Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
Country Of Origin:
South Korea (developed by Daewoo, marketed as Chevrolet in some regions)
Chassis Code:
KLA4 (typically)
Target Audience:
Do-it-yourself (DIY) owners and experienced automotive technicians looking for comprehensive service and repair information for their Chevrolet Rezzo.
Value Proposition:
Provides dealer-level service information at a fraction of the cost of professional labor and shop manuals. Enables cost-effective vehicle maintenance and repair.
Detail Level:
Highly detailed with hundreds of photos, illustrations, drawings, and diagrams to guide users through every procedure.
Instruction Format:
Step-by-step instructions with numbered steps, detailed substeps, notes, cautions, and warnings for critical information.
Illustration Enhancement:
Enlarged inset views for detailed examination of specific parts and components.
Navigation:
Numbered table of contents for quick and easy access to information.
Engine:
Comprehensive coverage including engine mechanical, lubrication, cooling, fuel system, ignition, starting, and charging.
Transmission:
Detailed procedures for both automatic and manual transmissions, including clutch, gearbox, transfer case (if applicable), drive shafts, and differentials.
Brakes:
Includes brake control systems, standard brakes, parking brake, and associated components.
Suspension Steering:
Coverage of axles, suspension systems, tires, wheels, steering column, and power steering.
Electrical:
Extensive electrical system diagnostics, troubleshooting, wiring diagrams, multiplex/CAN communication, lighting, meters, audio/visual systems, horn, and engine immobilizer.
Body Interior:
Covers engine hood, doors, exterior and interior trim, windshield, glass, mirrors, instrument panel, and seats.
Climate Control:
Detailed information on the air conditioning system.
Safety Restraint:
Includes supplemental restraint system (airbags) and seat belts.
Maintenance:
Routine maintenance procedures, fluid checks, filter replacements, and tune-ups.
Diagnostics:
Step-by-step diagnostic procedures for identifying and troubleshooting common and complex issues across all systems.
Repair:
Detailed, step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Troubleshooting:
Dedicated troubleshooting sections for electrical systems and general mechanical issues.
Depth:
Comprehensive, covering everything from basic fluid changes and inspections to complex engine overhauls, transmission rebuilds, and detailed electrical system diagnosis. Geared towards both DIY enthusiasts and professional mechanics.
Readability:
Searchable text content for efficient information retrieval.
Printability:
All pages are printable, allowing users to create hard copies of specific sections or the entire manual.
Binding:
Digital (no physical binding)
Paper:
N/A (Digital format)
Operating Systems:
Compatible with all PC-based Windows operating systems, Mac, and Linux.
Required Software:
WinZip (for extraction) and Adobe PDF Reader (for viewing).
Engine Options:
Typically equipped with 1.5L or 1.6L inline-4 gasoline engines. Diesel options may also exist for certain markets.
Typical Horsepower 1.6L:
Approximately 104 hp @ 5600 rpm (varies by market and specific engine code)
Typical Torque 1.6L:
Approximately 145 Nm (107 lb-ft) @ 3200 rpm (varies by market and specific engine code)
Fuel Delivery:
Multi-point Fuel Injection (MPI)
ECU Type:
Covered in the Control System section, likely featuring an ECU (Engine Control Unit) controlling fuel, ignition, and emissions.
Systems:
Detailed coverage of emission control systems, including catalytic converters, EGR (Exhaust Gas Recirculation), and PCV (Positive Crankcase Ventilation).
Transmission Types:
Available with both 5-speed manual transmission and 4-speed automatic transmission.
Optional Transmission:
4-speed automatic transmission
Clutch Type:
Hydraulically operated single dry plate clutch (for manual transmission).
Automatic Transmission Fluid:
Specifies required AT fluid type (e.g., DEXRON-III or equivalent, consult manual for exact specification).
Manual Transmission Fluid:
Specifies required manual transmission fluid type (e.g., GL-4 gear oil, consult manual for exact specification).
Body Style:
Compact MPV (Multi-Purpose Vehicle) / Minivan
Length Approx:
Around 4000-4200 mm (varies slightly by model year and market)
Width Approx:
Around 1700-1750 mm
Height Approx:
Around 1600-1650 mm
Curb Weight Approx:
Around 1200-1350 kg (depending on engine and transmission)
Cargo Capacity:
Designed for passenger and light cargo transport, with foldable rear seats for increased volume. Specific cubic footage details not provided in product description, but typical for the segment.
Crash Test Results:
Not readily available for this specific model in many major markets, as it was primarily sold in Asian and some European markets. Manual covers safety systems regardless of formal ratings.
ABS:
Anti-lock Braking System (ABS) availability varies by trim and market. Manual will cover its function and troubleshooting.
Airbags:
Front airbags for driver and passenger are standard on most models. Manual details SRS system operation and diagnosis.
Seat Belts:
Includes coverage of seat belt operation, adjustment, and pre-tensioners (if equipped).
Audio System:
Covers standard audio systems, including radio, CD player (if equipped), speaker diagnostics, and wiring.
Cruise Control:
Details on the operation and troubleshooting of the cruise control system.
Multiplex Can Communication:
Includes information on the vehicle's multiplex communication system, crucial for diagnosing modern electronic issues and understanding data flow between ECUs.
Engine Immobilizer:
Provides information and diagnostic procedures for the engine immobilizer system, enhancing vehicle security.
Oil Change Interval:
Typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type. Manual will provide precise recommendations.
Tune Up Interval:
Spark plug replacement, air filter, and fuel filter checks/replacements typically recommended every 30,000-60,000 km (18,000-36,000 miles). Manual provides specific intervals.
Timing Belt Replacement:
Critical service item for interference engines. Typically recommended every 60,000-100,000 km (36,000-60,000 miles). Manual will specify the exact interval and procedure.
Engine Oil Type:
API SG or higher, viscosity typically 10W-30 or 5W-30. Manual will specify exact API classification and viscosity grade.
Coolant Type:
Ethylene glycol-based coolant with appropriate corrosion inhibitors. Manual will specify the correct type and mixture ratio (e.g., 50/50).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify the exact requirement.
Common Problems:
Potential issues can include ignition system components (coils, plugs), exhaust system leaks, minor electrical gremlins, and wear on suspension components over time. The manual provides diagnostic steps for these.
Chevrolet Legacy:
While Chevrolet is a historic American brand, the Rezzo was a product of Daewoo's engineering and manufacturing, later integrated into GM's global portfolio. The manual reflects Chevrolet's branding of this vehicle.
Rezzo Development:
Developed by Daewoo as the successor to the Daewoo Nubira station wagon, intended to compete in the compact MPV segment. It was rebadged as the Chevrolet Rezzo for various markets.
Manufacturing Location:
Primarily manufactured in South Korea by Daewoo.
Production Span:
Produced from approximately 1997 (as Daewoo Nubira Wagon/MPV) through 2008 under the Chevrolet Rezzo nameplate. The manual covers the Chevrolet-branded years.
