Daewoo Kalos 2006-2012 Service Repair Workshop Manual Pdf
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🏷️ Basic Information Identification Make: Daewoo Model: Kalos Generation Codename: T200 Codes Chassis Code: T200 Engine Code Suffix Common: F14D3 (1.4L) 👋 Introduction Market Position Vehicle Segment: Subcompact car, often marketed as an economical and practical city car. Competitive Analysis Competitors Era: Competed with vehicles like Hyundai Accent, Kia Rio, Chevrolet Aveo (same platform), Ford Fiesta, Opel Corsa. Key Features Engine Options Common: Primarily offered with 1.4L and 1.6L gasoline engines. Body Styles: Available as a 3-door hatchback, 5-door hatchback, and 4-door sedan. Value Proposition Manual Value: Provides comprehensive DIY repair and maintenance capabilities for owners, saving on professional labor costs. 📋 Manual Details Coverage Areas Year Range: 2006-2012 Page Count Estimated Pages: Hundreds (as stated in description) Manual Type Type: Factory Service Repair Workshop Manual Language Primary Language: English (implied by product description) Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling. Engine Fuel System: Fuel injection system (ECU, injectors, fuel pump, pressure regulator), fuel tank, lines. Engine Ignition System: Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensor. Engine Emission Control: Catalytic converter, oxygen sensors, EVAP system. Transmission Manual: Clutch, gearbox assembly, shift linkage, internal components, fluid specifications. Transmission Automatic: Torque converter, valve body, internal hydraulic circuits, electronic control unit (ECU), fluid specifications. Drivetrain: Front-wheel drive system, drive shafts, CV joints, wheel bearings. Suspension: Front suspension (MacPherson struts, control arms, stabilizer bar), rear suspension (torsion beam or independent, depending on variant), shock absorbers, springs. Steering: Power steering system (hydraulic or electric), steering column, tie rods, steering rack. Brakes: Front disc brakes, rear drum or disc brakes, brake booster, master cylinder, ABS system (if equipped), brake lines, fluid specifications. Electrical System Basic: Battery, charging system (alternator), starter motor, lighting system (headlights, taillights, interior), fuses, relays. Electrical System Comfort: Power windows, power door locks, central locking, mirrors, climate control system. Electrical System Audio: Radio, speakers, antenna, wiring. Body And Frame: Body construction, panels, doors, hood, trunk lid, bumpers, glass, seals. HVAC: Air conditioning system, heater core, blower motor, refrigerant, control panel. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections. Troubleshooting: Diagnostic procedures for various systems, symptom-based problem solving. Repair Procedures: Detailed step-by-step instructions for component removal, installation, and repair. Component Rebuilding: Overhaul procedures for major components like engine, transmission, steering rack. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Technical Depth Diagnostics: Advanced diagnostic procedures, OBD-II (On-Board Diagnostics II) information, fault code interpretation. Specifications: Torque specifications for fasteners, clearances, pressures, electrical resistance values. Illustrations: Detailed photos and exploded diagrams for clarity. 📊 Manual Specifications File Format Compatibility: Windows & MAC OS compatible. Print Quality Print Ability: Printable single pages or entire manual. Binding Type Digital Binding: No physical binding as it's a digital download. Paper Type Digital Medium: Digital PDF format, viewable on computers, tablets, and smartphones. Usage Rights Licensing: Unlimited usage on multiple devices, no expiry. ⚙️ Engine Specifications Primary Engine Displacement Common: 1.4 Liters (1399 cc) Engine Type Common: Inline-4, DOHC, 16-valve Performance Horsepower 1.4L Approx: 94 hp @ 6300 rpm Torque 1.4L Approx: 130 Nm @ 4400 rpm Fuel System Injection Type: Multi-point Fuel Injection (MPI) Fuel Type Required Fuel: Unleaded Gasoline Cooling System Type: Liquid-cooled 🔧 Transmission Standard Type Common: 5-speed Manual Transmission Optional Type Optional: 4-speed Automatic Transmission Features Clutch Type: Hydraulic, single dry plate Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (Typical, consult manual for exact spec) Automatic Transmission Fluid: Dexron III / Mercon (Typical, consult manual for exact spec) 📐 Dimensions Exterior Length Hatchback Approx: 3995 mm Width Approx: 1680 mm Height Approx: 1500 mm Wheelbase Approx: 2480 mm Weights Curb Weight Approx Kg Manual: 1060 kg 🛡️ Safety Features Ratings Euroncap Rating Note: Models from this era often had varied safety ratings; specific Euro NCAP results for Kalos should be verified. Active Features ABS: Optional on some trims, standard on higher trims. Passive Features Airbags: Driver and passenger front airbags (standard/optional depending on market and trim). Seatbelts: Front and rear seat belts with pre-tensioners (driver/front passenger). 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player with basic speaker system. Driver Assistance Cruise Control: Optional on higher trim levels. Connectivity Aux Input: May be present on later models or as an aftermarket addition. 🔧 Maintenance Service Intervals Engine Oil Change: Every 7,500-10,000 miles or 6-12 months, whichever comes first (typical for synthetic oil). Air Filter Replacement: Every 15,000-30,000 miles or as needed based on driving conditions. Spark Plug Replacement: Every 30,000-60,000 miles depending on spark plug type (standard vs. platinum/iridium). Fluid Specifications Engine Oil Type Common: SAE 10W-30 or 10W-40 (API SJ or higher, consult manual for exact spec and viscosity for climate). Coolant Type: Ethylene Glycol based, 50/50 mix with distilled water (e.g., Dex-Cool compatible or...
Front suspension (MacPherson struts, control arms, stabilizer bar), rear suspension (torsion beam or independent, depending on variant), shock absorbers, springs.
Steering:
Power steering system (hydraulic or electric), steering column, tie rods, steering rack.
Brakes:
Front disc brakes, rear drum or disc brakes, brake booster, master cylinder, ABS system (if equipped), brake lines, fluid specifications.
Electrical System Basic:
Battery, charging system (alternator), starter motor, lighting system (headlights, taillights, interior), fuses, relays.
Electrical System Comfort:
Power windows, power door locks, central locking, mirrors, climate control system.
Electrical System Audio:
Radio, speakers, antenna, wiring.
Body And Frame:
Body construction, panels, doors, hood, trunk lid, bumpers, glass, seals.
HVAC:
Air conditioning system, heater core, blower motor, refrigerant, control panel.
Torque specifications for fasteners, clearances, pressures, electrical resistance values.
Illustrations:
Detailed photos and exploded diagrams for clarity.
📊 Manual Specifications
File Format
Compatibility:
Windows & MAC OS compatible.
Print Quality
Print Ability:
Printable single pages or entire manual.
Binding Type
Digital Binding:
No physical binding as it's a digital download.
Paper Type
Digital Medium:
Digital PDF format, viewable on computers, tablets, and smartphones.
Usage Rights
Licensing:
Unlimited usage on multiple devices, no expiry.
⚙️ Engine Specifications
Primary Engine
Displacement Common:
1.4 Liters (1399 cc)
Engine Type Common:
Inline-4, DOHC, 16-valve
Performance
Horsepower 1.4L Approx:
94 hp @ 6300 rpm
Torque 1.4L Approx:
130 Nm @ 4400 rpm
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Fuel Type
Required Fuel:
Unleaded Gasoline
Cooling System
Type:
Liquid-cooled
🔧 Transmission
Standard
Type Common:
5-speed Manual Transmission
Optional
Type Optional:
4-speed Automatic Transmission
Features
Clutch Type:
Hydraulic, single dry plate
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (Typical, consult manual for exact spec)
Automatic Transmission Fluid:
Dexron III / Mercon (Typical, consult manual for exact spec)
📐 Dimensions
Exterior
Length Hatchback Approx:
3995 mm
Width Approx:
1680 mm
Height Approx:
1500 mm
Wheelbase Approx:
2480 mm
Weights
Curb Weight Approx Kg Manual:
1060 kg
🛡️ Safety Features
Ratings
Euroncap Rating Note:
Models from this era often had varied safety ratings; specific Euro NCAP results for Kalos should be verified.
Active Features
ABS:
Optional on some trims, standard on higher trims.
Passive Features
Airbags:
Driver and passenger front airbags (standard/optional depending on market and trim).
Seatbelts:
Front and rear seat belts with pre-tensioners (driver/front passenger).
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with basic speaker system.
Driver Assistance
Cruise Control:
Optional on higher trim levels.
Connectivity
Aux Input:
May be present on later models or as an aftermarket addition.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500-10,000 miles or 6-12 months, whichever comes first (typical for synthetic oil).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Every 30,000-60,000 miles depending on spark plug type (standard vs. platinum/iridium).
Fluid Specifications
Engine Oil Type Common:
SAE 10W-30 or 10W-40 (API SJ or higher, consult manual for exact spec and viscosity for climate).
Coolant Type:
Ethylene Glycol based, 50/50 mix with distilled water (e.g., Dex-Cool compatible or similar).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific requirement).
Known Issues
Engine Mounts:
Degradation of engine mounts can lead to increased vibration.
Suspension Components:
Wear in ball joints, tie rod ends, and bushings due to age and mileage.
Power Steering Pump:
Potential for leaks or pump failure in older models.
Cooling System Leaks:
Hoses, radiator, and water pump can develop leaks over time.
📚 Vehicle History
Brand Heritage
Manufacturer:
Daewoo Motor Company (South Korea), later part of GM Daewoo and then Chevrolet.
Model Evolution
Platform Sharing:
The T200 platform is shared with other GM vehicles of the era, notably the Chevrolet Aveo/Sonic.
Production
Manufacturing Locations:
South Korea, Uzbekistan (Asaka), potentially other licensed production facilities.
🏆 Awards & Recognition
Recognitions
Market Reception:
Generally received moderate reviews, often praised for affordability and practicality in its class, with critiques sometimes focusing on build quality and refinement compared to European or Japanese rivals.