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2004-2006 Kia Picanto Workshop Service Repair Manual In Germ

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The Kia Picanto, specifically the first generation (BA) produced between 2004 and 2006, is a compact city car designed for efficient urban transportation. This subcompact hatchback, engineered by Kia, offers...
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SKU: 152708
2004-2006 Kia Picanto Workshop Service Repair Manual In Germ
The Kia Picanto, specifically the first generation (BA) produced between 2004 and 2006, is a compact city car designed for efficient urban transportation. This subcompact hatchback, engineered by Kia, offers a practical and economical solution for city commuters and first-time car buyers. Its design philosophy emphasizes a compact footprint, making it highly maneuverable in crowded city environments, and it competes with other vehicles in its segment known for their affordability and practicality. This comprehensive workshop service and repair manual provides detailed information for maintaining and repairing the Kia Picanto BA. It covers essential areas including engine mechanicals, fuel and ignition systems, transmission overhauls, brake systems, suspension, steering, and the complete electrical system. Furthermore, the manual details scheduled maintenance procedures, troubleshooting guides, diagnostic protocols, and step-by-step repair instructions for all major components and systems, ensuring owners and technicians can effectively manage the vehicle's upkeep and address any issues that may arise.
🏷️ Basic Information
Identification
Make:
Kia
Model:
Picanto
Model Generation:
First Generation (BA)
Model Years Covered:
2004, 2005, 2006
Codes
Chassis Code:
BA
👋 Introduction
Market Position
Market Segment:
City Car / Subcompact Hatchback
Competitive Analysis
Key Competitors:
Hyundai i10, Chevrolet Spark, Fiat Panda, Volkswagen Fox, Toyota Aygo
Key Features
Target Audience:
Urban commuters, first-time car buyers, budget-conscious consumers
Design Philosophy:
Compact, economical, practical urban transport
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair Manual
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Repair Procedures
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Comprehensive Workshop Service and Repair Manual
Language
Language:
German
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system
Engine Management:
Fuel injection system, ignition system, emission control, engine control module (ECM) diagnostics and programming
Transmission Manual:
Manual gearbox overhaul, clutch, driveshafts, differentials
Transmission Automatic:
Automatic transmission overhaul, torque converter, transmission control module (TCM) diagnostics
Brakes:
Front and rear brake systems (discs/drums), ABS, EBD, brake fluid service
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, wheel alignment
Steering:
Power steering system, steering rack, column, linkages
Electrical System:
Battery, charging system, starting system, lighting, instruments, interior electronics, fuses, relays
Body And Chassis:
Body panels, doors, hoods, trunk, interior trim, underbody components, structural repairs
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair
Safety Systems:
Airbag system (SRS), seatbelt pre-tensioners, diagnostics
Procedures Included
Scheduled Maintenance:
Detailed service intervals and procedures for oil changes, filter replacements, spark plugs, belts, etc.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Diagnostic Procedures:
Fault code diagnosis, live data interpretation, electrical system testing
Special Tools:
Identification and usage of specialized tools required for specific repairs
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission overhauls, including electrical diagnostics and bodywork
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, allowing for text searchability and easy navigation
Print Quality
Print Quality:
High-resolution digital reproduction suitable for printing key sections
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Petrol:
G4HD (1.1L SOHC)
Engine Displacement 1.1L:
1086 cc
Engine Configuration 1.1L:
Inline 4-cylinder
Valve Mechanism 1.1L:
SOHC (8 valves) or DOHC (16 valves)
Performance
Horsepower 1.1L Sohc:
62-66 PS (46-49 kW) at 5500-6000 rpm
Torque 1.1L Sohc:
96-100 Nm (71-74 lb-ft) at 3200-3500 rpm
Horsepower 1.1L DOHc:
67 PS (50 kW) at 5500 rpm
Torque 1.1L DOHc:
99 Nm (73 lb-ft) at 3200 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (Benzin)
Emissions Standard:
Euro 3 / Euro 4 (market dependent)
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
4-speed Automatic Transmission
Features
Clutch Type:
Dry single-plate, hydraulically actuated
📐 Dimensions
Exterior
Length:
Approx. 3495 mm (137.6 in)
Width:
Approx. 1595 mm (62.8 in)
Height:
Approx. 1470-1480 mm (57.9-58.3 in)
Wheelbase:
Approx. 2370 mm (93.3 in)
Cargo
Cargo Volume Rear Seats Up:
Approx. 165-175 Liters (6.0-6.2 cu ft)
Cargo Volume Rear Seats Folded:
Approx. 820-860 Liters (29.0-30.4 cu ft)
Weights
Curb Weight:
Approx. 820-900 kg (1808-1984 lb) depending on transmission and equipment
🛡️ Safety Features
Ratings
Euro Ncap Rating:
3 Stars (for some variants/testing periods)
Active Features
ABS:
Available on higher trims or as an option
Ebd:
Electronic Brakeforce Distribution (often paired with ABS)
Passive Features
Airbags Front:
Driver and Front Passenger Airbags (standard on most, market dependent)
Seatbelts:
Pre-tensioner front seatbelts
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM/CD player with auxiliary input, optional MP3 playback. Speakers typically 2 or 4.
Driver Assistance
Driver Assistance Features:
Limited; primarily focused on basic safety systems like ABS and EBD where equipped.
Connectivity
Connectivity Options:
Basic; often includes power outlets and auxiliary inputs, no Bluetooth or USB as standard on early models.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 10,000-15,000 km or 12 months, whichever comes first (check manual for specific grade)
Air Filter Replacement Interval:
Every 30,000-40,000 km
Spark Plug Replacement Interval:
Every 40,000-60,000 km (depending on plug type)
Timing Belt Replacement Interval:
Every 60,000-100,000 km (critical for SOHC/DOHC engines, check manual for specific interval)
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or ACEA A2/A3, SAE 5W-30 or 10W-40 (check manual for exact specification)
Engine Oil Capacity 1.1L:
Approx. 3.5 - 3.9 Liters with filter change
Coolant Type:
Ethylene glycol-based antifreeze, blue or green color (recommend genuine Kia coolant or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil
Transmission Fluid Automatic:
Dexron III / MERCON equivalent (check manual for exact specification and capacity)
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system components, wheel bearings
Potential Electrical Gremlins:
Occasional issues with window regulators, central locking, or dashboard illumination
Engine Considerations:
Timing belt replacement is crucial to prevent catastrophic engine damage. SOHC engines may have slightly less performance than DOHC variants.
Rust Prone Areas:
Wheel arches, sills, and boot lid edges, particularly in areas with road salt
📚 Vehicle History
Brand Heritage
Parent Company:
Hyundai Motor Group
Model Evolution
First Generation Launch:
2004
Platform Sharing:
Shared platform elements with Hyundai Getz
Production
Manufacturing Location:
South Korea (various Kia plants)
🏆 Awards & Recognition
Recognitions
Design Awards:
Often praised for its compact and distinctive design in its segment.
Ratings
Fuel Economy Ratings:
Generally good fuel economy for its class, making it an economical choice for city driving.
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