VAUXHALL ASTRA GTE MK1 CAR PERFORMANCE SPORTS TURBO
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Urgent Help please.
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Ash
Space Kadett
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Joined: 29 Jul 2005
Posts: 4717
Location: Germany/Morecambe

PostPosted: Thu Jun 05, 2014 9:23 pm    Post subject: Urgent Help please. Reply with quote

Hi everyone. Ok, driving back to work from Oschesleben I pulled up just before work and noticed a funny noise coming from the engine (Z20LET).
Then the oil light came on.

I gave it a few revs and the oil light went out but the noise persisted.
The oil light comes on at tick over permanently but goes out once revved.

I parked the car and looked under the bonnet.
A large Vacuum pipe had come off and was sucking air into the intake.

I reconnected the pipe and the engine stalled.
I started the engine again and it ran but very rough. Grumbling away.

I thought "ah sh$t, i've fucked it but its 11 at night and I can't do anything about it now.

I tried to start the car in the morning and it refused to start on any of the cylinders.

I flashed the codes and got P0170, fuel trim bank one malfunction.
Googled it and found lots of people with the same problem but nobody who had posted a cure once they fixed it.

I pulled the dip stick and noticed a very light metallic sheen to the oil.
I dropped the oil and put a magnet in the oil overnight. I had a small amount of metallic sludge but not big bits flakes or other evidence of major failure.

I made a Heath Robinson compression tester and tested all four cylinders.
Everyone but number 2 was ok. I thought, piston or a valve is toast at this point.

I pulled the head off it and found that the pisons and valves are ok.
I tested the valve seats and only one set didnt leak.

At this point I stripped the turbo but everything seams fine with that.

Sooooo, what could of caused low oil pressure and no compression on number 2?

I tried to remove the hydraulic lifters to see if i've clipped a valve but I can't get them to release. Does anyone know how to do this?

All in all I'm at a loss. It might be big end shells but I haven't managed to strip the bottom end off yet. All this is being done after work on the street.

Can anyone help please?
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DeadEye
Astra Legend
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Joined: 14 May 2007
Posts: 4534
Location: Oxfordshire

PostPosted: Thu Jun 05, 2014 10:12 pm    Post subject: Reply with quote

What dies the funny noise sound like exactly?
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Jon_Kadett
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PostPosted: Thu Jun 05, 2014 11:16 pm    Post subject: Reply with quote

Sounds like the oil pump has gone, and not sure on the rest of the faults. Maybe the turbo has seized?
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Ash
Space Kadett
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Joined: 29 Jul 2005
Posts: 4717
Location: Germany/Morecambe

PostPosted: Fri Jun 06, 2014 1:21 am    Post subject: Reply with quote

The oil pump has 130k miles on it and that was one of my concerns.
The engine will not run, (before I took it to pieces) it sounded like a car with a very loud timing chain. "rattle rattle".

Unfortunately the car is at that point in its life that it will be better financial sense to scrap it than repair it. I'm going to drop the bottom end tomorrow and look at the shells. If they are goosed, Good bye Astra Coupe Turbo
Crying or Very sad cry baby mad
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Sparko
Astra Messiah
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Joined: 03 Aug 2006
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Location: Essex

PostPosted: Fri Jun 06, 2014 8:53 am    Post subject: Reply with quote

Aww man :/ maybe we jinxed it at osch
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tuffty
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PostPosted: Fri Jun 06, 2014 8:56 am    Post subject: Reply with quote

If the oil pressure is too low the hydraulic tappets won't fill enough and will cause the valves not to open properly, which could be your starting issue.
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Ash
Space Kadett
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Joined: 29 Jul 2005
Posts: 4717
Location: Germany/Morecambe

PostPosted: Fri Jun 06, 2014 9:31 am    Post subject: Reply with quote

I'll order a new oil pump and rebuild stuff and see how that goes.

Ben - I think it got jealous. I should of at least washed it. The thing with this car is every time I do preventative maintenance. It spits its teddy out 48 hours later and refuses to work.

Whenever I change the oil I can almost guarantee it will eat another AFM, boost solenoid or MAF sensor. Its had at least 4 AFM so far.
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Ash
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Joined: 29 Jul 2005
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Location: Germany/Morecambe

PostPosted: Mon Jun 09, 2014 11:14 pm    Post subject: Reply with quote

I've taken most of the engine apart now and found no evidence of failure.

I believe it was oil pump as the cams and carrier assembly is lightly scuffed. It was so minor I polished it out with 1500 wet and dry in about 2 minutes per cap.

It must of given up as I was driving to work and I managed to catch it before any real damage was done. big grin

The head is getting rebuilt with new stem seals. The valves are caked in sh$t which I think has come from leaking stem seals.

It should more efficiently when all's done.

As for the metal i'm flushing the entire engine then once rebuilt drop the oil and change the filter after about 100 kms.

Its not a total rebuild but still cost almost 600 quid in parts alone.
Autovaux have supplied all the parts at a fraction of the cost you have to buy them here in germany. They are very helpful and I would recommend them.

The Hydraulic valve lifters just pull out but they do not want to come out for love nor money. Stubborn little buggers.

I even considered changing the gearbox as it crunches in 2nd but i've ran out of funds. At least when I do I know I can get all the bolts undone ok.

The subframe bolts under the wheel arches snapped of and sent me flying.
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Ash
Space Kadett
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Joined: 29 Jul 2005
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Location: Germany/Morecambe

PostPosted: Sun Jun 22, 2014 11:42 pm    Post subject: Reply with quote

Its been a while but I've found the culprit.

The Z20LET has balancer shafts fitted to the crank which smooths out the engine.

When I took the engine apart I took them off and thought nothing of them.
I had a closer look today and one of the shafts has moved and mangled one of the cover plates. It looks like one of the balancer shaft bearings has failed.

At least when I rebuild the engine I know is almost new and I found the problem.
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Jon_Kadett
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PostPosted: Mon Jun 23, 2014 12:51 am    Post subject: Reply with quote

Get the vxr balancer shaft delete kit. They apparently take 5bhp off your motor.
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warphi1970
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Joined: 15 May 2007
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Location: Bristol

PostPosted: Mon Jun 23, 2014 8:43 am    Post subject: Reply with quote

Jon_Kadett wrote:
Get the vxr balancer shaft delete kit. They apparently take 5bhp off your motor.


but surely they are there for a reason?

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Ash
Space Kadett
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Joined: 29 Jul 2005
Posts: 4717
Location: Germany/Morecambe

PostPosted: Mon Jun 23, 2014 6:19 pm    Post subject: Reply with quote

I did look into a deletion kit but I was put off by a few factors.
They cost 150 quid without postage and in the description it says that they should be used with a lightened and balanced crank.

I haven't got either of those things so i'm buying a second hand set for 1/3rd of the price and keeping her standard as this rebuild has wiped me out.
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Jon_Kadett
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PostPosted: Tue Jun 24, 2014 3:14 pm    Post subject: Reply with quote

A standard z20let will run better without the balance shafts. They are completely unnecessary on a 4 cylinder engine.
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Ash
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Joined: 29 Jul 2005
Posts: 4717
Location: Germany/Morecambe

PostPosted: Wed Jun 25, 2014 8:08 pm    Post subject: Reply with quote

I totally agree mate but its an extra 100 quid I just do not have.
Now I know the engine is going to be very healthy when I put it all back together then I might think about tuning it a little but only mildly.

Balancer shafts are meant to zap up to 10bhp which isn't bad for 150 quid.

I've seen on ebay you can get chips you solder in to your loom and gain as much as 20% more power. Not bad for 9.99 laughing

I have the knackered shafts so I can cut up the girdle and make my own kit.
To be fair its pretty simple and could be made from stuff down the DIY shop.
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Ash
Space Kadett
<font color=#FF8000>Space Kadett</font>


Joined: 29 Jul 2005
Posts: 4717
Location: Germany/Morecambe

PostPosted: Mon Jun 30, 2014 11:09 am    Post subject: Reply with quote

A used set of shafts arrived today and now I have something to compare, the old ones are well and truly buggered!

Let the rebuild commence cheers Dancing Pray

I took the head apart last night and the deposits on the exhaust valves are at least 2mm thick. The Valve stems must of been proper knackered.

It only used oil when doing stop start driving. It would do 1k miles on about 300ml of oil. Around town it would eat 500ml in a week.
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