This manual covers the Chevrolet Kalos, produced from 2002 through 2011. Built on the GM T platform, shared with models like the Daewoo Gentra, the Kalos is a compact 5-door hatchback designed for efficient urban and everyday transportation. It was offered with 1.4L and 1.6L Ecotec 4-cylinder gasoline engines, delivering approximately 93-104 horsepower respectively, paired with either a 5-speed manual or a 4-speed automatic transmission. Known for its value proposition and practicality, the Kalos aimed to provide reliable transportation, with safety features including standard front airbags and optional ABS and side airbags on select trims. This comprehensive factory service manual provides detailed information for the maintenance, repair, and troubleshooting of your Chevrolet Kalos. It covers all major systems, including powertrain, chassis, body, and electrical components, offering step-by-step instructions, clear diagrams, and diagnostic procedures. Whether you are a DIY owner, an independent repair shop, or a professional mechanic, this manual is an invaluable resource for ensuring your vehicle remains in optimal condition. With over 2500 pages of content, it offers professional-grade repair information, enabling cost-effective upkeep and addressing common wear items and potential issues specific to the Kalos. 🏷️ Basic Information Identification Make: Chevrolet Model: Kalos Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 Codes Platform: GM T platform (shared with Daewoo Gentra/Lacetti Hatchback) 👋 Introduction Market Position Target Audience: DIY car owners, independent repair shops, professional mechanics Competitive Analysis Value Proposition: Provides professional-grade repair information at a fraction of the cost of dealership service or proprietary software, enabling cost-effective maintenance and repairs. Key Features Usability: Step-by-step instructions, clear text, high-quality diagrams, and exploded views ensure ease of use for various skill levels. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, maintenance, and repair Page Count Estimated Page Count: Over 2500 pages (typical for full service manuals of this scope) Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format File Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, cooling system, exhaust system, ignition system, engine management, transmission (manual and automatic), driveline, clutch Chassis: Suspension (front and rear), steering system, braking system, wheels and tires Body And Electrical: Body construction and materials, interior components, HVAC system, exterior lighting, interior lighting, power accessories (windows, locks, mirrors), instrumentation, audio system, wiring diagrams, fuses and relays, anti-theft system Procedures Included Maintenance Procedures: Fluid checks and changes, filter replacements, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation Repair Procedures: Component removal and installation, engine overhaul, transmission rebuild, brake caliper overhaul, suspension component replacement, steering rack replacement, wiring harness repair Troubleshooting: Diagnostic procedures, fault code interpretation (OBD-II), symptom-based diagnostics, electrical circuit testing, common problem diagnosis and solutions Technical Depth Technical Depth: Detailed, from basic maintenance to complete engine and transmission rebuilds, including diagnostic strategies and electrical schematics 📊 Manual Specifications File Format File Format Details: High-quality PDF, fully searchable text, zoomable diagrams and images Print Quality Printability: Full printable, allows users to print specific sections or the entire manual Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: 1.4L (X14XE/Z14XE), 1.6L (X16XE/Z16XE) Ecotec 4-cylinder gasoline engines Performance 1.4L Ecotec Horsepower: Approx. 94 PS (93 bhp; 69 kW) 1.6L Ecotec Horsepower: Approx. 105 PS (104 bhp; 77 kW) Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Engine Management ECU Type: GM Ecotec Engine Control Module (ECM) variants 🔧 Transmission Standard Transmission Type Standard: 5-speed manual transmission Optional Transmission Type Optional: 4-speed automatic transmission Features Transmission Fluid Type: Refer to manual for specific DEXRON fluid type (e.g., DEXRON III/VI for automatic, specific gear oil for manual) 📐 Dimensions Exterior Body Styles: 5-door hatchback Weights Curb Weight Range: Approx. 1050-1150 kg (2315-2535 lbs) depending on engine and equipment 🛡️ Safety Features Ratings Euroncap Rating: Typically 3 to 4 stars for models of this era, specific results vary by year and equipment (e.g., 2004 model received 4 stars) Active Features Braking System: Front ventilated discs, rear drums (standard); optional ABS (Anti-lock Braking System) Passive Features Airbags: Driver and front passenger airbags standard; optional side airbags on some trims 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player, optional auxiliary input or MP3 capabilities on later models Driver Assistance ABS Availability: Optional ABS on higher trim levels and later production years Connectivity Bluetooth Connectivity: Rarely standard, may have been an dealer-installed option or found on higher trim late models. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using synthetic oil (refer to manual for exact specification) Timing Belt Interval: Recommended replacement every 90,000 - 120,000 km (56,000 - 75,000 miles) or 5-7 years, depending on engine type (refer to manual for specific engine) Fluid Specifications Engine...