Generation:
Third Generation (T85/T81/T80) / Fourth Generation (T92)
Platform Codes:
T85 (Astra F Hatchback/Estate), T81 (Astra F Sedan/Coupe), T80 (Astra F Convertible), T92 (Kadett E)
Product Name:
Vauxhall Opel Astra Kadett 1990-1999 Workshop Repair Manual
Target Audience:
DIY mechanics, independent repair shops, and owners seeking in-depth knowledge of their Astra/Kadett
Value Proposition:
Cost-effective alternative to dealership service, empowering users to perform their own repairs and maintenance
Comparison To Dealership:
Provides equivalent technical information to official dealer workshop manuals at a fraction of the cost
Comprehensiveness:
Covers all models and repairs A-Z, mechanical and electrical
Ease Of Use:
Easy layout format, printable pages, accessible via any PC/MAC
Lifetime Access:
No time-out or expiration, can be used as many times as needed
Content Quality:
Professional quality, detailed pictures and diagrams
Primary Coverage:
All models and repairs for Vauxhall/Opel Astra F and Kadett E
Geographic Scope:
Europe (primarily UK and continental Europe)
Estimated Page Count:
Extensive (Thousands of pages, exact count not specified but implied by 'tons of detailed pictures & diagrams')
Type:
Workshop Service Repair Manual
Delivery Format:
Digital Download (PDF)
Powertrain:
Engine mechanicals, lubrication, fuel system, emissions control, intake/exhaust systems, cooling system, ignition system, engine management
Drivetrain:
Clutch, manual transmission, automatic transmission, differential, driveshaft
Chassis:
Steering system, suspension (front and rear), braking system (including ABS)
Body And Interior:
Body panels, interior trim, doors, windows, HVAC (Heater and Air Conditioning, Automatic Climate Control), body electrical
Electrical:
Complete electrical system, wiring diagrams, SRS (Supplemental Restraint System), engine control units (ECUs), lighting
Routine Maintenance:
Oil changes, filter replacements, fluid level checks, tire rotation, spark plug replacement, belt inspection/replacement
Tune Up:
Comprehensive tune-up procedures for various engine types
Major Repairs:
Engine removal/installation, cylinder head overhaul, piston/ring replacement, crankshaft/bearing service, transmission overhaul, clutch replacement
Diagnostics And Troubleshooting:
System-specific diagnostic procedures, common fault finding, troubleshooting guides
Component Replacement:
Detailed instructions for replacing virtually all mechanical and electrical components
Timing Procedures:
Valve timing, chain/gear replacement, tensioner adjustments and release/reset methods
Depth:
A-Z coverage, from routine maintenance to complete mechanical and electrical repairs
Diagnostic Level:
Advanced diagnostics, including electrical system troubleshooting with wiring diagrams
Rebuild Level:
Comprehensive engine and transmission rebuild procedures
Engine Family:
Opel Family II / Ecotec (depending on specific model year and variant within the range)
Petrol Engines:
1.4L (C14NZ, C14SE), 1.6L (C16NZ, C16SE, X16XEL), 1.8L (C18XE, C18XEL), 2.0L (C20NE, C20XE, X20XEV)
Diesel Engines:
1.7L (X17DT)
Horsepower Range:
Approximately 60 HP to 150 HP (depending on engine variant)
Torque Range:
Approximately 110 Nm to 195 Nm (depending on engine variant)
Injection Type:
Multi-point fuel injection (MPI), Single-point fuel injection (SPI), Direct Injection (GSi/GTE models with C20XE)
Fuel Type:
Unleaded Petrol (Octane rating varies by engine, typically 95 RON minimum), Diesel
ECUs:
Various Bosch Motronic, Simtec, and other ECUs depending on engine and year
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically silicate-free (refer to manual for specific Opel/Vauxhall recommendation)
Manual Transmission:
F16/F18/F20 5-speed manual transmissions
Automatic Transmission:
4-speed automatic transmissions (e.g., TH125/F13-4) for some models
Manual Fluid Type:
GL-4 Gear Oil (Viscosity grade typically 75W-90 or 80W-90, refer to manual for specifics)
Automatic Fluid Type:
Dexron III (or equivalent ATFLUID specification)
Body Styles:
3-door Hatchback, 5-door Hatchback, 4-door Sedan (Saloon), 5-door Estate (Caravan), 2-door Convertible, 3-door Van (Commercial)
Curb Weight Range:
Approximately 950 kg to 1250 kg (depending on body style, engine, and equipment)
Crash Test History:
Limited data available for specific Euro NCAP ratings during this era, but generally considered safe for its class. Manual will detail structural information relevant to safety.
Braking System:
Front ventilated discs, rear drums standard. Optional ABS (Anti-lock Braking System) on higher trims/later models.
Airbags:
Driver airbag standard on later models, passenger airbag optional or standard on top trims. Manual covers SRS system.
Seatbelts:
Pre-tensioner seatbelts for front occupants on some variants.
Audio Systems:
Factory-fitted radio/cassette players, with options for CD players on later models. Speaker configurations vary by trim.
ABS:
Optional Anti-lock Braking System (ABS) available on higher trim levels and later production years, particularly with the 2.0L engines.
Traction Control:
Rarely fitted on standard models of this era, but potentially available on very high-performance variants or optional.
Original Connectivity:
Basic connectivity through radio/cassette system. No factory-fitted Bluetooth or USB ports.
Oil Change Interval:
Typically every 10,000-15,000 km or 12 months, whichever comes first (refer to specific engine type in manual).
Timing Belt Replacement:
Crucial for non-interference engines, typically every 60,000-90,000 km or 5-6 years for petrol engines. Diesel engines might have chains or different interval belts.
Spark Plug Replacement:
Varies by plug type (copper, platinum, iridium), typically 20,000-40,000 km.
Engine Oil Spec:
API SJ/SL or ACEA A3/B3, SAE Viscosity Grade 10W-40 or 5W-40 often recommended, but check manual for specific engine requirements (e.g., 1.8/2.0 16V may have specific needs).
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Coolant Capacity:
Approximately 5.5 - 6.5 liters (varies by engine and radiator size).
Common Problems Petrol:
Head gasket failures (especially on some 1.8/2.0 16V engines), coolant leaks from hoses/radiator, ABS sensor failures, ECU issues (cracked solder joints), gearbox synchromesh wear, minor electrical gremlins.
Common Problems Diesel:
Glow plug issues, turbocharger wear on higher mileage units, injector pump timing issues.
Common Issues Body Chassis:
Rust in wheel arches, sills, and boot floor; worn suspension bushings; aging CV joints; exhaust system corrosion.
Vauxhall Opel Legacy:
Part of Opel's highly successful Kadett lineage, transitioned to the Astra nameplate for the F generation in many markets.
Kadett E:
The Kadett E (T85 platform) was launched in 1984 and was known for its aerodynamic design. It shared many components with its predecessor and sister models.
Astra F:
The Astra F (introduced 1991) was the successor to the Kadett E. It represented a significant step forward in design, safety, and technology for Opel/Vauxhall in the compact segment.
Production Period:
Kadett E: 1984-1993 (in Europe). Astra F: 1991-1998 (in Europe).
Manufacturing Locations:
Primary manufacturing sites included Germany (Rüsselsheim), UK (Ellesmere Port), and other European facilities.
European Awards:
The Kadett E and Astra F were highly successful models in Europe, often featuring in 'Car of the Year' discussions and receiving positive reviews for practicality, value, and driving dynamics.
Specific Awards:
While no single award is consistently cited, the Astra F was a best-seller and a highly regarded compact car of its time, earning widespread market acceptance.
