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 3/DOHC cc 998 :1 10,5 Yes RON 95 Make Bosch Type Motronic ME7.6.1/2 Description Map-DI Cam / Crankshaft Make Bosch Type Motronic ME7.6.1 Description MFI-s Type Mass Yes Yes

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

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 75030 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 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 Make NGK Type ZFR5F mm 0,8

Fuel system
System pressure bar 3,8

Manufacturer: Vauxhall/Opel Engine code: Z10XEP Tuned for: R-Cat

Model: Corsa-C 1,0 Output: 44 (60) 5600 Year: 2003-07

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

Service checks and adjustments

Valve clearance -INLET Valve clearance -EXHAUST Compression pressure Oil pressure Thermostat opens Drive belt size - alternator Drive belt size - AC mm Hydraulic mm Hydraulic bar 14-16 bar/rpm 1,5/750 C 92 mm 1230 mm 1355

Lubricants and capacities

Engine oil options Ambient temperature range Engine oil grade 329 Engine oil classification Ambient temperature range Engine oil grade 330 Engine oil classification Ambient temperature range Engine oil grade 329 Engine oil classification Ambient temperature range Engine oil grade 330 Engine oil classification Ambient temperature range Engine oil grade 329 Engine oil classification Engine with filter(s) Other lubricants and capacities 148 Manual transmission oil grade Manual transmission Cooling system - total capacity Brake fluid Brake fluid SAE litres 1,6 litres 4,9 Type DOT 4 litres 0,5 SAE -30C > 40C SAE 0W/30, 0W/40 Synthetic API/ACEA SJ/A3 -30C > 40C SAE 0W/30, 0W/40 OEM GM-LL-A-025 -20C > 40C SAE 5W/30, 5W/40 Synthetic API/ACEA SJ/A3 -25C > 40C SAE 5W/30, 5W/40 OEM GM-LL-A-025 -20C > 40C 10W/30, 10W/40 Semisynthetic

API/ACEA SJ/A3 litres 3,0

Tightening torques
Cylinder head instructions Cylinder head Renew bolts Yes Stage 1 Stage 2 Stage 3 Stage 4 Other engine tightening torques Main bearings Main bearings Main bearings Renew bolts/nuts Yes Stage 1 10 Nm Stage 2 45+15 Tighten 25 Nm Tighten 60 Tighten 60 Tighten 60

Manufacturer: Vauxhall/Opel Engine code: Z10XEP Tuned for: R-Cat

Model: Corsa-C 1,0 Output: 44 (60) 5600 Year: 2003-07

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

Big end bearings 222 133 3 70 3 109 Big end bearings Oil pump to cylinder block Sump bolts Sump drain bolt Flywheel/driveplate Clutch pressure plate Crankshaft pulley/damper centre bolt Camshaft sprocket/gear Camshaft carrier/cap Camshaft/rocker cover Inlet manifold to cylinder head 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 111 273 3 3 3 185 377 Front hub Rear hub Steering wheel Steering rack/box mounting Steering track rod end Brake disc to hub Brake caliper to carrier Brake caliper carrier to hub ABS sensor Road wheels

Renew bolts/nuts Yes Stage 1 8 Nm 10 Nm 35 Nm+30 150 Nm+45 8 Nm 8 Nm 10 Nm 20 Nm 25 Nm 8 Nm 25 Nm 6 Nm 8 Nm 6 Nm 18 Nm 40 Nm 20 Nm 20 Nm 10 Nm

30 Nm 45 Nm+45+15 35 Nm Front 7 Nm Front 27 Nm Front 100 Nm Front 8 Nm 110 Nm

Starting and charging

Battery V/RC(Ah) 12

Brake disc and drum dimensions

Minimum disc thickness - solid Minimum disc thickness - ventilated Disc thickness variation Disc runout Maximum drum diameter 132 Minimum pad thickness Front 8 mm Front 17 mm Front 0,010 mm Front 0,03 mm Rear 201 mm Front 7 mm

Manufacturer: Vauxhall/Opel Engine code: Z10XEP Tuned for: R-Cat

Model: Corsa-C 1,0 Output: 44 (60) 5600 Year: 2003-07

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

Minimum shoe thickness Parking brake travel

Rear 2,5 mm No. of notches 7

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 2 Expansion valve Type R134a grams 650 Type 90 510 419 cm 150

Autodata Note 329 Engine oil grade ECO Service MY 2005 Autodata Note 330 Engine oil grade ECO Service Flex ECO Service MY 2006 Autodata Note 148 Gearbox oil grade Opel No. 93 165 290. 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.

Manufacturer: Vauxhall/Opel Engine code: Z10XEP Tuned for: R-Cat

Model: Corsa-C 1,0 Output: 44 (60) 5600 Year: 2003-07

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

Autodata Note 3 Use new nuts/bolts.

Autodata Note 70 Clutch pressure plate M7 bolts = 15 Nm M8 bolts = 28 Nm. Autodata Note 109 Camshaft sprocket Use new bolts and tighten in the following stages: 1) 50 Nm 2) 60. Autodata Note 111 Front hub Use new nut. Tighten as follows: 1) 120 Nm 2) Slacken off 3) 20 Nm + 90 4) If necessary, slacken nut to align split pin. Autodata Note 273 Rear hub Rear drum to hub = 175 Nm Rear stub axle to axle body = 50 Nm + 30 + 15 With rear brake disc = 60 Nm + 30 + 15 Use new nuts/bolts. Autodata Note 185 Brake caliper carrier to hub - front/rear Clean thread and use bolts with locking fluid. Autodata Note 377 Road wheels Lightly coat conical seat of bolt and mating surfaces between wheel centre hole and hub (use grease). Do NOT lubricate bolt thread. Autodata Note 132
Manufacturer: Vauxhall/Opel Engine code: Z10XEP Tuned for: R-Cat Model: Corsa-C 1,0 Output: 44 (60) 5600 Year: 2003-07 Autodata Limited 2010 Valid forever. 26-May-13 V8.500-

Minimum pad/shoe thickness Measurement includes lining and pad/shoe backing plate.

Cylinder layout

Tightening sequence

Manufacturer: Vauxhall/Opel Engine code: Z10XEP Tuned for: R-Cat

Model: Corsa-C 1,0 Output: 44 (60) 5600 Year: 2003-07

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