The Chevrolet Kalos, produced from 2002 to 2011, is a subcompact vehicle offered as a hatchback or sedan. Built on the GM U platform, it was designed with an emphasis on affordability, practicality, and straightforward engineering, targeting budget-conscious consumers seeking economical transportation. Available with 1.2L, 1.4L, and 1.6L gasoline engines from the GM Family II E-TEC II series, the Kalos provided reliable performance for daily commuting and general use. Its straightforward design and accessible maintenance made it a popular choice in its segment, competing with models like the Hyundai Accent and Kia Rio.
This comprehensive workshop service repair manual provides full factory service repair coverage for the Chevrolet Kalos. It details maintenance procedures, including periodic servicing, fluid changes, and inspections, alongside extensive diagnostics and repair instructions for all major mechanical, electrical, and chassis systems. The manual covers engine, drivetrain, brakes, steering, suspension, electrical systems, wiring diagrams, and body components. Its detailed troubleshooting guidance and technical specifications are designed to empower both owners and professional technicians to effectively maintain and repair their vehicles, ensuring longevity and optimal performance.
Production Years Covered:
2002-2011
Platform Code:
GM U platform (Daewoo T100/T150)
Segment:
Subcompact hatchback/sedan
Target Audience:
Budget-conscious consumers seeking reliable and economical transportation.
Key Competitors:
Hyundai Accent, Kia Rio, Ford Fiesta, Vauxhall/Opel Corsa, Renault Clio.
Design Philosophy:
Emphasis on affordability, practicality, and straightforward engineering.
Manual Value Proposition:
Empowers owners to perform maintenance and repairs, reducing long-term ownership costs.
Primary Coverage:
Full Factory Service Repair
Regions Covered:
Global (for models produced)
Estimated Page Count:
Extensive (typical factory manuals are 1000+ pages)
Type:
Workshop Service Repair Manual
Mechanical:
Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Drivetrain (Transmission, Drive Axles), Brakes, Steering, Suspension
Electrical:
Electrical System, Wiring Diagrams, Lighting, Ignition System, Starting and Charging System, Instrumentation, Body Electronics
Chassis And Body:
Chassis Components, Body Panels, Interior Trim, Exterior Trim
Maintenance:
Periodic maintenance, fluid changes, filter replacements, inspections
Diagnostics And Repair:
Troubleshooting procedures, component testing, repair instructions, disassembly/assembly of all major systems
Special Procedures:
Emission control system servicing, wheel alignment specifications, torque specifications
Depth:
Comprehensive; suitable for both DIY enthusiasts and professional technicians, covering detailed diagnostics and complex repairs.
Quality:
High-resolution, ensuring clear diagrams and readable text.
Printability:
Printable without restrictions, allowing for physical copies.
Delivery Format:
Digital Download (PDF)
Digital Requirements:
Adobe PDF Reader
Engine Families:
E-TEC II (GM Family II)
Common Engines:
1.2L (X12XE, Z12XE), 1.4L (X14XE, Z14XE), 1.6L (X16XE, Z16XE) gasoline engines.
1.2L Power:
Approx. 75-80 PS (55-59 kW)
1.4L Power:
Approx. 94 PS (69 kW)
1.6L Power:
Approx. 106 PS (78 kW)
Induction:
Electronic Multi-Point Fuel Injection (MPI)
Emission Controls:
Catalytic Converter, Oxygen Sensors, EGR (where applicable)
Transmission Types:
5-speed Manual Transmission (F13/F15 variants)
Automatic Transmission:
4-speed Automatic Transmission (AF13/AF17 variants)
Clutch Type:
Dry, single plate, diaphragm spring
Body Styles:
5-door Hatchback, 4-door Sedan
Wheelbase:
Approx. 2480 mm (97.6 in)
Overall Length Hatchback:
Approx. 3880 mm (152.8 in)
Overall Length Sedan:
Approx. 4290 mm (168.9 in)
Curb Weight Range:
Approx. 1000-1150 kg (2200-2535 lbs), depending on body style and engine.
Euro Ncap Rating:
3 Stars (early models, may vary by year and testing methodology)
Braking System:
Front disc brakes, Rear drum brakes (ABS optional on some trims)
Steering:
Power assisted rack and pinion (EPS or Hydraulic depending on variant)
Airbags:
Driver and front passenger airbags standard; side airbags optional on some models.
Seatbelts:
Pretensioner seatbelts for front occupants.
Standard Features:
Basic AM/FM/CD player, power windows/locks on higher trims.
Connectivity:
Limited by era; typically basic auxiliary input or pre-wiring for aftermarket systems.
Availability:
Minimal; ABS and airbags were the primary safety technologies, with more advanced systems not typically offered.
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (refer to manual for specific engine oil type).
Timing Belt Replacement:
Recommended every 90,000-120,000 km (56,000-75,000 miles) or 5-7 years, depending on engine variant. Crucial for interference engines.
Engine Oil Viscosity:
Typically 5W-30 or 5W-40 API SJ/SL or higher, or Dexos compatible (refer to manual for exact spec).
Coolant Type:
Ethylene Glycol based antifreeze/coolant, typically silicate-free or OAT type.
Transmission Fluid Manual:
API GL-4 gear oil, SAE 75W-90 or similar.
Transmission Fluid Automatic:
Dexron-III/VI or equivalent.
Common Problems Overview:
Potential for oil leaks (valve cover gasket, sump gasket), exhaust system corrosion, suspension wear (bushings, ball joints), and occasional electrical gremlins, particularly in older models.
Engine Idling Issues:
Can be related to dirty throttle bodies, faulty idle air control valves (IACV), or vacuum leaks.
Transmission Engagement:
Manual transmissions can develop stiff shifting or clutch wear. Automatic transmissions may exhibit delayed engagement or slippage if fluid is low or degraded.
Parent Company:
General Motors (GM) through its Daewoo division.
First Generation Release:
Originally launched as Daewoo Kalos in 2002.
Rebranding:
Rebadged and sold as Chevrolet Kalos in many markets starting around 2004.
Manufacturing Locations:
South Korea (main), Uzbekistan, potentially other GM assembly plants.
Facelift:
Received a significant facelift (T150 platform) around 2008, often marketed as Chevrolet Aveo (though the Kalos name persisted in some regions).
Award History:
The Kalos (and its Chevrolet Aveo rebadge) generally focused on value and economy, rather than winning major industry awards. It was often recognized for its affordability and practicality.
