📚 Vehicle Manual Information Fiat Ulysse 2.2i 16V 2002 Service Repair Manual 📋 Jump to Section... 🏷️ Basic Information 👋 Introduction 📋 Manual Details 📖 Manual Coverage 📊 Manual Specifications ⚙️ Engine Specifications 🔧 Transmission 📐 Dimensions 🛡️ Safety Features 💡 Technology Features 🔧 Maintenance 📚 Vehicle History 🏆 Awards & Recognition 🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2002 Engine Variant: 2.2i 16V 👋 Introduction Market Position Vehicle Segment: Large MPV (Multi-Purpose Vehicle) Target Audience: Families, businesses requiring versatile people or cargo transport. Competitive Analysis Key Competitors: Citroën C8, Peugeot 807, Lancia Phedra (all part of the PSA/Fiat platform sharing). Key Features 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 Coverage Areas 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 Page Count Estimated Pages: 1000+ Manual Type Type: Comprehensive Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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 File Format Format: PDF Searchable Text: Yes Printable: Yes Print Quality Image Resolution: High-resolution, clear diagrams and photographs. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Likely: EW10J4 (Peugeot/Citroën XU/EW engine family) Engine Code Likely Engine Type: Inline 4-cylinder, DOHC (Double Overhead Camshaft) Engine Displacement Displacement Cc: 2179 cc Engine Bore Stroke Bore X Stroke Mm: 85.0 mm x 96.0 mm Engine Compression Ratio Compression Ratio: 10.2:1 Performance Horsepower Ps: 136 PS @ 5300 rpm (approximate) Torque Nm: 200 Nm @ 4000 rpm (approximate) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (95 RON recommended) Cooling System Coolant Type: Ethylene Glycol-based antifreeze (specific Fiat specification required, typically long-life) Lubrication System 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 Drive Timing Belt Replacement Interval: Refer to manual, typically 75,000 - 120,000 km or 5-7 years (critical maintenance item). 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission (AL4/DPO based) Features Automatic Transmission Features: Electronic control, sport/snow modes (if equipped). Fluid Specifications Manual Manual Gearbox Oil Type: GL-4, SAE 75W-80 or 75W-90 (specific Fiat specification required) Fluid Specifications Automatic Automatic Gearbox Fluid Type: Specific ATF fluid (e.g., LT 71141 or equivalent - refer to manual) 📐 Dimensions Exterior Length Mm: 4746 mm Width Mm: 1830 mm Height Mm: 1748 mm Wheelbase Mm: 2820 mm Weights Curb Weight Kg: 1650 - 1800 kg (depending on configuration) Gross Vehicle Weight Rating Kg: 2400 - 2600 kg (approximate) Cargo Luggage Capacity Litres: Approximately 325 - 700 litres (with seats up/down, depending on configuration). 🛡️ Safety Features Ratings Euro Ncap Rating: 4 Stars (for similar platform models of the era) Active Features ABS: Standard (Anti-lock Braking System) Esp: Optional/Standard (Electronic Stability Program) Traction Control: Optional/Standard (ASR - Anti-Slip Regulation) Passive Features 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 Infotainment Audio System:...
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.
Procedures Included
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.
Technical Depth
Depth:
Comprehensive: Covers routine maintenance, advanced diagnostics, component-level repairs, and full system overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.
GL-4, SAE 75W-80 or 75W-90 (specific Fiat specification required)
Fluid Specifications Automatic
Automatic Gearbox Fluid Type:
Specific ATF fluid (e.g., LT 71141 or equivalent - refer to manual)
📐 Dimensions
Exterior
Length Mm:
4746 mm
Width Mm:
1830 mm
Height Mm:
1748 mm
Wheelbase Mm:
2820 mm
Weights
Curb Weight Kg:
1650 - 1800 kg (depending on configuration)
Gross Vehicle Weight Rating Kg:
2400 - 2600 kg (approximate)
Cargo
Luggage Capacity Litres:
Approximately 325 - 700 litres (with seats up/down, depending on configuration).
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 Stars (for similar platform models of the era)
Active Features
ABS:
Standard (Anti-lock Braking System)
Esp:
Optional/Standard (Electronic Stability Program)
Traction Control:
Optional/Standard (ASR - Anti-Slip Regulation)
Passive Features
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
Infotainment
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.
Driver Assistance
Parking Sensors:
Optional rear parking sensors.
Connectivity
Remote Central Locking:
Standard feature with key fob integration.
Cruise Control:
Optional cruise control system.
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
Engine Coolant Capacity:
Approx. 7.5 litres (refer to manual for exact type).
Brake Fluid Type:
DOT 4
Known Issues
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 Heritage
Brand:
Fiat is an Italian manufacturer with a long history in automotive production, known for practical and innovative vehicles.
Model Evolution
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).
Production
Manufacturing Location:
Sevel Nord plant, Valenciennes, France (joint venture facility).
Production Years
Model Generation Production:
2002 - 2008 (for this generation).
🏆 Awards & Recognition
Recognitions
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.
🏆 Professional Vehicle Manual Information
Comprehensive technical documentation for maintenance, repair, and operation
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