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16 March 2011

Holden Development Localisation work on the Series II Cruze range began soon after Holdens December 2008 announcement that it was to build a second carline, based on General Motors global Delta platform, at its Elizabeth manufacturing facility in South Australia. A dedicated Holden engineering team began the development process by forming collaborative relationships with GM counterparts in South Korea and elsewhere with shared responsibility for ongoing Delta-based model programs including Europe and the United States. The teams basic brief was to give the Series II Cruze a Holden feel; a performance character that satisfied driver expectations and suited Australian driving conditions. Equally imperative was a directive to improve the driving experience by taking a car that already scored better than average in noise and vibration measurement and refining it even further. Powertrain and chassis initiatives taken by the team and development decisions they made, tested and took through to sign-off include major moves such as the inclusion of GMs acclaimed 1.4 iTi turbo engine and Watts link performance suspension. Less documented here but just as important are the engineering efforts expended over a threeyear period the powertrain calibrations, pedal map revisions, insulation, sound-damping, noise barrier, body sealing work and so on that combine to make this comprehensively upgraded nextgeneration Cruze a noticeably more polished performer. Cruze Content Configuration: Four door sedan Models: Cruze CD (1.8L petrol, manual/automatic); 1.4 iTi petrol (manual/automatic); 2.0L diesel (manual/automatic) Cruze CDX (1.8L petrol, manual/automatic); 2.0L diesel (manual/automatic) Cruze SR-i (1.4 iTi petrol, manual/automatic) Cruze SRi-V (1.4 iTi petrol, manual/automatic)

Dimensions Length Width (no mirrors) Height Wheelbase Front track

Rear track

Leg/shoulder/head room (front) Leg/shoulder/head room (rear) Boot volume Engines

4597mm (CD,CDX); 4629mm (SRi, SRi-V) 1788mm 1477mm 2685mm 1545mm (16 petrol) 1541mm (16 diesel 1539mm (17 petrol/diesel) 1567mm (16 petrol) 1563mm (16 diesel) 1561 (17 petrol/diesel) 1074mm/ 1391mm/ 999mm 863mm/ 1370mm/ 963mm 445 litres

1.4 litre DOHC 16-valve 4-cylinder iTi turbo petrol Power: 103kW @ 4900 rpm Torque: 200 Nm 1850-4900 rpm 1.8 litre DOHC 16-valve 4-cylinder ECOTEC petrol Power: 104kW @ 6200 rpm Torque: 176Nm @ 3800 rpm 2.0 litre SOHC 16-valve 4-cylinder common rail turbo diesel Power: 120kWkW @ 3800 rpm Torque: 360Nm @ 1750 rpm Transmissions 5-speed manual transmission (1.8L petrol) 6-speed manual transmission (1.4L petrol; 2.0L diesel) 6-speed automatic transmission with Active Select (1.8L petrol; 1.4L petrol; 2.0L diesel) The 6-speed manual transmission is manufactured in Aspern, Austria, all other transmissions are manufactured in Gunsan, South Korea. Fuel economy (ADR 81/01) 6.4 litres/100km (1.4 petrol manual) 7.0 litres/100km (1.8 litre petrol manual) 5.6 litres/100km (2.0 litre diesel manual) Emissions 1.4 litre petrol,1.8 litre petrol and 2.0 litre diesel engines comply with Euro 5 emission standards CO2 emission levels (1.4L petrol manual): CO2 emission levels (1.4L petrol automatic): CO2 emission levels (1.8L petrol manual): CO2 emission levels (1.8L petrol automatic): CO2 emission levels (2.0L diesel manual): CO2 emission levels (2.0L diesel automatic): 153g/km 164 g/km 166 g/km 175 g/km 147 g/km 176 g/km (4.5 GVG rating) (4.0 GVG rating) (4.0 GVG rating) (4.0 GVG rating) (3.5 GVG rating) (3.5 GVG rating) 6.9 litres/100km (1.4 petrol automatic) 7.4 litres/100km (1.8 litre petrol automatic) 6.7 litres/100km (2.0 litre diesel automatic)

Engine Feature Highlights 1.4 litre DOHC 16-valve 4-cylinder iTi turbo petrol (sourced from Aspern, Austria) The 1.4 iTi turbo features premium design elements that give it world-class smoothness and durability, including:

Low-mass hollow-frame cast iron block Dual overhead camshafts with variable valve timing Chain-driven cams Roller-finger camshaft followers Piston-cooling oil jets and integrated oil cooler Variable-flow oil pump Electronically controlled thermostat

The turbocharger is integrated within the exhaust manifold for reduced weight and greater packaging flexibility. A reinforced crankshaft and stronger connecting rods deliver additional strength to support pressurised power and torque over a wide rpm band. Numerous massreducing features include a cast iron block with a hollow frame structure, hollow-cast camshafts and a plastic intake manifold. Turbo advantages GM research shows that turbo boosting can deliver comparable torque to a non-boosted engine that is 60 percent larger in displacement. The 1.4 iTi turbocharged engines power-boosting advantage comes from forcing greater airflow into the engine. Its pressurized charge packs more air into the cylinders, allowing them to process the air and fuel of a larger engine for momentary driving situations. Boosting of small-displacement engines is most effective on small vehicles such as Cruze that offer a favourable torque-to-kerb-weight ratio. This maximizes the efficiency of the engine while delivering the driving attributes customers expect. The 1.4 litre engine is designed for boosting, with technologies and supporting features such as transmission gearing that enhance low-rpm torque for a greater feeling of off-the-line performance. Cylinder block cast iron, with five reinforced main bearings. The block offers excellent thermal properties that suit the cylinder pressure and loads generated by a turbocharger system. To minimise weight, it features hollow-frame construction, making it about 20 per cent lighter than a conventional casting. The block also incorporates a cast iron bedplate that helps reduce engine vibration. Cylinders within the block are triple-honed for a smoother finish to minimise piston friction and overall wear, while optimising oil and fuel consumption. Crankshaft reinforced to provide greater strength and stiffness, particularly at higher rpm, to support the boosted cylinder pressure of the turbo system. Connecting rods and pistons designed to support the greater load of the turbo system. Connecting rods are forged steel and the lightweight hypereutectic pistons are designed with a thicker crown area and a unique ring pack to withstand the boost pressure and heat generated by the turbo system. The engines compression ratio is 9.5:1. Variable-flow oil pump a unique variable-flow system helps maximise fuel efficiency. Unlike a conventional fixed-flow pump, this crankshaft-driven, energy saving unit matches oil supply to the engine load, changing its capacity based on the engines demand for oil. Piston-cooling oil jets help to optimise performance, efficiency and emissions by minimising piston temperatures.

Oil-water cooler maintains optimum oil temperatures via a heat exchanger incorporated into the oil filter housing. The design optimises oil cooling with a minimal pressure loss. During cold starting, the system also enables faster heating of the engine oil for an earlier reduction of internal engine friction. Structural oil pan aluminium oil pan is designed as a key structural component of the engine, adding stiffness that helps improve vibration characteristics. Cylinder head aluminium with dual-overhead camshafts, four valves per cylinder. Its intake port design optimises performance, efficiency and emissions by promoting greater charge motion of the intake air and a more complete burn of the air/fuel mixture. Sodium-filled exhaust valves are designed for the higher combustion temperatures of the turbo system. Variable valve timing dual-overhead camshaft arrangement employs dual continuously variable cam phasing to adjust engine valve opening and closing timing for optimal performance, fuel efficiency and emissions across the rpm band including greater low-rpm torque. Intake and exhaust cams can be phased up to 60 crankshaft degrees. Cam phasing also eliminates the need for a conventional EGR, by optimising the amount of exhaust gas in the combustion chamber. A vane-type camshaft phaser with an integrated oilcontrol valve is used for lower weight and greater packaging flexibility. Hollow-cast, chain-driven camshafts are lighter than conventional solid shafts. They assist in engine weight reduction and lower inertia of the valve train, allowing the engine to rev higher and more quickly. The camshafts are driven by durable chains. Roller-finger camshaft followers low-mass DOHC roller-finger camshaft follower is used to minimise friction and maintenance. It operates with very low frictional losses, enhancing efficiency and lowering emissions. Hydraulic lash adjusters and chain cam are maintenance-free. Integrated turbocharger and exhaust manifold designed for lower weight, quicker throttle response and easier packaging. The turbocharger size was chosen with an emphasis on low-speed torque and throttle response. Typically, turbochargers are mounted at the outlet of the exhaust manifold or farther downstream in the exhaust system, but this design incorporates the turbocharger's turbine housing into the exhaust manifold as a single component. It requires fewer parts, is lighter than a conventional system, helps lower engine compartment temperatures and helps the engine warm up faster. The faster warm-up benefits emissions performance by enabling a close-coupled catalytic converter that promotes a quick light off. The turbocharger is lubricated by engine oil and is liquid cooled for long-term reliability. The pressurised air charge is cooled via an air-to-air inter-cooling system before entering the engine. This lowers the temperature of the inlet air for more a more effective boost charge. Electronically controlled thermostat optimises engine temperatures during different phases of operation to enhance fuel efficiency. The engine control module monitors sensors and controls the thermostat based on mapping that takes into account a wide range of engine operating conditions, including temperature and load.

1.8L DOHC 16-valve 4 cylinder ECOTEC petrol (sourced from Gunsan, South Korea) The naturally aspirated 1.8L engine shares many 1.4L turbo features. Compact and durable, it combines competitive performance with sophisticated technologies. Highlights include: Structural, lightweight (hollow-frame) cast iron cylinder block Dual-overhead camshaft configuration with four valves per cylinder Dual continuously variable camshaft phasing Variable intake manifold Lightweight direct-acting hydraulic tappets with reduced friction Hollow-cast camshafts Oil-water heat exchanger Piston-cooling oil jets Electronically controlled cooling system Extended-life coolant Long life spark plugs The two-stage variable intake manifold optimises fuel economy and performance. At engine speeds below 4,000 rpm, inlet air passes through 910 mm intake tracts that help increase torque. At speeds greater than 4,000 rpm, a rotary sleeve within the lightweight composite intake manifold closes off the full length of the intake tracts, forcing air through a shorter, 260 mm path that helps build power. The rotary sleeve helps minimise airflow resistance at higher speeds, ensuring the maximum cross-section area in the open position. The cross section of the intake runners is constant, with the length of the runners reduced by 60 per cent in the closed position (greater than 4,000 rpm). This two-stage manifold helps the 1.8L produce approximately 90 per cent of peak torque from 2,400 rpm to 6,500 rpm, giving it a strong, responsive feel in all driving conditions 2.0 litre turbo diesel engine feature highlights (sourced from Gunsan, South Korea) The 2.0 litre turbo diesel engine is a powerful and fuel efficient diesel offering. Highlights include: An advanced, electronically controlled turbocharger with intercooler that enables smooth driving, lower fuel economy and lower emissions. A high-pressure common rail system that delivers multiple injection performance and optimized injection quality within the combustion chamber. This ensures reduced combustion noise, fuel economy and reduced emissions. A diesel particulate filter system thats maintenance free for the life of the vehicle Transmissions Five- and six-speed manual transmissions feature: One-piece housing to enable compact, light design Needle bearings for all gears ensure low-friction gear meshing Enhanced low-gear engagement for smooth launch and shift characteristics Six-speed Active Select automatic transmission is optional across the range The 1.8L petrol engine is matched with a 6T30 unit; 1.4 iTi turbo petrol engine with 6T40 unit; 2.0L diesel with 6T45 unit. Features include: Clutch-to-clutch shift operation for precise, smoother shifts between gears Wide spread ratio first gear has brisk acceleration with its high ratio, 6th gear overdrive ratio keeps engine revolutions as low as possible for fuel-efficient highway cruising All have tap-up/tap-down Active Select feature which allows drivers to select and hold gears for a more spirited driving experience

Watts link suspension (SRi, SRi-V and CD 1.4 iTi) The well-positioned Watts link rear suspension supports lateral forces while cornering. It makes for more dynamic, agile handling without compromising stability and comfort. The combination of MacPherson strut front suspension and a compound crank rear axle with the Watts link reduces noise and vibration and retains the advantages of a compound crank over a multi-link axle. These include packaging and mass benefits, greater wheel camber stiffness, less camber loss due to body roll during cornering and less suspension friction. Carried on a small cross-member attached to the underbody, the Watts link sits just behind the rear-wheel centre line. It comprises a short, pivoting centre link with a ball joint at each end, to which lateral links from the wheels are bolted. During cornering, the Watts link minimises lateral deflection in the same manner as a multi-link suspension. The advantage of this intelligent system lies in the fact that it reduces axle-bush loads and allows softer bushings, improving isolation and further reducing road noise. Electric Power Steering (1.4 iTi) Compared to the constant power demand from a hydraulic unit, this power steering system only demands power from the electrical system when steering input is required. Resultant fuel economy savings are due to a lower ancillary power draw from the engine. The electric power steering system also allows for varied steering efforts according to vehicle speed, resulting in a better steering feel for sportier driving and a lower steering effort during parking manoeuvres. Technical Data Overview Drive axle: Front wheel drive Turning circle: 10.9 metres Fuel tank capacity: 60 litres Compression Ratio: 1.4 petrol - 9.5:1 1.8 Petrol - 10.5:1 2.0 Diesel - 16:5:1 Suspension: (1.8L and 2.0L): (1.4L): Front - independent MacPherson strut Rear - Watts link Steering: Hydraulic power steering (1.8L & 2.0L) Electric power steering (1.4L) Brakes: Petrol - 276mm front ventilated discs; 268mm rear solid discs Diesel - 300mm front ventilated discs; 292mm rear solid discs Electronic Stability Control (ESC) Four channel, four sensor ABS, EBD, TCS

Front - Independent MacPherson strut Rear - Compound crank

Towing: Petrol - 695kg (unbraked) / 1200kg (braked) Diesel - 750kg (unbraked) / 1200kg (braked) Wheels and tyres: CD 16 x 6.5 steel wheels; 205/60R16-92V tyres (4) CDX, SRi and SRi-V 17 x 7 alloy wheels; 215/50R17-91V tyres (4) CDX diesel 17" x 7" alloy wheels; 225/50R17-94V tyres (4)

Gear ratios (:1) 1.8L petrol 5sp Man 1st 3.818 2nd 2.158 3rd 1.481 4th 1.121 5th 0.886 6th Final Drive 3.722 Reverse 3.545

6sp Auto 4.449 2.908 1.893 1.446 1.000 0.742 3.72 2.871

2.0L turbo diesel 6sp Man 6sp Auto 4.167 4.584 2.13 2.964 1.321 1.912 0.954 1.446 0.755 1.000 0.623 0.746 3.348 3.917 2.64 2.94

1.4 iTi 6sp Man 3.818 2.053 1.302 0.959 0.756 0.614 4.176 3.545

6sp Auto 4.584 2.964 1.912 1.446 1.000 0.746 3.23 2.94

Weight - Curb Mass in kg Powertrain Engine 1.4 iTi 1.4 iTi 2.0 L 2.0 L 1.8 L 1.8L Fuel Petrol Petrol Diesel Diesel Petrol Petrol Trans Auto Man Auto Man Auto Man Specification in kg CD 1415 1391 1544 1529 1385 1365 CDX 1560 1547 1403 1383 SRi 1428 1404 SRi-V 1439 1415 -

Noise and vibration A stiffer structure helps to tune out and isolate powertrain, road and wind noise and create a quiet, pleasant cabin comfort level. The body on Cruze incorporates extensive sealing to help eliminate the most minute pins of daylight and the potential noise, wind or outside contaminants they might admit. All doors incorporate a triple-layered sealing system to reduce noise, vibration and airflow through the door and into the passenger compartment. A four-point isolated engine cradle helps minimize road and powertrain noise and vibration into the cabin. A formed fibreglass blanket on the underside of the hood serves as an effective barrier to engine noise that could pass through the windshield. The front-of-dash panel is sandwiched between two damping mats as an additional abatement to noise transfer. The headliner is of thermal fibre acoustic design and incorporates five layers for superior sound isolation. Floor carpet is precisely formed to the floor pan of Cruze to effectively damp out noise frequency and vibration. Composite wheel house liners at all four corners help damp rain noise and other impacts (such as gravel) that create sizzle noise from transferring into the passenger compartment. The boot is fully lined with a thick walled acoustic material. Safety Occupant safety was an overriding objective when developing Cruze, achieving a maximum 5-star ANCAP (Australian New Car Assessment Program) rating in Australia. Cruze incorporates a host of structural enhancements as well as a full range of active and passive safety systems standard across the range all designed to place it among the safest vehicles in its class. Cruze offers an impressive level of standard safety including: Electronic Stability Control (ESC) Anti-lock Braking System (ABS) Electronic Brakeforce Distribution (EBD) Traction Control (TC) Brake Assist 6 airbags (driver, front passenger, front side and curtain) Collapsible pedal release system Driver and front passenger seatbelt reminder Four-way adjustable headrests for whiplash protection Three-point seatbelts in all five seating positions Seatbelt retractor and lap pre-tensioners in driver and front passenger position Front seatbelt load limiters Child seat latching system at rear seating positions

An extremely strong structure and stiff body with efficient, effective load paths provide Cruze maximum protection in the event of a collision from virtually any direction. A unibody of high-strength steel incorporates full-length frame rails and a safety cage into a single, welded unit. It is designed with front and rear crush zones engineered to collapse in a

controlled manner to help absorb crash energy. Bumper systems are engineered to require minimal repairs after front or rear collisions. The front bumper is positioned for optimum safety in the event of a collision with another vehicle. Collapsible pedal release system reduces the chance of lower extremity injuries to the driver in the event of a front collision. For maximum protection in certain frontal collisions,60 litre driver airbag can fully inflate in 60 milliseconds; front passenger airbag can fully inflate to 130 litres in 70 milliseconds. Side airbags are mounted on the driver and front passenger seat for thorax protection of front row occupants. Curtain airbags are mounted to the roof rails between the A and C pillars for additional head and neck protection of both front and second-row seat occupants. Standard three-point lap and shoulder belts available for all passengers suit a wide range of physiques. Two side impact sensors mounted in the B pillars on both sides of Cruze trigger the side curtain roof rail air bags, seat-mounted thorax air bags and seatbelt pre-tensioners. Cargo/Storage Centre console incorporates CD storage beneath a fore/aft articulating armrest with an MP3 player plug and play auxiliary input plug. The lower IP storage contains an auxiliary power outlet and a sliding dual cup holder design that uses automatically adjusting pincher elements to carry any cup size. A 6.3 centimetre deep bin in the IP is located at the top of the centre stack Illuminated, lockable glove box provides additional storage space. Integrated bottle holders in all door pockets provide added beverage storage. Seatback pockets are large enough to carry books, road atlases or thin laptops. 60/40 split-folding rear seatbacks supply large pass-through access to the boot for longer items. Rear split-seat folding capability includes an articulating armrest with integrated dual cup holders. An acoustically trimmed, illuminated boot provides 445 litres of storage space. A shopping hook is positioned on the left side of the boot. Convenience Standard six-way manually adjustable driver and front-passenger seats. Front heated seats (standard on CDX and SRi-V) offer three levels of heated comfort low, medium and high. They are designed for quick warm-up and use an electronically controlled heat pad integrated into the seat cushion and back. Standard front and rear power windows with: Express down and up for driver Express down for front and rear passengers. Standard power door locks are automatic and programmable. Delayed entry and exit interior lighting (with theatre dimming) provides added convenience using rear courtesy lights and front map lights (located in overhead console). Follow me home lighting allows programmable timing of

up to three minutes which enable front headlamps to remain on after exit and locking of vehicle. Padded driver and front passenger visors (with ticket holder) and vanity mirrors provide added convenience. An overhead console with front map lights is standard. Overhead assist grips are located on the front-passenger door and rear doors while convenience hooks can be found in the rear and boot. An auxiliary power outlet in the lower IP is standard on all models and can be used with laptops and mobile phones. A second auxiliary power outlet on CDX and SRi models is located in the 2nd row below the centre console. Retained accessory power enables the power windows, radio to remain operational for ten minutes after the ignition is turned off, or until a door is opened. An electronic touch pad enables the opening of the boot. The boot can be opened from inside the cabin by depressing the door lock/unlock button continuously for three seconds. Servicing At 3000 km or three months (no cost inspection) then every 15,000km or 12 months, whichever comes first. Place of Manufacture Holden Vehicle Operations, Elizabeth, South Australia