Chevrolet Sonic

Chevrolet SonicModel Introduction Training For Approved Motor Body Repairers

CONTENTS

GENERAL

BODY

MECHANICAL

ELECTRICAL

4

13

25

28

30RESTRAINT SYSTEM

NoteThis self-study programme highlights the design and function of new vehicle models, new automotive components or new technologies.

The self-study programme is not a repair manual!All values given are intended as a guideline only.

For maintenance and repair work, always refer to the current technical literature.

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4 © 2012 General Motors Corporation. All rights reserved.

SONIC SEDAN

SONIC HATCHBACK

GENERAL

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5© 2012 General Motors Corporation. All rights reserved.

GENERAL

CHEVROLET SONIC HATCH LAUNCHED WITH THE CHOICE OF TWO MODEL

• Following on its first public showing in South Africa at the Johannesburg Interna-tional Motor Show,Chevrolets all new Sonic Hatch has now been officially launched by General Motors South Africa, GMSA.This exciting new small car from Chevrolet is available in LS trim with a choice of either a 1,4 litre or 1,6 litre petrol engines.

• The Sonic Hatch 1.4 LS is powered by Chevrolets new generation 1.4 litre four-cyl-inder double overhead camshaft engine with variable valve timing on both inlet and exhaust camshafts for an excellent balance between performance and econ-omy.This engine produces 74kW @ 6000 r/min with maximum torque of 130Nm @ 4000 r/min.The combined cycle fuel economy measured by Chevrolet engineers for this model is just 5,8 l/100km.

• The larger engine Sonic Hatch 1.6 LS also features a new generation four-cylinder

engine from Chevrolet,again, a 16-valve, dual overhead camshaft engine with vari-able valve timing for both inlet and exhaust.Maximum power for this engine is 85kW @ 6000 r/min with peak torque of 155Nm delivered at 4000 r/min. The combined cycle for this model, again as measured by Chevrolet engineers, is 6,5 l/100km.

• The Sonic 1.4 LS and 1.6 LS share a common specification level that offers an exceptional value proposition.

• The Chevrolet Sonic Hatch 1.4 and 1.6 LS are covered by a 5 year/ 120 000 kilo-metre warranty with roadside assistance for the full warranty period.The anti-corro-sion warranty provides cover for 5 years with no limit on kilometers driven.Service intervals are 15 000 kilometres or 1 year. A 3 year/60 000 kilometre Service Plan is included in the price.Available options (Comfort package) include an upgrade to the sound system that includes 6 speakers, a USB port,Bluetooth connectivity, and sat-ellite steering wheel mounted audio controls.Cruise control is also available as a fac-tory fitted option

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GENERAL

Specifications

• Alloy wheels fitted with 195/65 R15 tyres (a full size spare wheel is provided)

• Power steering.

• Height and reach adjustable steering column.

• Air conditioner.

• Power winders for the front windows.

• Heated rear windscreen.

• Power operated side mirrors with foldaway and heating functions.

• Tinted windows.

• Height adjustable drivers seat.

• Floor mounted console with cup holders.

• Sunglass holder.

• Driver and passenger vanity mirrors.

• RDS radio with front loading CD and MP3/Aux input and 4 speakers.

• On-board computer.

• ABS brakes with EBD (Electronic Brake Force Distribution).

• Front and side airbags for driver and front seat passenger.

• Passenger airbag de-activation switch.

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GENERAL

Interior

• The interior design and execution found in the new Sonic features a high level of craftsmanship and is styled to push the boundaries of the conventional design com-monly found in this segment.

The following provides interior point-by-point details:

• The mid-instrument panel surface is available in dark titanium and flows seamlessly into the upper doors. All are plastic-injection molded and carry a low gloss surface with textured three-dimensional technical grain.

• The upper instrument panel, upper door surfaces and lower surfaces are of a jet-black within contrasting (when compared to mid-IP), three-dimensional leather like grained surface;

• The shifter knob design features sporty sophistication and detailed execution. The manual shifter knob consist of a perforated polyurethane (PU) boot, PU head, and chrome-finished head with acrylic encapsulated cap;

• The HVAC outlets are of tubular shape, protrude from the IP surface, and are high lighted by Matte Silver ring finishes.

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Colour codes

GENERAL

Black Blue Topaz

Inferno Orange

Victory Red

Crystal Red

Summit White Silver Ice Metallic

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GENERAL

Wheels available on different models

15” Steel wheel cover Standard on LTZ

15” Painted Aluminium Standard on LS 5-Door

and LT

17” Painted Aluminium Standard on LS Sedan

and LT

Outside door handles

• Entry into the vehicle is provided by the matching body colour outside door han-dles.On hatchback models, the rear door handles are black and mounted flush to the body, giving a smooth flowing exterior appearance.

Lights

• The Sonic's quad-halogen reflector lamps have a sporty "high tech" design that offer, you,the driver excellent vision during night time driving conditions. These headlamps have no lens cover and the tail lamps offer the same style as do the headlamps.The hatchback and sedan have the same headlamps but have a little dif-ferent twist to the tail lamps to match the differences in the styling of these two cars.

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GENERAL

Lights variation

Front Rear Hatchback Rear Sedan

Hill-hold technology

• Makes navigating hilly terrain with a manual as effortless as an automatic, allowing drivers to get started without rolling back ward or forward.

• In a Sonic equipped with hill-hold, a pitch sensor detects the tilt of the body when the car is stopped on a slope and sends a signal to the stability control system. This triggers the electronically controlled brake hardware to keep the wheels clamped for up to two sec onds after the driver releases the brake pedal.

• It will retain the braking force that the driver applied with the chassis control system and hold the vehicle in place. That's long enough for the driver to safely apply the accelerator and let out the clutch for a smooth start, always heading in the right direction.

Instrument Panel Cluster

The IPC consists of a circular analogue tachometer on the left side and a Liquid CrystalDisplay (LCD) digital speedometer display on the right. The combination LCD/analoguedisplay provides all information in a digital/graphic format. A total of 12 circular insetsabove and below the LCD display contain ISO tell-tale driver information symbols. Allinstrument clusters include a digital fuel gauge, speedometer, and odometer/trip odom-eter. There is no engine coolant heat gauge provided.

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GENERAL

Maintenance Warning Indicators and Error Codes

• Certain vehicle faults or conditions cause the vehicle maintenance or warning indica-tor to illuminate.When one of these indicators illuminates the cluster shows a corre-sponding error code in the lower right corner.

Tell-tale/Warning Substituted

• High Mounted Brake Light Failure.

• Service Brake Lights

• Left Low Beam Failure

• Rear Fog Light Failure

• Right Low Beam Failure

• Left Front Position Light Failure

• Right Front Position Light Failure

• Reversing Light Failure

• License Plate Light Failure

• Left Front Turn Indicator Failure

• Left Rear Turn Indicator Failure

• Right Front Turn Indicator Failure

• Right Rear Turn Indicator Failure

• Hood Open (Start – Stop only)

• Tire Pressure Imbalance – Front (TPM only)

• Tire Pressure Imbalance – Rear (TPM only)

• Change Engine Oil Soon

• Engine Power Limited

Error Code

• 15

• 16

• 18

• 19

• 20

• 21

• 22

• 23

• 24

• 25

• 26

• 27

• 28

• 128

• 56

• 57

• 82

• 84

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General Specifications

Model Sonic Hatch1.4 LS Sonic Hatch1.6 LSSonic 1.6 LS

With comfort package

Power (kW) 74KW 85KW 85KW

Transmission 5 Speed 5 Speed 5 Speed

Auto Door Locks Std Std Std

Seatbelt Warning D+P D+P D+P

Rim & Type 15" Alloy 15" Alloy 15" Alloy

Power Windows Front Front Front

Cruise Control Opt Opt Std Part of Comfort Package

ABS & EBD Std Std Std

Brake Assist No No No

Driver & Passenger Airbags Std Std Std

Front Seat Side Air-bags Std Std Std

Air Conditioner Std Std Std

Central Locking Remote Remote Remote

Alarm Std Std Std

Immobiliser Std Std Std

Radio/CD/MP3 Std Std Std

Steering Wheel Con-trols Opt Opt Std Part of Comfort

Package

USB Port Opt Opt Std Part of Comfort Package

Bluetooth Opt Opt Std Part of Comfort Package

Speakers 4 4 6 Part of Comfort Package

GENERAL

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Bodyframe

The new 2012 Chevrolet Sonic comes with an array of safety features and sophisti-cated electronic control systems engineered to make it one of the safest vehicles in the small-car segment.

The safety cage is reinforced with welded tubular-section members that frame thedoor openings and support the roof. Beam reinforcements are fitted to the doors. The combination of a single piece door aperture and door beam reinforcements provides protection in the event of a side impact. Additional protection for side impacts comes from the use of ultra-high-strength steel in the strategic area around the forward portion of the side rockers and the center cross member.

Body

Reinforcements to this area, situated directly under the front seats, have an H formto provide excellent resistance to structural deformation.

Nearly 60 percent of the body structure, as well as the four-mount hydro-formed engine cradle,uses high-strength steel. Ultra-high-strength steel is strategically integrated in the forward portion of the rockers and the center cross bar. The Sonic's engine cradle distributes energy in frontal and side impacts. Together with the front bumper system and the engine compartment rails, the engine cradle bars absorb thebrunt of a frontal crash.

The next line of defense in the event of a front impact is a transition zone that consists of the A pillars and the instrument panel beam. This structure is designed todistribute energy around the passenger cell.

The floor pan, rocker panels, center tunnel, A- and B- pillars, and front mid-rails forma safety cage that supports the frontal crush zone and directs energy away from thepassenger area.

At the rear of the Sonic the focus is on providing protection for the fuel tank and itsconnections to avoid ruptures and spillage in the event of a rear end collision. Like thefront of the vehicle, the rear end incorporates a crush zone designed to absorb impactenergy.

Additional protection is provided by the strong rear suspension cross member. Thiselement of the vehicle assists in directing impact energy through to the side rockerpanels after the rear longitudinal crush structures have done their work to absorb theinitial forces. While most crash standards are based on rear impacts at a speed of 50km/h, General Motors safety standards raise this limit to 80km/h.

BODY

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BODY

Chevrolet Sonic Safety:

The backbone of Sonic's safety design is its exceptionally strong body structure consisting of a single welded unit of full-length, high-strength frame rails and a safety cage. Welded tubular-section members are used to frame door openings and to support the roof while steel members reinforce the doors.Nearly 60 percent of the body structure, as well as the four-mount hydro-formed engine cradle, uses high-strength steel. Ultra-high-strength steel is strategically integrated in the forward portion of the rockers and the center cross bar. The Sonic's engine cradle distributes energy in frontal and side impacts. Together with the front bumper system and the engine compartment rails, the engine cradle bars absorb the brunt of a frontal crash.Reinforced front hinge and A- and B-pillar zones help maintain the integrity of the passenger compartment. Should the vehicle roll over in a crash, its roof structure is designed to withstand forces more than four times the car's weight. A releasable pedal assembly can reduce the risk of injuries to the lower extremities.Sensors that control the deployment of 10 standard airbags is mounted into Sonic's structure. The sensing and diagnostic module receives data from the car's sensors and establishes the severity of the impact and whether to deploy the airbags.

The Sonic features:• Dual-stage airbags for the driver and the front passenger• Roof-rail mounted head curtain airbags with rollover protection. The bags stay

inflated longer than air bags developed only for side impacts, since rollover incidents can last longer. They also help keep occupants from being ejected.

• Seat mounted side-impact airbags for front and outboard rear seat passengers are activated by sensors in the B-pillar and front door impact beams

• A driver knee air bag and a segment-exclusive front passenger knee air bag can help reduce injury to lower extremities.

If the Sonic's onboard sensors register that the vehicle "tips up" on a flat road surface,the brakes are activated to reduce lateral force.

All five seating positions have three-point safety belts. Front safety belts include pretensioners and load limiters.The outboard rear seating positions are equipped with a LATCH system to help make attaching child seats easier.

Pedestrian protection has been designed into the Sonic with refinements to the bonnetdesign and hinge structure incorporated to reduce the possibility of injuries caused by apedestrians head or body impacting on the engine. This type of contact has been identified as a major source of serious injury in pedestrian accidents.

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BODY

Reinforced front hinge and A- and B-pillar zones help maintain the integrity of the pas-senger compartment.Should the vehicle roll over in a crash, its roof structure is designed to withstand forces more than four times the car's weight.A releasable pedal assembly can reduce the risk of injuries to the lower extremities.Effective crash impact energy management has been designed into the new Chevrolet Sonic starting with front and rear crumple zones that manage and absorb the initial im-pact energy in the event of a collision to help maintain the integrity of the passenger compartment.The front crush zone is made up of the engine compartment side rails and the frontbumper system together with the engine sub-frame. These elements are designed to take the brunt of the impact energy in a frontal collision. The engine compartment side rails are made of high-strength steel and will absorb energy whilst maintaining a high load capability as they collapse.The hydro-formed engine sub-frame has four mounting points and is designed to progressively deform as it absorbs impact energy whilst re-taining a high load bearing capability. This ultra-high strength structure assists in redi-recting impact energy as it deforms and is a key component in meeting the rigorous Euro NCAP 5-star standards.By increasing the space available between the engine and the bonnet, and by addressing the way in which the bonnet deforms on impact, the potential for serious injuries caused by contact with the engine and other “hard” under bonnet components has been signif-icantly reduced. The front bumper of the Sonic incorporates a foam energy absorber which surrounds the main bumper beam and lower bumper reinforcements to assist in cushioning pedestrian impacts. The front and rear bumpers are engineered to require only minimal repairs following a minor impact at a speed of up to 4 km/h. Tests conducted to verify this performance include a head on impact with a flat barrier; 30-degree impact with a flat barrier, and rear straight-on impact with a flat barrier.

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BODY

Rear View

Number Description Material

1 Rear End Panel Mild Steel

2 Tail Lamp Pocket Mild Steel

3 Rear Side Door Outer Panel Mild Steel

4 Front Side Door Outer Panel Mild Steel

5 Underbody Rear Side Rail High Strength Low Alloy Steel

6 Rear Compartment Floor Panel Mild Steel

7 Rear End Lower Panel Reinforcement High Strength Low Alloy Steel

8 Rear End Lower Panel Reinforcement Extension

Ultra High Strength Dual Phase Steel

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BODY

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Number Description Material

1 Front Compartment Side Rail (Front)

Inner Side Rail - High Strength Low Alloy Steel Outer Side Rail - High Strength Low Alloy Steel

2 Front Wheelhouse Panel Rein-forcement Mild Steel

3 Front Wheelhouse Front PanelFront Wheelhouse Front Panel - Mild Steel Front Suspension Strut Housing - High Strength Low Alloy Steel

4 Front Compartment Side Rail (Rear) High Strength Low Alloy Steel

5 Roof Front Header Panel Ultra High Strength Steel

6 Roof Outer Panel Mild Steel

7 Roof Rear Inner Panel Mild Steel

8 Centre Pillar Inner Panel Dual Phase Steel

9 Body Lock Pillar Inner Reinforce-ment Mild Steel

10 Rear Wheelhouse Outer Panel Mild Steel

11 Centre Pillar ReinforcementCentre Pillar - High Strength Low Alloy Steel Centre Pillar Upper - Dual Phase Steel Centre Pillar Lower - High Strength Low Alloy Steel

12 Quarter Outer Panel Mild Steel

13 Centre Pillar - Outer Mild Steel

14 Rocker Outer Panel Mild Steel

15 Body Hinge Pillar Upper Reinforce-ment High Strength Low Alloy Steel

16 Body Hinge Pillar Lower Reinforce-ment High Strength Low Alloy Steel

17 Rocker Inner Panel Ultra High Strength Dual Phase Steel

18 Body Side Frame Rocker Rein-forcement Ultra High Strength Dual Phase Steel

19 Front Compartment Upper Side Rail High Strength Low Alloy Steel

BODY

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Front Hinge Pillar Body Sectioning

1. Create cut lines (1) on the front hinge pillar body2. Cut the panel where sectioning is to be performed3. Locate and mark all the necessary factory welds of the front hinge pillar body.4. Drill all the factory welds. Note the number and location of welds for installation of

the service assembly5. Remove the damaged front hinge pillar body6. Cut the front hinge pillar body in corresponding locations to fit the remaining original7. panel. The sectioning joint should be trimmed to overlap the remaining original8. panel by 25mm at each joint location.

BODY

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Roof Outer Panel Replacement

1. Locate and mark all factory welds2. Drill all factory welds (1). Note the number and location of welds for installation of

the service assembly3. Cut the adhesive with an appropriate tool4. Remove the damaged roof panel.5. Drill 8mm holes for plug welding along the edges of the service panel as noted from

the original panel6. Clean and prepare the attaching surfaces for welding.7. Apply one-part windshield urethane adhesive as noted from the original panel8. Position the roof panel (1) on the vehicle9. Verify the fit of the panel.10.Clamp the panel into position11.Plug weld accordingly12.Apply the sealers and anti-corrosion materials to the repair area, as necessary.

BODY

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Rocker Inner Panel Replacement

1. Locate and mark all the necessary factory welds of the rocker inner panel2. Drill all factory welds (1). Note the number and location of welds for installation of

the service assembly3. Remove the damaged rocker inner panel4. Drill 8mm holes for plug welding along the edges of the quarter outer panel as noted

from the original panel5. Clean and prepare the attaching surfaces for welding6. Position the rocker inner panel on the vehicle7. Verify the fit of the panel.8. Clamp the rocker inner panel into position.9. Plug the weld accordingly10.Apply the sealers and anti-corrosion materials to the repair area, as necessary.

BODY

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Quarter Panel Removal Procedure

Removal Procedure:

1. Disable the SIR System.2. Disconnect the negative battery cable.3. Remove all related panels and components4. Visually inspect the damage. Repair as much of the damage as possible.5. Create cut lines on the quarter outer panel6. Cut the panel where sectioning is to be performed7. Locate and mark all the necessary factory welds of the quarter outer panel8. Drill all factory welds (1). Note the number and location of welds for installation of

the service assembly9. Remove the damaged quarter outer panel

Instalation Procedure:

10.Cut the quarter outer panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to overlap the remaining original panel by 25mm at each joint location

11.Prepare all mating surfaces as necessary12.Drill 8mm holes for plug welding along the edges of the quarter outer panel as

noted from the original panel13.Clean and prepare the attaching surfaces for welding14.Position the quarter outer panel on the vehicle15.Verify the fit of the quarter outer panel16.Clamp the quarter outer panel into position17.Plug weld accordingly18.To create a solid weld with minimum heat distortion, make 25mm stitch welds

along the seam with 25mm gaps between them. Then go back and complete the stitch weld.

BODY

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BODY

Front Bumper Fascia Removal

1. Remove the radiator opening upper cover2. Remove the front bumper opening lower cover3. Remove the front wheelhouse front liner4. Disconnect the ambient air temperature sensor from the lower grille5. Front Bumper Fascia Screw (Qty: 2)6. Front Bumper Fascia Lower Screw (Qty: 2)7. Front Bumper Fascia

Procedure:8. Carefully push a small nylon wedge between the fascia and the bracket. Insert a

small flat-bladed tool into the fascia slot and depress the tabs one at a time and pull on the fascia at the same time to gradually remove the fascia from the bracket

9. Disconnect the electrical connectors.10.On reassembly of the front fascia to the vehicle, ensure the 4 support retainers on

the inside of the radiator grille bumper are in position to the front bumper fascia cen-ter support bracket.

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BODY

Rear Bumper Fascia Removal

1. Remove the screws from the rear wheelhouse liners to the rear fascia2. Disconnect the rear electrical connectors3. Rear Fascia Screw (Qty: 2)4. Rear Fascia Lower Push-In Retainer (Qty: 2)

Procedure:5. Carefully push a small nylon wedge between the fascia and the rear fascia

guide.Insert a small flat-bladed tool into the fascia slot and depress the snaps one at a time and pull on the fascia at the same time to gradually remove the fascia from the rear fascia guide

6. Transfer parts as needed

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Engines

The 1.4L 16-valve engine offers the following technological highlights:

• silent chain cam drive• close-coupled catalytic converter• variable displacement oil pump (for improved fuel economy and less engine power

losses)• double continuously variable camshaft phasing (DCVCP)• coil-on-plug ignition• intake manifold port de-activation system (PDA)

A stainless steel fabricated exhaust manifold provides optimal exhaust flow characteristics and enhanced durability. The exhaust manifold includes an integrated,ose-coupled catalytic converter for enhanced emission performance. The 1.4 enginefeatures hollow, cast crankshafts that reduce rotating mass.

MECHANICAL

* 1.3 Diesel will be introduced at a later stage.

Engine 1.4 1.6 1.3D*

Bore (mm) 73.4 79 69.6

Stroke (mm) 82.6 81.5 82

Capacity (cc) 1398 1598 1248

Compression Ratio 10.5 10.8 16.8

Valve Train DOHC DOHC DOHC

Cylinders 4 4 4

Fuel System Multi-point injection Multi-point injection Multi-point injection

Power (kW @ r/min) 74 @ 6000 85 @ 6000 70 @ 4000

Torque (Nm @ r/min) 130 @ 4000 155 @ 4000 210 @ 1750-2500

The 1.3L turbo diesel engine calibrated to 70 kW is equipped with a high-performance common rail fuel injection system and ad-vanced electronically controlled variable ge-ometry turbocharger (VGT) with intercooler. The engine represents the first diesel offering on a Chevrolet small car in South Africa.

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MECHANICAL

Transmissions

Shift Mechanisms:

Global Small Vehicles are only equipped with cable shift systems in order to ensure pre-cise gear selection and shifting.

D16 Manual transmission:

The D16 five-speed manual transmission matches the 1.6L gasoline engine, and is a two-shaft,constant mesh, transverse design in a one-piece, aluminium die-cast housing that enables a compact and lightweight design. The D16 incorporates a synchromesh system with triple cone synchronizers for first and second gears. Carbon friction mate-rial is used at the first/second and third/fourth synchronizers. These synchronizersenhance low gear engagement for smooth and easy launch and shifting characteristics.Needle bearings for all gears ensure low friction gear meshing and shifting.

D16 Five-Speed Manual transmission

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MECHANICAL

Z-Link Rear Suspension System

The 2012 Chevrolet Sonic features a patented rear suspension, design that incorporates a torsion beam-compound crank rear axle with Watts Link linkage systemfor better side-to-side wheel control for greater stability and handling response. Atuning element tube is welded to the trailing arms also using a patented helical welding process and attached to the body through new hydraulic ride bushings for superior road noise and vibration isolation.

Electric Power Steering

Electronic power steering is standard, and eliminates the need for steering fluid and a pump needed with hydraulic systems. It features a wear compensator that continually adjusts the system interaction with the steering gear to ensure precise steering action over the life of the system.

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Infortainment

Multimedia Player Interface Module (MPIM):

Some of the models are equipped with a Multimedia Player Interface Module (MPIM).This module can receive signals via the USB connector, the auxiliary audio input jack ora Bluetooth connection.This module receives the incoming signals, and then sends thesignals as analogue audio inputs to the radio. The MPIM and the radio communicatethrough the low speed GMLAN network. On some models, the MPIM allows the radio tocontrol certain portable media devices, such as USB storage devices, iPod and Bluetoothaudio devices.

Audio System: The Global Small Vehicle radio is available in two styles, the Black Tie radio, or the Poke Thru radio. Both radios use the Low Speed (LS) GMLAN network to communicate with the other modules in the vehicle. All radios feature a liquid crystal display, an AM/FM tuner, and an auxiliary input jack and are available with a CD player. The driver can set the start-up volume which the radio will play at when the ignition is switched on. The start-up volume at start up is set through the configuration menu.

To enable this feature, the operator performs the following steps:1. Enter the configuration menu and set the maximum start-up volume using the menu

dial.2. Turn the ignition OFF and remove the key.3. Wait 15 seconds.

ELECTRICAL

Poke Thru RadioBlack Tie Radio

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Window Motor Normalized Procedure:

A window motor that has not been normalized will no longer perform the express up and express down functions, this may occur during the following conditions:

• When a window motor has been disconnected• When a door harness has been disconnected• When the battery has been disconnected or replaced

To normalize the window motor, follow these steps:

• Ignition ON.• Starting with the window completely UP, press and hold the power window switch

until the window is fully open and continue holding the switch down for approxi-mately 5 seconds after the window is completely open.

• Pull the power window switch up until the window is fully closed and continue hold-ing the switch up for approximately 5 seconds after the window is completely closed.

• The window should now be normalized and the window should perform the express up and express down functions.

To relearn the window motor, follow these steps:

• Ignition ON.• With a scan tool, select Module Diagnosis, Body Control Module, Configuration/

Reset Functions and then select the appropriate Clear Window Learn Values for the window motor requiring the relearn procedure.

• After the learn procedure, exit the scan tool learn procedure completely, the power window cannot be normalized and will not function until you exit the program.

• Starting with the window completely UP, press and hold the power window switch until the window is fully open and continue holding the switch down for approxi-mately 5 seconds after the window is completely open.

• Pull the power window switch up until the window is fully closed and continue hold-ing the switch up for approximately 5 seconds after the window is completely closed.

The window is now reprogrammed.

ELECTRICAL

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SIR Service Precautions

Warning: When performing service on or near the SIR components or the SIR wiring, the SIR sys-tem must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, per sonal injury, or unnec-essary SIR system repairs.

The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved en-ergy supply. The reserved energy supply provides deployment power for the SIR air-bags. Deployment power may be available for up to 60 seconds after disconnecting the vehicle power. Disabling the SIR system prevents deployment of the SIR air bags from the reserved energy supply.

Note: The following are general service instructions which must be followed in order to prop-erly repair the vehicle and return it to its original integrity:

• Do not expose air bags to temperatures above 65°C• Verify the correct replacement part number. Do not substitute a component from a

different vehicle• Use only original GM replacement parts available from your authorised GM dealer.• Do not use salvaged parts for repairs to the SIR system

Note: Discard any of the following components if it has been dropped from a height of 92 cm (3 ft) or greater:

• SDM• Passenger instrument panel air bag• Driver steering wheel air bag• Driver steering wheel air bag coil• Roof rail air bags• Front and /or side impact sensors• Seat belt achor and/or retractor pretensioners• Front seat side air bag

RESTRAINT SYSTEM

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Airbag Component Location

1. Passenger Instrument Panel Air Bag--Located at the top right under the instrument panel

2. Inflatable Restraint Sensing and Diagnostic Module (SDM)--Located underneath the centre console

3. Passenger Seat Belt Retractor Pretensioner--Located under the center pillar trim near the bottom

4. Right Front Side Impact Sensor (SIS)--Located under the center pillar trim near the bottom

5. Passenger Seat Side Air Bag--Located on the seat back of passenger seat6. Rear Compartment Lid Assist Rod--A gas shock is located under the rear trunk lid on

the passenger side (Hatchback Models)7. Rear Compartment Lid Assist Rod--A gas shock is located under the rear trunk lid on

the driver side (Hatchback Models)8. Driver Seat Side Air Bag--Located on the seat back of driver seat9. Left Front Side Impact Sensor (SIS)--Located under the center pillar trim near the

bottom10.Driver Seat Belt Retractor Pretensioner--Located under the center pillar trim near

the bottom11.Driver Steering Wheel Air Bag--Located on the steering wheel12.Vehicle Battery--Located under the hood on the right side

RESTRAINT SYSTEM

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RESTRAINT SYSTEM

Front End Inflatable Restraint Discriminating Sensor Replacement

Disable the supplemental inflatable restraint (SIR) system.Remove the radiator opening upper cover.Procedure:1. Disconnect electrical connector2. Loosen the bolts and slide the sensor out of the keyhole slots.3. The bolts are integral to the sensor assembly and DO NOT remove separately

Inflatable Restraint Side Impact Sensor Replacement

Preliminary Procedures:1. Disable the SIR system2. Remove the center pillar lower trim panel3. Disconnect electrical connector4. Loosen the fasteners and slide the sensor out of the keyhole slots.5. The bolts are integral to the sensor assembly, DO NOT remove separately

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NOTES:

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NOTES:

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Pedestrian Protection

The bumper provided good protection to pedestrians' legs in most areas, but was poorin places. The front edge of the bonnet provided poor or marginal levels protection.In most areas where the head of child might strike, the bonnet provided good protection. However, for an adult, the windscreen base and the A-Pillars offered predominantly poor levels of protection.

Safety Assist

Electronic stability control is fitted as standard equipment. The front seating positions have a seatbeltt reminder as standard. A reminder system is also available as an option for the rear seats; as it is expected to be fitted as standard equipment in the great ma-jority of sales, the system qualified for assessment by Euro NCAP.

RESTRAINT SYSTEM

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Adult occupant

The passenger compartment remained stable in the frontal impact, the windscreen pillar being deformed rearward only 3mm after the test. There was no excessive deformation of the driver's footwell or dangerous tearing of the metal. Dummy results indicated good protection of the knees and femurs for the front seat occupants. Additional tests showed that a similar level of protection would be offered to occupants of different siz-es and to those sat in different positions. In the side impact barrier test, the car scored maximum points for the protection it offered the driver. However, in the more severe side pole impact, deformation of the dummy's ribs indicated weak protection of the chest area. The seat and head restraint provided good protection against whiplash inju-ries in a rear-end impact.

Child occupant

Opel recommend an unusual method of installation for the restraint of the 3 year infant:as well as being fitted using the ISOFIX and top tether anchorages, the adult seatbelt isalso used to secure the restraint. Meriva owners should be aware that this is the methodof installation used by Euro NCAP in its tests and that the scores and ratings given tothe car reflect the performance of the restraint when used in this way.Forward move-ment of the 3 year dummy in the frontal impact was not excessive. In the side impact,both the 18 month and 3 year dummies were properly contained by the protective shellsof their restraints.The passenger airbag can be disabled to allow a rearward facing childrestraint to be used in that seating position.However,information provided to the driverabout the status of the airbag is not sufficiently clear.A permanently attached label warns clearly of the dangers of using a restraint in that position without first disablingthe airbag.

18 MONTH OLD CHILD Installation ADULT SEATBELT

3 YEAR OLD CHILDInstallation ISOFIX ANCHORAGE AND

TOP TETHER

RESTRAINT SYSTEM

TRAINING


Curtain Airbag Deployment

The curtain airbag system triggers in case of a side-on collision and provides a safety barrier in the head area on the respective side of the vehicle.This reduces the risk of injury to the head considerably in case of a side-on collision.

Active Head Restraints

In the event of a rear-end impact, the active head restraints automatically tilt forward a little. The head is more effectively supported b y the head restraint and the danger of injuries caused by whiplash in the neck area is reduced Active head restraints are iden-tified by the lettering ACTIVE on the head restraint guide sleeves.

RESTRAINT SYSTEM

TRAINING


Front passenger’s seat with seat occupancy recognition system. The seat occupancyrecognition system deactivates the passenger’ s front and side airbags if the frontpassenger’s seat is unoccupied, or a Opel child restraint system with transponderhas been fitted to the front passenger’s seat.

Frontal Airbag Deployment

A frontal collision of sufficient force will deploy the frontal air bags and/or pretensioners.The SDM contains a sensing device that converts vehicle velocity changes to an elec-trical signal. The SDM compares these signals to values stored in memory. If the signalsexceed 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 airbagsand pretensioners, or it will deploy the pretensioners only. The SDM, instrument panelmodule, steering wheel module, steering wheel module coil, seat belt retractor preten-sioners, and the connecting wires make up the frontal deployment loops. The SDM con-tinuously monitors the deployment loops for malfunctions and illuminates the airbag indicator and/or a message in the driver information center if a fault is detected.

Side Impact Airbag Deployment

The side airbag is triggered in the event of a side-on collision to form a safety cushion for the driver or front passenger in the respective door area.This substantially reduces the risk of injury to the upper body and pelvis.

RESTRAINT SYSTEM

TRAINING


Airbag Deployment

•3 rear 3 point seatbelts•Airbag deactivation switch•Curtain airbags•Driver/Front Passenger airbags•Electric child locks•Fasten seatbelt reminder

RESTRAINT SYSTEM

•Front seatbelt pretensioners + load lim-iters

•Height adjustable front seatbelts•Pedal release system•Rear seatbelt warning indicator•Seatbelt reminders for driver and front

The supplemental inflatable restraint (SIR) system supplements the protection offered by the occupants Seat Belt System. The SIR system may contain several inflator mod-ules located throughout the vehicle, i.e. steering wheel module, instrument panel mod-ule, side impact module or roof rail modules. In addition to inflator modules, the vehiclemay contain seat belt pretensioners that tighten the seat belt in the event of a collision,thus reducing the distance between the occupant and the seat belt when an inflator module is deployed. Each inflator module has a deployment loop that is controlled bythe sensing and diagnostic module (SDM) mounted inside the vehicle. The SDM deter-mines the severity of a collision with the assistance of various sensor inputs located atstrategic points on the vehicle. When the SDM detects a collision, it will process theinformation provided by the sensors to further support air bag or pretensioner deployment. The SDM will deploy the frontal air bags and pretensioners if it detects a collisionof sufficient force. If the force of the impact is not sufficient to warrant inflator moduledeployment, the SDM may still deploy the seat belt pretensioners. The SDM performscontinuous diagnostic monitoring of the SIR system electrical components. Upon detec-tion of a circuit malfunction, the SDM will set a DTC and inform the driver by illuminat-ing the air bag indicator and/or a message in the driver information center. The steering column are designed to absorb energy and compress during frontal collisions in order to decrease the chance of injury to the driver and passenger.

TRAINING


Flexy-Door Layout Front and Rear

Rear Flexy-Doors Lock Function

•Mechanical Child Lock (M-Child Lock / MCL) function•M-Child Lock lever engaged

Rear Flexy-Doors Lock Functions (ff)

Door Ajar function•Door Ajar Microswitch engaged

Door Ajar Microswitch engaged•Latch is open

ELECTRICAL

TRAINING


Parking Assist

Object Detection systems

•Parking assist makes parking easier•Still the drivers full responsibility•Four ultrasonic sensors in the rear•Front system consists of four additional sensors

Activation•By shifting into reverse gear •Separately by a switch•LED in switch is illuminated

Deactivation•By a speed threshold•The switch in the centre of the console•LED will go out

ELECTRICAL

TRAINING


Infortainment

Stay well informed, connected and entertained with the infotainment systems in the Opel Meriva. Its equipped with a CD Player & Aux-in connection as standard or you can choose the optional CD500 which includes an advanced navigation system with large colour display. Available on SC & SE models.•CD player with MP3 capability (standard)•Dual tuner for excellent reception (standard)•Aux-in to connect portable digital sound sources directly (standard)•Dynamic navigation with RDS-TMC on 7" colour display (optional with SC & SE

trims)•Bluetooth™ and mobile specific cradles for safe and convenient phone use (optional).

Adaptive Forward Lighting (AFL)

Night driving always has the potential to generate stress. Opel Meriva´s advanced hal-ogen AFL system projects the headlamp beam into bends, with extra side illumination in tight corners. The result? Less stress, more safety and driving fun.Depending on speed and steering input, the headlights swivel up to 15° in bends in ei-ther directionAdditional projectors are automatically activated, providing 90° side illumination on cor-ners and tight bendsTo assist the driver’s orientation when parking, the static cornering light goes on to il-luminate the parking area when reversing

ELECTRICAL

TRAINING


Manual Transmission

This 5-speed transmission assembly is a transmission of constantmesh design

•Combined in the assembly are•All forward gears•The reverse gear•The differential output

The manual transmission identification num-ber is attached to thetop of the transmission case near the en-gine.

Flex-Fix Bicycle Carrier

The popular Flex-Fix integrated rear bicycle carrier is now available for Meriva custom-ers. It can carry up to two bicycles and slides out from behind the rear bumper. It is fully integrated and, when not in use, is virtually invisible behind the rear bumper fascia.the carrier is easy to use and requires no special tools or additional components. Flex-Fix allows Meriva customers to carry a bike at any time, without having to plan in advance or drive around with a rack fitted when it’s not required.

MECHANICAL

TRAINING


Opel Meriva 1.4 Engine

Meriva Turbo Engine

All together, these measures reduce the 1.4 turbo fuel consumption – compared with the previous 1.8-liter version, also with 103 kW/140 hp – by two liters in the sedan to 5.7 liters per 100 kilometers. CO2 emissions are reduced by 45 grams to 134 grams per kilometer – in both cases a reduction of more than 25 percent. At the same time, the torque delivered by the most economical gasoline engine in its class was increased by almost 15 percent to 200 Nm.

MECHANICAL

TRAINING


Body Side Inner Panel Sectioning

Remove the quarterouterpanel

Locate and drill out all of the necessary factory weldsRemove the body lock pillar lower reinforcement

BODY

TRAINING


Roof Front Header Panel Replacement

1.Remove the roof outer panel2.Locate and drill out all of the necessary fac-

tory welds3.Remove the damaged roof front header

panel

4.Clean and prepare the attaching surfaces for welding

5.Apply bodywork repair through structural adhesive to body

6.Position the roof front header panel on the vehicle7.Verify the fit of the roof front header panel8.Clamp the roof front header panel into position9.Spot weld accordingly10. Apply the sealers and anti-corrosion materials11. Install the roof outer panel.

BODY

TRAINING


Center Pillar Sectioning

Remove centre pillar as per the repair manual.

1.Remove all related panels and components2.Remove the front side door3.Remove the rear side door4.Remove the driver or passenger seat belt retractor5.Visually inspect the damage6.Remove the sealers and anti-corrosion materials from the repair area, as necessary

BODY

TRAINING


Body Hinge Pillar Outer Panel Sectioning

1.Remove the front side door2.Remove the front fender Remove the

front side door upper and lower hinge3.Visually inspect the damage. Repair as

much of the damage as possible.4.Remove the sealers and anti-corrosion

materials from the repair area, as nec-essary.

5.Create cut lines (1) on the body hinge pillar outer panel6.Locate and mark all the necessary factory welds (1) of the body hinge pillar outer-

panel.7.Drill out all of the necessary factory welds8.Remove the damaged body hinge pillar outer panel.

BODY

TRAINING


Front Compartment Side Rail Sectioning

1.Locate and drill out all of the necessary factory welds

2.Locate and drill out all of the necessary factory welds at the battery tray

3.Remove the battery tray4.Create a cutline (1) at the front com-

partment front rail5.Remove the damaged front compart-

ment side rail

BODY

TRAINING


Front Bumper Energy Absorber Replacement

1.Disable the SIR System.2.Disconnect the negative battery cable.3.Remove the front bumper impact bar.4.Remove the four front bumper energy absorber fasteners.5.Locate and mark all of the clinch spots.6.Create a cut line (1) on the head lamp mount panel.7.Cut the head lamp mount panel at the cut line (1).8.Drill out the clinch spots (1).9.Remove the front bumper energy absorber.10.Position the front bumper energy absorber on the vehicle. The front bumper energ-

yabsorber has to be positioned underneath the head lamp mount panel

1.Install the four front bumper energy absorber fasteners (1) and tighten to the front-bumper energy absorber anchor plate

2.Install the front bumper impact bar3.Apply the sealers and anti-corrosion materials to the repair area, as necessary4.Paint the repaired area5.Connect the negative battery cable.6.Enable the SIR system

BODY

TRAINING


Rear Bumper Fascia Replacement

1.Remove the tail lamps2.Release the rear multifunction carrier splash shield3.Rear Bumper Fascia Fastener (Qty: 6)Tip: Reach underneath the wheelhouse to access the fastener4.Rear Bumper Fascia Retainer (Qty: 3)

Procedures:5.Disconnect any electrical connectors as needed6.Pull gently on the sides of the rear bumper fascia to disengage from the quarter

outer panel.7.Transfer any parts as needed

BODY

TRAINING


Front Bumper Fascia Replacement

1.Front Bumper Fascia Fastener (Qty: 6)2.Front Bumper Fascia Fastener (Qty: 6)Tip: Reach underneath the wheelhouse to access the fastener.3.Front Bumper Fascia Fastener (Qty: 2)4.Front Bumper Fascia Plastic Retainer (Qty: 3)

Procedure:5.Disconnect any electrical connectors6.Disconnect the hose from the front bumper fascia7.Transfer components as necessary

BODY

TRAINING


Interior Features

•12V power point for rear passengers•12V power point front•2 height adjustable rear headrests•Air conditioning•Ambient Lighting•Auxiliary input socket•Boot light•CD400 Radio/MP3 compatible CD player

+ graphic information display•Centre console with cupholders•Courtesy lights•Driver seat height adjustment•Driver sunglasses holder•Driver/passenger sunvisors and vanity

mirrors•Flex floor multi-level adjustable load

compartment•Flex5 seating

•FlexRails with sliding tray cup holder•Front centre dome lamp•Front head restraints•Front reading lights•Front seat back map pockets•Instrument lighting dimmer•Isofix system on outer rear seats•Passenger assist handle with coathook•Pollen filter•Rake/reach adjustable steering wheel•Rear door pockets•Rear reading lights•Rigid loadspace cover•Skyline/Atlantis cloth upholstery•Split folding 2nd row - 40/20/40•Steering wheel mounted audio controls•USB connection

Exterior Body Features

•Body colour bumpers•Body colour door handles•Body colour mirror housing•Body colour tailgate handle•Chrome grille•Dark tinted solar protect glass behind B

pillar•Daytime running lights•Door to door illumination•Electrically adjustable and heated door

mirrors

•Electric front windows•Electrochrome anti dazzle rear view mir-

ror•FlexDoors•Front fog lamps•Parking lights•Rear window defroster•Rear wipe automatic when in reverse +

front wipe on•Solid paint

BODY

TRAINING


Flexi-Rail

Inside, the biggest changes are ground-breaking, with upscale styling, innovative versa-tility and class-leading emphasis on wellness. The cabin features an improved FlexSpace rear seating system, greater interior storage space enhanced by FlexRail, a revolutionary concept for adaptable center console storage, front seats that offer the widest range of adjustments in the segment, and optional expert-certified back-friendly ergonomic front seats.

Glove boxBottle pocket

Sunglasses storage

GENERAL

TRAINING


Colours

•Casablanca White•Magma Red•Technical Grey•Star Silver•Warm Henna

Storage areas inside the Opel Meriva

Door pocketsDrivers open bin

GENERAL

TRAINING


Steering Wheel and Cluster

Heated Steering Wheel

GENERAL

TRAINING


Interior

Inside, the wraparound wing-shaped instrument panel, that has been loweredand moved forward, enhances the feeling of width and roominess, while the forward-leaning center stack also adds sculptured space. The cabin is available wîthsix different color and trim combinations, the widest choice ever offered for asingle Opel model.

New Innovative Styled Dash

New Interior Door Handle Design

GENERAL

TRAINING


Cockpit

As mentioned the car comes with extensive standard equipments including items like air conditioning, CD radio, on-board computer, a leather steering wheel, electric power windows front, electrically adjustable rear-view mirrors, cruise control, and the innova-tive FlexRail center console storage.

Infortainment CD 500

GENERAL

TRAINING


Powertrain: Downsized and turbo-charged for efficient performance

At 4288 mm, the new Meriva has a 15 mm longer wheelbase, with 39 mm wider front- and 45 mm rear tracks over the first generation for improved handling and greater ride comfort. Its front and rear axles are derived from the Zafira, bringing Opel’s new small monocab closer to the standards of the compact class. Electro-hydraulic power steering replaces the previous all-electric set-up. Standard active safety features include a brak-ing system with four discs, electronic stability control and traction control.

The new Meriva’s powertrain line-up is focused on efficient performance that under-scores Opel’s strategy of down-sizing and turbo-charging to deliver real world fuel econ-omy on a car with a comfortable and balanced ride. It ranges from 55 kW/75 hp to 103 kW/140 hp. All engines comply with the Euro 5 emissions standards.

The gasoline line-up contains three variants of the new generation 1.4-liter multi-valve engine•The entry 100 hp 1.4 liter is the only naturally-aspirated unit in the offer and fea-

tures variable valve timing for improved breathing•A brand-new 1.4 Turbo 88 kW/120 hp with 175 Nm of torque makes its world

debut in the Meriva, replacing the 1.6 with 105 hp, for a 10 percent reduction in CO2 and fuel consumption but a 15 percent increase in power

•A more powerful 1.4 Turbo 103 kW/140 hp version tops the offer. It provides 200 Nm of torque and is equipped with a 6-speed manual gearbox. Compared to the 1.8 of the previous generation Meriva, the new 1.4 Turbo engine offers a 12 percent increase in power and a 10 percent reduction in CO2 emissions.

GENERAL

TRAINING


Setting new standards in on-board versatility

Increased flexibility is extended to all areas of the new Meriva. The innovative FlexSpace rear seating system inherited from the first Meriva generation has been furtherdeveloped and refined. Fewer, more intuitive motions are now necessary to move therear seats and change configurations. One can either glide the rear seats backwardsand towards the center of the cabin to create lounge seating that provides morewidth and legroom for two. Or, slide the outboard seats forward to extend the luggage compartment and still accommodate three. Folding the seats down to obtain aloading compartment of up to 1500 is also easier now due to a simple strap systemallowing maneuvers with one single hand. Extra straps make folding the rear seatbacks possible from the cabin as well as from the luggage compartment

The seats from the FlexSpace system allow the rear passengers to also sit higherthan the occupants of the front seats in a so-called “theater-seating” that providesgreat visibility onto the road.

Throughout the cabin, storage space has increased considerably; the Meriva featuresin total up to 32 accessible locations for items which are most commonly carried.Among those, the revolutionary FlexRail console system consisting of exchangeablestorage units that slide on aluminum rails located between the front seats alsoenhance the ergonomics of the new Meriva and provide a slide-able comfort armrest.The FlexRail system was made possible because of the high mounted gear shift leverand the electric parking brake that is standard.

The new, generously proportioned Front Seats use a similar structure as those in theAstra and Insignia. They offer a class-leading range of adjustment – 240 mm forwards/backwards and 65 mm in height – making it possible for people of all sizes andshapes to find the most appropriate position. In addition, optional fully adjustableseats certified by AGR and featuring additional tilting, extra lumbar support and thighextension and four-way adjustable head-rests are also available.

Monocab expression of new Opel design

Meriva moves forward Opel’s new, expressive design language – sculptural artistrymeets German precision – with the same focus on dynamic elegance and qualityalready seen on the Insignia and the new Astra.

A lower, sweeping roof-line and Opel’s signature blade side-body motif combine witha wave rear window line to give the new Meriva a fresh, distinctive character. It alsoimproves the visibility for rear passengers, particularly children.

GENERAL

TRAINING


New Opel Meriva Opens the Door to Ergonomic Flexibility

•Flexibility meets ergonomic design: Innovative systems extend Meriva leadership•Coolness meets functionality: Rear-hinged FlexDoors improve cabin access.•Elegance meets efficiency: Refinement in design and technology.

Innovative, flexible and stylish: The second generation Opel Meriva is elegantly styled and packed with an array of innovative features engineered to optimize the flexible and easy use of space,making it a champion of ergonomic design.

On the exterior, it introduces FlexDoors, an innovative rear-hinged rear door system that highly facilitates cabin access, an especially important feature for a car such as the Meriva in which rear seats are often used. It is also an industry first for a volume manufacturer. And, optional FlexFix integrated rear bicycle carrier is not only easy to use; it is also gentle on the back

Inside, the biggest changes are ground-breaking, with upscale styling, innovative versatility and class-leading emphasis on wellness. The cabin features an improved FlexSpace rear seating system, greater interior storage space enhanced by FlexRail, a revolutionary concept for adaptable center console storage, front seats that offer the widest range of adjustments in the segment and optional expert-certified back-friendly ergonomic front seats.

Taken together the ergonomically designed features have convinced an association of independent back doctors and therapists in Germany that the Meriva’s ErgoFlex System focus on long-term back health. The Aktion Gesunder Rücken (AGR, Action for Healthy Backs) have given its seal of approval to the Meriva’s standard FlexDoors and FlexSpace rear seating systems, optional fully adjustable front seats and FlexFix bicycle carrier. It is the first vehicle to have so many features recommended by health experts.

FlexDoors opens a new era of cabin access

Meriva opens up a new dimension in rear seat access with its unique rearhinged rear doors. The FlexDoors are full-sized and open independently from the front doors, thanks to the use of a safe and robust B-pillar that ensures enhanced stiffness and passive safety. FlexDoors make it easy to enter and exit without twisting or sliding, even in tight spaces. For optimum access, FlexDoors can open up to 84 degrees – much wider than the usual 67 degrees of conventional doors – and come with sturdy grab handles on the B-pillar that are intuitively used. The Meriva’s front and rear occupants enjoy the same wide-opening access, combined with four angle openings.FlexDoors also add a touch of style. Stepping in and out of the vehicle not only feels much more natural, it looks cool and elegant.

GENERAL

CONTENTS

GENERAL

BODY

MECHANICAL

ELECTRICAL

61

53

44

42

39 RESTRAINT SYSTEM

NoteThis 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.

OPEL MERIVAModel Introduction Training For Approved Motor Body Repairers

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