Vauxhall Astra (2004 – 2009) Review

• May 2004: Astra goes on sale in the UK
• July 2004: Astra VXR joined the range
• April 2005
• January 2007: Facelfited versions introduced
• August 2008
• September 2008: Astra Ecoflex range extended

01-01-0001:

Radio switch fault on 2004 cars (switches itself on randomly) flattens batteries. Replacement radios on 'back order' in Jan 2006.

Complaints of clutch judder on 1.6 and 1.8. www.astra-sri.co.uk/forums/showthread.php?t=6121&highlight=clutch
www.astra-sri.co.uk/forums/showthread.php?t=4107&highlight=clutch
www.vauxhallownersnetwork.co.uk/showthread.php?t=71076

Have been problems with parking brakes and rollaways when drivers did not leave the cars parked in gear.

All models suffer with CIM (steering column module) fault: symptoms include no or hard to start and light/ wiper fault. Tailgate switch also fails, this is common on Vectra C and Zafira B. And engine thermostat failures also becoming a problem.

Also REC (rear electrical center) fail: symptoms normally fuel gauge reads incorrectly, cenral locking faults. and connectors in the bottom of rear doors separate sp the electric windows (if fitted) don't work and neither do the locks.

Water trap at top of front suspension turrets leads to premature corrosion there.

Wiper linkage wears very quickly resulting in excessive play in the wiper arms which causes them to bang off the edges of the windscreen. Make sure you check them as it's an expensive fix due to poor access.

Watch out for underbody corrosion around the front chassis members and sills. Reports of MoT advisories for corrosion in these areas on early models are becoming more common. Also watch for rust bubbling under the rubber strip on the kick plates (where the doors close onto).

On 1.9CDTI, timing belt drives waterpump and waterpump failure can fling it off in as little as 40k miles, wrecking the engine. By December 2008 this was becoming increasingly common at about 4 years old and circa 50k - 60k miles. So engines need new belts, tensioners, pulleys and waterpumps before 4 years old or 50k miles.

On 1.9 CDTI, failed inlet manifold swirl flaps (and the flaps can beak and be ingested by the engine). If the engine smokes or the car suddenly loses power, the secondary butterflies of the swirl actuator valve may have sooted up and seized. Possible to clean but this does not guarantee it won't happen again. Really requires the inlet manifold to be changed as the part where the actuator connects to jams and does not let the butterflies open. Job can take six hours as the fuel pump and cam belt have to be removed to get at it. A coincedental fault is sooting up of the EGR valve.

Early front suspension bush wear quite common on all models.

One report of the wrong size pistons having been fitted to a 1.9CDTI, making it very smokey.

Failed dual mass flywheels. Listen for any "shaving" noises when depressing the clutch pedal.

Clutch judder common on both petrol and diesel manuals. May be DMF trouble. By July 2008 an admitted problem on pre-June 2007 production and clutches and flywheels being replaced under warranty. GM introduced modified clutch/flywheel components to production in around mid 2007. Models affected by the change are apparently Astra H/ Zafira B with 1.6 and 1.8 litre petrol engines.

1.7 CDTI (Isuzu) diesel engines are generally very reliable but not as refined as the 1.9 CDTI (Fiat) variants. Crucial to fit the timing belt accurately for smooth running.

1.7 CDTI is known to have below average fuel consumption for its engine size.

On 1.7CDTI the Brake master cylinder and brake servo can fail at just over 3 years old.

Reports of gearbox problems on 09/59 plate 1.7 EcoFLEX models. When selecting 1st gear you actually get reverse gear. Only seems to affect the 1.7 EcoFLEX models. Vauxhall deny there is any problem. Further reading: http://www.astraownersnetwork.co.uk/showthread.php?t=95763

On 1.8 petrol, when timing belt is replaced at 40k miles, tensioner, pulleys and waterpump need replacing too.

With the 1.3CDTI (FIAT 1.25 Multijet) engine fitted with a diesel particulate filter, what can happen is that excess diesel fuel that was supposed to burn hotter and regenerate the dpf does not and instead seeps
into the sump, gradually raising the level of sump oil to the point that the engine starts to run on it, cannot be stopped and therefore self-destructs.

1.4 16v Twinport engines suffering same problem of camshaft bolts coming adrift as 1.2 16v Twinport engines in Corsas. Seem to have been traced to a batch from the engine plant in Spain and the engine numbers all begin with 19F*****

1.9 diesels can be good to drive, but give a lot of problems: Failed EGRs; Choked DPFs leading to failed turbos; Failed timing belts, often because the waterpump seized. Belt, tensioner, pulleys and waterpump need replacing every 40,000 miles. More info about 1.9CDTI timing belt failures here: 1.9CDTI Timing Belt Failures; Failed alternators. Typically fail around 40,000 miles; Failed manual gearboxes - particularly the 150hp models. £1300 to replace from Vauxhall. Listen for whining noises from the high gears on the test drive. Reports of them failing as early as 40,000 miles are not uncommon; Failed turbos.

On torque converter automatics the joints of the heat exchanger in the radiator header tank can fail, admitting coolant to the automatic transmission fluid and wrecking the transmission. £4,000 replacement job.

Reported on BBC Watchdog 22-4-2010: Horns seem to fail when headlights are on. Vauxhall offers a free fix.

31-05-2011:

Reports of door mirror glass repeatedly falling out from mirror pods of late Astra Hs.

14-03-2012:

Easytronic failures on the increase. Link: Easytronic failures

29-07-2012:

Reader fix for water leaks through front doors: "The water runs down the wiring inside the door to the lower radio speaker that is mounted in the door, it then seeps around or through the foam rubber gasket between the speaker and door frame and thence into the car. The cure is to take the door panel off (not a job for the faint hearted) and remove the 3 screws fixing the speaker to the door. Unplug and remove the speaker then carefully cut off all of the (useless) foam sealing gasket that is stuck to the speaker (important as the foam seal acts as a conduit for the water). Spread a generous ring of PU sealant/adhesive round the speaker edge (where the rubber gasket was) then refit the speaker to the door and re-assemble). This provided a complete cure on both of the front doors."

21-11-2012:

On earlier Z14XEP 1.4 litre petrol engines, the return hose can shear off the waterpump, leading to head gasket failure. This union was only made of plastic on the original engines, but has been stealthily replaced with a sturdy metal connection instead on subsequent revisions. However, no known TSB was issued.

25-11-2012:

Horn failures seem to be common due to a failed circuit board.

13-01-2013:

On 1.9 diesel engine, absolutely crucial to change the waterpump at the same time as the timing belt otherwise the tension of the new belt can wear its bearing very rapidly, leading to seizure and throwing off of the belt, though not necessarily valves hitting pistons.

05-02-2013:

Windscreen wiper motor and mechanism failures seem to be very common.

09-02-2013:

Same Brake Pressure Sensor problem in ATE/Teves Mk 60 ABS/ESP module as VAG cars and some Fords, Volvos and Mazdas. Can be fixed from from £225 by http://www.sinspeed.co.uk ; http://www.ecutestion.com or http://www.bba-reman.com among others, but unit needs to be removed and sent to them, then re-fitted.

30-06-2013:

56k mile 2006 1.4 required new throttle body and new 'Motronic' control unit at a cost of £1,719 (presumably an 'Easytronic').

12-05-2014:

Four reports of mirror glasses falling out of two 56/57 reg Astra and two 56/57 reg Zafira, all owned by the same family, but kept in different places and doing different mileages.

24-09-2014:

ABS/ESC failure on 74k mile 2006 Vauxhall Astra 1.8 SRI, code reading Co131 pressure sensor fault resulted in a quotation of £2,400 for replacement. Advised to send the module away for a new brake pressure sensor to ecutesting.com Entire job should cost £500 - £600.

31-03-2015:

Numerous typical used car problems reported with a 68k mile 2005 Astra diesel bought in 2011. DMF problems within first 6 months turned out to be causes by a fails shaft oil seal, not vovered by the Network Q warranty and reader did not know dealer legally had to cover it. Paid £1,200 bill. After about 8 months the alternator failed. Replaced by a local garage under the warranty. Both rear coil springs failed. After about 10 months rear brake discs found to be pitted with corrosion (fairly normal on a 6-7 year old car). Door light switches failed. Heater blower switch failed. Glow plugs failed.

26-11-2015:

Heater fan of 2008 Astra H would only work on 4th setting. Reader replaced the resistors and still the same. This is the same fault and same 'cure' that has been causing Zafiras to catch fire. The fault is probably water getting into the fan motor with the result that it will only work on max. Get the fan motor checked and check for water leaks from a badly fitted replacement windscreen or flooded bulkhead vent well. Do not under any circumstances bridge or fit a higher rated fuse to the resistor or the car wiring could catch fire.

26-07-2016:

Report that blower fan of 2005 Vauxhall Astra SRI used to work only in setting 4 and then stopped working altogether. Reader replaced the resistor pack but it still isn't working. Urged the reader to understand that when a fuse blows or a resistor separates it's because the component it is supplying power to has failed. Any attempt to bridge the fuse or resistor is likely to cause a wiring fire. The heater blower motor needs replacing.

30-01-2017:

Report of inlet manifold swirl flaps of 2007 Vauxhall Astra 1.6 breaking off, being ingested and destroying the engine.

25-06-2018:

Report of front brakes oc 2016 Vauxhall Astra H 1.6 automatic "catching fire", probably because the calipers stuck on the pins.