My car has been in and out of the shop since May. Mostly for stupid reasons. From a mechanic too "busy" to get around to it, from a completely incompetent series of shops that told me my car had one problem when it wasn't and I was right about it.
The car is a 99 Opel Astra SW. Diesel engine. Of a series fitted with a very finecky fuel pump. The GM engine is very efficient but also very delicate; the injection system resembles a petrol one and requires precise timing. After breaking the third accessories belt in less than six months, the car started knocking, badly, and the iginition failed.
When I bought it, it came out of timing, and it struggled with starting, having the fuel injection out of synch with the pump, due to a faulty engine cranckshaft sensor. It was fixed and the engine purred.
I told this to the shop when the accessories belt broke again but they ignored me and pointed the problem to the fuel pump. They did fix a broken rocker in the injection system but the engine still knocked and loudly. I asked if they had checked the engine timing and was insisted I had to replace the fuel pump, which is a 1500€ expense.
I called to a couple of diesel labs and they were in agreement: this particular pump is finecky but it has a virtue, as it does not have partial issues. If the electronics fail, the pump is done. If the mechanics fail, it shows. If the car was starting after insisting and running, the issue was somewhere else.
I found another mechanic. A crazy one. Of the good kind. Run the entire story through him. And he agrees something is off.
The issues list start to pile after a careful check. A faulty head gasket, leaking, barely, but nonetheless. A wobbling engine pully, the one that actuates the accessories belt, which is the cause for the constantly failing belts. Leaking injector rings. Small things but that do pile up and tell a story of poor service. And then is the fuel pump. Two bare wires that connect the pump control unit to the regulator. Two wires that are shorting each other. Two wires that when put apart allow the engine to start on the first try.
I trust my car to this guy. I order parts, as per his request, and he puts his hands to the work. And the bad news keep pilling.
The knocking was the fuel valves hitting the piston heads. The engine was not properly timed and was in fact two teeth ahead. The timing that was assured by three different mechanics when the rocker was replaced was moot. These engines are very demanding when it comes to be timed and require a special tool, an imobilizer, fitted through the vacuum pump housing, to keep everything in place. The timing had been attemped my marking relative positions on the outside of the engine. Not good.
The engine head was so beat up it risked cracking. Surfacing it was pointless. My mechanic found another, aluminium welded a small defect on it that was bothering him, had it rectified and fitted it. Mechanically, the engine was sound again.
But what about that cursed fuel pump?
Well, it so happens those damned wires were the downfall of the pump. Circuits don't enjoy being shorted. The mechanic took it out to check those wires and the board they connected to was in bad shape. It was technically a miracle how it still fired. But it was its dying breath and ended there. Mechanically, it was faultless. Very little wear, negligible. But the board was fried. We tried to get a used control unit but it proved to not be in good condition as well; on idle, the third cylinder would not get any fuel.
The pump was sent to a lab for diagnosis. Which promptly dismissed it as faulty and needing of replacement. I had to personally call the lab to find out if the problem was mechanical or circuit bound and after a short exchange they reluctantly told me the issue was the circuit board. 1500€, 12 month warranty, if installed at their shop.
No.
I called a few other places and the least I could get was around 1000€. Then I took the plunge and went online. And struck strong. I found the unit, abroad, for a third of the price. 36 months warranty. And a deposit return with the handover of the old fuel pump. And the shop that sold me the used control unit is open to receive it back for testing and if it proves faulty, they are willing to return that value as well.
The carrier order is already open, so it is just the waiting game now.
This just shows how precious investing a bit of our own personal time can be. I had to personally interfere in this whole process to things through and save some money, that I otherwise would hurt for.
After this, it is off to work in my side job to recoup the investment.