Opel Vauxhall Kadett 1986 Repair Service Manual

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🏷️ Basic Information Identification Make: Opel/Vauxhall Model: Kadett Year: 1986 Codes Internal Model Code: Kadett E / Astra F precursor Chassis Code: T85 👋 Introduction Market Position Historical Context: The Opel Kadett E (Vauxhall Astra Mk2 in the UK) was a highly successful model for GM Europe, known for its practicality, efficiency, and value, competing with the Ford Escort and Volkswagen Golf. Competitive Analysis Key Competitors: Ford Escort, Volkswagen Golf, Peugeot 309, Fiat Tipo, Renault 9/11. Key Features Manual Value Proposition: Provides professional-level repair and maintenance information accessible to DIY enthusiasts, enabling significant cost savings and extending vehicle lifespan. Vehicle Appeal: Practical, reliable, and relatively affordable compact car, popular across Europe, making service manuals essential for ongoing ownership. Manual Content Scope: Covers aspects typically found in factory service manuals and owner's manuals. 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, and Maintenance Page Count Estimated Page Count: Extensive (typical factory manuals for this era range from 500-1500+ pages) Manual Type Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed coverage of all engine variants (e.g., 1.2L, 1.3L, 1.4L, 1.6L petrol, 1.6L/1.7L diesel), including disassembly, assembly, troubleshooting, and component specifications. Transmission: Coverage of manual and automatic transmissions, including clutch, gearbox, differential, and driveline components. Includes fluid types and capacities. Brakes: Comprehensive information on hydraulic systems, disc and drum brake components, parking brake, and ABS (if equipped on specific trims). Electrical: Extensive wiring diagrams, component location, troubleshooting guides for ignition, starting, charging, lighting, instruments, and auxiliary systems. Suspension Steering: Detailed procedures for front and rear suspension components (struts, shocks, control arms, bushings), power steering systems, and wheel alignment specifications. Bodywork Chassis: Information on body panel removal/installation, structural components, doors, windows, trim, and rust repair considerations. Heating Ventilation Ac:...

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Description

🏷️ Basic Information

Identification

Make:

Opel/Vauxhall

Model:

Kadett

Year:

Codes

Internal Model Code:

Kadett E / Astra F precursor

Chassis Code:

👋 Introduction

Market Position

Historical Context:

The Opel Kadett E (Vauxhall Astra Mk2 in the UK) was a highly successful model for GM Europe, known for its practicality, efficiency, and value, competing with the Ford Escort and Volkswagen Golf.

Competitive Analysis

Key Competitors:

Ford Escort, Volkswagen Golf, Peugeot 309, Fiat Tipo, Renault 9/11.

Key Features

Manual Value Proposition:

Provides professional-level repair and maintenance information accessible to DIY enthusiasts, enabling significant cost savings and extending vehicle lifespan.

Vehicle Appeal:

Practical, reliable, and relatively affordable compact car, popular across Europe, making service manuals essential for ongoing ownership.

Manual Content Scope:

Covers aspects typically found in factory service manuals and owner's manuals.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service, Repair, and Maintenance

Page Count

Estimated Page Count:

Extensive (typical factory manuals for this era range from 500-1500+ pages)

Manual Type

Type:

Repair Service Manual / Workshop Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed coverage of all engine variants (e.g., 1.2L, 1.3L, 1.4L, 1.6L petrol, 1.6L/1.7L diesel), including disassembly, assembly, troubleshooting, and component specifications.

Transmission:

Coverage of manual and automatic transmissions, including clutch, gearbox, differential, and driveline components. Includes fluid types and capacities.

Brakes:

Comprehensive information on hydraulic systems, disc and drum brake components, parking brake, and ABS (if equipped on specific trims).

Electrical:

Extensive wiring diagrams, component location, troubleshooting guides for ignition, starting, charging, lighting, instruments, and auxiliary systems.

Suspension Steering:

Detailed procedures for front and rear suspension components (struts, shocks, control arms, bushings), power steering systems, and wheel alignment specifications.

Bodywork Chassis:

Information on body panel removal/installation, structural components, doors, windows, trim, and rust repair considerations.

Heating Ventilation Ac:

Coverage of HVAC system components, operation, diagnosis, and refrigerant handling (if applicable for the year).

Fuel System:

Carburetor tuning and rebuild, fuel pump diagnosis, fuel tank and lines.

Exhaust System:

Catalytic converter (if fitted), exhaust manifold, mufflers, pipes, and hangers.

Cooling System:

Radiator, fan (mechanical or electric), water pump, thermostat, hoses, and heater core.

Steering Wheel Column:

Steering rack/box, power steering pump and lines, steering column components, ignition switch.

Instrument Panel:

Speedometer, tachometer (if equipped), fuel gauge, temperature gauge, warning lights, and related sensors/actuators.

Procedures Included

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points, and inspections.

Troubleshooting:

Systematic diagnostic procedures and flowcharts for identifying and resolving common and uncommon faults.

Repair:

Step-by-step instructions for component removal, disassembly, repair, assembly, and reinstallation for virtually all vehicle systems.

Technical Specifications:

Torque specifications, clearances, tolerances, diagnostic values, and measurement procedures.

Installation:

Procedures for installing aftermarket parts or replacement components.

Diagnosis:

Diagnostic flowcharts, fault code interpretation (if applicable for the era's basic electronic systems), and common failure analysis.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, electrical diagnostics, and bodywork.

Engine Rebuild:

Detailed specifications for machining, bearing clearances, piston ring gap, valve lapping, and timing adjustments.

Electrical Diagnostics:

Troubleshooting voltage drops, circuit continuity checks, sensor testing, and component resistance values.

📊 Manual Specifications

File Format

PDF Features:

Zoomable, searchable text, printable pages.

Download Speed:

Instant Download

Print Quality

Printability:

Full Printable

Binding Type

Binding:

Digital Download (PDF)

Paper Type

Paper:

N/A (Digital)

Requirements

Software Requirements:

Adobe PDF Reader, WinZip or equivalent unzipping software

Compatibility

Operating Systems:

All Versions of Windows & Mac

Usefulness

Target Audience:

Professional technicians and experienced DIY mechanics.

⚙️ Engine Specifications

Primary Engine

Engine Options:

Multiple petrol engines including 1.2L (33-44 kW), 1.3L (44-55 kW), 1.4L (53-66 kW), 1.6L (55-70 kW), and 1.8L GTE variants. Diesel engines included 1.6L (40-44 kW) and 1.7L (42 kW).

Performance

Typical Hp Range:

33 kW (44 hp) to 85 kW (114 hp) for performance variants like the GTE.

Fuel System

Fuel Delivery:

Carburetor (various types like Solex, Pierburg) for most engines, with early fuel injection systems appearing on higher performance models.

Cooling System

Coolant Type:

Ethylene Glycol based coolant (e.g., G11 specification or equivalent) mixed with distilled water.

Ignition System

Ignition Type:

Conventional distributor-based ignition system with points or electronic ignition (HEI) depending on engine variant and year.

Engine Block Material

Material:

Typically cast iron.

Cylinder Head Material

Material:

Typically aluminum alloy.

🔧 Transmission

Standard

Manual Transmission:

4-speed and 5-speed manual transmissions common.

Optional

Automatic Transmission:

Optional 3-speed automatic transmission available on select models.

Features

Gearbox Oil Spec:

GL-4 manual transmission fluid (e.g., SAE 75W-90 or 80W-90).

📐 Dimensions

Exterior

Body Styles:

Hatchback (3-door and 5-door), Saloon (4-door), Estate/Caravan (5-door wagon).

Weights

Curb Weight Range:

Approximately 900 kg to 1150 kg, depending on body style and engine.

🛡️ Safety Features

Ratings

Crash Test Data:

Limited public crash test data available for this specific year and model. Euro NCAP was not established in its current form. General safety design typical of the era.

Passive Features

Standard Safety Features:

Seatbelts (front and often rear), energy-absorbing steering column, reinforced passenger cell. Optional features might include rear fog lights.

💡 Technology Features

Infotainment

Audio Systems:

Basic AM/FM radio, often with cassette player. Speaker configurations varied by trim.

Driver Assistance

Driver Aids:

No advanced driver-assistance systems. Focus on core driving mechanics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type.

Timing Belt Interval:

For interference engines (e.g., some 1.3L, 1.4L, 1.6L), replacement typically recommended every 60,000-80,000 km (36,000-50,000 miles) or 4-5 years.

Fluid Specifications

Engine Oil Spec:

API SF/CD or SG/CE equivalent, viscosity grade typically SAE 10W-40 or 15W-40, depending on climate. Check manual for exact recommendations.

Coolant Capacity:

Approximately 5-6 liters (check specific engine).

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Spec Auto:

Dexron II or equivalent ATF.

Power Steering Fluid:

ATF Dexron II or equivalent.

Known Issues

Common Problems:

Rust (wheel arches, sills, tailgate), carburetor issues, aging electrical components (switches, wiring), timing belt failure (on interference engines), suspension wear (bushings, ball joints).

Diesel Specific Issues:

Glow plug issues, injector pump problems.

📚 Vehicle History

Brand Heritage

Opel Vauxhall Legacy:

Opel and Vauxhall have a long history of producing reliable and accessible cars for the European market. The Kadett line has been a core model for decades.

Model Evolution

Kadett E Era:

The Kadett E, launched in 1984, was a significant departure from its predecessor, adopting a more aerodynamic and modern design. It was a precursor to the first-generation Astra.

Design Influences:

Aerodynamic wedge-shaped design influenced by other contemporary European hatchbacks and sedans.

Production

Manufacturing Locations:

Primarily manufactured in Germany (Opel) and the UK (Vauxhall), with production also occurring in other GM plants across Europe.

🏆 Awards & Recognition

Recognitions

Industry Awards:

The Kadett E was generally well-received and often featured in 'Car of the Year' discussions in various European markets, though specific major awards for the 1986 model year are not prominently documented.