2003-2006 Kia Picanto Sa Service and Repair Manual

This 2003-2006 Kia Picanto Service & Repair Manual Covers

• Complete factory workshop procedures
• Factory diagnostic information
• Component removal and installation
• Repair and overhaul procedures
• Technical specifications
• Maintenance procedures
• Factory wiring diagrams
• Torque specifications
• Fuse and relay information
• Diagnostic flow charts
• Troubleshooting procedures

Engine Options

• 1.0L Epsilon SOHC Inline-4 Petrol
• 1.1L Epsilon SOHC Inline-4 Petrol
• 1.1L CRDi Diesel, where fitted in applicable markets

Transmission Options

• 5-speed Manual Transaxle
• 4-speed Automatic Transaxle

Engine and Drivetrain Repair Coverage

• Engine overhaul procedures
• Cylinder head servicing
• Valve servicing
• Camshaft servicing
• Timing system inspection
• Timing component replacement
• Camshaft timing procedures
• Multi-Point Fuel Injection diagnostics
• Fuel injector testing
• Ignition system servicing
• Ignition coil diagnostics
• Throttle body servicing
• Intake system servicing
• Cooling system repairs
• Lubrication system servicing
• Emissions system diagnostics
• Manual transaxle servicing
• Automatic transaxle diagnostics
• Automatic transaxle servicing
• Driveshaft servicing
• CV joint inspection and repair

Diesel System Coverage

• Diesel engine diagnostics
• Diesel fuel system servicing
• Fuel injector diagnostics
• Glow plug system diagnostics
• Turbocharger diagnostics where fitted
• EGR system diagnostics
• Diesel engine electrical system
• Diesel emissions-control system

Chassis, Steering and Suspension

• Front suspension servicing
• Rear suspension servicing
• Steering system diagnostics
• Steering rack servicing
• Steering column servicing
• Power steering servicing
• Shock absorber replacement
• Coil spring inspection
• Stabiliser bar servicing
• Suspension bush inspection
• Wheel bearing servicing
• Wheel alignment specifications

Braking Systems

• Brake system inspection
• ABS diagnostics where fitted
• Brake hydraulic system bleeding
• Brake master cylinder servicing
• Brake booster servicing
• Front disc brake servicing
• Rear brake servicing
• Parking brake servicing
• Wheel speed sensor diagnostics
• ABS hydraulic control unit diagnostics

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Engine electrical system
• Fuel injection wiring
• Ignition system wiring
• Starting system diagnostics
• Charging system diagnostics
• Alternator servicing
• Battery testing
• Immobiliser diagnostics
• Instrument cluster diagnostics
• Body electrical system
• Lighting system diagnostics
• Audio system wiring
• Power window diagnostics
• Central locking diagnostics
• Power mirror diagnostics
• Wiper and washer circuits

Air Conditioning and HVAC

• Air conditioning system diagnostics
• Compressor servicing
• Refrigerant system repairs
• HVAC control system diagnostics
• Blower motor servicing
• Heater system servicing
• Blend door diagnostics
• Air distribution system servicing
• Ventilation system servicing

Body, Interior and Restraint Systems

• Body panel removal and installation
• Door servicing
• Door latch and lock servicing
• Bonnet and tailgate adjustment
• Dashboard removal procedures
• Interior trim servicing
• Seat servicing
• SRS airbag diagnostics
• Seat belt servicing
• Wiper and washer system servicing
• Exterior lighting servicing

Diagnostics and Troubleshooting

• Factory diagnostic procedures
• Scan-tool diagnostic procedures
• Symptom-based troubleshooting
• Engine Control Module diagnostics
• Transmission control diagnostics
• ABS diagnostics where fitted
• Sensor testing procedures
• Actuator testing
• Electrical fault isolation
• Component inspection procedures
• Emissions diagnostic procedures

Common Error Codes Covered

Engine Codes

• P0101 — Mass or Volume Air Flow Circuit Range/Performance
• P0113 — Intake Air Temperature Sensor Circuit High Input
• P0122 — Throttle/Pedal Position Sensor/Switch A Circuit Low
• P0171 — System Too Lean
• P0300 — Random/Multiple Cylinder Misfire Detected
• P0301 — Cylinder 1 Misfire Detected
• P0335 — Crankshaft Position Sensor A Circuit
• P0340 — Camshaft Position Sensor A Circuit
• P0401 — Exhaust Gas Recirculation Flow Insufficient
• P0420 — Catalyst System Efficiency Below Threshold

Diesel Codes

• P0087 — Fuel Rail/System Pressure Too Low
• P0191 — Fuel Rail Pressure Sensor Range/Performance
• P0234 — Turbocharger/Supercharger Overboost Condition
• P0299 — Turbocharger/Supercharger Underboost Condition
• P0380 — Glow Plug/Heater Circuit Malfunction
• P0401 — Exhaust Gas Recirculation Flow Insufficient

Transmission Codes

• P0700 — Transmission Control System Malfunction
• P0715 — Input/Turbine Speed Sensor Circuit Malfunction
• P0720 — Output Speed Sensor Circuit Malfunction
• P0731 — Gear 1 Incorrect Ratio
• P0732 — Gear 2 Incorrect Ratio
• P0733 — Gear 3 Incorrect Ratio
• P0734 — Gear 4 Incorrect Ratio
• P0741 — Torque Converter Clutch Performance or Stuck Off

Network Communication Codes

• U0100 — Lost Communication With ECM/PCM
• U0101 — Lost Communication With Transmission Control Module
• U0121 — Lost Communication With ABS Control Module
• U0140 — Lost Communication With Body Control Module

Plus many other diagnostic codes and manufacturer-specific faults included in the applicable workshop documentation.

Fuse Box Diagram

• Engine compartment fuse box layout
• Passenger compartment fuse box layout
• Fuse identification charts
• Relay locations
• Fuse amperage specifications
• Power distribution diagrams

Wiring Diagrams

• Engine management system
• Petrol fuel injection system
• Diesel fuel system where fitted
• Ignition system
• Starting and charging systems
• Manual transaxle
• Automatic transaxle
• ABS system
• Air conditioning system
• HVAC system
• SRS airbag system
• Instrument cluster
• Immobiliser system
• Body electrical system
• Lighting system
• Audio system
• Power windows
• Power mirrors
• Central locking
• Wiper and washer system

Timing and Drive System Information

• Accessory drive belt routing
• Drive belt inspection
• Drive belt replacement
• Timing system inspection
• Timing component replacement
• Camshaft timing specifications
• Timing component inspection
• Tensioner servicing

Torque Specifications

• Engine fastener torque values
• Cylinder head torque specifications
• Main bearing torque values
• Connecting rod torque values
• Intake and exhaust manifold torque values
• Timing component torque specifications
• Transmission torque specifications
• Driveshaft torque specifications
• Suspension torque specifications
• Steering component torque values
• Brake system torque values
• Wheel nut torque specifications

Maintenance and Service Information

• Factory scheduled maintenance intervals
• Engine oil and filter replacement
• Fuel filter replacement
• Automatic transmission fluid servicing
• Manual transaxle oil servicing
• Engine coolant replacement
• Brake fluid replacement
• Power steering fluid servicing
• Spark plug replacement
• Glow plug inspection where applicable
• Engine air filter replacement
• Cabin/air-conditioning filter servicing where fitted
• Drive belt inspection
• Timing system inspection
• Battery inspection
• Tyre rotation procedures
• Wheel alignment checks

Who Is This Manual For?

• Automotive workshops
• Independent repair garages
• Kia specialists
• Automotive technicians
• Auto electricians
• Diagnostic specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions