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Vauxhall

Vauxhall Astra 1986-1991 Workshop Service Repair Manual

Vauxhall Astra 1986-1991 Workshop Service Repair Manual

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$16.99
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Vehicle data plateRef 160792
Brand
Vauxhall
Vehicle
Cars
Models covered
Astra
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
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Vauxhall
Model:
Astra
Generation:
Mk2 (T85)
Relevant Years:
1986, 1987, 1988, 1989, 1990, 1991
👋 Introduction
Market Position
Positioning:
A comprehensive resource for owners and technicians to perform repairs and maintenance on the Vauxhall Astra Mk2, mimicking dealer-level information.
Key Features
Completeness:
Strives for accuracy and contains all necessary instructions for any repair.
Benefit To Owner:
Enables owners to be better informed and perform repairs knowledgeably like a professional.
Benefit To Owner
Cost Savings:
Allows for significant cost savings by avoiding dealer labor and overhead.
Target Audience
Audience:
Technicians familiar with general automobile practices and DIY enthusiasts.
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair and overhaul of Vauxhall Astra Mk2 (T85) models
Secondary Coverage:
Proprietary component manufacturer instructions integrated
Page Count
Estimated Page Count:
Difficult to ascertain without the PDF. Typically, these comprehensive manuals range from 500 to 1500+ pages.
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Delivery)
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage including disassembly, assembly, and overhaul of engine components.
Fuel System:
Detailed instructions on fuel injection and carburetor systems, fuel pump, lines, and filters.
Ignition System:
Procedures for ignition timing, distributor, coil, spark plugs, and electronic ignition components.
Lubrication System:
Details on oil pump, oil filter, oil pan, and oil pressure checks.
Exhaust System:
Information on exhaust manifold, catalytic converter, muffler, and pipe replacement.
Electrical System:
Extensive coverage including wiring diagrams, battery, alternator, starter motor, lighting, fuses, and relays.
Body:
Procedures for body repairs, panel replacement, trim, doors, windows, and interior components.
Transmission:
Detailed procedures for manual and automatic transmission overhaul, repair, and fluid services.
Procedures Included
Tune Ups:
Comprehensive tune-up procedures for optimal engine performance.
Maintenance:
Routine maintenance tasks, fluid checks and changes, filter replacements, and inspections.
Removal And Installation:
Step-by-step instructions for removing and installing major components and sub-assemblies.
Disassembly And Assembly:
Detailed procedures for the breakdown and reassembly of all vehicle systems and components.
Technical Depth
Depth:
Full workshop level repair, including complex engine and transmission rebuilds, electrical diagnostics, and bodywork.
Diagnostic Procedures:
Includes diagnostic procedures to follow when trouble occurs.
Special Tools:
Refers to special tools with Vauxhall part numbers and illustrations where required.
📊 Manual Specifications
File Format
Format:
PDF
Delivery:
Fast and free electronic delivery via email
Print Quality
Printable:
Yes
Binding Type
Binding:
Not applicable (Digital PDF)
Paper Type
Paper Type:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine Variants
Engine Options:
Likely covers a range of petrol and diesel engines common in the Astra Mk2. This typically includes 1.2L, 1.3L, 1.4L, 1.6L, 1.8L (petrol) and 1.6L, 1.7L (diesel) variants, including both carburetted and fuel-injected systems. Specific engine codes such as the Family I C16SE, C18XE are probable.
Performance
Horsepower Torque:
Specifications for horsepower and torque for various engine displacements will be detailed. (e.g., 1.6L engines typically produced between 75-90 hp depending on tuning and fuel delivery).
Fuel System
Injection Carburetion:
Details on both Bosch L-Jetronic/Motronic fuel injection systems and Zenith/Pierburg carburetors will be present.
Maintenance
Timing Belt:
Crucial information on timing belt replacement intervals and procedures, which is a critical maintenance item for interference engines.
🔧 Transmission
Standard
Manual Transmission:
Likely covers Getrag or Opel designed 4-speed and 5-speed manual transmissions.
Optional
Automatic Transmission:
May cover the GM TH125 (3T40) 3-speed automatic transmission or similar variants.
Features
Clutch System:
Procedures for clutch inspection, adjustment, and replacement.
📐 Dimensions
Exterior
Body Styles:
Covers hatchback (3-door and 5-door), saloon (4-door), and estate (Caravan) body styles prevalent in the Mk2 generation.
Weights
Curb Weight:
Typical curb weights would range from approximately 950 kg to 1150 kg depending on body style and engine.
Gross Vehicle Weight:
Information on GVW ratings for payload calculations.
🛡️ Safety Features
Passive Features
Seatbelts:
Details on seatbelt maintenance and adjustment.
Structural Integrity:
Implied coverage of body structure for repair, essential for maintaining safety integrity.
Active Features
Brakes:
Comprehensive brake system coverage including disc and drum brake overhaul, hydraulic system bleeding, and parking brake adjustments.
💡 Technology Features
Infotainment
Audio System:
Basic radio and cassette player options were common. Manual covers head unit removal and wiring.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was available as an option on higher trims and later models. Manual will include ABS system diagnostics.
Power Steering:
Power steering was often an option. Manual will detail its operation and repair.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000-9,000 miles or 12 months, depending on driving conditions. Specific recommendation will be in the manual.
Timing Belt Interval:
Crucial interval, often around 40,000-60,000 miles or 4-5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
Likely specifies API SF or SG quality oil, with viscosity grades like 10W-40 or 15W-40. Manual will provide precise grades and capacities.
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid specified.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, viscosity grade to be specified (e.g., 75W-90).
Transmission Fluid Automatic:
GM Dexron II or equivalent automatic transmission fluid.
Known Issues
Rusting:
Common for vehicles of this era, particularly around wheel arches, sills, and door bottoms. Manual provides body repair guidance.
Electrical Gremlins:
Age-related issues with wiring, connectors, and switches can occur. Detailed electrical diagrams are crucial.
Suspension Wear:
Wear in bushings, ball joints, and shock absorbers is typical. Manual covers replacement procedures.
Engine Management:
For fuel-injected models, issues with airflow meters, lambda sensors, and ECU sensors can arise.
📚 Vehicle History
Brand Heritage
Vauxhall Legacy:
Vauxhall, a long-standing British automotive manufacturer, known for producing practical and popular vehicles.
Model Evolution
Astra Mk2:
The Mk2 Astra (T85) was a significant evolution from the Mk1, featuring improved aerodynamics, updated styling, and a wider range of engine options and technologies. It was manufactured from 1984 to 1993, with this manual specifically covering the 1986-1991 period.
Production
Manufacturing Locations:
Primarily manufactured in the UK (Ellesmere Port) and Germany (Rüsselsheim) as the Opel Kadett E.
🏆 Awards & Recognition
Recognitions
European Car Of The Year Nominee:
The Opel Kadett E (which the Vauxhall Astra Mk2 is based on) was a contender for European Car of the Year in 1985, highlighting its contemporary design and engineering.

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

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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