📚 Vehicle Manual Information

FIAT ULYSSE 2.2I 16V 2002 Full Service Repair Manual

🏷️ Basic Information

Make:

FIAT

Model:

ULYSSE

Year:

2002

Engine Variant:

2.2I 16V

Engine Code Primary:

Likely 2.2 JTD (Diesel) or similar 16V petrol derivative depending on exact market, though '2.2I' typically implies petrol. For the 2002 Ulysse, the most common 2.2 litre was the diesel JTD. Further clarification would be needed for precise petrol variant.

Chassis Code:

220 (Ulysse Mk2)

👋 Introduction

Vehicle Segment:

Large MPV (Multi-Purpose Vehicle)

Target Audience:

Families, fleet operators, individuals requiring versatile passenger and cargo space.

Key Competitors 2002:

Citroën Evasion/Synergie, Peugeot 807, Lancia Zeta, Renault Espace, Ford Galaxy, Volkswagen Sharan, Seat Alhambra.

Modular Interior:

Flexible seating configurations for up to seven passengers, with removable seats for maximum cargo capacity.

Sliding Doors:

Convenient access to rear seating areas, particularly in confined parking spaces.

Engine Options:

Diverse engine range, including the featured 2.2 litre 16V unit known for a balance of performance and economy (often diesel in this size).

📋 Manual Details

Comprehensive Coverage:

Yes

Specific Systems:

Engine, Drivetrain, Chassis, Electrical, Bodywork, HVAC, Safety Systems

Estimated Page Count:

1500+

Type:

Full Service & Repair Manual

Language:

English

Format:

Digital (PDF likely)

📖 Manual Coverage

Powertrain:

Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), engine management, fuel system, ignition system, exhaust system, lubrication system, cooling system.

Drivetrain:

Manual and Automatic Transmissions (clutch, gear selection, torque converter, internal components), differential, drive shafts, CV joints.

Chassis Suspension Steering:

Front and rear suspension (struts, springs, shock absorbers, control arms, bushings), steering system (rack and pinion, power steering pump, steering column), wheel alignment specifications.

Brakes:

Front and rear brake systems (discs, pads, calipers, hydraulic lines, master cylinder, ABS modulator), parking brake system.

Electrical Systems:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior), wiring diagrams, fuse and relay locations, dashboard instrumentation, electronic control units (ECUs).

Body And Interior:

Body panels, doors, windows, locks, latches, sunroof, interior trim, seating, dashboard layout, HVAC (heating, ventilation, air conditioning) system components.

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant checks and changes, brake fluid replacement, transmission fluid checks and changes.

Diagnostics Troubleshooting:

Step-by-step diagnostic procedures for common faults, error code interpretation, symptom-based troubleshooting guides.

Component Replacement Repair:

Detailed instructions for replacing or repairing major components like engines, transmissions, alternators, starters, brake calipers, suspension arms, sensors, and ECUs.

Engine Rebuild:

Cylinder head removal and installation, piston and connecting rod service, crankshaft installation, timing belt/chain replacement, valve timing adjustments.

Transmission Overhaul:

Step-by-step instructions for transmission disassembly, component inspection, seal replacement, and reassembly for both manual and automatic variants.

Electrical Diagnostics:

Using multimeters, oscilloscopes, and diagnostic scanners; tracing electrical faults; wiring harness repair.

Depth:

Expert-level, covering routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Text-searchable for quick information retrieval.

Printability:

Printable, allowing for hard copy reference.

Quality:

High-resolution scans or original digital files ensuring clear diagrams and text.

Type:

N/A (Digital format)

Type:

N/A (Digital format)

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, 16-valve DOHC (likely based on common Fiat/PSA JTD or related petrol unit for the 2.2i designation)

Displacement:

2.2 Liters (2179 cc or similar)

Horsepower Output:

Approximately 120-150 HP (depending on specific 2.2 16V variant, diesel versions often in this range)

Torque Output:

Approximately 270-300 Nm (depending on specific variant, higher for diesel)

Injection System:

Likely Multi-point Fuel Injection (MPI) for petrol or Common Rail Direct Injection (CRDI) for diesel variants.

Fuel Type:

Unleaded Petrol or Diesel (depending on specific 2.2i interpretation)

Coolant Type:

Antifreeze coolant, typically ethylene glycol based. Specific OE coolant recommended.

Oil Type Recommendation:

API SN/SM/SL or ACEA A3/B4. Specific viscosity grade (e.g., 5W-40 or 10W-40) depending on climate and OE recommendation.

Timing Belt Or Chain:

Likely timing belt for this generation, requiring periodic replacement. Check manual for exact interval and belt component kit part numbers.

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Transmission Type:

4-speed Automatic Transmission

Automatic Transmission Features:

Electronically controlled, with potential for snow/sport modes depending on specification.

Manual Transmission Fluid:

GL-4 or GL-5 specification gear oil, with specific viscosity (e.g., 75W-80 or 75W-90). Check manual for exact OE specification.

Automatic Transmission Fluid:

Dexron III or equivalent ATF fluid. Refer to manual for exact fluid type and capacity.

📐 Dimensions

Length:

Approx. 4730 mm

Width:

Approx. 1830 mm

Height:

Approx. 1770 mm

Seating Capacity:

5-7 Passengers

Cargo Volume Min:

Approx. 325 liters (with 7 seats)

Cargo Volume Max:

Approx. 1800+ liters (with rear seats removed)

Curb Weight:

Approx. 1700 - 1850 kg

Gross Vehicle Weight:

Approx. 2400 - 2600 kg

🛡️ Safety Features

Euroncap Rating:

Likely 4-star or 5-star for earlier models, specific rating for 2002 would need verification.

ABS:

Standard Anti-lock Braking System

Esp:

Optional Electronic Stability Program (ESP) on higher trims or later production.

Traction Control:

Traction Control System (TCS) often paired with ESP.

Airbags:

Front airbags for driver and passenger, optional side airbags, and curtain airbags.

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners for all seats.

Child Seat Anchors:

ISOFIX mounting points for child safety seats.

💡 Technology Features

Audio System:

Factory fitted radio/cassette or CD player with speakers, potentially steering wheel controls on higher trims.

Navigation:

Optional factory-fitted satellite navigation system available on some models.

Cruise Control:

Available as an option on many variants.

Parking Sensors:

Rear parking sensors may have been an optional feature.

Bluetooth:

Likely not standard. Aftermarket solutions would be required for Bluetooth connectivity.

🔧 Maintenance

Engine Oil Filter Change:

Every 15,000 km or 12 months, whichever comes first (or as specified by specific OE oil/filter combination).

Timing Belt Replacement:

Typically 90,000 km or 5 years. Crucial to replace as a kit including tensioners and idlers. Failure can cause catastrophic engine damage.

Spark Plugs:

Depending on type (standard or iridium), every 30,000-60,000 km.

Brake Fluid Replacement:

Every 2 years or as per manual recommendation (DOT 3 or DOT 4).

Engine Coolant Capacity:

Approx. 7.0 - 8.0 Liters. Use a 50/50 mix of antifreeze and distilled water.

Power Steering Fluid:

Specific hydraulic fluid recommended by Fiat. Check manual for type and capacity.

Diesel Engine Particulate Filter:

Early diesel models (if 2.2i is diesel) may experience DPF regeneration issues if primarily used for short journeys.

Suspension Wear:

Bushes and ball joints in the suspension can wear over time due to the vehicle's weight and size, leading to knocking sounds and handling issues.

Electrical Gremlins:

Like many vehicles of this era, intermittent electrical faults or warning lights can occur. Thorough diagnosis using wiring diagrams is essential.

Exhaust Gas Recirculation Valve:

EGR valve can become clogged, especially in diesel variants, affecting performance and emissions.

📚 Vehicle History

Fiat Heritage:

Fiat, an Italian automotive manufacturer with a long history dating back to 1899, known for innovation and practical vehicle design, often in partnership with PSA Group for certain models like the Ulysse.

Fiat Ulysse Generations:

The Ulysse (Type 170) was Fiat's first large MPV, launched in 1994. The second generation (Type 220), for which this manual is relevant, debuted in 2002, sharing its platform with the SEAT Alhambra, Ford Galaxy, and PSA's Peugeot 807, Citroën C8, and Lancia Phedra. This was part of the Eurovan 2 project.

Manufacturing Location:

Primarily manufactured in France by Sevel (Société Européenne de Véhicules Légers) under a joint venture between Fiat and PSA Peugeot Citroën.

🏆 Awards & Recognition

Industry Awards:

As part of the Eurovan 2 project, the platform itself received positive reviews for its spaciousness and practicality, contributing to the overall reputation of the Fiat Ulysse as a capable family vehicle.

User Reviews:

Generally praised for practicality, seating flexibility, and comfort on longer journeys, though some common issues related to specific components have been noted by owners.

Emission Standards:

Compliant with European emission standards relevant for the 2002 model year (e.g., Euro 3).