Astra HD9 Series (Euro 5) since 2011, repair e-manual

Content

Introduction

• Preface
• General precautions
• Measures (international system)
• Standard tightening torques
• General operating instructions

General specifications

• Position of vehicle identification data plates
• Engine
• Manual transmission
• Automated transmission
• Automatic transmission
• Transfer distributor
• Front axle
• Rear axle
• Drum brakes
• Tyres
• Suspension
• Steering
• Electrical system
• Chassis
• Lubricant and hydraulic fluid tables

Engine

• Views of the engine
• Description
• Feeding
• Turbocharger
• Engine brake
• Cooling
• Engine cooling system
• Lubrication system
• NOX emission control system (SCR)
• Control device for emissions
• Changing the engine oil
• Changing the engine oil filters
• Radiator fluid replacement
• Feeding circuit bleeding
• Climate control compressor belt replacement
• Replacing the accessories drive belt
• Engine removal-refitting
• Radiator assembly removal radiators
• Fan removal-refitting
• Injector removal-refitting adblue
• Tank removal-refitting adblue
• Engine overhaul
• Cylinder head
• Timing gear
• Rocker shaft
• Rockers
• Completing the engine
• Hydrocar power take-off on timing system

Clutch

• Description
• Specifications and data
• Tightening torques
• Tools
• Diagnostics
• Clutch control oil replacement
• Brake pedal adjustment
• Clutch actuator adjustment
• Robotic transmission servo-clutch actuator adjustment
• Clutch assembly removal-refit Clutch thrust bearing removal-refit
• Clutch shaft support bearing removal-refit

Power take-off

• Description
• Special maintenance
• Removal — replacement of total power take off assembly
• Overhaul

Transmission ZF 16Sxx20

• Description
• Pneumatic controls diagram
• Cooling system with radiator
• Transmission removal-refitting
• Gearshift overhaul

Automatic transmission Allison 4700

• Description
• Cooling system
• Hydraulic diagnostics
• Transmission oil change
• Transmission removal-refitting

Automatized gearbox ZF 16AS 2601 (Astronic 2)

• Description
• Cooling system with radiator
• Transmission removal-refitting
• Overhauling the gearbox

Hydraulic retarder intarder 3

• Description
• Transmission removal-refitting
• Description of operation
• Removing and refitting the separate water-oil exchanger
• Intarder 3 overhaul procedure
• Intarder assembly
• Intarder refitting

Reduction gear unit VG 2700

• Description
• Changing the oil
• Removing and refitting the reducer-- transfer box
• Description of the operation
• Overhaul

Splitter — transfer unit TC 2200

• Description
• Operation
• Lubrication
• Transfer unit removal-refitting
• Flange removal-refitting transfer
• Splitter — transfer unit overhaul
• Epicyclic transfer group
• Countershaft
• Preload adjustment of bearings
• Assembly completion

Reducer-transfer case VG 2000-396

• Description
• Splitter-transfer unit removal-refitting
• Description of operation
• Overhaul all new

Propeller shafts

• Description
• Propeller shaft removal-refitting
• Description of operation
• Checking the propeller shafts on the vehicle

Axle

• Description
• Axle removal-refit
• Description of operation
• Second axle removal-refit
• Description of operation
• Hub overhaul
• Stub axle overhaul

Front drive axle

• Description
• Axle oil replacement front
• Description of operation
• Front axle removal-refit
• Description of operation
• Axle and wheel hub overhaul
• Clean-out and checks
• Greasing the stub axle pins
• Repairing the differential

Kessler drive axle

• Description
• Axle oil replacement front
• Description of operation
• Front axle removal-refit
• Epicyclic reducer overhaul
• Kingpin and axle shaft overhaul
• Differential overhaul

Second front axle section

• Description
• Second axle oil replacement front
• Second front axle removal-refit
• Checks on differential-transfer components

Single rear axle

• Description
• Axle oil replacement rear
• Axle removal-refit rear
• Rear axle assembly overhaul operations
• Wheel hubs and epicyclic reduction gear components check
• Differential box dismantling
• Fitting in place the differential housing

Intermediate axle in tandem

• Description
• Axle oil replacement intermediate tandem axle
• Splitter removal-refit (with axle on vehicle)
• Intermediate axle assembly repair operations
• Removal-refitting in place of the differential-reduction gear unit
• Differential-reduction gear unit overhaul
• Drive output shift

Rear axle tandem

• Description
• Axle oil replacement rear tandem axle
• Axle removal-refit rear tandem axle
• Rear axle assembly overhaul operations
• Wheel hubs and epicyclic reduction gear components check
• Differential box dismantling
• Differential box fitting

Wheels and tyres

• Description
• Wheel static balancing
• Correcting residual static imbalance
• Tyre pressure

Brakes

• Description
• Brake pedal adjustment
• Front brakes pneumatic cylinder removal-refitting
• Rear brakes pneumatic cylinder removal-refitting
• Front brakes overhaul
• Rear brakes overhaul
• Pneumatic system - brakes

Front suspensions

• Description
• Pneumatic alignment adjuster
• Shock absorbers
• Removal-refitting front stabilizer bar

2-axle vehicles rear suspensions

• Description
• Shock absorbers
• Removal-refitting leaf spring
• Removal-refitting rear shock absorber

Steering system

• Description
• Specifications and data
• Hydraulic fluid change steering system
• Steering angle adjustment
• Adjustment of automatic steering limiting devices
• Main steering pump removal-refitting
• Secondary steering pump removalrefitting
• Steering fluid tank removal-refitting

Electrical \ electronic system

• Multiplex system
• Ground points
• ST junction connectors
• Outfitters connector
• Fuse and relay plate
• Fuses
• Relays
• Instrument panel
• Functional diagrams

Cabin and chassis

• Cabin removal-refitting
• Door removal-refitting
• Cowl removal-refitting
• Windscreen washer arm removal-refitting
• Bumper removal-refitting
• Dashboard removal-refitting
• Cabin climate control
• Air conditioning
• Safety standards

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