Orlando - 2011

Chevrolet Orlando
Model Introduction Training For

Approved Motor Body Repairers
A thousand things to do in a day. Fun, entertainment and relaxation for family
and friends. That's the vacation spirit Chevrolet has packed into its first ever
European MPV. Like the Chevrolet models recently launched in other market
sectors, it doesn't follow convention. Chevrolet Orlando's design - part MPV,
part crossover - breaks the rules of a historically conservative segment; it makes
a statement and stands out from the crowd.
Chevrolet's new compact MPV brings swagger to the segment by adopting a bol-
der look with its low roofline and crossover inspired silhouette, while retaining the
distinctive and recognizable Chevrolet 'face' depicted by the split radiator grille
and bow-tie badge.
CONTENTS
GENERAL 4
BODY 11
MECHANICAL 22
ELECTRICAL 26
RESTRAINT SYSTEM 35
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
Introduction
There's no question that the Orlando will offer a refreshing alternative to many
of the family vans currently on the market. The distinctly recognizable Chevrolet
face is complemented by a profile characterized by the low swept roofline and
the muscular, protruding wheel-arches, housing 16, 17 or 18 inch wheels. The
wheel arches enhance a 'body in, wheel out' appearance while at the same time
ensuring Chevrolet Orlando keeps its agile, sporting stance.
Orlando's space, storage and safety

While the exterior of the new Chevrolet Orlando is sure to attract plenty of
attention, the interior too features many of the latest design cues from
Chevrolet such as the Corvette-inspired dual cockpit and ambient blue
backlighting to the centre console. Distinctive design is nothing without well-
thought-out functionality however, so the 'theater-style' seating arrangement of
the Orlando's three rows of seats, the generous load area and the numerous
storage solutions will also grab the attention of family motorists.
The interior seating is referred to as 'theater-style' because in spite of the
sweeping roof-line, designers have succeeded in raising the second and third
rows which allow the Chevrolet Orlando's occupants to get an even better view
both forwards and to the side and without compromising head-room. In fact
headroom in the third row of seats in the Orlando is superior to a number of
competitor MPVs.
Numerous seating configurations are possible with either second or third rows
folded independently or together to make a completely flat load area. The
second seat row also has a tumble-fold facility for both the left and right-hand
outer seats to allow easy access for passengers into and out of the third row.
4
© 2008 General Motors Corporation. All rights reserved.
General TRAINING
Any hard-working family car needs plenty of

storage space for all the bits and pieces that
collect inside. Like the original concept car,
the final production version of the Orlando
obliges with a range of compartments of
different shapes and sizes and different
locations, including a coin holder and two
large cup holders in the center console, map
and bottle holders integrated into the front
and rear doors and a number of individual
compartments in the cargo area.
However, perhaps the most ingenious is a

storage area hidden behind the front fascia of
the audio and within easy reach of the both
the driver and passenger. Seen originally on
the Orlando concept car, designers have
been able to integrate a usefully large area
which is revealed by flipping up the face of
the audio, and large enough for such items as
an MP3 player, sunglasses and wallets.
Within the space itself there is also a stan-
dard auxiliary jack and optional USB port for
MP3 or iPod connectivity, depending on the
trim level.
Safety for the vehicle's occupants is always a

paramount consideration for this class of car,
and in Chevrolet Orlando owners will be reas-
sured by both the attention to detail and the
inclusion of the latest technology that has
gone into this aspect of the car's design.
Should a collision occur, Orlando's occupants
will be protected by six airbags - twin front,
side and curtain.
5
TRAINING General
Orlando 1.8 LS M/T
– 104 kW 16V DOHC engine – Traction control (TC)

– 5-Speed manual transmission – Cruise control
– Front-wheel drive – Rear park assist
– ABS and EBD – 17” Alloy wheels
– Electronic stability programme (ESP) – 6 Airbags
Orlando 1.8 LT M/T
– 104 kW 16V DOHC engine – Anti-dazzle rear view mirror

– 5-Speed manual transmission – Climate control
– Front-wheel drive – Automatic lighting control
– ABS and EBD – Moisture sensitive wipers
– Electronic stability programme (ESP) – 18” Alloy wheels
– Traction control (TC) – Leather trim
6
General TRAINING
Specifications
Equipment LS LT
Wheels
Wheel type Alloy Alloy
Tyre size 225/50 R17 235/45 R18
Full size spare wheel Std Std
Convenience
Power steering Std Std
Tiltable and telescopic column Std Std
Door mirrors Heated/Electrical/Foldable Heated/Electrical/Foldable
Cruise control Std Std
Moisture sensitive windscreen wipers - Std
Automatic lighting control - Std
Rear Park Assist Std Std
Climate/Heating
Air conditioning Std Std
Climate control - Std
Infotainment
CD player with MP3 CD Std Std
No. of speakers 6 6
Steerin wheel mounted controls Std Std
Auxiiiiary input Std Std
MP3 compatibility Std Std
Safety
Front,side and curtain airbags Std Std
Passenger airbag deactivation Std Std
ABS Std Std
ESC Std Std
Traction control Std Std
Front seatbelts with pretensioner Std Std
Front seatbelt reminder Std Std
3-Point seat belt - All 7 seats Std Std
ISOFIX child seat Std Std
Security features
Remote central locking Std Std
Immobiliser Std Std
Anti-theft alarm Std Std
Motion auto-locking doors Std Std
7
TRAINING General
Engine
Engine Fuel Type Displacement Power Output Torque

LS 1.8i * Petrol 1796ccm 104kw 176nm
LS 2.0 VCDi(96kw) Diesel 1998ccm 96kw 315nm
LT 1.8i * Petrol 1796ccm 104kw 176nm
LT 2.0VCDi(96kw) Diesel 1998ccm 96kw 315nm
LT 2.0VCDi(120kw) Auto Diesel 1998ccm 120kw 360nm
LTZ 1.8i Petrol 1796ccm 104kw 176nm
LTZ 2.0VCDi(120kw) Diesel 1998ccm 120kw 360nm
LTZ 2.0VCDi(120kw) Auto Diesel 1998ccm 120kw 360nm
* The South African market at this stage will only be getting the 1.8L LS and the 1.8L LT
– 104kW DOHC
– 1.8L DCVCP
– Variable Intake Manifold
– Internal EGR
– NT4 Emission Rating
Transmission
– 5 Speed Manual Gearbox

– Model Code D20, Cruze also
uses this gearbox.
8
General TRAINING
Colours
Carbon Flash - GAR
Daydream Beige - GOZ
Gunsmoke Grey - GQK
Olympic White - GAZ
Velvet Red - GCS
Switchblade Silver - GAN
Pewter Grey - GCV
9
TRAINING General
Platform
The Orlando and Chev Cruze share the same platform which is the Delta II platform.
They share many mechanical parts which include Steering, suspension and brakes just
to name a few.Below is a size comparison of the two vehicles.
Height mm Length mm Width mm

Orlando 1625 4652 1836
Cruze 1580 4350 1755
Where does Orlando fit?
Cruze - Car C Orlando - MPV C Captiva - SUV C

Segment Segment Segment
Smaller Larger
10
Body TRAINING
Vehicle Identification Number

The VIN number can be found on two different places on the Chevrolet Orlando:
Left of front windscreen
Under carpet on drivers floor
Example: KL1 JF 75 5JBK 100001
Position No Definition Character Description

1 Country Of Origin K Korea
2 Manufacturer L General Motors
3 Make 1 Chevrolet
4 Carline J J309 ORLANDO
F Manual Transmission (MSA)
5 Transmission
A Automatic Transmission (MH8)
6&7 Body Style 75 5 – Door Monocab (7 Seat)
Vin Option Engine No Of Cam Fuel

Code Code Displace Cylinders Type System
8 Engine Type
Y LNP 2.0T L4 DOCH CRI
5 2HO 1.8L L4 DOHC MPFI
J Euro-4 (NT4)
9 Emission Level
9 Euro-5 (NE9)
10 Model Year B 2011
11 Plant Location B: Bupyung K: Kunsan
Production Sequence
12 to 17 *** 100001
Number
11
TRAINING Body
Body Construction
Safety for a vehicle's occupants is always a paramount consideration for this
class of car, and in Chevrolet Orlando owners will be reassured by both the atten-
tion to detail and the inclusion of the latest technology that has gone into this
aspect of the car's design. Most of Orlando's body structure is constructed of
high strength steel to form an effective passenger safety cage providing protec-
tion in the event of a collision to the front, rear and side of the car. Should a colli-
sion occur, Orlando's occupants will be protected by six airbags - twin front, side
and curtain.
One of the biggest challenges often faced by emergency services when assisting
at the scene of an incident is helping the occupants of vehicles when the doors are
locked. However, this is not a scenario that Chevrolet Orlando owners will be faced
with; Orlando is fitted with crash sensor technology, where the doors unlock auto-
matically on detection of an impact.
Starting with Chevrolet Orlando's

body shell, the body frame integral
(BFI) structure whereby the upper
body and chassis frame are engi-
neered as a single component ensures
high levels of stiffness. This torsional
rigidity of the body-chassis interface
will not just put a smile on any driver's
face through great handling; the upper
body shell of the Orlando is also ex-
ceptionally strong, with over 70% of
the body frame constructed from high
strength steel.
Chevrolet Orlando's passenger compartment is reinforced all round, including the

A and B-pillars, the cross sections that support the roof and along the lower sill sec-
tions. Occupants in effect sit inside a safety cage constructed to minimize intrusion
in the case of frontal, side or rear impact, while front and rear crumple zones are
designed to absorb and dissipate energy to minimize impact to the passenger com-
partment.
High-strength steels and aluminum are used in all the key areas in the car's cons-
truction. With the frontal area of any vehicle particularly vulnerable, Orlando is fit-
ted with a strong yet light aluminum crash-box for the front bumper cross-member
which sits in front of the engine cradle, with high-strength steel used for longitudi-
nal rails and the front sub-frame. Energy is absorbed by these sections and distri-
buted evenly along load paths, including a dual load path on the vehicle's
underbody, which channels energy away from the passenger compartment. The cr-
adle used to house the engine and which sits inside the front sub frame also has
high energy absorption properties where structural foam helps dissipate impacts.
Special attention has also been paid to the side structure of the body so that the
B-pillar section and where it joins the lower sill section and seat cross member on
the floorpan is especially strong, and designed to distribute loads safely around the
body frame.At the rear of the vehicle, a further reinforced sub frame is used on the
underbody which protects the fuel tank and its connections from penetration in the
case of a rear impact.The fuel tank itself is capable of withstanding minor compres-
sions without rupturing.
12
Body TRAINING
Body Structure
Dual Phase Steel

Mild Steel
High Strength Steel
Ultra-High Strength Steel
Aluminum
Mild Steel has a relatively low tensile strength, but is malleable. Surface hardness
can be increased through carburising. This type of steel normally has a tensile
strength less than 270 MPa.
High Strength Low Alloy Steel is a type of alloy steel that provides better mechanical
properties and greater resistance to corrosion than mild steel. This type of steel nor-
mally has a tensile strength range from 300 - 700 MPa.
Dual Phase Steel is a high-strength steel that has a ferrite and martensitic microstruc-
ture. This type of steel normally has a tensile strength up to and including 800MPa.
Advantages:
– Low yield strength

– High initial strain hardening rates
– A high strain rate sensitivity (faster energy absorbsion)
– Good fatigue resistance
– Good uniform elongation
Ultra-High Strength Steel normally has a tensile strength greater than 800 MPa.
13
TRAINING Body
Body Layout
No Name Material No Name Material

1&2 Front-wheel housing Mild steel 13 Quarter outer panel Mild steel
3 Front-side rail High strength 14 Rocker outer panel Mild steel

low alloy
4 Roof front head panel High strength 15 Body hinge pillar outer Mild steel
low alloy panel
5 Roof panel Mild steel 16 Body hinge pillar High strength

reinforcement low alloy
6 Roof rear panel High strength 17 Rocker inner Ultra high

low alloy reinforcement strength low
alloy
7 Floor panel crossbar rear High strength 18 Rocker inner panel High strength
low alloy low alloy
8 Floor panel crossbar front High strength 19 Front upper side rail Mild steel
low alloy
9 Body lock pillar upper High strength 20 Front end upper support High strength
reinforcment low alloy low alloy
10 Side inner panel Mild steel 21 Front wheel house rear Mild steel
reinforcement
11 Center pillar inner High strength 22 Headlight mount panel Mild steel
reinforcement low alloy
12 Center pillar exterior Mild steel 23 Front impact bar Aluminium
14
Body TRAINING
Side Panel
Bumper and Fascia
15
TRAINING Body
Front Bumper Removal

1. Remove the front fender wheel opening molding.
2. Remove the radiator opening upper cover.
1 Front bumper fascia upper retainer (Quantity: 2)

2 Front bumper fascia bolt (Quantity: 2)
3 Front wheel house liner bolt (Quantity: 2)
Sequence
For bolt removal, partially loosen the front wheel house liner.
6 Front bumper lower reinforcement bolt
7 Front bumper fascia lower retainer (Quantity: 4)
8 Front bumper fascia
Sequence
1. Insert a flat blade type plastic trim tool to release the retainer connected to the
front bumper fascia guide.
2. Take caution since fascia may tear if force is applied.
3. Undo the clip from the front bumper fascia guide.
4. Pull the front bumper fascia forward to remove.
5. Disconnect all wiring connectors.
Front Bumper Impact Bar Replacement

Removal Sequence
1. Disable the SIR.

2. Disconnect the (-) battery cable.
3. Detach all associated panels and parts.
4. Remove front bumper impact bar bolts (1).(Quantity: 8)
5. Cut the left and right side of the front bumper impact bar.
16
Body TRAINING
6. Indicate and mark all factory weld point locations.

7. Drill a hole in all factory weld points.
8. Remove remaining parts of the front bumper impact bar.
Mounting Sequence
1. Position front bumper impact bar on to the vehicle.

2. Place 8 front bumper impact bar bolts (1) and tighten.
Note: Use the original issued front bumper impact bar bolts. If damaged then
replace the bolt.
3. Paint the repaired part.

4. Assemble all associated panels and parts.
5. Connect the (-) battery cable. Enable the SIR.
17
TRAINING Body
Rear Bumper Removal

Remove the tail light.
1 Rear wheel house liner bolt (Quantity: 6)
2 Rear bumper fascia lower retainer (Quantity: 2)
3 Rear bumper fascia
Sequence
1. From the front edge, pull the rear bumper fascia forward and push in the clips
into the inboard fascia guide (underneath the tail light).
2. Release the clip fixture with an appropriate tool.
3. Until the exterior edge is separated outwards from the vehicle body and loud
popping sound is heard, continue pulling back the rear bumper fascia.
4. Separate electrical connectors as needed.
5. Remove the rear bumper fascia.
18
Body TRAINING
Rear Bumper Impact Bar Replacement

Remove the rear bumper fascia.
1 Rear bumper energy absorber nut (Quantity: 6)
Front Compartment Side Rail Sectioning
The front “chassis rail” can be partially replaced. Refer to the workshop manual for the
full procedure.
19
TRAINING Body
Body Hinge Pillar Outer Panel Sectioning
Rocker Inner Panel Replacement
The rocker panel must be replaced if damaged and can not be repaired due to the
Ultra high strength steel used.Please refer to the workshop manual for the full
procedure.
20
Body TRAINING
Rear Side Rail Sectioning
The rear “chassis leg” can be partially replaced. Please see the workshop manual
for the complete procedure.
Roof Front Header Panel Replacement
21
TRAINING Mechanical
Front Suspension
– McPherson layout on subframe

– Damping bushings between subframe and body
Note: Wheel bearing/hub bolts must be discarded and replaced if bearing/hub is

removed.
Rear Suspension
– One type of rear axle

– No adjustment possible
Note: Wheel bearing/hub bolts must be discarded and replaced if bearing/hub is

removed.
22
Mechanical TRAINING
Variable Steering System

The Variable Effort Steering (VES) system or MAGNASTEER varies the amount
of effort required to steer the vehicle as vehicle speed changes.At low speeds the
system provides minimal steering effort for easy turning and parking manoeuvres.
Steering effort is increased at higher speeds to provide firmer steering(road feel)
and directional stability.
The VES control module uses vehicle speed and steering wheel speed to com-
mand a current that is most appropriate for each speed to the VES actuator.The
actuator is a variable electromagnetic actuator.
At lowest speed, around 5 km/h the coils are polarised in such a way that the
manetic forces are repelling each other and hardly any effort is needed to turn the
steering.
At mid speed, around 70km/h no current is sent through the coils and steering is
assisted by hydraulics only.At high speeds the coils are polarised in such a way
that themagnetic forces are attracting each other and high effort is required to
turn the ring magnet between them.
The VES control module has the ability to detect malfunc-

tions in the actuator. Any malfunctions detected will cause
the system to supply zero amps. Steering will be assisted
by hydraulics only and a DTC is set.
23
TRAINING Mechanical
Fuel Tank Assembly
Petrol filter is in tank and not a service item. The filter is part of the pump.
Access to the fuel pump is via fuel tank removal. Tank Capacity is 60L.
Pedal Release System(PRS)

Orlando features the patented “pedal release system” (same as new Astra and
Corsa D), where the clutch and brake pedal decouple(drop down) in the event of a
severe frontal collision.
24
Mechanical TRAINING
Jacking Positions
Caution: Lifting the vehicle improperly can damage the vehicle and result in costly
repairs not covered by the warranty.
Always lift the vehicle on the correct positions.
Front Lift Pads
When lifting the vehicle with a frame-contact lift place the front lift pads on the
rocker outer panel weld flange, as shown
Rear Lift Pads
When lifting the vehicle with a frame-contact lift place the rear lift pads on the
rocker outer panel weld flange, as shown
25
TRAINING Electrical
Electrical Harness
The vehicle uses a CAN bus wiring harness.The CAN Bus is an automotive
bus developed by Robert Bosch, which has quickly gained acceptance into the
automotive and aerospace industries. CAN is a serial bus protocol to connect
individual systems and sensors as an alternative to conventional multi-wire
looms. It allows automotive components to communicate on a single or dual-
wire networked data bus up to 1Mbps.
General motors does not allow repairs to be carried out on this harness for
safety reasons.
Since the early 1940's, automakers have continually improved their vehicles'
technology by integrating an increasing amount of electronic components. As
technology progressed, the vehicles became more complex as electronic
components replaced mechanical systems and provided additional comforts,
convenience, and safety features. Up until the release of CAN Bus, vehicles
contained enormous amounts of wiring which was necessary to interconnect
all of the various electronic components.
An example of Can Bus wiring
26
Electrical TRAINING
Fuse Box Location
Left front of engine compartment Behind glove box
1. Ambient light/sunload sensor 10. Door lock switch- driver

2. Info Display model 11. Transmission shift lever
3. Radio Conrols 12. Cigarette lighter receptacle
4. Hazard warning switch 13. Park brake switch
5. Instrument cluster 14. Accessory power receptacle-centre console
6. Turn signal/Multifunction switch 15. Transmission shift lever indicator
7. Headlamp switch 16. HVAC controls
8. Windshield wiper/washer switch 17. Passenger airbag disable indicator
9. Steering wheel airbag 18. Passenger airbag disable switch
27
TRAINING Electrical
Main Electrical Component List
Name Location
Fuel pump and level sensor assembly Inside the fuel tank
A/C refrigerant pressure sensor Engine compartment,right side fan assembly
Wheel speed sensors front Front wheel hub
Wheel speed sensors rear Rear wheel hub
Clutch position sensor Inside vehicle on clutch pedal bracket assembly
Inside air temperature sensor In the HVAC assembly
Ambient air temperature sensor Left front vehicle bumper fascia
Ambient light/ sunload sensor Passenger compartment, top centre of dash board
Brake pedal position sensor Above the brake pedal
Hood ajar switch Front engine compartment hood latch
Intake air temperature sensor Engine compartment, Right rear corner
Rain sensor Top centre windshield
Body control module Passenger compartment, centre console
Electronic brake control module Engine compartment, top left rear
Engine control module To the left of engine
HVAC control module Passenger compartment behind centre console
Inflatable restraint sensing and diagnostic Under centre console behind gear lever
module
Rear park assist control module Left side behind rear wheel well
Immobiliser control module Lower right side steering column
Brake booster pump motor Rear of engine compartment near booster
Passenger airbag disable indicator Centre of instrument panel
Windshield washer pump Below left headlamp assembly
Blower motor control module Behind instrument panel, part of HVAC module
Seatbelt anchor pretensioner L/R Lower outside of seats
Seatbelt retractor pretensioner L/R In the B pillar at the bottom
Important! This table is a summary, please consult the workshop manual for a full breakdown
of the Master electrical component layout.
28
Electrical TRAINING
Diagnostic Link Connector(DLC)

Located on the right side of vehicle under the dash panel.
Instrument Panel Cluster

Only cosmetic and size difference, otherwise similar to Cruze
29
TRAINING Electrical
Infotainment
Infotainment uses the already familiar equipment from the Cruze.
CD 400 CD 500
Storage and media input
Release tab - slide upwards USB and 3mm stereo jack
30
Electrical TRAINING
Window Motor Programming – High Speed Function

Window Motor Standardization Sequence
Non-standardized window motors are no longer capable of high speed raising/lowering.

Such cases may occur in following conditions.
1 When window motor is separated

2 When door harness is separated
3 When battery is separated or replaced
Note: The door must be completely closed prior to window normalization.

The order in which the window motor is standardized is as follows:
1. Ignition switch in ON position.
2. Starting from the position where window is completely closed, maintain the power
window switch in pressed condition until window is completely opened then continue
pressing on the switch for approximately 5 seconds.
3. Pull on the power window switch until window is completely closed. After window
has been completely closed, press down on the switch for approximately 5 seconds.
Window is now standardized and window is capable of performing high speed raise and
lowering.
Window Motor Re-Learning Sequence
In relation to following conditions, there may be a need to perform re-learning sequence

of the local interconnect network (LIN):
1 When window glass has deviated from the aligned condition

2 When window glass has been replaced
3 When door has been replaced
4 When window regulator has been replaced
Note: Prior to executing the re-learning sequence, the vehicle must be on its wheels and
must be positioned on a flat surface and finally, all door must be completely closed.
Window motor re-learning sequence is as follows:
1. Ignition switch in ON position.
2. Using the scan tool, select module failure diagnosis, body control module, and confi-
guration/reset function then select to erase the applicable window learned values neces-
sary for re-learning sequence of the window motor.
3. Following the learning sequence, completely escape from learning sequence of the
scan tool. The power window cannot be normalized and will not be operational until
completely escaped from the program.
4. Starting from the position where window is completely closed, maintain the power
window switch in pressed condition until window is completely opened then continue
pressing on the switch for approximately 5 seconds.
5. Pull on the power window switch until window is completely closed. After window
has been completely closed, press down on the switch for approximately 5 seconds.
Window is now re-programmed.
31
TRAINING Electrical
Park Assist (PAS)

Overview
PAS is a system which detects location of objects using ultrasonic waves. The sys-
tem measures the time it takes for the waves to return after reflecting off the objects
and then converts the time into distance. The system then alerts the driver by soun-
ding various alarms depending on distance between the vehicle and the obejct in the
rear of the vehicle.
Alarm for detected obstacle is sounded through the rear speaker connected to the
radio silver box module via the LS-GMLAN communication circuit.
If the PAS develops a fault, then the PAS warning light in the instrument panel is lit
via the LS-GMLAN communication circuit and the fault code is stored in the PAS mo-
dule. If the PAS module is replaced, the new PAS module should be programmed
using the calibration data specific to the vehicle.
Component Mounting Position
PAS Component Locations
1. PAS Sensor: 4 mounted on rear bumper

2. PAS module: Inside the left side trim of the trunk
3. Body Control Module (BCM): Floor panel below the center of I.P
4. PAS Warning Light: Instrument Panel Cluster (IPC)
5. PAS warning alarm: Generated from the back seat speaker connected to audio
system
32
Electrical TRAINING
PAS Module: Inside the left side trim of the trunk
PAS Sensor: 4 mounted on rear bumper
Right corner Right centre Left centre Left corner
33
TRAINING Electrical
PAS Operating Conditions
By turning on the ignition switch to “IGN”, PAS warning light on the instrument
panel is lit and when no fault in the system is detected, then the light is turned
off after 3 seconds.
When gear lever is changed to “R” position, a signal is registered and the PAS
becomes operational.
Alarm is sounded if an object is within 30cm ~ 120cm range and there are total
of 8 levels of alarm depending on the distance of the object.
Conditions in which PAS is not Operated
1. When reversing speed is greater than 8km/h

2. When the PAS warning light in instrument panel is lit
PAS Fault Diagnosis
Turn on the ignition switch, and if PAS warning light in the instrument panel is
turned off after 3 seconds, then the PAS is working properly. If the light remains
turned on or turns on while driving, then there is a fault in the system.
34
Restaint System TRAINING
Restraint System
NCAP Rating
There is no official Euro NCAP rating yet for the Orlando as it has not been tested
yet.It is expected to be a four star rating.That may sound surprising with all the sa-
fety features in the new Orlando, but NCAP is upgrading its ratings each year.
That means that a vehicle that might have gained a five star rating in 2009 won’t
necessarily receive one now.So Orlando isn’t necessarily any less safe than a vehicle
which received a five star rating some time ago.
Up to 2009 NCAP carried out three types of testing - Adult occupation protection,
Child protection and pedestrian protection.It now also tests for whiplash neck injury
protection in a rear impact.And it also now rewards seatbelt reminders and speed
limiters and the standard fitment of electronic stability control. Orlando is expected
to receive a four star rating.
Supplemental Inflatable Restraint Overview

The supplemental inflatable restraint (SIR) system supplements the protection of-
fered by the seat belts. The SIR system contains an inflatable restraint sensing and
diagnostic module (SDM), inflator modules, seat belt pretensioners (anchor and re-
tractor), and impact sensors.
The SDM determines the severity of a collision with the assistance of side impact
sensors located at strategic points on the vehicle. When the SDM detects a collision,
the SDM will process the information provided by the sensors to further support air
bag or pretensioner deployment. The SDM will deploy the air bags and pretensioners
if it detects a collision of sufficient force. If the force of the impact is not sufficient
to warrant inflator module deployment, the SDM may still deploy the seat belt pre-
tensioners. The SDM contains a sensing device that converts vehicle velocity chang-
es to an electrical signal. The SDM compares these signals to values stored in
memory. If the signals exceed a stored value, the SDM will determine the severity
of the impact and either cause current to flow through the frontal deployment loops
deploying the frontal air bags and pretensioners, or it will deploy the pretensioners
only. The SDM continuously monitors the deployment loops for malfunctions and il-
luminates the SIR system AIR BAG indicator if a fault is detected.The SDM performs
continuous diagnostic monitoring of the SIR system electrical components. Upon de-
tection of a circuit malfunction, the SDM will set a DTC and inform the driver by il-
luminating the SIR system AIR BAG indicator.
35
TRAINING Restaint System
Passive Safety
Belt Pretensioners Seat Belt Height Seat Belt Force Limiters

Adjustment
Crash sensors
Pedal Release
System
Safety Steering Passenger Safety 6 Airbags ISOFIX System

Column Cage
Saftey steering column - will colapse in the event of a frontal colision either from
the impact of the drive colliding with the steering wheel or from the outside force
pushing upwards on the column
Pedal release system - lessens the risk of injures to the drivers feet and legs in a
collision, by swinging the pedals upwards
Crash sensors - not only for early warning in airbag deployment but to automatically
unlock the doors in the event of an accident
Seat belt pretensioners - to recude the slack in the seat belt in the event of an ac-
cident using a mcro gas generator to reduce the displacement of the passenger
Seat belt height adjustment - to ensure correct fitment of the seat belt
Seat belt force limiters - lessen the risk of upper body injuries by reducing the ma-
ximum shoulder belt force above a certain threshold.
ISOFIX child safety system - on second row seats features 2 lower anchors and 1
top tether anchor for robust installation of a child seat
Six airbags - front, side and curtain
Passenger saftey cage - High strength steel multi-crash load path structure for front
and rear. Provides highly effective protection to occupants of the vehicle in the
event of an accident. As part of this structure, high strength steel is used to protect
the fuel tank, this reduces potential hazards caused by fuel escaping following a
collision. The structure also includes highly efficient aluminium bumper reinforc-
ments and systems to protect occupants from impacts in side-on collisions.
36
Airbag System Component

4
6
5
3
1 Driver-side Airbag Module
2 2 Passenger-side airbag module

3 Airbag control module (SDM)
4 Roof airbag module (Curtain)
5 Side impact sensor
1 6 Front impact sensor
Additional components:
3
Side airbag module (embedded in the
seat),
Seat belt pretensioner (retractor
type)
Clock spring
Airbag Control Module (SDM)

Airbag control module is installed on the inner floor panel of the front console box.
37
TRAINING Restaint System
Airbag control Module(Sensing and Diagnostic Module)
The SDM is located in the centre of the vehicle(under the centre console) as this is
one of the safest places for this crucial module to be located.It is reasonably safe
from any side smash or front or rear collision.
The module has to be replaced in the event of a front smash and the front airbags
have deployed. In the event of a side smash and side airbags have deployed, it can
be recoded(reset) up to three times.
Front Driver-side Airbag Module

Driver-side airbag module is mounted in the steering wheel by two C-clips.
Holes for detaching module
C-clip
Direction to which
the C-clip is to be moved
for detaching the module
Steering wheel position for

detaching the module Position of the C-clip inside the steering
wheel after detaching the module
Method for attaching/detaching driver-side airbag module
1 Rotate the steering wheel as shown in the drawing on the in the Figure 1.
2 Diagonally push in a small flat-head screwdriver, 15cm or less, into the hole (refer
to #2 in the Figure 1) underneath the steering wheel.
3 At the position where the tension of the C-clip can be felt, press in the screwdri-
ver so as to push the C-clip clockwise or counterclockwise and detach either side
of the airbag module one at a time.
4 Airbag module can be attached by simply pushing the module into the steering
wheel when the C-clips are in their normal positions.
38
Right Left
side side
Detaching Detaching
position Inserting position
position
& Inserting
angle
Left Right Insertion angle and direction of turn for screwdriver

side side depending on positions of the holes
Side Impact Sensor and Seat Belt Pretensioner

Side impact sensors and seat belt pretensioners (retractor type) are installed at the
bottom of left and right “B” pillars in the interior of the vehicle.
Seat belt pretensioner
Photo: B pillar on the

left side of the vehicle
Side impact sensor
39
TRAINING
Front Impact Sensor

Front impact sensor is installed on the top of the radiator electric fan inside the engine
compartment.
Front impact sensor Securing bolt
Passenger Airbag de-activation switch

The front passenger airbag can be deactivated via a switch, a telltale light on the centre
dash console illuminates to inform the driver of the deactivated airbag.
The de-activation switch can be found on the left side of the dashboard(facing the front
door)
40
TRAINING
Airbag Warning Light

1. Airbag warning light
When the ignition switch is turned ON, the SDM diagnoses the system and depen-
ding on the fault type as shown belwo in the table, controls the airbag warning light
located in the instrument panel.
Fault Type Normal Not Programmed Fault

3.5 sec ON 0.5 sec ON 3.5 sec ON
State of the airbag
1.5 sec OFF 0.5 sec OFF 1.5 sec OFF
warning light
Continuously OFF Continuously Repeat Continuously ON
2. Driver-side seat belt indicator and chime bell
The driver-side seat belt fasten warning lamp on the instrument panel is lit for 3.5
seconds (warning lamp inspection) when the ignition switch is turned ON regardless
of whether or not the seat belt is fastened and when seat belt is fastened then the
warning lamp is turned OFF. Afterwards, depending on whether or not the seat belt
fastened, the seat belt warning light and chime bell are operated as shown in the be-
low table.
When seat belt is fastened When seat belt is not fastened

Condition Seat belt warning Seat belt warning
Chime bell Chime bell
light light
Ignition switched Flashes for 20 sec.
OFF OFF Rings 6 times
ON and then remain ON
Blinks for 35 sec. and

Condition “A” OFF OFF Rings 35 times
then remains ON
For Condition “A” the following 2 conditions must be met:

1. Seat belt not fastened for at least 50 seconds
2. Vehicle speed more than 25 Km or vehicle travels more than 250 m
Driver-side seat
Airbag warning light
belt warning light
41
TRAINING Notes
42
TRAINING

Orlando - 2011

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Chevrolet Orlando

Model Introduction Training For

Orlando's space, storage and safety

Any hard-working family car needs plenty of

However, perhaps the most ingenious is a

Safety for the vehicle's occupants is always a

Orlando 1.8 LS M/T

– 104 kW 16V DOHC engine – Traction control (TC)

Orlando 1.8 LT M/T

– 104 kW 16V DOHC engine – Anti-dazzle rear view mirror

Engine Fuel Type Displacement Power Output Torque

LS 2.0 VCDi(96kw) Diesel 1998ccm 96kw 315nm

LT 1.8i * Petrol 1796ccm 104kw 176nm

LT 2.0VCDi(96kw) Diesel 1998ccm 96kw 315nm

LT 2.0VCDi(120kw) Auto Diesel 1998ccm 120kw 360nm

LTZ 1.8i Petrol 1796ccm 104kw 176nm

LTZ 2.0VCDi(120kw) Diesel 1998ccm 120kw 360nm

LTZ 2.0VCDi(120kw) Auto Diesel 1998ccm 120kw 360nm

– 5 Speed Manual Gearbox

Carbon Flash - GAR

Daydream Beige - GOZ

Gunsmoke Grey - GQK

Olympic White - GAZ

Velvet Red - GCS

Switchblade Silver - GAN

Pewter Grey - GCV

Height mm Length mm Width mm

Where does Orlando fit?

Cruze - Car C Orlando - MPV C Captiva - SUV C

Vehicle Identification Number

Left of front windscreen

Under carpet on drivers floor

Example: KL1 JF 75 5JBK 100001

Position No Definition Character Description

Vin Option Engine No Of Cam Fuel

Starting with Chevrolet Orlando's

Chevrolet Orlando's passenger compartment is reinforced all round, including the

Dual Phase Steel

– Low yield strength

No Name Material No Name Material

3 Front-side rail High strength 14 Rocker outer panel Mild steel

5 Roof panel Mild steel 16 Body hinge pillar High strength

6 Roof rear panel High strength 17 Rocker inner Ultra high

12 Center pillar exterior Mild steel 23 Front impact bar Aluminium

Bumper and Fascia

Front Bumper Removal

1 Front bumper fascia upper retainer (Quantity: 2)

Front Bumper Impact Bar Replacement

1. Disable the SIR.

6. Indicate and mark all factory weld point locations.

1. Position front bumper impact bar on to the vehicle.

3. Paint the repaired part.

Rear Bumper Removal

Rear Bumper Impact Bar Replacement

Front Compartment Side Rail Sectioning

Body Hinge Pillar Outer Panel Sectioning

Rocker Inner Panel Replacement

Rear Side Rail Sectioning

Roof Front Header Panel Replacement

– McPherson layout on subframe

Note: Wheel bearing/hub bolts must be discarded and replaced if bearing/hub is

– One type of rear axle

Note: Wheel bearing/hub bolts must be discarded and replaced if bearing/hub is

Variable Steering System