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2004 KIA RIO CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT KIA REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Electrical Symbol & Wire Color Code Identification -> Wire Color Code Identification -> Imported Vehicles
Vehicle: 2004 KIA RIO Cinco 1.6 L4 GAS
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BRAKE SERVICE PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Kia -> Drum Brakes -> Brake Service -> Brake Shoes, Replace -> Installation -> Optima -> Removal -> Rio -> Sedona -> Spectra
Vehicle: 2004 KIA RIO 1.6 L4 GAS
Brake Shoes, Replace
Optima
- Raise and support vehicle, then remove wheel/tire assembly.
- Remove brake drum. If drum is difficult to remove, screw in bolts to pull drum out, Fig. .
- Remove end shoe springs, cylinder and hold-down spring.
- Remove shoes and adjuster as an assembly.
- Reverse procedure to install, noting the following:
- Apply suitable grease to backing plate shoe contact surfaces.
- Install shoe hold-down pin, then assemble return spring with the strut or pushrod shortened.
- Pull parking brake lever fully upward. Repeat process several times.
Rio
- Remove brake shoe components in numbered ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Kia -> Component Locations -> Rio
Vehicle: 2004 KIA RIO Cinco 1.6 L4 GAS
Refer to Fig. for...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
CV AXLE SHAFT, Replace -> Front
Vehicle: 2004 KIA RIO RX-V 1.6 L4 GAS
Front
- Raise and support vehicle and support it with safety stands in proper locations.
- Remove wheel nuts and front wheels.
- Remove drain plug and drain transaxle fluid in suitable container.
- Remove driveshaft cotter pin, castle nut and washer from front hub.
- Remove tension rod mounting nuts.
- Remove ball joint clamp mounting bolt from knuckle.
- Pry down lower arm and disconnect ball joint.
- Remove stabilizer bar from control link after loosening control link nut.
- Insert suitable tool between transaxle case and driveshaft assembly, then separate driveshaft...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Alternator, Replace
Vehicle: 2004 KIA RIO 1.6 L4 GAS
- Disconnect battery ground cable.
- Disconnect alternator B+ terminal wire and electrical connectors.
- Loosen pivot bolt and tensioner mounting bolt, but do not remove just yet.
- Mark running direction with felt pen or chalk, then remove alternator drive belt.
- Remove t...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Cabin Air Filter Service -> Kia -> 2001-05 Rio
Vehicle: 2004 KIA RIO RX-V 1.6 L4 GAS
Under normal operating conditions the cabin air filter should be replaced every 9,500 miles. In dusty areas change the cabin air filter more often.
- Remove the glove compartment.
- Pull the cabin air filter cover by sliding to the left.
- Rem...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Kia -> Malfunction Indicator Lamp (MIL) ->
Vehicle: 2004 KIA RIO 1.6 L4 GAS
The MIL will be illuminated when the ignition switch is in the On position and the engine is not running. When the engine is started, the lamp should go off. If it remains lit, a diagnostic trouble code has been stored.On models less OBD II, after diagnosis and repair are complete, place ignition switch in off position, then clear stored diagnostic trouble codes by disconnecting the battery ground cable for at least 20 seconds. On models equipped with OBD II, following diagnosis and repair of the system, the lamp may be turned off using a suita...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 KIA RIO 1.6 L4 GAS
Lower
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at radiator outlet.
- Remove hose from radiator.
- Reposition hose clamp at water inlet pipe.
- Remove hose from water inlet pipe.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 KIA RIO AUTOMOBILES
Serpentine Drive Belt, Replace -> Air Conditioning -> Alternator -> Power Steering
Vehicle: 2004 KIA RIO RX-V 1.6 L4 GAS
Alternator
- Disconnect battery ground cable from battery.
- Loosen alternator upper locknut.
- Loosen lower mounting nut.
- Push alternator inward toward engine.
- Remove alternator drive belt.
- Clean and inspect belt surfaces of all pulleys.
- Reverse procedure to install, noting the following:
- Torque alternator mounting nut and bolt to 18 ft. lbs.
- Torque alternator adjustment lockbolt to 11 ft. lbs.
- Torque alternator brace mounting bolt to 17 ft. lbs.
Air Conditi...
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COMPONENT LOCATION DIAGRAMS FOR 2004 KIA RIO AUTOMOBILES
Component location diagrams for most 2004 KIA RIO cars and light trucks sold in the U.S. from 1990+.
Underbody Components Diagram for 2004 KIA RIO RX-V 1.6 L4 GAS Components on diagram: |
Underbody Components Diagram for 2004 KIA RIO Cinco 1.6 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 KIA RIO AUTOMOBILES
OEM drawn wiring diagrams for most 2004 KIA RIO cars and light trucks sold in the U.S.
2004 KIA RIO 1.6 L4 GAS Wiring Diagram Components on diagram: |
2004 KIA RIO Cinco 1.6 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 KIA RIO AUTOMOBILES
OEM TSB listings for most 2004 KIA RIO cars and light trucks sold in the U.S. from 1985+.
Document: Torque Specifications on "Torque to Yield" Engine Component Bolts Vehicle: 2004 KIA RIO 1.6 L4 GAS Auto Systems: |
Document: Enhanced Dealer Feedback and Digital Camera Requirements to Support Kia Quality Initiatives Vehicle: 2004 KIA RIO 1.6 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 KIA RIO AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 KIA RIO cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 KIA RIO cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 KIA RIO cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 KIA RIO cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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