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HOLDEN BARINA TK 1.6L 2005-2011 Workshop Service Repair MANU
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Basic Information Identification Make: Holden Model: Barina TK Generation: TK Model Years: 2005-2011 Body Styles: Hatchback, Notchback Introduction Market Position Segment: Subcompact/Compact Car Target Audience: DIY mechanics, independent workshops, Holden...
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| Basic Information | |
| Identification | |
| Make: | Holden |
| Model: | Barina TK |
| Generation: | TK |
| Model Years: | 2005-2011 |
| Body Styles: | Hatchback, Notchback |
| Introduction | |
| Market Position | |
| Segment: | Subcompact/Compact Car |
| Target Audience: | DIY mechanics, independent workshops, Holden enthusiasts. |
| Competitive Analysis | |
| Competitors: | Ford Fiesta, Hyundai Getz, Toyota Yaris (during its production run). |
| Key Features Vehicle | |
| Platform: | GM global small car platform (shared with Opel Corsa C). |
| Key Features Manual | |
| Value Proposition: | Provides the critical technical data required for accurate and efficient servicing and repair, saving on dealership costs. |
| Manual Details | |
| Coverage Areas | |
| Manual Type: | Workshop Service Repair Manual |
| Language: | English |
| Format: | Digital (implied, common for workshop manuals) |
| Coverage Scope: | Comprehensive repair and servicing for all listed systems and models. |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Detailed procedures for engine overhaul, component replacement, timing, and diagnostics. |
| Engine Control System: | ECU, sensors, actuators, diagnostic trouble codes (DTCs) and troubleshooting. |
| Fuel System: | Fuel pump, injectors, pressure regulator, tank, lines, and emissions control. |
| Cooling System: | Radiator, thermostat, water pump, hoses, coolant specifications, and testing. |
| Engine Electrical: | Ignition system, spark plugs, coils, wiring diagrams, battery, charging system. |
| Exhaust System: | Catalytic converter, mufflers, pipes, gaskets, and emission components. |
| Battery Starting System: | Battery maintenance, testing, starter motor, and solenoid troubleshooting. |
| Automatic Transmission: | Aisin 81-40LE: overhaul, fluid specifications, shifting issues, solenoid testing. |
| Manual Transmission: | DWMC D16 and Y4M: clutch, gearbox overhaul, fluid specifications, shift linkage. |
| Anti-Lock Brake System: | ABS modulator, sensors, control module, bleeding procedures, and diagnostics. |
| Body Repair System: | Panel replacement, structural repairs, welding specifications, corrosion protection. |
| Clutch System: | Clutch disc, pressure plate, release bearing, hydraulic system, and bleeding. |
| Entertainment System: | Radio, speakers, wiring, troubleshooting. |
| Navigation System: | System components, software updates, troubleshooting (if applicable). |
| Disc Drum Brakes: | Brake pad/shoe replacement, caliper/wheel cylinder service, rotor/drum resurfacing. |
| Exterior Trim: | Bumpers, grilles, mouldings, trim piece replacement. |
| Windows System: | Power window regulators, motors, glass replacement, seals. |
| Drive Axle System: | CV joints, drive shafts, wheel bearings, hub replacement. |
| Suspension System: | Struts, shock absorbers, control arms, ball joints, bushings, alignment. |
| Hydraulic Brakes: | Brake fluid specifications, master cylinder, brake lines, bleeding procedures. |
| Immobilizer System: | Key programming, immobilizer unit troubleshooting (if applicable). |
| Instrument Panel: | Gauge clusters, warning lights, dashboard illumination, component replacement. |
| Console Trim: | Center console removal and installation, trim panel service. |
| Interior Trim: | Door panels, headliner, carpeting, trim piece replacement. |
| Lighting System: | Headlights, taillights, interior lights, bulb specifications, wiring. |
| Automatic HVAC: | Automatic climate control system diagnostics, components, refrigerant handling. |
| Manual HVAC: | Manual climate control system diagnostics, components, heater core, A/C evaporator. |
| Manual Steering: | Steering rack, tie rods, steering column components (manual systems). |
| Power Steering: | Power steering pump, fluid, hoses, rack and pinion, electric power steering components. |
| Parking Brake: | Parking brake cable adjustment, operation, maintenance. |
| Horn Mirrors Seat Seat Belts: | Horn operation, mirror adjustment/replacement, seat rail service, seat belt inspection and replacement. |
| Shift Lock Control: | Mechanism for preventing shifting out of Park without brake engagement. |
| Remote Function: | Keyless entry system operation, programming, and troubleshooting. |
| Steering Wheel Column: | Steering wheel removal, airbag system precautions, steering column disassembly. |
| Sunroof Anti-Theft: | Sunroof operation, motor, seals, and anti-theft system integration. |
| Vehicle Access: | Door lock mechanisms, keyless entry, and central locking system. |
| Wiper Washer: | Wiper motor, blades, linkage, washer pump, fluid reservoir, and nozzle adjustment. |
| Schematic Diagrams: | Electrical wiring diagrams for all systems, component locations. |
| Procedures Included | |
| Maintenance: | Routine checks, fluid changes, filter replacements, spark plug intervals. |
| Troubleshooting: | Diagnostic flowcharts, symptom-based problem solving, DTC interpretation. |
| Repair: | Step-by-step instructions for component removal, installation, and adjustment. |
| Overhaul: | Detailed instructions for complete engine and transmission rebuilds. |
| Diagnostics: | Testing procedures for electrical components, sensors, and actuators. |
| Technical Depth | |
| Depth Level: | Comprehensive professional-level diagnostics, repair, and overhaul. |
| Manual Specifications | |
| File Format | |
| File Type: | PDF (Assumed common format for digital manuals) |
| Searchability: | Text-searchable for quick information retrieval. |
| Printability: | Printable pages for hands-on use in a workshop environment. |
| Print Quality | |
| Image Resolution: | High-resolution images and diagrams for clarity. |
| Binding Type | |
| Binding: | N/A (for digital format) |
| Paper Type | |
| Paper: | N/A (for digital format) |
| Engine Specifications | |
| Primary Engine | |
| Engine Code Variant 1: | 1.6L 4-Cylinder Petrol Aspirated DOHC |
| Engine Code Variant 2: | 1.6L LXT/LXV I4 DOHC |
| Engine Code Variant 1 | |
| Displacement 1: | 1598 cc |
| Bore Stroke 1: | 79.0 mm x 81.5 mm (approximate, based on typical GM Ecotec variants) |
| Compression Ratio 1: | 10.5:1 (typical for this engine family) |
| Horsepower 1: | Approx. 105-115 hp @ 5800-6000 rpm (depending on specific tune) |
| Torque 1: | Approx. 150 Nm @ 3800-4000 rpm (depending on specific tune) |
| Engine Code Variant 2 | |
| Displacement 2: | 1598 cc |
| Horsepower 2: | Approx. 105-115 hp @ 5800-6000 rpm (depending on specific tune) |
| Torque 2: | Approx. 150 Nm @ 3800-4000 rpm (depending on specific tune) |
| Other Engines | |
| Engine Code Variant 3: | 1.2L I4 Petrol DOHC |
| Displacement 3: | 1199 cc |
| Horsepower 3: | Approx. 75-80 hp |
| Engine Code Variant 4: | 1.4L I4 L95/LDT DOHC/SOHC |
| Displacement 4: | 1362 cc |
| Horsepower 4: | Approx. 90-95 hp |
| Engine Code Variant 5: | 1.5L IN-LINE 4 |
| Displacement 5: | 1498 cc |
| Horsepower 5: | Approx. 95-100 hp |
| Fuel System | |
| Fuel Delivery: | Multi-point Fuel Injection (MPI) |
| Fuel Type: | Unleaded Petrol (RON 91 or higher recommended) |
| Engine Management | |
| ECU Type: | GM Electronic Control Unit (specific model varies by market and engine) |
| Ignition Type: | Electronic Ignition (Distributorless Ignition System - DIS, coil-on-plug) |
| Transmission | |
| Standard | |
| Transmission Type 1: | 5-Speed Manual Transmission DWMC D16 |
| Optional | |
| Transmission Type 2: | 4-Speed Automatic Transmission AISIN 81-40LE |
| Features | |
| Automatic Transmission Details: | Aisin-Warner designed, known for smoothness and reliability in its class. |
| Manual Transmission Details: | DWMC D16: Common, robust manual gearbox. Y4M: Also offered, potentially with different gear ratios or internal components. |
| Fluid Specifications | |
| Automatic Transmission Fluid: | Dexron III or Dexron VI equivalent (check manual for exact specification and capacity) |
| Manual Transmission Fluid: | API GL-4 75W-90 (or manufacturer-specified SAE 80W-90 manual transmission fluid) |
| Dimensions | |
| Exterior Hatchback | |
| Length: | Approx. 3,880 mm |
| Width: | Approx. 1,670 mm |
| Height: | Approx. 1,460 mm |
| Exterior Notchback | |
| Length: | Approx. 4,270 mm |
| Width: | Approx. 1,670 mm |
| Height: | Approx. 1,460 mm |
| Wheelbase | |
| Wheelbase: | Approx. 2,465 mm |
| Weights | |
| Kerb Weight: | Approx. 1050-1150 kg (depending on engine and specification) |
| Gross Vehicle Weight: | Approx. 1500-1570 kg (depending on specification) |
| Cargo | |
| Luggage Capacity Hatchback: | Approx. 240-260 Litres (seats up) |
| Luggage Capacity Notchback | |
| Luggage Capacity: | Approx. 450-470 Litres |
| Safety Features | |
| Ratings | |
| Ancap Rating 2006: | 4 Stars (for specific configurations, check ANCAP website for precise model year and features) |
| Active Features | |
| ABS: | Anti-lock Braking System (Standard on many models, optional on some early variants) |
| Ebs: | Electronic Brake-force Distribution (often paired with ABS) |
| Passive Features | |
| Airbags: | Driver and front passenger airbags standard; side airbags available on higher trims or as options. |
| Seat Belts: | Pre-tensioned front seatbelts with load limiters; 3-point rear seatbelts. |
| Body Structure: | Crumple zones and reinforced passenger safety cell designed to absorb impact energy. |
| Technology Features | |
| Infotainment | |
| Audio System: | Standard AM/FM radio with CD player. Higher trims may have MP3 capability, auxiliary input, or upgraded speaker systems. |
| Navigation: | Optional navigation system available on some higher-trim models, typically integrated into the dashboard. |
| Driver Assistance | |
| Cruise Control: | Cruise control system available on many models, allowing for consistent speed on highways. |
| Connectivity | |
| Bluetooth: | Limited or no integrated Bluetooth connectivity on base models; may be an aftermarket addition. |
| Maintenance | |
| Service Intervals Engine Oil | |
| Oil Change Interval: | 15,000 km or 12 months, whichever comes first (synthetic oil recommended). |
| Service Intervals Oil Filter | |
| Oil Filter Replacement: | Replace with every oil change. |
| Service Intervals Air Filter | |
| Air Filter Replacement: | Every 30,000 km or as needed based on driving conditions. |
| Service Intervals Spark Plugs | |
| Spark Plug Replacement: | 100,000 km for iridium or platinum-tipped plugs (check specific plug type). |
| Service Intervals Coolant | |
| Coolant Flush Interval: | Every 5 years or 100,000 km (using long-life coolant). |
| Service Intervals Brake Fluid | |
| Brake Fluid Replacement: | Every 2-3 years or 40,000-60,000 km (DOT 3 or DOT 4 recommended). |
| Fluid Specifications | |
| Engine Oil Specification: | API SN/SP, ACEA A3/B4 or A5/B5, SAE 5W-30 or 5W-40 (check owner's manual for precise viscosity and certification). |
| Coolant Type: | GM 6277M (Blue) or equivalent OAT (Organic Acid Technology) long-life coolant. |
| Known Issues | |
| Common Problems Engine: | Oil leaks from valve cover gasket or oil pan; occasional ignition coil failure; timing belt wear (if applicable, check engine type for belt vs chain). |
| Known Issues Transmission | |
| Common Problems Transmission: | Automatic transmission harsh shifting or slipping; manual clutch wear; synchromesh issues in manual transmissions. |
| Known Issues Suspension | |
| Common Problems Suspension: | Worn front suspension bushings; premature front shock/strut wear; wheel bearing noise. |
| Known Issues Electrical | |
| Common Problems Electrical: | Issues with power window regulators; instrument cluster faults; minor electrical gremlins common in older vehicles. |
| Known Issues Hvac | |
| Common Problems HVAC: | HVAC blower motor resistor failure; AC refrigerant leaks; heater core issues. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Holden (Australian subsidiary of General Motors) |
| Model Evolution | |
| Platform Basis: | Based on the Opel Corsa C platform, which was globally a very successful small car. |
| Rebadging: | The Barina TK was sold globally under various names within the GM family, including Opel/Vauxhall Corsa, Chevrolet Aveo, and Suzuki Swift (depending on market and generation). |
| Production | |
| Manufacturing Location: | Primarily South Korea (as Chevrolet Aveo/Daewoo Kalos), with some assembly potentially in other GM facilities globally. |
| Production Years | |
| Production Period: | The TK generation of the Barina was produced from roughly 2005 to 2011, succeeding the XC Barina. |
| Awards & Recognition | |
| Recognitions | |
| Vehicle Awards: | The Barina TK, as part of the global platform, contributed to Opel/Vauxhall Corsa and Chevrolet Aveo receiving various 'Car of the Year' awards or segment accolades in different markets. |
| Safety Awards: | Achieved 4-star ANCAP rating, indicating a good level of safety for its class and era. |