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Crankshaft Sensor Problem ? A must read !!

Discussion in 'Cavalier, Calibra, Vectra, Signum, Sintra & Insignia owners forum' started by myhouse, Oct 18, 2002.

  1. myhouse

    myhouse New Member

    Likes Received:
    East Anglia
    This post is huge, if you have Crank and Cam sensor problems, reading this might save you a fortune !! Sorry it is so long, but you need the whole 2 year story !!

    * ECU Fault Code No. 92 Camshaft Sensor Failure
    ECU Fault Code No. 19 Incorrect RPM Signal, Crankshaft Sensor failure

    Aug 2000 - EM light came on intermittently, ECU Fault No. 92 *, Camshaft sensor replaced, fault disappeared.

    EM light came on once in the blue moon, fault ignored, ECU 92 & 19 * Fault. Switch ignition of and re-start engine, fault would disappear for as long as 3 months.

    EM light came on more regularly, weekly then daily.

    Aug 2001 – Crankshaft Sensor replaced, fault disappeared for some months

    EM light came on once in blue moon, fault ignored, ECU 92 & 19 Fault.

    April 2002 – Cambelt, Rollers, idlers, tensioner and water pump replaced.

    June 2002 – EM light on again very regularly. Occasionally while driving, the rev counter would swing up to 7000 rpm and back down, up and down erratically, sometimes settle down sometimes causing the engine to cut out.

    July 2002 – EM light on every time engine started.
    Crankshaft sensor replaced, no effect on engine, fault still exists. Causing engine to stall often when stationary i.e at traffic lights.

    Wiring loom tested O.K. no short cct’s no high resistances.
    Removed sensor wires form main wiring loom within engine bay, to prevent interference. No effect on fault.

    Engine became increasingly difficult to start, but once started it could be used. Engine restricted to 4500rpm in limp mode and there are flat spots throughout the rev range.

    Sensor cables screened with foil and separately earthed, no affect on fault.

    Aug 2002 - Engine extremely difficult to start! Engine backfires and sometimes requires 4 – 5 attempts and up to 30 - 40 seconds of cranking before it starts. A spare battery has to be carried at all times.

    Oscilloscope reading taken from both camshaft and crankshaft while engine running.
    Crankshaft gave a clean sine wave of approx 1.2V peak to peak and 120Hz
    Camshaft gave a dirty sine wave (with ghost images) 1.2V peak to peak and 120Hz

    Starter motor finally gives up, purchased new one, removed the old one, only to find half of it missing. The end had snapped off and was somewhere inside the bell housing. Gearbox removed to retrieve the missing piece.

    Camshaft Sensor replaced. No effect on fault.

    Sept 2002 - Hired and fitted a used ECU. This had no effect on the existing fault. Engine starts much, much easier once at normal running temperature.

    The car was totally unreliable, un-drivable at times, wakes the neighbourhood up when starting it in the morning, gets really strange looks form the public, due to it’s god awful noise on starting.

    In Summary, where the money was spent (and had no effect)
    Crankshaft sensor Replaced £83
    Camshaft Sensor Replaced £55
    ECU Hired £65 inc postage
    New starter motor Purchased £120 (could not find one at 20 odd scrappies)
    Starter motor replaced, gearbox lift, fault investigated at Bosch specialists £267

    Suggestion from ‘Experts’ including Vox main dealers on what else I should replace.

    Set of HT Leads £80
    Dis Pack £65
    ECU £320
    Wiring Loom £ Dread to think
    Air Flow Mass Meter £100 ish ??
    Engine Temp Sensor £60 – 80 ish
    Alternator (It must be genuine Vox part ) £150 ish ?

    Honestly, I came very close to torching the damn thing on the vox dealers forecourt, as it is, this single fault cost me £710 to put right, If I had took the advice of all 20 – 25 Mechanics, Auto electricians and main dealers the bill would have been above £1800 (and that mainly just parts). For a car that would only fetch a £2000 MAX price tag if running perfectly, you can see my reluctance to change these parts.

    The Conclusion :

    The fault is now fixed, the car runs, performs and starts perfectly. The garage that sorted it (The 6th garage to look at it) was T & M Auto Electrical Co. Ltd. In Colchester, Essex. A guy called Ray (A Knight in Shinning Armour). The thing is, if only I knew 6 months ago what I know now, this fault would not have cost me a single penny. There was no faulty component (as such) on the car at all.

    You must be dying for an answer to the fault ??? You check back here in a couple of days and I’ll post a photo of the cause. I’m a bugger aren’t I?

    Much thanks goes to those of you that did try to help, especially ‘Mark CDX V6’ and thanks for reading this huge post. Check here soon for a photo and final explanation !!!!

    To be continued.
  2. LEE69

    LEE69 Active Member

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    Bloody hell its like a murder mystery ;)
  3. Richie

    Richie Me Cav is Shiney, Bonny Lad

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    near Glasgow.....
    Ahhh come on :p

    Mark, you got any ideas ??

    Only one I can think of is the cambelt tension but you say you did this already (Ecotec synchronises the camshaft and crankshaft sensors, if there is a loose cambelt then they are knocked off for a bit and the ECU light flashes)
  4. goonas

    goonas Active Member

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    One word I've just read a post that long and have no answer, why you....... :mad:

    Bit like a joke without the punchline!! :mad:
  5. Mark T

    Mark T Gas Powered

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    Chelmsford, Essex.
    Astra G Estate CDX, Zafira Elegance LPG, Zafira Design 1.9CDTI

    Hmm, maybe related to the Camshaft Sensor How to?

    Have to wait for the final installment to find out!!
  6. SteveW

    SteveW Guest

    Think Mark could well be correct, did the sensor need a bit of modifying?

    Awwww, come on, this isn't fair!
  7. Rooster

    Rooster New Member

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    Nottingham, UK
    Mnes had fault 19 for 6 months... a few more days wont hurt !!!
  8. daveybuc

    daveybuc New Member

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    its like a murder mystery im awaiting who did it
  9. madcav

    madcav Cavweb's new born hiker

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    sorted my bruv's fault 19 the other day the car runs sweet now.
  10. ChrisSRI

    ChrisSRI New Member

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    hhhmmm, mi mind boggled, lol, perhaps something as silly as a poor connection somewhere thats affected by heat and or vibration etc??? intermittant depending on conditions and temp??? bad earth affecting part of loom????

    cmon its like having a pair of boobies in front of ya and u cant touch em!!!!! lol

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