Hi,
just bought a 2002 stilo 1.6 which has cut out issues. No problem starting but the car randomly cuts out and comes up with the dreaded Engine Fault, ASR failure, Loose connection all together. It also has come up with alternator failure.
There doesn't seem to be any specific time for it to do this and i have to turn the key off and then back on again. The car starts again as if there were no problems.
Is there anyone has had these particular symptoms? I know there have been a lot of these electrical problems relating to the ECU, crankshaft sensor, poor battery or bad earth but i was wondering if anyone knows a specific fix for the problems i am experiencing.
thank you
Glenn

Hi,
I had the same symptoms. Check this topic especially at the end. I hope it helps. https://www.fiatforum.com/stilo/355773-stilo-1-6-ecu-mystery.html

Hi Glenn, and welcome to FF,

the Stilo is about the only FIAT, I've not had dealings with,

the D4 connector is apparently a common issue with "random faults",
SEARCH on FF is great in ADVANCED setting,

C|harlie - Oxford

Saw that post of yours and its something i will try to look into. Def worth a look into, weather permitting. Will let you know how i got on cheers

Glenn1970 said:

Saw that post of yours and its something i will try to look into. Def worth a look into, weather permitting. Will let you know how i got on cheers

Click to expand...

no problem,

will be interesting what you find,

Charlie

Glenn1970 said:

Hi,
just bought a 2002 stilo 1.6 which has cut out issues. No problem starting but the car randomly cuts out and comes up with the dreaded Engine Fault, ASR failure, Loose connection all together. It also has come up with alternator failure.
There doesn't seem to be any specific time for it to do this and i have to turn the key off and then back on again. The car starts again as if there were no problems.
Is there anyone has had these particular symptoms? I know there have been a lot of these electrical problems relating to the ECU, crankshaft sensor, poor battery or bad earth but i was wondering if anyone knows a specific fix for the problems i am experiencing.
thank you
Glenn

Click to expand...

hi glenn have same year and engine size as your stilo and i've experienced all the above faults your describing... ive tryed many a fix from, relocating ecu off of engine block, replacing brake switch, re soldering any dodgey looking pins on ecu pcb, as well as cleaning D4 connector and all earth points in engine bay doing all the above solved probs for a short while but then all above returned again...

the fix that iv'e found to work touch wood is to replace all earth points with new wires( the kind you'd use to wire up and after market sub and amp) and i ran new wires from neg on battery to all earth points i could find in engine bay and for the last 3 - 4 months ive not had any issues at all

I'm in the process of troubleshooting the usual "Loose connection, security, alternator failure, ASR Failure," etc stalls.
I've taken the ECU apart, checked the pins closely and found no broken solder, (not sure about the ball grid under the microprocessor).

cleaned all connectors (D4 and fuse box plugs) and rebuilt the fuse box

checking the grounds today, I noticed something I think might be odd, let me know if I'm off track.

Started the car and did a voltage check across the Negative terminal to most of the earth wires that I could get to. None of them showed much, if any, voltage, indicating good ground. Checked across the negative terminal to the little ground wire on the ecu and was seeing voltage there 0.25 or so volts) and between the negative and the ECU chassis itself.

My question is shouldn't those points, (ECU chassis and ECU ground) read 0, or at least miniscule, voltage when the engine is running , otherwise it indicates a bad ecu ground, right?

i will have to give the earth wires a go. Leaving the car in tomorrow for diagnostics check, which i know won't flag up the issue but want to see what fault codes are flagged up.

For the moment....touch wood..... bad earths seemed to be my nemesis. placed a new engine earth and removed the ECU from the ecu tray and ran an earthwire from the ECU to earth block on top of the negative post. the almost constant problems, whether driving or idling, are banished, at least for the moment.

Diagnostics today has flagged up a few codes. P0460 fuel sensor level B100B, C, D, E and G. I think these do seem to confirm there are earthing problems or a wiring problem. Maybe i am wrong - if there are any of these codes familiar to anyone can you let me know please

Not sure on the codes, simple check, though, is to use a multimeter, and check the earth's. Set to low voltage, place 1 lead on the negative terminal and use the other lead to check the block, cam cover, gearbox and other metallic areas (and earth points) for any voltage. Anything over .15 volts or so would be a hint towards earth issues, imo.

In my case, I was seeing wildly fluctuating voltage (.20-30 volts) at the ecu tray, engine block, throttle body and related points. The earth points were showing little if any voltage, so only checking those last week, I missed the issues at the engine side.

Check ABS unit for fault codes I had the dreaded cutting out and the only faults I had were in the ABS unit when Engine ecu crashes as the can lines go through Engine ecu first.

The only thing that sorted this out was new ecu.

Glenn1970 said:

Diagnostics today has flagged up a few codes. P0460 fuel sensor level B100B, C, D, E and G. I think these do seem to confirm there are earthing problems or a wiring problem. Maybe i am wrong - if there are any of these codes familiar to anyone can you let me know please

Click to expand...

Can't find anything for B100G, but the others are all instrument cluster codes.

B100B Fuel Gauge - No Signal
B100C Water Temperature Guage - No Signal
B100D Rev Counter - No Signal
B100E Speedometer - No Signal
.

this car is starting to do my head in. Drove home tonight 1hrs driving without cutting out (brilliant i thought). Stopped at garage and when i came out security failure came on along with engine fault and wouldn't start at all. After 5 mins it started (still with the engine light on). Took it home and left it for an hour - still has the security failure and engine fault but can get it going. Any ideas? Need it for work and worried its going to leave me sitting

Hi again,
they are bugs,
once it's running it should be fine,
as you're figuring out, it's likely to be poor earths,

TBH , you'd do well to Get MES set-up , ( @ £40)
will pay for itself in no time,

charlie

Something to keep an eye on when diagnosing your stalling.

I had one stall this morning, and it reminded me of something that happened before. I noticed that my fuel gauge had dropped from 1/4 tank to 1/8 tank (Triggering the Low Fuel warning). and 30 seconds or so later, I had the stall, car started right up, drove to my destination with no other problems. turned car back on for a second, and fuel gauge was back to 1/4. When it stalled I wasn't on a hill or anything that would affect the fuel level.

This reminded me that it had happened back when my stalling issues were much more severe, that it seemed like the fuel gauge and instrument lights were reading lower (Fuel gauge), and dimmer (Lights) when issues happened.

took the d4 connector off today and there was a bit of corrosion so cleaned it with contact cleaner. The relays above had some corrosion as well so gave them a clean also. The engine management light and fault have now gone but the asr / loose connection still comes up. Would it perhaps help if i replaced the relays that had the corrosion on them?

Does it have battery cover?

the battery and associated fuse have no cover on them. Seems to have been removed at some time and not put back. Do you think this may have a bearing on the problem?

It would be certainly something to look at as many folk have had elecrical gremlins from driving a stilo with no battery/fuseboard cover including myself when I left it off for one day which happend to be raining, it causes short circuits and burnt contacts in the layerd fuse board only way to tell is strip it down and check the circuit boards within the fuse board there is a guide on it in the guides section..personaly from my own experience I would never drive my stilo without a battery fuse board cover fitted.