training

Transcription

training

Opel Astra
Model Introduction Training For
Approved Body Repairers
CONTENTS
GENERAL
4
BODY
10
MECHANICAL
20
ELECTRICAL
26
RESTRAINT SYSTEM
31
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.
Note
TRAINING
General
Specifications
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© 2008 General Motors Corporation. All rights reserved.
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TRAINING
General
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TRAINING
General
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6
TRAINING
General
Colours
Silver Lake
Power Red
Technical Grey
Black Sapphire
Olympic White
Waterworld Blue
Wheels and Tyres
1.6 Essentia
17x7.0,multi-spoke
215/50R17
1.4T Enjoy
17x7.0,five-spoke
215/50R17
1.6T Sport
18x8.0,5-spoke
235/45R18
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TRAINING
General
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 comfort.
The 4-way adjustable seat is comfortable but supportive, 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 legroom. The steering wheel can be adjusted for reach
and rake. The gear lever is short, sporty, and ergonomically 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 30degree
angle, houses the main display, infotainment, air controls, and centre vents. All are easily reachable and intuitively easy to use. The driver’s convenience is
maximized by details such as outstanding storage possibilities within easy reach, including a special driver’s
storage bin.
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General
TRAINING
Interior
Friendly, stylish, and functional the new Opel Astra
keeps the comfort of all passengers in mind. The
longer wheelbase and wider track have translated
into a feeling of generous roominess. The interior
also offers a new sense of high quality and friendliness to maximize this increased spaciousness. Soft
curves and surfaces which overlap rather than meet
at a dividing point form awelcoming environment.
Quality and tactility have also played a dominant role
in the choice of fabrics at all trim levels.
Another up-markettouch that further reinforces the
welcoming nature is that much attention has been
paid to the ambient interior lighting. At night
red diffused light illuminates the base of the centre
stack and the door panels.
In the rear, the generous leg- and shoulder- room, improved deep-sculptured rear seats, and practical storages for items and drinks make the passengers
instantly feel at home.
Overall, the interior is one of the most effective
"first impression" sales factors with the new Opel
Astra.
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TRAINING
Body
Body Metals
Mild Steel
Bake Hardened Steel
High Strength Steel
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TRAINING
Body
Dual Phase Steel
Press Hardened Steel
Aluminium
Martensite
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TRAINING
Body
VIN (Vehicle Identification Number)
●
The VIN is located at the upper left side at
the instrument panel, seen through the
windscreen.
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The VIN is also stamped into right-hand floor,
in front of the front seat.
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The identification plate including the VIN, is
found on the left -hand B-pillar
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Body
TRAINING
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 including 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 Concept
The 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 industry 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 affixed by repairable
pins
Radiator pushblocks avoid
contact between radiator and
crash beam
Headlight catcher avoids
fender damage
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TRAINING
Body
Body Features - Rear
Guide rail connection designed to avoid interaction
with intruding parts
Bolted crash absorber system
Body Features - Passive Safety
“Self Repairing” Bumper
for impacts under 4km/h
Low density foam
structure
Lower bumper stiffener
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Body
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.
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
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
8 Bolts hold the Impact bar in place including
spotwelds.
Cutting the impact bar is needed to access
the spotwelds.
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TRAINING
Body
Rocker Panel Outer Panel Sectioning
Removal of the outer rocker panel.
Structural adhesive to be used as in illustration.
Centre Pillar Reinforcement Replacement
Drilling out spotwelds
Removal of damaged part
Slots to be created for MIG brazing
Spotwelding to be completed.
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TRAINING
Body
Front Door Outer Panel Replacement
Remove outer panel by grinding edges.
Apply urethane adhesive to door reinforcemnt
Apply structural adhesive on flanges
Work over hem flanges on door.
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Body
TRAINING
Roof Outer Panel Replacement
Drill out
welds
to remove
outerouter
damaged
Apply one part urethane windscreen adhesive.
Drillfactory
out factory
welds
to remove
damaged
part. part.
Apply structural adhesive
Clamp panel into position and spot weld accordingly as noted from the original panel.
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TRAINING
Mechanical
Engine
Three engines available
1.6L with 5 speed manual Transmission
1.4L Turbo with 6 speed manual transmission
1.6L Turbo with 6 speed manual transmission
1.6 L Ecotec
Output(KW) 85 @ 6000rpm
Torque(NM) 155 @ 4000rpm
1.4 L Turbo Ecotec
Torque(NM) 200 @ 1850-4900rpm
1.6 L Turbo Ecotec
Torque(NM) 230 @ 2200rpm
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TRAINING
Mechanical
Critical Service procedures - 1.4L oil pan
Sump Connection
Sealing compound around the
front of engine cover
Sealing compound around the screw
bore
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TRAINING
Mechanical
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 prevent relavant sideways motion between the
axle and body of the vehicle.
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TRAINING
Mechanical
Flex Ride
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Flex Ride is the
next generation of Continuous Damping Control (CDC) technology.
●
The modes for Flex Ride are: 1) Sport
2) Standard
3) Tour
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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
2 X Rear
2 X Front
Magnetic Valve
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TRAINING
Mechanical
Electric Power Steering
The power steering contains the following components:
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Control module
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Electric motor
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Rotation sensor
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Torque sensor
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Steering gear(rack and dual pinion)
Intergrated control module
Torque sensor
Motor with overload protection
If the steering column or steering angle sensor needs to be replaced, the vehicle will have to be
recalibrated using a scan tool.
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Mechanical
TRAINING
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.
Actuator spindle
Actuator motor
Electronic control unit
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TRAINING
Electrical
Fuse Boxes
Fuse box behind glove box
Main Fuse box left front of engine
compartment
Fuse box at left rear fender
Infotainment
Top of the range uses CD400 and the up
level 7 speaker system.
Standard range uses CD300 and the lower level 4 speaker system.
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TRAINING
Electrical
Multi Media Interface
AUX socket fitted as standard, USB optional, 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 drastically reduces the stress of night time driving. The vehicle adapts the headlights automatically to the
driving situation so that in every case the best possible 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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TRAINING
Electrical
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 camera detects head lights from oncoming vehicles it
switches the high beam off and back on when vehicle has passed. The system also detects taillights 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
for lights
Bright Lights
Head lights/Tail lights
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TRAINING
Electrical
Windscreen sensors
Humidity sensor
Rain/light sensor
Camera
Key Programming
Up to eight keys can be programmed to each car.
Alarm control module and its antenna are located
behind the dash board.
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TRAINING
Electrical
HVAC
High Pressure Service Port
Mounted in the engine bay on the small bore
refrigerant pipe, high up in front of the suspension 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 housing.
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TRAINING
Restraint System
Restraint System
Curtain
Airbag
Seatbelt
Pretensioner
Seat
Airbag
Side Crash
Sensor
Lap
Pretensioner
Airbag Control
Module
Front Crash
sensor
Driver/passenger Airbag
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
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TRAINING
Restraint System
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-Pillar to the C-Pillar. It is held in place by
3 bolts and 4 clips.
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Restraint System
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
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TRAINING
Restraint System
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 console 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.
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Restraint System
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 deactivated 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 restraints in the front that move up and forward in
the event of a rear end collision.
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Restraint System
TRAINING
Euro NCAP
Euro NCAP awarded the new Astra a five star rating.
Adult occupant
The 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 different 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 occupant
Based 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 controlled. 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.
Pedestrian
The 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 assist
Electronic 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.
36

training

Transcription

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