2006 Fiat Ulysse (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2006 Codes Generation: 2nd Generation (2002-2010) Platform: Sevel D-platform (shared with Peugeot 807, Citroën C8, Lancia Phedra) 👋 Introduction Market Position...

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标签: 2006 Car Cars Fiat Ulysse Ulysse (2nd gen)

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Description

🏷️ Basic Information

Identification

Make:

Model:

Ulysse

Year:

Codes

Generation:

2nd Generation (2002-2010)

Platform:

Sevel D-platform (shared with Peugeot 807, Citroën C8, Lancia Phedra)

👋 Introduction

Market Position

Vehicle Type:

Large MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

Families, fleet operators seeking versatile and spacious transportation

Competitive Analysis

Key Competitors:

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

Key Features

Design Philosophy:

European styling, practical interior, shared platform benefits

Unique Selling Points:

Spacious interior, sliding rear doors for easy access, flexible seating configurations

📋 Manual Details

Coverage Areas

Engines Covered:

2.0 L (1997 cc) EW10 J4 (Petrol), 2.0 L (1997 cc) EW10 A (Petrol), 2.0 L (1997 cc) DW10 TD/ATED (Diesel), 2.2 L (2179 cc) DW12 TED4 (Diesel)

Transmissions Covered:

5-speed manual, 4-speed automatic (AL4)

Trim Levels Covered:

All trim levels

Page Count

Page Count:

Approx. 2000+ pages (estimated for comprehensive service manual)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English (assumed for a widely distributed service manual)

Format

Format:

Digital (likely PDF), potentially available as printed

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanicals, cooling system, lubrication system, fuel system (injection), ignition system, emissions control, exhaust system, turbocharger (diesel variants)

Transmission Systems:

Manual transmission overhaul, automatic transmission diagnosis and repair (AL4), clutch system

Drivetrain Systems:

Front-wheel drive, driveshafts, CV joints

Suspension Steering:

Front suspension (MacPherson strut), rear suspension (torsion beam), power steering system, steering column

Braking Systems:

Front disc brakes, rear disc brakes, ABS, EBD, brake booster, hydraulic system

Electrical Systems:

Battery, charging system, starting system, lighting, instrumentation, dashboard, interior electronics, wiring diagrams, ECU diagnosis, multiplexing (CAN bus)

Body Chassis:

Body panels, doors, tailgate, windows, interior trim, chassis components, corrosion protection

HVAC Systems:

Air conditioning, heating, ventilation, climate control system

Safety Systems:

Airbags, seatbelts, SRS system

Procedures Included

Maintenance Procedures:

Routine maintenance, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, belt inspection/replacement

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation, wiring diagram usage

Repair Procedures:

Component removal and installation, engine overhaul, transmission rebuild, brake component replacement, electrical component repair

Component Replacement:

Detailed steps for replacing major and minor components across all systems

Specification Tables:

Torque specifications, clearances, fluid capacities, diagnostic values

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine/transmission rebuilds and electrical diagnostics)

Diagnostic Tools:

Information on using diagnostic scan tools (e.g., OBD-II scanners, manufacturer-specific tools if applicable)

Special Tools:

Identification and usage of special tools required for specific repair procedures

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format) - Searchable, printable

Print Quality

Print Quality:

High-resolution images, clear diagrams, sharp text

Binding Type

Binding Type:

N/A (if digital), perfect bound or spiral bound (if printed)

Paper Type

Paper Type:

N/A (if digital), high-quality paper suitable for workshop environments (if printed)

⚙️ Engine Specifications

Primary Engine

Petrol Engine 2.0:

2.0 L (1997 cc) EW10 J4/A I4, 16 valves. Power: ~101 kW (138 hp) @ 6000 rpm. Torque: ~192 Nm (142 lb-ft) @ 4100 rpm.

Diesel Engine 2.0:

2.0 L (1997 cc) DW10 TD/ATED I4 HDI (Turbocharged Diesel Injection). Power: ~66 kW (90 hp) to ~80 kW (109 hp). Torque: ~205 Nm (151 lb-ft) to ~250 Nm (184 lb-ft).

Diesel Engine 2.2:

2.2 L (2179 cc) DW12 TED4 I4 HDI (Turbocharged Diesel Injection). Power: ~94 kW (128 hp) @ 4000 rpm. Torque: ~314 Nm (231 lb-ft) @ 1750 rpm.

Performance

Top Speed:

Varies by engine, e.g., ~185 km/h (115 mph) for 2.0 petrol

Acceleration 0 60Mph:

Varies by engine, e.g., ~11.0 - 13.5 seconds

Fuel System

Fuel Delivery Petrol:

Multi-point fuel injection

Fuel Delivery Diesel:

Common Rail Direct Injection (CRDi) with Turbocharger

Fuel Type:

Unleaded Petrol (RON 95 recommended), Diesel

Cooling System

Coolant Type:

Ethylene glycol-based antifreeze (e.g., Mopar/Fiat coolant specification)

Lubrication System

Engine Oil Type Petrol:

API SL/SM, ACEA A3/B3 or A3/B4, SAE 10W-40 or 5W-40 (refer to manual for specific grades)

Engine Oil Type Diesel:

API CF/CG-4/CH-4, ACEA B3/B4 or C3, SAE 5W-40 (refer to manual for specific grades)

🔧 Transmission

Standard

Standard Transmission:

5-speed manual gearbox

Optional

Optional Transmission:

4-speed automatic transmission (AL4 - Peugeot/Citroën sourced)

Features

Clutch Type:

Hydraulically operated single dry plate clutch

Automatic Transmission Fluid:

LT 71141 or equivalent (for AL4 transmission)

📐 Dimensions

Exterior

Length:

~4.7 meters

Width:

~1.8 meters (excluding mirrors)

Height:

~1.7 meters

Interior

Seating Capacity:

7 seats (standard configuration, typically 2+2+3)

Cargo

Cargo Volume Seats Up:

~300 - 400 liters (with 7 seats in use)

Cargo Volume Seats Down:

~700 - 800 liters (with 3rd row folded)

Weights

Curb Weight:

~1700 - 1900 kg (depending on engine and equipment)

Gross Vehicle Weight:

N/A (refer to vehicle plate)

Towing Capacity:

N/A (refer to vehicle plate)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 stars (for the 2nd generation Ulysse in general, testing conducted on related platform vehicles)

Active Features

Standard Anti-lock Braking System

Optional or Standard Electronic Brakeforce Distribution (EBD)

Optional Electronic Stability Program (ESP)

Traction Control:

Optional Traction Control System (TCS)

Passive Features

Airbags:

Front airbags, side airbags, curtain airbags (depending on trim level)

Seat Belts:

Three-point seatbelts with pretensioners for all seats

Child Seat Anchors:

ISOFIX mounting points

💡 Technology Features

Infotainment

Audio System:

Factory-installed CD/radio system, potentially with steering wheel controls. Optional CD changer.

Navigation:

Optional integrated satellite navigation system on some models.

Driver Assistance

Cruise Control:

Available cruise control system

Parking Assistance:

Rear parking sensors available on higher trims

Connectivity

Bluetooth:

Bluetooth hands-free system available on later models/trims

Multiplexing:

Features a multiplexed electrical system (CAN bus) for communication between ECUs.

🔧 Maintenance

Service Intervals

Oil Change Petrol:

Every 15,000 km or 1 year, whichever comes first (check manual for exact recommendation based on oil spec)

Oil Change Diesel:

Every 20,000 km or 1 year, whichever comes first (check manual for exact recommendation based on oil spec and DPF)

Air Filter Replacement:

Every 30,000 km or 2 years

Fuel Filter Replacement Diesel:

Every 60,000 km or 4 years

Timing Belt Replacement:

Every 120,000 km or 5 years for 2.0 petrol (EW10), 2.0 diesel (DW10). Timing chain for some newer DW10 variants or check manual. 2.2 Diesel (DW12) typically has timing belt.

Fluid Specifications

Brake Fluid Type:

DOT 4

Power Steering Fluid Type:

Hydraulic fluid for power steering (specific type to be confirmed in manual, often ATF Dexron II/III compatible)

Coolant Capacity:

~7.5 - 8.0 liters

Known Issues

Common Diesel Issues:

DPF (Diesel Particulate Filter) clogging, EGR valve issues, turbocharger problems, injector failures (common to many modern diesels)

Common Petrol Issues:

Coil pack failures, oil leaks, exhaust manifold cracks (EW10 engine)

Common Transmission Issues:

AL4 automatic transmission can be prone to electronic control module failures, solenoid issues, and leaks.

Common Electrical Issues:

Multiplexing system glitches, sensor failures, dashboard warning lights.

Common Body Issues:

Sliding door mechanism issues, interior trim wear, potential for rust on older models.

📚 Vehicle History

Brand Heritage

Fiat Heritage:

Fiat is one of the oldest automotive manufacturers, with a long history of innovation and practical vehicle design dating back to 1899.

Model Evolution

Ulysse First Gen:

First generation Ulysse (1994-2002) was also a rebadged Eurovan (along with Citroën Evasion, Peugeot 806, Lancia Zeta).

Ulysse Second Gen:

Second generation (2002-2010) introduced a significant styling update and further platform sharing with PSA Peugeot Citroën, becoming part of the 'Eurovan 2' family.

Facelift:

Received a facelift in 2008 with minor styling and equipment updates.

Production

Manufacturing Location:

Sevel Sud plant in Val di Sangro, Italy (shared production facility with PSA)

Production Years:

2002 - 2010

🏆 Awards & Recognition

Recognitions

Family Car Awards:

While specific awards for the 2006 Fiat Ulysse are not widely publicized, the Eurovan platform vehicles generally received good reviews for practicality and family-friendliness.

Ratings

Market Reception:

Praised for interior space and versatility, though less critically acclaimed than some German or Japanese competitors in terms of overall refinement and reliability.

Certifications

Automotive Standards:

Manufactured to meet European automotive safety and emissions standards for the period.