Opel Astra K K/astrak11.pdf · The new Opel Astra, in its seventh-generation version, sits on an entirely new lightweight platform, some 130kg lighter on average than its predecessor

Model Introduction Training For Approved Motor Body Repairers

Opel Astra K

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Contents

Overview

Body

Technical

This introduction manual highlights the design and function of new vehicle models.

The introduction manual is not a repair manual!All values given are intended as a guideline only.

Some vehicle pictures may be overseas specification.

For body repair work, always refer to the current body repair manual.

Restraint System

Astra

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Overview

Introduction

The new Opel Astra, in its seventh-generation version, sits on an entirely new lightweight platform, some 130kg lighter on average than its predecessor. Take for example the bodyshell, which drops from 357kg to just 280kg.The chassis too, gets high-strength, low-weight steels added to the mix, and there are weight reductions along the front and rear axles.You’ll notice the sharper lines of the new car too, with hints of the excellent Monza concept. British designer Mark Adams was the man in charge of evolving the Astra’s design, and it’s a clean, smart result.It’s not just cleaner looking, but more space-efficient too. The new Astra is 5cm shorter and 3cm lower than its predecessor, but features more rear leg-room.There’s plenty of tech on board, including new LED matrix headlights, ‘OnStar’, along with lots of connectivity including Google Maps, Skype, WhatsApp and Apple CarPlay.Furthering the efficiency cause is a new range of turbopetrol engines in three sizes: 1.0, 1.4 and 1.6.

Essentially a slightly detuned version of the motor found in the latest Corsa and Adam, the

1-litre is good for 77kW and 170Nm, as well as a 200km/h top speed according to Opel.

It's mated to a five-speed manual gearbox, while the two bigger engines are fitted with either a six-speed manual, or a six-speed automatic gearbox in the case of the 1.4.

The brand new 1.4-litre direct injection turbopetrol produces 110kW as well as 230Nm in manual form and 245Nm if mated to the autobox. 100km/h comes in a claimed 8.5 seconds and the top speed is listed at 235km/h.

Its bigger 1.6-litre brother, with 147kW and 280Nm on tap, will allegedly reach 235km/h and sprint to 100 in seven seconds on the dot.

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Colours

Overview

Solid

Metallic

Switchblade Silver Carbon FlashMagnetic Silver

Bronze Brown

Emerald GreenGranite GreyDeep Sky Blue

Dark CaramelAsteroid Grey

Royal Blue Power RedSummit White

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SPECIFICATIONS

Overview

Category 1.0T 1.4T 1.6T

Engine

Cylinders 3 4 4

Power 77kW 110kW 147kW

Torque 170Nm 230Nm 280Nm

Transmission Manual Man/Auto Manual

Front & Rear Disc Std Std Std

ABS Std Std Std

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Dimensions

Overview

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VIN Number

Rims

Essentia: 16’’ Steel wheel6.5J x 16

Tyres 205/55 R16Code PWN

Sport/Plus: 18’’ Aloy wheel7.5J x 18

Tyres 225/40 R18Code 5PC

Enjoy: 17’’ Alloy wheel7.5J x 17

Tyres 225/45 R17Code RM6

Overview

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Overview

Intellilux LED Matrix Headlights

The new Astra brings premium-class features to the compact car class, and Intellilux LED Matrix headlights are another segment first. They adjust automatically so you can drive on high beam without the possibility of disturbing other drivers.

Opel puts intelligent technology to work where it counts:

• Intellilux LED Matrix headlights comprise 16 seperate LED elements• They react to other vehicles by cutting out single LEDs• High beam is glare free all the time• The beam is wider and longer for maximum visibility• Driving at night is safer and much more relaxed• Outstanding reliability ensures maximum longevity

The Intellilux LED Matrix system includes more advanced lighting options:

• Cornering lights further enhance safety• Country lights adjust automatically for better visibility on dark roads• Town lights perfectly complement better lit conditions• Freeway mode guarantees safe, glare-free travelling at high speeds

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The Opel Eye safety camera helps prevent collisions, speeding tickets and much more.It’s one of the most sophisticated assistance systems ever engineered in a car.

• Opel Eye is a system of advanced safety features• This camera-based system acts as an extra lookout• Continuous automatic assistance helps drivers stay vigilant• Active Lane Assist prevents unnecessary warnings

Overview

Opel Eye

1. Forward Collision Alert Gives you an audible and visible signal if you approach slower vehicles too fast from behind. To avoid rear-end collisions, up to speeds of 60 km/h the system automatically starts braking itself. The new Reflective LED windscreen display provides an extra level of safety with an additional warning in the driver’s field of view.2. Active Lane Keep Assist Warning signals protect against unintentional gradual drifting and the steering wheel even pushes back gently – if you start moving out of your lane without signalling. The real genius of this system? It won’t sound an alarm when you don’t need one. For example, if you have to swerve hard to avoid an obstacle.3. Traffic Sign Assist. This advanced sign-detection system displays speed limits and other traffic signs and even recognises temporary electronic signage.

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Shift Lock Manual Release (Automatic)

The Automatic transmission has an electric shift lock. The key must be in the ON/Run position and the brake pedal pressed, so the transmission selector lever can be moved from the P(Park) or the N(Neutral) position. If the battery has lost power, the selector cannot be moved unless the shift lock manual release is engaged manually.

Shift Lever Controls (Manual)

(1) Manual Transmission Shift Lever and Selector Lever Cable(2) Transmission Shift Lever Cable Adjuster(3) Selector Lever Cable Adjuster(4) Control Lever Release Pawl(5) Control Lever Knob(6) Transmission Control(7) Selector and Shift Lever Cable Bracket

Technical

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Front Suspension

(1) Front Wheel Bearing and Hub Assembly(2) Steering Knuckle(3) Shock Absorber(4) Front Spring Lower Insulator(5) Front Spring(6) Front Suspension Strut Bumper(7) Front Strut Mount(8) Front Strut Boot(9) Front Stabilizer Shaft Link(10) Front Stabilizer Shaft(11) Drivetrain and Front Suspension Crossmember Extension(12) Drivetrain and Front Suspension Cradle(13) Front Lower Control Arm Rear Bushing(14) Front Lower Arm

Technical

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(1) Rear Wheel Bearing and Hub Assembly(2) Rear Brake Caliper Bracket(3) Rear Axle Bracket Assembly(4) Rear Spring Insulator(5) Rear Spring(6) Rear Shock Absorber(7) Rear Axle(8) Rear Suspension Latch Link(9) Center Pivot Ball Joint(10) Equilizer Beam Support

Rear Suspension

Technical

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Astra K

Axle with Watts Link

• Available on specific vehicle and engine combinations• New A-bushing concept/position to get excellent ride comfort• Optimised Watts link concept• Delivers all of the advantages of multi-link rear suspension without any of the

complexities

Astra J

Technical

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Belt Driven Electric Power Steering

(1) Control module and motor

(2) Sensor Location

(3) Belt case

• Optimized in regards “direct steering feel” and mass• Reduced amount of power needed at any speed• Smooth Road Shake Compensation (SRSC)• Drift Pull Compensation (DPC)• Advanced Active Return• Supports optional driver assistance features:

Lane Keeping Assist (LKA)Stop Start capability

Steering Belt

Technical

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Body Structure

Body

Number Part Material Material Thickness

1 Front End Upper Tie Bar Mild Steel

1.1 Radiator Upper Support Mild Steel

1.2 Hood Adjust Front Bumper Mild Steel 1.2

2 Front End Upper Tie Bar Extension High Strength Low Alloy Steel

3 Front End Upper Tie Bar Bracket High Strength Low Alloy Steel 2.1

4 Drivetrain and Front Suspension Frame Front Support

see 5.1 and 5.2

5 Front Compartment Side Rail

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Body


5.1 Drivetrain and Front Suspension Frame Support Outer

Mild Steel 1.2

5.2 Drivetrain and Front Suspension Frame Support

High Strength Low Alloy Steel 1.2

5.3 Front Compartment Side Rail Dual Phase Steel 1.9

5.4 Front Compartment Side Rail High Strength Low Alloy Steel 1.9

5.5 Drivetrain and Front Suspension Frame Support


5.6 Front Compartment Side Rail Closeout Panel


5.7 Engine Mount Bracket Mild Steel 1.8

5.8 Dash Panel Front Lower Cross Bar High Strength Low Alloy Steel 1.5

5.9 Front Compartment Side Rail Plate High Strength Low Alloy Steel 3.0

6 Front Compartment Upper Side Rail Fender Bracket-Mild SteelRail Front-High Strength Low Alloy SteelRail Rear-Dual Phase Steel

1.00.7

1.8

6.1 Front Fender Bracket Mild Steel 1.0

7 Front Wheelhouse Panel Brace High Strength Low Alloy Steel 1.0

8 Front Wheelhouse Panel

8.1&8.2 Headlamp Mount Panel High Strength Low Alloy Steel 0.8

8.3 Front Compartment Side Rail High Strength Low Alloy Steel 1.3

8.4 Front Wheelhouse Panel Support High Strength Low Alloy Steel 1.2

8.5 Front Wheelhouse Panel Brace High Strength Low Alloy Steel 1.0

8.6 Front Wheelhouse Panel High Strength Low Alloy Steel 1.2

8.7 Front Suspension Strut Housing High Strength Low Alloy Steel 2.4

9 Front Compartment Rail Closeout Panel High Strength Low Alloy Steel 1.2

10 Body Hinge Pillar Outer Panel Ultra High Strength Steel 1.0

50 Dash Panel Lower Extension Mild Steel 0.85

51 Dash Panel Extension Mild Steel 0.8

52 Body Hinge Pillar Inner Panel Ultra High Strength Steel 1.1

53 Dash Panel Front Lower Cross Bar Mild Steel 1.0

54 Front Compartment Rear Side Rail Ultra High Strength Steel 2.0

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Body

Body Side


10 Body Hinge Pillar Outer Panel Reinforcement

Ultra High Strength Steel

1.0

11 Body Hinge Pillar Outer Panel Mild Steel 0.65

12 Rocker Outer Panel Mild Steel 0.65

13 Center Pillar - Outer Mild Steel 0.65

14 Center Pillar Reinforcement: Ultra High Strength SteelInner: Dual Phase Steel

1.3

1.0

15 Quarter Outer Panel Mild Steel 0.65

16 Body Side Outer Panel Extension Mild Steel 0.65

17 Body Side Tail Lamp Pocket Mild Steel 1.1

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Body


18 Body Side Outer Panel Rear Upper Extension Mild Steel 0.65

19 Body Side Outer Upper Panel Mild Steel 0.65

20 Rocker Outer Panel Reinforcement Ultra High Strength Steel 1.0

20 Rocker Outer Panel Reinforcement- Front Ultra High Strength Steel 1.0

20 Rocker Outer Panel Reinforcement- Center Ultra High Strength Steel 1.0

20 Rocker Outer Panel Reinforcement- Rear Ultra High Strength Steel 1.0

21 Rear Wheelhouse Outer Panel-Left and Right Mild Steel 0.65

22 Quarter Inner Panel Upper Reinforcement Mild Steel 1.2

23 Body side Inner Panel-Left and Right Mild Steel 0.65

25 Rear Wheelhouse Panel Mild Steel 0.7

26 Rear End Panel Mild Steel 0.65

30 Rear Wheelhouse Inner Panel Extension High Strength Low Alloy Steel

0.9-1.0

31 Rear Floor Panel Filler Mild Steel 0.7

32 Underbody Nr. 6 Cross Sill Reinforcemnt High Strength Low Alloy Steel

1.6

33 Rear Floor Panel Outer Extension High Strength Low Alloy Steel

1.3


55 Roof Outer Side Rail Ultra High Strength Steel 1.0

56 Roof Inner Side Rail Ultra High Strength Steel 1.2

57 Rocker Inner Panel Ultra High Strength Steel 1.3

58 Quarter Inner Panel Extension Dual Phase Steel 1.0

59 Body Lock Pillar Inner Panel Mild Steel 1.5

60 Back Body Pillar Inner Panel Mild Steel 1.1

61 Rocker Rear Inner Panel Mild Steel 1.5

62 Rear Wheelhouse Panel Extension Ultra High Strength Steel 1.1

63 Rear Floor Panel Filler Ultra High Strength Steel 1.1

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Rear End

Body


26 Rear End Panel Mild Steel 0.65

27 Rear Floor Rear Panel High Strength Low Alloy Steel 0.8

28 Floor Panel Number 5 Cross Bar High Strength Low Alloy Steel 0.8-1.1-1.4

29 Battery Tray Mild Steel 0.7

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Body


30 Rear Wheelhouse Inner Panel Extension High Strength Low Alloy Steel

0.9-1.0

31 Rear Floor Panel Filler Mild Steel 0.7

32 Underbody Number 6 Cross Sill High Strength Low Alloy Steel

1.6

33 Rear Floor Panel Outer Extension High Strength Low Alloy Steel

1.3

34 Underbody Rear Side Rail Extension High Strength Low Alloy Steel

2.5

35 Underbody Rear Side Rail Reinforcement High Strength Low Alloy Steel

2.5

36 Floor Panel Number 5 Cross Bar Extension Mild Steel 1.5

37 Underbody Rear Side Rail Dual Phase Steel 1.3

64 Rear Wheelhouse Panel Reinforcement Mild Steel 0.7

65 Underbody Rear Side Front Rail Ultra High Strength Steel 1.8

66 Underbody Number 5 Cross Sill High Strength Low Alloy Steel

1.7

67 Rear Floor Front Panel Mild Steel 0.65

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Body

Roof


37 Roof Panel Mild Steel 0.65

38 Roof Front Header Panel Upper: High Strength Low Alloy SteelLower: Dual Phase SteelExtension: High Strength Low Alloy Steel

0.7

1.01.0

39 Roof Panel Number 2 Bow Ultra High Strength Steel 0.75

40 Roof Panel Number 3 Bow High Strength Low Alloy Steel

0.65

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Body


41 Roof Rear Header Panel Mild Steel 0.65

22 Quarter Inner Panel Upper Reinforcement Mild Steel Upper: 1.2Lower: 0.6

55 Roof Outer Side Rail Ultra High Strength Steel 1.0

56 Roof Inner Side Rail Ultra High Strength Steel 1.2

59 Body Lock Pillar Inner Panel Mild Steel 1.5

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Floor

Body


28 Floor Panel Number 5 Cross Bar High Strength Low Alloy Steel

0.8-1.1-1.4

29 Battery Tray Mild Steel 0.7Side: 1.4

42 Underbody Front Side Rail Outrigger Dual Phase Steel Front: 1.0Rear: 1.5

50 Dash Panel Lower Extension Mild Steel 0.85


54 Front Compartment Rear Side Rail Ultra High Strength Steel 2.0

68 Drivetrain and Front Suspension Frame Rear Support

Mild Steel 2.5

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Front Bumper Impact Bar Replacement

Body

(1) Front Bumper Impact Bar Bolt [x8](2) Front Bumper Impact Bar

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Front Compartment Side Rail Replacement

Body

Locate and mark all factory welds (1)Drill out all factory welds

Locate and mark all factory welds (1)Drill out all factory welds

Removal

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Installation

Body

Drill holes for the high strength rivets A1. (1) [x11]

Drill holes for the high strength rivets A2. (1) [x5]Drill holes for the high strength rivets A1. (2) [x2]

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Body

Apply structural adhesive GL02. (1)

Apply tape (1) to the front compartment rear side rail as shown to prevent shunt circuit.Apply structural adhesive GL02. (2)


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Front Compartment Side Rail Install:• High Strength Rivet A1 (2) [x11]• 8 Spot welds (3)Remove tape from the front compartment rear side rail

Body

Front Compartment Front Side Rail Install:High Strength Rivet A2 (1) [x5]High Strength Rivet A1 (2) [x2]Apply the sealers and anti-corrosion materials to the repair area as necessary.

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Rocker Outer Panel Sectioning

Body

These instructions refer to the maximum possible sectional renewal area of the rocker outer panel (1). Smaller sectional areas are possible.

Select the shown cut lines on the basis of the damaged area.Create cut lines on the rocker outer panel. (1)NOTE: Do NOT damage any inner panels or reinforcements.Cut the rocker outer panel where sectioning is to be performed. [x2]

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Body

Locate and mark all factory welds. (1) at Rocker Outer Panel (2)Drill out all factory welds.Detach structural adhesive at the area of the rear wheelhouse.Open wheelhouse flanging.Remove damaged part of the rocker outer panel.

Drill holes for waterproof rivets B1 (1) according to sectional replacement of the rocker outer panel (2).• Lower body hinge pillar - 6 holes for waterproof rivets B1• Rocker outer panel front - 8 holes for waterproof rivets B1• Lower center pillar - 8 holes for waterproof rivets B1• Rear outer panel front - 8 holes for waterproof rivets B1

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Body

Apply Structural adhesive GL02. (1)Apply sealant (2).Position rocker panel on vehicle.

Install the rocker outer panel (1).• Lower body hinge pillar - 6 spotwelds and 6 waterproof rivets B1• Rocker outer panel front - 12 spotwelds and 8 waterproof rivets B1• Lower center pillar - 8 spotwelds and 8 waterproof rivets B1• Rear outer panel front - 15 spotwelds and 8 waterproof rivets B1

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Body

Braze the rocker outer panel accordingly (1).• 210mm stitch braze (2)• 334mm stitch braze (3)• 334mm stitch braze (4)• 330mm stitch braze (5)• 334mm stitch braze (6)• 300mm stitch braze (7)

Flanging to be completed with special toolsApply the sealers and anti-corrosion materials to the repair area.

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Rocker Outer Panel Reinforcement Replacement

Body

Locate and mark all factory welds. (1)Drill out all factory welds.Remove rocker outer panel reinforcement.


Install rocker outer panel reinforcement (1) accordingly with 79 spot welds.

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Center Pillar Replacement

Body

Locate and mark all the necessary factory welds of the center pillar reinforcement (1).Drill out all factory welds.Remove center pillar reinforcement.

Locate and mark all the necessary factory welds of the center pillar inner panel (1).Drill out all factory welds.Remove the center pillar inner panel.

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Body

Apply structural adhesive GL02. (1)Position the center pillar inner panel on the vehicle.Verify the fit of the panel.Clamp the panel into position.

Spot weld the center pillar inner panel (1) accordingly with 11 spot welds.Braze the center pillar inner panel with 6 x 15mm edge seams.

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Body

Drill holes for the high strength rivets A2. (1) [x20]Remove the center pillar reinforcement.

Apply structural adhesive GL02 (1) to door striker anchor plate (2).Position the door striker anchor plate (1) on the center pillar reinforcement service part (2).

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Body


Spot weld the center pillar reinforcement (1) accordingly with 4 spot welds.

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Body

Install high strength rivets A2. (1) [x20]

Spot weld the center pillar reinforcement when installing the center pillar panel outer.

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Quarter Outer Panel Replacement

Body

Create cut lines (1) on the quarter outer panel (2).NOTE: Do NOT damage any inner panels or reinforcements.Cut the quarter outer panel.

Locate and mark all factory welds (1) of the quarter outer panel (2).Drill out all factory welds.

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Locate and mark all factory welds (1) of the quarter outer panel (2).Drill out all factory welds.Open the wheelhouse flanging and remove quarter panel.

Cut the quarter panel (1) in corresponding locations to fit the remaining original panel.

Body

42

Drill 11 holes (1) for waterproof rivets B1 to the quarter outer panel.Clean and prepare the attaching surfaces for brazing, riveting and spot welding.

Apply structural adhesive GL02. (1)Apply window adhesive GL01. (3) (2)

Body

43

Right side only: Apply sealant (1) to body side inner panel filler.

Install the quarter panel (1) accordingly.• 370mm braze seam (2)• 3 waterproof rivets B1 (3)• 10 spot welds (4)• 8 waterproof rivets B1 and 1 spot weld (5)• 334mm braze seam (6)• 32 spot welds (7)

Body

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Install the quarter panel (1) accordingly.22 spot welds (2)

Pre-flange the wheelhouse flange.Finish closing the wheelhouse flange.Apply the sealers and anti-corrosion materials to the repair area as necessary.

Body

45

Front Bumper Lower Impact Bar Replacement

(1) Front Bumper Lower Impact Bar Bolt [x4](2) Front Bumper Lower Impact Bar

Body

46

Front Bumper Fascia Replacement

(1) Front Bumper Fascia Upper Bolt (1) - Remove [x6]

(1) Front Bumper Fascia Upper Bolt (1) - Remove [x2](2) Front Wheelhouse Liner Bolt (2) - Remove [x6]

Body

47

Pull the Front Bumper Fascia (1) carefully outwards and use a plastic tool in order to release the retaining tabs from the front bumper fascia outer guides.

Disconnect all electrical connectors.Remove Front Bumper Fascia (1).

Body

48

Headlamp Replacement (Halogen)

(1) Headlamp Bolt [x4](2) Headlamp

Headlamp Replacement (LED/Matrix)

(1) Headlamp Bolt [x4](2) Headlamp

Body

49

Outside Rearview Mirror Replacement

(1) Outside rearview mirror bolt [x2](2) Outside reaview mirror

Outside Rearview Mirror Glass Replacement

Release the mirror glass(1) from the mirror housing by pulling outward.Disconnect the electrical connector.

Body

50

Outside Rearview Mirror Housing Replacement

Remove the 3 outside rearview mirror frame bolts (1).Remove the outside rearview mirror frame (2).

Remove the outside rearview mirror housing (1)Unlock the retaining tabs.

Body

51

Body

Front Door Outside Handle Replacement

(1) Bolt access plug(2) Handle Bolt• Loosen the handle bolt until the outside handle cap could be removed.• The handle must be pulled rearward while the handle bolt is loosened.(3) Lock Cylinder Opening Cover.(4) Front Door Outside Handle• Pull the outside handle rearward to release it from the inside handle housing.

Rear Bumper Fascia Replacement

Rear Wheelhouse Liner Bolt (1) - Remove [x8]Rear Bumper Fascia Bolt (2) - Remove [x2]

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Body

Rear Bumper Fascia Bolt (1) - Remove [x2]Rear Bumper Fascia Lower Bolt (2) - Remove [x2]

Pull the rear bumper fascia (1) carefully outwards and use a plastic tool in order to release the retaining tabs from the rear bumper fascia outer guides.

53

Body

Pull the rear bumper fascia carefully outwards and use a plastic tool in order to release the retaining tabs from the rear bumper fascia guides (1).Disconnect all electrical Connectors.

Rear Bumper Fascia (1) - Remove

54

Body

Tail Lamp Replacement

(1) Tail Lamp Nut(2) Tail Lamp

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Supplemental Inflatable Restraint System

(1) Driver airbag(2) Passenger airbag(3) Front side airbags (x2)(4) Curtain airbags (x2)

(a) Front pretensioner (2 per seat)(b) Rear outboard belt pretensioner

Impact Sensors

The vehicle contains 3 impact sensors. They are located in the front of the vehicle, and 2 in the B-pillars (left and right).

Restraint System

56

Driver Airbag Module Removal

• Lower the steering column and move to the Maximum rear end position.• Turn the steering wheel so that the whole is at the top.• Insert a screwdriver or equivalent tool (2) through the access opening and push

the spring fastener (1) inward to release the steering wheel inflator from the steering wheel.

• Turn the steering wheel 180 degrees to access the second whole and repeat the procedure.

• Disconnect the electrical connector and remove airbag module.

NOTE: Always disable the SIR system before performing any work on the system.

Restraint System

57

Passenger Airbag Module Removal


• Unlock the retaining tabs [x6] on the module(1).

Restraint System

58

Front Seat Side Airbag


(1) Front Seat Side Airbag fastener [x2](2) Front Seat Side Airbag

Restraint System

59

Roof Curtain Airbag


Roof Curtain Airbag Retainer [x2]Roof Curtain Airbag Fastener [x5]Roof Curtain Airbag ClipRoof Curtain Airbag Electrical ConnectorRoof Curtain Airbag [Left and Right]

Restraint System

60

Airbag Sensing And Diagnostic Module


(1) Floor Front Air Outlet Duct Adaptor(2) Airbag Sensing and Diagnostic Module Nut [x3](3) Airbag Sensing and Diagnostic Module

Restraint System

Notes

Notes

Documents

Opel Astra K K/astrak11.pdf · The new Opel Astra, in its seventh-generation version, sits on an entirely new lightweight platform, some 130kg lighter on average than its predecessor