Captiva

Chevrolet Captiva
Model Introduction Training For

Approved Motor Body Repairers
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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
GENERAL 4
BODY 12
SUSPENSION and STEERING 30
ELECTRICAL 34
RESTRAINT SYSTEM 42
ALL WHEEL DRIVE 48
This self-study programme highlights the design and function of new vehicle models,
new automotive components or new technologies.
Note
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.

TRAINING General
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.
2008 General Motors Corporation. All rights reserved.

General TRAINING
Weights and Capacities
Curb weight (with driver)

Engine Transmission Weight
Manual Transmission 1.730 - 1,815 (5 seater) 1,760 - 1,845 (seven seater)
Z24SED
Automatic Transmission Still awaiting release
Manual Transmission Still awaiting release

Z32SED
Gross vehicle weight

Manual Transmission 2,180 (5 seater) 2,320 (seven seater)
Z24SED
Manual Transmission Still awaiting release

Z32SED
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

TRAINING General
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.
Front suspension type McPherson strut
Rear suspension type Four link
Alignment (unloaded) Camber Front - 0.55o +- 0.75o

:
Rear: - 0.35o +- 0.5o
Castor 2.18o +- 0.73o
Toe-in Front 0.1o +- 0.08o
Rear 0.09o +- 0.1o
Steering Type Power assisted rack and pinion
Overall gear ratio 18.5 : 1
Steering wheel diameter (mm) 390
Minimum turning radius (m) 5.75
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.
Tyre size Wheel dimension Tyre pressure (F/ Tyre pressure

R) in bar (F/R) in psi
(loaded)
16 wheel 215/70 R16 6.5J x 16
17 wheel 235/60 R17 7J x 17 2.1/2.1 2.3/2.4

18 wheel 235/55 R18 7J x 18
Emergency spare tyre T155/90 R16 4T x 16 0.6/0.6

General TRAINING
Engine and Transmission

Initially, three transversally mounted engines will The top-of-the-line 3.2 litre V6 engine (Z32SED)
be available for the Captiva. produces 165 kW (225 hp) at 6,000 rpm with a
maximum torque of 308 Nm at 3,500 rpm. Its
The first is the brand new, state-of-the-art GM combined fuel consumption is 11.7 l per 100 km.
common rail diesel engine (Z20DTH). The 16 valve
unit offers 110 kW (150 hp) at 4,000 rpm and All engines are standard equipped with a five
maximum torque of 316 Nm at 2,000 rpm. The speed manual transmission. An optional five speed
combined fuel consumption is 7.6 l per 100 km. automatic transmission is also available
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

TRAINING General
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 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

TRAINING General
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.
10

General TRAINING
Notes
11

TRAINING Body
Many innovations have been integrated in the Cap-

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

Body 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 The electric continuity properties of zinc plated
to a reduction in the amount of steel used, e.g. steel plate are different from ordinary steel
through the use of thinner sheet steels. plate. When spot welding, increase the current
This has been achieved with high strength sheet by 10-20% or increase the resistance welding
steels, in spite of the need to meet higher body time. Also increase the number of weld spots by
strength requirements at the same time. 10-20%.
High strength steels have a tensile strength and
yield strength as much as 30% higher than con- Note The MIG welding procedures for zinc
ventional steel. These properties must not be plated steel plate are the same as for
destroyed when carrying out repairs, e.g. by using ordinary steel plate.
excessive heat.
The zinc plated steel plate used in some panels of Before applying putty or body filler to the zinc
the vehicle requires different repair techniques plated steel plate, sand the zinc plating
than ordinary steel plate. thoroughly to promote adhesion and prevent
Take the following precautions when repairing zinc blistering.
plated steel:
Note Use only epoxy-based puttees and fillers
on zinc plated steel plate.
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.
13

TRAINING Body
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.
1. Isofix allowed positions 2. Isofix attachment 3. Isofix top tether

at second row seats indications anchors
14

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

TRAINING Body
Lifting and Jacking the Vehicle
Note 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.
Note 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.
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.
1. Frame Contact Lift - Front

2. Frame Contact Lift - Rear
16

Body 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.
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.
17

TRAINING Body
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 Note the number and location of the welds

for installation of the tie bar assembly.
7. Remove the damaged tie bar assembly.
Note 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.
Note 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.
18

Body 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.
19

TRAINING Body
Front Compartment Upper Side Rail Replacement
Removal Procedure

(SIR) system.


necessary.
Note 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.


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.
20

Body TRAINING

4. Position the front upper outer rail to the vehicle

using 3-dimensional measuring equipment.
Clamp the front upper outer rail into place.

21

TRAINING Body
Front Compartment Front Rail Replacement
Removal Procedure

(SIR) system.


necessary.

forcements.

of the front lower rail.
7. Remove the damaged front lower rail.
22

Body TRAINING



the original panel.

4. Position the front lower rail to the vehicle using

3-dimensional measuring equipment. Clamp the
front lower rail into place.

23

TRAINING Body
Body Rear End Panel Replacement
Removal Procedure

(SIR) system.


necessary.

forcements.

of the front lower rail.
7. Remove the damaged rear end panel.
24

Body TRAINING



the original panel.

4. Position the rear end panel to the vehicle using

3-dimensional measuring equipment. Clamp the
rear end panel into place.

25

TRAINING Body
Centre Pillar Sectioning
Removal Procedure
Note Section in specified areas only. Sectioning
outside of these areas may compromise the
structural integrity of the vehicle. The door
frame can be replaced at factory seams, but
requires the removal of the windshield and
the roof. The sectioning procedures have
been developed as a more cost-effective
alternative to complete replacement. The
specific area to be sectioned is determined
by the extent of the damage to the vehicle.

(SIR) system.

Foam sound deadeners must be removed

Note
from areas within 152.4 mm (6 in) of where
flame is to be used for body repairs. When
reinstalling foam sound deadeners, avoid
inhaling fumes as bodily injury may result.

necessary.
6. On the original outer door frame, measure down

from the lower edge of the door opening 135
mm (5.3 in) (A) and mark a horizontal line.
Note Do NOT damage any inner panels or rein-

forcements
7. Cut the panel where sectioning is to be per-

formed
26

Body TRAINING

number and location of the welds for installa-
tions of the service part.
9. Remove the damaged center pillar section.
1. Cut the replacement center pillar section in cor-

responding locations to fit the original panel.
The sectioning joint should be trimmed to allow
1 times the metal thickness at the sectioning
joint.
2. Create a 50-mm (2-in) backing plate (A) from

the unused portion of the service part. Trim the
backing plate as necessary to fit behind the sec-
tioning joint where there is no reinforcement.
27

TRAINING Body
3. Drill 8-mm (5/16-in) plug weld holes along the

sectioning cut on the remaining original part.
Locate these holes 13 mm (1/2 in) from the
edge and spaced 40 mm (1 in) apart.
Note In any area damaged beyond recognition, or

if structural Weld-Thru adhesive is present,
space the plug weld holes 40 mm (1 in)
apart.

the original panel and along the sectioning cut.
6. Apply 3M Weld-Thru coating P/N 05916 or

equivalent, to all mating surfaces.
7. Fit the backing plate halfway into the sectioning

joint, clamp and plug weld to the vehicle.
28

Body TRAINING
8. Position the center pillar.
To create a solid weld with minimum heat

Note
distortion make 25-mm (1-in) stitch welds
along the seam with 25-mm (1-in) gaps
between. Then go back and complete the
stitch weld.
10. Stitch the weld sectioning joint.
12. Apply the sealers and anti-corrosion materials

to the repair area, as necessary.
13. Paint and repair the area.
29

TRAINING Suspension and Steering
Suspension
Being a Sports Utility Vehicle, the Chevrolet Cap-
tiva has been engineered on an all new independ-
ent front and rear suspension. A fully automatic
Self Leveliser system is available as an option.
Front Suspension
1. Cradle type front suspension

2. Lower control arm
3. McPherson spring strut assembly
4. Stabiliser bar
5. Ventilated brake disc
6. Wheel hub assembly with integrated wheel
speed rotor
30

Suspension and Steering TRAINING
Rear suspension
1. Multi linked suspension

2. Stabiliser bar
3. Ventilated brake disc
4. Wheel hub assembly with integrate wheel speed
rotor
5. Optional Self Leveliser shock absorber
31

TRAINING Suspension and Steering
Self Leveliser
The Self Leveliser is used to maintain a constant

The Self Leveliser shock absorber is a closed and
vehicle body height at the rear axle under various
sealed unit and integrates the Self Leveliser func-
loading conditions. The Self Leveliser system con-
tionality.
sists of two rear shock absorbers with the inte-
grated self leveliser function. It is a fully automatic
The Self Leveliser shock absorbers are not service
system and has no electrical components.
repairable. Do not attempt to open or drill holes in
the shock absorber. Always replace malfunctioning
Upon loading the vehicle, the body will lower
Self Leveliser shock absorbers as an assembly.
according to the weight. As soon as the vehicle is
driven, the pumping action of the shock absorbers
The Self Leveliser shock absorbers can be mounted
starts to level the body. Upon unloading the vehi-
as an Aftersales accessory.
cle, the body height regains its normal height with-
out having to drive.
1. Outlet valve
2. Pump chamber
3. Check valve
4. Pump tube
5. Height sensor
6. Pump rod seal
7. Pump rod
8. Diaphragm
9. Nitrogen gas
10. High pressure chamber
11. Low pressure chamber
12. Relief orifice
13. Piston valve
14. Nitrogen gas
15. Inlet valve
16. Main seal
17. Oil seal
32

Suspension and Steering TRAINING
Steering
The standard steering is of the rack and pinion The Speed Sensitive Power Steering (SSPS) sys-
type with hydraulic steering assist. Speed Sensi- tem varies the driver effort required to steer as the
tive Power Steering (SSPS) is available as an vehicle speed changes. At low speeds, the system
option. provides maximum power assist for easy turning
and parking manoeuvres. At higher speeds, the
In addition to the steering function, the steering amount of steering assist is reduced to provide the
column provides safety and security. The energy- driver with firmer steering and directional stability.
absorbing column is designed to compress in a
front-end collision to minimise the chance of driver
injury.
1. Steering gear
2. Hydraulic power steering pump
3. Hydraulic fluid reservoir
4. Steering column
5. SSPS control module
6. SSPS actuator
33

TRAINING Electrical
CAN-Bus System
The extensive application on a CAN-Bus system in
the Captiva has thrown the conventional function-
ing of systems upside down. Although the differ- Data bus
ent functioning of the CAN-Bus system may not be
evident for a driver in everyday life, the way of A data bus can be visualised as an ordinary coach.
thinking about the electrical system for the after- As a coach transports large quantities of people
sales organisation must undergo changes to be between several locations, the data bus transports
able to understand and diagnose the system. large quantities of information between several
control modules: data exchange. The exchange of
The exchange of information between control data between the individual control modules lets
modules can be achieved using the following pos- the units operate as a functional system. The more
sibilities: information a control module has on the state of
the total system, the better it can co-ordinate its
1. Separate wires individual functions.
2. Data bus
Advantages
Fewer sensors and signal wires due to multiple
Separate wires
use of a sensor signal
Each piece of information is exchanged over a sep- Fewer wires in the cable harness
arate wire Considerable weight reduction in the wiring
harness
Disadvantage
Fewer plug-in terminals in the control module
With an increasing quantity of information, the connectors
number of wires in the cable harness also
Improved reliability and serviceability
increases, which increases the possibility of
faults Large variety of new comfort functions
Separate wires Data bus
34

Electrical TRAINING
Engine compartment fuse block

The fuse block in the engine compartment is
located next to the coolant reservoir. The fuse
block is covered by a cap. On the inside of this
cap, a reference of all fuses and relays of the fuse
block is shown.
35

TRAINING Electrical
Instrument Panel fuse block

The Instrument Panel (I/P) fuse block in the pas-
senger compartment is located in the side of the
centre console, near the foot well. The I/P fuse
block is covered by a panel. On the inside of the
panel, a reference of all visible fuses and relays of
the fuse block is shown.
Only two relays are visible on the I/P fuse block,

however the wiring diagram indicates many more
relays located on the I/P fuse block. These relays
are located inside the I/P fuse block on the internal
switching
unit.
36

Electrical TRAINING
Grounding Points
When working on the vehicle electric system,
either during troubleshooting sessions or when
installing accessories, always be aware of the
importance of the grounding points.
An overview of the grounding points can be found
in the workshop manual of the Captiva. The exact
layout of all the grounding points depends on the
engine type.
In the Captiva, two types of grounding points are

used: normal grounds and ground packs.
The normal grounds are numbered G on the wir-

ing diagram and the ground packs are number Gx.
There is also a difference in there appearance. The

normal grounds are connected to ground via an
ordinary cable eye. The ground packs are con-
nected to ground via a splice pack which connects
several wires to ground.
Grounding point
Grounding pack
37

TRAINING Electrical
Compass
The compass displays the vehicles driving direc-
tion. Eight direction indications can be shown: N,
NE, E, SE, S, SW, W, NW. Whenever the Driver
Information Centre (fitted to instrument panel cen-
tre consol) or the battery is disconnected, the com-
pass must be recalibrated.
Compass Calibration
The compass can be calibrated following the pro-

cedure below:
1. Press the MODE and SET button simultaneously

for more than two seconds, the compass display
flashes.
2. Drive the vehicle around slowly for 360o within

90 seconds. Or alternatively, drive the vehicle as
shown in the next picture.
3. When the calibration is finished, the compass

display does not flash anymore.
When the calibration procedure is not completed

the compass will not function correctly.
38

Electrical TRAINING
Body Control Module Remote Function Actuation receiver

The Body Control Module (BCM) is of great impor- The Remote Function Actuation (RFA) receiver
tance for the Captiva. It contains many functions communicates with the Body Control Module
which are crucial for correct operation of the vehi- (BCM) through the CAN-bus. When a button on a
cle. The BCM can be found in every Captiva and is transmitter is pressed, the transmitter sends a sig-
located behind the instrument panel centre con- nal to the RFA receiver. The RFA receiver sends a
sole. By removing the Heating, Ventilation and Air request to the BCM and the BCM performs the
Conditioning control panel the BCM is accessible. appropriate action.
The RFA receiver is located behind the A-pillar pan-

elling at the drivers side.
Body Control Module functions
The BCM related systems include, but are not lim-

ited to the following list:
Chimes
Content Theft Deterrent System
Vehicle Theft Deterrent System (Immobilizer)
Exterior Lighting System
Interior Lighting System
Remote Keyless Entry Note The RFA receiver is also called Remote Con-
trol Door Lock Receiver (RCDLR) in the
Wiper/Washer Control
workshop manual.
Power Door Locks
Power Windows
39

TRAINING Electrical
Exterior lighting
The exteior lighing is controlled by the BCM and
consists of the following lamps: Daytime Running Lights
Headlamps Daytime Running Lights (DRL) is an optional availa-
Fog lamps ble feature. DRL illuminate automatically when the
Parking lamps engine is started. DRL will turn OFF under the fol-
lowing conditions:
Tail lamps
License plate lamps Engine is stopped
Parking lamps switched ON
Turn signal lamps
Low-beam lamps switched ON
Stop lamps
Backup lamps
Interior lighting
The auto light is an optional feature. When fitted,
the light switch is different. The interior lighting consists of dimming and non-
dimming lamps.
Automatic Lamp control The interior lamps which cannot be dimmed are
courtsey lamps such as the door step, glove box
On vehicles with Automatic Lamp Control (ALC) and rear compartment lamps.
the headlamps can be switched ON in two differ- Those which can be dimmed make use of a combi-
ent ways. First, when the driver places the head- nation of LEDs and bulbs. The voltage signal from
lamp switch in the HEADLAMP position, for the dimmer switch is outputted to the BCM, which
mormal operation. Second, with the headlamp in turn provides the correct voltage to the various
switch placed in the AUTO position, for ALC. LEDs and bulbs.
Headlamp ON/OFF control is determined by the The dimmer switch is located in the mirror control
Body Control Module (BCM). It uses the signals of switch assembly next to the steering column.
the headlamp switch. When the headlamp switch
is in the AUTO position, the BCM determines head-
lamps ON/OFF by the voltage from the ambient
light sensor.
Ambient Light Sensor
The Ambient Light Sensor is a light-sensitive tran-

sistor that varies its voltage signal to the Body
Control Module (BCM) in response to the changes
in the outside (ambient) light level.
When the BCM receives this signal, the BCM
switches ON the low beam headlamps and the
exterior lamps for Automatic Lamp Control (ALC).
The ambient light sensor is located in the ins-

tument panel centre speaker grille.
40

Electrical TRAINING
Parking Assist System

The Parking Assist System (PAS) is an option for
the Captiva. The PAS is a stand alone system. The
main components of the PAS are:
PAS control module

Ultrasonic sensors
Alarm buzzer
PAS telltale in the Instrument Panel Cluster
The PAS control module is mounted behind the

right wheelhouse panel in the rear compartment.
The PAS uses four ultrasonic sensors which are

mounted into the rear bumper.
The alarm buzzer is used to output an audible indi-

cation of the distance measured by the ultrasonic
sensors. It is also used for diagnosis purposes. The
buzzer is mounted near the knee panelling under
the instrument panel.
41

TRAINING Restraint System
Restraint System Overview
42

Restraint System TRAINING
Sensing and Diagnostic Module (SDM)

The SDM is located on the floor beneath the centre
floor console assembly.
The SDM performs the following functions:
Monitors the SIR electrical components and

sets a diagnostic trouble code when a
malfunction is detected.
Records any faults that are discovered.
Displays SIR diagnostic trouble codes and
system status information when connected to
a scan tool.
Illuminates the airbag indicator to alert the
driver of any fault.
Provides a reserve power source to deploy the
airbags and pretensioners if an accident has
disabled the normal power source.
Monitors vehicle velocity changes to detect
frontal impacts using its internal crash sensor.
Monitors signals from the side impact sensors
to detect side impact.
Causes current to flow through the airbag
modules and pretensioners to cause
deployment if any impact equals the
requirements programmed in the SDM.
43

Airbag Modules
The airbag modules are of the hybrid type except
for the driver airbag module. The driver airbag is a
gas generator type airbag.
Volume
Driver Airbag 60 litres
Passenger Airbag 120 litres
Side Airbag 9.5 litres
Curtain Airbag 36 litres
Driver and passenger airbag are always deployed

together. The passenger airbag is integrated in the
upper dashboard panel. Replacement of the pas-
senger airbag after deployment requires at least
replacement of the complete upper dashboard
panel.
Curtain airbags
Curtain airbag
The curtain airbag modules are installed to the
inner panel of the roof rail at both sides.
Curtain airbags protect the first and second row

occupants against head injuries during side impact
collisions. They are designed to deploy only during
certain side impact collisions, depending on the
crash severity, angle and speed of impact.
44

Front seatbelt pretensioner

The front seatbelt pretensioners form one assem-
bly with the buckles. The pretensioner front seat-
belt buckle contains a mechanically controlled
pyrotechnical piston which reduces the seatbelt
slack when it is activated in a head-on or angled
front collision.
The front retractors have integrated load limitors.

They are designed to reduce the load of the occu-
pant torso during a crash event by allowing extrac-
tion of webbing from a locked retractor.
The pretensioner front seatbelt buckle must be

replaced after an accident that caused its activa-
tion. A deployed pretensioner can be recognised by
the shortened buckle strap.
Deployed pretensioner recognition

1. Non deployed pretensioner
2. Deployed pretensioner
45

Passenger seatbelt reminder sensor

The seatbelt reminder sensor determines front
passenger presence and enables the SDM to
control the passenger seatbelt warning indica-
tor and/or chime. The sensor monitors the
pressure profile of the front passenger seat and
sends it to the SDM.
The seatbelt reminder sensor is integrated in

the passenger seat cushion and cannot be
replaced separately. In case of a defective sen-
sor the complete cushion has to be replaced.
Side impact sensor
For side impact detection, side impact

sensors are mounted in the B-pillars of
the vehicle.
They provide crash signals to the SDM

which will calculate according to these
signals whether the side and curtain
airbags and the pretensioners have to
be deployed.
46

System operation
The SIR system operation is comparable to the
systems used in the current Chevrolet passenger
cars. The addition of the passenger seatbelt
reminder sensor, the new pretensioners and the
curtain do not change the SIR working principle
Passenger seatbelt reminder sensor

When the pressure form the passengers weight is
higher than a specified value, the SDM recognises
the passenger as present.
If passenger presence is recognised and passenger

seat belt is unbuckled, the SDM will have the pas-
senger warning indicator switched ON. If passen-
ger presence is not recognised, the passenger
warning indicator is switched OFF regardless of
the seat belt being buckled.
Curtain airbag
The side impact sensors trigger the SDM to deploy
the curtain airbags when the impact equals certain
conditions. The curtain airbag system is triggered
by the SDM together with the side airbag system.
Service and Diagnosis

SDM replacement
The SIR system is disabled as follows:
The Body Control Module (BCM) stores the vehi-
cles restraint ID from the vehicle identification 1. Turn the steering wheel to the straight-ahead
number (VIN) and the last four digits of the SDMs
position.
part number. When the ignition is switched ON,
the SDM compares this information to the informa- 2. Turn the ignition switch to LOCK and remove
tion stored in the BCM over the CAN-BUS commu-
the key.
nication circuit.
3. Remove the airbag fuses F5 and F6 from the I/P-
If the information matches, the SDM is in Lock
fuse block and wait more than one minute for
mode. The airbag warning light goes OFF after
blinking seven times at ignition ON. the capacitor to discharge.
If there is a mismatch between the information The SIR system is enabled as follows:
stored in the SDM and BCM, DTC B1001 will be
set and the SDM will disable all deployments. The Insert the airbag fuse F5 and F6 in the I/P-fuse
SDM is in this case in the unlock mode and the block.
airbag warning lamp flashes at 0.5 Hz continuously Turn the ignition switch to ON and verify that the
upon switching ON the ignition. Therefore, when airbag indicator flashes seven times and turns OFF
replacing the SDM make sure to program the BCM
using SCAN 100. The terminals in the SIR are made of special metal
to provide the necessary contact integrity for the
Precautions sensitive, low energy circuits.
The SDM can maintain sufficient voltage to deploy Do not repair any connectors of supplemental
the airbags and pretensioners for 1 minute after inflatable restraints (SIR). Replace any damaged
the power has been disconnected. Do not begin connector with a new one.
service until one minute after disconnecting power
to the SIR system also known as to disable the
Do not attempt to repair any of the SIR wires.
SIR system.
Always replace damaged wires with new wiring.
47

TRAINING All Wheel Drive
Being a Sports Utility Vehicle, the Captiva can be

equipped with an optional All Wheel Drive system.
An AWD system provide advantages like:
Engine power can be mor efficiently

tramsmitted to the road because the whole
vehicle mass acts in transferring engine power
to the road.
On a slippery surface the combination of AWD
and other systems like ESP enable better
traction and vehicle stability.
User operation System Components
The AWD system is an On Demand system. The Along with the engine (1) and gearbox (2), an
vehicle is not equipped with a driver switch to con- AWD vehicle is additionally equipped with:
trol the AWD system. The On Demand AWD sys-
tem will automatically switch ON with no action Transfer case (3)
from the driver required.
When the ignition is switched ON, a bulb test will

not be performed for the AWD warning indicator.
The AWD warning indicator will light up in the
case of a detected system failure. When the AWD
warning indicator is ON only Front Wheel Drive is
available.
Propeller shaft (4)

Rear Drive Module (5)
The Coupling Contol Module is attached to the
When the Rear Drive Module is overheated the

warning indicator will light up and only FWD is
available. When the temperature returns to normal
the warning indicator will turn off and AWD is
available again.
There is no indication for the driver when AWD is Rear Drive Module.
engaged.
48

Captiva

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Chevrolet Captiva

Model Introduction Training For

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SUSPENSION and STEERING 30

ALL WHEEL DRIVE 48

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The Captiva measures 4,635/1,850/1,720mm

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Weights and Capacities

Curb weight (with driver)

Manual Transmission Still awaiting release

Gross vehicle weight

Manual Transmission Still awaiting release

Item Capacity Classification

Z32SED 7.4 litres API SJ (ACEA A1) grade

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

Brake fluid 0.67 litres

Power steering fluid 1.1 litres DEXRON II D or DEXRON III

Transfer case fluid AWD 0.8 +- 0.1 litres

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Front suspension type McPherson strut

Rear suspension type Four link

Alignment (unloaded) Camber Front - 0.55o +- 0.75o

Rear: - 0.35o +- 0.5o

Castor 2.18o +- 0.73o

Toe-in Front 0.1o +- 0.08o

Rear 0.09o +- 0.1o

Steering Type Power assisted rack and pinion

Overall gear ratio 18.5 : 1

Steering wheel diameter (mm) 390

Minimum turning radius (m) 5.75

The four cylinder derivatives come standard with

Tyre size Wheel dimension Tyre pressure (F/ Tyre pressure

16 wheel 215/70 R16 6.5J x 16

17 wheel 235/60 R17 7J x 17 2.1/2.1 2.3/2.4

Emergency spare tyre T155/90 R16 4T x 16 0.6/0.6

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Engine and Transmission

The 2.4 litre gasoline engine (Z24SED) is an in-line

Engine Z24SED Z32SED Z20DTH

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

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The vehicle identification number (VIN) is also

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Body Identification Number Plate

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Diagnostic Link Connector

Engine oil life system