🏷️ Basic Information

Make:

FIAT

Model:

SCUDO

Year:

2004

Engine:

2.0 HDI 16V

Engine Code:

Likely derived from the DW10 family, common for PSA/Ford/Fiat collaboration

Chassis Code:

Fiat Ulysse / Peugeot 807 / Citroen C8 / Lancia Phedra platform basis, though SCUDO has its own specific design

👋 Introduction

Vehicle Segment:

Light Commercial Vehicle (LCV) / Panel Van / MPV

Key Competitors 2004:

Renault Trafic, Ford Transit, Peugeot Expert, Citroën Jumpy, Volkswagen Transporter

Vehicle Purpose:

Versatile platform for cargo transport, passenger carrying (MPV variants), and specialized conversions.

Target Audience:

DIY mechanics, independent repair shops, fleet maintenance personnel

Benefit To Owner:

Enables self-sufficiency in maintenance and repair, saving time and money, and ensuring proper vehicle upkeep.

📋 Manual Details

Regions Covered:

Global (as per product description's broad applicability)

Estimated Page Count:

Extensive (based on 'full service repair manual' and detailed coverage claims, likely 800+ pages)

Manual Type:

Full Service and Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Full disassembly and reassembly, internal components (pistons, rings, crankshaft, camshafts), timing systems, cooling, lubrication

Engine Electrical:

Ignition system, starter, alternator, sensors (crankshaft position, camshaft position, temperature, pressure), ECU diagnosis and wiring diagrams

Fuel System:

Common Rail Diesel Injection (HDI), fuel pump, injectors, fuel filter replacement, fuel pressure regulation, emissions control

Transmission:

Manual gearbox (likely 5 or 6-speed), clutch operation and replacement, gearbox oil specifications and replacement, drive shafts

Brakes:

Front and rear disc brake systems, ABS operation, brake fluid replacement, caliper service, pad and rotor replacement

Suspension:

Front MacPherson strut, rear torsion beam or independent suspension (depending on variant), shock absorber and spring replacement, wheel alignment specifications

Steering:

Power steering system (hydraulic), steering rack and column components, fluid type and replacement

HVAC:

Air conditioning system service, refrigerant types, cabin filter replacement, heater core and evaporator service

Bodywork:

Exterior panel removal and installation (doors, hood, tailgate), interior trim, glass replacement, sealant and weatherstripping

Electrical Body:

Lighting systems (headlights, taillights, interior), power windows, central locking, wipers, horn, fuse and relay identification

Engine Management Diagnostics:

In-depth coverage of ECU diagnostics, sensor readings, actuator testing, and common fault codes related to the 2.0 HDI engine.

Maintenance:

Scheduled maintenance tasks, oil and filter changes, fluid level checks and top-ups, belt replacement, spark plug replacement (if applicable for gasoline variants, not for this HDI)

Troubleshooting:

Diagnostic procedures for common faults, symptom-based fault finding, error code interpretation (OBD-II)

Repair:

Detailed step-by-step repair instructions for all major and minor components, from engine rebuilds to body panel repairs

Diagnostics:

ECU diagnostics, sensor testing, actuator testing, wiring harness continuity checks

Component Replacement:

Replacement procedures for common wear items like brakes, suspension components, filters, belts, and fluids

Wheel Alignment:

Detailed specifications for front and rear wheel alignment parameters (camber, caster, toe) to ensure proper handling and tire wear.

Airbag System Service:

Procedures for checking airbag system integrity, fault finding in the SRS module, and safe replacement of components.

Depth Of Information:

Comprehensive: Covers everything from basic maintenance to full engine and transmission overhauls. Includes torque specifications, assembly sequences, and calibration procedures.

📊 Manual Specifications

File Type:

PDF

Printability:

Full Printable (allows for printing of individual pages or sections)

Binding:

Digital (Downloadable PDF)

Paper Considerations:

N/A (Digital format avoids paper wear and tear)

Zoom Functionality:

YES (Allows for zooming in on detailed diagrams and text)

Delivery:

Instant Download

Requirements:

Adobe PDF Reader & WinZip

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder Diesel with Turbocharger and Intercooler (HDI - High-Pressure Direct Injection)

Displacement:

1997 cc (2.0 Liters)

Horsepower:

Approximately 94-110 PS (70-81 kW) depending on specific tuning and turbo configuration.

Torque:

Approximately 200-240 Nm (148-177 lb-ft) at low RPMs, typical for efficient diesel operation.

Injection Type:

Common Rail Direct Injection (Bosch or similar system)

Emissions Control:

Euro 3 or Euro 4 compliant (depending on specific market and build date), likely with EGR (Exhaust Gas Recirculation).

ECU System:

Proprietary Fiat or shared PSA ECU, requiring diagnostic tools for advanced troubleshooting.

Coolant Type:

Ethylene Glycol based coolant, typically a long-life formula (e.g., Paraflu UP)

Oil Type And Viscosity:

Likely 5W-40 or 10W-40 synthetic/semi-synthetic diesel engine oil meeting ACEA B3/B4 specifications.

🔧 Transmission

Gearbox Type:

5-speed Manual Transmission

Automatic Transmission:

Less common for this specific engine/year, but possible in some MPV variants or later updates.

Gear Ratios:

Specific ratios would be detailed in the manual, optimized for load carrying and fuel economy.

Transmission Fluid:

GL-4 or GL-5 specification gear oil, specific viscosity will be listed in the manual.

📐 Dimensions

Length:

Varies by wheelbase and body style, typically around 4.2-4.7 meters for standard and long versions.

Width:

Approximately 1.8-1.9 meters (excluding mirrors).

Height:

Approximately 1.8-1.9 meters.

Load Volume:

Significant, designed for commercial use, offering ample cubic meters of cargo space.

Gross Vehicle Weight Rating Gvwr:

Typically in the 2000-2500 kg range, depending on configuration.

Curb Weight:

Varies based on configuration, likely 1500-1800 kg.

🛡️ Safety Features

Euro Ncap Rating:

Varies by year and specific test conditions, generally aimed at commercial vehicle safety standards of the era. Likely 3-4 stars for adult occupant protection in earlier tests.

ABS:

Anti-lock Braking System (standard on most models)

Esp:

Electronic Stability Program (optional or standard on higher trims/later models)

Airbags:

Driver and front passenger airbags (standard), side airbags (optional on some variants)

Seatbelts:

3-point inertia reel seatbelts with pre-tensioners

💡 Technology Features

Audio System:

Factory fitted radio/CD player with basic controls, potentially steering wheel mounted audio controls on higher trims.

Parking Assistance:

Rear parking sensors may be an option on some models.

Auxiliary Input:

Limited for this era, typically no standard USB or Bluetooth connectivity unless an aftermarket unit is fitted.

🔧 Maintenance

Oil And Filter Change:

Typically every 15,000-20,000 km or 12 months, whichever comes first. Refer to manual for specific diesel particulate filter regeneration cycles if equipped.

Timing Belt Replacement:

Crucial for HDI engines. Typically around 120,000-150,000 km or 5-7 years. Failure can cause catastrophic engine damage. Manual will specify interval and procedure.

Fuel Filter Replacement:

Recommended every 30,000-40,000 km for diesel engines to prevent injector contamination.

Coolant Capacity:

Approx. 7.5-8.0 liters. Specific type and concentration required.

Brake Fluid Type:

DOT 4 or DOT 4 LV (Low Viscosity)

Common Problems:

Timing belt tensioner failure, EGR valve clogging, DPF regeneration issues (if fitted), injector issues due to fuel contamination, turbocharger wear.

Maintenance Tips:

Regularly check oil and coolant levels, adhere strictly to timing belt replacement intervals, use high-quality diesel fuel and fuel additives if necessary.

📚 Vehicle History

Fiat Commercial Vehicles:

Fiat has a long and established history in the commercial vehicle sector, dating back to the early 20th century with vehicles like the Fiat 626.

Scudo Generation 2004:

This represents the second generation of the Fiat Scudo, launched in 2004, which was developed in collaboration with PSA Peugeot Citroën (as part of the Sevel Sud joint venture). It shares its platform with the Citroën Jumpy/Dispatch and Peugeot Expert.

Manufacturing Location:

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

🏆 Awards & Recognition

Commercial Vehicle Awards:

While specific awards for the 2004 Scudo might be scarce, the platform it shares with the Expert/Jumpy often received positive reviews for practicality and versatility in the LCV segment.