Chevrolet Kalos MOT Failures
An analysis of 89,825 real DVSA MOT tests on the Chevrolet Kalos — what fails, how often, and how that compares to every other car on UK roads. Generations covered: T200 (2004–2011).
Where the Chevrolet Kalos fails its MOT
The single biggest MOT failure point on the Chevrolet Kalos is abs fault — this model is 123 times more likely to fail on this item than the average car on UK roads. That makes it an extreme outlier for anyone buying or owning this model. Across 89,825 MOT tests, 4.52% of all Chevrolet Kalos tests recorded this as a failure.
Brake failures on the MOT range from worn pads and discs (routine maintenance) to corroded brake lines and seized calipers (more serious). Check for any pulling under braking and listen for grinding.
Other notable weak points include headlight fault (63x the fleet average), seat mounting fault (46x the fleet average), structural corrosion (33x the fleet average), and steering rack wear (29x the fleet average). These ratios compare the Chevrolet Kalos's failure rate on each item against the national average for all cars tested — a ratio of 10x means this model fails ten times more often than a typical car.
The failures span 6 categories: Brakes, Lights & Electrics, Seatbelts & Airbags, Bodywork, Steering and others. If you're inspecting a Chevrolet Kalos before purchase, these are the areas to focus on — and if any have been flagged as advisories on a previous MOT, they're likely to become failures in the near future.
How failures change with mileage
The Chevrolet Kalos's weak points shift as the car covers more miles. Understanding these patterns helps you know what to expect — and what to budget for — at each stage of ownership.
Under 60,000 miles
At this mileage, most failures are either design-related or caused by age rather than wear. Components like bushes and drop links may not have been replaced yet, and original-fit parts can deteriorate even on low-mileage cars that spend a lot of time sitting.
For the Chevrolet Kalos specifically, the DVSA data shows the most common failures at this mileage are tyre valve seriously damaged or misaligned (85x the average) and headlight fault (63x). abs fault (54x) and structural corrosion (33x) also appear frequently.
60,000 to 100,000 miles
This is where routine wear items start to show up. Brake components, tyres, and exhaust parts have done serious work by this point. Cars that have been well serviced will show fewer of these failures — this mileage band is where good maintenance really separates the well-kept from the neglected.
For the Chevrolet Kalos specifically, the DVSA data shows the most common failures at this mileage are abs fault (107x the average) and suspension component damaged or corroded (26x). suspension pin, bush or joint (18x) and headlight fault (16x) also appear frequently.
Over 100,000 miles
High-mileage cars accumulate failures across multiple systems. The key question isn't whether things will need doing — they will — but whether the car has been maintained well enough to keep on top of them. Look for a consistent service history and recent MOT passes with minimal advisories.
For the Chevrolet Kalos specifically, the DVSA data shows the most common failures at this mileage are headlight fault (19x the average) and suspension pin, bush or joint worn (12x). light unit fault (10x) and electrical wiring fault (10x) also appear frequently.
The shift from tyre valve seriously damaged or misaligned at lower mileages to headlight fault at higher mileages is typical — early failures tend to be design or factory-related, while high-mileage failures reflect accumulated mechanical wear. A car that's been well maintained will usually dodge the worst of both.
Known issues beyond the MOT
An MOT only tests roadworthiness at a single point in time — it won't catch developing faults, intermittent problems, or issues that haven't yet reached the failure threshold. These are the issues that Chevrolet Kalos specialists and owners flag most frequently, drawn from manufacturer technical bulletins, workshop data, and verified owner reports.
Structural corrosion around suspension mounting points (T200) Dangerous
The Kalos suffers from severe structural corrosion around suspension component mounting points, particularly where the front subframe attaches to the body shell and where suspension struts mount to the inner wing. Affects T200; typical independent garage repair cost is £800–£2,000.
Body shell corrosion (T200) Major
The Kalos exhibits widespread body corrosion issues affecting structural integrity beyond normal surface rust. Affects T200; typical independent garage repair cost is £1,500–£3,000.
Excessive suspension component wear (T200) Major
The Kalos shows premature wear in suspension bushes, ball joints, and anti-roll bar links. Affects T200; typical independent garage repair cost is £150–£400.
Steering ball joint wear (T200) Major
Track rod ends and steering ball joints wear prematurely on the Kalos, with MOT failures occurring at 22.4 times the fleet average. Affects T200; typical independent garage repair cost is £120–£250.
For the complete picture — including repair costs across independent, specialist, and dealer garages — see the full Chevrolet Kalos common problems breakdown.
What to check before buying a Chevrolet Kalos
Based on the MOT failure data and known issues above, here's what to prioritise when inspecting a Chevrolet Kalos:
Brakes — check for abs fault. Lights & Electrics — check for headlight fault, light unit fault. Seatbelts & Airbags — check for seat mounting fault. Bodywork — check for structural corrosion.
Beyond the MOT items, ask specifically about structural corrosion around suspension mounting points and body shell corrosion. These won't show up on a standard MOT but can be expensive to fix — repairs start from £800. A specialist pre-purchase inspection is worth the investment on this model.
Always check the car's full MOT history for patterns — recurring advisories often become failures within 12 months. And verify the service history to confirm maintenance has been kept up to schedule. Enter any reg into our free car check to see the complete picture.
Looking at a specific Chevrolet Kalos?
Enter the reg to see its full MOT history, mileage records, write-off status, and finance checks.
Chevrolet Kalos MOT FAQs
What are the most common MOT failures on a Chevrolet Kalos?
Based on 89,825 DVSA MOT tests, the most common failure is abs fault — at 123x the national fleet average. Other frequent failures include headlight fault and seat mounting fault.
Is the Chevrolet Kalos reliable based on MOT data?
The Chevrolet Kalos has 15 MOT failure categories above the fleet average. Specialists also flag structural corrosion around suspension mounting points as a concern. A pre-purchase inspection and service history check are recommended.
What MOT failures should I expect at high mileage?
Above 100,000 miles, the Chevrolet Kalos most commonly fails on headlight fault and suspension pin, bush or joint worn. Under 60,000 miles, the main issues are tyre valve seriously damaged or misaligned and headlight fault.
How do I check a Chevrolet Kalos's MOT history?
Enter the registration number into our free car check above. You'll see every MOT test result, advisories and failures, mileage readings, write-off status, and finance checks.
MOT failure data sourced from DVSA bulk test records via data.gov.uk. Ratios compare this model's failure rate against the national fleet average. Known issues sourced from manufacturer bulletins, specialist workshops, and verified owner reports.