📚 Vehicle Manual Information

Fiat Ulysse 2.0i 16V 2002 Service Repair Manual

🏷️ Basic Information

Make:

Fiat

Model:

Ulysse

Year:

2002

Engine:

2.0i 16V (1998cc)

Engine Code Typical:

Likely an EW10J4 variant or similar PSA engine

👋 Introduction

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

Families and individuals requiring flexible passenger and cargo space.

Key Competitors:

Renault Scénic, Citroën Picasso, Peugeot 807, Ford Galaxy, Volkswagen Sharan, SEAT Alhambra.

Vehicle Strengths:

Versatile interior, comfortable ride, practical for family use, shared platform with other PSA models offering parts commonality.

Manual Value Proposition:

Provides comprehensive, in-depth technical guidance for maintenance, repair, and troubleshooting, empowering owners and independent mechanics to service the vehicle effectively.

📋 Manual Details

Systems Covered:

Engine mechanical, engine management, fuel system, ignition system, lubrication, cooling system, exhaust system, transmission (manual and automatic), clutch, driveline, axles, suspension (front and rear), steering, brakes (hydraulic and ABS), body electrical systems, lighting, instruments, HVAC, body panels, interior trim, safety systems (airbags, seatbelts), diagnosis and troubleshooting.

Page Count:

Estimated 1500-2500 pages (typical for comprehensive service manuals of this era)

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed component removal, inspection, repair, and reassembly for cylinder head, block, pistons, crankshaft, camshafts, valves, timing system.

Engine Management:

Engine Control Unit (ECU) functions, sensor data interpretation, diagnostic trouble codes (DTCs), emission control systems.

Fuel System:

Fuel pump, injectors, fuel pressure regulator, fuel filter replacement, fuel tank service, EVAP system.

Transmission Manual:

Clutch operation, gearbox overhaul, gear selection mechanisms, driveshaft removal and installation.

Transmission Automatic:

Torque converter operation, valve body diagnosis, fluid and filter changes, shift control systems (if applicable to the 2.0i 16V variant).

Brakes:

Brake pad and disc replacement, caliper service, master cylinder, brake booster, ABS system diagnostics and component testing.

Electrical Lighting:

Headlights, taillights, interior lighting, fuse box diagrams, relay functions, bulb replacement procedures.

Preventative Maintenance:

Scheduled oil changes, filter replacements, spark plug intervals, coolant flushes, timing belt/chain inspection and replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common drivability issues, starting problems, electrical faults, and system malfunctions based on symptoms.

Repair Procedures:

Detailed, illustrated instructions for component replacement, system overhauls, and complex repairs across all vehicle systems.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all circuits, allowing for accurate tracing and diagnosis of electrical faults.

Diagnostic Capabilities:

Covers onboard diagnostic (OBD-II) system, DTC interpretation, live data stream analysis, and sensor parameter checks.

Rebuild Instructions:

Provides specifications and procedures for rebuilding major components such as the engine, transmission, and braking system.

Torque Specifications:

Includes critical torque values for all fasteners to ensure proper assembly and prevent damage.

📊 Manual Specifications

File Format Details:

Searchable PDF format with clear, legible text and high-resolution images/diagrams. Hyperlinked table of contents for easy navigation.

Print Quality Description:

Digital file suitable for high-quality printing of individual sections or the entire manual.

Binding Type Digital:

N/A (Digital format)

Paper Type Digital:

N/A (Digital format)

⚙️ Engine Specifications

Engine Name:

Likely a variant of the Peugeot-Citroën (PSA) EW engine family, specifically EW10J4 or similar.

Engine Type:

Inline 4-cylinder, naturally aspirated petrol

Displacement:

1998 cc (2.0 Liters)

Bore X Stroke:

Typical for EW10J4: 85 mm x 88 mm

Compression Ratio:

Typical for EW10J4: 10.8:1

Valvetrain:

DOHC (Double Overhead Camshaft), 4 valves per cylinder (16 valves total), timing belt driven.

Horsepower:

Approx. 136-138 PS (134-136 bhp / 100-102 kW) at around 6000 rpm

Torque:

Approx. 190-200 Nm (140-148 lb-ft) at around 4100 rpm

Fuel Delivery:

Multi-point sequential electronic fuel injection (MPI/SFI)

Fuel Type:

Unleaded petrol (95 RON recommended)

Emission Control:

Catalytic converter, Lambda sensors (oxygen sensors), EGR (Exhaust Gas Recirculation) if applicable.

🔧 Transmission

Standard Transmission Type:

5-speed Manual Transmission

Optional Transmission Type:

4-speed Automatic Transmission (likely based on AL4/DP0 or similar PSA/Renault unit)

Clutch Type:

Hydraulically operated single dry plate clutch

Manual Transmission Fluid:

Refer to manual for specific API GL-4/GL-5 or equivalent specification, typically SAE 75W-80 or 75W-90.

Automatic Transmission Fluid:

Specific ATF (Automatic Transmission Fluid) as per manufacturer's recommendation, e.g., LT71141 or equivalent.

📐 Dimensions

Length:

Approx. 4250 mm (167.3 in)

Width:

Approx. 1780 mm (70.1 in)

Height:

Approx. 1640 mm (64.6 in)

Wheelbase:

Approx. 2690 mm (105.9 in)

Cargo Volume Seats Up:

Approx. 550-650 liters (19.4-22.9 cu ft) depending on seat configuration

Cargo Volume Seats Down:

Up to 1700-2000 liters (59.9-70.6 cu ft)

Curb Weight:

Approx. 1400-1550 kg (3086-3417 lbs)

Gross Vehicle Weight Rating:

Varies by configuration, typically around 2100-2300 kg

🛡️ Safety Features

Euro Ncap Rating Typical:

The Fiat Ulysse (and its platform mates like Peugeot 807/Citroën C8/Lancia Phedra) achieved 4 out of 5 stars in Euro NCAP crash tests for its generation.

ABS:

Anti-lock Braking System

Ebs:

Electronic Brakeforce Distribution (EBD) often standard with ABS.

Traction Control:

ASR (Antipatinage) or ESP (Electronic Stability Programme) may have been optional or standard on higher trims.

Airbags:

Front airbags for driver and passenger, side airbags, and curtain airbags were typically available depending on trim level and options.

Seatbelts:

3-point inertia reel seatbelts with pre-tensioners and load limiters for all occupants, ISOFIX child seat mounting points.

Child Safety:

Child safety door locks, child seat anchorages (ISOFIX).

💡 Technology Features

Audio System:

Factory fitted CD player and radio, often with steering wheel mounted audio controls. Optional navigation systems may have been available.

Cruise Control:

Typically optional or standard on higher trims.

Auxiliary Input:

May be available as an aftermarket addition or specific option depending on the head unit.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 1 year, whichever comes first. Consult the manual for precise mileage and time intervals.

Air Filter Replacement:

Recommended every 30,000 km (18,600 miles) or as needed based on operating conditions.

Cabin Filter Replacement:

Recommended annually or every 15,000 km (9,300 miles).

Spark Plug Replacement:

Typically every 60,000 km (37,000 miles) for standard spark plugs. Platinum or Iridium plugs may have longer intervals, consult manual.

Timing Belt Replacement:

Critical item for the 2.0i 16V (EW10J4) engine. Typically every 120,000 km (75,000 miles) or 5 years, whichever comes first. Failure can cause catastrophic engine damage. The manual will specify the exact interval and components (tensioners, idlers).

Engine Oil Specification:

API SL or higher, ACEA A3/B3 or A3/B4, viscosity typically SAE 5W-40 or 5W-30 as per manufacturer's recommendation for ambient temperature.

Coolant Specification:

OAT (Organic Acid Technology) coolant, typically purple or red, meeting PSA S76-1204 specification. Do not mix coolant types.

Brake Fluid Specification:

DOT 4

Common Problems:

Timing belt tensioner failure (critical), coil pack failure, ABS sensor issues, power window regulators, EGR valve issues, occasional gearbox selector cable issues (manual), automatic transmission control issues (DP0/AL4).

📚 Vehicle History

Fiat Heritage:

Fiat, an Italian automotive manufacturer founded in 1899, has a long history of producing practical and innovative vehicles, including commercial vehicles and passenger cars.

Ulysse Generation 2:

This 2002 model represents the second generation of the Fiat Ulysse, launched in 2002. It was a significant redesign based on the PSA platform shared with the Peugeot 807, Citroën C8, and Lancia Phedra. This generation moved from a more distinct Fiat design to a shared platform approach.

Platform Sharing:

Part of a joint venture between PSA Peugeot Citroën and Fiat, this vehicle was manufactured at the Sevel Sud plant in Italy.

Manufacturing Location:

Italy (Sevel Sud plant)

🏆 Awards & Recognition

Industry Awards:

As a platform shared with Peugeot and Citroën, the Ulysse benefited from the critical reception of its platform mates in the MPV segment, often praised for practicality and comfort.

Consumer Reviews General:

Generally well-regarded for family practicality and space, though reliability perceptions can vary, with common PSA platform issues being a factor.