🏷️ Basic Information Identification Make: Kia Model: Rio Year: 2005 Engine Variant: 1.6L DOHC 4-Cylinder Generation Generation Code: JB (Second Generation) 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, and vehicle owners seeking in-depth repair knowledge. Competitive Analysis Value Proposition: Provides OEM-level technical data, mirroring professional technician resources at a fraction of the cost of authorized dealership service. Key Features Accuracy: Based on official Kia factory service information. Clarity: Clear, concise text and illustrative diagrams facilitate understanding. Completeness: Bumper-to-bumper coverage for all systems and repair procedures. 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, and Maintenance Secondary Coverage: Diagnostics, Troubleshooting, Wiring Diagrams Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Factory Service Manual (FSM) / Shop Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, cooling system, lubrication system, fuel system, ignition system, emission control system, engine control module (ECM) diagnostics and repair. Transmission Systems: Manual transmission service, automatic transmission service, clutch system, driveline components. Brake Systems: Hydraulic brake system, ABS (Anti-lock Braking System), parking brake. Steering Suspension: Power steering system, steering linkage, suspension components (struts, shocks, springs, bushings), wheel alignment specifications. Electrical Systems: Battery, charging system, starting system, lighting system, instruments, gauges, body control modules, infotainment system wiring, power accessories, safety systems wiring. HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant handling. Body Structure: Body panel removal and installation, interior trim, exterior trim, door mechanisms, glass replacement. Safety Systems: Airbag system diagnosis and service, seat belt mechanisms. Procedures Included Routine Maintenance: Oil changes, fluid checks and replacements, filter replacements, spark plug replacement, tire rotation and inspection. Diagnostic Procedures: Troubleshooting charts for common symptoms, diagnostic trouble codes (DTCs) lookup and interpretation, on-board diagnostics (OBD-II) system analysis. Engine Repair: Engine disassembly and reassembly, piston and ring replacement, cylinder head service, timing belt/chain replacement (if applicable), valve adjustment. Transmission Repair: Clutch replacement, transmission fluid service, internal transmission component repair (manual and automatic). Brake Service: Brake pad and rotor replacement, brake caliper service, brake line bleeding, ABS component testing and replacement. Electrical Repair: Component testing (alternator, starter, battery), wiring harness repair, sensor replacement, actuator testing. Suspension Steering Repair: Strut and shock absorber replacement, ball joint and tie rod end replacement, power steering pump and rack replacement. Body And Interior Repair: Door lock actuator replacement, window regulator repair, bumper cover installation, interior panel removal and reinstallation. Technical Depth Depth Of Information: Comprehensive: Covers all aspects from routine maintenance to complete engine and transmission rebuilds. Diagnostic Capability: Advanced: Includes detailed diagnostic procedures, troubleshooting trees, and wiring diagrams for effective fault finding. Rebuild Procedures: Complete: Provides step-by-step instructions for engine, transmission, and major component overhauls. 📊 Manual Specifications File Format Digital Format: PDF Interactivity: Searchable text with index functionality. Print Quality Printability: Printable pages for physical reference. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Compatibility Operating Systems: Windows (95-11), macOS, Linux, iOS, Android (via PDF reader). ⚙️ Engine Specifications Primary Engine Engine Code: G4EE Engine Type: Inline 4-cylinder, DOHC (Double Overhead Camshaft) Displacement: 1599 cc (1.6 Liters) Bore X Stroke: 76.5 mm x 87.0 mm (approx.) Compression Ratio: 9.0:1 (approx.) Performance Horsepower: 105 hp @ 6000 rpm (approx.) Torque: 107 lb-ft @ 3200 rpm (approx.) Fuel System Fuel Delivery: Electronic Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management Engine Control Unit: ECM (Engine Control Module) with OBD-II diagnostics. Cooling System Coolant Capacity: Approximately 5.5 Liters (with heater core) Lubrication System Oil Capacity: 4.0 Liters (4.2 US Quarts) with filter change Recommended Oil Viscosity: API SL/SM, SAE 5W-20 or 5W-30 Ignition System Ignition Type: Electronic Ignition with Coil-on-Plug (COP) or distributorless ignition system. 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission Manual Transmission Fluid Fluid Capacity: Approximately 2.0 Liters Fluid Specification: API GL-4, SAE 75W-90 Automatic Transmission Fluid Fluid Capacity: Approximately 6.8 Liters (total capacity) Fluid Specification: Kia ATF SP-III or equivalent Clutch Clutch Type: Dry, single-plate diaphragm spring clutch 📐 Dimensions Exterior Length: 3990 mm (157.1 in) Width: 1695 mm (66.7 in) Height: 1470 mm (57.9 in) Wheelbase: 2500 mm (98.4 in) Weights Curb Weight: Approximately 1050 - 1100 kg (2315 - 2425 lbs) Gross Vehicle Weight Rating: 1500 kg (approx.) Cargo Trunk Volume: 274 Liters (9.7 cu ft) Wheels Tires Standard Wheel Size: 14 or 15 inch alloy or steel wheels Standard Tire Size: 175/70 R14 or 185/65 R15 Bolt Pattern: 4 x 100 mm 🛡️ Safety Features Ratings NHTSA Front Crash Test: Not explicitly rated for this specific model year/variant by NHTSA in many markets, but generally considered safe for its class. IIHS Crash Test: Good in frontal offset tests for similar contemporary Kia models. Active Features ABS: Available ABS (Anti-lock Braking System) on some trims. Passive Features...