Big problem with Astra 2.0 diesel turbo model G

Hi,
I hope someone has a good idea about this one. I lent my car to my son to
go on a long weekend break in Wales and he returned it back to me on a
transporter.

He said the car brokedown when he accelerated away from a round-about, the
engine management light came on and the car lost power with the engine
cutting-out. The engine will rotate on the starter motor but it will not
start running.

At home I have checked the camshaft is rotating when operating the starter,
battery voltage is 12.5V, fuel appears to be delivered by pump as I loosened
a union joint on output side of pump and fuel spurted from it.
I also checked fuses and relays - all seems ok. This makes me think it's an
electrical control unit at fault.

The car has covered 130k miles and is 6 years old (T reg).

So any ideas why it wont run or any other tests you think might point to the
faulty component?
Thanks for any help in advance.
Chris

 

Have you read what fault codes are in it?
There isn't much that will stop the car running as most sensors will just
put the car in limp home when they fail.
Crank sensor, ecu/pump, wiring and filling it with petrol by mistake are a
few that spring to mind.

 

This doesnt sound good. when you spin it over on the key, does it 'chug' as
each cylinder fights the compression, or is it a smooth spinning?

Mike

 

Hi Mike,
No just spins over normally on the starter. Are you thinking about cylinder
or ring failure? My son said no smoke from the exhaust was apparent.
Chris

 

Might be worth trying to tow it off in case it has pulled some air in. You
could start it with easy start if you don't mind the rattle when it kicks
into life.

 

Ok, I must admit that did cross my mind. Bearing in mind what you have said
so far, then try replacing the fuel filter. On cars they also tend to be the
water trap as well. you might have some water contamination of the fuel,
picked up from condensation in a fuel tank somewhere. Admittedly if the
filter was blocked, it would slowly die rather than suddenly cut out, but
filters arent that dear. you might need to go with me140's idea of a pull
start to get it going, as contamination can be a bugger.

Mike

BTW, when you drain the filter, try to catch the liquid in a clean container
then pour into a glass and hold to the light. might give you an idea.

 

Mike,
Now replaced fuel filter. Flattened battery trying to get it going - so now
on recharge before I know if it really worked.
Regards
Chris

 

Could be the injection pump, very common on this model, I know from
experience. The guy who repaired mine said he replaced ten vauxhall pumps a
week and always kept twenty in stock.

A recon pump cost me £1300, the Dealer price ws £2200.

Hope it's not the above though matey! I really do.

This was cheap compared to when the turbo failed sucking oil out the sump
and revving the engine to destruction though... Again, another
common thing with modern diesels!

 

Yep if its the diesel injector pump the car's scrapped! - at 7 yrs and 130k
miles it wouldn't be worth repairing. I've been quoted £2500 for the pump.
Clutch is worn needing changing soon, that's another £600 unless I do it
myself - makes public transport look more inviting - oh yea not to mention
the £150 Congestion penalty charges I've paid in the last yr, and £60
penalty for going through a red light. Why bother going to work - it's
cheaper to stay at home and claim benefits!
Thanks for your help - the advice has been sound - it just looks like
everything points to that damn pump. If only I could read the fault codes?
Yours truly stressed.
Chris

 

Try towing it off before you give up hope.

 

Dear All,
Well tried this afternoon to start it this afternoon after giving the
battery a good charge - no good.
Then towed it for about 1/2 mile in second gear - no sign of life - engine
will not fire up.
Will get those codes read first before sending it to the scrap yard.
Thanks
Chris

 

Ok everyone - I got the EOBD read - P1630 - I think that's it - the Diesel
Control Unit critical error. I will dismantle the top of the pump and
examine the printed circuit board - last hope.
Chris

 

Good luck.

Mike

 

Have you checked the main relay? It is K18 and feeds the pump/ecu. If it
goes down then the fault code 1630 pops in. It is in the relay box near the
battery. It is fed by fuse F6 and has a red, red/blue,black and I think
brown/yellow wires going to it.
With ignition on should be getting 12v ish at terminal 7 on the pump ecu
plug. Terminal 6 will be ground at a guess.
Just see if it is brown.