🏷️ Basic Information

Make:

Opel/Vauxhall

Model:

Astra

Generation Code:

Mk2 / T85

Production Years Covered:

1986-1991

Chassis Code:

T85

👋 Introduction

Segment:

Compact family car (C-segment), a strong competitor in the European market.

Key Competitors:

Ford Escort, Volkswagen Golf, Fiat Tipo, Peugeot 309, Renault 19.

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.

📋 Manual Details

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.

Total Pages:

243

Type:

Workshop Service Repair Manual

Language:

English

Digital Format:

PDF

📖 Manual Coverage

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 tank, fuel pump, fuel lines, injectors, carburettor (if applicable to certain engines), fuel pressure testing.

Brakes Rear:

Drum brake systems (common on some variants) or disc brake systems, including shoe/pad replacement, drum/rotor machining/replacement, and adjustment.

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.

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.

Heating Ventilation Air Conditioning:

Heater core, blower motor, ventilation controls, basic A/C system information (refrigerant types, component identification).

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.

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.

📊 Manual Specifications

Format Details:

PDF format, allowing for easy viewing, zooming, and searching.

Printability:

All pages are printable, enabling users to create hard copies of specific sections or the entire manual.

Binding:

N/A (Digital PDF format, no physical binding)

Paper Quality:

N/A (Digital PDF format, no physical paper)

Required Software:

Adobe Reader (or compatible PDF viewer)

Operating Systems:

Windows, macOS, Linux OS

⚙️ Engine Specifications

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.

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 Delivery:

Carburetion (e.g., Solex, Weber) for lower-end models, and multi-point fuel injection (MPI) for performance variants and later models.

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).

🔧 Transmission

Standard Transmission:

5-speed manual transmission.

Optional Transmission:

3-speed or 4-speed automatic transmission available on some engine variants.

Clutch Type:

Single dry plate clutch.

📐 Dimensions

Length:

Varies by body style, generally around 4000-4200 mm.

Width:

Approximately 1650-1700 mm.

Height:

Approximately 1380-1440 mm.

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.

🛡️ Safety Features

Crash Test Performance:

As per 1980s standards, likely received moderate ratings. Modern safety features were limited.

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 Safety:

Seat belts (likely 3-point front, 2-point rear initially), reinforced passenger cell, impact-absorbing steering column.

💡 Technology Features

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 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 Options:

N/A. No integrated Bluetooth, USB ports, or smartphone connectivity.

🔧 Maintenance

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.

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.

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.

📚 Vehicle History

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.

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 Locations:

Primarily manufactured in Germany (Opel) and the UK (Vauxhall), with production also occurring in other European countries through GM's network.

🏆 Awards & Recognition

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.