High FIAT DUCATO 2014 3.G Service Manual

BUMP STARTING
Never bump start the engine by
pushing, towing or driving downhill.
This could cause fuel to flow into the
catalytic converter and damage it
beyond repair.
WARNING
136) This procedure must be
performed by qualified personnel
as incorrect actions may cause
high-intensity electrical discharge.
Furthermore, battery fluid is
poisonous and corrosive: avoid
contact with skin and eyes. Keep
naked flames and lighted
cigarettes away from the battery
and do not cause sparks.
REPLACING A
WHEELGENERAL
INSTRUCTIONS
Wheel replacement and correct use of
the jack and spare wheel (for
versions/markets, where provided) call
for some precautions, which are listed
below.
137) 138) 139) 140) 141)
Please note that:
❒the jack weight is 4.5 kg;
❒the jack requires no adjustment;
❒the jack cannot be repaired: in the
event of a fault it must be replaced by
another original one;
❒no tool other than its cranking device
may be fitted on the jack.
142)
To change a wheel,
proceed as follows:
❒stop the vehicle in a position that is
not dangerous for oncoming traffic
where you can change the wheel
safely. The ground should be flat
if possible, and sufficiently firm;
❒stop the engine and pull the
handbrake;
❒engage first gear or reverse;
❒put on the reflective safety jacket
(compulsory by law in certain
countries) before getting out of the
vehicle;
❒indicate that the vehicle has broken
down using the devices required by
the law in the current country (e.g.
warning triangle, hazard lights, etc.);
❒take the extension arm and the
wrench from the tool box/bag under
the passenger seat (see
“Compartment under front passenger
seat” in the “Know your vehicle”
section);
❒for versions with alloy rims, remove
the press-fitted hub cap;
❒loosen the bolts on the wheel to be
replaced by one turn;
❒turn the ring nut to partly extend the
jack;
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191

138) The spare wheel supplied (for
versions/markets, where
provided) is specific for your
vehicle. Therefore, it must not be
used on other models. Do not
use spare wheels of other models
on your vehicle. The wheel bolts
are specific for your vehicle: do
not use them on different models
and do not use bolts from other
models on your car.
139) Have the wheel repaired and
refitted as soon as possible. Do
not apply grease to the bolt
threads before fitting: they could
come unscrewed.
140) Use the jack only to replace
wheels on the vehicle with which
it is supplied or on other vehicles
of the same model. Never use
the jack for other purposes, such
as lifting other car models. 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.
141) Never tamper with the inflation
valve. Never introduce tools of any
kind between rim and tyre. Check
tyre and spare wheel pressure
regularly, referring to the values
shown in the "Technical
specifications" section.142) No tools other than the crank
provided should be used with
the spare wheel lifting device; it
should be operated by hand only.
143) On versions equipped with
self-levelling air suspension, never
introduce the head or hands in
the wheel arch: the vehicle could
raise or lower automatically
depending on possible load or
temperature changes.
144) The device should only be
operated by hand, without using
any type of tool other than the
crank provided, like pneumatic or
electrical screwers.
145) The moving components of the
jack (screw and joints) can also
cause injuries: do not touch them.
If you come into contact with
lubricating grease, clean yourself
thoroughly.146) At the end of the operation of
raising/locking the spare wheel,
after having checked the correct
positioning of the wheel under the
platform (white notch inside the
window on the device), the key
must be extracted, taking care not
to turn it in the wrong direction
to facilitate the extraction of the
key itself, to prevent the
attachment device from being
released and the wheel assembly
not being securely retained fig.
188.
147) Each time the spare wheel is
moved, check that it is correctly
positioned in its housing under
the platform. If it is not correctly
positioned, this could adversely
affect safety.
195

Right central pillar optional fuse
box
(for versions/markets, where provided)
To gain access to the fuse box fig.
229, remove the protective cover fig.
228.
IMPORTANT
45) Never replace a blown fuse with
metal wires or other material.
WARNING
160) Never replace a fuse with
another with a higher amp rating;
DANGER OF FIRE. If a general
protection fuse (MEGA-FUSE,
MIDI-FUSE) is activated, contact a
Fiat Dealership.161) Before replacing a fuse, make
sure that the ignition key has
been removed and that all the
other services are switched off
and/or disengaged.
162) If the replaced fuse blows
again, contact a Fiat Dealership.
163) If a general protection fuse for
safety systems (airbag system,
braking system), power unit
systems (engine system,
transmission system) or steering
system blows, contact a Fiat
Dealership.
228
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229
F1A0218
214
IN AN EMERGENCY

Engine compartment fuse box
fig. 226 - fig. 227DEVICE PROTECTED FUSE AMPEREIgnition switch (+battery) F03 30
Heated filterF04 40
Vaporiser for Puma engine/Passenger compartment ventilation with Webasto,
robotised gearbox pump (+battery)F05 20/50
Engine cooling high speed fan (+battery) F06 40/60
Engine cooling low speed fan (+battery) F07 40/50/60
Passenger compartment fan (+key) F08 40
Rear power socket (+battery) F09 15
HornF10 15
Power socket (+battery) F14 15
Cigar lighter (+battery) F15 15
Powertrain Control Module, robotised gearbox control unit (+battery) F18 7,5
Air conditioning compressor F19 7,5
Windscreen wiper F20 30
Auxiliary control panel for mirror movement and folding (+key) F24 7,5
Mirrors demisting F30 15
217

The front ring is located in the tool box
beneath the passenger side seat. On
versions with Fix&Go kit and without
spare wheel, the tool box is available
only on request for versions/markets
where provided.
In the absence of the tool box the
vehicle front tow hook is housed in the
on-board documentation container,
together with the Owner Handbook.To use it, proceed as follows:
❒Open the flap A and remove it as
illustrated in fig. 232;
❒turn retaining knob B fig. 232
anticlockwise and remove it to allow
the box fig. 233 to come out;
❒take the screwdriver provided from
the box and prise up at the point
shown to raise the cap C fig. 235;
❒take the tow ring D from the box and
screw it onto the threaded pin fig.
235.
The rear ring B fig. 236 is located at the
point shown in the diagram.
WARNING
166) Screw on the tow hook and
check that it stops at the end
of travel position.
167) Before towing, switch off the
steering lock (see "Starting
device" paragraph under the
"Knowing your car" section).
168) Remember that the brake servo
and the electric power steering
are not available during towing
operations. Significantly greater
force must be exerted on the
brake pedal and on the steering
wheel to operate them.
169) Do not use flexible cables for
towing and avoid jerking. During
towing operations, make sure that
the fastened joint does not
damage adjoining components.
170) When towing the vehicle
comply with the specific rules of
the Highway Code regarding
the towing device and the
behaviour on the road.
171) Do not start the engine while
towing the vehicle.
234
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235
F1A0223
236
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221

To close the cap, operate as follows:
❒push the funnel fully until it locks;
❒close the cap.
180)
BRAKE FLUID
181) 182)49)
Undo the cap E fig. 237 - fig. 238 - fig.
239 and check that the liquid contained
in the reservoir is at the maximum
level.
The fluid level in the reservoir must not
exceed the MAX mark.
Use the brake fluid shown in the "Fluids
and lubricants" table (see "Technical
Specifications").
NOTE Carefully clean the cap of the
reservoir and the surrounding surface.
Take great care to ensure that
impurities do not enter the reservoir
when the plug is opened.
For topping-up, always use a funnel
with integrated filter with mesh equal to
or lower than 0.12 mm.
IMPORTANT Brake fluid absorbs
moisture. For this reason, if the vehicle
is mainly used in areas with a high
degree of atmospheric humidity, the
fluid should be replaced at more
frequent intervals than specified in the
“Scheduled Servicing Plan”.
IMPORTANT
46) When topping up, take care not
to mix up the various types of
fluids: they are not compatible
with each other and could
seriously damage the car.
47) The used engine oil and the filter
that has been replaced contain
substances that are harmful to
the environment. To change the
oil and filters, we advise you to
contact a Fiat Dealership.
48) PARAFLU
UP
antifreeze is used in
the engine cooling system. Use
fluid of the same type as that
contained in the cooling system
for any top-ups. PARAFLU
UP
cannot be mixed with any other
type of fluid. If this happens, do
not start the engine and contact a
Fiat Dealership.
49) Avoid allowing brake fluid, which
is extremely corrosive, to come
into contact with painted areas.
Should it happen, wash
immediately with water.
241
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SERVICING AND MAINTENANCE

50) Do not press the power steering
end of travel lock for longer than 8
consecutive seconds with the
engine running because it will
cause noise and risk damaging
the system.
WARNING
175) Never smoke when performing
operations in the engine
compartment. Flammable gases
and fumes may be present and
risk igniting.
176) Be very careful when working in
the engine compartment when
the engine is hot: you may get
burned. Remember that the fan
may start up if the engine is hot:
this could injure you. Scarves, ties
and other loose clothing might
be pulled by moving parts.
177) The cooling system is
pressurised. If necessary, only
replace the plug with another
original one or the operation of
the system may be adversely
affected. Do not remove the
reservoir plug when the engine is
hot: risk of burns.178) Do not travel with the
windscreen washer reservoir
empty: the windscreen washer is
essential for improving visibility.
179) Some commercial windscreen
washer additives are flammable.
The engine compartment contains
hot parts which could start a fire
on contact.
180) Do not release the cap from
the extension without previously
extracting the system using the
ring.
181) Brake fluid is poisonous and
highly corrosive. In the event of
accidental contact, immediately
wash the affected parts with
water and mild soap. Then rinse
thoroughly. Call a doctor
immediately if swallowed.
182) The
symbol on the container
indicates a synthetic brake fluid,
which is different from a mineral
fluid. Using a mineral fluid will
damage the special rubber seals
of the braking system beyond
repair.
183) Prevent power steering fluid
from coming into contact with
hot engine parts: it is flammable.
IMPORTANT
3) Power steering fluid consumption
is extremely low; if another top-up
is required after only a short
period of time, have the system
checked for leaks at a Fiat
Dealership.
235

IMPORTANT After turning the ignition
key to STOP and having closed the
driver side door, wait at least one
minute before disconnecting the
electrical supply from the battery. When
reconnecting the electrical supply to
the battery, make sure that the ignition
key is in the STOP position and the
driver side door is closed.
IMPORTANT If the charge level remains
under 50% for a long time, the battery
is damaged by sulphation, reducing
its capacity and efficiency at start-up.
The battery is also more prone to the
risk of freezing (at temperatures as high
as -10°C).
Refer to the paragraph "Car inactivity"
in "Starting and driving" if the car is
left parked for a long time.If, after buying the vehicle, you want to
install electrical accessories which
require permanent electric supply
(alarm, etc.) or accessories that in any
case burden the electrical supply,
contact a Fiat Dealership, whose
qualified personnel, in addition
to suggesting the most suitable devices
from Lineaccessori Fiat, will evaluate
the overall electrical consumption,
checking whether the vehicle’s electrical
system is capable of withstanding the
load required, or whether it should
be integrated with a more powerful
battery.
Since some of these devices continue
to consume electricity even when
the engine is off, they gradually run
down the battery.
IMPORTANT If a tachograph is fitted, if
the vehicle is parked for a long period
of 5 days, it is advisable to disconnect
the negative battery terminal to
maintain its charge.
If the vehicle is equipped with a battery
disconnection function (disconnector),
see the description of the procedure
in the "Controls" paragraph in the
"Dashboard and controls" section.
WARNING
184) Battery liquid is poisonous and
corrosive. Avoid contact with skin
and eyes. Keep naked flames
and sources of sparks away from
the battery: risk of explosion and
fire.
185) Using the battery with
insufficient fluid irreparably
damages the battery and may
cause an explosion.
186) Before performing any
operation on the electrical system,
disconnect the negative battery
cable through the suitable
terminal, after having waited at
least one minute from turning the
ignition key to STOP.
187) Always wear appropriate
goggles when working on or near
the battery.
238
SERVICING AND MAINTENANCE

IMPORTANT
51) Incorrect assembly of electrical
and electronic devices may cause
severe damage to your vehicle.
Contact a Fiat Dealership if you
want to install accessories after
purchasing the vehicle (alarms,
radiophone, etc.): they will
suggest the most suitable devices
and advise you whether a higher
capacity battery needs to be
installed.
52) If the vehicle needs to be off the
road for a long period under
conditions of intense cold, remove
the battery and take it to a
heated location, otherwise it may
freeze.
IMPORTANT
4) Batteries contain substances
which are very dangerous for the
environment. To replace your
battery, we recommend
contacting your Fiat Dealership to
dispose of your old battery in full
respect of the environment and in
compliance with all applicable
laws and regulations.
239

WHEELS AND TYRESCheck the pressure of each tyre,
including the space-saver wheel,
approximately every two weeks and
before long journeys: the pressure
should be checked with the tyre rested
and cold.
It is normal for the pressure to increase
when the vehicle is used; for the correct
tyre inflation pressure, see “Wheels” in
the “Technical specifications” section.
Incorrect pressure causes abnormal
tyre wear fig. 244:Anormal pressure: tread evenly worn;Blow pressure: tread particularly worn
at the edges;Chigh pressure: tread particularly worn
in the centre.
The tyres must be replaced when the
tread is less than 1.6 mm thick. In
any case, follow the laws in force in the
country you are in.188) 189) 190) 191)
IMPORTANT
INFORMATION
❒As far as possible, avoid sharp
braking and screech starts. Be
careful not to hit the kerb, potholes or
other hard obstacles. Driving for
long stretches over uneven roads can
damage the tyres;
❒periodically check that the tyres have
no cuts in the side wall, abnormal
swelling or irregular tyre wear.
Contact a Fiat Dealership if required;
❒avoid overloading the car when
travelling: this may cause serious
damage to the wheels and tyres;
❒if a tyre is punctured, stop
immediately and change it to avoid
damage to the tyre, the rim,
suspensions and steering system;❒tyres age even if they are not used a
great deal. Cracks in the tread and
on the side walls are a sign of ageing.
In any event, have the tyres checked
by specialised personnel if they
have been fitted for longer than 6
years. Remember to check the spare
wheel very carefully;
❒in the case of replacement, always fit
new tyres, avoiding those of
unknown origin;
❒if a tyre is changed, also change the
inflation valve;
❒to allow even wear between the front
and rear tyres, it is advisable to
change them over every 10–15
thousand kilometres, keeping them
on the same side of the vehicle so as
not to reverse the direction of
rotation.
IMPORTANT Replacing a tyre, check
that the tyre pressure monitoring
(TPMS) sensor is also taken from the
previous rim, together with the valve.244
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SERVICING AND MAINTENANCE