service FIAT DUCATO 244 2005 3.G User Guide

166VEHICLE MAINTENANCE
IMPORTANT - Pollen filter
If the vehicle is often used in dusty
or extremely polluted environments,
you should change the filter element
more frequently. It should be changed
especially if the amount of air intro-
duced into the passenger compart-
ment has decreased.
IMPORTANT - Diesel filter
Refuelling with diesel fuel not com-
plying with the grade of purity pre-
scribed by European Specification
EN590 might make it necessary to re-
place the filter more frequently than
indicated in the Service Schedule.
IMPORTANT - Battery
The charge in your battery should be
checked, where possible at the start
of the winter, to limit the risk of the
battery electrolyte freezing.
This check should be carried out
more frequently if the vehicle is mainly
used for short trips or if it is fitted
with accessories that permanently
take in electricity even when the igni-
tion key is removed, especially in the
case of after market accessories.You should check the battery fluid
(electrolyte) level more frequently
than shown in the Service Schedule if
the vehicle is used in hot climates or
particularly demanding conditions.
IMPORTANTAs concerns Camp-
ing Car versions, due to high electric
absorption, observe indications rele-
vant to battery contained in para-
graphs "Vehicle storage" (section
"Getting the best out of your vehicle")
and "Battery – Checking the charge"
(section "Vehicle maintenance").
Maintenance of your ve-
hicle should be entrusted
to a Fiat Dealership. For
ordinary routine maintenance
operations which you are able to
carry out yourself, ensure that
you have the necessary tools and
original Fiat spare parts and flu-
ids available. Do not carry out
servicing operations if you have
no experience.IMPORTANT - Engine oil
Change the engine oil more fre-
quently than shown in the Service
Schedule if the vehicle is normally dri-
ven in one of the following particular-
ly severe conditions:
– towing a trailer
– on dusty roads
– short distances (less than 7-8 km)
repeated and with external tempera-
tures below zero.
– frequently idling engines or long
distance low speed driving (e. g. taxis
or door-to-door deliveries) or in case
of a long term inactivity replace engine
oil more frequently than required on
Scheduled Maintenance Plan.
IMPORTANT - Air cleaner
Replace the air cleaner more fre-
quently if the vehicle is used on dusty
roads.
If you are in doubt about how often
the engine oil or the air cleaner should
be changed in relation to how you use
the vehicle, contact a Fiat Dealer-
ship.

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.

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

215TECHNICAL SPECIFICATIONS
FUEL SUPPLY/IGNITION
Petrol version
Electronic Multipoint sequential
phased integrated electronic injection
and ignition; a single injection system
controls both functions. It processes
both the time the injection lasts (for
fuel metering) and the ignition advance
angle.FUEL SUPPLY
JTD/JTD POWER versions
UNIJET (Common Rail) electronic
control direct injection, turbosuper-
charger with WASTEGATE valve and
intercooler (2.3 JTD, 2.8 JTD and 2.8
JTD POWER versions).SPARK PLUGS
The cleanness and soundness of the
spark plugs are very important for
keeping the engine efficient and pol-
luting emissions down.
The appearance of the spark plug, if
examined by an expert eyes, is a good
way of pinpointing a problem even if it
has nothing to do with the ignition sys-
tem. Therefore, if the engine has prob-
lems, it is important to have the spark
plugs checked at a Fiat Dealership.
The spark plugs must be
changed at the times
specified in the
SERVICE
SCHEDULE
. Only use the type of
plugs indicated: if the heat ratio
is less than required or the life
specified is not guaranteed, prob-
lems can arise.
Modifications or repairs to
the fuel feed 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.
WARNING

216TECHNICAL SPECIFICATIONS
BRAKES
SERVICE AND EMERGENCY
BRAKES
Front: disc, floating caliper with two
operating cylinders for each wheel and
pad wear warning light.
Rear: self-centring shoes and micro-
metric mechanism for clearance take-
up.
Certain versions are fitted with rear
disc brakes with Drum in hat device
(i.e. drum on disc to block the vehicle
when parked with handbrake en-
gaged).
Cross-over hydraulic circuit control.
Four sensors ABS system with EBD.
Automatic recovery of the friction
gasket wear; versions with rear disc
brake excluded (Drum in hat ver-
sions).
Lacking ABS system brakeforce dis-
tributor acting on rear brake hydraulic
circuit according to rear axle load.HANDBRAKE
Controlled by a lever, it works me-
chanically on the rear brake shoes.
For versions with rear disc brakes,
the handbrake works on the Drum in
hat device shoes.
IMPORTANTPull the handbrake
lever only when the vehicle is at a
standstill, or when the vehicle is run-
ning, but however only in case of a
failure of the hydraulic system.
Should the handbrake be exception-
ally used when the vehicle is running,
it is suggested to keep a moderate
traction to avoid causing the rear axle
block, entailing vehicle side skidding.
TRANSMISSION
CLUTCH
Hydraulically controlled without
travel-free pedal.
MECHANICAL GEARBOX
AND DIFFERENTIAL
Five forward gears and reverse with
synchromesh for front gear engage-
ment.
Cyclical gear reduction and differen-
tial assembly incorporated in the gear-
box.
Drive transmission to the front
wheels by means of drive shafts con-
nected to the differential assembly and
the wheels with CV joints.
Water, ice or salt on road
surfaces can deposit on
brake discs, reducing braking effi-
ciency on the first braking.
WARNING

247INDEX
I I
N N
D D
E E
X X
Bodywork ..................................... 181
- maintenance ............................ 181
- tips for keeping the body
in good conditions ................. 182
- versions .................................... 187
- warranty ................................... 182
Bodywork paint identification
plate ............................................. 186
Bodywork versions ..................... 187
Bonnet ........................................... 84
Bottle holder ................................ 74
Brake fluid level ........................... 172
Brake light replacement ............. 146
Brakes
- handbrake ......................... 108-216
- service and
emergency brake ................... 216
Bulb replacement ........................ 141
Bulb types ..................................... 142
Bump starting ............................... 137Capacities ................................... 239
Ceiling light .................................... 71
Cellular phone set-up ................ 100
Central door locking system .... 83
Changing a wheel ........................ 137
Cheap running that respects
the environment ....................... 127
Checking fluid levels ................... 167
Child restraint systems .............. 22
Cigar lighter ................................. 77
Cleaning seats and fabrics ......... 184
Cleaning the plastic parts .......... 184
Climate control system ............. 57
Clutch ............................................ 216
Controls ........................................ 71
Consumption
- engine oil .................................. 170
- fuel ............................................. 243
Coolant temperature gauge ..... 30ABS .............................................. 88
Additional heater ........................ 58
Adjusting the headlight beam ... 86
Airbags (front and side) ............. 90
Air cleaner .................................... 173
Air vents ........................................ 54
Annual inspection schedule ...... 165
Ashtray .......................................... 77
ASR system ................................... 96
At the filling station .................... 102
Automatic electronic gearbox .. 110
Battery ........................................ 174
- battery cut out ....................... 73
- checking the charge ............... 175
- jump starting .................... 136-157
- recharging ................................ 157
- replacement ............................ 174
- useful advice ............................ 175

250INDEX
Rev counter ................................. 30
Reversing light replacement ..... 146
Rims
- understanding rim markings .. 219
Roof rack/ski rack (presetting) .. 101
Rubber tubing .............................. 179
Safe driving.................................. 119
Scheduled Service ....................... 162
Seat belts ....................................... 15
Seats ............................................... 42
Self-standing supplementary
heater .......................................... 59
Service indicator .......................... 33
Service Schedule .......................... 163
Side central windows (opening) 78
Side/taillights ................................. 65
- front bulb replacement ......... 146
Smart wash ................................... 67
Snow chains .......................... 133-218
Snow tyres ............................ 132-221Sound system ............................... 98
- aerial ......................................... 100
- heavy set-up ............................ 98
- light set-up ............................... 98
Spare wheel .................................. 218
Spark plugs .................................... 215
Speed limiter ................................ 177
Speedometer ................................ 30
Spray nozzles ............................... 181
Starting the engine ...................... 105
- bump starting .......................... 137
- Diesel engine procedure ...... 106
- emergency starting ......... 107-135
- ignition switch ......................... 28
- jump starting .................... 136-157
- petrol engine procedure ...... 105
- stopping the engine ................ 108
- warming up the engine after
it has just started ................... 107
Steering ......................................... 218
Steering column lock .................. 28Steering column stalks ............... 65
Steering wheel ............................. 51
Sun visors ...................................... 78
Suspensions .................................. 217
Symbols ......................................... 7
Tank cap ................................ 99-103
Technical specifications........ 185
Third brake light
replacement ................................. 146
Tools ................................................ 138
Top speeds ..................................... 226
Tow hitch
(fitting diagrams)................... 130-131
Tow hitch installation .................. 129
Towing a trailer ............................. 129
Towing the vehicle ....................... 159
Transmission .................................. 216
Transporting children in safety .. 22
Tyre pressure ................................. 220
Tyres ......................................... 178-220