clutch FIAT DUCATO 2009 Owner handbook (in English)

REFUELLING
Only refuel with automotive diesel conforming
to the European specification EN590.
The use of other products or mixtures may
damage the engine beyond repair and
consequently invalidate the warranty depending
on the damage caused.
STARTING THE ENGINE
Make sure that the handbrake is engaged, set the
gear lever to neutral, fully depress the clutch
pedal without pressing the accelerator, then turn
the ignition key to MAR-ON and wait for the
warning lights
Yand mto go off; turn the
ignition key to AVV and release it as soon as the
engine has started.
PARKING ON FLAMMABLE MATERIAL
The catalytic converter develops high
temperatures during operation. Do not park on
grass, dry leaves, pine needles or other
flammable material: fire hazard.
RESPECTING THE ENVIRONMENT
The vehicle is fitted with a system that allows
continuous diagnosis of the emission-related
components in order to help protect the
environment.ELECTRICAL ACCESSORIES
If, after buying the vehicle, you decide to add
electrical accessories (with the risk of gradually
draining the battery), visit a Fiat Dealership. They
can calculate the overall electrical requirement
and check that the vehicle’s electrical system can
support the required load.
CODE card
Keep it in a safe place, not in the vehicle.
Make sure you have the electronic code written
on the CODE card with you at all times
.
SCHEDULED SERVICING
Correct vehicle servicing is essential for ensuring
it stays in tip-top condition and safeguards its
safety features, its environmental friendliness and
low running costs for a long time to come.
THE OWNER’S HANDBOOK CONTAINS…
...important information, advice and warnings
for correct use, driving safety and maintenance
of your vehicle over time. Pay special attention
to the symbols
"(personal safety)
#(environmental protection) !(vehicle
integrity).
VERY IMPORTANT
K


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KNOWING
YOUR CAR
SAFETY
STARTING
AND
DRIVING
WARNING
LIGHTS AND
MESSAGES
IN AN
EMERGENCY
MAINTENANCE
AND CARE
TECHNICAL
SPECIFICATIONS
INDEX
When travelling downhill with the device engaged, the
vehicle speed may slightly exceed the memorised one.
When the device is activated the warning light
Ücomes
on together with the relevant message on the
instrument panel.
STORING VEHICLE SPEED
Proceed as follows:
❒turn ring nut A toONand press the accelerator
pedal so that the vehicle reaches the desired speed;
❒move the lever upwards (+) for at least one second,
then release it. The car speed is memorised and it is
therefore possible to release the accelerator pedal.
If necessary (when overtaking for instance) acceleration
is possible by simply pressing the accelerator pedal:
releasing the accelerator pedal, the car will return to the
speed memorised previously.
RESTORING THE MEMORISED SPEED
If the device has been switched off, for example by
depressing the brake or clutch pedal, the memorised
speed can be restored as follows:
❒accelerate gradually until reaching a speed
approaching the memorised speed;
❒engage the gear selected at the time of speed
memorising;
❒press the button RES B.
F0N0040mfig. 79
CRUISE CONTROL
(for versions/markets where provided)
This is an electronic driving aid that allows you to drive
at a speed of above 30 km/h on long and straight dry
roads with few driving changes (e.g. motorways) at
a preset speed without having to press the accelerator
pedal. It is therefore not recommended to use this
device on country roads with traffic.
Do not use it in town.
DEVICE ACTIVATION fig. 79
Turn the ring nut A to the ON position.
The Cruise Control cannot be engaged in 1st or reverse
gear. It is advisable to engage it in 4
thor higher gears.
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INCREASING THE MEMORISED SPEED
This can be done in two ways:
❒by pressing the accelerator and then memorising the
new speed reached;
or
❒by moving the lever upwards (+).
Each operation of the lever will correspond to a slight
increase in speed of about 1 km/h, while keeping the
lever upwards will correspond to a continuous speed
increase.
REDUCING THE MEMORISED SPEED
This can be done in two ways:
❒by turning the device off and then storing a new
speed;
or
❒by moving the stalk downwards (–) until reaching the
new speed which will be memorised automatically.
Each movement of the lever will correspond to a slight
reduction in speed of about 1 km/h, while keeping the
lever held downwards will correspond to a continuous
speed reduction.SWITCHING THE DEVICE OFF
The device can be switched off by the driver in the
following ways:
❒turning the ring nut A to the OFFposition;
❒turning the engine off;
❒pressing the brake pedal or operating the handbrake;
❒pressing the clutch pedal;
❒requesting a gear change with an automatic gearbox
in sequential mode;
❒with vehicle speed below the set limit;
❒by pressing the accelerator pedal; in this case the
system is not really switched off but the request for
acceleration takes priority over the system. The
cruise control is, however, active and it will not be
necessary to press the RES button to restore the
previous conditions after the acceleration is over.
The device is automatically switched off in the following
cases:
❒if the ABSor ESPsystems cut in;
❒if there is a system failure.
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❒downhill: vehicle stationary on a road with a gradient
higher than 5%, engine running, clutch and brake
pedal pressed and reverse gear engaged.
At pickup the
ESPsystem control unit will maintain the
braking pressure at the wheels until the necessary torque
for starting is reached or, in any case, for a maximum of
2 seconds in order to move easily from the brake pedal
to the accelerator pedal. When two seconds have
elapsed, without starting, the system is automatically
deactivated, gradually releasing the braking pressure.
During this release stage, the typical brake
disengagement noise indicating that the vehicle is going
to move imminently will be heard.
Failure warning
The
áwarning light in the instrument panel will come
on in the event of a failure (see “Warning lights and
messages” section).
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
engaged first gear. FAILURE WARNING
In the event of a failure, the ESP will be automatically
switched off and the áwarning light will come on
constantly in the instrument panel along with a message
in the multifunction display (for versions/markets where
provided) (see “Warning lights and messages” section).
The LED in the ASR OFF button will light up. Contact
a Fiat Dealership as soon as possible if this happens.
Do not take unnecessary risks, even if
your vehicle is fitted with an ESP system.
Your driving style must always be suited to the
road conditions, visibility and traffic. The driver
is ultimately responsible for road safety.
WARNING
HILL HOLDER SYSTEM
This system is an integral part of the
ESPsystem and it is
provided to facilitate starting on hills.
It is automatically activated in the following conditions:
❒uphill: vehicle stationary on a road with a gradient
higher than 5%, engine running, clutch and brake
pedal pressed, gearbox in neutral or gear other than
reverse engaged;
For the correct operation of the ESP and
ASR systems, the tyres must absolutely be
the same make and type on all wheels, in perfect
condition and, above all, of the type, make and
size specified.
WARNING
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TECHNICAL
SPECIFICATIONS
INDEX
PROCEDURE FOR
Proceed as follows:
❒engage the handbrake;
❒put the gear lever into neutral;
❒turn the ignition key to MAR-ON: the warning lights
mand Yon the instrument 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 all the way down without
touching the accelerator;
❒turn the ignition key to AVVas soon as the warning
light
mturns off. Waiting too long will waste the
work done by the glow plugs. Release the key as
soon as the engine starts.
If the engine does not start at the first attempt, return
the ignition key to STOP before repeating starting.
STARTING THE ENGINE
The vehicle is fitted with an electronic engine lock
device: if the engine fails to start, see the paragraph
“The Fiat CODE system” in section “Dashboard and
controls”.
STARTING AND DRIVING
It is dangerous to let the engine run in
enclosed spaces. The engine consumes
the oxygen and discharges carbon dioxide,
carbon monoxide and other toxic gases.
WARNING
In the first period of use, we recommend
avoiding excessive stress on the car (for
instance excessive acceleration, extended
travel at maximum speed, sudden braking etc.).
When the engine is switched off never
leave the key into the ignition switch to
prevent useless current absorption from
draining the battery.
Remember that the brake servo and
power steering are not operational until
the engine has been started, therefore much
effort than usual is required on the brake pedal
and steering wheel.
WARNING
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F0N0074mfig. 160
USING THE MANUAL GEARBOX
To engage the gears, depress the clutch pedal fully and
shift the gear lever into the required positions (the
diagram is shown on the gear knob fig. 160).
To engage 6
thgear (where provided), operate the lever
by pressing it towards the right in order to avoid
engaging 4
thgear by mistake. The same applies to the
shift from 6thto 5thgear.
IMPORTANT Reverse may only be engaged when the
vehicle is at a standstill. With the engine running, wait
for at least 2 seconds with the clutch pedal fully pressed
before engaging reverse to prevent damage to the gears
and grating.
To engage reverse R from neutral, proceed as follows:
raise ring A under the knob and at the same time move
the gear lever to the right and then backwards.
Press the clutch pedal fully to change
gears correctly. For this reason, there
must be no obstacles on the floor under the
pedals: ensure that rubber mats (if any) are
lying flat and do not interfere with the pedals.
WARNING
Do not drive with your hand resting on
the gear lever, because this pressure, even
if light, over time can wear out the
internal gearbox components.
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TECHNICAL
SPECIFICATIONS
INDEX
Unnecessary actions
Avoid accelerating when starting at traffic lights or
before switching off the engine. The latter action, like
doubling the clutch, is unnecessary and causes increase
of consumption and pollution.
Gear selection
Use a higher gear as soon as traffic and road conditions
allow. Using a low gear for faster acceleration will increase
consumption. In the same way improper use of a high gear
increases consumption, emissions an engine wear.
Max. speed
Fuel consumption considerably increases with speed.
Keep your speed as even as possible, avoiding unnecessary
braking and acceleration, which cause excessive fuel
consumption and increased emissions.
Acceleration
Accelerating violently will greatly affect consumption and
emissions: acceleration should therefore be gradual and
should not exceed the maximum torque. Electric devices
Use electric devices only for the amount of time
needed. Rear heated window, additional headlights,
windscreen wipers and heater fan need a considerable
amount of energy, therefore increasing the requirement
of current increases fuel consumption (up to +25% in
the urban cycle).
Climate control system
The climate control system is an additional load which
greatly affects the engine leading to higher consumption
(on average up to +20%). When the temperature
outside the car permits it, use the air vents where
possible.
Devices for aerodynamic control
The use of non-certified devices for aerodynamic
control may adversely affect air drag and consumption
levels.
DRIVING STYLE
Starting
Do not warm the engine with the vehicle at a standstill or
at idle or high speed: under these conditions the engine
warms up much more slowly, increasing consumption and
emissions. It is therefore advisable to move off
immediately, slowly, avoiding high speeds. This way the
engine will warm faster.
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F0N0836mfig. 168F0N0165mfig. 169
❒use the wheel dismantling spanner to remove the
wheel from the vehicle fig. 169;
❒undo the retaining knob D-fig. 170 and release the
wheel releasing the support E.
❒turn wrench C-fig. 168 anticlockwise 1 to allow the
lowering of the spare wheel.
❒continue turning anticlockwise until the stop point,
signaled by the stiffening of the manoeuvre or a click
from the clutch present in the device.
F0N0835mfig. 167
The device should only be operated by
hand, without using any type of tool
other than the crank provided like pneumatic or
electrical screwers.
WARNING
The moving components of the jack
(screws and joints) can also cause
injuries: avoid touching them. In the event of
soiling with the lubricating grease, clean
thoroughly;
WARNING
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E
F0N0825mfig. 176
Automatic FIX&GO QUICK TYRE
REPAIR KIT
(for versions/markets where provided)
The automatic tyre Fix & Go repair kit is positioned at
the front of the vehicle passenger compartment and
includes:
❒cylinder A containing sealer and fitted with:
– a transparent filler pipe B;
– a black pressure restoring pipe E;
– an adhesive label C with the message “max.
80 km/h” to be applied in a position clearly visible
by the driver (on the dashboard) after repairing
the tyre;
❒instruction brochure (see fig. 177), to be used for
prompt and proper use of the quick repair kit and
then to be handed to the personnel charged with
handling the treated tyre;
Each time the spare wheel is moved,
check that it is correctly positioned in its
housing under the floor. If it is not correctly
positioned, this could adversely affect safety.
WARNING
❒introduce the supplied wrench C-fig. 168 with the
suitable extension B-fig. 167 on the screw A-fig. 167
of the spare wheel housing manoeuvring device and
turn clockwise 2 to lift the spare wheel back up until
it is fully supported in its housing beneath the floor
pan, checking that the attachment reference
D-fig. 168 appears in the window on the device.
❒Check the correct position of the replaced wheel
under the floor (the lifting system is supplied with
a clutch to limit the end of the stroke). Incorrect
positioning may jeopardise safety.
❒place the removal spanner back in the tool box;
❒place the tool box in its housing under the passenger
seat.
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Mac Pherson independent wheels
Rigid rear axle with tubular axle; longitudinal leaf spring
Self-adjusting pedal without idle stroke
Front
Modifications or repairs to the fuel
supply 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.
POWER SUPPLY
Supply system
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TECHNICAL
SPECIFICATIONS
INDEX
WARNING
Five forward gears plus reverse
with synchronisers for
forward gearsSix forward gears plus reverse
with synchronisers for
forward gears
Common Rail
direct injection
TRANSMISSION
100 Multijet 120 Multijet – 130 Multijet – 160 Multijet
Gearbox
Clutch
Traction
SUSPENSION
front
Rear
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