FIAT DUCATO 2009 3.G Owners Manual

190
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
IMPORTANT The Programmed Mainte-
nance coupons are specified by the Man-
ufacturer. The failure to have them car-
ried out may invalidate the warranty.
Scheduled Servicing is performed by all Fi-
at Dealership, at pre-established times.
If during each operation, in addition to the
ones programmed, the need arises for fur-
ther replacements or repairs, these may
be carried out only with the explicit agree-
ment of the Customer.IMPORTANT You are advised to contact
Fiat Dealership in the event of any minor
operating faults, without waiting for the
next service coupon.
If your vehicle is used frequently for tow-
ing, the interval between one service
coupon and the other must be reduced.SCHEDULED SERVICING
Correct maintenance is essential for en-
suring long life to your vehicle at top con-
ditions.
This is why Fiat has programmed a series
of checks and maintenance operations
every 40,000/45,000 km according to en-
gine models.
It is however important to remember that
scheduled servicing does not completely
cover all the vehicle requirements: also
in the initial period before 40,000/45,000
km service coupon and later, between one
coupon and another, ordinary care is still
required such as for example routine
check and topping up the level of fluids,
tyre pressure check, etc...

191
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
45 90 135 180 225
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SERVICE SCHEDULE (120 Multijet - 130 Multijet - 160 Multijet)
Thousands of km
Check tyre conditions/wear and adjust pressure if required
Check light system operation (headlights, direction
indicators, hazard lights, boot lights, instrument panel warning lights, etc.)
Check windscreen wiper/washer operation and adjust
nozzles, if required
Check windscreen blade position/wear
Check disk brake pad conditions and wear and front and rear disk brake
pad wear indicator operation
Sight inspect conditions and soundness:
Sight inspect the conditions of: bodywork, underbody protection, pipes
and hoses (exhaust - fuel - brakes) - Rubber parts (boots - sleeves -
bushes, etc.) - Brake and fuel system hoses
Sight inspect accessory drive belt conditions/tension
(excluding engines provided with automatic tighteners)
Check and adjust handbrake lever stroke, if required
Check exhaust emissions/smoke
Check cleanness of locks and lever cleanness and lubrication
Change engine oil and oil filter

192
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
45 90 135 180 225
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Thousands of km
Replace fuel filter
Replace air cleaner cartridge (▼)
Top up fluids
(engine coolant - brakes - power steering - windscreen washer - etc.)
Check timing belt (120 - 130 Multijet versions)
Replace accessory drive belt
Replace timing belt (120 - 130 Multijet versions) (*)
Check engine control system operation (through diagnosis socket)
Change brake fluid (or every 2 years)
Change pollen filter (or every 2 years)
(*) Or every 4 years for particularly demanding use (cold climates, driving in the city, idling for a long time, driving on dusty
roads or covered with sand and/or salt), or in any case every 5 years regardless of the km covered
(▼) If the vehicle is equipped with a specific air filter for dusty areas:
- Every 20,000 Km check-up and filter cleaning;
- Every 40,000 Km substitution of filter.

193
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
40 80 120 160 200
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SERVICE SCHEDULE (100 Multijet)
Thousands of km
Check tyre conditions/wear and adjust pressure if required
Check electric system operation (headlights, direction indicators,
hazard lights, boot light, instrument panel warning lights, etc.)
Check windscreen washer/wiper operation, adjust nozzles
if required
Check windscreen blade position/wear
Check disk brake pad conditions and front and rear disk brake
pad wear indicator operation
Sight inspect conditions and soundness:
Sight inspect the conditions of: bodywork, underbody protection,
pipes and hoses (exhaust - fuel - brakes), Rubber parts (boots - sleeves -
bushes - etc.) - Brake and fuel system hoses
Sight inspect accessory drive belt conditions
Check and adjust handbrake lever stroke, if required
Check exhaust emissions/smoke
Check cleanness of locks and lever cleanness and lubrication
Change engine oil and oil filter
Change fuel filter

194
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
40 80 120 160 200
●●●●●
●●●●●
●
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●●
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Thousands of km
Replace air cleaner cartridge (▼)
Check and top up fluids, if required
(engine coolant - brakes - power steering - windscreen washer - etc.)
Change accessory drive belt
Check engine control system operation (through diagnosis socket)
Change brake fluid (or every 2 years)
Change pollen filter (or every 2 years)
Should prevailing use of the vehicle be under one of the following specially heavy conditions:
❒trailer or caravan towing;
❒dusty roads;
❒short distances (less than 7-8 km) repeated and with external temperatures below zero;
❒frequently idling engines or long distance low speed driving (e.g. door-to-door deliveries) or in case of a long term inactivity;
❒driving in the city;
servicing operations shall be carried out every 30,000 km
(▼) If the vehicle is equipped with a specific air filter for dusty areas:
- Every 20,000 Km check-up and filter cleaning;
- Every 40,000 Km substitution of filter.

195
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
HEAVY-DUTY
Should prevailing use of the vehicle be un-
der one of the following specially heavy
conditions:
❒trailer or caravan towing;
❒dusty roads;
❒short distances (less than 7-8 km) re-
peated and with external tempera-
tures below zero;
❒frequently idling engines or long dis-
tance low speed driving (e.g. door-to-
door deliveries) or in case of a long
term inactivity;
❒driving in the city;
carry out the following checks more fre-
quently than required in the Service
Schedule:
❒check front disk brake pad conditions
and wear;
❒check cleanness of locks, bonnet and
boot and lever cleanness and lubri-
cation;
❒sight inspect the conditions of: engine,
gearbox, transmission, pipes and
hoses (exhaust - fuel - brakes), rub-
ber parts (boots, sleeves, bushes,
etc.);
❒check battery charge and fluid level
(electrolyte);
❒visual check on various drive belt con-
ditions;
❒check and replace pollen filter, if re-
quired;
❒check and replace air cleaner, if re-
quired.
ROUTINE
MAINTENANCE
Every 1,000 km or before long journeys,
check and top up if required:
❒engine coolant fluid level;
❒brake fluid level;
❒windscreen washer fluid level;
❒tyre pressure and conditions;
❒light system operation (headlights, di-
rection indicators, hazard lights, etc.);
❒windscreen wiper/washer operation
and windscreen/rear window blade
position/wear;
Every 3,000 km check and top up if re-
quired: engine oil level.
You are recommended to use FL
Selenia, products, designed and pro-
duced specifically for Fiat vehicles (see
table “Capacities” in section “Technical
specifications”).

196
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
CHECKING FLUID
fig. 1 - 100 Multijet versions
Never smoke while working
in the engine compartment;
gas and inflammable vapours may be
present, with the risk of fire.
WARNING
When topping up take care
not to confuse the various
types of fluids: they are all in-
compatible with one anoth-
er and could seriously damage the ve-
hicle.
1.Engine coolant
2.Power steering fluid
3.Windscreen washer fluid
4.Brake fluid
5.Engine oil.
F0N0099m
fig. 2 - 120 Multijet - 130 Multijet versionsF0N0100m

197
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
When topping up take care
not to confuse the various
types of fluids: they are all in-
compatible with one anoth-
er and could seriously damage the ve-
hicle.
fig. 3 - 160 Multijet versionsF0N0210m
1.Engine coolant
2.Power steering fluid
3.Windscreen washer fluid
4.Brake fluid
5.Engine oil.
Never smoke while working
in the engine compartment;
gas and inflammable vapours may be
present, with the risk of fire.
WARNING

198
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
ENGINE OIL CONSUMPTION
Max engine oil consumption is usually 400
grams every 1,000 km.
When the vehicle is new, the engine needs
to run in, therefore the engine oil con-
sumption can only be considered stabilised
after the first 5,000 - 6,000 km.
IMPORTANT The oil consumption de-
pends on driving style and the conditions
under which the vehicle is used. ENGINE OIL fig. 4-5-6
Check the oil level a few minutes (about
5) after the engine has stopped, with the
vehicle parked on level ground.
The oil level shall be included between the
MINand MAXmarks on the dipstick B.
The gap between the MINand MAX
marks corresponds to about one litre of
oil.
If the oil level is near or even below the
MINmark, add oil through the filler neck
A, until reaching the MAXmark.
Oil level shall never exceed the MAX
mark.
fig. 4 - 100 Multijet versionsF0N0101mfig. 5 - 120 - 130 Multijet versions
fig. 6 - 160 Multijet versionsF0N0102m
F0N0211m
When the engine is hot, take
care when working inside the
engine compartment to avoid burns.
Remember that when the engine is
hot, fan may cut in: danger of injury.
Scarves, ties and other loose cloth-
ing might be pulled by moving parts.
WARNING
Do not add oil with specifica-
tions other than that already
in the engine.
Used engine oil and filter con-
tain harmful substances for
the environment. Contact Fi-
at Dealership to have the oil
and filter changed, as they are
equipped to dispose of the waste oil
and filters respecting the nature and
the law.
IMPORTANT After adding or changing
the oil, let the engine turn over for a few
seconds and wait a few minutes after turn-
ing it off before you check the level.

199
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
ENGINE COOLANT fig. 7
The coolant level shall be checked with
cold engine and shall be within the MIN
and MAXmarks on the tank.
If the level is low, pour slowly a mixture
of 50% distilled water and 50%
PARAFLU UP of the FL Selenia Group
through the filler neck Auntil the level
reaches MAX.
A 50-50 mixture of PARAFLU UPand
distilled water gives freeze protection to
–35°C.
For particularly hard climate conditions, we
recommend use of a 60% PARAFLU UP
and 40% demineralized water mixture.
fig. 7F0N0103m
The engine cooling system us-
es protective antifreeze fluid
PARAFLU UP. Use the same
fluid type as that already in
the cooling system when topping up.
PARAFLU UP fluid cannot be mixed
with any other type of fluid. Should it
happen, under no circumstances start
the engine; contact a Fiat Dealership.
The cooling system is pres-
surised. If necessary, replace
the cap only with another genuine
one, otherwise system efficiency
could be compromised. Do not re-
move the reservoir cap when the en-
gine is hot: you risk scalding yourself.
WARNING