🏷️ Basic Information

Make:

Chevrolet

Model:

Rezzo

Year:

2006

Vin Prefix:

N/A (Rezzo primarily a Daewoo model rebranded for certain markets)

Generation:

First Generation (PK)

👋 Introduction

Market Position:

The Chevrolet Rezzo, a rebadged Daewoo Tacuma, was positioned as a compact multi-purpose vehicle (MPV) or minivan, targeting budget-conscious families and individuals seeking practicality and versatility in a smaller package. It competed in a segment with vehicles like the Kia Joice, Hyundai Lavita, and potentially entry-level models of larger MPVs or compact SUVs.

Competitive Analysis:

The Rezzo offered a unique blend of hatchback and minivan styling, providing a spacious and flexible interior for its size. However, it often lagged behind competitors in terms of perceived build quality, refinement, powertrain performance, and advanced features. This manual caters to owners who have chosen this pragmatic, often value-driven vehicle and require detailed technical support.

Key Features:

The 2006 Chevrolet Rezzo is characterized by its tall, boxy body providing ample interior space for its footprint, a flexible seating arrangement, and a focus on practicality over performance or luxury. This service manual ensures that owners and independent technicians can maintain and repair this specific platform accurately.

Target Audience For Manual:

DIY mechanics, independent automotive repair shops, and owners who are technically inclined and wish to perform their own maintenance and repairs to save costs and maintain their vehicles effectively. Especially valuable for those who cannot access dealership-specific resources.

📋 Manual Details

Coverage Areas:

All Models & All Repairs A-Z

Page Count:

Estimated 1500+ pages (typical for comprehensive service manuals of this era)

Manual Type:

Service and Repair Manual

Language:

English

Format:

Likely digital (PDF) for this product listing, often provided as a printable digital file.

📖 Manual Coverage

Systems Covered:

Engine mechanical, engine management (ECM), fuel system, ignition system, exhaust system, cooling system, lubrication system, starting and charging system, manual transmission, automatic transmission, driveline, suspension (front and rear), steering, brakes (front and rear), ABS, body electrical systems (lighting, wipers, horn, power accessories), climate control (HVAC), infotainment system, airbags, body and chassis, interior trim, exterior trim, diagnostics, troubleshooting.

Procedures Included:

Routine maintenance, scheduled servicing, detailed diagnostic procedures, component testing, removal and installation procedures for all major and minor mechanical and electrical components, troubleshooting guides for common and complex issues, wiring diagrams, component locations, specifications, tolerances, torque values, fluid capacities and types, replacement part recommendations, electronic diagnostics, repair procedures for body and interior components.

Technical Depth:

Expert/Professional Level. Equivalent to factory service information used by dealership technicians. Covers from basic fluid changes to complete engine and transmission rebuilds, complex electrical system diagnostics, and advanced troubleshooting.

Diagnostic Procedures:

Detailed diagnostic flowcharts, fault code interpretation (OBD-II), component testing procedures using multimeters and specialized tools, troubleshooting steps for driveability, electrical, and emissions-related issues. This manual includes specific diagnostic strategies for GM platforms of this era.

Major Repair Procedures:

Engine overhaul (cylinder head removal, piston/ring replacement, crankshaft/bearing service), transmission overhaul (manual and automatic), suspension component replacement (shocks, struts, ball joints, control arms), brake system overhaul (caliper, rotor, master cylinder replacement), power steering system repair, cooling system component replacement (radiator, water pump, thermostat). Detailed torque specifications and assembly sequences are provided.

Electrical Systems Coverage:

Comprehensive wiring diagrams for all circuits, component location indices for sensors and modules, starter and charging system troubleshooting, lighting system repair (headlights, taillights, interior), power accessory troubleshooting (windows, locks, mirrors), HVAC system electrical diagnostics, airbag system diagnostics and safety precautions, instrument cluster and gauge troubleshooting.

Body Chassis Coverage:

Body panel removal and installation (fenders, doors, hood, trunk lid), bumper repair and replacement, glass replacement (windshield, side windows), interior trim panel removal and installation, seat adjustment and removal, body sealant and weatherstrip replacement, chassis lubrication points, frame inspection and minor repair guidance.

Troubleshooting Guides Scope:

Comprehensive guides covering starting problems, charging system issues, engine performance problems (hesitation, misfires, rough idle), transmission shifting complaints, brake system faults, suspension noise, steering problems, AC not cooling, electrical component failures, and dashboard warning lamp illumination.

Torque Specifications Coverage:

Detailed torque specifications for critical engine components (cylinder head bolts, main bearing caps, connecting rod bolts), suspension fasteners, brake caliper mounting bolts, wheel lug nuts, and various other assembly points to ensure correct tightening and component integrity.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution scans of original factory documentation, ensuring clarity of text, diagrams, and images for printing.

Binding Type:

Not applicable for digital format; designed for printing and binding by user.

Paper Type:

Not applicable for digital format; optimized for standard printer paper.

Content Type:

Reprint of original factory service manual content, including text, diagrams, illustrations, and tables. Highly technical and practical.

Searchability:

If provided as a PDF, typically includes OCR (Optical Character Recognition) for keyword searching, allowing users to quickly locate specific information within the manual.

⚙️ Engine Specifications

Primary Engine:

1.6L (1598cc) DOHC 16-valve Inline-4 (Ecotec Family, likely GM's Fam 1 engine variant)

Horsepower:

Approximately 104 hp @ 6000 rpm

Torque:

Approximately 108 lb-ft (147 Nm) @ 4000 rpm

Fuel System:

Multi-point Fuel Injection (MPI)

Engine Management System:

GM ECM (Electronic Control Module), specific calibration for the Rezzo model.

Cooling System Type:

Pressurized liquid cooling system

Lubrication System Type:

Wet sump

Engine Codes:

Specific engine codes vary by market and exact specification, but often associated with GM's Fam1 family of engines. The 1.6L is commonly designated as A16DMS or similar. Accurate code will be detailed in the manual.

Fuel Delivery System:

Fuel pump, fuel filter, fuel injectors, fuel rail, pressure regulator.

Emission Controls:

Catalytic converter, oxygen sensors (upstream and downstream), EGR system (if applicable), evaporative emissions control (EVAP) system. Manual provides diagnostic procedures for these components.

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

4-speed Automatic Transmission

Transmission Features:

The manual covers both transmission types, detailing their specific maintenance, repair, and diagnostic procedures, including clutch replacement for manual and fluid/filter service for automatic units.

Transmission Codes:

Manual transmission likely F16/F18 family. Automatic transmission likely 4T40-E or similar GM 4-speed automatic. Specific codes detailed in manual.

Clutch System Details:

Manual transmission models cover clutch disc, pressure plate, release bearing, and flywheel inspection, replacement, and adjustment procedures.

📐 Dimensions

Length:

Approx. 4,065 mm (160.0 in)

Width:

Approx. 1,700 mm (66.9 in)

Height:

Approx. 1,680 mm (66.1 in)

Seating Capacity:

5 Passengers

Passenger Volume:

Generous for its class due to upright design.

Cargo Volume Rear Seats Up:

Approx. 360 liters (12.7 cu ft)

Cargo Volume Rear Seats Folded:

Expandable significantly by folding rear seats, offering substantial utility.

Curb Weight:

Approx. 1,200 - 1,300 kg (2,645 - 2,866 lbs), varies by trim and transmission.

Gross Vehicle Weight Rating:

Refer to vehicle's specific GVWR plate for exact figures.

Standard Tire Size:

Commonly 195/60R15 or 205/55R16, depending on trim level. Manual will confirm exact fitments.

Wheel Bolt Pattern:

Likely 4x100 or 5x110. Manual will provide exact specifications.

🛡️ Safety Features

Crash Test Ratings:

Limited independent crash test data available for the Chevrolet Rezzo/Daewoo Tacuma in many markets. Refer to specific country safety authority reports if available.

Active Safety Features:

Anti-lock Braking System (ABS) - standard on many models, Electronic Brake-force Distribution (EBD).

Passive Safety Features:

Front airbags for driver and passenger, front seatbelt pretensioners, side-impact door beams, crumple zones.

Child Safety Features:

ISOFIX child seat anchors, rear door child safety locks.

Front Brakes:

Ventilated Disc Brakes

Rear Brakes:

Drum Brakes or Disc Brakes (depending on trim/market). Manual covers both.

💡 Technology Features

Infotainment System:

Basic AM/FM stereo with CD player and 4-6 speakers. Some models may have optional premium audio or auxiliary inputs. Manual covers system diagnostics and component replacement.

Driver Assistance Features:

Limited by era; primarily ABS and EBD. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane-keeping assist are expected.

Connectivity Features:

Standard power outlets for charging devices. Some later models might have basic Bluetooth for hands-free calling, but this is not guaranteed for the 2006 model across all trims/markets.

Instrument Cluster Features:

Includes speedometer, tachometer (on some models), fuel gauge, engine temperature gauge, odometer, trip meter, various warning lights (check engine, ABS, airbag, etc.). Manual provides diagnostic information for cluster faults.

🔧 Maintenance

Routine Maintenance Intervals:

Oil and filter change: Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months. Air filter: Inspect every 15,000 miles (24,000 km), replace as needed. Spark plugs: Replace every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on type. Coolant: Flush and replace every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-4 years. Transmission fluid: Automatic transmission fluid and filter change every 30,000 - 60,000 miles (48,000 - 96,000 km). Manual transmission fluid inspection. Timing belt: If applicable to specific engine variant, check for replacement interval, typically 60,000 - 90,000 miles (96,000 - 144,000 km).

Engine Oil Specification:

API SM or newer, SAE 5W-30 or 5W-40 (check owner's manual for exact viscosity based on climate).

Engine Oil Capacity:

Approx. 4.0 - 4.5 liters (4.2 - 4.8 US quarts) with filter change.

Coolant Specification:

GM Dex-Cool (Orange) extended life coolant or equivalent. Mixture of 50/50 coolant and distilled water.

Automatic Transmission Fluid Specification:

Dexron III/VI or equivalent.

Manual Transmission Fluid Specification:

GL-4 SAE 75W-90 gear oil.

Brake Fluid Specification:

DOT 3

Common Issues:

Interior trim creaks and rattles, potential for premature wear on suspension components due to vehicle weight and typical usage, occasional issues with HVAC blower motor resistor, oxygen sensor failures, and early catalytic converter failures are not uncommon for vehicles of this age and origin. This manual would provide diagnostic procedures for these. Check for engine mounts wear.

Oil Filter Part Number:

GM Part Number dependent on exact engine variant, likely similar to ACDelco PF2057 or equivalent aftermarket.

Air Filter Part Number:

GM Part Number dependent, likely similar to ACDelco A3065C or equivalent aftermarket.

Spark Plug Part Number:

GM Part Number dependent, often ACDelco Iridium or Platinum plugs for this era. Manual will specify exact plug type and gap.

📚 Vehicle History

Brand Heritage:

Chevrolet, a marque of General Motors (GM), has a long history in producing a wide range of vehicles. In markets where the Rezzo was sold under the Chevrolet nameplate, it represented GM's effort to offer a value-oriented compact MPV, often leveraging platforms and technologies from its global acquisitions, notably Daewoo.

Model Evolution:

The Rezzo is a rebadged version of the Daewoo Tacuma, which was first launched in 2000. It underwent minor facelifts and updates during its production run. The 2006 model represents a specific iteration within this first generation (PK).

Production Years:

Daewoo Tacuma: 2000-2008 (continued as Chevrolet Rezzo in select markets).

Manufacturing Locations:

Primarily South Korea (Daewoo Motor Company, later GM Daewoo Auto & Technology).

Market Segments Served:

Compact MPV / Mini Van segment.

🏆 Awards & Recognition

Recognitions And Awards:

The Chevrolet Rezzo (as Daewoo Tacuma) did not receive significant industry awards or widespread critical acclaim in major automotive publications. Its market positioning was primarily as a value-oriented, practical vehicle rather than a segment leader in performance, safety, or innovation.

📄 Vehicle History

Platform Notes:

The Rezzo/Tacuma is built on a dedicated compact MPV platform. Understanding this platform is key to troubleshooting and repair, as shared components or design philosophies from other GM vehicles of the era might be present but should be verified specifically for this model.