Kia Carens Rondo II FL 2.0 CRDi 2006 Service Repair Manual
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🏷️ Basic Information Identification Make: Kia Model: Carens Rondo II FL Year: 2006 Engine Code: D4EA (2.0 CRDi) Chassis Code: FC 👋 Introduction Market Position Segment: Compact MPV (Multi-Purpose Vehicle) Target Audience: Families and individuals seeking versatile, practical, and economical transportation. Competitive Analysis Competitors: Ford Focus C-Max, Renault Scénic, Volkswagen Touran, Opel/Vauxhall Zafira. Key Features Key Selling Points: Spacious interior, flexible seating, fuel-efficient diesel engine, value for money. Manual Purpose Purpose: To provide comprehensive repair and maintenance guidance for the Kia Carens Rondo II FL 2.0 CRDi 2006. 📋 Manual Details Coverage Areas Coverage Type: Workshop Service Repair Page Count Estimated Pages: Hundreds of pages (exact count not specified but implied extensive) Manual Type Type: Official Full Factory Service Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, overhaul, and specifications for the 2.0 CRDi diesel engine. Fuel System: Common Rail Direct Injection (CRDi) system diagnosis, fuel pump, injectors, fuel lines, pressure sensors. Emission Control: Exhaust Gas Recirculation (EGR) system, Diesel Particulate Filter (DPF) if applicable, catalytic converter. Transmission: Manual and Automatic transmission repair, clutch, gearbox, torque converter, shift mechanisms. Drivetrain: Front-wheel drive components, axles, driveshafts, CV joints. Suspension: Front and rear suspension systems, shock absorbers, struts, control arms, bushings, springs. Steering: Power steering system diagnosis, pump, steering rack, steering column. Brakes: Front and rear brake systems (discs/drums), hydraulic system, ABS, parking brake. Electrical System: Battery, charging system, starter motor, ignition system (glow plugs for diesel), lighting, fuses, relays. Body And Chassis: Body panel repair, doors, hinges, locks, glass, interior trim, chassis components. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair. Diagnostics: On-board diagnostics (OBD-II), fault codes, diagnostic procedures. Procedures Included Maintenance: Regular maintenance procedures, fluid changes, filter replacements, lubrication. Repair: Step-by-step repair instructions for all major mechanical and electrical components. Disassembly: Complete disassembly procedures for all vehicle systems. Assembly: Detailed assembly instructions with torque specifications. Troubleshooting: Systematic troubleshooting guides for common problems. Inspections: Visual inspections and diagnostic checks for various components. Specifications: Critical technical specifications, tolerances, and settings. Wiring Diagrams: Comprehensive electrical wiring diagrams for all systems. Technical Depth Depth: Complete factory-level detail, suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Accessibility Zoom: Zoom IN/OUT capable Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, Turbocharged Diesel Displacement: 1991 cc (2.0 Liters) Bore X Stroke: 84.0 mm x 90.0 mm (typical for this engine) Compression Ratio: 17.7:1 (typical for D4EA) Performance Horsepower: 113 hp @ 4000 rpm (approximate) Torque: 245 Nm @ 1800-2500 rpm (approximate) Fuel System Injection Type: Common Rail Direct Injection (CRDi) Fuel Type: Diesel Engine Management ECU: Electronic Control Unit (ECU) for engine management. Turbocharger Type: Variable Geometry Turbocharger (VGT) 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Clutch: Hydraulically operated single dry plate clutch (Manual). 📐 Dimensions Exterior Length: 4475 mm (approximate) Width: 1790 mm (approximate) Height: 1620 mm (approximate) Wheelbase Wheelbase: 2720 mm (approximate) Weights Curb Weight: Approx. 1650-1750 kg (depending on transmission and trim) Gross Vehicle Weight: Approx. 2300-2400 kg Cargo Cargo Volume: Variable with 3rd-row seating, typically around 150-300 liters with all seats up, significantly more when folded. 🛡️ Safety Features Ratings Euro Ncap: Not definitively available for this specific 2006 facelift model year, but earlier Rondo models achieved 4 stars. Active Features ABS: Anti-lock Braking System Ebs: Electronic Brakeforce Distribution (EBD) Passive Features Airbags: Front airbags for driver and passenger, optional side and curtain airbags. Seatbelts: Three-point seatbelts with pre-tensioners for front seats. Child Anchors: ISOFIX child seat mounting points. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player, potentially with MP3 compatibility. Steering wheel audio controls may be present on higher trims. Driver Assistance Cruise Control: Available on some higher trim levels. Connectivity Auxiliary Input: May feature an auxiliary audio input for external devices on some models. 🔧 Maintenance Service Intervals Oil Change: Typically every 10,000-15,000 km or 12 months, whichever comes first (check specific manual for exact interval). Air Filter: Replace every 20,000-40,000 km or as needed based on driving conditions. Fuel Filter: Replace every 40,000-60,000 km for diesel models. Timing Belt Chain: The D4EA engine typically uses a timing chain, which is generally maintenance-free for the life of the engine. If it were a belt, intervals would be around 100,000-150,000 km. Fluid Specifications Engine Oil: API CF/CG-4 or ACEA B3/B4, viscosity SAE 5W-40 or 10W-40 (specific Kia approval recommended, e.g., Kia Premium Diesel). Coolant: Ethylene Glycol based coolant, typically a long-life (e.g., 50/50 mix with distilled water). Kia's specification is usually a specific...
Step-by-step repair instructions for all major mechanical and electrical components.
Disassembly:
Complete disassembly procedures for all vehicle systems.
Assembly:
Detailed assembly instructions with torque specifications.
Troubleshooting:
Systematic troubleshooting guides for common problems.
Inspections:
Visual inspections and diagnostic checks for various components.
Specifications:
Critical technical specifications, tolerances, and settings.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems.
Technical Depth
Depth:
Complete factory-level detail, suitable for professional technicians and advanced DIY mechanics.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Accessibility
Zoom:
Zoom IN/OUT capable
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, Turbocharged Diesel
Displacement:
1991 cc (2.0 Liters)
Bore X Stroke:
84.0 mm x 90.0 mm (typical for this engine)
Compression Ratio:
17.7:1 (typical for D4EA)
Performance
Horsepower:
113 hp @ 4000 rpm (approximate)
Torque:
245 Nm @ 1800-2500 rpm (approximate)
Fuel System
Injection Type:
Common Rail Direct Injection (CRDi)
Fuel Type:
Diesel
Engine Management
ECU:
Electronic Control Unit (ECU) for engine management.
Turbocharger
Type:
Variable Geometry Turbocharger (VGT)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Clutch:
Hydraulically operated single dry plate clutch (Manual).
📐 Dimensions
Exterior
Length:
4475 mm (approximate)
Width:
1790 mm (approximate)
Height:
1620 mm (approximate)
Wheelbase
Wheelbase:
2720 mm (approximate)
Weights
Curb Weight:
Approx. 1650-1750 kg (depending on transmission and trim)
Gross Vehicle Weight:
Approx. 2300-2400 kg
Cargo
Cargo Volume:
Variable with 3rd-row seating, typically around 150-300 liters with all seats up, significantly more when folded.
🛡️ Safety Features
Ratings
Euro Ncap:
Not definitively available for this specific 2006 facelift model year, but earlier Rondo models achieved 4 stars.
Active Features
ABS:
Anti-lock Braking System
Ebs:
Electronic Brakeforce Distribution (EBD)
Passive Features
Airbags:
Front airbags for driver and passenger, optional side and curtain airbags.
Seatbelts:
Three-point seatbelts with pre-tensioners for front seats.
Child Anchors:
ISOFIX child seat mounting points.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player, potentially with MP3 compatibility. Steering wheel audio controls may be present on higher trims.
Driver Assistance
Cruise Control:
Available on some higher trim levels.
Connectivity
Auxiliary Input:
May feature an auxiliary audio input for external devices on some models.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10,000-15,000 km or 12 months, whichever comes first (check specific manual for exact interval).
Air Filter:
Replace every 20,000-40,000 km or as needed based on driving conditions.
Fuel Filter:
Replace every 40,000-60,000 km for diesel models.
Timing Belt Chain:
The D4EA engine typically uses a timing chain, which is generally maintenance-free for the life of the engine. If it were a belt, intervals would be around 100,000-150,000 km.
Fluid Specifications
Engine Oil:
API CF/CG-4 or ACEA B3/B4, viscosity SAE 5W-40 or 10W-40 (specific Kia approval recommended, e.g., Kia Premium Diesel).
Coolant:
Ethylene Glycol based coolant, typically a long-life (e.g., 50/50 mix with distilled water). Kia's specification is usually a specific color (e.g., Green).
Brake Fluid:
DOT 3 or DOT 4.
Transmission Fluid Manual:
API GL-4, SAE 75W-90.
Transmission Fluid Automatic:
Kia Genuine ATF SP-III or equivalent.
Known Issues
Diesel Particulate Filter:
Potential for DPF clogging if driven primarily on short city journeys without regular regeneration cycles.
Ege Valve:
Exhaust Gas Recirculation (EGR) valve can become carboned up, leading to rough idling or loss of power.
Glow Plugs:
Glow plugs may require replacement for cold starting issues, common in diesel engines.
Suspension Wear:
Bushings and ball joints can wear over time, leading to knocking noises or poor handling.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kia Corporation, South Korea.
Model Evolution
Generation:
Second generation (UN) facelift model (FL).
Facelift Details:
The 'FL' indicates a facelift, typically involving updated styling (front and rear bumpers, grille, headlights, taillights), interior trim enhancements, and potential mechanical refinements.
Production
Production Period:
The second generation Carens (UN) was produced from 2006 to 2012. This manual specifically covers the 2006 model year, likely the initial release of the second generation or its facelift.