The ideal companion for work and free time
 

The New Ducato range features larger dimensions (length, height and width) and a higher volume: (from 8 to 17 m3). Load access and facility of loading have also been improved and this has become a point of excellence on this vehicle. Not overlooking the fact that the New Ducato ensures particularly low operating costs due to its attributes of quality and reliability. This is partly due to its three flexible, gradual Multijet power units, all Euro 4, that are outstanding for their high power and torque. Whatever its mission and professional use, therefore, the new model proves itself an ideal workmate that is really ready for anything. At the same time, however, due to the particular attention devoted at the design stage to comfort and ergonomics, the New Ducato confirms its vocation for leisure conversions. Suffice it to say that in recent years the Fiat model has taken over European leadership in this sector: two camper vans out of three are built on Ducato bases.

More accessible for easier loading

Particular attention has been devoted to the load space to facilitate daily use without stress or fatigue. The generous, square side and rear doors together with the low load threshold (535 mm), provide easy access to the load compartment even when loads are bulky. Drive cab accessibility has therefore also been improved. The access step to the cab is designed to optimise the position of the foot as it enters/leaves the passenger compartment and its height has been reduced to 450 mm (it was 500 mm on the previous model).

Again with the aim of further improving access to the vehicle, other improvements have been made. The shape of the exterior handles has been improved to make them easier to grip and the doors easier to open and close. In the same way, the position and shape of the partition separating the passenger compartment and load compartment have been altered to allow the seat backrest to recline further without penalising access to the load compartment through the sliding side door. Its capacity has also been optimised.

More room and interior volume

The parameters that determine posture, driver seat position and passenger seat position, overall passenger room and interior volume have been optimised to increase the available space inside the cab and also in the load compartment. The solutions adopted have allowed us to produce a vehicle that is at the top of its category with regard to the load compartment’s effective volume (which increases from 8 to 17 m3 according to the versions) and also optimum cab passenger and rear passenger space (in crew cab versions). Compared to the previous model, the new Ducato also increases the amount of space in the cab, particularly for the driver, in terms of length (from the accelerator to the cab and load compartment separation partition).

Due to the new vehicle engines, an increase in gross vehicle weight has also been achieved (up to 4 tonnes) and higher maximum permissible loads on the axles, benefiting those who use the vehicle for particularly heavy loads or for converted vehicles. Not to mention the fact that sophisticated self-levelling suspension systems have been introduced to ensure greater comfort for all uses and missions and constant vehicle attitude under all load conditions.

A passenger compartment for living in

The oceans of glass and the front pillar position ensure outstanding overall visibility, consolidating one of the strengths of the previous model. The large door mirror allows excellent rear visibility. Three types of rear mirrors are available with different widths: normal body (2100 mm) and wide bodies (2200 and 2350 mm) for versions used for conversions. As far as control accessibility and usability is concerned, the New Ducato benefits from the most up-to-date virtual ergonomic setting methods. We started by using an ergonomic diagram that provides the basis for defining the style of interior volumes and positioning the main controls and devices. More advanced programs were then used to carry out more targeted virtual checks, thus allowing a reduction in development times compared to the use of physical prototype tests. The final result is excellent: both the onboard instruments and the onboard controls are easily identifiable, readable, accessible and easy to use, all in an ergonomic position so the driver hardly needs to take his eyes off the road. All these factors mean that the new vehicle achieves a high level of comfort at the peak of its category.

The passenger room available on the New Ducato deserves a section of its own. To determine optimum postural comfort, ie. the correct combination of space and driving position, an essential factor for ensuring a sensation of wellbeing, the various conditions of use were reproduced using a sophisticated mathematical model. In this specific case, the computer simulations were carried out using the program ‘Abita 2000’, which uses Human Scale dummies representing the European population. The results achieved set the New Ducato at the head of its segment since it is able to accommodate men and women of all sizes with a good standard of comfort. This was made possible due to new driver’s seat specifications (its height from the floor, its distance from the roof and its settings) and an increase in longitudinal reach. The rake of the backrest was also increased from 18° to 21°, partly through a different profiling of the partition separating the cab and load compartment. The steering column rake has been altered from 52° to 41° in order to make a more car-standard driving position possible, ie. a less truck-like position.

The position of the gear lever on the dashboard, always one of the strengths of the previous Ducato, has been improved. The pedal unit and the steering column are now perfectly aligned (this technical feature facilitates driving) and the broad footrest surface is also new so that the foot can be rested during long journeys at constant speed (e.g. on the motorway). The seat lift control has also been optimised with improved positioning and easier access.

Low running and maintenance costs

The New Ducato is a byword for efficiency and productivity that translates into particularly low running costs for customers since they are able to count at all times on a vehicle that is ready for any mission, even the most demanding missions under the most severe climatic conditions. In particular, the power units on the new model are outstanding for their reliability (the standard of durability is that of a truck); for their long service intervals (up to 45,000 km); for their low fuel consumption (from 7 to 16% less than the previous model); for their outstanding performances (maximum power from 100 to 157 bhp) - and for their driving comfort (up to 400 Nm). Not to mention the fact that they are all gentle on the environment (Euro 4). These attributes are greatly appreciated by commercial vehicle customers who demand from their vehicle low running and service costs, reliability (and thus less time off the road), high mileage abilities, good pick-up qualities at low speed or even with the vehicle laden, and flexibility.

Powerful and flexible engines

To ensure that each customer can find in their own New Ducato a vehicle that meets their particular requirements in terms of performance and fuel consumption, the model offers a range of power units made up exclusively of latest generation Common Rail direct injection turbo diesels (Multijet) that offer completely outstanding torque and maximum power values in line with the lively image that the Fiat Ducato has always enjoyed. In detail, the customer may therefore choose between the 100 bhp 2.2 Multijet, the 120 bhp 2.3 Multijet (a 130 bhp version is available for the Camping Car sector) and a 157 bhp 3.0 Multijet.

The three power units fitted to the New Ducato have been designed in accordance with criteria of the greatest rationality, efficiency and reliability. They’re capable of outstanding performance that translates into reduced fuel consumption and emissions (they are all Euro 4), lower noise levels (due to the multipoint injection system); improved comfort (fewer alternating masses for fewer vibrations), and a satisfying drive (due to the very smooth torque delivery, which is guaranteed in turn by the possibility of improved control of combustion).

Other essential features of these engines include reliability and durability. For this reason, very severe tests were carried out that reproduced all service conditions (more than 7 million km). Very sophisticated devices (similar to the black boxes on aeroplanes) were installed on the vehicles tested to collect all the information on the way these new power units behaved during each type of service mission. The 2.3 and 3.0 Multijet units were combined with two new 6-speed gearboxes that are differentiated on the basis of the levels of torque delivered by the engine, while a 5-speed device is fitted to the 100 bhp 2.2 unit.

The Multijet system fitted to second generation JTD engines.

This system represents the technologically most advanced solution for controlling high injection pressures (up to 1600 bars), irrespective of engine rpm and the quantity of fuel injected. Compression is not linked only to engine rotation speed but also to various parameters indicated by the control unit by means of dedicated sensors (air and diesel temperature, engine rpm, accelerator, brake and clutch pedal position, vehicle speed, air and diesel pressure).

The key element of this system is the electronic control unit, which may make a series of injections that can be very closely spaced (hence the term Multijet). During each engine stroke, the number of injections may rise to as many as five instead of the conventional two. In this way, the same amount of diesel is burnt inside the cylinder but in several portions to achieve smoother combustion. This ensures very smooth operation under all service conditions, great driving flexibility and prompt responses that make these power units increasingly similar to those driven by petrol. The advantages include lower running noise, reduced emissions and an increase in performance. All this comes with a level of engine efficiency that improves vehicle handling still further.

Architecture of the three power units

All the New Ducato power units feature four cylinders in line – with four valves per cylinder and a twin overhead camshaft – and a fixed geometry turbine with intercooler. The engine cylinder head is built out of aluminium alloy while the engine block is in cast iron. The pistons are equipped with a cooling gallery (the geometry of the intake and exhaust ducts has been optimised). To favour fast cold starts, the electric fuel pump is submerged in the tank. This also offers the benefit of increasing the durability of the diesel filter and, if the fuel runs out, allows immediate restarting of the fuel supply without the need for service operations. This new pump allows improved overall performance.

The diesel filter offers a high water separation capacity. This means that problems of damage to the pump and injectors may be avoided. To reduce nitrogen oxide emissions, all these engines are equipped with an EGR system with cooling of exhaust gases by recirculation, controlled directly by the engine control unit. The exhaust gas post-treatment system (consisting of a pre-catalytic conversion and a main catalytic converter) complete gas oxidisation to ensure the new Euro 4 emission limits are respected. The technical and mechanical features of the three power units are given below.

2.2 100 Multijet

This engine offers low fuel consumption and great flexibility (suffice it to say that it boasts a practically steady torque curve from 1500 to 2700 rpm), which makes it the ideal solution for urban use. In detail, the power pack is a four cylinder in line unit with a capacity of 2198 cc and 16 valves, which develops a maximum power of 100 bhp (74 kW) at 2900 rpm and a torque of 25.5 kgm (250 Nm) at 1500 rpm. Particular care has been devoted to the design of the combustion system with the use of new air intake ports in the cylinder head. The new pistons are equipped with a new piston bowl geometry plus cooling galleries. This solution allows high pressure fuel injection at low rpm to guarantee higher torque levels.

The 100 bhp 2.2 Multijet engine is also outstanding for its reduced weight (only 180 kg). This attribute is very important for a light commercial vehicle since it ensures lower fuel consumption and particularly a higher payload for the same GVW. As far as service intervals are concerned, an oil change is required every 40,000 km and the timing chain is guaranteed for life.

2.3 120 Multijet

This new engine, a development of the tried and tested 2.3 JTD 110 bhp unit on the previous Ducato, has undergone a number of improvements that have allowed an increase in performance and torque plus lower running costs and an increase in productivity.
 

Suffice it to say that the engine has been designed for a longer effective life (300,000 km) and much longer service intervals: oil and filter change every 45,000 km (5.5 litres of oil) and timing belt change every 240,000 km.

Due to its Multijet injection system, the brand new 2.3 Multijet engine delivers a maximum power output of 120 bhp (88 kW) at 3600 rpm and a maximum torque of 32.6 kgm (320 Nm) at 2000 rpm, with a constant torque from 2000 to 2800 rpm.  These important values make this engine ideal for mixed use: sturdy and with outstanding performance, nimble in traffic, exhilarating on long trips. This is the ideal vehicle for people transport and also for local goods distribution. Not to mention that such a high torque allows the vehicle to take off with ease, even when heavily laden.

The structure of the new engine has been optimised through the adoption of a cast iron engine block base with integral bearings that allows vibrations to be minimised (distribution takes place through a tooth belt drive with automatic belt tensioner). The new power unit uses a turbocharger with wastegate valve that allows partial, progressive return of a proportion of exhaust gases at engine speeds higher than 2200 rpm. This improves the available torque delivery at all engine speeds to improve vehicle handling. The glow plugs are located directly inside the combustion chamber: they are controlled by the ECU and considerably reduce preheating and cranking time to help limit stress on the engine during cold starts with low outdoor temperatures. And more: the water/oil heat exchanger (Modine), oil pump, vacuum pump and centrifugal water pump are integral. Other new features include the oil sump (now suspended and with a capacity of 4.5 litres) and also the oil filter, which is two-stage.

To respect the limits imposed by Euro 4 legislation, the 120 bhp 2.3 Multijet is also fitted with a system incorporating an EGR (Exhaust Gas Recirculation) valve that is controlled by the control unit and partly recirculates the exhaust gas to contain emissions while the heat exchanger cools recycled gases before returning them to the combustion chamber. A camping car version of the 2.3 Multijet develops a power of 130 bhp (95.5 kW) at 3600 rpm and a torque of 32.6 kgm (320 Nm) at 2000 rpm. It should be emphasised that this value is held constant from 2000 to 2800 rpm. These highly appealing performance levels have been achieved using an oversized turbine and a special calibration setting.

3.0 160 Multijet POWER

This is the most powerful engine in the New Ducato range with a capacity of 2999 cc, a maximum power of 157 bhp (115.5 kW) at 3500 rpm and an outstanding maximum torque level. No less than 40.8 kgm (400 Nm) practically constant from 1700 to 2500 rpm. This exceptional flexibility makes for driving comfort together with a significant reduction in noise levels. As for the 120 bhp 2.3 Multijet unit, the 157 bhp 3.0 also uses a turbocharger with wastegate; spark plugs located directly inside the combustion chamber and controlled by the ECU - and an EGR valve to meter the recirculated exhaust gas flow. Another feature adopted to promote fast cold starting is a new electric fuel feed pump submerged in the tank. This also offers the advantage of increasing the durability of the diesel filter and, if the fuel runs out, allowing fuel delivery to be restored immediately without the need for servicing.

The 157 bhp 3.0 unit is also fitted with a cast iron engine block base with built-in bearings and a dual mass flywheel that has the effect of damping vibrations generated by the engine and bringing about a consequent significant reduction in noise levels. The timing system is chain driven with twin overhead camshafts. The 157 bhp 3.0 unit is altogether the ideal engine for tradesmen who are looking for power, torque and pick-up. It is strong and versatile enough to tackle all service situations in complete safety, ensuring the maximum ability to get out of trouble due to a torque reserve that is permanently available to the driver. From high volume and long distance Transport to security Transport, from leisure use (Campers and Motorhomes) to people-carrying: the new power unit always ensures great productivity, performance and low noise levels.

Each component has been designed for heavy duty, long-term operation: for example, the timing chain is built for life, while the oil and filter change intervals are 45,000 km. The 3.0 Multijet POWER also does not require all top-ups between one change and the next. At the recommended check intervals of 10,000 km, the oil level will always be within values that do not require topping up. During the design of this engine, it is worth noting that preventive action was taken on potential leakage points where minor leaks could occur that are not significant as far as oil consumption is concerned but nevertheless cause unpleasant deposits on the engine. To do this, for example, special oil channels were designed to cut the sealing points by more than half. The exterior cleanliness of the engine reflects its quality.

Sturdy, reliable gearboxes

To exploit the power and torque of these common rail diesel engines to the full, two new manual 6-speed gearboxes have been developed that allow the vehicle to travel, even on the motorway, at low engine speeds. Compared to conventional 5-speed gearboxes, the ‘6-speed’ improves vehicle handling while also benefiting noise levels, emissions and performance.

In particular, the 2.3 Multijet engine is combined with a 2-axle gearbox with maximum torque of 320 Nm and multicone synchronisers on 1st, 2nd and 3rd gear. The gearbox fitted to the 3.0 Multijet is 3 axle (small in size and installed transversely) and can transmit a maximum torque of 400 Nm with a maximum gross weight of 4000 kg, plus 2000-2500 kg for the trailer. The synchronisers are multicone type on all speeds (except 5th and 6th but including reverse) while the cable gear control system ensures comfortable manoeuvrability under all driving conditions. The 100 bhp 2.2 Multijet is instead fitted with a special 5-speed manual gearbox.

Maximum safety

Safe driving: this, in a nutshell, is the concept followed by designers throughout the development of the New Ducato. The aim was to ensure maximum practicality and quality as far as preventive, active and passive safety is concerned. The new model represents a real generation leap in relation to the previous model due to its new safety features. As evidenced by the numerous and sophisticated electronic devices adopted to ensure occupant protection and dynamic vehicle behaviour (from braking to traction).

Braking system

The power-assisted, hydraulic system comprises two cross-over independent circuits and is particularly effective, guaranteeing prompt, smooth braking combined with minimal stopping distances. In particular, throughout the range, the front wheels are fitted with ventilated discs (the diameter range is 280 or 300 mm according to the GVW) while on the rear wheels the discs are solid (diameter of 280 or 300 mm, again according to the GVW). The drum parking brake is also formed inside the disc brakes themselves (Drum in Hat) and the large diameter brake servos (11”) offer an aluminium pump and long travel to ensure a good reserve of pedal travel even under extreme conditions of overheating due to intensive use.

ABS

Apart from offering an excellent braking system, the New Ducato is also equipped as standard with an ABS 8 antilock braking system, the most advanced system of its type currently available. This consists of a hydraulic control unit with 8 solenoids, 4 active sensors and 4 channels with an EBD electronic brakeforce distributor. This device distributes the braking action over all four wheels to prevent locking and ensure full control of the vehicle in all conditions. The system also adapts its operation to wheel grip conditions and brake pad efficiency to reduce pad overheating.

E.S.P. (Electronic Stability Program)

The ESP is an active safety system that cuts in under emergency conditions to control the vehicle in dynamic manoeuvres. In particular, the VDC continually monitors tyre grip in both longitudinal and lateral directions. If the vehicle skids, it cuts in to restore directionality and ride stability. It uses sensors to detect rotation of the vehicle about its vertical axis (yaw speed), vehicle lateral acceleration and the steering wheel angle set by the driver (which indicates the chosen direction). It then goes on to compare these data with parameters generated by a computer and establishes – via a complex mathematical model – whether the vehicle is cornering within its grip limits or if the front or rear is about to skid (understeer or oversteer). To restore the correct trajectory, it then generates a yawing movement in the opposite direction to the movement that gave rise to the instability by braking the appropriate wheel (interior or exterior) individually and reducing engine power (via the throttle).

The following systems are an integral part of the ESP system:

• LAC (Load Adaptive Control). The New Ducato is the first Fiat vehicle to offer this new product. It takes the form of an adaptive load control system that identifies the vehicle’s load conditions while driving, in particular, the total mass and the centre of gravity. As these parameters change, the settings and operating thresholds of the ABS, ASR and ESP functions are adapted.
• Hill Holder. This system assists the driver on hill starts. It operates when the ESP control unit perceives a change in vehicle gradient by means of a longitudinal acceleration sensor located on the cab floor under the passenger seat. During hill starts, the control unit cuts in when first gear is engaged and both brake and clutch pedals are pressed. Front calliper pressure is thus maintained for about 2.5 seconds after the brake pedal is released so that the driver can set off with ease.
• HBA (Hydraulic Brake Assistance). This hydraulic braking assistance automatically increases brake circuit pressure during emergency braking.
• ASR (Anti Slip Regulation). The ASR (Anti Slip Regulation) system, an integral part of the ESP, optimises traction at any speed with the aid of the brakes and engine control. The device computes degree of slip on the basis of wheel rpm detected by the ABS sensors and activates two different control systems to restore grip: when an excessive power demand causes both drive wheels to slip (e.g. in the case of aquaplaning or when accelerating over an unsurfaced, snowy or icy road), it reduces engine torque by means of the engine management control unit; if only one wheel slips (e.g. the inside wheel following acceleration or dynamic load changes), this is automatically braked without the driver touching the brake pedal. The resulting effect is similar to that of a self-locking differential. This allows the New Ducato to get out of trouble easily on road surfaces with low grip.
• MSR (Motor Schleppmoment Regelung). The MSR system, an integral part of the ASR, cuts in in the event of sudden gear changes, while shifting down, to restore torque to the engine and thus prevent excessive driving of the drive wheels that could lead to a loss of vehicle stability, particularly under conditions of low grip.

The most sophisticated devices for total protection

The New Ducato adopts the most sophisticated technical devices and solutions for driver and passenger protection. To ensure this, it underwent 20,000 hours of computer modelling, 120 crash tests, 150 simulations on a HyGe slide and 200 tests on components and subsystems. These numbers demonstrate our engineers’ commitment to making the new model one of the safest commercial vehicles in its segment.

The chassis and body have been designed on the basis of their ability to absorb impact effectively and safely: the result is a rigid vehicle structure in the passenger part (in order to protect the occupants against damage due to items intruding into the vehicle), yet also equipped with areas with high energy absorbing capacity in the areas outside the passenger compartment. It is no coincidence that, compared to the previous model, the new vehicle's torsional rigidity (medium roof, medium wheelbase version) has been increased by 30% from 133,800 kgm/rad to 174,700 kgm/rad, even though the New Ducato is 300 mm longer and the load compartment is 1.5 m3 bigger.

The range of passive safety devices is extremely extensive. In addition to a driver’s airbag (with two activation stages), the New Ducato also offers a full size 120 litre airbag (which may be deactivated) for the passenger (it protects both passengers if the cab is fitted with a two-seater bench) and, as an option, it may also be equipped with sidebags (that protect the chest) and curtain bags that protect the heads of front seat occupants. All these airbags are controlled by a sophisticated electronic control unit that decides which, and how many, protection devices should be activated in the event of an accident by means of various sensors installed on the vehicle. All the seats are also equipped with generous head-restraints and seatbelts which have three-point reels (except for the central seat in the second row of Crew Cab versions).