📚 Vehicle Manual Information

1996 Fiat Ulysse (1st gen) Service and Repair Manual

🏷️ Basic Information

Make:

Fiat

Model:

Ulysse

Year:

1996

Generation:

1st Generation (X1/86)

Chassis Code:

X1/86

👋 Introduction

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle)

Key Competitors 1996:

Renault Espace, Peugeot 806, Citroën Evasion, Lancia Zeta, Ford Galaxy, Volkswagen Sharan, SEAT Alhambra.

Design Philosophy:

Designed as a practical and versatile family vehicle with flexible seating and ample interior space, built on a shared platform with other PSA Group and later Ford models.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

English

Format:

Print (likely)

Page Count:

Estimated 500+ pages (typical for this era's comprehensive manuals)

📖 Manual Coverage

Engine Mechanical:

Detailed descriptions of engine disassembly, assembly, troubleshooting, and overhaul for all gasoline and diesel variants.

Engine Electrical:

Ignition system, fuel injection systems (L-Jetronic, Motronic), starting and charging systems, sensor diagnostics, ECU pinouts, and wiring diagrams.

Transmission:

Manual and automatic transmission overhaul, clutch system, driveline, driveshafts, and differential.

Brakes:

Hydraulic brake system, ABS (where applicable), brake pad/disc replacement, caliper overhaul, bleeding procedures, and parking brake.

Suspension:

Front and rear suspension component identification, replacement of struts, shock absorbers, bushings, ball joints, and wheel bearing service.

Steering:

Power steering system, steering rack, column, and tie rod end replacement.

Fuel System:

Fuel pump, fuel injectors, fuel filter replacement, fuel tank service, and evaporative emission control system.

Cooling System:

Radiator, water pump, thermostat, cooling fan operation, and coolant flush procedures.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, and pipe replacement.

Electrical Systems:

Lighting systems, interior and exterior lamps, horn, wipers, washers, power windows, door locks, and central locking.

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair, including refrigerant system service and component replacement.

Body And Interior:

Body panel repair, door panel removal, interior trim, seat removal, and glass replacement.

Diagnostic Troubleshooting:

Comprehensive diagnostic charts, common fault finding procedures, and symptom-based troubleshooting guides.

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug service, belt adjustments, and fluid level checks.

Component Replacement:

Detailed step-by-step instructions for replacing virtually all serviceable components, from minor sensors to major assemblies.

Troubleshooting Guides:

Systematic approaches to diagnosing and resolving common and uncommon vehicle issues.

Wiring Diagrams:

High-quality, clear wiring schematics for all electrical circuits within the vehicle.

Torque Specifications:

Precise torque values for all fasteners during assembly and disassembly.

Depth Level:

Comprehensive (suitable for professional technicians and advanced DIYers)

Coverage Scope:

From basic scheduled maintenance to complete engine and transmission rebuilds, including electrical system diagnostics.

📊 Manual Specifications

File Format:

Print (historically accurate for the era)

Print Quality:

Professional, clear text and legible diagrams/illustrations.

Binding Type:

Likely perfect bound or stapled sections for a comprehensive manual.

Paper Type:

Durable paper stock suitable for workshop use.

⚙️ Engine Specifications

Engine Code:

Various, including F20A, F20B (derived from PSA XU engines)

Engine Type:

Inline 4-cylinder, SOHC or DOHC

Displacement Liters:

2.0 L

Bore X Stroke Mm:

Varies by specific engine code, e.g., 82.0 mm x 93.4 mm for F20A

Compression Ratio:

Typically 9.5:1 to 10.0:1

Horsepower Ps:

Approx. 125-136 PS (depending on specific engine variant and fuel injection)

Torque Nm:

Approx. 170-185 Nm (depending on specific engine variant)

Fuel System:

Multi-point fuel injection (MPI), electronically controlled.

Engine Code:

Various, including DW10TD, XUD11ATE

Engine Type:

Inline 4-cylinder, SOHC, Turbocharged Diesel

Displacement Liters:

2.1 L (XUD11ATE), 2.0 L (DW10TD)

Horsepower Ps:

Approx. 90-110 PS (depending on specific engine variant)

Torque Nm:

Approx. 190-250 Nm (depending on specific engine variant)

Fuel System:

Indirect Injection (IDI) or Direct Injection (DI) with Turbocharging and Intercooling for later models.

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Transmission Type:

4-speed Automatic Transmission

Clutch Type:

Hydraulically operated diaphragm spring clutch.

Automatic Features:

Lock-up torque converter for improved efficiency.

📐 Dimensions

Length Mm:

Approx. 4440 mm

Width Mm:

Approx. 1810 mm

Height Mm:

Approx. 1700 mm

Wheelbase Mm:

Approx. 2820 mm

Curb Weight Kg:

Approx. 1500-1650 kg (depending on engine and configuration)

Luggage Capacity Liters:

Highly variable due to modular seating, typically 400-1500+ liters with rear seats folded or removed.

🛡️ Safety Features

Crash Test Era Assessment:

As per 1996 standards, likely basic frontal and side impact protection. Euro NCAP was in its infancy.

ABS:

Optional Anti-lock Braking System (ABS) on some models.

Airbags:

Driver's airbag standard on most trims, optional front passenger airbag on later models.

Seatbelts:

Three-point seatbelts for all occupants, some with pre-tensioners.

💡 Technology Features

Audio System:

Factory fitted radio/cassette player, with options for CD changer. Speaker configuration typically 4-6 speakers.

Cruise Control:

Optional cruise control system available on higher trim levels.

Central Locking:

Standard central locking, with optional remote keyless entry.

🔧 Maintenance

Engine Oil Change:

Every 10,000 km or 12 months, whichever comes first. Check manual for specific oil type and capacity.

Air Filter Replacement:

Every 20,000 km or 24 months.

Fuel Filter Replacement:

Every 30,000 km (petrol), 40,000 km (diesel).

Engine Oil Spec:

API SG/SH or ACEA A2/A3, SAE 10W-40 or 5W-40 recommended. Consult manual for precise grade.

Coolant Spec:

Ethylene glycol based antifreeze, meeting Fiat/PSA specifications (e.g., TL-VW 774 C or similar).

Brake Fluid Spec:

DOT 3 or DOT 4.

Transmission Fluid Manual:

GL-4 75W-90 or 80W-90 gear oil. Capacity ~2.0 liters.

Transmission Fluid Auto:

Dexron III or equivalent ATF. Capacity ~3.0-4.0 liters.

Common Problems Electrical:

Intermittent faults in central locking, power windows, and dashboard warning lights due to aging wiring or connectors.

Common Problems Engine:

Oil leaks from rocker cover gasket, potential head gasket issues on higher mileage engines, wear in timing belt components (critical replacement intervals).

Common Problems Suspension:

Wear in front wishbone bushings, ball joints, and rear torsion bar bushings leading to knocking noises and poor handling.

Common Problems Diesel Engines:

Issues with glow plugs, fuel injection pump seals, and turbocharger wear on higher mileage XUD engines.

Spark Plug Gap Petrol:

Approx. 0.9-1.0 mm (verify specific engine code in manual).

Tire Pressure Psi:

Front: 30-32 psi, Rear: 30-32 psi (refer to door jamb sticker for exact pressures).

Timing Belt Interval:

Critical! Typically 80,000 km or 5 years. Failure leads to catastrophic engine damage. Manual will detail replacement procedure and tensioning.

📚 Vehicle History

Fiat History:

Fiat, an Italian automotive manufacturer with a long history dating back to 1899, known for its innovation and popular compact cars, expanded into the MPV segment with the Ulysse.

Ulysse Development:

The Fiat Ulysse was developed as part of a joint venture with PSA Peugeot Citroën, sharing its platform and many components with the Peugeot 806, Citroën Evasion, and Lancia Zeta. This collaboration allowed for cost-effective development of a modern MPV.

Production Years:

1994-2002 (1st Generation)

Manufacturing Location:

Sevel Sud plant, Italy (joint venture with PSA Peugeot Citroën).

🏆 Awards & Recognition

European Car Of The Year:

While the Ulysse itself did not win European Car of the Year, the platform it shared was highly regarded in the evolving MPV segment of the mid-1990s.