OpelArges

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Notes Specified value Measured value

Vehicle identification
No. of cylinders Capacity (Fiscal) Compression ratio Suitable for unleaded petrol Minimum octane rating Ignition system Ignition system Ignition system Trigger location Fuel system Fuel system Fuel system Air metering Combined ignition and fuel ECM Diagnostic socket Type 4/DOHC cc 1364 :1 10,5 Yes RON 91 Make Bosch Type Motronic ME7.6.1/2 Description Map-DI Cam / Crankshaft Make Bosch Type Motronic ME 7.6.1 Description MFI-s Type Mass Yes Yes

Ignition system
Ignition coil supply voltage Firing order + with ballast V 12,0 1-3-4-2

Tuning and emissions

Ignition timing - basic BTDC Ignition advance checks Idle speed Oil temperature for CO test CO level at idle speed - tailpipe HC level at idle speed CO2 level at idle speed O2 level at idle speed Increased idle speed for CO test CO content at increased idle speed Lambda at increased idle Engine/rpm Not adjustable Engine/rpm ECM Controlled rpm 80080 Not adjustable C 80 Vol. % CO 0,5 Max Not adjustable ppm 100 Vol. % CO2 14,5-16 Vol. % O2 0,1-0,5 rpm 2800-3200 Vol. % 0,3 0,97-1,03

Spark plugs
Spark plugs Spark plug Electrode gap Spark plugs Spark plug Electrode gap Original equipment Bosch Type FQR8LEU2 mm 0,85-0,95 Make Bosch Type FQR8LEU2 mm 0,85-0,95

Fuel system
System pressure bar 3,6-4,0

Service checks and adjustments

Valve clearance -INLET Valve clearance -EXHAUST Compression pressure Oil pressure mm Hydraulic mm Hydraulic bar 17,5 bar/rpm 1,5/730

Manufacturer: Vauxhall/Opel Engine code: Z14XEP Tuned for: R-Cat

Model: Astra-G 1,4 Output: 66 (90) 5600 Year: 2003-06

Autodata Limited 2010 Valid forever. 26-May-13 V8.500-

Thermostat opens

C 92

Lubricants and capacities

Engine oil options Ambient temperature range Engine oil grade Engine oil classification Ambient temperature range Engine oil grade Engine oil classification Ambient temperature range Engine oil grade Engine oil classification Engine with filter(s) Other lubricants and capacities 158 Manual transmission oil grade 157 Manual transmission Cooling system - total capacity Brake fluid Brake fluid Power steering fluid Power steering fluid SAE litres litres 6,3 AC= 6,6 Type DOT 4 litres 0,5 Type Pentosin CHF 202 litres 0,7-1,1 SAE -30C > 40C SAE 0W/30, 0W/40 Synthetic API/ACEA SJ/A3 -25C > 40C SAE 5W/30, 5W/40 Synthetic API/ACEA SJ/A3 -20C > 40C 10W/30, 10W/40 Semisynthetic

API/ACEA SJ/A3 litres 3,5

Tightening torques
Cylinder head instructions Cylinder head Renew bolts Yes Stage 1 Stage 2 Stage 3 Stage 4 Other engine tightening torques Main bearings 107 Main bearings Big end bearings 222 Big end bearings 133 Sump bolts 126 Sump drain bolt 108 Flywheel/driveplate Clutch pressure plate Crankshaft pulley/damper centre bolt 109 Camshaft sprocket/gear Camshaft carrier/cap Camshaft/rocker cover Inlet manifold to cylinder head 3 3 3 Exhaust manifold to cylinder head Exhaust downpipe to manifold Water pump Spark plugs Fuel rail Crankshaft position (CKP) sensor/engine speed (RPM) sensor Camshaft position (CMP) sensor Engine coolant temperature (ECT) sensor Lambda sensor (Oxygen) Knock sensor (KS) Engine oil pressure switch Oil filter Chassis tightening torques 219 Front hub 8 Nm 8 Nm 10 Nm 15 Nm 20 Nm 8 Nm 25 Nm 8 Nm 8 Nm 6 Nm 18 Nm 40 Nm 20 Nm 20 Nm 15 Nm 15 Nm 150 Nm+45 Renew bolts/nuts Yes Stage 1 Renew bolts/nuts Yes Stage 1 Tighten 25 Nm Tighten 60 Tighten 60 Tighten 60

Manufacturer: Vauxhall/Opel Engine code: Z14XEP Tuned for: R-Cat

Model: Astra-G 1,4 Output: 66 (90) 5600 Year: 2003-06

Autodata Limited 2010 Valid forever. 26-May-13 V8.500-

3 3 3

Front hub - wheel bearing housing bolts Rear hub - wheel bearing housing bolts Steering track rod end Brake disc to hub Brake caliper to carrier Brake caliper carrier to hub Brake disc to hub Brake caliper to carrier Brake caliper carrier to hub

90 Nm+30+15 50 Nm+30+15 20 Nm 50 Nm Front 7 Nm Front 25 Nm Front 100 Nm Rear 7 Nm Rear 25 Nm Rear 100 Nm 110 Nm

214 Steering wheel

377 Road wheels

Starting and charging

Battery V/RC(Ah) 12 (44)

Brake disc and drum dimensions

Minimum disc thickness - solid Minimum disc thickness - ventilated Minimum disc thickness Disc thickness variation Disc thickness variation Disc runout Disc runout Maximum drum diameter Minimum pad thickness Minimum pad thickness Minimum shoe thickness Front 8 mm Front 21 mm Rear 8 mm Front 0,010 mm Rear 0,010 mm Front 0,11 mm Rear 0,13 mm Rear 231 mm Front 2 mm Rear 2 mm Rear 1 mm

Air conditioning
No. of AC service connectors Air conditioning restrictor type Air conditioning refrigerant Air conditioning refrigerant quantity Air conditioning oil Air conditioning oil quantity Air conditioning oil viscosity 2 Expansion valve Type R134a grams 600 Type Dens Oil 8 cm 150 ISO 46

Autodata Note 158 Gearbox oil type F13/23/35 = Opel No. 93 165 290 F17 = Opel No. 90 540 998 Autodata Note 157 Gearbox capacity F13 + F17 = 1,6 litres F18 = 1,8 litres F23 = 1,75 litres. Autodata Note 107 Main bearings M8 Use new bolts and tighten in the following stages: 1) 25 Nm 2) 60 M6 Use new bolts and tighten in the following stages: 1) 10 Nm 2) 60.
Manufacturer: Vauxhall/Opel Engine code: Z14XEP Tuned for: R-Cat Model: Astra-G 1,4 Output: 66 (90) 5600 Year: 2003-06 Autodata Limited 2010 Valid forever. 26-May-13 V8.500-

Autodata Note 222 Big end bearings M6 Use new bolts and tighten as follows: 1) 10 Nm 2) 60 3) 15 M6.5 Use new bolts and tighten as follows: 1) 13 Nm 2) 60 3) 15. Autodata Note 133 Sump bolts Sump to cylinder block = 10 Nm Sump to transmission = 40 Nm. Autodata Note 126 Sump drain bolt Torx bolt = 10-15 Nm Hexagonal bolt = 45-55 Nm. Autodata Note 108 Flywheel Use new bolts and tighten in the following stages: 1) 35 Nm 2) 30. Autodata Note 109 Camshaft sprocket Use new bolts and tighten in the following stages: 1) 50 Nm 2) 60. Autodata Note 3 Use new nuts/bolts.

Autodata Note 219 Front hub Use new nut and tighten as follows: 1) 120 Nm 2) Slacken off 3) 20 Nm + 80 4) If necessary, turn nut further to align split pin. Autodata Note 214 Use new nuts/bolts. Apply locking fluid.

Autodata Note 377

Manufacturer: Vauxhall/Opel Engine code: Z14XEP Tuned for: R-Cat

Model: Astra-G 1,4 Output: 66 (90) 5600 Year: 2003-06

Autodata Limited 2010 Valid forever. 26-May-13 V8.500-

Road wheels Lightly coat conical seat of bolt and mating surfaces between wheel centre hole and hub (use grease). Do NOT lubricate bolt thread.

Cylinder layout

Tightening sequence

Manufacturer: Vauxhall/Opel Engine code: Z14XEP Tuned for: R-Cat

Model: Astra-G 1,4 Output: 66 (90) 5600 Year: 2003-06

Autodata Limited 2010 Valid forever. 26-May-13 V8.500-