The Kalos, produced between 2002 and 2006, is a subcompact car offered in both 5-door hatchback and 4-door sedan body styles. Designed by Italdesign Giugiaro, it features GM Family 0 (Ecotec) engines, with 1.4L and 1.6L variants providing approximately 94 to 106 horsepower respectively. Known for its European-influenced design and budget-friendly appeal, the Kalos was sold globally under various General Motors brands, including Chevrolet Aveo and Holden Barina. This generation typically utilized a 5-speed manual or a 4-speed automatic transmission and featured front ventilated disc brakes with optional ABS. This comprehensive factory service manual provides in-depth information for the Kalos, covering the model years 2002 through 2006. It is designed for DIY mechanics, independent repair shops, and owners seeking detailed knowledge for maintenance and repair. The manual offers extensive coverage across all major vehicle systems, including powertrain, chassis, and electrical components. Key areas include engine overhaul, transmission service, brake and suspension repair, HVAC system maintenance, and detailed troubleshooting procedures with diagnostic codes. With over 5000 pages of mechanic-grade documentation, it includes hundreds of illustrations and is presented in a printable format for practical use.