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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
All Opel gasoline straight-4 1.4 L Z 14 XEP engines 7.38 lbf⋅ft
Lower section of intake manifold 14.75 lbf⋅ft
Replace screws and nuts.
Upper section of intake manifold 5.9 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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
M10 40.57 lbf⋅ft
M8 14.75 lbf⋅ft
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 36.88 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 36.88 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreAir-conditioning compressor
All Opel gasoline straight-4 1.4 L Z 14 XEP engines 18.44 lbf⋅ft
Front 25.81 lbf⋅ft
Rear 14.75 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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
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 (2003.4–2009.7) 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 (2003.4–2009.7) 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 (2003.4–2009.7) 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 other modifications 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_moreAll other modifications
expand_moreAt the turbocharger
Support 8.85 lbf⋅ft
Otherwise 8.85 lbf⋅ft
Replace sealing rings.
expand_moreOn the engine block
Support 25.81 lbf⋅ft
Otherwise 25.81 lbf⋅ft
Union nuts 14.75 lbf⋅ft
expand_moreCooling system
expand_moreCoolant drain plug
Coolant pump 14.75 lbf⋅ft
expand_moreCoolant pump
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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
M6 16.23 lbf⋅ft
M8 19.91 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreCylinder head screws
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.7 L Z 17 DTL 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM.
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.7 L Z 17 DTL 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM.
First stage 28.76 lbf⋅ft
Use new screws See figure 1.
Second stage 60°
Third stage 60°
First stage 18.44 lbf⋅ft
Use new screws.
Second stage 60°
Third stage 60°
Fourth stage 60°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Replace screws. See figure 1.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 45°
expand_moreValve cover
All Opel diesel straight-4 1.7 L Z 17 DTL engines 7.38 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 100°
Third stage 15°
First stage 9.59 lbf⋅ft
Use new screws.
Second stage 60°
Third stage 15°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Replace screws and nuts.
Second stage 30°
expand_moreCrankcase ventilation
expand_moreAll other modifications
Crankcase ventilation pipe 5.9 lbf⋅ft
Use new seals.
expand_moreCrankshaft central screws
First stage 110.63 lbf⋅ft
Use new screw.
Second stage 45°
Third stage 15°
First stage 70.07 lbf⋅ft
Use new screw.
Second stage 30°
Third stage 15°
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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 Opel gasoline straight-4 1.4 L Z 14 XEP engines 5.9 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreFlywheel
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
Opel diesel straight-4 1.7 L Z 17 DTL 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM 64.91 lbf⋅ft
expand_moreM6
First stage 7.38 lbf⋅ft
Second stage 60°
expand_moreM8
First stage 18.44 lbf⋅ft
Second stage 60°
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
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 18.44 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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
Opel diesel straight-4 1.7 L Z 17 DTL 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM 47.2 lbf⋅ft
First stage 36.88 lbf⋅ft
Use new screw.
Second stage 60°
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
M10 25.81 lbf⋅ft
M6 5.9 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreToothed belt guard at the bottom
Opel gasoline straight-4 1.6 L Z 16 XEP 102 HP 4.43 lbf⋅ft
Opel diesel straight-4 1.7 L Z 17 DTL 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM 7.38 lbf⋅ft
All other modifications 2.95 lbf⋅ft
expand_moreToothed belt guard at the top
All Opel diesel straight-4 1.7 L Z 17 DTL engines 7.38 lbf⋅ft
All other modifications 2.95 lbf⋅ft
expand_moreToothed belt tensioning roller
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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
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
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
Replace sealing rings.
expand_moreOil filter
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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
expand_moreAll other modifications
At the turbocharger 14.75 lbf⋅ft
expand_moreOil pressure sensor
All Opel gasoline straight-4 1.4 L Z 14 XEP engines 14.75 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 14.75 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreOil pump
All Opel gasoline straight-4 1.6 L Z 16 XEP engines 14.75 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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 (2003.4–2009.7)
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
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
Clean the thread and use screw-locking compound.
expand_moreEngine management
expand_moreCamshaft sensor
All Opel diesel straight-4 1.7 L Z 17 DTL engines 7.38 lbf⋅ft
All other modifications 4.43 lbf⋅ft
Charge air pressure sensor 7.38 lbf⋅ft
expand_moreCrankshaft sensor
All Opel diesel straight-4 1.7 L Z 17 DTL engines 7.38 lbf⋅ft
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
Lambda sensor downstream of catalytic converter 29.5 lbf⋅ft
Lambda sensors in front of catalytic converter 22.13 lbf⋅ft
All other modifications 29.5 lbf⋅ft
Use assembly paste
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_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 Opel gasoline straight-4 1.4 L Z 14 XEP engines 14.75 lbf⋅ft
All other modifications 33.19 lbf⋅ft
expand_moreExhaust manifold
All Opel gasoline straight-4 1.4 L Z 14 XEP engines 11.06 lbf⋅ft
All Opel diesel straight-4 1.7 L Z 17 DTL engines 50.89 lbf⋅ft
Replace sealing rings.
All other modifications 16.23 lbf⋅ft
Replace screws and nuts.
expand_moreExhaust manifold heat shields
All other modifications 7.388.85 lbf⋅ft
expand_moreExhaust pipe
All other modifications 14.75 lbf⋅ft
Exhaust pipe bracket 14.75 lbf⋅ft
expand_moreExhaust pipe rear
All Opel gasoline straight-4 1.4 L Z 14 XEP engines 14.75 lbf⋅ft
All other modifications 5.9 lbf⋅ft
Exhaust system middle heat protection plate 2.95 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
All Opel diesel straight-4 1.7 L Z 17 DTL engines 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 2005 Opel Astra Wagon 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 Wagon 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 2005 Opel Astra Wagon you're not only saving money, but also also improving your technical skills and learning something new.

2005 Opel Astra Wagon generations

In 2005 Opel offered 2 generations of the Astra Wagon. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

Opel Astra Wagon G facelift model years

Units:
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