HOLDEN BARINA TK 1.6L 2005-2011 Workshop Service Manual

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🏷️ Basic Information Identification Make: Holden Model: Barina Model Code: TK Generation Generation Name: Third Generation (GM Gamma II platform) Codes Platform Code: GM Gamma II 👋 Introduction Market Position Market Position: The Holden Barina TK, based on the global GM Gamma II platform, was positioned as an affordable and economical small car in the Australian market, competing against models like the Ford Fiesta, Hyundai Getz, and Mazda 2. Competitive Analysis Competitive Analysis: The Barina TK offered a practical and fuel-efficient option in its segment, with Holden aiming to capture buyers seeking value for money. Its European design influence (shared with Opel Corsa and Chevrolet Aveo) gave it a modern appeal. Key Features Key Features: Fuel efficiency, compact dimensions for urban driving, choice of body styles, and a range of engine options catering to different needs. 📋 Manual Details Coverage Areas Body Styles Covered: Hatchback, Notchback Page Count Estimated Page Count: Varies by specific publication, typically 500-1500 pages for a comprehensive workshop manual. Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhauls, component testing, timing belt/chain, oil pump, pistons, rings, connecting rods, crankshaft, cylinder heads, valve train. Engine Control System: ECU diagnostics, sensor testing (MAP, TPS, O2, Crankshaft Position, Camshaft Position), actuator control (injectors, ignition coils), emissions control. Fuel System: Fuel pump testing, fuel injector cleaning and testing, fuel pressure regulation, fuel tank and lines, evaporative emission control (EVAP). Cooling System: Radiator, water pump, thermostat, cooling fan operation, coolant leaks, heater core troubleshooting. Engine Electrical: Ignition system components (plugs, coils, wires), starter motor, alternator, wiring diagrams, charging system diagnostics. Exhaust System: Exhaust manifold, catalytic converter, muffler, oxygen sensors (O2 sensors). Battery Starting System: Battery testing and replacement, starter motor diagnosis and repair, charging system analysis. Automatic Transmission: Aisin 81-40LE: hydraulic control, valve body, torque converter, solenoids, fluid type and capacity, shift logic, diagnostics. Manual Transmission: DWMC D16 & Y4M: gear engagement, clutch operation, synchronizers, shifting mechanisms, fluid type and capacity, troubleshooting. Anti Lock Brake System: ABS control module, wheel speed sensors, hydraulic modulator, ABS warning light diagnosis, bleeding procedures. Body Repair System: Structural repair, panel replacement, welding procedures, corrosion prevention, alignment specifications. Clutch System: Clutch disc, pressure plate, release bearing, clutch master cylinder, clutch slave cylinder, hydraulic system bleeding. Entertainment System: Radio, speakers, amplifier (if equipped), wiring, troubleshooting common audio issues. Navigation System: If equipped: GPS unit, antenna, wiring, basic operation and troubleshooting. Disc Drum Brakes: Brake pad/shoe replacement, rotor/drum resurfacing/replacement, caliper and wheel cylinder service, brake fluid type and bleeding. Exterior Trim: Bumpers, grilles, moldings, emblems, body panels, repair and replacement. Windows System: Power window regulators, motors, switches, manual window mechanisms, glass replacement, seal maintenance. Drive Axle System: CV joints, drive shafts, wheel bearings, differential (if applicable), lubrication. Suspension System: Shock absorbers, struts, coil springs, control arms, ball joints, sway bars, alignment specifications. Hydraulic Brakes: Brake lines, hoses, master cylinder, brake booster, fluid specifications, bleeding procedures. Immobilizer System: Key recognition, ECU interface, anti-theft diagnostics, component identification. Instrument Panel: Dashboard removal and reinstallation, gauge cluster, warning lights, switch replacement. Console Trim: Center console removal and installation, shifter surround, storage compartments. Interior Trim: Door panels, pillar trims, headliner, seat removal, carpet replacement. Lighting System: Headlights, taillights, interior lights, fog lights, bulb replacement, wiring diagrams. Automatic HVAC: Climate control system, sensors, actuators, blower motor, refrigerant system service (if automatic). Basic maintenance and troubleshooting. Manual HVAC: Heater core, evaporator core, blend doors, control cables, blower motor, AC system operation and basic service. Manual Steering: Steering rack and pinion, tie rod ends, steering column components (if manual steering system). Power Steering: Power steering pump, reservoir, hoses, steering rack, fluid specifications, bleeding procedures. Parking Brake: Parking brake mechanism, cables, adjustment, drum brake integration. Horn Mirrors Seat Seat Belts: Horn circuit, power mirror adjustments, seat removal and installation, seat belt maintenance and replacement. Shift Lock Control: Mechanism for preventing gear selection without brake application, troubleshooting. Remote Function: Key fob operation, remote entry system diagnostics, central locking system. Steering Wheel Column: Steering wheel removal, airbag system precautions, steering column assembly, ignition switch. Sunroof Anti Theft: Sunroof motor and mechanism, drainage, anti-theft system integration (if applicable). Vehicle Access: Door lock mechanisms, keyless entry, trunk/hatch operation. Wiper Washer: Wiper motor, linkages, blades, washer pump, fluid reservoir, nozzles, circuit. Schematic Diagrams: Comprehensive electrical wiring diagrams for all major systems, vacuum diagrams, fluid flow diagrams. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/shoe replacement. Troubleshooting Guidance: Diagnostic flowcharts, symptom-based troubleshooting, common fault code explanations. Repair Procedures: Step-by-step instructions for component removal, installation, and repair for all listed systems. Technical Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, pressure readings. Technical Depth Technical Depth: Comprehensive coverage from basic maintenance to advanced...

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Description

🏷️ Basic Information

Identification

Make:

Holden

Model:

Barina

Model Code:

Generation

Generation Name:

Third Generation (GM Gamma II platform)

Codes

Platform Code:

GM Gamma II

👋 Introduction

Market Position

Market Position:

The Holden Barina TK, based on the global GM Gamma II platform, was positioned as an affordable and economical small car in the Australian market, competing against models like the Ford Fiesta, Hyundai Getz, and Mazda 2.

Competitive Analysis

Competitive Analysis:

The Barina TK offered a practical and fuel-efficient option in its segment, with Holden aiming to capture buyers seeking value for money. Its European design influence (shared with Opel Corsa and Chevrolet Aveo) gave it a modern appeal.

Key Features

Key Features:

Fuel efficiency, compact dimensions for urban driving, choice of body styles, and a range of engine options catering to different needs.

📋 Manual Details

Coverage Areas

Body Styles Covered:

Hatchback, Notchback

Page Count

Estimated Page Count:

Varies by specific publication, typically 500-1500 pages for a comprehensive workshop manual.

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhauls, component testing, timing belt/chain, oil pump, pistons, rings, connecting rods, crankshaft, cylinder heads, valve train.

Engine Control System:

ECU diagnostics, sensor testing (MAP, TPS, O2, Crankshaft Position, Camshaft Position), actuator control (injectors, ignition coils), emissions control.

Fuel System:

Fuel pump testing, fuel injector cleaning and testing, fuel pressure regulation, fuel tank and lines, evaporative emission control (EVAP).

Cooling System:

Radiator, water pump, thermostat, cooling fan operation, coolant leaks, heater core troubleshooting.

Engine Electrical:

Ignition system components (plugs, coils, wires), starter motor, alternator, wiring diagrams, charging system diagnostics.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, oxygen sensors (O2 sensors).

Battery Starting System:

Battery testing and replacement, starter motor diagnosis and repair, charging system analysis.

Automatic Transmission:

Aisin 81-40LE: hydraulic control, valve body, torque converter, solenoids, fluid type and capacity, shift logic, diagnostics.

Manual Transmission:

DWMC D16 & Y4M: gear engagement, clutch operation, synchronizers, shifting mechanisms, fluid type and capacity, troubleshooting.

Anti Lock Brake System:

ABS control module, wheel speed sensors, hydraulic modulator, ABS warning light diagnosis, bleeding procedures.

Body Repair System:

Structural repair, panel replacement, welding procedures, corrosion prevention, alignment specifications.

Clutch System:

Clutch disc, pressure plate, release bearing, clutch master cylinder, clutch slave cylinder, hydraulic system bleeding.

Entertainment System:

Radio, speakers, amplifier (if equipped), wiring, troubleshooting common audio issues.

Navigation System:

If equipped: GPS unit, antenna, wiring, basic operation and troubleshooting.

Disc Drum Brakes:

Brake pad/shoe replacement, rotor/drum resurfacing/replacement, caliper and wheel cylinder service, brake fluid type and bleeding.

Exterior Trim:

Bumpers, grilles, moldings, emblems, body panels, repair and replacement.

Windows System:

Power window regulators, motors, switches, manual window mechanisms, glass replacement, seal maintenance.

Drive Axle System:

CV joints, drive shafts, wheel bearings, differential (if applicable), lubrication.

Suspension System:

Shock absorbers, struts, coil springs, control arms, ball joints, sway bars, alignment specifications.

Hydraulic Brakes:

Brake lines, hoses, master cylinder, brake booster, fluid specifications, bleeding procedures.

Immobilizer System:

Key recognition, ECU interface, anti-theft diagnostics, component identification.

Instrument Panel:

Dashboard removal and reinstallation, gauge cluster, warning lights, switch replacement.

Console Trim:

Center console removal and installation, shifter surround, storage compartments.

Interior Trim:

Door panels, pillar trims, headliner, seat removal, carpet replacement.

Lighting System:

Headlights, taillights, interior lights, fog lights, bulb replacement, wiring diagrams.

Automatic HVAC:

Climate control system, sensors, actuators, blower motor, refrigerant system service (if automatic). Basic maintenance and troubleshooting.

Manual HVAC:

Heater core, evaporator core, blend doors, control cables, blower motor, AC system operation and basic service.

Manual Steering:

Steering rack and pinion, tie rod ends, steering column components (if manual steering system).

Power Steering:

Power steering pump, reservoir, hoses, steering rack, fluid specifications, bleeding procedures.

Parking Brake:

Parking brake mechanism, cables, adjustment, drum brake integration.

Horn Mirrors Seat Seat Belts:

Horn circuit, power mirror adjustments, seat removal and installation, seat belt maintenance and replacement.

Shift Lock Control:

Mechanism for preventing gear selection without brake application, troubleshooting.

Remote Function:

Key fob operation, remote entry system diagnostics, central locking system.

Steering Wheel Column:

Steering wheel removal, airbag system precautions, steering column assembly, ignition switch.

Sunroof Anti Theft:

Sunroof motor and mechanism, drainage, anti-theft system integration (if applicable).

Vehicle Access:

Door lock mechanisms, keyless entry, trunk/hatch operation.

Wiper Washer:

Wiper motor, linkages, blades, washer pump, fluid reservoir, nozzles, circuit.

Schematic Diagrams:

Comprehensive electrical wiring diagrams for all major systems, vacuum diagrams, fluid flow diagrams.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/shoe replacement.

Troubleshooting Guidance:

Diagnostic flowcharts, symptom-based troubleshooting, common fault code explanations.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all listed systems.

Technical Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, pressure readings.

Technical Depth

Technical Depth:

Comprehensive coverage from basic maintenance to advanced diagnostics and component-level repairs. Suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, printable quality. Clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1 6L 4 Cyl DOHc:

Displacement: 1.6 Liters (1598 cc), Configuration: Inline 4-cylinder, Valve Train: DOHC (Double Overhead Camshaft), Aspirated: Naturally aspirated, Power: Approx. 77 kW (103 hp) @ 6000 rpm, Torque: Approx. 148 Nm (109 lb-ft) @ 4000 rpm.

Other Engines

Engine 1 2L I4 DOHc:

Displacement: 1.2 Liters, Configuration: Inline 4-cylinder, Valve Train: DOHC.

Engine 1 4L I4 DOHc Sohc:

Displacement: 1.4 Liters, Configuration: Inline 4-cylinder, Valve Train: DOHC/SOHC, Engine Codes: L95/LDT.

Engine 1 5L Inline 4:

Displacement: 1.5 Liters, Configuration: Inline 4-cylinder.

Engine 1 6L I4 DOHc Lxt Lxv:

Displacement: 1.6 Liters, Configuration: Inline 4-cylinder, Valve Train: DOHC, Engine Codes: LXT/LXV.

Performance

Performance Notes:

Performance figures are approximate and vary based on specific engine and transmission configuration. Focus is on economy and drivability.

Fuel System

Fuel System Type:

Multi-point Fuel Injection (MPI) or similar electronic fuel injection systems.

Fuel Type:

Unleaded Petrol (Gasoline)

🔧 Transmission

Standard

Standard Transmission:

5-Speed Manual Transmission (DWMC D16 / Y4M)

Optional

Optional Transmission:

4-Speed Automatic Transmission (Aisin 81-40LE)

Features

Auto Transmission Features:

Aisin 81-40LE: Known for reliability and smooth shifting in smaller vehicle applications.

Manual Transmission Features:

DWMC D16/Y4M: Standard 5-speed manual for efficiency and driver engagement. Y4M variant includes synchronized and sliding elements for smoother gear changes.

📐 Dimensions

Exterior

Exterior Dimensions Notes:

Dimensions vary slightly between hatchback and notchback models. Specific measurements would require detailed spec sheets, but generally: Length: ~3.9m, Width: ~1.7m, Height: ~1.5m.

Weights

Curb Weight Notes:

Curb weight typically ranges from 1050 kg to 1150 kg depending on engine and equipment.

🛡️ Safety Features

Ratings

Safety Ratings Notes:

ANCAP (Australasian New Car Assessment Program) ratings vary by year and specific test. Early models may have lower ratings than later ones. Expect 3-4 stars for the TK generation. The manual would detail specific safety system diagnostics.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) - availability depends on trim level and options.

Passive Features

Passive Safety Features:

Front airbags for driver and passenger, potentially side airbags in higher trims, seatbelt pretensioners, collapsible steering column.

💡 Technology Features

Infotainment

Infotainment System:

Base models featured a standard AM/FM radio with CD player and auxiliary input. Higher trims may have offered more advanced head units with improved speaker systems. The manual covers basic operation, fuse locations, and potential troubleshooting for these systems.

Driver Assistance

Driver Assistance Features:

Limited by modern standards. Primarily focused on ABS and EBD. No advanced driver-assistance systems like adaptive cruise control or lane-keeping assist were typically available on this model.

Connectivity

Connectivity Features:

Basic connectivity via auxiliary input for audio playback. No Bluetooth or USB connectivity as standard on most trims of this era.

🔧 Maintenance

Service Intervals

Recommended Service Intervals:

Typical intervals include: Oil and filter change every 10,000-15,000 km or 12 months. Air filter, cabin filter, spark plugs every 30,000-60,000 km. Brake fluid flush every 2-3 years. Transmission fluid change every 60,000-100,000 km (depending on transmission type and driving conditions). Timing belt (if applicable, check specific engine) replacement around 90,000-120,000 km or 5-7 years. Consult manual for precise intervals.

Fluid Specifications

Engine Oil Specification:

Likely API SN/SM/SL or ILSAC GF-5, SAE 5W-30 or 10W-40. Check specific engine requirement in manual. (e.g., Mobil 1 5W-30 Advanced Fuel Economy).

Automatic Transmission Fluid:

Aisin Wide Range Automatic Transmission Fluid (ATF), typically Dexron III/VI compatible. Check manual for specific Aisin fluid type (e.g., Mobil ATF 3309).

Manual Transmission Fluid:

GL-4 or GL-5 gear oil, typically 75W-90 or 80W-90. Check manual for specific viscosity and API rating.

Coolant Specification:

Ethylene glycol based coolant with silicate inhibitors (Asian or universal type), typically a 50/50 mix with distilled water. Often referred to as 'long-life' coolant. (e.g., Valvoline Zerex Asian Blue).

Known Issues

Common Issues:

Potential issues may include: Early generation coil pack failures, minor oil leaks from valve cover gaskets or oil pan, occasional issues with automatic transmission shift solenoids, wear in suspension components (bushings, ball joints) due to urban driving, HVAC blower motor resistors failing.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Holden, an Australian automotive icon, has a long history of manufacturing and selling vehicles tailored for the Australian market. The Barina nameplate has been a significant part of their small car offering for decades.

Model Evolution

Model Evolution:

The TK Barina (2005-2011) represented a significant update, moving to the global GM Gamma II platform, which also underpinned vehicles like the Opel Corsa C and Chevrolet Aveo (T250/T255). This platform change brought a more modern design and improved dynamics compared to its predecessors.

Production

Production Location:

While often marketed as an Australian car, the TK Barina was largely manufactured in South Korea by GM Daewoo (later GM Korea) and imported into Australia.

🏆 Awards & Recognition

Recognitions

Awards And Recognitions:

The Holden Barina TK generally received moderate reviews, focusing on its value proposition and practicality. Specific major awards were not a defining characteristic, but it served as a popular choice for budget-conscious buyers and new drivers.