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Fiat 1998 Marea Weekend, Service Manual

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Components key 

1 Left front light cluster 
2 Right front light cluster 

3 Power fuse box 
4 Junction unit: 

E1 Ignition discharge relay 
E2 Horn relay feed 
E3 Heated rear windscreen relay feed 

5 Dipped headlamps relay feed 
6 Instrument panel: 

A Automatic transmission failure warning light 

B Air Bag system failure warning light 
C Side lights warning light 

D Main beam headlamps warning light 

E Air filter blocked warning light 
F Injection system failure warning light 

G Battery recharging warning light 

H Insufficient engine oil pressure warning light 

I Seat belt warning light 

J Handbrake applied/insufficient brake fluid 

level warning light 

K Brake pad wear warning light 

L Fiat CODE device failure warning light 

M Anti-lock braking system failure warning 

light (ABS) 

N Maximum turbocharging pressure warning 

light 

0 Heater plugs warning light 

P Trailer lights warning light 

7 Steering column switch unit: 

A Windscreen wiper speed control switch 

B Switch for windscreen washer/headlamp 

washer/rearscreen washer 

C Rearscreen wiper control switch 

D Flasher control 

E Switch for dipped/main beam headlamps 

F Switch for side lights 

G Intermittent device for direction indicators/-
hazard warning lights 

H Switch for direction indicators 

1 Horn control 

8 Left front earth 
9 Right front earth 
0 Battery earth on engine 

)A Battery earth on bodyshell 
iB Battery earth for i.e. 
'C Battery earth for air conditioning 

1 Battery 
2 Ignition switch 
3 Front right/left cables connection 
4 Left no. plate light bulb 
5 Right no. plate light bulb 
6 Left rear light cluster 
7 Right rear light cluster 
8 Left rear earth 
9 Right rear earth 

10 Left front side direction indicator 
!1 Right front side direction indicator 
!2 Left dashboard earth 
'.3 Hazard warning lights switch unit 

A Hazard warning lights warning light 

B Hazard warning lights switch 

24 Windscreen wiper motor 
25 Wind/rearscreen washer electric pump 
26 Rearscreen wiper motor 
28 Dashboard/rear cables connection 
29 Front/fog lamp cables connection 
30 Left fog lamp 
31 Right fog lamp 
32 Fog lights relay 
33 Protective fuse for fog lights 
34 Switch controls: 

A Alarm on warning light 

B Rear fog lamps switch 

C Rear fog lamp relay feed 
D Rear fog lamps warning light 
E Heated rear windscreen control switch 
F Heated rear windscreen warning light 

G Switch control unit ideogram light 

H Fog lights warning light 
I Fog lights switch 

35 Dashboard/left front door cables connection 
36 Dashboard/right front door cables connec-

tion 

39 Heated rear windscreen 
40 Brake lights control switch 
41 Additional brake light 
42 Right dashboard earth 
43 Electrical actuator for left headlamp align-

ment correction 

44 Electrical actuator for right headlamp align-

ment correction 

45 Headlamp alignment control unit 
46 Left electric horn low tone 
47 Right electric horn high tone 
48 Radio receiver with clock 
49 Left front speaker (tweeter) 
50 Right front speaker (tweeter) 
51 Speaker in left front door 
52 Speaker in right front door 
53 Left rear speaker 
54 Right rear speaker 
55 Left front/engine cables connection 

55A Left front/engine cables connection 
55B Right front/engine cables connection 
55C Left front/engine cables connection 

56 Fuel gauge assembly 

A Fuel level sensor 

B Electric fuel pump 

57 Inertia switch 
58 Instrument panel light dimmer 
63 Thermostatic switch on radiator 
64 Glove compartment light bulb with switch 

incorporated 

65 Luggage compartment light bulb 
66 Electrically adjusted externa! rear view mir-

rors control panel 

67 Left external rear view mirror 

4F37AN 

Summary of Contents for 1998 Marea Weekend

Page 1: ...AS Varity EBC 430 anti lock brakes 506 763 11 V I 1 1 9 9 8 10 1 12 Fuel system TO 98 range system with hot film flow meter 506 763 11 V I 1 1 9 9 8 55 Index 14 1 14 4 Wiring diagrams update i p TD 98...

Page 2: ...pical curves 1 Cylinder block crankcase crankshaft and associated components 2 Timing system components 3 Timing diagrams 4 Fuel system 5 ELECTRICAL EQUIPMENT Starting This section contains data for v...

Page 3: ...E C E E 1 2 0 1 1 0 1 0 0 9 0 80 7 0 6 0 5 0 4 0 3 0 2 0 1 0 16v Typical power curves obtained by EEC method The power curves illustrated can be obtained with the engine overhauled and run in without...

Page 4: ...DESCRIPTION Ml6v Values in mm 33 0 0 Piston 0 10 2 86 352 86 362 86 359 86 371 86 368 86 378 0 4 Piston ring grooves 1 2 3 1 520 1 540 1 510 4 1 530 3 010 3 030 0 1 2 3 Piston rings 0 1 470 1 490 1 4...

Page 5: ...end bush 22 004 22 009 q j c p Gudgeon pin Small end bush 0 009 0 019 H A H Valve guide bore fl n c Y m c er head 12 950 12 977 45 20 45 20 L about 2 p j j E X Volume of combustion Ipfljfjjjj chamber...

Page 6: ...Pi 23 4 25 6 daN External valve spring Hi Hi 33 5 46 50 daN 24 5 17a 0 t 1 7 b T Cam lift Q 8 5 8 _ n r u iT L _ J J _ J _ t _ j i _ r 1 12a Bf l B Tappet housings 0 33 000 33 025 TIMING DIAGRAMS Tim...

Page 7: ...SIEMENS EC1 Butterfly casing M Marelli 46 SX F2 Idle adjustment actuator M Marelli IB 02 Injector M Marelli IWP 064 Fuel pressure regulator M Marelli RPM 84 Coolant temperature sender unit JAEGER 402...

Page 8: ...g test current speed voltage torque developed A rpm V daNm 360 380 1150 8 15 1 30 Engagement test current voltage torque developed A V daNm 680 700 4 9 3 11 Free running test current voltage speed A V...

Page 9: ...TER MOTOR WIRING DIAGRAM AND TYPICAL CURVES Starter motor wiring diagram for M Marelli M70R 1 3 12 KWNm V 2 1i 35i 14t 1 8 30 12 1 5 25 10 1 2 20 8 0 9 15 6 0 6 10 4 0 3 5 2 o 0 Typical curves for sta...

Page 10: ......

Page 11: ...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 Cooli...

Page 12: ...1A05C 185 AX B11 08 185 BX B11 12 w 185 AX C1A 02 185AXC1A02B A 182 A2 000 185 AXC1A02C ZFA 185 000 182 A2 000 185 BX C1A 06 w ZFA 185 000 185 BX C1A 06B A 185 CX C1A 06C 185 AX M1A 19 182 B7 000 185...

Page 13: ...Name of manufacturer B Homologation number C Vehicle type identification code D Chassis manufacture number E Maximum authorized weight of vehicle fully laden F Maximum authorized weight of vehicle ful...

Page 14: ...on the tow hook trailer with braking system 70 70 70 70 70 70 70 Without braking system 400 400 400 400 400 400 400 Xj m W with braking system 1200 1200 1200 1300 1300 1400 1300 1300 1400 Loads which...

Page 15: ...8 3 9 9 CO2 exhaust emissions g km Marea 170 197 195 246 199 192 234 CO2 exhaust emissions g km Marea Weekend 173 200 198 251 205 198 237 The fuel consumption figures in accordance with directive 93 1...

Page 16: ...95 39 Max clima ble gradient fully laden Marea 37 Marea Weekend 34 40 37 41 38 Marea Fuel consumption figures in ac cordance with directive 93 116 CE litres 100 km Urban Extra urban Combined 8 5 Marea...

Page 17: ...x14 43 6Jx15 43 881 2540 969 4390 1470 1470 1440 1440 1741 1425 l 6 C 5 Jx14 43 6Jx15 43 881 2540 969 4390 1470 1470 1440 1440 1741 1425 5V4Jx14 43 6Jx15 43 881 2540 969 4390 1470 1470 1440 1440 1741...

Page 18: ...0 1470 1440 1440 1741 1510 5 4Jx14 43 6Jx15 43 881 2540 1066 4487 1470 1470 1440 1440 1741 1510 5 4Jx14 43 6Jx15 43 881 2540 1066 4487 1470 1470 1440 1440 1741 1510 2 0 V 6Jx15 49 881 2540 1066 4487 1...

Page 19: ...p i SELENIA 20K y SAE10W 40 Total capacity 2 75 4 4 1 4 7 Petrol engines p i SELENIA 20K y SAE10W 40 m m Partial capacity periodic replacement 2 8 2 5 3 8 3 5 4 3 3 9 5 4 5 Petrol engines p i SELENIA...

Page 20: ...NIA E Turbo Diesel i H SAE 15W 40 0 Total capacity 4 2 4 25 4 7 Diesel Engines Hj SELENIA E Turbo Diesel i H SAE 15W 40 Partial capacity periodic replacement 4 5 4 2 4 3 4 5 4 7 Diesel Engines Hj SELE...

Page 21: ...RM2 0 003 TUTELA K H T0P4 I I 270 C without i l 1 T 7L a b s 0 40 TUTELA K H T0P4 I I 270 C y 1 without ABS Total capacity 0 45 3 AREXONS 30 I I P 5 3 AREXONS Cr 10 C 50 L 5 3 AREXONS Cr 10 C 50 L 6 4...

Page 22: ...as sisted steering TUTELA GI 2 DEXRON M type oil for automatic transmissions Automatic gearboxes TUTELA MRM2 Water repellant lithium soap based grease containing molybdenum disulphide consistency NLGI...

Page 23: ...electronic injection ignition Number of cylinders W 4 5 V ri 0 Cylinder liner Is il u mm Pol 70 80 82 1 1 1 l M Stroke mm wrn 78 86 75 65 8 capaci v c m 2 1242 1998 Compression ratio R 10 2 10 7 0 15...

Page 24: ...ical curves 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...

Page 25: ...713 51 717 21 72 21 80 63 705 63 718 0 Cylinder liner bore 0 70 800 70 810 82 000 82 010 70 810 70 820 82 010 82 020 70 820 70 830 82 020 82 030 X 12 5 70 760 70 770 81 952 81 962 0 70 770 70 780 81 9...

Page 26: ...40 1 190 1 230 1 210 1 230 2 490 2 530 2 010 2 030 0 X4l 1 170 1 190 1 180 1 160 1 175 1 190 1 190 1 170 2 475 2 490 1 990 1 970 Piston rings 0 Tsr 0 4 5 3 Piston rings Piston ring grooves 0 0 06 0 04...

Page 27: ...01 23 007 23 027 02 20 006 20 012 Small end bush 4 7 o a Gudgeon pin Small end bush 0 006 0 020 7 6 Small end bush Bush housing 0 035 0 088 Main journals 01 r 1 2 l 3 47 982 47 988 47 988 47 994 47 99...

Page 28: ...8 10 8 Oi O Cr ankshaft bearings Main journals 0 024 0 060 0 030 0 056 11 Thrust washers 2 310 2 360 2 342 2 358 0 127 11 8 Crankshaft end float 0 055 0 265 0 059 0 161 Diagram showing connecting rod...

Page 29: ...10 DESCRIPTION Values in mm Camshaft supports on cylinder head 0 26 045 26 070 19 100 19 150 12 n Valve guide bore In cylinder head 0 9 959 9 989 12 950 12 977 1 S a Valve seat 45 20 45 5 45 20 45 5...

Page 30: ...9 0 051 0 033 0 080 12 Tappet housing In cylinder head 0 33 000 33 025 0 1 5 974 5 992 14 01 L a 22 250 22 250 Valve m 01 5 974 5 992 0 2 22 250 22 550 a 6 975 6 930 29 900 30 200 45 30 5 6 960 6 975...

Page 31: ...26 015 19 250 19 330 17a A 1 7 b o Cam lift HQ 7 5 53 7 5 01 0 030 0 070 12 17a 12 17b SUP 0 2 0 030 0 070 Camshaft bearings Cylinder head supports 0 3 0 030 0 070 radial 0 030 0 070 axial 0 100 0 23...

Page 32: ...025 0 066 19 18 P Tappet Housing in N N camshaft housing 17 20 y A clearance for timing check 0 45 operational clearance Hydraulic tappets TIMING DIAGRAMS A JD A 1 nlA HQ opens before T D C 0 9 after...

Page 33: ...oil pump driven gear 27 0 0 01 19 900 20 000 02 46 989 47 000 Ball bearings for counter balance shaft 25 0 0 0 0 19 980 19 993 Counter balance shaft bearings Bearing seats in cylinder block crankcase...

Page 34: ...ull flow filter cartridge Insufficient oil pressure sender unit electrical between pump casing and Driven gear 0 100 0 210 I f n f H H j between edge of l y RJ gears and pump casing 0 110 0 180 pft be...

Page 35: ...C V 7 2nd stage 95 94 C 1s t speed 96 97 C Operated by nd control unit 2 speed 101 102 to engage l S t e r fan etnpj 1 Speed 93 h 94 C 2n d speed 98 99 C opening 81 85 C Engine coolant thermostat max...

Page 36: ...1 Butterfly casing Bosch 0 280 750 013 Motorized butterfly casing Bosch 0 250 003 052 Absolute pressure sensor Bosch 0 261 230 013 Injector Bosch 0 280 155 816 Bosch 0 280 155 770 Electric fuel pump B...

Page 37: ...stem Direct injection Turbocharger intercooler L 1 Number of cylinders Nl 4 in line 5 in line lh t 0 Cylinder liner L A nl mm Pol 0 r e 82 _ L J Stroke mm 90 4 8 8 M H I Capacity cm 1910 2387 Compress...

Page 38: ...o the figures recommended in the table complete the running in of the actual engine in the vehicle Test speed rpm Time in minutes Load on the brakes 800 1000 10 no load 1500 10 no load 2000 10 no load...

Page 39: ...1 720 21 800 1 Main bearing supports 63 691 63 732 0 Cylinder liner 0 82 000 82 010 82 010 82 020 82 020 82 030 0 X 81 920 81 930 81 930 81 940 81 940 81 950 Piston 10 81 930 81 940 81 940 81 950 81 9...

Page 40: ...988 Gudgeon pin 0 4 3 p Gudgeon pin Housing 0 011 0 022 0 003 0 014 0 5 Piston rings 2 568 2 597 2 575 2 595 1 970 1 995 1 970 1 990 T 3 2 970 2 990 2 975 2 990 0 0 4 0 6 0 4 Piston rings 5 3 p Piston...

Page 41: ...ig end bearing housing 02 53 897 53 909 53 883 53 923 g A Difference in weight between A connecting rods 01 29 018 29 038 1 Id 02 Small end bush 26 006 26 012 4 7 q p Gudgeon pin Small end bush 0 018...

Page 42: ...rings L 3 1 842 1 846 0 fl r 0 254 0 508 Crankshaft Vi H bearings Main journals 0 011 0 071 0 025 0 052 I 10 L J A Big end bearings L A 1 527 1 531 I 10 L J A Big end bearings L 1 530 1 534 I 10 L J A...

Page 43: ...PTION Values in mm Valve guide bore 0 in cylinder head 13 950 13 977 45 20 a 45 20 45 5 45 5 About 2 7 12 Valve seat I u i T L r i n n _ n n Ln_jW LJ H rLrLr L T 0 26 045 26 070 19 100 19 150 L Camsha...

Page 44: ...uide Bore in cylinder head 0 033 0 080 14 01 0i 7 974 7 992 02 35 40 35 60 a 45 30 15 Valve 37 40 37 70 45 30 5 0i 7 974 7 992 07 34 40 34 60 30 90 31 20 a 14 13 Valve Valve guid 45 30 5 0 030 0066 16...

Page 45: ...7 12 radial 0 030 0 070 17 12 axial 17 4 t t T Cam lift HQ 8 5 17 4 t t T Cam lift S3 8 5 n J u i r L _ u r i _ j _ r 1 9 Tappets 0 36 975 36 995 19 12 p Tappet Cylinder head 0 050 n n n n _ 20 7 T S...

Page 46: ...range Engine cylinder head andvalve gear components OO 10 TIMING DIAGRAMS 8 TIMING ANGLES A 1 nlnt H Q opens after TDC 0 6 i niei B H Q closes after BDC 32 26 C opens after BDC 32 26 txnausx D closes...

Page 47: ...ion through oil pump driven gear 0 27 0 01 02 Ball bearings for counter balance shaft 19 900 20 000 46 989 47 00 25 0 0 Counter balance shaft bearings 0 19 980 19 993 1 Bearing seats in cylinder block...

Page 48: ...operated through crankshaft Oil pressure relief valve incorported in crankshaft front cover between pump casing housing and driven gear 0 080 0 186 4 between upper side of n gears and pump cover Full...

Page 49: ...ankshaft Oil pressure relief valve incorporated in the crankshaft front cover IHimBl between edge of gears P and pump casing 0 110 0 180 y S I H B I between upper edge of W H l P P gears and pump casi...

Page 50: ...eed 101 102 C to engage fan stop 1s t speed 93 94 C 2n d speed 98 99 C opening 88 Engine coolant thermostat max opening 103 valve travel 9 5 mm Fitting clearance between impeller vanes and pump casing...

Page 51: ...t temperature sensor Jaeger 402 183 01 Diesel temperature sensor Bosch 0 281 002 209 Rpm sensor Bosch 0 281 002 214 Timing sensor Bosch 0 281 002 213 Turbochrager pressure sensor Bosch 0 281 002 215 F...

Page 52: ...1 002 215 Fuel temperature sensor 0 281 002 209X Electric fuel pump 0 580 464 984 Air flow meter 0 280 218 019 Fuel pressure sensor 0 281 002 210 Engine coolant temperature sensor 0 281 002 209 Timing...

Page 53: ...G Turbocharger operated by exhaust gases with waste gate pressure valve and air air heat exchanger intercooler COOLING SYSTEM Turbocharger type Garret GT 15 IHI VL6 variable geometry Maximum superchar...

Page 54: ...mechanism Spring Spring loading daN 430 600 485 600 01 Driven disc 01 200 230 215 235 01 Driven disc 02 137 155 147 165 1 Distance between i f pedal in end of travel position and pedal in Vfc rest po...

Page 55: ...0 21 27 GEARBOX Type C 514 5 13 C 510 5 21 Oft Synchronizers spring ring tff Porsche type XiS baulk ring type o f t oo Gears straight toothed helical toothed TO oo Gear ratios 3 909 2 158 1 480 1 121...

Page 56: ...nal housing bearing conical roller bearings Adjustment of bearing pre loading O by shims I H 7 a 0 05 1 70 2 60 R m m Thickness of shims L 0 10 2 00 3 00 p Recommended Jl interference for U exact bear...

Page 57: ...f L 1 P o r s c n e t y p e bzT T I I baulk ring L type f Synchronizers Jf m f straight f i g _ 1 toothed OO 060 helical tk G e a r s toothed Ai t f f 3 909 3 800 2 238 2 235 oo 838 1 444 1 360 Gear r...

Page 58: ...e loading O by shims ram m j m m 0 05 Thickness of shims I 1 70 2 60 1 25 1 60 n n Bearing 4 LldBo rolling V U torque 0 10 0 14 A 1 1 Recommended n g s n interference for jr exact bearing m m pre load...

Page 59: ...I pump 0 22 225 7 8 a S ffl j Brake servo Iso Vac 8 pneumatic vacuum acting on all four wheels J Distance of hydraulic piston push rod from master cylinder support plate L 22 45 22 65 REAR BRAKES 203...

Page 60: ...Master cylinder pump 0 23 81 15 16 Brake servo Iso Vac 8 7 pneumatic vacuum acting on all four wheels Distance of hydraulic pis ton push rod from master L cylinder support plate 22 45 22 65 REAR BRAKE...

Page 61: ...d pinion power assisted T 6 no of turns lock to lock 3 2 9 2 8 Ratio rack travel 142 1 5 mm 137 1 5 mm 132 1 5 mm Turning _ circle t1 10 7 11 11 4 Steering angle outer wheel 31 30 Steering angle inner...

Page 62: ...175 70 R14 84H 185 65 R14 86H 195 55 R15 84V 2 1 bar 2 2 bar 2 3 bar 2 5 bar 51 Jx15 43 195 60 R15 88V 2 4 bar 2 5 bar 2 3 bar 2 5 bar SPARE WHEEL 4Bx15 43 3 4Bx15 35 185 65 R14 86H A 125 80 R5 95m 4...

Page 63: ...38 10 30 2 51 30 1 1 mm 0 camber rear suspension toe in 2 thrust angle rear wheels A 0 52 00 30 0 85 2 mm Angles cannot be adjusted With the tyres inflated to the correct pressure and the vehicle in r...

Page 64: ...he telescopic damper ENGINE TYPE 16v Shock absorbers Type Double acting telescopic hydraulic Open start of damping action mm 508 2 5 501 2 5 Closed metal against metal mm 361 2 5 354 2 5 Travel mm 147...

Page 65: ...dard air conditioning and all options B A SPECIFICATIONS OF VARIOIJS SPRIN GS Coil springs A B C D E F G Diameter of wire mm 13 6 0 05 13 5 0 05 13 2 0 05 Number of coils 3 75 Direction of coil Clockw...

Page 66: ...ls 5 93 Direction of coil clockwise Height of spring released mm 3 16 Height of spring under a load of 360 daN mm 184 The springs are divided into two categories identifiable by a mark yellow 1 for th...

Page 67: ...coil clockwise Height of spring released mm 322 Height of spring under a load of 432 daN mm 184 The springs are divided into two categories identifiable by a mark yellow 1 for those 432 daN height of...

Page 68: ...R BUILT IN ELECTRONIC BATTERY 12V 50Ah 250A 12V 50Ah 250A 12V 60Ah 320A A 12V 60Ah 380A 12V 70Ah 450A 12V 65Ah 450A IGNITION SYSTEM Bosch M1 5 5 MPI integrated elec tronic injection ignition Bosch Mot...

Page 69: ...1720 2200 9 5 9 8 10 0 37 0 38 360 380 1150 8 15 1 30 Engagement test current A voltage V torque developed daNm 324 440 7 1 7 6 0 97 1 25 680 700 4 9 3 11 Free running test current A voltage V speed r...

Page 70: ...speed rpm voltage V torque developed daNm 500 1950 7 30 1 30 400 1400 9 60 1 40 600 1400 7 9 1 6 Engagement test current A voltage V torque developed daNm 1200 5 5 3 0 1100 1150 4 4 4 6 5 0 1110 1150...

Page 71: ...eld winding re sistance between the two slip rings n 2 4 2 6 Direction of rotation seen from control side Clockwise Diode power rectifiers Bridge Data obtained at an ambient temperature of 20 C Suppli...

Page 72: ...AKES Make Bosch Type 0 221 503 407 Ohmic resistance of primary winding at 20 C Q 0 45 0 55 Ohmic resistance of secondary winding at 20 C 12000 14600 TOP DEAD CENTRE AND RPM SENSOR Make and type Bosch...

Page 73: ...0 221 504 014 Ohmic resistance of primary winding at 20 C Q 0 4 Ohmic resistance of secondary winding at 20 C Q 8500 TOP DEAD CENTRE AND RPM SENSOR Make and type Bosch 0 261 210 160 Sensor winding res...

Page 74: ...ug 1855035000 Spanner 19 mm for removing and refitting gearbox 1860691000 Drift for removing and refitting gear hardening ball plug 1860851000 Crossmember for removing refitting gearbox 1860851001 Cro...

Page 75: ...ft for fitting clutch release control shaft bush 1871000000 Rotating stand for overhauling gearboxes and differentials 1871001014 Support for gearbox differential unit whilst overhauling to be fitted...

Page 76: ...0 90 Cylinder head to cylinder block fixing bolt M12 6 5 90 90 90 Engine support to cylinder block crankcase fixing bolt M8 2 2 Engine support to cylinder block crankcase fixing bolt M10 5 Camshaft ca...

Page 77: ...r fixing bolt M8 2 2 Compressor fixing bolt M10 5 o Auxiliary units fixed belt tensioner fixing nut and bolt M8 2 5 Power assisted steering pump fixing bolt M8 2 5 Pulley to power assisted steering pu...

Page 78: ...separator to inlet manifold fixing nut M6 0 9 Auxiliary support to cylinder block crankcase fixing flanged bolt M8 2 5 Auxiliary support to cylinder block crankcase fixing flanged bolt M10 5 Ring nut...

Page 79: ...reaction brackets fixing bolt M10 5 Vacuum unit to cylinder head fixing bolt M8 2 5 EGR valve to exhaust manifold fixing nut M8 2 5 Pipe to EGR valve fixing bolt M8 2 5 Pipe to exhaust or inlet manif...

Page 80: ...crankshaft for draining turbo charger oil fixing bolt M8 2 5 Air conditioning to support fixing bolt M8 2 5 Rigid pipe to power assisted steering pump fixing ring nut M16 3 5 Power assisted steering...

Page 81: ...aft housing front side M20 tapered 4 Plug in camshaft housing fixing manifold M18 3 Butterfly casing fixing bolt M6 0 7 Sensor to oil pump fixing bolt M6 1 Recharging cable to alternator fixing nut M8...

Page 82: ...assisted steering plate fixing bolt M8 2 2 Power assisted steering plate fixing bolt M10 5 Power assisted steering support to crank case fixing bolt M10 5 Compressor alternator rear support to crankc...

Page 83: ......

Page 84: ...NGINE Cylinder head and valve gear com ponents 2 Fuel system 3 ELECTRICAL EQUIPMENT Injection ignition 4 SPECIAL TOOLS 5 NOTE This section contains the variants for the 1747 16v version with a return...

Page 85: ...y for Germany ENGINE TYPE WEIGHTS in kg Marea 1085 1140 1165 1195 1255 m Marea 1145 1200 1225 1255 1315 Marea jg 5 7 5 n n V n n 1675 1730 1755 1785 1830 J Marea Weekend 595 Mllljjlljjl t k 580 n ii n...

Page 86: ...P Engine cylinder head and valve gear components 99 Update OO 10 TIMING DIAGRAMS 16v A Inlet HQ opens before TDC 0 after TDC B Inlet HQ closes after BDC 27 C Exhaust opens before BDC 29 D Exhaust clos...

Page 87: ...relli RPM 84 Coolant temperature sensor Jaeger 40218301 Elth 2690350 Electric fuel pump Marwall ESS 276 Lambda sensor NTK OZA 341 A1 Idle actuator HITACHI GL 108771 Butterfly valve position sensor pot...

Page 88: ...nce of secondary winding at 20 C Q RPM AND TOP DEAD CENTRE SENSOR Make and type HITACHI GE 110492 RS 314 Sensor winding resistance at 20 C Q 513 627 Distance gap between the sensor and the crankshaft...

Page 89: ...pecial tools 00 A Tool number TOOL NAME ENGINE TYPE Tool number TOOL NAME ENGINE 1860955000 Equipment for checking fuel consumption 1870684000 Connector for discharging petrol pressure 1870697000 Tool...

Page 90: ......

Page 91: ...Marengo 9 Introduction and technical data 1999 range Contents 00 INTRODUCTION page Identification data 1 Weights 2 TECHNICAL DATA Engine Rear front suspension 3 Copyright Fiat Auto...

Page 92: ...VERSION GEARBOX 666 k p T D 7 5 ZFA 185000 182 A8 000 185 CXF1A01 ZFA 185000 182 B4 000 185 CX N1A 02 F P4G001A1 Load carrying capacity 1590 dm3 Engine type DIMENSIONS mm Engine type A B C D E F G H...

Page 93: ...ances Fuel consumption Speed km h average load 36 36 Speed km h average load 62 62 Speed km h average load 96 97 Speed km h average load 135 136 Speed km h average load 163 183 Speed km h average load...

Page 94: ...323 Spring height under d g N m m a load of 207 Springs are sorted into two categories which are identified by markings yellow 1 springs exerting a load of 440 daN height of mm 207 green 1 springs 44...

Page 95: ......

Page 96: ...VING REFITTING EXHAUST MANIFOLD Removing refitting exhaust manifold 27 REMOVING REFITTING INLET MANIFOLD Removing refitting inlet manifold 28 REPLACING WATER PUMP Removing refitting water pump 30 REMO...

Page 97: ...to date as a result of modifications made by the Manufacturer at any time for reasons of a technical or commercial nature in addition to meet legal requirements in different countries Fiat Auto S p A...

Page 98: ...ar gloves and goggles during the operation of draining the system for protection against contact with any jets of R134A In order to facilitate the draining of the refrigerant from the vehicle air cond...

Page 99: ...olts fixing it to the bodyshell 3 Disconnect the reversing lights switch con nector and the earth lead 4 Working on the nut 1 and the locknut 2 disconnect the clutch cable from the control lever 5 Dis...

Page 100: ...embly to the side in the engine compartment 2 Disconnect the accelerator cable 3 Disconnect the bands illustrated in the dia gram then remove the air intake hose 4 Disconnect the vacuum pipe from the...

Page 101: ...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 discon...

Page 102: ...ure air condi tioning circuitn eedle valve undoing the bolt fixing it to the condenser 3 Open the band and disconnect the pipe between the radiator and the tank 4 Disconnect the air conditioning circu...

Page 103: ...nnect the electrical connection for the pressure sensor on the power assisted steering pump undo the connector for the rigid supply pipe open the band for the in let pipe then place the pipes to the s...

Page 104: ...ve the bolts fixing the shock absorber to the steering knuckle gearbox side then rotate the actual steering knuckle forwards releasing the brake pipe from the housing in the shock absorber 4 Disconnec...

Page 105: ...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...

Page 106: ...ell 3 Undo the fixing nuts and place the bracket shown to the side 4 Undo the bolts fixing the timing side power unit mounting bracket to the bodyshell 5 Extract the power unit from the lower part of...

Page 107: ...ng the starter motor to the gearbox 2 Undo the bolt shown in the diagram then remove the starter motor 3 Undo the bolts fixing the engine flywheel protection 4 Undo the bolts fixing the gearbox differ...

Page 108: ...ical cables pipes etc so that there is no possibility of interference when fitting take care when fitting the power unit to avoid damaging the individual components when fitting the engine coolant pip...

Page 109: ...which would look smooth and shiny dry or hardened sections with a consequent loss of grip If one of the above mentioned faults is pre sent the belt involved must be re placed 2 View of auxiliary shaf...

Page 110: ...ng bracket Using tool 1895762000 check that the tension of the new belt is between 36 45 daN If the same belt is re fitted the tension should be between 23 and 30 daN Alternator drive belt 3 After hav...

Page 111: ...0 daN if the same belt is refitted check that the tension is between 30 and 41 daN Then refit the components removed previ ously Air conditioning compressor drive belt After having removed the auxilia...

Page 112: ...R TIMING Before checking the valve gear tim ing the following must be removed the auxiliary shaft drive belts fol lowing the instructions given previ ously remove the upper part of the inlet manifold...

Page 113: ...ng small movements until the surface 1 on the moving part of the tool is in line with the plate 2 on the component fixed in the spark plug seat When both the tools positioned in the spark plug seats a...

Page 114: ...that the pistons are aligned i e with reference 1 perfectly aligned with reference 2 The engine is correctly timed in this configuration Tighten the timing pulley to the recom mended torque and proce...

Page 115: ...2 Disconnect the accelerator cable 3 Disconnect the connection shown and the brake servo vacuum pipe from the butterfly casing 4 Disconnect the pipes 1 and the connec tions 2 from the upper part of th...

Page 116: ...e away from the working area Remove the heat shield undoing the fixing nuts and bolts 3 Undo the bolts fixing the upper timing belt shield disconnect the connector for the rpm and TDC sensor then remo...

Page 117: ...ue of 0 5 daNm 4 Visually check the plug seats to ensure that the splining 1 on the camshafts is near the actual seats if not rotate the crankshaft through 360 restore the precise alignment of the pis...

Page 118: ...ill be in line with one another with piston no 1 in the descent intake stroke NOTE The pistons are also aligned at 180 from the correct position Once the pistons are aligned check that the pin on the...

Page 119: ...positioned previ ously for timing and locking the camshafts and rotate the crankshaft through two revolu tions in its normal direction of rotation 4 Loosen the tensioner fixing nut and make sure that...

Page 120: ...e the timing drive belt fol lowing the instructions given in the previous paragraph 2 Disconnect the connections 1 then re move the ignition coils acting on the fixing nuts and the engine cooling syst...

Page 121: ...e to the manifold 3 Undo the protective plugs for the bolts fixing the camshaft housing to the cylinder head Also remove the component 1 4 Using spanner 1860834000 undo the bolts fixing the camshaft h...

Page 122: ...ine coolant is evenly distributed throughout the entire cylinder block A exhaust side B inlet side ASTADUR type cylinder head gas kets are fitted On account of the special material from which these ga...

Page 123: ...itino the camshaft housing gasket on the cylinder head support plane 3 Position the camshaft housing on the cylin der head then remove the tappet retaining tools 1860988000 4 Using spanner 1860834000...

Page 124: ...G EXHAUST MANIFOLD 1 Disconnect the Lambda sensor connector 2 Undo the nuts fixing the first section of the exhaust pipe to the manifold 3 Undo the heat shield fastenings and remove it 4 Undo the nuts...

Page 125: ...of the resonator 2 Disconnect the accelerator cable 3 Disconnect the connections illustrated and the brake servo vacuum pipe from the butterfly cas ing 4 Disconnect the pipes 1 and the connections 2 f...

Page 126: ...rk area 2 Disconnect the output pipe from the heater and the connector 1 3 Undo the nuts fixing the intake manifold and release the engine oil dipstick retaining bracket 4 Gently extract the intake ma...

Page 127: ...Remove the timing drive belt as de scribed in the previous paragraphs 2 Remove the water pump acting on the fastenings illustrated Refit the components removed previ ously tension the timing belt as...

Page 128: ...nd remove the air intake disconnecting it from the air filter hose 3 Open the band and disconnect the pipe between the radiator and the tank 4 Remove the engine cooling fan undoing the fixing bolts th...

Page 129: ...the maximum temperature position red sector and the fan speed adjustment knob to the maximum ventilation position 4 Start up the engine and let it idle for about 2 3 minutes Partly 2 3 threads open th...

Page 130: ...g on heater inlet hose 6 Bleed plug on heater outlet hose 7 Coolant return pipe from car interior heater radiator to engine cooling radiator 8 Coolant supply pipe to car interior heater radiator 9 Coo...

Page 131: ...d the fan speed adjustment knob to the maximum ventilation position and switch the air conditioning OFF 4 Start up the engine and let it idle for about 2 3 minutes Partly 2 3 threads open the bleed sc...

Page 132: ...ug on heater outlet pipe 7 Coolant return pipe from car interior heater radiator to engine cooling radiator 8 Coolant supply pipe to car interior heater radiator 9 Coolant by pass thermostat 10 Coolan...

Page 133: ...f c...

Page 134: ...YSTEM 25 Injection ignition system wiring 25 Injection ignition ECU 25 Rpm and TDC sensor 29 Detonation sensor 31 Engine Fuel system 10 page Throttle case 32 Throttle position sensor 33 Coolant temper...

Page 135: ...circuit Emission control devices The system is able to monitor the following parameters by means of dedicated sensors 1 instantaneous engine rpm 2 position of each piston pair in relation to TDC of cy...

Page 136: ...m warning light 35 15 Injection ignition system fuses 16 Master fuse box 36 17 Throttle valve position sensor 37 18 Fuel supply manifold 38 19 Injectors 39 20 Air cleaner Spark plugs Ignition coils Co...

Page 137: ...ture both measured in the inlet manifold Volumetric efficiency is a parameter relating to the cylinder filling coefficient It is calculated on the basis of experimental tests carried out on the engine...

Page 138: ...letter X lambda _ quantity of air taken in by engine theoretical quantity of air required to burn all the fuel injected Thus we easily find that a ast X Stoichiometric ratio depends on fuel type For u...

Page 139: ...ive function which corrects idle speed actuator open ing when idling on the basis of changes due to throttle body leaks or natural engine ageing This specific correction is lost by disconnecting the b...

Page 140: ...gine does not stall Rpm is decreased as the temperature rises until the rated level is reached 850 30 Rpm when the en gine is warm The ECU governs the step motor to maintain idle speed constant even i...

Page 141: ...time is corrected according to changes in altitude and updated automatically by the ECU whenever the engine is started up and under certain conditions of throttle position and rpm dynamic adjustment...

Page 142: ...ions Protection against excess rpm When engine rpm exceeds a level of 6700 rpm for longer than 10 seconds or an upper threshold of 6900 rpm imposed by the manufacturer for any length of time engine op...

Page 143: ...n under the following conditions during start up during transient stages of acceleration and over run during cut off to stabilise idle speed when knock is present when required by the automatic transm...

Page 144: ...n advance point a processed by the computer advance a varies according to rpm The control unit ECU then controls spark advance in the different cylinders in relation to top dead cen tre and conduction...

Page 145: ...ylinders 1 4 and 2 3 are connected directly in pairs by means of high tension leads to coil secondary winding terminals and may be considered to be connected in series because the cylinder head joins...

Page 146: ...electronic key with a specific sender unit de signed for sending an identification code Once the key has been turned to STOP the FIAT CODE system de activates the engine control unit completely When...

Page 147: ...ent fuel vapours enriching the mixture excessively This condition persists until coolant temperature reaches 65 C with the engine warm the ECU sends the solenoid a square wave signal duty cycle contro...

Page 148: ...le the actuator is restored to normal position with a delay in relation to compressor de activation With regard to point 2 the ECU automatically controls compressor de activation for a few seconds tim...

Page 149: ...8 Diagnostic socket 9 Spark plugs 10 Ignition coils 11 Excessive coolant temperature warning light 12 Injection warning light 13 Coolant temperature gauge 14 Heating ventilation system 15 Engine coola...

Page 150: ...old 7 Engine idle speed actuator 2 Intake air temperature and pressure sensor 8 Upper resonator 3 Fuel evaporation control system point 9 Main crankcase gas intake 4 Engine block gas blow by gas intak...

Page 151: ...egulator 6 Reservoir Fuel is supplied to the system via an electrical pump submerged in the tank This takes up fuel and sends it to the injectors The fuel feed system is returnless i e only one pipe c...

Page 152: ...rs formed in the tank and fuel system from escaping into the atmosphere and releasing their load of polluting light hydrocarbons HC The system consists of a tank 5 multifunction valve 4 for controllin...

Page 153: ...s and lubricant oil vapours by recirculating them to the intake With the accelerator throttle open vent gases from the engine block reach the sleeve connecting the air cleaner throttle body 3 through...

Page 154: ...Engine Marea Marea Weekend 1 Fuel system 1998 range 10 INJECTION IGNITION SYSTEM WIRING DIAGRAM P4FZ0IJ01 20 Publication no 506 763 09...

Page 155: ...da probe and fuel vapour cut off solenoid 11 Lambda probe 12 Inertia switch 13 Electric fuel pump 14 Rev counter 15 Excessive coolant temperature warning light 16 Heating ventilation control unit and...

Page 156: ...haust gases simultane ously uncombused hydrocarbons HC carbon monoxide CO and nitrogen oxides NOx Two types of chemical reaction take place inside the catalytic converter oxidation of CO and HC to car...

Page 157: ...n sensor 7 Vehicle speed sensor 8 General 30A system fuse 9 Diagnostic socket 10 Battery 11 Earth on negative battery lead 12 Connection between injection earth and car body earth 13 Injection ignitio...

Page 158: ...15 54 power source 3 7 5A fuse protecting 30 power source 4 15A fuse protecting lambda probe and fuel vapour solenoid 5 Lambda probe lead junction EARTH POINTS fig 3 To increse electromagnetic compat...

Page 159: ...system control unit adopted is specific to this version It is connected to the elec trical wiring by two connectors These are 52 pin upper connector and 28 pin lower connector re spectively This digi...

Page 160: ...n the throttle is fully closed It also saves engine parameters and adapts them in time In other words the ECU uses the Lambda probe signal to modify and store an injection time correction factor that...

Page 161: ...change injection control units between different vehicles in order to check their efficiency Before replacing an ECU as a result of testing ensure it is really faulty because when a new ECU is activat...

Page 162: ...er Air conditioner compressor relay Not connected Lambda probe lead shielding Not connected Power source 15 Air conditioner activation request 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67...

Page 163: ...ting positive teeth facing sensor and negative gap facing sensor voltage is set up at coil terminals The sensor output voltage peak value depends on the gap beteween sensor and phonic wheel teeth if a...

Page 164: ...onding control unit pins NOTE Whenever repairs to the rpm and TDC sensor mount are necessary e g gap not as specified sensor not aligned etc the sensor must be positioned and aligned with the mount as...

Page 165: ...polarity The molecules are not oriented in any partic ular direction when at rest A When the crystal is subject to pressure or im pact B it takes up a different position The entity of the change is pr...

Page 166: ...n engine idle adjustment solenoid Under these conditions the throttle opening lever comes into contact with an anti bind screw which prevents the throttle becoming locked in closed position To prevent...

Page 167: ...tentiometer at a voltage of 5 Volt The pa rameter measured is throttle position from idle to full opening for injection control man agement The following graph indicates the voltage level supplied by...

Page 168: ...or also fails a throttle opening angle of 50 is adopted as a fixed value The strategy of gradually decreasing rpm when idling dashpot is blocked Idle self adaptation is blocked Mixture concentration s...

Page 169: ...tage divider the voltage is dis tributed between a resistance present in the ECU and the sensor N T C resistance The ECU is therefore able at any moment to as sess sensor resistance changes through vo...

Page 170: ...leaks through the closed throttle valve 4 during idling an additional quantity of air Q must be added to allow the engine to maintain rpm levels constant particularly during warm up and when electric...

Page 171: ...e and battery voltage Warming up stage Rpm levels are corrected according to engine coolant temperature With engine warm Idle control is dependent on a signal from the rpm sensor When external users a...

Page 172: ...nition point The sensor is fitted to the intake manifold Automatic diagnosis and recovery The self diagnostic function monitors the two sensor output signals This detects the following for both signal...

Page 173: ...over electric pumps which work on the volumetric principle low weight and reduced size Removing refitting electric fuel pump The pump is located in the tank Proceed as follows to remove Undo the faste...

Page 174: ...rear part of the right front wheel arch compartment trim 1 Fuel vapour cut off solenoid 2 Carbon filter Carbon filter This consists of carbon granules 4 that trap fuel vapour entering intake 5 Warm f...

Page 175: ...controls the quantity of fuel vapour sent to the intake to prevent significant changes in mixture concentration Under the service conditions listed below throttle in idle position speed less than 1 50...

Page 176: ...rom reaching active carbon filter and hence damage to the filter b the tank fuel level drops float 2 is lowered and rests upon ball 3 to open hole 1 When the pres sure exercised by fuel vapours on pla...

Page 177: ...speed can therefore be calculated from pulse frequency Removing refitting Disconnect electrical connection and remove the sensor Tightening torque 0 8 daNm Wiring diagram SAFETY AND VENTILATION VALVE...

Page 178: ...point when the intake stage has already begun The injectors are held in place by the fuel manifold which presses them into their seats on the intake ducts They are also anchored to the fuel manifold b...

Page 179: ...ectrical circuit to cut off the fuel pump earth connection and thus the fuel supply to the injection system To restore the pump earth connection push the seat back and press the switch until it clicks...

Page 180: ...n which gives them exceptional dielectric properties Because the primary winding is so close to the magnetic core little magnetic flux is lost and coupling with the secondary winding is maximised 1 HT...

Page 181: ...probes of an ohmmeter into contact between the two high tension outlet termi nals The secondary winding resistance reading on the gauge must be between 4500 and 5500 ohm at 23 C Recovery Inhibition o...

Page 182: ...presses an excess or lack of air supplied to the engine in relation to the theoretical required level the air fuel mixture is a ratio between these two substances that react chemically when combined P...

Page 183: ...e operates with a lambda factor continually fluctuating between 0 980 and 1 020 Below 300 C the ceramic material is not active and the probe does not send usable signals A special circuit in the contr...

Page 184: ...y negative lead Disconnect electrical connection located against the rear wall of the engine bay Remove the lambda probe from its seat on the exhaust pipe E When refitting spread the threaded part wit...

Page 185: ...t or disconnect the ECU multiple connector with the ignition key in MARC A posi tion a ways disconnect battery negative lead before carrying out electrical welding on vehicle Note that the memory of t...

Page 186: ...tening the second section of the intake manifold to the engine block and remove 3 Disconnect the fuel lines and remove the manifold together with injectors 4 Then remove the injectors as follows Disco...

Page 187: ...using spanner 1878077000 Remove the protective cover shown in the inset acting on the fixing bolts Disconnect the electrical connections from the pump and the fuel gauge sender unit Disconnect the br...

Page 188: ...g 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 r...

Page 189: ...bolts and plugs securing the tank to the body 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...

Page 190: ...pedal 2 In the engine bay turn the throttle valve control lever 1 and disconnect the ac celerator control cable Then withdraw cable 2 from its support bracket 3 Withdraw the flexible block from its a...

Page 191: ...lencer To check the concentration of carbon monoxide CO and unburnt hydrocarbons HC upstream of the catalyzer proceed as follows 1 Undo the cap or the nut on the exhaust pipe upstream of the catalyzer...

Page 192: ...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 1 Check that idling CO and HC levels are as s...

Page 193: ...special adap tor 18706844000 3 then reconnect injec tor supply connector 2 NOTE Device 1860955000 is fitted with adaptors for connection to different types of injection system Fit the appropriate ada...

Page 194: ...emove the protective bracket and disconnect injector supply connector as described in the previous paragraph on checking fuel feed pressure The fuel supply circuit is maintined at a constant pressure...

Page 195: ...el consumption road test in accordance with EU directive 93 116 CE litres x 100 km URBAN CYCLE includes a cold start followed by a simulated varied urban route OUT OF TOWN CYCLE includes frequent acel...

Page 196: ...me to rule out the possibilty of interference on the tester line Once this stage is over the error is considered to be present and stored in the RAM memory filtered error A check is then carried to en...

Page 197: ...a probe Vehicle speed Self adaptability Error counter Ignition coil load time Dwell Petrol vapour solenoid Start up counter Engine load Fiat CODE List of errors RPM sensor Throttle potentiometer Absol...

Page 198: ...ur solenoid Rev counter Air conditioner relay Injection system failure warning light Excessive coolant temperature warning light Engine idle speed actuator Fiat CODE Radiator fan Activation mode Relay...

Page 199: ...f fuel system 2 Location of components of fuel system 3 Input output signals between control unit and sensors actuators 4 Functional diagram of fuel system 6 Air temperature sensor 7 Engine coolant te...

Page 200: ...uperseded as a result of modifications adopted by the Manu facturer at any time due to technical and commercial reasons and in accordance with local regulations Fiat Auto S p A D M C M P S Servizi Pos...

Page 201: ...nstrument panel gauge Added intake air temperature sender unit which is no longer built into the flowmeter but is a single component located upstream of the new hot film flowmeter Modified fuel inject...

Page 202: ...tch 5 Accelerator potentiometer 6 Speedometer 7 Electronic control unit 8 Engine rpm sensor 9 Coolant temperature sensor 10 Instrumented fuel injector 11 Heater plugs 12 Borg Warner modulating valve 1...

Page 203: ...edal switch 3 Accelerator potentiometer 4 Electronic control unit 5 Diagnostic socket 6 Engine rpm sensor 7 Coolant temperature sensor 8 Fuel injectors 9 Heater plugs 10 Borg Warner modulating valve 1...

Page 204: ...ature sensor 5 Clutch pedal switch 6 Brake pedal switch 7 Air flowmeter 8 Instrumented fuel injector 9 Speedometer sensor 10 Engine rpm sensor 11 Rev counter 12 Diagnostic socket 13 Fuel injection fau...

Page 205: ...inside the control unit 1 signal requesting the switching on of the air conditioner compressor from the air conditioning system 15 Depending on the input values the electronic control unit 1 consults...

Page 206: ...ng control unit 7 Coolant temperature sensor 8 Engine rpm sensor 9 Speed sensor 10 Clutch pedal sensor 11 Brake pedal sensor 12 Accelerator potentiometer 13 Speedometer 14 Heater plug warning lamp 15...

Page 207: ...electrical resistance of the sensor decreases as the temperature in creases The two NTC thermistors are separate and they supply the temperature information to the specific gauge on the instrument pa...

Page 208: ...oint of engine operation Qgr the imbalance compared with the theoretical value of the quantity of recirculating gases If the quantity of recirculating gases is correct for a particular point of engine...

Page 209: ...original balanced value The increase in current which passes through the hot element is proportional to the air flow passing through the flowmeter This value thus gives the air flow to measure precise...

Page 210: ...system Marea Marea Weekend ft 98 range TD 10 WIRING DIAGRAM e a i d 6 I q cJ 0 0 Q l J V T 1 E T 6 o L r i i I o o I I Q D p L J I C J C O SO 42 52 s o O t3 0 8 T Q o o J g 8 ll 0 o 10 Publication no...

Page 211: ...er 12 Flowmeter 13 Engine rpm sensor 14 Engine coolant temperature sensor 15 Accelerator pedal potentiometer with idle switch 16 Instrumented fuel injector 17 Clutch pedal switch 18 Brake pedal switch...

Page 212: ...rsor position sensor reference winding 22 Not connected 23 Not connected 24 Not connected 25 Idle switch on accelerator pedal 26 Stop lights switch 27 Not connected 28 Clutch pedal switch 29 Vehicle s...

Page 213: ...take air temperature and pressure sensor 26 Vehicle speed sensor 27 Power assisted steering sensor 27 Detonation sensor 27 Ignition coils 28 INTAKE CIRCUIT 29 Butterfly casing 30 10 page Engine idle s...

Page 214: ...ided as a guide and may no longer be up to date as a result of modifications made by the Manufacturer at any time for reasons of a technical or marketing nature in addition to adaptations to meet lega...

Page 215: ...vehicle the battery voltage whether the air conditioning is switched on whether the power steering is in the end of travel position This information usually in analogue format is converted into digita...

Page 216: ...relay s 10 Radiator fan 13 Climate control connection 14 CODE connection 15 Diagnostic equipment connection 16 Rev counter 17 System failure bulb 18 Speedometer 19 Injectors 20 Spark plugs 21 Ignition...

Page 217: ...n relay s 10 Radiator fan 11 Compressor engagement relay 12 Compressor 14 CODE control unit 15 Diagnostic equipment connection 16 Rev counter 17 System failure light 18 Speedometer 19 Injectors 20 Spa...

Page 218: ...uipment connection 19 Injectors 20 Spark plugs 21 Ignition oil 22 Charcoal filter solenoid valve 24 Lambda sensor 25 Power assisted steering sensor 26 Coolant temperature sensor 27 Detonation sensor 2...

Page 219: ...from the Lambda sensor which according to suitable operating strategies determines a continuous fluctuation of the mixture strength around the stoichiometric value The system is therefore defined as...

Page 220: ...injection management strategies are designed to provide the engine with the correct quantity of fuel and at the correct time according to the engine operating conditions The management of the injectio...

Page 221: ...han the stoichiometric value and in this case the Lambda X 1 The strategy is designed to correctthe basic injection times so that the mixture strength continuously fluctuates at a high Hertz frequency...

Page 222: ...y complex having to take a large number of factors into account In general the injection time is increased for positive transitions and reduced for negative ones The extent of the correction basically...

Page 223: ...an anti theft function This function is achieved thanks to the presence of a special control unit FIAT CODE capable of conversing with the engine control unit and an electronic key with a special tran...

Page 224: ...ously varies in terms of the angle in relation to TDC for the explosion stroke of each cylinder and the greater the engine rotation speed the greater the advance since the time required to saturate th...

Page 225: ...rn dependent on the temperature of the coolant In particular the advance is increased if the speed decreases and descreases if the speed increases in order to guarantee the stability of the actual spe...

Page 226: ...eceleration In release conditions outside of idling the control unit controls the position of the butterfly through a par ticular flow rate curve dash pot curve i e it slows down the return of the but...

Page 227: ...if the engine is idling the control unit increases the air flow rate altering the position of the butterfly in advance of the compressor being switched on and conversely returns the butterfly to its...

Page 228: ...ding to the temperature of the coolant Low speed it comes on when the temperature of the coolant reaches T 1 96 5 C High speed it comes on when the temperature of the coolant reaches T 2 102 C It swit...

Page 229: ...d The detection of a confirmed fault usually in volves the warning light in the dashboard coming on the light goes out when the fault conditions disappear NOTE During starting the bulb comes on for ab...

Page 230: ...ects the other components to the control unit and constitutes the interface with the vehicle wiring engine side wiring B engine rpm sensor absolute pressure and air temperature sensor coolant temperat...

Page 231: ...29 Sensors supply 30 Lambda sensor signal 31 N c 32 Engine rpm sensor negative 33 N c 34 Operation of charcoal filter solenoid valve 35 Operation of idle speed actuator 36 N c 37 N c 38 Operation of c...

Page 232: ...CH M1 5 5 SYSTEM WIRING DIAGRAM Connector A vehicle side 12 3 4 5 i 1 t 9 1 0 1 1 1 2 1 3 H15 IU7 II 1 9 S igHg iHilfiiimHi lj li li l li fliJltH 8 c I 9 11 r K ill o 8 O O O O o o e o o o e o Q 10 11...

Page 233: ...low speed relay 5 Engine control system relay 6 Fuel pump relay 7 Front cable connection 8 Battery 9 Ignition switch 10 Inertia switch 11 Electric fuel pump 12 Air conditioning control unit on button...

Page 234: ...eekend 99 range 10 BOSCH Ml 5 5 SYSTEM WIRING DIAGRAM Connector B engine side r n m cE 1 2 3 4 3 i 7 8 9 1 1 1 II I 1 3 1 4 1 5 Ii 1 7 II 1 9 it 6 o o o o Q O o o o o e o o Q o o o o o e o 0 o 0 o o Q...

Page 235: ...rol unit 2 Active charcoal filter solenoid valve 3 Detonation sensor 4 Coolant temperature sensor 5 Engine idle adjustment actuator butterfly position sensor 6 Absolute pressure and air temperature se...

Page 236: ...el system Marea Marea Weekend 0 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 22 Print n 5...

Page 237: ...magnet 3 undergoes fluc tuations as a result of the alteration in the gap as the flywheel teeth pass These fluctuations produce an electro motive force in the winding 2 where an alternately positive t...

Page 238: ...nal is high voltage above 800 mV the control unit rec ognizes a rich mixture and decreases the injec tion time This sequence of interventions is repeated with a frequency in the order of tens of Hertz...

Page 239: ...ure increases The two thermistors are distinct and provide information concerning the temperature to the instrument in the panel A and to the engine control unit B The reference voltage for the latter...

Page 240: ...e this information is then used for calculating the injection time and the point of ignition The sensor is fitted on the inlet manifold Temperature C Resistance M 40 52600 38700 20 17500 13500 0 6500...

Page 241: ...e outlet pipe consists of a pressure switch which closes when the hydraulic pressure ex ceeds a level corresponding to the steering close to the end of travel position the infor mation is used to mana...

Page 242: ...ies that the discharge current in the secondary winding is always flowing in the same direction and therefore the sparks for the two cylinders connected to the coil strike in the opposite way in the s...

Page 243: ...ious 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 b...

Page 244: ...uator in order to be able to supply the additional air required according to the engine conditions The actuator also includes the butterfly position sensor 4F030PJ03 ENGINE IDLE SPEED ADJUSTMENT AC TU...

Page 245: ...ay complete with pump filter pressure regulator and gauge Supply pipe Returnless type fuel manifold complete with injectors FUEL CIRCUIT DIAGRAM 4F031PJ01 1 Air bleed connector 2 Injector manifold 3 S...

Page 246: ...arted up operation when the engine is started up The pump is equipped with an excess pressure valve which short circuits the supply with the inlet if the pressure in the supply circuit ex ceeds about...

Page 247: ...ted into the inlet manifold im mediately upstream of the inlet valves The injector is the top feed type with the sup ply of fuel from the top part of the body where the electrical winding connected to...

Page 248: ...rapid release mechanism located above the ball which forms a normally closed NC circuit When the mechanism is struck by the ball it changes position into a normally open NA circuit thereby interruptin...

Page 249: ...the fact that the mixture strength for the engine must be continuously fluctuating around the stoichiometric value which is achieved thanks to the feed back control which is carried out by the control...

Page 250: ...Engine Marea Marea Weekend Fuel system 99 range 10 ENGINE EXHAUST ASSEMBLY DIAGRAM 4F036PJO1 Key 1 Lambda sensor 2 Exhaust manifold 3 Catalytic silencer 4 Silencer 5 CO socket 36 Print n 506 763 14...

Page 251: ...est fractions of hydrocarbons which basically form i n the tank from being discharged into the atmosphere 1 Vapour supply pipe to the butterfly casing 2 Charcoal filter solenoid valve 3 Charcoal filte...

Page 252: ...the port 1 preventing the liquid fuel from reaching the active charcoal filter thereby avoiding damaging it b if the level of the fuel in the tank decreases the float 2 descends and rests on the ball...

Page 253: ...it the rear part of the right front wheel arch liner has to be removed It consists of granules of charcoal 4 which trap the petrol vapours entering through the intake 5 The air which enters through t...

Page 254: ...F040PJ02 DIAGRAM SHOWING EXCHANGE OF 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 petr...

Page 255: ...CONCENTRATION OF THE EMISSIONS The system manages the advance the carbon monoxide CO content and the idle air flow rate without the possibility for adjustments threfore no manual regulations are requ...

Page 256: ...utside of the recommended limit whilst that measured previously upstream of the catalyzer was correct the engine parameters are correct and therefore the cause of the problem should be sought in the d...

Page 257: ...adaptors as illustrated in the diagram The arrow shows the side to insert in the test equipment 1860955000 pressure gauge Draining supply circuit fuel pressure The fuel supply circuit is kept at a con...

Page 258: ...ion key to the ON position and check on the pressure gauge e that after having increased to a value of about 3 5 bar the pressure settles down at around 3 2 bar the decrease in pressure is due to the...

Page 259: ...nded figure check the seal of the fuel manifold and the injec tors following the procedure described in the next paragraph Injector seal check 4FM5PJ01 1 Complete electric pump 2 Fuel supply pipe 3 Ad...

Page 260: ...the pipes into the container reconnect the fuel supply pipe Check the fuel consumption using the FLOWTRONIC equipment 1866149001 To carry out the test the equipment must be configured with the connec...

Page 261: ...c pump 2 Fuel supply pipe 3 Female rapid connector 4 FLOWTRONIC equipment 5 Rapid connector 6 Fuel manifold carry out the fuel consumption road test in accordance with directive 93 116 CE litres per 1...

Page 262: ...age compartment lin ing and remove it then lift up the cover to gain access to the dust cover undo the bolts arrow and remove the dust cover _ disconnect the supply pipe 1 the breather pipe 2 and the...

Page 263: ...ifold as follows remove the bands shown arrow then undo the two bolts detail and rmeove the inlet hose complete with resonator turn the accelerator lever and release the end of the accelerator cable f...

Page 264: ...nect the rapid connector 4 undo the fixing bolts 5 then remove the complete fuel manifold When refitting reverse the order of the opera tions carried out for the removal Removing refitting injectors T...

Page 265: ...bracket B and move the ac celerator cable away disconnect the engine idle speed actuator connector 1 undo the four fixing bolts arrow and re move the butterfly casing When refitting reverse the order...

Page 266: ...ecognition signals synchronized checks NOTE If at least one of the parameters does not conform turn the ignition OFF and repeat the procedure If the non conformity persists check that the diagnostic c...

Page 267: ...moval ENGINE IDLE ADJUSTMENT ACTUA TOR BUTTERFLY POSITION SENSOR NOTE The engine idle adjustment actua tor butterfly position sensor should only be disconnected from the butter fly casing if it is bei...

Page 268: ...the engine idle adjustment actuator M D S as described in the BUTTERFLY CASING paragraph LAMBDA SENSOR Removing refitting Disconnect the electrical connection 1 and remove the sensor 2 from the housi...

Page 269: ...HI system wiring diagram 20 System relays 21 HITACHI system control unit pin out 22 HITACHI system control unit pin out 23 Engine rpm sensor 24 Engine timing sensor 25 Air flow meter 26 Lambda probe 2...

Page 270: ...to date as a result of modifications made by the Manufacturer at any time for reasons of a technical or commercial nature in addition to meet legal requirements in different countries Fiat Auto S p A...

Page 271: ...digital signals by the analogue digital con verters A D for use by the control unit In particular any engine operating point is identified by two parameters the engine rotation speed measured in revs...

Page 272: ...ev counter 12 Diagnostic equipment connector 13 System failure light 14 Butterfly position sensor 15 Butterfly casing with air flow meter incorpo rated 16 Engine idle adjustment actuator 17 Filler cap...

Page 273: ...19 Charcoal filter 4 System relay 20 Idle speed adjustment stepping motor 5 Electric fuel pump 21 Coolant temperature sensor 6 Climate control system 22 Vehicle speed sensor 7 Radiator fan relay 23 S...

Page 274: ...nation sensor 4 Engine timing sensor 5 Hitachi engine management control unit 6 Diagnostic socket 7 B u t t e r f l y casing with air flow meter 8 Butterfly valve position sensor 9 Idle speed adjustme...

Page 275: ...eciprocal position provide the control unti with a synchronized sequence of signals which the control unit is capable of recognizing These signals are composed as follows flywheel on the crankshaft it...

Page 276: ...quantity of fuel to be injected into each cylinder The latter is in turn determined by multiplying the quantity of air drawn in by each cylinder calculated according to the quantity of intake air and...

Page 277: ...atio and in this case the Lambda 1 The strategy is designed to correct the basic injection times so that the mixture strength continuously fluctuates at high frequency between 0 98 and 1 02 The fluctu...

Page 278: ...r a certain length of time the lower the temperature of the engine the longer this time K enrichment coefficient t time a engine temperature function decrease ON engine driven crank OFF engine started...

Page 279: ...se C injection time including enrichment OFF engine at stationary speed ON engine in transition Operation in deceleration conditions During this stage a negative transition strategy is implemented to...

Page 280: ...the presence of a specific FIAT CODE control unit capable of dialogue with the engine management control unit and an electronic key with a special transmitter for sending a recognition code Each time...

Page 281: ...en corrected on the basis of the different engine operating conditions The control unit determines the moment of the start of the conduction of the current in the coil primary winding according to the...

Page 282: ...se in the advance in relation to the value in the map is inversely proporational to the temperature of the engine Operation in cut off conditions The ignition advance is increased on entry into cut of...

Page 283: ...is gradually restored to the basic value or until the onset of the phenomenon again The advance increases are implemented gradually whilst the reductions are implemented immediately In acceleration co...

Page 284: ...uator in advance of the switching on Normal driving In these conditions the actuator is in the open loop position In deceleration conditions In deceleration conditions outside of idling the control un...

Page 285: ...adiator fan operation As far as point 1 is concerned if the engine is idling the control unit increases the air flow rate passing from the idle actuator in advance of the compressor being switched on...

Page 286: ...longer a thermal contact on the radiator Version without climate control There is a single fan which comes on when the temperature of the coolant exceeds 95 C The fan is switched off with a hysteresis...

Page 287: ...engagement of the fans also depends on the state of the climate control system three stage pressure switch which determines the switching on of the first fan and then with a certain delay that of the...

Page 288: ...il it is repaired The detection of a confirmed fault usually in volves the warning light in the dashboard coming on the light goes out when the fault conditions no longer exist NOTE During starting th...

Page 289: ...ce with the vehicle wiring NOTE The two connectors are the same therefore if the control unit is disman tled the fitting position arrow must be followed to prevent them from be ing mixed up vehicle si...

Page 290: ...Engine Fuel system 10 Hit TAG HI SYSTEM WIRING DIAGRAM Marea Marea Weekend 6 9 99 update I i 20 Wnf n 506 763 15...

Page 291: ...ply 15 for FIAT CODE 30 Supply 30 for FIAT CODE 31 Climate control compressor relay feed if fitted 32 Climate control compressor engagement intake if fitted 33 Engine coolant temperature gauge signal...

Page 292: ...8 Operation of coil for cylinder 2 30 N C 9 Operation of coil for cylinder 3 31 Engine timing sensor earth 10 Operation of coil for cylinder 4 32 N C 11 Engine coolant temperature earth 33 N C 12 Air...

Page 293: ...ection to earth only for ver 8 System failure light operation sions without climate control 9 Air conditioning compressor engagement 27 Three stage thermostat signal only for ver signal if fitted sion...

Page 294: ...undergoes the fluctuations produced by the variation in the gap These fluctuations produce an electro motive force in the winding 2 where there is an al ternately positive voltage tooth facing the se...

Page 295: ...of force perpendicular to the direc tion of the current produces a difference in power known as Hall voltage If the intensity of the current remains constant then the voltage produced only depends on...

Page 296: ...only part of the mass of air which passes through the flow meter is measured this quantity is however proportional to the overall mass passing through the flow meter The flow meter electrical output v...

Page 297: ...in the order of tens of Hertz so that the engine runs with a mixture strength continuously fluctuat ing around the stoichiometric level At temperatures below 300 C the ceramic ma terial is not activa...

Page 298: ...Engine Fuel system Marea Marea Weekend ft 99 update 3N30GJ01 3N30GJ02 28 Print n 506 763 15...

Page 299: ...increases The two thermistors are distinctive and provide information for the instrument panel A and the engine management control unit B re spectively The reference voltage for the latter is 5 Volt...

Page 300: ...at each impulse corresponds to a distance of one metre it is therefore possible to ascertain the speed of the vehicle from the frequency of the impulses DETONATION SENSOR This is a piezoelectric type...

Page 301: ...ry voltage 30 by means of the twin relay and is connected to earth via the built in power transistor whose base is con nected to the control unit pin 3N34GJ01 Interrupting the current to the base of t...

Page 302: ...el system 99 update DIAGRAM SHOWING AIR INTAKE CIRCUIT 4F032OJ01 1 Air filter 2 Exhaust manifold 3 Butterfly casing with air flow meter 4 i n t a k e vent 5 Engine speed adjustment actuator 6 Intake m...

Page 303: ...rfly opening angles corresponding to the pedal slightly pressed and large angles corre sponding to when it is very depressed With the pedal completely released engine decelerating or idling the additi...

Page 304: ...has two windings in the stator and a rotor which includes a certain number of pairs of permanent magnet poles a screw female screw type reduction gear which transforms the rotary motion into rectilin...

Page 305: ...pressure regulator and gauge float 3 Supply pipe 4 Returnless type fuel manifold 5 Air bleed connector FUEL SUPPLY CIRCUIT This circuit consists of the following components Fuel tank Drip tray comple...

Page 306: ...ic fuel pump 1 2 87a 87 86 85 30 I 1 j i t 1 Complete drip tray 2 Pressure regulator 3 Gauge 4 Float 5 Electric pump 6 Fuel filter 7 Pre filter 8 Single acting valve 9 Internal fuel return 10 Fuel sup...

Page 307: ...e in the supply circuit exceeds 5 bar to prevent the electric motor from overheating In addition a one way valve fitted on the supply prevents the entire fuel circuit from being drained when the pump...

Page 308: ...EL MANIFOLD is P d u C e d b y aluminium The fuel mtake s f xed by a tapered bolt Since the system is the returnless type there is no recirculation 2 3N42GJ02 1 Fuel manifold 2 Injectors 3 Bleed valve...

Page 309: ...ed When the current passes through the winding the magnetic field which is created attracts the shutter causing the opening of the injector and the flow of fuel Two seals provide the seal on the fuel...

Page 310: ...inertic forces the ball can be released from the mag netic clip and gradually come out of the tapered housing with an upwards movements which de pends on the angle of the cone There is a rapid releas...

Page 311: ...that the mixture strength on which the engine is running is continuously fluctuating around the stoichiometric value which is achieved thanks to the feed back control carried out by the control unit...

Page 312: ...he fuel vapours to reach the separator 2 thereby preventing fuel from escaping The fuel vapours reach the charcoal filter 6 when the pressure inside the tank causes the opening of the ventilation valv...

Page 313: ...l acceleration vehicle braking with the relevant movement of the mass of fuel as a result of the inertia force vehicle overturning 3N48GJ01 3N48GJ02 3N48GJ03 1 Normal operating conditions valve open 2...

Page 314: ...eather gases coming from the crankcase rise as far as the cylinder head and are directed into two different intakes at medium high accelerator butterfly openings the gases are drawn in by the duct imm...

Page 315: ...be The negative battery terminal must be disconnected in order to reset the self adjustment memory which could with new components involve the failure of the engine to start or the irregular be haviou...

Page 316: ...ide of the recommended limit whilst that measured previously upstream of the catalyzer was correct then the engine parameters are correct the cause of the problem should be sought in the decreased eff...

Page 317: ...illustrated in the diagram The arrow indicates the side to be in serted in the test equipment 1860955000 pressure gauge Draining supply system fuel pressure The fuel supply circuit is kept at a consta...

Page 318: ...rrectly engaged Turn the ignition key to the ON position and check on the gauge e that after increasing to around 3 5 bar the pressure then settles down at round 3 2 bar the fall in pressure is due to...

Page 319: ...are operating faults with the pressure regulator which is housed inside it Checking the seal of the injectors 3N55GJ01 1 Complete electric pump 5 Adapator B 2 Fuel supply pipe 6 Fuel manifold 3 Adapt...

Page 320: ...al fuel flow from the pipes into the container reconnect the fuel supply pipe to the fuel manifold 1866149001 Check the fuel consumption using the FLOWTRONIC equipment 1866149001 To carry out the test...

Page 321: ...C equipment 2 Fuel supply pipe 5 Male terminal 3 Female rapid connector 6 Fuel manifold carry out the road fuel consumption test in accordance with directive 93 116 CE litres per 100 km URBAN CYCLE th...

Page 322: ...electrical connections from the injectors and from the phase transformer and move the duct released previously aside disconnect the fuel supply pipe 1 from the manifold working in two stages A press...

Page 323: ...connector on the ad justment bracket and releasing the cable from the lever on the butterfly casing disconnect the electrical connectors from the butterfly position sensor 2 the idle adjustment solen...

Page 324: ...8 and insert the terminal 7 in the special housing Insert the clip 9 into the groove at the end of the cable 5 Reconnect the accelerator cable to the at tachment on the pedal Adjustment Working on th...

Page 325: ...NJECTION IGNITION SYSTEM WIRING DIAGRAM 14 Control unit ignition coils and in jectors connection 15 LOCATION OF INJECTION IGNI TION SYSTEM COM PON ENTS 16 10 page FUSES AND RELAYS 17 DIAGNOSTIC SOCKET...

Page 326: ...apours dispersed as finely and evenly as possible in the air As far as the optimum metering on the other hand is concerned it is calculated by the control unit fol lowing these measurements exact quan...

Page 327: ...tion sensors 7 Ignition switch 27 Coolant temperature sensor 8 System relay feed 28 Fuel vapour solenoid valve 9 Climate control compressor 29 Charcoal filter 10 Inertia switch 30 Coolant overheating...

Page 328: ...and 5 allow the control unit to recognize the cylinder where there is detonation or the onset of detonation and only correct the ignition ad vance for the spark plug of the cylinder concerned d An acc...

Page 329: ...lectronic control unit recognizes this condition and corrects the injection time according to the signal for the coolant temperature the intake air temperature the battery voltage and the engine speed...

Page 330: ...d exceeds 6 800 rpm the electronic control unit reduces the operating times for the injectors to avoid overloading the engine also protecting it outside of revs If the engine speed exceeds 7 000 rpm t...

Page 331: ...nction which memorizes the reductions in the advance which are continuously repeated to adapt the map to the various conditions in which the engine finds itself Phase transformer control The control u...

Page 332: ...e injection ignition system to be activated by means of an electronic code Each time the key is turned to the OFF position the Fiat CODE system completely deactivates the injec tion ignition control u...

Page 333: ...n The control unit directly controls the operation of the radiator fan according to the temperature of the en gine coolant and the engagement of the climate control system The fan comes on when the te...

Page 334: ...low meter 24 Butterfly casing actuator 7 Rpm sensor 25 Brake and clutch pedal switch 8 Coolant temperature sensor 26 Rev counter signal 9 Lambda sensor 27 Injectors 10 Battery 28 Radiator fan 1 s t sp...

Page 335: ...l supply system is the returnless type i e there is only one connecting pipe between the fuel tank and the engine This system makes it possible to keep the risk of the vehicle catching fire in the cas...

Page 336: ...or 4 from where on condensing they mainly return to the tank 7 If on the other hand the fuel splashes around whilst driving or the vehicle overturns the float valves 6 close preventing the escape of f...

Page 337: ...through the outlet 5 and are sent via the connector 4 on the air hose upstream of the butterfly valve to the manifold With the butterfly closed the vacuum in the inlet manifold draws in the gases thro...

Page 338: ...els of the three pollutant gases present in the exhaust gases unburnt hydrocarbons HC carbon monoxide CO and ni trogen oxides NOx Two types of chemical reaction take place inside the converter oxidati...

Page 339: ...Engine Fuel system Marea Marea Weekend 9 99 range 10 INJECTION IGNITION SYSTEM WIRING DIAGRAM P4F14QJ01 14 Print n 506 763 14...

Page 340: ...compressor Flow meter Air conditioning compressor Radiator fan 1 s t speed resis tance Air conditioning compressor electro magnet coupling relay Radiator fan 1 s t speed relay Radiator fan 2 n d spee...

Page 341: ...oid valve 4 lnjection ignition control unit 5 General system protective fuse 6 Flow meter air temperature sensor 7 Motorized butterfly casing 8 Engine coolant temperature sensor 9 Vehicle speed sensor...

Page 342: ...Marea Marea Weekend 99 range Engine Fuel system Copyright by Fiat Auto 17...

Page 343: ...nsformer solenoid avlve Fuel vapour cut out solenoid valve Variable geometry manifold solenoid valve Electric fuel pump including filter and pres sure regulator Injectors Ignition coils Spark plugs IN...

Page 344: ...nnected Connector M 9 10 11 12 13 Not connected Not connected Climate control gagement 14 Not connected 15 Supply from battery 16 Supply from relay 17 Not connected 18 Not connected 19 Not connected 2...

Page 345: ...iator fan high speed engagement go ahead 63 Flow meter reference voltage 64 Not connected Marea Marea Weekend 9 99 range Connector M 24 Butterfly casing potentiometer 1 signal 25 Engine coolant temper...

Page 346: ...supplies a spark plug without intermediate leads Checking coil primary circuit resistance The resistance is checked by connecting an ohmmeter to the connector outside pins pins 1 and 3 Primary resista...

Page 347: ...y with an opening is passed through the sensor As it moves the metal part of the ring covers the sensor stopping the magnetic field with a consequent low output signal conversely for the opening where...

Page 348: ...h varies as a result produces an alternating voltage whose fre quency depends on the number of revs The flywheel has 58 teeth plus a space equivalent to the missing two teeth The reference defined by...

Page 349: ...the inlet manifolds and be tween cylinders 1 2 and 4 5 These sensors have a bush to prevent incor rect torque tightening In the case of replacement do not place washers or shims between the cylinder...

Page 350: ...ates the pump 2 impeller and a support cover 3 which contains the electrical and hydraulic connections The electric pump stage is the peripheral flow single type with high performance in low volt age...

Page 351: ...any cylinder dur ing the expansion stroke until the inlet stroke has already commenced The injectors are fixed by the fuel manifold which presses them into the seats in the inlet manifold They are als...

Page 352: ...e One coil spring on the shaft guarantees the correct resistance to pressure whilst a second spring ensures the return on release Connector wiring The numbers indicte the corresponding control unit pi...

Page 353: ...to the engine is measured by a Wheatstone bridge and the signal is sent to the injection control unit 1 Covers 2 Electronic card 3 Sensor 4 Support plate 5 Support 6 Seal O Ring 7 Temperature sensor...

Page 354: ...ator The butterfly casing actuator has two potenti ometers connected in parallel so that one con trols the other and viceversa If the two potentiometers fail or if there is no supply the control unit...

Page 355: ...X 1 lean mixture X 1 rich mixture 4A30UI02 a Rich mixture lack of air b Lean mixture excess air The Lambda sensor in contact with the ex haust gases produces an electrical signal whose voltage value...

Page 356: ...l output by the left driveshaft coupling and trasmits informa tion concerning the vehicle speed to the con trol unit the signal is also used for the opera tion of the speedometer The sensor is the Hal...

Page 357: ...s above 40 C and the engine speed is below a certain level when the butterfly angle is greater than about 8 the solenoid 1 is energized pushing the valve chest 2 downwards In this position the oil com...

Page 358: ...ration of phase transformer 10 8708786 8530 1 Solenoid 2 Valve chest 3 Valve chest spring 4 Piston 5 Pinion 6 Camshaft element 7 Piston spring 8 Battery 9 Injection ignition system relay 10 Injection...

Page 359: ...or the injection system is 5 Volt becuse the con trol unit intake circuit is designed as a voltage divider so this voltage is divided between a re sistance in the control unit and the sensor NTC resis...

Page 360: ...act the ball is re leased by the magnetic clip and opens the normally closed NC electrical circuit inter rupting the connection to earth of the electric pump and consequently the injection system supp...

Page 361: ...he expansion of the mass of granules when the pres sure increases Vapour cut out solenoid valve 0 280 142 340 The function of this valve is to control the quan tity of petrol vapours drawn in by the c...

Page 362: ...t the engine never disconnect the battery from the system with the engine running to carry out the rapid charging of the battery disconnect it first from the system if the vehicle is going into a dryi...

Page 363: ...king idle concentration of CO and HC upstream of the catalytic silencer To check the concentration of carbon monoxide CO and unburnt hydrocarbons HC upstream of the catalyzer proceed as follows 1 Undo...

Page 364: ...pecial extension pipe which ensure the seal in the join area must be added 1 Check that the idle CO and HC concentration figures correspond to those in the table 2 If the HC value is different from th...

Page 365: ...lassification of the defect If a defect is detected for the first time and the error state persists for a time t V 0 5s then the defect is memorized as permanent If this defect later disappears it is...

Page 366: ...osch communication protocol The diagnostic equipment can provide the following information display of the engine parameters display of the errors active diagnosis List of errors Description Nature of...

Page 367: ...t memory The control unit is equippd with a permanent type memory EEPROM in other words the error is pre served even if the cause of the problem no longer exists and the ignition has been switched OFF...

Page 368: ...ng heater plugs 9 Removing refitting pressure pump 12 Removing refitting accelerator poten tiometer 20 Adjusting accelerator pedal end of travel 21 Servicing instructions when removing turbocharger 22...

Page 369: ...be up to date as a result of modifications made by the Manufacturer at any time for reasons of a technical or commercial nature in addition to meet legal requirements in different countries Fiat Auto...

Page 370: ...compartment on the right hand side and disconnect the negative battery terminal 1 Remove the upper engine protective cover 2 Undo the two bolts shown in the diagram and move the rigid pipe between the...

Page 371: ...doing the two bolts as shown in the diagram 2 Undo the fixing nuts and place the diesel filter to the side 3 Disconnect the electrical connection from the excess pressure sensor 4 Move the fuel return...

Page 372: ...them 3 Undo the retaining nuts and carefully re move the injector bracket Use tool 1870739000 to remove the injectors NOTE To refit carry out the above opera tions in reverse order and rep ace the wa...

Page 373: ...tion unit cover Disconnect the terminals and remove the battery 1920 JTD 1 Disconnect the electrical connection for the flow meter 2 Loosen the collars and remove the first pipe section between the ai...

Page 374: ...rations on vehicle 10 1 Remove the upper engine protective cover 2 Undo the bolts and place the rigid pipe between the E G R valve and the solenoid valve to the side 3 Disconnect the fuel return pipe...

Page 375: ...s and undo the fixing bolts and place the wiring to the side 2 Undo the fixing nuts and place the diesel filter aside 3 Disconnect the electrical connection from the excess pressure sensor 4 Disconnec...

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 ra...

Page 377: ...ining nut securing the rail and remove NOTE To refit carry out the above opera tions in reverse order and replace the washers underneath the injectors the pipes joining the manifold and pres sure pump...

Page 378: ...er Disconnect the terminals and remove the battery 1910 JTD 1 Disconnect the electrical connection for the flow meter 2 Loosen the bands and remove the first section of the pipe between the air filter...

Page 379: ...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 4 Disconnec...

Page 380: ...nsor 2 Move the oil vapour separator aside un doing the three fixing nuts 3 Move the fuel return manifold aside 4 Disconnect the electrical connection un doing the fixing nut and remove the heater plu...

Page 381: ...er Remove the right front wheel and the wheel arch liner 2 Act on the tensioning device to loosen the auxiliary shaft belt tension Remove the auxiliary shaft belt 1910 JTD 3 Rotate the tensioner until...

Page 382: ...ive pulley on the crankshaft the pulley on the 1910 JTD engine has four fixing bolts 3 Remove the auxiliary shaft belt idler fixed pulley to allow the subsequent removal of the lower timing belt shiel...

Page 383: ...the upper timing belt shield 3 Remove the oil pump fixing bolt in place of the bolt position the pin for tool 1860905000 for determining T D C 4 Position tool 1860905000 on the crank shaft drive gear...

Page 384: ...no 1 at T D C 2 Fix tool 1860905000 to the crankshaft drive gear using the bolt shown 3 Loosen the timing drive belt moving ten sioner nut and remove the timing belt 4 Tighten the two adjustment screw...

Page 385: ...n pipe from the in jectors 1 the fuel return pipe from the pressure pump 2 and the fuel return pipe from the filter 3 Disconnect the electrical connection from the fuel temperature sensor Acting on th...

Page 386: ...on car 10 1 Remove the fuel delivery pipe from the pressure pump to the rail pipe 2 Disconnect the electrical connection from the pressure regulator on the pressure pump 3 Undo the retaining nuts and...

Page 387: ...nifold side fittings must be tightened to a torque of 2 2 daNm Fitting and tensioning timing drive belt 1 Fit the timing belt to the crankshaft gear provisionally and remove the bolt indicated from th...

Page 388: ...maximum tension position then tighten the nut fixing the tensioner to the support Remove tool 1860905000 and rotate the engine through two revolutions in its nor mal direction of rotation 3 Loosen th...

Page 389: ...the pedals as sembly 1 Remove the potentiometer idler rod from the accelerator pedal 2 Undo the nuts fixing the potentiometer to the bracket for the steering column and remove the potentiometer Move t...

Page 390: ...ds as appropriate under the tunnel so that the movement of the climate control components is not impeded and there is no noise vibrations whilst the vehicle is moving ADJUSTING ACCELERATOR PEDAL END O...

Page 391: ......

Page 392: ...4 Heater plugs control unit 15 Accelerator pedal potentiometer 15 Brake pedal switch 16 Clutch pedal switch 16 Excess pressure sensor 16 Atmospheric pressure sensor 16 FUEL SUPPLY CIRCUIT 17 Immersed...

Page 393: ...injection control advance and duration of injection reduction in consumption reduction in emissions FUEL SYSTEM MANAGEMENT STRATEGIES The control unit memory contains the management programme software...

Page 394: ...warning 7 EGR valve 8 Pressure regulator 9 Excess pressure sensor 10 Fuel temperature sensor 11 Fuel pressure sensor 12 Injection system relay 13 Electronic control unit 14 Injectors 15 Heater plugs 1...

Page 395: ...s the following parameters the quantity of fuel introduced into the cylinders in relation to the duration of the injection the atomization of the fuel injected the penetration of the jet the delay bet...

Page 396: ...jectors Fuel temperature control The injection control unit is constantly informed of the temperature of the fuel by the snsor on the return manifold If the temperature of the fuel exceeds a certain v...

Page 397: ...lizer function control The system is equipped with an engine immobilizer function This function is achieved thanks to the pres ence of a special control unit Fiat CODE capable of conversing with the i...

Page 398: ...Engine Fuel system Marea Marea Weekend 99 range 6 Print n 506 763 14...

Page 399: ...ntrol unit 20 Excess pressure sensor 21 Injection system protective fuse 7 5A 15 supply from ignition switch 22 Injection control unit protective fuse 7 5A 30 supply from battery 23 Injection system m...

Page 400: ...ut 4F0O8NJ01 1 01 Battery positive 30 from main relay 2 10 Not connected 1 02 Not connected 2 11 Not connected 1 03 Not connected 2 12 Not connected 1 04 Earth 2 13 Positive 15 from ignition switch 1...

Page 401: ...es a variation in the magnetic flow sufficient to produce an alternating voltage from the counting of the teeth on the flywheel The peak output voltage value from the rpm sensor depends all things bei...

Page 402: ...ring moves it covers the sensor blocking the magnetic field with a consequent low output signal conversely corresponding to the opening and the presence of the magnetic field the sensor produces a hig...

Page 403: ...eration of the injector can be divided into three stages 1 rest position The coil 4 is de energized and the shutter 6 is in the closed position and does not al low the introduction of fuel into the cy...

Page 404: ...r a tem perature increase is higher at lower tempera tures than at higher ones 1 NTC resistance 2 Sensor body 3 Electrical connector FUEL TEMPERATURE SENSOR This sensor is fitted on the return manifol...

Page 405: ...upply im 4 37 Rpm sensor earth mersed in the tank 4 38 Not connected 3 31 Not connected 4 39 Not connected 3 32 Not connected 4 40 Not connected 3 33 Not connected 5 01 1910 JTD N C 3 34 Not connected...

Page 406: ...unit 7 Accelerator pedal potentiometer 8 Brake and clutch pedal switches 9 Fuel pressure sensor 10 Intake air temperature and quantity sensor flow meter 11 Engine coolant temperature sensor 12 Fuel t...

Page 407: ...ns 3 38 4 Injection control unit pins 3 51 5 Injection control unit pins 2 1 6 Battery positive 30 G Heater plugs only 4 outlets are used 4F015NJ02 ACCELERATOR PEDAL POTENTIOMETER The position of the...

Page 408: ...s used by the injection control unit to distinguish between gear en gaged and gear change conditions 4F016NJ02 EXCESS PRESSURE SENSOR This sensor is fitted on the inlet manifold and the signal transmi...

Page 409: ...high pressure circuit consists of a radialjet pressure pump supply manifold and injector 1 Fuel tank 2 Immersed auxiliary electric bly complete with gauge 3 Multi purpose valve 4 Pressure pump drive p...

Page 410: ...vent the fuel circuit draining when the pump is not working the second excess pressure valve 7 which recirculates the supply with the inlet when pressures in excess of 5 bar are created FUEL FILTER Th...

Page 411: ...pump is lubricated and cooled by the same diesel fuel by means of suitable ducts and is capable of supplying a maximum pressure of 1350 bar 1 Cylinder 2 Cam 3 Inlet valve 4 Supply ball valve 5 Piston...

Page 412: ...der these circumstances is to restore the pressure inside the tank through the intake of air Any problem with this function can cause irregular operation or the breakdown of the vehicle through proble...

Page 413: ...r the tunnel so that the latter does not impede the movement of the climate con trol unit and does not produce noise vibrations whilst the vehicle is being driven 2 Connect the diagnostic equipment to...

Page 414: ...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...

Page 415: ...Waste gate 5 Actuator TURBOCHARGER I JTD This is a variable geometry turbocharger con nected to the exhaust manifold it is designed to increase the engine thermal output The variable geometry turbocha...

Page 416: ...ine rotation speed gradually increases the kinetic energy of the exhaust gases As a result the speed of the turbine 1 in creases and therefore the pressure of the super charging also acting on the act...

Page 417: ...rough the cells heat the catalyzer triggering off the conversion of the pollutants into inert compounds The chemical oxidation of the CO HC and par ticulates is effective at temperatures of between 20...

Page 418: ...from the brake servo vacuum pump 5 to the EGR valve If the vacuum is sufficient the valve 4 opens placing the exhaust manifold in contact with the inlet manifold EGR MODULATING SOLENOID VALVE The vacu...

Page 419: ...n seals as well as lubricant oil vapours These are defined as blow by or breather gases The breather gases coming from both the crank case 2 and the cylinder head 5 reach the separator 1 In the separa...

Page 420: ......

Page 421: ...f fuel system 2 Location of components of fuel system 3 Input output signals between control unit and sensors actuators 4 Functional diagram of fuel system 6 Air temperature sensor 7 Engine coolant te...

Page 422: ...instrument panel gauge Added intake air temperature sender unit which is no longer built into the flowmeter but is a single component located upstream of the new hot filrn flowmeter Modified fuel inje...

Page 423: ...tch 5 Accelerator potentiometer 6 Speedometer 7 Electronic control unit 8 Engine rpm sensor 9 Coolant temperature sensor 10 Instrumented fuel injector 11 Heater plugs 12 Borg Warner modulating valve 1...

Page 424: ...pedal switch 3 Accelerator potentiometer 4 Electronic control unit 5 Diagnostic socket 6 Engine rpm sensor 7 Coolant temperature sensor 8 Fuel injectors 9 Heater plugs 10 Borg Warner modulating valve...

Page 425: ...ture sensor 5 Clutch pedal switch 6 Brake pedal switch 7 Air flowmeter 8 Instrumented fuel injector 9 Speedometer sensor 10 Engine rpm sensor 11 Rev counter 12 Diagnostic socket 13 Fuel injection faul...

Page 426: ...side the control unit 1 signal requesting the switching on of the air conditioner compressor from the air conditioning system 15 Depending on the input values the electronic control unit 1 consults th...

Page 427: ...eating control unit 7 Coolant temperature sensor 8 Engine rpm sensor 9 Speed sensor 10 Clutch pedal sensor 11 Brake pedal sensor 12 Accelerator potentiometer 13 Speedometer 14 Heater plug warning lamp...

Page 428: ...rmistors the electrical resistance of the sensor decreases as the temperature in creases The two NTC thermistors are separate and they supply the temperature information to the specific gauge on the i...

Page 429: ...int of engine operation Qgr the imbalance compared with the theoretical value of the quantity of recirculating gases If the quantity of recirculating gases is correct for a particular point of engine...

Page 430: ...alanced value The increase in current which passes through the hot element is proportional to the air flow passing through the flowmeter This value thus gives the air flow to measure precisely the cur...

Page 431: ...Engine Fuel system Matea Marea Weekend TD 98 range 10 WIRING DIAGRAM 6 i n 7 i CQ o o Q 1 1 o L o 0 Q D h r o o L 1 _ _ J q g H i 1 m L I Q O L i 10 Publication no 506 763 11...

Page 432: ...r 12 Flowmeter 13 Engine rpm sensor 14 Engine coolant temperature sensor 15 Accelerator pedal potentiometer with idle switch 16 Instrumented fuel injector 17 Clutch pedal switch 18 Brake pedal switch...

Page 433: ...g 22 Not connected 23 Not connected 24 Not connected 25 Idle switch on accelerator pedal 26 Stop lights switch 27 Not connected 28 Clutch pedal switch 29 Vehicle speed signal 30 Not connected 31 Not c...

Page 434: ...VARITY EBC 430 Composition 1 Electro hydraulic control unit 2 Wheel rpm sensors active 6 Description of the operation of the an ti lock braking system 9 Diagram showing A B S hydraulic sys tem 14 Wir...

Page 435: ...rtioning thereby eliminating the need for the conventional load proportioning valve in hydraulic braking systems The main system components are electronic control unit electro hydraulic control unit w...

Page 436: ...rcuits with resistances diodes transistors and inte grated logic circuits The core of the system comprises two CMOS microprocessors with 24 K of ROM The main 16 bit processor calculates the ABS respon...

Page 437: ...riments it has been proven that ge nerally it is possible to reach the maximum braking force with creeping values of between 10 and 20 This defines an optimum area within which the anti lock brakes op...

Page 438: ...If one of these faults is detected the anti lock brakes whilst still ensuring the normal operation of the conventional braking system switch off and signal this condition to the driver through the fai...

Page 439: ...replaced It is available as spares filled with brake fluid and with the solenoid valves not supplied The operation of bleeding and refilling the braking system is the same as for conventional systems...

Page 440: ...h alternating North South polarities around the circumference The multi polar ring can be fitted on the wheel bearing seal or on the hub rear wheels The sensor is supplied by the ABS electronic contro...

Page 441: ...re if the gap is outside of the tolerance check the condition of the sensor and the multi polar ring NOTE Each time an rpm sensor is fitted it should be lubricated with water repellant grease to preve...

Page 442: ...en driving at a speed of about 6 kph the system test cycle starts to operate If the system component responses are positive then the warning light remains switched off If the response is negative then...

Page 443: ...y pump motor 4 Recovery pump 5 Restricter 6 Brake pump 7 Brake servo 8 Multi polar ring 9 Pressurizing solenoid valve 10 Discharging solenoid valve 11 Brake caliper 12 Rpm sensor 13 Single acting valv...

Page 444: ...ure produced by the brake pump 6 reaches the brake caliper without undergoing variations because the solenoid valves 9 and 10 for the hydraulic unit are not connected to earth by the electronic contro...

Page 445: ...earth The hydraulic connection between the brake pump 6 and the brake caliper 11 in interrupted wait ing position The pressure in the brake caliper 11 is kept constant at the value reached previously...

Page 446: ...onnection between the brake caliper 11 and the low pressure accumulator 2 and the recovery pump 4 in such a way as to remove some of the fluid from the brake caliper 11 and decrease the pressure at th...

Page 447: ...achieved through a rapid opening and closing sequence of the pres surizing valve 9 When the electronic control unit 1 once again detects creeping conditions it activates the strategy described in the...

Page 448: ...ng solenoid valve Left front pressurizing solenoid valve Left front discharging solenoid valve Right front pressurizing solenoid valve Right front discharging solenoid valve Left rear pressurizing sol...

Page 449: ...A function makes the need for the hydraulic load proportioning valve acting according to the load on the rear axle superfluous which is why it has been eliminated from the vehicle braking circuit The...

Page 450: ...re implementation strategy operated by the electronic control unit on the basis of the input data represented by the signal for the rotation speed of the wheels on the two axles E Rear wheel speed F F...

Page 451: ...protective fuse 7 60A protective fuse 8 Braking system failure warning light EBA 9 Battery 10 Ignition switch 11 Diagnostic socket 12 Brake lights switch 13 A B S warning light Identification of termi...

Page 452: ......

Page 453: ...engine management control unit 1 Additional heater 3 Location of climate control system components 5 Compressor 7 SCROLL compressor 8 SANDEN SD7V16 compressor 10 DENSO 7SB16 compressor 11 Oil level r...

Page 454: ...date as a result of modifications made by the Manufacturer at any time for reasons of a technical or commercial nature in addition to meet legal requirements in different countries Fiat Auto S pA D M...

Page 455: ...ng not dealt with on the pages which follow refer to the descriptions in the Marea Marea Weekend Service Manual print n 506 763 01 4F01AH01 CONNECTION WITH ENGINE MANAGEMENT CONTROL UNIT The electroni...

Page 456: ...t 2 Climate control unit 3 Four stage pressure switch 4 Compressor relay 5 Compresor 1998 1910 JTD 2387 JTD Case B the signal a to switch on the compressor is sent via the climate control unit 2 to th...

Page 457: ...m towards the engine thermostat The three relays are connected near the diesel filter on a special bracket fastened to the engine compart ment bulkhead The system control unit is located under the das...

Page 458: ...down The information concerning the engine speed is used to prevent the operation of the heater plugs when the engine is not running the enablement figure is about 660 rpm Either one two or all three...

Page 459: ...he evaporator inlet duct various rigid and flexible pipes which connect the various system components a four stage pressure switch fitted on the drier filter There are two small pipes on the high and...

Page 460: ...n valve 6 Pipe between compressor and condenser 7 Pipe between condenser and drier filter 8 Pipe between filter and evaporator 9 Pipe between evaporator and compressor 10 Four stage pressure switch 11...

Page 461: ...as illustrated in the table below ENGINE TYPE COMPRESSOR 1242 16v SCROLL SCS08 1581 16v NIPPODENSO TV12 SC 1747 16v NIPPODENSO TV12 SC 1998 20v NIPPODENSO TV12 SC 1910 75cv NIPPODENSO TV12 SC 1910 JT...

Page 462: ...pulley creates a chamber whose volume decreases during the rotation allowing compression The adoption of this compressor consisting of two moving parts only has led to the following advan tages no ga...

Page 463: ...he pressurized gas The volume defined by the two scrolls decreases determining the compression mechanism for the gas stored The pressure gradually increases until the gas reaches the centre area where...

Page 464: ...is illustrated in the diagram below it consists of seven pistons 2 and connect ing rods 3 secured to a connecting rod holder plate 4 The rotary motion of the plate 4 on the shaft 5 produces the altern...

Page 465: ...inside the compressor casing according to the compressor inlet and outlet pressure The balancnig of the forces due to the pressure makes it possible to adjust the angle of the plate and consequently...

Page 466: ...duce the amount of oil in the compressor into a graduated test tube C taking care to let it drain well Remove the oil separator A from the new compressor and pour the amount of oil contained into a gr...

Page 467: ...tact III closes at around 20 bar engagement of second speed In addition the three stage pressure switch is designed to de energize the compressor pulley electro magnet coupling when in spite of the ac...

Page 468: ...clip and undo the bolts shown in the diagram fixing the wheel arch liner to the bodyshell 3 Undo the bolts shown in the diagram and remove the lower shield from the engine compartment 4 Acting on the...

Page 469: ...and the com pressor duct using suitable plugs Undo the bolt shown and release the pipe from the compressor inlet duct seal both the ends of the pipe and the compressor duct using suitable plugs Undo t...

Page 470: ...I...

Page 471: ...Marea Weekend 1998 range Electrical equipment Contents 55 page LOCATION OF COMPONENTS ON VEHICLE Location of relays and fuses on vehicle 1 Location of control units and tester sockets 2 Copyright Fiat...

Page 472: ...mittent function 90 Headlamp wiper fuse 122 Engine cooling fan low speed relay 123A Engine cooling fan high speed relay 124 Air conditioner compressor control relay 129 Engine cooling fan power fuse 1...

Page 473: ...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 139 Tester connection for injection system...

Page 474: ...Marea Marea Weekend Electrical system 98 range Wiring diagrams 55 page WIRING DIAGRAMS 1 Connector blocks 1 5 Copyright Fiat Auto...

Page 475: ...rning light 1 Fiat C O D E system and warning light 3 Thermostatically adjusted heater air conditioner 5 Versions with air conditioner Engine cooling system Coolant temperature gauge 7 Versions withou...

Page 476: ...O Q O CO T SO 00 IiL J J L L ijj M B R B N N B 21 137 BN B R i 1 2 X 10 13 2 T T t4m m R CB A G I 89 _TL C 3 89A BN BN BR BR M G LN N 307 3 HB HG 142 LN H B N D BN B R M G N i i H G H M IHB 3 55 _ I N...

Page 477: ...89A Left brake pad wear sensor cables connec tion 90 Handbrake on warning light switch 95 Front cables ABS cables connection 137 Car speed sensor 142 Low oil pressure warning light switch 181 ABS elec...

Page 478: ...D C D CO D CO ijj ijj IIJ L H R M i T 13 2 13 CB CB I C N D El rr TI r y y yi J 15 54 J I lirt n I D O S 15 54 1 lnt a pos 30 50 lirt stazr Oh 12 N D c c R R N D m L RV 195 29 13 25 ttt R N 308 237 N...

Page 479: ...E 308 Fuse protecting fuel injection and CODE N D Ultrasound soldered joint taped in wiring loom 55 6A Instrument panel AG n d LN 195A _ BN n d HN55 BR89A MN 131B HL 120B CN55 _RV95 HB55 L195A 31 B a...

Page 480: ...N A G 12 f r r if T f 3 o15 54 5 o rt VtLzP A R 1 7 c 5 244 N 232 Connections and components NOT present in the HEATER version BL N D N Ni N HN N D I N N D NZ N G N N D L RN G N G N n H BN N _ H r K...

Page 481: ...te control system 232 Earth for compressor 244 Integrated services electronic control unit 249 Diagnostic socket for climate control system 253 Climate control system control unit 254 Climate control...

Page 482: ...787 tit r B R 3 15 1 if AG I N 7 6 5 4 3 l7 GN 3 fa AN 4 CB A G N D I N D 22 C A G 1 c 12 A G J 15 54 I I rrt a I D O MINI A N A N M U 11 Sfffl 10 122 154 87 30 85 86 N C 129 237 c c N D CL a 40 H 195...

Page 483: ...eater unit cables connection 195 Fuel injection ignition electronic control unit 202 Light bulb for heater air conditioner con trols symbols 206 Car interior climate control fan 207 Electric fan speed...

Page 484: ...L I J I L I J r i L 2 2 1llllll 1 0 2 3 7 1 2 9 i n 3 0 7 HB 2 f3 CB CB N D HB HB 122 87 30 85 86 4 L CL N D A N A N AN A N 154 170 4 311 N H N D 3 0 9 AN 127 G R G A R CL CL AN N D AN 10C I 15 54 J...

Page 485: ...oling fan cables 154 Engine cooling fan 170 Resistor for engine cooling fan 195 Fuel injection ignition electronic control unit 237 Fuse protecting Fiat CODE 307 Water temperature double sender unit 3...

Page 486: ...N N R i 12 3 1 2 1 5 1 6 M B N N N Z 1 YJ 1 N Z 12 56B 57 1 8 N 0 22 1 5 0 87 30 85 86 m Z SB RV 139 I f IB R RN GV RV CB 3 6 8 1 3 1 I HM HM N D CN HN RN M CN HG NZ H M CN HN HG LN MG 55 M G LN _TL r...

Page 487: ...Petrol vapours cut off solenoid 307 136 Knock sensor 308 137 Vehicle speed sensor 138 Idle speed adjustment actuator M r 139 Diagnostic socket for fuel injection N D 141 Heated Lambda probe Ultrasound...

Page 488: ...40 94 88 R N A R N D AR AR J CB N D N D N D c c 96 nr N D N BN 95 BN N C B N RV BN BN LR RV M C H f r l t T fl 115 541 I In t a I D O S 15 54 I I lnt a J pos 30 50 in t s taz 31 T1 R B N RV J 2 12 2 1...

Page 489: ...for anti lock braking system A B S 178 Sensor on rear left wheel for anti lock braking system A B S 179 Sensor on front right wheel for anti lock braking system A B S 180 Sensor on rear right wheel f...

Page 490: ...Marea Marea Weekend Electrical system 98 range Connector blocks 55 N 195A N195A N131B P4F551 N03 J 97 ZB132 P4F551N04 4F27AN Copyright Fiat Auto 15...

Page 491: ...HQ ad HVn d C a AR244B AN AC N100B 88 Low brake fluid level sensor 05 Connection between front cables an ti lock braking system A B S BN n d BN181 P4F552N03 1 20B conditioner cables connection Z 7 0 A...

Page 492: ...n d 1 24 conditioner compressor relay MN 127 VNn d LN127 RV127 127 Connection between front left cable cable on relay bracket MN 124 RN98 1 29 P o w e r fuse protecting engine cooling fan R154 1 31 F...

Page 493: ...a a c t u a t o r VB 195B Ov5 v f GR 195B C 195R S J HN 195R P4F554N03 1 39 Diagnostic socket for fuel injection BR 195A P4F554N04 1 41 Heated Lambda probe ZB n d p s uT L 195A LN195A P4F554N05 1 44...

Page 494: ...jection relay Rn d C a d Zad SB 195A g J Engine cooling fan 3 R 129 N n d R129 N122 1 SS Ignition coils assembly LR195B CN ad QN195B 7Q Resistor for engine cooling fan L 311 7g Diagnostic socket for a...

Page 495: ...k braking system A B S 1 gQ Sensor on rear right wheel for anti lock braking system A B S V 181 M181 1 81 Electrohydraulic unit for anti lock braking system A B S 9 M180 15 C 9 5 21 BN95 10 V180 16 Nn...

Page 496: ...Marea Marea Weekend 98 range Electrical system Connector blocks 55 1 95A F u e l Nection ignition electronic control unit 1581 P4F557N02 4F33AW Copyright Fiat Auto 21...

Page 497: ...E B144 _68_ V306 _Z _ Z136 _ Z L HG194 _ Z L HL194 _ Z L RQ306 _ Z L BR 146 _ Z L NZ n d _ Z L HM 194 _ Z L HV 194 74 67 60 I I I l I I I l I I M I 1 1 I i i i i T T r 1 1 1 1 1 1 1 1 1 1 1 250 F u s...

Page 498: ...ical system Connector blocks 55 309 4 stage pressure switch AR 195A S195A 31 0 F u s e P r o t e c t m 9 headlamp washer and air conditioner VN a d VN127 311 Electric fan resistor connection Nad P4F55...

Page 499: ......

Page 500: ...ate control Engine cooling Engine coolant temperature gauge 7 Versions without climate control Engine cooling Engine coolant temperature gauge Manually operated heater car interior ventilation 9 Start...

Page 501: ......

Page 502: ...Marea Marea Weekend 98 range Electrical system Wiring diagrams 55 Instrument panel connections TD engine fr HMIIIrH 1 1 Copyright Fiat Auto VII 98 Uprltite 14 1...

Page 503: ...r TD 224 Instrumented fuel injector TD 228 Heater plugs TD 229 Engine cut out electrostop TD 266 Fuel injection electronic control unit 2387 TD 285 E G R solenoid TD 286 Diesel pump 2387 TD 287 Soleno...

Page 504: ...115 54 J M a J pos 50 Irrt ft i i i r M B N N NZ 1 142 N N 22 8 55C RN RN N Z 12 56 57 18 N G B R HV 4 5 6 131 R I R R RNl HL 137 291 VN LI N I VN I VN M B VN _TL M G VB CB ZB H LN HL NZ 86 85 30 87...

Page 505: ...rning light switch 143 Alternator 158 Water temperature sensor for gauge 181 Electrohydraulic control unit for anti lock brak ing system A B S 182 Right wheel brake pad wear sensor 182A Right wheel br...

Page 506: ...9 N D AN AN N D A G N D A G A G 12 T T T 1 t T V J 15 54J l lnt o I DOS 1 5 5 4 j Int Q pos 30 50 hrt sto zK 123B 154A 154 172 123A 122 rrrrn 87 87tx 30 85 86 N L A N N D M H R 126 N R N A R M n R N A...

Page 507: ...rotecting for engine cooling fan 129A Power fuse protecting 2nd engine cool ing fan 154 Engine cooling fan 1 154A Engine cooling fan 2 172 Two level thermal switch N D Ultrasound welding taped in cabl...

Page 508: ...Marea Marea Weekend Electrical equipment 98 range Key 55 4F36AN Copyright by Fiat Auto XII 98 Cancels and replaces 25...

Page 509: ...r 1 Right front side direction indicator 2 Left dashboard earth 3 Hazard warning lights switch unit A Hazard warning lights warning light B Hazard warning lights switch 24 Windscreen wiper motor 25 Wi...

Page 510: ...king 111 Right front central locking 113 Central locking protective fuse 114 Air bag electronic control unit 11 5 Passenger Air bag 116 Driver s Air bag 117 Air bag dashboard cables connection 120 Air...

Page 511: ...el for anti lock brakes A B S 181 Electro hydraulic control unit for anti lock brakes A B S 182 Right wheel brake pad wear sensor 182A Right wheel brake pad wear sensor cables connection 183 Ignition...

Page 512: ...artment light button 244 Integrated services electronic control unit 245 Rear courtesy light 247 Lambda sensor protective fuse 1370 1998 248 Radio controls on steering wheel 249 Diagnostic socket for...

Page 513: ...nit 1910TD 75 299 Water temperature sensor pre heating 1910TD 75 00 K S B thermostatic switch 1910TD 75 301 KSB device 1910TD 75 302 Diagnostic socket for EGR system 1910TD 75 303 Diesel pre heating p...

Page 514: ...d diagnostic sockets 10 Location of connector bridges 13 RADIO Radio Cassette Player model AD 182 H2 14 General Description 15 Operation 16 Cassette Player 25 CD player function 28 Radio Cassette Play...

Page 515: ...l system fuses were rated based on the nominal absorbtion of the loads activated at the same time to ensure intervention in cases of a clear short circuit The introduction of a box containing 4 maxifu...

Page 516: ...w i i 8 1 T T I X SERVIZI I j X SEHVICE 3D C R R R R C w w r n n 1 2 3 4 5 6 j n n n n s i j CB RN L LR V RG AG AN C O D E 12 B C C AN rrm n 4 J is 1 005 J I I 85 86 B7 30 ffl AN N 332 H r G O E Sr N...

Page 517: ...g g V D in w 3 2 9 x i E CO OJ 1 P4F003GL03 Component key 3B C Power fusebox 3A D Supplementary fusebox 4 Junction unit 10 Engine battery earth 10A Bodyshell battery earth 11 Battery 12 Ignition switc...

Page 518: ...it and location of fuses The connectors cannot be connected incor rectly as each has its own unique shape The letters identifying the connectors are the same as those used in the wiring diagrams 4TO2A...

Page 519: ...Panel 10 HL Left number plate light without Check Panel 11 N C 12 RG N C 13 RN N C 14 R Additional brake light Electrical equipment _____ Junction unit 55 CONNECTOR B Termi nal No Cable colour Circuit...

Page 520: ...B Hazard warning lights supply 11 AB Hazard warning lights supply 12 AR Direction indicators supply 13 R Instrument panel supply 14 N C 55 conf CONNECTOR H Termi nal No Cable colour Circuit involved 1...

Page 521: ...lamp Main beam headlamps warning light Central locking D Lug gage compartment light Hazard warning lights Interior lights front and rear Instrument sup ply Remote control re ceive and alarm control un...

Page 522: ...cted circuit Amp F1 Fuse protecting injection memory and CODE 7 5 F2 Fuse protecting compressor and air conditioner 7 5 F3 Fuse protecting ABS 10 F4 Fuse protecting injection and CODE 7 5 F5 Fuse prot...

Page 523: ...n high speed timer 124 Air condiitoning compressor control relay 129 Power fuse protecting engine coling fan 150 Injection system relay feed 151 Lambda probe control relay for fuel pump and injectors...

Page 524: ...r condiitoning compressor control relay 129 Engine cooling fan protection power fuse 129A Power fuse protecting engine cooling fan no 2 152 Fuse protecting injection system 303 Fuse protecting diesel...

Page 525: ...y feed 32 Fog lamp control relay 150 Injection sytem control relay 1747 JTD 151 Lambda probe control relay for fuel pump and injectors 152 Fuse protecting injection system 1747 JTD 250 Fuse protecting...

Page 526: ...trol unit 103 Tester socket for injection alarm 139 Tester socket for injection system 140 Injection ignition control unit 1242 160 Injection ignition control unit 1747 176 Diagnostic socket for anti...

Page 527: ...electronic control unit 103 Tester socket for injection alarm 139 Tester socket for injection system JTD 176 Diagnostic socket for anti lock brakes A B S 181 Electro hydraulic control unit for anti lo...

Page 528: ...ronic control unit 160 Ignition injection electronic control 1747 238 Rear electric windows control unit 244 Integrated services control system 249 Diagnostic socket for climate control sys tem 253 Ai...

Page 529: ...car These replace ultrasound welding and allow lines to be connected according to the specifications or options installed 4F013CL01 31 OA Connection bridges under the facia 31OD Rear connection bridg...

Page 530: ...t TRACK REPEAT function 11 Station storage button N2 CD player TRACK REPEAT function 12 Station storage button N3 select TRACK RANDOM function set time enter secret code number 13 Station storage butt...

Page 531: ...1 FM2 FM3 and in bands MW and LW Automatic station storage using Autostore function on buttons 1 2 3 4 5 6 in bands FM1 FM2 FM3 MW and LW Automatic DX function Distant maxi mum radio station search se...

Page 532: ...switch on off the radio To activate the system switch off the car radio then hold down station selection button 5 1 until IGN ON appears on the display then switch on the car radio using the VOL but t...

Page 533: ...ume is being adjusted BASS and TREBLE adjustment BASS and TREB Select the BASS or TREB function by pressing the AUDIO 2 button 1 or more times Once the function has been selected use the VOL 1 knob to...

Page 534: ...tion and displays the message LOUD Press the LOUD 1 button again to deactivate the function previously activated MUTE Function Press the Audio button 1 for about 3 sec onds to select the MUTE function...

Page 535: ...or AM bands Intelligent automatic tuning and search IS function Use the BAND 1 button to select band FM1 FM2 or FM3 Press the intelligent automatic search function IS button 2 When the search is ended...

Page 536: ...sitivity of the radio station search When the DX function is active the radio only selects stations with a power greater than a fixed ref erence value When the DX function is inac tive even the radio...

Page 537: ...ing any key for 60 seconds Listening to stored stations Proceed as follows 1 Use BAND button 1 to select the required band 2 Press one of the frequency selection keys 1 2 3 4 5 6 The display shows the...

Page 538: ...button to activate the TP function Point b If you want to receive traffic reports tune to a RDS TP station before inserting a tape or Compact Disc If a traffic report is transmitted while you are lis...

Page 539: ...e search Refer to the paragraphs below for further de tails Storing the types of programme required on the station selection buttons Press button TP 1 on above figure for about 6 seconds until the mes...

Page 540: ...display the programme types avail able from the list Identify the type of pro gramme required then press key or for about 2 seconds to start the automatic search The search stops when the radio tunes...

Page 541: ...ithout removing the cassette AUTOREVERSE function Inserting the cassette Open the cassette compartment flap Insert the cassette as far as it will go keeping your hand on it until the car radio draws i...

Page 542: ...less than three sec onds between them To activate this function press the MSS key 1 when the cassette is playing The message MSS ON is displayed To skip to the next track press key A 2 while to go bac...

Page 543: ...A P E appears on the screen and the radio s w i t c h e s on tuned to the most recent station listened to The cassette cannot be ejected if the radio is switched off Pausing cassette playback temporar...

Page 544: ...eader comes with a magazine with a capacity for up to 6 CDs Filling the CD magazine Remove one mount for every CD you want to play 1 s T i 1 s 1 3 1 2 T Insert the CD with the label or the printed sid...

Page 545: ...utton on the CD player in dicated by the arrow Removing the CDs from the magazine Remove the CDs and the mounts one by one from the magazine CD playback To play the CDs already inserted in the CD play...

Page 546: ...lay If the CD player has a mechanical fault the message MECHANIC appears on the display If the CD player is overheating the message TOO HOT appears on the display the situation described above occurs...

Page 547: ...t the current track continuously press station selection button 1 1 The message TRK ON is displayed Press station selection button 1 1 again to disable the TRACK REPEAT function previ ously selected T...

Page 548: ...stop CD play back and return to RADIO mode Displaying CD player status Press EXP button 1 to display any active special function e g TRK ON Never expose the CDs to heat sources or to dirext sunlight...

Page 549: ...l control Press key EXP 1 until the display shows the message EXPERT Select the adjustment you want to make using key or 2 3 Use the relevant frequency keys to set the re quired level Choosing the rel...

Page 550: ...is transmitted from various regional stations the radio may select the most powerful transmission The frequency selection keys required are key 5 1 to activate the function and key 4 2 to deactivate i...

Page 551: ...4 digit code The protection system makes the rdaio inoper able if it is removed from the facia as a result of a theft Secret code The secret 4 digit code is shown on the Se curity Code Card which com...

Page 552: ...d electronically To use the radio again the code must be entered as follows Switch on the radio using the VOL knob 1 the message SAFE is displayed followed by Enter the code using the previous example...

Page 553: ...Ignition activated 15 5 Supply aerial 6 Lights 7 Supply 30 8 Right dashboard earth CONNECTOR B HOUSING No Connection 1 Right rear speaker 2 Right rear speaker 3 Right front speaker 4 Right front speak...

Page 554: ...o n 7 Cassette fast f o r w a r d b u t t o n 8 B N b u t t o n select frequency range F M 1 F M 2 F M 3 M W start automatic IS f u n c t i o n select A U T O S T O R E f u n c t i o n 9 1 0 IS m e m...

Page 555: ...ith TP Traffic Program functions EON Automatic manual station tuning Manual storage of 5 stations in bands FM1 FM2 FM3 and in bands MW and LW Automatic station storage using Autostore function on butt...

Page 556: ...isplayed Select the switch on off via ignition switch setting using the keys A 2 and T 3 Press frequency selection key 5 4 to activate the function or if already active press fre quency selection key...

Page 557: ...to achieve the required sound To restore the default setting press the AUD button for about 3 seconds until the message 00 or appears on the display Adjusting balance between left and right speakers B...

Page 558: ...AUD key again The mesage MUTE OFF is displayed When the Mute function is selected the radio no longer sends signals to the speakers RADIO FUNCTION The reception conditions will vary greatly while driv...

Page 559: ...t three seconds until the message IS is displayed followed by IS ON Use key A or T to progressively recall the stored stations To deactivate the IS function press key A or for about three seconds unti...

Page 560: ...one of the frequency selection keys or by not pressing any key for 60 seconds Listening to stored stations D Select the required band using key BN Press one of the frequency selection keys The displa...

Page 561: ...b If you want to receive traffic information befor inserting the cassette tune to an RDS TP station If traffic information is broadcast on this station the cassette playback will stop and will automat...

Page 562: ...efer to the paragraphs below for further details Storing the types of programme re quired on the station selection buttons Press button TP 1 on above figure for about 6 seconds until the message PTY O...

Page 563: ...stening Classics Classical Music OTHER M Music programmes that cannot be classified eg folklore 3 3 BN H n T P 1 1 BN H n T P 1 4 5 1 E P IlL 4 5 1 E P flF flF OFF flF On WEATHER Weather forecasts FIN...

Page 564: ...cassette inserted into its compartment and the message TAPE A or TAPE B being displayed press keys 1 and 2 together The cassette player plays the other side of the tape The messages TAPE A and TAPE B...

Page 565: ...sation 3 Traffic report minimum volume 4 LRN switch on off 5 Switch on off automatic regional pro gram change 6 LOC on off 7 MONO on off 8 LOUDNESS on off EXPERT control level 9 FADER on off 10 Limit...

Page 566: ...ction key 4 3 subsequently to display the message SYNC OFF Minimum traffic information volume To set the required volume use frequency se lection keys 4 1 and 5 2 to respectively increase or decrease...

Page 567: ...ssion strength whereas if the function has not been selected the search is extended to lower strength transmissions To activate the LOC function press frequency selection key 5 1 until the message LOC...

Page 568: ...sound quality at low levels To activate the LOUDNESS function press frequency selection key 5 1 until the mes saage LOUD ON is displayed To deactivate the LOUDNESS function once activated press frequ...

Page 569: ...Telephone input sensitivity The telephone input sensitivity can be adjusted using frequency selection key 4 or 5 The display shows the message PHONE 00 or PHONE 03 respectively for a low or high sens...

Page 570: ...olts retaining the rear seat cush ion to the bodyshell then remove it from the car Marea Weekend Disconnect the rear seat cushion Undo the two retaining bolts Remove the control unit from its housing...

Page 571: ...ribed in the Service Manual for the Fiat Marea Marea Weekend volume 2 print no 506 761 01 In order to change the software configuration for the CODE system follow the special procedure below As well a...

Page 572: ...to the ON position 15 the CODE light will switch on for 0 7 sees When the CODE light switches off rotate the key 1 into the STOP position and re move it Repeat the operations as per key 1 for the seco...

Page 573: ...s would cancel all the stored codes Rotate the MASTER key into the ON position 15 the CODE warning light will come on for 0 7 sees Marea Marea Weekend 99 Range When the CODE light switches off rotate...

Page 574: ...hould switch off after 0 7 seconds when the key is rotated to the ON position otherwise the light will start to flash rapidly 1 6 Hz in which case you must repeat the programming procedure If you thin...

Page 575: ...light 10 Low brake fluid level and handbrake ap plied EBD system failure warning light 11 Rev counter NOTE The previous control panel configuration is mission 12 Engine coolant temperature gauge 13 A...

Page 576: ...in beam warning light H Air Bag fault warning light I ABS failure warning light J Fuel reserve warning light K Fuel level gauge L FIAT CODE system warning light M Injection system failure warning ligh...

Page 577: ...sup ply 15 HB Engine coolant temperature 16 HL Outdoor temperature signal 17 HM Speedometer signal 18 L Rev counter signal not connected in this version Pin no Wiring colours Circuit 1 RG Left brake...

Page 578: ...ing light On some outfits the ABS and Air Bag systems are suppied as options If these systems are NOT fitted to the car the built in circuit will indicate a continuous fault because it is not connecte...

Page 579: ...eam warning light bulb M M Total mileage reset Total mileage may be reset to zero within the first 200 km following transfer in the factory or before hand over to the customer If the instrument is new...

Page 580: ......

Page 581: ...Marea Marea Weekend 99 range Electrical equipment Connector blocks 55 page Meaning of codes on connector blocks 116 Cable colour code 116 Connector blocks 117 Copyright Fiat Auto 115...

Page 582: ...ocks are depicted from the lead input side Cable colour code A Light blue BG White Yellow LB Dark blue White B White BL White Dark blue L G Dark blue Yellow C Orange BN White Black LN Dark blue Black...

Page 583: ...N8 Polyelliptical headlamps wire not connected V N 4 C GL n d HN n d N 8 1 Left front light cluster VN 4C AV4D HN4C Reflector headlamps B 2 Right front light cluster B GV n d G V 1 3 A n d Polyellipti...

Page 584: ...range 55 3 A Power fusebox Electrical system Connector block R n d _ M n d C VN127 ARn d P4F918N01 3 D Power fusebox R n d R n d C n d Cn d from Nov 99 up to Nov 99 118 XII 99 Cancels and replaces Pu...

Page 585: ...on unit Rn d 4Q Junction unit 4C MB 556 MB 55 HN 1A RN 120A Junction unit AB70 AN 70 AN n d H 13 Reflector headlamps AV70 With Check Panel RN n d 4D Junction unit 4E Junction unit AB 13 RN n d AR40 AV...

Page 586: ...Junction unit AN 16 Rn d cs MN39 MB 56 RG 16 R236B RN 17 Marea Weekend without Check Panel 4G Junction unit 4G Junction unit GN28A GN28A A17 RN 107B RN 107A Marea with Check Panel RN245 Marea without...

Page 587: ...8A GN310A H7B 6A Instrument panel 1 1 9 9 8 1 LN 190A LN 5 5 _ _ AG n d BN n d JTD HN n d HN 55 B R 8 9 A MN131 C L 5 5 JTD 1747 agg S L160A HG55 R V 9 5 L190A l998 6B Instrument panel C117 HG 28A GL3...

Page 588: ...15 16 17 17 18 18 18 18 VB 190A 1998 VB55A JTD VB 160A 1747 VB 195A 1581 l j i _r VB140A I 1242 AG n d CN 55 H B 5 5 HL70 HM55 L n d JTD L 190A 1998 L160A L195A L140A 18 14 1747 1581 1242 6B Instrume...

Page 589: ...switch unit A4H LR 23B CB28B CL28B AN4H HL34A CB 41 LN 41 LB23A 8 Left front earth 8A Left front earth N 123A NZ 103 N 100A NZ 13 NZ24 N7A N 1B N98 N20 N 121 N 126 NZ 43 NZ 55 N 305 1910 75 NZ 45 N88...

Page 590: ...Electrical system Marea Marea Weekend Connector block 99 range 55 122 b Xfl 99 Update Publication n 506 763 19...

Page 591: ...Marea Marea Weekend 99 range Electrical equipment Connector blocks P4F923N03 1 0 Battery earth on engine Copyright Fiat Auto 123...

Page 592: ...eft front cables G44 H2A SN 25 RN 97 ZB 132 1 1 5 8 1 1 V 2 A 1581 RG132 15811 1747 MN 147 S25 1 1 5 8 1 1 RG 195A 1581 1 4 Left no plate light HL4E I Marea Without Check Panel 1 4 Left no plate light...

Page 593: ...light cluster 1 7 Right rear light cluster GR 4E _ Bn d B 4 G N 19 A 4 G RN 4E GR28A Marea N 19 Without Check Panel P4F926N03 G R 4 E _ Marea Weekend Without Check Panel P4F925N04 18 Left rear earth...

Page 594: ...rning lights switch unit 24 Windscreen wiper motor A4H L R 7 C AN4H HN7A HG7A GV7A 25 Electric windscreen rearscreen washer pump 26 Windscreen wiper motor S 1 3 SN13 NZ n d 28A Facia rear lead connect...

Page 595: ...RN n d V107A 28A Facia rear lead connection RN 31 OB RN310A NZ22 AR120 MB34A C310B HG 6B Marea Weekend without Check Panel BR 66 28 B Facia rear lead connection BH n d S 120B H G 7 0 HG310C Z120B AG4...

Page 596: ...NZ n d SN n d BN35 S36 HG310D CL236B CB 236B Marea Weekend with alarm without alarm 28C Facia rear lead connection _V n d S n d LR n d Sn d Ln d R92A 29 Front fog lamp lead connection M70 Nn d Mn d 3...

Page 597: ...9 range Electrical system Connector block 55 34 B Switch control panel P4F929N03 35 Connection between dashboard left front door cables P4F929N02 from Nov 99 up to Nov 99 Copyright Fiat Auto XH 99 Can...

Page 598: ...ht front door cables S 2 8 B HG 310D GN 244A Z 2 8 B AG n d B310E MN n d LR 66 BN 111B HV 66 39 Heated rear windscreen MN 4E 39 Heated rear windscreen Marea MN 236B N236B Marea Weekend 40 Brake lights...

Page 599: ...n d Marea Weekend 42 Right dashboard earth N 5 43 Electrical actuator for left headlamp alignment j M Electrical actuator for right headlamp alignment H4D HB 13 45 Headlamp alignment control unit 46...

Page 600: ...n d AB 28B AG28B 48C Radio receiver with clock ZN248 Z319 49 Left front speaker tweeter 50 Right front speaker tweeter BN n d RG n d SN n d NZ n d 51 Speaker in left front door 52 Speaker in right fr...

Page 601: ...R140A N 131 CN 137 RN 145 B 159 NZ137 55 Front engine lead connection 1581 CN6A HG6A HN6A CN n d MB6A NZ8 HM6A CN n d 143 55 Front engine lead connection 1747 HB6A HM6A AR n d L 6 A CN6A RN 12A Cn d L...

Page 602: ...333C Nn d G333C LN 137 MG 137 N 137 HL 333D NB335 B335 C333B SN 333B M145 HV33C HB334 55A Front engine lead connection 1747 agg 99 HR n BR n d R G 127 N 131 HB6A 55A Front engine lead connection GV13...

Page 603: ...ont engine lead connection GN 333B 55C Front engine lead connection 56 Fuel gauge unit 1747 Rn d MB 4E 57 Inertia switch 58 Control panel light dimmer N56 NZ18 GN4J GR 6B 64 Glove compartment light bu...

Page 604: ...2 B2 C2 VG 127 V328 HR100B A3 B3 C3 H 100B AG n d HN 100B A3 B4 C4 VN 55 LN 100B HG 100B c A4 B5 C5 HL6A AV4D HV100B A5 B6 C6 CB 100A AB4D G L n d A6 B7 C7 S 100B AN4C G V 1 3 A7 B8 C8 V100A A8 A1 B1...

Page 605: ...92 G V 1 3 11 GV 12 AN 120 B8 GL C7_ C8 GV Without Check Panel without Alarm 73A Pushbutton unit for front electric win dows on left arm rest Rn d Nn d CB35 CN 35 73 B Pushbutton unit for front elect...

Page 606: ...82 Pushbutton unit for left rear windows on left front door electric 83 Pushbutton unit for right rear electric windows on right rear door N86 RN86 LN86 N87 RN 87 BN 87 LV86 BV87 84 Left rear electri...

Page 607: ...or BN6A 89A Left brake pad wear sensor cable con nection BR6A 90 Switch signalling handbrake applied 92A Electric sun roof lead connection BN 28A R 2 8 C N 18 Without automatic window closure 92A Elec...

Page 608: ...lamp washer intermittence N 8 A VN 127 HL127 SG 127 1 OOA Alarm electronic control unit G105A 100B Alarm electronic control unit H G 7 0 1 03 Tester socket for injection alarm BR 100A NZ8 AR n d HR70...

Page 609: ...urtesy light RN 4G Marea Weekend P4F941N02 1 08A Left rear central locking 1 08C Left rear central locking G86 H86 M 108C N86 M 108C HN86 1 09A Right rear central locking 1 09C Right rear central lock...

Page 610: ...nt central locking G36 H36 BN 36 B36 N36 A 36 With automatic window closing 111 B Right f r o n t central locking 111 C R ght front central locking A 36 N36 M 111C HG36 M 111C Without automatic window...

Page 611: ...18 HG 353 40 N n d 6 N240 19 HL353 7 MN240 22 ZB 355 9 BR 130 23 ZN 355 10 V239 24 RN 355 11 VN 239 25 V355 26 27 I I I ETJ CT3 I I CE2 Z D With Side Bag 115 Passenger Air Bag G 114 GN 114 116 Driver...

Page 612: ...2 Engine cooling fan low speed relay N8A M 154 AG 127 C 127 R128A 1998 1747 agg 99 1747 1581 1242 RN 129A AG 127 Cn d 2387 JTD 1 22 Engine cooling fan low speed relay H N8A I Cn d R154A ag R 129A 4fl...

Page 613: ...N 13 J L AB 140A AG 140A ARn d MG 140A A6 M3A _A7_M N 55 A8 Cn d _Ji_ S 140A J L VN 3A _BJLB 140A _ Z_ VG 70 PiLBN 140A JlLHLn d 21 SG n d _A2_ RN 98 L AV 123 g _A5_ A G 122 A 1 M 1 2 4 g t J L MN 124...

Page 614: ...MN 124 IS C3 HL98 A8 Cn d C4 SG 98 B1 MB 151 C5 HR 152A B2 AN 124 a i B3 MG 124 C7 GL368 P4F946N02 1 27 Connection between left front cable cable on relay holder bracket 1998 A R n d RN 13 BG 190A AB...

Page 615: ...C 1 SG 98 J i L M 124 gf _ 3_Cn d C 5 V37f _ i L MB 370 MG 305 I O Q A Connection between front radiator ca bles M 123 1998 1747 agg 99 1747 R129 I O Q A Connection between front radiator ca bles N8A...

Page 616: ...3 fuse R154 1242 1581 1747 agg 99 1747 1998 R 123 1910 75 1910 JTD 2387 JTD Rn d 1 9QA n c Engine cooling fan protective power fuse 1 30 Diagnostic socket for Air Bag RN 122 1910 75 1910 JTD 2387 JTD...

Page 617: ...t solenoid valve 1747 RN 55B SG 55B 1581 1242 NZ 140B _ G n d P4F949N03 1 Q A Connection between rear driver s heated seat cables o r Connection between rear passenger 1 f heated seat cables S n d s s...

Page 618: ...Electrical equipment Connector blocks Marea Marea Weekend 99 range 55 136 Detonation sensor LN 140B _ L140B N 55 150 Print n 506 763 77...

Page 619: ...L L S127 4 AB127 16 GV131 3 4 B127 7 SR n d 17 HR n d _ JL BN127 8 Cn d 18 RV n d 9 G150 19 MG127 10 M371 22 R55 11 BR 139 27 V B 6 A 1242 10 19 38 28 1 40B Injection ignition control unit 1242 1 Nad...

Page 620: ...Electrical system Marea Marea Weekend Connector block 99 range 55 141 Heated Lambda sensor N n d _ V160C 152 Publication n 506 763 19...

Page 621: ...ical equipment 99 range Connector blocks 55 1 44 R P M a n d T D C sensor B R P4F953M01 1 45 Starter motor R11 1 45A Starter motor RN 55 11 I 1 1 I JTD N I 1910 75 RN n d I R143 P4F953NQ2 1747 1998 Rn...

Page 622: ...n butterfly valve 1581 1747 N n d S 195B BR 195B VN n d V160C B 160D 1747 agg 99 Z160B 1 47 Compressor for air conditioning 1910 75 MN 55 1581 MN 13 115811 N235 1747 MN55 119981 N232 1747 M 13 1 48 Ea...

Page 623: ...relay feed 1 5 0 Injection system relay feed 1 5 8 1 1747 Cn d Cn d RV n d N 148 RN n d P4F955N03 P4F955N04 1 5 0 Injection system relay feed 1 5 0 Injection system relay feed 1747 agg 99 RG n d G368...

Page 624: ...mbda sensor electric fuel pump injectors JTD ZG 55C SN 333C Rn d 1 52 Injection system protective fuse 1 52 Injection system protective fuse 1747 JTD 1 52A Injection system protective fuse 1 52A Injec...

Page 625: ...tion system 1 54 Engine cooling fan 1747 agg 99 1998 1242 1581 1 54 Engine cooling fan M 122 R129 1 54 Engine cooling fan 1747 agg 99 1747 1998 1242 1581 1910 JTD 154A 1 55 Ignition coil unit 1910 JTD...

Page 626: ...139 R144 Nn d Rn d VN n d LN n d RN n d BR n d N n d Nn d 1 60A Injection ignition electronic control unit 1747 1747 agg 99 _ L GL 127 _2_ C n d _ L BM n d _f_ BL n d J L RZ n d J L RV n d _ L BG 127...

Page 627: ...38 LV138 5 N n d 15 G 146 24 V144 39 LR138 6 Nn d 16 C334 25 N n d 40 LB 138 7 RB 155 17 Z146 26 Nn d 8 VB 155 18 Bn d 27 LG 132 9 HB 155 19 G 136 28 N n d 39 f XXXXXXXXXXXXOCCCCCO Q C X X X X D O O O...

Page 628: ...Injector 2 1747 GR 160A Rn d 1 63 Injector 2 1747 agg 99 1 63 Injector 2 1998 Vn d B 190B 1 64 Injector 3 MB n d NR 194 1242 1581 1 64 Injector 3 1747 GR 160A 1 64 Injector 3 1747 agg 99 Rn d 164 Inj...

Page 629: ...quipment Connector blocks 55 1 65 Injector 4 1747 GR 160A Rn d 165 Injector 4 1747 agg 99 1 65 Injector 4 165A Injector 5 1998 1998 1998 Bn d G 190B 1 66 die adjustment actuator 1747 HV160A HG 160A 1...

Page 630: ...Engine cooling fan resistor Rn d R 122 1 70 Engine cooling fan resistor 1242 1581 Mn d L122 174 Power earth for A B S 176 Diagnostic socket for A B S Nn d P4F962N04 1 77 Sensor on left front wheel for...

Page 631: ...ol unit 9 M 180 18 Rn d 10 V180 19 N n d 11 BR 176 20 RV95 12 M 179 21 BN95 13 B 179 22 M 178 14 M 177 23 G 178 15 C 9 5 24 LR 95 16 Nn d 25 R177 17 Rn d O 0 0 O O O l O O O O O O O O O O O Q 182A Rig...

Page 632: ...RN n d BG 127 G 127 BVn d L6A HB291 BN 127 VB 70 44 46 47 48 50 53 54 56 57 V B 6 A LN6A Cn d BVn d AG 127 BR 139 MN 167 ZN291 V167 59 62 63 49 33 190B 11998 B Injection ignition electronic control un...

Page 633: ...0B 1 94 Injection injector braid lead connection 1581 195A Ignition injection control unit 1581 1581 4 L 6 A 26 LN6A S 1 2 7 5 V252 0 27 N 193 NZ252 9 LN 141 28 N193 50 VB 70 13 GV131 29 RN n d 5 0 V...

Page 634: ...4 GR138 76 BR 146 NZ n d HM 194 HV194 74 67 60 80 73 T T T i i i i i T r i i 53 M i i i r z c I I yl Li 59 66 201 A Glow plug preheating control unit 1910 75 JTD Rn d R228 201 C Glow plug preheating c...

Page 635: ...ol actuator A R 2 5 3 B M 253B 211 Frost sensor Z 253B _ Nn d 222 Earth for climate control system N n d 223 RPm sensor 1910 75 1998 P4F967M04 O O f i Diagnostic socket for FIAT CODE sys tern 1910 TD...

Page 636: ...ut out electrostop TD 1910 75 S 55A y N148 P4F968N01 231 Clock spring connector P4F968N02 232 Earth for compressor 1998 N 14Q P4F96SN03 233 Thermal switch on water pump 1910 75 MG 127 O i O S127 P4F96...

Page 637: ...F V244C O O Q Connection between Air Bag left pre tensioner cables Connection between Air Bag right pre tensioner cables V114 VN 114 M 114 MN 114 VN 241 V241 MN242 P4F969N03 241 Left pretensioner 242...

Page 638: ...A HN n d Integrated services electronic control unit C 92A 244C Integrated services electronic control unit BL107B RN 65 BR 245 C 92A A107A HN n d B 107A L238B BL 107B RN 236B BR n d B 107A Marea Auto...

Page 639: ...e control controls with passenger S 120B H254 NZn d N255A HN256 Z 2 1 l g t B 120B RG 255A compartment temperature sensor b n d _ H 253B HN n d Nn d Rn d i g z n d g VG 120B CB120B M209 AR209 L253A BN...

Page 640: ...Nn d C253A 259 Temperature adjustment switch N n d 260 MAX DEF microswitch 261 Tailgate locking unlocking actuator AN n d Bn d H263B G263B 262 Seat belts warning light switch 264 Left rear courtesy li...

Page 641: ...N 268 N278 267R Automatic transmission control unit LN 284 HM 280 MN269 MB 279 S279 GN252 SN 280 268 Connection between automatic trans mission front cables 269 MN 267R Z267L GN280 Connection between...

Page 642: ...transmission system protec tive fuse 276 Starting go ahead relay R268 Rn d RN 55 RN n d R12A RN n d P4F974N04 278 Diagnostic socket for automatic trans mission BR 267L 279 Automatic transmission gear...

Page 643: ...rol unit for automatic trans mission B282 NZn d B270 BR 270 L281 HM269 VN 269 Rn d 284 Connection for automatic transmission on gearbox VN 267L M267L HN 267L B267R LN 267R MB 267L MN 267L 285 EGR devi...

Page 644: ...Mates Weekend 99 range 296 Accelerator control lever potentiometer 1910 75 G298 298 E G R electronic control unit 1910TD 75 1910 75 1 Rn d 7 Cn d 2 B n d 8 AR 296 3 BR 229 9 N 148 4 VG 157 10 MG 55 5...

Page 645: ...ch K S B 1910TD 75 1910 75 Cn d C301 301 KSB device 191OTD 75 302 Tester point for EGR system 191 OTD 75 1910 75 1910 75 C300 303 F u s e protecting diesel preheating 304 Diesel preheating protection...

Page 646: ...0B GN 34B HB 34A C N 6B 31 OB Connection shunt HR 6 C HR70 R 7 0 RN 28A RN 6C C 2 8 A C64 H34B 31 OC Connection shunt HG 28C HG 6 C HG 70 HR 28B HN 28B H 6 B A B 4 I 31 OD Connection shunt H 236B HG28...

Page 647: ...5 31 OE Conecting bridge B244B G244B Marea Weekend 31 OF Connecting bridge C 107A 319 Connection for radio phone GN310A V48C Z48C N22 BV48A 320 Aerial feeder RV48A 321 Connection for TELEPASS 322 Conn...

Page 648: ...23 Connection for seat lumbar adjustment 325 Connection for additional heater R347 326 Additional heater control unit N 8 AR325 AG n d R325 AB 325 AV n d 328 Hazard warning lights relay 332 Power rela...

Page 649: ...139 9i 6 S150 9iL7 CV 285 Pi8 S 55A C 3 8 C 2 0 1 B 25 _ HG285 PiPzNSSA 211 MG201B PiPMZSSA 212 SN151 2i5 GL 55C D1 CN 167 D8 LR343 D2 C168 D11 VN 167 D3 L168 D13 LG342 D4 NZ167 D14 HR167 D6 HM343 D15...

Page 650: ...der unit HB 55 LN 333D B55C Gn d BN 333D V190B HB55C H MOB HB55C N n d SN 1951 B 160B C 160B 336 Injector for cylinder 1 JTD NV n d NL 333E 337 Injector for cylinder 2 JTD VN n d V333E 338 Injector fo...

Page 651: ...essure regulator JTD HB 333D CB 333D 342 Fuel pressure sensor JTD 343 Turbo pressure sensor JTD HV 333D LR 333D 344 l E protective fuse JTD 345 Fuel temperature sensor JTD B n d B333C C333A NZ 333C 34...

Page 652: ...control switch AB n d Nn d N351 Nn d Rn d 349 Additional heater protective fuse 350 Additional heater sensor 351 Additional heater heater plug N n d P4F9S4N03 N348 N n d N n d 352 Left Side Bag connec...

Page 653: ...e a r t n N n d P4F986N01 355 Pretensioner connections Without Side Bag P4F985N02 356 Left Side Bag sensor ZB 355 RN 355 P4F985N03 357 Right Side Bag sensor ZN 355 V355 P4F985N04 358 Left Side Bag HB...

Page 654: ...d B 190B 364 Motorized butterfly casing 365 4 stage pressure switch 1998 V190B BN 127 N 8AL S 127 N 127 J T D 365 4 stage pressure switch 368 Diode for injection system relay 1910 75 1747 AB n d GL 12...

Page 655: ...tion for tester M 140A 372 Modular actuator C 140B RV 140B RN 140B 373 Air temperature and pressure sensor 373 Air temperature and pressure sensor 1242 1581 Nn d ZB 195B V195B RN 195B 374 Power steeri...

Page 656: ......

Page 657: ...Marea Marea Weekend 99 range Electrical equipment Wiring diagrams 55 page Electrical symbols 1 Explanation of how to read wiring diagrams 4 Wiring diagrams 5 Key 189 Copyright Fiat Auto...

Page 658: ...3 14 13 14 13 14 Versions with Check Panel without alarm Direction indicators and warning light Hazard warning lights Brake lights Reversing light 15 16 15 16 15 16 15 16 15 16 15 16 15 16 Versions wi...

Page 659: ...rs and failure warning light 51 51 51 51 51 51 51 51 51 Air Bag with Side Bag and pretensioners and failure warning light 53 53 53 53 53 53 53 53 53 Windscreen wash wipe Rear wash wipe Horn Heated rea...

Page 660: ...ht Rev couner 101 99 99 97 95 93 Starting Electronic injection Recharging and warning light Low engine oil pressure warning light Glow plug preheating warning light Injection system failure warning li...

Page 661: ...ure i X l Cold starting choke O Hi 120 Km h Water in fuel filter Heater plugs Turbocharging pressure Rear fog lamp Fog light Brake pad wear Turbocharging pressure Automatic transmission fluid temperat...

Page 662: ...I L O C K S T O P Trip computer operation Electronic injection Engine oil level Brake fluid level Japanese Version Doors open Central locking Controlled damping suspension Sport Function Transistor Ai...

Page 663: ...iiiiiiiiiiiii S 3 E 3 l l l l l l l l l l l Digital speedometer Digital rev counter Digital fuel gauge Analogue fuel gauge Analogue engine coolant temperature gauge Econometer Digital engine coolant t...

Page 664: ...N D AR AR TIST RN N D N D t LR N D c c 96 izjr R R N D B 95 RV LR LR RV M C C ffll I I ffi u R RV 12 179 M B NZ AB BR 176 181 AB BR LR 20 J 6 2 NZ RV ii L c l n 12 ai 3 13 L 4 14 23 L 5 15 24 Lf 6 16...

Page 665: ...g light No plate lights 11 x x x x if l r Mill N N k N D B R H N H N N D GL AB GV 70 fc GV AV AB GL AV AV AB 10 13 sDJoocO too l E FF GV H GV GV V V mGV N mr N N D HN j V VN N D 13 1 6 4 5 6 7 2 3 r r...

Page 666: ...between rear cable and tail 13 Connection between right left front ca gate bles 310 Connecting bridge 14 Left no plate light 13 Connction between right left front cables G44 SN 25 RN 97 Z B 132 11581...

Page 667: ...GVAV 70 t GV GL IGV 16 s G N N 16 3 0 0 GN B M m GV H HN HN N D AV 0 A B H N VN 2 3 4 5 u 4 5 6 7 2 F3 BR I 2 N D C CB L 1 3 R m 6 S LB u g GN 3 CB d CB L T J 13 G V f GV V V N D j B R 8787a 4 30 85...

Page 668: ...h 19 Right rear earth 22 Left facia earth 42 Right facia earth 236 Connection between rear cables and tail gate 310 Connection bridge 55 Left front light cluster B GL70 1 3 Connection between right le...

Page 669: ...U 5 u 4 5 6 7 2 g BR E N IN GR HL 3 G R 16 x 16 H 8 g 00 HB GN H R LR IT4I4 a N D BR M H N D R R R 6 L B n g GN 1 1 e i C B I HL i i i i i i i i HB GN GN LRl N D 4 c CB L T J 12 IT f fl J 15 54 J AN G...

Page 670: ...3 Connection between right left front cables 14 Left number plate light bulb 15 Right number plate light bulb 16 Left rear light cluster 17 Right rear light cluster 18 Left rear earth 19 Right rear ea...

Page 671: ...N D AN AN AN 54 I 15 54 GV N D 50 int Int a I D O S S t Q Z ft t f f l 12 N i N D M N N D 32 M Gpn 70 M N D M M N I rtfi 87 30 85 86 GV RN GV GV HL CB GV LN A N n E D N a N 22 HB iHL Hfij M N LN GN c...

Page 672: ...lead connection RN 310B RN 31 OA H n d HG 6B With Check Panel 28A Facia rear lead connection RN 310B HG 6B Without Check Panel 29 Front fog lamp lead connection M70 N 8 70 Connection between dashbora...

Page 673: ...N AR AR I AR 3A r 1 4J R G AN 4 N 0 1 HgH 8 00c A N R G AR m AN B A RN B R 9 1415 18 RN RN N D A R R N N D A p A A 13 N D f 40 AN 1 2 3 7 14 RNIRGI AN k i m LTJ TT11 R A BN B C B RN RG AN R A B AB B C...

Page 674: ...light 10 Battery earth on engine 55 Connection between front engine cables 11 Battery 100 Alarm electronic control unit 12 Ignition switch 107 Central locking remote control receiver 13 Connection bet...

Page 675: ...Or ID ID oo AN 159 AN 16 H 8 AN RG B N N AR j AR AR I AR 3A 1 ii J _ I AR RN RN N D AR RN N D A A A E 1 13 N D J 40 AN AN A RN 9 1415 18 1 2 3 7 14 RN RG AN RN RG kH LTJ 1 A BN B CB AN R i AB 100 B C...

Page 676: ...light switch unit 28 Connection between facia rear cables 40 Brake lights control switch 41 Additional brake light 55 Connection between front engine cables 100 Alarm electronic control unit 107 Door...

Page 677: ...AN R G BN N A R A R I A R 3A Ii A R N D AR AR RN RN N D N D A t A A AR A N B A R N B R 40 N I 10 13 ID ID 3 e Li i ii i n r RN J 3b TTTH 87 87o 30 86 85 AN N D f H 328 9 1415 1 8 12 3 7 1 4 5 6 7 R A...

Page 678: ...ront engine cables 11 Battery 70 Connection between dashboard front 12 Ignition switch cables 13 Connection between right left front cables 107 Central locking remote control receiver 16 Left rear lig...

Page 679: ...N N D A f A A AR N D A N o B 32 tj A R N 40 N K 10 13 A S A ID ID9ooj Li TiJ LUJ LUj E n r f c RN 3b ITYTH 87 87a 30 86 85 4 9 1 4 1 5 1 8 12 3 7 1 4 5 6 7 RNiRGi ANi RN T O AN N D A A 328 G G AN R i...

Page 680: ...light switch unit 28 Connection between facia rear cables 40 Brake lights control switch 41 Additional brake light 55 Connection between front engine cables 70 Connection between dashborad front ca bl...

Page 681: ...ithout C h e c k Panel with alarm Direction indicators and warning light Hazard warning lights Brake lights Reversing light P4F817N02 Variant for Marea Weekend Variant up to Nov 99 Automatic transmiss...

Page 682: ...light switch unit 28 Connection between facia rear cables 40 Brake lights control switch 41 Additional brake light 55 Front engine lead connection 100 Alarm electronic control unit 107 Door remote con...

Page 683: ...ions 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 s...

Page 684: ...ction between facia rear cables 40 Brake lights control switch 41 Additional brake light 55 Front engine lead connection 70 Connection between dashborad front ca bles 107 Door remote control receiver...

Page 685: ...G N I G N 110 E 35 HV HV N N N N N D f HV N G N C 3 2 3 3 1 34 3D RN RN 310A G N GNl IGN N G N G N GR GR N tj t j 1 8 1 9 K I I7 69 58 N D HV HV i E 86 22 HN HN f N H N HN N D HN HN 108 HV 244 RN HG...

Page 686: ...age compartment light 69 Cigar lighter 86 Connection between rear left rear door ca bles 87 Connection between rear right rear door cables 107 Door remote control receiver 108 Left rear door lock 109...

Page 687: ...EL N G N E3i 331 34 3D RN RN 3 RN G N 310A G N IGN xx N G N 1 G N G R 031 i r G R N I7 69 58 E c 86 3 HN HN f N H N HN HV 22 X H V N D HN HN N 108 42 HV 244 R N H G B R BL RV N D HR HR H N H R 1 2 3...

Page 688: ...n between rear left rear door ca bles 87 Connection between rear right rear door cables 107 Door remote control receiver 108 Left rear door lock 109 Right rear door lock 110 Left front door lock 111 R...

Page 689: ...Marea Weekend 99 range Electrical system Wiring diagrams 55 Radio system high level AD 185 H Cigarette lighter Predisposition for CD Variant up to Nov 99 Copyright Fiat Auto XII 99 Cancels and replace...

Page 690: ...ht front tweeter speaker 51 Speaker in left front door 52 Speaker in right front door 53 Left rear speaker 54 Right rear speaker 69 Cigar lighter 248 Radio controls on steering wheel 310 Connection br...

Page 691: ...5 t B N R G 51 B N R G N X 22 ft 17 30 87 30 85 B6 B M B R 3 3 2 S J AN N A N CB N D I N D A N C _ J A N 0 m 30 50 lnt n t s taz 53 12 AR 3D 5 B R L U CB fe N D 3 r 8 10 2 2 5 9 101112 B 0 1 Q T J N 4...

Page 692: ...weeter 50 Right front speaker tweeter 51 Speaker in left front door 52 Speaker in right front door 69 Cigar lighter 248 Radio controls on steering wheel 332 Power relay controlled by ignition 55 28B C...

Page 693: ...N 1 RN RN ZG ZG CBH W CN CN KV KV BV N i RN C C N D 0 IT f fi i15 54 J s t a z r 12 0 UJ _ it tj H BR 1 1 N D Ji 28C CD 3D LR C iltjl 1 4 I J I T N D 1 R R CB N D c 2 8 A L 77 36 BR SB ZB ZB GN GN c...

Page 694: ...73 Control panel for front electric windows on left armrest 74 Control panel for right electric front window on right armrest 76 Left front electric window motor 77 Right front electric window motor...

Page 695: ...GN 86 BV LV RN ZG Z G N N LN LN BV LG r 12 I 15 54 I N D c c m I DOS irrt a pos staz rrftj R E N 18 XXX X i t 1 T J 85 B R 87 N D c N D L 28C L B L C ZB C 0 C 28A CN CB BV BR BR BN BN c RN N N N N LJ...

Page 696: ...ght rear door 84 Left rear electric window motor 85 Right rear electric window motor 86 Connection between rear left rear door cables 87 Connection between rear right rear door cables 238 Electric rea...

Page 697: ...15 54 I Int o I H 15 54 I lnt a pos 30 50 Int stazK 12 N i 10 r 4 3A 1747 1998 agg 99 1747 15811 1242 190 160 160 160 140 J L 13 J L 30 J L 20 J L 13 J L 16 B GV GV CB N D N D RV RV Llx E M N 2 S L 22...

Page 698: ...lectronic control unit 1747 190 Injection ignition electronic control unit 1998 195 Ignition injection control unit 1581 199 FIAT CODE aerial 55 3 A Power fusebox CA95 R n d M n d AR n d C n d M n d 5...

Page 699: ...B M B N D 55 1910 75 226 127c N D C CB V C M B HL r 2 M B 1 T 2 13 5 L T J R R N D R CB 4 ii 4 J 3A RV C I l _ R M B CB N D C CB frT 1 fry I 15 541 I Irrt a 15 54 I lnt a J pos 30 50 Int stazK 1 M B N...

Page 700: ...ntrol unit 148 Earth for electronic injection 152 Fuse protecting injection system 199 FIAT CODE aerial 226 Tester socket for Fiat CODE system 1910 TD 75 229 Electric engine stop device TD 333 Injecti...

Page 701: ...6 105 BR NZ NZ N N N D AR AR NZ GN T T AN A N D N D AN AB A G N D AG CB N D AB AB AB AN AB HV AG HG HV N Z H N AN HN HG HV HR N fc HR HN 1 70 R N 107A AG HG HV 310C HV RV 28Ac HN i HR 310B c RV RN l H...

Page 702: ...ic socket for alarm 105 Alarm off switch 106 Alarm switch on bonnet lid 107 Central locking remote control receiver 108 Left rear central locking 109 Right rear central locking 110 Left front central...

Page 703: ...3 106 105 B R NZ N n NZ ft N D AR AR ID CN L 1516 107A NZ T T AN A N D G N N D AN ofh310C G AB _ J L R N CB HV 28Ac H R H N R N LN A G N D A G C B AN LN HV A G H G HV NZ A R H N H G CB HV H R H N H N...

Page 704: ...ont 111 Right front door lock door cables 236 Connection between rear cables and tail 36 Connection between dashboard right gate front door cables 243 Luggage compartment light button 42 Right facia e...

Page 705: ...N c N D N D i C CB BR N D R R 12 310F t r y n I l i r t Q I DOS 1 15 54 J i t r t Q I pos 30 50 lrrt s t o z H ft C 1 C RN n28A N D CB B 8 I R N m N D 100 i 3D 2 CB CB jjj 261 J j N D CB 28A 236B 86 H...

Page 706: ...236 Connection between rear cable and tail 35 Connection between dashboard left gate front door cables 244 Integrated services electronic control 36 Connection between dashboard right unit front door...

Page 707: ...G B G 3 BR UJ 3D CB N D c 28A 310F N D AG AG AG AG CN LR HV N 0 18 G R ZB BR 66 r HIIIIIH 10 11 1R JZ UJ B B R C A G N D N D C A N A N G 12 I 15 54 I Irrt a I N D MN MN 15 54 J Irrt a J pos 30 50 irrt...

Page 708: ...cables 36 Connection between dashboard right front door cables 42 Right dashboard earth 66 Electrically adjustable door mirror con trol buttons 67 Left external rear view mirror 68 Right external rea...

Page 709: ...i 15 54 int a pos 30 5 0 Int stazH U t 1 ft y y y 12 c J 9 BR 3D ri r I ij C V I I N D itti 2 1 4r 1 B R n 1 0 2 711 1 2 G N G N L RV 310B 310F CB N D C B 28A 1 C CB N D N 0 G N 310A G N C C 1 R BV a...

Page 710: ...48 Radio receiver with clock 69 Cigar lighter 310 Connection bridge 319 Connection for car phone 321 Connection for TELEPASS 332 Ignition activated power relay 3D Power fusebox R n d C n d CB 310B R N...

Page 711: ...l equipment Wiring diagrams Electrically operated sun roof 55 1 0 HIIIII 11 1 JL JL JL 4 Ol The ftTl 12 N D R R 332 B7 30 85 86 A N N e 22 N D S R N D v 2 28C 92A N 18 R C i J I fcti L J 244 Automatic...

Page 712: ...ted sun roof cables 93 Electrically operated sun roof control unit Integrated services electronic control 244 unit 332 Power relay controlled by ignition 55 3D Power fuse box R n d R n d CB n d RN 32...

Page 713: ...lignment 55 N Z N Z IN Z I 8 43 G H N Z G I H B H i n0 12 3 6 7 8 UJ UJ h n 12 3 4 ji J H R LR LR n A N 54 J L1 12 11 rHiiiii 10 1 B R G G N D N D R R N D R R AN AN N D LR A N mm 87870 30 85 86 I H R...

Page 714: ...ctrical actuator for left headlamp alignment 44 Electrical actuator for right headlamp alignment 45 Headlamp alignment control unit 55 Dipped headlamps relay feed HR4F Rn d LR 4F H 7 B 7 B Stalk unit...

Page 715: ...10 w 1 1 1 1 1 1 r fm i i OJ r 1 Z r T T J T Tr N D R R N D AN AN A N I 15 54 I 1 n n 15 54 I int a pos 30 50 Int staz 12 I I 1 IB i 3 m frfH 87 30 85 86 S I A N V N 332 N 0 22 19 N D R R S S N D 322...

Page 716: ...een rear driver s heated seat cables 135 Connection between rear passenger heated seat cables 322 Connection for seat height adjustment 323 Connection for seat lumbar adjustment 332 Power relay contro...

Page 717: ...241 J lei J L U c 6 3D R G C 117 C f C R N D i CB 12 I 15 54 I I Int o I M 15 54 I I Int o J pos 50 int LI 362 355t BV B N j 1 T CB R 114 U J N J in 2327 1 2 3 4 5 6 7 8 9101112131415 mm G N M N B R...

Page 718: ...nections 130 Tester socket for Air Bag 231 Clock spring connector 239 Air Bag left pretensioner cables connec tion 240 Air Bag right pretensioner cables connec tion 241 Left pretensioner 242 Right pre...

Page 719: ...12 14 16 IB 20 22 24 26 28 30 32 34 36 38 40 42 44 46 4B 50 1 3 5 17 19 11 I 13 I 15 17 19 21 I 23 I 25 I 27 I 29 I 31 I 33 35 I 37 I 39 41 I 43 I 45 I 47 I 49 LN G N L G M N 5 17 19 11 I 13 I 15 17 1...

Page 720: ...for Air Bag 231 Clock spring connector 239 Air Bag left pretensioner cables connec tion 240 Air Bag right pretensioner cables connec tion 241 Left pretensioner 242 Right pretensioner 352 Left side bag...

Page 721: ...99 range Electrical system Wiring diagrams 55 Windscreen wash wipe Rear wash wipe Horns Heated rear window Headlamp washers 10 N 4i JJrh i Variants for Marea Weekend Copyright Fiat Auto X l 9 9 Cance...

Page 722: ...6 Left low tone horn 47 Right high tone horn 97 Headlamp washer pump 98 Headlamp washer intermittence 120 Connection for air conditioning unit ca bles 127 Connection between front left cable cable on...

Page 723: ...Marea Marea Weekend Electrical equipment 99 range Wiring diagrams 55 Instrument panel connections Copyright Fiat Auto 57...

Page 724: ...sender unit Electrical equipment Component location 55 Marea Marea Weekend 99 ranee 6A Instrument panel H L N 1 9 0 A L N 5 5 _ __ AG n d BN n d H G 5 5 1747 agg 99 L 160A RV95 L 190A 11998 6B Instru...

Page 725: ...3 a g _ a g _ CB N D I 15 54 I I 15 54 I Irrt a J pos 30 5 0 int stazr n ni 12 B N HB J 158 1910 75 55 c H M N 1 1 G H M IHB C N N Z H G J H G CN A G H B 0 HM I D 1 2 3 4 5 6 7 8 9 10 1 1 1 2 1 3 1 4...

Page 726: ...rature sensor for instrument 262 Seat belt warning light switch 334 Dual engine temperature sending unit 55 Instrument panel 1 2 3 4 4 5 6 6 6 6 6 7 7 8 10 BV95 BN 8 8 BR 89A CL 55 1910 75 CL55A JTD M...

Page 727: ...0 H wig n N D I D 40 A R Ii i AI nr GL _ RN L N N D GV GL 70 5 K 13 GV GV GV GL 110 R N El 4 fe RN RV HV 108 N N N D H N HN 16 oni 3 GN V N 16 r g 0 GN 111111111111111111 1 I 3 I 5 I 7 I 9 I 1 1 1 13...

Page 728: ...onnection between rear left rear door cables 87 Connection between rear right rear door cables 108 Left rear central locking 109 Right rear central locking 110 Left front central locking 111 Right fro...

Page 729: ...XX XX _ 5 Mini O iO lc U B N D C CB B C 12 frr T r J 15 54 J Jnt o J pas staz mm N D HV HV 10 310C HV 28Bf H N HG HV HRL HN HG H R RN N 131 243 i T 2 13 CB R L T J H 3 m 310A 1 1 c CN R 1516 22 3 28A...

Page 730: ...oor lock 110 Left front door lock 111 Right front door lock 236 Connection between rear cables and tail gate 243 Luggage compartment light button 310 Connection bridge 55 6B Instrument panel 1 2 3 4 6...

Page 731: ...ge Electrical system Wiring diagrams 55 Climate control unit heater with thermostatic control 1998 X X X X P R i zl rr g 2 6 0 259 207 2 U 2 5 8 202 202 Variants up to Nov 99 Copyright Fiat Auto XII 9...

Page 732: ...m 249 Tester socket for air conditioner system 253 Air conditioner control unit 254 Climate control system controls with inte rior temperature sensor 255 Electronic speed variator for climate control...

Page 733: ...M N I M N A N 259 207 2 U 2 5 8 N fe VG VG M G ZB 5 5 C c 3 t 3 55A S M G 1 I 13t3 N D M N 70 RN AN VG HL RN 120A N D RN AN VG VG rAN HL GN If 310A GN 1 I AR RG VG CB GN A R 28Asi3 A R A N V r ftT I1...

Page 734: ...ir conditioner control unit 254 Climate control system controls with inte rior temperature sensor 255 Electronic speed variator for climate control fan 256 Air mixing control actuator 258 Treated air...

Page 735: ...747 QQ 99 147 160 VG M G 9 1 0 t M N I M N N ft A N 13c M G N D B M N 70 RN VG AN HL RN 120A N D RN AN HL VG VG AN HL GN i i GN 1 If 310A r AR CB GN A R 2 8 A t 3 A R A N I 1 I int a I 1 15 54 J int a...

Page 736: ...m 249 Tester socket for air conditioner system 253 Air conditioner control unit 254 Climate control system controls with inte rior temperature sensor 255 Electronic speed variator for climate control...

Page 737: ...Weekend 99 range Electrical system Wiring diagrams 55 Climate control system heater with thermostatic adjustment 1747 259 207 XX XX 211 258 Variants up to Nov 99 Copyright Fiat Auto XII 99 Cancels and...

Page 738: ...m 233 Thermal switch on engine coolant pump 244 Integrated services control system 249 Tester socket for air conditioner system 253 Air conditioner control unit 254 Climate control system controls wit...

Page 739: ...4 N G L J L M N M G A NVG A N i n 1 4 7 15811 1 9 5 VG M G 48 41 M G IT M N I M N 1 3 A M N 3 2 3 5 N 2 3 2 A N 8 ffi N D 7 0 RN VG AN HL RN 1 2 0 A M D RN AN AN _ H V _ G V G H L I GN GN IF 3 1 0 A G...

Page 740: ...Connection for air conditioning compres sor cables 244 Integrated services control system 249 Tester socket for air conditioner system 253 Air conditioner control unit 254 Climate control system contr...

Page 741: ...L C 3 235 AN B VG VG S I M G i l M G 55 c N 232 N D G M N 70 RN AN VG HL RN 120A N D RN AN l GN GN 310A GN 1 AR S RG B VG CB GN AR 28AC3 AR 1 AN 3 G _ _ N GL N 0 1 I fBl H 1 15 54 I I Irrt a J pos 50...

Page 742: ...35 Air conditioner compressor lead connec tion 244 Integrated services control system 249 Tester socket for air conditioner system 253 Air conditioner control unit 254 Climate control system controls...

Page 743: ...A N 147 1242 140 VG M G 3 1 1 9 f M G i r M N I M N 13 db M N A N 259 207 2 U 2 5 8 N 148 N N S BL 148A B N D i 70 RN VG AN HL RN 120A N D RN AN VG VG rAN HL GN I I GN 310A GN HL AR RG VG CB GN A R 28...

Page 744: ...sor 222 Earth for air conditioning system 244 Integrated services control system 249 Tester socket for air conditioner system 253 Air conditioner control unit 254 Climate control system controls with...

Page 745: ...t i 15 54 irrt a J pos 30 50 Int stazH mil AV W 3A 349 333 ZN 347 PTTH 1 7 30 86 8 M I AG R 1 I R M L_ N D j i 55A ZN N D 346 348 ri 87 30 8 d 1 n 6 85 V R AR 7a3C m 8787a 30 85 86 AG A G 350 AV 325...

Page 746: ...tch 349 Additional heater protective fuse 350 Additional heater sensor 351 Additional heater heater plug 55A Connection between front engine cables JTD C L 6 A LN6A ARn d SN n d BL 29 RN 12A GV131 HB6...

Page 747: ...xxP R K it i it Ii r 1 44 3A 1 c B 12 11 A llllll K 10 1998 1747 129 129 in R R J 1 C B N D T r f T T I I Irrt a I nos Hi EOT 154 170 1280 c l 128 11 365 123 ft 87 30 86 85 I BN AB C C i C C BN AG B A...

Page 748: ...BG 190A A4 AB 190A A 5 AR 190A A 6 MSA A7 A8 MN 55 C n d B1 B2 B3 B4 B5 B6 B7 C2 C3 C4 MB4C AN n d MG 190A S 190A VN3A B 190A VG 70 BN190A HLn d S G n d HR n d ARn d G 190A J L R n d RN 98 BV 151 _A...

Page 749: ...t 4 11 A nun io 369 87 87a 30 85 86 N D 1261k 129A 129 R N N D CB N D 3A 154A 154 122 123 m fi r 126 He fa rfH Wf 87 30 86 85 0 7 a n i N N X8A R N A G 87 3 0 86 85 r i c A B A B AB A B 365 B N 127 c...

Page 750: ...switch 369 Engine cooling fan remote control switch 3A Power fuse box C A 9 5 CB n d R n d M n d C n d VN127 AR n d C n d 55C Connection between front engine cables JTD BN 127 M B 4 C AG 127 _ S 127...

Page 751: ...1 1 1 1 H 1 0 R L R 369 154A 154 122 N D 129A 129 N D N D CB 3A 1 c B 12 1 1 m t o 1 m RN RN AB N N X8A rrrrn fafrn fl 87 87ci 30 85 86 0 7 a a 0 7 D t Q l 87 30 86 85 r 1 A G 87 30 86 85 AG AB AG B...

Page 752: ...BN 365 A5 GN 304 B8 VN 98 A6 HN 304 C1 SG 98 A7 AG 122 C2 M 124 g j e A8 RG 304 C3 C n d B1 RN 98 C4 AB n d B2 HL98 C8 R152 B3 S 3 6 5 P4F882N04 The cables concerned are marked in the wiring diagram...

Page 753: ...P R it I it Iit i r1 i i t 11 1 1 1 1 1 h H 1 0 3A 1 c a 12 129 CB N D J 15 54 J I irrt a I 15 54 int a pos 30 50 Int s t a z H T 1 154 170 128H 2 128 c 121 123 87 30 86 85 A B C C i C A B 127c C A B...

Page 754: ...tion electronic control unit 1747 170 Resistor for engine cooling fan 55 3A Power fuse box CA95 ARn d C n d C n d C n d M n d 55C Connection between front engine cables 1747 HB6A HM6A AR n d L 6 A CN6...

Page 755: ...M _ w e g I I I H I N H 10 11 r 1 it i i 3A A H T f r r f I 15 54 J 1 Int a J D O S 1 12 129 1 3 3T R NU CB C 154 170 4 3 6 5 1 2 7 B N B N B 1 A G A B i i t I f k N AG A B B N A G A B B N A B A G 122...

Page 756: ...n d C n d M n d 1 27 Connection between left front cable cable on relay holder bracket 1242 RN 13 AB 140A _ A L A G 140A _ L ARn d J L MG 140A S 140A VN 3A _B6_ B 1 4 0 A A6 A7 A8 M3A MN 55 Cn d B7 VG...

Page 757: ...1 c B 12 129A 129 R N I I I N D CB C N D T r f T Y T 1 J lnt a 1 Dos m 15 54 I l n t a J pos 30 50 int siaz 369 154A 154 172 87 87a 30 85 86 I N D 128Hc 128 m H R Ul 128E c A G 365 123 122 TO A B N D...

Page 758: ...h 365 4 stage pressure switch 369 Engine cooling fan remote control switch ca ca 55 3A Power fuse box C A 9 5 CB n d R n d M n d C n d VN127 AR n d C n d C n d M n d 1 28A Connection between front rad...

Page 759: ...Marea Marea Weekend 99 range Electrical equipment Wiring diagrams 55 Versions without climate control Engine cooling petrol engine 162 163 164 165 Copyright Fiat Auto 89...

Page 760: ...0 1 27 Connection between left front cable cable on relay holder bracket 1747 agg 99 A1 Rn d _A _ RN 13 A 3 BG 160A LAB 160A A 5 AG 160A _A 5_ M 3A A7 MN 13 _AS_ C n d JLL MB 4C _ L AN n d 6 3 MG 160A...

Page 761: ...i 96 N Is CB R N N D N D f LR 5 4 i N D 3A B N 95 B N B N BV RV BN BN CA LR IR RV B N RV n B C C _ Wl J J fBl I I Irrt n I 1 5 5 4 J W iJ pos 30 50 int staz ffiM 12 22 1 1 0 17 2C 5 5 19 179 M B NZ B...

Page 762: ...Sensor on left front wheel A B S 178 Sensor on left rear wheel A B S 179 Sensor on right front wheel A B S 180 Sensor on right rear wheel A B S 181 Electro hydraulic control unit 3A Power fusebox C A...

Page 763: ...tronic ignition and injection Recharging and warning light Insufficient engine oil pressure warning light Injection system failure warning ilight Rev counter 1998 t 11111IH I 168 223 167 165A 165 164...

Page 764: ...meter 334 Dual engine temperature sending unit 363 Variable valve timing actuator 998 364 Motorized throttle body 55 55C Front engine lead connection N 131B BV n d AR n d HB6A M 148 1 27 Connection be...

Page 765: ...4 GL H R H R B R GL N D RV RZ HR t ZB H R N D RV BR 55 H RG R HR RN HN 55 m H N LN 15 54 int a pos 30 50 Int staz iztW M B N N N Z N Z 12 56B 57 18 6 70 r VB jj VB VB VB N R i 7 6 IB IS 9 23 28 1 M03...

Page 766: ...d 164 Injector 3rd 165 Injector 4th 167 Air flow meter debimeter 168 Timing sensor 334 Dual engine temperature sending unit 368 Relay diode for injection system control 371 Tester connection 55 55A Fr...

Page 767: ...RN HG CN I NZ N LN LN MB HN HG i CB N N Z 22 8 I I 142 H N MG HM H M R 55C R CB R N R N R N to BR BR B R SHRV B R GR R JGlfa G N R GV 121 j u u y y H G HV 121 r 2 3 4 162 163 164 165 166 LG 55B SG R N...

Page 768: ...45 146 Potentiometer on butterfly valve 150 Injection system relay feed 152 Injection system protective fuse 157 Water temperature sensor for injection system 160 Injection ignition electronic control...

Page 769: ...JL RV N D RN 70 VB jj VB CN HN RN M CN HN 55 LU 7 6 IB 18 1 H 3 I 16 H 9 23 88 14 M 17 N 0 22 H N 132 139 if BR ZB RG r1 RG ZB 1 13 ZB ZB RG ZB 141 ZB N N N LN CN HV H M HG 194 4 GR CN M B HL RV I LR...

Page 770: ...Injector 1st 163 Injector 2nd 164 Injector 3rd 165 Injector 4th 193 Earth for electronic injection 194 Injection lead injector braid connection 195 Ignition injection control unit 1581 334 Dual engin...

Page 771: ...H R 145 rt R R M JL 143 m 1 H N 372 334 1 2 3 4 5 6 7 W1 RB HR H R H N LN 71 mm M B N N N Z 1 N Z 0 12 56B 57 18 6 7 l r VB VBJ HR MB HN RN HR HN BG RV 55 VB VB N 7 6 16 12 1 H 3C 16 9 23 22 14C 1 7...

Page 772: ...n system 165 Injector 4th 194 Injection lead injector braid connection 334 Dual engine temperature sending unit 371 Tester connection 372 Modular actuator 373 Air pressure and temperature sensor 374 P...

Page 773: ...arting 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 Varian...

Page 774: ...ne temperature sending un 336 Injector 1 cyl JTD 337 Injector 2 cyl JTD 338 Injector 3 cyl JTD 339 Injector 4 cyl JTD 340 Injector 5 cyl 2387 JTD 341 Fuel pressure regulator JTD 342 Fuel pressure sens...

Page 775: ...lectronic 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 3...

Page 776: ...it 336 Injector 1 cyl JTD 337 Injector 2 cyl JTD 338 Injector 3 cyl JTD 339 Injector 4 cyl JTD 341 Fuel pressure regulator JTD 342 Fuel pressure sensor JTD 343 Turbo pressure sensor JTD 344 i e protec...

Page 777: ...30 50 X T R R RN J L 143 370 87 30 85 86 CBTCB M B L B I U J NJi t k 131 c v M B 3 127 55A BR GV GV BR BR N D M B 55 3A CB CL H N M B N N NZ LU J NZ 0 RN CL L HN RN AG r LN HN R H 228 201 Li HH ZB BC...

Page 778: ...ensor for injection system 223 Rpm sensors 226 Tester socket for Fiat CODE system 1910 TD 75 228 Glow plugs TD 229 Electric engine stop device TD 285 EGR control solenoid 289 Thermal contact PCT 290 H...

Page 779: ...5 49 16 T36 V AJ V 7 N Z G N LR BV N D H V HV 12 244 7 30 8J m 87 30 85 86 R N R N R N N D AR AR N D 110 L U N Z 268 N C i NZ AR LN NZ AR LR 252 GN H NZ NZ V L R GN 269 MN HN GN MN HM N VN 270 GN BV...

Page 780: ...tor for automatic 40 Brake lights control switch transmission 55 Connection between front engine cables 281 Shift Lock solenoid 110 Left front central locking 282 Additional PARK interruption for auto...

Page 781: ...R N Z 253 8 9 12 VG CB N D Z N 130 B R I N Z N N D N X 354 249 VGICB N 124g 140 B R B R l5811 l747 195 160 J L J L 25 23 BR B R N T B R I B R j B R I N 139 1747 160 BR 1998 190 1747 BR 100 B R 103 N Z...

Page 782: ...47 174 Power earth for A B S 176 Diagnostic socket for A B S 181 A B S electro hydraulic control unit 190 Injection ignition electronic control unit 1998 195 Injection ignition electronic control unit...

Page 783: ...el engine 55 1 1 4 V J L 9 I BR N Z 130 TO BRI NZ N N D N 253 U U 8 9 12 VG CB Z 354 249 VGICB N N D Z N 1910 75 298 I JTD I 333 B R 28 Q B R B R B R N 1 N 1 B m Lrib 55A E I J IL N 1910 75 1910 75 23...

Page 784: ...gnostic socket for FIAT CODE sys tem 191 OTD 75 249 Diagnostic socket for climate control system 253 Climate control unit 298 E G R electronic control unit 191 OTD 75 298 E G R electronic control unit...

Page 785: ...nel without alarm Direction indicators and warning light Hazard warning lights Brake lights Reversing light 15 16a 15 16a 15 16a 15 16a 15 16a 15 16a 15 16a Versions without Check Panel with alarm Dir...

Page 786: ...51 51 51 51 51 Air Bag with Side Bag and pretensioners and failure warning light 53 53 53 53 53 53 53 53 53 Windscreen wash wipe Rear wash wipe Horn Heated rear window Headlamp washers 55 55 55 55 55...

Page 787: ...9 99 97 95 93 Starting Electronic injection Recharging and warning light Low engine oil pressure warning light Glow plug preheating warning light Injection system failure warning light Fuel preheating...

Page 788: ......

Page 789: ...R El El 8685308787 ten 2 1 5 LU A N A G N GN m 4 N 22 IIIIIH j10 A G N D A N A N 12 54 I I 1 fBl 15 54 I lnt a J pos 30 5 0 Int staz 71 ft trtftj 70 A N A N G N I I G N 310A 120A A N G N A N G R H N V...

Page 790: ...shboard cables A1 B1 C1 R N 4 C M29 AN 4C A2 B2 C2 VG127 V328 HR100B A3 B3 C3 H100B AG n d HN100B A4 B4 C4 HL6A LN100B HG 100B A5 B5 C5 CB 100A BN 375 HV 100B A6 B7 C7 S100B A N 4 C GV335 JTD A7 B6 C8...

Page 791: ...s 24 Windscreen wiper motor on left front door 25 Electric windscreen rearscreen washer 80 Electric rear windows inhibitor switch pump 82 Control panel for left rear electric win 26 Rearscreen wiper m...

Page 792: ...2 Petrol vapour cut out solenoid valve 182 Right wheel brake pad wear sensor 134 Connection between rear heated driver s 182A Connection for right wheel brake pad wear seat cables sensor cables 134A D...

Page 793: ...277 Diagnostic socket for automatic transmis sion 279 Automatic transmission gear selector 280 ICE SPORT selector for automatic trans mission 281 Shift Lock electro magnet 282 Additional PARK interrup...

Page 794: ...dular actuator 373 Air temperature and pressure sensor 374 Power assisted steering pump sensor N D Ultrasound welding taped in cable loom Cable colour code A Light blue B White C Orange G Yellow H Gre...

Page 795: ...ag Side Bag system 10 Removing refitting deceleration sensor 11 Removing refitting front seat wit pas senger presence sensor and side bag 13 Perspective view of side bag module 16 Removing refitting s...

Page 796: ...tion of air bag and side bag system components on the car 1 Air bag control unit 2 Driver air bag module 3 Passenger air bag module 4 Air bag system failure warning light 5 Tester connection 6 Junctio...

Page 797: ...to the electronic control unit that manages the air bag system The ECU which also controls the pretensioner is connected electrically to the system via a cable with a yellow sheath The cable con necto...

Page 798: ...o detect a weight of at least 12 kg under all service conditions from 35 to 70 C For lower weights the reponse depend on service conditions temperature shape and position of the weight trim type prese...

Page 799: ...5 Available 6 Not connected 7 Not connected 8 Available 9 Serial line K for testers 10 Not connected 11 Not connected 12 Available 13 Not connected 14 Not connected 15 Ignition operated power supply...

Page 800: ...a different pin out the control unit is connected to the system via a 50 pin connection The system with side bags operates in the same way as the system with front air bags The control unit is calibra...

Page 801: ...connected 35 Short circuit 11 Not connected 36 Short circuit 12 Available 37 Passenger presence sensor 13 Not connected 38 Short circuit 14 Not connected 39 Short circuit 15 15 ignition operated power...

Page 802: ...n in relation to the occupant regardless of seat position or occupant size The side bag modules consist mainly of a bag measuring about 12 litres in volume and made out of permeable cloth that is able...

Page 803: ...air bag system it is OBLIGATORY to check system function using special test equipment at the end of the procedure It is STRICTLY NECESSARY to observe the contents of identification and warning plates...

Page 804: ...Electronic interface device An electronic device located in the lower part of the seat acts as an interface between signals from the control unit and signals from the passenger presence sensor PPD DE...

Page 805: ...STEMS The following rules MUST BE ADHERED TO when carrying out any operations on cars equipped with an air bag side bag system System components must be assembled and disassembled ONLY by authorised t...

Page 806: ...key to STOP posi t on and remove Tnen disconnect tne battery 1 Prise up the fastener cover and u n s c r e w the bolt securing the front seat belt 2 Undo the sill plate bolts s h o w n in the fig ure...

Page 807: ...ar trim 2 Raise the front sill plate then unscrew the underlying bolt securing the pillar trim 3 Raise the pillar trim then unscrew the bolts securing the side bag deceleration sensor support bracket...

Page 808: ...end of its travel and undo the bolts securing the guides to the floor Before removing the seat disconnect the battery terminals wait at least 10 minutes before dis connecting the passenger presence s...

Page 809: ...ag and connector 2 controlling the pres ence sensor remove the seat from the car Do not remove the seat from its hous ing using the seat control lever ar rowed in the figure or the guides may become m...

Page 810: ...s stage move the seat to FULLY BACK position at the end of its travel using the guide control lever Ensure the guide control lever is cor rectly fitted clicks into place fit and tighten the front reta...

Page 811: ...ismantling the side bag Side bag modules are fitted beneath the squab trim and do not significantly alter original seat style and size 4F016FL01 1 Plastic cover 2 Metal box 3 Side bag module connector...

Page 812: ...as described in the paragraph FRONT SEAT WITH PASSEN GER PRESENCE SENSOR AND SIDE BAG 2 Prise up the plug securing the seat rake adjustment knob 3 Remove the seat rake adjustment knob 4 Unscrew the re...

Page 813: ...plug C from inside after removing the trim Recover claw washer B 2 Release the plastic squab section from its retaining system 3 Undo the hooks two on each side secur ing the cover to the padding usin...

Page 814: ...ous ing and disconnect the safety connection remove tne s de oagr mocfu efrom its sup p y eacf Adhere scrupulously to the instruc tions in the General Warnings chapter when handling the side bag modul...

Page 815: ...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 secure the seat squab cover to t...

Page 816: ...joining the ten sioning elastic operation applies to driver s seat 3 Release the two links A from the housing as shown in the magnified section turn spring B Remove head restraint C then remove cover...

Page 817: ...justment knob B Unscrew bolts C securing trim D 2 Disconnect electrical connection A sup plying the lumbar adjustment and electrical connection B supplying the seat ride ad justment Undo lock ring A o...

Page 818: ...tion carrier box to one side 3 Release plastic section A at the rear as shown in the figure 4 Remove plastic section B beginning from the rear side area Prise up with the aid of a screwdrier then remo...

Page 819: ...he new cover 3 Remove the seat cushion cover from its housing NOTE Reverse removal instructions to refit Secure the cushion cover hooks using tool 1878077000 Fitting 4 Refit the sealed cushion module...

Page 820: ...that covers the heat pad NOTE Remove the squab lowering lever and frame 2 Cut the retaining collar 1 and disconnect the electrical supply connection 2 With draw the lead by pulling it in front of the...

Page 821: ...supply connection 2 and withdraw the wiring Remove the cushion cover as described in the paragraph Removing refitting front seat cushion cover 3 Under the heat pad switch bolts discon nect the heat p...

Page 822: ...s fitted as a guarantee that the 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...

Page 823: ...ing 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 Whenever working on the air bag sy...

Page 824: ...a adjustment knob B unscrew bolts C securing trim D 2 Disconnect lumbar adjustment electrical supply connection A and seat ride adjust ment electrical supply connection B 3 Unscrew lock ring A of the...

Page 825: ...er box to one side 3 Release the plastic section A at the rear working as shown in the figure 4 Remove plastic section B beginning from the rear side are Prise out with the aid of a screwdriver then r...

Page 826: ...s 2 Remove the side bag supply lead from the conection carrier box shown in the figure 3 Remove rivet 1 securing the earth lead extend retaining collar 20 and disconnect side bag supply lead 3 from th...

Page 827: ...ct lumbar adjustment motor elec trical connection 1 then disconnect col lars 2 retaining the supply lead and undo bolts 3 securing the motor to the bracket 2 Undo the hooks securing the lumbar ad just...

Page 828: ...quab cover as de scribed in the paragraph Removing refitting front seat squab cover except for the head restraint Disconnect the lumbar adjustment motor electrical supply connection undo the motor ret...

Page 829: ...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 3 Prise up the frame and the head r...

Page 830: ...l equipment 1999 range Air Bag New features 55 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 4A...

Page 831: ...ment 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...

Page 832: ...NG REFITTING FRONT SEAT SQUAB COVER Remove the preformed padding from its seat to gain access to the side bag frame then use a drill with a 4 mm bit at the points in dicated Remove the side bag frame...

Page 833: ...N SOR AND SIDE BAG T Position the seat on the bench and discon nect the height adjustment motor supply connection 2 Use a suitable drift to remove the upper pin securing the height adjustment motor ad...

Page 834: ...ab heat pad 6 Squab and cushion heat pad connector 7 Cushion heat pad 8 Heat pad supply lead 9 Heat pad warning light 10 Heat pad switch 11 Heat pad power supply 12 Side bag 13 Side bag supply lead 14...

Page 835: ...y lead 5 Heat pad warning light 6 Heat pad switch 7 Heat pad power supply 8 Side bag 9 Side bag supply lead 10 Side bag earth 11 Side bag power supply 12 Passenger presence sensor PPD interface contro...

Page 836: ...seat foldable backrest R R 1 Attachment lock for foldable rear seat foldable backrest R R 2 Rear seat central headrest R R 3 Rear seat central headrest Disas sembly and reassembly 5 Rear seat side he...

Page 837: ...1a and remove side seatbelt link 1b 2 Lower the backrest 3 Disengage the retainers and remove the the boot compartement lining from the back rest 4 Undo the backrest bracket retaining bolts 5 Remove t...

Page 838: ...o the backrest bracket retaining bolts 5 Remove the complete backrest NOTE To refit reverse the operations used for removal ATTACHMENT LOCK FOR REAR SEAT FOLDABLE BACKREST R R Removal Remove the rear...

Page 839: ...bolt 5 Remove the lock Refitting 1 Disconnect the lock 1a removing the button 1b Refit by reversing the operations used for re moval NOTE To help reattach lock pin cable A first fit the lock pin itse...

Page 840: ...ining 1a along the edges of the backrest up to the headrest area 1b 1 Remove lining 1a and padding 1b from sleeves 1c 1 Carefully remove the lining and the pad ding 2 Remove the headrest retaining sle...

Page 841: ...lows 4 Disconnect the hook from the retaining 5 Disconnect the side retainers from the bel lows 6 Disconnect the 2 lining retaining strips 7 Remove the metal retaining points all along the edge of th...

Page 842: ...he ar row NOTE When disconnecting the retainers 1c proceed carefully in order to prevent breakages 1 Fit padding 1a onto casing 1b 2 Fit the lining 3 Fit the lining all along the edge using the metal...

Page 843: ...the guides 1a into housing 1b on the cas ing until retainers 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 th...

Page 844: ...l 2 Push the retainers and remove the headrest MOTE To refit reverse the operations used for removal REAR SEAT SIDE HEADREST Disas sembly Removal 1 Undo the bolts 2 Remove the panel 3 Remove the metal...

Page 845: ...retaining pins 2 Remove the backrest cover 3 Undo the bolts and remove the cover 4 Undo the bolt and remove the seatbelt slide 1 the Undo bolts 1a and 1b and remove cover 1c then retighten the bolts U...

Page 846: ...e corresponding C housings of the connec tion assembly 1 Turn over the seat frame and undo the cover retaining bolts 2 Remove the cover 3 Disconnect the seatbelt unhook control ca ble 4 Undo the reel...

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