FIAT DUCATO 244 2005 3.G Owners Manual

170VEHICLE MAINTENANCE
Engine oil consumption
Maximum engine oil consumption is
approx. 450 grams every 1000 Km.
During the beginning of the vehicle’s
life the engine is tuning in. Engine oil
consumption can only be considered
stabilised after the first 5,000 - 6,000
km.
IMPORTANTEngine oil consump-
tion depends on the conditions the ve-
hicle is being used in.ENGINE COOLANT
Check coolant level when the engine
is cold. The level should be included
between the MIN and MAXrefer-
ence lines on the reservoir.
If the level is low, loosen the expan-
sion tank cap A-fig. 9and top up
slowly through the filler with the flu-
id specified in “Fluids and lubricants”
table in section “Technical Specifica-tions”, until the level approaches the
MAX line; contact Fiat Dealership
for this operation.
Coolant mixture gives freeze pro-
tection to – 40°C.
Used engine oil and re-
placed oil filters contain
substances which can
harm the environment. We rec-
ommend you have the vehicle
seen at a Fiat Dealership for the
oil and filter change. It is suitably
equipped for disposing of used oil
and filters in an environmentally-
friendly way that complies with
the law.
fig. 9
F0D0065m
The cooling system is pres-
surised. If necessary, re-
place the cap with a genuine spare
part to avoid compromising the sys-
tem efficiency.
WARNING
Do not remove the reservoir
cap when the engine is hot:
you risk scalding yourself.
WARNING
Top up only with the
same fluid contained in
the cooling circuit.
PARAFLU UP (red) cannot be
mixed with PARAFLU 11 (blue)
or with other fluids. Should this
take place, donot start the engine
and contact Fiat Dealership.

171VEHICLE MAINTENANCE
WINDSCREEN WASHER
FLUID
To add fluid, remove cap A-fig. 10
from the reservoir and slowly pour in
a mixture of water and TUTELA
PROFESSIONAL SC35fluid in the
following concentrations:
– 30% ofTUTELA PROFES-
SIONAL SC35and 70% of water in
summer.
– 50% ofTUTELA PROFES-
SIONAL SC35and 50% of water in
winter.
If the temperature falls below –20°C,
useTUTELA PROFESSIONAL
SC35undiluted.
POWER STEERING
FLUID
Check the oil level when the engine
is cold. It should be slightly under the
reference line on the reservoir.
When the oil is hot, the level can ex-
ceed the reference line.
When topping up, remove the reser-
voir cap A-fig. 11 and make sure that
the oil has the same specifications as
the oil in the system.Oil consumption is ex-
tremely low. If the oil
level needs topping up
again after a short period of
time, have the system checked
for leakage at a Fiat Dealership.
fig. 10
F0D0068m
fig. 11
F0D0066m
Do not let the power steer-
ing fluid come into contact
with hot engine parts. It catches fire
very easily.
WARNINGSome windscreen washer
additives on the market are
flammable. The engine compart-
ment contains hot parts which
could ignite the fluid in the event of
contact.
WARNING
Do not travel with the wind-
screen washer reservoir
empty. The windscreen washer is
fundamental for improving visibility.
WARNING

172VEHICLE MAINTENANCE
BRAKE FLUID
Loosen plug A-fig. 12and check
that the level of the fluid in the reser-
voir is at the maximum
Check at regular intervals that the
level of the fluid in the reservoir is at
the maximum.
Use only DOT 4 fluid only for top-
ping up. We recommend TUTELA
TOP 4that the braking system was
originally filled with.
IMPORTANTBrake fluid is hy-
groscopic (meaning it absorbs humid-
ity). This is why the fluid should be
changed more frequently than shown
in the Service Schedule if the vehicle
is mainly driven in areas with a high
percentage of humidity in the air. Make sure that the
highly corrosive brake
fluid does not drip onto
the paintwork. If it does, wash it
off immediately with water.
fig. 12
F0D0067m
The symbol πon the con-
tainer indicates synthetic
brake fluid distinguishing it from
mineral fluid. Using mineral type
fluid would damage the special rub-
ber braking system gaskets beyond
repair.
WARNING
Brake fluid is poisonous
and very corrosive. In the
event of accidental contact, wash
the affected part with water and
mild soap and rinse. If the fluid is
swallowed, call a doctor immedi-
ately.
WARNING

173VEHICLE MAINTENANCE
AIR CLEANER
REPLACEMENT
Unscrew the screws A-fig. 13and
remove cap B.
Remove the filtering element C-
fig. 14to be replaced.
fig. 13
F0D0295m
fig. 14
F0D0070m
POLLEN FILTER
Have the filter changed at the fre-
quency specified in the Service Sched-
ule.
Have the change made at a Fiat
Dealership.
IMPORTANTIf the vehicle is of-
ten used in dusty or extremely pol-
luted environments, you should
change the filter more frequently. It
should be changed especially if the
amount of air introduced into the pas-
senger compartment has decreased.
DIESEL FILTER
DRAINING THE
CONDENSATION
The presence of water in
the fuel feed circuit can
severely damage the in-
jection system and make the en-
gine misfire. Go to a Fiat Dealer-
ship as soon as possible when the
cwarning light comes on to have
the bleeding operation carried
out. If the warning light comes on
immediately after refuelling, wa-
ter is probably present in the
tank: turn the engine off imme-
diately and contact Fiat Dealer-
ship.

174VEHICLE MAINTENANCE
REPLACING THE BATTERY
If required, replace the battery with
a genuine spare part presenting the
same specifications. If a battery with
different specifications is fitted, the fre-
quencies shown in the “Service Sched-
ule” will no longer be valid. Refer to
the instructions provided by the bat-
tery manufacturer.
Batteries contain sub-
stances that are very
harmful for the environ-
ment. You are advised to have the
battery changed at a Fiat Dealer-
ship. It is properly equipped for
disposing of used batteries in an
environmentally-friendly way that
complies with the law.
Incorrect fitting of elec-
trical and electronic ac-
cessories can seriously
damage the vehicle. If you want
to add accessories after buying
the vehicle antitheft system, ra-
dio, free-hand phone kit, etc.) vis-
it a Fiat Dealership. They can sug-
gest the most suitable acces-
sories to get and check whether
the electric system can support
the required load or whether a
higher capacity battery is re-
quired.
The liquid in the battery is
poisonous and corrosive.
Do not let it touch the skin or eyes.
Do not bring naked flames or pos-
sible sources or sparks near the bat-
tery: risk of fire and explosion.
WARNING
fig. 15
F0D0244m
BATTERY
Fiat Ducato battery is of the “Limit-
ed maintenance” and is fitted with in-
dicator A-fig. 15to check the elec-
trolyte level and the charge.
Under normal conditions of use it
does not require topping up with dis-
tilled water. However, check it peri-
odically through the control optical in-
dicator that is placed on the battery
cover and must be dark with a cen-
tral green area.
If the indicator is a bright colour, or
dark without the green central area,
contact a Fiat Dealership.

175VEHICLE MAINTENANCE
When working on the bat-
tery or near it, always wear
the proper goggles.
WARNING
Running the battery with
low fluid level can damage
the battery beyond repair and
could also cause its explosion.
WARNING
If the vehicle is to stand for
a long time in the cold, re-
move the battery and store it in a
warm place to avoid it freezing.
WARNINGCHECKING THE CHARGE
The battery charge may be checked
satisfactorily through the indicator and
acting according to the colour the in-
dicator shows.
Refer to the table below or to the la-
belB-fig. 15on the battery.USEFUL ADVICE FOR
LENGTHENING THE LIFE OF
YOUR BATTERY
When you park the vehicle, ensure
the doors are closed properly. The
ceiling lights must be off.
Do not keep accessories (e.g.: sound
system, hazard lights, etc.) switched
on for a long time when the engine is
not running.
IMPORTANTA battery which is
kept at a charge of less than 50% for
any length of time will be damaged by
sulphation leading to a reduction in
cranking power and a higher risk of the
battery electrolyte freezing (this may
even occur at –10 °C).
Bright white colour
Dark colour without green
area in the centre
Dark colour with green
area in the centreTop up electrolyte
Low charge level
Electrolyte level
and charge sufficientContact a
Fiat Dealership
Charge the battery
(advisable to contact a Fiat
Dealership)
No action

176VEHICLE MAINTENANCE
Furthermore, remember that high in-
take electric devices (such as baby bot-
tle warmers, vacuum cleaners, cellular
phones, mini-fridges, etc.) powered
when the engine is offcan deploy
the battery.
IMPORTANTWhen installing ad-
ditional systems on the vehicle, bear
in mind that improper branches on
connections of the vehicle wiring are
dangerous, particularly if safety devices
are involved.
Battery
60 Ah
88 Ah
100 Ah
The total intake of these systems
(factory and after-market) must be
less than 0.6 mA x Ah (of the bat-
tery) as shown in the following table:
Maximum
admitted stand-by
intake
36 mA
52.8 mA
60 mA
If the vehicle is inactive for a long pe-
riod of time, refer to the “Vehicle stor-
age” paragraph in section “Getting the
best out of you vehicle”.
Before performing any operation on
the electrical system, disconnect the
battery negative cable.
Battery terminals shall always be
perfectly separated.
If you want to add accessories after
buying the vehicle (antitheft system,
free-hand phone kit, radio navigator,
etc.) visit a Fiat Dealership. They
can suggest the most suitable acces-
sories to get and check whether the
electric system can support the
required load or whether a higher
capacity battery is required.
These devices will, in fact, run off
the battery even when the key is not
inserted (vehicle parked, engine off).

177VEHICLE MAINTENANCE
ELECTRONIC
CONTROL UNIT
When the vehicle is being used nor-
mally, special measures are not nec-
essary.
The following instructions must be
followed very carefully however, if
you work on the electrical system or
in cases where emergency starting is
necessary:
– never disconnect the battery from
the electric system while the engine is
running;
– disconnect the battery from the
electric system if you are recharging it;
– never perform emergency starting
with a battery charger. Always use an
auxiliary battery;
– be particularly careful when con-
necting the battery to the electric sys-
tem. Make sure that the polarity is
correct and that the connection is ef-
ficient;
– do not connect or disconnect the
terminals of the electronic units while
the ignition key is at MAR;
– do not check polarity through
sparking;– disconnect the electronic control
units if you are electrically welding the
vehicle body. Remove the units if tem-
peratures exceed 80 °C (special op-
erations on the bodywork, etc.).
IMPORTANTIf the sound system
or vehicle alarm systems are not in-
stalled correctly, they can interfere
with the working of the electronic
control units.
Modifications or repairs to
the electrical system car-
ried out incorrectly and without
bearing the features of the system
in mind can cause malfunctions
with the risk of fire.
WARNING
SPEED LIMITER
On certain version, the injection con-
trol unit is set to limit the vehicle
speed at a max. preset limit.
Speed limits are the following:
– for Minibus versions (M2 homolo-
gation category): 100 km/h;
– for good Transport versions (ve-
hicle dead weight: > 3.5 t) (N2 ho-
mologation category): 90 km/h;
Label (fig.16) with admitted top
speed (90 or 100 km/h according to
versions) is applied on the wind-
screen.
This limit has been established by Eu-
ropean Directive 2002/85/EC, what-
ever violation is therefore punishable
by law.
IMPORTANTWhen the device
comes into action, the speed value
displayed on the instrument panel
could be approx. 10% higher than the
actual one.
fig. 16
F0D0299m

178VEHICLE MAINTENANCE
WHEELS AND
TYRES
Check the pressure of each tyre, in-
cluding the spare, every two weeks
and before long journeys.
The pressure must be checked when
the tyre is rested and cold.
It is normal for pressure to rise
when you are driving. If you have to
check or restore the pressure when
the tyres are warm, remember that
the pressure value must be 0.3 bar
above the specified value.
See “Wheels” in “Technical specifi-
cations” chapter for the correct tyre
inflation pressure.Wrong pressure causes uneven
wear of the tyres fig. 17:
A- correct pressure: tyre wears
evenly
B- under-inflated tyre: shoulder
tread wear
C- over-inflated tyre: centre tread
wear.IMPORTANTAs far as possible
avoid sharp braking and screech starts.
Be careful not to hit the kerb, pot-
holes or other obstacles. Driving for
long stretches over bumpy roads can
damage the tyres.
Periodically check that the tyres have
no cuts in the side wall, abnormal
swelling or irregular tyre wear. If any
of these occur, have the vehicle seen
to at a Fiat Dealership.
Avoid overloading your vehicle: this
can seriously damage wheels or tyres.
If you get a flat tyre, stop immedi-
ately and change it so as not to dam-
age the tyre, the wheel, the suspen-
sion and the steering.
fig. 17
F0D0027m
If the pressure is too low,
the tyre overheats and this
can cause it serious damage.
WARNING
Tyre pressure must be cor-
rect to ensure good road
holding.
WARNING
Tyres must be replaced when the
tread wears down to 1.6 mm. In any
case, comply with the laws in the coun-
try where the vehicle is being driven.

179VEHICLE MAINTENANCE
Tyres age even if they are not used
very much. Cracking of the tread rub-
ber and the side walls are a sign of this
ageing. In any case, if the tyres have
been fitted for more than six years
they should be examined by an expert
who can judge whether they are still
fit for use. Remember to check the
spare tyre particularly carefully too.
If a replacement is necessary, always
use new tyres and avoid using ones
the origin of which you are not cer-
tain about.
The Ducato uses tubeless tyres. Un-
der no circumstances use an inner
tube with these tyres.
If you replace a tyre it is a good idea
to change the inflation valve, too.To ensure the front and rear tyres all
wear evenly, you are advised to change
the tyres over every 10 - 15 thousand
kilometres keeping them on the same
side of the vehicle so as not to reverse
the direction of rotation.RUBBER TUBING
Follow the Service Schedule carefully
in the case of braking and fuel supply
system rubber tubing.
Ozone, high temperatures and long
absence of fluid in the system can in
fact cause the hardening and cracking
of the pipes with possible loss of fluid.
A careful check is therefore essential.
Do not change the tyres
over in criss-cross fashion
by moving a tyre from the left-hand
side of the vehicle to the right and
vice versa.
WARNING
Never submit alloy rims to
repainting treatments re-
quiring to use temperatures ex-
ceeding 150°C since the mechani-
cal properties of the wheels could
be impaired.
WARNING