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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
Vauxhall gasoline straight-4 2.0 L F4R 720 118 HP 12.54 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 8.85 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 8.85 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 20.65 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 20.65 lbf⋅ft
All other modifications 6.64 lbf⋅ft
expand_moreAuxiliary assemblies
expand_moreAuxiliary drive belt deflection pulley
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 22.13 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 22.13 lbf⋅ft
All other modifications 32.45 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
Vauxhall gasoline straight-4 2.0 L F4R 720 118 HP 40.57 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines 14.75 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines 14.75 lbf⋅ft
expand_moreAir-conditioning compressor
All other modifications 18.44 lbf⋅ft
expand_moreAir-conditioning compressor bracket
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 22.13 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 22.13 lbf⋅ft
Air-conditioning compressor pressure line 5.9 lbf⋅ft
Replace the O ring.
expand_moreAlternator
All other modifications 18.44 lbf⋅ft
expand_moreGenerator bracket
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 22.13 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 22.13 lbf⋅ft
Hydraulic lines at the servo-steering pump 17.7 lbf⋅ft
Servo pump pulley 7.38 lbf⋅ft
expand_moreServo steering pump
Vauxhall gasoline straight-4 2.0 L F4R 720 118 HP 18.44 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 18.44 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 18.44 lbf⋅ft
All other modifications 15.49 lbf⋅ft
expand_moreVacuum pump
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 16.96 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 16.96 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 16.96 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 16.96 lbf⋅ft
All other modifications 11.06 lbf⋅ft
expand_moreCarburetion
Exhaust gas return valve 15.49 lbf⋅ft
expand_moreFuel-distributing pipe
All Vauxhall gasoline straight-4 2.0 L F4R 720 engines 6.64 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines 16.23 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines 16.23 lbf⋅ft
All other modifications 18.44 lbf⋅ft
High-pressure line 18.44 lbf⋅ft
High-pressure pump 22.13 lbf⋅ft
expand_moreHigh-pressure pump pulley
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 66.38 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 66.38 lbf⋅ft
expand_moreAll other modifications
First stage 11.06 lbf⋅ft
Second stage 60°
expand_moreInjection nozzle (injector)
expand_moreStud screws
First stage 1.48 lbf⋅ft
Replace the stud bolt.
expand_moreNuts on the front side
Second stage 4.43 lbf⋅ft
Replace nuts.
expand_moreNuts on the flywheel side
Third stage 4.43 lbf⋅ft
Replace nuts.
Fourth stage 330390°
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 18.44 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 18.44 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreCharging
expand_moreTurbo charger
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines 17.7 lbf⋅ft
Use new seals.
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines 17.7 lbf⋅ft
Use new seals.
All other modifications 20.65 lbf⋅ft
on exhaust manifold
Turbocharger oil feed line 16.23 lbf⋅ft
Use new parts.
Turbocharger oil return line 8.85 lbf⋅ft
Use new seals.
expand_moreCooling system
expand_moreCoolant pump
Vauxhall gasoline straight-4 2.0 L F4R 720 118 HP 12.54 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 7.38 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 7.38 lbf⋅ft
All other modifications 18.44 lbf⋅ft
Coolant pump pulley 15.49 lbf⋅ft
Coolant thermostat housing 7.38 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines 14.75 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines 14.75 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreCylinder head screws
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 100°
Third stage 100°
Figure 1. Cylinder head, Cylinder head screws, Vauxhall diesel straight-4 2.5 L G9U 730 133 HP.
Figure 1. Cylinder head, Cylinder head screws, Vauxhall diesel straight-4 2.5 L G9U 730 133 HP.
First stage 22.13 lbf⋅ft
Replace screws. See figure 1.
Second stage 22.13 lbf⋅ft
Third stage 22.13 lbf⋅ft
Fourth stage 294306°
First stage 22.13 lbf⋅ft
Tighten the new screws evenly in several steps.
Second stage 230°
Oil the screw lightly.
First stage 22.13 lbf⋅ft
Replace screws. See figure 1.
Second stage 22.13 lbf⋅ft
Control tensioner
Third stage 230°
expand_moreAll other modifications
Figure 2. Cylinder head, Cylinder head screws, All other modifications.
Figure 2. Cylinder head, Cylinder head screws, All other modifications.
First stage 3.69 lbf⋅ft
Replace screws. See figure 2.
Second stage 22.13 lbf⋅ft
Third stage 300°
expand_moreCylinder head screws shank length (maximum)
2.0 16V with gasoline straight-4 2.0 L 118 HP engine (2001.8–2006.12) 4.67 in
Rocker bridge 9.59 lbf⋅ft
from outside to inside
expand_moreValve cover
First stage 5.9 lbf⋅ft
Second stage 8.85 lbf⋅ft
First stage 1.48 lbf⋅ft
Second stage 8.85 lbf⋅ft
All other modifications 8.85 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
First stage 18.44 lbf⋅ft
Replace screws.
Second stage 4961°
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 40°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Second stage 55°
expand_moreCrankshaft central screws
First stage 29.5 lbf⋅ft
Replace screws.
Second stage 110°
First stage 36.88 lbf⋅ft
Second stage 8496°
First stage 14.75 lbf⋅ft
Use new screw.
Second stage 100130°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Second stage 85°
expand_moreCrankshaft pulley
First stage 29.5 lbf⋅ft
Replace screws.
Second stage 110°
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 115°
Third stage 15°
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 115±15°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Second stage 85°
Engine block closure screws 18.44 lbf⋅ft
expand_moreFlywheel
Vauxhall gasoline straight-4 2.0 L F4R 720 118 HP 36.8840.57 lbf⋅ft
Replace screws.
First stage 14.75 lbf⋅ft
Clean the thread, use new screws and screw-locking compound.
Second stage 45°
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 40.57 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 40.57 lbf⋅ft
expand_moreAll other modifications
First stage 22.13 lbf⋅ft
expand_moreSecond stage
First step 25.81 lbf⋅ft
Second step 40°
expand_moreMain bearing
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 5866°
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines Component must not be knocked down.
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines Component must not be knocked down.
expand_moreAll other modifications
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 140160°
expand_moreEngine control
expand_moreCamshaft drive belt deflection pulley
All Vauxhall gasoline straight-4 2.0 L F4R 720 engines 36.88 lbf⋅ft
All other modifications 22.13 lbf⋅ft
Camshaft timing chain guide rail 18.44 lbf⋅ft
Replace bolt.
Camshaft timing chain tensioner 7.38 lbf⋅ft
Camshaft timing chain tensioning rail 18.44 lbf⋅ft
expand_moreCamshaft timing gear
First stage 22.13 lbf⋅ft
Replace nuts.
Second stage 86°
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines 44.25 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines 44.25 lbf⋅ft
expand_moreAll other modifications
expand_moreLeft
First stage 7.38 lbf⋅ft
Second stage 40°
expand_moreRight
First stage 14.75 lbf⋅ft
Second stage 35°
Chain tensioner 7.38 lbf⋅ft
expand_moreInlet camshaft wheel
First stage 22.13 lbf⋅ft
Replace nuts.
Second stage 8092°
All other modifications 7.38 lbf⋅ft
expand_moreOutlet camshaft wheel
First stage 22.13 lbf⋅ft
Replace nuts.
Second stage 8092°
All other modifications 7.38 lbf⋅ft
expand_moreTiming case cover
First stage 3.69 lbf⋅ft
Use sealant.
expand_moreM6
Second stage 11.8 lbf⋅ft
expand_moreM8
Second stage 13.28 lbf⋅ft
Toothed belt guard 7.38 lbf⋅ft
expand_moreToothed belt guard at the bottom
M6 5.9 lbf⋅ft
M8 13.28 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreToothed belt guard at the top
M10 28.03 lbf⋅ft
M8 13.28 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines 7.38 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines 7.38 lbf⋅ft
All other modifications 18.44 lbf⋅ft
Toothed belt guard center 7.38 lbf⋅ft
expand_moreToothed belt tensioning roller
First stage 5.16 lbf⋅ft
Second stage 20.65 lbf⋅ft
Nuts 36.88 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreEngine lubrication
Oil cooler 40.57 lbf⋅ft
expand_moreOil drain plug
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 14.75 lbf⋅ft
Replace sealing rings.
All other modifications 13.28 lbf⋅ft
Replace sealing rings.
expand_moreOil filter housing
expand_moreAll other modifications
Oil filter cover 18.44 lbf⋅ft
Replace sealing rings.
Oil pressure sensor 28.03 lbf⋅ft
expand_moreOil pump
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 15.49 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 15.49 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 18.44 lbf⋅ft
Replace screws.
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 18.44 lbf⋅ft
Replace screws.
expand_moreAll other modifications
First stage 3.69 lbf⋅ft
Second stage 18.44 lbf⋅ft
expand_moreOil sump
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 6.64 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 6.64 lbf⋅ft
First stage 5.9 lbf⋅ft
Second stage 11.06 lbf⋅ft
expand_moreAll other modifications
First stage 3.69 lbf⋅ft
Second stage 11.8 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 3.69 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 3.69 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreCrankshaft sensor
All Vauxhall diesel straight-4 1.9 L F9Q 760 engines 2.95 lbf⋅ft
All Vauxhall diesel straight-4 1.9 L F9Q 762 engines 2.95 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreGlow plugs
Vauxhall diesel straight-4 2.5 L G9U 630 133 HP 11.06 lbf⋅ft
Vauxhall diesel straight-4 2.5 L G9U 730 133 HP 11.06 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 11.06 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 11.06 lbf⋅ft
All other modifications 13.28 lbf⋅ft
Knock sensor 14.75 lbf⋅ft
expand_moreLambda sensor
All Vauxhall gasoline straight-4 2.0 L F4R 720 engines 33.19 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
M10 44.25 lbf⋅ft
Replace screws.
M12 73.76 lbf⋅ft
Replace screws.
All other modifications 44.25 lbf⋅ft
expand_moreEngine mounting
Nuts 32.45 lbf⋅ft
Replace screws.
Screws 32.45 lbf⋅ft
Replace screws.
Screws on the engine bracket 44.25 lbf⋅ft
Screws on the engine mounting 32.45 lbf⋅ft
expand_moreAll other modifications
On engine bracket nuts 44.25 lbf⋅ft
Screws on the engine bracket 32.45 lbf⋅ft
expand_moreSubframe
Front 77.44 lbf⋅ft
Rear 88.51 lbf⋅ft
expand_moreTorque arm
On chassis 73.76 lbf⋅ft
On engine bracket 73.76 lbf⋅ft
expand_moreExhaust system
expand_moreCatalytic converter
At the turbocharger 14.75 lbf⋅ft
Use new seals.
expand_moreCatalytic converter bracket
Flywheel side 15.49 lbf⋅ft
expand_moreNuts
Front side 22.13 lbf⋅ft
expand_moreScrews
Front side 32.45 lbf⋅ft
expand_moreExhaust manifold
Vauxhall gasoline straight-4 2.0 L F4R 720 118 HP 16.23 lbf⋅ft
Nuts 22.13 lbf⋅ft
Stud screws 5.9 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 762 79 HP 20.65 lbf⋅ft
Vauxhall diesel straight-4 1.9 L F9Q 760 99 HP 22.86 lbf⋅ft
expand_moreAll other modifications
First stage 13.28 lbf⋅ft
Second stage 24.34 lbf⋅ft
Exhaust manifold heat shields 7.38 lbf⋅ft
Exhaust pipe 15.49 lbf⋅ft
Exhaust pipe rear 15.49 lbf⋅ft
Exhaust system middle heat protection plate 11.06 lbf⋅ft
expand_moreFuel supply
expand_moreFuel filter housing
Fuel filter cover 4.43 lbf⋅ft
Fuel lines 19.91 lbf⋅ft
on high-pressure pump
expand_moreIgnition system
expand_moreSpark plugs
All Vauxhall gasoline straight-4 2.0 L F4R 720 engines 19.91 lbf⋅ft
expand_moreStart system
expand_moreStarter
All other modifications 32.45 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2003 Vauxhall Vivaro Box 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.

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 Vivaro Box 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 Vivaro Box Van you're not only saving money, but also also improving your technical skills and learning something new.

Vauxhall Vivaro Box Van First generation (MK1) model years

Units:
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