October 2000

Opel´s 2001 engine strategy

More Power and Lower Emissions

High-torque direct-injection turbo diesels charge up the model range

Rüsselsheim. Although they are already among the most economical and efficient in
their respective classes, Opel’s ECOTEC engines have been comprehensively up-
graded for the 2001 model year. The result: even lower exhaust emissions and fuel
consumption combined with higher power output and torque. In addition, the ultra-
modern 2.2-liter, 16-valve aluminum engine – which already powers the Astra Coupé
and the Speedster – will be available for the Astra, Zafira and Vectra as well. The
direct-injection diesels under the hoods of these models have been given a boost, too.
The Vectra and Omega feature a new 2.6-liter V6 gasoline unit and Astra Coupé
buyers can now opt for the new, top-of-the-range Turbo with 140 kW / 190 hp. Almost
all the gasoline engines for the 2001 model year comply with the strict Euro 4 exhaust
emission limits, qualifying them for tax concessions in many countries.

Another important step forward for 2001: the inspection intervals for almost the
complete engine range have been extended to 30,000 kilometers. This has been made
possible by the use of new grades of lubricating oil in accordance with the ACEA
A3/B3-98 specification, and classified as 0W-X, 5W-X, or 10W-X according to their
viscosity. For safety reasons, all the Opel models that qualify for these longer servicing
intervals are equipped with a brake pad wear indicator.
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The diesel range: modern, direct-injection units with higher power outputs

The 2001 engine line-up also includes up-graded diesels which provide higher power
and torque while still complying with the Euro 3 exhaust emission limits.

One of the most innovative highlights in Opel’s 2001 model range is the Astra Eco 4.
With fuel consumption of only 4.4 liters per 100 kilometers (MVEG standard), this Astra
with its 1.7-liter DI engine is the first “four-liter car” in the compact class. The Eco 4
demonstrates how comfortable family cars with a high safety standard, ample interior
and good performance figures can still be exceptionally economical. Opel is offering
the Astra Eco 4 at very competitive prices and expects it to sell in considerable
numbers – with a correspondingly beneficial effect on the brand’s fleet consumption.
The 55 kW / 75 hp direct-injection engine, also powers the Astra 1.7 DTI and the new
Corsa.

There are equally interesting new developments at the other end of the performance
scale. In addition to further detail work on the VP 44 radial-piston injection pump, which
now delivers fuel at up to 1800 bar to the injectors and operates with pilot or pre-
injection, the forced aspiration system on the new 2.2-liter engine has also received the
engineers’ attention. This is the first Opel engine to feature a VTG turbocharger (a
turbocharger with variable turbine geometry). The vacuum-controlled guide vanes in
the Garrett GT 18 unit enable it to obtain maximum energy from the exhaust gas flow.
In practice, this results in more rapid response at all engine speeds. This elaborate
system also includes a charge air-intercooler for the intake air before it reaches the
engine. The resulting increase in the density of the air enables correspondingly more
fuel to be injected, so that power output rises. The charge-air intercooler also reduces
the thermal loads on the engine. This powerful turbo diesel has two counter-rotating
balance shafts for exceptionally smooth running.

In the Vectra, the 2.2-liter DTI 16V develops 92 kW / 125 hp and generates its
maximum torque of 270 Nm at an engine speed of only 1500 rpm. With slightly different
performance data it is also installed in the Omega.
 -3-

Gasoline engines: Euro 4 classification for almost every powerplant

The significantly improved emission levels achieved by the ECOTEC gasoline engines
derive mainly from engine design measures such as new camshafts for modified valve
timing and changes to the engine management system. Improvements to the catalytic
converters such as installation very close to the exhaust manifold, have also lowered
these engines’ exhaust emissions by enabling the converters to reach their light-off
temperature sooner after a cold start. The new, 2.2-liter aluminum engine, which
already complies with the Euro 4 standard, also uses a starting converter.

Bringing the gasoline engines into line with future exhaust emission limits involved a
thorough design revision which, in many cases, resulted in higher power output. An
example of this is the Astra’s 1.6-liter engine, which has been converted from central to
multi-point fuel injection and now has new intake and exhaust manifolds among other
improvements. Its output has gone up from 55 kW / 75 hp to 62 kW / 85 hp. This
progress is all the more satisfactory because the Astra 1.6 16V’s fuel consumption
(MVEG standard) has gone down by 0.2 liter per 100 kilometers to only 7.0 l/100 km.

The Astra 1.6 16V is a good example of the cumulative effect of reduced exhaust
emissions. Based on the German sales figures for 2000, and assuming that each Astra
1.6 16V covers 15,000 kilometers annually, the improvements over the previous model
reduce emissions of hydrocarbons (HC) by more than 56 and oxides of nitrogen (NOx)
by more than 27 tonnes a year.

Another engine that delivers high performance allied to excellent economy is an entire-
ly new development: the innovative 2.2-liter aluminum engine that had its European
premiere in the Astra Coupé. This 16-valve unit is now also available in the Astra,
Zafira and Vectra. An ECOTEC unit developing 108 kW / 147 hp, it replaces the pre-
vious 2.0 16V with 100 kW / 136 hp. The higher power output and the torque of
203 Nm – 90 percent of which is available at 1900 rpm – result in improved perform-
ance while at the same time fuel consumption has gone down by a further 0.1 liter per
100 kilometers to only 8.4 l/100 km. This new aluminum engine, like the Astra’s 1.2-liter
engine, already complies with the Euro 4 exhaust emission standard.
 -4-

Featuring two counter-rotating balance shafts for very smooth running, the lightweight
aluminum 2.2-liter four-cylinder unit is the new top-of-the-range engine for the Astra
and Zafira. The Vectra is also available with a 2.6-liter V6. This engine, too, has been
extensively revised: it now develops 125 KW / 170 hp and, with 250 Nm at 3400 rpm,
has a higher maximum torque than its 2.5-liter predecessor. The new 2.6-liter V6 is
also available in the Omega, where it is rated at 132 kW / 180 hp. In the spring of 2001
there will also be a V6 engine enlarged to 3.2 liters and developing 160 kW / 217 hp for
the Omega. It will be available with automatic transmission only.
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Spotlight

The Euro 3, Euro 4 and D4 exhaust emission standards

The Euro 4 and German D4 limits are identical if D4 classification is based on the Euro
3 standard. The earlier D4 standard was based on Euro 2 and had marginally stricter
limits, determined according to the old MVEG-A test cycle. The fundamental difference
was that in contrast to the new MVEG-B cycle the test car was allowed to warm up at
idle speed for 40 seconds before the test started, so that its catalytic converter was
ready to light off sooner when the actual test period was reached. Euro 4 also calls for
an additional cold-start test at –7°C.

An additional requirement for gasoline engines to qualify for the Euro 3 category is the
presence of an “On-Board Diagnosis System”. This monitors the electronics of all
emissions-relevant components, and reports any system faults by illuminating a
warning light on the instrument panel. The faults are stored in the control unit’s
memory and can then be analyzed by Opel Service with a suitable diagnostic device.
The “EOBD” (European On Board Diagnosis) requirement is satisfied by every Opel
with Euro 3/D4 classification for the 2001 model year, which have the necessary
warning light in the cockpit to inform the driver.

Exhaust emission limits for gasoline engines

CO (g/km) HC (g/km) NOX (g/km) HC+NOX (g/km)
Euro 2* 2.2 - - 0.5
Euro 3 (since 1.1.2001) 2.3 0.2 0.15 -
Euro 4 (from 1.1.2006) 1.0 0.1 0.08 -
* MVEG-A test cycle

Exhaust emission limits for diesel engines

CO (g/km) NOx (g/km) HC+NOX (g/km) Particles (g/km)
Euro 2* 1.0 - 0.9 0.1
Euro 3 (since 1.1.2001) 0.64 0.5 0.56 0.05
Euro 4 (from 1.1.2006) 0.5 0.25 0.3 0.025
* MVEG-A test cycle
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Opel passenger-car exhaust emission categories

Model Output Emission Code number Engine Transmission

kW/hp category type
Agila 1.0 43/58 Euro 4 62 Z10XE 5-speed
manual
Agila 1.2 55/75 Euro 4 62 Z12XE 5-speed
manual
Corsa 1.0 43/58 Euro 4 62 Z10XE 5-speed
manual
Corsa 1.2 55/75 Euro 4 62 Z12XE 5-speed
manual
Corsa 1.2 55/75 Euro 4 62 Z12XE Easytronic
Corsa 1.4 66/90 Euro 4 53 Z14XE 5-speed
manual
Corsa 1.4 66/90 Euro 4 53 Z14XE 4-speed
automatic
Corsa 1.8 92/125 Euro 4 53 z18 Xe 5-speed
manual
Corsa1.7 DI 48/65 Euro 3 44 Y17DTL 5-speed
manual
Corsa 1.7 DTI 55/75 Euro 3 44 Y17DT 5-speed
manual
Astra 1.2 55/75 Euro 4 62 Z12XE 5-speed
manual
Astra 1.6 62/85 Euro 3 and D4 53 Z16SE 5-speed
manual
Astra 1.6 62/85 Euro 3 and D4 53 Z16SE 4-speed
automatic
Astra 1.6 74/100 Euro 3 and D4 53 Z16XE 5-speed
manual
Astra 1.6 74/100 Euro 3 and D4 53 Z16XE 4-speed
automatic
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Astra 1.8 92/125 Euro 3 and D4 53 Z18XE 5-speed

manual
Astra 1.8 92/125 Euro 3 and D4 53 Z18XE 4-speed
automatic
Astra 2.2 108/147 Euro 4 62 Z22SE 5-speed
manual
Astra 2.2 108/147 Euro 4 62 Z22SE 4-speed
automatic
Astra1.7 DI 55/75 Euro 3 44 Y17DT 5-speed
manual
Astra Eco 4 55/75 Euro 3 45 Y17DT 5-speed
manual
Astra 2.0 DI 60/82 Euro 3 44 Y20DTL 4-speed
automatic
Astra 2.0 DTI 74/100 Euro 3 44 Y20DTH 5-speed
manual
Astra Coupé 1.8 92/125 Euro 4 53 Z18XE 5-speed
manual
Astra Coupé 2.2 108/147 Euro 4 62 Z22SE 5-speed
manual
Astra Coupé 2.2 108/147 Euro 4 62 Z22SE 4-speed
automatic
Astra Coupé 140/190 Euro 4 62 Z20LET 5-speed
Turbo manual
Zafira 1.6 74/100 Euro 4 53 Z16XE 5-speed
manual
Zafira 1.8 92/125 Euro 4 53 Z18XE 5-speed
manual
Zafira 1.8 92/125 Euro 4 53 Z18XE 4-speed
automatic
Zafira 2.2 108/147 Euro 4 62 Z22SE 5-speed
manual
 -8-

Zafira 2.2 108/147 Euro 4 62 Z22SE 4-speed

automatic
Zafira 2.0 DTI 74/100 Euro 3 44 Y20DTH 5-speed
manual
Vectra 1.6 74/100 Euro 4 53 Z16XE 5-speed
manual
Vectra 1.6 74/100 Euro 4 53 Z16XE 4-speed
automatic
Vectra 1.8 92/125 Euro 4 53 Z18XE 5-speed
manual
Vectra 1.8 92/125 Euro 4 53 Z18XE 4-speed
automatic
Vectra 2.2 108/147 Euro 4 62 Z22SE 5-speed
manual
Vectra 2.2 108/147 Euro 4 62 Z22SE 4-speed
automatic
Vectra V6 2.6 125/170 Euro 3 44 Y26SE 5-speed
manual
Vectra V6 2.6 125/170 Euro 3 44 Y26SE 4-speed
automatic
Vectra 2.0 DTI 74/100 Euro 3 44 Y20DTH 5-speed
manual
Vectra 2.2 DTI 92/125 Euro 3 44 Y22DTR 5-speed
manual
Omega 2.2 106/144 Euro 4 53 Z22XE 5-speed
manual
Omega 2.2 106/144 Euro 3 44 Z22XE 4-speed
automatic
Omega V6 2.6 132/180 Euro 3 44 Y26SE 5-speed
manual
Omega V6 2.6 132/180 Euro 3 44 Y26SE 4-speed
automatic
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Omega V6 3.0 155/211 D4 32 X30XE 5-speed

manual
Omega V6 3.0 155/211 D4 32 X30XE 4-speed
automatic
Omega 2.2 DTI 88/120 Euro 3 44 Y22DTH 5-speed
manual
Omega 2.5 TD 96/130 Euro 2 26 X25DT 5-speed
manual
Omega 2.5 TD 96/130 Euro 2 26 X25DT 4-speed
automatic
Frontera 2.2 100/136 Euro 3 44 Y22SE 5-speed
manual
Frontera 3.2 151/205 Euro 3 44 6VD1 5-speed
manual
Frontera 3.2 151/205 Euro 3 44 6VD1 4-speed
automatic
Frontera 2.2 DTI 85/115 98/69/EG III;A 51 Y22DTH 5-speed
manual
Frontera 2.2 DTI 85/115 98/69/EG III;A 51 Y22DTH 5-speed
manual
Speedster 108/147 Euro 4 53 Z22SE 5-speed
manual
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October 2000

Interview with Eckhard Zickwolff,

Director of Powertrain Engineering
at Opel’s International Technical Development Center

“High-Tech for the Benefit of the Customer”

Opel builds more engines with four valves per cylinder than any other European
manufacturer

Question: Almost all the engines in the Opel program have been modified for the 2001
model year. What have you achieved?

Zickwolff: We have made progress in four main areas. We have lowered emissions so
that almost every gasoline engine complies with Euro 4. All our diesels comply with
Euro 3. We have boosted power output and torque across the whole engine range.
Thanks to the measures we have taken, fuel consumption has improved still further.
And last but not least, we have been able to extend the oil-change and inspection
intervals to 30,000 kilometers or once a year.

Question: Until now, lower exhaust emissions were usually in conflict with higher
power output and lower fuel consumption. How have you managed to optimize both at
once?

Zickwolff: By means of intensive development work including a large number of

computer simulations. On the ECOTEC gasoline engines we put a great deal of work
into lowering internal friction, optimizing the valve timing and improving the electronic
engine management still further. Many models will now be powered by our brand new
2.2-liter four-cylinder engine – an ultra-modern aluminum powerplant. We also took a
 - 11 -

thorough look at our V6 engines, increased their displacement, boosted their torque
and lowered their fuel consumption and emissions.

All the ECOTEC diesels now have four valves per cylinder and direct injection. By
adopting turbochargers with variable turbines, charge-air intercooling and advanced
engine management systems, we have obtained greater power from these engines too
and lowered their fuel consumption. Incidentally, if you take our gasoline and diesel
engines together, Opel builds more engines with four-valves technology than any other
manufacturer in Europe.

Question: More and more power – is that appropriate to the times we live in?

Zickwolff: It certainly is! If you increase the power output from the same size of engine,
you make it run more efficiently. This is weight-saving design in its most practical form.
Take the turbocharged engine in the Astra Coupé as an example. It develops 190
horsepower from a displacement of two liters and only consumes 8.9 liters of fuel per
100 kilometers. Or look at the Astra Eco 4: it is a roomy, fully fledged family car and a
brisk performer, but its direct-injection diesel engine is content with only 4.4 liters of fuel
per 100 kilometers. That’s a truly fascinating development.

Question: What will come next? Will you be able to reduce fuel consumption any
further without taking all the fun out of driving?

Zickwolff: I think we will. The combination of transmission and engine will be an

important area for us to look at. We have already made significant progress by
introducing the “Easytronic” – our automatically shifted manual transmission – on the
Corsa 1.2 16V. This innovative, automated manual gearbox weighs scarcely more than
a conventional manual-shift unit, but it can do a whole lot more. It means a definite gain
in driver convenience and, because it makes full use of the engine’s ideal operating
points, it cuts fuel consumption. We will definitely be introducing more models with
Easytronic before long, and we are also working on six-speed gearboxes.
 - 12 -

Question: What about gasoline direct injection?

Zickwolff: There’s plenty of potential in this area too. As you can imagine, we’re pre-
pared for this new technology. Our new aluminum engine, for example, was designed
from the start for conversion to direct injection. The first move, however, must be for
reliable supplies of fuel with an extremely low sulfur content to become available all
over Europe. We have to offer customers a genuine advantage. As far as our cars’ fuel
consumption is concerned, we are right up there among the leaders and we still have
any number of ideas that should help us to stay there and even improve our position –
even without gasoline direct injection.

Question: What part will the new joint venture with Fiat play in all this?

Zickwolff: I’m looking forward to cooperating with Fiat. Pooling their know-how and
Opel’s will open up all kinds of new opportunities. Our corporate policy is to supply
high-quality technologies at affordable prices. Cooperating with Fiat will broaden both
companies’ technical foundation and enable them to achieve economies of scale. The
customer cannot fail to benefit in the long run.

Question: Everything you have mentioned affects production, too. What developments
can we expect in that area?

Zickwolff: We’re working on the transition to fully-automatic machining and assembly

processes. More intensive cooperation with our suppliers is another way of lowering
production costs and at the same time raising quality standards further still. In future
our suppliers will deliver more and more pre-assembled and quality-tested modules to
our assembly lines.