Removal, repair and installation of the front suspension strut (Opel Astra G)

Both struts should be replaced simultaneously to maintain the vehicle's stability and handling characteristics. It is also recommended that all threaded fasteners be replaced without fail.

Front suspension strut design

Removal

1. Set the parking brake, jack up the front of the vehicle and place it on stands. Remove the corresponding front wheel.

2. Using an open-end wrench to prevent the pin from turning by the flats, loosen the nut securing the vertical stabilizer bar link. Disconnect the link from the suspension strut.



3. Remove the retainer and release the hose from the support bracket on the stand.



4. Release the brake pad wear sensor wiring from the retainer on the stand models with ABS disconnect the wiring from the wheel sensor.



5. Mark the position of the strut relative to the steering knuckle, unscrew the two bolts (2) securing the strut to the steering knuckle - try to remember the installation position of the bolts. Release the knuckle from the bracket (1) on the strut and place it on a suitable support.



6. Ask an assistant to hold the strut through the wheel arch. In the engine compartment, remove the protective cap of the upper strut support and loosen the upper mounting nut, - hold the shock absorber rod from turning with a second key.



7. Remove the upper support plate from the stand, - zafira models in order to gain access to the nut (2), it will be necessary to remove the plastic deflector installed in front of the windshield.





8. Lower the strut and remove it through the wheel arch.

Repair

To perform this operation you will need a device for compressing coil springs.

1. Clamp the rack assembly in a vice with soft jaws and use a special device to compress the coil spring, completely removing the load from the cups. Ensure that the compression device is securely seated on the spring - follow the instructions in the manufacturer's instructions strictly.



2. Holding the shock absorber rod with a wrench, unscrew the nut.





3. Remove the upper rubber damper, the upper spring cup with bearing, the compression stroke buffer (if provided) and a coil spring (see illustration Front suspension strut design).

4. Inspect the components for mechanical damage, check the smoothness of the shock absorber rod. Replace the failed components.

5. Inspect the shock absorber for signs of developing leaks. Make sure that there are no signs of metal corrosion or mechanical damage along the entire length of the rod. Holding the shock absorber vertically, check its proper functioning, both at full and short (50-100 mm) stroke of the rod. In both cases, the resistance should be soft, even and constant. If signs of malfunction are detected, both shock absorbers should be replaced.

6. Remove the spring compression device and carefully inspect it for signs of deformation and mechanical damage. If necessary, replace both front suspension springs. Springs that have sagged or do not develop the required force must also be replaced.

7. Check the condition of other rack assembly components. Replace any faulty parts.

8. Compress the spring again and install it on the stand, resting its lower end against the stopper.





9. Install the bump stop, upper cup and damper with bearing.

10. Screw on the stem nut and tighten it to the required force, holding the stem from turning with a second key.

11. Slowly release the spring and make sure that both ends of the spring rest against the cup stops. If necessary, adjust the cup positions accordingly, only then completely remove the compression device from the spring.

Installation

Installation is performed in the reverse order of dismantling the components. Please note the following points.

1. Replace the two strut-to-steering knuckle mounting bolts and both upper nuts.

2. Tighten all fasteners to the required torque.

3. Finally, take the car to a specialized workshop to check and adjust the front wheel alignment angles.