Daewoo Kalos 2002-2011 Service & Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daewoo Model: Kalos Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 Generation Generation Code: First Generation (KL1S) 👋 Introduction Market Position Segment: Subcompact car Target Audience: DIY enthusiasts, independent repair shops, and owners seeking to understand their vehicle's maintenance and repair needs. Competitive Analysis Key Competitors: Chevrolet Aveo (North America), Holden Barina (Australia), Suzuki Ignis, Hyundai Getz, Ford Fiesta Key Features Value Proposition: Provides comprehensive, factory-level repair and maintenance information, enabling cost-effective servicing and repairs. Visual Aids: Hundreds of detailed photos and diagrams, including exploded views for clarity. 📋 Manual Details Coverage Areas Coverage Scope: Complete factory service, repair, and workshop procedures Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Type: Service and Repair Workshop Manual Language Language: English (implied by product description) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Engine Control System (ECU) Drivetrain: Manual Transmission, Automatic Transmission, Clutch System, Drive Shafts, Axles, Differential Chassis: Suspension System (Front and Rear), Steering System, Brake System (Front and Rear, ABS), Wheels and Tires Electrical: Battery, Starting and Charging Systems, Lighting System, Ignition System, Instrument Panel, Gauges, Warning Lights, Power Accessories, Audio System, HVAC Controls, Body Control Modules (BCM), Engine Control Unit (ECU), Transmission Control Unit (TCU), Anti-lock Braking System (ABS) module Body And Interior: Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Seats, Interior Trim, HVAC System (Air Conditioning and Heating), SRS Airbag System Procedures Included Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change, belt inspection/replacement, battery maintenance Repair: Engine component replacement (e.g., head gasket, piston rings, valve seals), transmission overhaul, clutch replacement, brake component replacement (rotors, pads, calipers), suspension component replacement (shocks, struts, ball joints, control arms), steering component replacement (tie rod ends, power steering pump), electrical component troubleshooting and replacement, body panel repair and replacement Troubleshooting: Diagnostic procedures for engine performance issues, starting problems, charging system faults, transmission shifting problems, brake system malfunctions, electrical gremlins, HVAC system failures Diagnostics: Diagnostic Trouble Codes (DTCs) interpretation, sensor testing, actuator testing, wiring harness continuity checks, using diagnostic scan tools Technical Depth Depth: Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Licensing Usage License: Unlimited lifetime usage on multiple devices/computers Updates Update Policy: No expiry, no renewal fees, no extra fees Compatibility Operating Systems: Windows and MAC compatible ⚙️ Engine Specifications Primary Engine Engine Code: F14D3 (common variant) Engine Type: Inline 4-cylinder, DOHC, 16-valve Displacement: 1.4 Liters (1399 cc) Performance Horsepower Ps: ~94 PS @ 6300 RPM (for F14D3) Torque Nm: ~130 Nm @ 4400 RPM (for F14D3) Fuel System Induction: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management ECU Type: Specific ECU part numbers would be detailed in the manual. Cooling System Coolant Type: Ethylene glycol-based antifreeze (refer to manual for specific OEM specifications and mixture ratios) Lubrication System Oil Type: API SG or SH, SAE 10W-30 or 10W-40 (refer to manual for exact specifications based on climate) Oil Capacity Liters: ~3.7 Liters with filter change (engine specific) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Features Automatic Transmission Control: Electronically controlled (specific TCU details in manual) Fluid Specifications Manual Transmission Fluid: GL-4 SAE 75W-90 Gear Oil (refer to manual for OEM part numbers) Automatic Transmission Fluid: Dexron III or equivalent (refer to manual for specific OEM part numbers) 📐 Dimensions Exterior Length Mm: ~3925 mm Width Mm: ~1670 mm Height Mm: ~1500 mm Wheelbase Mm: ~2480 mm Weights Curb Weight Kg: ~1000-1050 kg (depending on configuration) 🛡️ Safety Features Ratings Latin Ncap Rating: Likely 3-star (early models, subject to specific test year and configuration) Active Features ABS: Available on higher trims/optional Ebs: Electronic Brakeforce Distribution (often paired with ABS) Passive Features Airbags: Driver and front passenger airbags standard; side airbags optional on some models. Seatbelts: Pre-tensioning front seatbelts 💡 Technology Features Infotainment Audio System: Basic AM/FM/CD player with speaker system. Some models may have auxiliary input or steering wheel controls. Driver Assistance Cruise Control: Available on higher trim levels. Connectivity Auxiliary Input: Potentially available on later models or as an aftermarket addition. 🔧 Maintenance Service Intervals Engine Oil Change: Every 7,500 miles (12,000 km) or 12 months, whichever comes first (typical recommendation, verify in manual). Air Filter Replacement: Every 30,000 miles (48,000 km) or 24 months (typical recommendation, verify in manual). Spark Plug Replacement: Every 60,000 miles (96,000 km) (typical...
Suspension System (Front and Rear), Steering System, Brake System (Front and Rear, ABS), Wheels and Tires
Electrical:
Battery, Starting and Charging Systems, Lighting System, Ignition System, Instrument Panel, Gauges, Warning Lights, Power Accessories, Audio System, HVAC Controls, Body Control Modules (BCM), Engine Control Unit (ECU), Transmission Control Unit (TCU), Anti-lock Braking System (ABS) module
Body And Interior:
Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Seats, Interior Trim, HVAC System (Air Conditioning and Heating), SRS Airbag System
Procedures Included
Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change, belt inspection/replacement, battery maintenance
Repair:
Engine component replacement (e.g., head gasket, piston rings, valve seals), transmission overhaul, clutch replacement, brake component replacement (rotors, pads, calipers), suspension component replacement (shocks, struts, ball joints, control arms), steering component replacement (tie rod ends, power steering pump), electrical component troubleshooting and replacement, body panel repair and replacement
Troubleshooting:
Diagnostic procedures for engine performance issues, starting problems, charging system faults, transmission shifting problems, brake system malfunctions, electrical gremlins, HVAC system failures
Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Printable (single pages or entire manual)
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
Licensing
Usage License:
Unlimited lifetime usage on multiple devices/computers
Updates
Update Policy:
No expiry, no renewal fees, no extra fees
Compatibility
Operating Systems:
Windows and MAC compatible
⚙️ Engine Specifications
Primary Engine
Engine Code:
F14D3 (common variant)
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1.4 Liters (1399 cc)
Performance
Horsepower Ps:
~94 PS @ 6300 RPM (for F14D3)
Torque Nm:
~130 Nm @ 4400 RPM (for F14D3)
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Specific ECU part numbers would be detailed in the manual.
Cooling System
Coolant Type:
Ethylene glycol-based antifreeze (refer to manual for specific OEM specifications and mixture ratios)
Lubrication System
Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 (refer to manual for exact specifications based on climate)
Oil Capacity Liters:
~3.7 Liters with filter change (engine specific)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Automatic Transmission Control:
Electronically controlled (specific TCU details in manual)
Fluid Specifications
Manual Transmission Fluid:
GL-4 SAE 75W-90 Gear Oil (refer to manual for OEM part numbers)
Automatic Transmission Fluid:
Dexron III or equivalent (refer to manual for specific OEM part numbers)
📐 Dimensions
Exterior
Length Mm:
~3925 mm
Width Mm:
~1670 mm
Height Mm:
~1500 mm
Wheelbase Mm:
~2480 mm
Weights
Curb Weight Kg:
~1000-1050 kg (depending on configuration)
🛡️ Safety Features
Ratings
Latin Ncap Rating:
Likely 3-star (early models, subject to specific test year and configuration)
Active Features
ABS:
Available on higher trims/optional
Ebs:
Electronic Brakeforce Distribution (often paired with ABS)
Passive Features
Airbags:
Driver and front passenger airbags standard; side airbags optional on some models.
Seatbelts:
Pre-tensioning front seatbelts
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM/CD player with speaker system. Some models may have auxiliary input or steering wheel controls.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Auxiliary Input:
Potentially available on later models or as an aftermarket addition.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500 miles (12,000 km) or 12 months, whichever comes first (typical recommendation, verify in manual).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or 24 months (typical recommendation, verify in manual).
Spark Plug Replacement:
Every 60,000 miles (96,000 km) (typical recommendation for iridium/platinum plugs, verify in manual).
Timing Belt Replacement:
Critical: 75,000 miles (120,000 km) or 5 years, whichever comes first. Failure can cause severe engine damage. (Verify in manual, as this is a common failure point if neglected).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific OEM specification)
Power Steering Fluid:
ATF Dexron II or III (refer to manual)
Coolant Capacity Liters:
~5.5 Liters (typical for 1.4L engine)
Known Issues
Common Problems:
Timing belt failure (if not replaced on schedule), catalytic converter issues, EGR valve problems, minor electrical gremlins, clutch wear (manual transmission).
Typical Repairs Covered:
Detailed procedures for timing belt replacement, catalytic converter diagnostics and replacement, EGR valve cleaning/replacement, clutch assembly replacement, and electrical system troubleshooting.
📚 Vehicle History
Brand Heritage
Parent Company:
Daewoo Motor, later part of General Motors (GM).
Model Evolution
Design Origin:
Designed by Italdesign Giugiaro, sharing a platform with the Chevrolet Aveo.
Production
Manufacturing Locations:
South Korea (main), potentially other GM assembly plants globally.
🏆 Awards & Recognition
Recognitions
Safety Award Example:
While specific awards may vary by region and year, Latin NCAP rated the early generations of its sister car, the Chevrolet Aveo/Kalos, with varying scores, highlighting the importance of detailed safety system coverage in the manual.
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