radiator FIAT MAREA 2001 1.G Workshop Manual

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
2000 range (§)
Technical Data
Automatic transmission - differential
GEARBOX
AUTOMATIC AISIIM
ENGINE TYPE
00.21-27
Speeds .1. ooooq
ooooo
.1,
OOOOO
ooooo
Gear ratios OOOOO
oooo©
2.807
1.479
1.000
0.735
2.769
Idler ratio 1.019 (54/53)
Torque converter 0 mm 216
T X Drive torque ratio 2.150
Quantity of
oil
Total, with gearbox con­
verter, radiator and pipes
empty
GI/2 Replacement only
6 litres (5.4 kg)
4.3 litres (3.9 kg)
DIFFERENTIAL
Ratio crown wheel
and pinion
reduction
Final drive ratio
3.505 (82/23)
3.633 (54/53x82/23)
OOOOO
OOOOO
OOOOO
Ratio at the wheels OOOOO
OOOO©
10.198
5.373
3.633
2.670
10.060
Copyright by Fiat Auto 35

Marea-Marea Weekend •
2000 range (§)
4F005WJ02
Engine
Fuel feed system
10.
REMOVING-REFITTING HEAT
SHIELD
Removing
- Position the vehicle on a lift.
- Disconnect the negative battery terminal.
1. Undo the fixing bolts (1a) and remove the
air duct (1b).
2. Open the retaining band (1a) and place the
engine coolant return pipe to the radiator
(1b) at the side in order to undo the bolts
(1c) fixing the upper section of the heat
shield.
3. Undo the upper bolts (1a) fixing the fan
and disconnect the electrical connector
(1b).
4F005WJ03
Copyright by Fiat Auto 5

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 ©
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

Engine Marea- Marea Weekend 9 ™
Fuel feed system 2000 range @
10.
ELECTRONIC INJECTION CONTROL UNIT
The control unit processes signals from the various sensors by applying software algorithms and controls
the actuators accordingly (particularly the injectors and pressure regulator) to achieve the best possible
engine service conditions.
The control unit is "flash E.P.R.O.M." type, i.e. it can be reprogrammed from outside without andy need
to adjust the hardware.
The injection control unit contains a built-in absolute pressure sensor and is connected to the wiring by
means of a 121 pin connector.
Control unit connection identification (PIN-out)
4 5 43 24 6 25 96 106 113 105 119 120 121
1 Earth 25 Not connected
2 Earth 26 Not connected
3 Earth 27 Not connected
4 Actuator power supply 28 Not connected
5 Injector/ECU power supply 29 Not connected
6 Not connected 30 Not connected
7 Not connected 31 Not connected
8 Not connected 32 Not connected
9 Not connected 33 Not connected
10 Not connected 34 Not connected
11 Fiat CODE 35 Not connected
12 Not connected 36 Not connected
13 Injection relay
14 Glow plug control
15 Throttle body solenoid
16 EGR valve
17S VGT solenoid
18 Air conditioner relay
19 Radiator fan high speed relay
20 Radiator fan low speed relay
21 Diagnostic warning light control
22 Glow plug activation control
23 Not connected
24 Auxiliary fuel pump relay
10 Publication no. 506.763/24

Electrical equipment
Component location
Marea-Marea Weekend
2000 range ©
Engine cooling (1910 JTD)
Component key
3 Power fusebox
8 Left front earth
10 Engine battery earth
11 Battery
12 Ignition switch
22 Left facia earth
122 Engine cooling fan low speed relay feed
123 Engine cooling fan high speed relay feed
127 Connection between front left cable/cable
on relay holder bracket
128 Connection between front/radiator cables
129 Engine cooling fan protective power fuse
154 Engine cooling fan
170 Resistance for engine cooling fan
333 Injection control unit (JTD)
365 Pressostato a 4 livelli
369 Engine cooling fan remote control switch
55.
3A Power fusebox
CA95
R n.d.
M n.d.
AR n.d.
C n.d. .C n.d.
*C n.d M n.d.
1 22 Engine cooling fan low speed relay
U]*N8A
[#]*R154A
[§]*R129A
H*R170B h>j
* AG 127.
Cn.d.
1 23 Engine cooling fan high speed relay
'Cn.d.
' N8A.
•AB 127
. R n.d.
1 27 Connection between front left cable/cable on relay holder bracket
JTD
HL BR n.d.
HL MN 13
HL AR n.d.
HL MG 333A
_§! RN 13
_§L HLn.d.
_§L S 333A B4 B333A* A5 GN 55
HL AR n.d.
HL AG 333A'
HL RG 289
VG70 _B6_ N8.
_§7_ BN 333A'
_§§_VN3A
J2L SG n.d.
02 M3A
_2L RV n.d. *
04 AB 333A * C8 Rn.d.
HL BR 303
HL MN 124
A3 AR 1?4
HL MG 124
.AJLGN 304
HL HN 304
HL AG 122"
HL RG 304
JLL.RN98
_§£_HL98
_?LS365
_Bf_ B 365 .
_§L VG 365
_§?_ N 365 *
_§L BN 365 * B8 VN98
_2LSG 98
M 124 [§]
_2L c n.d. *
_9L AB n.d. * C8 R152
4F062MLQ5
* The cables involved in the wiring diagram are marked with an asterisk.
62 Print n° 506.763/23

Electrical equipment
Connector blocks
Marea-Matea Weekend
2000 range ©
55.
1 27 Connection between front left cable/cable on relay holder bracket
JTD
HL BR n.d.
HL MN 13
HL AR n.d.
HL MG 333A
JUL GN 55
HL AR n.d.
HL AG 333A
HL RG 289
B1
B2
B3
B4
B5
B6
B7
B8
RN 13
HLn.d.
S333A
B333A
VG70
N8
BN 333A
VN 3A
A1 BR 303 B4 B365
HL MN 124 B5 VG365 A3 AR124 3jr B6 N365 A4 MG 124 i> B7 BN 365 A5 GN 304 B8 VN98 A6 HN304 C1 SG 98 A7 AG 122 C2 M 124 [ A8 RG304 C3 Cn.d. B1 RN98 C4 AB n.d. B2 HL 98 C8 R152 B3 S365
128A Connection between front/radiator ca­
bles
M n.d.
R129
1998
1 28B (-'onnect'on between front/radiator ca-
Mn.d.
L122
1998
129 Power fuse protecting engine cooling
fan 1 9Q Power fuse protecting engine cooling
' ^ fan
R 128A
1998
R154
1998
1596
1 *>Q Power fuse protecting engine cooling
1 ^ fan 1 29A '3°w6r *use ProtectiN9 engine cooling
R 123
1910-JTD
R 123
Rn.d
1910-JTD
Rn.d
4F108ML07
108 Print n° 506.763/23

A
21
128 Connection between front/radiator cables
129 Engine cooling fan protection power fuse
129A Power fuse protecting engine cooling fan
no.2
131 Fiat-CODE electronic control unit
132 Petrol vapours cut-out solenoid valve
134 Connection between rear/heated driver's
seat cables
135 Connection between rear/heated passenger
seat cables
136 Detonation sensor
136A 2nd Detonation sensor
137 Vehicle speed sensor
138 Idle adjustment actuator
139 Tester socket for injection system
141A Heated Lambda sensor (upstream of cat.)
141B Heated Lambda sensor (downstream of
cat.)
142 Switch signalling insufficient engine oil
pressure
143 Alternator
144 Rev and TDC sensor
145 Starter motor
146 Throttle valve potentiometer
147 Compressor for air conditioning
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
152A Fuse protecting injection system
152B Fuse protecting injection system
154 Engine cooling fan
155 Ignition coil unit
156 Spark plugs
159 Reversing lights control switch
162 Injector (1)
163 Injector (2)
164 Injector (3)
165 Injector (4)
165A Injector (5) (1998)
166 Idle adjustment actuator
167 Air flow meter
168 Timing sensor
170 Resistance for engine cooling fan
174 Power earth for A.B.S.
177 Sensor on left front wheel for A.B.S.
178 Sensor on left rear wheel for A.B.S.
179 Sensor on right front wheel for A.B.S.
180 Sensor on right rear wheel for A.B.S.
181 A.B.S. hydraulic control unit
182A Right brake pad wear sensor cable connec­
tion
183 Ignition coil (1°)
184 Ignition coil (2°)
185 Ignition coil (3°)
186 Ignition coil (4°)
187 Ignition coil (5°) (1998)
189 Variable valve timing
190 Injection/ignition electronic control unit
(1998)
193 Earth for electronic injection
194 Injection/injector braid lead connection
195 Injection/ignition electronic control unit
(1596)
199 FIAT CODE aerial
201 Heaer plugs control unit
202 Heater/air conditioning unit symbol lighting
bulbs
206 Car interior climate control fan
209 Intake air flap control actuator
211 Frost sensor
222 Climate control system earth
223 RPM sensor
228 Heater plugs (TD)
231 Clock spring connector
236 Connection betwen rear lead and tail-gate
238 Rear electric windows control unit
239 Connection between Air Bag/left preten­
sioner cables
240 Connection between Air Bag/right preten­
sioner cables
241 Left pretensioner
242 Right pretensioner
243 Luggage compartment light button
244 Integrated services control system
245 Rear courtesy light
248 Radio controls on steering wheel
252 Connection between automatic transmis­
sion/engine cables
253 Air conditioner control unit
254 Climate control system controls with pas­
senger compartment temperature sensor
255 Electronic speed governor for climate con­
trol fan
256 Air mixture control actuator
257 Fuel pump relay feed
258 Treated air temperature sensor
259 Required temperature adjustment switch
260 MAX-DEF microswitch
261 Tailgate locking/unlocking actuator
262 Seat belts warning light switch
264 Left rear vehicle interior courtesy light
265 Right rear vehicle interior courtesy light
267 Automatic transmission control unit
268 Connection between automatic transmis­
sion/front cables
269 Connection between automatic transmis­
sion/dashboard cables
270 Connection between automatic transmis­
sion/rear cables
271 Kick-down switch
272 Ignition switch solenoid
273 Automatic transmission system protective
fuse
Co