📚 Vehicle Manual Information

FIAT ULYSSE 2.2 HDI (WITH PARTICLE FILTER) 2002 Manual

🏷️ Basic Information

Make:

Fiat

Model:

Ulysse

Year:

2002

Engine Variant:

2.2 HDI (with Particle Filter)

Platform:

SEMP 2000 (shared with Peugeot 807, Citroën C8, Lancia Phedra)

👋 Introduction

Segment:

Large MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

Families, individuals requiring flexible cargo and passenger space.

Competitors:

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

Design Philosophy:

European styling, practical interior layout, emphasis on passenger comfort and safety.

Notable Features:

Spacious interior, flexible seating configurations, sliding rear doors for easy access, availability of advanced diesel engines like the 2.2 HDI with DPF.

📋 Manual Details

General Coverage:

Comprehensive service, repair, and maintenance for Fiat Ulysse 2.2 HDI (with Particle Filter) models from 2002 onwards.

Estimated Pages:

~1500-2000 (typical for comprehensive service manuals)

Type:

Workshop Manual / Service and Repair Manual

Language:

English

Format:

Digital (PDF) - Searchable, Printable

📖 Manual Coverage

Powertrain:

Engine (2.2 HDI DW12TED4), fuel system, exhaust system, particle filter (DPF) system, cooling system, lubrication system.

Transmission:

Manual Transmission (e.g., M66), clutch system, gearbox components, differential.

Chassis:

Suspension (front and rear), steering system, braking system (ABS, EBD), wheels and tires.

Electrical:

12V electrical system, battery, charging system, starter, lighting, ignition, engine control unit (ECU), body control module (BCM), multiplexed wiring systems, diagnostic connectors (OBD-II).

Body And Interior:

Body panels, doors, hinges, locks, interior trim, seats, climate control (HVAC), safety restraint systems (airbags, seatbelts), power windows, mirrors, sliding doors.

Maintenance:

Scheduled maintenance intervals, oil and filter changes, air filter replacement, fuel filter replacement, coolant flush and fill, brake fluid change, timing belt replacement (if applicable), DPF regeneration procedures.

Repair And Overhaul:

Engine disassembly and reassembly, cylinder head servicing, piston and connecting rod servicing, crankshaft servicing, turbocharger overhaul, fuel injector testing and replacement, DPF cleaning and replacement, transmission removal and repair, clutch replacement, brake caliper overhaul, suspension component replacement, steering rack repair, electrical component diagnosis and replacement.

Troubleshooting:

Diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting guides for engine, transmission, braking, electrical, and climate control systems, electrical wiring diagrams, component testing procedures.

Depth:

In-depth technical procedures, torque specifications, clearances, diagnostic flowcharts, component identification, system overviews, wiring diagrams, special tool requirements.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Print Readability:

High resolution for clear diagrams and text, suitable for printing.

Binding:

Not Applicable (Digital Format)

Paper Quality:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Engine Code:

DW12TED4

Engine Type:

Inline 4-cylinder, Turbocharged Diesel with Intercooler, Direct Injection (Common Rail), Diesel Particulate Filter (DPF)

Displacement:

2179 cc (2.2 Liters)

Horsepower:

128 hp (95 kW) @ 4000 rpm (approx.)

Torque:

314 Nm (231 lb-ft) @ 2000 rpm (approx.)

Injection System:

Bosch Common Rail High-Pressure Fuel Injection

Emission Control:

Euro 3 / Euro 4 compliant (with DPF)

Bore X Stroke:

85 mm x 96 mm (approx.)

Compression Ratio:

17.5:1 (approx.)

Valve Train:

DOHC (Double Overhead Camshaft), 4 valves per cylinder, Belt Driven

🔧 Transmission

Transmission Type:

5-speed or 6-speed Manual Transmission (e.g., M59, M66)

Transmission Type:

Automatic Transmission (likely ZF 4HP20 or similar for earlier models, later models may vary)

Gear Ratios:

Specific ratios available in manual.

Clutch Type:

Hydraulically operated, Dry Single Plate Clutch

📐 Dimensions

Length:

4710 mm (approx.)

Width:

1878 mm (approx.)

Height:

1735 mm (approx.)

Wheelbase:

2823 mm (approx.)

Seating Capacity:

5-8 Seats (configurable)

Cargo Volume Seats Up:

Variable, up to 1236 liters behind the third row (approx.)

Cargo Volume Seats Down:

Significantly larger with rear seats folded or removed.

Curb Weight:

~1750-1850 kg (depending on configuration)

Gross Vehicle Weight:

2500 kg (approx.)

Towing Capacity:

1800 kg (braked, approx.)

🛡️ Safety Features

Euro Ncap Rating:

Likely 4 or 5 stars for this generation (specific rating may vary based on exact test year and equipment).

ABS:

Anti-lock Braking System (ABS)

Ebs:

Electronic Brakeforce Distribution (EBD)

Esp:

Optional Electronic Stability Programme (ESP)

Traction Control:

Traction Control System (TCS)

Airbags:

Driver, front passenger, side airbags, curtain airbags (depending on trim level).

Seatbelts:

3-point seatbelts with pre-tensioners for all occupants, ISOFIX child seat anchor points.

Body Structure:

Reinforced safety cell and crumple zones.

💡 Technology Features

Audio System:

Factory fitted radio/CD player with multiple speaker options. Later models may feature upgraded systems.

Navigation:

Optional satellite navigation system available on some trims.

Cruise Control:

Standard or optional cruise control for long-distance driving.

Parking Sensors:

Optional rear parking sensors.

OBD Interface:

OBD-II (On-Board Diagnostics II) compliant, allowing for engine diagnostics and emissions testing via compatible scanners.

Multiplexing:

Utilizes multiplexed wiring systems for various electronic functions, simplifying wiring but requiring specialized diagnostic tools.

🔧 Maintenance

Oil Change Interval:

Every 20,000 km or 1 year, whichever comes first (synthetic oil recommended).

Air Filter Replacement:

Every 40,000 km or 2 years.

Fuel Filter Replacement:

Every 60,000 km or 3 years.

Coolant Change:

Every 5 years or 100,000 km.

Timing Belt Replacement:

Refer to manual for specific interval (typically around 120,000 km or 5-6 years).

Engine Oil:

API CI-4 / ACEA B4 or C3 compliant, SAE 5W-30 or 5W-40 synthetic diesel engine oil.

Coolant:

Paraflu UP / Fiat 9.55597 - ECT (Extended Life Coolant) based on Ethylene Glycol.

Brake Fluid:

DOT 4

Transmission Oil Manual:

GL-4 SAE 75W-80 or 75W-90 gear oil.

Power Steering Fluid:

ATF Dexron III or equivalent.

Diesel Particulate Filter:

Potential for DPF clogging if regeneration cycles are incomplete, leading to increased fuel consumption and loss of power. Requires proper maintenance and driving conditions.

Turbocharger:

Variable geometry turbocharger can be prone to sticking or failure if oil is not changed regularly or if contamination occurs.

Egr Valve:

Exhaust Gas Recirculation (EGR) valve can become clogged with carbon deposits, leading to rough idling, reduced power, and increased emissions.

Electrical Systems:

As with many vehicles of this era, intermittent electrical issues and failures of sensors or control modules can occur. Multiplexed systems can be complex to diagnose.

Bodywork:

Rust can be a concern, especially around wheel arches, sills, and tailgate. Check for corrosion.

📚 Vehicle History

Fiat Heritage:

Fiat, an Italian automotive manufacturer with a long history dating back to 1899, known for innovation and mass production.

Ulysse Development:

The Fiat Ulysse is part of a joint venture project ('SEMP 2000') with PSA Peugeot Citroën, leading to the development of a shared platform and common vehicles.

Generation Details:

This manual covers the second generation of the Fiat Ulysse (1999-2010), which underwent a facelift and updates around 2002, including the introduction of the 2.2 HDI engine.

Manufacturing Plant:

Likely produced at the Sevel Nord plant in France (jointly operated by Fiat and PSA).

🏆 Awards & Recognition

Segment Acclaim:

While specific awards for the 2002 Fiat Ulysse are not widely publicized, the platform it shares with its PSA counterparts received recognition for its practicality and versatility within the MPV segment.

Consumer Reviews:

Reviews often highlight its spaciousness and comfort, though reliability can be a mixed bag depending on maintenance history and specific components.