2003 Vauxhall Astra Van engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


All other modifications	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Use new screws or nuts

expand_moreIntake manifold support


On intake manifold	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Support on cylinder head	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt tensioner

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


Self-locking nuts	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Otherwise	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAir-conditioning compressor


1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m

expand_moreAir-conditioning compressor bracket

expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)


M10 nuts	33.93 lbf⋅ft33.93 lbf⋅ft46 N⋅m
M10 screws	35.4 lbf⋅ft35.4 lbf⋅ft48 N⋅m
M14 screws	50.15 lbf⋅ft50.15 lbf⋅ft68 N⋅m

expand_moreAir-conditioning compressor pressure line


1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreGenerator bracket


1.7 TD with diesel straight-4 1.7 L 67 HP at 4500 RPM, 132 N⋅m at 2400 RPM engine (1998.8–2006.8)	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreCarburetion

expand_moreExhaust recirculation pipe


1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m
Replace sealing rings.

expand_moreInjection hoses


All Vauxhall diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m

expand_moreInjection nozzle (injector)


All Vauxhall diesel straight-4 1.7 L X 17 DTL engines	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m

expand_moreAll Vauxhall diesel straight-4 2.0 L X 20 DTL engines


First stage	hand-screwed
Second stage	360°360°360°

expand_moreInjection pump pulley


All Vauxhall diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m

expand_moreCharging

expand_moreCharge air pipes

expand_more1.7 TD with diesel straight-4 1.7 L 67 HP at 4500 RPM, 132 N⋅m at 2400 RPM engine (1998.8–2006.8)


Clamps	2.58 lbf⋅ft2.58 lbf⋅ft3.5 N⋅m

expand_moreTurbo charger

expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)


On exhaust manifold	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m
Replace sealing rings.

expand_moreTurbocharger bracket


1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreTurbocharger oil feed line

expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)


At the turbocharger	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
On the engine block	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCooling system

expand_moreCoolant pump


All Vauxhall gasoline straight-4 1.6 L Z 16 SE engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCoolant pump pulley


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Vauxhall diesel straight-4 2.0 L X 20 DTL engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCylinder head screws

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

Figure 1. Cylinder head, Cylinder head screws, Vauxhall diesel straight-4 1.7 L X 17 DTL.


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°
Fifth stage	Warm-up run
Sixth stage	30°30°30°
Seventh stage	15°15°15°

expand_moreAll Vauxhall diesel straight-4 2.0 L X 20 DTL engines

expand_moreScrews 1 – 10

Figure 2. Cylinder head, Cylinder head screws, Vauxhall diesel straight-4 2.0 L X 20 DTL, Screws 1 – 10.


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 2.
Second stage	65°65°65°
Third stage	65°65°65°
Fourth stage	65°65°65°
Fifth stage	65°65°65°
Sixth stage	15°15°15°

expand_moreScrews 11 – 14


Seventh stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Eighth stage	30°30°30°
Ninth stage	5°5°5°

expand_moreAll other modifications

Figure 3. Cylinder head, Cylinder head screws, All other modifications.


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 3.
Second stage	60°60°60°
Third stage	60°60°60°
Fourth stage	60°60°60°

expand_moreValve cover


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	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 SE engines


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

expand_moreAll other modifications


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

expand_moreCrankcase ventilation


Crankcase ventilation pipe	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Use new seals.

expand_moreCrankshaft central screws

expand_moreAll Vauxhall diesel straight-4 1.7 L X 17 DTL 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 diesel straight-4 2.0 L X 20 DTL engines


First stage	110.63 lbf⋅ft110.63 lbf⋅ft150 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreAll other modifications


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


Crankshaft pulley	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFlywheel

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


First stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Replace screws and nuts.
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreAll Vauxhall diesel straight-4 2.0 L X 20 DTL engines


First stage	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace screws and nuts.
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 diesel straight-4 2.0 L X 20 DTL engines


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	15°15°15°

expand_moreAll other modifications


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

expand_moreEngine control

expand_moreCamshaft drive belt deflection pulley


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	59 lbf⋅ft59 lbf⋅ft80 N⋅m

expand_moreCamshaft timing gear

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


First stage	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	5°5°5°

expand_moreAll Vauxhall diesel straight-4 2.0 L X 20 DTL engines


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	30°30°30°


All other modifications	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreChain tensioner


Cap	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreToothed belt guard at the bottom


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m

expand_moreToothed belt guard at the top


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m

expand_moreToothed belt tensioning roller


All Vauxhall diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Vauxhall gasoline straight-4 1.6 L Z 16 SE engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreToothed belt tightener

expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)


Tension pulley with leaf spring	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
Tensioning roller with spiral spring	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 X 17 DTL engines


One-part sump	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Two-part oil sump	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	57.53 lbf⋅ft57.53 lbf⋅ft78 N⋅m

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

expand_moreAluminium oil sump


Hexagon head screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Torx screws	10.33 lbf⋅ft10.33 lbf⋅ft14 N⋅m


Sheet-steel sump	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m


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

expand_moreOil filter housing


All Vauxhall diesel straight-4 2.0 L X 20 DTL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOil sump

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

expand_moreOil sump top part


At the gearbox	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
On the engine block	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOil sump lower part


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Second stage	30°30°30°


One-part sump	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreAll Vauxhall diesel straight-4 2.0 L X 20 DTL engines

expand_moreAt the gearbox


M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


On the engine block	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll Vauxhall gasoline straight-4 1.6 L Z 16 SE 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

expand_moreEngine management

expand_moreCamshaft sensor


All Vauxhall gasoline straight-4 1.6 L Z 16 SE engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCrankshaft sensor


1.6 i with gasoline straight-4 1.6 L 83 HP engine (2000.9–2006.8)	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreGlow plugs


All Vauxhall diesel straight-4 1.7 L X 17 DTL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Vauxhall diesel straight-4 2.0 L X 20 DTL engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreKnock sensor


All Vauxhall gasoline straight-4 1.6 L Z 16 SE engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreLambda sensor


All Vauxhall gasoline straight-4 1.6 L Z 16 SE engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreEngine mounting


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreAll Vauxhall gasoline straight-4 1.6 L Z 16 SE 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_moreExhaust system

expand_moreCatalytic converter


1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m

expand_moreExhaust manifold


All Vauxhall diesel straight-4 1.7 L Y 17 DT engines	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
Replace screws and nuts.
All other modifications	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.

expand_moreExhaust manifold heat shields


1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreExhaust pipe

expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)


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

expand_moreExhaust pipe rear


1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2001.4–2006.8)	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreIgnition system


Spark plugs	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreStart system


Starter	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 2003 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 2003 Vauxhall Astra Van you're not only saving money, but also also improving your technical skills and learning something new.

2003 Vauxhall Astra Van Fourth generation facelift (MK4) Engine Fastener Tightening Specifications

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Conquer your fears and never give up!

Vauxhall Astra Van Fourth generation facelift (MK4) model years

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