🏷️ Basic Information

Make:

Fiat

Model:

Ulysse

Year:

2002

Engine Variant:

2.2 HDi With particle filter

Engine Code Hdi:

Likely derived from PSA's DW12 engine family, specific Fiat code may vary but often shared with Peugeot/Citroën models.

👋 Introduction

Market Position:

The Fiat Ulysse, particularly in its 2.2 HDi iteration, was positioned as a versatile family MPV (Multi-Purpose Vehicle) / minivan, competing in a segment dominated by European and Japanese manufacturers. It offered practicality, comfort, and diesel efficiency, often sharing platforms and powertrains with contemporary PSA Peugeot Citroën models.

Competitive Analysis:

Key competitors in 2002 included the Renault Espace, Ford Galaxy, Volkswagen Sharan, Seat Alhambra, Citroën C8, Peugeot 807, and Chrysler Voyager. The Ulysse aimed to differentiate through Italian styling flair (though often sharing body shells) and Fiat's specific feature packaging and pricing.

Key Features:

Spacious interior, flexible seating configurations, strong diesel torque from the 2.2 HDi engine, potential for a diesel particulate filter (DPF) for reduced emissions, comfortable ride, good for families and long journeys.

📋 Manual Details

Coverage Areas:

Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Clutch, Transmission (Manual/Automatic), Driveline, Suspension (Front/Rear), Steering, Brakes (ABS/EBD), Body Electrical System, Climate Control, Body & Chassis, Interior Components, Exterior Components, Diagnostic Trouble Codes (DTCs), Troubleshooting, Maintenance Procedures, Wiring Diagrams.

Page Count:

Estimated 1500+ pages (typical for comprehensive workshop manuals of this era and complexity)

Manual Type:

Workshop Manual / Service and Repair Manual

Language:

Likely English, with potential for other European languages depending on the source

Format:

Digital (PDF) - searchable, printable

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, inspection, and overhaul of the 2.2 HDi engine. Includes cylinder head, pistons, connecting rods, crankshaft, camshafts, valve train, engine block, seals, gaskets, timing system (belt/chain), oil pump, oil pan.

Engine Management:

Fuel injection system (common rail), glow plug system, exhaust gas recirculation (EGR), turbocharger system, sensors (MAP, MAF, Lambda, Crankshaft Position, Camshaft Position), actuators, engine control unit (ECU) diagnosis and parameters, particle filter regeneration and management.

Transmission Manual:

Clutch operation, gearbox disassembly, assembly, inspection, repair, gear shift mechanism, lubrication, input/output shafts, bearings, synchronizers.

Transmission Automatic:

If applicable, coverage would include hydraulic systems, torque converter, valve body, electronic control unit, clutch packs, planetary gears, cooling, fluid types, and basic troubleshooting.

Brakes:

Hydraulic system, brake fluid specifications, master cylinder, brake booster, front and rear brake calipers, brake pads, brake discs, brake lines, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) operation, bleeding procedures.

Suspension Steering:

Front and rear suspension components (struts, shock absorbers, springs, control arms, bushings), wheel bearings, steering rack, power steering system (hydraulic/electric), steering column, alignment specifications.

Electrical System:

Battery, starter motor, alternator, lighting (headlights, taillights, interior), fuses, relays, wiring harnesses, body control module (BCM), power windows, central locking, mirrors, wipers, horn, dashboard instruments, diagnostic connectors (OBD-II).

Climate Control HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant R134a, drier), heating system, ventilation, blower motor, control panel, cabin air filter replacement.

Bodywork Chassis:

Body panel removal/installation, doors, hood, tailgate, bumpers, glass replacement, interior trim, underbody components, rust prevention, structural repair guidelines.

Maintenance Procedures:

Oil and filter change, air filter replacement, fuel filter replacement, cabin filter replacement, coolant flush and replacement, spark plug replacement (if applicable, though unlikely for HDi), brake fluid change, gearbox oil change, differential oil change (if applicable), belt inspection/replacement, tire rotation, battery maintenance.

Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues. Includes symptom-based troubleshooting, electrical circuit tracing, fault code interpretation, and corrective actions.

Repair Procedures:

Detailed instructions for component removal, repair, reassembly, and adjustment for all major vehicle systems.

Diagnostic Procedures:

Use of diagnostic scan tools, understanding sensor data, reading and clearing DTCs, performing actuator tests, live data analysis for engine and system management.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, including component identification, circuit layouts, and connector pinouts.

Technical Depth:

Comprehensive; covers basic routine maintenance, complex diagnostics, component-level repair, and complete system overhauls. Suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High resolution, suitable for printing individual pages or sections. Clear diagrams and text.

Binding Type:

N/A (Digital Product)

Paper Type:

N/A (Digital Product)

Searchability:

Text-searchable PDF, allowing quick access to specific topics and keywords.

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder Turbocharged Diesel with Intercooler

Displacement:

2.2 Liters (2179 cc)

Bore X Stroke:

Typical for DW12: 85.0 mm x 96.0 mm

Compression Ratio:

Typically around 17.5:1 or 18:1

Valve Train:

DOHC (Double Overhead Camshaft), 16 Valves (4 valves per cylinder)

Fuel System:

Common Rail Direct Injection (CRDI) with high-pressure fuel pump and injectors

Emission Control:

Euro 3 or Euro 4 compliant, featuring Diesel Particulate Filter (DPF) for improved emissions control.

Horsepower Ps:

Approximately 130-136 PS (96-100 kW) at around 4000 rpm

Torque Nm:

Approximately 315-320 Nm (232-236 lb-ft) at around 1700-2000 rpm

Fuel Type:

Diesel

Fuel Filter Part Number:

Specific part number varies by manufacturer and filter supplier (e.g., Bosch, Mahle, Mann-Filter). Check manual for exact OEM number or equivalent.

🔧 Transmission

Transmission Type Standard:

Likely a 6-speed Manual Transmission

Transmission Type Optional:

Possibly a 4-speed or 5-speed Automatic Transmission (depending on market and trim)

Transmission Fluid Spec:

Specific manual or automatic transmission fluid (e.g., GL-4 for manual, ATF for automatic) with specific viscosity (e.g., 75W-90 for manual, Dexron III/VI for auto). Check manual for exact OEM specification and capacity.

📐 Dimensions

Length Mm:

Approximately 4750 - 4770 mm

Width Mm:

Approximately 1840 mm (excluding mirrors)

Height Mm:

Approximately 1750 - 1770 mm

Wheelbase Mm:

Approximately 2820 - 2830 mm

Cargo Volume Liters:

Variable depending on seat configuration, typically ranging from 300-400 liters (with 7 seats) to over 1500 liters (with rear seats folded).

Curb Weight Kg:

Approximately 1750 - 1900 kg

Gross Vehicle Weight Rating Kg:

Typically around 2400 - 2500 kg

Towing Capacity Kg:

Typically around 1500 - 2000 kg (braked)

🛡️ Safety Features

Euro Ncap Rating:

Likely 4 stars for adult occupant protection, based on contemporary assessments of similar vehicles in the segment.

ABS:

Standard - Anti-lock Braking System

Ebd:

Standard - Electronic Brakeforce Distribution

Esp Asr:

Optional or standard on higher trims - Electronic Stability Program (ESP) and/or Traction Control System (ASR).

Airbags Front:

Driver and front passenger airbags (standard)

Airbags Side:

Optional or standard on higher trims - side airbags, potentially curtain airbags.

Seatbelts:

Pre-tensioned seatbelts with force limiters for front occupants, three-point seatbelts for all rear passengers.

Child Seat Anchors:

ISOFIX mounting points for child safety seats.

💡 Technology Features

Infotainment System:

Base infotainment systems typically include an AM/FM radio, CD player, and basic speaker setup. Higher trims might feature a more integrated system with a small display, potentially steering wheel controls.

Driver Assistance Features:

Standard features like ABS and EBD. Optional features may include parking sensors, cruise control.

Connectivity Options:

Limited by era. May include auxiliary input for audio, but no Bluetooth or USB connectivity as standard. May have provisions for aftermarket hands-free kits.

🔧 Maintenance

Oil Change Interval Km:

Typically 15,000 - 20,000 km or 12 months, whichever comes first, depending on driving conditions. Check manual for specific recommendation.

Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

Typically 30,000 - 40,000 km or as needed based on inspection.

Fuel Filter Replacement:

Typically 40,000 - 60,000 km. Critical for diesel engines.

Cabin Filter Replacement:

Typically 15,000 - 20,000 km or annually.

Timing Belt Replacement:

Critical interval, typically 100,000 - 120,000 km or 5-6 years. Failure can cause catastrophic engine damage.

Brake Fluid Change:

Every 2 years, regardless of mileage.

Engine Oil Spec:

ACEA A3/B4 or A5/B5, API CF, SAE 5W-30 or 5W-40 synthetic oil is typically recommended for HDi engines. Check manual for specific Fiat approval.

Engine Oil Capacity Liters:

Approximately 5.5 - 6.0 liters (with filter).

Coolant Spec:

Ethylene glycol-based coolant with anti-corrosion inhibitors, typically a blue or pink OAT (Organic Acid Technology) type. Check manual for specific Fiat OAT specification (e.g., Fiat 9.55523).

Coolant Capacity Liters:

Approximately 7.5 - 8.5 liters.

Power Steering Fluid Spec:

Specific hydraulic fluid or ATF (Automatic Transmission Fluid) compatible with the system. Check manual for correct specification.

Known Issues:

Common issues for HDi engines of this era can include: DPF regeneration problems (especially with short-trip driving), EGR valve sticking, turbocharger issues (variable geometry vanes), injector problems, glow plug failures, timing belt tensioner failure, and potential clutch wear (depending on usage). Suspension wear (bushings, ball joints) and electrical gremlins are also not uncommon in older vehicles.

📚 Vehicle History

Brand Heritage:

Fiat has a long history of producing passenger cars and commercial vehicles, with a significant presence in the European market. Known for innovation and practical designs.

Model Evolution:

The Fiat Ulysse is a large MPV that was developed in conjunction with PSA Peugeot Citroën. It is part of a joint venture that also produced the Citroën C8 and Peugeot 807, as well as the Lancia Phedra. The second generation, launched in 2002, marked a significant redesign and platform update.

Production Period:

The second generation Ulysse (Type 179) was produced from 2002 to 2010. The 2.2 HDi engine variant was a key offering during this period.

Manufacturing Location:

Shared production facilities with PSA Peugeot Citroën, typically in France (e.g., Sevelnord plant).

🏆 Awards & Recognition

Recognitions:

The Fiat Ulysse, as part of the joint venture MPV family, generally received positive reviews for its practicality and space. Specific awards for the 2.2 HDi variant in 2002 would be tracked by automotive publications of the time, often focusing on its diesel engine performance and fuel economy in the MPV class.