Technical 1.6 cutting out and ASR failure etc etc

[Most Easterly Pandas]

I've had a search, and it's been covered a few times, but without any confirmed success from what I can see.

So friend purchased a 1.6 2003 Dynamic 5-door a few weeks back. Done the usual repair for the seat airbags due to fault codes relating to them, and am just waiting on an emulator to resolve the last airbag fault with the OCS.

It's intermittently been cutting out, checked battery connections, seem ok, earths seem clean.

It's now got to the point it sometimes won't restart, will just turn over. It's now had to be recovered by the AA, mechanic started mucking about with the coil packs, still no change.

When it cuts out it sometimes comes up with ASR failure. It will sometime cutout without this message I believe, and will cut out both in motion, and when stationary. When stationary it'll just die as though the key has been switched to off. No juddering or hesitation, and when she runs it's as sweet as a whistle.

Now I'm thinking possible crack shaft possition sensor failure. Am planning on getting a replacement if I make it to the scrappy tomorrow. I've also asked my mate to charge The battery, incase it's on it's way out, although it does look new, but having said that the car does still have a battery cover

Now I remember seeing something about a strange issue with an Aircon pressure sensor causing some sort of an electrical gremlin with a Stilo before. Cannot remember what it was, and cannot find it for the life of me, does this ring any bells with anyone

We've also checked the ECU connections, and they seem fine, as well as all visible engine bay electrical connectors? So has anyone got any more ideas as to what could be causing the cutting out, and has anyone ever successfully resolved it

Cheers,

Jon.

 

[yellowstilo]

yes,you might try to replace the crankshaft sensor (although i would prefer to put a new one in instead of a scrappy one) and you can pull the connector off the aircon pressure switch (on the right bottom side of the radiator) but i'm afraid this is an ecu problem.
It's a known issue of the 1.6 Stilo and replacing the ecu solves this problem in most cases.
Keep in mind you will need a new or reprogrammed (revirginised) ecu to accept the immo data - when you can't find one in UK i can help you with this (ecu and/or revirginising)
good luck!

 

[moschino02]

@MEP

Are you getting "loose connection"? If so, that makes it 5 fiat owners currently experiencing this fault

Like you say alot of threads never state if they managed to solve the issue, but there are ones that do and can be a range of things - following an extensive search, i listed my findings onto another thread on the main page feel free to have a look but each fiat may be different. Sorry cannot offer any further help.


hope you keep us posted .good luck

yellowstilo

I had a new crank sensor fitted today but if that doesnt work i will get my ecu tested first. Will they able to detect if faulty?? if i require a new one, i know where to find you.

 

[yellowstilo]

it's difficult to test these ecu's as they work ok till they suddenly stop working without being able to store any fault codes.
Of course it's good to check other possible causes first but in most cases these kind of faults are caused by a faulty ecu....

 

[Most Easterly Pandas]

The loose connection comes up with ASR failure sometimes, but this isn't always linked to the cutting out I don't think (sometimes it flashes when it cuts out, sometimes not).

So how do the ECUs go faulty then? Dry solders etc

And is it me or does it seem to be mainly just the 1.6 that suffers from this

 

[yellowstilo]

in most cases it is a BGA microprocessor problem, you can compare it with the failing game computers where the processor gets too hot and suffers from cracks in the tiny soldering balls on the bottom of the processor.
for a decent repair you will have to desolder all connector pins, remove the circuit board, remove the processor, clean the pcb and processor and reball the pcb / processor soldering connections.
To prevent these kind of problems it would be best to relocate the ecu away from the engine but the wiring loom does not allow for a quick solution...

 

[Most Easterly Pandas]

So ultimately the cause is excessive heat soak from the engine block then?

On a small update, purchased a spare engine bay fuse board from a scrappy, took it a part out of interest and it was all corroded up.

Suspect the one on the car is the same, so plan on cleaning up the split one, then trying that in the car.

 

[moschino02]

Good luck @MEP.Its worth a try.is the one already in the car badly corroded then? Out of interest, How much one of them set you back? I may have to look into one..its got to be from a 1.6engine i take it?Let us know how you get on.

 

[Most Easterly Pandas]

Good luck @MEP.Its worth a try.is the one already in the car badly corroded then? Out of interest, How much one of them set you back? I may have to look into one..its got to be from a 1.6engine i take it?Let us know how you get on.

Haven't removed the one in the car yet. The one we got and took a part more out of interest was from a 1.6 in a scrappy. Cost £15.

Will let you know how we get on

 

[ricardo]

Hi All

Last week my car was cutting out every day. It seems ok so far this week.

I've got the following fault codes :
P0460 Fuel level sensor circuit malfunction
P0571 Brake Switch A circuit malfunction

I'll try fitting brake switch this week.

I'd like to ask Moschino if fitting a new crankshaft sensor has fixed his Stilo.

 

[Stormwatch]

If anyone has relocated the ECU on an 1.6 please post a couple of photos just to give us an idea...

 

[moschino02]

@ricardo

fingers crossed - it has not cut out yet BUT saying that i have driven it 2 miles back and forth to work since sunday

i remember you also saying the problem started soon after you had your cambelt done? same as me - did some research and alot of people on this forum have had similar problems on 1.6 engines after cambelt fitted - so its always worth checking that out - i checked mine out at garage on sunday but fortunately it was fitted correctly

after i had my cambelt replaced - i remember it started cutting out - fault code revealed brake light switch - had that replaced too which fixed problem for short period


@Stormwatch - yes i would be interested too

 

[moschino02]

another thread https://www.fiatforum.com/stilo/296...lure-security-failure-engine-cutting-out.html

someone posted

"Hi Stilo all fixed. I phoned Fiat direct, got a shocking reply that they didn't even want me to bring it down and wasn't worth them looking at it. So I found a very good auto sparks and they came out, checked it over and replaced the digital barrel £300 all in."

does anyone know what a digital barrel is??

 

[Most Easterly Pandas]

My friend has charged the battery on her Stilo incase it was a voltage issue, still cutting out and its getting worse

 

[ricardo]

Thanks Moschino

I've changed the brake light switch and my Stilo has not cut out yet. I've driven about 20 miles since fitting it.

Have you had any OBD codes that indicate it was the crankshaft sensor on your Stilo?

I'm also going to get a lead so that I can use Fiat ECUscan, I got OBD codes from a Sealey code reader which was easy to use.

 

[Stilonine]

Hi all, I have the same problem... Have you check that? Turning the key to MAR the battery lamp on dashboard turn on over 1 sec . Normally battery lamp turn on and after engine start should go out.

 

[moschino02]

Thanks Moschino

I've changed the brake light switch and my Stilo has not cut out yet. I've driven about 20 miles since fitting it.

Have you had any OBD codes that indicate it was the crankshaft sensor on your Stilo?

I'm also going to get a lead so that I can use Fiat ECUscan, I got OBD codes from a Sealey code reader which was easy to use.

No probz man ..Hope it solves your issue long term.

OBD codes? FES scan? Aint got a clue to be honest, im not that handy with cars.

I got my MOT booked for friday -i pray the cutting out doesnt return, as a failed MOT is the last thing i need right now:worship:

 

[moschino02]

Hi all, I have the same problem... Have you check that? Turning the key to MAR the battery lamp on dashboard turn on over 1 sec . Normally battery lamp turn on and after engine start should go out.

Sorry, dont mean to be rude what is it your asking? You say your having similar problems? Explain the fault messages your getting on your dash? Ie loose connection..does the car start then? Or Is it just cutting out randomly - Have you tried anything?

 

[Stilonine]

I have engine fault with the lamp and sometimes flashing airbag.When i have asr failure loose conection the car stop and after restart ok.Sometimes i have car security failure and i cant restart.After 15 min restart ok... It was for 2 weeks in michanichs but he didnt found problem. Now i have leakage and my battery died in 3-5 days...The battery its new.I have not changed chrankshaft sensor.I will go the car in michanichs next week again...
p.s. the symptoms with battery lamp is always but start ok the car..

 

[moschino02]

Try the crank sensor and let us know how you get on