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Saturn Astra 2008-2009 Factory Service Workshop Repair Manual

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🏷️ Basic Information Identification Make: Saturn Model: Astra Model Years Covered: 2008, 2009 Codes Platform: GM Delta II 👋 Introduction Market Position Positioning: The Saturn Astra was positioned as a compact hatchback, competing in a segment with vehicles like the Honda Civic, Toyota Corolla, and Ford Focus. Competitive Analysis Competitors: Honda Civic, Toyota Corolla, Ford Focus, Mazda3, Volkswagen Golf. Key Features Features: European-engineered platform (Opel Astra sibling), good handling characteristics, practical hatchback design, distinct styling. 📋 Manual Details Coverage Areas Comprehensive Service And Repair: Covers all aspects of vehicle maintenance, repair, and diagnostics. Manual Type Type: Factory Service Workshop Repair Manual Language Language: English Format Format: PDF with index 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, crankshaft, pistons, connecting rods, camshafts, timing, valve train. Engine Electrical: Ignition system, starting system, charging system, engine control module (ECM) operation and diagnostics. Emission Control: Exhaust system, catalytic converter, evaporative emission control (EVAP), onboard diagnostics (OBD-II). Fuel System: Fuel tank, fuel pump, fuel injectors, fuel lines, fuel pressure regulator, diagnosis of fuel delivery issues. Clutch System: Clutch disc, pressure plate, release bearing, clutch pedal assembly, hydraulic clutch system. Manual Transaxle: Gearbox assembly, shift linkage, internal components, lubrication, troubleshooting. Automatic Transaxle: Torque converter, planetary gear sets, valve body, transmission control module (TCM), fluid type and capacity. Driveshaft And Axle: CV joints, drive axles, wheel bearings, hubs, differential components. Suspension System: Front and rear suspension components, struts, shock absorbers, control arms, springs, anti-roll bars. Steering System: Steering rack, power steering pump (if applicable), steering column, tie rods, alignment procedures. Restraint System: Airbag system components, seat belts, SRS module diagnostics and replacement procedures. Brake System: Brake calipers, rotors, pads, brake lines, master cylinder, ABS system, bleeding procedures. Body Interior Exterior: Body panel removal and installation, door mechanisms, glass, interior trim, upholstery, bumpers. Body Electrical: Lighting systems, power windows, power locks, instrument cluster, wipers, horn, wiring diagrams. Heating Ventilation Air Conditioning: HVAC system components, refrigerant, compressor, blower motor, climate control panel, diagnostics. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tune-ups, tire rotation. Repair: Component replacement (e.g., alternator, starter, water pump), engine rebuilds, transmission overhauls. Diagnostics: Troubleshooting guides, fault code interpretation, system-specific diagnostic trees. Installation: Installation procedures for various components and accessories. Technical Depth Depth: Comprehensive, covering basic maintenance to complete vehicle rebuilds and advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text enabled by index. Print Quality Quality: High-resolution, clear diagrams and text for easy reproduction. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: Z18XER (Commonly found in North American models) Engine Type: 1.8L DOHC 16-valve Inline-4 Performance Horsepower: Approximately 138 hp @ 6300 rpm Torque: Approximately 125 lb-ft @ 3800 rpm Fuel System Injection Type: Multi-port Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline Engine Management ECU Type: GM ECM (specific model varies) 🔧 Transmission Standard Type: 5-speed Manual Transaxle Optional Type: 4-speed Automatic Transaxle Features Automatic Features: Includes Adaptive Shift Control. 📐 Dimensions Exterior Wheelbase: Approximately 102.4 inches (2601 mm) Length: Approximately 169.7 inches (4310 mm) Width: Approximately 69.3 inches (1760 mm) Height: Approximately 58.7 inches (1491 mm) Weights Curb Weight: Varies by trim and transmission, typically 2900-3100 lbs. Cargo Cargo Volume Rear Seats Up: Approximately 16.9 cubic feet (with rear seats folded: ~37.3 cubic feet) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star (for 2008 model year) NHTSA Front Impact Passenger: 5-Star (for 2008 model year) IIHS Side Impact: Good (for models equipped with side airbags) Active Features ABS: Standard Anti-lock Braking System Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Frontal airbags, optional side-impact airbags and curtain airbags. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Audio System: Available CD player, MP3 playback, auxiliary input. Optional premium audio systems might be available. Driver Assistance Cruise Control: Standard Cruise Control. Connectivity Connectivity Options: Auxiliary audio input for connecting external devices. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to Owner's Manual; typically 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type. Air Filter Replacement: Inspect every 15,000 miles; replace as needed. Cabin Air Filter Replacement: Inspect every 15,000 miles; replace as needed. Coolant Flush: Refer to Owner's Manual; typically every 5 years or 100,000 miles for Dex-Cool coolant. Fluid Specifications Engine Oil Type: SAE 5W-30 (API SN or newer, GM dexos1™ approved recommended) Engine Oil Capacity: Approximately 4.5 quarts (4.25 liters) with filter change. Transmission Fluid Manual: GM Manual Transmission Fluid (MTF) - Refer to manual for specific specification. Transmission Fluid Automatic: Dexron VI Automatic Transmission Fluid (ATF). Coolant Type: GM DEX-COOL® 50/50 antifreeze/coolant (Orange) Brake Fluid Type: DOT 3 or DOT 4. Known Issues Common Problems: Minor electrical gremlins, occasional suspension component wear (e.g., control arm bushings), potential for oil leaks from valve cover...
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Saturn Astra 2008-2009 Factory Service Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Saturn
Model:
Astra
Model Years Covered:
2008, 2009
Codes
Platform:
GM Delta II
👋 Introduction
Market Position
Positioning:
The Saturn Astra was positioned as a compact hatchback, competing in a segment with vehicles like the Honda Civic, Toyota Corolla, and Ford Focus.
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Mazda3, Volkswagen Golf.
Key Features
Features:
European-engineered platform (Opel Astra sibling), good handling characteristics, practical hatchback design, distinct styling.
📋 Manual Details
Coverage Areas
Comprehensive Service And Repair:
Covers all aspects of vehicle maintenance, repair, and diagnostics.
Manual Type
Type:
Factory Service Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF with index
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, crankshaft, pistons, connecting rods, camshafts, timing, valve train.
Engine Electrical:
Ignition system, starting system, charging system, engine control module (ECM) operation and diagnostics.
Emission Control:
Exhaust system, catalytic converter, evaporative emission control (EVAP), onboard diagnostics (OBD-II).
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel lines, fuel pressure regulator, diagnosis of fuel delivery issues.
Clutch System:
Clutch disc, pressure plate, release bearing, clutch pedal assembly, hydraulic clutch system.
Manual Transaxle:
Gearbox assembly, shift linkage, internal components, lubrication, troubleshooting.
Automatic Transaxle:
Torque converter, planetary gear sets, valve body, transmission control module (TCM), fluid type and capacity.
Driveshaft And Axle:
CV joints, drive axles, wheel bearings, hubs, differential components.
Suspension System:
Front and rear suspension components, struts, shock absorbers, control arms, springs, anti-roll bars.
Steering System:
Steering rack, power steering pump (if applicable), steering column, tie rods, alignment procedures.
Restraint System:
Airbag system components, seat belts, SRS module diagnostics and replacement procedures.
Brake System:
Brake calipers, rotors, pads, brake lines, master cylinder, ABS system, bleeding procedures.
Body Interior Exterior:
Body panel removal and installation, door mechanisms, glass, interior trim, upholstery, bumpers.
Body Electrical:
Lighting systems, power windows, power locks, instrument cluster, wipers, horn, wiring diagrams.
Heating Ventilation Air Conditioning:
HVAC system components, refrigerant, compressor, blower motor, climate control panel, diagnostics.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tune-ups, tire rotation.
Repair:
Component replacement (e.g., alternator, starter, water pump), engine rebuilds, transmission overhauls.
Diagnostics:
Troubleshooting guides, fault code interpretation, system-specific diagnostic trees.
Installation:
Installation procedures for various components and accessories.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete vehicle rebuilds and advanced diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text enabled by index.
Print Quality
Quality:
High-resolution, clear diagrams and text for easy reproduction.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
Z18XER (Commonly found in North American models)
Engine Type:
1.8L DOHC 16-valve Inline-4
Performance
Horsepower:
Approximately 138 hp @ 6300 rpm
Torque:
Approximately 125 lb-ft @ 3800 rpm
Fuel System
Injection Type:
Multi-port Fuel Injection (MPFI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
GM ECM (specific model varies)
🔧 Transmission
Standard
Type:
5-speed Manual Transaxle
Optional
Type:
4-speed Automatic Transaxle
Features
Automatic Features:
Includes Adaptive Shift Control.
📐 Dimensions
Exterior
Wheelbase:
Approximately 102.4 inches (2601 mm)
Length:
Approximately 169.7 inches (4310 mm)
Width:
Approximately 69.3 inches (1760 mm)
Height:
Approximately 58.7 inches (1491 mm)
Weights
Curb Weight:
Varies by trim and transmission, typically 2900-3100 lbs.
Cargo
Cargo Volume Rear Seats Up:
Approximately 16.9 cubic feet (with rear seats folded: ~37.3 cubic feet)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star (for 2008 model year)
NHTSA Front Impact Passenger:
5-Star (for 2008 model year)
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags:
Frontal airbags, optional side-impact airbags and curtain airbags.
Seatbelts:
Three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Available CD player, MP3 playback, auxiliary input. Optional premium audio systems might be available.
Driver Assistance
Cruise Control:
Standard Cruise Control.
Connectivity
Connectivity Options:
Auxiliary audio input for connecting external devices.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to Owner's Manual; typically 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type.
Air Filter Replacement:
Inspect every 15,000 miles; replace as needed.
Cabin Air Filter Replacement:
Inspect every 15,000 miles; replace as needed.
Coolant Flush:
Refer to Owner's Manual; typically every 5 years or 100,000 miles for Dex-Cool coolant.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SN or newer, GM dexos1™ approved recommended)
Engine Oil Capacity:
Approximately 4.5 quarts (4.25 liters) with filter change.
Transmission Fluid Manual:
GM Manual Transmission Fluid (MTF) - Refer to manual for specific specification.
Transmission Fluid Automatic:
Dexron VI Automatic Transmission Fluid (ATF).
Coolant Type:
GM DEX-COOL® 50/50 antifreeze/coolant (Orange)
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Problems:
Minor electrical gremlins, occasional suspension component wear (e.g., control arm bushings), potential for oil leaks from valve cover gaskets or oil pan. Heater core issues can also be reported on some models.
📚 Vehicle History
Brand Heritage
Saturn Brand:
Saturn was an American brand of automobiles introduced by General Motors (GM) in 1985, known for its innovative composite plastic body panels and customer-focused retail experience. The brand ceased operations in 2010.
Model Evolution
Astra Origins:
The Saturn Astra was essentially a rebadged Opel Astra, a model developed by GM's European subsidiary. It was introduced to the North American market for the 2008 model year.
Production
Production Years Na:
2008-2009
Manufacturing Location:
Antwerp, Belgium (for European production of Opel Astra, which served as the basis for the Saturn Astra)
🏆 Awards & Recognition
Recognitions
Safety Awards:
Achieved 5-star front impact safety ratings from NHTSA.
Ratings
IIHS Ratings:
Received 'Good' ratings in some IIHS crashworthiness tests, particularly side impacts when equipped with side airbags.
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