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Daewoo Kalos Aveo 2002-2008 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Daewoo / Chevrolet Model: Kalos / Aveo Generation: First Generation (T200) Model Years Covered: 2002-2008 Codes Chassis Code: T200 👋 Introduction Market Position Segment: Subcompact...
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厂商:
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Daewoo Kalos Aveo 2002-2008 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Daewoo / Chevrolet
Model:
Kalos / Aveo
Generation:
First Generation (T200)
Model Years Covered:
2002-2008
Codes
Chassis Code:
T200
👋 Introduction
Market Position
Segment:
Subcompact car / Economy car
Competitive Analysis
Key Competitors:
Hyundai Getz, Kia Rio, Ford Fiesta, Opel Corsa, Toyota Yaris
Key Features
Value Proposition:
Affordable pricing, practical interior, and respectable fuel economy for its class.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (Daewoo/Chevrolet branding applicable)
Page Count
Estimated Pages:
High (hundreds of pages, exact count not specified)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English (assumed based on common availability)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, emissions control
Transmission:
Manual transmission, automatic transmission (if applicable to specific models within the range)
Chassis:
Suspension (front and rear), steering system, braking system (ABS if equipped)
Electrical:
Battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules, wiring diagrams
Body:
Body panels, doors, windows, interior trim, HVAC system
Procedures Included
Maintenance:
Scheduled maintenance, routine inspections, fluid changes, filter replacements, tune-ups
Repair:
Component removal, installation, and overhaul for all major systems
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation
Diagnostics:
On-board diagnostics (OBD-II) system, sensor testing, actuator testing
Timing Belt Service:
Detailed procedure for replacement (if applicable, as some Ecotec variants used timing chains).
Brake System Overhaul:
Includes caliper, rotor, drum, and shoe replacement procedures, bleeding procedures.
Suspension Component Replacement:
Struts, shocks, control arms, ball joints, tie rods, bushings.
HVAC System Repair:
Component replacement for blower motor, evaporator, condenser, heater core, and refrigerant recharge procedures.
Electrical Component Testing:
Alternator, starter motor, battery, sensors, actuators, fuses, relays.
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds. Includes detailed diagrams and step-by-step instructions.
Torque Specifications:
Extensive list of torque values for all critical fasteners.
Diagrams And Illustrations:
Hundreds of detailed photos and exploded view diagrams for clear visual guidance.
📊 Manual Specifications
File Format
Type:
PDF
Compatibility:
Windows and macOS
Print Quality
Printable:
Yes, single pages or entire manual
Binding Type
Type:
Digital Download (Not a physical binding)
Paper Type
Type:
Digital (N/A)
Licensing
Usage Rights:
Unlimited use on multiple devices, no expiry date, no renewal fees
⚙️ Engine Specifications
Primary Engine
Engine Code:
Ecotec (GM family)
Displacement:
1.4L (1399 cc) / 1.6L (1598 cc)
Configuration:
Inline 4-cylinder, DOHC
Performance
Horsepower Range:
Approximately 85-105 hp (depending on engine variant and market)
Torque Range:
Approximately 120-145 Nm (depending on engine variant and market)
Fuel System
Type:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
GM ECU (specific model to be detailed in manual)
Emissions Control:
Catalytic converter, oxygen sensors, EGR system (if equipped)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Clutch Type:
Dry single plate (Manual)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 SAE 75W-90 (or equivalent, confirm in manual)
Automatic Transmission Fluid:
Dexron III (or equivalent, confirm in manual)
📐 Dimensions
Exterior
Length:
Approx. 3890-3940 mm (depending on body style)
Width:
Approx. 1665-1670 mm
Height:
Approx. 1500-1525 mm
Weights
Curb Weight:
Approx. 1040-1150 kg
Gross Vehicle Weight Rating:
Varies by model, detailed in manual
🛡️ Safety Features
Ratings
Crash Test Performance:
Mixed results; Euro NCAP awarded 3 stars overall for early models. Specific safety equipment varied by market.
Active Features
Braking:
Front ventilated discs, rear drums. Optional ABS available on higher trims/later models.
Passive Features
Airbags:
Driver and front passenger airbags standard on many models. Side airbags optional or unavailable on base trims.
Seatbelts:
Three-point seatbelts with pretensioners in front.
💡 Technology Features
Infotainment
Features:
Basic audio systems, often with CD player and AM/FM radio. Auxiliary input or USB may be present on later/higher trims.
Driver Assistance
Availability:
Limited. ABS and traction control were optional or market-dependent. No advanced driver-assistance systems (ADAS).
Connectivity
Features:
Basic Bluetooth connectivity for phone calls might be available on higher trims, but not a primary feature.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500-10,000 miles (12,000-15,000 km) or 12 months, whichever comes first. Refer to manual for specific recommendations.
Air Filter Replacement:
Recommended every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Typically every 60,000-100,000 miles (96,000-160,000 km) for iridium/platinum plugs, shorter for conventional. Confirm in manual.
Fluid Specifications
Engine Oil Type:
API SN/SP, ILSAC GF-5/GF-6, SAE 5W-30 or 10W-40 (confirm viscosity based on climate and engine variant in manual).
Coolant Type:
GM Type II Pink Coolant (or equivalent G11/G12 antifreeze).
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
GM Power Steering Fluid or Dexron III ATF (verify in manual).
Known Issues
Common Problems:
Transmission issues (especially automatic), electrical gremlins, suspension wear, interior rattles, potential catalytic converter issues.
Engine Variations:
The Ecotec engines are generally reliable but can be sensitive to maintenance neglect. Timing chain wear can occur at higher mileages on some variants.
📚 Vehicle History
Brand Heritage
Parent Company:
Daewoo Motors, later acquired by General Motors (GM).
Model Evolution
Development:
Developed by Daewoo Motors, later rebadged and sold globally as the Chevrolet Aveo under GM's ownership. Designed to be a budget-friendly compact.
Production
Manufacturing Locations:
South Korea (primary), various other GM assembly plants globally.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
Generally not a recipient of major automotive awards, positioned as an affordable and practical transportation solution.
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