2009 Fiat Ulysse (2nd gen) Service and Repair Manual
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Basic Information Identification Make: Fiat Model: Ulysse Year: 2009 Generation: 2nd Generation (Facelift 2) Codes Platform Code: SE28 Introduction Market Position Vehicle Segment: Large MPV (Multi-Purpose Vehicle) / Minivan Target Audience: Families, executive transport, fleet users seeking practicality and space. Competitive Analysis Key Competitors: Citroën C8, Peugeot 807, Lancia Phedra (all part of the SEVEL platform sharing). Key Features Versatility: Spacious interior with flexible seating configurations, ideal for passenger transport. Design: Stylish Italian design influenced by Fiat's contemporary styling cues of the era. Platform Sharing: Based on the widely recognized and robust Eurovan platform. Manual Details Coverage Areas Primary Coverage: Service and Repair Regional Applicability: European Markets Page Count Estimated Page Count: 700-1000 Manual Type Manual Type: Workshop Manual / Service Manual Language Language: English Format Format: Digital (PDF) Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, diagnostics, and repair for all specified engine variants. Engine Management: ECU diagnostics, sensor testing, fuel injection system, ignition system, emissions control. Transmission Manual: Service, repair, and overhaul of manual transmissions. Transmission Automatic: Service, repair, and overhaul of automatic transmissions (if applicable to specific engine/trim). Drivetrain: Front-wheel drive system, CV joints, driveshafts, differential service. Suspension: Front and rear suspension components, alignment procedures, shock absorbers, springs, control arms. Steering: Power steering system, steering rack, tie rods, steering column. Brakes: Hydraulic system, ABS, EBD, brake discs, pads, calipers, brake lines, parking brake. Electrical System: 12V battery, charging system, starter motor, lighting systems, horn, power windows, mirrors, central locking. Body Electrical: Instrument cluster, dashboard controls, interior lighting, exterior lighting schematics. HVAC: Air conditioning system, heating system, climate control operation, component testing. Body Panels: Door mechanisms, hood, tailgate, bumpers, trim removal and installation. Interior: Seat removal, dashboard trim, center console, headliner. Safety Systems: Airbag system diagnostics and replacement procedures. Procedures Included Scheduled Maintenance: Detailed instructions for routine maintenance services at specified intervals. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon faults. Repair Procedures: Step-by-step instructions for component removal, installation, and repair. Diagnostic Procedures: Guidance on using diagnostic tools and interpreting fault codes. Component Replacement: Specific procedures for replacing key components across all major systems. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Torque Specifications: Detailed torque values for all critical fasteners. Fluid Capacities And Types: Exact specifications for all fluids (engine oil, coolant, brake fluid, transmission fluid, etc.). Technical Depth Depth Level: Comprehensive - Covers everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Focus: Advanced diagnostic strategies, including sensor data analysis and ECU reset procedures. Manual Specifications File Format File Format: Searchable PDF Print Quality Image Resolution: High resolution for clear diagrams and illustrations Readability: Optimized for digital viewing and printing Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) Engine Specifications Primary Engine Engine Code Examples: RPO codes may vary, common for PSA sourced engines: DW10ATED4 (2.0 HDi), EW10J4 (2.0 Petrol), EW12J4 (2.2 Petrol), DW12TED4 (2.2 HDi). Engine Type: Inline 4-cylinder, Turbocharged Diesel, Naturally Aspirated Petrol Performance 2.0 Jtd (16V) Diesel Power: Approx. 136 PS (134 hp; 100 kW) 2.0 Jtd (16V) Diesel Torque: Approx. 320 Nm (236 lb-ft) 2.0 Petrol Power: Approx. 136 PS (134 hp; 100 kW) 2.0 Petrol Torque: Approx. 190 Nm (140 lb-ft) 2.2 Hdi Diesel Power: Approx. 128 PS (126 hp; 94 kW) - early, and 170 PS (168 hp; 125 kW) - later facelifted models 2.2 Hdi Diesel Torque: Approx. 330 Nm (243 lb-ft) - early, and 370 Nm (273 lb-ft) - later facelifted models Fuel System Diesel Injection: Common Rail Direct Injection (CRDi) Petrol Injection: Multi-point Fuel Injection (MPI) Emissions Emissions Standard: Euro 4 compliant for most variants Transmission Standard Transmission Type: 5-speed Manual Optional Transmission Type: 4-speed Automatic (likely with 2.0 Petrol and some Diesel variants) Features Clutch Type: Hydraulically operated single dry plate clutch Transmission Fluid Spec: Manual: API GL-4, SAE 75W-80. Automatic: ATF type as specified by manufacturer (e.g., Dexron III or equivalent). Dimensions Exterior Length: Approx. 4,770 mm (187.8 in) Width: Approx. 1,900 mm (74.8 in) (excluding mirrors) Height: Approx. 1,750 mm (68.9 in) Wheelbase: Approx. 2,823 mm (111.1 in) Interior Seating Capacity: 7 Seats (standard configuration) Cargo Cargo Volume All Seats Up: Approx. 320-400 Litres (variable depending on seating configuration) Cargo Volume Rear Seats Folded: Approx. 1,800-2,000 Litres Weights Kerb Weight: Approx. 1,700 - 1,900 kg (depending on engine and equipment) Safety Features Ratings Euro Ncap Rating: 4 Stars (for the 2nd generation Ulysse, achieved during its initial release period). Active Features ABS: Standard Anti-lock Braking System Ebd: Standard Electronic Brakeforce Distribution Esp: Optional Electronic Stability Programme (ESP) on some models/trims Traction Control: Traction Control System (TCS) often integrated with ESP Passive Features Airbags: Front airbags for driver and passenger, optional side airbags and curtain airbags. Seatbelts: Three-point seatbelts with pre-tensioners for all seats. Child Seat Anchors: ISOFIX mounting points for child safety seats. Technology Features Infotainment Audio System: Factory fitted CD/MP3 player with radio, potentially with steering wheel audio controls. Navigation: Optional satellite navigation system available on higher trims. Driver Assistance Parking Sensors: Optional rear parking sensors. Cruise Control: Available cruise control system. Connectivity Bluetooth: Optional Bluetooth hands-free system for mobile phones. Maintenance Service Intervals Engine Oil Change: Every 20,000 km (12,500 miles) or 1 year, whichever comes first (diesel), 30,000 km (18,750 miles) or 1 year (petrol). Timing Belt Replacement: Every 120,000 km (75,000 miles) or 5 years (for diesel engines, consult specific engine manual). Air Filter Replacement: Every 40,000 km (25,000 miles) or 2 years. Cabin Filter Replacement: Every 20,000 km (12,500 miles) or 1 year. Fluid Specifications Engine Oil Petrol: SAE 5W-40, API SL/SM, ACEA A3/B4 or A5/B5 Engine Oil Diesel: SAE 5W-30, API CF, ACEA B4 or B5 (Low SAPS for DPF engines) Coolant Type: Ethylene glycol based antifreeze/coolant, Type OAT (Organic Acid Technology), Mopar MS-90032 or equivalent. Brake Fluid: DOT 4 Known Issues Diesel Dpf: Diesel Particulate Filter (DPF) clogging, especially with short journeys. Requires regeneration or cleaning. Eletric Window Motors: Failure of electric window motors and regulators. Suspension Wear: Front suspension components (e.g., ball joints, bushings)...
Air conditioning system, heating system, climate control operation, component testing.
Body Panels:
Door mechanisms, hood, tailgate, bumpers, trim removal and installation.
Interior:
Seat removal, dashboard trim, center console, headliner.
Safety Systems:
Airbag system diagnostics and replacement procedures.
Procedures Included
Scheduled Maintenance:
Detailed instructions for routine maintenance services at specified intervals.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon faults.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair.
Diagnostic Procedures:
Guidance on using diagnostic tools and interpreting fault codes.
Component Replacement:
Specific procedures for replacing key components across all major systems.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Torque Specifications:
Detailed torque values for all critical fasteners.
Fluid Capacities And Types:
Exact specifications for all fluids (engine oil, coolant, brake fluid, transmission fluid, etc.).
Technical Depth
Depth Level:
Comprehensive - Covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Focus:
Advanced diagnostic strategies, including sensor data analysis and ECU reset procedures.
Manual Specifications
File Format
File Format:
Searchable PDF
Print Quality
Image Resolution:
High resolution for clear diagrams and illustrations
Readability:
Optimized for digital viewing and printing
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
Engine Specifications
Primary Engine
Engine Code Examples:
RPO codes may vary, common for PSA sourced engines: DW10ATED4 (2.0 HDi), EW10J4 (2.0 Petrol), EW12J4 (2.2 Petrol), DW12TED4 (2.2 HDi).
Engine Type:
Inline 4-cylinder, Turbocharged Diesel, Naturally Aspirated Petrol
Performance
2.0 Jtd (16V) Diesel Power:
Approx. 136 PS (134 hp; 100 kW)
2.0 Jtd (16V) Diesel Torque:
Approx. 320 Nm (236 lb-ft)
2.0 Petrol Power:
Approx. 136 PS (134 hp; 100 kW)
2.0 Petrol Torque:
Approx. 190 Nm (140 lb-ft)
2.2 Hdi Diesel Power:
Approx. 128 PS (126 hp; 94 kW) - early, and 170 PS (168 hp; 125 kW) - later facelifted models
2.2 Hdi Diesel Torque:
Approx. 330 Nm (243 lb-ft) - early, and 370 Nm (273 lb-ft) - later facelifted models
Fuel System
Diesel Injection:
Common Rail Direct Injection (CRDi)
Petrol Injection:
Multi-point Fuel Injection (MPI)
Emissions
Emissions Standard:
Euro 4 compliant for most variants
Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Transmission Type:
4-speed Automatic (likely with 2.0 Petrol and some Diesel variants)
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Transmission Fluid Spec:
Manual: API GL-4, SAE 75W-80. Automatic: ATF type as specified by manufacturer (e.g., Dexron III or equivalent).
Dimensions
Exterior
Length:
Approx. 4,770 mm (187.8 in)
Width:
Approx. 1,900 mm (74.8 in) (excluding mirrors)
Height:
Approx. 1,750 mm (68.9 in)
Wheelbase:
Approx. 2,823 mm (111.1 in)
Interior
Seating Capacity:
7 Seats (standard configuration)
Cargo
Cargo Volume All Seats Up:
Approx. 320-400 Litres (variable depending on seating configuration)
Cargo Volume Rear Seats Folded:
Approx. 1,800-2,000 Litres
Weights
Kerb Weight:
Approx. 1,700 - 1,900 kg (depending on engine and equipment)
Safety Features
Ratings
Euro Ncap Rating:
4 Stars (for the 2nd generation Ulysse, achieved during its initial release period).
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brakeforce Distribution
Esp:
Optional Electronic Stability Programme (ESP) on some models/trims
Traction Control:
Traction Control System (TCS) often integrated with ESP
Passive Features
Airbags:
Front airbags for driver and passenger, optional side airbags and curtain airbags.
Seatbelts:
Three-point seatbelts with pre-tensioners for all seats.
Child Seat Anchors:
ISOFIX mounting points for child safety seats.
Technology Features
Infotainment
Audio System:
Factory fitted CD/MP3 player with radio, potentially with steering wheel audio controls.
Navigation:
Optional satellite navigation system available on higher trims.
Driver Assistance
Parking Sensors:
Optional rear parking sensors.
Cruise Control:
Available cruise control system.
Connectivity
Bluetooth:
Optional Bluetooth hands-free system for mobile phones.
Maintenance
Service Intervals
Engine Oil Change:
Every 20,000 km (12,500 miles) or 1 year, whichever comes first (diesel), 30,000 km (18,750 miles) or 1 year (petrol).
Timing Belt Replacement:
Every 120,000 km (75,000 miles) or 5 years (for diesel engines, consult specific engine manual).
Air Filter Replacement:
Every 40,000 km (25,000 miles) or 2 years.
Cabin Filter Replacement:
Every 20,000 km (12,500 miles) or 1 year.
Fluid Specifications
Engine Oil Petrol:
SAE 5W-40, API SL/SM, ACEA A3/B4 or A5/B5
Engine Oil Diesel:
SAE 5W-30, API CF, ACEA B4 or B5 (Low SAPS for DPF engines)
Coolant Type:
Ethylene glycol based antifreeze/coolant, Type OAT (Organic Acid Technology), Mopar MS-90032 or equivalent.
Brake Fluid:
DOT 4
Known Issues
Diesel Dpf:
Diesel Particulate Filter (DPF) clogging, especially with short journeys. Requires regeneration or cleaning.
Eletric Window Motors:
Failure of electric window motors and regulators.
Suspension Wear:
Front suspension components (e.g., ball joints, bushings) can wear prematurely due to vehicle weight.
Exhaust Gas Recirculation Egr:
EGR valve fouling and failure, particularly on diesel engines.
Climate Control Actuators:
Malfunctioning HVAC actuators causing incorrect air direction.
Vehicle History
Brand Heritage
Fiat Heritage:
Fiat, an Italian automotive manufacturer, has a long history of producing family-oriented vehicles and MPVs.
Model Evolution
Ulysse First Gen:
The first generation Fiat Ulysse was launched in 1994, sharing its platform with the Lancia Zeta, Peugeot 806, and Citroën Evasion (Eurovan project).
Ulysse Second Gen:
The second generation (2002-2010) was a significant redesign, continuing the platform sharing with the Citroën C8, Peugeot 807, and Lancia Phedra, featuring a facelift in 2008.
Production
Manufacturing Location:
Produced at the Sevel Nord plant in Hordain, France (a joint venture between PSA Peugeot Citroën and Fiat).
Production Years:
2nd Generation: 2002–2010 (Facelift 2: 2008-2010)
Awards & Recognition
Recognitions
Euro Ncap:
Achieved a 4-star safety rating from Euro NCAP, demonstrating a good level of occupant protection for its class and time.