brake OPEL ZAFIRA 2009 Service Manual

Vehicle care
187
Towing
Towing the vehicle Version with cover strip: Disengage
strip at bottom, slide to side and
remove.
Version with cover cap: Disengage
cap at bottom and remove
downwards.
The towing eye is stowed with the
vehicle tools
3 173. Screw in the towing eye as far as it will
go until it stops in a horizontal
position.
Attach
a tow rope – or better still a tow
rod – to the towing eye.
The towing eye must only be used for
towing and not recovering the vehicle.
Switch on ignition to release steering
column lock and to permit operation
of brake lamps, horn and windscreen
wipers.
Open&Start system 3 29.
Transmission in neutral. Caution
Drive slowly. Do not drive jerkily.
Excessive tractive force can
damage the vehicle.
When the engine is not running,
considerably

more force is needed to
brake and steer.
To prevent the entry of exhaust fumes
from the towing vehicle, switch on the
air recirculation and close the
windows.
Vehicles with automatic transmission
must be towed facing forwards, not
faster than 80 km/h and further than
100 km. Otherwise or if the
transmission is defective, the front
axle must be raised off the ground.
Seek the assistance of a workshop.
Manual transmission automated
3 136.
After towing, unscrew the towing eye
clockwise and refit the cover.

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.

Service and maintenance
195Service operations by year
1)
km ( x 1000) 1) 1
30 2
60 3
90 4
120 5
150
Check coolant level, anti-freeze (pale orange)
2)
, correct
Note freeze protection temperature in the Service and Warranty Booklet (confirmation
fields) X X X X X
Check for leaks and correct seating of the coolant hoses X X X X X
Check brake fluid level
2)
, correct X X X
Check battery terminals are firmly located, check battery eye X X X X X
Vehicle system check with TECH2 X X X X X
Replace pollen filter or activated carbon filter X X
+o
If air is badly polluted, has a high dust or sand content, or pollen, smell of the air
conditioning Agreement with customer
Replace air cleaner insert Every 4 years / 60.000 km
+ Replace spark plugs Z 16 XE1, Z 16 XER, Z 18 XER, Z 20 LEH, Z 20 LER Every 4 years / 60.000 km
Z 16 YNG Every 2 years / 30.000 km
Z 22 YH Every 8 years / 120.000 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
199
International service schedule
The international service schedule is valid for the countries which are not listed at the European service schedule. Service operations by year
3)
km ( x 1000) 1) 1
15 2
30 3
45 4
60 5
75
Check visually control unit, lighting unit and signalling equipment as well as airbag,
check steering and ignition lock X X X X X
Replace batteries for remote control (Do not forget the second key) Every 2 years
Check and correct windscreen wipers, screen wiper system, and headlamp washer
system X X X X X
Check coolant level, anti-freeze (pale orange)
4)
, correct
Note freeze protection temperature in the Service and Warranty Booklet (confirmation
fields) X X X X X
Check for leaks and correct seating of the coolant hoses X X X X X
Check brake fluid level
4)
, correct X X X
Check battery terminals are firmly located, check battery eye X X X X X
Vehicle system check with TECH2 X X X X X
3)
Whichever occurs first.
1) Whichever occurs first.
4) In case of too high consumption / leakage, perform additional work with customer's agreement.

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.

Service and maintenance
203Service operations by year
3)
km ( x 1000) 1) 1
15 2
30 3
45 4
60 5
75
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
205
Engine oil quality for European
service schedules
GM-LL-
A-025 = Petrol engines
GM-LL-
B-025 = Diesel engines
without DPF
ACEA-C3 = Diesel engines with DPF
GM = General Motors Europe
LL = Longlife
A or B = Engine oil quality specification
025 = Validity index
Opel engine oil meets classifications
GM-LL-A-025 and GM-LL-B-025 and
is therefore suitable for both petrol
and diesel engines.
Engine oil quality for international
service schedules
ACEA-A3 = Petrol engines
ACEA-B4 = Diesel engines without diesel particle filter
ACEA-C3 = Diesel engines with diesel particle filter These oil qualities must only be used
with the international service
schedule.
Topping up engine oil
Engine
oils of different manufacturers
and brands can be mixed as long as
they comply with the required engine
oil (quality and viscosity).
If engine oil of the required quality is
not available, a maximum of 1 litre of
ACEA A3/B4 or A3/B3 grade may be
used (only once between each oil
change). The viscosity should be of
the correct rating.
Use of ACEA A1/B1 and A5/B5
engine oil is expressly forbidden,
since they can cause long-term
engine damage under certain
operating conditions.
Engine oil additives
The use of engine oil additives could
cause damage and invalidate the
warranty.
Engine oil viscosity
Use only engine oil viscosities SAE
0W-30, 0W-40, 5W-30 or 5W-40. The SAE viscosity rating defines the
ability of an oil to flow. When cold, oil
is more viscous than when hot.
Multigrade oil is indicated by two
figures. The first figure, followed by
a W, indicates low temperature
viscosity and the second figure the
high temperature viscosity.
Coolant and antifreeze
Use
only silicate-free long life coolant
(LLC) antifreeze.
The system is factory filled with
coolant designed for frost protection
down to approx. -28 °C. This
concentration should be maintained
all year-round.
Coolant additives intended to give
additional corrosion protection or seal
against minor leaks can cause
function problems. Liability for
consequences resulting from the use
of coolant additives will be rejected.
Brake and clutch fluid
Only use DOT4 brake fluid.