New Opel Astra - Details

Press Release

New Opel Astra

High-Tech and Dynamics in The Compact Class

• Distinctive design sets Astra apart from the competition
• Premiere: IDSPlus adaptive suspension with continuous damping control (CDC)
• Segment-first: Steering-linked AFL headlamp system
• More passenger room, largest trunk in class, high quality and safety

Progressive design and driving dynamics are the outstanding features that distinguish the new five-door Opel Astra. This third-generation of the Opel bestseller will make its sales debut in March. The Astra introduces into the segment the adaptive IDSPlus suspension with Continuous Damping Control (CDC), which was previously reserved for luxury vehicles and for exclusive sports cars. Other technical highlights include the steering-linked AFL (Adaptive Forward Lighting) headlamp system with dynamic curve light - another a first in the segment - newly-developed Infotainment systems, and a broad range of ECOTEC engines (80 - 200 hp), including new TWINPORT gasoline and common rail turbo-diesel units. Passengers in the new five-door Astra have more room compared to the preceding model, and 380 liters of trunk space make it the leader in its class. "The new Astra symbolizes the dynamics and the quality of the Opel brand more than any previous volume model. The Astra also offers advanced technology that meets customer needs, at really fair prices. I'm convinced that the new Astra will make a bold statement in the compact segment," says Opel Chairman and Managing Director, Carl-Peter Forster. Following the debut of the five-door Astra, Opel will introduce a station wagon with longer wheelbase and a performance oriented three-door. The new Astra is offered in five equipment lines and six engine combinations. Despite the increased standard specification, prices are lower than similar previous models. The latest electronic stability program, ESPPlus, head curtain airbags, active head restraints on the front seats, a height and reach-adjustable steering column and heated power mirrors are among the standard features. The new 66 kW (90 hp), 1.4-liter engine with fuel saving TWINPORT technology provides lively and economical performance.

Dynamic design: Clearly different from the competition

The new Astra, with its exciting and dynamic appearance, sets itself apart from its competitors and sends a clear signal within the compact segment. Its well-balanced proportions are the basis for the harmonious, aerodynamic form (Cd: 0.32). Taut surfaces, crisp lines, technically crafted details and distinctive graphic elements underscore Opel's new design language. Measuring 4.25 meters long, 1.75 meters wide, 1.46 meters high, with a 2.61-meter long wheelbase, the dimensions of the five-door Astra are among the most generous in its class. It is about 35 mm higher, 44 mm wider and 139 mm longer than its predecessor. Shoulder room in the front and in the rear, as well as the headroom in the rear, are noticeably increased. The already generous amount of legroom for the Astra's rear passengers has grown by an additional 17 mm. The new Astra also has a lot of space for luggage. In combination with a tire repair kit (available from the summer of 2004) the new Astra offers a class-leading trunk volume of 380 liters (VDA standard). This expands to a maximum of 1300 liters when the rear seat backs are folded down. Intelligent packaging, together with the longer wheelbase, is the key to the Astra's improved roominess.

Interior: High-quality, ergonomic and spacious

Interior design was of great importance during the development of the new Astra, as displayed by the high level of visual and textural quality. The interior forms harmonize perfectly with the car's dynamic exterior. A characteristic styling cue is the crease on the clearly arranged center console, carried over from the hood. Further eye-catching design elements in the Astra cockpit include the three-dimensional instruments and the centrally positioned, easy to read 6.5-inch monitor. The seats feature state-of-the-art ergonomics with enhanced contours, higher lateral supports, longer cushions and optimized adjustment. Particularly agile handling and high levels of active safety were the development objectives for the new Astra's IDS chassis (Interactive Driving System). The suspension features McPherson struts and a subframe at the front, and a patented torsion beam with double-walled, U-shaped profile at the rear. The state-of-the-art design used in the new Astra not only retains all the advantages of a conventional torsion beam axle - such as minimal space requirements, low weight and high camber control - it can also be precisely tuned to the specific requirements of different variants within a model range.

Advanced chassis: Premiere for IDSPlus with electronic adaptive suspension CDC

A completely new dimension of balance between comfort and active safety can be experienced in the new Astra with the optional, adaptive IDSPlus suspension system and electronic Continuous Damping Control (CDC). This integrated chassis control network (ICC), where the control units and sensors of ESPPlus, ABS and CDC communicate constantly via the high-speed CAN (Controller Area Network) data bus system, is making its premiere in the compact segment. With IDSPlus, Astra drivers can activate a special performance mode by pressing the Sport Switch. This selects suspension settings for the enthusiast-driver, adapts the steering and accelerator response and, with automatic and "Easytronic" transmissions, adjusts the shift points higher up the rpm range.

State of the art: New TWINPORT gasoline and common-rail turbo-diesel engines

The new front-wheel drive Astra will be available with five gasoline and three turbo-diesel engines, with displacements from 1.4 to 2.0 liters and power outputs of 59 to 147 kW (80 - 200 hp). The new Astra can reach top speeds of more than 230 km/h and needs less than eight seconds to accelerate from zero to 100 km/h. All engines are state-of-the-art, four-cylinder ECOTEC units with four valves per cylinder, and comply with the Euro 4 exhaust emission limits which do not become mandatory until 2006. The TWINPORT gasoline engines and common rail turbo-diesels are especially pro-environmental, thanks to their low fuel consumption. For example, the combined fuel consumption of the new 1.4 TWINPORT with 66 kW (90 hp) is only 6.3 l/100 km, while that of the 59 kW (80 hp) 1.7 CDTI diesel is even lower at 4.9 l/100 km. Particularly fun-to-drive are the newly developed 2.0-liter turbocharged gasoline engine 125 kW (170 hp), the new 110 kW (150 hp) 1.9 CDTI 'power diesel' with optional diesel particulate filter, and the 200 hp gasoline turbo at the top of the range. These three engines are supplied as standard with a new six-speed manual transmission. In addition, Opel offers a five-speed manual gearbox, an automatic and a further developed version of its "Easytronic" automated manual transmission for the new Astra. "Easytronic" now features as standard a sport mode and HSA (Hill Start Assist), which prevents the car from rolling backwards on a slope. HSA is also available with manual transmissions.

Specification: Comprehensive standard equipment and SAFETEC safety package

In addition to its advanced chassis and engine technology, the new Astra also impresses with its exceptionally extensive standard and safety equipment, including SAFETEC. This comprehensive protection system consists of passive and active safety features such as the highly stable body shell with deformation zones, the IDS chassis with ESPPlus, TCPlus traction control, CBC (Cornering Brake Control) and ABS with brake assistant and four disk brakes. Front and thorax/pelvis side airbags for the driver and front seat passenger, head curtain airbags in the front and for the outer rear seats, active head restraints in the front, lap-and-shoulder seat belts for all passengers, two mountings in the rear for the ISOFIX child's seat system, pedals which automatically release in the event of a frontal collision (PRS, Pedal Release System) and a steering column which can be adjusted for reach and height are all part of the SAFETEC package. Visual and acoustic warning signals remind the driver and front passenger that seat belts should be fastened.

Model range: Five different versions for various customer requirements

With a total of five versions (Astra, Enjoy, Elegance, Sport and Cosmo), each with differing looks and functions, the Astra fulfills the most varied of customer requirements. There are also eight equipment packages and many options tailor-made for individual preferences and requirements. These include leather trim, the steering-linked AFL (Adaptive Forward Lighting) headlamp system with dynamic curve light, bi-xenon headlamps with automatic beam adjustment and cleaning system, TPMS (Tire Pressure Monitoring System), electronic climate control with air quality sensor and automatic air recirculation, and Quickheat. This heating system prevents windows already freed of ice from fogging up again in winter, and it speeds up the interior heating process. There is also a new generation of infotainment systems. The audio and telematic units now available cater for a wide range of customers, from price-conscious radio and cassette listeners to multimedia fans. The systems are in a user-friendly double-DIN format, which means that features such as a telephone and a 6 x CD changer can be directly integrated. With the Twin Audio system passengers in the front and rear of the new Astra can also listen to different music or radio programs. In addition to the already popular voice-based service, Opel's "OnStar" mobility portal now offers server-supported off-board navigation, electronic travel log and an emergency call function with tele-diagnosis.

Quality: More than one billion euro invested in production and employee training

The new generation Astra also fulfills the highest requirements in terms of quality, reliability and durability, thanks to the high production standards and strict quality control at the Astra plants in Antwerp (Belgium), Ellesmere Port (United Kingdom) and Bochum (Germany). Opel has invested more than one billion euro in the modernization of these Astra production facilities and the training of their staff.

Lots of Space Thanks to Intelligent Packaging

• Development target: lots of space for passengers, as little as necessary for technology
• Long wheelbase is basis for spacious interior
• Compact torsion beam rear axle enables low center of gravity and agile handling

The dimensions of the new Opel Astra are among the largest in its segment – 4.25 meters long, 1.75 meters wide, 1.46 meters high and with a 2.61 meter wheelbase, it is 35 millimeters higher, 44 mm wider and 139 mm longer than the previous model. There is a clearly noticeable increase in shoulder room in the front and rear and, in particular, in the amount of headroom in the rear. The already good legroom for the Astra’s rear passengers has been increased by another 17 mm. The new Astra also has a lot of space for luggage: Here again, it is one of the best in its segment with 350 liters cargo volume (VDA standard, with temporary spare). The key reason for the generous amount of space in the Astra interior is, besides its long wheelbase, intelligent packaging. What is packaging exactly? Frank Leopold, Manager, Vehicle Integration and Packaging at Opel’s International Technical Development Center (ITDC), defines the task of his department, “Our job is to optimally divide up the available space between the car’s technical components, its passenger cell and its luggage compartment so that our customers have the maximum benefit possible.� Opel goes against the trend in the compact segment by not giving the new Astra the form of a small van but instead by creating a dynamic compact car with a generous amount of space. This made it a particularly interesting task for Leopold and his 28-member team to find the best packaging solutions. The experts were able to use the 2614 mm long wheelbase as the basis for the Astra’s large interior. The packaging begins with the engines and builds up from there, explains Leopold. When planning, it is not only a matter of considering the space requirement of the engines and transmissions, but their movements in the event of a frontal collision are also taken into consideration. The front bulkhead – separating the engine compartment from the interior – in the Astra and other Opel models is not just a plain wall. It is a complex sheet-metal component with many contours, and thanks to this it can be installed far towards the front. The space gained frees up more room in the interior. In the engine compartment, all components are very closely positioned; a key component in this jigsaw is the large brake booster. This is linked to the brake pedal and may push it only slightly into the interior in the event of a frontal collision. The position of the pedals, according to Leopold, is a central parameter for the packaging; “A man who is 1.90 m tall sits back in a low reclined position in the driver’s seat while a 1.55 m woman sits right at the front in a medium to high position. We must ensure that she can also reach the clutch pedal without difficulty and that she can see at an angle of at least 6.7 degrees over the hood, so the area immediately in front of the vehicle is visible. From this range, we define the area in which we put the hip(H)-point, the pivot between the trunk of the body and the legs, for the front seats.� The H-point describes the position of the person in the car as a starting point for all measurements, such as the distance to the gearshift lever or the pedals. The so-called 50-percentile woman and the 98-percentile man are used as virtual car drivers in development work at Opel, as are more than 50 other individual people-templates. Their measurements are scanned and stored in a program called “Ramsis�. Ramsis is a computer-aided anthropological/mathematical system for passenger simulation. With the help of this high-tech tool, Leopold’s colleagues from the so-called ‘seats group’ are able to simulate all the measurements and operating forces inside the car’s interior on a computer, long before the first prototype is built. Ramsis quickly finds the answer to questions like: “Does the décor strip in the door trim disturb the driver’s knee?� and, therefore, saves on the time-consuming construction of models. “The interior of the new Astra fits like a glove. It provides typical ‘feel-good’ dimensions,� says Leopold. It boasts greater comfort than its predecessor, and not only because it is 30 mm wider. The comparatively upright side windows ensure a pleasant, spacious and airy feeling at eye level. And the slightly raised and greatly lengthened roof contributes to the increase in headroom. Compared to the previous model, there is an additional 10 mm in height and 40 mm more length. The passengers sitting in the rear seat of the new Astra now also have the comfort of two centimeters more shoulder distance. The large rear doors with their special shape mean climbing into the car is simple and there is no risk of banging the back of the head on the C-pillar. They also facilitate the installation of children’s seats. The long windowpanes improve the view for the rear passengers and also the driver’s peripheral vision. The larger rear window and the slightly angled A- and C-pillars also have a positive effect here. On top of these measurable gains in the interior, there are also clever details: The rounded transitions from the cockpit into the door trims, the structure of the center console, the horizontal décor strips, the two optically integrated central ventilation ducts and the flat design of the door handles are all elements which enhance the perception of space. With the dynamic design of the new Astra a significant increase in height was out of the question from the beginning of the packaging plans. “With Agila, Meriva and Zafira we already have three high-roofed vans in our portfolio,� explains Leopold. “The Astra, however, is a particularly dynamic model. For its agile handling we needed a low center of gravity.� The space-saving layout of the rear axle helped here. The improved torsion beam design is so compact that Leopold and his colleagues were able to position the fuel tank deep between the wheels and also place the rear seats in a correspondingly low position. This gives the passengers a feeling of security and lowers the vehicle’s center of gravity further. Another advantage of the compact rear axle: The floor of the trunk is flat, even with a full-size spare wheel/tire (instead of the standard temporary spare).

New Generation Infotainment Systems

Intuitive operation, excellent sound quality and superb communication

• Unique variety: Seven state-of-the-art audio and telematic systems
• Simple and easy: New operating and display concept “Opel Media Portalâ€ÂÂÂ�
• Safe and comfortable: Remote controls on steering wheel and telephone voice control
• First class: Digital Sound Processor (DSP) enables individual audio adaptation
• Industry first: OnStar* mobility service offers vehicle-integrated off-board navigation

The new generation of infotainment systems launched in the new Opel Astra sets operation and functionality standards in the compact car class and beyond. In addition to the uniquely broad range of functions, the particular highlight of this audio and telematic program is the newly developed operating and display concept “Opel Media Portal�. The perfect look and feel of integration into the Astra cockpit enhances its intuitive operation and clearly structured, easy-to-read display. The large – up to 6.5 inch – monitor, mounted high on the instrument panel, is optimally placed in the driver’s line of vision. The new generation of infotainment systems in practical double-DIN format will also be available in other Opel models as of this fall. Thanks to the standard Digital Sound Processor (DSP), the systems can be acoustically tuned to every different car body. The infotainment range encompasses seven systems (see summary on bottom of page), including models with digital radio reception in CD quality, CD-player with MP3 compatibility, navigation (on and off-board) or integrated mobile telephone including internet access. All systems are designed in double-DIN panel format, enabling direct integration of features such as a mobile telephone and 6 x CD changer. Varnished surfaces give the center of the cockpit the look of high-end stereo systems. An identical, ergonomically optimal layout with four buttons circling a central operating knob simplifies operation and ensures a clear, uniform appearance. Alternatively the control units can be operated via remote controls on the steering wheel, consisting of two scroll buttons with turn or turn/push functions next to four other buttons, or by voice commands. All systems have an audio output of 4 x 20 watt (CDC 40 Opera: 3 x 20 watt plus 2 x 45 watt), speed-dependent volume and bass control, and RDS (Radio Data System) with integrated EON function (Enhanced Other Networks). This allows traffic announcements to come through even when the selected station does not broadcast any traffic updates. Program-type identification (PTY) is a standard feature and searches for stations according to program type e.g news, sport or pop, provided this function is supported by the RDS-stations. The CD 70 Navi and CDC 40 Opera boast special technical extras. Both have a second tuner (double tuner concept), eliminating switchover delays when the system automatically tunes to the same broadcast on another frequency. The top-of-the-range CDC 40 Opera can be equipped with Digital Audio Broadcasting (DAB) reception upon request. Digital broadcasting technology enables interference-free radio reception with CD quality and the digital display of various information, e.g. song titles, artists or traffic updates Internet access via WAP (Wireless Application Protocol) is available with systems including integrated mobile telephones and enables the posting and receipt of short messages (SMS – Short Message Service), while E-Mails can be sent and received over the multimedia devices CD 60 MMedia and CDC 80 MMedia. Joining this new generation is also MP3-technology (Motion Pictures Experts Group Audio Layer 3), which enables space-saving storage of audio files without loss of sound quality. Thanks to its intense compression, instead of 70 minutes 10 hours of music can be saved on a single CD-ROM. All audio devices in the new Astra equipped with a CD-player (except for the CDC 40 Opera) are MP3-compatible. With the Twin Audio System, first seen in Opel’s Meriva and Signum models, rear seat passengers in the Astra can enjoy their own choice of music or radio program over headsets, while the driver or front seat passenger can listen to a different CD or radio program simultaneously.

OnStar: World´s first fully integrated off-board navigation and e-logbook

Opel’s mobility portal OnStar (currently available only in Germany), with its numerous new functions, is a versatile and practical travel companion. In addition to voice services, in which OnStar personnel answer drivers’ calls from a computer-aided workstation, other features will be available from early summer 2004. These include as an industry-first server-supported and fully vehicle-integrated off-board navigation and electronic logbook (e-logbook). OnStar additionally offers online automobile breakdown service with remote diagnosis for the most important automobile functions. The units CD 60 MMedia and CDC MMedia featuring GPS (Global Positioning System) and a gyroscope for independent positioning can be equipped with an automatic emergency call function.

Consistently high acoustic quality: Sophisticated audio adjustment via sound processor

The audio quality of these new devices is superb. Thanks to dynamic bandwidth control, which effectively suppresses interference from neighboring stations, radio-mode reception is first-rate in all of the audio systems. In models with a CD player, a central loudspeaker delivers spatial sound with a “stage effect�. To ensure the same sound quality in every Astra version, the interiors of all body variants are acoustically measured to determine the standard Digital Sound Processor (DSP) settings accordingly at the factory. Normally the sound of audio devices varies from car body to car body – due to its larger resonance capacity, a station wagon, for example, has a different frequency response than a hatchback model. Opel’s audio experts were able to offset all of these differences and produce identical sound characteristics on a consistently high level, rivaling that of home stereo systems. After technicians defined the desired acoustic range, the audio device in the different models created a standardized signal. Using a microphone placed by the drivers’ ears, model-specific frequency responses were determined and aligned by programming the Digital Sound Processor (DSP) accordingly. At the end of production, the audio device needs to be “told� which model it will be fitted into before installation in the vehicle. The owner can choose a DSP setup for specific music categories, for example classical, pop or jazz. The top-of-the-line CDC 40 Opera allows even more precise personal settings with its seven-channel graphic equalizer for driver and passengers. In addition, sound can be optimized specifically for driver or front seat passenger via the “surround sound� function.

Intuitive and easy: New operating and display concept

The new generation of infotainment systems boasts an innovative operating and display concept called “Opel Media Portal�, premiered in the new Astra. Thanks to its operating simplicity this sophisticated dialog system contributes considerably to active safety, as the driver intuitively operates it and is not distracted from the road. The fact that the “Opel Media Portal� sets ergonomic standards well beyond those usually found in the compact segment was already highlighted during its development phase. A survey with approximately 80 drivers showed that they found the system to be the most user-friendly in comparison to two other systems already on the market. The most important components are the large screen display and a central, easy-to-reach operating element in the middle of the radio panel, the so-called turn/push button. Those who choose the multi-functional steering wheel have a button on the left spoke with an easy-grip operating element that has exactly the same function. With this button, the driver selects settings in the various screen menus from the areas communication, navigation and entertainment. All menus can also be operated over separate buttons located on the central console. Both the monochrome (graphic info display, standard for the CD 50 phone and above) and color display (color info display, optional for CDC 40 Opera and CD 70 Navi), with their 4.2 and 6.5 inch (10.7 and 16.5 cm) screens, display the data “large and clear�. With the exception of the map display, the monochrome version has the same range of functions as the color screen. So that it only takes a quick glance at the monitor to get information, the Opel “man and machine� interface specialists decided on large typeface and a limited amount of data on each screen page. The same thought and consideration went into other details of the operating system, such as:

• The preview concept: The right side of the screen shows comments, explanations or displays the next page.
• The menu level indicator: Bars on the side indicate which sub-menu the user is in.
• The return function: The pages have uniform layout; at the top of the screen the user can return to the previous screen display, the cursor at the bottom takes the user back to the main menu.
• The pop-up windows: Large windows on the screen display information such as the selected air conditioning temperature. If these figures are not changed, the windows close after five seconds.

The perfect co-pilot: Telephone units listen and read out loud – dialing obsolete

The Opel Astra not only obeys its owner at the push of a button, but also at the sound of his or her voice. All infotainment systems with telephones (CD 50 Phone, CD 60 MMedia, CDC 80 MMedia) have the “Voice Control� function as a standard feature – a debut for the Opel brand and available as of early summer 2004. The voice recognition function is easily activated by the driver at the push of a button on the steering wheel, and the microphone is conveniently located near the driver’s head next to the interior light. Dialing telephone numbers is now a thing of the past – voice commands activate both dialing and retrieval of telephone book entries. The speed dialing function, where up to ten names can be programmed (so-called “Voice Tags�) as words combined with a phone number, is particularly convenient. Anyone using this function simply has to say the name of the person they want to call, and the intelligent telephone takes care of the rest. Easy use and safety in road traffic are just two of the advantages of the “Text-to-Speech� function in CD 60 MMedia and CDC 80 MMedia, which read out E-Mails and SMS-Messages (Short Message Service) to the Astra driver. The voice delivery is based on a complex software algorithm, which first breaks down the texts into so-called phonemes – the smallest meaningful elements of a word – and then reproduces these in form of synthesized speech.

Extensive tests: Interference-free radio enjoyment – even in tunnels and mountains

Weak radio signals, rough road surfaces, or a hot interior – infotainment devices in cars do not have it easy. To ensure optimal sound and mobile communication under all conditions, all of Opel’s audio, navigation and telematic components undergo exhaustive testing both in laboratories and in real road traffic. Radios, for instance, have to demonstrate their reception performance on two demanding test routes long before production. One of the routes takes Opel’s engineers and vehicles to southern Europe, where numerous tunnels and the Alps pose a real challenge to radio reception. The second “proving ground� is located in Great Britain, as British radio stations work with a different modulation process than continental Europe. Having interference-free radio reception under these technical conditions is not only important for customers of Opel’s sister brand Vauxhall, but also for all Opel owners visiting England by car. Further practical testing procedures assess the navigation systems (How long does it take to calculate the route? What is the quality of directions?) and the mobile phone devices (How fast does domestic and international roaming – the handoff from radio cell to radio cell – work?). Ultimately, their electromagnetic compatibility with all the other electronic components in the vehicle is guaranteed by extensive EMC tests.

Overview: All infotainment systems in new Opel Astra and their functions

*OnStar: Only available in Germany Information concerning specifications and equipment applies to the models offered in Germany. There may be differences in other markets. Subject to alteration.

Premiere for Integrated Chassis Control

• State-of-the-art, adaptive suspension technology offers enhanced active safety
• Continuous Damping Control (CDC) available for first time in compact segment
• Push-button â€ÂÂÂ�Sportâ€ÂÂÂ�-mode activates high-performance driving characteristics

The new Opel Astra not only brings a dynamic look to compact cars, the agile suspension also delivers the promise of the progressive design. With the optional IDSPlus (Interactive Driving System) adaptive chassis system, the third generation Astra opens a new dimension of suspension performance with an optimum balance of driving comfort and active safety. Opel´s new compact is the first car in its segment with an integrated chassis control network. In addition to ABS and ESPPlus, the network also includes CDC (Continuous Damping Control), which is a major component of the IDSPlus system. This is the first time that CDC, usually reserved for luxury or exclusive sports cars, has become available to so many customers, underlining Opel’s philosophy of offering advanced, yet practical engineering in popular market segments. For the first time Astra drivers can activate a special sport mode at the touch of a button. This selects suspension settings for the enthusiast-driver, adapts the steering and accelerator response and, with automatic and Easytronic transmissions, adjusts the shift points higher up the rpm range.

Front Suspension: Numerous Improvements to Proven Concept

Impressive agility and a high level of safety were the development objectives for the new Astra’s IDS suspension. With a wheelbase of 2614 mm it features further developed McPherson struts with lateral control arms attached to a hydroformed subframe at the front. The new strut mounts are decoupled, effectively reducing noise and vibration, and for improved response, the banana-shaped coil springs provide enhanced compensation of the lateral forces acting on the shock-absorber piston. In order to achieve equally good ride-comfort for all engine variants, the spring-rates are adapted to the front axle-load in 30-kg-steps. The weight-dependent spring rates allow an almost constant ride-frequency of the front axle across the whole engine range – from the 1.4 TWINPORT to the 2.0 turbo or the 1.9 CDTI – despite up to 200 kg variation in axle-load. Flexible manufacture of the new steering knuckle allows a greater difference in tread-angle for improved steering response, contact with the road and self-centering. Thanks to the new production method, Opel can offer two lengths of steering arms. A more direct steering ratio (14:1 instead of 15:1) is thus available for the Astra with sport-chassis and 15-mm lower body. The fuel saving electro-hydraulic power-steering (EHPS) is map controlled. The most important parameters are vehicle speed and steering input, the optimum power assistance for every driving condition is provided. By selecting the optional sport-mode, the steering map is shifted towards �direct� at the push of a button.

Rear Suspension: Multiple Variations of Torsion Beam Design

At the rear the new Astra features a specifically adapted torsion beam with double-walled, U-shaped profile at the rear. In the new Astra this design combines all the advantages of a conventional torsion beam axle – such as minimum space requirements – with low weight and consistent camber control. It can also be precisely tuned to the specific requirements of different versions within the model range. The major difference to other torsion beam designs is the patented �magnetic-arc� welding process used to attach the beam with the control arms. This production-technology makes possible different thickness of the torsion beam (anti-roll bar effect) and different attachment angles between the beam and the trailing arm (self-steering control). The advantage is the adjustment of roll-rate and roll-steer to individual engines, vehicle weights and body styles (e.g. station wagon with high payload), and electronic systems like ESP. This adaptability is used comprehensively in the Astra. Additional benefits include improved stance and more interior space from the wider tread (up to 32 mm), and improved noise and vibration attenuation from the larger (70 mm) bushings. Intensive development of the beam’s twisting characteristics also led to further improved driving stability as well as more agile self-steering. The space-saving layout of the rear axle also helped the engineers to achieve a low center of gravity for high agility. Thanks to the compact design, the fuel tank fits between the wheels, enabling lower positioning of the seats.

Premiere: IDSPlus Chassis System for Integrated Active Safety

A completely new dimension of ride-quality can be experienced in the new Opel Astra with the optional, adaptive IDSPlus suspension system including electronic Continuous Damping Control (CDC) and an integrated chassis control network (ICC). The basis for the networked communication of the various control units is a new electronic architecture with three CANBUS (Controler Area Network) systems, where the high-speed data bus (500 kbit per second, or eight times faster than ISDN – 64 kbit/s) is used for the particularly sensitive powertrain and chassis controls. The CDC-system in the new Astra comprises four hydraulic shock absorbers, that continuously adapt to the vehicle condition, the road surface and the driving style. The goal is to keep the body calm by permanently minimizing its rolling, dipping or vertical movements. Together with a lateral acceleration sensor and additional data from the CANBUS (e.g. brake and vehicle-speed signals), three body and two wheel acceleration sensors deliver all the information required for the best possible damping to the electronic control unit. Using a map, this calculates in real time the necessary damping force for each wheel and sends the corresponding electrical signal to the four proportional solenoid valves, which control the oil flow and the damping characteristic of each damper. Each wheel receives in milliseconds the optimum damping force, thus improving the handling and increasing active safety. The Opel engineers achieved another significant safety benefit through the electronic integration of CDC, ABS and ESPPlus. When cornering at higher speeds, ESPPlus increases stability in two stages: first, when the new Astra nears the ESP-limit, the system adjusts the damper forces at each wheel. Then, if necessary, ESP applies the brakes at one or more wheels in order to bring the car back under control. The result is later and significantly more sensitive ESP-activation. Under braking the shock absorber settings adapt to the road surface for optimum ABS-control, which leads to improved braking characteristics, especially on bumpy roads. Firmer settings on the front axle also reduce the dipping movement at the front of the vehicle. In total, IDSPlus with CDC and integrated chassis control makes the new Astra very dynamic to drive, with good ride comfort as well as a high level of active safety. A 15-inch (16-inch with more powerful engines) brake system with disks all round delivers strong deceleration in all driving situations. In the event of emergency braking – signaled by hard and fast pressing of the brake pedal – a dual-rate brake booster immediately increases the brake pressure, thus shortening the braking distance.

Agile: Sport set-up by the touch of a button

Additionally, with the IDSPlus system, the Astra driver can switch to a firmer, more agile sport mode at the touch of the SportSwitch in the cockpit; this regulates the damping characteristics, accelerator response and the characteristics of the electro-hydraulic steering. With automatic transmission or Easytronic, the shift points are raised to higher rpm levels, for a sportier driving style. For special requirements the latest generation ESPPlus can be deactivated. Opel engineers have improved the efficiency of ESPPlus and ABS by the intelligent networking of sensors and controlling programs, and added a series of further functions, including:

• Understeer Control Logic (UCL): If understeer occurs, road speed is first reduced by closing the throttle and secondly by braking both front wheels. If the ESP control range is reached, braking pressure at the outer front wheel is decreased and built up in parallel at the inner rear wheel until the car follows the chosen course again.
• Hill-Start Assistant (HSA): The systems enables comfortable drive-off on uphill gradients, rolling back does not have to be avoided by using the handbrake. After releasing the brake pedal, pressure in the system is maintained for 1.5 seconds, giving the driver enough time to select a gear and squeeze the accelerator. As soon as the car starts to travel forward, brake pressure is released.
• Trailer Stability Program (TSP): This system monitors the yaw movements of the car-trailer combination. If the limit is exceeded, the car and trailer are slowed by closing the throttle and applying the brakes, until stability returns.
• Deflation Detection System (DDS): With the aid of signals from the wheel speed sensors, a warning lamp tells the driver if tire pressure has been lost. The system detects the probable loss of pressure by identifying a drop in the tire’s circumference as a higher rotational speed in relation to the other wheels. The warning signal is triggered off if the pressure loss reaches about 30 percent.

Another system that makes an important contribution to active safety is the Tire Pressure Monitoring System (TPMS), the world’s first to integrate the DDS function. TPMS detects deviations of up to 0.1 bar from the correct tire pressure using special sensors on each wheel. The signals come in to a central receiver in the passenger compartment and actual pressure is shown on the on-board computer display in the cockpit. If it drops below a given figure, the driver is warned. Since the DDS system needs no special tire sensors, it complements the tire pressure control system effectively, for instance if winter tires without TPMS sensors are fitted. Commenting on the new Astra’s sophisticated chassis and active safety systems, Hans Demant, Opel’s Executive Director of Engineering says: �Many of these features from the luxury and sports car segments are appearing for the first time on a car in this class. Apart from emphasizing the new Astra’s outstanding dynamics, they also demonstrate our technological leadership in an automobile market segment where many customers can benefit from them.