James' 1993 Cavalier LS

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James McGrath
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James' 1993 Cavalier LS

Post by James McGrath »

I thought it was about time I did a proper WIP thread so I can update you all on what I've been doing recently, so here goes.

First allow me to introduce myself and the car.

Well it’s a 1993 1.6i (C16NZ2) engine LS with currently roughly 168600 miles on the clock I've been driving the cavalier for 2 years now using it to commute to college and back every day. In that time I've had no serious faults and she has never let me down.

Some history:
The Cavalier was first registered on the 24th June 1993 when it was purchased by the post office and used as a company car until it was bought by my father in September 1996 it was then used by my mother and later my father as the main family car alongside my fathers 1984 MK2 Cavalier 1.3 L which my sister and I lovingly nicknamed "Rusty" for obvious reasons. In the whole time it’s been in my family it has never broken down and it has only failed to start first time once and that was because of a flat battery!

Here is one of the only photos I have of old Rusty very late in its life:
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When the MK2 sadly gave up in 2001 after covering about 160,000 miles my father bought another car and later bought a new car for my mother leaving the Cavalier practically redundant until I started driving it 2 years ago.

Here is a photo of her when I first started driving.
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At the moment I'm mainly trying to just maintain her so most of my work will be replacing broken bits ect. Although I do have a few long term goals such as getting the bodywork sorted out, removing any rust and under-sealing for example. One thing I will not be doing however are any major modifications. I certainly have no intention of replacing in my opinion the very underrated C16NZ2 engine.

I will add some posts of the work I’ve been doing this summer over the next couple of days. However for now I will leave you with some more recent photos, enjoy.

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planetc
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Re: James' 1993 Cavalier LS

Post by planetc »

:thumb
"No the temperature gauge doesn't work........
we've driven 150 miles today........
the heater went cold last Thursday........
they check the level when it's serviced don't they?"
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Re: James' 1993 Cavalier LS

Post by Envoy CDX »

Looks good, however I'm confused, is it a prefacelift with facelift parts, or vice versa?
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Re: James' 1993 Cavalier LS

Post by James McGrath »

Envoy CDX wrote:Looks good, however I'm confused, is it a prefacelift with facelift parts, or vice versa?

It's a long story but basically it's a facelift model with a pre-facelift bonnet.

This is because my father was unfortunate enough to have an accident involving a 9 foot tall stag at night on the 30th December 2007 which crumpled the left front corner of the car.
When it came to repairing the damage the mechanic made a mistake and put the wrong bonnet on. :roll:

Unfortunately this incident has caused a few other niggley inconsistencies such as the fact that I have one electrically adjusted headlamp and the other is manually adjusted, I will be addressing this as soon as the part arrives. :thumb
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Re: James' 1993 Cavalier LS

Post by Envoy CDX »

Ah, funky monkeys! :)
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Re: James' 1993 Cavalier LS

Post by jimmy »

Looking good there buddy :thumb
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Re: James' 1993 Cavalier LS

Post by James McGrath »

Ok, as promised here is the first set of jobs that I've been up to so far this summer armed only with a Haynes manual and a good set of spanners...

First the slightly dangerous broken wiper blade arm.
How this happened God only knows. However the finger of blame does point rather strongly at the "lovely" caps down at kwik-fit who did my MOT as it was fine when I dropped it off and I noticed this the day after. :evil:

No matter, it’s an easy fix;

Tip: use masking tape to outline where the arm is supposed to lye before you take the old one off.

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For those like me who couldn’t find where the nut was; :geek:
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The finished product. (Please excuse the top of my head in this photo);
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Working in-between rain showers second is the broken rear light cluster. I did this by reversing into a bit metal recycling bin. :geek:
The trickiest part about this job is undoing the 4 retaining screws because there is no room to move a spanner around. i managed to just get at them with a ratchet spanner.

Before;
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During;
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Gave it all a quick clean and smeared a bit of Vaseline over any areas that looked as if rust could form.
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After;
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Next, the indicator stalk. This is a very common problem where the flash doesn’t work. Or in my case both the flash and the main beam. I don’t know if there is a way to repair this it looks like a sealed unit to me so I just replaced it instead

Once the plastic casing is removed it’s a simple job of unplugging the old and fitting the new.
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Full beam headlights now working :D
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Just a bit of detail next

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Next post: my long prepared for EGR valve blanking modification!
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Re: James' 1993 Cavalier LS

Post by James McGrath »

Ok this has been a long time in the making. My main problem was getting the parts, more specifically the blanking plate itself.

Eventually I did find one that fits, but it wasn't made for a cavalier. It was made for a Daewoo Tacuma of all things!

Ok first of all get the top hat off the air intake assembly to allow easier access to the valve itself. Mow if yours is anything like mine you’ll probably want to take the opportunity to give this and the breather pipes a thorough clean. Mine was absolutely filthy, I doubt it had ever even been opened let alone cleaned. There was a layer of sludge half and inch thick around the inside of the casing!


Top hat off and cleaned up;
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Hint for anyone who is planning to do this themselves. You need just the right type of spanner to remove the valve; one with a thin rim around it otherwise you wont be able to get it around the bolts holding the valve in place.

Something like this will do nicely;
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EGR valve finally off;
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Blanking plate fitted at last, with a nice new pair of bolts to match :thumb
You can also see in this photo what I used to block the vacuum hose up with. A rather good idea originally from planetc, a tight fitting screw and electrical tape!
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I have noticed a difference in running after removing the valve it seems more willing to accelerate and the engine seems a tad smother as a whole.

Only snag is that I now need to clean the rest of the engine bay up to match the shiny blanking plate! :cheers
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Re: James' 1993 Cavalier LS

Post by Peanut_119 »

very nice '93 ls saloon is cool (mines the same model :D )

were did u get the number plate light cover from?
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Re: James' 1993 Cavalier LS

Post by Envoy CDX »

All good :)
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Re: James' 1993 Cavalier LS

Post by James McGrath »

Peanut_119 wrote:very nice '93 ls saloon is cool (mines the same model :D )

were did u get the number plate light cover from?
I got it from that ever trusty friend, eBay. :thumb
Here is the link:

http://www.ebay.co.uk/itm/290585366937? ... 1439.l2649

But I'm sure you could get an original Vauxhall part either second hand from eBay or from a Vauxhall parts dealer if you wanted.
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Re: James' 1993 Cavalier LS

Post by James McGrath »

Right, cracked wing mirror next.
The thing I found most annoying about this is that there was a spider that was living inside the crack so I would find a perfect spiders web that had been woven between the door and the outside edge of the mirror casing, relentlessly this spider would weave a new one every morning. Most frustrating really.

You can see daylight through this hole;
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Mirror removed, I once again used Vaseline on any rust vulnerable areas;
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Finally the new wing mirror is on and that dam spider evicted, hopefully for ever. :cheers
Image
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Re: James' 1993 Cavalier LS

Post by Peanut_119 »

James McGrath wrote:
Peanut_119 wrote:very nice '93 ls saloon is cool (mines the same model :D )

were did u get the number plate light cover from?
I got it from that ever trusty friend, eBay. :thumb
Here is the link:

http://www.ebay.co.uk/itm/290585366937? ... 1439.l2649

But I'm sure you could get an original Vauxhall part either second hand from eBay or from a Vauxhall parts dealer if you wanted.

thanks :) my missus treated me to one... and now just need new number plates to match :)
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Re: James' 1993 Cavalier LS

Post by James McGrath »

Gave my cam cover a good clean yesterday.
Soaked it in swarfega degreaser for 3 hours and gave it a good scrub with a wire brush for a further 3 hours, or what seemed like 3 hours anyway.
Here are the results, sorry no during photos this time,

Before:
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After:
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I've also bought some red heat resistant enamel paint that I’m going to use to paint it with. I'll also book her in for a steam clean to clean up the rest of the engine bay because despite my best efforts it's still filthy!

A quick update on the things I have in the pipeline. I've ordered a new dipstick assembly and gasket as the original one is rusted to hell and I believe it's just started to leak. I've also got a new electric headlamp that's got to go on which will finally replace the left-hand side lamp which is only manual that I’ve had on there for the last few years. I'm also looking for the part number for the battery holder/plate as that too has rusted so if anyone knows the number your help will be much appreciated.
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Re: James' 1993 Cavalier LS

Post by James McGrath »

I've been busy today. First of all I've finally got around to fitting the new electric headlamp. (Adjuster motor courtesy of Robsy, thanks again for that :thumb )
While I was removing the headlamp what did I find but both the original headlamp rubbers tucked inside the bumper. I thought they had been lost years ago! :D
They were a bit stiff but I ran them under a hot tap and gave them a scrub down and they were good as new.
I also found a few other things lurking behind the front grill including about 3 screws, a bolt, a clip for the HT leads and the inevitable broken glass probably left over from the fabled accident involving a stag a few years ago!
So after removing the other headlamp and giving everything a clean and once again Vaseline where it was needed I spent about an hour trying to figure out how to put them on. :evil:
I eventually got them on by attaching them to the front sill first then putting the headlamp on and then using a flat-blade screwdriver to prise the flap over the glass.

Anyway here are the photos.

Front grill and lights removed, everything cleaned and vaselined.
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Headlamps finally in and working...
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... and the rubbers fitted. :D
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After I'd finished I decided now was as good as ever to finish off the cam cover as well.
For this I used "High Temperature Engine Enamel Paint" bought from Halfords.
I just hope it does what it says on the tin!
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It's nice to finally have 2 working electric headlamps again after all these years... well... 3 years.
And I think the can cover has worked out quite nicely. I wasn’t going for a super shiny mirror finish or anything, I thought that would look out of place.
I just hope that when I get it steam cleaned it doesn’t take the paint off!
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Re: James' 1993 Cavalier LS

Post by Envoy CDX »

Nice efforts :)
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Re: James' 1993 Cavalier LS

Post by cavboy180 »

Nice work! I have to say im very interested about the egr mod, not because I have problems but it could run smoother, odd times it feels like I have a flat spot. Anyway, great work!
" LS was MORE!! "
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Re: Re: James' 1993 Cavalier LS

Post by planetc »

cavboy180 wrote: odd times it feels like I have a flat spot.
1600 comes standard with one big flat spot? ;-)

Simple test, since your egr is currently operating, unplug the vac pipe and put a self tapping screw into it to plug it. Then give the egr valve a couple of taps with something tappy to make sure it's fully returned to its seat. EGR is now as good as blanked. Mine has been running in this state for about 1000 miles now, definitely smoother, particularly on overun.
"No the temperature gauge doesn't work........
we've driven 150 miles today........
the heater went cold last Thursday........
they check the level when it's serviced don't they?"
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Re: James' 1993 Cavalier LS

Post by cavboy180 »

This is so true lol but they're so amazingly reliable and not bad with the old juice:-)
" LS was MORE!! "
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Re: James' 1993 Cavalier LS

Post by James McGrath »

cavboy180 wrote:This is so true lol but they're so amazingly reliable and not bad with the old juice:-)
Yeah, I'm a big fan of the engine myself. Modern 1.6 engines are very boring in comparison, especially when it comes to sound. Do you get that fantastic whistle tone at about 2500-3000 rpm?
Talking of reliability, I can honestly say that in the whole time my family has owned it, it has never once broken down or even failed to start first time.
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Re: James' 1993 Cavalier LS

Post by cavboy180 »

To be fair it is quite rorty from about 2000 revs, am gonna try that test, thanks! Take it you are going to the meet?
" LS was MORE!! "
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Re: James' 1993 Cavalier LS

Post by James McGrath »

It's not really a test, it's just what my engine does really. Try it in 3rd gear at about 30-35 mph, I'm fascinated to know if it's just my Cav that does it.

I don’t think I am going to the meeting at Rownhams services if that’s the one your talking about, it’s just a bit too far for me.
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Re: Re: James' 1993 Cavalier LS

Post by planetc »

James McGrath wrote: I don’t think I am going to the meeting at Rownhams services if that’s the one your talking about, it’s just a bit too far for me.
We'll have to have our own little meet James, then we can post a photo of ourselves poking our tongues out at the lads from Bournemouth!
"No the temperature gauge doesn't work........
we've driven 150 miles today........
the heater went cold last Thursday........
they check the level when it's serviced don't they?"
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Re: Re: James' 1993 Cavalier LS

Post by James McGrath »

planetc wrote:We'll have to have our own little meet James, then we can post a photo of ourselves poking our tongues out at the lads from Bournemouth!
That sounds like a plan!! :lol:
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Re: James' 1993 Cavalier LS

Post by James McGrath »

New part arrived for me at the Vauxhall parts garage in St Leonard’s for me to collect on Monday.
I ended up doing a journey all the way from my University in Canterbury to St Leonard’s to get it but oh well.
Anyway back at base camp in Robertsbridge I got to work.

Here's the new part
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Yep, a bran spanking new dipstick housing, breather pipe assembly thingy... that is its real name... honest.

For whoever is interested here are the part numbers.
Gasket: 90500571
Dipstick/breather pipe assembly: 90499502


This was the state of the old one, rusted and weeping oil slightly
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The garter that connects the assembly to the cylinder head had also turned into a consistency comparable to warm Liquorice.
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After a quick walk down to Culverwells, my local machinery/farm shop that normally specialises in tractors and Subaru’s (Strange combination I know), I found a suitable replacement in the form of a hose-bypass normally for a Massey Ferguson tractor (part number S 41317). After being cut to size it fitted perfectly!

A quick clean up and everything went well after that.
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And yes I did paint the supporting fixture red, after giving it a rub down with a wire brush. It was that or leave it as exposed rust.


I also gave her a bit of an interim service at the same time in preparation to the increased amount of driving I’ll be doing at University (I’m not living on campus).
New HT leads and spark plugs.
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After that the old girl seems to be running much better.

I probably won’t be able to as much work as I had hoped until around Christmas time now, what with Uni work and everything. But I plan to do some more major work around that time perhaps under-sealing her and some rust removal depending on available funds of course. I’ll be moving on from the engine bay for now and probably won’t do any work under the bonnet for some time as I have loads of little jobs to do in the interior that I need to see to, door cards, bulbs, and broken clips for example. But for now I will leave you with this rather amusing picture that I meant to upload a few month ago.

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Scary, huh?
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