Chevrolet KALOS 2002-2011 Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Kalos Production Years Covered: 2002-2011 Platform Code: GM U platform (Daewoo T100/T150) 👋 Introduction Market Position Segment: Subcompact hatchback/sedan Target Audience: Budget-conscious consumers...

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Type: Car

Vendor:

Sku: 63965

Tags: 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Car Cars Chevrolet KALOS

Product variants

Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Kalos

Production Years Covered:

2002-2011

Platform Code:

GM U platform (Daewoo T100/T150)

👋 Introduction

Market Position

Segment:

Subcompact hatchback/sedan

Target Audience:

Budget-conscious consumers seeking reliable and economical transportation.

Competitive Analysis

Key Competitors:

Hyundai Accent, Kia Rio, Ford Fiesta, Vauxhall/Opel Corsa, Renault Clio.

Key Features

Design Philosophy:

Emphasis on affordability, practicality, and straightforward engineering.

Manual Value Proposition:

Empowers owners to perform maintenance and repairs, reducing long-term ownership costs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Factory Service Repair

Regions Covered:

Global (for models produced)

Page Count

Estimated Page Count:

Extensive (typical factory manuals are 1000+ pages)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Mechanical:

Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Drivetrain (Transmission, Drive Axles), Brakes, Steering, Suspension

Electrical:

Electrical System, Wiring Diagrams, Lighting, Ignition System, Starting and Charging System, Instrumentation, Body Electronics

Chassis And Body:

Chassis Components, Body Panels, Interior Trim, Exterior Trim

Procedures Included

Maintenance:

Periodic maintenance, fluid changes, filter replacements, inspections

Diagnostics And Repair:

Troubleshooting procedures, component testing, repair instructions, disassembly/assembly of all major systems

Special Procedures:

Emission control system servicing, wheel alignment specifications, torque specifications

Technical Depth

Depth:

Comprehensive; suitable for both DIY enthusiasts and professional technicians, covering detailed diagnostics and complex repairs.

📊 Manual Specifications

File Format

Quality:

High-resolution, ensuring clear diagrams and readable text.

Print Quality

Printability:

Printable without restrictions, allowing for physical copies.

Binding Type

Delivery Format:

Digital Download (PDF)

Paper Type

Digital Requirements:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Families:

E-TEC II (GM Family II)

Common Engines:

1.2L (X12XE, Z12XE), 1.4L (X14XE, Z14XE), 1.6L (X16XE, Z16XE) gasoline engines.

Performance

1.2L Power:

Approx. 75-80 PS (55-59 kW)

1.4L Power:

Approx. 94 PS (69 kW)

1.6L Power:

Approx. 106 PS (78 kW)

Fuel System

Induction:

Electronic Multi-Point Fuel Injection (MPI)

Emission Controls:

Catalytic Converter, Oxygen Sensors, EGR (where applicable)

🔧 Transmission

Standard

Transmission Types:

5-speed Manual Transmission (F13/F15 variants)

Optional

Automatic Transmission:

4-speed Automatic Transmission (AF13/AF17 variants)

Features

Clutch Type:

Dry, single plate, diaphragm spring

📐 Dimensions

Exterior

Body Styles:

5-door Hatchback, 4-door Sedan

Wheelbase:

Approx. 2480 mm (97.6 in)

Overall Length Hatchback:

Approx. 3880 mm (152.8 in)

Overall Length Sedan:

Approx. 4290 mm (168.9 in)

Weights

Curb Weight Range:

Approx. 1000-1150 kg (2200-2535 lbs), depending on body style and engine.

🛡️ Safety Features

Ratings

Euro Ncap Rating:

3 Stars (early models, may vary by year and testing methodology)

Active Features

Braking System:

Front disc brakes, Rear drum brakes (ABS optional on some trims)

Steering:

Power assisted rack and pinion (EPS or Hydraulic depending on variant)

Passive Features

Airbags:

Driver and front passenger airbags standard; side airbags optional on some models.

Seatbelts:

Pretensioner seatbelts for front occupants.

💡 Technology Features

Infotainment

Standard Features:

Basic AM/FM/CD player, power windows/locks on higher trims.

Connectivity:

Limited by era; typically basic auxiliary input or pre-wiring for aftermarket systems.

Driver Assistance

Availability:

Minimal; ABS and airbags were the primary safety technologies, with more advanced systems not typically offered.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (refer to manual for specific engine oil type).

Timing Belt Replacement:

Recommended every 90,000-120,000 km (56,000-75,000 miles) or 5-7 years, depending on engine variant. Crucial for interference engines.

Fluid Specifications

Engine Oil Viscosity:

Typically 5W-30 or 5W-40 API SJ/SL or higher, or Dexos compatible (refer to manual for exact spec).

Coolant Type:

Ethylene Glycol based antifreeze/coolant, typically silicate-free or OAT type.

Transmission Fluid Manual:

API GL-4 gear oil, SAE 75W-90 or similar.

Transmission Fluid Automatic:

Dexron-III/VI or equivalent.

Known Issues

Common Problems Overview:

Potential for oil leaks (valve cover gasket, sump gasket), exhaust system corrosion, suspension wear (bushings, ball joints), and occasional electrical gremlins, particularly in older models.

Engine Idling Issues:

Can be related to dirty throttle bodies, faulty idle air control valves (IACV), or vacuum leaks.

Transmission Engagement:

Manual transmissions can develop stiff shifting or clutch wear. Automatic transmissions may exhibit delayed engagement or slippage if fluid is low or degraded.

📚 Vehicle History

Brand Heritage

Parent Company:

General Motors (GM) through its Daewoo division.

Model Evolution

First Generation Release:

Originally launched as Daewoo Kalos in 2002.

Rebranding:

Rebadged and sold as Chevrolet Kalos in many markets starting around 2004.

Production

Manufacturing Locations:

South Korea (main), Uzbekistan, potentially other GM assembly plants.

Facelift:

Received a significant facelift (T150 platform) around 2008, often marketed as Chevrolet Aveo (though the Kalos name persisted in some regions).

🏆 Awards & Recognition

Recognitions

Award History:

The Kalos (and its Chevrolet Aveo rebadge) generally focused on value and economy, rather than winning major industry awards. It was often recognized for its affordability and practicality.