Chevrolet Spark 2010 informacion de taller

Chevrolet Spark Model Introduction Training For Approved Motor Body Repairers

“Fresh Design, Functional and Fuel Efficient”

CONTENTS

GENERAL

4

BODY

10

MECHANICAL

20

ELECTRICAL

23

PASSENGER PROTECTION

26

This self-study programme highlights the design and function of new vehicle models, new automotive components or new technologies.

The self-study programme is not a repair manual! All values given are intended as a guideline only. For maintenance and repair work, always refer to the current technical literature.

Note

General

TRAINING

History

M100

M200

M300

4

© 2008 General Motors Corporation. All rights reserved.

General

TRAINING

Introduction

The new Spark will substantially enhance Chevrolet’s offerings in the small car segment in South Africa and will be available in 2 models; namely the Spark L model and the Spark LS model, both sharing the 1,2 litre engine. South Africa joins numerous markets around the world who have already successfully introduced this stylish and modern vehicle.

Design Spark design conveys a sense of motion from front to back, with dramatic, crisp lines, and aggressive front fascia, large elliptical-shaped headlamps, clean body sides free of cladding and a standard lip spoiler. Hidden rear door handles give the illusion of a stylish two-door vehicle but with the functionality of four-doors. Front leg and head room rate among the best in this segment. These design elements help Spark transcend the small car segment and deliver a fresh, energetic appearance that looks good from any angle.

5


General

TRAINING

Exterior Design

Dramatically swept windscreen adds to the sleek, “in motion” appearanc

Body sides are free of any cladding or appliqués for a clean, uncluttered appearance.

Hidden rear door handles deliver a sporty three-door appearance without sacrificing five-door utility Wheel arches convey a sense of motion, while tight wheel-tobody relationships provide a planted appearance

Two-tier grille is a Chevrolet design hallmark, with a large bow tie that demonstrates Spark’s proud heritage

Elliptical-shaped headlamps stretch from front fascia to the A-pillar to provide an aggressive, swept-back appearance. The dual-bezel design is a refinement not typically seen in the car-A segment

Integrated moulded-in spoiler is a segment-exclusive standard feature, and contributes to the vehicle’s impression of movement

Vehicle sides slope inward as they rise to the roof, making the track appear even wider without sacrificing interior space

Rear tail lamps are large in ratio and incorporate a clear polycarbonate lens that allows viewing of the distinctive dual-bezel design.

Rear fascia is body colour

6


General

TRAINING

Colours The new Chevrolet Spark is available in seven exterior colours, which compliment the unique interior trim:

●

Olympic White

●

Green Cocktail

●

Super Red

●

Moroccan Blue

●

Carbon Flash

●

Misty Lake

●

Switchblade Silver

7


General

TRAINING

Specifications

Chevrolet Spark

1.2 L

1.2 LS

DIMENSIONS Exterior Dimensions Length (mm)

3640

3640

Width (mm)

1597

1597

Height (mm)

1522

1522

Wheelbase (mm)

2375

2375

Track front/rear (mm)

1410/1417

1410/1417

DIMENSIONS Interior

1.2 L

1.2 LS

Leg Room front/rear (mm)

1067/893

1067/893

Shoulder Room front/rear

1288/1263

1288/1263

Head Room front/rear (mm)

1009/952

1009/952

CAPACITIES

1.2 L

1.2 LS

Luggage capacity (L)

170

170

Fuel tank capacity (L)

35

35

ENGINE

1.2 L

1.2 LS

Bore (mm)

69.7

69.7

Stroke (mm)

79

79

Capacity (cc)

1206

1206

Compression ratio

9.8

9.8

Valve Train

DOHC 16 Valve

DOHC 16 Valve

Cylinders

4

4

Fuel System

MPFI

MPFI

Power (kW)

60kW

60kW

Torque (Nm)

110

110

TRANSMISSION

1.2 L

1.2 LS

Drive Axle

Front Wheel Drive

Front Wheel Drive

Transmission

5SPD M/T

5SPD M/T

CHASSIS

1.2 L

1.2 LS

Wheel suspension front

McPherson Strut

McPherson Strut

Wheel suspension rear

Torsion Beam Axle

Torsion Beam Axle

Dimensions

(mm)

8


General

EXTERIOR STYLING Headlamps Door Handles Colour coded bumpers Exterior mirrors (manual fold-

TRAINING

1.2 L

1.2 LS

Halogen

Halogen

Black *

Colour Coded *

*

ing) *

Exterior mirrors (electric, heated) WHEELS

1.2 L

1.2 LS

Wheels

Steel

Alloy

155/70 R14

155/70 R14

Power steering

1.2 L *

1.2 LS *

Air Conditioner

*

*

Rear window defogger

*

*

Tinted Windows All Round

*

*

Tinted Windscreen

*

*

Cup Holders

*

*

Tyre size CONVENIENCE

*

Power windows - Front *

Fuel Cap Opener

* *

Remote Tailgate Release Intermittent Wiper

*

*

Headrests - Front

*

* *

Height Adjustable Driver Seat Split Rear Seats 60/40 INFORMATION

*

*

1.2 L

1.2 LS

*

CD frontloader *

Radio RDS SECURITY

1.2 L

ABS Brakes

1.2 LS * *

Electronic Brakeforce Distri bution (EBD) Airbag – Driver & Passenger Front Brake Discs

*

*

*

* *

High Level Brake Light Collapsible Steering Column

*

*

Rear Wiper

*

* *

Seatbelts - Height Adjustable Side Impact Protection Bars Security Immobiliser Alarm

*

*

1.2L

1.2LS

* *

* * *

Auto-Locking Doors Central Locking

*

* 9


Body

TRAINING

Body Metal Usage

Mild Steel High Strength Low Alloy Steel : 66.5% Ultra High Strength Dual Phase Steel : 16%

Underbody

●

Crash Box Front: Bolted, replaceble

●

Crash Box Rear: Bolted, replaceble

10


Body

●

TRAINING

High Strength Bar: In rear crash event, absorb impact and protect the fuel tank

●

H - Spyder Type Bar: Ultra high strength dual phase spyder type bar prevents serious deformation of body structure from side impact.

Upper body

Framing Assembly - Side Complete

Framing Assembly - Side Inner

11


Body

TRAINING

TWB Processed “B-Pillar” Panel A and B with different strengths attached to each other by the Tailor Welded Blanking process are deformed without edged deformation likely to attack passenger’s side body.

Body Closure - Side Door

Side Door Inner ●

Front door window glass thickness: 3.5mm

●

Rear door window glass thickness: 2.5mm

Single Rail Window Regulators 12


Body

TRAINING

Body Closure - Front End

Pedestrian Protection ●

Space between the hood and the top of the engine reduces head injury

Special construction of the front bumper with: – reinforced structure in the lower section – A very high absorbing capacity in the upper section reduces the danger of injuries in the leg and knee area ●

Body Closure - Rear End

Key Cylinder on tail gate

13


Body

TRAINING

Body Exterior - Fronr Bumper

Body Exterior - Rear Bumper

Bulk Head Replacement - Bolted

14


Body

TRAINING

Rear Wheel House Hemming After replacement of the side outer panel, the hemming of the rear wheel house should be implemented with portable hemming tool.

Hemming Tools

15


Body

TRAINING

Vehicle Identification Number (VIN) Location

KL1MF48DJAC141668 VIN Interpretation ●

K – Country of origin ; Korea

●

D – Engine type ; LMU 1206cc

●

L – Manufacturer ; GMDAT

●

J – Emission level ; Euro 4

●

1 – Trade Name ; Chevrolet

●

A – Model year ; 2010

●

M – Carline ; M300

●

C – Plant code ; Changwon

●

F – Transmission ; FWD, MT

●

141668 – Production sequence number

●

48 – Body style ; 4dr hatchback

16


Body

TRAINING

Regular Production Codes

Uses of RPO codes ●

Ensuring the correct replacement parts are ordered

●

Determing options fitted to vehicle

●

Accurate navigation when using wiring diagrams

●

Ensuring correct options are programmed into controllers

●

Ensuring relevant checking procedures are used

17


TRAINING

Body

Spare Parts Front

Rear

18


Body

TRAINING

Side Panel

Sound Deadening

19


Mechanical

TRAINING

Engine

The Spark is powered by a four-cylinder petrol engine delivering exceptional fuel economy and class leading power. The 1,2 litre engine is mated to a standard 5-speed manual transmission. 1.2 L & 1.2LS ●

Power - 60kW

●

Torque - 110Nm

B10D1

B12D1

Cylinders

L4

L4

Block

Cast Ir on

Cast Iron

Cylinder Head

Alu minium

Aluminium

Weig ht

93.3kg

94.1kg

Engin e Capacity (cm³)

995cc

1206cc

Bore / Stroke

68.5mm / 67.5mm

69.7mm / 79mm

Compr ession Ratio

9.8 : 1

9.8 : 1

Power @rpm

50 kilowatts @ 6400rpm (67 hp)

60 kilowatts @ 6400rpm (80.5hp)

Torque

89 Nm @ 4800rpm (66 lb.-ft.)

110 Nm @ 48 00rpm (81 l b.-ft.)

Mechan ical B ucket T appet

Mechani cal B ucket Tappe t

Valve Adju stment Performance

-

Top speed

151 kph

0 - 100kph - 12.1sec 162 kp h

143 kph (AT) CO Emissions

-

119g/km

Engin e Oil Capacity

3.75 Lt

3.75 Lt

Estimated city/highway c ombined fuel efficiency

4.8L/100 km (49 miles per gallon)

5.0L/100 km (47 miles per gallon)

Fuel tank capacity

35 liters (9.3 gallons)

35 liter s (9.3 gallons)

Tran smissions

5 sp manual; fwd

5 sp manual; fwd

4 sp automatic; fwd

20


-

Mechanical

Items

Capacity

Serv ice Interv al

TRAINING

Fluid

Engine Oil (W/Filter)

3.75L

Normal condition : 15,000 km or 1 year SAE 5W-30, API SM Severe condition : (ILSAC GF-lV) grade 7,500 km or 6 months

Engine Coolant

4.74L

240,000 km or 5 years Dex-cool coolant

Manual Transaxle (1.2D)

2.1 L

30,000 km (Change 15,000 km at first)

Auto matic Transaxle

5.87 ±0.2 L

Inspect every 15,000 km

Brake & Clutch

0.5 L

30,000 km or 2 years

Power Steering

1.1 L

SAE 75W85W

ESSO JWS 3309 or TOTAL FLUID lll G

DOT-3 (or DOT-4)

Inspect every 15,000 km DEXRON VI

Suspension

The suspension on the 2010 Spark is tuned to deliver a smooth, refined ride with responsive handling. All trim levels feature identical front/rear suspension combinations.

21


Mechanical

TRAINING

Braking System All models feature a front disc/rear drum configuration with Antilock Brake System (ABS) for the LS model. The braking system on the Spark is a very efficient, cost-effective system that provides solid pedal feel and stopping performance. The brake assist system that is available on the LS model applies more pressure to the callipers during urgent stops. The Electronic Brake Control Module (EBCM) and Brake Pressure Modulator Valve (BPMV) is located on the right hand side of the engine Compartment.

1. EBCM Securing Bolts 2. Brake Pressure Modulator Valve 3. Electronic Brake Control Module (EBCM)

Steering The hydraulic power steering pump is a constant displacement vane-type pump that provides hydraulic pressure and flow for the power steering gear.

Steering Wheel And Column The steering column can be adjusted vertically and longitudinally.The steering wheel and column have safety features to protect the driver.The energy-absorbing steering column compresses in the event of a front-end collision, which reduces the chance of injury to the driver. The energyabsorbing feature, collapsible steering shaft, and break away mounting features help reduce the injury in the event of an accident.

22


Electrical

TRAINING

Electrical There are two fuse boxes in the new Spark. The main fuse box is situated in the left front of the engine compartment and the secondry fuse box under the right side dash board.

The following relays are internal to the secondry fuse box and cannot be replaced seperately: Park Lamp Relay Rear Fog Lamp relay Rear Defog Relay Wiper Relay Door Lock Relay Door Unlock Relay

Immobiliser

●

Attached to the right hand side of the steering Column

1. Securing Screws 2. Theft Deterrent Module * Left Hand Drive Model Depicted

23


Electrical

TRAINING

Immobiliser Systems Two Immobiliser versions: ●

Basic System (BAE)

●

Uk Only version (BAH) with additional auxiliary immobiliser module

Theft Deterrent Module

●

Located left hand side of the radio (RHD)

1. Securing Bracket Nuts 2. Keyless Entry Controller * Left Hand Model Depicted

Remote Functions The following remote functions are available for Spark: ●

remote central locking only

●

with optional theft-deterrent alarm system

Vehicles with the alarm will have Bonnet Open Switch, Horn Relay Control Function and Security Indicator.

Driver Information

Malfunction Indicator Lamp(MIL)

Fuel Level Gauge

Engine Coolant Temperature Lamp(ECT)

Seat Belt Warning Lamp

24


Electrical

TRAINING

Entertainment ●

Single disk CD Player MP3

●

Auxiliary input jack - iPod

●

Mini USB

Heating Ventilation And Airconditioning

●

The HVAC system for the new spark is only available in Manual

HVAC Actuators

Inlet actuator

Mode actuator

Temperature actuator

25


Passenger Safety

TRAINING

Passenger Safety

Euro NCAP ●

European New Car Assessment Programme

●

Euro NCAP 4 star rating

●

Maximum 5 star rating for child protection

●

ESC - 90% - one point needed for 5 star rating

Restraint System Components 1

2

3

4

1) Driver Airbag Module 2) Passenger Airbag Module 3) Sensing And Diagnostic Module 4) Seatbelt Retractor

26


Passenger Safety

TRAINING

Driver Airbag Module The driver airbag is located in centre of the steering wheel. To remove the driver airbag modul e, insert suitable tools(2) into the openings(1) on both sides of the steering wheel. Release the springs in the direction of the arrows by pushing the tool horizontally. Disconnect the electrical connector.

Warning: Always diconnect the vehicle battery when working on the Supplemental inflatab le restraint system!

Passenger Airbag Module The Passenger Airbag Module is located on the dashboard and is bolt ed on from the bottom with two bolts.

Sensing And Diagnostic Module (SDM) The SDM is located on top of the floor tunnel between the gearlever and handbrake lever.

27


Passenger Safety

TRAINING

Seat Belt Retractors The vehicle has front and rear seat belts that are the primary means of occupant restraint. Seat belts help to keep the occupants inside the passenger compart ment and to gradually reduce the impact forces during the following events: • Frontal impact type crashes • Rear impact type crashes • Side impact type crashes • Roll-over type crashes

Repairs and Inspections required after a collision After a collision involving air bag deployment, replace the following components. ●

Passenger instrument panel air bag

●

Driver steering wheel air bag

●

Inflatable restraint sensing and diagnostic module (SDM)

●

Driver/Passenger seat belt anchor and/or retractor pretensioners

Perform additional inspections on the following components. ●

Steering wheel air bag coil and the coil wiring pigtail - inspect for melting , scorching or other damagecaused from excessive heat.

●

Mounting points or mounting hardware for the passenger instrument panel air bag, steering wheel air bag, SDM and seat belt anchor and/or pretensioners - inspect for any damage and repair or replace if needed.

Impact Sensor Replacement Guidelines The impact sensor replacement policy requires replacing sensors in the area of the accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a object. If the vehicle has an impact sensor mounted forward of the radiator, it must be replaced. ●

Replace the impact sensor whether or not the air bags have deployed.

●

Replace the impact sensor even if it appears to be undamaged.

Impact sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR system. Do not try to determine whether the impact sensor is undamaged, replace the impact sensor. Also, if you follow a diagnostic trouble code (DTC) procedure and a malfunctioning impact sensor is indicated, replace the impact sensor.

28


Chevrolet Spark 2010 informacion de taller

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