Voltage FIAT MAREA 2000 1.G Workshop Manual

Technical Data Marea- Marea Weekend
Electrical system 2000 range (§)
00.55
i^p} 16v J^M) 20v
STARTER MOTOR
Bosch
DW -12V -1.1 kW
Valeo
DGRA-12V-1,3kW(B)
Bosch
0 74.5-1.1/12V
Bosch
O 78.5-2 kW/12V
ALTERNATOR
Bosch
KCB1-14V-45/80A
Bosch
KCB2-14V-50/90A
(•) n
M. Marelli
A127IR-14V-55/100A
M. Marelli
A115IM-14V-55/105A
M. Marelli
A115IR-14V-70/120A
(•)
VOLTAGE REGULATOR BUILT IN ELECTRONIC
BATTERY
12V-50Ah-250A
12V-60Ah-380A
(A) n
12V-50Ah-250A 12V-60Ah-380A
12V-70Ah-450A (A)
IGNITION SYSTEM
Integrated electronic
injection-ignition
MPI I.A.W.
Weber-Marelli
Injection-ignition
Bosch Motronic MPI
integrated electronic
-
IGNITION
COIL M. Marelli BAE 920 A Bosch 0.221.504.014 -
SPARK PLUGS NGK BKR5EZ
Champion RC10YCC Champion RC8BYC -
CONTROL UNIT
INJECTION ADVANCE ELEC­
TRONIC
--Bosch EDC 15 C7
(•) For vehicles with climate control system (*) North European version (A) For the TAXI version
(•) Alternative
46 Print n° 506.763/23

Marea- Marea Weekend Technical Data
2000 range (§) Electrical equipment: starting
00.55
STARTER MOTOR l^p| 20v I^P) JTD
Make Bosch
DW -12V -1,1 kW
Bosch
0 74.5-1.1/12
Bosch
0 78.5-2 KW/12
Voltage V 12
Nominal power kW 1.1 1.1 2
Rotation, pinion side clockwise
No. of poles 6 4 6
Winding windings in series permanent magnets
Engagement free wheel
Operation solenoid
End float of armature shaft mm 0.1-0.5 0.1-0.5 0.1-0.5
Data for bench test
Operating test (*):
current A
speed rpm
voltage V
torque developed daNm
-
360-380
1150
8.15
1.30
500
1950
7.30
1.30
Engagement test (*):
current A
voltage V
torque developed daNm
-680-700
4.9
3.11
1200
5.5
3.0
Idle test (*):
current A
voltage V
speed rpm
-
60-80
4.9
4040
70-80
11.5
5450-5750
Relay [ pull in Q -0.33-0.37 0.4
Winding
resistance (*) 1 hold in Q -1.13-1.27 1.7
Lubrication
Internal splines and
shaft bushes
VS+ SAE 10W
Enagement sleeve and intermediate
disc TUTELA MR3
(*) Data obtained at an ambient temperature of 20°C.
NOTE When overhauling it is not necessary to undercut the insulator between the commutator bars
Copyright by Fiat Auto 47

Technical Data Marea-Marea Weekend
Electrical equipment: recharging 2000 range @)
00.55
ALTERNATOR
l^p) lev rgp> JTD
Make
Bosch
KCB1-14V-45/80A
M. Marelli A127IR-14V-55/100A
M. Marelli A115IM-14V-55/105A
Make
Bosch KCB2-14V-
50/90A (•) (*)
M. Marelli A127IR-14V-55/100A M. Marelli
A127IR-14V-70/120A
(•)
Nominal voltage y
of system 14 14 14
Maximum current A 80 (90) (*)(•) 100 105 (120)(«)
Nominal current at 1800 rpm rpm 45 (50) (*)(•) 55 55 (70)(»)
Nominal current at 6000 rpm A 80 (90) (*)(•) 100 105 (120)(«)
Field winding resistance between
the two slip rings (A)
2.66-2.94
(2.47-2.73) (*)(•) 2.66-2.94 -
Direction of rotation (seen from control
side) Clockwise
Diode power rectifiers preconstituted bridge
(A) Data obtained at an ambient temperature of 20°C. (•) For vehicles with climate control system C) For the TAXI version
VOLTAGE REGULATOR Electronic, built-in
Make BR1 RTM 151 B RTM 151A
Alternator speed rpm
for test 7000
Thermal stabilization corrector ^ -
Test current A -
Regulation voltage (A) y 14.3-14.6
(A) Data obtained at an ambient temperature of 23°C.
48 Print n° 506.763/23

Technical Data
Electrical equipment: recharging
00.55
Bosch KCB1-14V-45/80A
Bosch KCB2-14V-50/90A
M. Marelli A127IR-14V-55/100A
M. Marelli A115IM-14V-55/105A
M. Marelli RTM 151 B
Marea- Marea Weekend
2000 range ©)
Alternator wiring diagram
Typical voltage regulator curves
M. Marelli RTM 151 A
Copyright by Fiat Auto 49

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

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

Engine
Fuel feed system
10.
4F012XJ03
Marea- Matea Weekend 9 ™
2000 range (Q)
RPM SENSOR
The rpm sensor is fitted to the engine crank-
case and faces the phonic wheel on the
crankshaft.
The sensor is inductive type, i.e. it works by
varying a magnetic field generated when the
phonic wheel teeth (60-2 teeth) pass in front
of the sensor element.
The injection control unit uses the rpm sensor
signal to determine crankshaft speed and an­
gular position.
Operation
The changeover from full to empty due to the
presence or absence of teeth sets up a mag­
netic flux change sufficient to generate an in­
duced alternating voltage proportional to the
number of teeth on the phonic wheel.
The peak sensor output voltage value, all
things being equal, depends on the distance
between the sensor and the tooth (gap).
1. Steel bush
2. Permanent magnet
3. Sensor case
4. Winding
5. Core
6. Phonic wheel
7. Electrical connection
To obtain the correct signal, the specified gap
between phonic wheel and sensor should be
between 0.8 and 1.5 mm
This distance is not adjustable. When the gap
is not as specified, check the condition of the
sensor and phonic wheel.
Winding resistance
860 Ohm ±110% at 20 °C
1. Maximum magnetic flux
2. Minimum magnetic flux
3. Induced alternate voltage
12 Publication no, 506.763/24

Marea- Marea Weekend 9"°
2000 range ©
Engine
Fuel feed system
10.
TIMING SENSOR
The Hall effect sensor is fitted to the cylinder head and faces the camshaft pulley.
An opening on the pulley allows the timing sensor to detect the engine timing position and indicate it to
the injection control unit.
The injection control unit uses the timing sensor signal to detect TDC at the end of compression.
Operation
A semi-condulator layer, through which a current passes, immersed in a magnetic field (lines of force per­
pendicular to the direction of the current), produces a difference in power, known as Hall voltage.
If the intensity of the current remains constant, the voltage produced only depends on the intensity of the
magnetic field. The intensity of the field can simply be altered periodically to produce a modulated electri­
cal signal. Signal frequency is proportional to the speed with which the magnetic field changes.
To achieve this change, the sensor is crossed by a metal ring (inner part of the pulley) with an opening.
When it moves, the metal part of the ring covers the sensor to magnetic field and the output signal is
therefore low; Conversely, the sensor generates a high signal at the opening when the magnetic field is
present.
This signal, together with the rpm and TDC signals, allows the injection control unit to identify piston po­
sition and determine injection point.
AIR FLOW METER
(DEBIMETER)
The debimeter is located on the air intake
sleeve and is hot film type.
The debimeter contains an intake air tem­
perature sensor.
Operation
The principle of operation is based on a
heated membrane fitted into a measurement
channel through which engine intake air
flows.
The hot film membrane is maintained at a
constant temperature (about 120 °C higher
than incoming air) by the heater coil.
The mass of air flowing through the measure­
ment channel tends to take heat from the
membrane. To keep the membrane at constant
temperature, a certain current level must flow
through the resistance.
Because this current is proportional to the
mass of air that flows to the engine, it can be
measured with a Wheatstone bridge and the
resulting signal is sent to the injection control
unit.
1. Covers
2. Electronic card
3. Sensor
4. Mounting plate
5. Mount
6. o-ring
7. Temperature sensor
Copyright by Fiat Auto 13

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 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 Electrical system
2000 range @ Radio System
55.
TECHNICAL DATA
Radio power (H4 and H3 versions)
- 4 x 15W (with standard sound system made up of mid-woofer + tweeter and full range speakers).
Radio power (version M2)
- 2x15W (with standard sound system made up of mid-woofer + tweeter speakers).
- 4 x 5W (with optional 4-channel speaker system that can be installed by After Market).
WARNING The standard system is 2 x 15W, If a 2 x 15W system is fitted, an adaptor is fitted be­
tween radio and wiring.
Fuse
The radio is fitted with a 10A fuse (D). (5A for the M2 version)
.Li.
3 6
2 5
B I M 5i I
T^l A 4| 6| |
I I I
2| 4| | |
CONNECTIONS
Connector A
A1 SCV signal ( + ) for adjusting volume ac­
cording to speed
A2 Phone Mute signal for mobile phone
A4 +12V ignition-operated voltage supply
A5 aerial supply output +12V (max. 0.5A)
A6 +12V display lighting output voltage
A7 +12V direct supply voltage
A8 Earth
Connector B
B1 rear speaker (right +)
B2 rear speaker (right -)
B3 front speaker (right +)
B4 front speaker (right -)
B5 front speaker (left +)
B6 front speaker (left -)
B7 rear speaker (left +)
B8 rear speaker (left -)
Copyright by Fiat Auto XII 00 Update 21