engine FIAT DUCATO 244 2005 3.G Service Manual

115GETTING THE BEST OUT OF YOUR VEHICLE
Moving the lever back to position D
the gearbox instantly resumes the au-
tomatic mode selecting the ratio ac-
cording to the driving characteristics.
IMPORTANTThe electronic con-
trol unit is programmed to change
gear one at a time, therefore repeat-
ed fast actuations will not result in re-
peated engagements of the gears. The
higher or lower gear is engaged mov-
ing the lever to the (+) or (–) position
when the previous request has been
performed.
In the event of a fault to the sequen-
tial manual system, the system will se-
lect the automatic mode.FAILURE INDICATIONS
Automatic gearbox faults are indi-
cated by the warning light A-fig. 9 on
the instrument panel.
Turning the ignition key to MARthe
warning light should turn on and go
out after about 4 seconds. If the warn-
ing light stays on or if turns on when
travelling, this indicates a gearbox fault
(flashing light) or gearbox oil over-
heating (steadily glowing light).– Warning light glowing steadi-
ly= automatic gearbox oil maximum
temperature.
If the warning light turns on and
glows steadily when travelling, this in-
dicates that the gearbox oil has
reached the maximum temperature.
You are therefore advised to stop the
vehicle with the engine at idle speed
and gearshift lever in “N” or “P” (in
this case engine cooling fans are on),
until the warning light goes out and re-
sume your journey without pushing
the engine to peak performance.
If the warning light turns on again, it
is necessary to stop again with the en-
gine idling until it goes out.
If there are less than 15 minutes be-
tween one turning on of the warning
light and the next, you are advised to
stop the vehicle, do not switch off the
engine but allow the engine-gearbox
unit to cool down completely (both
engine cooling fans off).
fig. 9
F0D0192m

116GETTING THE BEST OUT OF YOUR VEHICLE
BUMP STARTING
Starting by pushing or towing the ve-
hicle is not possible. In the event of an
emergency, when the battery is flat,
start the vehicle with a suitable emer-
gency battery, following the instruc-
tions given in section “In an emer-
gency” at paragraph “Jump starting”.
TOWING THE VEHICLE
IMPORTANTFor towing the ve-
hicle comply with current local regu-
lations and follow the instructions giv-
en in section “In an emergency” at
paragraph “Towing the vehicle”.If the vehicle is to be towed, adhere
to the following recommendations:
– if possible, carry the vehicle on the
floor of a rescue vehicle;
– if this is not possible, tow the ve-
hicle raising the driving wheels (front)
from the ground;
– if this, too, is not possible, the ve-
hicle should not be towed for more
than 200 km at a speed of no more
than 50 km/h.
When towing, the gearshift lever
should be at N.
Do not start the engine
while the vehicle is being
towed.
The failure to comply
with these instructions
may cause serious dam-
age to the automatic gearbox.
When travelling with the
gearbox faulty, drive with
the utmost care in consideration of
the limited performance (in terms
of acceleration and speed) that the
vehicle can offer.
WARNING
When travelling with the
gearbox faulty, the revers-
ing gear lock might not be active:
absolutely never move the lever to
the R position with the vehicle on
the move.
WARNING– Warning light flashing= auto-
matic gearbox fault.
Warning light flashing at starting or
when travelling indicates a fault in the
automatic gearbox.
The automatic control system sets
an “emergency programme” engaging
the 3
rdgear.
Switching the engine off and then on
again, the self-test system could ex-
clude the fault and therefore turn off
the warning light. The failure is how-
ever stored and the automatic gear-
box shall be checked at a Fiat Deal-
ership.

117GETTING THE BEST OUT OF YOUR VEHICLE
CONSTRUCTION FEATURES
DUCATO automatic gearbox is con-
trolled electronically with four for-
ward gears and reverse.
It is controlled by an electronic con-
trol unit which handles:
– the torque distributor;
– gearshifting;
– specific programmes.
The gearbox is coupled with a flow
power torque distributor with piloted
antislip device which makes it possible
to obtain demultiplication ratios.
The characteristic of this gearbox
which works without idle gear enables:
– higher compactness and weight re-
duction;
– improved output due to less fric-
tion;
– lower stress of transmission com-
ponents.GENERAL FEATURES
Electronic gearbox control makes it
possible to obtain gearshifting suited
to momentary engine characteristics
with a certain elasticity.
The electronic control unit has the
following task:
– adapting the oil pressure for
gearshifting to the engine torque;
– activating safety functions;
– defining the manual gearshifting
programme;
– system diagnostics.
For controlling these operating log-
ics the control unit uses the follow-
ing signals:
– engine rpm;
– engine temperature;
– engine torque;
– vehicle speed;
– gearbox oil temperature;– gearshift lever position;
– accelerator pedal position;
– brake pedal position.
The control unit also communicates
with the injection system electronic
control unit.
Conditions of use analysed by
the control unit
The control unit analyses each single
condition of use of the vehicle, dis-
criminating it on the basis of the sig-
nals received from the various sensors.
Analysed conditions are the follow-
ing:
– starting (position/accelerator ped-
al changing speed);
– acceleration (accelerator pedal
completely pushing down speed);
– full load (number of engine full load
kickdown signals or position mainte-
nance time);

118GETTING THE BEST OUT OF YOUR VEHICLE
– braking (accelerator pedal release
time and braking system operation);
– type of programme (gearshift se-
lector lever position);
– winter driving (driving wheel
torque reduction);
– driving with trailer or uphill (vehi-
cle speed in relation to transmitted
torque)
– driving downhill (vehicle accelera-
tion in relation to the position of the
accelerator pedal);
– driving in towns or queues (accel-
erator pedal position and vehicle
speed);
– gear required by the driver
(gearshift lever position);
– cold starting (engine temperature).Gearshift programme control
To optimise vehicle handling the
electronic control unit has the fol-
lowing memorised programmes:
– automatic operation;
– manual operation;
– winter driving (to be selected
through buttonWINTER);
– engine warming up;
– protection against excessive gear-
box oil temperature .Automatic programme
This comprises 16 gearshifting pro-
grammes.
In relation to the vehicle speed and
torque transmitted, the control unit
detects the slope of the road surface
and depending on the sporty features
chosen, it autonomously chooses the
programme most suited to the situa-
tion.
During gearshifting, the gearbox con-
trol unit asks the injection control unit
to momentarily reduce the torque.
The duration of torque reduction
varies depending on the travelling con-
ditions.

119GETTING THE BEST OUT OF YOUR VEHICLE
Manual sequential programme
This function enables manual se-
quential use of the gearbox merely
moving the selector lever to the left.
Each time the lever is pressed only
one gear is shifted: more than one shift
cannot be obtained.
To avoid overevving or excessively
low engine rpm, the control unit in-
hibits requests for gearshifting that
would cause such situations.
Winter driving programme
This programme is engaged by press-
ing button WINTERnear the
gearshift lever,
in case of driving wheel skidding and
it changes to specific gears.
Starting is possible only in 2
ndgear.
On snowy roads use however snow
chains and/or tyres.
The WINTERfunction shall always
be off on slopes.Engine warming up programme
This programme allows the engine to
reach normal operating temperature
in the shortest time possible (de-
pending on the outside temperature)
highering the gearshifting points, in re-
lation to engine temperature.
The programme engages automati-
cally after starting, if the engine tem-
perature is below 30 °C and it remains
active up to 34 °C.
Excessive gearbox oil
temperature programme
This is activated when the gearbox
oil temperature reaches 120 °C and it
remains active down to 117 °C.
To facilitate oil cooling, this pro-
gramme inhibits gearshifting, either up
or down. It is however possible to use
the manual programme.
SAFE DRIVING
In designing Ducato, Fiat has made
every effort to come up with a vehicle
able to provide driver and passengers
with top-class levels of safety. Never-
theless it is always the behaviour of the
person at the wheel that determines
road safety.
In the following pages you will find
some simple tips to help you travel in
safety under different conditions. You
will no doubt be familiar with many of
them already but it will be useful to
read them all carefully.

120GETTING THE BEST OUT OF YOUR VEHICLE
BEFORE GETTING BEHIND
THE WHEEL
– Make sure all light, including the
headlights, are working properly;
– adjust the position of seats and dri-
ving and door mirrors properly for the
best driving position;
– make sure that nothing (mats, etc.)
gets in the way of the pedals when
they are pushed down;
– make sure that any child restraint
systems (child seats, cradles, etc.) are
properly fixed;
– place any objects in the load com-
partment in such a way that they can-
not be thrown forwards in the event
of an accident;
– light eating will help keep your re-
flexes prompt. Above all, do not have
anything alcoholic to drink.
Remember to periodically check:
– tyre pressure,
– engine oil level,
– engine coolant level and cooling
system conditions,– brake fluid level,
– windscreen washer fluid level.
WHEN TRAVELLING
– The first rule of safe driving is pru-
dence;
– prudence also means putting your-
self into a position where you can pre-
dict wrong or imprudent behaviour
from other drivers;
– stick closely to the rules of the
road in the particular country where
the vehicle is being driven and, above
all, do not exceed speed limits;
– ensure that, besides yourself, all the
other passengers in the vehicle have
their seat belts fastened, that children
are sitting in the appropriate child
seats and any animals in the vehicle are
placed in suitable compartment;
– you should be physically fit and
mentally alert before setting out on
long journeys.
Always fasten both front
and back seat belts
(Panorama, Minibus, Combi and
Crew Cab versions). Travelling with
the seat belts unfastened increas-
es the risk of injury or death if you
are in a collision.
WARNING
Driving while drunk or un-
der the influence of drugs
or certain medicines is dangerous
for both you and other road users.
WARNING

121GETTING THE BEST OUT OF YOUR VEHICLE
– Do not drive too many hours at a
time but stop at intervals to stretch
your legs and recoup your energy;
– make sure the air in the passenger’s
compartment is being changed
continuously;
– never coast downhill (i.e. with the
engine off): if you do, you lose the aid
of engine braking, power brakes and
power steering so that braking re-
quires greater effort on the pedal and
steering requires greater effort on the
steering wheel.DRIVING AT NIGHT
These are the main rules to follow
when you are driving at night:
– drive especially carefully: it is hard-
er to drive at night;
– slow down especially if the road is
not lit;
– at the first signs of sleepiness, stop:
continuing would be a risk for yourself
and everybody else. Only start driving
again when you have had enough rest;
– keep a greater safety distance from
the vehicles in front of you than dur-
ing daylight hours: it is hard to judge
how fast other vehicles are going when
all you can see are their lights;
– make sure the headlights beams are
properly positioned: if they are too
low, they reduce visibility and strain
your eyes. If they are too high they can
dazzle other drivers. Adjust headlight
beam according to transported load;
– only use main beam headlights
when you are driving outside town
and when you are sure they do not an-
noy other drivers. dip your headlights
Water, ice or salt sprinkled
on the road can deposit on
the brake discs and reduce effi-
ciency of the first braking.
WARNING
Do not drive with objects
on the floor in front of the
driver’s seat: they could caught un-
der the pedals making braking or
accelerating impossible.
WARNING
Pay attention to the mats:
even a small problem to the
braking system may require in-
creased brake pedal stroke with re-
spect to normal.
WARNING

123GETTING THE BEST OUT OF YOUR VEHICLE
– if you are forced to stop your ve-
hicle (breakdown, limited visibility,
etc.) try to stop off the road. Turn on
the hazard lights and, if possible, the
dipped beam headlights. Rhythmically
sound the horn if you release anoth-
er vehicle is coming.
DRIVING IN THE
MOUNTAINS
– Check fluid levels (oil, brake fluid,
coolant) and tyre wear before driving
in the mountains;
– when driving downhill use the en-
gine braking effect by engaging a low
gear so as not to overheat the brakes;
– under no circumstances should you
drive downhill with the engine off or
with the gear in neutral, let alone with
the ignition key out;
– drive at moderate speed and avoid
“cutting” corners;
– remember that overtaking while
going uphill is slower and therefore re-
quires more free road. If you are be-
ing overtaken while driving uphill,
make it easier for the other vehicle
to pass.DRIVING ON SNOW
AND ICE
Here are some tips for driving in
these conditions:
– keep your speed down;
– use chains if the roads are covered
with snow;
– do not park the vehicle with the
engine running for long periods of
time: snow could divert exhaust fumes
into the passenger compartment;
– mainly use the braking effect of the
engine and under all circumstances
avoid braking sharply;
– when braking a vehicle not fitted
with ABS, reduce the possibility of the
wheels locking by varying the pressure
you exert on the brake pedal;
– do not accelerate suddenly and
avoid swerving;– in the winter, even apparently dry
roads may have icy patches. Be care-
ful therefore when driving over
stretches that do not get much expo-
sure to the sun or are lined with trees
or rocks where ice might not have
melted;
– keep a good distance from the ve-
hicles in front.
DRIVING WITH ABS
– ABS is a braking system that es-
sentially offers two advantages:
1) It prevents wheel lock and con-
sequent skidding in emergency stops,
particularly when the road does not
offer much grip.
2) it makes it possible to brake and
steer at the same time and direct the
vehicle where you want while braking.

125GETTING THE BEST OUT OF YOUR VEHICLE
Electric devices
Use electric devices for the neces-
sary time only. The heated rear win-
dow, fog lights, windscreen wipers,
heater fan require large amounts of
electricity and increasing the request
for power will also increase fuel con-
sumption (up to +25% when driving in
towns).
Climate control system
The climate control system is an ad-
ditional load which greatly affects the
engine leading to higher consumption.
When the temperature outside the
vehicle allows it, use the air vents
where possible.
DRIVING STYLE
Starting
Do not warm the engine when the
vehicle is stationary or at high or low
speed: in this way the engine will warm
up gradually increasing consumption
and emissions. You should drive off
slowly straight away avoiding high revs
so that the engine will warm up more
quickly.Unnecessary actions
Avoid revving the engine when
stopped at traffic lights or before
switching off the engine and avoid dou-
bling the clutch as these actions have
no purpose on modern vehicles and
serve only to increase consumption
and pollution.
Gear selections
As soon as the traffic and road con-
ditions allow it, shift to a higher gear.
Using a low gear to liven up accelera-
tion greatly increases consumption. In
the same way improper use of high
gears will increase consumption, emis-
sions and engine wear.
On passenger transportation versions
fitted with 2.3, 2.8 JTD and 2.8 JTD
POWER engines, fuel consumption can
be optimised by starting (on level road)
in 2nd gear instead of 1st gear.Top speeds
Fuel consumption increases consid-
erably as speed increases. Your speed
should be kept as even as possible and
superfluous braking and acceleration
avoided as this increases both con-
sumption and emissions.
Acceleration
Accelerating violently increasing the
revs will greatly affect consumption
and emissions; acceleration should be
gradual and should not exceed the
maximum torque.

126GETTING THE BEST OUT OF YOUR VEHICLE
CONDITIONS OF USE
Cold starting
Frequent cold starting will not enable
the engine to reach optimal running
temperature. It follows, therefore,
that consumption will be higher (from
+15 to +30% in towns) as will the
production of toxic emissions.
Traffic and road conditions
Heavy traffic and higher consumption
are synonymous: for example, when
driving slowly with frequent use of low-
er gears or in towns where there are
numerous traffic lights.
Winding roads, mountain roads and
bumpy roads also have a negative effect
on consumption.
Enforced halts
During prolonged stops (traffic lights,
level crossings, etc.) the engine should
be switched off.LOAD
RECOMMENDATIONS
The version of the Ducato you are
driving has been designed and ap-
proved on the basis of several set
maximum weights (see the tables
“Weights” in section “Technical spec-
ifications”):
– kerb weight
– payload
– total weight
– total weight on the front axle
– total weight on the rear axle
– towable weight
fig. 10
F0D0047m
Each of these limits must be
borne in mind and MUST
NEVER BE EXCEEDED under any
circumstances. In particular, never
exceed the maximum weight per-
mitted on the front and rear axles
when arranging loads in vehicle (es-
pecially for special version vehicles).
WARNING
Chance knocks or sudden
braking can cause sudden
shifts of the load which could jeop-
ardise the safety of the driver and
the passengers: before you start off
make sure the load is firmly secured
by using the hooks built into the
floor for that purpose fig. 10. Use
metal cables, ropes or straps strong
enough to support the weight of
the load to be fixed.
WARNING