2003 Opel Astra Sedan G facelift Engine Fastener Tightening Specifications

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Condition Value
expand_moreAir intake system
expand_moreIntake 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) 6.64 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.9–2005.1) 14.75 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 14.75 lbf⋅ft
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
Lower section of intake manifold 14.75 lbf⋅ft
Replace screws and nuts.
Upper section of intake manifold 5.9 lbf⋅ft
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) 17.7 lbf⋅ft
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) 18.44 lbf⋅ft
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 14.75 lbf⋅ft
Use new screws or nuts
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1)
Lower section of intake manifold 16.23 lbf⋅ft
Replace screws and nuts.
Upper section of intake manifold 5.9 lbf⋅ft
expand_more2.0 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)
Lower section of intake manifold 16.23 lbf⋅ft
Replace nuts.
Upper section of intake manifold 5.9 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 6.64 lbf⋅ft
expand_more2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
Lower section of intake manifold 16.23 lbf⋅ft
Replace screws and nuts.
Upper section of intake manifold 5.9 lbf⋅ft
All other modifications 16.23 lbf⋅ft
Replace screws and nuts.
expand_moreIntake manifold support
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.9–2005.1) 14.75 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 14.75 lbf⋅ft
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 14.75 lbf⋅ft
expand_moreAll other modifications
On intake manifold 14.75 lbf⋅ft
Support on cylinder head 25.81 lbf⋅ft
expand_moreAuxiliary assemblies
expand_moreAuxiliary drive belt deflection pulley
All Opel diesel straight-4 1.7 L Z 17 DTL engines 28.03 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
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)
M10 40.57 lbf⋅ft
M8 14.75 lbf⋅ft
1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12) 36.88 lbf⋅ft
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) 18.44 lbf⋅ft
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) 36.88 lbf⋅ft
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) 36.88 lbf⋅ft
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
With air-conditioning 18.44 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1) 30.98 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.9–2005.1) 30.98 lbf⋅ft
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) 30.98 lbf⋅ft
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) 30.98 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 31.72 lbf⋅ft
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) 30.98 lbf⋅ft
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 30.98 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreAir-conditioning compressor
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.9–2005.1) 25.81 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 25.81 lbf⋅ft
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.9–2005.1)
Front 25.81 lbf⋅ft
Rear 14.75 lbf⋅ft
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
Front 25.81 lbf⋅ft
Rear 14.75 lbf⋅ft
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⋅ft
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) 14.01 lbf⋅ft
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) 14.01 lbf⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
Front 25.81 lbf⋅ft
Rear 14.75 lbf⋅ft
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 25.81 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 15.49 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreAir-conditioning compressor bracket
All Opel gasoline straight-4 2.0 L X 20 XEV engines 14.75 lbf⋅ft
expand_moreAll Opel diesel straight-4 1.7 L Y 17 DT engines
M10 nuts 33.93 lbf⋅ft
M10 screws 35.4 lbf⋅ft
M14 screws 50.15 lbf⋅ft
expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTL engines
M10 nuts 33.93 lbf⋅ft
M10 screws 35.4 lbf⋅ft
M14 screws 50.15 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreAir-conditioning compressor pressure line
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.9–2005.1) 16.23 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 16.23 lbf⋅ft
All other modifications 14.75 lbf⋅ft
Replace sealing rings.
expand_moreAlternator
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
Bottom 25.81 lbf⋅ft
Top 14.75 lbf⋅ft
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)
M10 33.93 lbf⋅ft
M8 14.01 lbf⋅ft
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)
M10 33.93 lbf⋅ft
M8 14.01 lbf⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
Bottom 25.81 lbf⋅ft
Top 14.75 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 15.49 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreGenerator bracket
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) 14.75 lbf⋅ft
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) 14.75 lbf⋅ft
All other modifications 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_moreVacuum pump
All Opel diesel straight-4 2.0 L X 20 DTH engines 5.9 lbf⋅ft
All Opel diesel straight-4 2.0 L Y 20 DTH engines 5.9 lbf⋅ft
expand_moreCarburetion
Injection pump drive wheel 20.65 lbf⋅ft
expand_moreExhaust gas return cooler
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) 20.65 lbf⋅ft
Replace sealing rings.
expand_moreExhaust gas return valve
All Opel diesel straight-4 1.7 L Z 17 DTL engines 17.7 lbf⋅ft
Replace sealing rings.
All other modifications 14.75 lbf⋅ft
expand_moreExhaust recirculation pipe
All Opel diesel straight-4 1.7 L Y 17 DT engines 20.65 lbf⋅ft
Replace sealing rings.
expand_moreFuel-distributing pipe
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) 2.95 lbf⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
At the exhaust manifold 5.9 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 6.64 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreHigh-pressure line
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) 18.44 lbf⋅ft
expand_moreHigh-pressure pump pulley
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⋅ft
expand_moreInjection hoses
All Opel diesel straight-4 1.7 L Y 17 DT engines 16.96 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreInjection nozzle (injector)
All Opel diesel straight-4 1.7 L Y 17 DT engines 16.23 lbf⋅ft
All Opel gasoline straight-4 1.2 L Z 12 XE engines 4.43 lbf⋅ft
Distributor pipe
expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTL engines
First stage 29.5 lbf⋅ft
Second stage slacken
Third stage 23.6 lbf⋅ft
expand_moreAll other modifications
First stage hand-screwed
Second stage 360°
Injection pump 18.44 lbf⋅ft
expand_moreInjection pump pulley
All Opel diesel straight-4 1.7 L Y 17 DT engines 51.63 lbf⋅ft
expand_moreCharging
expand_moreCharge air pipes
All Opel diesel straight-4 1.7 L Y 17 DT engines 17.7 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 17.7 lbf⋅ft
expand_moreTurbo charger
expand_moreAll Opel diesel straight-4 1.7 L Y 17 DT engines
On exhaust manifold 19.91 lbf⋅ft
Replace sealing rings.
expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTL engines
On exhaust manifold 19.91 lbf⋅ft
Replace seals and nuts.
expand_moreTurbocharger bracket
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) 19.91 lbf⋅ft
expand_moreTurbocharger oil feed line
expand_moreAll Opel diesel straight-4 1.7 L Y 17 DT engines
At the turbocharger 15.49 lbf⋅ft
On the engine block 7.38 lbf⋅ft
expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTL engines
At the turbocharger 15.49 lbf⋅ft
Replace sealing rings.
On the engine block 20.65 lbf⋅ft
Replace sealing rings.
expand_moreTurbocharger oil return line
expand_moreCooling system
expand_moreCoolant drain plug
Coolant pump 14.75 lbf⋅ft
expand_moreCoolant pump
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) 17.7 lbf⋅ft
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) 7.38 lbf⋅ft
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 18.44 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1) 14.75 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.9–2005.1) 14.75 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 16.96 lbf⋅ft
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) 14.75 lbf⋅ft
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 14.75 lbf⋅ft
All other modifications 5.9 lbf⋅ft
Use new screws with the screw- locking compound.
expand_moreCoolant pump pulley
All Opel diesel straight-4 1.7 L Y 17 DT engines 7.38 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 8.85 lbf⋅ft
All other modifications 14.75 lbf⋅ft
Fan wheel 3.69 lbf⋅ft
expand_moreRadiator mounting
Bottom 11.06 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
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)
M6 16.23 lbf⋅ft
M8 19.91 lbf⋅ft
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)
M10 31.72 lbf⋅ft
M8 16.23 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1) 11.06 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.9–2005.1) 11.06 lbf⋅ft
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) 11.06 lbf⋅ft
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) 11.06 lbf⋅ft
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
Guide bearing 16.96 lbf⋅ft
Otherwise 6.64 lbf⋅ft
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) 11.06 lbf⋅ft
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 11.06 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreCylinder head screws
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)
First stage 18.44 lbf⋅ft
Use new screws.
Second stage 60°
Third stage 60°
Fourth stage 60°
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
Figure 1. Cylinder head, Cylinder head screws, 1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1).
Figure 1. Cylinder head, Cylinder head screws, 1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1).
First stage 18.44 lbf⋅ft
Replace screws. See figure 1.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 45°
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.9–2005.1)
First stage 18.44 lbf⋅ft
Use new screws See figure 1.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 45°
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
First stage 18.44 lbf⋅ft
Replace screws. See figure 1.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 45°
expand_more1.6 with gasoline straight-4 1.6 L 83 HP at 5400 RPM, 138 N⋅m at 2600 RPM engine (2000.9–2005.1)
First stage 18.44 lbf⋅ft
Replace screws. See figure 1.
Second stage 60°
Third stage 60°
Fourth stage 60°
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)
First stage 28.76 lbf⋅ft
Use new screws See figure 1.
Second stage 60°
Third stage 60°
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)
First stage 28.76 lbf⋅ft
Use new screws See figure 1.
Second stage 60°
Third stage 13°
Fourth stage 60°
Fifth stage 13°
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
First stage 18.44 lbf⋅ft
Replace screws. See figure 1.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 45°
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
First stage 18.44 lbf⋅ft
Use new screws See figure 1.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
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 (2001.3–2005.1), M10.
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 (2001.3–2005.1), M10.
First stage 22.13 lbf⋅ft
Use new screws. See figure 2.
Second stage 75°
Third stage 75°
Fourth stage 15°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Use new screws.
Second stage 65°
Third stage 65°
Fourth stage 65°
Fifth stage 65°
Sixth stage 15°
expand_moreValve cover
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) 7.38 lbf⋅ft
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) 7.38 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 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 (2001.3–2005.1)
First stage 5.9 lbf⋅ft
Replace screws.
Second stage 30°
expand_moreConnecting rod bearing
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_moreM6
First stage 7.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_moreM6,5
First stage 9.59 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
First stage 18.44 lbf⋅ft
Second stage 30°
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)
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 100°
Third stage 15°
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)
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 100°
Third stage 15°
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
First stage 25.81 lbf⋅ft
Replace screws and nuts.
Second stage 45°
Third stage 15°
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1)
First stage 25.81 lbf⋅ft
Second stage 45°
Third stage 15°
expand_more2.0 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)
First stage 25.81 lbf⋅ft
Second stage 45°
Third stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 50°
Third stage 50°
Fourth stage 10°
expand_more2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
First stage 25.81 lbf⋅ft
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
Crankcase ventilation pipe 5.9 lbf⋅ft
Use new seals.
expand_moreCrankshaft central screws
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)
First stage 110.63 lbf⋅ft
Replace screws and nuts.
Second stage 45°
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
First stage 70.07 lbf⋅ft
Use new screw.
Second stage 30°
Third stage 15°
expand_more1.6 with gasoline straight-4 1.6 L 83 HP at 5400 RPM, 138 N⋅m at 2600 RPM engine (2000.9–2005.1)
First stage 70.07 lbf⋅ft
Second stage 30°
Third stage 15°
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) 144.56 lbf⋅ft
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) 144.56 lbf⋅ft
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
First stage 95.88 lbf⋅ft
Use new screw.
Second stage 40–50°
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1)
First stage 110.63 lbf⋅ft
Replace screws and nuts.
Second stage 45°
Third stage 15°
expand_more2.0 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)
First stage 110.63 lbf⋅ft
Replace screws and nuts.
Second stage 45°
Third stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
First stage 73.76 lbf⋅ft
Second stage 75°
Third stage 15°
expand_more2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
First stage 110.63 lbf⋅ft
Replace screws and nuts.
Second stage 45°
Third stage 15°
expand_moreAll other modifications
First stage 70.07 lbf⋅ft
Use new screw.
Second stage 45°
Third stage 15°
expand_moreCrankshaft pulley
All other modifications 14.75 lbf⋅ft
expand_moreDrive plate
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 44.25 lbf⋅ft
Replace screws.
expand_moreFlywheel
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)
First stage 25.81 lbf⋅ft
Replace screws and nuts.
Second stage 60°
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
First stage 25.81 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
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)
First stage 21.39 lbf⋅ft
Clean the thread, use new screws and screw-locking compound.
Second stage 60°
Third stage 15°
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)
First stage 21.39 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 15°
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
First stage 25.81 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
First stage 47.94 lbf⋅ft
Replace screws. Use screw-locking compound.
Second stage 30°
Third stage 15°
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1)
First stage 33.19 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
expand_more2.0 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)
First stage 33.19 lbf⋅ft
Replace screws.
Second stage 30°
Third stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
First stage 39.09 lbf⋅ft
Clean the thread, use new screws and screw-locking compound.
Second stage 25°
expand_more2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
First stage 33.19 lbf⋅ft
Use new screw.
Second stage 30°
Third stage 15°
expand_moreAll other modifications
First stage 25.81 lbf⋅ft
Second stage 30°
Third stage 15°
expand_moreMain bearing
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_moreM6
First stage 7.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
expand_moreM8
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 60°
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
First stage 36.88 lbf⋅ft
Second stage 45°
Third stage 15°
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) 64.91 lbf⋅ft
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) 64.91 lbf⋅ft
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1)
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_more2.0 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)
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
expand_moreM10
First stage 14.75 lbf⋅ft
Second stage 70°
Third stage 15°
M8 16.96 lbf⋅ft
expand_more2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
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
expand_moreCamshaft drive belt deflection pulley
1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12) 18.44 lbf⋅ft
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) 59 lbf⋅ft
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) 59 lbf⋅ft
expand_moreAll other modifications
Inlet camshaft 18.44 lbf⋅ft
Outlet camshaft 18.44 lbf⋅ft
expand_moreCamshaft timing chain guide rail
All Opel gasoline straight-4 2.2 L Z 22 SE engines 7.38 lbf⋅ft
All other modifications 5.9 lbf⋅ft
Camshaft timing chain slip rail 5.9 lbf⋅ft
Use screw-locking compound.
Camshaft timing chain tensioner 5.9 lbf⋅ft
expand_moreCamshaft timing chain tensioning rail
All Opel gasoline straight-4 2.2 L Z 22 SE engines 7.38 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreCamshaft timing gear
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)
First stage 36.88 lbf⋅ft
Replace screws and nuts.
Second stage 60°
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) 33.19 lbf⋅ft
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) 47.2 lbf⋅ft
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) 47.2 lbf⋅ft
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1)
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 30°
expand_more2.0 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)
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 30°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
First stage 62.69 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
expand_more2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
First stage 66.38 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 30°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_moreChain tensioner
expand_moreAll Opel diesel straight-4 2.0 L X 20 DTH engines
Cap 44.25 lbf⋅ft
expand_moreAll Opel gasoline straight-4 2.2 L Z 22 SE engines
Balance shaft timing chain 7.38 lbf⋅ft
Camshaft timing chain 55.32 lbf⋅ft
Clean the thread.
All other modifications 5.9 lbf⋅ft
Chain tensioner locking screws 44.25 lbf⋅ft
Control drive chain guide rail 5.9 lbf⋅ft
expand_moreInlet camshaft wheel
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
First stage 36.88 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_moreOutlet camshaft wheel
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
First stage 36.88 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_moreTiming case cover
expand_moreAll Opel gasoline straight-4 1.2 L Z 12 XE engines
M10 25.81 lbf⋅ft
M6 5.9 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 15.49 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreToothed belt guard
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 2.95 lbf⋅ft
expand_moreToothed belt guard at the bottom
1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12) 4.43 lbf⋅ft
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) 7.38 lbf⋅ft
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) 7.38 lbf⋅ft
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 4.43 lbf⋅ft
All other modifications 2.95 lbf⋅ft
expand_moreToothed belt guard at the top
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) 7.38 lbf⋅ft
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) 7.38 lbf⋅ft
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 4.43 lbf⋅ft
All other modifications 2.95 lbf⋅ft
expand_moreToothed belt tensioning roller
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) 28.03 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreToothed belt tightener
expand_moreAll Opel diesel straight-4 1.7 L Y 17 DT engines
Tension pulley with leaf spring 28.03 lbf⋅ft
Tensioning roller with spiral spring 36.14 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 28.03 lbf⋅ft
All Opel gasoline straight-4 1.8 L Z 18 XE engines 14.75 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil cooler
All Opel diesel straight-4 1.7 L Y 17 DT engines 8.85 lbf⋅ft
expand_moreOil cooler lines
expand_moreOil drain plug
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
Torx screws 10.33 lbf⋅ft
With hexagon-head screws 33.19 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.9–2005.1) 33.19 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP at 6000 RPM, 150 N⋅m at 3600 RPM engine (1998.9–2005.1) 33.19 lbf⋅ft
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
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
expand_more1.6 with gasoline straight-4 1.6 L 83 HP at 5400 RPM, 138 N⋅m at 2600 RPM engine (2000.9–2005.1)
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
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)
Aluminium screws for engines with number from 1493405 14.75 lbf⋅ft
Up to engine number 1493404, steel screws 57.53 lbf⋅ft
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) 57.53 lbf⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
Torx screws 10.33 lbf⋅ft
With hexagon-head screws 33.19 lbf⋅ft
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
Torx screws 7.38 lbf⋅ft
With hexagon-head screws 33.19 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 18.44 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreOil filter
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) 18.44 lbf⋅ft
Lubricate the seal with engine oil.
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)
Oil filter cover 18.44 lbf⋅ft
Slightly oil sealing lips.
All other modifications 11.06 lbf⋅ft
Slightly oil sealing lips.
expand_moreOil filter housing
expand_moreAll Opel diesel straight-4 2.0 L X 20 DTH engines
X20DTH engine 18.44 lbf⋅ft
Y20DTH engine 14.75 lbf⋅ft
All Opel diesel straight-4 1.7 L Y 17 DT engines 81.13 lbf⋅ft
Replace sealing rings.
expand_moreAll Opel gasoline straight-4 1.2 L Z 12 XE engines
On the engine block 14.75 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 81.13 lbf⋅ft
Replace sealing rings.
expand_moreAll Opel gasoline straight-4 1.8 L Z 18 XE engines
On the engine block 33.19 lbf⋅ft
All Opel gasoline straight-4 2.2 L Z 22 SE engines 18.44 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreOil lines
At the turbocharger 14.75 lbf⋅ft
expand_moreOil pressure sensor
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) 14.75 lbf⋅ft
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) 14.75 lbf⋅ft
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) 14.75 lbf⋅ft
Replace sealing rings.
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 29.5 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreOil pump
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.9–2005.1) 7.38 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 7.38 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.9–2005.1) 7.38 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP at 6000 RPM, 150 N⋅m at 3600 RPM engine (1998.9–2005.1) 7.38 lbf⋅ft
1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12) 14.75 lbf⋅ft
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) 7.38 lbf⋅ft
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) 7.38 lbf⋅ft
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) 7.38 lbf⋅ft
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 7.38 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreOil pump chain wheel
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)
First stage 44.25 lbf⋅ft
Replace screws.
Second stage Wait 60 seconds.
Third stage Unscrew nut(s).
Fourth stage 44.25 lbf⋅ft
expand_moreOil sump
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)
At the gearbox 38.35 lbf⋅ft
Otherwise 7.38 lbf⋅ft
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
At the gearbox 14.75 lbf⋅ft
On the engine block 7.38 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.9–2005.1) 5.9 lbf⋅ft
Clean the thread and use screw-locking compound.
1.6 16V with gasoline straight-4 1.6 L 99 HP at 6000 RPM, 150 N⋅m at 3600 RPM engine (1998.9–2005.1) 5.9 lbf⋅ft
Clean the thread and use screw-locking compound.
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)
At the gearbox 29.5 lbf⋅ft
Oil sump lower part 7.38 lbf⋅ft
Oil sump top part 7.38 lbf⋅ft
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)
Oil sump lower part 7.38 lbf⋅ft
Oil sump top part 7.38 lbf⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
At the gearbox 29.5 lbf⋅ft
On the engine block 7.38 lbf⋅ft
Clean the thread and use screw-locking compound.
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
At the gearbox 29.5 lbf⋅ft
Oil sump lower part 14.75 lbf⋅ft
Oil sump top part 14.75 lbf⋅ft
Clean the thread and use screw-locking compound.
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1)
expand_moreAt the gearbox
M10 29.5 lbf⋅ft
M8 14.75 lbf⋅ft
On the engine block 14.75 lbf⋅ft
expand_more2.0 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)
expand_moreX20DTH engine
Oil sump lower part 5.9 lbf⋅ft
Oil sump top part 14.75 lbf⋅ft
expand_moreY20DTH engine
On the engine block 14.75 lbf⋅ft
expand_moreAt the gearbox
M10 29.5 lbf⋅ft
M8 14.75 lbf⋅ft
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
At the gearbox 29.5 lbf⋅ft
On the engine block 16.96 lbf⋅ft
expand_more2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1)
expand_moreAt the gearbox
M10 29.5 lbf⋅ft
M8 14.75 lbf⋅ft
On the engine block 14.75 lbf⋅ft
expand_moreAll other modifications
At the gearbox 29.5 lbf⋅ft
On the engine block 7.38 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
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) 5.9 lbf⋅ft
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) 7.38 lbf⋅ft
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 5.9 lbf⋅ft
All other modifications 4.43 lbf⋅ft
expand_moreCharge air pressure sensor
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) 7.38 lbf⋅ft
expand_moreCrankshaft sensor
1.4 16V with gasoline straight-4 1.4 L 89 HP at 6000 RPM, 125 N⋅m at 4000 RPM engine (1998.9–2005.1) 7.38 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 7.38 lbf⋅ft
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) 7.38 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreGlow plugs
All Opel diesel straight-4 1.7 L Y 17 DT engines 13.28 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 13.28 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreKnock sensor
1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.9–2005.1) 9.59 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP at 6000 RPM, 150 N⋅m at 3600 RPM engine (1998.9–2005.1) 9.59 lbf⋅ft
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 9.59 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 16.96 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreLambda sensor
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) 29.5 lbf⋅ft
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
Lambda sensor downstream of catalytic converter 29.5 lbf⋅ft
Lambda sensors in front of catalytic converter 22.13 lbf⋅ft
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) 29.5 lbf⋅ft
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 29.5 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 40.57 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
All Opel diesel straight-4 1.7 L Y 17 DT engines 40.57 lbf⋅ft
expand_moreAll Opel gasoline straight-4 1.6 L Z 16 XEP engines
expand_moreOn the engine block
Right 36.88 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 29.5 lbf⋅ft
expand_moreAll other modifications
On engine mounting 40.57 lbf⋅ft
expand_moreEngine mounting
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⋅ft
expand_moreOn chassis
Right 25.81 lbf⋅ft
On engine bracket 40.57 lbf⋅ft
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⋅ft
Right long screws 40.57 lbf⋅ft
Right short screws 25.81 lbf⋅ft
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⋅ft
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1)
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
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⋅ft
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⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
expand_moreAt the cylinder head
First stage 8.85 lbf⋅ft
Second stage 8.85 lbf⋅ft
All other modifications 33.19 lbf⋅ft
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⋅ft
Replace screws and nuts.
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
X14XE engine 16.23 lbf⋅ft
Replace screws and nuts.
Z14XE engine 8.85 lbf⋅ft
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⋅ft
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⋅ft
Replace screws and nuts.
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 8.85 lbf⋅ft
Replace screws and nuts.
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 8.85 lbf⋅ft
Replace nuts.
All other modifications 16.23 lbf⋅ft
Replace screws and nuts.
expand_moreExhaust manifold heat shields
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) 7.38 lbf⋅ft
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) 8.85 lbf⋅ft
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) 8.85 lbf⋅ft
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 5.9 lbf⋅ft
All other modifications 7.38–8.85 lbf⋅ft
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⋅ft
Replace sealing rings.
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 25.81 lbf⋅ft
Replace screws.
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1) 18.44 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 11.8 lbf⋅ft
Replace nuts.
All other modifications 14.75 lbf⋅ft
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 (1998.9–2005.1) 14.75 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 14.75 lbf⋅ft
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⋅ft
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1) 25.81 lbf⋅ft
Replace nuts.
All other modifications 5.9 lbf⋅ft
expand_moreFuel supply
Fuel filter housing 4.43 lbf⋅ft
expand_moreFuel lines
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1)
On fuel-distributing pipe 11.06 lbf⋅ft
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⋅ft
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⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 5.9 lbf⋅ft
All other modifications 11.06 lbf⋅ft
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 (2001.3–2005.1) 14.75 lbf⋅ft
All other modifications 18.44 lbf⋅ft
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 (1998.9–2005.1) 29.5 lbf⋅ft
1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.9–2005.1) 29.5 lbf⋅ft
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.9–2005.1)
Bottom 18.44 lbf⋅ft
Top 29.5 lbf⋅ft
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⋅ft
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⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.6–2005.1)
At the gearbox 29.5 lbf⋅ft
On the engine block 18.44 lbf⋅ft
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.9–2005.1)
At the gearbox 29.5 lbf⋅ft
On the engine block 33.19 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.9–2005.1) 33.19 lbf⋅ft
2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.9–2005.1) 33.19 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2001.3–2005.1) 29.5 lbf⋅ft
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⋅ft
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 33.19 lbf⋅ft
All other modifications 18.44 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2003 Opel Astra Sedan 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.

Table of Contents

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 Sedan 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 Sedan you're not only saving money, but also also improving your technical skills and learning something new.

Opel Astra Sedan G facelift model years

Units:
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