GEARBOX FIAT MAREA 2000 1.G Workshop Manual

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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
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Marea-Marea Weekend Introduction
2000 range (§) Identification data
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CHASSIS ENGINE VERSION MAREA MAREA
WEEKEND
GEARBOX
CHASSIS ENGINE VERSION MAREA MAREA
WEEKEND 999
666
ZFA 185 000
182B6.000
185AXR1A 25 •
•
ZFA 185 000
182B6.000
185BXR1A 26 •
•
ZFA 185 000
182B6.000
185AXR11 27 •
•
ZFA 185 000
182B6.000
185BXR11 28 •
•
ZFA 185 000
185A8.000
185AXS1A29 •
•
ZFA 185 000
185A8.000
185BXS1A30 •
•
ZFA 185 000
186A6.000
185AXT1A 31 •
•
ZFA 185 000
186A6.000
185BXT1A 32 •
•
NOTE
This section deals with the EEC F3 2000 range engine types.
For the subjects not dealt with, refer to the Marea-Marea Weekend manual print n° 506.763 and subse­
quent updates.
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Marea-Marea Weekend
2000 range (§)
Introduction
Product characteristics FL Group
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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)
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Marea-Marea Weekend Technical Data
2000 range (j§) Engine: fuel system - special tools
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INTEGRATED ELECTRONIC INJECTION/IGNITION SYSTEM
COMPONENTS
Electronic control unit
Manual gearbox I.A.W. 4EF. B3
Electronic control unit
Automatic transmission I.A.W. 4EF. L1
Air pressure sensor M. Marelli TPRT 05
Fuel vapour solenoid valve M. Marelli EC2
Throttle case M. Marelli 46 SX F2
Idle adjustment actuator M. Marelli IB 02
Injector M. Marelli IWP 109
Fuel pressure regulator MARWALL RPM 84
Coolant temperature sender unit SYLEA 402.386.01
Top Dead Centre and rpm sensor M. Marelli CVM 02
Throttle position sensor (potentiometer) M. Marelli IPF 2C
Detonation sensor NGK KNE 11
Electric fuel pump (*) MARWALL ESS 291
Lambda sensor upstream of catalyzer NTK OZA 534 A1
Lambda sensor downstream of catalyzer NTK OZA 532 A1
Fuel filter MARWALL FA 5325 IN
Timing sensor SYLEA SFA 200
Ignition coil Champion BAE 920A/
BERU 0.040.100.029
SPECIAL TOOLS
(*) Use tool 1870736000 for removing-refitting the fuel pump retaining ring nut
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Marea- Marea Weekend
2000 range (§)
Technical Data
Gearbox and differential
00.21-27
20v IgB) JTD
Make
GEARBOX
C.513.5.13 C.510.5.21
snap
_T|4fl_ (Porsche type) ^$13?
-
o u V baUlk I 1
Synchronizers rjng
r straight (| S
I teeth I'S
oo ^
„ spur
Gears V teeth H|
HI
3.909 3.545 3.909
2.238 2.238 2.238
$ oo W>
1.444 1.520 1.444
Gear ratios
1.029 1.156 1.029
0.872 0.919 0.767
Si
3.909 3.909 3.909
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Technical Data
Gearbox and differential
Marea-Marea Weekend
2000 range ©
00.21-27
DIFFERENTIAL m 20v 20v JTD
-J-Ratio crown
wheel and pinion
reduction
3.823
(17/65)
3.733
(15/56)
3.150
(20/63)
14.944 13.233 12.313
8.556 8.354 7.050
5.520 5.674 4.549
3.934 4.315 3.241
Ratio at the wheels 3.334 3.431 2.416
14.944 14.592 12.313
Differential internal housing bearing conical roller bearings
Adjustment of bearing pre-loading with snap rings
Spare snap ring thickness
mm 0.05 1.70 -2.60
T
Recommended
interference for
exact bearing
pre-loading
mm
mm
Clearance between planet/satellite gears
bonrings not loaded 0.12
beatings loaded (350 daN) 0.08
0.10
30c
Adjustment of clearance between planet/satellite gears
by
shims
no adjustment
mm 0.80 - 1.25
Spare snap ring thickness
34 Print n° 506.763/23

Marea- Marea Weekend
2000 range (§)
Technical Data
Automatic transmission - differential
GEARBOX
AUTOMATIC AISIIM
ENGINE TYPE
00.21-27
Speeds .1. ooooq
ooooo
.1,
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Gear ratios OOOOO
oooo©
2.807
1.479
1.000
0.735
2.769
Idler ratio 1.019 (54/53)
Torque converter 0 mm 216
T X Drive torque ratio 2.150
Quantity of
oil
Total, with gearbox con­
verter, radiator and pipes
empty
GI/2 Replacement only
6 litres (5.4 kg)
4.3 litres (3.9 kg)
DIFFERENTIAL
Ratio crown wheel
and pinion
reduction
Final drive ratio
3.505 (82/23)
3.633 (54/53x82/23)
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Ratio at the wheels OOOOO
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10.198
5.373
3.633
2.670
10.060
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Technical Data Marea-Marea Weekend
Electrical equipment: electronic injection- ignition 2000 range ©)
00.55
INTEGRATED ELECTRONIC
INJECTION/IGNITION SYSTEM r^p) lev
Make I.A.W. M.P.I. WEBER - MARELLI
Firing order 1-3-4-2
INJECTION/IGNITION CONTROL UNIT
Make and versions with manual gearbox I.A.W. 4EF. B3
type versions with automatic transmission I.A.W. 4EF. L1
IGNITION COIL WITH 4 HIGH TENSION INTAKES
Make Champion
Type BAE 920 A
Ohmic resistance of primary winding at 20°C Q 0.580
Ohmic resistance of secondary winding at 20°C Q 9100
SPARK PLUGS
Make and type NGK BKR5EZ
CHAMPION RC10YCC
Thread on engine M14x1.25
Spark gap mm 0.8
TOP DEAD CENTRE AND RPM SENSOR
Make M. Marelli
Type CVM 02
Sensor winding resistance at 20°C Q 575-750
Distance (gap) between sensor and
crankshaft pulley tooth 0.5 + 1.5
ADVANCE ON ENGINE
With engine idling 700±50/min 4°
50 Print n° 506.763/23

Marengo fl ™ Introduction
2000 range Identification data
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CHASSIS ENGINE VERSION
GEARBOX
666
ICSS) JTD ZFA 185.000 186A6000 185CXT1A 03 o
Engine type
DIMENSIONS (mm)
Engine type
A B C D AND F G H
Icii3i JTD 4490 1741 1510 2540 1470 1440 884 1066
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Marea Weekend 9 mnoocv Introduction
2000 range @> Identification data - Performance - Fuel consumption
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CHASSIS ENGINE VERSION GEARBOX
iQpl JTD 100 CV ZFA 185.000 182B9.000 185BXU1A 9f ?
666
ENGINE TYPE sHU) JTD 100 CV
Speed km/h (medium load)
36
62
97
136
184
36
Maximum climable
gradient fully laden
Fuel consumption
according to directive
1999/100/CE (litres/100 km)
Urban
Extra-urban
Combi
7.2
4.4
5.5
CO2 exhaust emissions (g/km) 145
The fuel consumption figures in accordance with 1999/100 EC standards were determined during the course of homologation
tests which include:
- an urban cycle which includes a cold start followed by a simulated varied urban cycle.
- an extraurban cycle which includes frequent acceleration in all gears simulating normal out of town usage of the vehicle.
The speed varies between 0 and 120 km/h.
- the average combined consumption figure includes 37% of the urban cycle and 63% of the non-urban cycle.
The type of route, traffic conditions, driving style, weather conditions, trim level/equipment/accessories, presence of special
equipment and the state of the vehicle in general can lead to different fuel consumption figures from those established
using the above mentioned procedures.
The CO2 exhaust emissions (in g/km) are measured during the combined average cycle.
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