FIAT ULYSSE 2.0 HDI (WITH PARTICLE FILTER) 2002 Manual

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🏷️ Basic Information Identification Make: FIAT Model: ULYSSE Year: 2002 Engine Variant: 2.0 HDI (with Particle Filter) Codes Engine Code General: DW10 Platform Code: Z 👋 Introduction Market Position Vehicle Segment: Large MPV (Multi-Purpose Vehicle) / Minivan Brand Perception: FIAT's Ulysse offered a European alternative to established MPVs, focusing on practicality and comfort for families. Competitive Analysis Direct Competitors: Renault Espace, Citroën C8, Peugeot 807, Lancia Phedra, Volkswagen Sharan, Ford Galaxy, Seat Alhambra. Key Features Versatility: Flexible seating configurations, ample interior space, designed for passenger comfort and cargo hauling. Engine Technology: The 2.0 HDI engine represents modern turbodiesel technology, known for its torque and fuel efficiency. The inclusion of a particle filter (FAP/DPF) signifies Euro 3/4 emissions compliance. 📋 Manual Details Coverage Areas Manual Type: Workshop Manual / Service Manual Language: English Format: Digital (PDF) Page Count Estimated Pages: 1500-2000 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, component testing, timing belt, fuel system, lubrication, cooling system, exhaust system, emission control (including Particle Filter system). Transmission: Manual transmission (MLG variants) overhaul, clutch system, gear selection mechanism, differential, driveshafts, fluid specifications and change intervals. Brakes: Hydraulic system, ABS, EBD, brake discs, pads, calipers, lines, master cylinder, rear drum/disc brakes, parking brake, bleeding procedures. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, anti-roll bars, wheel alignment specifications. Steering: Power steering system, steering rack, column, pump, fluid types, diagnostics and repair. Electrical: 12V system, battery, alternator, starter motor, fuses, relays, lighting system (headlights, taillights, interior), wiring diagrams, diagnostic connector (OBD-II), ECU functions. Bodywork: Body panel removal and installation, door mechanisms, glass, interior trim, bumpers, corrosion protection. HVAC: Air conditioning system (refrigerant types, servicing, leak testing), heating system, ventilation, climate control unit. Safety Systems: Airbag system (diagnostics, component replacement), seat belt pre-tensioners, ISOFIX. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement (if applicable), coolant checks, brake fluid checks, tire pressure checks. Component Repair: Engine rebuild procedures, turbocharger servicing, injector testing and replacement, EGR valve cleaning/replacement, DPF regeneration and replacement procedures, transmission rebuild, brake caliper overhaul, suspension bush replacement, power steering pump replacement. Diagnostics: Troubleshooting charts for common drivability issues, electrical faults, starting problems, braking issues. Use of diagnostic tools and interpretation of fault codes (DTCs). Technical Specifications: Torque wrench settings for all critical fasteners, engine timing specifications, valve clearances (if applicable), wheel alignment angles, fluid capacities. Wiring Diagrams: Detailed electrical schematics for all major systems, component location charts. Technical Depth Depth Level: Comprehensive: Covers basic maintenance, intermediate repairs, and advanced engine/transmission overhauls and diagnostics. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Text-searchable PDF for efficient information retrieval. Print Quality Printable: Printable, allowing users to create physical copies of specific sections or the entire manual. Binding Type Physical Binding Type: N/A (Digital Format) Paper Type Physical Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder Turbocharged Diesel (HDI - High Pressure Injection) Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85 mm x 88 mm Compression Ratio: 17.9:1 (typical for DW10 HDi) Valve Train: DOHC (Double Overhead Camshaft), 16 valves Fuel System: Common Rail Direct Injection (Bosch EDC15C or similar ECU) Turbocharger: Variable Geometry Turbocharger (VGT) Emission Control: Diesel Particulate Filter (DPF/FAP), Exhaust Gas Recirculation (EGR). Performance Horsepower Ps: 109 PS @ 4000 rpm (approximate) Torque Nm: 250 Nm @ 1750 rpm (approximate) Fuel System Fuel Type: Diesel Recommended Fuel Grade: EN 590 compliant Diesel fuel Fuel Tank Capacity: 80 Liters 🔧 Transmission Standard Type: 5-speed Manual Transmission Transmission Code Example: MLG 44 Optional Type: 4-speed Automatic Transmission (AL4 - likely on other variants, confirm for this specific engine/year) Features Clutch Type: Hydraulically operated, single dry plate 📐 Dimensions Exterior Length: 4737 mm Width: 1812 mm Height: 1751 mm Wheelbase: 2823 mm Interior Seating Capacity: 7 Seats (typical configuration) Cargo Luggage Capacity Seats Up: Approx. 485 liters (configurable) Luggage Capacity Seats Down: Over 1500 liters (with rear seats folded) Weights Curb Weight: Approx. 1750 - 1850 kg (depending on configuration) Gross Vehicle Weight: Approx. 2400 - 2500 kg 🛡️ Safety Features Ratings Euro Ncap Rating: 4 Stars (Euro NCAP test conducted on similar Lancia Phedra/Peugeot 807 platform in 2003 - likely representative) Active Features ABS: Anti-lock Braking System Ebd: Electronic Brakeforce Distribution Esp: Electronic Stability Program (Optional, may vary by market/trim) Traction Control: ASR (Anti-Slip Regulation) / Traction Control (often linked with ESP) Passive Features Airbags: Driver, front passenger, side airbags (front), curtain airbags (optional/later models). Seatbelts: Three-point seatbelts with pre-tensioners and load limiters for all seats. Child Seat Anchors: ISOFIX anchor points for child seats. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player with speaker system. Controls may be on steering wheel. Manual will cover basic operation and fuse locations. Driver Assistance Cruise Control: Often available as an...

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Description

🏷️ Basic Information

Identification

Make:

Model:

ULYSSE

Year:

Engine Variant:

2.0 HDI (with Particle Filter)

Codes

Engine Code General:

Platform Code:

👋 Introduction

Market Position

Vehicle Segment:

Large MPV (Multi-Purpose Vehicle) / Minivan

Brand Perception:

FIAT's Ulysse offered a European alternative to established MPVs, focusing on practicality and comfort for families.

Competitive Analysis

Direct Competitors:

Renault Espace, Citroën C8, Peugeot 807, Lancia Phedra, Volkswagen Sharan, Ford Galaxy, Seat Alhambra.

Key Features

Versatility:

Flexible seating configurations, ample interior space, designed for passenger comfort and cargo hauling.

Engine Technology:

The 2.0 HDI engine represents modern turbodiesel technology, known for its torque and fuel efficiency. The inclusion of a particle filter (FAP/DPF) signifies Euro 3/4 emissions compliance.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Manual / Service Manual

Language:

English

Format:

Digital (PDF)

Page Count

Estimated Pages:

1500-2000

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, component testing, timing belt, fuel system, lubrication, cooling system, exhaust system, emission control (including Particle Filter system).

Transmission:

Manual transmission (MLG variants) overhaul, clutch system, gear selection mechanism, differential, driveshafts, fluid specifications and change intervals.

Brakes:

Hydraulic system, ABS, EBD, brake discs, pads, calipers, lines, master cylinder, rear drum/disc brakes, parking brake, bleeding procedures.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, anti-roll bars, wheel alignment specifications.

Steering:

Power steering system, steering rack, column, pump, fluid types, diagnostics and repair.

Electrical:

12V system, battery, alternator, starter motor, fuses, relays, lighting system (headlights, taillights, interior), wiring diagrams, diagnostic connector (OBD-II), ECU functions.

Bodywork:

Body panel removal and installation, door mechanisms, glass, interior trim, bumpers, corrosion protection.

HVAC:

Air conditioning system (refrigerant types, servicing, leak testing), heating system, ventilation, climate control unit.

Safety Systems:

Airbag system (diagnostics, component replacement), seat belt pre-tensioners, ISOFIX.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement (if applicable), coolant checks, brake fluid checks, tire pressure checks.

Component Repair:

Engine rebuild procedures, turbocharger servicing, injector testing and replacement, EGR valve cleaning/replacement, DPF regeneration and replacement procedures, transmission rebuild, brake caliper overhaul, suspension bush replacement, power steering pump replacement.

Diagnostics:

Troubleshooting charts for common drivability issues, electrical faults, starting problems, braking issues. Use of diagnostic tools and interpretation of fault codes (DTCs).

Technical Specifications:

Torque wrench settings for all critical fasteners, engine timing specifications, valve clearances (if applicable), wheel alignment angles, fluid capacities.

Wiring Diagrams:

Detailed electrical schematics for all major systems, component location charts.

Technical Depth

Depth Level:

Comprehensive: Covers basic maintenance, intermediate repairs, and advanced engine/transmission overhauls and diagnostics.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Text-searchable PDF for efficient information retrieval.

Print Quality

Printable:

Printable, allowing users to create physical copies of specific sections or the entire manual.

Binding Type

Physical Binding Type:

N/A (Digital Format)

Paper Type

Physical Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder Turbocharged Diesel (HDI - High Pressure Injection)

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85 mm x 88 mm

Compression Ratio:

17.9:1 (typical for DW10 HDi)

Valve Train:

DOHC (Double Overhead Camshaft), 16 valves

Fuel System:

Common Rail Direct Injection (Bosch EDC15C or similar ECU)

Turbocharger:

Variable Geometry Turbocharger (VGT)

Emission Control:

Diesel Particulate Filter (DPF/FAP), Exhaust Gas Recirculation (EGR).

Performance

Horsepower Ps:

109 PS @ 4000 rpm (approximate)

Torque Nm:

250 Nm @ 1750 rpm (approximate)

Fuel System

Fuel Type:

Diesel

Recommended Fuel Grade:

EN 590 compliant Diesel fuel

Fuel Tank Capacity:

80 Liters

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Transmission Code Example:

MLG 44

Optional

Type:

4-speed Automatic Transmission (AL4 - likely on other variants, confirm for this specific engine/year)

Features

Clutch Type:

Hydraulically operated, single dry plate

📐 Dimensions

Exterior

Length:

4737 mm

Width:

1812 mm

Height:

1751 mm

Wheelbase:

2823 mm

Interior

Seating Capacity:

7 Seats (typical configuration)

Cargo

Luggage Capacity Seats Up:

Approx. 485 liters (configurable)

Luggage Capacity Seats Down:

Over 1500 liters (with rear seats folded)

Weights

Curb Weight:

Approx. 1750 - 1850 kg (depending on configuration)

Gross Vehicle Weight:

Approx. 2400 - 2500 kg

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 Stars (Euro NCAP test conducted on similar Lancia Phedra/Peugeot 807 platform in 2003 - likely representative)

Active Features

Anti-lock Braking System

Electronic Brakeforce Distribution

Electronic Stability Program (Optional, may vary by market/trim)

Traction Control:

ASR (Anti-Slip Regulation) / Traction Control (often linked with ESP)

Passive Features

Airbags:

Driver, front passenger, side airbags (front), curtain airbags (optional/later models).

Seatbelts:

Three-point seatbelts with pre-tensioners and load limiters for all seats.

Child Seat Anchors:

ISOFIX anchor points for child seats.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player with speaker system. Controls may be on steering wheel. Manual will cover basic operation and fuse locations.

Driver Assistance

Cruise Control:

Often available as an option or standard on higher trims. Manual will cover operation and basic troubleshooting.

Connectivity

Diagnostic Interface:

OBD-II (On-Board Diagnostics II) connector, typically located under the dashboard, used for engine management and emissions diagnostics.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 20,000 km or 12 months, whichever comes first.

Oil Filter Replacement:

At every engine oil change.

Air Filter Replacement:

Every 30,000 km or 24 months.

Fuel Filter Replacement:

Every 40,000 km or 24 months.

Timing Belt Replacement:

Every 120,000 km or 5 years (crucial interval for HDI engines).

Coolant Replacement:

Every 60,000 km or 4 years.

Fluid Specifications

Engine Oil Specification:

ACEA A3/B4 or C2/C3; API CF; VW 505 01 (for VW spec, but generally indicates quality for diesel with DPF) - consult manual for exact FIAT spec, often PSA B71 2290 or similar low-SAPS oil.

Engine Oil Capacity:

Approx. 6.0 Liters (with filter)

Coolant Type:

Antifreeze coolant (ethylene glycol based), typically Type 3 (blue or green) or equivalent.

Brake Fluid Type:

DOT 4

Power Steering Fluid:

ATF Dexron II or III, or specific PSA hydraulic fluid.

Transmission Fluid Manual:

API GL-4, SAE 75W-80 (e.g., PSA B71 2315 equivalent).

Known Issues

Dpf Clogging:

Diesel Particulate Filter can become clogged with soot, especially with short journeys. Requires regular regeneration cycles. Manual will detail regeneration procedures and troubleshooting.

Egr Valve Issues:

Exhaust Gas Recirculation valve can get dirty and stick, leading to performance issues and increased emissions. Requires cleaning or replacement.

Injection System:

HDI injectors can be sensitive to fuel quality. Issues may include rough running or starting problems. Manual covers testing and replacement.

Timing Belt Tensioner:

Failure of the timing belt tensioner or idler pulleys can lead to catastrophic engine damage. Adhering to the replacement interval is critical.

Electrical Gremlins:

Common in vehicles of this era, can include issues with sensors, ECUs, or wiring harness faults. Detailed wiring diagrams are essential for diagnosis.

📚 Vehicle History

Brand Heritage

Automaker:

FIAT (Fabbrica Italiana Automobili Torino) is one of Italy's oldest and largest automotive manufacturers, founded in 1899.

Model Evolution

Ulysse Generation:

This 2002 model represents the second generation of the FIAT Ulysse, which was part of a collaborative project with PSA Peugeot Citroën (resulting in the Ulysse, C8, 807, and Phedra).

Platform Sharing:

Shares the 'Eurovan 2' platform with its PSA counterparts, benefiting from shared development and manufacturing expertise.

Production

Production Period For This Generation:

2002 - 2010 (for the second generation Ulysse)

Manufacturing Location:

Primarily manufactured in Italy (Sevel Nord plant, also used by PSA).

🏆 Awards & Recognition

Recognitions

Segment Awards:

While specific awards for the 2002 Ulysse might be scarce, the PSA/FIAT joint venture platform was recognized for its practicality and space, making it a competitive offering in the MPV segment upon its release.