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Fiat Ulysse Complete Workshop Service Repair Manual 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Model Generation: Second Generation (2002-2010) Applicable Years: 1994-2008 👋 Introduction Market Position Segment: Large MPV (Multi-Purpose Vehicle) Key Attributes: Spacious interior, versatile...
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Fiat Ulysse Complete Workshop Service Repair Manual 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
🏷️ Basic Information
Identification
Make:
Fiat
Model:
Ulysse
Model Generation:
Second Generation (2002-2010)
Applicable Years:
1994-2008
👋 Introduction
Market Position
Segment:
Large MPV (Multi-Purpose Vehicle)
Key Attributes:
Spacious interior, versatile seating configurations, family-oriented transport.
Competitive Analysis
Competitors:
Citroën Evasion, Peugeot 806, Lancia Zeta (all part of the Eurovan platform), Renault Espace, Volkswagen Sharan, Ford Galaxy.
Key Features
Platform:
Shared platform with Citroën, Peugeot, and Lancia models (Sevel Sud platform).
Versatility:
Modular interior with removable and reconfigurable seating.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive workshop service and repair
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Service & Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
All gasoline and diesel engine variants, including diagnostics, overhaul, and component testing.
Transmission:
Manual and automatic transmission systems, including diagnosis, repair, fluid changes, and clutch/torque converter servicing.
Brakes:
Hydraulic and ABS braking systems, including caliper, rotor, master cylinder, and brake line servicing, plus ABS sensor and module diagnostics.
Suspension:
Front and rear suspension components, including shock absorbers, struts, springs, control arms, bushings, and wheel alignment procedures.
Steering:
Power steering system, including pump, rack, and hoses, along with steering column and linkage repair.
Electrical:
Complete electrical system coverage, including wiring diagrams, fuse box locations, component testing, and diagnostic procedures for lighting, accessories, ECUs, and sensors.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, including refrigerant handling, compressor, condenser, evaporator, and blower motor servicing.
Body Interior:
Body panel removal and installation, door mechanisms, interior trim, seating, and glass replacement.
Body Exterior:
Exterior bodywork, including bumpers, fenders, hood, trunk lid, and associated trim.
Emissions Control:
Diagnosis and repair of emission control systems, including catalytic converters, oxygen sensors, and EVAP systems.
Procedures Included
Maintenance:
Detailed routine maintenance schedules, oil change procedures, filter replacements, fluid checks and top-offs, and spark plug replacement.
Troubleshooting:
Extensive diagnostic charts and troubleshooting guides for common and uncommon issues across all vehicle systems.
Repair:
Step-by-step repair instructions for virtually all mechanical and electrical components, from minor adjustments to major overhauls.
Disassembly Reassembly:
Detailed instructions for the removal and installation of all major and minor components, including torque specifications.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, including component location and harness routing.
Technical Depth
Depth:
Extremely High: Covers everything from basic fluid changes and filter replacements to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Quality:
High-resolution scans ensuring clarity of text and diagrams, suitable for printing.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
Searchability
Text Search:
Likely includes searchable text for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Family Gasoline:
PSA EW/ES (XU family superseded)
Engine Family Diesel:
PSA XUD/DW (common rail HDI)
Performance
Typical Power Output Gasoline:
Ranges from approximately 110 hp to 138 hp depending on engine size (e.g., 2.0L).
Typical Power Output Diesel:
Ranges from approximately 90 hp to 110 hp for naturally aspirated and turbo diesel, up to 136 hp for 2.0 HDi.
Fuel System
Gasoline Injection:
Multi-point Fuel Injection (MPI)
Diesel Injection:
Direct Injection (DI), Turbocharged Direct Injection (TD), Common Rail Direct Injection (CDi/HDi)
Displacement Options
Gasoline Displacements:
1.8L, 2.0L
Diesel Displacements:
1.9L (TD, naturally aspirated), 2.0L (HDi)
🔧 Transmission
Standard
Manual Transmission Type:
5-speed Manual
Optional
Automatic Transmission Type:
4-speed Automatic (AL4 derived or similar)
Features
Clutch Type:
Dry single-plate clutch (manual transmission)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 SAE 75W-80 or 75W-90 synthetic gear oil (refer to specific model year for exact spec).
Automatic Transmission Fluid:
ATF Dexron III or equivalent (refer to specific model year for exact spec).
📐 Dimensions
Exterior
Length Mm:
~4750
Width Mm:
~1800
Height Mm:
~1750
Interior
Seating Capacity:
7-seater configuration standard, with up to 8 possible depending on layout.
Cargo
Luggage Capacity Min Seats Up:
~500-700 liters (behind third row, variable)
Luggage Capacity Max Seats Folded:
~2500-3000 liters (all seats removed/folded)
Weights
Curb Weight Kg:
~1600-1800 kg (depending on engine and equipment)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4-star (for models tested during its lifecycle)
Active Features
ABS:
Standard on most models, often with EBD (Electronic Brakeforce Distribution).
Traction Control:
Optional or standard on higher trims/later models.
Passive Features
Airbags:
Driver and front passenger airbags standard, side airbags optional.
Seatbelts:
Three-point seatbelts for all occupants, often with pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette/CD player, with optional premium sound systems.
Navigation:
Optional GPS navigation systems available on higher trim levels.
Driver Assistance
Cruise Control:
Available on most models, standard on higher trims.
Parking Sensors:
Optional rear parking sensors available on later models.
Connectivity
Central Locking:
Remote central locking standard.
Power Windows Doors:
Power front windows standard, power rear windows and electric sliding doors available on higher trims or as options.
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Typically 15,000 km or 1 year, whichever comes first (check manual for specific engine).
Oil Change Interval Diesel:
Typically 10,000-15,000 km or 1 year (check manual for specific engine, especially HDi).
Timing Belt Replacement Gasoline:
Around 90,000 - 120,000 km or 5-6 years (critical for engine longevity, highly model-specific).
Timing Belt Replacement Diesel:
Around 90,000 - 120,000 km or 5-6 years (critical for engine longevity, highly model-specific).
Fluid Specifications
Coolant:
IAT (Inorganic Acid Technology) or OAT (Organic Acid Technology) coolant, typically purple or red. Check manual for specific type and concentration (50/50 mix with distilled water).
Brake Fluid:
DOT 4
Power Steering Fluid:
Typically ATF or specific hydraulic fluid, consult manual for exact specification.
Known Issues
Common Wear Items:
Front suspension bushings, ball joints, exhaust system components, catalytic converter (especially on higher mileage models).
Electrical Gremlins:
Can be prone to minor electrical issues, particularly related to door modules, window regulators, and dashboard warning lights if not maintained.
Diesel Particulate Filter Issues:
On later models with Diesel Particulate Filters (DPF), regeneration issues or clogging can occur if driven primarily on short journeys.
📚 Vehicle History
Brand Heritage
Fiat Mpv History:
Fiat has a history of MPVs dating back to the Fiat Multipla of the 1950s and later the Fiat Idea.
Model Evolution
First Generation Ulysse:
Launched in 1994, based on the first generation Eurovan platform.
Second Generation Ulysse:
Launched in 2002, representing a significant redesign and updated technology.
Production
Manufacturing Location:
Sevel Sud plant in Italy (shared with partner brands).
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards for the Fiat Ulysse itself might be limited, the Eurovan platform it shares was generally well-regarded for its practicality and space in the MPV segment during its production run.
Ratings
Safety Testing Performance:
Referenced Euro NCAP ratings indicate a solid safety performance for its class and era.
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