Holden Kalos - Service Manual - Repair Manual

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HOLDEN KALOS - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for vehicles Holden Kalos.


CONTENTS:

SECTION 00B
 
Section : 0b General Information
- Specifications
- Technical Data
- Vehicle Dimensions And Weights
- Standard Bolt Specifications
- Maintenance And Repair
- Maintenance And Lubrication
- Owner Inspections And Services
- Whle Operating The Vehicle
- At Each Fuel Fill
- At Least Monthly
- At Least Twice A Year
- Each Time The Oil Is Changed
- At Least Annually
- Recommended Fluids And Lubricants
- General Description And System Operation
- General Repair Instructions
- General Description
- Vehicle And Component Identification
- Vehicle Lifting Procedures

SECTION 01A
 
Section : 1a - General Engine Information
- Diagnosis
- Compression Test
- Oil Pressure Test
- Oil Leak Diagnosis
- Knock Diagnosis
- Noise Diagnosis
- General Information
- Cleanliness And Care
- On–Engine Service

SECTION 01B01
 
Section : 1b1 - 1.2 Sohc Engine Mechanical
- Specifications
- Engine Specifications
- Fastener Tightening Specifcations
- Special Tools
- Special Tools Table
- Component Locator
- Cylinder Head
- Engine Block
- Manifold & Air Flow System
- Timing Belt
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Cylinder Head And Valve Train
- Engine Block
- Crankshaft
- Connecting Rod
- Piston, Piston Ring And Piston Pin
- Timing Belt And Pulley
- Engine Mount
- Exhaust Gas Recirculation Valve

SECTION 01B02
 
Section : 1b2 - 1.4/1.5 Sohc Engine Mechanical
- Specifications
- Engine Specifications (1.4 Sohc)
- Engine Specifications (1.5 Sohc)
- Fastener Tightening Specifcations
- Special Tools
- Special Tools Table
- Component Locator
- Upper End
- Lower End
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Cylinder Head And Gasket
- Crankahaft
- Timing Belt
- Oil Pump
- Oil Pan
- Exhaust Manifold
- Intake Manifold
- Camshaft
- Exhaust Gas Recirculation Valve

SECTION 01D
 
Section : 1d - Engine Cooling
- Specifications
- Cooling System Specification
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Thermostat Test
- Surge Tank Cap Test
- Cooling Systen Diagnosis
- Component Locator
- Radiator/Fan (1.2 Sohc)
- Radiator/Fan (1.4/1.5 Sohc)
- Radiator/Fan (1.4 Dohc)
- Coolant Pump/Thermostat (1.2 Sohc)
- Coolant Pump/Thermostat (1.4/1.5 Sohc)
- Coolant Pump/Thermostat (1.4 Dohc)
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- General Description
- Radiator
- Surge Tank
- Coolant Pump
- Thermostat
- Electric Cooling Fan
- Coolant Temperature Sensor
- Engine Block Heater

SECTION 01E
 
Section : 1e - Engine Electrical
- Specifications
- Starter Specifications
- Generator Specifications
- Battery Specifications
- Fastener Tightening Specifications
- Schematic And Routing Diagrams
- Startimg System
- Charging System (1.4 Sohc/Dohc/1.5 Sohc)
- Charging System (1.2 Sohc)
- Component Locator
- Staring System (1.2 Sohc)
- Staring System (1.4 Sohc/Dohc/1.5 Sohc)
- Charging System (Valeo : Mando)
- Charging System (1.4 Sohc/Dohc/1.5 Sohc)
- Diagnosis
- No Crank
- Starter Motor Noise
- Battery Load Test
- Genrator Output Test
- Generator System Check
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Battery
- Ratings
- Reserve Capacity
- Cold Cranking Amperage
- Built – In Hydrometer
- Charging Procedure
- Charging Time Required
- Charging A Completely Discharged Battery (Off The Vehicle)
- Jump Starting Procedure
- Generator
- Charging System
- Starter
- Starting System

SECTION 01F
 
Section : 1f - Engine Controls
- Specifications
- Engine Data Display Tables
- Engine Data Display Table Definitions
- Fastener Tightening Specifications
- Fuel System Specifications
- Temperature Vs Resistance
- Schematic And Routing Diagrams
- Ecm Wiring Diagram (1.2l Sohc – 1 Of 7)
- Ecm Wiring Diagram (1.2l Sohc – 2 Of 7)
- Ecm Wiring Diagram (1.2l Sohc – 3 Of 7)
- Ecm Wiring Diagram (1.2l Sohc – 4 Of 7)
- Ecm Wiring Diagram (1.2l Sohc – 5 Of 7)
- Ecm Wiring Diagram (1.2l Sohc – 6 Of 7)
- Ecm Wiring Diagram (1.2l Sohc – 7 Of 7)
- Ecm Wiring Diagram (1.5l Sohc – 1 Of 6)
- Ecm Wiring Diagram (1.5l Sohc – 2 Of 6)
- Ecm Wiring Diagram (1.5l Sohc – 3 Of 6)
- Ecm Wiring Diagram (1.5l Sohc – 4 Of 6)
- Ecm Wiring Diagram (1.5l Sohc – 5 Of 6)
- Ecm Wiring Diagram (1.5l Sohc – 6 Of 6)
- Connector End View
- Component Locator
- Component Locator (1.2l Sohc)
- Component Locator (1.5l Sohc)
- Diagnosis
- System Diagnosis
- Trouble Code Diagnosis (1.2l Sohc)
- Trouble Code Diagnosis (1.5l Sohc)
- Symptom Diagnosis
- Important Preliminary Checks
- Intermittents
- Hard Start
- Surges Or Chuggles
- Lack Of Power, Sluggishness, Or Sponginess
- Detonation/Spark Knock
- Hesitation, Sag, Stumble
- Cuts Out, Misses
- Poor Fuel Economy
- Rough, Unstable, Or Incorrect Ldle, Stalling
- Excessive Exhaust Emissions Or Odors
- Dieseling, Run–On
- Backfire
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Ignition System Operation
- Electronic Ignition System Ignition Coil
- Crankshaft Position Sensor
- Camahaft Position Sensor
- Idle Air System Operation
- Fuel Control System Operation
- Oxygen Sensor (Unleaded Fuel Only)
- Co Adjuster (Leaded Fuel Only)
- Evaporative Emission Control System Operation
- Evaporative Emission Canister
- Positive Crankcase Ventilation System Operation
- Engine Coolant Temperature Sensor
- Throttle Position Sensor
- Exhaust Gas Recirculation Valve
- Intake Air Temperature Sensor
- Idle Air Control Valve
- Manifold Absolute Pressure Sensor
- Engine Control Module
- Fuel Injector
- Knock Sensor
- Comprehensive Component Monitor Diagnostic Operation

SECTION 01G
 
Section : 1g - Engine Exhaust
- Specifications
- Fastener Tightening Specifications
- Component Locator
- Exhaust System
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Exhaust System
- Muffler
- Catalytic Converters

SECTION 02A
 
Section : 2a - Suspension Diagnosis
- Diagnosis
- General Diagnosis
- Torque Steer
- Tapered Roller Bearing

SECTION 02B
 
Section : 2b - Wheel Alignment
- Specifications
- Wheel Alignment Specifications
- Difference Between Left And Right
- Fastener Tightening Specifications
- Diagnosis
- Tire Diagnosis
- Radial Tire Lead /Pull
- Vibration Diagnosis
- Preliminary Inspection
- Front Toe Adjustment
- Front Camber And Caster Check
- Rear Camber Check
- Rear Toe Check
- General Description And System Operation
- Four Wheel Alignment
- Toe
- Caster
- Camber
- Steering Axis Inclination
- Included Angle
- Scrub Radius
- Setback
- Turning Angle

SECTION 02C
 
Section : 2c - Front Suspension
- Specifications
- General Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Strut Dampener
- Ball Joint And Knuckle
- Excessive Friction Check
- Component Locator
- Front Suspension
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Front Suspension

SECTION 02D
 
Section : 2d - Rear Suspension
- Specifications
- Fastener Tightening Specifications
- Conponent Locator
- Rear Suspension
- Special Tools
- Special Tools Table
- Diagnosis
- Excessive Friction Test
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Rear Suspension

SECTION 02E
 
Section : 2e Tires And Wheels
- Specifications
- Tire Size And Pressure Specifications
- Inflation Pressure Conversion Pecifications
- Fastener Tightening Specifications
- Diagnosis
- Wheel Runout
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Tire And Wheel Balancing
- Replacement Tires
- Tire Chain Usage
- All Season Tires
- Inflation Of Tires
- Passenger Metric Sized Tires
- Tire Label
- Spare Tire
- Wheels

SECTION 04A
 
Section : 4a Hydraulic Brakes
- Specifications
- General Specifcations
- Fastener Tightening Specifications
- Component Locator
- Brake System (Abs)
- Brake System (Non–Abs)
- Diagnosis
- Brake System Testing
- Brake Hose Inspection
- Warning Lamp Operation
- Brake Lamp Warning Circuit Diagnosis
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Hydraulic Fluid

SECTION 04B
 
Section : 4b Master Cylinder
- Specifications
- Fastener Tightening Specifications
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Master Cylinder
- Proportioning Valves
- Fluid Level Sensor

SECTION 04C
 
Section : 4c Power Booster
- Specifications
- Fasrener Tightening Specifications
- Diagnosis
- Power Booster Functional
- Check
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Power Booster

SECTION 04D
 
Section : 4d Front Disc Brakes
- Specifications
- Fastener Tightening Specirications
- Diagnosis
- Lining Inspection
- Rotor Inspection
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Disc Brake Caliper Assembly

SECTION 04E
 
Section : 4e Rear Drum Brakes
- Diagnosis
- Lining Inspection
- Drums
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Drum Brakes
- Specifications
- Fastener Tightening Specifications

SECTION 04F
 
Section : 4f Antilock Brake System
- Specifications
- General Specifications
- Fastener Tightening Specifications
- Schematic And Routing Diagrams
- Abs System Circuit (I)
- Abs System Circuit (Ii)
- Electrical Schematic
- Hecu Harness Connector End View And Pin Layout
- Hydraulic Diagram
- Component Locator
- Abs System
- Diagnosis
- Diagnostic Trouble Code And Description
- Diagnostic Circuit Check
- No Communication With Hecu
- Abs Warning Lamp Inoperative/No Dtc Set
- Abs Warning Lamp On/No Dtc Set
- Brake Warning Lamp On
- Brake Warning Lamp Inoperative/No Dtc Set
- C1101 Battery Voltage Too High
- C1102 Battery Voltage Too Low
- C1200 Left Front Wheel Speed Sensor Circuit Open Or Shorted
- C1201 Left Front Wheel Speed Excessive Variation
- C1202 Left Front Wheel Speed Sensor No Signal
- C1203 Right Front Wheel Speed Sensor Circuit Open Or Shorted
- C1204 Right Front Wheel Speed Excessive Variation
- C1205 Right Front Wheel Speed Sensor No Signal
- C1206 Left Rear Wheel Speed Sensor Circuit Open Or Shorted
- C1207 Left Rear Wheel Speed Excessive Variation
- C1208 Left Rear Wheel Speed Sensor No Signal
- C1209 Right Rear Wheel Speed Sensor Circuit Open Or Shorted
- C1210 Right Rear Wheel Speed Excessive Variation
- C1211 Right Rear Wheel Speed Sensor No Signal
- C1604 Hecu Internal Fault
- C2112 Valve Relay Or Fuse Failure
- C2402 Pump Motor Failure
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- General System Description
- Basic Knowledge Required
- Abs System Components
- Base Braking Mode
- Antilock Braking Mode – Apply
- Antilock Braking Mode – Hold
- Antilock Braking Mode – Release
- Ddrp (De–Coupled Dynamic Rear Proportioning)
- Ddrp (De–Coupled Dynamic Rear Proportining) Failure Modes
- Hecu (Hydraulic Electronic Control Unit)
- Solenoid Relay
- Wheel Speed Sensors And Rings
- Abs Warning Lamp (Amber)
- Brake Warning Lamp (Red)

SECTION 04G
 
Section : 4g Parking Brake
- Specifications
- Fastener Tightening Specifications
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Parking Brake

SECTION 05A
 
Section : 5a Aisin Automatic Transaxle
- Specifications
- General Specifications
- Transaxle Gear Ratio
- Fluid Capacity
- Line Pressure Specification
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Schematic Diagrams
- Transmission Control Module (1of 4)
- Transmission Control Module (2 Of 4)
- Transmission Control Module (3 Of 4)
- Transmission Control Module (4 Of 4)
- Shift Mode Diagram
- Component Locator
- Shift Select Control
- Automatic Transaxle Components
- Bearing And Races Installation Position And Direction
- Diagnosis
- Electric Connector View
- Wiring Harness And Connector Inspection
- Function Check
- Unit Inspection
- On–Vehicle Repair (Matrix Chart)
- Diagnostic Trouble Code Diagnosis
- Diagnostic Trouble Code Chart
- Dtc P0562 System Voltage Low
- Dtc P0563 System Voltage High
- Dtc P0604 Internal Transmission Control Module (Tcm) Random Access Memory Error
- Dtc P0705 Park/Neutral Position Switch Circuit Malfunction
- Dtc P0712 Transmission Fluid Temperature (Tft) Sensor Circuit Low Input
- Dtc P0713 Transmission Fluid Temperature (Tft) Sensor Circuit High Input
- Dtc P0717 Input Shaft Speed (Iss) Sensor Circuit No Signal
- Dtc P0722 Ouput Shaft Speed (Oss) Sensor Circuit No Signal
- Dtc P0727 Engine Speed Input Circuit No Signal
- Dtc P0741 Torque Converter Clutch (Tcc) Citcuit Stuck Off
- Dtc P0742 Torque Converter Clutch (Tcc) Citcuit Stuck On
- Dtc P0743 Torque Converter Clutch (Tcc) Electrical
- Dtc P0748 Pressure Control Solenoid (Pcs) Electrical
- Dtc P0751 Shift Solenoid 1 (Ss1) Stuck Off
- Dtc P0753 Shift Solenoid 1 (Ss1) Electrical
- Dtc P0756 Shift Solenoid 2 (Ss2) Stuck Off
- Dtc P0758 Shift Solenoid 2 (Ss2) Electrical
- Dtc P1701 Engine Coolant Temperature (Ect) Signal Error
- Dtc P1702 Engine Torque Signal Error
- Dtc P1710 Timing Solenoid (St) Electrical
- Dtc P1790 Internal Transmission Control Module (Tcm) Random Access Memory (Ram) Checksum Error
- Dtc P1791 Throttle Position Signal Error
- Dtc U2105 Can Error
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Transaxle Description
- Electronical Components
- Hydraulic Control System
- Automatic Transaxle System

SECTION 05B01
 
Section : 5b1 Five-Speed Manual Transaxle (D16)
- Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Isolate Noise
- Symptom Diagnosis
- Component Locators
- Gears And Case
- Bearing Plate
- Differential Gear
- Shift Linkage
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Five–Speed Manual Transaxle

SECTION 05B02
 
Section : 5b2 Five-Speed Manual Transaxle (Y4m)
- Specifications
- General Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- General Diagnosis
- Checking Fluid Level
- Changing Fluid
- Checking Transaxle Noise
- Checking Bearing Noise
- Component Locators
- Gear Shift Control
- Input Shaft And Counter Shaft Gear
- Gear Shift Fork
- Differential And Case
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Five–Speed Manual Transaxle
- Reverse Gear Misshift Preventing Mechanism
- Differential

SECTION 05C01
 
Section : 5c1 Clutch (Hydraulic Type)
- Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Clutch Operation
- Component Locator
- Hydraulic Clutch
- Clutch Pedal
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Driving Members
- Driven Members
- Operating Members

SECTION 05C02
 
Section : 5c2 Clutch (Cable Type)
- Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- General Diagnosis
- Clutch Pedal Operation
- Clutch Cable Adjustment
- Clutch Cable
- Component Locator
- Clutch Components
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Driving Members
- Driven Members
- Operating Members

SECTION 06A
 
Section : 6a Power Steering System
- Specifications
- Fastener Tighteming Specifications
- Special Tools
- Special Tools Table
- Component Locator
- Rack And Pinion Steering Gear
- Power Steering System
- Diagnosis
- Power Steering System Pressure Test
- Power Steering System Leak Test
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Power Steering System

SECTION 06B
 
Section : 6b Power Steering Pump
- Specifications
- General Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Power Steering Pump Diagnosis
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Power Steering Pump
- Seals

SECTION 06C
 
Section : 6c Power Steering Gear
- Specifications
- General Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Power Rack And Pinion Steering Gear
- Power Rack And Pinion Steering Gear Bench Testing
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Power Rack And Pinion

SECTION 06D
 
Section : 6d Manual Steering Gear
- Specifications
- General Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Manual Rack And Pinion Steering Gear
- Straight–Ahead Check
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Manual Rack And Pinion

SECTION 06E
 
Section : 6e Steering Wheel And Column
- Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Diagnosis
- Steering Column Diagnosis
- Maintenance And Repair
- On–Vehicle Service
- Unit Repair
- General Description And System Operation
- Steering Wheel And Column

SECTION 07A
 
Section : 7a Heating And Ventilation System
- Specifications
- Heater Temperature Specifications
- Fastener Tightening Specifications
- Schematic And Routing Diagrams
- Non–A/C Diagrams
- Airflow Through Vents With Rear Heating Duct*
- Diagnosis
- Heater System
- Insufficient Heating Or Defrosting
- Blower Electrical
- Improper Air Delivery Or No Mode Shift
- Too Much Heat
- Controls
- Blower Noise
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Heating And Ventilation Systems

SECTION 07B
 
Section : 7b Manual Control Heating, Ventilation And Air Conditioning System
- Specifications
- General Specifications (V5 System)
- General Specifications (Sp10 System)
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Schematic And Routing Diagrams
- A/C Refrigerant System (Typical)
- A/C Airflow (Typical)
- A/C Schematic
- Diagnosis
- General Diagnosis
- Air Conditioning System Diagnosis
- Symptom Diagnosis
- Component Locator
- V5 Compressor
- Sp10 Compressor
- Maintenance And Repair
- On–Vehicle Service
- General A/C System Service Procedures
- Serviceable Components
- Unit Repair
- V5 Air Conditioning Compressor Overhaul
- Sp10 Air Conditioning Compressor Overhaul
- General Description And System Operation
- General Information

SECTION 08A
 
Section : 8a Seat Belts
- Specifications
- Fastener Tightening Specifications
- Schematic And Routing Diagrams
- Driver Seat Belt Warning
- Diagnosis
- Seat Belt Warning Lamp Is Inoperative
- Maintenance And Repair
- On–Vehicle Service
- General Description And System Operation
- Operational And Functional Checks
- Driver Seat Belt Warning
- Three–Point Elr Front Seat Belt
- Three–Point Clr Seat Belt
- Two–Point Lap Rear Center Seat Belt

SECTION 08B
 
Section : 8b Supplemental Inflatable Restraints (Sir)
- Specifications
- General Specifications
- Fastener Tightening Specifications
- Special Tools
- Special Tools Table
- Schematic And Routing Diagrams

AND MORE......