Fiat Ulysse 2.0 HDi With particle filter 2002 Service Repair Manual
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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Generation: Second Generation (2002-2010) Year: 2002 Codes Engine Code Prefix: HDi (High-pressure Direct Injection) Chassis Code: 179 👋 Introduction Market Position Segment: Large MPV (Multi-Purpose Vehicle) / Minivan Target Audience: Families, individuals needing versatile passenger and cargo space Competitive Analysis Key Competitors 2002: Citroën C8, Peugeot 807, Lancia Phedra, Renault Espace, Volkswagen Sharan, Ford Galaxy, Seat Alhambra Key Features Upholstery Options: Cloth, Alcantara (depending on trim level) Seating Capacity: 5-7 or 8 seats (configurable) Door Configuration: Standard front doors, sliding rear doors Body Style: MPV 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Digital (likely PDF) Page Count Estimated Page Count: 800-1200 📖 Manual Coverage Systems Covered Engine Systems: 2.0 HDi Diesel Engine (DW10ATED4), Fuel System (Common Rail, Injectors, Glow Plugs), Cooling System, Lubrication System, Intake and Exhaust Systems, Turbocharging, Emission Control (DPF - Diesel Particulate Filter, EGR) Transmission Systems: Manual Transmission (MLGU, BE4R), Clutch System, Driveshafts Chassis Systems: Front and Rear Suspension, Steering System, Braking System (ABS, EBD), Wheel Alignment Electrical Systems: Engine Control Unit (ECU), Body Control Module (BCM), Lighting Systems (Headlamps, Taillamps), Dashboard Instruments, Audio System, HVAC Controls, Power Windows and Locks, Central Locking, Immobilizer System, Diagnostic Trouble Codes (DTCs) Body And Interior: Body Panels, Doors, Hood, Tailgate, Bumpers, Seating Systems, Interior Trim, HVAC Components (Recirculation, Filters) Procedures Included Maintenance Procedures: Scheduled Maintenance (Oil Changes, Filter Replacements), Timing Belt Replacement, Fluid Level Checks and Top-ups, Brake Pad/Disc Replacement, Spark Plug/Glow Plug Replacement Diagnostic Procedures: Troubleshooting Common Problems, Reading Diagnostic Trouble Codes (DTCs) via OBD-II, Symptom-based Diagnostics Repair Procedures: Engine Overhaul (Partial/Full), Transmission Repair, Suspension Component Replacement, Brake System Overhaul, Electrical Component Replacement, Body Panel Repair/Replacement Special Procedures: Diesel Particulate Filter (DPF) Regeneration and Replacement, EGR Valve Cleaning/Replacement, Turbocharger Diagnosis and Replacement, Common Rail System Diagnosis and Repair Technical Depth Depth: Comprehensive: Covers routine maintenance, troubleshooting, diagnostics, and complete repair procedures for all major vehicle systems. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable Text (if converted properly from original source) Print Quality Resolution: High-resolution diagrams and text Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-Cylinder Diesel Engine Name: DW10ATED4 Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85 mm x 88 mm Compression Ratio: 17.7:1 Valve Train: DOHC (Double Overhead Camshaft), 4 Valves per Cylinder Ignition Type: Compression Ignition (Diesel) Performance Horsepower: 109 PS (107 bhp; 80 kW) @ 4000 rpm Torque: 270 Nm (199 lb-ft) @ 1750 rpm Fuel System Fuel Type: Diesel Fuel Fuel Delivery: Common Rail Direct Injection (CRDi) with Turbocharging and Intercooler Emission Control: Euro 3 Compliant, Equipped with Diesel Particulate Filter (DPF) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Manual Gear Ratios: Gear ratios vary by specific transmission model (e.g., MLGU, BE4R), typically around 3.167:1 (1st), 1.870:1 (2nd), 1.281:1 (3rd), 0.919:1 (4th), 0.771:1 (5th), 3.300:1 (Reverse), 3.765:1 (Final Drive) Optional Transmission Type Optional: 4-Speed Automatic Transmission (AL4/DP0 - likely) Features Clutch Type: Hydraulically Operated Dry Single-Plate Clutch 📐 Dimensions Exterior Length: 4756 mm (187.2 in) Width: 1854 mm (73.0 in) Height: 1735 mm (68.3 in) Wheelbase: 2823 mm (111.1 in) Front Track: 1575 mm (62.0 in) Rear Track: 1570 mm (61.8 in) Interior Passenger Volume: Approx. 3300-3600 Liters (depending on seating configuration) Cargo Luggage Capacity Seats Up: Approx. 400-700 Liters (depending on seating configuration) Luggage Capacity Seats Down: Approx. 1500-2000+ Liters (with rear seats removed) Weights Curb Weight: Approx. 1700-1850 kg (3748-4079 lbs) Gross Vehicle Weight Rating Gvwr: Approx. 2400-2500 kg (5291-5511 lbs) Towing Capacity Braked: Approx. 1500-1800 kg (3307-3968 lbs) 🛡️ Safety Features Ratings Euro Ncap Rating 2003: 4 Stars (Adult Occupant Protection) Active Features ABS: Standard Anti-lock Braking System Ebd: Standard Electronic Brakeforce Distribution Traction Control: Optional (likely on higher trims) Passive Features Airbags Front: Driver and Front Passenger Airbags Airbags Side: Optional Side Airbags and Curtain Airbags Seatbelts: 3-point Seatbelts with Pretensioners for all seats Isofix Mounting Points: Standard for rear seats 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player with steering wheel controls, speaker configurations vary by trim level. Navigation: Optional satellite navigation system available on higher trim levels. Driver Assistance Cruise Control: Available as an option or standard on higher trims. Parking Sensors: Optional rear parking sensors available. Connectivity OBD Ii Port: Standard OBD-II (On-Board Diagnostics) port for engine and emissions diagnostics. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 15,000 miles (24,000 km) or 12 months, whichever comes first. Timing Belt Replacement: Recommended every 72,000 miles (120,000 km) or 5 years. Air Filter Replacement: Every 24,000 miles (40,000 km) or 24 months. Fuel Filter Replacement: Every 36,000 miles (60,000 km) or 36 months. Fluid Specifications Engine Oil Type: ACEA A3/B4 or A5/B5, API CF, SAE 5W-30 or 5W-40 (check specific vehicle requirement) Engine...
Front and Rear Suspension, Steering System, Braking System (ABS, EBD), Wheel Alignment
Electrical Systems:
Engine Control Unit (ECU), Body Control Module (BCM), Lighting Systems (Headlamps, Taillamps), Dashboard Instruments, Audio System, HVAC Controls, Power Windows and Locks, Central Locking, Immobilizer System, Diagnostic Trouble Codes (DTCs)
Troubleshooting Common Problems, Reading Diagnostic Trouble Codes (DTCs) via OBD-II, Symptom-based Diagnostics
Repair Procedures:
Engine Overhaul (Partial/Full), Transmission Repair, Suspension Component Replacement, Brake System Overhaul, Electrical Component Replacement, Body Panel Repair/Replacement
Special Procedures:
Diesel Particulate Filter (DPF) Regeneration and Replacement, EGR Valve Cleaning/Replacement, Turbocharger Diagnosis and Replacement, Common Rail System Diagnosis and Repair
Technical Depth
Depth:
Comprehensive: Covers routine maintenance, troubleshooting, diagnostics, and complete repair procedures for all major vehicle systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text (if converted properly from original source)
Print Quality
Resolution:
High-resolution diagrams and text
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-Cylinder Diesel
Engine Name:
DW10ATED4
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85 mm x 88 mm
Compression Ratio:
17.7:1
Valve Train:
DOHC (Double Overhead Camshaft), 4 Valves per Cylinder
Ignition Type:
Compression Ignition (Diesel)
Performance
Horsepower:
109 PS (107 bhp; 80 kW) @ 4000 rpm
Torque:
270 Nm (199 lb-ft) @ 1750 rpm
Fuel System
Fuel Type:
Diesel Fuel
Fuel Delivery:
Common Rail Direct Injection (CRDi) with Turbocharging and Intercooler
Emission Control:
Euro 3 Compliant, Equipped with Diesel Particulate Filter (DPF)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Manual Gear Ratios:
Gear ratios vary by specific transmission model (e.g., MLGU, BE4R), typically around 3.167:1 (1st), 1.870:1 (2nd), 1.281:1 (3rd), 0.919:1 (4th), 0.771:1 (5th), 3.300:1 (Reverse), 3.765:1 (Final Drive)
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (AL4/DP0 - likely)
Features
Clutch Type:
Hydraulically Operated Dry Single-Plate Clutch
📐 Dimensions
Exterior
Length:
4756 mm (187.2 in)
Width:
1854 mm (73.0 in)
Height:
1735 mm (68.3 in)
Wheelbase:
2823 mm (111.1 in)
Front Track:
1575 mm (62.0 in)
Rear Track:
1570 mm (61.8 in)
Interior
Passenger Volume:
Approx. 3300-3600 Liters (depending on seating configuration)
Cargo
Luggage Capacity Seats Up:
Approx. 400-700 Liters (depending on seating configuration)
3-point Seatbelts with Pretensioners for all seats
Isofix Mounting Points:
Standard for rear seats
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with steering wheel controls, speaker configurations vary by trim level.
Navigation:
Optional satellite navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Available as an option or standard on higher trims.
Parking Sensors:
Optional rear parking sensors available.
Connectivity
OBD Ii Port:
Standard OBD-II (On-Board Diagnostics) port for engine and emissions diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 miles (24,000 km) or 12 months, whichever comes first.
Timing Belt Replacement:
Recommended every 72,000 miles (120,000 km) or 5 years.
Air Filter Replacement:
Every 24,000 miles (40,000 km) or 24 months.
Fuel Filter Replacement:
Every 36,000 miles (60,000 km) or 36 months.
Fluid Specifications
Engine Oil Type:
ACEA A3/B4 or A5/B5, API CF, SAE 5W-30 or 5W-40 (check specific vehicle requirement)
Engine Oil Capacity:
Approx. 5.2 Liters (5.5 US Quarts) with filter change
Coolant Type:
Antifreeze/Coolant, typically OAT (Organic Acid Technology) based, blue or green color, with a 50/50 mix of coolant and distilled water.
Coolant Capacity:
Approx. 8.0 Liters (8.5 US Quarts)
Brake Fluid Type:
DOT 4
Power Steering Fluid Type:
Use specific power steering fluid as per manufacturer recommendation (e.g., PSA S71 2710 or equivalent)
Transmission Fluid Type Manual:
API GL-5, SAE 75W-80
Transmission Fluid Type Automatic:
LF (Low Friction) ATF fluid compatible with AL4/DP0 transmissions
Known Issues
Diesel Particulate Filter Dpf:
DPF clogging due to short journeys or incorrect driving cycles, leading to reduced performance and warning lights. Requires forced regeneration or cleaning.
Egr Valve:
EGR (Exhaust Gas Recirculation) valve can get clogged with carbon deposits, causing rough idling and loss of power.
Timing Belt Tensioner:
Potential failure of the timing belt tensioner, leading to premature belt wear or failure.
Glow Plugs:
Glow plugs can fail, impacting cold-start performance.
Suspension Components:
Wear on suspension bushes and ball joints can lead to knocking noises and compromised handling.
Electrical Gremlins:
As with many vehicles of this era, minor electrical issues can arise, often related to wiring harnesses or sensor failures.
Parts Catalogue Reference
Common Filters:
Oil Filter: Mann-Filter W 719/5, Mahle OC 220; Air Filter: Mann-Filter C 26 004; Fuel Filter: Mann-Filter WK 820/17
📚 Vehicle History
Brand Heritage
Fiat Heritage:
Fiat, an Italian manufacturer, has a long history dating back to 1899, known for innovation in various automotive segments including compact cars and commercial vehicles.
Model Evolution
Ulysse Generation 2 Platform:
This generation (2002-2010) was developed under the Sevel (Società Europea Veicoli) joint venture between Fiat Group and PSA Peugeot Citroën, sharing its platform with the Citroën C8, Peugeot 807, and Lancia Phedra.
Production
Manufacturing Location:
Sevel Nord plant, Hordain, France
Production Years:
2002-2010 (for this generation)
🏆 Awards & Recognition
Recognitions
Automotive Press Reviews:
While specific awards for the 2002 Ulysse 2.0 HDi are not widely publicized, the model generally received positive reviews for its practicality, spaciousness, and comfortable ride, aligning with the strengths of its platform siblings.