Fiat Ulysse 2.2i 16V 2002 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Fiat Model: Ulysse Year: 2002 Engine Variant: 2.2i 16V Codes Engine Code Range: Likely ES9A or similar EW12J4 variant, requires manual verification Chassis Code: Type 171/220 👋 Introduction Market Position Segment: Large MPV (Multi-Purpose Vehicle) Platform Sharing: Shared platform with Citroën C8, Peugeot 807, and Lancia Phedra Competitive Analysis Key Competitors: Ford Galaxy, Volkswagen Sharan, Renault Espace, Chrysler Voyager Key Features Vehicle Type: Spacious and versatile family MPV Unique Selling Points: Comfortable ride, flexible seating configurations, practical interior space, European styling 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital (PDF) Page Count Page Count: Est. 1500-2000 pages (typical for comprehensive workshop manuals) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, block, pistons, connecting rods, crankshaft, camshafts, valve train Engine Management: Fuel injection, ignition system, sensors, actuators, ECU diagnostics, emission control systems Transmission: Manual and Automatic transmission overhaul, clutch, gearbox internals, torque converter (if applicable), shift mechanisms Drivetrain: Front-wheel drive system, drive shafts, CV joints, differential Brakes: Front and rear brake systems, ABS, EBD, hydraulic circuits, calipers, discs, pads, brake booster, master cylinder Suspension: Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, alignment specifications Steering: Power steering system, steering rack, column, tie rods, hydraulic pump Electrical System: Battery, charging system, starter, lighting, wipers, horn, central locking, power windows, mirrors, fuses, relays Body And Chassis: Body panel removal and installation, interior trim, exterior trim, doors, tailgate, hood, bumpers, chassis repair HVAC: Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant circuits, components Comfort And Convenience: Seating systems, sunroof, cruise control, interior lighting Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt replacement Diagnostics: Troubleshooting guides, symptom-based diagnosis, fault code interpretation, electrical circuit testing Repair Rebuild: Step-by-step repair procedures for all major vehicle systems, component replacement, major overhauls Adjustment: Valve clearance adjustment, handbrake adjustment, headlight aim adjustment Installation Replacement: Component replacement (e.g., alternator, starter, fuel pump), body panel replacement, interior trim installation Specifications: Detailed torque specifications, clearances, fluid capacities, electrical component data Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics) Target Audience: Professional mechanics, experienced DIY enthusiasts, automotive technicians 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (if text-based PDF) 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) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, DOHC, 16 Valves Displacement: 2179 cc Bore X Stroke: 87.0 mm x 90.6 mm (typical for ES9A/EW12J4) Compression Ratio: 10.5:1 (typical) Performance Horsepower: 136 PS (134 hp; 100 kW) at 5300 rpm (typical) Torque: 207 Nm (153 lb-ft) at 3250 rpm (typical) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (Petrol) Catalytic Converter: Standard 🔧 Transmission Standard Transmission Type: 5-speed Manual Optional Transmission Type: 4-speed Automatic (likely AL4 or similar) Features Clutch Type: Hydraulically operated single dry plate clutch (Manual) Transmission Fluid Spec: Refer to manual for specific type (e.g., MTF for manual, ATF Dexron III/VI for automatic) 📐 Dimensions Exterior Length: Approx. 4700 mm (185.0 in) Width: Approx. 1800 mm (70.9 in) Height: Approx. 1750 mm (68.9 in) Wheelbase: Approx. 2820 mm (111.0 in) Interior Seating Capacity: 7 Seats (2+3+2 configuration typical) Cargo Volume Seats Up: Varies significantly with seat configuration, typically around 200-300 litres with all seats in use. Cargo Volume Seats Down: Can exceed 1500 litres with rear seats folded/removed. Weights Curb Weight: Approx. 1600-1750 kg (3527-3858 lbs) Gross Vehicle Weight Rating: Refer to vehicle placard 🛡️ Safety Features Ratings Euroncap Rating: Likely 4 or 5 stars for this generation (based on sibling models) Active Features ABS: Standard Ebd: Standard (Electronic Brakeforce Distribution) Traction Control: Optional (ASR - Antipatinage) Esp: Optional on higher trims or later models Passive Features Airbags: Front airbags, side airbags, curtain airbags (depending on trim level) Seatbelts: 3-point seatbelts with pretensioners for all occupants, ISOFIX child seat anchors Child Safety: Rear door child locks, ISOFIX anchor points 💡 Technology Features Infotainment Infotainment System: Basic radio/cassette or CD player with standard speaker system. Optional premium audio available on higher trims. Navigation: Optional factory fitted navigation system available on some models. Driver Assistance Cruise Control: Optional Parking Sensors: Optional rear parking sensors. Connectivity Aux Input: Rarely standard, typically aftermarket additions. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 15,000 km (9,300 miles) or 1 year, whichever comes first (refer to manual for precise interval and oil type). Timing Belt Interval: Crucial for the 2.2i 16V engine. Typically around 120,000 km (75,000 miles) or 5-6 years. Check manual for exact interval and replacement of tensioners/water pump. Air Filter Replacement: Every 30,000 km (18,600 miles) or 2 years. Cabin Filter Replacement: Every 15,000 km...
Component replacement (e.g., alternator, starter, fuel pump), body panel replacement, interior trim installation
Specifications:
Detailed torque specifications, clearances, fluid capacities, electrical component data
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics)
Target Audience:
Professional mechanics, experienced DIY enthusiasts, automotive technicians
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (if text-based PDF)
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)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, DOHC, 16 Valves
Displacement:
2179 cc
Bore X Stroke:
87.0 mm x 90.6 mm (typical for ES9A/EW12J4)
Compression Ratio:
10.5:1 (typical)
Performance
Horsepower:
136 PS (134 hp; 100 kW) at 5300 rpm (typical)
Torque:
207 Nm (153 lb-ft) at 3250 rpm (typical)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (Petrol)
Catalytic Converter:
Standard
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Transmission Type:
4-speed Automatic (likely AL4 or similar)
Features
Clutch Type:
Hydraulically operated single dry plate clutch (Manual)
Transmission Fluid Spec:
Refer to manual for specific type (e.g., MTF for manual, ATF Dexron III/VI for automatic)
📐 Dimensions
Exterior
Length:
Approx. 4700 mm (185.0 in)
Width:
Approx. 1800 mm (70.9 in)
Height:
Approx. 1750 mm (68.9 in)
Wheelbase:
Approx. 2820 mm (111.0 in)
Interior
Seating Capacity:
7 Seats (2+3+2 configuration typical)
Cargo Volume Seats Up:
Varies significantly with seat configuration, typically around 200-300 litres with all seats in use.
Cargo Volume Seats Down:
Can exceed 1500 litres with rear seats folded/removed.
Weights
Curb Weight:
Approx. 1600-1750 kg (3527-3858 lbs)
Gross Vehicle Weight Rating:
Refer to vehicle placard
🛡️ Safety Features
Ratings
Euroncap Rating:
Likely 4 or 5 stars for this generation (based on sibling models)
Active Features
ABS:
Standard
Ebd:
Standard (Electronic Brakeforce Distribution)
Traction Control:
Optional (ASR - Antipatinage)
Esp:
Optional on higher trims or later models
Passive Features
Airbags:
Front airbags, side airbags, curtain airbags (depending on trim level)
Seatbelts:
3-point seatbelts with pretensioners for all occupants, ISOFIX child seat anchors
Child Safety:
Rear door child locks, ISOFIX anchor points
💡 Technology Features
Infotainment
Infotainment System:
Basic radio/cassette or CD player with standard speaker system. Optional premium audio available on higher trims.
Navigation:
Optional factory fitted navigation system available on some models.
Driver Assistance
Cruise Control:
Optional
Parking Sensors:
Optional rear parking sensors.
Connectivity
Aux Input:
Rarely standard, typically aftermarket additions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 km (9,300 miles) or 1 year, whichever comes first (refer to manual for precise interval and oil type).
Timing Belt Interval:
Crucial for the 2.2i 16V engine. Typically around 120,000 km (75,000 miles) or 5-6 years. Check manual for exact interval and replacement of tensioners/water pump.
Air Filter Replacement:
Every 30,000 km (18,600 miles) or 2 years.
Cabin Filter Replacement:
Every 15,000 km (9,300 miles) or 1 year.
Fluid Specifications
Engine Oil Type:
Fully synthetic 5W-40 or 5W-30 meeting ACEA A3/B4 or API SN/CF specifications. Confirm with manual.
Coolant Type:
OAT (Organic Acid Technology) coolant, typically pink or red. Refer to manual for specific Fiat specification (e.g., Paraflu UP).
Brake Fluid Type:
DOT 4
Known Issues
Common Issues Engine:
Timing belt tensioner failure (potential catastrophic engine damage if not replaced on schedule), occasional oil leaks, carbon buildup on intake valves.
Common Issues Transmission:
Automatic transmission (AL4) can be prone to hydraulic control issues, solenoid failures, and torque converter problems if fluid is not maintained.
Common Issues Electrical:
Intermittent electrical faults, issues with body control modules (BCM), power window regulators, and central locking actuators are not uncommon in vehicles of this age.
Common Issues Suspension Steering:
Worn suspension bushes, noisy wheel bearings, and power steering fluid leaks can occur with age and mileage.
Common Issues HVAC:
A/C compressor failures, blend door actuator malfunctions, and refrigerant leaks.
📚 Vehicle History
Brand Heritage
Brand Focus:
Fiat is a long-standing Italian automobile manufacturer known for its diverse range of vehicles, including small cars, family cars, and commercial vehicles.
Model Evolution
Generation Context:
The Fiat Ulysse is part of the second generation (2002-2010) of this large MPV, a collaborative project with PSA Peugeot Citroën. This generation replaced the original Ulysse (1994-2002).
Platform Basis:
Based on the PSA platform shared with Citroën Evasion, Peugeot 806, and Lancia Zeta.
Production
Manufacturing Location:
Sevel Sud plant, Val di Sangro, Italy
Production Years:
2002-2010 (for this generation)
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