2002 Fiat Ulysse (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2002 Generation: 2nd Generation (2002-2011) Codes Chassis Code: 179 Platform Shared With: PSA Group (Peugeot 807, Citroën C8, Lancia Phedra) 👋...

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Type: Car

Vendor:

Sku: 584732

Tags: 2002 Car Cars Fiat Ulysse Ulysse (2nd gen)

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Description

🏷️ Basic Information

Identification

Make:

Model:

Ulysse

Year:

Generation:

2nd Generation (2002-2011)

Codes

Chassis Code:

Platform Shared With:

PSA Group (Peugeot 807, Citroën C8, Lancia Phedra)

👋 Introduction

Market Position

Segment:

Large MPV (Multi-Purpose Vehicle)

Target Audience:

Families, fleet operators, individuals requiring flexible passenger and cargo space.

Competitive Analysis

Key Competitors:

Ford Galaxy, Volkswagen Sharan, SEAT Alhambra, Renault Espace, Chrysler Voyager (European variants).

Key Features

Design Philosophy:

Practicality, spaciousness, modular interior, shared platform with PSA for cost efficiency and component standardization.

Distinctive Traits:

Flexible seating configurations, large sliding doors for easy access, significant interior volume.

📋 Manual Details

Coverage Areas

Primary Markets:

Europe (primarily)

Vehicle Variants:

All 2002 Fiat Ulysse models

Page Count

Estimated Pages:

Over 1000 pages (typical for comprehensive service manuals)

Manual Type

Type:

Official Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Full coverage including diagnostics, repair, and overhaul for all petrol and diesel variants.

Transmission:

Manual and Automatic transmission service, overhaul, clutch, and drive axles.

Brakes:

Hydraulic system, ABS, EBD, brake pads, discs, calipers, and hydraulic lines.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, and wheel alignment.

Steering:

Power steering system, steering rack, column, and associated components.

Electrical:

Complete wiring diagrams, lighting, ignition system, battery, alternator, starter, and control modules.

Climate Control:

HVAC system, refrigerant circuits, blower motor, evaporator, condenser, and controls.

Body And Chassis:

Sliding door mechanisms, tailgate, and associated trim.

Safety Systems:

Airbag system diagnostics and replacement, seatbelt mechanisms.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, and lubrication.

Troubleshooting:

Diagnostic fault codes, symptom-based troubleshooting guides, and common issue resolution.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation.

Diagnostics:

OBD-II diagnostics, sensor testing, and ECU troubleshooting.

Specifications:

Torque specifications, clearances, timing procedures, and electrical values.

Engine Rebuild:

Detailed procedures for engine disassembly, inspection, and reassembly.

Bodywork Repair:

Minor body panel alignment and repair guidance.

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including electrical system diagnostics.

📊 Manual Specifications

File Format

Format:

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable for offline use and workshop reference.

Print Quality

Image Resolution:

High-resolution images, diagrams, and schematics.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.0 L (1997 cc) EW10 J4 I4 (Petrol), 2.0 L (1997 cc) DW10 TD/ATED I4 (Diesel), 2.0 L (1997 cc) DW10 BTED4 I4 (Diesel - HDi), 2.2 L (2179 cc) DW12 TED4 I4 (Diesel - HDi)

Performance

2.0I 16V (Ew10 J4) Power:

136 PS (134 hp; 100 kW) at 6000 rpm

2.0I 16V (Ew10 J4) Torque:

190 Nm (140 lb-ft) at 4100 rpm

2.0 Hdi 110 (Dw10 Td) Power:

109 PS (108 hp; 80 kW) at 4000 rpm

2.0 Hdi 110 (Dw10 Td) Torque:

250 Nm (184 lb-ft) at 1750 rpm

2.0 Hdi 136 (Dw10 Bted4) Power:

136 PS (134 hp; 100 kW) at 4000 rpm

2.0 Hdi 136 (Dw10 Bted4) Torque:

310 Nm (229 lb-ft) at 2000 rpm

2.2 Hdi 16V (Dw12 Ted4) Power:

128 PS (126 hp; 94 kW) at 4000 rpm

2.2 Hdi 16V (Dw12 Ted4) Torque:

314 Nm (231 lb-ft) at 1750 rpm

Fuel System

Petrol Injection:

Multi-point Fuel Injection (MPI)

Diesel Injection:

Common Rail Direct Injection (CRDi) with turbocharging and intercooler

Emissions Standard:

Euro 3 (for most variants)

🔧 Transmission

Standard

Gearbox Options:

5-speed Manual Transmission (often with M56 gearbox code), 4-speed Automatic Transmission (often with 4HP20 gearbox code)

Optional

Automatic Transmission Provider:

ZF (4HP20)

Features

Automatic Features:

Adaptive shift logic, torque converter lock-up

Fluid Specification

Manual Fluid:

API GL-4, SAE 75W-80 or 75W-90 (check manual for exact spec)

Automatic Fluid:

ZF LifeguardFluid 5 (or equivalent ATF, e.g., Mopar 7176)

📐 Dimensions

Exterior

Length:

Approx. 4700 mm (185.0 in)

Width:

Approx. 1860 mm (73.2 in) (excluding mirrors)

Height:

Approx. 1760 mm (69.3 in)

Wheelbase

Wheelbase:

Approx. 2820 mm (111.0 in)

Cargo

Cargo Volume Seats Up:

Varies significantly with seating configuration, typically 300-500 liters behind the third row.

Cargo Volume Seats Down:

Up to ~2000 liters with rear seats folded or removed.

Weights

Gross Vehicle Weight:

Approx. 2500-2700 kg (depending on engine and configuration)

Towing Capacity:

Typically around 1800 kg (braked trailer)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 Stars (for the 2nd generation, achieved with prior PSA models)

Active Features

Standard Anti-lock Braking System

Standard Electronic Brakeforce Distribution

Optional Electronic Stability Programme (ESP) on some models

Passive Features

Airbags:

Front airbags for driver and passenger, optional side airbags and curtain airbags.

Seatbelts:

Three-point seatbelts with pre-tensioners for all occupants, ISOFIX child seat anchorage points.

Child Safety:

Rear door child locks.

💡 Technology Features

Infotainment

Head Unit:

Factory fitted radio/CD player, often with integrated display. Limited connectivity by modern standards.

Speaker System:

Basic 4-6 speaker system standard. Higher trims may offer better audio.

Driver Assistance

Cruise Control:

Available as an option on many models.

Parking Sensors:

Rear parking sensors available on higher trim levels or as an option.

Connectivity

Bluetooth:

Rarely factory fitted on 2002 models. Aftermarket solutions are common.

Not available from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 20,000 km (12,500 miles) or 1 year, whichever comes first (for most petrol/diesel engines, check manual for specifics).

Timing Belt Replacement:

120,000 km (75,000 miles) or 5 years for 2.0 HDi and 2.2 HDi engines (critical replacement item).

Air Filter Replacement:

Every 40,000 km (25,000 miles) or 2 years.

Cabin Filter Replacement:

Every 20,000 km (12,500 miles) or 1 year.

Fluid Specifications

Engine Oil Type:

Fully Synthetic 5W-30 or 5W-40 (ACEA A3/B4 or specific Fiat/PSA approvals, refer to manual).

Coolant Type:

Antifreeze/coolant, ethylene glycol-based, OAT (Organic Acid Technology) type, colour may vary (e.g., blue/green or pink/red). Check for Fiat 9.55523 specification.

Brake Fluid Type:

DOT 4

Known Issues

Diesel Particulate Filter:

DPF regeneration issues on HDi engines, especially with short journeys. May require manual regeneration or cleaning.

Diesel Injectors:

Common Rail injector issues, particularly on higher mileage engines. Diagnosis and replacement can be costly.

Electrical Gremlins:

Can suffer from minor electrical faults, often related to body control modules or multiplexed systems. Wiring diagrams are crucial.

Sliding Doors:

Electric sliding door mechanisms can be prone to faults due to wear and tear, moisture ingress, or motor failure. Manual override is usually present.

Suspension Wear:

Worn suspension bushes, ball joints, and anti-roll bar links are common due to the vehicle's weight and usage.

📚 Vehicle History

Brand Heritage

Fiat Heritage:

Fiat, an Italian manufacturer with a long history in automotive production, known for innovative design and practical vehicles.

Model Evolution

First Generation:

Fiat Ulysse (1994-2002), also a joint venture with PSA.

Second Generation:

2002-2011, based on the PSA platform sharing with Peugeot 807, Citroën C8, and Lancia Phedra. Known for improved styling and technology.

Third Generation:

Launched in 2014, based on a different platform (Fiat Freemont derived).

Production

Manufacturing Location:

Sevel S.p.A. factory in Hordain, France (shared with PSA and Lancia).

🏆 Awards & Recognition

Recognitions

Industry Awards:

As part of the PSA/Lancia joint venture, it benefits from the established reputation of these platforms in the MPV segment, often praised for practicality and interior space.