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KIA Rondo 2.4L 2012 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: KIA Model: Rondo Year: 2012 Engine: 2.4L Codes Chassis Code: UN (Second Generation) 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose Vehicle) / Crossover...
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KIA Rondo 2.4L 2012 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
KIA
Model:
Rondo
Year:
2012
Engine:
2.4L
Codes
Chassis Code:
UN (Second Generation)
👋 Introduction
Market Position
Vehicle Segment:
Compact MPV (Multi-Purpose Vehicle) / Crossover
Target Audience:
Families seeking a versatile and practical vehicle with flexible seating and cargo space in a relatively compact footprint.
Competitive Analysis
Key Competitors:
Toyota Matrix, Mazda5, Ford Focus Wagon, Honda Fit (in terms of practicality, though Rondo is larger).
Key Features
Seating Configuration:
Typically offered with 5 or 7-seat configurations, providing excellent passenger flexibility.
Practicality:
Emphasis on cargo capacity, fold-flat rear seats, and an elevated driving position for ease of entry/exit.
Value Proposition:
Positioned as a budget-friendly and practical option within the compact MPV segment, offering a good balance of features and utility for the price.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital PDF
Page Count
Estimated Page Count:
Approximately 2000+ pages (typical for a comprehensive workshop manual)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system (chain, guides, tensioner), lubrication system (oil pump, oil filter, oil passages), cooling system (radiator, water pump, thermostat, coolant passages).
Engine Electrical:
Ignition system (spark plugs, coils, wiring), fuel system (injectors, fuel pump, fuel filter, fuel pressure regulator), starting and charging system (starter motor, alternator, battery, wiring harnesses), engine control module (ECM/PCM) diagnostics and component testing, sensor and actuator operation (e.g., crankshaft position sensor, camshaft position sensor, throttle position sensor, MAF sensor).
Transmission Manual:
Clutch system, gearbox assembly, shift mechanism, internal components (gears, shafts, synchronizers), clutch master/slave cylinders, hydraulic lines.
Transmission Automatic:
Transmission fluid (ATF) system, torque converter, planetary gear sets, valve body, solenoids, transmission control module (TCM) diagnostics and component testing, hydraulic circuits, cooler lines.
Drivetrain:
Front-wheel drive (FWD) system, drive axles (CV joints, boots), differential assembly, wheel bearings.
Suspension:
Front suspension (struts, coil springs, control arms, ball joints, sway bar, bushings), rear suspension (multi-link or torsion beam depending on configuration, shock absorbers, coil springs, trailing arms, bushings), wheel alignment specifications.
Steering:
Power steering system (hydraulic pump, reservoir, steering rack/gearbox, power steering fluid specifications), steering column, tie rods, steering linkage.
Brakes:
Front disc brakes (calipers, rotors, pads), rear disc or drum brakes (calipers, rotors/drums, pads/shoes), parking brake system, ABS (Anti-lock Braking System) components and diagnostics, brake fluid specifications (e.g., DOT 3 or DOT 4), hydraulic lines, master cylinder.
Electrical Body:
Lighting system (headlights, taillights, interior lights), wipers and washers, power windows, power locks, mirrors, horn, central locking system, keyless entry system, fuse box diagrams and component locations.
HVAC:
Air conditioning (compressor, condenser, evaporator, refrigerant, charging procedures), heating system (heater core, blower motor, climate control modules), cabin air filter replacement, ducting.
Safety Systems:
Airbag system (SRS - Supplemental Restraint System) components, sensors, control module, and diagnostic procedures; seat belt mechanisms.
Body Exterior:
Body panel removal and installation (doors, hood, fenders, bumpers), glass replacement, exterior trim.
Body Interior:
Interior trim panel removal and installation, dashboard, seats, headliner, carpeting.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, coolant flushes, brake fluid changes, transmission fluid checks/changes, differential fluid checks/changes.
Diagnostics:
Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) and their meanings, component testing procedures, using diagnostic scan tools.
Repair Procedures:
Step-by-step instructions for component removal, replacement, and installation for all major systems. Includes torque specifications for critical fasteners.
Rebuilding Overhauling:
Detailed procedures for engine, transmission, and brake system overhauls, including specifications for machining and assembly.
Electrical Diagnostics:
Wiring diagrams, circuit descriptions, testing of electrical components, continuity checks, voltage drop tests.
Suspension Steering Repair:
Replacement of ball joints, tie rod ends, control arms, bushings, struts, shock absorbers, steering rack/gearbox.
Brake System Repair:
Brake pad and rotor replacement, brake caliper servicing, bleeding the brake system, ABS component replacement.
HVAC System Repair:
Refrigerant recovery and recharge, AC compressor replacement, heater core replacement, blower motor replacement.
Bodywork:
Door alignment, panel replacement, glass installation, bumper repair/replacement.
Technical Depth
Depth Of Information:
Comprehensive. Covers everything from basic scheduled maintenance to complex component repair, system diagnostics, and major component overhauls. Includes detailed specifications, diagrams, and troubleshooting flowcharts.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Printability:
Printable pages, allowing for physical copy creation.
Binding Type
Binding Type For Printed:
N/A (Digital Download)
Paper Type
Paper Type For Printed:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC (Dual Overhead Camshaft)
Engine Code:
Theta II G4KD
Displacement:
2.4 Liters (2359 cc)
Performance
Horsepower:
Approximately 175 hp @ 6000 rpm
Torque:
Approximately 169 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI - Multi-Point Injection)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87 AKI (Anti-Knock Index)
Technical Features
Valve Actuation:
Variable Valve Timing (VVT) for intake camshaft.
Emissions Control:
Catalytic converter, oxygen sensors, EGR system (where applicable).
🔧 Transmission
Standard
Transmission Type:
6-speed Automatic Transmission
Transmission Model:
A6MF2 (typically)
Features
Transmission Features:
Electronically controlled, lock-up torque converter, manual shift mode (Sportmatic).
Fluid Specifications
Automatic Transmission Fluid:
KIA Genuine ATF SP-IV or equivalent Dexron-VI/Mercon LV compatible fluid.
📐 Dimensions
Exterior
Length:
Approximately 174.0 inches (4420 mm)
Width:
Approximately 68.9 inches (1750 mm)
Height:
Approximately 63.0 inches (1600 mm)
Wheelbase:
Approximately 104.0 inches (2640 mm)
Weights
Curb Weight:
Approximately 3200 - 3350 lbs (1450 - 1520 kg), depending on configuration.
Cargo
Cargo Volume Behind 2Nd Row:
Approximately 28.0 - 31.0 cubic feet (varies with 5/7 seat option).
Cargo Volume With 2Nd Row Folded:
Approximately 65.0 - 70.0 cubic feet (varies with 5/7 seat option).
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test Rating:
4 Stars (for 2012 model year - driver and passenger).
NHTSA Side Crash Test Rating:
4 Stars (for 2012 model year - front and rear passengers).
IIHS Moderate Overlap Frontal Offset Rating:
Good (for similar model years).
Active Features
ABS:
Standard Anti-lock Braking System.
Esc:
Standard Electronic Stability Control (ESC).
Traction Control:
Standard Traction Control System (TCS).
Passive Features
Airbags:
Frontal airbags (driver and passenger), front side-impact airbags, overhead curtain airbags for all rows (standard on most trims).
Seatbelts:
3-point seatbelts with pretensioners and load limiters for all seating positions, LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD/MP3 player with auxiliary input. Optional upgrades include SiriusXM satellite radio and premium audio systems.
Connectivity:
Auxiliary audio input jack. Bluetooth connectivity may be optional on higher trims.
Driver Assistance
Rearview Camera:
Optional on some trims, integrated into the infotainment display.
Parking Sensors:
Optional rear parking sensors.
Comfort Convenience
Cruise Control:
Standard cruise control.
Keyless Entry:
Standard keyless entry, optional push-button start.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first, under normal driving conditions. Every 3,750 miles or 6 months under severe driving conditions.
Air Filter Replacement:
Every 15,000 miles or 12 months.
Cabin Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement:
Every 60,000 miles (using iridium-tipped plugs).
Coolant Replacement:
Initial replacement at 100,000 miles or 10 years, then every 50,000 miles or 5 years thereafter.
Brake Fluid Replacement:
Every 30,000 miles or 24 months.
Fluid Specifications
Engine Oil Type:
SAE 5W-20, API SM or higher certified.
Engine Oil Capacity:
Approximately 4.7 US quarts (4.4 liters) with filter change.
Coolant Type:
Ethylene Glycol based coolant, OAT (Organic Acid Technology) type, color may vary (typically orange or red).
Power Steering Fluid:
Power Steering Fluid (refer to owner's manual or specific workshop manual for exact type, often Dexron-III compatible).
Known Issues
Engine Issues:
Occasional reports of oil consumption, potential for catalytic converter failure if misfires occur, but generally reliable.
Transmission Issues:
Some models may experience rough shifting or torque converter shudder if ATF is not maintained.
Suspension Steering Issues:
Wear in control arm bushings and ball joints, power steering pump leaks are possible over time.
Electrical Issues:
Power window regulators, HVAC blower motor issues can occur with age and mileage.
📚 Vehicle History
Brand Heritage
Kia Motors History:
Founded in 1944, Kia is South Korea's oldest manufacturer of motor vehicles, known for its rapid growth and expanding global presence, particularly in the affordable and value-oriented segments.
Model Evolution
Rondo Generation 1:
Launched in 2006 (as Kia Carens in some markets), based on the Spectra platform. Offered with smaller engine options and primarily a 5-seat configuration.
Rondo Generation 2:
Introduced for the 2007/2008 model year, significantly redesigned on a new platform, offering a longer wheelbase, more modern styling, and available 7-seat configurations. The 2012 model is part of this second generation, representing a mid-cycle update.
Production
Production Location:
Primarily manufactured in South Korea (Hwaseong Plant).
Production Years:
First Generation: 2006-2013 (global; US market ended 2012). Second Generation: 2007-2013 (global). The 2012 model falls into the second generation.
🏆 Awards & Recognition
Recognitions
Safety Awards:
The Rondo, in its second generation, generally performed well in safety tests, contributing to Kia's growing reputation for safety.
Ratings
Fuel Economy Ratings:
EPA estimated MPG for 2.4L FWD: Approximately 21 MPG City / 27 MPG Highway (actual mileage may vary).
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