Safety FIAT DUCATO 2016 3.G Service Manual

The general recommendation is to
avoid emptying the petrol tank
completely, as this may lead to a
risk for the driver:
After the METHANE level has
dropped below the reserve threshold,
the vehicle will continue to run on petrol
until it runs out;
the vehicle has run out of petrol
during a previous mission and while
running on METHANE it has reached
the METHANE reserve pressure
threshold: in this case, the system
forces switching to petrol and the
vehicle turns off while it is in motion.RESTRICTIONS ON USE
Passing from running on methane to
running on petrol causes the maximum
speed to be limited to 90 km/h;
therefore, after the first methane reserve
indication, it is advisable to refuel and
after the second indication of gaseous
fuel running out (double beep), avoid
"risky" conditions such as overtaking at
high speed on the motorway.
NOTE Make sure that the key is in the
OFF position when refuelling with
methane. If, in fact, the system has
already forced running on petrol and
you refuel with methane with the key in
the ON position, the engine will
continue running on petrol until the next
time it is started.
WARNING
37)Fiat Ducato Natural Power is equipped
with a high pressure methane system
designed to run at 200 bar. It is dangerous
to stretch the system with higher
pressures. If there is a problem with the
methane system, only contact a Fiat
Dealership. Do not alter the methane
system configuration or components; they
are designed exclusively for the Fiat
Ducato Natural Power. The use of other
components or materials could cause
malfunctions and prejudice safety.38)When oven painting, the cylinders must
be removed from the vehicle and refitted
by a Fiat Dealership. Although the methane
system has numerous safety features, it is
advisable to close the manual tap on the
cylinders every time the vehicle is not
in use for a long period, transported on
other vehicles or moved in an emergency
as a result of a breakdown or accident.
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STARTING AND DRIVING

LOADING ADVICE
The Fiat Ducato version used by you
has been designed and type approved
on the basis of certain maximum
weights (see "Weights" table in the
"Technical Data" chapter): kerb weight,
payload, total weight, maximum weight
on front axle, maximum weight on
rear axle, towable weight.
IMPORTANT The maximum permitted
load on the floor fastenings is 500
kg; the maximum permitted load on the
side panel is 150 kg.
IMPORTANT For versions with right and
left side flaps, it is advisable to
reposition the release lever in the closed
position before lowering the sides.
133) 134) 135)
39)In addition to these general
precautions, some simple precautions
can improve driving safety, travelling
comfort and vehicle durability:
distribute the load evenly over the
platform: if it is necessary to
concentrate it in a single area, choose
an area mid-way between both axles;
lastly, remember that the vehicle’s
dynamic behaviour is affected by the
weight transported: in particular, the
stopping distances are longer,
especially at high speed.
WARNING
133)Bumpy roads and abrupt braking may
cause unexpected load shifting with
consequently hazardous situations for the
driver and passengers: before setting
off, secure the load tightly using the
partition and appropriate hooks, steel
cables, ropes or chains strong enough to
hold the items to be secured.
134)Even when the car is stopped on a
steep hill or side slope, opening the rear or
side doors could cause unsecured goods
to fall out.
135)If you wish to carry a reserve of petrol
in a can, observe the legal restrictions
and only use a can that is type-approved
and properly secured to the load
anchorage eyebolts. In the event of a
collision the fire risk is increased all the
same.
WARNING
39)Each of these must be strictly
observed and MUST NEVER BE
EXCEEDED in any case. In particular,
ensure that you never exceed the
maximum permitted weights on the front
and rear axles when arranging the load on
the vehicle (particularly if the vehicle is
equipped with a specific trim level).
133

WARNING
141)Never replace a fuse with another with a higher amp rating; RISK OF FIRE. If a general protection fuse (MEGA-FUSE, MIDI-FUSE) is
activated, contact a Fiat Dealership.
142)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.
143)If the replaced fuse blows again, contact a Fiat Dealership.
144)Contact Fiat Dealership if a safety system (airbags, brakes), engine system (engine, gearbox) or steering system general protection fuse
blows.
WARNING
47)Never replace a faulty fuse with metal wires or anything else.
164
IN AN EMERGENCY

CHANGING A WHEEL
GENERAL
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.
145) 146) 147) 148) 149)
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.
150)
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 must be flat and sufficiently
compact;
switch off 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.);
In the event of a wheel change on a
slope or on unsurfaced roads, put
any object as stop under the wheels;
take the tool bag from under the
passenger seat (see "Compartment
under the front passenger side seat" in
the "Internal equipment" chapter in
"Knowing the vehicle").
The container includes these tools:
A - tow hook
B - rod for spanner
C - bolt spanner
D - jack
E - extension for spanner
F - screwdriver gripG - screwdriver bit
if the tool container is not provided,
for special trim versions, a bag
containing the above tools may be
provided;
for versions with alloy rims, remove
the press-fitted hub cap;
take the extension for spanner, the
bolt spanner and the rod for spanner
from the tool container;
with the tools assembled correctly,
loosen the fixing bolts for the wheel
to be changed by one turn;
turn the ring nut to partly extend the
jack;
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170
IN AN EMERGENCY

go to the rear side of the vehicle
where the spare wheel is located;
make sure that all of the cable for
the spare wheel lifting device has been
unrolled, grip the bell and position it
inside the circular bracket fig. 167;
tighten the knob onto the screw to
secure the bracket fig. 168.
rest the bracket on the inside of the
allow wheel fig. 169.
use the Allen key to tighten the three
special screws on the bracket's nuts
fig. 170 and secure the wheel;
insert the assembled tool fig. 162
equipped with the dedicated extension
B fig. 161 onto the screw A fig. 161
of the operating device on the spare
wheel compartment and turn it
clockwise to allow the spare wheel to
raise, until it rests fully against the
sub-platform, making sure that the the
locking mark D fig. 164 has appeared in
the window on the device.
Check that the position of the
replaced wheel under the platform is
correct (the lifting system is equipped
with a clutch to limit the end of the
stroke, incorrect positioning may
jeopardise safety;)
place the removal tools back in the
tool bag / compartment;
place the tool box / compartment in
its housing under the passenger seat.
155) 156)
WARNING
145)Use your hazard lights, warning
triangle, etc. to show that your vehicle is
stationary. Passengers should get out
of the vehicle, particularly if it is heavily
loaded, and wait for the wheel to be
changed away from the traffic. Apply the
handbrake. in the event of a wheel change
on a slope or on unsurfaced roads, put
any object as stop under the wheels.
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168F1A0425
169F1A0426
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173

146)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.
147)Repair and refit the standard wheel as
soon as possible. Do not apply grease to
the bolt threads before fitting: they could
come unscrewed.
148)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 vehicle 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 the
one shown on its label.
149)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.
150)No tools other than the crank
provided should be used with the spare
wheel lifting device; it should be operated
by hand only.
151)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.152)The device should only be operated
by hand, without using any type of tool
other than the crank provided like
pneumatic or electrical screwers.
153)The moving components of the jack
(screws and joints) can also cause injuries:
avoid touching them. If you come into
contact with lubricating grease, clean
yourself thoroughly.
154)At the end of the operation of
raising/locking the spare wheel, after
checking that the wheel is positioned
correctly under the platform (yellow notch
inside the window on the device), extract
the operating wrench. Take care not to turn
the wrench in the wrong direction (as in
fig. 166) to facilitate extracting it, to prevent
the attachment device from being
released and to ensure that the wheel
assembly remains safely fastened.
155)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.
156)The spare wheel lifting device is
equipped with a clutch safety system for its
own protection; this could activated if an
excessive load is applied on the
maneuvering screw.FIX & GO
AUTOMATIC QUICK
TYRE REPAIR KIT
(for versions/markets, where provided)
The Fix & Go automatic quick tyre
repair kit is located at the front of the
vehicle passenger compartment and
includes fig. 171:
bottle A containing sealer and fitted
with:
– a transparent filler pipe B;
– a black pressure restoring pipe E;
– sticker C bearing the notice “max. 80
km/h”, to be placed in a position visible
to the driver (on the instrument panel)
after fixing the tyre;
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174
IN AN EMERGENCY

VERSIONS WITH
START&STOP SYSTEM
To recharge, proceed as follows:
disconnect the connector A
(pressing the button B) from the sensor
C monitoring the battery conditions,
on the negative pole D of the battery;
connect the positive battery charger
lead to the positive battery terminal E
and the negative lead to the sensor
terminal F as in fig. 178;
turn on the charger;
at the end of the charging process,
switch the battery charger off;
after disconnecting the charger,
reconnect the connector A to the
sensor C as in fig. 178.
WARNING
168)Battery fluid is poisonous and
corrosive: avoid contact with your skin and
eyes. The battery should be charged in a
well ventilated place, away from naked
flames or possible sources of sparks:
danger of explosion and fire.
169)Do not attempt to charge a frozen
battery: it must be thawed first, otherwise it
may explode. If freezing has occurred, the
battery should be checked by skilled
personnel to make sure that the internal
elements are not damaged and that the
body is not cracked, with the risk of leaking
poisonous and corrosive acid.
FUEL CUT-OFF
SWITCH
The vehicle is fitted with a safety switch
that, in the event of a crash, comes
into operation by cutting off the fuel
supply and turning off the engine as a
consequence.
When the inertia switch cuts in, it cuts
off the fuel supply and also activates
the hazard warning lights, side lights
and courtesy lights while releasing
all the doors and displaying the relevant
message; they are deactivated by
pressing button A. On some versions,
there is also a safety relay that activates
in the event of impact to cut off the
electrical supply. In this way, fuel is
prevented from escaping if the pipes
are broken and the formation of sparks
or electrical discharges following
damage to the vehicle electrical
components is avoided.
170) 171)
IMPORTANT After an accident,
remember to remove the key from the
ignition device to prevent the battery
from running down. If no fuel leaks
or damage to vehicle's electrical
devices (e.g. headlights) are detected
after the impact and the vehicle is
able to set off again, reactivate the
automatic fuel cut-off switch.
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179

SERVICING AND CARE
Correct maintenance permits the
performance of the car to be
maintained over time, as well as limited
running costs and safeguarding the
efficiency of the safety systems.
This chapter explains how.SCHEDULED SERVICING ...............183
PERIODIC CHECKS ........................183
DEMANDING VEHICLE USE ...........184
SCHEDULED SERVICING PLAN .....185
CHECKING LEVELS........................192
AIR CLEANER/POLLEN FILTER ......199
BATTERY ........................................199
WINDSCREEN WIPER ....................201
LIFTING THE VEHICLE....................202
WHEELS AND TYRES.....................203
SNOW TYRES ................................204
SNOW CHAINS...............................204
BODYWORK ...................................205
INTERIOR .......................................206
RUBBER HOSES ............................207
182
SERVICING AND CARE

SNOW TYRES
A Fiat Dealership will be happy to
provide advice concerning the most
suitable type of tyre for the customer's
requirements.
The performance of these tyres is
considerably reduced when the tread
depth is less than 4 mm. Replace them
in this case.
Due to the specific characteristics of
snow tyres, in normal weather
conditions or on long motorway
journeys, the performance of these
tyres is lower than that of standard
tyres. Their usage should therefore be
restricted in accordance with their
type approval.
IMPORTANT When using snow tyres
with a maximum speed index below the
one that can be reached by the vehicle
(increased by 5%), place a notice in
the passenger compartment, plainly in
view, which states the maximum speed
allowed by the snow tyres (as per EC
Directive).
All four tyres should be the same (brand
and track) to ensure greater safety
when driving and braking as well as a
good manoeuvrability.Remember that you should not change
the rotation direction of the tyres.200)
WARNING
200)The maximum speed for snow tyres
marked “Q” is 160 km/h, while it is 190
km/h for “T” tyres and 210 km/h for "H"
tyres. You should, however, always stick to
the speed limits of the highway code.
SNOW CHAINS
The use of snow chains should be in
compliance with local regulations of
each country.
Snow chains can be fitted to the tyres
of the front wheels (drive wheels) only.
Use of Lineaccessori Fiat snow chains
is recommended. Check the tension
of the snow chains after the first few
metres have been driven.
57)
IMPORTANT With snow chains, use the
accelerator with extreme care to
prevent, or to limit as much as possible,
slipping of the drive wheels that could
cause chain breakage, resulting in
damage to the car body or mechanical
components.
IMPORTANT For versions fitted with
225/75 R16 tyre, use snow chains with
max. thickness 16 mm.
When travelling on snowy roads with
snow chains, it may be helpful to turn
the ASR off: in fact, in these conditions,
the driving wheels skidding when
moving off gives you better traction.
204
SERVICING AND CARE

WHEELS
RIMS AND TYRES
Alloy or pressed steel rims. Tubeless
radial carcass tyres.
All approved tyres are listed in the
Vehicle Registration Document.
IMPORTANT If there are any
discrepancies between the Owner
Handbook and the Registration
Document, take the information from
the latter. To ensure driving safety, make
sure that all the wheels are fitted with
tyres of the same make and type.
IMPORTANT Do not use inner tubes
with Tubeless tyres.
SPARE WHEEL
Pressed steel rim. Tubeless tyre.
WHEEL GEOMETRY
Front wheels toe-in measured between
rims: -1 ±1 mm.
The values refer to the vehicle in
running order.
217