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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
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
All other modifications 16.23 lbf⋅ft
Replace screws and nuts.
expand_moreIntake manifold support
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
1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12) 36.88 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
All other modifications 25.81 lbf⋅ft
expand_moreAir-conditioning compressor
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
1.7 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
All other modifications 14.75 lbf⋅ft
expand_moreAir-conditioning compressor bracket
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
All other modifications 14.75 lbf⋅ft
Replace sealing rings.
expand_moreAlternator
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
All other modifications 25.81 lbf⋅ft
expand_moreGenerator bracket
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_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_moreFuel-distributing pipe
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 other modifications 22.13 lbf⋅ft
expand_moreInjection nozzle (injector)
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_moreCharging
expand_moreCharge air pipes
All Opel diesel straight-4 1.7 L Z 17 DTL engines 17.7 lbf⋅ft
expand_moreTurbo charger
On exhaust manifold 19.91 lbf⋅ft
Replace seals and nuts.
expand_moreTurbocharger oil feed line
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
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 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
All other modifications 5.9 lbf⋅ft
expand_moreCylinder head screws
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
Figure 1. Cylinder head, Cylinder head screws, 1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12).
Figure 1. Cylinder head, Cylinder head screws, 1.6 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_more1.7 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_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
All other modifications 5.9 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod 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)
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 100°
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_more1.6 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°
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
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_moreFlywheel
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_moreAll other modifications
First stage 25.81 lbf⋅ft
Second stage 30°
Third stage 15°
expand_moreMain bearing
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
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
expand_moreAll other modifications
Inlet camshaft 18.44 lbf⋅ft
Outlet camshaft 18.44 lbf⋅ft
expand_moreCamshaft timing chain guide rail
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 other modifications 14.75 lbf⋅ft
expand_moreCamshaft timing gear
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
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws and nuts.
Second stage 60°
Third stage 15°
expand_moreChain tensioner
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_moreTiming case cover
All other modifications 14.75 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
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
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
All Opel diesel straight-4 1.7 L Z 17 DTL engines 28.03 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil cooler lines
expand_moreOil drain plug
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_more1.7 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.
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.
All other modifications 11.06 lbf⋅ft
Slightly oil sealing lips.
expand_moreOil filter housing
All Opel diesel straight-4 1.7 L Z 17 DTL engines 81.13 lbf⋅ft
Replace sealing rings.
All other modifications 14.75 lbf⋅ft
expand_moreOil lines
At the turbocharger 14.75 lbf⋅ft
expand_moreOil pressure sensor
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
All other modifications 22.13 lbf⋅ft
expand_moreOil pump
1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12) 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) 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_more1.7 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_moreAll other modifications
At the gearbox 29.5 lbf⋅ft
On the engine block 7.38 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
1.7 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
All other modifications 4.43 lbf⋅ft
expand_moreCrankshaft sensor
All other modifications 5.9 lbf⋅ft
expand_moreGlow plugs
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
All other modifications 14.75 lbf⋅ft
expand_moreLambda sensor
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
All other modifications 22.13 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
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_more1.6 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
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
All other modifications 33.19 lbf⋅ft
expand_moreExhaust manifold
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.
All other modifications 16.23 lbf⋅ft
Replace screws and nuts.
expand_moreExhaust manifold heat shields
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
All other modifications 7.388.85 lbf⋅ft
expand_moreExhaust pipe
All other modifications 14.75 lbf⋅ft
expand_moreExhaust pipe rear
All other modifications 5.9 lbf⋅ft
expand_moreFuel supply
Fuel filter housing 4.43 lbf⋅ft
expand_moreFuel lines
All other modifications 11.06 lbf⋅ft
expand_moreIgnition system
expand_moreSpark plugs
All other modifications 18.44 lbf⋅ft
expand_moreStart system
expand_moreStarter
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
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 2006 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.

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 2006 Opel Astra Sedan you're not only saving money, but also also improving your technical skills and learning something new.

2006 Opel Astra Sedan generations

In 2006 Opel offered 2 generations of the Astra Sedan. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

Units:
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