brake sensor FIAT MAREA 2001 1.G Workshop Manual

Marea- Marea Weekend 9 \) JTD
2000 range O
Engine
Index
FUEL SYSTEM
- Introduction
- System management strategies
- Fuel system functional diagram
- Diagram showing information ente­
ring/leaving the control unit and
sensors/actuators
INJECTION SYSTEM WIRING DIA­
GRAM
- Injection electronic control unit
- Rpm sensor
- Timing sensor
- Air flow meter
- Injectors
- Engine coolant temperature sensor
- Fuel temperature sensor
- Fuel pressure sensor
- Heater plugs control unit
- Accelerator pedal potentiometer
- Brake pedal switch
- Clutch pedal switch
- Excess pressure sensor
- Atmospheric pressure sensor
page
1
1
1
2
8
10
12
13
13
14
15
15
15
16
16
17
17
17
17
THROTTLE CASING
- Removing-refitting
E.G.R. VALVE
- Removing-refitting
E.G.R. VALVE SELF-ADJUSTMENT
MOTOR
- Removing-refitting
E.G.R. VALVE HEAT EXCHANGER
- Removing-refitting
SOLENOID VALVE ON VACUUM
RESERVOIR FOR THROTTLE CA­
SING PNEUMATIC VALVE
- Removing-refitting
VACUUM RESERVOIR
- Removing-refitting
10.
page
30
31
32
32
34
34
FUEL SUPPLY CIRCUIT 18
- Immersed (auxiliary) pump and fuel
gauge assembly 19
- Fuel filter 19
- Pressure pump 20
- Fuel pressure regulator 20
- Multifunction valve 21
- Supply manifold (rail) 21
- Inertia safety switch 22
AIR SUPPLY CIRCUIT 23
- Throttle case 24
- Turbocharger 25
SUPERCHARGING PRESSURE
CONTROL SOLENOID VALVE
- Removing-refitting 35
FUEL FILTER
- Removing-refitting 35
PRESSURE REGULATOR
- Removing-refitting 36
EMISSION CONTROL DEVICES 27
- Oxidizing catalytic converter 27
- Exhaust gas recirculation circuit
(EGR) 27
- Recirculation circuit for crankcase
vapours (blow-by) 29
Copyright by Fiat Auto VI 01 Cancels anil replaces

Engine
Fuel feed system
Marea- Marea Weekend © ™
2000 range ©
10.
FUEL SYSTEM OPERATING DIAGRAM
1. Pressure pump
2. Electrically-controlled EGR valve
3. Flow meter
4. Pressure regulator
5. Fuel filter
6. Instrument panel
7. Glow plug preheating control unit
8. Electronic control unit
9. Injection system relay
10. Return manifold (low pressure)
11. RPM sensor
12. Glow plugs
13. Engine coolant temperature sensor
14. Potentiometer on accelerator pedal
15. Switch on brake pedal
16. Switch on clutch pedal
17. Variable geometry turbocharger
18. Timing sensor
19. Injectors
20. Fuel pressure sensor
21. Variable geometry turbocharger control sole­
noid
22. Auxiliary fuel pump
23. Glow plug preheating warning light
24. System failure warning light
25. Pressure relief sensor
26. Fuel temperature sensor
27. Throttle valve
28. Variable geometry actuator
29. Vacuum tank
30. Exhaust gas heat exchanger
2 Publication no. 506.763/24

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 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

Ma tea- Ma tea Weekend !@ ™
2000 range ©
Engine
Fuel feed system
10.
37 Not connected
38 Not connected
39 Not connected
40 Not connected
41 Not connected
42 Not connected
43 Not connected
44 Not connected
45 Not connected
46 Not connected
47 Engine rpm signal output
48 Diagnostic line k
49 Vehicle speed signal input
50 Not connected
51 Activation signal from 4-stage pressure switch
52 Activation signal from 3-stage pressure switch
53 Not connected
54 Not connected
55 Not connected
56 Not connected
57 Not connected
58 Key ON signal
59 Brake switch
60 Air conditioner activation request
61 Clutch switch
62 Glow plug diagnosis
63 Not connected
64 Not connected
65 Not connected
66 Not connected
67 Not connected
68 Not connected
69 Not connected
70 Not connected
71 Not connected
72 Not connected
73 Not connected
74 Not connected
75 Not connected
76 Accelerator pedal 1 earth
77 Accelerator pedal 1 signal
78 Accelerator pedal 1 power supply
79 Accelerator pedal 2 earth
80 Accelerator pedal 2 signal
81 Accelerator pedal 2 power supply
82 Diesel temperature sensor (pin 1)
83 Diesel temperature sensor (pin 2)
84 Coolant temperature sensor (pin 1)
85 Coolant temperature sensor (pin 2)
86 Air flow meter (pin 1)
87 Not connected
88 Air flow meter (pin 3)
89 Air flow meter (pin 5)
90 Fuel pressure sensor (pin 3)
91 Fuel pressure sensor (pin 2)
92 Fuel pressure sensor (pin 1)
93 Turbo pressure sensor (pin 1)
94 Turbo pressure sensor (pin 3)
95 Turbo pressure sensor (pin 2)
96 Not connected
97 Air flow meter (pin 4)
98 Not connected
99 RPM sensor (pin 1)
100 RPM sensor (pin 2)
101 RPM sensor (pin 3)
102 RPM sensor (pin 1)
103 Timing sensor (pin 2)
104 Timing sensor (pin 3)
105 Not connected
106 Not connected
107 Not connected
108 Fuel pressure regulator
109 Fuel pressure regulator
110 Not connected
111 Heater relay control Fuel filter
112 Not connected
113 Not connected
114 Cylinder 4 injector control
115 Not connected
116 Not connected
117 Cylinder 1 and 2 injector power supply
118 Cylinder 3 and 4 injector power supply
119 Cylinder 1 injector control
120 Cylinder 2 injector control
121 Cylinder 3 injector control
Copyright by Fiat Auto 11

Marea-Marea Weekend 9 -™ Engine
2000 range (j§) Fuel feed system
10.
I I TEST
4F017XJ01
A switch (1) on the brake pedal con­
trols the car brake lights; the same
switch sends a signal to pin 59 of the
injection control unit
The control unit uses the "brake pedal
depressed" signal to:
- detect a situation of over-run;;
- check the plausibility of the signal
from the accelerator potentiometer
CLUTCH PEDAL SWITCH
A switch (2) on the clutch pedal is connected to pin 61 of the injection control unit.
The injection control unit uses the "brake pedal operated" signal to distinguish gear engaged and gear
shift conditions.
PRESSURE RELIEF SENSOR
The sensor is fitted to the intake manifold and
the signal sent to the injection control unit is
used to:
- regulate injection pressure;
- regulate injection duration.
The figure alongside shows the sensor and
electrical connector with the following pin-
out:
1. pressure signal
2. Earth
3. Fuel feed system
ATMOSPHERIC PRESSURE SENSOR
The atmospheric pressure signal is built into the injection control unit. It is responsible for measuring at­
mospheric pressure in order to correct measured air flow and reference air flow values to control the EGR
function.
Copyright by Fiat Auto 17

Electrical system
Component location
Marea-Marea Weekend
2000 range ©
INSTRUMENT PANEL CONNECTIONS
Component key
3
4
6
8
10
11
12
18
22
28
55
56
70
88
89
90
Power fusebox
Junction unit
Instrument panel
Left front earth
Engine battery earth
Battery
Ignition switch
Left rear earth
Left facia earth
Connection between facia/rear cables
Connection between front/engine cables
Fuel level gauge control unit
Connection between facia/front leads
Insufficient brake fluid level sensor
Left brake pad wear sensor
Switch indicating handbrake applied
137 Vehicle speed sensor
142 Switch indicating insufficient engine oil
pressure
262 Seat belt warning light switch
334 Engine temperature twin sender unit
335 Sensor for detecting water in diesel filter
55.
Instrument panel
1
2
3
4
5
6
7
8
9
9
10
11
11
F3V95
BN 88*
BR 89A*
CL 333A I JTD
MN 131B
LN 333A | JTD
HN55
HG55*
LN 190A 1998
LN 195A | 1596
RV95
GN 195A 1596
GN 190A 1998
12
12
12
13
14
14
15
16
17
17
18
18
18
VB 333A JTD
VB 190A 1998
1596
1998
VB 195A | 1596
AG n.d. *
CN 55 *
CN 55C *
HB 55
HL70
HM 55*
HM 55C * |
L190A
Ln.d.
L195A
•••••••
•••••••
18 10
JTD
1596
1998
1998
JTD
1581
6B Instrument panel
13
1
2
3
4
5
6
8
9
11
12
13
14
RG4J
RV n.d.
RV n.d.
C117
GV 70 *| JTD
M28A*
A4H
AN4H
GN n.d.
LB4J
BN 28A *
RN 4H
15
16
18
19
20
21
22
23
25
26
H70
CN n.d.
GR 58
N22*
HG 28A *
GL34A
R4I *
N22*
VN48A
HM309
•••••••••••
•••••••••••
26 14
4F048ML03
The cables concerned are marked in the wiring diagram with an asterisk
48 Publication no. 506.763/24

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ®
Instrument panel connections (C.A. version)
Component key
3 Direction indicator
4 Junction unit
6 Instrument panel
8 Left front earth
10 Engine battery earth
11 Battery
12 Ignition switch
18 Left rear earth
22 Left facia earth
28 Connection between facia/rear cables
55 Connection between front/engine cables
56 Fuel level gauge control unit
70 Connection between dashborad/front ca­
bles
88 Insufficient brake fluid level sensor
89 Left brake pad wear sensor
90 Switch signalling handbrake applied
137 Vehicle speed sensor
142 Switch signalling insufficient engine oil
pressure
262 Seat belt warning light switch
334 Dual engine temperature sending unit
55.
6A Instrument panel
AG n.d. * BR 89A *
MN 131
HG 55 *HM55
RV95
6B Instrument panel
GL34A
*N22
AN4H
28A Facia/rear lead connection
RN n.d
GN 309
NZ22
AR120
MB34A
V70
RN n.d.
V107A
70 Connection between dashborad/front cables
A1 B1 C1 — RN4C — M29 — AN4C A2 B2 C2 — VG127 — V328 — HR100B A3 B3 C3 — H100B — AG n.d. * — HN 100B A4 B4 C4 — HL6A — LN 100B — HG 100B A5 B5 C5 — CB 100A — BN 375 — HV 100B A6 B6 C7 | — S100B — B375 — GV335 JTD A7 B8 C8 • — V 100A — MN n.d. — RB 307 I TAXI A8 C8 — N 8 — GN 195A ^
A1 — RN120 A2 — VG120 A3 — H6B A4 — HL120 A5 — CB28A A6 — Rn.d. A7 — A34A A8 — N312
B1 — M 310C B2 — V28A B3 — AG 41* B4 — AB4I B5 — BN120 B6 — B117 B7 — AN 120 B8
C1 — AN 120 C2 — HR28B C3 — HN28B C4 — HG28B C5 — HV28B C7 — GV6B C8 JTD
C8 RB312 TAXI
RN315 — GN6BCS
4F060ML05
* The cables involved in the wiring diagram are marked with an asterisk.
50 Print n° 506.763/23

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ©
55.
ANTI-LOCKING BRAKING SYSTEM (ABS) AND FAILURE WARNING LIGHT
Component key
3 Power fusebox
4 Junction unit:
6 Instrument panel
8 Left front earth
10 Engine battery earth
11 Battery
12 Ignition switch
40 Brake lights control switch
88 Insufficient brake fluid level sensor
95 Connection between front cables/anti-
lock brakes A.B.S.
96 60A fuse protecting anti-lock brakes (A.B.S.)
174 Power earth for A.B.S.
176 Diagnostic socket for A.B.S.
177 Sensor on left front wheel (A.B.S.)
178 Sensor on left rear wheel (AB.S.)
179 Sensor on right front wheel (AB.S.)
180 Sensor on right rear wheel (AB.S.)
181 Electro-hydraulic control unit
375 Standardized diagnostic socket
3A Power fusebox
*CA95 CB n.d.
R n.d.
M n.d.
X n.d
.VN127
AR n.d.
.C n.d.
C n.d M n.d.
95 Connection between front cables/anti-lock brakes A.B.S. leads
LN 375
BN n.d.
*CA3A
BN 181
*CN 181
1 81 A.B.S. hydraulic control unit
9 M 180* 18 N n.d. *
10 V180* 19 R n.d. *
11 LN 95 20 RV95*
12 M 179* 21 BN 95*
13 B 179* 22 M 178*
14 M 177* 23 G 178*
15 C95* 24 LR 95*
16 N n.d. * 25 R 177*
17 Rn.d.*
4FQ68ML04
The cables involved in the wiring diagram are marked with an asterisk.
68 Print n° 506.763/23

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ®
Starting - Electronic ignition and injection - Recharging and warning light
light- Injection system failure warning ilight - Rev counter (1998)
Insufficient engine oil pressure warning
Component key
3 Power fusebox
4 Junction unit
6 Instrument panel
8 Left front earth
10 Engine battery earth
12 Ignition switch
18 Left rear earth
22 Left facia earth
40 Brake lights control switch
55 Connection between front/engine cables
57 Inertia switch
70 Connection between dashborad/front
cables
68 Right door mirror
70 Connection between dashborad/front
cables
127 Connection between front left cable/ca­
ble on relay holder bracket
132 Petrol vapour cut out solenoid valve
136 Knock sensor
141A Heated Lambda sensor (upstream of cat.)
141 B Heated Lambda sensor (downstream of
cat.)
143 Alternator
145 Starter motor
148 Earth for electronic injection
150 Injection system relay feed
151 Relay feed for Lambda sensor, electric
fuel pump, injectors
152 Fuse protecting injection system
162 Injector (1st)
163 Injector (2nd)
164 Injector (3rd)
165 Injector (4th)
167 Air flow meter
168 Timing sensor
184 Ignition coils (2nd)
185 Ignition coils (3rd)
186 Ignition coils (4th)
187 Ignition coils (5th) (1998)
189 Variable valve timing
193 I.E. control unit earth
223 Rpm sensors
291 Potentiometer on accelerator pedal
292 Clutch pedal switch
296 Accelerator control lever potentiometer
334 Dual engine temperature sender unit
363 Variable valve timing actuator (998)
364 Motorized throttle body
375 Standardized diagnostic socket
376 Acceleration sensor
55.
55 Front/engine lead connection
1998
* BV n.d
MN 127
' HN 6A
* AR n.d
1 27 Connection between front left cable/cable on relay holder bracket
1998
A1 R n.d.'
HL RN 13
HL BG 190A
A4 AB 190A
HL AG 190A
A6 M3A
HL MN55
HL C n.d. *
J*L MB 4C *
J*L AN n.d.
_§§_ MG 190A
_§£. S 190A
VN3A
66 B190A
_§7_ VG70
R n.d.
C2 BN190A
_2L HL n.d.
C4_ SG n.d.
C5 HRn.fi.'
C6 AR n.d. *
_5L G 190A
A1 R n.d. * B4 S365
HL RN98 B5 VN 98 A3 BV 151 * B6 B365 A4 AB 123 J7_ VG365 J*I
HL AG 122 B8 R 150 A6 M 124 C2 BN365 A7 MN 124 C3 HL98 A8 Cn.d.* C4 SG 98 B1 MB 151 * C5 HR152A* B2 AN 124 C6 AR 152B *
B3 MG 124 C7 G 150*
1 90A Injection/ignition electronic control unit (1998)
1998 3 GV131 22 GN6A 41 BN 127 57 V 167*
6 S 127 24 ZB 291 * 44 VB6A* 59 SB 292 *
7 AN 291 * 25 A n.d* 46 LN6A* 62 AB 127
"U 8 GN 291 * 27 RN n.d. * 47 Cn.d* 63 H 167* "U
9 B 127 30 BG 127 * 48 BV n.d *
13 MG 127 31 G 127* 50 AG 127
15 RV n.d. * 32 BV n.d * 53 BR 375 *
16 BV n.d * 35 L6A* 54 MN 167 *
21 VG376 40 HB 291 * 56 ZN 291 *
32 16
49 33
1 90B Injection/ignition electronic control unit (1998)
1998 1 G n.d. * 17 V n.d. * 32 V184* 52 L165A*
2 G 141B* 19 V162* 33 B n.d. * 54 L 136*
3 G 165* 20 V164* 34 B 141A* 55 L 141 *
4 G 189* 22 V136* 35 B 163* 58 L364*
5 G 132* 23 V141A* 36 B363* 59 L223*
6 G 136A* 24 V364* 38 B 136A*. 60 L141B*
10 G223* 25 V334* 40 B364*
14 G 185* 26 V n.d. * 42 B 168*
15 G 186* 28 V 141B* 49 L n.d. *
16 G 183* 31 V187* 51 L 168*
49 33
* The cables involved in the wiring diagram are marked with an asterisk.
72 Print n° 506.763/23