ignition OPEL COMBO 2010 Workshop Manual

151
Self-help, vehicle care
Bulb replacement Switch off the ignition and switch off the
relevant switch or close the doors.
Only hold a new bulb at the base! Do not
touch the bulb glass with your bare hands.
The replacement bulb must be in
accordance with the data on the base of
the defective bulb. Do not exceed wattage
given on bulb base.
To change the bulbs on the left side, open
the fuse box cover. With the Z 13 DTJ
engine
1), also pull the relay box in front of
the fuse box upwards out of the guides.
Pull off the air hose on the air filter on the
right.
Picture no: 16074s.tif
Halogen headlamp system,
dipped and main beam The headlamp system has separate
systems for dipped beam 1 (outer bulbs)
and main beam 2 (inner bulbs).
Dipped beam
1. Open bonnet and engage support.
Picture no: 16075s.tif
2. Rotate the cap anticlockwise and
remove.
6
1)Sales designation
3184.

165 Opel Service, maintenance
European service plan⊕Additional work.
o Intervals are shorter under extreme operating conditions and when such is necessary due to conditions specific to the country.
Service work after year
1)
km (x 1000)
1)
1)Whichever occurs first.
1
302
603
904
1205
150
Visually inspect control, lighting and signal devices as well as airbags;
check steering column lock and ignition switchxxxxx
Remote control: replace batteries (don’t forget the spare key) every 2 years
Check and correct windscreen wipers, windscreen washer system and headlamp
washer systemxxxxx
Check and correct coolant level and frost protection (pale orange)
2)
Note freeze protection temperature in the Service and Warranty Booklet
(confirmation box)
2)If loss is great/leaks are present, carry out follow-up work with customer consent.
xxxxx
Check water hoses for leaks and check to make sure they are firmly seated x x x x x
Check and correct brake fluid level
2) xxx
Check battery clamps to make sure they are firmly seated and check the battery eye x x x x x
Vehicle System Check with TECH 2 x x x x x
Replace pollen filter or active charcoal filter x x
⊕o
if the air is heavily polluted or there are high levels of airborne dust, sand or pollen,
the air-conditioning system will produce an odourVerbal arrangement between the
customer and Opel Partner
Replace the air filter element every 4 years/60,000 km
⊕
Replace spark plugsevery 4 years/60,000 km
Z 16 YNGevery 2 years/30,000 km
Visually inspect the ribbed V-belt every 2 years/60,000 km
⊕
Replace ribbed V-belt
Y 13 DTJ, Z 13 DTJ, Y 13 DT, Z 13 DT, Z 17 DTH every 10 years/150,000 km
⊕
Check valve play and adjust
Z16 XEP, Z 17 DTHevery 10 years/150,000 km

167 Opel Service, maintenance
⊕Additional work.
o Intervals are shorter under extreme operating conditions and when such is necessary due to conditions specific to the country.
Service work after year
1)
km (x 1000)
1)
1)Whichever occurs first.
1
302
603
904
1205
150
Visually inspect steering bellows, track rods and axle drive xxxxx
Check track-rod ends and suspension ball joints xxxxx
⊕
Change brake and clutch fluid (manual transmission automated) every 2 years
Undo wheel mounting and tighten to 110 Nm torque
xx During assembly, lightly lubricate wheel bolt tapers with grease or oil
Check tyre condition; check and correct tyre pressures (including the spare wheel)
With tyre inflation system, check the set to make sure that it is complete and not out
of date. Replace sealant bottle every 4 years
⊕
Annual service check when the annual mileage is more than 20,000 km
Visually inspect the first-aid kit (present and stowed in the right place, intact and not
out of date), lashing eyes and warning triangleevery 2 years
Check and correct headlamp aiming (including auxiliary headlamps) x x
⊕o
Lubricate door hinges, door brakes, lock cylinders, strikers, bonnet closure and
tailgate hinges.xx
Road test, final inspection (check steering column lock, ignition switch, instruments
and control indicators, entire brake system, steering, air conditioning system, engine,
body and chassis), reset service interval display using TECH 2xxxxx
⊕
For Germany only: carry out emissions inspection (AU), general inspection (HU) First after 3 years and then every
2 years thereafter
With commercial passenger transport, taxis, ambulances, hired vehicles, etc. annually
⊕
Carry out gas system test (GAP) and note it in the Service and Warranty Booklet First after 3 years and then every
2 years thereafter
With commercial passenger transport, taxis, ambulances, hired vehicles, etc. annually

168 Opel Service, maintenanceInternational service plan⊕Additional work.
o Intervals are shorter under extreme operating conditions and when such is necessary due to conditions specific to the country.
Service work after year
1)
km (x 1000)
1)
1)Whichever occurs first.
1
152
303
454
605
75
Visually inspect control, lighting and signal devices as well as airbags;
check steering column lock and ignition switchxxxxx
Remote control: replace batteries (don’t forget the spare key) every 2 years
Check and correct windscreen wipers, windscreen washer system and headlamp
washer systemxxxxx
Check and correct coolant level and frost protection (pale orange)
2)
Note freeze protection temperature in the Service and Warranty Booklet
(confirmation box)
2)If loss is great/leaks are present, carry out follow-up work with customer consent.
xxxxx
Check water hoses for leaks and check to make sure they are firmly seated x x x x x
Check and correct brake fluid level
2) xxx
Check battery clamps to make sure they are firmly seated and check the battery eye x x x x x
Vehicle System Check with TECH 2 x x x x x
Replace pollen filter or active charcoal filter x x
⊕o
if the air is heavily polluted or there are high levels of airborne dust, sand or pollen,
the air-conditioning system will produce an odourVerbal arrangement between the
customer and Opel Partner
Replace the air filter element every 4 years/60,000 km
⊕
Replace spark plugsevery 4 years/60,000 km
Z 16 YNGevery 2 years/30,000 km
Visually inspect the ribbed V-belt every 2 years/60,000 km
⊕
Replace ribbed V-belt
Y 13 DTJ, Z 13 DTJ, Y 13 DT, Z 13 DT, Z 17 DTH every 10 years/150,000 km
⊕
Check valve play and adjust
Z16 XEP, Z 17 DTHevery 10 years/150,000 km

170 Opel Service, maintenance⊕Additional work.
o Intervals are shorter under extreme operating conditions and when such is necessary due to conditions specific to the country.
Service work after year
1)
km (x 1000)
1)
1)Whichever occurs first.
1
152
303
454
605
75
Visually inspect steering bellows, track rods and axle drive x x x x x
Check track-rod ends and suspension ball joints x x x x x
⊕
Change brake and clutch fluid (manual transmission automated) every 2 years
Undo wheel mounting and tighten to 110 Nm torque
xx During assembly, lightly lubricate wheel bolt tapers with grease or oil
Check tyre condition; check and correct tyre pressures (including the spare wheel)
With tyre inflation system, check the set to make sure that it is complete and not
out of date. Replace sealant bottle every 4 years
⊕
Annual service check when the annual mileage is more than 20,000 km
Visually inspect the first-aid kit (present and stowed in the right place, intact and
not out of date), lashing eyes and warning triangleevery 2 years
Check and correct headlamp aiming (including auxiliary headlamps) x x
⊕o
Lubricate door hinges, door brakes, lock cylinders, strikers, bonnet closure and
tailgate hinges.xx
Road test, final inspection (check steering column lock, ignition switch, instruments
and control indicators, entire brake system, steering, air conditioning system, engine,
body and chassis), reset service interval display using TECH 2xxxxx
⊕
Carry out gas system test (GAP) and note it in the Service and Warranty Booklet First after 3 years and then every
2 years thereafter
With commercial passenger transport, taxis, ambulances, hired vehicles, etc. annually

173
Opel Service, maintenance
Picture no: 14419s.tif
Inspection systemIn order to ensure economical and safe
vehicle operation and to maintain the
value of your vehicle, it is of vital
importance that all maintenance work is
carried out at the proper intervals as
specified.
Fixed service interval
When service is due, InSP appears in
the odometer display for approximately
10 seconds when the ignition is switched
on. Have the next service performed by a
workshop within one week or 500 km
(whichever occurs first). The service interval display takes account
of off-the-road periods during which the
battery is disconnected.
Flexible service interval 3
The length of the service intervals is based
on several parameters stemming from
usage. For this reason, various
engine-specific data is continually
gathered and is used to calculate the
remaining distance until the next service.
If the remaining distance is less than
1500 km, InSP is displayed with a
remaining distance of 1000 km when the
ignition is switched on and off. If less than
1000 km remains, InSP is displayed for
several seconds. Have the next service
performed by a workshop within one week
or 500 km (whichever occurs first).
Display of remaining distance:
1. Switch off ignition.
2. Briefly press the trip odometer reset
button. The odometer reading is shown.
3. Press and hold the reset button for about
2 seconds. InSP and the remaining
distance are displayed. Further information on maintenance and
the inspection system can be found in the
Service and Warranty Booklet, which is
located in the glove compartment.
Have maintenance work – and repair work
on the body and the equipment – carried
out professionally by a workshop. We
recommend using your Opel Partner, who
has excellent knowledge of Opel vehicles
and has the necessary special tools and
up-to-date service instructions from Opel.
It is particularly advisable to use an Opel
Partner during the warranty period in order
to prevent invalidation of the warranty.
Further information can be found in the
Service and Warranty Booklet.
Separate anti-corrosion service
Carry out according to the intervals
specified in the Service and Warranty
Booklet.

174 Opel Service, maintenanceGenuine Opel Parts and
Accessories We recommend that you use "Genuine
Opel Parts and Accessories" and
conversion parts approved expressly for
your vehicle type. These parts have
undergone special tests to establish their
reliability, safety and specific suitability for
Opel vehicles. Despite continuous market
monitoring, we cannot assess or guarantee
these attributes for other products, even if
they have been granted approval by the
relevant authorities or in some other form.
"Genuine Opel Parts and Accessories" and
conversion parts approved by Opel can be
obtained from your Opel Partner, who can
provide comprehensive advice on
permitted technical changes and ensure
correct installation.
Picture no: 17922s.tif
Performing work To avoid injury from moving parts and
cables conducting ignition voltage, only
carry out engine compartment checks
(e. g. checking brake fluid or engine oil
level) when the ignition is switched off.
Picture no: 11671s.tif
To aid identification, the caps used when
topping up engine oil, coolant and washer
fluid as well as the oil dipstick are coloured
yellow.
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 Warning
The ignition system 3 and Xenon
headlamps 3 use extremely high
voltage. Do not touch.

180 Opel Service, maintenance
Picture no: 11678s.tif
Windscreen washer system Reservoir for windscreen washer and rear
windscreen washer at driver’s side in
engine compartment.
Fill with clean water mixed with cleaner
and anti-freeze.
Make sure there is sufficient anti-freeze
protection.
When closing the reservoir, press the lid
firmly over the beaded edge all the way
round.
Picture no: 13488a.tif
Battery The vehicle battery is maintenance-free.
Batteries do not belong in household
waste. They must be disposed of at an
appropriate recycling collection point.
The retrofitting of electrical or electronic
accessories may subject the battery to
additional loading and cause it to become
discharged. Please seek advice concerning
the technical options, such as installing a
more powerful battery. Laying up the vehicle for more than
4 weeks can lead to battery discharge.
Disconnect the negative terminal of the
vehicle battery.
Ensure the ignition is switched off before
connecting or disconnecting the vehicle
battery.
Protecting electronic components In order to prevent faults in electronic
components in the electrical system, never
connect or disconnect battery with engine
running or ignition switched on. Never start
engine with battery disconnected, e.g.
when starting using jump leads.
To avoid damaging the vehicle, do not
make any modifications to the electrical
system, e. g. connecting additional
consumers or tampering with electronic
control units (chip tuning).
9 Warning
Electronic ignition systems generate very
high voltages. Do not touch the ignition
system; high voltage can be fatal.

181
Opel Service, maintenance
Laying the vehicle up for a long
period of time If the vehicle is to be laid up for several
months, the following work should be
undertaken to prevent damage.
zWash and wax the vehicle 3161.
zHave the wax in the engine
compartment and underbody checked.
zClean and preserve rubber seals.
zChange engine oil.
zCheck anti-freeze and corrosion
protection 3177.
zCheck the coolant level; top up
anti-freeze if necessary 3178.
zDrain the windscreen washer system.
zIncrease tyre pressure to the value
specified for full load 3121, 3191. zPark the vehicle in dry and
well-ventilated place. With manual
transmission select first or reverse gear;
with manual transmission automated 3
move the selector lever to the centre
position before switching the ignition off.
Use chocks or the like to prevent the
vehicle from rolling.
zDo not apply hand brake.
zDisconnect the clamp from the negative
terminal of the vehicle battery.
Putting the vehicle back into
servicePerform the following work before
recommissioning the vehicle:
zConnect the clamp to the negative
terminal of the vehicle battery.
zCheck tyre pressure 3121, 3191.
zTop up the windscreen washer system
3180.
zCheck engine oil level 3175.
zCheck coolant level 3178.
zFit the number plate if necessary.

184 Technical dataEngine data Sales designation
Engine identifier code1.4 TWINPORT
Z 14 XEPCNG
Z 16 YNG1.3 CDTI
Z 13 DTJ1.7 CDTI
Z 17 DTH
Number of cylinders 4 4 4 4
Piston displacement [cm
3 ] 1364 1598 1248 1686
Brake horse power [kW/bhp]
at rpm 66
560069
620055
400074
4400
Torque [Nm]
at rpm 125
4000133
4200170
1750 to 2500240
2300
Fuel type
1)
1)Standard high-quality fuels, unleaded DIN EN 228, diesel DIN EN 590. Any commercially available natural gas containing methane can be used for
natural gas operation.
Petrol Natural gas/petrol Diesel Diesel
Octane requirement [RON]
2)
recommended
possible
possible
Cetane requirement [CN]
2)
2)Standard high-quality fuels: R = Regular, P = Premium, PP = Premium Plus, D = Diesel. Value printed in bold: recommended fuel.
95 (P)
3)
98 (PP)
3)
91 (R)
3)4)
–
3)Knock control system automatically adjusts ignition timing according to type of fuel used (octane number). 4)Slight reduction in engine output and torque if 91 RON is used.
95 (P)
3)
98 (PP)
3)
–
––
–
–
49 (D)
5)
5)A lower value is possible with winter diesel fuels.
–
–
–
49 (D)
5)
Max. permissible engine speed,
continuous operation approx. [rpm ]. 6200 6400 5020 to 5180 5000 to 5200
Oil consumption [l/1000 km] 0.6 0.6 0.6 0.6