Opel Astra
Early 2.0 L common-rail diesel. Solid basic design, but EGR valve and injectors are weak points. Check dual-mass flywheel at high mileage.
Acceptable diesel
74 kW and good torque make the 2.0 DTI in the Astra G a usable commuter car.
Engine Weaknesses 4
Bosch injectors leak at the copper sealing rings or internally. Diesel smell and rough running are the result.
Symptoms: Diesel smell in engine bay, rough cold start, black smoke, knocking.
The dual mass flywheel wears from the diesel-typical torsional vibrations. In extreme cases it locks up the clutch.
Symptoms: Rattling at idle, vibrations when pulling away, shuddering on clutch engagement.
The variable vanes in the turbocharger stick together through soot deposits. Turbo fails to build pressure.
Symptoms: Power loss, turbo no longer spools up, limp mode, boost pressure fault code.
The EGR valve clogs with soot, especially in short-trip use. Engine enters limp mode.
Symptoms: Power loss, black smoke, engine warning light, rough idle.
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.
