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Opel Vauxhall
Opel Vauxhall Astra 1986-1991 Workshop Service Repair Manual
Opel Vauxhall Astra 1986-1991 Workshop Service Repair Manual
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Vehicle data plateRef 149253
- 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
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- Download link opens on the order page immediately
- The same link is emailed to you โ re-download any time
- Open on phone, tablet or PC; print only the pages you need
- Not sure it covers your model year? Ask us before you buy
๐ท๏ธ Basic Information
Identification
Make:
Opel/Vauxhall
Model:
Astra
Generation Code:
Mk2 / T85
Production Years Covered:
1986-1991
Codes
Chassis Code:
T85
๐ Introduction
Market Position
Segment:
Compact family car (C-segment), a strong competitor in the European market.
Competitive Analysis
Key Competitors:
Ford Escort, Volkswagen Golf, Fiat Tipo, Peugeot 309, Renault 19.
Key Features
Design Philosophy:
Known for its practical design, good interior space for its class, and a range of efficient engines. The Mk2 generation brought styling updates and improved aerodynamics.
Vehicle Strengths:
Reliability, fuel efficiency on smaller engines, comfortable ride, good handling for its era, and a reputation for being a solid workhorse.
๐ Manual Details
Coverage Areas
Market Regions:
Primarily European markets (Opel and Vauxhall branding)
Body Styles Covered:
Likely includes Hatchback (3-door, 5-door), Sedan (4-door), and potentially Estate/Caravan variants, common for this generation.
Page Count
Total Pages:
243
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
๐ Manual Coverage
Systems Covered
Engine Mechanical:
Detailed procedures for engine disassembly, assembly, overhaul, including cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing systems (belt/chain).
Engine Management:
Fuel injection systems (Bosch, Lucas), ignition systems, emissions control, sensors, actuators, basic diagnostics and testing.
Cooling System:
Radiator, fan, water pump, thermostat, hoses, coolant types and capacities.
Transmission Manual:
Manual gearbox overhaul, clutch replacement, gear shift mechanism, lubrication.
Transmission Automatic:
If applicable to specific models covered, automatic transmission removal, installation, fluid changes, and basic diagnostics.
Drivetrain:
Front-wheel drive system, driveshafts, CV joints, differential (integrated within gearbox).
Suspension Front:
MacPherson strut system, control arms, anti-roll bar, springs, shock absorbers, steering knuckle, wheel bearing replacement.
Suspension Rear:
Torsion beam axle with trailing arms or independent suspension (depending on specific model), shock absorbers, springs, bushings.
Brakes Front:
Disc brake systems, caliper overhaul, pad replacement, rotor replacement, brake fluid specifications and bleeding procedures.
Steering System:
Rack and pinion steering system, power steering pump, steering column, tie rods, wheel alignment specifications.
Fuel System
Fuel System:
Fuel tank, fuel pump, fuel lines, injectors, carburettor (if applicable to certain engines), fuel pressure testing.
Brakes Rear
Brakes Rear:
Drum brake systems (common on some variants) or disc brake systems, including shoe/pad replacement, drum/rotor machining/replacement, and adjustment.
Electrical System
Charging System:
Alternator testing and replacement, battery specifications, charging system diagnostics.
Starting System:
Starter motor testing and replacement, ignition switch operation.
Lighting System:
Headlights, taillights, interior lighting, bulb types, wiring diagrams for lighting circuits.
Instrument Panel:
Gauges, warning lights, speedometer, tachometer, fuel gauge, sender unit testing and replacement.
Wiring Diagrams:
Comprehensive wiring schematics for various vehicle systems (engine, lighting, ignition, etc.), crucial for troubleshooting.
Bodywork
Body And Frame:
Body panel removal and installation, door mechanisms, hood, trunk, bumpers, glass replacement.
Interior Trim:
Dashboard removal, seat removal, door panel removal, interior trim component installation/replacement.
Hvac
Heating Ventilation Air Conditioning:
Heater core, blower motor, ventilation controls, basic A/C system information (refrigerant types, component identification).
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid level checks and changes, filter replacements, lubrication points, timing belt replacement intervals.
Troubleshooting:
Systematic diagnostic procedures for common malfunctions, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Adjustment:
Procedures for adjusting brakes, clutch, ignition timing, idle speed, wheel alignment, and door latches.
Diagnostics:
Guidance on using diagnostic tools (if applicable), reading fault codes, and interpreting test results.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, including detailed torque specifications and wear limits.
Diagrams And Illustrations:
Includes detailed pictorial diagrams, exploded views, and schematics to guide repairs and component identification.
Special Tools:
References to required special service tools, including their part numbers and usage illustrations where necessary.
๐ Manual Specifications
File Format
Format Details:
PDF format, allowing for easy viewing, zooming, and searching.
Print Quality
Printability:
All pages are printable, enabling users to create hard copies of specific sections or the entire manual.
Binding Type
Binding:
N/A (Digital PDF format, no physical binding)
Paper Type
Paper Quality:
N/A (Digital PDF format, no physical paper)
Software Requirements
Required Software:
Adobe Reader (or compatible PDF viewer)
Compatibility
Operating Systems:
Windows, macOS, Linux OS
โ๏ธ Engine Specifications
Primary Engine
Engine Variants:
The Astra Mk2 featured a range of petrol engines including 1.2L, 1.3L, 1.4L, 1.6L (carbureted and injected), and 1.8L (often with fuel injection). Diesel variants like the 1.7D were also available.
Performance
Horsepower Range:
Approximately 55 HP (1.2L) to 115 HP (1.8L GSI models), with diesel engines typically in the 50-60 HP range.
Torque Range:
Varies significantly by engine, from around 90 Nm to 150+ Nm.
Fuel System
Fuel Delivery:
Carburetion (e.g., Solex, Weber) for lower-end models, and multi-point fuel injection (MPI) for performance variants and later models.
Engine Design
Engine Layout:
Inline-4 cylinder, transverse-mounted.
Block Material:
Cast iron block.
Cylinder Head:
Aluminum alloy cylinder head.
Timing Drive:
Typically a toothed timing belt, requiring regular replacement (e.g., 60,000 km or 4 years).
๐ง Transmission
Standard
Standard Transmission:
5-speed manual transmission.
Optional
Optional Transmission:
3-speed or 4-speed automatic transmission available on some engine variants.
Features
Clutch Type:
Single dry plate clutch.
๐ Dimensions
Exterior
Length:
Varies by body style, generally around 4000-4200 mm.
Width:
Approximately 1650-1700 mm.
Height:
Approximately 1380-1440 mm.
Weights
Curb Weight:
Typically between 950-1150 kg, depending on engine and equipment.
Wheelbase:
Approximately 2550 mm.
Track Width Front:
Approximately 1400-1420 mm.
Track Width Rear:
Approximately 1390-1410 mm.
๐ก๏ธ Safety Features
Ratings
Crash Test Performance:
As per 1980s standards, likely received moderate ratings. Modern safety features were limited.
Active Features
Active Safety:
Four-wheel disc brakes on higher trims, anti-lock braking system (ABS) was an optional extra on some models towards the end of the production run.
Passive Features
Passive Safety:
Seat belts (likely 3-point front, 2-point rear initially), reinforced passenger cell, impact-absorbing steering column.
๐ก Technology Features
Infotainment
Infotainment System:
Basic radio and cassette player systems were common. Features would include AM/FM radio, cassette tape playback, and basic speaker systems. Higher trims might have offered more advanced sound systems.
Driver Assistance
Driver Assistance Features:
Very limited by modern standards. Features like ABS were optional and not widespread. Cruise control was also a rare option on higher-spec models.
Connectivity
Connectivity Options:
N/A. No integrated Bluetooth, USB ports, or smartphone connectivity.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km or 6 months, depending on driving conditions (check manual for specific engine oil type and capacity).
Timing Belt Replacement:
Critical maintenance item, usually around 60,000 km or 4 years. Failure can lead to catastrophic engine damage. The manual will specify exact intervals and part numbers.
Fluid Specifications
Engine Oil Type:
Varies by engine and ambient temperature, often SAE 10W-40 or 15W-40 mineral oil. Synthetic oils were also becoming more common. Manual will list specific API/ACEA classifications.
Coolant Type:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Manual will specify correct type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify exact requirement and replacement interval.
Transmission Fluid Type Manual:
API GL-4 manual transmission gear oil, viscosity typically SAE 75W-90 or 80W-90. Manual will specify exact type and capacity.
Transmission Fluid Type Automatic:
Dexron II or equivalent Automatic Transmission Fluid (ATF). Manual will specify correct type and capacity.
Known Issues
Common Faults:
Rusting (especially wheel arches, sills, and rear suspension mounts), electrical gremlins (faulty grounds, worn wiring), aging plastic components, carburetor issues (on non-injected models), exhaust system corrosion.
Wear And Tear Items:
Clutch wear, brake component wear, suspension bushings, exhaust components, engine mounts.
๐ Vehicle History
Brand Heritage
Opel Vauxhall Legacy:
Opel and Vauxhall have a long history of producing reliable and popular compact cars in Europe, with the Astra (and its predecessor, the Kadett) being a cornerstone of their model lineup.
Model Evolution
Kadett To Astra:
The Astra Mk2 (T85) replaced the highly successful Opel Kadett E. It was the first model to bear the 'Astra' nameplate in many markets, signifying a new era for the brand, though mechanically it was an evolution of the Kadett.
Production
Production Locations:
Primarily manufactured in Germany (Opel) and the UK (Vauxhall), with production also occurring in other European countries through GM's network.
๐ Awards & Recognition
Recognitions
European Car Of The Year:
The Astra Mk2 (T85) itself was not a 'Car of the Year' winner, but its predecessor, the Kadett E, won European Car of the Year in 1985. The Astra inherited much of the Kadett's success and reputation.
Delivery & file format
Delivery & file format
This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.
Check the model year and engine before you buy
Check the model year and engine before you buy
Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.
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Opel Vauxhall Astra 1986-1991 Workshop Service Repair Manual
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