📚 Vehicle Manual Information

Fiat Ulysse 2.0 HDi With particle filter 2002 Service Repair Manual

🏷️ Basic Information

Make:

Fiat

Model:

Ulysse

Generation:

Second Generation (2002-2010)

Year:

2002

Engine Code Prefix:

HDi (High-pressure Direct Injection)

Chassis Code:

179

👋 Introduction

Segment:

Large MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

Families, individuals needing versatile passenger and cargo space

Key Competitors 2002:

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

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

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital (likely PDF)

Estimated Page Count:

800-1200

📖 Manual Coverage

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)

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

Depth:

Comprehensive: Covers routine maintenance, troubleshooting, diagnostics, and complete repair procedures for all major vehicle systems.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable Text (if converted properly from original source)

Resolution:

High-resolution diagrams and text

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

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)

Horsepower:

109 PS (107 bhp; 80 kW) @ 4000 rpm

Torque:

270 Nm (199 lb-ft) @ 1750 rpm

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

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)

Transmission Type Optional:

4-Speed Automatic Transmission (AL4/DP0 - likely)

Clutch Type:

Hydraulically Operated Dry Single-Plate Clutch

📐 Dimensions

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)

Passenger Volume:

Approx. 3300-3600 Liters (depending on seating configuration)

Luggage Capacity Seats Up:

Approx. 400-700 Liters (depending on seating configuration)

Luggage Capacity Seats Down:

Approx. 1500-2000+ Liters (with rear seats removed)

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

Euro Ncap Rating 2003:

4 Stars (Adult Occupant Protection)

ABS:

Standard Anti-lock Braking System

Ebd:

Standard Electronic Brakeforce Distribution

Traction Control:

Optional (likely on higher trims)

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

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.

Cruise Control:

Available as an option or standard on higher trims.

Parking Sensors:

Optional rear parking sensors available.

OBD Ii Port:

Standard OBD-II (On-Board Diagnostics) port for engine and emissions diagnostics.

🔧 Maintenance

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.

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

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.

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

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.

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.

Manufacturing Location:

Sevel Nord plant, Hordain, France

Production Years:

2002-2010 (for this generation)

🏆 Awards & Recognition

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.