Ignition 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

Technical Data
Engine
Marea-Marea Weekend
2000 range @
OO.io
SPECIFICATIONS
Cycle OTTO 4 stroke
^Q\^ Timing gear TOHC
1 Fuel system type Integrated electronic injection - ignition
L—,1 Number of cylinders
Ml • • •
4 5
Vt—•F-jZf Cylinder liner
Is—A \ mm
W (bore)
80.5 82
j^J |q| Stroke mm 78.4 75.65
fifi-9 0> °-ace" cm3
1596 1998
^|*^^ Compression
= 9 ratio
ft
10.50 ±0.15 10.5 ±0.15
kW
r _ (bhp) X Maximum
76
(103)
110
(150)
/ power CEE
/ .. ... • rpm 5750 6500
daNm
(kgm)
Maximum
14.5
(14.8)
18.1
(18.5)
, torque CEE
... \ > rpm 4000 3750
10 Print n° 506.763/23

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

Marea-Marea Weekend Technical Data
2000 range (j§) Engine: fuel system - special tools
OO.io
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
Copyright by Fiat Auto 27

Technical Data Marea- Marea Weekend
Engine: fuel system - special tools 2000 arnge ©)
OO.io
INTEGRATED ELECTRONIC INJECTION/IGNITION SYSTEM COMPO­
NENTS
Injection/ignition system electronic control unit Bosch ME31F001
Motorized throttle body Bosch 0.250.003.052
Injector Bosch 0.280.155.770
Electric fuel pump (*) Bosch 0.580.313.011
Air flow meter Bosch 0.281.002.199
Engine coolant temperature sensor ELTH 2690350 - SYLEA
402.183.01
Lambda sensor (one upstream and one downstream of the catalyzer) Bosch LS F4
0.258.006.193
Fuel vapour solenoid valve Bosch 0.280.142.340
Detonation sensor Bosch 0.261.231.131
Hall effect injection timing sensor Bosch 0.232.101.036
Top Dead Centre and rpm sensor Bosch 0.261.210.160
Ignition coil Bosch 0.221.504.014
SPECIAL TOOLS
(*) Use tool 1870736000 for removing-refitting the fuel pump retaining ring nut
28 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: 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

Marea- Marea Weekend Technical Data
2000 range © Electrical equipment: electronic injection- ignition
00.55
INTEGRATED ELECTRONIC
INJECTION/IGNITION SYSTEM I^P) 20v
Make Bosch ME31F001
Firing order 1-2-4-5-3
IGNITION COIL (1 PER SPARK PLUG)
Make Bosch
Type 0.221.504.014
Ohmic resistance of primary winding at 20°C Q 0.,4
Ohmic resistance of secondary winding at 20°C Q 8500
TOP DEAD CENTRE AND RPM SENSOR
Make and type Bosch 0.281.002.102
Sensor winding resistance at 20°C Q 774 + 946
Distance (gap) between sensor and
crankshaft pulley tooth 0.8 H- 1.5
DETONATION SENSOR
Make Bosch
Type 0.261.231.095
SPARK PLUGS
Make and type CHAMPION RC8BYC
Thread on engine M 14x 1.25
Spark gap mm 0.8
Copyright by Fiat Auto 51

Marea- Marea Weekend • *» Engine
2000 range (§) Fuel feed system
10.
Pages
FUEL FEED SYSTEM
- Engine management system 1
- Diagram showing engine exhaust assem­
bly 1
- Fuel anti-evaporation system ~2
- Location of diagnostic socket 2
- Location of injection/ignition system
components in the engine compartment 3
- Front Lambda sensor . 4
- Rear Lambda sensor 4
- Catalytic converter heat shield 5
- Catalytic converter 5
- Exhaust manifold 6
- Electric fuel pump with level sender unit 7
Copyright by Fiat Auto

Marea- Marea Weekend • ^ Engine
2000 range (Q) Fuel feed system
10.
ENGINE MANAGEMENT SYSTEM
The Marea-Marea Weekend 1596 16v has a 4 cylinder in line engine, with 16 valves, 1596 cc, twin over­
head camshaft and a Marelli IAW 4EF integrated electronic injection/ignition system.
The fuel system differs from the one described for the 1581 16v "99 range" version through the addition
of several variants to make it compatible with the EEC Stage 3 EOBD regulations.
The main modifications to the system can be summarized as follows:
- Engine management control unit with IAW 4EF
- Catalytic converter near the exhaust manifold to take maximum advantage of the heat of the gases.
- Two Lambda senors, one upstream (front) and one downstream (rear) which check the quality of the
exhaust gases and the operation of the catalyzer.
- Adoption of a timing sensor on the inlet side timing pulley.
DIAGRAM SHOWING ENGINE EXHAUST ASSEMBLY
1. Exhaust manifold
2. Catalytic converter
3. Front Lambda sensor
4. Rear Lambda sensor
5. Silencers
Copyright by Fiat Auto 1