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.
Note
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.
TRAINING General

History

M100 M200

M300

2008 General Motors Corporation. All rights reserved.

 General TRAINING

Introduction

The new Spark will substantially enhance Chevrolets 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.

2008 General Motors Corporation. All rights reserved.

 TRAINING General

Exterior Design

Body sides are free of

Hidden rear door handles
any cladding or
deliver a sporty three-door
appliqus for a clean,
Dramatically swept appearance without
uncluttered appearance.
windscreen adds to the sacrificing five-door utility
sleek, in
motion Wheel arches convey
appearanc a sense of motion,
while tight wheel-to-
body relationships
Two-tier grille is provide a planted
a Chevrolet appearance
design hallmark,
with a large bow
Elliptical-shaped
tie that demon-
headlamps stretch from
strates Sparks
front fascia to the A-pillar
proud heritage
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 Vehicle sides slope inward as

is a segment-exclusive they rise to the roof, making
standard feature, and the track appear even wider
contributes to the vehicles without sacrificing interior
impression of movement space

Rear tail lamps are large in

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

2008 General Motors Corporation. All rights reserved.

 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

2008 General Motors Corporation. All rights reserved.

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 1.2 L 1.2 LS
Dimensions
Leg Room front/rear (mm) 1067/893 1067/893
Shoulder Room front/rear 1288/1263 1288/1263
(mm)
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

2008 General Motors Corporation. All rights reserved.

 General 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 frontloader
RDS * *
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 * *

2008 General Motors Corporation. All rights reserved.

TRAINING Body

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

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2008 General Motors Corporation. All rights reserved.

 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

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2008 General Motors Corporation. All rights reserved.

TRAINING Body

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 passengers 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

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2008 General Motors Corporation. All rights reserved.

 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

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2008 General Motors Corporation. All rights reserved.

TRAINING Body

Body Exterior - Fronr Bumper

Body Exterior - Rear Bumper

Bulk Head Replacement - Bolted

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 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

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TRAINING Body

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

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2008 General Motors Corporation. All rights reserved.

 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

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2008 General Motors Corporation. All rights reserved.

TRAINING Body

Spare Parts

Front

Rear

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 Body TRAINING

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 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 Iron Cast Iron

Cylinder Head Aluminium Aluminium

Weight 93.3kg 94.1kg

Engine Capacity (cm) 995cc 1206cc

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

Compres sion Ratio 9.8 : 1 9.8 : 1

Power @rpm 50 kilowatts @ 6400rpm 60 kilowatts @ 6400rpm (80.5hp)

(67 hp)
Torque 89 Nm @ 4800rpm 110 Nm @ 4800rpm
(66 lb.-ft.) (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 4.8L/100 km 5.0L/100 km

fuel efficiency (49 miles per gallon) (47 miles per gallon)
Fuel tank capacity 35 liters (9.3 gallons) 35 liter s (9.3 gallons)

Transmissions 5 sp manual; fwd 5 sp manual; fwd

4 sp automatic; fwd -

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2008 General Motors Corporation. All rights reserved.

 Mechanical TRAINING

Items Capacity Service Interval Fluid

Normal condition :
Engine Oil 15,000 km or 1 year SAE 5W-30, API SM
3.75L
(W/Filter) Severe condition : (ILSAC GF-lV) grade
7,500 km or 6 months

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

Manual 30,000 km
Transaxle 2.1 L (Change 15,000 km SAE 75W85W
(1.2D) at first)

Automatic 5.87 ESSO JWS 3309 or

Inspect every 15,000 km
Transaxle 0.2 L TOTAL FLUID lll G

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

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

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.

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2008 General Motors Corporation. All rights reserved.

TRAINING Mechanical

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 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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2008 General Motors Corporation. All rights reserved.

 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

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2008 General Motors Corporation. All rights reserved.

TRAINING Electrical

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) Engine Coolant Temperature Lamp(ECT)

Fuel Level Gauge Seat Belt Warning Lamp

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2008 General Motors Corporation. All rights reserved.

 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

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2008 General Motors Corporation. All rights reserved.

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 Module

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

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2008 General Motors Corporation. All rights reserved.

 Passenger Safety TRAINING

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 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 inflatable re-
straint system!

Passenger Airbag Module

The Passenger Airbag Module is located on the dashboard and is bolted 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.

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2008 General Motors Corporation. All rights reserved.

TRAINING Passenger Safety

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 compartment 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.

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2008 General Motors Corporation. All rights reserved.