engine OPEL MERIVA 2009 Workshop Manual

184 Self-help, vehicle care
Picture no: 14436s.tif Picture no:
No. Circuit
42 Engine cooling, lighting
43 Left parking lamp
44 Right parking lamp
45 Fog tail lamp
46 Fog lamps
47 Towing equipment, accessory
socket
48 Diesel filter heater
49 –
50 Diesel filter heater
No. Circuit
51 Left dipped beam:
Xenon headlamp
Halogen headlamp
52 Right dipped beam:
Xenon headlamp
Halogen headlamp
53 Sun roof, electric windows, radio
54 Main beam (left)
55 Main beam (right)
56 –
Picture no: 14213s.tif
Fuse box in engine compartment
The fuse box is at the front left of the
engine compartment.
Disengage cover of fuse box from lug and
lift off.
Some circuits may be protected by several
fuses.
9 Warning
Turn off engine before opening fuse
box, risk of injury.

185
Self-help, vehicle care
Picture no: 14214s.tif
The following fuses are Maxi fuses.
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.
Replace the bulb, checking that the data
on the base matches that of the defective
bulb.
To replace a bulb, pull off the relay box on
the left side. On the right side, pull off the
air hose to the air filter.
Picture no: 16085s.tif
Halogen headlamp systemHeadlamp system has separate bulbs for
dipped beam 1 (bottom bulbs) and main
beam 2 (top bulbs).
No. Circuit
1 Interior fan
2 Power steering
3 ABS
4 Easytronic diesel preheating
system
5 Heated rear window
6 Engine cooling
7 Starter
8 Engine cooling

198 Self-help, vehicle careWindows and windscreen wiper blades
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. Pre ss 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. 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
Look after areas in the engine
compartment that are painted in the same
colour as the vehicle like any other
paintwork.
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 Braking
System 3, the automatic air conditioning
system 3 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. 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.

199
Service and maintenance
Service and
maintenance
Scheduled maintenanceThese service intervals apply only under
normal driving conditions. If conditions are
more arduous 3206
Service interval display 3208.
European service intervals
Every 30 000 km or annually, whichever
occurs first.
International service intervals
Every 15 000 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 ..................... 199
Service schedule .................................. 199
Additional service work ....................... 206
Recommended fluids and lubricants .. 206
Inspection system ................................ 208
Genuine Opel Parts and Accessories .. 209
Performing work .................................. 209
Engine oil .............................................. 210
Diesel fuel filter .................................... 212
Coolant ................................................. 212
Brakes ................................................... 213
Brake fluid ............................................ 214
Windscreen wiper replacement .......... 215
Windscreen and headlamp washer
systems 3........................................... 215
Battery .................................................. 216
Protecting electronic components ..... 216
Laying the vehicle up for a long period of time .................................... 217
Putting the vehicle back into service ... 217

201
Service and maintenance
⊕ additional work.
o The intervals are shorter where driving conditions are more arduous or country-specific.
Service work
after year
1)
km (x 1000)
1)
1)Depending on what occurs first.
1
30 2
60 3
90 4
120 5
150
⊕
Replace timing belt and tension pulley
Z 18 XE every 6 years/90 000 km
Z 17 DTH every 10 years/90 000 km
Z 16 LET, Z 16 XEP, Z 17 DTR, Z 17 DTR every 10 years/150 000 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 EN 590)
Z 13 DTJ, Z 17 DTH xx
Replace fuel filter, petrol (grade EN 228), outer Z 16 LET every 4 years/60 000 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. x
xxxx
⊕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 agr
eement with the customer.
xx
Annual service check if the annual distance travelled is greater than 20 000 km.
Carry out a visual check of the engine, tran smission (AT, MT), check air conditioning
compressor for leaks
2)
xxxxx

202 Service and 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 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 20 000 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 xx
Lubricate door hinges, check arms, cylinder lo ck, door latch, bonnet catch, rear panel
hinge xx
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 tran sport passengers, taxis, ambulances, hire cars etc annually

204 Service and maintenance⊕additional work.
o The intervals are shorter where driving conditions are more arduous or country-specific.
Service work
after year
1)
km (x 1000)
1)
1)Depending on what occurs first.
1
15 2
30 3
45 4
60 5
75
⊕
Replace timing belt and tension pulley
Z 18 XE every 6 years/90 000 km
Z 17 DTH every 10 years/90 000 km
Z 16 LET, Z 16 XEP, Z 17 DTR, Z 17 DTR every 10 years/150 000 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 EN 590)
Z 13 DTJ, Z 17 DTH xx
Replace fuel filter, petrol (grade EN228), outer Z 16 LET every 4 years/60 000 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. x
xxxx
⊕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 agr
eement with the customer.
xx
Annual service check if the annual distance travelled is greater than 20 000 km.
Carry out a visual check of the engine, tran smission (AT, MT), check air conditioning
compressor for leaks
2)
xxxxx

205
Service and maintenance
⊕ additional work.
o The intervals are shorter where driving conditions are more arduous or country-specific.
Service work
after year
1)
km (x 1000)
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/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 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 20 000 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 xx
Lubricate door hinges, check arms, cylinder lo ck, door latch, bonnet catch, rear panel
hinge xx
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

207
Service and maintenance
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
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.
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
ACEA-A3: Petrol engines
ACEA-B4: Diesel engines
without diesel
particulate filter
ACEA-C3 Diesel engines with diesel particulate
filter

208 Service and maintenance
Picture no: 18602s.tif
Inspection system In order to guarantee 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.
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 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 inst ructions from Opel.
It is particularly advisable to use an Opel
Partner during the warranty period in order
to prevent loss of warranty. Further
information can be found in the Service
and Warranty Booklet.
Separate anti-corrosion service
Have this work done at the intervals given
in the Service and Warranty Booklet.