Known faults for the Opel Astra H.

Engine / equipment

Naturally aspirated 1.0, 1.2 and 1.4 Ecotec (Z10XEP, Z12XEP, Z14XEP, A12XER, A14XER): Corsa C, D and E, Adam, Astra H and J, Meriva A and B, Tigra TwinTop

Period mentioned

2003–2019

Symptoms

Engine rattle, especially on start-up, power loss and misfires (P0300 to P0304).

Possible cause described

The timing chain stretches on these naturally aspirated engines. On the 2004–2010 Astra H the same symptoms can come from camshaft bearing blocks tightened to too low a torque at the factory; cars already corrected have a yellow mark on the timing cover.

Check for the garage

Listen to a cold start, read misfire codes, look for the yellow mark on the timing cover (Astra H) and check chain stretch.

Cost cited in the source

Chain: approx. €650–1,400 (converted from dollars); re-torquing the bearing blocks: far lessA rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Getrag M32 six-speed manual: Opel Astra H and J, Insignia A, Zafira B and C, Vectra C, Meriva B, Cascada, Corsa OPC and some Fiats with the T-Jet engine

Period mentioned

2004–2019

Symptoms

A whine that rises with speed, mainly in 5th and 6th (also in 1st and 2nd), a loose gear lever that moves on and off the throttle and, when advanced, gears jumping out. Left unrepaired, the bearing can break through the casing.

Possible cause described

The bearings wear, mainly the shaft bearing next to 6th gear: the rollers develop play and the shaft moves under load, which reaches the lever. A specialist blames incorrect factory shimming. Second-generation boxes with the revised end case fail far less, according to an Australian repairer.

Check for the garage

In a garage test: confirm whether the noise depends on road speed (wheel bearing, tyre) or the gear engaged (gearbox), and whether the lever moves under load. Check the oil for metal debris. Repair early: replacing all bearings and fitting the revised end case costs far less than a new gearbox.

Cost cited in the source

One owner replaced only the main bearing for about £47 in parts versus about £1,000 for a rebuilt gearbox; another quotes about €600 at a specialist.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.3 Multijet / 1.3 JTD / 1.3 CDTI (Fiat Panda, 500, Punto, Doblò; Opel Corsa, Astra, Meriva, Combo; Lancia Ypsilon and Musa; Alfa MiTo; Peugeot Bipper and Citroën Nemo)

Period mentioned

2003–2020

Symptoms

Chain rattle on cold starts; oil level rising and smelling of diesel; particulate filter warning; power loss from a dirty EGR or the turbo.

Possible cause described

Single-row timing chain that is very sensitive to oil quality and long intervals: it stretches and the tensioner loses pressure, with a risk of breaking. In town use the DPF cannot finish regenerating and diesel dilutes the oil, which speeds up chain and turbo wear.

Check for the garage

Listen to a cold start, check whether the oil is above maximum or smells of diesel, read the DPF status and check the oil change history.

Cost cited in the source

Chain kit: €150–300 in parts plus €600–1,200 labour; DPF cleaning: €200–400A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 80,000–120,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

1.9 JTD / Multijet (8 and 16 valves), 2.4 JTD and JTDm in Fiat, Alfa Romeo 147, 156, 159, GT and Brera, Lancia and the Opel 1.9 CDTI

Period mentioned

1997–2012

Symptoms

Power loss, rough idle and an engine light with “swirl actuator malfunction”; soot around the intake manifold; vibration and knocks in low gears (dual-mass flywheel).

Possible cause described

On the 16-valve 1.9 and 20-valve 2.4, the intake flaps seize with EGR soot and oil, and the control rod comes off as its plastic bushes wear. The EGR fouls in town use and the dual-mass flywheel wears between 80,000 and 150,000 km. The 8-valve 1.9 has no flaps.

Check for the garage

Check the rod and flap operation on top of the manifold, read actuator codes, inspect the EGR and listen to the flywheel when starting and stopping.

Cost cited in the source

Intake manifold: €400–900 in parts; EGR cleaning: €150–250A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 80,000–150,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

Opel 1.6 CDTI (B16DTH), 1.7 CDTI (A17DTR) and 2.0 CDTI (A20DTH) diesels: Astra, Insignia, Meriva, Mokka, Zafira, Corsa and Cascada

Period mentioned

2006–2019

Symptoms

Coolant loss with no visible leak or white smoke (cracked EGR cooler); power loss and rough idle (clogged EGR); on the 2.0 CDTI, water pump noise before the belt breaks.

Possible cause described

On the 2.0 CDTI the EGR cooler cracks internally (common between 100,000 and 180,000 km) and the timing belt, on an interference engine, breaks early, often because the water pump seizes. On the 1.7 CDTI the EGR fills with carbon between 80,000 and 150,000 km. On the 1.6 CDTI the EGR cooler also leaks internally.

Check for the garage

Watch the coolant level, check whether the 2.0 CDTI belt and water pump were replaced together and inspect the EGR.

Cost cited in the source

2.0 CDTI EGR cooler: approx. €550–1,650; belt kit with pump: €450–750 at a German garage; 1.7 CDTI EGR: €370–1,100 (converted from dollars)A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 80,000–180,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database