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.

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

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

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

:

- 0.55

o

+- 0.75

o

Rear: - 0.35

o

+- 0.5

o

Castor 2.18

o

+- 0.73

o

Toe-in Front 0.1

o

+- 0.08

o

Rear 0.09

o

+- 0.1

o

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

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

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

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

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

11

TRAINING

General

Notes

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

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

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

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

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

1. Frame Contact Lift - Front

2. Frame Contact Lift - Rear

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.

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

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.

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

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

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Chevrolet CAPTIVA - S User manual

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