Opel Astra - automx.co.za Astra J... · new Astra, based on the 3rd generation of Hella’s Vario...

Opel AstraModel Introduction Training For Approved Body Repairers

CONTENTS

Note

GENERAL

BODY

MECHANICAL

ELECTRICAL

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10

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31RESTRAINT SYSTEM

This self-study programme highlights the design and function of new vehicle models, new automotive components or new technologies.

The self-study programme is not a repair manual!All values given are intended as a guideline only.

For maintenance and repair work, always refer to the current technical literature.

© 2008 General Motors Corporation. All rights reserved.

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Specifications

General

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TRAININGGeneral

Colours

Wheels and Tyres

Silver Lake

Olympic White Waterworld Blue

Black SapphireTechnical Grey

Power Red

1.6T Sport18x8.0,5-spoke235/45R18

1.4T Enjoy17x7.0,five-spoke215/50R17

1.6 Essentia17x7.0,multi-spoke215/50R17


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Cockpit

The interior design of the new Opel Astra harmonizes convincingly with the bold and modern exterior. The first impression for the driver is of well-organized com-fort.

The 4-way adjustable seat is comfortable but supporti-ve, and everything is within easy reach. Both this and the 6-way adjustable ergonomic sports seat (available in the 1.6T Sport) have increased travel both in height and length for maximum comfort in positioning and le-groom. The steering wheel can be adjusted for reach and rake. The gear lever is short, sporty, and ergonomi-cally shaped for the hand. Together these features add up to give an impression of quality and control.

The instruments are housed in pods, and the main dials are angled inward towards the driver, emphasizing the driver-focused feeling. New attention to detail includes the high quality feel of the steering wheel controls and the whole impact of higher quality materials throughout the cockpit.

The centre stack, mounted at a user-friendly 30degreeangle, houses the main display, infotainment, air cont-rols, and centre vents. All are easily reachable and in-tuitively easy to use. The driver’s convenience is maximized by details such as outstanding storage pos-sibilities within easy reach, including a special driver’s storage bin.

General


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Interior

Friendly, stylish, and functional the new Opel Astrakeeps the comfort of all passengers in mind. Thelonger wheelbase and wider track have translatedinto a feeling of generous roominess. The interioralso offers a new sense of high quality and friend-liness to maximize this increased spaciousness. Softcurves and surfaces which overlap rather than meetat a dividing point form awelcoming environment.Quality and tactility have also played a dominant rolein the choice of fabrics at all trim levels.

Another up-markettouch that further reinforces thewelcoming nature is that much attention has beenpaid to the ambient interior lighting. At nightred diffused light illuminates the base of the centrestack and the door panels.

In the rear, the generous leg- and shoulder- room, im-proved deep-sculptured rear seats, and practical stor-ages for items and drinks make the passengersinstantly feel at home.

Overall, the interior is one of the most effective"first impression" sales factors with the new OpelAstra.

General


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Body Metals

Mild Steel

Bake Hardened Steel

High Strength Steel

Body


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Press Hardened Steel

Aluminium

Martensite

Body

Dual Phase Steel


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VIN (Vehicle Identification Number)

● The VIN is located at the upper left side at the instrument panel, seen through the windscreen.

● The VIN is also stamped into right-hand floor, in front of the front seat.

● The identification plate including the VIN, is found on the left -hand B-pillar

Body


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Opel Astra Safety

The highly rigid, computer-designed and optimized body structure utilizes high- strength steel grades, defined load paths and deformation zones to enable a high level of passive safety performance. The safety cell of the new Opel Astra offers one of the largest crash protection survival spaces in this class. In high-speed front impacts, the energy is distributed along three controlled load paths inclu-ding the front sub-frame. In side- impact events, the diagonally mounted door beams effectively transfer load into ultra high strength steel B pillars, side sills, and floor cross-members.

Low Speed ConceptThe new Opel Astra is the first car in its class designed to meet the new bumper design guidelines from Research Council of Automobile Repairs(RCAR),an international association for insurance indus-try research.The aluminium bumper beam sections and crash boxes are strategically positioned to avoid override/ underride events in low speed crash impacts. This results in reduced damage and helps to save repair costs. In addition, the new Opel Astra has special radiator and headlamp mountings to avoid the need to replace expensive components in low speed impacts.

Radiator pushblocks avoid contact between radiator and crash beam

Radiator affixed by repairable pins

Headlight catcher avoids fender damage

Body


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Body Features - Rear

Bolted crash absorber sys-tem

Guide rail connection desi-gned to avoid interaction with intruding parts

Body Features - Passive Safety

“Self Repairing” Bumper for impacts under 4km/h

Low density foam structure

Lower bumper stiffener

Body


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TRAINING

Pedestrian Protection - Head Impact

Optimised package ensures sufficient space between the bonnet and the stiff components and structures below, for deformation and energy absorption.

Body

Pedal Release System (PRS)

Opel’s Pedal Release System decouples the clutch and brake pedals in the event of a serious frontal accident. This reduces the risk of injury in the foot region.


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TRAINING

Body repairs

Front Rail Replacement

Create cut lines on the centre reinforcement left side (1) or right side (2).

Removal of the left side front rail

Front Bumper Impact Bar Replacement

Cutting the impact bar is needed to access the spotwelds.

8 Bolts hold the Impact bar in place including spotwelds.

Body


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TRAINING

Rocker Panel Outer Panel Sectioning

Removal of the outer rocker panel. Structural adhesive to be used as in illustrati-on.

Centre Pillar Reinforcement Replacement

Drilling out spotwelds Removal of damaged part

Slots to be created for MIG brazing Spotwelding to be completed.

Body


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TRAINING

Front Door Outer Panel Replacement

Remove outer panel by grinding edges. Apply structural adhesive on flanges

Work over hem flanges on door.Apply urethane adhesive to door reinforcemnt

Body


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TRAINING

Roof Outer Panel Replacement

Drill out factory welds to remove outer damaged part.

Clamp panel into position and spot weld accor-dingly as noted from the original panel.

Apply structural adhesive

Apply one part urethane windscreen adhesive.Drill out factory welds to remove outer damaged part.

Body


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TRAINING

Engine

Three engines available

1.6L with 5 speed manual Transmission1.4L Turbo with 6 speed manual transmission1.6L Turbo with 6 speed manual transmission

1.6 L Ecotec

Output(KW) 85 @ 6000rpmTorque(NM) 155 @ 4000rpm

1.6 L Turbo Ecotec

Output(KW) 132 @ 5500rpmTorque(NM) 230 @ 2200rpm

1.4 L Turbo Ecotec

Output(KW) 103 @ 4900rpmTorque(NM) 200 @ 1850-4900rpm

Mechanical


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TRAINING

Critical Service procedures - 1.4L oil pan

Sump Connection

Sealing compound around the front of engine cover

Sealing compound around the screw bore

Mechanical


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Turbo Charger Coolant Feed Pipe

– Using a standard wrench could twist the coolant feed pipe.

– This could result in leakage of fluid and engine failure

Suspension

One of the largest innovations of the new Astra is its new rear suspension.It uses what is called a “watts” linkage.The axle assembly attaches to the underbody through a rubber bushing and bracket located at the front of each trailing arm.The Watt linkage is used as a performance improvement.This method is intended to pre-vent relavant sideways motion between the axle and body of the vehicle.

Mechanical


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TRAINING

Flex Ride

● Flex Ride is the next generation of Continuous Damping Control (CDC) technology.

● The modes for Flex Ride are: 1) Sport 2) Standard 3) Tour

● These settings effect the steering, the damper tuning, throttle progression, the shift points of the automatic transmission and the illumination of the instrument panel.

Flex Ride Shock Absorbers

Magnetic Valve

2 X Rear

2 X Front

Mechanical


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TRAINING

Electric Power Steering

The power steering contains the follo-wing components:

● Control module

● Electric motor

● Rotation sensor

● Torque sensor

● Steering gear(rack and dual pinion)

Motor with overload protection

Torque sensor

Intergrated control module

Mechanical

If the steering column or steering angle sensor needs to be replaced, the vehicle will have to be recalibrated using a scan tool.


25

TRAININGMechanical

Parking Brake

There are two parking brake systems for the Astra:

Self adjusting manual parking brake

Electric parking brake

Self adjusting parking brake

The SACS automatically adjusts the tension of the cable by a mechanical tension spring.The park brake system does not require adjustment under normal operating conditions and the plastic coated cables do not need lubrication.The tension on the cables can be disable and enabled when necessary for servicing of the brakes.

Electric Parking Brake (EPB)

The electronic parking brake replaces the manual parking brake. It can be ordered as an option and may be standard with certain trim levels.In the Electronic Parking Brake System the brake cables are pulled by the motor in the electric parking brake contol module.

The EPB is mounted behind the left rear wheel arch.

Electronic control unitActuator motor

Actuator spindle


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TRAINING

Fuse Boxes

Electrical

Main Fuse box left front of engine compartment

Fuse box behind glove box

Top of the range uses CD400 and the up level 7 speaker system.

Infotainment

Standard range uses CD300 and the lo-wer level 4 speaker system.

Fuse box at left rear fender


27

TRAININGElectrical

Multi Media Interface

AUX socket fitted as standard, USB opti-onal, with external power source in centre and behind centre console

Antenna Versions

Rod antenna used for AM/FM

Shark fin used for cell phone/GPS

Rear screen antenna used for AM/FM

Advanced adaptive forward lighting(AFL)

The improved Adaptive Forward Lighting of the new Astra, based on the 3rd generation of Hella’s Vario Xenon-System, is an innovative, high-tech feature which increases driving safety and drastical-ly reduces the stress of night time driving. The ve-hicle adapts the headlights automatically to the driving situation so that in every case the best pos-sible light performance is given. Through movable elements the light pattern can be changed and the automatic high beam makes sure that on coming traffic is not disturbed.AFL functions include: Country light Motorway light Town light Pedestrian light Adverse weatherlight Increased high beam Dynamic bending light Static bending light High beam assist(HBA) Daytime running light with LED


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AFL High Beam Assist (HBA)

High Beam Assist makes use of a camera mounted in front of the rear view mirror that picks up light conditions in front of the vehicle. When the came-ra detects head lights from oncoming vehicles it switches the high beam off and back on when ve-hicle has passed. The system also detects tail-lights from slower moving vehicles.

•A=•System turns off high beams when it detects the headlights of oncoming vehicles

•B=•When oncoming vehicle reaches point B, system turns on high beams again

•C=•System turns off high beams when it detects the rear lights of preceding vehicles

Sensor searches Bright Lights Head lights/Tail lights for lights

Electrical


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TRAINING

Key Programming

Up to eight keys can be programmed to each car.

Alarm control module and its antenna are located behind the dash board.

Windscreen sensors

Humidity sensor

Camera

Rain/light sensor

Electrical


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TRAINING

HVAC

High Pressure Service Port

Mounted in the engine bay on the small bore refrigerant pipe, high up in front of the sus-pension strut housing.

Low Pressure Service Port

Mounted in engine bay on the large bore refrigerant pipe, low down to the rear of the right suspension strut hou-sing.

Electrical


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TRAINING

Restraint System

Seat Airbag

Curtain Airbag

Seatbelt Pretensioner

Side Crash Sensor

Airbag Control Module

Driver/passen-ger Airbag

Lap Pretensioner

Front Crash sensor

Driver Airbag

Removal Procedure

1. Disable the supplemental In flatable Restraint System(SIR)

2.Insert appropriate tools in the openings (A) on both sides of the steering wheel.

3. Release the springs in the di rection of the arrows (B).

4. Disconnect the electrical con nectors

Restraint System


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TRAINING

Passenger Airbag

The passenger airbag (2) is secured by 6 nuts (1) under the dashboard.

Seat Airbag

The side (seat) airbag is located in the backrest of both front seats and is held in place by 2 nuts(1).

Curtain Airbag

The curtain airbag is located along the top of the roof running from the A-Pil-lar to the C-Pillar. It is held in place by 3 bolts and 4 clips.

Restraint System


33

TRAINING

Pretensioner Seat belts

Pretensioner seat belts are mounted on the B-Pillar just above the sill. The seat belt is secured to a lap tensioner which is also pyrotechnically activated.

Seat Lap Tensioner

Restraint System


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TRAINING

Side Crash Sensor

The sensor is mounted on the inside of the B-Pillar towards the front of the vehicle.

Front Crash Sensor

The sensor is mounted on the inside of the engine compartment just above the radiator fan.

Airbag Control Module (SDM)

The SDM is located under the centre con-sole behind the gear lever.

NB: There is a 1 minute waiting period after the battery is disconnected, before work can commence on the restraint system.

Restraint System


35

TRAINING

Passenger Airbag De-activation

The passenger airbag can be de-activated by the switch that is located on the right outer side of the dashboard.When the passenger airbag OFF indicator is illuminated,the front passenger airbag is de-activated and will not inflate in the event of a collision.A child restraint system can then be fitted on the seat.

Head Restraints

The new Astra also fetures active head res-traints in the front that move up and forward in the event of a rear end collision.

Restraint System


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TRAINING

Euro NCAP

Euro NCAP awarded the new Astra a five star rating.

Adult occupantThe passenger compartment remained stable in the frontal impact, the windscreen pillar moving rearward less than 2mm. Dual pretensioners restrained the dummies well and readings indicated that the knees and femurs of both the driver and passenger were well protected. Opel were able to show that occupants of different sizes, and those sat in dif-ferent seating positions, would be similiarly well protected. The Astra scored maximum points for its protection of the front passenger occupant in the frontal impact. Protection of the chest was adequate in the side barrier impact and marginal in the more severe side pole test, with good protection of all other body regions in both tests. Protection against whiplash injuries in rear impacts was rated as good.

Child occupantBased on dummy readings in the frontal and side impacts, the Astra scored maximum points for protection of the 3 year dummy. Forward movment of the head was well con-trolled. In the side barrier test, both dummies were properly contained by their restraints. The passenger airbag can be disabled to allow a rearward facing child restraint to be used in that seating position. However, information provided to the driver regarding the status of the airbag is not sufficiently clear. The dangers of using a rearward facing child seat in that position without first disabling the airbag are clearly explained in a label attached to the passenger's sun visor.

PedestrianThe car scored maximum points for the protection offered to pedestrians' legs by the bumper. However, the protection provided by the front edge of the bonnet was poor and scored no points in Euro NCAP's tests. In most areas likely to b struck by the head of a child, the bonnet offered marginal protection. In all areas likely to be struck by an adult's head, the bonnet provided poor protection.

Safety assistElectronic Stability Control (ESC) is standard equipment across the whole of the model range as is a seatbelt reminder system for the driver and front passenger seats.

Restraint System

Opel Astra - automx.co.za Astra J... · new Astra, based on the 3rd generation of Hella’s Vario...

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