Technical Stilo ASR Failure, Loose connection etc.

[Roman2897]

Hello everyone,


I'm looking for someone who can help me with my faulty Stilo. I have 1.6l 2002 76kw. It has about 325 000km. For last 1 year I have changed fuel pump, battery (63Ah), ECU, ignition switch, oil pressure sensor, crankshaft position sensor, coolant temperature sensor and nothing helped me. Every part was brand new, no used.


Problem is when I'm driving sometimes one time per hour, sometimes 15 times per hour it shows an ASR failure, then loose connection with engine still running but no smoothly, it's like on 75% of power. Everything is working except of RPM meter. The ECU was changed above 25 000km ago.


On the OBD it shows some CAN faults and also P0230 which is fuel pump circuit. Very curious thing is that when I refill my tank to full, the Engine Fault icon dissapears and nothing happens for about 2 days. The fuel pump is new it costs about 120€.


Only thing I haven't changed is the dashboard. Could be problem there or the fuel tank is dirty? I am refilling fuel at quality gas stations.


Thank for every resposne to this thread and I apologize for my English if it is bad.

 

[Moreno83]

Your english is fine.

This is what you can do your self with minimal costs.


1) Is the ECU still in the same original position? If so , I would open it and check all the pins on the ecu for bad solder. The 1.6 is notorious for bad ECU because it is located directly on the engine.


2) Locate the D4 connector. It is located under the fuse box. Open it and clean it with good contact spray like "Kontakt60". Dont use WD40!!


3) Clean your ground connectors. Above D4 , next to the fusebox is a small black box , open it and clean it with contact spray. You can clean the ground connectors with sanding paper. Usually alot of corrosion is present....
Just follow the negative leads on the battery.


Bad gound and dirty D4 connector can give ghost symptoms like yours.


4) Re-position the ECU , it is best to place it next to the battery.


Good luck!

 

[Moreno83]

I would also open up the fusebox and clean it , just pull some of the big fuses and you know what i'm talking about....

 

[Roman2897]

Thanks guys, I will do it during the weekend

 

[Roman2897]

Hello there,

so after cleaning all what I could clean it is still the same. But all errors are showing only when I got low fuel or full. When I refill the fuel tank to half of it's capacity it doesn't show any error. ASR disappear, Engine Fault disappear and car it's going like new.

Do you guys think I should change the dashboard?

Thanks.