Opel Astra
Isuzu-based 1.7-litre unit-injector diesel. Economical and long-lived with correct maintenance, but a characteristic weakness in the electronic injection pump ECU (EDU), whose solder joints crack from engine vibrations.
Diesel without soul
55 kW in the hatchback is tight even for 1998 – needs a run-up and doesn't sound pleasant doing it.
Engine Weaknesses 8
The EDU suffers from cold solder joints caused by engine vibration. The engine suddenly stops running warm or cuts out under load. Fault code P0251 is typical. Specialist repair is possible; a new pump is very expensive.
Symptoms: Engine cuts out when warm and will not restart; rough idle; engine does not respond to throttle; fault code P0251
The Y17DTL is an interference engine. A broken timing belt causes engine damage through valve-to-piston contact. Prescribed replacement intervals are often not adhered to.
Symptoms: Engine suddenly will not start; tearing noise
The control unit integrated into the injection pump head on the Y17DTL typically fails under heat: engine judders, loses power and will not restart when hot. Fault code P0251 is typical. Replacement pumps cost 400–800 EUR.
Symptoms: Engine dies at operating temperature, starts cold but not when warm, juddering and power loss, fault code P0251.
The pump control unit on the Y17DTL develops cold solder joints through engine vibration. Fault code P0370 is typical. Replacement of the pump ECU is necessary, approx. 300–500 EUR.
Symptoms: Engine cuts out at operating temperature, starting problems when warm, fault code P0370 or P0335.
Glow plugs seize in the cylinder head through corrosion and frequently snap during removal. This creates a complex repair job. Poor cold starting and the glow plug warning light are the symptoms.
Symptoms: Poor cold starting especially below 5 °C, glow plug warning light illuminated permanently, white smoke on cold start
On the Y17DTL, the injectors sit under the cam cover gasket and are subject to crankcase pressure. A blocked crankcase ventilation builds up pressure which forces oil past the injector seals. All four injectors affected simultaneously.
Symptoms: Oil seeping around injectors, smoke from engine block, contaminated engine bay, increased oil consumption.
The crankshaft sensor on the Y17DTL fails frequently and causes starting problems when the engine is warm. Fault code P0335 often appears. Cheap to replace and solves the problem reliably.
Symptoms: Engine starts only when cold, warm engine does not start or only starts after several attempts.
The EGR valve on the Y17DTL clogs with soot deposits, especially with frequent short-trip use. The result is reduced engine power, increased fuel consumption and rough idle. Cleaning or replacement costs 80–300 EUR.
Symptoms: Juddering under load, rough idle, power loss, increased fuel consumption, black smoke under acceleration.
Vehicle Weaknesses 14
Notorious weak point: the rear wheel arches rust from the inside out because the full galvanising was applied before welding. There was a recall.
The rear axle spring seats and the mounting points beside the rear axle mounting are affected by rust across all models. Severe rust can lead to MOT failure.
The brake lines run partially in contact with the bodywork and corrode from the outside, leading to MOT failure or brake failure.
The structural sills are a known rust attack point. Rust-through requires extensive repair with replacement sill sections and is a safety concern.
Tie rod ends and steering linkage wear above average, causing play in the steering and MOT failures.
The firm suspension transmits vibrations to the headlights and loosens the bulb contacts. Soldering a resistor wire to the socket permanently fixes the problem. Typical for the 1998–2002 build years.
The EGR valve on the Astra G sticks open due to soot deposits, causing false air ingestion at low RPM and making the engine stall.
The exhaust systems on the Astra G corrode prematurely, especially at the joints and the rear silencer. Vehicles without regular cavity protection are almost universally affected.
The electrohydraulic power steering on the Astra G can fail through pump failure or leaks, making steering — especially at low speeds — very heavy.
On the Astra G front axle, the control arms corrode and the control arm rubber bushings crack. Typical from 120,000 km: imprecise steering, clunking over bumps, MOT failures for worn bushings.
The cable in the electric window regulator snaps frequently. The system is designed as a complete unit, making individual repairs difficult.
The heater blower resistor burns out. The fan then only works on the highest speed setting. Common from 80,000–100,000 km; inexpensive part but awkward to access behind the glovebox.
The foam seal under the scuttle panel detaches. Rainwater runs directly into the blower motor and exits in the passenger footwell. Very widespread on older examples.
In the Astra G, plastic clips and foam dampers in the dashboard detach with age. Creaking and rattling, especially in cold temperatures and on rough road surfaces.
