brake FIAT DUCATO 2016 3.G Workshop Manual

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”.
COMFORT-MATIC
GEARBOX HYDRAULIC
SYSTEM FLUID
To check the gearbox oil level and to
change the clutch hydraulic fluid, go to
a Fiat Dealership.
190)
WARNING
181)Never smoke while working in the
engine compartment: inflammable gases
and vapours may be present, constituting
a fire risk.
182)Be very careful 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.
183)The cooling system is pressurised. If
necessary, only replace the plug with
another original or the operation of the
system may be adversely affected. Do not
remove the reservoir plug when the engine
is hot: you risk scalding yourself.184)Prevent power steering fluid from
coming into contact with hot engine parts:
it is flammable.
185)Do not travel with the windscreen
washer fluid reservoir empty: the
windscreen washer is essential for
improving visibility.
186)Some commercial windscreen washer
additives are flammable. The engine
compartment contains hot parts which
could start a fire if they come into contact.
187)Do not release the cap from the
extension without previously extracting the
system using the ring.
188)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.
189)The symbol
, on the brake fluid
container indicates if a brake fluid is
synthetic or mineral­based. Use of mineral
type fluids will damage the special rubber
seals of the braking system beyond repair.
190)Used transmission fluid contains
substances that are harmful to the
environment. It is advisable to have the oil
changed by a Fiat Dealership where it
will be disposed of respecting the
environment and according to legal
requirements.
WARNING
49)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 vehicle.
50)Used engine oil and replaced oil filters
contain substances which are harmful to
the environment. To change oil and filters,
we advise you to contact a Fiat Dealership.
51)PARAFLU
UPanti-freeze fluid is used
in the cooling system. Use fluid of the
same type as that contained in the cooling
system for any top-ups. PARAFLU
UP
fluid cannot be mixed with any other type
of fluid. If this occurs, do not start the
engine and contact your Fiat Dealership
immediately.
52)Do not press on the power steering
end of travel with engine on for more than
8 consecutive seconds, since noise is
produced and there is a risk of system
damages.
53)Prevent brake fluid, which is highly
corrosive, from coming into contact with
painted parts. Should it happen,
immediately wash with water.
WARNING
4)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.
198
SERVICING AND CARE

WARNING
6)Detergents pollute the water. The
vehicle should be washed in areas
equipped for collecting and purifying the
liquid used in the washing process.
INTERIOR
Regularly check that water is not
trapped under the mats (due to water
dripping off shoes, umbrellas, etc.),
as this could cause oxidation of the
sheet metal.
201) 202)
SEATS AND FABRIC
PARTS
Remove dust with a soft brush or a
vacuum cleaner. It is advisable to use a
moist brush on velvet upholstery.
Rub the seats with a sponge moistened
with a solution of water and neutral
detergent.
PLASTIC PARTS
It is advisable to clean interior plastic
parts with a moist cloth and a solution
of water and non-abrasive mild soap.
Use specific products for cleaning
plastic, without solvents and specifically
designed to prevent damage to the
appearance and colour of the treated
parts, to remove grease and tough
stains.
IMPORTANT Do not use alcohol,
petrols or derivatives to clean
the instrument panel glass.LEATHER STEERING
WHEEL/GEAR LEVER
KNOB/HANDBRAKE
(for versions/markets, where provided)
These components must be cleaned
with mild soap and water only. Never
use alcohol or alcohol-based products.
WARNING
201)Never use flammable products, such
as petroleum ether or modified petrol, to
clean the inside of the car. The
electrostatic charges which are generated
by rubbing during the cleaning operation
may cause a fire.
202)Do not keep aerosol cans in the
vehicle: they might explode. Aerosol cans
must not be exposed to a temperature
exceeding 50°C. When the vehicle is
exposed to sunlight, the internal
temperature can greatly exceed this value.
206
SERVICING AND CARE

RUBBER HOSES
As far as the brake system and fuel
supply system rubber hoses are
concerned, follow the "Scheduled
Servicing Plan" in this chapter carefully.
Ozone, high temperatures and
prolonged lack of fluid in the system
may cause hardening and cracking of
the hoses, with possible leaks. Careful
checking is therefore necessary.
207

WEIGHTS AND
LOADS
To identify the weights and loads for
your vehicle, refer to the plate shown in
fig. 204 and described in the
“Identification data plate” chapter or
refer to the vehicle registration
certificate showing the type-approved
weights (for markets, where provided)
EMaximum permitted weight of fully
laden vehicle (GVW).
FMaximum permitted weight of the
vehicle (GVW) fully laden plus trailer. If
there is no value in the field or if
there is a dash, it means that the
vehicle cannot tow
GMaximum permitted weight on first
axle (front).
HMaximum permitted weight on
second axle (rear).To calculate the towable weight with a
braked trailer, take the difference
between values F and E shown on the
plate.
E.g.: F=6000 kg - E=3500 kg
Braked trailer=2500 kg
IMPORTANTDo not exceed the given
trailer and towable weights.
IMPORTANTComply with the vehicle
towing capacities.
The tables show the towable weight for
engine version.
204F1A0245
234
TECHNICAL DATA

TOWABLE WEIGHTS (kg)
Key:
A= TOWABLE WEIGHT
B= UNBRAKED TRAILER
C= LOAD ON TOW HOOK
VERSION (GVW) ENGINE A B C
LIGHT2800 2.0 115 Multijet 2 2000 750 100
3000 (3150 / 3300 /
3500 / 3650)2.0 115 Multijet 2 2000 750 100
2.3 130 - 150 Multijet 2 / 180 Multijet 2
Power
2.3 130 Multijet 2 with AdBlue
2.3 150 ECOJET
3.0 140 Natural Power (excluding
Panorama)2500 750 100
MAXI (HEAVY)35002.3 130 - 150 Multijet 2 / 180 Multijet 2
Power
2.3 130 Multijet 2 with AdBlue
2.3 150 ECOJET
3.0 140 Natural Power3000
(*)750
120(*)
40052.3 130 - 150 Multijet 2 / 180 Multijet 2
Power
3.0 140 Natural Power2500 750 100
42502.3 130 - 150 Multijet 2 / 180 Multijet 2
Power
3.0 140 Natural Power2250 750 100
44002.3 150 Multijet 2 / 180 Multijet 2
Power2100 750 100
(*) For Special T.L. 2500 Kg (towable weight = 100 Kg)
235

Use Features SpecificationOriginal fluids and
lubricantsApplications
Lubricants and greases
for drive transmissionSAE 75W grade synthetic
lubricant9.55550 - MZ2TUTELA
TRANSMISSION
EXPERYA
Contractual Technical
Reference No. F002.F13Mechanical transmission
and differential (MLGU
transmission)
SAE 75W-85 grade
synthetic lubricant9.55550-MZ3 or
MS.90030-M2TUTELA
TRANSMISSION
GEARTECH
Contractual Technical
Reference No. F704.C08Manual gearbox and
differential
Special oil with "ATF
DEXRON III" type additive-TUTELA CAR CS
SPEEDCOMFORT-MATIC
transmission hydraulic
actuator system
Molybdenum disulphide
grease, for use at high
temperatures.
Consistency NLGI 1-29.55580 - GRAS IITUTELA ALL STAR
Contractual Technical
Reference No. F702.G07Wheel side constant
velocity joints
Grease for constant
velocity joints with low
friction coefficient.
Consistency NLGI 0-19.55580 - GRAS IITUTELA STAR 700
Contractual Technical
Reference No. F701.C07Differential side constant
velocity joints
Lubricant for power
steering. Exceeds "ATF
DEXRON III" specifications9.55550-AG2TUTELA
TRANSMISSION GI/E
Contractual Technical
Reference No. F001.C94Hydraulic power steering
Lubricant for power
steering. "ISO VG 2" – "2F
TE_ML 02K"9.55550-AG3TUTELA
TRANSMISSION GI/R
Contractual Technical
Reference No. F428.HD4Electro-Hydraulic Power
Steering
Brake fluidSynthetic fluid for brake
and clutch systems.
Exceeds specifications:
FMVSS N° 116 DOT 4,
ISO 4925, SAE J 1704.9.55597 or MS.90039TUTELA TOP 4
Contractual Technical
Reference No. F001.A93
or
TUTELA TOP4/S
Contractual Technical
Reference No. F005.F15Hydraulic brakes and
hydraulic clutch controls
243

NOTE The priority for the automatic
reconnection is determined according
to the order of connection. The last
phone connected will have the highest
priority.
Making a phone call
The operations described below can
only be accessed if supported by
the mobile phone in use.
For all functions available, refer to the
mobile phone owner's handbook.
A call can be made by:
selecting "Contacts" (Phonebook
......);
selecting "Recent Calls list";
selecting "Keypad".
Dialling the phone number using
the "keypad" on the display
Enter the phone number using the
graphic keypad displayed. Proceed as
follows:
press the PHONE button on the
front panel;
select "Keypad" on the display and
use the right "BROWSE/ENTER" knob
to enter the number
select the icon to make the call.Dialling the phone number using
the mobile phone
It is possible to dial a phone number
with the mobile phone and continue
using the system (never allow yourself
to be distracted while driving).
When a phone number is dialled with
the keypad of the mobile phone, the
audio of the call is played over your
vehicle's sound system.
WARNING
208)When connecting a device (USB or
iPod) to the USB port, make sure that
it does not obstruct the operation of the
handbrake lever.
209)When connecting a device to the AUX
socket, make sure that it does not
obstruct the operation of the handbrake
lever.
271

WARNING
LUGGAGE CARRIER
Follow the instructions contained in the assembly kit carefully. Assembly must be performed by qualified personnel.
After travelling for a few kilometres, check to ensure that the fixing screws for the attachments are well tightened. Distribute the load
evenly and pay attention to side winds when driving.
Fully comply with the regulations in force concerning maximum clearance. Never exceed the maximum permitted loads (see chapter
"Technical specifications").
ACCESSORIES PURCHASED BY THE OWNER
Take care when fitting additional spoilers, alloy wheels or non-standard wheel hubs: they could reduce the ventilation of the brakes and
affect efficiency under sharp, repeated braking or on long descents. Make sure that nothing obstructs the pedal stroke (mats, etc.).
PROTECTING THE ENVIRONMENT
The Diesel particulate filter (DPF) reaches high temperatures during normal operation. Therefore, do not park the vehicle on flammable
material (grass, dry leaves, pine needles etc.): fire hazard.
RIM PROTECTOR TYRES
DO NOT fit wheel hub caps when using integral hub caps fixed (with springs) to the steel rim and after sale tyres provided with a Rim
Protector. Use of unsuitable tyres and wheel caps may cause sudden decrease of tyre pressure.
283

INDEX
4
-Seater bench (Crew Cab Van
versions)
...................................... 20
ABS (System)
.............................. 81
ABS system ................................... 81
Additional heater ............................ 37
Additional rear climate control
(Panorama/Combi) ....................... 41
Additional rear heating
(Panorama/Combinato) ................ 40
Additive for diesel emissions
AdBlue (UREA) ............................. 130
Advice for extending battery life...... 200
Air cleaner ...................................... 199
Air suspension ............................... 45
ASR (system) ................................. 83
ASR system ................................... 83
Automatic climate control
system ......................................... 36
Automatic headlight sensor ............ 26
Automatic main beam headlights ... 25
Battery
– Replacement ............................. 199
Battery (disconnector) .................... 31
Battery (recharging) ........................ 178
Battery disconnector ...................... 31
Battery replacement ....................... 199
Body
– Advice for preserving the
bodywork .................................. 205body paintwork identification
plate............................................. 209
Bodywork
– Protection from atmospheric
agents ....................................... 205
Bodywork version .......................... 211
Bonnet ........................................... 42
Brake fluid ...................................... 197
Bump starting ................................ 178
Cargo space
................................. 17
Carrying children safely
– Arrangement possibilities for
child restraint systems ............... 99
– Child restraint systems .............. 96
– Safety regulations ...................... 100
Changing a wheel .......................... 170
Chassis marking ............................ 209
Checking levels .............................. 192
Climatizzatore manual .................... 35
CO2 emissions............................... 252
Comfort-matic Gearbox ................. 117
Compartment beneath
passenger side front seat ............. 44
Compatibility of vehicle seats
with Isofix child seats ................... 103
Conditions of use ........................... 134
Controls ......................................... 29
Courtesy lights ............................... 28
Cruise Control ................................ 119
Cylinder marking ............................ 210
Daytime running lights.............................. 24
Dead lock device ........................... 13
Demanding vehicle use .................. 184
Dimensions .................................... 222
Dipped beam headlights ................ 24
Direction indicators ........................ 26
Display
– Standard screen ........................ 52
Door locking................................... 31
Doors ............................................. 12
Driving Advisor (system) ................. 89
Driving Advisor System .................. 89
Driving style.................................... 134
Electric windows
........................... 41
Electronic alarm ............................. 11
Engine............................................ 213
Engine codes ................................. 211
Engine coolant ............................... 196
Engine marking .............................. 210
Engine oil ....................................... 196
Engine oil level gauge ..................... 53
EOBD system ................................ 49
ESC (system) ................................. 82
External lights................................. 24
Fiat CODE system
......................... 8
Fix&Go Automatic quick tyre
pressure restoration ..................... 174
Flashing ......................................... 25
Flex Floor rear seat......................... 19

Fluids and lubricants ...................... 242
Follow Me Home device ................. 26
Front airbags .................................. 107
– Front airbag driver's side ........... 107
– Manually deactivating the
front airbag and side bag........... 108
– Passenger side front airbag ....... 108
Front fog lights ............................... 29
Front light clusters .......................... 146
Front roof light (changing a bulb) .... 151
Fuel consumption .......................... 245
Fuel cut-off switch .......................... 179
Fuel tank cap ................................. 126
Fuses (replacement) ....................... 151
Gateway fms module
.................... 165
Gear Shift Indicator ........................ 52
Hazard warning lights
................... 29
HBA (Hydraulic Brake Assist)
system ......................................... 83
HBA (system) ................................. 83
Head restraints
– Front ......................................... 43
Headlight alignment corrector ....... 27
Headlight washers ......................... 33
Headlights
– Headlight alignment corrector.... 27
– Light beam direction.................. 27
Heated rear window ....................... 30
Heating and ventilation ................... 34Heating and ventilation controls...... 35
Hill Descent .................................... 84
Hill Descent Control System ........... 84
Hill Holder (system) ........................ 82
Hill Holder system .......................... 82
Identification data
.......................... 209
Ignition switch ................................ 10
Independent additional heater ........ 38
Inflation pressure ............................ 221
Inflation procedure ......................... 175
Instrument panel ............................ 50
Interior ........................................... 206
Interior fittings ................................ 44
Isofix child restraint systems
(setup)
– Arrangement possibilities for
child restraint system on
seats of vehicle.......................... 103
Jump starting
................................ 177
Lifting the vehicle
.......................... 202
Light beam direction ...................... 27
Light bulbs
– Bulbs types ............................... 144
Lights off ........................................ 24
Loading advice............................... 133
Main beam headlights
.................. 25
Maintenance and care - regular
checks ......................................... 183
Maintenance and care -
Scheduled Servicing .................... 183Maintenance and care -
scheduled servicing plan .............. 185
Manually deactivating the front
airbag and side bag ..................... 108
MSR (System) ................................ 81
MSR system .................................. 81
Multifunction display
– Control buttons ......................... 53
– Setup menu .............................. 54
Nozzles
......................................... 202
Number plate lights ........................ 150
On-board instruments
................... 50
Parking lights
................................ 26
Parking sensors ............................. 122
Performance .................................. 232
Pollen filter ..................................... 199
Power Socket ................................ 44
Power steering ............................... 216
Power steering fluid........................ 196
Pre-tensioners................................ 94
Prolonged vehicle inactivity............. 141
Radio
............................................ 260
Rain sensor .................................... 32
Rear door with two wings............... 14
Rear fog lights ................................ 29
Rear view mirrors ........................... 22
Rear-view camera .......................... 123
Refuelling ....................................... 237
Refuelling the vehicle ...................... 125