2004 Vauxhall Astra Hatchback engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Use new screws or nuts

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


All Vauxhall diesel straight-4 1.7 L Z 17 DTH engines	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTJ engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAuxiliary drive belt tensioner


All Vauxhall gasoline straight-4 1.8 L Z 18 XE engines	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


With air-conditioning	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Without air-conditioning system	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m


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


Air-conditioning compressor	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAir-conditioning compressor bracket


1.7 CDTI with diesel straight-4 1.7 L 99 HP at 4400 RPM, 240 N⋅m at 2300 RPM engine (2004.1–2009.5)	31.72 lbf⋅ft31.72 lbf⋅ft43 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 (2004.1–2009.5)	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m

expand_moreExhaust recirculation pipe


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

expand_moreAll Vauxhall diesel straight-4 1.9 L Z 19 DT engines


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


High-pressure pump pulley	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m

expand_moreCharging

expand_moreTurbo charger

expand_more1.7 CDTI with diesel straight-4 1.7 L 99 HP at 4400 RPM, 240 N⋅m at 2300 RPM engine (2004.1–2009.5)


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

expand_moreTurbocharger oil feed line

expand_moreAll Vauxhall 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.

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines

expand_moreAt the turbocharger


Banjo screws	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Replace sealing rings.
Support	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreOn the engine block


Support	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m


Union nuts	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace sealing rings.

expand_moreTurbocharger oil return line

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


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_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


At the turbocharger	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Replace sealing rings.
On the engine block	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace sealing rings.

expand_moreCooling system


Coolant pump	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Coolant pump pulley	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreRadiator mounting


1.9 CDTI with diesel straight-4 1.9 L 118 HP engine (2004.1–2009.5)	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCylinder head screws

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

Figure 1. Cylinder head, Cylinder head screws, Vauxhall diesel straight-4 1.9 L Z 19 DTH.


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws. See figure 1.
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 Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines

Figure 2. Cylinder head, Cylinder head screws, Vauxhall gasoline straight-4 2.0 L Z 20 LEL.


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 2.
Second stage	90°90°90°
Third stage	90°90°90°
Fourth stage	90°90°90°
Fifth stage	15°15°15°

expand_moreValve cover


All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

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


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

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


First stage	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreCrankshaft central screws


All Vauxhall diesel straight-4 1.2 L Z 13 DTH engines	169.64 lbf⋅ft169.64 lbf⋅ft230 N⋅m

expand_moreAll Vauxhall gasoline straight-4 1.6 L Z 16 XER engines


First stage	70.07 lbf⋅ft70.07 lbf⋅ft95 N⋅m
Replace screws.
Second stage	45°45°45°
Replace screws.
Third stage	15°15°15°
Replace screws.


All Vauxhall diesel straight-4 1.7 L Z 17 DTH engines	144.56 lbf⋅ft144.56 lbf⋅ft196 N⋅m
All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	144.56 lbf⋅ft144.56 lbf⋅ft196 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	250.77 lbf⋅ft250.77 lbf⋅ft340 N⋅m
Use new screw. (left-hand thread)
All Vauxhall diesel straight-4 1.9 L Z 19 DTJ engines	250.77 lbf⋅ft250.77 lbf⋅ft340 N⋅m
Use new screw. (left-hand thread)

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


First stage	95.88 lbf⋅ft95.88 lbf⋅ft130 N⋅m
Replace screws.
Second stage	40–50°40–50°40–50°

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LER engines


First stage	95.88 lbf⋅ft95.88 lbf⋅ft130 N⋅m
Use new screw.
Second stage	40–50°40–50°40–50°

expand_moreAll other modifications


First stage	70.07 lbf⋅ft70.07 lbf⋅ft95 N⋅m
Use new screw.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreCrankshaft pulley


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

expand_moreFlywheel


All Vauxhall diesel straight-4 1.2 L Z 13 DTH engines	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
Retap thread in holes and use new screws.

expand_moreAll Vauxhall gasoline straight-4 1.4 L Z 14 XEL engines


First stage	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Clean the thread, use new screws and screw-locking compound.
Second stage	30°30°30°
Third stage	15°15°15°


All Vauxhall diesel straight-4 1.9 L Z 19 DT engines	118.01 lbf⋅ft118.01 lbf⋅ft160 N⋅m
Retap thread in holes and use new screws.
All Vauxhall 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 Vauxhall 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 Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


First stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Replace screws. Use screw-locking compound.
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreAll other modifications


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°

expand_moreMain bearing

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


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Tighten new bolts helically in outside to inside order.
Second stage	100°100°100°

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°


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

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley

expand_moreAll Vauxhall gasoline straight-4 1.6 L Z 16 XER engines


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Second stage	120°120°120°
Third stage	15°15°15°


All Vauxhall diesel straight-4 1.7 L Z 17 DTH engines	59 lbf⋅ft59 lbf⋅ft80 N⋅m
All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	59 lbf⋅ft59 lbf⋅ft80 N⋅m

expand_moreAll Vauxhall gasoline straight-4 1.8 L Z 18 XE engines


Exhaust side	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Intake-side	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTJ engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.

expand_moreCamshaft timing gear

expand_moreAll Vauxhall diesel straight-4 1.2 L Z 13 DTH engines


Inlet camshaft	110.63 lbf⋅ft110.63 lbf⋅ft150 N⋅m
Outlet camshaft	110.63 lbf⋅ft110.63 lbf⋅ft150 N⋅m


All Vauxhall diesel straight-4 1.7 L Z 17 DTH engines	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m

expand_moreAll Vauxhall diesel straight-4 1.7 L Z 17 DTL 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

expand_moreAll Vauxhall gasoline straight-4 1.8 L Z 18 XE engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	15°15°15°


All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	88.51 lbf⋅ft88.51 lbf⋅ft120 N⋅m

expand_moreChain tensioner


1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2004.1–2009.5)	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreControl drive chain guide rail


1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2004.1–2009.5)	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreControl drive chain tensioning rail


1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2004.1–2009.5)	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreInlet camshaft wheel


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	15°15°15°

expand_moreOutlet camshaft wheel


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	15°15°15°

expand_moreTiming case cover


1.3 CDTI with diesel straight-4 1.2 L 89 HP engine (2004.1–2009.5)	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreToothed belt guard


All Vauxhall gasoline straight-4 1.8 L A 18 XER engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
All Vauxhall gasoline straight-4 1.6 L Z 16 XER engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
All Vauxhall gasoline straight-4 1.8 L Z 18 XE engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m
All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreAll Vauxhall 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 guard at the bottom


All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All Vauxhall gasoline straight-4 1.8 L Z 18 XE engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m
All other modifications	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreToothed belt guard at the top


All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All Vauxhall gasoline straight-4 1.8 L Z 18 XE engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m
All other modifications	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreToothed belt tensioning roller


All Vauxhall diesel straight-4 1.7 L A 17 DTJ engines	36.14 lbf⋅ft36.14 lbf⋅ft49 N⋅m

expand_moreAll Vauxhall gasoline straight-4 1.6 L Z 16 XER engines


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Second stage	120°120°120°
Third stage	15°15°15°


All Vauxhall diesel straight-4 1.7 L Z 17 DTH engines	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
All Vauxhall diesel straight-4 1.7 L Z 17 DTJ engines	36.14 lbf⋅ft36.14 lbf⋅ft49 N⋅m
All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTJ engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.

expand_moreEngine lubrication

expand_moreOil drain plug


All Vauxhall diesel straight-4 1.9 L Z 19 DT engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Replace sealing rings.

expand_moreAll other modifications


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.

expand_moreOil filter housing


All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOil sump

expand_moreAll Vauxhall 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 Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


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

expand_moreOil sump lower part


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Replace screws and nuts.
Second stage	30°30°30°


Oil sump top part	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine management

expand_moreCamshaft sensor


All Vauxhall gasoline straight-4 1.8 L Z 18 XE engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LEH engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LER engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Replace sealing rings.

expand_moreGlow plugs


1.9 CDTI with diesel straight-4 1.9 L 148 HP engine (2004.1–2009.5)	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreKnock sensor


2.0 Turbo with gasoline straight-4 2.0 L 168 HP engine (2004.1–2009.5)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


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

expand_moreEngine mounting

expand_moreEngine bracket


All Vauxhall gasoline straight-4 1.6 L Z 16 XER engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreAll Vauxhall 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.


All Vauxhall diesel straight-4 1.7 L Z 17 DTL engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreAll Vauxhall diesel straight-4 1.9 L Z 19 DTJ 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 Vauxhall gasoline straight-4 1.6 L Z 16 XER engines


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

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


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

expand_moreAll Vauxhall diesel straight-4 1.7 L Z 17 DTL engines


On chassis	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
On the engine block	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Replace screws.

expand_moreAll Vauxhall gasoline straight-4 1.8 L Z 18 XE engines


On chassis	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
On engine bracket	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Replace screws.


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

expand_moreAll other modifications


On chassis	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
On engine bracket	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m


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

expand_moreExhaust system

expand_moreCatalytic converter

expand_moreAll Vauxhall diesel straight-4 1.9 L Z 19 DT engines


Clamps	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m
Nuts	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

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


Clamps	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m


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

expand_moreExhaust manifold


All Vauxhall diesel straight-4 1.7 L Z 17 DTH engines	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LEL engines


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Note correct order of tensioning.
Second stage	Wait 5 minutes.
Replace the nuts and use fitting paste
Third stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m


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

expand_moreExhaust pipe

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


Front	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreIgnition system

expand_moreSpark plugs


2.0 Turbo with gasoline straight-4 2.0 L 168 HP engine (2004.1–2009.5)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Vauxhall Astra Hatchback 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 Vauxhall 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 Vauxhall Astra Hatchback 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 Vauxhall Astra Hatchback you're not only saving money, but also also improving your technical skills and learning something new.

2004 Vauxhall Astra Hatchback generations

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

Fourth generation facelift (MK4)

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

2004 Vauxhall Astra Hatchback Fifth generation (MK5) Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2004 Vauxhall Astra Hatchback generations

Fourth generation facelift (MK4)

Vauxhall Astra Hatchback Fifth generation (MK5) model years

Suggest edit