Technical Please help! Tried everything! ASR, ecu fault, loose connection Stilo 2003 16v 1.6

[SoDunn]

I'm at my wit's end so welcome all serious suggestions.

For the past 4 months I've been getting the dreaded ASR, Alternator, loose connection fault in my 2003 Stilo 16v 1.6.

So far I have:

-Replaced the ECU with a new one
-Checked all Earths
-Checked battery voltage and alternator charge
-Cleaned MAP sensor
-Cleaned all battery contacts
-Cleaned entire fuse box
-Checked wiring harness connection to ECU

And since that did not fix the problem:

-Died a little inside

I'm really hoping that you guys can offer some sage advice on what could be the problem. I've read so many forums on this d*mn problem and no one seems to have a solution. The strange thing is, sometimes it does the asr, loose connection fault, while other times the engine just cuts out dramatically with the engine light on. Two different symptoms of the same problem?

Thanks for the help!

 

[Ralf S.]

If the battery is holding charge then it's possibly a bad earth. There's a couple of earth points in the engine bay.. one on each wing (at least on mine - a 1.9JTD).

Locate each earth point, detach the earth cable from the body, clean up the contact area (use degreaser first and then wire wool etc. on both the cable and the body) then refit it. Once it's tightened up put some grease around it to stop it corroding (Vaseline is best, since it conducts electricity.. otherwise any grease better than no grease).

That should do it.

Check the battery voltage too. It should be 12.6 volts with the engine not running.. and about 14.5 at a fast idle. 11.x volts or less (engine off) is a duff battery.


Ralf S.

 

[bri1232]

it could be your Ecu is faulty does your engine cut out.

 

[SoDunn]

Ok, went in with a code reader today and it came up with a bunch for the throttle position sensor (low voltage, incorrect position etc.) as well as a number of other circuitry errors.

I've replaced the ECU with a new, virginised one so it's not that, and my battery readouts are healthy, but could it possibly be a battery problem?

Or could Earth corrosion cause voltage problems in the circuits?

The engine Earths are damn hard to get to so I'm considering that a last resort!

 

[Davren]

Which fault codes did you get?
.