brakes FIAT DUCATO 244 2005 3.G Owners Manual

15GETTING TO KNOW YOUR VEHICLE
SEAT BELTS
USING THE SEAT BELTS
The belt should be worn keeping the
chest straight and rested against the
seat back.
To fasten the seat belts, take hold the
fastener tongue A-fig. 10and insert
it into the buckle B, until hearing the
locking click.The seat belt reel mechanism en-
sures that the belt automatically ad-
justs to the wearer allowing him or
her to move in complete freedom.
When the vehicle is parked on a
steep slope the reel mechanism may
block; this is normal. The reel mech-
anism also prevents the webbing com-
ing out when it is jerked or if the ve-
hicle brakes sharply, is in a collision or
when cornering at high speed.
fig. 10
F0D0050m
Never press button C when
travelling.
WARNING
At removal, if it jams, let it rewind for
a short stretch, then pull it out again
without jerking.
To unfasten the seat belts, press but-
ton C. Guide the seat belt with your
hand while it is rewinding, to prevent
it from twisting.

39GETTING TO KNOW YOUR VEHICLE
AIRBAG FAILURE
(red) (where provided)
The warning light comes on when
there is a failure in the system.
¬
HANDBRAKE
ENGAGED/LOW
BRAKE FLUID LEVEL
(red)
In three cases:
1- when engaging the handbrake
2- when the brake fluid level drops
under the minimum level
3- with the
>warning light to in-
dicate an EBD(electronic brakeforce
distributor) failure.SEAT BELTS (red)
(for countries/markets
where applicable)
When the driver’s seat belt is not fas-
tened properly.
DOORS OPEN (red)
When cab door/doors
is/are not perfectly closed.
The warning light is provided only on
certain versions.
FRONT BRAKES
WORN (red)
When the front brake pads
are worn. Have them replaced and
check the rear brake pads too.
x<
´
d
If the ¬warning light does
not turn on when turning
the ignition key to MAR or if it stays
on when travelling, this could indi-
cate a failure in safety retaining sys-
tems; under this condition air bags
or pretensioners could not trigger
in the event of collision or, in a re-
stricted number of cases, they could
trigger accidentally. Stop the car
and contact Fiat Dealership to have
the system checked immediately.
WARNING
If xwarning light comes
on when travelling, check
whether the handbrake is on. If the
warning light stays on and the
handbrake is off, stop immediate-
ly and contact a Fiat Dealership.
WARNING

88GETTING TO KNOW YOUR VEHICLE
If you have never driven a vehicle
with ABS before, you should practice
using the system on slippery terrain,
obviously with the necessary safety
precautions and keeping to the High-
way Code of the country you are in.
It is also a good idea to read the fol-
lowing information carefully.
The advantage in using the ABS sys-
tem is that it continues to give you
maximum manoeuvrability even when
braking hard in conditions of poor grip
by preventing the wheels locking.
You should, however, not expect the
braking distance to always decrease:
for example surfaces with gravel or
fresh snow on a slippery road will in
fact increase the braking distance.
To exploit the ABS system to the full
in the event of necessity, you should
take heed of the following advice:ABS
The vehicle is fitted with an ABS
braking system (optional), which pre-
vents the wheels from locking when
braking, makes the most of road grip
and gives the best control when emer-
gency braking under difficult road con-
ditions.
The driver can tell the ABS system
has come into play when he feels the
brake pedal pulsating slightly and the
system gets noiser.
This should not be interpreted as a
fault in the brakes; on the contrary it
is a sign that the ABS system is work-
ing: it tells the driver that the vehicle
is travelling at the limit of its road grip
and that he should alter his speed to
fit the type of road surface.
The ABS system is an addition to the
basic braking system. If there is a mal-
function, the system turns off auto-
matically and only the ordinary brakes
continue to work.
If a failure occurs, and consequently
the anti-lock function is not effective,
the braking system will continue to
work as usual.
If the ABS system cuts in it
is a sign that the grip be-
tween the tyre and the road surface
has reached the limit: you must
slow down to match the speed to
the road grip available.
WARNING
If there is a fault, the warn-
ing light >will light up on
the dashboard. At this point, reduce
speed and go to a Fiat Dealership
to have your vehicle checked and
put right immediately.
WARNING
The ABS exploits the tyre-
road grip available to the
full, but it cannot improve it; you
should therefore take every care
when driving on slippery surfaces,
and not take unnecessary risks.
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.

159IN AN EMERGENCY
WITH A SHOP JACK
The vehicle can be raised on a shop
jack if it is empty. This is only possi-
ble from the side by placing the jack at
the points provided in the underbody
as indicated infig. 41.
WITH AN ARM HOIST
The vehicle must be raised by plac-
ing the ends of the arms at the points
indicated in fig. 41.TOWING THE
VEHICLE
The vehicle has two eyes for an-
choring the tow hitch fig. 42.
A- Front eye
B- Rear eye (for towing another ve-
hicle).
fig. 42
F0D0177m
Before starting to tow, turn
the ignition key to MAR
and then to STOP. Do not remove
the key. If the key is removed, the
steering lock engages automatical-
ly which prevents the wheels being
turned.
WARNING
While the vehicle is being
towed with the engine off,
remember that the brake pedal and
steering will require more effort as
you no longer have the benefit of
the power brakes and power steer-
ing. Do not use flexible cables to
tow. Avoid jerking. Whilst towing,
ensure that coupling to the vehicle
does not damage the surrounding
components.
WARNING

163VEHICLE MAINTENANCE
SERVICE SCHEDULE
thousands of kilometres
Check tyre conditions and wear and adjust pressure, if required
Check lighting system operation (headlights, direction indicators, hazard lights,
load compartment light, ceiling lights, warning lights, etc.)
Check windscreen wiper/washer operation, adjust nozzles
Check windscreen/rear window wiper blade position/wear
Check front and rear (where fitted) disc brake pad conditions and wear
Check rear drum brake linings conditions and wear (where fitted)
Inspect conditions and soundness of:
– outer bodywork and underbody protection;
– piping (exhaust - fuel feed and brakes)
– rubber parts (boots, sleeves, bushings, etc.)
– fuel feed and braking system hosing
Check tension and conditions of various control belts and adjust, if required
(excluding engines with automatic belt tighteners)
Check accelerator pedal stroke and adjust, if required
Check handbrake lever stroke and adjust, if required
Check tappet clearance and adjust, if required (2.8 JTD version)
Check tappet clearance and adjust, if required (petrol versions)
Check exhaust emissions
30 60 90 120 150 180
●●●●●●
●●●●●●
●●●●●●
●●●●●●
●●●●●●
●●●
●●●●●●
●●
●●●●●●
●●●●●●
●
●●●●●●
●●●●●●

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
●●●
●●●●●●
●●●
●●●
●●●●●●
●●
●
●●●●●●
●●●●●●
●●●
●●●●●●
●●●●●●
●●●
●●●●●●

165VEHICLE MAINTENANCE
ANNUAL
INSPECTION
SCHEDULE
The following annual inspection
schedule is required for vehicles trav-
elling 15,000 Kmapprox. a year. The
schedule includes the following oper-
ations:
– check tyre condition and wear and
adjust pressure, if required (including
spare wheel);
– check operation of lights (head-
lights, direction indicators, hazard
lights, boot light, passenger compart-
ment light, instrument panel lights,
etc.);
– check windscreen wiper/washer
and adjust nozzles;
– check position and wear of wind-
screen/rear window wiper blades;
– check front pad conditions and
wear;
– check for bonnet and boot lock
cleanness, lever cleanness and lubri-
cation;– inspect conditions of: engine, gear-
box, transmission, piping (exhaust, fu-
el feed, brakes), rubber parts (boots,
sleeves, bushings, etc.), brake and fu-
el line hoses;
– check battery charge status;
– check conditions of various control
belts;
– check and top up fluid levels (en-
gine coolant, brakes, windscreen
washer, battery, etc.);
– check and top up engine oil;
– replace pollen filter.
ADDITIONAL
CHECKS
Every 1,000 km or before long
trips, check and top up as necessary:
– engine coolant level
– brake fluid level
– power steering fluid level
– battery electrolyte level
– windscreen washer fluid
– tyre pressure and conditions.
Every 3,000 km or before long
trips, check and top up as necessary:
engine oil
Every 10,000 kmor at cwarning
light coming on (diesel engines only):
bleed water from fuel filter.
You are recommended to use FL
Seleniaproducts designed and pro-
duced for Fiat vehicles (see the “Ca-
pacities” table in the “Technical Spec-
ifications” section).

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