My grey GTE

[johnl]

I was going to do the body work on my current car but the GTE Tom Stickland was selling came at the right price and looked in good nick so went down to take a look and its now sitting on my drive :veryhappy:

My plans are as follows.

Spend the time to prep and carry out preventative work
Put the engine and interior etc out of my current car

Pictures and updates will follow

[Harvey]

Get on with it them as we want pictures pictures pictures...

[Brett]

you've got stickers old Red 8v shell??

[Tom]

Get on with it them as we want pictures pictures pictures...
Give the man a chance lol

[johnl]

Its the Grey shell he had for the sale the end of last month.

I've not really done much yet as I only picked it up last night and was in work this morning. :(

I've basically just been checking what I'm letting myself in for before start changing the engine over etc. I'm surprised at how solid the shell a checking behind the rear arch's you can see where its been previously wax oiled. Thats one less job for me to. :veryhappy:

[johnl]

Well its been a busy weekend so far I've removed the dash and carpet out of the car to check the condition of floor/bulkhead. Have to excuse the pics taken on phone

Passenger side of the car is in really good condition theres only on hole and thats quite high in the wheel arch. Never had one go there before?
http://valver.co.uk/astramk2/hole_pass_arch.jpg
There was also one rust bubble that quickly cleared with the wire brush.
http://valver.co.uk/astramk2/Rust_bubble_pass.jpg
Drivers side is also in pretty good nick just the usual bulkhead issue.
http://valver.co.uk/astramk2/drivers_floor.jpg
http://valver.co.uk/astramk2/bulkhead.jpg

The only cause for concern with the sills is a hole on the drivers side.
http://valver.co.uk/astramk2/driversill.jpg

Just got to wait for my mate to turn up with the welder and then I can carry on.

[Black Magic]

would it not be easier to get brand new sills?

[johnl]

Not really as thats the only hole/rust on them and its not really that big.

[mking]

i had a hole almost exactly like that, same size and everything. i ran the grinder over it a few times, and discovered it became slightly bigger. but i still had it welded as it was far easier than replacing a whole sill ;)

[johnl]

Tell me about it I replaced the sills on the white one. Not a nice job at all took ages as well. :(

[Sipo]

Good luck with the project matey, sounds like a plan! I was going to bu the shell from Tom to put my LET in and move the champ on, but it worked out too much time/money. Glad you are happy with the buy :)

[westurbo]

sounds good m8...good luck and keep the pics coming...

[GazJevs84]

looks like a nice example then lol

[johnl]

Well I've booked at few days of work to allow me to sort the car out. Started to day getting new brake disc's pads fuel lines etc. Still waiting for my mate to turn up with the welder :( (Anyone in the Manchester area that can weld in exchange for beer tokens get in touch)

Started stripping the white cars interior down to fit in the new one. got most of the boot changed over will post pictures tomorrow. As been out on the beer tonight with me been another year older :grumpy:

[johnl]

Impatient after a beer ignore the double post :)

[johnl]

Well the rear seats have been fitted as have front wings that came from Hadrians. Just need to spray them up. Not many pictures taken due to it been so cold. Also for some reason the pictures are all coming out with a blue tint :confused:

http://valver.co.uk/astramk2/DSC00870.jpg

http://valver.co.uk/astramk2/DSC00871.jpg

http://valver.co.uk/astramk2/DSC00872.jpg

[johnl]

Finally got the welding done :Banane47: :Banane44: :bananajump:

Heres the pictures going to put another layer of paint and then underseal it.

Bulkhead now repaired.
http://valver.co.uk//astramk2/bulkhead1.jpg

Passenger wheel arch
http://valver.co.uk/astramk2/pwa.jpg

Random picture after the work had been finished.
http://valver.co.uk/astramk2/car.jpg

Would have taken more picture of the work been carried out but it was to cold. :(

[johnl]

Been doing a bit more on the car this morning before heading into work. basically sprayed the bumper and wing. Paint is slightly the wrong shade :( Going to go to the local paint place once the car is on the road and get them to get me an exact match of the colour for the car and then get it sprayed properly. For now though it will do looks better than the black primer that was on there orignally.

http://valver.co.uk/car1.jpg

[johnl]

Well its been a busy day today. the engine and gear box have been removed from the white car and fitted in to the Grey one. Just need to fit the rad and connect everything up and then the car's sorted. Also booked it in for its MOT on monday morning.

[johnl]

Been finishing off all the jobs on the car. Ran out of light though so going to get up early so I can finish in time for the MOT tomorrow. Just go to fit the exhaust, fuel pump and bleed the brakes. Been to busy to take pictures plus with it raining I didn't want to mess the camera up.

[johnl]

Finally fitted the exhaust and fuel pump (didn't manage to get it sorted the other day as my mate let me down :grumpy:) Turned the key and it fired into life :) Going to book it in for its test tomorrow will get some pic's taken if the weather clears up.

[johnl]

:grumpy: I've got the feeling this car's never going to get to the mot station........

Had to cancel the test the other day as there was a fuel leak. Fixed the leak this morning. Booked it in for its test this afternoon. :) drove it off the drive just to just double check everthing etc. only for it to cut out. :( Wouldn't restart :confused: After a few obvious checks the fuel pump is knackered. :hissyfit: Had to cancel the test. Going to sort it all out this weekend and book it in monday morning. If anything else goes wrong any one want to buy it?

[Brett]

sure its not the relay mate!

Ive got a fuel pump here for a GTE 16v if you need it, worked fine on my old 16v!

Dont give up on it mate, not when you've done all thar work to it!

[Harvey]

It'll get there just keep at it and don't let it win as...remember your in charge

[johnl]

Cheers. I've calmed down a bit now had chance to think about it. gives me more time to go over it and make sure everything is spot on before it goes for the test. I've just spent ages on it this week been getting up and starting work on it before I went to work and then doing stuff when I finished work. Each time I think I've sorted it all out something happened. :(

I'll let you know about the Fuel pump Brett I should be picking a temporary one tomorrow morning. Changed the relay made no difference even powered the pump direct from the battery. I'll probably get home tonight and it will jump into life.

[johnl]

:bananajump: :Banane44: :Banane47: Swapped the fuel pump over this morning and its started up. Just need to wait till Monday now for its MOT. Fingers crossed it will be taxed and tested Monday now.

[johnl]

Got to the MOT station this morning only to find out I was ment to be there 20 minutes earlier :duh: so they weren't able to test it :grumpy:

Rebooked it in for Wednesday morning and have left my number with them in case they get any appointments between now and then.

On a plus note car drove really well there and back. It feels very solid and tight on the road. :)

[johnl]

:Banane47: :bananajump: :Banane43: :Banane44: :Banane42:


Car went in for its retest today and has passed.

Also had a quote to have the front wings and front bumper repainted so they will match the rest of the car £220 and if I want the rear archs doing at the same time it will be £75 a side on top.

John

[johnl]

Not really done much on the car other than drive it recently. Washed it today and whilst it was at my parents house I made use of the cleaning stuff in the garage (My dad works at an undertakers so theres loads of weird and wonderful cleaning products) Took some pics of the car will post them up later.

Pic as promised
http://valver.co.uk/astramk2/DSC009021.jpg

[johnl]

Well it's been a while since I've put down anything that I've been up to. This weekend I've been sorting out the new head I bought a couple of months ago lapping the valves etc will be fitting it tomorrow. Will upload pictures etc of the job. I've interested to see the condition of the engine really as its done well over 200k now and As far as I know the head's never been off.

[johnl]

I've been busy to day removing the old head and cleaning the block up etc. The new head has been fitted and is all torqued up but couldn't start it as I've got to pick up some new ignition leads as the ones that were on the car have snapped :( I took some picture's whilst I carried out the work forgot to bring the camera home with me though :(

[johnl]

Well I've given up for the moment on trying to get the car to start as the 7battery is getting a little to flat to be able to turn the car over and getting it to start. Here's the pictures from yesterday.

Started stripping it down
http://www.valver.co.uk/astramk2/DSC01000.JPG

I think this is the cause of the miss fire the car had :(

http://www.valver.co.uk/astramk2/DSC01001.JPG

The cam shafts didn't seam to show any sign's of major ware even though the engines done over 200k

http://www.valver.co.uk/astramk2/DSC01002.JPG

Head's completely off looks like the gasket had gone on number one so the head might not have cracked.

http://www.valver.co.uk/astramk2/DSC01009.JPG

New Coscast head fitted :)

http://www.valver.co.uk/astramk2/DSC01012.JPG

New camshaft cover fitted :)

http://www.valver.co.uk/astramk2/DSC01013.JPG

Just need to get the thing to start now.

[johnl]

Well it started :D Just got to flush the coolant and refit the heat shield and cambelt cover

[johnl]

After nearly a year of owning this car I thought I'd do an update with plans for this coming year. After changing the head I've ended up having to replace the oil pump as the pressure relief valve kept sticking on it. After fitting the pump the engine sprung a leak and lost oil pressure. I ended up replacing the engine which was fine for about 1 month before the oil pump died :( I've since replaced the pump however I'm not 100% happy with the replacement pump as the engine can be really temperamental on how much oil pressure there is. So I've started stripping my original block down so that it can be rebuilt whilst keeping the car on the road at the same time. I will post pictures and updates with the rebuild as and when I carry out the work which hopefully should all be completed over the next couple of months in time for the MOT.

[johnl]

Well not much has really happened on the engine rebuild side of things :( mainly due to work and other commitments. However this month I've started getting stuff together. Hopefully will have the crank out and sent of to be checked and grind-ed if needed by the end of the month.

In the mean time I've Replaced the seats as the set that were in there had started to show their mileage. Will get picture of the new seats over the weekend :)

I also fitted a new bumper to fix the damage that had happened from where another drive clipped it when they turned to soon when going between me and another car in traffic.

Have given the car a once over ready for it's MOT on Tuesday replaced both front CV boots as they has started to crack took all of an hour if that My mates got a cone that allows you to stretch the boot and fit it with out having to remove the joint from the shaft. However looks like I will need to replace the lower ball joint on the passengers side as there is slight play so I've picked up a replacement lower arm will be fitting it over the weekend. Other than that I don't think there is anything else needed for it to pass the test.

[johnl]

Carried out some pre MOT checks on the car yesturday/today I could only find 2 things wrong. 1, number plate bulb had blown 2, play in the suspension on the passenger side. turned out to be lower ball joint. Decieded to replace the complete lower arm rather than just fit a replacement ball joint. Didn't get any pictures off the work as the local scum were out in force with it been sunny and I didn't fancy any hassle over the camera or tools. The job however went really well took it out for a test drive and the difference is amazing. Going to do the other side after the MOT.

[bigdrifter]

Good stuff to hear it doesn't want much, didn't realise yours had done that sort of mileage - very tidy still considering.

[johnl]

The car it's self has only done 107k (I love driving it to much) The engine thats currently in has done about the same but the engine pictured ended up doing 210k before the oil pump packed up. That's the engine I'll be rebuilding as there doesn't appear to be any real wear since I started cleaning it up. Just need to find a price on rings as I only really want to have to do the job once.

[johnl]

Well as I've had the rest of the day to myself after it passing its MOT I've done a few odd jobs on the car :)

Fitted the pump and wiring loom for the headlight washers that I got from Harvey the other week. They are now working as they should :)

Also finished fitting the alarm (only taken 12 months :() got it working remote central locking working as mentioned in another thread connected 2 wires from the alarm (lock and unlock) to the central locking ECU and then fitted a cav boot motor in the drivers door. Going back out now to sort out the interior light and then probably give it a wash as well.

Plans now for the car.

Fit the Cav window motors that I picked up last month and have them triggered of the alarm for total closure.

Upgrade the central locking to a vectra setup so I can get deadlocks :)

Rebuild the engine. hope to have this sorted 1st really as the only real concern with the car is having to keeping an eye on the oil pressure gauge.

Get the rear arches sorted out as they are starting to bubble :(

look at fitting electric rear windows

[richie00boy]

So the engine had already gone at some point then been replaced with the 200k miles one? Good to see the high miles one is still good. I have a 190k mile 8v that I've got off my breaker just this weekend, now tucked away in the storage bin. It was such a job getting it into the storage bin from the car that I'm scared it will be a past-it engine. So you have given me hope :)

Also look forward to the report on the Cav motors if they are more powerful, and the deadlocking. Another two mods I'm thinking about.

[johnl]

The original engine in the car was swaped for a LET the 200k engine was from my other GTE but the oil pump went on it after I changed the head (due to it mixing oil and water) I've since bought a replacment engine from Appitiser (sp) but that suffered the same fate with the oil pump. So I'm going to be rebuilding my orignal engine whilst still driving round with engine thats currently fitted. As for the other mods I will carry these out either at my parents house or during a time when the locals are not about so that I can get pictures of the work. :)

[johnl]

Well this weekend I took the chance to clean the car whilst in the garage I noticed the hot air gun so for what the heck I will give it a try on the skirts and bump strips. I'll let the photo's do the talking really.

Before:
http://www.valver.co.uk/astramk2/before.jpg

I've already done the lower part before I took the picture however the the trim was all the same faded shade of grey.

After:

http://www.valver.co.uk/astramk2/after.jpg

To say I was impressed is an understatement. Would never have thought of doing that till I read OrangePeels diary.

Just some pictures of the side skirts.
http://www.valver.co.uk/astramk2/skirts1.jpg
http://www.valver.co.uk/astramk2/sideskirt.jpg
Just before it was finihsed off. (ok I admit it I had some help :))
http://www.valver.co.uk/astramk2/Carclean.jpg

And here's a picture of the seats I picked up last month and fitted.
http://www.valver.co.uk/astramk2/seats.jpg

[mick g]

Dont them bumper inserts come up well, im going to give it a go

[johnl]

Just wish I'd done a proper shot of them before and after I was really suprised with the difference.

[James C]

Dont them bumper inserts come up well, im going to give it a go

It is worth it - thats how I do mine.

Also it is good to put back to black on first then heat gun as the top layer of plastic melts it accepts the back to black.

[johnl]

It is worth it - thats how I do mine.

Also it is good to put back to black on first then heat gun as the top layer of plastic melts it accepts the back to black.


might try it that way next time.

[johnl]

Going to start ordering more of the bits for the engine rebuild this week. Going to get the oil pump from Vauxhall but also getting the pressure relief valve from SBD. Going to send the Crank of to check if it needs a regrind or just a polish (hopefully by next weekend) After which it should just be a case of bolting it all back together once the rings arrive.

[johnl]

Dropped the crank off from the old engine to the local machine shop they have checked the crank over and it's going to need to be reground due to some scoring on the bearing journals. Should be ready for collection on Thursday :)

[johnl]

Got a call to say it was ready to be collected :) just got back with the crank now.

Here's a picture of the crank
http://valver.co.uk/astramk2/rebuild/DSC01108.JPG

Here's a pic from the piston I've started to clean up I'm surprised on the condition really due to the mileage the car had done.

http://valver.co.uk/astramk2/rebuild/DSC01109.JPG

[Alex mac]

Looking Good, take a opportunity now and install ARP rod bolts, for piece of mind

But you will never get it cleaned with WKD particularly orange lol

[johnl]

lol tell me about it. :)

[johnl]

Had another call to say the bearings and rings have arrived so now I just need to get head set and bottom set together oil pump and then I can start builind it all up :)

[johnl]

Well I've spent most of this morning stripping the old block and cleaning it up only to find that bore number 3 has a massive lip on one side making the block scrap. Looks for all the world as its been pushed out. Not sure whats happened with it as there were no symptoms when the engine was last running to show there was this kind of ware. It had healthy compression etc.

Anyway this will just be a little set back as I will now either use my current block and take the car of the road for around a week whilst I strip it down etc or source another block. Didn't get any pictures as I forgot to take my camera
:(

[richie00boy]

Annoying when things like that happen.

[johnl]

tell me about it. not overly fussed though just means I either take the car of the road for a bit longer than 1st planned or source a new block. Taking the car of the road's not to bad as I'll possibly get the use of my mates jag :)

[johnl]

Well after this weekend I've made my mind up the car's coming of the road next week to get the engine sorted once and for all. Pressure relief valve has stuck both Saturday and Sunday. Granted it took all of 30 minutes to strip down and clean etc. Just don't fancy it doing it whilst out etc.

I've just booked the week of work to allow me enough time. So get ready for a load of pic's whilst I carry out the rebuild etc.

Long term plans for the car have possibly changed. Going to get the engine sorted out and then possibly go down the v6 route. Externally however the car will remain standard as possible.

[johnl]

Well This morning the car came off the road. Was meant to be happening yesterday but due to been on call over the weekend and having to move 40 servers due to power issues on Sunday night I gave working on the car a miss. I also bought a gazebo to try keep the weather off me whilst working on the car :D Pleased to say it worked a treat.

Just after got started.
http://www.valver.co.uk/astramk2/DSC01117.JPG

Looks like the manifold had a little leak.
http://www.valver.co.uk/astramk2/gasket.jpg

Plugs are all like this one bar number 3 (hoping this is just because of the gasket)
http://www.valver.co.uk/astramk2/plug.jpg

Cam Cover removed
http://www.valver.co.uk/astramk2/stripdown1.jpg

Finally removed the head (rear pipe that comes from the back of the water pump was a pain to remove)

http://www.valver.co.uk/astramk2/headremoved.jpg

The bores look in good condition can still see the honing marks and there's no lip :)

http://www.valver.co.uk/astramk2/bore1.jpg

Although there is a large carbon build up on the 3rd Bore.

http://www.valver.co.uk/astramk2/bore3.jpg

Again number 3 is carbonized up

http://www.valver.co.uk/astramk2/head1.jpg
http://www.valver.co.uk/astramk2/head2.jpg

Had a few issues removing the engine one of the issues are in the following picture can anybody notice anything missing here?

http://www.valver.co.uk/astramk2/opps.jpg

That right the input shaft came out as well :(
http://www.valver.co.uk/astramk2/opps2.jpg

Anyway here's the block fully removed from the car

http://www.valver.co.uk/astramk2/blockremoved.jpg

Once the engine was removed I set about stripping it down ready for cleaning and painting.

Here's the crank. doesn't appear to be any wear at all.

http://www.valver.co.uk/astramk2/crank.jpg

And here's the block after the crank and pistons were removed.

http://www.valver.co.uk/astramk2/block.jpg

When removing the 3rd piston one of the compression rings fell off in about 20 pieces didn't get a picture of this though :( Anyway after a tin of Gunk I had a clean block ready for painting. Which I managed to paint before I packed up for the night. Hopefully should be just a case of rebuilding the engine now with all the bits I've been collecting.

[johnl]

Well another days hard graft. (Well sort of I over slept :(

here's a pic of the block after it was all painted up :)

http://www.valver.co.uk/astramk2/rebuild/paint1.jpg
http://www.valver.co.uk/astramk2/rebuild/paint2.jpg

Didn't get any pictures of the pistons been fitted :( was getting carried away with the piston ring compressor :)

Fitted the crank into position with plenty of fresh engine oil every bearing got a cap full of oil and then the crank journals got at least 2 cap fulls over them.
http://www.valver.co.uk/astramk2/rebuild/newbearings.jpg

http://www.valver.co.uk/astramk2/rebuild/newbearings1.jpg

http://www.valver.co.uk/astramk2/rebuild/rebuild1.jpg

Forgot to take picture then till I had fitted the head and replacement gear box. :(
http://www.valver.co.uk/astramk2/rebuild/rebuild2.jpg

http://www.valver.co.uk/astramk2/rebuild/rebuild3.jpg

http://www.valver.co.uk/astramk2/rebuild/rebuild4.jpg

http://www.valver.co.uk/astramk2/rebuild/rebuild5.jpg

Anyway how the engine bay was left tonight

http://www.valver.co.uk/astramk2/rebuild/emptybay.jpg

Mental note to ones self don't leave the tray of used engine oil under the car I managed to knock a new box of gloves (the only box I had left I might add)
http://www.valver.co.uk/astramk2/rebuild/shitbox.jpg

After the mishap with the gloves I called it a night. How I've left everything tonight. Car's in the make shift garage. Been a real god send with the British summer been as it is.

http://www.valver.co.uk/astramk2/rebuild/DSC01154.JPG

[johnl]

Well today's not been very productive :( Started tightening the head bolts only for one of the bolts to strip the thread out of the block :(

[richie00boy]

Sorry to hear that mate, was looking good as well.

Where did you get the gazebo and are they expensive?

[johnl]

The gazebo was from Makro cost 39.99 + vat weird thing is they had them with out the sides for £99.99 So I went for the cheap option and opted to have sides :D

All's not lost with the engine been on the phone to the place that did the crank for me they've put me in touch with a bloke that sorts these kind of issues out all the time :D Got to take the head back off and take the block round to him tomorrow morning :D He recons around 30 minutes and it will be as good as new :D Ao going to use the time between now and then to tidy the engine bay up a little.

[johnl]

The guy has got back to me today. The tool he needs to do the job hasn't arrived yet looks like it will be tomorrow now before he will be able to do it :( So I'm going to refit the engine and box in the car and then get it towed down to him. Hopefully this will mean all I will need to do is then refit the head, cambelt etc tomorrow

[richie00boy]

Was hoping to see you at Billing for a chat but looks like not!

[johnl]

Tell me about it. Guess there is always next year :)

[johnl]

Well it was all systems go today. Took the block down to the guy. Was there 20 minutes at most and the hole had a new thread in it :D Got the block home after fighting with all the traffic in Stockport due to road works on the A6 (Main road through from Manchester) Refitted the head and then proceeded to tighten the head bolts. My face must have been a picture lol whilst carrying it out needless to say they all took well. Got the engine back in the car filled it with oil and started turning it over via the key with no plugs in or the injection loom plugged in. needless to say 30 seconds of cranking there was full oil pressure and no stange noises :D :Banane48: :bananajump: :Banane47: :Banane08: :action: Carried on refitting everything. Gave up this evening. Just got the drivers side drive shaft to fit and the rad and then fill the water up :)

[johnl]

Well all's good Finished all the jobs off this morning and it fired in to life. Done around 30 miles with only 2 issues. 1, Steering rack leaks :( 2, one of the belts squeals. Other than that all seems good so far.

[johnl]

Well the car will have covered over 60 miles by the time I get home tonight. Going to drop the oil out fit the oil cooler and fresh oil and get a picture of the finished engine.

[MK2-JOHN]

Glad your getting it sorted with no major problems John

[richie00boy]

Sounds good John, hopefully that should be it for a long time now.

[johnl]

Thanks for the comments. Well I managed to get the bolt I needed from vauxhall (or so I thought) Dropped the oil out and replaced the washer on the sump bolt. (where I thought I'd noticed it leaking) Anyway to cut a long story short. The bolt from Vauxhall isn't right it's to short :( and the sump bolt wasn't leaking there's a hairline crack in the sump and the oils making it's way down on the outside to the bolt. Which means the sumps going to have to come back off again. But on the plus side it's still running fine :)

[johnl]

Here's the engine all finished

http://www.valver.co.uk/astramk2/car/DSC01182.JPG
http://www.valver.co.uk/astramk2/car/DSC01183.JPG
http://www.valver.co.uk/astramk2/car/DSC01186.JPG

Replaced the engine earth strap with a positive battery lead from a jag

http://www.valver.co.uk/astramk2/car/DSC01184.JPG
http://www.valver.co.uk/astramk2/car/DSC01185.JPG

Also replaced the gearbox linkage with the linkage from the gearbox I picked up the start of the month.

http://www.valver.co.uk/astramk2/car/DSC01187.JPG

Here's one of the jobs I've got left to sort. Leaking steering rack

http://www.valver.co.uk/astramk2/car/DSC01189.JPG

The car after it's 1st wash in nearly 3 weeks.

http://www.valver.co.uk/astramk2/car/DSC01181.JPG
http://www.valver.co.uk/astramk2/car/DSC01198.JPG
http://www.valver.co.uk/astramk2/car/DSC01196.JPG


Both rear arch's are starting to bubble :(

http://www.valver.co.uk/astramk2/car/DSC01193.JPG
http://www.valver.co.uk/astramk2/car/DSC01194.JPG

[richie00boy]

Good it's up and running again.

F16???

[johnl]

Good it's up and running again.

F16???

Gave up trying to remove 5th gear on the f20 whilst it was in the car. Also after the input shaft decieded it was going to come out with the engine I decieded I'm going to give the box a once over and replace any worn parts. (dependant on how many there are)

[johnl]

Well the engine developed a tap this morning and died on the way home :( Need to have a proper look in day light to see how bad the damage is.

[sri kid]

I believe in preventive maintenance....not reactive.....thats why my 88 sri still has original sills.....but thats no help if you are buying a mk 2 today... you have to work with what you have.....waxoyl is my god it does what it says on the can... I have read Toms exploits with his red gte on the web he has my respect seems a top bloke...do you know him ?? its great that you are keeping it alive !!!:grinning-smiley-043

[johnl]

I believe in preventive maintenance....not reactive.....thats why my 88 sri still has original sills.....but thats no help if you are buying a mk 2 today... you have to work with what you have.....waxoyl is my god it does what it says on the can... I have read Toms exploits with his red gte on the web he has my respect seems a top bloke...do you know him ?? its great that you are keeping it alive !!!:grinning-smiley-043

Only met him twice when he had the car for sale the other was when he came for to a mig meet in Warrington. Like your self though I've read about his exploits with his red one.

[johnl]

Well not really done much yet on the car been to busy. :( Anyway here the pics so far of the damage to the engine :( Might add the seeds etc are from where they've been left out side since been removed from the engine. Oil (well what was left) came out clean and in the bottom there was a flattened big end bearing and a few bigish bits of metal.

Hole in the sump
http://www.valver.co.uk/astramk2/GTEPics/DSC01202.JPG

Baffle
http://www.valver.co.uk/astramk2/GTEPics/DSC01203.JPG
http://www.valver.co.uk/astramk2/GTEPics/DSC01204.JPG
http://www.valver.co.uk/astramk2/GTEPics/DSC01205.JPG

Hard to see but it's there the hole in the back of the block also looks like the cranks taken a beating as well.
http://www.valver.co.uk/astramk2/GTEPics/DSC01209.JPG

[johnl]

Well picked up the replacement engine last night took it out the van this morning before I headed into work. Hopefully should be all fitted and running tomorrow.

[johnl]

Well Started a little later than planed this morning Head's off the old engine. Managed to bend 2 of the exhaust valves when it chucked a con rod. Other than that the head appears to be fine. Stopped for some breakfast before I remove the final bolts and drop the rest of the block and box. Pics to follow.

[johnl]

Engines in and running. Just need to connect and align the linkage for the selector put a few nuts and bolts back on and then its all done :) Pics to follow just getting some food :)

[johnl]

Starting to remove the old engine. I had feeling of deja vu
http://www.valver.co.uk/astramk2/rebuild/DSC01210.JPG

Head removed you can see where the exhaust valves have made contact with piston number 2. Looking at it there's not to much damage.
http://www.valver.co.uk/astramk2/rebuild/DSC01215.JPG

Here's the rest of the damage to the block.
http://www.valver.co.uk/astramk2/rebuild/DSC01225.JPG
http://www.valver.co.uk/astramk2/rebuild/DSC01226.JPG

Little helper know who to blame if the clutch slips. 3 year nephew who's GTE mad
http://www.valver.co.uk/astramk2/rebuild/DSC01216.JPG

Gearbox attached and ready for re-fitting.
http://www.valver.co.uk/astramk2/rebuild/DSC01228.JPG
http://www.valver.co.uk/astramk2/rebuild/DSC01229.JPG

Here's the back box that I got as well. Going to fit that tomorrow with any luck.

http://www.valver.co.uk/astramk2/rebuild/DSC01230.JPG
http://www.valver.co.uk/astramk2/rebuild/DSC01231.JPG

Think the spiders going to get a shock when it attached and the car starts :)
http://www.valver.co.uk/astramk2/rebuild/DSC01233.JPG

[johnl]

Engines probably got to come out :( It's got a knock. Not sure where from got a feeling it's one of the big ends.

[Danny]

Hope you get that fixed soon mate.
Nice to see your nephew enjoying working on marky twos.

[johnl]

He insisted in helping. Anyway I've won a Calibra from ebay that will be donating it's engine. :)

[johnl]

Well the engines in and running. Calibra had a few nice touches I wasn't expecting with it been the later style XE. Equal length drive shafts. Made a big difference in the way the car drives now. The front manifold has been customized and the cat is attached straight on. I know cat's reduces the power slightly etc. but i'm not that fussed I'm happy that it's got the lambda sensor fitted. Car's so much more responsive now :D Also fitted the wheels from the Calibra will get a picture etc once the weather makes it's mind up.

[Dale]

souinds good, but i would get rid of the cat! :)

[johnl]

Will be doing. Just wanted to get the car on the road with out to much messing with swapping the engine over to dizzy etc.

[johnl]

Well here's a pic of the replacement engine,

I liked the colours. Just didn't like the knocking noise it made. :(
http://www.valver.co.uk/astramk2/car/DSC01239.JPG

Found a use for a rover. It's in the bottom left hand corner of the picture attached to the tow rope. :)
http://www.valver.co.uk/astramk2/car/DSC01240.JPG

Engine fitted as you have probably noticed I've kept it with the later style managent system.
http://www.valver.co.uk/astramk2/car/DSC01262.JPG

The best bit oil pressure stays full all the time now :D
http://www.valver.co.uk/astramk2/car/DSC01263.JPG

Also grabbed the Gearstick from the calibra as the it's shorter in length
http://www.valver.co.uk/astramk2/car/DSC01265.JPG
http://www.valver.co.uk/astramk2/car/DSC01264.JPG

Only issue I've come across so far is that the exhaust sticks out a little more now due to using the calibra mainfold
http://www.valver.co.uk/astramk2/car/DSC01273.JPG

Here's the manifold as you can see where it normal would join has been cut off.
http://www.valver.co.uk/astramk2/car/DSC01270.JPG

Might have noticed I've also grabbed the wheels from the calibra as well

http://www.valver.co.uk/astramk2/car/DSC01261.JPG

Just an arty shot
http://www.valver.co.uk/astramk2/car/DSC01271.JPG

Drivers door now has a car park dent in it now :(
http://www.valver.co.uk/astramk2/car/DSC01267.JPG

[GazJevs84]

Looks nice mate

[Davey J]

Come on leaps and bounds that John. Sorry the engine you got from me did not work out. As per text will arrange to get up soon and pick up the scrap bits from you and see it in the flesh!

[kev_vaux]

this used to be mine many moons ago, archs havnt got much worse in 4 years!Lol

get that turbo back in that car was so quick in its day!

[johnl]

Well I've had a busy weekend. I fitted cav window mechanism. Followed the how to on Mark-t's web site. They work a treat now :D Both windows go up and down nice and quick. Didn't get much in the way of pictures as I was full of grease from the old winders.

[johnl]

Well car's been running like a dream. (Hope I've not just jinxed myself) It's really smooth even when in traffic doesn't kangaroo at all :D not noticed any flat spot's either manging to pull away in 5th from tick over which is around 28mph (granted not as fast as if I drop a few cogs but it picks up straight away)

Just really waiting now for 8th when it goes in for the body work to be carried out.

Might add the window's are still working a treat and would recommend them to anyone that suffers from slow windows or just fancy 1 touch :D. Although every now and then the drivers side goes up half way and then stop and goes back down an inch I think the runners a little dry

Anyway here where's I've stuck the Club sticker :)
http://www.valver.co.uk/astramk2/bits/DSC01495.JPG

Didn't realize the car was so dirty either :(

[johnl]

Well I had a spare hour tonight so I thought I would fit the seat rail from the Calibra so that the passenger side now has height adjustment :)

Took the drivers side out 1st and swapped the runners over also fitted the plastic seat edge. Didn't look to dirty but whilst it was in the house I thought I'd take the oppotunity to clean it properly.

Before
http://www.valver.co.uk/astramk2/seat/DSC01496.JPG

picture of the pretensioner (not 100% sure what this does guessing its on there for a reason though) and plastic seat edge.
http://www.valver.co.uk/astramk2/seat/DSC01498.JPG

White seats anyone?
http://www.valver.co.uk/astramk2/seat/DSC01499.JPG
http://www.valver.co.uk/astramk2/seat/DSC01500.JPG

All clean just need to run the hover over it.
http://www.valver.co.uk/astramk2/seat/DSC01501.JPG
http://www.valver.co.uk/astramk2/seat/DSC01502.JPG

Not saying it was dirty but the brush on the can used to be a nice red and the nail brush was once white. :wasntme:
http://www.valver.co.uk/astramk2/seat/DSC01503.JPG
http://www.valver.co.uk/astramk2/seat/DSC01504.JPG

[Gteman]

The seats cleaned up a treat.

The pretensioner when triggered pulls the seat belt socket down via cables so to tighten the seat belt pulling you back into the seat in an accident.

[johnl]

The seats cleaned up a treat.

The pretensioner when triggered pulls the seat belt socket down via cables so to tighten the seat belt pulling you back into the seat in an accident.

So it's a good idea leaving them fitted then?

They've both come up really well didn't realise how bad there were.

[Gteman]

Yip leave them connected. They can be dangerous if messed about if they are set off by mistake, although there is a tag that needs fitting to make them safe for removal.

[johnl]

Not sure what it is at the moment but I seam to be getting loads of little odd jobs done on the car this month. Each one is making a noticeable difference in how the car looks/drives.

Today I nipped over to Alistair j and picked up the strut brace he had for sale. When I got back to the office I thought it would be rude not to fit it. Not got any pictures of it fitted yet :(.

I wouldn't say it's made loads of difference if any to tell the truth on 1st impressions. That was until on the way home from work I went through Trafford Park (its an industrial estate for those of you that don't know Manchester) which has some sweeping bends and a few roundabouts.
Safe to say it has made a noticeable difference to the handling when giving the car a little stick

[johnl]

Well the car's been dropped of at the body work shop should be able to collect it on Thursday/Friday depending on how bad the rear arches are underneath. So for the 1st time in 9 years of driving there's not a mk2 outside my house :( I've got a crapy 57 Fiesta as a hire car.

[johnl]

Well picked the car up this afternoon, the guy has took quite a bit of time to sort the car out but I've got it back and that's all that matters. So here's all the pics just need to sort out some new rear tyres or look at getting the new arches rolled.

Here's the hire car :yuck:
http://valver.co.uk/astramk2/hire/DSC01565.JPG

and here's mine all back front end has been sprayed (wing's bumper and bonnet) New rear arches and the scratch's from the fench removed.

http://valver.co.uk/astramk2/car/DSC01566.JPG

http://valver.co.uk/astramk2/car/DSC01567.JPG

http://valver.co.uk/astramk2/car/DSC01568.JPG

http://valver.co.uk/astramk2/car/DSC01569.JPG

http://valver.co.uk/astramk2/car/DSC01570.JPG

http://valver.co.uk/astramk2/car/DSC01571.JPG

http://valver.co.uk/astramk2/car/DSC01572.JPG

http://valver.co.uk/astramk2/car/DSC01573.JPG

http://valver.co.uk/astramk2/car/DSC01574.JPG

http://valver.co.uk/astramk2/car/DSC01575.JPG

http://valver.co.uk/astramk2/car/DSC01576.JPG

http://valver.co.uk/astramk2/car/DSC01577.JPG

Overall I'm pleased with the results however it's not 100%
John

[richie00boy]

Looks good. I thought you were getting the whole car painted?

[johnl]

Looks good. I thought you were getting the whole car painted?

The amount of messing that has happened just getting the bits done I told the guy not to bother. It's took 6 coats to get it as it is. (Was supplied the wrong shade of grey at 1st.)

[johnl]

Car's going back to the bodywork place on Wednesday. After looking at the work on the car there are some really good bits of work that he's carried out and then other bits look as if he was either in a rush or had other things on his mind. He's not painted all the panels he said he would, just put lacquer over them :( Which wouldn't be to bad if bits of crap hadn't got in to it before it had dried. In street lighting you can see where he's not feathered the paint in :(

On a plus side I've made a list of jobs left to sort out on the car Glad to say most of them now are just routine maintence.

Change/check gearbox oil level.
Change engine oil (and fit oil level sensor as the current ones a little faulty)
General service new plugs air filter etc
Check rear bearings
Adjust the hand brake.
Fit the fuel pump I bought of Harvey a few months back. (try and track the intermitent smell of petrol)
Get the heating elements fitted to the seats.
Change the steering rack (current one leaks)
Fit the back box and get the pin hole welded on the exhaust. (more than likely will do that this weekend.)
Go under the car and make sure the under seal is all intact from when the engine went bang.

[richie00boy]

I feel your pain. I don't think there's any bodyshops unless you pay an absolute fortune that do everything just right.

For the fuel check under the rear passenger footwell area under the car on the drivers side as there is some rubber hoses there that go.

[Brett]

I'll echo Richies thoughts on the bodyshop front. The only car Ive ever seem come out of a bodyshop in perfect condition is Ganders Kadett - and I know what he paid for that quality of work, it was a lot:(

[johnl]

I feel your pain. I don't think there's any bodyshops unless you pay an absolute fortune that do everything just right.

For the fuel check under the rear passenger footwell area under the car on the drivers side as there is some rubber hoses there that go.

Cheers I'll have a look around there as thats roughly were the smell is strongest. As for the body shop don't get me wrong I'm not expecting it to come out prestine but it's more in places it looks like it has been rushed at the last minute. Where as there are other bits that are really good.

[johnl]

Picked the car back up tonight after work. I dropped it off with the body work place for him to sort the rear arch that was catching on the rear drivers wheel and also to sort some of the issues with the quality of the painting.

From what I saw in the light it looks a lot better and he's managed to remove some of the bigger bits that we're in the lacquer. In all honesty I think the only way it would improve now would be for somebody else to paint the car really. It's as if he's cut corners and instead of painting the whole side or blending/feathering the paint the paint over a larger area he's tried keeping the painted area's to a minimum. Perhaps I'm just been a little to fussy looking on the bright side it's not cost me anything and all the actual structural work has now been do so a full respray wouldn't be anywhere near as expensive if it still doesn't look 100%.

[johnl]

Not updated for quite a while. :( but thats not to say I've not been doing stuff to the car. I Finally got both rear bump strips to stay stuck on the car. New drivers side from Vauxhall and some "no more nails on a roll" for the other side After cleaning it and warming it up with a hair dryer.

Tonight I've been messing with the vents that arrived from TomGTE I followed Darren's how to on stopping them whistling. Didn't get any pic's as I couldn't find the camera. I just need to swap them over.

Job's left to do
1, Track down the rattle/rumble coming from the front. (I know it's not engine or gearbox as these have both been changed.)
2, Swap the Radiator as it's leaking
3, Change the Gearbox oil
4, Track down the oil leak.
5, Sort out the rear speakers as one of the connectors have snapped off :(
6, Tidy up under the bonnet
7, Refit both front wings as they are not sitting 100% correct at the moment.

[InnesKongSX]

Cars looking good:) Good work, nice color too;) lol Innes

[johnl]

Well I've spent the last few months getting things ready so I can do most if not all the jobs on the car in 1 go. I nicked a lot of ideas from Darren (hope you don't mind) Also been doing the odd little job as well

Anyway as they say pics speak a 1000 words.

After Selling the Nexia vents I've gone back to good old GTE ones. I think they suit the car better, as they don't stick out as much.
http://valver.co.uk/astramk2/car/vent.JPG
Also re-stuck the griffin back on the bonnet so the car is now wearing the full sticker set :thumbsup: (might add noticed it's already picked up a couple of stone chips :()
http://valver.co.uk/astramk2/car/sticker.JPG

Due to the phone I have from work not having a car charger etc. I've fitted an extra cig lighter so that I can run the power converter I picked up without cluttering the dash up.
http://valver.co.uk/astramk2/car/additional_socket.JPG

Also fitted the cubby hole after following Darren's how2 in the members area.
http://valver.co.uk/astramk2/car/cubby.JPG

The air vents I bought from TomGTE, have been cleaned and again following the how to from Darren I've re foamed them :)
http://valver.co.uk/astramk2/car/vents2.JPG

Got the following to fit soon. Bought it from Harvey a while ago.
http://valver.co.uk/astramk2/car/pump.JPG

Been waiting to find a Bracket to clean up so I can swap it over at the same time Current bracket is held on with cable ties. :wasntme:
http://valver.co.uk/astramk2/car/bracket.jpg

Picked up front struts from Brightspark the other weekend will be fitting them hopefully next weekend. So I've picked up the following:
anti roll bars
http://valver.co.uk/astramk2/car/antiroll.JPG
Track rod ends
http://valver.co.uk/astramk2/car/trackrod.JPG
Drivers side wishbone (passengers side was replaced before the last MOT
http://valver.co.uk/astramk2/car/wishbone.JPG
Should then mean the front suspension is all new.

If your wondering why the vents haven't been fitted yet. Saving it till I fit this (bought from Ally):
http://valver.co.uk/astramk2/car/alarm.JPG

[Spankee]

Great restore thread mate :thumbsup:

Whats the damage for the lower wishbone going to replace mine soon
http://valver.co.uk/astramk2/car/wishbone.JPG

[johnl]

Great restore thread mate :thumbsup:

Whats the damage for the lower wishbone going to replace mine soon
http://valver.co.uk/astramk2/car/wishbone.JPG

cheers, wishbone cost about £38 from the local trade place. its not a genuine part but the quality looks good and had no issues with the passegers side.

[richie00boy]

Interesting to see those wishbones have the ball joint bolted on rather than the rivets from Vauxhall. I think I prefer bolts and locknuts!

How much were the TRE? I paid I think about £35/pair from Autovaux for Bilstein ones.

[G.TERI.E]

plenty to keep you busy John, will be looking good:thumbsup:

[johnl]

Interesting to see those wishbones have the ball joint bolted on rather than the rivets from Vauxhall. I think I prefer bolts and locknuts!

How much were the TRE? I paid I think about £35/pair from Autovaux for Bilstein ones.

Paid the following:

2x Anti roll bar's -£4.25 (each)
1x Lower Wishbone - £39
2x Track Rod ends £5.15 (each)
1x ball joint (for the passengers side) - £6.65

Must admit the bolt on lower Ball joints are allot easier as when you come to do any work that would normally need it splitting you can just undo the nuts and replace the nylock nuts.

[johnl]

Well I started early this morning. Helped my mate shift the engine and gearbox out of his jag before starting on mine. Replaced both front legs. Passengers front wheel bearing was well and truly goosed. Although the play was only present when the drive shaft was removed.

http://valver.co.uk/astramk2/GTEPics/DSC01632.JPG

Can't really see the damage/play on the pic but if you spun the hub the outer part of the bearing kept sticking.

http://valver.co.uk/astramk2/GTEPics/DSC01633.JPG
after the job was all finsihed.
Just need to get the tracking sorted and give it a wash.

[johnl]

Been on a rattle ilimanation mission today and fitted one of my birthday presents :)

http://valver.co.uk/astramk2/GTEPics/DSC01634.JPG

There were 2 rattles coming from the front of the car, One I've tracked down to the cv joint. Nipped to the local brakers and picked up a replacement shaft. (Wished I kept the ones from the old engine now.) Also the metal bar that holds the horn in place around 3 inch's in length was loose at both ends. Tightened it all up, result 1 rattle of the list now :bananajump:. I just need to sort the cv joint out and that will be the other one out of the way. I couldn't get the shaft to come out of the gearbox as it started to rain I called it a day.

[johnl]

Well finally got round to fitting the heating elements in to the front seats. Done a how2 in the members section.

Heres the back element in place
http://www.valver.co.uk/astramk2/seats/tophalf.jpg
and the base element in place
http://www.valver.co.uk/astramk2/seats/base-element.jpg

Just waiting for the switches to arrive (which should be in the next few days)

[johnl]

These 2 beauties arrived this morning thanks to opel-classicparts.

http://valver.co.uk/astramk2/GTEPics/seats.JPG

So now I need to fit them and then run the wires from the seats to the passenger foot well.

[G.TERI.E]

nice i could do with a pair of them, do they fit into the blanks?
are the part numbers the same?
how much were them switch's delivered John?

[DarrenH]

lovely job on that respray :)

p.s is this any use to you ??

http://www.oddball123.pwp.blueyonder.co.uk/carstuff/Dscn1592.jpg

[johnl]

nice i could do with a pair of them, do they fit into the blanks?
are the part numbers the same?
how much were them switch's delivered John?

Yup they will replace the switch blanks as they are the RHD version.
Part number is 90191923 they were 13.75 Euro's each plus 19 euros to be delivered.

[johnl]

lovely job on that respray :)

p.s is this any use to you ??

http://www.oddball123.pwp.blueyonder.co.uk/carstuff/Dscn1592.jpg

Cheers Darren, it was after I picked up an early Haynes manual that I decided to go down the route of correct switches and using the loom thats already there.

[johnl]

Well I fitted the switches today. Here's a shot of the dash at the start.

http://valver.co.uk/astramk2/car/before.JPG

All fitted and back together. (Flash on the camera canceled out the fact they were lit up :()
http://valver.co.uk/astramk2/car/after.JPG

A quick test with a multi meter shows it's getting 12 volts when the switches are turned on. Can't see it to well again due to the flash.

http://valver.co.uk/astramk2/car/power.JPG

Just need to run the wire from the footwell to the seat's and then it's done.

[DarrenH]

awesomeness !

incidentally those other two wires (blue clip, grey clip) are the +12v for the side repeaters arent they ?

every astra i've seen, the drivers side wire is just draped accross the floor pan under the carpets then up past the ecu to the inner wing.

another bodgetastic afterthought by vauxhall, like the bonnet lamp wiring.

[johnl]

awesomeness !

incidentally those other two wires (blue clip, grey clip) are the +12v for the side repeaters arent they ?

every astra i've seen, the drivers side wire is just draped accross the floor pan under the carpets then up past the ecu to the inner wing.

another bodgetastic afterthought by vauxhall, like the bonnet lamp wiring.

Cheers, now you mention it every astra I've looked at is the same. I've always wondered what they were for.

[Gteman]

Lol I couldn't remember where the drivers repeater wire was routed and spend ages passing it through the dash stupid:

[johnl]

Well the seats are fitted so thats another job of my list. Gave the car a semi proper clean of the year instead of just a quick wash and wax.

http://valver.co.uk/astramk2/GTEPics/cleancar1.JPG
http://valver.co.uk/astramk2/GTEPics/cleancar2.JPG
http://valver.co.uk/astramk2/GTEPics/rear.JPG

Whilst fitting the wiring for the seats I noticed there's a small hole in the passenger foot well. So that will be getting sorted this week with any look.

Also got a replacement drive shaft to fit. Current one makes a noise when accelerating or when on full lock.

Should also have the replacement tyres for the front this week :) Other than that I think everything sorted for it MOT in April.

Also going to need to get the drivers rear arch looked at as there's rust forming :( :hissyfit: not to happy considering it's only been about 6 months since the body shop did them.

So on the list of jobs is:

Fit uprated Alternator
Replace Drive shaft.
Get rear arch looked at
Fit the alarm
Get the hole in the passenger foot well sorted.

On a side note I can honestly say Krust doesn't work.

[bigdrifter]

Looking good John, l much prefer the GSI rims its sitting on now. Handy to know about the wiring as l'm about to do the same thing in mine, only difference being l'm using all mk3 dash, console and seats so the switches are down by the handbrake instead.

[johnl]

Looking good John, l much prefer the GSI rims its sitting on now. Handy to know about the wiring as l'm about to do the same thing in mine, only difference being l'm using all mk3 dash, console and seats so the switches are down by the handbrake instead.

Cheers, I was going to fit the switches from a Calibra which are also down by the handbrake. Changed my mind once I found I could get the correct switches.

[johnl]

Well might as well keep this upto date. You might have seen my post about a mis fire. Anyway done a compression test and there's no compression on 3 or 4 also looks like number 1 also has a leak. Not sure what I'm going to do yet. ie. Sell the car as is or fix it. Won't be breaking it though.

[G.TERI.E]

John fix the problem dont even think about getting rid:angry-smiley-034:
in all honesty it wont cost much to put right even if you were to swap engine's, top side's £250 & weekend of work???
then again you could drop a v6 or qwer Let it.

too good to sell it especially with all the work youv'e had done.

[johnl]

Well started stripping the head off. Ended up braking both splined sockets that I've got :( Going to nip to the local motor factors and try and pick one up. So have to watch this space.

[johnl]

Well I've managed to get the head off.

The head gasket's failed. Not to sure if I should be happy or not. On the one hand I know the cause of the misfire. But on the other I don't know the cause of the gasket failing. I filled it up last Saturday night. Went out to Blackpool Sunday spent a good 5 hours there did a bit of driving round etc and then drove home. About half way home it started to miss but nothing major.

http://valver.co.uk/astramk2/headgasket/head-gasket.jpg
http://valver.co.uk/astramk2/headgasket/head-gasket1.jpg
http://valver.co.uk/astramk2/headgasket/head-gasket2.jpg

Didn't take many pictures due to the rain.

John

[DarrenH]

doesnt look too bad, pretty substantial failure there though. you must have driven it a few hundred miles to get the gasket eaten away between bores like that.

have a good clean up, check the head with a straight edge and feela guage (make sure the blown section of the gasket hasnt eaten the head away too) then refit with *new GM gasket*

imho that is just a patter headgasket gone bad, i say that because in my experience pattern headgasket leave crap loads of gasket stuck the the head and block, patches here and there. GM gasket tend to pop right off in a whole lump leaving no remenants.

[johnl]

Will be ordering the Gaskets from Vauxhall Monday morning. With new cambelt and headbolts. The head it's self looks smooth and un damaged(doesn't show up to well on the picture) just full of carbon deposits where the gasket had failed. As for driving must have done about 40 - 60 miles after the miss fire started. It's then been started a few times after during fault finding.

[DarrenH]

sorted. i know it sounds like an unecessary extravagance, but whenever i take a head off i fit a ARP stud kit. only 110 quid or there abouts, re-usable, superior to bolts, and the next time the head comes off you can have it on the bench in an hour !!

[bigdrifter]

Thats blown good and proper there John!

[vauxmad]

just don't have much luck with the engines in this do you mate, still at least its a fairly simple fix and the block gets to stay in the bay this time!!!

[johnl]

sorted. i know it sounds like an unecessary extravagance, but whenever i take a head off i fit a ARP stud kit. only 110 quid or there abouts, re-usable, superior to bolts, and the next time the head comes off you can have it on the bench in an hour !!

Cheers for the advice. Will have to see how much funds are available. Don't get my bonus money from work till next month so might have to stick with bolts for now and then studs next time.


Thats blown good and proper there John!

Your not wrong there lol After the compression test all sorts were going through my mind.


just don't have much luck with the engines in this do you mate, still at least its a fairly simple fix and the block gets to stay in the bay this time!!!

I think I have unlucky patches with engines. My last GTE never missed a beat Racked up over 200k just the body work let it down in the end. This one the body works fine but engines are another matter. :(

[Ian T]

Good to see you've got to the bottom of it, even if this wasn't an easy fix. I acquired an Omega that had suffered a similar fate, but had been driven for much longer like that and had eaten about 2mm deep into the head between pots 3 and 4. Got it welded and skimmed, was as good as new afterwards.

Ian.

[johnl]

Well a tin of carb cleaner later. Looks like I've been lucky as the heads not marked :D. There are a few marks on the pistons also the heads got a few marks in the combustion chamber. At first I thought it was from where the metal bits of the gasket have broke off. However I'm thinking possible there were there before hand as all 4 pistons have a few little marks on them that's now visible after the carb cleaner. Made a start on the wiring as well. Will remember to take the camera out later if I do some more on it. If not it will be through the week after I've picked up the gaskets etc.

[johnl]

Well ordered all the bits I need from Vauxhall so they should be in stock Wednesday. :)

[johnl]

Got a call from the Vauxhall deallers this morning. All the stuff has arrived :) So picked it up on my way to work

Here's a sneak preview.

Got a complete headset
http://valver.co.uk/astramk2/headgasket/headset.jpg
Also the replacement heater matrix pipe.
http://valver.co.uk/astramk2/headgasket/waterpipe.jpg

[johnl]

Well the idea was to get up early and attack the car today and get it up and running again.

Working till 4am this morning put a stop to that. Got up at 10:30 and started shortly after then. In between the hail stone showers I've managed to get the head back on and tightened down, Cambelt fitted and exhaust manifold. Just need to change the oil and fit a couple of nuts and bolts plug a couple of the sensors in etc and then it should be good to go.

Given up for the day now though as I'm starting to get tired and hungry

[johnl]

Well it's running again. Just in time to beat the snow :D

[johnl]

I've done another thing on my list of jobs :)

Fit uprated Alternator
Replace Drive shaft.
Get rear arch looked at
Fit the alarm
Get the hole in the passenger foot well sorted. - Done last night. The hole was the size of a 10p.

Will be doing the drive shaft this week probably Wednesday as I'm off work then. Once thats done I'll be booking it in for it's mot.

[Ian T]

Getting there quickly then, don't forget to bleed the fuel rail if you disconnected the fuel lines, that's my favourite thing to forget and always results in lumpy running, which is a worry when you've got it all back together and turn the key for the first time!

Ian.

[johnl]

left fuel line connected making that mistake last time lol. done 80 miles already. apart from an oil leak cam cover gasket twisted slightly when I refitted it after the final head tightening stage. its been a pleasure to do.

[johnl]

Starting to really enjoy the jobs list it's getting smaller :)

Fit uprated Alternator - still waiting to do this.
Replace Drive shaft. - Done yesterday (read bellow for details)
Get rear arch looked at - Done today booked back in at the body shop
Fit the alarm - still need to do this.


Changed the drive shaft ready for it's MOT today. Was a complete ******* of a job. No mater how much I tried to lever the shaft out of the gearbox it wasn't having any of it. I decided to remove the diff cover plate in the end as I planed on changing the gear box oil anyway. Yuk is all I will say for the oil that was in there. Don't think it had been changed in the life of the gearbox. A quick tap with a hammer and chisel on the end of the drive shaft and out she popped.

As for the rear arch the drivers side has got a couple of specs of rust coming through. Will get pictures over the weekend. Whilst at the MOT station I nipped in to the bodywork place that did the work in the 1st place. Reckons on of the rust spots are from a stone chip but the other 2 spots he's not sure off. Either way he's going to sort it out for me under the guarantee :) Only downside is I've got to wait till the 28th of this month.

[johnl]

Well thought it was time I uploaded some pictures.

Here's the bits on the drivers side arch that its going back for.

This is the one he's said looks to have been caused by a stone chip.
http://valver.co.uk/astramk2/april/arch1.JPG

This one he's not sure whats caused it
http://valver.co.uk/astramk2/april/arch2.JPG

Same with this one
http://valver.co.uk/astramk2/april/arch3.JPG

Here's part of where I was tidying up the wires. Under the bonnets a little oily now really so need to pull my finger out. And finshs tidying the wires up.
http://valver.co.uk/astramk2/april/wires1.JPG

Anyway thought I'd try the new cleaning products my Dad's got in his work. Not sure what it's the soap/wax is called its orange and cost's about £40 for bottle of it. You only need a cap full in a bucket and it seams to do a really good job. Seems to restore a bit of the colour to the plastic.
http://valver.co.uk/astramk2/april/clean1.JPG

Next was the polish. Spray it on (pink in colour) and then buff off I'll let the relfection do the talking :D

http://valver.co.uk/astramk2/april/polish1.JPG
http://valver.co.uk/astramk2/april/polish2.JPG

[johnl]

Going to have a go a refitting the wings tonight on the car as I've never been happy with the gaps/shape. Will post before and after pics later on. Anyways this is all for preperation for it going back to body work place on Monday.

Can't remember if I put in the diary or not that it passed the mot with out any issues. Last couple of weeks it's been fine done well over a 1000 miles now. The exhaust has started blowing so will need to track down the cause and fix it. :( Also not been able track the rattle it has every so often when accelerating or pulling away from the passengers foot well. It's had all the front suspension replaced drive shaft on that side. It's had a different gear box and engine. But the rattle is still there. Any sugestions welcome.

[johnl]

Well carried out the work last night.

The before pictures didn't come out for some reason. Probably a case of user error and beer.

Anyway I'm happier with the panel fit now. Still not perfect but not as obvious as it was.

Here's the top half of the passengers side
http://valver.co.uk/astramk2/april/passengers-side-upper.JPG
Lower half. Can't get it to sit flush with the sil for some reason but the gaps apear correct
http://valver.co.uk/astramk2/april/passengers-side-lower.JPG

Drivers side was a lot worse to start with Here's the lower side.
http://valver.co.uk/astramk2/april/drivers-side-lower.JPG
and the upper half
http://valver.co.uk/astramk2/april/drivers-side-upper.JPG

Just before leaving my parents house one of the lads that work with my Dad had left his car. I know some of you like VW's so here a couple of pics next to each other.
http://valver.co.uk/astramk2/april/cars.JPG
http://valver.co.uk/astramk2/april/cars-front.JPG

Anyway will post pics of the rear arch when I get the car back from the body shop

[DarrenH]

good job, your cars looking great

[bigdrifter]

Certainly got a good shine on there John. Are your's pattern wings as mine aren't the greatest fit in the world either and keep meaning to adjust them?

[JOE_MK2_SXI]

pattern wings are a little bit of a nightmare!cheap but do your head in

[johnl]

Certainly got a good shine on there John. Are your's pattern wings as mine aren't the greatest fit in the world either and keep meaning to adjust them?

To tell the truth I'm not 100% sure id they are pattern parts or not. I picked them up as a stop gap from a lad on here that was breaking a GTE.


good job, your cars looking great

Cheers Darren, must be on the right track with it :D


Forgot to mention Whilst refitting the wings I had the skirts off. The sils are as they were when I got the car :thumbsup:

[johnl]

Got the car back from the body shop this evening.

http://valver.co.uk/astramk2/april/reararch1.JPG
http://valver.co.uk/astramk2/april/reararch2.JPG
http://valver.co.uk/astramk2/april/reararch3.JPG
http://valver.co.uk/astramk2/april/reararch4.JPG

Hopefully it last's this time.

[johnl]

No Pictures for the last few jobs. Just listing them really for the diary sake.

Tracked down a knock that had developed after catching a pot hole. Passengers calliper was lose. Tightened it up and the cars quiet over bumps again. :D

Picked up some EBC green brake pads from Richie00boy on Saturday morning fitted them tonight. Took the car for a quick test drive and the brakes seem to bite a lot more. (Could just be down to the pads been new will have to wait and see)

Saturday was spent fixing the exhaust where it had split. Only fixed it as a temporary measure till all the replacement bits arrive. As the Manifold from the Calibra and seems to catch on speed bumps etc. Also means I will be able to loose the cat thats been welded on to the manifold.

[johnl]

No Pictures at the minute :( Still on the camera.

Basically had an issue with the oil pressure gauge dropping randomly at tickover. This only started happening after changing the oil and finding small bits of metal swarf. Anyway booked last Friday off to investigate. Removed the sump to investigate further and found a few flakes in the bottom. Replaced the Big ends whilst they were accessable. There wasn't any real wear on them will post the pictures tonight.

Over the weekend the guy that does keeps the limo's and hurse paint in tip top condition had a look over the car he was impressed with the condition. More importantly he recons he'd be able to get the imperfections in the paint sorted out from where the body shop have resprayed it. He's coming back in the next month to finish of the work he was doing and offered to sort out if I bring the car round best of all he'll do it for free :)

[johnl]

Just had a call from the local vauxhall dealler, exhaust parts are in stock so will be picking them up tomorrow morning. This means I will be able to get rid of the Calibra manifold and cat. :D

[johnl]

Here's the big end bearings I removed the a week ago today. Car's done 350 miles so far and is running fine. Going to remove the sump tomorrow and check everythings still nice and tight.

http://valver.co.uk/astramk2/may/DSC01706.JPG

Here's the replacement manifold thanks to DarrenH. I'll be fitting tomorrow with the rest of the exhaust. Finally getting rid of the Calibra manilfold and the cat. :bananajump: Gave it a quick paint with high temp paint.

http://valver.co.uk/astramk2/may/DSC01709.JPG
http://valver.co.uk/astramk2/may/DSC01710.JPG

[johnl]

Well a quick trip to Vauxhall this morning. to pick up the following.

Spings, Rubber bush, metal insert for rubber bush, nut and gasket.
http://valver.co.uk/astramk2/may/DSC01712.JPG

Heat shield for the either the front silencer or middle one (Can't remember which they said they could get) Others apparantly are NLS
http://valver.co.uk/astramk2/may/DSC01713.JPG

Front pipe so I will be able to remove the Cat now. :)
http://valver.co.uk/astramk2/may/DSC01714.JPG

Just letting the car cool down a little bit before I start on it. More pics to follow.

[DarrenH]

nice job!!! is that front pipe a germany item ? i know one out of the 3 is, might be the middle section.

i've noticed early cars didnt have that headtshield, my F reg didnt, but my J reg has whole underbody kit.

[johnl]

Well the works done let here's whats been done.

Out with the old oil.
http://valver.co.uk/astramk2/may/DSC01716.jpg

Here you can see where the old Calibra manifold was cut and welded to the cat
http://valver.co.uk/astramk2/may/DSC01718.jpg

The dreaded cat
http://valver.co.uk/astramk2/may/DSC01717.jpg

Off with the old.
http://valver.co.uk/astramk2/may/DSC01719.jpg

Here a comparison between the old one and the new manifold and front pipe. There's not much difference in the total length between them
http://valver.co.uk/astramk2/may/DSC01720.jpg

Heat shield fitted. :)
http://valver.co.uk/astramk2/may/DSC01721.jpg

Manifold bracket built up ready to be fitted to the mount.
http://valver.co.uk/astramk2/may/DSC01724.jpg

Fitted to the rear engine mount.
http://valver.co.uk/astramk2/may/DSC01725.jpg

Manifold fitted
http://valver.co.uk/astramk2/may/DSC01726.jpg

And from under the car you can see where the bracket attaches to the manifold.
http://valver.co.uk/astramk2/may/DSC01728.jpg

Here's two clips of it all running. Have to excuse the smoke it's from the paint. Also have to excuse the quality

Right click and save as (http://valver.co.uk/astramk2/may/MOV01730.MPG)

Right click and save as (http://valver.co.uk/astramk2/may/MOV01729.MPG)

[johnl]

nice job!!! is that front pipe a germany item ? i know one out of the 3 is, might be the middle section.

i've noticed early cars didnt have that headtshield, my F reg didnt, but my J reg has whole underbody kit.

Not sure it's got made in France on the label or should I say it did have.

As for the heat shields my H reg 1 had them but none of the others did This ones got the pegs for it the shields to bolt to so I thought I'd try and source them all.

[laney]

just seen your pics of exhaust, may be a little late, but i have a piper stainless decat at home im not using, if you want it make me an offer.

[johnl]

just seen your pics of exhaust, may be a little late, but i have a piper stainless decat at home im not using, if you want it make me an offer.

Cheers for the offer but going to stick with the standard setup.

Anyway decieded to give the car a clean both on top and the underside.

Here's a shot from the rear. Forgot the rear arm had been painted
http://valver.co.uk/astramk2/may/DSC01748.jpg

The exhaust no longer sticks out at the back. Could do with cleaning the tail pipes.
http://valver.co.uk/astramk2/may/DSC01757.jpg

Safe to say the heat proof paint isn't very heat resitant it's already peeled in places. Might have had something to do with the jet wash.
http://valver.co.uk/astramk2/may/DSC01746.jpg

Cleaned under the bonnet. Need to get some gunk or similar to clean the gear box though really.
http://valver.co.uk/astramk2/may/DSC01747.jpg

Whilst under the bonnet I thought I'd grab a shot of how I monunted one the modules from the later style loom. Expansion bottle bracket.
http://valver.co.uk/astramk2/may/DSC01758.jpg

Here's the one of the outside.
http://valver.co.uk/astramk2/may/DSC01744.jpg

Here's a couple of arty shots.
http://valver.co.uk/astramk2/may/DSC01752.jpg
http://valver.co.uk/astramk2/may/DSC01755.jpg

Best of all now it's sorted it's quieter only got 2 rattles to track down now.
http://valver.co.uk/astramk2/may/DSC01754.jpg

[DarrenH]

what paint did you use ? halfords to 2 types, a high temp paint and very high temp paint. the latter is the obvious choice for the manifold

not to worry though, i know silver looks better but dont forget the stock manifolds are stainless steel :)

good work all round though, cant believe that calibra exhaust didnt sheer off, no flexi join !!!

[johnl]

what paint did you use ? halfords to 2 types, a high temp paint and very high temp paint. the latter is the obvious choice for the manifold

not to worry though, i know silver looks better but dont forget the stock manifolds are stainless steel :)

I think it was Hycote spray can jobbie which said it's suitable for manifolds. Came out very dull so I painted over it will an aluiminum coloured heat proof paint. Think it's this one thats peeled move than the base one.



good work all round though, cant believe that calibra exhaust didnt sheer off, no flexi join !!!

Cheers starting to get it how I want it.

It sheered last month just after the cat. At first I thought the noise was bearing related. When I fitted it was only ment to be a temp fittment and ended up staying on for all this time.

[johnl]

Time for an update on the old diary front. Finally tracked down the rattle on the engine. Been told the oil gauge is faulty reading higher pressure than there actually is and the engine's suffering oil pressure loss at certain engine speeds.

Anyway short term plan is to change the engine so that the current one can be stripped and checked over fully.

Engine should be coming out tomorrow and changed for the one Alistair J dropped off tonight :)

[johnl]

Not put any updates on here for quite a while :( Swapped the engine over and it's not given me any issues since appart from randomly smoking when accelerating. Anyway picked up some tinted lookiing indicators from TomGTE fitted them this weeked. Whilst fitting them I also stripped the headlights down and cleaned the lens as well as polishing the reflector also carried out the modification Tom has discribed in the members area.

Here's the old lights next to the new ones

http://valver.co.uk/astramk2/car/DSC01828.JPG

Heres the drivers side all done passengers side still to be done.

http://valver.co.uk/astramk2/car/DSC01830.JPG

All done and the car washed

http://valver.co.uk/astramk2/car/DSC01836.JPG

from another angle

http://valver.co.uk/astramk2/car/DSC01837.JPG

Just need to clean the inside of the car out now.

Going to start rebuilding the old engine as the current one now smokes every time under hard acceleration :(

[mick g]

looking good mate...

[Belmont turbo]

looking good mate liking those head lights might have to do that to mine! are the indicators proper tinted or modded like the head lights?

[johnl]

Cheers for the comments. They are modded the same way as the headlights.

[Belmont turbo]

cool they look better than the proper tinted ones

[Tom]

Looks great John :thumbsup:

[astramad]

as above like the look of them very smart mate

[johnl]

Well not put much on here as to whats been done. Brief run down. I replace the sump gasket for the 8v single rubber gasket in an attempt to solve the rather bad oil leak. 4 litres every 1000 miles. :( Sump hasket has made a very big difference just got to sort the leak on the oil pump. Engine seems to be smoking less as well which is weird.

I've had new Shocks fitted to the front as these were to blame for the knocking noise at the front.

Today I refitted the Strut brace and I've also fitted the Door cards F'Astra was selling the other week. Also fitted a complete set of Vauxhall wiper blades. Didn't manage to get any pictures as the battery was flat on the camera :(

[Gteman]

4 litres every 1000 miles (shock)

Now that's some full on rust proofing going on there (bow)

[johnl]

4 litres every 1000 miles (shock)

Now that's some full on rust proofing going on there (bow)

Tell me about it. Wish I'd known about the other leak as i would have attacked that at the same time.

[johnl]

Car's parked up in my dad's garage for the time been. It started to tap/knock on the motorway. Only does it under load. Not looked at it probably won't get around to looking at it either till after xmas now. :(

[johnl]

Had a spare 1hr this afternoon. Car's running on 2 maybe 3 cyclinders. Checked it for compression and cyclinders 1 and 2 get cracking compression however 3 and 4 are not so good. They do however appear to hold what little compression they get. Going to remove the head and go from there.

[johnl]

Spent an hour on the car today. The head is ready to be lifted off ran out of light called it quits till tomorrow. Forgot to take the camera with me so didn't get chance to take any pictures. Saying that though I'm pretty sure we've all seen a head been removed by now. Whilst the head is off going to check the pistons. And look at replacing the rings whilst it's half stipped down. I'm also going to use the time to replace the oil pump gasket.

[johnl]

Well got the head off this morning. Headgasket has gone between 3 and 4. Will upload a pic later.

[johnl]

Still not uploaded the picture of the gasket :( Anyway more has been done. I've removed the piston's and made a start on lapping all the valves in on the head and cleaned the pistons. Ordered headset, rings, bearings and cambelt kit from autovaux. They have all arrived so it's just a case of building the engine back up now

[johnl]

Still not got around to uploading any pictures :( Anyway Head's half done. Lapping the valves in and replacing the valve stem seals. Forgot to mention that it looks like only 1 cylinder was burning oil as no. 2 cylinder was very badly coked up with carbon where as the other 3 had no deposits on them. Same with the head and valves no.2 full of carbon deposits. Not got round to doing the stem seals on this that half of the head yet so don't know if they were to blame. One thing I did notice when removing the piston was the bottom ring was not in brilliant condition.

[johnl]

Well spent a good 3 hours on the head. All the valve stem seals have been replaced. Valves have all been lapped in. Started to clean the matting face up. There's residue from the head gasket on there still.

More importantly I've took some pics and uploaded them (shock)

Here's the head gasket. it's the wrong way round on the pic as in the hole was between 3 and 4 not 1 and 2

http://valver.co.uk/astramk2/2009/DSC01447.JPG

Valve stem seals. Old vs new as can be seen the center hole is quiet a bit larger compared to the new one. Also the rubber part of the seal seamed very brittle in comparison.

http://valver.co.uk/astramk2/2009/DSC01982.JPG

It looks like somebody has tried doing some work on the head. The inlet valve throats all seamed to have some attempt at smoothing them.

Not to clear on these pictures
http://valver.co.uk/astramk2/2009/DSC01966.JPG
http://valver.co.uk/astramk2/2009/DSC01981.JPG

All the inlet valves have cleaned up nicely. With a bit of elbow grease. :)

http://valver.co.uk/astramk2/2009/DSC01978.JPG

Going to finish cleaning the head up tonight and then building the engine back up over the weekend whilst the weather is meant to be a bit warmer.

[laney]

woo, i have seen a few blow between the bores, i would advise that you have the head faced, just as a precaution.

[johnl]

No pictures from today's work. Anyway the following has been done.

Cleaned the mating faces on both the head and block. Checked the head where the gasket had blown and it's all fine :D Fitted new rings on the pistons and fitted them back in the block. Engines back in the car Just need to fit the head and sump. Hopefully will be done tomorrow.

[richie00boy]

Good luck John. How did you hone the bores? Yourself with one of those things that fits in a drill or did you take it to a machine shop?

[johnl]

Good luck John. How did you hone the bores? Yourself with one of those things that fits in a drill or did you take it to a machine shop?

Fingers crossed. I've getting abit fed of removing and refittings engines now though. As for the bores I mate has one of those tools. So gave it a quick going over.

On the down side I can't find where I put the big end bolts I bought from F'astra. So at the minute it's built up using the old bolts. :( All I remember is I put them in a safe place.

[johnl]

Well started late today. Found the big end bolts So they have been fitted torqued down and the old ones removed. Got the head on and it's been torqued dow. Got fed up of the cam cover been painted in Red hammerite. So I've made a start on cleaning it up. At present it's now in grey primmer. Will be spraying it mistral grey hopfully in the next couple of days. Will get pictures whilst thisi is done.

[Mr-G]

Making good pregress matey, keep it up :)

[johnl]

Making good pregress matey, keep it up :)

Cheers Hopefully willl be running next weekend. Not going to be able to touch it much this week. Due to work and taking the kitten to the vets bottom jaws to short and his top fangs are digging in to his bottom lip.

Anyway here are pics of the covers. Only in primer at the minute. Just waiting for it to dry so I can get rid of any imperfections.

http://valver.co.uk/astramk2/2009/DSC01987.JPG

[johnl]

The covers have both been prep'd now. Hopefully will manage to get the 1st coat of paint on them in the morning before work weather dependant.

[johnl]

Well been on call and working on cars doesn't mix to well. Saturday got most of the engine built back up. Kept getting calls so couldn't put all my time on finishing it off. Ended up having to down to the servers and fix them :( Today was a lot better next to no calls all morning so I finished fitting the cambelt and inlet manifold. Filled her up with oil and started turning her over. Battery didn't have enough charge to turn over quick enough to build up oil pressure so left the jump leads on and carried on with the little odd's and sods. Next minute there was smoke bellowing out from the engine and inside the car. Couldn't find the 10mm spanner to diconnect the battery so a frantic yanking on cables and I spotted the spanner. For some reason the injection loom has decieded to fry it's self all 4 wires for the air flow meter. So had to rip the loom out of the car. and run fresh wires where the old ones had melted. An hour later the loom was repaired. As I was running out of light and getting cold I just pluged in all the sensors and tucked the ecu out of the wy under the scuttle panel. Re attached the jump leads and flicked the key.... after a bit of a cough she sprung in to life :) Called it a day after that as i need to run up to temp and do the last tightening of the head bolts. Check for leaks etc. Probably won't get chance now till Saturday :(

[laney]

f**k me mate, sounds like a close call with the wiring, something short out? glad you have it sorted though.

[johnl]

f**k me mate, sounds like a close call with the wiring, something short out? glad you have it sorted though.

If I tried saying I didn't shit my self it would be a lie. Glad the Anna had nipped back in the house so she didn't see me panic.

Wasn't in the best place to have a car fire either. Was parked next to one of my Dad's work cars. Just glad I got it to start.

[laney]

bet it was a nightmare mate, i remember my mate changing a battery on his mrs corsa, was the wrong battery for the car and he had put it in the tray round the wrong way and wondered why the terminals were different, he put the live on 1st and he only hammered the earth onto the live terminal, it then had a massive spark and the loom melted its self to the block, loads of smoke and he even had a fire extinguisher and didnt use it, he had massive burns on his hands where he was trying to get the terminals off in a panic. luckily his mrs had a screwdriver and prized the terminal off, panic over. i had the nice job of sorting it though, only needed engine loom, alternator and even burned ste starter out too. think he learned a lesson that day. lol

[johnl]

i was lucky only melted 1 wire the full length of the loom. Then 3 next to the air flow meter needed to have a section cut out and replaced. Not sure what caused it to melt thought as the air flow meter was un-pluged

[laney]

i would be checkin the rest of the loom mate, it dont just short for no reason?
just incase of a repeat, may not be so lucky next time, (hope it never happens though)

[johnl]

i would be checkin the rest of the loom mate, it dont just short for no reason?
just incase of a repeat, may not be so lucky next time, (hope it never happens though)


yup stripped the whole loom took a while to remove the plastic/rubber cover. Think the wires had degraded and shorted out as the rest of the loom turned out to be fine.

[laney]

cool, nice work mate, glad u have sorted it :thumbsup:

[johnl]

Well she's running again :D let her get up to temp this morning and then carried out the final head tightening sequence. Done all of 5 miless so far driving from my mum and dads home. Boy did it feel low after driving round in the landrover for the last month. Sure I was lifting my bum when going over speed bumps for the fear of it catching on them. It felt good to be back behind the wheel. Even the cat got back on his spot in the car and layed across the passenger side of the dash.

[johnl]

Forgot to update this on Sunday. Car started up fine. Pulled off the drive and there was a small pool of oil. Had a quick look and couldn't see any obvious leaks. Checked the oil level and this was just below max. So I drove the car back to my mum and dads so I could finish tidying up from where I'd been working on the car. Pulled up outside there house for the low oil level light to come on. Turned the car off and checked the level and it was just bellow minimum. :( Also able to see the oil leak. Cam cover gasket looks to have been pinched in a couple of places. So I've parked the car back up in the garage and back to using the Landrover. Orderd a replacement gasket from Vauxhall should be here Wednesday. Total mileage done so far is 20 miles.

[mick g]

Just teething problems....

[johnl]

Just teething problems....

Yup felt good to be able to drive it again even if it was only a couple of miles.

[astravanmk2]

any news john?

[johnl]

Called Vauxhall this morning to check if the replacement gasket has arrived yet. They were just unloading the pallet and told me they will give us a call back to confirm if it's there or not. Other than that it's just sat there waiting for the gasket to be replaced.

[johnl]

Well got the car this morning changed the cam cover gasket. Topped the oil back up and re connected the battery. Into life she started. So far so good have now covered 55 miles in total. :D

[laney]

nice one mate, glad u sorted it :thumbsup:

[johnl]

For the sake of the diary the cars now covered 250 miles. So will be getting an oil change. Only 1 issue has cropped up and that is it tappets tap for around 30 seconds in the morning or if the cars not been run for around 10hours. Which it never used to do. Hopfully it will be resolved once the oil's changed if not I will get a set of new tappets at a later stage.

[STEVEBOXER]

RESPECT!!!!!!!!!!!:grinning-smiley-043

You must be so determined,fair play:thumbsup:

[DarrenH]

its hard to judge whats "normal" when you are running in because theres a few grammes of engine going round in the oil system, lol

glad its going ok though.

maybe not very practicle but it will love you more if you do all the mile intervals at once, like plan a day out somewhere a few hours away, and do it all on b-roads for entertainment and engine workout.

[johnl]

Parked in the NCP carpark under work last night pulling upto the barrier theres a huge speed bump. Car bottomed out on it :( I wouldn't say the car is really low and it's the 1st time I've had it happen. Anyway looks like the only damage is the exhaust brackets has snapped. So I need to get under the car and re mount the exhaust properly. Luckily I had a couple of cable ties so was able to get it home.

I was going to do that orignally Darren however after planning the day out for the sunday I ended up having to take the car back off the road due to the cam cover leaking. The following weekend I had stuff on so had to stick with doing the 1st batch of mileage and then changing the oil. It's since then really only done trips down a/b roads so that I can vary the speeds.

[johnl]

Well I changed to oil and filter. Also re hung the exhaust one of the rubber hoops had snapped and the one at the rear box had slid of the back box. Took all of 5 minutes and it was sorted.

Car's done another 100 miles. Going to give it a polish this weekend Also going to get and try a nylon relief valve from SBD

[richie00boy]

Have you noticed much 'metallicness' to the oil?

[johnl]

there was a metalicc look to the oil.

[DarrenH]

the scary glitter ! makes you appreciate how little the oil fliter is actually picking up lol

[johnl]

the scary glitter ! makes you appreciate how little the oil fliter is actually picking up lol

Thats the one.

[johnl]

Not put much of what I've done to the car since it going back on the road. There's been a bit of activity Anyway had to replace the back at the start of the month. Whilst under the car fitting the box I spotted a couple of patches that needed to be painted up as the exhaust had caught a couple of spots. Whilst driving home from work Last Wednesday I started getting a grating noise after coming of the motorway. Sounded similar to when a stone guard catches on the disc. Anyway After checking the front of the car over couldn't find them catching. Moved to the back of the car. Bingo sounds like the bearings need adjusting as the grease looked a little past it I decided to strip it all down and give it a check over. So Saturday morning I stripped the rear hub down. Going to need to get new rear discs looks like it's the original disc. So they are on order should be here tomorrow. Going to do the fronts a the same time. Whilst sorting the rear disc's out I noticed a bit seam sealer flaking behind the rear section of the skirt. So removing the rear section of skirt showed the extent of how much the body shop bodged the work. There's a gaping hole in the sill at the rear. I'll get some pictures as it's weird how it's gone. The inner sill is fine and no signs of rust on it. The outer edge of the sill is also fine it's just the bottom part thats missing. Also the extra support section is also still attached to the outer skin. Car's going to be patched up on Wednesday/Thursday. In the mean time I've put a coat of paint on there so that it doesn't rust etc.

[johnl]

Well here's some pic's. You'll have to excuse the quality and the tie.

http://www.valver.co.uk/astramk2/sills/IMAG0132.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0133.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0134.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0135.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0136.jpg

[richie00boy]

Bodgetastic!

I went to a 'medium price' bodyshop to get the arches rust cut out, plated and full respray. The rust was not that bad but I wanted it doing before it got bad. Cost me about £1200 all in 4 years ago. When my dad was doing the sills the other week he said he could see that they had not put any new metal in at all and it's all just filler :eek:

I'm only going to use top bodyshops from now on or do it myself. It's not worth the hassle of it all falling apart again later and having to pay again.

[johnl]

Tell me about it. A lad that works with my Dad is going to sort it for me. He really takes pride in his work and it shows. Showed him the car and he reckons he'll be able to sort it out for around £40. Last time I had any work done by him you could hardly see the welding afterwards. So will get some decent pictures up after he's patched it up.

[johnl]

Didn't get chance to get the drivers side due to the way the car's parked on the drive. But it's a whole lot worse. The outer skin was only attached to the inner arch in places with Seam sealer. I'll try and get a picture tonight after work.

[G.TERI.E]

:eek:f****** bodger's thats well out of order, i think i would be having words with them at the bodyshop, thats upsetting to see after you have paid out x-amount of ££'s to have a job done and then you find big holes like that.

[johnl]

And here's the drivers side.

http://www.valver.co.uk/astramk2/sills/IMAG0138.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0139.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0140.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0145.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0147.jpg
http://www.valver.co.uk/astramk2/sills/IMAG0148.jpg

The lighter colour of paint is from where I put some silver paint on after I started shifting the seam sealer with a wire brush.

[johnl]

Well I got carried away with the jet wash. I managed to remove the umder seal see pics bellow.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00300.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00302.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00290.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00291.jpg

So I used some spray can paint. After cleaning the metal with a wire brush

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00292.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00293.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00303.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00305.jpg

After which some underseal has been applied. Going to let this dry of and then go over it with some mystral grey paint

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00294.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00295.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00296.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00307.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00306.jpg

And here a pic of the passenger mounting of the braided front brake pipe hopefully it shows what has to been done to fit them.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00297.jpg

Still need to shift the bottom pulley bolt so I can sort the oil leak. Once the under seal has had time to dry off I will go over the arch with another proper coloir spray can and laqure it.

[Danny]

Nice job done there, John.

Looks very nice.

[johnl]

Whilst the sun was out today I did a little bit more on the car.

Replaced the power steering belt. As it was jumping about a lot when the engine was revved. Didn't get any pics pretty sure I got a video clip though. Not uploaded it yet.

Anyway heres the other work I carried out. Here's old faded orange tax disc holder.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01573.jpg

On the floor waiting to be binned.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01575.jpg

It left a glue residue on the glass :(

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01574.jpg

Some glass cleaner and some elbow work and a bit of time all gone :)

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01576.jpg

New club tax disc holder :)

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01577.jpg

Also gave the car a polish.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01569.jpg

The last to lots of pictures have all been taken using my new phone which I'm really impressed with the pictures it takes.

Here's one of the dash I took.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC00231.jpg

Makes the dash look dirty :(

[johnl]

Well I've painted the passenger wheel arch. And laquered it. Forgot to get a picture before Putting the wheel back on

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01595.jpg

3 more to go.

[johnl]

Well I've had a busy couple of days on the car. Took the time of to spend it with the other half and ended up chasing oil leaks in stead.

Started of with nipping to my mates garage and borrowing the air ratchet. 2 seconds later the pulley bolt was off. He refitted it for me so I could drive home and sort out it there.

Anyway got home removed the bottom pulley and started the strip down
http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01609.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01611.jpg

On this one you might notice the cam shaft seal also looked to be leaking.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01610.jpg

Built back up

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01612.jpg

minus the crank shaft seal as I left that at my parents house. Short car journey later and I got home just in time for the heavens to open. so no more pic's :( replaced the cam shaft seal and took the car for a test drive so far so good. Going to jet was the underneath to tell for certain.

Also need to replace the alternator as it whines a little.

[johnl]

Well I've managed to cover around 60 miles in the car. No longer looks to be loosing oil (touch wood)

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01616.jpg

[richie00boy]

Good news John, do you know what air ratchet your mate used, it would be handy to know as I've just got myself a compressor.

[johnl]

I'll try and find out. All I know is apparantly it's got quite a kick to it.

[Mr-G]

Good job there fella :D

[johnl]

Good job there fella :D

Cheers. Hopefully over this weekend I'll get the drivers arch painted the same as the passenger side. Then got the rear arches to do.

Also got an under tray to fit thanks to Mark (mshaw1980) :Banane47:

[johnl]

Well the joy of driving the GTE is on stop for the time been. Drove home from work fine tonight no issues however 5 minutes later I started the car up to go out to the shop and you could hear a couple of tappets and the oil gauge only showed the 1st straight bar. Couple of seconds later the pressure picked up to half way and the tappet quietened up. turned the car off and it did exactly the same. If the engine is kept at 2k it reads full pressure for aroun 30 seconds and then drops to 3/4s anything above or bellow and the pressure drops straight away to either 3/4's or half. Crawled over to my parrents house and put the car in the garage. Will take a look at weekend.

[johnl]

Well its been a busy weekend for myself. Father in laws car failed it's MOT on Friday. Front wish bone bush and a small patch needed on the rear boot floor. As he works shifts I othered to run him to work as he started his 1st of 4 5am starts on Saturday. If you wonder what this has to do with the diary for my Astra then hopefully it will explain why some of my pictures have been taken in at 5am.

Anyway the Engine under tray was delievered at the start of the week so I thought I would clean it up and make some repairs to the bolt holes.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01655.jpg

After cleaning it up I thought it might look better with some black paint on for good measure.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01657.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01658.jpg

Now all fitted.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01661.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01662.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01663.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01668.jpg

Not sure how long it will stay in 1 piece though due to the speed bumps round here. Didn't think the car was that low.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01665.jpg

Whilst I was hard at work the cat helped like normal.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01659.jpg

[johnl]

Cars done close to 200 miles since sorting the oil pressure out and it been fine. Under tray has survied with out catching any speed bumps as well :Banane47:

Well I had a spare hour tonight so I thought I'd made a start under sealing the rear drivers side arch.

Going to have to shift the fuel pipes out of the way and the rear shock but for tonight it was mainly to clean the mud from the arch and get the underseal coat on.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01698.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01699.jpg

Need to leave it a day or so to dry off before I put the grey paint and laqure to match the front archs. Whilst carrying work out it's made me realise I'm going to need to replace the rear springs at some point as they are looking a little worse for wear. Also need to paint the floor etc.

[laney]

nice job mate, and believe me ur gonna love doing the floor, i looked like a black man for days after i done the whole underneath of mine, i did 3 coats too, took 2 bloody weeks, laughing about it now but at the time i remember being red raw trying to get that stuff off.

[johnl]

nice job mate, and believe me ur gonna love doing the floor, i looked like a black man for days after i done the whole underneath of mine, i did 3 coats too, took 2 bloody weeks, laughing about it now but at the time i remember being red raw trying to get that stuff off.

I'd say it's bad enough getting of your fingers doing the arches but at the moment I've got a lack of feeling in my hands at the moment so can scrub as hard as I like to shift it.

A mates offered me the use of the ramps at his garage so I don't have to lie on back to get the floor done. Whilst doing the floor going to replace the brake lines and fuel pipes. Going to also try a find a decent body shop to replace the drivers side arch as the one I used wasn't brilliant. The arch pannel the fitted has start to go just behind the rear bumper.

[laney]

its defo a git to get off, especially when it gets in a hair. i used 1.5 meter axle stands when i did mine, so could just about sit under the car, got my hair in it every night, lol

[johnl]

its defo a git to get off, especially when it gets in a hair. i used 1.5 meter axle stands when i did mine, so could just about sit under the car, got my hair in it every night, lol

I manged to get some in my hair tonight. Stuck my head in the arch and looked up to try and make sure I had got the side thats out of site. Only to think to my self it would have been better to paint that side 1st as I lent in the arch a bit to far. :banghead:

Will just have to remember when I do the passenger side.

[johnl]

Well I've spent around 5 hours on the car today as Anna wasn't well so I left her in bed whilst I worked out side on the car. Also spent an hour cleaning up afterwards.

I Remeber I'd never took pictures of the welding after I'd had the Arch/sill repaired from the body shop doing half a job. To say I'm impressed with his work is an understatement. The guy really takes pride in his work and makes sure when doing welding work that the job is painted/protected on both sides afterwards. Can hardly see where he's patched the hole.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01706.jpg

Any way I made start on the on the passenger rear wheel arch cleaned it all up and then painted it in Zinc primer Applied to coats. here's the finished results.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01707.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01710.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01712.jpg

Whilst waiting for it to dry I decieded to finish of the drivers side rear arch.
3 coats of Mistral grey over the underseal and then 2 coats of laquer Also touched up the paint on the calipers and disks. After removing the fuel filler pipe I need to source a replacement screw, as the original one's thread has rusted away so it looks like a nail instead. Hopefully the local Vauxhall dealler has them in stock.

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01713.jpg
http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01715.jpg

After I'd finished I went back to the passenger side and applied 2 coats of under seal. And like an idiot I manged to get a good amount in my hair (hence why it took me an hour to clean up after I'd finished

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01716.jpg

http://i682.photobucket.com/albums/vv187/superstartaxi/DSC01718.jpg

[johnl]

Well finally finish the last wheel arch this weekend. Also made a start on cleaning the wheels up on the inside 17 years of road dirt, brake dust and the odd split CV boot they were quite a mess. So far just jet washed and some oven cleaner later. they are a lot better. Just need to give them another going over then going to be painting them. Didn't get any pictures of the wheels due to the amount of crap I ended up been covered in.

Here's a picture of the finished wheel arch. Forgot to take a picture till after the car was back on the ground.

http://www.valver.co.uk/astramk2/GTEPics/DSC01753.JPG

For some reason the laqure has discoloured the paint layer. Not sure if it because I didn't leave the paint long enough to dry or if it's because the under seal was thicker in places?
http://www.valver.co.uk/astramk2/GTEPics/DSC01754.JPG

You can see the passenger arch has started to go in the same place as the drivers side. It's just at the corner. The body shop tried saying it was been caused by the rear bumper rubbing on it when it went back due to some issues with the finish. But whilst doing the rear arches I checked and the bumper has plenty of clearance so I can't see it been that. More inclinded to say it's their shoddy work. :(
http://www.valver.co.uk/astramk2/GTEPics/DSC01755.JPG

[johnl]

Well you might have seen my post about possible head gasket failure, I removed the head off to investigate the water loss and the system pressurising.

Here's what the expansion tank looked like

http://www.valver.co.uk/astramk2/headgasket/DSC01968.JPG

Remove the head and the gasket didn't really show any signs of damage on the most part till the metal section going around no4 cyclinder. The coating had started to wear off. Further looking at the head revealed the cause.

http://www.valver.co.uk/astramk2/headgasket/DSC02002.JPG

http://www.valver.co.uk/astramk2/headgasket/DSC02003.JPG

Going to take it to the local engineering place on Monday and see what they say about sorting it.

[richie00boy]

What do you think did that? Speck of dirt when you put it back together?

[johnl]

Not sure what's caused the damage to tell the truth. If I'm honest I've been toying with the idea of giving up and moving on from the Astra and getting either a Cav GSI or Cav Turbo.