2004 Fiat Stilo 1.4L Petrol · HG54 BBV

The 2004 Fiat Stilo passed its most recent MOT on 30 September 2025 at 146,278 miles, but the record reveals a vehicle with persistent structural corrosion and recurring mechanical faults that demand careful scrutiny. The maintenance trend is mixed rather than clearly improving. The tester flagged a corroded front sub-frame and rear suspension spring mountings again in September 2025, both noted as not seriously weakened, yet these items have appeared consistently across multiple tests since at least September 2023. A failure on 26 September 2025, just four days before the pass, exposed excessive corrosion on both outer sills significantly reducing structural strength, a split offside front CV boot, defective headlamp lenses, and excessive carbon monoxide emissions at fast idle. That the car passed days later suggests temporary repairs rather than lasting remediation. Corrosion advisories on sub-frames, sills, and suspension mounting points have recurred on nearly every test since 2023, indicating a long-term pattern of underbody deterioration that has never been permanently resolved. Mileage accumulation is broadly typical for a 22-year-old vehicle, averaging roughly 6,649 miles per year. The record shows 143,124 miles in September 2023, 144,460 miles in September 2024, and 146,278 miles by late September 2025, representing approximately 1,300 to 1,800 miles per year in recent use. There are no dramatic gaps or sudden spikes that would suggest long-term storage or clocking. The annual test pattern is consistent, with each test falling in late September, suggesting the owner has maintained a regular yearly cycle. The mileage progression is steady and unremarkable, meaning wear on consumables and mechanical components should be proportionate to age rather than excessive use. A buyer should inspect the underside thoroughly, paying close attention to the front sub-frame, rear sub-frame, and both outer sills where corrosion has been repeatedly flagged. The September 2025 failure specifically cited excessive corrosion on the offside centre outer sill and nearside rear outer sill significantly reducing structural strength, which raises questions about whether welding repairs were cosmetic or structurally sound. Suspension spring mounting points on both sides of the rear axle have also appeared as advisories across multiple years, so check for cracked or weakened metal around those areas. The split offside front CV boot noted in the 2025 failure should have been replaced, but verify the joint itself has not been contaminated by dirt and moisture from prolonged exposure. The braking system warrants close examination. Binding brakes have been flagged on both the offside front and nearside rear across multiple tests in 2024 and 2025, and the September 2023 test noted parking brake efficiency only just meeting the required standard. This pattern suggests calipers, cables, or adjusters may be deteriorating unevenly. The headlamp lenses were seriously defective in both the 2024 and 2025 failures, so confirm whether the units have been replaced or merely polished, as degraded lenses scatter light and compromise night-time visibility. Finally, the excessive carbon monoxide reading in September 2025 points to a combustion or exhaust system issue that may have been temporarily masked for the retest rather than properly diagnosed. A compression test, exhaust gas analysis, and inspection of the catalytic converter and lambda sensors would be prudent before purchase.