🏷️ Basic Information

Make:

Kia

Model:

Picanto

Year:

2004

Engine Variant Covered:

1.1 SOHC

Transmission Variants Covered:

M5EF2 (5-Speed Manual), FRA (Automatic)

Engine Code Identifier:

G4HD (1.1L SOHC I4)

👋 Introduction

Vehicle Segment:

Subcompact/City Car

Key Selling Points:

Affordability, Fuel Efficiency, Compact Size for Urban Driving

Primary Competitors 2004:

Hyundai Getz, Chevrolet Aveo, Ford Fiesta, Peugeot 206, Renault Clio

Target Audience:

First-time car buyers, budget-conscious consumers, urban commuters

Manual Value Proposition:

Empowers owners and independent mechanics with detailed, manufacturer-level repair and maintenance information, reducing reliance on costly dealership services.

📋 Manual Details

Systems Covered:

Engine (1.1 SOHC), Engine Electrical, Emissions Control (1.1 SOHC), Clutch, Manual Transmission (M5EF2), Automatic Transmission (FRA), Drive Shafts and Axles, Wheel Suspension, Steering, Brake System, Body (Interior & Exterior), Electrical System, HVAC, Restraint System (Airbags & Seatbelt Pretensioners), Emission Control & Fuel System (1.1 SOHC)

Procedures Included:

Routine Maintenance, Diagnostics, Troubleshooting, Component Repair, System Overhauls, Electrical Schematics, Bodywork Repair, HVAC System Servicing, Safety System (Airbag) Inspection and Replacement, Fuel System Diagnosis and Repair

Estimated Page Count:

Over 1000 pages (typical for comprehensive service manuals)

Manual Type:

Service and Repair Manual

Language:

German

Download Format:

Digital Download (likely PDF)

File Format:

Likely PDF. Designed for digital download, offering searchability and easy access to information.

Print Quality:

High quality digital reproduction, typically with clear diagrams and text. Printability is a key feature.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

📖 Manual Coverage

Powertrain:

1.1L SOHC Engine (G4HD), M5EF2 5-Speed Manual Transmission, FRA Automatic Transmission, Clutch Assembly, Fuel Delivery and Emission Control Systems

Chassis:

Front and Rear Suspension (MacPherson struts, Torsion beam), Power and Manual Steering Systems, Hydraulic Disc/Drum Brake System, ABS (if equipped)

Body And Electrical:

Interior and Exterior Body Panel Repair, Electrical System Wiring Diagrams, HVAC System Operation and Repair, Restraint System (Airbag, Seatbelt Pretensioner) Diagnostics and Service

Diagnostic Procedures:

Troubleshooting charts for common symptoms, Diagnostic Trouble Codes (DTC) interpretation, Specific component testing procedures

Repair Procedures:

Step-by-step instructions for disassembly, repair, and reassembly of all major components. Includes torque specifications, special tool requirements, and alignment procedures.

Maintenance Procedures:

Scheduled maintenance tasks, fluid changes, filter replacements, belt adjustments, spark plug replacement, brake fluid flushes.

Depth Of Coverage:

Comprehensive. Covers everything from basic fluid checks and tire rotations to in-depth engine rebuilds, transmission overhauls, and complex electrical system diagnostics.

Diagnostic Tools Referenced:

OBD-II scanner, multimeter, pressure gauges, specialized Kia diagnostic tools (if applicable).

⚙️ Engine Specifications

Engine Type:

Inline 4-Cylinder, SOHC (Single Overhead Camshaft)

Displacement:

1.1 Liters (1099 cc)

Bore X Stroke:

Approx. 71.5 mm x 69.0 mm (typical for this class)

Compression Ratio:

Approx. 9.5:1 to 10.0:1

Horsepower:

Approx. 60-67 PS (44-49 kW) at around 5500-6000 rpm

Torque:

Approx. 96-100 Nm (71-74 lb-ft) at around 3200-3500 rpm

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (Octane rating as specified in manual)

Emission Control Systems:

Catalytic Converter, Oxygen Sensors (Lambda Sensors), EGR (Exhaust Gas Recirculation) - depending on market regulations

🔧 Transmission

Standard Transmission:

M5EF2 - 5-Speed Manual Transmission

Optional Transmission:

FRA - 4-Speed Automatic Transmission

Manual Transmission Gear Ratios:

Specific gear ratios will be detailed in the manual, critical for performance and economy tuning.

Automatic Transmission Features:

Torque converter, planetary gear sets, hydraulic control unit. Details on fluid type and capacity are vital.

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (typical specification, confirm with manual)

Automatic Transmission Fluid:

Kia Genuine ATF SP-III or equivalent (critical for longevity, confirm with manual)

📐 Dimensions

Length:

Approx. 3495 mm

Width:

Approx. 1595 mm

Height:

Approx. 1470 mm

Wheelbase:

Approx. 2360 mm

Curb Weight:

Approx. 850 - 900 kg (depending on transmission and equipment)

Gross Vehicle Weight Rating Gvwr:

Typically around 1300 - 1350 kg

Towing Capacity:

Generally not recommended or very limited for this vehicle class.

🛡️ Safety Features

Euro Ncap Rating Approx:

Likely 3 or 4 stars for this generation and class, but specific 2004 data may vary by region and test protocol. Refer to Euro NCAP archives.

Braking System:

Front Ventilated Discs, Rear Drums (standard). ABS available as an option on higher trims.

Traction Control System TCS:

Optional on some higher-spec models.

Airbags:

Driver and Front Passenger Airbags standard. Side airbags may be optional.

Seatbelt Pretensioners:

Standard for front occupants, often with force limiters.

Body Structure:

Reinforced safety cell, crumple zones designed for its class.

💡 Technology Features

Audio System:

Basic AM/FM/CD player, often with 2 or 4 speakers. Aux-in or USB ports not common in this era.

Navigation:

Not available.

Cruise Control:

Optional on higher trim levels.

Parking Assistance:

Rear parking sensors were an optional accessory.

Bluetooth:

Not available in this model year.

🔧 Maintenance

Oil Change Interval:

Every 15,000 km or 1 year, whichever comes first (using synthetic oil).

Air Filter Replacement Interval:

Every 30,000 km or 2 years.

Spark Plug Replacement Interval:

Every 60,000 km (using iridium or platinum plugs).

Timing Belt Replacement Interval:

This engine uses a timing CHAIN, not a belt, for increased durability and reduced maintenance.

Engine Oil Capacity:

Approx. 3.4 Liters (3.6 US Quarts) with filter change (confirm with manual).

Engine Oil Type:

API SM/SN or ILSAC GF-4/GF-5, SAE 5W-20 or 5W-30 (confirm with manual for specific viscosity grades by climate).

Coolant Type:

Ethylene Glycol-based antifreeze/coolant, typically a blue or green long-life formula (e.g., HOAT). Mixture ratio 50/50 with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 (confirm with manual, DOT 4 is generally preferred for better performance).

Common Wear Items:

Clutch wear (manual transmission), suspension bushings, brake components, exhaust system components.

Engine Specific Concerns:

Minor oil leaks from gaskets, potential for carbon buildup on intake valves with high mileage, though generally robust for its class.

Electrical Concerns:

Occasional issues with power window motors or central locking actuators, but generally reliable electrical systems.

📚 Vehicle History

Manufacturer Origin:

South Korea

Brand Focus:

Known for producing value-oriented, fuel-efficient vehicles with improving quality and features over time.

First Generation Launch:

2002 (in South Korea), 2004 (in many European markets)

Platform Sharing:

Shared platform and some components with Hyundai Getz.

Manufacturing Location:

Gwangmyeong, South Korea (primarily)

🏆 Awards & Recognition

Typical Awards:

While not typically winning major awards in its segment, the Picanto was recognized for its value, affordability, and suitability for urban environments by various automotive publications in its target markets.

Fuel Economy Ratings:

Generally rated highly for fuel efficiency in its class, often exceeding 5.5 L/100km (approx. 43 MPG US) on the highway.