Astra 45k mile service - inexpensive & runs like new!

[AstraFasta]

Originally Posted by tackepj

What code reader do you use for your Astra? Do you recommend it?

I use the ScanGauge2. That is just for monitoring and not diagnosing. It was great 10 years ago but there are better items now.

[AstraFasta]

For diagnosing P2096 the Astra Service Manual (ID 2006061) steps are linked above. Below summarizes most of the testing I did tonight:

1. Closed loop with engine warmed up shows no obvious clues (ScanGauge2). Car still shows "not ready" for testing as we just cleared the code:

Fuel trims (typical)
ST 0-5
LT 0-5

o2 sensors
B1 0-90%
B2 0-90%
Both -->0 gliding with foot off the gas pedal
Both-->90 accelerating hard

Water temp ~92*C

Barometric pressure ~14.6 PSI

Ambient air temp 35*F

MAF ~5 g/s at idle. ~30 mild acceleration. ~50 hard acceleration

Engine sounds great and is perfectly responsive.

2. Based on the Service Manual, I think next steps to check are:
- EVAP purge valve and vacuum hoses
- Leaking exhaust from HO2S forward (the flex pipe!)

[tackepj]

Originally Posted by AstraFasta

I use the ScanGauge2. That is just for monitoring and not diagnosing. It was great 10 years ago but there are better items now.

Such as? Just curious. Always wanted to have one on hand but didn't know what would be appropriate.

[AstraFasta]

Originally Posted by tackepj

Such as? Just curious. Always wanted to have one on hand but didn't know what would be appropriate.

No idea m8. Better scanners provide Saturn-specific codes & can display data real-time on a x-y graph.

[AstraFasta]

Replaced RH door mirror glass/ heating element/ plastic. That is one part and looks to be good quality overall; the glass is pretty clear and not wavy. Box label stated part was made in Taiwan. Took 30 seconds to install.

Original German seller did not want to ship to US, so purchased from Bulgarian ebay seller maxiarbitrage for under $25 shipped.

FYI - c.2015, the OEM door mirror glass fell off as is typical with the Astras. We replaced just the door mirror glass with an eBay kit that came with 2 sided tape. The replacement was a bit wavy but flattened after a year or so. In 2020, the RH mirror "silver" coating was failing, so large blotches started forming. Hence, the new glass for RH mirror. LH mirror looks fine...for now.

[AstraFasta]

Replaced 4 plastic roof rack covers with parts from Latvia for about $12 shipped. ebay seller almets_cnc

60 seconds to install all 4. I think the design is clever with big tabs, so I don't see these failing or falling off. The plastic looks to be good quality, flexible, and well molded. Shipping was about 2 weeks.

Roof looks much nicer with these 4 plastic covers (plus we just repainted the 2 metal gutter bars.) Very happy with this upgrade. Goob also received and installed his 4 covers today.

[AstraFasta]

I think the 4 plastic roof rack covers reduce highway wind noise quite a bit. They don't fit 100% perfectly but are a big improvement over the 4 holes. Good enough for this neighborhood.

P2A01 popped up when we started driving today. Cleared the code and it did not pop up again.
"HO2S Circuit Closed Loop (CL) Performance Bank 1 Sensor 2 (PCM)"

P2096 popped up last month
"Post Catalyst Fuel Trim System Too Lean Bank 1"

First guess is these are related to the flex pipe. Second guess is rear O2 sensor (although real-time voltage from both 02 sensors seems fine).

http://www.saturnfans.com/forums/sho...d.php?t=219869

[AstraFasta]

Codes haven't returned and code reader shows "ready". Might still replace flexpipe anyways.

Rear heat shield fell down on top of the muffler and started rattling. The fastening holes just grew too big (from mechanical wear) for the nuts. I soaked the nuts in WD-40, removed the nuts, inserted some big stainless washers, reused the old nuts. I only saw 2 nuts but will look for a front nut to "fix" tomorrow.

[AstraFasta]

I upgraded the back nut of the rear heat shield. Drilled a hole in the trunk floor, rustproofed, installed a stainless bolt, nut, and big washer. Test drove and found heat shield to be well secured and silent now.

[AstraFasta]

Some codes have been popping up:
P0141
P2096
P2A01

I see goob had that issue May 2016 and downstream 02 sensor cleared it for him.

[AstraFasta]

Replaced Downstream 02 Sensor (GM GENUINE 55565000). The two 02 wrenches didn't seem to grip well. So we moved to a hammer, a few days of WD40, a huge 22mm socket with a socket wrench with a flexible head, and a few hours of effort.

Astra idles quieter. Engine feels more peppy and does not seem to lug (or bog down) on acceleration which I thought was just a characteristic of the engine. Codes disappeared (we just drove it a few miles so OBD still reads: no codes- not ready.)

Will replace the upstream sensor next week (GM GENUINE 93191307) even though it showed no codes. My friends said the 02 sensors work better in matched pairs, so the old front sensor is getting lazy and suboptimal.

Replaced oil, filter, and T45 drainplug. Used Wix filter, Mobil 1 full synthetic oil, and 8 ounces of Redline Engine Oil Break in Additive, "providing an extra package of protection otherwise not found in most motor oils." The Redline is to help prevent any dieseling sound at startup from the cam phasers, hopefully.

[AstraFasta]

New Bosch Windshield Wipers.

AC is not working. Probably a leak. We will have Saab specialist look at this next week.
- AC was weak this summer. Recharged in July and was working OK for a few months.

- Cabin fan and cabin temp selector work fine.

- Heat and fresh air work fine.

- When AC button is depressed
-- Slightly cooler air comes out of ducts
-- Yellow AC button light turns on
-- I see compressor clutch engage
-- Fan at front of car will spin

- With engine off, compressor spins easily by hand

[AstraFasta]

Replaced a few heat shield bolts above muffler.

Cleaned hub threads for one bolt.

AC compressor was leaking. Replaced AC compressor and some seals with GM OEM parts. AC blows cold and all underhood creaking noises are gone.

Previously we tried to attack chirping, squealing, and creaking noises with new: accessory belt, tensioner, alternator decoupling pulley, and water pump. At that point we assumed the creaking noise was the cam phaser (gears) but today found out it was the cheap replacement AC compressor.

[jbuenavides]

Are you still modifying the same car?

[AstraFasta]

Replaced Upstream 02 Sensor (GM GENUINE 93191307).

Cut the wires and used a huge 22mm socket and breaker bar to remove the old sensor. This one was easy to break loose. To protect manifold threads, slowly rotated old sensor a bit anti-clockwise, a bit clockwise, sprayed WD40. Repeated many times until old sensor was removed. Cleaned threads. Installed new O2 sensor and tightened with an O2 sensor wrench. There is not much space so I would recommend having so a few types of articulating wrenches and extensions to do this job.

Checked air box for acorns and debris; just wiped out a bit of dust. Air filter looked ok.

Accelerator pedal is smooth and responsive; no lag. New AC compressor is frigid and doesn't sound like a bunch of marbles, so recommend anyone getting genuine GM AC compressor not some off brand junk that we used before.

[AstraFasta]

New Air Filter (Wix 49522)

New Cabin Air Filter (Wix 49364)

At about 90k miles now.

[AstraFasta]

New exhaust flex pipe. They cut past the downstream o2 bung and replaced, as more and more OEM straight pipe is cut each time the flex pipe is replaced.

New rear wiper blade

[AstraFasta]

The Astra is so much quieter with the new flexpipe. That was an awesome upgrade.

I think it is using less fuel but will have to drive more to confirm. Or the fuel gauge is stuck lol.