159 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

Technical Data
Engine
Marea-Marea Weekend
2000 range @
OO.io
SPECIFICATIONS
Cycle OTTO 4 stroke
^Q\^ Timing gear TOHC
1 Fuel system type Integrated electronic injection - ignition
L—,1 Number of cylinders
Ml • • •
4 5
Vt—•F-jZf Cylinder liner
Is—A \ mm
W (bore)
80.5 82
j^J |q| Stroke mm 78.4 75.65
fifi-9 0> °-ace" cm3
1596 1998
^|*^^ Compression
= 9 ratio
ft
10.50 ±0.15 10.5 ±0.15
kW
r _ (bhp) X Maximum
76
(103)
110
(150)
/ power CEE
/ .. ... • rpm 5750 6500
daNm
(kgm)
Maximum
14.5
(14.8)
18.1
(18.5)
, torque CEE
... \ > rpm 4000 3750
10 Print n° 506.763/23

Marea- Marea Weekend • ^ Engine
2000 range (Q) Fuel feed system
10.
ENGINE MANAGEMENT SYSTEM
The Marea-Marea Weekend 1596 16v has a 4 cylinder in line engine, with 16 valves, 1596 cc, twin over­
head camshaft and a Marelli IAW 4EF integrated electronic injection/ignition system.
The fuel system differs from the one described for the 1581 16v "99 range" version through the addition
of several variants to make it compatible with the EEC Stage 3 EOBD regulations.
The main modifications to the system can be summarized as follows:
- Engine management control unit with IAW 4EF
- Catalytic converter near the exhaust manifold to take maximum advantage of the heat of the gases.
- Two Lambda senors, one upstream (front) and one downstream (rear) which check the quality of the
exhaust gases and the operation of the catalyzer.
- Adoption of a timing sensor on the inlet side timing pulley.
DIAGRAM SHOWING ENGINE EXHAUST ASSEMBLY
1. Exhaust manifold
2. Catalytic converter
3. Front Lambda sensor
4. Rear Lambda sensor
5. Silencers
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Marea- Marea Weekend
2000 range CJ
Auxiliary Units
Index
Compressor ( 1596 engine)
Compressor ( 1910 JTD)
Compressor ( 1998 engine)
Specifications
50
page
1
2
3
4
FOR ANYTHING NOT DEALT WITH,
REFER TO THE BASIC MANUAL, SECTION 50.
Copyright by Fiat Auto

Marea- Marea Weekend
2000 range ©
Auxiliary Units
Climate control
50
COMPRESSOR ( 1596 engine)
The compressor fitted on this version is the HR V5 variable capacity type, illustrated in the diagram below,
and consists of:
- a crankcase (7) which contains the bores in which the pistons (4) slide;
- an assembly comprising a shaft on which an inclined plate (6) is fitted on which a disc (2) guided by
a pin (5) integral with the five connecting rods (3) controlled by the pistons (4) rotates on roller bear­
ings;
- a cylinder head which contains the intake and supply ducts as well as the housing for the regulation
valve (9);
- a plate (8), between the crankcase and the cylinder head, which contains the inlet and supply valves;
- a pulley assembly with an electro-magnet coupling (1).
1. Pulley with coupling
2. Disc
3. Connecting rod
4. Piston
5. Disc guide pin
6. Inclined plate
7. Crankcase
8. Valve holder plate
9. Regulation valve
10. Valve control bellows
Operation
The alternating drive required for the sliding of the pistons in the bores/liners is produced by the rotary
motion of the inclined plate (6), whilst the variation in the capacity, dependent on the piston stroke, is
chieved through the alteration in the angle of the disc (2) controlling the connecting rods (3).
The inclination of the above mentioned disc depends on the difference in pressure between the intake
duct and the inside of the compressor. This difference, measured by the bellows (10), operates the regu­
lation valve (9) and consequently causes the movement of the disc (2).
When the request for conditioned air is high, the regulation valve (9) is positioned in such a way that it
uncovers an opening which places the intake side in contact with the inside of the compressor; as, in this
case, there is no difference in pressure, the compressor operates at maximum capacity corresponding to
the position of the disc illustrated in the previous section.
When the air request is less, the valve is positioned so that the supply section is in contact with the crank­
case and, at the same time, it stops the flow between the latter and the intake side activated previously.
Copyright by Fiat Auto 1

Auxiliary Units
Climate control
50
SPECIFICATIONS
TABLE SHOWING QUANTITIES OF OIL AND GAS FOR CLIMATE CONTROL SYSTEM
The table below summarizes the types of oil and the quantities of oil and coolant.
ENGINE TYPE COMPRESSOR TYPE OF
OIL
QUANTITY
OF OIL (cm3)
QUANTITY
OF GAS (g)
1596 16V HR V5 UNICON RL
488 265 600 ± 25
1998 20V SD6V12 SP10 135 600 ± 25
1910 JTD SD 7V16 SP10 135 600 ± 25
FOR ANYTHNING NOT DEALT WITH,
REFER TO THE BASIC MANUAL, ASSEMBLY 50.
Marea-Marea Weekend
2000 range ©
4 Print n' 506.763/23

Marea- Marea Weekend
2000 range ©
Electrical equipment
Protection and security devices
55.
PROTECTION AND SAFETY DEVICES
All the vehicle supply lines were designed taking into account the most up-to-date directives in terms of
safety and protection, especially to prevent fires.
There are 2 types of protection:
- active protection, aims to reduce the causes of faults "at source"
- passive protection, aims to limit the effects of a fault as much as possible
The first category includes a carefully designed wiring layout with wires positioned and carefully anchored
on tracks that are repaired and protected if necessary.
The cables connected to the alternator and the motor were modified for this reason by adding protective
caps etc. A strengthened sheath was also introduced for some of the more exposed sections of wiring.
The passive protection includes all interventions to reduce faults due to high current (overload, short cir­
cuit).
All system fuses were rated based on the nominal absorbtion of the loads activated at the same time, to
ensure intervention in cases of a clear short circuit.
The introduction of a box containing 4 maxifuses with other fuses connected on the outside means all
the supplies can be protected except for the cable that connects the battery to the starter motor and the
cable that connects the starter motor to the recharging alternator. These cables are therefore protected by a
strengthened supplementary sheath.
In "MAXI" fusebox A:
EFI electronic injection fuse (petrol)
GLOW: plug fuse (diesel)
IGN: ignition switch fuse
J/B2 fuse master supply .
J/B1 fuse master supply
Next to the box.
B: fan fuse (see table)
C: ABS 60A fuse
D: second fan fuse: 40A (JTD)
115961 1998
iFil 30A IJ/B21 BOA
fiGNl 4OA IJTBTI BOA
1910JTD
IGLOWl 60A P7B21 80A
MGNI 40A IJ/Bll 80A
FUSE B
30A engine petrol without air conditioner
40A 1596 with air conditioning, JTD
50A 1998 wth air conditioning
Copyright by Fiat Auto 1

Marea-Marea Weekend
2000 range ©
Electrical system
Wiring diagrams
55.
DIRECTION INDICATORS AND WARNING LIGHT (WITH ALARM) - HAZARD WARNING LIGHTS - BRAKE LIGHTS (WITH CHECK) - REVERSING
LIGHTS
20
N -
-AN-
16
-3—AN-
•i-RG-
•-BN-
1 11
N
§D ;OQ:- ID
AN N.D.
'<^AN—
AN
B R
N —H>
10 ID 3>»? |D A
159 AN
-AR-(•)
AR
t AR I AR
3A
n
AR
N.D. -AR—•—AR
40
N.D,
-AR--RN-f=3b
13 N.D. 1 A-A-Q-A A_|
HI AN A RN
9 1415 18
1
7 1 3 14 5 6 7 2 11 1 91213
*VU gj4vK ffH+P JAN RNIRGI r)
-AN-IRN RG
C —•—CB-
N.D, ^ B C C „
13 A i „ j M
AVAR
AVJAB
AN
2 1
100
A -i
-AB—•—AB-
LB
12
H^T 'j' T T V-115/54 J„ , Jrrt/aJ pos
0 N
.31
Hffl
-NZ
236
(*)
LR
AN
RV-
RV
AN RG RV RN
Si3
N N
22
1K««) U<wO 12 3 14
LJ
NZ-»-NZ-
NZ
NZ N
J5_
il8 41
—i
i N
N-g
A
21
LR A AR LB
AN
23
17 <*>
Variant for Marea Weekend Variant for AT. • Automatic transmission: see specific wiring diagram
Copyright by Fiat Auto XIJ-00 - Supersedes prev$>Os verjsfon 11

Electrical system
Component location
Marea- Marea Weekend
2000 range ©
DIRECTION INDICATORS AND WARNING LIGHT (WITH ALARM)
LIGHTS
Component key
1 Left front light cluster
2 Right front light cluster
3 Power fusebox
4 Junction unit
6 Instrument panel
7 Stalk unit
8 Left front earth
9 Right front earth
10 Battery earth on engine
11 Battery
12 Ignition switch
13 Connection between right/left front cables
16 Left tail light cluster
17 Right tail light cluster
18 Left rear earth
19 Right rear earth
HAZARD WARNING LIGHTS - BRAKE LIGHTS (WITH CHECK) - REVERSING
20 Left front side direction indicator
21 Right front side direction indicator
22 Left facia earth
23 Hazard warning light control switch unit
28 Connection between dashborad/rear ca­
bles
40 Brake lights control switch
41 Additional brake light
55 Connection between front/engine cables
100 Alarm electronic control unit
107 Door lock remote control receiver
159 Reversing lights control switch
236 Connection between rear cable and tail-gate
310 Connection shunt
55.
Left front light cluster
VN4C
AV4D
B
* AN n.d.
HN4C N8
1 3 Connection between right/left front cables
H2A
23A Hazard warning lights switch unit
'LB 7D
*AB4I
'AR4I
23B Hazard warning lights switch unit
*A4H .
' LR 7C AN 4H'
236 Connection between rear cable and tail-gate
CB28B
CB 26
HL 4E
RG4G
Marea Weekend
"The cables concerned are marked in the wiring diagram with an asterisk
12 XII 00 &jiii!-»cdes OMtfiuii.-. vtrsiun Publication no. 506.763/24

Marea-Marea Weekend
2000 range ©
Electrical system
Wiring diagrams
55.
DIRECTION INDICATORS AND WARNING LIGHT (WITHOUT ALARM) - HAZARD WARNING LIGHTS - BRAKE LIGHTS (WITHOUT CHECK) - RE­
VERSING LIGHT
20
• N -
-AN-
16 (*)
r®~l
•-®—L|« «i—RG-"
— AN—
N-
H8H-
3>o;
-AN-
-RG-
-BN-
1 11
\<t"> %E> 3><£ ID i|. .|j u.T -r
N a
OJ 10 WD 9><6 |D
AN N.D.
AN 159 -AN-
-AR-
AR
AR I
AR
3A
?
4 i
m (•>i
AN B
N.D. -AR—•—AR
A RN AR A
dpv dp ?4? dp
9 1415 18
N.D.
A —J— A •
40
N.D.
-AR-F -T-i -RN-fe ' 1
7 13 12 14 5 6 7
TYTH 87 87a 30 86 85
13 N.D. f
A-T0~A ~ A T
LAM=t
2 11 1 91213
-AN
A jBN B I CB |AV|AR
A -AN-
328
A -i
AN RN RG R
RN B
C —•—CB-
N.D.
AVJAB
N.D,
-AB-
N LB B C C IAI I J ,I [51
H"P rf 'f T v I 15/54 I ht/n I nos i. 15/54 ' , .ht/a J pos 30 50 irrt stozK
31
-NZ-
12
236
(*)
AN LRf
70
G pf—G—
28A
Lv
•AB-
" i G V
AN
N N
22
7(**> 1<X*I) 11<»>
-NZ--NZ-
I NZ V
41
i i
i i
®
X 19
^N-g
A
LR A
21
AN
AR
AB LB
—
a
23
vT0 17 (x)
107
-RN-
- A — *
- B — >
r- N - >
r-«h rH8H
—®-
<§- —®-'
17
RN-
->o;-
i§££t
H8>-
-0-
Variant for Marea Weekend Variant for A.T. • Automatic transmission: see specific wiring diagram
Copyright by Fiat Auto XII 00 - Supersedes previous version 13