🏷️ Basic Information

Make:

Daewoo / Holden

Model:

Kalos / Barina

Platform Codename:

T200 (Daewoo Kalos) / XC Barina (Holden)

Model Years Covered:

2000 onwards (MY2000+)

Chassis Codes:

T200 (Kalos), XC (Barina)

👋 Introduction

Target Audience:

Designed for automotive technicians, dealership service departments, and experienced DIY enthusiasts undertaking maintenance, diagnostics, and repairs on the Daewoo Kalos and Holden Barina (XC).

Manual Equivalence:

This manual is equivalent in content and detail to the official Factory Service Manuals (FSM) used by dealership technicians, providing authoritative repair information.

Versatility:

Covers multiple engine options (1.2, 1.4, 1.5 SOHC, DOHC) and transmission types (manual, automatic), offering broad applicability for the Daewoo Kalos and its rebadged Holden Barina counterpart.

Completeness:

Provides comprehensive coverage across all major vehicle systems, ensuring a complete resource for all repair and maintenance needs.

📋 Manual Details

Systems Covered:

General Information, Specifications, Maintenance and Repair, General Description and System Operation, Engine Mechanical (1.2 SOHC, 1.4/1.5 SOHC, DOHC), Engine Cooling, Engine Electrical, Engine Controls, Suspension Diagnosis, Wheel Alignment, Front Suspension, Rear Suspension, Tires and Wheels, Automatic Transaxle Drive Axle, Manual Transaxle Drive Axle, Hydraulic Brakes, Master Cylinder, Power Booster, Front Disc Brakes, Rear Drum Brakes, Antilock Brake System (ABS), Aisin Automatic Transaxle, Five-Speed Manual Transaxle (D16), Five-Speed Manual Transaxle (Y4M), Clutch (Hydraulic Type), Clutch (Cable Type), Power Steering System, Power Steering Pump, Power Steering Gear, Manual Steering Gear, Steering Wheel and Column, HVAC (Heating, Ventilation, and Air Conditioning), Manual Control HVAC, Body Wiring System, Lighting Systems, Horn, Wipers/Washer Systems, Instrumentation/Driver Information, Audio Systems, Interior Trim, Seats, Water Leaks, Wind Noise, Squeaks and Rattles, Glass and Mirrors, Exterior Trim, Frame and Underbody, Bumpers and Fascias, Doors, Roof, Body Front End, Body Rear End, Remote Keyless Entry and Anti-Theft System, Immobilizer Anti-Theft System.

Estimated Page Count:

Extensive (indicative of a full factory service manual, typically 1000+ pages for comprehensive coverage)

Manual Type:

Factory Service Manual (FSM)

Language:

English

Format:

PDF Download (RAR archive)

📖 Manual Coverage

Powertrain:

Complete engine mechanicals for 1.2 SOHC, 1.4/1.5 SOHC, and DOHC variants, including diagnosis, repair, and overhaul. Covers engine cooling, electrical systems, and engine control units (ECUs).

Drivetrain:

Detailed coverage of both manual and automatic transaxles, including specific Aisin automatic units and D16/Y4M manual gearboxes. Includes drive axle components, clutches (hydraulic and cable), and associated systems.

Chassis:

Comprehensive sections on front and rear suspension systems, diagnosis, wheel alignment procedures, and tire/wheel specifications. Covers power steering systems (pump, gear), manual steering, and steering wheel/column assembly.

Braking:

In-depth information on hydraulic brake systems, including master cylinder, power booster, front disc brakes, rear drum brakes, and Antilock Brake System (ABS) operation and diagnosis.

HVAC:

Detailed guides for heating and ventilation systems, including manual and potentially automatic climate control units.

Electrical Body:

Extensive coverage of body electrical systems, including wiring diagrams, lighting, horn, wipers/washers, instrumentation, audio systems, interior trim, seats, and anti-theft systems (keyless entry, immobilizer).

Maintenance:

Includes routine maintenance procedures, fluid change intervals, and component replacement guidelines.

Diagnostics:

Provides diagnostic strategies, symptom-to-cause troubleshooting charts, and specific diagnostic procedures for various vehicle systems.

Repair Rebuild:

Detailed step-by-step repair and overhaul procedures for all major mechanical and electrical components.

Specifications:

Includes all necessary torque specifications, clearances, fluid capacities, and electrical data.

Depth:

Comprehensive Factory Service Manual (FSM) level, suitable for professional technicians and advanced DIY mechanics. Covers everything from basic maintenance to complex engine rebuilds and electrical diagnostics.

📊 Manual Specifications

Compression Type:

RAR archive; requires WinRAR or compatible software for extraction.

Indexing:

Includes HTML index, though functionality may vary across different PDF readers and operating systems.

Quality Assessment:

High quality, typically derived from original factory documentation. Diagrams and text are usually clear and legible.

Binding Type Digital:

Digital download, no physical binding.

Paper Type Digital:

Digital format, no physical paper.

⚙️ Engine Specifications

Engine Variants Covered:

1.2L SOHC, 1.4L SOHC, 1.5L SOHC, and DOHC variants.

Power Torque Details:

Manual provides specific horsepower and torque figures for each engine variant, critical for diagnostics and performance checks.

Fuel And Emission Control:

Detailed information on fuel delivery, injection systems, and emission control components, including diagnostic procedures for related fault codes.

Mechanical Components:

Includes detailed specifications and procedures for cylinder heads, pistons, crankshafts, camshafts, and valve train for all engine types.

🔧 Transmission

Standard Transmission Type:

Five-speed manual transmission (variants D16 and Y4M).

Optional Transmission Type:

Aisin automatic transaxle.

Transmission Diagnostics:

Covers diagnostic procedures, fluid specifications, and repair information for both manual and automatic transmissions.

📐 Dimensions

Body Styles:

Manual likely covers various body styles including hatchback and sedan variants typical of the Kalos/Barina generation.

Curb Weight Range:

Technical specifications would include curb weight ranges for different engine and transmission configurations.

🛡️ Safety Features

Crash Test Results Reference:

While the manual itself doesn't contain crash test results, it details systems that contribute to safety, such as the Antilock Brake System (ABS) and restraint systems.

ABS Operation:

Detailed explanation of the Antilock Brake System's operation and diagnostic procedures for potential faults.

Airbag System:

Information on airbag system components and potential repair procedures, though specific system design details may vary.

💡 Technology Features

Audio Systems:

Includes specifications and repair procedures for the factory audio systems, speaker configurations, and wiring.

ABS System:

Provides detailed technical information and diagnostic troubleshooting for the Antilock Brake System (ABS).

Remote Keyless Entry:

Covers the operation, diagnosis, and potential repair of the remote keyless entry and alarm systems.

Immobilizer System:

Includes information related to the vehicle's immobilizer and anti-theft systems.

🔧 Maintenance

Typical Intervals:

The manual provides detailed service schedules for oil changes, filter replacements, fluid checks, timing belt replacement (if applicable), spark plug replacement, and brake system servicing.

Engine Oil:

Specifies recommended engine oil viscosity grades (e.g., 5W-30, 10W-40) and API service classifications based on engine type and operating temperature.

Coolant:

Details recommended coolant types (e.g., ethylene glycol-based with specific inhibitor packages) and the correct mixture ratio.

Transmission Fluid:

Specifies the correct Automatic Transmission Fluid (ATF) type for the Aisin automatic transaxle and gear oil specifications for the manual transmissions.

Brake Fluid:

Indicates the required DOT specification for brake fluid (e.g., DOT 3 or DOT 4).

Common Wear Items:

While not explicitly listed as 'known issues', the manual's detailed coverage of components like suspension bushings, exhaust systems, and clutch components implies areas that may require regular inspection and replacement due to wear and tear.

Electrical Diagnostics:

The extensive electrical system coverage is invaluable for diagnosing intermittent faults or issues common in vehicles of this era.

📚 Vehicle History

Daewoo Kalos Development:

The Daewoo Kalos (T200) was developed during the period of Daewoo's independence before its acquisition by GM. It represented a move towards more modern styling and European design influences.

Holden Barina Xc Rebadge:

The Holden Barina XC was a rebadged version of the Daewoo Kalos, sold in Australia and other markets. This manual covers the commonalities and specific Holden branding aspects.

Manufacturing Locations:

Daewoo Kalos was produced in South Korea. Holden Barina was produced in South Korea and also in other GM facilities depending on the market.

🏆 Awards & Recognition

Awards And Ratings Context:

The Daewoo Kalos/Holden Barina (XC) did not receive prominent automotive industry awards or high safety ratings in major publications compared to some competitors of its time. The manual's value lies in its technical detail, not in historical accolades for the vehicle itself.