Charles the Cavalier - Mk3 Cavalier SRi 2.0 16v Project Thread

[Banshee]

As some of you know I've brought a Vauxhall Cavalier SRi 2.0 16v EcoTec (not redtop) it's the 136bhp version and still shifts like a monster

2 owners from new, 90,000 miles, 3 documented timing belt kits, has some niggles that I will be attempting to fix myself and who knows I may end up keeping it or I may sell, I just don't know at the moment but know that as long as it's got faults it's OK to sit on the drive so I have some thinking time

This was it when I insured it to get it home, I stopped and gave it a quick jet wash

 

[Banshee]

Road Test and Faults Found

I had the car insured for 24 hours after that it will be locked in my Garage, so I wanted to do some varied driving in it to ensure I knew of all it's niggles so I could repair them while it's off the road.

I put 142 miles on it and gave it a good look over from end to end, top to bottom and these are the issues I have found that will need fixing.

• Fault code present for Crankshaft Position Sensor - car stalls at idle sometimes when sat in traffic and engine is up to temp

• Ticking Sound - The car ticks at startup and through some of the other rev ranges however not always present. Suspected exhaust blow too, can smell when engine is running.

• Drivers side wing mirror glass missing - Internal plastics appear intact and undamaged

• Driver side front tyre has a slow puncture

 

[Banshee]

Valet

I decided before any jobs were started that the first job was to valet inside and out to see what I was really working with as a base here.

I decided to hand wash it again after it's jet wash as there was a lot of green moss growing on the black rubber trim for the sunroof and the side windows etc as it had been parked under a tree.

There were guttingly a lot of what appeared to be nasty scratches and marks on some of the panels, I attacked them all with the T cut and amazingly 80% of them came out, I was so happy I ran round the cul de sac spinning the microfibre cloth around my head, the paintwork is still so so glossy, not flat like many other cars of this vintage and I've still yet to claybar and wax it.

One thing that was bothering me badly was the beat up plastics, they had seen better days and had gone the dreaded grey colour, I faced this exact predicament with the Maverick and consequently have tried EVERY product under the sun to re-blacken plastics including Peanut Butter and a heat gun!!!!

I haven't given my new formula away yet but after trawling the internet for about 2 hours one evening a few years ago I found this product and haven't looked back since, bets thing is it permeates back into the plastic and stays shiny, doesn't streak in the rain and is actually waterproof :naughty

Before

After :sly

 

[Banshee]

Decided last night I was going to tackle the nastiest job first, the ticking engine.

I removed the heat shield that was attached with female Torx and the problem was immediately apparent, I could see a sooty build up and knew that the exhaust manifold gasket had blown but wasn't sure how it could be causing the ticking.

I hit google up and it appears to be a very common issue with the 16v EcoTec engine, further reading scared me a little as the two studs nearest the timing belt are prone to seizing and snapping off in the head this isssue does cause the ticking sound too so looked like a cheap fix as long as I can get all the studs out, so I went for it

I'd already gave all the nuts and bolts I suspected I'd need to remove a good helping of GT85 a few days before just to get things free a little and that coupled with the old tighten, undo a little, retighten, spray, undo and repeat allowed me to get 9 of the 10 nuts off the studs, I have one that I have managed to round which also happens to be one of the problematic danger studs!!!!!!! I've just purchased an extraction kit from Screwfix so I hope to remove it tonight :thumbs

Note the soot build up

Note the bottom nut that has become rounded, thankfully access is OK in that area :bow

 

[Blocky10]

Looks like it'll be a good car once again.
How long are you going to make is suffer until you tell us your black secret? :nenau

 

[rustic]

Looks like it'll be a good car once again.
How long are you going to make is suffer until you tell us your black secret? :nenau

spill the beans lol...:thumb2

 

[Banshee]

spill the beans lol...:thumb2

Looks like it'll be a good car once again.
How long are you going to make is suffer until you tell us your black secret? :nenau

Thanks mate, that's the aim :thumb2

OK OK you got me boys, but don't tell a soul!!!

I use Raw Linseed Oil on a Microfibre cloth, it penetrates the plastics, apply it until the plastic rejects it and it starts pooling in little bubbles on the top :naughty

No streaks and water repellent :thumbs

 

[emjaybee]

If you're using linseed oil BEWARE! !!

LEAVE RAGS FLAT, AND OUTSIDE UNTIL THEY ARE BONE DRY, OR BURN THEM.

Linseed oil on rags creates heat, enough to spontaneously combust.

DON'T EVER LEAVE THEM SCREWED UP IN A CUPBOARD.

A local pub got burnt down by linseed oil on a screwed up rag.



Nice car bloke, I had a 2.0 mk4 , loved it. Never did less than 35mph, and would do an indicated 135mph.

:thumb2

 

[Banshee]

If you're using linseed oil BEWARE! !!

LEAVE RAGS FLAT, AND OUTSIDE UNTIL THEY ARE BONE DRY, OR BURN THEM.

Linseed oil on rags creates heat, enough to spontaneously combust.

DON'T EVER LEAVE THEM SCREWED UP IN A CUPBOARD.

A local pub got burnt down by linseed oil on a screwed up rag.



Nice car bloke, I had a 2.0 mk4 , loved it. Never did less than 35mph, and would do an indicated 135mph.

:thumb2

Thanks mate!!! I do like it a lot :naughty

Jesus I didn't know that about Linseed oil

And yep you've guessed it, I've got a cloth folded up in the corner of the garage with it on

Can't wait for work to finish.

Why is there no warning of this by law on the bottle? Really angry now, as I feel really irresponsible but only through being ill informed.

Thats why I love this forum!!! Never mind my tenner saving me money, it probably just saved lives!!!!

 

[emjaybee]

Thanks mate, that's the aim :thumb2

OK OK you got me boys, but don't tell a soul!!!

I use Raw Linseed Oil on a Microfibre cloth, it penetrates the plastics, apply it until the plastic rejects it and it starts pooling in little bubbles on the top :naughty

No streaks and water repellent :thumbs

I don't doubt the finish you're getting, it looks fantastic, but I would like someone more knowledgeable than I to explain how linseed oil penetrates plastic.

:nenau

 

[Banshee]

I don't doubt the finish you're getting, it looks fantastic, but I would like someone more knowledgeable than I to explain how linseed oil penetrates plastic.

:nenau

Yeah I did wonder myself, that's what I've read and been told, I understand how wood does ot of course, does seem to be true as eventually it refuses to take anymore and starts beading on the surface and you have to wipe off

Sent from my SM-G900F using Tapatalk

 

[emjaybee]

There's some good info videos on YouTube about linseed oil fires. Including a massive high rise fire in Philidelphia.

Take heed!

:thumb2

 

[Blocky10]

There's some good info videos on YouTube about linseed oil fires. Including a massive high rise fire in Philidelphia.

Take heed!

:thumb2

Cheeeeese! Be careful!

 

[Banshee]

Confirmed Gasket Issue!!!!

Managed to get that pesky nut off, jesus it was mangled!!

Yep it was the gasket responsible

 

[Bigbunny2007]

Looks sweet that mate :thumb2
My parents had two when I was growing up, the 2nd been the 16v red top :thumb2 used to beast it round the block when I got chance :sly

 

[emjaybee]

Have you shifted those rags out of your garage yet?

:thumb2

 

[Banshee]

Looks sweet that mate :thumb2
My parents had two when I was growing up, the 2nd been the 16v red top :thumb2 used to beast it round the block when I got chance :sly

Mate they fly don't they!!! This is the 136bhp the redtops were 150bhp? I beasted this thing down the motorway the night I brought it, wow!!!! That's all

I remember my old man having one as well but it was a povo spec bergundy/maroon 1.7 TD, Izuzu though which i was told was a well reliable lump

 

[Banshee]

Have you shifted those rags out of your garage yet?

:thumb2

First job when I got home mate, thank you for reminding me though

 

[emjaybee]

First job when I got home mate, thank you for reminding me though

I'd hate to see you homeless!

:lol

 

[Banshee]

I'd hate to see you homeless!

:lol

I wouldn't, I don't need any more encouragement to go and live in the country in a Caravan somewhere with my Terrano :naughty