VAUXHALL OPEL ASTRA BELMONT Service Repair Manual 80-95
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🏷️ Basic Information Identification Make: Vauxhall / Opel Model: Astra Belmont Generation Code: Mk3 (T85) Production Years Covered: 1980-1995 👋 Introduction Market Position Segment: Compact/Small family car (often referred to as C-segment) Brand Perception: Reliable, practical, and affordable European hatchback/sedan Competitive Analysis Key Competitors: Ford Escort, Volkswagen Golf, Peugeot 309, Fiat Tipo Key Features Model Variant: Belmont signifies the saloon (sedan) body style of the Astra Mk3 Value Proposition: Offered a balance of practicality, comfort, and value for money in its segment 📋 Manual Details Coverage Areas Primary Market: UK (Vauxhall) / Europe (Opel) Trim Levels Covered: All Belmont variants including L, GL, GLS, CD, GSi (specific engine variants may vary) Page Count Estimated Pages: Hundreds (specific number not provided, but described as comprehensive) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full overhaul and repair of all engine variants (see engine_specs for details) Fuel System: Carburetor and Fuel Injection (Bosch LE2-Jetronic, Motronic M1.5/M2.5) systems, fuel pumps, injectors, lines Ignition System: Distributor, ignition coils, spark plugs, ECU control (where applicable) Cooling System: Radiator, water pump, thermostat, hoses, fans Exhaust System: Manifolds, catalytic converter (if fitted), mufflers, pipework Transmission Manual: F16, F18, F20 gearboxes, clutch, linkages, overhaul procedures Transmission Automatic: THM180, AF13/14 automatic transmissions, control systems, overhaul procedures Drivetrain: Front-wheel drive, driveshafts, CV joints, differential Suspension Front: McPherson struts, control arms, anti-roll bar, steering knuckles Suspension Rear: Torsion beam axle, shock absorbers, trailing arms Steering System: Manual and power steering rack, pump, column, universal joints Brakes Front: Disc brake calipers, pads, rotors, lines Brakes Rear: Drum brake systems (or disc on performance models), wheel cylinders, shoes, drums Brake Control: Master cylinder, brake booster, proportioning valve, ABS (if fitted) Electrical System: 12V system, battery, alternator, starter motor, fuses, relays Lighting: Headlights, taillights, interior lights, wiring diagrams Instrument Panel: Gauges, warning lights, switchgear Body Exterior: Body panel repair, doors, hood, trunk, bumpers, glass replacement Body Interior: Seating, trim panels, dashboard, carpet replacement HVAC: Heating, ventilation, air conditioning system (if equipped) Body Electronics: Central locking, power windows, mirrors (if equipped) Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, coolant checks, brake fluid flushes Troubleshooting: Diagnostic procedures for common faults, fault codes (where applicable) Engine Repair: Engine removal/installation, cylinder head overhaul, piston/ring replacement, bearing replacement Transmission Repair: Clutch replacement, gearbox overhaul, automatic transmission service Brake System Repair: Brake pad/shoe replacement, rotor/drum replacement, caliper/wheel cylinder rebuild, bleeding Suspension Component Replacement: Shock absorber, strut, control arm, ball joint, tie rod end replacement Steering Component Replacement: Steering rack replacement, power steering pump service Electrical Component Diagnosis And Replacement: Alternator, starter, battery testing and replacement, wiring harness repair Bodywork Procedures: Dent repair, rust prevention and repair, panel alignment HVAC System Service: Component replacement, refrigerant handling (professional advice implied) Technical Depth Depth: Comprehensive (from basic maintenance to full rebuilds) Diagnostic Level: Detailed diagnostic charts and procedures Torque Specifications: Included for all critical fasteners Clearances And Tolerances: Provided for engine and drivetrain components Wiring Diagrams: Detailed electrical schematics for all systems 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF (standard for quality manuals) Print Quality Resolution: High resolution, suitable for printing Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Families: Family I (GM 'small block') Engine Variants Covered Petrol Engines: 1.4L (C14SE, C14NZ), 1.6L (C16SE, C16NZ), 1.8L (C18XE - 16v DOHC, C18NZ - 8v SOHC), 2.0L (C20NE - 8v SOHC, C20XE - 16v DOHC 'Red Top') Diesel Engines: 1.7L (4EC1, 4EE1 - Isuzu-sourced indirect injection) Performance Horsepower Range: Approximately 60 hp (1.4L) to 150 hp (2.0L C20XE) Torque Range: Approximately 100 Nm to 180 Nm Fuel System Fuel Delivery: Carbureted (Stromberg, Pierburg) or Electronic Fuel Injection (EFI) Cylinder Head Valve Train: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) Engine Management ECU Systems: Opel/Vauxhall ECUs, Bosch Motronic variants 🔧 Transmission Standard Transmission Type: 5-speed manual (F16/F18/F20) Optional Transmission Type: 3-speed automatic (THM180, AF13/14) Features Clutch Type: Hydraulically operated single dry plate clutch Fluid Specifications Manual Transmission Fluid: GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, consult manual for specific viscosity) Automatic Transmission Fluid: Dexron II (or equivalent) 📐 Dimensions Exterior Body Styles: 3-door hatchback, 5-door hatchback, 4-door saloon (Belmont), 5-door estate (Caravan/Tourer) Wheelbase: Approx. 2570 mm (exact for Belmont variant) Weights Curb Weight: Approx. 1000-1200 kg (depending on engine/trim) 🛡️ Safety Features Ratings Crash Test History: Euro NCAP testing began later; earlier models relied on national standards. Generally considered safe for its era. Active Features Braking Assistance: Optional ABS (Anti-lock Braking System) on higher trims/engines Passive Features Airbags: Driver airbag often optional or standard on higher trims, passenger airbag less common for early models. Seatbelts: Pre-tensioner seatbelts on front seats (standard on later models) 💡 Technology Features Infotainment Audio System:...
Euro NCAP testing began later; earlier models relied on national standards. Generally considered safe for its era.
Active Features
Braking Assistance:
Optional ABS (Anti-lock Braking System) on higher trims/engines
Passive Features
Airbags:
Driver airbag often optional or standard on higher trims, passenger airbag less common for early models.
Seatbelts:
Pre-tensioner seatbelts on front seats (standard on later models)
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette players, often with 2 or 4 speakers. Aftermarket upgrades common.
Driver Assistance
Cruise Control:
Optional on higher-spec models, particularly with automatic transmission or 2.0L engines.
Connectivity
Connectivity Features:
None in the modern sense; basic wired connections for audio systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 6,000-9,000 miles or 12 months (refer to manual for exact engine/oil type)
Spark Plug Replacement:
Every 18,000-24,000 miles for standard plugs, longer for platinum/iridium
Timing Belt Replacement:
Crucial: 40,000-60,000 miles or 4-5 years for most petrol engines (non-interference engines like C16NZ might tolerate failure, but C20NE/C20XE are interference engines and require timely replacement).
Fluid Specifications
Engine Oil Capacity:
Approx. 3.5 - 4.5 liters (depending on engine, consult manual)
Coolant Type:
Ethylene Glycol based antifreeze (e.g., GM DEX-COOL or equivalent blue/green coolant)
Oil leaks from sump gasket/rocker cover, thermostat housing leaks, early diesel engines can be prone to glow plug issues.
Suspension Wear:
Front suspension top mounts, ball joints, and track rod ends are common wear items.
Body Corrosion:
Wheel arches, sills, rear spring mounting points, and tailgate/boot aperture are susceptible to rust.
Exhaust System:
Corrosion and failure of mufflers and pipework, especially in humid climates.
📚 Vehicle History
Brand Heritage
Manufacturer:
Vauxhall/Opel, part of General Motors (GM) at the time
Model Evolution
Predecessor:
Vauxhall/Opel Kadett E
Successor:
Vauxhall/Opel Astra Mk4 (G)
Production
Manufacturing Locations:
Ellesmere Port (UK), Rüsselsheim (Germany), and other GM plants globally
Market Reception:
Generally well-received for its practicality and diverse engine range, though criticized by some for a less engaging driving experience compared to rivals like the Golf GTI.
🏆 Awards & Recognition
Recognitions
Class Awards:
The Astra Mk3 range as a whole received various 'Car of the Year' nominations and awards from automotive publications in different countries during its lifecycle.
Ratings
Reliability:
Generally considered to be reasonably reliable when properly maintained, but common issues do exist due to age.
Certifications
Emissions Standards:
Compliant with European emissions standards of the time (Euro 1/2).