «LOCK» DURING HAULAGE OPERATIONS. FAILURE TO OBSERVE THIS PRECAUTION MAY CAUSE LOSS OF CONTROL OVER THE VEHICLE AND CAUSE ACCIDENTS.

∙NEVER HAUL THE VEHICLE IN THIS WAY UNLESS THE WHEELS, AXLE, STEERING, AND BRAKES ARE IN GOOD CONDITION.

WARNING

∙NEVER HAUL A VEHICLE WITH AUTOMATIC TRANSMISSION IN THIS WAY. ALWAYS USE A TOWING CARRIAGE.

∙WHILE PULLING THE HOOK, ALWAYS KEEP IT IN AN UPRIGHT POSITION TO AVOID DAMAGING IT. NEVER PULL IT SIDEWARDS OR VERTICALLY. ALSO AVOID SUDDEN MOVEMENTS.

∙CONNECT THE TOWING ROPE, CABLE OR SIMILAR ITEMS ONLY TO THE HOOKS ON THE VEHICLE BODY. IF THE TOWING ROPE, CABLE OR SIMILAR ITEMS ARE CONNECTED TO PARTS OTHER THAN THE HOOKS PROVIDED, THIS COULD SERIOUSLY DAMAGE THESE COMPONENTS.

∙CHECK THAT THE HOOKS ARE FIRMLY FIXED TO THE VEHICLE BODY BEFORE STARTING HAULAGE OPERATIONS.

1.Fix the «Towing eye» to the towing rod, avoid using ropes.

2.The driver must be inside the hauled vehicle.

3.Release the hand brake and take the gearshift lever to neutral.

4.For models with four wheel drive (4WD) move the central differential locking switch to the free position.

N.B.

∙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 COMPLETELY FREE.

5.Move the ignition switch to «ACC».

6.Start haulage operations.

Lifting points

Support point for 4 arm lift Front part:

Support the vehicle at the bodywork points indicated in the figure.

(A): Front support Point

Rear part

Support the vehicle under the leaf spring.

(P): Rear support Point

Support points for jack Front part

Place the jack on the cross-member of the front suspension.

Rear part

Place the jack under the differential.

Maintenance guidelines

5. LOCKING TORQUE

For operations which require locking torque check, the relevant value is indicated in bold type. Make sure to check the relevant locking torque.

3. SPECIAL TOOLS

The code of special tools necessary for individual operations is indicated in bold type.

4. MAINTENANCE PROCEDURE

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

DESCRIPTION OF MANUAL USE

1.COMPONENT SKETCH

∙The component sketch shown at the beginning of each section describes the nomenclature and the fitting conditions of each individual component.

∙Those parts marked with ( * ) can not be reused. Be careful to replace these parts with new components during the assembly.

∙During the assembly, lubricate the parts marked in the figure.

(Example)

1.Brake main cylinder unit 2. Reservoir cap 3. Reservoir cap spacer 4. Reservoir diaphragm 5. Float switch 6. Main cylinder reservoir subassembly 7. Clamp 8. Fixing bolt 9. Gasket 10. Gasket 11. Main cylinder repair kit *: Non-reusable parts

2.MAINTENANCE PROCEDURE

—As a rule, the maintenance procedure is described in the following sequence:

∙removal

∙inspection

∙fitting and removal

∙inspection

∙assembly

—The explanation indicates the detailed maintenance procedure, specifications and notes.

—The main point of each item describes the section about maintenance and relevant procedure, with the aid of illustrations.

(Example); Brake pipe fitting,

∙Temporarily fit the brake pipe on the wheel cylinder, manually

∙Tighten the brake pipe on the wheel cylinder, using the special tool «A».

Specific tooling

09751-36011-000 tool description

— The inspection comprises only the checking operations. Therefore, if malfunctions are detected, it is necessary to replace the defective parts with new ones.

Circuit check

Electric fault repair

DIAGNOSIS CONNECTOR (DLC Data Link Connector).

The Electronic Control Unit of the vehicle complies with the ISO protocol 14230 (Euro-OBD). Regarding the position, the configuration of the connector and the terminal pre-installation, the DLC complies with the ISO 15031-3 (SAEJ1962) and ISO 14230 standards.

The OBD II serial data line (K line) is used for the OBD II general scanning device or for the specific diagnostic tester, to communicate with the electronic control unit.

OBD DIAGNOSIS CONNECTOR TERMINALS:

A = OBD (DLC) Diagnosis connector

1.(+B) Battery positive (Voltage always detected: 9 ÷ 14V)

2.ECU-T

3.EFI-T

4.(REV) Engine rpm signal

5.(-) Chassis ground (Resistance < 10 Ω, always detected ).

6.(- ECU) Electronic control unit ground

7.(K line) OBD serial data line (generation of pulses on the line during transmission.

GENERAL INSTRUCTIONS FOR MAINTE-

NANCE OPERATIONS ON THE CABLE HAR-

NESS

1.Do not pull or press connectors during the transport or fitting of the electrical cable harness. To prevent possible malfunctions.

2.Do not scratch or cut the cable harness during transport or fitting.

3.Cable harness fixing system: if there are resin clamps, make sure that the flaps of the fixing clip are properly inserted into the chassis hole.

—Make sure that the fixing clip does not come out of its hole by pulling it gradually in the arrow direction.

—If there are metal clamps welded to the chassis, make sure to fit the cable harness so that it does not make contact with the welded metal surface or with sharp edges to prevent possible malfunctions.

(A)Correct

(B)Incorrect

— In the case of guides or references which indicate the fastening clamp position, make sure that it is placed inside the guides. As regards fixing with references, make sure that the clamp is fastened with a maximum error of ± 10 mm.

C = Guide for clamp

D = The fastening clamp shall be inserted between two points.

— Terminals and connectors

E = Reference for fixing position F = Fixing shall be carried out with a tolerance of ± 10 mm with respect to the reference.

4. Terminals and connectors Connector connection:

—Connector with safety lock, make sure that the lock is properly inserted.

—Connector without lock, insert the connector until it stops at the end of the stroke.

Fixing with screws

—When the locking torque is specified, strictly follow the specifications.

—Make sure that the protruding section is not on the fixing surface.

—After fixing, pull the terminal gradually to make sure that it is not loose.

—While carrying out other operations, make sure not to accidentally disconnect connectors.

A = Correct B = Incorrect (terminal bent)

Using resin clamps

When using resin clamps, do not use pliers or similar tools, as improper use could damage or cut them.

CABLE HARNESS

—THE DIMENSION AND CAPACITY OF EACH CABLE ARE SPECIFIC TO GUARANTEE THE PROPER OPERATION OF THE ELECTRICAL SYSTEM.

—THEREFORE, DO NOT POWER OTHER POSSIBLE ACCESSORIES USING THE EXISTING CABLE HARNESS. FAILURE TO OBSERVE THIS PRECAUTION MAY CAUSE A SYSTEM MALFUNCTION AND ALSO FIRE HAZARD.

Disconnection of connectors with safety lock

— Press the locking lever, as shown in the figure, then pull the connector. Do not pull the cable harness, otherwise the terminals could come out of their seats.

The locking connector can be the following types of connector: a push-piece opening, traction opening, spring closing, one-way closing mechanism and so on.

Once the type of locking has been identified, open the lock. Disconnect the connector holding it.

—NEVER PULL THE CABLE HARNESS WHILE DISCONNECTING.

—MAKE SURE TO TAKE OUT THE CONNECTOR IN AN UPRIGHT POSITION SO AS NOT TO DAMAGE THE TERMINAL.

2. Connection.

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

3. Terminal removal. Terminal with bayonet lock

Insert a small screwdriver (B) inside the connector opening between the terminal and the locking lever. Lever on the locking lever (A) and take out the terminal.

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.

Identification

Chassis Identification

(1)Manufacturer’s label.

(2)Chassis identification number

Manufacturer label:

A — Type-approval number B — Vehicle Identification Number C — Technically permissible maximum total weight D — Vehicle plus trailer maximum weight (*) E — Maximum weight permissible on front axle F — Maximum weight permissible on rear axle G — Vehicle model H — Type of engine

(*) NB: This option is not available in some models.

Engine Identification:

(3)Engine identification number

(4)Type of engine

Engine number and type

—The engine number is stamped on the cylinder block.

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

PASSENGER PROTECTION DEVICE

IMPIANTO ELETTRICO

Van

Pick-Up

Tightening torques

ENGINE

PROPELLER SHAFT AND DIFFERENTIAL

* Value to be determined according to pinion bearing preloading.

GEAR RETAINERS

CLUTCH RETAINERS

Piston ring oversizes

OPENING CLEARANCE AFTER USE — PISTON RINGS

STANDARD OPENING — PISTON RINGS

THICKNESS — PISTON RINGS

Valve guide — Valve stem

Tooling

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

ues.

0.20200y Oil seal extractor

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

Suggested products chart

PRODOTTI CONSIGLIATI

Engine assembly

N.B.

∙ADJUSTMENTS OR SERVICES DESCRIBED IN THIS SECTION ARE CARRIED OUT AS A GENERAL RULE WHEN THE ENGINE IS HOT.

∙A «HOT ENGINE» MEANS THAT CONDITION IN WHICH THE COOLING FAN HAS BEEN ACTIVATED AT LEAST ONCE.

∙CHECK THAT ALL THE ACCESSORY SWITCHES ARE SET TO OFF.

∙THE GEARSHIFT LEVER SHALL BE IN NEUTRAL.

∙PULL THE HANDBRAKE ALL THE WAY.

∙POSITION THE STEERING WHEEL SO THAT THE WHEELS ARE PERFECTLY ALIGNED.

∙CHECK THAT THOSE PARTS REMOVED FOR ADJUSTMENTS OR CHECKS ARE REFITTED.

Air filter

1.Remove the filtering element from the air filter housing.

2.Visually inspect the filtering element and check that it is not too dirty, damaged or oily. If necessary, replace the filtering element.

3.Blow compressed air over the entire lower section A of the filtering element. Then, do the same with the upper section B.

4.Refit the filtering element into the filter housing. Close the housing.

Engine oil replacement

Engine oil level check

Check that the engine oil level is between the «L» and «F» marks on the dipstick to check oil level.

If the oil level is below the reference mark «L», top up with recommended oil until the reference mark «F» is reached. Make sure that there are no leaks.

∙USE SPECIFIC OIL OR OIL WITH A HIGHER

COEFFICIENT OF VISCOSITY.

∙THE QUANTITY OF OIL BETWEEN THE «L»

AND «F» REFERENCE MARKS IS EQUIVALENT TO APPROX. ONE LITRE.

Characteristic

Engine oil capacity at «MAX» level

3.5 l («F» level)

Engine oil capacity at «MIN» level

2.5 l («L» level)

Engine oil capacity (engine sump + filter)

3.7 l

Total engine oil capacity

4.2 l

Oil quality check

Check that the engine oil is not deteriorated, discoloured or diluted, and that there is no water infiltration.

N.B.

∙PARK THE VEHICLE ON A LEVEL SURFACE.

SAE 80W-90, API GL-5

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

Locking torques (N*m)

Gearbox cover for filler cap 30 ÷ 49

Oil leaks

Check the gearbox for oil leaks. Check the gearbox oil level.

1. Remove the filler cap.

2. The gearbox oil level must reach the level inspection hole or should be below 5 mm.

Differential oil replacement

Differential oil change

1.Remove the drainage plug and the filler cap. Drain the differential oil.

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

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

Recommended products

AGIP ROTRA MP 80W-90 Differential oil

SAE 80W-90, API GL-5

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

Locking torques (N*m)

Differential oil cap 39 ÷ 59 Nm

Oil leak

Check that the differential does not leak oil.

G. Pour coolant in the radiator. When the coolant starts coming out through hole 2 located on the engine side and through the heater bleed pipe, close both openings.

H. Pour coolant until the fluid comes out through the radiator fill opening.

I. Close the radiator cap 3 completely.

L. Clean the expansion tank internal side. Fill up with coolant.

M. Start the engine and warm it up to the operating temperature.

N. Make sure there are no leaks.

O. After the fluid temperature decreases, remove plug 2 located on the engine side. Check the coolant level. If the level is too low, add coolant. Tighten plug 2 again.

DURING THIS PHASE, NEVER OPEN THE RADIATOR CAP 3 SO THAT COOLANT DOES NOT COME OUT THROUGH CAP 2.

KEY:

1.Radiator cap

2.Radiator cap

3.Radiator cap

4.Radiator

5.Engine

P. Check the coolant level in the expansion tank. Add water until the maximum level is reached. Refit the expansion tank cap.

Leaks

A. Fill up the radiator with coolant. Connect the tester to the radiator cap.

B. Warm up the engine.

C. Apply a 117 kPa pressure to the cooling system by means of the tester connected to the radiator cap.

D. Make sure there are no leaks.

Spark plug

Cable check

1.Disconnect the ignition coil connector. Afterwards, remove the ignition coil by taking out the fixing nuts.

2.Disconnect the spark plug from the cable.

3.Carefully remove the spark plug cable from the ignition coil.

4.Visually inspect the spark plug cable by checking if there are signs of wear, cracks or any other damage.

Spark plug check

1.Remove the spark plugs.

2.Spark plug visual inspection.

Visually inspect the spark plug by checking whether the electrodes are worn and that the thread or the insulator is damaged. If necessary, replace the spark plug.

3. Electrode gap inspection.

Measure the electrode gap with the appropriate thickness gauge.

Install the AUTODOC CLUB app!

Your personal car expenses manager, maintenance tips, reminders about upcoming appointments and service intervals, DIY repair instructions – all this on your phone.

Your profile is your personal assistant.

It can track car expenses, keep a car log and replacement schedule, and save favourite materials, notes and documents

Manuals for DAIHATSU HIJET models

• • Manuf. year (from — to): (12/1992 — 05/1998)
  • Car body type: Van
  • Power (HP): 27 — 82
  • Power (KW): 20 — 60
  • Type of drive: Rear-Wheel Drive
  • Engine type: Diesel, Petrol Engine
• • Manuf. year (from — to): (12/1992 — 05/1998)
  • Car body type: Platform/Chassis
  • Power (HP): 37 — 48
  • Power (KW): 27 — 35
  • Type of drive: Rear-Wheel Drive
  • Engine type: Diesel, Petrol Engine
• • Manuf. year (from — to): (04/1998 — …)
  • Car body type: Pickup, Platform/Chassis
  • Power (HP): 38 — 97
  • Power (KW): 28 — 71
  • Type of drive: All-wheel Drive, Front-Wheel Drive, Rear-Wheel Drive
  • Engine type: Diesel, Petrol Engine
• • Manuf. year (from — to): (06/1993 — …)
  • Car body type: Bus
  • Power (HP): 48 — 65
  • Power (KW): 35 — 48
  • Type of drive: All-wheel Drive, Rear-Wheel Drive
  • Engine type: Petrol Engine
• • Manuf. year (from — to): (07/1986 — 10/1990)
  • Car body type: Platform/Chassis
  • Power (HP): 39 — 45
  • Power (KW): 29 — 33
  • Type of drive: All-wheel Drive, Rear-Wheel Drive
  • Engine type: Petrol Engine
• • Manuf. year (from — to): (12/2004 — …)
  • Car body type: Platform/Chassis
  • Power (HP): 88 — 97
  • Power (KW): 65 — 71
  • Type of drive: Rear-Wheel Drive
  • Engine type: Petrol Engine
• • Manuf. year (from — to): (06/1986 — 10/1990)
  • Car body type: Van
  • Power (HP): 39 — 45
  • Power (KW): 29 — 33
  • Type of drive: All-wheel Drive, Rear-Wheel Drive
  • Engine type: Petrol Engine
• • Manuf. year (from — to): (06/1986 — 06/1990)
  • Car body type: Bus
  • Power (HP): 39 — 45
  • Power (KW): 29 — 33
  • Type of drive: Rear-Wheel Drive
  • Engine type: Petrol Engine

Description:

Daihatsu Hijet Workshop Repair Manual Download

Workshop Repair and Service Manual for Daihatsu Hijet containing comprehensive illustrations and wiring diagrams, accurate, clear, step by step instructions and procedures, with all technical information and manufacturer specifications. Including all maintenance operations, scheduled service information, wiring diagrams, tightening torques and operating fluids. Contains all procedures to maintain, service or repair Daihatsu Hijet.

Model: Covers the 1998 facelift Piaggio and daihatsu collaboration Hijet S85.

Engine:
Petrol Gasoline
1.3 L 16v

Transmission
manual

Covers Years:
2010, 2009, 2008, 2007, 2006, 2005, 2004, 2003, 2002, 2001, 2000, 1999.

right and left-hand drive.

Daihatsu Hijet Workshop Repair Manual PDF

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