Vauxhall Astra 1984-1991 Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Vauxhall Model: Astra Generation Generation Code: Mk II / T-Car platform Codes Chassis Codes: Astra Mk II (Kadett E basis) 👋 Introduction Market Position Market Segment: Compact/Small Family Car Competitive Analysis Competitors: Ford Escort, Volkswagen Golf, Peugeot 309, Fiat Uno, Renault 9/11 Key Features Platform: Based on the Opel Kadett E, known for its aerodynamic design and efficient packaging. Body Styles: Hatchback (3-door and 5-door), Saloon (4-door), Estate/Caravan (5-door), Convertible, and Van variants. 📋 Manual Details Coverage Areas Covered Years: 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Page Count Page Count: 243 Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Compatibility Operating Systems: Compatible with Windows, Mac, and Linux OS. Requirement Software Requirement: Adobe Reader or compatible PDF viewer. Delivery Delivery Method: Instant Download after payment confirmation. 📖 Manual Coverage Systems Covered Engine: Engine removal/installation, disassembly/assembly, diagnosis, lubrication, cooling system, fuel system (carburetor and early fuel injection), ignition system, exhaust system, emission controls, engine specifications. Transmission: Manual and automatic transmission removal/installation, disassembly/assembly, diagnosis, adjustments, fluid specifications. Drivetrain: Clutch system, drive axles, differentials, propshafts (if applicable). Suspension: Front and rear suspension components, steering system, wheel alignment specifications, removal/installation procedures. Brakes: Hydraulic brake system, disc and drum brakes, brake caliper/wheel cylinder overhaul, parking brake, bleeding procedures, specifications. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, ignition system components, wiring diagrams, fuse/relay locations, diagnosis of electrical faults. Bodywork And Trim: Body panel removal/installation, doors, hood, trunk lid, bumpers, interior trim, glass replacement, chassis identification. Heating Ventilation Air Conditioning: HVAC system components, operation, diagnosis, and repair (where applicable). Wheels And Tires: Wheel bolt patterns, tire pressure specifications, wheel alignment data. Fuel Tank And Lines: Removal, installation, and inspection of fuel system components. Lighting And Signals: Headlights, taillights, turn signals, interior lighting, bulb types, and wiring. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication points, tune-up procedures. Repair: Component removal, installation, disassembly, assembly, overhaul, and replacement procedures for all major systems. Troubleshooting: Systematic diagnostic procedures for common faults, symptom-based troubleshooting guides. Adjustments: Carburetor idle speed and mixture, ignition timing, clutch pedal free play, brake adjustment, wheel alignment. Technical Depth Depth Of Coverage: Comprehensive step-by-step instructions, detailed explanations, pictorial diagrams, exploded views, and photographs for a wide range of repair and maintenance tasks, from basic servicing to more complex component overhauls. Diagnostic Procedures: Includes methods for diagnosing engine performance, electrical faults, and transmission issues using specifications and test procedures. Special Tools: References specific special service tools required for various repair and adjustment operations, with associated illustrations. Torque Specifications: Provides crucial torque values for all critical fasteners, essential for proper assembly and safety. Wear Limits: Includes specified wear limits for various components (e.g., brake discs, engine parts) to ensure correct repair and replacement. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable, high-resolution pages suitable for professional use. Binding Type Binding Type: Digital (Instant Download) Paper Type Paper Type: Not applicable (digital format) ⚙️ Engine Specifications Primary Engine Engine Family: Family II (GM 'Camira' family) and Family 1 (GM 'Family 1' family) engines. Engine Displacement Options: 1.2L, 1.3L, 1.4L, 1.6L, 1.8L (petrol), 1.5L, 1.6L, 1.7L (diesel). Performance Horsepower Range: Approximately 55 hp (1.2L) to 115 hp (1.8L GTE models). Fuel System Fuel Delivery: Carburetor (e.g., Pierburg 2E2) and early Electronic Fuel Injection (EFI) systems (e.g., Bosch LE2-Jetronic). Technical Details Ignition System: Distributor-based, electronic ignition (e.g., Hall effect sensor). 🔧 Transmission Standard Manual Transmission: 4-speed and 5-speed manual transmissions. Optional Automatic Transmission: 3-speed automatic transmission (e.g., GM TH125/180). Features Clutch Type: Single dry plate, diaphragm spring clutch. 📐 Dimensions Exterior Length: Approx. 4030 mm (Hatchback) Width: Approx. 1660 mm Height: Approx. 1400 mm (Hatchback) Weights Curb Weight: Approx. 900-1100 kg, depending on body style and engine. Wheelbase: Approx. 2520 mm 🛡️ Safety Features Ratings Crash Test Performance: Information not readily available for this specific generation's Euro NCAP ratings, but generally considered to meet standards of its era. Active Features Braking System: Front disc brakes, rear drum brakes. ABS was an option on later models. Passive Features Seat Belts: Front seat belts, rear seat belts (lap belts in rear, often diagonal front only as standard initially). 💡 Technology Features Infotainment Audio System: Basic radio/cassette players, often with optional amplifier or upgraded speaker systems. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature on higher trim levels and later production models. Connectivity Diagnostic Ports: OBD-I (On-Board Diagnostics I) system, with proprietary GM diagnostic connectors often used for initial fault finding. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 12,000 km or 12 months, whichever comes first (may vary by engine and oil specification). Timing Belt Replacement: Recommended replacement interval for most engines is around 60,000 km or 4 years. Fluid Specifications Engine Oil Grade: Refer...
Comprehensive step-by-step instructions, detailed explanations, pictorial diagrams, exploded views, and photographs for a wide range of repair and maintenance tasks, from basic servicing to more complex component overhauls.
Diagnostic Procedures:
Includes methods for diagnosing engine performance, electrical faults, and transmission issues using specifications and test procedures.
Special Tools:
References specific special service tools required for various repair and adjustment operations, with associated illustrations.
Torque Specifications:
Provides crucial torque values for all critical fasteners, essential for proper assembly and safety.
Wear Limits:
Includes specified wear limits for various components (e.g., brake discs, engine parts) to ensure correct repair and replacement.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable, high-resolution pages suitable for professional use.
Binding Type
Binding Type:
Digital (Instant Download)
Paper Type
Paper Type:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Family II (GM 'Camira' family) and Family 1 (GM 'Family 1' family) engines.
Approx. 900-1100 kg, depending on body style and engine.
Wheelbase:
Approx. 2520 mm
🛡️ Safety Features
Ratings
Crash Test Performance:
Information not readily available for this specific generation's Euro NCAP ratings, but generally considered to meet standards of its era.
Active Features
Braking System:
Front disc brakes, rear drum brakes. ABS was an option on later models.
Passive Features
Seat Belts:
Front seat belts, rear seat belts (lap belts in rear, often diagonal front only as standard initially).
💡 Technology Features
Infotainment
Audio System:
Basic radio/cassette players, often with optional amplifier or upgraded speaker systems.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on higher trim levels and later production models.
Connectivity
Diagnostic Ports:
OBD-I (On-Board Diagnostics I) system, with proprietary GM diagnostic connectors often used for initial fault finding.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 12,000 km or 12 months, whichever comes first (may vary by engine and oil specification).
Timing Belt Replacement:
Recommended replacement interval for most engines is around 60,000 km or 4 years.
Fluid Specifications
Engine Oil Grade:
Refer to manual for specific grades (e.g., 10W-40 or 15W-40 API SF/CD).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Fluid Manual:
GL-4 75W/80 or 80W/90 gear oil.
Transmission Fluid Automatic:
Dexron II or equivalent automatic transmission fluid (ATF).
Known Issues
Common Wear Items:
Suspension bushes (especially front wishbone), exhaust system corrosion, clutch wear, aging rubber hoses, fuel pump reliability, carburetor issues on older models.
Electrical Faults:
Corrosion in connectors, alternator issues, starter motor problems, faulty dashboard warning lights/gauges.
📚 Vehicle History
Brand Heritage
Vauxhall Legacy:
Vauxhall, as a British marque of General Motors, has a long history of producing reliable and practical family cars.
Model Evolution
Astra Mk2 Development:
The Astra Mk II, launched in 1984, was a significant redesign based on the new front-wheel-drive Opel Kadett E platform, emphasizing aerodynamics and efficiency. It replaced the rear-wheel-drive Astra Mk I (Belmont).
Production
Production Period:
1984-1991
Manufacturing Locations:
Primarily Ellesmere Port, United Kingdom (Vauxhall production).
🏆 Awards & Recognition
Recognitions
Design Awards:
The Opel Kadett E (basis for Vauxhall Astra Mk II) won the 'European Car of the Year' award in 1984, reflecting its advanced design for the time.
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