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2007 Fiat Ulysse (2nd gen) Service and Repair Manual

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Basic Information Identification Make: Fiat Model: Ulysse Year: 2007 Generation: 2nd Gen (2002-2010) Codes Platform: PSA EW/ES platform (shared with Citroën C8, Peugeot 807, Lancia Phedra) Introduction Market Position Segment:...
Type: Cars
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Sku: 584728
Tags: Fiat Ulysse
2007 Fiat Ulysse (2nd gen) Service and Repair Manual
Basic Information
Identification
Make: Fiat
Model: Ulysse
Year: 2007
Generation: 2nd Gen (2002-2010)
Codes
Platform: PSA EW/ES platform (shared with Citroën C8, Peugeot 807, Lancia Phedra)
Introduction
Market Position
Segment: Large MPV (Multi-Purpose Vehicle)
Target Audience: Families, taxi services, fleet operators seeking a versatile and spacious vehicle.
Competitive Analysis
Competitors: Citroën C8, Peugeot 807, Lancia Phedra, Renault Espace, Ford Galaxy, Volkswagen Sharan, SEAT Alhambra, Opel Zafira (larger variants)
Key Features
Interior Flexibility: Modular seating system, sliding rear doors for easy access, ample cargo space.
Platform Sharing: Benefits from PSA's extensive engineering and component sharing, contributing to availability of parts and established service procedures.
Manual Details
Coverage Areas
Engines: 2.0L 16V (EW10J4), 2.2L 16V (EW12J4), 2.0L JTD (DW10ATED4), 2.2L JTD (DW12ATED4)
Transmissions: 5-speed manual (MLGU), 4-speed automatic (AL4)
Body Styles: MPV
Regions: Europe
Page Count
Estimated Pages: Approx. 1000+
Manual Type
Type: Service and Repair Manual
Language
Language: English
Format
Format: PDF
Manual Coverage
Systems Covered
Powertrain: Engine mechanicals (including cylinder head, pistons, crankshaft, camshafts), Fuel system (injection, pumps, injectors, pressure regulation), Ignition system (coils, spark plugs, sensors), Cooling system (radiator, water pump, thermostat), Lubrication system (oil pump, oil filter, oil galleries), Exhaust system (manifold, catalytic converter, muffler), Turbocharging (for diesel variants)
Transmission: Manual transmission overhaul and repair, Automatic transmission diagnosis, repair, and fluid service
Chassis: Suspension systems (front MacPherson struts, rear torsion beam), Steering system (hydraulic power steering), Brake system (ABS, EBD, disc/drum configurations, hydraulic lines, callipers, master cylinder), Wheel and tire specifications, Wheel alignment
Electrical: Battery, charging system (alternator, starter motor), Lighting systems (headlights, taillights, interior lights), Fuses and relays, Wiring diagrams, Instrument cluster, Body control module (BCM), Central locking, Power windows, Audio system, Air conditioning control unit
Body: Exterior body panels, Doors, Windows, Locks, Hinges, Bumpers, Interior trim, Seats, Dashboard, HVAC system (evaporator, condenser, blower motor, ducting), Sunroof (if equipped)
Procedures Included
Maintenance: Scheduled maintenance intervals, Oil and filter changes, Air filter replacement, Spark plug replacement, Fuel filter replacement, Coolant flush and replacement, Brake fluid flush, Timing belt/chain inspection and replacement (engine dependent)
Troubleshooting: Diagnostic trouble codes (DTCs) and their meanings, Symptom-based troubleshooting guides, Electrical diagnostic procedures
Repair: Engine component replacement, Transmission repair, Brake component replacement, Suspension and steering component replacement, Electrical component repair and replacement, Body panel repair and replacement
Diagnostics: OBD-II diagnostic procedures, Use of diagnostic scan tools, Live data interpretation
Technical Depth
Depth: Comprehensive, covering routine maintenance to major component overhauls. Includes detailed diagnostic procedures, torque specifications, and repair sequences. Suitable for professional technicians and advanced DIY enthusiasts.
Manual Specifications
File Format
Quality: High-resolution PDF with searchable text and clear, legible diagrams.
Print Quality
Pages Printable: Printable
Binding Type
Format Type: Digital (PDF)
Paper Type
Digital Features: Hyperlinked chapters for easy navigation, embedded image quality.
Engine Specifications
Primary Engine
Gasoline 1: 2.0L (1997cc) EW10J4 I4, 16V DOHC, naturally aspirated
Gasoline 2: 2.2L (2230cc) EW12J4 I4, 16V DOHC, naturally aspirated
Diesel 1: 2.0L (1997cc) DW10ATED4 HDi I4, 16V DOHC, turbocharged common rail direct injection
Diesel 2: 2.2L (2179cc) DW12ATED4 HDi I4, 16V DOHC, turbocharged common rail direct injection (with Diesel Particulate Filter - DPF)
Performance
2.0L Gasoline Hp: 136 hp (100 kW) @ 6000 rpm
2.0L Gasoline Torque: 190 Nm (140 lb-ft) @ 4100 rpm
2.2L Gasoline Hp: 158 hp (116 kW) @ 6000 rpm
2.2L Gasoline Torque: 217 Nm (160 lb-ft) @ 3900 rpm
2.0L Diesel Hp: 109 hp (80 kW) @ 4000 rpm
2.0L Diesel Torque: 270 Nm (199 lb-ft) @ 1750 rpm
2.2L Diesel Hp: 128 hp (94 kW) @ 4000 rpm
2.2L Diesel Torque: 314 Nm (231 lb-ft) @ 2000 rpm
Fuel System
Gasoline Injection: Multi-point Fuel Injection (MPI)
Diesel Injection: Common Rail Direct Injection (CRDi) with Bosch or Delphi systems
Transmission
Standard
Manual: 5-speed Manual Transmission (MLGU)
Optional
Automatic: 4-speed Automatic Transmission (AL4)
Features
Automatic Modes: Possibly includes Comfort/Sport modes depending on trim
Fluid Specifications
Manual Transmission Fluid: GL-4 SAE 75W-80 or similar, capacity approx. 2.1-2.3 liters
Automatic Transmission Fluid: ATF LT 71141 or equivalent (e.g., Mobil ATF LT 71141), capacity approx. 3.5-4.0 liters for torque converter fill
Dimensions
Exterior
Length: 4750 mm (187.0 in)
Width: 1900 mm (74.8 in) (incl. mirrors)
Height: 1740 mm (68.5 in)
Wheelbase: 2820 mm (111.0 in)
Interior
Seating Capacity: 7 seats
Cargo
Luggage Capacity Seats Up: Approx. 140 liters (behind 3rd row)
Luggage Capacity Seats Down: Approx. 750 liters (behind 2nd row), Over 2000 liters with all rear seats folded
Weights
Curb Weight: Approx. 1700-1900 kg (depending on engine and trim)
Safety Features
Ratings
Euroncap Rating: 4 Stars (for the second generation model)
Active Features
Braking: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Stability: Electronic Stability Program (ESP) - optional or standard on higher trims
Passive Features
Airbags: Frontal airbags for driver and passenger, Side airbags (front), Curtain airbags (front and rear)
Seat Belts: Three-point seatbelts with pretensioners for all occupants, ISOFIX child seat anchor points
Technology Features
Infotainment
Audio System: Factory fitted radio/CD player, potentially with steering wheel controls. Optional navigation system might be available on higher trims.
Climate Control: Manual or automatic dual-zone climate control systems.
Driver Assistance
Cruise Control: Standard or optional cruise control.
Parking Sensors: Optional rear parking sensors available.
Connectivity
Bluetooth: Likely not standard, but some later models or aftermarket installations might include Bluetooth connectivity.
Maintenance
Service Intervals
Oil Change Gasoline: Every 15,000 km (9,300 miles) or 1 year, whichever comes first
Oil Change Diesel: Every 10,000-15,000 km (6,200-9,300 miles) or 1 year, depending on driving conditions and oil type
Timing Belt Gasoline 2.0L: 120,000 km (75,000 miles) or 5 years
Timing Belt Gasoline 2.2L: 100,000 km (62,000 miles) or 5 years
Timing Belt Diesel 2.0L: 120,000 km (75,000 miles) or 5 years
Timing Belt Diesel 2.2L: 150,000 km (93,000 miles) or 5 years
Fluid Specifications
Engine Oil Gasoline: SAE 5W-40, API SL/SM, ACEA A3/B4 (e.g., Selenia Star Pure Energy 5W-40)
Engine Oil Diesel: SAE 5W-30, API CF, ACEA B4/B5 (e.g., Selenia WR Diesel 5W-30) - Check for specific DPF compatibility for 2.2 JTD
Coolant: Paraflu UP (Parafreeze) - Blue, 50/50 mix with demineralized water (ethylene glycol based)
Brake Fluid: DOT 4
Known Issues
Diesel Dpf: Diesel Particulate Filter (DPF) regeneration issues, particularly in urban driving, can lead to clogging and warning lights if not addressed.
Electrical Gremlins: Common for vehicles of this era, especially related to body control modules, window regulators, and central locking. Loose connections or failing sensors.
Suspension Wear: Front suspension components (bushings, ball joints) and rear suspension components can experience wear due to the vehicle's weight and usage.
Hdi Injectors: Common rail diesel injectors can be sensitive to fuel quality and may require cleaning or replacement over time.
Automatic Transmission Al4: The AL4 automatic transmission can be prone to solenoid issues, jerky shifting, or overheating if not properly maintained or if the hydraulic system has leaks.
Vehicle History
Brand Heritage
Fiat Legacy: Fiat has a long history in automotive manufacturing, known for practical and innovative vehicles, including earlier MPV designs like the Fiat Multipla.
Model Evolution
Ulysse Generations: First generation (1994-2002) was a joint venture with PSA. Second generation (2002-2010) continued the platform sharing with Citroën C8, Peugeot 807, and Lancia Phedra, representing a significant update in design and technology.
Production
Manufacturing Location: Sevel Sud plant, Hordain, France (as part of the PSA Group joint venture)
Production Years 2Nd Gen: 2002-2010
Awards & Recognition
Recognitions
Mpv Segment Performance: While the Ulysse itself didn't win specific major awards, its shared platform with the Peugeot 807 and Citroën C8 meant it inherited a design lauded for practicality and space, contributing to their popularity in the MPV segment.
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