ignition FIAT DUCATO 2006 3.G Service Manual

135IN AN EMERGENCY
I I
N N
A A
N N
E E
M M
E E
R R
G G
E E
N N
C C
Y Y
EMERGENCY
START-UP
DIESEL VERSIONS
Emergency start-ups cannot be per-
formed on versions with a diesel en-
gine; contact aFiat Dealership.
PETROL VERSIONS
If the Fiat CODE cannot deactivate
the engine immobiliser, the Yand
Uwarning lights stay on and the en-
gine will not start. Follow the emer-
gency start-up procedure to start the
engine.
Read the whole procedure care-
fully before trying to carry it out.
If you make a mistake, you must turn
the ignition key back to STOPand re-
peat the whole operation from the be-
ginning (step 1).1) Read the 5-figure electronic code
given on the CODE card.
2) Turn the ignition key to MAR.
3)Press and hold down the accel-
erator pedal. Warning light
Uwill
come on for about 8 seconds, and
then go out. At this point release the
accelerator pedal and get ready to
count the flashes of the warning light
U.
4) Count the number of flashes that
corresponds to the first figure of the
code on the CODE card, then press
the accelerator pedal and keep it there
until the warning light
Ucomes on
for four seconds and then goes out;
release the accelerator pedal.
5) Warning light
Uwill start flash-
ing again: after it has flashed the num-
ber of times that corresponds to the
second figure on the CODE card,
press the accelerator pedal and keep
it pressed.
6) Do the same for the remaining fig-
ures on the CODE card.7) Once the final figure has been en-
tered, keep the accelerator pedal
pressed. Warning light
Uwill light up
for four seconds and then go out; re-
lease the accelerator pedal.
8)Warning light
Uwill flash rapid-
ly for about 4 seconds to indicate that
the operation has been completed
correctly.
9) Start the engine by turning the ig-
nition key from MARto AVV.
If, however, the warning light
U
stays on, turn the ignition key to
STOPan repeat the procedure from
step 1).
IMPORTANT After an emergency
start-up, you should contact a Fiat
Dealership otherwise you will have
to repeat the procedure described
each time you want to start the en-
gine.

136IN AN EMERGENCY
JUMP STARTING
If the battery is flat, you can use an-
other battery to start the engine. Its
capacity must be the same or slightly
greater than the flat battery.
Proceed as follows fig. 1:
1) connect positive terminals1and
2 (+sign near terminal) of the two
batteries with a jump lead;
2) with a second lead, connect the
negative terminal 3(– sign near the
terminal) of the auxiliary battery to an
earthing point 4(E) on the engine or
gearbox of the vehicle to be started;IMPORTANTDo not directly
connect the two negative terminals:
sparks could ignite the flammable gas
from the battery. If the other battery
is fitted in a vehicle, prevent acciden-
tal contacts between the metal parts
of the two vehicles.
3) Start the engine.
4)when the engine has been start-
ed, remove the leads reversing the or-
der above.
If the engine fails to start after a few
attempts, do not keep turning the key
but have the vehicle seen at a Fiat
Dealership.
fig. 1
F0D0203m
Under no circumstances
should a battery charger
be used to start the en-
gine: it could damage the elec-
tronic systems and in particular
the ignition and injection control
units.
Do not carry out this pro-
cedure if you lack experi-
ence; if it is not done correctly it
can cause very intense electrical
discharges and the battery might
even explode. The liquid in the bat-
tery is poisonous and corrosive.
Keep it away from the eyes and
skin. You are also advised not to put
naked flames or lighted cigarettes
near the battery and not to cause
sparks: risk of fire and explosion.
WARNING

149IN AN EMERGENCY
Before changing a fuse,
check the ignition key has
been removed and that
all the other electric devices have
been turned off/disabled.IF A FUSE BLOWS
GENERAL FEATURES
A fuse is an element for protecting
the electrical system. A fuse will trip
(i.e. blow) in the event of a failure or
improper interventions in the electri-
cal system.
If an electric device is not working,
check whether the respective fuse is
blown (i.e. the conductor is broken
fig. 33). If required, replace the blown
fuse with another with the same am-
perage (same colour).B- Undamaged fuse.
C- Fuse with broken filament.
Use the tongs Din the fusebox to
extract the fuse.
To locate the fuse, refer to the tables
on the following pages.
fig. 33
F0D0029m
Never replace a broken
fuse with anything other
than a new fuse. Always
use a fuse of the same colour.
If the fuse blows again,
have the vehicle inspected
at a Fiat Dealership.
WARNING
Never change a fuse with
another amperage: FIRE
RISK!
WARNING
Do not attempt to repair a
blown MAXI-FUSE. Go to a
Fiat Dealership.
WARNING

155IN AN EMERGENCY
System/Component
ABS control unit
Airbag control unit
Power mirrors
Cruise control
Phone
Chronotachograph
Remote control
Alarm
Brake lights
Instrument panel
PCC
Ignition switch
Cab fan (with Webasto system)
Webasto control unit
Cab fan (with climate control)
CVM (engine compartment fusebox)
Radiator fan low-speed resistor (2.0 with climate control system)
Engine control unit (2.0 with climate control system)
Engine cooling fan (2.0 with climate control system)
Engine control unit (2.0 with climate control system)
Engine cooling fan (2.0 with climate control system)
Engine control unit (2.0 with climate control system)
CFB protection
E.I. primary services
E.I. primary services
E.I. secondary services
Horn
Steering column stalk controlFuse no.
F 42
F 50
F 27
F 27
F 27
F 27
F 27
F 27
F 26
F 37
F 37
F 31
F 55
F 55
F 55
F 06
F 06
F 06
F 06
F 07
F 07
F 01
F 17
F 22
F 11
F 10
F 10Ampere
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
10
10
10
30
30
30
40
40
40
40
40
40
60
5
20
10
15
15Location
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 36
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41
Fig. 41

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

159IN AN EMERGENCY
WITH A SHOP JACK
The vehicle can be raised on a shop
jack if it is empty. This is only possi-
ble from the side by placing the jack at
the points provided in the underbody
as indicated infig. 41.
WITH AN ARM HOIST
The vehicle must be raised by plac-
ing the ends of the arms at the points
indicated in fig. 41.TOWING THE
VEHICLE
The vehicle has two eyes for an-
choring the tow hitch fig. 42.
A- Front eye
B- Rear eye (for towing another ve-
hicle).
fig. 42
F0D0177m
Before starting to tow, turn
the ignition key to MAR
and then to STOP. Do not remove
the key. If the key is removed, the
steering lock engages automatical-
ly which prevents the wheels being
turned.
WARNING
While the vehicle is being
towed with the engine off,
remember that the brake pedal and
steering will require more effort as
you no longer have the benefit of
the power brakes and power steer-
ing. Do not use flexible cables to
tow. Avoid jerking. Whilst towing,
ensure that coupling to the vehicle
does not damage the surrounding
components.
WARNING

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

177VEHICLE MAINTENANCE
ELECTRONIC
CONTROL UNIT
When the vehicle is being used nor-
mally, special measures are not nec-
essary.
The following instructions must be
followed very carefully however, if
you work on the electrical system or
in cases where emergency starting is
necessary:
– never disconnect the battery from
the electric system while the engine is
running;
– disconnect the battery from the
electric system if you are recharging it;
– never perform emergency starting
with a battery charger. Always use an
auxiliary battery;
– be particularly careful when con-
necting the battery to the electric sys-
tem. Make sure that the polarity is
correct and that the connection is ef-
ficient;
– do not connect or disconnect the
terminals of the electronic units while
the ignition key is at MAR;
– do not check polarity through
sparking;– disconnect the electronic control
units if you are electrically welding the
vehicle body. Remove the units if tem-
peratures exceed 80 °C (special op-
erations on the bodywork, etc.).
IMPORTANTIf the sound system
or vehicle alarm systems are not in-
stalled correctly, they can interfere
with the working of the electronic
control units.
Modifications or repairs to
the electrical system car-
ried out incorrectly and without
bearing the features of the system
in mind can cause malfunctions
with the risk of fire.
WARNING
SPEED LIMITER
On certain version, the injection con-
trol unit is set to limit the vehicle
speed at a max. preset limit.
Speed limits are the following:
– for Minibus versions (M2 homolo-
gation category): 100 km/h;
– for good Transport versions (ve-
hicle dead weight: > 3.5 t) (N2 ho-
mologation category): 90 km/h;
Label (fig.16) with admitted top
speed (90 or 100 km/h according to
versions) is applied on the wind-
screen.
This limit has been established by Eu-
ropean Directive 2002/85/EC, what-
ever violation is therefore punishable
by law.
IMPORTANTWhen the device
comes into action, the speed value
displayed on the instrument panel
could be approx. 10% higher than the
actual one.
fig. 16
F0D0299m

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.

215TECHNICAL SPECIFICATIONS
FUEL SUPPLY/IGNITION
Petrol version
Electronic Multipoint sequential
phased integrated electronic injection
and ignition; a single injection system
controls both functions. It processes
both the time the injection lasts (for
fuel metering) and the ignition advance
angle.FUEL SUPPLY
JTD/JTD POWER versions
UNIJET (Common Rail) electronic
control direct injection, turbosuper-
charger with WASTEGATE valve and
intercooler (2.3 JTD, 2.8 JTD and 2.8
JTD POWER versions).SPARK PLUGS
The cleanness and soundness of the
spark plugs are very important for
keeping the engine efficient and pol-
luting emissions down.
The appearance of the spark plug, if
examined by an expert eyes, is a good
way of pinpointing a problem even if it
has nothing to do with the ignition sys-
tem. Therefore, if the engine has prob-
lems, it is important to have the spark
plugs checked at a Fiat Dealership.
The spark plugs must be
changed at the times
specified in the
SERVICE
SCHEDULE
. Only use the type of
plugs indicated: if the heat ratio
is less than required or the life
specified is not guaranteed, prob-
lems can arise.
Modifications or repairs to
the fuel feed system that
are not carried out properly or do
not take the system’s technical
specifications into account can
cause malfunctions leading to the
risk of fire.
WARNING