Page 1 (I V / 1 999) 1 - 27 Fuel system i ^ p t JTD 1 - 21 Operations on vehicle JTD l ^ p | JTD 1 -42 Fuel system ! ^ p | 20v 99 range Copyright by Fiat Auto...
Page 2 - Timing diagrams - Fuel system ELECTRICAL EQUIPMENT - Starting This section contains data for vehicles fitted with the 1581 16v STEP A engine. For anything not dealt with, refer to the information in the previous section 00. Copyright by Fiat Auto...
Page 3: Technical Data
NOTE The data and the curve on this page refer to the 1581 16v engine order no. 46474405 6 0 0 0 7 0 0 0 P 4 F 0 1 F A O l Copyright by Fiat Auto...
Page 4 Technical data Weekend®^ Marea-Marea Engine: cylinder block/crankcase, crankshaft and associated components 98 range OO.io -f\H Ml6v DESCRIPTION Values in mm 10,2 86,352 + 86,362 86,359 - 86,371 86,368 + 86,378 Piston 1,520 - 1,540 Piston ring 1,510 1,530 grooves 3,010 - 3,030 1,470 - 1,490 1,470 - 1,490 3,000...
Page 5 I Hi I Hi I Hi * ^ - H * ^ - H * ^ - H * ^ - H 17,6-19,6 daN 18,5 Internal valve spring Internal valve spring Internal valve spring Internal valve spring Copyright by Fiat Auto...
Page 6 Technical data Marea-Marea Weekend®* Engine: cylinder head assembly and valve gear components 98 range OO.io | j £ g | | Values in mm D E S C R I P T I O N 23,4 + 25,6 daN 33,5 46 - 50 daN 24,5 External valve spring...
Page 7 Twin relay feed for electric fuel pump and injection/ignition control unit BITRON Electric fuel pump MARWALL ESS 291 Lambda sensor NTK 0ZA 334-A1 Fuel filter MARWALL FA 5325 IN Detonation sensor NTK KNE 03 Ignition coils COOPER BAE 920 A Copyright by Fiat Auto...
Page 8 Technical data Marea-Marea Weekend®^ Electrical equipment: starting 98 range 0 0 . 5 5 STARTER MOTOR M. Marelli Type M70R-12V-1,3 kW (with reduction gear) Voltage Nominal power Rotation, pinion side clockwise No. of poles Field coil winding series-parallel Engagement free wheel Operation solenoid End float of armature shaft...
Page 9 1, 8 " 30- 12- 1, 5 - 25- 10- 1 , 2 - 20- 8- 0,9- 15- 6- 0,6- 10- 4- 0,3- 5- 2 - Typical curves for starter motor o- 0^ M. Marelli M70R-1,3/12 (with epicyclic reduction gear) Copyright by Fiat Auto...
Page 11 TIGHTENING TORQUES Cooling system Fuel system Engine @).m>l@t JTD Technical data Typical curves Cylinder block/crankcase and asso- ciated components Cylinder head and valve gear com- ponents Counter-balance shafts Lubrication Cooling system - fuel system Fuel system Supercharging Copyright by Fiat Auto...
Page 12 182 B4.000 • 185 BX N1A 22 • 185 A X Q 1 A 2 3 185 A6.000 185 A6.000 • 185 BX Q1A 24 (A) Versions for specific markets (France) ( • ) Voluntary for Germany Copyright by Fiat Auto...
Page 13: Identification Data
Introduction Marea- Marea Weekend Identification data 98 range A. Name of manufacturer A. Vehicle type identification code and chassis B. Homologation number number C. Vehicle type identification code B. V.I.N. Plate (EEC regulations) D. Chassis manufacture number C. Engine type and number E.
Page 14 NOTE FOR VERSIONS WITH ACCESSORIES: In the presence of special equipment (non standard air conditioning, sun roof, trailer towing device, etc.), the empty weight increases and therefore the carrying capacity may decrease in relation to the maximum permissible loads. Copyright by Fiat Auto...
Page 15 Introduction Marea-Marea Weekend Performance • Fuel consumption 99 range OO.o .dfmmm \^^) rCpl ENGINE TYPE 16v C.A. 5 § g Speed km/h (average load) S o S (185)* (185)* (171)* (185)* (193)* (208)* (*) For Marea Weekend version Marea ^ ^ ^ 3 7 - ^ - * ^ ^ ^ 3 7 - ^ - * Max.
Page 16 Marea Extra-urban Marea Weekend Fuel consumption figures in a c - Marea cordance with directive Combined 9 3 / 1 1 6 / C E Marea Weekend (litres/100 km) Marea CO2 exhaust emissions (g/km) Marea Weekend Copyright by Fiat Auto...
Page 17 Introduction Marea Dimensions 98 range 00.0 Luggage compartment capacity (VDA regulations): 430 d m The height refers to an unladen vehicle Wheel rim Engine types 5l4Jx14-37 1480 1455 1741 1425 2540 4390 ( g i l l s * 1470 1440 6 J x 1 5 - 4 3 1440...
Page 18 1480 1455 1741 1510 2540 1066 4490 6Jx15-43 1470 1440 5 ^ J x 1 4 - 4 3 1470 1440 1741 1510 2540 1066 4490 6Jx15-43 1470 1440 5!4Jx15-46 1435 1741 1505 2540 1066 4490 1480 Copyright Fiat Auto...
Page 19 Introduction Marea-Marea Weekend Capacities 99 range OO.o Description Units • n > Petrol > O.R. 95 • n j Unleaded • (5.6 • ) (7.4 • ) (5.6 • ) (6.7 • ) <& capacity cooling Total system • • 2.75 Petrol engines Petrol engines...
Page 20 1.65 1.65 1.98 TUTELA ZC TUTELA ZC 9 Q 0 9 Q 0 n t h n t h • ( A ) Distilled water ( • ) For versions with air conditioning Engine sump only Copyright by Fiat Auto...
Page 21 Introduction Marea-Marea Weekend Capacities 99 range 00.0 Q u a n t i t y Description Description Units Units ( l ) TUTELA TUTELA 0.003 • • MRM2 without 0.40 —• i l 1 . T~7L a b s TUTELA TUTELA T0P4 T0P4...
Page 22 Introduction Marea-Marea Weekend 99 range Specifications of Fiat Lubricant products 00.0 Name of Description Application product International designation Semi-synthetic SAE 10W40 multigrade engine oil. Temperature SELENIA 20K Exceeds specifications ACEA A3-96/CCMC G5 and API - 25°C - 40°C Mineral or semi-synthetic SAE 15W40 multigrade engine SELENIA oil.
Page 23 Introduction Marea- Marea Weekend Engine 99 range OO.10 SPECIFICATIONS Cycle OTTO 4 stroke Timing TOHC Type of fuel system Integrated electronic injection - ignition ,—, Number of cylinders • • • V—ri-0 Cylinder liner 70.80 Is—il P o l w r n 1 , 1 1 l ^ M Stroke 78.86...
Page 24 Power curves obtained through the CEE method The power curves illustrated are those obtained using overhauled engines which have been run in, with- out a fan and with an exhaust silencer and air filter fitted, at sea level. Copyright Fiat Auto...
Page 25 Technical data Marea-Marea Weekend Engine: cylinder block/crankcase, crankshaft and associated 99 range OO.10 Values in mm DESCRIPTION 19.14-19.20 21.72-21.80 51.705-51.709 51.709-51.713 63.705-63.718 51.713-51.717 Main bearing supports 70.800-70.810 82.000-82.010 0 Cylinder 70.810-70.820 82.010-82.020 liner/bore 70.820-70.830 82.020-82.030 12.5 70.760-70.770 81.952-81.962 70.770-70.780 81.959-81.971 70.780-70.790 81.968-81.978 Piston...
Page 26 Opening at end of 0.250-0.450 0.250-0.500 Q| p piston rings in cylinder M r liner 0.200-0.450 0.250-0.500 l T 0 i Small end bush or 17.939-17.956 22.939-22.972 pin housing 2 Big end bearing 45.128-45.138 51.354-51.366 housing Copyright by Fiat Auto...
Page 27 Technical data Marea-Marea Weekend Engine: cylinder block/crankcase, crankshaft and associated 99 range OO.10 Values in mm DESCRIPTION Gudgeon pin 0.014-0.035 small end 23.007-23.027 20.006-20.012 Small end bush Gudgeon pin o ^ a 0.006-0.020 Small end bush Small end bush 0.035-0.088 Bush housing 47.982-47.988 59.994-60.000...
Page 28 (The arrow shows the direction of rotation of the engine as seen from the timing side) Value (in mm) of offset between connecting rod axis and piston axis D=0.85-1.15 (for 1242 1 6v) D=0.10- 0.60 (for 1998 20v) Copyright Fiat Auto...
Page 29 Technical data Marea-Marea Weekend Engine: cylinder head and valve gear components 99 range OO.10 Values in mm DESCRIPTION Camshaft supports 26.045-26.070 on cylinder head 19.100-19.150 Valve guide bore 9.959-9.989 12.950-12.977 In cylinder head 45°±20' 45°±5' 1 £S 45°±20' 45°±5' Valve seat about 2 Volume of combustion...
Page 30 29.900-30.200 45° 30'±5' Valve 5.974-5.992 6.960-6.975 22.250-22.550 25.900-26.200 45° 30'±5' 0.032-0.065 Valve ® 0.030-0.066 14-13 Valve guide 0.047-0.080 11.08-12.07daN 29.5 21.58-23.54 daN Inner valve spring 22.5 daN 27.7-29.43 daN 42.3 48.46-52.38 daN 24.5 Outer valve spring Copyright by Fiat Auto...
Page 31 Technical data Marea-Marea Weekend Engine: cylinder head and valve gear components range OO.io Values in mm DESCRIPTION 35.000-35.015 48.000-48.015 49.000-49.015 . . . 26.000-26.015 Camshaft bearings 19.250-19.330 17a A Cam lift 1 7 b 0.030-0.070 12-17a 0.030-0.070 0.030-0.070 Camshaft bearings Cylinder head supports radial 0.030-0.070...
Page 32 B.D.C. opens before 32° 42' 40° B.D.C. A • | A txnausi closes after 0° 0° T.D.C. (*) With intervention of phase transformer opening 9° before TDC (**) With intervention of phase transformer closing 31° after BDC Copyright Fiat Auto...
Page 33 Technical data Marea- Marea Weekend Engine: counter balance shaft 99 range OO.10 Values in mm DESCRIPTION through oil pump driven Counter-balance shaft operation gear 19.900 - 20.000 46.989 - 47.000 Ball bearings for counter-balance shaft 19.980 - 19.993 Counter-balance shaft bearings Bearing seats in cylinder 46.975 - 47.000 block/crankcase...
Page 34 1 bar (^^) ( ^ ) when idling Operating pressure 4 bar 4 0 0 Q a t 4 U U U r p m At a temperature of 100°C 11.73-- 12.51 Oil pressure relief valve spring Copyright by Fiat Auto...
Page 35 Technical data Marea-Marea Weekend Engine: cooling system 99 range OO.10 COOLING SYSTEM coolant circulation via coolant circulation via centrifugal pump, radia- centrifugal pump, radia- Cooling circuit tor, expansion tank and tor and two speed fan fan operated by thermal operated by engine con- switch trol unit Water pump operation...
Page 36 Lambda sensor Bosch 0.258.006.071 Bosch 0.258.006.072 Fuel vapour solenoid valve Bosch 0.280.142.330 Bosch 0.280.142.340 Detonation sensor Bosch 0.261.231.007 Bosch 0.261.231.131 Hall effect injection timing sensor Bosch 0.232.101.036 Bosch 0.281.210.124 Top Dead Centre and rpm sensor Bosch 0.261.210.160 Copyright by Fiat Auto...
Page 37 Technical data Marea-Marea Weekend Engine 99 range OO.10 SPECIFICATIONS Diesel 4 stroke Cycle Timing SOHC through 1 counter- Engine balancing balance shaft Direct injection Type of fuel system Turbocharger + intercooler 4 in line 5 in line L—,1 Number of cylinders Nl •...
Page 38 Typical engine curves obtained using the CEE method The power curves illustrated can be obtained with the engine overhauled and run in, without a fan, with a silencer and air filter fitted, at sea level. Copyright Fiat Auto...
Page 39 Technical data Marea-Marea Weekend Engine: cylinder block/crankcase, crankshaft and associated 99 range OO.10 Values in mm DESCRIPTION 21.750 - 22.250 21.720 - 21.800 22.300 - 22.700 21.750 - 22.250 63.691 - 63.732 Main bearing supports 82.000 - 82.010 82.010 - 82.020 «...
Page 40 Opening at end of 0.250 - 0.500 j p piston rings in cylinder liner 0.250 - 0.500 (*) Measured on the 73.8 mm diameter (**) Measured 1.5 mm from the outside edge (1) Measured on the 79 mm diameter Copyright by Fiat Auto...
Page 41 Technical data Marea-Marea Weekend Engine: cylinder block/crankcase, crankshaft and associated range OO.10 Values in mm DESCRIPTION DESCRIPTION ffi~T" ffi~T" S m a S m a " " e n c i D u s n e n c i D u s n 28.939 - 28.972 pin housing pin housing...
Page 42 0.254 - 0.508 ^ jp 10-8 Big end bearings - Main journals 0.030-0.056 0.016-0.070 2.469 - 2.485 2.342 - 2.358 S I H ^ T > 0.127 11-8 Crankshaft end float 0.049 - 0.211 0.059 - 0.221 Copyright by Fiat Auto...
Page 43 Technical data Marea-Marea Weekend Engine: cylinder head and valve gear components range OO.10 Values in mm DESCRIPTION Valve guide bore 13.950 - 13.977 in cylinder head 45° ±20' 45° ±5' 45° ±20' 45°±5' About 2.7 12 Valve seat 26.045 - 26.070 I —...
Page 44 • — ^ - n _ m _ ^ j - i M r - i _ - - j _ i - i — m 23.10 - 23.70 WT-i—^B-Lj-^-*^ -T_r-B 19.25 - 19.30 19.25 - 19.33 Copyright by Fiat Auto...
Page 45 Technical data Marea-Marea Weekend Engine: cylinder head and valve gear components range OO.10 I I I ! -0 • Values in mm DESCRIPTION radial 0 030 0 070 17-12 17-12 axial 8 . 5 4 t t 4 t t Cam lift Cam lift 8 .
Page 46 Technical data Marea-Marea Weekend Engine: cylinder head and valve gear components range OO.10 TIMING DIAGRAMS TIMING ANGLES opens after 6° 0° 1 nlnt i niei closes after 32° 26° opens after 32° 26° txnausx closes after 0° 6° Copyright Fiat Auto...
Page 47 Technical data Marea-Marea Weekend Engine: counter- balance shafts 99 range OO.io Values in mm DESCRIPTION Counter-balance shafts n° Shaft operation through oil pump driven gear 19.900 - 20.000 • 46.989 - 47.00 Ball bearings for counter-balance shaft 19.980 - 19.993 Counter-balance shaft bearings Bearing seats in cylinder 46.975 - 47.000...
Page 48 Full flow filter Insufficient oil pressure sender unit electrical © © 3.43 - 4.9 bar Operating pressure at a temperature of 100°C 6.27 - 7.06 daN Oil pressure relief valve spring Copyright by Fiat Auto...
Page 49 Technical data Marea-Marea Weekend 99 range Engine: lubrication OO.10 Values in mm LUBRICATION forced circulation, via geared pump with cartridge Engine lubrication circuit filter in series Oil pump geared, located in the crankshaft front cover Pump operated by chain driven by crankshaft Oil pressure relief valve incorporated in the crankshaft front cover IHimBl...
Page 50 Pressure for checking calibration of exhaust spring 1 ± 0.1 bar on expansion tank FUEL SYSTEM Firing order 1 - 2 - 4 - 5 - 3 Rotary piston injection pump RADIALJET Nozzle Injector setting pressure « S 1300 bar Copyright by Fiat Auto...
Page 51 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...
Page 52 Air flow meter 0.280.218.019 Fuel pressure sensor 0.281.002.210 0.281.002.209 Engine coolant temperature sensor Timing sensor 0.281.002.213 Top Dead Centre and rpm sensor 0.281.002.214 0.281.002.202 Potentiometer on accelerator pedal Pressure regulator (DVR) Borg Warner - Bitron E.G.R. solenoid valve Copyright by Fiat Auto...
Page 53 Technical data Marea-Marea Weekend Engine: supercharging range OO.10 SUPERCHARGING Turbocharger operated by exhaust gases with waste-gate pressure valve and air/air heat exchanger (intercooler) COOLING SYSTEM IHI VL6 Turbocharger: type Garret GT 15 variable geometry Maximum supercharging pressure 1.05 bar 4A46A01 CROSS SECTION O F TURBOCHARGER Print n°...
Page 54 • D riven disc D riven disc Distance between ^ i f pedal in end of travel position and pedal in rest position mechanical hydraulic Clutch operation 16.05 Clutch operating (3/4") pump Operating 25.4 (1") cylinder Copyright by Fiat Auto...
Page 55 Technical data Marea-Marea Weekend Gearbox and differential 99 range 00.21.27 Type C. 514.5.13 C.510.5.21 GEARBOX spring ring (Porsche type) XiS baulk ring type Synchronizers straight toothed helical Gears toothed 3.909 3.545 2.158 2.238 1.480 1.520 1.121 1.156 Gear ratios 0.897 0.919 4.071 3.909...
Page 56 (350daN) = 0.08 pre-loading ^oycr Clearance between planet/satellite gears adjustment no adjustment is carried out carried out shims Adjustment of clearance between planet/satellite gears 0 . 0 5 ) ™ 0.80 - 1.25 Thickness of shims Copyright by Fiat Auto...
Page 57 Technical data Marea- Marea Weekend Gearbox and differential 99 range 00.21.27 l^p| C. 510.5.21 Type C.530.5.31.01 GEARBOX spring / ^ N (fiTr) • f ring — I I f L P o r s c n e t y p e ) bzT T=I I baulk ring L type...
Page 58 ^ j r exact bearing pre-loading lll!ll(^B^^P^lBi|l( 0.10 - 0.20 ^ojjcy Clearance between planet/satellite gears ® adjustment shims Adjustment of clearance between planet/satellite gears ( ^ 0 . 0 5 ) 1.8 - 2.2 Thickness of shims Copyright by Fiat Auto...
Page 59 Technical data Marea- Marea Weekend Brakes 99 range 00.33 FRONT BRAKES >- 19.80 - 20.10 11.80-12.10 Disc Disc 11.10 18.55 <C^ allowed 10.20 18.20 Brake pads s < allowed P_jw]^0 Caliper Master cvlinder . m v n - n i i 22.225 (7/8") 22.225 (7/8") L T ^ I (pump)
Page 60 — i 10.80 + 11.10 D i s c D i s c 10.10 9.20 allowed Brake S ^ allowed pads Caliper acting on rear wheels Load proportioning valve 0.36 \ S r ^ Ratio (reduction) Copyright by Fiat Auto...
Page 61 Technical data Marea-Marea Weekend Steering 99 range 00.41 ENGINE TYPE Type Rack and pinion power assisted 6 © — T - no. of turns lock to lock Ratio 142±1.5 mm 137±1.5 mm 132±1.5 mm rack travel Turning 10.7 11.4 circle ! <...
Page 62 3 bar for all versions. (*) Speed limit: 80 km/h (•) Special tyres for the Marea version (•) Special tyres for the Marea Weekend version ( A ) For the TAXI version Copyright by Fiat Auto...
Page 63 Technical data Marea- Marea Weekend Wheels 99 range 00.44 unladen vehicle (•) WHEEL GEOMETRY camber (**) - 38' 10» ± 30' caster (**) 2° 51' ± 30' -1 - 1 mm front toe in suspension offset 0° front wheel • camber (**) 0°...
Page 64: Front Suspension
Shock absorbers Type: double acting, telescopic low pressure gas Open (start of damping action) 508 ± 2.5 501 ± 2.5 354 ± 2.5 Closed (metal against metal) 361 ± 2.5 Travel Anti-roll bar Diameter of anti-roll bar Copyright by Fiat Auto...
Page 65 Technical data Marea- Marea Weekend Front suspension 98 range 00.44 CLASSIFICATION OF SPRINGS ACCORDING TO VARIOUS VERSIONS AND ENGINE TYPES ENGINE TYPES VERSIONS VERSIONS Standard Standard with ABS With air conditioning With air conditioning and all options With conditioning, ABS and all options With air conditioning and With ABS (fitted as stan- dard)
Page 66: Rear Suspension
(1) Springs of the same type must be fitted. Shock absorbers double acting, telescopic, gas Type Open (start of damping action) 321 ± 2 Closed (metal against metal) 224 ± 2 Travel Anti-roll bar Diameter of anti-roll bar Copyright by Fiat Auto...
Page 67 Technical data Marea Weekend 99 range Rear suspension 00.44 Rear suspension independent with track control arms anchored to an auxiliary crossmember. Variable flexibility coil springs and anti-roll bar. Gas shock absorbers with low friction coefficient lower bushes. ENGINE TYPE l ^ p ) 20v r | P >...
Page 68: Electrical Equipment
HEATER BOSCH 0.250.202.028 PLUGS ( • ) For vehicles with air conditioning ( A ) TAXI version only (1) Validity also extended to vehicles with air conditioning (2) For vehicles with air conditioning and additional heater Copyright by Fiat Auto...
Page 69 Technical data Marea-Marea Weekend Electrical equipment: starting 99 range 00.55 | ^ p | r | p > STARTER MOTOR BOSCH 0 74,2 M. Marelli 12V - 1.1 kW Type E80-12V-0,9 kW (with reduction gear) Voltage Nominal power Rotation, pinion side clockwise No.
Page 70 Internal splines and shaft bushes Enagement sleeve and intermediate disc TUTELA MR3 (*) Data obtained at an ambient temperature of 20°C. NOTE When overhauling it is not necessary to undercut the insulator between the commutator bar. Copyright by Fiat Auto...
Page 71 Technical data Marea-Marea Weekend Electrical equipment: recharging 99 range 00.55 r^P> 20v (•) l O p ) | | p ) f g p l JTD ( A ) f ^ p t JTD(M) l^P» JTD (•) r ^ j p f JTD ALTERNATOR A115I-14V A127IR-14V...
Page 72 Sensor winding resistance at 20°C 486 + 594 Distance (gap) between sensor and 0.8 + 1.5 crankshaft pulley tooth SPARK PLUGS FIAT RA4 HCX Make and type FIAT DCPR BEKC M 14x 1.25 Thread Electrode gap Copyright by Fiat Auto...
Page 73 Technical data Marea-Marea Weekend Electrical equipment: electronic injection/ignition 99 range 00.55 INTEGRATED ELECTRONIC INJECTION/IGNITION SYSTEM Bosch 0.261.204.271 Make Firing order 1 - 2 - 4 - 5 - 3 IGNITION COIL (1 PER SPARK PLUG) Make Bosch Type 0.221.504.014 Ohmic resistance of primary winding at 20°C 0.,4 Ohmic resistance of secondary winding at 20°C 8500...
Page 74 • 1870007000 Grip for drifts and fitting tools • Drift for fitting hubs and gears on main and layshafts 1870152000 • Tool for fitting main shaft gasket on bell housing (to be used 1870419000 with 1870007000) Copyright by Fiat Auto...
Page 75 Technical data Marea- Marea Weekend • Special tools 99 range 00.A ENGINE TYPE Tool NAME OF TOOL number ®hev • Tool for fitting differential bearing (to be used with 1870469000 1870007000) • Drift for fitting differential housing cover gasket (to be used 1870629000 with 1870007000) •...
Page 76 Crankshaft gear fixing bolt (*) Crankshaft gear fixing bolt (*) • • Auxiliary pulley to crankshaft gear fixing, bolt • • • Gear on camshaft (inlet and/or exhaust) fixing, bolt (*) The bolt should not be lubricated Copyright by Fiat Auto...
Page 77 Technical data Marea-Marea Weekend Tightening torques 99 range Tighten- Tighten- ENGINE TYPE torque torque DESCRIPTION DESCRIPTION DESCRIPTION Thread Thread Thread daNm • • Sensors to cylinder block/crankcase and cylinder head fixing, flanged bolt • • Oil pump to crankcase fixing, bolt Oil pump to crankcase fixing, bolt •...
Page 78 • • Complete injector • Fuel filter to inlet manifold fixing, nut • • Turbocharger to exhaust manifold fixing, nut • Exhaust manifold connector to turbocharger fixing, nut • Filler for oil supply pipe to turbocharger Copyright by Fiat Auto...
Page 79 Technical data Marea- Marea Weekend Tightening torques 99 range Tighten- Tighten- ENGINE TYPE torques torques DESCRIPTION DESCRIPTION Thread Thread daNm daNm ® J T 0 • • Thermostatic valve fixing connector • • Complete jet to cylinder block/crankcase fixing, bolt •...
Page 80 Camshaft housing fixing, bolt • Plate to oil pump casing fixing, bolt • Camshaft housing fixing bolt sealing plug • Pulley fixing bolt (flywheel) • Mounting to engine support fixing, nut • Oil temperature switch tapered Copyright by Fiat Auto...
Page 81 Technical data Marea- Marea Weekend Tightening torques 99 range Tighten- Tighten- ENGINE TYPE torques torques DESCRIPTION DESCRIPTION Thread Thread daNm daNm • Connector on inlet duct for vacuum intake tapered • Inlet manifold fixing, bolt • Valve gear timing stud sealing plugs •...
Page 82 • • Alternator fixing, bolt Alternator fixing, bolt • Tensioner/alternator fixing, bolt • Plate to crankcase fixing, bolt • • Engine support to cylinder block/crankcase Engine support to cylinder block/crankcase fixing, nut fixing, nut Copyright by Fiat Auto...
Page 84 - Injection/ignition SPECIAL TOOLS NOTE - This section contains the variants for the 1747 16v version with a return/ess fuel system. For anything not dealt wi{h, refer to the information in print no. 506.763 and subsequent updates. Copyright by Fiat Auto...
Page 85 NOTES FOR VERSIONS WITH ACCESSORIES: In the presence of special equipment (non standard air conditioning, sun roof, trailer towing device, etc.), the empty weight increases and therefore the carry- ing capacity may decrease in relation to the maximum permissible loads. Copyright by Fiat Auto...
Page 86 Tehnical data Marea- Marea Weekend I P ' Engine: cylinder head and valve gear components OO.10 99 Update TIMING DIAGRAMS | 16v opens before 0° after TDC Inlet Inlet closes after 27° opens before 29° ® ® Exhaust Exhaust closes after 2°...
Page 87 Fuel vapour solenoid valve MARELLI EC1 Top Dead Centre and rpm sensor HITACHI RS - 3 1 4 Detonation sensor NGK KNE 03-A Timing sensor Bosch B.232.101.037 Butterfly casing HITACHI M646 WA (*) Specific versions for German market Copyright by Fiat Auto...
Page 88 Technical data Marea- Marea Weekend • Electrical equipment: electronic injection/ignition 99 Update 00.55 INTEGRATED ELECTRONIC INJECTION/IGNITION SYSTEM Type HITACHI MFI - 1 Firing order 1 - 3 - 4 - 2 COIL (1 PER SPARK PLUG) HITACHI Make GE 215492 Type Ohmic resistance of primary winding at 20°C 0.66...
Page 89 Special tools 99 Update 00.A ENGINE TYPE Tool Tool TOOL NAME TOOL NAME number number ENGINE • 1860955000 Equipment for checking fuel consumption • Connector for discharging petrol pressure 1870684000 • 1870697000 Tool for timing camshaft Copyright by Fiat Auto...
Page 91 Introduction and technical data Marengo 1999 range Contents page INTRODUCTION - Identification data - Weights TECHNICAL DATA Engine - Rear - front suspension Copyright Fiat Auto...
Page 92 185 CX N1A 02 182 B4.000 P4G001A1 - Load carrying capacity 1590 dm DIMENSIONS (mm) Engine type Engine type 1741 1510 2540 1440 1066 4490 1470 W ^ ^ ) TD 7 5 - 1 0 5 Copyright Fiat Auto...
Page 93 Introduction Marengo ® * TD7S-JTD 1999 range Weights OO.o IOp> JTD 105 ENGINES WEIGHTS (values expressed in kg) 1245 1275 ^ ^ ^ ^ ^ ^ 1815 1845 tikk fill + 570 = 1060 1060 Maximum loads permitted on ax Maximum loads permitted on ax 1060 1060...
Page 94 (1) When assembling, fit together springs with the same marking Dampers gas, telescopic, double-acting Type 321 ± 2 Open (start of damping effect) 224 ± 2 Closed (steel against steel) Travel Anti-roll bar Anti-roll bar diameter FRONT SUSPENSION Anti-roll bar Anti-roll bar diameter Copyright Fiat Auto...
Page 96 - Removing-refitting inlet manifold REPLACING WATER PUMP - Removing-refitting water pump REMOVING-REFITTING RADIATOR - Removing-refitting radiator - Procedure for filling engine cooling circuit for versions with heaters - Procedure for filling engine cooling circuit for versions with air condi- tioning Copyright Fiat Auto...
Page 97 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...
Page 98 4. Undo the bolt retaining the relay casing cover and remove it, then unto the nuts fixing the casing to the battery drip tray and place the casing at the side. Copyright Fiat Auto...
Page 99 Engine Marea- Marea Weekend © 99 range Removing- refitting 1. Disconnect the injection cable coupling shown in the diagram. 2. Remove the battery drip tray, undoing the bolts fixing it to the bodyshell. 3. Disconnect the reversing lights switch con- nector and the earth lead.
Page 100 4. Disconnect the vacuum pipe from the brake servo. 5. Disconnect the connector shown in the diagram from the injection/ignition control unit and remove the earth lead from the control unit support. Copyright Fiat Auto...
Page 101 Engine Marea- Marea Weekend & Removing- refitting 99 range 1. Disconnect the fuel supply pipe acting on the rapid attachment. 2. Disconnect the air conditioning system compressor supply and inlet pipes. 3. Disconnect the fuel vapour recovery pipe acting on the rapid attachment, remove the canister soleniod valve opening electrical connection, then remove the entire pipe from the mounting bracket, disconnecting...
Page 102 3. Open the band and disconnect the pipe between the radiator and the tank. 4. Disconnect the air conditioning circuit con- denser rigid inlet pipe. 5. Remove the radiator, complete with fan, undoing the two bolts fixing it to the bodyshell. 4A05HX03 Copyright Fiat Auto...
Page 103 Engine Marea- Marea Weekend © Removing- refitting 99 range 4A06HX01 4A06HX02 Disconnect the coolant pipe from the ex- pansion tank, remove it from the retaining springs and place it at the side. Draw off the power assisted steering fluid from the reservoir. Disconnect the electrical connection for the pressure sensor on the power assisted steering pump, undo the connector for the...
Page 104 5. Disconnect the timing side drivehaft using suit- able leverage at the engagement point; position it at the side and secure it suitably. Copyright Fiat Auto...
Page 105 Engine Marea- Marea Weekend © Amoving- refitting 99 range 1. Position the universal hoook 1860592000, fitted to a hoist, in the special power unit mounting brackets. Using the hoist, then the power unit supporting cables. NOTE The positioning of the hooks in the special power unit mounting brackets is illustrated in the diagrams below.
Page 106 5. Extract the power unit, from the lower part of the engine compartment, suitably ma- noeuvring the hoist and the lift. With the help of a second operator, rest the power unit on a support, making sure that it is in a stable position. Copyright Fiat Auto...
Page 107 Engine Marea- Marea Weekend © Removing- refitting 99 range SEPARATING GEARBOX- DIFFERENTIAL UNIT 1. Disconnect the electrical connections and undo the bolts fixing the starter motor to the gearbox. 2. Undo the bolt shown in the diagram, then remove the starter motor. 3.
Page 108 To refit the engine cooling circuit, refer to the instructions in the section in the "Removing-refitting radiator" chapter. Once the power unit has been positioned, check that the bolts fixing the power unit support to the bodyshell are correctly tightened. Clutch pedal height. Copyright Fiat Auto...
Page 109 Engine Marea- Marea Weekend © 99 range Replacing auxiliary shaft drive belt REMOVING-REFITTING AUXILIARY SHAFT DRIVE BELTS Position the vehicle on a lift, disconnect the negative battery terminal, remove the right front wheel, then proceed as described below: 1. Remove the auxiliary shaft drive belt shield. Check the condition and the tension of the auxiliary shaft drive belts and, in particular, make sure that there are...
Page 110 4. Loosen the alternator drive belt tension, acting on the bolts shown in the diagram and on the rear bolt fixing it to the alterna- tor bracket. Copyright Fiat Auto...
Page 111 Engine Marea- Marea Weekend ©» 99 range Replacing auxilary shaft drive belt 1. Remove the alternator drive belt from the drive pullies and remove it. Fitting 2. Position the alternator drive belt and ten- sion it, acting on the alternator fixing bolts. Using tool 1895762000, check that the new belt tension is between 48 and 60 daN;...
Page 112 (1) from the opposite side is located by the rpm and TDC sensor (3). Operation to be carried out to place the pistons approxi- mately in line with one another. 3. Remove the sealing plugs illustrated in the diagram from the camshaft housing. Copyright Fiat Auto...
Page 113 Engine Marea- Marea Weekend © Replacing auxiliary shaft belt 99 range 1. Disconnect the H.T. leads from the spark plugs and, using a USAG 279 MG spanner or similar tool, remove the spark plugs. 2. Position tools 1860992000 in the seats for the spark plugs for cylinders 1 and 2, tight- ening the tool components (1) by hand to a maximum torque of 0.5 daNm.
Page 114 (1) is opposite the rpm and TDC sensor (3), then undo the fixing bolts and remove it. In addition, unto the bolts for the timing belt lower shield. Copyright Fiat Auto...
Page 115 Engine Marea- Marea Weekend © Replacing timing belt 99 range 1. Disconnect the bands illustrated and undo the bolts fixing the resonator, then discon- nect the oil vapour pipe band and remove the resonator complete with hose. 2. Disconnect the accelerator cable. 3.
Page 116 TDC sensor, then remove the up- per shield. 4. Undo the fixing bolts and remove the lower shield for the timing drive belt. 5. Disconnect the H.T. leads from the spark plugs. 4A19HX04 4A19HX05 Copyright Fiat Auto...
Page 117 Engine Marea- Marea Weekend © Replacing timing belt 99 range Remove the spark plugs using spanner USAG 279 MG or a similar spanner. Remove the two sealing plugs, illustrated in the diagram, from the camshaft housing. 3. Position the tools 1860992000 in the housings for the spark plugs for cylinders 1 and 2, tightening the tool components (1) by hand to a maximum torque of 0.5 daNm.
Page 118 Fitting and tensioning timing drive belt 3. The camshaft drive pulley has slots; to fa- cilitate the correct matching between the pulley teeth and the timing belt, loosen the bolts fixing the actual pulley using tool 1860831000. Copyright Fiat Auto...
Page 119 Engine Marea- Marea Weekend Replacing timing belt 99 range 1. Before fitting the timing belt, make sure that the camshafts are timed and secured using tools 1860985000 and that the pistons are aligned checking the position of the pins for tool 1860992000 as described previously.
Page 120 (1). 4. Undo the bolt fixing the engine oil dipstick retaining bracket to the cylinder head. 5. Disconnect the fuel vapour solenoid valve connection and undo the mounting bracket fixing bolt. Copyright Fiat Auto...
Page 121 Engine Marea- Marea Weekend Removing- refitting cylinder head 99 range 1. Release the injection cables from the lower part of the intake manifold, undoing the mounting bracket fixing bolts. 2. Undo the nuts fixing the first section of the exhaust pipe to the manifold. 3.
Page 122 - not lubricated with oil or dirtied, taking care that the surface of the cylinder head and cylinder block are clean. 3-4. Position the cylinder head and tighten the bolts to a torque of 2 daNm follow- ing the order illustrated. Copyright Fiat Auto...
Page 123 Engine Marea- Marea Weekend © Removing- refitting cylinder head 99 range 1. Tightening bolts fixing cylinder head to cylinder block: STAGE 1: Tighten the bolts to a torque of 3 daNm, following the order illus- trated previously. STAGE 2: Tighten the bolts through 90° using tool 1860942000.
Page 124 2. Undo the nuts fixing the first section of the exhaust pipe to the manifold. 3. Undo the heat shield fastenings and remove 4. Undo the nuts fixing the exhaust manifold and remove it complete with the gasket un- derneath. 4A27HX02 Copyright Fiat Auto...
Page 125 Engine Marea- Marea Weekend >© Removing- refitting intake manifold 99 range REMOVING-REFITTING INTAKE MANI- FOLD 1. Remove the resonator, complete with air intake hose, disconnecting the bands shown and u n - doing the fixing bolts. Also disconnect the oil vapour recovery pipe from the lower part of the resonator.
Page 126 4. Gently extract the intake manifold and re- lease the injection cables from the lower part, acting on the bolts fixing the retaining brackets. 5. Then extract the lower part of the intake manifold. Copyright Fiat Auto...
Page 127 Engine Marea-Marea Weekend Removing- refitting water pump 99 range REMOVING-REFITTING WATER PUMP 1. Positin the vehicle on a lift, disconnect the negative battery lead, then drain the engine coolant, disconnect the hose shown from the lower part of the radiator. Remove the timing drive belt as de- scribed in the previous paragraphs.
Page 128 3. Open the band and disconnect the pipe between the radiator and the tank. 4. Remove the engine cooling fan, undoing the fixing bolts then undo the bolts fixing the radiator to the condenser and to the bodyshell and extract the radiator upwards. Copyright Fiat Auto...
Page 129 Engine Marea- Marea Weekend & ^ Removing- refitting radiator 99 range PROCEDURE FOR REFILLING ENGINE COOLING SYSTEM (version with heater) Total capacity of system: 4.67 litres Method for draining circuit If necessary, the system can be drained as follows: 1. Remove the cap from the expansion tank (3) and open the bleed screw (5) on the radiator, the bleed screw (6) on the heater inlet hose and the bleed screw (7) on the heater outlet hose.
Page 130 8. Coolant supply pipe to car interior heater radiator 9. Coolant by-pass thermostat 10. Coolant supply pipe from thermostat to engine cooling radiator 11. Coolant return pipe from radiator to pump 12. Connecting pipes from radiator to expansion tank 13. Car interior heater radiator Copyright Fiat Auto...
Page 131 Engine Marea- Marea Weekend >©> «* Removing- refitting radiator 99 range PROCEDURE FOR REFILLING ENGINE COOLING SYSTEM (version with air conditioning) Total capacity of system: 4.45 litres Method for draining the circuit The system can, if necessary, be drained as follows: 1.
Page 132 8. Coolant supply pipe to car interior heater radiator 9. Coolant by-pass thermostat 10. Coolant supply pipe from thermostat to engine cooling radiator 11. Coolant return pipe from radiator to pump 12. Connecting pipes from radiator to expansion tank 13. Car interior heater radiator Copyright Fiat Auto...
Page 134: Fuel System
- Multifunction valve - Injection management - Vehicle speed sensor - Ignition management - Safety and ventilation valve - Fiat CODE ignition immobiliser man- - Injectors agement - Inertia safety switch - Radiator fan management - Ignition coils - Engine idle control...
Page 135 ECU. The resulting data output is used to control system actuators, in other words the devices used to operate the engine, namely: 1. injectors; 2. ignition coils; 3. solenoids of various types; 4. electric fuel pump; 5. engine idle speed actuator; 6. control relays. Copyright Fiat Auto...
Page 136 6. Battery Fuel vapour cut-off solenoid 7. Ignition switch Active carbon trap filter 8. Injection system relay Air conditioner compressor 9. FIAT CODE control unit Lambda probe 10. Inertia switch 3 1 . Catalytic converter 11. Vehicle speed sensor Injection - ignition control unit 12.
Page 137 System operating strategies are essentially as follows: -injection management; -ignition management; -Fiat CODE immobiliser function management; -radiator fan management -engine idle control; -fuel vapour recirculation management; -test management...
Page 138 Engine Marea-Marea Weekend®^ Fuel system 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 proportions are no longer stoichiometric.
Page 139 Once start-up has taken place, the factor is gradually reduced to zero within a given time period, which is in inverse proportion to engine temperature. k : enrichment factor t : time a : decrease proportional to engine temperature ON: engine cranked OFF: engine running P4F05IJ01 Copyright Fiat Auto...
Page 140 Engine Marea-Marea Weekend Fuel system 1998 range 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 in the rolling resistance of internal engine components which also serves to ex- acerbate matters.
Page 141 At very high speeds, cut-off takes place even when the throttle valve is not fully closed but pressure in the intake manifold is particularly low (partial cut-off). Version with manual gearbox 1. 1350 rpm 2. 1270 rpm Version with automatic transmission 1. 1750 rpm 2. 1650 rpm A. entering cut-off B. leaving cut-off Copyright Fiat Auto...
Page 142 Engine Marea-Marea Weekend Fuel system 1998 range 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 sensor.
Page 143 1 -4 in correspondence to falling front of 20th tooth. Once the ECU (see following page) has received the correct T.D.C. signal configuration, it establishes the point at which conduction (supply) to primary circuits of coils (6) begins through internal power module (5). Copyright Fiat Auto...
Page 144 Engine Marea-Marea Weekend®^ Fuel system 1998 range 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 conduction time the H.T. coil needs in order to store sufficient ener- gy is also defined by DWELL management strategies.
Page 145 1. Rpm and TDC sensor 7. Injection system relay 2. Crankshaft pulley with phonic wheel 8. Electronic injection-ignition control unit 3. Battery 9. Injection-ignition system fuse 4. Ignition switch 10. Injection-ignition control unit fuse 5. Spark plugs 6. Ignition coils Copyright Fiat Auto...
Page 146 When the key is turned to MAR, the following operations take place in sequence: 1 - the engine control unit (whose memory contains a secret code) sends the FIAT CODE a request de- manding that a secret code be sent to de-activate the function lock: 2 - the FIAT CODE control unit responds by sending the secret code only after receiving a recognition code sent by the ignition key;...
Page 147 If sensors or actuators are found to be faulty, signal reconstruction strategies are immediately activated (recovery) so that the engine is able to operate at an acceptable level without affecting function. The car can then be driven to a service point for the necessary repairs. Copyright Fiat Auto...
Page 148 Engine Marea-Marea Weekend ® Fuel system 1998 range 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); 2. compressor activation is enabled via pin 4 1 , when certain pre-established conditions are satisfied; 3.
Page 149 14. Heating/ventilation system 1. Electronic control unit 2. Speedometer sensor 15. Engine coolant temperature sensor 3. FIAT CODE control unit 16. Intake air pressure and temperature sensor 4. Rev counter 17. Butterfly valve position sensor 5. Engine idle speed actuator 18.
Page 150 Engine Marea-Marea Weekend® Fuel system 1998 range 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. 7. Engine idle speed actuator 1.
Page 151 The electric fuel pump is enclosed in a basket. This also houses the fuel pressure regulator, fuel level gauge and fuel filter. The system is also fitted with an inertia switch. This cuts off fuel flow from the electric fuel pump in the case of vehicle impact. Copyright Fiat Auto...
Page 152 Engine Marea-Marea Weekend ® Fuel system 1998 range FUEL EVAPORATION CONTROL CIRCUIT DIAGRAM P4F18IJ01 1. Fuel vapour cut-off valve 5. Reservoir 2. Active carbon trap filter 6. Fuel vapour intake fitting in intake mani- fold 3. Safety and ventilation valve 7.
Page 153 (3) through pipe (2). This contains a flame trap (1) which prevents combustion caused by flame flashing back from throttle body (4). With the throttle closed (engine idling), the vacuum in the intake manifold takes up gas (in limited quantities) directly through pipe (5) and calibrated hole (6). Copyright Fiat Auto...
Page 154 Engine Marea-Marea Weekend ® Fuel system 1998 range INJECTION-IGNITION SYSTEM WIRING DIAGRAM P4FZ0IJ01 Publication 506.763/09...
Page 155 18. Ignition coils 19. Fuel vapour cut-off solenoid 20. Injectors 21. Injection - ignition system failure warning light 22. FIAT CODE control unit 23. Speedometer sensor (vehicle speed) 24. Pressure switch (four stage) 25. Engine idle speed actuator (step motor) 26.
Page 156 Engine Marea-Marea Weekend®^ Fuel system 1998 range ENGINE EXHAUST ASSEMBLY DIAGRAM 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. The lambda probe readings allow the electronic control unit to correct the concentration continually to maintain the air/fuel ratio constant.
Page 157 20 Lambda probe 9 Diagnostic socket 21 Detonation sensor 10 Battery 22 Spark plugs 11 Earth on negative battery lead 23 Fuel vapour cut-off solenoid 12 Connection between injection earth and 24 Carbon filter car body earth Copyright Fiat Auto...
Page 158 Engine Marea-Marea Weekend® Fuel system 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 and lift lid.
Page 159 Data acquisition and coding section This consists of a set of electronic components (A/D converters) designed to receive data in the form of analogue electrical signals. Inside, the signals are converted into digital signals, processed and stored. Copyright Fiat Auto...
Page 160 One of its functions is to receive from the RAM STAND-BY recordings of anomalies that have arisen during engine operation and send these through the diagnostic socket to a Fiat-Lancia Tester. A Fi- at-Lancia Tester must be used in active diagnosis in order to delete the anomalies.
Page 161 Before replacing an ECU as a result of testing, ensure it is really faulty because when a new ECU is activated, the secret Fiat CODE system code is memorised and this makes the unit completely unusable on other vehicles.
Page 162 Rpm sensor (positive) Lambda probe (negative) Earth for coolant temperature, air pres- Not connected sure/temperature and throttle valve po- FIAT CODE control unit sition sensors. Radiator fan high speed control (ver- Inlet air temperature sions with air conditioner) Knock sensor (positive)
Page 163 1 -4 is located at 114° before TDC. 1. Sensor 2. Winding 3. Permanent magnet 4. Sensor connector 5. Output signal 6. Signal corresonding to the two missing teeth 7. Crankshaft pulley with phonic wheel Copyright Fiat Auto...
Page 164 Engine Marea-Marea Weekend ® Fuel system 1998 range 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 pins.
Page 165 Pin 1 - Earth Pin 2 - Signal Pin 3 - Shielding The numbers in boxes indicate the corre- sponding control unit pins. Removing - refitting Disconnect electrical connection, unscrew screw retaining the knock sensor and re- move. Copyright Fiat Auto...
Page 166 Engine Weekend©^ Marea-Marea Fuel system 1998 range 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 fastened to the intake manifold by four screws.
Page 167 The potentiometer is linear (single-ramp): its main specifications are as follows: Effective electrical angle: 90° ± 2° Total mechanical travel: 110° ± 8° Temperature service range: -30°C - +125°C Copyright Fiat Auto...
Page 168 Engine Marea-Marea Weekend^i Fuel system 1998 range 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 pins A and B to check fixed resistance is...
Page 169 Removing-refitting Disconnect electrical connection and remove the sensor. Tightening torque 2.2 daNm. Wiring connector Connection to coolant temperature gauge The numbers in boxes indicate the corre- on instrument panel sponding control unit pins. Copyright Fiat Auto...
Page 170 Engine Marea-Marea Weekend^ Fuel system 1998 range 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 - An electric step motor with two windings in the stator and a rotor that contains a certain number of perma- nent magnet pairs.
Page 171 - check condition of thoroid seal and remove any impurities from the case seat; - refit the actuator, checking that the plunger fits easily without forcing. Tightening torque of step motor screws 0.35 - 0.45 da Nm. Wiring connector The numbers in boxes indicate the corre- sponding control unit pins Copyright Fiat Auto...
Page 172 Engine Marea-Marea Weekend^ Fuel system 1998 range INTAKE AIR PRESSURE AND TEMPERA- TURE SENSOR (T-PRT 03) The intake air pressure and temperature sen- sor is an integral component. It measures air pressure and temperature inside the intake manifold. The injection control unit needs both items of information to establish the amount of air taken up by the engine.
Page 173 Disconnect electrical connection to the pump and fuel level sender unit. Disconnect the fuel delivery line. Unscrew the lock-ring retaining the electric pump to the tank using tool 1860893000 and one box wrench. Disconnect fuel pump assembly. P4F39IJ03 Copyright Fiat Auto...
Page 174 Engine Weekend©^ Marea-Marea Fuel system 1998 range 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.
Page 175 Fuel vapour recirculation self-adaption is in- hibited. Mixture self-adaption is inhibited. Checking resistance Solenoid resistance may be measured by dis- connecting the connector and connecting an ohmmeter as shown in the figure. Resistance: 17.5 - 23.5 ohm at 20 C Copyright Fiat Auto...
Page 176 Engine Marea-Marea Weekend © Fuel system 1998 range 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 filter; - ventilates the tank if a vacuum builds up inside.
Page 177 0.13 - 0.18 bar, excess fuel vapours are vented to the outside (pressure-relief func- tion). - If, on the other hand, a vacuum builds up inside the tank, equivalent to 0.020 - 0.030 bar, air is taken into the tank (ventilation function). Copyright Fiat Auto...
Page 178 Engine Marea-Marea Weekend^** Fuel system 1998 range 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 jets at a differential pressure of 3 bars leave the injector and are immediately nebulised to form two propogation cones.
Page 179 Components of inertia s w i t c h 1. Inertia switch assembly 2. Sheath 3. Button 4. Upper end 5. Fitting end 6. Permanent magnet 7. Permanent magnet seat 8. Steel ball C= Common terminal N.C. Normally closed N.A. Normally open Copyright Fiat Auto...
Page 180 Engine Marea-Marea Weekend &t iev Fuel system 1998 range 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) carries both windings.
Page 181 If circuit is broken, or short-circuit to earth, charge time is assumed to be dependent up- on battery voltage. Removing refitting 1. Disconnect HT leads from spark plugs. 2. Unscrew the bolts indicated and remove the ignition coils Copyright Fiat Auto...
Page 182 Engine Marea-Marea Weekend Fuel system 1998 range 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. To obtain an optimum mixture, the quantity of fuel injected must be as close as possible to a theoretical quantity that could be fully burnt for a given amount of air taken in by the engine.
Page 183 Heater resistance = 4.3 - 4.7 ohm Recovery Lambda data are ignored (open loop). Wiring connector The numbers in boxes indicate correspond- ing control unit pins. Copyright Fiat Auto...
Page 184 Engine Weekend©*^ Marea-Marea Fuel system 1998 range 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.
Page 185 Then tighten nut (1) to lock. P4F51IJ01 REMOVING-REFITTING FUEL MANI- FOLD AND INJECTORS Disconnect the first section of the oil dipstick mount and the oil filler pipe, then disconnect the injector lead coupling (1). P4F51IJ02 Copyright Fiat Auto...
Page 186 Engine Marea-Marea Weekend^i Fuel system 1998 range 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 remove.
Page 187 Undo the ring nut fixing the electric pump to the tank using tool 1860893000 to- gether with a polygonal spanner. Undo the plug and remove the boot for the fuel filler from its housing. Copyright by Fiat Auto...
Page 188 Engine Marea-Marea Weekend^i Fuel system 1998 range 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 in order to support it during removing-re- fitting operations.
Page 189 2. Gradually lower the hydraulic jack. Check that the tank is properly balanced, then disconnect the fuel vapour recovery pipe. 3. If necessary, also disconnect breather pipe (2) on the tank. 4. Fuel tank. P4F56IJ04 Copyright Fiat Auto...
Page 190 Engine Marea-Marea Weekend ^ i Fuel system 1998 range REMOVING-REFITTING ACCELERATOR CABLE 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 throttle valve control lever (1) and disconnect the ac- celerator control cable.
Page 191 - the valve gear timing; - the engine compression Pollutant emissions tolerance figures table HC (p.p.m.) CO (%) Upstream of the catalyzer 0,4 - 1 > 12 ^ 0,35 Downstream of the catalyzer «c 90 3s 13 Copyright by Fiat Auto...
Page 192 Engine @* i* Marea-Marea Weekend Fuel system 1998 range 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 tail-pipe shape will not allow the probe to be fully introduced, add an extension pipe to ensure a seal in the joint area.
Page 193 Select fuel pump test when in active test mode; the pressure gauge should show a pressure increase of up to 4 bars, disconnect device 1860955000 from fuel manifold and refit bracket (1). Copyright Fiat Auto...
Page 194 Engine Weekend©^ Marea-Marea Fuel system 1998 range 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 (2), which must be connected to the fuel manifold via fitting (1).
Page 195 - check that the readings correspond to specifications in the "Introduction and technical data" section. Copyright Fiat Auto...
Page 196 Engine Weekend @> Marea-Marea Fuel system 1998 range 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 output with a stored signal (recovery) so that the engine can continue to operate.
Page 197 Ignition coil load time (Dwell) Butterfly valve opening angle Petrol vapour solenoid Battery voltage Start-up counter Number of engine idle speed actuator open/¬ Engine load close steps Fiat CODE Advance List of errors RPM sensor Signal absent Throttle potentiometer A.C.-D.C. Absolute pressure sensor A.C.-D.C.
Page 198 Excessive coolant temperature warning light Warning light activation for 10 s Engine idle speed actuator Activation for 32 forward/backward steps Fiat CODE Recovery procedure to allow engine start-up Radiator fan Activation for 10 s at both high and low speed Publication 506.763/09...
Page 199 - Input/output signals between control unit and sensors/actuators - Functional diagram of fuel system - Air temperature sensor - Engine coolant temperature sensor - Hot-film air flowmeter - Wiring diagram - Control unit pins Copyright Fiat Auto...
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-...
Page 201 This section only covers the parts of the 2387 TD engine fuel system which are different in relation to the previous version. For aspects not covered in the following pages, see the descriptions give in the "Fuel system of 2387 TD" in the basic edition, contained in volume 1. Copyright Fiat Auto...
Page 202 Engine Marea- Marea Weekend Fuel s y s t e m '98 range GENERAL DIAGRAM OF FUEL SYSTEM P 4 F 0 2 U 0 1 10. Instrumented fuel injector 1. Battery 11. Heater plugs 2. Relay 3. Clutch pedal switch 12.
Page 203 10. Borg Warner modulating valve 4. Electronic control unit 11. Bosch fuel injection pump 5. Diagnostic socket 12. Flowmeter 6. Engine rpm sensor 13. Plug preheating control unit 7. Coolant temperature sensor 14. Intake air temperature sensor Copyright Fiat Auto...
Page 204 6. Brake pedal switch 16. Heater plugs warning light 7. Air flowmeter 17. Plug preheating control unit 8. Instrumented fuel injector 18. Fiat CODE control unit 9. Speedometer sensor 19. Battery 10. Engine rpm sensor 20. Intake air temperature sensor Publication 506.763/11...
Page 205 The control unit also has the function of blocking engine starting (Fiat CODE). This function is carried out by a specific control unit (Fiat CODE) (18), which can dialogue with the electronic control unit (1), and an electronic key with a special transmitter for sending a recognition code.
Page 206 Engine Marea- Marea Weekend & r Fuel system '98 range FUNCTIONAL DIAGRAM OF THE FUEL SYSTEM 1. Borg Warner modulating valve 12. Accelerator potentiometer 13. Speedometer 2. Bosch fuel injection pump 3. Instrumented fuel injector 14. Heater plug warning lamp 15.
Page 207 2. NTC for instrument panel gauge °C °C 512-602 15970 1150 The tables opposite give the resistance values 9620 184-208 which the NTC elements can assume in ac- 5975 76-88 cordance with the coolant temperature. 3816 2500 2044 1679 Copyright Fiat Auto...
Page 208 Engine Marea- Marea Weekend @ W D Fuel system '98 range 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: - calculate the quantity of fuel to be injected, so as to obtain the maximum fuel flow rate while main- taining an acceptible level of smoke in the exhaust;...
Page 209 The hot element consists of platinum. For the same area, film technology offers shorter response times than hot wire. In addition, having a larger area than wire, it has greater immunity to inorganic contami- nation. Copyright Fiat Auto...
Page 210 Engine Marea- Marea Weekend Fuel system '98 range WIRING DIAGRAM a i d > <6 « i — - I — o I q;;;;cJ }: -I—Q - 0 - 0 T 1 E : : : T O t3 ® ! L r i ;...
Page 211 21. Plug preheating warning light 22. Rev counter 23. Speedometer 24. Speedometer sensor 25. Air conditioner compressor relay 26. Air conditioner compressor 27. Three-stage pressure switch 28. Anti-frost thermostat 29. Air temperature sensor Location of diagnostic socket P4F21FJ01 Copyright Fiat Auto...
Page 212 Engine Marea- Marea Weekend ft '98 range Fuel system CONTROL UNIT PINS " l J ^ y k - d — i r a D D D O D D n n c x i D D n n i x i D raj •rzr 55 37 19 1 20 38...
Page 213 Engine exhaust diagram MANAGEMENT STRATEGIES Anti-evaporation circuit diagram Anti-evaporation system compo- Management of the injection nents Management of the Fiat CODE Diagram showing recirculation of anti-theft function exhaust gases coming from the en- Management of the ignition gine crankcase (blowby)
Page 214 Removing-refitting ENGINE RPM AND TDC SENSOR Removing-refitting Checking the gap COPYRIGHT by Fiat Auto S.p.A. Any reproduction of the text and illustrations is prohibited. The information contained in this publication is provided as a guide and may no longer be...
Page 215 NOTE The BOSCH M1.5.5 injection/ignition system does not require any adjustments as it is the self- regulating type. NOTE The numbers in the drawings and the diagrams indicate the corresponding pins for the engine control unit (number/A for connector A, number/B for connector B). Copyright by Fiat Auto...
Page 216 Engine Marea- Marea Weekend @» Fuel system 99 range BOSCH M1.5.5 INJECTION/IGNITION SYSTEM FUNCTIONAL DIAGRAM 1. Engine control unit 17. System failure bulb 2. Battery 18. Speedometer 3. Ignition switch 19. Injectors 4. Engine control system relay 20. Spark plugs 5.
Page 217 28. Engine idle adjustment actuator and butterfly 14. CODE control unit position sensor 15. Diagnostic equipment connection 29. Engine rpm and TDC sensor 16. Rev counter 30. Absolute pressure and air temperature sensor 17. System failure light Copyright by Fiat Auto...
Page 218 Engine Marea- Marea Weekend Fuel system 99 range 1. Engine control unit 22. Charcoal filter solenoid valve 2. Battery 24. Lambda sensor 4. Engine control system relay 25. Power assisted steering sensor 5. Electric fuel pump relay 26. Coolant temperature sensor 6.
Page 219 - using a particular strategy, the control unit is capable, by failing to operate a certain injector, of evaluat- ing the consequent variation in speed (not noticeable by the driver), of recognizing to which cylinder the injector not operated belongs and, consequently, of determining the correct cylinder sequencing (software timing). Copyright by Fiat Auto...
Page 220 Engine Marea- Marea Weekend Fuel system 99 range In particular, the signals are made up as follows. There are sixty teeth on the flywheel, two of which have been removed to create a space: the angle be- tween two consecutive teeth is therefore 6 degrees: The point of synchronism is recognized at the end of the first tooth following the two missing teeth: the flywheel is fitted so that as this tooth passes the pair of cylinders 1 -4 is 17 teeth before TDC.
Page 221 If the control unit is replaced, a road test must be carried out where the engine is allowed to reach oper- ating temperature and the control unit intervenes in the self-adjustment mode (especially during idling stops). Copyright by Fiat Auto...
Page 222 Engine Marea- Marea Weekend © Fuel system 99 range Starting and operation when cold During cold starting the injection is managed simultaneously (full-group), i.e. not phased: this situation persists until a certain coolant temperature is reached (about 0°C), after which the management becomes phased.
Page 223 1. the engine control unit (whose memory contains a secret code) sends the FIAT CODE control unit a request to send the secret code to deactivate the immobilizer function; 2. the FIAT CODE control unit responds by only sending the secret code after having, in turn, received the recognition code transmitted by the ignition key;...
Page 224 Engine Marea- Marea Weekend Fuel system 99 range MANAGEMENT OF THE IGNITION The management of the ignition mainly consists of determining the desired ignition advance according to the engine operating conditions and implementing it by operating the power transistor, located inside the control unit.
Page 225 (for example, the use of a low octane rating fuel). The strategy is capable of restoring the advance to the value memorized if the conditions which caused the reduction disappear. Copyright by Fiat Auto...
Page 226 Engine Marea- Marea Weekend & Fuel system 99 range MANAGEMENT OF THE ENGINE IDLE SPEED CONTROL The general objective of the strategy is to keep the engine speed around the value memorized (engine warm: 800 rpm); the position of the butterfly depends on the engine conditions and speed and the vehicle speed.
Page 227 - in high engine power requirement conditions (fierce acceleration); - during vehicle take-off; - as long as the following critical conditions exist: - temperature of the engine coolant above a pre-set level (engine overheated); - engine speed below 700 rpm Copyright by Fiat Auto...
Page 228 Engine Marea- Marea Weekend Fuel system 99 range MANAGEMENT OF THE RADIATOR FAN NOTE Since the temperature of the coo/ant is measured by the sensor there is no longer a thermal con- tact on the radiator. The engine control unit controls the engagement of the radiator fan according to the temperature of the coolant and whether or not there is a climate control system.
Page 229 - activation of some actuators (active diagnosis). Recovery strategy If a fault is detected with the sensors/actuators, the control unit, where possible, replaces the missing data, reconstructing it using software (recovery) to allow the operation of the engine. Copyright by Fiat Auto...
Page 230 Engine Marea- Marea Weekend ft Fuel system 99 range ELECTRICAL/ELECTRONIC CIRCUIT Wiring The system has two distinct sets of wiring for the control unit connectors: the engine side wiring (B) connects the components fitted on the engine to the engine control unit, the vehi- cle side wiring (A), on the other hand, con- nects the other components to the control unit and constitutes the interface with the vehicle...
Page 231 34. Four stage thermostat signal (if fitted) 35. Operation of idle speed actuator 35. Four stage thermostat signal (if fitted) 36. N.c. 36. N.c. 37. N.c. 37. N.c. 38. Operation of coil for cylinders 1 -4 38. N.c. Copyright by Fiat Auto...
Page 232 Engine Marea- Marea Weekend & Fuel system 99 range BOSCH M1.5.5 SYSTEM WIRING DIAGRAM Connector A (vehicle side) 1 2 3 4 5 t 9 1 0 1 1 1 2 1 3 H15 IU7 II 1 9 igHg(iHilfiiimHi)lj)li)li)l»li)fliJltH) ' 1 1 r.
Page 233 12. Air conditioning control unit (on button) 13. Four stage pressure switch 14. Compressor relay A. 30Afuse B. 40Afuse C. 40Afuse D. 7.5A fuse E. 7.5A fuse F. 7.5A fuse G. 7.5A fuse H. 15Afuse L. 15A fuse Copyright by Fiat Auto...
Page 234 Engine Marea- Marea Weekend © Fuel system 99 range BOSCH Ml.5.5 SYSTEM WIRING DIAGRAM Connector B (engine side) 1 2 3 4 3 7 8 9 1 1 1 II I! 1 3 1 4 1 5 Ii 1 7 II 1 9 it r^n——...
Page 235 3. Detonation sensor 4. Coolant temperature sensor 5. Engine idle adjustment actuator/butterfly position sensor 6. Absolute pressure and air temperature sensor 7. Front cable connection 8. Lambda sensor 9. Engine rpm sensor 10. Coil 11. Injector section Copyright by Fiat Auto...
Page 236 Engine Marea- Marea Weekend Fuel system 99 range LOCATION OF FUSES AND RELAYS NOTE For more information, see Group 55-E/ectricai equipment Main fuses (maxi-fuse) A. System fuse B. Ignition switch fuse Print n° 506.763/14...
Page 237 (gap). Wiring connector The sensor resistance can be measured by dis- connecting the connector and connecting an ohmmeter to the sensor Resistance: 9600+10% ohm at 20°C Copyright by Fiat Auto...
Page 238 Engine Marea- Marea Weekend Fuel system 99 range LAMBDA SENSOR The Lambda sensor measures the oxygen content of the exhaust gases: it is fitted on the exhaust pipe upstream of the catalytic silencer. The sensor output signal is sent to the control unit for feed back correction of the mixture strength.
Page 239 590-560 6300-5700 obtaining temperature information 430-400 4000-3600 315-300 2600-2400 235-225 2100-1950 137-133 1750-1600 The table illustrates the sensor specifications which can be measured by disconnecting the connector and connecting an ohmmeter as il- lustrated. Connector wiring Copyright by Fiat Auto...
Page 240 Engine Marea- Marea Weekend & Fuel system 99 range INTAKE AIR TEMPERATURE AND PRES- SURE SENSOR The intake air temperature and pressure sensor is an integrated component which has the task of measuring the pressure and the temperature of the air inside the inlet manifold. Both pieces of information are used by the injection control unit in defining the quantity of air drawn in by the engine;...
Page 241 When engine knocking, cylinder block/crankcase vibrations of a particular fre- quency are produced and they are transformed by the sensor into a voltage signal proportional to their intensity. i_r—L 2 B - Connector wiring Copyright by Fiat Auto...
Page 242 Engine Marea- Marea Weekend Fuel system 99 range IGNITION COILS The ignition circuit is the inductive discharge static advance type, where the high tension is supplied by two twin outlet coils fitted laterally to the cylinder head. The coils used are the closed magnetic circuit type, with windings in a plastic container im- mersed in epoxide resin.
Page 243 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 position sensor 5. Butterfly casing 6. Inlet manifold Copyright by Fiat Auto...
Page 244 Engine Marea- Marea Weekend Fuel system 99 range BUTTERFLY CASING The butterfly casing has the task of metering the quantity of air drawn in by the engine (and therefore the power developed) according to the driver's request via the accelerator. The butterfly casing is fixed to the inlet mani- fold: the butterfly is opened via a lever through a gradual opening law (small butterfly opening...
Page 245 - Returnless type fuel manifold complete with injectors FUEL CIRCUIT DIAGRAM 4F031PJ01 1. Air bleed connector 2. Injector manifold 3. Supply pipe 4. Tank filler pipe 5. Drip tray complete with pump, filter, pressure regulator and gauge 6. Fuel tank Copyright by Fiat Auto...
Page 246 Engine Marea- Marea Weekend ® 99 range Fuel system FUEL DRIP TRAY ASSEMBLY Electric fuel pump The pump is housed inside the fuel tank on a special drip tray which also supports the gauge and is equipped with a filter on the pump inlet. The pressure regulator is also fitted on the pump supply.
Page 247 Connector wiring The injector resistance can be measured by disconnecting the connector and connecting an ohmmeter as illustrated in the diagram. + — 1 7 B 1 6 B 4F033PJ03 Resistance value: 14.5 5%±ohm. 4F033PJ04 Copyright by Fiat Auto...
Page 248 Engine Marea- Marea Weekend 99 range Fuel system INERTIA SAFETY SWITCH The inertia switch has the task of cutting off the electrical supply for the electric fuel pump if the vehicle suffers violent deceleration (im- pacts) to prevent the escape of fuel in case the fuel manifold or the supply pipe is damaged with a consequent risk of fire.
Page 249 As a result, the high tension leads should not be disconnected, under any circumstances, with the engine running: when carrying out tests, the silencer must be replaced with a suitable length of pipe. Copyright by Fiat Auto...
Page 250 Engine Marea- Marea Weekend © Fuel system r a n g e ENGINE EXHAUST ASSEMBLY DIAGRAM 4F036PJO1 1. Lambda sensor 2. Exhaust manifold 3. Catalytic silencer 4. Silencer 5. CO socket Print n° 506.763/14...
Page 251 1. Vapour supply pipe to the butterfly casing 5. Safety and ventilation valve 2. Charcoal filter solenoid valve 6. Multi-purpose valve 3. Charcoal filter 7. Tank 4. Vapour supply pipe from the tank to the 8. Injection/ignition control unit charcoal filter Copyright by Fiat Auto...
Page 252 Engine Marea- Marea Weekend Fuel system 99 range ANTI-EVAPORATION SYSTEM COMPONENTS Multi-purpose valve This valve is used to carry out various functions, namely: - preventing the flow of liquid fuel, if the tank is too full or if there is an accident during which the vehicle overturns.
Page 253 There are also two springs (7) which allow the expansion of the mass of granules when the pressure increases. Copyright by Fiat Auto...
Page 254 Engine Marea- Marea Weekend Fuel system 99 range Charcoal filter solenoid valve The function of this valve is to control the quantity of fuel vapours drawn in by the active charcoal filtr and directed to the inlet manifold which is achieved by means of the injec- tion/ignition electronic control unit.
Page 255 6. In the same conditions, check that the HC concentration is below 500 p.p.m. 7. If these figures are not obtained, proceed with tuning the engine, in particular checking the: - valve gear timing; - engine compression. Copyright by Fiat Auto...
Page 256 Engine Marea- Marea Weekend Fuel system range 4F042PJ01 Table summarizing pollutant emission tolerance values CO (%) HC (p.p.m.) Upstream of the catalyzer 0.4 - 1 « S 500 ^ 12 Downstream of the catalyzer *S 0,35 s S 90 ^ 13 Checking exhaust concentration of CO and HC The concentration of carbon monoxide (CO) and unburnt hydrocarbons (HC) at the exhaust is measured by inserting a suitably calibrated tester probe at least 30 cm into the end of the exhaust pipe.
Page 257 - disconnect the adaptor from the attachment and refit the protective cover. Copyright by Fiat Auto...
Page 258 Engine Marea- Marea Weekend Fuel system 99 range Fuel supply circuit pressure check Prepare the test equipment 1860955000 using the adaptors produced previously and fitted as illustrated in the diagram below using the valves (a), (b) and (d) in the maximum opening position and valve (c) in the closed position.
Page 259 3.5 bar, the pressure settles down at around 3.2 bar, then close the valve (a) and check that the pressure remains constant for at least one minute; if this is not the case, there is a leak from one or more of the injectors. Copyright by Fiat Auto...
Page 260 Engine Marea- Marea Weekend & Fuel system 99 range Removing test equipment Remove the test equipment 1860955000 with the ignition key in the OFF position proceeding as follows: - introduce the end of the pipe connected to the valve (c) in a suitable container; - open the valve (c) and drain the excess fuel into the container;...
Page 261 NOTE Traffic conditions, driving styles, atmospheric conditions, trim levels/accessories, the presence of a roof rack, special equipment and the state of the vehicle in general can lead to fuel consumption figures which differ from those obtained using the procedures described above. Copyright by Fiat Auto...
Page 262 Engine Marea-Marea Weekend Fuel system 99 range FUEL DRIP TRAY ASSEMBLY NOTE In order to extract the unit from the tank, the fuel should not come above the maximum level. Removing-refitting Proceed with the removal of the fuel drip tray assembly as follows: - using tool 187807700, remove the buttons (arrow) fixing the luggage compartment lin-...
Page 263 (B) and move the accelerator cable away; disconnect the engine idle speed actuator connector (1); undo the bolts (arrow) fixing the upper half manifold and remove the vapour recirculation pipe (2). Copyright by Fiat Auto...
Page 264 Engine Marea- Marea Weekend ft> Fuel system 99 range - disconnect the pressure and air temperature sensor connector (2)., the injector cable con- nector (1) and remove the charcoal filter in- take pipe (3); - partly raise the half manifold and remove the brake servo vacuum intake pipe (arrow);...
Page 265 NOTE // the butterfly casing is being re- placed, connect the diagnostic equip- ment (Examiner) to the diagnostic socket and carry out the zeroing and self-learning procedures for the engine idle adjustment actuator data (M.D.S.) Copyright by Fiat Auto...
Page 266 Engine Marea- Marea Weekend ft **> 99 range Fuel system Zeroing - Make sure that the ignition switch is in the OFF position. - Check that the climate control is switched off, that the accelerator pedal is not pressed and the accel- erator control cable is correctly adjusted (see paragraph below).
Page 267 To remove the actuator, disconnect the con- nector and undo the fixing bolts (arrow). NOTE When refitting, the zeroing and self- learning procedures for the engine idle adjustment actuator data (M.D.S.) must be carried out as described in the "BUTTERFLY CASING"paragraph. Copyright by Fiat Auto...
Page 268 Engine Marea- Marea Weekend Fuel system 99 range ENGINE CONTROL UNIT Removing - refitting Proceed with the removal of the control unit as follows: - disconnect both connectors, working in two stages: A) turn the metal hook upwards to release the connection;...
Page 269 Inertia safety switch MANAGEMENT STRATEGIES EMISSION CONTROL DEVICES Management of the signals Management of the injection Catalytic silencer - . Management of the FIAT-CODE Fuel anti-evaporation system anti-theft function Exhaust gas recirculation system Management of the ignition (blow-by) Management of the engine idle...
Page 270 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...
Page 271 NOTE The numbers in the boxes in the drawings and the wiring diagrams denote the corresponding HI- TACHI engine management control unit pins (a number followed by A, indicates connector A, a number followed by B, indicates connector B). Copyright Fiat Auto...
Page 272 13. System failure light 31. Lambda probe 14. Butterfly position sensor 32. Catalytic silencer 15. Butterfly casing with air flow meter incorpo- 33. FIAT CODE control unit rated 16. Engine idle adjustment actuator 17. Filler cap with safety valve Print n°...
Page 273 22. Vehicle speed sensor 7. Radiator fan relay 23. Speedometer 8. Radiator fan 24. Butterfly position sensor 9. FIAT-CODE control unit 25. Detonation sensor 10. Air flow meter 26. Engine timing sensor 11. Fuel pump relay 27. Engine rpm sensor 12.
Page 274 Engine Marea- Marea Weekend © 99 update Fuel system LOCATION OF HITACHI INJECTION/IGNITION SYSTEM COMPONENTS IN ENGINE COM- PARTMENT 1. Ignition coils 8. Butterfly valve position sensor 2. Charcoal filter 9. Idle speed adjustment actuator 3. Detonation sensor 10. Charcoal filter solenoid valve 4.
Page 275 1. cylinder TDC 2. Crankshaft angles 3. Crankshaft flywheel signal (engine rpm sensor) 4. Camshaft wheel signal (engine timing sensor) NOTE The numbers relating to the signals indicate the crankshaft angles in advance of the next TDC. Copyright Fiat Auto...
Page 276 Engine Marea- Marea Weekend Fuel system 99 update MANAGEMENT OF THE INJECTION The injection management strategies are designed to provide the engine with the correct amount of fuel at the desired time according to the engine operating conditions. NOTE The presence of the flow meter allows the intake air mass to be measured directly making the pres- ence of the intake air temperature sensor superfluous.
Page 277 The strategy is disabled whilst the charcoal filter solenoid valve is open. If the control unit is replaced, the vehicle must be road tested allowing the engine to reach operating tem- perature and the control unit self-adjustment function to intervene (especially during idling stops). Copyright Fiat Auto...
Page 278 Engine Marea- Marea Weekend Fuel system 99 update Starting and post-starting During starting, the engine timing cannot be recognized therefore the phased injection cannot be imple- mented. Whilst the engine is first running, an initial simultaneous injection is carried out (also because the consid- erable fluctuations in the rotation speed do not allow the injection timing to be calculated correctly) and later on the injection becomes the phased type.
Page 279 (signal from the butterfly potentiometer) and the engine speed is above 1600 rpm (with the engine warm). The supply to the engine is re-enabled when the butterfly is recognized not to be in the closed position or when the engine speed goes below 1200 rpm (with the engine warm). Copyright Fiat Auto...
Page 280 MOT E The presence of the FIAT CODE anti-theft system means that it is not advisable to use another en- gine management control unit during fault diagnosis. In such a case, the FIA T CODE control unit would transfer the (unrecognized) code to the test control unit which could then no longer be used on any other vehicle.
Page 281 The moment of the start of conduction is corrected according to the battery voltage. 1. System relay 2. Interface connector 3. Single ignition coil (pencil-coil) Copyright Fiat Auto...
Page 282 Engine Marea- Marea Weekend Fuel system 99 update Starting During starting, the normal management of the advance cannot be carried out because the considerable fluctuations in the rotation speed do not allow the dwell and the advance to be calculated correctly. 97 6 5 97 6 5 The advance is therefore managed taking the...
Page 283 (for example, the use of a low octane rating fuel). The strategy is capable of restoring the advance to the map vaule if the conditions which caused the reduction no longer exist. Copyright Fiat Auto...
Page 284 Engine Marea-Marea Weekend®** 99 update Fuel system MANAGEMENT OF THE ENGINE IDLE The general aim of this strategy is to keep the engine speed around the value memorized (engine warm: 850 rpm): the position assumed by the actuator depends on the speed of the engine and the speed of the vehicle.
Page 285 - as long as the critical conditions persist: - at engine coolant temperatures above 114°C, - at engine speeds below 750 rpm. 1. Compressor 4. Battery 2. Compressor relay feed 5. Climate control unit 6. Three stage pressure switch 3. Fuse box Copyright Fiat Auto...
Page 286 Engine Marea- Marea Weekend 99 update Fuel system MANAGEMEIMT OF THE RADIATOR FANS The control unit directly controls the operation of the radiator fans according to the temperature of the en- gine coolant and whether or not there is a climate control system. NOTE Since the temperature of the engine is detected by the appropriate sensor, there is no longer a thermal contact on the radiator.
Page 287 1. Condition of three stage pressure switch 2. Condition of high speed fan 3. Condition of low speed fan 4. Engine coolant temperature progress 5. Three stage pressure switch engagement/disenagement delay ON: fan/pressure switch activated OFF: fan/pressure switch deactivated Copyright Fiat Auto...
Page 288 Engine Marea- Marea Weekend Fuel system 99 update DIAGNOSTICS The system has an autodiagnostic function which is designed to check for any irregularities in the follow- ing components: Actuators Sensors injectors engine rpm sensor coils engine timing sensor charcoal filter solenoid valve air flow meter engine idle adjustment Lambda sensor...
Page 289 Lambda sensor vehicle speed sensor diagnostic equipment detonation sensor FIAT CODE control unti injectors coils instrument panel connection supply from battery idle speed stepping motor supply from ignition switch charcoal filter solenoid valve...
Page 290 Engine < 6 9 » Marea- Marea Weekend Fuel system 99 update Hi t TAG HI SYSTEM WIRING DIAGRAM I—|i> © © © n° 506.763/15...
Page 291 27. Fuel pump relay 3. Engine timing sensor 4. Detonation sensor 28. I.E. relay 29. Supply ( + 15) for FIAT CODE 5. Injectors 30. Supply (+30) for FIAT CODE 6. Charcoal filter solenoid valve 31. Climate control compressor relay feed (if 7.
Page 292 Engine Marea- Marea Weekend Fuel system 99 update 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.
Page 293 10. Air conditioning compressor relay opera- 28. N.C. tion (if fitted) 29. N.C. 11. N.C. 30. Connection with FIAT CODE 12. N.C. 31. Reprogramming 13. N.C. 32. Line K 14. Low speed fan relay operation 33. N.C.
Page 294 Engine Marea- Marea Weekend Fuel system 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 electrical winding (2): As a result of the flywheel teething passing, the magnetic flow produced by the magnet (3)
Page 295 The alternating of the signals therefore de- pends on the succession of the openings (see - 31A chapter on "signal management"). Copyright Fiat Auto...
Page 296 Engine Marea- Marea Weekend 'fuel system 99 update 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.
Page 297 Excess air, the CO values tend to be low X< 1 Rich mixture an ohmmeter as illustrated in the diagram. Lack of air; the CO values tend to be high Resistance: 4.5 ± 0.5 ohm at 20°C Wiring connector Copyright Fiat Auto...
Page 298 Engine Marea- Marea Weekend 99 update Fuel system 3N30GJ01 3N30GJ02 Print n° 506.763/15...
Page 299 9620 76-88 5975 3816 2502 2044 1679 The table illustrates the sensor progress, which can be measured by disconnecting the con- nector and connecting an ohmmeter as shown in the diagram. T H 2 0 Wiring connector Copyright Fiat Auto...
Page 300 Engine Marea- Marea Weekend Fuel system 99 update 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 used for the operation of the speedometer.
Page 301 Wiring connector 1. Cylinder 1 ignition coil 2. Cylinder 2 ignition coil 3. Cylinder 3 ignition coil 4. Cylinder 4 ignition coil 5. Interface connector 6. Engine earth 7A 8A 9A 10A Copyright Fiat Auto...
Page 302 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 vent 4 . i n t a k e 5. Engine speed adjustment actuator 6.
Page 303 3N36GJ01 6. Accelerator control lever 1. Air flow meter 7. Accelerator cable adjustment bracket 2. Butterfly position sensor 3. Engine coolant inlet 8. Idle speed adjustment actuator 9. Anti-tamper screw 4. Engine coolant outlet 5. PCV valve Copyright Fiat Auto...
Page 304 Engine Marea- Marea Weekend Fuel system 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 engine with the butterfly closed in all conditions where it is required (idling, de- celeration).
Page 305 5. Air bleed connector FUEL SUPPLY CIRCUIT This circuit consists of the following components: - Fuel tank - Drip tray complete with pump, filter, pressure regulator and gauge float - Supply pipe - Returnless type fuel manifold complete with injectors Copyright Fiat Auto...
Page 306 Engine Marea- Marea Weekend © Fml system 99 update FUEL DRIP TRAY Electric fuel pump 87a 87 86 85 30 1. Complete drip tray 8. Single-acting valve 2. Pressure regulator 9. Internal fuel return 3. Gauge 10. Fuel supply 4. Float 11.
Page 307 (3) op- posted by the calibrated spring (2). When the calibration pressure is exceeded, the valve opens and the excess fuel (4) returns to the tank, thereby stabilizing the pressure in the cir- cuit. Copyright Fiat Auto...
Page 308 A«. Marea- Marea Weekend Fuel system FUEL MANIFOLD £ - ™ aluminium d u C The fuel mtake ,s f.xed by a tapered bolt. Since the system is the returnless type, there is no recirculation 3N42GJ02 1. Fuel manifold 2. Injectors 3.
Page 309 The injector resistance can be measured by dis- connecting the connector and connecting an ohmmeter as illustrated in the diagram. Wiring connector Resistance value: 14.5 ± 5% ohm. Copyright Fiat Auto...
Page 310 Engine Marea- Marea Weekend Fuel system 99 update 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 equipped with an inertia switch, located under the dashboard on the driver's side, fas- tened to the left side panel, near the bonnet re- lease.
Page 311 As a result, the connector for the coils must never, under any circumstances, be disconnected with the engine running: in the case of tests, the silencer must be replaced with an equivalent length of pipe. Copyright Fiat Auto...
Page 312 Engine Marea- Marea Weekend Fuel system 99 update 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 consists of the tank, the vapour separator, two float valves, a two-way ventilation valve, the charcoal filter and a charcoal filter solenoid valve controlled by the control unit.
Page 313 Charcoal folter solenoid valve This normally closed type valve, controls the flow of vapours reaching the intake manifold, being operated by the control unit in a duty- cycle. 1. From the charcoal filter 2. To the intake manifold 3N49GJ03 Copyright Fiat Auto...
Page 314 Engine Marea- Marea Weekend Fuel system 99 update 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, causing them to be recirculated and burnt in the engine.
Page 315 6. In the same conditions, check that the concentration of HC is below 500 p.p.m. 7. If the values do not correspond, tune the engine, checking, in particular: - the valve gear timing; - the engine compression. Copyright Fiat Auto...
Page 316 Engine Marea- Marea Weekend Fuel system 99 update Table summarizing pollutant emission tolerance figures CO (%) HC (p.p.m.) Upstream of the catalyzer 04 - 1 < 500 > 12 Downstream of the catalyzer <0.35 <90' > 13 Checking exhaust concentration of CO and HC The concentration of carbon monoxide (CO) and unburnt hydrocarbons (HC) at the exhaust is measured by inserting a suitably calibrated tester sensor at least 30 cm into the end of the exhaust pipe.
Page 317 - disconnect the adaptor and refit the protective cover. Copyright Fiat Auto...
Page 318 Engine Marea- Marea Weekend Fuel system 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) in the closed position.
Page 319 3.5 bar, settles down at a pressure of around 3.2 bar, then close valve (a) and check that the pressure remains constant for at least a minute; if this is not the case, then one or more of the injectors is leaking. Copyright Fiat Auto...
Page 320 Engine Marea- Marea Weekend © 99 update Fuel system 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 (c) and drain the excess fuel into the container;...
Page 321 NOTE The type of route, traffic cnditions, driving style, weather conditions, trim level I accessories, pres- ence of a roof rack, presece of special equipment and the state of the vehicle in general, can lead to different fuel consumption figures from those established during the above mentioned proce- dures. Copyright Fiat Auto...
Page 322 Engine Marea- Marea Weekend Fyel system 99 update FUEL MANIFOLD AND INJECTORS U U U U U 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 springs (arrow) attaching the cable duct to the manifold;...
Page 323 - remove the coolant connecting pipes from the inlet and outlet pipes, sealing them suitably. NOTE Do not remove the layer of molybdenum disulphide applied to the edge of the butterfly. Copyright Fiat Auto...
Page 324 Engine Marea- Marea Weekend Fuel system 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) from the pulley (8).
Page 325 Connectin with diagnostic equip- ment INJECTION/IGNITION SYSTEM List of errors WIRING DIAGRAM Parameters displayed Control unit/ignition coils and in- Active diagnosis jectors connection Recovery Permanent memory LOCATION OF INJECTION / IGNI- TION SYSTEM COM PON ENTS Copyright by Fiat Auto...
Page 326 In the case of detonation it is possible to selectively delay the ignition for the individual cylinder, recog- nized by the combination of figures transmitted by the detonation sensors and the timing sensor. Copyright by Fiat Auto...
Page 327 34. Safety valve 15. Air flow meter 35. Fuel vapour separator 16. Butterfly casing electronic actuator 36. Multi-purpose valve 17. Clutch pedal switch 37. Fiat CODE control unit 18. Fuel manifold 38. Coolant temperature gauge 19. Injectors Print n° 506.763/14...
Page 328 - connection with engine immobilizer device - restricting the maximum number of revs; (Fiat CODE); - controlling combustion via the Lambda sensor; - management of the climate control system; - fuel vapour recovery; - management of the radiator fans. Copyright by Fiat Auto...
Page 329 Engine Marea- Marea Weekend © Fuel system 99 range SYSTEM MANAGEMENT STRATEGIES Adjustment of injection times Digital technology has made it possible to ensure optimum consumption and performance using pro- grammed maps, stored inside the control unit memory, according to the engine speed and load conditions. The control unit operates the injectors with great speed and precision, calculating the opening time on the basis of the engine load (number of revs and air flow rate), also taking into account the battery voltage and the temperature of the engine coolant.
Page 330 Copyright by Fiat Auto...
Page 331 Engine Marea- Marea Weekend 99 range Fuel system Fuel vapour recovery The fuel vapours (pollutant according to the regulations) are sent to an active charcoal filter and from there to the engine where they are burnt; this takes place by means of a solenoid valve which is only op- erated by the control unit when the engine load conditions allow correct combustion without the opera- tion of the engine being "disturbed": in effect, the control unit compensates for this quantity of petrol en- tering with a reduction in the injector supply.
Page 332 A special two-way serial line allows the exchange of data between the injection/ignition control unit and the Fiat CODE control unit. If there is a failure in the Fiat CODE system it is still possible to start up the vehicle using the emergency procedure.
Page 333 Engine Marea- Marea Weekend © Fuel system 99 range 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 engage the compressor from the climate control unit via pin F6 and operates the various interventions (additional air);...
Page 334 30. Radiator fan 13. Timing sensor 31. Radiator fan 2nd speed relay 14. Air conditioning compressor relay 32. Fiat CODE control unit 15. Climate control system 33. Engine coolant temperature gauge 16. Electric fuel pump relay 17. Electric fuel pump 18.
Page 335 Engine Marea- Marea Weekend ft *>* Fuel system 99 range FUEL SUPPLY CIRCUIT DIAGRAM 1. Fuel supply manifold 4. Electric fuel pump with filter and pressure 2. Fuel supply pipe to the injectors regulator 3. Tank 5. Injectors 6. Breather pipe The fuel is supplied through an electric pump immersed in the tank which draws in the fuel and sends it to the filter and then to the injectors.
Page 336 (5), located near the cap, allows the pressure to be discharged outwards. If nec- essary, this valve can open in the opposite direction to ventilate the tank and prevent the vacuum reaching excessive levels. Copyright by Fiat Auto...
Page 337 Engine Marea- Marea Weekend Fuel system 99 range SYSTEM FOR RECIRCULATING GASES COMING FROM THE CYLINDER BLOCK/CRANKCASE (BLOW-BY) This system controls the emission, from the cylinder block/crankcase, of breather gases consisting of air/petrol mixtures and burnt gases which escape from the piston seals in addition to lubricant oil vapours, recirculating them to the inlet.
Page 338 It is vital for the injection/ignition system to be working perfectly, therefore the spark plug leads should not be disconnected, for any reason, with the engine running and the catalytic con- verter should be replaced with an equivalent length of pipe when carrying out tests. Copyright by Fiat Auto...
Page 339 Engine Marea- Marea Weekend Fuel system 99 range INJECTION/IGNITION SYSTEM WIRING DIAGRAM P4F14QJ01 Print n° 506.763/14...
Page 340 Control unit/ignition coil and injector connection Key: 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 Detonation sensor 2 Engine coolant temperature...
Page 341 Engine Marea- Marea Weekend •§! Fuel system 99 range LOCATION OF INJECTION/IGNITION SYSTEM COMPONENTS 4A16U01 9. Vehicle speed sensor 1. Phase transformer solenoid valve 10. Variable geometry manifold actuator sole- 2. Injectors noid valve 3. Fuel vapour cut out solenoid valve 11.
Page 342 Engine Marea-Marea Weekend Fuel system 99 range Copyright by Fiat Auto...
Page 343 Engine Marea- Marea Weekend 9 Fuel system 99 range DIAGNOSTIC SOCKET The exchange of data between the injec- tion/ignition control unit and the diagnostic equipment takes place via a two-way serial line (line K) using the standard Bosch communica- tion protocol. The positive logic transmission and the coding of the data is carried out through the NRZ methods (Non Return Zero) at a rate of 4.8...
Page 344 Connector M 1. Engine coolant overheating warning light 1. Butterfly casing motor (¬ 2. Not connected 2. Not connected 3. Fiat CODE control unit 3. Injector for cylinder 4 4. Not connected 4. Variable geometry manifold actuator 5. Not connected 5.
Page 345 Engine Marea- Marea Weekend 99 range Fuel system Connector F Connector M 24. Accelerator pedal potentiometer 1 earth 24. Butterfly casing potentiometer 1 signal 25. Accelerator pedal potentiometer 2 earth 25. Engine coolant temperature and air flow meter 26. Temperature sensor, butterfly casing po- tentiometers 1 and 2 reference earth 26.
Page 346 1 2 3 Connector wiring The numbers connector to pin 1 indicate the corresponding pins for the control unit ar- M16 M32 M15 M31 *- F16 F32 F48 ranged in the order of the cylinder numbers. Copyright by Fiat Auto...
Page 347 Engine Marea- Marea Weekend © Fuel system 99 range TIMING SENSOR (0.232.101.026) The injection system in the Bosch Motronic ME 3.1 system is the phased, sequential type, i.e. the injection of the fuel takes place in sequence for each cylinder during the inlet stroke. To achieve this, in addition to the rpm and TDC signal, the electronic control unit also uses a tim- ing signal to determine the point of injection.
Page 348 The numbers indicate the corresponding con- trol unit pins. Checking the resistance The sensor resistance can be measured by dis- connecting the connector and connecting an ohmmeter to the sensor terminals. Resistance: 774-946 ohm at 20°C Copyright by Fiat Auto...
Page 349 Engine Marea-Marea Weekend <0> Fuel system 99 range Checking the gap The rpm and TDC sensor is fixed directly to the cylinder block/crankcase and therefore the gap and the angular position no longer need to be adjusted. If a fault is suspected it is, however, possible to check the gap, proceed- ing as follows: - remove the rpm and TDC sensor;...
Page 350 The fuel manifold is fixed to the inner part of the inlet manifold and its function is to send fuel to the in- jectors. The fuel manifold is made from die-cast aluminium and incorporates the injector seats. The fuel intake is achieved through a tapered fixing bolt. Copyright by Fiat Auto...
Page 351 Engine Marea- Marea Weekend Fuel system 99 range INJECTORS (0.280.155.770) The twin jet type injectors are fitted on the inlet manifolds, immediately before the inlet valves. These injectors are specific to engines with 4 valves per cylinder, in effect making it possible to direct the jets towards the two inlet valves.
Page 352 There is a switch (2) on the clutch pedal connected to pin F59 of the injection control unit. The "clutch pedal operated" signal is used by the injection control unit to distinguish the gear engaged and gear change conditions. Copyright by Fiat Auto...
Page 353 Engine Marea- Marea Weekend I P > Fuel system 99 range FLOW METER (0.281.002.199) The flow meter is located on the air inlet hose and is the "heated film" type. The intake air temperature sensor is inside the flow meter. The operation is based on a heated diaphragm located in a measuring duct through which the intake air entering the engine flows.
Page 354 30 sees. - Turn the ignition key to the OFF position for 5 sees. - Turn the key to the ON position and start up the engine. Connector wiring The numbers indicate the corresponding control unit pins. Copyright by Fiat Auto...
Page 355 Engine Marea- Marea Weekend Fuel system 99 range LAMBDA SENSOR (B.258.040.092) The Lambda sensor is the "planar" type, fitted on the front section of the exhaust pipe and informs the injection control unit of the prog- ress of the combustion (stoichiometric ratio). To obtain an ideal mixture the quantity of air drawn in by the engine must be equal to the theoretical amount required to burn all the fuel...
Page 356 The control unit uses this information to im- prove the management of the engine idle ad- justment actuator and for the CUT-OFF strat- egy. 4A31LJ02 Connector wiring The numbers indicate the corresponding con- trol unit pins. Copyright by Fiat Auto...
Page 357 Engine Marea- Marea Weekend 0» Fuel system 99 range PHASE TRANSFORMER In order to ensure a good compromise between high performance in terms of power at high speeds and good torque at low speeds, this engine is fitted with an (electronically controlled, hydraulically operated) phase transformer for the inlet camshaft.
Page 358 Diagram showing operation of phase transformer 8708786 ® 8530 7. Piston spring 1. Solenoid 8. Battery 2. Valve chest 9. Injection/ignition system relay 3. Valve chest spring 10. Injection/ignition control unit 4. Piston 11. Ignition switch 5. Pinion 6. Camshaft element Copyright by Fiat Auto...
Page 359 Engine Marea- Marea Weekend fii Fuel system 99 range ENGINE COOLANT TEMPERATURE SEN- (Jaeger 402.183.01) (Elth 2690350) This sensor is fitted on the thermostat casing; it comprises a brass casing which affords pro- tection to the actual resistive elements con- sisting of two NTC (Negative Temperature Co- efficient) type thermistors where the electrical resistance of the sensor decreases as the tem-...
Page 360 Inertia switch components Complete inertia sensor Outer casing Button Upper side Engagement side Permanent magnet Permanent magnet housing Steel ball Common terminal N.C. Normally closed contact N.A. Normally open contact A. C Copyright by Fiat Auto...
Page 361 Engine Marea- Marea Weekend f P > Fuel system 99 range ANTI-EVAPORATION SYSTEM COMPONENTS Charcoal filter and fuel vapour cut out solenoid valve These components form part of the fuel vapour recovery and anti-evaporation system. The charcoal filter is located in the right wheel arch; to gain access to it the rear section of the right front wheel arch liner has to be removed.
Page 362 Disconnecting the battery means that this information will be lost and can only be acquired again after a certain length of time therefore this operation should be carried out as infrequently as possible. Copyright by Fiat Auto...
Page 363 Engine Marea- Marea Weekend Fuel system 99 range ENGINE IDLE SPEED CONTROL If the engine idle speed is not 750±50/min and the injection/ignition control unit is the self-adjusting type then it is not possible to carry out any adjustments so it is necessary to check that the accelerator linkage is correctly adjusted and the cause of the problem should be sought by carrying out a complete fault diagnosis using the diagnostic equipment.
Page 364 Table summarizing pollutant emission tolerance values CO (%) HC (p.p.m.) Upstream of the catalyzer 0.4 - 1 > 90 > 13 Downstream of the catalyzer 0,35 «S P 4 F 3 9 Q J 0 I Copyright by Fiat Auto...
Page 365 Engine Marea- Marea Weekend © Fuel system 99 range DIAGNOSTICS The complete fault diagnosis of the system can be carried out through active dialogue with the diagnostic equipment. If a failure at the sensors is detected, the electronic control unit replaces the information coming from the faulty sensor with pre-memorized (recovery) data to allow the operation of the engine.
Page 366 Signal not plausible Flow meter Signal not plausible Timing sensor Detonation sensor Signal not plausible Speedometer sensor Signal missing or not plausible Phase transformer C.C. C.C. Electric fuel pump Fiat-CODE Code not recognized or not received Copyright by Fiat Auto...
Page 367 Lambda sensor Self-adjustment Flow meter Engine knock (detonation) Vehicle speed Petrol vapour cut out solenoid valve Fiat-CODE Atmospheric pressure Active diagnosis The following active tests can be carried out using the diagnostic equipment: - Phase transformer - Injector - Failure warning light...
Page 368 - Adjusting accelerator pedal end of travel - Servicing instructions when removing turbocharger Where'the capacity is expressed, the validity of the operation only relates to the engine type specified. IX 00 * Cancels and replaces Copyright by Fiat Auto...
Page 369 COPYRIGHT by Fiat Auto S.pA 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...
Page 370 2. Undo the two bolts shown in the diagram and move the rigid pipe between the E.G.R. valve and the solenoid valve aside. 3. Disconnect the fuel return pipe from the injectors, acting on the spring. Copyright by Fiat Auto...
Page 371 Engine Marea-Marea Weekend®™ ®™ Operations on vehicle 99 range 1. Disconnect the electrical connections from the injectors and move the wiring aside, undoing the two bolts as shown in the diagram. 2. Undo the fixing nuts and place the diesel filter to the side.
Page 372 Manifold side and injector side pipe fittings must be tightened to a torque of 2.2 daNm. 11-00 Supersedes previous version Copyright Fiat Auto...
Page 373 Engine Marea-Marea Weekend®™ ®™ Interventions on car '99 range REMOVING-REFITTING RAIL Disable the alarm (if present) by means of the switch under the junction unit cover. Disconnect the terminals and remove the battery (1920 JTD). 1. Disconnect the electrical connection for the flow meter.
Page 374 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...
Page 375 Engine Marea- Marea Weekend ©> ™ & Operations on vehicle r a n g e 1. Disconnect the electrical connections from the injectors and undo the fixing bolts and place the wiring to the side. 2. Undo the fixing nuts and place the diesel filter aside.
Page 376 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 injectors and remove them Copyright Fiat Auto...
Page 377 E n g i n e Marea-Marea Weekend®™ ®m> Interventions on vehicle range ' 9 9 1. Remove the fuel delivery pipe from the pressure pump to the rail pipe. 2. Disconnect the electrical connection from the fuel pressure sensor 3.
Page 378 2. Loosen the bands and remove the first section of the pipe between the air filter casing and the turbocharger. 3. Loosen the bands and remove the second section of the pipe between the air filter casing and the turbocharger. Copyright by Fiat Auto...
Page 379 Engine Marea-Matea Weekend®™ ®™ Operations on vehicle 99 range Remove the upper engine protective cover. 2. Undo the fixing bolts and place the rigid pipe between the E.G.R. valve and the solenoid valve to the side. 3. Undo the fixing nuts and place the diesel filter aside.
Page 380 3. Move the fuel return manifold aside. 4. Disconnect the electrical connection un- doing the fixing nut and remove the heater plugs using a suitable spanner. NOTE When refitting, carry out the proce- dures described above in the reverse order. Copyright by Fiat Auto...
Page 381 Engine Marea-Marea Weekend®™ ®™ Operations on vehicle 99 range P4F38MJ05 REMOVING-REFITTING PRESSURE PUMP Place the car on a lift. Disable the alarm (if fitted), located in the luggage compartment on the right hand side and disconnect the negative battery terminal. 1.
Page 382 4. Undo the fixing bolt and remove the single drive belt fixed tensioner. 5. Remove the lower timing belt shield and remove the flywheel lock. Copyright by Fiat Auto...
Page 383 Engine ® j m Marea-Marea Weekend®™ Operations on vehicle 99 range 1. Remove the reaction rod and support, acting on the fixings shown in the dia- gram, in order to allow the subsequent removal of the upper timing belt shield. 2.
Page 384 4. Tighten the two adjustment screws in the special housings to lock the pressure pump drive pulley and undo the fixing nut. 5. Using tool 1860854000 shown in the dia- gram to remove the pulley. Copyright by Fiat Auto...
Page 385 Engine Marea- Marea Weekend @>™ ®>™ Operations on vehicle 99 range Disconnect the following from the return manifold: the fuel return pipe from the in- jectors (1), the fuel return pipe from the pressure pump (2) and the fuel return pipe from the filter (3).
Page 386 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 Fiat Auto...
Page 387 E n g i n e Marea-Marea Weekend®™ ® Interventions on vehicle '99 range Refitting Reverse procedure described for removal to the point where the pressure pump is refitted. Then refit and tension the timing belt and auxiliary drivebelt. NOTE The pipe leading from the pressure pump to the rail must be replace whenever it is disassembled and both...
Page 388 (1) on the tensioner coincides with the fixed reference (2), then tighten the nut fixing the tensioner (3) to the recom- mended torque. Copyright by Fiat Auto...
Page 389 Engine Marea-Marea Weekend®™ ®™ Operations on vehicle 99 range REMOVING - REFITTING ACCELERA- TOR PEDAL POTENTIOMETER Disable the alarm (if fitted) via the switch under the junction unit cover and discon- nect the negative battery terminal. Remove the shield under the pedals as- sembly.
Page 390 3.8V ± 1V. 3. To correct the voltage values with the ac- celerator in the maximum position, regu- late the adjustment device and repeat the procedure using the diagnostic equipment. Copyright by Fiat Auto...
Page 392 Multi-purpose valve Supply manifold (rail) Inertia safety switch AIR SUPPLY CIRCUIT Turbocharger Exhaust gas circuit EMISSION CONTROL DEVICE Catalytic converter Exhaust gas recirculation circuit (EGR) EGR solenoid valve Circuit recirculating vapours coming from the crankcase (blow- Copyright by Fiat Auto...
Page 393 - controlling the engagement of the climate - controlling the restriction of the maximum control system; speed; - controlling the engine immobilizer function - controlling the restriction of the maximum (Fiat CODE); torque; - autodiagnosis. - controlling the fuel temperature; Copyright by Fiat Auto...
Page 394 3. Vehicle speed 18. Climate control system connector 4. Rev counter 19. Diagnostic socket 5. Heater plugs warning light 20. Fiat CODE system connector 6. Infocenter (system failure warning) 21. Flow meter 7. EGR valve 22. Timing sensor 8. Pressure regulator 23.
Page 395 The fuel cut-off strategy is implemented when the injection control unit receives the information from the potentiometer that the accelerator pedal is released. Under these circumstances the control unit cuts off the supply to the injectors and reactivates before the idle speed is reached. Copyright by Fiat A uto...
Page 396 Engine Marea- Marea Weekend »°9> ™ Fuel system 99 range 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 idle speed constantly stable.
Page 397 2. the Fiat CODE control unit responds by only sending the secret code after having, in turn, received the recognition code transmitted by the ignition key;...
Page 399 13. Engine 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. Excess pressure sensor 21. Injection system protective fuse (7.5A) (+15 supply from ignition switch) 22.
Page 400 Engine @ > ™tp> ™ Marea- Marea Weekend Fuel system 99 range 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 injectors and pressure regulator) to ensure the best possible operation of the engine.
Page 401 Winding resistance: 860 Ohm ±110% at 20 1. Maximum magnetic flow 2. Minimum mangetic flow 3. Alternating voltage Copyright by Fiat Auto...
Page 402 Engine Marea- Marea Weekend ™>W> Fuel system 99 range 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 to the injection control unit.
Page 403 (6) to the closed position recreating an 12. Supply duct 13. Electrical connection equilibrium which returns the pin (2) to a 14. Fuel inlet connector (high pressure) closed position and consequently ends the in- 15. Spring jection. Copyright by Fiat Auto...
Page 404 Engine Marea- Marea Weekend 9^9 ™ Fuel system 99 range ENGINE COOLANT TEMPERATURE SEN- 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 technology, therefore if the temperature of the sensor element increases as the temperature of...
Page 405 3-10 Accelerator pedal potentiometer 1 signal 4-16 Not connected 3-11 Not connected 4-17 Rpm sensor screening 3-12 Not connected 4-18 Not connected 3-13 Fiat CODE control unit 4-19 Not connected 3-14 Not connected 4-20 Not connected 3-15 Not connected 4-21 Fuel pressure regulator 3-16...
Page 406 5. Engine radiator fan 17. Battery 6. Heater plugs control unit 18. Four stage pressure switch 7. Accelerator pedal potentiometer 19. Fiat CODE control unit 8. Brake and clutch pedal switches 20. Diagnostic socket 9. Fuel pressure sensor 21. Fuel pressure regulator 10.
Page 407 (2), in an axial position, con- nected to the two potentiometers (3): one main one and one safety one. A coil spring on the shaft ensures the correct resistance to pressure, whilst a second spring ensures the return on release. 4F015NJ02 Copyright by Fiat Auto...
Page 408 Engine Marea- Marea Weekend © ™ Fuel system 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"...
Page 409 12. Pressure regulator 4. Pressure pump drive pulley 13. Fuel temperature sensor 5. Diesel filter cartridge 14. Fuel pressure sensor 6. Pressure pump 15. Diesel heater 7. High pressure pipes 16. Thermal switch 8. Supply manifold (rail) Copyright by Fiat Auto...
Page 410 Engine Marea- Marea Weekend ® ™ Fuel system 99 range IMMERSED (AUXILIARY) ELECTRIC FUEL PUMP ASSEMBLY AND GAUGE The assembly basically consists of: - a roller type electric pump; - a fuel gauge; - a fuel filter The electric pump immersed in the fuel is the volumetric roller type with a motor with perma- nently energized magnets.
Page 411 The pressure regulaor consists mainly of the fol- lowing components: 1. Ball shutter 2. Pin 3. Valve 4. Pre-loading spring 5. Coil 6. Corpo 7. Keeper Copyright by Fiat Auto...
Page 412 < § ! > ^9 ™ Engine Marea- Marea Weekend Fuel system 99 range 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 and 75 mbar by means of a valve resting on a sealing...
Page 413 3.8V ± IV. 3. To correct the voltage readings with the accelerator in the maximum position, regulate the adjustment device and repeat the measuring procedure using the diag- nostic equipment. 4F47MJ02 Copyright by Fiat Auto...
Page 414 Engine ft ™ Marea- Marea Weekend 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 filler (1) no. 4640121 for the connector for the flexible supply pipe to the turbo (cylinder block/crankcase side) when there is an oil filter (3) fitted as il- lustrated in figure 1.
Page 415 The control of the speed (kinetric energy) of the exhaust gases makes it possible to have greatre engine torque at low speeds and increased maximum power at high speeds. Copyright by Fiat Auto...
Page 416 Engine ft * » f t ™ Marea- Marea Weekend Fuel system 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 pressure.
Page 417 This system makes it possible to send some of the exhaust gases to the inlet in certain engine operating conditions. This dilutes the fuel mixture with inert gases lowering the peak temperature in the combustion chamber; this contains the formation of nitrogen oxides (NOx) producing a 30-50% reduction at the exhaust. Copyright by Fiat Auto...
Page 418 Engine Marea- Marea Weekend ft> j » f t ™ Fuel system 99 range 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.
Page 419 In the separator (1) the gases lose part of the oil dissolved in them which returns to the sump in the form of droplets via the pipe (3). The remaining gases, on the other hand, are di- rected to the intake circuit via the pipe (4). Copyright by Fiat Auto...
Page 421 - Input/output signals between control unit and sensors/actuators - Functional diagram of fuel system - Air temperature sensor - Engine coolant temperature sensor - Hot-film air flowmeter - Wiring diagram - Control unit pins Copyright Fiat Auto...
Page 422 This section only covers the parts of the 2387 TD engine fuel system which are different in relation to the previous version. For aspects not covered in the following pages, see the descriptions give in the "Fuel system of 2387 TD" in the basic edition, contained in volume 1. Copyright Fiat Auto...
Page 423 Engine Marea- Marea Weekend®™ Fuel system '98 range GENERAL DIAGRAM OF FUEL SYSTEM P4F02LJ01 1. Battery 10. Instrumented fuel injector 2. Relay 11. Heater plugs 3. Clutch pedal switch 12. Borg-Warner modulating valve 4. Brake pedal switch 13. Bosch fuel injection pump 5.
Page 424 10. Borg Warner modulating valve 3. Accelerator potentiometer 11. Bosch fuel injection pump 4. Electronic control unit 5. Diagnostic socket 12. Flowmeter 13. Plug preheating control unit 6. Engine rpm sensor 7. Coolant temperature sensor 14. Intake air temperature sensor Copyright Fiat Auto...
Page 425 6. Brake pedal switch 16. Heater plugs warning light 7. Air flowmeter 17. Plug preheating control unit 8. Instrumented fuel injector 18. Fiat CODE control unit 9. Speedometer sensor 19. Battery 10. Engine rpm sensor 20. Intake air temperature sensor Publication 506.763/11...
Page 426 The control unit also has the function of blocking engine starting (Fiat CODE). This function is carried out by a specific control unit (Fiat CODE) (18), which can dialogue with the electronic control unit (1), and an electronic key with a special transmitter for sending a recognition code.
Page 427 Engine Marea- Marea Weekend®™ Fuel system '98 range 1 0 . FUNCTIONAL DIAGRAM OF THE FUEL SYSTEM P4F06LJ01 12. Accelerator potentiometer 1. Borg Warner modulating valve 2. Bosch fuel injection pump 13. Speedometer 14. Heater plug warning lamp 3. Instrumented fuel injector 15.
Page 428 2. NTC for instrument panel gauge °C 15970 512-602 1150 The tables opposite give the resistance values 9620 184-208 which the NTC elements can assume in ac- 5975 76-88 cordance with the coolant temperature. 3816 2500 2044 1679 Copyright Fiat Auto...
Page 429 Engine Marea- Marea Weekend® Fuel system '98 range 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: - calculate the quantity of fuel to be injected, so as to obtain the maximum fuel flow rate while main- taining an acceptible level of smoke in the exhaust;...
Page 430 The hot element consists of platinum. For the same area, film technology offers shorter response times than hot wire. In addition, having a larger area than wire, it has greater immunity to inorganic contami- nation. Copyright Fiat Auto...
Page 431 Engine Matea- Marea Weekend ® Fuel system '98 range WIRING DIAGRAM © 6 « i n;;;;7 i D— ^h-©-r> -o-o- •<o)- _ _ J > 1 < > g ^ - - H i ' Publication 506.763/11...
Page 432 21. Plug preheating warning light 22. Rev counter 23. Speedometer 24. Speedometer sensor 25. Air conditioner compressor relay 26. Air conditioner compressor 27. Three-stage pressure switch 28. Anti-frost thermostat 29. Air temperature sensor Location of diagnostic socket P4F21 FJ01 Copyright Fiat Auto...
Page 433 Engine Marea- Marea Weekend v n> Fuel system '98 range CONTROL UNIT PINS 55 37 19 20 38 1. Fuel flow actuator 28. Clutch pedal switch 2. Fuel flow actuator 29. Vehicle speed signal 30. Not connected 3. Engine cut-out solenoid 4.
Page 434: Braking System
- Electro-hydraulic control unit - Wheel rpm sensors (active) - Description of the operation of the an- ti-lock braking system - Diagram showing A.B.S. hydraulic sys- - Wiring diagram for A.B.S. LUCAS Vari- ty EBC 430 system Copyright by Fiat Auto...
Page 435 3. Vacuum servo brake 9. Handbrake switch 4. Brake fluid reservoir 10. Diagnostic socket 5. Front wheel rpm sensor 11. Rear wheel rpm sensor 6. Front disc brakes 12. Rear drum brakes 13. Rear disc brakes Copyright by Fiat Auto...
Page 436 Braking system Marea - Marea Weekend Anti-lock brakes The system is completed by: - the hydraulic system pipes; - specific electric wiring; - a switch on the brake pedal for detecting the braking condition; - an ABS warning light and a braking system failure warning light, in the instrument panel. ELECTRO-HYDRAULIC CONTROL UNIT The electro-hydraulic control unit is composed of two sections fixed to one another: an electronic con- trol unit and an electro-hydraulic control unit.
Page 437 Manufacturer. Copyright by Fiat Auto...
Page 438 Braking system Marea - Marea Weekend Anti-lock brakes If snow chains are fitted, the rolling condition gives rise to signals which are suitably filtered in the con- trol unit and the anti-lock brakes are not excluded if driving over hard, compact snow. In conditions where the grip conditions are poor and/or the engine torque is incorrect distributed (aqua- planing), the electronic control unit is informed through the rpm sensors on each wheel of an irregular condition whereby the driving wheels tend to rotate at a different speed from the driven wheels.
Page 439 HL. Supply connector to left rear brake caliper M12x1 VR. Supply connector to the right front brake caliper M10x1 HR. Supply connector to right rear brake caliper M10x1 1. Electro-hydraulic control unit 2. Electric recovery pump 3. Electronic control unit Copyright by Fiat Auto...
Page 440 Braking system Marea - Marea Weekend Anti-lock brakes WHEEL RPM SENSORS (ACTIVE) The operation of the "active sensors" is based on the variation of the internal electrical resistance de- pending on the intensity and the direction of the lines of force of an external magnetic field producing a square wave signal whose frequency varies according to the rotation speed of the wheel, but whose am- plitude is constant.
Page 441 Posi t i o ni n g of r e a r w h e e l s e n s o r Version with drum Version with disc 1. Active sensor P4F07BD04 P4F07BD05 P4F07BD02 2. Multi-polar ring Copyright by Fiat Auto...
Page 442 Braking system Marea - Marea Weekend Anti-lock brakes Warning light signalling A.B.S. failure 1. ABS warning light 2. Braking system failure warning light P4F0SBD01 With the ignition switch in the ON position, the control unit carries out a static self-control cycle during which the warning lights (1 and 2) come on.
Page 443 The recovery pump (4) sends the brake fluid which flows from the brake calipers, during the pressure re- duction stage, to the brake pump through the restricter (5), which has the task of damping the pressure and the impulses generated by the pump perceived by the driver. Copyright by Fiat Auto...
Page 444 Braking system Marea - Marea Weekend Anti-lock brakes On the basis of the signals received from the rpm sensors on the front and rear wheels, the electronic control unit operates the electro-hydraulic control unit which, in turn, varies the pressure of the brake fluid sent to the calipers in accordance with three stages: pressure increase, maintenance or decrease.
Page 445 (1). At this point the control unit moves on from the pressure maintenance stage to the increase stage (if the wheel is accelerating) or to the decrease stage (if the wheel tends to lock). Copyright by Fiat Auto...
Page 446 Braking system Marea - Marea Weekend Anti-lock brakes Pressure reduction stage pressure increase MWMXI i pressure decrease +12V +12V E C U 1. Electronic control unit 8. Multi-polar ring 2. Low pressure accumulator (reservoir) 9. Pressurizing solenoid valve 3. Recovery pump motor 10.
Page 447 2. Low pressure accumulator (reservoir) 9. Pressurizing solenoid valve 3. Recovery pump motor 10. Discharging solenoid valve 4. Recovery pump 11. Brake caliper 5. Restricter 12. Rpm sensor 13. Single-acting valve 6. Brake pump 7. Brake servo Copyright by Fiat Auto...
Page 448 Braking system Marea - Marea Weekend Anti-lock brakes DIAGRAM SHOWING A.B.S. HYDRAULIC SYSTEM Twin circuit cross-over braking system 1. Brake pump Right rear discharging solenoid valve 2. Brake servo Left front pressurizing solenoid valve 3. Restricter Left front discharging solenoid valve 4.
Page 449 B. Ideal distribution, with vehicle fully laden As it can be noted, the EBD function for the ABS system is capable of adapting to the ideal pressure curve, always exploiting the available adhesion in all braking conditions. Copyright by Fiat Auto...
Page 450 Braking system Marea - Marea Weekend Anti-lock brakes The integration of the EBA function in the regular ABS system logic gives the possibility of two simulta- neous strategies; the system usually intervenes to keep the creeping of the rear wheels within values which are very close to the ideal figures, with the possibility, however, of intervening with the ABS strat- egy when one of the rear wheels tends to lock (for example when driving over a surface with poor adhe- sion).
Page 451 Left rear sensor Spare Brake lights switch Right rear sensor Left front sensor Right rear sensor Spare Diagnostic line Spare Right front sensor Right front sensor Spare Left front sensor Spare 1 0 A fuse Spare Earth Spare Copyright by Fiat Auto...
Page 453 - Additional heater - Location of climate control system components - Compressor - SCROLL compressor - SANDEN SD7V16 compressor - DENSO 7SB16 compressor - Oil level restoration - Four stage pressure switch - Removing and refitting compressor Copyright Fiat Auto...
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...
Page 455: Climate Control
NOTE For the 1910 TD 75 version, which does not have an engine management control unit, the go ahead for the operation of the compressor is given by a speical thermal switch and by the EGT control unit in addition to the four stage pressure switch. Copyright Fiat Auto...
Page 456 r l l i a r y units Marea-Marea Weekend Climate control 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 correct, this signal is interrupted.
Page 457 70°C to 65°C if the theoretical temperature of the air is higher. III-9&- Update Copyright Fiat Auto...
Page 458 Auxiliary units Marea-Marea Weekend Climate control 9 9 range 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 one, two or all three of the heater plugs are gradually deactivated.
Page 459 4. Evaporator 11. Needle valve for draining system (low 5. Expansion valve pressure side) 6. Pipe between compressor and condenser 12. Needle valve draining and re- 7. Pipe between condenser and drier filter pressurizing system (high pressure side) Copyright Fiat Auto...
Page 460 Auxiliary units Marea-Marea Weekend Climate control 99 range 1242 16v ENGINE TYPE 1. Compressor 8. Pipe between filter and evaporator 2. Condenser 9. Pipe between evaporator and compressor 3. Drier filter 10. Four stage pressure switch 4. Evaporator 11. Needle valve for draining system (low 5.
Page 461 NIPPODENSO TV12 SC (.) 1910 75cv NIPPODENSO TV12 SC (•) 1910 JTD SANDEN SD 7V16 2387 JTD DENSO 7SB16 (•) this is the same compressor used on the previous version: see the description in the Marea-Marea Weekend Service Manual. Copyright Fiat Auto...
Page 462 Auxiliary Units Marea-Marea Weekend Climate control 99 range 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 consists of a fixed casing (1) and an orbital casing (2);...
Page 463 Naturally, the cycle is continuous, therefore the moment a compres- sion phase occurs, a gas intake phase is starting as the same time and the previous stage ends with the release of pressurized gas. Copyright Fiat Auto...
Page 464 Auxilliary units Marea-Marea Weekend Climate control 99 range 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 reduced (up to 10.4 cm^/rev) according to the system load variations.
Page 465 The muffler (5) reduces the intake gas impulses and consequently the noise and vibrations. 1. Shaft 6. Valve 2. Plate 7. Swash plate mechanism 3. Pad 8. Minimum capacity spring 4. Piston 9. Pulley 5. Intake muffler Copyright Fiat Auto...
Page 466 Auxiliary units Marea-Marea Weekend 99 range Climate control TOPPING UP OIL LEVEL Replacing compressor 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 compressor positioned exactly as illustrated in the diagram below (with the cover facing upwards).
Page 467 10 degrees C (and the thermal load conditions are not sufficient to evaporate the R134a fluid) the pressure of the fluid reaches a value below around 2.5 bar (contact I). li, J, J, i, ir 4F13DH01 Copyright Fiat Auto...
Page 468 Auxiliary units Marea-Marea Weekend Climate control 99 range 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 from the retaining band;...
Page 469 - seal both the ends of the pipe and the compressor duct using suitable plugs; - Undo the bolts shown in the diagram and remove the compressor; Refitting To refit, suitably reverse the order of the op- erations carried out for the removal. 4A26CH03 Copyright Fiat Auto...
Page 471 Electrical equipment Marea-Marea Weekend®^ 1998 range Contents page LOCATION OF COMPONENTS ON VEHICLE - Location of relays and fuses on vehicle - Location of control units and tester sockets 2 Copyright Fiat Auto...
Page 472 237. FIAT CODE fuse 96. ABS system power fuse 250. Fuel pump fuse 98. Headlamp washer intermittent function 308. Injection system and Fiat CODE fuse 90. Headlamp wiper fuse 310. Headlamp washer and air conditioner fuse 122. Engine cooling fan low speed relay ( •...
Page 473 Electrical equipment Marea-Marea Weekend®^ Location of components on vehicle 1998 range LOCATION OF CONTROL UNITS AND TESTER SOCKETS (ENGINE BAY) P4F005L02 100. Alarm electronic control unit 181. Hydraulic control unit for anti-lock brakes 103. Tester connection for alarm (A.B.S.) 195. 139.
Page 474: Electrical System
Electrical system Marea-Marea Weekend '98 range Wiring diagrams page - W I R I N G D I A G R A M S - Connector blocks Copyright Fiat Auto...
Page 475 - Speedometer - Total mileage counter/trip recorder and reset button - Coolant tem- perature gauge - Low engine oil pressure warning light - Front brake pad wear warning light - Seat belt warning light Fiat C O D E system and warning light Thermostatically-adjusted heater/air conditioner Versions with air conditioner...
Page 476 10 1 1 12 13 14 15 16 17 18 19 20 £ 28A 'f T 't f - t ' NZ-Q-NZ- „„ 15/54 I ^ lnt/a ' pos staz^ lnt/a ' D O S XZjL 9BBBB8 N Z N (®) Copyright Fiat Auto...
Page 477 Electrical system Marea-Marea Weekend® Location of components '98 range Instrument panel Instrument panel • AG n.d. N 22 LN 195A _ * BN n.d. HN 269 HN55 C117 • R41 » HQ 28A RV95 GL 34A AN4H HL120B H B 5 5 » •...
Page 478 Electrical system Marea-Marea Weekend® Wiring diagrams '98 range Fiat C O D E system and warning light Location of components 29 13 25 <c < E <r <c C D C D C D C D \D CO IIJ L H i j j i j j I •...
Page 479 * RV n.d. • CB nd. • GV195A N10B* 1 95A ' injection/ignition electronic control unit Fiat C O D E system and warning light Key to components 3 Power fusebox L 6 A N10B 4 Fuse and relay unit...
Page 480 ..N. D , " - 12 ' f r r 5'o rt^VtLzP" 15/54 N A N GN N G N N 12 3 4 c « 5 Connections and components NOT present in the HEATER version Copyright Fiat Auto...
Page 481 Electrical system Marea-Marea Weekend®^ Location of components '98 range Front right/left c a b l e s c o n n e c t i o n g j R N 1 2 7 _ , W R N 9 8 RG195A [ §...
Page 482 • 3 - f a - A N - CB A G HVW- N . D . N . D . C A G J. 15/54 I I [rrt/a I 14 17 F^X — I Sfffl (*) For thermostatically-adjusted heater, see preceding pages Copyright Fiat Auto...
Page 483 22 Left dashboard earth 208 Fan speed resistor • AN 171 55 Front left/engine cables connection 237 Fuse protecting Fiat CODE 307 Water temperature double sender unit 70 Dashboard/front cables connection • N n.d. 122 Engine cooling fan low speed relay 129 Power fuse protecting engine cooling fan N.D.
Page 484 1 2 7 •CL -AN- N.D. {N.D. N.D, A R CL I 15/54 J lirt/a > D Q S „„ 15/54 I , lnt/a J 14 17 S"toz 14 21 35 40 • - ' 1 9 5 Copyright Fiat Auto...
Page 485 195 Fuel injection/ignition electronic control 11 Battery SB 150 RV127 unit 12 Ignition switch 237 Fuse protecting Fiat CODE L141 C n d 22 Left dashboard earth 307 Water temperature double sender unit 55 Front left/engine cables connection AR309 *...
Page 486 ^ 1 5 6 ^ l 3 ) 1307 3 0 6 1 3 8 1 4 6 T3l. 1 * 2' 3* 4* 56B 57 1 8 162 1 6 3 1 6 4 1 6 5 Copyright Fiat Auto...
Page 487 NZ ad. • 56 Fuel gauge sender unit 57 Inertial switch SN 307 • HM194* 3 0 6 131 Fiat C O D E electronic control unit 132 Petrol vapours cut-off solenoid GR138* HV194* 136 Knock sensor 137 Vehicle speed sensor VB 138 •...
Page 488 — e . 2i -BN- N.C- -RV- -RV- N N N Z N,D, c — • — c • — H"f „ 15/54 I I lnt/a J pos 50 in-t s-taz I In-t/a I D O S 115/541 Copyright Fiat Auto...
Page 489 Electrical system Marea-Marea Weekend®^ Location of components '98 range Stop lights switch Instrument panel BR89A MN131B • RN n.d. • AR ad. Connection between front cables/an- 1 7 6 Diagnostic socket for anti-lock braking ti-lock braking system (A.B.S.) system (A.B.S.) * BN ad.
Page 490 Electrical system Marea-Marea Weekend '98 range Connector blocks N 195A N195A N131B P4F551 N03 J 97 ZB132 P4F551N04 4 F 2 7 A N Copyright Fiat Auto...
Page 491 Electrical system Marea-Marea Weekend Connector blocks '98 range Dashboard/front cables connection Z34A RN n.d. C 2 8 A N100A Z 3 6 N100B N100A Z120B AG ad. H R a d . HNad. HQ ad. HVn.d. C a , AR244B N100B Low brake fluid level sensor Connection between front cables/an-...
Page 492 R154 1 32 P e t r o ' vapour cut-off solenoid (canister) 1 31 control unit MN 6A. RV n.d CB n.d. GV 195A. N10B Copyright Fiat Auto...
Page 493 Electrical system Marea-Marea Weekend Connector blocks '98 range 1 36 Knock sensor *| 27 Vehicle speed sensor V ^ W ^ ^ N LN55 MGS5_ ( ^ X / ^ L195B Z195B P4F554N01 P4F554N02 1 39 Diagnostic socket for fuel injection e S D e e a "...
Page 494 Ignition coils assembly » | 7Q Resistor for engine cooling fan L 311 LR195B CN ad. QN195B 1 77 » | 7g Diagnostic socket for anti-lock braking Sensor on front left wheel for anti-lock braking system (A.B.S.) system (A.B.S.) Copyright Fiat Auto...
Page 495 Electrical system Marea-Marea Weekend Connector blocks '98 range 1 yg Sensor on rear left wheel for anti-lock 1 79 Sensor on front right wheel for anti-lock braking system (A.B.S.) braking system (A.B.S.) G1S1 M 181 1 gQ Sensor on rear right wheel for anti-lock braking system (A.B.S.) V 181 M181 1 81...
Page 496 Electrical system Marea-Marea Weekend Connector blocks '98 range 1 95A F u e l Nection/ignition electronic control unit (1581) P4F557N02 4F33AW Copyright Fiat Auto...
Page 497 Electrical system Marea-Marea Weekend '98 range Connector blocks 195B F u e ' Nection/ignition electronic control unit (1581) R144 J E - B144 J i _ Nad. _68_ V306 ZB306 _Z°_ Z136 L136 I I I l I I I l I I _ Z L HG194 J Z _...
Page 498 Connector blocks 31 0 F u s e r o t e c t m 9 headlamp washer and air 4-stage pressure switch conditioner AR 195A VN a d VN127 S195A Electric fan resistor connection Nad. P4F559N03 4F35AN Copyright Fiat Auto...
Page 500 - Engine coolant temperature gauge - Insufficient engine oil pres- sure warning light - Front brake pad wear warning light - Seat belt warning light 1 Fiat C O D E and warning light Climate control/thermostatically adjusted heater...
Page 502 Electrical system Marea-Marea Weekend '98 range Wiring diagrams Instrument panel connections (TD engine) fr'-HMIIIrH Copyright Fiat Auto VII 98 Uprltite 14/1...
Page 503 292 Clutch pedal switch ( 2 3 8 7 T D ) relay holder bracket 303 Diesel preheating fuse (TD) 131 Fiat C O D E electronic control unit 304 Diesel preheating relay (TD) 137 Vehicle speed sensor...
Page 504 M B N „ N NZ (e>) 115/54 „ , J M / a J pos 50 Irrt N G B R HV 4 5 6 V I I - 9 8 - Update Copyright Fiat Auto 1 4 / 3...
Page 505 114 Air Bag electronic control unit SN 266 117 Air Bag/dashboard cables connection 120 Air conditioner cables connection Fiat C O D E electronic control unit * The wires involved in the wiring diagram are marked with an asterisk. VII 98 - Update Publication 506.763/71...
Page 506 | N . D , 121A T T T ™ 4 j „ ' Int/Q ' pos 1 5 / 5 J . 15/54J. 50 hrt l.lnt/o I DOS sto.z 1 4 / 5 Copyright by Fiat Auto XII-98 - Update...
Page 507 Electrical equipment Marea-Marea Weekend Location of components 98 range Engine cooling fan relay - 1 1 23A Engine cooling fan relay - 2 AN n.d.' AN n.d. * R 1 2 9 * C 1 2 9 A ' R N 126A * H R 1 2 6 B A G n.d.
Page 508 Electrical equipment Marea-Marea Weekend 98 range 4 F 3 6 A N Copyright by Fiat Auto XII-98 - Cancels and replaces...
Page 509 35 Dashboard/left front door cables connection K Brake pad wear warning light 36 Dashboard/right front door cables connec- L Fiat CODE device failure warning light tion M Anti-lock braking system failure warning 39 Heated rear windscreen light (ABS)
Page 510 130 Diagnostic socket for Air Bag 83 Right rear electric window control panel on 131 Fiat CODE electronic control unit right rear door 132 Petrol vapour cut out solenoid valve (canis- 84 Left rear electric window motor...
Page 511 196 Multiple relay (1581) 197 Absolute pressure sensor (1581) 198 Protective fuse for injection/ignition con trol unit (1581) 199 Aerial for Fiat CODE 200 Electrostop relay feed (TD) 201 Heater plugs control unit (TD) 202 Heater unit/air conditioning controls ideo-...
Page 512 212 Engine cooling fan relay feed (1747) 222 Earth for climate control system 223 Rpm sensor (2387) 224 Instrument injector (2387) 226 Diagnostic socket for Fiat code system (1910 227 Diagnostic socket for injection system (1747) 228 Heater plugs (TD)
Page 513 C a b l e c o l o u r c o d e 271 Kick down switch 272 Ignition switch solenoid valve Light blue 273 Protective fuse for automatic transmission White 274 Protective fuse for automatic transmission Orange 275 Automatic transmission fluid radiator fan re- Yellow Grey...
Page 514 - Cassette Player SERVICE CONTROL UNIT - Service control unit R & R FIAT CODE - Ignition key programming INSTRUMENT PANEL - Instrument panel (from November 1999) - Smart warning light r:3tn-«li. «-J n p\.v f-s Vn 2000 Copyright by Fiat Auto...
Page 515 QSN] 40A [J/Blj 80A |GL0W| 60A |J/B2 80A 1910 75, 1910 JTD flGNl 40A |j/B1 80A FUSE B engine petrol without air conditioner 1242,1581, 1747 updated. 99 with air conditioner, JTD, 1910 TD 75 1747, 1998 with air conditioner Copyright by Fiat Auto...
Page 516 Electrical equipment Marea-Marea Weekend Protection and safety devices '99 range Main supplies wiring diagram (petrol engine types) (©) •R <r <c «x <c C D C D C D C D VD 00 |— R — R — 9 t — R — i 1 2 7 c z ^ | BR L T J...
Page 517 201 Heaer plugs control unit 332 Ignition activated power relay 10 Engine battery earth 10A Bodyshell battery earth 11 Battery 12 Ignition switch 96 Power fuse protecting A.B.S 129 Engine cooling fan protection power fuse. ' Vl'i-2000 -'Cancels and replaced Copyright by Fiat Auto...
Page 518 Electrical equipment Marea-Marea Weekend '99 range Junction unit Junction unit =»F13~ ~ F 9 ~ | I-F11-I I - F 1 - I I-F10-II Front view of control unit and location of fuses. =F15= | «F2c=»| I-F14-I l « F 5 = l - F 3 - H <=F12- | I - F 7 - H The connectors cannot...
Page 519 Right rear side light (without Check Panel) Dipped headlamps control Left number plate light (without N.C. Check Panel) Main beam headlamps control N.C. N.C. N.C. Supply for side lights controlled by N.C. ignition Additional brake light VII-00 Update Copyright by Fiat Auto...
Page 520 Electrical equipment Marea- Marea Weekend Junction unit '99 range DESCRIPTION OF CABLES AND CONN ( c o n f ) CONNECTOR H CONNECTOR G Termi- Termi- Cable Cable Cable Circuit involved Circuit involved colour colour colour Right direction indicator warning Right number plate light (without Check Panel)
Page 521 Left dipped headlamp - Air conditioning control Headlamp alignment unit - Vehicle interior corrector - Headlamp fan motor (with heater) washer enablement. (*) Replaced with 15A if the tow hook is fitted VII-2^00 - C;iiK:clt. an<\ n-p|iro-s Copyright by Fiat Auto...
Page 522 Electrical equipment Marea-Marea Weekend Protection and safety devices r a n g e SUPPLEMENTARY FUSEBOX Many shunt fuses are found under the facia just above the junction control unit The fuses are grouped in two special multiple connectors, one for the front wiring the other for the facia wiring, according to a pre-set po- sition and located as shown in the figure.
Page 523 150 Injection system relay feed 151 Lambda probe control relay for fuel pump ( • • ) Versions with air conditioning and injectors (*) 1581 with automatic transmission. 152 Fuse protecting injection system 152A Fuse protecting injection system Copyright by Fiat Auto...
Page 524 Electrical equipment Marea- Marea Weekend Location of components on the car '99 range LOCATION OF RELAYS AND FUSES ON THE VEHICLE (BONNET - Diesel engine types ) 305 1910-751 370 11910-751 -304 348 Additional heater remote control swictch 3B/C Power fusebox 349 Additional heater protective fuse 96 Power fuse protecting A.B.S 369 Engone cooling fan remote control switch...
Page 525 150 Injection sytem control relay (1747) (JTD) 344 Protection fuse ie. (JTD) 151 Lambda probe control relay for fuel pump and injectors 152 Fuse protecting injection system (1747) (JTD) 250 Fuse protecting fuel pump (1747) VII-2000 Cancels and replaces Copyright by Fiat Auto...
Page 526 Electrical equipment Marea- Matea Weekend Location of components on the car '99 range LOCATION OF CONTROL UNITS AND TESTING SOCKETS (BONNET - petrol engine types) 100 Alarm electronic control unit 176 Diagnostic socket for anti-lock brakes 103 Tester socket for injection alarm (A.B.S.) 139 Tester socket for injection system 181 Electro-hydraulic control unit for anti-lock...
Page 527 181 Electro-hydraulic control unit for anti-lock 103 Tester socket for injection alarm brakes (A.B.S.) 139 Tester socket for injection system (JTD) 226 Diagnostic socket for Fiat CODE system 176 Diagnostic socket for anti-lock brakes (1910TD-75) (A.B.S.) 302 Tester socket for EGR system (1910 TD-75)
Page 528 LOCATION OF CONTROL UNITS AND TESTING SOCKETS (PASSENGER COM PARTEM ENT) 114 Air bag electronic contol unit 249 Diagnostic socket for climate control sys- 130 Tester socket for Air Bag 131 Fiat-CODE electronic control unit 253 Air conditioner control unit 160 Ignition/injection electronic control unit...
Page 529 4F013CL01 31 OA Connection bridges under the facia 31OD Rear connection bridges 31 OB Connection bridges under the facia 31OE Rear connection bridges 31OC Connection bridges under the facia 31 OF Rear connection bridges Copyright Fiat Auto...
Page 530: Radio System
Electrical equipment Marea-Marea Weekend Radio system 99 range RADIO CASSETTE PLAYER MODEL AD 182 H2 1. VOL BUTTON: switch radio on / off, volume control increase/decrease and Balance/Fader functions 2. Cassette eject button 3. MODE button: select Radio, Cassette Player and CD player functions; temporary cassette mute 4.
Page 531 Clock section - Hour/min adjustment - Expert control level section - Anti-theft protection (*) The DOLBY noise reduction circuit is manufactured under license from Dolby Laboratories Licensing Corporation. DOLBY and the double D symbol are their registered trademarks. Copyright Fiat Auto...
Page 532 Electrical equipment Marea-Marea Weekend Car Radio system 99 range Operation Switching on car radio Press the VOL (1) button once to switch on DIBTTAL. S T E R E O the car radio. If the car radio is switched on when the engine is not running it will auto- m a t i c a l switch off after about 20 mins.
Page 533 The selectable values range from 0 to 15 To restore the default settings, press the AUDIO button for about 3 seconds until the message "00" or appears on the display. B f l L L - - R Copyright Fiat Auto...
Page 534 Electrical equipment Marea-Marea Weekend Radio system 99 range Adjusting the balance between front and rear speakers (FADER) Select the FADER function to change the vol- ume distribution between the front and rear speakers. To select the FADER function press the AUDIO (1) button 1 or more times until the message "FAD 0"...
Page 535 " T " button (3,4) for about 3 seconds until the message "IS- -" is displayed followed by "IS ON". Press button "A" or " T " to recall the stored stations one by one. is o n Copyright Fiat Auto...
Page 536 Electrical equipment Marea-Marea Weekend Radio system 99 range RDS stations automatic search and tun- Select the required FM or A M frequency band using the BAND button (1). The IS function should not be active for this selection. If the IS function is active press ei- ther the "A"...
Page 537 - search only for RDS stations that transmit traffic information; - receive traffic information even when the cassette or Compact Disc player function is active; - receive traffic information at a minimum pre-set level even if the radio voulme is set to zero. Copyright Fiat Auto...
Page 538 Electrical equipment Marea- Marea Weekend Radio system 99 Range NOTE The following are instructions for car- rying out all the operations shown in points a), b) and c) previously indi- cated. Point a) To select a station with traffic reports service press TP button (1) The message "TP"...
Page 539 The selected programme type is displayed. The automatic search can be started by pressing buttons "A" (2), " T " (3) for about 2 seconds. The search stops when a station that transmits the type of programme requested is found. Copyright Fiat Auto...
Page 540 Electrical equipment Marea- Marea Weekend Radio system 99 Range Tuning to the type of programme using the list Activate the TPY function by pressing the TP button (1) for about six seconds until the message "PTY ON" is displayed. Keep pressing buttons (2,3) to pro- gressively display the programme types avail-...
Page 541 BAND key ( 1 ) When the end of the tape is reached the side changes automatically. The messages "TAPE A" and "TAPE B" refer to the upper and lower sides of the tape. Copyright Fiat Auto...
Page 542 Electrical equipment Marea-Marea Weekend Radio system 99 Range Fast forward / rewind During playback press key "A" or " T " (2) re- spectively to fast forward or rewind the tape. The message "WIND"" or ""WIND" is dis- played during this operation. To stop this function briefly press key "A"...
Page 543 Dirt on the cassette player heads from the tapes will eventually cause a reduction in the higher tones during playback so clean the playback heads every now and then with an appropriate non- abrasive cassette head cleaner. Copyright Fiat Auto...
Page 544 Cars fitted with radio AD 182 H2 have the wiring for a Compact Disc(CD) player to be installed, consist- ing of a multi pole lead that ends on the left side of the luggage compartment. A kit is available from FIAT Accessories consisting of a Compact Disc player, an extra multi pole connection lead and mount for fitting the lead.
Page 545 During playback the message "CD" appears on the screen as well as the track number (e.g "T03" = third track), the play time "03:14" =3 minutes and 14 seconds) and the CD number CHECK S1CD (e.g. "4"). Copyright Fiat Auto...
Page 546 Electrical equipment Marea-Marea Weekend Radio system 99 Range Possible error messages: If the magazine has not been inserted correctly into the C D player the message "MAGAZINE" appears on the display. If the magazine does not contain any C D s , the mesage "NO C D " appears on the display. If CD is damaged or is inserted incorrectly into the magazine, the mesage "...
Page 547 3 (2). The message "RND ON" is displayed". To stop the random track search press station selection key 3 (2). The display s h o w s the message "RND O F F " . Rno o n O F F Copyright Fiat Auto...
Page 548 Electrical equipment Marea- Marea Weekend Radio system 99 Range Once all tracks have been played another CD is selected and so on. Once all CDs have been played, random playback restarts in the same mode. NOTE // "CD repeat" mode has been previ- ously selected, only the tracks of the selected CD are played randomly.
Page 549 The frequency selection buttons used are: key 5 to activate the synchronisation key 4 to deactivate the synchronisation Press frequency selection key 5 to display the message "SYNC ON"; press frequency selection key 4 sub- sequently to display the message "SYNC OFF". Copyright Fiat Auto...
Page 550 Electrical equipment Marea-Marea Weekend Radio system 99 Range Minimum traffic information volume To set the required volume, use frequency s e - lection keys (4) (1) and 5 (2) to respectively increase or decrease the volume. During the adjustment the display shows the message "TAVOL YY"...
Page 551 The secret 4 digit code is shown on the "Se- curity Code Card" which comes with the vehi- cle "Fiat Code Card". The secret code must be kept in a safe place (e.g together with the car documents) but not inside the car.
Page 552 Electrical equipment Marea-Marea Weekend Radio system 99 Range Deactivating the code The code must be deactivated before remov- ing the radio. To deactivate the code, proceed as follows: Press key EXP (1) and press keys "A" " T " (2,3) until the message " S A F E " is displayed. Press frequency selection key 2 (4);...
Page 553 CD data input - Right front speaker + Left front speaker CD Earth - Right front speaker + CD supply + Left rear speaker + Service - Left rear speaker CD AF Earth Left CD channel Right CD channel Copyright Fiat Auto...
Page 554 Electrical equipment Marea-Marea Weekend Radio system Range CAR RADIO TAPE PLAYER MODEL AS 182 M V O L b u t t o n : s w i t c h o n / o f f car r a d i o , a d j u s t Bass, T r e b l e , B a l a n c e , Fader. A U D - M U T E b u t t o n : s e l e c t Bass, T r e b l e , B a l a n c e a n d Fader f u n c t i o n s , a c t i v a t e M U T E .
Page 555 - Minimum volume for LRN traffic information - Regional programme automatic change - Switch/on off at same time as vehicle ig- nition - LOC function - MONO function - Audio cut-off when car phone operating - LOUDNESS function - Telephone input sensitivity Copyright Fiat Auto...
Page 556 Electrical equipment Marea-Marea Weekend Car Radio system 99 range Operation Switching on radio Press the V O L (1) button once to switch on the car radio. If the car radio is switched on when the engine is not running it will auto- maticaly switch off after about 20 mins.
Page 557 (2) knob to adjust the balance as required. The selectable values range from 0 to 15. To restore the default settings, press the AUDIO button for about 3 seconds until the message "00" or appears on the display. Copyright Fiat Auto...
Page 558 Electrical equipment Marea- Marea Weekend Car radio system 99 Range Adjust balance betwen left and right speakers (FADER) To adjust consult section "EXPERT level control" and the relevant heading "FADER Function". Loudness function To adjust consult the section "Expert control level" and the relevant heading "LOUDNESS function". / V O L / V O L / V O L...
Page 559 If you want to store the station on one of the selection buttons (1,2,3,4,5) press the preselected key for about 2 seconds. The car radio will turn off the sound until the storing process is complete. Copyright Fiat Auto...
Page 560 Electrical equipment Marea- Weekend Marea Car radio system 99 Range Tuning and manual storing of a station. Select the frequency band by pressing key BAND (1). The display shows the selected band: "FM1", "FM2", "FM3", "MW" or "LW". Once the band has been selected, press key "...
Page 561 EXP key (1) until the message "EXPERT" is displayed. Then press keys "A" or " T " until the message "TA VOL" is displayed. Use keys 4 (4) and 5 (5) to select the required volume. The volume can vary between 5 and 31. Copyright Fiat Auto...
Page 562 Electrical equipment Marea-Marea Weekend Radio system 99 Range EON (Enhanced Other Network) Function In some countries a circuit is active that groups together stations that transmit traffic reports. In these cases, the RDS TP station broadcast will be interrupted to receive traffic reports if these are transmitted by a station in the same circuit.
Page 563 TP button (1) for about 3 seconds until flF -- the message "AF--" appears on the display followed by "AF OFF". To activate the AF function again press the TP button until the flF OFF message "AF OFF" is displayed followed by "AFF ON". Copyright Fiat Auto...
Page 564 Electrical equipment Marea-Marea Weekend Car radio system 99 range CASSETTE PLAYER Activating the cassette player The car radio comes equipped with a cassette player which is turned on by inserting a cassette directly into the cassette compartment. The player allows you to listen to both side of the cassette without removing the cassette to turn it over. Insert the cassette as far as it will go, keeping your hand on it until the car radio draws it in automatically and starts the playback.
Page 565 The frequency selection keys used depend on the adjustment you want to make. To identify them, refer to the following para- graphs relating to the individual adjustments possible. To stop the adjustments, press the EXP key for EXPERT about 3 seconds. 4A72HL02 Copyright Fiat Auto...
Page 566 Electrical equipment Marea-Marea Weekend 99 Range Car radio system TIME setting The frequency selection keys required for set- ting the time are: Keys 2 and 3 for setting the hour. Keys 4 and 5 for setting the minutes. To start the clock precisely to the second press key EXP.
Page 567 (1) until the message "MONO ON" is displayed. To deactivate the MONO n o n o o n n o n o OFF function press frequency selection key 4 (2) until the message "MONO OFF" is displayed. Copyright Fiat Auto...
Page 568 Electrical equipment Marea- Marea Weekend Car radio system 99 Range Limiting the volume at start-up The car radio start-up volume can be selected using frequency selection keys 5 (1) and 4 (2) to respectively increase or decrease the volume. Press key 4 or 5 to display the message "ON VOL xx"...
Page 569 The switch voltage for both outputs is +12 V with a maximum current of 0.5 A. Speakers for radio system AD182H The sound system comprises of: - 2 tweeter-dome ferrofluid speaker, 40 W max. each. 130 mm speakers, 40 W max each. Fuses The car radio has a 10A protection fuse. Copyright Fiat Auto...
Page 570 Electrical equipment Marea-Marea Weekend Services Control Unit 99 Range S E R V I C E S CONTROL UNIT R&R Marea - Undo the bolts retaining the rear seat cush- ion to the bodyshell, then remove it from the car. Marea Weekend - Disconnect the rear seat cushion.
Page 571 PROGRAMMING THE IGNITION KEY (only on 1910 JTD versions) For any subjects not dealt with in the following pages, refer to the Fiat CODE system de- scribed in the Service Manual for the Fiat Marea-Marea Weekend volume 2 (print no.
Page 572 Electrical equipment Marea-Marea Weekend Fiat CODE 99 Range When the CODE light switches off, rotate the MASTER key into the STOP position and re- move it. Within 10 seconds: insert a new key (1) into the ignition block and rotate to the ON position ( + 15); the CODE light will switch on for 0.7 sees.
Page 573 Electrical equipment Marea-Marea Weekend 99 Range Fiat CODE When the CODE light switches off, rotate the MASTER key into the OFF position an leave it there for between 4 and 9 seconds. Do not leave the MASTER key in the...
Page 574 Electrical equipment Marea-Marea Weekend Fiat CODE 99 Range Rotate the MASTER key to the STOP posi- tion; remove then replace it; the programming procedure is finished. If the timing and operations of the procedure have been correct, the CODE light should switch off after 0.7 seconds when the key is rotated to the ON position, otherwise the light will start to flash rapidly...
Page 575 8. Right direction indicator warning light 18. Generator warning light 9. Main beam warning light 19 Injection system failure warning light 20. FIAT CODE system warning light 10. Low brake fluid level and handbrake ap- plied/EBD system failure warning light 21. Glow plug warning light 11.
Page 576 J. Fuel reserve warning light Y. Electronic module K. Fuel level gauge Y1 Speed control module L. FIAT CODE system warning light Z. Mileometer - trip counter/outdoor tem- perature gauge M. Injection system failure warning light O. Glow plug warning light Z1 Odometer reset button P.
Page 577 Brake light switch Brake pad wear Air Bag system fault Glow plug preheating (only for T D and J T D versions) Passenger air bag off (*) FIAT CODE Seat belt N.C. Injection system fault Left turn signal Battery recharging...
Page 578 Electrical system Marea- Marea Weekend Protection and security devices '99 range SMART WARNING LIGHTS For the "Air Bag" and "ABS" functions, the ordinary warning lights have been replaced by an electronic circuit which performs a SMART WARNING LIGHT function. - the indicator comes on upon a signal from the control unit, which produces a fault or alarm signal; - the indicator comes on even when a mis-connection or short-circuit to earth is detected between con- trol unit and panel.
Page 579 If the zero reset key is pressed for longer than three seconds before the first 200 km, the letter H disap- pears and the counter is reset to "000000" This operation can be carried out once only! Copyright Fiat Auto...
Page 581 Electrical equipment Marea-Marea Weekend 99 range Connector blocks page - Meaning of codes on connector blocks - Cable colour code - Connector blocks Copyright Fiat Auto...
Page 582 Electrical equipment Marea-Marea Weekend 99 range Connector blocks A Identification N° of connector block with refer- ence to the wiring diagrams. B Cable colour code identification number (see ta- ble at foot of page). C Identification NT of designated connector block for cable marked with relevant code.
Page 583 Right front light cluster V 1 3 *GV n.d. A n.d. G V 1 3 G V n . d Polyelliptical headlamps (*) with Check Panel Right front light cluster A n.d. G V 1 3 1 1 7 Copyright Fiat Auto...
Page 584 Electrical system Marea- Marea Weekend Connector block '99 range Power fusebox VN127 A R n . d . R n.d. M n.d. P4F918N01 Power fusebox R n.d. R n.d. C n . d . C n.d (*) from Nov. '99 (««) up to Nov.
Page 585 AB 13 AN 16 RN n.d. R n . d . cs A R 4 0 MN39 A V 1 A MB 56 R 4 1 Without Check Panel Marea, with Check Panel XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 586 Electrical system Marea- Marea Weekend Connector block '99 range Junction unit Junction unit AN 16 AN 16 Rn.d. MN39 MN 39 MB 56 R236B MB 56 RG 16 Marea, without Check Panel Marea Weekend, with Check Panel Junction unit Junction unit AN 16 R n .
Page 587 R G 4 J HV310C HG 28A GL34A HG 310C RN 4H AN4H A B 7 0 H 2 8 A CA269 With Check Panel (**) up to Nov. 99 (*) from Nov. 99 XII-99 - Cancels and lpplanrf Copyright Fiat Auto...
Page 588 Electrical system Marea-Marea Weekend Connector block '99 range Instrument panel (*) B V 9 5 V B 190A | 1998 BN 88 V B 5 5 A BR 89A V B 160A • • • • • • • 1747 •...
Page 589 . N n.d. | N127 1747 N 2901 JTD | L e f t f r o n t e a r t h Left front earth 1910-75 2387-JTD N 3 6 5 XII-99 - Update 122/a Copyright Fiat Auto...
Page 590 Electrical system Marea-Marea Weekend Connector block '99 range 122/b Xfl-99 - Update Publication n° 506.763/19...
Page 591 Electrical equipment Marea-Marea Weekend Connector blocks 99 range P4F923N03 Battery earth on engine Copyright Fiat Auto...
Page 592 Electrical equipment Marea- Marea Weekend Connector blocks 99 range 1 2A Ignition switch 1 2B Ignition switch M n.d. _ AN n.d. C n.d C n . d . B 3 C RN 55 Connection between right/left front cables G 4 4 SN 2 5 RN 97 ZB 132 1 1 5 8 1 1...
Page 593 *N 265 @ N 2 7 0 N244A N 135 N 3 5 *NZ 236B N236B *N264 Marea Weekend Marea * Marea Weekend Marea Left front side direction indicator Right front side direction indicator A n.d. AN n.d. Copyright Fiat Auto...
Page 594 Electrical system Marea-Marea Weekend Connector block '99 range Left facia earth Hazard warning lights switch unit LB 7D AR4I Windscreen wiper motor Hazard warning lights switch unit L R 7 C HN7A A N 4 H H G 7 A G V 7 A Electric windscreen/rearscreen washer Windscreen wiper motor...
Page 595 • • • H V 3 1 0 C / • * H V 7 0 / " H V 3 1 0 C SN n.d. NZ n.d. . ( • • ) without allarme ( • ) with alarm Marea (**) up to Nov. 99 (*) from Nov. 99 XII-99 • Cancels and replaces 1 2 7 Copyright Fiat Auto...
Page 596 Electrical system Marea-Marea Weekend Connector block '99 range Facia/rear lead connection BH n.d. S120B AG48B • * H G 7 0 / HG310C . o - o r , Z120B AB54 AR48B BN35 CL 7D HG310D CB 7D RG n.d. ' •...
Page 597 Electrical system Marea-Marea Weekend '99 range Connector block 34 B Switch control panel P4F929N03 Connection between dashboard/left front door cables P4F929N02 (*) from Nov. 99 (**) up to Nov. 99 XH-99 - Cancels and replaces Copyright Fiat Auto...
Page 598 Electrical system Marea-Marea Weekend Connector block '99 range Connection between dashboard/right front door cables HG 310D S 2 8 B . GN 244A Z 2 8 B A G n.d B 3 1 0 E BN 111B MN n.d LR 66 HV 66 Heated rear windscreen Heated rear windscreen...
Page 599 NZ n.d Marea Weekend j, M Electrical actuator left headlamp Electrical actuator for right headlamp alignment alignment HB 13 Headlamp alignment control unit Left low tone horn Right high tone horn Radio receiver with clock BN 319 Copyright Fiat Auto...
Page 600 Electrical equipment Marea- Marea Weekend 99 range Connector blocks Radio receiver with clock 48 B Radio receiver with clock NZn.d BN n.d B R 2 8 B AR 28B R G n . d AB 28B SN n.d A G 2 8 B Z 3 1 9 ZN248 Left front speaker (tweeter)
Page 601 C n . d . H G 6 A LN 160B Front/engine lead connection 1910-75 H B 6 A HM6A A R n.d. L 6 A C N 6 A RN 12A V 1 2 7 HN6A H G 6 A Copyright Fiat Auto...
Page 602 Electrical system Marea-Matea Weekend '99 range Connector block Front/engine lead connection C L 6 A H G 6 A L N 6 A S 3 3 3 C AR n.d. MZ 333C S N n.d. C 3 3 3 B HG 142 B L 2 9 HN n.d.
Page 603 N 5 6 N Z 1 8 GR 6B Glove compartment light bulb with built Luggage compartment light in switch Marea (*) from Nov. 99 ( " ) Up to Nov. 99 XII-99 - Cancels end replaces Copyright Fiat Auto...
Page 604: Luggage Compartment Light
Electrical system Marea-Marea Weekend Connector block '99 range Electrically-adjustable door mirror con- Luggage compartment light trol buttons RN 236A G R 4 E RN 236B N 18 Marea Weekend Left door mirror Right door mirror N n.d. S 3 6 Z 3 6 Cigar lighter G N 4 J...
Page 605 N 3 6 ZG 35 B V 3 5 S B 36 GN36 Pushbutton unit for rear electric win- Right front electric window motor dows on left front door (**) up to Nov. 99 XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 606 Electrical system Marea- Marea Weekend '99 range Connector block Pushbutton unit for rear electric win- 7 8 B e a r electric window inhibition switch dows on left front door Nn.d. Cn.d G V 3 5 Rn.d. Pushbutton unit for left rear electric Pushbutton unit for right rear electric...
Page 607 A.B.S. leads ' B V 6 A ' BN n.d. C 2 4 4 C BN 181 With automatic window closure (*) from Nov. 99 (**) up to Nov. 99 XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 608 Electrical system Marea-Marea Weekend Connector block '99 range Power fuse for anti-lock brakes Electric headlamp washer pump Rn.d. RN 13 R 1 1 Headlamp washer intermittence 1 OOA Alarm electronic control unit N 8 A . H L 1 2 7 S G 127 G 1 0 5 A 100B...
Page 609 H R 8 7 M 109C 11 OB Left front central locking 11 OA Left front central locking G 3 5 A 35 N n.d H 3 5 B 3 5 BN 35 With automatic window closing Copyright Fiat Auto...
Page 610 Electrical equipment Marea- Marea Weekend Connector blocks 99 range 11 OB Left front central locking 11 OC Left front central locking A 35 Nn.d. HV35 Without automatic window closing Right front central locking Right front central locking BN 36 A 36 With automatic window closing f r o n Right...
Page 611 C 1 1 4 1 20 Connection for air conditioning unit cables Z 2 8 B . . Zn.d. N 2 2 . AN 70 . AR 28A RN 7 0 . . G N 3 1 0 A Copyright Fiat Auto...
Page 612 Electrical equipment Marea-Marea Weekend Connector blocks 99 range 1 21 Three stage pressure switch 1 22 Engine cooling fan low speed relay L 1 2 8 B 1747 C n . d . S 1 2 7 V G 127 B 127 AG 127 P4F944N02...
Page 613 B7 VG 365 M 3 A A8 C n . d . C2 B N 3 6 5 [ § ] MN 13 BN 195A _ALcn.d. C3 HL 98 HLn.d. C4 SG 98 SG n.d. P4F945N06 1 4 5 Copyright Fiat Auto...
Page 614 Electrical equipment Marea - Ma tea Weekend Connector blocks 99 range 1 27 Connection between left front cable/cable on relay holder bracket B2 AN 124 1747 A2 RN 98 B3 MG 124 B2 AN n.d. A4 AV123 B4 S 121 A2 RN 13 B3 MG 55 A5 AG 122...
Page 615 Connection between front/radiator ca- bles 1998 1747 agg.'99 1747 L 122 Cn.d HR123 O O D A A Q Connection between front/radiator ca- Connection between front/radiator ca¬ « bles bles 2387-JTD 1910-75 AB n.d. M 123 P4F947N06 Copyright Fiat Auto...
Page 616 Electrical equipment Marea-Marea Weekend Connector blocks 99 range A Q A Connection between front/radiator ca- Engine cooling fan protective power fuse 1910-75 1747 agg.'99 1747 1998 R 128A Engine cooling fan protective power Engine cooling fan protective power fuse fuse 1242 1910-75 1581...
Page 617 Connection between rear/driver's heated 1 » f heated seat cables • seat cables S n.d. / ^ ^ ^ % s < * ^ s ^ N1fi N 18 P4F949N03 P4F949N02 1 3 6 A 2nd detonation sensor P4F949IM04 Copyright Fiat Auto...
Page 618 Electrical equipment Marea-Marea Weekend Connector blocks 99 range Detonation sensor LN 140B _ L140B N 55 1 5 0 Print n° 506.763/77...
Page 619 S373 L136 GVn.d. C372 M373 H334 Z372 RB n.d. BR 194 BV194 V141 BL 194 BN 194 B144 RG 141 CB n.d. NZ132 (*) from Nov. 99 (**) up to Nov. 99 XI!-99-r C.incdlb dnd replaces -jg^ Copyright Fiat Auto...
Page 620 Electrical system Marea-Marea Weekend Connector block '99 range Heated Lambda sensor N n.d. _ V160C Publication n° 506.763/19...
Page 621 Marea-Marea Weekend Electrical equipment Connector blocks range 1 44 sensor P4F953M01 1 45 Starter motor R 1 4 3 P4F953NQ2 1 45A Starter motor 1747 1998 Rn.d. RN 55 JTD | 1910-75 RN n.d 1 5 3 Copyright Fiat Auto...
Page 622 Electrical equipment Marea-Marea Weekend Connector blocks 99 range 1 46 Potentiometer on butterfly valve 1581 1747 1747 agg.'99 VN n.d. V160C N n.d. S 1 9 5 B . B 160D BR 195B Z 1 6 0 B 1 4 7 Compressor for air conditioning 1910-75 MN 55 1747...
Page 623 1747 1998 agg.'99 RG n.d. C n . d . G368 G 127 P4F955N05 Relay for Lambda sensor, electric fuel 1 5 0 Injection system relay feed pump, injectors 1747 agg.'99 1998 Rn.d BN n.d. Cn.d. P4F955N07 Copyright Fiat Auto...
Page 624 Electrical equipment Marea-Marea Weekend 99 range Connector blocks Relay for Lambda sensor, electric fuel Relay for Lambda sensor, electric fuel pump, injectors pump, injectors 1242 Rn.d. C n . d . SN 333C B V 1 4 0 A R n . d 1 52 Injection system protective fuse 1 52...
Page 625 1998 M 122 1242 R129 1581 1 54 Engine cooling fan 1 54 Engine cooling fan 1242 1910-JTD 1581 1 55 Ignition coil unit 154A 1910-JTD GV n.d 1 57 Coolant temperature sensor for injection system 1910-75 Copyright Fiat Auto...
Page 626 Electrical system Marea-Marea Weekend Connector block '99 range 1 58 Coolant temperature sensor for sensor 1 59 Reversing lights control switch 1747 1910-75 HB55 1 60 Injection/ignition electronic control unit (1747) 17471 N 148 ZB161 HG 166 SB 161 GR 162 HV166 N n.d.
Page 627 1 61 Ignition power module* Injector (1) 1747 1242 1581 MB n.d. CB 160B GR194 ZB 160B Injector (1) Injector (1) 1747 1747 agg.'99 GR 160A Rn.d. Injector (1) 1 63 Injector (2) 1242 1998 1581 Gn.d. V190B Copyright Fiat Auto...
Page 628 Electrical equipment Marea-Marea Weekend Connector blocks 99 range 1 63 Injector ( 2 ) 1 63 Injector ( 2 ) 1747 1747 agg.'99 GR 160A Rn.d. 1 63 Injector ( 2 ) 1 64 Injector (3) 1998 1242 1581 Vn.d. MB n.d.
Page 629 Injector (4) 1747 1747 agg.'99 GR 160A Rn.d. 1 6 5 A Injector (5) (1998) 1 65 Injector (4) 1998 1998 Bn.d. G 190B 1 66 'die adjustment actuator 1747 HV160A HG 160A 1 67 Air flow meter Copyright Fiat Auto...
Page 630 Electrical equipment Marea-Marea Weekend Connector blocks 99 range 1 68 Timing sensor 1 70 Engine cooling fan resistor 1 70 Engine cooling fan resistor 1242 1581 Mn.d. Rn.d. L122 R 122 Power earth for A.B.S. Diagnostic socket for A.B.S. Nn.d. P4F962N04 1 77 Sensor on left front wheel for A.B.S.
Page 631 R177 Rn.d. Right brake pad wear sensor cable con- 182A Ignition coil (1°) nection 1998 A 148 Gn.d BR 13 G 190B 1 84 Ignition coil (2°) 1 85 Ignition coil (3°) 1998 1998 A148 A 148 Copyright Fiat Auto...
Page 632 Electrical system Marea-Marea Weekend Connector block '99 range 1 86 Ignition coil (4°) Ignition coil (5°) (1998) 1998 1998 V 148 A 148 Gn.d G190B 1 89 Variable valve timing 1998 Gn.d. V 1 9 0 B 1 9 0 A Injection/ignition electronic control unit (1998) GV131 A n.d...
Page 633 L R 2 5 2 GN 252 AG 127 L141 MG 127 BN 127 sch 141 B R 139 C n . d . (*) from Nov. 99 (**) up to Nov. 99 XII-99 • Ccincols nnd rtpl.i.-t-s Copyright Fiat Auto...
Page 634 Electrical system Marea- Marea Weekend Connector block '99 range 1 9 5 B Ignition / injection control unit. (1581) R144 1581 VB 138 NZ n.d. Nn.d. LR155 HM 194 ZB278 B 144 HV194 67„ T ~ T L136 V278 T i ^ i T —...
Page 635 M 253B. Earth for climate control system N n.d. sensor 1910-75 1998 P4F967M04 Diagnostic socket for FIAT CODE sys- O O f i H e a t e r gs ( T D ) tern (1910 TD-75) 1910-75 1910-75 BR 5 5 A .
Page 636 Electrical equipment Marea-Marea Weekend Connector blocks 99 range Engine cut out electrostop (TD) Clock spring connector 1910-75 y^^^^ S 55A N148 P4F968N01 P4F968N02 Earth for compressor Thermal switch on water pump 1910-75 1998 / ^ O ^ i ^ O MG 127 N 14Q S127...
Page 637 MN 114 VN 241 MN242 V241 P4F969N03 Left pretensioner Right pretensioner V 2 3 9 M 240 VN 239 MN240 P4F969N05 Luggage compartment light button Luggage compartment light button RN n.d. Marea Marea Weekend P4F969N07 1 6 9 Copyright Fiat Auto...
Page 638 Electrical equipment Marea-Marea Weekend 99 range Connector blocks 244A 244B m t e r a t e a " s e r v c e s electronic control n t e r a t e c services electronic control unit unit N 19 H 31OU...
Page 639 ' pump relay feed Mixing air control actuator Cn.d. HN 2 5 3 B n.d. n.d. L 2 5 3 B G 2 5 3 B g j ] B R 2 5 0 S N 1 6 0 A Copyright Fiat Auto...
Page 640 Electrical equipment Marea- Marea Weekend Connector blocks 99 range Treated air temperature sensor Temperature adjustment switch N n.d Nn.d. C253A MAX-DEF microswitch Tailgate locking/unlocking actuator H263B AN n.d. Bn.d. G263B Seat belts warning light switch Left rear courtesy light M28A N 18 Marea Weekend r e a r...
Page 641 Connection between automatic trans- Connection between automatic trans- mission/dashboard cables mission/front cables MN 267R Z267L GN280 GN310A Connection between automatic trans- Kick-down switch mission/rear cables B 2 8 3 . BR 283. BN283 Rn.d N 22 MN269 1 7 3 Copyright Fiat Auto...
Page 642 Electrical equipment Marea-Marea Weekend Connector blocks 99 range 0 " 7 O Automatic transmission system protec¬ Ignition switch electro-magnet tive fuse N 2 6 9 . C 2 6 8 C n . d P4F974N02 0-7/1 Automatic transmission system protec¬ Starting go ahead relay tive fuse RN 55...
Page 643 LN 267R MB 267L MN 267L EGR device control solenoid 1910-75 CV 333C HV 298 HG 333C N 148 Heater resistor (PCT) Thermal contact (PCT) J T D R G 127 R G 127 1 7 5 Copyright Fiat Auto...
Page 644 Electrical equipment Marea-Mates Weekend Connector blocks 99 range Accelerator control lever potentiometer 1910-75 G298 - electronic control unit (1910TD-75) 1910-75 R n . d . C n . d . B n.d. AR 296 BR 229 N 148 V G 157 MG 55 V 2 9 6 HV 285...
Page 645 F u s e protecting diesel preheating Diesel preheating protection relay HN 127 RV304 R G 1 2 7 GN 127 R127 R V 3 0 3 Compressor deactivation relay 1910-75 LN 124 MN 127 MG 127 Copyright Fiat Auto...
Page 646 Electrical system Marea-Marea Weekend Connector block '99 range 31 OA Connection shunt GN 6B GN 41 * RN 28A . GN 319 ' C 6 C GN 120B GN 34B ** HB 34A ' C N 6B 31 OB Connection shunt ** HR 6 C C 2 8 A * ' H R 7 0...
Page 647 31 OE Conecting bridge G244B B244B Marea Weekend 31 OF Connecting bridge C 107A Connection for radio phone Aerial feeder GN310A. V48C. Z48C. N22. RV48A BV48A Connection for seat height adjustment Connection for TELEPASS R310F N 19 Copyright Fiat Auto...
Page 648 Electrical equipment Marea-Marea Weekend Connector blocks 99 range Connection for seat lumbar adjustment Connection for additional heater R347 Hazard warning lights relay Additional heater control unit N 8 . A R 3 2 5 A G n.d. AB 325 R 3 2 5 AV n.d.
Page 649 1910-JTD E4 VN n.d. E9 NL336 P n F I n F1 VN n.d. F7 VB 339 F3 V G 3 4 0 MV 338 2387-JTD F4 NV n.d. F9 V 3 3 7 F5 NL336 P4F981NOT Copyright Fiat Auto...
Page 650 Electrical equipment Marea-Marea Weekend Connector blocks 99 range Engine temperature twin sender unit HB 55 B 5 5 C LN 333D Gn.d BN 333D V190B HB55C HB55C H MOB N n.d. SN 1951 B 160B C 160B Injector for cylinder 1 (JTD) Injector for cylinder 2 (JTD) NV n.d.
Page 651 B 3 3 3 C C333A NZ 333C Additional heater relay Additional heater relay A R 3 2 5 Mn.d R n . d Rn.d Rn.d. AG n.d. AG n.d. R 3 2 5 P4F983N08 Copyright Fiat Auto 1 8 3...
Page 652 Electrical equipment Marea-Marea Weekend Connector blocks 99 range Additional heater remote control switch Additional heater protective fuse AB n.d. Nn.d Nn.d. Rn.d. N351 Additional heater sensor Additional heater heater plug N n.d. N348 N n.d. N n.d. P4F9S4N03 Left Side Bag connection HB 114 HL 114 H L 3 5 8...
Page 653 * Without Side Bag P4F985N02 Right Side Bag sensor Left Side Bag sensor ZB 355 ZN 355 > V355 RN 355 P4F985N04 P4F985N03 Right Side Bag Left Side Bag HB361 HRSR1 HB 360 HR 3R0 P4F985N06 P4F985N05 1 8 5 Copyright Fiat Auto...
Page 654 Electrical equipment Marea-Marea Weekend Connector blocks 99 range Passenger presence sensor Phase transformer actuator (1998) 1998 BN 355 Vn.d. B 190B N 3 5 5 R355 Motorized butterfly casing 4 stage pressure switch 1998 BN 127 N 8AL S 127 N 127 V190B J T D...
Page 655 RV 140B RN 140B M 140A Air temperature and pressure sensor Air temperature and pressure sensor 1581 1242 Nn.d ZB 195B V 1 9 5 B RN 195B Power steering pump sensor P4F987N05 XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 657 Electrical equipment Marea-Marea Weekend 99 range Wiring diagrams page Electrical symbols Explanation of how to read wiring diagrams Wiring diagrams Copyright Fiat Auto...
Page 658 Radio system (mid-level: AD 185 M) - Cigarette lighter Electric front windows Rear electric windows FIAT C O D E and warning light NOTE The numbers in the table correspond to the page number of the wiring diagram From November '99...
Page 659 Electrical system Marea- Marea Weekend Wiring diagrams range Marea-Marea Weekend DESCRIPTION DESCRIPTION DESCRIPTION 1910 1581 1747 1910 2387 1242 1581 1747 1998 a.c. agg. TD-75 37** 37** 37** 37** 37** 37** 37** 37** 37** Alarm/Door check device 38** 38** 38** 38** 38** 38**...
Page 660 Automatic transmissiono device - System failure warning light Diagnostic sockect connections I l l NOTE The numbers in the table correspond to the page number of the wiring diagram XII-93 - Cancels and leplaces Copyright Fiat Auto...
Page 661: Wiring Diagrams
Automatic transmission Electronically operated Direction indicator fluid temperature sun roof Handbrake applied and ( C D ) insufficient brake fluid Catalytic silencer Km/h level Speed limit temperature Recharing Fuel gauge Resistance Engine coolant Engine oil pressure temperature Diode Copyright Fiat Auto...
Page 662 Electrical equipment Marea-Marea Weekend Wiring diagrams 99 range Electrical symbols Warning light Trip computer operation Differential lock Automatic transmission Bulb Electronic injection fluid temperature Fuse Engine oil level Temperature Brake fluid level 3 R ft K E Switch open (Japanese Version) Anti-theft Selector switch Doors open...
Page 663 Analogue fuel gauge E > 3 Analogue engine coolant temperature gauge Econometer Digital engine coolant temperature gauge l l l l l l l l l l l Engine oil temperature Engine oil pressure gauge Voltmeter Copyright Fiat Auto...
Page 664 Electrical equipment Marea-Marea Weekend Wiring diagrams 99 range Explanation of how to read wiring diagrams H Million 'If— N- rrxi <: <c 4 <c i z j r m ID H £ AB-- BR-- TIST N . D . R CB L-c l R |R —(•...
Page 665 — 6-^LB- 310A 70 fc u-f3-GN- g-CB- GL AV 3-CB- N . D . H R LR L T J • C — » - C B - 17 <*) Variants for Marea Weekend • Wire not connected Copyright Fiat Auto...
Page 666 Electrical equipment Marea-Marea Weekend Component location 99 range Connction between right/left front cables SN 25 RN 97 132 11581 V 2 A * M [j58l] ggg/99 MN 127 1747 RG132| 1581 MN 147 Connection between dashboard/rear cables R N 3 1 0 B . RN n.d.
Page 667 H B j 14 C W ) ) 15 Wire not connected * Variant for Marea Weekend Variant up to Nov. '99 Copyright Fiat Auto x l 1 " " C a n c e , s l a c e s...
Page 668 Electrical system Marea-Marea Weekend Component location '99 range Left front light cluster •GL70 Connection between right/left front cables SN25 SN7A RN 97 RN 127 * H 2A 1 1 5 8 1 1 ZB n.d. ZB 132 115811 F*58l] RG 195A agg/99 MN 127 1747 agg.' 9 9...
Page 669 - N Z - - - —<g>—| ;00; -GN- -GR- - 0 - X 19 HL J HB J f] Cl G 1 D Variant for Marea Weekend Variant up to Nov. '99 Copyright Fiat Auto " - " Cancels and replaces...
Page 670 Electrical system Marea-Marea Weekend Component location '99 range Left front light cluster * V N 4C ' A V 4 D H N 4 C Dipped headlamps relay feed * HR 4 F ' R n . d . H 7 B ' * LR 4 F * N 4 2 Connection between right/left front cables...
Page 671 • - ® - ;00; H — * — H • - ® - H8>- N.D, Variant for Marea Weekend Variant up to Nov. '99 • Without Check Panel all versions from November '99 XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 672 Electrical system Marea-Marea Weekend Component location '99 range 2 8 A Facia/rear lead connecti on RN 310B RN 31 OA * H n.d HG 6B BR 66 With Check Panel 2 8 A Facia/rear lead connection RN 310B HG 6B BR 66 Without Check Panel Fog lights - Rear fog lamps...
Page 673 S ^ - - - " N Z N Z - n - A N - ' - 0 - 1 ;00c - R G - 'HgH J J L ~(8)- (*) Variants for Marea Weekend (•) Automatic transmission: see specific wiring diagram Copyright Fiat Auto...
Page 674 Electrical equipment Marea-Marea Weekend Component location 99 range Left front light cluster VN 4 C G L 7 0 *GL n.d HN n.d Connection between right/left front cables Hazard warning lights control switch Hazard warning lights control switch 23 B unit * LB 7D * AB n.d.
Page 675 I lnt/a I nos s-taz H 8 ^ -AN- -RG- -®- ^ - B N - ® 1 1 8 Variants for Marea Weekend Automatic transmission: see specific diagram Copyright Fiat Auto x l 1 1 4 / a...
Page 676 Electrical system Marea-Marea Weekend Component location '99 range Left front light cluster VN 4 C G L 7 0 Connection between right/left front cables S N 25 R N 9 7 H 2 A Z B 1 3 2 115811 1 1 5 8 1 1 R G 1 9 5 A V 2 A S r^T] 1747...
Page 677 ^---~NZ - • - N Z — i "N~D~. -NZ- -AN- - R G - N i N | • — ® — -BN- -<8>- • N - Variant for Marea Weekend (•) Automatic transmission: see specific wiring diagram Copyright Fiat Auto...
Page 678 Electrical equipment Marea-Marea Weekend Component location 99 range Left front light cluster G L 7 0 Connection between right/left front cables SN 25 RN 97 ZB 13211581 15811 RG 195A 1747 agg.'99 RG132 1581 MN 147 Hazard warning lights control switch Hazard warning lights control switch 23 B ' AB n.d...
Page 679 » - N — - , -NZ —•—NZ—i N . D . R—•—R- -AN- H8>- -RG- " J -BN- - N - Variants for Marea Weekend Automatic transmission: see specific diagram XII-99 - Update Copyright Fiat Auto 1 6 / a...
Page 680 Electrical system Marea-Marea Weekend Component location '99 range Left front light cluster G L 7 0 Connection between right/left front cables 15811 1581 |1581| 1747 RG132|l58l| agg.'99 H 4 C MN 147 2 3 A Hazard warning lights switch unit Hazard warning lights switch unit * LB 7 D .
Page 681 Versions without C h e c k Panel, with alarm Direction indicators and warning light - Hazard warning lights - Brake lights - Reversing light P4F817N02 • Automatic transmission: see specific diagram Variant for Marea Weekend Variant up to Nov. '99 Copyright Fiat Auto XW-99 - Cancels and replaces...
Page 682 Electrical system Marea-Marea Weekend Component location '99 range Left front light cluster VN 4 C A V 4 D H N 4 C Connection between right/left front cables SN 25 RN97 ZB 132 1 1 5 8 1 1 1 1 5 8 1 1 195A |1581| 1747 V 2A 1581...
Page 683 Versions without Check Panel, without alarm Direction indicators and warning light - Hazard warning lights - Brake lights - Reversing light Variant for Marea Weekend Variant up to Nov. '99 • Automatic transmission: see specific diagram Copyright Fiat Auto XII-99 - Cancels and replaces...
Page 684 Electrical system Marea-Marea Weekend Component location '99 range Left front light cluster V N 4 C A V 4 D H N 4 C Connection between right/left front cables SN 25 RN 97 ZB 132 1 1 5 8 1 1 |1S81| RG 195A 1747 agg.'99...
Page 685 — d p —H— R —T—RN- N.D. H N H R ,_,BR BL lei. I|Z^2 rj""j? n 1 2 3 1 2 3 7 1314 J 65 Variant up to Nov. '99 Copyright Fiat Auto - " Cancels and replaces...
Page 686 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/left front door cables P4F822N04 Fia Marea — P4F822N02 Car interior ghting - Symbol lighting Connection between dashboard/right front door cables Component key 3 power fusebox: 87 Connection between rear/right rear door 4 Junction unit: cables 6 Instrument panel...
Page 687 Electrical system Matea-Marea Weekend '99 range Wiring diagrams Fiat Marea W e e k e n d Car interior lighting - Symbol lighting 5 - r J I I I I I „ - , C\J P Z « pq ™...
Page 688 '99 range Connection between dashboard/left front door cables P4F824N02 Connection between dashboard/right front door cables P4F824N04 Fiat Marea Weekend Car interior ghting - Symbol lighting Component key 3 power fusebox: 69 Cigar lighter 86 Connection between rear/left rear door ca-...
Page 689 Electrical system Marea-Marea Weekend Wiring diagrams '99 range Radio system (high level: AD 185 H) - Cigarette lighter Predisposition for C D Variant up to Nov. '99 XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 690 Electrical system Marea-Marea Weekend Component location '99 range 2 8 B Facia/rear lead connection * BN n.d S 120B HG310C Z120B HR 310B MN n.d HV310C ' NZ n.d Marea 2 8 B Facia/rear lead connection * BN n.d. S 120B HG 310C Z120B HV310C...
Page 691 A N CB ® N. D , I } N.D. A N C 2l8TT _, -J><£ Ikn/hl A G A R 50 lnt' n t / < s-taz A G A R - A G -AB- -AR- Copyright Fiat Auto...
Page 692 Electrical equipment Marea-Marea Weekend Component location 99 range Connection between dashboard/rear cables * BN n.d S 120B HG310C Z120B HV310C * NZ n.d. Marea Connection between dashboard/rear cables * BN n.d S 120B AG48B HG310C Z 120B AB 48B AR 48B BR 53 * S N 36 BR 48B...
Page 693 • 17 • 18 • 19 • 20 • C N.D. i l t j l Nl N I J I T N.D, N.D. { i15/54 J. s t a z 2 8 A L ^ 310P^j= Copyright Fiat Auto...
Page 694 Electrical equipment Marea-Marea Weekend Component location 99 range Connection between dashboard/left front door cables P4F830N02 Connection between dashboard/right front door cables P4F830N01 Electric front windows Key to components 3 Direction indicator 74 Control panel for right electric front 4 Junction unit window on right armrest 10 Battery earth on engine 76 Left front electric window motor...
Page 695 —•— c - - 14 - 15 - 16 • 17 • 18 - 19 • 20 I 15/54 I irrt/a ' I DOS s t a z rrftj ( | ) Versions with automatic locking Copyright Fiat Auto...
Page 696 Electrical equipment Ma tea- Marea Weekend Component location 99 range Connection between dashboard/left front door cables HV 244B ' C n . d . ZB 67 R n . d . ZG 244A GV 78B * B 3 1 0 E AG 67 C B 244A BV 244A...
Page 697 Electrical system Marea-Marea Weekend Wiring diagrams '99 range Fiat - C O D E device and failure warning light (petrol engine) - f i l l - 1 7 4 7 •N—||i | 1 2 4 2 | |1998| agg.'99...
Page 698 * R n.d. M n.d . C n.d. M n.d. Front/engine lead connection Fiat - C O D E device and failure warning light (petrol engine) H B 6 A V B 7 0 Component key AR n.d C N 6 A...
Page 699 Marea-Marea Weekend Wiring diagrams ' 9 9 range Fiat - C O D E device and failure warning light (Diesel engine) | JTD | | 1 9 1 0 - 7 5 | 111111—i - | 1 9 1 0 - 7 5 |...
Page 700 S 3 3 3 C AR n.d S N n.d. MZ 333C C 3 3 3 B Fiat - C O D E device and failure warning light (Diesel engine) BL 29 HG 142 HN n.d. R N 12A HN 143 S N 333B L n.d.
Page 701 N ! N ® N.D. -HN- -HR—•—HR -HR- 236B N — H — N t±±3 N — H N I N _"R—J1::!:: "" i — T - Variants for Marea W e e k e n d Copyright Fiat Auto...
Page 702 Electrical equipment Marea-Marea Weekend Component location 99 range Connection between dashboard/left front door cables HV 2 7 0 0 * HV n.d. C n . d . MN n.d AV 238B ZB 67 * N 19 R n . d . G V 78B A G 67 Alarm...
Page 703 - H R - -HR- g ^ H N - H N - 236B t i p N I N < * ) N — ^ N ^ N N -•-NZ—' ! Variants for Marea Weekend XH-99 " P<J'"«e Copyright Fiat Auto...
Page 704 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/left front door cables ' HV n.d. R V 244A R G 5 1 G 3 1 0 E AV 238B ZB 67 G N 7 8 B * N 19 G 110A R n .
Page 705 C B — j j j - 2-^-CB ,_, G — 1 4 16 ?28A 236B 13 15 H — H • * Variants for Marea W e e k e n d Only for versions with automatic locking Copyright Fiat Auto...
Page 706 Electrical equipment Marea-Marea Weekend Component location 99 range Connection between dashboard/left front door cables Connection between dashboard/right front door cables P4F840N01 Central locking Key to components 3 Direction indicator 87 Connection between rear/right rear door 4 Junction unit cables 10 Battery earth on engine 100 Alarm electronic control unit 107 Central locking remote control receiver 11 Battery...
Page 707 50 irrt s t a z Safety thermal contact: It o p e n s in the c a s e of overheating and is restored w h e n the cable cools d o w n . Copyright Fiat Auto...
Page 708 Electrical equipment Marea-Marea Weekend Component location 99 range Connection between dashboard/left front door cables Connection between dashboard/right front door cables P4F842N01 Electrically adjustable, heated external rear view mirrors Key to components 3 Direction indicator 4 Junction unit 10 Battery earth on engine 11 Battery 12 Ignition switch 18 Left rear earth...
Page 709 ,' int/a . pos 15/54 5 0 Int staz < 111 > ( i M ) •> 7 9 8 12 1314151617181920 ® \ y y y Variants up to Nov. '99 Copyright Fiat Auto XII-99 - Cancels and replaces...
Page 710 Electrical system Marea-Marea Weekend Component location '99 range Power fusebox R n.d. n.d.' C n . d . * C n.d ' CB 3 1 0 B . R N 3 2 . L28C . R G 117 LR 28C V n.d.
Page 711 • R — » — R • B7 30 85 N . D . ^ v — N. D , S — — R • 92A [ I fct i L J ( , ) Automatic w i n d o w locking Copyright Fiat Auto...
Page 712 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box R n.d. R n.d.' C n . d . C B n.d. RN 32 L R 28C V n.d. Connection between dashboard/rear ca- Q 9 A Connection for electrically operated sun 2 8 C bles roof cables...
Page 713 12 3 6 7 8 UJ UJ 87870.30 85 'R—•—R> N . D . • R — — R • 12 3 4 j i > ^ J H R LR -AN—•—AN- N . D , ® /54 J Copyright Fiat Auto...
Page 714 Electrical equipment Marea-Marea Weekend Component location 99 range Dipped headlamps relay feed Stalk unit ' H R 4 F L R 4 F ' R n . d . 7 B ' * LR 4F GVn.d Connection between right/left front cables •...
Page 715 R • L i J frfH 87 30 85 N.D. S — • — S N.D. N.D. AN—•—AN- • 28C N.D, ] 323 I 15/54 I 15/54 ' I, int/a ' pos n n ^ staz^ 134A 135A Copyright Fiat Auto...
Page 716 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box R n.d. R n.d. R n.d. . R n.d. C n . d . C n.d. C B n.d. R N 3 2 . L28C . 1 1 7 LR 28C V n.d.
Page 717 M N B R VN C L G M N Z V CB R 2311 N.D. I 15/54 I 15/54 I , I Int/o J pos I Int/o I 50 int 17(H) Variant up to Nov. '99 Copyright Fiat Auto Cancels and replaces...
Page 718 Electrical system Marea-Marea Weekend Component location '99 range Power fusebox R n.d. R n.d. C n . d . CB n.d. R N 3 2 L R 28C Air Bag/facia cables connection Air Bag, pretensioners and failure warning light Component key ' R n.d.
Page 719 3 5 6 3 5 7 3 5 4 3 5 8 3 5 9 it—rl 3 5 3 3 5 2 HN-H-HN -BN- 3 6 2 Variant up to Nov. '99 XII-99 - Cancels and leplaces Copyright Fiat Auto...
Page 720 Electrical system Marea-Marea Weekend Component location r a n g e Power fusebox R n.d. R n.d. C n . d . C B n.d. R N 3 2 LR 28C Air Bag/facia cables connection Air Bag with Side Bag and pretensioners and failure warning light Component key ' R n.d.
Page 721 Electrical system Marea-Marea Weekend Wiring diagrams '99 range wash/wipe - Rear wash/wipe - Horns - Heated rear window - Headlamp washers Windscreen 10 ^ 4i!!!JJrh"i Variants for Marea Weekend Copyright Fiat Auto X ! l " Cancels and replaces...
Page 722 Electrical system Marea- Marea Weekend Component location '99 range Connection between right/left front cables Facia/rear lead connection RN 310B RN n.d. GN 4G NZ56 AR 244B * MB 244B * GR 6C HL 6C HB 6C V107A Facia/rear lead connection BH n.d S120B HG 310C...
Page 723 Electrical equipment Marea-Marea Weekend Wiring diagrams range Instrument panel connections Copyright Fiat Auto...
Page 724 Electrical equipment Marea- Marea Weekend Component location 99 ranee Instrument panel H L N 1 9 0 A L N 5 5 _ __ A G n.d. * BN n.d * H G 5 5 R V 9 5 1747 agg.'99 L 160A L 190A 11998| Instrument panel...
Page 725 . I Irrt/a J pos 5 0 int staz n., ,ni ( ® ) ^ y y y y * y ^ ' ^ f i ^ ^ y y y XII-99 Update 5 8 / a Copyright Fiat Auto...
Page 726 Electrical system Marea-Marea Weekend Component location '99 range Instrument panel B V 9 5 VB 190A BN 8 8 * V B 5 5 A BR 8 9 A ' VB 160A • • • • • • • • • • • • • • 1910-75 1581 C L 55...
Page 727 - H N — HN- 16(*) -,oni =3—GN V — N - r ® - — ® - | ' - ® - -;-GN- — < g > - Variants for Marea W e e k e n d Copyright Fiat Auto...
Page 728 Electrical equipment Marea-Marea Weekend Component location 99 range Instrument panel GN 28A * G R 28A * R V 4 H * G L 7 0 * C 3 1 0 A • H R 3 1 0 B HN 310B R G 4J * H V 3 1 0 C ' H G 3 1 0 C...
Page 729 N,D, N.D, -HN- HR — • — 1 - 1 N.D, i 3 3 236B W [ N.D. | RN N NZ N • RN 1 3 1 243 (*) Variant for Marea Weekend Copyright Fiat Auto XII-99 - Update...
Page 730 Electrical system Marea-Marea Weekend Component location '99 range Instrument panel R G 4 J RV n.d. HG 28A • • • • • • • • • • • RV n.d. G L 3 4 A • • • • • • • • • • • C 117 R 4 I * M28A...
Page 731 Weekend '99 range Wiring diagrams Climate control unit/heater with thermostatic control (1998) 2 5 8 X X X X P ~ i - . g « « Variants up to Nov. '99 Copyright Fiat Auto XII-99 - Cancels and replaces...
Page 732 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/right front door cables H G 3 1 0 D * S 2 8 B . G N 244A Z 2 8 B SN 28B AG n.d BN 111B B 3 1 0 E MN n.d.
Page 733 15/54 I ,1 irrt/a J pos 50 Int staz j A R N A N G N N r|" i r|"|"|" i [ L J31 12 3 Variants up to Nov. '99 Copyright Fiat Auto - " Cancels and leplaces...
Page 734 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/right front door cables HG 310D GN 244A 2 8 B . Z 2 8 B * AG n.d BN 111B B 3 1 0 E MN n.d LR 66 HV66 Climate control system/heater with thermostatic adjustment (1910-2387 JTD) 1 20...
Page 735 H N G <15*« (14**) „„15/54 J„ ' int/a ' pas I int/a I 50 Int staz N A N G N N £3 12 3 4 Variants up to Nov. '99 Copyright Fiat Auto x l 1 " Cancels and replaces...
Page 736 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/right front door cables H G 3 1 0 D * s 2 8 B . G N 244A Z 2 8 B N 19 A n.d A G n.d BN 111B B 3 1 0 E MNn.d...
Page 737 Electrical system Marea-Marea Weekend Wiring diagrams '99 range Climate control system/heater with thermostatic adjustment (1747) Variants up to Nov. '99 XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 738 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/right front door cables HG 310D * S 2 8 B . GN 244A Z 2 8 B n.d. n.d. BN 111B B 3 1 0 E L R 6 6 HV 66 Climate control system/heater with thermostatic adjustment (1747) 1 20...
Page 739 L 12 3 4 2 4 4 2 5 6 2 0 6 2 5 5 2 0 9 2 0 2 2 0 2 Variants up to Nov. '99 Copyright Fiat Auto x l 1 " Cancels and replaces...
Page 740 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/right front door cables H G 3 1 0 D * S 2 8 B . GN 244A Z 2 8 B A G n.d BN 111B B 3 1 0 E MN n.d L R 66 HV 66...
Page 741 _ E 2 _ 15/54 I , I Irrt/a J pos (15**) (14**) 50 Irrt staz N AN - T - G N N 12 3 4 Variants up to Nov. '99 Copyright Fiat Auto XII-99 - Cancels and replaces...
Page 742 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/right front door cables HG310D ' S 2 8 B . GN 244A Z 2 8 B * A G n.d. BN 111B B 3 1 0 E MN n.d. LR 66 HV 66 H 111A...
Page 743 --15/54 ' ,', int/o. J pos 5 0 Int stoz _ L _ N A N rj^^i G N N G N N T 7 H 12 3 4 Variants up to Nov. '99 Copyright Fiat Auto XII-99 - Cancels and replaces...
Page 744 Electrical system Marea-Marea Weekend Component location '99 range Connection between dashboard/right front door cables HG310D ' S 28B. GN 244A Z28B* N 19. A n.d AG n.d. BN 111B B 3 1 0 E . MN n.d LR 66 HV 66 1 20 Connection for air conditioning unit cables Climate control system/heater with thermostatic adjustment (1242)
Page 745 R AR AV AV AB rji rji rji r|i N.D, -ZN- • c —•— c T T T „„ 15/54 ' , ' irrt/a J pos staz I i n t / f l n n ^ •mil P4FS75N01 Copyright Fiat Auto...
Page 746 Electrical equipment Marea-Marea Weekend Component location 99 range 5 5 A Connection between front/engine cables C L 6 A H G 6 A L N 6 A S 3 3 3 C A R n . d MZ 333C SN n.d. C 3 3 3 B HN n.d.
Page 747 C-i- 1 2 8 0 c 128(11: ! BN ! AG' - C B - N.D. — * — * — - i - f T T ^ I Irrt/a I |1998| 1747 E O T <igg.'99 Copyright Fiat Auto...
Page 748 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box C A 9 5 CB n.d. VN127 ARn.d. R n.d. M n.d. C n.d * C n.d 1 27 Connection between left front cable/cable on relay holder bracket R n.d. 1998 RN 98 S 3 6 5...
Page 749 N,D, 1261k 126 He -AB- i— 129A <— c • A G I 127 c C A B N.D. -CB- N.D, A G 1 A B B N 55Cc G N BG GL B [c]BG [B]GN [gCL Copyright Fiat Auto...
Page 750 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box C A 9 5 C B n.d. VN127 AR n.d. R n.d. M n.d. C n.d ' C n.d 5 5 C Connection between front/engine cables * BN 127. M B 4 C .
Page 751 87 30 86 87 87ci 30 85 ™> ™ a , ; N.D. 129A N.D. N.D. AG B 55CC G L B m t / o HGN [c]GL [c]BG [g] B J T D P4F881N01 Version without air conditioning Copyright Fiat Auto...
Page 752 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box C A 9 5 . CB n.d. .VN127 AR n.d. R n.d. M n.d. C n.d C n.d. " C n.d M n.d. 5 5 C Connection between front/engine cables * BN 127.
Page 753 A A G -CB- N.D, _ . G I—?L|_ - . 1 5 / 5 4 ' J 15/54 J , ' i n t / a ' I irrt/a I s t a z |1747| , T 1 Copyright Fiat Auto...
Page 754 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box C A 9 5 ARn.d. C n.d C n.d. ' C n.d M n.d. 5 5 C Connection between front/engine cables 1747 HB6A HM6A A R 1 5 9 AR n.d HM n.d L 6 A...
Page 755 1 2 7 ^ • > A' B \ • — C 34 35 13 3 5 21 40 14 1 9 5 115811 |1242| H^T f r r'f I 15/54 J. Int/a J D O S Copyright Fiat Auto...
Page 756 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box CA95 AR n.d. C n.d C n.d. * C n.d M n.d. 1 27 Connection between left front cable/cable on relay holder bracket _§L ARn.d. B2 AN 124 1242 RN 98 B3 MG 124 MG 140A...
Page 757 I I I N.D. -AB- •AB- -AG- -AG- N,D, N.D. • — C • N.D. f T Y T ' 15/54 I , ' l n t / a J pos •J. ' lnt/a siaz D o s Copyright Fiat Auto...
Page 758 Electrical equipment Marea-Marea Weekend Component location 99 range Power fuse box C A 9 5 C B n.d. .VN127 AR n.d. R n.d. M n.d. C n.d C n.d. * C n.d M n.d. 1 2 8 A Connection between front/radiator cables 1910-75 ' N 8 A .
Page 759 Electrical equipment Marea-Marea Weekend Wiring diagrams 99 range Versions without climate control Engine cooling (petrol engine) 162 163 164 165 Copyright Fiat Auto...
Page 760 Electrical equipment Marea-Marea Weekend Component location 99 range 1 27 Connection between left front cable/cable on relay holder bracket A1 R n . d . 1998 A2 RN 98 B4 S 3 6 5 M B 4 C A3 BV 151 B5 VN 98 AN n.d.
Page 761 - . B C Wl, J 17<»« 2C*5«5 19<«> I Irrt/n I W/iJ pos 1 5 / 5 4 , „ J„ 50 int staz ffiM ©; 2> Variants up to Nov. '99 XII-99 - Cancels and replaces Copyright Fiat Auto...
Page 762 Electrical system Marea-Marea Weekend Component location '99 range Power fusebox ' C A 9 5 CB n.d. VN127 AR n.d. R n.d. M n.d. ' C n.d C n.d Connection between front cables/anti-lock brakes A.B.S. leads ' B V 6 A Anti-locking braking system (ABS) and failure warning light Component key 3 Power fusebox...
Page 763 Starting - Electronic ignition and injection - Recharging and warning light - Insufficient engine oil pressure warning light - Injection system failure warning ilight - Rev counter (1998) t—11111IH---I 165A 165 164 163 162 Variants up to Nov. '99 X " - 9 9 Copyright Fiat Auto Cancels and replaces...
Page 764 Electrical system Marea-Marea Weekend Component location '99 range Front/engine lead connection N 131B * BV n.d * A R n.d HB6A M 148 1 27 Connection between front left cable/cable on relay holder bracket R n.d. * 1998 A2 RN 98 S 3 6 5 B1 MB 4 C * A3 BV 151 *...
Page 765 ' 15/54 ' , int/a ' pos RBIHB 50 Int staz int/a I Dos C B A iztW 18 6 1 5 6 ^ ® 164 165 162 163 Variants up to Nov. '99 Copyright Fiat Auto " ~ Cancels and leplaces...
Page 766 Electrical system Marea- Marea Weekend Component location '99 range 5 5 A Front/engine lead connection 1747 agg.'99 * HR n * B R n.d. ' R G 127 N 131 H B 6 A R n . d . 5 5 B Front/engine lead connection 1747 agg.'99...
Page 767 N I N I N N 1 2 1 1 2 1 JGlfa. R N C 22 8 M B N N N Z irvt/o. J pos 3° J331 S"tQZ 162 163 164 165 R N SG Copyright Fiat Auto...
Page 768 Electrical equipment Marea-Marea Weekend 99 range Component location Connection between front/engine cables HB6A AG 127 1747 * HM 6A ARn.d *L6A L160B* HB 158 *CN6A M N 127 AN 160B * RN 12A CB 137* M 147 * MB 257 *Cn.d.
Page 769 ^ r | ' 'f T T C B A M B N N NZ ""EG ' iirfc/a ' pos staz rti. szh. 1 2 1 1334 2° 3* 4* 162 163 164 165 Variants up to Nov. '99 Copyright Fiat Auto " Cancels and replaces...
Page 770 Electrical system Marea- Marea Weekend Component location '99 range Front/engine lead connection 1581 * C N 6 A H G 6 A * HN 6A CN n.d. M B 6 A NZ 8 CN n.d. 1 4 3 * HM6A 1 9 5 A Ignition / injection control unit.
Page 771 M B N N N Z ,' irrt/o ' pos "- staz 148A 148 ^ 1 5 6 ^ 3* 4" 18 6 162 163 164 165 Variants up to Nov. '99 Copyright Fiat Auto XII-99 - Cancels and leplaces...
Page 772 Electrical system Marea-Marea Weekend Component location '99 range Front/engine lead connection 1242 AR159 HB6A *VB 70 L140 ARn.d. MN 147. CN 6A CN 137 CB137 *BG194 *R155 ' RN 12A * G n.d NZ 8 N 148 M 145 * HN 6A * RV 274 HRn.d.
Page 773 Starting - Electronic ignition - Recharging and warning light - Low engine oil pressure warning light - Glow plug pre- heating warning light - Injection system failure warning light - Fuel preheating (2387 JTD) Variants up to Nov. '99 Copyright Fiat Auto XII-99 - Cancels and replaces 1 0 3...
Page 774 Electrical system Marea-Marea Weekend Component location '99 range Injection control unit (JTD) n R n C344* — Nn.d.* N n.d. * *L Bn.d.* A? Bn.d.* N n.d. * [ U z = L J ] B1 G201B* B8 SN 55A * B2 BL 55A * B13 C55A* —...
Page 775 Starting - Electronic injection - Recharging and warning light - Low engine oil pressure warning light - Glow plug pre- heating warning light - Injection system failure warning light - Fuel preheating (1910 JTD) 339 338 337 336 Variants up to Nov.'99 XII 99 Cancels and leplaces Copyright Fiat Auto...
Page 776 Electrical system Marea-Marea Weekend Component location '99 range 3 3 3 Injection control unit (JTD) n F=ln | / — C 3 4 4 * — N n . d . * A 7 • _ J * — N n . d . * —...
Page 777 N N I NZ I N N RN C £ 1 1 M B N , , N NZ £31 Irrt/a J pos 15/54 staz 50 Int .E3)(nir Variants up to Nov. '99 Copyright Fiat Auto x l 1 " " Cancels and replaces 1 Q7...
Page 778 MG 5 5 * 223 Rpm sensors V 2 9 6 * HV 285 * 226 Tester socket for Fiat CODE system (1910 TD-75) G 2 9 6 * (*) The cables involved in the wiring diagram are marked with an asterisk.
Page 779 H N LN L A ] M N V M B VN 15/54 Irrt/a J i n i S t Q 2 N.D. lEIBIWIIPIMiE 1 2 3 4 5 6 7 8 9 10 11 13 -HV- Copyright Fiat Auto...
Page 780 Electrical equipment Marea-Marea Weekend Component location 99 range 267L Automatic transmission control unit i.d. P4F910N01 Automatic transmission - System failure warning light ( 1581 c.a. engine) P4F910M03 Connection between automatic transmission/front cables Key to components 3 Direction indicator 270 Connection between automatic trans- mission/rear cables 4 Junction unit 6 Instrument panel...
Page 781 8 9 12 B R I B R j B R I N VGICB N.D. Z —»— N 1581 e s s 21 22 23 • i "t Z | N N.D, (e>) Version with Side Bag Copyright Fiat Auto...
Page 782 Electrical equipment Marea-Marea Weekend Component location 99 range 1 03 Diagnostic socket for alarm * B R 1 0 0 A _ * N Z 8 1 39 Diagnostic sockect for injection system * BR 160C * N 148 1747 agg.99 * BR 190A * N 8...
Page 783 1 1 4 |1910-75| JTD I N.D. N ( * ) • L r i b 55A E 1910-75 [1910-75| |2387| 8 9 12 VGICB CB Z N.D. Z - • — N • • Copyright Fiat Auto 1 1 3...
Page 784 174 Power earth for A.B.S. P4F914N04 176 Diagnostic socket for A.B.S. Diagnostic socket for climate control system 181 A.B.S. electro-hydraulic control unit 226 Diagnostic socket for FIAT CODE sys- tem (191 OTD-75) 249 Diagnostic socket for climate control system 253 Climate control unit 298 E.G.R.
Page 785 " ( • ) Fiat Marea Car interior ghting - Symbol lighting Fiat Marea W e e k e n d Car interior lighting - Symbol lighting Radio system (high level: AD 185 H) - Cigarette lighter Radio system (mid-level: AD 185 M) - Cigarette lighter...
Page 786 Electrical equipment Marea-Marea Weekend Wiring diagrams '99 range Marea-Marea Weekend DESCRIPTION DESCRIPTION DESCRIPTION 1910 1581 1747 1910 2387 1242 1581 1747 1998 TD-75 a.c. agg. 99 Alarm/Door check device 38a** 38a** 38a** 38a** 38a** 38a** 38a** 38a** 38a** Central locking Electrically-adjustable, heated door mirror Predisposition for car phone and T E L E P A S S Electric sun-roof...
Page 787 I l l I l l 114a Manually operated heater NOTE The numbers in the table correspond to the page number of the wiring diagram V I I - 2 0 0 0 - Cancels and replaces Copyright by Fiat Auto...
Page 789 N.D, 310A -<*-{ N.D. N,D.{ ,„ , 1 fBl 15/54 ' , I lnt/a J pos 5 0 Int staz^ trtftj P4F081ML01 Copyright by Fiat Auto Cancels and replaces V I I - 2 0 0 0 1 1 4...
Page 790 Electrical equipment Marea-Marea Weekend Component location '99 range Connection for front dashboard cables — R N 4 C — M 2 9 — AN 4 C * — R N 1 2 0 — M 310C AN 120 * — V G 1 2 7 —...
Page 791 Electrical equipment Marea-Marea Weekend 99 range Key to components Right front speaker (tweeter) Left front light cluster Right front light cluster Speaker in right front door Power fuse box Left rear speaker Right rear speaker Junction unit Dipped headlamps relay feed Connection between front/engine cables Instrument panel Fuel gauge assembly...
Page 792 Earth for climate control system Injection system protective fuse Rpm sensor 152A Injection system protective fuse Diagnostic socket for FIAT CODE system 152B Injection system protective fuse (1910 TD-75) Engine cooling fan Diagnostic socket for injection system (1747)
Page 793 ICE/SPORT selector for automatic trans- Engine cut out electrostop (TD) mission Clock spring connection Shift Lock electro-magnet Earth for compressor Additional PARK interruption for auto- Thermal relay on water pump matic transmission Connection for air conditioning compres- sor cables Safety control unit for automatic trans- mission Connection between rear cable and tail- gate...
Page 794 « Cable colour code Additional heater protective fuse Light blue Additional heater sensor 351A Additional heater heater plug White 351 B Additional heater heater plug Orange 351 C Additional heater heater plug Yellow Left Side Bag connection Grey Right Side Bag connection Blue Air Bag earth Brown...
Page 795 - Removing-refitting side bag power cable - Removing-refitting lumbar adjust- ment device - Dismantling head restraint - Removing-refitting side bag frame 37¬ - Removing-refitting set height ad- justment - Loction of driver's seat components - Location of passenger seat compo- nents Copyright Fiat Auto...
Page 796 INTRODUCTION The 1999 Fiat Marea - Marea Weekend range is fitted with a new Air Bag system. This differs from the current system in the addition of a passenger presence sensor PPD on the front seat. This allows the pas- senger side air bag and pretensioner to go off only if the seat is occupied.
Page 797 Electrical equipment Marea-Marea Weekend Air bag - New features 1999 range PASSENGER PRESENCE SENSOR PPD The 1999 range air bag system now comes with a passenger presence sensor that prevents the front pas- senger air bag and passenger side bag (where fitted) going off if a passenger is not present. Passenger side seat w i t h passenger presence sensor (PPD) 4F002FL01 1.
Page 798 ELECTRONIC CONTROL UNIT FOR AIR BAG SYSTEM AND PASSENGER PRESENCE SENSOR (PPD) The air bag system fitted to the 1999 range Fiat Marea-Marea Weekend comes with a new electronic con- trol that differs from the previous system in the addition of a connection to the passenger presence sensor and the integration of control functions.
Page 799 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range Diagram showing connections between control unit and components • > c z i ° czi rzzi « • 1. Electronic control unit Driver air bag module Passenger air bag module 2.
Page 800 If an anomaly is detected, the red failure warning light is activated and the system operates in conventional manner to keep the driver and passenger side air bags operational at all times. Copyright Fiat Auto...
Page 801 Electrical equipment Marea-Marea Weekend 1999 range Air Bag - New features Diagram showing connections between control unit and components 4F006FL01 Control unit pin out Driver's air bag Short circuit Short circuit Driver's air bag Passenger air bag Short circuit Passenger air bag Short circuit Available Not connected...
Page 802 SIDE BAG MODULES The side bag modules fitted to the Fiat Marea - Marea Weekend are fitted by a bracket to the inside of the squab on the side facing the outside of the structure. This is an improvement on the version where the modules are fitted to the door because the bag is always in optimal position in relation to the occupant regardless of seat position or occupant size.
Page 803 Electrical equipment Marea- Marea Weekend 1999 range Air bag - New features GENERAL WARNINGS IT IS ABSOLUTELY FORBIDDEN to use any type of seat cover that is not specifically designed for this type of seat. When replacing, take the greatest care to install in the correct position: the wording SIDE BAG must be on the same side of the squab as the side bag module.
Page 804 If the impact is on the passenger side, the main control unit compares the signal from the deceleration sensor with a signal from the passenger presence sensor to determine whether or not to set off the side bag module. Copyright Fiat Auto...
Page 805 System components must be assembled and disassembled ONLY by authorised technical personnel, re- membering that the components need handling with care. Component shipping and storage is governed by the handling procedures described in Section 55 - Electrical Equipment of the Fiat Marea - Marea Weekend Workshop Manual (volume 2).
Page 806 4. U n d o the bolt s e c u r i n g t h e pillar trim. Copyright Fiat Auto...
Page 807 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range II 1 1. Raise the rear sill plate, then undo the un- derlying bolt securing the pillar trim. 2. Raise the front sill plate, then unscrew the underlying bolt securing the pillar trim. 3.
Page 808 3. Tilt the seat back to gain access to the connections, then disconnect the lumbar adjustment connector, heat pad and seat belt, if present. Prise up the connector holder box safety cap. 4. Remove the connection holder box flap. Copyright Fiat Auto...
Page 809 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range Two connections are present on the passenger side seat (side bag and pas- senger presence sensor), while only the side bag connection is present on the driver's seat. Disconect connector (1) controlling the side bag and connector (2) controlling the pres- ence sensor;...
Page 810 NOTE Whenever work is carried out on the air bag system, it is COMPULSORY check the system is working properly using the relevant testers. Copyright Fiat Auto...
Page 811 Electrical equipment Marea-Marea Weekend Air Bag • New features 1999 range PERSPECTIVE VIEW OF SIDE BAG Dismantling the side bag Side bag modules are fitted beneath the squab trim and do not significantly alter original seat style and size. 4F016FL01 1.
Page 812 2. Prise up the plug securing the seat rake adjustment knob. 3. Remove the seat rake adjustment knob. 4. Unscrew the retaining bolts shown in the figure and remove the outer seat cover. 5. Undo the inner seat cover retaining bolt. Copyright Fiat Auto...
Page 813 Electrical equipment Marea- Marea Weekend Air Bag - New features 1999 range 1. Remove cover A by manoeuvring to release washer B. Take care to avoid breakage. Push plug C from inside after removing the trim. Recover claw washer B. 2.
Page 814 NOTE To refit, reverse removal instructions. Ensure the side bag module safety connector is reconnected in all cases, otherwise the warning light on the in- strument facia will come on to indicate a fault. Copyright Fiat Auto...
Page 815 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range REMOVING-REFITTING FRONT SEAT Removing-refitting front seat squab cover. - Remove the side bag module as described in the "SIDE BAG MODULE" chapter. - remove the cover in the outer compartment of the side bag from the Velcro;...
Page 816 4. View of inside of cover A. Cover B. Elastic retainer C. Retaining hooks NOTE Reverse removal Instructions to refit. Secure the squab cover hooks using tool 1878077000, taking care to do up the links correctly. Use new hooks. Copyright Fiat Auto...
Page 817 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range Removing-refitting front seat cushion cover. Remove the front seat as described in the chapter "FRONT SEAT WITH PASSENGER PRESENCE SENSOR AND SIDE BAG" 1. Remove plug (A) and squab adjustment knob (B).
Page 818 Prise up with the aid of a screwdrier, then remove the cushion. Remove the cushion complete with cover from its seat, taking care with the electrical wiring and in particular with the passenger presence sensor and heat pad. Copyright Fiat Auto...
Page 819 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range 1. Remove hooks (A) securing the cover to the padding using cutting pliers. 2. Turn the cover over and remove retaining hooks B located at the sealing edges. Remove any remaining hooks con- nected to the padding to prevent dam- age to the new cover.
Page 820 Re- connect the electrical connectin and refit the squab cover as shown. Refit the front seat squab cover. as described in the paragraph "Dismantling assembling front seat squab cover". Copyright Fiat Auto...
Page 821 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range Removing-refitting cushion heat pad 1. Release the squab plastic section from its retaining system. 2. Remove the seat cover partly to cut retain- ing collar (1), disconnect electrical supply connection (2) and withdraw the wiring.
Page 822 PPD sensor is working correctly. As soon as the seal is removed for any reason, the manufacturer's warranty is cancelled. When refitting, replace the warranty seal with an original Fiat seal. Release the passenger presence sensro supply lead from the retaining collar.
Page 823 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range Refitting - To refit, position the PPD sensor with the adhesive side facing the padding; - insert the PPD sensor into the notches in the cushion padding shown in the figure; - reposition the PPD electrical wiring and re- store the warranty seal.
Page 824 B. 4. Unscrew bolt A securing trim B to undo claw washer D, taking care to avoid break- age. Push cap C from the inside after re- moving the trim, recovering claw washer D. Copyright Fiat Auto...
Page 825 Electrical equipment Marea- Marea Weekend Air Bag - New features 1999 range 1. Undo the connector carrier box retaining bolt. 2. Remove the box flap, undo the underlying bolt and place the connector carrier box to one side. 3. Release the plastic section (A) at the rear, working as shown in the figure.
Page 826 3. Remove rivet (1) securing the earth lead, extend retaining collar (20 and disconnect side bag supply lead (3) from the seat. 4. Cut the collar securing the supply lead to the seat squab frame. NOTE Reverse removal instructions to refit. Copyright Fiat Auto...
Page 827 Electrical equipment Marea- Marea Weekend Air Bag - New features 1999 range REMOVING-REFITTING LUMBAR JUSTMENT DEVICE Raise the front seat squab cover as described in the paragraph "Removingrefitting front seat squab cover". 1. Disconnect lumbar adjustment motor elec- trical connection (1), then disconnect col- lars (2) retaining the supply lead and undo bolts securing the motor to the...
Page 828 - Disconnect the lumbar adjustment motor electrical supply connection; - undo the motor retaining bolts shown in the figure; - remove the lumbar adjustment device from its seat. NOTE Reverse removal instructions to refit. Copyright Fiat Auto...
Page 829 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range DISMANTLING THE HEAD RESTRAINT Remove the head restraint as described in the paragraph "Removing-refitting front seat squab cover". 1. Undo the cover retaining plate bolts. 2. Raise the panel and remove from the head restraint.
Page 830 1999 range Air Bag - New features - Prise up the trim from the head restraint padding; - separate the padding from the head restraint structure; - structure (1), padding (2), trim (3), frame (4), button (5); 4A35JL03 Copyright Fiat Auto...
Page 831 Electrical equipment Marea- Marea Weekend Air Bag - New features 1999 range - position the head restraint height adjustment button in its housing; press button (A) and position head restraint rod (B) at the end of its course'; remove the button fitted previously; handle detent insert (B) carefully to prevent the retaining clip coming out, the remove head restraint rod (A).
Page 832 - Remove the side bag frame from the seat squab frame. Refitting - Position the side bag frame and fit rivets of the size shown in the figure at the points in- dicated by arrows. 4F037FL03 Copyright Fiat Auto...
Page 833 Electrical equipment Marea-Marea Weekend Air Bag - New features 1999 range REMOVING-REFITTING SEAT HEIGHT- ADJUSTMENT MOTOR Remove the front seat as described in the paragraph "REMOVING-REFITTING FRONT SEAT WITH PASSENGER PRESENCE SEN- SOR AND SIDE BAG" T. Position the seat on the bench and discon- nect the height-adjustment motor supply connection.
Page 834 Height adjustment motor Squab and cushion heat pad connector Cushion heat pad Wiring Height adjustment power supply Heat pad supply lead Heat pad warning light Safety circuit power supply Heat pad switch Heat pad power supply Side bag Copyright fiat Auto...
Page 835 Electrical equipment Marea-Marea Weekend 1999 range Air Bag - New features LOCATION OF PASSENGER SEAT COMPONENTS Squab heat pad Side bag power supply Squab and cushion heat pad connector Passenger presence sensor PPD interface Cushion heat pad control unit Passenger presence sensor connector Heat pad supply lead...
Page 836 - Rear seat central headrest - R & R - Rear seat central headrest - Disas- sembly and reassembly - Rear seat side headrest - R&R - Rear seat side headrest - Disassembly. - Rear central searbelt with reel - R&R Copyright Fiat Auto...
Page 837 NOTE To refit, reverse the operations used for removal. REAR SEAT COMPLETE FOLDABLE BACKREST - R&R 1. Remove the rear seat cushion. 2. Undo the bolt and move the end of the seat belt. When reassembling, tighten to a torque of 4 daNm. Copyright Fiat Auto...
Page 838 Body Marea-Marea Weekend Seats 99 range 1. Undo the front central bolt. 2. Lower the backrest. 3. Disengage the retainers and remove the the boot compartement covering from the backrest. 4. Undo the backrest bracket retaining bolts. 5. Remove the complete backrest. NOTE To refit, reverse the operations used for removal.
Page 839 REAR SEAT CENTRAL HEADREST - R & R . Removal 1. Push and lift the head rest fiirst from one side (1a) then from the other, after discon- necting the pins from their sleeves (1 b). 2. Retrieve the headrest. Copyright Fiat Auto...
Page 840 Body Marea-Marea Weekend Seats. 99 range - Lift the rear seat cushion and lower left backrest. 1. Remove the lining (1a) along the edges of the backrest, up to the headrest area (1b). 1. Remove lining (1a) and padding (1b) from sleeves (1c).
Page 841 8. Remove the lining and the padding. 1. Turn over the headrest and disconnect the bellows from the retainers. 2. Retrieve the bellows. Disassembly Use the following procedure to refit the lining. Js°xu—m 1. Undo the bolts Copyright Fiat Auto...
Page 842 Body Marea-Marea Weekend Seats 99 Range 1. Turn over the headrest structure and re- move casing (1a) from lifting mechanism (1b), disconnecting the retainers (1c), then move (1a) upwards (1a) following the ar- row. NOTE When disconnecting retainers (1c), proceed carefully in order to prevent breakages.
Page 843 (1c) are engaged in the housings (1d). 1. Tighten the bolts 1. Connect the bellows side retainers. 2. Connect the flexible retainer hook. 3. Engage the bellows retaining pins. 4. Fit the panel. 5. Fit the button. Copyright Fiat Auto...
Page 844 Body Marea-Marea Weekend Seats 99 range REAR SEAT SIDE HEADREST - R&R Removal 1. Lift the headrest to the end of its travel. 2. Push the retainers and remove the headrest. MOTE To refit, reverse the operations used for removal. REAR SEAT SIDE HEADREST - Disas- sembly...
Page 845 Remove the headrest sleeves. Remove the armrest cover. Remove armrest (5a) disengaging it from retainers (5b). 6. Remove the lining from all around the edge of the seat. 7. Remove the lining with the padding. Copyright Fiat Auto...
Page 846 Body Marea- Marea Weekend Seats 99 Range L W h e n reassembling the cover (1a) check that the B retainers correctly insert into the corresponding C housings of the connec- tion assembly. 1. Turn over the seat frame and undo the cover retaining bolts.

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