Astra Mk4 – Bitten off more than I can chew?

23/09/2024 – So, now I have a MK4 Astra..

So, picked up this wee beast from a family member at the weekend to get my hands back in to mechanical work, bodywork and such – a 2004 MK4 Astra Auto.

We have a fair bit of work to do just to get her drivable, and over 80 error codes logged in the ECU when plugging a computer into it.
The bodywork has seen better days, as has the paint – but for the most part – things look fairly solid, just the usual Vauxhall arches, and likely sills once I get the covers off and have a poke about and the fuel filler port, which I’ve never seen before on a Vauxhall in my ownership.

As you can see, she’s looking a bit sorry for herself, a good clean will do wonders I am sure. Engine is misfiring, so hopefully that is something straightforward (plugs, coil pack or leads).
New camshaft is on the shelf ready to go in which will happen in a couple of weeks time (lobes are worn for cylinder 3 and 4).

24/09/2024 – Astra has a bath.

So today, I was looking at the wee beast, and though to myself – she needs a bath, the weather here isn’t the best, so it was a bit of a quick rinse rather than a proper wash and clean up, however – the results are a little better than I was expecting.

05/10/2024 – Christmas comes early for the Astra.

So, the Astra was in dire need of a service. My friend John came round and we got to work. Plugs, oil, oil filter, air filter. The difference was immediately apparent, from missing on cylinder 2, to running solidly, but still rich.

Christmas comes early?
Number 2: Plug has taken a hit
Dirty, dirty plugs
Breathing issues… no wonder it sounded like a two stroke!
Anyone have this part?
Temporary Repairs
Is that normal? Plug hole seems a little damaged.
Headlights are cloudy as sin..
Masking up.
Star of the show
Polishing up – shows a different.
It’s a little better again
And clear coated, polished – lets see how long that lasts..

So, after that little bit of work, codes started to clear up. The exhaust is leaking at the flexi, so a new front section has been ordered (£42 quid). That should then sort the running rich issue. As watching the information live via Op-Com, showed the lamda readings fluctuating, and the levels trying to straighten themselves out, so it’s not a lamda issue.

In the next couple of weeks, a new Cam shaft, and fitting the exhaust front section will be done (weather permitting. After which I am in two minds to put the Astra in for an MOT, or continue doing more work for now.

The header tank for the coolant was almost empty, and has been topped off, the coolant that is in there appears ‘greasy’ so unsure if the head gasket is away, compression test is perhaps on the cards. I need a cam cover gasket anyhow, so ordered an Elring headset for around the same money that the gasket would have cost anyhow – got to love a bargain!