air conditioning 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

Marea- Marea Weekend Introduction
2000 range (§) Capacities
OO.o
Product Parts to be filled dm3
(I) Kg
16v 20v JTD
Petrol > O.R. 95
Unleaded •
63 63 -
^ft diesel i •' • • ir-FI-•
--63
50% p n
Total capacity of cooling
system
•
7
(6.7 •)
7.6
(7.4 •)
6
(5.6 •)
50% p
TP
n
Total capacity of cooling
system
•
7
(6.7 •)
7.6
(7.4 •)
6
(5.6 •)
Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
Total capacity
• 4.5 5.5 4.8 Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
Total capacity
• 4 4.7 4.25
Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
m-m
Partial capacity
(scheduled changes)
• 3.8
(3.5*)
5
(4.5*)
4.3
(4*)
Petrol engines
SELENIA 20K
(SAE 10W/40) (•)
g|l Diesel Engines:
SELENIA TURBO
DIESEL
(SAE 10W/40) (••)
m-m
Partial capacity
(scheduled changes) • 3.4
(3.1*)
4.45
(4*)
3.75
(3.55*)
TUTELACAR frQQ
ZC 75 Synth
• 1.98 1.98 1.65 TUTELACAR frQQ
ZC 75 Synth • 1.8 1.8 1.5
TUTELA *
GI/2 -J»
• 4.3 --TUTELA *
GI/2 -J» • 3.9 --
(•) Distilled water
(•) For versions with air conditioning
(*) Engine sump only
(•) For temperatures below -20°C the use of SELENIA PERFORMER SAE 5W-30 is recommended
(••) For temperatures below -15°C the use of SELENIA WR DIESEL 5W-40 is recommended
Copyright by Fiat Auto 7

Technical Data
Front suspension
Marea- Marea Weekend
2000 range @
00.44
Front suspension independent, Mac Pherson type with transverse lower track control arms secured to an
auxiliary crossmember. Offset coil springs and double acting, telescopic, hydraulic shock absorbers. Anti-
roll bar connected to the telescopic damper.
CLASSIFICATION OF SPRINGS ACCORDING TO VARIOUS VERSIONS AND ENGINE TYPES
VERSIONS
ENGINE TYPES
VERSIONS
Standard E C
Standard with ABS E C
With air conditioning D B
With air conditioning, ABS and all options D B
With air conditioning and ABS D B
Standard with automatic transmission D
Standard with automatic transmission and ABS D
With air conditioning and automatic transmission C
With air conditioning, ABS and all options C
With ABS (fitted as standard) B
With ABS (fitted as standard) and air condi­
tioning A
With ABS (fitted as standard), air conditioning
and all options A
SPECIFICATIONS OF VARIOUS SPRINGS
Coil springs A B C D E
Wire diameter mm 13.6±0.05 13.5±0.05 13.2±0.05 13.2±0.05
Number of effective coils 3.75
Coil direction Clockwise
Released spring height mm 449 448 434 425 413
Load under which spring height is .
173 mm am 432±17 417±17 397±16 353-383 336-364
The springs have been divided into two cate­
gories identifiable by a mark
yellow (*) for those with a height of >173 mm
under a load of:
green (*) for those with a height of <173 mm
under a load of:
432 daN 417 daN 397 daN 368 daN 350 daN
( ) Springs of the same type must be fitted
42 Print n° 506.763/23

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

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 ©) 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

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 Electrical equipment
2000 range (§) Location of components on the car
55.
LOCATION OF RELAYS AND FUSES ON THE VEHICLE (BONNET - Petrol engine types)
Fi998l152B 273 274 i * *
3B-3C Power fusebox
96 Power fuse protecting ABS
98 Headlamp washer intermittent function
122 Engine cooling fan low speed relay
123 Engine cooling fan high speed timer
124 Air condiitoning compressor control relay
129 Power fuse protecting engine coling fan
150 Injection system relay feed
151 Lambda probe control relay for fuel pump
and injectors
152 Fuse protecting injection system
152A Fuse protecting injection system
152B Fuse protecting injection system
273 Fuse protecting automatic transmission
system
274 Fuse protecting automatic transmission
system
276 Starter enablement relay
(••) Versions with air conditioning
(*) With automatic transmission
Copyright by Fiat Auto 9

Electrical equipment Marea-Marea Weekend
Location of components on the car 2000 range (§)
55.
LOCATION OF RELAYS AND FUSES ON THE VEHICLE (BONNET - Diesel engine types )
152
3B/C Power fusebox
96 Power fuse protecting A.B.S
98 Headlamp washer intermittent function
122 Engine cooling fan low speed relay
123 Engine cooling fan high speed timer
124 Air condiitoning compressor control relay
129 Engine cooling fan protection power fuse
129A Power fuse protecting engine cooling fan
no. 2
152 Fuse protecting injection system
303 Fuse protecting diesel preheating
304 Diesel preheating protection relay.
346 Additional heater relay
347 Additional heater relay
348 Additional heater remote control swictch
349 Additional heater protection fuse
369 Engone cooling fan remote control switch
(••) Versions with air conditioning
10 Print n° 506.763/23

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ©
WINDSCREEN WASH/WIPE - REAR WASH/WIPE - HORN - HEATED REAR WINDOW - HEADLAMP WASHERS
Component key
3 Power fusebox
4 Junction unit
7 Stalk unit
8 Left front earth
9 Right front earth
10 Engine battery earth
11 Battery
12 Ignition switch
13 Connection between right/left front cables
18 Left rear earth
19 Right rear earth
22 Left facia earth
24 Windscreen wiper motor
25 Front/rear washer pump
26 Rear wiper motor
28 Connection between facia/rear cables
34 Switch control unit
39 Heated rear window
46 Left low tone horn
47 Right high tone horn
97 Headlamp washer pump
98 Headlamp washer intermittence
120 Connection for air conditioning unit ca­
bles
127 Connection between front left cable/cable
on relay holder bracket
236 Connection between rear cables and tail­
gate
244 Integrated services control system
253 Air conditioner control unit
55.
Connection between right/left front cables
28A Facia/rear lead connection
RN n.d.
GN 309
NZ 22
HG 6B
28 B Facia/rear lead connection
BN 31 OA S 120B HG 70
Z120B
MN n.d.
HV70
NZ 31 OA
236 Connection betwen rear lead and tail-gate
* CB 28B
HL4E
RG4G
Marea Weekend
RN n.d.
GN4G NZ 56 AR 244B *
MB 244B *
V107A
CL 236 *
CB26*
* The cables involved in the wiring diagram are marked with an asterisk.
46 Print n° 506.763/23