Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011
Platform:
GM T platform (shared with Daewoo Gentra/Lacetti Hatchback)
Target Audience:
DIY car owners, independent repair shops, professional mechanics
Value Proposition:
Provides professional-grade repair information at a fraction of the cost of dealership service or proprietary software, enabling cost-effective maintenance and repairs.
Usability:
Step-by-step instructions, clear text, high-quality diagrams, and exploded views ensure ease of use for various skill levels.
Powertrain:
Engine mechanical, fuel system, cooling system, exhaust system, ignition system, engine management, transmission (manual and automatic), driveline, clutch
Chassis:
Suspension (front and rear), steering system, braking system, wheels and tires
Body And Electrical:
Body construction and materials, interior components, HVAC system, exterior lighting, interior lighting, power accessories (windows, locks, mirrors), instrumentation, audio system, wiring diagrams, fuses and relays, anti-theft system
Maintenance Procedures:
Fluid checks and changes, filter replacements, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation
Repair Procedures:
Component removal and installation, engine overhaul, transmission rebuild, brake caliper overhaul, suspension component replacement, steering rack replacement, wiring harness repair
Troubleshooting:
Diagnostic procedures, fault code interpretation (OBD-II), symptom-based diagnostics, electrical circuit testing, common problem diagnosis and solutions
Technical Depth:
Detailed, from basic maintenance to complete engine and transmission rebuilds, including diagnostic strategies and electrical schematics
Engine Options:
1.4L (X14XE/Z14XE), 1.6L (X16XE/Z16XE) Ecotec 4-cylinder gasoline engines
1.4L Ecotec Horsepower:
Approx. 94 PS (93 bhp; 69 kW)
1.6L Ecotec Horsepower:
Approx. 105 PS (104 bhp; 77 kW)
Fuel Delivery:
Multi-point fuel injection (MPI)
ECU Type:
GM Ecotec Engine Control Module (ECM) variants
Transmission Type Standard:
5-speed manual transmission
Transmission Type Optional:
4-speed automatic transmission
Transmission Fluid Type:
Refer to manual for specific DEXRON fluid type (e.g., DEXRON III/VI for automatic, specific gear oil for manual)
Euroncap Rating:
Typically 3 to 4 stars for models of this era, specific results vary by year and equipment (e.g., 2004 model received 4 stars)
Braking System:
Front ventilated discs, rear drums (standard); optional ABS (Anti-lock Braking System)
Airbags:
Driver and front passenger airbags standard; optional side airbags on some trims
Audio System:
Basic AM/FM radio with CD player, optional auxiliary input or MP3 capabilities on later models
ABS Availability:
Optional ABS on higher trim levels and later production years
Bluetooth Connectivity:
Rarely standard, may have been an dealer-installed option or found on higher trim late models.
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using synthetic oil (refer to manual for exact specification)
Timing Belt Interval:
Recommended replacement every 90,000 - 120,000 km (56,000 - 75,000 miles) or 5-7 years, depending on engine type (refer to manual for specific engine)
Engine Oil Specification:
API SN/SP, ACEA A3/B4, SAE 5W-30 or 5W-40 (verify with manual for specific engine and climate)
Coolant Specification:
GM-approved silicate-free long-life coolant (e.g., Dexcool or equivalent, typically orange/red in color)
Common Wear Items:
Suspension components (bushings, ball joints), exhaust system rust, minor electrical gremlins, clutch wear (manual transmission)
Engine Specific Notes:
Some early Ecotec engines may have had issues with PCV systems and oil consumption. Timing chain tensioners and guides on some variants can be a concern if not maintained.
Manufacturer Origin:
Chevrolet is an American automotive division of General Motors (GM). The Kalos was originally developed by Daewoo, a South Korean manufacturer acquired by GM.
Rebadging:
Sold under various GM brands globally, including Daewoo Kalos, Daewoo Gentra, Chevrolet Aveo, Holden Barina.
Production Period:
First generation (T200/T250) production ran from 2002 to 2011 globally, with minor facelifts.