engine FIAT DUCATO 244 2005 3.G Manual PDF

171VEHICLE MAINTENANCE
WINDSCREEN WASHER
FLUID
To add fluid, remove cap A-fig. 10
from the reservoir and slowly pour in
a mixture of water and TUTELA
PROFESSIONAL SC35fluid in the
following concentrations:
– 30% ofTUTELA PROFES-
SIONAL SC35and 70% of water in
summer.
– 50% ofTUTELA PROFES-
SIONAL SC35and 50% of water in
winter.
If the temperature falls below –20°C,
useTUTELA PROFESSIONAL
SC35undiluted.
POWER STEERING
FLUID
Check the oil level when the engine
is cold. It should be slightly under the
reference line on the reservoir.
When the oil is hot, the level can ex-
ceed the reference line.
When topping up, remove the reser-
voir cap A-fig. 11 and make sure that
the oil has the same specifications as
the oil in the system.Oil consumption is ex-
tremely low. If the oil
level needs topping up
again after a short period of
time, have the system checked
for leakage at a Fiat Dealership.
fig. 10
F0D0068m
fig. 11
F0D0066m
Do not let the power steer-
ing fluid come into contact
with hot engine parts. It catches fire
very easily.
WARNINGSome windscreen washer
additives on the market are
flammable. The engine compart-
ment contains hot parts which
could ignite the fluid in the event of
contact.
WARNING
Do not travel with the wind-
screen washer reservoir
empty. The windscreen washer is
fundamental for improving visibility.
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

176VEHICLE MAINTENANCE
Furthermore, remember that high in-
take electric devices (such as baby bot-
tle warmers, vacuum cleaners, cellular
phones, mini-fridges, etc.) powered
when the engine is offcan deploy
the battery.
IMPORTANTWhen installing ad-
ditional systems on the vehicle, bear
in mind that improper branches on
connections of the vehicle wiring are
dangerous, particularly if safety devices
are involved.
Battery
60 Ah
88 Ah
100 Ah
The total intake of these systems
(factory and after-market) must be
less than 0.6 mA x Ah (of the bat-
tery) as shown in the following table:
Maximum
admitted stand-by
intake
36 mA
52.8 mA
60 mA
If the vehicle is inactive for a long pe-
riod of time, refer to the “Vehicle stor-
age” paragraph in section “Getting the
best out of you vehicle”.
Before performing any operation on
the electrical system, disconnect the
battery negative cable.
Battery terminals shall always be
perfectly separated.
If you want to add accessories after
buying the vehicle (antitheft system,
free-hand phone kit, radio navigator,
etc.) visit a Fiat Dealership. They
can suggest 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 required.
These devices will, in fact, run off
the battery even when the key is not
inserted (vehicle parked, engine off).

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

183VEHICLE MAINTENANCE
Do not wash the vehicle after it has
been parked in the sun or while the
bonnet is hot: it could take the shine
off the paint.
Outside plastic parts must be
cleaned following the usual vehicle
washing procedure.
Where possible avoid parking the
vehicle under trees; the resinous sub-
stances that certain species of tree
shed dull the paintwork and increase
the possibility of rust forming.To better protect the paintwork,
polish with protective wax from time
to time, that leaves a protective layer
on the paintwork.
When the paintwork tends to lose
its shine because of the build-up of
smog, use a wax (polish) which has a
slightly abrasive as well as protective
action.
Front headlights
IMPORTANTNever use aromat-
ic substances (e.g.: petrol) or ketones
(e.g.: acetone) for cleaning front head-
light plastic lens.
Windows
Use specific window cleaners to
clean the windows. Use very clean
cloths to avoid scratching the glass or
damaging its transparency.
IMPORTANTTo prevent damage
to the electric heater element, wipe
the inside of the heated rear window
(where fitted) gently in the same di-
rection as the elements.Engine compartment
At the end of each winter season,
carefully clean the engine compart-
ment. Have this done at a garage.
IMPORTANTThe engine com-
partment should be washed while the
engine is cold and with the ignition key
at STOP. After washing, make sure
that the various protections (e.g. rub-
ber boots and various guards) have
not be removed or damaged.
Detergents pollute wa-
ter. For this reason, the
vehicle must be washed
in an area equipped for the col-
lection and purification of the liq-
uids used while washing.
IMPORTANTBird droppings
must be washed off immediately and
with great care as their acid is partic-
ularly aggressive.
Detergents pollute wa-
ter. The vehicle must
therefore be washed in an
area equipped for the collection
and purification of the liquids
used while washing.

185TECHNICAL SPECIFICATIONS
T T
E E
C C
H H
N N
I I
C C
A A
L L
S S
P P
E E
C C
I I
F F
I I
C C
A A
T T
I I
O O
N N
S S
VEHICLE
IDENTIFICATION
DATA
CHASSIS MARKING fig. 1
This is stamped on the wheelhouse
near the passenger seat. It can be
reached by lifting the special plastic
flap in the carpeting over the wheel
arch and it includes:
– vehicle model ZFA 244.000
– chassis serial number.ENGINE MARKING
The marking is stamped on the cylin-
der block and includes the model and
the serial number.
See the following pages for the en-
gine codes together with the body-
work codes.MODEL PLATE
The model plate fig. 2includes the
following identification data:
A - Manufacturer’s name
B - Homologation number
C - Vehicle type code
D- Vehicle ID code (Chassis serial
number)
fig. 1
F0D0126m
fig. 2
F0D0026m

186TECHNICAL SPECIFICATIONS
E- Maximum vehicle weight fully
loaded
F - Maximum vehicle weight fully
loaded with trailer
G - Maximum vehicle weight on
front axle
H - Maximum vehicle weight on rear
axle
I - Engine type
L - Body version code
M - Smoke opacity index (for diesel
engines).
This plate is fastened to the front
crossmember in the engine compart-
ment A-fig. 3.BODYWORK PAINT
IDENTIFICATION PLATE
The plateA-fig. 4 is set on the left-
hand inner side of the bonnet.It bears the following data fig. 5:
A - Paint manufacturer
B - Colour name
C - Fiat colour code
D- Respray and touch up code.
fig. 3
F0D0188m
fig. 4
F0D0189m
fig. 5
F0D0025m

187TECHNICAL SPECIFICATIONS
ENGINE CODES - BODYWORK VERSIONS
Version 11
Van short wheelbase
Van short wheelbase
Van medium wheelbase
Van high sided medium wheelbase
Van high sided medium wheelbase
Truck medium wheelbase
Truck short wheelbase
Chassis cab short wheelbase
Chassis cab short wheelbase Camping Car
Chassis cab medium wheelbase
Chassis cab medium wheelbase Camping Car
Transport ambulance short wheelbase
Panorama short wheelbase
Combi 6 seater short wheelbase
Chassis cab with load bed short wheelbase
Chassis cab with load bed short wheelbase Camping Car
Chassis cab with load bed medium wheelbase
Chassis cab with load bed medium wheelbase Camping Car
Van short wheelbase
Van short wheelbase
Van medium wheelbaseEngine
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0 JTD
2.0 JTD
2.0 JTDEngine
code
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RFL
RHV
RHV
RHVBodywork
version
244ATMFA AX
244ATMFA BX
244ATMFB AX
244ATMNB AX
244ATMNB BX
244ATMDB AX
244ATMDA AX
244ATMAA AX
244ATMAA AXC
244ATMAB AX
244ATMAB AXC
244ATMTA AX
244ATMPA 00
244ATMRA 01
244ATMCA AX
244ATMCA AXC
244ATMCB AX
244ATMCB AXC
244AAMFA AX
244AAMFA BX
244AAMFB AX

188TECHNICAL SPECIFICATIONS
Version 11
Van high sided medium wheelbase
Van high sided medium wheelbase
Chassis cab short wheelbase
Chassis cab short wheelbase Camping Car
Truck short wheelbase
Chassis cab with load bed short wheelbase
Chassis cab with load bed short wheelbase Camping Car
Chassis cowl short wheelbase
Chassis cowl short wheelbase Camping Car
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
Panorama short wheelbase
Combi 6 seater short wheelbase
Combi short wheelbase low roof
Combi medium wheelbase low roof
Chassis cowl short wheelbase “city centre”
Chassis cab with load bed short wheelbase “city centre”
Truck short wheelbase “city centre”
Chassis cab with load bed medium wheelbase “city centre”
Truck medium wheelbase “city centre”
Van short wheelbase low roof “city centre”
Van short wheelbase high roof “city centre”
Van medium wheelbase low roof “city centre”
Van medium wheelbase high sided “city centre”
Van medium wheelbase extra high “city centre”
Van short wheelbase low roof (9 q)Engine
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTD
2.0 JTDEngine
code
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHV
RHVBodywork
version
244AAMNB AX
244AAMNB BX
244AAMAA AX
244AAMAA AXC
244AAMDA AX
244AAMCA AX
244AAMCA AXC
244AAMBA AX
244AAMBA AXC
244AAMAB AX
244AAMAB AXC
244AAMDB AX
244AAMCB AX
244AAMCB AXC
244AAMPA 02
244AAMRA 03
244AAMFA ZX
244AAMRB 26
244AAMRA 03
244DAMBA AX
244DAMCA AX
244DAMDA AX
244DAMCB AX
244DAMDB AX
244DAMFA AX
244DAMFA BX
244DAMFB AX
244DAMNB AX
244DAMNB BX