Chevrolet Lumina Hummer Cadillac Saab Niche Market

Transcription

Niche Market
Chevrolet Lumina
Hummer
Cadillac
Saab
Model Introduction Training For Niche
Approved Motor Body Repairers
CONTENTS
Chevrolet Lumina
Hummer
Cadillac/Saab
●
General
●
Body
●
Restriant system
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General
●
Body
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Restriant system
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General
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Body
●
Restriant system
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.
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Note
Chevrolet Lumina
TRAINING
Chevrolet Lumina
General
The overall design of the Lunina is focused on the theme of poise and stance. The positioning of the four wheels closer to the corners give it an authoritative stand. Its visual strength
lies in the bold body-to-glass proportions; balancing dynamic form and design elements, giving the perception that the car is smaller. Minimised gaps and margins result in visibly
greater quality, fit and finish. Subtle sporting details such as fender belts and dual exhaust
outlets pay tribute to the manufacturer's motorsport heritage.
The interior themes revolve around function, luxury and performance conveying the sports
car cockpit effect. A fresh looking interior is of superior standards with impeccable quality.
To minimise distraction the controls have been intelligently designed so that the primary
information is placed in front of the driver in a display within the instrument cluster.
The Lumina also sports red illumination with sport instrumentation complimented by a high
mounted auxiliary display above the centre vents.
The colour and trim of the Lumina SS comprises of carefully selected finishes materials and
textures with lasting charm. The soft trim makes use of fabric leather and carpet with new
grain textures that enhance surface vision and touch with emphasis on quality. Modern fine
metallic paints define smooth surfaces, while the jewelled modern satin chrome highlights
demonstrate functionality and purpose.
Supple and luxurious, perforated leather constructions give the seat and door trim added
class while the new seats allow greater flexibility and comfort.
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© 2008 General Motors Corporation. All rights reserved.
TRAINING
Chevrolet Lumina
Safety
Unequalled safety: Lumina’s advanced safety system implements a range of active and passive safety features. ABS is standard and is accompanied by the advanced Electronic Brake
Assist and Electronic Brakeforce Distribution systems, ensuring braking distances are minimized in panic situations. Lumina has a reinforced safety cell and body structure with front
and rear crumple zones. Dual-stage frontal airbags, seatbelt pretensioners and force-limiting
belts surround occupants with state-of-the-art safety.
Active safety: Up to 200 times a second – that’s how often Lumina’s active safety systems
monitor on-road dynamics. Everything from the vehicle’s speed, lateral acceleration and
rotation, to the steering wheel angle and brakeforce you apply. When normal tolerances are
exceeded, counter-measures are initiated to help ensure you always have maximum control
of the vehicle.
Passive safety: A collision is a contest between impact energy and your vehicle’s safety
features. You want everything possible on your side. That’s why Lumina features an Adaptive Occupant Restraint System. Most impressive of all, in a frontal crash, Lumina can automatically initiate and co-ordinate all on-board passive safety measures in an incredible 90
milliseconds – about the time it takes to snap your fingers.
Introduction to VE
The new range of VE series vehicles represents the most significant changes that this
model line has seen in the last decade. The body shell , steering, suspension and braking
systems have been completely redesigned. The electrical architecture has been revised with
a large increase in the number of control modules.
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Chevrolet Lumina
TRAINING
Features
VE Lumina SV6
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195 KW V6 engine with:
6-speed manual transmission
5-speed automatic transmission
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Dual exhaust - chrome tip
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17’’ alloy wheels and 225/55R17 tyres
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Sport facias, body kit and spoilers
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Front fog lamps
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Body colour mirrors & door handles
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Single window instrument cluster
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Leather steering wheel with luminated controls
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Single CD with 7 speakers
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Airconditioner
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Bluetooth connectivity
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Side airbags
VE Lumina SS
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270 KW V8 engine with:
6-speed manual transmission
6-speed automatic transmission
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Limited slip differential
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Quad exhaust with chrome tips
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18’’ alloy wheels
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Sport facias, body kit and spoilers
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Alloy pedals
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High mounted SS spoiler
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Folding keys
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Front fog lamps
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6 stack CD changer, MP3 and iPod aux jack
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Amplifier and sub-woofers
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Bluetooth
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Side and curtain airbags
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TRAINING
Chevrolet Lumina
Colours Available
SS
UTE
Vehicle Identification Number
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Chevrolet Lumina
TRAINING
Drive Line
Rear differential
The rear differential is a ZF unit with an aluminium housing.The differential assembly is a cast
aluminium two-piece housing design. The differential is mounted to the rear suspension assembly by three rubber mounts, one either side of the piion flange at the front and the third at the
rear of the housing.
Note: In service, VE rear differentials will be replaced as a complete unit initially but become
repairable once a procedure and tooling is available.
Propeller Shaft
The propeller shaft is a two piece tube supported by a sealed for life centre bearing and nonservicable universal joint. It has a rubber coupling at each end joining the propeller shaft to the
transmission and the differential. All propeller shafts are fixed to the rubber couplings by 3 bolts
and 3 micro-encapsulated nuts which are discarded when removed.The rubber couplings are
then mounted to the differential with 3 bolts and the transmission with 3 bolts and 3 microencapsulated nuts which are also dicarded when removed.
Drive shafts
The drive shaft assemblies are flexible assemblies consisting of an inner and outer constant
velocity joint connected by an axle shaft.The outer constant velocity joint is secured to the
wheel/hub assembly with a locking nut.The nut must be peened over onto the flat of the outer
constant velocity joint to secure. The nut is discarded after removal.
Steering
The VE steering system has been redesigned with the following changes:
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Forward of the front axle centreline and rigidly mounted
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Variable ratio (15%change)
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Power steering cooler in lower condenser tube
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Dexron VI power steering fluid
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TRAINING
Chevrolet Lumina
Front Suspension
The VE front suspension has been redesigned as a Multi link McPherson Strut system. It is fully
adjustable for camber, castor and toe.It has a wider track 1602mm versus 1569 for VZ.
Rear Suspension
The VE rear suspension has been redesigned as a Multi link independant suspension with coil
over shock absorbers.
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TRAINING
Chevrolet Lumina
ABS Brakes
Integrated Park
Brake Lever
Pedal Release
System
ESP® System
Standard
Foundation
Brakes
upgraded
All VE models now come standard with ABS(anti-lock braking system), TCS(traction control system) and ESP(electronic stability program).
The wheel speed sensors are 2-wire hall effect active type sensors. This type of sensor is able to
measure wheel speeds down to 0.5km/h compared to passive inductive type sensors which
were only accurate to 5km/h.
Brake Pedal Assembly
●
Pedal release system
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TRAINING
Chevrolet Lumina
Electrical
The Chevrolet Lumina uses three seperate fuse boxes, in the engine compartment, left side of
passenger footwell and in the trunk. The battery is also located in the trunk. With the UTE the
battery is situated in the cabin behind the passenger seat.To prevent explosive and potentially
harmfull gases from entering the passenger compartment, the battery is fitted with an external
ventilation tube, which carries gases to the outside. Replacement battery must incorporate the
external ventilation tube feature.
There are jump start points in the engine compartment for easy access. They are located on the
left side of the engine compartment.
Important: Do not use the Positive terminal at the fuse box for jump starting.
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Chevrolet Lumina
TRAINING
Control module locations
ECM
Engine Control Module
TCM
Transmission Control Module
EBCM Electronic Brake Control Module
BCM
Body Control Module
TDM
Theft Deterrent Module
RFA
Remote Function Actuator
SDM
Sensing and Diagnostic Module
HVAC Heating Ventilation and Cooling
RSE
Rear Seat Entertainment
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TRAINING
Chevrolet Lumina
Body
Crumple Zone and Occupant Safety Cell
In frontal collisions, two separate parts of the body structure perform different functions.
The front is designed to act as a crumple zone, managing and absorbing crash energy by
collapsing in a controlled manner, so that the impact affects the car and not the occupants.
Vehicle occupants are further protected by a strongly constructed and reinforced passenger
safety cell which has been engineered to withstand high energy crash loads.
Advanced side structure design reduces the risk of serious head and neck injury in a side
impact crash. The central side (B) pillar is designed to deform in a certain way when
impacted, changing and reducing the impact velocity profile and directing energy away from
the fragile upper body. Energy-absorbing foam between the door trim and the door structure
absorbs and dissipates energy from pelvis contact in a lateral collision. The door trim profile
is shaped to minimise localised loading into an occupant’s torso.
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Chevrolet Lumina
TRAINING
Lumina’s advanced body structure design, with its
rigid passenger cell and defined deformation zones and side impact protection,
makes an essential contribution to the minimisation of injury risks in frontal, side
and rear impact collisions.
Front Structure
For optimum occupant protection, a front structure must incorporate three
competing characteristics.
1. An initially ‘soft’ structure – needed to keep crash forces on occupants as
low as possible in low speed collisions, which are the most frequent.
2. A stiffer structure – needed to absorb the energy of high speed crashes with
minimum risk to occupants.
3. A structure which is not aggressive towards other vehicles.
Designed for real world angled and offset crashes, the front structure of the Lumina is highly
efficient at absorbing crash energy. Crush initiators promote a smooth, continuous collapse
of the angled frames, which are connected by a large front suspension crossmember with a
breakaway feature for greater energy absorption.
Passenger Cell Structure
A very rigid, strong cabin structure is designed to manage extreme crash energy
loading without compromising occupant survival space.
Side Structure
The side structure is designed to offer improved energy management in real world car, truck
and pole collisions, increasing protection from the risk of head, neck and chest injury.
A substantial, closed section of roof frame and full length A (front) and
B (centre) pillar reinforcements form part of a continuous frame right around the
doors; floor and roof frames provide lateral load paths to manage crash energy.
The B pillar is designed to deform in a certain way when impacted, which
produces an impact velocity profile that is designed to direct energy away from
the fragile upper body. A conventional B pillar folds in the middle on impact,
directing impact velocity at the occupant’s most fragile areas: the head, neck
and chest.Lumina’s B pillar is designed to ‘swing’ with a pendulum effect,
so that the impact velocity profile is reduced at areas of high injury risk and
directed towards the seat and the less vulnerable lower third of the body.
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TRAINING
Chevrolet Lumina
Frame and Underbody Description
The following components are supported by a front crossmember frame which is rigidly
bolted to the body rail at 6 locations.
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The engine
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The front suspension components
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The steering linkage
The following components are supported by the rear suspension frame which is attached to
the body rail through rubber insulators at 4 locations.
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The rear drive axle assembly
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The rear suspension components
The transmission support is rigidly bolted to the floor pan and supports the transmission
extension.
The underbody frames must be properly aligned to maintain the correct transmission, suspension and wheel alignment.
Important: In the event there is evidence of structural damage to the frames they must be
replaced.
The individual underbody components contribute directly to the overall strength of the unibody. Use proper metal panel bonding techniques during service repair operations to the
underbody. Refer to Metal Panel Bonding for metal panel bonding information and for vehicle
preparation.
The components must be corrosion protected whenever body repair operations damage or
destroy the original sealing surfaces. Use a two part catalysed primer when corrosion protection is needed to welded surfaces. Apply the sealers and anti-corrosion materials as necessary. Refer to Anti-Corrosion Treatment and Repair. Do not combine paint systems. Refer to
Basecoat/Clearcoat Paint Systems, for further information.
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Chevrolet Lumina
TRAINING
VE Metal Usage
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TRAINING
Chevrolet Lumina
Sectioning Procedures
Front Compartment Side Rail Sectioning
Dimension “A” (210mm) indicates where the cut is
to be made for the sectioning procedure.
Dimension “A” (50mm) indicates where the inner
front rail needs to be cut (from the original cut) to
stagger the join.
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Chevrolet Lumina
TRAINING
Rear Pillar Inner Upper panel replacement
Dimension “A” indicates where the rear panel
can be cut. It is 250mm from hole “B”.
Rear Rail replacement
Figure “1” shows where the rear rail is
welded to the vehicle.
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TRAINING
Chevrolet Lumina
Spare Wheel Carrier Replacement
Cut along the bonding to remove spare
wheel carrier. After refitting new part do
not drive the vehicle for 24 hours.
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Chevrolet Lumina
TRAINING
Occupant Protection
Seat Belts
The seat belt remains the basis for occupant protection across the Chevrolet
Lumina range. Front seat belts are fitted with load limiters and pyrotechnic
buckle pre-tensioners. At a given force, the load limiter will release seat belt webbing in a controlled manner, reducing the pressure acting on an occupant’s chest. In a moderately severe
impact, pyrotechnic buckle pre-tensioners will ignite a small explosive
charge which pulls the belt buckle downwards to take up any ‘belt slack’,
minimising forward movement by the seat occupants. If the crash is severe,
depending on collision circumstances, airbags will also deploy.
Seat belt buckles are mounted on the seats to ensure that belt geometry
remains correct regardless of seat position. Some models also feature height
adjustable upper seat belt anchorages, which can be set to ensure the belt
geometry is correct for the size of the occupant. Three lap/sash rear seat belts
are standard fitment across the Lumina range.
Research data indicates a two-thirds injury risk reduction with the use
of a lap/sash belt.
Head Restraints
Monash University Accident Research Centre data verifies that padded front
and rear seat head restraints with height adjustment help to reduce the risk
of head and ‘whiplash’ neck injury.
Seat Structures
Front and rear seat structures are shaped to support occupants in a crash
and prevent small occupants in particular from ‘submarining’, or sliding
under the lap section of the seat belt.
Driver, Passenger and Side Impact Airbags
Designed to protect in real world collisions in the modern traffic environment,
Chevrolet’s technologically advanced airbags are an integral part of Lumina’s safety technology. They offer world’s best practice in non-aggressive occupant
protection and are effective in reducing head, neck and chest injuries to front
seat occupants of all sizes and ages, in all seating positions, in severe frontal,
frontal offset, angled and side impact collisions.
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TRAINING
Chevrolet Lumina
Airbags
Background
Head injury accounts for 70 per cent of road fatalities. If a crash victim survives a serious chest
injury, he or she can generally expect a full recovery. Brain and neck injuries are different; many
people never fully recover. The cost to sufferers and to the community of long-term and irrecoverable brain and neck injury is tragically high.
The prevention of head and neck injury is, therefore, a major focus of Chevrolet safety development. Since 1990, Chevrolet has conducted a national field accident research program in conjunction with the Monash University Accident Research Centre (MUARC).
Data analysis from this ongoing program allows Chevrolet to identify safety priorities and design
protective measures accordingly. It also offers conclusive evidence that Chevrolet airbags are
responsible for significant and lifesaving reductions in the incidence of facial, head, neck and chest
injuries.
Lumina’s driver and passenger airbag system was developed expressly to help reduce the risk of
head, facial and chest injury caused by contact with the steering wheel and dashboard in severe
frontal collisions. The seat-mounted side impact airbag (SIAB) system was developed to help protect against head, neck and chest injury in lateral collisions. Research shows that the side airbag
reduces the risk of head and chest injury by 63 per cent and 56 per cent respectively.
In a collision, vehicle occupants will have differing protection requirements, epending on their size,
gender and age. The same minor crash that bruises a 20 year-old can be life-threatening to a 60
year-old, because our bones become more fragile as we age (bone strength halves from the ages
of 20 to 40, then halves again by 65). Small-statured people face bigger risks, and babies and
children need special protection. It has also been established that females, because of their generally smaller stature and more fragile necks, are 50 per cent more likely to suffer neck injuries, and
they are up to 100 per cent more at risk of being injured in a side impact crash than male occupants.
Driver and Passenger Airbag Performance
Chevrolet has optimised the performance of its driver and passenger airbags to suit seatbelt-wearing occupants. This means that Lumina airbags will not deploy in collision situations where seatbelts provide sufficient protection, or situations where airbags cannot contribute to occupant
protection.
The airbags will deploy in the case of a severe frontal or offset frontal collision that carries a high
injury risk. TheChevrolet airbag features a ‘soft’, non-aggressive inflation onset. Its unique E-fold
pattern and interior tethers cause it to inflate with a flat surface, eliminating the risk of it catching
under the chin and causing neck injury.
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Chevrolet Lumina
TRAINING
Supplemental Inflatable Restraint System
Component Overview:
(1) Inflatable Restraint Roof Rail Module (Left Side)
(2) Inflatable Restraint Side Impact Module (Left Side)
(3) Inflatable Restraint Instrument Panel Module
(4) Inflatable Restraint Roof Rail Module (Right Side)
(5) Inflatable Restraint Front End Sensor (Left Side)
(6) Inflatable Restraint Steering Wheel Module
(7) Inflatable Restraint Front End Sensor (Right Side)
(8) Inflatable Restraint Side Impact Sensor (Right Side)
(9) Inflatable Restraint Side Impact Module (Right Side)
(10) Seat Belt Buckle Pretensioners
(11) Sensing and Diagnostic Module (SDM)
(12) Inflatable Restraint Side Impact Sensor (Left Side)
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TRAINING
Chevrolet Lumina
Driver and Passenger Deployment sequence
0 ms
15 ms
The crash begins
when the front of
the bumper
contacts the
impacting object.
The crash sensor
decides that the
collision is severe
enough to deploy
the airbags.
One millisecond (ms) = one thousandth of a second
20 ms
45 ms
55 ms
60 ms
70 ms
100 ms
150 ms
The seat belt buckle
pre-tensioners
trigger, driver and
passenger airbags
begin to inflate.
The large (60 litre)
driver airbag is fully
inflated. Interior
tethers and a
unique E-fold
pattern keep it flat
on the facing side.
The passenger
airbag is fully
inflated. It is
115 litres in size
and also presents
a flat surface to the
occupant.
The driver’s head
and chest contact
the airbag, which is
large enough to
completely cover
the steering wheel.
The passenger’s
head and chest
contact the airbag.
Front seat
occupants sink
deeply into their
respective,
continually deflating
airbags. Upon
reaching forward
displacement limits,
occupants begin to
rebound.
Occupants continue
to travel rearwards
until making
contact with seat
backs and head
restraints, which
support them
before coming
to rest.
During the inflation process, occupants begin to move forward.
Seat belts progressively restrain them and elongate at particular
force limits.
Upon occupant contact, the airbags immediately begin to
deflate. Their large area evenly distributes energy loads on the
head and chest, significantly reducing risks of severe injury.
Following airbag deployment, side or frontal, the Body Control Module will turn off the engine and fuel pump, unlock doors and
turn the interior light on, if battery power remains available.
Repairs and Inspections Required after a collision
Important: After any collision, inspect the following components as indicated. If you detect any
damage, replace the component. If you detect any damage to the mounting points or mounting
hardware, repair the component or replace the hardware as needed.
●
The Instrument panel area- inspect for bending, twisting, buckling etc.
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The steering column, inspect for excessive movement(check for shear capsule seperation)
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The seat belts
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The Instrument panel mounting points and brackets
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The seats and seat mounting points
Before working on the restraint system the vehicle battery needs to be disconnected. There is a two minute
waiting period before work can continue on the SRS.
Accident with Frontal Air Bag deployment
Important: The following must be replaced after a accident:
●
SDM
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Front end sensors
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Seat belt pretensioners
●
Driver Airbag
●
Steering Column
●
Steering wheel
●
Coil and the coil electrical harness
●
All occupied seat belts
●
All occupied seats
Note: The SDM needs to be replaced only after airbag deployment or after 3 seat belt deployments.
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Chevrolet Lumina
TRAINING
Accident with side air bag deployment
Important: The following must be replaced after a accident:
●
Side impact sensors(SIS), on the side of the impact.
●
Side impact airbags, on the side of the impact
●
Roof rail module, on the side of the impact.
●
The steering column, inspect for excessive movement.
●
Inflatable restraint sensing and diagnostic module SDM.
●
All occupied seatbelts, including seat belt on impacted side.
Sensor Replacement Guidelines
Important: The SIR front/side air bag sensor replacement policy requires replacing sensors in the
area of accident damage. The area of accident damage is defined as the portion of the vehicle
which is crushed, bent, or damaged due to a collision. An example of this would be a moderate
collision where the front of the vehicle impacts a tree. The SIR front sensor must be replaced.
●
Replace the sensor whether or not the airbags have deployed.
●
Replace the sensor even if it appears to be undamaged.
Important: Sensor damage which is not visible, such as slight bending of the mounting bracket or
cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system.
Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow
a diagnostic trouble code (DTC) table and a malfunctioning sensor is indicated, replace the sensor.
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TRAINING
Hummer
Hummer(H3)
Introduction
The Hummer H1 and H2 models - adapted from the Humvee vehicle developed for military
uses - have been sold primarily in the US and Canada, although GM began exporting the H2
to countries in Europe, Asia and the Middle East in 2004.
GM describes the H3 as "an authentic Hummer, offering the brand's iconic design and famed
off-road capability in a midsize and more accessible package.
In addition, H3 delivers surprisingly comfortable on-road manners and a clean, well-crafted
interior."
The South African-built H3 will be available with a new 242 horsepower (180 KW) Vortec
inline 5-cylinder engine, choice of manual or automatic transmissions, and a premium, fulltime four-wheel-drive system. General Motors SA has introduced a 5.3-litre V8 engine to its
H3 Hummer range.
The engine is the 224kW/434Nm unit used in the US-built H3A and is being imported, complete with transmission, from the US. It makes 44kW more power, 104Nm more torque and
has 861kg more towing capacity than the 3.7-litre version
The V8 has been hooked to a Hydra-Matic electronically controlled four-speed auto transmission rated to tow 2448kg.
.
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Hummer
TRAINING
H3
Components and Features
Engine: Vortec 3700 3.7L
Power: 180kw @ 5600rpm
Torque: 328nm @4600rpm
Transmission/Drivetrain: Full-time 4WD with 5-speed manual or 4 speed automatic
Steering: Power-assisted, rack and pinion with tri brushing mount design
Brakes: Electro-hydraulic power 4-wheel disc
Wheels and Tyres: 16in. x 7.5 in. aluminium wheels, 265/75R16 all-terrain tyres
Standard Equipment
Stabili Track Stability Enhancement System
Electronically controlled 2-speed transfer case
Cruise control
Power windows, including “express down” driver window
Power door locks
Dual front airbags with Passenger Sensing System (NOTE 1)
Roof-rail airbags with rollover sensors (NOTE 1)
Seating for 5
Cloth seats
Fold-down 60/40 split rear seat
Remote keyless entry with panic button
Electric rear window defogger
Manually controlled front air conditioning system
with electronic controls
AM/FM stereo with CD player
TheftLockTM for radio
Swing gate mounted full-size spare tire
Driver Information Center with up to 26 alerts
Carpeted floor mats
Electrochromic rearview mirror with 8-point compass and outside
temperature display
Retained accessory power
Traction control
Content alarm anti-theft system
PASSLock® anti-theft vehicle security system
Battery rundown protection
3 power points (2 front and 1 rear)
Front and rear bumper with recovery hooks
25
TRAINING
Hummer
Continued
Fog lamps
TuflorTM rubberized flooring in cargo area
Front and rear assist handles
Trailer hitch
Full underbody protection
Optional Equipment
Leather-appointed front and rear seats
Heated front seats with 8-way power adjustment
Premium 7-speaker Monsoon® sound system
Touch screen DVD-based navigation radio
Grille brush guard
Chrome or black tubular assist steps
Chrome hood louvre
Trailer wiring harness
Sunroof with “express open” and “express close”
In-dash 6-disc CD changer
16 in. x 7.5 in. chrome wheels
Smoker’s Package
Hydra-Matic 4L60-E 4-speed automatic transmission
Specifications
HEIGHT: 1893 mm (without optional roof-rack crossbars)
WIDTH: 1989 mm (excluding foldable mirrors, including fender flares)
LENGTH: 4782 mm (with rear tire cover)
WHEELBASE: 2841 mm
MAXIMUM TOW LOAD: 2448 kg
FUEL CAPACITY: 87L
SIDE SLOPE CAPABILITY: 40%
Interior Colours
Leather trim colors: Ebony, Light Cashmere and Ebony with
Morocco-toned inserts
Cloth trim colors: Ebony with Pewter inserts, Ebony with Light
Cashmere inserts
26
TRAINING
Hummer
Available Colours
Black
Birch White
Yello
Arctic Silver
Victory Red
Ocean Blue
Lunar Grey
Dimensions
27
TRAINING
Hummer
Suspension
H3 provides a surprisingly smooth, comfortable ride, along with the responsive handling and braking
control that one wants for daily driving. Key chassis features that contribute to this combination of
smoothness and control, both on- and off-road, include:
●
A fully welded ladder-type frame, with a modular, three-piece design that incorporates fully boxed
components for outstanding strength and stiffness.
●
An independent front SLA torsion bar suspension and "Hotchkiss" design multi-leaf, semi-elliptic,
single-stage leaf spring rear suspension. The standard suspension provides excellent on-highway
comfort and outstanding off-road capability, while the optional Off-Road Adventure package
delivers more extreme off-road capability.
●
Underbody protection that includes four standard protective shields, including the front skid plate;
an oil pan skid plate that also protects the front axle; and a transfer case shield and a fuel tank
shield. Additional protection is also available from optional chassis-bolted rocker panel protectors.
●
A highly sophisticated standard power rack-and-pinion steering system, with a three-bushing
design and a 17:1 ratio that contributes to a very maneuverable 37-foot curb-to-curb turning
circle.
●
Electro-hydraulic four-wheel anti-lock disc brakes with Dynamic Rear Proportioning, for quick,
controlled stops.
●
Standard single-wheel, full-function traction control that uses a combination of engine intervention
and brake management to allow as many as three wheels on a slippery surface and still provide
impressive traction capability. It also interacts with the transfer case to provide additional off-road
operating modes.
●
StabiliTrak vehicle stability enhancement system, which enhances safety, stability and control on
all roads.
28
Hummer
TRAINING
Engine and Drivetrain
Specifically designed as a truck engine, the Vortec 3700 is a 3.7L inline five-cylinder offering an
excellent combination of power and efficiency. The engine delivers 180KW at 5600 rpm and
322Nm of torque at 4600 rpm. In terms of performance, the Vortec 3700 provides the H3 with
excellent power and control for off-roading, with comfortable and capable on-road characteristics,
including acceleration that equals the V-8 powered H2 in most driving conditions. The Vortec
3700 brings premium features and advanced technologies –- including dual overhead cams, variable valve timing, electronic throttle control and low mass. The engine also features unique
counter-rotating balance shafts to help minimize noise, vibration and harshness.
The Vortec 3700 is available in the H3 with either a standard, smooth-shifting five-speed manual
transmission or a Hydra-Matic 4L60-E electronically controlled four-speed automatic transmission. The automatic transmission includes shift modes specific to low-range operation, which, combined with speed-based throttle progressions, help optimize driveability in low-range, off-highway
operation.
The H3 also has a standard new Borg-Warner two-speed electrically controlled full-time fourwheel-drive system with a 2.64:1 ratio low-range gear reduction for highly controlled off-road
obstacle climbing. An optional version provides aggressive low range gearing –- a 4.03:1 ratio –
- for ultimate obstacle-climbing control.
29
TRAINING
Hummer
Fuse Block
Fuse Block is located in the left front of the engine compartment, directly in front of the
battery.
Vehicle identification sticker can be located inside the right rear door opening.
30
Hummer
TRAINING
Body
HUMMER owners value the inherent strength and feeling of security their trucks exude.A reinforced passenger compartment safety cage helps provide protection against side and front
impacts. The strong, rigid steel structure surrounds the passenger compartment, runs from the
A-pillars to the roof rail, back to the D-pillars and includes the bottom rocker panels, under-floor
longitudinals and frame. The all-steel body panels and exceptionally strong frame further protect
occupants in a collision. The fully welded, ladder-type frame optimizes crash performance, in
addition to standing up to rigorous off-road requirements.
Mild Steel
High Strength Low Alloy Steel
31
TRAINING
Hummer
Repair Prodecures
Front Hinge Pillar Sectioning
Note: Section in specific areas only.Sectioning outside these areas may compromise the structural
integrity of the
vehicle.
Measure down from the lower edge of
the hole 10mm and that is your cut line.
32
Hummer
TRAINING
Centre Pillar Sectioning
Measure down 200mm from the lower edge of the door opening(1) to create the cut line(5).
Rear Pillar Sectioning
Measure down 200mm from the lower striker
hole to locate the cut line.
Create a 50mm backing plate(A) and a
100mm backing plate(B) from the unused
portion of the service part.
33
TRAINING
Hummer
Quarter Panel Sectioning
Create backing plates from the unused portion of the service part to reinforce the sectioning joint.
Front Side Door Outer Panel Replacement
Locate and drill out all factory welds.
Grind the edges of the outer panel to seperate
the outer panel from the door shell.
34
Hummer
Warning: Inspection of the door guard beam
for damage must be performed before replacement of the door outer panel.
Using a hammer re-hem the hem flanges around the
door shell.
TRAINING
Bond outer panel to door shell.
Weld the door outer panel to the door frame.
35
TRAINING
Hummer
Supplemental Inflatable Restraint System
Component Location
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Inflatable Restraint Front End Sensor - Right--Located on the front of the vehicle in the
engine compartment
Inflatable Restraint I/P Module--Located at the top right under the instrument panel
Inflatable Restraint Side Impact Sensor (SIS) - Right--Located under right front door trim
near the lower rear of door frame
Inflatable Restraint Roof Rail Module - Right--Located in the headliner along roof rail
Passenger Presence System--Located under passenger seat
Seat Belt Retractor Pretensioner - Right--Located on the floor next to the right front seat
Rear Liftgate Start-A Gas Shock--Located at rear of vehicle
Rear Liftgate Start-A Gas Shock--Located at rear of vehicle
Inflatable Restraint Seat Position Switch - Right--Located on the side of the right front seat
Seat Belt Retractor Pretensioner - Left--Located on the floor next to the left front seat
Inflatable Restraint Vehicle Rollover Sensor--Located under driver seat
Inflatable Restraint Side Roof Rail Module - Left--Located in the headliner along the roof rail
Inflatable Restraint Side Impact Sensor (SIS) - Left--Located under left front door trim near
the lower rear of door frame
Inflatable Restraint Seat Position Switch - Left--Located on the side of the left front seat
Inflatable Restraint Sensing and Diagnostic Module (SDM)--Located under center floor con
sole
Inflatable Restraint Steering Wheel Module--Located on the steering wheel
Battery and Underhood Fuse Block - SIR Fuse--Located in engine compartment on left side
Inflatable Restraint Front End Sensor - Left--Located on the front of the vehicle in the
engine compartment
36
Hummer
TRAINING
Restraint system
The Supplemental Inflatable Restraint (SIR) System consists of the following components:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
AIR BAG indicator located on the instrument panel cluster (IPC)
Driver and passenger knee bolsters
Inflatable restraint front end sensors (left/right)
Inflatable restraint PASSENGER AIR BAG ON/OFF indicator located on the instrument panel
Inflatable restraint Passenger Presence System (PPS)
Inflatable restraint passenger seat belt tension sensor
Inflatable restraint seat position sensors (SPS) (driver/passenger)
Inflatable restraint sensing and diagnostic module (SDM)
Inflatable restraint steering wheel module
Inflatable restraint steering wheel module coil
Inflatable restraint wiring harnesses
Seat belt pretensioners (driver/passenger)
Steering wheel and column
Inflatable restraint roof rail modules (left/right)
Inflatable restraint side impact sensors (SIS) (left/right)
Inflatable restraint vehicle rollover sensor
SDM
The sensing and diagnostic module (SDM) is a microprocessor and the control center for the
Supplemental Inflatable Restraint (SIR) System. The SDM contains internal sensors along with
several external sensors, if equipped, mounted at various locations on the vehicle. In the event
of a collision, the SDM performs calculations using the signals received from the internal and
external sensors. The SDM compares the results of the calculations to values stored in memory.
When these calculations exceed the stored value, the SDM will cause current to flow through
the appropriate deployment loops to deploy the air bags.
PPS
The PPS is used to monitor the weight of an occupant on the front outboard passenger seat and
communicate the status to the sensing and diagnostic module (SDM) whether to enable or suppress the deployment of the instrument panel (I/P) module. The PPS consist of an electronic
control module, silicone filled sensor pad, pressure sensor, seat belt tension sensor, wiring harness, and PASSENGER AIR BAG ON/OFF indicators. The silicone filled sensor pad is located
under the passenger seat foam cushion. The weight of the occupant sitting in the front passenger seat is measured as a pressure change within the bladder by the pressure sensor. The pressure sensor sends a voltage signal to the PPS module. If the pressure from the occupants weight
is less than a specified value, the PPS module will send a suppress signal to the SDM to disable
the I/P module. If the pressure from the occupants weight is higher than a specified value, the
PPS module will send an enable signal to the SDM to enable the I/P module. The PPS module
will notify the customer of the enable/disable status by turning on one of the PASSENGER AIR
BAG ON/OFF indicators located on the instrument panel.
37
TRAINING
Hummer
SPS
The seat position sensor (SPS) is used to determine the proximity of a front driver or passenger
seat position with respect to the frontal air bag. The SPS interfaces with the sensing and diagnostic module (SDM). The state of the SPS allows the SDM to disable stage 2 of the frontal air
bag for a front seat that is forward of a forward/rearward point in seat track travel. The SPS is a
Hall effect sensor that is mounted on the outboard seat track of both the driver and passenger
seats. The seat track includes a metal bracket that shunts the SPS magnetic circuit creating two
states of seat position.Its important to understand that the SPS is secondary to the passenger
presence system (PPS) in the disable mode the passenger air bag will not deploy regardless of
the SPS status.
Inflatable Restraint Seat Belt Passenger Sensor
The seat belt tension sensor is used to enhance the Passenger Presence System (PPS) when an
infant car seat is properly restrained on the front outboard passenger seat. The seat belt tension
sensor is a 3-wire potentiometer mounted on the lower seat belt anchor and provides an input to
the PPS module. When an infant car seat is properly restrained on the front passenger seat, the
seat belt is tightly secured through the infant car seat. The seat belt pulls on the tension sensor
and changes the voltage signal to the PPS module. The PPS module uses the voltage signal to
help determine if a tightly belted infant car seat is installed. The PPS uses the inputs from the
seat belt tension sensor and the PPS pressure sensor to determine if the instrument panel (I/P)
module should be suppressed or enabled.
Inflatable Restraint Vehicle Rollover sensor
The vehicle rollover sensor is used to supplement the side Supplemental Inflatable Restraint
(SIR) System. The sensing and diagnostic module (SDM) uses the input from the vehicle rollover
sensor to assist in determining the severity of a vehicle rollover or near rollover condition. If the
SDM determines a deployment is warranted, the SDM will send a signal for the curtain airbags
to deploy.
Airbag Indicator
The AIR BAG indicator, located on the instrument panel cluster (IPC) is used to notify the driver
of Supplemental Inflatable Restraint (SIR) System malfunctions and to verify that the sensing
and diagnostic module (SDM) is communicating with the IPC.
38
Hummer
TRAINING
Passenger Air Bag ON/OFF Indicators
The PASSENGER AIR BAG ON/OFF indicators located on the instrument panel are used to notify
the driver when the Passenger Presence System (PPS) has enabled or disabled the instrument
panel (I/P) inflator module.
Dual Stage Inflator Modules
Dual stage inflator modules contain a housing, inflatable air bag, 2 initiating devices, canister of
gas generating material and, in some cases, stored compressed gas. The 2 initiators are part of
the inflator module deployment loop. The inflator modules have 2 stages of deployment, which
varies the amount of restraint to the occupant according to the collision severity. For moderate
frontal collisions the inflator modules deploy at less than full deployment which consists of stage
1 of the inflator module. For more severe frontal collisions a full deployment is initiated which
consists of stage 1 and stage 2 of the inflator module.
Steering Wheel Coil
The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of 2 or more current-carrying coils. The coils
allow the rotation of the steering wheel while maintaining continuous electrical contact between
the driver airbag and steering column.
Front End Sensors
The front end sensors are electronic and provide inputs to the sensing and diagnostic module
(SDM).
Wiring Harness
The wiring harnesses connect the sensing and diagnostic module (SDM), inflator modules, Passenger Presence System (PPS), front end sensors, seat position sensors (SPS), passenger seat
belt tension retractor sensor, and the serial data circuit together using weather pack connectors.
Seat Belt Pretensioner
The seat belt pretensioner consist of a housing, a seat belt retractor, the seat belt webbing, an
initiator, and a canister of gas generating materials. When the vehicle is involved in a collision of
sufficient force, the sensing and diagnostic module (SDM) causes current to flow through the
seat belt deployment loops to the initiator. Current passing through the initiator ignites the material in the canister producing a rapid generation of gas. The gas produced from this reaction
deploys the seat belt pretensioner and retracts the seat belt webbing, which removes all of the
slack in the seat belts. Depending on the severity of the collision, the seat belt pretensioner may
deploy without the frontal inflator modules deploying, or they will deploy immediately before the
frontal inflator modules deploy.
39
TRAINING
Hummer
Steering Wheel and Column
The steering wheel and column are designed to absorb energy when driver contact is made with the steering
wheel or inflated air bag. In a frontal collision the driver may contact the steering wheel directly or load the
steering wheel and column through the inflated air bag. When the driver applies load to the air bag or steering
wheel the column will compress downward absorbing some of the impact, helping to reduce bodily injuries to
the driver. The steering wheel and column must be inspected for damage after a collision.
Driver and Passenger Knee Bolsters
The knee bolsters are designed to help restrain the lower torsos of front seat occupants by
absorbing energy through the front seat occupants upper legs. In a frontal collision the front seat
occupants legs may come in contact with the knee bolsters. The knee bolsters are designed to
crush or deform absorbing some of the impact, which helps to reduce bodily injuries. The driver
and passenger knee bolsters are located in the lower part of the instrument panel and must be
inspected for damage after a collision.
40
Cadillac
TRAINING
Cadillac BLS
Introduction
The front-wheel drive BLS offers expressive design, outstanding ride and acoustic comfort.The BLS was developed for luxury customers, with particular attention to the demands
of the European and other international markets.The Cadillac BLS design was conceived by
an international team of designers led by GM's Vice President of Design Ed Welburn. The
vehicle has clear, sharply defined contours, striking wedge shape and an elegant interior.
In a Cadillac first, the BLS will be available with a turbodiesel variant. The 1.9L four-cylinder unit, with common-rail direct injection technology and 150 hp, is fitted with a maintenance-free diesel particulate filter and complies with Euro 4 emissions standards. The range
of gasoline engines - all turbo-charged - includes two 2.0L four-cylinder versions (175/210
hp) and a high-tech 2.8L six-cylinder unit at 255 horsepower with twin-scroll turbocharger
and variable phasing of the intake camshafts. The BLS offers five- or six-speed manual transmissions and five- or six-speed automatic transmissions, depending on engine type.
The chassis, which has McPherson struts in front and a four-link rear axle, is designed for the
powerful engines and the high demands of a premium vehicle. The chassis tuning ensures
dynamic handling performance without compromising comfort.
41
TRAINING
Cadillac
Specifications
Technical Specification
BLS 1.9D
BLS 2.0
BLS 2.8 V6
1910cc
1998cc
2792cc
4 valves per cyl
4 valves per cyl
4 valves per cyl
4
4
V6
Engine
Size
Valve Train
Number of cylinders
Power Kw @ r/min
110/4000
131/5500
184/5500
Torque Nm
320/2000
265/2500
365
Bosch/ Common rail
Trionic/Multi point
Trionic/Multi point
Type
6 speed man
6 speed man/5 sp auto
6 speed auto
Drive
FWD
FWD
FWD
Ignition/ Fuel Injection
Transmission
Wheels and Tyres
Rim Size
6.5j x 16”
6.5j x 16”
7.5j x 17”
Tyre Size
215/55 R16
215/55 R16
235/45 R17
x
x
x
x
x
Full size spare wheel
Chassis
ESP
ESP plus
x
Cruise Control
x
x
x
ABS
x
x
x
Traction Control
x
x
x
StabiliTrack
x
x
x
Length
4680
4680
4680
Curb Weight(kg)
1510
1450
1560
425
425
425
5
5
5
Leather Steering Wheel
x
x
x
Telescopic Adjustable
x
x
x
Leather seat trim
x
x
x
Electric Windows
x
x
x
Single Zone Climate Con.
x
x
Dimensions
Luggage capacity(L)
Seating Capacity
Steering
Comfort
Dual Zone Climate Con.
x
8 Way power Adjustable
Drivers seat
x
Audio Controls on Steering
x
x
x
CD player
x
x
x
Adjustable Centre Armrest
x
x
x
Rear Armrest
x
x
x
42
Cadillac
TRAINING
Colours
Parchment Silver Metallic
Pepper Green Metallic
Th
Quicksilver Metallic
Titan Grey Metallic
Grounding Points
Jet Black Metallic
Nocturne Blue Metallic
Black
43
TRAINING
Cadillac
Located inside the engine compartment on firewall.
Fuse Box Location
Engine compartment, inside vehicle and in the trunk.
44
TRAINING
Cadillac
Grounding Points
Inside of left A-Pillar
On top of tunnel under centre console.
45
TRAINING
Saab
Saab 9-3
Introduction
Saab's new 9-3 range, has been expanded to eight and includes sedans, convertibles and – for
the first time in this market – a station wagon, the five-door SportCombi.
Each has new front styling with a wing motif in the centre of the grille and a strong, curved
line around the front of the clamshell bonnet drawn from the company's heritage as an aircraft manufacturer.
Saab 9-3 buyers can now choose from four turbocharged and intercooled engines, starting
with a two-litre LPT engine that produces a claimed 110kW at 5500rpm and 240Nm at
2000rpm but only in a sedan.An uprated version, the 2.0T Linear for which Saab quotes
129kW at 5500rpm and 265Nm at 2500rpm, is available in the convertible with a choice fivespeed manual or semi-auto transmission, or in the SportCombi as a semi-auto only.The twolitre engine has been boosted further, to 154kW at 5300rpm and 300Nm at 2500, for the Vector sedan, also only with a semi-auto.The top-of-the-range Aero sedan and convertible models are fitted with a 2.8-litre V6 capable of 184kW at 5500rpm and 350Nm at 2000rpm and
driving through a six-speed semi-auto transmission.
There's also a 1.9-litre, common-rail injection diesel with a variable-nozzle turbo for the
sedan; it's rated at 110kW at 4000rpm and 320Nm at 2000rpm.
Saab has designed the new 9-3 "from the driver outwards". The main instrument panel, for
example, curves in front of the driver and a wide range of functions can be set to personal
preferences, including the dual-zone auto aircon.
46
TRAINING
Saab
Trim Levels
Body and Exterior styling
Linear
Body Coloured bumper and side skirts
Body Coloured door mirrors
Vector
Aero
-
std
-
std
std
std
Colour matched door handles
-
-
std
Exterior sports body kit
-
-
std
std
std
std
FRont fog lamps
Performance
Electronic stability programme plus (ESP Plus)
-
-
std
Electronic stability programme (ESP)
std
std
-
Manual 5-speed transmission-Petrol
std
-
-
Diesel
Petrol
-
Manual 6-speed transmission
Sentronic 6-speed automatic transmission
Traction control system
-
-
std
std
std
std
Comfort
Adjustable Front armrest
std
std
std
Automatic Climate control
std
std
std
Electrically operated windows
std
std
std
Electically operated/heated door mirrors
std
std
std
Safety and security
Anti lock braking system(ABS)
std
std
std
Anti-theft alarm incl. immobiliser
std
std
std
Cornering brake control
std
std
std
Drivers airbag
std
std
std
Electronic brake force distribution(EBD)
std
std
std
Front seat side airbags
std
std
std
Passengers airbag front
std
std
std
Rear head restraints
std
std
std
Active head restraints front
std
std
std
Roof rail airbag
std
std
std
Seatbelt pretensioners ,front seats
std
std
std
Remote central locking
std
std
std
High level brake light
std
std
std
47
TRAINING
Saab
Specifications
Measurements (mm.)
Luggage compartment 425 dm3 VDA; 450 dm3 SAE. Rear seats fold down completely or 60/40 %
Fuel tank capacity 58 liters
Max towing weight 1400-1600 kg (braked), 750 kg (unbraked)
Max roof load 100 kg
Kerb weight 1410-1690 kg depending on specification
Max total weight 1970-2020 kg depending on specification
Seating Capacity 5
Drive train Front wheel drive
Manual 5 speed Transverse drive unit, full synchromesh, manual gearbox.
Manual 6 speed Transverse drive unit, full synchromesh, manual gearbox.
Sentronic five-speed automatic Electronically controlled automatic transmission with manual shift possibility.
Direct mechanical lock-up in third, fourth and fifth gears.
Sentronix six-speed automatic Electronically controlled automatic transmission with manual shift possibility.
Direct mechanical lock-up in third, fourth, fifth and six gears.
ENGINE SPECS
1.8t 110 kW
Petrol engine
Four-cylinder in-line, Aluminium cylinder head and block. Turbocharger, intercooled. DOHC,16-valve. Balancer shafts
Ignition/Fuel injection Saab Trionic 8 engine management. Direct ignition. Multi-point fuel injection.
Displacement (dm3) 1,998
Bore/Stroke (mm) 86 / 86
Compression ratio 9.5:1
Max boost pressure (bar) 0.5
Max. Power 110 kW (150 hp) at 5500 r/min
Max. Torque 240 Nm @ 2000 - 3500 r/min
Recommended fuel (octane) 95 (min. 91)
2.0T 154 kW
Petrol engine
Four-cylinder in-line, Aluminium cylinder head and block. Turbocharger, intercooled. DOHC, 16-valve. Balancer shafts
Bore/Stroke (mm) 86 / 86
48
Saab
TRAINING
2.8 V6 Turbo 184 kW
Petrol engine
Six-cylinder V6, Aluminium cylinder heads and block. Twin-scroll turbocharger, intercooled.
DOHC, 24-valve. Variable valve timing (inlet). Dual-mass flywheel.
Bore/Stroke (mm) 89 / 74.8
1.9TiD 110 kW
Diesel engine
Four-cylinder in-line, Aluminium cylinder head, cast iron block. DOHC 16v. Common rail,
direct and multiple injection. Turbocharged. VNT, intercooled. Dual-mass flywheel. Maintenance-free particulate filter. Euro 4
Emissions (Jan 06) compliant
Ignition/Fuel injection Bosch EDC 16. Ignition/ fuel-injection system.
Bore/Stroke (mm) 90.4 / 82
Max. Power 110kW (150 hp) @ 4,000 rpm
49
TRAINING
Saab
Colours
1
2
3
4
5
6
7
8
9
10
1 Black
5 Jet Black
2 Laser Red
6 Nocturne Blue
10 Snow Silver
3 Fusion Blue
7 Parchment Silver
11 Titan Grey
4 Ice Blue
8 Pepper Green
11
9 Smoke Beige
Mag Wheel Options
Paint code
Paint code is displayed on sticker in glove com
partment.
50
Cadillac/Saab
TRAINING
Cadillac/Saab Body
Among the characteristic elements of the Saab 9-3 Sport Sedan's body are high torsional rigidty,
a sturdy and stable cabin enclosure, generous front and rear deformation zones and very effective
side impact protection.
The body of the Saab 9-3 Sport Sedan is constructed to create a survival zone for the driver and all
passengers in the event of a collision. The large front deformation zones are designed to create a
stable and robust deformation characteristics.
The central member distributes the force to a large surface. The front structure has three load
routes per side. These load routes are linked together via crossmembers to distribute the force.
The most important component in the event of a side impact is the B-pillar, which is designed to
make use of the "pendulum effect". The B-pillar is extremely stiff in the middle and slightly softer
in its upper and lower sections. This results in the B-pillar acting as a pendulum and distributing
forces via the sill into the car. The front doors have angled door members that direct the forces
into the B-pillar and intensify the pendulum effect. Because of the powerful design of the B-pillar
and the pendulum effect, a greater portion of the force is directed towards the lower midsection of
the body instead of the softer areas at chest height.
51
TRAINING
Cadillac/Saab
It is of great importance that the characteristics of the energy-absorbing deformation zones and the
stabile cabin enclosure are not impaired or changed if the body is repaired. The cabin enclosure must
never be weaker after a repair. At the same time, the deformation zones must never be made stronger than they were before the damage was done. If the front or rear is too strong, it will intensify the
forces instead of retarding them, which, in turn, will increase the strain on the passengers.
Body Reinforcements
The body is reinforced in the areas that are most vulnerable in the event of a collision. These reinforcements are manufactured with high-strength steel.
1) Lower section of A-pillar
2) Upper section of A-pillar
3) Sill
4) B-pillar
5) Upper part of wheel housing
6) Lower part of wheel
52
TRAINING
Cadillac/Saab
In addition to the reinforcements, high strength steel (HSS) is used in order to make the cabin frame
as structually stable as possible. The illustration shows which parts of the body structure are made
from HSS.
Permissible Joint Locations
A- Pillar
Sill and B-Pillar
C_Pillar
53
TRAINING
Cadillac/Saab
Front frame member
Rear frame member
A-Pillar upper section repair
No. 6 indicates the bottom cut line 70mm
from the door opening anchorage point.
No. 7 indicates the top cut line 25mm from
clip hole.
Inner cover plate also has to be removed to fit
new A-Pillar.
54
Cadillac/Saab
TRAINING
Outer Sill
Middel Section Replacement
No. 2 shows permissable cuts on front and
rear of sill.
No.3 shows cut on bottom of B-pillar.
Front Section Replacement
Dark lines indicate the permissible cuts.
55
TRAINING
Cadillac/Saab
B-pillar
Illustrates permitted cuts
points.
No. 5 shows inner cut on B-pillar.
No.36 -38 shows the seam welds.
56
Cadillac/Saab
TRAINING
Bumper member with intergrated collision box
Remove all bolts (2),4 per side.
Drill out spot welds (1).
Part of front frame member
The top illustration shows the right-hand frame
member.
The bottom illustration shows the left-hand
member and if the battery bracket has been
removed, the cut can be made in the middle of
the bracket location.
Front frame member assembly
No. 7 shows the spot welds to be drilled through
to remove frame member.
57
TRAINING
Cadillac/Saab
Rear side panel
No. 2 and 3 show the cut points for panel.
Rear frame member
Cut the frame member as indicated by the
marks. Do not cut further forwards than illustrated. The upper illustration refers to the
right-hand side and the lower illustration to
the left-hand side.
58
TRAINING
Cadillac/Saab
Body Sealers
Illustrates where underseal is to be applied.
Illustrates where sealers are to be used.
Illustrates where sealers are to be used.
59
TRAINING
Cadillac/Saab
Restraint System
Component Location
Front crash sensor left and right
Front and rear side crash sensors,
left and right of vehicle.
Driver and passenger airbag.
Curtain airbag left and right.
60
Cadillac/Saab
TRAINING
Seat airbag, left and right front seats
Seat belt pretensioners located in reel at bottom
of B-pillar.Left and right front seats.
Airbag control unit situated under centre console
on top of tunnel.
Steering wheel contact unit.
Passenger Presence module under passenger front
seat.
61
TRAINING
Cadillac/Saab
Passenger presence sensor
Seat position sensor, left and right front seats.
Replacing components after a crash
During the repair of cars with only activated seat belt tensioners and/or side airbags and inflatable curtain/roll bars (CV), components must be replaced as follows.
The control module can be used for a maximum of three times with activation of seat belt tensioners and/or side airbags and inflatable curtain/roll bars (CV).
Check and rectify the wiring harness if necessary for the side impact sensors, side airbags, inflatable curtain/roll bars (CV) and seat belt tensioner.
Cars with activated seat belt tensioners
During the repair of cars with activated seat belt tensioners the following components should
always be replaced:
• All seat belts with seat belt tensioners on the front seat used during the accident.
• Both seat belts on the outer seats on the rear seat.
• The seat belt for the centre seat on the rear seat, if used during the accident (3)
62
Cadillac/Saab
TRAINING
Cars with activated side airbags and inflatable curtains.
During the repair of cars with side airbags and inflatable curtain the following components must
always be replaced:
• Side impact sensors, inflatable curtain, side airbag and backrest upholstery bag (3). (The side
impact sensors do not need to be replaced if there has been no mechanical damage to the
sensor and if the sensor does not give an trouble code).
Cars with activated front airbags
During the repair of cars with activated airbags the following components should always be
replaced:
• Steering wheel and airbag and the steering column assembly (1)
• Contact roller (2)
• Control module (3)
• All seat belts with seat belt tensioners on the front seat used during the accident (4)
• Both the seat belts on the outer seats. The seat belt for the centre seat on the rear seat, if
used during the accident (5).
• The passenger side airbag (where appropriate) and the dashboard (6)
• The side airbags, with respective sensors and backrest upholstery bags, which have been activated during the accident. (The side impact sensors do not need to be replaced if there has
been no mechanical damage to the sensor and if the sensor does not give a diagnostic trouble
code) (7).
• Front sensors, (The front sensors do not need to be replaced if there has been no mechanical
damage to the sensor and if the sensor does not give an trouble code) (8)
• Inflatable curtains, which have been activated during the accident, with A-, B-, C-pillar trim
and headlining
63

Chevrolet Lumina Hummer Cadillac Saab Niche Market

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