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Opel Vauxhall

Opel Vauxhall Astra 1986-1991 Service Repair Manual

Opel Vauxhall Astra 1986-1991 Service Repair Manual

$16.99
$16.99
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Vehicle data plateRef 173992
Brand
Opel Vauxhall
Vehicle
Cars
Models covered
Astra, Vauxhall
Years
1986, 1987, 1988, 1989, 1990, 1991
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
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🏷️ Basic Information
Identification
Make:
Opel/Vauxhall
Model:
Astra
Generation:
Mk2/F
Model Years Covered:
1986, 1987, 1988, 1989, 1990, 1991
Codes
Chassis Code:
T85
👋 Introduction
Market Position
Market Position:
The Opel/Vauxhall Astra Mk2 (T85) was a significant model for GM Europe, offering a blend of practicality, modern styling (for its time), and competitive pricing. It competed with established players like the Ford Escort, Volkswagen Golf, and Renault 19.
Key Features
Key Features:
Known for its aerodynamic design, front-wheel drive layout, and a range of efficient petrol and diesel engines. Available in hatchback, saloon, and estate body styles, catering to a broad market segment. Featured advanced (for the era) features like fuel injection and electronic engine management on higher trims.
Model Variants:
Available in various body styles including 3-door hatchback, 5-door hatchback, saloon (Belmont), and estate (Caravan), all covered by this comprehensive manual.
Competitive Analysis
Competitive Analysis:
The Astra Mk2 aimed to offer a European alternative to Japanese and American compact cars, often characterized by its German engineering and assembly quality, providing a solid value proposition in its segment.
📋 Manual Details
Coverage Areas
Coverage Areas:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagrams, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection, Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle
Page Count
Page Count:
Hundreds of Pages (Exact count not specified, but indicated as comprehensive)
Manual Type
Manual Type:
Factory Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
Delivery Method:
Speed Download, no expiry dates, complete access to all information.
Completeness
Manual Completeness:
Complete Official Full Factory Service Repair Manual, covering all styles and systems of the specified model years.
Usability
Usability:
Designed for both do-it-yourselfers and experienced mechanics, providing clear, step-by-step instructions with hundreds of photos and illustrations.
Printing Flexibility:
Users can print the entire manual or just the specific pages needed for a particular repair or maintenance task.
File Format
Searchability:
Likely a searchable PDF, allowing users to quickly find specific information by keywords.
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, fuel injection systems (including early electronic injection), fuel delivery, ignition systems, emission controls, cooling system, lubrication system, engine management.
Transmission Systems:
Manual and automatic transmission service, clutch operation and replacement, gearbox repairs, differential and drive axle maintenance.
Chassis Systems:
Brake system diagnostics and repair (including ABS on some models), suspension component service (struts, shocks, bushings), steering system (power steering, tie rods, alignment), wheel bearings, and axle components.
Electrical Systems:
Complete wiring diagrams, lighting systems, ignition system diagnostics, starter and alternator service, instrument cluster, power windows/locks, HVAC controls, and radio systems.
Body And Interior:
Chassis and bodywork repairs, door mechanisms, seat adjustment, interior trim, HVAC (heater and air conditioning), restrains systems (seat belts, potentially early airbags).
Fuel Delivery Systems:
Covers fuel pumps (in-tank or inline), fuel filters, fuel lines, and pressure regulators for both carbureted and fuel-injected systems.
Exhaust Systems:
Details on exhaust manifold, catalytic converter (if fitted), muffler, and pipe replacement, as well as oxygen sensor (Lambda sensor) service.
Emission Controls:
Covers systems like Exhaust Gas Recirculation (EGR), catalytic converters, and Lambda (oxygen) sensors, along with their testing and maintenance for emissions compliance.
Body Panels:
Instructions for removing and installing body panels such as doors, hoods, fenders, and bumpers, including alignment and adjustment.
Heating And Ventilation:
Detailed coverage of the HVAC system, including blower motor, heater core, A/C compressor (if fitted), refrigerant system, and control panel.
Procedures Included
Repair Procedures:
Step-by-step repair instructions for complete disassembly and reassembly of all major components, diagnostic procedures, troubleshooting guides, component testing and adjustment.
Maintenance Procedures:
Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and top-offs, ignition timing adjustments, brake adjustments, lubrication points.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues across all vehicle systems.
Alignment Specifications:
Provides factory specifications for wheel alignment (camber, caster, toe) for optimal tire wear and handling.
Electrical Diagnostics:
In-depth diagnostics for electrical faults, including fuse box layouts, relay testing, sensor readings, and troubleshooting common wiring issues.
Technical Depth
Technical Depth:
Comprehensive, covering basic maintenance to advanced engine and transmission overhauls, detailed electrical diagnostics, and chassis component repair. Suitable for both DIY enthusiasts and professional mechanics.
Illustrations Photos:
Hundreds of photos and illustrations are included to guide the reader through each service and repair procedure, enhancing understanding and accuracy.
Torque Specifications:
Provides detailed torque specifications for critical fasteners across all systems, ensuring proper assembly and preventing component damage.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable (high-quality reproduction of original factory manual content, including photos and illustrations)
Binding Type
Binding Type:
N/A (Digital PDF format, printable)
Paper Type
Paper Type:
N/A (Digital PDF format)
Software Requirements
Software Requirements:
Adobe PDF Reader, Winzip (or equivalent for unzipping files)
Compatibility
Compatibility:
All Versions of Windows, Mac, accessible via web browser on any computer or mobile device.
⚙️ Engine Specifications
Primary Engine
Engine Variants Covered:
The manual covers a range of petrol engines, likely including the 1.2L (12S, 12NV), 1.3L (13SB), 1.4L (14NV, C14NZ), 1.6L (16SV, C16NZ, 18E), and 1.8L/2.0L (20SEH, C20NE) performance engines. It also covers diesel variants (e.g., 1.7L diesel).
Performance
Horsepower Range:
Ranges from approximately 55 hp (1.2L diesel/petrol) to over 115 hp (2.0L GSi variants).
Fuel System
Fuel System Types:
Carbureted (e.g., Pierburg, Solex) and early multi-point fuel injection (MPI) systems (e.g., Bosch LE2-Jetronic, Motronic).
Engine Management
Engine Management System:
Includes diagnosis and repair procedures for early engine control units (ECUs) and sensors, such as Crankshaft Position Sensors (CKP), Camshaft Position Sensors (CMP), Throttle Position Sensors (TPS), and Lambda (O2) sensors.
🔧 Transmission
Standard
Standard Transmission:
Typically a 4-speed or 5-speed manual transmission (e.g., F16, F18, F20).
Optional
Optional Transmission:
3-speed or 4-speed automatic transmission (e.g., THM).
Features
Transmission Fluid:
Specifics for manual (e.g., GM Synchromesh Type A) and automatic transmissions (e.g., Dexron II) are detailed within the manual.
📐 Dimensions
Exterior
Exterior Dimensions:
Varies by body style (3-door/5-door hatchback, saloon, estate). Length typically around 4020-4370 mm, width around 1660-1680 mm, height around 1380-1440 mm. (Specific figures vary by variant and should be confirmed in manual).
Weights
Curb Weight:
Typically ranging from 950 kg to 1150 kg depending on engine and body style.
Interior
Interior Features:
Details on seat adjustment, dashboard layout, interior trim removal/installation, and HVAC system components.
🛡️ Safety Features
Ratings
Safety Ratings:
Euro NCAP ratings were not standardized in the same way as today for this era. The manual would detail the vehicle's construction and safety features relevant to passive safety (e.g., crumple zones, seat belts).
Active Features
Active Safety Features:
Front disc brakes, rear drum brakes (often with optional ABS on higher trims or later models). Power assisted steering available on some variants.
Passive Features
Passive Safety Features:
Three-point front seat belts, two-point rear seat belts (likely three-point on later models), reinforced safety cage, collapsible steering column.
💡 Technology Features
Infotainment
Infotainment Features:
Basic radio systems with AM/FM, cassette player. Speakers were typically 2 or 4. Manual will cover removal and installation of these units.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Features might include power steering (optional), anti-lock braking system (ABS) on some models. Manual will detail operation and maintenance of these.
Connectivity
Connectivity Features:
No significant connectivity features like Bluetooth or USB. Primarily focused on basic vehicle functionality.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000-10,000 miles or 12 months, depending on driving conditions and oil type used. The manual will specify exact intervals for different engines and oils.
Spark Plug Replacement:
Varies by spark plug type (copper vs. platinum). Intervals could range from 15,000 to 30,000 miles. Specific types and intervals will be detailed.
Timing Belt Replacement:
Crucial for interference engines. Intervals typically around 40,000-60,000 miles or 4-5 years. The manual will specify the correct interval and procedure, including idler pulleys and tensioners.
Transmission Fluid Change:
Manual specifies intervals for both manual and automatic transmission fluid changes, typically around 40,000-60,000 miles, depending on transmission type and usage.
Fluid Specifications
Engine Oil Type:
Typically 10W-40 or 15W-40 API SF/SG quality oil for petrol engines. Diesel engines might require specific diesel-rated oils. The manual will provide exact API and viscosity recommendations.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water. Typically a 50/50 mix. The manual will specify the correct coolant type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. The manual will specify the required type and bleeding procedures.
Transmission Fluid Manual:
GL-4 rated gear oil is typically specified for manual transmissions, with specific viscosity (e.g., 75W-90 or 80W-90) depending on temperature. Capacity will be listed.
Transmission Fluid Automatic:
Dexron II or equivalent ATF is commonly specified for GM automatic transmissions of this era. Capacity and change intervals will be detailed.
Power Steering Fluid:
Likely Dexron II or a specific GM power steering fluid. The manual will specify the correct type and procedure for checking and topping up.
Wheel Bearing Grease:
Manual specifies suitable high-temperature wheel bearing grease and replacement procedures.
Known Issues
Common Issues:
Rust formation (especially around wheel arches, sills, and rear hatch), aging electrical components (wiring, relays, sensors), worn suspension bushings, clutch wear, thermostat housing leaks, and potential fuel system issues related to older injectors or carburetors.
Cooling System Issues:
Common issues include radiator leaks, failing water pumps, thermostat failures, and degradation of coolant hoses, all of which are covered in the manual.
Brake System Issues:
Worn brake pads and discs, seized caliper pistons, leaking brake lines, and potential ABS sensor faults on models equipped with ABS. Detailed diagnostic procedures are included.
Engine Performance Issues:
Common issues can include rough idling, misfires due to worn spark plugs or ignition components, and poor fuel economy if fuel injection or carburetor systems are not maintained.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Opel, a German automaker, has a long history of producing reliable and accessible vehicles. Vauxhall is the British counterpart, selling rebadged Opel models. The Astra nameplate replaced the popular Kadett series.
Model Evolution
Model Evolution:
The Mk2 Astra (T85) was introduced in 1984 (as the Kadett E) and sold as the Astra from 1986 in many markets. It represented a significant step forward in design and technology from its predecessor, the Kadett D. It was succeeded by the Astra Mk3 (F) in 1991.
Engine Options Evolution:
The Mk2 Astra offered a broad range of engines, from economical 1.2L units to more powerful 2.0L 16-valve engines in the GSi variants, reflecting the market's demand for diverse performance options.
Production
Production Period:
1984-1993 (Kadett E / Astra Mk2).
Production Locations
Production Locations:
Primarily manufactured in Germany (Rüsselsheim), Belgium, and the UK (Luton) for Vauxhall models.

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