2000 FIAT MAREA exhaust

Marea-Marea Weekend
2000 range ©
Engine
Fuel feed system
10.
CATALYTIC CONVERTER HEAT SHIELD
Removing-refitting
- Position the vehicle on a lift and disconnect
the negative battery terminal.
1. Raise the vehicle and undo the bolts (1)
fixing the heat shield for the driveshaft
boot, then detach the heat shield (2); undo
the other lower bolt for the catalyzer heat
shield.
- Lower the vehicle and detach the front
Lambda sensor as described in the relvant
paragraph.
2. Loosen the bands shown and detach the
air hose from the filter to the throttle cas­
ing, complete with resonator.
3. Undo the upper bolts fixing the heat shield
and detach it.
CATALYTIC CONVERTER
Removing-refitting
- Position the vehicle on a lift and disconnect
the negative battery terminal.
- Disconnect the front Lambda senor as de­
scribed in the relevant paragraph.
- Detach the catalytic converter heat shield
as described in the relevant paragraph.
4. Undo the nuts fixing the catalytic converter
to the exhaust manifold.
Copyright by Fiat Auto 5

Engine
Fuel feed system
16v Marea- Marea Weekend ©
2000 range @
1. Loosen the band securing the catalyzer
acting on the bolt (1) and undo the bolts
(2) fixing the band to the bracket.
2. Disconnect the connector for the rear
Lambda sensor and release the cable from
the retaining bands along the routing.
3. Raise the vehicle, undo the bolts fixing the
catalytic converter to the rear exhaust pipe
and detach the converter, complete with
rear Lambda sensor.
EXHAUST MANIFOLD
Removing-Refitting
- Position the vehicle on a lift, disconnect
the negative battery terminal and discon­
nect the following components, as de­
scribed in the relevant paragraphs.
- Front Lambda sensor
- Catalytic converter heat shield
- Catalytic converter.
4. Remove the protective cover for the power
assisted steering pump drive belt.
6 Print n° 506.763/23

Marea- Marea Weekend •
2000 range ©
16v Engine
Fuel feed system
10.
1. Loosen the belt tension using the lock nut
(2) and the adjustment screw (1); then re­
lease the belt from the pulley.
2. Undo the bolts fixing the bracket for the
power assisted steering pump mounting
and detach the pump.
3. Undo the nuts fixing the exhaust manifold
to the cylinder head and detach the mani­
fold.
- To refit, reverse the order of the operations
carried out for the removal; tension the
power assisted steering pump drive belt,
using the adjustment screw; use tool
189576200 to check that the tension is
between 32 and 45 daN.
ELECTRIC FUEL PUMP WITH LEVEL
SENDER UNIT
Removing-refitting
- Disconnect the negative battery terminal.
- Lift up the lining in the luggage compart­
ment and remove the fuel pup protective
cover.
- Disconnect the electrical connection for the
electric pump assembly and the fuel supply
and breather pipes.
4. Undo the ring nut fixing the electric fuel
pump to the tank using tool 1870736000.
The gasket on the tank housing should be
replaced each time the pump drip tray is
removed-refitted.
NOTE The position of the fuel pump is fixed
and is established by a reference in
the housing in the tank which sou Id
correspond to the projection on the
pump drip tray.
Copyright by Fiat Auto 7

Marea- Marea Weekend & Engine
2000 range (§) Fuel feed system
ENGINE MANAGEMENT SYSTEM
Foreword
The Marea-Marea Weekend 1998 20v is equipped with a 5 cylinder in line engine with 20 valves, 1998
cc, twin overhead camshaft and a Bosch ME3.1 integrated electronic injection/ignition system.
The fuel system differs from the one described for the 1998 20v "99 range" version through the addition
of several variants to make it compatible with the EEC Stage 3 EOBD regulations.
The main modifications to the system can be summarized as follows:
- Catalytic converter near the exhaust manifold to take maximum advantage of the heat of the gases.
- Two Lambda sensors, one upstream (front) and one downstream (rear) which check the quality of the
exhaust gases and the operation of the catalyzer.
- Adoption of an accelerometre sensor on the right shock absorber turret, used to distinguish between
engine torque variations doe to the uneveness of the road surface and those due to failed ignition in
the combustion chamber (misfire).
- Adoption of a timing sensor on the inlet side timing pulley.
- Multi-purpose valve on the tank to prevent leaks.
- Adoption of raipd attachment connectors for the anti-evaporation system pipes.
- Cap on the fuel filler with an attachment cable.
For further information on the fuel system, refer to publication 507137.
DIAGRAM SHOWING ENGINE EXHAUST ASSEMBLY
4F001WJ01
Key
1. Exhaust manifold
2. Catalytic converter
3. Front Lambda sensor
4. Rear Lambda sensor
5. Silencers
Copyright by Fiat Auto 1

Marea- Marea Weekend 9
2000 range ©
Engine
Fuel feed system
10.
REMOVING-REFITTING CATALYTIC
CONVERTER
Removing
- Position the vehicle on a lift.
- Disconnect the negative battery terminal.
- Remove: the upper and lower heat shields,
the front and rear Lambda sensors, carrying
out the operations described in the relevant
chapters.
- Lower the lift.
1. Undo the fixing nuts (1a) and separate the
catalytic converter (1b) from the exhaust
manifold (1c).
E
Nuts la: 3.2 daNm
- Raise the lift.
2. Undo the fixing nuts (1a) and separate the
exhaust pipe (1 b).
EI
Nuts 1a: 4.2 daNm
3. Undo the nuts (1a) and the bolts (1b) and
remove the bracket (1c).
E
E
Nuts 1a: 2.5 daNm
Bolts 1b: 2.5 daNm
- Remove the catalytic converter.
Refitting
- Reverse the order of the operations carried
out for the removal.
Copyright by Fiat Auto 7

Marea- Marea Weekend 9 \) JTD
2000 range O
Engine
Index
FUEL SYSTEM
- Introduction
- System management strategies
- Fuel system functional diagram
- Diagram showing information ente­
ring/leaving the control unit and
sensors/actuators
INJECTION SYSTEM WIRING DIA­
GRAM
- Injection electronic control unit
- Rpm sensor
- Timing sensor
- Air flow meter
- Injectors
- Engine coolant temperature sensor
- Fuel temperature sensor
- Fuel pressure sensor
- Heater plugs control unit
- Accelerator pedal potentiometer
- Brake pedal switch
- Clutch pedal switch
- Excess pressure sensor
- Atmospheric pressure sensor
page
1
1
1
2
8
10
12
13
13
14
15
15
15
16
16
17
17
17
17
THROTTLE CASING
- Removing-refitting
E.G.R. VALVE
- Removing-refitting
E.G.R. VALVE SELF-ADJUSTMENT
MOTOR
- Removing-refitting
E.G.R. VALVE HEAT EXCHANGER
- Removing-refitting
SOLENOID VALVE ON VACUUM
RESERVOIR FOR THROTTLE CA­
SING PNEUMATIC VALVE
- Removing-refitting
VACUUM RESERVOIR
- Removing-refitting
10.
page
30
31
32
32
34
34
FUEL SUPPLY CIRCUIT 18
- Immersed (auxiliary) pump and fuel
gauge assembly 19
- Fuel filter 19
- Pressure pump 20
- Fuel pressure regulator 20
- Multifunction valve 21
- Supply manifold (rail) 21
- Inertia safety switch 22
AIR SUPPLY CIRCUIT 23
- Throttle case 24
- Turbocharger 25
SUPERCHARGING PRESSURE
CONTROL SOLENOID VALVE
- Removing-refitting 35
FUEL FILTER
- Removing-refitting 35
PRESSURE REGULATOR
- Removing-refitting 36
EMISSION CONTROL DEVICES 27
- Oxidizing catalytic converter 27
- Exhaust gas recirculation circuit
(EGR) 27
- Recirculation circuit for crankcase
vapours (blow-by) 29
Copyright by Fiat Auto VI 01 Cancels anil replaces

Marea- Marea Weekend © ™ Engine
2000 range Q Fuel feed system
10.
FUEL SYSTEM
INTRODUCTION
Marea and Marea Weekend 1.9 JTD cars are equipped with a 4 cylinder in line, 1910 cc turbodiesel en­
gine with two valves per cylinder, an overhead camshaft, turbocharger and intercooler and electronic in­
jection.
The fuel system ensures correct engine operation and can be divided into the following subsystems:
- Fuel feed circuit with common rail injection;
- air feed circuit;
- exhaust circuit;
- blow by vapour recirculation circuit;
- Exhaust Gas Recirculation (EGR) circuit
Operation of the various circuits making up the fuel system is optimised by an electronic control system
managed by a special control unit.
The main feature of the fuel system is common rail fuel injection. Common rail is a higher pressure elec­
tronic injection system for fast direct injection diesel engines.
The main features of the common rail system are as follows:
- availability of high injection pressures (up to 1350 bars);
- possibility of modulating these pressures (from a minimum of 150 bars to a maximum of 1350 bars)
independently of engine speed (rpm) and engine load;
- ability to operate at high engine speeds (up to 6000 rpm);
- precise injection control (injection advance and duration);
- reduced fuel consumption;
- reduced emissions.
FUEL SYSTEM MANAGEMENT STRATEGIES
The management program (software) is stored inside the control unit memory and consists of a series of
strategies, each of which manages a precise system control function.
Through the use of information providd by the various sensors (input), each strategy processes a set of
parameters based on data stored in special control unit memory areas. It then controls system actuators
(output), i.e. the devices that allow the engine to operate.
The main purpose of these management strategies is to determine the exact amount of fuel to be injected
into the cylinders with timing (injection advance) and pressure designed to achieve the best possible en­
gine performance in terms of power, fuel consumption, fumes, emissions and handling.
The main system management strategies are essentially as follows:
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of injected fuel quantity;
of injection advance;
of injection pressure;
of auxiliary fuel pump;
of injection during over-run (cut-off);
of idle speed;
of maximum speed limitation;
of maximum torque limitation;
of fuel temperature;
of engine coolant temperature;
of air turbocharging pressure;
of glow plugs;
of exhaust fumes;
of exhaust gas recirculation (EGR);
of climate control system activation;
control of engine immobiliser operation (Fiat
CODE);
self-diagnosis
Copyright by Fiat Auto 1

Engine
Fuel feed system
Marea- Marea Weekend © ™
2000 range ©
10.
FUEL SYSTEM OPERATING DIAGRAM
1. Pressure pump
2. Electrically-controlled EGR valve
3. Flow meter
4. Pressure regulator
5. Fuel filter
6. Instrument panel
7. Glow plug preheating control unit
8. Electronic control unit
9. Injection system relay
10. Return manifold (low pressure)
11. RPM sensor
12. Glow plugs
13. Engine coolant temperature sensor
14. Potentiometer on accelerator pedal
15. Switch on brake pedal
16. Switch on clutch pedal
17. Variable geometry turbocharger
18. Timing sensor
19. Injectors
20. Fuel pressure sensor
21. Variable geometry turbocharger control sole­
noid
22. Auxiliary fuel pump
23. Glow plug preheating warning light
24. System failure warning light
25. Pressure relief sensor
26. Fuel temperature sensor
27. Throttle valve
28. Variable geometry actuator
29. Vacuum tank
30. Exhaust gas heat exchanger
2 Publication no. 506.763/24