Clutch maintenance FIAT DUCATO 2006 Owner handbook (in English)

63
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
CRUISE CONTROL
(where provided)
It is a device able to support the driver,
with electronic control, which allows dri-
ving at speed over 30 km/h on long and
straight dry roads (e.g.: motorways), at a
desired speed, without pressing the ac-
celerator pedal. Therefore it is not sug-
gested to use this device on extra-urban
roads with traffic. Do not use it in town
DEVICE ENGAGEMENT
fig. 62
Turn knurled ring Ato ON.
The Cruise Control cannot be engaged
in first or reverse gear. It is advisable to
engage it in 4
thor higher gears.
Travelling downhill with the device en-
gaged, the vehicle speed may increase
more than the memorised one.
When the device is activated the warn-
ing light
Üturns on together with the rel-
evant message on the instrument panel.TO MEMORISE SPEED
Proceed as follows:
❒turn the knurled ring Ato ON and
press the accelerator pedal to the re-
quired speed;
❒move the stalk upwards (+) for at least
one second, then release it. The ve-
hicle speed is memorised and it is
therefore possible to release the ac-
celerator pedal.
In the case of need (when overtaking for
instance) acceleration is possible simply
pressing the accelerator pedal: releasing
the accelerator pedal, the vehicle will re-
turn to the speed memorised previously.
TO RESET THE MEMORISED
SPEED
If the device has been disengaged for ex-
ample pressing the brake or clutch pedal,
the memorised speed can be reset as fol-
lows:
❒accelerate gradually until reaching a
speed approaching the one memo-
rised;
❒engage the gear selected at the time of
speed memorising;
❒press button RES B.
fig. 62F0N0040m

64
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
TO INCREASE THE MEMORISED
SPEED
The speed memorised can be increased in
two ways:
❒pressing the accelerator and then
memorising the new speed reached;
or
❒moving the stalk upwards (+).
Each operation of the stalk will corre-
spond to a slight increase in speed (about
1 km/h), while keeping the stalk upwards
will correspond to a continuous speed in-
crease.
TO REDUCE MEMORISED
SPEED
The speed memorised can be increased in
two ways:
❒disengaging the device and then mem-
orising the new speed;
or
❒moving the stalk downwards (–) until
reaching the new speed which will be
memorised automatically.
Each operation of the stalk will corre-
spond to a slight reduction in speed (about
1 km/h), while keeping the stalk down-
wards will correspond to a continuous
speed reduction.DEVICE DISENGAGEMENT
The device can be disengaged in the fol-
lowing ways:
❒turning the knurled ring Ato OFF;
❒turning the engine off;
❒pressing the brake pedal or engaging
the hand brake;
❒pressing the clutch pedal;
❒shifting gear with automatic transmis-
sion in sequential mode;
❒with vehicle speed below the preset
limit;
❒pressing the accelerator pedal; in this
case the system is not really disen-
gaged but the request for acceleration
takes priority over the system. The
cruise control is however active and it
will not be necessary to press button
RES to resume previous conditions
after ending acceleration.The device is automatically deactivated in
one of the following cases:
❒ABS or ESP system cut-in;
❒system failure.
When travelling with the de-
vice on, never set the
gearshift lever to neutral.
In the event of device mal-
function or failure, turn the
knurled ring A to OFF and contact a
Fiat Dealership after checking the
protection fuse integrity.
WARNING
WARNING

86
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
ESP SYSTEM ACTIVATION
The ESP system is automatically activat-
ed when the vehicle is started and cannot
be de-activated.
FAILURE INDICATIONS
In the event of failure, the ESP system is
automatically disconnected, the warning
light
á, comes on with fixed light on the
instrument panel, together with the mes-
sage on the multifunction display (where
provided) (see section “Warning lights and
messages”) and with the button led ASR.
In this case contact a Fiat Dealership as
soon as possible.
Performance of the ESP sys-
tem, in terms of active safe-
ty should not induce the driver to take
pointless and unnecessary risks. The
style of driving must in any case al-
ways be adapted to the conditions of
the road surface, visibility and traffic.
Road safety is always the driver’s re-
sponsibility.
WARNING
HILL HOLDER SYSTEM
This system is an integral part of the ESP
system and it is provided to facilitate start-
ing on slopes.
It will activate automatically with the fol-
lowing conditions:
❒uphill: vehicle at a standstill on a road
with a gradient higher than 5%, engine
running, clutch and brake pedal
pressed, gearbox to neutral or en-
gaged gear other than reverse.
❒downhill: vehicle at a standstill on a
road with a gradient higher than 5%,
engine running, clutch and brake ped-
al pressed and reverse gear engaged.
At pickup the ESP system control unit will
keep brake force on wheels until reaching
the torque suitable for starting, or in any
case for max. 2 seconds in order to pass
easily from the brake pedal to the accel-
erator pedal.
After two seconds without starting, the
system will deactivate automatically by re-
leasing gradually the brake force.
At releasing, the typical brake disengage-
ment noise indicating that the vehicle is
going to move will be heard.Failure indications
System failure is indicated by the turning
on of warning light
á(see section “Warn-
ing lights and messages”).
IMPORTANT The Hill Holder system is
not a parking brake therefore, never leave
the vehicle without having engaged the
handbrake, turned the engine off and en-
gaged the first speed.
For correct operation of the
ESP and ASR systems, the
tyres must absolutely be of the same
brand and type on all wheels, in per-
fect conditions and, above all, of
type, brand and size specified.
WARNING

116
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
ENGINE
STARTING
The vehicle is fitted with an electronic en-
gine lock device: if the engine fails to start,
see the paragraph “The Fiat CODE sys-
tem” in section “Dashboard and controls”.
We recommend that during
the initial period you do not
drive to full vehicle perfor-
mance (e.g.: excessive accel-
eration, long journeys at top speed,
sharp braking, etc.).
When the engine is switched
off never leave the key into
the ignition switch to prevent
pointless current absorption
from draining the battery.
Running the engine in con-
fined areas is extremely dan-
gerous. The engine consumes oxygen
and produces carbon monoxide
which is a highly toxic and lethal gas.
WARNING
Remember that the servo-
brake and power steering
are not operational until the engine
has been started, therefore much ef-
fort than usual is required on the
brake pedal and steering wheel.
WARNING
STARTING PROCEDURE
Proceed as follows:
❒engage the handbrake;
❒put the gear lever into neutral;
❒turn the ignition key to MAR: the
warning lights
mand Yon the in-
strument panel will turn on;
❒wait for the warning lights Yand
mto turn off. The hotter the engine
is, the quicker this will happen;
❒press the clutch pedal down to the
floor without pressing the accelerator;
❒turn the ignition key to AVVas soon
as warning light
mturns off. If you
wait too long you will lose the bene-
fit of the work done by the glow plugs.
Release the key as soon as the engine
starts.

118
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLEWhen the handbrake lever is pulled up
and the ignition key is at MAR, the in-
strument panel warning light
xwill turn
on.
To release the handbrake:
❒slightly lift the handbrake and press the
release button A;
❒keep button Apressed and lower the
lever. Warning light xwill turn off.
Press the brake pedal when carrying out
this operation to prevent the vehicle mov-
ing accidentally.
IMPORTANT Pull the handbrake only
when the vehicle is stationary or, with
vehicle running only if the hydraulic sys-
tem is failing. Should it be necessary to
use the handbrake with the vehicle run-
ning, pull it slowly to prevent rear axle
locking and vehicle side skid as a conse-
quence.
PARKING THE VEHICLE
Proceed as follows:
❒stop the engine and engage the hand-
brake;
❒engage a gear (on a slope, engage
first gear if the vehicle is faced uphill
or reverse if it is faced downhill) and
leave the wheels steered.
Block the wheels with a wedge or a
stone if the vehicle is parked on a steep
slope. Do not leave the key in the igni-
tion switch to prevent draining the bat-
tery. Always remove the key when you
leave the vehicle.
HANDBRAKE fig. 1
The handbrake lever is located on the left-
hand side of the driver’s seat.
Pull the handbrake lever upwards until the
vehicle cannot be moved. Four or five
clicks are generally enough when the ve-
hicle is on level ground while nine or ten
may be required if the vehicle is on a steep
slope or laden.
IMPORTANT If this is not the case, con-
tact Fiat Dealership to have the handbrake
adjusted.
Never leave children unat-
tended in the vehicle. Always
remove the ignition key when leaving
the vehicle and take it out with you.
WARNING
fig. 1F0N0073m
USING THE MANUAL
GEARBOX
To engage the gears, press the clutch ped-
al fully and shift the gear lever into one of
the required positions (the diagram is
shown on the knob fig. 2).
To engage the 6th gear (where provided)
move the gearshift lever pressing slightly
rightwards to prevent engaging the 4th
gear accidentally. Do the same for shifting
from 6th to 5th gear.
IMPORTANT The vehicle can only be put
into reverse gear when it has stopped
moving completely. With the engine run-
ning, before engaging the reverse, wait at
least 2 seconds with the clutch pedal ful-
ly down to prevent damage and grating of
the gears.

119
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
fig. 2F0N0074m
To change gears properly
you must push the clutch
pedal fully down. It is therefore es-
sential that there is nothing under the
pedals: make sure the mats are lying
flat and do not get in the way of the
pedals.
WARNING
Do not drive with your hand
resting on the gear lever as
the force exerted, even if
slight, could lead over time to
premature wear on the gearbox inter-
nal components.
To engage reverse R from neutral, pro-
ceed as follows: raise the sliding ring Aun-
der the knob and at the same time move
the gearshift lever leftwards and then for-
ward.
LOAD
RECOMMENDATIONS
The version of the Fiat Ducato you are
driving has been designed and approved
on the basis of several set maximum
weights (see the tables “Weights” in sec-
tion “Technical specifications”): kerb
weight; payload; total weight; total weight
on the front axle; total weight on the rear
axle; towable weight
Each of these limits must be
borne in mind and MUST
NEVER BE EXCEEDED under any cir-
cumstances. In particular, never ex-
ceed the maximum weight permitted
on the front and rear axles when ar-
ranging loads in vehicle (especially for
special version vehicles).Chance knocks or sudden
braking can cause sudden
shifts of the load which could jeop-
ardise the safety of the driver and the
passengers: before you start off make
sure the load is firmly secured by us-
ing the hooks built into the floor for
that purpose. Use metal cables, ropes
or straps strong enough to support
the weight of the load to be fixed.
WARNING
WARNING
Even if the vehicle is sta-
tionary on a steep hill or
sideways incline, goods not properly
secured could fall out when the back
or side doors are opened.
WARNING
IMPORTANT Max. admitted load on floor
fixings is 500 kg; max. admitted load on
body side is 150 kg.

121
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
Acceleration
Accelerating violently increasing the revs
will greatly affect consumption and emis-
sions: acceleration should be gradual and
should not exceed the maximum torque.
CONDITIONS OF USE
Cold starting
Short journeys and frequent cold starts do
not allow the engine to reach optimum op-
erating temperature. This results in a sig-
nificant increase in consumption levels
(from +15 to +30% on the urban cycle)
and emission of harmful substances.
Traffic and
road conditions
Rather high consumption levels are tied to
situations with heavy traffic, for example
in queues with frequent use of the lower
gears or in cities with many traffic lights.
Also winding mountain roads and rough
road surfaces adversely affect consump-
tion.
Traffic hold-ups
During prolonged hold-ups (level crossings)
the engine should be switched off.TOWING TRAILERS
IMPORTANT NOTES
For towing caravans or trailers the vehi-
cle must be fitted with a certified tow
hook and an adequate electric system. In-
stallation should be carried out by spe-
cialised personnel who release a special
document for circulation on the road.
Install any specific and/or additional rear-
view mirrors as specified by law.
Remember that when towing a trailer,
steep hills are harder to climb, the brak-
ing spaces increase and overtaking takes
longer depending on the overall weight.
Engage a low gear when driving downhill,
rather than constantly using the brake.
The weight the trailer exerts on the ve-
hicle tow hook reduces by the same
amount the actual vehicle loading capaci-
ty. To make sure the maximum towable
weight is not exceeded (given in the log
book) account should be taken of the ful-
ly laden trailer, including accessories and
personal belongings. DRIVING STYLE
Starting
Do not warm the engine when the vehi-
cle is stationary or at high or low speed:
in this way the engine will warm up grad-
ually increasing consumption and emis-
sions. You should drive off slowly straight
away avoiding high revs so that the engine
will warm up more quickly.
Unnecessary actions
Avoid accelerating when waiting at traffic
lights or before switching off the engine.
This and also double declutching is ab-
solutely pointless on modern vehicles and
also increase consumption and pollution.
Gear selection
As soon as the conditions of the traffic and
road allow, use a higher gear. Using a low
gear to obtain brilliant performance in-
creases consumption.
In the same way improper use of a high
gear increases consumption, emissions an
engine wear.
Top speed
Fuel consumption considerably increases
with speed. Avoid superfluous braking and
accelerating, which cost in terms of both
fuel and emissions.

199
WARNING
LIGHTS AND
MESSAGES
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
FUEL FEED
Fuel feed Direct injection “Common Rail”
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
TRANSMISSION
100 Multijet 120 Multijet - 130 Multijet
Gearbox
Clutch
DriveSelf-adjusting pedal without idle stroke
Front Five forward gears and reverse with synchromesh for
forward gear engagementSix forward gears and reverse
with synchromesh for forward
gear engagement

Synthetic-based oil, grade SAE 75W-80
that passes API GL-4 specifications
Molibdenum disulphide, lithium soap based grease.
NL.GI. 2 consistency
Lithium soap based grease.
NL.GI. 0 consistency
Poly-urea oil synthetic-based grease suitable for
high temperatures.
NL.GI. 2 consistency
Lubricant for power steering and automatic
transmissions that passes ATF DEXRON III specifications
Synthetic fluid FMVSS no. 116 DOT 4, ISO 4925
SAE J1704, CUNA NC 956- 01
Protective with antifreeze action, red colour based
on inhibited monoethylen glycol and organic formula,
that passes CUNA NC 956-16, ASTM D 3306
specifications
Additive for diesel fuels with protective action
for Diesel engines
Mixture of alcohol, water and surfactants
CUNA NC 956-II
226
WARNING
LIGHTS AND
MESSAGES
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
TUTELA CAR
EXPERYA
TUTELA STAR 500
TUTELA
MRM ZERO
TUTELA STAR 325
TUTELA GI/E
TUTELA TOP 4
PARAFLU UP (*)
DIESEL MIX
TUTELA
PROFESSIONAL
SC 35Mechanical gearbox
and differential
CV joints on
wheel side
CV joints on
differential side
CV joints on
differential side
Hydraulic power
steering
Brake and clutch
hydraulic controls
Cooling circuits,
proportion: 50% wa-
ter and 50%
PARAFLU UP
To be mixed with
diesel fuel
(25 cc per 10 litres)
To be used diluted or
undiluted in wind-
screen/rear window
washer/wiper systems Lubricants
and greases
for transmission Use Fluid and lubricant quality specifications Genuine flluids Applications
for correct vehicle operation and lubricants
Brake fluids
Protective agent
for radiators
Additive for
diesel fuel
Windscreen/
rear window
washer fluid
(*) IMPORTANT Do not top up or mix with fluids having characteristics different from those specified.