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Astra HD8Ec, repair e-manual

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Publisher: © "Motorist"
ISBN: 978-036-000-329-3
Number of pages: 760
Format: file PDF

About the manual

Engine type: F3B WG (380 CV) / F3B VG (420 CV)

In the manual you will find

  • Step-by-step guide to repair various components and assemblies
  • Self-care and maintenance instructions
  • Car design and prevention information
  • Information for a trip to the service station, if self-repair is not possible
Publisher: Motorist
Categories: Astra , Dump trucks
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "Motorist"
ISBN: 978-036-000-329-3
Number of pages: 760
Format: file PDF

About the manual

Engine type: F3B WG (380 CV) / F3B VG (420 CV)

In the manual you will find

  • Step-by-step guide to repair various components and assemblies
  • Self-care and maintenance instructions
  • Car design and prevention information
  • Information for a trip to the service station, if self-repair is not possible

Content

Introduction

  • Preface
  • Definitions adopted in the current manua
  • Introduction
  • Graphs and symbols
  • Measures (international system)
  • Conversion values for British units
  • Standard tightening torques
  • Screws and nuts with metric thread

General specifications

  • Composition of the model
  • Position of vehicle identification data
  • Model identification plate
  • Chassis
  • Manufacturer’s plate
  • Position of assembly identification data
  • Engine
  • Engine dependent power take-off
  • Gearbox 16 S 1620 TD
  • Gearbox 16 S 2320 TD
  • Distributor-reducer (transfer)
  • Front and rear drive axles
  • Power steering boxes
  • Cab
  • Lubricant and hydraulic fluid tables

Engine - F3B

  • Views of the engine
  • Technical specification
  • General characteristics
  • Assembly clearance data
  • Diagnosis
  • Blink code
  • Fault checking/identification procedure
  • Fault memory cancellation procedure from drivers seat
  • MS 6.2 EDC electronic control unit blink code table
  • Diagnosis tools
  • IT2000
  • Upper level diagnosis
  • Control unit diagnosis
  • Engine diagnosis (engine test)
  • Auxiliary functions
  • Troubleshooting
  • Introduction
  • Troubleshooting (blink code)
  • Troubleshooting by symptoms
  • Tightening torques
  • Tightening order of gearbox to engine
  • Block fastening screws
  • Tools
  • Engine removal replacement
  • Removal
  • Replacement
  • Bleeding air from supply system
  • Checks and controls
  • Dismantling the engine on the bench
  • Repair operations
  • Holset HX 50W (Turbine wastegate)
  • Pressure limiter valve
  • Pressure limiter valve control and adjustment
  • Fuel feed
  • Pump-injector
  • Pumping element
  • Nozzle
  • Solenoid valve
  • Replacing pump-injectors
  • Injection phases
  • Filling phase
  • Injection phase
  • Pressure reduction phase

Clutch

  • Description
  • Hydraulic control
  • Master cylinder
  • Specifications and data
  • Diagnostics
  • Hydraulic oil change
  • Bleeding off air
  • Maintenance
  • Tightening torques
  • Tools
  • Removing and refitting
  • Removal
  • Checks
  • Refitting
  • Removing-refitting collar bearing
  • Replacing the support bearing of the clutch shaft
  • Clutch pedal adjustment
  • Clutch actuator adjustment
  • Vehicles with robotic transmission
  • Servoclutch adjustment
  • Mounting servoclutch in clutch housing

Power take off

  • Description
  • Operation
  • Power take off disengaged
  • Power take off engaged
  • Features and data
  • Driving torques
  • Tools
  • Special maintenance
  • Oil replacement
  • Stripping down refitting integral power take-off
  • Stripping down
  • Refitting
  • Strip down main housing
  • Strip down bearing for shaft with toothed crown
  • Strip down output shaft
  • Strip down oil pump
  • Cleaning and checking the parts
  • Fitting
  • Oil pump
  • Fitting the bearings for shaft with toothed crown
  • Output shaft unit
  • Setting the taper bearings on the output shaft
  • Fitting the main housing
  • Setting the ball bearings

Manual gearbox

  • Description
  • Operation
  • Slow range
  • Fast range
  • Reduced gears
  • Normal gears
  • Servoshift
  • Specifications and data
  • Diagnostics
  • Tightening torques
  • Tools
  • Gearbox removal-refit
  • Removal
  • Refit
  • Overhauling operations
  • Preliminary operations
  • Removal gear command box
  • Refitting gear command box
  • Epicyclic reduction unit (E.R.U.) removal
  • Disassembling the epicyclic reduction unit (E.R.U.)
  • Assembling the epicyclic reduction unit (E.R.U.)
  • Refitting the epicyclic reduction unit (E.R.U.)
  • Disassembling the gearbox
  • Disassembling the main shaft
  • Disassembling the input shaft
  • Disassembling the transmission shaft
  • Checks
  • Gearbox
  • Hubs - sliding sleeves - forks
  • Bearings
  • Shafts - gears
  • Synchronisers
  • Single cone synchronisers type BK
  • Assembling the input shaft
  • Assembling the main shaft
  • Adjusting the main shaft - version with straight tooth epicyclic reduction unit
  • Adjusting the main shaft - version with helical tooth epicyclic reduction unit
  • Assembling the gearbox
  • Oil pump
  • Adjusting the transmission shaft end float
  • Input shaft cover
  • Adjusting the input shaft end float
  • Completion
  • Version fitted with intarder
  • Description
  • General characteristics
  • Tightening torques
  • tools
  • Stripping down-refitting gearbox
  • Versions with separate exchanger
  • Removal
  • Refitting
  • Versions with built-in exchanger
  • Removal
  • Refitting
  • Repair operations
  • Removing the hydraulic retarder
  • Refitting the hydraulic retarder
  • Removing the epicyclic reduction unit (E.R.U.)
  • Disassembling the epicyclic reduction unit (E.R.U.)
  • Epicyclic reduction group components
  • Assembling the epicyclic reduction unit (E.R.U.)
  • Refitting the epicyclic reduction unit (E.R.U.)

Reduction gear unit TC1800

  • Description
  • On road 
  • Transmission of motion pictorial diagram: on-road Off road 
  • Transmission of motion pictorial diagram: off road
  • Specifications and data
  • Tightening torques
  • Tools
  • Stripping down-refitting the reduction gear unit
  • Stripping down
  • Refitting
  • Disassembling the reduction gear unit at the bench
  • Dis-assembling the input shaft
  • Dis-assembling the countershaft
  • Dis-assembling the epicyclic reduction gear
  • Replacing the seal rings of driving shaft covers
  • Clean out and checks
  • Fitting in place the input shaft
  • Fitting in place the counter shaft
  • Fitting in place the epicyclic reduction gear unit
  • Assembling the reduction gear unit at the bench
  • Adjustments
  • Shaft bearings pre-load adjustment
  • Indication switch adjustment
  • Pulse transmitter adjustment

Reduction gear unit TC2200

  • Description
  • On road
  • Transmission of motion pictorial diagram: on road
  • Off road
  • Transmission of motion pictorial diagram: off road
  • Specifications and data
  • Tightening torques
  • Tools
  • Stripping down refitting the reduction gear unit
  • Stripping down
  • Re-fitting
  • Disassembling the reduction gear unit at the bench
  • Disassembling the input shaft
  • Disassembling the countershaft
  • Disassembling the epicyclic reduction gear
  • Replacing the seal rings of driving shaft covers
  • Clean out and checks
  • Fitting in place the input shaft
  • Fitting in place the countershaft
  • Fitting in place the epicyclic reduction gear unit
  • Assembling the reduction gear unit at the bench
  • Adjustment
  • Shaft bearings pre-load adjustment
  • Indication switch adjustment
  • Pulse trasmitter adjustment

Propeller shafts

  • Description
  • Diagnostic
  • Tightening torques
  • Tools
  • Removing and re-fitting in place the propeller shaft
  • Universal joint
  • Removing
  • Cleaning
  • Checks
  • Assembling
  • Checking the propeller shafts on the vehicle

Axle

  • Description
  • Characteristics and data
  • Diagnostic
  • Tightening torques
  • Tools
  • Removing and re-fitting the axle
  • Removal
  • Refitting
  • Disassembling
  • Checking disassembled parts
  • Axle body checks and measurements
  • Leaf spring contact surfaces check using gauge 99305111
  • Kingpin holes camber angle check using gauge 99305111
  • Refitting

Front drive axle

  • Description
  • Specifications and data
  • Driving torques
  • Tools
  • Diagnostics
  • Removing - refitting the front drive axle
  • Removal
  • Refitting
  • Repairing the axle and wheel hubs
  • Removing the fork support
  • Removing the stub axle
  • Removing the epicyclic reduction gear
  • Clean-out and checks
  • Checking the axle casing camber angle and caster angle
  • Fitting in place the fork support
  • Fitting in place the stub axle
  • Fitting in place the epicyclic reduction gear support
  • Greasing the stub axle pins
  • Epicyclic units lubrication
  • Removing the differential (with axle on stand 99322215)
  • Axle casing check
  • Refitting in place the differential (with axle on stand 99322215)
  • Repairing the differential
  • Removal

Single rear axle

  • Description
  • Specifications and data
  • Tightening torques
  • Tools
  • Diagnostic
  • Removing - refitting the rear axle
  • Removal
  • Refitting
  • Rear axle assembly overhaul operations
  • Removing the epicyclic reduction gear
  • Removing the wheel hubs
  • Wheel hubs and epicyclic reduction gear components check
  • Fitting in place the wheel hubs
  • Fitting in place the epicyclic reduction gear
  • Removal and re-fitting in place the differential
  • Removal
  • Re-fitting in place
  • Removing the differential housing
  • Removing the gear housing
  • Removing the bevel pinion support
  • Differential components check
  • Fitting in place the gear housing
  • Fitting in place the bevel pinion support
  • Procedure to determine the thickness of the bevel pinion rolling torque adjusting ring
  • Fitting in place the differential housing
  • Adjusting the rolling torque of the gear housing bearings
  • Total rolling torque Nm

Intermediate axle in tandem

  • Description
  • Specifications and data
  • Tightening torques
  • Tools
  • Diagnostic
  • Removing - refitting the intermediate axle
  • Removal
  • Refitting
  • Removing-refitting in place the differential-reduction gear unit (with axle on vehicle)
  • Removal
  • Refitting
  • Intermediate axle assembly repair operations
  • Removal
  • Removing the epicyclic reduction unit
  • Removing the wheel hubs
  • Checks on the wheel hubs and epicyclic reduction gear components
  • Fitting in place the wheel hubs
  • Fitting in place the epicyclic reduction unit
  • Removal-refitting in place of the differential-reduction gear unit (with axle on stand 99322215)
  • Removal
  • Refitting
  • Differential-reduction gear unit repair operations
  • Removal
  • Removing the gear housing
  • Removing the differential-reduction gear unit
  • Check on differential-reduction gear unit components
  • Refitting the differential-reduction gear unit
  • Fitting in place the gear housing
  • Fitting in place the bevel pinion housing
  • Procedure to determine the adjusting ring thickness for the bevel pinion rolling torque
  • Fitting in place the differential housing
  • Adjusting the rolling torque for the gear housing bearings
  • Adjusting the end play between bevel gear pair and pinion
  • Driving shaft
  • Removal
  • Checking components
  • Refitting in place

Rear axle in tandem

  • Description
  • Specifications and data
  • Tightening torques
  • Tools
  • Diagnostics
  • Removing - refitting the rear axle
  • Removal
  • Refitting
  • Rear axle assembly repair operations
  • Removing the epicyclic reduction unit
  • Removing the wheel hubs
  • Wheel hubs and epicyclic reduction gear components check
  • Fitting in place the wheel hubs
  • Fitting in place the epicyclic reduction uni
  • Removal and refitting in place the differential
  • Removal
  • Refitting
  • Differential repair operations
  • Removing the differential housing
  • Removing the gear housing
  • Removing the bevel pinion support
  • Differential components check
  • Fitting in place the gear housing
  • Fitting in place the bevel pinion support
  • Procedure to determine the thickness of the bevel pinion rolling torque adjusting ring
  • Fitting in place the differential housing
  • Adjusting the rolling torque of the gear housing bearings
  • Adjusting the end play between bevel gear pair and pinion

Brakes

  • Description
  • Specifications and data
  • Diagnostics
  • Tightening torques
  • Tools
  • Front brakes
  • Removal
  • Drum tuning
  • Replacing brake linings
  • Fitting in place
  • Rear brakes
  • Removal
  • Fitting in place
  • Setting the brake peda
  • Floor pedal unit
  • Hanging pedal unit

Wheels and tyres

  • Description
  • Specifications and data
  • Tightening torques
  • Tools
  • Checks and requirements
  • Wheel static balancing
  • Correcting residual static imbalance
  • Tyre pressure
  • How tyre behaviour depends on pressure

Front suspensions

  • Description
  • 1st axle suspension
  • 2nd axle suspension
  • Hydraulic shock absorbers
  • Noise
  • Changes in braking effect
  • Characteristics and specifications
  • Leaf springs
  • Shock absorbers
  • Diagnostics
  • Tightening torques
  • Tools
  • Leaf spring removal-replacement (axle)
  • Removal
  • Replacement
  • Leaf spring removal replacement (drive axle)
  • Removal
  • Replacement
  • Repair operations
  • Removing the rear leaf spring
  • Checks
  • Fitting in place the leaf spring

Rear suspensions

  • Description
  • 2-axle vehicle suspension
  • 3 and 4-axle vehicle suspension
  • Hydraulic shock absorbers
  • Noise
  • Changes in braking effect
  • Specifications and data
  • Leaf springs
  • Shock absorbers
  • Diagnostics
  • Tightening torques
  • 2-axle vehicles
  • Front suspension
  • 3 and 4-axle vehicles
  • Front suspension
  • Tools
  • Leaf spring removal-replacement (2-axle vehicles)
  • Removal
  • Replacement
  • Removing-refitting the leaf spring (3-axle and 4-axle vehicles)
  • Removal
  • Replacement
  • Repair operations
  • Removing the rear leaf spring
  • Checks
  • Fitting in place the leaf spring
  • Replacing the floating arm pin (3-axle and 4-axle vehicles)
  • Removal
  • Fitting in place
  • Refitting and adjusting the floating support (3-axle and 4-axle vehicles)

Steering system

  • Description
  • 2-axle and 3-axle vehicles
  • 2 and 3-axle vehicle hydraulic servosteering system
  • 4-axle vehicles
  • 4-axle vehicle hydraulic power steering system
  • Scheme
  • Power steering - 2 axles and 3 axles vehicles
  • Power steering - 4 axles vehicles
  • Steering hydraulic limitation
  • Automatic steering regulation
  • Specifications and data
  • 2 and 3 axle vehicles
  • Steering angle and toe-in - 2 and 3 axle vehicles
  • Hydraulic system - 4 axle vehicles
  • Steering angle and toe-in - 4 axle vehicles
  • First axle / axle set steering angle
  • Second axle / axle set steering angle
  • Diagnostics
  • Tightening torques
  • Power steering box
  • Linkage
  • Tools
  • Steering box removal-replacement
  • 2 and 3-axle vehicles
  • Removal
  • Replacement
  • 4-axle vehicles
  • Removal

Pneumatic system - brakes

  • Description
  • Service braking
  • Emergency braking
  • Slow-down braking
  • Parking braking
  • Braking system diagrams
  • 4x4 vehicles without tow hook
  • 4x4 vehicles with tow hook
  • 6x4 and 6x6 vehicles without tow hook
  • 6x4 and 6x6 vehicles with tow hook
  • 6x4T and 6x6T vehicles with tow hook
  • 8x4 vehicles without tow hook
  • 8x4 vehicles with tow hook
  • Pneumatic system diagrams (services)
  • 2-axle vehicles
  • 3-axle and 4-axle vehicles
  • Diagnostics
  • Tightening torques
  • Tools
  • Braking system main components check
  • Braking system main components
  • Compressor
  • Head locking screw torques
  • Drier
  • Four-way safety valve
  • Duplex distributor
  • Pressure reducer
  • Triple control servo distributor
  • Coupling heads
  • Check valve
  • Parking brakes control hand distributor
  • Relay valves
  • Engine brake control pedal valve
  • Engine brake control operator cylinder
  • Diaphragm brake cylinder
  • Combined brake cylinder
  • Combined cylinder emergency relief device
  • Repair operations
  • Braking control
  • Adjusting the load sensing valve on the vehicle
  • Brake anti-lock distributor
  • RPM sensors
  • Phonic wheels
  • Pipes and couplings
  • General
  • End forming on rigid pipes
  • Bending rigid pipes
  • Cutting rigid pipes
  • Replacing flexible hoses with threaded couplings
  • Replacing flexible hoses with quick-connection couplings
  • RPM sensor phonic wheel

Electrical system

  • Technical data
  • International system units (S.I.)
  • Main elements - resistivity and temperature coefficient
  • Resistor colour codes
  • Wires
  • Composition and characteristics
  • General instructions
  • General precautions
  • General precautions for electronic components
  • The concept of earth and electromagnetic compatibility
  • Practical hints
  • Cable colour codes
  • 4-digit cable colour codes
  • 4-digit component codes
  • 5-digit component codes
  • Fuses
  • Remote switches
  • Electrical system diagrams

Cab and chassis

  • Description
  • Cab repair
  • Introduction
  • Surface repairs
  • Structural repairs
  • Chassis
  • Specifications
  • Chassis
  • Auxiliary chassis
  • Repair operations checks
  • Modifying the chassis
  • Finding chassis lateral bending
  • Finding chassis bending up and down
  • Finding chassis displacement
  • Axle position
  • Finding chassis twist
  • Precautions
  • Welds on the chassis

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