2003 Opel Vivaro Bus engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


Lower section of intake manifold	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Upper section of intake manifold	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m


All Opel diesel straight-4 2.5 L G9U 730 engines	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
All other modifications	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreAuxiliary drive belt tensioner


All Opel gasoline straight-4 2.0 L F4R 720 engines	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
All Opel diesel straight-4 2.5 L G9U 730 engines	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m


Auxiliary drive belt tensioner	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAir-conditioning compressor


All Opel diesel straight-4 2.5 L G9U 730 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAir-conditioning compressor pressure line


2.0 16V with gasoline straight-4 2.0 L 118 HP engine (2001.8–)	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreAlternator


All Opel gasoline straight-4 2.0 L F4R 720 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 2.5 L G9U 730 engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_morePower steering pump bracket


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Servo pump pulley	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreServo steering pump


All Opel diesel straight-4 2.5 L G9U 730 engines	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Vacuum pump	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m

expand_moreCarburetion


Exhaust gas return valve	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreFuel-distributing pipe


All Opel gasoline straight-4 2.0 L F4R 720 engines	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
All Opel diesel straight-4 2.5 L G9U 730 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	16.23 lbf⋅ft16.23 lbf⋅ft22 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 Opel diesel straight-4 2.5 L G9U 730 engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreInjection hoses


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreInjection nozzle (injector)


All Opel diesel straight-4 1.9 L F9Q 760 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 1.9 L F9Q 762 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 1.9 L F9Q 774 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines

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

expand_moreInjection pump


1.9 DTI with diesel straight-4 1.9 L 99 HP engine (2001.8–)	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreCharging

expand_moreTurbo charger


All Opel diesel straight-4 1.9 L F9Q 760 engines	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Use new seals.
All Opel diesel straight-4 1.9 L F9Q 762 engines	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Use new seals.
All Opel diesel straight-4 1.9 L F9Q 774 engines	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Use new seals.
All Opel diesel straight-4 2.5 L G9U 730 engines	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m


Turbocharger oil feed line	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Use new parts.
Turbocharger oil return line	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Use new seals.

expand_moreCooling system

expand_moreCoolant pump


All Opel gasoline straight-4 2.0 L F4R 720 engines	12.54 lbf⋅ft12.54 lbf⋅ft17 N⋅m

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


Gear wheel on the coolant pump	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Otherwise	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


All other modifications	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m


Coolant thermostat housing	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCylinder head


Camshaft bearing	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCylinder head screws

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Second stage	100°100°100°
Third stage	100°100°100°

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace screws.
Second stage	300°300°300°

expand_moreAll other modifications

Figure 1. Cylinder head, Cylinder head screws, All other modifications.


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Tighten the new screws evenly in several steps. See figure 1.
Second stage	230°230°230°
Oil the screw lightly.

expand_moreRocker bridge


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
from outside to inside

expand_moreValve cover

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Second stage	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m


All other modifications	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.
Second stage	55°55°55°

expand_moreAll other modifications


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

expand_moreCrankshaft central screws

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage	110°110°110°

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


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

expand_moreAll other modifications


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Use new screw.
Second stage	100–130°100–130°100–130°

expand_moreCrankshaft pulley

expand_more2.0 16V with gasoline straight-4 2.0 L 118 HP engine (2001.8–)


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage	110°110°110°

expand_moreFlywheel


All Opel gasoline straight-4 2.0 L F4R 720 engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Clean the thread, use new screws and screw-locking compound.
Second stage	45°45°45°


All other modifications	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m


Main bearing	Component must not be knocked down.

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


All Opel gasoline straight-4 2.0 L F4R 720 engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Opel diesel straight-4 2.5 L G9U 730 engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreCamshaft timing gear

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace nuts.
Second stage	86°86°86°


All Opel diesel straight-4 1.9 L F9Q 760 engines	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
All Opel diesel straight-4 1.9 L F9Q 762 engines	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
All Opel diesel straight-4 1.9 L F9Q 774 engines	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreInlet camshaft wheel


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreOutlet camshaft wheel


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


Toothed belt guard	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreToothed belt guard at the bottom

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


M6	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
M8	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m


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

expand_moreToothed belt guard at the top

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


M10	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
M8	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m


All Opel diesel straight-4 2.5 L G9U 730 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


Toothed belt guard center	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreToothed belt tensioning roller

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


Nuts	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m


All Opel diesel straight-4 2.5 L G9U 730 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


Nuts	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreToothed belt tightener


Variant 1	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Variant 2	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Pre-tensioner
Variant 3	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Tensioning roller/deflection pulley baseplate toothed belt

expand_moreEngine lubrication


Oil cooler	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreOil drain plug


All Opel gasoline straight-4 2.0 L F4R 720 engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Opel diesel straight-4 1.9 L F9Q 760 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace sealing rings.
All Opel diesel straight-4 1.9 L F9Q 762 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace sealing rings.
All Opel diesel straight-4 1.9 L F9Q 774 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace sealing rings.

expand_moreOil filter housing


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Oil pressure sensor	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m

expand_moreOil pump


All Opel gasoline straight-4 2.0 L F4R 720 engines	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
All Opel diesel straight-4 1.9 L F9Q 762 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.
All Opel diesel straight-4 1.9 L F9Q 774 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


M6	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreOil sump

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


At the gearbox	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Variant 1	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Variant 2	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


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

expand_moreAll other modifications


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

expand_moreEngine management

expand_moreCamshaft sensor


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreGlow plugs


All Opel diesel straight-4 1.9 L F9Q 760 engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Opel diesel straight-4 1.9 L F9Q 762 engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Opel diesel straight-4 1.9 L F9Q 774 engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Opel diesel straight-4 2.5 L G9U 730 engines	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m

expand_moreKnock sensor


2.0 16V with gasoline straight-4 2.0 L 118 HP engine (2001.8–)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreLambda sensor


2.0 16V with gasoline straight-4 2.0 L 118 HP engine (2001.8–)	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket


All Opel gasoline straight-4 2.0 L F4R 720 engines	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


M10	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Replace screws.
M12	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
Replace screws.

expand_moreEngine mounting

expand_moreAll Opel gasoline straight-4 2.0 L F4R 720 engines


On engine bracket nuts	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Screws on the engine bracket	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


Nuts	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Replace screws.
Screws	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Replace screws.

expand_moreAll other modifications


Screws on the engine bracket	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Screws on the engine mounting	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
On engine sump	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreSubframe

expand_more2.0 16V with gasoline straight-4 2.0 L 118 HP engine (2001.8–)


Front	77.44 lbf⋅ft77.44 lbf⋅ft105 N⋅m
Rear	88.51 lbf⋅ft88.51 lbf⋅ft120 N⋅m

expand_moreTorque arm


On chassis	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
On engine bracket	73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m

expand_moreExhaust system

expand_moreCatalytic converter


All Opel gasoline straight-4 2.0 L F4R 720 engines	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


At the turbocharger	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m

expand_moreAll other modifications


At the turbocharger	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Use new seals.

expand_moreCatalytic converter bracket


Flywheel side	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreNuts


Front side	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreScrews


Front side	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m

expand_moreExhaust manifold


All Opel gasoline straight-4 2.0 L F4R 720 engines	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m
All Opel diesel straight-4 2.5 L G9U 730 engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
from inside to outside
All other modifications	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m


Exhaust pipe	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Exhaust pipe rear	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Exhaust system middle heat protection plate	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreFuel supply

expand_moreFuel filter housing


Fuel filter cover	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreFuel lines


2.5 DTI with diesel straight-4 2.5 L 133 HP engine (2003.5–)	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreIgnition system

expand_moreSpark plugs


2.0 16V with gasoline straight-4 2.0 L 118 HP engine (2001.8–)	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreStart system

expand_moreStarter

expand_moreAll Opel diesel straight-4 2.5 L G9U 730 engines


Nuts	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
Screws	32.45 lbf⋅ft32.45 lbf⋅ft44 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 Vivaro Bus 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

Chassis and Body Fastener Tightening Specifications
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 Vivaro Bus 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 Vivaro Bus you're not only saving money, but also also improving your technical skills and learning something new.

2003 Opel Vivaro Bus A Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Opel Vivaro Bus A model years

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