2003 Opel Movano Box Van engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m
All other modifications	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


Opel diesel straight-4 2.5 L G9U 754 113 HP	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Opel diesel straight-4 2.5 L G9U 720 113 HP	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Opel diesel straight-4 2.5 L G9U 724 113 HP	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreOpel diesel straight-4 2.2 L G9T 720 89 HP


Without air-conditioning system	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m


Opel diesel straight-4 2.5 L G9U 754 98 HP	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
All other modifications	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreAuxiliary drive belt tensioner


All Opel diesel straight-4 3.0 L ZD3 200 engines	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
All Opel diesel straight-4 3.0 L ZD3 202 engines	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
All other modifications	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m


Auxiliary drive belt tensioner	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreAir-conditioning compressor


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m


Air-conditioning compressor bracket	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Air-conditioning compressor pressure line	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreAlternator

expand_moreOpel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM


Lower screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Upper screws	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m


Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All other modifications	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m


Generator bracket	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreHydraulic lines at the servo-steering pump


2.5 DTi with diesel straight-4 2.5 L 98 HP engine (2003.10–)	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreServo pump pulley


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m
All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreServo steering pump


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreVacuum pump


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
All other modifications	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m

expand_moreCarburetion

expand_moreFuel-distributing pipe


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	14.75–17.7 lbf⋅ft14.75–17.7 lbf⋅ft20–24 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	14.75–17.7 lbf⋅ft14.75–17.7 lbf⋅ft20–24 N⋅m
Opel diesel straight-4 2.2 L G9T 750 89 HP	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
Opel diesel straight-4 2.2 L G9T 720 89 HP	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
Opel diesel straight-4 2.2 L G9T 722 89 HP at 3650 RPM, 260 N⋅m at 1500 RPM	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


G9U 750 engine	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Otherwise	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m

expand_moreHigh-pressure pump pulley

expand_moreAll Opel diesel straight-4 1.9 L F9Q 774 engines


First stage	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Second stage	60°60°60°


All other modifications	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m

expand_moreInjection hoses


On injector	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Otherwise	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreInjection nozzle (injector)


Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreAll other modifications

expand_moreFlywheel side


First stage	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
Second stage	360°360°360°


Front side	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m


Injection pump	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreInjection pump pulley


Nuts	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
Screws	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m

expand_moreCharging

expand_moreTurbo charger


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreOpel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM


On exhaust manifold	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
Replace sealing rings.


All other modifications	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m


Turbocharger bracket	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Turbocharger oil feed line	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace sealing rings.
Turbocharger oil return line	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Replace sealing rings.

expand_moreCooling system

expand_moreCoolant pump

expand_moreOpel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM


Nuts	35.4 lbf⋅ft35.4 lbf⋅ft48 N⋅m
30 mm screws	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
80 mm screws	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
85 mm screws	35.4 lbf⋅ft35.4 lbf⋅ft48 N⋅m


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


Coolant pump pulley	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m
Radiator mounting	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Opel diesel straight-4 1.9 L F9Q 772 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Opel diesel straight-4 1.9 L F9Q 774 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines


First stage	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Second stage	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreCylinder head screws

expand_moreOpel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM

Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM.


First stage	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Replace and lightly oil the screws. See figure 1.
Second stage	100°100°100°
Third stage	slacken
Fourth stage	30.98 lbf⋅ft30.98 lbf⋅ft42 N⋅m
Fifth stage	90°90°90°
Sixth stage	90°90°90°

expand_moreOpel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Second stage	294–306°294–306°294–306°

expand_moreOpel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM

Figure 2. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM.


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace screws. See figure 2.
Second stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Control tensioner
Third stage	224–236°224–236°224–236°

expand_moreAll other modifications


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace screws. See figure 2.
Second stage	294–306°294–306°294–306°


Rocker bridge	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Valve cover	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing


Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	59 lbf⋅ft59 lbf⋅ft80 N⋅m
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	59 lbf⋅ft59 lbf⋅ft80 N⋅m

expand_moreOpel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	40°40°40°

expand_moreAll other modifications


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Second stage	49–61°49–61°49–61°

expand_moreCrankshaft central screws


All Opel diesel straight-4 3.0 L ZD3 200 engines	280.27 lbf⋅ft280.27 lbf⋅ft380 N⋅m
All Opel diesel straight-4 3.0 L ZD3 202 engines	280.27 lbf⋅ft280.27 lbf⋅ft380 N⋅m

expand_moreAll other modifications


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	84–96°84–96°84–96°

expand_moreCrankshaft pulley


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Second stage	115–±15°

expand_moreFlywheel


Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	125.39 lbf⋅ft125.39 lbf⋅ft170 N⋅m
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	125.39 lbf⋅ft125.39 lbf⋅ft170 N⋅m

expand_moreOpel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Second stage	70°70°70°

expand_moreOpel diesel straight-4 2.2 L G9T 720 89 HP

expand_moreG9T 720 and G9T 722 engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.
Second stage	32.45–41.3 lbf⋅ft32.45–41.3 lbf⋅ft44–56 N⋅m

expand_moreG9T 750 engine


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	32.45–41.3 lbf⋅ft32.45–41.3 lbf⋅ft44–56 N⋅m

expand_moreAll other modifications


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	39–51°39–51°39–51°

expand_moreMain bearing


Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m

expand_moreAll other modifications


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	140–160°140–160°140–160°

expand_moreEngine control


Camshaft drive belt deflection pulley	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Camshaft timing chain guide rail	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m
Camshaft timing chain tensioning rail	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m
Camshaft timing gear	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Chain tensioner	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
Control drive chain tensioning rail	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m
Inlet camshaft wheel	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Outlet camshaft wheel	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Timing case cover	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
Use sealant.
Toothed belt guard	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Toothed belt guard at the bottom	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Toothed belt guard at the top	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreToothed belt tensioning roller


All Opel diesel straight-4 1.9 L F9Q 772 engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Opel diesel straight-4 1.9 L F9Q 774 engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreToothed belt tightener


Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreEngine lubrication

expand_moreOil drain plug


Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	25.08 lbf⋅ft25.08 lbf⋅ft34 N⋅m
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	25.08 lbf⋅ft25.08 lbf⋅ft34 N⋅m
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOpel diesel straight-4 2.2 L G9T 720 89 HP


G9T 720 and G9T 722 engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
G9T 750 engine	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreAll other modifications


G9U 750 engine	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil filter housing

expand_moreOpel diesel straight-4 2.5 L G9U 754 113 HP


Oil filter cover	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
On the engine block	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOpel diesel straight-4 2.5 L G9U 754 98 HP


Oil filter cover	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
On the engine block	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


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

expand_moreOil lines

expand_moreOpel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM

expand_moreOil feed lines


At the turbocharger	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreOil feed lines at the turbo charger


On the engine block	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreOpel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM

expand_moreOil feed lines


At the turbocharger	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreReturn line


At the turbocharger	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreOpel diesel straight-4 2.2 L G9T 720 89 HP

expand_moreOil feed lines


At the turbocharger	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOpel diesel straight-4 2.5 L G9U 754 98 HP

expand_moreOil feed lines


At the turbocharger	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreReturn line


At the turbocharger	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreAll other modifications

expand_moreOil feed lines


At the turbocharger	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreReturn line


At the turbocharger	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m


Oil pump	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil sump


Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	5.16 lbf⋅ft5.16 lbf⋅ft7 N⋅m
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	5.16 lbf⋅ft5.16 lbf⋅ft7 N⋅m

expand_moreOpel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Second stage	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m


Opel diesel straight-4 2.2 L G9T 720 89 HP	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Opel diesel straight-4 2.2 L G9T 750 89 HP	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Opel diesel straight-4 2.2 L G9T 722 89 HP at 3650 RPM, 260 N⋅m at 1500 RPM	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreAll other modifications


First stage	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
Second stage	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreEngine management


Camshaft sensor	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Crankshaft sensor	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreGlow plugs

expand_moreOpel diesel straight-4 2.5 L G9U 754 113 HP


G9U 750 engine	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m
Otherwise	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOpel diesel straight-4 2.2 L G9T 720 89 HP


G9T 720 and G9T 722 engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
G9T 750 engine	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m


All other modifications	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket


On the engine block	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreEngine mounting

expand_moreAll Opel diesel straight-4 1.9 L F9Q 774 engines


Nuts	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Screws	45.73 lbf⋅ft45.73 lbf⋅ft62 N⋅m

expand_moreAll Opel diesel straight-4 2.5 L G9U 650 engines


M10 × 55 screws	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
M12 × 40 screws	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Nuts	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m

expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines


Right	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m

expand_moreAll other modifications


Nuts on the chassis	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Replace screws.
Screws on the chassis	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Replace screws.
Screws on the engine bracket	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Replace screws.

expand_moreExhaust system

expand_moreCatalytic converter

expand_moreOpel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM


At the turbocharger	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
On the engine block	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreOpel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m


At the turbocharger	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m


All other modifications	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreExhaust manifold


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	30.98 lbf⋅ft30.98 lbf⋅ft42 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	30.98 lbf⋅ft30.98 lbf⋅ft42 N⋅m

expand_moreOpel diesel straight-4 2.2 L G9T 720 89 HP


G9T 750 engine	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Otherwise	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m


All other modifications	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreExhaust pipe


Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
All other modifications	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m


Primary catalytic converter	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Replace sealing rings.

expand_moreStart system

expand_moreStarter


Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All other modifications	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2003 Opel Movano Box 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 Movano Box 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 2003 Opel Movano Box Van you're not only saving money, but also also improving your technical skills and learning something new.

2003 Opel Movano Box Van generations

In 2003 Opel offered 2 generations of the Movano Box Van. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

2003 Opel Movano Box Van A2 Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2003 Opel Movano Box Van generations

A

Opel Movano Box Van A2 model years

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