Engine light FIAT DUCATO 2006 3.G Service Manual

156IN AN EMERGENCY
System/Component
Front fog lights
Windscreen wiper motor
Engine cooling fan 2nd speed
Engine control unit 2nd speed
Radiator fan 2nd speed remote switch coil (climate control)
Engine cooling fan 1st speed
Engine control unit 1st speed
Cab fan (climate control)
ABS control unit
Ignition switch
Glow plug preheating
Right-hand dipped beam headlight
Left-hand dipped beam headlight
E.I. system
Fiat code
Automatic gearbox control unit
Fiat code
Compressor
Engine control unit
PTC
Engine control unit
Fuel pump
Engine control unit
Automatic gearbox control unit
Main beam headlights
Windscreen washer pumpFuse no.
F 09
F 08
F 07
F 07
F 07
F 06
F 06
F 05
F 04
F 03
F 02
F 14
F 15
F 16
F 16
F 24
F 18
F 19
F 18
F 20
F 11
F 21
F 17
F 23
F 30
F 08Ampere
15
30
40/60
40/60
40/60
40
40
30
50
30
50
10
10
7.5
7.5
15
7.5
7.5
7.5
30
10
15
5
10
15
30Location
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41

160IN AN EMERGENCY
IF AN ACCIDENT
OCCURS
– It is important to keep calm.
– If you are not directly involved in
the accident, stop at least ten metres
away from the accident.
– If you are on a motorway, do not
obstruct the emergency lane with
your vehicle.
– Turn the engine off and the haz-
ard lights on.
– At night, illuminate the scene of the
accident with your headlights.
– Act carefully, you must not risk be-
ing run over.
– Mark the accident by putting the
red triangle at the regulatory distance
from the vehicle where it can be clear-
ly see.
– If the doors are blocked, do not at-
tempt to smash the windscreen to get
out of the vehicle. It is made of layered
glass and is very hard. Side and rear
windows are much more easily bro-
ken. VEHICLE WITH AUTOMATIC
GEARBOX
If towing is not due to gearbox faults,
proceed as follows:
– gearshift lever to N;
– do not exceed 50 km/h;
– the vehicle should not be towed
for more than 200 km.
If towing is due to gearbox faults or
the vehicle should be towed for more
than 200 km, tow the vehicle raising
the front wheels from the ground.– Call for rescue making the infor-
mation you give as accurate as you
can.On the motorway use the special
column-mounted emergency phones.
– In pile-ups on the motorway, par-
ticularly when the visibility is bad,
there is a high risk of other vehicles
running into those already
stopped.Get out of the vehicle imme-
diately and take refuge behind the
guard rail.
– Remove the ignition keys from the
vehicles involved.
– If you can smell petrol or other
chemicals, do not smoke and make
sure all cigarettes are extinguished.
– Use a fire extinguisher, blanket, sand
or earth to put out fires no matter how
small they are. Never use water.
When towing the vehicle
you must comply with the
specific traffic regulations regard-
ing the tow hitch and how to tow
on the road.
WARNING

163VEHICLE MAINTENANCE
SERVICE SCHEDULE
thousands of kilometres
Check tyre conditions and wear and adjust pressure, if required
Check lighting system operation (headlights, direction indicators, hazard lights,
load compartment light, ceiling lights, warning lights, etc.)
Check windscreen wiper/washer operation, adjust nozzles
Check windscreen/rear window wiper blade position/wear
Check front and rear (where fitted) disc brake pad conditions and wear
Check rear drum brake linings conditions and wear (where fitted)
Inspect conditions and soundness of:
– outer bodywork and underbody protection;
– piping (exhaust - fuel feed and brakes)
– rubber parts (boots, sleeves, bushings, etc.)
– fuel feed and braking system hosing
Check tension and conditions of various control belts and adjust, if required
(excluding engines with automatic belt tighteners)
Check accelerator pedal stroke and adjust, if required
Check handbrake lever stroke and adjust, if required
Check tappet clearance and adjust, if required (2.8 JTD version)
Check tappet clearance and adjust, if required (petrol versions)
Check exhaust emissions
30 60 90 120 150 180
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165VEHICLE MAINTENANCE
ANNUAL
INSPECTION
SCHEDULE
The following annual inspection
schedule is required for vehicles trav-
elling 15,000 Kmapprox. a year. The
schedule includes the following oper-
ations:
– check tyre condition and wear and
adjust pressure, if required (including
spare wheel);
– check operation of lights (head-
lights, direction indicators, hazard
lights, boot light, passenger compart-
ment light, instrument panel lights,
etc.);
– check windscreen wiper/washer
and adjust nozzles;
– check position and wear of wind-
screen/rear window wiper blades;
– check front pad conditions and
wear;
– check for bonnet and boot lock
cleanness, lever cleanness and lubri-
cation;– inspect conditions of: engine, gear-
box, transmission, piping (exhaust, fu-
el feed, brakes), rubber parts (boots,
sleeves, bushings, etc.), brake and fu-
el line hoses;
– check battery charge status;
– check conditions of various control
belts;
– check and top up fluid levels (en-
gine coolant, brakes, windscreen
washer, battery, etc.);
– check and top up engine oil;
– replace pollen filter.
ADDITIONAL
CHECKS
Every 1,000 km or before long
trips, check and top up as necessary:
– engine coolant level
– brake fluid level
– power steering fluid level
– battery electrolyte level
– windscreen washer fluid
– tyre pressure and conditions.
Every 3,000 km or before long
trips, check and top up as necessary:
engine oil
Every 10,000 kmor at cwarning
light coming on (diesel engines only):
bleed water from fuel filter.
You are recommended to use FL
Seleniaproducts designed and pro-
duced for Fiat vehicles (see the “Ca-
pacities” table in the “Technical Spec-
ifications” section).

171VEHICLE MAINTENANCE
WINDSCREEN WASHER
FLUID
To add fluid, remove cap A-fig. 10
from the reservoir and slowly pour in
a mixture of water and TUTELA
PROFESSIONAL SC35fluid in the
following concentrations:
– 30% ofTUTELA PROFES-
SIONAL SC35and 70% of water in
summer.
– 50% ofTUTELA PROFES-
SIONAL SC35and 50% of water in
winter.
If the temperature falls below –20°C,
useTUTELA PROFESSIONAL
SC35undiluted.
POWER STEERING
FLUID
Check the oil level when the engine
is cold. It should be slightly under the
reference line on the reservoir.
When the oil is hot, the level can ex-
ceed the reference line.
When topping up, remove the reser-
voir cap A-fig. 11 and make sure that
the oil has the same specifications as
the oil in the system.Oil consumption is ex-
tremely low. If the oil
level needs topping up
again after a short period of
time, have the system checked
for leakage at a Fiat Dealership.
fig. 10
F0D0068m
fig. 11
F0D0066m
Do not let the power steer-
ing fluid come into contact
with hot engine parts. It catches fire
very easily.
WARNINGSome windscreen washer
additives on the market are
flammable. The engine compart-
ment contains hot parts which
could ignite the fluid in the event of
contact.
WARNING
Do not travel with the wind-
screen washer reservoir
empty. The windscreen washer is
fundamental for improving visibility.
WARNING

173VEHICLE MAINTENANCE
AIR CLEANER
REPLACEMENT
Unscrew the screws A-fig. 13and
remove cap B.
Remove the filtering element C-
fig. 14to be replaced.
fig. 13
F0D0295m
fig. 14
F0D0070m
POLLEN FILTER
Have the filter changed at the fre-
quency specified in the Service Sched-
ule.
Have the change made at a Fiat
Dealership.
IMPORTANTIf the vehicle is of-
ten used in dusty or extremely pol-
luted environments, you should
change the filter more frequently. It
should be changed especially if the
amount of air introduced into the pas-
senger compartment has decreased.
DIESEL FILTER
DRAINING THE
CONDENSATION
The presence of water in
the fuel feed circuit can
severely damage the in-
jection system and make the en-
gine misfire. Go to a Fiat Dealer-
ship as soon as possible when the
cwarning light comes on to have
the bleeding operation carried
out. If the warning light comes on
immediately after refuelling, wa-
ter is probably present in the
tank: turn the engine off imme-
diately and contact Fiat Dealer-
ship.

175VEHICLE MAINTENANCE
When working on the bat-
tery or near it, always wear
the proper goggles.
WARNING
Running the battery with
low fluid level can damage
the battery beyond repair and
could also cause its explosion.
WARNING
If the vehicle is to stand for
a long time in the cold, re-
move the battery and store it in a
warm place to avoid it freezing.
WARNINGCHECKING THE CHARGE
The battery charge may be checked
satisfactorily through the indicator and
acting according to the colour the in-
dicator shows.
Refer to the table below or to the la-
belB-fig. 15on the battery.USEFUL ADVICE FOR
LENGTHENING THE LIFE OF
YOUR BATTERY
When you park the vehicle, ensure
the doors are closed properly. The
ceiling lights must be off.
Do not keep accessories (e.g.: sound
system, hazard lights, etc.) switched
on for a long time when the engine is
not running.
IMPORTANTA battery which is
kept at a charge of less than 50% for
any length of time will be damaged by
sulphation leading to a reduction in
cranking power and a higher risk of the
battery electrolyte freezing (this may
even occur at –10 °C).
Bright white colour
Dark colour without green
area in the centre
Dark colour with green
area in the centreTop up electrolyte
Low charge level
Electrolyte level
and charge sufficientContact a
Fiat Dealership
Charge the battery
(advisable to contact a Fiat
Dealership)
No action

183VEHICLE MAINTENANCE
Do not wash the vehicle after it has
been parked in the sun or while the
bonnet is hot: it could take the shine
off the paint.
Outside plastic parts must be
cleaned following the usual vehicle
washing procedure.
Where possible avoid parking the
vehicle under trees; the resinous sub-
stances that certain species of tree
shed dull the paintwork and increase
the possibility of rust forming.To better protect the paintwork,
polish with protective wax from time
to time, that leaves a protective layer
on the paintwork.
When the paintwork tends to lose
its shine because of the build-up of
smog, use a wax (polish) which has a
slightly abrasive as well as protective
action.
Front headlights
IMPORTANTNever use aromat-
ic substances (e.g.: petrol) or ketones
(e.g.: acetone) for cleaning front head-
light plastic lens.
Windows
Use specific window cleaners to
clean the windows. Use very clean
cloths to avoid scratching the glass or
damaging its transparency.
IMPORTANTTo prevent damage
to the electric heater element, wipe
the inside of the heated rear window
(where fitted) gently in the same di-
rection as the elements.Engine compartment
At the end of each winter season,
carefully clean the engine compart-
ment. Have this done at a garage.
IMPORTANTThe engine com-
partment should be washed while the
engine is cold and with the ignition key
at STOP. After washing, make sure
that the various protections (e.g. rub-
ber boots and various guards) have
not be removed or damaged.
Detergents pollute wa-
ter. For this reason, the
vehicle must be washed
in an area equipped for the col-
lection and purification of the liq-
uids used while washing.
IMPORTANTBird droppings
must be washed off immediately and
with great care as their acid is partic-
ularly aggressive.
Detergents pollute wa-
ter. The vehicle must
therefore be washed in an
area equipped for the collection
and purification of the liquids
used while washing.

242TECHNICAL SPECIFICATIONS
Use
Lubricants and grease
for transmission
Products for brakes
Radiatorantifreeze
Diesel fuel
additive
Windscreen/
rear window/
headlight washer fluid
(*) IMPORTANTThese two fluids cannot be mixed with each other. Contact Fiat Dealership for topping up.
Recommended
fluids and lubricants
TUTELA CAR
MATRYX
TUTELA GI/A
TUTELA HP 20
TUTELA
W 90/M-DA
TUTELA TOP 4
PARAFLU 11 (*)
or
PARAFLU UP (*)
DIESEL MIX
TUTELA
PROFESSIONAL
SC 35 Fluid and lubricant specifications
for correct vehicle operation
Fully synthetic lubricant SAE 75W-85 meeting API GL-4,
FIAT 9.55550
Lubricant for transmissions with ATF DEXRON II D LEV
properties
ATF DEXRON III oil type
Lubricant, grade SAE 80W-90 that passes API GL5, MIL-L-
2105 D, IVECO 18-1804, FIAT 9.55550 and FIAT 9.55523
specifications
Synthetic fluid, FMVSS n° 116 DOT 4, ISO 4925,
SAE J-1704, CUNA NC 956 - 01
Protective with antifreeze action based on
inhibited monoethylen glycol, CUNA NC 956-16
Protective with antifreeze action (red colour) based on inhib-
ited monoethylen glycol, with O.A.T. formulation, that passes
CUNA NC 956-16, ASTM D 3306 specifications.
Diesel fuel additive providing diesel engine protection
Mixture of alcohol and surfactants CUNA NC 956 -IIApplications
Mechanical
transaxles developping
high temperatures
Power steering system
Automatic gearbox
EP oil for standard and
self-locking differentials
Hydraulic brake and
clutch controls
Cooling circuits.
Proportion: 50% down
to -35° C Not to be
mixed with products
having different
formulas.
To be mixed with
diesel fuel
(25 cc every 10 litres)
To be used pure
or diluted

247INDEX
I I
N N
D D
E E
X X
Bodywork ..................................... 181
- maintenance ............................ 181
- tips for keeping the body
in good conditions ................. 182
- versions .................................... 187
- warranty ................................... 182
Bodywork paint identification
plate ............................................. 186
Bodywork versions ..................... 187
Bonnet ........................................... 84
Bottle holder ................................ 74
Brake fluid level ........................... 172
Brake light replacement ............. 146
Brakes
- handbrake ......................... 108-216
- service and
emergency brake ................... 216
Bulb replacement ........................ 141
Bulb types ..................................... 142
Bump starting ............................... 137Capacities ................................... 239
Ceiling light .................................... 71
Cellular phone set-up ................ 100
Central door locking system .... 83
Changing a wheel ........................ 137
Cheap running that respects
the environment ....................... 127
Checking fluid levels ................... 167
Child restraint systems .............. 22
Cigar lighter ................................. 77
Cleaning seats and fabrics ......... 184
Cleaning the plastic parts .......... 184
Climate control system ............. 57
Clutch ............................................ 216
Controls ........................................ 71
Consumption
- engine oil .................................. 170
- fuel ............................................. 243
Coolant temperature gauge ..... 30ABS .............................................. 88
Additional heater ........................ 58
Adjusting the headlight beam ... 86
Airbags (front and side) ............. 90
Air cleaner .................................... 173
Air vents ........................................ 54
Annual inspection schedule ...... 165
Ashtray .......................................... 77
ASR system ................................... 96
At the filling station .................... 102
Automatic electronic gearbox .. 110
Battery ........................................ 174
- battery cut out ....................... 73
- checking the charge ............... 175
- jump starting .................... 136-157
- recharging ................................ 157
- replacement ............................ 174
- useful advice ............................ 175