KALOS
Body Repair Manual
0. SERVICE NOTICE
1. GENERAL INFORMATION
2. PREPARATIONS OF BODYWORK
3. WELDING AND TOOLS
4. FRONT
5. ROOF, BACK PANEL AND REAR FLOOR PANEL
6. FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER
7. FENDER, HOOD, TAILGATE AND TRUNK LID
8. BODY DIMENSION
9. SEALING, CAULKING AND DEADNER
10. RUST PREVENTION
11. BODY-FRAME REPAIR EQUIPMENT
Electrical Wiring Diagrams
LHD - Left-Hand Drive
1. HOW TO READ ELECTRICAL WIRING DIAGRAM
2. POSITION OF CONNECTORS AND GROUNDS
3. WIRING DIAGRAM FOR POWER SUPPLIES
4. USAGE AND CAPACITY OF FUSES IN FUSE BLOCK
5. ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM
2. ECM (ENGINE CONTROL MODULE) : MR - 140
3. ECM (ENGINE CONTROL MODULE) : HV - 240
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D4
5. TCM (TRANSMISSION CONTROL MODULE)
6. AIR CONDITIONER
7. RADIATOR COOLING FAN
8. HEAD LAMP & HEAD LAMP LEVELING DEVICE (HLLD) CIRCUIT
9. DRL (DAY TIME RUNNING LIGHT) CIRCUIT
10. ILLUMINATION
11. FRONT & REAR FOG LAMP CIRCUIT
12. HAZARD & TURN SINGNAL LAMP CIRCUIT
13. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL) & REVERSE LAMP CIRCUIT
14. HORN, CIGAR LIGHTER & POWER JACK CIRCUIT
15. LAMPS (ROOM, TRUNK ROOM, DOOR OPENING WARNING) CIRCUIT
16. CHIME BELL, SEAT BELT & KEY REMIND SWITCH CIRCUIT
17. WIPER CIRCUIT
18. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM CIRCUIT
19. ELECTRIC OSRV (OUTSIDE REAR VIEW) MIRROR CIRCUIT
20. POWER WINDOW CIRCUIT
21. CENTRAL DOOR LOCKING SYSTEM CIRCUIT
22. CLUSTER
23. CLOCK
24. AUDIO CIRCUIT
25. ANTI LOCK BRAKE SYSTEM (ABS)
26. AIR BAG (SDM : SENSING & DIAGNOSTIC MODULE)
27. SUN ROOF CIRCUIT
28. IMMOBILIZER SYSTEM CIRCUIT
29. ANTI-THEFT CONTROL SYSTEM CIRCUIT
30. BATTERY SAVER CIRCUIT
RHD - Right-Hand Drive
1. HOW TO READ ELECTRICAL WIRING DIAGRAM
2. POSITION OF CONNECTORS AND GROUNDS
3. WIRING DIAGRAM FOR POWER SUPPLIES
4. USAGE AND CAPACITY OF FUSES IN FUSE BLOCK
5. ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM
2. ECM (ENGINE CONTROL MODULE) : MR - 140
3. ECM (ENGINE CONTROL MODULE) : HV - 240
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D4
5. TCM (TRANSMISSION CONTROL MODULE)
6. AIR CONDITIONER
7. RADIATOR COOLING FAN CIRCUIT
8. HEAD LAMP & HEAD LAMP LEVELING DEVICE (HLLD) CIRCUIT
9. ILLUMINATION
10. FRONT & REAR FOG LAMP CIRCUIT
11. HAZARD & TURN SIGNAL LAMP CIRCUIT
12. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL) & REVERSE LAMP CIRCUIT
13. HORN, CIGAR LIGHTER & POWER JACK CIRCUIT
14. LAMPS (ROOM, TRUNK ROOM & DOOR OPENING WARNING) CIRCUIT
15. CHIME BELL, SEAT BELT & KEY REMIND SWITCH CIRCUIT
16. WIPER CIRCUIT
17. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM CIRCUIT
18. ELECTRIC OSRV (OUTSIDE REAR VIEW) MIRROR CIRCUIT
19. POWER WINDOW CIRCUIT
20. CENTRAL DOOR LOCKING SYSTEM CIRCUIT
21. CLUSTER
22. CLOCK
23. AUDIO CIRCUIT
24. ANTI LOCK BRAKE SYSTEM (ABS)
25. AIR BAG (SDM : SENSING & DIAGNOSTIC MODULE)
26. SUN ROOF CIRCUIT
27. IMMOBILIZER SYSTEM CIRCUIT
28. ANTI-THEFT CONTROL SYSTEM CIRCUIT
29. BATTERY SAVER CIRCUIT
Labour Time Guide
0. General Information
1. Engine
SOHC ENGINE MECHANICAL
DOHC ENGINE MECHANICAL
ENGINE COOLING
ENGINE ELECTRICAL
ENGINE CONTROLS
ENGINE INTAKE & EXHAUST
2. Suspension
FRONT SUSPENSION
REAR SUSPENSION
TIRES & WHEEL
3. Driveline Axle
4. Brakes
HYDRAULIC BRAKE
MASTER CYLINDER & POWER BOOSTER
FRONT BRAKES
REAR BRAKES
ANTI-LOCK BRAKES SYSTEM
PARKING BRAKES
5. Transmissions/Transaxle
ZF 16HP AUTO TRANSAXLE
AISIN AUTO TRANSAXLE
FIVE-SPEED MANUAL TRANSAXLE: D16, D20
FIVE-SPEED MANUAL TRANSAXLE: Y4M
CLUTCH
6. Steering
POWER STEERING SYSTEM
MANUAL STEERING GEAR
STEERING WHEEL & COLUMN
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING & VENTILATION
HVAC CONTROL
8. Restraints
SEAT BELTS
RESTRAINTS S. I. R (SUPPLEMENTAL INFLATABLE RESTRAINTS)
9. Body and Accessories
BODY WIRING SYSTEM
LIGHTING SYSTEM
WIPER/WASHER SYSTEM
INSTRUMENT DRIVER SYSTEM
AUDIO & ANTI-THEFT SYSTEM
INTERIOR TRIM
SEATS
GLASS & MIRRORS
EXTERIOR PARTS
BUMPERS & FASCIAS
DOORS
ROOF
BODY FRONT END
BODY REAR END
10. Paint
Pre-delivery Inspection
FOREWORD
GENERAL INTRODUCTION
ENGINE COMPARTMENT
BODY - ACCESSORIES
UNDER VEHICLE
ROAD TEST
APPEARANCE
ANNEX
Service Manual
0. General Information
1. Engine
GENERAL ENGINE INFORMATION
1.2 SOHC ENGINE MECHANICAL
SPECIFICATIONS
SPECIAL TOOLS
COMPONENT LOCATOR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Oil Pump
Oil Pan
Engine Mount
Intake Manifold
Exhaust Manifold
Engine
UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
1.4/1.5 SOHC ENGINE MECHANICAL
SPECIFICATIONS
SPECIAL TOOLS
COMPONENT LOCATOR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Oil Pump
Oil Pan
Engine Mount
Intake Manifold
Exhaust Manifold
Camshaft Gear
Rear Timing Belt Cover
Engine
Pistons and Rods
UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
DOHC ENGINE MECHANICAL
SPECIFICATIONS
SPECIAL TOOLS
COMPONENT LOCATOR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Oil Pump
Oil Pan
Engine Mount
Intake Manifold
Exhaust Manifold
Camshaft Gears
Rear Timing Belt Cover
Engine
Pistons and Rods
UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
ENGINE COOLING
ENGINE ELECTRICAL
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
COMPONENT LOCATOR
DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
ENGINE CONTROLS
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
COMPONENT LOCATOR
DIAGNOSIS
SYSTEM DIAGNOSIS
Diagnostic Aids
Idle Learn Procedure
TEC (TOOTH ERROR CORRECTION) Learn Procedure
ON-Board Diagnostic (EOBD) System Check (1.2L SOHC)
ON-Board Diagnostic (EOBD) System Check (1.4L SOHC/DOHC)
Multiple ECM Information Sensor DTCs Set
Engine Cranks But Will Not Run (1.2L SOHC)
Engine Cranks But Will Not Run (1.4L SOHC/DOHC)
No Malfunction Indicator Lamp (1.2L SOHC)
No Malfunction Indicator Lamp (1.4L SOHC/DOHC)
Malfunction Indicator Lamp On Steady (1.2L SOHC)
Malfunction Indicator Lamp on Steady (1.4L SOHC/DOHC)
Fuel System Diagnosis
Fuel Pump Relay Circuit Check (1.2L SOHC)
Fuel Pump Relay Circuit Check (1.4L SOHC/DOHC)
Main Relay Circuit Check (1.2L SOHC)
Manifold Absolute Pressure Check (1.2L SOHC)
Manifold Absolute Pressure Check (1.4L SOHC/DOHC)
Idle Air Control System Check (1.2L SOHC)
Idle Air Control System Check (1.4L SOHC/DOHC)
Ignition System Check (1.2L SOHC)
Ignition System Check (1.4L SOHC/DOHC)
Engine Cooling Fan Circuit Check - Single Fan (1.2L SOHC)
Engine Cooling Fan Circuit Check - Single Fan (1.4L SOHC/DOHC)
Data Link Connector Diagnosis (1.2L SOHC)
Data Link Connector Diagnosis (1.4L SOHC/DOHC)
Fuel Injector Balance Test
TROUBLE CODE DIAGNOSIS (1.2L SOHC)
Clearing Trouble Codes
Diagnostic Trouble Codes (1.2L SOHC)
DTC P0107
DTC P0108
DTC P0112
DTC P0113
DTC P0117
DTC P0118
DTC P0122
DTC P0123
DTC P0131
DTC P0132
DTC P0133
DTC P0135
DTC P0137
DTC P0138
DTC P0140
DTC P0141
DTC P0171
DTC P0172
DTC P0222
DTC P0223
DTC P0261
DTC P0262
DTC P0264
DTC P0265
DTC P0267
DTC P0268
DTC P0270
DTC P0271
DTC P0300
DTC P0327
DTC P0335
DTC P0336
DTC P0337
DTC P0341
DTC P0342
DTC P0351
DTC P0352
DTC P0400
DTC P0404
DTC P0405
DTC P0406
DTC P0420
DTC P0444
DTC P0445
DTC P0462
DTC P0463
DTC P0480
DTC P0481
DTC P0501
DTC P0510
DTC P0562
DTC P0563
DTC P0601
DTC P0604
DTC P0605
DTC P0656
DTC P1230
DTC P1231
DTC P1320
DTC P1321
DTC P1382
DTC P1385
DTC P1402
DTC P1403
DTC P1404
DTC P1511
DTC P1512
DTC P1513
DTC P1537
DTC P1538
DTC P1610
DTC P1611
DTC P1628
DTC P1629
DTC P1660
DTC P1661
TROUBLE CODE DIAGNOSIS (1.4 SOHC/DOHC)
Clearing Trouble Codes
Diagnostic Trouble Codes (1.4 SOHC/DOHC)
DTC P0106
DTC P0107
DTC P0108
DTC P0112
DTC P0113
DTC P0117
DTC P0118
DTC P0122
DTC P0123
DTC P0131
DTC P0132
DTC P0133
DTC P0134
DTC P0135
DTC P0137
DTC P0138
DTC P0140
DTC P0141
DTC P0171
DTC P0172
DTC P0201
DTC P0202
DTC P0203
DTC P0204
DTC P0300
DTC P0301
DTC P0302
DTC P0303
DTC P0304
DTC P0317
DTC P0325
DTC P0327
DTC P0336
DTC P0337
DTC P0341
DTC P0342
DTC P0351
DTC P0352
DTC P0401
DTC P0402
DTC P0404
DTC P0405
DTC P0406
DTC P0420
DTC P0443
DTC P0461
DTC P0462
DTC P0463
DTC P0502
DTC P0506
DTC P0507
DTC P0532
DTC P0533
DTC P0562
DTC P0563
DTC P0601
DTC P0607
DTC P0700
DTC P1106
DTC P1107
DTC P1111
DTC P1112
DTC P1114
DTC P1115
DTC P1121
DTC P1122
DTC P1133
DTC P1134
DTC P1167
DTC P1171
DTC P1336
DTC P1380
DTC P1381
DTC P1391
DTC P1392
DTC P1393
DTC P1404
DTC P1601
DTC P1607
DTC P1626
DTC P1631
DTC P1650
DTC P1655
SYMPTOM DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
ENGINE EXHAUST
2. Suspension
SUSPENSION DIAGNOSIS
WHEEL ALIGNMENT
FRONT SUSPENSION
REAR SUSPENSION
TIRES AND WHEELS
3. Driveline Axle
AUTOMATIC TRANSAXLE DRIVE AXLE
MANUAL TRANSAXLE DRIVE AXLE
4. Brakes
HYDRAULIC BRAKES
MASTER CYLINDER
POWER BOOSTER
FRONT DISC BRAKES
REAR DRUM BRAKES
ANTILOCK BRAKE SYSTEM
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
COMPONENT LOCATOR
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
GENERAL DESCRIPTION AND SYSTEM OPERATION
PARKING BRAKE
5. Transmissions/Transaxle
AISIN AUTOMATIC TRANSAXLE
SPECIFICATIONS
SPECIAL TOOLS
SCHEMATIC DIAGRAMS
COMPONENT LOCATOR
DIAGNOSIS
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
Diagnostic Trouble Code Chart
DTC P0562
DTC P0563
DTC P0604
DTC P0705
DTC P0712
DTC P0713
DTC P0717
DTC P0722
DTC P0727
DTC P0741
DTC P0742
DTC P0743
DTC P0748
DTC P0751
DTC P0753
DTC P0756
DTC P0758
DTC P1701
DTC P1702
DTC P1710
DTC P1790
DTC P1791
DTC U2105
MAINTENANCE AND REPAIR
UNIT REPAIR
Major Component Disassembly
Major Component Assembly
Oil Pump
Direct Clutch
Planetary Ring Gear
One-Way Clutch
Forward and Reverse Clutch
Counter Driven Gear
Valve Body
Differential Case
GENERAL DESCRIPTION AND SYSTEM OPERATION
FIVE-SPEED MANUAL TRANSAXLE (D16)
FIVE-SPEED MANUAL TRANSAXLE (Y4M)
SPECIFICATIONS
SPECIAL TOOLS
DIAGNOSIS
COMPONENT LOCATORS
MAINTENANCE AND REPAIR
UNIT REPAIR
Major Component Disassembly
Input Shaft and Cluster Gear
Mainshaft
Housing Case
Differential
Major Component Assembly
GENERAL DESCRIPTION AND SYSTEM OPERATION
Five-Speed Manual Transaxle
Reverse Gear Misshift Preventing Mechanism
Differential
CLUTCH (HYDRAULIC TYPE)
CLUTCH (CABLE TYPE)
6. Steering
POWER STEERING SYSTEM
POWER STEERING PUMP
POWER STEERING GEAR
MANUAL STEERING GEAR
STEERING WHEEL AND COLUMN
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING AND VENTILATION SYSTEM
MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
SPECIFICATIONS
SPECIAL TOOLS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
COMPONENT LOCATOR
MAINTENANCE AND REPAIR
UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
8. Restraints
SEAT BELTS
SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
SPECIFICATIONS
SPECIAL TOOLS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
Diagnostic Trouble Code(DTC)
Scan Tool Diagnostics
SIR Diagnostic System Check
Sensing and Diagnostic Module(SDM) Integrity check
Diagnostic TIC Trouble Code (DTC) 1
DTC 2
DTC 3
DTC 4
DTC 5
DTC 6
DTC 7
DTC 8
DTC 9
DTC 10
DTC 11
DTC 12
DTC 13
DTC 14
DTC 15
DTC 16
DTC 23
DTC 24
DTC 25
DTC 31
DTC 32
DTC 33
DTC 34
DTC 35
DTC 38
DTC 52
DTC 53
DTC 54
DTC 55
DTC 56
DTC 57
DTC 58
DTC 59
DTC 80
DTC 81
DTC 82
DTC 83
DTC 84
DTC 85
DTC 86
DTC 87
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
9. Body and Accessories
BODY WIRING SYSTEM
LIGHTING SYSTEMS
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
HORN
WIPERS/WASHER SYSTEMS
INSTRUMENTATION/DRIVER INFORMATION
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
AUDIO SYSTEMS
INTERIOR TRIM
SEATS
WATERLEAKS
WINDNOISE
SQUEAKS AND RATTLES
GLASS AND MIRRORS
EXTERIOR TRIM
FRAME AND UNDERBODY
BUMPERS AND FASCIAS
DOORS
ROOF
BODY FRONT END
BODY REAR END
REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM
IMMOBILIZER ANTI-THEFT SYSTEM