engine OPEL CORSA 2009 Repair Manual

208 Self-help, vehicle careElectrical system Fuses
Data on the replacement fuse must match
the data on the defective fuse.
There are three fuse boxes in the vehicle:
zfront left, in the engine compartment,
z in the interior behind the light switch, or,
in right-hand drive cars, behind the
glove compartment,
z on the left of the luggage compartment,
behind a cover.
Before replacing a fuse, turn off the
respective switch and the ignition.
A blown fuse can be recognised by its
melted wire. Do not replace the fuse until
the cause of the fault has been remedied.
Only fit fuses of the specified current
rating. Each fuse has its current rating
written on it, the ratings are also colour
coded.
Picture no: 17259t.tif
Some functions are protected by several
fuses.
There may be fuses inserted with no
function.
Picture no: 17260t.tif
Different versions of fuses are used.
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209
Self-help, vehicle care
Picture no: 18588s.tif
Fuses and the most important
circuits they protectFuse box in engine compartment
The fuse box is at the front left side of the
engine compartment.
To open, disengage the cover, fold cover
up and remove.
Picture no: 18589s.tif Picture no:
No. Circuit
1 Starter
2 Air conditioning system
3 Diesel fuel filter heater
4 Horn
5 Manual transmission automated,
automatic transmission
6 Engine control unit
7 Fog lamps
8 Engine cooling
9 Engine cooling
No. Circuit
10 Automated manual transmission
11 Glow plugs, ignition system
12 Headlamp range adjustment,
Adaptive Forward Lighting
13 Air conditioning system
14 Automated manual transmission
15 Main beam (right)
16 Main beam (left)
17 Main relay
18 Engine control unit
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230 Self-help, vehicle careWindows
Use a soft lint-free cloth or chamois leather
together with window cleaner and insect
remover.
When cleaning the rear window, make sure
the heating element inside the window is
not damaged.
For mechanical removal of ice, use a sharp-
edged ice scraper. Press the scraper firmly
against the glass so that no dirt can get
under it and scratch the glass.
Clean smearing wiper blades with a soft
cloth and window cleaner.
Sun roof 3
Never clean with solvents or abrasives,
fuels, aggressive agents (e.g. paintwork
cleaner, solutions containing acetone,
etc.), acidic or strongly alkaline agents or
scourers.
No stickers may be applied to the sun roof. Locks
The locks are lubricated with a high-quality
locking cylinder grease
in the factory. Only
use de-icer in urgent cases, since it has a
de-greasing effect and affects the
operation of the locks. Have the locks re-
greased in a workshop after using de-icer.
Engine compartment
Clean painted surfaces in the engine
compartment like any other painted
surface.
It is advisable to wash the engine
compartment before and after winter and
preserve it with wax. Cover 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 at
components of the anti-lock brake system,
the air conditioning system, the climate
control system, belt drive or the fuse box.
After an engine wash, have all engine room
components preserved thoroughly by a
workshop using protective wax.
Do not use high-pressure jet cleaners. 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 more protective wax
applied 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.
Towing equipment
Do not clean the coupling ball bar with a
steam-jet or high-pressure jet cleaner.
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231
Opel Service, maintenance
Opel Service,
maintenance
Scheduled maintenanceThese service intervals apply only under
normal driving conditions. If conditions are
more arduous3238.
Service interval display 3240.
European service intervals
Every 30000 km or annually, whichever
occurs first.
International service intervals
Every 15000 km or annually, whichever
occurs first.
Validation
Service is validated using the spaces
provided in the Service and Warranty
Booklet. The date of service and kilometre
reading are added, stamped and signed
by the service workshop.
Ensure that the Service and Warranty
Booklet is filled in correctly - an
uninterrupted service history is important
when making guarantee or goodwill
claims, and is also an advantage when
selling the vehicle on.
Service scheduleThe service schedule applies in the
following countries: Andorra, Austria,
Belgium, Cyprus, Czech Republic,
Denmark, Estonia, Finland, France,
Germany, Great Br itain, Greece,
Greenland, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta,
Netherlands, Norway, Poland, Portugal,
Slovakia, Slovenia , Spain, Sweden,
Switzerland.
The international serv ice schedule applies
in all other countries.
Scheduled maintenance ..................... 231
Service schedule .................................. 231
Additional service work ....................... 238
Recommended fluids and lubricants . 238
Inspection system ................................ 240
Genuine Opel Parts and Accessories . 241
Performing work .................................. 241
Engine oil .............................................. 242
Diesel fuel filter .................................... 244
Coolant ................................................. 244
Brakes ................................................... 245
Brake fluid ............................................ 246
Windscreen wiper replacement .......... 247
Windscreen washer system ................. 248
Battery .................................................. 248
Protecting electronic
components ..... 249
Laying the vehicle up for a long period of time .................................... 249
Putting the vehicle back into service . 249
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233
Opel Service, maintenance
⊕ Additional work.
o The intervals are shorter where driving conditions are more arduous or country-specific.
Service work
after year
1)
km (x1000)
1)
1)Depending on what occurs first.
1
30 2
60 3
90 4
120 5
150
⊕
Replace timing belt and tension pulley
Z 16 LEL, Z 16 LER, Z 17 DTR every 10 years/150000 km
Change engine oil and replace filter xxxxx
⊕o
Drain water from fuel filter, diesel (if the air humidity is high or the fuel of lower quality)xxxxx
Replace fuel filter and drain water, diesel (grade EN590)
Z 13 DTJ, Z 17 DTH xx
Replace fuel filter, petrol (g rade EN228), outer Z 16 LEL, Z 16 LER every 4 years/60000 km
Check handbrake, adjust if necessary (unl aden wheels); carry out a visual check of
wheel suspension and suspension front and re ar, brake lines, brake pressure hose, fuel
lines and exhaust system xx
Check external bodywork / underseal, note any damage in the Service and Warranty
Booklet. xxxxx
⊕o
Carry out a visual check on the front and rear wheel brakes
2)
2)If the loss is too great or there are leaks, carry
out remedial work in agreement with the customer.
xx
Annual service check if the annual distance travelled is greater than 20000 km.
Carry out a visual check of the engine, tran smission (AT, MT), check air conditioning
compressor for leaks
2)
xxxxx
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234 Opel Service, maintenance⊕Additional work.
o The intervals are shorter where driving conditions are more arduous or country-specific.
Service work
after year
1)
km (x1000)
1)
1)Depending on what occurs first.
1
30 2
60 3
90 4
120 5
150
⊕o
Remove brake drum, clean, carry out visual check every 4 years/60 000 km
Visually inspect steering system boots, track rods, final drive xxxxx
Check track rod end and supporting ball joint xxxxx
⊕
Change brake and clutch fluids (manual transmission automated) every 2 years
Loosen wheel mounting and tighten to 110 Nm
xx
Grease or apply oil to
bolt taper when fitting.
Check tyre condition and pressure (inclu ding spare wheel), correct if necessary.
If there is a tyre inflation system, check that the set is complete and the use-by date is
still valid. Replace sealant bottle every four years.
⊕
Annual service check if the annual distance travelled is greater than 20000 km.
Visually check the first aid kit (that it is wher e it should be, that it is undamaged and that
the use by date is still valid), lashing eyes and warning triangle every 2 years
Check headlamp settings (including auxi liary headlamps), adjust if necessary x x
⊕o
Lubricate door hinges, check arms, cylinder lo ck, door latch, bonnet catch, rear panel
hinge xx
OPC: check function of central locking system
clean door lock from outside and grease xxxxx
Test run, final check (check steering and ig nition lock, instrument and warning lamps,
entire brake system, steering, air conditioni ng system, engine, bodywork and chassis,
reset service/interval display with TECH 2. xxxxx
⊕
Germany only: carry out emissions check, main inspection
First time after three years, then every 2 years
If used commercially to transport passengers, taxis, ambulances, hire cars etc. annually
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236 Opel Service, maintenance⊕Additional work.
o The intervals are shorter where driving conditions are more arduous or country-specific.
Service work
after year
1)
km (x1000)
1)
1)Depending on what occurs first.
1
15 2
30 3
45 4
60 5
75
⊕
Replace timing belt and tension pulley
Z 16 LEL, Z 16 LER, Z 17 DTR every 10 years/150000 km
Change engine oil and replace filter xxxxx
⊕o
Drain water from fuel filter, diesel (if the air humidity is high or the fuel of lower quality)xxxxx
Replace fuel filter and drain water, diesel (grade EN590)
Z 13 DTJ, Z 17 DTH xx
Replace fuel filter, petrol (g rade EN228), outer Z 16 LEL, Z 16 LER every 4 years/60000 km
Check handbrake, adjust if necessary (unl aden wheels); carry out a visual check of
wheel suspension and suspension front and re ar, brake lines, brake pressure hose, fuel
lines and exhaust system xx
Check external bodywork / underseal, note any damage in the Service and Warranty
Booklet. xxxxx
⊕o
Carry out a visual check on the front and rear wheel brakes
2)
2)If the loss is too great or there are leaks, carry
out remedial work in agreement with the customer.
xx
Annual service check if the annual distance travelled is greater than 20000 km.
Carry out a visual check of the engine, tran smission (AT, MT), check air conditioning
compressor for leaks
2)
xxxxx
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237
Opel Service, maintenance
⊕ Additional work.
o The intervals are shorter where driving conditions are more arduous or country-specific.
Service work
after year
1)
km (x1000)
1)
1)Depending on what occurs first.
1
15 2
30 3
45 4
60 5
75
⊕o
Remove brake drum, clean, carry out visual check every 4 years/60000 km
Visually inspect steering system boots, track rods, final drive xxxxx
Check track rod end and supporting ball joint xxxxx
⊕
Change brake and clutch fluids (manual transmission automated) every 2 years
Loosen wheel mountings and tighten to 110 Nm
xx
Grease or apply oil to
bolt taper when fitting.
Check tyre condition and pressure (inclu ding spare wheel), correct if necessary.
If there is a tyre inflation system, check that the set is complete and the use-by date is
still valid. Replace sealant bottle every four years.
⊕
Annual service check if the annual distance travelled is greater than 20000 km.
Visually check the first aid kit (that it is wher e it should be, that it is undamaged and that
the use by date is still valid), lashing eyes and warning triangle every 2 years
Check headlamp settings (including auxi liary headlamps), adjust if necessary x x
⊕o
Lubricate door hinges, check arms, cylinder lo ck, door latch, bonnet catch, rear panel
hinge xx
OPC: check function of central locking system
clean door lock from outside and grease xxxxx
Test run, final check (check steering and ig nition lock, instrument and warning lamps,
entire brake system, steering, air conditioni ng system, engine, bodywork and chassis,
reset service/interval display with TECH 2. xxxxx
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238 Opel Service, maintenanceAdditional service workAdditional work ⊕
Additional work is not always necessary at
each service, but can be carried out at the
same time as a regular service.
T h e c o s t o f th i s t y p e o f w o r k i s n o t i n c l ud e d
in the charge for a regular service and will
be invoiced separately. It is, however, more
c o s t - e f f e c t i v e t o h a v e t h i s w o r k d o n e a t t h e
same time as a scheduled service rather
than have it done separately.
Hard driving conditions o
Conditions are considered hard when one
or more of the following situations occurs
more frequently:
z cold start,
z stop and go,
z caravan/trailer towing,
z inclines or steep climbs,
z poor road conditions,
z sand and dust,
z extreme temperature fluctuations.
Police vehicles, taxis and driving school
vehicles are classified as being subjected to
hard driving conditions. With hard driving conditions it might be
necessary to carry out certain service work
more frequently than the scheduled
intervals.
We recommend seeking technical advice
with regard to servic
ing requirements for
your particular driving circumstances.
Recommended fluids and
lubricants Only use products which have been tested
and approved. Damage caused by using
operating materials which have not been
approved is not covere d by the guarantee.
Engine oil
Engine oil is graded by quality and
viscosity. When choosing an engine oil, the
quality grade is more important than the
viscosity. Engine oil for Service schedule Europe
Opel engine oil is GM-LL-A-025
and GM-LL-B-025 grade and therefore
suitable for both petrol and diesel engines.
Engine oil for International service
9
Warning
Operating materials are dangerous and
must be handled carefully. If swallowed,
seek medical help immediately. Do not
breath in fumes and avoid contact with
the skin. Keep away from children.
These materials are forbidden to con-
taminate waste water, surface water,
groundwater or soil. Dispose of empty
containers correctly. Always remember
that operating materials are dangerous.
GM-LL-A-025: Petrol engines
GM-LL-B-025: Diesel engines
GM General Motors Europe
LL Long life A or B Details of engine oil grade
025 Validity code
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239
Opel Service, maintenance
scheduleEngine oil: top up
Oils from different manufacturers and
different brands of oil can be mixed as long
as the grades (quality and viscosity) are
the same.
Not all the engine oils available on the
market are of a suitable quality. Always
check that the required specification and
classification are given on the cans.
If engine oil of a suitable quality cannot be
obtained, use no more than 1 litre of
category ACEA A3/B4 or A3/B3 (once
between two oil changes). The viscosity
must be suitable for requirements.
It is forbidden to use engine oil of
grades ACEA A1/B1 and A5/B5. Under
certain circumstances, these oils can
cause long-term damage to the engine. Engine oil additives
The use of motor oil additives can lead to
damage and will invalidate the guarantee.
Engine oil viscosity
Only use engine oils with viscosity
grades 0W-30, 0W-40, 5W-30 or 5W-40.
The SAE viscosity grading system indicates
the oil’s flowability. Oil is more viscous
when cold than when warm.
Multigrade oil has two numbers. The first,
followed by a W, indicates the viscosity at
low temperatures and the second indicates
the viscosity at high temperatures.
ACEA-A3: Petrol engines
ACEA-B4: Diesel engines without
diesel particulate filter
ACEA-C3 Diesel engines with diesel particulate filter
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