Technical ASR Failure Loose Connection [ECU defective?]

[robbie-rocket-pants]

Re: stilo 1.6 asr failure/loose connection problems

Whilst trying to figure out my ABS warning problems, I did notice that when you unclip the chunky connector on the ABS control unit and start the car you get the ABS warning and loose connector warning - maybe you could try unclipping, cleaning and re-seating that connector.

RRP

 

[BravaBufger]

1.6 Active Dropping out from idle

Morning Stilo fans.

Last week i was driving along at 50mph when the engine cut out, the warning ASR failure and message loose connection came up. I keyed off and keyed back on and it got me home without any mil lights staying on. The next day i gave it a little run around to see if i could repeat the failure and it happened 4 times at all engine temps at speeds of 10-20mph, 30 and twice at 40. I got an OBD reader from work and the next day started the investigation. 2 faults P0105 and P0460 - i noted these and cleared them and tried to repeat the failure to single it out, all weekend i couldnt repeat it!

I came on here and had a search for similar symptoms and found some info on Wheel sensors, D4 connectors and brake switches. The brake switch is fine (plus its new, replaced it last year), the wheel sensors are fine but the D4 was a bit mucky - i cleaned that and the rest of the harnesses in that area and put it all back together. I never had a repeat fault until yesterday...

Yesterdays fault was at 50mph again but then later on i had the same fault whilst stationary when it was idle and just dropped out and threw up the same ASR warning.

I can leave the car idle for 2-3 minutes and it just loses revs and dies on me. Now im trying to figure out the correlation between it doing this at speed (pressumably with high enough revs that the idle control shouldnt be being used!?!) and it doing this when idle.

I dont know anything about how the idle control works on this car but i am suspecting its that at the moment. Any ideas or similar experiences? ive had a forum search but havent discovered anything with the keywords entered so far.

Ta very much!

 

[Deckchair5]

Re: 1.6 Active Dropping out from idle

I'd go with a poor earth connection.Your car is saying "Lost connection" and ASR drop out, P0460 out of limits fuel level sensor reading and even MAP sensor P0105 can all be caused by sudden low voltage

Check the main battery earth (see Stilo Guides) and monitor battery voltage between batt + and an earth on the engine (not the batt -)

Gettiing a really strong starter action or is it down on power sometimes?

Check your ECU earth too

If you can use FiatEcuScan or a similar prog then monitor your car voltage as you drive around

 

[BravaBufger]

Re: 1.6 Active Dropping out from idle

I'm getting a strong starter action every time so i cant see any problem there, i havent noticed a low voltage output but i will check it anyway. I'll also check the ECU earth when i get home too.

I only have access to a general OBDII reader rather than the laptop software/cable setup. Cheers for the advice, i'll check it out and get back to you.

Anyone else experienced anything similar yet?

 

[BravaBufger]

Re: 1.6 Active Dropping out from idle

Ok checked again, ECU earth is ok and the voltage isnt dropping but...

Its still dropping out when idle, it seems to be only in the low temp ranges. The first time it said alternator fail then ASR failure and the second time it didnt say anything but just displayed the engine warning light. I would say 9/10 now its in the cold temp ranges (although ambient temp isnt too bad at all around here lately).

Could it be the alternator? maybe the auto choke? im so confused on this one the failures dont make any sense!!

Any help is greatly appreciated, it'll save me from pulling my hair out :worship:

Much love <3

 

[Deckchair5]

Re: 1.6 Active Dropping out from idle

Its still dropping out when idle, it seems to be only in the low temp ranges.
Do you mean you only have problems when the engine is warming up from cold? No problems when engine is hot?

Could it be the alternator?
Not if it's producing around 14v, that's why i said monitor your voltage

maybe the auto choke?
No choke on modern fuel injection these days but the electronics do all the equivilent of fuel/air mix

Alternator fail and ASR fail -lost connection- are more often power supply or earth problems so if your power supply voltage is good then it's more likely an earth problem. I'd do a volt drop test from battery neg to a shiny earth on engine with engine running -looking for 0volts- anything more than 0.3volts and there's a problem

 

[BravaBufger]

Re: 1.6 Active Dropping out from idle

im sure the first time it happened it would have been hot as i was 15 miles into my journey home but each time it stalls from idle its whilst the engine is warming up and when i try to repeat the fail it hasnt happened with a warm engine. It may just be coincidence so far as i cant replicate the fault all the time but it is getting more frequent.

I'll check all the earths and all of the fuses and relays and see if i can find anything. The strange thing is its not registering any fault code except P0460 (it had this one again since i did the diagnostic check over the weekend).

I was also thinking, if there was a hole in the fuel breather pipe or somewhere else in the system (obviously not feed/return!) that it may cause the same symptoms? but i would also think it would register a code when the system checks for pressure.

I'll get back to you when ive checked every single earth the car has tomorrow. Thanks for taking the time to try and help me!

 

[Deanostilo10]

ASR Failure Loose Connection

Hi All!

Ive got a stilo 02 1.6
and every now and again im getting ASR failure loose connection up on the display which is most annoying because the engine just cuts out, so i have to pull up and turn the engine on again then all seems to be fine until it happens next. usually once every week or so.
i done a couple of things, i cleaned the D4 connector but that didint make any defference, i tired to clean the sensor's on each wheel but couldnt get the allen screw out (to chewed)
ive heard brake light switch is most common problem with this but cant see how???

thanks

 

[12[X]]

As there are no takers – i will answer (apologies if this is of limited use – am not into electrics much)

Brake light switch can cause an ASR/ESP/ABS error but it will not cause your engine to cut out. It seems the problem is a bit more serious (one of the main junctions to from ECU) you might like to put it on an examiner (as the engine cuts out there are many systems that get disconnected.. knowing which these are could point you to the shared join/connections that all the systems are routed through). It could be anything though, including the engine earth, ECU plugs or the battery bay fuse box and any connections cables there in and in between (especially if you had it running with no cover on the battery bay) it can even be related to coils!

First things first though - see the guide for D4 and follow for all the connections in the battery bay.. also clean everything running to from the battery bay fuse box and the ecu plugs + the engine earth (this is all free) after that (if fault is still there) take it for diagnostics (since you are asking.. you are not a tech.. and this would be a hard one to diagnose.. now don’t necessarily let em fix it.. but a 30 min diagnostic charge is all it takes to be connected to the examiner and see if the fault is simple/traceable) all else failing (after you did the above) you could also use the search button on this forum or ask for further help (some people here, not me obviously, have more knowledge when it comes to fiats than my local dealer and some are Fiat trained hehe)

 

[Deanostilo10]

Thanks for you reply very grateful

thanks for the info you gave me, ill think ill start easy and check all the earths clean them up and then go on and check connections
do you think im should clean all the connections going to the battery?
i havent got a radio code so wood have to get that before i start
examiner im guess that is abit of machinery that can source the problem?
will my local dealer have such a thing (i wood of thought so)
i did have the engine running once without the battery cover on do you think that could of loosened something?
ill have to get a guide where the ecu is because i really dont know where that is, and check the plugs like you said =]
the battery bay fuse box is that under near the battery is?
the one with most of the fuses in.
coils? that sound serious what do they do?
it did go into my local fiat dealer and they couldnt find nothing wrong but didnt charge me so wonder if they checked atall

thanks very much

 

[12[X]]

You will have to disconnect the battery but, in my experience, should not require to re-enter the radio code (this is conveniently stored on the body computer for you). The fuse box is further than the battery but above it (look at the guide in the guides section). Coils provide the spark and sit on top of the spark plugs. Fiat examiner would be available at a fiat approved dealer (normally is to expensive/specialised for small garages to have). Start by following the guide and clean all the connections under the fuse box. If you have been running with no cover water could’ve gotten in thus oxidising the contacts (use contact cleaner and follow the guide!: https://www.fiatforum.com/stilo-guides/99828-d4-connector.html you can also use the search link (above) as your issues are fairly common

 

[Deckchair5]

I'd go with one of 12X's first suggestons and dive straight for the battery to engine earth. Have a look in Stilo Guides for tests and curing a main battery earth problem as it's quite common for the lead terminals to surface corrode with age

For it to stop the engine then it has to be on the main power supply and ASR is one of the first systems to complain of too low voltage. Your car is telling you "loose connection" but, for that, read it as "Lost connection" and that's exactly what it is, open circuit through poor contact

 

[Deanostilo10]

Ok ill take your word for it =]
ok thank ill take alook at them guides and clean all the connections, i did clean the D4 connector because that was the most commen prob but had no joy =[
if i get no joy think thats the road i shou
ld go down seening my local fiat dealer but ill deffo check them earths
should i clean the fusess aswell?
any charge u no where the earths are on the car or if there is a guide ?
i can see one the right pannel

Deckchair,
could this be an alternator problem ive got, thats why im lossen power?
battery wood only cur the problem for so long im guessing?
do u no where the circuit board is? and how to locate it?

thanks for all your help =]

 

[sasha015]

Have the same problem for 4 months,since i bought car.Examiner says its everything ok.I check battery,engine earth,change break light switch and problem is still here.It just cut me of while im driwing,and turn off engine.today wont start finaly,after 1 minut since i start engine he cut me of.Seys asr failure,car security falure.I tray and tray for 15 minutes and finaly engine starts and now work fine....
do no what to do...burn the car,sell it....:bang::bang:
It never cut me of on highway,only in town,in first 5 -10 minutes driwing.Yesterday a drow 60 miles and everything was just fine,but today in 100m he cut me 2 times,and finaly for the first time wont start,cos first time with asr failure says car security failure.try with 2 keys,same sh...

p.s.sory for bad english....but i think all of you will understand....

 

[12[X]]

Alex - try changing your crank sensor and recharge the battery

 

[crnisale]

Reballing ECU processor.So I solved the problem

 

[Argonought]

Excellent post but can you provide more info on what you've discovered ?

 

[spyshagg]

its a common problem on lower quality electronics. Particularly ones that heat a lot.

The trick to fix them is to place a copper plate on top of the problematic chip and heat the board in the oven for a few minutes at 200ºc. Or a heat gun.

Many HP laptops with nvidia cards suffer the same problem.

 

[Argonought]

Many HP laptops with nvidia cards suffer the same problem.

Careful ...... don't let all the secrets out of the bag


Actually I was referring to the original symptoms?

 

[Deckchair5]

ASR is one of the first systems to notice and warn of a low voltage condition. But to stop the engine then there are major power supply problems and the loose connection (lost connection really) is your clue. I'd check the main battery earth (see Stilo Guides) and the ECU earth