air condition FIAT MAREA 2000 1.G Workshop Manual

Marea- Marea Weekend
2000 range @
Introduction
Weights
ENGINE TYPE
16v 20v
OO.o
Marea
Marea Weekend
+590=
(575)' ¥¥¥¥¥
Marea
+595=
(580)*
Marea Weekend
mrirnT
1140
1165 (•)
1200
1225 (•)
1730
1755 (T)
1795
1820 (T)
1255
1315
1830
1895
1000 1000
Permissible loads on the axles
1000 1000
Maximum permitted load on roof 80 80
Load on tow hook ball
(trailer with braking system) 70 70
Without braking
system 400 400
With braking
system 1200 1300
(1400)«
I Loads that should never be exceeded
(*) Specific figures for 1998 20v version
(•) Specific figures for the Marea Weekend
(T) Specific figures for the 1596 16v automatic transmission version
NOTE FOR VERSIONS WITH ACCESSORIES: In the presence of special equipment (non standard air conditioning, sun
roof, trailer towing device, etc.), the empty weight increases and therefore the carrying capacity may decrease in relation to
the maximum permissible loads.
Copyright by Fiat Auto 3

Marea- Marea Weekend Introduction
2000 range (§) Capacities
OO.o
Product Parts to be filled dm3
(I) Kg
16v 20v JTD
Petrol > O.R. 95
Unleaded •
63 63 -
^ft diesel i •' • • ir-FI-•
--63
50% p n
Total capacity of cooling
system
•
7
(6.7 •)
7.6
(7.4 •)
6
(5.6 •)
50% p
TP
n
Total capacity of cooling
system
•
7
(6.7 •)
7.6
(7.4 •)
6
(5.6 •)
Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
Total capacity
• 4.5 5.5 4.8 Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
Total capacity
• 4 4.7 4.25
Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
m-m
Partial capacity
(scheduled changes)
• 3.8
(3.5*)
5
(4.5*)
4.3
(4*)
Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
m-m
Partial capacity
(scheduled changes) • 3.4
(3.1*)
4.45
(4*)
3.75
(3.55*)
TUTELACAR frQQ
ZC 75 Synth
• 1.98 1.98 1.65 TUTELACAR frQQ
ZC 75 Synth • 1.8 1.8 1.5
TUTELA *
GI/2 -J»
• 4.3 --TUTELA *
GI/2 -J» • 3.9 --
(•) Distilled water
(•) For versions with air conditioning
(*) Engine sump only
(•) For temperatures below -20°C the use of SELENIA PERFORMER SAE 5W-30 is recommended
(••) For temperatures below -15°C the use of SELENIA WR DIESEL 5W-40 is recommended
Copyright by Fiat Auto 7

Technical Data
Front suspension
Marea- Marea Weekend
2000 range @
00.44
Front suspension independent, Mac Pherson type with transverse lower track control arms secured to an
auxiliary crossmember. Offset coil springs and double acting, telescopic, hydraulic shock absorbers. Anti-
roll bar connected to the telescopic damper.
CLASSIFICATION OF SPRINGS ACCORDING TO VARIOUS VERSIONS AND ENGINE TYPES
VERSIONS
ENGINE TYPES
VERSIONS
Standard E C
Standard with ABS E C
With air conditioning D B
With air conditioning, ABS and all options D B
With air conditioning and ABS D B
Standard with automatic transmission D
Standard with automatic transmission and ABS D
With air conditioning and automatic transmission C
With air conditioning, ABS and all options C
With ABS (fitted as standard) B
With ABS (fitted as standard) and air condi­
tioning A
With ABS (fitted as standard), air conditioning
and all options A
SPECIFICATIONS OF VARIOUS SPRINGS
Coil springs A B C D E
Wire diameter mm 13.6±0.05 13.5±0.05 13.2±0.05 13.2±0.05
Number of effective coils 3.75
Coil direction Clockwise
Released spring height mm 449 448 434 425 413
Load under which spring height is .
173 mm am 432±17 417±17 397±16 353-383 336-364
The springs have been divided into two cate­
gories identifiable by a mark
yellow (*) for those with a height of >173 mm
under a load of:
green (*) for those with a height of <173 mm
under a load of:
432 daN 417 daN 397 daN 368 daN 350 daN
( ) Springs of the same type must be fitted
42 Print n° 506.763/23

Fuel feed system
Engine Marea- Marea Weekend 9 ™
2000 range (Q)
10.
Control of idle speed
On the basis of signals from the rpm sensor and engine coolant temperature sensor, the injection control
unit controls the pressure governor and alters the injector control times to maintain idle speed stable at all
times.
Under certain conditions, the idle speed control unit also considers battery voltage.
Control of maximum speed limitation
According to rpm level, the injection control unit limits maximum speed by means of two types of inter­
vention:
- as maximum speed approaches, it reduces the amount of fuel injected to reduce line pressure;
- when maximum speed is exceeded, it inhibits operation of the auxiliary pump and injectors.
Control of maximum torque limitation
On the basis of rpm level, the injection control unit computes limit torque and maximum permitted fume
index parameters on the basis of predefined, stored maps.
It then corrects the above parameters using engine coolant temperature and car speed data. The resulting
values are then used to modulate the amount of fuel to be injected by adjusting the pressure regulator and
injectors.
Control of fuel temperature
The injection control uint is kept constantly informed of fuel temperature by a sensor on the return mani­
fold.
If fuel temperature exceeds a set value (about 110 °C), the control unit reduces line pressure by adjusting
the pressure governor, leaving injection times unaltered.
Control of coolant temperature
The injection control unit is constantly informed of coolant temperature by a sensor on the thermostat.
If engine coolant temperature or air conditioning fluid pressure exceeds certain levels, the control unit
performs the following actions:
- It reduces the amount of fuel injected by adjusting the pressure governor and injectors (power reduc­
tion);
- it controls the engine radiator cooling fan.
Control of glow plugs
The injection control unit controls operation of the glow plug preheating control unit to bring the tem­
perature in the combution chambers up to levels that promote fuel self-ignition and thus make start-up
easier.
The control unit controls the operation of the glow plug control unit for a certain time both before (pre­
heating) and after (postheating) engine start-up and also controls activation of the warning light on the
control panel.
Preheating, postheating and glow plug warning light activation times vary according to engine coolant
temperature.
4 Publication no. 506.763/24

Marea-Marea Weekend 9]
2000 range (j§)
I) JTD
Fuel feed system
Engine
10.
Exhaust fumes control
Through this function the injection control unit limits any exhaust fumes that could be produced during
transition speeds.
To satisy these requirements the control unit processes the signals supplied by the accelerator pedal po­
tentiometer, the rpm sensor and the air flow meter and controls the fuel pressure regulator and the injec­
tors to meter the correct amount of fuel to inject.
Exhaust gas recirculation control
On the basis of the signals supplied by the rpm sensor, intake air quantity sensor, engine coolant tempe­
rature sensor and accelerator pedal position sensor, the control unit calculates the operating times for the
EGR valve so that the exhaust gases are partly recirculated in certain engine operating conditions in line
with Euro 3 pollution control standards.
Air conditioning system engagement control
The injection control unit manages the operation of the air conditioning system compressor electro­
magnet coupling following a logic aimed at preventing operating conditions that would adversely affect
engine performance.
- When the compressor is switched on the injection control unit increases the quantity of fuel during
idling to allow the engine to adjust to the increased power requirements and momentarily interrupts the
supply to the compressor in high engine power requirement conditions (strong acceleration).
Engine immobilizer function control
The system is equipped with an engine immobilizer function. This function is achieved through the pre­
sence of a specific control unit (Fiat CODE), capable of conversing with the injection control unit and an
electronic key with a special transmitter for sending a recognition code.
Each time the key is turned to the OFF position, the Fiat CODE system completely deactivates the injecti­
on control unit.
When the key is turned to the ON position the following operations take place, in order:
1. the injection control unit (whose memory contains a secret code) sends the Fiat CODE control unit a
request to send the secret code to deactivate the immobilizer functions;
2. the Fiat CODE control unit responds by only sending the secret code after, in turn, having received the
recognition code transmitted by the ignition key;
3. the recognition of the secret code allows the deactivation of the injection control unit immobilizer func­
tion and its normal operation.
Autodiagnosis
The complete electronic fault diagnosis of the injection system is carried out by connecting the special
equipment (EXAMINER or EXAMINER PLUS) to the standardized diagnostic socket (EOBD).
The system is also equipped with a self-diagnostic function which recognizes, memorizes and signals any
faults.
If a fault is detected in the sensors or actuators, the recovery strategy is immediately activated in order to
ensure that the engine functions at an acceptable level. The vehicle can be driven to a service centre for
the appropriate repairs to be carried out.
Copyright by Fiat Auto 5

Fuel feed system
Engine Marea- Marea Weekend © ™
2000 range @
10.
The control unit autodiagnostic system checks the signals coming from the sensors and compares them
with the figures allowed:
- signalling faults during starting
- warning light on for 4 seconds indicates test stage
- warning light off after 4 seconds indicates no fault with components that could alter the pollution con­
trol standard figures
- warning light on after 4 seconds indicates fault.
- signalling faults during operation
- warning light on indicates fault
- warning light off indicates no fault with components that could alter the pollution control standard fig­
ures.
- recovery
- from time to time, the control unit defines the type of recovery according to the components which are
faulty
- the recovery parameters are managed by components which are not faulty.
Control of cylinder balancing during idling
According to the signals coming from the sensors, the injection control unit controls the idle speed torque,
altering the injector operating times.
Control of irregular operation
Depending on the signals coming from the sensors, the injection control unit corrects the amount of fuel
to be injected in order to improve driveability and reduce jerking whilst driving.
The correction is achieved through the fuel pressure regulator and by varying the injector operating times.
Control of electrical balance
According to the battery voltage, the injection control unit alters the idle speed, to guarantee a sufficient
current supply from the alternator in situations where the consumers are absorbing a great deal of power.
The variation in the idle speed is achived by regulating the fuel pressure and altering the injector operat­
ing times.
VGT variable geometry turbocharger control (1910 JTD 110 CV)
The injection control unit processes the signal coming from the supercharging sensor, at the various en­
gine operating speeds, and determines the quantity of fuel to be injected, acting on the fuel pressure
regulator and the injector opening times.
In addition, through the solenoid valve, the control unit regulates the geometry of the turbine in order to
ensure optimum performance in all operating conditions.
Turbocharger waste gate valve control (1910 JTD 100 CV)
At the various engine operating speeds, the injection control unit processes the signal coming from the
supercharging sensor and determines the amount of fuel to inject, acting on the fuel pressure regulator
and the injector opening times.
In addition, the control unit controls the opening of the turbocharger waste gate valve, via the solenoid
valve, in order to ensure excellent performance in all operating conditions.
Control of throttle closing when engine is switched off
When the engine is switched off (ignition key in OFF position) the injection control unit closes the throt­
tle valve located on the air intake duct via the special solenoid valve.
This action makes it possible to limit the tiresome shuddering of the engine whilst it is switching off.
6 .i. V!-01-.Cancelftand replaces Print n° 506.763/25

Marea- Marea Weekend 9 ™
2000 range ©) Fuel feed system
Engine
10.
Compents of injection system wiring diagram
1. Vehicle speepd
2. Rev counter
3. Engine radiator fan low speed relay
4. Radiator fan high speed activation relay
5. Potentiometer on accelerator pedal
6. Timing sensor
7. Fuel pressure sensor
8. EGR system modulator solenoid
9. Fuel pressure regulator
10. Glow plug preheating warning light on control panel
11. Injection system failure warning light
12. Air conditioning system relay
13. Coolant temperature sensor
14. Rpm sensor
15. Fuel temperature sensor
16. Diagnostic socket
17. Fiat CODE control unit
18. Four stage pressure switch
19. Injection electronic control unit
20. Pressure relief sensor
21. 7.5A fuse protecting electronic injection system ( + 15 power supply from ignition switch)
22. 7.5A fuse protecting electronic injection system ( + 30 power supply from ignition switch)
23. Main injection system relay
24. 30A fuse protecting injection system
25. Auxiliary fuel pump relay
26. Glow plug preheating control unit
27. Intake air flow and temperature sensor (debimeter)
28. Brake pedal switch
29. Clutch pedal switch
30. Ignition switch
31. Battery
32. Inertia switch
33. Auxiliary fuel pump (submerged in tank)
34. 60A fuse protecting glow plug control unit
35. Cylinder no. 1 glow plug
36. Cylinder no. 2 glow plug
37. Cylinder no. 3 glow plug
38. Cylinder no. 4 glow plug
39. Cylinder no. 1 injector
40. Cylinder no. 2 injector
41. Cylinder no. 3 injector
42. Cylinder no. 4 injector
43. Throttle valve control solenoid
44. Variable geometry turbocharger control solenoid
45. Diesel filter heater relay
Copyright by Fiat Auto 9

Engine Marea- Marea Weekend 9 ™
Fuel feed system 2000 range @
10.
ELECTRONIC INJECTION CONTROL UNIT
The control unit processes signals from the various sensors by applying software algorithms and controls
the actuators accordingly (particularly the injectors and pressure regulator) to achieve the best possible
engine service conditions.
The control unit is "flash E.P.R.O.M." type, i.e. it can be reprogrammed from outside without andy need
to adjust the hardware.
The injection control unit contains a built-in absolute pressure sensor and is connected to the wiring by
means of a 121 pin connector.
Control unit connection identification (PIN-out)
4 5 43 24 6 25 96 106 113 105 119 120 121
1 Earth 25 Not connected
2 Earth 26 Not connected
3 Earth 27 Not connected
4 Actuator power supply 28 Not connected
5 Injector/ECU power supply 29 Not connected
6 Not connected 30 Not connected
7 Not connected 31 Not connected
8 Not connected 32 Not connected
9 Not connected 33 Not connected
10 Not connected 34 Not connected
11 Fiat CODE 35 Not connected
12 Not connected 36 Not connected
13 Injection relay
14 Glow plug control
15 Throttle body solenoid
16 EGR valve
17S VGT solenoid
18 Air conditioner relay
19 Radiator fan high speed relay
20 Radiator fan low speed relay
21 Diagnostic warning light control
22 Glow plug activation control
23 Not connected
24 Auxiliary fuel pump relay
10 Publication no. 506.763/24

Ma tea- Ma tea Weekend !@ ™
2000 range ©
Engine
Fuel feed system
10.
37 Not connected
38 Not connected
39 Not connected
40 Not connected
41 Not connected
42 Not connected
43 Not connected
44 Not connected
45 Not connected
46 Not connected
47 Engine rpm signal output
48 Diagnostic line k
49 Vehicle speed signal input
50 Not connected
51 Activation signal from 4-stage pressure switch
52 Activation signal from 3-stage pressure switch
53 Not connected
54 Not connected
55 Not connected
56 Not connected
57 Not connected
58 Key ON signal
59 Brake switch
60 Air conditioner activation request
61 Clutch switch
62 Glow plug diagnosis
63 Not connected
64 Not connected
65 Not connected
66 Not connected
67 Not connected
68 Not connected
69 Not connected
70 Not connected
71 Not connected
72 Not connected
73 Not connected
74 Not connected
75 Not connected
76 Accelerator pedal 1 earth
77 Accelerator pedal 1 signal
78 Accelerator pedal 1 power supply
79 Accelerator pedal 2 earth
80 Accelerator pedal 2 signal
81 Accelerator pedal 2 power supply
82 Diesel temperature sensor (pin 1)
83 Diesel temperature sensor (pin 2)
84 Coolant temperature sensor (pin 1)
85 Coolant temperature sensor (pin 2)
86 Air flow meter (pin 1)
87 Not connected
88 Air flow meter (pin 3)
89 Air flow meter (pin 5)
90 Fuel pressure sensor (pin 3)
91 Fuel pressure sensor (pin 2)
92 Fuel pressure sensor (pin 1)
93 Turbo pressure sensor (pin 1)
94 Turbo pressure sensor (pin 3)
95 Turbo pressure sensor (pin 2)
96 Not connected
97 Air flow meter (pin 4)
98 Not connected
99 RPM sensor (pin 1)
100 RPM sensor (pin 2)
101 RPM sensor (pin 3)
102 RPM sensor (pin 1)
103 Timing sensor (pin 2)
104 Timing sensor (pin 3)
105 Not connected
106 Not connected
107 Not connected
108 Fuel pressure regulator
109 Fuel pressure regulator
110 Not connected
111 Heater relay control Fuel filter
112 Not connected
113 Not connected
114 Cylinder 4 injector control
115 Not connected
116 Not connected
117 Cylinder 1 and 2 injector power supply
118 Cylinder 3 and 4 injector power supply
119 Cylinder 1 injector control
120 Cylinder 2 injector control
121 Cylinder 3 injector control
Copyright by Fiat Auto 11

Marea-Marea Weekend 9 -™ Engine
2000 range (j§) Fuel feed system
10.
I I TEST
4F017XJ01
A switch (1) on the brake pedal con­
trols the car brake lights; the same
switch sends a signal to pin 59 of the
injection control unit
The control unit uses the "brake pedal
depressed" signal to:
- detect a situation of over-run;;
- check the plausibility of the signal
from the accelerator potentiometer
CLUTCH PEDAL SWITCH
A switch (2) on the clutch pedal is connected to pin 61 of the injection control unit.
The injection control unit uses the "brake pedal operated" signal to distinguish gear engaged and gear
shift conditions.
PRESSURE RELIEF SENSOR
The sensor is fitted to the intake manifold and
the signal sent to the injection control unit is
used to:
- regulate injection pressure;
- regulate injection duration.
The figure alongside shows the sensor and
electrical connector with the following pin-
out:
1. pressure signal
2. Earth
3. Fuel feed system
ATMOSPHERIC PRESSURE SENSOR
The atmospheric pressure signal is built into the injection control unit. It is responsible for measuring at­
mospheric pressure in order to correct measured air flow and reference air flow values to control the EGR
function.
Copyright by Fiat Auto 17