New Fiat Ducato.

Conversion and fitting-out manual

 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 execution, 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 model 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.
¾ Any modification, conversion or other operation not foreseen in the manual, and not
explicitly authorised by FIAT GROUP AUTOMOBILES S.p.A. in writing shall relieve FIAT
of any liability, and specifically, if the vehicle is covered by warranty, this shall be
immediately forfeit.
FIAT GROUP 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 specifically foreseen
in this publication.
The functional, efficiency and safety conditions foreseen by FIAT GROUP AUTOMOBILES S.p.A.
must be restored immediately after any conversion works. Contact the FIAT GROUP
AUTOMOBILES S.p.A. network for any necessary vehicle tuning.
FIAT GROUP 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 GROUP 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 GROUP 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 instructions.
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.
Respect the environment
Indicates behaviour code for use of the vehicle in the most environmentally friendly manner
possible.
¾ NOTE Provides any necessary additional information.
 1.2

AUTHORISATION
Observance of the instructions contained in this manual does not oblige the manufacturer 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 GROUP AUTOMOBILES S.p.A.
FIAT LIGHT COMMERCIAL VEHICLES
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.
 1.3
CONTENTS

Overview 1.5
Bodywork and chassis 2.1
Electrical system 3.1
Main dimensions 4.1
1.4
 1.5
OVERVIEW

Purpose of coach builders instructions 1.6

FIAT GROUP AUTOMOBILES S.p.A. approval of conversions and fitting-out 1.6
Liability 1.6
Warranty 1.7
Application for approval 1.7
Markings and logos 1.7
Legal requirements 1.8
Seat belt anchor points 1.8
Seats 1.8
Interior shelves 1.8
Operations on vehicle structure and floor 1.8
Ambulances 1.9
Accident prevention 1.9
Choice of materials: Environment – Recycling 1.9
Vehicle hand-over 1.10
Presentation of the range 1.11
 1.6

Purpose of coach builder’s instructions

This document provides instructions about how to make modifications and/or fit-out original FIAT
GROUP AUTOMOBILES S.p.A. vehicles while maintaining the correct function, safety and
reliability of the vehicle itself and its component parts.
FIAT GROUP 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 GROUP AUTOMOBILES S.p.A. only concerns the technical/
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 GROUP
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.
 1.7
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 GROUP
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 GROUP 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 GROUP 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 GROUP 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 Authorities 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
GROUP AUTOMOBILES S.p.A. These must be placed in the immediate vicinity of the existing
FIAT GROUP AUTOMOBILES S.p.A. trademarks and logos.
FIAT GROUP 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.
 1.8

Legal requirements
With the vehicle completed, the coach-builder must verify that all works done (modifications,
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 requirement 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 compliance with legal
standards.
Seats
The seat floor anchors are realised in compliance with legal standards on retainer systems.
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.
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 members) 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
concentrated
- holes for floor anchors must be protected and sealed against water, gas and dust
infiltration.
 1.9
Ambulanze
Ambulances
We advise special attention in:
- connection of the side panelling and under-roof, using the anchor zones and holes already
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 requirements.
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,
fluorocarbons, 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 recycled
materials.
Always apply markings in compliance with standards in force.
 1.10

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.
 1.11
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 dimensions, refer to
the chapter ‘Dimensions’ from page 4.1.

Van

Van with windows

1.12
Chassis cab

Special chassis cab

Chassis cab with platform

 1.13
Basic chassis

Special basic chassis

Double cab
1.14
 2.1
Bodywork and Chassis

Maximum permitted weights 2.2

Towing capacity 2.3
Centre of gravity 2.4
Profile limits 2.6
Modifying rear overhang 2.7
Chassis cab lengthening limits 2.8
Overhang lengthening methods 2.9
Tow hook 2.11
Attachment pre-fittings 2.12
Finishing elements 2.13
Indications for modifying front 2.14
Modifications to the roof 2.15
Wheel arch dimensions 2.17
Wheels and suspension 2.18
Cab habitability diagram (van version) 2.19
Spare wheel 2.20
Relocation of spare wheel for chassis cab and basic chassis versions 2.21
Indications for connecting superstructures 2.22
Fitting the counterframe 2.23
Plan and reference holes for superstructure application (Camping Car) 2.24
Side load retention 2.32
Instructions for eliminating ‘Crash box’ cross members 2.36
Fuel supply system 2.37
Piping technical specifications 2.38
Fitting a roof rack 2.39
Sections of roof rack attachment points 2.40
Positioning attachments 2.43
Opening of a hatch in the roof 2.44
Making a window in the side 2.45
Installing heater 2.46
Fittings for supplementary heater/air-conditioner 2.47
Air suspension 2.49
Changes to the wheelbase 2.52
 2.2

MAXIMUM PERMITTED WEIGHTS

Overall vehicle weights and the maximum admissible weights per axIe 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 axles.
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 surfaces, 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 vehicle ground
weight
- Rear axle: weight at ground always between 30% and 60% of the total vehicle ground
weight.
According to the weight distribution, the total ground weight and/or maximum admissible weights
on the axes may not be fully saturated.

Vehicle diagram identification data table

New Ducato "X2/50" W (Kg) W1 (kg) W2 (kg) R

30 3000 1600 1650 R 15"

33 3300 1750 1900 R 15"
35 3500 1850 2000 R 15"
Maxi 35 3500 2100 2400 R 16"
Maxi 40 4000 2100 2400 R 16"

W: GVW; L
W1: Max. Load on front axle;
W2: Max. Load on rear axle;
R: Wheels.
 2.3
TOWING CAPACITY

The limits given in FIAT GROUP 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.

New Ducato Towing Capacity

W (Kg)
"X2/50" (kg)
30 3000 2000
33 3300 2000
35 3500 2000
Maxi 35 3500 2500
Maxi 40 4000 2500

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.
¾ 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 problems with vehicle
geometry.
 2.4
CENTRE OF GRAVITY
The height from ground of the non-converted chassis cab vehicle centre of gravity is given 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 GROUP AUTOMOBILES S.p.A. to assure good
vehicle dynamic behaviour (e.g. transverse stability in motion).

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)
 2.5

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 reduced 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 established 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.
 2.6
PROFILE LIMITS (chassis cabs)
Motorhome conversion

A. Wheelbase
B. Overhang = 60% of wheelbase (65% of wheelbase 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 or equal to 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.
 2.7
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 requirements
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 overhang in relation to
the vehicle’s wheelbase.
Lengthening the overhang may involve repositioning the underrun protection bar in compliance
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.

1: indicative outline of structure for lengthening overhang.

 2.8
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.
 2.9
Overhang lengthening methods
Normal chassis cab (with sub-frame)
Sections

SEC. A-A

Perspective view

1: longitudinal member; 2: structure by coach-builder; 3: holes for fastening structure, 4: ring nut.
 2.10
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.
 2.11
TOWING HOOK

Overview
A towing hook can be applied without requesting authorisation to FIAT GROUP AUTOMOBILES
S.p.A. only on the specific cross-member provided and only on vehicles that FIAT GROUP
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 GROUP AUTOMOBILES S.p.A..

¾ NOTE: Since tow bars are an important element for vehicle driving safety, all limitations
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 existing holes
on the vehicle transom bar, modifications can be authorised if suitable reinforcing is applied.
 2.12

Attachment pre-fittings

The drawing shows the pre-fittings for applying the towing hook. The solution is valid for all
Camping car.

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 approved
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
 2.13
Finishing elements
If a different mat to the original is used on the floor of the driver’s side, it must not interfere 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
 2.14

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.
 2.15
MODIFICATIONS TO THE ROOF
Instructions for cutting roofs of chassis cabs with OPT 59E.
The cab roof can be cut as shown below:
 2.16

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).
 2.17
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
¾ 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
 2.18

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).
ALL VERSIONS

WHEEL TRIM Vehicle unladen (*)

Camber (**)

Incidence (**)

Front
suspension Toe-in

Camber (**)

Rear Toe-in
suspension

(*) With tyres inflated to required pressure with vehicle ready for road
(**) Angles not adjustable
WHEELS AND TYRES
LIGHT HEAVY
3000 3300 3500 3500 4000
215/70 R15C 225/75 R15C 225/75 R16C
Basic tyre
109 S 112 S 118 R

Camping Car 215/70 R15CP 225/75 R16CP

(OPT 143) 109a CAMPING 116a CAMPING

WHEEL BEARINGS
FRONT Rear LIGHT Rear HEAVY

A 54 76 76

X=72 X=79

B 90 Y=100,950 Y=100,950

C 55 42 42
 2.19

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
 2.20
SPARE WHEEL
The spare wheel is positioned in the rear part of the vehicle, in the external compartment 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
 2.21
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 lengthening 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).
¾ NOTE: restore the wheel upper fastening points by means of two cross members (5).
 2.22
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 longitudinal 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.
 2.23
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 intended job.
For its construction, keep in mind that the material must have good mechanical weldability
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 hardness < 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.
 2.24

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.
 2.25
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 reinforcement
(1).
If it is considered necessary to interface a new structure with the cab of the basic vehicle, 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.
 2.26
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
 2.27

Chassis cab sections

 2.28

Chassis cab with platform version sections

 2.29
Chassis cab with platform version sections
 2.30
Van roof sections

SEC. A1

SEC. A2

SEC. A3
 2.31

Van side sections

 2.32

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.
 2.33
Load retaining hooks on floor
Short wheelbase
 2.34
Load retaining hooks on floor
Medium wheelbase
 2.35
Load retaining hooks on floor
Long wheelbase

SECTION A-A

SECTION B-B
 2.36

INSTRUCTIONS FOR ELIMINATING ‘CRASH BOX’ CROSS MEMBER (ONLY FOR VEHICLES
WITHOUT AIR-BAG)

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

¾ Removal of the cross-member is only possible in cases of complete vehicle conversion
(‘basic chassis’ versions).

Front crash-box for all versions

2: front crash box cross-member - 1: controlled impact absorption strut - 3: centring pin.

¾ NOTE: for vehicles fitted with air-bag, restore the structure with technical specifications
similar to those removed.
 2.37
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 drawing
given below.
The tank capacity is 60 lt (optional), 90 lt (standard) or 125 lt (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: 125 L tank.
B: 90 L tank.
1: breather pipe; 2: corrugated connector pipe; 3: fuel filler
 2.38

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.
 2.39
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
¾ NOTE: The limit of 25 kg for each attachment on the roof must not be exceeded. 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
Anchor point distances (mm) ‘Y’ distance
(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 1392.8 1414.7 1193.5 - 740.0
MH2)
Long wheelbase, medium roof van (LH2) 1392.8 1414.7 713.5 1065 - 740.0
Extra long wheelbase, medium roof van 1392.8 1414.7 713.5 716 714 740.0
(XLH2)
Long wheelbase, high roof van (LH3) 1392.8 1619.7 509.0 927 - 747.5
Extra long wheelbase, high roof van 1392.8 1619.7 509.0 716 576 747.5
(XLH3)
 2.40

Roof rack attachment point sections

CH1 van sections

sec. 1

sec. 2 sec. 3
 2.41
Roof rack attachment point sections

MH2 – LH2 van sections

sec. 1

sec. 3

sec. 2
 2.42

Roof rack attachment point sections

XLH3 – LH3 van sections

sec. 3

sec. 1

sec. 4

sec. 2
sec. 5
 2.43
Attachment positioning
 2.44
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

¾ NOTE: If the hatch has to be opened in a different area of the roof to (a), cutting of the
structural ribs (b) is not permitted. The structure must in all cases be restored to its original
conditions of function and rigidity.
 2.45
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 longitudinal 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 - 2. seal - 3. glass. 1. pillar - 2. bonding material - 3. glass.

 2.46
Heater installation
If a supplementary heater is required, it is advisable to use only the types foreseen by FIAT
GROUP AUTOMOBILES S.p.A.
For vehicles on which FIAT GROUP 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 GROUP 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.
 2.47
Supplementary heater/air-conditioner system pre-fittings
All ‘free time’ versions can fit air-conditioner and heaters with connections for a supplementary
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 specifications 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.
¾ NOTE: Refer to the Use and Maintenance Handbook for the technical specifications of
liquids/freon.
 2.48
Supplementary system

The drawing shows one possible location for the supplementary group.
Technical specifications
Max.power absorption
Weight Air flow-rate (Stdm3/h -
Model X2/50 (A. @12V - VENT max
(Kg.) VENT max cold)
cold)
Main heater group 7.00 420 19
Manual conditioner group 8.50 420 24

Automatic conditioner group 9.50 420 24

Auxiliary heater
2.40 210 2,5
(under seat)
Supplementary rear heater
4.90 380 21
group

Installed mass
Air flow rate Engine coolant flow rate Thermal power
thermal power
(Stdm3/h) (l/h) (BTU/h)
(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 23,900 7.00
400
500 20,500 6.00

Air flow rate Thermal power Evaporator thermal power

(Stdm3/h) (BTU/h) installed (kW)
Main group evaporator thermal power
400 22,300 6.50
Auxiliary rear group evaporator thermal power
350 17,000 5.00
 2.49
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.
 2.50
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 longitudinal, 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.
 2.51

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 between the pipe and
the filter and fit back the opening collar (5).
 2.52
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 GROUP AUTOMOBILES 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 4035mm wheelbase.
If you have to change the wheelbase, the length added must never exceed 10% the length of the
original wheelbase and, in any event, the final length must never exceed 4035mm.
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 longitudinals. 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 torsional 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).
Electrical System 3.1
 3.2

1. DESCRIPTIVE KEY 3.3

1.1 List of acronyms in diagrams 3.3
1.2 Key to terminology 3.3
1.3 Cable colour table 3.4
2. OVERVIEW 3.5
2.1 Moving supplementary group and equipment components and attachments 3.5
3. SPECIFICATIONS FOR COACH BUILDERS 3.6
3.1 Connectors provided for conversions 3.6
3.2 Auxiliary alternators and batteries 3.7
3.3 Batteries 3.8
3.4 Fuse and relay box under dashboard 3.9
3.5 Fuse box on battery 3.10
3.6 Right pillar fuse and relay box 3.11
3.7 Ground points 3.11
4. CONNECTORS PROVIDED 3.12
4.1 Connector C036 L1A (15-way) – Coach-builder’s socket 3.12
4.2 Connector C036L1B (6-way) – Coach-builder’s socket 3.19
4.3 Connector C036L1C (2-way) – Coach-builder’s socket 3.22
4.4 Connector Y203L4A (12-way) – Rear lights 3.23
5. FRONT DOOR AND AERIAL CONNECTORS 3.25
5.1 Connector Y001LA (24-way) – Driver’s side door 3.26
5.2 Connector Y002LA (24-way) – Passenger side door 3.29
5.3 Connector Y121LA (4-way) – Driver’s side door (opt) 3.32
5.4 Connector Y116LA (4-way) – Passenger side door (opt) 3.34
5.5 Connector XO50PA (1-way) – AM/FM radio aerial 3.35
5.6 Connector Y050PB (2-way) – GSM aerial 3.36
5.7 Connector Y050PC (2-way) – GSM aerial 3.36
5.8 Connector Y050PD (2-way) – Amplified radio aerial power supply 3.37
6. GENUINE NEW DUCATO COMPONENTS 3.38
6.1 Locks 3.38
6.2 Front lights 3.39
6.3 Rear lights 3.40
6.4 Windscreen wiper 3.41
6.5 Windscreen washer pump 3.43
6.6 Left hand external rear view mirror 3.44
6.7 Right hand external rear-view mirror 3.45
6.8 Ceiling light 3.47
6.9 Driver’s side door control pad 3.48
6.10 Passenger side door control pad 3.49
6.11 Electric windows 3.50
7. STANDARD FIAT GROUP AUTOMOBILES S.P.A. COMPONENT DRAWINGS 3.51
7.1 20A micro relay switch 3.51
7.2 30A micro relay switch 3.52
7.3 50A maxi relay switch 3.53
8. TIPS FOR INSTALLATION 3.54
8.1 Refrigerator power supply 3.54
8.2 Coachbuilders socket in engine bay 3.54
8.3 Anti-theft system 3.59
8.4 Trailer 3.59
8.5 Robotised gearbox 3.59
 3.3

1 DESCRIPTIVE KEY
1.1 List of acronyms in diagrams
ACRONYM DESCRIPTION
CCT Chrono Tachograph Control unit
CDC Codriver Door Command (passenger door control pad)
CGP Door Management Control unit (locks)
CRM Trailer Control Unit
CRS Auxiliary Heater Control Unit (Webasto)
CSA Theft Alarm Control Unit
CSG Steering Servo Control Unit
CSP Rain / Twilight Sensor Control Unit
CSS Central Stack Switch (central control pad)
DDC Driver Door Command (Driver’s door control pad)
DEV Combi Switch
LSS Left Stack Switch (left hand control pad)
NAB AirBag Hub
NAS Steering Angle Hub
NBC Body Computer Hub
NCA Automatic Gearbox Hub
NCL Air-conditioner Hub
NCM Engine Control Hub
NCV ConVergence Hub (telematic info system)
NFR Braking Hub (ABS, ASR, VDC)
NMA Air-Springs Hub (self-levelling suspension)
NQS Instrument Panel Hub
NRR Radio Receiver Hub
NSC Automatic Gearbox Selector Hub
NSP Parking Sensor Hub
NYL Yaw Sensor Hub

1.2 Key to terminology:

+30: permanent +12V power supply
+KEY: signal active at +12V when ignition switch is in position (MAR)
+LIGHTS: signal active at +12V when position lights are on.
BATT. AUX: auxiliary battery installed by coach-builder.
P.M. connector: connector suitable for receiving male terminals
P.F. connector: connector suitable for receiving female terminals
 3.4

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
 3.5

2 OVERVIEW
2.1 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.

Figure 1
 3.6

3 SPECIFICATIONS FOR COACH BUILDERS

3.1 Connectors provided for conversions
For the coach-builders to effectively and correctly use the basic system on the NEW DUCATO
model, FIAT GROUP 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
 3.7

3.2 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 supplementary 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 component 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 GROUP
AUTOMOBILES S.p.A..
Current take off
For information on current take off points, see the description on the following page.

Figure 3

Bigger-sized alternator OPT 4WP 180A.

NOTE: DRAWINGS FOR INFORMATION ONLY

 3.8

3.3 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
it is possible to use:
A) recombination batteries (AGM or gel)
B) traditional batteries.
In both cases, adequate separation must be provided between the battery and the
passenger compartment, with a suitable container capable of ensuring seal in case of:
- vapour emissions (for example in case of alternator voltage regulator fault);
- battery explosion;
- electrolyte leakage, even in the event of roll (type B batteries only).
In addition, with type A batteries it is necessary:
- to provide a breather toward the compartment exterior.
When installing type B batteries, the batteries must have:
- a cover with a gas evacuation system, with a pipe for conveying acid spray externally;
- -a flame arrestor system.
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).

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).
 3.9

3.4 Fuse and relay box under dashboard

Figure 5

APPLICATION A
FUSES
F12 RIGHT HEADLIGHT 7.5
F13 LEFT HEADLIGHT/HEADLIGHT ADJUSTER 7.5
F31 + KEY FOR CVM, NBC RELAY COIL 7.5
F32 MINIBUS INTERIOR LIGHTS (EMERGENCY) 10
F33 REAR POWER SOCKET 15
F34 NOT CONNECTED -
F35 CRUISE CONTROL, REVERSING LIGHT, DIESEL H2O SENSOR 7.5
F36 +30 DOOR LOCK/UNLOCK CONTROL UNIT 20
F37 CLA (N.C.), THIRD STOP, NQS 10
F38 +30 FOR NBC INTERNAL RELAY 10
NRR, EOBD DIAGNOSTICS SOCKET, CSA, CAV, CCT, COMANDO A/C, WEBASTO
F39 10
TIMER
F40 LH HEATED REAR WINDOW, DRIVER’S SIDE MIRROR DEFROSTER 15
F41 RH HEATED REAR WINDOW, PASSENGER SIDE MIRROR DEFROSTER 15
F42 +KEY FOR NFR, NAS, NYL, CLA (N.C.) 7.5
F43 WINDSCREEN WIPER 30
F44 CIGAR LIGHTER, FRONT POWER SOCKET 20
F45 DDC, CDC 7.5
F46 NOT CONNECTED -
F47 DRIVER SIDE WINDOW WINDER 20
F48 PASSENGER SIDE WINDOW WINDER 20
+KEY FOR NSP, CSP, CSS, LSS, CAV, STEREO, NCV, ILLUM. SEAT HEATER CONTROLS,
F49 7.5
WINDOW WINDER, DRIVER’S SIDE, AUX CONTROL PAD, PARKING CAMERA
F50 +KEY NAB 7.5
F51 +KEY CSG, CCT, NBC 7.5
F52 +KEY CCO RELAY COIL 7.5
F53 NQS, REAR FOG 7.5
RELAYS
T01 HEADLIGHTS 30
T11 HEATED REAR WINDOW 30
T12 UTILITIES 1 30
T13 UTILITIES 2 50
 3.10

3.5 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).

Figure 6

Connections key and description:

1) main battery under-dashboard fuse and relay box (70 A)
2) dashboard fuse and relay box auxiliary power (50 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) starter motor and alternator power;
6) interconnective control unit on battery.
 3.11

3.6 Right pillar fuse and relay box

Figure 7
T30

T66
T25

Code Application In [A]

FUSES
F54 NOT PRESENT 15
F55 SEAT HEATER 15
F56 MINIBUS REAR 12V SOCKET 15
F57 AUXILIARY HEATER UNDER SEAT 10
F58 NOT PRESENT -
F59 +30 NMA 20
RELAYS
T25 MINIBUS INTERIOR LIGHTS 30
T30 NOT PRESENT -
T31 AUXILIARY HEATER UNDER SEAT 30
T66 +KEY FOR HEATED SEATS 30

3.7 Ground points

If ground points A, B or C are used, the fastening nut must be tightened to torque of 8 Nm ± 10%.
 3.12

4 CONNECTORS PROVIDED
4.1 Connector C036 L1A (15-way) – Coach-builder’s socket

4.1.1 3D view of connector

Figure 8

View from cable entry side

 3.13
4.1.2 Description of connector functions

cable section

cable colour
Minimum

[mm2]
Pin Function/Connector part number Notes

15-way Tyco connector p/n 0-926647-1 Reference to diagram C036-L1A

Counterpart: Tyco p/n 1-480710-0 (by
coach builder)
1 Third stop light 0.5 B PMAX= 21W at 12V (in alternative to
the one on Y203L4A)
2 D+ (active at ground) 0.5 MB IMAX= 300mA (1 Fiat Group
Automobiles S.p.A. standard relay
coil)
3 Vehicle speed repeater (VSO) 0.5 GR IMAX= 5mA (see Figure 11)
4 Door lock control 1.5 RN IMAX= 12A (for actuation times see
Table 1)
5 Door unlock control 1.5 NR IMAX= 12A (for actuation times see
Table 1)
6 Side and rear door status signal 0.5 NZ Use an N.O. to ground switch
(minimum clean contact current 10
mA)
7 Driver 20W SBMT timed ceiling light 0.5 RV Power supply (+) for timed ceiling
power supply light, 15’ with key-off
(PMAX= 20W at 12V)
8 Ceiling light negative control (dimmer) 0.5 BV Ceiling light control (-)
PMAX= 20W at 12V
9 B-CAN Low 0.35 BS Fitting for Fiat Group Automobiles
S.p.A. accessory line anti-theft (1)
10 B-CAN High 0.35 NS Fitting for Fiat Group Automobiles
S.p.A. accessory line anti-theft (1)
11 Side markers negative control relay 0.5 Z IMAX= 300 mA (1 Fiat Group
Automobiles S.p.A. standard relay
coil)
12 A/C request 0.5 GV Air conditioner on positive signal
IMAX= 300 mA (1 Fiat Group
Automobiles S.p.A. standard relay
coil)
13 Key-on power (+KEY) 0.5 L IMAX=600 mA (2 Fiat Group
Automobiles S.p.A. standard relay
coils)
14 Auxiliary heater positive control 0.5 H IMAX= 600 mA (2 Fiat Group
Automobiles S.p.A. standard relay
coils)
15 Not connected - - -
(1)
not for use with other applications
 3.14

4.1.3 Third stop light (3rd stop)

Figure 9

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.

4.1.4 Charging in progress signal (D+)

* Figure 10

Ground point nearest to

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

+ Key

4.1.5 Vehicle speed signal (VSO)

Figure 11

Signal
processing

Body Computer 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.
 3.15
4.1.6 Rear locks and ceiling light control

Figure 12

LOCK

UNLOCK

DOOR OPEN SWITCH

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

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 Group Automobiles 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 difference 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.
 3.16
Table 1
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
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 - - + 400 + t1 ms
Front/Rear
Final State - - - Unlocked Unlocked
TOLERANCES 0<t1<10%
0<t2<10ms
 3.17
4.1.7 Side marker lights

Figure 13
30 87

86 85

+ Lights

Body Computer
Ground point nearest to
! component: choice
between A, B, C or pin 2
of connector C036L1C
4.1.8 Rear heater enable control
Figure 14 +12V
+12V

C036 L1A Rear heater

10A
14

Electrovalve
Rear heater control
Ground point nearest to
! component: choice
between: A, B, C or pin 2
4.1.9 Conditioner on signal connector C036L1C

Figure 15

Conditioner
control
30 87 AUXILIARY
CONDITIONER
86 85

Ground point nearest to

! component: choice
between A, B, C or pin 2
of connector C036L1C
 3.18

4.1.10 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 30 87 Replicate signal

+ key
86 85

+ key

Ground point nearest to

! component: choice
between A, B, C or pin 2
of connector C036L1C
 3.19

4.2 Connector C036L1B (6-way) – Coach-builder’s socket

4.2.1 3D view of connector

Figure 17

Cables input side view

4.2.2 Description of connector functions
cable section

cable colour
Minimum

[mm2]

Pin Function/Connector part number Notes

Connector 6-way Tyco p/n 1-480705-0 Reference to diagram C036-L1B

Counterpart: Tyco p/n 1-480704-0
(by coachbuilder)
1 Permanent 12V power supply (+30) for radio 1.5 RG Permanent supply from auxiliary
battery to radio cable present only
from C036-L1A to Y028L1A (1)
(2)
2 Rear RH loudspeaker + 1 AR
(2)
3 Rear RH loudspeaker - 1 AN
(2)
4 Rear LH loudspeaker + 1 BR
(2)
5 Rear LH loudspeaker - 1 BV
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 Group Automobiles S.p.A. radio power output: 13.4W at 14V
Fiat Group Automobiles S.p.A. radio drivers: 4 ohm equivalent for each channel
Fiat Group Automobiles S.p.A. Tweeters: 15W RMS max
Fiat Group Automobiles S.p.A. Mid-range and Full-range: 20W RMS max
 3.20

4.2.3 Rear loudspeaker connection

Figure 18

C036L1B

Radio
 3.21
4.2.4 Radio permanent power supply
(1)
If the radio requires a permanent power supply even with the key off (+KEY= off) the following
circuit is possible.

Figure 19
X028PA C036L1B

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 accidental reciprocal
contact or with metal parts.
Figure 20

(1)
Operation only allowed with radio installed aftermarket (for example Fiat Group Automobiles
S.p.A. accessory line).
ATTENTION: this modification is not allowed with a Fiat Group Automobiles S.p.A. standard
radio.
 3.22

4.3 Connector C036L1C (2-way) – Coach-builder’s socket

4.3.1 3D view of connector

Figure 21

1. Connector C036 L1C, 2-way – 2. Connector provided by Fiat Group Automobiles S.p.A. for
wiring by coach-builder.

4.3.2 Description of connector functions

cable section

cable colour
Minimum

[mm2]

Pin Function/Connector Part number Notes

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

4.3.3 +12V power supply from main battery

See paragraph 4.1.4

4.3.4 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.
 3.23

4.4 Connector Y203L4A (12-way) – Rear lights

4.4.1 2D view of connector
Figure 22

Minimum cable
section [mm2]

Cable colour
PIN

X2/50 Function / Connector Part number Notes

Connector 12-way Tyco p/n 284844-1

Counterpart: p/n 284848-3 (by coach-builder)
1 Rear lights ground 2.5 N
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
8 Third stop light 0.5 L
PMAX= 21W at 12V alternative 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

4.4.2 Description of connector functions

(1)
It is also possible to install a single 21W – 12V rear fog warning light (for example GSX, left fog
light only).
NOTE: In the case of modifications to the system that are not described here (for example,
installing LED lights), works should be co-ordinated with Fiat Group Automobiles S.p.A..
 3.24

4.4.3 Rear lights

Figure 23

Mar. LH

Mar. RH

Dir. LH

Dir. RH

Stop LH

Stop RH

Third Stop (1)

Rear fog warning LH

Rear fog warning RH

License Plate lights

Reversing lights

(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.
 3.25

5 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, GPS and GSM aerial connectors
 3.26

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

5.1.1 3D view of connector
Figure 25

5.1.2 Description of connector functions

Minimum cable
section [mm2]

Cable colour
PIN

Function/Connector part number Notes

24-way FCI connector p/n 17212401

Counterpart: FCI p/n 17212400 (by coach-builder)
1 LED cargo bay door status 0.35 BH
2 Direction indicators 0.5 AB 1 16W - 12V bulb
3 Door open signal 0.35 BS N.O. state door closed (1)
4 External mirror defroster power supply 0.5 CL PMAX= 30W at 13.5V
5 +15 power supply for window winder motor 0.35 HV Signal power IMAX= 0.5A
6 DDC illumination/power supply 0.35 BL Driver’s door control pad
7 Not connected - -
8 Lock/unlock signal from knob 0.5 LN
9 Window winder power 2.5 SB Power supply IMAX= 10A
10 Ground (direction indicator, lock, mirror defroster) 1 N
11 Window winder ground 2.5 N
12 Cargo bay lock/unlock signal 0,35 SZ From driver’s door control pad
13 P.S. window up signal from DDC 0,35 HV From driver’s door control pad
14 P.S. window down signal from DDC 0,35 HR From driver’s door control pad
15 P.S. main ext. mirror up/down 0,35 MN From driver’s door control pad
16 P.S. main ext. mirror left/right 0,35 BR From driver’s door control pad
17 P.S. secondary ext. mirror up/down 0,35 BZ From driver’s door control pad
18 P.S. secondary ext. mirror left/right 0,35 BV From driver’s door control pad
19 P.S. ext. mirror common servos 0,35 HN From driver’s door control pad
20 DDC signal ground 0,35 NZ Driver’s door control pad
21 Loudspeaker (+) 0,75 AN
22 Loudspeaker (-) 0,75 A
23 Door lock control 1,5 S
24 Door unlock control 1,5 NG
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.
 3.27
5.1.3 Side direction indicator lights
Figure 26

Weld Ground
Body Computer
- Mirror defroster
- Lock

5.1.4 Driver’s side lock control

Figure 27

CGP
Lock
Unlock
Door status

Lock Knob Weld

Ground
Unlock
- Mirror defroster
R = 620 Ω - Direction indicator

5.1.5 External electric mirror

Figure 28

At the connector Y002LA Driver’s door

control pad

Ground
Body Computer - Lock
- Direction indicator
 3.28

5.1.6 Driver’s side loudspeaker

Figure 29

Tweeter on piller

Radio

Woofer on door

5.1.7 Electric window winder

Figure 30

Driver’s door control pad

+Key
At the connector Y002LA
 3.29

5.2 Connector Y002LA (24-way) – Passenger side door

5.2.1 3D view of connector

Figure 31

5.2.2 Description of connector functions

Minimum cable
section [mm2]

Cable colour
PIN

Function/Connector part number Notes

24-way FCI connector p/n 17212401

Counterpart: FCI p/n 17212400 (by coach-builder)
1 Not connected - -
2 Direction indicators 0.5 AV 1 16W - 12V bulb
3 Door open signal 0.35 BN N.O. status door closed (1)
4 External mirror defroster 0.5 CL PMAX= 30W at 13.5V
5 Not connected - -
6 CDC illumination/power (utilities relay T13) 0.35 BL Passenger side door control pad
7 Not connected - -
8 Not connected - -
9 Window winder power supply 2.5 S Power supply IMAX= 10A
10 Ground (direction indicators, lock, mirror defroster) 1 N
11 Window winder ground 2.5 N
12 Not connected - - From driver’s side door control pad
13 Window up signal from DDC 0.35 HV From driver’s side door control pad
14 Window down signal from DDC 0.35 HR From driver’s side door control pad
15 Main ext. mirror up/down 0.35 MN From driver’s side door control pad
16 Main ext. mirror left/right 0.35 BR From driver’s side door control pad
17 Secondary ext. mirror up/down 0.35 BZ From driver’s side door control pad
18 Secondary ext. mirror left/right 0.35 BV From driver’s side door control pad
19 External mirror common servo 0.35 HN From driver’s side door control pad
20 CDC signal ground 0.35 NZ Passenger side door control pad
21 Loudspeaker (+) 1.5 CB
22 Loudspeaker (-) 1.5 C
23 Lock/lock control 1.5 SG
24 Lock/unlock control 1.5 NZ

Note: This connector is supplied as pre-fitting if the original New Ducato doors are not present.
(1)
if door not present leave unconnected
 3.30

5.2.3 Side direction indicator light

Figure 32

Weld Ground
Body Computer
- Mirror defroster
- Lock

5.2.4 Passenger side door control

Figure 33

Lock

Unlock

Door status
Weld
Saldatura Ground
- Sbrinatore
Mirror defroster
specchio
- Luce
Direction indicator
di direzione

5.2.5 Electric external mirror

Figure 34

Electric external mirror

on passenger side

At the connector
Y001LA

GROUND
- Lock
Weld
- Direction indicator
 3.31
5.2.6 Passenger side loudspeaker

Figure 35

Tweeter on piller

Radio

Woofer on door

5.2.7 Electric window winder

Figure 36

Passenger’s side door control

pad

From the connector

Y001LA
 3.32

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

5.3.1 2D view of connector

Figure 37

5.3.2 Description of connector functions

Minimum cable
section [mm2]

Cable colour
PIN

Function/Connector part number Notes

4-way Tyco connector p/n 174929-1

Counterpart: Tyco p/n 174922-1 (by
coach builder)
1 P.S. ext. mirror deflect 0.5 HM External mirror electric deflection
2 P.S. ext. mirror restore 0.5 N External mirror electric deflection
3 External temperature sensor (high) 0.35 HR Necessary with automatic air-conditioner
4 External temperature sensor (low) 0.35 HV Necessary with automatic air-conditioner

5.3.3 External rear-view mirror deflection

Figure 38

At the connector Driver’s side doors control pad

Y116L1A

Driver’s door external

rear-view mirror
 3.33

5.3.4 External temperature sensor

Figure 39

External temperature sensor

(on mirror)

Body Computer

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

Parameter Value

Resistance at 25°C (R25) 10 kΩ

Tolerance at R25 ±3%

Maximum dissipation 500 mW

Response time 1.2 s

Working temperature range from -40 to +125

°C

Climatic category 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.
 3.34

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

5.4.1 3D view of connector

Figure 40

5.4.2 Description of connector functions

Minimum cable
section [mm2]

Cable colour
PIN

Function/Connector part number Notes

4-way Tyco connector p/n 174929-1

Counterpart: Tyco p/n 174922-1 (by coach-builder)
1 Not connected
2 P.S. ext mirror deflection 0.5 HM External mirror electric deflection
3 P.S. ext. mirror restore 0.5 N External mirror electric deflection
4 Not connected - -

5.4.3 External rear view mirror deflection

Figure 41

From the connector Passenger’s side

Y121LA external mirror
 3.35

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

5.5.1 3D view of connector
Figure 42

5.5.2 Description of connector functions

PIN

Function/Connector part number Notes

Shielded ASK connector p/n COMA Y050PA

Counterpart: ASK p/n COFE (by coach-builder)
1 AM/FM radio aerial signal AM/FM aerial on roof or in external mirror
 3.36

5.6 Connector Y050PB (2-way) – GSM aerial

5.6.1 3D view of connector
Figure 43

5.6.2 Description of connector functions

PIN

Function/Connector part number Notes

Shielded Hirose GT5 connector p/n 755-0040-0

GREEN colour
Counterpart: Hirose GT5 p/n 755-0038-9 (by coach-builder)
1 GSM aerial signal For telematic info system
2 Shield

5.7 Connector Y050PC (2-way) – GSM aerial

5.7.1 3D view of connector
Figure 44

5.7.2 Description of connector functions

PIN

Function/Connector part number Notes

Shielded Hirose GT5 connector p/n 755-0005-0

GREY colour
Counterpart: Hirose GT5 p/n 755-0004-7 (by coach-builder)
1 GPS aerial signal For satellite navigator
2 Shield
 3.37

5.8 Connector Y050PD (2-way) – Amplified radio aerial power supply

5.8.1 2D view of connector
Figure 45

5.8.2 Description of connector functions

PIN

Function/Connector part number Notes

2-way Sumitono connector p/n 6098-0240

(Y050PD)
B
Counterpart: Sumitomo p/n 6098-0239 (by coach-
builder)
Power supply from radio for amplified AM/FM radio
1 Present only for aerial in external mirror
aerial
2 Not connected

5.8.3 Amplifier power supply

Figure 46

Amplified radio aerial in

external mirror

+ Lights
 3.38

6 GENUINE NEW DUCATO COMPONENTS

6.1 Locks
6.1.1 3D view of connector
Figure 47

Interface connector with genuine New Ducato locks

6.1.2 Description of connector functions

Minimum cable
section [mm2]
Pin

Function/Connector part number Notes

10-way Tyco connector on wiring

p/n 6-1355688-1
1 Not connected -
2 Lock/unlock signal from knob 0.5 Present only on driver’s side door
3 Switch ground 0.5
4 Door open switch 0.5 N.O. to ground (10 mA clean contact)
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 Not connected -
9 Not connected -
10 Not connected -
 3.39

6.2 Front lights

6.2.1 2D view of connector
Figure 48

6.2.2 Description of connector functions

Minimum cable
section [mm2]
PIN

Function/Connector part number Notes

14-way FCI connector p/n BTBFHPE14BK08A

1 Headlight 0.5
2 High beam 1
3 Blind cavity -
4 Side markers 0.35 1 5W - 12V bulb
5 Blind cavity -
6 Direction indicator 0.5 1 21W - 12V bulb
7 Closed cavity -
8 Closed cavity -
9 Headlight levelling signal 0.35
10 Blind cavity -
11 Levelling power supply 0.5 Active with headlights on
12 Bind cavity -
13 Headlight levelling ground 0.5
14 Bulb ground 1.5
 3.40

6.3 Rear lights

6.3.1 2D view of connector
Figure 49

6.3.2 Description of connector functions

Minimum cable section

[mm2]
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 -
 3.41

6.4 Windscreen wiper

6.4.1 3D view of connector on windshield wiper motor
Figure 50

6.4.2 3D view of connector on wiring

Figure 51

1
5

6.4.3 Description of connector functions

Minimum cable
section [mm2]
PIN

Function/Connector part number Notes

5-way Delphi connector p/n 15342484 - Reference to diagram M012AA

1 Ground 2.5
2 Power supply 2.5
3 Speed selector 0.5
4 On/off 0.5
5 Parking contact 0.5
 3.42

6.4.4 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 Group Automobiles S.p.A. group.

Figure 52 Figure 53

Figure 54
 3.43

6.5 Windscreen washer pump

6.5.1 2D view of connector
Figure 55

6.5.2 Description of connector functions

Minimum cable
section [mm2]
PIN

Function/Connector part number Notes

2-way Delphi connector on wiring p/n 12185025 (401589)

1 Power supply 1.5
2 Ground 1.5
 3.44

6.6 Left hand external rear view mirror

6.6.1 3D view of connectors

Figure 56

NOTE: The figure shows the counter-connectors.

6.6.2 Description of connector functions

Minimum cable
section [mm2]
PIN

Function / Connector part number Notes

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
 3.45

cable section
Minimum

[mm2]
PIN Function/Connector part number Notes

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 Group Automobiles S.p.A. rear view mirrors are used, refer to the connections
described in the preceding paragraphs of this document.

6.7 Right hand external rear-view mirror

6.7.1 3D view of connectors
Figure 57

3x

NOTE: The figure shows the connector counterparts.

 3.46

6.7.2 Description of connector functions

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

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 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 -

Shielded Hirose GT5 connector p/n 755-0037-6

BROWN colour
Counterpart: Hirose p/n 755-0039-1
1 Radio aerial signal -
2 Shield -

Shielded Hirose GT5 connector p/n 755-0004-7

GREY colour
Vehicle side connector 2v. Hirose GT5 p/n 755-0005-0
1 GPS signal aerial -
2 Shield -

Shielded Hirose GT5 connector p/n 755-0038-9

GREEN colour
Vehicle side connector 2v. Hirose p/n 755-0040-0
1 GSM aerial signal -
2 Shield -
NOTE: If Fiat Group Automobiles S.p.A. rear view mirrors are used, refer to the connections
described in the preceding paragraphs of this document.
 3.47

6.8 Ceiling light

6.8.1 2D view of connector
Figure 58

6.8.2 Description of connector functions

Minimum cable
section [mm2]
PIN

Function/Connector part number Notes

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
 3.48

6.9 Driver’s side door control pad

6.9.1 2D view of connectors
Figure 59

6.9.2 Description of connector functions

Minimum cable
section [mm2]
PIN

Function / Connector part number Notes

8-way Tyco connector on wiring p/n 1745000-1

1 LH window up control 0.35
2 Rear door status LED 0.35
3 Ground 0.5
4 Rear comp. lock/unlock 0.35
5 LH window down control 0.35
6 Power supply/illumination 0.5
7 RH window down control 0.35
8 RH window up control 0.35

12-way Tyco connector on wiring p/n 1534093-1 + p/n

- Cap + terminal holder unit
1534100-1
1 Ground 0.5
2 RH Main mirror up/down 0.35
3 RH auxiliary mirror left/right 0.35
4 LH main mirror left/right 0.35
5 Power supply/illumination 0.5
6 LH auxiliary mirror up/down 0.35
7 Power supply 0.5
8 Mirror servos common 0.35
9 LH main mirror up/down 0.35
10 RH auxiliary mirror left/right 0.35
11 RH auxiliary mirror up/down 0.35
12 RH main mirror left/right 0.35

6-way Tyco connector on wiring p/n 284802-1 -

1 Power supply 0.75
2 Ground 0.75
3 LH mirror deflection 0.5
4 LH mirror restore 0.5
5 RH mirror deflection 0.5
6 RH mirror restore 0.5
 3.49

6.10 Passenger side door control pad

6.10.1 2D view of connector

Figure 60

6.10.2 Description of connector functions

Minimum cable
section [mm2]
PIN

Function / Connector part number Notes

4-way Tyco connector on wiring p/n 1-1534150-1 + 1534149-1 Connector + secondary lock
1 P.S window down control 0.35
2 Power supply/illumination 0.5
3 Ground 0.5
4 P.S. window up control. 0.35
 3.50

6.11 Electric windows

6.11.1 2D view of connector

Figure 61

6.11.2 Description of connector functions

Minimum cable section

[mm2]
PIN

Function / Connector part number Notes

6-way FCI connector on wiring p/n 211PC069S0049

1 Window up control 0.35
2 Not connected -
3 Power supply +30 2.5
4 Ground 2.5
Present only on driver’s side
5 +15 from signal 0.5
window control
6 Window up control 0.35
 3.51

7 STANDARD FIAT GROUP AUTOMOBILES S.P.A. COMPONENT

DRAWINGS
7.1 20A micro relay switch
 3.52

7.2 30A micro relay switch

 3.53

7.3 50A maxi relay switch

 3.54

8 TIPS FOR INSTALLATION

8.1 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 common
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).

8.2 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 cable (min. sec. 4mm2) GDX vehicle
Ground cable
Engine bay
Engine bay From C036L1A fuse/relay box
fuse/relay box

Grommet (-)
Grommet (-)
Door module
relay/fuses

CVM CVM
Grommet (+)
Bulkhead
Junction passage seal Junction Door module
box box relay/fuses

Grommet (+)

Drivers Passenger Passenger Drivers

side side side side
seat seat seat seat

Coachbuilders Coachbuilders
connector C036 L1A connector C036 L1A
 3.55
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.
• 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 harness
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 prevent
infiltration into the cabin.
• Lay the cables in the cabin following the route shown in figure 65.
 3.56
Figure 62

Engine bay – CVM box and view of junction box

Figure 63

Engine bay – view of ground pin

 3.57

Figure 64

Engine bay – front view of GSX cable layout

Figure 65

Cabin – view of GSX cable layout

 3.58
The wiring realised by the coachbuilder must be adequately protected by means of abrasion
resistant tape.

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 sealing tape applied.
3. In vehicles with automatic gearbox, the relay/fuse block is already present 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:

Figure 66
Weld Grommet (+)
Door module
relays/fuse
4mm2 6mm2

+30
4mm2

Ground

+15

13
Weld Coachbuilders connector
C036 L1A
Grommet (-)

NOTES:

1. The fuses must be correctly sized according to the minimum section of the protected wires.
2. The relays must be Fiat Group Automobiles S.p.A. standard type (see chapter 7)
 3.59

8.3 Anti-theft system

If an anti-theft system has to be installed, we recommend using the original kit of the Accessories
Line, made by an official Fiat Group 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

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

8.5 Robotised gearbox

On chassis-cowls or any vehicle without the original cab doors, the use of a robotised gearbox
(option 407) requires the installation of an exterior temperature sensor (see par. 5.5.4) and a
driver side door status switch (see par. 5.1.4).

Ellebi s.r.l. Westfalia-Automotive GmbH & Co.

Strada Statale 63, n°189 KG
42040 S. Vittoria di Gualtieri - Reggio Emilia - (Italy) Am Sandberg 45
Telephone Postfatch 26 40
Switchboard: +39 0522 834111 33354 Rheda Wiedenbrück
Fax Telephone
Switchboard: +39 0522 833640 Switchboard: +49 5242 907 0
Sales Office: +39 0522 833226 Fax
Customer care: +39 0522 834209 Switchboard: +49 5242 907 195
Web Web
Information: [email protected] Web site: www.westfalia-automotive.de
Customer service: [email protected]
Web site: www.ellebi.com
3.60
 3.61

Ambulance conversion
electrical system components
3.62

1. AMBULANCE CIRCUITRY 3.63

1.1 20-pin connector C036 AD 3.63
1.1.1 View and position of connector 3.63
1.1.2 Functions of the connector 3.64
1.1.3 Engine starting inhibition circuit 3.65
1.1.4 Flasher power supply 3.65
1.1.5 Siren power supply 3.66
1.1.6 High beam lights On signal 3.67
1.1.7 Horn control 3.67
1.1.8 Reverse gear engaged signal 3.68
1.2 Fiat Group Automobiles S.p.A. Ambulance Control Panel 3.69
 3.63

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

Figure 01

¾ NOTE: In the detailed view, the connector is seen from the cable entry side
 3.64

1.1.2 Functions of the connector

cable size
Minimum

[mm2]
Pin Connector function/Part number Notes

Tyco 20-pin connector on vehicle side, See diagram C036-AD

p/n 284879-3
Counterpart on conversion side: Tyco
p/n 284875-2 (supplied by Fiat Group
Automobiles S.p.A.)
Starter relay coil command (to be short-
1 Power supply: +50 from ignition switch 2.50
circuited with pin 11)
Positive command for 1 standard relay
2 + key cut out during starting (Ign/SW) 0.5
(max 300mA)
Positive command for 1 standard relay
3 High beam lights on signal 0.5
(max 300mA)
INPUT: manages the horn relay by means of
a negative signal from switch
4 Horn control 0.35
OUTPUT: negative command for 1 standard
relay (max 300mA)
GND for ambulance control panel by Fiat Suitable for use on other control panels
5 0.5
Group Automobiles S.p.A. (max 4A)
Power supply + key for backlighting of
Suitable for use on other control panels
6 Fiat Group Automobiles S.p.A. 0.5
(max 300mA)
ambulance control panel
Power supply for ambulance control Suitable for use on other control panels
7 0.5
panel: +30 (max 2A)
Positive command for 1 standard relay
8 Reverse gear engaged signal 0.5
(max 300mA)
If the Fiat Group Automobiles S.p.A.
ambulance control panel is not used, provide
9 Siren relay positive command (INPUT) 0.5
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 Group Automobiles S.p.A.
ambulance control panel is not used, provide
19 Flasher relay positive command (INPUT) 0.5
for protection of cable sized 0.5mm2 (max
7.5A fuse)
20 Flasher power supply (OUTPUT) 2.50 Max 20A
 3.65

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

C036AD

1
+50

11

Starter motor

1.1.4 Flasher power supply

Figure 03

FLASHER
RELAY C036AD +
+ 20A size ≥ 2.5 mm2 Flasher
20
Flasher -
control
19

size ≥ 0.5 mm2

7
GND
+ 7.5A for siren circuit

Ultrasound welding
or equivalent equipotential 2
connection
C036L1C
 3.66

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
C036AD size ≥ 2.5 mm2
+ 20A
10 +
Siren
9 Standard relay -
Siren control (max 300mA)

+ 7.5A
size ≥ 0.5 mm2
7
C036L1C
size ≥ 0.5 mm2
2
Ign/SW Ultrasound welding 2
or equivalent equipotential
Ignition switch connection

NOTES:
1. If the Fiat Group 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.
 3.67

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

C036AD by high beam lever on
+ size ≥ 0.5 mm2
steering wheel
3
High beam lights control
5 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.
Figure 06

INPUT mode operation

HORN
RELAY Horn
+
C036AD
size ≥ 0.5 mm2
4
Control

Steering wheel mounted control

5
 3.68

Figure 07

OUTPUT mode operation

HORN Horn
RELAY Power supply controlled
by steering wheel
+ C036AD mounted lever

size ≥ 0.5 mm2

4
Standard relay
(max 300mA)

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

C036AD by reverse gear
+ size ≥ 0.5 mm2
engagement
8
Reverse switch
5 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.
 3.69

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

POS. A POS. B

POS. C

POS. D

POS. E

POS. F

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
3.70
Main dimensions 4.1
4.2
Sheet metal van – Cargo bay internal dimensions
4.3

Bulkhead intrusion

Width between wheelarches

Width between internal sides (against panelling)

 4.4
Sheet metal van – Short wheelbase H1
 4.5
Sheet metal van – Medium wheelbase H1/H2
 4.6

Sheet metal van – Long wheelbase H2/H3

 4.7
Sheet metal van – Extra-long overhang H2/H3
 4.8

Short wheelbase chassis cab

STDA: Height from ground: 650 ± 3 mm

 4.9
Medium wheelbase chassis cab

STDA: Height from ground: 646 ± 3 mm

 4.10

Medium-long wheelbase chassis cab

STDA : Height from ground: 650 mm (Payload 3000) – 647 mm (Payload 3300)
645 mm (Payload 3500)
 4.11
Long wheelbase chassis cab

1035

STDA: Height from ground: 642 ± 3 mm

 4.12

Extra-long overhang chassis cab

1035

STDA: Height from ground: 640 ± 3 mm

 4.13
Double cab medium wheelbase chassis cab
 4.14

Double cab long wheelbase chassis cab

 4.15
Double cab extra long overhang chassis cab
 4.16

Short wheelbase chassis cab with platform

STDA: Height from ground: 536 ± 1 mm

 4.17
Medium wheelbase chassis cab with platform

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

 4.18

Medium-long wheelbase chassis cab with platform

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

521 ± 1 mm (Payload 3300 and 3500)
 4.19
Long wheelbase chassis cab with platform

STDA: Height from ground: 518 ± 2 mm

 4.20

Extra-long overhang chassis cab with platform

STDA: Height from ground: 521 ± 1 mm

 4.21
Short wheelbase basic chassis
 4.22

Medium wheelbase basic chassis

 4.23
Medium-long wheelbase basic chassis
 4.24

Long wheelbase basic chassis

 4.25
Extra-long overhang basic chassis
 4.26

Short wheelbase special chassis cab

 4.27
Medium wheelbase special chassis cab
 4.28
Medium-long wheelbase special chassis cab
 4.29
Long wheelbase special chassis cab
 4.30
Extra-long overhang special chassis cab
 4.31
Short wheelbase special basic chassis
 4.32
Medium wheelbase special basic chassis
 4.33
Medium-long wheelbase special basic chassis
 4.34
Long wheelbase special basic chassis
 4.35
Extra-long overhang special basic chassis
4.36