🏷️ Basic Information Identification Make: Kia Model: Rio Year: 2004 Codes Chassis Code: DC Engine Code Prefix: G4EH 👋 Introduction Market Position Segment: Subcompact hatchback/sedan Target Audience: Budget-conscious consumers, first-time car buyers, urban commuters. Competitive Analysis Key Competitors: Hyundai Accent, Toyota Yaris, Honda Fit, Ford Fiesta, Chevrolet Aveo. Distinguishing Factors: Affordability, fuel efficiency, surprisingly spacious interior for its class, decent reliability for its price point. Key Features Design Philosophy: Practical, no-frills transportation with a focus on value. Powertrain Options: Primarily offered with a small displacement inline-4 engine, emphasizing fuel economy. Body Styles: Available as a 4-door hatchback and a 4-door sedan. 📋 Manual Details Coverage Areas Primary Coverage: North America (USDM/CDM) Secondary Coverage: Other Global Markets (GDMs with potential regional variations) Page Count Estimated Pages: 1500+ Manual Type Type: Service and Repair Manual Scope: Comprehensive Diagnostic, Repair, and Maintenance Language Language: English Format Format: Digital (likely PDF, searchable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete teardown, assembly, inspection, and repair of all engine components (pistons, rings, bearings, valves, camshafts, crankshafts, cylinder heads, blocks). Engine Management: Fuel injection system (MPI), ignition system, emissions control systems (EVAP, EGR), sensor testing and replacement, ECU diagnostics, troubleshooting DTCs. Transmission Manual: Removal, installation, clutch system, internal component inspection and repair, shift linkage adjustments. Transmission Automatic: Removal, installation, hydraulic control systems, torque converter, internal component inspection and repair, fluid service, shift control. Drivetrain: CV joints, drive axles, differentials, wheel bearings. Suspension: Front and rear suspension components (struts, shock absorbers, control arms, ball joints, bushings), alignment procedures and specifications. Steering: Power steering system (pump, rack and pinion, fluid), steering column, wheel alignment. Brakes: Front and rear brake systems (discs/drums), hydraulic system (master cylinder, calipers, wheel cylinders, lines), ABS system components and diagnostics. Electrical System: Battery, starting system, charging system (alternator), lighting system, fuses, relays, wiring diagrams, multiplexing (if applicable). Body Interior: Door mechanisms, interior trim, seats, HVAC controls, dashboard removal and installation. Body Exterior: Bumpers, fenders, hood, trunk lid, door panels, glass replacement, seals. HVAC: Air conditioning system, heater core, blower motor, refrigerant handling, diagnostics. Safety Systems: Airbag system (SRS) components, testing, and replacement procedures (cautionary notes emphasized). Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake fluid flush, coolant flush. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, DTC code interpretations and corrective actions. Repair Procedures: Step-by-step instructions for component removal, installation, and repair with torque specifications and special tool requirements. Diagnostics: Detailed diagnostic procedures for all major systems, including electrical tests, sensor readings, and actuator tests. Specifications Data: All relevant torque values, clearances, fluid capacities, electrical resistance values, and component tolerances. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Diagnostic Level: Advanced, including electrical schematics and component-level testing. Rebuild Capability: Full engine, transmission, and sub-assembly rebuilds are detailed. 📊 Manual Specifications File Format Digital Format: PDF Searchability: High (text-searchable) Print Quality Illustrations: Clear line drawings, diagrams, and some photographic representations. Text Clarity: Excellent, professional typesetting. Binding Type Digital Binding: N/A (Digital) Paper Type Digital Paper Simulation: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: G4EH Configuration: Inline 4-cylinder Displacement: 1.5 Liters (1495 cc) Valvetrain: SOHC (Single Overhead Camshaft), 16 Valves Bore X Stroke: 71.0 mm x 77.0 mm (approx.) Compression Ratio: 9.4:1 (approx.) Performance Horsepower: 95 hp @ 5500 rpm (approx.) Torque: 97 lb-ft @ 3000 rpm (approx.) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Emissions Control: Catalytic Converter, EGR, EVAP system 🔧 Transmission Standard Type: 5-speed Manual Optional Type: 4-speed Automatic Features Manual Gear Ratios: Specific ratios detailed in manual, typically geared for fuel economy. Automatic Transmission Fluid Type: SPIII (or equivalent SP-III compatible fluid) Clutch Type: Dry, single plate (for manual) 📐 Dimensions Exterior Length Hatchback: 3800 mm (approx.) Length Sedan: 4220 mm (approx.) Width: 1670 mm (approx.) Height: 1470 mm (approx.) Wheelbase: 2430 mm (approx.) Ground Clearance: 150 mm (approx.) Cargo Cargo Volume Hatchback: 253 Liters (seats up, approx.) Cargo Volume Sedan: 340 Liters (approx.) Weights Curb Weight Manual: 1050 kg (approx.) Curb Weight Automatic: 1070 kg (approx.) Gross Vehicle Weight Rating: 1530 kg (approx.) Wheels Tires Standard Wheel Size: 14-inch Steel (with covers) or 15-inch Alloy Standard Tire Size: 175/70R14 or 185/65R15 Bolt Pattern: 4x100 mm Center Bore: 54.1 mm Lug Nut Size: M12 x 1.5 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated for this specific model year, but generally expected to be average for the class at the time. IIHS Frontal Offset: Not rated for this specific model year. Active Features ABS: Optional on some trims, standard on higher trims. Electronic Brakeforce Distribution: Often paired with ABS if equipped. Passive Features Airbags: Driver and front passenger airbags (standard). Seat Belts: 3-point front and rear seat belts, pretensioners for front belts. Child Seat Anchors:...