start 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

137IN AN EMERGENCY
BUMP STARTING IF A TYRE IS
PUNCTURED
General instructions
Observe the instruc-
tions on this and the fol-
lowing pages to use the
jack and spare wheel correctly.Catalysed vehicles must
not be bump started
(pushed, towed or
coasted downhill) as this could
cause fuel to flow into the cat-
alytic exhaust system and dam-
age it beyond repair.
Never start the engine
when the vehicle is jacked
up.
WARNING
Remember that until the
engine has started the
brake booster and power steering
systems will not work and a greater
effort will therefore be required to
depress the brake pedal or turn the
steering wheel.
WARNING
If you are towing a trailer,
remove the trailer before
jacking up the vehicle.
WARNING
The jack should only be
used to changed a wheel on
the vehicle for which it was de-
signed. It should not be put to oth-
er uses or employed to raise other
models. Under no circumstances
should it be used when carrying out
repairs under the vehicle. An incor-
rectly positioned jack may cause
the vehicle to fall. Do not use the
jack to lift loads exceeding that in-
dicated on the label attached to the
to the jack itself.
WARNING

157IN AN EMERGENCY
IF THE BATTERY
IS FLAT
IMPORTANTBattery recharging
procedure is given as information on-
ly since this operation shall be only
performed at a Fiat Dealership.
RECHARGING THE BATTERY
You are advised to recharge the bat-
tery slowly for a period of approxi-
mately 24 hours at a low amperage.
Charging for too long could damage
the battery.
Proceed as follows:
1) disconnect the electrical system
from the battery terminals;
IMPORTANTIf the vehicle is fit-
ted with the alarm system, deactivate
it by the remote control (see “Elec-
tronic alarm” in chapter “Getting to
know your vehicle”).JUMP STARTING
See “Jump starting” in this section. 2)connect the charger cables to the
battery terminals;
3)turn the charger on;
4)when you have finished, turn the
charger off before disconnecting the
battery;
5) reconnect the cables to the bat-
tery terminals. Make sure the polari-
ty is correct.
The liquid in the battery is
poisonous and corrosive.
Do not let it touch the skin or eyes.
Recharging the battery should be
done in a well-ventilated area away
from naked flames or possible
sources of sparks: explosion and fire
risk.
WARNING
Do not attempt to recharge
a frozen battery. Thaw it
first otherwise it could explode. If
the battery froze, make sure the in-
ternal elements are not broken
(short-circuit risk) and that the cas-
ing is not cracked (risk of spilling
the poisonous and corrosive fluid.
WARNING

158IN AN EMERGENCY
JACKING
THE VEHICLE
WITH THE JACK
See “If a tyre is punctured”, in this
section.Please note:
– the jack requires no adjustments;
– the jack cannot be repaired. If it
breaks it must be replaced with a new
jack;
– no other tool, apart from the ex-
tension and the ratchet wrench shown
in section “If a tyre is punctured” can
be fitted to the jack.
fig. 41
F0D0200mDo not use the jack to lift
loads exceeding that indi-
cated on the label attached to the
jack.
WARNING
The jack should only be
used to change a wheel on
the vehicle for which it was de-
signed. It should not be put to oth-
er uses or employed to raise other
models. Under no circumstances
should it be used when carrying out
repairs under the vehicle.
WARNING
Never start the engine
when the vehicle is jacked
up.
WARNING
An incorrectly positioned
jack may cause the vehicle
to fall.
WARNING
If you are towing a trailer,
remove the trailer before
jacking up the vehicle.
WARNING

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

166VEHICLE MAINTENANCE
IMPORTANT - Pollen filter
If the vehicle is often used in dusty
or extremely polluted environments,
you should change the filter element
more frequently. It should be changed
especially if the amount of air intro-
duced into the passenger compart-
ment has decreased.
IMPORTANT - Diesel filter
Refuelling with diesel fuel not com-
plying with the grade of purity pre-
scribed by European Specification
EN590 might make it necessary to re-
place the filter more frequently than
indicated in the Service Schedule.
IMPORTANT - Battery
The charge in your battery should be
checked, where possible at the start
of the winter, to limit the risk of the
battery electrolyte freezing.
This check should be carried out
more frequently if the vehicle is mainly
used for short trips or if it is fitted
with accessories that permanently
take in electricity even when the igni-
tion key is removed, especially in the
case of after market accessories.You should check the battery fluid
(electrolyte) level more frequently
than shown in the Service Schedule if
the vehicle is used in hot climates or
particularly demanding conditions.
IMPORTANTAs concerns Camp-
ing Car versions, due to high electric
absorption, observe indications rele-
vant to battery contained in para-
graphs "Vehicle storage" (section
"Getting the best out of your vehicle")
and "Battery – Checking the charge"
(section "Vehicle maintenance").
Maintenance of your ve-
hicle should be entrusted
to a Fiat Dealership. For
ordinary routine maintenance
operations which you are able to
carry out yourself, ensure that
you have the necessary tools and
original Fiat spare parts and flu-
ids available. Do not carry out
servicing operations if you have
no experience.IMPORTANT - Engine oil
Change the engine oil more fre-
quently than shown in the Service
Schedule if the vehicle is normally dri-
ven in one of the following particular-
ly severe conditions:
– towing a trailer
– on dusty roads
– short distances (less than 7-8 km)
repeated and with external tempera-
tures below zero.
– frequently idling engines or long
distance low speed driving (e. g. taxis
or door-to-door deliveries) or in case
of a long term inactivity replace engine
oil more frequently than required on
Scheduled Maintenance Plan.
IMPORTANT - Air cleaner
Replace the air cleaner more fre-
quently if the vehicle is used on dusty
roads.
If you are in doubt about how often
the engine oil or the air cleaner should
be changed in relation to how you use
the vehicle, contact a Fiat Dealer-
ship.

169VEHICLE MAINTENANCE
Do not add oil with dif-
ferent specifications from
the oil already in the en-
gine.
ENGINE OIL
Fig. 5:2.0 versions
Fig. 6:2.0 JTD versions
Fig. 7:2.3 JTD versions
Fig. 8: 2.8 JTD - 2.8 JTD POWER
versions
Check engine oil with the vehicle on
level ground and while the engine is
still warm (approximately 10 minutes
after stopping the engine). The oil
level should be included between the
MINand MAXreference lines on
the dipstick.
The gap between MINand MAX
reference lines corresponds to ap-
proximately 2 litres oil.
The oil level must never exceed the
MAXline.If the oil level is near or even below
the MINline, pour in oil through the
filler hole until it reaches the MAX
line.
fig. 5
F0D0063m
fig. 6
F0D0064m
fig. 7
F0D0211m
fig. 8
F0D0183m
Be very careful under the
bonnet: you risk burning
yourself. Remember that when the
engine is hot, the fan can start up
and cause injuries.
WARNINGIMPORTANT After topping up or
changing the oil, let the engine turn
for a few seconds and wait a few min-
utes after stopping it before you check
the level.

170VEHICLE MAINTENANCE
Engine oil consumption
Maximum engine oil consumption is
approx. 450 grams every 1000 Km.
During the beginning of the vehicle’s
life the engine is tuning in. Engine oil
consumption can only be considered
stabilised after the first 5,000 - 6,000
km.
IMPORTANTEngine oil consump-
tion depends on the conditions the ve-
hicle is being used in.ENGINE COOLANT
Check coolant level when the engine
is cold. The level should be included
between the MIN and MAXrefer-
ence lines on the reservoir.
If the level is low, loosen the expan-
sion tank cap A-fig. 9and top up
slowly through the filler with the flu-
id specified in “Fluids and lubricants”
table in section “Technical Specifica-tions”, until the level approaches the
MAX line; contact Fiat Dealership
for this operation.
Coolant mixture gives freeze pro-
tection to – 40°C.
Used engine oil and re-
placed oil filters contain
substances which can
harm the environment. We rec-
ommend you have the vehicle
seen at a Fiat Dealership for the
oil and filter change. It is suitably
equipped for disposing of used oil
and filters in an environmentally-
friendly way that complies with
the law.
fig. 9
F0D0065m
The cooling system is pres-
surised. If necessary, re-
place the cap with a genuine spare
part to avoid compromising the sys-
tem efficiency.
WARNING
Do not remove the reservoir
cap when the engine is hot:
you risk scalding yourself.
WARNING
Top up only with the
same fluid contained in
the cooling circuit.
PARAFLU UP (red) cannot be
mixed with PARAFLU 11 (blue)
or with other fluids. Should this
take place, donot start the engine
and contact Fiat Dealership.

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