service SATURN ASTRA 2009 Repair Manual

Rear disc brake pads do not have
built-in brake pad wear indicators.
Periodic visual inspection of the rear
brake pads is required to determine
when to replace the pads. Visually
inspect the rear brake pads
whenever the rear wheels are
removed such as during tire rotation.
1. Set the parking brake and make
sure that the brakes have been
given enough time to cool.
2. Remove the rear wheels.
3. Visually inspect the rear brake
inner pads (C) at each rear
wheel through the inspection
window in the brake caliper (A).Brake pads should be replaced
when the inner pad (C) is
worn to 5/64 in (2 mm) of pad
thickness (B). New brake pads,
with no wear, are 25/64 of
an inch (10 mm) thick.
4. After brake pad inspection or
replacement, install the rear
wheels.
Some driving conditions or climates
can cause a brake squeal when
the brakes are rst applied or
lightly applied. This does not mean
something is wrong with the brakes.Properly torqued wheel bolts are
necessary to help prevent brake
pulsation. When tires are rotated,
inspect brake pads for wear
and evenly tighten wheel bolts in
the proper sequence to torque
specications inCapacities
and Specifications on page 10-2.
Brake linings should always
be replaced as complete axle sets.
Brake Pedal Travel
See your dealer/retailer if the brake
pedal does not return to normal
height, or if there is a rapid increase
in pedal travel. This could be a
sign that brake service might
be required.
Brake Adjustment
Every brake stop, the disc brakes
adjust for wear.
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Replacing Brake System Parts
The braking system on a vehicle
is complex. Its many parts have to
be of top quality and work well
together if the vehicle is to have
really good braking. The vehicle was
designed and tested with top-quality
brake parts. When parts of the
braking system are replaced — for
example, when the brake linings
wear down and new ones are
installed — be sure to get new
approved replacement parts. If this
is not done, the brakes might not
work properly. For example,
if someone puts in brake linings
that are wrong for the vehicle, the
balance between the front and
rear brakes can change — for the
worse. The braking performance
expected can change in many other
ways if the wrong replacement
brake parts are installed.
Battery
This vehicle has a maintenance free
battery. When it is time for a new
battery, see your dealer/retailer
for one that has the replacement
number shown on the original
battery’s label. SeeEngine
Compartment Overview on page 9-6
for battery location.
Warning:Battery posts, terminals,
and related accessories contain
lead and lead compounds,
chemicals known to the State of
California to cause cancer and
reproductive harm. Wash hands
after handling.
Vehicle Storage
{CAUTION
Batteries have acid that can burn
you and gas that can explode.
You can be badly hurt if you are
not careful. SeeJump Starting
on page 9-69for tips on
working around a battery without
getting hurt.
Infrequent Usage: If the vehicle is
driven infrequently, remove the
black, negative (−) cable from the
battery. This helps keep the battery
from running down.
Extended Storage: For extended
storage of the vehicle, remove
the black, negative (−) cable from
the battery or use a battery
trickle charger. This helps maintain
the charge of the battery over
an extended period of time.
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Headlamp Aiming
The optical headlamp aiming system
has been preset at the factory and
should need no further adjustment.
However, If the vehicle is damaged
in a crash, the headlamp aim may be
affected and adjustment may be
necessary.
If oncoming vehicles ash their high
beams at you, this may also mean
the vertical aim needs to be adjusted.
It is recommended that the vehicle
is taken to your dealer/retailer for
service if the headlamps need to be
re-aimed. It is possible however,
to re-aim the headlamps as
described.The vehicle should:Be placed so the headlamps
are 25 ft. (7.6 m) from a light
colored wall.
Have all four tires on a perfectly
level surface which is level all
the way to the wall.
Be placed so it is perpendicular
to the wall.
Not have any snow, ice, or
mudonit.
Be fully assembled and all other
work stopped while headlamp
aiming is being done.
Have a full tank of fuel and
one person or 160 lbs (75 kg)
on the driver seat.
Have all tires properly inated.
Headlamp aiming is done with
the vehicle’s low-beam headlamps.
The high-beam headlamps will
be correctly aimed if the low-beam
headlamps are aimed properly.To adjust the vertical aim on the
headlamps:
1. Open the hood. SeeHood
Release on page 9-5for
more information.
2. Locate the aim dot on the lens of
the low-beam headlamp.
3. Record the distance from the
ground to the aim dot on the
low-beam headlamp.
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4. At a wall, measure from the
ground upward (A) to the
recorded distance from Step 3
and mark it.
5. Draw or tape a horizontal line (B)
on the wall the width of the
vehicle at the height of the mark
in Step 4.Notice:Do not cover a headlamp
to improve beam cut-off when
aiming. Covering a headlamp may
cause excessive heat build-up
which may cause damage to the
headlamp.
6. Turn on the low-beam headlamps
and place a piece of cardboard
or equivalent in front of the
headlamp not being adjusted.
Do not place it directly on
the headlamp. This allows only
the beam of light from the
headlamp being adjusted to be
seen on the at surface.7. Locate the vertical headlamp
aiming screws, which are
under the hood near each
headlamp assembly.
The adjustment screw can be
turned with a 6 mm socket
wrench.
8. Turn the vertical aiming screw
until the headlamp beam is
aimed to the horizontal
tape line. Turn it clockwise or
counterclockwise to raise
or lower the angle of the beam.
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9. Make sure that the light from
the headlamp is positioned
at the bottom edge of the
horizontal tape line. The lamp
on the left (A) shows the correct
headlamp aim. The lamp on the
right (B) shows the incorrect
headlamp aim.
10. Repeat Steps 7 through 9 for
the opposite headlamp.
Bulb Replacement
For the proper type of replacement
bulbs, seeReplacement Bulbs
on page 9-34.
For any bulb changing procedure
not listed in this section, contact
your dealer/retailer.
Halogen Bulbs
{CAUTION
Halogen bulbs have pressurized
gas inside and can burst if you
drop or scratch the bulb. You or
others could be injured. Be sure
to read and follow the instructions
on the bulb package.
Front Turn Signal Lamps
1. The bulbs of the turn signal lamp
are replaced through openings in
the front wheel wells. Turn the
wheel to gain access to the push
tabs and remove the cover.
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2. Turn the bulb socket
counterclockwise and pull
straight out.
3. Turn bulb counterclockwise
and remove.
4. Install new bulb.
5. Reverse Steps 2 through 4 to
reinstall.
Center High-Mounted
Stoplamp (CHMSL)
1. Open the liftgate. See “Liftgate”
for more information.
2. Remove the two pins in the
tailgate trim.3. Remove the tailgate trim.
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4. Unlock the six Center
High-Mounted Stoplamp
(CHMSL) clips.
5. Remove the CHMSL from the
top of the tailgate.
6. Reverse Steps 1 through 3 to
reinstall the lamp assembly.
Taillamps
(Five-Door Hatchback)
A. Backup Lamp
B. Taillamp
C. Taillamp/Stoplamp/Turn
Signal Lamp
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To replace one of these bulbs:
1. Open the liftgate.
2. To replace the bulbs on the
driver side, turn both locks
and remove the cover.
To replace the bulbs on the
passenger side, turn the
lock clockwise and remove
the cover.
3. Detach the plug connector from
the bulb assembly.4. Turn the nuts counterclockwise
and hold the outside of taillamp
assembly.
5. Pull the taillamp assembly
straight out.
6. Remove the three nuts.
7. Press on the tabs on the outside
of bulb assembly and remove the
bulb assembly.
8. Remove the bulb from the bulb
assembly.9. Install a new bulb without
touching the glass.
10. Reinstall the bulb assembly in
taillamp assembly.
11. Make sure the seals are applied
to the taillamp assembly and
screws.
12. Insert the taillamp assembly
into the body.
13. Reinstall the three nuts.
14. Attach the plug connector to the
bulb assembly.
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Taillamps
(Three-Door Hatchback)
A. Backup Lamp
B. Taillamp
C. Taillamp/Stoplamp/Turn
Signal LampTo replace one of these bulbs:
1. Open the liftgate. SeeLiftgate on
page 2-6for more information.
2. Detach the plug connector from
the bulb assembly.
3. Turn the nuts counterclockwise
and hold the outside of taillamp
assembly.
4. Pull the taillamp assembly
straight out.5. Remove the seal.
6. Press on the tabs on outside of
bulb assembly and remove the
bulb assembly.
7. Remove the bulb from the bulb
assembly.
8. Install a new bulb without
touching the glass.
9. Reinstall the bulb assembly in
taillamp assembly.
10. Make sure the seals are applied
to the taillamp assembly and
screws.
11. Insert the taillamp assembly
into the body.
12. Reinstall the three nuts.
13. Attach the plug connector to the
bulb assembly.
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License Plate Lamp
To replace one of these bulbs:
1. Push tab in and pull down on it to
remove the license plate lamp.2. Turn and pull the license plate
lamp toward you through the
opening.3. Turn the bulb socket
counterclockwise and pull the
bulb straight out of the socket.
4. Install the new bulb.
5. Reverse Steps 1 through 3 to
reinstall the license plate lamp.
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