Fiat Ducato 2007 User Manual

This Supplement describes the procedure for using the COMFORT-MATIC electronically controlled manual gearbox on the
Fiat Ducato.

For the correct use of the gearbox, it is essential to read this Supplement in full to find out at the outset which operations are
correct and permissible.

For additional information, consult the User Handbook to which this Supplement is attached.

22

CONTENTS

COMFORT-MATIC GEARBOX ........................................................................................................................................................................ 3

READY TO START ............................................................................................................................................................................................... 3

OPERATING PROCEDURE ............................................................................................................................................................................... 4

WARNING LIGHTS AND MESSAGES ............................................................................................................................................................. 10

IF THE VEHICLE NEEDS TO BE TOWED ..................................................................................................................................................... 13

IF A FUSE BLOWS ................................................................................................................................................................................................. 13

SERVICE SCHEDULE............................................................................................................................................................................................. 14

CHECKING FLUID LEVELS ................................................................................................................................................................................. 14

AIR CLEANER ........................................................................................................................................................................................................ 14

ENGINE CODES - BODYWORK VERSIONS ................................................................................................................................................ 15

PERFORMANCE .................................................................................................................................................................................................... 16

TRANSMISSION .................................................................................................................................................................................................... 16

CAPACITIES ............................................................................................................................................................................................................ 17

FUEL CONSUMPTION / CO

2

EMISSIONS .................................................................................................................................................... 18

3

READY TO START

MANUAL MODE

IMPORTANT For correct use of the sys­tem, it is advisable to use your right foot
only to operate the pedal.

❒

Press the brake pedal.

❒

Start the engine.

❒

Push the gear lever towards + (shift up)
fig. 1 to engage first gear (if starting

from N or R simply move the lever to
the central position) or R fig. 2 to en­gage reverse.

❒

Release the brake pedal and press the
accelerator pedal.

❒

When driving, push the gear lever to­wards (+) fig. 1 to engage a higher gear
or towards (–) fig. 1 to engage a low­er gear.

COMFORT-MATIC
GEARBOX

Your vehicle is equipped with an elec­tronically controlled manual gearbox
known as the “COMFORT-MATIC” that
is able to operate in two modes: MAN-
UAL and AUTO.

The gearbox consists of a conventional
manual transmission equipped with a lever
A-fig. 1, to which has been added an elec­tronically-controlled hydraulic device that
controls the clutch and gear shifts auto­matically.

fig. 1

F0N0350m

fig. 2

F0N0351m

4

AUTOMATIC MODE

IMPORTANT For correct use of the sys­tem, it is advisable to use your right foot
only to operate the pedal.

❒

Press the brake pedal.

❒

Start the engine.

❒

Push the gear lever to A/M fig. 3, to
engage automatic mode + (higher gear)
fig. 1 to engage the first gear, if start­ing from N or R move the lever to cen­tral position R fig. 2 to engage reverse.

❒

Release the brake pedal and press the
accelerator pedal.

OPERATING MODE

The gearbox can operate in two operat­ing modes:

❒

the first is manual (MANUAL), where
the driver decides directly when to shift
gear;

❒

the second fully automatic (AUTO),
where the system decides when to shift
gear. This mode allows you to use the
UP function (steep road function),
which allows you to shift gears at high­er speeds to allow you to drive up very
steep roads easily with any load. To en­gage this function, press the UP but­ton - fig. 4 between the controls on the
dashboard. Select the gear and the op­erating mode MANUAL or AUTO)
by operating the control lever at any
speed.

fig. 3

F0N0352m

fig. 4

F0N0353m

CONTROL LEVER

Control lever A-fig. 1, on the central
tunnel is a floating multistable lever, i.e. it
can take up three stable positions and
three unstable positions.

The three stable positions correspond to
neutral N-fig. 2, reverse R-fig. 2 and the
central position between the unstable po­sitions (–) and (+) fig. 1.

The unstable positions, i.e. positions left
by the lever as soon as it is released, are
upshift request (+), downshift request (–)
and automatic mode request (A/M)
fig. 3.

5

The system is returned to manual mode
by returning the lever to A/M position.

With the vehicle at a standstill and the key
out, the lever may be moved with/without
the brake pedal pressed. The system does
not carry out any action after the lever has
been shifted and remains in the gear
stored before the key was removed.

IMPORTANT With the engine running, a
buzzer sounds to indicate errors between
the lever position and the gear effectively
engaged until the inconsistency is resolved.

MANUAL OPERATION
(MANUAL)

In this operating mode, the driver is re­sponsible for choosing the best gear ra­tio to engage, depending on vehicle ser­vice conditions.

Proceed as follows to shift gear:

❒

shift the lever to (+) position fig. 1 to
engage a higher gear;

or

❒

shift the lever to (–) position fig. 1 to
engage a lower gear.

The accelerator pedal need not be re­leased during the gear change.

The system will not allow the gear change
if the gear shift request could impair cor­rect operation of the engine and gearbox.

In this case, the system will notify the dri­ver that it is not possible to change gear
by displaying a dedicated message on the
multifunction display (see “Warning lights
and messages” paragraph), accompanied
by a buzzer.

The system will shift down through the
gears automatically when the engine is
idling (e.g. during deceleration).

Avoid keeping your hand on
the lever when you are not re­questing a gear shift or an
Auto/Manual mode change.

AUTOMATIC OPERATION
(AUTO)

to engage/release automatic mode (AU­TO) press the lever to A/M position fig.
3; activation is indicated by the message
AUTO fig. 5 and the gear engaged ap-

pearing on the multifunction display.

fig. 5

F0N0355m

6

Avoid keeping your hand on
the lever when you are not re­questing a gear shift or an
Auto/Manual mode change.

Automatic operation
(AUTO with UP function engaged)

The UP can only be activated with auto­matic mode engaged.

The UP function is engaged by pressing
the UP key-fig. 4, located among the con-
trols on the dashboard.

With the UP active, the system will select
the most appropriate gear on the basis of
vehicle speed, engine rpm and pressure on
the accelerator pedal, with the aim of
overcoming steep gradients in the easiest,
most comfortable manner.

Where necessary (e.g. overtaking), the
system will react to the accelerator be­ing pressed to the floor by shifting down
through one or more gears in order to de­liver the power and torque required to
give the vehicle the acceleration required
by the driver (all this takes place in auto­matic mode, irrespective of whether the
UP function is on or off).

In AUTO mode, the system will shift
gears on the basis of vehicle speed, engine
rpm and the pressure applied to the ac­celerator pedal. A gear shift may be re­quested by operating the gear lever, but
without necessarily disengaging this mode:
this function, known as ‘gear suggestion’,
suspends automatic mode for the time re­quired to select the ratio requested by the
driver.

INFORMATION ON DISPLAY

When the ignition key is turned to MAR,
after one second, the multifunction display
shows the gear engaged and the last mode
used (AUTO or MANUAL):

N = neutral;

1 = first gear;

2 = second gear;

3 = third gear;

4 = fourth gear;

5 = fifth gear;

6 = sixth gear;

R = reverse.

7

Activation of the UP function is indicat­ed on the display by lighting of the letter
“E” fig. 6.

IMPORTANT If the display does not show
the gear engaged after 10 seconds with the
ignition key on MAR, turn the ignition to
STOP, wait for the display to turn off and
then repeat the manoeuvre. If the prob­lem persists, contact the Fiat Dealer-

ship.

ENGINE STARTING

The system permits engine start-up with
a gear engaged and also with the gearbox
in neutral (N); the brake pedal must al­ways be pressed with the gear engaged.

It is advisable to place the gear lever in
neutral (N) before starting the engine.

After start-up:

❒

the gearbox automatically engages neu­tral (N)

❒

the lever remains in the same position
as the last time the engine was turned
off

❒

the multifunction display shows the
message (N) and an acoustic signal in­dicates any inconsistency between lever
position and the gear engaged

❒

the gears that may be engaged are 1st,
2ndor reverse (R), with the brake ped­al pressed.

IMPORTANT If start-up is requested with
the gearbox is a position other than N and
without the brake pedal pressed, the mul­tifunction display shows a dedicated mes­sage see “Warning lights and messages”).
In this case, repeat the start-up manoeu­vre, pressing the brake pedal.

IMPORTANT If start-up is requested with
the gearbox faulty, run the “Delayed start­up” procedure (see also associated mes­sages): hold the key on AVV position for
at least 7 seconds with the brake depressed
and the engine will start. The system will
remain in recovery mode (maximum speed
permitted: 3

rd

, Auto mode not available).
If the engine does not start, contact a Fiat
dealership.

IMPORTANT When the driver’s door is
opened, the system activates the auto­matic part to prepare it for subsequent en­gine start-up.

If the engine does not start
with the gear engaged, a po­tentially hazardous situation

because the gearbox has au­tomatically shifted to neutral is indi­cated by a buzzer.

fig. 6

F0N0355m

8

DRIVING OFF IN THE VEHICLE

Driving off in the vehicle, take-off, is per­mitted in 1

st

gear, 2

nd

gear (recommend­ed on road surfaces with poor grip) and
reverse (R).

To engage 1

st

gear

❒

press the brake pedal;

❒

with the lever in (N) or (R) shift the
lever to central position;

❒

with the lever already in central posi­tion, move the lever toward + (higher
gear) fig. 1;

❒

release the brake pedal and press the
accelerator pedal.

To engage 2

nd

gear

❒

press the brake pedal;

❒

with the lever in (N) or (R) fig. 2
move the lever to central position and
then towards + (higher gear) fig. 1;

❒

with the lever already in central posi­tion, move the lever twice toward +
(higher gear) fig. 1;

❒

release the brake pedal and press the
accelerator pedal.

To engage reverse (R)

❒

press the brake pedal;

IMPORTANT If the vehicle is moving, the
request is accepted and carried out if the
vehicle speed is less than 3 km/h within 1.5
seconds of the request: if the request is
not implemented, the system will maintain
the gear engaged or if vehicle speed drops
below 10 km/h it will put the gearbox in
neutral (N) and the manoeuvre must then
be repeated.

❒

Shift the lever to (R) fig. 2;

❒

release the brake pedal and press the
accelerator pedal.

BUZZER WARNINGS

For safety reasons, a buzzer warning
sounds when the vehicle is parked with
the gearbox in neutral (N) (the warning
sounds when the ignition key is turned to
STOP).

With the vehicle at a standstill, engine run­ning and (1), (2) or (R) gear engaged, the
system turns on the buzzer and automat­ically shifts the gearbox to neutral (N)
when:

❒

the accelerator and/or brake pedals are
not operated for at least 3 minutes;

❒

the brake pedal is pressed for longer
than 10 minutes;

❒

the driver’s door is opened and the ac­celerator and brake are not operated
for at least 1.5 seconds;

❒

a fault has been detected in the gear­box.

9

PARKING THE VEHICLE

To park safely, it is essential to engage 1

st

gear or reverse (R) gear with your foot
on the brake pedal. If parking on a slope,
operate the brake pedal. It is also essen­tial to wait until the gear engaged disap­pears from the multifunction display be­fore releasing the brake pedal.

IMPORTANT NEVER leave your vehicle
with the gearbox in neutral (N).

GENERAL WARNINGS

❒

With the vehicle at a standstill and a
gear engaged, keep the brake pedal
pressed until you decide to set off.
Then release the brake and accelerate
gradually;

❒

when parked for long periods with the
engine running, it is advisable to keep
the gearbox in (N);

❒

to safeguard clutch efficiency, do not
use the accelerator to keep the vehi­cle at a standstill (e.g.: parking on a hill);
the clutch could be damaged by over­heating. Use the brake pedal instead
and operate the accelerator only when
you are ready to set off;

❒

use second gear only when you need
more control of take-off during ma­noeuvres on surfaces with low grip;

❒

if, with reverse (R) engaged, you need
to engage first speed or vice versa, on­ly change gear when the vehicle has
come to a stop and the brake pedal is
pressed;;

❒

although very inadvisable, if the vehi­cle is unexpectedly allowed to roll
downhill with the gearbox in neutral
(N) the system will automatically en­gage the gear best suited to vehicle
speed when a gear shift is requested to
allow drive to be correctly transmitted
to the wheels;

❒

If necessary, with the engine off, it is pos­sible to engage 1st, R or N with the key
in MAR position and the brake pressed.
In this case, gear shifts must be made al­lowing at least 5 minutes to elapse be­tween one gear shift and the next to
safeguard the operation of the hydraulic
system and the pump in particular;

❒

during hill st arts, accelerate gradually
but fully immediately after releasing the
handbrake or brake pedal to allow the
engine to increase its rpm to a greater
extent and overcome higher gradients
with more torque.

10

WARNING LIGHTS
AND MESSAGES

REDUCE GEAR CHANGES

The message appears on the display to in­dicate that the driver is using the gearbox
incorrectly.

Incorrect use (by the driver) could auto­matically activate a procedure for pro­tecting the system.

MANUAL MODE NOT
AVAILABLE

The message appears on the multifunc­tion display when it is not possible to se­lect MANUAL mode with the engine
running.

“COMFORT-MATIC”

GEARBOX FAULT (red)

When the ignition key is

turned to MAR, the warning
light turns on and should go off after a few
seconds.

The warning light on the dial comes on ei­ther steady or blinking (together with a
message on the multifunction display and
a buzzer) to indicate that the gearbox is
faulty.

t

If a fault is present, contact
a Fiat Dealership as soon as
possible to check the sys­tem.

Contact a Fiat Dealership if
the message remains on the
display.

Contact a Fiat Dealership if
the message remains on the
multifunction display.

11

AUTOMATIC MODE
NOT AVAILABLE

The message appears on the multifunction
display when it is not possible to select

AUTO mode with the engine running.

CLUTCH OVERHEATING

The message appears on the multifunction
display together with a buzzer when the
clutch overheats.

In this situation, limit take-off and gear
shifts or if necessary park (turning off the
engine) until conditions are optimum.

PRESS BRAKE PEDAL ­DELAYED START-UP

The multifunction display shows these
messages alternately and in sequence to­gether with an warning buzzer when the
system does not recognise the brake ped­al to be operational during a starting at­tempt.

In this situation, keep the key on AVV for
at least 7 seconds with the brake pressed:
the engine start. The system will be in re­covery mode (maximum speed permitted:
3

rd

).

IMPORTANT Messages are displayed on­ly if start-up takes place in a gear other
than neutral (N).

Contact a Fiat Dealership if
the message remains on the
multifunction display.

If the message still appears on
the multifunction display,
contact a Fiat Dealership.

To safeguard clutch efficien­cy, do not use the accelerator
to keep the vehicle at a stand-

still (e.g.: parking on a hill);
the clutch could be damaged by over­heating. Use the brake pedal instead
and operate the accelerator only when
you are ready to set off;

Contact a Fiat Dealership if
the messages remain on the
multifunction display.

12

GEAR NOT AVAILABLE

This message appears on the multifunction
display together with a warning buzzer in
the following cases:

❒

when it is not possible to change gear
due to a fault in the system;

or

❒

when, due a fault in the system, is is on­ly possible to engage 1st(1), 2nd(2), 3

rd

(3) or reverse (R).

MANOEUVRE NOT PERMITTED

The message appears on the multifunction
display together with a warning buzzer
when the system will not accept a gear
change via the control lever because cer­tain conditions required for acceptance of
the gear change are missing.

PRESS BRAKE PEDAL
AND REPEAT MANOEUVRE

The message appears on the multifunction
display accompanied, in some cases, by a
warning buzzer for safety reasons if you
attempt to change gear with the vehicle
parked without previously pressing the
brake pedal.

PLACE GEAR LEVER IN N
(neutral)

This message appears on the multifunction
display together with a warning buzzer
when the system asks the driver to per­form the manoeuvre.

When the gearbox is shifted to (N) the
message on the display should go off.

Contact a Fiat Dealership if
the message remains on the
multifunction display.

Contact a Fiat Dealership if
the message remains on the
multifunction display.

Contact a Fiat Dealership if
the message remains on the
multifunction display.

13

TOWING THE VEHICLE

Ensure the gearbox is in neutral (N) (by
checking that the vehicle moves when
pushed) and tow in the same way as a nor­mal vehicle with a manual gearbox (see in­structions in Owner Handbook).

If it is not possible to put the gearbox in
neutral, do not tow the vehicle and con­tact a Fiat Dealership.

IF A FUSE BLOWS

For the location of fuses, see the illustrations in the paragraph “if a fuse blows” in the
“In an emergency” section of the Owner Handbook.

FUSE AMPS

COMFORT-MATIC gear control system and gear
selector lever (power supply + ignition) F24 7.5

COMFORT-MATIC gearbox pump F26 30

COMFORT-MATIC gearbox control unit
(power supply + battery) F27 10

14

CHECKING FLUID LEVELS

COMFORT-MATIC GEARBOX HYDRAULIC OPERATING SYSTEM FLUID

To check the gear oil and check/replace the hydraulic clutch operating system fluid, contact only a Fiat dealership.

AIR CLEANER

Have the air cleaner replaced by a Fiat Dealership.

Used gear oil contains substances that are hazardous for the environment. It is ad­visable to have oil changed by a Fiat Dealership where used oil will be disposed of

according to the law.

WARNING

SCHEDULED SERVICING PLAN

Check gearbox every
oil level 45,000 km

Check fluid in hydraulic every
clutch operation system 45,000 km

Check fluid in hydraulic every
clutch operation system 90,000 km (or every 2 years)

15

ENGINE CODES - BODYWORK VERSIONS

Version Engine code

100 Multijet 4HV

120 Multijet SOFIM F1AE0481D

130 Multijet SOFIM F1AE0481N

160 Multijet SOFIM F1CE0481D

The following body version code and key is an example that may be applied to all
body version codes :

Key: 250 A A M F A AX

MODEL

PAYLOAD

ENGINE

ENGINE TRANSMISSION/AXLES

BODYWORK

WHEELBASE

VERSION

PAYLOAD
A 3000 kg
B 3300 kg
C 3500 kg LIGHT
D 3500 kg HEAVY
E 4005 kg

ENGINES
A 100 Multijet

C 120 Multijet
D 160 Multijet
E 130 Multijet

TRASMISSION
M Manual gearbox

A Automatic gearbox

BODYWORK
A Chassis cab

B Chassis without cab
C Low loader with cab
D Box
E Primary school bus
L Middle school bus
F Van

WHEELBASE
A Short wheelbase

B Medium wheelbase
C Long wheelbase
D Medium-long wheelbase
G Box with long cab
H Chassis with long cab
M Minibus
P Panorama
R 6/9 seater crew cab
U Chassis without low loader

drive cab

16

TRASMISSION

Six speeds plus reverse

Gearbox with electronically-controlled

hydraulic system

Clutch

Single dry plate with

hydraulic engagement

Drive Front

PERFORMANCE

For top speeds, see “Performance” in the “Technical Data” section of the Owner Handbook.

17

Specified fuels

Recommended products

TUTELA CAR CS SPEED -

Specific fluid with“ATF DEXRON
III” additive

TUTELA TOP4

Synthetic fluid FMVSS n° 116 DOT
4, ISO 4925 SAE JI704, CUNA NC
956-01

CAPACITIES

COMFORT-MATIC
gearbox hydraulic operating system

Clutch hydraulic operating system

litres

0.7

0.050

kg

0.59

–

18

FUEL CONSUMPTION AND CO2EMISSIONS

Fuel consumption according to Directive 1999/100/EC (litres x 100 km)

CO2emissions according to 1999/100/CE Directive (g/km).

Payload Fuel consumption CO2emissions

Urban Extraurban Combined Combined

Short wheelbase Ducato 9.2 6.9 7.7 204

Medium wheelbase Ducato 9.6 7.2 8.1 213

Ducato MAXI 10.0 7.6 8.5 224

Combi versions (*)

Payload Fuel consumption CO2emissions

Urban Extraurban Combined Combined

Ducato all types 10.0 7.6 8.5 224

Panorama versions (*)

19

Payload Fuel consumption CO2emissions

Urban Extraurban Combined Combined

Ducato: Van CH1-MH1/Truck CH1
MH1-MLH1-LH1 – Chassis cabs 10.3 7.7 8.7 229
and without drive cabs(**)

Ducato: Van MH2-LH2-LH3/
Truck XLH1-Crew cab MH1-LH1

10.6 8.0 9.0 237

Chassis cabs and without
drive cab (**)

Ducato MAXI: Truck MH1 – Chassis

10.5 7.9 8.9 233

chassis cabs and without drive cab (**)

Ducato MAXI: Van MH1-MH2
LH2-LH3/Truck MLH1-LH1-XLH1

10.9 8.2 9.2 242

Crew cab MH1-LH1 – Chassis
cabs and without drive cabs (**)

Ducato MAXI: Van XLH2-XLH3/
Crew cab truck XLH1 – Chassis 10.9 8.2 9.2 242
cabs and without drive cabs (**)

(*) Fuel consumption figures recorded in AUTO mode
(**) Fuel consumption figures apply to pre-conversion vehicles

Goods transport versions (*)

Fiat Group Automobiles S.p.A.

Servizi al Cliente - Assistenza Tecnica - Ingegneria Assistenziale

Largo Senatore G. Agnelli, 5 - 10040 Volvera - Torino (Italia)

Print n. 603.83.789 - 10/2007 - 1

st

edition