2004-2010 Chevrolet Kalos Service & Repair Manual

KALOS SECTION 0B GENERAL INFORMATION SPECIFICATIONS Technical Data Performance - Manual Transaxle Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Maximum Speed 157 km/h (97.6 mph) - EURO III 156 km/h (96.9 mph) - EURO III 170 km/h (105.6 mph) 176 km/h (109.4 mph) Minimum Turning Radius 4.8 m (15.7 ft) 4.8 m (15.7 ft) 4.8 m (15.7 ft) Performance - Automatic Transaxle Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Maximum Speed 153 km/h (95.1 mph) - 170 km/h (105.6 mph) Minimum Turning Radius 4.8 m (15.7 ft) - 4.8 m (15.7 ft) Engine Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Engine Type Overhead Cam L-4 ← ← Bore 68.5 mm (2.70 in.) 77.9 mm (3.06 in.) ← Stroke 78.0 mm (3.07 in.) 73.4 mm (2.89 in.) ← Total Displacement 1150 cc (70.2 in.³) 1399 cc (85.4 in³) ← Compression Ratio 9.3 : 1 9.5 : 1 ← Maximum Power 53 kw (71.1 hp) (at 5,400 rpm) 61 kw (81.8 hp) (at 5,600 rpm) 69 kw (92.5 hp) (at 6,200 rpm) Maximum Torque 104 N•m (76.7 lb-ft) (at 4,400 rpm) 123 N•m (90.7 lb-ft) (at 3,000 rpm) 130 N•m (95.9 lb-ft) (at 3,400 rpm) Ignition System Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Ignition Type Direct Ignition System ← ← Ignition Timing (BTDC) 1° (at 800 rpm) 10° 4° Ignition Sequence 1-3-4-2 ← ← Spark Plug Gap 1.0 ~ 1.1 mm (0.039 ~ 0.043 in.) 0.7 ~ 0.8 mm (0.028 ~ 0.031 in.) 1.0 ~ 1.1 mm (0.039 ~ 0.043 in.) Spark Plug Maker Woojin Champion NGK Spark Plug Type BPR5EY-11 RN9YC BKR6E-11 Clutch Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Type Single Dry Plate ← ← Outside Diameter 184 mm (7.2 in.) 215 mm (8.5 in.) ← Inside Diameter 127.5 mm (5.0 in.) 145 mm (5.7 in.) ← Thickness 8.4 mm (0.331 in.) ← ← Fluid Common Use: Brake Fluid ← ← Manual Transaxle Application 1.2L SOHC 1.4L SOHC Wide Ratio 1.4L DOHC Semi-Wide Ratio Maker DWMC DWMC DWMC Type or Model Y4M D-16 ← Gear Ratio : . . . 1st 2nd 3rd 4th 5th Reverse 3.416 : 1 1.950 : 1 1.280 : 1 0.971 : 1 0.757 : 1 3.272 : 1 3.545 : 1 1.952 : 1 1.276 : 1 0.892 : 1 0.707 : 1 3.333 : 1 3.545 : 1 1.952 : 1 1.276 : 1 0.971 : 1 0.763 : 1 3.333 : 1 Final Drive Ratio 4.105 : 1 4.176 : 1 3.944 : 1 Oil Capacity 2.1L (2.2 qt) 1.8L (2 qt) 1.8L (2 qt)

Automatic Transaxle Application 1.2L SOHC 1.4L DOHC Semi-Wide Ratio Maker - AISIN Type or Model - 81-40LE Gear Ratio : . . 1st 2nd 3rd 4th Reverse - - - - - 2.875 : 1 1.568 : 1 1.000 : 1 0.697 : 1 2.300 : 1 Final Drive Ratio - 4.052 Oil Capacity - 5.9 ± 0.2L (6.2 ± 0.2 qts) Brake Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Booster Size 241.3 mm (9.5 in.) ← ← Master Cylinder Diameter 22.22 mm (0.875 in.) ← ← Booster Ratio 5 : 1 ← ← Front Brake : . . . Disc Type Disc Size Ventilated 236 mm (9.29 in.) ← ← ← ← Rear Brake : . . . Drum Inside Diameter Wheel Cylinder Diameter 200 mm (7.9 in.) 19.05 mm (0.750 in.) ← ← ← ← Fluid Capacity 0.5L (0.5 qt) ← ← Tire and Wheel Application 1.2 L SOHC / 1.4L SOHC / 1.4L DOHC Tire Size 155/80R13 175/70R13 185/60R14 Standard Wheel Size 5.0Jx13 (steel) ← 5.5Jx14 (steel) Optional Wheel Size - - 5.5Jx14 (Aluminum) Inflation Pressure at Full Load: . 155/80R13/175/70R13, 185/60R14 30 psi Steering System Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Gear Type Power Rack and Pinion ← ← Overall Gear Ratio . . . Manual Steering Power Steering 21.5 : 1 16 : 1 ← ← ← ← Wheel Diameter . . . W/ Air Bag W/O Air Bag 380 mm (15.0 in.) 370 mm (14.5 in.) ← ← ← ← Wheel Alignment : (Based on 2 Occupants) Front : . . . Toe-In Caster Camber 2' ± 10' 2°30' ± 45' -24' ± 45' ← ← ← ← ← ← Rear : Toe-In Camber 15' ± 20' -1°30' ± 30' ← ← ← ← Oil Capacity 1.1L (1.2 qt) ← ← Suspension Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Front Type Macpherson Strut ← ← Rear Type Torsion Beam Axle ← ← Fuel System Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Fuel Delivery MPI ← ← Fuel Pump Type Electric Motor Pump ← ← Fuel Filter Type Cartridge ← ← Fuel Capacity 45L (11.9 gal) ← ← Lubricating System

Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Lubricating Type Forced Feed ← ← Oil Pump Type Rotary (Trochoid) ← ← Oil Filter Type Cartridge (Full Flow) ← ← Oil Pan Capacity . . . Including Oil Filter 3.2L (3.4 qt) 3.75L (3.96 qt) ← Cooling System Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Cooling Type Forced Water Circulation ← ← Radiator Type Cross-flow ← ← Water Pump Type Centrifugal ← ← Thermostat Type Pellet Type ← ← Coolant Capacity : . . . Standard Heavy Duty 4.2L (4.4 qt) 4.2L (4.4 qt) 6.0L (6.3 qt) 6.0L (6.3 qt) ← ← Electric System Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Battery 430 Cold Cranking Amps 550 Cold Cranking Amps ← Alternator 75 Amps 85 Amps ← Starter (No-Load Test Current Draw) 0.8 KW Maximum 53 Amps (at 11.5 volts) 5,000 rpm Min. 1.2 KW Maximum 90 Amps (at 11.5 volts) 2,600 rpm Min. ← Vehicle Dimensions and Weights Vehicle Dimensions Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Overall Length : . . . 4 Door 5 Door 4,235 mm (166.7 in.) 3,880 mm (152.6 in.) ← ← ← ← Overhang : Front : . . . 4 Door 5 Door 813 mm (32.0 in.) 813 mm (32.0 in.) ← ← ← ← Rear : 4 Door 5 Door 942 mm (37.1 in.) 587 mm (23.1 in.) ← ← ← ← Overall Width 1,670 mm (65.7 in.) ← ← Overall Height 1,495 mm (58.9 in.) ← ← Minimum Ground Clearance 150 mm (5.9 in.) ← ← Wheel Base 2,480 mm (97.6 in.) ← ← Tread : . . . Front Rear 1,450 mm (57.1 in.) 1,410 mm (55.1 in.) ← ← ← ← Vehicle Weights – 4 Door Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Manual : Curb Weight : . . . Standard Optional 960 kg (2,116.4 lb) 1,025 kg (2,259.7 lb) 995 kg (2,193.6 lb) 1,060 kg (2,336.9 lb) 1,030 kg (2,270.8 lb) 1,095 kg (2,414.1 lb) Gross Vehicle Weight 1,455 kg (3,207.7 lb) 1,500 kg (3.306.9 lb) 1,535 kg (3,384.1 lb) Automatic : Curb Weight : . . . Standard Optional - - - - 1,035 kg (2,281.8 lb) 1,100 kg (2,425.1 lb) Gross Vehicle Weight - - 1,540 kg (3,395.1 lb) Passenger Capacity - 5 ← Vehicle Weights – 5 Door Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Manual : Curb Weight : . . . Standard Optional 960 kg (2,116.4 lb) 1,025 kg (2,259.7 lb) 995 kg (2,193.6 lb) 1,060 kg (2,336.9 lb) 1,030 kg (2,270.8 lb) 1,095 kg (2,414.1 lb) Gross Vehicle Weight 1,455 kg (3,207.7 lb) 1,500 kg (3,306.9 lb) 1,535 kg (3,384.1 lb) Automatic : Curb Weight : . . .

Application 1.2L SOHC 1.4L SOHC 1.4L DOHC Standard Optional 980 kg (2,161 lb) 1,040 kg (2,292.8 lb) - - 1,035 kg (2,281.8 lb) 1,100 kg (2,425.1 lb) Gross Vehicle Weight - - 1,540 kg (3,395.1 lb) Passenger Capacity 5 ← ← Optional Weight : ABS, Sun Roof, A/C Standard Bolt Specifications Bolt* 4T - Low Carbon Steel 7T - High Carbon Steel 7T - Alloy Steel M6 X 1.0 4.1-8.1 N•m (36-72 lb-in) 5.4-9.5 N•m (48-84 lb-in) - M8 X 1.25 8.1-17.6 N•m (72-156 lb-in) 12.2-23.0 N•m (108-204 lb-in) 16-30 N•m (12-22 lb-ft) M10 X 1.25 20-34 N•m (15-25 lb-ft) 27-46 N•m (20-34 lb-ft) 37-62 N•m (27-46 lb-ft) M10 X 1.5 19-34 N•m (14-25 lb-ft) 27-45 N•m (20-33 lb-ft) 37-60 N•m (27-44 lb-ft) M12 X 1.25 49-73 N•m (36-54 lb-ft) 61-91 N•m (45-67 lb-ft) 76-114 N•m (56-84 lb-ft) M12 X 1.75 45-69 N•m (33-51 lb-ft) 57-84 N•m (42-62 lb-ft) 72-107 N•m (53-79 lb-ft) M14 X 1.5 76-115 N•m (56-85 lb-ft) 94-140 N•m (69-103 lb-ft) 114-171 N•m (84-126 lb-ft) M14 X 2.0 72-107 N•m (53-79 lb-ft) 88-132 N•m (65-97 lb-ft) 107-160 N•m (79-118 lb-ft) M16 X 1.5 104-157 N•m (77-116 lb-ft) 136-203 N•m (100-150 lb-ft) 160-240 N•m (118-177 lb-ft) M16 X 2.0 100-149 N•m (74-110 lb-ft) 129-194 N•m (95-143 lb-ft) 153-229 N•m (113-169 lb-ft) M18 X 1.5 151-225 N•m (111-166 lb-ft) 195-293 N•m (144-216 lb-ft) 229-346 N•m (169-255 lb-ft) M20 X 1.5 206-311 N•m (152-229 lb-ft) 270-405 N•m (199-299 lb-ft) 317-476 N•m (234-351 lb-ft) M22 X 1.5 251-414 N•m (185-305 lb-ft) 363-544 N•m (268-401 lb-ft) 424-636 N•m (313-469 lb-ft) M24 X 2.0 359-540 N•m (265-398 lb-ft) 431-710 N•m (318-524 lb-ft) 555-831 N•m (409-613 lb-ft) * Diameter X pitch in millimeters MAINTENANCE AND REPAIR MAINTENANCE AND LUBRICATION Normal Vehicle Use The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: To carry passengers and cargo within the limitation indicated on the tire placard located on the edge of the driver's door. To be driven on reasonable road surfaces and within legal operating limits. Explanation of Scheduled Maintenance Services The services listed in the maintenance schedule are further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants. Drive Belt Inspection When a separate belt drives the power steering pump, the air conditioning compressor and the generator, inspect it for cracks, fraying, wear and proper tension. Adjust or replace the belt as needed. Engine Oil and Oil Filter Change API Classifications of Engine Oil The International Lubricant Standardization and Approval Committee (ILSAC) and American Petroleum Institute classifies engine oils according to their performance quality. Always use oil rated API-SL (ILSAC GF-III) or better. Engine Oil Viscosity Engine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold weather performance; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. Using oils of any viscosity other than those viscosities recommended could result in engine damage.

Cooling System Service Drain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section. Fuel Micro-Filter Replacement Replace the engine fuel filter every 45,000 km (30,000 miles). Air Cleaner Element Replacement Replace the air cleaner element every 45,000 km (27,000 miles). Replace the air cleaner more often under dusty conditions. Throttle Body Mounting Bolt Torque Check the torque of the mounting bolts. Tighten the throttle body mounting bolts to 15 N•m (11 lb-ft) if necessary. Spark Plug Replacement Replace spark plugs with the same type. Spark Plug Wire Replacement Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the DIS module and at the spark plugs. Replace the wires as needed. Brake System Service Check the disc brake pads and the drum brake linings every 15,000 km (10,000 miles) or 12 months. Check the pad and the lining thickness carefully. If the pads or the linings are not expected to last to the next scheduledmaintenance service, replace the pads or the linings. Check the breather hole in the brake fluid reservoir cap to be sure it is free from dirt and the passage is open. Transaxle Service The manual transaxle fluid does not require changing. For automatic transaxles, refer to "Scheduled Maintenance Charts" in this section. Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Refer to "Each Time The Oil Is Changed" in this section. Tire Rotation Scheduled Maintenance Charts Engine Maintenance Item Maintenance Interval . Kilometers or time in months, whichever comes first x 1,000 km 15 30 45 60 75 90 105 120 x 1,000 miles 10 20 30 40 50 60 70 80 Months 12 24 36 48 60 72 84 96 Drive belts (Alternator, power steering and A/C belt) - 1.4 S/D I I I I Drive Belt (Alternator) - 1.2 S I I R I I R I I Drive Belt (Power Steering, A/C) - 1.2 S I I I I R I I I Engine oil & engine oil filter (1) (3) R R R R R R R R Cooling system hose & connections I I I I I I I I Engine coolant (3) I I R I I R I I

2004-2010 Chevrolet Kalos Service & Repair Manual

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