engine FIAT DUCATO 2009 3.G Manual PDF

197
WARNING
LIGHTS AND
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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

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WARNING
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TECHNICAL
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INDEX
DASHBOARD
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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
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TECHNICAL
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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

Prevent brake fluid, which is
highly corrosive, from coming
into contact with painted
parts. Should it happen, im-
mediately wash with water.
200
WARNING
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TECHNICAL
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INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
At plug opening, pay maximum attention
in order to prevent any impurities from
entering the tank.
For topping up, always use a funnel with
integrated filter with mesh equal to or
lower than 0.12 mm.
IMPORTANT Brake fluid absorbs mois-
ture, for this reason, if the vehicle is main-
ly used in areas with a high degree of at-
mospheric humidity, the fluid should be
replaced at more frequent intervals than
specified in the “Service schedule”.
fig. 9F0N0107m
Do not travel with the wind-
screen washer reservoir emp-
ty: the windscreen washer is funda-
mental for improving visibility.
WARNING
Certain commercial addi-
tives for windscreen washers
are inflammable. The engine com-
partment contains hot components
which may set it on fire.
WARNING
WINDSCREEN/REAR WINDOW
WASHER FLUID/
HEADLIGHT WASHERS fig. 8
To top up, remove the cap A.
Pour a mixture of water and TUTELA
PROFESSIONAL SC35, in the follow-
ing concentrations:
30% TUTELA PROFESSIONAL
SC35and 70% water in summer.
50% TUTELA PROFESSIONAL
SC35and 50% water in winter.
In case of temperatures below –20°C, use
undiluted TUTELA PROFESSIONAL
SC35fluid.
Check level through the reservoir.
fig. 8F0N0105m
BRAKE FLUID fig. 9
Unscrew cap A: check that the fluid level
in the reservoir is at maximum.
Fluid level in the reservoir shall not exceed
the MAXmark.
If fluid has to be added, it is suggested to
use the brake fluid in table "Fluids and lu-
bricants" (see chapter "Technical charac-
teristics").
NOTE Clean accurately the tank cap A
and the surrounding surface.

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DASHBOARD
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CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
Brake fluid is poisonous and
highly corrosive. In the event
of accidental contact, wash the parts
involved immediately with neutral
soap and water, then rinse thor-
oughly. Call the doctor immediately
if the fluid is swallowed.
WARNING
The symbol πon the con-
tainer indicates synthetic
brake fluid, distinguishing it from the
mineral kind. Using mineral fluids ir-
reversibly damages the special brak-
ing system rubber seals.
WARNING
POWER STEERING
FLUID fig. 10
Check whether the fluid level in the tank
is at max. level. This operation should be
carried out with the vehicle on level
ground, engine not running and cold.
Check whether the fluid level is at MAX
mark on the dipstick integral with the tank
cap (for cold check use the level shown
on the 20 °C side on the dipstick).If the fluid level in the reservoir is below
the specified level, top up with one of the
products specified in table “Fluids and lu-
bricants” in section “Technical Specifica-
tions”, proceed as follows:
❒Start the engine and wait until the flu-
id level in the reservoir has stabilized.
❒With the engine started, turn repeat-
edly the steering wheel fully right-
wards and leftwards.
❒Top up until reaching the MAXmark
then refit the cap.
fig. 10F0N0109m
Do not allow the power
steering fluid to touch the
hot parts of the engine: it is inflam-
mable.
WARNING
Do not press down the pow-
er steering with the engine
running for over 8 seconds,
noise and risk of damages will
result.
Power steering fluid con-
sumption is extremely low. If
the fluid level needs topping
up again after a short period
of time, have the system checked for
leakage at a Fiat Dealership.
AIR CLEANER
Air cleaner replacement shall be carried
out at Fiat Dealership.
AIR FILTER – DUSTY ROADS
(where necessary)
The air filter specific for dusty areas is
equipped with a visual blockage signalling
device A-fig. 11. It is therefore necessary
to periodically check the blockage sensor
indicator (Please refer to the “Pro-
grammed Maintenance Plan” shown in the
Chapter “Maintenance and care”)

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TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
ATTENTION: Use a jet of air so as to
clean the air filter, do not use water or liq-
uid detergents.
Such filter is specific for the versions suit-
able for dusty areas; therefore it is advis-
able to seek help from the Fiat Assistance
Network for the substitution of the filter.
POLLEN FILTER
Pollen filter replacement shall be carried
out at Fiat Dealership.
BATTERY
The battery is of the “Limited mainte-
nance” type: under normal conditions of
use the electrolyte does not need topping
up with distilled water.
The battery is located inside the passen-
ger’s compartment in front of the pedal as-
sy. Remove the protection cover to find it.
Contact Fiat Dealership to have the bat-
tery checked/replaced.
CHECKING
THE CHARGE fig. 12
The battery charge may be checked
through the indicator A(where required)
set on the battery cover and acting ac-
cording to the colour the indicator shows.
The liquid in the battery is
poisonous and corrosive.
Avoid contact with eyes and skin. Do
not bring naked flames or possible
sources of sparks near the battery:
risk of fire and explosion.
WARNING
Running the battery with
low fluid level can damage
the battery beyond repair and could
also cause its explosion.
WARNING
Should the battery be not fitted with bat-
tery charge inspection device (optical elec-
trolyte indicator), inspection operations
shall be carried out by skilled personnel
only.
To check the battery charge, loosen the
two fastening screws and open the cov-
er. Then, close the cover accurately avoid-
ing pinching and short circuits.
Refer to the table below.
Upon reaching the calibration value, the
indicator is activated B-fig. 11aand it
switches to the red light position, even
when the engine is switched off. In order
to reset the signalling device, proceed with
the cleaning/substitution of the cartridge
as with normal equipment and reset the
indicator by pressing button C-fig. 11a.
fig. 11F0N0253m
fig. 11aF0N0254m

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WARNING
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TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
❒do not keep accessories (e.g.: sound
system, hazard lights, etc.) switched on
for a long time when the engine is not
running;
❒before performing any operation on
the electrical system, disconnect the
battery negative cable;
❒battery terminals shall always be per-
fectly tightened.
IMPORTANT A battery which is kept at
a charge of less than 50% (optical indica-
tor with dark colour without green area
in the middle) for any length of time will
be damaged by sulphation leading to a re-
duction in cranking power.
Moreover, this might lead to a higher risk
of the battery electrolyte freezing (this
may even occur at –10° C). If the vehicle
is inactive for a long period of time, refer
to “Vehicle inactivity”, in section “Correct
use of the vehicle”. USEFUL ADVICE FOR
LENGTHENING THE LIFE OF
YOUR BATTERY
To avoid draining your battery and length-
en its life, observe the following indica-
tions:
❒when you park the vehicle, ensure the
doors are closed properly. The ceiling
lights must be off;
❒turn the ceiling lights off. The vehicle
however, is provided with an auto-
matic system for switching off internal
lights;
When working on the bat-
tery or near it, always wear
the proper goggles.
WARNINGIf after buying the vehicle, you want to in-
stall electric accessories which require
permanent electric supply (alarm, etc.)
contact Fiat Dealership whose qualified
personnel, in addition to suggesting the
most suitable devices, will evaluate the
overall electric absorption, checking
whether the vehicle’s electric system is ca-
pable of withstanding the load required,
or whether it should be integrated with
a more powerful battery.
In fact, since these devices continue ab-
sorbing energy even when the ignition key
is off, they gradually run down the battery.

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DASHBOARD
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CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEICHLE
MAINTENANCE
BODY AND UNDERBODY
WARRANTY
Your vehicle is covered by warranty
against perforation due to rust of any orig-
inal element of the structure or body.
For the general terms of this warranty, re-
fer to Fiat Warranty Booklet.
ADVICE FOR PRESERVING THE
BODYWORK
Paint
Paintwork does not only serve an aesteth-
ic purpose, but also protects the under-
lying sheet metal.
In the case of deep scrapes or scores, you
are advised to have the necessary touching
up carried out immediately to avoid the for-
mation of rust. For touching up use only
original products (see “Bodywork paint
identification plate” in section “Technical
specifications”).
Normal paint maintenance consists in
washing at intervals depending on the con-
ditions and environment of use. For exam-
ple, in highly polluted areas, or if the roads
are sprayed with salt, it is wise to wash the
vehicle more frequently. These include:
❒Painting products and systems which
give the vehicle particular resistance
to corrosion and abrasion;
❒Use of galvanised (or pretreated)
steel sheets, with high resistance to
corrosion;
❒Spraying the underbody, engine com-
partment, wheelhouse internal parts
and other parts with highly protective
wax products;
❒Spraying of plastic parts, with a pro-
tective function, in the more exposed
points: underdoor, inner fender parts,
edges, etc;
❒Use of “open” boxed sections to pre-
vent condensation and pockets of
moisture from triggering rust inside.
BODYWORK
PROTECTION FROM
ATMOSPHERIC AGENTS
The main causes of corrosion are the fol-
lowing:
❒atmospheric pollution;
❒salty air and humidity (coastal areas,
or hot humid climates);
❒seasonal environment conditions.
Not to be underestimated is also the abra-
sive action of wind-borne atmospheric
dust and sand and mud and gravel raised
by other vehicles.
On your vehicle, Fiat implemented the
best manufacturing technologies to effec-
tively protect the bodywork against cor-
rosion.

209
WARNING
LIGHTS AND
MESSAGES
TECHNICAL
SPECIFICATIONS
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
To correctly wash the vehicle:
❒remove the aerial from the roof to
prevent damage to it if the vehicle is
washed in an automatic system;
❒wash the body using a low pressure jet
of water;
❒wipe a sponge with a slightly soapy so-
lution over the bodywork, frequently
rinsing with the sponge;
❒rinse well with water and dry with a
jet of air or a chamois leather.
When drying, take particular care with the
less visible parts like door surrounds, bon-
net and around the headlights where wa-
ter may stagnate. The vehicle should not
be taken to a closed area immediately, but
left in the open so that residual water can
evaporate.Do not wash the vehicle after it has been
left in the sun or with the bonnet hot: this
may alter the shine of the paintwork.
Exterior plastic parts must be cleaned in
the same way as the rest of the vehicle.
Where possible, do not park under trees;
the resinous substance many species re-
lease give the paint a dull appearance and
increase the possibility of triggering rust
processes.
For best paint protection, from time to
time polish the bodywork with special
waxes; when paint becomes mat due to
smog, polish the bodywork with polish
waxes that have also a light abrasive effect.
IMPORTANT Bird droppings must be
washed off immediately and thoroughly as
the acid they contain is particularly ag-
gressive.
Detergents cause water pollu-
tion. Therefore the engine
compartment should be
washed in areas equipped for
collecting and purifying the liquid used
in the washing process.
Windows
Use specific window cleaner products.
Use also clean cloths to avoid scratching
the glass or damaging the transparency.
IMPORTANT The inside of the rearscreen
should be wiped gently with a cloth in the
direction of the filaments to avoid damag-
ing the heating device.
Engine compartment
At the end of the winter the engine com-
partment should be carefully washed,
without directing the jet against electron-
ic control units. Contact a specialised
workshop to have this done.
IMPORTANT The vehicle should be
washed with the engine cold and the ig-
nition key at STOP. After washing make
sure that the various protections (e.g. rub-
ber caps and various covers) have not
been damaged or removed.
Front headlights
IMPORTANT Never use aromatic sub-
stances (e.g.: petrol) or ketones (e.g.: ace-
tone) for cleaning front headlight plastic
lens.

211
WARNING
LIGHTS AND
MESSAGES
INDEX
DASHBOARD
AND CONTROLS
SAFETY
DEVICES
CORRECT USE
OF THE
VEHICLE
IN AN
EMERGENCY
VEHICLE
MAINTENANCE
TECHNICAL
SPECIFICATIONS
IDENTIFICATION DATA ................................................. 212
ENGINE CODES - BODYWORK VERSIONS .............. 214
ENGINE .................................................................................. 216
FUEL FEED ............................................................................. 217
TRANSMISSION .................................................................. 217
BRAKES................................................................................... 218
SUSPENSIONS....................................................................... 218
STEERING............................................................................... 218
WHEELS.................................................................................. 219
DIMENSIONS......................................................................... 223
PERFORMANCE................................................................... 229
WEIGHTS............................................................................... 230
CAPACITIES .......................................................................... 261
FLUIDS AND LUBRICANTS.............................................. 262
FUEL CONSUMPTION....................................................... 264
CO
2EMISSIONS .................................................................. 265
RADIO FREQUENCY REMOTE CONTROL:
MINISTERIAL CERTIFICATIONS .................................... 266
TT T
E E
C C
H H
N N
I I
C C
A A
L L
S S
P P
E E
C C
I I
F F
I I
C C
A A
T T
I I
O O
N N
S S