2004 Kia Rio Service and Repair Manual
Every figure in the 2004 Kia Rio factory service and repair manual comes from the documentation Kia published for this exact model year, engine and trim, so the specifications and sequences you work to on your sedan or wagon are the ones written for your car rather than values carried over from a neighboring year of the Rio.
Engines covered
- 1.6L inline-four — DOHC, naturally aspirated, gasoline
Body styles covered
- 4-door sedan
- 4-door wagon
- 5-door wagon
Trims covered
- Base
- Cinco
- RX-V
Known issues on the 2004 Rio. Two recalls are on federal record for this model year. The first concerns the child seat anchorage: certain vehicles fail to conform to Federal Motor Vehicle Safety Standard No. 225 for child restraint anchorage systems, and a child seat that is not properly installed can lead to personal injury in a crash. The second covers the fuel delivery system, where the fuel intake nipple of the fuel distributor can fracture or crack during removal of the quick connect coupling securing the main fuel tube assembly, and fuel leakage in the presence of an ignition source may result in a fire. Owners have filed 53 complaints for the year and Kia has issued 11 technical service bulletins. The factory diagnostic and repair procedures behind each of those systems are here.
From inspecting the fuel distributor and its couplings to checking the child restraint anchorages or keeping the 1.6L DOHC engine on its service schedule, the manual holds you to Kia's own procedure and the correct specification for your specific 2004 Rio.
CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, 'CHILD RESTRAINT ANCHORAGE SYSTEMS.' CERTAIN CHILD RESTRAINT ANCHORS WILL NOT FULLY LATCH ONTO THE LOWER LATCH ANCHORS LOCATED BETWEEN THE REAR SEAT BACK AND REAR SEAT CUSHION BECAUSE OF INTERFERENCE BETWEEN THE CHILD SEAT ANCHORS AND A METAL WIRE LOCATED IN THE FRAME OF THE REAR SEAT BACK. UNTIL THE RECALL REPAIR IS COMPLETED, FOLLOW THE INSTRUCTIONS PROVIDED BY YOUR CHILD SEATS MANUFACTURER ON HOW TO PROPERLY INSTALL THE CHILD SEAT WITH YOUR VEHICLE'S REAR SAFETY BELTS RATHER THAN USING THE LATCH SYSTEM.
IN THE EVENT OF A VEHICLE CRASH, IF THE CHILD SEAT IS NOT PROPERLY INSTALLED, PERSONAL INJURY OR DEATH COULD OCCUR.
DEALERS WILL REPLACE THE LOWER ANCHORS FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 30, 2006. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
ON CERTAIN PASSENGER VEHICLES, THE FUEL INTAKE NIPPLE OF THE FUEL DISTRIBUTOR IS SUBJECT TO FRACTURE OR CRACKING DURING REMOVAL OF THE QUICK CONNECT COUPLING SECURING THE MAIN FUEL TUBE ASSEMBLY TO THE FUEL INTAKE NIPPLE, OR WHEN FORCE IS ACCIDENTALLY APPLIED TO THE INTAKE NIPPLE DURING THE VEHICLE ASSEMBLY PROCESS OR DURING ENGINE COMPARTMENT REPAIRS.
FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
DEALERS WILL REPLACE THE FUEL DISTRIBUTOR AND MAIN FUEL TUBE ASSEMBLIES. THE RECALL BEGAN JUNE 18, 2004. OWNERS SHOULD CONTACT KIA AT 1-800-333-4542.
TECHNICAL SERVICE BULLETIN: INFORMATION FOR HEADLAMP CONDENSATION AND MOISTURE - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This b
TSB - USE OF AFTERMARKET USB CHARGING CABLES IN USB/12V PORTS - This article provides information regarding the use of USB ports and 12V power outlets to connect/charge mobile phones. Customers may experience issues with their head units th
PITSTOP - ENGINE COMPONENT RE-USE GUIDELINES - In general, parts and components removed during engine repairs should be considered serviceable, and should be thoroughly cleaned and transferred to the new engine.
TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners, which are designed to lock into place once fully attached, are utilized in various Kia models and are strictly intended for ?one time use.? Some example
TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners utilized in various Kia models are strictly intended for ?one time use?. Though not limited to the following, some examples are: axle shaft nuts with sta
TSB: AUTOMATIC TRANSMISSION FLUID APPLICATION GUIDE - THIS BULLETIN PROVIDES INFORMATION RELATING TO THE CORRECT AUTOMATIC TRANSMISSION FLUIDS THAT ARE REQUIRED FOR EACH KIA MODEL. REFER TO THE SHOP MANUAL ON KGIS FOR THE SPECIFIC KIA MODEL
KIA: ALL MODELS. ARTICLE PROVIDES INFORMATION RELATING TO THE IMPROVED DURABILITY OF BULB LIFE FOR REAR COMBINATION BULB; REAR STOP LAMP/TAIL LAMP BULB UTILIZED ON MULTIPLE KIA MODELS. *PE
RIO (BC) ENGINE HARD TO START, RUNS ROUGH AND STALLS -- WHAT TO CHECK -- CRANK POSITION SENSOR (CKP) TONE RING. *NJ
Showing the 8 most recent of 12 technical service bulletins on file with NHTSA.
TL*THE CONTACT OWNS A 2004 KIA RIO. THE CONTACT WAS INVOLVED IN A HEAD-ON CRASH WHILE DRIVING 25 MPH. THE AIR BAGS FAILED TO DEPLOY. THE VEHICLE WAS DESTROYED. THE CONTACT SUSTAINED MAJOR INJURIES WHILE WEARING HIS SEAT BELT. A POLICE REPORT WAS FILED. NO OTHER VEHICLE INFORMATION WAS AVAILABLE.
DURING A FRONTAL-IMPACT ACCIDENT, THE DRIVER AIRBAG FAILED TO DEPLOY UNTIL AFTER I HIT THE STEERING WHEEL. I THEN SAW THE PASSENGER AIRBAG DEPLOY. NEITHER THE SEAT BELT NOR THE AIRBAG STOPPED ME FROM HITTING THE STEERING WHEEL CAUSING CHEST WALL CONTUSIONS AND MUSCLE STRAINS IN CHEST AND BACK. I'M STILL OUT OF WORK DUE TO THE INJURIES. THE CAR WAS TOTALED.*AK
DT: WHILE DRIVING ON THE HIGHWAY AT 55-60 MPH THE STEERING WENT OUT. THE CAR WAS MOVING ON ITS OWN ACCORD FROM ONE SIDE OF THE LANE TO THE OTHER, AND STEERING BECAME UNRESPONSIVE. PUMPING THE BRAKES MADE THE REACTION WORSE. THE VEHICLE WAS STRUCK ON THE PASSENGER'S SIDE , SLOWING THE CAR,AND STEERING ENGAGED AGAIN. PULLED THE CAR OVER TO THE LEFT SHOULDER OF THE HIGHWAY.*AK
DT*: THE CONTACT STATED WHILE DRIVING 30 MPH, THE BRAKE PEDAL WAS DEPRESSED AND THE BRAKES DID NOT RESPOND. THE VEHICLE STOPPED WHEN HITTING ANOTHER VEHICLE. THERE WAS A POLICE REPORT TAKEN AT THE SCENE. THE VEHICLE WAS DRIVEN TO THE DEALERSHIP WHERE IT WAS DETERMINED THE CALIPERS WERE BLOWN OUT.
THE CAR WAS IN AN ACCIDENT AND THE AIR BAGS NEVER DEPLOYED ON THE DRIVER SIDE OR THE PASSENGER SIDE. NOTHING WAS DONE TO FIX IT .THE CAR NOW HAS TO HAVE THE WHOLE FRONT END FIXED AND NEED TO HAVE THEM CHECKED TO SEE WHY THEY DIDN'T DEPLOY. *TR
THE CAR CAUGHT ON FIRE, KIA SAYS THEY SENT A NOTIFICATION TO THE ORIGINAL OWNER, YEARS AGO. WE FEEL THAT WE WERE ENTITLED TO A RECALL NOTICE BEFORE THE CAR BURNED DOWN. WE FEEL THIS IS NOT A SMALL RECALL, IT WAS A FIRE, A FIRE IS VERY DANGEROUS AND CAN BURN AND KILL PEOPLE. WE HAD 22 KIAS RIOS IN OUR FLEET AND NEVER RECEIVED RECALL NOTICES ON ANY OF THEM. KIA DID SEND NOTICES TO THE ORIGINAL OWNER HOWEVER THEY HAD THE INFORMATION AS TO WHICH CARS RECEIVED THE RECOMMENDED REPAIRS AND WHICH CA
OUR CAR CAUGHT ON FIRE. KIA SAYS THAT RECALL NOTICES WERE SENT OUT TO THE PREVIOUS OWNER TO TAKE THE CAR TO A KIA DEALER FOR REPAIRS. NOTICE WAS SENT OUT YEARS AGO (2002). KIA KNEW THAT THE REPAIRS WERE NEVER DONE BECAUSE NO DEALERSHIP HAD BILLED KIA FOR REPAIRS. FOR NINE (9) YEARS THIS CAR WAS ON THE ROAD WITHOUT A SAFETY RECALL BEING PERFORMED FOR FIRE. FOR NINE YEARS WE REGISTERED THIS CAR AND KIA MADE NO ATTEMPT TO FIND OUT WHO OWNS THE VEHICLE. KIA IS BEING VERY UNETHICAL BECAUSE THEY
I WAS DRIVING WITH MY GIRLFRIEND, HEADED OUT TO DINNER, GOING 15 TO 20 MPH THROUGH TOWN (25 MPH SPEED LIMIT), WHEN SUDDENLY A LOUD CLUNKING NOISE STARTED, COMING FROM PASSENGER SIDE REAR WHEEL. I PULLED OVER IN A BUSINESS LOT & REMOVED TIRE TO FIND THAT THE REAR AXEL WHERE THE SHOCK ABSORBER CONNECTS TO HAD RUSTED OFF & THE SHOCK ABSORBER SWINGING, DISCONNECTED FROM THE AXEL MOUNT. I NURSED THE VEHICLE HOME & CHECKED THE DRIVERS SIDE REAR AXLE & FOUND THAT IT TOO WAS READY TO SNAP OFF.
DT*: THE CONTACT STATED WHILE DRIVING 70 MPH ON NORMAL ROAD CONDITIONS A LOST OF ENGINE POWER WAS NOTICED. THERE WERE NO ENGINE WARNING LIGHTS TO ALERT THE CONTACT OF AN ENGINE PROBLEM. THE VEHICLE WAS TAKEN TO AN INDEPENDENT CERTIFIED MECHANIC WHO DETERMINED THE ENGINE BLEW OUT DUE TO THE PRESENCE OF COOLANT MIXED WITH THE ENGINE OIL AND RECOMMENDED ENGINE PEPLACEMENT. THE DEALERSHIP AND MANUFACTURER HAVE NOT BEEN CONTACTED. THE VEHICLE REMAINED INOPERABLE. THE CONTACT WAS CONCERN BECAUSE
I WAS AT A STOP SIGN AND MY 2004 KIA RIO DIED , I PUSHED IT TO THE MECHANIC AND WAS TOLD THE TIMING BELT LOST ITS TEETH AND THERE IS NOW NO COMPRESSION IN 3 AND 4 , THE MILEAGE ON CAR IS 68040. I WAS TOLD BASICALLY THE ENGINE IS TOAST AND I WASN'T EVEN MOVING ,I WAS TOLD BY A COUPLE OF MECHANICS THAT THE BELT THAT KIA USED IS FAULTY . THE OWNERS MANUAL SAYS REPLACE 60,000 MILES BUT REPLACE IT 105,000 IN CALIFORNIA. HOW WOULD A BELT BE BAD IN 49 STATES EXCEPT CALIFORNIA. I FOUND ON AUTO MD .CO
DT: THE CONTACT STATED VEHICLE JERKED AND CUT OUT. WHEN THIS HAPPENED THE ENGINE LIGHT CAME , ON AND THERE WAS A BURNING SMELL. THE VEHICLE WAS TAKEN TO THE DEALERSHIP SEVEN TIMES, AND THEY STATED IT WAS AN ELECTRICAL PROBLEM. THEY REPLACED THE ELECTRICAL THROTTLE MODULE EVERY TIME, AND STATED THERE WAS A POOR CONNECTION AT THE ENGINE BULK. THE PROBLEM HAS NOT BEEN CORRECTED AT THIS TIME. *AK
TL* THE CONTACT OWNS A 2004 KIA RIO. THE CONTACT STATED THAT THE MANUAL DOOR LOCKS ON BOTH THE INTERIOR AND EXTERIOR FRONT DRIVER'S SIDE DOORS WOULD NOT RELEASE. THE CONTACT HAD TO ENTER THE VEHICLE THROUGH THE FRONT PASSENGER SIDE DOOR AND EXIT IN THE SAME MANNER. THE VEHICLE WAS NEITHER DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 21,599.
I HAVE A 2004 KIA RIO. I HAD NO PROBLEMS WITH THIS VEHICLE TILL THE MONTH OF OCTOBER WHEN IT FAILED INSPECTION FOR EMISSIONS. I TOOK IT TO THE SHOP AND IT TOOK A WHILE BEFORE THEY FOUND OUT IT WAS A SENSOR. SO THEN I HAD THE CAR BACK FOR A WEEK AND MY HUSBAND WHO DRIVES THE CAR EVERYDAY WAS DRIVING HOME FROM WORK HEARD A LOUD NOISE AND THE CAR DIED. COME TO FIND OUT THE TIMING BELT WENT ON THE VEHICLE. WHICH COME TO FIND OUT YOU ARE SUPPOSE TO CHANGE THESE AT 60,000 ACCORDING TO THEIR BOOK.
DT*: THE CONTACT STATED THE VEHICLE CONTINUOUSLY STALLED. THE VEHICLE WAS TAKEN TO THE SERVICE DEALER SIX TIMES BUT THE DEALER WAS UNABLE TO DUPLICATE THE PROBLEM. UPDATED 12/01/06. *JB
CHECK ENGINE SOON LIGHT CAME ON AND THERE WAS NOT ACCELERATION WHILE IN 1ST GEAR. REPLACED FUEL INJECTOR HARNESS. *BF THE DEALER ALSO REPLACED THE AIR CLEANER LID WITH A NEWLY DESIGNED ONE, MASS AIR FLOW SENSOR AND TIGHTENED PIN CONNECTORS. *NM
Showing the 15 most serious of 50 complaints filed with NHTSA.
