Fiat Ulysse 2.2i 16V 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2002 Engine Variant: 2.2i 16V Codes Engine Code Range: Likely ES9A or similar EW12J4 variant, requires manual verification Chassis Code: Type...

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Taper: Car

Distributeur:

UGS: 584705

Mots clés: 2002 Car Cars Fiat Ulysse

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Model:

Ulysse

Year:

Engine Variant:

2.2i 16V

Codes

Engine Code Range:

Likely ES9A or similar EW12J4 variant, requires manual verification

Chassis Code:

Type 171/220

👋 Introduction

Market Position

Segment:

Large MPV (Multi-Purpose Vehicle)

Platform Sharing:

Shared platform with Citroën C8, Peugeot 807, and Lancia Phedra

Competitive Analysis

Key Competitors:

Ford Galaxy, Volkswagen Sharan, Renault Espace, Chrysler Voyager

Key Features

Vehicle Type:

Spacious and versatile family MPV

Unique Selling Points:

Comfortable ride, flexible seating configurations, practical interior space, European styling

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

Page Count

Page Count:

Est. 1500-2000 pages (typical for comprehensive workshop manuals)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block, pistons, connecting rods, crankshaft, camshafts, valve train

Engine Management:

Fuel injection, ignition system, sensors, actuators, ECU diagnostics, emission control systems

Transmission:

Manual and Automatic transmission overhaul, clutch, gearbox internals, torque converter (if applicable), shift mechanisms

Drivetrain:

Front-wheel drive system, drive shafts, CV joints, differential

Brakes:

Front and rear brake systems, ABS, EBD, hydraulic circuits, calipers, discs, pads, brake booster, master cylinder

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, alignment specifications

Steering:

Power steering system, steering rack, column, tie rods, hydraulic pump

Electrical System:

Battery, charging system, starter, lighting, wipers, horn, central locking, power windows, mirrors, fuses, relays

Body And Chassis:

Body panel removal and installation, interior trim, exterior trim, doors, tailgate, hood, bumpers, chassis repair

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant circuits, components

Comfort And Convenience:

Seating systems, sunroof, cruise control, interior lighting

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt replacement

Diagnostics:

Troubleshooting guides, symptom-based diagnosis, fault code interpretation, electrical circuit testing

Repair Rebuild:

Step-by-step repair procedures for all major vehicle systems, component replacement, major overhauls

Adjustment:

Valve clearance adjustment, handbrake adjustment, headlight aim adjustment

Installation Replacement:

Component replacement (e.g., alternator, starter, fuel pump), body panel replacement, interior trim installation

Specifications:

Detailed torque specifications, clearances, fluid capacities, electrical component data

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics)

Target Audience:

Professional mechanics, experienced DIY enthusiasts, automotive technicians

📊 Manual Specifications

File Format

File Type:

Searchable:

Yes (if text-based PDF)

Printable:

Print Quality

Resolution:

High resolution for clear diagrams and text

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-4 Cylinder, DOHC, 16 Valves

Displacement:

2179 cc

Bore X Stroke:

87.0 mm x 90.6 mm (typical for ES9A/EW12J4)

Compression Ratio:

10.5:1 (typical)

Performance

Horsepower:

136 PS (134 hp; 100 kW) at 5300 rpm (typical)

Torque:

207 Nm (153 lb-ft) at 3250 rpm (typical)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (Petrol)

Catalytic Converter:

Standard

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Optional

Transmission Type:

4-speed Automatic (likely AL4 or similar)

Features

Clutch Type:

Hydraulically operated single dry plate clutch (Manual)

Transmission Fluid Spec:

Refer to manual for specific type (e.g., MTF for manual, ATF Dexron III/VI for automatic)

📐 Dimensions

Exterior

Length:

Approx. 4700 mm (185.0 in)

Width:

Approx. 1800 mm (70.9 in)

Height:

Approx. 1750 mm (68.9 in)

Wheelbase:

Approx. 2820 mm (111.0 in)

Interior

Seating Capacity:

7 Seats (2+3+2 configuration typical)

Cargo Volume Seats Up:

Varies significantly with seat configuration, typically around 200-300 litres with all seats in use.

Cargo Volume Seats Down:

Can exceed 1500 litres with rear seats folded/removed.

Weights

Curb Weight:

Approx. 1600-1750 kg (3527-3858 lbs)

Gross Vehicle Weight Rating:

Refer to vehicle placard

🛡️ Safety Features

Ratings

Euroncap Rating:

Likely 4 or 5 stars for this generation (based on sibling models)

Active Features

Standard

Standard (Electronic Brakeforce Distribution)

Traction Control:

Optional (ASR - Antipatinage)

Optional on higher trims or later models

Passive Features

Airbags:

Front airbags, side airbags, curtain airbags (depending on trim level)

Seatbelts:

3-point seatbelts with pretensioners for all occupants, ISOFIX child seat anchors

Child Safety:

Rear door child locks, ISOFIX anchor points

💡 Technology Features

Infotainment

Infotainment System:

Basic radio/cassette or CD player with standard speaker system. Optional premium audio available on higher trims.

Navigation:

Optional factory fitted navigation system available on some models.

Driver Assistance

Cruise Control:

Optional

Parking Sensors:

Optional rear parking sensors.

Connectivity

Aux Input:

Rarely standard, typically aftermarket additions.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 15,000 km (9,300 miles) or 1 year, whichever comes first (refer to manual for precise interval and oil type).

Timing Belt Interval:

Crucial for the 2.2i 16V engine. Typically around 120,000 km (75,000 miles) or 5-6 years. Check manual for exact interval and replacement of tensioners/water pump.

Air Filter Replacement:

Every 30,000 km (18,600 miles) or 2 years.

Cabin Filter Replacement:

Every 15,000 km (9,300 miles) or 1 year.

Fluid Specifications

Engine Oil Type:

Fully synthetic 5W-40 or 5W-30 meeting ACEA A3/B4 or API SN/CF specifications. Confirm with manual.

Coolant Type:

OAT (Organic Acid Technology) coolant, typically pink or red. Refer to manual for specific Fiat specification (e.g., Paraflu UP).

Brake Fluid Type:

DOT 4

Known Issues

Common Issues Engine:

Timing belt tensioner failure (potential catastrophic engine damage if not replaced on schedule), occasional oil leaks, carbon buildup on intake valves.

Common Issues Transmission:

Automatic transmission (AL4) can be prone to hydraulic control issues, solenoid failures, and torque converter problems if fluid is not maintained.

Common Issues Electrical:

Intermittent electrical faults, issues with body control modules (BCM), power window regulators, and central locking actuators are not uncommon in vehicles of this age.

Common Issues Suspension Steering:

Worn suspension bushes, noisy wheel bearings, and power steering fluid leaks can occur with age and mileage.

Common Issues HVAC:

A/C compressor failures, blend door actuator malfunctions, and refrigerant leaks.

📚 Vehicle History

Brand Heritage

Brand Focus:

Fiat is a long-standing Italian automobile manufacturer known for its diverse range of vehicles, including small cars, family cars, and commercial vehicles.

Model Evolution

Generation Context:

The Fiat Ulysse is part of the second generation (2002-2010) of this large MPV, a collaborative project with PSA Peugeot Citroën. This generation replaced the original Ulysse (1994-2002).

Platform Basis:

Based on the PSA platform shared with Citroën Evasion, Peugeot 806, and Lancia Zeta.

Production

Manufacturing Location:

Sevel Sud plant, Val di Sangro, Italy

Production Years:

2002-2010 (for this generation)