2004 Fiat Ulysse (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2004 Codes Generation: 2nd Gen (179) 👋 Introduction Market Position Vehicle Segment: Large MPV (Multi-Purpose Vehicle) / Minivan Target Audience: Families,...

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Type: Car

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Sku: 584729

Tags: 2004 Car Cars Fiat Ulysse Ulysse (2nd gen)

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Description

🏷️ Basic Information

Identification

Make:

Model:

Ulysse

Year:

Codes

Generation:

2nd Gen (179)

👋 Introduction

Market Position

Vehicle Segment:

Large MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

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

Competitive Analysis

Key Competitors:

Renault Espace, Citroën C8, Peugeot 807, Lancia Phedra, Ford Galaxy, Volkswagen Sharan.

Key Features

Design Philosophy:

European styling, emphasis on practicality, modular interior, passenger comfort.

Platform Sharing:

Shared platform with Peugeot 807, Citroën C8, and Lancia Phedra (PSA Group).

📋 Manual Details

Coverage Areas

Regions Covered:

European Market

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Factory Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanicals, fuel system, ignition system, exhaust system, lubrication system, cooling system, engine management (ECU, sensors).

Transmission:

Manual and Automatic transmission overhaul, clutch, gearbox, torque converter, electronic control.

Chassis:

Suspension (front and rear), steering system, braking system (ABS, EBD, ESP), wheel alignment.

Electrical Systems:

Body electrical, lighting, instrumentation, power windows, central locking, remote control, audio system, diagnostic connectors (OBD-II).

Body And Trim:

Body panel removal and installation, interior trim, doors, seats, safety restraints (airbags, seatbelts).

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt replacement.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation, wiring diagrams.

Repair And Overhaul:

Detailed step-by-step instructions for component removal, repair, and reassembly (engine, transmission, brakes, suspension, etc.).

Specifications And Data:

Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters.

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical troubleshooting and bodywork repairs.

📊 Manual Specifications

File Format

File Format:

Print Quality

Searchability:

Searchable text enabled

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

RHR (DW10ATED4 / DW10BTED4) - 2.0L HDi Diesel

Engine Type:

Inline 4-cylinder Turbocharged Diesel Common Rail

Displacement:

1997 cc

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

17.6:1

Power Output Hdi:

110 PS (80.9 kW) @ 4000 rpm

Torque Output Hdi:

250 Nm (184 lb-ft) @ 1750 rpm

Performance

Engine Code Petrol:

RFN (EW10J4) - 2.0L Petrol

Engine Type Petrol:

Inline 4-cylinder Naturally Aspirated DOHC

Displacement Petrol:

1997 cc

Power Output Petrol:

136 PS (100 kW) @ 6000 rpm

Torque Output Petrol:

190 Nm (140 lb-ft) @ 4100 rpm

Engine Code Petrol V6:

ES9J4S (3.0 V6 24V) - 3.0L Petrol

Engine Type Petrol V6:

60-degree V6 DOHC

Displacement Petrol V6:

2946 cc

Power Output Petrol V6:

204 PS (149 kW) @ 6000 rpm

Torque Output Petrol V6:

285 Nm (210 lb-ft) @ 3750 rpm

Fuel System

Fuel Delivery Petrol:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Petrol (RON 95 recommended), Diesel

Emission Control Hdi:

Diesel Particulate Filter (DPF) may be present on later models, EGR valve

🔧 Transmission

Standard

Standard Transmission Hdi:

5-speed Manual (ML5C)

Optional

Optional Transmission Petrol:

4-speed Automatic (AL4)

Optional Transmission V6:

4-speed Automatic (DP0)

Features

Transmission Features:

Hydraulic clutch actuation (Manual), Electronic control with limp-home mode (Automatic).

📐 Dimensions

Exterior

Length:

4729 mm

Width:

1905 mm

Height:

1760 mm

Wheelbase:

2823 mm

Interior

Seating Capacity:

7 Seats (standard)

Sliding Doors:

Twin sliding rear doors

Cargo

Cargo Volume All Seats Up:

Approx. 485 litres

Cargo Volume Seats Folded:

Approx. 1800 litres

Weights

Kerb Weight Hdi:

Approx. 1750 kg

Gross Vehicle Weight:

Approx. 2400 kg

🛡️ Safety Features

Ratings

Euroncap Rating:

4 Stars (2003)

Active Features

Standard (Anti-lock Braking System)

Standard (Electronic Brakeforce Distribution)

Optional/Standard on higher trims (Electronic Stability Program)

Traction Control:

Optional/Standard on higher trims (ASR - Traction Control)

Passive Features

Airbags:

Driver, front passenger, side airbags, curtain airbags (depending on trim).

Seatbelts:

3-point seatbelts with pretensioners and load limiters for all seats.

Child Seat Anchors:

ISOFIX points

💡 Technology Features

Infotainment

Infotainment System:

Optional CD player, radio, navigation system (RT3/RT4).

Speaker System:

Standard 4-6 speaker system, optional JBL upgraded system.

Driver Assistance

Cruise Control:

Available on most models

Parking Sensors:

Rear parking sensors available as an option.

Connectivity

Auxiliary Input:

Optional or aftermarket

Bluetooth:

Rare, primarily on later models with upgraded infotainment systems.

🔧 Maintenance

Service Intervals

Oil Change Interval Hdi:

Every 20,000 km or 12 months (whichever comes first)

Oil Change Interval Petrol:

Every 15,000 km or 12 months (whichever comes first)

Cambelt Replacement Hdi:

Every 120,000 km or 6 years (whichever comes first), inspect regularly.

Cambelt Replacement Petrol 2.0:

Every 120,000 km or 6 years (whichever comes first), inspect regularly.

Air Filter Replacement:

Every 40,000 km or 24 months

Fuel Filter Replacement Hdi:

Every 60,000 km or 36 months

Fluid Specifications

Engine Oil Spec Hdi:

API CF/SJ or ACEA B3/B4, SAE 5W-40 (Synthetic)

Engine Oil Spec Petrol:

API SL/SJ or ACEA A3/B3, SAE 5W-40 (Synthetic)

Coolant Type:

Antifreeze/coolant, ethylene glycol based, 50% dilution (e.g., Paraflu UP)

Brake Fluid Type:

DOT 4

Transmission Fluid Manual:

API GL-4, SAE 75W-80

Transmission Fluid Automatic Al4:

LF-3/LF-ATF (ExxonMobil LT 71141 or equivalent)

Known Issues

Common Diesel Issues:

DPF clogging (especially on short-trip use), EGR valve issues, injector problems, turbocharger wear.

Common Petrol Issues:

Ignition coil failure, timing belt tensioner issues, oil leaks from valve cover gasket.

Common Automatic Transmission Issues:

AL4 transmission (PPR) can suffer from solenoid issues, overheating, and jerky shifts. Fluid changes are critical.

Electrical Faults:

Can bus communication issues, dashboard warning lights, power window motor failures, central locking problems.

Suspension And Steering:

Wear in ball joints, tie rod ends, and wishbone bushes leading to knocking noises and poor handling. Power steering pump leaks.

📚 Vehicle History

Brand Heritage

Manufacturer Heritage:

Fiat Auto S.p.A. is an Italian automotive manufacturer founded in 1899, known for innovation and mass-produced vehicles.

Model Evolution

Previous Generation:

1st Gen Fiat Ulysse (1994–2002)

Platform Development:

2nd generation Ulysse based on the PSA EW/ES platform.

Production

Production Years:

2002–2010

Manufacturing Location:

Sevel Nord plant, Hordain, France (joint venture with PSA Group).

🏆 Awards & Recognition

Recognitions

European Car Of The Year Nomination:

The Ulysse (and its platform siblings) were often contenders in European 'Car of the Year' discussions for the MPV segment.