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Daewoo Kalos Complete Workshop Service Repair Manual 2006 2007 2008 2009 2010 2011 2012

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🏷️ Basic Information Identification Make: Daewoo Model: Kalos Product Name: Daewoo Kalos Complete Workshop Service Repair Manual Generation First Generation Years: 2002-2008 Codes Chassis Code: T200 👋 Introduction Market Position...
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Daewoo Kalos Complete Workshop Service Repair Manual 2006 2007 2008 2009 2010 2011 2012Daewoo Kalos Complete Workshop Service Repair Manual 2006 2007 2008 2009 2010 2011 2012Daewoo Kalos Complete Workshop Service Repair Manual 2006 2007 2008 2009 2010 2011 2012Daewoo Kalos Complete Workshop Service Repair Manual 2006 2007 2008 2009 2010 2011 2012
🏷️ Basic Information
Identification
Make:
Daewoo
Model:
Kalos
Product Name:
Daewoo Kalos Complete Workshop Service Repair Manual
Generation
First Generation Years:
2002-2008
Codes
Chassis Code:
T200
👋 Introduction
Market Position
Segment:
Subcompact hatchback and sedan
Target Audience:
Budget-conscious consumers seeking an economical and practical vehicle.
Competitive Analysis
Key Competitors:
Hyundai Getz, Kia Rio, Chevrolet Aveo (often shared platforms/engines), Ford Fiesta, Volkswagen Polo.
Key Features
Value Proposition:
Affordable entry-level transportation with a focus on practicality and fuel efficiency.
Design Language:
Often characterized by rounded, friendly styling, particularly in its initial generation.
Manual Benefit
Cost Savings:
Enables owners to perform DIY repairs and maintenance, significantly reducing dealership or independent mechanic costs.
Empowerment:
Empowers vehicle owners with the knowledge and instructions to understand and maintain their Daewoo Kalos effectively.
📋 Manual Details
Coverage Areas
Models Covered:
All Daewoo Kalos models, engines, trim levels, and transmission types
Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012
Page Count
Estimated Page Count:
Varies based on specific model year and engine, typically 1000+ pages for a complete workshop manual
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, engine management.
Fuel System:
Fuel injection system (MPI), fuel pump, fuel filter, fuel tank, evaporative emission control (EVAP).
Ignition System:
Ignition coils, spark plugs, ignition control module, timing.
Transmission Manual:
Clutch, gearbox assembly, gears, synchronizers, shift linkage, transmission fluid.
Transmission Automatic:
Torque converter, planetary gear sets, hydraulic control system, valve body, transmission fluid, electronic control unit (ECU).
Drivetrain:
Front wheel drive shafts (CV axles), differential, wheel bearings.
Suspension:
Front suspension (MacPherson struts, control arms, stabilizer bar), rear suspension (torsion beam or multi-link), shock absorbers, springs, bushings.
Steering:
Power steering system (hydraulic or electric), steering column, steering rack, tie rods.
Brakes:
Front disc brakes, rear drum or disc brakes, brake booster, master cylinder, ABS (Anti-lock Braking System), brake lines, parking brake.
Electrical System:
Battery, charging system (alternator), starter motor, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams.
Body And Chassis:
Body panels, doors, hood, trunk, interior trim, glass, chassis components, rust prevention.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, climate control, refrigerant, compressor, evaporator, condenser.
Interior Components:
Seats, dashboard, upholstery, airbags, seatbelts.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, cabin), fluid checks and top-ups, tire rotation, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation, symptom-based diagnostics.
Major Repairs:
Engine overhaul, transmission rebuild, clutch replacement, brake system overhauls, suspension component replacement.
Component Replacement:
Detailed instructions for replacing specific parts like alternator, starter, water pump, fuel injectors, sensors, etc.
Electrical Diagnostics:
Wiring diagrams, circuit testing, troubleshooting of electrical faults.
Body Repairs:
Panel replacement, door hinge adjustments, bumper repairs, glass replacement.
HVAC Service:
Refrigerant recharge, component replacement (compressor, condenser, blower motor), leak detection.
Safety Systems Service:
ABS diagnostics and repair, airbag system safety precautions and replacement.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complex mechanical and electrical repairs, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All PC & MAC Computers, tablets, smartphones (requires Adobe Reader, free download available).
Print Quality
Printability:
High-resolution, printable pages allowing users to print individual pages, chapters, or the entire manual.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Download)
Searchability
Text Search:
Likely searchable text within the PDF for quick access to specific topics.
⚙️ Engine Specifications
Primary Engine
Engine Family:
GM Ecotec family (common across Daewoo/Chevrolet platforms)
Available Displacement 1:
1.4L (1399 cc)
Available Displacement 2:
1.6L (1598 cc)
Performance
Horsepower 1 4L Approx:
~94 hp @ 6300 rpm
Torque 1 4L Approx:
~130 Nm @ 4000 rpm
Horsepower 1 6L Approx:
~105 hp @ 6000 rpm
Torque 1 6L Approx:
~147 Nm @ 3600 rpm
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Engine Control Unit (ECU) managing fuel, ignition, and emissions.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Clutch Type:
Hydraulically actuated dry single-plate clutch (for manual)
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4, SAE 75W-85 or 75W-90 (refer to specific manual for exact OEM spec)
Automatic Transmission Fluid Type:
Dexron III or equivalent (refer to specific manual for exact OEM spec)
📐 Dimensions
Exterior
Body Styles:
5-door Hatchback, 4-door Sedan
Length Hatchback Approx:
3880 mm
Length Sedan Approx:
4340 mm
Width Approx:
1665 mm
Height Approx:
1500 mm
Wheelbase Approx:
2470 mm
Weights
Curb Weight Approx Min:
1020 kg
Curb Weight Approx Max:
1150 kg
Cargo
Cargo Volume Hatchback Seats Up Approx:
245 Liters
Cargo Volume Hatchback Seats Down Approx:
1000+ Liters
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Pre-facelift T200 received 3-star Euro NCAP rating.
Active Features
ABS:
Optional or standard depending on trim level and market.
E Brake:
Mechanical parking brake, typically cable-actuated.
Passive Features
Airbags:
Driver and passenger airbags standard; side airbags optional on some trims.
Seatbelts:
Pretensioner seatbelts for front occupants.
Child Anchors:
ISOFIX child seat anchor points (availability may vary by market).
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player, optional MP3 capability. Speaker configuration typically 2 or 4 speakers.
Display:
Simple digital display for radio/clock, basic climate controls.
Driver Assistance
Cruise Control:
Optional on higher trim levels.
Parking Sensors:
Rarely offered, if at all.
Connectivity
Aux Input:
Potentially available on later models or as an aftermarket addition.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500 - 10,000 miles or 6-12 months, whichever comes first (refer to manual for exact specification).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Typically every 60,000 - 100,000 miles for iridium/platinum plugs (refer to manual for plug type).
Timing Belt Replacement:
Crucial for interference engines. Check manual, but generally around 60,000-90,000 miles. Failure can cause severe engine damage.
Fluid Specifications
Engine Oil Viscosity Approx:
5W-30 or 10W-40 (API SN/SP, ILSAC GF-5/GF-6 certified) - consult manual.
Coolant Type:
Ethylene glycol-based coolant (OAT or HOAT, typically orange or pink, silicate-free) - consult manual.
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid Type:
ATF Dexron III or specific power steering fluid (consult manual).
Known Issues
Common Problem 1:
Cooling system leaks (radiator, hoses, water pump).
Common Problem 2:
Ignition coil failure, leading to misfires and rough running.
Common Problem 3:
Front suspension wear (bushings, ball joints, tie rod ends) due to road conditions.
Common Problem 4:
Automatic transmission issues (slipping, harsh shifts) can occur with age and mileage.
Common Problem 5:
Window regulator failures (power or manual).
Common Problem 6:
Catalytic converter issues (clogging, failure).
📚 Vehicle History
Brand Heritage
Manufacturer:
Daewoo Motor Company (South Korea)
Acquisition By Gm:
Daewoo was acquired by General Motors (GM) in 2002, leading to some models being rebadged and sold under GM brands.
Model Evolution
Introduction Year:
2002
Facelift:
A significant facelift occurred around 2004/2005, altering styling (e.g., headlights, grille) and introducing minor interior and mechanical updates.
Production
Manufacturing Locations:
Primarily South Korea; potentially other GM plants globally through rebadging.
Discontinuation:
The Daewoo brand was phased out in many markets, with the Kalos being rebranded as the Chevrolet Aveo.
🏆 Awards & Recognition
Recognitions
Awards Achieved:
Generally positioned as a value-focused vehicle rather than a recipient of major automotive awards. Its success was more in affordability and market penetration in specific regions.
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