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Old 01-15-2016, 01:26 AM   #21
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Windshield washer tank is full and pump sounds like it is working but no fluid is sprayed on the windscreen or the hatch window.

I suspect a hose at the pump failed or dislodged itself.
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Old 01-16-2016, 08:13 PM   #22
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Default Re: Astra 45k mile service - inexpensive & runs like new!

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Windshield washer tank is full and pump sounds like it is working but no fluid is sprayed on the windscreen or the hatch window.

I suspect a hose at the pump failed or dislodged itself.
This morning I looked at this issue and the pump was not operating. The problem was a blown fuse for the windshield washer pump (10A at #7 under the hood on my car).
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Old 01-16-2016, 08:17 PM   #23
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Default Re: Astra 45k mile service - inexpensive & runs like new!

The Key FOB plastic body splits when I open the metal key with the "switchblade" action - very irritating.

There is a video showing how to reglue at:

https://www.youtube.com/watch?v=H389kjDPzrA

I will just use the spare key for now. . .
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Old 01-24-2016, 10:21 AM   #24
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Last night while brushing the snow off the car, I snapped the rear windshield wiper arm.

I had the arm lifted off the window but a light tap in the cold weather was enough to break it.

It appears the Saab part number 93178858 with the Astra 93178858...
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Old 04-02-2016, 04:47 PM   #25
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Low coolant warning indicator is lighting again, although coolant is filled.

And error codes 2122 & 2138 are on again. I will try drying out the UEC (Underhood Electrical Centre) once again and sealing the box with some dielectric grease.

And the driver's side door is leaking more than ever.

Never a dull month with the Astra...
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Old 05-15-2016, 12:08 PM   #26
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Default Re: Astra 45k mile service - inexpensive & runs like new!

code 2122 is back again although it cleared itself out today.

I will check the UEC for drying again (sigh)...
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Old 06-18-2017, 09:55 PM   #27
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Default Re: Astra 45k mile service - inexpensive & runs like new!

At 62k miles -

Recent work:

- Auto transmission full rebuild bypassing defective shared cooling with new independent transmission radiator (~ $2,000)

- New A/C compressor and related accessories (~$800)

- "Repair" defective "low coolant" warning on middle screen ($0)

Pending work for this week, most DIY:

- Refurbish yellowed polycarbonite headlight covers ($30)

- Replace air filter, replace pollen filter, change oil ($60)

- Replace broken wiper arm (and blade) on back window ($25)

- Repaint peeling roof rack tracks ($10)

- Polish paint & deep clean interior ($50)

- Flush engine coolant (it looks like milk chocolate again) ($)
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Old 07-06-2017, 01:08 AM   #28
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Default Re: Astra 45k mile service - inexpensive & runs like new!

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Originally Posted by AstraFasta View Post
At 62k miles -

Recent work:

- Auto transmission full rebuild bypassing defective shared cooling with new independent transmission radiator (~ $2,000)

- New A/C compressor and related accessories (~$800)

- "Repair" defective "low coolant" warning on middle screen ($0)

- Refurbish yellowed polycarbonite headlight covers. Look like new. Took 10+ hours. Used Mothers kit with power ball. I needed to use some 600 and 1500 grit wet paper from home as the kit did not have enough sandpaper ($30)

- Replace air filter, replace pollen filter, change oil ($80)

- Replace broken wiper arm (and blade) on back window ($25)

- Repaint peeling roof rack tracks. Peeled paint by hand, quick sand with 400 grit dry paper, clean with Alcohol, paint with black engine spray paint I had in basement ($0)

- Flush engine coolant (it looks like milk chocolate again). Got a good Saab mechanic to do a real 1 week long flush and replace hoses ($900) : (

- Fix defective AC squealing / moaning. Replaced accessory belt, accessory belt tensioner, defective GM alternator pulley (see TSB for auto transmission cars). DIY cost was under $150 but replacing the pulley was the worst 10 hour project of my life. Documented in the "Alternator Pulley?... " thread. Very painful, frustrating, and difficult.

- Polish paint & deep clean interior (after the alternatory pulley nightmare, no polishing this year!)
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Old 08-09-2017, 10:47 PM   #29
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Default Re: Astra 45k mile service - inexpensive & runs like new!

- Replaced defective Takada airbag on warranty recall ($0)

- Cleaned throttle body and MAF again ($0)

- Rear left power window does not work. Painful wiring repair is documented at saturnfans.com but I'll pass on that

Car runs like new and still looks nice. I also notice a lot more pep with premium fuel.

No more scheduled maintenance other than oil changes for the next few years. . .
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Old 11-29-2017, 07:55 PM   #30
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Default Re: Astra 45k mile service - inexpensive & runs like new!

P0496 code popped up. That is EVAP System No Flow During Purge.

I think the repair is to replace the purge valve which is easy access (part 55562350 for about 70$.

I will try removing the part, checking electrics and cleaning it with MAF cleaner.
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Old 11-30-2017, 08:06 PM   #31
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Default Re: Astra 45k mile service - inexpensive & runs like new!

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P0496 code popped up. That is EVAP System No Flow During Purge.

I think the repair is to replace the purge valve which is easy access (part 55562350 for about 70$.

I will try removing the part, checking electrics and cleaning it with MAF cleaner.
I think cleaning the purge valve did the trick.

Took about 30 minutes total and very easy to access. Removing the two hoses takes some strength.

Purge valve is a black cylinder about 2" in diameter x about 2" in length. It is very easy to access. It is also quite delicate.

Some steps I tried but you need to do more research before starting. There can be fuel vapours so use extra caution (e.g. outside in ventalated area, no smoking, no electronics, no sparks, etc.).

- disconnected the battery

- carefully removed the two hoses at the valve

- removed the electrical connector

- removed the purge valve from the car

- sealed the two hoses with plastic tees

- cleaned the valve gently spraying MAF sensor inside both holes then draining a few times

- tapped both sides of the valve gently on a hard clean surface to help drain cleaner and perhaps loosen any debris

- gently used some compressed air in both openings (at a distance with very low pressure)

- Let dry and reconnected purge valve

- cleared the P0496 code manually with an OBD reader

While using the compressed air, I noticed a few small black pebbles on my workarea. They looked just like the activated carbon in my home airfilter. Those might have been the problem. Owners of other cars have reported carbon bits clogged the valve resulting in similar codes.

I've driven a few miles and the yellow engine light has not returned.
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Old 12-02-2017, 06:31 PM   #32
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Drove a few days and P0496 has not returned. Engine also runs smooth and peppy again so I think the cleaning worked fine.

Cost 0$
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Old 12-04-2017, 06:59 PM   #33
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Default Re: Astra 45k mile service - inexpensive & runs like new!

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Drove a few days and P0496 has not returned. Engine also runs smooth and peppy again so I think the cleaning worked fine.

Cost INCREASING
P0496 is back, unfortunately.

I suppose this could be a vacuum leak, dirty purge valve, broken purge valve.

Ordered replacement valve.

Last edited by AstraFasta; 12-04-2017 at 07:10 PM.
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Old 12-14-2017, 01:41 PM   #34
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Default Re: Astra 45k mile service - inexpensive & runs like new!

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P0496 is back, unfortunately.

I suppose this could be a vacuum leak, dirty purge valve, broken purge valve.

Ordered replacement valve.
Replaced the purge valve with an AC Delco part (it is labeled Bosch) and after a few hundred miles, no codes have returned. Cost 70$

There are two obvious ways to install the unit (after detaching the electrical connection). I would recommend #2.

1. The AC Delco comes with ~40cm of new curvy vacuum hose attached to the valve. If you want to use that new curvy hose, then remove the vacuum hose on the left of the unit. Then remove the far end of the ~40cm of old curvy vacuum hose at the back of the engine.

2. Remove the vacuum lines attached directly to the valve (discard the ~40cm of new curvy hose)

- All the vacuum lines require a lot of strenght and effort to remove.

- Removing the curvy hose at the back of the engine is a bit difficult as there is very little space to pull.

- The original curvy hose was in great shape but had a small split on the connector at the back of the engine. At first, I though that was a failure of a very hefty rubber connection (which looks like the end of a sparkplug wire). But, I actually think that rubber hose fitting is too narrow to fit over the metal nipple so the rubber end of the hose was split at the factory to facilitate fitting. To get the new curvy hose to fit I tried soap, a file, muscle and finally had to split the new hose end a about one cm with a box knife.

Unfortunately that split causes a slight a vacuum leak I can hear "wooshing" just after briefly stepping on the accelerator from idle. If I force the curvy hose back into place the "wooshing" goes away for a few hours.

So, I will try to seal the cracked connection by wrapping the fitting with some high-temp electrical tape and then tighening a bit with a small metal adjustable hose clamp. Any tips are welcomed.
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Old 12-15-2017, 09:11 AM   #35
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Default Re: Astra 45k mile service - inexpensive & runs like new!

How on earth are you having so many issues at such low mileage? You must have gotten quite the lemon. I'm pushing 100k miles soon and it's been relatively trouble-free.
...
'08 Astra XE 5-speed
'72 Chevrolet El Camino
'31 Ford Model A pickup
'69 Lotus Europa
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Old 12-15-2017, 11:16 AM   #36
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Default Re: Astra 45k mile service - inexpensive & runs like new!

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How on earth are you having so many issues at such low mileage? You must have gotten quite the lemon. I'm pushing 100k miles soon and it's been relatively trouble-free.
GM put a team of idiot engineers on the auto transmission (the Asin transmission box has a solid reputation). I had a gut fear that might be an issue as the car was designed for a manual transmission. That team of hopefully unemployed moron engineers is the root of the expensive issues:

- replacement transmission
- install of separate auto transmission cooler to fix engineering design error
- expensive coolant flush
- painful install of the correct alternator pulley (vs the wrong metal disk included)
- needless replacement of the serpintine belt & tensioner
- broken AC compressor

There are a few other design defects in the car but they are generally easy DIY fixes or not so problematic, or I don't care too much about them.

That said, the car really does run like new, is a blast to drive, and is very practical.
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Old 01-14-2018, 11:42 AM   #37
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Lots of rain and then very cold temperatures seem to have frozen or shorted the heater fan. Doesn't respond at any setting. Hopefully it will work soon when things warm up a bit...

One well-documented design defect of the Astra is seen during rainstorms a small amount of water seems to trickle down the windscreen and into the heater fan box and passenger rug. This is particuarly bad when parked on an incline with the nose upwards.

If you remove the fan from your car, you will see the bottom of the fan will be somewhat oxidized.

Fortunately, I have a the original Astra fan in the basement (I purchased a second fan unit for the resistor pack, which fails when the cabin air filter becomes clogged). Unfortunately, changing the fan is painful and takes some time. Easier now I have done it before...
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Old 01-16-2018, 10:21 PM   #38
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Heater fan "works" on all settings now. Almost.

Non-freezing day I tried the fan and heard what sounded like the blower fan break some ice. Then it sounded like ice cubes in a blender.

Quickly turned off the fan.

Before using the heater fan, I will just let the warm weather melt the ice inside the blower fan and wait for the water to drain through the cheap electric motor brass bearing at the bottom of the housing, and drip onto the passenger-side rug.
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Old 02-04-2018, 06:06 PM   #39
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Heater blower fan stopped working again after rains and freezing temperatures. Got it unfrozen on a warmer day.

But it killed the resistor pack. That is an extremely painful change, especially when the plastics are cold and inflexible. I replaced the resistor pack c.2013 due to clogged pollen filter. At least fan speeds 0 & 4 work.

Also spent the afternoon trying to figure how rain water is entering the heater blower fan. Tried removing the scuttle panel but the windshield wiper arms have fused to the motor shafts so could not get them out. Not sure it matters much.

I was able to remove the long rubber seal and partially lift the scuttle panel. Don't see any obvious obstructions. Cleaned the rubber seal and mating surface and carefully placed back into position.

Also took some hot water and poured over windshield on left & right sides to confirm water drainage is coming from wheel wells and hopefully clear some debris. The scuttle seems to drain water on either side of the car at the back of the wheel wells. But I can't see exactly where the drains were due to the plastic wheelwell skirts.

Also, under the scuttle panel on passenger side is a plastic grille about 4inches x 8inches (runs parallel to firewall). That seems to be the air intake for the blower fan; could be a path for water ingress but I couldn't really get to it because couldn't remove the scuttle panel.

Next steps:

- Repace blower fan resistor pack (probably wait for spring then make my own)

- Figure how to clear any drainage paths from scuttle panel from under the car. I think that will require removing the wheel and plastic wheelwell skirts. Then insert a barrel shaped brush or wire into the dranage pipes.

Really getting sick of this car...
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Old 03-24-2018, 09:29 AM   #40
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Default Re: Astra 45k mile service - inexpensive & runs like new!

Looks like the two major leaks have been fixed. Repair is documented in these two posts (with photos):

Water getting in through a closed door (driver's door but soaking back rug)
http://www.saturnfans.com/forums/sho...d.php?t=167895

Heater blower ice after winter rain (& blower resistor DIY fix)
http://www.saturnfans.com/forums/sho...d.php?t=233742


NEW PROBLEM-
Got the P2138 code (it rained a few days prior). Car drives fine.

I think this has popped up a few times and drying out the control box under the hood (driver's side) resolved the problem. Maybe I will take the time to put a ton of silicone in the box entry & o-ring this time. . .
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