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[terry paget]

2010 Astra H 1.6 petrol manual
engine light on code p0301-01 cylinder 1 misfire detected
Son Jonny popped home today, happened to mention engine light on, he assumed it was emissions. I plugged in diagnoser, up came the code P0301-01 cylinder 1 misfire detected. I could detect a misfire on pickup too.
I removed plug cover and ignition stick of 4 coils, and saw oil in cylinders 2 and 3, plugs barely visible. I sucked the oil out, then removed the coil assembly and all 4 plug. I washed them in petrol, plug gaps were all about 1mm, so I reduced them to 0.9mm, and reassembled. Misfire is still present, code soon reappears.
I presume I need to change the cam cover gasket and the plugs. I had hoped my cleaning of the plugs and coil sticks would have cured the misfire temporarily, but it has not.

Please advise.

[dave the builder]

If you've cleaned it all and swapped plugs and there is still a miss-fire on the same cylinder then suspect the coil pack
you have another 1.6 astra spares car ?
also there is a 1 way pcv valve built into the rocker cover
new covers with gaskets are cheap and available ,or you can replace just the pcv rubber valve
check if the dipstick sucks with the engine running , and if the oil filler cap sucks with the engine running
if it does,suspect the pcv in the rocker cover
worth checking before you replace the gasket
another issue ,the torx bolts above the manicat that hold the front of the rocker cover can seize in ,sheer off 
I know this from experience  had to drill and re-tap

[terry paget]

If you've cleaned it all and swapped plugs and there is still a miss-fire on the same cylinder then suspect the coil pack
you have another 1.6 astra spares car ?
also there is a 1 way pcv valve built into the rocker cover
new covers with gaskets are cheap and available ,or you can replace just the pcv rubber valve
check if the dipstick sucks with the engine running , and if the oil filler cap sucks with the engine running
if it does,suspect the pcv in the rocker cover
worth checking before you replace the gasket
another issue ,the torx bolts above the manicat that hold the front of the rocker cover can seize in ,sheer off 
I know this from experience  had to drill and re-tap

Thanks for dvice nd quick response, Dave. I did not replace the plugs, had no spares, just cleaned, regapped and replaced. I can buy new tomorrow, at Halfords, they might cure it. As you sasy, I hae a spare plug stick in my donor car.
Where is the 1 way pcv valve built into the rocker cover?
What is the manicat?

[dave the builder]

If you've cleaned it all and swapped plugs and there is still a miss-fire on the same cylinder then suspect the coil pack
you have another 1.6 astra spares car ?
also there is a 1 way pcv valve built into the rocker cover
new covers with gaskets are cheap and available ,or you can replace just the pcv rubber valve
check if the dipstick sucks with the engine running , and if the oil filler cap sucks with the engine running
if it does,suspect the pcv in the rocker cover
worth checking before you replace the gasket
another issue ,the torx bolts above the manicat that hold the front of the rocker cover can seize in ,sheer off 
I know this from experience  had to drill and re-tap

Thanks for dvice nd quick response, Dave. I did not replace the plugs, had no spares, just cleaned, regapped and replaced. I can buy new tomorrow, at Halfords, they might cure it. As you sasy, I hae a spare plug stick in my donor car.
Where is the 1 way pcv valve built into the rocker cover?
What is the manicat?

the PCV is built into the underside (inside) the rocker cover ,hence test before you just fit a gasket ,it may need a new rocker cover or valve 
manicat is the combined cat and exhaust manifold, bolted to the head at the front of the engine
Halfords is a terrible place to buy things like plugs , twice or three times the cost of a good factors ,whip a spare plug out the spares car, along with the coil pack for now  spend money when you need to

[terry paget]

If you've cleaned it all and swapped plugs and there is still a miss-fire on the same cylinder then suspect the coil pack
you have another 1.6 astra spares car ?
also there is a 1 way pcv valve built into the rocker cover
new covers with gaskets are cheap and available ,or you can replace just the pcv rubber valve
check if the dipstick sucks with the engine running , and if the oil filler cap sucks with the engine running
if it does,suspect the pcv in the rocker cover
worth checking before you replace the gasket
another issue ,the torx bolts above the manicat that hold the front of the rocker cover can seize in ,sheer off 
I know this from experience  had to drill and re-tap

Thanks for dvice nd quick response, Dave. I did not replace the plugs, had no spares, just cleaned, regapped and replaced. I can buy new tomorrow, at Halfords, they might cure it. As you sasy, I hae a spare plug stick in my donor car.
Where is the 1 way pcv valve built into the rocker cover?
What is the manicat?

the PCV is built into the underside (inside) the rocker cover ,hence test before you just fit a gasket ,it may need a new rocker cover or valve 
manicat is the combined cat and exhaust manifold, bolted to the head at the front of the engine
Halfords is a terrible place to buy things like plugs , twice or three times the cost of a good factors ,whip a spare plug out the spares car, along with the coil pack for now  spend money when you need to

If you've cleaned it all and swapped plugs and there is still a miss-fire on the same cylinder then suspect the coil pack
you have another 1.6 astra spares car ?
also there is a 1 way pcv valve built into the rocker cover
new covers with gaskets are cheap and available ,or you can replace just the pcv rubber valve
check if the dipstick sucks with the engine running , and if the oil filler cap sucks with the engine running
if it does,suspect the pcv in the rocker cover
worth checking before you replace the gasket
another issue ,the torx bolts above the manicat that hold the front of the rocker cover can seize in ,sheer off 
I know this from experience  had to drill and re-tap

Thanks for dvice nd quick response, Dave. I did not replace the plugs, had no spares, just cleaned, regapped and replaced. I can buy new tomorrow, at Halfords, they might cure it. As you sasy, I hae a spare plug stick in my donor car.
Where is the 1 way pcv valve built into the rocker cover?
What is the manicat?

the PCV is built into the underside (inside) the rocker cover ,hence test before you just fit a gasket ,it may need a new rocker cover or valve 
manicat is the combined cat and exhaust manifold, bolted to the head at the front of the engine
Halfords is a terrible place to buy things like plugs , twice or three times the cost of a good factors ,whip a spare plug out the spares car, along with the coil pack for now  spend money when you need to

Thanks again. I will investigate the valve tomorrow, it's a bit late now.
I agree Halfords are very dear. I will plunder the donor car for plugs, and check out plug stick. I have suffered before struggling to remove exhaust manifolds, so hope that does not prove necessary.

[Shackeng]

If you've cleaned it all and swapped plugs and there is still a miss-fire on the same cylinder then suspect the coil pack
you have another 1.6 astra spares car ?
also there is a 1 way pcv valve built into the rocker cover
new covers with gaskets are cheap and available ,or you can replace just the pcv rubber valve
check if the dipstick sucks with the engine running , and if the oil filler cap sucks with the engine running
if it does,suspect the pcv in the rocker cover
worth checking before you replace the gasket
another issue ,the torx bolts above the manicat that hold the front of the rocker cover can seize in ,sheer off 
I know this from experience  had to drill and re-tap

Thanks for dvice nd quick response, Dave. I did not replace the plugs, had no spares, just cleaned, regapped and replaced. I can buy new tomorrow, at Halfords, they might cure it. As you sasy, I hae a spare plug stick in my donor car.
Where is the 1 way pcv valve built into the rocker cover?
What is the manicat?

the PCV is built into the underside (inside) the rocker cover ,hence test before you just fit a gasket ,it may need a new rocker cover or valve 
manicat is the combined cat and exhaust manifold, bolted to the head at the front of the engine
Halfords is a terrible place to buy things like plugs , twice or three times the cost of a good factors ,whip a spare plug out the spares car, along with the coil pack for now  spend money when you need to

With a trade card they are very competitive, sometimes even cheaper than Eurocraparts

[TheBoy]

Yes, Halfords Trade bring them into just that "a bit expensive, but acceptable and convenient" bracket, in the same way an ECP 50% off does.

[dave the builder]

 I have suffered before struggling to remove exhaust manifolds, so hope that does not prove necessary.

It isn't necessary to remove the manifold,manicat , you've misunderstood .
the bolts that hold down the plastic rocker cover at the front (directly above the manifold ) are the bolts that seize 

a complete rocker cover ,with built in PCV valve  and the gasket ,and all new bolts where less than £30 off ebay with UK stock . the last 2 i did 

[Andy B]

WTF is a plug stick?.

[dave the builder]

WTF is a plug stick?.

it's Bristol speak for coil pack 

[Andy B]

WTF is a plug stick?.

it's Bristol speak for coil pack 

Ah! It's puzzled me since the thread started. 
Why doesn't Tel call it a coil pack then ..... 

[dave the builder]

WTF is a plug stick?.

it's Bristol speak for coil pack 

Ah! It's puzzled me since the thread started. 
Why doesn't Tel call it a coil pack then ..... 

it's short for ....

magic sparky lightning maker plug box that sticks to the top of the engine   

[Andy B]

....
it's short for ....

magic sparky lightning maker plug box that sticks to the top of the engine   

[terry paget]

 I have suffered before struggling to remove exhaust manifolds, so hope that does not prove necessary.

It isn't necessary to remove the manifold,manicat , you've misunderstood .
the bolts that hold down the plastic rocker cover at the front (directly above the manifold ) are the bolts that seize 

a complete rocker cover ,with built in PCV valve  and the gasket ,and all new bolts where less than £30 off ebay with UK stock . the last 2 i did 

Really? I was about to pay more than that for a gasket. Please send me a reference.
Cam belt is due a change (5 years and 80000 miles old), and I thought I would do it at the same time. I have no record of a water pump change, that could be due (175,000 miles) too.
I shall call it a coil pack henceforth.

[Andy B]

....
I shall call it a coil pack henceforth.

 

[dave the builder]

sorry , took a while to find 

Please send me a reference.

this one ? is yours the same ? £28.60 inc P&P

Cam belt is due a change (5 years and 80000 miles old), and I thought I would do it at the same time. I have no record of a water pump change, that could be due (175,000 miles) too.

cambelt is 100k or 10 years
waterpump is up to you , i replace them with the cambelt kit (about £85 for gates ),but you don't have too
and didn't last time 

[terry paget]

Thanks Dave. Cam cover ordered.
On reflection, the code is specific to cylinder 1. Having cleaned and replaced all plugs and the coil pack, cylinder 1 misfire still present points strongly to the coil pack.
Cambelt change 100K or 10 years, is it? In that case it can wait.

[Nick W]

Thanks Dave. Cam cover ordered.
On reflection, the code is specific to cylinder 1. Having cleaned and replaced all plugs and the coil pack, cylinder 1 misfire still present points strongly to the coil pack.

coil pack is possible, and being a cheap to buy and fit consumable part should be top of the list. But there's a number of other causes, like wiring faults, injector issues and mechanical problems that you should at least consider.

[dave the builder]

have you tried the coil pack from the spares car ? with a different plug , and cleared the codes ? (after cleaning ALL oil from the wells)
if you still have a missfire after that then as Nick says , it could be something more complex to resolve 

[Marks DTM Calib]

And beware the cheap pattern coil packs, been there, done that!

[terry paget]

I had washed the plugs and coilpack in petrol yesterday. However, on removing the coilpack today, I saw(see above) there was still some oil and water on the coils of 1,2 & 3. I substituted the coilpack from my donor Astra and started engine, no misfire. I plugged in diagnoser and cancelled the fault code, on restart no fault code reappeared. So fault is traced and rectified.
I have on order a new cam cover with gaskets,when it arrives (Wednesday?) I shall fit it and deem the car recommissioned. Is there anything else I should do?
Thanks to all for advice.

[dave the builder]

good news then  well done Terry 
as the car had been running with a miss fire ,I advise you do an oil change 
also worth checking the car over and checking the strength of anti-freeze and strong screen wash .
winter will soon be upon us and i've seen reports of "worst/coldest winter in 50 years" 
not sure how true that is
hope the cam cover bolts come out easy for you 

[STEMO]

good news then  well done Terry 
as the car had been running with a miss fire ,I advise you do an oil change 
also worth checking the car over and checking the strength of anti-freeze and strong screen wash .
winter will soon be upon us and i've seen reports of "worst/coldest winter in 50 years" 
not sure how true that is
hope the cam cover bolts come out easy for you 

You been reading the daily star again? 

[dave the builder]

good news then  well done Terry 
as the car had been running with a miss fire ,I advise you do an oil change 
also worth checking the car over and checking the strength of anti-freeze and strong screen wash .
winter will soon be upon us and i've seen reports of "worst/coldest winter in 50 years" 
not sure how true that is
hope the cam cover bolts come out easy for you 

You been reading the daily star again? 

It was on the internet ,so must be true 

[Marks DTM Calib]

good news then  well done Terry 
as the car had been running with a miss fire ,I advise you do an oil change 
also worth checking the car over and checking the strength of anti-freeze and strong screen wash .
winter will soon be upon us and i've seen reports of "worst/coldest winter in 50 years" 
not sure how true that is
hope the cam cover bolts come out easy for you 

Not actually necessary, the ECU setups since the early noughties disable the injection on a misfiring cylinder

[terry paget]

About to fit the new cam cover. Haynes does not mention any sealant in the sharp corner at the timing sprocket end, unlike I have always done on Omegas. I presume this is correct.

[dave the builder]

About to fit the new cam cover. Haynes does not mention any sealant in the sharp corner at the timing sprocket end, unlike I have always done on Omegas. I presume this is correct.

I didn't use any sealant on the 2 I replaced, neither have leaked

[terry paget]

I have bought the wrong cover. This is a 2010 Astra H 1.6. Here is the cam cover.


The gasket is labelled 55 354237 GM.
I cannot find one on e-bay. Please help.

[dave the builder]

i did say "is yours the same "  when i posted the link 
looks to be the 115 hp engine code Z16XER
not the 103 hp z16xep
so just a gasket
https://www.ebay.co.uk/itm/Vauxhall-ASTRA-CORSA-INSIGNIA-MERIVA-1-6-1-8-CAM-ROCKER-COVER-GASKET-NEW/192975394112?epid=12032720026&hash=item2cee3ad540:g:WeMAAOSwNYVdHg6b

unless you want a branded one ?

did you check if the pcv valve was ok BEFORE removing the cover ? 

[terry paget]

i did say "is yours the same "  when i posted the link 
looks to be the 115 hp engine code Z16XER
not the 103 hp z16xep
so just a gasket
https://www.ebay.co.uk/itm/Vauxhall-ASTRA-CORSA-INSIGNIA-MERIVA-1-6-1-8-CAM-ROCKER-COVER-GASKET-NEW/192975394112?epid=12032720026&hash=item2cee3ad540:g:WeMAAOSwNYVdHg6b

unless you want a branded one ?

did you check if the pcv valve was ok BEFORE removing the cover ? 

No, didn't check the valve, seemed simplest to change the cover complete. I shall check now. The cover seemed all right, it said 2010 car I thought.
All my Astras are different! I have a 2004, a 2006, a 2008 and a 2010. They are all Astra H 1.6 petrol manual, th coil packs are the same on the 2004 and the 2010, but as I learned earlier, the cam belt arrangements are not the same.

[dave the builder]

the cam cover you ordered will probably fit one of your astras

you can buy just an orange DIAPHRAGM if it is split and the filler cap/dipstick  has a big vacuum 

[dave the builder]

video valve in johnny foreigner speak ,but it shows the DIAPHRAGM

[terry paget]

+Thanks for the reference for the gasket, Dave. Is there a similar cheap cam cover available for this Astra?
Thanks or the video of the orange gasket. I will reserch mine today, but if I can buy the whole cover for £28 I will do so.
When I removed the old cam cover the spring clip which holds on the hose from the manifold went pinging off somewhere and vanished. Problem?

[dave the builder]

is it this one clicky Rocker Cover 55564395    
£28.49

you will need to CHECK the part number on the original cover matches

if the pcv valve is fine ,why not just replace the gasket 

[terry paget]

is it this one clicky Rocker Cover 55564395    
£28.49

you will need to CHECK the part number on the original cover matches

if the pcv valve is fine ,why not just replace the gasket 

Thanks Dave, that's the one, right part number, and all the pictures correspond.
Thanks for the video, instructive, pity it's not in English. Not clear how I check the pcv valve - do I lift the dip stick engine running and listen, same with filler cap?
The cam cover is now off and the gasket is ruined, making diaphragm checking impossible, it looks quite tricky to remove the pcv valve and replace the diaphragm, and gasket delivery was to be December 28-30, while the rocker cover delivery was December 22-24, and I would like the car recommissioned ASAP; all reasons to buy the complete cover.

[dave the builder]

Thanks Dave, that's the one, right part number, and all the pictures correspond.
Thanks for the video, instructive, pity it's not in English. Not clear how I check the pcv valve - do I lift the dip stick engine running and listen, same with filler cap?

when assembled and running engine, the oil cap should lift off, if there is a big vacuum pulling the cap on ,the pcv valve is  duff.
similarly, if if you pull the dip-stick and theres a big vacuum , the pcv valve is duff .

as for the lost horse shoe clip that retains the pipe between rocker cover and throttle body, is there one on the spares car ?
it's pretty important as it holds that pipe on .

[terry paget]

Thanks Dave, that's the one, right part number, and all the pictures correspond.
Thanks for the video, instructive, pity it's not in English. Not clear how I check the pcv valve - do I lift the dip stick engine running and listen, same with filler cap?

when assembled and running engine, the oil cap should lift off, if there is a big vacuum pulling the cap on ,the pcv valve is  duff.
similarly, if if you pull the dip-stick and theres a big vacuum , the pcv valve is duff .

as for the lost horse shoe clip that retains the pipe between rocker cover and throttle body, is there one on the spares car ?
it's pretty important as it holds that pipe on .

Sadly, no. I have already used it on another job. I looked on e-bay for a spare hose with clips, but could not find one. I was hoping I could improvise with a bit of wire. Of course it might be under the car, but I cannot see it.

[terry paget]

https://www.ebay.co.uk/itm/VAUXHALL-OPEL-ASTRA-H-G-VECTRA-C-ZAFIRA-A-B-CRANKCASE-DIAPHRAGM-VALVE-COVER/273216769724?hash=item3f9cfd0ebc:g:ADcAAOSwPHxbGUfx
Phew, found one!

[dave the builder]

https://www.ebay.co.uk/itm/VAUXHALL-OPEL-ASTRA-H-G-VECTRA-C-ZAFIRA-A-B-CRANKCASE-DIAPHRAGM-VALVE-COVER/273216769724?hash=item3f9cfd0ebc:g:ADcAAOSwPHxbGUfx
Phew, found one!

that's just a replacement diaphragm in your link ,which will be fitted to the replacement cover anyway .
I assume you posted a wrong link and have found a pipe or horse shoe clip replacement

[dave the builder]

the complete pipe with 2 clips is 55556495 and expensive 
clicky link
you can probably get the clips ,i'm sure quite a few have pinged off ,never to be seen again 

[terry paget]

video valve in johnny foreigner speak ,but it shows the DIAPHRAGM

I fitted the correct cam cover to Jonny's car and returned it him, misfire cured, no more fault codes, thanks for your help.
As a challenge I tried to remove the diaphragm, and see if it was broken. The video was very useful, but I am struggling to remove the diaphragm holder. It seems to be designed for easy assembly, not for ease of dismantling.

[dave the builder]

video valve in johnny foreigner speak ,but it shows the DIAPHRAGM

I fitted the correct cam cover to Jonny's car and returned it him, misfire cured, no more fault codes, thanks for your help.
As a challenge I tried to remove the diaphragm, and see if it was broken. The video was very useful, but I am struggling to remove the diaphragm holder. It seems to be designed for easy assembly, not for ease of dismantling.

well done on the fix terry 

if you want to remove the diaphragm, gently heat the plastic with a hot air paint stripper to soften it
word of warning though , be careful ,the oil residue could catch fire
eyebrows do grow back eventually though 

[terry paget]

Thanks for the advice Dave. I had already used a hot air blower to soften the plastic, but it still would not shift. Trying harder, all I achieved was to damage the cam cover. I released the end clips all right, but heaving away on the circular join all I did was break off the plastic around the clips. I am puzzled, because the diapragm is available as a spare part. Maybe on young cars these parts come apart more easily. Haynes does not seem aware of the diaphragm. The availability of complete cam covers as spares suggests this is the way to go.