Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Nezza
I’m hoping someone may be able to help me with a fault which has developed on my car. It is currently off the road due to now having a company car, and has only been used half a dozen times since last November. It is a Mk5 Astra 2.0 petrol engine.

So I went to take the car out of the garage yesterday and it would not start. I did use it last week to jump start my lawnmower a few times so I expected I had flattened the battery. So the battery has now been charged up and the car starts ok. It idles fine for 30 seconds-ish then the engine light comes on and it sounds like it is mis-firing.

I have tried a few times and each time the same thing happens. I am a competent engineer so able to check things but have absolutely no knowledge of engines. I have the following thoughts but any advice would be most welcome.

A) As the battery has been flattened could it be the battery is not good enough for the spark to be ok on each cylinder causing a misfire? I thought once a car was started it should run which would rule out the battery?
B) The car has not been filled up with fresh petrol at all and is sat with a quarter of a tank of fuel. I buy the super unleaded from the local Texaco garage. Could this have gone bad? It did start and idle fine last week for a good half hour.

Any help would be appreciated, it may be old but it has never let me down until now.

Thanks.

Edited by Nezza on 03/05/2020 at 14:25

Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - elekie&a/c doctor
Nothing wrong with old Astras . The battery sounds like it’s low on charge or passed its prime , but that wouldn’t cause your misfire . Most commonly on these , it’s usually the spark plugs or the ignition coil “cassette pack “.
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Nezza
Thank you for the feedback elekie&a/c doctor. I will change the plugs regardless as they are not expensive. (Would you happen to know the correct gap setting for this engine?) Do I take it the coil pack is what generates the voltage to create the spark which I will find at the other end of the ht leads?
Seems odd as it idles fine for 30 seconds then it starts to splutter as if the car has detected a mixture fault and then shows an engine fault. Would it not be rough on initial start up with a plug or coil issue? That is why I was questioning the fuel theory.
Thanks again.
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - elekie&a/c doctor
Spark plugs come pre gapped . Use Bosch or NGK brand . You will need to remove the coil pack to replace the spark plugs and need a long reach spark plug tool . Don’t think the fuel has deteriorated in such a short period .
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Nezza
Ok, I will try that this week once the local motor shop has opened up. Thanks again.
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Railroad.

I worked in a Vauxhall dealership from 1980 - 1995, and then was a roadside patrol until 2007. There's one thing in particular I learned in that time from a huge amount of experience, and that is Vauxhalls do not like non-genuine spark plugs. They're fine for the first few hundred miles, but after that they can be difficult to start from cold and in the damp. If you have NGK or Champion plugs chuck them away and fit genuine Bosch plugs from a dealer. There is a scientific reason for this. It's to do with the internal resistance of the plug. Some might not believe me, but I have attended hundreds of Vauxhall cars struggling to start in the morning which have had non-genuine plugs fitted. Replacing them with genuine cures it every time.

Having said that this may not apply to newer models.

Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Nezza
Thanks Railroad, I will keep that in mind for the future, however this morning I have just bought NGK and fitted them :-( along with a new coil pack. The issue still persists. Checked the air system and can see no split hoses. I did however also get a code reader which says cylinder 2 and also cylinder 3 misfire which put me off the idea of a plug issue but have changed them anyway as was stripping it down.

I was impressed by how easy it was to change these over though and just shows how long it has been since I messed under a bonnet as I expected ht leads.

Anyone any more ideas I could try?
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Railroad.

Not being familiar anymore with specific models, how many coils does your engine have? Do you have one coil pack for all four cylinders, two coils each for a pair of cylinders, or one coil for each cylinder individually?

With the exception of coil per cylinder, bear in mind that cylinders 1 and 4 will fire together, and so will 2 and 3. If you have a misfire on 2 and 3 it could be that either the 12v supply for the coils that fire those two cylinders could be missing due to a broken wire, or the coil negative to the ECM wire could be broken. Check for continuity between the coil and ECM. Or the transistor that switches coils 2 and 3 inside the ECM could be blown which means you'll need to either get it repaired by a specialist or replaced.

Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - elekie&a/c doctor
I guess this is an Astra H . What exact year is it ? How many wires going to the coil plug?
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Nezza
It is a 2005, yes Astra H. The coil pack is one unit which slots onto all four spark plugs with one multi plug adapter on the right hand side. (If you need me to count the number of pins I can do).

I’m thinking of locating the EGR and checking that to see if it is stuck in one position or blocked. If nothing else, I am learning about the car as I go.
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - elekie&a/c doctor
It’s probably got 5 or 6 pins to the coil pack . In which case it will be sequential firing of the plugs , one after the other. Looks like more in depth testing is needed .
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Railroad.

It will then be four coils in one pack. Each coil fires one cylinder. On the multi plug if there are six wires, one will be coil positive common to all four, one will be earth, and four will be each of the coil negatives to the ECM.

Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Big John

The original fault sounds like the coil pack - although you mention it has been changed since. Was this a new original equipment one? I've encountered quite a few sub standard ones in my time.

Edited by Big John on 08/05/2020 at 21:16

Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Nezza

I changed it for a Bosch unit. The numbers on it are marked identical to the original and the unit looks identical so I believe the original OEM may be Bosch too. There were signs of a brown dust on two of the rubber gaiters but the fault still exists. I have not cleared the codes and will get my mechanic to take a look once he opens back up. (I presume once the fault has gone the fault codes and engine light will clear themselves).

I have been advised by someone (not on here) to give it a good blast as soon as I start the engine but I do not like the sound of that given the engine will be cold, has a potential serious fault and is also turbo charged.
Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Railroad.

Remove the coil pack from the engine but leave the multiplug connected. Fit a spark plug to each of the four coils and lay it on top of the engine. If you can use a suitable piece of wire to earth the body of each plug. Then get an assistant to crank the engine while you look to see if each plug is sparking. Before you do though I would pull the fuel pump fuse or relay to prevent the fuel pump from running.

If only two spark plugs are sparking then you'll need to check the wiring to see if you have a live feed to all four coils. If you have then you'll need to check to see if all four are switching. The feed to all four coils probably comes from one common wire, or they may be fed in pairs. That's why you'll need to check. You'll either have one live with ignition on at the plug, or there may be two. You'll have to figure that out.

To check for coil switching use a voltmeter. Connect between each switching wire in turn and earth. Crank the engine and read the voltage. It will switch between 12v and 0v. BUT, a digital voltmeter cannot react quickly enough to this constant change back and forth, so it will sit somewhere in between, eg around 2v or 4v. There is not an exact figure, but if it stays on 12v or 0v then the coil is not switching. In this case check the wiring for continuity from the coil multiplug to the ECM multiplug. If there's a break in the wiring you'll need to trace and repair it, and if the wiring's good then a transistor has gone down inside the ECM.

Vauxhall Astra Mk 5 2.0 Petrol - Misfire after 30 seconds. - Nezza
A little update on the fault.

So from Railroads suggestion above, I decided to go and have a tinker about yesterday to see what else I can find.

First thing, I decided to clear the faults and then restart to check the same faults re-occur. They did, however the battery seemed very weak during start up. Trying to start again, the immobiliser kicked in. This suggests the battery is bad to me as it was only fully charged last week. So I put a spare battery I have in the garage, on charge overnight. So today I have swapped the batteries over. Tried to start and...... NO FAULTS.

So left the engine idling for half an hour to warm through and make sure I have fresh fuel through the system. Turned off and tried to start again, again NO FAULT.

So it appears the fault all along has been a bad battery. I will go and get another when I am near the car shop but for now I will leave this spare on.

It makes me wonder if the alternator is doing it’s job correctly however I am happy it is nothing more serious and that I have not wasted any more money on parts I do not need. I will keep the original coil pack as a spare and the plugs for any future fault finding.

The car had never let me down until now and even then it is just a consumable part that has failed so I am happy.

Thank you for all the comments and help, I am a regular reader, but not a regular contributor. I know how annoying it is to not find out the outcome of a problem so thought I would close the loop.

Thanks again everyone.