22 · Diagnostics

Engine cuts out whilst driving

Make: Fiat
Model: Stilo Factory Service Manual
Year: 2001–2007
Section: Engine › Engine cuts out whilst driving

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Fault diagnosisEngine cuts out whilst driving

ENGINE CUTS OUT WHILST DRIVING

1.2 16v, 1.6 16v, 1.8 16v, 2.4 20v

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	First check: that the earth is correctly fastened on the engnie; See E1020 EARTHS that the positive battery terminal and the cables connected to it are correctly fastened; See E1010 SUPPLY no water in the fuel filter	Continue to Step 1	Earth lead incorrectly fastened	Renew or, if necessary, replace the battery earth lead Op. 5530B22
			Battery postive incorrectly fastened	Restore battery positive leadOp. 5530B26
			Presence of water in the fuel	Replace the fuel
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket. Verify: that there are no faults in the engine management control unit the plausibility of all the parameters.	Continue to Step 2	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
		Continue to Step 2	Incoherent parameter	Continue following the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle, reproducing the conditions in which the fault arises, keeping the diagnostic equipment connected. Verify: that there are no faults in the engine management control unit the plausibility of all the parameters.	Continue to Step 3	Error arises suddenly in the control unit	Continue according to the instructions for the diagnostic equipment
			Incoherent parameter	Continue according to the instructions for the diagnostic equipment
			Loss of communication between the control unit and diagnostic instrument	Restore the control unit circuit supply See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
3	FUEL PRESSURE ROAD TEST	All OK	Problems met	Operation
	Road test the vehicle and check the fuel supply pressureOp. 0510C10 Make sure that the conditions in which the problem occurs are reproduced	Continue to Step 4	Pressure not correct: obstructions in the pipe	Remove the obstructions in the fuel pipe, and if necessary replace it
		Continue to Step 4	Pressure incorrect: fuel pump damaged	Replace fuel pump assembly Op. 1040A70
4	CHECKING CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present		Fault persists: control unit defective	Replace control unit Op. 1056B82 Search for the fault starting from another symptom'

1.9 JTD 8v

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	First check: that there is fuel in the tank; the engine wiring is properly connected to earth battery earth correctly fixed correct fixing of positive battery terminal and that all leads are connected no water in the fuel filter	Continue to Step 1	No fuel	Introduce fuel
			Fastenings slack or oxidized	Re-attach correctly
			Presence of water in the fuel filter	Clean the tank and pipes and replace the filter element
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket. Verify: that there are no errors in the control unit	Continue to Step 2	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle, reproducing the conditions in which the fault arises, keeping the diagnostic equipment connected. Verify: that there are no errors in the control unit;	Continue to Step 3	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
3	INJECTOR HIGH PRESSURE CHECK	All OK	Problems met	Operation
	Check that the diesel leaks from the injector recirculation connections are small and about the same as one another See Test 1060C Injector high pressure fuel circuit check.	Continue to Step 4	Persistent leak from one injector	Replace the injector
4	HIGH PRESSURE CHECK	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket. Check that the diesel pressure parameter is correct. See Test 1060D Check high pressure fuel circuit	Continue to Step 12	Pressure not correct	Continue to Step 5
5	CHECK RETURN LOW PRESSURE	All OK	Problems met	Operation
	Check that the pressure in the return pipe to the tank is less than 1 bar See Test 1060A Low return fuel pressure circuit check	Continue to Step 6	Pressure above maximum limit: return pipe to tank blocked	Repair the pipe; if necessary replace it
6	CHECK ON DELIVERY LOW PRESSURE	All OK	Problems met	Operation
	Check that the diesel pressure between filter and pressure pump is between 2 and 3 bar See Test 1060B Low fuel pressure supply circuit check	Continue to Step 12	Pressure below minimum limit or above maximum limit	Continue to Step 7
7	CHECK ON DELIVERY LOW PRESSURE	All OK	Problems met	Operation
	Choke the return pipe from the pressure regulating valve and repeat the test See Test 1060B Low fuel pressure supply circuit checkwith the pipe choked, checking that the pressure at the filter outlet is below 2 bar	Continue to Step 8	Pressure rises to 5 bar: pressure regulating valve on filter mounting out of adjustment	Replace the valve Op. 1044B16
8	CHECK ON DELIVERY LOW PRESSURE	All OK	Problems met	Operation
	Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Continue to Step 9	Difference in pressure over 1 bar	Replace the diesel filter cartridge Op. 1044B20
9	CHECK ON DELIVERY LOW PRESSURE	All OK	Problems met	Operation
	Check that the pressure of the supply pump at the filter inlet is over 2.2 bar	Continue to Step 12	Pressure below 2.2 bar	Continue to Step 10
10	CHECK ON DELIVERY LOW PRESSURE	All OK	Problems met	Operation
	Measure the difference in pressure between electric pump outlet and filter inlet, checking that it is less than 0.3 bar	Continue to Step 11	Pressure difference greater than 0.3 bar	Replace the pipe
11	CHECK ON DELIVERY LOW PRESSURE	All OK	Problems met	Operation
	Check that the pump supply voltage is 12 V and that the absorbed current is between 2 and 10 amp. See Test 1040AA Check supply voltage and absorption current	Continue to Step 12	Voltage < 12 V	Check electric wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current > 10 amp: pump faulty	Replace fuel pump assembly Op. 1040A70
			Current < 2 Amp.: pump blocked	Replace fuel pump assembly Op. 1040A70and clean the fuel tank
12	CHECKING CORRECT OPERATION	All OK	Problems met	Operation
	Replace the DRV high-pressure valve and check that the fault is no longer present		Fault persists	Continue to Step 13
13	CHECKING CORRECT OPERATION	All OK	Problems met	Operation
	Replace the pressure pump and check that the fault is no longer present		Fault persists	Contact Technical Service for further information on the problem Search for the fault starting from another symptom'

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Parts & tools for this job For 2001 Fiat Stilo

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