automatic FIAT DUCATO 244 2005 3.G Service Manual

210TECHNICAL SPECIFICATIONS
Version MAXI
Truck short wheelbase
Chassis cab short wheelbase automatic gearbox
Chassis cab short wheelbase Camping Car automatic gearbox
Truck short wheelbase automatic gearbox
Chassis cab medium wheelbase
Chassis cab medium wheelbase Camping Car
Truck medium wheelbase
Chassis cab with load bed medium wheelbase
Chassis cab with load bed medium wheelbase Camping Car
Chassis cab medium wheelbase automatic gearbox
Chassis cab medium wheelbase Camping Car automatic gearbox
Truck medium wheelbase automatic gearbox
Chassis cab with load bed medium wheelbase automatic gearbox
Chassis cab with load bed medium wheelbase
Camping Car automatic gearbox
Chassis cowl short wheelbase
Chassis cowl short wheelbase Camping Car
Chassis cowl short wheelbase automatic gearbox
Chassis cowl short wheelbase Camping Car automatic gearbox
Chassis cowl medium wheelbase
Chassis cowl medium wheelbase Camping Car
Chassis cowl medium wheelbase automatic gearbox
Chassis cowl medium wheelbase Camping Car automatic gearbox
Chassis cab long wheelbase
Chassis cab long wheelbase Camping Car
Truck long wheelbase
Chassis cab with load bed long wheelbase
Chassis cab with load bed long wheelbase Camping Car
Chassis cab long wheelbase automatic gearbox
Chassis cab long wheelbase Camping Car automatic gearbox
Truck long wheelbase automatic gearboxEngine
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTDEngine
code
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43SBodywork
version
244CPMAA AXC
244CPAAA AX
244CPAAA AXC
244CPADA AX
244CPMAB AX
244CPMAB AXC
244CPMDB AX
244CPMCB AX
244CPMCB AXC
244CPAAB AX
244CPAAB AXC
244CPADB AX
244CPACB AX
244CPACB AXC
244CPMBA AX
244CPMBA AXC
244CPABA AX
244CPABA AXC
244CPMBB AX
244CPMBB AXC
244CPABB AX
244CPABB AXC
244CPMAC AX
244CPMAC AXC
244CPMDC AX
244CPMCC AX
244CPMCC AXC
244CPAAC AX
244CPAAC AXC
244CPADC AX

211TECHNICAL SPECIFICATIONS
Version MAXI
Chassis cab with load bed long wheelbase automatic gearbox
Chassis cab with load bed long wheelbase
Camping Car automatic gearbox
Chassis cowl long wheelbase
Chassis cowl long wheelbase Camping Car
Chassis cowl long wheelbase automatic gearbox
Chassis cowl long wheelbase Camping Car automatic gearbox
Chassis cab 4050 wheelbase
Chassis cab 4050 wheelbase Camping Car
Truck 4050 wheelbase
Chassis cab 4050 wheelbase automatic gearbox
Chassis cab 4050 wheelbase Camping Car automatic gearbox
Truck 4050 wheelbase automatic gearbox
Chassis cowl 4050 wheelbase
Chassis cowl 4050 wheelbase Camping Car
Chassis cowl 4050 wheelbase automatic gearbox
Chassis cowl 4050 wheelbase Camping Car automatic gearbox
Chassis cab medium wheelbase crew cab
Chassis cab medium wheelbase crew cab Camping Car
Truck medium wheelbase crew cab
Chassis cab long wheelbase crew cab
Chassis cab long wheelbase crew cab Camping Car
Truck long wheelbase crew cab
Minibus long wheelbase Engine
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTDEngine
code
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43SBodywork
version
244CPACC AX
244CPACC AXC
244CPMBC AX
244CPMBC AXC
244CPABC AX
244CPABC AXC
244CPMAG AX
244CPMAG AXC
244CPMDG AX
244CPAAG AX
244CPAAG AXC
244CPADG AX
244CPMBG AX
244CPMBG AXC
244CPABG AX
244CPABG AXC
244CPMHB AX
244CPMHB AXC
244CPMGB AX
244CPMHC AX
244CPMHC AXC
244CPMGC AX
244CPMMC AX

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

217TECHNICAL SPECIFICATIONS
ELECTRONIC AUTOMATIC
GEARBOX
(2.8 JTD versions only)
Automatic gearbox with four speeds
plus reverse with self-adapting control
(i.e. capable of adapting to the driver’s
driving style), which transmits power
continuously and with very fast elec-
tro-hydraulic gear engagement times.SUSPENSIONS
FRONT
Independent wheel, McPherson sus-
pension.
Telescopic dampers with flexible an-
chorage to the body and dust guards
on buffers.
Coil springs offset with shock ab-
sorbers and knock-guard buffers.
Lower wishbone with twin taper
rubber bushing on chassis and ball
head on wheel stud.REAR
Rigid tubular axle type.
Lengthways single blade (two-blades
as optional) leaf spring.
Vertical shock absorbers anchored
above on the body (on the inside of
the wheelhouse) and down on the
axle flange.
Knock-guard buffer fixed to the side
member.
Coupling for brake load proportion-
ing.

240TECHNICAL SPECIFICATIONS
Fuel tank:
including a reserve of:
Engine cooling
system:
Engine sump:
Engine sump and filter:
Transaxle:
Automatic gearbox
Hydraulic power steering:
Front and rear hydraulic
brake circuit:
11-15 versions
MAXI versions
Hydraulic brake circuit
with ABS:
11-15 versions
MAXI versions
Windscreen and rear window
liquid reservoir:2000 JTD 2300 JTD
Litres
80
8 ÷ 10
9
–
6.25
2.7
–
1.3
0.59
0.62
0.59
0.62
4.2Litres
80
8 ÷10
10
5.8
6.3
2.7
–
1.3
0.59
0.62
0.59
0.62
4.2 kg
–
–
–
5.6
2.43
–
–
–
–
–
–
–kg
–
–
5.2
5.7
2.43
–
–
–
–
–
–
–Litres
80
8 ÷10
10
5.0
5.7
2.7
8.2
1.3
0.59
0.62
0.59
0.62
4.2kg
–
–
4.5
5.1
2.43
–
–
–
–
–
–
–Prescribed fuel
Recommended products
Diesel fuel for motor vehicles
(EN590 specifications)
Mixture of distilled water and
PARAFLU 11(blue) at 50% or
PARAFLU UP(red) at 50%
SELENIA WR
TUTELA CAR MATRYX
TUTELA HP 20
TUTELA GI/A
TUTELA TOP 4
TUTELA TOP 4
Mixture of water and TUTELA
PROFESSIONAL SC 35 2800 JTD -
2800 JTD POWER

242TECHNICAL SPECIFICATIONS
Use
Lubricants and grease
for transmission
Products for brakes
Radiatorantifreeze
Diesel fuel
additive
Windscreen/
rear window/
headlight washer fluid
(*) IMPORTANTThese two fluids cannot be mixed with each other. Contact Fiat Dealership for topping up.
Recommended
fluids and lubricants
TUTELA CAR
MATRYX
TUTELA GI/A
TUTELA HP 20
TUTELA
W 90/M-DA
TUTELA TOP 4
PARAFLU 11 (*)
or
PARAFLU UP (*)
DIESEL MIX
TUTELA
PROFESSIONAL
SC 35 Fluid and lubricant specifications
for correct vehicle operation
Fully synthetic lubricant SAE 75W-85 meeting API GL-4,
FIAT 9.55550
Lubricant for transmissions with ATF DEXRON II D LEV
properties
ATF DEXRON III oil type
Lubricant, grade SAE 80W-90 that passes API GL5, MIL-L-
2105 D, IVECO 18-1804, FIAT 9.55550 and FIAT 9.55523
specifications
Synthetic fluid, FMVSS n° 116 DOT 4, ISO 4925,
SAE J-1704, CUNA NC 956 - 01
Protective with antifreeze action based on
inhibited monoethylen glycol, CUNA NC 956-16
Protective with antifreeze action (red colour) based on inhib-
ited monoethylen glycol, with O.A.T. formulation, that passes
CUNA NC 956-16, ASTM D 3306 specifications.
Diesel fuel additive providing diesel engine protection
Mixture of alcohol and surfactants CUNA NC 956 -IIApplications
Mechanical
transaxles developping
high temperatures
Power steering system
Automatic gearbox
EP oil for standard and
self-locking differentials
Hydraulic brake and
clutch controls
Cooling circuits.
Proportion: 50% down
to -35° C Not to be
mixed with products
having different
formulas.
To be mixed with
diesel fuel
(25 cc every 10 litres)
To be used pure
or diluted

245TECHNICAL SPECIFICATIONS
Consumption according to Directive Urban Extra-urban Combined CO
2emissions at exhaust
99/100/EC (litres/100 km)according to Directive
99/100/EC (g/km)
Engine 2.3 JTD (*)
Version 11Panorama short wheelbase 9.0 7.7 8.1 216Combi short wheelbase 8.7 7.3 7.8 208
Version 15Combi medium wheelbase 8.7 7.3 7.8 208
Combi medium wheelbase high sided 9.0 7.7 8.1 216
Panorama medium wheelbase 9.2 8.0 8.4 223
Engine 2.8 JTD (*)
Version 11Panorama short wheelbase 10.9 8.8 9.6 234
Panorama short wheelbase
automatic gearbox 13.7 10.0 11.3 301
Combi short wheelbase 10.6 8.5 9.3 246
Panorama short wheelbase 4x4 11.1 9.0 9.8 261
Version 15Combi medium wheelbase 10.6 8.5 9.3 246
Combi medium wheelbase high sided10.9 8.8 9.6 234
Combi medium wheelbase
automatic gearbox 13.4 9.8 11.1 295
Combi medium wheelbase high sided
automatic gearbox13.7 10.0 11.3 301
Panorama medium wheelbase 11.1 9.0 9.8 261
Panorama medium wheelbase
automatic gearbox 13.9 10.2 11.5 307
Combi short wheelbase 4x4 10.9 8.8 9.6 234
Combi medium wheelbase 4x4 11.1 9.0 9.8 261
(*) Test was performed with start-up in second gear.

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

248INDEX
Cruise Control ............................ 68
Current socket ............................ 76
Dashboard ................................. 5
Demisting ...................................... 56
Diesel fuel filter ........................... 173
Differential .................................... 216
Digital clock .................................. 32
Dimensions ........................... 222-224
Dipped beam headlights ............ 65
- bulb replacement ................... 143
Direction indicators ................... 66
- front bulb replacement ......... 145
- rear bulb replacement .......... 146
- side bulb replacement ........... 145
Doors ............................................ 79
- 270° opening ........................... 82
- central door locking .............. 83
- driver’s cab doors .................. 79
- rear door ................................. 81
- remote control ....................... 9- side sliding door ..................... 80
- window regulators ................ 83
Driving style affecting fuel
consumption .............................. 124
Electric windows ....................... 83
Electronic alarm .......................... 11
Electronic automatic gearbox .. 110
Electronic control units ............. 177
- speed limiter ........................... 177
Emergency starting .............. 107-135
Emission control devices ........... 128
Engine ............................................ 214
- starting diesel engines ........... 106
- starting petrol engines .......... 105
- stopping the engine ............... 108
- supply/ignition ......................... 215
- warming up the engine ......... 107
Engine/bodywork codes ............ 187
Engine compartment .................. 183
Engine coolant gauge .................. 30
Engine coolant level .................... 170Engine marking ............................ 185
Engine oil ....................................... 169
- consumption ........................... 170
Engine oil level ............................. 169
Engine oil level gauge ................. 32
EOBD system .............................. 95
Fiat Code (system) ................... 7
First aid kit .................................... 161
Flashing the headlights ............... 66
Fluids and lubricants ................... 241
Front/rear ceiling light
replacement ............................... 148
Front fog light replacement ...... 145
Fuel cut-off switch ...................... 72
Fuel gauge ..................................... 31
Fuses (replacement) ................... 149
Getting to know
your vehicle............................ 5
Getting the best out of
your vehicle............................ 105

251INDEX
Understanding rim markings ... 219
Understanding tyre markings ... 219
Using the automatic gearbox ... 110
Using the manual gearbox ........ 109
Vehicle maintenance........... 162
Vehicle storage ............................. 134
Ventilation...................................... 56
Warming up the engine
after it has just started ............. 107
Warning lights ............................. 35
Washing the vehicle ................... 182
Weights ......................................... 227
Wheel geometry ......................... 218
Wheels and tyres ........................ 178
- changing a wheel .................... 137
- inflation pressure ................... 220
- snow chains ............................ 133
- snow tyres .............................. 132
- spare wheel ............................. 218- understanding tyre
markings ................................... 219
- wheel geometry ..................... 218
Windows ...................................... 183
Windscreen washer ............ 66-181
Windscreen washer
fluid level .................................... 171
Windscreen
wiper (blades) ..................... 66-180
Writing/reading desk ................. 74