2003 Fiat Ulysse (2nd gen) Service and Repair Manual

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Basic Information Identification Make: Fiat Model: Ulysse Year: 2003 Codes Chassis Code: 220 Generation: 2nd Generation (1999-2002 facelift) Introduction Market Position Segment: 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 (4th gen), Ford Galaxy (Mk2), Volkswagen Sharan (7M). Key Features Vehicle Platform: Developed under the Sevel (Société Européenne de Véhicules) joint venture with PSA Peugeot Citroën, sharing platform with the Citroën C8, Peugeot 807, and Lancia Phedra. Design Philosophy: Emphasis on practicality, spaciousness, and modularity for passenger and cargo carrying. Manual Details Coverage Areas Engine Variants Covered: 2.0 L (1998 cc) EW10J4 I4, 2.0 L (1997 cc) turbo I4, 2.2 L (2179 cc) EW12J4 I4, 2.0 L (1997 cc) DW10ATED HDi I4 Diesel, 2.2 L (2179 cc) DW12TED4 HDi I4 Diesel Transmission Types Covered: 5-speed Manual, 4-speed Automatic (AL4) Page Count Total Pages: 600+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital PDF Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train, timing system, lubrication system, cooling system, fuel delivery system, emission control system. Engine Management: Ignition system, fuel injection system (MPI/Common Rail), sensors (crankshaft position, camshaft position, MAF, MAP, coolant temperature, lambda, knock, etc.), actuators (injectors, throttle body, EVAP purge valve, EGR valve), ECU diagnostics, OBD-II system. Transmission Manual: Clutch operation, gearbox assembly, gear shifting mechanism, driveshafts, differentials. Transmission Automatic: Transmission fluid, torque converter, valve body, planetary gear sets, hydraulic control system, electronic control unit (TCU), shift solenoids, cooling system integration. Suspension: Front suspension (McPherson struts, wishbones, anti-roll bar), rear suspension (torsion beam/independent, shock absorbers, springs), wheel alignment specifications. Brakes: Front and rear disc brakes, brake calipers, master cylinder, brake booster, ABS system (hydraulic unit, wheel speed sensors, control module), parking brake. Steering: Power steering system (hydraulic pump, steering rack, fluid), steering column, wheel angle sensor. Electrical System: Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior), instrument cluster, power windows, central locking, body control module (BCM), comfort systems. HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant, dryer), heater core, blower motor, climate control unit, cabin air filter. Body And Chassis: Body panels, doors, hood, tailgate, interior trim, seats, glass, chassis components, corrosion protection. Procedures Included Maintenance Procedures: Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flush and fill, brake fluid flush, transmission fluid change, timing belt/chain inspection/replacement, serpentine belt replacement, drive axle boot replacement, battery testing and replacement. Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical circuit testing, component testing procedures, common fault diagnosis. Repair Procedures: Engine overhaul (partial/full), cylinder head removal/installation, transmission removal/installation, brake caliper overhaul, suspension component replacement, steering rack replacement, starter/alternator replacement, HVAC component replacement, body panel repair/replacement. Technical Specifications: Torque specifications for all fasteners, fluid capacities and types, engine timing specifications, valve clearances, diagnostic parameter ranges, wear limits. Technical Depth Depth: Comprehensive, covering everything from basic scheduled maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and electrical schematics. Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text content for quick information retrieval. Resolution: High-resolution images and diagrams for clarity. Print Quality Printability: Printable pages for easy workshop use. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Engine Specifications Primary Engine Engine Code Petrol 2.0: EW10J4 Engine Displacement Petrol 2.0: 1997 cc Engine Configuration Petrol 2.0: Inline 4-cylinder, DOHC, 16-valve Engine Code Petrol 2.0 Turbo: 2.0 Turbo (derived from XU/PSA family) Engine Displacement Petrol 2.0 Turbo: 1998 cc Engine Configuration Petrol 2.0 Turbo: Inline 4-cylinder, SOHC, 8-valve Engine Code Petrol 2.2: EW12J4 Engine Displacement Petrol 2.2: 2179 cc Engine Configuration Petrol 2.2: Inline 4-cylinder, DOHC, 16-valve Engine Code Diesel 2.0 Hdi: DW10ATED Engine Displacement Diesel 2.0 Hdi: 1997 cc Engine Configuration Diesel 2.0 Hdi: Inline 4-cylinder, DOHC, 16-valve, Turbocharged Common Rail Diesel Engine Code Diesel 2.2 Hdi: DW12TED4 Engine Displacement Diesel 2.2 Hdi: 2179 cc Engine Configuration Diesel 2.2 Hdi: Inline 4-cylinder, DOHC, 16-valve, Turbocharged Common Rail Diesel Performance Horsepower 2.0 Petrol: 136 hp (134 bhp; 100 kW) @ 6000 rpm Torque 2.0 Petrol: 192 Nm (142 lb-ft) @ 4100 rpm Horsepower 2.0 Turbo Petrol: 150 hp (148 bhp; 110 kW) @ 5500 rpm Torque 2.0 Turbo Petrol: 235 Nm (173 lb-ft) @ 2000 rpm Horsepower 2.2 Petrol: 160 hp (158 bhp; 118 kW) @ 5800 rpm Torque 2.2 Petrol: 217 Nm (160 lb-ft) @ 3800 rpm Horsepower 2.0 Hdi: 109 hp (108 bhp; 80 kW) @ 4000 rpm Torque 2.0 Hdi: 270 Nm (199 lb-ft) @ 1750 rpm Horsepower 2.2 Hdi: 130 hp (128 bhp; 96 kW) @ 4000 rpm Torque 2.2 Hdi: 314 Nm (231 lb-ft) @ 2000 rpm Fuel System Fuel Type Petrol: Unleaded gasoline (95 RON recommended) Fuel Type Diesel: Diesel fuel Injection System Petrol: Multi-point fuel injection (MPI) Injection System Diesel: Bosch Common Rail Direct Injection (CRDI) Emissions Standards: Euro 3 (for most variants) Transmission Standard Manual Gearbox: 5-speed Manual (e.g., BE4 series for some variants) Optional Automatic Gearbox: 4-speed Automatic (AL4/DP0) Features Clutch Type: Hydraulically operated single dry plate clutch Automatic Features: Electronic control, Sport/Snow modes available on some AL4 units. Dimensions Exterior Length: 4719 mm (185.8 in) Width: 1804 mm (71.0 in) Height: 1745 mm (68.7 in) Wheelbase: 2823 mm (111.1 in) Interior Seating Capacity: 7 seats (typically 2+3+2 configuration) Interior Flexibility: Sliding and removable rear seats, foldable third-row seats. Cargo Cargo Volume All Seats Up: ~397 liters (14.0 cu ft) Cargo Volume Rear Seats Folded: ~739 liters (26.1 cu ft) Cargo Volume Max: ~2300 liters (81.2 cu ft) Weights Curb Weight Approx: 1600-1800 kg (3527-3968 lbs) depending on engine and specification Gross Vehicle Weight Rating Approx: 2400-2500 kg (5291-5512 lbs) Safety Features Ratings Euro Ncap Rating 2003: 4 out of 5 stars (based on similar platform vehicles of the era) Active Features ABS: Standard Anti-lock Braking System Ebs: Optional Electronic Brake-force Distribution (EBD) Esp: Optional Electronic Stability Program (ESP) / VDC Traction...

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Description

Basic Information
Identification
Make:	Fiat
Model:	Ulysse
Year:	2003
Codes
Chassis Code:	220
Generation:	2nd Generation (1999-2002 facelift)

Introduction
Market Position
Segment:	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 (4th gen), Ford Galaxy (Mk2), Volkswagen Sharan (7M).
Key Features
Vehicle Platform:	Developed under the Sevel (Société Européenne de Véhicules) joint venture with PSA Peugeot Citroën, sharing platform with the Citroën C8, Peugeot 807, and Lancia Phedra.
Design Philosophy:	Emphasis on practicality, spaciousness, and modularity for passenger and cargo carrying.

Manual Details
Coverage Areas
Engine Variants Covered:	2.0 L (1998 cc) EW10J4 I4, 2.0 L (1997 cc) turbo I4, 2.2 L (2179 cc) EW12J4 I4, 2.0 L (1997 cc) DW10ATED HDi I4 Diesel, 2.2 L (2179 cc) DW12TED4 HDi I4 Diesel
Transmission Types Covered:	5-speed Manual, 4-speed Automatic (AL4)
Page Count
Total Pages:	600+
Manual Type
Type:	Service and Repair Manual
Language
Language:	English
Format
Format:	Digital PDF

Manual Coverage
Systems Covered
Engine Mechanical:	Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train, timing system, lubrication system, cooling system, fuel delivery system, emission control system.
Engine Management:	Ignition system, fuel injection system (MPI/Common Rail), sensors (crankshaft position, camshaft position, MAF, MAP, coolant temperature, lambda, knock, etc.), actuators (injectors, throttle body, EVAP purge valve, EGR valve), ECU diagnostics, OBD-II system.
Transmission Manual:	Clutch operation, gearbox assembly, gear shifting mechanism, driveshafts, differentials.
Transmission Automatic:	Transmission fluid, torque converter, valve body, planetary gear sets, hydraulic control system, electronic control unit (TCU), shift solenoids, cooling system integration.
Suspension:	Front suspension (McPherson struts, wishbones, anti-roll bar), rear suspension (torsion beam/independent, shock absorbers, springs), wheel alignment specifications.
Brakes:	Front and rear disc brakes, brake calipers, master cylinder, brake booster, ABS system (hydraulic unit, wheel speed sensors, control module), parking brake.
Steering:	Power steering system (hydraulic pump, steering rack, fluid), steering column, wheel angle sensor.
Electrical System:	Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior), instrument cluster, power windows, central locking, body control module (BCM), comfort systems.
HVAC:	Air conditioning system (compressor, condenser, evaporator, refrigerant, dryer), heater core, blower motor, climate control unit, cabin air filter.
Body And Chassis:	Body panels, doors, hood, tailgate, interior trim, seats, glass, chassis components, corrosion protection.
Procedures Included
Maintenance Procedures:	Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flush and fill, brake fluid flush, transmission fluid change, timing belt/chain inspection/replacement, serpentine belt replacement, drive axle boot replacement, battery testing and replacement.
Troubleshooting:	Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical circuit testing, component testing procedures, common fault diagnosis.
Repair Procedures:	Engine overhaul (partial/full), cylinder head removal/installation, transmission removal/installation, brake caliper overhaul, suspension component replacement, steering rack replacement, starter/alternator replacement, HVAC component replacement, body panel repair/replacement.
Technical Specifications:	Torque specifications for all fasteners, fluid capacities and types, engine timing specifications, valve clearances, diagnostic parameter ranges, wear limits.
Technical Depth
Depth:	Comprehensive, covering everything from basic scheduled maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and electrical schematics.

Manual Specifications
File Format
File Type:	PDF (Portable Document Format)
Searchability:	Searchable text content for quick information retrieval.
Resolution:	High-resolution images and diagrams for clarity.
Print Quality
Printability:	Printable pages for easy workshop use.
Binding Type
Binding:	N/A (Digital Format)
Paper Type
Paper Quality:	N/A (Digital Format)

Engine Specifications
Primary Engine
Engine Code Petrol 2.0:	EW10J4
Engine Displacement Petrol 2.0:	1997 cc
Engine Configuration Petrol 2.0:	Inline 4-cylinder, DOHC, 16-valve
Engine Code Petrol 2.0 Turbo:	2.0 Turbo (derived from XU/PSA family)
Engine Displacement Petrol 2.0 Turbo:	1998 cc
Engine Configuration Petrol 2.0 Turbo:	Inline 4-cylinder, SOHC, 8-valve
Engine Code Petrol 2.2:	EW12J4
Engine Displacement Petrol 2.2:	2179 cc
Engine Configuration Petrol 2.2:	Inline 4-cylinder, DOHC, 16-valve
Engine Code Diesel 2.0 Hdi:	DW10ATED
Engine Displacement Diesel 2.0 Hdi:	1997 cc
Engine Configuration Diesel 2.0 Hdi:	Inline 4-cylinder, DOHC, 16-valve, Turbocharged Common Rail Diesel
Engine Code Diesel 2.2 Hdi:	DW12TED4
Engine Displacement Diesel 2.2 Hdi:	2179 cc
Engine Configuration Diesel 2.2 Hdi:	Inline 4-cylinder, DOHC, 16-valve, Turbocharged Common Rail Diesel
Performance
Horsepower 2.0 Petrol:	136 hp (134 bhp; 100 kW) @ 6000 rpm
Torque 2.0 Petrol:	192 Nm (142 lb-ft) @ 4100 rpm
Horsepower 2.0 Turbo Petrol:	150 hp (148 bhp; 110 kW) @ 5500 rpm
Torque 2.0 Turbo Petrol:	235 Nm (173 lb-ft) @ 2000 rpm
Horsepower 2.2 Petrol:	160 hp (158 bhp; 118 kW) @ 5800 rpm
Torque 2.2 Petrol:	217 Nm (160 lb-ft) @ 3800 rpm
Horsepower 2.0 Hdi:	109 hp (108 bhp; 80 kW) @ 4000 rpm
Torque 2.0 Hdi:	270 Nm (199 lb-ft) @ 1750 rpm
Horsepower 2.2 Hdi:	130 hp (128 bhp; 96 kW) @ 4000 rpm
Torque 2.2 Hdi:	314 Nm (231 lb-ft) @ 2000 rpm
Fuel System
Fuel Type Petrol:	Unleaded gasoline (95 RON recommended)
Fuel Type Diesel:	Diesel fuel
Injection System Petrol:	Multi-point fuel injection (MPI)
Injection System Diesel:	Bosch Common Rail Direct Injection (CRDI)
Emissions Standards:	Euro 3 (for most variants)

Transmission
Standard
Manual Gearbox:	5-speed Manual (e.g., BE4 series for some variants)
Optional
Automatic Gearbox:	4-speed Automatic (AL4/DP0)
Features
Clutch Type:	Hydraulically operated single dry plate clutch
Automatic Features:	Electronic control, Sport/Snow modes available on some AL4 units.

Dimensions
Exterior
Length:	4719 mm (185.8 in)
Width:	1804 mm (71.0 in)
Height:	1745 mm (68.7 in)
Wheelbase:	2823 mm (111.1 in)
Interior
Seating Capacity:	7 seats (typically 2+3+2 configuration)
Interior Flexibility:	Sliding and removable rear seats, foldable third-row seats.
Cargo
Cargo Volume All Seats Up:	~397 liters (14.0 cu ft)
Cargo Volume Rear Seats Folded:	~739 liters (26.1 cu ft)
Cargo Volume Max:	~2300 liters (81.2 cu ft)
Weights
Curb Weight Approx:	1600-1800 kg (3527-3968 lbs) depending on engine and specification
Gross Vehicle Weight Rating Approx:	2400-2500 kg (5291-5512 lbs)

Safety Features
Ratings
Euro Ncap Rating 2003:	4 out of 5 stars (based on similar platform vehicles of the era)
Active Features
ABS:	Standard Anti-lock Braking System
Ebs:	Optional Electronic Brake-force Distribution (EBD)
Esp:	Optional Electronic Stability Program (ESP) / VDC
Traction Control:	Available Traction Control System (TCS)
Passive Features
Airbags Standard:	Driver and front passenger airbags, front side airbags.
Airbags Optional:	Rear side airbags, curtain airbags.
Seatbelts:	3-point seatbelts with pretensioners for all seats.
Child Seat Anchors:	ISOFIX mounting points.

Technology Features
Infotainment
Audio System:	Factory-fitted radio/CD player with steering wheel controls, optional CD changer, available navigation system.
Display:	Multi-function display for trip computer, audio, and climate control information.
Driver Assistance
Cruise Control:	Available cruise control system.
Parking Sensors:	Optional rear parking sensors.
Rain Sensing Wipers:	Optional rain-sensing automatic wipers.
Automatic Headlights:	Optional automatic headlamp activation.
Connectivity
Bluetooth:	Not standard, potentially available as an aftermarket option or early OEM integration on later facelift models.
Aux Input:	Likely available on factory audio systems.

Maintenance
Service Intervals Petrol 2.0 16V
Oil Change Interval:	Every 20,000 km or 1 year, whichever comes first.
Air Filter Replacement Interval:	Every 40,000 km or 2 years.
Spark Plug Replacement Interval:	Every 60,000 km or 4 years (for Iridium/Platinum plugs).
Timing Belt Replacement Interval:	Every 120,000 km or 5 years (critical interval, check manual for exact type).
Service Intervals Diesel Hdi
Oil Change Interval:	Every 20,000 km or 1 year, whichever comes first.
Fuel Filter Replacement Interval:	Every 40,000 km or 2 years.
Timing Belt Replacement Interval:	Every 120,000 km or 5 years (critical interval for DW12TED4, DW10ATED might have chain or belt depending on variant, verify).
Fluid Specifications
Engine Oil Petrol:	API SN/CF, ACEA A3/B4, SAE 5W-40 or 10W-40 (refer to manual for specific engine variant and climate).
Engine Oil Diesel Hdi:	API CF/SJ, ACEA B4/A3, SAE 5W-40 (low SAPS recommended for DPF equipped models, if applicable).
Coolant:	Ethylene glycol-based antifreeze, OAT type, 50% mix with demineralized water.
Brake Fluid:	DOT 4.
Power Steering Fluid:	ATF Dexron II or III, or specific PSA fluid.
Automatic Transmission Fluid:	ESSO LT 71141 or equivalent.
Known Issues
Common Problems Petrol Ew Engines:	Oil leaks from rocker cover gasket, intake manifold gasket failures, VANOS/VVT solenoid issues (if equipped), timing belt tensioner failure leading to belt slip/jump.
Common Problems Diesel Hdi:	EGR valve clogging, turbocharger actuator issues, injector seal leaks, glow plug failure, timing belt tensioner/pulley wear.
Common Problems Automatic Al4:	Solenoid wear, valve body issues, torque converter clutch judder, overheating due to inadequate cooling.
Common Problems Electrical:	Faulty window regulators, central locking issues, dashboard warning light malfunctions, CAN bus communication errors.
Common Problems Suspension Brakes:	Front suspension wear (ball joints, drop links), rear torsion beam bushes, brake disc warping, ABS sensor failures.

Vehicle History
Brand Heritage
Fiat Heritage:	Fiat is an Italian automotive manufacturer with a long history dating back to 1899, known for its innovation in small cars and practical vehicles.
Model Evolution
First Generation Ulysse:	The first generation Fiat Ulysse (Type 170) was launched in 1994, also as part of the Sevel MPV project with PSA.
Second Generation Ulysse:	The second generation (Type 220) was introduced in 1999 and received a facelift in 2002, which this manual covers. This generation saw updated styling, engines, and interior features.
Production
Production Period 2Nd Gen:	1999-2002 (pre-facelift), 2002-2010 (facelifted model covered by this manual)
Manufacturing Plant:	Sevel Sud plant in Val di Sangro, Italy.

Awards & Recognition
Recognitions
Mpv Segment Awards:	The Fiat Ulysse and its Sevel platform siblings have been well-regarded in the MPV segment for their practicality and interior space, though specific individual awards for the 2003 model year are not prominently documented outside of general segment reviews.