🏷️ Basic Information Identification Make: Daewoo / Holden Model: Kalos / Barina Product Name: Daewoo Kalos Holden Barina Workshop Manual 1998 - 2008 PDF Download Generation First Generation Production Years: 1998-2008 (for specific market variants) Codes Chassis Code Daewoo: KL1M Chassis Code Holden: TB, XC, YG, ZT (depending on generation/market rebadge) 👋 Introduction Market Position Segment: Subcompact / Compact Car Target Audience: Budget-conscious consumers seeking an economical and practical vehicle. Competitive Analysis Key Competitors: Hyundai Getz/Accent, Kia Rio, Ford Fiesta, Vauxhall/Opel Corsa, Renault Clio, Volkswagen Polo. Key Features Distinguishing Features: Affordability, compact dimensions suitable for urban environments, relatively simple mechanicals for its class. Holden branding provided wider market access in Australia. 📋 Manual Details Coverage Areas Covered Years: 1998-2008 Model Years Engine Coverage: 0.8 Liter, 1.0 Liter, and other variants as applicable to the model range within the specified years Page Count Estimated Page Count: Varies significantly based on specific engine and model year, typically hundreds to over a thousand pages for a comprehensive FSM. Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Digital Format: HTML Delivery Format: Downloadable RAR archive requiring extraction software (e.g., WinRAR) Viewing Requirements Browser Requirement: Microsoft Internet Explorer v6 or greater Operating System Compatibility: Windows 95, 98, Me, NT, 2000, Server 2003, XP, Vista, Windows 7 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed procedures for engine assembly, disassembly, inspection, and repair, including timing, valve train, pistons, crankshafts, and cylinder heads. Engine Lubrication And Cooling: Oil pump, oil filter, oil cooler, water pump, radiator, thermostat, coolant passages, and lubrication system diagnostics. Engine Fuel And Emission Control: Fuel injection systems (MPI), fuel pump, injectors, fuel filter, evaporative emission control (EVAP), oxygen sensors, catalytic converter, and EGR system. Accelerator Control: Throttle body, accelerator cable/pedal assembly, cruise control (if equipped). Fuel And Exhaust Systems: Fuel tank, fuel lines, mufflers, exhaust manifolds, and piping. Clutch: Clutch disc, pressure plate, release bearing, clutch hydraulics (master and slave cylinders), and clutch pedal assembly. Manual Transmission: Gearbox disassembly, assembly, internal component inspection, shifting mechanisms, and lubrication. Automatic Transmission: Transmission removal, installation, internal components, torque converter, valve body, and shift control systems. Driveline Axle: Propeller shaft (if applicable, though front-wheel drive is typical), driveshafts, CV joints, differential carrier, and hub bearings. Front Axle: Wheel bearings, hub assemblies, and steering knuckle components. Rear Axle: Rear suspension mounting points, bearing assemblies, and drum/disc brake mounting. Front Suspension: MacPherson struts, control arms, ball joints, sway bar, and bushings. Rear Suspension: Torsion beam axle or independent suspension (depending on variant), shock absorbers, and trailing arms. Brake System: Front and rear brake components (disc/drum), hydraulic system (lines, master cylinder, brake booster), ABS system (if equipped), parking brake. Steering System: Power steering system (pump, fluid, lines), steering rack, tie rods, steering column, and wheel alignment specifications. HVAC: Heating, ventilation, and air conditioning system components, refrigerant handling, blower motor, heater core, evaporator, and controls. Restraints: Seat belts, SRS (Supplemental Restraint System) airbags, control module, and related sensors. Body And Accessories: Exterior and interior trim, doors, hood, trunk, bumpers, glass, mirrors, and seals. Includes body repair and rust prevention. Electrical System: Wiring diagrams, fuses, relays, battery, charging system (alternator), starting system, lighting, instrument cluster, power windows, locks, and audio system. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, inspections, and tune-ups. Diagnostics: Troubleshooting guides, symptom-based diagnosis, identification of common faults, and diagnostic trouble codes (DTCs) if applicable to OBD-II systems. Repair: Step-by-step instructions for component replacement, adjustment, and repair across all vehicle systems. Installation: Procedures for installing new or replacement parts and accessories. Technical Depth Depth: Comprehensive, technician-level detail covering from basic adjustments to complete component overhauls and system diagnostics. 📊 Manual Specifications File Format Primary File Type: HTML (HyperText Markup Language) Delivery Archive Type: RAR (Roshal Archive) Print Quality Printability: HTML files are typically printable, but layout may vary. Designed for digital viewing. Quality depends on browser rendering. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Daewoo: F8CV (0.8L), F10D (1.0L), A12S3 (1.2L) - may vary by market and year Engine Type: Inline 3-cylinder (0.8L), Inline 4-cylinder (1.0L, 1.2L, 1.4L, 1.6L variants exist in later models/markets) Displacement 0.8L: 796 cc Displacement 1.0L: 995 cc Bore Stroke 0.8L: Approx. 72.0 mm x 69.3 mm Bore Stroke 1.0L: Approx. 70.0 mm x 63.5 mm Performance Horsepower 0.8L: Approx. 52 PS (38 kW) @ 6000 rpm Torque 0.8L: Approx. 72 Nm (53 lb-ft) @ 4200 rpm Horsepower 1.0L: Approx. 61 PS (45 kW) @ 6000 rpm Torque 1.0L: Approx. 87 Nm (64 lb-ft) @ 4300 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (Gasoline) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (availability may vary by market and engine) Features...
Windows 95, 98, Me, NT, 2000, Server 2003, XP, Vista, Windows 7
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed procedures for engine assembly, disassembly, inspection, and repair, including timing, valve train, pistons, crankshafts, and cylinder heads.
Engine Lubrication And Cooling:
Oil pump, oil filter, oil cooler, water pump, radiator, thermostat, coolant passages, and lubrication system diagnostics.
Engine Fuel And Emission Control:
Fuel injection systems (MPI), fuel pump, injectors, fuel filter, evaporative emission control (EVAP), oxygen sensors, catalytic converter, and EGR system.
Accelerator Control:
Throttle body, accelerator cable/pedal assembly, cruise control (if equipped).
Fuel And Exhaust Systems:
Fuel tank, fuel lines, mufflers, exhaust manifolds, and piping.
Clutch:
Clutch disc, pressure plate, release bearing, clutch hydraulics (master and slave cylinders), and clutch pedal assembly.
Manual Transmission:
Gearbox disassembly, assembly, internal component inspection, shifting mechanisms, and lubrication.
Automatic Transmission:
Transmission removal, installation, internal components, torque converter, valve body, and shift control systems.
Driveline Axle:
Propeller shaft (if applicable, though front-wheel drive is typical), driveshafts, CV joints, differential carrier, and hub bearings.
Front Axle:
Wheel bearings, hub assemblies, and steering knuckle components.
Rear Axle:
Rear suspension mounting points, bearing assemblies, and drum/disc brake mounting.
Front Suspension:
MacPherson struts, control arms, ball joints, sway bar, and bushings.
Rear Suspension:
Torsion beam axle or independent suspension (depending on variant), shock absorbers, and trailing arms.
Brake System:
Front and rear brake components (disc/drum), hydraulic system (lines, master cylinder, brake booster), ABS system (if equipped), parking brake.
Steering System:
Power steering system (pump, fluid, lines), steering rack, tie rods, steering column, and wheel alignment specifications.
HVAC:
Heating, ventilation, and air conditioning system components, refrigerant handling, blower motor, heater core, evaporator, and controls.
Restraints:
Seat belts, SRS (Supplemental Restraint System) airbags, control module, and related sensors.
Body And Accessories:
Exterior and interior trim, doors, hood, trunk, bumpers, glass, mirrors, and seals. Includes body repair and rust prevention.
Electrical System:
Wiring diagrams, fuses, relays, battery, charging system (alternator), starting system, lighting, instrument cluster, power windows, locks, and audio system.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, inspections, and tune-ups.
Diagnostics:
Troubleshooting guides, symptom-based diagnosis, identification of common faults, and diagnostic trouble codes (DTCs) if applicable to OBD-II systems.
Repair:
Step-by-step instructions for component replacement, adjustment, and repair across all vehicle systems.
Installation:
Procedures for installing new or replacement parts and accessories.
Technical Depth
Depth:
Comprehensive, technician-level detail covering from basic adjustments to complete component overhauls and system diagnostics.
📊 Manual Specifications
File Format
Primary File Type:
HTML (HyperText Markup Language)
Delivery Archive Type:
RAR (Roshal Archive)
Print Quality
Printability:
HTML files are typically printable, but layout may vary. Designed for digital viewing. Quality depends on browser rendering.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Daewoo:
F8CV (0.8L), F10D (1.0L), A12S3 (1.2L) - may vary by market and year
Engine Type:
Inline 3-cylinder (0.8L), Inline 4-cylinder (1.0L, 1.2L, 1.4L, 1.6L variants exist in later models/markets)
Displacement 0.8L:
796 cc
Displacement 1.0L:
995 cc
Bore Stroke 0.8L:
Approx. 72.0 mm x 69.3 mm
Bore Stroke 1.0L:
Approx. 70.0 mm x 63.5 mm
Performance
Horsepower 0.8L:
Approx. 52 PS (38 kW) @ 6000 rpm
Torque 0.8L:
Approx. 72 Nm (53 lb-ft) @ 4200 rpm
Horsepower 1.0L:
Approx. 61 PS (45 kW) @ 6000 rpm
Torque 1.0L:
Approx. 87 Nm (64 lb-ft) @ 4300 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (Gasoline)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (availability may vary by market and engine)
Features
Drivetrain:
Front-Wheel Drive (FWD)
📐 Dimensions
Exterior
Length:
Approx. 3,870 mm (152.4 in) for early models, may vary slightly with generation/facelifts.
Width:
Approx. 1,670 mm (65.7 in)
Height:
Approx. 1,470 mm (57.9 in)
Wheelbase:
Approx. 2,445 mm (96.3 in)
Weights
Curb Weight:
Approx. 950-1050 kg (2094-2315 lbs) depending on engine and specification.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Early models received low Euro NCAP ratings (e.g., 1 or 2 stars), particularly for adult occupant protection. Later models and different safety configurations may differ. Manual will cover any safety features and repairs related to them.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option or standard on higher trims/later models.
Passive Features
Airbags:
Driver and front passenger airbags were standard on most later models; side airbags were less common. Manual covers SRS system diagnostics and repair.
Seatbelts:
Pre-tensioning front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette tape player. Manual details audio system removal, installation, and speaker replacement.
Driver Assistance
Cruise Control:
Available on some higher trim levels, manual covers diagnosis and repair of the system.
Connectivity
Power Features:
Power windows, power door locks, and power mirrors were optional or standard on higher trims. Manual covers their electrical circuits.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first, depending on driving conditions and oil type.
Air Filter Replacement:
Recommended every 20,000-30,000 km (12,000-18,000 miles) or as per manual inspection.
Spark Plug Replacement:
Varies by plug type (copper, platinum, iridium), typically 30,000-100,000 km. Manual will specify.
Fluid Specifications
Engine Oil Specification:
API SJ or higher, viscosity typically 5W-30 or 10W-40. Manual will specify exact OEM recommendation and capacities.
Coolant Specification:
Ethylene glycol-based coolant (e.g., Dex-Cool equivalent or specific Daewoo/Holden coolant). Capacity typically around 5.5 liters. Manual provides exact type and capacity.
Transmission Fluid Manual:
GL-4 gear oil, SAE 75W-90 or similar. Manual will specify exact type and capacity (approx. 2.0-2.5 liters).
Transmission Fluid Automatic:
Dexron III or equivalent automatic transmission fluid (ATF). Manual will specify type and capacity (approx. 5.5-6.0 liters for a full flush).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid. Manual specifies exact type and capacity for the system.
Known Issues
Common Wear Items:
Ignition coils, spark plugs, front suspension components (bushings, ball joints), clutch wear, HVAC blower motor failure, radiator leaks, catalytic converter issues (on higher mileage vehicles).
Electrical Gremlins:
Corrosion in connectors, faulty door lock actuators, and intermittent dashboard warning lights can occur, all detailed in electrical troubleshooting sections.
📚 Vehicle History
Brand Heritage
Daewoo Context:
The Daewoo Kalos was a model developed by Daewoo Motors before its acquisition by General Motors. It represented Daewoo's effort to compete in the global subcompact segment.
Model Evolution
Holden Rebadge:
In many markets, particularly Australia, the Daewoo Kalos was rebadged and sold as the Holden Barina (often the XC series). This provided Holden with an entry-level model.
Facelifts And Updates:
The model underwent facelifts during its production run, with styling updates and potential mechanical revisions, all covered within this comprehensive manual.
Production
Manufacturing Locations:
Primary production in South Korea (Daewoo), with assembly in other locations for specific markets.
🏆 Awards & Recognition
Recognitions
Market Perception:
The Kalos/Barina was generally perceived as a no-frills, economical option. Its awards were typically related to affordability and value in its segment rather than performance or luxury.
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