expand_more2.0 OPC with gasoline straight-4 2.0 L 197 HP engine (2002.11–2005.1)
First stage
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Use new screws.
Second stage
90°90°90°
Third stage
90°90°90°
Fourth stage
90°90°90°
Fifth stage
15°15°15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
expand_moreM10
Figure 2. Cylinder head, Cylinder head screws, 2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1), M10.
expand_more1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
expand_moreAt the axle support
Front
40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
expand_moreOn chassis
Right
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
On engine bracket
40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
expand_moreOn the engine block
Front
40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Right long screws
40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Right short screws
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
expand_more1.7 CDTI with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2009.12)
On chassis
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
On the engine block
40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Replace screws.
1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.1)
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
expand_moreAt the gearbox
Front
44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
expand_moreOn chassis
Left
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Right
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
expand_moreOn front axle
Front
40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
expand_moreAll other modifications
On chassis
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
On engine bracket
40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Replace screws.
expand_moreSubframe
First stage
66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage
45°45°45°
Third stage
15°15°15°
expand_moreExhaust system
expand_moreCatalytic converter
1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.1)
47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
expand_moreAt the cylinder head
First stage
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Second stage
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
expand_more2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1)
At the turbocharger
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace bolts.
All other modifications
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
expand_moreExhaust manifold
1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace screws and nuts.
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.2–2005.1)
X14XE engine
16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.
Z14XE engine
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Replace screws and nuts.
1.7 CDTI with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2009.12)
50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m
Replace sealing rings.
1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.1)
17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Replace screws and nuts.
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Replace screws and nuts.
expand_more2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1)
First stage
5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Note correct order of tensioning.
Second stage
Wait 5 minutes.
Replace the nuts and use fitting paste
Third stage
5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Replace nuts.
All other modifications
16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.
expand_moreExhaust manifold heat shields
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All other modifications
7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
expand_moreExhaust pipe
expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.1)
At the turbocharger
19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m
Replace sealing rings.
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1)
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1)
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
11.8 lbf⋅ft11.8 lbf⋅ft16 N⋅m
Replace nuts.
All other modifications
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Exhaust pipe bracket
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
expand_moreExhaust pipe rear
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.2–2005.1)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.2–2005.1)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
1.6 with gasoline straight-4 1.6 L 83 HP at 5400 RPM, 138 N⋅m at 2600 RPM engine (2000.9–2005.1)
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace nuts.
expand_more2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1)
M8
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
All other modifications
5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Exhaust system middle heat protection plate
2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m
expand_moreFuel supply
Fuel filter housing
4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
expand_moreFuel lines
2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 230 N⋅m at 1950 RPM engine (1999.8–2005.1)
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All other modifications
11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
expand_moreIgnition system
expand_moreSpark plugs
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreStart system
expand_moreStarter
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.2–2005.1)
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.2–2005.1)
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.2–2005.1)
Bottom
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Top
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
1.7 CDTI with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2009.12)
44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.1)
28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
At the gearbox
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
On the engine block
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1)
At the gearbox
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
On the engine block
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.2–2005.1)
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
expand_more2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1)
At the gearbox
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
On the engine block
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1)
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All other modifications
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2003 Opel Astra Hatchback 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.
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 Hatchback 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 2003 Opel Astra Hatchback you're not only saving money, but also also improving your technical skills and learning something new.