air con FIAT DUCATO 244 2005 3.G Owner's Guide

164VEHICLE MAINTENANCE
thousands of kilometres
Replace fuel filter cartridge (Diesel versions)
Replace air cleaner cartridge (Diesel versions)
Replace air cleaner cartridge (petrol versions)
Replace spark plugs (petrol versions)
Top up fluids (engine coolant, brakes, power steering,
battery, windscreen washer, etc.)
Check timing belt conditions (***)
Replace timing belt and various control belts
(or every 48 months) (*)
Check engine control systems via diagnostic socket
Change gearbox - transmission - rear axle oil (4WD version)
Check gearbox/differential oil level (automatic transmission)
Change engine oil (**)
Replace engine oil filter (**)
Change brake fluid (or every 24 months)
Replace pollen filter (or every 12 months)
(*) Replace every 240,000 km or every 60 months for 2.3 JTD versions.
(**) Change/replace engine oil filter and oil every 40,000 km for 2.3 JTD versions
(***) Every 120,000 km for 2.3 JTD versions
30 60 90 120 150 180
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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.

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

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

182VEHICLE MAINTENANCE
– the use of zinc-plated sheet steel
which is highly resistant to rust;
– the spraying of the underbody, en-
gine compartment, inside the wheel-
houses and other parts with wax-
based products with a high protective
capacity;
– spraying plastic-coating materials
to protect the most exposed points:
under the door, inside the wings, the
edges, etc.;
– the use of “open” box sections to
prevent condensation and water from
building up and rusting the inside of
the parts.
BODY AND UNDERBODY
WARRANTY
Your Ducato is covered by warranty
against any original structural or body
part being perforated by rust. Refer to
the Warranty Booklet for the general
terms.TIPS FOR KEEPING THE BODY
IN GOOD CONDITIONS
Paintwork
The paintwork is not only to make
your vehicle look attractive but also
to protect the steel.
If the paint is scuffed or scratched
deeply you are therefore advised to
touch up as necessary to prevent rust
from forming.
Only use genuine products when
touching up the paintwork (see sec-
tion “Technical Specifications”).
Ordinary maintenance of the paint-
work means washing it. The frequency
you should do this depends on the
conditions and the environment the
vehicle is driven in.
For example:
– areas with a high level of air-pollu-
tion;
– roads sprinkled with road saltwash;
– parking under trees which drop
resin. In these cases, wash your vehi-
cle more frequently.To wash the vehicle properly:
1)wash the body using a low pres-
sure jet of water;
2) wipe a sponge with a slightly
soapy solution over the bodywork,
frequently rinsing the sponge;
3) rinse well with water and dry
with a jet of air or a chamois leather.
When drying the vehicle, be careful
to get at those parts which are not so
easily seen, e.g. the door frames, bon-
net and around the headlights where
water can most readily collect. You
should leave the vehicle out in the
open so that any water remaining can
evaporate more easily.

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

243TECHNICAL SPECIFICATIONS
FUEL CONSUMPTION - CO2EMISSIONS
RUNNING AND USE CONDITIONS AFFECTING FUEL CONSUMPTION
(examples and differences with respect to goods transportation vehicle data)
IMPORTANT
Although fuel consumption mea-
surements procedure aim at defining
realistic values, fuel consumption is in-
fluenced by factors such as:
Driving style and vehicle usehigh
speed, frequent acceleration, frequent
gear shifting, door-to-door deliveries,
etc.
Just for passenger transportation
versions with 2.3 and 2.8 JTD engines,
reduced consumption can be obtained
by starting (on level road) in 2nd gear
instead of 1st gear.
Traffic and road conditions
queues, bending roads, steep roads,
bad road surface, etc.Weather conditions and tem-
peratures
low temperatures, thinner air, wind,
rain etc…;
Vehicle conditions
Poor maintenance (tyre pressure, fil-
ters, spark plugs, etc.), damaged body-
work
Load conditions
Heavy weights, not optimal load dis-
tribution, large weights on roof rack,
etc.
Use of electric devices
Climate control, heater and electric
devices in general
Special conditions of use
Special vehicle conditions of use: roof
rack, trailer, open side windows, type
of tyres, etc.Special trim and adaptations
caravan, motor home, mega box, can-
vas cover, etc.
Some of these conditions are illus-
trated in these figures on the next
pages.
For more information, refer to the
advice in the chapter “Cheap running
that respects the environment.
The fuel consumption values shown
in the table in following pages were de-
fined according to the type-approval
specifications in European Directives.
Consumption values are defined by
means of the following procedures:
– an urban cycle: consisting of a
cold start and a simulated drive in city
streets;
– an extra-urban cycle: consisting
in frequent accelerations, in all gears,

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