🏷️ Basic Information

Make:

Chevrolet

Model:

Kalos

Model Years Covered:

2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011

Platform:

GM T platform (shared with Daewoo Gentra/Lacetti Hatchback)

👋 Introduction

Target Audience:

DIY car owners, independent repair shops, professional mechanics

Value Proposition:

Provides professional-grade repair information at a fraction of the cost of dealership service or proprietary software, enabling cost-effective maintenance and repairs.

Usability:

Step-by-step instructions, clear text, high-quality diagrams, and exploded views ensure ease of use for various skill levels.

📋 Manual Details

Coverage Scope:

Comprehensive service, maintenance, and repair

Estimated Page Count:

Over 2500 pages (typical for full service manuals of this scope)

Manual Type:

Factory Service Manual / Workshop Manual

Language:

English

File Format:

PDF (Downloadable)

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, cooling system, exhaust system, ignition system, engine management, transmission (manual and automatic), driveline, clutch

Chassis:

Suspension (front and rear), steering system, braking system, wheels and tires

Body And Electrical:

Body construction and materials, interior components, HVAC system, exterior lighting, interior lighting, power accessories (windows, locks, mirrors), instrumentation, audio system, wiring diagrams, fuses and relays, anti-theft system

Maintenance Procedures:

Fluid checks and changes, filter replacements, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation

Repair Procedures:

Component removal and installation, engine overhaul, transmission rebuild, brake caliper overhaul, suspension component replacement, steering rack replacement, wiring harness repair

Troubleshooting:

Diagnostic procedures, fault code interpretation (OBD-II), symptom-based diagnostics, electrical circuit testing, common problem diagnosis and solutions

Technical Depth:

Detailed, from basic maintenance to complete engine and transmission rebuilds, including diagnostic strategies and electrical schematics

📊 Manual Specifications

File Format Details:

High-quality PDF, fully searchable text, zoomable diagrams and images

Printability:

Full printable, allows users to print specific sections or the entire manual

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

1.4L (X14XE/Z14XE), 1.6L (X16XE/Z16XE) Ecotec 4-cylinder gasoline engines

1.4L Ecotec Horsepower:

Approx. 94 PS (93 bhp; 69 kW)

1.6L Ecotec Horsepower:

Approx. 105 PS (104 bhp; 77 kW)

Fuel Delivery:

Multi-point fuel injection (MPI)

ECU Type:

GM Ecotec Engine Control Module (ECM) variants

🔧 Transmission

Transmission Type Standard:

5-speed manual transmission

Transmission Type Optional:

4-speed automatic transmission

Transmission Fluid Type:

Refer to manual for specific DEXRON fluid type (e.g., DEXRON III/VI for automatic, specific gear oil for manual)

📐 Dimensions

Body Styles:

5-door hatchback

Curb Weight Range:

Approx. 1050-1150 kg (2315-2535 lbs) depending on engine and equipment

🛡️ Safety Features

Euroncap Rating:

Typically 3 to 4 stars for models of this era, specific results vary by year and equipment (e.g., 2004 model received 4 stars)

Braking System:

Front ventilated discs, rear drums (standard); optional ABS (Anti-lock Braking System)

Airbags:

Driver and front passenger airbags standard; optional side airbags on some trims

💡 Technology Features

Audio System:

Basic AM/FM radio with CD player, optional auxiliary input or MP3 capabilities on later models

ABS Availability:

Optional ABS on higher trim levels and later production years

Bluetooth Connectivity:

Rarely standard, may have been an dealer-installed option or found on higher trim late models.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using synthetic oil (refer to manual for exact specification)

Timing Belt Interval:

Recommended replacement every 90,000 - 120,000 km (56,000 - 75,000 miles) or 5-7 years, depending on engine type (refer to manual for specific engine)

Engine Oil Specification:

API SN/SP, ACEA A3/B4, SAE 5W-30 or 5W-40 (verify with manual for specific engine and climate)

Coolant Specification:

GM-approved silicate-free long-life coolant (e.g., Dexcool or equivalent, typically orange/red in color)

Common Wear Items:

Suspension components (bushings, ball joints), exhaust system rust, minor electrical gremlins, clutch wear (manual transmission)

Engine Specific Notes:

Some early Ecotec engines may have had issues with PCV systems and oil consumption. Timing chain tensioners and guides on some variants can be a concern if not maintained.

📚 Vehicle History

Manufacturer Origin:

Chevrolet is an American automotive division of General Motors (GM). The Kalos was originally developed by Daewoo, a South Korean manufacturer acquired by GM.

Rebadging:

Sold under various GM brands globally, including Daewoo Kalos, Daewoo Gentra, Chevrolet Aveo, Holden Barina.

Production Period:

First generation (T200/T250) production ran from 2002 to 2011 globally, with minor facelifts.

🏆 Awards & Recognition

Safety Awards:

Achieved 4-star Euro NCAP safety rating for certain configurations, indicating a reasonably safe vehicle for its class and era.