Chevrolet Spark

Model Introduction Training For

Approved Motor Body Repairers

Fresh Design, Functional and Fuel Efficient

CONTENTS

GENERAL

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

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

Dramatically swept
windscreen adds to the
sleek, in
motion
appearanc

Body sides are free of

any cladding or
appliqus 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 Sparks
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 vehicles
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

2008 General Motors Corporation. All rights reserved.

TRAINING

General

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
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

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.

TRAINING

General

EXTERIOR STYLING
Headlamps
Door Handles
Colour coded bumpers
Exterior mirrors (manual folding)

1.2 L

1.2 LS

Halogen

Halogen

Black
*

Colour Coded
*

*
*

Exterior mirrors (electric,

heated)
WHEELS

1.2 L

Wheels
Tyre size
CONVENIENCE
Power steering
Air Conditioner
Rear window defogger
Tinted Windows All Round
Tinted Windscreen
Cup Holders

1.2 LS

Steel

Alloy

155/70 R14

155/70 R14

1.2 L
*

1.2 LS
*

*
*

Power windows - Front

Fuel Cap Opener

Remote Tailgate Release
Intermittent Wiper
Headrests - Front
Height Adjustable Driver
Seat
Split Rear Seats 60/40
INFORMATION
Radio
RDS
SECURITY

*
*

*
*

1.2 L

1.2 LS

CD frontloader
*

1.2 L

ABS Brakes
Electronic Brakeforce Distribution (EBD)
Airbag Driver & Passenger
Front Brake Discs
Collapsible Steering Column
Rear Wiper
Seatbelts - Height Adjustable
Side Impact Protection Bars
Immobiliser
Alarm
Auto-Locking Doors
Central Locking

*
*

*
*

High Level Brake Light

Security

1.2 LS
*

*
*

1.2L

1.2LS

*
*

*
*
*

*
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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.

TRAINING

Body

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

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 process 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.

TRAINING

Body

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

2008 General Motors Corporation. All rights reserved.

TRAINING

Body

Body Exterior - Fronr Bumper

Body Exterior - Rear Bumper

Bulk Head Replacement - Bolted

14

2008 General Motors Corporation. All rights reserved.

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

2008 General Motors Corporation. All rights reserved.

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

18

2008 General Motors Corporation. All rights reserved.

Body

TRAINING

Side Panel

Sound Deadening

19

2008 General Motors Corporation. All rights reserved.

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
(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

Top speed

151 kph

0 - 100kph - 12.1sec
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 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.

TRAINING

Mechanical

Items

Capacity

Service Interval

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)

Automatic
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.

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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 energyabsorbing 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)

Fuel Level Gauge

Engine Coolant Temperature Lamp(ECT)

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

25

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

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 restraint 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.