What is life like with your car? Let us know and win £500 in John Lewis vouchers | No thanks
Premature camshaft failure - Vol 1 [Read Only] - Lta

***** This thread is now closed, please CLICK HERE to go to Volume 2 *****

You might have seen my previous post about the camshaft snapping at 24K miles in my Corsa 1.2. Vauxhall as of yesterday were holding out at 60%.

I'm now in contact with another Corsa driver whose camshaft snapped yesterday at 31K and we've both contacted watchdog.

I am trying to build up a case to take to vauxhall and watchdog that says there is a known fault with the timing chain that could cause this. Any help would be greatly appreciated or if you can put me in contact with someone who the same thing has happened to.

Thanks!

Edited by Dynamic Dave on 11/04/2009 at 22:26

Camshafts snapping prematurely in Corsa C's - julesdav
Hi, my car has done 30.000 and just out of warranty. corsa 1.2 sxi o5. cam shaft snapped with no warning.dealer said it was my fault as no oil in car however taken to another garage for new engine/better price and there is 2-3 litres of oil in the engine. I have already contacted watchdog as loads on the internet about this problem. think i need to have words with the dealer but not happy as shelling out nerly 2 grand.
Hope this helps.
Camshafts snapping prematurely in Corsa C's - brum
The dealer blaming the oil level makes me think......If the 1.2 engine has a camchain then this sounds suspiciouly similar to the VAG 1.2 camchain problem pre 2003/2004.

In the VAG 1.2 3cylinder engine, the camchain tensioner is hydraulically operated and relies on oil pressure. If the oil level drops below a certain level, and the driver turns or brakes suddenly, the oil pump is momentarily starved and oil pressure is lost. The tensioner slackens and the chain goes loose and jumps a sprocket or two.

AFAIK VAG never acknowledged a design problem, but curiously fitted a modified tensioner design around 2003/2004.

Perhaps a Vauxhall technician could comment.

Of course the first mistake the owner made was buying a Corsa in the first place (I should know - I have one!)

Camshafts snapping prematurely in Corsa C's - Dynamic Dave
there is 2-3 litres of oil in the engine.


According to the data I have to hand, your engine requires 3½ litres of oil (including filter). Dipstick when on min level marking indicates that you have 2½ litres of oil left in the engine. You need to obtain proof that more than 2½ litres of oil was in the engine prior to it going bang. Saying 2-3 litres isn't really accurate enough.
Camshafts snapping prematurely in Corsa C's - jayeastanglia
the corsa engines do go bang from the cam chain snapping its a known fault in them..and its usually not only due to low oil but lack of proper oil and oil filter and oil change on time and milage...these engines also dont like running slow they need to be revved other wise the vlave heads and guides can carbon up.
Camshafts snapping prematurely in Corsa C's - L'escargot
the Corsa engines do go bang from the cam chain snapping its a known fault
in them .....


If it's that well known, why do people buy them?
Camshafts snapping prematurely in Corsa C's - mandi713

I have just experienced the same problem as you. my corsa was new from 2005 and on the 19th nov 2008 my cam shaft snapped. i contacted the dealer where i bought this as i felt that at 26000 miles this was far too premeture. i was informed that as i hadnt had the 3rd service (due to a family bereavement) i was held responsible. i accepted this and told the to go ahead with the work. I have now been told that due to modification of new timing chains( apparently fittings/connections are different) i will also need to purchase a new cam sensor dispite mine being in apparently good working order. i have contacted vauxhall the manufacturers who have totally ignored me. i would be intrested to know if you have resolved your problem or have any ideas where i can go now as i feel that i may as well write out a sighned blank cheque
thanks


No need to quote the OP. Just makes your post difficult to read


Edited by Pugugly on 13/12/2008 at 11:10

Camshafts snapping prematurely in Corsa C's - CorsaOwner
I have also experienced the same problem with my Corsa (1.4 2005 plate). The camshaft has snapped and I have been told that Vx will pay 70% and I need to pay the remaining 30% which will be £450. They haven't repaired the car yet and I am worried that the costs may escalate as I've heard this depends on whether there is any valve damage. I have also contacted Vx on Thurs (it happened Tues) to complain as it took them two days to tell me what was wrong. They have so far ignored me too.

Just wondering if anyone has had a reponse from Vauxhall or any other advice from Trading Standards etc. I am not happy at having to pay £450 when there seems to have been a fault with the car in the first place and nearly everyone I have spoken to say it shouldn't have gone at 23,000 miles.

Would be happy to join in any ongoing action as the more of us that complain, the better chance we have got I suppose.

Regards
Camshafts snapping prematurely in Corsa C's - maniacal
I have also experienced the same problem this week on my 2005 SXi Corsa in which the cam shaft has snapped completely. The warranty has just run out at the end of November in which case I have to pay for the repairs myself. My car has only done 30,000 miles in which case this shouldn?t have happened. I have been in touch with Vauxhall and the manager was meant to get back to me as he said Vauxhall may be able to contribute to the repairs. However only if the car is fixed at Vauxhall so the costs will still be high and I have not got that kind of money before Christmas, especially as it is not my fault and Vauxhall should pay all of it.

Also I took my car in not long before the warranty ran out as I kept hearing noises from the engine. Vauxhall took it in and explained I had a noisy starter motor and replaced this. I believe at this point they should have checked the car properly as this was obviously not the problem and there was obviously a problem with something from the engine. They failed to identify this and now I am stuck with no car as the cam shaft is now broken in two.

If anyone else is having the same problem and wants to do something further as it is obviously a manufacturing fault then get in touch with any information to kevo1987@live.co.uk

Tried making it readable in English with some punctuation and capitals... maybe kevo will get a keyboard with a shift key for Christmas :-) Rob

Edited by rtj70 on 17/12/2008 at 12:32

Camshafts snapping prematurely in Corsa C's - SherwoodWilliams
OK seems this is a regular occurance after searching on the internet, and it happened to us at the weekend in my girlfriends Corsa..

We were travelling on the motorway at 70mph and the car suddenly lost power and the power steering failed. Luckily she managed to manouvre it onto the hard shoulder and we got it towed to an independant garage. Seems the Camshaft snapped by itself for no apparent reason. We checked the oil before we left, and it was a millimetre or two above the minimum level which you would think shouldn't be a problem, since this the indicator for the "minimum level"!!!

The car is only 3.5 years old and out of warranty. 50k on the clock and it's been serviced regulary by Vauxhall but was overdue for this one by 5 weeks. It's the version with a camchain rather than a cambelt.

My old man went to have a look at the damage this morning in the garage, and he had a look at the snapped camshaft. The mechanic hadn't ever heard of this happening to a car so new, when he showed my dad the camshaft it was HOLLOW on the inside - seems like it's a low-cost budget job from Vauxhall, a complete design flaw. We're going to have to get the repair done with the independant garage and try to claim compensation back from Vauxhall.

Can someone contact me if they need to about bringing this to Trading Standards / Watchdog's attention? If the ball's already rolling, then add our name to the list. Seems like this has happened to hundreds of people in the last few months.

Edited by SherwoodWilliams on 17/12/2008 at 19:53

Camshafts snapping prematurely in Corsa C's - Bill Payer
We checked the oil before we left and it was a millimetre
or two above the minimum level which you would think shouldn't be a problem since
this the indicator for the "minimum level"!!!

No idea how critical it is but I wouldn't dream of knowingly driving with oil level 1-2mm above min - particularly in a car with a small engine that probably holds little oil anyway.
Camshafts snapping prematurely in Corsa C's - 659FBE
I would prefer not to drive a car in this condition either, but a "millimetre or two" above minimum is within tolerance for oil level. If correctly designed, the engine should therefore operate to specification.

GM quite clearly have a serious problem with this engine.

I hope their customers achieve fair redress - there's not a lot of spare cash around in Detroit.

659.
Camshafts snapping prematurely in Corsa C's - Steve05sxi
Yeah the same happened to my 2005 Corsa at 27k. About a month ago i was driving and the emissions warning light came on and the car lost power, then just before i pulled over there was a knocking noise comeing from the engine. I phoned the AA and the machanic said i might be a broken valve spring.

After having the car towed home i went down to vx and they said to repaire a broken valve spring would be £900-1000. I then went to a good local garage and they said they could do it for £600-700.

So last monday i arranged for the AA to tow the car to the garage FOC, which was very nice of them as it had been about 3 weeks since they recovered it. Anyway they only got round to looking at it on friday and found the camshaft had broken because the timing chain had slipped, which he said wasn't uncommon on these cars (as we all now know). So he got back to me today with a price of £1000, but said that would be the most i would pay because he thinks he can get some parts cheaper, which could bring it down to about £800. That would include a new valve that was damaged, gaskets, camshaft, ect.

Should have the car back by middle of next week, but its alot of money to shell out just before christmas.

Thanks for reading and best of luck to you all.
Camshafts snapping prematurely in Corsa C's - oilrag
Are these cars on Vauxhalls two year oil change intervals? is it 20,000 or 30,000 these days? Has the correct long life oil been used... by the dealers?
just a thought....

Hope you all get sorted..
Camshafts snapping prematurely in Corsa C's - stunorthants26
I think you lot should get together and contact Watchdog, see what they come up with.
Camshafts snapping prematurely in Corsa C's - jase1
Are these cars on Vauxhalls two year oil change intervals? is it 20 000 or
30 000 these days?


These are Suzuki engines aren't they? ISTR that Suzuki themselves specify 9000-mile changes -- perhaps this is part of the problem?
Camshafts snapping prematurely in Corsa C's - CorsaOwner
I received a response to my letter of complaint from Vauxhall Head Office yesterday stating that they were willing to contribute 70% towards the cost of repair and that was their full and final offer.

I just wanted to know whether anyone had contacted trading standards or watchdog. My car is currently being repaired and it looks like I'm going to have to pay the 30%. I really need the car back as it has been in the garage since last week.

I am willing to get involved with any action that may be on-going and as it would be better if we all got together rather than contact them individually...
Camshafts snapping prematurely in Corsa C's - Number_Cruncher
>>ISTR that Suzuki themselves specify 9000-mile changes

I don't know, but what's important is not just the interval, but the oil quality, and filter type.

I've been chatting to my friend who I used to work with in the Vauxhall garage, and his view is that there aren't problems when all the longlife instructions are followed properly. He said you only get trouble when people use the wrong oil and run it for too long, or top up with the wrong oil.

Camshafts snapping prematurely in Corsa C's - bimmer-driver
Bingo. 99% of the time when one of the garages with an account at the motor factors I work at phone up for service bits for a Corsa, they simply won't put the long life vauxhall grade oil in. 'Its only a Corsa' they say, put in some 10/40 semi synthetic at half the price and go away. Either that or if we send them the 5/30 fully synthetic stuff recommended by Vauxhal they just send it back unused.
Camshafts snapping prematurely in Corsa C's - SherwoodWilliams
What about the fact that this Camshaft is hollow, cheap and not fit for purpose?

It's a design flaw in the first place, secondly if the engine oil does need to be kept at 3.5litres at all times, why on earth put a dipstick in with the minimum level at 2.5 litres?
Camshafts snapping prematurely in Corsa C's - Number_Cruncher
>>Camshaft is hollow

Hollow is good design - the material near the centre of the shaft contributes little to the torsional strength, the torsional stiffness, the bendiung strength or the bending stiffness. Making them hollow must be costing money, over a solid one.

Where Vauxhall (Opel) have been poor for a long time is in the design of the details on cams which make them resistant to fatigue. I remember changing camshafts on cars like Carltons, Mantas, Astras and Cavaliers where the timing belt had been fitted too loose, and the cam was subject to torsional shock.

Vauxhall had great troubles with their cams wearing, and the solution was TIG hardening - at the cost of reduced fatigue strength.

Camshafts snapping prematurely in Corsa C's - TheOilBurner
99% of the time when one of the garages with an account at the
motor factors I work at phone up for service bits for a Corsa they simply
won't put the long life vauxhall grade oil in.


This is exactly why I do my own servicing. Main dealers want to bleed you dry, independents are difficult to trust. Even the main dealers can be iffy with putting the right oil in though, to be fair...

It's amazing in this day and age that such a laissez faire attitude can exist with complicated modern engines.
Camshafts snapping prematurely in Corsa C's - SherwoodWilliams
Right, we've now had the snapped camshaft replaced and the car now runs, but it keeps losing power and cutting out. The emissions light keeps coming on as this happens. Switching the ignition off and back on again seems to fix the problem temporarily but the same thing happens within a couple of miles. The garage said that the diagnostics was showing up a "multi-cylinder misfire" fault, but we're having to take it to Vauxhall themselves as it's apparently mechanically sound, but something to do with the ECU or electrics is making this happen.

Any ideas anyone?
Camshafts snapping prematurely in Corsa C's - adamstapylton
My 2005 corsa sxi camshaft snapped yesterday at 60 mph I bought the car in April this year at 10,000 miles it has now done 16,000 miles when the camshaft went. Im going to contact vauxhall today this shouldn't happen at such a low mileage ive read that quite a few of these corsas are doing this maybe vauxhall need to do a recall on these corsa's.

Ill let you know how i get on with vauxhall
Camshafts snapping prematurely in Corsa C's - jayeastanglia
speaking to other recovery people(Thats what i do btw)its only really affecting 2004/05 corsa engines...My girlfriend has a 06 corsa with 30000 miles on it shes had it since 10000 miles but i service it every 5000 miles with decent oil and as yet no problems..she does a lot of stop start driving as she is a home help carer .
Camshafts snapping prematurely - Andy12
Hi,

My daughter has an 05 plate 1.2 Sxi which has done 25,000 miles and the camshaft snapped on Friday evening. It has been taken to an independent garage in our local town as the nearest Vaxhall dealer is over ten miles away. They have said that the chain gear all needs to be changed as well as the camshaft, is that what others here would advise as there seems to be a potential problem here with the chain tension possibly going slack. The oil level in her engine was sat just beow the high level. The garage has said today that they can not get a camshaft from anywhere but have placed one on order, it may take more than a week to come in. They seem to think that this is because Vaxhall know about the problem and are re-working the design to prevent future problems. Let's hope!

She bought it from snip in Feb last year and their customer service was not good at the time. They did say that they had serviced the car before she picked it up and stamped the service book. As these are not a Vaxhall dealer do you think that will affect any claim we have against the company? They did also tell us they had put an MOT on the car when we picked it up but were waiting for the certificate to be sent through. After a couple of weeks of ringing every day we found out that it had not even been sent to the MOT test centre. Never trust a salesman! Then they took weeks to get a couple of minor issues sorted out such as getting a second key.

I believe from reading all these messages that there is an design issue here, but reading about the possibility of the wrong oil spec being used, I do believe that snip may not of used the correct grade if it would save them a couple of quid.

Any advice please, do you think it is still worth contacting Vaxhall or a complete waste of time. I know they will find any little reason not to pay out even if they are fully aware of the issue.

Andy.

Edited to remove the dealer name to avoid name and shame, Rob

Edited by rtj70 on 05/01/2009 at 20:33

Camshafts snapping prematurely - martyc
Same problem guys and gals, Camshaft has snaped in 2. Car was bought last January 12000 on clock , it now has 26500 .Been VX serviced since new and everyone I have spoken to about this says the same thing a camshft should not break. I have a friend who is a senior racing instructor at Knockhill in fife he also races himself and knows alot about engines and the way they work and he can't belive this has happened . There is no sign on the camshaft which I have of any damage from other parts of the engine
so it has just snaped for no apparent reason other than design or manufacturing faults
which says to me that VX are 100% liable for this problem.

Contacted dealship where car was bought and they said to phone GM and they should offer you a goodwill gesture. I called them today but I have not heard back from them.

The repair bill is £1220 a goodwill gesture will not cut the mustard at that price and considering a lot of people seem to be having the same issue I belive this should be taken as far as possible. If any one wants to contact me or if anyone has started anything with TS or watchdog please get in touch as I will add to the fight also !!
Camshafts snapping prematurely - susieque123
Same Ole....My 2005 camshaft has snapped,
Vauxhall recommended a new engine..£5000 plus.. or offered me £200 - £300, part exchange if I bought ANOTHER Vauxhall from them.
I took it to an independant garage who couldn't understand why the camshaft would snap.
I am wondering if anyone has taken this any further..ie. watchdog or trading standards.
I have already paid for a nearly new engine to be put in my car...yes you've guessed...
I've had it replaced with a 2005 engine!
What can we do?
Susie.
Camshafts snapping prematurely - Rattle
They offered you £300 for a 4 year old car!! Which ever guy told you that is very lucky he didn't spend the night in A&E. Well done for keeping your cool.

I assume BBC watchdog has been informed about all this? I can't understand why the media are not in open arms about it.
Camshafts snapping prematurely - susieque123
Iknow Raffle, and just for the record its only just over three years old! Its a late 2005 which i've had from new, and they were only offering that if a bought another one from them!!
I'm a driving instructor and have been unable to work for 2 weeks, im gutted at the way Vauxhall have treated me.
I hope someone can let me know if they have had any luck with Vauxhall.
Camshafts snapping prematurely - susieque123
Please will anyone who has had the same problem get in touch,
Email address....
susieque123@tiscali.co.uk
Many thanks
Susie,
Camshafts snapping prematurely - jejeyorke
On 28th January I too had an engine seizure on my 55 Corsa Breeze. When I took my independent garage he informed me I had no pressure in my second cylinder. Vauxhall were contacted but as we were 4 months out of warranty they would only look at the problem for a price. They quoted us over £1000, if it was just a rebuild and about £3000 for a new engine. (this was after a %40 off parts and %10 off labour). We investigated further and found exactly the problem you have all described of a cam shaft snapping in two. The car was bought used in 2006, registerd 2005, had 11,000 miles on the clock and currently only has 22,000 miles. I have been back to my dealer who although is contacting Vauxhall was not hopeful that we would get any more off the repair price. We claimed that the car was not fit for purpose as a cam shaft should not snap at this low mileage with full service histroy and good maintenance. Legal advice has suggested I search the internet for simialr problems. Thankfully there appear to be many so I am now getting in touch with Watchdog, Trading Standards and anyone else who will listen.

Please let me know if you have had the smae issues wioth your corsa.
Camshafts snapping prematurely - Barb36
Hi, I?ve just picked up my car today (18th Feb) after being in the garage since 5th January. The camshafts have both been replaced along with the cylinder head, gaskets and timing chain and other bits and pieces.

Vx would only offer 60% towards the cost of the repair so my contribution was £791.92. As I?ve said in my original post my car was only 15 weeks out of warranty andhad only done 15,000 miles, to say that I?m disappointed in Vx?s offer would be an understatement.

I would be very interested in joining anyone who is taking this to Watchdog as, judging by the growing number of cases that are appearing on these forums, there is very obviously a problem with the camshafts on these particular aged vehicles.
Camshafts snapping prematurely - yorkiebar
SOGA somebody?

Sounds like support action needed imo.

"Hollow is good design - the material near the centre of the shaft contributes little to the torsional strength, the torsional stiffness, the bendiung strength or the bending stiffness. Making them hollow must be costing money, over a solid one."

Still stand with that comment NC after all these failures? Sounds like a design problem to me !

Edited by yorkiebar on 18/02/2009 at 22:19

Camshafts snapping prematurely - Number_Cruncher
Yes!

Just like prop shafts were hollow, it's good design for a shaft - the material on the central axis if the shaft is purely dead weight, it provides *no* strength.

Any design problem with these engines is most probably not caused by the shaft being hollow.

I've heard 2 reasons for this failure, but I don't know the truth of either;

1) The chain wears, and the camshafts whip as the slack gets taken up abruptly

2) The bearings become loose, and the shafts bend and snap

Mechanism 1) is a torsional failure - in torsion, there is zero shear stress on the axis of a shaft

Mechanism 2) is a bending failure - in bending, there is no bending stress on the neutral axis of the shaft, i.e., on the centreline.

So, for both of these mechanisms, the shafts being hollow is a distraction, an irrelevance.


Camshafts snapping prematurely - yorkiebar
But a solid camshaft would not break (as easily)!

Camshafts snapping prematurely - Number_Cruncher
I know this may not be intuitively obvious , but there would be very little difference YB - the material inside the bar contributes little to the shaft's strength, but plenty to its weight, and it's the material near the outer surface which is vital.

The shafts being hollow is almost certainly not at the root of this problem.



Camshafts snapping prematurely - yorkiebar
Im not even half prepared to take you on at such a subject as this one.

But,

simply put in my theory, I do not think a solid cam would be breaking. Something else might, I agree, but the force needed to snap a solid cam is a lot more than is needed for a hollow cam.

My explanation of that, I can bend and therefore, bend back and forth and break, a pipe of a fair size. A solid bar of the same size = no chance. There must be more strenght in a solid cam.

How many solid cams have you ever known break? Not more than a handful?
Camshafts snapping prematurely - Number_Cruncher
>>Im not even half prepared to take you on at such a subject as this one.

>>But,

OK, here's a question for you YB.

If you have a hollow shaft that's 35mm outside diameter, 25mm internal (so, 5mm wall thickness), what size of solid shaft is that equivalent to in terms of bending or torsional stiffness?

>>There must be more strenght in a solid cam.

Yes, but not a huge difference - most of the metal near the centre is utterly wasted.

>>How many solid cams have you ever known break? Not more than a handful?

I've only known cams fail when there's been another problem - usually, a loose cam belt allowing them to whip, and for torsional fatigue to begin near changes in section.

Edited by Number_Cruncher on 18/02/2009 at 23:09

Camshafts snapping prematurely - yorkiebar
Im not taking you on Nc,

I just cant see a hollow cam having anywhere near the strength of a solid one!

I have had 1 solid cam break recently (sept 08) that I can remember (Daewoo), no other fault found on the engine. Due to its age and value it was repaired with a scrap yard cam (and nothing else) and is still running ok now!

Now these hollow cams seem to be failing a plenty? I would love to see a solid cam in its place to see what happened.

Whilst I will disagree often with you (whats life if everybody agrees?) I am in no way qualified to discuss strength of x versus y.

But in practical terms I still dont agree with you!
Camshafts snapping prematurely - Number_Cruncher
>>But in practical terms I still dont agree with you!

There's no difference between what I'm talking about and "practical terms".

There are some areas of science where what is thought and theorised about might not exist or happen - gravitational waves for an example, despite having been written about by Einstein in 1918 have never been measured directly.

However, the bending and torsion of shafts have been very well understood for a very long time, and all of the shafts in cars, trucks, aircraft, and all machines are designed using these principles. There's no gap between theory and practice.

In terms of stiffness, a hollow shaft of OD 35, and ID 35 is equivalent to a solid shaft of diameter.....


32.46mm


Not exactly a huge difference is there?

Edited by Honestjohn on 11/04/2009 at 17:45

Camshafts snapping prematurely - yorkiebar
Sorry if you took it as a personal attack, it wasnt meant like that, but

generally

solid cams dont break; hollow ones obviously do !

Still doesnt explain why I can break a hollow tube and not a solid one of the same diameter!

Lets leave it there, we are not going anywhere ?
Camshafts snapping prematurely - Number_Cruncher
>>Sorry if you took it as a personal attack, it wasnt meant like that

No, not at all - no offence taken, and hopefully, none given.


>>solid cams dont break

Not true - I've seen a number of Vauxhalls (Astras, Cavaliers, Carltons, Mantas) with snapped cams, and a number of MBs too.


>>hollow ones obviously do !

In this engine, yes, but, we don't know why, and we don't hear anything of other hollow cams which work well.

>>Still doesnt explain why I can break a hollow tube and not a solid one of the same diameter!

That's almost certainly untrue - the only way I might believe it is if you're talking about thin walled hollow tubes, where the thin wall can locally buckle and significantly weaken the shaft. These cams aren't thin walled tubes.

>>Lets leave it there, we are not going anywhere ?

What do you think about the numbers?


Camshafts snapping prematurely - yorkiebar
The numbers mean zilch to me !

But in my opinion its not a bearing caps issue, maybe a tensioner isssue; but far more likely an oil quality issue !

But if it was oil quality, I would have expected more wear on the cams (a la old astras and cavs etc). Not that the oil was the problem with those, but the wear if you understand!

And as an aside? why arent the SOGA proclaimers shouting from the rooftops over these failures?
Camshafts snapping prematurely - Number_Cruncher
>>The numbers mean zilch to me !

I'll try to provide some interpretation.

All I'm talking about is comparing the bending or twisting of a hollow shaft with a solid shaft which would behave in the same way if loaded equivalently.

So, a hollow shaft 35mm OD, and 25mm ID is equivalent to a solid shaft of about 32.5mm diameter.

We have 2 shafts, the hollow one is 7% larger in diameter than the solid one, but, less than HALF the weight, and the 2 shafts *are* completely equivalent in terms of how far they deflect under a given load.

Camshafts snapping prematurely - Number_Cruncher
>>but the wear if you understand!

That was finally solved by Vauxhall beginning to use a TIG hardening process in about 1989/1990. Prior to that, replacing Vauxhall OHC camshafts was a really common job - for wear on the cam lobes, exactly as you say.

>>but far more likely an oil quality issue !

For that to be the case, there has to be a chain of events between a breakdown in lubrication, and the cams snapping - one might expect to see pick up or damage in the wearing surfaces of the bearings. Has anyone seen such damage? (I don't "know" the answer here - I would really like to find out some more to obtain some pointers what the root cause of this failure actually is)

My friend and ex-colleague says he's found loose cam bearing caps on Corsas with snapped cams - whether that is cause or effect, (or irrelevant even!), I don't know.
Camshafts snapping prematurely - 1400ted
I agree with NC. I have known solid shafts to break, particularly on chain cam engines.
The Merc 190 4 pot petrol is a case in point. If the cam tensioner is fitted incorrectly, the chain is far too tight and the shaft breaks at the first oil drilling like a bread stick.
Ted
Camshafts snapping prematurely - yorkiebar
". If the cam tensioner is fitted incorrectly, the chain is far too tight and the shaft breaks at the first oil drilling "

Failing at an oil drilling would point to poor oil supply; with or without too much tension! Or a weak point in the cam? (ie not a solid point)
Camshafts snapping prematurely - Number_Cruncher
>>Failing at an oil drilling would point to poor oil supply; with or without too much tension! Or a weak point in the cam?

No!

In Ted's example, the cam failing points only to a mis-fitted tensioner, which overloads the cam - exactly where the cam fails in that case is irrelevant.

In the same way, if the bearing caps are coming loose on these Corsas, the cam is suddenly exposed to a bending stress that it was never designed for - the fault being in the bearing caps - not the cam.

Camshafts snapping prematurely - 659FBE
A shaft of OD = 35 and ID = 35 would represent a degree of material saving even GM would be proud of...

Still missing my (proper) SAAB - may they RIP after a decade or so of being owned by gangsters.

659.
Camshafts snapping prematurely - Number_Cruncher
Ha!, sorry, I meant to write 25!, as I hope I did when I originally posed the question.
Camshafts snapping prematurely - 659FBE
I know - I reversed your calculation and came to that result - couldn't resist it though!

659.
Camshafts snapping prematurely - bathtub tom
>>Just like prop shafts were hollow, it's good design for a shaft - the material on the central axis if the shaft is purely dead weight, it provides *no* strength.


Purely pedant mode here, should that be 'dead mass'?
Camshafts snapping prematurely - Number_Cruncher
Quite so BT
Camshafts snapping prematurely - bathtub tom
Thank you NC. I'll keeep quiet from now (or try to ;>) )
Camshafts snapping prematurely - susieque123
In reply to the above posts, the garage which removed my engine have told me they could see no reason whatsoever for my camshaft to have snapped. They say it is a clean break. I have had the car serviced whenever due, there was clean oil & filters on it?
I'm not a mechanic, but camshafts snapping on so many of these engines, surely it has got to be a manufacturing fault?
Susie.
Camshafts snapping prematurely - Number_Cruncher
If anyone has their broken camshafts, and the fracture faces aren't further damaged by running against each other, it might be worth taking some good quality pictures of the fracture faces and posting them up on a hosting site - *sometimes* it's possible to obtain hints from the appearance of the fracture surface about the cause of the failure (although to do it properly needs much more magnification than an ordinary camera can provide)

Camshafts snapping prematurely - ecarter674
My daughter's car broke down this week with exactly the same problem. It's only done 30k and just out of warranty. Reading all these messages is very depressing! I'm up for reporting them to Watchdog, Trading Standards & the safety group etc.
It seems to me that this model should have been recalled and all repairs for out of warranty should be paid by Vauxhall in full.
The car is still with a Vauxhall garage at the moment; I've asked them for a detailed report of what is wrong, what tests they've carried out, breakdown of estmated costs (inc. testing we are told!) & why head office are not willing to make a contribution.
I'm then going to write to Head Office detailing when it was bought etc, quoting sections of the Sale of Goods Act (not for for purpose), list of any other complaints I can get my hands on & get them to put in writing why they won't accept responsibility even though they have mounting evidence that there is a design fault in this model.
I expect they will refuse to make any contribution so, I will look for alternative estimates of cost & then pay to get the car back on the road.
I'll then use all of this evidence to go to the Small Claims Court.
I think that if I can evidence to the Court that Vauxhall know there is something wrong with this vehicle but are refusing to rectify that, I'll win...... that will then set a precident for all you other Guys to get your money back!
So, will you be willing to write me a letter (I'll draft out some ideas for you to follow) and allow me to use as evidence in Court?
We can't let them get away with this .... if we stick together, they'll have to pay up!
Look forward to hearing from you
Liz
Camshafts snapping prematurely - corsacamshaftfailure@yahoo.co.
Same problem yesterday with 1.2 Corsa 09/05 with 26k on the clock. Last service at 20K miles. Vauxhall customer service are not interested and have tried to suggest that they have no obligation to a vehicle that has been serviced outside of franchise which I confess the last one had been, although it was a Bosch listed service station that uses genuine parts.
My cousin happens to be quite high up in the BBC and I will speak to him later to try and get a good contact within the Watchdog office to take the case too. It would be helpful if anyone knows of any more links or forums where this problem is being discussed to get a justifiable number of people with the same issue for them to take an interest.
Camshafts snapping prematurely - ecarter674
If anyone would like to write me a letter (I will supply draft showing what information to include) please contact me at ecarter674 at aol dot com

I hope to hear from as many people as possible!
Thanks Liz
Camshafts snapping prematurely - Vansboy
I've mentioned previously, regarding the possibilty of taking legal action against a company/individual, something many will forget, that they probably already have 'Legal Cover' on their home insurance.

This is usually included, or added on for £20ish/year, offers free advice & covers a significant amount of the costs, towards action - assuming there is anticipated success - without it affecting premiums.

Might be worth a try!

VB
Camshafts snapping prematurely - x delboy x
I am reading all your messages and it feels a bit like dejavu. i to have a corsa breeze o5 plate it has a 1 ltr engine with 18000 miles on the clock, i was driving to school to pick up my son when it started to loose power the engine management light started flashing and it was making a back fireing noise. panicking i called a mechanic friend who got me to a garage, they put it on a machine to see where the problem lay.
I have been told that the camshaft has snapped and could cost in exsess of £400 pounds to fix. this is of course they do not find any more problems when the new camshaft has been connected up which is also common and could leave me hundreds of pounds out of pocket.

my queiry is that my car is only 3yr old and has full servise history so surely this problem should not have occured and also where do i stand with claiming compo.

WOULD GLADLY ACCEPT ANY HELP ON THIS ISSUE ASAP.
Camshafts snapping prematurely - pete and ed
My sons Corsa 1.2 sxi 2005 33k miles has experianced the same Cam Shaft failure,
It happened on the M5 in rush hour at 75mph.
I have investigated at the Vauxhall garage and talked to the mechanic, I was told that the screws holding down the Cam Shaft bearing Caps were loose, and could be unscrewed by hand. So it seems these bolts are not fitted correctly at the Vauxhall Assembly Plant.
I intend to fight for 100% compensation thru, the Small Claims court.
Camshafts snapping prematurely - Number_Cruncher
>>So it seems these bolts are not fitted correctly at the Vauxhall Assembly Plant.

You can't make this conclusion.

You might be right, but, there are other possibilities, and although you have an interesting piece of evidence, finding the bolts to be loose does not identify the root cause of the problem.
Camshafts snapping prematurely - pete and ed
I am a mechanical design engineer and I do make that conclusion.

1) The car has full Vauxhall Service History, although this problem would never be checked or found during a service.
2) The Vauxhall mechanic has stated on his work sheet, that 3 Cam Shaft Bearing Caps were Loose.
3) These bolts have no lock washers under the heads, and it seems they are only tightened to 8Nm of torque on initial assembly at the Vauxhall Assembly Plant.
4) Following are statements taken from a Corsa Workshop Manual:-
A)"Working in a spiral pattern from the outside to the inside,slacken the each bolts half a turn at a time. Ensure that the camshaft rises uniformly and does not jam in its bearings".
B)"Progressively loosen the bearing cap bolts, a half or one turn at a time,in the inward spiral sequence shown. this is necessary to progressively relieve the tension in the valve springs, and prevent undue stress on the Camshaft".
Just consider if any of these bolts (there are 10 per Camshaft) are not tightened to the correct torque, over the passage of time and miles, they will slowly vibrate loose, in a uncontrolled sequence and cause undue pressure on the Camshaft.

There are Corsa's being driven at the moment with a ticking time bomb under the bonnet.

I have sent a letter of intent to seek 100% compensation thru' the Small Claim Court.

Camshafts snapping prematurely - Number_Cruncher
You are nowhere near finding the root cause for this failure. The questions you should be asking now are;

Why were the bearing cap bolts found to be loose? What had caused the loss of preload in the bolts?

Is there evidence of them having been loose for a period of time?

Is there any associated damage to the cam bearing / housing?

Is there any evidence of fretting at either the joint face, or the interface under the head of the bolts?

Is there any evidence of pull through of the female thread in the cylinder head?

On the cam bearings which were not loose, is there any evidence of damage under the bolt heads? any evidence of bolt bearing stresses being too high?

What is the length of these bolts which were found to be loose? How does that compare with the length of a new bolt?

Did the bolts come loose before the camshaft broke?, or as the camshaft broke were the bearings overloaded?

I would hope very much not to see lock washers under bolts like this, lock washers have absolutely no place in a high performance non-relative-rotating joint.

>>it seems they are only tightened to 8Nm of torque

Depending upon the design of the bolt and joint, that may be correct - are they M6 bolts? (If I remember correctly, the cam bearing caps on my MB diesel are 10Nm)

A well designed and assembled bolted joint will not vibrate loose.

>>I am a mechanical design engineer and I do make that conclusion.

!!!


You can conclude that the joint has failed. At the moment, you can't ascribe a reason, cause, or mechanism for the joint failure.

Camshafts snapping prematurely - pete and ed
Why should I need to to find a reason for the bolt failure. The fact is, the bolts should not have come loose by them selves, these bolts should be to the correct spec,and fitted to the correct torque, which is the responsibilty of Vauxhall UK.
Camshafts snapping prematurely - Dynamic Dave
which is the responsibilty of Vauxhall UK.


It is the responsibilty of the designers/assemblers of the engine. Was yours a Vauxhall or Suzuki engine? You can't very well point the finger of blame at Vauxhall if it wasn't their engine.
Camshafts snapping prematurely - FotheringtonThomas
It was in the car that they supplied.
Camshafts snapping prematurely - pete and ed
Vauxhall UK problem,refer to posting above - Mon 16 Mar.
Camshafts snapping prematurely - Dynamic Dave
Vauxhall UK problem refer to posting above - Mon 16 Mar.


In which you said "I have investigated at the Vauxhall garage and talked to the mechanic, I was told that the screws holding down the Cam Shaft bearing Caps were loose, and could be unscrewed by hand. So it seems these bolts are not fitted correctly at the Vauxhall Assembly Plant."

Now who's to say that Vauxhall don't just buy these engines in ready assembled from Suzuki and bolt them into the Corsa engine bay. I can't see why Vauxhall would be assembling these engines at the plant when it's not their own.

Like you, I am surmising as I don't know the facts of where these engines are built either.

Edited by Dynamic Dave on 19/03/2009 at 18:44

Camshafts snapping prematurely - Number_Cruncher
I agree that it is Vauxhall's problem - they supplied this engine.

What I didn't agree with was the wording of your conclusion, which went beyond your evidence.

Camshafts snapping prematurely - pete and ed
Why dont you agree, the car has a full service history by Vauxhall, nobody has taken the Cam shaft cover of or done any work in this area, the last person to work on these bolts prior to the current mechanic would have been at the Vauxhall engine assembly plant.

ps Do you work at Vauxhall !!!
Camshafts snapping prematurely - Number_Cruncher
Here's what you said.

>>So it seems these bolts are not fitted correctly at the Vauxhall Assembly Plant.

There are a number of possible mechanisms where joints within which the bolts have been correctly fitted may fail. I presented a few possibilities in my earlier email - there are more.

You can say that the joint has failed, and no-one can argue with you, but, you cannot say that the joint has failed because the bolts were fitted incorrectly - you don't and cannot KNOW that.

By my objection to the wording of your conclusion, I'm not saying that Vauxhall are or are not to blame, only that the wording of your conclusion was not reasonable, and could not be reached by the evidence presented.
ps Do you work at Vauxhall !!!


No, I don't.

I am interested to find out what the root cause of the problem is from the point of view of my own technical curiosity, and I don't have an axe to grind either way with respect to your quest for some help from Vauxhall.

Of course, your arguments against Vauxhall will be strengthened by using sound engineering logic, and weakened by making statements which aren't supported by the facts.
Camshafts snapping prematurely - Lud
from the point of view of my own technical curiosity,


Likewise NC. But surely the finding of several loose camshaft bearing cap bolts in a car that has suffered this catastrophic failure must count as evidence in logic (if not engineering logic in its purest form)?

You yourself suggested, when I said the camshaft wasn't strong enough for the job, that a possible cause of the breakages might be faulty assembly, specifically the bolts coming loose. You gave a long list of possible causes for the breakages, including loose bolts and, if I remember correctly, two general reasons at the end: faulty design, and faulty assembly. Or, of course, 'a combination of two or more of the above' or words to that effect.

No doubt whoever makes these engines for General Motors has now tightened up, tee hee, its assembly checks; no doubt too that the company doesn't want to pay for any more replacement engines than it has to. But to a rational person, it begins to look as if assembly may be at fault in (obviously) a small proportion of these engines. If I had one of these cars I would have the cambox off immediately and torque those bolts down a whisker tighter than specification...

and I might check them again after 3,000 miles or so to see if they had come loose again.

Edited by Lud on 19/03/2009 at 17:29

Camshafts snapping prematurely - Number_Cruncher
>>You yourself suggested

Yes, absolutely, it's one possible cause, not necessarily THE cause.

Yes, it is evidence, again, there's no argument from me on that score, but, it's a starting point for enquiry, not a conclusion. We don't even know if it's a cause or an effect of the failure.

>>now tightened up, tee hee, its assembly checks;

Possibly - if the assembly process has been found to be at the root cause of the fault. If the assembly process isn't at the root of the problem, then any improvements in assembly procedure are tilting at windmills.

>>But to a rational person..

I can see the temptation, and assembly problems are a possibility. In problems with fasteners, it's very easy to blame the operators, and sometimes, that's valid, but, not always.

Yes, I too would be taking the cam cover off, but probably replacing each bolt in turn with new ones, torquing down to the exact specification given by Vauxhall.

>>down a whisker tighter than specification...

If these are M6 bolts, I don't yet know why they aren't torqued to 10Nm, which is a more usual spec - perhaps the female thread in the cylinder head yields in shear before 10Nm can be applied. I would be wary of going beyond spec - it's as likely to cause problems as to fix them, although I have in one case fixed a bolt fatigue failure problem on a rail vehicle suspension by identifying that the preload torque could be usefully increased.

As I'm sure you'll know, bolts don't necessarily need to rotate to become loose in the joint - there are other possible mechanisms.


Camshafts snapping prematurely - Lud
>> probably replacing each bolt in turn with new ones, torquing down to the exact specification given by Vauxhall.

Yes. That did occur to me as the correct solution after I had posted, these throwaway stretch bolts, or as you demurely point out, skimping on thread depth or metal quality in the cylinder head casting... I preferred it when things were too strong and made of iron and steel.

Don't you sometimes feel NC that production engineers and upstairs beancounters (perhaps with engineering backgrounds) sometimes yield to the temptation to cut things a little too fine? To put it another way, wouldn't you rather have a Subaru than a Corsa?
Camshafts snapping prematurely - Number_Cruncher
>>yield to the temptation to cut things a little too fine?

In your point, you raise a number of issues.

We don't always know where the cliff edge is. Although we are in a much better position than Victorian engineers who didn't have consistent material to work with, they didn't have the analysis tools, and they didn't have a good understanding of failure mechanisms which are routinely taken into account at desing time today. For example, the use of fracture mechanics methods to model and predict crack growth has really only become widespread and commonly used and accepted in the engineering community since the 1960s.

We never understand how close to the cliff edge our customer is going to go. If all cars were designed with the loads and stresses imposed by Grandma's weekly drive to church, cars would be falling aprt when used with more gusto and panache, but if cars were designed to withstand the rigours of the boy racer, they would be over-designed for everyone else. Somewhere in this broad mixture of usage, between pedantic fussing and abuse, the manufacturer must choose to set a design standard. It's not surprising that they sometimes get it wrong.

It easy not to realise there's a cliff edge there. Most engineering is standards based. If you want to design a welded structure, look at BS7608 to assess its fatigue resistance, look at BS5750 to assess its structural strength, if you want to design a bolted joint, look at VDI 2230, etc, etc. This is fine until you unwittingly go beyond the remit and scope of the standard - for example, the Millenium bridge as originally designed was compliant with the relevant standards of the time, but the phenomenon of lateral excitation by pedestrians beginning walking in step with the vibration was unknown at the time.

Camshafts snapping prematurely - Lud
Yes, I was most disappointed not to get to the millennium bridge in time to experience its Tacoma act...'Company.... break step!'

As for car design, I'll take the one designed to withstand the boy racer every time, and so will anyone else with any sense.
Camshafts snapping prematurely - Number_Cruncher
>>As for car design, I'll take the one designed to withstand the boy racer every time, and so will anyone else with any sense.

That's the one that's so heavy it can barely move, and don't even begin to think of the cost!

Camshafts snapping prematurely - Lud
Good heavens. I didn't mean survive for ever.

You wouldn't catch a boy racer in a thing like that either. I repeat: wouldn't you rather have a Subaru than a Corsa?
Camshafts snapping prematurely - Number_Cruncher
>>I repeat: wouldn't you rather have a Subaru than a Corsa?

Can I say neither?

However, as the car I drive every day is a W124, perhaps that answers the question obliquely.

Edited by Number_Cruncher on 20/03/2009 at 00:12

Camshafts snapping prematurely - Lud
a W124... perhaps that answers the question obliquely.


It'll do, NC, it'll do...

Camshafts snapping prematurely - crystalbaby
Hi there

The camshaft on my 55 plate corsa sxi, snapped on saturday evening whilst driving at 70 miles an hour on the motorway. My car has done 20,000 miles.
The mechanic looking at my car says he is quite concerned as to what has caused this to happen to a car that hasn't done many miles when there is plenty of oil in it.

I am just waiting on news as to what damage has been done to the engine. My car is 4 months out of warranty and Vauxhall have said they won't pay because I never had a service done in December, although I don't remember them saying when I bought it that if you don't have the car serviced every 12 months on the dot, it will result in huge damage to the car!

Can you please tell me how you got on with watchdog?

Thanks

SQ

Edited by Dynamic Dave on 05/03/2009 at 21:08

Camshafts snapping prematurely - Lud
From ones I have seen, camshafts are quite often pressure die castings on which the bearing journals and cams are then machined. They are hollow because they need to carry oil to the cam surfaces and bearings, although one assumes the oil pressure in valve gear is lower than it is at the bottom end.

It seems obvious that the camshafts for this engine are either badly cast, perhaps from iron that is too impure, perhaps with the central hollow not properly centralised, or are simply badly designed, not strong enough for the job. GM should supply new ones and fitting free of charge, or new engines with good camshafts, in these cases of premature breakage. In fact camshafts should wear out, very slowly of course, not break.
Camshafts snapping prematurely - Number_Cruncher
Yes, Vauxhall camshafts have been drilled for lubrication purposes for 30 years or so - it's nothing new.

As yet, there have been lots of posts on the subject, but nothing that would help anyone see what the root cause of the problem might be.

Camshafts snapping prematurely - Lud
Might not the root cause of the problem be weak camshafts? For example, how many bearings do they have? Valve springs are quite strong and if, e.g., there are only three bearings, some sort of resonant flexing or whipping of the camshaft might easily occur in certain rpm bands. And cast iron as we know isn't very elastic.

That camshaft is too weak. It needs to have thicker walls or be made of better stuff.
Camshafts snapping prematurely - Number_Cruncher
Might not the root cause of the problem be weak camshafts?

Yes, it might.

>>That camshaft is too weak.

Possibly, but, possibly not.

It could be a looseness in the drive causing whip

It could be a problem with the bearings becoming loose

It could be a misalignemt of the bearings causing bending of the shaft

It could be a misfire causing torsional oscillation

It could be a problem with the torsional damper on the crank nose

It could be a manufacturing problem

It could be a design problem

It could be poor material

It could be,.......

It could be a subtle combination of one or more of the above.
Camshafts snapping prematurely - Lud
All too likely I would think.
Camshafts snapping prematurely - 659FBE
More likely the GM bean counter division at work. Camshafts from India or China, perhaps?

659.
Camshafts snapping prematurely - susieque123
Hi,
I have posted on here previously as my camshaft has broken prematurley too.

Could anyone who has experienced this please either leave an email address on your posting, or email me at

susieque123 at tiscali dot co dot uk

Thanks
Susie.

Edited by Pugugly on 07/03/2009 at 07:29

Camshafts snapping prematurely - crystalbaby
Ok, had the damage to the engine assessed........the valves are bent and the head gasket is knackered. Its easier/cheaper to get a new engine/refurbed engine fitted than paying for all new parts seperately. The mechanic looking at the car is wondering whether there is a fault with the oil pressure thing in the engine? This is something that wouldn't have been picked up on in a service anyway, or so I'm told.

Anyways, I will NEVER buy another vauxhall car again.
Camshafts snapping prematurely - radio listener
Hi all

Don't know if this is any help but I live in Bedfordshire and one of our radio stations, BBC Three Counties, has been talking about this issue today. They have apparently received several calls and are asking for people to make contact with the same problem. They have not mentioned the vehicle but I think it obvious from he discussion that it is the same one.
Their website is www.bbc.co.uk/threecounties and the programme is the Jonathon Vernon-Smith programme. Their number is 0845945555. It may be worth a few of you getting in contact as they seem to be quite interested in the problem.
Camshafts snapping prematurely - bathtub tom
Don't bother wasting your time.

I've tried contacting this person at this radio staion myself on more than one occasion, to no avail. He doesn't respond.

I was tuned in to the station yesterday while waiting for an updated traffic report and he was having a rant about companies not responding to communication!

This is also the station that has stopped traffic reports automatically switching to radios in TA mode, because, allegedley, of complaints from listeners. They don't seem to understand that anyone tuned to the station will still get the traffic reports, while anyone not tuned to the station need only to switch off TA mode.
Camshafts snapping prematurely - radio listener
Totally disagree. They are based in Vauxhalls plant area so have a local interest. Someone has also told me they were talking about it yesterday as well so assume you must have heard it!

For all those with the problem losing large sums of money on the repairs surely any attempt to get something back must be worth trying, especially when free!
Camshafts snapping prematurely - Eddieuk
Hello all..

i bought a corsa C, 1 year ago for just over 6 grand.

I was on the motorway last monday, tryed to overtake a lorry and lost all drive and coasted to the hardshoulder. Anyway i found out the it had snapped, and the engineer told me that it was because it was built with some screws loose that caused it to flex and snap in half.

I rang up vauxhall but they are only willing to give me a 30% discount

total at the moment is £1200 and im extremely anoyed as i cant get the work, because i cant get a hire car because im only 20

only 30k miles on the clock and its on a 55 plate

Edited by Eddieuk on 13/03/2009 at 20:03

Camshafts snapping prematurely - corsacamshaftfailure@yahoo.co.
Hello all,

This happened to me a couple of weeks ago and I have just had a repair bill of £1700.

Vauxhall will not do anything to help and their attitude has made me very angry.

I have been in contact with the BBC Three Counties radio programme mentioned elsewhere in this forum. They have been extremely helpful so far and are taking the matter seriously as they appear to have had several other callers with the same problem and I have also made them aware of this forum.

I have put together a quick list of all of the similar cases that I have found on the internet and have found many other people that this has happened to. Interestingly almost every car is the 1.2 engine within a timespan of 4 months of age and within 10k miles of each other when the problem occurs.

The garage has given me back the broken camshaft, which is hollow, and the metal at the break is dull and powdery suggesting a faulty product.

I have set up an email address, corsacamshaftfailure@yahoo.co.uk, should you wish to forward me your contact details and outline your problem as I do not intend to let this rest and can keep you updated on progress.

Alternatively if you wish to contact BBC 3CR yourselves I am sure they would be interested to hear from you.
Camshafts snapping prematurely - Number_Cruncher
and the metal at the break is dull and powdery suggesting a faulty product.


How do you reach that conclusion? Can you post a picture of the break? (that'll have to be on another site).

I haven't seen anything that would allow anyone to say what the root cause of these failures actually is.