Fiat 1998 Marea Weekend Service Manual

Page 1

Marea-marea weekend summary service manual composition at present, april 1999, the marea-marea weekend 3rd volume manual is composed of the following sections print l\t sections page nos. Comments 00 1 - 7 technical data 16v 98 range 10 1 - 6 4 fuel system i6v 98 range 506.763/09 (v/1998) 55 1 - 2 e...

Page 4: Technical Data

Technical data marea-marea weekend®^ engine: cylinder block/crankcase, crankshaft and associated components 98 range oo.Io 10 11 -f\h 8 description ml6v values in mm 3 3 0 0 piston 0 10,2 86,352 + 86,362 86,359 - 86,371 86,368 + 86,378 0,4 piston ring grooves 1 2 3 1,520 - 1,540 1,510 4- 1,530 3,010...

Page 8: Technical Data

Technical data marea-marea weekend®^ electrical equipment: starting 98 range 0 0 .55 starter motor type m. Marelli m70r-12v-1,3 kw (with reduction gear) voltage v 12 nominal power kw 1,3 rotation, pinion side clockwise no. Of poles 4 field coil winding series-parallel engagement free wheel operation...

Page 11: Marea-Marea Weekend

Marea-marea weekend introduction and technical data 99 range index introduction identification data weights performance - fuel consumption dimensions capacities specifications of fiat lubricant product technical data engine @t lev l£p> 20v specifications typical curves cylinder block/crankcase and a...

Page 13: Introduction

Marea-marea weekend©^ technical data 98 range engine: crankshaft and associated components and timing system components ~ oo.10 3 10 6 1 7 3 2 0

Page 16: Marea-Marea Weekend

Marea-marea weekend @ t ^ i n t r o d u c t i o n a n d t e c h n i c a l d a t a 98 range _ ^ index o o . Page t e c h n i c a l data e n g i n e ! ®

Page 21: Introduction

Introduction capacities marea-marea weekend 99 range 00 .0 description units q u a n t i t y description units d m 3 ( l ) kg g tutela - 0.8 tutela • • mrm2 - 0.003 ^ \ tutela k h t0p4 i i! (270°c) without —• i l 1 . T~7l a b s 0.40 - ^ \ tutela k h t0p4 i i! (270°c) y 1 without abs total capacity 0...

Page 23: Introduction

Introduction engine marea- marea weekend 99 range oo.10 specifications cycle otto 4 stroke timing tohc 1 1 type of fuel system integrated electronic injection - ignition ,—, number of cylinders w • • • 4 5 v—ri-0 cylinder liner is —il /u \ mm p o l ( ^ 70.80 82 1 , 1 1 l ^ m stroke mm wrn 78.86 75.6...

Page 25: Technical Data

Technical data marea-marea weekend engine: cylinder block/crankcase, crankshaft and associated 99 range oo.10 description values in mm 19.14-19.20 51.705-51.709 0 51.709-51.713 main bearing supports 51.713-51.717 21.72-21.80 63.705-63.718 0 cylinder liner/bore 0 70.800-70.810 82.000-82.010 70.810-70...

Page 27: Technical Data

Technical data marea-marea weekend engine: cylinder block/crankcase, crankshaft and associated 99 range oo.10 description values in mm 4-6 gudgeon pin small end 0.014-0.035 01 23.007-23.027 02 20.006-20.012 small end bush 4-7 o ^ a gudgeon pin small end bush 0.006-0.020 7-6 small end bush bush housi...

Page 30: Marea-Marea Weekend

Marea-marea weekend technical data 99 range engine: cylinder head and valve gear components oo.Io description 16v 20v values in mm 13 v 1 01 ^ 6.022-6.040 valve guide [ hq 0 2- "02 1 ® 10.010-10.030 0 2 s t 7.022-7.040 13.010-13.030 0.05-0.010-0.25 13-12 valve guide bore in cylinder head hq 8 3 0.04...

Page 33: Technical Data

Technical data engine: counter balance shaft marea- marea weekend 99 range oo.10 description values in mm 25 counter-balance shaft operation through oil pump driven gear 27 . 0 0 01 19.900 - 20.000 02 46.989 - 47.000 ball bearings for counter-balance shaft 25 \ 0 \0 \0 0 19.980 - 19.993 counter-bala...

Page 35: Technical Data

Technical data engine: cooling system marea-marea weekend 99 range oo.10 cooling system cooling circuit coolant circulation via centrifugal pump, radia- tor, expansion tank and fan operated by thermal switch coolant circulation via centrifugal pump, radia- tor and two speed fan operated by engine co...

Page 37: Technical Data

Technical data engine marea-marea weekend 99 range oo.10 specifications cycle diesel 4 stroke timing sohc engine balancing - through 1 counter- balance shaft type of fuel system direct injection turbocharger + intercooler l—,1 number of cylinders nl • • • 4 in line 5 in line lh-^t-0 cylinder liner l...

Page 39: Technical Data

Technical data marea-marea weekend engine: cylinder block/crankcase, crankshaft and associated 99 range oo.10 description values in mm 21.750 - 22.250 l1 22.300 - 22.700 l2 21.750 - 22.250 21.720 - 21.800 1 main bearing supports 63.691 - 63.732 0 cylinder liner 0 « 82.000 - 82.010 82.010 - 82.020 82...

Page 41: Technical Data

Technical data marea-marea weekend engine: cylinder block/crankcase, crankshaft and associated 99 range oo.10 description description values in mm ffi~t" 01 s m a " e n c i d u s n o r i pin housing ] ^ l ~ j 0 2 big end bearing housing 01 28.939 - 28.972 ffi~t" 01 s m a " e n c i d u s n o r i pin ...

Page 43: Technical Data

Technical data marea-marea weekend engine: cylinder head and valve gear components 99 range oo.10 description values in mm valve guide bore 0 in cylinder head 13.950 - 13.977 45° ±20' a 45° ±20' 45° ±5' 45°±5' about 2.7 12 valve seat i — u — i t l r - i n n _ n — n l n _ j w - - l j ^ h - r l r l r ...

Page 45: Technical Data

Technical data marea-marea weekend engine: cylinder head and valve gear components 99 range oo.10 i ^ i i i ! -0 • ^ 16 i 1 19 h 14 description values in mm 17-12 radial 0 030 0 070 17-12 axial 1 7 4 t t t cam lift hq 8.5 1 7 4 t t t cam lift s3 8.5 . N ^ j - u - i r ~ l _ — u r ~ ^ — i _ j - ~ \ _ ...

Page 47: Technical Data

Technical data engine: counter- balance shafts marea-marea weekend 99 range oo.Io description m jtd values in mm 25 counter-balance shafts n° 1 shaft operation through oil pump driven gear 0 27 , 0 01 • 02 ball bearings for counter-balance shaft 19.900 - 20.000 46.989 - 47.00 25 \0 \0 counter-balanc...

Page 49: Technical Data

Technical data marea-marea weekend engine: lubrication 99 range oo.10 lubrication values in mm engine lubrication circuit forced circulation, via geared pump with cartridge filter in series oil pump geared, located in the crankshaft front cover pump operated by chain driven by crankshaft oil pressur...

Page 51: Technical Data

Technical data marea-marea weekend engine: fuel system 99 range oo.10 bosch c o m m o n rail e l e c t r o n i c fuel s y s t e m c o m p o n e n t s control unit bosch 0.281.001.928 flow meter bosch 0.281.002.199 engine coolant temperature sensor jaeger 402.183.01 diesel temperature sensor bosch 0....

Page 53: Technical Data

Technical data marea-marea weekend engine: supercharging 99 range oo.10 supercharging turbocharger operated by exhaust gases with waste-gate pressure valve and air/air heat exchanger (intercooler) cooling system turbocharger: type garret gt 15 ihi vl6 variable geometry maximum supercharging pressure...

Page 58: Marea-Marea Weekend

Marea-marea weekend 99 range technical data gearbox and differential 00.21-27 differential 12.568 12.741 1 „ n s§s 7.049 7.494 4.549 4.560 rc 3.241 3.256 rc jtio at the wheels ( j ^ ^ 2.416 2.370 rc 12.313 11.887 /tnnh t differential internal housing bearing conical roller bearings adjustment of bea...

Page 61: Technical Data

Technical data steering marea-marea weekend 99 range 00.41 engine type type rack and pinion power assisted — t - ' 6 © no. Of turns lock to lock 3 2.9 2.8 ratio rack travel 142±1.5 mm 137±1.5 mm 132±1.5 mm / \ turning ' _, \ circle ! 1 10.7 11 11.4 steering angle outer ^ wheel 31° ± 30' steering ang...

Page 64: Marea-Marea Weekend

Marea-marea weekend 99 range technical data front suspension 00.44 front suspension independent, mac pherson type with transverse lower track control arms secured to an auxiliary crossmember. Offset coil springs and double acting, telescopic, hydraulic shock absorbers. Anti- roll bar connected to th...

Page 68: Marea-Marea Weekend

Marea-marea weekend 99 r a n g e technical data electrical equipment 00.55 lev i^p) jtd rgp) jtd starter motor m. Marelli e80e-12v-0,9 kw bosch 0 74,2 12v-1.1 kw (with reduction gear) bosch 0 78.5 - 12v - 2.0 kw (with reduction gear) m. Marelli m70r-12v-1,8 kw (with reduction gear) m. Marelli e9er-1...

Page 72: Marea-Marea Weekend

Marea-marea weekend technical data 99 range electrical equipment: electronic injection/ignition 00.55 integrated electronic injection/ignition control module i$v type bosch 0.261.204.578 firing order 1 - 3 - 4 - 2 ignition coil with 4 high tension intakes make bosch type 0.221.503.407 ohmic resistan...

Page 74: Marea-Marea

Marea-marea weekend •«* technical data 99 range special tools 00.A engine type tool number name of tool gearbox-differential 1842133000 tool for dismantling differential bearing and gearbox gears • 1842134000 tool for dismantling gears and gearbox hubs • 1845028000 tool for removing differential bea...

Page 76: Marea-Marea Weekend

Marea-marea weekend 99 range technical data tightening torques oo description thread tighten- ing torques engine type description thread tighten- ing torques description thread danm engine bearing cap fixing, flanged bolt m10 2+90° • bearing cap fixing, flanged bolt m12 2+100° • • shield (dust cover...

Page 78: Marea-Marea Weekend

Marea-marea weekend 99 range technical data tightening torques oo description thread tighten- ing torques danm engine type description thread tighten- ing torques danm automatic belt tensioner to alternator mounting fixing, bolt m8 3.2 • automatic belt tensioner to alternator mounting fixing, bolt m...

Page 81: Technical Data

Technical data tightening torques marea- marea weekend 99 range oo description thread tighten- ing torques danm engine type description thread tighten- ing torques danm connector on inlet duct for vacuum intake m14 tapered 3.4 • inlet manifold fixing, bolt m6 0.7 • valve gear timing stud sealing plu...

Page 84: Marea-Marea Weekend®"*

Marea-marea weekend®"* introduction and technical data 99 range index 00 pag e introduction - identification data - weights 1 technical data engine - cylinder head and valve gear com- ponents 2 - fuel system 3 electrical equipment - injection/ignition 4 special tools 5 note - this section contains t...

Page 87: Marea-Marea Weekend 9^

Marea-marea weekend 9^ 99 update technical data engine: fuel system oo.10 integrated electronic injection/ignition system components electronic control unit hitachi mfi - 155 hitachi mfi - 160 (*) injector marelli iwp 006 fuel pressure regulator (incorporated in the electric pump) marelli rpm 84 coo...

Page 89: Marea-Marea Weekend®**

Marea-marea weekend®** 99 update technical data special tools 00.A tool number tool name engine type tool number tool name engine 1860955000 equipment for checking fuel consumption • 1870684000 connector for discharging petrol pressure • 1870697000 tool for timing camshaft • copyright by fiat auto 5.

Page 93: Introduction

Introduction weights marengo ® * td 7s-jtd 105 1999 range oo.O engines iop> jtd 105 weights (values expressed in kg) 1245 1275 ^ ^ ^ ^ ^ ^ fill + 570 = tikk 1815 1845 maximum loads permitted on ax 1060 1060 maximum loads permitted on ax les 1060 1060 'erformances - fuel consumption speed km/h (avera...

Page 96: Marea- Marea Weekend ©

Marea- marea weekend © 16v engine 99 range index 10. Page removing-refitting - removing-refitting power unit - separating gearbox-differential unit 10 replacing auxiliary shaft drive belt - removing-refitting auxiliary shaft replacing timing belt - removing-refitting timing drive belt 17 removing-re...

Page 98: Marea- Marea Weekend ©>

Marea- marea weekend ©> 99 range 16v engine removing- refitting removing-refitting power unit position the vehicle on a lift, remove the front wheels, then proceed as described below: 1. Undo the three fixing bolts and remove the air intake, disconnecting it from the air filter first. 2. Drain the a...

Page 100: Marea- Marea Weekend ©>

Marea- marea weekend ©> 99 range 16v engine removing- refitting 1. Disconnect the gear selector cable track rod end, lift up the retaining fork shown in the diagram, then position the assembly to the side in the engine compartment. 2. Disconnect the accelerator cable. 3. Disconnect the bands illustr...

Page 102: Marea- Marea Weekend ©

Marea- marea weekend © 99 range engine removing- refitting 10. 1. Disconnect the engine cooling fan electrical supply connections. 2. Disconnect the high pressure air condi- tioning circuitn eedle valve undoing the bolt fixing it to the condenser. 3. Open the band and disconnect the pipe between the...

Page 104: Marea- Marea Weekend ©

Marea- marea weekend © 99 range 16v engine removing- refitting 1. Remove the right plastic wheel arch liner acting on the fixing bolts and button. 2 . Remove the nut fixing the steering track rod end to the steering knuckle (gearbox s i d e ) , then ex- tract the actual track rod end using tool 1847...

Page 106: Marea- Marea Weekend 0

Marea- marea weekend 0 99 range lev engine removing- refitting 1. Undo the bolts fixing the power unit sup- port, gearbox side. 2. Undo the bolt fixing the timing side power unit mounting bracket to the bodyshell. 3. Undo the fixing nuts and place the bracket shown to the side. 4. Undo the bolts fix...

Page 108: Marea- Marea Weekend 0

Marea- marea weekend 0 16v engine 99 range removing- refitting 10. Note to refit the gearbox-differentia/ unit to the engine, suitably reverse the order of the operations de- scribed for the removal. To refit the power unit, simply reverse the order of the operations described for the removal. - pre...

Page 110: Marea- Marea Weekend ©

Marea- marea weekend © 99 range 16v engine replacing auxiliary shaft drive belt 1. Remove the power assisted steering pump pulley shield, then remove the drive belt. Fitting 2. Tension the power assisted steering drive belt acting on the bolts securing the pump mounting bracket. Using tool 189576200...

Page 112: Marea-Marea Weekend Ffi

Marea-marea weekend ffi 99 range m x6v engine replacing auxiliary shaft drive belt 10. Fitting position the compressor drive belt on the drive pullies and tension it acting on the bolts fixing the compressor mounting bracket. Using tool 1895762000, check that the new belt tension is between 48 and 6...

Page 114: Marea- Marea Weekend ©

Marea- marea weekend © 99 range m i6v engine replacing timing belt 10. 1. If tools 1860985000 do not engage in the housings in the camshafts, the engine tim- ing is not correct, therefore, the crankshaft must be rotated, using small movements, until the tools (2) are perfectly aligned with the shaft...

Page 116: Marea- Marea Weekend ©»

Marea- marea weekend ©» 99 range 4a19hx04 engine replacing timing belt 10. 2 4a19hx01 undo the bolts fixing the fuel manifold, re- move it complete with injectors and place it to the side away from the working area. Remove the heat shield, undoing the fixing nuts and bolts. 3. Undo the bolts fixing ...

Page 118: Marea- Marea Weekend ©

Marea- marea weekend © 99 range m i6v engine replacing timing belt 10. 1. The timing is carried out with the four pis- tons in line, therefore the crankshaft has to be rotated until the reference (1) on the moving part of the tool is in line with the reference (2) on the fixed component in the spark...

Page 120: Marea- Marea Weekend 9

Marea- marea weekend 9 99 range engine removing- refitting cylinder head removing-refitting cylinder head position the vehicle on a lift, disconnect the negative battery lead, then proceed as de- scribed below: 1. Drain the engine coolant, disconnecting the hose shown in the diagram from the lower p...

Page 122: Marea- Marea Weekend ©

Marea- marea weekend © 99 range 16v engine removing- refitting cylinder head 10. 1. Using usag spanner diameter 10 233 1/2 s or a similar tool, undo the bolts fixing the cylinder head to the cylinder block/crankcase; then remove the cylinder head and the gasket underneath. Fitting cylinder head 2. F...

Page 124: Marea- Marea Weekend 0

Marea- marea weekend 0 99 range 4a27hx01 engine removing- refitting exhaust manifold 10. 4a24hx02 removing-refitting exhaust manifold 1. Disconnect the lambda sensor connector. 2. Undo the nuts fixing the first section of the exhaust pipe to the manifold. 3. Undo the heat shield fastenings and remov...

Page 126: Marea- Marea Weekend ©>

Marea- marea weekend ©> 99 range 16v engine removing- refitting intake manifold 1. Undo the bolts fixing the fuel manifold, re- move it, cmoplete with injectors, and posi- tion it outside of the work area. 2. Disconnect the output pipe from the heater and the connector (1). 3. Undo the nuts fixing t...

Page 128: Marea- Marea Weekend ©

Marea- marea weekend © 99 range 16v engine removing- refitting radiator 1. Disconnect the fan supply connections. 2. Undo the three bolts and remove the air intake, disconnecting it from the air filter hose. 3. Open the band and disconnect the pipe between the radiator and the tank. 4. Remove the en...

Page 130: Marea- Marea Weekend ©>

Marea- marea weekend ©> 99 range engine removing- refitting radiator 10. Engine cooling system components (version with heater) 4a33hx01 1. Engine coolant radiator 2. Engine cooling fan 3. Coolant expansion tank 4. Engine cooling system pump 5. Bleed plug on heater inlet hose 6. Bleed plug on heater...

Page 132: Engine

Marea- marea weekend ©> **» 99 range engine removing- refitting radiator 1. Engine cooling radiator 2. Engine cooling fan 3. Coolant expansion tank 4. Engine cooling system pump 5. Bleed plug on heater inlet pipe 6. Bleed plug on heater outlet pipe 7. Coolant return pipe from car interior heater rad...

Page 134: Marea-Marea Weekend®^

Marea-marea weekend®^ 1998 range page integrated injection-ignition system - m. Marelli- weber i.A.W.-49f 1 - introduction 1 s y s t e m o p e r a t i n g s t r a t e g i e s 1 injection-ignition system operating diagram 2 - injection management 3 - ignition management 9 - fiat code ignition immobil...

Page 136: Engine

Engine fuel system marea-marea weekend®^ 1998 range 10. Injection-ignition system operating diagram 18 t t t t o o o o 15 8 1. Safety and ventilation valve 2 1 . 2. Fuel tank 22. 3. Electric fuel pump 23. 4. Idle speed actuator 24. 5. Radiator fan high and low speed control re- 25. Lays 26. 6. Batte...

Page 138: Engine

Engine fuel system 10 marea-marea weekend®^ 1998 range a stoichiometric ratio is achieved by using a hot lambda probe. This probe continually monitors the amount of oxygen in the exhaust gas and then informs the ecu. This unit in turn uses mapped data to correct the fuel air mixture on-line if propo...

Page 140: Engine

Engine marea-marea weekend @ t fuel system 1998 range 10. When cold under these conditions, the mixture becomes naturally leaner due to reduced evaporation and heavy fu- el condensation on the intake manifold internal walls. The greater viscosity of the lubrication oil also brings about an increase ...

Page 142: Engine

Engine fuel system marea-marea weekend 01 1998 range 10. Acceleration during this stage, the ecu increases the amount of fuel required by the engine (to achieve maximum torque) on the basis of signals from the following sensors: - throttle potentiometer; - absolute pressure sensor; - rpm and tdc sen...

Page 144: Engine

Engine fuel system marea-marea weekend®^ 1998 range 10. The rising side of signal (graph b in figure on previous page) therefore represents a moment within which alternative primary winding conduction could take place. This point can be established only by the control unit power module. The conducti...

Page 146: Engine

Engine marea-marea weekend® ^ fuel system 1998 range 10. Controlling knock this function detects the presence of knock by processing signals from relevant sensors. The ecu con- tinually compares signals from sensors with a threshold level which is continually updated in turn to take into account bac...

Page 148: Engine

Engine marea-marea weekend ® 1* fuel system 1998 range 10. Heating/ventilation system management the injection-ignition control unit is connected operationally to the air conditioning system because: 1. A compressor activation request is received and appropriate action is taken (supplementary air); ...

Page 150: Engine

Engine marea-marea weekend® ** fuel system 1998 range 10. Air intake circuit management p4f16ij01 the air intake circuit consists of various parts which are responsible for carrying the amount of air re- quired by the engine under various service conditions. 1. Inlet manifold 7. Engine idle speed ac...

Page 152: Engine

Engine marea-marea weekend ® i * fuel system 1998 range 10. Fuel evaporation control circuit diagram p4f18ij01 1. Fuel vapour cut-off valve 2. Active carbon trap filter 3. Safety and ventilation valve 4. Multifunction valve the tank ventilation system is closed-loop type. This system prevents fuel v...

Page 154: Engine

Engine marea-marea weekend ® 1* fuel system 1998 range 10. Injection-ignition system wiring diagram p4fz0ij01 20 publication no. 506.763/09.

Page 156: Engine

Engine fuel system 10. Engine exhaust assembly diagram marea-marea weekend®^ 1998 range 4. Silencers p4f22ij01 in the i.A.W. System, closed-loop mixture concentration control is activated by a lambda probe sensor. This measures the amount of oxygen in exhaust gas upstream of the catalytic converter....

Page 158: Engine

Engine fuel system 10. P4f24ij03 marea-marea weekend® ^ 1998 range injection - ignition system fuses and relays general system protection fuse (fig. 1) the general fuse (30a) protecting the injec- tion-ignition system (1) is housed inside a con- tainer; to gain access to the fuse, undo side clips an...

Page 160: Engine

Engine marea-marea weekend®^ fuel system 1998 range 10. B. Microprocessor this electronic component is responsible for computing and managing acquired data. It is thus a true computer and its main tasks include: consulting memories, comparing data input with sample data, managing actuator control ci...

Page 162: Engine

Engine fuel system marea-marea weekend®^ 1998 range 10. Identifying connections on injection-ignition control unit (pin-out) @ @ © © @ @ © © @ @ © © ® @ @ © @ © @ © © @ © © © © © © © © © ® © © @ @ @ @ © © © © © © © © ® © © @ © @ © © © © © © © © © © © © @ © © © © © © © © © © © © © © © 10 1-3. 4. 5. 6...

Page 164: Engine

Engine fuel system marea-marea weekend ® ^ 1998 range 10. Wiring connector the sensor is connected to the ecu by means of twisted wires covered by a shield- ed, interference-proof sheath. Pin 1 - signal pin 2 - earth pin 3 - shielding note the numbers in boxes indicate corre- sponding control unit p...

Page 166: Engine

Engine marea-marea weekend©^ fuel system 1998 range 10. Throttle body (46 sxf 2) the throttle body is responsible for metering the quantity of air supplied to the engine (and thus control- ling engine power output) according to accelerator position determined by the driver. The throttle body is fast...

Page 168: Engine

Engine fuel system marea-marea weekend^i 6v 1998 range 10. Wiring connector the numbers in boxes indicate the corre- sponding control unit pins. Pin a - earth pin b - positive pin c - signal checking resistance sensor resistance may be measured as fol- lows - by connecting an ohmmeter across sensor ...

Page 170: Engine

Engine fuel system marea-marea weekend^ 1998 range 10. Engine idle speed actuator (step motor) (ib02) 1. Bearing 5. Screw 2. Lead screw 6. Anti-rotation 3. Coils grooves 4. Magnets 7. Plunger the actuator is fitted to the throttle body and consists of: - an electric step motor with two windings in t...

Page 172: Engine

Engine fuel system marea-marea weekend^ 1* 1998 range 10. P4f38ij02 wiring connector pin 1 -air pressure sig- nal pin 2-positive pin 3-air temperature signal pin 4-negative the numbers in boxes indicate the corre- sponding control unit pins. Checking resistance the table alongside shows resistance v...

Page 174: Engine

Engine fuel system marea-marea weekend©^ 1998 range 10. Fuel manifold (cb 168) the fuel manifold is fastened to the inner part of the intake manifold. Its function is to direct fuel to the injectors. The fuel manifold is pressure cast in alumini- um and incorporates injector seats. The fuel intake i...

Page 176: Engine

Engine marea-marea weekend © 1* fuel system 1998 range 10. Multifunction valve (sirio 0175.00) this valve performs the following functions: - prevents fuel flowing out when tank is over-filled or in case the vehicle overturns in an accident; - vents fuel vapours from tank to the active carbon trap f...

Page 178: Engine

Engine marea-marea weekend^** fuel system 1998 range 10. I n j e c t o r s (iwp 064) the twin-jet top-feed injectors (spray is inclined in relation to the injector centre-line) are specific for four valve per cylinder engines. They allow the jets to be directed toward the two intake valves. Fuel jet...

Page 180: Engine

Engine fuel system marea-marea weekend &t iev 1998 range 10. Ignition coils (bae 920a) (beru 0.040.100.029) the coils are fastened by means of a bracket to the camshaft covers and are closed mag- netic loop type. They are formed from a lay- ered pack, whose central core (broken by a narrow gap) carr...

Page 182: Engine

Engine marea-marea weekend fuel system 1998 range 10. Lambda probe (ntk 0za334-a1) this sensor measures exhaust gas oxygen content. The sensor output signal is sent to the electronic control unit to adjust the air-fuel mixture in order to maintain the ratio as close as possible to theoretical levels...

Page 184: Engine

Engine fuel system marea-marea weekend©*^ 1998 range 10. Removing - refitting lambda probe - place the vehicle on a lift - disconnect battery negative lead - disconnect electrical connection located against the rear wall of the engine bay. Remove the lambda probe from its seat on the exhaust pipe. E...

Page 186: Engine

Engine fuel system marea-marea weekend^i 6v 1998 range 10. 1. Unscrew the bolts fastening both sections of the fuel supply manifold and remove the first section (1). 2. Unscrew the fuel manifold retaining bolts and the bolts fastening the second section of the intake manifold to the engine block and...

Page 188: Engine

Engine fuel system marea-marea weekend^i 6v 1998 range 10. Remove the bolt shown and the plug re- taining the fuel filler fitting to the body. 2-3. Open the collars arrowed and release the parking brake control cables from their anchorages on the fuel tank. Arrange a hydraulic jack beneath the tank ...

Page 190: Engine

Engine fuel system marea-marea weekend ^ i 6 v 1998 range 10. Removing-refitting cable accelerator disconnect the battery lead, then proceed as follows: 1. Working from inside the vehicle, discon- nect the control cable from its anchorage on the accelerator pedal. 2. In the engine bay, turn the thro...

Page 192: Engine

Engine marea-marea weekend @* i* fuel system 1998 range 10. Checking co and hc levels at exhaust to measure levels of carbon monoxide (co) and unburnt hydorcarbons (hc) in exhaust emissions, in- sert the probe of an appropriately calibrated tester until at least 30 cm inside tail pipe. If exhaust ta...

Page 194: Engine

Engine fuel system marea-marea weekend©^ 1998 range 10. Checkign fuel feed pressure using a tester fuel feed pressure can also be checked using an examiner or sdc station. In this case, firstly remove the protective bracket as de- scribed in the previous paragraph, connect the tester to transducer (...

Page 196: Engine

Engine marea-marea weekend @> fuel system 1998 range 10. Fault diagnosis full fault diagnosis can be carried out on the injection-ignition system through active dialogue with an examiner or sdc station. If the sensors are found to be faulty, the electronic control unit replaces the faulty data outpu...

Page 198: Engine

Engine marea-marea weekend^ fuel system 1998 range 10. Active diagnosis when in active diagnosis mode, some components can be activated and certain specific functions can be carried out, e.G. The error deletion command described in the following table. During active diagnosis, the ignition key must ...

Page 200

Copyright fiat auto s.P.A. Total or partial reproduction of the text or il- lustrations is forbidden. The information in this publication is inten- ded as a guide and could be superseded as a result of modifications adopted by the manu- facturer at any time due to technical and commercial reasons an...

Page 202: Engine

Engine marea- marea weekend fuel s y s t e m '98 range 10. General diagram of fuel system p 4 f 0 2 u 0 1 1. Battery 2. Relay 3. Clutch pedal switch 4. Brake pedal switch 5. Accelerator potentiometer 6. Speedometer 7. Electronic control unit 8. Engine rpm sensor 9. Coolant temperature sensor 10. Ins...

Page 204: Engine

Engine fuel system marea- marea weekend 9 > n > '98 range 10. Input/output signals between control unit and sensors/actuators 1. Electronic control unit 2. Injection pump 3. Accelerator pedal potentiometer 4. Engine coolant temperature sensor 5 clutch pedal switch 6. Brake pedal switch 7. Air flowme...

Page 206: Engine

Marea- marea weekend & r d '98 range engine fuel system 10. Functional diagram of the fuel system 1. Borg warner modulating valve 2. Bosch fuel injection pump 3. Instrumented fuel injector 4. Heater plug 5. Egr valve 6. Plug preheating control unit 7. Coolant temperature sensor 8. Engine rpm sensor ...

Page 208: Engine

Engine marea- marea weekend @ w d fuel system '98 range 10. Hot-film air flowmeter this component measures the quantity of air drawn in by the engine. The electrical signal (proportional to the air flow) which the flowmeter gives as an output is sent to the engine control unit. This is used to: - ca...

Page 211: Marea- Marea Weekend Fti

Marea- marea weekend fti td engine '98 range fuel system 10. Key to wiring diagram 1. Electronic control unit 2. System protection relay 3. Borg-warner modulating solenoid 4. Fuel injection advance actuator 5. Fuel quantity actuator 6. Fuel quantity actuator position control 7. Inertial switch 8. En...

Page 213: Marea- Marea Weekend ©>

Marea- marea weekend ©> 99 range engine index page bosch ml .5.5 integrated in- jection/ignition system 1 introduction 1 functional diagram 2 diagram showing information enter- ing/leaving the bosch m1.5.5 in- jection/ignition system control unit and sensors/actuators in the engine compartment 3 - l...

Page 215: Marea-Marea

Marea-marea w e e k e n d e n g i n e 99 range fuel system 10. Bosch m1.5.5 integrated injection/ignition system introduction the bosch m1.5.5 system fitted on the 1242 16v engine belongs to the category of static advance digi- tal electronic ignition systems integrated with phased multiple intermit...

Page 217: Marea-Marea Weekend

Marea-marea weekend w > 1 6 v 99 range engine fuel system 10. Diagram showing information entering/leaving the control unit and sensors/actuators for the bosch m1.5.5 injection/ignition system 4f0o3pjo1 1. Engine control unit 2. Battery 3. Ignition switch 4. Engine control system relay 5. Electric f...

Page 219: Marea- Marea Weekend Ft

Marea- marea weekend ft engine 99 range fuel system 10. System management strategies operating principle any engine operating point is identified by two parameters: - rotation speed; - engine load. If these parameters are known through suitable processing it is possible to calculate and then impleme...

Page 221: Marea- Marea Weekend 9

Marea- marea weekend 9 engine 99 range fuel system 10. Controlling the mixture strength (feed back control) note the mixture ratio is defined and denoted by the greek fetter a (a/fa). Quantity of air drawn in by the engine quantity of fuel injected this is defined as the stoichiometric ratio and is ...

Page 223: Marea- Marea Weekend Ft

Marea- marea weekend ft 16v engine 99 range fuel system 10. Rotation speed restricter this strategy restricts the maximum speed which can be reached by the engine enabling the cut-off. There are two different cut-off levels: - static restricter (the engine speed approaches the level slowly): maximum...

Page 225: Marea-Marea Weekend

Marea-marea weekend ft** engine 99 range fuel system 10. Starting during starting, it is not possible to carry out the normal management of the advance because the consid- erable fluctuations in the rotation speed do not allow the correct calculation of the dwell and the advance. The control unit im...

Page 227: Marea- Marea Weekend Ft

Marea- marea weekend ft engine 99 range fuel system 10. Management of the climate control system the injection/ignition control unit is functionally connected to the climate control system, as follows: 1. It receives the request to switch on the compressor and operates the various interventions (add...

Page 229: Marea- Marea Weekend

Marea- marea weekend ©> engine 99 range fuel system 10. Diagnostics the system is equipped with an autodiagnostic function which is designed to check for irregularities with the following components: actuators sensors injectors engine speed sensor coils vehicle speed sensor charcoal filter soleniod ...

Page 231: Marea-Marea Weekend

Marea-marea weekend 99 range engine fuel system 10. Bosch ml .5.5 system control unit pin out connector b (engine side) 1. Sensors earth 2. Detonation sensor signal 3. Intake air temperature sensor signal 4. Butterfly position senor signal 5. Coolant temperature sensor signal 6. Operation of injecto...

Page 233: Marea- Marea Weekend

Marea- marea weekend © engine 99 range fuel system 10. Bosch ml .5.5 system wiring diagram key connector a (vehicle side) 1. Control unit 2. Radiator fan 3. Fan high speed relay 4. Fan low speed relay 5. Engine control system relay 6. Fuel pump relay 7. Front cable connection 8. Battery 9. Ignition ...

Page 235: Marea- Marea Weekend ©>

Marea- marea weekend ©> engine 99 range fuel system 10. Bosch m1.5.5 system wiring diagram key connector b (engine side) 1. Control unit 2. Active charcoal filter solenoid valve 3. Detonation sensor 4. Coolant temperature sensor 5. Engine idle adjustment actuator/butterfly position sensor 6. Absolut...

Page 237: Marea-Marea Weekend9

Marea-marea weekend9 99 range engine fuel system 1 z 3 32b 22b 10. Engine rpm and tdc sensor the engine rpm and tdc sensor (1) is fixed on the cylinder block/crankcase and is facing the flywheel on the crankshaft pulley. Operating principle the sensor consists of a tubular casing (1) which contains ...

Page 239: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 range 16v engine fuel system injection ntc °c m °c m -20 16900-15000 40 1200-1100 -10 10100-9100 50 830-780 0 6300-5700 60 590-560 10 4000-3600 70 430-400 20 2600-2400 80 315-300 25 2100-1950 90 235-225 30 1750-1600 100 137-133 10. Engine coolant temperature sen- sor this ...

Page 241: Marea- Marea Weekend 0

Marea- marea weekend 0 99 range engine fuel system _ n n _ 1 2 i_r—l 3 2 b - -=- 11b 10. Vehicle speed sensor this sensor is positioned at the differential output, by the left driveshaft coupling and transmits information concerning the vehicle speed to the speedometer: the signal is then sent to th...

Page 243: Marea-Marea Weekend

Marea-marea weekend ft engine 99 range fuel system intake circuit this consists of various components which ensure the air flow rate required by the engine in the various operating conditions. 4f029pj01 1. Intake vent 2. Air filter 3. Resonator 4. Engine idle speed adjustment actuator and butterfly ...

Page 245: Marea- Marea Weekend

Marea- marea weekend & engine 99 range fuel system fuel supply circuit this circuit consists of the following components: - fuel tank - drip tray complete with pump, filter, pressure regulator and gauge - supply pipe - returnless type fuel manifold complete with injectors fuel circuit diagram 4f031p...

Page 247: Marea-Marea Weekend^

Marea-marea weekend^ 16 * 99 range + — 1 6 b 1 7 b 1 6 b 7 b 4f033pj03 4f033pj04 engine fuel system fuel manifold the fuel manifold, which has the task of dis- tributing the fuel to the injectors, is made from die-cast aluminium and incorporates the seats for the injectors and the air bleed valve. T...

Page 249: Marea-Marea

Marea-marea w e e k e n d e n g i n e 99 range fuel system 10. Emission control devices the devices used for this purpose have two objectives; - to keep down the levels of the pollutant substances in the exhaust, through the catalytic silencer; - to eliminate the outwards dispersion of unburnt hydro...

Page 251: Marea-Marea Weekend

Marea-marea weekend 99 range lev engine fuel system 10. Anti-evaporation circuit diagram the anti-evaporation system is designed to prevent the fuel vapours, consisting of the lightest fractions of hydrocarbons which basically form i-n the tank, from being discharged into the atmosphere. 1. Vapour s...

Page 253: Marea-Marea Weekend0»*

Marea-marea weekend0»* 99 range engine fuel system j. 10. Safety and ventilation valve this valve is located in the fuel filler cap and, according to the pressure in the tank, carries out the following functions: - when the pressure inside the fuel tank ex- ceeds 0.13 - 0.18 bar, it allow the excess...

Page 255: Marea-Marea

Marea-marea w e e k e n d e n g i n e 99 range fuel system checks, adjustments and repair operations on the bosch m1.5.5 s y s t e m when working on a vehicle equipped with a bosch m1.5.5 system, observe the following precau- tions: - do not start up the engine with the electrical connection termina...

Page 257: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 range 16v engine fuel system a 10. Checks on fuel supply circuit carry out these operations in the presence of a suitable vapour purification and exa- hust system fuel supply circuit pressure check check the fuel supply pressure and the fuel system seal following the instr...

Page 259: Marea-Marea Weekend W>

Marea-marea weekend w> 16v 99 range engine fuel system 10. If there is a decrease in pressure greater than the figures given above, check the seal of the system in the section upstream of the manifold and, if there are no leaks or damage to the fuel supply pipe, replace the electric fuel pump drip t...

Page 261: Marea-Marea Weekend Ft

Marea-marea weekend ft 99 range engine fuel system 10. - discharge the fuel prssure inside the supply pipe and disconnect the pipe from the rapid connector, fol- lowing the instructions given in the previous paragraphs; - connect the end of the supply pipe to the female rapid connector for the flowt...

Page 263: Marea-Marea Weekend

Marea-marea weekend 1 ® 16 * 99 range engine fuel system 10. Fuel manifold and injectors note before removing the manifold, dis- charge the pressure inside, following the instructions given at the start ol this chapter. Removing-refitting fuel manifold proceed with the removal of the manifold as fol...

Page 265: Marea-Marea Weekend®

Marea-marea weekend® 99 range 16v engine fuel system 10. Butterfly casing removing-refitting proceed with the removal of the butterfly cas- ing as follows: - remove the bands illustrated (arrow); then undo the two bolts (detail) and remove the inlet hose complete with resonator; - release the end of...

Page 267: Engine

Marea- marea weekend * § i 99 range m iev engine fuel system 10. Removing-refitting proceed with the removal of the accelerator cable as follows: - working from inside the vehicle (a), discon- nect the control cable from the mounting on the accelerator pedal (b); - turn the accelerator lever to rele...

Page 269: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 update engine index page , hitachi integrated injec- tion/ignition system 1 introduction 1 functional diagram of hitachi injection/ignition system 2 diagram showing information enter- ing/leaving hitachi injec- tion/ignition system control unit and sensors/actuators 3 loca...

Page 271: Marea- Marea Weekend 0

Marea- marea weekend 0 engine 99 update fuel system 10. Hitachi integrated injection/ignition system introduction the hitachi system fitted on the marea-marea weekend versions with the 1747 i.E. 16v engine belongs to the category of static advance, digital electronic ignitino systems integrated with...

Page 273: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 update engine fuel system 10. Diagram showing information entering/leaving hitachi injection/ignition system control unit and sensors/actuators 4f0o3ojo1 1. Hitachi engine management control unit 17. Injectors 2. Battery 18. Charcoal filter solenoid valve 3. Ignition switc...

Page 275: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 update 16v engine fuel system 10. System management strategies management of the signals during starting, the control unit recognizes the phasing of the injection and the ignition which are vital for the subsequent operation of all strategies. This recognition is based on ...

Page 277: Marea- Marea Weekend

Marea- marea weekend & engine 99 update fuel system 10. Control of the mixture strength (feed-back control) note the mixture strength is defined by the following ratio and is denoted by the greek letter a (alfa): quantity of air drawn in by the engine quantity of fuel injected the stoichiometric rat...

Page 279: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 update 16v engine fuel system 10. Operation in acceleration conditions during this stage, the control unit increases the quantity of fuel supplied. The "basic" injection time is multiplied by a coefficient which depends on the temperature of the engine and the opening spee...

Page 281: Marea- Marea Weekend ©

Marea- marea weekend © 99 update engine fuel system 10. Managment of the ignition the ignition management strategies are designed to strike the spark with the desired advance according to the engine operating conditions. The management of the ignition basically consists of determining the ignition a...

Page 283: Marea-

Marea- marea weekend 0 16v engine 99 update fuel system 10. Control of detonation this strategy has the task of detecting the presence of detonation by processing the signal coming from the appropriate sensor. The strategy continuously compares the signal coming from the sensor with a level which is...

Page 285: Marea- Marea Weekend ©>

Marea- marea weekend ©> 99 update engine fuel system 10. Management of the climate control system the hitachi engine management control unit is functionally connected to the climate control system in as far as: 1. It receives the request to switch on the compressor via pin 9/b and operates the inter...

Page 287: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 update engine fuel system 10. Diagram showing engagement of fans for version with air conditioning low speed fan: it comes on when the temperature of the coolant reaches 95°c. High speed fan: it comes on when the temperature of the coolant reaches 100°c: the first fan is o...

Page 289: Marea- Marea Weekend Ft

Marea- marea weekend ft 99 update engine fuel system 4f018oj01 engine side wiring (a) butterfly position sensor coolant temperature sensor air flow meter engine rpm sensor engine timing sensor vehicle speed sensor detonation sensor injectors coils idle speed stepping motor charcoal filter solenoid v...

Page 292: Engine

Engine fuel system marea- marea weekend ft 99 update 10. Hitachi system control unit pin-out 4f020oj01 connector a 1. Operation of injector for cylinder 1 23. Engine rpm sensor positive 2. Operation of injector for cylinder 2 24. Engine rpm sensor negative 3. Operation of injector for cylinder 3 25....

Page 294: Engine

Engine fuel system 16v marea- marea weekend ft 99 update engine rpm sensor this sensor is fixed to the cylinder block/crankcase: the flywheel is in one piece with the crankshaft crank. Operating principle the sensor consists of a tubular casing (1) which contains a permanent magnet (3) and an electr...

Page 296: Engine

Engine 'fuel system 16v marea- marea weekend ft 99 update wiring connector air flow meter the air flow meter is the hot wire type and is incorporated in the butterfly casing. The upper part contains a duct parallel to the main flow in which the heated filament is lo- cated. Part of the flow of intak...

Page 298: Engine

Engine fuel system marea- marea weekend ft 99 update 3n30gj01 3n30gj02 28 print n° 506.763/15.

Page 300: Engine

Engine fuel system 16v marea- marea weekend 9 99 update wiring connector wiring connector vehicle speed sensor this sensor is positioned at the differential output, by the left driveshaft coupling and it transmits information to the control unit con- cerning the vehicle speed: the signal is also use...

Page 302: Engine

Engine marea- marea weekend ®> *» fuel system 99 update diagram showing air intake circuit 4f032oj01 1. Air filter 2. Exhaust manifold 3. Butterfly casing with air flow meter 4 . I n t a k e vent 5. Engine speed adjustment actuator 6. Intake manifold 3 2 print n° 506.763/15.

Page 304: Engine

Engine fuel system 16v marea- marea weekend 9 99 update engine idle speed adjustment actuator the actuator, fitted on the butterfly casing, in- tercepts a flow of air which, taken from up- stream of the butterfly, returns it downstream: it has the task of guaranteeing the additional air for the engi...

Page 307: Marea- Marea Weekend 9

Marea- marea weekend 9 99 update engine fuel system 10. The pump is the volumetric type and is designed to run on unleaded fuel. The rotor is driven by a d.C. Electric motor supplied with the battery voltage directly by the twin relay operated by the control unit in order to ensure: - that the pump ...

Page 310: Engine

Engine fuel system 16v marea- marea weekend ft 99 update 10. R x 7 — i ncv ! \ n c % na i nc na c 1. Inertia sensor 2. Button for restoring operation of electric fuel pump inertia safety switch in order to improve the safety of the occupants of the vehicle in the case of an impact, the vehi- cle is ...

Page 312: Engine

Engine fuel system marea- marea weekend ft 99 update 10. Fuel anti-evaporation system the anti-evaporation system is designed to prevent the fuel vapours, composed of the lightest fractions of hydrocarbons which basically form in the tank, from being discharged into the atmosphere. The system consis...

Page 314: Engine

Engine marea- marea weekend ft fuel system 99 update 16; exhaust gas recirculation system (blow-by) this system controls the emission of breather gases from the crankcase which consist of mixtures of air, fuel vapours and burnt gases which escape from the piston seals and lubricant oil vapours, caus...

Page 316: Engine

Engine fuel system marea- marea weekend 9 99 update 10. Table summarizing pollutant emission tolerance figures co (%) hc (p.P.M.) c 0 2 (%) upstream of the catalyzer 04 - 1 > 12 downstream of the catalyzer > 13 checking exhaust concentration of co and hc the concentration of carbon monoxide (co) and...

Page 318: Engine

Engine fuel system 16v marea- marea weekend ft 99 update checking fuel supply circuit pressure prepare the test equipment 1860955000, using the adapators constructed previously and fitted as illus- trated in the diagram below, with ball valves (a), (b) and (d) in the fully open position and valve (c...

Page 320: Engine

Engine fuel system 16v marea- marea weekend © 99 update 10. Removing test equipment remove the test equipment 1860955000 with the ignition key in the off position, proceeding as de- scribed below: - introduce the end of the pipe connected to the valve (c) into a suitable container; - open the valve ...

Page 322: Engine

Engine fyel system iev marea- marea weekend 0 99 update 10. A u u u u u fuel manifold and injectors before removing the manifold, drain the internal pressure following the instructions at the beginning of this chapter. Proceed with removing the manifold, as fol- lows: - release the front and rear sp...

Page 324: Engine

Engine fuel system 10. 8 marea- marea weekend ft 99 update accelerator control cable removing - working from inside the vehicle, disconnect the accelerator cable from the attachment on the pedal. - loosen the accelerator cable, acting on the adjustment screw (2), then release the end of the cable (7...

Page 326: Marea-Marea Weekend

Marea-marea weekend engine 9 9 range fuel system 10. Bosch motronic me 3.1 m.P.I. Integrated injection/ignition system introduction the bosch motronic system fitted on the 1998 5 cylinder 20 valve version belongs to the category of static advance, inductive discharge, digital electronic ignition sys...

Page 328: Marea-Marea Weekend®^

Marea-marea weekend®^ 99 range engine fuel system 10. These values are obtained experimentally by means of a long series of practical tests carried out on proto- types at the engine test bench to identify the advances which give the best possible compromise between the conflicting requirements of ma...

Page 330: Marea-Matea Weekend®*»

Marea-matea weekend®*» engine 99 range fuel system 10. Having reached this condition, the normal functions for idling and cut-off during overrun are only reacti- vated when the fuel cut-off level is exceeded to ensure that the engine runs smoothly. The levels for re- storing the supply and fuel cut-...

Page 332: Marea-Marea Weekend®

Marea-marea weekend® 20 * 99 range engine fuel system 10. System self-adjustment the control unit is equipped with a self-adjustment function which has the task of recognizing the changes which take place in the engine due to bedding in over time and the ageing of both the compo- nents and the actua...

Page 334: E N G I N E

Marea-marea w e e k e n d ® e n g i n e 99 range fuel system 10. Diagram showing information entering/leaving the injection/ignition system control unit and sensors/actuators 4a09lj01 1. Electronic control unit 20. Diagnostic socket 2. Four stage pressure switch 21. Variable geometry inlet manifold ...

Page 336: Marea-Marea Weekend®^

Marea-marea weekend®^ 99 range engine fuel system 10. Fuel anti-evaporation circuit diagram 1. Fuel vapour cut out solenoid valve 5. Safety and ventilation valve 2. Charcoal filter 6. Float valve 3. Multi-purpose valve 7. Tank 4 . Fuel vapour separator 8 . Injection/ignition control unit the anti-ev...

Page 338: Marea-Marea Weekend®

Marea-marea weekend® 99 range 20v engine fuel system engine exhaust assembly diagram 10. 1. Exhaust manifold 2. Lambda sensor 3. Catalytic silencer 4. Silencers 5. Co intake the closed-loop control of the mixture strength is activated by the lambda senor which measures the oxygen content of the exha...

Page 340: Marea-Marea Weekend®^

Marea-marea weekend®^ 99 range engine fuel system control unit/ignition coil and injector connection i key: 10. Injection/ignition system fail- ure warning light rev counter signal climate control engagement fiat code control unit vehicle speed senor engine rpm and tdc sensor detonation sensor 1 det...

Page 342: Marea-Marea Weekend

Marea-marea weekend 99 range engine fuel system copyright by fiat auto 17.

Page 344: Marea- Marea Weekend

Marea- marea weekend 99 range 20v engine fuel system 10. Identification of control unit connections (pin out) m o o o o o o o o o o o o o o o o o o o o o o o o o o o o g o o o o o o o o o o o o o o g o o o o o o o o o o o o o o 1 17 33 49 49 " b o o o o o o o o o o o o o o i > o o o o o o o o o o o ...

Page 346: Marea-Marea Weekend *tp

Marea-marea weekend *tp 99 range engine fuel system 3 4 —o *d-2- 1 k « 1 -5 3 — > 10. Ignition coilens (0.221.504.014) the ignition is the static advance electronic type with one single coil for each cylinder; this solution eliminates the high tension circuit, in- creasing reliability and safety and...

Page 348: Marea-Marea Weekend®^

Marea-marea weekend®^ 99 range engine fuel system 4a23lj01 1. Rpm sensor 2. Toothed pulley 3. Engine flywheel ; • l. R 10. Engine rpm and tdc sensor (0.261.210.160) this sensor which measures the engine speed and tdc is the inductive type, i.E. It operates through the variation in the magnetic field...

Page 350: Marea-Marea Weekend

Marea-marea weekend (p** 99 range engine fuel system 10. Electric fuel pump (0.580.313.011) the electric fuel pump is located inside the fuel tank, housed in a drip tray which also incor- porates: - the fuel pressure regulator; - the fuel gauge; - the fuel filter. 1. Electric fuel pump; 2. Fuel filt...

Page 352: Engine

Marea- marea weekend 0 > 99 range 20v engine fuel system 10. Accelerator pedal potentiometer (0.281.002.203) the position of the accelerator pedal is trans- formed into an electrical voltage signal and sent to the injection control unit by the poten- tiometer connected to the pedal. The accelerator ...

Page 354: Marea-Marea Weekend

Marea-marea weekend 99 range m 20v engine fuel system 10. 1 2 3 4 5 connector wiring the numbers indicate the corresponding control unit pins. F54 6 +30 f57 l f 6 3 f25 butterfly casing actuator the actuator is fixed to the inlet chamber and regulates the quantity of air drawn in by the en- gine. Ac...

Page 356: Marea- Marea Weekend ©

Marea- marea weekend © 20v 99 range engine fuel system 10. The sensor can be rapidly put out of action by the presence of even slight amounts of lead in the fuel. Checking the resistance the resistance of the heater and the senor can be measured by disconnecting the connector and connecting an ohmme...

Page 358: Marea-Marea Weekend®^

Marea-marea weekend®^ 99 range engine fuel system diagram showing operation of phase transformer 10. 8708786 8530 ® 1. Solenoid 2. Valve chest 3. Valve chest spring 4. Piston 5. Pinion 6. Camshaft element 7. Piston spring 8. Battery 9. Injection/ignition system relay 10. Injection/ignition control u...

Page 360: Marea-Marea Weekend®

Marea-marea weekend® 20 * 99 range engine fuel system 10. Inertia switch in order to improve the safety of the occupants of the vehicle in the case of an impact, the ve- hicle is equipped with an inertia switched lo- cated inside the passenger compartment, on the left panel under the dashboard on th...

Page 362: Marea-Marea Weekend®^

Marea-marea weekend®^ 99 range engine fuel system 10. Checking the resistance the resistance of the solenoid valve can be measured by disconnecting the connector and connecting an ohmmeter as illustrated in the diagram. Resistance: 17.5-23.5 ohm at 20 c connector wiring the numbers indicate the corr...

Page 364: Marea- Marea Weekend

Marea- marea weekend 9 20v 99 range engine fuel system 10. Checking exhaust concentration of co and hc the exhaust concentration of carbon monoxide (co) and unburnt hydrocarbons (hc) is meaured by in- serting a suitably calibrated co tester probe at leat 30 cm into the end of the exhaust pipe as ill...

Page 366: Marea-Marea Weekend

Marea-marea weekend 0> engine 99 range fuel system 10. Cancelling the error when the frequency counter reaches 0, the fault and the parameters associated with it are cancelled. The immediate cancellation of the entire errors memory takes place through the "cancelling errors memory" command sent by t...

Page 368: Engine

Marea-marea weekend®™ ®™ engine '99 range index 10. Page operations on vehicle - removing-refitting injectors 1 - removing-refitting repair manifold 4 - removing-refitting heater plugs 9 . - removing-refitting pressure pump 12 - removing-refitting accelerator poten- tiometer 20 - adjusting accelerat...

Page 370: Engine

Marea-marea weekend®™ ®™ 99 range engine operations on vehicle 10 removing-refitting injectors disable the alarm (if fitted), located in the luggage compartment on the right hand side and disconnect the negative battery terminal. 1. Remove the upper engine protective cover. 2. Undo the two bolts sho...

Page 372: Engine

Marea-marea weekend®*™ ®™ '99 range engine interventions on car 10. 1. Take off the oil vapour separator by und- screwing the three retaining nuts. 2. Undo the manifold end pipe fittings from the rail leading to the injectors and remove them 3. Undo the retaining nuts and carefully re- move the inje...

Page 374: Engine

Marea-marea weekend®™ ® 99 range jtd engine operations on vehicle 10 1. Remove the upper engine protective cover. 2. Undo the bolts and place the rigid pipe between the e.G.R. Valve and the solenoid valve to the side. 3. Disconnect the fuel return pipe from the injectors. Copyright by fiat auto 5.

Page 376: Marea-Marea Weekend®™ 0

Marea-marea weekend®™ 0 '99 range jtd engine interventions on car 10. 1. Undo the injector end pipe fittings from the rail leading to the injectors. 2. Remove the oil vapour separator by un- screwing the three retaining nuts. 3. Undo the manifold end pipe fittings from the rail leading to the inject...

Page 378: Engine

Marea-marea weekend®™ ® m 99 range engine operations on vehicle 10 removing-refitting plugs heater disable the alarm (if fitted) via the switch under the junction unit cover. Disconnect the terminals and remove the battery (1910 jtd). 1. Disconnect the electrical connection for the flow meter. 2. Lo...

Page 380: Marea- Marea Weekend

Marea- marea weekend 0> 99 range jtd v jtd engine operations on vehicle 1. Disconnect the electrical connection from the fuel temperature sensor. 2. Move the oil vapour separator aside un- doing the three fixing nuts. 3. Move the fuel return manifold aside. 4. Disconnect the electrical connection un...

Page 382: Engine

Marea-marea weekend®™ ®™ 99 range engine operations on vehicle 1. Remove the lower engine shield and lock the flywheel using tool 1860898000. 2. Remove the auxiliary shaft drive pulley on the crankshaft (the pulley on the 1910 jtd engine has four fixing bolts). 3. Remove the auxiliary shaft belt idl...

Page 384: Engine

Marea-marea weekend®™ ® 99 range jtd engine operations on vehicle 1. Check that the reference on the timing toothed pulley is aligned with the refer- ence mark for the timing of cylinder no. 1 at t.D.C. 2. Fix tool 1860905000 to the crankshaft drive gear using the bolt shown. 3. Loosen the timing dr...

Page 386: Engine

Marea-marea weekend®™ ®™ '99 range engine interventions on car 10. 1. Remove the fuel delivery pipe from the pressure pump to the rail pipe. 2. Disconnect the electrical connection from the pressure regulator on the pressure pump 3. Undo the retaining nuts and remove the pressure pump. Copyright fia...

Page 388: Engine

Marea-marea weekend®™ ® 99 range jtd engine operations on vehicle 10 lower the lift. 1. Rotate the driven pulley so that the timing references line up. Raise the lift and complete the fitting of the timing belt, checking the timing. 2. Using a screwdriver, apply force to the automatic tensioner so t...

Page 392: Engine

Marea-marea weekend®™®™ 99 range engine index 10. Page fuel system 1 introduction 1 system management strategies 1 fuel system functional diagram 2 injection system wiring dia- gram 6 injection electronic control unit 8 diagram showing information en- tering/leaving the control unit and sensors/actu...

Page 394: Engine

Engine fuel system marea- marea weekend •fp ™ 99 range 10. Fuel system functional diagram note the 1910 jtd (4 cylinder) engine is illustrated; the diagram for the 2387 jtd version only dif- fers through the presence of the 5th cylinder. 1. Auxiliary electric fuel pump 2. Heater plugs control unit 3...

Page 396: Engine

Engine marea- marea weekend 9 »°9> ™ fuel system 99 range 10. Control of idle speed according to the signals coming from the rpm sensor and the engine coolant temperature sensor, the in- jection control unit operates the pressure regulator and alters the operating times for the injectors to keep the...

Page 398: Engine

Engine fuel system marea- marea weekend © ™ 99 range 6 print n° 506.763/14.

Page 400: Engine

Engine marea- marea weekend @> ™tp> ™ fuel system 99 range 10. Injection electronic control unit the injection electronic control unit processes the signals coming from the various sensors through the application of software algorhythms and controls the operation of the actuators (in particular the ...

Page 402: Engine

Engine marea- marea weekend 9 ™>w> nd fuel system 99 range 10. Timing sensor this sensor is the hall effect type and is fitted on the cylinder head facing the camshaft pulley (exhaust). There is an opening in the pulley which allows the timing sensor to detect and signal the engine timing position t...

Page 404: Engine

Engine fuel system marea- marea weekend 9^9 ™ 99 range engine coolant temperature sen- sor this sensor is fitted on the thermostat and measures the temperature of the engine cool- ant by means of an ntc thermistor with a negative resistance coefficient. The sensor is produced using semiconductor tec...

Page 406: Engine

Engine marea- marea weekend ft "°ft ™ fuel system 99 range 10. Diagram showing information entering/leaving the injection control unit and sensors/actuators 4f010nj01 1. Auxiliary electric fuel pump 2. Climate control compressor 3. Egr solenoid valve 4. Rev counter 5. Engine radiator fan 6. Heater p...

Page 408: Engine

Engine fuel system marea- marea weekend © ™ 99 range brake pedal switch there is a switch (1) on the brake pedal which operates the brake lights; the same switch sends a signal to pins 2-8 of the injection control unit. The "brake pedal pressed" signal is used by the control unit for: understanding ...

Page 410: Engine

Engine fuel system marea- marea weekend ® ™ 99 range 1. Impeller 2. Volumes 3. Inlet port 4. Supply port 5. Rollers 6. Outer seal 7. Excess pressure valve immersed (auxiliary) electric fuel pump assembly and gauge the assembly basically consists of: - a roller type electric pump; - a fuel gauge; - a...

Page 412: Engine

Engine marea- marea weekend ^9 ™ fuel system 99 range 10. ~ i multi-purpose valve the multi-purpose valve is icoated on the fuel tank and carries out the following tasks: - pressurizing the tank - ventilation - seal in case of overturning pressurizing the tank the tank pressure is kept at between 55...

Page 414: Engine

Engine marea- marea weekend ft ™ biieirvimtlons on vehicle '99 range servicing instructions to be followed when dismantling the turbocharger in the case of "major" repairs to the engine (e.G. Overhauling) or when the turbocharger assembly (2- fig.1) is dismantled it is necessary to replace the fille...

Page 416: Engine

Engine fuel system marea- marea weekend ft * » f t ™ 99 range operation at low rotation speeds when the engine is rotating slowly, the exhaust gases possess a small amount of kinetic energy: under these circumstances a traditional turbine would rotate slowly, providing a limited super- charging pres...

Page 418: Engine

Engine marea- marea weekend ft> j » f t ™ fuel system 99 range 10. The recirculation of the exhaust gases is only permitted at medium-low loads, when the air/fuel ratio is very high and the operation of the engine is not adversely affected by the presence of inert gases in place of the air. The reci...

Page 421: Marea-Marea

Marea-marea weekend® to engine '98 range fuel system 10. Page fuel system - introduction 1 - general diagram of fuel system 2 - location of components of fuel system 3 - input/output signals between control unit and sensors/actuators 4 - functional diagram of fuel system 6 - air temperature sensor 7...

Page 423: Engine

Engine marea- marea weekend®™ fuel system '98 range 10. General diagram of fuel system p4f02lj01 1. Battery 2. Relay 3. Clutch pedal switch 4. Brake pedal switch 5. Accelerator potentiometer 6. Speedometer 7. Electronic control unit 8. Engine rpm sensor 9. Coolant temperature sensor 10. Instrumented...

Page 425: Engine

Engine fuel system marea- marea weekend ft™ '98 range 10. Input/output signals between control unit and sensors/actuators 1. Electronic control unit 2. Injection pump 3. Accelerator pedal potentiometer 4. Engine coolant temperature sensor 5. Clutch pedal switch 6. Brake pedal switch 7. Air flowmeter...

Page 427: Engine

Engine marea- marea weekend®™ fuel system '98 range 1 0 . Functional diagram of the fuel system p4f06lj01 1. Borg warner modulating valve 2. Bosch fuel injection pump 3. Instrumented fuel injector 4. Heater plug 5. Egr valve 6. Plug preheating control unit 7. Coolant temperature sensor 8. Engine rpm...

Page 429: Engine

Engine marea- marea weekend® td fuel system '98 range 10. Hot-film air flowmeter this component measures the quantity of air drawn in by the engine. The electrical signal (proportional to the air flow) which the flowmeter gives as an output is sent to the engine control unit. This is used to: - calc...

Page 431: Engine

Engine fuel system matea- marea weekend ® td '98 range 10. Wiring diagram © 6 « i n;;;;7 i cq, - o - o - q, 1 1 -o l - o + 0 -q d— ^h-©-r> • o l > 1 _ _ j q g ^ - - h i ' 1 m l - i q o l i 10 publication no. 506.763/11.

Page 433: Engine

Engine fuel system marea- marea weekend v n> '98 range 10. Control unit pins 55 37 19 1 20 38 1. Fuel flow actuator 2. Fuel flow actuator 3. Engine cut-out solenoid 4. Infocenter 5. Instrumented fuel injector 6. E.G.R. Solenoid 7. Not connected 8. Activation of plug preheating control unit 9. A.C. C...

Page 435: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes 33. A n t i - l o c k b r a k e s (lucas varity e b c 430) c o m p o s i t i o n the varity ebc 430 system is extremely compact (easy to fit), light and reliable. The use of new microhybrid electronic components, the improvement of the mangetic f...

Page 437: Marea • Marea Weekend

Marea • marea weekend braking system anti-lock brakes 33. The wheel speed signals are sent by the active sensors to the electronic control unit. The frequency of these signals provides the controlunit with the corresponding speed, acceleration or deceleration values for the individual wheels. A refe...

Page 439: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes 33. The eight solenoid valves and the electric recovery pump are operated by the electronic control unit ac- cording to the signals from the four rpm sensors. In particular, the pump allows the recovery of brake fluid during the pressure reductio...

Page 441: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes 33. The recommended distance (gap), to obtain the correct signals, between the end of the sensor and the multi-polar ring should be between: 0,17 + 2,02 mm for the front wheels 0,57 -r 1,53 mm for the rear wheels this distance cannot be adjusted,...

Page 443: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes 33. Description of the operation of the anti-lock brakes rest position each branch of the abs ebc 430 system hydraulic circuit is equipped with two two-way solenoid valves; all the solenoid valves are managed by the control unit (1). When the pre...

Page 445: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes 33. Pressure maintenance stage p4f11bd01 1. Electronic control unit 2. Low pressure accumulator (reservoir) 3. Recovery pump motor 4. Recovery pump 5. Restricter 6. Brake pump 7. Brake servo 8. Multi-polar ring 9. Pressurizing solenoid valve 10. ...

Page 447: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes 33. The abs stops working at speeds below 5 kph to allow the wheels to lock completely with the vehicle stationary. Pressure increase stage when the tendency to slip is over, the discharging solenoid valve (10) closes. The system enters the press...

Page 449: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes 33. Eba function (electronic brake apportioning) the introduction of the ebc 430 makes it possible to distribute the brake force between the front and rear axles using a special function of the electronic control unit. With this in mind, the elec...

Page 451: Marea - Marea Weekend

Marea - marea weekend braking system anti-lock brakes wiring diagram for lucas varity ebc 430 system 33. ® 14 25 11 22 2 3 iff 18 17 15 24 21 31 30 29 28 27 r s n r g i r g i r s j 26 25 24 23 22 21 20 r g i r o i r a n r a n r s i r g i r n i 19 18 n n q 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 ^ r ...

Page 454

Copyright by fiat auto s.P.A. Any reproduction of the text or illustrations is prohibited. The information contained in this publication is supplied as a guide and may no longer be up to date as a result of modifications made by the manufacturer, at any time, for reasons of a technical or commercial...

Page 456: Rlliary

Rlliary units marea-marea weekend climate control 99 range case a: the engine management control unit (1) receives the signal for switching on the compressor (a) directly from the climate control unit (2) and the four stage pressure switch (3): if the pressure in the re- frigerant circuit is not cor...

Page 458: Auxiliary Units

Auxiliary units climate control marea-marea weekend 9 9 range 50. The second piece of information is the electric power level available and this is obtained from the battery voltage; if the voltage is higher than 12.8 v then the operation of the heater plugs is enabled and below this value either on...

Page 460: Auxiliary Units

Auxiliary units climate control marea-marea weekend 99 range 50. 1242 16v engine type 1. Compressor 2. Condenser 3. Drier filter 4. Evaporator 5. Expansion valve 6. Pipe between compressor and condenser 7. Pipe between condenser and drier filter 8. Pipe between filter and evaporator 9. Pipe between ...

Page 462: Auxiliary Units

Auxiliary units climate control marea-marea weekend 99 range 50. Scroll compressor (engine 1242) the compressor fitted on this version is the scroll type and has a system which deactivates it when the temperature of the evaporator reaches levels where freezing might take place. The compressor consis...

Page 464: Auxilliary Units

Auxilliary units climate control marea-marea weekend 99 range 50. Saimden sd7v16 compressor (engine 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 redu...

Page 466: Auxiliary Units

Auxiliary units climate control 50. Topping up oil level replacing compressor a the compressor is avaiable as spares pressurized with nitrogen to prevent the intake of dampness and impurities; therefore, when fitting, the plugs for the inlet and outlet connectors must be re- moved slowly with the co...

Page 468: Auxiliary Units

Auxiliary units climate control marea-marea weekend 99 range 50. Compressor removing 1. Position the vehicle on a lift, disconnect the negative battery lead and drain the cli- mate control system, then carry out the following operations in the order given: - disconnect the connector and release it f...

Page 470

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Page 472: Marea-Marea Weekend

Marea-marea weekend ^ n * , electrical equipment 1998 range location of components on vehicle 55. Location of relays and fuses on vehicle 2 5 0 1 5 0 3 0 8 2 3 7 9 4 9 9 310 3. Power fuse box 94. Abs fuse 96. Abs system power fuse 98. Headlamp washer intermittent function 90. Headlamp wiper fuse 122...

Page 474: Marea-Marea Weekend

Marea-marea weekend electrical system '98 range wiring diagrams 55. Page - w i r i n g d i a g r a m s 1 - connector blocks 1 5 copyright fiat auto.

Page 476: ^—H I • 11 In—

Marea-marea weekend® '98 range 16v electrical system wiring diagrams 55. Fuel level gauge and reserve warning light - handbrake on and low brake fluid warning light - speedometer - total mileage counter/trip recorder and reset button - engine coolant temperature gauge - low engine oil pressure warni...

Page 478

Marea-marea weekend® ^ '98 range electrical system wiring diagrams 55. Fiat code system and warning light 11 r cd cd cd cd co \d co i j j i j j iij lh r m i t 13 2 13 cb cb i c } n.D. El. Rr~"~ ti r' y y yi j 15/54 j i lirt'/n i dos ..15/54 1 . Lnt/a ' pos 30 50 lirt s t a z r o h 12 n.D. C —•— c • ...

Page 480

Marea-marea weekend® '98 range 16v electrical system wiring diagrams thermostaticaly-adjusted heater/air conditioner 55. Rxrx c3 cp o o co \d co lij ljj i n j r • r — llllll—i 260 259 207 11 10 310(*) 1 2 4 ( * ) el 8685308787 3 1 14 195 309 an ag 12 ' f r r i f t 'f ^ 3'o 15/54 5'o rt^vtlzp" ar 17 ...

Page 482

Marea-marea weekend®^ '98 range electrical system wiring diagrams versions without air conditioner engine cooling system - coolant temperature gauge - manual heater: car interior ventilation 55. 11 jcttx «t o cd o n i n oo 3 r. £ ljj i ijj h br el 8685308787 tit r br 3 15 1 if -ag—i n • 7 • - 6 5 • ...

Page 485

Electrical system location of components marea-marea weekend \® '98 range 16v versions with air conditioner engine cooling system - coolant temperature gauge key to components 3 power fusebox 4 fuse and relay unit 6 instrument panel 8 front left earth 10 battery earth on engine 10a battery earth on ...

Page 487

Electrical system location of components marea-marea weekend @ » i 6 v '98 range 55. Starter - electronic ignition and fuel injection fuel injection fault warning light key to components p4f511n01 recharging and warning light - low engine oil pressure warning light 3 power fusebox 1 4 2 4 fuse and r...

Page 490

Marea-marea weekend electrical system '98 range connector blocks 55. N 195a n195a n131b p4f551 n03 j 97 zb132 p4f551n04 4 f 2 7 a n copyright fiat auto 1 5.

Page 492

Marea-marea weekend '98 range electrical system connector blocks 55. 123a e n 9 ' n e c o o l i n 9 f a n n i 9 n s p e e d r e l a y g127 nn.D. An n.D. . N n.D. 1 24 conditioner compressor relay mn 127 vnn.D. .Ln127 rv127 127 c o n n e c t i o n b e t w e e n front left c a b l e / c a b l e on rel...

Page 496

Marea-marea weekend '98 range electrical system connector blocks 55 1 95a f u e l nection/ignition electronic control unit (1581) p4f557n02 4f33aw copyright fiat auto 21.

Page 498

Marea-marea weekend '98 range electrical system connector blocks 55. 309 4-stage pressure switch ar 195a s195a 31 0 f u s e p r o t e c t m 9 headlamp washer and air conditioner vn a d vn127 311 electric fan resistor connection n a d . P4f559n03 4 f 3 5 a n copyright fiat auto 2 3.

Page 503

Electrical system location of components marea-marea weekend 55. Starting - electronic injection - recharging and warning light - low engine oil pressure warning light - heater plug warn- ing light - fuel injection fault warning light - fuel preheating (2387 engine) key to components 3 p o w e r fus...

Page 505

Electrical system location of components marea-marea weekend 55. Instrument panel connections (to engine) key to components 3 power fuse box 4 fuse and relay unit 6 instrument panel 8 front left earth 1 0 battery earth on engine 1 0 a battery earth on body shell 11 battery 12 ignition switch 1 3 rig...

Page 508: Marea-Marea Weekend