My grey GTE [Archive] - Page 2 - Astra MK2 Owners Club

johnl

10-08-2009, 08:22 PM

Well nipped down to the parents (cars second home) so I could strip the head down so it can be taken to the machine shop tomorrow.

Looks like the heads got a hair line crack and isn't just a chip just uploading the pictures at the minute.

Cheers for the kind comments about the car Ian, I'd love either a gsi or Turbo but I'd probably miss the GTE. Might look at getting one if I can arrange storage for one of them

Ian T

10-08-2009, 08:26 PM

Kind comments are welcome as you know.

I had an Omega head TIG welded to repair a blown-through land between two bores for about £40 a few years ago, they obviously had to skim it at the same time, so what I got back was a head with an immaculate mating surface at the end of it. I'd think your crack could be dealt with in the same way, grind out and weld fill, then face off.

Can't see it being a problem unless you've had it skimmed a couple of times already, even then you could use a 'special' gasket.

Ian.

johnl

10-08-2009, 08:32 PM

Just the news I wanted to hear :D

heres the pictures for the diary's sake

http://www.valver.co.uk/astramk2/headgasket/DSC02014.JPG

http://www.valver.co.uk/astramk2/headgasket/DSC02010.JPG

johnl

11-08-2009, 12:30 PM

Well the heads with the engineering shop. They are going to get back to me with what they are going to come back with if it can be sorted or not and the costs.

johnl

28-08-2009, 11:21 AM

The engineering shop got back a couple of days later. The crack went all the way to the valve seat so the heads scrap. Sourced a replacement head from Cemex Which my parents collected last Sunday for me. Due to work commitments I paid the machine shop to check the head over and clean it etc. £100 lighter and heres the result.

http://www.valver.co.uk/astramk2/bits/DSC02189.JPG

http://www.valver.co.uk/astramk2/bits/DSC02190.JPG

Plan is to try and get it all fitted over the weekend. Should be possible however I'm on call so that could eat into the car time quite a bit.

mike2007

28-08-2009, 01:00 PM

That was a good read. ausome work done on the car buddy.

Gteman

29-08-2009, 12:02 PM

I'm glad your sticking with it John the head should only take a couple of hours to refit if you get your finger out m8 :veryhappy:

johnl

01-09-2009, 12:50 PM

Well I made a start on the car this weekend. Didn't get as much as I would have liked done due to waiting on the head bolts and also getting called out due to work.

Here's how the car was left after stipping the head off.

http://www.valver.co.uk/astramk2/2009/DSC02177.JPG

Anyway spents a while cleaning the block and pistons. Didn't get any pictures though. Even stuck the over flow bottle in the dish washer but it didn't come out much cleaner :( Going to attack it again with some degresser and try again,

Anyway got the Head on the block

http://www.valver.co.uk/astramk2/2009/DSC02204.JPG
http://www.valver.co.uk/astramk2/2009/DSC02205.JPG

Removed the protective tape from the inlet side ready to fit the inlet manifold when I got called out.
Thought I'd grab a pic of the the valves Would love to know what they used to clean the head and the valves up.

http://www.valver.co.uk/astramk2/2009/DSC02206.JPG

At the minute the Later style head bolts are on holding the head in place. I'm off work tomorrow so will be picking up the washers for the early style bolts so with any luck the car should be running again tomorrow night. Although it depends on What Anna has planned for tomorrow as we're both off work.

johnl

06-09-2009, 08:46 PM

Well the cars all done and running again :D Will upload the pictures tomorrow. Going to replace the oil pump soon with a z20let oil pump

richie00boy

06-09-2009, 09:18 PM

The head will have been dipped in a very nasty acid. The valves have been put in a bench drill and sanded smooth.

Did the engine place do the porting or was it already like that?

johnl

06-09-2009, 10:52 PM

Ports were already like that.

richie00boy

06-09-2009, 11:07 PM

Bargain then! Does it feel any different?

johnl

06-09-2009, 11:18 PM

It does feel a little more responsive than it did but not sure if thats cause the other head was cracked. It didn't at 1st nearly had a few bent valves. Timed it all up and turned the engine over by hand all was good. Turned it over on the starter motor with the plugs out etc and then checked the timing still was good so started it up and it ran fine for about a minute then it started hunting on the revs. Nearly died a couple of times so I turned it of thought I'd double check everthing only to find the auto tensoner had moved so the inlet pulley was nearly a full tooth out :hissyfit: Re did the timing and tripple checked everything and it was fine.

Think the pressure relief value is sticking slightly/slow to respond some times though or one of the tappets are a little lazy. As it's got a tapping noise that keeps coming and going every so often. So going to check it over tomorrow after work. When I say every so often it does it for around 2 minutes and then stops for at least a good 20 minutes.

johnl

07-09-2009, 09:45 AM

Well as promissed here's the pictures.

Cam's re fitted.
http://www.valver.co.uk/astramk2/2009/DSC02215.JPG

All finished bar the air box. Really does need a tidy up in here.
http://www.valver.co.uk/astramk2/2009/DSC02225.JPG

Could have sworn I took more pictures but can't find them.

johnl

08-09-2009, 09:40 AM

Well removed the oil pressure valve and cleaned it out. Refitted it. Can see why most GTE's don't have the under tray on. Adds quite a bit of time to doing some jobs on the car. Anyway started the car up no ticking noise. Left it ticking over for a good 10 minutes still no ticks. Turned it off. Put the tools away and then took her for a test drive. Everything was ok still no ticking/tapping. Did around 20 miles and then the tapping returned. So I drove the final 2 miles home got there as I pulled on the drive the tapping stopped. All I know is the noise is coming from the top end of the engine. Sounds like a single tappet. Going to see if I can track down which one it is. Also need to look at the alternator as it's making a whining noise. If I slacken the belt it slips. Take the belt off and rotate the alternator by hand it sounds a little rough. Part of me wonders if it's the alternator thats making the tapping noise.

johnl

12-09-2009, 04:57 PM

Well I cleaned a set of tappets following the guide that was posted up on here. Anyway fitted them today took the car out for a test and they are still making a racket. Going to drive it for a little while and see how it goes. Might try and source a decent replacement engine there again I might just cut my losses and except GTE's just not meant to be.

Joker

16-09-2009, 06:34 PM

don't give up hope mate, good thread. I'm going to be cleaning my head soon. Looks very clean after a dip! Nice work.

Joker

johnl

17-09-2009, 08:56 AM

Well car's been given a stay of excution. :D Thought I'd try some engine flush on it So last night I put some engine flush followed the instructions as run and then droped the oil. Fitted some of Vauxhall's finest 10 40 in and fired her up. Tappets made a noise for around 5 seconds and then stopped. Took it for a test drive and still quiet. Nipped down to my parents on the way home had a blast with a Vectra GSI going up the slip road to the motorway. Wasn't much in it but I believe the timings out on the car as it's a little rough at tickover I put it down orignally to the tappets not pressurising properly but now there're sorted It can only really be the timing now. Going to sort that tonight after work. Either way engine will be coming out of the car and going on ebay. As I have another plan for the car now.

johnl

04-10-2009, 09:04 PM

Well today I picked up the xe that Mick G had for sale from his Champion. It's currently sitting in the back garden with a sheet of plastic over it to keep the elements off it before I get it fitted. Plan to give the block a lick of paint and do belt change and water pump. Then I'll get the old engine out and sell it and fit this one. It's either going to be done this month or the start of next month depending what day's I can get off work.

johnl

12-10-2009, 01:34 PM

I've booked 2 day's of in the 1st week of november to carry out the engine change. In the mean time I'm getting a list of bits and pieces I need to carry out the covnersion. On a plus note I've got use of the garage at my dads work again to carry out the work so should keep us dry. Dropped the engine off there yesterday into a make shift engine trolly. Will get a picture and post it up when I get my phone back from O2 as its in for repairs after getting wet in the rain. Will also be putting a coat of paint on the block.

johnl

17-10-2009, 06:37 PM

Well as promissed here's the pictures of the engine trolley.

http://www.valver.co.uk/astramk2/lastchance/DSC02277.JPG

http://www.valver.co.uk/astramk2/lastchance/DSC02278.JPG

http://www.valver.co.uk/astramk2/lastchance/DSC02279.JPG

Now I'm not 100% sure but i don't believe the engine has been cleaned whilt in Mick's car or after it was removed but it looks like the sump gasket doesn't leak and the block seemed very clean especially when compared to the engine I removed out of the calibra which was mean to have had quite a bit of work doing to it.

Anyway an hour later with some engine paint and wire brush

http://www.valver.co.uk/astramk2/lastchance/DSC02286.JPG

http://www.valver.co.uk/astramk2/lastchance/DSC02288.JPG

not finished yet :) going to let it dry and then will put another coat of paint and clean the top half of the engine.

johnl

06-11-2009, 08:20 AM

Whilst I've not posted much on here over the last week I've not stopped spending the odd 20 minutes here and there on it. Just had a few other things that have taken priority. Anyway I managed to lend crane from one of my mates :D So started working on the car yesterday morning around 10am By 12 the engine was out. Took it out through the top. Just had to shift the oil filter and bottom pulley. Also withdrew the input shaft. Anyway with the engine removed I slapped some paint in the hard to reach places and got some food whilst waiting for it to dry. Fitted the new engine but had to leave it at that as I'm waiting on stuff from AutoVaux to arrive. Here's hoping it's hear today then I'll be able to finish it all off. Didn't really get much in the way of pictures so will make sure I take plenty today.

Davey J

06-11-2009, 12:29 PM

Nice to see my old GTE alive and kicking. Surprised you have had so much bad luck with it man!

1st time I have seen the thread too. Tom Stickland never owned this motor by the way. He sold it on my behalf in my absence away from the workshop. Shame I had to sell really, but then I have what I have now as a result...............and I am happy.

Keep up the good work matey.

johnl

06-11-2009, 08:30 PM

Well after chasing the order from AutoVaux they didn't have the nut's for the inlet and exhaust manifold in stock they've not sent the rest of the order. So waiting till Monday now for all the bits to arrive. Not to fussed as I'll spend a few hours this weekend. Cleaning the bay etc up.

johnl

09-11-2009, 08:53 PM

Well here's the engine been removed although the rope looks a little long I re-adjusted the rope to a better length.

http://www.valver.co.uk/astramk2/lastchance/DSC02345.JPG

There was a nice big parcel waiting when I got home :D
1 Timing belt kit
http://www.valver.co.uk/astramk2/lastchance/DSC02350.JPG

1 set of inlet gaskets inlet and exhaust
http://www.valver.co.uk/astramk2/lastchance/DSC02351.JPG

1 new oil pressure sender, 1 bosch Lambda sensor and exhaust studs.
http://www.valver.co.uk/astramk2/lastchance/DSC02352.JPG

1 water pump and throttle body gasket and a cv joint.
http://www.valver.co.uk/astramk2/lastchance/DSC02353.JPG

One cleaned and painted inlet manifold
http://www.valver.co.uk/astramk2/lastchance/DSC02354.JPG

Going to make a start on fitting them all tonight after work.

richie00boy

09-11-2009, 09:26 PM

Do you still need that waterpump then mate?

Also can you resize your pics as they are huge and your thread takes an absolute age to load and slows the whole internet connection down! I use the program from www.xnview.com to do it, suggest 640x480.

johnl

09-11-2009, 10:16 PM

Will send you a pm about the water pump.

Resizing the pic's now. lol I'd forgot all about doing it when i've been uploading them

mick g

10-11-2009, 08:41 AM

It's looking good mate, lots of shiney new bits too:thumbsup:

johnl

10-11-2009, 08:49 PM

Well I've spent a an hour or two today after work. Got the oil pressure switch fitted and bottom engine loom.
http://www.valver.co.uk/astramk2/lastchance/DSC02355.JPG

Rear water pipes inlet manifold throttlebody called it a night at 8 as had to get my mum from the hospital. Here's how I left it last night
http://www.valver.co.uk/astramk2/lastchance/DSC02357.JPG

richie00boy

10-11-2009, 09:12 PM

How much are the pressure senders? I imagined they would be quite expensive.

Mr-G

10-11-2009, 09:13 PM

about £40 iirc?

johnl

10-11-2009, 09:35 PM

from Vauxhall they are about £100 from what I remember. G's right with the price from AutoVaux about £37 plus vat

Mr-G

10-11-2009, 09:37 PM

the thing that shocks me is that vaux sell them for £100, autovaux sell them for £40 and yet both parts are supplied by Bosch?

johnl

10-11-2009, 09:39 PM

the thing that shocks me is that vaux sell them for £100, autovaux sell them for £40 and yet both parts are supplied by Bosch?

Tell me about it. The parts guy at vauxhall couldn't believe the price when he checked it for me. He did however recommend autovaux and a couple of other parts places.

Mr-G

10-11-2009, 09:46 PM

I have a general idea of what it will be Bosch are one of our main suppliers at work and i speak to the Kent depot on a regular basis. they price and supply on a demand basis, If autovaux are purchasing in larger and more regular quantities then vauxhall then Bosch will do them a much better price, therefore they can afford to sell it much much cheaper.

When i bought the new discs and pads for my GTE my local vauxhall dealership quoted me £39 for GM equipment. I phoned Bosch and being a good customer of theirs i paid £28 for Bosch discs and pads ;)

johnl

11-11-2009, 09:08 PM

Well only managed to get an hour on the car tonight. Not all bad though oil filter oil cooler pipes and oil cooler all fitted. Didn't manage to get any pictures.

Got the following left to finish off
1, fit exhaust manifold
2, fill with oil
3, fit injector loom
4, refit bonnet
5, reconnect selector
6, flush rad
7, refit front bumper
8, fit rad and connect the water pipes
9, fit power steering belt and alternator belt.

With any luck will get these all done tomorrow night

johnl

15-11-2009, 07:48 PM

Well had a coulpe of days break from the car spent some time on Saturday working on it. Spent about 2 hours flushing the rad. Got soaked so called it a day and headed over to the parents this morning and finsihed the car off this morning around 7am. Car was running for 9am. Ran some radiator flush on the car to make sure the heater matrix was all clean.

Only got a couple of pics as I was on a bit of role finishing it off. Well chuffed with the engine. For some reason it's quieter and smooter than the other engine that had been rebuilt. Will up load the pics I have in a bit.

DarrenH

15-11-2009, 10:48 PM

i got a bosch FPR via my local motor factors and it was 40 ish

johnl

19-11-2009, 10:01 AM

Well the car's done just under 150miles now since the engine change. It's not missed a beat and has been a pleasure to drive again :D Going to attack the drivers CV joint as it's been clicking for a couple of months now on Saturday. Need to also sort the slight gearbox oil leak I've now got. Only other thing left to sort is the issue with the alarm thats only just started happening. When the car start's the windows won't work for about 10 seconds after which they then work as they should. Around the same time the doors also lock as they should. Next issue is when you turn the car off where it should unlock the doors straight away it doesn't happen for around the same amount of time it takes the electric ariel to fully retract. Only started happening after I swapped the wiring round going from the late Dispac setup to the early dizzy stuff. So got a feeling I've caught a wire somewhere.

mick g

19-11-2009, 10:14 AM

Good to see youre happy with the engine, it is a good un.. :thumbsup:

johnl

19-11-2009, 10:55 AM

Good to see youre happy with the engine, it is a good un.. :thumbsup:

More than happy with it. Was a little tappy when it 1st started but it soon went quiet and has not made a noise since. Also looks like it doesn't leak from the sump either as thats still clean :D