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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
All Opel diesel straight-4 1.2 L Z 13 DTH engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 16.23 lbf⋅ft
Use new screws or nuts
All other modifications 17.7 lbf⋅ft
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⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 18.44 lbf⋅ft
All other modifications 36.88 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
All Opel diesel straight-4 1.7 L A 17 DTJ engines 66.38 lbf⋅ft
All Opel diesel straight-4 1.7 L A 17 DTR engines 66.38 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTJ engines 66.38 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTR engines 66.38 lbf⋅ft
All other modifications 36.88 lbf⋅ft
expand_moreAir-conditioning compressor
All Opel diesel straight-4 1.2 L Z 13 DTH engines 16.23 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreAir-conditioning compressor bracket
All Opel diesel straight-4 1.2 L Z 13 DTH engines 14.75 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 36.88 lbf⋅ft
All other modifications 31.72 lbf⋅ft
Air-conditioning compressor pressure line 14.75 lbf⋅ft
expand_moreAlternator
All Opel diesel straight-4 1.2 L Z 13 DTH engines 16.23 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 51.63 lbf⋅ft
expand_moreAll other modifications
M10 33.93 lbf⋅ft
M8 14.01 lbf⋅ft
expand_moreGenerator bracket
All Opel diesel straight-4 1.2 L Z 13 DTH engines 16.23 lbf⋅ft
expand_moreAll other modifications
M10 35.4 lbf⋅ft
M14 50.15 lbf⋅ft
expand_moreVacuum pump
First stage 3.69 lbf⋅ft
Second stage 14.75 lbf⋅ft
All other modifications 17.7 lbf⋅ft
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⋅ft
expand_moreExhaust recirculation pipe
All Opel diesel straight-4 1.7 L Z 17 DTH engines 21.39 lbf⋅ft
Replace sealing rings.
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
Screws 18.44 lbf⋅ft
Replace sealing rings.
expand_moreHigh-pressure pump pulley
All Opel diesel straight-4 1.9 L Z 19 DT engines 36.88 lbf⋅ft
All other modifications 50.89 lbf⋅ft
expand_moreInjection hoses
All Opel diesel straight-4 1.9 L Z 19 DT engines 16.96 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreInjection nozzle (injector)
All Opel diesel straight-4 1.2 L Z 13 DTH engines 14.75 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 23.6 lbf⋅ft
First stage hand-screwed
Second stage 360°
expand_moreAll other modifications
First stage 29.5 lbf⋅ft
Second stage slacken
Third stage 23.6 lbf⋅ft
expand_moreInjection pump
M7 11.06 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreCharging
expand_moreTurbo charger
All Opel diesel straight-4 1.2 L Z 13 DTH engines 18.44 lbf⋅ft
On exhaust manifold 19.91 lbf⋅ft
Replace seals and nuts.
expand_moreAll other modifications
First stage 17.7 lbf⋅ft
Replace nuts.
Second stage 35.4 lbf⋅ft
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.
All Opel diesel straight-4 1.9 L Z 19 DT engines 11.06 lbf⋅ft
Replace sealing rings.
All Opel diesel straight-4 1.9 L Z 19 DTH engines 11.06 lbf⋅ft
Replace sealing rings.
All Opel diesel straight-4 1.9 L Z 19 DTJ engines 11.06 lbf⋅ft
Replace sealing rings.
expand_moreTurbocharger oil return line
At the turbocharger 6.64 lbf⋅ft
Replace sealing rings.
On the engine block 18.44 lbf⋅ft
Replace sealing rings.
expand_moreCooling system
expand_moreCoolant pump
All Opel diesel straight-4 1.2 L Z 13 DTH engines 6.64 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 18.44 lbf⋅ft
All other modifications 17.7 lbf⋅ft
expand_moreCoolant pump pulley
All Opel diesel straight-4 1.7 L Z 17 DTH engines 8.85 lbf⋅ft
All other modifications 11.8 lbf⋅ft
expand_moreRadiator mounting
1.9 CDTI with diesel straight-4 1.9 L 118 HP engine (2005.9–) 11.06 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
M6 16.23 lbf⋅ft
M8 19.91 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 18.44 lbf⋅ft
expand_moreAll other modifications
Figure 1. Cylinder head, Camshaft bearing, All other modifications.
Figure 1. Cylinder head, Camshaft bearing, All other modifications.
Nuts 16.23 lbf⋅ft
Tighten in several steps. See figure 1.
Screws 19.91 lbf⋅ft
expand_moreCylinder head screws
First stage 36.88 lbf⋅ft
Use new screws.
Second stage 90°
Third stage 90°
Figure 2. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.2 L Z 13 DTH.
Figure 2. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.2 L Z 13 DTH.
First stage 29.5 lbf⋅ft
Use new screws. See figure 2.
Second stage 90°
Third stage 90°
First stage 29.5 lbf⋅ft
Use new screws
Second stage 60°
Third stage 60°
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
Figure 3. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.9 L Z 19 DT.
Figure 3. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.9 L Z 19 DT.
First stage 18.44 lbf⋅ft
Replace screws. See figure 3.
Second stage 47.94 lbf⋅ft
Third stage 90°
Fourth stage 90°
Fifth stage 90°
First stage 14.75 lbf⋅ft
Use new screws. See figure 3.
Second stage 47.94 lbf⋅ft
Third stage 90°
Fourth stage 90°
Fifth stage 90°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws.
Second stage 90°
Third stage 90°
expand_moreValve cover
Figure 4. Cylinder head, Valve cover, Opel diesel straight-4 1.2 L Z 13 DTH.
Figure 4. Cylinder head, Valve cover, Opel diesel straight-4 1.2 L Z 13 DTH.
M7 13.28 lbf⋅ft
See figure 4.
M8 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 5.9 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
First stage 14.75 lbf⋅ft
Use new screws.
Second stage 40°
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 100°
Third stage 15°
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
First stage 18.44 lbf⋅ft
Use new screws.
Second stage 60°
First stage 18.44 lbf⋅ft
Use new screws.
Second stage 60°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 100°
Third stage 25°
expand_moreCrankshaft central screws
All Opel diesel straight-4 1.2 L Z 13 DTH engines 169.64 lbf⋅ft
Left-hand thread
All Opel diesel straight-4 1.9 L Z 19 DT engines 250.77 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 250.77 lbf⋅ft
Left-hand thread
All other modifications 144.56 lbf⋅ft
expand_moreCrankshaft pulley
All Opel diesel straight-4 1.2 L Z 13 DTH engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 18.44 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreFlywheel
All Opel diesel straight-4 1.2 L Z 13 DTH engines 32.45 lbf⋅ft
First stage 62.69 lbf⋅ft
Clean the thread, use new screws and screw-locking compound.
Second stage 30°
Third stage 15°
All Opel diesel straight-4 1.9 L Z 19 DT engines 118.01 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 118.01 lbf⋅ft
Clean the thread and use screw-locking compound.
First stage 118.01 lbf⋅ft
Clean the thread, use new screws and screw-locking compound.
Second stage Wait 10 minutes.
Third stage 118.01 lbf⋅ft
Control tensioner
expand_moreAll other modifications
First stage 62.69 lbf⋅ft
Retap thread in holes and use new screws.
Second stage 30°
Third stage 15°
expand_moreMain bearing
expand_moreInside (M10)
Figure 5. Engine block, Main bearing, Opel diesel straight-4 1.2 L Z 13 DTH, Inside (M10).
Figure 5. Engine block, Main bearing, Opel diesel straight-4 1.2 L Z 13 DTH, Inside (M10).
First stage 14.75 lbf⋅ft
Use new screws. See figure 5.
Second stage 90°
expand_moreOutside
M8 22.13 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTH engines 64.91 lbf⋅ft
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
First stage 18.44 lbf⋅ft
Use new screws.
Second stage 100°
helically from the inside out
First stage 18.44 lbf⋅ft
Use new screws.
Second stage 100°
helically from the inside out
expand_moreAll other modifications
First stage 28.76 lbf⋅ft
helically from the inside out
Second stage 60°
Use new screws.
Vibration damper 18.44 lbf⋅ft
expand_moreEngine control
expand_moreCamshaft drive belt deflection pulley
All Opel diesel straight-4 1.9 L Z 19 DT engines 36.88 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 36.88 lbf⋅ft
All other modifications 59 lbf⋅ft
expand_moreCamshaft timing gear
All Opel diesel straight-4 1.2 L Z 13 DTH engines 110.63 lbf⋅ft
Drive wheel toothed belt
Part number 97320335 47.2 lbf⋅ft
Part number 98021306 81.87 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 88.51 lbf⋅ft
Replace screws.
All Opel diesel straight-4 1.9 L Z 19 DTH engines 88.51 lbf⋅ft
All other modifications 81.87 lbf⋅ft
expand_moreChain tensioner
1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2005.8–) 6.64 lbf⋅ft
expand_moreControl drive chain guide rail
1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2005.8–) 6.64 lbf⋅ft
expand_moreControl drive chain tensioning rail
1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2005.8–) 6.64 lbf⋅ft
expand_moreTiming case cover
1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2005.8–) 6.64 lbf⋅ft
expand_moreToothed belt guard
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
M6 6.64 lbf⋅ft
M8 18.44 lbf⋅ft
M6 6.64 lbf⋅ft
M8 18.44 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreToothed belt tensioning roller
All Opel diesel straight-4 1.7 L Z 17 DTH engines 28.03 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 18.44 lbf⋅ft
All other modifications 36.14 lbf⋅ft
expand_moreToothed belt tightener
1.9 CDTI with diesel straight-4 1.9 L 148 HP engine (2004.9–) 18.44 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil drain plug
Engine oil 14.75 lbf⋅ft
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 14.75 lbf⋅ft
expand_moreOil filter housing
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
On the engine block 36.88 lbf⋅ft
Otherwise 18.44 lbf⋅ft
expand_moreAll other modifications
Oil filter cover 18.44 lbf⋅ft
expand_moreOil lines
expand_moreOil feed lines at the turbo charger
Banjo screws 11.06 lbf⋅ft
Replace sealing rings.
expand_moreReturn line at the cylinder head
M8 18.44 lbf⋅ft
Replace sealing rings.
expand_moreReturn line at turbocharger
M6 6.64 lbf⋅ft
Replace sealing rings.
expand_moreOil pump
All Opel diesel straight-4 1.9 L Z 19 DT engines 6.64 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreOil sump
All Opel diesel straight-4 1.2 L Z 13 DTH engines 6.64 lbf⋅ft
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 Opel diesel straight-4 1.9 L Z 19 DT engines
M10 18.44 lbf⋅ft
M6 6.64 lbf⋅ft
At the gearbox 29.5 lbf⋅ft
expand_moreOn the engine block
M6 6.64 lbf⋅ft
M8 18.44 lbf⋅ft
expand_moreAll other modifications
At the gearbox 29.5 lbf⋅ft
Otherwise 7.38 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
All Opel diesel straight-4 1.2 L Z 13 DTH engines 5.16 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 6.64 lbf⋅ft
All other modifications 7.38 lbf⋅ft
Replace sealing rings.
expand_moreCharge air pressure sensor
All Opel diesel straight-4 1.2 L Z 13 DTH engines 6.64 lbf⋅ft
All other modifications 3.69 lbf⋅ft
expand_moreCrankshaft sensor
All Opel diesel straight-4 1.2 L Z 13 DTH engines 6.64 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 6.64 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreGlow plugs
All Opel diesel straight-4 1.2 L Z 13 DTH engines 7.38 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTH engines 13.28 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 5.9 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 7.38 lbf⋅ft
All other modifications 10.33 lbf⋅ft
Lambda sensor 29.5 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
On the engine block 36.88 lbf⋅ft
Replace screws.
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
M10 36.88 lbf⋅ft
M8 18.44 lbf⋅ft
M10 36.88 lbf⋅ft
M8 18.44 lbf⋅ft
All other modifications 44.25 lbf⋅ft
expand_moreEngine mounting
On engine bracket 40.57 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 25.81 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 25.81 lbf⋅ft
expand_moreAll other modifications
expand_moreOn chassis
Left 14.75 lbf⋅ft
Right 25.81 lbf⋅ft
expand_moreOn the left side of tje engine bracket
Right 40.57 lbf⋅ft
expand_moreOn the rear side of the front axle
Front 40.57 lbf⋅ft
Engine suspension 40.57 lbf⋅ft
expand_moreSubframe
First stage 66.38 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_moreSubframe stiffening plate
First stage 66.38 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_moreTorque arm
expand_moreAt the subframe
Bottom 40.57 lbf⋅ft
Replace nuts.
expand_moreAt the gearbox
Bottom 40.57 lbf⋅ft
expand_moreExhaust system
expand_moreCatalytic converter
At the turbocharger 18.44 lbf⋅ft
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
Clamps 47.2 lbf⋅ft
Nuts 18.44 lbf⋅ft
Screws 18.44 lbf⋅ft
Clamps 47.2 lbf⋅ft
expand_moreAll other modifications
At the turbocharger 33.19 lbf⋅ft
Catalytic converter bracket 18.44 lbf⋅ft
expand_moreExhaust manifold
First stage 11.06 lbf⋅ft
Replace screws and nuts.
Second stage 30°
All Opel diesel straight-4 1.9 L Z 19 DT engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DTH engines 18.44 lbf⋅ft
Replace nuts.
All other modifications 50.89 lbf⋅ft
expand_moreExhaust pipe
On primary catalytic converter 14.75 lbf⋅ft
expand_moreAll Opel diesel straight-4 1.9 L Z 19 DT engines
Front 14.75 lbf⋅ft
Front 14.75 lbf⋅ft
expand_moreFuel supply
expand_moreFuel lines
M12 17.7 lbf⋅ft
M14 20.65 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreStart system
expand_moreStarter
All Opel diesel straight-4 1.2 L Z 13 DTH engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.9 L Z 19 DT engines 18.44 lbf⋅ft
expand_moreAll other modifications
At the gearbox 44.25 lbf⋅ft
On the engine block 28.03 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2009 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.

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 2009 Opel Astra Van you're not only saving money, but also also improving your technical skills and learning something new.

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