Chevrolet Orlando

Model Introduction Training For Approved Motor Body Repairers A thousand things to do in a day. Fun, entertainment and relaxation for family and friends. That's the vacation spirit Chevrolet has packed into its first ever European MPV. Like the Chevrolet models recently launched in other market sectors, it doesn't follow convention. Chevrolet Orlando's design - part MPV, part crossover - breaks the rules of a historically conservative segment; it makes a statement and stands out from the crowd.

Chevrolet's new compact MPV brings swagger to the segment by adopting a bol- der look with its low roofline and crossover inspired silhouette, while retaining the distinctive and recognizable Chevrolet 'face' depicted by the split radiator grille and bow-tie badge. CONTENTS

GENERAL 4

BODY 11

MECHANICAL 22

ELECTRICAL 26

RESTRAINT SYSTEM 35

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

Introduction There's no question that the Orlando will offer a refreshing alternative to many of the family vans currently on the market. The distinctly recognizable Chevrolet face is complemented by a profile characterized by the low swept roofline and the muscular, protruding wheel-arches, housing 16, 17 or 18 inch wheels. The wheel arches enhance a 'body in, wheel out' appearance while at the same time ensuring Chevrolet Orlando keeps its agile, sporting stance.

Orlando's space, storage and safety While the exterior of the new Chevrolet Orlando is sure to attract plenty of attention, the interior too features many of the latest design cues from Chevrolet such as the Corvette-inspired dual cockpit and ambient blue backlighting to the centre console. Distinctive design is nothing without well- thought-out functionality however, so the 'theater-style' seating arrangement of the Orlando's three rows of seats, the generous load area and the numerous storage solutions will also grab the attention of family motorists. The interior seating is referred to as 'theater-style' because in spite of the sweeping roof-line, designers have succeeded in raising the second and third rows which allow the Chevrolet Orlando's occupants to get an even better view both forwards and to the side and without compromising head-room. In fact headroom in the third row of seats in the Orlando is superior to a number of competitor MPVs. Numerous seating configurations are possible with either second or third rows folded independently or together to make a completely flat load area. The second seat row also has a tumble-fold facility for both the left and right-hand outer seats to allow easy access for passengers into and out of the third row.

Any hard-working family car needs plenty of storage space for all the bits and pieces that collect inside. Like the original concept car, the final production version of the Orlando obliges with a range of compartments of different shapes and sizes and different locations, including a coin holder and two large cup holders in the center console, map and bottle holders integrated into the front and rear doors and a number of individual compartments in the cargo area.

However, perhaps the most ingenious is a storage area hidden behind the front fascia of the audio and within easy reach of the both the driver and passenger. Seen originally on the Orlando concept car, designers have been able to integrate a usefully large area which is revealed by flipping up the face of the audio, and large enough for such items as an MP3 player, sunglasses and wallets. Within the space itself there is also a standard auxiliary jack and optional USB port for MP3 or iPod connectivity, depending on the trim level.

Safety for the vehicle's occupants is always a paramount consideration for this class of car, and in Chevrolet Orlando owners will be reassured by both the attention to detail and the inclusion of the latest technology that has gone into this aspect of the car's design. Should a collision occur, Orlando's occupants will be protected by six airbags - twin front, side and curtain.

Orlando 1.8 LS M/T

– 104 kW 16V DOHC engine – Traction control (TC) – 5-Speed manual transmission – Cruise control – Front-wheel drive – Rear park assist – ABS and EBD – 17” Alloy wheels – Electronic stability programme (ESP) – 6 Airbags

Orlando 1.8 LT M/T

– 104 kW 16V DOHC engine – Anti-dazzle rear view mirror – 5-Speed manual transmission – Climate control – Front-wheel drive – Automatic lighting control – ABS and EBD – Moisture sensitive wipers – Electronic stability programme (ESP) – 18” Alloy wheels – Traction control (TC) – Leather trim

Specifications

Equipment LS LT Wheels Wheel type Alloy Alloy Tyre size 225/50 R17 235/45 R18 Full size spare wheel Std Std Convenience Power steering Std Std Tiltable and telescopic column Std Std Door mirrors Heated/Electrical/Foldable Heated/Electrical/Foldable Cruise control Std Std Moisture sensitive windscreen wipers - Std Automatic lighting control - Std Rear Park Assist Std Std Climate/Heating Air conditioning Std Std Climate control - Std Infotainment CD player with MP3 CD Std Std No. of speakers 6 6 Steerin wheel mounted controls Std Std Auxiiiiary input Std Std MP3 compatibility Std Std Safety Front,side and curtain airbags Std Std Passenger airbag deactivation Std Std ABS Std Std ESC Std Std Traction control Std Std Front seatbelts with pretensioner Std Std Front seatbelt reminder Std Std 3-Point seat belt - All 7 seats Std Std ISOFIX child seat Std Std Security features Remote central locking Std Std Immobiliser Std Std Anti-theft alarm Std Std Motion auto-locking doors Std Std

Engine

Engine Fuel Type Displacement Power Output Torque

LS 1.8i * Petrol 1796ccm 104kw 176nm

LS 2.0 VCDi(96kw) Diesel 1998ccm 96kw 315nm

LT 1.8i * Petrol 1796ccm 104kw 176nm

LT 2.0VCDi(96kw) Diesel 1998ccm 96kw 315nm

LT 2.0VCDi(120kw) Auto Diesel 1998ccm 120kw 360nm

LTZ 1.8i Petrol 1796ccm 104kw 176nm

LTZ 2.0VCDi(120kw) Diesel 1998ccm 120kw 360nm

LTZ 2.0VCDi(120kw) Auto Diesel 1998ccm 120kw 360nm

* The South African market at this stage will only be getting the 1.8L LS and the 1.8L LT

– 104kW DOHC – 1.8L DCVCP – Variable Intake Manifold – Internal EGR – NT4 Emission Rating

Transmission

– 5 Speed Manual Gearbox – Model Code D20, Cruze also uses this gearbox.

Colours

Carbon Flash - GAR

Daydream Beige - GOZ

Gunsmoke Grey - GQK

Olympic White - GAZ

Velvet Red - GCS

Switchblade Silver - GAN

Pewter Grey - GCV

Platform

The Orlando and Chev Cruze share the same platform which is the Delta II platform. They share many mechanical parts which include Steering, suspension and brakes just to name a few.Below is a size comparison of the two vehicles.

Height mm Length mm Width mm Orlando 1625 4652 1836 Cruze 1580 4350 1755

Where does Orlando fit?

Cruze - Car C Orlando - MPV C Captiva - SUV C Segment Segment Segment

Smaller Larger

Vehicle Identification Number

The VIN number can be found on two different places on the Chevrolet Orlando:

Left of front windscreen

Under carpet on drivers floor

Example: KL1 JF 75 5JBK 100001

Position No Definition Character Description 1 Country Of Origin K Korea 2Manufacturer L General Motors 3Make 1 Chevrolet 4Carline J J309 ORLANDO F Manual Transmission (MSA) 5 Transmission A Automatic Transmission (MH8) 6 & 7 Body Style 75 5 – Door Monocab (7 Seat) Vin Option Engine No Of Cam Fuel Code Code Displace Cylinders Type System 8 Engine Type Y LNP 2.0T L4 DOCH CRI 5 2HO 1.8L L4 DOHC MPFI J Euro-4 (NT4) 9 Emission Level 9 Euro-5 (NE9) 10 Model Year B2011 11 Plant Location B: Bupyung K: Kunsan Production Sequence 12 to 17 *** 100001 Number

Body Construction

Safety for a vehicle's occupants is always a paramount consideration for this class of car, and in Chevrolet Orlando owners will be reassured by both the attention to detail and the inclusion of the latest technology that has gone into this aspect of the car's design. Most of Orlando's body structure is constructed of high strength steel to form an effective passenger safety cage providing protection in the event of a collision to the front, rear and side of the car. Should a collision occur, Orlando's occupants will be protected by six airbags - twin front, side and curtain.

One of the biggest challenges often faced by emergency services when assisting at the scene of an incident is helping the occupants of vehicles when the doors are locked. However, this is not a scenario that Chevrolet Orlando owners will be faced with; Orlando is fitted with crash sensor technology, where the doors unlock automatically on detection of an impact.

Starting with Chevrolet Orlando's body shell, the body frame integral (BFI) structure whereby the upper body and chassis frame are engi- neered as a single component ensures high levels of stiffness. This torsional rigidity of the body-chassis interface will not just put a smile on any driver's face through great handling; the upper body shell of the Orlando is also ex- ceptionally strong, with over 70% of the body frame constructed from high strength steel.

Chevrolet Orlando's passenger compartment is reinforced all round, including the A and B-pillars, the cross sections that support the roof and along the lower sill sections. Occupants in effect sit inside a safety cage constructed to minimize intrusion in the case of frontal, side or rear impact, while front and rear crumple zones are designed to absorb and dissipate energy to minimize impact to the passenger compartment.

High-strength steels and aluminum are used in all the key areas in the car's construction. With the frontal area of any vehicle particularly vulnerable, Orlando is fitted with a strong yet light aluminum crash-box for the front bumper cross-member which sits in front of the engine cradle, with high-strength steel used for longitudi- nal rails and the front sub-frame. Energy is absorbed by these sections and distri- buted evenly along load paths, including a dual load path on the vehicle's underbody, which channels energy away from the passenger compartment. The cradle used to house the engine and which sits inside the front sub frame also has high energy absorption properties where structural foam helps dissipate impacts. Special attention has also been paid to the side structure of the body so that the B-pillar section and where it joins the lower sill section and seat cross member on the floorpan is especially strong, and designed to distribute loads safely around the body frame.At the rear of the vehicle, a further reinforced sub frame is used on the underbody which protects the fuel tank and its connections from penetration in the case of a rear impact.The fuel tank itself is capable of withstanding minor compres- sions without rupturing. 12 © 2008 General Motors Corporation. All rights reserved. Body TRAINING

Body Structure

Dual Phase Steel Mild Steel High Strength Steel Ultra-High Strength Steel Aluminum

Mild Steel has a relatively low tensile strength, but is malleable. Surface hardness can be increased through carburising. This type of steel normally has a tensile strength less than 270 MPa.

High Strength Low Alloy Steel is a type of alloy steel that provides better mechanical properties and greater resistance to corrosion than mild steel. This type of steel normally has a tensile strength range from 300 - 700 MPa.

Dual Phase Steel is a high-strength steel that has a ferrite and martensitic microstruc- ture. This type of steel normally has a tensile strength up to and including 800MPa. Advantages:

– Low yield strength – High initial strain hardening rates – A high strain rate sensitivity (faster energy absorbsion) – Good fatigue resistance – Good uniform elongation

Ultra-High Strength Steel normally has a tensile strength greater than 800 MPa.

Body Layout

No Name Material No Name Material

1&2 Front-wheel housing Mild steel 13 Quarter outer panel Mild steel

3 Front-side rail High strength 14 Rocker outer panel Mild steel low alloy

4 Roof front head panel High strength 15 Body hinge pillar outer Mild steel low alloy panel

5 Roof panel Mild steel 16 Body hinge pillar High strength reinforcement low alloy

6 Roof rear panel High strength 17 Rocker inner Ultra high low alloy reinforcement strength low alloy

7 Floor panel crossbar rear High strength 18 Rocker inner panel High strength low alloy low alloy

8 Floor panel crossbar front High strength 19 Front upper side rail Mild steel low alloy

9 Body lock pillar upper High strength 20 Front end upper support High strength reinforcment low alloy low alloy

10 Side inner panel Mild steel 21 Front wheel house rear Mild steel reinforcement

11 Center pillar inner High strength 22 Headlight mount panel Mild steel reinforcement low alloy

12 Center pillar exterior Mild steel 23 Front impact bar Aluminium

Side Panel

Bumper and Fascia

Front Bumper Removal

1. Remove the front fender wheel opening molding. 2. Remove the radiator opening upper cover.

1 Front bumper fascia upper retainer (Quantity: 2) 2 Front bumper fascia bolt (Quantity: 2) 3 Front wheel house liner bolt (Quantity: 2) 4 Front wheel house liner bolt (Quantity: 2)

Sequence

For bolt removal, partially loosen the front wheel house liner. 5 Front wheel house liner bolt (Quantity: 6) 6 Front bumper lower reinforcement bolt 7 Front bumper fascia lower retainer (Quantity: 4) 8 Front bumper fascia

Sequence

1. Insert a flat blade type plastic trim tool to release the retainer connected to the front bumper fascia guide. 2. Take caution since fascia may tear if force is applied. 3. Undo the clip from the front bumper fascia guide. 4. Pull the front bumper fascia forward to remove. 5. Disconnect all wiring connectors.

Front Bumper Impact Bar Replacement

Removal Sequence

1. Disable the SIR. 2. Disconnect the (-) battery cable. 3. Detach all associated panels and parts. 4. Remove front bumper impact bar bolts (1).(Quantity: 8) 5. Cut the left and right side of the front bumper impact bar.

6. Indicate and mark all factory weld point locations. 7. Drill a hole in all factory weld points. 8. Remove remaining parts of the front bumper impact bar.

Mounting Sequence

1. Position front bumper impact bar on to the vehicle. 2. Place 8 front bumper impact bar bolts (1) and tighten.

Note: Use the original issued front bumper impact bar bolts. If damaged then replace the bolt.

3. Paint the repaired part. 4. Assemble all associated panels and parts. 5. Connect the (-) battery cable. Enable the SIR.

Rear Bumper Removal

Remove the tail light. 1 Rear wheel house liner bolt (Quantity: 6) 2 Rear bumper fascia lower retainer (Quantity: 2) 3 Rear bumper fascia

Sequence

1. From the front edge, pull the rear bumper fascia forward and push in the clips into the inboard fascia guide (underneath the tail light). 2. Release the clip fixture with an appropriate tool. 3. Until the exterior edge is separated outwards from the vehicle body and loud popping sound is heard, continue pulling back the rear bumper fascia. 4. Separate electrical connectors as needed. 5. Remove the rear bumper fascia.

Rear Bumper Impact Bar Replacement

Remove the rear bumper fascia. 1 Rear bumper energy absorber nut (Quantity: 6)

Front Compartment Side Rail Sectioning

Body Hinge Pillar Outer Panel Sectioning

Rocker Inner Panel Replacement

The rocker panel must be replaced if damaged and can not be repaired due to the Ultra high strength steel used.Please refer to the workshop manual for the full procedure.

Rear Side Rail Sectioning

The rear “chassis leg” can be partially replaced. Please see the workshop manual for the complete procedure.

Roof Front Header Panel Replacement

Front Suspension

– McPherson layout on subframe – Damping bushings between subframe and body

Note: Wheel bearing/hub bolts must be discarded and replaced if bearing/hub is removed.

Rear Suspension

– One type of rear axle – No adjustment possible

Note: Wheel bearing/hub bolts must be discarded and replaced if bearing/hub is removed.

Variable Steering System

The Variable Effort Steering (VES) system or MAGNASTEER varies the amount of effort required to steer the vehicle as vehicle speed changes.At low speeds the system provides minimal steering effort for easy turning and parking manoeuvres. Steering effort is increased at higher speeds to provide firmer steering(road feel) and directional stability.

The VES control module uses vehicle speed and steering wheel speed to com- mand a current that is most appropriate for each speed to the VES actuator.The actuator is a variable electromagnetic actuator.

At lowest speed, around 5 km/h the coils are polarised in such a way that the manetic forces are repelling each other and hardly any effort is needed to turn the steering.

At mid speed, around 70km/h no current is sent through the coils and steering is assisted by hydraulics only.At high speeds the coils are polarised in such a way that themagnetic forces are attracting each other and high effort is required to turn the ring magnet between them.

The VES control module has the ability to detect malfunctions in the actuator. Any malfunctions detected will cause the system to supply zero amps. Steering will be assisted by hydraulics only and a DTC is set.

Fuel Tank Assembly

Petrol filter is in tank and not a service item. The filter is part of the pump. Access to the fuel pump is via fuel tank removal. Tank Capacity is 60L.

Pedal Release System(PRS)

Orlando features the patented “pedal release system” (same as new Astra and Corsa D), where the clutch and brake pedal decouple(drop down) in the event of a severe frontal collision.

Jacking Positions

Caution: Lifting the vehicle improperly can damage the vehicle and result in costly repairs not covered by the warranty. Always lift the vehicle on the correct positions.

Front Lift Pads

When lifting the vehicle with a frame-contact lift place the front lift pads on the rocker outer panel weld flange, as shown

Rear Lift Pads

When lifting the vehicle with a frame-contact lift place the rear lift pads on the rocker outer panel weld flange, as shown

Electrical Harness

The vehicle uses a CAN bus wiring harness.The CAN Bus is an automotive bus developed by Robert Bosch, which has quickly gained acceptance into the automotive and aerospace industries. CAN is a serial bus protocol to connect individual systems and sensors as an alternative to conventional multi-wire looms. It allows automotive components to communicate on a single or dual- wire networked data bus up to 1Mbps.

General motors does not allow repairs to be carried out on this harness for safety reasons.

Since the early 1940's, automakers have continually improved their vehicles' technology by integrating an increasing amount of electronic components. As technology progressed, the vehicles became more complex as electronic components replaced mechanical systems and provided additional comforts, convenience, and safety features. Up until the release of CAN Bus, vehicles contained enormous amounts of wiring which was necessary to interconnect all of the various electronic components. An example of Can Bus wiring

Fuse Box Location

Left front of engine compartment Behind glove box

1. Ambient light/sunload sensor 10. Door lock switch- driver 2. Info Display model 11. Transmission shift lever 3. Radio Conrols 12. Cigarette lighter receptacle 4. Hazard warning switch 13. Park brake switch 5. Instrument cluster 14. Accessory power receptacle-centre console 6. Turn signal/Multifunction switch 15. Transmission shift lever indicator 7. Headlamp switch 16. HVAC controls 8. Windshield wiper/washer switch 17. Passenger airbag disable indicator 9. Steering wheel airbag 18. Passenger airbag disable switch

Main Electrical Component List

Name Location

Fuel pump and level sensor assembly Inside the fuel tank

A/C refrigerant pressure sensor Engine compartment,right side fan assembly

Wheel speed sensors front Front wheel hub

Wheel speed sensors rear Rear wheel hub

Clutch position sensor Inside vehicle on clutch pedal bracket assembly

Inside air temperature sensor In the HVAC assembly

Ambient air temperature sensor Left front vehicle bumper fascia

Ambient light/ sunload sensor Passenger compartment, top centre of dash board

Brake pedal position sensor Above the brake pedal

Hood ajar switch Front engine compartment hood latch

Intake air temperature sensor Engine compartment, Right rear corner

Rain sensor Top centre windshield

Body control module Passenger compartment, centre console

Electronic brake control module Engine compartment, top left rear

Engine control module To the left of engine

HVAC control module Passenger compartment behind centre console

Inflatable restraint sensing and diagnostic Under centre console behind gear lever module

Rear park assist control module Left side behind rear wheel well

Immobiliser control module Lower right side steering column

Brake booster pump motor Rear of engine compartment near booster

Passenger airbag disable indicator Centre of instrument panel

Windshield washer pump Below left headlamp assembly

Blower motor control module Behind instrument panel, part of HVAC module

Seatbelt anchor pretensioner L/R Lower outside of seats

Seatbelt retractor pretensioner L/R In the B pillar at the bottom

Important! This table is a summary, please consult the workshop manual for a full breakdown of the Master electrical component layout.

Diagnostic Link Connector(DLC)

Located on the right side of vehicle under the dash panel.

Instrument Panel Cluster

Only cosmetic and size difference, otherwise similar to Cruze

Infotainment

Infotainment uses the already familiar equipment from the Cruze.

CD 400 CD 500

Storage and media input

Release tab - slide upwards USB and 3mm stereo jack

Window Motor Programming – High Speed Function

Window Motor Standardization Sequence

Non-standardized window motors are no longer capable of high speed raising/lowering. Such cases may occur in following conditions.

1 When window motor is separated 2 When door harness is separated 3 When battery is separated or replaced

Note: The door must be completely closed prior to window normalization. The order in which the window motor is standardized is as follows: 1. Ignition switch in ON position. 2. Starting from the position where window is completely closed, maintain the power window switch in pressed condition until window is completely opened then continue pressing on the switch for approximately 5 seconds. 3. Pull on the power window switch until window is completely closed. After window has been completely closed, press down on the switch for approximately 5 seconds.

Window is now standardized and window is capable of performing high speed raise and lowering.

Window Motor Re-Learning Sequence

In relation to following conditions, there may be a need to perform re-learning sequence of the local interconnect network (LIN):

1 When window glass has deviated from the aligned condition 2 When window glass has been replaced 3 When door has been replaced 4 When window regulator has been replaced

Note: Prior to executing the re-learning sequence, the vehicle must be on its wheels and must be positioned on a flat surface and finally, all door must be completely closed. Window motor re-learning sequence is as follows: 1. Ignition switch in ON position. 2. Using the scan tool, select module failure diagnosis, body control module, and confi- guration/reset function then select to erase the applicable window learned values necessary for re-learning sequence of the window motor. 3. Following the learning sequence, completely escape from learning sequence of the scan tool. The power window cannot be normalized and will not be operational until completely escaped from the program. 4. Starting from the position where window is completely closed, maintain the power window switch in pressed condition until window is completely opened then continue pressing on the switch for approximately 5 seconds. 5. Pull on the power window switch until window is completely closed. After window has been completely closed, press down on the switch for approximately 5 seconds.

Window is now re-programmed.

Park Assist (PAS)

Overview

PAS is a system which detects location of objects using ultrasonic waves. The system measures the time it takes for the waves to return after reflecting off the objects and then converts the time into distance. The system then alerts the driver by soun- ding various alarms depending on distance between the vehicle and the obejct in the rear of the vehicle. Alarm for detected obstacle is sounded through the rear speaker connected to the radio silver box module via the LS-GMLAN communication circuit. If the PAS develops a fault, then the PAS warning light in the instrument panel is lit via the LS-GMLAN communication circuit and the fault code is stored in the PAS module. If the PAS module is replaced, the new PAS module should be programmed using the calibration data specific to the vehicle.

Component Mounting Position

PAS Component Locations

1. PAS Sensor: 4 mounted on rear bumper 2. PAS module: Inside the left side trim of the trunk 3. Body Control Module (BCM): Floor panel below the center of I.P 4. PAS Warning Light: Instrument Panel Cluster (IPC) 5. PAS warning alarm: Generated from the back seat speaker connected to audio system

PAS Module: Inside the left side trim of the trunk

PAS Sensor: 4 mounted on rear bumper

Right corner Right centre Left centre Left corner

PAS Operating Conditions

By turning on the ignition switch to “IGN”, PAS warning light on the instrument panel is lit and when no fault in the system is detected, then the light is turned off after 3 seconds. When gear lever is changed to “R” position, a signal is registered and the PAS becomes operational. Alarm is sounded if an object is within 30cm ~ 120cm range and there are total of 8 levels of alarm depending on the distance of the object.

Conditions in which PAS is not Operated

1. When reversing speed is greater than 8km/h 2. When the PAS warning light in instrument panel is lit

PAS Fault Diagnosis

Turn on the ignition switch, and if PAS warning light in the instrument panel is turned off after 3 seconds, then the PAS is working properly. If the light remains turned on or turns on while driving, then there is a fault in the system.

Restraint System

NCAP Rating

There is no official Euro NCAP rating yet for the Orlando as it has not been tested yet.It is expected to be a four star rating.That may sound surprising with all the safety features in the new Orlando, but NCAP is upgrading its ratings each year. That means that a vehicle that might have gained a five star rating in 2009 won’t necessarily receive one now.So Orlando isn’t necessarily any less safe than a vehicle which received a five star rating some time ago. Up to 2009 NCAP carried out three types of testing - Adult occupation protection, Child protection and pedestrian protection.It now also tests for whiplash neck injury protection in a rear impact.And it also now rewards seatbelt reminders and speed limiters and the standard fitment of electronic stability control. Orlando is expected to receive a four star rating.

Supplemental Inflatable Restraint Overview

The supplemental inflatable restraint (SIR) system supplements the protection of- fered by the seat belts. The SIR system contains an inflatable restraint sensing and diagnostic module (SDM), inflator modules, seat belt pretensioners (anchor and retractor), and impact sensors.

The SDM determines the severity of a collision with the assistance of side impact sensors located at strategic points on the vehicle. When the SDM detects a collision, the SDM will process the information provided by the sensors to further support air bag or pretensioner deployment. The SDM will deploy the air bags and pretensioners if it detects a collision of sufficient force. If the force of the impact is not sufficient to warrant inflator module deployment, the SDM may still deploy the seat belt pretensioners. The SDM contains a sensing device that converts vehicle velocity changes to an electrical signal. The SDM compares these signals to values stored in memory. If the signals exceed a stored value, the SDM will determine the severity of the impact and either cause current to flow through the frontal deployment loops deploying the frontal air bags and pretensioners, or it will deploy the pretensioners only. The SDM continuously monitors the deployment loops for malfunctions and illuminates the SIR system AIR BAG indicator if a fault is detected.The SDM performs continuous diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a DTC and inform the driver by il- luminating the SIR system AIR BAG indicator.

Passive Safety

Belt Pretensioners Seat Belt Height Seat Belt Force Limiters Adjustment

Crash sensors

Pedal Release System

Safety Steering Passenger Safety 6 Airbags ISOFIX System Column Cage

Saftey steering column - will colapse in the event of a frontal colision either from the impact of the drive colliding with the steering wheel or from the outside force pushing upwards on the column Pedal release system - lessens the risk of injures to the drivers feet and legs in a collision, by swinging the pedals upwards Crash sensors - not only for early warning in airbag deployment but to automatically unlock the doors in the event of an accident Seat belt pretensioners - to recude the slack in the seat belt in the event of an accident using a mcro gas generator to reduce the displacement of the passenger Seat belt height adjustment - to ensure correct fitment of the seat belt Seat belt force limiters - lessen the risk of upper body injuries by reducing the ma- ximum shoulder belt force above a certain threshold. ISOFIX child safety system - on second row seats features 2 lower anchors and 1 top tether anchor for robust installation of a child seat Six airbags - front, side and curtain Passenger saftey cage - High strength steel multi-crash load path structure for front and rear. Provides highly effective protection to occupants of the vehicle in the event of an accident. As part of this structure, high strength steel is used to protect the fuel tank, this reduces potential hazards caused by fuel escaping following a collision. The structure also includes highly efficient aluminium bumper reinforc- ments and systems to protect occupants from impacts in side-on collisions.

Airbag System Component

4 6

5 3

1 Driver-side Airbag Module

2 2 Passenger-side airbag module 3 Airbag control module (SDM) 4 Roof airbag module (Curtain) 5 Side impact sensor

1 6 Front impact sensor Additional components: 3 Side airbag module (embedded in the seat), Seat belt pretensioner (retractor type) Clock spring

Airbag Control Module (SDM) Airbag control module is installed on the inner floor panel of the front console box.

Airbag control Module(Sensing and Diagnostic Module)

The SDM is located in the centre of the vehicle(under the centre console) as this is one of the safest places for this crucial module to be located.It is reasonably safe from any side smash or front or rear collision. The module has to be replaced in the event of a front smash and the front airbags have deployed. In the event of a side smash and side airbags have deployed, it can be recoded(reset) up to three times.

Front Driver-side Airbag Module

Driver-side airbag module is mounted in the steering wheel by two C-clips.

Holes for detaching module

C-clip

Direction to which the C-clip is to be moved for detaching the module

Steering wheel position for detaching the module Position of the C-clip inside the steering wheel after detaching the module

Method for attaching/detaching driver-side airbag module

1 Rotate the steering wheel as shown in the drawing on the in the Figure 1. 2 Diagonally push in a small flat-head screwdriver, 15cm or less, into the hole (refer to #2 in the Figure 1) underneath the steering wheel. 3 At the position where the tension of the C-clip can be felt, press in the screwdriver so as to push the C-clip clockwise or counterclockwise and detach either side of the airbag module one at a time. 4 Airbag module can be attached by simply pushing the module into the steering wheel when the C-clips are in their normal positions.

Right Left side side

Detaching Detaching position Inserting position position & Inserting angle

Left Right Insertion angle and direction of turn for screwdriver side side depending on positions of the holes

Side Impact Sensor and Seat Belt Pretensioner

Side impact sensors and seat belt pretensioners (retractor type) are installed at the bottom of left and right “B” pillars in the interior of the vehicle.

Seat belt pretensioner

Photo: B pillar on the left side of the vehicle

Side impact sensor

Front Impact Sensor

Front impact sensor is installed on the top of the radiator electric fan inside the engine compartment.

Front impact sensor Securing bolt

Passenger Airbag de-activation switch

The front passenger airbag can be deactivated via a switch, a telltale light on the centre dash console illuminates to inform the driver of the deactivated airbag. The de-activation switch can be found on the left side of the dashboard(facing the front door)

Airbag Warning Light

1. Airbag warning light

When the ignition switch is turned ON, the SDM diagnoses the system and depending on the fault type as shown belwo in the table, controls the airbag warning light located in the instrument panel.

Fault Type Normal Not Programmed Fault

3.5 sec ON 0.5 sec ON 3.5 sec ON State of the airbag 1.5 sec OFF 0.5 sec OFF 1.5 sec OFF warning light Continuously OFF Continuously Repeat Continuously ON

2. Driver-side seat belt indicator and chime bell

The driver-side seat belt fasten warning lamp on the instrument panel is lit for 3.5 seconds (warning lamp inspection) when the ignition switch is turned ON regardless of whether or not the seat belt is fastened and when seat belt is fastened then the warning lamp is turned OFF. Afterwards, depending on whether or not the seat belt fastened, the seat belt warning light and chime bell are operated as shown in the below table.

When seat belt is fastened When seat belt is not fastened Condition Seat belt warning Seat belt warning Chime bell Chime bell light light

Ignition switched Flashes for 20 sec. OFF OFF Rings 6 times ON and then remain ON

Blinks for 35 sec. and Condition “A” OFF OFF Rings 35 times then remains ON

For Condition “A” the following 2 conditions must be met: 1. Seat belt not fastened for at least 50 seconds 2. Vehicle speed more than 25 Km or vehicle travels more than 250 m

Driver-side seat Airbag warning light belt warning light