2009 Vauxhall Astra TwinTop engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


All Vauxhall gasoline straight-4 1.6 L Z 16 XEP engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Use new screws or nuts
All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Use new screws or nuts
All Vauxhall gasoline straight-4 2.0 L Z 20 LER engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Use new screws or nuts

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAuxiliary drive belt tensioner

expand_moreAll Vauxhall gasoline straight-4 2.0 L Z 20 LER 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

expand_moreAir-conditioning compressor


1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreCarburetion

expand_moreInjection nozzle (injector)


1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreCharging

expand_moreTurbocharger oil feed line


All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	11.06 lbf⋅ft11.06 lbf⋅ft15 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

expand_moreTurbocharger oil return line

expand_moreAll Vauxhall diesel straight-4 1.9 L Z 19 DTH 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_moreCylinder head

expand_moreCamshaft bearing


All Vauxhall gasoline straight-4 1.6 L Z 16 XEP engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	5.9 lbf⋅ft5.9 lbf⋅ft8 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 gasoline straight-4 2.0 L Z 20 LER engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCylinder head screws

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

Figure 1. Cylinder head, Cylinder head screws, Vauxhall gasoline straight-4 1.6 L Z 16 XEP.


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 1.
Second stage	90°90°90°
Third stage	90°90°90°
Fourth stage	45°45°45°

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


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 1.
Second stage	90°90°90°
Third stage	90°90°90°
Fourth stage	45°45°45°

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

expand_moreRibe screws

Figure 2. Cylinder head, Cylinder head screws, Vauxhall diesel straight-4 1.9 L Z 19 DTH, Ribe screws.


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws. See figure 2.
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_moreTorx screws


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
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°
Sixth stage	90°90°90°

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

Figure 3. Cylinder head, Cylinder head screws, Vauxhall gasoline straight-4 2.0 L Z 20 LER.


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 3.
Second stage	90°90°90°
Third stage	90°90°90°
Fourth stage	90°90°90°
Fifth stage	15°15°15°


Valve cover	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

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


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws and nuts.
Second stage	30°30°30°

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


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

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


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

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


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

expand_moreCrankshaft central screws

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


First stage	70.07 lbf⋅ft70.07 lbf⋅ft95 N⋅m
Use new screw.
Second stage	30°30°30°
Third stage	15°15°15°

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 1.9 L Z 19 DTH engines	265.52 lbf⋅ft265.52 lbf⋅ft360 N⋅m
Use new screw. (left-hand thread)

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


First stage	95.88 lbf⋅ft95.88 lbf⋅ft130 N⋅m
Replace screws and nuts.
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 gasoline straight-4 2.0 L Z 20 LEL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LER engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFlywheel

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


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Retap thread in holes and use new screws.
Second stage	45°45°45°
Third stage	15°15°15°


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 gasoline straight-4 2.0 L Z 20 LER 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	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreMain bearing

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


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

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


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

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


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

expand_moreVibration damper

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


First stage	70.07 lbf⋅ft70.07 lbf⋅ft95 N⋅m
Second stage	30°30°30°
Third stage	15°15°15°


All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	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 1.9 L Z 19 DTH engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

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


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


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

expand_moreCamshaft timing gear

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


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

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


Locking screws	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreWith camshaft adjuster


First stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Second stage	120°120°120°
Third stage	15°15°15°

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


Outlet camshaft	88.51 lbf⋅ft88.51 lbf⋅ft120 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_moreToothed belt guard


All Vauxhall gasoline straight-4 1.6 L Z 16 LET 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 XER engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

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


M6	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


Toothed belt guard at the bottom	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
Toothed belt guard at the top	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreToothed belt tensioning roller

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 1.9 L Z 19 DTH 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_moreToothed belt tightener


All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	14.75 lbf⋅ft14.75 lbf⋅ft20 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 gasoline straight-4 2.0 L Z 20 LER engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine lubrication

expand_moreOil drain plug


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.
All Vauxhall gasoline straight-4 2.0 L Z 20 LER engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	10.33 lbf⋅ft10.33 lbf⋅ft14 N⋅m

expand_moreOil filter housing


All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

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


Heat-exchanger on oil filter housing	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Otherwise	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Use screw-locking compound.


All Vauxhall gasoline straight-4 2.0 L Z 20 LER engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOil sump

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


At the gearbox	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
On the engine block	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

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 LER 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


Camshaft sensor	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreGlow plugs


1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m


Knock sensor	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreLambda sensor

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


Lambda sensor downstream of catalytic converter	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Lambda sensors in front of catalytic converter	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m


All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
All Vauxhall gasoline straight-4 2.0 L Z 20 LER engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket

expand_more1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)


M10	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
M8	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreEngine mounting


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

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

expand_moreEngine suspension


1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreExhaust system

expand_moreCatalytic converter

expand_more1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)


Clamps	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m

expand_moreCatalytic converter bracket


1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreExhaust manifold


All Vauxhall gasoline straight-4 1.8 L Z 18 XER engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace nuts.

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	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.

expand_moreExhaust pipe

expand_more1.9 CDTi with diesel straight-4 1.9 L 148 HP engine (2006.1–2010.11)


Front	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreIgnition system


Spark plugs	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 2009 Vauxhall Astra TwinTop 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 TwinTop 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 Vauxhall Astra TwinTop you're not only saving money, but also also improving your technical skills and learning something new.

2009 Vauxhall Astra TwinTop Fifth generation (MK5) Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Vauxhall Astra TwinTop Fifth generation (MK5) model years

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