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.
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TRAINING
History
General
M300
M200M100
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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
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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.
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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
© 2008 General Motors Corporation. All rights reserved.
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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
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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
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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
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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
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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
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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
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TRAINING
Body Exterior - Fronr Bumper
Body Exterior - Rear Bumper
Bulk Head Replacement - Bolted
Body
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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
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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
© 2008 General Motors Corporation. All rights reserved.
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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
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TRAINING Body
Spare Parts
Front
Rear
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TRAININGBody
Side Panel
Sound Deadening
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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)
5.0L/100 km (47 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
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 liters (9.3 gallons)
Transmissions 5 sp manual; fwd 5 sp manual; fwd
4 sp automatic; fwd -
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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
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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.
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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
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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
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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
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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
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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.
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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.