2009 Vauxhall Astra Van engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system


Intake manifold	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
helically from the inside out

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


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

expand_moreAuxiliary drive belt tensioner


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


Air-conditioning compressor	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Air-conditioning compressor bracket	31.72 lbf⋅ft31.72 lbf⋅ft43 N⋅m
Air-conditioning compressor pressure line	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAlternator


M10	33.93 lbf⋅ft33.93 lbf⋅ft46 N⋅m
M8	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m

expand_moreGenerator bracket


M10	35.4 lbf⋅ft35.4 lbf⋅ft48 N⋅m
M14	50.15 lbf⋅ft50.15 lbf⋅ft68 N⋅m


Vacuum pump	17.7 lbf⋅ft17.7 lbf⋅ft24 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 (2005.3–2011.11)	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 line	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
High-pressure pump	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
High-pressure pump pulley	50.15 lbf⋅ft50.15 lbf⋅ft68 N⋅m

expand_moreInjection nozzle (injector)


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Second stage	slacken
Third stage	23.6 lbf⋅ft23.6 lbf⋅ft32 N⋅m

expand_moreCharging

expand_moreTurbo charger

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


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

expand_moreAll other modifications


First stage	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Replace screws and nuts.
Second stage	35.4 lbf⋅ft35.4 lbf⋅ft48 N⋅m

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.


All Vauxhall diesel straight-4 1.9 L Z 19 DT engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace sealing rings.
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_moreTurbocharger oil return line


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_moreCooling system

expand_moreCoolant pump pulley


All Vauxhall diesel straight-4 1.7 L Z 17 DTH engines	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
All other modifications	11.8 lbf⋅ft11.8 lbf⋅ft16 N⋅m

expand_moreRadiator mounting


1.9 CDTi with diesel straight-4 1.9 L 118 HP engine (2005.3–2011.11)	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing

Figure 1. Cylinder head, Camshaft bearing.


Nuts	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Tighten in several steps. See figure 1.
Screws	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreCylinder head screws

Figure 2. Cylinder head, Cylinder head screws.


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Use new screws. See figure 2.
Second stage	90°90°90°
Third stage	90°90°90°


Valve cover	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws and nuts.
Second stage	100°100°100°
Third stage	25°25°25°

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 XEP engines


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


All other modifications	144.56 lbf⋅ft144.56 lbf⋅ft196 N⋅m


Crankshaft pulley	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 diesel straight-4 1.7 L Z 17 DTH engines


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°


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.

expand_moreAll Vauxhall diesel straight-4 1.9 L Z 19 DTH 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 other modifications


First stage	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
Retap thread in holes and use new screws.
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreMain bearing


First stage	28.76 lbf⋅ft28.76 lbf⋅ft39 N⋅m
helically from the inside out
Second stage	60°60°60°
Use new screws.


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

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


All Vauxhall gasoline straight-4 1.6 L Z 16 XE1 engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall gasoline straight-4 1.6 L Z 16 XEP engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DT engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	59 lbf⋅ft59 lbf⋅ft80 N⋅m

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 other modifications	81.87 lbf⋅ft81.87 lbf⋅ft111 N⋅m

expand_moreChain tensioner


1.3 CDTi with diesel straight-4 1.2 L 89 HP engine (2005.8–)	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 (2005.8–)	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 (2005.8–)	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreTiming case cover


1.3 CDTi with diesel straight-4 1.2 L 89 HP engine (2005.8–)	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m

expand_moreToothed belt guard

expand_moreAll Vauxhall diesel straight-4 1.9 L Z 19 DT 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 gasoline straight-4 1.6 L Z 16 XE1 engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
All Vauxhall gasoline straight-4 1.6 L Z 16 XEP engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreToothed belt guard at the top


All Vauxhall gasoline straight-4 1.6 L Z 16 XE1 engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m
All Vauxhall gasoline straight-4 1.6 L Z 16 XEP engines	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreToothed belt tensioning roller


All Vauxhall gasoline straight-4 1.6 L Z 16 XE1 engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Vauxhall gasoline straight-4 1.6 L Z 16 XEP engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
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 1.9 L Z 19 DT engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall diesel straight-4 1.9 L Z 19 DTH engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	36.14 lbf⋅ft36.14 lbf⋅ft49 N⋅m

expand_moreEngine lubrication

expand_moreOil drain plug

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


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.


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOil filter housing


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

expand_moreOil sump


At the gearbox	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Oil sump lower part	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Oil sump top part	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreEngine management


Camshaft sensor	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Charge air pressure sensor	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
Crankshaft sensor	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Glow plugs	10.33 lbf⋅ft10.33 lbf⋅ft14 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket

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.

expand_moreAll Vauxhall diesel straight-4 1.9 L Z 19 DT 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 diesel straight-4 1.7 L Z 17 DTH engines


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


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


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreSubframe stiffening plate


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreTorque arm

expand_moreAt the subframe


Bottom	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Replace nuts.

expand_moreAt the gearbox


Bottom	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreTorque support bracket

expand_moreAt the gearbox


Front	59 lbf⋅ft59 lbf⋅ft80 N⋅m
Rear	59 lbf⋅ft59 lbf⋅ft80 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 DTH engines


Clamps	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m

expand_moreAll other modifications


At the turbocharger	33.19 lbf⋅ft33.19 lbf⋅ft45 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
All Vauxhall diesel straight-4 1.9 L Z 19 DT engines	18.44 lbf⋅ft18.44 lbf⋅ft25 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 other modifications

expand_moreScrews, bottom


First stage	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m
helically from the inside out

expand_moreTop screws


Second stage	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m
Replace screws and 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 DT engines


Front	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreStart system

expand_moreStarter


At the gearbox	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
On the engine block	28.03 lbf⋅ft28.03 lbf⋅ft38 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 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 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 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 2009 Vauxhall Astra Van you're not only saving money, but also also improving your technical skills and learning something new.

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

Table of Contents

Conquer your fears and never give up!

Vauxhall Astra Van Fifth generation (MK5) model years

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