in your garage to make future searches easy.

Condition Value
expand_moreAir intake system
expand_moreIntake manifold
Lower section of intake manifold 16.23 lbf⋅ft
Replace screws and nuts.
Upper section of intake manifold 5.9 lbf⋅ft
Lower section of intake manifold 14.75 lbf⋅ft
Replace screws and nuts.
Upper section of intake manifold 5.9 lbf⋅ft
All Opel gasoline straight-4 1.8 L Z 18 XE engines 14.75 lbf⋅ft
Use new screws or nuts
All Opel gasoline straight-4 2.2 L Z 22 SE engines 6.64 lbf⋅ft
All other modifications 16.23 lbf⋅ft
Use new screws or nuts
expand_moreIntake manifold support
On intake manifold 14.75 lbf⋅ft
Support on cylinder head 25.81 lbf⋅ft
expand_moreAuxiliary assemblies
expand_moreAuxiliary drive belt deflection pulley
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.5) 25.81 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
All Opel diesel straight-4 2.2 L Y 22 DTR engines 30.98 lbf⋅ft
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 36.88 lbf⋅ft
All Opel gasoline straight-4 1.8 L Z 18 XE engines 25.81 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 31.72 lbf⋅ft
expand_moreAll other modifications
With air-conditioning 18.44 lbf⋅ft
expand_moreAir-conditioning compressor
All Opel diesel straight-4 2.2 L Y 22 DTR engines 14.75 lbf⋅ft
Front 25.81 lbf⋅ft
Rear 14.75 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 15.49 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreAir-conditioning compressor bracket
Opel gasoline straight-4 1.8 L Z 18 XE 123 HP 25.81 lbf⋅ft
Opel gasoline straight-4 2.0 L Z 20 LET 189 HP 25.8131.72 lbf⋅ft
Opel gasoline straight-4 2.0 L Z 20 LET 197 HP 25.8131.72 lbf⋅ft
Air-conditioning compressor pressure line 14.75 lbf⋅ft
Replace sealing rings.
expand_moreAlternator
Bottom 25.81 lbf⋅ft
Top 14.75 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 15.49 lbf⋅ft
expand_moreAll other modifications
Bottom 25.81 lbf⋅ft
Generator bracket 25.81 lbf⋅ft
expand_morePower steering pump bracket
At the subframe 16.23 lbf⋅ft
expand_moreHydraulic lines at the servo-steering pump
Manufacturer Delphi 19.91 lbf⋅ft
Manufacturer TRW 22.13 lbf⋅ft
expand_moreServo steering pump
At the bracket 5.16 lbf⋅ft
expand_moreCarburetion
expand_moreExhaust gas return valve
expand_moreExhaust recirculation pipe
expand_moreFuel-distributing pipe
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 5.9 lbf⋅ft
At the exhaust manifold 5.9 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 6.64 lbf⋅ft
All other modifications 10.33 lbf⋅ft
expand_moreInjection hoses
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.5) 22.13 lbf⋅ft
expand_moreInjection nozzle (injector)
expand_more2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.5)
First stage hand-screwed
Second stage 360°
expand_moreInjection pump
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.5) 18.44 lbf⋅ft
expand_moreCharging
Charge air pipes 2.58 lbf⋅ft
expand_moreTurbocharger oil feed line
expand_moreAt the turbocharger
Support 8.85 lbf⋅ft
Otherwise 8.85 lbf⋅ft
Replace sealing rings.
expand_moreOn the engine block
Support 25.81 lbf⋅ft
Otherwise 25.81 lbf⋅ft
Union nuts 14.75 lbf⋅ft
expand_moreTurbocharger oil return line
At the turbocharger 5.9 lbf⋅ft
Replace sealing rings.
On the engine block 22.13 lbf⋅ft
Replace sealing rings.
expand_moreCooling system
expand_moreCoolant drain plug
Coolant pump 14.75 lbf⋅ft
expand_moreCoolant pump
All Opel diesel straight-4 2.2 L Y 22 DTR engines 14.75 lbf⋅ft
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 5.9 lbf⋅ft
All Opel gasoline straight-4 1.8 L Z 18 XE engines 5.9 lbf⋅ft
Use new screws with the screw- locking compound.
All Opel gasoline straight-4 2.2 L Z 22 SE engines 16.96 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreCoolant pump pulley
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.5) 14.75 lbf⋅ft
expand_moreFan wheel
expand_moreRadiator mounting
Bottom 11.06 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
All Opel diesel straight-4 2.2 L Y 22 DTR engines 11.06 lbf⋅ft
Guide bearing 16.96 lbf⋅ft
Otherwise 6.64 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreCylinder head screws
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 2.2 L Y 22 DTR 123 HP.
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 2.2 L Y 22 DTR 123 HP.
First stage 18.44 lbf⋅ft
Use new screws. See figure 1.
Second stage 65°
Third stage 65°
Fourth stage 65°
Fifth stage 65°
Sixth stage 15°
expand_moreM10
Figure 2. Cylinder head, Cylinder head screws, Opel gasoline straight-4 2.2 L Z 22 SE 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM, M10.
Figure 2. Cylinder head, Cylinder head screws, Opel gasoline straight-4 2.2 L Z 22 SE 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM, M10.
First stage 22.13 lbf⋅ft
Use new screws. See figure 2.
Second stage 75°
Third stage 75°
Fourth stage 15°
Figure 3. Cylinder head, Cylinder head screws, Opel gasoline straight-4 2.0 L Z 20 LET 189 HP.
Figure 3. Cylinder head, Cylinder head screws, Opel gasoline straight-4 2.0 L Z 20 LET 189 HP.
First stage 18.44 lbf⋅ft
Replace screws. See figure 3.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 15°
First stage 18.44 lbf⋅ft
Use new screws. See figure 3.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 15°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Replace screws. See figure 3.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 45°
expand_moreValve cover
All Opel gasoline straight-4 2.2 L Z 22 SE engines 6.64 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreEngine block
expand_moreBalance shaft gear wheel
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.9–2005.5)
First stage 5.9 lbf⋅ft
Replace screws.
Second stage 30°
expand_moreConnecting rod bearing
First stage 25.81 lbf⋅ft
Second stage 45°
Third stage 15°
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 50°
Third stage 50°
Fourth stage 10°
First stage 25.81 lbf⋅ft
Replace screws and nuts.
Second stage 45°
Third stage 15°
First stage 25.81 lbf⋅ft
Use new screws.
Second stage 45°
Third stage 15°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 30°
expand_moreCrankcase ventilation
expand_more1.6 16V with gasoline straight-4 1.6 L 102 HP engine (2000.3–2005.5)
Crankcase ventilation pipe 5.9 lbf⋅ft
Use new seals.
expand_moreCrankshaft central screws
First stage 110.63 lbf⋅ft
Replace screws and nuts.
Second stage 45°
Third stage 15°
First stage 70.07 lbf⋅ft
Use new screw.
Second stage 30°
Third stage 15°
First stage 70.07 lbf⋅ft
Use new screw.
Second stage 45°
Third stage 15°
First stage 73.76 lbf⋅ft
Second stage 75°
Third stage 15°
expand_moreAll other modifications
First stage 95.88 lbf⋅ft
Use new screw.
Second stage 4050°
expand_moreCrankshaft pulley
Opel gasoline straight-4 2.0 L Z 20 LET 189 HP 14.75 lbf⋅ft
Opel gasoline straight-4 2.0 L Z 20 LET 197 HP 14.75 lbf⋅ft
expand_moreDrive plate
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5) 44.25 lbf⋅ft
Replace screws.
expand_moreFlywheel
First stage 33.19 lbf⋅ft
Use new screw.
Second stage 30°
Third stage 15°
First stage 25.81 lbf⋅ft
Second stage 30°
Third stage 15°
First stage 25.81 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
First stage 39.09 lbf⋅ft
Clean the thread, use new screws and screw-locking compound.
Second stage 25°
expand_moreAll other modifications
First stage 47.94 lbf⋅ft
Replace screws. Use screw-locking compound.
Second stage 30°
Third stage 15°
expand_moreMain bearing
First stage 36.88 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_moreM10
First stage 14.75 lbf⋅ft
Second stage 70°
Third stage 15°
M8 16.96 lbf⋅ft
First stage 36.88 lbf⋅ft
Use new screws.
Second stage 45°
Third stage 15°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws and nuts.
Second stage 45°
Third stage 15°
expand_moreEngine control
Camshaft drive belt deflection pulley 18.44 lbf⋅ft
expand_moreCamshaft timing chain guide rail
All Opel diesel straight-4 2.2 L Y 22 DTR engines 5.9 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 7.38 lbf⋅ft
expand_moreCamshaft timing chain slip rail
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.9–2005.5) 5.9 lbf⋅ft
Use screw-locking compound.
expand_moreCamshaft timing chain tensioning rail
All Opel diesel straight-4 2.2 L Y 22 DTR engines 14.75 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 7.38 lbf⋅ft
expand_moreCamshaft timing gear
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 30°
First stage 36.88 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 15°
First stage 62.69 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
First stage 36.88 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 15°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_moreChain tensioner
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.9–2005.5)
Balance shaft timing chain 7.38 lbf⋅ft
Camshaft timing chain 55.32 lbf⋅ft
Clean the thread.
expand_moreChain tensioner locking screws
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.5) 44.25 lbf⋅ft
expand_moreInlet camshaft wheel
expand_moreOutlet camshaft wheel
expand_moreTiming case cover
All Opel diesel straight-4 2.2 L Y 22 DTR engines 14.75 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 15.49 lbf⋅ft
expand_moreToothed belt guard
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5) 2.95 lbf⋅ft
expand_moreToothed belt guard at the bottom
All Opel gasoline straight-4 1.8 L Z 18 XE engines 2.95 lbf⋅ft
All other modifications 4.43 lbf⋅ft
expand_moreToothed belt guard at the top
Opel gasoline straight-4 2.0 L Z 20 LET 189 HP 4.43 lbf⋅ft
Opel gasoline straight-4 2.0 L Z 20 LET 197 HP 4.43 lbf⋅ft
All other modifications 2.95 lbf⋅ft
Toothed belt tensioning roller 14.75 lbf⋅ft
Toothed belt tightener 14.75 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil cooler
On the engine block 14.75 lbf⋅ft
expand_moreOil drain plug
Aluminium oil sump (Torx screws) 10.33 lbf⋅ft
Aluminium oil sump (hexagon-head screws) 33.19 lbf⋅ft
Sheet-steel sump 40.57 lbf⋅ft
Torx screws 10.33 lbf⋅ft
With hexagon-head screws 33.19 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 18.44 lbf⋅ft
All other modifications 7.38 lbf⋅ft
Replace sealing rings.
expand_moreOil filter
Oil filter cover 11.06 lbf⋅ft
Slightly oil sealing lips.
expand_moreOil filter housing
All Opel diesel straight-4 2.2 L Y 22 DTR engines 14.75 lbf⋅ft
On the engine block 33.19 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 18.44 lbf⋅ft
expand_moreOil lines
At the turbocharger 14.75 lbf⋅ft
expand_moreOil feed lines
Turbo charger union nuts 14.75 lbf⋅ft
Replace sealing rings.
expand_moreOil feed lines at the turbo charger
At the bracket 25.81 lbf⋅ft
expand_moreReturn line
Turbo charger 5.9 lbf⋅ft
Replace sealing rings.
expand_moreReturn line at the turbo charger
Banjo screws 22.13 lbf⋅ft
Replace sealing rings.
expand_moreOil feed lines
Turbo charger union nuts 14.75 lbf⋅ft
Replace sealing rings.
expand_moreOil feed lines at the turbo charger
At the bracket 25.81 lbf⋅ft
expand_moreReturn line
Turbo charger 5.9 lbf⋅ft
Replace sealing rings.
expand_moreReturn line at the turbo charger
Banjo screws 22.13 lbf⋅ft
Replace sealing rings.
expand_moreOil pressure sensor
All Opel gasoline straight-4 1.8 L Z 18 XE engines 22.13 lbf⋅ft
All other modifications 29.5 lbf⋅ft
expand_moreOil pump
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 14.75 lbf⋅ft
All Opel gasoline straight-4 1.8 L Z 18 XE engines 7.38 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreOil sump
expand_moreAt the gearbox
M10 29.5 lbf⋅ft
M8 14.75 lbf⋅ft
On the engine block 14.75 lbf⋅ft
At the gearbox 29.5 lbf⋅ft
On the engine block 7.38 lbf⋅ft
At the gearbox 29.5 lbf⋅ft
On the engine block 7.38 lbf⋅ft
Clean the thread and use screw-locking compound.
At the gearbox 29.5 lbf⋅ft
On the engine block 16.96 lbf⋅ft
expand_moreAll other modifications
At the gearbox 29.5 lbf⋅ft
expand_moreOil sump lower part
First stage 5.9 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Oil sump top part 14.75 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
All Opel gasoline straight-4 1.8 L Z 18 XE engines 5.9 lbf⋅ft
All other modifications 4.43 lbf⋅ft
expand_moreCrankshaft sensor
All Opel diesel straight-4 2.2 L Y 22 DTR engines 5.9 lbf⋅ft
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 5.9 lbf⋅ft
All Opel gasoline straight-4 1.8 L Z 18 XE engines 5.9 lbf⋅ft
expand_moreGlow plugs
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.5) 7.38 lbf⋅ft
expand_moreKnock sensor
All Opel gasoline straight-4 2.2 L Z 22 SE engines 16.96 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreLambda sensor
Lambda sensor downstream of catalytic converter 29.5 lbf⋅ft
Lambda sensors in front of catalytic converter 22.13 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 40.57 lbf⋅ft
All other modifications 29.5 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
On engine mounting 40.57 lbf⋅ft
expand_moreOn the engine block
Right 36.88 lbf⋅ft
On the engine block 40.57 lbf⋅ft
expand_moreEngine mounting
expand_moreOn the engine block
Front 40.57 lbf⋅ft
Right long screws 40.57 lbf⋅ft
Right short screws 25.81 lbf⋅ft
expand_moreAt the gearbox
Front 44.25 lbf⋅ft
expand_moreOn chassis
Left 14.75 lbf⋅ft
Right 25.81 lbf⋅ft
expand_moreOn front axle
Front 40.57 lbf⋅ft
expand_moreAll other modifications
On chassis 25.81 lbf⋅ft
Replace screws.
On engine bracket 40.57 lbf⋅ft
Replace screws.
expand_moreSubframe
First stage 66.38 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_moreExhaust system
expand_moreCatalytic converter
expand_moreAt the cylinder head
First stage 8.85 lbf⋅ft
Second stage 8.85 lbf⋅ft
At the turbocharger 14.75 lbf⋅ft
Replace bolts.
At the turbocharger 14.75 lbf⋅ft
Replace bolts.
expand_moreExhaust manifold
All Opel diesel straight-4 2.2 L Y 22 DTR engines 16.23 lbf⋅ft
Replace screws and nuts.
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 16.23 lbf⋅ft
Replace screws and nuts.
All Opel gasoline straight-4 1.8 L Z 18 XE engines 8.85 lbf⋅ft
Replace screws and nuts.
All Opel gasoline straight-4 2.2 L Z 22 SE engines 8.85 lbf⋅ft
Replace nuts.
expand_moreAll other modifications
First stage 5.9 lbf⋅ft
Note correct order of tensioning.
Second stage Wait 5 minutes.
Replace the nuts and use fitting paste
Third stage 5.9 lbf⋅ft
expand_moreExhaust manifold heat shields
All Opel gasoline straight-4 1.8 L Z 18 XE engines 5.9 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreExhaust pipe
All Opel gasoline straight-4 1.8 L Z 18 XE engines 25.81 lbf⋅ft
Replace screws.
All Opel gasoline straight-4 2.2 L Z 22 SE engines 11.8 lbf⋅ft
Replace nuts.
All other modifications 14.75 lbf⋅ft
Exhaust pipe bracket 14.75 lbf⋅ft
expand_moreExhaust pipe rear
All Opel gasoline straight-4 1.8 L Z 18 XE engines 25.81 lbf⋅ft
Replace nuts.
expand_moreAll other modifications
M8 8.85 lbf⋅ft
Exhaust system middle heat protection plate 2.95 lbf⋅ft
expand_moreFuel supply
expand_moreFuel lines
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 11.06 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 5.9 lbf⋅ft
expand_moreIgnition system
expand_moreSpark plugs
All Opel gasoline straight-4 2.2 L Z 22 SE engines 14.75 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreStart system
expand_moreStarter
All Opel diesel straight-4 2.2 L Y 22 DTR engines 33.19 lbf⋅ft
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 18.44 lbf⋅ft
At the gearbox 29.5 lbf⋅ft
On the engine block 18.44 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 29.5 lbf⋅ft
expand_moreAll other modifications
At the gearbox 29.5 lbf⋅ft
On the engine block 33.19 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2002 Opel Astra Coupe user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Opel warranty policy for your region. In some regions DIY service may invalidate your warranty.

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Opel Astra Coupe service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2002 Opel Astra Coupe you're not only saving money, but also also improving your technical skills and learning something new.

2002 Opel Astra Coupe generations

In 2002 Opel offered 2 generations of the Astra Coupe. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

Opel Astra Coupe G facelift model years

Units:
facebook twitter reddit linkedin messenger whatsapp telegram skype email chat