Hi, new here and looking for help.

I bought a 53 plate Stilo 1.9 JTD Dynamic a few days ago, everything was fine but then had a big loss of fuel (1/4 tank in 8 miles) on return from work yesterday that turned out to be a split in fuel supply to the injectors.

I've replaced this line and everything was working fine but on drive last night I got engine warning and the car cut out completely. Under the bonnet there was burning smell around the fuses and various issues, headlights would not switch off, cooling fan on.

I'm assuming that diesel got sprayed over the area and has burnt some contacts so took it all apart and tried to clean, fitted new relays and and maxi fuses but now the engine won't start.

I'm getting the fault car security loose connection, the engine will turn over but not start. Also the headlight issue is still there in that I can't turn them off.

Looking for any ideas on things to check and fairly cheap repairs as it was only a cheap buy, if you think I'm better to cut my losses please say, I don't want to throw money at it and not fix the problem, even tho I do like the car.

All help much appreciated

Since it's a diesel it shouldn't need much more that engine cranking, a good battery , fuel pressure and injectors firing to start.
What I'm thinking:
- Did the fuel pumps run dry ?? you have 2 fuel pumps one low pressure electrical pump that is in the tank and one mechanical high pressure on the engine.
Diesel should not conduct electricity.. so the first burning smell might have been because of burned fuses/relays because the electrical pump ran dry .. got damaged and then after you fixed the problem .. id just sucked to much current, more that the wires/fuses/relays could handle.

The lights problem was probably unrelated and caused by you when playing with the fuse box.


What to do:
1. get the fuse box sorted!
2. get the "loose connection errors" sorted!... maybe you have left something unatattched
3. check low pressure fuel pump to see if it's working.
3.1 check fuel pressure on the low pressure side
At this point the engine should start if there are no errors with the injectors and more importantly if the high pressure fuel pump did not get damaged, and it can still put out enough pressure.
4. check fuel pressure on high pressure side.

Except for putting the fuse box back together you would need some more specialized tools:
-MES/FES /Examiner .. might show fuel pressure in the common rail.
-low pressure fuel tester
-high pressure fuel tester

on your recent drive ..did you drive the car in wet conditions with no cover for the battery fuse/relay area as if so there is a very good chance you have shorted the circuit board and fuse/relays attached, would require stripping down the fuse board to try and clean the contacts up and dry the board ( info in guides section ) or if it has shorted to point of no repair possioble source a replacement, checking part number first, the car seems as it is not starting due to immobiliser issue which could well be linked to fault at the fuse board along with the cooling fan and headlight problems. having a fault code reader such as above mentioned will assist though still you would have to fix the issue, buring smell points to fault at the fuseboard,

Thanks for the answers.

I'm fairly sure the fuel pumps are fine, I followed info I found on here and elsewhere for bleeding/priming after the repair and then drove the car quite a bit during the day, a good 40 miles, and all was good. Also the light problem started at the time of the engine failure but before I did anything with the fuse box.

On the breakdown drive, yes there were wet conditions and my battery and fuse box has no cover so quite possible that it got wet from that.

What do I need for the fault code reader and how much is it likely to cost ?

Also on the fuse board are there many different types, I've seen some on ebay that look very similar but just lack a relay or fuse here and there, is this just option related (air con etc) or are they a completely different build inside?

https://www.fiatforum.com/stilo/357743-wet-fuse-box-jtd-80-a-2.html

I posted a link to the page in ePers that lists all of the part numbers for the Stilo fuse boxes. Hope that helps.

Thanks again.

Took the fuse box apart bad it is fried inside so looking to buy a replacement, I read about the engine immobiliser fiat code thing with the key, will this effect this and need something resetting?

Relay T07 was completely burnt out which I read controls the rad fan, also T02 was quite bad, any ideas what that is or any suggestion of other damage that could be done?

Also what relay controls the glow plugs ?

Relay T02 is for the headlight main beams.

The glow plug relay is inside the glow plug control unit mounted on the bulkhead behind the EGR valve.

Thanks, the T02 being the headlights explains the issue with the lights then so hopefully a new fuse board will have me up and running, fingers crossed.