HOLDEN TK 1.6L 2005-2011 Full Workshop Service Manual

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Basic Information Identification Make: Holden Model: TK Generation: First Generation (2005-2011) Body Styles Covered: Hatchback, Notchback Codes Model Code: TK Introduction Market Position Vehicle Segment: Subcompact/Compact Car (Holden TK is based on the Daewoo Lacetti/Suzuki Forenza platform, competing in the B/C segment). Competitive Analysis Key Competitors: Ford Focus, Toyota Corolla, Mazda 3, Hyundai Elantra, Mitsubishi Lancer. Key Features Vehicle Platform: Global compact platform shared with Daewoo Lacetti, Chevrolet Lacetti, Suzuki Forenza, and Buick Excelle. Manual Details Coverage Areas Primary Coverage: Full Workshop Service and Repair Engine Variants Covered: 1.2L I4 Petrol (DOHC), 1.4L I4 Petrol (L95/LDT, DOHC/SOHC), 1.5L Inline-4 Petrol, 1.6L 4-Cylinder Petrol (Aspirated DOHC), 1.6L LXT/LXV I4 DOHC Transmission Variants Covered: 4-Speed Automatic (Aisin 81-40LE), 5-Speed Manual (DWMC D16), 5-Speed Manual (Y4M Synchronized/Sliding) Page Count Estimated Page Count: High (comprehensive coverage implies significant page count, typically 1000+ pages for full workshop manuals) Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair procedures for all covered engine variants. Includes cylinder head, block, pistons, crankshaft, camshafts, valve train, timing systems, lubrication. Engine Control System: ECU diagnosis, sensor operations (MAP, TPS, CKP, CMP, O2, MAF), actuator control (injectors, ignition coils), emissions control strategies, diagnostic trouble codes (DTCs) and troubleshooting. Fuel System: Fuel pump operation, fuel filter replacement, fuel injector testing and replacement, fuel pressure regulation, evaporative emission control (EVAP). Cooling System: Radiator, water pump, thermostat, coolant hoses, coolant types, bleed procedures, fan operation, temperature sensor diagnostics. Engine Electrical: Ignition system (spark plugs, coils, wiring), starting system (starter motor, solenoid, battery), charging system (alternator, regulator), sensor and actuator wiring diagrams. Exhaust System: Exhaust manifold, catalytic converter, muffler, exhaust pipes, oxygen sensors, heat shields, repair and replacement procedures. Battery Starting System: Battery testing, charging, terminal maintenance, starter motor testing and replacement, starter solenoid diagnostics. Automatic Transmission: Aisin 81-40LE operation, fluid types, capacity, filter replacement, torque converter, valve body, solenoids, diagnostic procedures. Manual Transmission: DWMC D16 and Y4M transmission overhaul, clutch operation, gear selection, synchronizers, bearings, seals, fluid specifications, repair procedures. Anti Lock Brake System: ABS modulator, wheel speed sensors, ABS control module, hydraulic unit, diagnostic procedures, bleeding procedures. Body Repair System: Structural repair guidelines, panel replacement, welding specifications, frame straightening, corrosion protection, collision repair. Clutch System: Clutch disc, pressure plate, release bearing, clutch master cylinder, clutch slave cylinder, hydraulic line maintenance, adjustment, and replacement. Entertainment System: Radio, CD player, speaker diagnostics and replacement, antenna system. Navigation System: Navigation unit operation, antenna, GPS receiver diagnostics (if applicable). Disc Drum Brakes: Brake pad and shoe replacement, rotor and drum resurfacing/replacement, caliper and wheel cylinder overhaul, brake fluid type and bleeding. Exterior Trim: Bumper covers, grille, door handles, mirrors, trim moldings, replacement and alignment. Windows System: Power window regulators, motors, switches, glass replacement, seals, window tinting guidelines. Drive Axle System: CV joints, drive shafts, wheel bearings, differential (if applicable), lubrication, and repair. Suspension System: Struts, shock absorbers, control arms, ball joints, tie rods, bushings, springs, wheel alignment specifications. Hydraulic Brakes: Brake lines, hoses, master cylinder, brake booster, pedal assembly, fluid specifications, diagnostic troubleshooting. Immobilizer System: Key programming, anti-theft module operation, security system diagnostics. Instrument Panel: Dashboard removal and installation, gauge cluster diagnostics, warning lights, switches, illumination. Console Trim: Center console disassembly, shifter bezel, storage compartments, trim panel removal. Interior Trim: Door panels, headliner, seat removal, carpet, pillar trim, reassembly procedures. Lighting System: Headlights, taillights, turn signals, interior lighting, bulb replacement, wiring, fuse information. Automatic HVAC: Automatic climate control system operation, sensors, actuators, control module, troubleshooting (if applicable to specific variants). Manual HVAC: Heater core, A/C evaporator, blower motor, control cables, refrigerant system diagnostics, cabin filter replacement. Manual Steering: Steering rack, tie rod ends, steering knuckle, wheel alignment procedures. Power Steering: Power steering pump, fluid, hoses, steering rack, electric power steering components (if applicable), bleeding, troubleshooting. Parking Brake: Parking brake mechanism, cables, adjustment, operation. Horn Mirrors Seat Seat Belts: Horn operation, mirror adjustment and replacement, seat track maintenance, seat belt retractors and pre-tensioners. Shift Lock Control: Shift interlock system operation and troubleshooting, park-to-start interlock. Remote Function: Remote key fob operation, central locking system, door lock actuators, receiver module. Steering Wheel Column: Steering wheel removal, airbag system safety precautions, steering column tilt and telescope mechanisms, ignition switch. Sunroof Anti Theft: Sunroof motor, track, switch operation, anti-theft system integration. Vehicle Access: Door latch mechanisms, keyless entry system, central locking, trunk/hatch release. Wiper Washer: Wiper motor, linkage, blades, washer pump, fluid reservoir, nozzles, control switch. Schematic Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, engine management, lighting, comfort, and safety features. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes (oil, coolant, brake, transmission), filter replacements, inspections, lubrication. Troubleshooting: System-specific diagnostic trees, symptom-based problem diagnosis, fault code interpretation, testing procedures for components and circuits. Repair: Step-by-step instructions for component removal, installation,...

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Description

Basic Information
Identification
Make:	Holden
Model:	TK
Generation:	First Generation (2005-2011)
Body Styles Covered:	Hatchback, Notchback
Codes
Model Code:	TK

Introduction
Market Position
Vehicle Segment:	Subcompact/Compact Car (Holden TK is based on the Daewoo Lacetti/Suzuki Forenza platform, competing in the B/C segment).
Competitive Analysis
Key Competitors:	Ford Focus, Toyota Corolla, Mazda 3, Hyundai Elantra, Mitsubishi Lancer.
Key Features
Vehicle Platform:	Global compact platform shared with Daewoo Lacetti, Chevrolet Lacetti, Suzuki Forenza, and Buick Excelle.

Manual Details
Coverage Areas
Primary Coverage:	Full Workshop Service and Repair
Engine Variants Covered:	1.2L I4 Petrol (DOHC), 1.4L I4 Petrol (L95/LDT, DOHC/SOHC), 1.5L Inline-4 Petrol, 1.6L 4-Cylinder Petrol (Aspirated DOHC), 1.6L LXT/LXV I4 DOHC
Transmission Variants Covered:	4-Speed Automatic (Aisin 81-40LE), 5-Speed Manual (DWMC D16), 5-Speed Manual (Y4M Synchronized/Sliding)
Page Count
Estimated Page Count:	High (comprehensive coverage implies significant page count, typically 1000+ pages for full workshop manuals)
Manual Type
Manual Type:	Workshop Service Manual
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanical:	Detailed disassembly, assembly, inspection, and repair procedures for all covered engine variants. Includes cylinder head, block, pistons, crankshaft, camshafts, valve train, timing systems, lubrication.
Engine Control System:	ECU diagnosis, sensor operations (MAP, TPS, CKP, CMP, O2, MAF), actuator control (injectors, ignition coils), emissions control strategies, diagnostic trouble codes (DTCs) and troubleshooting.
Fuel System:	Fuel pump operation, fuel filter replacement, fuel injector testing and replacement, fuel pressure regulation, evaporative emission control (EVAP).
Cooling System:	Radiator, water pump, thermostat, coolant hoses, coolant types, bleed procedures, fan operation, temperature sensor diagnostics.
Engine Electrical:	Ignition system (spark plugs, coils, wiring), starting system (starter motor, solenoid, battery), charging system (alternator, regulator), sensor and actuator wiring diagrams.
Exhaust System:	Exhaust manifold, catalytic converter, muffler, exhaust pipes, oxygen sensors, heat shields, repair and replacement procedures.
Battery Starting System:	Battery testing, charging, terminal maintenance, starter motor testing and replacement, starter solenoid diagnostics.
Automatic Transmission:	Aisin 81-40LE operation, fluid types, capacity, filter replacement, torque converter, valve body, solenoids, diagnostic procedures.
Manual Transmission:	DWMC D16 and Y4M transmission overhaul, clutch operation, gear selection, synchronizers, bearings, seals, fluid specifications, repair procedures.
Anti Lock Brake System:	ABS modulator, wheel speed sensors, ABS control module, hydraulic unit, diagnostic procedures, bleeding procedures.
Body Repair System:	Structural repair guidelines, panel replacement, welding specifications, frame straightening, corrosion protection, collision repair.
Clutch System:	Clutch disc, pressure plate, release bearing, clutch master cylinder, clutch slave cylinder, hydraulic line maintenance, adjustment, and replacement.
Entertainment System:	Radio, CD player, speaker diagnostics and replacement, antenna system.
Navigation System:	Navigation unit operation, antenna, GPS receiver diagnostics (if applicable).
Disc Drum Brakes:	Brake pad and shoe replacement, rotor and drum resurfacing/replacement, caliper and wheel cylinder overhaul, brake fluid type and bleeding.
Exterior Trim:	Bumper covers, grille, door handles, mirrors, trim moldings, replacement and alignment.
Windows System:	Power window regulators, motors, switches, glass replacement, seals, window tinting guidelines.
Drive Axle System:	CV joints, drive shafts, wheel bearings, differential (if applicable), lubrication, and repair.
Suspension System:	Struts, shock absorbers, control arms, ball joints, tie rods, bushings, springs, wheel alignment specifications.
Hydraulic Brakes:	Brake lines, hoses, master cylinder, brake booster, pedal assembly, fluid specifications, diagnostic troubleshooting.
Immobilizer System:	Key programming, anti-theft module operation, security system diagnostics.
Instrument Panel:	Dashboard removal and installation, gauge cluster diagnostics, warning lights, switches, illumination.
Console Trim:	Center console disassembly, shifter bezel, storage compartments, trim panel removal.
Interior Trim:	Door panels, headliner, seat removal, carpet, pillar trim, reassembly procedures.
Lighting System:	Headlights, taillights, turn signals, interior lighting, bulb replacement, wiring, fuse information.
Automatic HVAC:	Automatic climate control system operation, sensors, actuators, control module, troubleshooting (if applicable to specific variants).
Manual HVAC:	Heater core, A/C evaporator, blower motor, control cables, refrigerant system diagnostics, cabin filter replacement.
Manual Steering:	Steering rack, tie rod ends, steering knuckle, wheel alignment procedures.
Power Steering:	Power steering pump, fluid, hoses, steering rack, electric power steering components (if applicable), bleeding, troubleshooting.
Parking Brake:	Parking brake mechanism, cables, adjustment, operation.
Horn Mirrors Seat Seat Belts:	Horn operation, mirror adjustment and replacement, seat track maintenance, seat belt retractors and pre-tensioners.
Shift Lock Control:	Shift interlock system operation and troubleshooting, park-to-start interlock.
Remote Function:	Remote key fob operation, central locking system, door lock actuators, receiver module.
Steering Wheel Column:	Steering wheel removal, airbag system safety precautions, steering column tilt and telescope mechanisms, ignition switch.
Sunroof Anti Theft:	Sunroof motor, track, switch operation, anti-theft system integration.
Vehicle Access:	Door latch mechanisms, keyless entry system, central locking, trunk/hatch release.
Wiper Washer:	Wiper motor, linkage, blades, washer pump, fluid reservoir, nozzles, control switch.
Schematic Diagrams:	Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, engine management, lighting, comfort, and safety features.
Procedures Included
Maintenance:	Scheduled maintenance tasks, fluid changes (oil, coolant, brake, transmission), filter replacements, inspections, lubrication.
Troubleshooting:	System-specific diagnostic trees, symptom-based problem diagnosis, fault code interpretation, testing procedures for components and circuits.
Repair:	Step-by-step instructions for component removal, installation, overhaul, and replacement, including specifications and torque values.
Diagnostics:	On-board diagnostics (OBD-II) procedures, use of scan tools, interpretation of sensor data, live data analysis.
Adjustments:	Clutch adjustment, parking brake adjustment, wheel alignment procedures.
Technical Depth
Depth Of Coverage:	Comprehensive: Covers everything from routine maintenance to complete engine and transmission overhauls, electrical system diagnostics, and body repair.

Manual Specifications
File Format
File Format:	PDF
Print Quality
Searchable Text:	Likely Yes (standard for modern PDF manuals)
Image Quality:	High resolution diagrams and photographs expected for a workshop manual.
Binding Type
Binding Type:	N/A (Digital Download)
Paper Type
Paper Type:	N/A (Digital Download)

Engine Specifications
Primary Engine
Engine Code Example:	1.6L DOHC Aspirated (likely GM Family II engine variant)
Performance
1 6L DOHc Aspirated Power Output:	Typically around 105-115 PS (77-85 kW) depending on specific market tuning.
1 6L DOHc Aspirated Torque Output:	Typically around 150-160 Nm (111-118 lb-ft) depending on specific market tuning.
1 4L L95 Ldt Power Output:	Generally lower than 1.6L, around 90-100 PS (66-74 kW).
1 2L I4 Power Output:	Smallest displacement, typically around 70-80 PS (51-59 kW).
Fuel System
Fuel Delivery:	Multi-point Fuel Injection (MPI)
Fuel Type:	Unleaded Petrol (RON 91 or higher recommended)
Engine Layout
Cylinder Configuration:	Inline 4-Cylinder

Transmission
Standard
Standard Transmission:	Likely a 5-speed manual (DWMC D16 or Y4M)
Optional
Optional Transmission:	4-speed automatic (Aisin 81-40LE)
Features
Automatic Transmission Features:	Lock-up torque converter for improved efficiency.

Dimensions
Exterior
Wheelbase Approximate:	2600 mm (2.6 meters)
Length Hatchback Approximate:	4250 mm (4.25 meters)
Width Approximate:	1725 mm (1.725 meters)
Height Approximate:	1450 mm (1.45 meters)
Weights
Curb Weight Range:	Approximately 1200-1350 kg (depending on engine and transmission)

Safety Features
Ratings
Ancap Rating Example:	Likely 3 or 4 stars (typical for vehicles of this era and segment, specific results varied by test year and configuration).
Active Features
ABS Availability:	Available as an option on lower trims, standard on higher trims.
Traction Control Availability:	Less common on base models, may be available on higher trims.
Passive Features
Airbag Count:	Standard front airbags, optional side airbags on some models.
Seat Belt Pre Tensioners:	Standard on front seats.

Technology Features
Infotainment
Infotainment Features:	Basic AM/FM radio, CD player, possibly MP3 playback. Aux input may be present on later models.
Driver Assistance
Cruise Control System:	Available on higher trim levels, offering speed regulation for highway driving.
Connectivity
Usb Aux Ports:	USB connectivity was not standard in early production, Aux ports became more common as the model evolved. Check specific vehicle configuration.

Maintenance
Service Intervals
Engine Oil Change Interval:	Every 10,000 - 15,000 km or 6-12 months (refer to manual for exact specification).
Coolant Change Interval:	Every 40,000 - 60,000 km or 2-3 years.
Spark Plug Replacement Interval:	Depending on type: Iridium plugs typically 80,000-100,000 km; Copper plugs 30,000-40,000 km.
Fluid Specifications
Engine Oil Specification:	API SM/SN or ACEA A3/B3/B4, viscosity typically 5W-30 or 10W-40 (check manual).
Coolant Specification:	GM Dex-Cool (OAT) or equivalent (ethylene glycol-based, extended life, orange/pink color).
Transmission Fluid Automatic:	Dexron III/VI or equivalent for Aisin 81-40LE (check manual).
Transmission Fluid Manual:	GL-4 gear oil, viscosity typically 75W-90 or 80W-90 (check manual).
Brake Fluid Specification:	DOT 3 or DOT 4.
Known Issues
Common Issue Engine Mounts:	Premature wear of engine and transmission mounts leading to vibration and noise.
Common Issue Suspension Bushings:	Wear in control arm bushings and other suspension components leading to clunking noises and poor handling.
Common Issue Ignition Coils:	Coil-on-plug ignition systems can be prone to failure, causing misfires.
Common Issue A C System:	Leaks in the AC system, particularly at the compressor or condenser, can lead to loss of cooling.
Common Issue Exhaust Leaks:	Corrosion of exhaust components can lead to leaks and increased noise.

Vehicle History
Brand Heritage
Holden History Context:	Holden, an Australian automotive manufacturer, primarily sold rebadged General Motors (GM) vehicles in later years. The TK was a global GM product.
Model Evolution
Platform Origin:	Based on the GM Epsilon platform, specifically the GM Theta platform used for compact vehicles.
Production
Production Years:	2005-2011
Manufacturing Location:	Primarily South Korea (Daewoo plant), also other GM global facilities.

Awards & Recognition
Recognitions
Model Awards:	The Holden TK received mixed reviews, with some praising its value and practicality, while others criticized its performance and refinement compared to some competitors. No major industry awards are prominently associated with this specific Holden rebadge.