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Sorry its been a long while. Just an update. It was the head gasket that went, but the mechanic AND the cylinder repair shop advised the head be changed due the head becoming malleable from overheating (not sure how true this was but I did cross-check with another diesel mechanic about 5 suburbs...

I'm positive the Astra battery I have is around 500-650 CCA from memory. It was the same size as the D40 battery compartment. Will check when I'm off work. But I'm going to need a bigger battery for the Nav anyway when its all fixed, so no harm in buying the right one now.

Turned over pretty well first couple days before the engine cut off on the third day. After that it started to get worse. Doubt its the battery as I did swap my good battery out of another car and same thing happens. I had a pretty good bet on cracked head, thought it might be hydrolock aswell...

My first thought was that the battery in it was not the right battery, as it was too small to even sit in the battery case. Swapped it over to a heavy duty battery from my Astra. There was 12v going into the original battery. The Nav sounds like its trying to turn over but not combusting.

Hi guys, first post. Only just bought this guy not last Saturday but the Saturday before. Its a D40 STX 2007, and ran perfectly fine till last Saturday when I took it to a 4WD beach and cooked it because I was inexperienced with beach driving and had it in low 3-4 pushing the car pretty hard...