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vauxdoc, GM Europe master tech
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Experience:  25 years GM factory trained ATA UK registered
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Vauxhall Astra: 05 vauxhall astra 1.6 petrol: Tappet noise

Resolved Question:

05 vauxhall astra 1.6 petrol: Tappet noise coming from back of engine increases with engine revs. Noise distinctly coming from induction box or through it . Changed trottle body , no good : cams not scored : valve caps not broken : cam shafts seem quiet when running engine : (rocker cover off). Runs perfect, plenty of power. Noise loud.
Submitted: 4 years ago.
Category: Car
Expert:  vauxdoc replied 4 years ago.
Welcome to Just Answer, Without being able to hear the noise I am at a disadvantage, however there is a quite common noise on this engine series and the symptoms are the same as yours.

The noise stems from the multi-port mechanism in the inlet manifold and to cure it a new manifold will need to be fitted, as I say it is a known fault and Vauxhall have issued a technical remedy bulletin on this, there is an extract below.

I hope this helps, best regards, Vauxdoc.

Field Remedy: 2219
Subject: Engine Z16XE/XEP/YNG - Rattling noise
Models: Engines: Option:
Astra-G 2003...2005,Astra-H 2004...2005,Zafira 2004...2005 Z16XE| Z16XEP| Z16YNG,Z16XEP,Z16XEP| Z16YNG
Complaint: Rattling noise from cylinder head area. The noise becomes louder with increasing number of revolutions independent of load. During idle nearly not audible.
Cause: Vibration/rattle noise due to of loosen parts inside of the air intake manifold.
Production: Improved intake manifolds have been introduced in produktion (May 2005) as of engineno.: 20FG2871.


In case of customer complaint exchange the intake manifold according Service Information document "Replace intake manifold".
FunctionalGroup: J - Engine
Complaint Group: 14 - Noises or Vibrations
Trouble Code: None

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