ESP FIAT MAREA 2000 1.G Workshop Manual

Marea- Marea Weekend •
2000 range ©
16v Engine
Fuel feed system
10.
1. Loosen the belt tension using the lock nut
(2) and the adjustment screw (1); then re­
lease the belt from the pulley.
2. Undo the bolts fixing the bracket for the
power assisted steering pump mounting
and detach the pump.
3. Undo the nuts fixing the exhaust manifold
to the cylinder head and detach the mani­
fold.
- To refit, reverse the order of the operations
carried out for the removal; tension the
power assisted steering pump drive belt,
using the adjustment screw; use tool
189576200 to check that the tension is
between 32 and 45 daN.
ELECTRIC FUEL PUMP WITH LEVEL
SENDER UNIT
Removing-refitting
- Disconnect the negative battery terminal.
- Lift up the lining in the luggage compart­
ment and remove the fuel pup protective
cover.
- Disconnect the electrical connection for the
electric pump assembly and the fuel supply
and breather pipes.
4. Undo the ring nut fixing the electric fuel
pump to the tank using tool 1870736000.
The gasket on the tank housing should be
replaced each time the pump drip tray is
removed-refitted.
NOTE The position of the fuel pump is fixed
and is established by a reference in
the housing in the tank which sou Id
correspond to the projection on the
pump drip tray.
Copyright by Fiat Auto 7

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

Marea- Marea Weekend 9™
2000 range (§)
4F015XJ03
Engine
Fuel feed system
ijo.
ENGINE COOLANT TEMPERATURE
SENSOR
The sensor is fitted to the thermostat and
measures the temperature of the engine cool­
ant by means of an NTC thermistor with a
negative resistance coefficient.
Because the sensor is made using semicon­
ductor technology, the resistance falls if sen­
sor element temperature rises with increasing
coolant temperature.
Because resistance does not change in linear
manner, it is higher at low temperatures than
at high temperatures for the same temperature
increase.
1. NTC resistance
2. Sensor case
3. Electrical connector
FUEL TEMPERATURE
SENSOR
The sensor is fitted on the return manifold and
measures fuel temperature by means of an
NTC thermistor with a negative resistance co­
efficient.
Refer to the previous description of the cool­
ant temperature sensor for sensor operation.
FUEL PRESSURE SENSOR
The sensor is fitted in the middle of the fuel
delivery manifold (rail) and is responsible for
providing a return signal (feedback) to the
control unit in order to:
- adjust injection pressure;
- regulator injection duration.
Copyright by Fiat Auto 15

Engine
Fuel feed system
JTD Marea-Marea Weekend ©
2000 range ©
10.
iH
ft
B I 0 ] I D
[ 0 0 1 1
D
0 1 <fi=2 1 1 15J
GLOW PLUG PREHEATING CONTROL
UNIT
The glow plugs are controlled by means of a
preheating control unit under the direct con­
trol of the injection control unit.
The preheating control unit contains a smart
relay that sends a return response (feedback)
to the injection control unit, which is thus in­
formed of faults in the preheating control unit
or glow plug short-circuits to earth.
The figure shows the connectors on the base
of the preheating control unit and the pin-out
1. Earth
2. Injection control unit (pin 22)
3. Power supply from main injection relay
4. Not connected
5. Injection control unit (pin 62)
8. Positive from battery (+30)
G. Glow plugs (only four outputs are used)
ACCELERATOR
PEDAL POTENTIOMETER
Accelerator pedal position is converted to an
electrical voltage signal and send to the injec­
tion control unit by a potentiometer connected
to the accelerator pedal.
Accelerator pedal position is processed to­
gether with rpm information to provide injec­
tion times and pressure.
The sensor consists of a case (1) secured to
the pedal by a flange, which contains an axi-
ally-positioned shaft (2) connected to two
potentiometers (3): main and safety potenti­
ometers.
A coil spring on the shaft ensures the correct
resistance to pressure while a second spring
ensures return upon release.
16 Publication no. 506.763/24

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

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

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
Radio System
55.
OPERATION
ON/OFF
The set can be turned on and off in two ways.
1. Press knob A (VOL).
2. Turn on/off by means of car ignition switch. This function may be set in the EXPERT control level.
Manual activation and deactivation are possible at all times in this case.
Note: // the EXPERT "IGN" function is not active, the radio goes off automatically 20 minutes after the
engine is turned off.
ADJUSTING VOLUME AND SOUND
Volume
Adjust to required volume by means of knob A (VOL),
the display shows: «VOL 00» D «V0L 31».
Adjusitng sound
For each of the settings BASS, TREBLE, FADER, BALANCE, LOUDNESS:
1. Select functions by pressing the AUD key once or more.
2. Select the required sound setting by means of key A or select the basic setting: press the AUD key for
longer than 2 seconds until the display shows «CENTER» Or «- -«.
3. Finish adjustment: press the AUD key several times until the display shows «V0L ...».
NOTE: the radio comes with a sound reproduction condition memory specific to each source type.. This
makes it possible to set different sound geometries (FADER, BALANCE) and frequency responses
(BASS, TREBLE, LOUDNESS) for radio, cassette and phone sources (Automatic Sound Memory
function)..After about 5 seconds, the control level with the current settings is automatically aban­
doned.
Copyright by Fiat Auto XII 00 - Update 33
4F033L01

Marea-Marea Weekend
2000 range (§)
Electrical system
Radio System
55.
Range selection
FM range: press the BN key repeatedly until the display shows the required range «FM 1», «FM 2» or «FM
3».
AM Range: press the BN key repeatedly until the display shows «MW» (medium wave) or «LW» (long
wave).
Last station memory
Once the selection has been made, the last programme tuned on this range can be played (Last Station
Memory) While in Last Station Memory mode, the set stores the settings present before it is turned off:
selected station, CD or TAPE, and plays them when the set is turned on again.
Stereo reception - FM
When a stereo station is received, the display shows the corresponding symbol.
Traffic information reception (TP)
TP (Traffic Program): RDS station able to transmit traffic broadcasts.
TP function activation
Give the TP key a short press This enables the traffic broadcast reception function: the display shows the
message "TP"
When traffic information is received with the TP function active and another sound source is playing (e.g.
CD or tape), the source is interrupted to listen to the radio information and the display shows the message
"TA INFO" for 10 seconds.
At the end of the traffic information, the soruce is automatically switched to the source selected originally.
NOTE: if the station tuned in is not an RDS station able to broadcast traffic information, a search is
automatically started for an RDS station when the TP function is selected.
Interrupting traffic information
Give the TP key a short press. The function still remains active to receive future traffic information.
Because the radio offers the EON service, another station belonging to the same network may tune in
while listening to a radio station to provide traffic information (only with TP function enabled); it will re­
turn to the original station automatically at the nd of the news.
NOTE: traffic information is provided at minimum volume. This volume may be adjusted by means of the
EXPERT control menu.
// only traffic information is to be played, activate the function by means of the TP key and set
the volume to zero using knob A
Alternative frequency (AF)
During reception of an RDS programme that is broadcast by several stations at different frequencies, the
radio will automatically switch to the frequency with the best local reception.
NOTE: in a very poor reception area, the user may become aware of attempts to switch between sound
frequencies due to frequent pauses. In this case, it is advisable to deactivate the AF function
RDS-EON
temporarily.
Copyright by Fiat Auto XII-00 - Updatp. 35

Electrical system Marea- Marea Weekend
Radio System 2000 range @
55.
Tuning RDS programmes (IS LEARN) function (see EXP)
The IS LEARN function (which can be run only after activating the EXPERT function) can be used to
store up to 30 programmes in the IS memory (virtual memory area that does not correspond to storage
keys).
Stored programmes can be called up one by one as described in the EXP section.
The IS memory is useful when the station selection keys are restored or when the tuning stops on a new
reception field and you do not wish to deleted stored stations from preset keys.
Starting the automatic IS LEARN function
Use the BN key to select the range «FM 1», «FM 2» or «FM 3».
Press the SRC key for longer than 2 seconds. «IS ...» will appear on the display, the receiver starts the
search.
If an attempt is made to start the IS LEARN search without the IS mode being active (see EXPERT), the
display will show the message "EXPERT".
NOTE: Always wait for the end of the automatic intelligent search (IS).
If no reception is possible, the automatic intelligent research may stay on, e.g. in an underground garage
or if the aerial is defective. In this case, the automatic search can be interrupted by pressing one of the
station selection keys from 1 to 6.
The automatic intelligent search IS ensures up to 30 stations can be stored with optimum reception.
During automatic intelligent search IS, RDS programmes are stored first ordered by programme code, fol­
lowed by FM stations.
Calling up the contents of the IS memory
Stations can be called up from the memory in the required direction by giving a short press to one of the
keys A or B. «IS-SCAN» appears on the display during station selection.
Programme types (PTY)
Many radio programmes offer the programme type service (PTY) in the FM range (FM1, FM 2, FM3) The
message «NEWS» is displayed during a news programme, for example.
The PTY function activates a search filter that allows the radio to tune only to stations that broadcast pro­
grammes with a preset PTY code.
Programme types
The types of programme offered by a radio station vary according to the type of programme transmitted.
NEWS News and topical matters
AFFAIRS Politics and events
INFO Special information programmes
SPORT Sports broadcasts
EDUCATE Education and training
DRAMA Radio plays and readings
CULTURE Culture, church and religion
SCIENCE Science
VARIED Various
POP Pop music (hits and chart music)
ROCK M Rock music
EASY M Easy listening
LIGHT M Light classical music
CLASSICS Classical music
OTHER M Unclassified music programmes
(*) differs from phone-in function, activated only
WEATHER Weather forecasts
FINANCE Financial news
CHILDREN Children's programmes
SOCIAL A Social information
RELIGION Religious and philosophical
broadcasts
PHONE IN Listeners' phone-ins (*)
TRAVEL Tourist information
LEISURE Leisure, hobbies and pastimes
JAZZ Jazz music
COUNTRY Country music
NATIONAL National broadcasts
OLDIES Golden Oldies
FOLK M Folk music
DOCU Special documentaries
NO PTY No identification code
the handsfree connection for mobile phone
38 XII-00 - Update Publication no. 506.763/24