Ulysse Factory Service Manual (2002-2010): Engine
General
Maintenance
Diagnostics
Engine
Transmission
Brakes
Steering & suspension
Heating & A/C
Electrical
Body & interior
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
General2 pages
Engine and power unit8 pages
- Power unit with manual gearbox - r.r
- Power unit with automatic transmission r + r
- Engine - dismantle and reassemble following operation 1004e10 - wash and check dismantled parts - refit cylinder head an
- Engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal
- Engine removed, general overhaul
- Power unit (manual gearbox), removed, dismantle and reassemble
- Power unit (automatic transmission) removed, remove and re-build
- Engine - position on stand and remove
Power unit supports10 pages
- Power unit rigid support - gearbox side - r.r.
- Power unit rigid support - timing side - r.r.
- Rear rigid mount - r r
- Power unit front support flexible mounting (timing side) - replace
- Gearbox side support flexible mounting(s) - replace
- Power unit intermediate mount flexible block - replace
- Power unit upper support - r r
- Engine link bracket - r r
- Power unit lower reaction link - r.r.
- Bracket on engine for lower reaction rod - r.r.
- Engine crankcase › Lower engine block - r r clean mating surfaces and apply sealant with engine removed
Cylinder head/s19 pages
- Single cylinder head - r.r. and replace gasket
- Single camshaft housing - replace gasket
- Single camshaft housing - r.r. with timing belt removed - replace gasket
- Left camshaft housing - replace gasket
- Right camshaft housing - replace gasket
- Sound-proofing cover - r + r
- Cam cover with built in oil vapour separator r r
- Tappet cover with oil vapour separator built into left cylinder head - r.r.
- Tappet cover with oil vapour separator built into the right cylinder head - r.r.
- Left cam cover - r + r and replace gasket
- Right-hand cam cover - r + r and replace gasket
- Ignition coil cover on cylinder head- r+r
- Left hand cylinder head ignition coil cover - r+r
- Left hand cylinder head -r+r and replace gasket with engine removed
- Right hand cylinder head - r+r and replace gasket with engine removed
- Single cylinder head, removed - overhaul
- L cylinder head - overhaul
- R cylinder head - overhaul
- Cylinder heads - overhaul
Crankcase sump and covers14 pages
- <x>CRANKCASE SUMP - R&R AND REPLACE GASKET</x>
- Engine oil drain plug - replace
- Crankcase oil sump - r.r clean surfaces for sealant application
- Crank case oil sump - r + r and replace gasket with engine removed
- Crank case oil sump - r + r clean seals for sealant application with engine removed
- Oil sump bulkhead - r r
- Front crankshaft oil seal cover - r.r and replace seals for versions with oil pump on crankshaft, timing side
- Front crank shaft oil seal cover - r + r and replace seals with timing belt removed
- Crankshaft oil seal front cover - r.r. replace gasket with timing belt removed - includes cleaning matching surfaces and
- Front crank shaft oil seal cover - r + r and replace seals
- Engind front cover - r r
- Front crank shaft cover oil seal - replace
- Flywheel side oil seal - replace
- Flywheel end oil seal- r+r with flywheel removed
Crankshaft and flywheel5 pages
Timing system29 pages
- Toothed timing belt - r + r for timing adjustment or replacement
- Toothed timing belt - r r with engine removed
- Toothed-driven pulley (one) - r + r with timing belt removed
- Toothed drive pulley - r + r with timing belt removed
- Toothed drive pulley - r + r
- Toothed driven pulley (one) - r + r
- Moving timing tensioner - r.r. with timing belt/chain removed
- Mobile timing system tensioner - r + r for 24 valve engines
- Fixed timing system tensioner - r + r with timing belt removed
- Fixed timing tensioner - r r
- Fixed timing system tensioner (one) r + r
- Timing system protective cover(s) - r + r
- Camshaft flywheel - r.r.
- Camshafts in camshaft housing - r.r - includes camshaft housing replacement, if necessary
- Front oil seal of one overhead camshaft - replace with timing belt removed
- Timing variator on cylinder head intake camshaft - r r
- Camshaft in cylinder head - r r on vehicle
- Camshaft in cylinder head - r r on vehicle
- Timing shaft of one cylinder head, lh or rh - r r with cylinder head removed
- Camshaft controlling valves in left camshaft housing - r.r. - includes replacement of camshaft housing, if necessary
- Camshaft in lh head extension - r+r with head extension and timing belt removed
- Camshaft controlling intake valves in top head - r + r with top head removed - includes replacement of top head if neces
- Camshaft in rh head extension - r+r with head extension and timing belt removed
- Front oil seal of camshaft of one l/h or r/h top head - replace with timing belt removed
- Valve control rocker shaft - r r
- Hydraulic tappet (one) - replaced with camshaft removed
- Hydraulic tappet (one) - replace with camshaft housing removed
- Hydraulic tappets all r r
- Hydraulics tappets all r r camshaft removed
Fuel tank and pipes23 pages
- Introduction
- ELECTRIC FUEL PUMP ASSEMLBY (low pressure)
- Check on the supply voltage and the absorption current for the submerged pump
- Fuel tank - r + r and decant fuel
- Fuel tank - r + r for replacement
- Fuel tank - r + r and decant fuel for versions with evaporation control system
- Fuel tank - r + r for versions with evaporation control system for replacement
- Oil seal cover, fly wheel side - r + r and replace seals
- Label not available
- Lh fixed timing belt tensioner - r r for versions with air conditioner
- Plug for fuel filler pipe - r + r
- Submerged pump assembly complete with level guage control - r + r
- Submerged pump assembly complete with fuel guage - r r with tank removed
- Fuel filter supply pipe (front section) - r.r.
- Fuel filler pipe union sleeve - r + r
- Intermediate fuel delivery hose r r
- Rear fuel delivery line - r r
- Filter/carburettor line - r r
- Fuel line from manifolds - r r
- Intermediate fuel return pipe r r
- Fuel return line - r r
- Fuel return line from injection pump to filter - r r
- Fuel cooling device for tank return circuit - r.r.
Fuel circuit pump/s and devices4 pages
Engine air supply circuit17 pages
- Subassembly graphic index
- Vacuum air circuit
- Air filter assembly - r.r.
- Air cleaner assembly - r r for versions with automatic transmission
- Air cleaner filtering element - replace.
- Cold air intake - r r
- Rigid pipe connecting air cleaner to inlet manifold rigid pipe r r
- Sleeve from air cleaner to rigid pipe - r r
- Hose from filter to turbocharger air inlet pipe - replace
- Sleeve from rigid pipe to throttle body - r r
- Air inlet pipe to turbo charger - r + r
- Upper resonator device - r r
- Tubazione da debimetro a manicotto corpo farfallato - s.r.
- Rigid air delivery pipe between turbo charger and heat exchanger - r + r
- Air delivery pipe between turbo charger and heat exchanger - replace
- Air delivery sleeve from heat exchanger to intake manifold - r + r
- Turbo charger intercooler - r + r
Petrol injection system22 pages
- Multi-point injection system (mpi)
- Air flow meter - r + r
- Throttle case - r + r
- Throttle body intergral with mds - r r
- Throttle case throttle position switch - r + r
- Air pressure sensor - r.r.
- Intake air temperature sensor - r + r
- Coolant temperature sensor - r + r
- Cam angle sensor r + r
- Right head cam angle sensor - r.r.
- Right head timing phase transformer solenoid - r.r.
- Single fuel manifold pipe, with injectors - r + r
- L/h and r/h fuel pipe assembly - with injectors - r + r
- Left head phase transformer solenoid - r.r.
- L/h fuel manifold pipe, with injectors - r + r
- R/h fuel manifold pipe, with injectors - r + r
- Set of injectors - r + r with fuel manifold pipe removed - includes seal replacement
- Injector (one) - r + r with fuel manifold pipe removed - includes seal replacemnt
- Injection/ignition contro unit guard - r r
- Injection/ignition system e.c.u. (one) - r + r
- System cable bundle - r + r
- Electrical connection bridge between left and right heads - r.r.
Diesel injection system30 pages
- Subassembly graphic index
- Bosch edc 15c2 hdi injection system
- View of assembly
- Introduction
- Pressure pump
- Injector
- Engine management node ncm
- Low return fuel pressure circuit check
- Low fuel pressure supply circuit check
- Injector high pressure, fuel circuit leakage test
- Electronic diesel injection control
- Pipe from pressure pump to fuel manifold - r.r.
- Fuel injectors
- Fuel delivery manifold - r r
- Lines to injectors - r r
- Lines to injectors - r r
- Fuel return manifold - r r
- Pipe to return manifold - r r
- Throttle body - r.r
- Flow meter - r r
- Engine coolant temperature sensor - r r
- Fuel temperature sensor - r r
- Rpm and timing sensor - r r
- Cam angle sensor - r r
- Fuel pressure sensor - r r
- Solenoid on vacuum tank for throttle body pneumatic valve r r
- Ds electric injection control unit - r r
- Pressure pump - r r
- Pressure pump pulley - r r
- Supplementary pressure pump - r r
- Engine supercharging system › Subassembly graphic index
- Turbo charging system › Supercharging pressure check
Accelerator controls2 pages
Exhaust emission control system51 pages
- Idling c.o. level - check with special equipment
- Exhaust gas test - using special equipment in front of catalytic converter
- Supply pipe from electric pump to exhaust air injection system cut off valve - r.r.
- Left catalytic preconverter r r or replace cylinder head gasket
- Exhaust air injection system cut off valve - r.r.
- Right catalytic preconverter r r or replace cylinder head gasket
- Air intake for exhaust air injection system electric pump - r.r.
- Catalytic converter - r + r
- Left upper lambda sensor r r
- Right upper lambda sensor r r
- Front lambda probe with catalitic converter r r
- Rear lambda probe with catalitic converter r r
- Left rear lambda sensor on catalytic converter r r
- Right rear lambda sensor on catalytic converter r r
- Lambda sensors (all) - r.r.
- E.g.r. valve - r + r
- E.g.r. system solenoid - r + r
- Pipe carrying exhaust gas from e.g.r. valve to inlet manifold - r + r
- Egr system vacuum tank - r r
- Exhaust gas water heat exchanger for EGR valve r r
- Pipe carrying engine oil vapours from intake to separator - r + r
- Pipe from engine oil vapour separator to intake - r + r
- Single pipe from left and right cylinder head oil vapour separators to inlet - r.r.
- Engine oil vapour separator - r + r
- Active carbon filter for fuel vapours - r + r
- Fuel vapour active charcoal filter mounting - r.r.
- Fuel vapour cut out valve from filter - r.r.
- Fuel vapour pipe from tank to active charcoal filter - r.r.
- Pipe from fuel vapour separator to solenoid - r r
- Pipe from cut out solenoid valve to throttle casing - r.r.
- Catalytic converter - r.r.
- Particle filter - r.r.
- Seal between catalytic converter and particle filter - r.r.
- Reservoir for additive - r.r.
- Pressure pump with level sensor on additive reservoir - r.r.
- Safety valve on additive reservoir - r.r.
- Additive injector in fuel tank - r.r.
- F.a.p. system control unit - r.r.
- Fuel filler cap presence sensor - r.r.
- Catalytic converter front or rear temperature sensor (one) - r.r.
- Front or rear differential pressure sensor (one) - r.r.
- Pipe from front or rear differential pressure sensor (one) - r.r.
- Solenoid valve for the inflow of engine coolant to fap system heat exchanger - r.r.
- Air/coolant heat exchanger for f.a.p. system air circuit - r.r.
- Engine coolant / fap system air sucked (into air filter box) heat exchanger - r.r.
- Engine coolant pipe from thermostat to f.a.p. system air heat exchanger - r.r.
- Coolant pipe from f.a.p. air heat exchanger to engine oil/engine coolant heat exchanger - r.r.
- Air supply hose from turbocharbger to rigid air supply connector to intercooler and f.a.p. system heat exchanger - r.r.
- Rigid supply connector from turbocharger for intercooler and f.a.p. system heat exchanger - r.r.
- Air supply hose from turbocharger rigid supply connector to f.a.p. system heat exchanger - r.r.
- F.a.p. system heat exchanger air supply hose to throttle casing - r.r.
Engine lubrication18 pages
- Engine oil level sensor - r + r
- Pipe from sender unit to engine oil pressure w/l - replace
- Oil dip stick pipe - r r
- Engine oil filler - r r
- Engine oil temperature sender unit - r + r
- Engine oil pressure warning light switch - r.r. with interfering components removed
- Engine oil heat exchanger - r + r
- Engine oil pump - r + r with crankcase sump removed
- Engine oil pump - r+r
- Engine oil pump - r+r with power unit removed
- Engine oil pump, removed - check at bench
- Emgine oil intake duct - r r
- Engine oil intake pump - r + r with crankcase sump removed
- Engine oil filter r r
- Cartridge engine oil filter support - r + r
- Engine oil filter mounting - r.r. with intefering components removed
- Engine oil delivery pipe to turbocharger - r + r
- Engine oil return pipe from turbo - r + r
Engine cooling22 pages
- Introduction
- Rigid pipe/connector (one) for engine cooling circuit - r.r.
- Lower sleeve for coolant outlet from radiator - r + r
- Upper sleeve for coolant inlet to radiator - r + r
- Hose between rigid pipe and thermostat - r.r.
- Water pump inlet connector - r.r.
- Rigid pipe for coolant inlet to water pump - r + r
- <x>COOLANT MANIFOLD IN CYLINDER HEAD - R&R</x>
- Oil exchange sleeve - r r
- Rigid supply or return pipes for engine oil heat exchanger - r.r.
- Engine cooling tank - r + r
- Engine cooling radiator - r + r
- Engine cooling radiator protections/air ducts - arrange
- Coolant level sensor - r.r.
- Engine cooling radiator support beam - r r
- Water pump - r + r
- Water pump - r + r with drive belt removed
- Water pump - r + r with engine removed
- Thermostat unit - r+r
- Thermostat- r + r
- <x>LEFT ENGINE COOLING FAN OR FANS - R&R</x>
- <x>RIGHT ENGINE COOLING FAN - R&R</x>
Engine component miscellaneous drives9 pages
- Crankshaft pulley - r + r
- Crankshaft pulley - r+r for versions with air conditioner
- Power steering pump/self levelling suspension pump pulley - r + r with belt removed
- Engine components single drive belt - r.r. for versions with air conditioning
- Single engine belt r r
- Engine component single belt mobile tensioner - r + r
- Engine component single belt mobile temperature - r rwith belt removed
- Engine component single belt fixed tensioner - one - r + r
- Engine component single belt fixed tensioner - r rwith belt removed