2001 FIAT MAREA removing refitting

Engine
Fuel feed system
Marea- Marea Weekend 9
2000 range ©
- Release the electrical wiring for the front
Lambda sensor from the retaining bands
and remove the sensor.
Refitting
NOTE Apply special grease (e.g. Bosch VS
14016- FT) to the threaded part ot
the sensor
- Place the Lambda sensor in position and
tighten to torque.
E Lambda sensor : 4.5 daNm
Reverse the order of the operations de­
scribed for the removal.
REMOVING-REFITTING REAR LAMBDA
SENSOR
Removing
- Position the vehicle on a lift.
- Disconnect the negative battery terminal.
1. Disconnect the electrical connector (1a)
and release the electrical wiring from the
retaining bands.
- Raise the lift.
2. Undo the lower fixing bolts (1a) and the
side fixing bolts (1b) and remove the
shield (1c) under the engine.
3. Use tool USAG 875 (1a), shown in the
diagram or a similar tool to undo the rear
Lambda sensor.
Refitting
NOTE Apply special grease (e.g. Bosch VS
14016- FT) to the threaded part of
the sensor.
- Place the Lambda sensor in position and
tighten to torque.
E Lambda sensor: 4.5 daNm
Reverse the order of the operations carried
out for the removal.
4 Print n° 506.763/23

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

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

Engine
Fuel feed system
Marea-Marea Weekend
2000 range ©
THROTTLE CASING
Removing-refitting
- Remove the battery from the engine com­
partment, then proceed as described below;
1. Remove the engine oil filler cap (1), then
undo the fixing nuts (2) and remove the
sound insulation cover (3).
2. Disconnect the vacuum intake pipe (1)
from the vacuum unit acting on the retain­
ing band. Also disconnect the pipe (2)
connected to the vacuum reservoir.
3. Undo the bolts fixing the connector pipe
between the throttle casing and the hose
connected to the intercooler.
4. Disconnect the oil vapour recovery pipe
from the tappet cover, acting on the re­
taining band.
30 Print n° 506.763/25

Marea- Marea Weekend 9 *°
2000 range @)
Engine
Fuel feed system
10.
1. Undo the bolts (1) fixing the expansion
joint to the E.G.R. valve, disconnect the
pipe connecting the pneumatic valve and
the solenoid valve, then undo the bolts (3)
and remove the throttle casing.
2. At the bench, undo the bolts (1) and
separate the expansion joint from the throt­
tle casing.
The pneumatic valve (2) is secured to the
throttle casing.
E.G.R. VALVE
Removing-refitting
- Remove the throttle casing, following the
description in the previous paragraph.
3. Loosen the bolts (1) fixing the pipe con­
necting the E.G.R. and the heat exchanger.
4. Disconnect the electrical connection (1) for
the E.G.R. valve self-adjustment motor; undo
the bolts (2) fixing the E.G.R. valve to the
intake manifold, then lift up the valve and
remove the bolts fixing the pipe connected to
the heat exchanger (loosened previously).
Copyright by Fiat Auto VI 01 i ndate 31

Engine
Fuel feed system
JTD Marea-Marea Weekend 9
2000 range ©
E.G.R.
TOR
VALVE SELF-ADJUSTMENT MO-
Removing-refitting
- Disconnect the negative battery lead, then
remove the sound insulation shield follow­
ing the instructions in the previous para­
graphs.
1. Disconnect the electrical connection (1),
then loosen the bolts fixing the E.G.R.
valve self-adjustment motor and remove it.
E.G.R. VALVE HEAT EXCHANGER
Removi ng - ref itti ng
- Remove the throttle casing and the E.G.R.
valve following the instructions in the pre­
vious paragraphs.
2. Remove the hose connecting the throttle
casing to the intercooler.
- Drain the engine coolant.
3. Disconnect the pipes shown in the figure
from the thermostat, acting on the retaining
bands, then disconnect the electrical con­
nection (1) for the engine coolant tem­
perature sensor.
4. Undo the bolts fixing the heat exchanger
pipe to the exhaust manifold.
32 0"" Und«r 4 Print n° 506.763/25

Engine
Fuel feed system
Marea- Marea Weekend 9 ™
2000 range ©
SOLENOID VALVE ON VACUUM RES­
ERVOIR FOR THROTTLE CASING
PNEUMATIC VALVE
Removing-refitting
- Disconnect the negative battery lead, then
remove the sound insulation shield follow­
ing the instructions in the previous para­
graphs.
1. Disconnect the electrical connections (1)
at the fuel filter and the supply and return
pipes (2) at the reservoir and the supply
pipe to the pump, then loosen the nuts (3)
fixing the fuel filter mounting. Lift up the
filter and disconnect the electrical connec­
tion (4) for the water in the diesel sensor.
- Release the power assisted steering fluid
supply pipe from the reservoir to the pump
from the retaining band.
2. Disconnect the pipe (1) connected to the
vacuum reservoir and the pipe (2) con­
nected to the vacuum intake pipe from the
solenoid valve. Disconnect the electrical
connector (3), then undo the fixing bolts
(4) and remove the solenoid valve.
VACUUM RESERVOIR
Removing-refitting
- Disconnect the negative battery lead, then
remove the sound insulation shield and the
fuel filter, following the instructions in the
previous paragraphs.
- Release the power assisted steering fluid
supply pipe from the reservoir to the pump
from the retaining band.
3. Disconnect the pipe (1) connected to the
vacuum reservoir and the pipe (2) con­
nected to the vacuum intake pipe from the
solenoid valve. Disconnect the electrical
connector (3), then undo the fixing bolts
(4) and remove the bracket, complete with
solenoid valve, for the throttle casing
pneumatic valve.
34 VI-01 Update IN Print n° 506.763/25