2005 Chevrolet Rezzo Service and Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Rezzo Year: 2005 👋 Introduction Market Position Market Segment: Compact MPV (Multi-Purpose Vehicle) Competitive Analysis Key Competitors: Nissan Almera Tino, Ford Focus C-Max,...

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Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Rezzo

Year:

👋 Introduction

Market Position

Market Segment:

Compact MPV (Multi-Purpose Vehicle)

Competitive Analysis

Key Competitors:

Nissan Almera Tino, Ford Focus C-Max, Renault Scénic, Volkswagen Golf Plus, Opel Zafira.

Key Features

Vehicle Philosophy:

Designed as a practical and versatile family vehicle offering a balance of space, efficiency, and affordability.

📋 Manual Details

Coverage Areas

Coverage Areas Overview:

Complete A-Z service and repair for all 2005 Chevrolet Rezzo models.

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management (ECM/PCM).

Transmission Systems:

Automatic transmission (diagnosis, overhaul, service), manual transmission (diagnosis, overhaul, service), clutch system.

Drivetrain Systems:

Front-wheel drive (FWD) axle shafts, differential, driveshaft.

Suspension Systems:

Front and rear suspension components, steering linkage, power steering system, shock absorbers, struts, springs, control arms, wheel alignment.

Brake Systems:

Front and rear brake systems (disc/drum), hydraulic system, ABS (Anti-lock Braking System), parking brake.

Electrical Systems:

Battery, charging system, starting system, lighting, instrumentation, body control module (BCM), power windows, power locks, mirrors, wipers, horns.

HVAC Systems:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant cycle, controls, blower motor, evaporator, condenser, compressor.

Body And Frame:

Body panels, doors, windows, latches, hinges, interior trim, exterior trim, frame straightening, underbody coatings.

Restraint Systems:

Airbag system (SRS), seat belts, pre-tensioners.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection and replacement.

Diagnostics And Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, wiring diagrams, diagnostic flowcharts, electrical testing procedures.

Engine Repairs:

Cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing belt/chain replacement, fuel injector testing/replacement, manifold removal/installation.

Transmission Repairs:

Transmission fluid and filter change, torque converter replacement, valve body service, seal replacement, clutch assembly replacement.

Brake Repairs:

Brake pad and rotor replacement, caliper servicing, brake line and hose replacement, brake fluid flush, ABS component testing and replacement.

Suspension And Steering Repairs:

Strut and shock absorber replacement, ball joint and tie rod end replacement, power steering pump and rack replacement, wheel bearing replacement.

Electrical Diagnostics And Repair:

Component testing, circuit diagnosis, wiring harness repair, module programming and replacement, sensor testing and replacement.

HVAC Service:

Refrigerant charging, leak detection, component replacement (compressor, evaporator, condenser), cabin air filter replacement.

Body And Interior Repairs:

Door panel removal, window regulator replacement, bumper repair/replacement, trim piece installation, seat removal/installation.

Technical Depth

Depth Of Coverage:

Comprehensive factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format Details:

High-resolution PDF, searchable text, bookmarked chapters for easy navigation.

Print Quality

Print Quality:

Designed for clear digital viewing and printing of diagrams and text.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

F16D3 / F18D2 (GM Family II)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement 1.6L:

1598 cc (97.5 cu in)

Displacement 1.8L:

1796 cc (109.6 cu in)

Performance 1.6L

Horsepower 1.6L:

105 hp (78 kW) @ 6000 rpm

Torque 1.6L:

148 Nm (109 lb-ft) @ 3200 rpm

Performance 1.8L

Horsepower 1.8L:

125 hp (93 kW) @ 6000 rpm

Torque 1.8L:

165 Nm (122 lb-ft) @ 3600 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug

Emissions Control

Emission Standard:

Euro 3 / Equivalent

Cooling System

Coolant Type:

Dex-Cool Extended Life Antifreeze (GM Specification 6277M)

Lubrication System

Engine Oil Viscosity:

SAE 5W-30

Engine Oil Capacity:

4.0 L (4.2 US qt) with filter

Timing Drive

Timing Belt Or Chain:

Timing Belt (F16D3), Timing Chain (F18D2)

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission

Optional

Transmission Type Optional:

4-speed Automatic Transmission

Features

Transmission Fluid Type Auto:

Dexron III or equivalent

Transmission Fluid Capacity Auto:

Approximately 6.5 L (6.9 US qt) for a complete fill

Transmission Fluid Type Manual:

GL-4 SAE 75W-90

Clutch Type:

Dry single plate, hydraulically actuated

📐 Dimensions

Exterior

Length:

4205 mm (165.6 in)

Width:

1725 mm (67.9 in)

Height:

1655 mm (65.2 in)

Wheelbase:

2600 mm (102.4 in)

Front Track:

1480 mm (58.3 in)

Rear Track:

1470 mm (57.9 in)

Interior

Seating Capacity:

5-7 passengers (depending on configuration)

Cargo

Cargo Volume Min:

Approx. 450 liters (15.9 cu ft) with rear seats up

Cargo Volume Max:

Approx. 1500 liters (52.9 cu ft) with rear seats folded

Weights

Curb Weight:

1330 - 1430 kg (2932 - 3153 lbs) depending on configuration

Gross Vehicle Weight Rating Gvwr:

1900 kg (4189 lbs) approx.

Wheels And Tires

Wheel Size:

15-inch or 16-inch alloy or steel wheels

Tire Size Std:

195/65R15 or 205/55R16

Wheel Bolt Pattern:

5x110 mm

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A specific ratings publicly available for all markets, but equipped with standard safety features for its class.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD).

Passive Features

Passive Safety Features:

Driver and front passenger airbags, side airbags (optional), three-point seat belts with pretensioners, ISOFIX child seat anchors.

💡 Technology Features

Infotainment

Infotainment System:

Basic AM/FM stereo with CD player, optional MP3 playback and satellite radio preparation.

Driver Assistance

Driver Assistance Features:

Limited to ABS and EBD; advanced driver-assistance systems (ADAS) are not typically found on this model year.

Connectivity

Connectivity Options:

No factory-integrated Bluetooth or USB ports; aftermarket solutions are available.

🔧 Maintenance

Service Intervals General

Oil Change Interval:

Every 15,000 km (9,300 miles) or 12 months, whichever comes first.

Air Filter Replacement:

Every 30,000 km (18,600 miles) or 24 months.

Cabin Filter Replacement:

Every 15,000 km (9,300 miles) or 12 months.

Spark Plug Replacement 1.6L:

Every 60,000 km (37,200 miles).

Spark Plug Replacement 1.8L:

Every 90,000 km (55,900 miles) (if equipped with long-life plugs).

Timing Belt Replacement:

Every 90,000 km (55,900 miles) or 5 years (F16D3).

Brake Fluid Flush:

Every 2 years or 40,000 km (24,800 miles).

Coolant Flush:

First at 240,000 km (150,000 miles) or 5 years, then every 120,000 km (75,000 miles) or 5 years.

Fluid Specifications

Brake Fluid Specification:

DOT 3 or DOT 4

Power Steering Fluid:

Dexron III or equivalent ATF

Known Issues

Common Complaints:

Occasional reports of minor electrical gremlins, premature wear on suspension bushings, and potential for coolant leaks from the water pump seal.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

South Korea (Daewoo Motors) / Global GM

Model Evolution

Model Introduction:

The Rezzo (also known as Tacuma and Vivant in some markets) was originally developed by Daewoo Motors and later integrated into the Chevrolet lineup following GM's acquisition.

Production

Production Years:

2000 - 2008 (Daewoo/Chevrolet)

Assembly Locations:

South Korea, Egypt, Poland, Vietnam.

🏆 Awards & Recognition

Recognitions

Awards And Accolades:

While specific awards for the 2005 Rezzo are not widely documented, it was generally positioned as a value-oriented option in the MPV segment, appreciated for its practicality by families.