🏷️ Basic Information

Make:

Fiat

Model:

Ulysse

Year:

2003

Chassis Code:

220

Generation:

2nd Generation (1999-2002 facelift)

👋 Introduction

Segment:

Large MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

Families, fleet operators seeking versatile and spacious transportation.

Key Competitors:

Citroën C8, Peugeot 807, Lancia Phedra, Renault Espace (4th gen), Ford Galaxy (Mk2), Volkswagen Sharan (7M).

Vehicle Platform:

Developed under the Sevel (Société Européenne de Véhicules) joint venture with PSA Peugeot Citroën, sharing platform with the Citroën C8, Peugeot 807, and Lancia Phedra.

Design Philosophy:

Emphasis on practicality, spaciousness, and modularity for passenger and cargo carrying.

📋 Manual Details

Engine Variants Covered:

2.0 L (1998 cc) EW10J4 I4, 2.0 L (1997 cc) turbo I4, 2.2 L (2179 cc) EW12J4 I4, 2.0 L (1997 cc) DW10ATED HDi I4 Diesel, 2.2 L (2179 cc) DW12TED4 HDi I4 Diesel

Transmission Types Covered:

5-speed Manual, 4-speed Automatic (AL4)

Total Pages:

600+

Type:

Service and Repair Manual

Language:

English

Format:

Digital PDF

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train, timing system, lubrication system, cooling system, fuel delivery system, emission control system.

Engine Management:

Ignition system, fuel injection system (MPI/Common Rail), sensors (crankshaft position, camshaft position, MAF, MAP, coolant temperature, lambda, knock, etc.), actuators (injectors, throttle body, EVAP purge valve, EGR valve), ECU diagnostics, OBD-II system.

Transmission Manual:

Clutch operation, gearbox assembly, gear shifting mechanism, driveshafts, differentials.

Transmission Automatic:

Transmission fluid, torque converter, valve body, planetary gear sets, hydraulic control system, electronic control unit (TCU), shift solenoids, cooling system integration.

Suspension:

Front suspension (McPherson struts, wishbones, anti-roll bar), rear suspension (torsion beam/independent, shock absorbers, springs), wheel alignment specifications.

Brakes:

Front and rear disc brakes, brake calipers, master cylinder, brake booster, ABS system (hydraulic unit, wheel speed sensors, control module), parking brake.

Steering:

Power steering system (hydraulic pump, steering rack, fluid), steering column, wheel angle sensor.

Electrical System:

Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior), instrument cluster, power windows, central locking, body control module (BCM), comfort systems.

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant, dryer), heater core, blower motor, climate control unit, cabin air filter.

Body And Chassis:

Body panels, doors, hood, tailgate, interior trim, seats, glass, chassis components, corrosion protection.

Maintenance Procedures:

Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flush and fill, brake fluid flush, transmission fluid change, timing belt/chain inspection/replacement, serpentine belt replacement, drive axle boot replacement, battery testing and replacement.

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical circuit testing, component testing procedures, common fault diagnosis.

Repair Procedures:

Engine overhaul (partial/full), cylinder head removal/installation, transmission removal/installation, brake caliper overhaul, suspension component replacement, steering rack replacement, starter/alternator replacement, HVAC component replacement, body panel repair/replacement.

Technical Specifications:

Torque specifications for all fasteners, fluid capacities and types, engine timing specifications, valve clearances, diagnostic parameter ranges, wear limits.

Depth:

Comprehensive, covering everything from basic scheduled maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and electrical schematics.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text content for quick information retrieval.

Resolution:

High-resolution images and diagrams for clarity.

Printability:

Printable pages for easy workshop use.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code Petrol 2.0:

EW10J4

Engine Displacement Petrol 2.0:

1997 cc

Engine Configuration Petrol 2.0:

Inline 4-cylinder, DOHC, 16-valve

Engine Code Petrol 2.0 Turbo:

2.0 Turbo (derived from XU/PSA family)

Engine Displacement Petrol 2.0 Turbo:

1998 cc

Engine Configuration Petrol 2.0 Turbo:

Inline 4-cylinder, SOHC, 8-valve

Engine Code Petrol 2.2:

EW12J4

Engine Displacement Petrol 2.2:

2179 cc

Engine Configuration Petrol 2.2:

Inline 4-cylinder, DOHC, 16-valve

Engine Code Diesel 2.0 Hdi:

DW10ATED

Engine Displacement Diesel 2.0 Hdi:

1997 cc

Engine Configuration Diesel 2.0 Hdi:

Inline 4-cylinder, DOHC, 16-valve, Turbocharged Common Rail Diesel

Engine Code Diesel 2.2 Hdi:

DW12TED4

Engine Displacement Diesel 2.2 Hdi:

2179 cc

Engine Configuration Diesel 2.2 Hdi:

Inline 4-cylinder, DOHC, 16-valve, Turbocharged Common Rail Diesel

Horsepower 2.0 Petrol:

136 hp (134 bhp; 100 kW) @ 6000 rpm

Torque 2.0 Petrol:

192 Nm (142 lb-ft) @ 4100 rpm

Horsepower 2.0 Turbo Petrol:

150 hp (148 bhp; 110 kW) @ 5500 rpm

Torque 2.0 Turbo Petrol:

235 Nm (173 lb-ft) @ 2000 rpm

Horsepower 2.2 Petrol:

160 hp (158 bhp; 118 kW) @ 5800 rpm

Torque 2.2 Petrol:

217 Nm (160 lb-ft) @ 3800 rpm

Horsepower 2.0 Hdi:

109 hp (108 bhp; 80 kW) @ 4000 rpm

Torque 2.0 Hdi:

270 Nm (199 lb-ft) @ 1750 rpm

Horsepower 2.2 Hdi:

130 hp (128 bhp; 96 kW) @ 4000 rpm

Torque 2.2 Hdi:

314 Nm (231 lb-ft) @ 2000 rpm

Fuel Type Petrol:

Unleaded gasoline (95 RON recommended)

Fuel Type Diesel:

Diesel fuel

Injection System Petrol:

Multi-point fuel injection (MPI)

Injection System Diesel:

Bosch Common Rail Direct Injection (CRDI)

Emissions Standards:

Euro 3 (for most variants)

🔧 Transmission

Manual Gearbox:

5-speed Manual (e.g., BE4 series for some variants)

Automatic Gearbox:

4-speed Automatic (AL4/DP0)

Clutch Type:

Hydraulically operated single dry plate clutch

Automatic Features:

Electronic control, Sport/Snow modes available on some AL4 units.

📐 Dimensions

Length:

4719 mm (185.8 in)

Width:

1804 mm (71.0 in)

Height:

1745 mm (68.7 in)

Wheelbase:

2823 mm (111.1 in)

Seating Capacity:

7 seats (typically 2+3+2 configuration)

Interior Flexibility:

Sliding and removable rear seats, foldable third-row seats.

Cargo Volume All Seats Up:

~397 liters (14.0 cu ft)

Cargo Volume Rear Seats Folded:

~739 liters (26.1 cu ft)

Cargo Volume Max:

~2300 liters (81.2 cu ft)

Curb Weight Approx:

1600-1800 kg (3527-3968 lbs) depending on engine and specification

Gross Vehicle Weight Rating Approx:

2400-2500 kg (5291-5512 lbs)

🛡️ Safety Features

Euro Ncap Rating 2003:

4 out of 5 stars (based on similar platform vehicles of the era)

ABS:

Standard Anti-lock Braking System

Ebs:

Optional Electronic Brake-force Distribution (EBD)

Esp:

Optional Electronic Stability Program (ESP) / VDC

Traction Control:

Available Traction Control System (TCS)

Airbags Standard:

Driver and front passenger airbags, front side airbags.

Airbags Optional:

Rear side airbags, curtain airbags.

Seatbelts:

3-point seatbelts with pretensioners for all seats.

Child Seat Anchors:

ISOFIX mounting points.

💡 Technology Features

Audio System:

Factory-fitted radio/CD player with steering wheel controls, optional CD changer, available navigation system.

Display:

Multi-function display for trip computer, audio, and climate control information.

Cruise Control:

Available cruise control system.

Parking Sensors:

Optional rear parking sensors.

Rain Sensing Wipers:

Optional rain-sensing automatic wipers.

Automatic Headlights:

Optional automatic headlamp activation.

Bluetooth:

Not standard, potentially available as an aftermarket option or early OEM integration on later facelift models.

Aux Input:

Likely available on factory audio systems.

🔧 Maintenance

Oil Change Interval:

Every 20,000 km or 1 year, whichever comes first.

Air Filter Replacement Interval:

Every 40,000 km or 2 years.

Spark Plug Replacement Interval:

Every 60,000 km or 4 years (for Iridium/Platinum plugs).

Timing Belt Replacement Interval:

Every 120,000 km or 5 years (critical interval, check manual for exact type).

Oil Change Interval:

Every 20,000 km or 1 year, whichever comes first.

Fuel Filter Replacement Interval:

Every 40,000 km or 2 years.

Timing Belt Replacement Interval:

Every 120,000 km or 5 years (critical interval for DW12TED4, DW10ATED might have chain or belt depending on variant, verify).

Engine Oil Petrol:

API SN/CF, ACEA A3/B4, SAE 5W-40 or 10W-40 (refer to manual for specific engine variant and climate).

Engine Oil Diesel Hdi:

API CF/SJ, ACEA B4/A3, SAE 5W-40 (low SAPS recommended for DPF equipped models, if applicable).

Coolant:

Ethylene glycol-based antifreeze, OAT type, 50% mix with demineralized water.

Brake Fluid:

DOT 4.

Power Steering Fluid:

ATF Dexron II or III, or specific PSA fluid.

Automatic Transmission Fluid:

ESSO LT 71141 or equivalent.

Common Problems Petrol Ew Engines:

Oil leaks from rocker cover gasket, intake manifold gasket failures, VANOS/VVT solenoid issues (if equipped), timing belt tensioner failure leading to belt slip/jump.

Common Problems Diesel Hdi:

EGR valve clogging, turbocharger actuator issues, injector seal leaks, glow plug failure, timing belt tensioner/pulley wear.

Common Problems Automatic Al4:

Solenoid wear, valve body issues, torque converter clutch judder, overheating due to inadequate cooling.

Common Problems Electrical:

Faulty window regulators, central locking issues, dashboard warning light malfunctions, CAN bus communication errors.

Common Problems Suspension Brakes:

Front suspension wear (ball joints, drop links), rear torsion beam bushes, brake disc warping, ABS sensor failures.

📚 Vehicle History

Fiat Heritage:

Fiat is an Italian automotive manufacturer with a long history dating back to 1899, known for its innovation in small cars and practical vehicles.

First Generation Ulysse:

The first generation Fiat Ulysse (Type 170) was launched in 1994, also as part of the Sevel MPV project with PSA.

Second Generation Ulysse:

The second generation (Type 220) was introduced in 1999 and received a facelift in 2002, which this manual covers. This generation saw updated styling, engines, and interior features.

Production Period 2Nd Gen:

1999-2002 (pre-facelift), 2002-2010 (facelifted model covered by this manual)

Manufacturing Plant:

Sevel Sud plant in Val di Sangro, Italy.

🏆 Awards & Recognition

Mpv Segment Awards:

The Fiat Ulysse and its Sevel platform siblings have been well-regarded in the MPV segment for their practicality and interior space, though specific individual awards for the 2003 model year are not prominently documented outside of general segment reviews.