🏷️ Basic Information

Make:

Fiat

Model:

Ulysse

Year:

2002

Engine Variant:

2.2i 16V

👋 Introduction

Vehicle Segment:

Large MPV (Multi-Purpose Vehicle)

Target Audience:

Families, businesses requiring versatile people or cargo transport.

Key Competitors:

Citroën C8, Peugeot 807, Lancia Phedra (all part of the PSA/Fiat platform sharing).

Versatility:

Spacious interior, flexible seating configurations, practical for family use and hauling.

Engine Performance:

The 2.2i 16V engine (likely the EW10J4 or a variant) offers a balance of power and fuel economy for its class.

Practicality:

Sliding rear doors for easy access in confined spaces, ample storage solutions.

📋 Manual Details

Primary Coverage:

Service and Repair

Engine Systems:

Engine mechanical, engine electrical, fuel system, cooling system, lubrication system, exhaust system

Drivetrain Systems:

Transmission (manual and automatic), clutch, drivetrain components, differentials

Chassis Systems:

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

Body And Interior:

Body construction, exterior trim, interior trim, seating, HVAC system, body electrical, doors, windows, locks

Electrical Systems:

Wiring diagrams, lighting systems, power distribution, instrument cluster, ECUs, diagnostics

Troubleshooting:

Diagnostic procedures, common faults, symptom-based troubleshooting guides

Estimated Pages:

1000+

Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, and reassembly procedures for engine components, including cylinder head, pistons, crankshaft, camshafts, valve train, timing belt/chain.

Engine Management:

Ignition system, fuel injection system (EFI), emission control systems, sensor and actuator diagnostics, ECU identification and function.

Transmission Manual:

Overhaul procedures, component identification, torque specifications, clutch operation and adjustment, gearbox internal components.

Transmission Automatic:

Operation principles, fluid specifications, external adjustments, diagnostic codes, common faults and repairs (if applicable for this engine/model combination).

Suspension System:

Front and rear suspension component replacement (struts, shock absorbers, control arms, bushings), spring replacement, anti-roll bar systems.

Braking System:

Brake pad and disc replacement, caliper servicing, brake fluid bleeding, hydraulic system diagnostics, ABS/ESP component testing and replacement.

Steering System:

Power steering pump, rack and pinion unit, tie rod ends, steering column, alignment specifications.

Electrical Schematics:

Comprehensive, detailed wiring diagrams for all vehicle systems, including power distribution, lighting, engine control, body control modules, and comfort features.

Body Electrical:

Power windows, central locking, remote keyless entry, interior and exterior lighting, wipers, horn, alarm system.

HVAC System:

Air conditioning system servicing (refrigerant type, pressures), heater core replacement, blower motor diagnosis, climate control unit troubleshooting.

Maintenance Tasks:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, timing belt replacement (critical interval).

Diagnostic Procedures:

OBD-II diagnostic trouble code (DTC) interpretation, live data analysis, sensor testing methods, component circuit testing using multimeters.

Repair Procedures:

Step-by-step repair instructions for all major vehicle components, including engine rebuilds, transmission overhauls, suspension component replacement, and body panel repair.

Component Replacement:

Detailed guidance on replacing parts such as alternators, starters, fuel pumps, water pumps, radiators, EGR valves, and catalytic converters.

Safety System Repair:

Airbag system inspection and replacement (with safety precautions), seatbelt servicing.

Depth:

Comprehensive: Covers routine maintenance, advanced diagnostics, component-level repairs, and full system overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.

Diagnostic Tools Required:

Specifies required diagnostic tools, scan tools, multimeters, torque wrenches, specialty tools (e.g., timing belt tools).

Torque Specifications:

Provides precise torque values for all critical fasteners across engine, chassis, and body components.

Clearances And Tolerances:

Includes specified clearances and tolerances for engine internal components (bearings, piston rings, valve guides) for precision rebuilding.

📊 Manual Specifications

Format:

PDF

Searchable Text:

Yes

Printable:

Yes

Image Resolution:

High-resolution, clear diagrams and photographs.

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code Likely:

EW10J4 (Peugeot/Citroën XU/EW engine family)

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Camshaft)

Displacement Cc:

2179 cc

Bore X Stroke Mm:

85.0 mm x 96.0 mm

Compression Ratio:

10.2:1

Horsepower Ps:

136 PS @ 5300 rpm (approximate)

Torque Nm:

200 Nm @ 4000 rpm (approximate)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Petrol (95 RON recommended)

Coolant Type:

Ethylene Glycol-based antifreeze (specific Fiat specification required, typically long-life)

Oil Type:

API SL/CF, ACEA A3/B3 or A3/B4, SAE 5W-40 or 10W-40 (refer to manual for exact specification)

Oil Capacity Litres:

Approximately 4.5 - 5.0 litres (with filter)

Timing Belt Replacement Interval:

Refer to manual, typically 75,000 - 120,000 km or 5-7 years (critical maintenance item).

🔧 Transmission

Transmission Type Standard:

5-Speed Manual Transmission

Transmission Type Optional:

4-Speed Automatic Transmission (AL4/DPO based)

Automatic Transmission Features:

Electronic control, sport/snow modes (if equipped).

Manual Gearbox Oil Type:

GL-4, SAE 75W-80 or 75W-90 (specific Fiat specification required)

Automatic Gearbox Fluid Type:

Specific ATF fluid (e.g., LT 71141 or equivalent - refer to manual)

📐 Dimensions

Length Mm:

4746 mm

Width Mm:

1830 mm

Height Mm:

1748 mm

Wheelbase Mm:

2820 mm

Curb Weight Kg:

1650 - 1800 kg (depending on configuration)

Gross Vehicle Weight Rating Kg:

2400 - 2600 kg (approximate)

Luggage Capacity Litres:

Approximately 325 - 700 litres (with seats up/down, depending on configuration).

🛡️ Safety Features

Euro Ncap Rating:

4 Stars (for similar platform models of the era)

ABS:

Standard (Anti-lock Braking System)

Esp:

Optional/Standard (Electronic Stability Program)

Traction Control:

Optional/Standard (ASR - Anti-Slip Regulation)

Airbags:

Front airbags for driver and passenger, optional side airbags.

Seatbelts:

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

Child Seat Anchors:

ISOFIX mounting points on rear seats.

💡 Technology Features

Audio System:

Factory fitted radio/CD player with speaker system. Potential for upgraded units depending on trim.

Navigation:

Optional satellite navigation system available on higher trims.

Parking Sensors:

Optional rear parking sensors.

Remote Central Locking:

Standard feature with key fob integration.

Cruise Control:

Optional cruise control system.

🔧 Maintenance

Engine Oil Filter Change:

Every 15,000 km or 1 year, whichever comes first (check manual for specific conditions).

Air Filter Replacement:

Every 30,000 km or 2 years.

Fuel Filter Replacement:

Every 60,000 km.

Spark Plug Replacement:

Every 60,000 km for standard plugs, longer for iridium/platinum.

Timing Belt Replacement:

CRITICAL: 75,000 miles (120,000 km) or 5 years, whichever comes first. Failure can cause catastrophic engine damage.

Engine Coolant Capacity:

Approx. 7.5 litres (refer to manual for exact type).

Brake Fluid Type:

DOT 4

Engine Management Sensors:

Potential for crank angle sensor, camshaft sensor, and lambda sensor failures leading to rough running or no-start conditions.

Exhaust Gas Recirculation:

EGR valve clogging can lead to performance issues and check engine lights.

Timing Belt Tensioner:

Tensioner failure can occur before the belt itself, leading to belt jumping and valve damage.

Suspension Bushings:

Wear in suspension control arm bushings and anti-roll bar links can cause knocking noises and poor handling.

Electrical Connectors:

Corrosion in electrical connectors, particularly for lighting and body control modules, can cause intermittent faults.

HVAC Blower Resistor:

Failure of the blower motor resistor can lead to loss of fan speed control.

📚 Vehicle History

Brand:

Fiat is an Italian manufacturer with a long history in automotive production, known for practical and innovative vehicles.

Model Lineage:

The Fiat Ulysse is part of a joint venture with PSA Peugeot Citroën, sharing its platform with models like the Citroën C8, Peugeot 807, and Lancia Phedra. This generation (second) was launched in 2002, succeeding the first generation Ulysse (1994-2002).

Manufacturing Location:

Sevel Nord plant, Valenciennes, France (joint venture facility).

Model Generation Production:

2002 - 2008 (for this generation).

🏆 Awards & Recognition

Awards Received:

As part of the PSA/Fiat platform, these vehicles often received favorable reviews for practicality and space upon launch, though specific awards for the Ulysse model are less prominent than the platform as a whole.