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Introduction
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Market Position
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Market Position:
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The Fiat Ulysse (2nd Gen) was positioned as a versatile family MPV (Multi-Purpose Vehicle) or Minivan, competing in a segment with established European and Japanese rivals.
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Target Audience:
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Families requiring a spacious and flexible vehicle, fleet operators, and independent garages specializing in European vehicles.
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Competitive Analysis
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Competitive Analysis:
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Competed against vehicles such as the Citroën C8, Peugeot 807, Lancia Phedra (all part of the SEVEL platform sharing), Renault Espace, Volkswagen Sharan, Ford Galaxy, and Opel/Vauxhall Zafira.
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Key Features
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Key Features:
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Spacious and flexible interior, comfortable ride, available with a range of diesel and petrol engines, practical for families, significant emphasis on safety features for its time.
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Manual Coverage
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Systems Covered
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Systems Covered:
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Engine Mechanical, Engine Control System (ECU), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (FWD), Suspension (Front & Rear), Steering System, Brake System (ABS, EBD), Climate Control (HVAC), Electrical System (Wiring Diagrams, Components), Bodywork & Interior, Body Electronics, Safety Systems (Airbags, Seatbelts), Diagnostic Procedures, Troubleshooting.
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Body Electronics:
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Body control modules (BCM), central locking, power windows, remote central locking, interior lighting, exterior lighting, wipers, washers, horn, instrument panel, trip computer.
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Chassis And Body:
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Body structural components, body panels, doors, tailgate, sliding doors, bumpers, glazing, interior trim, seating, and dashboard assembly.
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Procedures Included
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Procedures Included:
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Routine Maintenance, Scheduled Servicing, Component Removal and Installation, Overhaul Procedures, Diagnostic Fault Finding, Electrical Troubleshooting, Adjustment Procedures, Clutch Replacement, Brake Pad/Disc Replacement, Suspension Component Replacement, Timing Belt/Chain Replacement, Engine Rebuild, Transmission Service/Rebuild, Air Conditioning Servicing, Body Panel Repair, Interior Trim Removal/Installation.
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Diagnostics Procedures:
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OBD-II diagnostic trouble code (DTC) reading and interpretation, specific diagnostic routines for each system, data stream analysis, actuator testing.
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Airbag System Service:
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Removal and installation of airbag modules, SRS system diagnostics, reset procedures after deployment.
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Suspension Component Replacement:
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Shock absorbers, springs, control arms, anti-roll bar links, bushings.
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Brake System Repair:
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Brake pad replacement, brake disc replacement, caliper overhaul, brake line replacement, ABS sensor diagnostics and replacement.
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Technical Depth
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Technical Depth:
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Comprehensive. Covers basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring schematics.
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Wiring Diagrams Quality:
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Detailed, color-coded wiring diagrams for all major electrical systems, including power distribution, engine management, chassis electronics, body electronics, and comfort systems.
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Engine Specifications
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Primary Engine
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Primary Engine:
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2.0L (DW10ATED) HDi Diesel
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Alternative Engine 1:
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2.2L (DW12TED4) HDi Diesel
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Alternative Engine 2:
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2.0L (EW10J4) Petrol
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Engine Code 2.0 Hdi:
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DW10ATED
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Engine Code 2.2 Hdi:
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DW12TED4
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Engine Code 2.0 Petrol:
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EW10J4
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Performance
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2.0L Hdi Power:
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109 PS (80 kW; 108 bhp) at 4000 rpm
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2.0L Hdi Torque:
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270 Nm (199 lb-ft) at 1750 rpm
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2.2L Hdi Power:
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128 PS (94 kW; 126 bhp) at 4000 rpm
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2.2L Hdi Torque:
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317 Nm (234 lb-ft) at 1750 rpm (with Overboost)
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2.0L Petrol Power:
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136 PS (100 kW; 134 bhp) at 6000 rpm
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2.0L Petrol Torque:
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190 Nm (140 lb-ft) at 4100 rpm
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Fuel System
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2.0L Hdi Fuel System:
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Common Rail Direct Injection (Bosch)
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2.0L Petrol Fuel System:
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Multi-Point Fuel Injection (MPFI)
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 20,000 km (12,500 miles) or 2 years, whichever comes first (for HDi Diesel); 15,000 km (9,300 miles) or 1 year (for Petrol). Check manual for exact Diesel Particulate Filter (DPF) regeneration intervals if applicable.
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Timing Belt Replacement:
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Every 120,000 km (75,000 miles) or 5 years, whichever comes first for DW10 and DW12 diesel engines. For EW10 petrol engine, check manual for specific interval, often around 100,000 km.
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Automatic Transmission Fluid Change:
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Recommended every 60,000 km (37,000 miles) or 4 years, whichever comes first. Inspect for leaks and condition regularly.
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Fluid Specifications
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Engine Oil 2.0 Hdi:
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ACEA C3 or A3/B4, API SN/CF, SAE 5W-30 or 5W-40 (e.g., Total Quartz INEO MC3 5W-30 or equivalent)
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Engine Oil 2.0 Petrol:
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ACEA A3/B4, API SL/CF, SAE 5W-40 (e.g., Total Quartz 7000 5W-40 or equivalent)
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Coolant:
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Antifreeze/Coolant, silicate-free, long-life (e.g., Paraflu UP or equivalent), typically 50% mix with distilled water.
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Brake Fluid:
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DOT 4 (or DOT 4 LV for ABS/ESP systems, refer to manual)
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Transmission Fluid Manual:
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SAE 75W-80 GL-4 (e.g., Total Transmission BV 75W-80)
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Transmission Fluid Automatic:
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LF-ATF (Low Friction Automatic Transmission Fluid) or equivalent specified by manufacturer (e.g., Total Fluide AT4)
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Power Steering Fluid:
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Hydraulic fluid type LHM+ or Dexron III/Mercon equivalent, check manual for specific recommendation.
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Known Issues
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Known Issues:
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DPF clogging (on early HDi models without proper usage), EGR valve issues, suspension component wear (bushings, ball joints), electrical gremlins (especially door modules and comfort electronics), automatic transmission (AL4) potential issues (solenoids, torque converter), timing belt tensioner failure on some DW engines if not replaced on schedule.
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Known Issues Detail 1:
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Early HDi models (pre-2006) with DPFs may require regular longer drives to ensure proper regeneration. If primarily used for short trips, DPF regeneration failures and subsequent limp mode can occur.
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Known Issues Detail 2:
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The AL4 automatic transmission is known for its sensitivity to fluid condition and temperature. Regular fluid changes are crucial to prevent premature wear of the valve body and solenoids.
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Filter Part Numbers
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Oil Filter 2.0 Hdi:
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Mann-Filter HU 721 x, Bosch 0 451 103 275
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Air Filter 2.0 Hdi:
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Mann-Filter C 25 324, Bosch F 026 400 046
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Cabin Filter 2.0 Hdi:
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Mann-Filter CU 22 007 (Activated Carbon)
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Vehicle History
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Brand Heritage
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Brand Heritage:
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Fiat, an Italian automotive manufacturer founded in 1899, has a long history of producing a wide range of vehicles, from small city cars to commercial vehicles and larger passenger cars.
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Model Evolution
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Model Evolution:
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The Fiat Ulysse is part of a collaborative project between Fiat Group and PSA Peugeot Citroën. The first generation (1994-2002) was launched alongside the Peugeot 806, Citroën Evasion, and Lancia Zeta. The second generation (2002-2010), which this manual covers, was a substantial redesign built on the SEVEL UNIBODY platform, sharing its underpinnings with the Citroën C8, Peugeot 807, and Lancia Phedra.
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Production
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Production Years:
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2002-2010 (2nd Generation)
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Manufacturing Location:
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Sevel sud plant, Val di Sangro, Italy
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