Climate FIAT MAREA 2001 1.G Workshop Manual

Marea- Marea Weekend Summary
TECHNICAL SERVICE MANUAL COMPOSITION
At present, June 2001, the Marea-Marea Weekend 4th volume manual is composed of the following
sections
Print N° Sections Page
Nos. Notes
506.763/18
(XI/1999)
00 1 - 12 Marea bipower technical data (99 range)
506.763/18
(XI/1999) 10 1 - 59 Marea bipower fuel system (99 range) 506.763/18
(XI/1999)
55 1 - 2 Marea bipower wiring diagram (99 range)
506.763/21
(IX/2000) 10
1 - 38 Marea bipower (99 range) fault diagnosis
506.763/21
(IX/2000) 10
60 - 61
Marea bipower (99 range) fuel system
Replacing solenoid valve on methane canister
506.763/23
(IX/2000)
00 1 - 51 2000 range technical data
506.763/23
(IX/2000)
10
1 - 7 Fuel system l^pl i6v 2000 range
506.763/23
(IX/2000)
10
1 - 7 Fuel system l^pt 20v 2000 range 506.763/23
(IX/2000)
50 1 - 4 2000 range climate control
506.763/23
(IX/2000)
55
1 - 18 2000 range electrical equipment
506.763/23
(IX/2000)
55
1 - 141 2000 range wiring diagrams
506.763/24
(XII/2000)
00
15 - 16 2000 range technical data update
506.763/24
(XII/2000)
00
1 - 3 Marengo 2000 range technical data
506.763/24
(XII/2000)
10 1 - 29 Fuel system l^p) JTD 2000 range
506.763/24
(XII/2000)
55 5 - 8
19-52 2000 range electrical equipment update
Copyright by Fiat Auto

Marea - Marea Weekend Summary
TECHNICAL SERVICE MANUAL COMPOSITION
As of December 2000, the Marea-Marea Weekend 4th volume manual is composed of the sections
listed below
Print N° Sections Page
Nos. Notes
506.763/18
(XI/1999)
00 1 - 12 Marea bipower technical data (99 range)
506.763/18
(XI/1999) 10 1 - 59 Marea bipower fuel system (99 range) 506.763/18
(XI/1999)
55 1 - 2 Marea bipower wiring diagram (99 range)
506.763/20
(IV/2000)
00 1 - 15 Marea GPL technical data
506.763/20
(IV/2000) 10 1 - 26 Marea GPL fuel system 506.763/20
(IV/2000)
55 1 - 9 Marea GPL wiring diagram
506.763/21
(IX/2000) 10
1 - 38 Marea bipower fault diagnosis (99 range)
506.763/21
(IX/2000) 10
60 - 61 Marea bipower fuel system (99 range)
Replacing solenoid on methane canister
506.763/23
(IX/2000)
00 1 - 50 2000 range technical data
506.763/23
(IX/2000)
10
1 - 7 2000 range lev fuel system
506.763/23
(IX/2000)
10
1 - 7 2000 range ^||) 20v fuel system 506.763/23
(IX/2000)
50 1-4 2000 range climate control system
506.763/23
(IX/2000)
55
1 - 18 2000 range electrical equipment
506.763/23
(IX/2000)
55
1 - 141 2000 range wiring diagrams
Copyright by Fiat Auto

Marea- Marea Weekend Summary
TECHNICAL SERVICE MANUAL COMPOSITION
At present, September 2000, the Marea-Marea Weekend 4th volume manual is composed of the fol­
lowing booklets
Print N° Sections Page
Nos. Notes
506.763/18
(XI/1999)
00 1 - 12 Technical data on Marea bipower (99 range)
506.763/18
(XI/1999) 10 1 - 59 Marea bipower fuel system (99 range) 506.763/18
(XI/1999)
55 1 - 2
Marea bipower electrical equipment wiring diagrams (99
range)
506.763/20
(IV/2000)
00 1 - 15 Marea GPL technical data
506.763/20
(IV/2000) 10 1 - 26 Marea GPL fuel system 506.763/20
(IV/2000)
55 1 - 9 Marea GPL electrical equipment wiring diagram
506.763/21
(IX/2000) 10
1 - 38 Marea bipower fault diagnosis (99 range)
506.763/21
(IX/2000) 10
60 - 61
Marea bipower fuel system (99 range)
Replacing solenoid valve on methane canister
506.763/23
(IX/2000)
00 1 - 50 Technical data 2000 range
506.763/23
(IX/2000)
10
1 - 7 Fuel system @> 16v 2000 range
506.763/23
(IX/2000)
10
1 - 7 Fuel system l^l 20v 2000 range
506.763/23
(IX/2000)
50 1 - 4 Climate control system 2000 range
506.763/23
(IX/2000)
55
1 - 18 Electrical equipment 2000 range
506.763/23
(IX/2000)
55
1 - 141 Electrical equipment wiring diagrams 2000 range
Copyright by Fiat Auto

Technical Data Marea-Marea Weekend
Engine: cooling system • fuel system 2000 range (§)
OO.io
COOLING
Cooling circuit coolant circulation via centrifugal pump, radiator
and two speed fan operated by engine control unit
Water pump operated via belt
fl (^+\ STA9E 1 90°H-94°C 96°+97T
^ Engagement vj^/ ?
of fan stage Z 95°+99°C (•) 101+102°C
\f Operated by v .
control unit (s\oo\ 9 85V89X 93°-H94T
• v y
v—' stage 2 90°+94°C (•) 98+99T
opening starts 81° - 85°C
Engine coolant
thermostat rnax opening 99+103°C 101DC+105'C
valve travel 9.5 mm
Fitting clearance between impeller p
vanes and pump casing j |< 0.3:1.1 mm 0.4 : 0.95 mm
Pressure for checking system water tightness 0.98 bar
Pressure for checking exhaust valve on expansion
tank cap 0.98 bar
(•) Versions with climate control
FUEL FEED SYSTEM
Make
Electronic integrated
injection-ignition
MPI - I.A.W.
Weber-Marelli
Electronic integrated
injection-ignition
MPI - BOSCH Motronic
Pump electric immersed in the tank
Output > 120 l/h
Fuel pressure regulator setting 3 bar
26 Print n° 506.763/23

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

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

Marea- Marea Weekend © ™ Engine
2000 range Q Fuel feed system
10.
FUEL SYSTEM
INTRODUCTION
Marea and Marea Weekend 1.9 JTD cars are equipped with a 4 cylinder in line, 1910 cc turbodiesel en­
gine with two valves per cylinder, an overhead camshaft, turbocharger and intercooler and electronic in­
jection.
The fuel system ensures correct engine operation and can be divided into the following subsystems:
- Fuel feed circuit with common rail injection;
- air feed circuit;
- exhaust circuit;
- blow by vapour recirculation circuit;
- Exhaust Gas Recirculation (EGR) circuit
Operation of the various circuits making up the fuel system is optimised by an electronic control system
managed by a special control unit.
The main feature of the fuel system is common rail fuel injection. Common rail is a higher pressure elec­
tronic injection system for fast direct injection diesel engines.
The main features of the common rail system are as follows:
- availability of high injection pressures (up to 1350 bars);
- possibility of modulating these pressures (from a minimum of 150 bars to a maximum of 1350 bars)
independently of engine speed (rpm) and engine load;
- ability to operate at high engine speeds (up to 6000 rpm);
- precise injection control (injection advance and duration);
- reduced fuel consumption;
- reduced emissions.
FUEL SYSTEM MANAGEMENT STRATEGIES
The management program (software) is stored inside the control unit memory and consists of a series of
strategies, each of which manages a precise system control function.
Through the use of information providd by the various sensors (input), each strategy processes a set of
parameters based on data stored in special control unit memory areas. It then controls system actuators
(output), i.e. the devices that allow the engine to operate.
The main purpose of these management strategies is to determine the exact amount of fuel to be injected
into the cylinders with timing (injection advance) and pressure designed to achieve the best possible en­
gine performance in terms of power, fuel consumption, fumes, emissions and handling.
The main system management strategies are essentially as follows:
contro
contro
contro
contro
contro
contro
contro
contro
contro
contro
contro
contro
contro
contro
contro
of injected fuel quantity;
of injection advance;
of injection pressure;
of auxiliary fuel pump;
of injection during over-run (cut-off);
of idle speed;
of maximum speed limitation;
of maximum torque limitation;
of fuel temperature;
of engine coolant temperature;
of air turbocharging pressure;
of glow plugs;
of exhaust fumes;
of exhaust gas recirculation (EGR);
of climate control system activation;
control of engine immobiliser operation (Fiat
CODE);
self-diagnosis
Copyright by Fiat Auto 1

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
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

Auxiliary Units
Climate control
Marea-Marea Weekend
2000 range O
50
COMPRESSOR (1910 JTD)
The compressor fitted on this version is the SANDEN SD7V16 variable capacity type.
The capacity of the compressor varies starting from the maximum value (161.3 cm^/rev) and is gradually
reduced (up to 10.4 cm^/rev) according to the system load variations. - changed outside temperature
and/or humidity conditions or sharp variations in the engine load.
This solution is defined as "unlimited variable capacity".
The compressor is the alternating piston type: the variation in capacity is achieved by tilting the connect­
ing rod holder plate with a consequent variation of the piston stroke: the movement of the plate is acti­
vated by an internal regulation valve according to the balance of pressure upstream and downstream of
the compressor. In particular, a low intake pressure involves the shuttering of the compressor (reduced ca­
pacity), whilst a high pressure involves operation at maximum power (maximum capacity).
7 6 4 3 2
5 9
1 Diaphgram valve
2 Pistons
3 Connecting rods
4 Connecting rod plate
5 Shaft
6 Pin
7 Arm
8 Slide
9 Guide
Pa Intake pressure
Pi Pressure inside the compressor
Pm Supply pressure
Operation
The SD7V16 compressor is illustrated in the diagram; it consists of seven pistons (2) and connecting rods
(3) fastened to a connecting rod holder plate (4). The rotary motion of the plate (4), on the shaft (5)
produces the alternating movement of the pistons.
A change in the plate angle allows an alteration in capacity: maximum inclination (as in the diagram) for
maximum capacity; almost zero inclination (vertical position) for minimum capacity (virtually nil).
The plate (4) rotates around the pin (6) hinged on the shaft (5) arm (7).
The movement of the plate (4) in relation to the shaft (5) takes place by means of splining made from a
low resistance material.
The plate (4) slides below along a guide (9) via a runner (8) made from a low friction material.
The diaphragm valve (1) controls the flow rate adjustment according to the difference between Pa (intake
pressure) and Pi (pressure inside the compressor).
N.B. the solution adopted for this compressor is designed to keep the internal pressure Pi constant, with
advantages in terms of ease of adjustment and quiet, smooth operation.
2 Print n° 506.763/23