Chevrolet Sail 2010 User manual

I Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Table of Contents
1Vehicle Introduction........................................................................................................................1
1.1 Vehicle Identification .................................................................................................................1
1.1.1 Vehicle VIN Code.............................................................................................................1
1.1.2 Vehicle Nameplate...........................................................................................................2
1.2 Vehicle Fit-out Table..................................................................................................................4
2Engine..............................................................................................................................................7
2.1 Engine Identification..................................................................................................................7
2.1.1 Identification of Engine Label...........................................................................................7
2.1.2 Significance of Engine Serial Number..............................................................................8
2.2 Engine Parameters ...................................................................................................................8
2.2.1 Engine Oil........................................................................................................................8
2.2.2 Spark plugs......................................................................................................................8
2.2.3 Corresponding Temperature and Resistance Values of Engine Coolant Temperature
Sensor and Intake Air Temperature Sensor................................................................................9
2.2.4 Ignition System Specifications .........................................................................................9
2.3 Engine Identification Diagram.................................................................................................11
2.3.1 1.2L LMU .......................................................................................................................11
2.3.2 1.4L LCU........................................................................................................................15
2.4 Engine Maintenance and Service............................................................................................21
2.4.1 Timing Calibration..........................................................................................................21
2.4.2 Valve Clearance Adjustment （1.2&1.4）.....................................................................22
2.5 Engine Management System..................................................................................................23
2.5.1 ECM Input......................................................................................................................23
2.5.2 ECM Output...................................................................................................................24
2.5.3 EGR Valve .....................................................................................................................24
2.5.4 Programming and Setting of Engine Control Module.....................................................24
2.5.5 Idle Read-In Program.....................................................................................................25
2.6 Circuit Diagrams......................................................................................................................28
2.6.1 Vehicle Speed Sensor Schematic Diagram （1.2MT）.................................................28
2.6.2 Ignition Control Sensor Schematic Diagram （1.2MT）...............................................29
2.6.3 Ignition Control - Ignition System Schematic Diagram （1.2MT）................................30
2.6.4 Engine Cooling System Schematic Diagram （1.2MT）..............................................31
2.6.5 Engine Data Sensor - Pressure and Temperature Schematic Diagram （1.2MT）......32
2.6.6 Engine Data Sensor - Oxygen Sensor Schematic Diagram （1.2MT）........................33

II
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
2.6.7 Module Power, Grounding and Serial Data Schematic Diagram （1.2MT）.................34
2.6.8 Startup and Charging Schematic Diagram （1.2MT）..................................................35
2.6.9 Fuel Control System - Fuel Pump Control System and Oil Injector Schematic Diagram
（1.2MT）................................................................................................................................36
2.6.10Equipment Control Schematic Diagram （1.2MT）......................................................37
2.6.11Controlled and Monitored Parts Schematic Diagram （1.2MT）..................................38
2.6.12Evaporator Schematic Diagram （1.2MT）..................................................................40
2.6.13Ignition Control Sensor Schematic Diagram （1.4）....................................................42
2.6.14Ignition Control - Ignition System Schematic Diagram （1.4）.....................................43
2.6.15Engine Data Sensor - Pressure and Temperature Schematic Diagram （1.4）...........44
2.6.16Engine Data Sensor - Oxygen Sensor Schematic Diagram （1.4）.............................46
2.6.17Module Power, Grounding and Serial Data Schematic Diagram （1.4）......................47
2.6.18Startup and Charging Schematic Diagram （1.4）.......................................................48
2.6.19Fuel Control System - Fuel Pump Control System and Oil Injector Schematic Diagram
（1.4）.....................................................................................................................................49
2.6.20Equipment Control Schematic Diagram （1.4）...........................................................50
2.6.21Controlled and Monitored Parts Schematic Diagram （1.4）.......................................51
2.6.22Pedal Position - Throttle Schematic Diagram （1.4）...................................................52
3Transmission.................................................................................................................................54
3.1 Transmission Identification......................................................................................................54
3.2 Transmission Oil .....................................................................................................................55
3.3 Transmission Specifications....................................................................................................55
3.3.1 SH63-MT Specifications.................................................................................................55
3.3.2 SH63A-MT Specifications ..............................................................................................56
3.4 Transmission Identification......................................................................................................56
3.4.1 SH63 Housing................................................................................................................56
3.4.2 SH63A Housing..............................................................................................................57
3.4.3 EMT Housing.................................................................................................................58
3.4.4 SH63 Gear Unit..............................................................................................................59

III Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
3.4.5 SH63 Gear Unit..............................................................................................................60
3.4.6 SH63 Input Shaft............................................................................................................61
3.4.7 Output Shaft...................................................................................................................62
3.4.8 Differential......................................................................................................................63
3.5 Oil Level Inspection.................................................................................................................63
3.6 Vehicle Speed Sensor.............................................................................................................64
4Electrical System ..........................................................................................................................65
4.1 Windows Adjustment...............................................................................................................65
4.2 Adjustment of Outer Front Door Handle Lever........................................................................65
4.3 Adjustment of Outer Rear Door Handle Lever ........................................................................66
4.4 Description and Operation of Data Link Communication.........................................................66
4.4.1 Universal Asynchronous Receiver Transmitter （UART）Data Circuit........................67
4.4.2 Keyword 2000 data circuit..............................................................................................67
4.5 Audio Security System............................................................................................................67
4.6 Area Code of Audio System....................................................................................................68
4.7 ElectricalAppliances Circuit Diagrams....................................................................................69
4.7.1 Power Windows Circuit Diagram 1.................................................................................69
4.7.2 Power Windows Circuit Diagram 2.................................................................................70
4.7.3 Demister Circuit Diagram...............................................................................................71
4.7.4 Horn Circuit Diagram .....................................................................................................72
4.7.5 Headlamps Circuit Diagram...........................................................................................73
4.7.6 Signal and License Plate Lamps Circuit Diagram..........................................................74
4.7.7 Turn Lamps and Hazard Warning Lights Circuit Diagram..............................................75
4.7.8 Reverse Lamps Circuit Diagram....................................................................................76
4.7.9 Brake Lamps Circuit Diagram........................................................................................77
4.7.10Fog Lamps Circuit Diagram ...........................................................................................78
4.7.11Exterior Mirrors Circuit Diagram.....................................................................................79
4.7.12Door Pillar Switch Circuit Diagram.................................................................................80
4.7.13Central Door Lock Control Module Circuit Diagram.......................................................81
4.7.14Wiper & Scrubber Circuit Diagram.................................................................................82
4.7.15Data Communication Circuit Diagram............................................................................83
4.7.16Cigarette Lighter Circuit Diagram...................................................................................84
4.7.17Sunroof Circuit Diagram.................................................................................................85
4.7.18Air Conditioning Compressor Control.............................................................................86
4.7.19Air Conditioning Blower Control.....................................................................................87
4.7.20Audio System.................................................................................................................88
4.7.21Instrument Circuit Diagram............................................................................................
89
4.7.22Instrument & Alarm Indicator Light.................................................................................90
4.7.23Instrument Indicator Lights and Illumination...................................................................91
5Braking System.............................................................................................................................92
5.1 MGH-25ABS Oil Circuit Diagram............................................................................................92
5.2 System Introduction ................................................................................................................92
5.3 Operation mode ......................................................................................................................93

IV
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
5.3.1 Normal Braking Mode....................................................................................................93
5.3.2 Anti-Lock Braking Mode - Connection............................................................................94
5.3.3 Anti-Lock Braking Mode - Maintenance.........................................................................95
5.3.4 Anti-Lock Braking Mode - Separation ............................................................................96
5.4 Decoupled Dynamic Rear Proportioning （DDRP）..............................................................97
5.5 Electronic Brake Control Module （EBCM）.........................................................................99
5.6 Solenoid Valve Relay..............................................................................................................99
5.7 Wheel Speed Sensor and Toothed Ring .................................................................................99
5.8 Anti-Lock Braking System（ABS）Warning Light.................................................................100
5.9 Brake Warning Light..............................................................................................................100
5.10 Rear Drum Brake..................................................................................................................100
5.11 Drum Brakes Adjustment ......................................................................................................101
5.12 The Wear-in Of Brake Shoes and Brake Drums ...................................................................102
5.13 Hydraulic Braking System Exhaust.......................................................................................102
5.14 Hand Brake Adjustment ........................................................................................................105
5.15 Braking System Circuit Diagrams..........................................................................................106
5.15.1Power and Ground Circuit Diagram of Braking System...............................................106
5.15.2ABS Wheel Speed Sensor Circuit Diagram .................................................................107
5.15.3ABS Circuit Diagram....................................................................................................108
5.15.4Braking Warning System Circuit Diagram....................................................................109
6Steering System..........................................................................................................................110
6.1 Power Steering System Specifications..................................................................................110
6.2 Component Identification ......................................................................................................111
6.2.1 Component Diagram （1.2L）....................................................................................111
6.2.2 Component Diagram （1.4L）....................................................................................112
6.3 Power Steering System Exhaust...........................................................................................112
7Suspension System....................................................................................................................114
7.1 Suspension System Specifications .......................................................................................114
7.2 Component Identification of Suspension System..................................................................114
7.2.1 Front Suspension.........................................................................................................114
7.2.2 Rear Suspension .........................................................................................................115
8MDI/RDS and Programming .......................................................................................................116
8.1 MDI .......................................................................................................................................116
8.1.1 MDI Identification.........................................................................................................116

1 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
1Vehicle Introduction
1.1 Vehicle Identification
1.1.1 Vehicle VIN Code
1. VIN Code
2. Position of VIN Code （1）
Thevehicleidentificationlabel（1）isinthetopleft
cornerofthedashboard,andyoucanseeitfromoutside
throughthewindscreen.
3. Position of VIN Code （2）
Vehicle Identification Number （VIN）is engraved in
the top right side of the bulkhead.

2
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
4. VIN Code Identification:
Position Definition Character Description
1-3 Global Manufacturing Identification LSG Shanghai General Motors Co., Ltd.
4-5 Brand and Vehicle Model SA SGM7120MT, SGM7120AMT, SGM7142MT,
SGM7142AMT Passenger Vehicle
6 Vehicle Body Style 5 3-Compartment, 4-Door Passenger Vehicle
6 2-Compartment, 4-Door Passenger Vehicle
7 Protecting Device System 2 Manual Safety Belt, Driver and Front
Passenger Front Airbag
8 Manual Safety Belt and Driver Front Airbag
8 Engine Type S 1.2L, 1.4, MFI, DOHC
M 1.2L, 1.4, MFI, DOHC
9 Check Digit 0-9 o X Check Code
10 Production Year A 2010
11 Manufacturing Plant Y Shanghai General Motors Yantai Plant
12-17 Manufacturing Plant Serial Number
1.1.2 Vehicle Nameplate
Certificate
1. Seats
2. Total Vehicle Weight
3. Vehicle Model
4. Engine Model
5. Engine Displacement
6. Rated Engine Power
7. Vehicle Identification Number （VIN）
8. Production Date
Position of Certificate

3 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
The certificate label is on the radiator support.
Tire Information Label
The tire label is permanently posted at the back of the driver left-rear door. Please refer to the label for tire
information. The label lists the maximum carrying capacity of the vehicle, tire size （includes spare wheel）and
cold inflation pressure （includes spare wheel）.
RPO Code Label
1. Vehicle Identification Number
2. Engineering Design Model
（Vehicle Classification, Series, and Body Style）
3. Interior Trim Parts and Trim Level
4. Contents of Optional Vehicle Parts
Engine Compartment Positioning

4
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
1. Air Filter
2. Electronic Throttle
3. Intake Manifold
4. Brake Oil Tank
5. Engine Coolant Storage Tank
6. Fuse Box
7. Washing Liquid Storage Tank
8. Engine Control Module
9. Accumulator
10. Power Steering Fluid Storage Tank
11. Transmission
12. Ignition Coil Cap
13. Exhaust Manifold
14. Engine Oil Cap
15. Engine Oil Dipstick
1.2 Vehicle Fit-out Table
Fit-out Table
MKT Type
1.2
SL
MT
1.2
SE
MT
1.2
SE
EM
T
1.4
SX
MT
1.4
SX
EM
T
1.2
SL
MT
1.2S
EMT
1.2SE
EMT
1.4
SX
MT
1.4S
X
EM
T
Engine Model
1S
R
69
1SS69 1ST69
1S
R
48
1SS48 1ST48
Optional Type
NG
S
1
NG
S
2
NG
S
3
NG
S
4
NG
S
5
NG
S
6
NGS
7
NGS
8
NG
S
9
NG
S
10
Vehicle Body
Color
Exterior: Primary Color, Cool
Blue, MET O O O O O
Exterior: Primary Color，Flame
Red O O O O O O O O O O
Exterior: Primary Color，Dynamic
Orange O O O O O O O O O O
Exterior: Primary Color，Bright
White O O O O O O O O O O

5 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Exterior: Primary Color，Sky Blue O O O O O O O O O O
Exterior: Primary Color，Classic
Green O O O O O O O O O O
Exterior: Primary Color，Galaxy
Silver O O O O O O O O O O
SCOYellow O O O O O
Engine
LCU
Gasoline Engine, 4 Cylinders,
1.4L,MFI,DOHC,PDA,FAMA/B,
GMDAT
X X X X
LMU Gasoline Engine, 4 Cylinders, ,
L4,1.2L,MFI,DOHC,GMDAT X X X X X X
Transmission
Manual 5-Speed, China,
Transmission Ratio of First Gear:
3.462, Transmission Ratio of 5th
Gear: 0.756, Torque: 140Nm
X X X X
Manual 5-Speed, China,
Transmission Ratio of First Gear:
3.462, Transmission Ratio of 5th
Gear: 0.756, Torque: 140Nm
X X X X X X
Exhaust System Exhaust System EEC 05 X X X X X X X X X X
Gear Shifting
System
Electrically Controlled Gear Shift
and Mechanical Transmission X X X X
Braking System
BRAKE SYSTEM PWR, Front
Disc, Rear Drum, Cast Iron, ABS,
FRT & RR WHL
X X X X X X X X
BRAKE SYSTEM PWR, Front
Disc, Rear Drum, Cast Iron X X
Interior Trim Interior Trim: Dark Titanium /
Light Titanium X X X X X X X X X X
Wheels Wheel Hubs 13 X 5, Steel, Paint X X
Wheel Hubs 14 X 5.5, Steel, Paint X X X X X X X X
Safety System
Seat Belt, Inflation Protection,
Front Driver Seat
Seat Belt, Inflation Protection,
Two Front Side Seats X X X X X X X X X X
Sunroof Power Sunroof X X X X
Door Locks
Electrically Controlled Side Door
Locks X X X X X X
Electrically Controlled and
Automatic Side Door Locks X X X X
Steering System Power-Assisted Steering - Fixed X X X X X X X X X X
Side Windows Front-Door Power Windows X X X X X X
Four-Door Power Windows X X X X
Audio System
AM/FM Stereophonic Receiver,
Automatic Channel Search, Clock
and Electronic Tuning
X X X X X X
AM/FM Stereophonic Receiver,
Automatic Channel Search, CD, X X X X

6
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Automatic Equalization, Clock,
Electronic Tuning and MP3
Speakers Two Front Side Speakers X X X X X X
Four Speakers X X X X
Air conditioning Front Side Manual
Air-Conditioning System X X X X X X X X X X
Miscellaneous
STRAIGHT,CHILE,ONLY
Child Seat X X X X X X X X X X
External Tail Lamps and Brake
Lamps
Global License Plate Position
Manual Leveling of Headlamps
Wax Injection
FILM APPLY
Symbol "X" denotes optional fit-out packages

7 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
2Engine
2.1 Engine Identification
2.1.1 Identification of Engine Label
1.4LLCU
The steel seal number （2）of the 1.4L engine is
in the left rear side of the engine cylinder block and is
impressed or laser engraved on the cylinder block in the
assembly plant. In addition, the same serial number
label and engine communication code label（1）are on
the engine cover.
1.2L LMU
The steel seal number （2）of the 1.2L engine is
in the left rear side of the engine cylinder block and is
impressed or laser engraved on the cylinder block in
assembly plant. In addition, the same serial number
label and engine communication code label（1）are on
the front engine cover.

8
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Identification of Engine Label
Bar Code
2. Engine Assembly Number
3. Engine Code （1.4L LCU: LF, 1.2L LMU: LL）
4. Nine-Digit Serial Number
5. Engine Factory Code （Fixed Code: U）
6. Separative Sign
7. Engine Code （1.4L LCU: LF, 1.2L LMU: LL）
8. Separative Sign
9. Part identification number: engine number is 10.
2.1.2 Significance of Engine Serial Number
1. Year Code
2. Month Code
1-9: January－September; A: October;
B: November; C: December
3. Date Code
4. Engine Production Line Code（Fixed Code:2）
5. Production Sequence Number（From 1 To 9999）
2.2 Engine Parameters
2.2.1 Engine Oil
Recommended Engine Oil API SM（ILSAC GF-IV）Grade: SAE 5W-30
Volume 1.2L LMU 3.75L
1.4L LCU 3.75L
2.2.2 Spark plugs
Engine Models Spark Plug Models Spark Plug Gap
1.4L Dual Overhead Camshaft NGK BKR6E-11 1-1.1 mm （0.039-0.043 in.）

9 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
1.2L Dual Overhead Camshaft Tech RA7YC 0.8-0.9 mm （0.031-0.035 in.）
2.2.3 Corresponding Temperature and Resistance Values of Engine Coolant Temperature
Sensor and Intake Air Temperature Sensor
℃
Engine Coolant
Temperature（ECT）
Sensor
Intake Air Temperature
（IAT）Sensor
Ohm
Temperature And Resistance Values - Approximate Value
100 212 177 187
90 194 241 246
80 176 332 327
70 158 467 441
60 140 667 603
50 122 973 837
45 113 1188 991
40 104 1459 1180
35 95 1802 1412
30 86 2238 1700
25 77 2796 2055
20 68 3520 2500
15 59 4450 3055
10 50 5670 3760
5 41 7280 4651
0 32 9420 5800
-5 23 12300 7273
-10 14 16180 9200
-15 5 21450 9200
-20 -4 28680 15080
-30 -22 52700 25600
-40 -40 100700 45300
2.2.4 Ignition System Specifications
Ignition System Specifications （1.2）
Application 1.2L Dual Over Head Camshaft
Ignition Type Direct Ignition System
Iiti Tii
（
Bf T D dC t
）
4~5º
Ignition Sequence 1-3-4-2
Spark Plug Gap
08
09M
（
0 031
0035i
）
Spark Plug Manufacturer Selim Tech

10
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Spark Plug Type RA7YC

11 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Ignition System Specifications （1.4）（Delphi）
Application Specifications
Metric Units English Units
Ignition Sequence 1-3-4-2 1-3-4-2
Ignition Timing 8º（BTDC）
Ignition Type Direct Ignition System
Spark Plug Gap 1.0 – 1.1 Mm 0.039 – 0.043 in
Spark Plug Manufacturer TORCH
Spark Plug Model K6RF-11
2.3 Engine Identification Diagram
2.3.1 1.2L LMU
Cylinder Head

12
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
1. Spark Plug Cable Cover
2. Engine Oil Filler Cap
3. Cylinder Head Cover
4. Cylinder Head Cover Gasket
5. Spark Plug Cable
6. Spark Plug
7. Ignition Coil（Direct Ignition System）Bracket
8. Ignition Coil（Direct Ignition System）
9. Camshaft Cover
10. Camshaft（Air Intake）
11. Camshaft（Exhaust）
12. Valve Tappet
13. Valve Cotter
14. Valve Spring Snap Ring
15. Valve Spring
16. Valve Stem Sealing Element
17. Cylinder Head
18. Valve（Air Intake）
19. Valve（Exhaust）
20. Cylinder Head Gasket
21. Cylinder Cover Bolt
22. Camshaft Position Sensor
23. Coolant Outlet Housing Gasket
24. Coolant Outlet Housing
25. Coolant Temperature Sensor
26. Exhaust Gas Recirculation Valve Gasket
27. Exhaust Gas Recirculation Valve

13 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Cylinder Block
1. Piston Ring
2. Piston
3. Piston Pin Fixture
4. Piston Pin
5. Connecting Rod Cap Stud
6. Connecting Rod
7. Connecting Rod Bearing
8. Connecting Rod Cap
9. Alignment Pin
10. Cylinder Block
11. Timing Chain Cover
12. Crankshaft Front Oil Seal
13. Oil Pump Inner Rotor
14. Oil Pump Outer Rotor
15. Oil Pump Cover
16. Metering Valve
17. Metering Valve Spring
18. Metering Valve Cap
19. Metering Valve Fixture
20. Oil Cleaner Stud
21. Oil Cleaner
22. Keyway
23. Crankshaft
24. Crankshaft Bearing Cover
25. Engine Oil Filter Screen
26. Oil Pan
27. Rear Crankshaft Oil Seal
28. Cylinder Block Plate Plug
29. Cylinder Block Plate Plug Gasket

14
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
Manifold and Air Intake System
1. Resonator
2. Pipeline
3. Air Filter Draft Tube
4. Air Filter Lower Housing
5. Air Filter Cartridge
6. Air Filter Upper Cover
7. Air Exhaust Hose
8. Resonator
9. Resonator
10. Throttle Body
11. Idle Air Control Valve （IACV）
12. Throttle Position Sensor
13. Intake Manifold
14. Exhaust Gas Recirculation Tube
15. Exhaust Gas Recirculation Tube Gasket
16. Exhaust Gas Recirculation Valve
17. Thermostat Housing
18. Coolant Outlet Housing
19. Fuel Distributing Pipe
20. Oil Injector
21. Exhaust Manifold
22. Exhaust Manifold Thermal Baffle
Timing System and Support

15 Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
1. Timing Chain
2. Camshaft Sprocket （Air Intake）
3. Camshaft Sprocket （Exhaust）
4. Lining
5. Camshaft Sprocket fixing bolt
6. Timing Chain Rod
7. Timing Chain Tensioner
8. Timing Chain Guide Plate
9. Crankshaft Sprocket
10. Engine Support Assembly
11. Rear Support Bracket
12. Transmission Rear Support
13. Transmission Support Assembly
14. Transmission Support Bracket
2.3.2 1.4L LCU
Cylinder Head

16
Chevrolet 2010 New Sail New Technical Training
- Learner's Manual
1. Crankshaft Fresh Air Pipe
2. Ignition Coil Cap Bolt
3. Ignition Coil Cap
4. Ignition Coil Bolt
5. Ignition Coil
6. Spark Plug
7. Engine Oil Fill Up Cap
8. Camshaft Cover Bolt
9. Forced Crankshaft Draft Tube
10. Harness Fixing Support
11. Camshaft Cover
12. Camshaft Sealing Gasket
13. Camshaft Cover Bolt
14. Camshaft Cover
15. Air Intake Camshaft
16. Exhaust Camshaft
17. Camshaft Position Sensor
18. Valve Tappet
19. Valve Cotter
20. Valve Spring Snap Ring
21. Valve Spring
22. Valve Tappet Sealing Element
23. Valve Tappet （Air Intake）
24. Valve Tappet （Exhaust）
25. Spout Plug
26. Cylinder Cover Bolt
27. Spout Plug
28. Cylinder Head
29. Cylinder Head Sealing Gasket
30. Exhaust Gas Recirculation Valve
31. Exhaust Gas Recirculation Valve Sealing Gasket
32. Coolant Outlet Housing
33. Coolant Outlet Housing Sealing Gasket
34. Coolant Temperature Sensor