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2004 Fiat Ulysse (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2004 Codes Generation: 2nd Gen (179) 👋 Introduction Market Position Vehicle Segment: Large MPV (Multi-Purpose Vehicle) / Minivan Target Audience: Families, fleet operators, individuals requiring flexible passenger and cargo space. Competitive Analysis Key Competitors: Renault Espace, Citroën C8, Peugeot 807, Lancia Phedra, Ford Galaxy, Volkswagen Sharan. Key Features Design Philosophy: European styling, emphasis on practicality, modular interior, passenger comfort. Platform Sharing: Shared platform with Peugeot 807, Citroën C8, and Lancia Phedra (PSA Group). 📋 Manual Details Coverage Areas Regions Covered: European Market Page Count Estimated Page Count: 800+ Manual Type Manual Type: Factory Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, lubrication system, cooling system, engine management (ECU, sensors). Transmission: Manual and Automatic transmission overhaul, clutch, gearbox, torque converter, electronic control. Chassis: Suspension (front and rear), steering system, braking system (ABS, EBD, ESP), wheel alignment. Electrical Systems: Body electrical, lighting, instrumentation, power windows, central locking, remote control, audio system, diagnostic connectors (OBD-II). Body And Trim: Body panel removal and installation, interior trim, doors, seats, safety restraints (airbags, seatbelts). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt replacement. Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation, wiring diagrams. Repair And Overhaul: Detailed step-by-step instructions for component removal, repair, and reassembly (engine, transmission, brakes, suspension, etc.). Specifications And Data: Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters. Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical troubleshooting and bodywork repairs. 📊 Manual Specifications File Format File Format: PDF Print Quality Searchability: Searchable text enabled Image Resolution: High-resolution diagrams and illustrations Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Common: RHR (DW10ATED4 / DW10BTED4) - 2.0L HDi Diesel Engine Type: Inline 4-cylinder Turbocharged Diesel Common Rail Displacement: 1997 cc Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 17.6:1 Power Output Hdi: 110 PS (80.9 kW) @ 4000 rpm Torque Output Hdi: 250 Nm (184 lb-ft) @ 1750 rpm Performance Engine Code Petrol: RFN (EW10J4) - 2.0L Petrol Engine Type Petrol: Inline 4-cylinder Naturally Aspirated DOHC Displacement Petrol: 1997 cc Power Output Petrol: 136 PS (100 kW) @ 6000 rpm Torque Output Petrol: 190 Nm (140 lb-ft) @ 4100 rpm Engine Code Petrol V6: ES9J4S (3.0 V6 24V) - 3.0L Petrol Engine Type Petrol V6: 60-degree V6 DOHC Displacement Petrol V6: 2946 cc Power Output Petrol V6: 204 PS (149 kW) @ 6000 rpm Torque Output Petrol V6: 285 Nm (210 lb-ft) @ 3750 rpm Fuel System Fuel Delivery Petrol: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (RON 95 recommended), Diesel Emission Control Hdi: Diesel Particulate Filter (DPF) may be present on later models, EGR valve 🔧 Transmission Standard Standard Transmission Hdi: 5-speed Manual (ML5C) Optional Optional Transmission Petrol: 4-speed Automatic (AL4) Optional Transmission V6: 4-speed Automatic (DP0) Features Transmission Features: Hydraulic clutch actuation (Manual), Electronic control with limp-home mode (Automatic). 📐 Dimensions Exterior Length: 4729 mm Width: 1905 mm Height: 1760 mm Wheelbase: 2823 mm Interior Seating Capacity: 7 Seats (standard) Sliding Doors: Twin sliding rear doors Cargo Cargo Volume All Seats Up: Approx. 485 litres Cargo Volume Seats Folded: Approx. 1800 litres Weights Kerb Weight Hdi: Approx. 1750 kg Gross Vehicle Weight: Approx. 2400 kg 🛡️ Safety Features Ratings Euroncap Rating: 4 Stars (2003) Active Features ABS: Standard (Anti-lock Braking System) Ebd: Standard (Electronic Brakeforce Distribution) Esp: Optional/Standard on higher trims (Electronic Stability Program) Traction Control: Optional/Standard on higher trims (ASR - Traction Control) Passive Features Airbags: Driver, front passenger, side airbags, curtain airbags (depending on trim). Seatbelts: 3-point seatbelts with pretensioners and load limiters for all seats. Child Seat Anchors: ISOFIX points 💡 Technology Features Infotainment Infotainment System: Optional CD player, radio, navigation system (RT3/RT4). Speaker System: Standard 4-6 speaker system, optional JBL upgraded system. Driver Assistance Cruise Control: Available on most models Parking Sensors: Rear parking sensors available as an option. Connectivity Auxiliary Input: Optional or aftermarket Bluetooth: Rare, primarily on later models with upgraded infotainment systems. 🔧 Maintenance Service Intervals Oil Change Interval Hdi: Every 20,000 km or 12 months (whichever comes first) Oil Change Interval Petrol: Every 15,000 km or 12 months (whichever comes first) Cambelt Replacement Hdi: Every 120,000 km or 6 years (whichever comes first), inspect regularly. Cambelt Replacement Petrol 2.0: Every 120,000 km or 6 years (whichever comes first), inspect regularly. Air Filter Replacement: Every 40,000 km or 24 months Fuel Filter Replacement Hdi: Every 60,000 km or 36 months Fluid Specifications Engine Oil Spec Hdi: API CF/SJ or ACEA B3/B4, SAE 5W-40 (Synthetic) Engine Oil Spec Petrol: API SL/SJ or ACEA A3/B3, SAE 5W-40 (Synthetic) Coolant...
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SKU: 584729
Colecciones: ALL Fiat

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2004 Fiat Ulysse (2nd gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Fiat
Model:
Ulysse
Year:
2004
Codes
Generation:
2nd Gen (179)
👋 Introduction
Market Position
Vehicle Segment:
Large MPV (Multi-Purpose Vehicle) / Minivan
Target Audience:
Families, fleet operators, individuals requiring flexible passenger and cargo space.
Competitive Analysis
Key Competitors:
Renault Espace, Citroën C8, Peugeot 807, Lancia Phedra, Ford Galaxy, Volkswagen Sharan.
Key Features
Design Philosophy:
European styling, emphasis on practicality, modular interior, passenger comfort.
Platform Sharing:
Shared platform with Peugeot 807, Citroën C8, and Lancia Phedra (PSA Group).
📋 Manual Details
Coverage Areas
Regions Covered:
European Market
Page Count
Estimated Page Count:
800+
Manual Type
Manual Type:
Factory Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals, fuel system, ignition system, exhaust system, lubrication system, cooling system, engine management (ECU, sensors).
Transmission:
Manual and Automatic transmission overhaul, clutch, gearbox, torque converter, electronic control.
Chassis:
Suspension (front and rear), steering system, braking system (ABS, EBD, ESP), wheel alignment.
Electrical Systems:
Body electrical, lighting, instrumentation, power windows, central locking, remote control, audio system, diagnostic connectors (OBD-II).
Body And Trim:
Body panel removal and installation, interior trim, doors, seats, safety restraints (airbags, seatbelts).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation, wiring diagrams.
Repair And Overhaul:
Detailed step-by-step instructions for component removal, repair, and reassembly (engine, transmission, brakes, suspension, etc.).
Specifications And Data:
Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters.
Technical Depth
Depth Of Coverage:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical troubleshooting and bodywork repairs.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Searchability:
Searchable text enabled
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
RHR (DW10ATED4 / DW10BTED4) - 2.0L HDi Diesel
Engine Type:
Inline 4-cylinder Turbocharged Diesel Common Rail
Displacement:
1997 cc
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
17.6:1
Power Output Hdi:
110 PS (80.9 kW) @ 4000 rpm
Torque Output Hdi:
250 Nm (184 lb-ft) @ 1750 rpm
Performance
Engine Code Petrol:
RFN (EW10J4) - 2.0L Petrol
Engine Type Petrol:
Inline 4-cylinder Naturally Aspirated DOHC
Displacement Petrol:
1997 cc
Power Output Petrol:
136 PS (100 kW) @ 6000 rpm
Torque Output Petrol:
190 Nm (140 lb-ft) @ 4100 rpm
Engine Code Petrol V6:
ES9J4S (3.0 V6 24V) - 3.0L Petrol
Engine Type Petrol V6:
60-degree V6 DOHC
Displacement Petrol V6:
2946 cc
Power Output Petrol V6:
204 PS (149 kW) @ 6000 rpm
Torque Output Petrol V6:
285 Nm (210 lb-ft) @ 3750 rpm
Fuel System
Fuel Delivery Petrol:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (RON 95 recommended), Diesel
Emission Control Hdi:
Diesel Particulate Filter (DPF) may be present on later models, EGR valve
🔧 Transmission
Standard
Standard Transmission Hdi:
5-speed Manual (ML5C)
Optional
Optional Transmission Petrol:
4-speed Automatic (AL4)
Optional Transmission V6:
4-speed Automatic (DP0)
Features
Transmission Features:
Hydraulic clutch actuation (Manual), Electronic control with limp-home mode (Automatic).
📐 Dimensions
Exterior
Length:
4729 mm
Width:
1905 mm
Height:
1760 mm
Wheelbase:
2823 mm
Interior
Seating Capacity:
7 Seats (standard)
Sliding Doors:
Twin sliding rear doors
Cargo
Cargo Volume All Seats Up:
Approx. 485 litres
Cargo Volume Seats Folded:
Approx. 1800 litres
Weights
Kerb Weight Hdi:
Approx. 1750 kg
Gross Vehicle Weight:
Approx. 2400 kg
🛡️ Safety Features
Ratings
Euroncap Rating:
4 Stars (2003)
Active Features
ABS:
Standard (Anti-lock Braking System)
Ebd:
Standard (Electronic Brakeforce Distribution)
Esp:
Optional/Standard on higher trims (Electronic Stability Program)
Traction Control:
Optional/Standard on higher trims (ASR - Traction Control)
Passive Features
Airbags:
Driver, front passenger, side airbags, curtain airbags (depending on trim).
Seatbelts:
3-point seatbelts with pretensioners and load limiters for all seats.
Child Seat Anchors:
ISOFIX points
💡 Technology Features
Infotainment
Infotainment System:
Optional CD player, radio, navigation system (RT3/RT4).
Speaker System:
Standard 4-6 speaker system, optional JBL upgraded system.
Driver Assistance
Cruise Control:
Available on most models
Parking Sensors:
Rear parking sensors available as an option.
Connectivity
Auxiliary Input:
Optional or aftermarket
Bluetooth:
Rare, primarily on later models with upgraded infotainment systems.
🔧 Maintenance
Service Intervals
Oil Change Interval Hdi:
Every 20,000 km or 12 months (whichever comes first)
Oil Change Interval Petrol:
Every 15,000 km or 12 months (whichever comes first)
Cambelt Replacement Hdi:
Every 120,000 km or 6 years (whichever comes first), inspect regularly.
Cambelt Replacement Petrol 2.0:
Every 120,000 km or 6 years (whichever comes first), inspect regularly.
Air Filter Replacement:
Every 40,000 km or 24 months
Fuel Filter Replacement Hdi:
Every 60,000 km or 36 months
Fluid Specifications
Engine Oil Spec Hdi:
API CF/SJ or ACEA B3/B4, SAE 5W-40 (Synthetic)
Engine Oil Spec Petrol:
API SL/SJ or ACEA A3/B3, SAE 5W-40 (Synthetic)
Coolant Type:
Antifreeze/coolant, ethylene glycol based, 50% dilution (e.g., Paraflu UP)
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
API GL-4, SAE 75W-80
Transmission Fluid Automatic Al4:
LF-3/LF-ATF (ExxonMobil LT 71141 or equivalent)
Known Issues
Common Diesel Issues:
DPF clogging (especially on short-trip use), EGR valve issues, injector problems, turbocharger wear.
Common Petrol Issues:
Ignition coil failure, timing belt tensioner issues, oil leaks from valve cover gasket.
Common Automatic Transmission Issues:
AL4 transmission (PPR) can suffer from solenoid issues, overheating, and jerky shifts. Fluid changes are critical.
Electrical Faults:
Can bus communication issues, dashboard warning lights, power window motor failures, central locking problems.
Suspension And Steering:
Wear in ball joints, tie rod ends, and wishbone bushes leading to knocking noises and poor handling. Power steering pump leaks.
📚 Vehicle History
Brand Heritage
Manufacturer Heritage:
Fiat Auto S.p.A. is an Italian automotive manufacturer founded in 1899, known for innovation and mass-produced vehicles.
Model Evolution
Previous Generation:
1st Gen Fiat Ulysse (1994–2002)
Platform Development:
2nd generation Ulysse based on the PSA EW/ES platform.
Production
Production Years:
2002–2010
Manufacturing Location:
Sevel Nord plant, Hordain, France (joint venture with PSA Group).
🏆 Awards & Recognition
Recognitions
European Car Of The Year Nomination:
The Ulysse (and its platform siblings) were often contenders in European 'Car of the Year' discussions for the MPV segment.
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