Chevrolet Sail 2010 Learner’S Manual Download

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Chevrolet 2010 New Sail New Technical Training
- Learner's Manual

17. Crank Belt Pulley
18. Coolant Inlet Pipe

（

Equipped with

Thermostat Housing

）

19. Thermostat
20. Oil Pump Sealing Ring
21. Oil Pump inner Gear Rotor
22. Oil Pump External Gear Rotor
23. Oil Pump Housing Cover
24. Metering Valve

resistive Ring

40. Crankshaft
41. Crankshaft Position Sensor
42. Flywheel Bolt
43. Flywheel
44. Rear Crankshaft Oil Seal
45. Cylinder Block Blank Cover
46. Knocking Sensor
47. Heating and Ventilation Return Water Pipe

Summary of Contents for Sail 2010

Page 1: ...ons 9 2 3 Engine Identification Diagram 11 2 3 1 1 2L LMU 11 2 3 2 1 4L LCU 15 2 4 Engine Maintenance and Service 21 2 4 1 Timing Calibration 21 2 4 2 Valve Clearance Adjustment 1 2 1 4 22 2 5 Engine Management System 23 2 5 1 ECM Input 23 2 5 2 ECM Output 24 2 5 3 EGR Valve 24 2 5 4 Programming and Setting of Engine Control Module 24 2 5 5 Idle Read In Program 25 2 6 Circuit Diagrams 28 2 6 1 Veh...

Page 2: ...essure and Temperature Schematic Diagram 1 4 44 2 6 16Engine Data Sensor Oxygen Sensor Schematic Diagram 1 4 46 2 6 17Module Power Grounding and Serial Data Schematic Diagram 1 4 47 2 6 18Startup and Charging Schematic Diagram 1 4 48 2 6 19Fuel Control System Fuel Pump Control System and Oil Injector Schematic Diagram 1 4 49 2 6 20Equipment Control Schematic Diagram 1 4 50 2 6 21Controlled and Mon...

Page 3: ...gram 71 4 7 4 Horn Circuit Diagram 72 4 7 5 Headlamps Circuit Diagram 73 4 7 6 Signal and License Plate Lamps Circuit Diagram 74 4 7 7 Turn Lamps and Hazard Warning Lights Circuit Diagram 75 4 7 8 Reverse Lamps Circuit Diagram 76 4 7 9 Brake Lamps Circuit Diagram 77 4 7 10Fog Lamps Circuit Diagram 78 4 7 11Exterior Mirrors Circuit Diagram 79 4 7 12Door Pillar Switch Circuit Diagram 80 4 7 13Centra...

Page 4: ...rake Drums 102 5 13 Hydraulic Braking System Exhaust 102 5 14 Hand Brake Adjustment 105 5 15 Braking System Circuit Diagrams 106 5 15 1Power and Ground Circuit Diagram of Braking System 106 5 15 2ABS Wheel Speed Sensor Circuit Diagram 107 5 15 3ABS Circuit Diagram 108 5 15 4Braking Warning System Circuit Diagram 109 6 Steering System 110 6 1 Power Steering System Specifications 110 6 2 Component I...

Page 5: ...fication 1 1 1 Vehicle VIN Code 1 VIN Code 2 Position of VIN Code 1 The vehicle identification label 1 is in the top left corner of the dashboard and you can see it from outside through the windscreen 3 Position of VIN Code 2 Vehicle Identification Number VIN is engraved in the top right side of the bulkhead ...

Page 6: ... Passenger Vehicle 7 Protecting Device System 2 Manual Safety Belt Driver and Front Passenger Front Airbag 8 Manual Safety Belt and Driver Front Airbag 8 Engine Type S 1 2L 1 4 MFI DOHC M 1 2L 1 4 MFI DOHC 9 Check Digit 0 9 o X Check Code 10 Production Year A 2010 11 Manufacturing Plant Y Shanghai General Motors Yantai Plant 12 17 Manufacturing Plant Serial Number 1 1 2 Vehicle Nameplate Certifica...

Page 7: ...or Please refer to the label for tire information The label lists the maximum carrying capacity of the vehicle tire size includes spare wheel and cold inflation pressure includes spare wheel RPO Code Label 1 Vehicle Identification Number 2 Engineering Design Model Vehicle Classification Series and Body Style 3 Interior Trim Parts and Trim Level 4 Contents of Optional Vehicle Parts Engine Compartme...

Page 8: ...il Cap 15 Engine Oil Dipstick 1 2 Vehicle Fit out Table Fit out Table MKT Type 1 2 SL MT 1 2 SE MT 1 2 SE EM T 1 4 SX MT 1 4 SX EM T 1 2 SL MT 1 2S EMT 1 2SE EMT 1 4 SX MT 1 4S X EM T Engine Model 1S R 69 1SS69 1ST69 1S R 48 1SS48 1ST48 Optional Type NG S 1 NG S 2 NG S 3 NG S 4 NG S 5 NG S 6 NGS 7 NGS 8 NG S 9 NG S 10 Vehicle Body Color Exterior Primary Color Cool Blue MET O O O O O Exterior Prima...

Page 9: ...hift and Mechanical Transmission X X X X Braking System BRAKE SYSTEM PWR Front Disc Rear Drum Cast Iron ABS FRT RR WHL X X X X X X X X BRAKE SYSTEM PWR Front Disc Rear Drum Cast Iron X X Interior Trim Interior Trim Dark Titanium Light Titanium X X X X X X X X X X Wheels Wheel Hubs 13 X 5 Steel Paint X X Wheel Hubs 14 X 5 5 Steel Paint X X X X X X X X Safety System Seat Belt Inflation Protection Fr...

Page 10: ...peakers X X X X X X Four Speakers X X X X Air conditioning Front Side Manual Air Conditioning System X X X X X X X X X X Miscellaneous STRAIGHT CHILE ONLY Child Seat X X X X X X X X X X External Tail Lamps and Brake Lamps Global License Plate Position Manual Leveling of Headlamps Wax Injection FILM APPLY Symbol X denotes optional fit out packages ...

Page 11: ...sed or laser engraved on the cylinder block in the assembly plant In addition the same serial number label and engine communication code label 1 are on the engine cover 1 2L LMU The steel seal number 2 of the 1 2L engine is in the left rear side of the engine cylinder block and is impressed or laser engraved on the cylinder block in assembly plant In addition the same serial number label and engin...

Page 12: ...fication number engine number is 10 2 1 2 Significance of Engine Serial Number 1 Year Code 2 Month Code 1 9 January September A October B November C December 3 Date Code 4 Engine Production Line Code Fixed Code 2 5 Production Sequence Number From 1 To 9999 2 2 Engine Parameters 2 2 1 Engine Oil Recommended Engine Oil API SM ILSAC GF IV Grade SAE 5W 30 Volume 1 2L LMU 3 75L 1 4L LCU 3 75L 2 2 2 Spa...

Page 13: ...241 246 80 176 332 327 70 158 467 441 60 140 667 603 50 122 973 837 45 113 1188 991 40 104 1459 1180 35 95 1802 1412 30 86 2238 1700 25 77 2796 2055 20 68 3520 2500 15 59 4450 3055 10 50 5670 3760 5 41 7280 4651 0 32 9420 5800 5 23 12300 7273 10 14 16180 9200 15 5 21450 9200 20 4 28680 15080 30 22 52700 25600 40 40 100700 45300 2 2 4 Ignition System Specifications Ignition System Specifications 1 ...

Page 14: ...10 Chevrolet 2010 New Sail New Technical Training Learner s Manual Spark Plug Type RA7YC ...

Page 15: ...i Application Specifications Metric Units English Units Ignition Sequence 1 3 4 2 1 3 4 2 Ignition Timing 8º BTDC Ignition Type Direct Ignition System Spark Plug Gap 1 0 1 1 Mm 0 039 0 043 in Spark Plug Manufacturer TORCH Spark Plug Model K6RF 11 2 3 Engine Identification Diagram 2 3 1 1 2L LMU Cylinder Head ...

Page 16: ...nition System 9 Camshaft Cover 10 Camshaft Air Intake 11 Camshaft Exhaust 12 Valve Tappet 13 Valve Cotter 14 Valve Spring Snap Ring 15 Valve Spring 16 Valve Stem Sealing Element 17 Cylinder Head 18 Valve Air Intake 19 Valve Exhaust 20 Cylinder Head Gasket 21 Cylinder Cover Bolt 22 Camshaft Position Sensor 23 Coolant Outlet Housing Gasket 24 Coolant Outlet Housing 25 Coolant Temperature Sensor 26 E...

Page 17: ... 10 Cylinder Block 11 Timing Chain Cover 12 Crankshaft Front Oil Seal 13 Oil Pump Inner Rotor 14 Oil Pump Outer Rotor 15 Oil Pump Cover 16 Metering Valve 17 Metering Valve Spring 18 Metering Valve Cap 19 Metering Valve Fixture 20 Oil Cleaner Stud 21 Oil Cleaner 22 Keyway 23 Crankshaft 24 Crankshaft Bearing Cover 25 Engine Oil Filter Screen 26 Oil Pan 27 Rear Crankshaft Oil Seal 28 Cylinder Block P...

Page 18: ...r 7 Air Exhaust Hose 8 Resonator 9 Resonator 10 Throttle Body 11 Idle Air Control Valve IACV 12 Throttle Position Sensor 13 Intake Manifold 14 Exhaust Gas Recirculation Tube 15 Exhaust Gas Recirculation Tube Gasket 16 Exhaust Gas Recirculation Valve 17 Thermostat Housing 18 Coolant Outlet Housing 19 Fuel Distributing Pipe 20 Oil Injector 21 Exhaust Manifold 22 Exhaust Manifold Thermal Baffle Timin...

Page 19: ... Sprocket Exhaust 4 Lining 5 Camshaft Sprocket fixing bolt 6 Timing Chain Rod 7 Timing Chain Tensioner 8 Timing Chain Guide Plate 9 Crankshaft Sprocket 10 Engine Support Assembly 11 Rear Support Bracket 12 Transmission Rear Support 13 Transmission Support Assembly 14 Transmission Support Bracket 2 3 2 1 4L LCU Cylinder Head ...

Page 20: ...mshaft Cover Bolt 14 Camshaft Cover 15 Air Intake Camshaft 16 Exhaust Camshaft 17 Camshaft Position Sensor 18 Valve Tappet 19 Valve Cotter 20 Valve Spring Snap Ring 21 Valve Spring 22 Valve Tappet Sealing Element 23 Valve Tappet Air Intake 24 Valve Tappet Exhaust 25 Spout Plug 26 Cylinder Cover Bolt 27 Spout Plug 28 Cylinder Head 29 Cylinder Head Sealing Gasket 30 Exhaust Gas Recirculation Valve 3...

Page 21: ... Pump 13 Water Pump Belt Pulley 14 Water Pump Sealing Ring 15 Crank Belt Pulley Bolt 16 Crank Belt Pulley Washer 25 Metering Valve Plug Cover 26 Engine Oil Pressure Switch 27 Engine Oil Filter Switch Port 28 Engine Oil Filter 29 Engine Oil Dipstick and Conduit 30 Driving Belt Tensioner 31 Air Conditioning Compressor Bracket 32 Oil Suction Pipe Sealing Ring 33 Oil Suction Pipe Equipped with Oil Suc...

Page 22: ...hermostat 20 Oil Pump Sealing Ring 21 Oil Pump inner Gear Rotor 22 Oil Pump External Gear Rotor 23 Oil Pump Housing Cover 24 Metering Valve resistive Ring 40 Crankshaft 41 Crankshaft Position Sensor 42 Flywheel Bolt 43 Flywheel 44 Rear Crankshaft Oil Seal 45 Cylinder Block Blank Cover 46 Knocking Sensor 47 Heating and Ventilation Return Water Pipe ...

Page 23: ...pe 10 Throttle Body Heater Water Outlet Pipe 11 Fuel Evaporative Emission Solenoid Valve Vacuum Tube 12 Manifold Absolute Pressure Sensor 13 Fuel Evaporative Emission Solenoid Valve 14 Intake Manifold 15 Intake Manifold Bracket 16 Exhaust Gas Recirculation Tube 17 Fuel Distributing Pipe Support 18 Oil Injector 19 Exhaust Manifold Gasket 20 Exhaust Manifold 21 Front Heating Type Oxygen Sensor 22 Ex...

Page 24: ...ing Chain Tensioner Gasket 4 Timing Chain Main Guide Plate Bolt 5 Timing Chain Main Guide Plate 6 Timing Chain Guide Plate Bolt 7 Timing Chain Guide Plate 8 Timing Chain 9 Camshaft Timing Sprocket Bolt 10 Camshaft Timing Sprocket Washer 11 Intake Camshaft Timing Chain Wheel 12 Exhaust Camshaft Timing Chain Wheel 13 Crankshaft Timing Sprocket ...

Page 25: ...on the timing chain and then mount the timing chain 2 Align the mark on the crankshaft sprocket with the mark on the timing chain 3 Push the timing chain tensioner rod and fix it through mounting the tensioner pin EN 49073 4 Assemble the timing chain guide plate Fastening fasten the fixed bolts of the timing chain guide plate to 12 N m 106 in lbf 5 Assemble the timing chain main guide plate ...

Page 26: ...lign the mark on the crankshaft sprocket with the mark on the timing chain 3 Push the timing chain tensioner rod and fix it through mounting the tensioner pin EN 49073 4 Assemble the timing chain guide plate Fastening fasten the fixed bolts of the timing chain guide plate to 10 N m 7 4 foot pound 5 Assemble the timing chain main guide plate Fastening fasten the fixed bolts of the timing chain rod ...

Page 27: ...ylinder to the top dead center 3 Check the camshaft sprocket and the timing chain and align the timing marks respectively 4 Measure the valve clearance of each point according to the diagram 5 Turn the crank belt pulley to 360 and adjust the belt pulley groove to the 0 point 6 Measure the valve clearance for each point according to the diagram Intake valve specifications 0 075 0 125 mm coolant tem...

Page 28: ...Control Modules z Air Conditioning Relay z Cooling Fan Relay z Vehicle Speed Sensor VSS Output z Malfunction Indicator Lamp MIL Control 2 5 3 EGR Valve 1 Position Sensor 2 Coil Assembly 3 Base 4 Pivot 5 Exhaust Entry 6 Armature 2 5 4 Programming and Setting of Engine Control Module The following servicing programs need to be programmed or set to complete repair The replacement of the engine contro...

Page 29: ...employ a diagnostic instrument if equipped to reset residual life of transmission oil to the recorded original percentage before module replacement Reprogramming of engine control module z If the engine control module ECM needs to be reprogrammed please refer to Service Programming System SPS Residual engine oil life employ a diagnostic instrument if equipped to reset residual engine oil life to t...

Page 30: ...e in idle for 10 minutes Switch on the air conditioning if equipped for 1 minute Switch off the air conditioning if equipped for 1 minute Pull the hand brake up and shift the transmission into drive D Maintain the engine in idle for 1 minute Switch on the air conditioning if equipped for 1 minute Shut down the ignition switch By now the idle read in program is complete z Manual Transmission Run th...

Page 31: ...27 Chevrolet 2010 New Sail New Technical Training Learner s Manual ...

Page 32: ...28 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 Circuit Diagrams 2 6 1 Vehicle Speed Sensor Schematic Diagram 1 2MT ...

Page 33: ...29 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 2 Ignition Control Sensor Schematic Diagram 1 2MT ...

Page 34: ...30 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 3 Ignition Control Ignition System Schematic Diagram 1 2MT ...

Page 35: ...31 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 4 Engine Cooling System Schematic Diagram 1 2MT ...

Page 36: ...32 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 5 Engine Data Sensor Pressure and Temperature Schematic Diagram 1 2MT ...

Page 37: ...33 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 6 Engine Data Sensor Oxygen Sensor Schematic Diagram 1 2MT ...

Page 38: ...34 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 7 Module Power Grounding and Serial Data Schematic Diagram 1 2MT ...

Page 39: ...35 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 8 Startup and Charging Schematic Diagram 1 2MT ...

Page 40: ...36 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 9 Fuel Control System Fuel Pump Control System and Oil Injector Schematic Diagram 1 2MT ...

Page 41: ...37 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 10 Equipment Control Schematic Diagram 1 2MT ...

Page 42: ...38 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 11 Controlled and Monitored Parts Schematic Diagram 1 2MT ...

Page 43: ...39 Chevrolet 2010 New Sail New Technical Training Learner s Manual ...

Page 44: ...40 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 12 Evaporator Schematic Diagram 1 2MT ...

Page 45: ...41 Chevrolet 2010 New Sail New Technical Training Learner s Manual ...

Page 46: ...42 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 13 Ignition Control Sensor Schematic Diagram 1 4 ...

Page 47: ...43 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 14 Ignition Control Ignition System Schematic Diagram 1 4 ...

Page 48: ...44 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 15 Engine Data Sensor Pressure and Temperature Schematic Diagram 1 4 ...

Page 49: ...45 Chevrolet 2010 New Sail New Technical Training Learner s Manual ...

Page 50: ...46 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 16 Engine Data Sensor Oxygen Sensor Schematic Diagram 1 4 ...

Page 51: ...47 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 17 Module Power Grounding and Serial Data Schematic Diagram 1 4 ...

Page 52: ...48 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 18 Startup and Charging Schematic Diagram 1 4 ...

Page 53: ...49 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 19 Fuel Control System Fuel Pump Control System and Oil Injector Schematic Diagram 1 4 ...

Page 54: ...50 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 20 Equipment Control Schematic Diagram 1 4 ...

Page 55: ...51 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 21 Controlled and Monitored Parts Schematic Diagram 1 4 ...

Page 56: ...52 Chevrolet 2010 New Sail New Technical Training Learner s Manual 2 6 22 Pedal Position Throttle Schematic Diagram 1 4 ...

Page 57: ...53 Chevrolet 2010 New Sail New Technical Training Learner s Manual ...

Page 58: ...ont of the transmission housing and close to the engine Transmission label identification 1 Transmission Assembly Code z Sh63 Manual Transmission Assembly HM z Sh63a Automatic Transmission Assembly AM 2 Part Number 3 Transmission Code 61 denotes transmission assembly 4 Last 4 Digits of Part Number 5 Supplier Code 6 Year For instance 9 2009 A 2010 B 2011 C 2012 7 Month A October B November C Decemb...

Page 59: ...elector Low Pressure Oil Pipe Pressure Sensor Accumulator Harness Clutch Position Sensor Gear Shifting Position Sensor Oil Can Clutch Performer Oil Pump Motor High Pressure Oil Pipe Transmission Control Module Clutch Assembly 2 Solenoid Valve Gear Box Oil Pump Relay Gear Shift Lever 3 3 Transmission Specifications 3 3 1 SH63 MT Specifications Application Specifications Metric Units English Units G...

Page 60: ...3A MT Specifications Application Specifications Metric Units English Units Gear Ratio 1Gear 3 462 2Gear 1 952 3Gear 1 323 4Gear 0 943 5Gear 0 743 Reverse Gear 3 454 Main Reduction Ratio 3 684 Engine Oil Capacity 1 8L 1 9Quart Style or Model SH63A MT 3 4 Transmission Identification 3 4 1 SH63 Housing ...

Page 61: ...Bolt 10 Gear Shift Stop Bolt 11 Gear Shift Stop Bolt Washer 12 Gear Shift Bracket 13 Control Cover Alignment Pin 14 Gear Shift Rocker and Bracket Assembly 15 Bolt 16 Gear Shift Paddle 17 Control Cover Assembly 18 Odometer Bolt 19 Odometer Driven Gear Assembly 20 Release Shift Fork Positioning Bolt 21 Clutch Release Shift Fork 22 Release Bearing Assembly 23 Clutch Release Rocker Component 24 Front ...

Page 62: ...olt 11 Gear Shift Stop Bolt Washer 12 Gear Shift Bracket 13 Control Cover Alignment Pin 14 Gear Shift Rocker and Bracket Assembly 15 Bolt 16 Gear Shift Paddle 17 Control Cover Assembly 18 Odometer Bolt 19 Odometer Driven Gear Assembly 20 Positioning Bolt of Release Shift Fork 21 Clutch Release Shift Fork 22 Release Bearing Assembly 23 Clutch Release Rocker Component 24 Front Housing 25 Housing Bol...

Page 63: ... Socket Head Cap Screw 13 Odometer Bolt 14 Odometer Driven Gear 15 Seal Ring 16 Positioning Bolt of Release Shift Fork 17 Clutch Release Shift Fork 18 Clutch Release Rocker Component 19 Clutch Throw out Bearing Assembly 20 Housing Bolt 21 Front Housing Assembly 22 Rear Housing Assembly 3 4 4 SH63 Gear Unit 1 Differential Assembly 2 Differential Rear Bearing Adjusting Gasket If Equipped 3 Output Sh...

Page 64: ...elf Locking Bolt 14 Self Locking Spring 15 Steel Ball 16 Front Housing Assembly 19 Rear Bearing Baffle 20 Rear Bearing Baffle Screw 21 3rd 4th 5th Gear Needle Bearing 22 5th Driven Gear 23 5th Driving Gear 24 Output Shaft Locknut 25 3rd 4th 5th Gear Synchronizer Toothed Ring 26 3rd 4th 5th Gear Synchronizer Slide Block 27 5th Gear Synchronizer Assembly 28 Axle Retainer Ring If Equipped 29 5th Gear...

Page 65: ... Locking Bolt 14 Self Locking Spring 15 Steel Ball 16 Front Housing Assembly 17 Output Shaft Rear Bearing Adjusting Gasket If Equipped If Equipped 19 Rear Bearing Baffle 20 Rear Bearing Baffle Screw 21 3rd 4th 5th Gear Needle Bearing 22 5th Driven Gear 23 5th Driving Gear 24 Output Shaft Locknut 25 3rd 4th 5th Gear Synchronizer Toothed Ring 26 3rd 4th 5th Gear Synchronizer Slide Block 27 5th Gear ...

Page 66: ...Bush 3 4 7 Output Shaft 1 4th Driven Gear 2 3rd 4th Gear Spacing Ring 3 3rd Driven Gear 4 2nd Driven Gear 5 1st 2nd Driven Gear Needle Bearing 6 1st 2nd Gear Synchronizer Inner Cone Ring 7 1st 2nd Gear Synchronizer Adapter Ring 8 1st 2nd Gear Synchronizer Outer Cone Ring 9 Retainer Ring If Equipped 10 1st 2nd Gear Synchronizer Slide Block 11 1st 2nd Gear Synchronizer Assembly 12 1st Driven Gear 13...

Page 67: ... any leakage dismount the oil level plug screw and inspect the oil level and the oil situation 1 Run the engine until it reaches its normal working temperature coolant temperature 80 90 C 176 194 F 2 Stop the engine and lift the vehicle 3 Dismount the engine oil level plug screw and inspect the oil level 4 Oil should be able to spill a little from the engine oil level plug screw hole 5 If the oil ...

Page 68: ...ommended oil 7 Mount new engine oil level plug screw a Engine oil discharging plug screw b Engine oil level plug screw Fastening fasten the engine oil level plug screw to 25 35 N m 18 26 foot pound 3 6 Vehicle Speed Sensor Position Assembly a Vehicle Speed Sensor b Speedometer Driven Gear ...

Page 69: ...the side window screw 5 Shut down the vehicle 4 2 Adjustment of Outer Front Door Handle Lever 1 Place the outer front door handle lever 2 in the middle of the buckle clamp 1 and clear up any clearance on the outer door handle 2 Move the outer front door handle lever thread in the buckle clamp to adjust the handle stroke 3 Close the buckle clamp and firmly fix the threaded portion of the outer fron...

Page 70: ...rogram a vehicle communication system This connector must have the following characteristics z Able to connect with all trouble diagnostic instruments as a 16 pin connector z Should always supply accumulator power for the trouble diagnostic instrument through its 16th pin z Should always provide ground point for the trouble diagnostic instrument through its 4th pin z Should always provide a clean ...

Page 71: ...tocol employs a single two way data line between the module and the diagnostic instrument to communicate The message structure is a request response arrangement The keyword serial data is only for the diagnosis of the diagnostic instrument Neither module exchanges data through these systems Keyword 2000 Serial Data Circuit z The Keyword 2000 serial data circuit allows the following component to co...

Page 72: ... from the accumulator At this point the radio must be connected to the accumulator prior to carrying out the code entering procedure in order to restore the audio system 4 6 Area Code of Audio System AF will be displayed when pressing the power button Users must select the area code according to the map in the user s manual If a wrong code is selected the audio connector must be reinstalled or the...

Page 73: ...69 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 Electrical Appliances Circuit Diagrams 4 7 1 Power Windows Circuit Diagram 1 ...

Page 74: ...70 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 2 Power Windows Circuit Diagram 2 ...

Page 75: ...71 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 3 Demister Circuit Diagram ...

Page 76: ...72 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 4 Horn Circuit Diagram ...

Page 77: ...73 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 5 Headlamps Circuit Diagram ...

Page 78: ...74 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 6 Signal and License Plate Lamps Circuit Diagram ...

Page 79: ...75 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 7 Turn Lamps and Hazard Warning Lights Circuit Diagram ...

Page 80: ...76 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 8 Reverse Lamps Circuit Diagram ...

Page 81: ...77 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 9 Brake Lamps Circuit Diagram ...

Page 82: ...78 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 10 Fog Lamps Circuit Diagram ...

Page 83: ...79 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 11 Exterior Mirrors Circuit Diagram ...

Page 84: ...80 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 12 Door Pillar Switch Circuit Diagram ...

Page 85: ...81 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 13 Central Door Lock Control Module Circuit Diagram ...

Page 86: ...82 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 14 Wiper Scrubber Circuit Diagram ...

Page 87: ...83 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 15 Data Communication Circuit Diagram ...

Page 88: ...84 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 16 Cigarette Lighter Circuit Diagram ...

Page 89: ...85 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 17 Sunroof Circuit Diagram ...

Page 90: ...86 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 18 Air Conditioning Compressor Control ...

Page 91: ...87 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 19 Air Conditioning Blower Control ...

Page 92: ...88 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 20 Audio System ...

Page 93: ...89 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 21 Instrument Circuit Diagram ...

Page 94: ...90 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 22 Instrument Alarm Indicator Light ...

Page 95: ...91 Chevrolet 2010 New Sail New Technical Training Learner s Manual 4 7 23 Instrument Indicator Lights and Illumination ...

Page 96: ...ar 11 Right Front 5 2 System Introduction The MGH 25 anti lock braking system ABS consists of a normal hydraulic braking system and anti lock components The normal braking system consists of a vacuum booster a Master Cylinder front and rear disc brakes rear drum brakes hydraulically interconnected brake oil pipe and hose a brake fluid level sensor and a brake warning light The anti lock braking sy...

Page 97: ... power accumulators and two dampers The hydraulic unit controls the front brake calipers and the oil pressure of the rear brake wheel cylinders through regulating the oil pressure to prevent wheel lockup 5 3 Operation mode 5 3 1 Normal Braking Mode The normal braking mode of the MGH 25 anti lock braking system ABS adopted by this vehicle is a diagonally shunted braking system In this system an oil...

Page 98: ... 5 3 2 Anti Lock Braking Mode Connection If in pressure maintaining or pressure drop mode the electronic brake control module detects that the wheel slip rate has been reduced then the electronic brake control module will increase the brake fluid pressure of the corresponding wheel through applying the Master Cylinder pressure At this point the intake valve is open and the outlet valve is closed s...

Page 99: ... Power Accumulator 21 Displacement Pump 22 Damper 23 Orifice 5 3 3 Anti Lock Braking Mode Maintenance When the electronic brake control module detects wheel slip it will close the intake valve and maintain the outlet valve in the brake pressure regulator valve as closed to isolate the system In this way the stability of the oil pressure in the brakes can be maintained so that there is no oil press...

Page 100: ...ck Braking Mode Separation If the electronic brake control module still detects wheel slip in the pressure maintaining mode then the electronic brake control module will decline the brake fluid pressure of the corresponding wheel The intake valve remains closed and the outlet valve is open Redundant oil and pressure are temporarily stored in the power accumulator inside the brake pressure regulato...

Page 101: ...ed by the rear wheels through the rear intake and outlet valves of the anti lock braking system ABS to provide effective braking effect and vehicle stability In the DDRP system the power of the rear maintaining solenoid valve is supplied by the ignition circuit If one of the following malfunctions occurs the red brake warning light will be illuminated z The two wheel speed sensors on the same axle...

Page 102: ...rt Circuited Against The Accumulator High Side Open Circuited Motor Connected Performance Reduction Motor Speed Loss Connected Performance Reduction Front Connected Solenoid Valve Short Circuited or Open Circuited Connected Performance Reduction Front Separate Solenoid Valve Short Circuited or Open Circuited Connected Performance Reduction Rear Connected Solenoid Valve Short Circuited or Open Circ...

Page 103: ...ol module continuously controls the pressure of each oil circuit until the slip disappears The electronic brake control module EBCM also continuously monitors whether the operation of the anti lock braking system ABS is proper If a malfunction is detected the electronic brake control module will shut down the functions of the anti lock braking system and illuminate the ABS warning light on the das...

Page 104: ...completely loose or the brake fluid level switch is closed the switch will be closed when the brake fluid level in the fluid storage tank of the Master Cylinder is too low the warning light will also be illuminated When the brake level switch is closed the indicating fluid level is too low At this point the malfunction s must be repaired otherwise the brake warning light won t go out Some malfunct...

Page 105: ...ke Wheel Cylinder Fixing Screw 15 Brake Shoe Alignment Pin 16 Brake Shoe Lower Tense Return Spring 17 Adjusting Bracket Spring 18 Brake Shoe Upper Tense Return Spring 5 11 Drum Brakes Adjustment z For brake drum dismounting please refer to brake drum replacement z Screw a rear brake adjusting nut into the regulator assembly until adequate elongation is generated on the brake drums z Employ a stop ...

Page 106: ... z Step down the brake pedal with a varying force from moderate to heavy Do not cause the brake to become overheated Special precautions Emergency brake should be avoided within 200 km driving distance after the brake lining is replaced 5 13 Hydraulic Braking System Exhaust 1 When the engine is stopped continuously press the brake pedal several times until the reserved pressure in the booster is c...

Page 107: ...ence should be followed for vehicles without an anti lock braking system right back left front left rear and right front Important precautions quickly pressing and releasing the brake pedal in a back and forth manner will cause the Master Cylinder sub piston to be pressed down along the oil cylinder This will result in the air in the system becoming harder to be exhausted 16 Connect a hyaline tube...

Page 108: ...104 Chevrolet 2010 New Sail New Technical Training Learner s Manual above procedures need to be repeated in order to exhaust all air ...

Page 109: ...ase refer to rear brake adjustment 2 Release the hand brake 3 Lift and properly support the vehicle 4 Inspect whether the hand brake cable is free to move 5 Turn the adjusting nut 1 in the brake bar assembly until wheels are hard to move 6 Unscrew the nut 1 until the rear wheel is just able to be free to rotate 7 Lower the vehicle ...

Page 110: ...106 Chevrolet 2010 New Sail New Technical Training Learner s Manual 5 15 Braking System Circuit Diagrams 5 15 1 Power and Ground Circuit Diagram of Braking System ...

Page 111: ...107 Chevrolet 2010 New Sail New Technical Training Learner s Manual 5 15 2 ABS Wheel Speed Sensor Circuit Diagram ...

Page 112: ...108 Chevrolet 2010 New Sail New Technical Training Learner s Manual 5 15 3 ABS Circuit Diagram ...

Page 113: ...109 Chevrolet 2010 New Sail New Technical Training Learner s Manual 5 15 4 Braking Warning System Circuit Diagram ...

Page 114: ...cifications Application Specifications Metric Units English Units Steering System Oil Capacity Oil Type DEXRON Ⅲ Oil 12378494 4L 或 12378495 1L Steering Gear Style Rack And Pinion Transmission Ratio 42 3 Mm Rev Steering Pump High Flow Capacity Pressure of Relief L Min Gal Min KPa LBF Sq In 5 5 1 45 6350 7150 921 1037 ...

Page 115: ... Storage Tank Outlet Pipe 2 Power Steering Pump Fluid Storage Tank 3 Power Steering Machine Oil Return Pipe 4 Steering Gear 5 Steering Gear Inner Tie Rod Shield 6 Steering Gear Inner Tie Rod 7 Steering Gear Outside Link Self Locking Nut 8 Steering Gear Outer Tie Rod 9 Power Steering High Pressure Pipe 10 Steering Pump Belt Pulley 11 Power Steering Pump ...

Page 116: ...e maintenance manual z Every time when adding steering fluid or completely replacing it make sure to use power steering fluid meeting the SGM specifications or power steering fluid with equivalent quality and please refer to power steering system specifications If improper power steering fluid is used the power steering hose and sealing parts might be damaged the steering fluid might leak and the ...

Page 117: ... fluid storage tank z Stop the engine and check the fluid level Maintain the fluid level at the MIN minimum mark z Do not reuse exhausted steering fluid 3 Return the steering wheel to the middle position Run the engine for 2 3 minutes 4 Test the vehicle on the road and make sure that the steering function operates properly without noise 5 Recheck the fluid level according to step 1 and step 2 Make...

Page 118: ...on Beam 7 2 Component Identification of Suspension System 7 2 1 Front Suspension 1 Front Beam 2 Front Control Arm 3 Front Wheel Hub 4 Front Wheel Bearing 5 Steering Knuckle 6 Front Wheel Bearing Snap Ring 7 Front Shock Strut 8 Front Shock Absorber Self Locking Nut 9 Stabilizer Bar Connecting Rod 10 Stabilizer Bar Bracket 11 Stabilizer Bar Vibration Isolator 12 Stabilizer Bar ...

Page 119: ...w Technical Training Learner s Manual 7 2 2 Rear Suspension 1 Rear Wheel Pivot 2 Rear Cross Beam Lining 3 Rear Coil Spring 4 Rear Coil Spring Upper Stopper 5 Rear Vibration Absorber 6 Rear Cross Beam 7 Rear Coil Spring Lower Stopper ...

Page 120: ...116 Chevrolet 2010 New Sail New Technical Training Learner s Manual 8 MDI RDS and Programming 8 1 MDI 8 1 1 MDI Identification ...

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