Chevrolet CAPTIVA - S User manual

Chevrolet Captiva
Model Introduction Training For
Approved Motor Body Repairers

The new Captiva is the first product to be designed and developed
by Chevrolet for the European market.
Its sleek yet bold design is accentuated by strong wheel arches and
a sweeping feature line that runs from the front fender vent through
to the tail lamps. The wide tailgate with its integrated opening win-
dow underlines the practical side of the Captiva.
Value for money to the customer is key yet levels of specification are
comprehensive on all derivatives, i.e front and curtain airbags are
standard across the range.

CONTENTS
Note
GENERAL
BODY
SUSPENSION and STEERING
ELECTRICAL
4
12
30
34
42
RESTRAINT SYSTEM
48
ALL WHEEL DRIVE
This self-study programme highlights the design and function of new vehicle models,
new automotive components or new technologies.
The self-study programme is not a repair manual!
All values given are intended as a guideline only.
For maintenance and repair work, always refer to the current technical literature.

© 2008 General Motors Corporation. All rights reserved.
4
TRAINING
Exterior Dimensions
The Captiva measures 4,635/1,850/1,720mm
(length/width/height) and stands on a wheelbase
of 2,705mm. In five passenger configuration, it
offers a trunk volume of 405 litres. All seats,
including the front passenger seat, can be folded
forward and down, achieving a flat surface. It
offers plenty of storage space, including a wide net
below the instrument panel.
General

© 2008 General Motors Corporation. All rights reserved.
5
TRAINING
Weights and Capacities
Curb weight (with driver)
Engine Transmission Weight
Z24SED
Manual Transmission 1.730 - 1,815 (5 seater) 1,760 - 1,845 (seven seater)
Automatic Transmission Still awaiting release
Z32SED
Manual Transmission Still awaiting release
Automatic Transmission Still awaiting release
Gross vehicle weight
Z24SED
Manual Transmission 2,180 (5 seater) 2,320 (seven seater)
Automatic Transmission Still awaiting release
Z32SED
Manual Transmission Still awaiting release
Automatic Transmission Still awaiting release
Item Capacity Classification
Fuel 65.0 litres RON 95 or higher/Diesel
Engine oil (inc. oil filter) Z24SED 4.5 litres API SL (ILSAC GF-III) grade
SAE 5W-30
Hot area: SAE 10W-30
Z32SED 7.4 litres API SJ (ACEA A1) grade
SAE 0W-30
Z20DTH 6.5 litres Still awaiting release
Engine coolant 9.0 litres Dex-cool coolant
Automatic transaxle fluid 6.85 +- 0.15 litres JWS 3309 US ATF
Manual transaxle fluid FWD 2.1 litres
SAE 75W-90
AWD 2.3 litres
Brake fluid 0.67 litres
DOT 4
Clutch fluid 0.06 litres
Power steering fluid 1.1 litres DEXRON II D or DEXRON III
Transfer case fluid AWD 0.8 +- 0.1 litres
Synthetic Hypoid 75W-90
Differential carrier fluid AWD 0.6 +- 0.1 litres
General

© 2008 General Motors Corporation. All rights reserved.
6
TRAINING
Chassis
The Captiva has an all new fully independent front
and rear suspension with McPherson strut assem-
blies at the front and a multi-link suspension type
at the rear. An optional automatic Self Leveliser
System can be fitted at the rear to ensure a correct
body height at all loads.
Power assisted steering is standard and a Speed
Sensitive Power Steering is available as an optional
extra.
Wheels
The four cylinder derivatives come standard with
215/70R16 tyres on 6.5Jx16 inch wheels.
The V6 derivatives come standard 235/60R17
tyres on 7.0Jx17 inch wheels.
Front suspension type McPherson strut
Rear suspension type Four link
Alignment (unloaded) Camber Front
:
- 0.55o+- 0.75o
Rear: - 0.35o+- 0.5o
Castor 2.18o+- 0.73o
Toe-in Front 0.1o+- 0.08o
Rear 0.09o+- 0.1o
Steering Type Power assisted rack and pinion
Overall gear ratio 18.5 : 1
Steering wheel diameter (mm) 390
Minimum turning radius (m) 5.75
Tyre size Wheel dimension Tyre pressure (F/
R) in bar
Tyre pressure
(F/R) in psi
(loaded)
16” wheel 215/70 R16 6.5J x 16
2.1/2.1 2.3/2.4
17” wheel 235/60 R17 7J x 17
18” wheel 235/55 R18 7J x 18
Emergency spare tyre T155/90 R16 4T x 16 0.6/0.6
General

© 2008 General Motors Corporation. All rights reserved.
7
TRAINING
Engine and Transmission
Initially, three transversally mounted engines will
be available for the Captiva.
The first is the brand new, state-of-the-art GM
common rail diesel engine (Z20DTH). The 16 valve
unit offers 110 kW (150 hp) at 4,000 rpm and
maximum torque of 316 Nm at 2,000 rpm. The
combined fuel consumption is 7.6 l per 100 km.
The 2.4 litre gasoline engine (Z24SED) is an in-line
DOHC four cylinder, delivering 104 kW (142 hp) at
5,200 rpm and a torque maximum of 224 Nm at
4,000 rpm. Its average fuel consumption is 9.9 l
per 100 km.
Engine Z24SED Z32SED Z20DTH
Fuel Petrol petrol diesel
Type 4-cylinder / in-line 6-cylinder / V 4 cylinder / in-line
Displacement (cc) 2.405 3.195 1.991
Bore x stroke (mm) 87 x 100.0 89 x 85.6 83 x 92.0
Compression ratio 9.6 : 1 10.2 : 1 17.5 : 1
Max. power (kW/rpm) 100/5,000 165/6,000 110/4,000
Max. torque (Nm/rpm) 220/2,200 308/3,500 310/2,000
Fuel system Multi-point injection Multi-point injection High pressure Direct
injection
The top-of-the-line 3.2 litre V6 engine (Z32SED)
produces 165 kW (225 hp) at 6,000 rpm with a
maximum torque of 308 Nm at 3,500 rpm. Its
combined fuel consumption is 11.7 l per 100 km.
All engines are standard equipped with a five
speed manual transmission. An optional five speed
automatic transmission is also available
General

© 2008 General Motors Corporation. All rights reserved.
8
TRAINING
Vehicle Identification
The vehicle identification number (VIN) is attached
to the top of the front panel support.
The vehicle identification number (VIN) is also
engraved in the top right side of the bulkhead.
General

© 2008 General Motors Corporation. All rights reserved.
9
TRAINING
Body Identification Number Plate
The vehicle identification number plate is attached
to the top of the front panel support.
1. P/O Number
2. Check digit
3. Drive
4. Body type
5. Production month
6. Production date
7. Sequential Number
8. Trunk lid
9. Exterior colour
10. Export country
11. Car type
General

© 2008 General Motors Corporation. All rights reserved.
10
TRAINING
Diagnostic Link Connector
The Diagnostic Link Connector is located under the
instrument panel near to the A-column at the driver
side.
Engine oil life system
The vehicle engine oil life system informs when to
change the engine oil. Based on driving conditions,
the mileage at which an oil change will be indi-
cated can vary considerably. For the oil life system
to work properly, reset the system every time the
oil is changed.
Resetting the Engine Oil Life System
The Engine Oil Life System calculates when to
change the engine oil and filter based on vehicle
use. Anytime the engine oil is changed, reset the
system so it can calculate when the next oil
change is required. To reset the Engine Oil Life
System, do the following:
1. Turn the ignition key to ON with the engine
OFF.
2. Fully press and release the accelerator pedal
three times within five seconds.
3. Turn the key to LOCK.
General

© 2008 General Motors Corporation. All rights reserved.
11
TRAINING
General
Notes

© 2008 General Motors Corporation. All rights reserved.
12
TRAINING
Many innovations have been integrated in the Cap-
tiva’s body structure to obtain a high degree of
occupant safety, and also to protect pedestrians
against severe injuries in case of unfortunate colli-
sions.
Crumple zones
To accommodate the impact energy in case of a
crash, the front, sides and rear of the passenger
compartment are surrounded by crumple zones
that deform and protect in a controlled manner.
At both front and rear of the vehicle, crash boxes
have been integrated to absorb impact energy at
an early stage of a collision.
At the front these crash boxes can be replaced
separately but at the rear they are part of the longi-
tudinal chassis beams.
At higher impact speeds, the deformation energy is
transferred to the front frame in a defined manner.
In frontal impacts, the impact energy is distributed
through three load paths:
●Upper load path
●Middle load path
●Lower load path via the hydro-formed sub-frame
In a frontal collision, the separate steering column
cross member and a collapsible column design limit
the penetration of the steering wheel into the pas-
senger compartment. This also ensures the correct
airbag position.
The side doors are reinforced with side-impact
beams, creating a rigid profile at waist level.
Together with the high strength steel “B”-pillars
and the large-dimensioned rocker sills, the penetra-
tion of the doors in side impacts is reduced, thus
providing a protective cage around the passenger
compartment. Energy-absorbing padding on the
inside of the doors further increases occupant pro-
tection.
In the event of a rear-end collision, several struc-
tural measures to protect the vehicle occupants
are brought to bear, including:
●The steel bumper cross member, which is
securely connected to the rear end structure,
absorbs impact energy in smaller collisions and
reduces repair costs.
●The rear frames are reinforced and pass on the
impact forces below the passenger
compartment. An additional load deflection
route is built up over the wheels.
●The fuel system is properly located in a safe
area in front of the rear axle.
Body

© 2008 General Motors Corporation. All rights reserved.
13
TRAINING
Pedestrian Protection
Absorbing material in the front bumper and struc-
tural design of the front facia and hood minimise
pedestrian injury in case of a collision.
For example, the retaining brackets of the head-
lamps are flexible and absorb a high amount of
energy. The hood incorporates crumple zones that
deform and absorb energy when the pedestrian
hits the vehicle.
This has been tested using weights and forms rep-
resenting the pedestrian.
Use of new materials
The requirement for reduced body weight has lead
to a reduction in the amount of steel used, e.g.
through the use of thinner sheet steels.
This has been achieved with high strength sheet
steels, in spite of the need to meet higher body
strength requirements at the same time.
High strength steels have a tensile strength and
yield strength as much as 30% higher than con-
ventional steel. These properties must not be
destroyed when carrying out repairs, e.g. by using
excessive heat.
The zinc plated steel plate used in some panels of
the vehicle requires different repair techniques
than ordinary steel plate.
Take the following precautions when repairing zinc
plated steel:
●Before spot welding the zinc plated steel plate,
remove the paint from both sides of the flange
to be welded. Apply sealer to the flange after
welding.
●The electric continuity properties of zinc plated
steel plate are different from ordinary steel
plate. When spot welding, increase the current
by 10-20% or increase the resistance welding
time. Also increase the number of weld spots by
10-20%.
The MIG welding procedures for zinc
plated steel plate are the same as for
ordinary steel plate.
●Before applying putty or body filler to the zinc
plated steel plate, sand the zinc plating
thoroughly to promote adhesion and prevent
blistering.
Use only epoxy-based puttees and fillers
on zinc plated steel plate.
Body
Note
Note

© 2008 General Motors Corporation. All rights reserved.
14
TRAINING
Seven seat concept
To tilt the second row seatbacks, lift the lever on top of the seat-
back until the seatback is adjusted to the desired position.
With the same lever, the second row seatbacks can be folded
down separately. Make sure that the headrests are fully down
when doing so.
To enter the 3rd row seating, the second row seats have to be tumbled. To do so
make sure the second row seatbacks are in the non-reclined position. Use the han-
dle on the outside of the second row seatbacks to fold down the seatback. The
seat will tumble forward automatically and air-pressurised support rods will hold
the seats folded.
The 3rd row seats can be folded by lifting the lever at the back of the 3rd
row seatback.
Once the second and third row are folded down and the passenger seat
has been folded down a maximum flat loading surface is available.
The two outboard positions at the second row seats are equipped with an isofix child seat restraint system.
Body
1. Isofix allowed positions
at second row seats
2. Isofix attachment
indications
3. Isofix top tether
anchors

© 2008 General Motors Corporation. All rights reserved.
15
TRAINING
Power sunroof
The power sunroof is an optional item.
Next to the fully open and closed function it incor-
porates a tilt function. A retractable sunshade pro-
tects the occupants from unwanted sun radiation
when the glass roof is closed.
The Sunroof Control Module has been designed to
memorise closing and opening steps. A loss of the
memorised positioning data can occur when the
operating current increases above the maximum
operating current of 3.5 - 4.0 Ampere. This is the
case when for example foreign material is on the
sunroof guide rail or an object blocks the sunroof
closing during operation.
Once the roof has been checked and released from
blocking objects or foreign material the sunroof
can be re-calibrated by following the next proce-
dure:
1. Press the switch in the rearward direction until
the sunroof tilts open. Release the switch when
the sunroof has fully opened. If the sunroof
opens slightly and stops, release and then press
the switch and hold it. Repeat these steps until
the sunroof opens fully.
2. Press the switch in a forward direction until the
sunroof closes fully.
3. Press the switch in a rearward direction until the
sunroof opens for 15 seconds.
4. Confirm the re-calibration procedure by
performing the sunroof opening and closing
operation.
Body
1. Sunroof control module
2. Sunroof motor
Body

© 2008 General Motors Corporation. All rights reserved.
16
TRAINING Body
Perform the following steps before beginning any
vehicle lifting or jacking procedure:
●Remove or secure all of the vehicle's contents in
order to avoid any shifting or any movement
that may occur during the vehicle lifting or
jacking procedure.
●The lifting equipment or the jacking equipment
weight rating must meet or exceed the weight
of the vehicle and any vehicle contents.
●The lifting equipment or the jacking equipment
must meet the operational standards of the
lifting equipment or jacking equipment's
manufacturer.
●Perform the vehicle lifting or jacking procedure
on a clean, hard, dry, level surface.
●Perform the vehicle lifting or jacking procedure
only at the identified lift points. DO NOT allow
the lifting equipment or jacking equipment to
contact any other vehicle components.
Lifting and Jacking the Vehicle
To avoid any vehicle damage, serious personal injury or death when major components are removed
from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the
opposite end from which the components are being removed and strap the vehicle to the hoist.
To avoid any vehicle damage, serious personal injury or death, always use the jack stands to support
the vehicle when lifting the vehicle with a jack.
Note
Note
1. Frame Contact Lift - Front
2. Frame Contact Lift - Rear

© 2008 General Motors Corporation. All rights reserved.
17
TRAINING
Front Bumper Fascia Energy Absorber Replacement
Removal Procedure
1. Remove the front bumper fascia.
2. Remove the retaining clips on the energy
absorber.
3. Remove the upper and lower energy
absorbers from the front fascia.
Body
Installation Procedure
1. Install the upper and lower energy absorbers
to the front fascia.
2. Install the retaining clips to the energy
absorbers.
3. Install the front bumper fascia.

© 2008 General Motors Corporation. All rights reserved.
18
TRAINING
Tie Bar Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint
(SIR) system.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to
factory specifications.
5. Note the location and remove the sealers and
anti-corrosion materials from the repair area, as
necessary.
6. Locate and drill out all factory welds.
Note the number and location of the welds
for installation of the tie bar assembly.
7. Remove the damaged tie bar assembly.
Body
Note
Note
Note
Installation Procedure
If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru
adhesive. It is necessary to replace the
weld-thru adhesive with an additional spot
weld between each factory spot weld.
1. Drill 8-mm (5/16-in) plug weld holes in the
service part as necessary in the locations noted
from the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.

© 2008 General Motors Corporation. All rights reserved.
19
TRAINING
4. Position the tie bar assembly to the vehicle
using 3-dimensional measuring equipment.
Clamp the tie bar assembly into place.
5. Plug weld accordingly.
6. Apply the sealers and anti-corrosion materials to
the repair area, as necessary.
7. Clean and prepare all welded surfaces.
8. Paint the repair area.
9. Install all related panels and components.
10. Connect the negative battery cable.
11. Enable the SIR system.
Body

© 2008 General Motors Corporation. All rights reserved.
20
TRAINING
Front Compartment Upper Side Rail Replacement
Body
Removal Procedure
1. Disable the supplemental inflatable restraint
(SIR) system.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to
factory specifications.
5. Note the location and remove the sealers and
anti-corrosion materials from the repair area, as
necessary.
Do not damage any inner panels or rein-
forcements.
6. Locate and drill out all factory welds. Note the
number and location of the welds for installation
of the front upper outer rail.
7. Remove the damaged front upper outer rail.
Installation Procedure
If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru
adhesive. It is necessary to replace the
weld-thru adhesive with an additional spot
weld between each factory spot weld.
1. Drill 8-mm (5/16-in) plug weld holes in the serv-
ice part as necessary in the locations noted from
the original panel.
Note
Note
Note