engine OPEL ZAFIRA 2009 Manual PDF

192
Service and maintenance
Service and
maintenance
General information ...................192
Scheduled maintenance ............194
Recommended
fluids, lubricants
and parts .................................... 204 General information
Service information
In 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.
European service intervals
Due every 30,000 km or 1 year,
whichever occurs first.
International service intervals
Due every 15,000 km or 1 year,
whichever occurs first.
Confirmations
Confirmation of service is recorded in
the Service and Warranty Booklet.
The date and mileage is completed
with the stamp and signature of the
servicing workshop.
Make sure that the Service and
Warranty Booklet is completed
correctly as continuous proof of
service is essential if any warranty or goodwill claims are to be met, and is
also a benefit when selling the
vehicle.
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).
Flexible service interval
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

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.

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.

204
Service and maintenance
Additional servicing
Additional operations +
Additional operations are not required
every service but can be performed in
conjunction with a regular service.
Time allowances for such work are
not included in the scope of regular
services and will be charged for
additionally. It is more economic if
these operations are performed as
part of a scheduled service than
having them performed separately.
Extreme operating conditions o
Extreme operating conditions are
given when at least one of the
following occurs frequently:
■ cold starts,
■ stop and go,
■ trailer towing,
■ gradients and/or high altitudes,
■ poor road surfaces,
■ sand and dust,
■ extreme temperature fluctuations. Police vehicles, taxis and driving
school vehicles are also classified as
operating under extreme conditions.
Under extreme operating conditions,
it may be necessary to have certain
scheduled service work done more
frequently than the scheduled
intervals.
Seek technical advice on the
servicing
requirements dependent on
the specific operating conditions. Recommended fluids,
lubricants and parts
Recommended fluids and
lubricants
Only use products that have been
tested and approved. Damage
resulting from the use of non-
approved materials will not be
covered by the warranty.
9
Warning Operating materials are
hazardous and could be
poisonous. Handle with care. Pay
attention to information given on
the containers.
Engine oil
Engine oil is identified by its quality
and also its viscosity. Quality is more
important than viscosity when
selecting which engine oil to use.

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.

Technical data
209
Vehicle data
Engine data
Sales designation 1.61.6 1.61.6 CNG
Engine identifier code Z 16 XEP Z 16 XER Z 16 XE1 Z 16 YNG
Number of cylinders 4 4 4 4
Piston displacement [cm
3
] 1598 1598 1598 1598
Brake horse power [kW/bhp]
7788 7769
at rpm 6000 6000 6000 6200
Torque [Nm]
150155 150133
at rpm 3900 4000 3900 4200
Fuel type Petrol Petrol Petrol Natural gas/petrol
Octane rating RON
recommended
9595 9595
possible 9898 9898
possible 91 91 91 –
Oil consumption [l/1000 km] 0.6 0.6 0.6 0.6