Astra Press Pack - DOC by liuqingyan


									Astra Press Pack


   1. OVERVIEW & MARKET                                           Pg.2

   2. EXTERIOR DESIGN                                             Pg.6
      - Return of the„Blade‟

   3. INTERIOR DESIGN                                             Pg.8
      - Storage & Packaging
      - Materials & Quality

   4. POWERTRAINS                                                 Pg.11
        - Petrol engines in detail
        - Diesel engines in detail
        - New automatic gearbox

   5. DRIVING DYNAMICS                                            Pg.16
         - Front & rear suspension in detail
         - Bespoke UK steering settings
         - FlexRide
         - Braking & electronic safety systems

   6. SAFETY, INNOVATION & EQUIPMENT                              Pg.22
        - AFL+
        - Occupant safety
        - Seat technology
        - Flex-Fix & FlexFloor
        - Infotainment

   7. MODEL RANGE                                                 Pg.27

   8. EQUIPMENT HIGHLIGHTS                                        Pg.28

   9. TECHNICAL DATA OVERVIEW                                     Pg.33


Britain’s best selling UK-built car is re-born and revitalised

                                                                 Page | 1
Launched at the 2009 Frankfurt Motor Show, Vauxhall‟s all-new Astra is poised to raise
the bar for compact cars sold in the UK, with a combination of stylish design, class-
leading dynamics, ultra-efficient powertrains and upscale quality.
On sale now, and in UK showrooms from December, the new Astra will uphold
Vauxhall‟s tradition of offering buyers levels of innovation and technology normally
found in a class above, but at a price point embedded in the value sector. New Astra
prices start at £15,675 for the comprehensively equipped 1.4-litre, 87PS Exclusiv
model and extend to £23,695 for the luxurious 2.0CDTi 160PS Elite automatic.
With a range of eight engines and five trim levels, the new Astra will initially be
available as a five-door hatchback only, built at the Ellesmere Port plant in Cheshire,
home to all Vauxhall‟s compact-class cars since it opened 46 years ago.
Ellesmere Port will be responsible from launch for manufacturing all Astras sold across
Europe, but UK buyers will take the lion‟s share, amounting to 25 per cent of total
production. Small wonder, then, that even in its outgoing form, the Astra is Britain‟s
best-selling UK-built car and one that is almost always seen in the top three sales

What‟s more, the Lower Medium Sector, in which the Astra sits, is hugely significant in
the UK, accounting for 17.5 per cent of all retail car sales. With style-conscious buyers
choosing Vauxhall more and more, the Astra has a large part to play in this success,
along with its continued appeal to buyers in the fleet market.

“As with the Insignia, the Astra is an all-new car, continuing the transformation of the
Vauxhall product range which started five years ago with the launch of the Mk 5
model,” said Andy Gilson, Vauxhall‟s Marketing Director. “Also like the Insignia, the
Astra aims to attract a new group of buyers, those who may never have considered a
Vauxhall before, but now see cars like the new Astra as offering all the style and
quality of a premium product, such as an Audi A3, but at a far more affordable price
point. “

Mark Adams and his team execute yet another design masterstroke

With its strong, cab-forward silhouette, steeply raked windscreen and sloping rear
roofline, the Astra makes ingenious use of many of the design features found in the
Insignia, but in a fresh and innovative way. Also like the Insignia, it has spent over 600
hours in the wind tunnel, benefiting performance, economy and overall refinement.
                                                                                   Page | 2
“We‟re continuing with the same premium design cues as the Insignia,” said Mark
Adams, Vice President of Design for GM Europe. “However, the main design themes,
liked the wing-shaped signatures and the blade, needed an individual execution to
avoid „cloning‟ the model ranges.”

Upmarket design, quality materials and clever packaging define new Astra’s

Echoing the flowing forms of its bodywork, the new Astra‟s interior marks a major shift
towards premium design and quality in the compact sector. It employs the recurring
wing and blade motifs that were first introduced in the Insignia and are now used in a
fresh and innovative way.

Ambient lighting enhances the feeling of quality in the cabin, with lighting points framing
the gearshift surround, the area above the centre console and within the door handle
recesses, depending on trim level.

Unparalleled in this sector is the Astra‟s raft of clever cabin storage solutions, some of
which have even been patented. Rather than focusing on the compartment size alone,
the Astra‟s cabin is full of bespoke storage areas designed specifically for the 20 most
common items buyers have been found to carry in their car, from an MP3 player to a
1.5-litre drinks bottle.

Efficient, yet powerful, Astra’s engines are low on C02 but high on power

The new Astra will be available with a range of eight engines, ranging from 87PS to
180PS, all of which offer impressive efficiency and an overall cut in emissions of 13.3
per cent compared with the current Astra range.

Diesel engines are expected to represent almost half of all Astra sales, and will range
from a 1.7-litre producing 110PS to a 2.0-litre generating 160PS, but will never emit
more than 129g/km when fitted with a manual transmission.

Crucially, there will be an important ecoFLEX model, equipped with a 95PS 1.3 CDTi
available in Spring 2010. Fitted with this engine, the ecoFLEX will achieve 109g/km,
while retaining driveability and refinement.

There will also be five petrol engines available, ranging from an 87PS 1.4-litre to a
180PS 1.6-litre Turbo. Included in this line up will be a new 1.4-litre turbocharged
engine, producing 140PS, replacing the 1.8-litre motor used in the current range. This
new powertrain perfectly illustrates Vauxhall‟s engine downsizing philosophy which
provides drivers with all the performance of a larger capacity engine, but with far fewer
                                                                                   Page | 3
Innovative Watt’s link rear axle equals fine dynamics and superior packaging

The new Astra‟s front and rear tracks have been increased by 56mm and 70mm
respectively, while its wheelbase has been increased by 71mm, the cumulative effect
being improved handling and ride quality, as well as more space and comfort for

Continuing Vauxhall‟s trend for innovation, its engineers have combined the size,
weight and efficiency benefits of a compound crank rear axle with a cleverly positioned
Watt‟s link, which helps support lateral forces during cornering.

Complementing this system is a new version of Vauxhall‟s FlexRide adaptive damping
system, which adjusts the suspension character automatically depending on the
driver‟s needs, while also offering three programmable damper settings.

Finally, a core body structure, stiffer than that of the outgoing car, enhances the new
Astra‟s ride and handling still further, while also reducing noise and vibration inside the

Illustrating Vauxhall‟s commitment to developing its cars specifically for British roads
and drivers, the new Astra has bespoke UK steering settings developed in conjunction
with the Vauxhall Engineering Centre, based at GM‟s Millbrook Proving Ground in

Vauxhall brings technology and innovation to the compact class

While the Insignia succeeded in making new, high-tech innovations accessible in the
mid-size sector, Vauxhall has set itself an even more ambitious goal in bringing most of
these features to the compact sector with the new Astra. These include:

   -   Advanced Forward Lighting (AFL+) – Vauxhall‟s third generation AFL+ which
       changes its intensity and reach to suit prevailing driving and road conditions
       using nine different light functions
   -   Ergonomic Driver’s Seat – featuring 6-way adjustment (4-way on front
       passenger seat), 4-way lumbar adjustment and an extendable seat cushion.
       Available on all trim levels, both the driver‟s and front passenger‟s seats provide
       enhanced support for overall body comfort.
   -   FlexFloor – provides flexible solutions to boot storage, and features a boot floor
       which is moveable and can be mounted in a choice of three positions according
       to owners‟ needs.

                                                                                    Page | 4
-   Flex-Fix – Vauxhall‟s innovative bike carrier is integrated into the rear bumper.
    This optional feature, which slides out of the rear bumper like a draw, provides
    an easy and convenient method of transporting up to two bikes.

                                                                               Page | 5
      Design cues from much-praised Insignia reinterpreted for new Astra
      Sculptural shapes combined with sporty proportions
      Powerful shoulder-line and rakish profile re-define Vauxhall‟s design language
The next generation Astra brings a new look to the compact class, with its strong
coupe-like lines, elegant surfaces and its unique interpretation of Vauxhall‟s design
At 4.42 metres the new Astra grows by some 17 centimetres compared with its
predecessor, positioning itself right between the Corsa (4.0 metres) and the Insignia
(4.83 metres). The wheelbase increases by 71 millimetres, improving rear passenger
space and adding comfort for all occupants.
A slim but low trapezoidal grille incorporating the latest Griffin logo dominates the front
of the car, while the familiar blade sculpted into the side panels of the new Astra
sweeps upward and visually connects with the side window-line, balancing the car‟s
Eagle eye-shaped headlamps, that encompass the prominent wing-shaped daytime
running lights, blend with a graceful flowing silhouette that connects the new car‟s
muscular shoulder lines with its distinctive rear hatch area.
“We carried forward the work we began with Insignia,” says Mark Adams, Vice
President Design GM Europe. “This time we‟ve given our design language a fresh
expression for the compact class segment. Think of it as if the Insignia and Astra are
members of a family. You can recognize the same gene pool, yet each car has its own
personality and character.”
The raked A-pillars flow into a diving bonnet-line, leading to narrow headlamp units,
housing lights mounted on a dark inner surface, which add depth and a three-
dimensional quality. The signature wing graphic on the daylight running lights sits
inside sharp, eagle-eye headlamps.
The front indicator lights are now located separately in the front bumper recesses and
are accented with chrome, while the neatly shaped repeater units are set into the upper
front wings.

New body design sees reappearance of the ‘Blade’
A crisply-executed soft shoulder line runs along the side of the body into the sculpted
rear light units. Above these, the car‟s windows on most models are framed by a matt
chrome surround, unique in the compact class.

                                                                                    Page | 6
Pressed into the side panel just ahead of the rear wheels is the unmistakable blade
motif, echoing the distinctive design cue in the front doors of the Insignia. On the new
Astra, though, the blade swings upward in a rearward movement, providing the car with
its own individual identity.
In profile, the car‟s svelte proportions are accentuated by the triangular shape of the
rear side window, the falling roof, the wraparound rear screen and the upward direction
of the blade feature.

Coupe styling with hatchback functionality
The new Astra‟s side view hints at a sleek, almost coupé-like look, which belies the
Astra‟s generous passenger accommodation, suitable for five adults.
Viewed from behind, the shoulder line extends along the side of the body into the
sculpted rear lights in one, continuous flow. Designers achieved the muscular rear
proportions by creating strong rear body shoulders, combined with a wraparound C-
panel and tapered rear window.
The tail light units are set apart to accentuate the width of the vehicle‟s stance, and
viewed at night, their double wing graphic creates an instantly recognisable
appearance. This is enhanced by an upper rear spoiler, which also serves to improve
the car‟s aerodynamics.

                                                                                 Page | 7

      Clever packaging offers more occupant comfort and space
      Distinctive exterior design cues echoed in cabin
      Tactile feel throughout cabin enhanced by extensive use of premium materials

Echoing the flowing forms of its bodywork, the new Astra‟s interior marks a major shift
towards premium design and quality in the UK‟s compact sector, and continues
Vauxhall‟s design evolution which started five years ago with the current Astra, followed
by a further step-change last year with the launch of the Insignia.
The Astra‟s interior employs the recurring wing and blade motifs that were first
introduced in the Insignia and are now used in a fresh and innovative way. The blade
theme is expressed in details like the gooseneck shape of the door grab handles and
the trim for the gearshift moulding and steering wheel.
As you look at the Astra‟s wraparound instrument panel, which embraces both front
seat occupants, the wing design is immediately visible as it arcs across the cabin into
the door-top mouldings. The dashboard has a black, grained finish with a subtly
different texture to other mouldings in the cabin.
Ambient lighting enhances the quality feel of the cabin, with lighting points framing the
gearbox surround, and providing illumination from above the centre console and within
the doorhandle recesses, depending on trim level.
The feeling of cabin space and depth is illustrated by a centre panel mounted at a
shallow 30-degree angle, which sweeps down from the top of the instrument panel to
the centre console, creating a flowing surface that incorporates the gearshift. Like the
Insignia, the Astra‟s main clocks and gauges are ringed with chrome, with the
speedometer and tachometer pods angled inwards towards the driver.
Special emphasis has gone into the design and engineering of the Astra‟s seats, which
now have industry-leading levels of adjustment. Their height can be raised by up to
65mm, while their fore and aft range extends to 280mm, allowing all drivers and
passengers to find their ideal seating position. In addition, the Ergonomic Sports Seats
(standard in all Elite models) have improved tilt adjustment (driver‟s seat only), four-
way power lumbar support, superior side support and supporting foam pads.

Storage and packaging
„So do people actually put gloves in their gloveboxes?‟
Using feedback from a customer survey, the interior team first compiled a list of the 20
most common items stored in cars: pens, coins, a flashlight, a road atlas, a parking
disc, sunglasses, a wallet, paper tissues, a mobile phone, CDs, sweets, cups,

                                                                                  Page | 8
magazines, newspapers, fruit, a first aid kit, a jacket, a 1.5/1.0/0.5-litre drinks bottle.
And, of course, gloves.
Next, they noted where owners wanted to keep the items and looked for practical
solutions. They found that car companies tended to focus on storage size alone, and
that led to irritating problems, such as CDs being stored in the centre console,
preventing the arm rest from being fully dropped down.
Max Kuncl, the team‟s Performance Integration Manager likened the challenge to a
puzzle: “It was important for the team not only to find places for the items to fit, but for
the new Astra‟s interior to still look great, and maintain high quality standards
throughout the cabin.”
This painstaking attention to detail has resulted in a variety of simple, but effective
storage solutions. A hard-shelled sunglass case has been inserted above the door
opening on the driver‟s side; coin slots and pen holders are moulded into the inside
edge of the glove box lid; and the glove box itself has two removable compartments,
while a second mini-glove box has been added just below the light switch.
Further storage innovation appears in the centre console, which can accommodate
nine CD cases, as well as having a small storage area and an insert for two cup
holders. There‟s also the option of an under-seat drawer beneath the passenger seat
which is big enough to hold a pair of shoes. Rear passengers also benefit, with a 12-
volt connection available for MP3 players, in addition to space for drinks bottles.
The new Astra‟s boot also came under close scrutiny. A recess was created in the side
of the boot to accept either a first aid kit or warning triangle, while a patented FlexFloor
was devised to offer further under-floor storage, while the floor itself can be fixed at
different heights.
And those gloves? According to the survey, most owners don‟t keep them in the
glovebox at all. They usually get thrown in the door‟s side pocket, next to the ice

Materials and quality
“Our goal was to make the perceptual quality in the interior of the next generation Astra
as great as that of the Vauxhall Insignia,” says Peter Hasselbach, in charge of Design
Appearance Quality. “This is in line with Vauxhall‟s mission to bring innovations and
quality to the compact class.”
The quality of the materials used in the new Astra can be seen in areas like the grained
surfaces, the textured panels, the chrome trim elements and the feel and operation of
the buttons and switches. In addition, all the Astra‟s main surfaces are textured with
upscale materials and top grains to give a strong, premium feel.

                                                                                       Page | 9

      Downsized petrol engines and ultra-efficient diesels with power range from 87-
      Significant reduction in emissions and fuel consumption over current Astra
      New 1.4-litre Turbo engine promises strong performance with meagre running
      ecoFLEX model to join range next year with 109g/km combined emissions
Boasting an eight-engine line-up from launch, the new Astra range will be on average
13.3 per cent cleaner and more economical than that of its predecessor, without
denting the performance of any specific models. A ninth engine will be available in
Spring 2010 and will power the first ecoFLEX model in the range, its 1.3 CDTi engine
producing 95PS and achieving combined emissions of just 109g/km*.
Downsizing has been key to achieving lower emissions and fuel consumption, while a
clear focus on high specific outputs and low-end torque values have ensured that
strong performance is retained across the range.
The new 1.4-litre Turbo is a perfect example of this philosophy, producing 140PS and
139g/km combined C02 emissions, compared with the outgoing 1.8-litre engine, which
produces the same power but with an extra 33g/km.
Sitting below the 1.4 Turbo in the petrol engine range are two normally aspirated 1.4-
litre units producing 87 and 100PS respectively. Complementing these engines are two
1.6s: an un-blown unit with 115PS and a turbocharged version with 180PS.
The CDTi diesel line-up includes two 1.7-litre engines and one 2.0-litre unit, all of
which feature common rail with multiple fuel injection and are equipped with particulate
filters (DPFs). These range in power from 110PS for the lowest power 1.7 CDTi to
160PS for the 2.0 CDTi.
All Astra engines meet Euro 5 emissions standards and each of the four-cylinder units
is mounted transversely and features an aluminium cylinder head, with dual overhead
camshafts operating four valves per cylinder.
Cast iron blocks have been used across the range for strength and reduced noise
resonance, with a hollow-frame design for minimized weight. A die-cast, structural
aluminium oil pan adds further stiffness and noise suppression.
Continuously variable valve timing, for both inlet and exhaust sides, is adopted on all
engines, except the 1.6 Turbo. The camshafts have hydraulically operated vane-type
phasers which vary the angle of each camshaft relative to the crankshaft by up to 60
degrees on the inlet, and 45 degrees on the exhaust side.
Cam phasing allows the engine control module to adjust the timing of the valve opening
and closing according to varying conditions, such as engine speed and load. The many
                                                                                Page | 10
benefits include a broader spread of torque, higher maximum power and improved fuel
consumption. Cam phasing is also an effective tool for controlling exhaust emissions,
managing valve overlap at optimum levels to eliminate the need for a separate exhaust
gas recirculation (EGR) unit.
*Final figure to be confirmed

1.4-litre (87 & 100PS versions)
The entry-level 1.4-litre, naturally-aspirated engine, with a specific power output of
71.4PS per litre (100PS unit), has excellent fuel economy and returns a combined
The camshafts are chain-driven for maintenance-free operation and feature automatic
hydraulic adjustment. Further refinements include the use of hollow camshafts, for
reduced weight and lower reciprocating mass, and a flywheel with a torsional vibration
damper for improved running refinement. The fuel injection system also features port
deactivation under part load for improved exhaust gas recirculation, giving lower
emissions and improved fuel consumption.
Maximum power of either 87PS or 100PS is generated at 5600rpm or 6,000rpm with
peak torque of 130Nm available at 4000rpm.
Developing 115PS at 6,000rpm, the normally-aspirated 1.6-litre has an even higher
specific power output (72.5PS per litre) than its 1.4-litre, naturally-aspirated cousin.
Maximum torque of 155Nm is generated at 4,000rpm, with more than 90 per cent of
this value available from 3,000rpm.
Fitted with this engine, the Astra will achieve a 0-60mph time of 10.9 seconds and a
combined fuel consumption of 44.8mpg – only 8 per cent more than the 1.4-litre
(100hp) engine.
A two-stage variable intake manifold is fitted, and for increased torque at engine
speeds below about 4,000rpm, the fuel/air intake charge passes through 620mm long
inlet tracts. Above 4,000rpm, the engine management system transmits a signal to
channel the air along shorter 288mm tracts, which has the effect of increasing top-end
engine power.
The engine‟s cylinder barrels are laser-etched for an extremely smooth finish, giving
minimal piston friction and wear characteristics, while also benefiting oil and fuel
consumption. Under-skirt piston oil cooling also features.
1.4-litre Turbo

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Strong performance and flexibility are the core strengths of this new-to-range engine,
which produces 140PS. Torque generation is even more impressive, with 200Nm
available from just 1,850rpm to 4,900rpm, translating to a 0-60mph acceleration time of
9.0 seconds.
The water-cooled turbocharger, spinning at up to 200,000 rpm, is integrated into the
exhaust manifold, close to the engine, for a fast throttle response. Air-to-air intercooling
increases the intake charge density.
The adoption of a steel crankshaft with reinforced pistons and con-rods allows the use
of a relatively high 9.5: 1 compression ratio, despite higher stresses and loads. Under-
skirt piston oil cooling jets and exhaust valves filled with sodium are further measures
to ensure durability under higher internal temperatures.
1.6-litre Turbo
The most powerful engine in the Astra‟s line-up produces 180PS and achieves a
specific output of just over 100PS per litre. Available in both SE and sport chassis-
equipped SRi models, the 1.6 Turbo is the most powerful series production engine in its
displacement class.
The 1.6 Turbo‟s high power is matched by an impressively wide plateau of torque, with
230Nm available from 2,200rpm to 5,400rpm. With this engine, the new Astra can
accelerate from 0-60mph in 7.9 seconds, and from 50-70mph in fifth gear in just 8.4
In common with the 1.6 naturally-aspirated engine, the cylinder barrels are laser-etched
for minimal piston friction. To withstand higher operating temperatures, the exhaust
valves are filled with sodium and under-skirt piston cooling with oil jets is used. A map-
based thermostat control raises the coolant temperature at low engine speeds, or
under light loads, to help reduce internal lubricant friction and improve fuel

All Astra diesel engines are fitted with:

    16-valve, dual overhead camshafts
    A weight-saving aluminum cylinder head
                                                                                   Page | 12
    Threaded intake ports for exceptional „swirl‟ and burn characteristics
    Oil jet cooled pistons
    A dual-mass flywheel and a maintenance-free exhaust particulate filter.
The main technical features include:
Common Rail, Multiple Fuel Injection
Operating at high pressures up to 1,800 bar, this sophisticated fuel delivery system
ensures extremely fine atomisation in the combustion chamber and enables up to five
injection pulses per cycle to extract as much energy as possible from a given amount of
fuel. The result is exceptionally low fuel consumption and exhaust emissions, as well as
reduced engine noise. Multiple injection helps iron out the strong vibrations associated
with compression ignition. For example, a pre-injection during the warm-up period
reduces cold-start „knock‟ to a barely perceptible level.
Variable Geometry Turbocharger (VGT)
The pitch of the vanes on the turbine wheel is continuously varied according to engine
load and speed, giving an excellent throttle response, particularly during pick up from
low speeds.
Improved Exhaust Gas Recirculation (EGR)
The electronically-controlled EGR system has an additional cooling function. Electro-
pneumatically operated bypass flaps, controlled by the engine management system,
ensure that the exhaust gas reaches a temperature suitable for combustion on its way
back into the cylinder. This contributes to increased power, as well as reduced
The diesel line-up comprises:
1.7 CDTi
Available in two states of tune, providing either 110PS and 260Nm of torque, or 125PS
and 280Nm. Combined cycle fuel consumption for both is 60.1mpg.
2.0 CDTi
The 2.0 CDTi packs 160PS with an exceptionally strong 350Nm of torque from just
1,750rpm. This helps it achieve a 0-60mph time of just 8.5 seconds and 50-70mph in
6.4 seconds, together with a combined fuel consumption of just 57.6mpg.

Six-speed manual gearboxes, offering a wide spread of ratios and a tall, fuel-saving top
gear, are standard fit across the entire range, with the exception of the naturally-
aspirated 1.4/1.6-litre engines, all of which have five-speed gearboxes (for optimum
fuel economy, these two-shaft units are fitted in preference to a six-speed, three-shaft

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gearbox). All gearboxes include triple cone synchronization on first and second gears
for easy engagement, while the six-speed units also have a synchronized reverse gear.
New Auto for new Astra
An all-new, GM Hydra-Matic six-speed automatic transmission is offered with all petrol
engines, except the naturally-aspirated 1.4-litre and 1.6-litre Turbo unit, which are
manual only.
Instead of the new auto transmission being „folded‟ around the end of a transversely-
mounted engine, the gear sets are now on the same axis as the engine crankshaft
centreline, which makes the entire powertrain unit much shorter fore-to-aft. This „on-
axis‟ design provides more compact packaging, allowing enhanced crumple zone
performance, increased interior space, and a lower bonnet line than possible with a
conventional off-axis design. Shifts are accomplished by applying and disengaging
clutches simultaneously, which provides increased functionality and a more direct feel
for the driver compared to „freewheeling‟ gear change mechanisms.
On the road, a wide selection of shift patterns is adapted to the style and habits of the
driver, anticipating when maximum acceleration or maximum efficiency is required. The
electronic control will also adapt to the prevailing road conditions, reducing gear shifting
when climbing or descending and using engine braking assistance during down
ActiveSelect allows the driver the option of sequential gear selection via the shift lever.
The driver also benefits from a “neutral” gear disengagement at idle, which reduces
vibration and contributes to improved fuel consumption.
Hydraulically-damped mountings for improved NVH performance
All powertrains are bolted in position via hydraulically-damped mountings that minimize
vibration through the body structure. Adaptor plates enable the same four fixing points
to be used for all applications, two on the front sub-frame and one on each longitudinal
The fuel supply system uses an electric pump and filter mounted in the 56-litre fuel
tank, which is located low under the rear seat for optimal weight distribution and crash
impact protection.

     New chassis with longer wheelbase and wider tracks
     Watt‟s link rear suspension combines superb handling with clever packaging
     FlexRide adaptive suspension offers drivers choice of dynamic settings
     UK-specific steering settings tuned and developed on British roads

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The new Astra will not only feature a longer wheelbase and wider tracks for improved
stability and ride comfort, but also a rear suspension system combining a compound
crank with a Watt‟s link – the first of its type in the world - that is set to offer drivers
class-leading handling and ride comfort.

The Astra‟s front and rear tracks have been increased by 56mm and 70mm
respectively, while its wheelbase has been increased by 71mm, the cumulative effect
being improved handling and ride quality, as well as more space and comfort for

Illustrating Vauxhall‟s commitment to developing its cars specifically for British roads
and drivers, the new Astra has bespoke steering UK settings developed in conjunction
with the Vauxhall Engineering Centre, based at GM‟s Millbrook Proving Ground in

And continuing Vauxhall‟s trend for innovation, its engineers have combined the size,
weight and efficiency of its own patented compound crank rear axle layout with a
cleverly positioned Watt‟s link, which supports lateral forces during cornering.

The FlexRide adaptive damping system, first seen in the European Car of the Year-
winning Insignia and rare in the compact class, adjusts the suspension character
automatically depending on drivers‟ needs, while also offering three programmable
damper settings.

Enhancing this sophisticated system is an increase in the Astra‟s torsional body
stiffness of 43 per cent, and of 10 per cent in bending stiffness, compared with the
previous Astra, improving the car‟s handling and ride quality, as well as making a
significant reduction in noise, vibration and harshness (NVH).

Advanced front suspension design and clever Watt’s link at rear for superb

The Astra‟s new suspension layout combines MacPherson strut front suspension with a
clever, newly developed compound crank rear axle with a Watt‟s link.

Front suspension is by MacPherson strut, with de-coupled top mountings that separate
the paths of spring and damper loadings. To reduce unsprung weight and improve
weight distribution, the combined strut carrier and the lower control arm are made from
aluminium and the anti-roll bar is formed from hollow-section steel.

For optimum stability, the L-shaped control arm is attached through two bushings to the
front sub-frame. The suspension geometry, and the tuning of the bushes, is designed
to provide both lateral stiffness and longitudinal compliance for excellent handling and
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good ride comfort. The rearmost bushing of the L-arm is also hydraulically damped for
excellent road isolation.

The Astra‟s unique compound crank/Watt‟s link rear suspension system has many
advantages over a multi-link design, including improved packaging, greater wheel
camber stiffness and less lower suspension friction. It also creates less camber loss
due to body roll, while the Watt‟s link ensures that lateral stability is maintained.

The torsion beam of the patented compound crank axle is attached between the trailing
links, about half way between the axle bush and the rear wheel. The open, U-shaped
profile between the attachment points has now been lengthened and the wall thickness
generally increased to provide more roll stiffness. In addition, beams with different wall
thicknesses are fitted to give the required roll-steer characteristics.

The Watt‟s link is carried on a small cross-member attached to the underside of the car,
just behind the rear wheel centre line. It comprises a short, pivoting centre link with a
ball joint at each end, to which the lateral links from the wheels are bolted.

In a straight line, the set up ensures excellent stability, but during cornering it minimizes
lateral deflection in the same way a modern multi-link system would do. Vauxhall‟s
engineers estimate that the new linkage absorbs around 80 per cent of all lateral
loadings on the rear suspension. In addition, the Watt‟s link reduces axle bush loads to
allow softer bushings, which further isolate occupants from road noise and vibration.

                                                                                   Page | 16
                      New Astra’s compound crank rear axle with Watt’s link

Bespoke UK steering settings to cater for Britain’s unique road infrastructure

Right from the start of the Astra‟s development, Vauxhall‟s UK engineering arm
recognized that the car needed to fulfill the very specific needs of British drivers
travelling on the kind of road surfaces that are not replicated anywhere else in Europe.

Connection, Assistance, Responsiveness, Isolation, and Smoothness were cited
as the key fundamentals in the Astra‟s steering DNA, and after exhaustive testing on
the notoriously demanding roads around GM‟s Millbrook Proving Ground in
Bedfordshire, Vauxhall has produced a system which provides acceptable assistance
levels for a broad spectrum of drivers, while ensuring that the driver feels connected
with the road at all times.

The Astra uses a rack and pinion steering system with speed sensitive assistance. But
in order to provide drivers with more steering feedback, the system‟s electric motor is
mounted directly on the steering rack, as opposed to the base of the steering column.

The key benefits of using an electric power steering (EPS) are well known. At low
speeds, the level of power assistance is increased to minimize steering effort. At higher
speeds, assistance is automatically reduced to ensure a high degree of steering feel for
the driver. The second important benefit is that because it does not require an energy
consuming pump, and responds directly to the amount of power needed at any speeds,
fuel consumption is also reduced.

FlexRide system makes welcome return

First seen in the Insignia, and a rarity in this sector, FlexRide offers the driver three
settings - Standard, Sport and Tour – while being fully and continually adaptive to
changes in driving style and cornering speed. The system is offered as an option on
SE, Elite and SRi models with all engines, except the normally-aspirated 1.4-litre petrol

                                                                                Page | 17
FlexRide provides electronic control on all four dampers and continuously adapts their
settings within milliseconds, according to the prevailing road conditions, vehicle
movements and individual driving styles, thereby enhancing driver safety.

In addition, FlexRide offers three settings that the driver can programme via dashboard
buttons. In Standard mode, FlexRide continuously adapts to all driving conditions, but
drivers can also opt for either Tour or Sport settings, too.

Tour mode relaxes the damper settings for a more comfortable ride and also reduces
the steering effort, benefiting drivers on long journeys.

Sport mode offers a more connected driving experience: the dampers stiffen; the
steering sharpens and the electronic throttle offers a swifter pedal response. To
underline this effect, the instrument panel illumination changes from white to red, and if
fitted, the Adaptive Forward Lighting system reacts even more quickly. Cars fitted with
automatic transmission also have higher change-up points.

As a further refinement, Sport mode includes a customisation menu, where the driver
can de-select the damper and steering-assistance elements.

The electronic brain behind FlexRide is the Driving Mode Control module. Using vehicle
dynamics information, the DMC constantly monitors driving style and conditions,
including acceleration, braking and cornering to optimise the chassis‟ behaviour.

Apart from a more rewarding driving experience, the FlexRide system offers safety
benefits in emergency situations. For an avoidance manoeuvre in Tour mode, for
example, chassis sensors convey this information to the DMC and the dampers are
stiffened within a millisecond to provide maximum stability.

Electronic Parking Brake (EPB)

This easy-to-use function, which is standard on all SE, Elite and SRi models, replaces
the conventional mechanical handbrake. As well as providing added convenience, the
EPB also frees up valuable additional storage space in the centre console.

Instead of pulling a handbrake lever, the driver simply pulls a switch located near the
gearshift. This sends an electrical signal to actuators in the rear brake calipers. The

                                                                                 Page | 18
EPB can secure the car on gradients as steep as 30 per cent and is automatically
disengaged when the vehicle moves off.

The EPB is combined with Hill Start Assist (HSA), which helps minimize downhill
movement of the car when taking off on an uphill slope. HSA briefly maintains pressure
at all four brakes to minimize the possibility of vehicle movement when the driver steps
from the brake to accelerator pedal while engaging the clutch.

Braking system: Two systems depending on the performance level

The dual-circuit braking system features two brake disc combinations. The “15-inch”
specification uses 276 mm ventilated front discs and 268 mm solid rear discs, clamped
by single piston calipers. The “16-inch” version has 300 mm ventilated front discs and
292 mm solid rear discs with single piston calipers.

The four channel ABS (Anti-lock Braking System) is fitted as standard, together with
the Electronic Brakeforce Distribution (EBD), which ensures that optimal braking
force is applied on both axles for maximum stability under heavy breaking.

The Electronic Stability Control (ESC) including Traction Control (TC) is also fitted
as standard across the range offering a high level of active safety. The ESC yaw
sensor in the centre of the car detects movement around the vertical axis, and a sensor
on the steering column measures the steering angle being applied. Inputs from these
sources are then correlated with the speed of the car. The system is programmed to
execute whatever actions will most effectively prevent the onset of a loss of control.
Depending upon the driving situation, it is possible for braking to be applied via the
ESC system to one, two or three wheels at once, or, if necessary, the electronic throttle
opening is also reduced.

Other braking functions under ESC direction are:

Cornering Brake Control (CBC) is activated when the car is braking while cornering.
Brake pressure is individually varied between all four wheels in order to keep the car
perfectly stable.

Cornering Torque Control (CTC) prevents the inner wheel from slipping when
cornering under acceleration. If wheel speed sensors detect the onset of any slippage,
the inner wheel is slowed by applying brake pressure, thereby minimising any
understeer tendency. As soon as grip is restored, the braking pressure is released.

Electronic Drag Torque Control (EDC) prevents loss of grip if the driver steps off the
throttle or downshifts too quickly.
                                                                                Page | 19
Brake Assist System (BAS) is designed to provide the driver with additional braking
assistance in an emergency situation.

Hydraulic Brake Fade Assist (HBFA) automatically raises braking pressure to
compensate for brake fade under repeated applications of heavy braking.

Trailer Stability Assist (TSA) is active when a Vauxhall-approved towing hitch is fitted.
TSC counters any vehicle instability that may occur when towing a trailer or caravan by
reducing the engine torque and applying brake pressure to selected wheels. ESC
engages TSC when any oscillation from the attached trailer is transferred over the hitch
point to the vehicle and detected as sufficient to cause instability.


      Third generation AFL+ lighting brings upscale technology to compact class
      Unparalleled levels of safety and comfort kit available across Astra range
      Innovative features such as Flex-Fix and FlexFloor add practicality and
Adaptive Forward Lighting
Vauxhall has played a pioneering role in automotive lighting technology in recent years
and its Adaptive Forward Lighting (AFL+) is now in its third generation. However, the
new Astra will be the first compact class Vauxhall to adopt this (optional) feature,
illustrating the premium nature of the car, albeit at Vauxhall‟s traditional value price

                                                                                Page | 20
With multi-xenon headlamps, AFL+ can be specified on all new Astras, except S and
Exclusiv models, as part of a Premium Forward Lighting Pack. This also includes High
Beam Assist, automatic headlight-beam switching, LED daytime running lights and
headlamp washers.
AFL+ includes two new functions – Town Light and Adverse Weather Light – and two
improved functions – Highway Light and Country Road Light. There are a total of nine
functions, each automatically engaged to suit prevailing road profiles and driving

      Dynamic Curve Light – Illuminates surface around bends; linked with Sport
       switch in FlexRide
      Country Road Light – Provides brighter and wider illumination of both sides of
       the road
      Static Cornering Light – Illuminates area up to 90 degrees to the left and right
       of car to aid low speed manoeuvres
      Highway Light - Automatically engages at over 60mph to provide a more
       intense and higher-level main beam
      Town Light – Operates between 20 and 35mph to provide a broader, less
       intense beam to help drivers see pedestrians at either side of the road
      Pedestrian Area Light – Activated at speeds up to 20mph in areas where
       drivers must exercise extreme caution, such as pedestrian areas
      Adverse Weather Light – Activated during rain or snow, the left headlamp
       increases in intensity to pick out lane markers, while the right beam intensity
       reduces from 35 to 32 Watt‟s to avoid blinding oncoming drivers
      High Beam Light – Provides maximum headlight beam and range, with output
       increasing from 35 to 38 Watt‟s
      Automatic headlight beam switching – senses the headlights from oncoming
       cars and activates dipped/full beam accordingly

Occupant safety
Occupant safety has played a major role in the new Astra‟s development, and a
comprehensive set of active and passive safety systems are standard an all models.
All Astra variants are fitted with dual-front seat belt pre-tensioners, which provide over
the shoulder and across the occupant‟s lap. They are pyrotechnically activated to
restrain forward body movement in the event of a severe impact.
Other standard safety equipment includes two front airbags, two side airbags and a pair
of roof rail-mounted airbags that cover the entire glass area between the A- and C-
pillars. Three, three-point seatbelts are provided for rear seat passengers, and the front
passenger-side airbag can be de-activated if the seat is occupied by a rear-facing child

                                                                                  Page | 21
Whenever the airbags and pre-tensioners are deployed, a series of additional safety
features is activated: the hazard warning lights come on; all doors unlock; the interior
lights illuminate; and the heating/ventilation fan and fuel pump are both switched off.
The latest generation active head restraints, developed from those on the Insignia, are
fitted as standard to all models, and provide enhanced protection from whiplash injuries
if the car suffers a rear-end impact.
Other occupant safety features include:

    Seatbelt reminder – with audible warning. Operates on all five seating positions
    Front seat frames – with ramps to restrict occupant movement in a frontal
    Enhanced Pedal Release System (PRS) – in heavy frontal impacts, clutch and
     brake pedals are de-coupled to prevent foot and lower leg injuries
    ISOFIX child seat mounts for the outer rear seats, plus seatback-mounted top
     tether brackets for all rear seating positions
    Height-adjustable rear head restraints (optional for centre position)
    Adaptive brake lights – warn drivers behind by pulsing five times per second if
     the ABS is engaged above 20mph.
Seat Technology
Vauxhall‟s target was to produce best-in-class seating for the new Astra, with special
attention paid to comfort, position, range and protection during an accident.
The front seats offer the industry‟s best range of adjustment, with fore and aft
movement extending to 280mm. The driver‟s seat is also adjustable for height by up to
65mm and the steering wheel can also be adjusted for reach and rake, ensuring that
drivers of virtually all shapes and sizes will feel comfortable and in control.
Apart from excellent comfort and support, the new Astra‟s seats also provide a high
level of safety, featuring the latest generation of active head restraints which offer
protection against whiplash injuries. High strength steel in the seat frames increases
rigidity, but reduces weight, saving up to three kilograms per car.
Shields in the front backrests provide protection against objects from the luggage
compartment flying through the cabin, especially if the rear seat is folded down during
a rear impact.
The Ergonomic Sports Seats are offered as an option across all trim levels, with either
manual or powered lumbar support. The driver‟s seat features a six-way adjustment, a
four-way adjustment of the lumbar support and an extendable seat cushion.
On SE and SRi models, the Ergonomic Sports Seats are available in leather, together
with heating for the front seats. On Elite models, both these features are standard.
Flex-Fix integrated bike carrier
                                                                                 Page | 22
A unique feature in the sector is Vauxhall‟s innovative Flex-Fix bike carrier, which will
be available as an option across the new Astra range in the near future.
The system, which is integrated with the car‟s rear bumper, makes transporting bikes
easy and convenient, while eliminating the need to fit a rack on the car‟s tow hitch, or
lift bikes on to a roof rack.
The FlexFix carrier can accommodate up to two bikes and slides out from the rear
bumper like a drawer when a release lever near the boot‟s lip is pulled. Maximum
weight capacity is 40kgs, and it can accept bikes with wheel sizes up to 28 inches. No
fixing tools or special parts are required and, when not in use, FlexFix is pushed back
to stow almost invisibly behind the bumper.
FlexFloor – the moveable boot floor
Vauxhall‟s FlexFloor, available as an option on S and Exclusiv Astras and standard on
all other models, is an adaptable stowage system for a wide range of cargo, from
shopping bags to large boxes.
The boot floor is moveable and can be positioned at three levels by engaging
ergonomically designed fixing channels near each corner of the boot.
In its highest position, FlexFloor brings the height of the boot floor up to bumper level,
making it easy to load and slide in heavy items with minimal effort. In this mode, the
system provides a hidden storage compartment beneath the temporary floor.
With FlexFloor in its middle position, the boot floor aligns with the height of the folded
rear seat backs, providing a flat-bed cargo area. Underneath, a smaller stowage area
is still available for slimmer items, such as clothing and shoes.
In its lowest position, FlexFloor is positioned directly above the boot floor.
The new Astra offers a class-leading choice of infotainment and communications
systems. Audio packages offer four to eight speakers, ranging in power from 80 to 350
Watt‟s. A DAB-enabled radio is available with all trims, apart from S. The complete
range comprises two audio packages and one navigation system:
CD 400 (Standard)

      Radio/CD
      Aux in for MP3/iPod connectivity
      Seven speakers
      Graphic information display
      Graphic equalizer
      Secondary tuner function for areas with poor reception

                                                                                  Page | 23
CDC 400 (in addition to CD400)

      6 CD changer
CD 500 Navi

      Seven premium speakers
      7-inch colour monitor
      Digital travel guide / scroll & zoom functions
      iPod/MP3 ports, with iPod interface offering functions such as track list
      1 GB internal flash memory, allowing individual country maps to be downloaded
      Post code recognition
Infinity Premium Audio

    Superb sound reproduction from auxiliary amplifier
    Seven premium speakers
    Sub-woofer located under boot floor
Hands-free ‘phone system

    Choice of connection via wireless BlueTooth or a universal cradle in the car‟s
     centre console
    Cradle charges „phone and provides enhanced reception through car‟s main
    Voice command facility in addition to steering wheel-mounted controls
    All information shown on main display screen

                                                                              Page | 24
The Astra range comprises five models – S, Exclusiv, SRi, SE and Elite – each of
which comes with high levels of equipment as standard, including ESP, six airbags, air
conditioning, daytime running lights and electric windows.
Complementing the Astra‟s Automatic Forward Lighting, FlexRide and Ergonomic
Sports Seats is a comprehensive list of optional equipment that allows drivers to
personalise their car to a high degree. Highlights include CD500 satellite navigation,
Dual Zone Electronic Climate Control, front and rear parking sensors and a tyre
pressure monitoring system.
High quality begins with the S entry level. The interior features black Cordoba cloth trim
and a raft of standard equipment, including CD400 CD player/stereo radio with MP3
format and aux-in socket, electrically adjustable/heated door mirrors and remote control
central locking. Also included are 16-inch steel wheels with flush covers, a driver‟s seat
height adjuster, 60:40 split rear seat and reach/rake adjustable steering wheel.
Engine                            Insurance
Availability                      Groups (ABI)
                                  20    50
1.4i 16v VVT (100PS)                    3E   9E
1.6i 16v VVT                      4E    12E
1.6i 16v VVT automatic            4E    12E
                                                                                 Page | 25
1.7CDTi 16v (110PS)                       4E     13E
The Exclusiv is available in black Scene cloth trim, and in addition to the S, the interior
features a chrome-bezelled steering wheel and ambient lighting in the centre console
and roof. Cruise control is standard, and the steering wheel incorporates audio
controls. There are supplementary storage areas in the front seat-backs and a covered
storage container in the centre console.
Engine                             Insurance
Availability                       Groups (ABI)
                                   20    50
1.4i 16v VVT (87PS)                      3E   9E
1.4i 16v VVT (100PS)                     3E   9E
1.6i 16v VVT                             4E   12E
1.6i 16v VVT automatic             4E    12E
1.4i 16v VVT Turbo                 7E    17E
1.4i 16v VVT Turbo automatic       7E    17E
1.7CDTi 16v (110PS)                      4E     13E
SRi models ride on 17-inch, 5-spoke alloy wheels, and all apart from the 1.4-litre come
with lowered and uprated sports suspension as standard. SRis interiors are trimmed in
black Lace cloth and feature an electric park brake, sports front seats, a multi-function
computer and front seat armrest. In addition, the SRi has illuminated vanity mirrors, a
three-spoke leather steering wheel and ambient lighting in the front doors. Outside, the
SRi is easily identified by dark-style headlights, front fog lights and a chrome-effect side
window surround. A Flex-Floor luggage compartment and front door sill covers
complete the package.
For those buyers who wish to personalize their SRi further, Vauxhall will be offering a
range of SRi Line models in the near future. This adds 18-inch, 5-twinspoke alloy
wheels, a front lower spoiler, rear lower skirt, rear roof spoiler and side sills to the
standard SRi spec.

Engine                              Insurance
Availability                       Groups (ABI)
                                   20    50
1.4i 16v VVT (100PS)                     4E   9E
1.6i 16v VVT                             5E   12E
1.6i 16v VVT automatic              5E 12E
1.4i 16v VVT Turbo                 8E    17E
1.4i 16v VVT Turbo automatic       8E    17E
                                                                                  Page | 26
1.6i 16v Turbo                           TBA    TBA
1.7CDTi 16v (110PS)                      5E     15E
1.7CDTi 16v (125PS)                      5E     15E
2.0CDTi 16v                       10E    20E
2.0CDTi 16v automatic             10E    20E

Externally SE (and Elite) models are identifiable by their unique 17-inch 10-spoke alloy
wheels. Inside, the cabin is trimmed with Ribbon / Morrocana fabrics and equipped with
rain sensitive windscreen wipers, automatic lighting control with tunnel detection, an
electro-chromatic anti-dazzle rear-view mirror and electric rear windows.

Engine                            Insurance
Availability                      Groups (ABI)
                                  20     50
1.6i 16v VVT                            4E     12E
1.6i 16v VVT automatic            4E     12E
1.4i 16v VVT Turbo                8E    17E
1.4i 16v VVT Turbo automatic      8E    17E
1.6i 16v Turbo                          TBA TBA
1.7CDTi 16v (110PS)                     5E   15E
1.7CDTi 16v (125PS)                     5E   15E
2.0CDTi 16v                       10E 20E
2.0CDTi 16v automatic             10E 20E

The range-topping Astra Elite‟s cabin is trimmed in perforated leather as standard and,
in addition to the equipment found in the SE, comes with Ergonomic Front Seats which
are heated and feature extendable cushions and electric adjustment. Dual-zone
electronic climate control, electrically foldable door mirrors and a fold-down rear-seat
centre armrest are also standard.

Engine                            Insurance
Availability                           Groups (ABI)
                                  20   50
1.6i 16v VVT                           5E   12E
1.6i 16v VVT automatic            5E 12E
                                                                               Page | 27
      1.4i 16v VVT Turbo                               9E         18E
      1.4i 16v VVT Turbo automatic                     9E         18E
      1.7CDTi 16v (125PS)                                         6E          15E
      2.0CDTi 16v                                      10E        20E
      2.0CDTi 16v automatic                            10E        20E


                                                                                Electric folding mirrors      Alarm system
                                                    Alarm system                Alarm system                  Sports chassis
                                                    Front & rear electric       Front & rear electric
                                                    windows                     windows
                                                    Foglamps front              Foglamps front                Foglamps front
                                                    Board Computer and          Board Computer and            Board Computer and Check
                                                    Check Control               Check Control                 Control
                                                    Sight & Light Pack 1        Sight & Light Pack 1
                          Ambient light in centre   Ambient light centre        Ambient light centre          Ambient light centre stack,
                          stack & roof              stack, roof & doors         stack, roof & doors           roof & doors
                          Cruise control            Cruise control              Cruise control                Cruise control
                                                                                Leather sports
Front seats, comfort      Front seats, comfort      Front seats, comfort                                      Sports seats
                                                                                (Ergonomic) seats
Single tone horn          Single tone horn          Dual tone horn              Dual tone horn                Dual tone horn
                                                    Center console with 2       Center console with 2
Center console with 2     Center console with 2     covered cupholders,         covered cupholders,           Center console with 2 covered
cupholders, open          cupholders, open          enclosed storage,           enclosed storage,             cupholders, enclosed storage,
storage tray, manual      storage tray, manual      adjustable armrest,         adjustable armrest,           adjustable armrest, electric
park brake and ashtray    park brake and ashtray    electric park brake, 12V    electric park brake, 12V      park brake, 12V rear power
provision                 provision                 rear power outlet, and      rear power outlet, and        outlet, and ashtray provision
                                                    ashtray provision           ashtray provision
Moulding bodyside         Moulding bodyside
                                                    Moulding beltline chrome    Moulding beltline chrome      Moulding beltline chrome
upper black               upper black
                          Steering Wheel, PU,       Steering Wheel, Leather-    Steering Wheel, Leather-      Steering Wheel, Perforated
Steering Wheel,
                          with bezel decoration     wrap with bezel             wrap with bezel               Leather-wrap with bezel
Polyurethane (PU)
                          CC & IRC                  decoration, CC, and IRC     decoration, CC, and IRC       decoration, CC, and IRC
                                                                                Air conditioning with
Air conditioning with     Air conditioning with     Air conditioning with       particle & odor filter, air
                                                                                                              Air conditioning with particle
particle filter, manual   particle filter, manual   particle filter, manual     quality sensor, humidity
                                                                                                              filter, manual controls
controls                  controls                  controls                    sensor & Dual Zone Auto
16” steel wheels with     16” steel wheels with
                                                    17” 10 spoke alloy wheels   17” 10 spoke alloy wheels     17” 5 spoke alloy wheels
covers                    covers
CD400 with 7              CD400 with 7
                                                    CD400 with 7 speakers,      CD400 with 7 speakers,
speakers, GID (UAG)–      speakers, GID (UAG)–                                                                CD400 with 7 speakers, GID
                                                    GID (UAG)–includes          GID (UAG)–includes
includes radio, CD,       includes radio, CD,                                                                 (UAG)–includes radio, CD,
                                                    radio, CD, MP3, aux-in,     radio, CD, MP3, aux-in,
MP3, aux-in, GID (155     MP3, aux-in, GID (155                                                               MP3, aux-in, GID (155 x 60),
                                                    GID (155 x 60), 7           GID (155 x 60), 7
x 60), 7 speakers, rod    x 60), 7 speakers, rod                                                              7 speakers, rod antenna
                                                    speakers, rod antenna       speakers, rod antenna
antenna                   antenna
Airbags – Front, Driver   Airbags – Front, Driver
                                                    Airbags – Front, Driver &   Airbags – Front, Driver &     Airbags – Front, Driver & Co-
& Co-driver, Side         & Co-driver, Side
                                                    Co-driver, Side Pelvis      Co-driver, Side Pelvis        driver, Side Pelvis Thorax,
Pelvis Thorax, seat-      Pelvis Thorax, seat-
                                                    Thorax, seat-mounted,       Thorax, seat-mounted,         seat-mounted, driver & co-
mounted, driver & co-     mounted, driver & co-
                                                    driver & co-driver          driver & co-driver            driver
driver                    driver
Head Curtain Airbags      Head Curtain Airbags      Head Curtain Airbags        Head Curtain Airbags          Head Curtain Airbags
Seat belt warning         Seat belt warning         Seat belt warning device,   Seat belt warning device,     Seat belt warning device, all
device, all seats         device, all seats         all seats                   all seats                     seats
Headrests, 2-way front,   Headrests, 2-way front,   Headrests, 2-way front,     Headrests, 2-way front,
                                                                                                              Headrests, 2-way front, active
active                    active                    active                      active
Electronic Stability      Electronic Stability      Electronic Stability        Electronic Stability          Electronic Stability Program

                                                                                                                          Page | 28
Program (ESP)         Program (ESP)               Program (ESP)               Program (ESP)               (ESP)
Anti-Lock Braking     Anti-Lock Braking           Anti-Lock Braking System    Anti-Lock Braking System    Anti-Lock Braking System
System (ABS)          System (ABS)                (ABS)                       (ABS)                       (ABS)

         S              Exclusiv                           SE                        Elite                           Sri

              Above list is not definitive and is for representation purposes only.

     Vauxhall Astra: Technical Data Overview

      Astra hatchback
      Petrol engines                                   1.4              1.6           1.4            1.6
                                                      87/100                        TURBO          TURBO

      Emission classification                         Euro 5         Euro 5          Euro 5         Euro 5
      Fuel                                           95 RON         95 RON          95 RON         95 RON
      Number of
      cylinders/Valves per
      cylinder                                           4/4            4/4             4/4              4/4
      Displacement                        in cm³       1398           1598            1364           1598
      Bore                                in mm         73.4           79.0            72.5              79.0
      Stroke                              in mm         82.6           81.5            82.6              81.5
      Max. output                         in PS       87/100           115             140               180
                                          at rpm       6000           6000            4900           5500
      Max. torque                         in Nm         130            155             200               230
                                                                                      1850-          2200-
                                          at rpm       4000           4000            4900           5400
      Compression ratio                               10.5 : 1       10.8 : 1        9.5 : 1        8.8 : 1

                                                                                                                     Page | 29
5-speed manual                     standard standard            -    -
6-speed manual                         -             -   standard standard
6-speed automatic                      -        option    option     -

Astra hatchback
Diesel engines                       1.7      1.7 CDTI 2.0 CDTI

Emission classification            Euro 5      Euro 5    Euro 5
Diesel Particle Filter             standard standard standard

Number of
cylinders/Valves per
cylinder                             4/4        4/4        4/4
Displacement              in cm³    1686       1686       1956
Bore                      in mm     79.0        79.0      83.0
Stroke                    in mm     86.0        86.0      90.4
Max. output               In PS      110        125       160
                          at rpm    3800       4000       4000
Max. torque               in Nm      260        280       350
                          at rpm    1800       2300       1750
Compression ratio                  18.0 : 1   18.0 : 1   16.5 : 1
5-speed manual                        -          -          -
6-speed manual                     standard standard standard
6-speed automatic                     -          -       option

                                                                             Page | 30
Vauxhall Astra hatchback - Performance Data

Driving performance, fuel consumption and emissions
                   Driving performance      Fuel consumption        CO2
                                         according to 1999/100/EU emissions
                  Maximum Acceleration   Urban   Extra-   Combined Combined
                   speed    from 0 –             urban
                             60mph       (mpg)             (mpg)    (mpg)
                   (mph)   (seconds)             (mpg)

1.4 (87PS)          106        13.8       39.2   62.8       51.4     129
1.4 (100PS)         111        13.1       39.2   62.8       51.4     129
1.6 – MT5           118        10.9       34.0   55.4       44.8     147
1.6 – AT6           114        12.5       28.8   50.4       39.8     167
1.4 Turbo –         128         9.0       36.2   58.9       47.9     139
1.4 Turbo - AT6     126         9.4       29.1   51.4       40.4     164
1.6 Turbo - MT6     138         7.9       32.1   50.4       41.5     159

1.7 CDTI            113        11.8       49.6   68.9       60.1     124
(110PS) - MT6
1.7 CDTI            122        10.7       49.6   68.9       60.1     124
(125PS) - MT6
2.0 CDTI            134         8.5       44.1   68.9       57.6     129
(160PS) - MT6
2.0 CDTI            131         8.6       35.8   61.4       48.7     154
(160PS) - AT6

                                                                     Page | 31
All data refer to the European base model with standard equipment. The
consumption data according to 1999/100/EC takes into consideration the vehicle‟s kerb
weight as stipulated by this regulation. Additional equipment can lead to slightly higher
fuel consumption and therefore CO2 exhaust emissions than the declared values. In
addition, they can raise the vehicle‟s kerb weight and in some cases also increase the
gross vehicle weight, the maximum allowable axle loads and respectively reduce the
permitted trailer load. Therefore the maximum speed may be decreased while
acceleration time can be increased. The published performance figures are possible
with the vehicle‟s kerb weight.

Vauxhall Astra : Dimensions & Weights

Vehicle dimensions in mm
Length                                             4419
Width (without/with mirrors)                    1814/2013
Height                                             1510
Wheelbase                                          2685
Track, front                                       1544
Track, rear                                        1558
Turning circle in mm
Wall to wall                                       11.4
Kerb to kerb                                       10.9
Boot dimensions in mm
(according to ECIE)
Length on floor to rear seat back                  836
Length on floor with rear seat back
folded forward                                     1549
Width between wheel housings                       1027
Max. opening width                                 904
Opening height                                     772

                                                                                Page | 32
Boot capacity in litres (according
to ECIE)
Luggage compartment only (up to
cover)                               370
With rear seats backs folded
forward (up to seats backs)          795
With rear seats backs folded
forward (up to ceiling)              1235
Weight and axle loads in kg
(according to 70/156/EU)
Kerb weight incl. driver (base
model)                               1393
Permissible gross vehicle weight     1870
Payload                              497
Permissible axle load, front         960
Permissible axle load, rear          920
Permissible roof load                75
Fuel tank capacity (in litres)       56



                                                         Page | 33
      World-class manufacturing facility producing Britain‟s best selling UK-built car
      New Astra will be tenth major model-line to be built at EP
      Provides employment for more than 2000 people in UK‟s Northwest region

For 46 years, Ellesmere Port has been the manufacturing home of every compact class
Vauxhall sold in the UK, and is now set to become the launch factory for not only the
sixth generation of Astra, but also all Opel versions sold across Europe.

The new Astra is the tenth generation of compact car to be built at Ellesmere. It opened
its lines to the original Vauxhall Viva HA in 1963, and went on to produce a further two
Viva models, the Chevette and then each successive Astra in five door and Astravan

General Motors‟ plan to locate its revolutionary production facility at Ellesmere Port in
1961 was a vital shot in the arm for the economy in England‟s Northwest region. Based
on a 440-acre, ex-RAF station, the plant now employs 2200 people and has, in total,
produced nearly 4.5 million vehicles since that first Viva HA rolled of its lines

Today, the current Vauxhall Astra is the best-selling UK-built car in Britain, and thanks
to Ellesmere Port‟s ultra-modern and efficient infrastructure - which in the last 17 years
has received nearly £1 billion of GM investment - its set to pass on this mantle to the
new Astra.

No surprise, then, that it has a capacity to produce 190,000 vehicles per year on a
three-shift system, equating to 40 cars and vans per hour, or one Astra rolling off the
line approximately every 90 seconds. With its own press, producing 60 panels per hour,
840 robots in Body, and a state-of-the-art paint shop, Ellesmere is one of the most
advanced facilities in the UK, and one which is already being mooted to take on
production of the Ampera, Vauxhall‟s revolutionary E-Rev model set to hit UK
showrooms in early 2012.

Achieving a Green Organisation 4-star status last year, Large Enterprise of the Year at
the Northwest Automotive Alliance Awards and an incredible 18,670,000 days without a
lost work day has galvanised Ellesmere Port‟s position as one of the most successful
car factories in Europe, and one which is in rude health for the future.

The Ellesmere Port roll-call: from Viva HA to Mk 6 Astra in 46 years!
                                                                                 Page | 34
Viva HA

While Vauxhall‟s first foray into the compact family car market came in 1936 with the H-
Type – the world‟s first unitary construction (monocoque) model, it was the launch of
the Viva in 1963 that really saw the Griffin gain momentum in what rapidly became, and
remains, the best-selling sector of the market. Launched in 1963, the Viva was initially
built in Luton, with production transferring to the brand new Ellesmere Port facility the
following year – home to each generation of compact Vauxhall family car ever since.
Light, simple to maintain and neatly styled the HA Viva was just the ticket for motorists
who wanted a no-nonsense, inexpensive family car and its ease-of-maintenance gave
it particular appeal in the days when part of Dad‟s weekly routine was to spend an hour
tinkering on a Sunday! Over 300,000 Viva HAs were sold in a relatively short lifespan of
just three years, although the Bedford Van variant – the HAV – continued well into the
1980s thanks to its fleet appeal.

Viva HB

Whereas the Viva HA‟s appeal lay very much in its simplicity, its successor moved
Vauxhall‟s compact car offering up towards a far more mature and discerning audience.
Gone were the original car‟s simple transverse leaf suspension and narrow track,
replaced by a car that used sophisticated coil springs all round. The styling was also
much more modern – the famous „coke bottle‟ swage line seen in many cars of the era
made its debut on the HB Viva, giving it a look that still appears relatively fresh today. It
was also offered in more body styles than ever before – two and four-door saloons, as
well as a stylish estate. Performance versions included the „Brabham‟ Viva, developed
for GM by the 1966 F1 champion Jack Brabham and sold through his own dealership,
and the even more potent Viva GT with trademark matt black bonnet and the ability to
crack 100mph, making it a firm favourite among the motorsport fraternity. Over half a
million Viva HBs were sold in four years.

Viva HC

The longest production run of any Viva model was enjoyed by the HC, which remained
a stalwart of the Vauxhall range from its introduction in 1970 through till the end of
1979. So advanced was the HB Viva‟s four-link rear and independent front suspension
set-up that it was carried over directly to the HC, along with much of the car‟s structural
and mechanical architecture. Where the HC differed was in its styling, substituting the
curvy HB look with more angular, straight lines. Many styling cues were taken from
Detroit, with the car‟s fluted bonnet resembling that of a contemporary Pontiac, rear

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lamp units reminiscent of a Buick Regal and unusual „wave‟ effect wheelarches, which
gave the car a forward-leaning appearance. The HC also reflected the rapidly growing
fleet market in the UK, with a much broader range of engines and trim levels than ever
before. The two-door and four-door saloons were complemented by an unusual looking
estate, as well as the Firenza – a two-door coupe that squared up to Ford‟s Capri in
this style conscious sector of the market. In 1973, the Magnum appeared, effectively a
renamed version of the larger-engined HC Vivas aimed at more upmarket audience –
the car was pitched as much more of a rival to the Triumph Dolomite than it was to the
Morris Marina, for example. Perhaps the most iconic versions of the HC, despite their
minuscule volumes, were the „Droop Snoot‟ Firenza and Sporthatch models, finished in
Silver Starfire metallic paint and fitted with unusual polyurethane „beak‟ containing triple
headlights. They are by far the most collectable HC variants today.


Launched in 1975 and sold alongside the HC Viva for the first half of its life, the
Chevette featured distinctive „shovel-nosed‟ styling courtesy of Vauxhall‟s then design
boss Wayne Cherry. The aerodynamic look was exclusive to Vauxhall despite the
Chevette being the first ever global GM project. Dubbed T-Car, compact models based
on the Chevette architecture appeared in various markets, as the Chevrolet Chevette in
the States, Holden Gemini in Australia, Isuzu Gemini in Japan and Opel Kadett C in
continental Europe, although they all looked distinctly different. Initially sold only as
Vauxhall‟s first ever hatchback, thus protecting Viva sales, the three-door was joined by
four-door saloon and estate models in late 1976. It was also built as a panel van, the
Chevanne, which was the precursor to today‟s incredibly successful Astravan range. As
well as enjoying success in the showrooms (over 415,000 Chevettes were sold by the
time it was withdrawn in 1984) the short wheelbase and rear-wheel-drive made the car
ideal for rallying, and the rally-tuned HS and HSR versions of the Chevette achieved
some fine results for Vauxhall‟s dealer-backed race team, DTV. The Chevette was
facelifted in 1981, gaining rubber bumpers and a revised dashboard, and it sold
alongside the Astra as a lower-priced entry-level model until the Astra Mk 2 debuted in

Astra Mk 1

By far the most significant of Vauxhall‟s new compact models yet, the 1979 Astra Mk 1
represented a complete transformation for the brand, and also set new standards of
comfort, handling and refinement for its class. The newcomer was the first front-wheel-
                                                                                   Page | 36
drive compact family car from Vauxhall and it rose head-on to the challenge of the VW
Golf, a car that had won over pundits across Europe for its quality, front-wheel-drive
handling and packaging, but which would finally meet its nemesis at the hands of
Vauxhall‟s new offering. The Mk 1 was neatly styled and exceptionally well made,
offering comfort and build quality never before seen in a Vauxhall of this size. It was
also offered in a myriad of bodystyles, including three and five-door hatchbacks, a four-
door saloon, three and five-door estates and a panel van. A new range of OHC engines
and a 1.6-litre diesel (another first for Vauxhall in this area of the market) added further
to the car‟s appeal, especially in the key fleet market. The Mk 1 also saw the birth of
the first Astra GTE, a performance icon that would become one of the best-known hot
hatches of the 1980s. Over half a million MK 1 Astras were sold.

Astra Mk 2

By the mid-1980s, aerodynamic efficiency was very much in vogue, and the Astra Mk 2
certainly didn‟t disappoint. It carried over the platform and powertrains from the first
generation car, but the design team had been set the task of achieving a drag co-
efficient of less than 0.30 – a figure more akin to a sports car than to a family
hatchback. Launched in 1984, the Mk 2 was quite a surprise, featuring such innovation
as flush-fitting guttering and windows, a wraparound bumper and a curvaceous,
windcheating front end that successfully combined handsome looks with the desired
aerodynamic efficiency. The result of the designers‟ efforts was a car that, even today,
doesn‟t look outdated in modern traffic, and which quite deservedly won the 1985
European Car of the Year award. Again, the number of engines and trim levels were
vast, as were the different body styles – although this time the four-door saloon was
sold as a standalone model named Belmont, and there was also a two-door convertible
styled by Bertone. The GTE was once again the iconic figurehead of the range,
especially from 1990 when it gained a new 16v engine, developing 150bhp. Over
600,000 Astra Mk 2s were sold in a seven-year period.
Astra Mk 3

Introduced in 1991, the Astra Mk 3 built further on the success of the Mk2 by adopting
a similarly slippery body shape, albeit taller, wider and longer than the car it replaced in
order to increase passenger space and comfort. The newcomer was 34 per cent stiffer
than the outgoing car, which made for tidy, well-composed handling, while interior
quality and trim levels were also improved in what had become a particularly
competitive area of the market, especially among fleet customers. The car was
launched at the 1991 Frankfurt Motor Show, where it became the first Opel to adopt a
name from Vauxhall – GM‟s continental European arm deciding to drop the established

                                                                                   Page | 37
Kadett moniker after 55 years in favour of that used by the British. As one of the safest
and best-equipped cars in its segment, the Mk 3 was hugely popular with British buyers
and the Mk 3 was never out of the top 10 sellers charts throughout its life – with total
UK sales of over 600,000 when it was finally withdrawn in 1998.

Astra Mk 4

Some of the greatest innovations in motoring aren‟t visible to the naked eye, and in the
case of the Astra Mk 4 its fully-galvanised bodyshell may not have had the showroom
appeal of stacks of standard equipment, but it did ensure that, even today, a Mk 4 Astra
with any signs of rust is a rarely-witnessed sight. This longevity was part of a
programme instigated at the car‟s design stage to deliver a level of quality, integrity and
solidity that buyers had come to expect from more upmarket brands, yet deliver them to
Vauxhall‟s target, mainstream customer – a message that went down especially well
with fleet customers, who lapped up Mk 4 Astras as fast as the Ellesmere Port plant
could produce them. The Mk 4 Astra was a tempting showroom proposition, with
excellent equipment levels, well-sorted dynamics and class-leading performance from
its most popular engine choices. Of particular interest were the Bertone-styled (and
built) coupe and convertible models introduced in 2000, the latter of which had a button
on the keyfob with which you could remotely raise and lower the roof. The Mk 4 was
also the first Astra (and, indeed, the first compact hatchback in the UK) to comply with
the Euro 4 emissions legislation that has become the norm today – all 1.7 CDTi models
from 2002 onwards met the new criteria, proving that GM was ahead of the game when
it came to predicting future trends.

Astra Mk 5

The current Astra replaced the Mk 4 in 2004 and brought with it a new era of stylish
design and driving dynamics, moving the Astra up a gear in terms of its showroom
appeal and winning universal praise at launch for its handsome good looks. Building on
the car‟s visual attributes were a new range of engines including 1.9-litre CDTi diesels,
which offered all the performance of a high-powered petrol engine with none of the
associated running costs. Indeed, the 1.9 CDTi 150 version of the Astra has exactly the
same power output as the Astra Mk 2 GTE 16v – a car renowned for its phenomenal
performance. Following on from the five-door hatch and estate models at launch,
Vauxhall introduced the three-door „Sport Hatch‟ in 2005, combining the appeal of a
coupe and a three-door hatchback in one body style, and introducing such options as
the new „Panoramic‟ windscreen, with a glass area that cut back into the roof to give
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incredible airiness and visibility. A panel van joined the line-up in 2006, along with the
new Astra TwinTop – a hard-roofed coupe that could be turned into an open top at the
push of a button. Like all its predecessors, the Mk 5 Astra has been built from launch at
Ellesmere Port, Cheshire, where 127,962 cars were produced in 2007.

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