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Kia Carens Rondo II F L 2.0 CRDi 2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Carens Rondo II F L Year: 2006 Engine: 2.0 CRDi Codes Chassis Code: RP 👋 Introduction Market Position Vehicle Type: Compact MPV (Multi-Purpose...
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Kia Carens Rondo II F L 2.0 CRDi 2006 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kia
Model:
Carens Rondo II F L
Year:
2006
Engine:
2.0 CRDi
Codes
Chassis Code:
RP
👋 Introduction
Market Position
Vehicle Type:
Compact MPV (Multi-Purpose Vehicle) / Minivan
Segment:
Family-oriented vehicle, competitor to models like the Ford Focus C-Max, Renault Scénic, and Opel Zafira in its primary markets.
Competitive Analysis
Key Strengths:
Practicality, spacious interior for its class, value for money, and the availability of a fuel-efficient diesel engine.
Key Features
Versatility:
Flexible seating arrangements, often with sliding and folding rear seats to maximize cargo or passenger space.
Engine Variant:
The 2.0 CRDi engine offers a balance of performance and economy, making it a popular choice for the Carens.
Manual Utility:
This manual provides the in-depth technical knowledge required for DIY maintenance and repair, saving on dealership costs.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF
Page Count:
Extensive (typically 1000+ pages for comprehensive manuals)
📖 Manual Coverage
Systems Covered
Engine:
Full Engine Overhaul, Tuning, Diagnostics, Fuel System (CRDi), Lubrication, Cooling, Emission Control Systems
Transmission:
Manual and Automatic Transmission Overhaul, Clutch, Gearbox, Drive Axles, Differentials
Brakes:
Hydraulic System, ABS, EBD, Brake Discs, Pads, Calipers, Lines, Fluid Service
Suspension:
Front and Rear Suspension Assembly, Shock Absorbers, Springs, Bushings, Alignment Specifications
Steering:
Power Steering System, Rack and Pinion, Steering Column, Linkages
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting, Fuses, Relays, Wiring Diagrams, ECU Diagnostics
Bodywork:
Body Panels, Doors, Hood, Tailgate, Interior Trim, Bumpers, Glass, Sealing
Climate Control:
Air Conditioning System, Heating, Ventilation, Blower Motor, Refrigerant Servicing
Safety Systems:
Airbag System, Seatbelts, Pre-tensioners, SRS Module Diagnostics
Chassis Body:
Frame and Body Structure, Corrosion Protection, Welding Procedures
Wheels Tires:
Wheel Specifications, Tire Pressure Monitoring System (TPMS) if applicable, Tire Rotation
Procedures Included
Maintenance:
Scheduled Maintenance Intervals, Oil Changes, Filter Replacements, Fluid Checks and Top-ups, Spark Plug Replacement, Belt Inspections
Troubleshooting:
Systematic Fault Diagnosis, Diagnostic Trouble Codes (DTCs), Common Problems and Solutions
Repair:
Component Removal and Installation, Engine Rebuild, Transmission Overhaul, Brake System Repairs, Suspension Component Replacement
Diagnostics:
OBD-II Diagnostics, Sensor Testing, Actuator Testing, ECU Programming (if covered)
Alignment:
Wheel Alignment Specifications and Procedures
Wiring Diagrams:
Detailed Electrical Schematics for all Systems
Specifications:
Torque Specifications for all Fasteners, Material Specifications, Tolerances
Lubrication:
Lubrication Points, Grease Types, Fluid Capacities
Body Repair:
Panel Replacement, Dent Repair, Painting Procedures (general)
Safety Inspection:
Pre-delivery Inspection (PDI) Checklists, Periodic Safety Inspections
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for quick information retrieval
Resolution:
High-resolution for clear display of diagrams and text
Print Quality
Printability:
Printable for physical reference
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
Likely a variant of Kia's A diesel engine family (e.g., D4EA or similar)
Displacement:
1991 cc
Configuration:
Inline 4-cylinder, turbocharged diesel with common rail direct injection
Performance
Horsepower:
Typically around 112-115 PS (metric horsepower) or 110-113 bhp (brake horsepower) at approximately 4000 rpm.
Torque:
Around 240-255 Nm (Newton-meters) or 177-188 lb-ft at approximately 1750-2750 rpm.
Fuel System
Injection Type:
Common Rail Direct Injection (CRDi)
Fuel Type:
Diesel
Emission Control
Emission Standard:
Euro 3 or Euro 4 compliant, depending on market.
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Hyundai/Kia Long Life Coolant)
Lubrication System
Oil Grade:
API CF/CG-4 or ACEA B3/B4 recommended for this era of diesel engines. Specific viscosity likely 5W-30 or 10W-40, consult manual for exact specification.
Turbocharger
Type:
Variable Geometry Turbocharger (VGT) likely present for improved response and efficiency.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Clutch Type:
Hydraulically operated, dry single plate clutch (for manual transmission)
Transmission Fluid Manual:
GL-4 rated gear oil (e.g., 75W-90 or 80W-90, consult manual for specific viscosity and API rating)
Transmission Fluid Automatic:
ATF SP-III or equivalent (consult manual for specific type and capacity)
📐 Dimensions
Exterior
Length:
Approximately 4,550 mm (179.1 inches)
Width:
Approximately 1,795 mm (70.7 inches)
Height:
Approximately 1,630 mm (64.2 inches)
Wheelbase:
Approximately 2,720 mm (107.1 inches)
Interior
Seating Capacity:
5 or 7 seats (depending on configuration)
Cargo
Cargo Volume Seats Up:
Variable, designed for practicality, often around 400-500 liters with 5 seats.
Cargo Volume Seats Down:
Significantly increased when rear seats are folded or removed.
Weights
Curb Weight:
Approximately 1550-1650 kg (3417-3638 lbs) depending on transmission and equipment.
Gross Vehicle Weight Rating:
Typically around 2100-2250 kg.
🛡️ Safety Features
Ratings
Euro Ncap:
Likely achieved a 3 or 4-star safety rating in Euro NCAP crash tests for its generation, though specific 2006 Carens Rondo II results should be verified.
Active Features
ABS:
Anti-lock Braking System standard on most models.
Ebd:
Electronic Brakeforce Distribution likely standard with ABS.
Esp:
Electronic Stability Program (ESP) or Electronic Stability Control (ESC) might be optional or standard depending on market and trim level for 2006.
Traction Control:
Traction Control System (TCS) often paired with ESP.
Passive Features
Airbags:
Front driver and passenger airbags standard. Side airbags and curtain airbags may be optional or standard on higher trims.
Seatbelts:
3-point seatbelts with pre-tensioners for front seats. ISOFIX child seat anchor points.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player. Higher trims may feature multi-speaker systems. Aux input might be available.
Navigation:
Optional factory-fitted navigation system may have been available on higher trim levels.
Driver Assistance
Cruise Control:
Cruise control was often an optional feature on higher specification models.
Parking Sensors:
Rear parking sensors may have been an optional accessory or factory fit on some variants.
Connectivity
Bluetooth:
Bluetooth hands-free calling was generally not standard on this model year and would likely be an aftermarket addition or a rare factory option on top trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 - 15,000 km (6,000 - 9,000 miles) or 12 months, whichever comes first. Consult manual for exact interval and driving conditions.
Air Filter Replacement:
Every 30,000 - 40,000 km (18,000 - 25,000 miles) or as per manual, dependent on dust levels.
Fuel Filter Replacement:
Diesel fuel filters are critical; typically recommended replacement around 40,000 - 60,000 km (25,000 - 37,000 miles). Crucial for CRDi systems.
Timing Belt Replacement:
This engine uses a timing belt. Replacement interval typically around 90,000 - 120,000 km (56,000 - 75,000 miles) or 5-7 years. Critical to follow, as failure can cause severe engine damage.
Coolant Replacement:
Initial change at 5 years or 100,000 km, then every 2-3 years or 40,000-60,000 km thereafter.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 brake fluid (consult manual for specific requirement).
Power Steering Fluid:
Specific power steering fluid, consult manual for type (often Dexron II/III or a Kia specific fluid).
Known Issues
E Grinding Noise:
Some reports of DMF (Dual Mass Flywheel) wear, especially with manual transmissions under heavy use. This can manifest as juddering or rattling on acceleration/deceleration.
Diesel Particulate Filter:
While DPFs were less common on this specific 2006 CRDi engine in many markets compared to later models, if fitted, issues related to clogging due to short journeys or incorrect regeneration cycles can occur.
Injectors And Pump:
As with many common rail diesels of this era, long-term reliability of fuel injectors and high-pressure fuel pump is dependent on fuel quality and regular fuel filter changes. Injector nozzle clogging can impact performance and emissions.
Turbocharger Wear:
Turbocharger seals or bearings can wear over time, leading to oil consumption or reduced boost pressure. Regular oil changes with correct oil are crucial.
Suspension Bushings:
Wear in suspension bushings (e.g., control arm bushings) can lead to knocking noises, poor handling, and uneven tire wear.
Egr Valve:
Exhaust Gas Recirculation (EGR) valve can become clogged with carbon deposits, affecting engine performance and emissions. Cleaning or replacement may be necessary.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kia Motors Corporation, a South Korean automotive manufacturer known for producing reliable and value-oriented vehicles.
Model Evolution
Generation:
The Carens Rondo II (RP) represents the second generation of the Kia Carens MPV, launched in 2006, replacing the first generation Carens (FC).
Design Philosophy:
Evolved design with a more modern and aerodynamic appearance compared to its predecessor, focusing on family utility and practicality.
Production
Manufacturing Locations:
Primarily manufactured in South Korea, with potential production or assembly in other Kia facilities globally depending on market.
Production Years
Production Span:
The second generation (RP) was produced from 2006 to 2012.
🏆 Awards & Recognition
Recognitions
Category:
While the Carens as a model has received various accolades in different markets over its life, specific awards for the 2006 Rondo II F L 2.0 CRDi are not widely publicized as major awards. Its recognition is more in terms of practicality and value within the MPV segment.
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