i've a problem with my newly purchased 2002 1.9 jtd 3 door. Brake fluid low warning keeps coming on intermittently, sometimes a few seconds, sometimes 10 to 20 minutes, have checked fluid, any ideas appreciated

You get the whole BRAKE FLUID LEVEL LOW -STOP -ENGINE stuff but the fluid level is ok?

yep, some days it happens, some days its fine!

gotta be a sensor fault then, i'd give it a clean and see if that helps.
Have you had any brake work done recently? or was any done before you bought it that you know off?

minimad99 said:

gotta be a sensor fault then, i'd give it a clean

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.......and also anything it's plugged into

You ARE sure it's the brake fluid level and not just "Handbrake on" as the warning light is the same?

Stilo is a bit different in that you can't just take the low fluid level sensor out without spilling hydraulic fluid all over the place. It's not one of the "float in the cap" type fluid level sensors but one that is situated well down at the low level point so it's more than a bit of a job taking the sensor out as you have to drain/syphon the fluid out first

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What I would do is
1 just check the sensor by back probing the sensor connector with ign off and check it for resistance. Should be max resistance with normal fluid level. Then shake the reservoir and see if the sensor gives a wrong signal by zero resistance ie straight to earth as if it's on minimum low level

2 The signal wire to the sensor may have an insulation problem and be grounding to earth somewhere so I would disconnect the low fluid connector at the reservoir and wiggle the cable around with ign on and see if you can reproduce the fault. Look for somewhere the wire may be grounding to earth

Excellent help from Decks there.

This isn't Stilo-specific but I thought I'd state the obvious just in case: as the pads wear down, the fluid level drops by a large amount, I know it IS obvious but it's generally the reason for 'low fluid level' warnings in my FIATs. I don't think I've ever had a false alarm, but maybe the Stilo is different. Of course if you do top it up, then when you change the pads, you have to remember to take some fluid out. So I tend to check the pads before topping-up.

-Alex

Couldn't be the front brake pads being low that is triggering the warning light? Or are they seperate warning lights?

Just a thought, as on the 1.6 at 42K and neigh on metal to metal contact, the rust rim on the front disc outer had half cut through the sensor wire but no warning light Thats why I am am changing pads earlier on the JTD for my own peace of mind...

The "brake pads worn" is a different warning light but only shows if the wire grounds to earth through the pad disc so if the wire is cut/damaged then there's no warnings as there's no circuit

Interesting to know what this one is though as it's the first time i've heard of a problem with the "Lo Brake Fluid" warning

wotnowarninglight said:

Couldn't be the front brake pads being low that is triggering the warning light?

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Yes - in an indirect way. That was the gist of my message; the pads worn down cause a drop in the fluid level, so assuming for a moment that the warning is not a false alarm, it could be due to the pads.

Electrically-speaking then no, they are separate as Decks said.

Incidentally the much-older FIATs (e.g. Croma) had a different system where two wires went to a loop in the brake pad. The advantage being that the warning came on either when the loop was grounded or when the loop broke. There were lots of false alarms (ironic, huh...) so the system was re-wired with the two wires bridged at a plug and a single wire running to the pad.

-Alex

have tried disconnecting sensor, gives an immeidiate warning light, think it must see it as low level, will try resistance on sensor in next day or so. pads have loads of life, but warning is on lcd on dash and is specific to low level, any other assistance is much appreciated. thanks for making me welcome!!!!

forgot to say i do not know of any recent brake work, but there is enough fluid, up to max, yesterday done about 100 miles, no warning, today done about 10 miles came on 3 times!

"have tried disconnecting sensor, gives an immeidiate warning light"
Now that's interesting, spray some contact cleaner on the connector terminals as a bad connection there will trigger a warning

tried conntact cleaner but still coming on, although i have done about 350 miles and it only came on for a couple of seconds!, can not get to terminals to check with meter, may need to remove sensor, can not replicate fault by moving loom, no visible damage.