1.

New Fiat Ducato 2016

Converters’ and Upfitters’ Manual

Overview 1
1.1
FOREWORD

This publication gives the information, features and instructions for vehicle fitting out
and conversion and is addressed to qualified, specialist personnel.
The coach builder is responsible for the fitting-out or conversion project and its execu-
tion, and must guarantee compliance with standards given in this publication in addition
to all other applicable standards.
Before undertaking any works, make certain to have the publication on the vehicle mod-
el on which the works are to be done, as well as all the required accident prevention
equipment, which, for information, includes goggles, hard hat, safety shoes, etc., in
addition to all necessary tools, lifting and transport gear, etc. The equipment and tools
must all be available and efficient, and the vehicle itself must be in condition to permit
safe execution of the works.
When carrying out the works the coach builder must strictly adhere to the instructions
given in the publication, using the components described, and guarantee that the works
carried out are technically correct.

Any modification, conversion or other operation not foreseen in the manual,

and not explicitly authorised by FIAT CHRYSLER AUTOMOBILES S.p.A. in writ-
ing shall relieve FIAT of any liability, and specifically, if the vehicle is covered
by warranty, this shall be immediately forfeit.

FIAT CHRYSLER AUTOMOBILES S.p.A. is available to provide any clarification necessary

for execution of the works, as well as instructions for any cases or situations not specifi-
cally foreseen in this publication.
The functional, efficiency and safety conditions foreseen by FIAT CHRYSLER AUTOMO-
BILES S.p.A. must be restored immediately after any conversion works. Contact the FIAT
CHRYSLER AUTOMOBILES S.p.A. network for any necessary vehicle tuning.
FIAT CHRYSLER AUTOMOBILES S.p.A. shall not be held liable for the effective execution
of the conversion or fittingout works.
The data and information contained in this publication may not be up to date as a result
of the alterations that FIAT CHRYSLER AUTOMOBILES S.p.A. reserves the right to make
at any time for technical or commercial reasons, or for the need to adapt the vehicle to
the requirements of specific local laws.
In case of discrepancy between the contents of this publication and the effective
condition of the vehicle, please contact FIAT CHRYSLER AUTOMOBILES S.p.A. before
proceeding with any works.

Symbols - Warnings

Hazard to personal safety

Serious hazard to personal safety in case of failure to fully comply with these in-
structions.

Risk of damage to vehicle

Serious risk of vehicle damage, warranty forfeit, in case of failure to fully comply
with these instructions.

General hazard
Combines the risks of the two symbols described above.

Overview 2
1.1
Respect the environment
Indicates behaviour code for use of the vehicle in the most environmentally friendly
manner possible.

NOTE: Provides any necessary additional information.

1.2
AUTHORISATION

Observance of the instructions contained in this manual does not oblige the manufactur-
er to grant authorisation.
The conversion coach builder must ask the manufacturer for authorisation by sending
the appropriate documentation (see sections below) to the following address:
- FIAT CHRYSLER AUTOMOBILES S.p.A.
- FIAT PROFESSIONAL
- MERCATO ITALIA - SERVIZIO ALLESTITORI
(Italian Market - Coach-builders Service)
Corso Agnelli 200
1° piano ufficio B56
(1st floor, office B56)
In order to grant authorisation, the manufacturer reserves the right to demand that the
conversion coach builder carry out any test or verification considered necessary.

AUTHORISATION “NULLA OSTA”

Compliance with the indications contained in this manual does not oblige the Manufac-
turer to grant authorisation.
The Manufacturer reserves the right to ask the Converter to carry out the tests and trials
deemed needed for obtaining authorisation.

DOCUMENTS NEEDED FOR AUTHORISATION

List of documents needed to obtain authorisation:

Documents for the Local Motor Vehicle Registration Office for test request.

The amount of copies to be sent to us (two copies if on paper, one copy if electronic) and
the amount of copies needed by the Registration Office.

a. Sketch of the converted vehicle with indication of main dimensions (height, length,
width, wheelbase, overhangs, empty vehicle ground clearance). The converted vehi-
cle drawing must include four views on one sheet, normally on 1:20 scale (without
indications of structures or calculations checks). Drawings on different scales may be
accepted providing they are specifically requested by the Local Vehicle Registration
Office in charge of the following testing.
b. Technical report to be submitted to the Local Vehicle Registration Office (this docu-
ment must clearly and exhaustively illustrate all the changes made to the vehicle).

Overview 3
1.3

c. Accurate vehicle type indication. This information must be taken from the vehicle
registration document if the converted vehicle was previously registered (in this case,
submit a copy of the vehicle registration document) or declaration of conformity or
certificate of origin if the vehicle was converted prior to registration.

D.G.M.: Refer to the D.G.M. datasheets at http://www.fiatprofessional-converters.com.

Integrative documents needed by Fiat Chrysler Automobiles for evaluating con-

version for authorisation purposes

d. Detailed drawings stamped by an authorised professional engineer of:

- connection system between additional superstructure and basic vehicle;
- any changes to the basic vehicle body (opening of windows, doors, cuts etc.);
- any changes to mechanical parts and/or electric system;
- any wiring diagram of conversion and interfacing with basic vehicle;
- additional structures integrating basic vehicle structure (mandatory for interventions
on “chassis cab with load platform”).

e. Calculation of weights respecting basic vehicle type-approval values with determi-

nation of gross vehicle weights and capacities in the various conditions of use.

f. Type of mission for which the vehicle is intended (prevalent/exceptional loads,

routes, environment conditions etc.).

g. Document releasing Fiat Chrysler Automobiles of liability with regards to faults or

failures occurring on the vehicle and related in any manner to its conversion.

GUIDELINES FOR GOOD OPERATION AND ACCESSIBILITY OF VEHICLE

COMPONENTS

Special care must be adopted during conversions to prevent altering performance and
functional features of original parts in any manner.
Specifically:

- Ensure accessibility to all points which need to be inspected and serviced.

- Do not alter the possibility of disassembling mechanical assemblies.

- Maintain the original engine cooling and intake conditions

(radiator, air ducts, cooling lines).

- Maintain adequate brake ventilation.

- Ensure free rear wheel shaking and position the wheel arches appropriately.

- Ensure correct headlight adjustment.

Overview 4
TECHNICAL APPROVAL FOR MULTISTAGE CONTRACT (2007/46/EC)

The Manufacturer reserves the right to ask the upfitter

to carry out the tests and trials deemed necessary with a view to obtaining
Technical Approval.

TECHNICAL APPROVAL DOCUMENTATION

List of documents required for Technical Approval:

The number of copies to be sent to Fiat Chrysler Automobiles
(two copies if in print form, one copy if digital).
a) Detailed technical report (this document must clearly and exhaustively illustrate all
the changes made to the vehicle).
b) Sketch of the converted vehicle with indication of main dimensions (height, length,
width, wheelbase, overhangs, unladen vehicle ground clearance). The converted
vehicle drawing must include four views on one sheet, normally on 1:20 scale
(without indications of structures or calculations checks)
d. Detailed drawings, stamped by a professional engineer, of:
- connection system between additional superstructure and base vehicle;
- any changes to the base vehicle body (opening of windows, doors, cuts etc.);
- any changes to mechanical parts and/or electric system;
- any wiring diagram of conversion and interfacing with base vehicle;
- additional structures integrating base vehicle structure (mandatory for interventions on
“chassis cab with load platform”).
d) List of parts removed and modified of the original vehicle
e) List of additional parts
f) Calculation of weights respecting basic vehicle type-approval values with
determination of gross vehicle weights and capacities in the various conditions of use.
g) The vehicle’s mission profile (prevalent/exceptional loads, routes, environment
conditions etc.).
h) Accurate vehicle type indication. This information must be taken from the vehicle
registration document if the converted vehicle was previously registered (in this case,
submit a copy of the vehicle registration document) or declaration of conformity or
certificate of origin if the vehicle was converted prior to registration.
i) Copy of reports of any tests carried out at recognised technical centres
j) Copy of reports of any structural calculations carried out on the conversion or on its
components
k) Description of the production process leading to vehicle conversion.
l) Document releasing Fiat Chrysler Automobiles from liability with regards to faults or
failures occurring on the vehicle and related in any manner to its conversion.

D.G.M.: Refer to the D.G.M. datasheets at

http://www.fiatprofessional-converters.com

Generalità 5
1.5
CONTENTS

Overview 1.6
Bodywork and chassis 2.1
Electrical system 3.1
Main dimensions 4.1

Overview 6
1.6
OVERVIEW

Purpose of coach builders instructions 1.7

FIAT CHRYSLER AUTOMOBILES S.p.A. approval
of conversions and fitting-out 1.7
Liability 1.7
Warranty 1.8
Application for approval 1.8
Markings and logos 1.8
Legal requirements 1.9
Seat belt anchor points 1.9
Seats 1.9
Interior shelves 1.9
Operations on vehicle structure and floor 1.9
Ambulances 1.10
Accident prevention 1.10
Choice of materials: Environment – Recycling 1.10
Vehicle hand-over 1.11
Vehicle management in compounds 1.12
Presentation of the range 1.14

Overview 7
1.7
Purpose of coach builder’s instructions

This document provides instructions about how to make modifications and/or fit-out
original FIAT CHRYSLER AUTOMOBILES S.p.A. vehicles while maintaining the correct
function, safety and reliability of the vehicle itself and its component parts.

FIAT CHRYSLER AUTOMOBILES S.p.A. approval for conversions and fitting-out

Modifications must be made according to the criteria given below.

Liability

The approval given by FIAT CHRYSLER AUTOMOBILES S.p.A. only concerns the techni-
cal/ conceptual feasibility of the modification and/or fitting-out to apply to an original
FIAT vehicle.
The coach-builder is therefore liable for:
- The design of the modification and/or fitting;
- The choice of specifications of the products/materials used;
- The execution of the modification or fitting-out;
- Compliance of the design and realisation with all instructions provided by FIAT CHRYS-
LER AUTOMOBILES S.p.A.;
- Compliance of the design and realisation with all standards in force in the country in
which the vehicle is registered;
- The function, safety and reliability and, in general, efficient performance of the vehicle,
as well as the effects that the modification or fitting-out may have on the performance
and characteristics of the vehicle.

Overview 8
1.8
Warranty

The coach-builder responsible for building the superstructure or making modifications

to the chassis must guarantee that the works have been carried out in a workmanlike
manner and in full compliance with the instructions given in this publication. The
warranty given by FIAT CHRYSLER AUTOMOBILES S.p.A. on the vehicle shall be forfeit if:
- The instructions given are not followed, or the conversion/fitting-out is not authorised;
- The conversion is carried out on a chassis not suitable for the foreseen use;
- The specifications and instructions that FIAT CHRYSLER AUTOMOBILES S.p.A. makes
available for the correct execution of certain kinds of conversion are not followed;
- The original parts and components that FIAT CHRYSLER AUTOMOBILES S.p.A.
manufactures for certain types of conversions are not used.

Application for approval

Applications for approval or assistance in the realisation of conversion works must be

sent to the pertinent FIAT CHRYSLER AUTOMOBILES S.p.A. market agents.
To obtain approval the coach-builder must provide sufficient documentation illustrating
the foreseen conversion, type of use and use conditions for the vehicle. All drawings
must clearly show any differences to the instructions provided.
The coach-builder shall be responsible for obtaining approval by the competent Authori-
ties of the conversion and/or fitting-out.

Markings and logos

Factory markings, logos and names must not be altered or moved in relation to their
original positions; the validity of the vehicle’s image must also be upheld.

The application of conversion or fitting/out trademarks or logos must be authorised by

FIAT CHRYSLER AUTOMOBILES S.p.A. These must be placed in the immediate vicinity of
the existing FIAT CHRYSLER AUTOMOBILES S.p.A. trademarks and logos.

FIAT CHRYSLER AUTOMOBILES S.p.A. reserves the right to remove its trademark or logo
if the fitting-out or conversion has any features not in compliance with its requirements;
in such cases the coach-builder shall be totally liable for the entire vehicle.

Overview 9
1.9
Legal requirements

With the vehicle completed, the coach-builder must verify that all works done (modifica-
tions, structural applications.) comply with all legal requirements of the country in which
the vehicle is registered (i.e. weight, dimensions, braking capacity, emissions, noise
levels).

The vehicles described in this manual comply with EU Directives. This compliance must
be maintained even after conversion and/or fitting-out. Possible exceptions to this re-
quirement may include cases in which it is possible to obtain local approval, different to
that of the EU.

Seat belt anchor points

Works undertaken on zones in the vicinity of seat belt anchor points may alter their
compliance with EU certification and therefore the coachbuilder must always check com-
pliance with legal standards.

Seats

The seat floor anchors are realised in compliance with legal standards on retainer sys-
tems.

If they are moved from the original position, passenger safety may not be assured, nor
the quality of the conversion works. It is therefore forbidden.

Altering the configuration of the cabin seats (number of places) is also forbidden.

Interior shelving

These structures must be designed and realised to be self-supporting and sufficiently

rigid.
The internal fastening must be to the floor supporting structure (cross and side mem-
bers) and mealised such as to distribute the load evenly.
Anchors to side structures, realised without creating any pre-stress, may be fastened to:
- the boxed pillar structure, where specific holes and anchor points are already provided
(see paragraph – LOADS ON SIDES)
- the upper side connector members.

Operations on vehicle structure and floor

Following the instructions and precaustions already described in the previous paragraph.
In particular, note that:
- when perforating non-structural box sections, avoid zones where stress is more con-
centrated
- holes for floor anchors must be protected and sealed against water, gas and dust infil-
tration.

Overview 10
1.10
Ambulances

We advise special attention in:

- connection of the side panelling and under-roof, using the anchor zones and holes al-
ready present on the body shell, both on cross and side members, avoiding any cutting
that may weaken the structure.
- checking to verify that the application and use of medical equipment does not interfere
with the basic vehicle electrical/electronic systems.

Accident prevention

The structures and systems applied to the vehicles must comply with all accident
prevention and safety standards in force in the individual countries to which the
vehicles are destined.
All precautions dictated by technical knowledge and common sense must also be taken
to prevent breakdowns or functional defects.
The manufacturer of the applied structure or system is obliged to comply with these re-
quirements.

Choice of materials: Environment - Recycling

During the design phase, an increasing amount of attention must be paid to the choice
of materials to use, in particular as regards aspects associated with the environment and
recycling, and especially in the light of continually changing national and international
standards governing waste disposal.
Here are a few guidelines:
- It is forbidden to use materials that are harmful to human health, or that may present
a potential hazard, such as those containing asbestos, lead, halogen additives, fluoro-
carbons, cadmium, mercury, hexavalent chromium, etc.
- Always use materials that produce a minimal amount of waste when processed, and
that permit easy recycling after first use.
- With composite type synthetic materials, use components that are compatible with
each other, envisaging their possible use even combined with other recovered or recy-
cled materials. Always apply markings in compliance with standards in force.

Overview 11
1.11
Vehicle hand-over

Before handing-over the vehicle, the coach builder must:

- Make certain that the conversion and/or fitting-out has been correctly realised;
- Fully tune the vehicle and/or fitting-out applied;
- Check vehicle and/or fitting-out function and safety;
- Prepare and hand-over to the end user all the necessary instructions for operating and
maintaining the vehicle version and any additional systems fitted;
- Include all new data on specific information plates on the vehicle;
- Provide confirmation that the works carried out comply with the instructions given by
the vehicle Manufacturer and all legal requirements;
- Issue a warranty for the modifications made to the vehicle.
The vehicle leaves the factory with “Logistic Mode” (LM) function on.
By deactivating some electric loads, such as radio, roof lights, main beam headlights,
etc., this function preserves the battery charge while the vehicle is on stock.
The battery warning light blinks on the instrument panel when the LM function is on.
The correct instrument (EXAMINER or RD 380) is needed for deactivating the function if
the outfitter finds loads deactivated by the LM function during conversion.
The LM function must be activated again after vehicle conversion.
WYTECH Plus: the diagnosis equipment used in all FGA authorised workshops for running
diagnosis on vehicles and for deactivating the Logistic Mode function.

Supplier:
ACTIA ITALIA S.r.l. (After-Sales Division)
Via Europa, 31-20010 PREGNANA MILANESE (MI)
Fax: +39 02 93 59 50 40
Web site: www.actiaitalia.com – www.wytechplus.com
Email: [email protected]

RD380: Instrument which rapidly allows the activation and deactivation of Logistic
Mode. It has no other functions.

Supplier:
SIX TAU S.p.A.
Via Guglielmo Marconi, 810040 DRUENTO (TO)
Ph. +39 011 994 08 24
Fax +39 011 994 04 08
Web site: www.sixtau.com
Email: [email protected]

Overview 12
1.12

Vehicle management in compounds

Subject of the document

This procedure is a set of mandatory regulations for vehicles on compounds aimed at
preserving the original quality of the product and avoiding malfunctions for the end cus-
tomers.

Area of application
This procedure described applies to all vehicles parked at compounds.

Procedure
Parking position
• Battery: disconnect the battery by disconnecting the negative battery pole.
If the vehicle is provided with a battery master switch, turn the ignition switch to the
“BATT” position.

• Windscreen wipers: lift the blades from the glass.

• Handbrake: leave gear in idle position and engage first gear
(in case of Comfort-Matic robotised gearbox, set lever in position N).

Maintenance
• Battery: check battery charge state one month after the production of the vehicle and
then once every three months (it is advisable to carry out the measurements two hours
after having connected it).
◦ Change the battery if the voltage is lower than 12.1 V.
◦ Recharge the battery if the voltage is from 12.1 V to 12.49 V.
◦ The battery is charged if voltage is higher than 12.5 V.
It is important to keep track of checks and measurements on a specific form.
• Tyres: check inflation pressure of tyres one month after the production of the vehicle
and then once every three months. Pressure must be measured when cold and corre-
spond to the values shown in the Owner Handbook.
Restore the correct pressure, if required.

Commissioning
• Battery: before dispatching the vehicle, reconnect the negative battery pole by correct-
ly connecting the terminal. If an optional “battery master switch” is fitted, simply turn

Overview 13
1.13
the key to the “MAR” position.
• Tyres: re-establish correct pressure.
• Fuel: for storage over three months, pour antibacterial protection in the tank
(e.g. Petronas “Tutela Professional Diesel TMF PLUS”).
1.14
Presentation of the range

The range of vehicles suitable for conversion includes the following versions:
- Van;
- Van with windows;
- Chassis cab;
- Special chassis cab;
- Chassis cab with platform;
- Basic chassis;
- Special basic chassis;
- Double cab;

The drawings listed are for information only. For all the wheelbases and main dimen-
sions, refer to the chapter ‘Dimensions’ from page 4.1.

VAN

VAN WITH WINDOWS

Overview 14
1.15
CHASSIS CAB

SPECIAL CHASSIS CAB

CHASSIS CAB WITH PLATFORM

Overview 15
1.16
BASIC CHASSIS

SPECIAL BASIC CHASSIS

DOUBLE CAB

Overview 16
2.1
BODYWORK AND CHASSIS

Maximum permitted weights 2.2

Towing capacity 2.4
Centre of gravity 2.5
Profile limits 2.6
Modifying rear overhang 2.7
Chassis cab lengthening limits 2.8
Overhang lengthening methods 2.10
Tow hook 2.12
Attachment pre-fittings 2.13
Finishing elements 2.14
Indications for modifying front 2.15
Modifications to the roof 2.16
Wheel arch dimensions 2.18
Wheels and suspension 2.19
Cab habitability diagram (van version) 2.20
Spare wheel 2.21
Relocation of spare wheel for chassis cab and basic chassis versions 2.22
Indications for connecting superstructures 2.23
Fitting the counterframe 2.24
Plan and reference holes for superstructure application
(Camping Car) 2.25
Side load retention 2.33
Instructions for eliminating ‘Crash box’ cross members 2.37
Fuel supply system 2.38
Piping technical specifications 2.39
Fitting a roof rack 2.40
Sections of roof rack attachment points 2.41
Positioning attachments 2.44
Opening of a hatch in the roof 2.45
Making a window in the side 2.46
Installing heater 2.47
Fittings for supplementary heater/air-conditioner 2.48
Air suspension 2.50
Changes to the wheelbase 2.53
ESC system 2.54

Bodywork and Chassis 17

2.2
Maximum permitted weights

Overall vehicle weights and the maximum admissible weights per axle are given in the
table below. The tare weights refer to STDA configuration (unladen weight with 90% of
fuel);
Special equipment may cause variations to weight and weight distribution over the ax-
les.
Before carrying out the conversion, check vehicle unladen weight and weight distribution
per axle.
To ensure constant and correct set-up and peak capacity, even on low grip road surfac-
es, safe dynamic behaviour reliability and the required performance, weight distribution
must be within the following limits (that must not be exceeded) in all load conditions:
- Front axle: weight at ground always between 70% and 40% of the total vehi-
cle ground weight
- Rear axle: weight at ground always between 30% and 60% of the total vehi-
cle ground weight.
According to the weight distribution, the total ground weight and/or maximum admissi-
ble weights on the axes may not be fully saturated.

Vehicle diagram identification data table

Ducato
version GVW Kg Max. front Max. rear Payload q wheels
axle Kg axle Kg
12 Q 3000 1630 1650 11-12 R” 15
15 Q 3300 1750 1900 13-15 R” 15
17 Q 3500 1850 2000 15-17 R” 16
Ducato Maxi
17 Q 3500 2100 2400 14-16 R” 16
20 Q 4000 2100 2400 18-20 R” 16
22 Q 4250 2100 2400 18-22 R” 16

Camping-car chassis-cabs and chassis-cowls

Ducato
version GVW Kg Max. front Max. rear Payload q wheels
axle Kg axle Kg
30 Q 3000 1630 1650 - R”15
33 Q 3300 1750 1900 - R”15
36,5 Q 3650 1850 2000 - R”15/16
Ducato Maxi
42,5 Q 4250 2100 2400 - R”16
44 Q (180HP) 4400 2100 2500* - R”16

* standard on 150-180 HP

Bodywork and Chassis 18

2.3

W: GVW;
W1: Max. Load on front axle;
W2: Max. Load on rear axle;
R: Wheels.

Bodywork and Chassis 19

2.4
Towing capacity

The limits given in FIAT CHRYSLER AUTOMOBILES S.p.A. documents must be respected.
Special attention must be paid to vehicles with load concentrated on the rear overhang
and short wheelbase vehicles with high centre of gravity.
The positioning of auxiliary equipment and superstructures must ensure even transverse
load distribution. For each wheel, a variation in the nominal load on the wheel (1/2 the
load on the axle) of ±4% with respect to the permitted tyre loading is possible without
jeopardising braking capacity and vehicle driving stability.

Version GVW (Kg) Towing weight

(Kg)

30 3000 2000
33 3300 2000
35 3500 2000
36,5 3650 1850
Maxi 35 3500 2500
Maxi 40 4000 2500
Maxi 42,5 4250 2250
Maxi 44 4400 2100

The rear overhang of the superstructure must be realised considering the maximum
permitted axle loading, the minimum load required on the front axle, length limits, the
position of the two hook and the underrun protection bar foreseen by various standards.

Special exceptions to the maximum permitted weights may be given for special uses, for
which precise use limits will be nevertheless established, along with any reinforcing to
apply to vehicle organs.

These exceptions, if they exceed legal limits, must be authorised by the administrative
Authorities.

NOTE: With the vehicle ready for the road (conversion completed) the difference in
weight between the right side and left side must not exceed 100 kg, to prevent prob-
lems with vehicle geometry.

Bodywork and Chassis 20

2.5

Centre of gravity

The height from ground of the non-converted chassis cab vehicle centre of gravity is giv-
en in the specific technical documentation for each model/version.

To test the vehicle complete with superstructure, the coach-builder must check that the
height of the equipment centre of gravity (including the payload) or the entire vehicle
under full load respects the maximum permitted values.

These limits are defined in compliance with national and international standards (e.g. EU
Directives on braking), or are required by FIAT CHRYSLER AUTOMOBILES S.p.A. to as-
sure good vehicle dynamic behaviour (e.g. transverse stability in motion).

Full functionality of ESC system is assured when those limits are respected.

K = Centre of gravity G position in all converted vehicle load conditions

L = Vehicle wheelbase
Cm = Gauge (maximum between fr. and rear)
WG = Total maximum ground weight
WA = Front axle max admissible weight
WP = Rear axle max admissible weight
A = WG - WA)*L/WG (minimum distance from front axle)
P = L* WP/ WG (maximum distance from front axle)
G = P – A (G longitudinal range)
H = 0,7*Cm (G vertical range)

Bodywork and Chassis 21

2.6
In version where the payload can shift sideways (e.g. suspended loads, transport of
fluids, etc.), higher dynamic loads may be generated when turning, resulting in re-
duced vehicle stability. This must be considered in the vehicle operating instructions,
or for any reductions to centre of gravity height.

Particular attention must be given to ensuring compliance with the weight limits es-
tablished for the individual axles and the overall weight limit, also considering the
foreseen number of passengers and a sufficient margin for the loads that may be
transported with them, such as:
- luggage, tents, sports equipment;
- water tank capacity, toilets;
- gas bottles, etc.

Bodywork and Chassis 22

2.7
PROFILE LIMITS (chassis cabs)

A. Wheelbase
B. Overhang = 60% of wheelbase
(65% of wheel base for motorhome)
with coach-builder responsible for approvals (•)
C. Height = 3500 mm (with unladen vehicle)
L* 2050 mm with standard mirrors
2200 mm with long arm mirrors
2350 mm with extra-long arm mirrors
L** 2430 mm – conversion from basic chassis
vehicle into motorhome
(•) For all wheelbases longer than 3800 mm,
the maximum permitted overhang must not exceed
2400 mm.

Elimination of mounting for Webb hook

Cutting area
Webb hook support

NOTE The mounting must be cut as shown. Restore anti-rust treatment after cutting.

Bodywork and Chassis 23

2.8
Modifying rear overhang

Modifying the rear overhang causes a significant change in the distribution of ground
loads on the axles. Lengthening works must take this into account, checking that the
values of the maximum loads permitted for each axle are nevertheless observed.

The operation to modify the overhang must be carried out in accordance with the re-
quirements given on the following pages.

In addition, the possible lengthening operations may be deduced from the diagrams (see
following page), where the shaded area defines all the possible dimensions of the over-
hang in relation to the vehicle’s wheelbase.

Lengthening the overhang may involve repositioning the underrun protection bar in com-
pliance with regulations in force.

The modification must be made without making welds on chassis box sections, as this
procedure would involve destroying the internal treatment obtained by cataphoresis;
in addition, the vehicle is already equipped with holes for fastening overhang extension
structures (see following pages).

NOTE: Do not make cuts in areas where stresses are highly concentrated.
In addition the cutting lines must not affect existing holes on the
longitudinal members.
For materials of the added structures, refer to the specifications of
the original longitudinal members.
For overhang lengthening instructions, see the following pages.
Per le indicazioni di allungamento dello sbalzo, vedere le pagine seguenti.

1: indicative outline of structure for lengthening overhang.

Bodywork and Chassis 24

2.9
Chassis cab lengthening limits.

The permitted extensions to the overhang can be deduced from the diagram below.

1. Maximum overhang length according to wheelbase (60% for all versions excluding
Camping-car).
2. Maximum overhang limit according to wheelbase (65% for Camping-car versions).
3. Original wheelbase.
4. Original overhangs (*).
For all wheelbases that exceed 3800 mm the maximum length of the projecting part
must not exceed 2400 mm.
(*) - Chassis cabs, chassis cab with platform and standard basic chassis: 860 mm;
(extra-long overhang: 1225 mm).
- Special cabs, chassis cab with platform and special basic chassis: 880 mm;
(extra-long overhang: 1245 mm).
A: Wheelbase length.
B: Overhang length.

Bodywork and Chassis 25

2.10
Overhang lengthening methods
Normal chassis cab (with sub-frame)
Sections

Perspective view

1: longitudinal member; 2: structure by coach-builder; 3: holes for fastening structure, 4: ring nut.

Bodywork and Chassis 26

2.11
Special chassis cab (without sub-frame)

Sections

Perspective view

1: longitudinal member; 2: structure by coach-builder; 3: holes for fastening structure;

4: ring nut x: maximum length of reinforcing: 560 mm.

Bodywork and Chassis 27

2.12
Towing hook

Overview
A towing hook can be applied without requesting authorisation to FIAT CHRYSLER AU-
TOMOBILES S.p.A. only on the specific cross-member provided and only on vehicles that
FIAT CHRYSLER AUTOMOBILES S.p.A. has declared suitable for towing trailers.
Installation of towing hooks on vehicles for which towing is not originally foreseen must
be authorised by FIAT CHRYSLER AUTOMOBILES S.p.A..

NOTE: Since tow bars are an important element for vehicle driving safety, all limita-
tions imposed by standards in force must be respected, such as minimum space for
braking and electrical system connections, minimum distance between axles, towing
pin and rear edge of superstructure.
In the case the dimension of the hook attachment flange does not coincide with the ex-
isting holes on the vehicle transom bar, modifications can be authorised if suitable rein-
forcing is applied.

Bodywork and Chassis 28

2.13
Attachment pre-fittings

The drawing shows the pre-fittings

for applying the towing hook.
The solution is valid for all
Cr x Sn
Camping car. S1

1: structure of the vehicle on which the towing hook transom bar is fastened; 2: tow
hook stringer; 3: towing hook attachment flange; 4: holes for fastening assembly to
chassis; 5: nut.

Calculation of maximum towable weight after vehicle conversion.

If overhang is lengthened, or the towing hook position changed with respect to the ap-
proved position, the towable weight can be calculated by means of the following
formula:

C1= Cr x Sn
S1

Where: S1 = Overhang with moved hook

C1 = New towable weight
Sn = Overhang with standard hook
Cr = Standard towable weight

Minimum distance from exhaust

As a result of the high temperatures reached by

the exhaust pipe during the regeneration of the
particulate filter (DPF), the following minimum
distances from the “hot” elements should be
observed when developing the underbody layout:
- Clearance of 100 mm on the sides from the
areas where there is no heat shield*
- Clearance of 40 mm, in all directions, from the
areas where there is a heat guard.”

(*) Do NOT plan any component above the hot zone if there is no heat shield.

Bodywork and Chassis 29

2.14
Finishing elements

If a different mat to the original is used on the floor of the driver’s side, it must not in-
terfere with the excursion of the pedals, limiting them (accelerator, brake, clutch).

Engine compartment

When making the conversion (motor-home), the front radiator grill must be designed to
ensure at least the same passage of air as the original, as on the version with the same
chassis cab.
Correct engine cooling must also be ensured, as on the original vehicle, making no
changes to the inlet air permeability area, which must be no lower than that defined and
visible on the version with similar cab.
When necessary, it is also recommended to implement an air flow conveyor, such as, for
instance, the one in the attached diagram, in order to allow a regular flow toward the
radiator.
No alterations or additional elements must be made to the areas of the engine that emit
most heat (e.g. shields).

Dynamic flow WITHOUT conveyance on radiator – intercooler and air inlet cross
member

1: Upper cross member 4: Lower conveyance 7: Intercooler

2: Upper conveyance 5: Lower cross member 8: Engine radiator
3: LH lateral conveyance 6: RH lateral conveyance 9: Air flow

Bodywork and Chassis 30

2.15
Indications for modifying front.

Technical specifications of intake air permeability surface in engine bay on basic vehicles.

A 14.8 dm2 A: upper air intake

B 3.9 dm2 B: lower air intake
C 18.7 dm2 C: total area

If modifications to the vehicle front are required, the air permeability surface must be
uniformly distributed, maintaining the values used on the original version, over the areas
corresponding to the radiator (see diagram below).

Warning: failure to observe the indications provided may result in serious engine damage.

Bodywork and Chassis 31

2.16

Modifications to the roof

Instructions for cutting roofs of chassis cabs with OPT 59E.

The cab roof can be cut as shown below:

Bodywork and Chassis 32

2.17

X: maximum permitted limit cutting roof.

Installations and modifications to realise specific versions must be carefully carried out
in order to safeguard structural rigidity and maintain the function and protection offered
by the cab, as well as the seat belt top anchor points (see detail A).

Bodywork and Chassis 33

2.18
Wheelarch dimensions

The graphic shows the maximum wheel excursion with the vehicle in use.
Respect the dimensions given when modifying the wheel arch.

Section A-A

Track Tyres Y L L1 W Z
225/70 R15 C 83 290 365 350 400
Normal
225/75 R16 C 83 290 380 370 450

225/70 R15 C 173 300 365 350 410

Widened
225/75 R16 C 173 300 380 370 460

NOTE: The values given in the diagram include maximum play of 10 mm in relation to
tyre (without chains) in conditions of asymmetrical jolting with maximum buffering.

Section B-B

Bodywork and Chassis 34

2.19
Wheels and suspension

For vehicles converted by coach-builders, a check on toe-in and suspension geometry

must be made by the coach-builder/converter, prior to handing the vehicle over to the
customer (tractor cabs only).

WHEEL TRIM ALL VERSIONS

Vehicle unladen (*)

Camber (**)

Incidence (**)

Front
Toe-in
suspension

Camber (**)

Rear Toe-in
suspension

(*) With tyres inflated to required pressure with vehicle ready for road
(**) Angles not adjustable

WHEEL BEARINGS

FRONT Rear LIGHT Rear HEAVY

Bodywork and Chassis 35

2.20
Cab habitability diagram

Reference mm
d9 390
h30 435
h61 1081
h70 740
h74 165
h93 330
h157 199
h326 450
h445 257
l9 500
l13 635
l22 523
l23 170
l31 1004
l34 985
l53 670
l63 465

Bodywork and Chassis 36

2.21
Spare wheel

The spare wheel is positioned in the rear part of the vehicle, in the external compart-
ment under the chassis.
The complete device is fastened to the cross-member (4):
- at the centre by the wheel lifting/lowering cylinder (1),
- to the side by the control (3) with cables and brackets (5).

Spare wheel position for chassis cab and basic chassis versions

Bodywork and Chassis 37

2.22
Relocation of spare wheel for chassis cab and basic chassis versions

If the spare wheel mounting (3) and (2) has to be repositioned (for instance for length-
ening the overhang, see detail 4), the anchor points must b transferred to the new
structure, at the same distances used for its installation on the original vehicle (see
drawings on previous page).

In this condition the device will function correctly.

When repositioning, easy access must be maintained not only to the spare wheel, but
also to the control must (detail 3 in diagram below).

NOTE: restore the wheel upper fastening points by means of two cross
members (5).

Bodywork and Chassis 38

2.23
Indications for connecting superstructures

Drilling holes in the chassis

To fit additional assemblies to the chassis or bodyshell, as a general rule existing holes
should be used.
If new holes have to be made they should be made on the vertical wall of the longitudi-
nal member and thoroughly de-burred and reamed.
For the drilling, keep to the figure, and so:
- under no circumstances should the dimension ‘a’ be less than 30% of the chassis
height (h);
- the distance between adjacent holes must never be less than 50 mm;
- the maximum diameter of the holes must not exceed 12 mm;
- the new holes must not be made near areas under greater stress, such as:
areas for spring mountings, shock absorbers, brackets, crossmember attachments.
When necessary, fit spacers in the original structures. Make the weld as shown in the
diagram and then apply corrosion protection.

1- Chassis; 2 - Spacer bush

For chassis cab versions with sub-frame, superstructures can be mounted on the upper
longitudinal member present on the basic version (fig. A). For ‘special’ versions, holes
are provided for use as shown in figure (B).

1: upp. plate - 2: longitudinal member - 3: attachment - 4: reinforcing plate

5: superstructure fastening holes - 6: box-member reinforcing bush.
C: fastening solution with addition of an external U-bolt.
D: fastening solution with addition of internal bush.

Bodywork and Chassis 39

2.24
Fitting the counterframe

The purpose of a counterframe is to ensure an even distribution of the loads over the
vehicle frame and to contribute to the stiffness of the vehicle as a function of its intend-
ed job.
For its construction, keep in mind that the material must have good mechanical weld-
ability properties. The elements anchoring the counterframe to the vehicle frame must
be designed to ensure a stable connection under the effects of lengthwise and crosswise
thrusts (due to the loads when cornering and when the brakes are applied).
Interpose an elastic block, made of canvas rubber or a similar material with Shore hard-
ness < 70, under the first fastener at the cab end. Interpose rigid spacers under the
other connections.

1: Counterframe; 2: Frame; 3: Spacer; A: Gap between the frames: 4-5 mm.

4: Bracket on frame; 5: Bracket on counterframe.

‘Special chassis-cab with flatbed’ versions come with holes that can be used as shown in
figure (A).

1: Upper plate - 2: Longitudinal - 3: Connection - 4: Anchoring screws

5: Boxed reinforcement
U-bolt - 6: Boxed reinforcement bushing - 7: Flatbed.
B: Fastening solution with the aid of an external U-bolt.
C: Fastening solution with the aid of an internal bushing.

Note: for box-bodies or dropside it’s suggested to keep a maximum distance between
structure and body not exceeding 80 mm.

Bodywork and Chassis 40

2.25
Plan and reference holes for superstructure application (Camping Car)
Reference holes for superstructures

A: reference holes for conversion works by coach-builders;

B: bodyshell reference points.

Bodywork and Chassis 41

2.26
Cab interface for application of superstructure (Camping Car)

1: structural reinforcement; 2: recommended interface area; 3: direction of travel.

In the ‘cut roof’ chassis cab version the angular structure of the side/rear wall, has rein-
forcement (1).
If it is considered necessary to interface a new structure with the cab of the basic vehi-
cle, we recommend using the reinforcement (1) as anchor point in the indicated position
( ).
The configuration of the basic vehicle structure, shown in section A-A, is the same along
the entire area indicated in the drawing by (2).
The drawing shows the recommended distances between the various interface points
between the structures.

Bodywork and Chassis 42

2.27
The main sections of all versions are given below. These provide general information on
the condition of the structure and are strictly for information only.

Cab sections

Bodywork and Chassis 43

2.28
Chassis cab sections

Bodywork and Chassis 44

2.29
Chassis cab with platform version sections

Bodywork and Chassis 45

2.30
Chassis cab with platform version sections

Bodywork and Chassis 46

2.31
Van roof sections

SEC. A1

SEC. A2

SEC. A3

Bodywork and Chassis 47

2.32
Van side sections

Bodywork and Chassis 48

2.33
Side Load Retention

The quantity and relative position of the anchor points for loads are the same as those
for all ‘van’ version wheelbases.
The anchor points are shown below.

1: FRONT WHEEL CENTRE;

2: UPPER FLOOR PROFILE ALIGNMENT;
3: REAR WHEEL CENTRE;
4: LOAD ANCHOR REINFORCING.

Bodywork and Chassis 49

2.34
Load retaining hooks on floor

Short wheelbase

A-A

A-A

Bodywork and Chassis 50

2.35
Load retaining hooks on floor

Medium wheelbase

A-A

B-B

Bodywork and Chassis 51

2.36
Load retaining hooks on floor

Long wheelbase

SECTION A-A

SECTION B-B

Bodywork and Chassis 52

2.37
Instructions for eliminating ‘crash box’ cross member
(only for vehicles without air-bag)

All basic versions are fitted with impact absorbing cross-members.

Removal of the cross-member is only possible in cases of vehicles without airbag

(‘chassis-cowl’ versions).

Front crash-box for all versions

2: front crash box cross-member - 1: controlled impact absorption strut

3: centring pin.

NOTE: for vehicles fitted with air-bag, restore the structure with technical
specifications similar to those removed.

Bodywork and Chassis 53

2.38
Fuel supply system

The fuel supply system is identical on all versions (vans, basic chassis vehicles, etc.)
The passage cone for the fuel filler pistol (model VP std. SAE J 1140) is shown on the draw-
ing given below.
The tank capacity is 60 lt (optional), 90 lt (standard) or 120 L (optional).

Modifications to fuel filler position.

A corrugated flexible pipe can be fitted between the tank and filler, taking care to comply with
regulations in force.

If necessary the corrugated pipe (2) or pipe (1) must be replaced with others
with the same technical specifications (materials, cross-section and fastening,
see diagram on following page).

Descriptive outline

A: 120 L tank.
B: 90 L tank.
1: breather pipe; 2: corrugated connector pipe; 3: fuel filler

Bodywork and Chassis 54

2.39
Pipe technical specifications

Component technical data:

a: letter in relief for correct mounting on vehicle;
c: metal insert with extraction load >= 100 N.
d: flexible collar;
e: nylon corrugated pipe;
L: max. length 261. 8 mm.

Bodywork and Chassis 55

2.40
Fitting a roof rack

The roof rack must be fitted using the attachments on the roof, following the instructions
of the roof rack manufacturer; maximum admissible load condition (including roof rack)
must in any case be respected.
Short wheelbase - 150 Kg
Medium wheelbase - 150 Kg
Long wheelbase - 150 Kg

NOTE: The limit of 25 kg for each attachment on the roof must not be ex-
ceeded. The maximum permitted weight of 150 kg is an absolute limit, even
if the wheelbase is lengthened.

Diagram of roof rack attachment

7. Top exterior. – 8. roof – 9. roof rack pin – 10. roof rack attachment reinforcement –
X0. front wheel axis
‘Y’ distance
Anchor point distances (mm)
(mm)(width)
Load anchor point positions 1 2 3 4 5 6
Short wheelbase,
low roof van (CH1) 1392.8 1244.7 920,5 - - 740.0

Medium wheelbase,
low roof van (MH1) 1392.8 1414.7 1201 - - 740.0

Medium wheelbase,
medium roof van MH2) 1392.8 1414.7 1193.5 - 740.0

Long wheelbase,
medium roof van (LH2) 1392.8 1414.7 713.5 1065 - 740.0

Extra long wheelbase,

medium roof van (XLH2) 1392.8 1414.7 713.5 716 714 740.0

Long wheelbase,
high roof van (LH3) 1392.8 1619.7 509.0 927 - 747.5

Extra long wheelbase,

high roof van (XLH3) 1392.8 1619.7 509.0 716 576 747.5

Bodywork and Chassis 56

2.41
Roof rack attachment point sections

CH1 van sections

Bodywork and Chassis 57

2.42
Roof rack attachment point sections

MH2 – LH2 van sections

MH2 - LH2

sec. 1

sec. 3

sec. 2

Bodywork and Chassis 58

2.43
Roof rack attachment point sections

XLH3 – LH3 van sections

XLH3 - LH3

sec. 3

sec. 1

sec. 4

sec. 2
sec. 5

Bodywork and Chassis 59

2.44
Attachment positioning

Bodywork and Chassis 60

2.45
Opening a hatch in the roof

A hatch may be opened in the roof, providing that the works do not involve the ribs and
the ensure seal and strength of the modified part.

The figure shows an installation example.

1: Sealant - 2: Cut area - 3: Attachment profile - 4. hatch

NOTE: If the hatch has to be opened in a different area of the roof to (a), cut-
ting of the structural ribs (b) is not permitted. The structure must in all cases
be restored to its original conditions of function and rigidity.

Bodywork and Chassis 61

2.46
Making a window in the side

It is permitted to make one or more side windows, provided that they are not on the
structural pillars. If it is necessary to make the window at the structure, the opening
must comprise a perimetral frame that is connected to the original pillars and longitudi-
nal members (see solution B) in order to restore the structural rigidity of the bodyshell.

A: Original solution; B: solution with added peripheral frame.

Make the cut as shown in the diagram, taking care to maintain a perimeter profile with
minimum width of:
- 15 mm for windows fitted with rubber seal (fig. C);
- 20 or 25 mm for bonded windows (fig. D);

1. pillar 1. pillar
2. seal 2. bonding material
3. glass. 3. glass.

NOTE: Before cutting or welding, it is necessary to protect the original body

work not involved in the conversion with sheets or adequate protective
masks in order to prevent damage resulting from the rework activities.

Bodywork and Chassis 62

2.47
Heater installation

If a supplementary heater is required, it is advisable to use only the types foreseen by

FIAT CHRYSLER AUTOMOBILES S.p.A.
For vehicles on which FIAT CHRYSLER AUTOMOBILES S.p.A. has not foreseen
supplementary heaters, these must be installed according to the heater Manufacturer’s
instructions (i.e. boiler, piping, electrical system arrangement etc.) and as per the
instructions given below.
All pertinent national regulations must be respected (i.e. testing, special versions for
hazardous goods transport, etc.). The supplementary heater must not use vehicle
systems subject to homologation, if their use may negatively alter performance.

In addition:
- the correct function of vehicle components and systems must be safeguarded
(i.e. engine cooling);

- for the electrical system, check that battery capacity and alternator power are
sufficient for the increased power absorption (see ELECTRICAL SYS. SECTION).
Fit the new circuit with a fuse;

- for fuel supply, connect the supply system to an auxiliary fuel tank connected to the
return pipe from the engine. Direct connection to the engine fuel tank is only permitted
if this is independent to the engine supply lines and the new circuit has a hermetic seal;

- define the routes of pipes and electrical cables, arrangement of brackets and flexible
joints, taking into account their dimensions and the affect of heat from the various
components on the chassis. Avoid passages and arrangements with exposure that could
present a hazard when travelling, adopting covers or guards wherever necessary;

- for water heaters, when the original vehicle heater and engine cooling circuits are
involved, in order to obtain correct system function and ensure the original safety level:
- define the connection points between the supplementary system and the original
with special attention, if necessary in agreement with FIAT CHRYSLER AUTOMOBILES
S.p.A.;
- arrange piping rationally, avoiding kinks and siphon sections;
- apply breather valves to ensure correct system filling;
- ensure the possibility of complete system drain, fitting any additional plugs required;
- adopt, where necessary, adequate protection to limit heat loss.

- In air heaters and in cases in which the heater is installed directly in the cabin, special
attention must be given to the flu (to prevent combustion gases accumulating in the
interior) and the correct distribution of hot air, to avoid direct flows;

- The entire system must be installed to permit good accessibility and ensure rapid
maintenance.

Bodywork and Chassis 63

2.48
Supplementary heater/air-conditioner system pre-fittings

All ‘free time’ versions can fit air-conditioner and heaters with connections for a supple-
mentary conditioner/heater group.
These pre-fittings obviously concern the rear of the passenger compartment.
As can been seen in the diagram below, the fitting has been realised by means of an
extension to the attachments on the cab air-conditioning group.
If a new group is required, it is advisable to use components with similar technical speci-
fications to the existing ones.

Diagram

1: engine coolant delivery and return pipes;

2: coolant fluid delivery and return pipes;
3: cab air-conditioner;
4: freon pipe connections;
5: heating fluid pipe connection.

NOTE: Refer to the Use and Maintenance Handbook for the technical specifi-
cations of liquids/freon.

Bodywork and Chassis 64

2.49
Supplementary system

The drawing shows one possible location for the supplementary group.

Technical specifications

Air flow-rate Max.power absorption

Model X2/50 Weight (Kg.)
(Stdm3/h - VENT max cold) (A. @12V - VENT max cold)
Main heater
7.00 420 19
group
Manual conditioner
8.50 420 24
group
Automatic conditioner
9.50 420 24
group
Auxiliary heater
2.40 210 2,5
(under seat)
Supplementary rear
4.90 380 21
heater group

Air flow rate Engine coolant flow rate Thermal power Installed mass thermal
(Stdm3/h) (l/h) (BTU/h) power (kW)

Main group radiant mass thermal power

800 37.700 11,00

400
500 35.500 10,40
Under seat group radiating mass thermal power
210 1000 16.400 4,81
Supplementary rear group radiant mass thermal power
800 37.700 11,00
400
500 35.500 10,40

Air flow rate (Stdm3/h) Thermal power (BTU/h) Evaporator thermal power installed (kW)

Main group evaporator thermal power

400 22.300 6,50
Auxiliary rear group evaporator thermal power
350 17.000 5,00

Bodywork and Chassis 65

2.50
AIR SUSPENSION
Installation of air intake on special chassis-cabs and chassis-cowls with flatbed

NOTICE! install the air intake in a zone shielded from dust and not exposed to direct
water jets.

NOTICE! install the air intake opening at a distance from the ground of at least 600mm

1: Air intake; 2: Motorhome cab; 3: Ground line

Location and preparation for installation

The pipe, complete with filter (2) and air intake (5), is situated above the rear air
suspension cross-member and is held together and restrained by clamps or tape (3).
Release the pipe (1) from the clamps or tape (3). To facilitate the installation,
separate the filter from the pipe working from the opening collar (4).

1: Pipe; 2: Air filter; 3: Packaging tape; 4: Opening collar;

5: Reversed-U-shaped air intake.

Bodywork and Chassis 66

2.51
Installation

In the figures below you will find the indications on how to fit the rubber pipe.

Drill a hole (3), of appropriate size for the passage of the rubber pipe, in the cab floor in
the proximity of the left side wall and the rear suspension, as shown in the figure.

Introduce the reversed-U-shaped part (1) through the hole (3). Anchor it to the inner
side of the left wall by means of a small bracket (2) and the relative fasteners.

Extend the pipe towards the inner part of the frame through the hole (4) in the longitu-
dinal, which is not used due to the absence of the rear bushing for the connection of the
mechanical suspension.

NOTICE! To ensure a sufficient flow of air to the compressor, do not perforate the pipe
and do reduce its cross-sectional area; the flow of intake air to the compressor must be
in accordance with the specifications.
- It is important that the end part of the pipe (1) retains the reversed U shape in order
to prevent the penetration of dust and water. The air intake (1) anchoring point must
be positioned at a sufficient distance from the ground, at least 600mm, in a dried,
shielded area.

Bodywork and Chassis 67

2.52

Run the pipe (3) along the left longitudinal. To fasten the rubber pipe to the corrugated
sleeve of the electrical system (2) we suggest using commercially available polyamide
clamps with double ring or strip (4). If you use fasteners of a different type, make sure
that the cross-section of the pipe is not altered.

NOTICE:
The flow of air through the pipe must remain the same as it was before the
application of the fasteners. A narrower section or a hole, no matter how small,
might undermine system operation.

Make sure there are no loose portions of the pipe and complete the installation
as necessary by anchoring to the floor the portions of the pipe not fastened to
the corrugated sleeve (2), using small brackets or similar fasteners.

The pipe is ca 2000mm long and is longer than necessary. To shorten it, cut the
excess portion on the side of the air filter (6). Then restore the connection be-
tween the pipe and the filter and fit back the opening collar (5).

Bodywork and Chassis 68

2.53
Changes to the wheelbase

It is not advisable to change the vehicle wheelbase. You should always address any
problem by making use of the wheelbase lengths specified by FIAT CHRYSLER AUTOMO-
BILES S.p.A.
The versions on which it is possible to make the change in question are chassis-cabs and
chassis-cowls without option 555 (air suspension).
It is absolutely prohibited to make this change to: all the vans, the chassis-cabs and
chassis-cowls with flatbed, and all the vehicles with 4035 mm and 4300 mm wheelbase.
If you have to change the wheelbase, the length added must never exceed 10% of the
original wheelbase for vehicles with ABS and 5% for vehicles with ESC and, in any event,
the final length must never exceed 4300 mm.
The figure shows a method for the lengthening of the wheelbase. For the materials of
the added portions (parts 2 and 3 in the figure), see the characteristics of the original
longitudinal. The quantity and the positions of the connections or welds given in the
figure are only indicative. The change must always ensure appropriate bending and tor-
sional stiffness of the structure.

wheelbase

1: Original frame; 2: Reinforcing boxed section; 3: Additional frame;

4: Cutting zone for wheelbase modification;
x: wheelbase lengthening variable dimension
(max. 10% of original wheelbase length for vehicles with ABS, 5% with ESC).

Bodywork and Chassis 69

2.54
ESC system – Electronic Stability Control

ESC system was developed considering the weight of a completely upfitted vehicle in the
respect of the limits indicated in this manual.
When and only if the vehicles does respect the limits indicated at pag. 2.5 for weight
distribution and positioning of the centre-of-mass, the full ESC system functionality is
ensured, without needing further testing.

Bodywork and Chassis 70

3.1
ELECTRICAL SYSTEM

Electrical system 71
3.2

1. DESCRIPTIVE KEY 3.4

1.1 List of acronyms in diagrams 3.4
1.2 Key to terminology 3.4
1.3 Cable colour table 3.5
2. OVERVIEW 3.6
2.1 Moving supplementary group and equipment components and attachments 3.7
3. SPECIFICATIONS FOR COACH BUILDERS 3.7
3.1 Connectors provided for conversions 3.7
3.2 Auxiliary alternators and batteries 3.8
3.3 Batteries 3.10
3.4 Fuse and relay box under dashboard 3.12
3.5 Fuse box on battery 3.13
3.6 Right pillar fuse and relay box 3.14
3.7 Ground points 3.14
4. CONNECTORS PROVIDED 3.15
4.1 Connector C036 L1A (15-way) – Coach-builder’s socket 3.15
4.2 Connector C036L1B (6-way) – Coach-builder’s socket 3.22
4.3 Connector C036L1C (2-way) – Coach-builder’s socket 3.25
4.4 Connector Y203L4A (12-way) – Rear lights 3.27
5. FRONT DOOR AND AERIAL CONNECTORS 3.28
5.1 Connector Y001LA (24-way) – Driver’s side door 3.29
5.2 Connector Y002LA (24-way) – Passenger side door 3.33
5.3 Connector Y121LA (4-way) – Driver’s side door (opt) 3.36
5.4 Connector Y116LA (4-way) – Passenger side door (opt) 3.39
5.5 Procedure for setting radio switching off time after key-off 3.40
5.6 Vehicles provided with “5BH” - Steering wheel controls for outfitters 3.41
5.7 Connector Y050PA (1-way) – AM/FM radio aerial 3.42
5.8 Phantom-box – Amplified radio aerial power supply 3.46
5.9 Headlight Alignment Corrector 3.46
6. GENUINE NEW DUCATO COMPONENTS 3.47
6.1 Locks 3.47
6.2 Front lights 3.48
6.3 Fog lights 3.49
6.4 Rear lights 3.50
6.5 Taillights 3.51
6.6 Windscreen wiper 3.53
6.7 Windscreen washer pump 3.55
6.8 Left hand external rear view mirror 3.56

Electrical system 72
3.3
6.9 Right hand external rear-view mirror 3.57
6.10 Ceiling light 3.59
6.11 Driver’s side door control pad 3.60
6.12 Passenger side door control pad 3.61
6.13 Electric windows 3.62
7. STANDARD FIAT CHRYSLER AUTOMOBILES S.P.A. COMPONENT DRAWINGS 3.63
7.1 20A micro relay switch 3.63
7.2 30A micro relay switch 3.64
7.3 50A maxi relay switch 3.65
8. TIPS FOR INSTALLATION 3.66
8.1 Refrigerator power supply 3.66
8.2 Coachbuilders socket in engine bay 3.66
8.3 Anti-theft system 3.72
8.4 Trailer 3.72
8.5 Robotised gearbox 3.73
8.6 Truck Upfitter Module 3.74
8.7 TPMS 3.90
8.8 LDWS 3.94

Electrical system 73
3.4
Descriptive key

List of acronyms in diagrams

ACM Automatic Climate Module Key to terminology:

AHCU Additional Heater Control Unit
+30: permanent +12V vehicle
ASM Air Suspension Module power supply
ASS Auxiliary Stack Switches
+KEY: signal active at +12V
ASU Alarm Siren Unit
vehicle when ignition switch is in
BCM Body Computer Module position (MAR)
BSM Brake System Module
+LIGHTS: signal active at +12V
CDC Co-Driver Door Command when position lights are on.
CSM Column Switch Module
CSS Central Stack Switches BATT. AUX: auxiliary battery
installed by coach-builder.
CTCU Chrono Tachograph Control Unit
CTM Convergence Telematic Module P.M. connector: connector
DDC Driver Door Command suitable for receiving male
terminals
DSHS Driver Seat Heater System
ECM Engine Control Module P.F. connector: connector
suitable for receiving female
FCLU Front Ceiling Light Unit
terminals
GPCU Glow Plug Control Unit
IBS Intelligent Battery Sensor
IPC Instrument Panel Cluster
LDWS Lane Departure Warning System
LSS Left Stack Switches
MCD Manual Climate Device
MTA Manual Transmission Automated
PAM Parking Aid Module
PSHS Passenger Seat Heater System
RLS Rain Light Sensor
RMCD Rear Manual Climate Device
RRM Radio Receiver Module
SAS Steering Angle Sensor
SDM Sensing and Diagnostic Module
SLU Shift Lever Unit
SSCU Servo Steering Control Unit
SWC Steering Wheel Command
TPMS Tire Pressure Monitoring System
TUM Truck Upfitter Module
VPAS Video Parking Aid System
VSU Voltage Stabilizer Unit

Electrical system 74
3.5
1.3 Cable colour table

Code Colour
A Light blue
B White
C Orange
G Yellow
H Grey
L Blue
M Brown
N Black
R Red
S Pink
V Green
Z Purple
W Light brown

Electrical system 75
3.6
Overview

Moving supplementary group and equipment components and attachments

If to apply equipment and realise various types of transformation it is necessary to move

any existing groups (misc. components, fuel tank, spare wheel, etc.), this is permitted
provided that the function of the same is maintained and the original type of connection
is maintained, and that their position is not substantially altered in a crosswise direction
on the chassis, if heavy.
If an object has to be installed on the route of a cable of the original electrical system,
the route may be altered provided that the cable is not cut and the same fixation system
is used.

Figure 1

Electrical system 76
3.7
Specifications for coach builders

1.5 Connectors provided for conversions

For the coach-builders to effectively and correctly use the basic system on the NEW
DUCATO model, FIAT CHRYSLER AUTOMOBILES S.p.A. has provided specific connection
points to which supplementary systems can be connected.
This type of provision is necessary to prevent any kind of tampering or manipulation of
the basic design, and to ensure function integrity and validity of the vehicle warranty.
In addition to the main interconnection points foreseen for connection to supplementary
systems, this section illustrates and describes a number of other subjects (dashboard
control unit, battery, etc.) that are the exclusive domain of the basic system, and as
such must not be altered in any way by the persons responsible for the conversion.

Figure 2

1. Dashboard fuse control unit – 2. Battery fuse box – 3. Connector group for doors
and aerials – 4. Side fuse/relay box with 16, 15 and 2-way connectors for coach-builder
interfaces – 5. Rear services connector – 6. Possible location of auxiliary battery
7. Main system battery – 8. Alternator – A. B. C. ground points

Electrical system 77
3.8
Auxiliary alternators and batteries

The installation of high power absorption electrical equipment (i.e. frequently used
electric motors, or electric motors used less frequently but for long periods without the
support of the engine, such as loading platforms for city use), or a large number of sup-
plementary electrical utilities, could demand power levels that the normal vehicle system
is not capable of supplying. In these cases supplementary batteries of suitable capacity
must be installed.
The vehicle system is sized to supply the power requirements of standard equipment, all
of which is provided with specific protection and connected with suitably sized cables.
Applications of supplementary equipment must also foresee adequate protection and
must not overload the vehicle system.
If higher capacity batteries are installed, due to the higher current draw, make certain
that a suitably oversized alternator is also installed. In no case should the increase in
battery exceed 20% of the standard battery capacity, to prevent damage to any compo-
nent of the system.
If it is necessary to make alterations to the system other than the ones described in this
manual (for example, additional batteries in parallel), the works must be co-ordinated
with FIAT CHRYSLER AUTOMOBILES S.p.A.
Current take off
For information on current take off points, see the description on the following page.

Available oversized alternator summary table

Engine Opt Brand Model Size Regulator Regulator voltage features

2,0 JTD 065 Denso SC2 150 A GL6 Vreg = 14.5 V at 25°C and 6000 rpm
Thermal compensation -10 mV/°C

2,3 F1A 4WP Valeo FG18 180 A YR208 Vreg = 14.55 V at 25°C and 6000 rpm
Euro 4-5 Thermal compensation -10 mV/°C

2,3 F1A 7KK Valeo FGN20 200 A YR208 Vreg = 14.55 V at 25°C and 6000 rpm
Euro 6 LPEGR Thermal compensation -10 mV/°C

3,0 F1C-3,0 4WP Valeo FG18 180 A YR208 Vreg = 14.55 V at 25°C and 6000 rpm
CNG Thermal compensation -10 mV/°C

Electrical system 78
3.9
Figure 3

Note: drawings for information only

Electrical system 79
3.10
1.7 Batteries

Figure 4

1. Main battery – 2. Auxiliary battery – 3. Two-way connector

The above drawing (detail 2) shows one possible location for the auxiliary battery.
If the main battery is removed/replaced, check correct function of the gas/liquid
drain pipe.

Note: For auxiliary battery installation:

- in the cargo bay;
- in passenger compartment
recombination batteries (AGM or gel) are advised.
Adequate separation must be provided between the battery and the passenger com-
partment, with a suitable container capable of ensuring seal in case of:
- vapour emissions (for example in case of alternator voltage regulator fault);
- battery explosion;
- to provide a breather toward the compartment exterior.

It is also necessary that the gas evacuation system is located as far as possible from any
potential sources of spark, and from mechanical/electrical/electronic components, opting
for a breather system that prevents vacuum formation in the battery.
There is a two-way connector (3) at the base of the passenger side door, for connecting
the auxiliary battery (see Figure 10).

When charging system for the secondary battery are installed, it’s also allowed the man-
agement of the main battery if compatible with the battery specifications and through a
connection properly protected by a fuse.

The auxiliary battery ground connection must be made with an adequately sized cable,
as short as possible and using the points provided on the vehicle (see Figure 2).

Electrical system 80
3.11
1.8 Scatola fusibili e relè sottoplancia

Figure 5

Fuse table

Fuse Function Rating

F12 RH DIPPED HEADLIGHT 7,5A
F13 LH DIPPED HEADLIGHT 7,5A
F31 INT/A 5A
F32 SBMT 7,5 A
F33 START & STOP 7,5 A
F34 MINIBUS 7,5 A
F36 +30 NRR, NCV, CCT, CSA, NCL, WEBASTO TIMER,
10 A
BATTERY MASTER SWITCH
F37 INT CLA (NA), NQS 7,5A
F38 DOOR LOCK 20 A
F42 INT NFR, NAS, CLA (NC) 5A
F43 WINDOW WASHER PUMP 20 A
F47 ELECTRIC WINDOW DRIVER'S SIDE 20 A
F48 ELECTRIC WINDOW PASSENGER'S SIDE 20 A
INT NSP, CAV, RADIO AFTERM. / NCV, STEERING WHEEL
F49 5A
CONTROLS, CSS, LSS, CSP, AUX PANEL, 5QD
F50 INT NAB 7,5 A
INT POWER STEERING ECU, REVERSE, H20 DIESEL FILTER,
F51 5A
FLOW METER, NCL, CLUTCH, CCT, NAV. AFTERM.
F53 +30 NQS 7,5 A
F90 LH MAIN BEAM 7,5 A
F91 RH RIGHT BEAM 7,5 A
F92 LH FOG LIGHT 7,5 A
F93 RH FOG LIGHT 7,5 A

Electrical system 81
3.12
1.9 Fuse box on battery

The vehicle main battery has an interconnection unit which has a socket for an auxiliary
battery.
The connection foreseen for coach-builders is the 50A fuse (3).
The cable involved is complete with two-way connector located in the compartment at
the base of the passenger side pillar (see Figure 4).

No Minibus vehicle type

Figure 6A

Connections key and description:

1) auxiliary battery power (50A) via 2-way connector:

2) dashboard fuse and relay box auxiliary power (50 A)
3) main battery under-dashboard fuse and relay box (70 A)

NOTE: install a power relay between the two-way connector and the auxiliary
battery positive, so that with the engine off the system added by the
coachbuilder is separated from the main vehicle system

5) starter motor and alternator power (MEGA 500);

6) interconnected control unit on battery.

Electrical system 82
Minibus and CNG vehicle type

Figure 6B

BDS

Connections key and description:

1) dashboard fuse and relay box auxiliary power (50 A)

2) main battery under-dashboard fuse and relay box (70 A)
3) auxiliary battery power (50A) via 2-way connector:

NOTE: install a power relay between the two-way connector and the
auxiliary battery positive, so that with the engine off the system added by
the coachbuilder is separated from the main vehicle system

4) engine bay fuse and relay box power (150 A);

5) BDS – Battery Distribution System, Emergency Push Button;
6) interconnected control unit on battery.

Electrical system 83
3.13
1.10 Right pillar fuse and relay box

No Minibus, Full OPT vehicle type

Figure 7A

Cod. Relè [micro] In[A]

T23 Elettroventola riscaldatore 30
supplementare
T24 Condizionatore supplementare 30
bassa velocità
T29 Abilitazione condizionatore 30
supplementare
T30 Lunotto termico 30
T31 Riscaldatore supplementare 30
sottosedile
T66 + Chiave sedili riscaldati 30
Cod. Fuse [a0] In[A]
F54 Ventola aspirazione/ventilazione 15
minibus
F55 Sedili riscaldati 15
F56 Presa 12v trasporto persone/ 15
trasformatori
F57 Risc. Sottosedile/ elettrovalvola/ 10
enable risc. suppl.
F58 Lunotto termico sx 15
F59 Lunotto termico dx 15
Cod. Fuse [a] In[A]
= Relè e fusibili presenti in P030 Riscaldatore/condizionatore 10
configurazione full opt. supplementare
P031 Riscaldatore/condizionatore 30
supplementare

Electrical system 84
Minibus, Full OPT vehicle type

Figure 7B

Cod. Relè [micro] In[A]

T67 Ventilazione minibus 30
T68 Ventilazione minibus 30
T25 Luci interne minibus 30
Cod. Fuse [a0] In[A]
T69 Sidemarker 30
T30 Lunotto termico 30
T31 Riscaldatore supplementare 30
sottosedile
T66 + Chiave sedili riscaldati 30
Cod. Fuse [a] In[A]
F54 Ventola aspirazione/ventilazione 15
minibus
F55 Sedili riscaldati 15
F56 Presa 12v trasporto persone/ 15
trasformatori

F57 Risc.Sottosedile/ elettrovalvola/ 10

enable risc.
Suppl.
F58 Lunotto termico sx 15
F59 Lunotto termico dx 15
= Relè e fusibili presenti in Cod. Fuse [a] In[A]
configurazione full opt. P053 Sidemarker 10

1.11 Ground points

If ground points A, B or C are used, the fastening nut must be tightened to torque of 8
Nm ± 10%.

Electrical system 85
3.14
Connectors provided

Connector C036 L1A (15-way) – Coach-builder’s socket

3D view of connector

Figure 8

Electrical system 86
3.15
Description of connector functions

Minimum
cable cable
Pin Function/Connector part number Notes
section colour
[mm2]

15-way Tyco connector p/n 0-926647-1

Counterpart: Tyco p/n 1-480710-0 Reference to diagram C036-L1A
(by coach builder)
PMAX= 21W at 12V (in alternative to
1 Third stop light 0,5 B
the one on Y203L4A)
IMAX= 300mA
2 D+ (active at ground) 0,35 MN (1 Fiat Chrysler Automobiles S.p.A.
standard relay coil)
3 Vehicle speed repeater (VSO) 0,35 MV IMAX= 5mA (see Figure 11)
IMAX= 12A
4 Door lock control 1,5 RN
(for actuation times see Table 1)
IMAX= 12A
5 Door unlock control 1,5 NR
(for actuation times see Table 1)
Use an N.O. to ground switch
6 Side and rear door status signal 0,35 NZ (minimum clean contact current
10 mA)
Power supply (+) for timed ceiling
Driver 20W SBMT#1 timed ceiling
7 0,35 RV light, 15’ with key-off
light power supply
(PMAX= 20W at 12V)
Ceiling light control (-)
8 Ceiling light negative control (dimmer) 0,75 BV
PMAX= 20W at 12V
Fitting for Fiat Chrysler Automobiles
9 B-CAN Low 0,35 B
S.p.A. accessory line anti-theft (1)
Fitting for Fiat Chrysler Automobiles
10 B-CAN High 0,35 L
S.p.A. accessory line anti-theft (1)
IMAX= 300 mA
11 Side markers negative control relay 0,5 GR (1 Fiat Chrysler Automobiles S.p.A.
standard relay coil)
Air conditioner on positive signal
IMAX= 300 mA
12 A/C request 0,5 GV
(1 Fiat Chrysler Automobiles S.p.A.
standard relay coil)
IMAX=600 mA
13 Key-on power (+KEY) from F49 0,35 LG (2 Fiat Chrysler Automobiles S.p.A.
standard relay coils)
IMAX= 600 mA
14 Auxiliary heater positive control 0,35 MV (2 Fiat Chrysler Automobiles S.p.A.
standard relay coils)
15 Not connected - - -

(1)
not for use with other applications

Electrical system 87
3.16
Luce di arresto supplementare (3° stop)

Figure 9 CO36L1A

1
Stop light switch

Ground point nearest to component: choice between A, B, C or pin 2 connector C036L1C

Alternatively the third stop light can be connected to connector Y203L4A - pin 8.

ATTENTION: it is forbidden to connect either pin 1 of connector C036L1A, or

pin 8 of connector Y203L4A.

Charging in progress signal (D+)

Figure 10

Ground point nearest

to component: choice
between A, B, C or pin
2 of connector C036L1C

Vehicle speed signal (VSO)

Figure 11

Signal
processing

Input interface

VSO reader control unit by coach-builder

The VSO signal is defined as 275.714 mm/pulse, thus for the receiver, speed is equal to:
V.vehicle [mm/s] = Frequency VSO [Hz] * 275.714 [mm/pulse]
When vehicle velocity is 0 kph the VSO signal has high digital level and 0 pulse/s, instead,
when vehicle velocity is not valid the VSO signal has low digital level.

Electrical system 88
3.17
Rear locks and ceiling light control

Figure 12 C036L1A

LOCK Max 12A @ 13,5V

UNLOCK
(1)
(1)

DOOR OPEN SWITCH

N.O. With closed door
N.C. With open door

Ground point nearest component:

choice between A, B, C or pin
2 of connector C036L1C

Note (1): In the absence of door open switch (if original Fiat Chrysler Auto-
mobiles S.p.A. locks are not used, see chapter 6) pin 6 of connector C036L1A
can be left disconnected.
Attention: in this case the rear lock/s may be locked even with the door/s
open. The instrument panel will not indicate door status and the rear ceiling
light/s will not be commanded.
It is therefore the responsibility of the coach builder to illustrate the differ-
ence in function to that described in the use and Maintenance Handbook.

Note (2): pin 7 of connector C036L1A provides +12V for 15 minutes after the
key is removed(+KEY = off), after which time the rear ceiling light will not be
usable until the next rear door open switch status change (where present),
otherwise until the door is unlocked or the key turned (+KEY = on).

• Function with 2 key remote control: releases the two driver cab locks and turns on the
in-cab light fixture.

• Function with 3 key remote control: separate front/rear unlock and separate switch on
of corresponding interior lights.

Electrical system 89
3.18
Action FrontLock RearLock UnlockCom Act. Time Front State Rear State
Lock Rear
Initial State - - - - Any Any
Lock Rear - + - 400 + t1 ms
Final State - - - - No Change Locked
Lock Front
Initial State - - - - Any Any
Lock Rear + - - 400 + t1 ms
Final State - - - - No Change Locked
Lock Front/Rear
Initial State - - - - Any Any
Lock Rear + + - 400 + t1 ms
Final State - - - - Locked Locked
Lock Front/Rear
Initial State - - - - Any Any
Lock Rear + + - 400 + t1 ms
Final State - - - - Locked Locked
Unlock Rear (Front locked)
Initial State - - - - Locked Any
Confirm Lock
+ + - 20 + t2 ms
Front/Rear
Unlock Rear + - + 400 + t1 ms
Confirm
+ - - 20 + t2 ms
Unlock Front
Final State - - - Locked Unlocked
Unlock Rear (Front unlocked)
Initial State - - - - Unlocked Any
Confirm Lock
- + - 20 + t2 ms
Front/Rear
Unlock Rear + - + 400 + t1 ms
Confirm
- - + 20 + t2 ms
Unlock Front
Final State - - - Unlocked Unlocked
Unlock Front (Rear locked)
Initial State - - - Any Locked
Confirm Lock
+ + - 20 + t2 ms
Front/Rear
Unlock Front - + + 400 + t1 ms
Confirm Lock
- + - 20 + t2 ms
Rear
Final State - - - Unlocked Locked

Electrical system 90
Unlock Front (Rear unlocked)
Initial State - - - Any Unlocked
Confirm Lock
+ - - 20 + t2 ms
Front
Unlock Rear - + + 400 + t1 ms
Confirm
- - + 20 + t2 ms
Unlock Front
Final State - - - Unlocked Unlocked
Unlock Front/Rear
Initial State - - - Any Any
Confirm Lock
+ + - 20 + t2 ms
Front/Rear
Unlock Front/
- - + 400 + t1 ms
Rear
Final State - - - Unlocked Unlocked

Tollerances 0<t1<10%
0<t2<10ms
3.19
Side marker lights

Figure 13
Ground point nearest to
component: choice between
A, B, C or pin 2 of connector
C036L1C

Rear heater enable control

Figure 14

REAR
HEATER

Ground point nearest to

component: choice be-
ELECTROVALVE tween: A, B, C or pin 2
REAR HEATER connector C036L1C
CONTROL

Conditioner on signal

Figure 15
CONDITIONER
C036L1A
CONTROL AUXILIARY Ground point nearest to
CONDITIONER component: choice be-
tween A, B, C or pin 2 of
connector C036L1C

Electrical system 91
3.20
Key ON signal (+KEY)

If it is necessary to replicate the +KEY signal, for example for piloting loads with total
current > 600 mA, the following circuit is possible

Figure 16

C036L1A
REPLICATE SIGNAL
+ KEY

+ KEY

Punto di massa più vicino al

componente: a scelta tra A, B,
C o pin 2 connettore C036L1C

Electrical system 92
3.21
Connector C036L1B (6-way) – Coach-builder’s socket

3D view of connector

Figure 17

Cables input side view

Description of connector functions

Minimum cable
Pin Function/Connector part number cable colour Notes
section [mm2]
Connector 6-way Tyco p/n 1-480705-0
Reference to diagram
Counterpart: Tyco p/n 1-480704-0
C036-L1B
(by coachbuilder)
Permanent supply from
Permanent 12V power supply (+30) auxiliary battery to radio
1 1,5 RG
for radio cable present only from
C036-L1A to Y028L1A(1)

2 Rear RH loudspeaker + 1 LR (2)

3 Rear RH loudspeaker - 1 LN (2)

4 Rear LH loudspeaker + 1 B (2)
5 Rear LH loudspeaker - 1 BV -2
6 Not connected - - -

(1)
NOTE: the connection from connector Y028L1A to radio is made by the coach-builder,
who must suitably isolate the radio power supply present in the vehicle main system
(see description in paragraph 4.2.4 – Figure 19)

(2)
Fiat Chrysler Automobiles S.p.A. radio power output: 13.4W at 14V
Fiat Chrysler Automobiles S.p.A. radio drivers: 4 ohm equivalent for each channel
Fiat Chrysler Automobiles S.p.A. Tweeters: 15W RMS max
Fiat Chrysler Automobiles S.p.A. Mid-range and Full-range: 20W RMS max

Electrical system 93
3.22
Rear loudspeaker connection

Figure 18

Radio

Electrical system 94
3.23
Radio permanent power supply

If the radio requires a permanent power supply even with the key off (1) (+KEY= off)
the following circuit is possible.

CAUTION: This setting can cause a faster main battery discharge.

Figure 19

Key:
a- cable by coach-builder
b- cable present on vehicle
c- weld
d- radio (ISO 16-way connector)
e- power from AUX BATT

Terminal for hole 9 of connector X028PA: Tyco p/n 282375-1 (cable 1.5 mm2)

After removing the terminals of the original wires from position A4 and A7 on the radio
16-way ISO connector, apply an adequate amount of insulating tape to prevent acciden-
tal reciprocal contact or with metal parts.

Figure 20

Operation only allowed with radio installed aftermarket (for example Fiat Chrysler
(1)

Automobiles S.p.A. accessory line).

ATTENTION: this modification is not allowed with a Fiat Chrysler Automobiles

S.p.A. standard radio.

Electrical system 95
3.24
Retrocamera

Electrical system 96
3.25
Connector C036L1C (2-way) – Coach-builder’s socket

3D view of connector

Figure 21

1. Connector C036 L1C, 2-way – 2. Connector provided by Fiat Chrysler Automobiles

S.p.A. for wiring by coach-builder.

Description of connector functions

Minimum cable
Pin Function/Connector Part number cable colour Notes
section [mm2]
Connector, 2-way MTA
p/n 45.40300 Reference to diagram C036-L1C
Counterpart: MTA p/n 45.40400
1 +30 power supply 10 R Fuse nominal current 50A
2 Power ground 10 N Max. constant current 53A

+12V power supply from main battery

See paragraph 4.1.4

Power ground (pin 2)

Used in alternative to ground points A, B and C on chassis (see Figure 2)

Protect added cables in specific sheathing or corrugated conduits.
Minimum cable section must always be as specified in the description tables.

Electrical system 97
3.26
Connector Y203L4A (12-way) – Rear lights
2D view of connector

Figure 22

Electrical system 98
3.27

Description of connector functions

X2/50 Function / Connector Part Minimum cable

Pin Cable colour Notes
number section [mm2]
Connector 12-way Tyco
p/n 284844-1
Counterpart: p/n 284848-3
(by coach-builder)
1 Side - marker 0.5 GR 2 5W - 12V bulbs

2 LH rear marker light 0.5 GV 2 5W - 12V bulbs

3 RH rear marker light 0.5 G 2 5W - 12V bulbs

4 LH rear direction indicator 0.5 SN 1 21W - 12V bulb
5 RH rear direction indicator 0.5 S 1 21W - 12V bulb
6 LH stop light 0.5 VN 1 21W - 12V bulb
7 RH stop light 0.5 V 1 21W - 12V bulb
PMAX= 21W at 12V al-
8 Third stop light 0,5 L ternative to the one on
C036L1A
9 LH rear fog warning (1) 0,5 MN 1 21W - 12V bulb
10 RH rear fog warning (1)
0,5 M 1 21W - 12V bulb
11 License plate lights
0,5 GN PMAX= 10W at 12V
12 Reversing lights 1,5 BR PMAX= 42W at 12V

(1)
It is also possible to install a single 21W – 12V rear fog warning light
(for example GSX, left fog light only).

NOTE: For coachbuilders willing to use lights with different power absorption
(lower power or LED), the failure diagnosis can be deactivated via the
WYTECH Plus tool.
On some versiont those diagnosis is already switched off.

Electrical system 99
3.28

Taillights

Figure 23

(1)
Alternatively, the third stop can be connected to pin 8 of connector
Y203L4A - pin 8.

ATTENTION: it is forbidden to connect either pin 1 of connector C036L1A,

or pin 8 of connector Y203L4A.

Electrical system 100

3.29

Front door and aerial connectors

Figure 24

1 and 2 – front door connectors (Y001LA and Y002LA)

3 and 4 – front door opt. connectors (Y121L1A and Y116L1A)
5 – AM/FM aerial connectors

Electrical system 101

3.30

Connector Y001LA (24-way) – Driver’s side door

3D view of connector
Figure 25

Description of connector functions

Wire cross-section
Pin Operation/Part number Connector Wire colour
area (mm2)
L side: F.C. 24-way FCI p/n 1 721 24 01 (Y001LA)
S side: M.C. 24-way FCI p/n 1 721 24 00 (X001SA)
1 Load compartment door state LED 0,35 BH
2 Driver's side direction indicator 0,35 ZR
3 Door open signal 0,35 BZ
4 Door mirror defroster supply 0,75 RV
5 External temperature sensor - GND 0,35 HR
6 Supply/lighting for DDC and comfort enable mirror controls 0,5 BL
7 Load compartment doors lock/unlock signal 0,35 HB
8 Lock/unlock signal from lock 0,35 LG
9 Electric window motor supply - Up 1,5 RN
10 Earth (direction indicators, lock, mirror defroster) DDC 1 N
11 Electric window motor supply - Down 1,5 NR
12 External temperature sensor - Signal 1,5 H
13 Passenger side electric window up signal from DDC 0,35 HV
14 Passenger side electric window down signal from DDC 0,35 HM
15 Main passenger's side door mirror up/down 0,35 MN
16 Main passenger's side door mirror left/right 0,35 BR
17 Secondary passenger's side door mirror up/down 0,35 BZ
18 Secondary passenger's side door mirror left/right 0,35 BV
19 Passenger's side door mirror motor common 0,35 HN
20 Not Connected
21 Driver's side speaker (+) 0,5 G
22 Driver's side speaker (-) 0,5 GN
23 Feed for Door Motor Lock 1 BN
24 Feed for Door Motor Unlock 1 CV

Note: This connector is supplied as fitting if the original New Ducato doors are not used.
(1)
for the versions with robotised gearbox (option 407), the pin must be connected
according to the scheme in figure 27.

Electrical system 102

3.31

Side direction indicator lights

Lampada da 16W - 12V

Figure 26

Driver’s side lock control

Figure 27

Electrical system 103

3.32

External electric mirror

Figure 28

Electrical system 104

3.33

Driver’s side loudspeaker

Figure 29 Tweeter on piller

Radio

Woofer on door
Woofer su porta

Electric window winder

Figure 30 Driver’s door control pad

Control cluster – driver side

Electrical system 105

3.34

Connector Y002LA (24-way) – Passenger side door

3D view of connector
Figure 31

Description of connector functions

Wire cross-section
Pin Operation/Part number Connector Wire colour
area (mm2)
L side: F.C. 24-way FCI p/n 1 721 24 01 (Y002LA)
D side: M.C. 24-way FCI p/n 1 721 24 00 (X002DA)
1 Not connected - -
2 Passenger's side direction indicator 0,35 ZB
3 Door open signal (CTRL_GND) 0,35 BN
4 Wing mirror defroster 0,75 RV
5 Not connected - -
6 CDC supply/lighting (service 2 T13 relay) 0,5 BL
7 Not connected - -
8 Not connected - -
9 Passenger's side window winder supply 2,5 R
10 Earth (direction indicators, lock, mirror defroster) 1 N
11 Passenger's side window winder earth 2,5 NZ
12 Not connected - -
13 Not connected - -
14 Passenger side window winder down signal 0,35 HR
15 Main passenger's side wing mirror up/down 0,35 MN
16 Main passenger's side wing mirror left/right 0,35 BR
17 Secondary passenger's side wing mirror up/down 0,35 BZ
18 Secondary passenger's side wing mirror left/right 0,35 BV
19 Passenger's side wing mirror motor common 0,35 HN
20 Not connected - -
21 Passenger's side speaker (+) 0,5 ZC
22 Passenger's side speaker (-) 0,5 ZN
23 Lock/unlock control 1 BN
24 Lock motors common 1 CV

Note: This connector is supplied as pre-fitting if the original New Ducato

doors are not present.
(1)
if door not present leave unconnected

Electrical system 106

3.35

Side direction indicator light

Figure 32

Passenger side door control

Figure 33

Lock

Unlock

Door
Statostatus
porta
Weld Ground
- Mirror defroster
- Direction indicator

Electric external mirror

Figure 34
Electric external mirror
on passenger side

At the
connector
Y001LA

Ground
MASSA
- -Lock
Serratura
Weld
Saldatura
- -Direction indicator
Luce di direzione

Electrical system 107

3.36

Passenger side loudspeaker

Figure 35

Tweeter on piller

Radio

Woofersu
Woofer onporta
door

Electric window winder

Figure 36

Passenger’s side door

control pad

For internal scheme of the control panel refer to Sec. 1.16.7 for the power
window winder only.

Electrical system 108

3.37

Connector Y121LA (4-way) – Driver’s side door (opt)

2D view of connector

Figure 37

Description of connector functions

Minimum cable Cable
Pin Function/Connector part number Notes
section [mm2] colour
4-way Tyco connector p/n 174929-1
Counterpart: Tyco p/n 174922-1 (by coach builder)

External mirror
1 P.S. ext. mirror deflect 0,5 HM
electric deflection

External mirror
2 P.S. ext. mirror restore 0,5 N
electric deflection
External mirror
3 MIRROR FOLDING +KEY 0,35 HR
electric deflection
4 DEAD LOCK 0,35 HV Dead-lock control

External rear-view mirror deflection

Figure 38

Electrical system 109

3.38

Highlighted section refers to mirror folding module.

1.17.1.2 Specification of folding module for external rear-view mirrors

- Max Time-Out time: 8 sec (i.e. in the event of a system malfunctioning power to mirror
motors is cut after 8 second from activation);
- Reading and memorization of start-up current;
- Current reading during actuation;
- Lock current check (defines as 80% of the start-up current);
- Checks if the lock current is permanent or a spike only and cut the power within
500msec;
- The control can be activated 5-6 times within 2min; after that, the actuation is
inhibited for 30sec; if the 5th actuation is to open, the control is inhibited, if the 5th
actuation is to close, a further open is still allowed;
- Pin 1 and 6 are respectively Ground and Power Plus (+30);
- Pin 2 and 3 feed RH motor and during actuation (open or close) invert the current in
the motor itself;
- Pin 3 and 4 feed LH motor and during actuation (open or close) invert the current in
the motor itself;
- Pin 6 of 8-pin connector must be fed by Plus Signal, otherwise the electronics doesn’t
activate any control
- Button driven functions always activate simultaneously both the motors connected to
Pin 2-3 and 4-5
- all the system is developed considering the characteristic current curve of Type 250
folding mirror.

Each folding motor has a rolling current of about 200÷400mA and a lock current of
2÷2,5A.

Electrical system 110

3.39

5.3.4 External temperature sensor

Figure 39 Y001LA

12
External temperature
sensor (on mirror)
5

Body Computer

If the original New Ducato mirrors are not fitted, it is necessary to use an NTC thermis-
tor with the following specifications:

Parametro Valore
Resistenza a 25°C (R25) 10 kΩ

Tolleranza su R25 ±3%

Dissipazione massima 500 mW

Tempo di risposta 1,2 s
Range operativo
da -40 a +125 °C
di temperatura
Categoria climatica 40/125/56

NOTE: In vehicles fitted with

automatic climate control
(option 140) and/or robotised
gearbox (option 407),
it is necessary to fit an exterior
temperature sensor.

Electrical system 111

3.40

Connector Y116LA (4-way) – Passenger side door (opt)

3D view of connector

Figure 40

Description of connector functions

Minimum cable Cable
Pin Function/Connector part number Notes
section [mm2] colour
4-way Tyco connector p/n 174929-1
Counterpart: Tyco p/n 174922-1 (by coach-builder)

1 Not connected

External mirror
2 P.S. ext. mirror deflection 0,5 HM
electric deflection
External mirror
3 P.S. ext. mirror restore 0,5 N
electric deflection
4 Not connected - -

External rear view mirror deflection

Figure 41

From Passenger’s side

the connector external
Y121LA mirror

Electrical system 112

3.41

Procedure for setting radio switching off time after key-off

(applicable in presence of opt 7BY, 7BZ, 6Q2, 6Q3, 6Q8, 6Q9 only)

1. Switch on the radio.

2. 4. Press MENU to access the menu.
5. Select “System Settings” and press OK button.
6. Thick the “Power OFF” # min. Delay” checkbox, where # is the PROXI set value (180
minutes).

Radio VP1

Radio VP2

Electrical system 113

3.42

Vehicles provided with “5BH” - Steering wheel controls for Upfitters

The connector in the radio compartment where the pins of these commands are located
is connector B 1/08847/87 20-way FCI.

The resistance coding of Ducato radio controls is as follows:

The pins concerned are:

Signal A: pin 10
Signal B: pin 11
Ground: pin 12

Consequently, it is important to ensure that the radio uses the same resistance coding.

Electrical system 114

3.43

Connector XO50PA (1-pin) – AM/FM radio aerial

According to option configuration, the following type of antenna can be fitted:

Figure 42

Electrical system 115

3.44

Electrical system 116

3.45

Electrical system 117

3.46

FAKRA antenna connectors

Pin Function/ Connector Part number Notes

Shielded connector ASK p/n COMA Y050PA
Counterpart: ASK p/n COFE (by upfitter)

1 AM/FM radio aerial signal AM/FM aerial on roof or in door mirror

Electrical system 118

3.47

Phantom Box

TBD

Headlight Alignment Corrector

The resistance coding of the Headlight Alignment Corrector (CAF) of Ducato is as follows:

Consequently, it is important to ensure that the headlights use the same resistance
coding.

Electrical system 119

3.48

GENUINE NEW DUCATO COMPONENTS

Locks
3D view of connector

Figure 47

Interface connector with genuine New Ducato locks

Description of connector functions

Minimum cable
Pin Function/Connector part number Notes
section [mm2]
10-way Tyco connector on wiring
p/n 6-1355688-1
1 Not connected -
2 Lock/unlock signal from knob 0,35 CTRL_GND from FT_DRV_Door_Limit_SW
3 Switch ground 0,35 GND from FT_driver_DR_SW
4 Door open switch 0,35 CTRL_GND from FT_DRV_Door_Ajar_SW
5 Not connected -
6 Door lock control 1,0 Max 15A (For actuation times see tab. page 3.16)
7 Door unlock control 1,0 Max 15A (For actuation times see tab. page 3.16)
8 Dead-lock power 1,0
9 Not connected -
10 Not connected -

Electrical system 120

3.49

Front lights
2D and 3D view of connector

Figure 48

Description of connector functions

Minimum
cross-sec- Wire colour Wire colour
Pin Operation/Part number Connector
tion area wire (LH headlight) (RH headlight)
[mm2]
14-pin connector Fiat code Fiat 1/05285/87 tb
91349/40 (Fci 17261405B)
1 Dipped beam supply 0,5 VN VB
2 Turn lights supply 0,35 LB LN
3 - -
4 Parking lights supply 0,35 GV GH
5 DRL supply form driver #1 0,35 LG LG
6 Dipped beam signal for levelling 0,35 BC BC
7 - -
8 - -
9 DRL supply form driver 0,5 VG VG
10 Ground 0,5 NV NV
11 Headlight levelling signal 0,35 CB LG
12 - -
13 Main beam supply 0,5 HN H
14 Ground 1,5 N N

Electrical system 121

3.50

1.23 Fog lights

Wire cross-sec- Wire colour

Pin Operation/Part number Connector Wire colour LH
tion area [mm2] RH
Connector 2 v. p/n 1/11039/97 Tab.91337/55
FCI240PC023S4019
1 Supply 0,75 MN MR
2 Earth 0,75 NZ NZ

Connessione fendinebbia
Collegando fendinebbia di tipo diverso da quelli di produzione, e di conseguenza non
utilizzando i cavi paraurti previsti di produzione per alimentare correttamente la funzione
DRL nel proiettore principale ( ove presente ) occorre ponticellare i pin 3-4 tra di loro
nel connettore di collegamento briglia fendinebbia presente sul cavo anteriore, come da
schema seguente.

Pin out
1 – Positivo Fendinebbia
2 – Negativo Fendinebbia
3 – Ponticello DRL con pin 4
4 – Ponticello DRL con pin 3

DA TRADURRE IN INGLESE

Electrical system 122

3.51
DA TRADURRE IN INGLESE

1.1 Aftermarket LED DRL

System configuration
Luci DRL a LED di terze parti possono venire installate in alternativa a quelle originali
escludendo queste e deviandone l’alimentazione per alimentare i nuovi gruppi ottici.
Tale circuitazione viene realizzata con l’inserzione della briglia sotto indicata che viene
fornita di primo impianto richiedendo l’ Opt. 75N (schema briglia in allegato).
L’omologazione è a carico del carrozziere.

Electrical system 123

3.52

1.25 Taillights for chassis-cabs/cowls

2D view of connector

Figure 49

6.4.2 Description of connector functions

Pin Function/Connector part number Notes
LH light – 7-way Tyco connector on wiring p/n 967650-1
1 Bulb ground 1
2 Rear fog warning light 0,5
3 Stop light 0,5
4 Direction indicator 0,5
5 Not connected -
6 Side marker light 0,5
7 Not connected -

RH light – 7-way Tyco connector p/n 967650-1

1 Bulb ground 1
2 Not connected -
3 Stop light 0,5
4 Direction indicator 0,5
5 Reversing light 1
6 Side marker light 0,5
7 Not connected -

Electrical system 124

3.53

Taillights for vans

2D view of connector

Minimum cable
Pin Function / Connector part number Colour Notes
section [mm2]
LH lighting cluster – 8-pin DELPHI 13545280 connector
A Parking light GV 0,35
B Stop VN 0,5
C Turn light LB 0,5
D Not connected
E Not connected
F Fog light MN 0,5
G Reverse light BV 1
H Ground N 1

RH lighting cluster – 8-pin DELPHI 13545280 connector

A Parking light GV 0,35
B Stop VN 0,5
C Turn light LB 0,5
D Not connected
E Not connected
F Fog light MN 0,5
G Reverse light BV 1
H Ground N 1

Electrical system 125

3.54

Windscreen wiper
3D view of connector on windshield wiper motor

Figure 50

3D view of connector on wiring

Figure 51

Description of connector functions

Minimum cable
Pin Function/Connector part number Notes
section [mm2]
Riferimento a
5-way Delphi connector p/n 15342484 -
schema M012AA
1 Ground 2,5
2 Power supply 2,5
3 Speed selector 0,35
4 On/off 0,35
5 Parking contact 0,35

Electrical system 126

3.55

Windscreen wiper motor specifications

Nominal voltage 12V

Working voltage 9 - 16V
Intermittence 10 - 18
Number of cycles (speed I) 45 ± 5
Number of cycles (speed II) 65 ± 5

NOTE: In case of windscreen wiper group installation, the converter has to

fit a group with the same electrical specifications as the original Fiat Chrysler
Automobiles S.p.A. group.

Figure 52 Figure 53

Figure 54

Electrical system 127

3.56

Windscreen washer pump

2D view of connector

Figura 55
Figure

Description of connector functions

Minimum cable
Pin Function/Connector part number Notes
section [mm2]
2-way Delphi connector on wiring p/n 12185025 (401589) -
1 Power supply 1,5
2 Ground 1,5

Electrical system 128

3.57

Left hand external rear view mirror

3D view of connectors

Figure 56

NOTE: The figure shows the counter-connectors.

Description of connector functions

Minimum cable
Pin Function / Connector part number Notes
section [mm2]
8-way Tyco connector on mirror p/n 1745000-1
BLACK colour
Counterpart: Tyco p/n 284869-1
1 Direction indicator power supply 0,5 1 16W - 12V bulb
2 Direction indicator and defroster ground 0,75
3 Main mirror servo right/left control 0,5
4 Main mirror servo up/down control 0,5
5 Auxiliary mirror servo right/left control 0,5
6 Auxiliary mirror servo up/down control 0,5
7 Mirror servos common connection 0,5
8 Defroster power supply 0,75

Electrical system 129

3.58

Minimum cable
Pin Function/Connector part number Notes
section [mm2]
8-way Tyco connector on mirror p/n 1745000-2
GREY colour
Counterpart: Tyco p/n 284869-2
1 External temperature sensor (ref) 0,5 -
2 External temperature sensor (signal) 0,5 -
3 Deflector servo control 0,5 -
4 Deflector servo ground 0,5 -
5 Not connected - -
6 Not connected - -
7 Not connected - -
8 Not connected - -

NOTE: if Fiat Chrysler Automobiles S.p.A. rear view mirrors are used, refer to
the connections described in the preceding paragraphs of this document.

Right hand external rear-view mirror

3D view of connectors

Figure 57

3x

NOTE: The figure shows the connector counterparts.

Electrical system 130

3.59

Description of connector functions

Minimum cable
Pin Function/Connector part number Notes
section [mm2]
8-way Tyco connector on mirror p/n 1745000-1
BLACK colour
Counterpart: Tyco p/n 284869-1
1 Direction indicator power supply. 0,5 1 Lampada da 16W - 12V
2 Direction indicator and defroster ground 0,75
3 Main mirror servo left/right control 0,5
4 Main mirror servo up/down control 0,5
5 Auxiliary mirror servo left/right control 0,5
6 Auxiliary mirror servo up/down control 0,5
7 Mirror servos common connection 0,5
8 Defroster power supply 0,75

8-way Tyco connector on mirror p/n 1745000-2

GREY colour
Counterpart: Tyco p/n 284869-2
1 Radio aerial power supply 0,5
2 Not connected -
3 Deflector servo control 0,5
4 Deflector servo ground 0,5
5 Not connected -
6 Not connected -
7 Not connected -
8 Not connected -

NOTE: if Fiat Chrysler Automobiles S.p.A. rear view mirrors are used, refer to
the connections described in the preceding paragraphs of this document.

Electrical system 131

3.60

Ceiling light
2D view of connector

Figure 58

Description of connector functions

Minimum cable
Pin Function/Connector part number Notes
section [mm2]
3-way Tyco connector on wiring p/n 282627-1 -
1 Bulb ground 0,5
2 Power supply +30 (SBMT) 0,5
3 Negative control 0,5

Electrical system 132

3.61

Driver’s side door control pad

2D view of connectors

Figure 59

Description of connector functions

Wire cross-sec- Wire colour Wire colour

Pin Operation/Part number Connector
tion area [mm2] LHD RHD
8-way connector p/n Tyco 1/08807/97 -
1 not connected 0,35 HN HV
2 not connected 0,35 BH BH
3 Earth 0,35 NZ NZ
4 not connected 0,35 SZ SZ
5 LH electric window up/down control 0,35 HM HR
6 LH electric window enablement control 0,35 BL BL
7 not connected 0,35 HR HM
8 RH electric window up/down control 0,35 HV HN
12-way connector p/n 1/08402/07 Tab. 91300 (Tyco
-
1534100 Cover 1534093)
1 Earth 0,5 N N
2 RH main mirror UP/DOWN 0,35 MN BH
3 LH secondary mirror LH/RH 0,35 SZ BV
4 LH main mirror LH/RH 0,35 HM BR
5 Power supply/lighting 0,5 BL BL
6 LH secondary mirror up/down 0,35 SV BZ
7 Supply 0,5 BL BL
8 Mirror motor common 0,35 HN HN
9 LH main mirror up/down 0,35 BH MN
10 RH secondary mirror LH/RH 0,35 BV SZ
11 RH secondary mirror up/down 0,35 BZ SV
12 RH main mirror LH/RH 0,35 BR HM
6 pin connector p/n Tyco 284802-1 -
1 Earth 0,75 NS NS
2 RH mirror folding motor control 0,75 HM HM
3 RH mirror folding motor earth 0,5 N N
4 LH mirror folding motor positive control 0,5 NZ NZ
5 LH mirror folding motor earth 0,5 HB HB
6 Supply 0,5 BL BL

Electrical system 133

3.62

Passenger side door control pad

2D view of connector

Figure 60

Description of connector functions

Wire cross-sec-
Pin Operation/Part number Connector Wire colour
tion area [mm2]
4-way connector 1/08332/07 Tab. 91353
1 Passenger's side window down control 0,35 HR
2 Supply/lighting 0,35 BL
3 Earth 0,35 NZ
4 Passenger's side window up control 0,35 HV

Electrical system 134

3.63

Electric windows
2D view of connector

Figure 61

Description of connector functions

Wire cross-sec-
Pin Operation/Part number Connector Wire colour
tion area [mm2]
6-way connector p/n 1/01538/97 Tab. 91337/45
1 - - -
2 - - -
3 Window up supply 1,5 R
4 Window down supply 1,5 NZ
5 - - -
6 - - -

Electrical system 135

3.64

Standard Fiat Chrysler Automobiles S.p.A. Component drawings

20a micro relay switch

Electrical system 136

3.65

1.36 30A micro relay switch

Electrical system 137

3.66

1.37 T 50A maxi relay switch

Electrical system 138

3.67

Tips for installation

Refrigerator power supply

Having to power the refrigerator in parallel to the auxiliary battery charger circuit, in order
to reduce voltage drop, we recommend one of the following solutions:
a - Double the main power supply (+30) starting from connector C036L1C with an 8mm2
(for the battery) and with a 6mm2 cable (for the fridge) clamped together.
b - Use a 16mm2 section cable from connector C036L1C and for the entire section of com-
mon line.

In both cases it is a good idea to make the fridge negative terminal connection with a high
cross-section cable that is as short as possible (using a ground point chosen between A, B,
C or pin 2 of connector C036L1C).

Coachbuilders socket in engine bay

This paragraph describes the solution for arranging specific power supplies in the engine bay
(for example for the Xenon lights control unit). The diagram below shows the correct layout
of the additional wiring that has to be installed by the coachbuilder.

GSX vehicle +12V

Cavo cable
+12V(min.
(sez.sec.
min.4mm ))
2 2
4mm GDX vehicle
Veicolo GSX Veicolo GDX
Ground cable
Cavo Massa
Engine
Scatola bay
Engine
Scatola bay From
Cavi C036L1A
da C036L1A fuse/relay
fusibili/relè box
fuse/relay box
fusibili/relè vano vano motore
motore

Grommet
Occhiello(-)
(-)
Grommet
Occhiello(-)
(-)
Door module
Modulo porta
relay/fuses
relè/fusibili

CVM Grommet CVM

Occhiello (+)
(+)
Bulkhead
Guarnizione
passage seal
passa-parete Nodo di Door
Modulomodule
porta
Nodo di Junction box
Junction box relay/fuses
relè/fusibili
derivazione derivazione

Grommet
Occhiello (+)
(+)

Drivers
Sedile Passenger
Sedile Passenger
Sedile Drivers
Sedile
sideLato side Lato side Lato sideLato
Guida
seat seat
Passeggero Passeggero
seat Guida
seat

Presa Carrozzieri
Coachbuilders Presa Carrozzieri
Coachbuilders
Connettore
connector C036
C036 L1AL1A Connettore
connector C036
C036 L1AL1A

Electrical system 139

3.68

List of materials:

• Door module relay/fuse box: MTA p/n 03.01560

• Module mounting bracket: MTA p/n 03.00475
• Bulkhead passage seal: SUMITOMO drawing number 1334413080
• Grommet (+): MTA p/n 17.06711 (M8 hole)
• Grommet (-): M8 hole
(for cable sections from 1 to 2.5 mm2 recommended MTA p/n 17.06731)
• M8 nut: M8 hexagonal nut with nylon ring

Description of installation procedure:

• Remove the relay/fuse box cover in the engine bay by removing the nuts.
• Unscrew the nut from the junction box pin (see figure 62), overlay the grommet (+)
on the one already present (ATTENTION, vice-versa not permitted), then re-tighten
the nut to torque of 15Nm ± 10%.
• Connect the grommet (-) to the ground pin present in the frontal area (see figure 63),
after which apply an M8 nut, tightening it to torque of 15Nm ± 10%.
• Insert the door module relay/fuse box in the seat in the box in the engine bay.

Electrical system 140

3.69

• Replace the box cover paying attention to the correct arrangement of the cables.
• Lay the cables as shown in figure 64 using the retainer clips of the main wiring har-
ness already installed on the vehicle.
• Drill through the flame bulkhead and remove the closing plug of the passage toward
the cabin.
• Fit the bulkhead seal paying attention to correctly fasten it to the sheet metal to pre-
vent infiltration into the cabin.
• Lay the cables in the cabin following the route shown in figure 65.

Figure 62

Engine bay – CVM box and view of junction box

Electrical system 141

3.70

Figure 63

Engine bay – view of ground pin

CAUTION: for emergency starter ground use a screw that allows to connect
the booster cables.

Electrical system 142

3.71

Figure 64

Engine bay – front view of GSX cable layout

Figure 65

Cabin – view of GSX cable layout

Electrical system 143

3.72

The wiring realised by the coachbuilder must be adequately protected by means of abra-
sion resistant tape with same performance as COROPLAST 880X o with a corrugate hose
of proper section.

NOTES:
1. The insulating material of the flame bulkhead is predisposed for drilling in
the vicinity of the hole.
2. In vehicles equipped with chrono-tachograph, the bulkhead passage is
already present. The sealing tape already present has to be removed, the
cables passed along with those of the chrono-tachograph and a new seal-
ing tape applied.
3. In vehicles with automatic gearbox, the relay/fuse block is already pres-
ent in the CVM box, in this case to fit the additional fuses and relays it is
possible to use the free positions in the block.

Example of circuit for +30 and +15 power supplies in engine bay:

Weld Grommet (+)

Figure 66 Door module
Saldatura Occhiello (+)
Modulo porta
relays/fuse
relè/fusibili
4mm 2 6mm 2

+30
4mm 2

Ground
Massa

+15

13
Weld
Saldatura Coachbuilders connector
Presa Carrozzieri
C036 L1A C036 L1A
Connettore
Grommet (-)
Occhiello (-)

NOTES:
1. The fuses must be correctly sized according to the minimum section
of the protected wires.
2. The relays must be Fiat Chrysler Automobiles S.p.A. standard type
(see chapter 7)

Electrical system 144

3.73

Anti-theft system

If an anti-theft system has to be installed, we recommend using the original kit p/n
50926750 by the Accessories Line, made by an official Fiat Chrysler Automobiles S.p.A.
supplier:

Metasystem S.p.A.
Via Galimberti, n°8
42100 Reggio Emilia (Italy)
Telephone
Switchboard: +39 0522 364 111
Fax
Switchboard: +39 0522 364 150
Web
Information at: [email protected]
Web site: www.metasystem.it

Trailer

Insertion of non-conforming control units into the main circuit of the New Ducato to con-
trol additional lights may cause a malfunction in the vehicle electrical/electronic system,
for this reason Fiat Chrysler Automobiles S.p.A. recommends using original Accessory
Line components. Any customisation can be agreed with the official suppliers of the com-
ponent (see list below).

Westfalia-Automotive GmbH & Co. KG

Am Sandberg 45
Postfatch 26 40
33354 Rheda Wiedenbrück
Telephone
Switchboard: +49 5242 907 0
Fax
Switchboard: +49 5242 907 195
Web
Web site: www.westfalia-automotive.de

Electrical system 145

3.74

Opt. Towing Hook scheme

250 Ducato FL 2014 versione Cabinato / Scudato - Interfaccia elettrica gancio traino
20A
Alimentazione
Alimentazione
+batteria
+batteria
Alimentazione
+chiave
20A

Presa per Gancio Traino 13 poli Massa Centralina controllo illuminazione esterna su rimorchio connettore 12 vie
codice Molex 33472-1202
telaio polarizzazione B
2,50 Alimentazione
9 +batteria
Positivo di alimentazione +batteria Alimentazione +batteria lato destro (luce retromarcia,
2,50 Massa luce posizione lato destro, luce arresto lato destro, 1
11 luce indicatore lato destro, centralina elettronica)
Massa per circuito pin 9 presa gancio traino 13
2,50
telaio
10 Alimentazione +batteria lato sinistro (luce retronebbia,
10 2
Positivo di alimentazione sotto chiave
2,50
Centralina luce posizione lato sinistro, luce arresto lato sinistro,
luce indicatore lato sinistro, centralina elettronica)
Alimentazione
+chiave INT
Massa Massa luci rimorchio (luce
Massa per circuito pin 10 presa gancio traino 11 parcheggio 9 posizione, side marker, luce
Alimentazione +chiave 3
telaio targa, luce stop)
non collegato 4
Massa luci su rimorchio 3 Massa Diodo su 8
Massa luci rimorchio (luce
retronebbia, luce indicatore
verificare lunghezza cavo massa (richiesto l=150mm)
Massa telaio lato destro (luce retromarcia,
telaio cavo direzione, luce retromarcia)
luce posizione lato destro, luce arresto lato destro, Massa telaio
ponticello da prevedere lato rimorchio 5
luce indicatore lato destro, centralina elettronica)
Pin identificazione
(Riservato per future applicazioni)
Pin riconoscimento presenza rimorchio 12 12 presenza rimorchio
Massa telaio lato sinistro (luce retronebbia, da verificare eventuali criticità di shift ground Centralina body computer BCM
(con diodo) 6
luce posizione lato sinistro, luce arresto lato sinistro,
Luce retromarcia (2 x 21W) 8 7 Comando luce retromarcia luce indicatore lato sinistro, centralina elettronica)
7 3 7 B CAN B (high)
Luce posizione / side marker / targa lato sinistro (6 x 5W) Comando luce posizione lato sinistro B CAN B (high)
6 6 8 B CAN A (low)
Luce stop (2 x 21W) Comando luce stop B CAN A (low)
5 1 9 18 HS01 Comando luce direzione lato destro
Luce posizione / side marker / targa lato destro (6 x 5W) Comando luce posizione lato destro Comando luce direzione posteriore lato destro
2 2 10 19 HS02 Comando luce direzione lato sinistro
Luce retronebbia (2 x 21W) Comando luce retronebbia Comando luce direzione posteriore lato sinistro
4 4 11 32 HS08 Comando luce arresto lato destro
Luce direzione lato destro (21W) Comando luce direzione lato destro Comando luce arresto lato destro

1 5 12 2 HS09 Comando luce arresto lato sinistro

Luce direzione lato sinistro (21W) Comando luce direzione lato sinistro Comando luce arresto lato sinistro
connettore 12 vie LF
connettore 13 poli codice Molex 33472-1201 Luce stop
std ISO11446-2 polarizzazione A
(tenuta immersione) Luce direzione Massa
Note: 1 - con rimorchio presente NON devono essere spente Note: 1 - la centralina rimorchio pilota (ed egsegue diagnosi) correttamente i carichi su rimorchio relativi al
telaio
le luci su fanale posteriore della vettura come da
richiesta regolamentazione ECE48 / 04 capitolo 6
sistema illuminazione esterna solamente se questi garantiscono un assorbimento pari o superiore a 100mA Massa telaio
2 - la centralina rimorchio esegue diagnosi dei carichi relativi all' illuminazione esterna lato rimorchio (specie Luce direzione Luce stop
6.4 Luce retromarcia
luci direzione la cui diagnosi è obbligatoria) ed invia segnalazione su rete BCAN
6.5 Luce indicatore di direzione
6.7 Luce arresto 3 - necessario ponticello lato rimorchio tra pin 12 e pin 3 per riconoscimento rimorchio da parte della centralina
6.8 Luce targa rimorchio e della centralina parcheggio
6.10 Luce posizione posteriore 4 - la centralina rimorchio deve comunicare su rete BCAN la presenza del rimorchio, la centralina body computer BCM
6.11 Luce retronebbia (facoltativo) deve fare gateway del messaggio su rete C CAN
5 - in normale funzionamento, la centralina rimorchio riconosce inserzione luci da messaggio su rete BCAN
6 - gli ingressi comando luce direzione sono ingressi risveglianti in caso di inserzione luci emergenza con chiave key off
21W 21W 21W 21W
7 - prevedere risveglio centralina luci rimorchio da rete B CAN con inserzione luci parcheggio con chiave in posizione key off
8 - prevedere risveglio centralina luci rimorchio da rete B CAN con inserzione funzione luci stazionamento
con chiave in key off: su modello 250 Ducato FL 2014 non e' comunque presente tale funzione Fanale posteriore Fanale posteriore
9 - sia in caso di recovery (rete B CAN assente) sia in caso di Limp home (microprocessore della centralina lato destro versione lato sinistro
rimorchio danneggiato), la centralina rimorchio accende le luci posizione su rimorchio e replica in uscita
quanto riceve in ingresso per quanto concerne le luci stop e le luci direzione Cabinato / Scudato versione Cabinato / Scudato
10 - occorre prevedere opportune strategie per segnalazioni guasto centralina rimorchio da parte del
quadro strumento (diagnosi luci, diagnosi luci emergenza, recovery, Limp home)

Robotised gearbox

When the robotised gearbox (opt 407) is installed on chassis cowl vehicles, or in any
case without original cab doors, the external temperature sensor (see par. 5.3.4) and
driver’s door status switch (see par. 5.1.4) must also be installed.

Electrical system 146

3.75

COMPONENT : TUM - TRUCK UPFITTER MODULE

Part number : 1374095080

Type of vehicle : FIAT Ducato
Version : 250FL
Timing : 20’

Electrical system 147

3.76

TUM - TRUCK UPFITTER MODULE

TUM - TRUCK UPFITTER MODULE

This document describes the component called Truck Upfitter Module (TUM) and explains
its installation.
The TUM is an electronic control unit that operates as a gateway from the vehicle’s high
and low-speed CANs to an external high-speed network that uses protocol J1939 and
sends messages according to the Fleet Management System (FMS) version 2.0 standard.
The messages available on the FMS network are described in Annex 1. For a complete
description of the standard, visit the consortium1 website.

1
http://www.fms-standard.com

KIT COMPOSITION

ID Component name Quantity

A ECU TUM 1
B ECU TUM 1

A B

Figure 1 - TUM Electronic Control Unit Figure 2 - Connection harness

Electrical system 148

3.77

INSTALLATION STEPS

Disconnect the negative battery terminal.

Locate the box containing the fuses in the dashboard area, in the compartment under
the steering wheel (this information is found in the owner handbook).
Remove the passenger compartment fuse box cover.
Having removed the cover, you will find the fuses right in front of you and you can locate
termination C.

Figure 3 - Passenger compartment fuse box

After locating termination C, remove connector D.

C D

Figure 4 - Connector ready for Figure 5 - Termination

connecting harness B connector

Electrical system 149

3.78

Secure termination B5 of the connection harness to termination C.

B5

Figure 6 - Termination of the

connection harness

Secure terminations B1, B2, B3 to connectors A1, A2, A3 of the TUM, respectively

B4

B3 A3
A2
B1 A1
B2

Figure 7 - Terminations of the Figure 8 - TUM control unit

connection harness connectors

After connection, the previously removed parts of the car can be reassembled.
Final positioning and fastening of the control unit is at the converter’s discretion.

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3.79

INSTALLATION REQUIREMENTS AND RECOMMENDATIONS

The control unit is not waterproof and must therefore be installed in a dry area,
preferably in the passenger compartment.
Make provision for two fastening points 136 mm apart.
The space occupied by the control unit (size) is: 150 mm x 110 mm x 40 mm.

Connectors Side

Figure 9 - TUM control unit dimensions

Electrical system 151

3.80

It is advisable to secure the control unit onto a flat surface, using one of the following
positions.

1. Horizontal (Connections seen from the front)

Direction of the output wiring: toward the left side.

2. Vertical 3. Vertical
(Connections seen on the right side) (Connections seen at the bottom)
Direction of the output wiring: Direction of the output wiring:
downwards. toward the left side.

Figure 10 - Recommended positions for securing the TUM control unit

Connector B4 is a standard connector used by the control unit users to collect the vehi-
cle’s information, so it is advisable to ensure it is located at an easily accessible point to
facilitate its use.

B4

Figure 11 - Standard connector for users

The connector Pin Out for the users is defined and set by the FMS standard. An extract of
the standard with a description of its outputs is provided below. For a complete descrip-
tion of the standard, visit the consortium1 website.

http://www.fms-standard.com
1

Electrical system 152

3.81

Figure 12 – Connector Pin Out for the users (*)

*Extract of the FMS standard

NOTE FOR USERS

The terminal resistance is currently not activated on the TUM control unit. If necessary,
an internal terminal resistance of 120 Ω may be activated by short circuiting pins 10 and
17 of connector B3 of the connection harness (see Figure 7).

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3.82

TRUCK UPFITTER MODULE (TUM) FUNCTIONS

The TUM supports the following FMS standard versions:

• FMS-Standard Interface description Vers. 02
(available on http://www.fms-standard.com/Truck/index.htm)
• Bus FMS-Standard Interface description Vers. 02
(available on http://www.fms-standard.com/Bus/index.htm)
All the signals available to the control units that interface with the TUM are listed in the
following table.

Message Signal Description

Parking Brake Switch Indicates that the parking brake is engaged
Wheel based speed Indicates the vehicle speed
CCVS Clutch switch Indicates that the clutch pedal is pressed
Brake switch Indicates that the brake pedal is pressed
Cruise control active Indicates that the cruise control is enabled
Accelerator pedal position 1 Indicates the accelerator pedal position

EEC2 Indicates the ratio between the percentage of

Engine Percent Load At Current Speed engine torque and the maximum torque indicated
at current engine speed
Indicates the total fuel consumed during vehicle
LFC Engine total fuel used
operation
Indicates the ratio of fuel volume out of the total
DD Fuel Level
tank volume
EEC1 Engine speed Indicates the engine speed
VDHR High resolution total vehicle distance Indicates the total distance travelled by the vehicle
ET1 Engine coolant temperature Indicates the engine coolant temperature
AMB Ambient Air Temperature Indicates the temperature outside the vehicle
Indicates the quantity of fuel consumed by the
Fuel Rate
engine by time unit
LFE
Indicates the ratio between quantity of fuel
Instantaneous Fuel Economy
consumed and current vehicle speed
Indicates the distance that can be travelled by the
SERV Service distance
vehicle before the scheduled servicing
HOURS Total engine hours Indicates the total engine operation time
DC1 Position of doors Indicates the current door status
AS Alternator Status 1 Indicates the current alternator status
Selected Gear (1)
Indicates the next expected gear ratio
ETC2
Current Gear (1)
Indicates the current gear ratio
Minutes Indicates the minutes
Hours Indicates the hours
TD Month Indicates the month
Day Indicates the day
Year Indicates the year

Electrical system 154

3.83

High beam, main beam Indicates the active status of the main beam headlights

Low beam Indicates the active status of the low beam headlights
Turn signals Indicates the active status of the direction indicators
Hazard warning Indicates the active status of the hazard warning lights
Parking Brake Indicates that the parking brake is engaged
Brake failure/brake system malfunction Indicates a failure of the braking system
Hatch open Indicates that the rear door is not closed
Fuel level Indicates that the fuel reserve warning light is on
Indicates that the maximum engine coolant temperature
Engine coolant temperature
warning light is on
Battery charging condition Indicates that the low battery charge warning light is on
Indicates that the low engine oil pressure warning light
Engine oil
is on
Position lights,side lights Indicates the active status of the position lights
FMS1(2)
Front fog light Indicates the active status of the fog lights
Rear fog light Indicates the active status of the rear fog lights
Indicates that the EOBD/injection system warning light
Engine / Mil indicator
is on
Indicates that the scheduled servicing indicator is
Service, call for maintenance
displayed
Transmission failure/malfunction Indicates a failure on the transmission system
Anti-lock brake system failure Indicates that the ABS system failure warning light is on
Worn brake linings Indicates that the brake pad wear warning light is on
Malfunction/general failure Indicates that the general failure warning light is on
Indicates that the active suspension indicator is
Height Control (Levelling)
displayed
Engine Emission system failure (Mil Indicates that the particle filter blocked warning light is
indicator) on
Indicates that the stability control system warning light
ESC indication
is on
TCO1 Tachogr. vehicle speed (3)
Indicates the vehicle speed stored by the tachograph
Open Status Door 1 Indicates the status of the driver's door
Open Status Door 2 Indicates the status of the passenger's door
DC2 Open Status Door 3 (4)
Indicates the status of the rear door(s)
Open Status Door 4 (4)
Indicates the status of the sliding side doors
Open Status Door 5 (4)
Indicates the status of the sliding side doors
Indicates whether the TUM is able to respond to the
Requests supported
requests made by the external FMS module
Indicates whether the TUM supports the requests to
FMS Diagnostics supported
send diagnostic information
Indicates the version of the FMS Standard supported by
FMS-standard SW-version supported
the TUM

(1)
Available in the vehicle versions with robotised gearbox
(2)
The signal values come from the information displayed on the instrument panel
(3)
The car speed signal is available even if there is no tachograph
(4)
The transmitted signal takes the closed value if there is no content

Electrical system 155

3.84

DUCATO 250 –Truck Upfitter Module installation

Installation details

Adobe Acrobat
Document

Installation cycle

- Turn the key on STOP and remove it.

- Slide completely backward the driver seat.
1. Remove fixing buttons (1a) and remove cover (1b).

Electrical system 156

3.85

1. Rotate the lever (1a) as illustrated and disconnect the negative terminal (1b) from the
battery.

2. Undo the fixing screws.(1).

3. Remove the fuse access cover (2).

Electrical system 157

3.86

4. Undo the screw (1a) fixing the lower left trim of the dashboard (1b) located to the
right of the steering wheel.

5. Undo the screws (1a) fixing the lower left trim of the dashboard (1b) located to the
left of the steering wheel.

Electrical system 158

3.87

6. Remove the lower left trim of the dashboard from the vehicle.

7. Undo the fixing screws (1a) for the centre pillar trim lower element (1b).

Electrical system 159

3.88

8. Undo the fixing screws (1a) and remove the kick plate connector (1b).

9. Undo the fixing screws (1a) and remove the kick plate (1b).

Electrical system 160

3.89

10. Remove the wiring retaining button and move it to the side (1).

11. Thoroughly grease the rear surface of the control unit (1a) with heptane (or isopro-
pyl alcohol) and apply a Velcro cutting (1b) of a size that ensures that the control unit
remains secured.

1b

1a

Electrical system 161

3.90

12. Thoroughly grease the surface of the body where the control unit will be positioned
with heptane (or isopropyl alcohol). Remove the protective film of the adhesive surface
from the Velcro, then position the control unit on the vehicle as shown in the figure,
making sure it is firmly secured.

13. Take the wiring supplied in the kit and connect the electrical connections (1a) to the
control unit, then use the bands (1b) on the vehicle to secure the control unit wiring and
that of the vehicle previously unfastened.

1b

1a

Electrical system 162

3.91

14. Place the wiring (1a) of the control unit inside the cable duct (1b) positioned on the ve-
hicle, then secure using the clips provided.

1a

1b

15. Place the wiring (1a) of the control unit inside the retaining clips (1b) of the vehicle
wiring.

1b

1a

Electrical system 163

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16. Place the wiring (1a) of the control unit inside the retaining clips (1b) of the vehicle
wiring.

1a

1b

NOTE: If the wiring cannot be inserted in the duct and/or retaining clips as
previously explained, it should be placed beside the original wiring of the ve-
hicle and secured to it using plastic bands.

17. Disconnect the Body Computer.

Electrical system 164

3.93

18. Undo the screws (1a) and the nut (1b) securing the Body Computer.

1b
1a

19. Remove the Body Computer being careful not to damage the wiring-harness.

Electrical system 165

3.94

20. Press the retaining clip (1a), then disconnect and remove the short circuit connector
(1b).

1b

1a

21. Connect the electrical connection of the control unit wiring, and position the wiring in
the lower part of the Body Computer mounting bracket.

Electrical system 166

3.95

- Put back in place the Body Computer screw it.

- Connect all the electric connections.

22. Roll up the exceeding length of wiring and fix it on the Body Computer bracket with
a strip, keeping about 25 cm of free wiring, so that it can be easily removed if needed.

25 cm

23. Put back in place the sill mould (1a) and fix it with screws (1b).

Electrical system 167

3.96

24. Put back in place the sill mould corner part (1a) and fix it with screws (1b).

25. Put back in place the B-pillar lower cover (1a) and fix it with screws (1b).

Electrical system 168

3.97

26. Put back in place the lower dashboard cover.

27. Put back in place the screws (1a) to fix the lower dashboard cover (1b) on the left
side of the steering-wheel.

Electrical system 169

3.98

28. Put back in place the screws (1a) to fix the lower dashboard cover (1b) on the right
side of the steering-wheel.

29. Put back in place the fuse-box cover (1) and fix it with the screws (2).

Electrical system 170

3.99

30. Connect the battery negative pole (1a) and turn the lever (1b) as shown in the
picture.

31. Put back in place the cover (1a) and fix with the plugs (1b).

Electrical system 171

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TPMS – installation prescriptions

When a TPMS system is present, additional prescriptions have to be considered.

TMPS system allows to monitor tires status by a radio transmission of the inflation pres-
sure values, read by sensors integrated in the inflation valve.
Not to interfere with the data transmission, positioning any power cable near (150 mm)
the receiver module is forbidden (see picture XXX). Also devices causing its overheating
are not allowed, therefore exhaust pipes of vehicle cabin heating systems have to be
positioned far enough.

Position of TPMS module seen from the back

Electrical system 172

3.101

Position of TPMS module seen from under the engine

Installation requirements for pressure sensors integrated in tire inflation valve

Sensors integrated into the inflation valve, to correctly transmit the read data to the re-
ceiver module must be installed respecting the system supplier prescriptions.
Assembly specifications on the rims follow:

Electrical system 173

3.102

Steel rims

Light-alloy rims

Electrical system 174

3.103

Electrical system 175

3.104

LDWS – installation prescriptions

LDWS system - overview

• LDW (Lane Departing Warning):

• Is activated by a button on the central control panel, with an ON / OFF telltale light
• Once active, the system works over 60 Km/h. Between 0 and 60 Km/h it’s inhibited
and shows it’s not functioning keeping on two yellow light in the instrument cluster;
once reached 60 Km/h the lights switch off and only work switching on left or right
one to warn a deviation from road stripes.

• HBC (automatic main light dipping) with light sensor:

• Is activated by the column stalk ring, setting it on AUTO; it switches on both HBC
and light sensor.

• HBC without light sensor:

• Is activated when parking, by the vehicle menu setting.

• TSR (Traffic Signal Recognition)

• Is activated when parking, by the vehicle menu setting.

Prescriptions for vehicles with LDWS system – camera calibration

Due to the wide angle that the suspension geometry can have on the Ducato (different
weight distribution according to upfitting needs), the standard calibration done in the
production factory can be not enough, therefore the system has a self-calibration func-
tion that allows it to memorize the correct calibration while running. This function is acti-
vated when a change in the geometry moves the camera outside its working angle (e.g.
when a chassis-cab is converted in a camping-car).
Re-calibration phase last about 2 min, if the system finds the required conditions (almost
straight road, with only wide bends, and good weather and visibility), going on for up
to one hour if the process fails. During calibration phase the system is inhibited and the
driver is warned by the two yellow lights in the instrument cluster.

Not to void the system functionality, obstructions must not be present in the camera
view angle.

Electrical system 176

3.105

In the following picture, the vertical view angle of the camera is highlighted. It’s 27°
wide, with the centerline positioned at 1,06° over the horizon.
For a proper functioning of the system, additional body parts must never interfere with
the camera view-angle. This prescription is both for fixed (e.g. a camper cabover) or
temporary (e.g. a roof-rack) items.

LDWS view-angle

Electrical system 177

3.106
AMBULANCE CONVERSION
ELECTRICAL SYSTEM COMPONENTS

Electrical system 178

3.107

1 AMBULANCE CIRCUITRY 3.108

1.1 20-pin connector C036 AD 3.108
1.1.1 View and position of connector 3.108
1.1.2 Functions of the connector 3.109
1.1.3 Engine starting inhibition circuit 3.110
1.1.4 Flasher power supply 3.110
1.1.5 Siren power supply 3.111
1.1.6 High beam lights On signal 3.112
1.1.7 Horn control 3.112
1.1.8 Reverse gear engaged signal 3.113
1.2 Fiat Chrysler Automobiles S.p.A. Ambulance Control 3.114
Panel

Electrical system 179

3.108

1 AMBULANCE CIRCUITRY
1.1 20-pin connector C036 AD
1.1.1 View and position of connector

Figure 01

Figura 66

NOTE: In the detailed view, the connector is seen from the cable entry side

Electrical system 180

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1.1.2 Functions of the connector

Minimum
Pin Connector function/Part number cable size Notes
[mm2]
Tyco 20-pin connector on vehicle side, p/n 284879-3
Counterpart on conversion side: Tyco p/n 284875-2 See diagram C036-AD
(supplied by Fiat Chrysler Automobiles S.p.A.)

Starter relay coil command

1 Power supply: +50 from ignition switch 2,50
(to be short- circuited with pin 11)

Positive command for 1 standard

2 + key cut out during starting (Ign/SW) 0,5
relay (max 300mA)
Positive command for 1 standard
3 High beam lights on signal 0,5
relay (max 300mA)
INPUT: manages the horn relay by
means of a negative signal from
4 Horn control 0,35 switch
OUTPUT: negative command for 1
standard relay (max 300mA)
GND for ambulance control panel Suitable for use on other control
5 0,5
by Fiat Chrysler Automobiles S.p.A. panels (max 4A)
Power supply + key for backlighting of Fiat Chrysler Suitable for use on other control
6 0,5
Automobiles S.p.A. ambulance control panel panels (max 300mA)
Suitable for use on other control
7 Power supply for ambulance control panel: +30 0,5
panels (max 2A)
Positive command for 1 standard
8 Reverse gear engaged signal 0,5
relay (max 300mA)
If the Fiat Chrysler Automobiles
S.p.A. ambulance control panel is
9 Siren relay positive command (INPUT) 0,5 not used, provide for protection of
cable sized 0.5mm2
(max 7.5A fuse)
10 Siren power supply (OUTPUT) 2,50 Max 20A
11 Starter coil power supply 2,50 To be short-circuited with pin 1
12 Not connected
13 Not connected
14 Not connected
15 Not connected
16 Not connected
17 Not connected
18 Not connected
If the Fiat Chrysler Automobiles
S.p.A. ambulance control panel is
19 Flasher relay positive command (INPUT) 0,5 not used, provide for protection of
cable sized 0.5mm2
(max 7.5A fuse)
20 Flasher power supply (OUTPUT) 2,50 Max 20A

Electrical system 181

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1.1.3 Engine starting inhibition circuit

The ambulance connector contains a short-circuit jumper, between pin 1 and pin 11,
which can be removed to cut out the starting command and produce an inhibition circuit
as the need arises.

IMPORTANT: this being a circuit of primary importance, it must be installed

with the greatest possible care, paying special attention to cable crimping on
the cable lug.

Figure 02

Ignition switch Switch

Starter motor

1.1.4 Flasher power supply

Figure 03

FLASHER
RELAY

Flasher
Flasher
control

GND
for siren circuit

or equivalent
equipotential
connection

Electrical system 182

3.111

1.1.5 Siren power supply

If the current absorbed by the siren exceeds 5A, it is advisable to set up the power
supply circuit described below so as to ensure trouble-free i.c. engine starting in critical
conditions.

Figure 04

SIREN
RELAY

Siren
Standard relay
Siren control (max 300mA)

Ign/SW Ultrasound welding

or equivalent
Ignition switch equipotential

NOTES:
1. If the Fiat Chrysler Automobiles S.p.A. ambulance control panel is used,
pins 7, 9 and 19 are already connected.
2. Pin 7 must be used to power both (flasher and siren) controls; if these
controls consist of two separate buttons, it is necessary to link them
by means of ultrasound welding or make an equivalent equipotential
connection on the wiring. We recommend that you do NOT use multiple
crimping on the cable lugs.
3. If a power source other than pin 7 is used (e.g., pin 1 of connector
C036L1C), the power supply circuits of the relay coils (pin 9 and pin 19)
should be protected with fuses with capacity ≤ 7.5A.

Electrical system 183

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1.1.6 High beam lights On signal

This is a positive command activated when the high beam lights are turned on
(including flashing mode).
A wiring diagram for this circuit is exemplified below.

Figure 05

Power supply
controlled by high beam lever
on steering wheel

High beam lights control

Standard relay
(max 300mA)

1.1.7 Horn control

Pin 4 of connector C036AD is bidirectional. This notion is illustrated in the two examples
given below regarding two different operating modalities.

INPUT mode operation

Figure 06

HORN RELAY Horn

Control

Steering wheel mounted control

Electrical system 184

3.113

OUTPUT mode operation

Figure 07

Horn
HORN RELAY
Power supply
controlled
by steering wheel
mounted lever

Steering wheel
mounted control

Steering wheel
mounted control

1.1.8 Reverse gear engaged signal

If it proves necessary to activate loads that can be powered only with the reverse gear is
engaged, this can be done by installing the following circuit.

Figure 08

Power supply controlled

by reverse gear
engagement

Reverse switch

Standard relay
(max 300mA)

NOTE: When using pin 5 of connector C036AD (frame GND) for several
devices (ΣI ≤ 4A), we recommend resorting to ultrasound welding or an
equivalent equipotential connection. We strongly recommend that you do
NOT use multiple crimping on the cable lugs.

Electrical system 185

3.114

1.2 Fiat Chrysler Automobiles S.p.A. Ambulance Control Panel

LIST OF BUTTONS

Susp. UP Susp. DOWN Plug Beacon Siren

STACK COMPOSITION LIST

POSITION
CONVERSION WIRING DIAGRAM

AMBULANCE TYPE 1
AMBULANCE + SELF-LEVELLING SUSP. TYPE 1

Electrical system 186

4.1
MAIN DIMENSIONS

Main dimensions 187

4.2

Sheet metal van – Cargo bay internal dimensions

Main dimensions 188

4.3

Sheet metal van – Short wheelbase H1

Main dimensions 189

4.4

Sheet metal van – Medium wheelbase H1/H2

Main dimensions 190

4.5

Sheet metal van – Long wheelbase H2/H3

Main dimensions 191

4.6

Sheet metal van – Extra-long overhang H2/H3

Main dimensions 192

4.7

Short wheelbase chassis cab

STDA: Height from ground: 650 ± 3 mm

Main dimensions 193

4.8

Medium wheelbase chassis cab

STDA: Height from ground: 646 ± 3 mm

Main dimensions 194

Main dimensions
Medium-long wheelbase chassis cab

STDA : Height from ground: 650 mm (Payload 3000) – 647 mm (Payload 3300)
645 mm (Payload 3500)

195
4.9
4.10

Long wheelbase chassis cab

STDA: Height from ground: 642 ± 3 mm

Main dimensions 196

4.11

Extra-long overhang chassis cab

STDA: Height from ground: 640 ± 3 mm

Main dimensions 197

4.12

Double cab medium wheelbase chassis cab

Main dimensions 198

4.13

Double cab long wheelbase chassis cab

Main dimensions 199

4.14

Double cab extra long overhang chassis cab

Main dimensions 200

4.15

Short wheelbase chassis cab with platform

STDA: Height from ground: 536 ± 1 mm

Main dimensions 201

4.16

Medium wheelbase chassis cab with platform

STDA: Height from ground: 545 mm (Payload 3000)

Main dimensions 202

Main dimensions
Medium-long wheelbase chassis cab with platform

STDA: Height from ground: 550 mm (Payload 3000)

521 ± 1 mm (Payload 3300 and 3500)

203
4.17
4.18

Long wheelbase chassis cab with platform

STDA: Height from ground: 518 ± 2 mm

Main dimensions 204

4.19

Extra-long overhang chassis cab with platform

STDA: Height from ground: 521 ± 1 mm

Main dimensions 205

4.20

Short wheelbase basic chassis

Main dimensions 206

4.21

Medium wheelbase basic chassis

Main dimensions 207

4.22

Medium-long wheelbase basic chassis

Main dimensions 208

4.23

Long wheelbase basic chassis

Main dimensions 209

4.24

Extra-long overhang basic chassis

Main dimensions 210

4.25

Short wheelbase special chassis cab

Main dimensions 211

4.26

Medium wheelbase special chassis cab

Main dimensions 212

4.27

Medium-long wheelbase special chassis cab

Main dimensions 213

4.28

Long wheelbase special chassis cab

Main dimensions 214

4.29

Extra-long overhang special chassis cab

Main dimensions 215

4.30

Short wheelbase special basic chassis

Main dimensions 216

4.31

Medium wheelbase special basic chassis

Main dimensions 217

4.32

Medium-long wheelbase special basic chassis

Main dimensions 218

4.33

Long wheelbase special basic chassis

Main dimensions 219

4.34

Extra-long overhang special basic chassis

Main dimensions 220