2004 Opel Astra Van engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


All Opel diesel straight-4 1.9 L Z 19 DTH engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Use new screws or nuts
All other modifications	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
helically from the inside out

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


All Opel diesel straight-4 1.7 L Z 17 DTH engines	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
All Opel diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreAuxiliary drive belt tensioner


All other modifications	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreAir-conditioning compressor


All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAir-conditioning compressor bracket


All other modifications	31.72 lbf⋅ft31.72 lbf⋅ft43 N⋅m


Air-conditioning compressor pressure line	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAlternator

expand_moreAll other modifications


M10	33.93 lbf⋅ft33.93 lbf⋅ft46 N⋅m
M8	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m

expand_moreGenerator bracket

expand_moreAll other modifications


M10	35.4 lbf⋅ft35.4 lbf⋅ft48 N⋅m
M14	50.15 lbf⋅ft50.15 lbf⋅ft68 N⋅m

expand_moreVacuum pump


All other modifications	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m

expand_moreCarburetion

expand_moreExhaust gas return cooler


1.7 CDTI with diesel straight-4 1.7 L 99 HP at 4400 RPM, 240 N⋅m at 2300 RPM engine (2004.3–)	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m

expand_moreExhaust recirculation pipe


All Opel diesel straight-4 1.7 L Z 17 DTH engines	21.39 lbf⋅ft21.39 lbf⋅ft29 N⋅m
Replace sealing rings.

expand_moreHigh-pressure pump pulley


All other modifications	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m

expand_moreInjection hoses


All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection nozzle (injector)

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTH engines


First stage	hand-screwed
Second stage	360°360°360°

expand_moreAll other modifications


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Second stage	slacken
Third stage	23.6 lbf⋅ft23.6 lbf⋅ft32 N⋅m

expand_moreInjection pump


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCharging

expand_moreTurbo charger

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


On exhaust manifold	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m
Replace seals and nuts.

expand_moreAll other modifications


First stage	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Replace nuts.
Second stage	35.4 lbf⋅ft35.4 lbf⋅ft48 N⋅m

expand_moreTurbocharger oil feed line

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


At the turbocharger	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Replace sealing rings.
On the engine block	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m
Replace sealing rings.


All Opel diesel straight-4 1.9 L Z 19 DTH engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace sealing rings.
All Opel diesel straight-4 1.9 L Z 19 DTJ engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace sealing rings.

expand_moreTurbocharger oil return line


At the turbocharger	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
Replace sealing rings.
On the engine block	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace sealing rings.

expand_moreCooling system

expand_moreCoolant pump


All other modifications	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m

expand_moreCoolant pump pulley


All Opel diesel straight-4 1.7 L Z 17 DTH engines	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
All other modifications	11.8 lbf⋅ft11.8 lbf⋅ft16 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


M6	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
M8	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m


All Opel diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications

Figure 1. Cylinder head, Camshaft bearing, All other modifications.


Nuts	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Tighten in several steps. See figure 1.
Screws	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreCylinder head screws

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Use new screws
Second stage	60°60°60°
Third stage	60°60°60°

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTH engines

Figure 2. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.9 L Z 19 DTH.


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Use new screws. See figure 2.
Second stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Third stage	90°90°90°
Fourth stage	90°90°90°
Fifth stage	90°90°90°

expand_moreAll other modifications


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreValve cover


All Opel diesel straight-4 1.9 L Z 19 DTH engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws and nuts.
Second stage	100°100°100°
Third stage	15°15°15°

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTH engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Use new screws.
Second stage	60°60°60°

expand_moreAll other modifications


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws and nuts.
Second stage	100°100°100°
Third stage	25°25°25°

expand_moreCrankshaft central screws


All Opel diesel straight-4 1.9 L Z 19 DTH engines	250.77 lbf⋅ft250.77 lbf⋅ft340 N⋅m
Left-hand thread
All other modifications	144.56 lbf⋅ft144.56 lbf⋅ft196 N⋅m

expand_moreCrankshaft pulley


All Opel diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFlywheel

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


First stage	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Clean the thread, use new screws and screw-locking compound.
Second stage	30°30°30°
Third stage	15°15°15°


All Opel diesel straight-4 1.9 L Z 19 DTH engines	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Clean the thread and use screw-locking compound.

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTJ engines


First stage	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Clean the thread, use new screws and screw-locking compound.
Second stage	Wait 10 minutes.
Third stage	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Control tensioner

expand_moreAll other modifications


First stage	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Retap thread in holes and use new screws.
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreMain bearing


All Opel diesel straight-4 1.7 L Z 17 DTH engines	64.91 lbf⋅ft64.91 lbf⋅ft88 N⋅m

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTH engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Use new screws.
Second stage	100°100°100°
helically from the inside out

expand_moreAll other modifications


First stage	28.76 lbf⋅ft28.76 lbf⋅ft39 N⋅m
helically from the inside out
Second stage	60°60°60°
Use new screws.


Vibration damper	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


All Opel diesel straight-4 1.9 L Z 19 DTH engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	59 lbf⋅ft59 lbf⋅ft80 N⋅m

expand_moreCamshaft timing gear

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


Part number 97320335	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m
Part number 98021306	81.87 lbf⋅ft81.87 lbf⋅ft111 N⋅m


All Opel diesel straight-4 1.9 L Z 19 DTH engines	88.51 lbf⋅ft88.51 lbf⋅ft120 N⋅m
All other modifications	81.87 lbf⋅ft81.87 lbf⋅ft111 N⋅m

expand_moreToothed belt guard

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTJ engines


M6	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreToothed belt tensioning roller


All Opel diesel straight-4 1.7 L Z 17 DTH engines	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
All Opel diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	36.14 lbf⋅ft36.14 lbf⋅ft49 N⋅m

expand_moreToothed belt tightener


1.9 CDTI with diesel straight-4 1.9 L 148 HP engine (2004.9–)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreEngine lubrication

expand_moreOil drain plug

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


Aluminium screws for engines with number from 1493405	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Up to engine number 1493404, steel screws	57.53 lbf⋅ft57.53 lbf⋅ft78 N⋅m
Replace sealing rings.


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOil filter housing

expand_moreAll other modifications


Oil filter cover	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil lines

expand_moreOil feed lines at the turbo charger


Banjo screws	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace sealing rings.

expand_moreReturn line at the cylinder head


M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace sealing rings.

expand_moreReturn line at turbocharger


M6	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
Replace sealing rings.

expand_moreOil pump


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreOil sump

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


At the gearbox	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Oil sump lower part	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Oil sump top part	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTH engines


At the gearbox	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreOn the engine block


M6	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


At the gearbox	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Otherwise	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreEngine management

expand_moreCamshaft sensor


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Replace sealing rings.

expand_moreCharge air pressure sensor


All other modifications	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m

expand_moreCrankshaft sensor


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreGlow plugs


All Opel diesel straight-4 1.7 L Z 17 DTH engines	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m
All Opel diesel straight-4 1.9 L Z 19 DTH engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	10.33 lbf⋅ft10.33 lbf⋅ft14 N⋅m


Lambda sensor	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


On the engine block	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTH engines


M10	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All other modifications	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreEngine mounting

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


On engine bracket	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m


All Opel diesel straight-4 1.9 L Z 19 DTH engines	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreAll other modifications

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 the left side of tje engine bracket


Right	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreOn the rear side of the front axle


Front	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m


Engine suspension	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

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_moreSubframe stiffening plate


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreTorque arm

expand_moreAt the subframe


Bottom	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Replace nuts.

expand_moreAt the gearbox


Bottom	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreExhaust system

expand_moreCatalytic converter

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTJ engines


Clamps	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m

expand_moreAll other modifications


At the turbocharger	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


Catalytic converter bracket	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreExhaust manifold


All Opel diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace nuts.
All other modifications	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m

expand_moreExhaust pipe

expand_moreAll Opel diesel straight-4 1.7 L Z 17 DTH engines


On primary catalytic converter	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll Opel diesel straight-4 1.9 L Z 19 DTJ engines


Front	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFuel supply

expand_moreFuel lines


All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreStart system

expand_moreStarter

expand_moreAll other modifications


At the gearbox	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
On the engine block	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Opel Astra Van 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.

Maintenance Items

Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

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 Van 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 2004 Opel Astra Van you're not only saving money, but also also improving your technical skills and learning something new.

2004 Opel Astra Van generations

In 2004 Opel offered 2 generations of the Astra Van. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

G facelift

T Platform (T-body, GM2700, GM3000) 1979-2012

2004 Opel Astra Van H Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2004 Opel Astra Van generations

G facelift

Opel Astra Van H model years

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