Segment:
Subcompact hatchback and sedan
Competitors:
Hyundai Accent, Ford Fiesta, Toyota Yaris, Volkswagen Polo, Nissan Tiida.
Vehicle Strengths:
Affordability, fuel efficiency, practical interior space for its class, robust construction for its segment.
Purpose:
To provide comprehensive repair and maintenance information for DIY mechanics and professional technicians working on the Chevrolet Sail 2005-2009 models.
Engine:
Complete engine overhaul, diagnosis, timing components, cooling system, lubrication system, fuel delivery, ignition system, emissions control.
Transmission:
Manual and Automatic transmission repair, clutch system, gearbox overhaul, fluid specifications, diagnosis.
Drivetrain:
Front-wheel drive system, CV joints, axles, differential.
Brakes:
Front and rear brake systems (disc/drum), ABS (if equipped), hydraulic systems, parking brake.
Steering:
Power steering system, steering column, tie rods, wheel alignment specifications.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel bearings.
Electrical:
Full electrical system diagrams, wiring harnesses, fuses, relays, battery, charging system, starting system, lighting, instrument cluster, interior electronics.
Bodywork:
Body panel removal and installation, interior trim, exterior components, glass replacement, rust repair.
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair, refrigerant handling.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plugs, belts, hoses, brake fluid changes, coolant flushes.
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components, including engine, transmission, suspension, brakes, and electrical systems.
Diagnostics:
Detailed diagnostic flowcharts and explanations for various systems.
Component Replacement:
Instructions for replacing specific parts like alternators, starters, radiators, fuel pumps, etc.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds. Includes detailed specifications, tolerances, and diagnostic procedures.
Engine Code:
X14SE (example, may vary by region)
Engine Type:
Inline 4-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
1.4 Liters (approx. 1389 cc)
Horsepower:
Approx. 94-96 HP (70-72 kW) @ 6000-6200 RPM (specifications may vary)
Torque:
Approx. 128-130 Nm (94-96 lb-ft) @ 3200-3600 RPM (specifications may vary)
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
ECU:
GM Electronic Control Unit (ECU) - specific model number to be found in manual.
Crash Test Data:
Limited independent crash test data available for early models in all markets. Manual will provide passive safety system details.
ABS:
Optional/Standard depending on trim level and market. Manual covers diagnostic and repair procedures.
E Brake:
Mechanical parking brake system.
Airbags:
Driver and front passenger airbags (standard/optional depending on market). Manual covers airbag system service and diagnostics.
Seatbelts:
Three-point seatbelts with pre-tensioners (front seats).
Audio System:
Basic AM/FM radio with CD player. May feature auxiliary input. Manual covers head unit removal and speaker wiring.
Instrument Cluster:
Analog gauges for speedometer, tachometer, fuel level, and temperature. Warning lights for various systems. Manual details cluster diagnostics.
ABS:
As mentioned, available on higher trims. Manual details ABS sensor locations and diagnostic procedures.
Usb Aux:
Limited connectivity features typical for the era. Aux-in ports may be present. Manual covers audio system interfaces.
Oil Change Interval:
Typically every 7,500-10,000 km (4,500-6,000 miles) or 6-12 months, whichever comes first (refer to manual for exact specifications).
Air Filter Replacement:
Every 20,000-30,000 km (12,000-18,000 miles) or as needed based on environment.
Spark Plug Replacement:
Every 60,000-100,000 km (36,000-60,000 miles), depending on plug type (standard or iridium).
Coolant Flush:
Every 40,000-60,000 km (24,000-36,000 miles) or 2-3 years.
Engine Oil Grade:
API SG/SH/SJ or higher, SAE 5W-30 or 10W-40 recommended (refer to manual for precise grade and capacity).
Coolant Type:
GM-spec (typically OAT or HOAT) ethylene glycol based coolant.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Complaints:
Minor oil leaks from valve cover gasket, starter motor issues, clutch wear (manual transmission), potential ABS sensor faults, exhaust system corrosion.
Electrical Quirks:
Occasional issues with door locks, power windows, and dashboard indicator lights reported in some units. Manual provides wiring diagrams for diagnosis.
Manufacturer:
Chevrolet (a division of General Motors)
Platform Origin:
Based on GM's Global Small Vehicle (GSV) platform, codenamed Gamma II.
Segment Introduction:
Chevrolet Sail was introduced as GM's entry into the growing subcompact segment, particularly for emerging markets.
Manufacturing Locations:
Primarily manufactured in China (by SAIC-GM Wuling) and other GM facilities globally catering to specific markets.
Production Years:
Model years 2005-2009 covered by this manual. The Sail nameplate has seen subsequent generations and rebadging.
