2005 FIAT DUCATO 244 exhaust

37GETTING TO KNOW YOUR VEHICLE
EOBD ENGINE
FAILURE CONTROL
SYSTEM
(petrol versions only) (amber)
In normal conditions, the warning
light will come on when the ignition
key is turned to MARand should go
out as soon as the engine is started.
The initial lighting up shows that the
warning light is working properly.
If the warning light either stays on or
comes on while travelling:
1. Fixed light- warning of a fuel
feed/ignition system failure which may
increase emissions in exhaust or cause
possible drops in performance, poor
handling and high consumption.
In such conditions, you can contin-
ue driving but you should not tax the
engine and you should moderate the
speed. Prolonged use with the warn-
ing light on can cause damage. Contact
a Fiat Dealershipas soon as possi-
ble. The warning light will go out when
the failure disappears. In any case, the
system will store the error.
2. Flashing- warning that the cata-
lyst can be damaged (see “EOBD sys-
tem” in this chapter).
If the warning light starts flashing, re-
lease the accelerator pedal and slow
the engine until the warning light stops
flashing. Continue driving at moderate
speed, preventing the warning light
from coming on again. Contact a Fi-
at Dealership as soon as possible.INJECTION SYSTEM
FAILURE
(diesel versions) (red)
When there is a fault in the injection
system.
The warning light should come on
when the ignition key is turned to
MARand go out after a few seconds.
The warning light will stay on or come
on when travelling to indicate imperfect
operation of the injection system with
possible loss of performance, poor han-
dling and higher consumption.
In these conditions, you can contin-
ue driving but you should avoid de-
manding efforts from the engine or
high speeds. Contact a Fiat Dealer-
shipas soon as possible.
Prolonged use of the vehicle with the
warning light on can cause damage to
the engine, especially in the event of
misfiring. The vehicle can only be dri-
ven for a short period of time at low
speeds.
Occasional and brief lighting of the
warning light is meaningless.
UU
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 light or flashing
light, when travelling. Warning
light
Uoperation 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.

59GETTING TO KNOW YOUR VEHICLE
SELF-STANDING SUPPLEMENTARY
HEATER (where provided)
The vehicle can be equipped, upon re-
quest, with two different self-standing
heaters:one is totally automatic
whereas the other is programmable.
AUTOMATIC VERSION
The supplementary heater is totally in-
dependent from the engine.
This heater is switched on automat-
ically (if required) when turning the ig-
nition key to MAR. LOOKING AFTER THE
SYSTEM
During the winter, the climate con-
trol system must be turned on at least
once a month for about ten minutes.
Before summer, have the system
checked at a Fiat Dealership.PROGRAMMABLE VERSION
The supplementary heater is totally
independent from the engine and can
be used to:
– heat the passenger compartment
when the engine is off;
– defrost the windows;
– heat the engine coolant and con-
sequently the engine before starting.
The system consists of:
– a diesel burner to heat coolant with
exhaust fume muffler;
– a metering pump connected to the
vehicle fuel pipes to feed the burner;
– a heat exchanger connected to the
engine cooling system pipes; The system is filled with
R134a refrigerant which
will not pollute the envi-
ronment in the event of leakage.
Under no circumstances should
R12 fluid be used as it is incom-
patible with the system compo-
nents and contains CFC.
The heater burns fuel in the
same way as the engine,
though, of course, to a lesser degree
and therefore to avoid intoxication
and suffocation, never use the sup-
plementary heater in closed areas,
garages or workshops not equipped
with specific exhaust evacuation
devices even for short periods of
time.
WARNING

64GETTING TO KNOW YOUR VEHICLE
– Always remember to turn the
heater off when refuelling or standing
in service stations to avoid fires and
explosions.
– Do not park the vehicle over in-
flammable material such as paper, dry
grass or leaves: fire risk!
– The temperature near the heater
must never exceed 120°C (e.g. during
painting operations in a workshop
oven). Higher temperatures could
damage the electronic control unit
components.
– When the engine is off, the heater
runs off the battery: it is consequently
important to run the engine for a cer-
tain period of time in order to restore
the battery charge.– Follow the prescriptions in “Vehi-
cle maintenance” section at paragraph
“Engine coolant level” to check the
coolant level. The coolant in the cir-
cuit must contain at least 10% an-
tifreeze fluid.
– Maintenance and repairs must al-
ways be carried out by a Fiat Deal-
ershipand only genuine spare parts
must be used.
MAINTENANCE
Have the heater checked at a Fiat
Dealership periodically (always be-
fore winter). This will ensure safe and
cheap running and long appliance life.
The heater burns fuel in the
same way as the engine,
though, of course, to a lesser degree
and therefore to avoid intoxication
and suffocation, never use the sup-
plementary heater in closed areas,
garages or workshops not equipped
with specific exhaust evacuation
devices even for short periods of
time.
WARNING

102GETTING TO KNOW YOUR VEHICLE
DIESEL ENGINES
The vehicle must only
be filled with diesel fuel
for motor vehicles, in
compliance with European Spec-
ification EN590. The use of other
products or mixtures may ir-
reparably damage the engine
with invalidation of the warran-
ty due to the damage caused. In
the event of accidentally filling
with another type of fuel, do not
start the engine and empty the
tank. If the engine has been run
even for only a very short time,
in addition to the tank, it is also
necessary to drain out the whole
fuel circuit.AT THE FILLING
STATION
PETROL ENGINES
Use unleaded petrol only.
However, to avoid mistakes, the fu-
el filler is too small for the leaded
petrol pump.
Octane rating (R.O.N.) must not be
lower than 95.
fig. 151
F0D0193m
Never put even the tini-
est amount of leaded
petrol in the fuel tank of
your Ducato even in an emer-
gency. You would damage the
catalytic converter beyond re-
pair.
An inefficient catalytic
converter will allow
harmful exhaust fumes to
be emitted and thus contribute
to air pollution.

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

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.

128GETTING THE BEST OUT OF YOUR VEHICLE
LOOKING AFTER EMISSION
CONTROL DEVICES
The correct use of pollution control
devices not only ensures respect for
the environment but also has an effect
on the vehicle’s performance.
Keeping these devices in good con-
ditions is therefore a fundamental rule
for driving that is easy on your pock-
et and on the environment too.
The first step to take is to follow the
Service Schedule to the letter.
If your vehicle has a petrol engine
with catalytic converter use only un-
leaded petrol.
if you have trouble starting, do not
keep turning the ignition key for long
periods. Be especially careful to avoid
bump starting the vehicle by pushing,
towing or rolling downhill: these are
all manoeuvres that can damage the
catalyst.
Use an auxiliary battery for start-ups
only.If the engine begins to “loose its
smoothness” when travelling, contin-
ue your journey but reduce the de-
mands you are making on the engine
and have the vehicle seen to at a Fi-
at Dealershipas soon as you can.
When the instrument panel fuel re-
serve warning light comes on, fill up as
soon as possible. A low fuel level may
cause an uneven supply of fuel to the
engine with inevitable increase in the
temperature of the exhaust gas and se-
rious damage to the catalytic con-
verter.
Never run the engine with one or
more spark plugs disconnected, even
for testing purposes.
Do not warm up the engine by let-
ting it idle for a while before moving
off unless the outside temperature is
very low and, even in this case, only
do so for less than thirty seconds.
Do not install heat shields and do not
remove those already fitted to the cat-
alytic converter and exhaust pipe.
Do not allow anything to
be sprayed onto the cat-
alytic converter, lambda sensor and
exhaust pipe.
WARNING
Ignoring the above rules
may lead to fire.
WARNING
When functioning normal-
ly the catalytic converter
reaches high temperatures. For this
reason do not park the vehicle over
inflammable material (grass, dry
leaves, pine needles, etc.): fire haz-
ard.
WARNING

131GETTING THE BEST OUT OF YOUR VEHICLE
Truck and Chassis cab versions -
fig. 12
An additional tow hitch - specific for
chassis cab and truck versions is shown
in fig. 12. The structure Ømust be se-
cured to the points shown with a total
of twelve M 10 screws.
Fit the tow hitch with the light cluster
crossmember in its original position. If
the crossmember has been removed,
replace it with another crossmember
of the same size and resistance.
IMPORTANTFasten a tag in
clearly visible position at the same
height as the tow hitch. This tag is
compulsory. It must be adequately
sized, made of suitable material and
carry the following information:
MAX ADMITTED LOAD ON
HITCH 80 kg.
fig. 12
F0D0243m
Holes to boreHoles to bore
Existing holes
2 shims
Vehicle centre line
2 shims
After assembly, seal the fas-
tening screw holes to pre-
vent exhaust fumes from entering
the vehicle.
WARNING