🏷️ Basic Information Identification Make: Kia Model: Rio Year: 2004 Codes Chassis Code: DC Platform: Kia Rio (First Generation) 👋 Introduction Market Position Segment: Subcompact Car Target Audience: Budget-conscious consumers, first-time car buyers, urban commuters Competitive Analysis Competitors: Hyundai Accent, Ford Fiesta, Chevrolet Aveo, Toyota Echo, Honda Fit (early models) Key Features Value Proposition: Affordability, fuel efficiency, decent reliability for its class Design Philosophy: Practical and functional design with a focus on economy and ease of use. 📋 Manual Details Coverage Areas Markets Covered: Global (North America, Europe, Asia) Trim Levels Covered: All trim levels (e.g., LX, SE, RS) Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, powertrain control module (PCM), automatic transmission, manual transmission, drivetrain (front-wheel drive) Chassis: Suspension (front and rear), steering system, braking system (ABS optional), wheels and tires Electrical: Battery, charging system, starting system, lighting system, instrumentation, body electricals (power windows, locks, mirrors), HVAC controls, audio system, wiring diagrams Body: Exterior body panels, interior trim, safety systems (airbags, seatbelts), body sealing, glass and mirrors Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), component testing procedures, circuit testing Repair: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair, exhaust system repair, HVAC system repair Installation: Component replacement procedures for all major systems Technical Depth Depth: Comprehensive: covers routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and electrical schematics. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear text and legible diagrams. Searchability: Fully searchable text for quick access to information. Print Quality Printable: Printable pages for use in a workshop environment. Binding Type Digital Format: PDF Paper Type Digital Medium: Digital Download ⚙️ Engine Specifications Primary Engine Engine Code Usdm: G4HD (1.6L) Engine Code Eudm: G4HD / G4EE (1.6L), G4EA (1.3L) Displacement 1.6L: 1599 cc Displacement 1.3L: 1341 cc Performance 1.6L Horsepower 1.6L: 106 hp @ 6000 rpm Torque 1.6L: 107 lb-ft @ 3200 rpm Performance 1.3L Horsepower 1.3L: 82 hp @ 5500 rpm Torque 1.3L: 84 lb-ft @ 3500 rpm Fuel System Injection Type: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Valvetrain Configuration: DOHC (Dual Overhead Camshafts), 16 valves (4 per cylinder) 🔧 Transmission Standard Type Usdm: 5-Speed Manual Type Eudm: 5-Speed Manual Optional Type Usdm: 4-Speed Automatic Type Eudm: 4-Speed Automatic Features Clutch Type: Hydraulically actuated, dry single plate (manual transmission) Automatic Transmission Control: Electronic control unit (ECU) with adaptive shift logic 📐 Dimensions Exterior Length: Approx. 3,810 mm (149.9 in) Width: Approx. 1,665 mm (65.5 in) Height: Approx. 1,470 mm (57.9 in) Wheelbase: Approx. 2,430 mm (95.7 in) Weights Curb Weight Manual: Approx. 1020 kg (2249 lbs) Curb Weight Automatic: Approx. 1050 kg (2315 lbs) Cargo Trunk Volume: Approx. 274 liters (9.7 cu ft) 🛡️ Safety Features Ratings NHTSA Frontal Driver: Not extensively tested for this model year in the US market. NHTSA Frontal Passenger: Not extensively tested for this model year in the US market. Active Features ABS: Optional (Anti-lock Braking System) Electronic Brake Force Distribution: Often paired with ABS if equipped Passive Features Airbags Driver: Standard (Frontal) Airbags Passenger: Standard (Frontal) Seatbelts: 3-point front and rear seatbelts, pretensioners for front seats Child Seat Anchors: LATCH system (Lower Anchors and Tethers for CHildren) 💡 Technology Features Infotainment Audio System: Basic AM/FM stereo with CD player, 4-6 speakers. Some models may have an auxiliary input. Navigation: Not available on this model year. Driver Assistance Cruise Control: Available on higher trim levels. Parking Sensors: Not typically available. Connectivity Bluetooth: Not available. Usb Port: Not available. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (refer to manual for exact intervals). Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) Spark Plug Replacement: Every 60,000-100,000 miles (96,000-160,000 km), depending on plug type (e.g., iridium recommended for longevity). Timing Belt Replacement: Not applicable - Engines use timing chains. Fluid Specifications Engine Oil Type 1.6L: API SG or higher, SAE 5W-30 or 5W-40 (check manual for ambient temperature suitability). Engine Oil Capacity 1.6L: Approx. 3.8 liters (4.0 US quarts) Coolant Type: Ethylene glycol-based antifreeze/coolant (Asian vehicle specific or universal blue/green). Transmission Fluid Manual: API GL-4 SAE 75W-90 manual transmission fluid. Transmission Fluid Automatic: Kia Genuine ATF SP-III or equivalent (e.g., Dexron III compatible). Brake Fluid Type: DOT 3 or DOT 4 brake fluid. Known Issues Engine Mounts: Can degrade over time leading to vibration and engine noise. Clutch Wear: Manual transmission clutches can wear out, especially with aggressive driving. Suspension Components: Ball joints, tie rod ends, and...
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair, exhaust system repair, HVAC system repair
Installation:
Component replacement procedures for all major systems
Technical Depth
Depth:
Comprehensive: covers routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and electrical schematics.
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear text and legible diagrams.
Searchability:
Fully searchable text for quick access to information.
Print Quality
Printable:
Printable pages for use in a workshop environment.
Binding Type
Digital Format:
PDF
Paper Type
Digital Medium:
Digital Download
⚙️ Engine Specifications
Primary Engine
Engine Code Usdm:
G4HD (1.6L)
Engine Code Eudm:
G4HD / G4EE (1.6L), G4EA (1.3L)
Displacement 1.6L:
1599 cc
Displacement 1.3L:
1341 cc
Performance 1.6L
Horsepower 1.6L:
106 hp @ 6000 rpm
Torque 1.6L:
107 lb-ft @ 3200 rpm
Performance 1.3L
Horsepower 1.3L:
82 hp @ 5500 rpm
Torque 1.3L:
84 lb-ft @ 3500 rpm
Fuel System
Injection Type:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Valvetrain
Configuration:
DOHC (Dual Overhead Camshafts), 16 valves (4 per cylinder)
🔧 Transmission
Standard
Type Usdm:
5-Speed Manual
Type Eudm:
5-Speed Manual
Optional
Type Usdm:
4-Speed Automatic
Type Eudm:
4-Speed Automatic
Features
Clutch Type:
Hydraulically actuated, dry single plate (manual transmission)
Automatic Transmission Control:
Electronic control unit (ECU) with adaptive shift logic
📐 Dimensions
Exterior
Length:
Approx. 3,810 mm (149.9 in)
Width:
Approx. 1,665 mm (65.5 in)
Height:
Approx. 1,470 mm (57.9 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Weights
Curb Weight Manual:
Approx. 1020 kg (2249 lbs)
Curb Weight Automatic:
Approx. 1050 kg (2315 lbs)
Cargo
Trunk Volume:
Approx. 274 liters (9.7 cu ft)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
Not extensively tested for this model year in the US market.
NHTSA Frontal Passenger:
Not extensively tested for this model year in the US market.
Active Features
ABS:
Optional (Anti-lock Braking System)
Electronic Brake Force Distribution:
Often paired with ABS if equipped
Passive Features
Airbags Driver:
Standard (Frontal)
Airbags Passenger:
Standard (Frontal)
Seatbelts:
3-point front and rear seatbelts, pretensioners for front seats
Child Seat Anchors:
LATCH system (Lower Anchors and Tethers for CHildren)
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo with CD player, 4-6 speakers. Some models may have an auxiliary input.
Navigation:
Not available on this model year.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Not typically available.
Connectivity
Bluetooth:
Not available.
Usb Port:
Not available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (refer to manual for exact intervals).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km)
Spark Plug Replacement:
Every 60,000-100,000 miles (96,000-160,000 km), depending on plug type (e.g., iridium recommended for longevity).
Timing Belt Replacement:
Not applicable - Engines use timing chains.
Fluid Specifications
Engine Oil Type 1.6L:
API SG or higher, SAE 5W-30 or 5W-40 (check manual for ambient temperature suitability).
Engine Oil Capacity 1.6L:
Approx. 3.8 liters (4.0 US quarts)
Coolant Type:
Ethylene glycol-based antifreeze/coolant (Asian vehicle specific or universal blue/green).
Transmission Fluid Manual:
API GL-4 SAE 75W-90 manual transmission fluid.
Transmission Fluid Automatic:
Kia Genuine ATF SP-III or equivalent (e.g., Dexron III compatible).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Mounts:
Can degrade over time leading to vibration and engine noise.
Clutch Wear:
Manual transmission clutches can wear out, especially with aggressive driving.
Suspension Components:
Ball joints, tie rod ends, and bushings can wear, leading to steering looseness and uneven tire wear.
Rear Wheel Bearings:
Can develop noise and require replacement.
Power Window Motors:
Can fail, requiring replacement of the motor or regulator assembly.
📚 Vehicle History
Brand Heritage
Kia Origins:
Founded in 1944, initially as a manufacturer of steel tubing and bicycle parts. Entered automotive manufacturing in the late 1960s.
Model Evolution
First Generation Launch:
Introduced in 1997 in Korea, with international markets receiving it from 1999. The 2004 model year represents the facelifted version of the first generation.
Facelift Details:
The 2004 model year typically featured updated exterior styling (headlights, grille, bumpers), revised interior trim, and potential powertrain refinements.
Production
Manufacturing Locations:
South Korea, Malaysia, Philippines, Vietnam
Production Years First Gen:
1997-2005
🏆 Awards & Recognition
Recognitions
J D Power Reliability:
Generally rated as average to below average for reliability in its class by JD Power and Associates for this generation.
Ratings
Consumer Reports:
Mixed reviews, often cited for value but some concerns regarding long-term reliability and build quality compared to Japanese competitors.
Certifications
Safety Certifications Usdm:
Meets US Federal Motor Vehicle Safety Standards (FMVSS).