2001 Fiat Ulysse (1st gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2001 Codes Chassis Code: 220 Platform: SE24 👋 Introduction Market Position Segment: Large MPV (Multi-Purpose Vehicle) Target Audience: Families, fleet operators, individuals requiring versatile passenger and cargo space. Competitive Analysis Key Competitors: Citroën Evasion, Peugeot 806, Lancia Zeta, Renault Espace, Volkswagen Sharan, Ford Galaxy. Key Features Versatility: Modular seating arrangements, spacious interior, multiple sliding doors for easy access. Design Philosophy: Practicality, comfort, and European styling. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete diagnosis, repair, and overhaul procedures for all available engine variants. Transmission: Manual and automatic transmission servicing, repair, and overhaul. Fuel System: Fuel injection, fuel pump, injectors, fuel filter replacement, and diagnostic procedures. Electrical System: Wiring diagrams, component testing, fuse identification, lighting, starter, alternator, and battery systems. Brakes: Brake system components, hydraulic system, ABS, brake pad and disc replacement, caliper servicing. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment procedures. Steering: Power steering system diagnosis, pump, rack, tie rod ends, and steering column. Cooling System: Radiator, thermostat, water pump, cooling fan, hoses, and coolant specifications. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, and emissions control. Climate Control: Air conditioning system servicing, refrigerant recharge, heater core, and blower motor. Body And Interior: Body panel removal/installation, door mechanisms, interior trim, seat adjustments, glass replacement. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks. Troubleshooting: Diagnostic flowcharts and step-by-step troubleshooting for common and uncommon faults. Repair: Detailed step-by-step repair instructions for all major components and systems. Rebuilding: Engine and transmission rebuilding procedures, including torque specifications and clearances. Diagnostics: Diagnostic trouble codes (DTCs), on-board diagnostics (OBD-II) interpretation, sensor testing. Technical Depth Depth: Comprehensive coverage from basic fluid changes to complex engine and transmission overhauls, suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format Searchable Text: Yes Printable: Yes Print Quality Resolution: High-resolution for clear diagrams and text. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) Page Count Estimated Pages: ~1000-1500 pages (typical for comprehensive manuals of this era) ⚙️ Engine Specifications Primary Engine Engine Code 1: XU7JP (1.8L) Engine Description 1: Naturally aspirated inline-4 cylinder, SOHC, 8-valve Displacement 1: 1761 cc Bore X Stroke 1: 83 mm x 81.4 mm Compression Ratio 1: 9.2:1 Horsepower 1: 99 hp (74 kW) @ 5500 rpm Torque 1: 153 Nm (113 lb-ft) @ 3000 rpm Fuel System 1: Multi-point fuel injection (MPI) Engine Code 2: XU7JP4 (1.8L) Engine Description 2: Naturally aspirated inline-4 cylinder, DOHC, 16-valve Displacement 2: 1761 cc Horsepower 2: 110 hp (81 kW) @ 5500 rpm Torque 2: 155 Nm (114 lb-ft) @ 4000 rpm Fuel System 2: Multi-point fuel injection (MPI) Engine Code 3: XU10J2TE (2.0L Turbo) Engine Description 3: Turbocharged inline-4 cylinder, SOHC, 8-valve Displacement 3: 1998 cc Bore X Stroke 3: 86 mm x 86 mm Compression Ratio 3: 8.5:1 Horsepower 3: 147 hp (108 kW) @ 5300 rpm Torque 3: 205 Nm (151 lb-ft) @ 2200 rpm Fuel System 3: Multi-point fuel injection (MPI) with turbocharger Engine Code 4: DW10TD (2.0L HDI) Engine Description 4: Turbocharged inline-4 cylinder, DOHC, 16-valve, Common Rail Diesel Injection Displacement 4: 1997 cc Bore X Stroke 4: 85 mm x 88 mm Compression Ratio 4: 17.9:1 Horsepower 4: 90 hp (66 kW) @ 4000 rpm Torque 4: 192 Nm (142 lb-ft) @ 1900 rpm Fuel System 4: Direct injection, Common Rail (HDI) Engine Code 5: ES9J4S (3.0L V6) Engine Description 5: Naturally aspirated V6 cylinder, DOHC, 24-valve Displacement 5: 2946 cc Bore X Stroke 5: 93 mm x 72.7 mm Compression Ratio 5: 10.5:1 Horsepower 5: 190 hp (140 kW) @ 6000 rpm Torque 5: 267 Nm (197 lb-ft) @ 4000 rpm Fuel System 5: Multi-point fuel injection (MPI) Performance Acceleration 0 60 Mph Turbo: Approx. 10.0-10.5 seconds Top Speed Turbo: Approx. 190 km/h (118 mph) Fuel Economy Highway Hdi: Approx. 6.0-6.5 L/100km (36-39 MPG US) 🔧 Transmission Standard Transmission Type 1 8: 5-speed manual Transmission Type 2 0 Turbo: 5-speed manual Optional Transmission Type 2 0 Naturally Aspirated: 4-speed automatic (optional) Transmission Type Hdi: 5-speed manual Transmission Type V6: 4-speed automatic (standard on V6) Features Gear Ratios: Specific gear ratios detailed for each engine and transmission combination within the manual. Clutch Type: Hydraulic, single dry plate Automatic Transmission Fluid: Refer to manual for specific ATF type (e.g., ATF DEXRON III). 📐 Dimensions Exterior Length: 4484 mm (176.5 in) Width: 1801 mm (70.9 in) Height: 1745 mm (68.7 in) Wheelbase: 2821 mm (111.1 in) Interior Seating Capacity: 7 passengers (standard configurations) Cargo Volume: Variable, up to 2880 liters with rear seats folded/removed Weights Curb Weight 1 8 Manual: Approx. 1560 kg (3439 lbs) Gross Vehicle Weight Rating Gvwr: Approx. 2100-2300 kg (4630-5070 lbs),...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Ulysse

Year:

Codes

Chassis Code:

Platform:

👋 Introduction

Market Position

Segment:

Large MPV (Multi-Purpose Vehicle)

Target Audience:

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

Competitive Analysis

Key Competitors:

Citroën Evasion, Peugeot 806, Lancia Zeta, Renault Espace, Volkswagen Sharan, Ford Galaxy.

Key Features

Versatility:

Modular seating arrangements, spacious interior, multiple sliding doors for easy access.

Design Philosophy:

Practicality, comfort, and European styling.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete diagnosis, repair, and overhaul procedures for all available engine variants.

Transmission:

Manual and automatic transmission servicing, repair, and overhaul.

Fuel System:

Fuel injection, fuel pump, injectors, fuel filter replacement, and diagnostic procedures.

Electrical System:

Wiring diagrams, component testing, fuse identification, lighting, starter, alternator, and battery systems.

Brakes:

Brake system components, hydraulic system, ABS, brake pad and disc replacement, caliper servicing.

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment procedures.

Steering:

Power steering system diagnosis, pump, rack, tie rod ends, and steering column.

Cooling System:

Radiator, thermostat, water pump, cooling fan, hoses, and coolant specifications.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, and emissions control.

Climate Control:

Air conditioning system servicing, refrigerant recharge, heater core, and blower motor.

Body And Interior:

Body panel removal/installation, door mechanisms, interior trim, seat adjustments, glass replacement.

Procedures Included

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks.

Troubleshooting:

Diagnostic flowcharts and step-by-step troubleshooting for common and uncommon faults.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Rebuilding:

Engine and transmission rebuilding procedures, including torque specifications and clearances.

Diagnostics:

Diagnostic trouble codes (DTCs), on-board diagnostics (OBD-II) interpretation, sensor testing.

Technical Depth

Depth:

Comprehensive coverage from basic fluid changes to complex engine and transmission overhauls, suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Searchable Text:

Printable:

Print Quality

Resolution:

High-resolution for clear diagrams and text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

Page Count

Estimated Pages:

~1000-1500 pages (typical for comprehensive manuals of this era)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

XU7JP (1.8L)

Engine Description 1:

Naturally aspirated inline-4 cylinder, SOHC, 8-valve

Displacement 1:

1761 cc

Bore X Stroke 1:

83 mm x 81.4 mm

Compression Ratio 1:

9.2:1

Horsepower 1:

99 hp (74 kW) @ 5500 rpm

Torque 1:

153 Nm (113 lb-ft) @ 3000 rpm

Fuel System 1:

Multi-point fuel injection (MPI)

Engine Code 2:

XU7JP4 (1.8L)

Engine Description 2:

Naturally aspirated inline-4 cylinder, DOHC, 16-valve

Displacement 2:

1761 cc

Horsepower 2:

110 hp (81 kW) @ 5500 rpm

Torque 2:

155 Nm (114 lb-ft) @ 4000 rpm

Fuel System 2:

Multi-point fuel injection (MPI)

Engine Code 3:

XU10J2TE (2.0L Turbo)

Engine Description 3:

Turbocharged inline-4 cylinder, SOHC, 8-valve

Displacement 3:

1998 cc

Bore X Stroke 3:

86 mm x 86 mm

Compression Ratio 3:

8.5:1

Horsepower 3:

147 hp (108 kW) @ 5300 rpm

Torque 3:

205 Nm (151 lb-ft) @ 2200 rpm

Fuel System 3:

Multi-point fuel injection (MPI) with turbocharger

Engine Code 4:

DW10TD (2.0L HDI)

Engine Description 4:

Turbocharged inline-4 cylinder, DOHC, 16-valve, Common Rail Diesel Injection

Displacement 4:

1997 cc

Bore X Stroke 4:

85 mm x 88 mm

Compression Ratio 4:

17.9:1

Horsepower 4:

90 hp (66 kW) @ 4000 rpm

Torque 4:

192 Nm (142 lb-ft) @ 1900 rpm

Fuel System 4:

Direct injection, Common Rail (HDI)

Engine Code 5:

ES9J4S (3.0L V6)

Engine Description 5:

Naturally aspirated V6 cylinder, DOHC, 24-valve

Displacement 5:

2946 cc

Bore X Stroke 5:

93 mm x 72.7 mm

Compression Ratio 5:

10.5:1

Horsepower 5:

190 hp (140 kW) @ 6000 rpm

Torque 5:

267 Nm (197 lb-ft) @ 4000 rpm

Fuel System 5:

Multi-point fuel injection (MPI)

Performance

Acceleration 0 60 Mph Turbo:

Approx. 10.0-10.5 seconds

Top Speed Turbo:

Approx. 190 km/h (118 mph)

Fuel Economy Highway Hdi:

Approx. 6.0-6.5 L/100km (36-39 MPG US)

🔧 Transmission

Standard

Transmission Type 1 8:

5-speed manual

Transmission Type 2 0 Turbo:

5-speed manual

Optional

Transmission Type 2 0 Naturally Aspirated:

4-speed automatic (optional)

Transmission Type Hdi:

5-speed manual

Transmission Type V6:

4-speed automatic (standard on V6)

Features

Gear Ratios:

Specific gear ratios detailed for each engine and transmission combination within the manual.

Clutch Type:

Hydraulic, single dry plate

Automatic Transmission Fluid:

Refer to manual for specific ATF type (e.g., ATF DEXRON III).

📐 Dimensions

Exterior

Length:

4484 mm (176.5 in)

Width:

1801 mm (70.9 in)

Height:

1745 mm (68.7 in)

Wheelbase:

2821 mm (111.1 in)

Interior

Seating Capacity:

7 passengers (standard configurations)

Cargo Volume:

Variable, up to 2880 liters with rear seats folded/removed

Weights

Curb Weight 1 8 Manual:

Approx. 1560 kg (3439 lbs)

Gross Vehicle Weight Rating Gvwr:

Approx. 2100-2300 kg (4630-5070 lbs), varies by engine

Towing Capacity Unbraked:

750 kg (1653 lbs)

Towing Capacity Braked:

1500 kg (3307 lbs)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Not formally rated by Euro NCAP during its initial launch phase, but based on shared platform characteristics with other models, expected to offer moderate protection.

Active Features

Standard on most models, with EBD (Electronic Brake-force Distribution) on some variants.

Traction Control:

Optional on some higher-trim or later models.

Passive Features

Airbags:

Driver, front passenger airbags standard. Optional side airbags available on some trims.

Seatbelts:

Three-point seatbelts with pretensioners for all seating positions.

Child Seat Anchors:

ISOFIX mounting points in rear seats.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette or CD player with speakers, basic amplification.

Navigation:

Optional satellite navigation system available on higher trim levels or as an aftermarket fitment.

Driver Assistance

Cruise Control:

Optional on some models.

Parking Sensors:

Optional rear parking sensors available on later or higher-specification models.

Connectivity

Auxiliary Input:

Typically not standard; may have been an option or aftermarket addition.

Bluetooth:

Not available on this generation as a factory option.

🔧 Maintenance

Service Intervals

Oil Change Interval Petrol:

Every 15,000 km or 12 months, whichever comes first.

Oil Change Interval Diesel:

Every 10,000 km or 12 months, whichever comes first (for HDI models).

Timing Belt Replacement:

Every 90,000 km or 5 years for petrol engines (XU series). Specific intervals for DW10TD HDI engine may vary; consult manual.

Air Filter Replacement:

Every 30,000 km or 24 months.

Fuel Filter Replacement Diesel:

Every 40,000 km or 24 months for HDI models.

Fluid Specifications

Engine Oil Specification Petrol:

API SJ/CF, ACEA A3/B3, SAE 10W-40 or 5W-40.

Engine Oil Specification Diesel:

API CF/CG-4, ACEA B3/B4, SAE 5W-40 or 10W-40 (synthetic or semi-synthetic).

Coolant Specification:

Antifreeze coolant, ethylene glycol-based, meeting Fiat specification (typically HOAT or OAT types).

Brake Fluid Specification:

DOT 4

Power Steering Fluid:

Specific hydraulic fluid (e.g., LHM or ATF depending on system type).

Manual Transmission Fluid:

API GL-4, SAE 75W-80 or 75W-90.

Known Issues

Common Issue 1:

Timing belt failure on XU engines if not replaced at recommended intervals, leading to severe engine damage.

Common Issue 2:

Electrical gremlins, particularly related to the body control module (BCM) and door electronics. Fuse box issues.

Common Issue 3:

Wear on suspension bushings and ball joints leading to knocking noises and poor handling.

Common Issue 4:

Power steering leaks or pump failure.

Common Issue 5:

Catalytic converter efficiency degradation, particularly on higher mileage vehicles.

Common Issue 6:

Glow plug issues on HDI diesel engines.

Common Issue 7:

Dashboard warning lights illumination due to sensor faults or wiring issues.

📚 Vehicle History

Brand Heritage

Fiat History:

Fiat has a long-standing history in automotive manufacturing, known for small cars and increasingly for MPVs and commercial vehicles. The Ulysse represents Fiat's entry into the European MPV segment, built upon a collaborative effort.

Model Evolution

Platform Sharing:

The Fiat Ulysse (1st generation) was part of the large MPV 'Eurovan' project, a collaboration between PSA Peugeot Citroën and Fiat Auto. This resulted in the Fiat Ulysse, Citroën Evasion, Peugeot 806, and Lancia Zeta, sharing a common platform and many components.

Production

Production Years:

1994–2002 (1st generation)

Manufacturing Location:

Sevelnord factory, Hordain, France.

Facelift:

Received a facelift in 1999, incorporating updated styling and revised features.