October 2007 Archives

For 2008, Saturn is introducing the ASTRA, a contemporary European-inspired vehicle available in two body styles and two trim levels (fig. 1). 

The layout features short overhangs, a long wheelbase and a wide track.

POWERTRAIN

Engine 

ASTRA uses a 1.8L Ecotec DOHC engine, offering 138 hp and 125 lb.ft. of torque (fig. 2). 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 operation.

The long-life maintenance intervals are:

The 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.

TIP: See the Oil Life article for resetting details.

Transmissions

The ASTRA offers two transmissions. A manual 5-speed is standard on all models, and a
4-speed automatic is available on all models.

The manual 5-speed transmission (fig. 3) is accompanied by hydraulic (instead of solid) fluid-filled engine mounts, for better isolation of drivetrain 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.

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 automatically engages when the brake pedal is released.

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 -- Press the Winter Driving Mode button, located on the center console, to turn the winter driving mode on or off. The Winter Driving Mode light on the instrument panel cluster illuminates when the winter driving mode is active. The amount of torque at the front wheels is reduced and the transmission is directed to start in third gear. This reduces the tendency for the drive wheels to slip on low-traction surfaces.

Once the vehicle is moving, the transmission will shift normally. Winter driving mode is deactivated if the transmission is manually shifted to second or first gear.

The automatic transmission is filled with T-IV Automatic Transmission Fluid p/n 88900925 (22689186 in Canada), which is replaced at 100,000 miles (50,000 miles severe).

CHASSIS

Brakes

ASTRA is equipped with 4-wheel disc brakes, ABS and dual-rate booster. Front rotors are vented 12.1-inch, rear rotors are 10.4-inch.

Brake service facts:

- Brake fluid must be changed at 24 month intervals.

- Use only Super DOT-4 brake fluid GM p/n 88958860 (89021186 Canada).

IMPORTANT: Do not replace DOT-4 with DOT-3 fluid. This is indicated in the maintenance schedule and owner manual.

Suspension

Front suspension uses an enhanced McPherson system mounted to a hydroformed subframe (fig. 4). The subframe is, in turn, isolated from the underbody.

This suspension design uses side load-compensated coil springs and a stabilizer bar.

Rear suspension uses a semi-independent torsion link axle (fig. 5). It includes coil springs, shock absorbers and stabilizer bar. The compact design does not intrude into the luggage space as it does in some other vehicles.

Steering

ASTRA is equipped with electro-hydraulic power steering (EHPS) (fig. 6). An electrically driven hydraulic pump provides boost instead of an engine belt-driven pump, working only when needed.

Some models also include variable assist and a quicker ratio (14:1 vs 15:1).

The EHPS unit (fig. 7) 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 diagnostics line on the HS CAN, and can set 11 DTCs.

TIP: Use GM Power Steering Fluid p/n 88901975 (88901976 Canada).

The steering wheel is adjustable for tilt (40 mm) and telescope (50mm) using a single clamping lever below the column. The steering wheel has a magnesium frame for reduced mass, and is equipped with accessory controls.

TIP: The steering wheel controls include a unique thumb wheel on the left spoke, which can be operated by rotating up or down as well as by depressing.

Wheels and Tires

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

TIP: Summer-only performance tires available on the 3-door XR MUST be replaced with winter tires in northern climates. They are not designed for snow/ice-covered pavement.

COMMUNICATION NETWORK

ASTRA uses three different car area networks (CAN):

The CAN buses are connected together by two gateway modules which act as signal converters. Signals must be converted so low speed data can be transmitted on the high speed bus.

DLC terminal designations

1            LSCAN

3            MSCAN - high

4            Ground

5            Ground

6            HSCAN - high

11          MSCAN - low            

14          HSCAN - low

16          Battery power

USING THE TECH 2

Separate ASTRA-only software must be downloaded onto a Flash card for use in the Tech 2. See the accompanying article for details and precautions.

IMPORTANT: Do not operate the Tech 2 with both a 32MB and a 10MB card installed at the same time.

BODY AND FEATURES

ASTRA provides halogen headlamps with automatic control to turn lamps on when needed. This includes a 20-second delay off feature. XR models also provide integral halogen projector beam fog lamps.

Rainsenseâ„¢ wipers are standard equipment. They automatically adjust wiper operation depending on the amount of water on the windshield. Flat blades are used to conform to
the shape of the windshield, for better wiping. They also resist ice buildup.

The cabin air filter has a service interval of 35,000 miles.

ASTRA uses a convenient flip-key with integral remote entry fob. A side-milled blade provides greater security. See the new key article elsewhere in this issue for more details.

- Thanks to Dan Fernandez

Usage of a European style key design, already seen on the Pontiac GTO and Saab 9-3 and 9-5, is being expanded in 2008 with the introduction of the Saturn Astra (fig. 9) and the Pontiac G8 (fig. 10).

The key is already in use on many premium vehicles around the world. It is typically referred to as a "flip" key, due to the way the blade stores in the key fob and flips out for use when a button is pressed.

The proper term for these keys is "high security," or "side-milled," which describes the location of the security cut, a groove milled into the wide side of the key blade. A traditional key has the security cut on the edge of the blade.

TIP: The Astra key follows the European milling style (fig. 11). The G8 key is milled in a variation of the style (fig. 12). Both keys can be milled on the same equipment.

One key fits all locks on the vehicle (doors, luggage compartment, ignition switch, glove box). Due to the symmetrical design of the key blade, it can be inserted into the lock either way; there is no "top" or "bottom."

Advantages of Side Milling

There are three main advantages to the side milled key. All three advantages are related to the shape of the key blade and the location of the security cut in the side of the blade.

Security -- A side-milled key is much more difficult to duplicate. Duplication requires a unique key-cutting device known as a computer-controlled end mill. No hand cutter is capable of cutting the groove for this style key. The key code remains 5 digits. The ignition lock cylinder has 8 tumblers. The key has 8 cuts, each with 4 possible depths.

Tumbler Actuation -- The traditional edge cut key activates the tumblers in the lock cylinder by moving each tumbler against a small spring. The side-milled key positively locates the tumblers during insertion; the tumblers still have springs, but they play no role in location. Tests at the Milford Proving Ground showed that 30% of ignition lock failures are the result of debris in the lock cylinder causing tumblers to stick. This problem is eliminated by the side-mill design.

Hang Load Tolerance -- Due to the sturdy rectangular shape of the blade, a side-milled key has a larger load bearing area. This increases tolerance to the heavy hang load of a key chain full of keys and trinkets.

Service Considerations of the Side-Milled Key

Replacement keys may be obtained several ways. As introduced with the GTO, a replacment key may be ordered through the normal GM parts channel, using the key code. The code is available from the vehicle security card or from the DealerWorld key code lookup system (in Canada, the GM Parts Locator and Information Services application). If the key vendor has the request by noon, a replacement will be shipped the next day through normal GMSPO shipping channels.

A dealer may choose to purchase the key milling equipment. Although it is expensive, it can have a favorably short payback period. Because side-milled keys are already used on a wide variety of vehicles, there is a ready market for replacements, including vehicles on your used car lot. Data memory cards for the key cutter are available for the vehicles of various manufacturers.

Replacement lock cylinder kits are available, as they already are for edge-cut keys. Refer to SI for the lock cylinder coding procedure.

- Thanks to Will Godfrey and Bob Hiser 

SIDE MILLED KEY EQUIPMENT

Contact GM Dealer Equipment for information on these cutting devices for side milled keys.

Barnes Distribution BD Laser Code Cut and Duplicator (fig. 13)

Kaba Ilco Tricode HS Code Cut and Duplicator (fig. 14)

Kaba Ilco Matrix S Duplicator (fig. 15)

The 2008 Saturn ASTRA will require the use of a separate Tech 2 software version to perform Service Programming (SPS) and Diagnostics. This version contains only support for the Saturn ASTRA and is standalone from the regular North American (N.A.) software. Additionally, the N.A. Tech 2 software will not contain diagnostic support for the ASTRA.

The Saturn ASTRA software can be loaded onto either a 32MB or 10MB Tech 2 flash card. The 10MB cards were used by Saturn retailers when the Tech 2 was first released. Using the 10MB card for the Saturn ASTRA will allow you to keep the N.A. Tech 2 software separately on the 32MB card.

Downloading Saturn ASTRA Version 27.010

From the TIS 2 Web application, select Tech 2 Software Download (SWDL).

TIP: The Tech 2 must be connected to the Techline PC before beginning SWDL.

Once in SWDL, select Custom from the Update Mode selection and select Next. From the Select Applications screen, scroll to the Saturn ASTRA 27.001 folder in the Applications
For Downloading box, select the folder and then Download to begin the download to the Tech 2. 

IMPORTANT: Do not operate the Tech 2 with the 32MB and 10MB cards inserted into the Tech 2 at the same time. You may experience intermittent programming or diagnostic errors when trying to perform functions on the 32MB card. Run the 10MB card separately and always remove the 10MB card when not in use.

- Thanks to Mark Stesney

On the 2008 Chevrolet Malibu, use the following tips to aid in removal of the driver airbag module (DAB).

Insert a flat ended 4mm Allen wrench or similar blunt ended tool into one of the back cover holes (either side) until it touches the DAB wire (fig. 16).

Apply pressure to the Allen key so the DAB wire is displaced about 5mm and simultaneously pull the DAB cover away from the horn towers (fig. 17).

TIP: Using a quick pull will help separate the DAB from the wheel.

- Thanks to Joel Ebner