2009 OPEL ZAFIRA check engine

Vehicle care
155
■ Check the engine oil level.
■ Check the coolant level.
■ Fit the number plate if necessary.
End-of-life vehicle
recovery
Information on end-of-life vehicle
recovery centres and the recycling of
end-of-life vehicles is available on our
website www.opel.com. Only entrust
this work to an authorised recycling
centre. Vehicle checks
Performing work
9
Warning Only perform engine compartment
checks when the ignition is off.
The cooling fan may start
operating

even if the ignition is off. 9
Danger The ignition system and Xenon
headlamps use extremely high
voltage. Do not touch.
The caps for topping up the engine oil,
the

coolant, the washing fluid and the
oil dipstick handle are yellow for ease
of identification.
Bonnet
Opening

156
Vehicle care
Pull the release lever and return it to
its original position. Lift the safety catch upwards and
open the bonnet.
Air intake 3 125. Secure the bonnet support.
Closing
Before closing the bonnet, press the
support into the holder.
Lower
the bonnet and allow it to drop
into the catch. Check that the bonnet
is engaged.
Engine oil
Engine oil level is checked
automatically 3 91. It is advisable to
check the engine oil level manually
before embarking on a long journey. Check with the vehicle on a level
surface. The engine must be at
operating temperature and switched
off for at least 5 minutes.
Pull out the dipstick, wipe it clean,
insert

it to the stop on the handle, pull
out and read the engine oil level.
Insert dipstick to the stop on the
handle and make half a turn. Different dipsticks are used
depending on engine variant.

190
Vehicle care
Clean smearing wiper blades with
a soft cloth and window cleaner.
Moonroof
Never
clean with solvents or abrasive
agents, fuels, aggressive media (e.g.
paint cleaner, acetone-containing
solutions etc.), acidic or highly
alkaline media or abrasive pads. Do
not apply wax or polishing agents to
the middle part of the moonroof.
Wheels and tyres
Do not use high-pressure jet
cleaners.
Clean rims with a pH-neutral wheel
cleaner.
Rims are painted and can be treated
with the same agents as the body.
Paintwork damage
Rectify minor paintwork damage with
a touch-up pen before rust forms.
Have more extensive damage or rust
areas repaired by a workshop. Underbody
Some
areas of the vehicle underbody
have a PVC undercoating while other
critical areas have a durable
protective wax coating.
After the underbody is washed, check
the underbody and have it waxed if
necessary.
Bitumen/rubber materials could
damage the PVC coating. Have
underbody work carried out by
a workshop.
Before and after winter, wash the
underbody and have the protective
wax coating checked.
Engine compartment
Areas of the engine compartment that
are painted in the same colour as the
vehicle must be looked after like any
other painted surface.
It is advisable to wash the engine
compartment before and after winter
and preserve it with wax. Protect the
alternator and brake fluid reservoir
with plastic sheets before washing
the engine. When washing the engine with
a steam-jet cleaner, do not direct the
steam jet towards components of the
antilock brake system, air
conditioning system or the belt drive
and its components.
After
an engine wash, have all engine
room components preserved
thoroughly by a workshop using
protective wax.
Do not use high-pressure jet
cleaners.
Natural gas system
Do not direct the steam jet or high-
pressure jet towards natural gas
system components. It is particularly
important to protect the natural gas
tank and the pressure valves on the
vehicle underbody and the bulkhead
in the engine compartment.
These components must not be
treated using chemical cleaners or
preservatives.
Have components of the natural gas
system cleaned by a workshop
authorised to carry out maintenance
of natural gas vehicles.

196
Service and maintenanceService operations by year
1)
km ( x 1000) 1) 1
30 2
60 3
90 4
120 5
150
Visually inspect ribbed V-belt X X
Replace ribbed V-belt,
Z 19 DT, Y/Z 19 DTH, Z 19 DTL Every 10 years / 120.000 km
+ Check valve clearance, adjust
Z 16 XE1, Z 16 XER, Z 18 XER, A 17 DTJ, A 17 DTR Every 10 years / 150.000 km
Z 19 DT, Z 19 DTL X X
+ Replace toothed belt and tension roller,
Z 20 LER, Z 20 LEH Every 8 years / 120.000 km
Z 16 YNG Every 6 years / 90.000 km
Z 16 XE1, Z 16 XER, Z 18 XER, A 17 DTJ, A 17 DTR, Z 19 DT, Y/Z 19 DTH, Z 19 DTL Every 10 years / 150.000 km
Inspect power steering for leaks, check / correct fluid level
2) X X X X X
Check electro-hydraulic power steering (EHPS) oil level (cap with dipstick) X X X X X
Change engine oil and filter X X X X X
+o Drain water from fuel filter, diesel (with high humidity and / or lower grade fuel) X X X X X
Drain CNG oil-separator, Z 16 YNG Every 4 years / 60.000 km
2)
In case of too high consumption / leakage, perform additional work with customer's agreement.

Service and maintenance
197Service operations by year
1)
km ( x 1000) 1) 1
30 2
60 3
90 4
120 5
150
Replace and drain fuel filter, diesel (grade EN 590) X X
Replace fuel filter, external, CNG (grade EN 228), Z 16 YNG Every 4 years / 60.000 km
Check and adjust parking brake (no weight on wheels); visually inspect wheel mounting
and suspension springs front and rear, brake lines, brake pressure hoses, fuel lines,
gas lines of CNG vehicles, level control and exhaust system X X
Check exterior of body/underbody corrosion protection and note any damage in the
Service Booklet X X X X X
+o
Visually inspect front and rear wheel brakes
2)
, if a tyre pressure monitoring system is
fitted, do not swap wheels over X X
Annual service check if annual mileage exceeds 20 000 km
Engine, transmission (AT, MT), inspect air-conditioning compressor for leaks
2) X X X X X
Visually inspect folding covers on steering, tie rods and axle drive X X X X X
Tie rod and supporting joint checking X X X X X
+ Change brake and clutch fluid automated manual transmission (MTA) Every 2 years
2)
In case of too high consumption / leakage, perform additional work with customer's agreement.

198
Service and maintenanceService operations by year
1)
km ( x 1000) 1) 1
30 2
60 3
90 4
120 5
150
Undo wheel fastening (take care if tyre pressure monitoring system is present) and
tighten to torque: 110 Nm.
The wheel bolt taper should be greased or oiled lightly during assembly.
Check tyre condition. Check/correct tyre pressure (including spare wheel)
With tyre repair system - check completeness and expiry date of kit. Replace sealant
bottle every 4 years. X X
+
Annual service check if annual mileage exceeds 20 000 km
Visually inspect first-aid kit, (presence in designated stowage compartment,
completeness and expiry date), lashing eyes and warning triangle Every 2 years
Check/correct headlamp adjustment (including auxiliary headlamps) X X
Grease door hinges, door stop, lock cylinder, striker plate, bonnet lock, tailgate hinges,
wipe door stop check strap clean before greasing X X
Test drive, final inspection (check steering and ignition locks, instruments and indicator
lamps,
entire brake system, steering, air conditioning, engine, body and running gear),
reset service interval display with TECH 2) X X X X X
+: Additional operations.
o: Under extreme operating conditions and if required by country-specific conditions, the intervals are reduced.

Service and maintenance
201Service operations by year
3)
km ( x 1000) 1) 1
15 2
30 3
45 4
60 5
75
+ Replace toothed belt and tension roller,
Z 20 LER, Z 20 LEH Every 8 years / 120.000 km
Z 16 YNG Every 6 years / 90.000 km
Z 16 XE1, Z 16 XER, Z 18 XER, A 17 DTJ, A 17 DTR, Z 19 DT, Y/Z 19 DTH, Z 19 DTL Every 10 years / 150.000 km
Inspect power steering for leaks, check / correct fluid level
4) X X X X X
Check electro-hydraulic power steering (EHPS) oil level (cap with dipstick) X X X X X
Change engine oil and filter X X X X X
+o Drain water from fuel filter, diesel (with high humidity and / or lower grade fuel) X X X X X
Drain CNG oil-separator, Z 16 YNG Every 4 years / 60.000 km
Replace and drain fuel filter, diesel (grade EN 590) X X
Replace fuel filter, external, CNG (grade EN 228), Z 16 YNG Every 4 years / 60.000 km
Check and adjust parking brake (no weight on wheels); visually inspect wheel mounting
and suspension springs front and rear, brake lines, brake pressure hoses, fuel lines,
gas lines of CNG vehicles, level control and exhaust system X X
Check exterior of body/underbody corrosion protection and note any damage in the
Service Booklet X X X X X
4)
In case of too high consumption / leakage, perform additional work with customer's agreement.

202
Service and maintenanceService operations by year
3)
km ( x 1000) 1) 1
15 2
30 3
45 4
60 5
75
+o
Visually inspect front and rear wheel brakes
4)
, if a tyre pressure monitoring system is
fitted, do not swap wheels over X X
Annual service check if annual mileage exceeds 20 000 km
Engine, transmission (AT, MT), inspect air-conditioning compressor for leaks
4) X X X X X
Visually inspect folding covers on steering, tie rods and axle drive X X X X X
Tie rod and supporting joint checking X X X X X
+ Change brake and clutch fluid automated manual transmission (MTA) Every 2 years
Undo wheel fastening (take care if tyre pressure monitoring system is present) and
tighten to torque: 110 Nm.
The wheel bolt taper should be greased or oiled lightly during assembly.
Check tyre condition. Check/correct tyre pressure (including spare wheel)
With tyre repair system - check completeness and expiry date of kit. Replace sealant
bottle every 4 years. X X
+
Annual service check if annual mileage exceeds 20 000 km
Visually inspect first-aid kit, (presence in designated stowage compartment,
completeness and expiry date), lashing eyes and warning triangle Every 2 years
Check/correct headlamp adjustment (including auxiliary headlamps) X X
4)
In case of too high consumption / leakage, perform additional work with customer's agreement.