For 1990-2009 cars

# Astra - New Model Features and Service Guide

Subject: | Astra - New Model Features and Service Guide

Models: | 2008-2009 Saturn Astra

This bulletin is being revised to add 2009 model year. Please discard Corporate Bulletin Number 07-00-89-058B (Section 00 -- General Information).

This is a special bulletin to introduce the new Saturn Astra. The purpose of this bulletin is to make you familiar with the vehicle's features and describe the action that your Service Department will need to take to ensure that you are able to fully service this exciting new model.

### ABOUT THE VEHICLE

The purpose of this section is to familiarize you with the technical aspects of the vehicle.

#### Models

The Astra comes in 2 models:

• | XE - Base level 5 door hatchback only

• | XR - Uplevel 3 door and 5 door hatchback

### Powertrain

#### Engine

Astra will have a 1.8L Ecotec (RPO 2H0) DOHC engine, producing 138 hp and 125 lb-ft of torque. Variable valve timing and two-stage intake manifold are used to enhance engine performance. A rotary valve in the intake manifold (instead of conventional flaps) transitions between low and high rpm.

The engine will be part of a exchange program for the launch of the vehicle. Information will be provided in a upcoming bulletin.

#### Engine Oil Life System

The engine also comes with the GM Engine Oil Life System to optimize the oil change frequency. Refer to the Owner Manual for the appropriate maintenance schedule.

The Engine Oil Life System monitors conditions and engine operation, not mileage alone, to determine the optimum time for an oil change. This simplifies the maintenance schedule and minimizes environmental waste.

When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. The letters "InSP" will appear in the odometer display. The number that displays with "InSP" is the remaining distance that can be driven until service is required. Change the oil as soon as possible within the mileage indicated on the display.

Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change the oil prior to the letters InSP appearing in the odometer display, reset the system.

How to reset the Engine Oil Life System:

1. Turn the ignition key to LOCK/OFF.
2. Press the instrument panel cluster stem until the odometer is displayed.
3. Press and hold the cluster stem until the letters "InSP" are displayed (approximately three seconds).
4. Keep pressing the cluster stem and also depress the brake pedal, holding both down.
5. Holding both the cluster stem and the brake pedal down, turn the ignition key to ON/RUN.
6. Continue to hold both down until the service interval display changes.
7. After approximately 10 seconds the I/P displays "InSP 10,000 mls".
8. If the letters "InSP" and the remaining mileage for the next oil change appear in the instrument cluster display, the system is properly reset.

#### Transmission

The ASTRA offers two transmissions. A 5MT (M25) 5 speed manual is standard on all models, and a 4AT (MNF) 4 speed automatic is available on all models.

The manual 5-speed transmission is accompanied by hydraulic (instead of solid) fluid-filled engine mounts, for better isolation of driveline vibrations from the chassis. The clutch hydraulic fluid is drained, flushed and refilled every two years, using DOT-4 fluid.

The 4-speed Aisin automatic transmission is electronically controlled. The transmission control module (TCM) is mounted below the heater unit.

#### Automatic Transmission Neutral Idle

The automatic transmission shifts into neutral at complete stops to help reduce fuel consumption when the vehicle is not moving. The neutral idle function is activated when the transmission is in Drive (D), the brake pedal is depressed, the vehicle is stationary, the accelerator is not depressed and the transmission fluid temperature is greater than 32°F (0°C). The transmission will automatically engage when the brake pedal is released.

#### Automatic Transmission Downhill Grade Braking

The transmission automatically shifts to a lower gear on a downhill grade when the transmission controller detects an increase in speed when the brake pedal is applied over a specified period of time. An increase in engine RPM will occur when the transmission downshifts.

#### Winter Driving Mode Automatic Transmission (If Equipped)

The winter driving mode reduces the amount of torque at the front wheels and directs the transmission to start in third gear. This reduces the tendency for the drive wheels to slip on low-traction surfaces.

Press the winter driving mode button (snowflake symbol), located on the center console, to turn the winter driving mode on or off. The winter driving mode light (snowflake symbol) on the instrument panel cluster will illuminate when the winter driving mode is active. Once the vehicle is moving, the transmission will shift normally. Winter driving mode is deactivated if the transmission is shifted to second (2) or first (1) gear manually.

### Chassis

#### Power Steering

The Astra is equipped with electro-hydraulic power steering system (EHPS). An electrically driven hydraulic pump provides boost instead of a belt driven pump. Some models also include variable assist and a quicker ratio (14.1 vs 15.1).

The EHPS unit is sealed and contains no serviceable components. The unit is bled by starting and stopping the engine three times with a brief pause before each restart. The hydraulic system is bled by starting the engine, then turning the steering wheel from left stop to right stop three times. EHPS has a diagnostic line on the HS CAN, and can set 11 DTCs.

#### Suspension

The front suspension uses an enhanced McPherson system mounted to a hydroformed subframe. The subframe is isolated from the underbody. This suspension design uses side loaded compensated coil springs and a stabilizer bar. The rear suspension uses a semi independent torsion link axle. This includes coil springs, shock absorbers, and a stabilizer bar. This compact design does not intrude into the luggage space as it may do in other vehicles.

#### StabiliTrak (If Equipped)

StabiliTrak is an advanced computer controlled vehicle stability and traction enhancement system that assists with directional control of the vehicle in difficult driving conditions by reducing engine power and applying the brakes to individual wheels. It turns on automatically every time you start your vehicle. To limit wheel spin and help maintain directional control, you should always leave the system on. However, if your vehicle becomes stuck and rocking the vehicle is required, the system should be turned off.

To turn off the StabiliTrak system, press and hold the (StabiliTrak Off) button, located on the center console, until the indicator light illuminates in the button.

#### Brakes

The Saturn Astra comes standard with four-wheel disc brakes, ABS and a dual rate booster. The Astra brake fluid is DOT 4, that will require a fluid flush and change every two years.

Important: Do not use DOT 3 fluid in the Astra.

To set the parking brake, hold the brake pedal down and pull up on the parking brake lever.

#### Wheels/Tires

Wheel offerings range from 16 inch steel wheel to 17 and 18 inch alloy wheels.

To prevent corrosion or rust build up on the wheels, lightly coat the wheel hub center and the cone-shaped surface of each wheel bolt with wheel bearing grease during a wheel change.

Summer only performance tires are available on the 3-door XR. These tires should be replaced with winter or all season tires in northern climates. The summer tires are not designed for snow/ice covered pavement. Please see owners manual for additional information.

#### Tire Pressure Monitoring

Notice: Liquid tire sealant can damage the tire pressure monitor sensors.

All Astra vehicles come standard with a tire pressure monitoring (TPM) system. This system uses air pressure sensors in each wheel to monitor changes in pressure. The sensor is part of the valve stem assembly. The sensor in the valve stem sends a radio frequency transmission to the Tire Pressure Monitor Receiver (TPMR) which sends a serial data message to the Instrument Panel Cluster (IPC).

### Safety and Security

#### Remote Keyless Entry (RKE)

The remote Keyless Entry (RKE) transmitter allows you to lock and unlock your vehicle and perform other functions while outside the vehicle. RKE Functions include:

• | (Unlock) Press this button to unlock all of the doors, liftgate and the fuel tank door.

• | (Lock) Press this button to lock all the doors, liftgate, and fuel tank door. The doors will not lock if the drivers door is open.

#### Key

The vehicles key, used for the ignition and all locks is located within the RKE transmitter, commonly called a "flip" key. To extend or retract the key, press the small chrome button on the transmitter. For replacement keys and FOBs, reference October 2007 TECHLink article and future TSB for information.

#### Security System

• | To arm the content theft-deterrent alarm system, press the lock button on the RKE transmitter.

• | To disarm the system, press the unlock button on the RKE transmitter or turn on the ignition.

#### Comfort Open Windows

The comfort open feature allows the use of the RKE transmitter to lower the vehicle's windows. This is especially helpful when entering the vehicle on warm days. Lowering the windows lets the warn air inside the vehicle escape, enabling the interior to be cooled more efficiently. To lower the windows, press the unlock button on the FOB once, press the unlock button a second time and hold.

#### Door Locks

The power door locks can only be operated when the ignition is on or the vehicle is in Retained Accessory Power (described later in this bulletin).

The central locking button is located on the center of the instrument panel near the hazard warning flashers button. Press the central locking button to lock or unlock all doors, liftgate and the fuel fill door. The indicator light on the button will illuminate when the doors are locked. The doors will not lock if the driver's door is open. With the key in the ignition, all doors must be closed to lock them. The vehicle's auto lock system will lock the doors when the vehicle reaches 13 km/h (8 mph). The doors will unlock when the vehicle is turned off and the key is removed from the ignition.

#### Supplemental Inflatable Restraint (Airbags)

The Astra vehicle comes standard with six airbags. Occupant protection measures include head-curtain air bags as well as seat-mounted side-impact air bags with both pelvic and thorax protection for front occupants. Additional safety features include active front head restraints that automatically move into the upright position in the event of a rear collision, and a pedal release system to reduce intrusion of the pedals into the driver’s foot space upon impact

Note: The passenger presence system (PPS) ON/OFF indicator is located in the inside rearview mirror.

Passenger Sensing System automatically disables the front air bag if a sensor in the seat determines the occupant is a child or person of small stature

#### Seat Belts

Three-point safety belts for all seating positions. It Includes seatbelt pretensioners and load limiters up front, and rear-seat outboard child comfort guides for a better fit. Rear seats also have three removable headrests.

Front seat belt dual pretensioners and load limiters reduce belt slack and then gradually loosen to manage occupant energy in a collision.

### Body

#### Driver Information Center (DIC)

The base level DIC, located above the infotainment system, displays the time, outside temperature, date, trip computer information (if equipped), vehicle warning messages and audio system information. To scroll through most DIC menus and to change the settings use either the left and right arrow buttons and the OK button on the infotainment system or the left thumbwheel (if equipped) on the steering wheel.

The uplevel level DIC displays the time, outside temperature, date, trip computer information, vehicle warning messages and audio system information. The DIC is located above the infotainment system. To scroll through the DIC menus and to change the settings use either the multifunction knob on the infotainment system or the left thumbwheel (if equipped) on the steering wheel.

#### Radio

The Astra is offered with three different radios:

• | CD 30 Single Disc CD

• | CD 30 Single Disc CD with MP3

• | CDC 40 Opera Audio System

Reference the Owner Manual and Audio Systems Quick Reference Guide for additional information on the operation of the infotainment system.

#### Front Windshield Wipers

The Astra is equipped with Rain Sense™. This feature allows the wiper speed, when set on intermittent to increase decrease with vehicle speed.

To operate the wipers and washers, use the lever located on the right side of the steering column. After activation, the lever will return to the starting position. It will not remain in an up or down position.

#### To Activate the Wipers

Press the lever up slightly (do not pass the detent) to activate the next higher wiper mode (Intermittent/Rainsense, Low, High). Press the lever down slightly to activate the next lower wiper mode (High, Low, Intermittent/Rainsense, Off).

#### Low and High Modes

The Low mode also can be activated by pressing the lever up fully one time (pass the detent). Press the lever down fully one time (pass the detent) to turn off the wipers.

The High mode also can be activated by pressing the lever up fully two times (pass the detent). Press the lever down fully one time to activate the Low mode or press the lever down fully two times to turn off the wipers.

#### Mist

When the wipers are off, press the lever down once for a single wipe.

#### Washer

Pull the lever toward you to spray washer fluid on the windshield.

#### Intermittent/Rainsense Mode Delay

With the wipers off, press down and hold the lever for the desired time interval. Release the lever. Press up the lever to activate the Intermittent/Rainsense mode with the new sensitivity level

#### Rear Window Wiper/Washer

The rear wiper adjusts with the windshield wipers.

• | To turn the rear wiper on or off, push the wipers lever toward the instrument panel. The rear wiper also turns on automatically when the windshield wipers are turned on and shift lever is in reverse.

• | To spray washer fluid on the rear window, push and hold the wiper lever toward the instrument panel.

#### Power Windows

#### Express-Down Feature

To operate this feature, press the desired window switch fully and the window will lower automatically. To stop the window, pull or press on the switch momentarily. Press the switch partway to lower the window a small amount.

Anytime battery power is lost or the Rear Fuse Block is replaced, the express-down and comfort feature will need to be relearned. To relearn this feature, follow these steps.

1. Turn the ignition to the on position.
2. Run all windows to the full up position.
3. Hold each power window switch on the driver's door to the full up position for 5 seconds.
4. Turn off the ignition and remove key.
5. Lock the doors with the FOB.
6. Unlock the doors with the FOB.
7. Verify that the express down and comfort feature is working by holding the unlock button on the FOB a second time, all door glass should go down.

#### Rear Door Lockout Feature (5 Door Only)

To enable this feature, slide the lockout switch located on the driver's door window switch between the rear window buttons forward. Slide the switch rearward to turn off this feature.

#### Automatic Headlamp System

The Automatic Headlamp System turns on the headlamps and other exterior lamps at night or when necessary. The system uses a light sensor located on top of the windshield to determine light conditions.

The light sensor also is used to activate the Daytime Running, which will turn on under the following conditions:

• | The engine is running.

• | The light sensor determines it is daytime.

• | The light sensor determines it is night, and the exterior lamps control is in the Off position.

#### Exterior Lamp Control

The exterior lamps control, located on the left side of the instrument panel, can be rotated to the following positions:

• | AUTO (Automatic Headlamp System): This position enables the Automatic Headlamp System.

• | Off: This position turns off all exterior lamps.

• | Parking Lamps: This position turns on the parking lamps and taillamps.

• | Headlamps: This position turns on the headlamps, parking lamps and taillamps.

• | Fog Lamps (if equipped): Press this button on the left side of the instrument panel to turn the fog lamps on or off.

#### Sunroof (available on 5-door models only)

The Astra has an optional power sunroof (RPO CF5) available. The sunroof and sunshade switches are located in the overhead console.

• | To open the sunshade press and release the rear part of the sunshade switch on the passenger side. To close the sunshade press and hold the front part of the passengers side switch.

• | To open the sunroof to the vent position press and release the rear part of the driver's side switch. To express open the sunroof from the vent position, press and release the rear part of the driver's side switch. The sunshade will open with the sunroof. To close the sunroof press and hold the front part of the driver's side switch.

#### Steering Wheel Adjustment

The steering column is adjustable both up and down (tilt) and in and out (telescoping). To adjust the steering column, pull down on the lever on the left side of the steering column. After the lever is loose, raise or lower the steering wheel and also push in or pull out on the wheel to position it in a comfortable position. Once the wheel is in a comfortable position, raise the lever to lock the column in position.

### UNIQUE VEHICLE CHARACTERISTICS

#### Retained Accessory Power (RAP)

The vehicle is in the RAP mode after the ignition is turned to LOCK/OFF and the driver's door remains closed. As soon as the driver's door is opened, RAP mode is off.

#### Power Door Locks

While in the RAP mode, the power door locks may be used for up to five minutes after the key is turned to LOCK/OFF.

#### Power Windows

While in the RAP mode, the power windows may be used for up to five mintues after the key is turned to LOCK/OFF.

#### Power Mirrors

While in the RAP mode, the power mirrors may be used for up to five minutes after the key is turned to LOCK/OFF.

#### Sunroof

While in the RAP mode (key out of ignition), the sunroof will operate to vent and open positions. The sunroof will not close in the RAP mode. This is a normal condition.

#### Turn Signals/Park Lamps

If the turn signal lever is pushed up or down after the key is removed from the ignition with the drivers door opened or closed, the indicator on the dash will come on and the park lamp for that side will stay on until the lever is pushed back or the key is returned to the ignition and turned ON. A chime will also sound 4 times. This is called park position light and to indicate that the park lamp on that side is on. This is a normal condition.

### SERVICE SUPPORT

#### Electronic Service Information

All required service information is currently online on GM SI. Dealerships can also find the most current Owner Manual and Labor Time Guide online at the SI website via GM Dealerworld (in Canada, the GM infoNET).

### TRAINING

Additional Saturn Astra product training for U.S. retailers may be found on the GM training web site (http://www.gmtraining.com). Some of the classes that may be useful are:

Course # | Course Name
--- | ---
10207.56W (U.S.) | 2008 Saturn Astra New Model Features
10458.10V (U.S.) | Astra Systems and Service
50525.03W (Canada) | What's New -- 2008 Saturn Astra
80321.16H (Canada) (available in February 2008) | Saturn Astra Features

Retailers in Canada should refer to the latest training availability in the GM Canada Product Service Training Course Catalogue located on GM infoNET under Service & Body Training.

### FLUIDS AND LUBRICANTS

Many of the fluids and lubricants specified for the Astra may differ from those used in other GM products. Please ensure that only correct fluids and lubricants are used. Damage may result from use of incorrect materials. The following chart summarizes some of the most critical. Please refer to Service Information (SI) and Owner Manual for a complete list.

Usage | Fluid/Lubricant
--- | ---
Engine Oil | Engine oil which meets GM Standard GM6094M and displays the American Petroleum Institute Certified for Gasoline Engines starbust symbol. To determine the proper viscosity for the vehicle's engine, see "Engine Oil" in the Owner Manual.
Engine Coolant | 50/50 mixture of clean, drinkable water and use only DEX-COOL® Coolant. See "Engine Coolant" in the Owner Manual.
Hydraulic Brake/Clutch System | Hydraulic Brake Fluid. Use only P/N. U.S. 88958860, in Canada 88901244, Super DOT-4 brake fluid.
Windshield Washer | Optikleen® Washer Solvent.
Power Steering System | GM Power Steering Fluid (P/N U.S. 88901975, in Canada 88901976).
Automatic Transmission | Use only T-IV Automatic Transmission Fluid (P/N U.S. 88900925, in Canada 22689186).
Manual Transmission | Manual Transmission Fluid (P/N U.S. 88862472, in Canada 88862473).
Key Lock Cylinders | Multi-Purpose Lubricant, Superlube (P/N U.S. 12346241, in Canada 10953474).
Hood Latch Assembly, Secondary Latch, Pivots, Spring Anchor, and Release Pawl | Lubriplate Lubricant Aerosol (P/N U.S. 89021668, in Canada 89021674) or lubricant meeting requirements of NLGI #2, Category LB or GC-LB.
Hood and Door Hinges | Multi-Purpose Lubricant, Superlube (P/N U.S. 12346241, in Canada 10953474).
Weatherstrip Conditioning | Weatherstrip Lubricant (P/N. U.S. 3634770, in Canada 10953518) or Dielectric Silicone Grease (P/N U.S. 12345579, in Canada 10953481).

### QUALITY PRE-DELIVERY INSPECTION (PDI)

Performing a quality pre-delivery inspection is one of the most important functions the Retailer can do for the customer. Most customers consider the condition of their new vehicle during delivery as a direct reflection of the Retailer and your service department. A quality PDI is essential to improving a customer's perception of your facility and increasing his/her satisfaction with their new vehicle.

#### Delivery Condition

Vehicles are delivered in the following condition:

• | A plastic film known as "RAPGARD-F" is applied to external horizontal painted surfaces to provide protection from all types of industrial fallout, acid rain, rail dust, scratches, iron dust, and bird droppings etc. This protection should be left on all vehicles during storage. It has been tested and approved for up to six months. After removal of RAPGARD-F, some vehicles may exhibit temporary paint discoloration or paint swelling. This temporary swelling is caused by the paint finish absorbing moisture trapped under the film. This swelling will disappear with exposure to sun light or heat lamps within 2-3 hours. Severe paint swelling may require 2-3 days to recover. DO NOT buff or refinish paint for this condition.

• | A package (U.S. only) containing the Owner's Manual, Warranty/Maintenance/Owner Assistance Information Book, Getting to Know your Astra Guide and Radio Guide are included in the glove compartment. It is important that the individual that receives the car from the carrier inspects for any missing pieces when the car is dropped off by the carrier.

• | Tire pressures can greatly affect the handling of the vehicle. Incorrect tire pressures are a main cause of owner complaints for vehicles that pull to the left or right and or rough ride. The tire pressures should be set to the specified pressure (Refer to tire placard) prior to the car being delivered to the customer. The new PDI process requires a test drive to insure there car does not have leads, pulls or vibrations when the car is delivered. The tire pressure and the road test odometer reading are to be recorded on the new PDI form.

• | Battery life can be affected by the length of time a vehicle has been sitting without being started as well as short starts and stops. Part of GM’s new pre-delivery process requires the dealership to check the state of the battery charge, record the reading on the PDI form and charge the battery if the voltage is below 12.6 volts. This must be performed before the car is delivered to the customer to insure the customer has a fully charged battery.

#### PDI Instructions

Special attention should be paid to the following areas prior to delivery to the customer.

• | Remove paint film protection.

• | Use a fuse puller to move the 20 amp infotainment (radio) fuse from cavity F11 (1) to cavity F35 (2) in the underhood junction block (UHJB).

• | Use a fuse puller to move the 7.5 amp OnStar® fuse from cavity F12 (1) to cavity F36 (2) in the underhood junction block (UHJB).

• | To install the license plate, use only the screws supplied with the vehicle. Use of incorrect screw could strip the holes in the fascia.

• | Check contents of "loose items" pack and fit components to vehicle.

• | Remove all interior protection.

• | Verify the OnStar® is activated and operating properly, if equipped.

• | Set clock time in radio.

• | Communicate to driver the importance of shifting into reverse prior to shutting off the ignition on manual equipped transmissions.

• | Reset all MPH, MPG and trip odometers settings to zero.

• | Set tire pressures to specified pressure (Refer to tire placard).

### SUBMITTING PRODUCT REPORTS

As with any new vehicle, or vehicle technology, prompt detailed feedback on owner concerns and/or vehicle conditions in the field is of great value to the manufacturer. To provide Voice Mail reports (for U.S. retailers only) or an electronic Product Information Report (for Canadian retailers only) on the product, the retailer should reference the latest version of bulletin 02-00-89-002D - "Information for Dealers on How to Submit a Field Product Report (FPR)."