clutch FIAT MAREA 2001 1.G Workshop Manual

marea-marea vvvttnviiu miruuuCuuu ciilu iwnniCai data
2000 range © Index
00.
page
INTRODUCTION
- Identification data 1
- Weights 3
- Performance - Fuel consumption 4
- Dimensions 5
- Capacities 7
- Product specifications
FL Group 9
TECHNICAL DATA
Engine l^^) lev |^^) 20v
- Specifications 10
- Typical curves 11
- Cylinder block/crankcase and associ­
ated components 12
- Auxiliary shaft 17
- Cylinder head and valve gear compo­
nents 18
- Timing diagrams 22
- Counter-balance shaft 23
- Lubrication 24
- Cooling system 26
- Fuel feed system 26
- Special tools 27
Engine I^^JJTD
- Specifications 29
- Timing diagrams 30
- Supercharging 31
CLUTCH 32
GEARBOX AND DIFFERENTIAL 33
AUTOMATIC TRANSMISSION DIF­
FERENTIAL 35
BRAKING SYSTEM 36
STEERING 39
WHEELS 40
FRONT SUSPENSION 42
REAR SUSPENSION 44
ELECTRICAL EQUIPMENT 46
- Ignition 47
1 - Recharging 48
- Electronic injection/ignition 50
Copyright by Fiat Auto

Marea-Marea Weekend
2000 range (§)
Introduction
Product characteristics FL Group
OO.o
Name of
product
Description
International designation Application
SELENIA 20K
Synthetic SAE 10W40 multigrade engine oil.
Exceeds specifications ACEA A3-96/CCMC G5 and API
SJ
SELENIA
PERFORMER
Synthetic SAE 5W-30 multigrade engine oil. Exceeds
specifications ACEA A1 and API SJ
Temperatures below
- 20°C
SELENIA
Turbo Diesel
Synthetic SAE 10W40 multigrade engine oil
Exceeds specifications ACEA B3 and API CD
SELENIA
WR DIESEL
Synthetic SAE 5W-40 multigrade engine oil. Exceeds
specifications ACEA B3 and API CF
Temperatures below
- 15°C
TUTELA CAR
ZC 75 SYNTH
SAE 75W-80 EP oil. Satisfies standards MIL-L-2105 D
LEV and API GL 5
Manual gearboxes and
differentials
TUTELA Gl/A «ATF DEXR0N II D LEV» SAE 10W type oil for hydraulic
power assisted steering
Hydraulic power as­
sisted steering
TUTELA GI/2 « ATF DEXRON II D LEV» SAE 10W type oil for auto­
matic transmissions
Automatic
gearboxes
TUTELA MRM2 Water repellant, lithium soap based grease containing
molybdenum disulphide, consistency NLGI = 2 Constant velocity joints
TUTELA TOP 4 Synthetic fluid NHTSA n° 116 D0T4, ISO 4925, SAE
J-1703 and CUNA NC 956-01
Hydraulic brakes and
hydraulically operated
clutches
DP1 Mixture of alcohol, water and surface active agents
CUNA NC 956-11
To be used undiluted
or diluted in windscreen
washer systems
Paraflu11
Anti-freeze for cooling systems with mono-ethylene gly­
col base
CUNA NC 956-16
Cooling circuits
Percentage to be used
50% up to -35°C
Diesel Mix Additive for diesel fuel with protective action for Die­
sel engines
To be mixed with die­
sel fuel (25 cc per 10
litres)
Copyright by Fiat Auto 9

Technical Data Marea- Marea Weekend
Clutch 2000 range ©
00.18
Values in mm
Make @ V
dry, single plate with bearing
contact
Operating mechanism Spring
Spring loading daN 400 600 485
200 230 215
«
01
200 230 215
«
01
137 155 147 02
Pressure plate
137 155 147
^t/ f I Distance between pedal in end of
/ r travel position and pedal in rest posi-
tC/ tion
163 144.5
Clutch operation mechanical Hydraulic
^EflHi^SBMj^0 Clutch operating pump Q -16.05
(3/4»)
[f^^^^UHL 0 Operating cylinder Q -25.4
(1»)
32 Print n° 506.763/23

Marea- Marea Weekend 9 \) JTD
2000 range O
Engine
Index
FUEL SYSTEM
- Introduction
- System management strategies
- Fuel system functional diagram
- Diagram showing information ente­
ring/leaving the control unit and
sensors/actuators
INJECTION SYSTEM WIRING DIA­
GRAM
- Injection electronic control unit
- Rpm sensor
- Timing sensor
- Air flow meter
- Injectors
- Engine coolant temperature sensor
- Fuel temperature sensor
- Fuel pressure sensor
- Heater plugs control unit
- Accelerator pedal potentiometer
- Brake pedal switch
- Clutch pedal switch
- Excess pressure sensor
- Atmospheric pressure sensor
page
1
1
1
2
8
10
12
13
13
14
15
15
15
16
16
17
17
17
17
THROTTLE CASING
- Removing-refitting
E.G.R. VALVE
- Removing-refitting
E.G.R. VALVE SELF-ADJUSTMENT
MOTOR
- Removing-refitting
E.G.R. VALVE HEAT EXCHANGER
- Removing-refitting
SOLENOID VALVE ON VACUUM
RESERVOIR FOR THROTTLE CA­
SING PNEUMATIC VALVE
- Removing-refitting
VACUUM RESERVOIR
- Removing-refitting
10.
page
30
31
32
32
34
34
FUEL SUPPLY CIRCUIT 18
- Immersed (auxiliary) pump and fuel
gauge assembly 19
- Fuel filter 19
- Pressure pump 20
- Fuel pressure regulator 20
- Multifunction valve 21
- Supply manifold (rail) 21
- Inertia safety switch 22
AIR SUPPLY CIRCUIT 23
- Throttle case 24
- Turbocharger 25
SUPERCHARGING PRESSURE
CONTROL SOLENOID VALVE
- Removing-refitting 35
FUEL FILTER
- Removing-refitting 35
PRESSURE REGULATOR
- Removing-refitting 36
EMISSION CONTROL DEVICES 27
- Oxidizing catalytic converter 27
- Exhaust gas recirculation circuit
(EGR) 27
- Recirculation circuit for crankcase
vapours (blow-by) 29
Copyright by Fiat Auto VI 01 Cancels anil replaces

Engine
Fuel feed system
Marea- Marea Weekend © ™
2000 range ©
10.
FUEL SYSTEM OPERATING DIAGRAM
1. Pressure pump
2. Electrically-controlled EGR valve
3. Flow meter
4. Pressure regulator
5. Fuel filter
6. Instrument panel
7. Glow plug preheating control unit
8. Electronic control unit
9. Injection system relay
10. Return manifold (low pressure)
11. RPM sensor
12. Glow plugs
13. Engine coolant temperature sensor
14. Potentiometer on accelerator pedal
15. Switch on brake pedal
16. Switch on clutch pedal
17. Variable geometry turbocharger
18. Timing sensor
19. Injectors
20. Fuel pressure sensor
21. Variable geometry turbocharger control sole­
noid
22. Auxiliary fuel pump
23. Glow plug preheating warning light
24. System failure warning light
25. Pressure relief sensor
26. Fuel temperature sensor
27. Throttle valve
28. Variable geometry actuator
29. Vacuum tank
30. Exhaust gas heat exchanger
2 Publication no. 506.763/24

Marea- Marea Weekend 9 ™
2000 range ©
Engine
Fuel feed system
10.
DIAGRAM SHOWING INFORMATION FLOW BETWEN THE INJECTION CONTROL UNIT AND
SENSORS/ACTUATORS
1. Auxiliary fuel pump
2. Variable geometry turbocharger control sole­
noid
3. Climate control compressor
4. Electric EGR valve
5. Rev counter
6. Engine radiator fan
7. Glow plug preheating control unit
8. Potentiometer on accelerator pedal
9. Brake and clutch pedal switches
10. Fuel pressure sensor
11. Intake air flow and temperature sensor (de-
bimeter)
12. Coolant temperature sensor
13. Fuel temperature sensor
14. Pressure relief sensor
15. Timing sensor
16. Rpm sensor
17. Vehicle speed signal
18. Battery
19. Four stage pressure switch
20. Fiat CODE control unit
21. Diagnostic socket
22. Fuel pressure regulator
23. Injectors
24. Throttle valve control solenoid
25. Glow plug preheating warning light
26. Injection system failure warning light
Copyright by Fiat Auto 1

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

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

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ®
Starting - Electronic ignition and injection - Recharging and warning light
light- Injection system failure warning ilight - Rev counter (1998)
Insufficient engine oil pressure warning
Component key
3 Power fusebox
4 Junction unit
6 Instrument panel
8 Left front earth
10 Engine battery earth
12 Ignition switch
18 Left rear earth
22 Left facia earth
40 Brake lights control switch
55 Connection between front/engine cables
57 Inertia switch
70 Connection between dashborad/front
cables
68 Right door mirror
70 Connection between dashborad/front
cables
127 Connection between front left cable/ca­
ble on relay holder bracket
132 Petrol vapour cut out solenoid valve
136 Knock sensor
141A Heated Lambda sensor (upstream of cat.)
141 B Heated Lambda sensor (downstream of
cat.)
143 Alternator
145 Starter motor
148 Earth for electronic injection
150 Injection system relay feed
151 Relay feed for Lambda sensor, electric
fuel pump, injectors
152 Fuse protecting injection system
162 Injector (1st)
163 Injector (2nd)
164 Injector (3rd)
165 Injector (4th)
167 Air flow meter
168 Timing sensor
184 Ignition coils (2nd)
185 Ignition coils (3rd)
186 Ignition coils (4th)
187 Ignition coils (5th) (1998)
189 Variable valve timing
193 I.E. control unit earth
223 Rpm sensors
291 Potentiometer on accelerator pedal
292 Clutch pedal switch
296 Accelerator control lever potentiometer
334 Dual engine temperature sender unit
363 Variable valve timing actuator (998)
364 Motorized throttle body
375 Standardized diagnostic socket
376 Acceleration sensor
55.
55 Front/engine lead connection
1998
* BV n.d
MN 127
' HN 6A
* AR n.d
1 27 Connection between front left cable/cable on relay holder bracket
1998
A1 R n.d.'
HL RN 13
HL BG 190A
A4 AB 190A
HL AG 190A
A6 M3A
HL MN55
HL C n.d. *
J*L MB 4C *
J*L AN n.d.
_§§_ MG 190A
_§£. S 190A
VN3A
66 B190A
_§7_ VG70
R n.d.
C2 BN190A
_2L HL n.d.
C4_ SG n.d.
C5 HRn.fi.'
C6 AR n.d. *
_5L G 190A
A1 R n.d. * B4 S365
HL RN98 B5 VN 98 A3 BV 151 * B6 B365 A4 AB 123 J7_ VG365 J*I
HL AG 122 B8 R 150 A6 M 124 C2 BN365 A7 MN 124 C3 HL98 A8 Cn.d.* C4 SG 98 B1 MB 151 * C5 HR152A* B2 AN 124 C6 AR 152B *
B3 MG 124 C7 G 150*
1 90A Injection/ignition electronic control unit (1998)
1998 3 GV131 22 GN6A 41 BN 127 57 V 167*
6 S 127 24 ZB 291 * 44 VB6A* 59 SB 292 *
7 AN 291 * 25 A n.d* 46 LN6A* 62 AB 127
"U 8 GN 291 * 27 RN n.d. * 47 Cn.d* 63 H 167* "U
9 B 127 30 BG 127 * 48 BV n.d *
13 MG 127 31 G 127* 50 AG 127
15 RV n.d. * 32 BV n.d * 53 BR 375 *
16 BV n.d * 35 L6A* 54 MN 167 *
21 VG376 40 HB 291 * 56 ZN 291 *
32 16
49 33
1 90B Injection/ignition electronic control unit (1998)
1998 1 G n.d. * 17 V n.d. * 32 V184* 52 L165A*
2 G 141B* 19 V162* 33 B n.d. * 54 L 136*
3 G 165* 20 V164* 34 B 141A* 55 L 141 *
4 G 189* 22 V136* 35 B 163* 58 L364*
5 G 132* 23 V141A* 36 B363* 59 L223*
6 G 136A* 24 V364* 38 B 136A*. 60 L141B*
10 G223* 25 V334* 40 B364*
14 G 185* 26 V n.d. * 42 B 168*
15 G 186* 28 V 141B* 49 L n.d. *
16 G 183* 31 V187* 51 L 168*
49 33
* The cables involved in the wiring diagram are marked with an asterisk.
72 Print n° 506.763/23