engine FIAT DUCATO 2009 3.G Workshop Manual

150
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
WARNING
LIGHTS AND
MESSAGES
ç
FUEL RESERVE
(amber)
Turning the ignition key to
MARthe warning light turns on, but it
should go off after few seconds.
The warning light turns on when about
10/12 litres fuel (according to versions) are
left in the tank.
IMPORTANT The warning light flashes to
indicate a failure, contact Fiat Dealership
as soon as possible to have the system
checked. INJECTION SYSTEM
FAILURE
(amber)
Under normal conditions, turning
the ignition key to MAR, the warning light
turns on but it should go off after engine
starting.
If the warning light stays on or turns on
when travelling, means a fault in the sup-
ply/ignition system which could cause high
emissions at the exhaust, possible lack of
performance, poor handling and high con-
sumption levels.
On certain versions the dedicated message
is displayed.
In these conditions it is possible to con-
tinue driving without however requiring
heavy effort or high speed from the en-
gine. In any case, contact Fiat Dealership
as soon as possible.
U
INEFFICIENT ABS
SYSTEM (amber)
Turning the ignition key to
MARthe warning light turns on, but it
should go off after few seconds.
The warning light turns on when the sys-
tem is inefficient or unavailable. In this case
the braking system keeps its effectiveness
unchanged, but without the potential of-
fered by the ABS system. Caution is ad-
visable and it is necessary to contact Fiat
Dealership.
On certain versions the dedicated message
is displayed.
>F
FRONT PASSENGER’S
AIR BAG
DEACTIVATED
(amber)
(where provided)
Warning light Fcomes on when front
passenger’s air bag is deactivated.
With front passenger’s air bag on, turn-
ing the ignition key to MAR, warning light
Fcomes on steadily for about 4 sec-
onds, it flashes for other 4 seconds and
then it shall go off.
Warning light Findicates
also warning light ¬failures.
This is indicated by intermittent flash-
ing, over 4 seconds, of warning light
F. In this event warning light ¬
indicates that there could be a failure
in safety systems. Contact Fiat Deal-
ership immediately to have the sys-
tem checked.
WARNING

151
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
WARNING
LIGHTS AND
MESSAGES
GLOW PLUG
WARMING
(Multijet versions -
amber)
GLOW PLUG
WARMING FAILURE
(Multijet versions -
amber)
Glow plug warming
Turning the ignition key to MAR, the
warning light turns on and it will turn off
when glow plugs reach the preset tem-
perature. Start the engine immediately af-
ter warning light switching off.
IMPORTANT With hot ambient temper-
ature, warning light stays on for very short
time.
Glow plug warming failure
The warning light turns on when there is
a failure in the glow plug warming system.
Contact Fiat Dealership as soon as possi-
ble.
On certain versions the dedicated message
is displayed.
m
WATER IN DIESEL
FUEL FILTER
(Multijet versions - amber)
Turning the ignition key to MARthe
warning light turns on, but it should go off
after few seconds.
The warning light turns on when there is
water in the diesel fuel filter.
On certain versions the dedicated message
is displayed.
c
The presence of water in the
fuel circuit may cause serious
damage to the entire injec-
tion system and cause irreg-
ular engine operation. If the warning
light cturns on (on certain versions to-
gether with the message on the display)
contact Fiat Dealership as soon as pos-
sible to have the system relieved. If the
above indications come on immedi-
ately after refuelling, water has prob-
ably been poured into the tank: turn
the engine off immediately and contact
Fiat Dealership.
VEHICLE PROTECTION
SYSTEM FAILURE -
FIAT CODE
(amber)
Turning the key to MARthe warning light
shall flash only once and then go off.
The warning light turned on glowing
steadily with key at MAR, indicates:
❒possible failure (see” Fiat Code sys-
tem” in section “Dashboard and con-
trols”);
❒possible attempt to break-in with
alarm on; in this case the warning light
will turn off after about 10 seconds.
If with the engine running the warning light
Yflashes, this means that the vehicle is
not protected by the engine inhibitor de-
vice (see “Fiat Code system” in section
“Dashboard and controls”).
Contact Fiat Dealership to have all the key
memorised.
Y

152
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
WARNING
LIGHTS AND
MESSAGES
GENERIC FAILURE
INDICATION
(amber)
The warning light turns on in the follow-
ing circumstances.
Engine oil pressure
sensor failure
The warning light comes on when the en-
gine oil pressure sensor is faulty. Contact
Fiat Dealership as soon as possible.
Inertial fuel cut-off switch
intervened
The warning light comes on when the in-
ertial fuel cut-off switch is triggered.
The display will show the dedicated mes-
sage.
è
EXTERNAL LIGHT
FAILURE (amber)
The warning light turns on
when one of the following lights
is failing:
– sidelights
– brake lights
– rear fog guards
– direction indicators.
The failure referring to these lights could
be: one or more blown bulbs, a blown
protection fuse or an electric connection
cut-off.
On certain versions the dedicated message
is displayed.
W
REAR FOG LIGHTS
(amber)
The warning light turns on
when the rear fog lights are turned on.
4
Rain sensor failure
(versions with multifunction
display)
The warning light on the dial turns on
when the rain sensor is faulty. Contact Fi-
at Dealership.
The display will show the dedicated mes-
sage.
Parking sensor failure
(versions with multifunction
display)
See what described for warning light
t.

157
WARNING
LIGHTS AND
MESSAGES
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
ENGINE STARTING ........................................................... 158
IF A TYRE IS PUNCTURED............................................... 159
QUICK TYRE REPAIR KIT
FIX & GO automatic ........................................................... 163
WHEN NEEDING TO CHANGE A BULB ................... 168
IF AN EXTERIOR LIGHT BURNS OUT.......................... 170
IF AN INTERIOR LIGHT BURNS OUT.......................... 176
IF A FUSE BLOWS................................................................ 177
IF THE BATTERY IS FLAT .................................................. 185
JACKING THE VEHICLE ................................................... 186
TOWING THE VEHICLE ................................................... 186
II 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
In an emergency we recommend that you call the toll-free number found on the
Warranty Booklet. You can also connect to the site www.fiat.com
to search for the nearest Fiat Dealership point

158
WARNING
LIGHTS AND
MESSAGES
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
IINDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
ENGINE
STARTING
EMERGENCY START-UP
If the instrument panel warning light
Yturns on glowing steadily, contact im-
mediately Fiat Dealership.
JUMP STARTING fig. 1-2
If the battery is flat, it is possible to start
the engine using an auxiliary battery with
the same capacity or a little higher than
the flat one.
Contact Fiat Dealership to have the bat-
tery checked/replaced.Proceed as follows:
❒lift the lid Ato connect to the battery
positive terminal fig. 1.
❒connect positive terminals (+near
the terminal) of the two batteries
with a jump lead;
❒connect with a second cable the nega-
tive terminal (–) of the auxiliary battery
to the ground point as shown in fig. 2;
❒start the engine;
❒when the engine has been started, re-
move the leads reversing the order
above.
If after a few attempts the engine does not
start, do not insist but contact the near-
est Fiat Dealership.
fig. 1F0N0075m
The starting procedure must
be carried out by qualified
personnel because incorrect opera-
tions may cause electrical discharge of
considerable intensity. The liquid con-
tained in the battery is poisonous and
corrosive. Avoid contact with the skin
and eyes. Keep naked flames and light-
ed cigarettes away from the battery
and do not cause sparks.
WARNING
fig. 2F0N0076m

159
WARNING
LIGHTS AND
MESSAGES
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
IMPORTANT Never connect the negative
terminals of the two batteries directly:
sparks could ignite explosive gas released
from the battery. If the auxiliary battery is
installed on another vehicle, avoid any
metal parts on the latter and the vehicle
with the flat battery from accidentally
coming into contact.
BUMP STARTING
Never jump start the engine by pushing,
towing or driving downhill. This could
cause a flow of fuel into the catalytic con-
verter and damage it beyond repair.
IMPORTANT Remember that the brake
servo and the power steering system are
not activated until the engine is started, a
greater effort will therefore be required
to press the brake pedal or turn the steer-
ing wheel.CHANGING
A WHEEL
GENERAL INSTRUCTIONS
To chage a wheel and the use the jack and
spare wheel correctly, observe some of
the precautions listed below.
Signal that the vehicle is sta-
tionary in accordance with
the following legal requirements:
hazard warning lights, emergency
warning triangle, etc. It is advisable
for the people in the vehicle to get
out, especially if the vehicle is heavi-
ly laden, and wait until the repair is
carried out, well away from any dan-
gerous traffic. Apply the handbrake
WARNING
The spare wheel is specific
for your vehicle. Therefore,
it must not be used on vehicles of a
different model. Do not use spare
wheels of different models on your ve-
hicle. The wheel bolts are specific for
your vehicle. Do not use them on ve-
hicles of different models. Do not use
bolts of different models on your ve-
hicle.
WARNING
Repair and refit the wheel
changed as soon as possible.
Do not apply grease to the bolt
threads before assembly: the bolts
could come loose unexpectedly.
WARNING

160
WARNING
LIGHTS AND
MESSAGES
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
IINDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
To change a wheel proceed
as follows:
❒stop the vehicle in a position where
it does not present a danger for on-
coming traffic and where you can
change the wheel safely. The ground
must be flat and compact;
❒turn the engine off and apply the hand-
brake;
❒engage first gear or reverse;
❒wear a high visibility safety jacket
(compulsory by law in certain coun-
tries) before getting out of the vehicle;
❒indicate that the vehicle has broken
down using the devices required by
the law of the country (e.g. warning
triangle, hazard lights etc.);
❒take the extension and the wrench
from the tool kit under the passenger
seat (see “Compartment under front
passenger seat” in the “Dashboard and
Controls” section);
The jack may only be used to
change wheels which come
with the vehicle or from other vehi-
cles of the same model. Never use the
jack for other purposes, such as lift-
ing other models of vehicle. Never use
the jack to carry out repairs under the
vehicle. Incorrect positioning of the
jack may cause the lifted vehicle to
fall. Do not use the jack for loads
higher than those shown on the label.
WARNING
Never tamper with the in-
flation valve. Never intro-
duce tools of any kind between the
rim and the tyre. Check the tyre and
spare wheel pressure regularly refer-
ring to the values shown in the “Tech-
nical Specifications” chapter.
WARNING
Important notes:
❒the jack weighs 4.5 kg;
❒the jack requires no adjustment;
❒the jack cannot be repaired: replace
with an original spare part if damaged;
❒no tool other than the cranking device
may be fitted on the jack.
fig. 3F0N0193m
No tools other than the
crank provided should be
used with the spare wheel lifting de-
vice; it should be operated by hand,
only.
WARNING

166
WARNING
LIGHTS AND
MESSAGES
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
IINDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
❒insert the pin E-fig. 14in the near-
est 12V current socket and start the
engine. Turn the selector D-fig. 13
anti-clockwise to the repair position.
Activate the kit by pressing the
on/off switch. Inflate the tyre to the
pressure specified in the “Inflation
pressure” paragraph, in the “Technical
Data” chapter.For a more accurate reading, it is
advisable to check the pressure
reading on the pressure gauge F-
fig. 13with the compressor off and
without moving the centre selector
from the repair position;
❒if a pressure of at least 3 bar is not
reached within 10 minutes, detach
the transparent filler pipe from the
valve and switch off the 12V current
pin, then move the vehicle about 10
metres forward to distribute the
sealant liquid inside the tyre and
repeat the inflation operation;
❒if, in this case too, within 10 minutes
of turning the compressor on, a
pressure of at least 3 bar is not
reached, do not start driving again
because the tyre is too damaged and
the quick repair kit is not sufficient in
this situation and it is necessary to
go to a Fiat Dealership;
❒if the tyre reaches the pressure spec-
ified in “Inflation pressure” pressure
in the “Technical Data” chapter,
start driving immediately;
fig. 13F0N0827m
fig. 14F0N0182m
Apply the adhesive label in a
position clearly visible by the
driver as a reminder that the tyre has
been treated with the quick repair
kit. Drive carefully, particularly on
bends. Do not exceed 80 km/h. Do
not accelerate or brake suddenly.
WARNING
❒after driving for about 10 minutes,
stop and check the tyre pressure
again; remember to engage the
handbrake;
❒if, on the other hand, a pressure of at
least 3 bar is reached, restore the cor-
rect pressure recommended in the
“Tyre inflation” paragraph in the
“Technical Data” chapter (with engine
running and handbrake on) and
resume driving;
Stop if the pressure has
dropped to less than 3 bar:
The automatic Fix & Go fast repair
kit cannot work properly if the tyre
is excessively damaged. Go to a Fiat
Dealership.
WARNING

167
WARNING
LIGHTS AND
MESSAGES
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
❒drive with the utmost care to the
nearest Fiat Dealership.
FOR CHECKING AND
RESTORING PRESSURE ONLY
The compressor may also be used for
restoring pressure only.
❒Engage the handbrake
❒Undo the cap for the tyre valve, extract
the black pipe and tighten the ring nut
on the tyre valve.
❒Insert the pin in the nearest 12V cur-
rent socket and start the engine.
❒Rotate the selector clockwise to the
pressure renewal position.
❒Activate the kit by pressing the
on/off switch. Inflate the tyre to the
pressure specified in the “Inflation
pressure” paragraph, in the
“Technical Data” chapter.
NOTE If the tyre has to be deflated,
press the dedicated button Billustrated
in fig. 16.
For a more accurate reading, it is advis-
able to check the pressure reading on the
pressure gauge with the compressor off
and without moving the centre selector
from the repair position.CANISTER REPLACEMENT
PROCEDURE
To replace the canister, proceed as fol-
lows:
❒push button A-fig. 17to release the
replacement part;
❒fit the new cansiter and press until it
is automatically engaged.
❒fit the new cylinder and turn it
clockwise;
❒fit connection Aand connect tube
Binto its seat.
Remember to inform the
workshop that the tyre has
been treated with a quick repair kit.
Hand the leaflet over to the staff
who will be dealing the the tyre
treated using the tyre repair kit.
WARNING
If different tyres from the
ones supplied with the vehi-
cle are used, the repair cannot be
carried out. If the tyres are being
changed, it is advisable to used ones
approved by the manufacturer.
Consult a Fiat Dealership.
WARNING
fig. 16
B
F0N0830m
fig. 17F0N0829m
fig. 15F0N0828m

178
WARNING
LIGHTS AND
MESSAGES
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
IINDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
FUSE LOCATION
Fuses are grouped into three fuse boxes
to be found respectively on the dashboard,
on the passenger compartment right pil-
lar and in the engine compartment.
Fuse box on the
dashboard
To gain access to the fuses in the fuse box
on the dashboard, loosen the fastening
screws A-fig. 39and remove the cover.
fig. 40F0N0096m
fig. 39F0N0095m