The Kia Rio, produced from 2000 to 2005, is a subcompact car designed for economy-conscious buyers and first-time car owners. This model, part of the first generation (DC), offered a practical design with a focus on affordability and fuel efficiency, competing with vehicles like the Hyundai Accent and Ford Focus. Available with either a 1.3L or 1.5L inline 4-cylinder engine, it provided dependable performance for daily commuting and general transportation needs. The 2002 model year saw minor updates, building upon the foundation of this reliable and accessible vehicle. This comprehensive workshop service manual provides detailed technical information for the Kia Rio, covering all major systems including the engine, transmission, brakes, suspension, steering, and electrical systems. It includes procedures for routine maintenance, troubleshooting, component diagnosis, and in-depth repair processes such as engine rebuilds and transmission overhauls. With mechanic-grade detail, diagnostic charts, torque specifications, and wiring diagrams, this manual is an essential resource for owners and technicians alike, ensuring the proper maintenance and repair of the vehicle. 🏷️ Basic Information Identification Make: Kia Model: Rio Year: 2002 Codes Platform Code: DC 👋 Introduction Market Position Segment: Subcompact Car Target Demographic: Economy-conscious buyers, first-time car owners Competitive Analysis Key Competitors 2002: Hyundai Accent, Ford Focus, Chevrolet Cavalier, Toyota Echo, Honda Civic Key Features Value Proposition: Affordability, fuel efficiency, practical design Manual Value: Provides detailed technical information for DIY repairs and professional servicing. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Page Count Estimated Page Count: 1500+ Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Yes Transmission: Yes Brakes: Yes Suspension: Yes Steering: Yes Electrical System: Yes Climate Control: Yes Body And Chassis: Yes Interior Components: Yes Exhaust System: Yes Fuel System: Yes Cooling System: Yes Ignition System: Yes Emissions Control: Yes Procedures Included Routine Maintenance: Yes Troubleshooting Guides: Yes Component Diagnosis: Yes Engine Rebuild: Yes Transmission Overhaul: Yes Brake System Repair: Yes Suspension And Steering Repair: Yes Electrical Diagnostics And Repair: Yes Bodywork Repair: Yes HVAC System Service: Yes Scheduled Maintenance: Yes Technical Depth Depth: Comprehensive Detail Level: Mechanic-Grade Diagnostic Charts: Included Torque Specifications: Included Wiring Diagrams: Included Component Identification: Detailed 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes Print Quality Printability: High-Resolution, Printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: G4HD (for 1.3L), G4EH (for 1.5L) Engine Type: Inline 4-cylinder, SOHC/DOHC Displacement 1.3L: 1298 cc Displacement 1.5L: 1493 cc Performance Horsepower 1.3L: 70-77 hp @ 5500-6000 rpm Torque 1.3L: 112-116 Nm @ 3200-3400 rpm Horsepower 1.5L: 90-96 hp @ 5500-6000 rpm Torque 1.5L: 125-132 Nm @ 3400-4000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Recommended Octane Rating: 87 AKI (91 RON) Engine Management ECU Type: Proprietary Kia ECU (specifics detailed in manual) 🔧 Transmission Standard Type Standard: 5-Speed Manual Optional Type Optional: 4-Speed Automatic Features Clutch Type: Single Dry Plate Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (or as specified by Kia) Automatic Transmission Fluid: Kia Genuine ATF SP-III or equivalent 📐 Dimensions Exterior Length: 3,930 mm (154.7 in) Width: 1,695 mm (66.7 in) Height: 1,440 mm (56.7 in) Wheelbase: 2,430 mm (95.7 in) Front Track: 1,470 mm (57.9 in) Rear Track: 1,470 mm (57.9 in) Weights Curb Weight: 1020-1060 kg (2250-2337 lbs) Gross Vehicle Weight Rating: Approx. 1450 kg (3197 lbs) Towing Capacity: Not Recommended/Not Specified Cargo Cargo Volume: Approx. 271 liters (9.6 cu ft) with rear seats up 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Not Rated (for 2002 model year) NHTSA Front Impact Passenger: Not Rated (for 2002 model year) IIHS Small Overlap Frontal: Not Tested (for 2002 model year) Active Features ABS: Optional on some trims Traction Control: Not Available Passive Features Airbags Driver: Standard Airbags Passenger: Standard Seatbelts: 3-point front and rear (with pretensioners on front) Child Seat Anchors: LATCH system (Rear) 💡 Technology Features Infotainment Audio System: Base AM/FM/Cassette or optional CD player Speakers: 2 or 4 speakers Driver Assistance Cruise Control: Optional on higher trims Connectivity Aux Input: Not available Bluetooth: Not available 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months Air Filter Replacement: Every 15,000 miles (24,000 km) Spark Plug Replacement: Every 60,000 miles (96,000 km) Coolant Flush: Every 30,000 miles (48,000 km) or 2 years Fluid Specifications Engine Oil Type: API SJ or higher, SAE 5W-30 Engine Oil Capacity: 3.5 liters (3.7 US qts) with filter Coolant Type: Ethylene Glycol based coolant, Kia Long Life Coolant or equivalent Brake Fluid Type: DOT 3 Power Steering Fluid: Dexron II/III or equivalent (check manual for specific) Known Issues Engine Timing Belt: Crucial to follow replacement intervals to prevent catastrophic failure. Manual details replacement procedure. Rear Wheel Bearings: Can wear prematurely,...