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Fiat JTD crank/ RPM sensor removal and replacement
If your JTD cuts out intermitantly and then restarts after a while, this is for you!
Published by a1ant
24-05-2008
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Fiat JTD crank/ RPM sensor removal and replacement

Diagnosis:
A common fault with JTD engines that have done over 50000 miles is intermittent cutting out. This normally occurs once then engine has warmed up, and the engine will the simply cut out. Often, it will not restart again until it has been left for a while to cool down a bit. However it will turn over fine. Once the engine has restarted, it will then run fine again for a while, until again it cuts out. This is a common fault, and classic symptoms of a faulty crank shaft sensor or RPM sensor as it is sometimes known.
A new crank/RPM sensor will set you back about £30-40 from Fiat, or around £20 from somewhere like Shop4parts.co.uk
  • Jack front of car up and support on axel stands, or use ramps. Don’t work under a car just supported by a jack! If it fails, it WILL hurt!
  • Undo the 5 bolts that secure the undo tray to the car. 3 torx bolts at the front, 2 x 10mm bolts at the rear. Remove the under tray from the car.
  • Crawl under the car and look up at the rear side of the engine.. Just the right of the exhaust, you will see a large red cable clipped into a plastic bracket. There is also a smaller black cable. This is the lead for the RMP/crank sensor.
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  • At the top of the bracket, the connector for the crank sensor is clipped into the bracket. This is almost impossible to remove in situ, and the easiest way to disconnect it, is to remove the single 13mm bolt that secures the plastic bracket the rear of the engine.With the 13mm bolt removed, pull the plastic bracket down, and unclip the crank sensor connector from it. Then disconnect the crank sensor connector.
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  • Now follow the black cable back towards the rear left hand side of the engine, just below the starter motor. The crank sensor is bolted into the engine with a single T40 Torx bolt. Undo the torx bolt and pull the crank sensor out of the engine. Be careful as it may have oil on it and you don’t want it in your eye!!
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  • Make sure that the rubber washer that sits around the base of the sensor is removed too.
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Replacement is the reverse of removal!

Hope that helps,
Alan
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Old 04-06-2008   #1
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Can this actually stop the car from starting? I have a JTD Multipla and from time to time it won't start but turns over fine and runs fine all other times. I have been told it is the RPM sensor. But I have also been told it could be the high pressure fuel pump anf the EGR valve.

What would you say?
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Old 04-06-2008   #2
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Hi there, and WELCOME TO THE FORUM!!

Yes a faulty crank/rpm sensor can stop the car starting. It basically controls the injectors so without a signal the injectors do not fire, and thus the car turns over fine but does not actually start. I would not have though a faulty EGR would prevent the car from starting as it only really starts working once the car is up to temp.
Fuel pump could potentially also cause it to not start, but it is unusal for a fuel pump to not give any other symptoms.

Alan
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Old 05-06-2008   #3
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Ive been having problems starting as well as cutting out, the crank sensor will show up on a diagnostic test right?
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Old 06-06-2008   #4
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Hi mate,

Yes it should show up on diagnostic, but if its just inside tolerances but giving a poor signal it may not. If its cut out and the engine management light has come on then the fault code should be stored.

Alan
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Old 15-06-2008   #5
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Hello, My name is Hans and I'm from the Netherlands.


I did buy my Fiat Stilo 1.9 JTD 115 Pk in 2003, but I think it is build early 2002.

Engine version 192BXE1A 09
I have had a lot of problems with it, to much to tel here.

Recently the problem is similar to what is described here but,
I do not have the “Lose connection” warning.
the motor stops running, I get a “Engine Failure” and sometimes “Low oil pressure“
Have to wait a couple of minutes before it will start again.
Sometimes I also hear a gargling sound form behind when a turn on the contact key.

The dealer cant find the problem and advices to replace a € 300,- part and pray for good luck.

NO WAY.

Can this be the same problem or can I better have inspection at the fuel pomp first.
Can I do some measurement to find if the crank sensor is okay or not?
I have the backseat on a real sliding forward and backward, believe the fuel tank is underneath, any advice how to get there?
Well thats a lot of questions for a newbie is it not.


Hans.
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Old 07-08-2008   #6
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Re: Fiat JTD crank/ RPM sensor removal and replacement

I have had some starting problems with my multipla diesel. It starts fine when cold but after a journey will not re-start but turns over. After replacing the EGR valve (problem not solved) the Fiat garage then said it could be the RPM sensor, which having read other posts seems possible. I have also been told that it could be the crankshaft itself that is the problem. Not wanting to buy a new engine can anyone shed any light on this?
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Old 05-09-2008   #7
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Hi mate,

Sounds like Speed/Crank sensor to me. Would be unlikely to be the crank shaft itself damaged.

Alan
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Old 17-10-2008   #8
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Thanks for this post. My multipla had the exact problem. Without your detailed post here I wouldn't have been able to fix it myself - although it was damn fiddly with such poor access.

After fitting the new sensor the car wouldn't start at first. To get it to work I had to remove a small ring at the base of the new sensor. This allowed it to be pushed further into the engine. I guess the same part is made to fit two different engines.
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Old 18-10-2008   #9
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Nice one! Glad it helped.

Alan
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Old 20-01-2009   #10
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Quote Originally Posted by OldMan View Post
Hello, My name is Hans and I'm from the Netherlands.


I did buy my Fiat Stilo 1.9 JTD 115 Pk in 2003, but I think it is build early 2002.

Engine version 192BXE1A 09
I have had a lot of problems with it, to much to tel here.

Recently the problem is similar to what is described here but,
I do not have the “Lose connection” warning.
the motor stops running, I get a “Engine Failure” and sometimes “Low oil pressure“
Have to wait a couple of minutes before it will start again.
Sometimes I also hear a gargling sound form behind when a turn on the contact key.

The dealer cant find the problem and advices to replace a € 300,- part and pray for good luck.

NO WAY.

Can this be the same problem or can I better have inspection at the fuel pomp first.
Can I do some measurement to find if the crank sensor is okay or not?
I have the backseat on a real sliding forward and backward, believe the fuel tank is underneath, any advice how to get there?
Well thats a lot of questions for a newbie is it not.


Hans.
Dear Hans. I have Fiat Stylo 1.9 JTD 2003 with some problem like you.
"Engine fielure" and "Low oil presure" If you have some advice please write me. Pleeeeeease. Tank you.
Laci
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Old 16-02-2009   #11
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Hi Alan

The information you posted regarding this information was excellent but unfortunately it did not solve my problem.

I think it has something to do with the amount of fuel I have, when low it will cut out and if I keep turning it over for about 30sec it will come to life.

In day to day driving it sometimes seems as if there is momentary lose of power/fuel starvation.

Have you any ideas?

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Old 25-03-2009   #12
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Nice tutorial. Mine just had this sensor changed in the weekend
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Old 30-03-2009   #13
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Re: Fiat JTD crank/ RPM sensor removal and replacement

just like to say thanks for your guide to replacing crankshaft/rpm sensor. knowing what the job entailed (process, tools etc.) really really helped. Damn fiddly to get to though !! pictures helped enormously. Great job Alan.
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Old 31-03-2009   #14
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Re: Fiat JTD crank/ RPM sensor removal and replacement

Thanks,

Im glad it was of some use

Alan
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