Technical Throttle twitching and overhaul

[oowop]

I have finally put together my poor Stilo (see here: https://www.fiatforum.com/stilo/300858-stilo-abarth-ripped-apart-diy.html) and after putting key in MAR position I get only three errors.

1. Fan works constantly with fatal error in FES.
2. Selespeed stuck in N with error about clutch sensor high signal. I did replace clutch driven plate maybe that is the cause.
3. Throttle butterfly or flap is jerking all the time. Annoying as hell.

I haven't fired up the engine yet. Fan and hydraulic pump drained battery. Tommorow I turn the key to ignition what ever happens.

I do have FiatECUscan. Any suggestions?

I spent about 800€ on parts and fluids and about 120 work hours. It's my first (hoping also last) overhaul.

120 h x 30€ = 3600€ but I pay myself 1€/h so labor is only 120€.
parts = 800 €

 

[Entonox]

i now when the oil temp. sensor cable is disconnected, the fan goes to full speed when ignition is on.

The clutch sensor signal seems to me that a connector is loose, please check if the clutch sensor connector is loose and also check the one behind the chassis beam / below the left head light. (connector is located in the left wheel well)

So all connector related i guess....

 

[oowop]

Thanks Entonox for contribution will try those connectors.

 

[oowop]

I tried to started it it's cranking but no go. Engine light is on which probably has immobilised ignition. Errors present clutch sensor (high signal) and fan control (no signal). I'm betting on clutch sensor immobilising ignition.

or

my cam timing is upside down.

btw

I'm cranking without exhaust it has nice sound like Harley.

 

[oowop]

Re: Throttle twitching and overhaul and selespeed now

I have fixed clutch sensor which was full of something no error except fan.

I watched pressure plate travel which was 12.116mm when i engage clutch solenoid it goes to 1,156mm and returns to 12,116mm. Then I engaged odd gear solenoid which pressure plate travel went to 1,155mm and stayed there. I hear clutch trying to press and gear box light comes on without errors on FES. It says it's in 1st gear but wheels turn freely. Keep in mind I did change the clutch which could cause problems regardin travel but I can't adjust it since requires starting a car and driving even.

Any suggestions on how to adjust for new clutch? or set gear indicator to Neutral since it really is in neutral and not in 1st gear like it says on dash.

Selection solenoid test can't be done it's clicking 2 - 4 times then returns err. "no right conditions..."

other solenoid tests successfull.

 

[MarkThompson4]

Re: Throttle twitching and overhaul and selespeed now

Have you had the gearbox ecu (or whatever it is) re-calibrated to the new clutches thickness? If the ecu hasn't been made aware of a new(thicker) clutch being installed then it will cause problems.

 

[oowop]

I have solved selespeed issue. I mixed even and odd gear engagement solenoid now it works. I haven't done any clutch adjustments since I can't drive the car.

Now I'm left with only one error which is fan control no signal and the car won't start it just cranks which is still i think immobilizer since no smoke comes out.

Oh two errors which is throttle flap it jerks every time i turn the key to MIL. No error on FES for this one.

Does it have to relearn it's position or do I have to do it? If so where can be done since in FES there is no function regardin throttle body.

 

[MarkThompson4]

Throttle re-learn: https://www.fiatforum.com/stilo/291918-p0105-engine-cutting-off.html?p=2947358

Post #7

Fan control no signal could be to do with the coolant temp sensor??

Just to be sure, remove one of the spark plugs and check for fuel, if so then stick a mutimeter on one of the coil wiring plugs and check for voltage. If it was an immobilizer issue would you not have the security light on the dash?

You can do an "actuator test" in FES, one of whch I know is a fan speed check. Once you've connected to the engine ecu there should be a tab at the top of the window which says actuator tests, click it and you should have a list of tests you can do, one should be the fan speed.

 

[oowop]

Mark thanks for reply.

I did get for a brief moment immobiliser fault when I was cranking a bit longer.

Now I tried running actuators for fan speed and injectors 1 - 6 all failed. I also recorded inside cylinder #5 no fuel there.

After trying those actuator tests I turned off and set to ignition again **** hit the fan. Fan went in to fastest speed and now does it every time. Errors on gearbox, asr, esp and immobiliser. Unable to connect to FES now. Will have to try later again it's 40C outside.

 

[oowop]

oh and Loose connection too

 

[MarkThompson4]

Are you sure the usb didn't become disconnected from your laptop? This causes those faults to come up and loose connection warning. So cylinder #5 has no fuel, what about the other cylinders? The injector test failed then?

What condition is your battery in? Is it brand new?

 

[oowop]

I did manage to connect to Body computer which shows CAN errors. still no luck with engine computer. No fuel in all 5 cylinders.

Could it be that ECU died on me?

Battery is not new but is fully charged.

I will disconect neg. connection on battery if it helps.

 

[oowop]

What's it worth at least engine light isn't on.

 

[oowop]

I tried just about everything. Took out breake pedal switch put it appart all looked ok.

I now took apart multibox under hood (see pics) cleaned it. But haven't found any issues with it. I also took apart ever releay on multibox (see pic) and checked for faults all ok.

img. Multibox without relays

img. Inside multibox

img. Inside relay on multibox

https://plus.google.com/u/0/photos/instantupload/5756553562222298466

video. Brake pedal switch

https://plus.google.com/u/0/photos/instantupload/5756467087479448754

video. cranking almost inside cylinder #5

 

[oowop]

video is a no-go for non-G+ users

 

[oowop]

Oh, did I show you around my workshop.

And the tools needed for doing overhaul on 2.4L

If you were wondering what those two market scales are doing on my workshop bench those are torque wrenches.

 

[MarkThompson4]

I like it My workshop has a roof or sorts

Are you able to specify what the CAN errors are?

Are you sure you need to be able to drive the car to adjust the clutch? I was always under the impression it was only needing programmed into the ecu to be calibrated, but I've never owned the 2.4 so what do I know

Have you checked for a spark also?

 

[oowop]

According to manual it needs to be driven at least 300m. I did try without it but with failure.

Haven't figured out yet that CAN trouble. Maybe battery since it was emptied again will try tomorow and for sparks also. I did try hooking with cables from Golf Diesel but I don't have much confidence in that. I also cleaned earths and grinded them to copper finish C1, C12 and C10 and one on the gearbox other earths I can't find.

Mechanical part of overhaul was nice. But this electrical part is just pain in the... back, actually.