warning FIAT DUCATO 244 2005 3.G Repair Manual

95GETTING TO KNOW YOUR VEHICLE
The correct operation of
front and side airbags and
pretensioners is only ensured if the
vehicle is not overloaded.
WARNINGEOBD SYSTEM
(petrol versions only)
The EOBD (European On Board Di-
agnosis) system fitted on the vehicle
complies with Directive 98/69/CE
(EURO 3).
This system continuously monitors
the engine emission system compo-
nents. Furthermore, the system warns
the driver of deterioration concerning
the emission system components by
means of the Uwarning light on the
instrument panel.
The objective is to:
– monitor system efficiency;
– warn when failures can increase
emissions over the threshold estab-
lished by the European regulations;
– warn of the need to replace dete-
riorated components.
Remember that with the
key engaged and in the
MAR position, even with the en-
gine not running, the airbags may
be triggered on a stationary vehi-
cle if it is bumped by another mov-
ing vehicle. Therefore, never seat
children on the front seat even
when the vehicle is stationary. On
the other hand, remember that
with the vehicle stationary, with-
out the key engaged and turned,
the airbags are not triggered in the
event of an impact; in these cases,
failure to come into action of the
airbags cannot be considered as a
sign that the system is not working
properly.
WARNING
On vehicles equipped with
side bags, do not cover the
backrest of the front seats with
trims or covers.
WARNING
The airbag does not substi-
tute the seat belts, but on-
ly increases their effectiveness.
Moreover, since the front airbags
do not come into operation in the
event of front impact at low speed,
side collisions, bumps from behind
or overturning, in these circum-
stances the occupants would only
be protected by the seat belts which
must therefore always be fastened.
WARNING
Do not wash the seat back
in vehicles with side bags
with pressurised steam or water in
automatic seat washing station.
WARNING

96GETTING TO KNOW YOUR VEHICLE
The action of the ASR is particularly
helpful in the following circumstances:
– slipping of the inner wheel due to
the effect of dynamic load changes or
excessive acceleration.
– too much power transmitted to
the wheels also in relation to the con-
ditions of the road surface.
– acceleration on slippery, snowy or
frozen surfaces.
– in the case of loss of grip on a wet
surface (aquaplaning). Furthermore, the system is equipped
with a connector for interfacing with
specific tools used to read the error
codes stored in the control unit mem-
ory along with a set of diagnostic and
engine specific parameters.ASR SYSTEM
(Antislip Regulation)
The ASR system controls the vehicle
drive and cuts in automatically every
time one or both driving wheels slip.
In slipping conditions, two different
control systems are activated:
– if the slipping involves both the dri-
ving wheels, the ASR function inter-
venes reducing the power transmitted
by the engine;
– if slipping involves only one driving
wheel, the ASR system cuts in auto-
matically braking the wheel that is slip-
ping.
IMPORTANTAfter eliminating the
problem, your Fiat Dealershipwill
run a bench test to fully check the sys-
tem. In some cases, a long road test
may be required.Contact a Fiat Dealer-
ship as soon as possible if
the Uwarning light ei-
ther does not come on when the
key is turned to MAR or comes
on, with fixed or flashing light,
when travelling. Warning light U
operation can be checked by
means of special equipment by
traffic agents. Always comply
with the road traffic regulations
in force in the Country where you
are travelling.
The performance of the
system, in terms of active
safety should not induce the driver
to take pointless and unnecessary
risks. The style of driving must in
any case always be adapted to the
conditions of the road surface, vis-
ibility and traffic. Road safety is al-
ways the driver’s responsibility.
WARNING

97GETTING TO KNOW YOUR VEHICLE
SWITCHING THE ASR
SYSTEM ON AND OFF
The ASR function switches on auto-
matically each time the engine is
started.
When travelling the device can be
switched off and on again pressing
switch A-fig. 143 on the centre con-
sole.
Function deactivation is indicated by
the instrument panel warning light A-
fig. 144coming on. If the ASR func-
tion is turned off when travelling, it
will be restored at the following start-
up.For correct operation of the ASR
system the tyres must absolutely be of
the same brand and type on all
wheels, in perfect conditions and,
above all, of the specified type, brand
and size.
IMPORTANTWhen travelling on
snowy road with snow chains, it may
be helpful to turn the ASR device off:
in fact, in these conditions, slipping of
the driving wheels when moving off
makes it possible to obtain better
drive.
fig. 143
F0D0206m
ASR system failure indication
In the event of malfunctioning, the
ASR system is automatically discon-
nected and the warning light Von
the instrument panel comes on with
fixed light.
Press once button A-fig. 143to
check that the signalled information is
correct:
– button pressed, the warning light
goes off, no ASR system faults are de-
tected;
– button pressed, the warning light
stays on, ASR system fault detected.
In this case the vehicle will go o as a
vehicle not equipped with this system.
Anyway, you are recommended to go
to a Fiat Dealershipas soon as pos-
sible.
fig. 144
F0D0251m

100GETTING TO KNOW YOUR VEHICLE
The wiring connection diagram is:
1Sound system MUTE function.
2Spare.
3Cellular phone INPUT ground
signal (–).
4Cellular phone INPUT ground
signal (+).
5Spare
6Spare
7Ignition switch power (+15).
8Spare
9Battery power (+).
10Ground.
Max. aerial power is 20W.
WARNINGConnector B
B1Door speaker
passenger’s side (+)
B2Door speaker
passenger’s side (-)
B3Dashboard speaker
right side (+)
B4Dashboard speaker
right side (-)
B5Dashboard speaker
left side (+)
B6Dashboard speaker
left side (-)
B7Door speaker
driver’s side (+)
B8Door speaker
driver’s side (-)
AERIAL
Aerial is built into the passenger’s
door mirror.CELLULAR PHONE
SET-UP
IMPORTANTThe optional cellu-
lar phone set-up is bound to “Heavy
set-up” or “Radio” purchase.
The system set-up consists of:
– dual-purpose aerial (sound system
+ cellular phone), built into the pas-
senger’s door mirror;
– dual-purpose aerial connection
wires and ten-pin connector wiring
fig. 149;
– front door speakers.
fig. 149
F0D0106m
See the information given
in the “Accessory installa-
tion” section when making electri-
cal connections so as not to dam-
age the system.
WARNING

104GETTING TO KNOW YOUR VEHICLE
IMPORTANTThe airtight seal of
the cap may lead to a slight increase of
pressure in the tank. A hissing sound
when the cap is removed is therefore
quite normal.
After refuelling, screw the cap until
hearing one or more clicks, turn the
key and then remove it.. close the lid.
IMPORTANTMoreover, before
starting the engine, for the sake of
safety, check whether the refuelling
gun is properly hung onto the fuel
pump.If required, replace the
fuel cap with another gen-
uine cap to avoid affecting
the efficiency of the fuel vapour
recovery system.
fig. 153
F0D0140m
PROTECTING THE
ENVIRONMENT
Protection of the environment has
been the guiding principle in the design
of the Fiat Ducato right from the start.
The result is the use of materials and
creation of devices that can reduce or
considerably curtail harmful influences
on the environment.
The devices for curtailing petrol en-
gine emissions are:
– a three-way catalytic converter;
– a lambda sensor;
– a fuel evaporation system.
The devices for curtailing diesel en-
gine emissions are:
– an oxidising catalytic converter;
– an exhaust gas recirculation system
(E.G.R.) (for certain versions).
Consequently, the Fiat Ducato is
ready to travel well ahead of the most
stringent international pollution control
standards.
Keep naked flames or light-
ed cigarettes away from
the fuel filler hole as there is a dan-
ger of fire. Do not bend too close to
the hole either so as not to breathe
in harmful vapours.
WARNING

105GETTING THE BEST OUT OF YOUR VEHICLE
G G
E E
T T
T T
I I
N N
G G
T T
H H
E E
B B
E E
S S
T T
O O
U U
T T
O O
F F
Y Y
O O
U U
R R
V V
E E
H H
I I
C C
L L
E E
STARTING
THE ENGINE HOW TO START PETROL
VERSIONS
IMPORTANT Do not press the
accelerator until the engine has start-
ed.
1) Ensure that the handbrake is up.
2)Put the gear lever into neutral.
3)Press the clutch pedal down to
the floor without touching the accel-
erator.
4) Turn the ignition key to AVVand
release it as soon as the engine starts.
If the engine does not start at the
first attempt, return the ignition key
to STOP before trying to start the
engine again.
If the warning light Ystays on when
the ignition key is at MAR, turn the
key to STOPand then to MAR; if the
warning light stays on, try with the
other keys provided.
If you are still unable to start the en-
gine, go to a Fiat Dealership.IMPORTANTDo not leave the ig-
nition key at MAR when the engine is
off.
Minibus and School Bus versions:
press the ignition enable button lo-
cated to the left of the steering col-
umn as shown in the specific supple-
ment to this handbook.
Never touch the high volt-
age cables (spark plug ca-
bles) when the engine is running.
WARNING
It is dangerous to let the en-
gine run in a garage of oth-
er closed area. The engine con-
sumes oxygen and gives off carbon
dioxide, carbon monoxide and oth-
er poisonous fumes.
WARNING

106GETTING THE BEST OUT OF YOUR VEHICLE
HOW TO START DIESEL
VERSIONS
1) Ensure that the handbrake is up.
2)Put the gear lever into neutral.
3)Press the clutch pedal down to
the floor without touching the accel-
erator.
4) Turn the ignition key to MAR. In-
strument panel warning lights mand
Ywill come on.
5)Wait for the instrument panel
warning light Yto go out.
6) Wait for the instrument panel
warning light mto go out. The hot-
ter the engine is, the quicker this will
happen.
7) Turn the key to AVVimmediate-
ly after the mwarning light goes out.
If you wait too long, you will lose the
benefit of the work done by the glow
plugs.
Release the key as soon as the engine
starts.Intake air heater (Heat Flange)
An air heating device is fitted on the
intake manifold inlet in 2.8 JTD ver-
sions to facilitate starting the engine in
cold weather.
This device will be switched on au-
tomatically when the key is turned to
MAR.
The heater is fitted in all 2.8 JTD ver-
sions with EGR system. It is optional
for other JTD versions.
The engine start-up procedure is the
same with and without the heater.GENERAL NOTES
If the engine does not start first time,
return the key to STOPbefore try-
ing to start the engine again.
If warning light Yremains lit when
the ignition key is at MAR, turn the
key to STOPand then to MAR; if the
warning light stays on, try with the
other keys provided. The warning light m
will flash (for approxi-
mately 60 seconds) at
start-up or during prolonged
cranking to signal a fault in the
glow plug heating system. You
can use the vehicle as usual if the
engine starts but you should con-
tact a Fiat Dealership as soon as
possible to have problem seen to.
SELENIA 20K (petrol en-
gines) is recommended
when the vehicle is mainly
used in relatively mild climates. If
however, the vehicle is mainly
used where the climate is partic-
ularly severe, the use of SELENIA
PERFORMER MULTIPOWER
(petrol engines) or SELENIA WR
(diesel engines) is recommended.

107GETTING THE BEST OUT OF YOUR VEHICLE
If you still cannot start the engine,
get in touch with a Fiat Dealership.
IMPORTANT When the outside
temperature is low, it is important to
note that the use of a more fluid oil
will facilitate starting the cold engine.
Therefore, in winter, follow the advice
in chapter “Technical specifications”,
paragraph “Fluids and lubricants”.
IMPORTANTNever leave the igni-
tion key at MARwhen the engine is off.
Minibus and School Bus versions:
press the ignition enable button lo-
cated to the left of the steering col-
umn as shown in the specific supple-
ment to this handbook.HOW TO WARM UP
THE ENGINE AFTER IT
HAS JUST STARTED
(petrol and diesel versions)
– Begin to move forward slowly let-
ting the engine turn at medium revs.
Do not accelerate abruptly.
– Do not push the engine to its lim-
it for the first few kilometres. You are
recommended to wait until the
coolant temperature indicator starts
to move.
EMERGENCY START-UP
If the Fiat CODE system fails to
recognise that code transmitted by the
ignition key (warning light Yon the
instrument panel lit) the emergency
start-up can be performed by using the
CODE card code.
See the “In an emergency” section.Catalysed vehicles must
not be bump started
(pushed, towed or coast-
ed downhill) as this could cause
fuel to flow into the catalytic ex-
haust system and damage it be-
yond repair.
Remember that until the
engine has started the
brake booster and power steering
systems will not work and a greater
effort will therefore be required to
depress the brake pedal or turn the
steering wheel.
WARNING

108GETTING THE BEST OUT OF YOUR VEHICLE
SWITCHING OFF
THE ENGINE
Turn the ignition key to STOPwhile
the engine is idling.
IMPORTANTAfter a taxing drive
you should allow the engine to “catch
its breath” before turning it off by let-
ting it idle to allow temperature in the
engine compartment to fall.PARKING
Switch off the engine, pull up the
handbrake and engage a gear (1st gear
or reverse, according to whether the
vehicle is facing up or downhill) and
leave the wheels turned. If the vehi-
cle is left on a steep slope, wedges or
a rock should be used to lock the
wheels.
Do not leave the ignition key at
MAR to prevent running the battery
down. Always remove the key when
you leave the vehicle.HANDBRAKE
The handbrake lever is located on
the left-hand side of the driver’s seat.
Pull the lever upwards as far as it will
go to apply the handbrake. Instrument
panel warning light xwill come on
when the key is turned to MAR.
IMPORTANTThe vehicle must be
blocked after three or four lever re-
leases when the vehicle is empty; the
number of releases necessary to block
it depend on the load and on the road
slope.
In case of problems, contact a Fiat
Dealershipto have it adjusted. A quick burst on the ac-
celerator before turning
off the engine serves ab-
solutely no practical purpose and
wastes fuel. It can also damage
turbo-charged engines.
fig. 1
F0D0044m
Never leave children unsu-
pervised in the vehicle.
WARNING

109GETTING THE BEST OUT OF YOUR VEHICLE
To release the handbrake:
1)slightly lift the handbrake and press
release button A-fig. 1;
2)keep the button pressed and low-
er the lever. Warning light xwill go
out;
3)press the brake pedal when car-
rying out this operation to prevent the
vehicle moving accidentally.
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 fail-
ure of the hydraulic system.
Should the handbrake be exception-
ally used when the vehicle is running, it
is suggested to keep a moderate trac-
tion to avoid causing the rear axle
block, entailing vehicle side skidding.USING THE
MANUAL GEARBOX
Press the clutch fully before shifting
the gear stick into one of the positions
shown in the diagram fig. 2(the dia-
gram is also on the gear lever knob).
To engage reverse, lift the sliding ring
Aunder the knob and shift the lever
to the left and forth.IMPORTANTOnly engage the re-
verse gear when the vehicle is com-
pletely stationary.
With the engine running, before en-
gaging reverse, wait for at least 2 sec-
onds with the clutch pedal pressed to
avoid damaging the gears and grating.
fig. 2
F0D0057m
You must press the clutch
fully down to change gear
properly. It is therefore essential
that there is nothing under the ped-
als. Make sure that mats are lying
flat and do not get in the way of
pedals.
WARNING