chevrolet spark 2010 informacion de taller

Chevrolet SparkModel Introduction Training For Approved Motor Body Repairers

“Fresh Design, Functional and Fuel Efficient”

CONTENTS

Note

GENERAL

BODY

MECHANICAL

ELECTRICAL

4

10

20

23

26PASSENGER PROTECTION

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.

© 2008 General Motors Corporation. All rights reserved.

4

TRAINING

History

General

M300

M200M100


5

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.

General


6

TRAINING

Exterior Design

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

General

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

Two-tier grille is a Chevrolet design hallmark, with a large bow tie that demon-strates 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

Wheel arches convey a sense of motion, while tight wheel-to-body relationships provide a planted appearance

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


7

TRAINING

Colours

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

General

● Olympic White

● Super Red

● Carbon Flash

● Switchblade Silver

● Green Cocktail

● Moroccan Blue

● Misty Lake


8

TRAINING General

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 Dimensions

1.2 L 1.2 LS

Leg Room front/rear (mm) 1067/893 1067/893 Shoulder Room front/rear (mm)

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


9

TRAINING

EXTERIOR STYLING 1.2 L 1.2 LS Headlamps Halogen Halogen Door Handles Black Colour Coded Colour coded bumpers * *

Exterior mirrors (manual fold-ing)

*

Exterior mirrors (electric, heated)

*

WHEELS 1.2 L 1.2 LS Wheels Steel Alloy Tyre size 155/70 R14 155/70 R14 CONVENIENCE 1.2 L 1.2 LS Power steering * *

Air Conditioner * *

Rear window defogger * *

Tinted Windows All Round * *

Tinted Windscreen * *

Cup Holders * *

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 Radio CD frontloaderRDS * *

SECURITY 1.2 L 1.2 LS ABS Brakes *

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 1.2L 1.2LS

Immobiliser * *Alarm * *

Auto-Locking Doors *

Central Locking * *

General


10

TRAINING

Body

Metal Usage

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

Underbody

● Crash Box Front: Bolted, replaceble ● Crash Box Rear: Bolted, replaceble

Body


11

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

Body


12

TRAINING

TWB Processed “B-Pillar”

Panel A and B with different strengths attached to each other by the Tailor Welded Blanking pro-cess 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

Body


13

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

Body


14

TRAINING

Body Exterior - Fronr Bumper

Body Exterior - Rear Bumper

Bulk Head Replacement - Bolted

Body


15

TRAINING

Rear Wheel House Hemming

After replacement of the side outer panel, the hemming of the rear wheel house should beimplemented with portable hemming tool.

Hemming Tools

Body


16

TRAINING Body

Vehicle Identification Number (VIN) Location

KL1MF48DJAC141668VIN Interpretation

● K – Country of origin ; Korea

● L – Manufacturer ; GMDAT

● 1 – Trade Name ; Chevrolet

● M – Carline ; M300

● F – Transmission ; FWD, MT

● 48 – Body style ; 4dr hatchback

● D – Engine type ; LMU 1206cc

● J – Emission level ; Euro 4

● A – Model year ; 2010

● C – Plant code ; Changwon

● 141668 – Production sequence number


17

TRAININGBody

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

Regular Production Codes


18

TRAINING Body

Spare Parts

Front

Rear


19

TRAININGBody

Side Panel

Sound Deadening


20

TRAINING Mechanical

Engine

The Spark is powered by a four-cylinder petrol engine delivering exceptional fuel economy andclass 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 Iron Cast Iron

Cylinder Head Aluminium Aluminium

Weight 93.3kg 94.1kg

Engine Capacity (cm³) 995cc 1206cc

Bore / Stroke 68.5mm / 67.5mm 69.7mm / 79mm

Compression 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 @ 4800rpm(81 lb.-ft.)

Valve Adjustment Mechanical Bucket Tappet Mechanical Bucket Tappet

Performance - 0 - 100kph - 12.1sec

Top speed 151 kph 162 kph

143 kph (AT) -

CO Emissions - 119g/km

Engine Oil Capacity 3.75 Lt 3.75 Lt

Estimated city/highway combined fuel efficiency

4.8L/100 km (49 miles per gallon)


Fuel tank capacity 35 liters (9.3 gallons) 35 liters (9.3 gallons)

Transmissions 5 sp manual; fwd 5 sp manual; fwd

4 sp automatic; fwd -

B10D1 B12D1

Cylinders L4 L4

Block Cast Iron Cast Iron

Cylinder Head Aluminium Aluminium

Weight 93.3kg 94.1kg

Engine Capacity (cm³) 995cc 1206cc

Bore / Stroke 68.5mm / 67.5mm 69.7mm / 79mm

Compression 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 @ 4800rpm(81 lb.-ft.)

Valve Adjustment Mechanical Bucket Tappet Mechanical Bucket Tappet

Performance - 0 - 100kph - 12.1sec

Top speed 151 kph 162 kph

143 kph (AT) -

CO Emissions - 119g/km

Engine Oil Capacity 3.75 Lt 3.75 Lt

Estimated city/highway combined fuel efficiency



Fuel tank capacity 35 liters (9.3 gallons) 35 liters (9.3 gallons)

Transmissions 5 sp manual; fwd 5 sp manual; fwd

4 sp automatic; fwd -


21

TRAINING

Items Capacity Service Interval Fluid

Engine Oil(W/Filter) 3.75L

Normal condition : 15,000 km or 1 yearSevere condition : 7,500 km or 6 months

SAE 5W-30, API SM (ILSAC GF-lV) grade

Engine Coolant 4.74L 240,000 km or 5 years Dex-cool coolant

Manual Transaxle(1.2D)

2.1 L30,000 km(Change 15,000 km at first)

SAE 75W85W

Automatic Transaxle

5.87±0.2 L Inspect every 15,000 km

ESSO JWS 3309 orTOTAL FLUID lll G

Brake & Clutch 0.5 L 30,000 km or 2 years DOT-3 (or DOT-4)

Power Steering 1.1 L Inspect every 15,000 km DEXRON VI

Suspension

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

Mechanical


22

TRAINING

1. EBCM Securing Bolts2. Brake Pressure Modulator Valve3. Electronic Brake Control Module (EBCM)

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.

Mechanical

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 energy-absorbing feature, collapsible steering shaft, and break away mounting features help reduce the injury in the event of an accident.


23

TRAINING

Electrical

There are two fuse boxes in the new Spark. The main fuse box is situated in the left front of theengine 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 RelayRear Fog Lamp relayRear Defog RelayWiper RelayDoor Lock RelayDoor Unlock Relay

Immobiliser

● Attached to the right hand side of the steering Column

1. Securing Screws2. Theft Deterrent Module* Left Hand Drive Model Depicted

Electrical


24

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)

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

Electrical

1. Securing Bracket Nuts2. Keyless Entry Controller* Left Hand Model Depicted

Malfunction Indicator Lamp(MIL) Engine Coolant Temperature Lamp(ECT)

Fuel Level Gauge Seat Belt Warning Lamp


25

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

Inlet actuator

Mode actuator

Temperature actuator

Electrical


26

TRAINING Passenger Safety

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 Module2) Passenger Airbag Module3) Sensing And Diagnostic Module4) Seatbelt Retractor


27

TRAININGPassenger Safety

Driver Airbag Module

The driver airbag is located in centre of the steering wheel. To remove the driver airbag module,insert suitable tools(2) into the openings(1) on both sides of the steering wheel. Release thesprings in the direction of the arrows by pushing the tool horizontally. Disconnect the electricalconnector.

Warning: Always diconnect the vehicle battery when working on the Supplemental inflatable re-straint system!

Passenger Airbag Module

The Passenger Airbag Module is located on the dashboard and is bolted on from the bottom withtwo bolts.

Sensing And Diagnostic Module (SDM)

The SDM is located on top of the floor tunnel between the gearlever and handbrake lever.


28

TRAINING Passenger Safety

Seat Belt Retractors

The vehicle has front and rear seat belts that are the primary means of occupant restraint. Seatbelts help to keep the occupants inside the passenger compartment and to gradually reduce theimpact 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.

chevrolet spark 2010 informacion de taller

Documents