inertia switch 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

Ma tea- Marea Weekend 9 ™
2000 range (Q) Fuel feed system
Engine
10.
Control of injected fuel quantity
The control unit controls the fuel pressure regulator and injectors on the basis of output signals from the
accelerator pedal potentiometer, flow meter and rpm sensor.
The timing and thus the injection sequence are determined when the engine is started up using signals
from the rpm and timing sensor (synchronisation stage); injection timing is then implemented using the
rpm sensor signal alone and considering a injection sequence of 1 -3-4-2.
The control unit inhibits injection in the following cases:
- fuel pressure level greater than 1500 bars;
- fuel pressure level lower than 120 bars;
- engine speed higher than 6000 rpm.
When the engine has warmed up, maximum injection duration (injector opening time) is 1500 ns, but it
can reach 3000 ns during the start-up stage.
Control of injection advance
The electronic control unit determines injection advance mainly on the basis of the quantity of fuel to be
injected.
The injection advance is then corrected on the basis of coolant temperature and speed in order to com­
pensate for ignition delays due to low temperatures in the combustion chamber during warm-up.
The optimum injection point is also processed to ensure driving comfort and emission limits laid down by
Euro 3 legislation.
Control of injection pressure
This control is of particular importance because injection pressure influences the following parameters:
- amount of fuel taken into the cylinders for the same injection time duration;
- injected fuel nebulation;
- spray penetration;
- lag between electrical control to injection and actual injection start and end times.
The above parameters engine behaviour significantly, particularly in terms of power output, exhaust emis­
sions, noise levels and handling.
The injection control unit controls the pressure governor on the basis of engine load to obtain an optimal
line pressure at all times.
When the engine is cold, injection pressure is corrected on the basis of engine speed and engine coolant
temperature to meet engine needs at different operating temperatures.
Control of auxiliary fuel pump
The auxiliary fuel pump submerged in the tank is supplied by the injection control unit by means of a relay
when the ignition key is turned on.
Fuel supply to the pump is inhibited when one of the following condition occurs:
- when the ignition has been turned on for a certain length of time without the engine running;
- if the inertia switch cuts in.
Control of injection during over-run (cut-off)
The fuel cut-off strategy is implemented when the injection control unit receives information that the ac­
celerator pedal has been released from the potentiometer.
Under these conditions, the control unit cuts off the fuel supply to the injectors and restores it before idle
speed is reached.
Copyright by Fiat Auto 3

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

Engine
Fuel feed system
Marea- Marea Weekend W)JTD
2000 range ©
INERTIA SAFETY SWITCH
To increase car occupant safety in the case of
impact, the car is fitted with an inertia switch
located inside the passenger compartment se­
cured to the inside of the left panel.
This sensor reduces the possibility of fire (due
to emerging fuel) by deactivating the auxiliary
fuel pump that supplies the injection circuit.
The switch consists of a steel ball, fitted in a
tapered housing, kept in place by the attrac­
tion force of a permanent magnet.
In the case of violent impact, the ball is released from the magnetic detent and opens the normally closed
(NC) electrical circuit to cut off the auxiliary fuel pump connection to earth, and as a consequence the
supply to the injection system.
To restore the auxiliary pump earth connection, move back the seat and press the switch until a click is
heard.
Even after an apparently slight impact, if there is a smell of fuel or there are leaks from the fuel
system, do not turn the switch back on, but search for the fault and remedy it to prevent the risk
of fire.
'N.C. N.A. C
Inertia switch components
1. Inertia switch assembly
2. Sheath
3. Button
4. Upper side
5. Engagement side
6. Permanent magnet
7. Permanent magnet seat
8. Steel ball
C Common terminal
N.C. Normally closed contact
N.A. Normally open contact
22 Publication no. 506.763/24

Marea-Marea Weekend
2000 range Q
DESCRIPTION OF WIRING AND CONNECTORS
CONNECTOR A
N.
No.
Wiring
colour Circuit involved
1 R Supply (+30) from fuse box
2 BR Supply (+30) from fuse box
CONNECTOR c
N. No.
Wiring colour Circuit involved
1 RN Car interior fan power supply (with
air conditioner), air conditioner
control unit
2 MB Fuel pump control, inertia switch
3 AN Car interior fan power supply (only heater), air conditioner control unit
4 H Right dipped beam headlamp
5 HN Left dipped beam, headllamp en­
ablement
6 VN Left main beam
7 V Right main beam
CONNECTOR E
N.
No.
Wiring colour Circuit involved
1 RN Right brake light
2 GR Rear view mirror control light
3 RG Left brake light
4 MN Rear window power supply
5 MB Fuel pump, inertia switch
6 -N.C.
7 AN Left rear turn signal
8 -N.C.
9 GR Right rear side light (without check
panel)
10 HL Left number plate light (without
check panel)
11 -N.C.
12 RG N.C.
13 RN N.C.
14 R Supplementary brake light
Electrical system
Junction unit
55.
CONNECTOR B
N. No.
Wiring
colour Circuit involved
1 R Power supply to electric windows, door lock, service control unit, main beam relay, fog lamp, sun-roof, heated seats, cigar lighter
CONNECTOR D
N.
No.
Wiring colour Circuit involved
1 G Left headlamp alignment
2 G Right headlamp alignment
3 G Headlamp alignment control
4 AN Front and left side turn signal
5 AR Alarm control unit power supply
6 HB Right headlamp alignment power
supply
7 H Left headlamp alignment power
supply
8 H Headlamp alignment control
9 B Reversing light control
10 Z Horns.
11 Z Horns.
12 -N.C.
13 GV Right front side light
14 AR Brake light power supply
15 A Front and right side turn signal
16 GL Left front side light
17S -N.C.
18 RN Brake light control
CONNECTOR F
N.
No.
Wiring colour Circuit involved
1 HR Dipped beam control
2 -N.C.
3 LR Main beam control
4 -N.C.
5 G Side light power supply from ignition
Copyright by Fiat Auto 5

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ©
55.
Starting - Electronic ignition and injection - Recharging and warning light
light - Injection system failure warning light - Rev counter (1596)
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
2 Left facia earth
55 Front/engine lead connection
56 Fuel level gauge control unit
57 Inertia switch
70 Connection between dashborad/front
cables
132 Petrol vapour cut out solenoid valve
136 Knock sensor
138 Idle adjustment actuator
141A Heated Lambda sensor (upstream of
cat.)
141 B Heated Lambda sensor (downstream of
cat.)
143 Alternator
144 Rpm and TDC sensor
145 Starter motor
146 Potentiometer on throttle valve
150 Injection system relay feed
152 Fuse protecting injection system
155 Ignition coil unit
156 Spark plugs
162 Injector (1st)
163 Injector (2nd)
164 Injector (3rd)
165 Injector (4th)
168 Timing sensor
193 Earth for electronic injection
194 Injection lead/injector braid connection
195 Ignition/ injection control unit (1596)
334 Dual engine temperature sender unit
373 Air pressure and temperature sensor
375 Standardized diagnostic socket
55 Front/engine lead connection
1596
CN6A.
HG6A.
* HN 6A
1 CN n.d.
MB6A.
NZ8_
* ZB n.d
*RG195A_
HM6A
CN n.d. HN 143 *
HG 142
1 95A Injection/ignition electronic control unit (1596)
1596 1 N 141A* 20 L 141A* 29 RN n.d. *
2 NZ141B* 21 BN 127 35 B 127
4 L6A* 23 GN 6A* 36 LR252 [c*
5 V252 0 23 GN70 0 40 AG 127
9 LN 141A* 24 B141B* 41 MG 127
12 R 141B* 25 BR n.d. 0 44 Vn.d.*
13 GV131 25 BR 375 * 46 BG 268 [a
14 AB 127 26 LN6A* 47 C n.d. *
15 SB 150* 27 N 193* 48 S 127
16 GN 252 [cal 28 N 193* 49 NZ252
27 282,9 41 52
O I I I I I I -r-r-r'n , , r'l -r-
rrrri '/ 1 1 1 1 1 1 1 1 1 1 1 \1 L/-HJ 'A i I I i i ,I
40
1 95B Injection/ignition electronic control unit (1596)
1596 53 R144* 65 VB 138* JL. NZn.d. *
54 N n.d. * 66 LR 155 * _ZL HM194*
55 ZB 278 * 67 B 144* _7JL HV194*
56 L136* 68 V278*
57 C138* 69 B 168*
58 HN 138* 70 Z136*
59 GN 155 * 71 HG 194 *
60 S 146* 72 HL194*
62 SN 339 * 75 RN 278 *
64 GR138* 76 BR 146 *
74
67-Jf Mill i i r r-l I I I
60-
IE
L -j |l
53 59
The cables involved in the wiring diagram are marked with an asterisk.
70 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

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ©
55.
Starting - Electronic injection - Recharging and warning light - Low engine oil pressure warning
warning light - Injection system failure warning light - Fuel preheating (1910 JTD)
ight - Heater plugs
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 Front/engine lead connection
56 Fuel level gauge control unit
57 Inertia switch
70 Connection between dashborad/front ca­
bles
127 Connection between front left ca­
ble/cable on relay holder bracket
143 Alternator
144 Rpm and TDC sensor
145 Starter motor
150 Injection system relay feed
151 Relay feed for Lambda sensor, electric
fuel pump, injectors
152 Fuse protecting injection system
167 Air flow meter (debimeter)
168 Timing sensor
193 I.E. control unit earth
201 Heater plugs control unit
228 Heater plugs (TD)
289 Thermal contact (PCT)
290 Heater coil (PCT)
291 Potentiometer on accelerator pedal
292 Clutch pedal switch
303 Diesel preheating protection fuse
304 Diesel preheating protection relay
333 Injection control unit (JTD)
334 Dual engine temperature sender unit
336 Injector 1 cyl (JTD)
337 Injector 2. cyl (JTD)
338 Injector 3. cyl (JTD)
339 Injector 4. cyl (JTD)
341 Fuel pressure regulator (JTD)
342 Fuel pressure sensor (JTD)
343 Turbo pressure sensor (JTD)
344 I.E. protective fuse (JTD)
334B I.E. protective fuse (JTD)
345 Fuel temperature sensor (JTD)
375 Standardized diagnostic socket
377 Variable geometry solenoid valve
378 Throttle adjustment solenoid valve
379 EGR solenoid valve
333A Injection control unit (JTD)
JTD 1 N n.d. * 16 BV55* 48 BR 375 76 ZB 291 *
2 N n.d. * 17 CR 377 * 49 VB6A* 77 GN 291 *
3 N n.d. * 18 MG 127 51 BN 127 78 ZN 291 * A 4 Rn.d.* 19 AB 127 52 B 127 79 A 291 *
5 RN n.d. * 20 AG 127 58 CB n.d. * 80 MB 291 * ,
11 GV131 21 LN6A 59 LRn.d. * 81 AN 291 * ' >
13 SB 150 22 RV201B* 60 S 127
14 CL6A 24 SN 151 * 61 BL 292 * 1
15 BG55* 47 Ln.d. * 62 NZ 201B*
5 43 24
-o
T7
2 62 81
oooooooooooooooooc oooooooooooooooooc
oooooooooooooooooc oooooooooooooooooc
~7
63 44
333B Injection control unit (JTD)
JTD 82 SN55* 92 H342* 103 L168* 120 V337*
83 S55* 93 LR 343* 104 C 168* 121 MV 338 *
84 BN 334 * 94 HM 343 * 108 CB 341 *
85 LN 334 * 95 HN 343 * 109 HB 341 *
86 G 167* 97 CN 167* 111 MB 55*
88 NZ167* 99 R144* 114 VB 339 *
89 HR167* 100 B 144* 117 VN n.d. *
90 LG 342 * 101 N 144* 118 NVn.d. *
91 HV 342 * 102 BV168* 119 NL 336 *
114
AA 115 117
116.
89 97 82 90
oooooc OOOOOOG OOOOOOO 'OOOOOC
119113105106 98
* The cables involved in the wiring diagram are marked with an asterisk.
74 Print n° 506.763/23

Electrical equipment
Connector blocks
Marea- Marea Weekend
2000 range ©
55.
57 Inertia switch
N56
NZ 18
58 Control panel light dimmer
GN4J
GR 6B
CA Glove compartment light bulb with built
" in switch 65 Luggage compartment light
Marea
65 Luggage compartment light 66
RN 236A
RN 236B
Electrically-adjustable door mirror con­
trol buttons
BR 35.
HV36.
ZB35.
LR36
GR4E
N n.d.
Marea Weekend
67 Left door mirror 68 Right door mirror
Nn.d
S36 Z36
98 Print n° 506.763/23

nent
Key
55.
Component key
1 Left front light cluster
2 Right front light cluster
3 Power fusebox
4 Junction unit
5 Dipped headlamps relay feed
6 Instrument panel
7 Steering column switch unit
8 Left front earth
9 Right front earth
10 Engine battery earth
10A Bodyshell battery earth
11 Battery
12 Ignition switch
13 Connection between right/left front cables
14 Left number plate light bulb
15 Right number plate light bulb
16 Left rear light cluster
17S Right rear light cluster
18 Left rear earth
19 Right rear earth
20 Left front side direction indicator
21 Right front side direction indicator
22 Left facia earth
23 Hazard warning lights switch unit
24 Windscreen wiper motor
25 Electric windscreen/rearscreen washer pump
26 Windscreen wiper motor
28 Connection between dashboard/rear cables
29 Connection between front/fog light cables
30 Left fog light
31 Right fog light
32 Fog lamp control relay
34 Switch control panel
35 Connection between dashboard/left front
door cables
36 Connection between dashboard/right front
door cables
39 Heated rear windscreen
40 Brake lights control switch
41 Additional brake light
42 Right dashborad earth
43 Left headlamp alignment corrector actuator
44 Right headlamp alignment corrector actuaor
45 Headlamp alignment control unit
46 Left low tone horn
47 Right high tone horn
48 Radio receiver with clock
49 Left front tweeter speaker
50 Right front tweeter speaker
52 Speaker in right front door
53 Left rear speaker
54 Right rear speaker
55 Front/engine lead connection
56 Fuel gauge unit
57 Inertia switch
58 Control panel light dimmer
64 Glove compartment light bulb with built in
switch
65 Luggage compartment light
66 Electrically-adjustable door mirror contro
buttons
67 Left door mirror
68 Right door mirror
69 Cigar lighter
70 Connection between dashborad/front ca­
bles
73 Pushbutton unit for front electric windows
on left arm-rest
74 Pushbutton unit for right front electric win­
dows on right arm-rest
76 Left front electric window motor
77 Right front electric window motor
78 Pushbutton unit for rear electric windows
on left front door
80 Rear electric window inhibition switch
82 Pushbutton unit for left rear electric win
dows on left front door
83 Pushbutton unit for right rear electric win­
dows on right rear door
84 Left rear electric window motor
85 Right rear electric window motor
86 Connection between rear/left rear door ca
bles
87 Connection between rear/right rear doo
cables
88 Insufficient brake fluid level sensor
89A Left brake pad wear sensor cable connec
tion
90 Switch signalling handbrake applied
92A Electric sun-roof lead connection
93A Electric sun roof control unit
95 Connection between front/anti-lock brake;
A.B.S. cables
96 Power fuse for anti-lock brakes A.B.S.
97 Electric headlamp washer pump
98 Headlamp washer intermittence
100 Alarm electronic control unit
105 Alarm deactivation switch
106 Alarm switch on engine bonnet
107A Door remote control receiver
107B Vehicle interior front courtesy light
108 Left rear central locking
109 Right rear central locking
110 Left front central locking
111 Right front central locking
114 Air bag electronic contol unit
115 Passenger Air Bag
116 Driver's Air Bag
117 Air Bag/facia cables connection
120 Connection for air conditioning unit cables
121 Three stage pressure switch
122 Engine cooling fan low speed relay
122 Engine cooling fan low speed relay
123 Engine cooling fan high speed relay feed
124 Air condiitoning compressor control relay
127 Connection between front left cable/cabli
on relay holder bracket
141