Kia RIO 2005 Configuration guide

GENERAL

GI -2 GENERAL INFORMATION
GENERAL
IDENTIFICATION NUMBER
LOCATIONS EE840C2D
Engine number
(See page GI - 3)
Vehicle Identification number
(See page GI - 3)
Manual Transaxle number
(See page GI - 4)
Automatic Transaxle number
(See page GI - 4)
LAJF001A

GENERAL GI -3
IDENTIFICATION NUMBER DESCRIPTION
VEHICLE IDENTIFICATION NUMBER
6 0000015222EDANK
1 2 3 4 5 6 7 8 9 10 11 12~17
1
LAJF002A
1-3:M
ake/Vehicletype
-KNE,KNA = Kia Passenger Car
4-5:Ve
hicle Line / Series
-DE=PR
IDE
6-7:Bo
dy type
-22=4D
oor Sedan
-24=5D
oor Hatchback
8 : Enginetype
-1=1.4G
asoline (G4EE)
-2=1.6G
asoline (G4ED)
-4=1.5D
iesel (D4FA)
9:Trans
axle type
- Check digit
- 2 = 5 speedmanual
-3=Autom
atic
10 : Model year
- 5 = 2005, 6 = 2006
11 : Plant location
-6=Sohap
lant
12 : Sequential number
- 000001 ~ 999999
PAINT CODE
CODE COLOR
UD CLEAR WHITE
6C CLEAR SILVER
J1 POLAR SILVER
J4 CASHMERE BEIGE
2D SOFT GREEN
T5 SAPPHIRE
06 SUNSET ORANGE
08 TROPICAL RED
7V OLIVE GRAY
9B MIDNIGHT BLACK

GI -4 GENERAL INFORMATION
ENGINE IDENTIFICATION NUMBER
GEC45000001
1 2 3 4 5 6~11
AAJF003A
1. Engine fuel
- G = Gasoline
2. Engine range
- 4 = 4 cycle 4 cylinder
3. Engine development order
-E=ALP
HA Engine
4. Engine capacity
- D = 1,599cc
-E=1,399cc
5. Production year
- 5 : 2005, 6 : 2006
6. Engine production sequence number
- 000001 ~ 999999
TRANSMISSION IDENTIFICATION NUMBER
MANUAL
MANUAL
R 18735 000001
12 3 4
AAJF004A
1. Model
-R=M5CF1
-P=M5CF2
2. Production year
- 5 : 2005, 6 : 2006
3. Gear ratio(Tooth number)
<Diffe
rential drive gear tooth number / Output shaft
gear tooth number >
- 1873 = 73/18 = 4.056
4. Transaxle production sequence number
- 000001 ~ 999999
AUTOMATIC
TNUD5
1234 5 6
AAJF005A
5. Modle
-T=A4
AF3
6. Production year
- 5 : 2005, 6 : 2006
7. Gear ratio
-N=4.041
8. Detailed chassification
-UD=1
.4 DOHC
-WD=1
.6 CVVT
9. Spare
10. Transaxle production sequence number
- 000001 ~ 999999

GENERAL GI -5
WARNING / CAUTION LABEL LOCATIONS
AIRDUCT WARNING
BATTERY CAUTION
FAN CAUTION
RADIATOR CAP
CAUTION
SIDE AIRBAG INFORMATION
ATTENTION
SRSVEHICLE
THIS CAR IS EQUIPPED WITH A SUPPLEMENTAL
RESTRAINT SYSTEM.TO PROVIDE CONTINED RELIABLITY,
CERTAIN ELEMENTS OF THE SUPPLEMENTAL RESTRAINT
SYSTEM SHALL BE SERVICED OR REPLACED BY AUTHORIZED
DEALER TENYEARS AFTER VEHICLE LABEL. FOR FURTHER
INFORMATION.
SEE OWNER'S MANUAL.
SIDE AIR BAG
THIS CAR IS EQUIPPED WITH A SIDE AIRBAG SYSTEM.
TO PROVIDE CONTINUED RELIABILITY, CERTAIN ELEMENTS
OF THE SIDE AIRBAG SYSTEM SHALL BE SERVICED OR
VEHICLE MANUFACTURE DATE SHOWN ON CERTIFICATION LABEL.
FOR FURTHER INFORMATION
SEE OWNER'S MANUAL.
LAJF003A

GI -6 GENERAL INFORMATION
AIR BAG WARNING / CAUTION LABEL
CAUTION
AIRBAG : Handing is limited to trained personnel.
To be used only in prescribed vehicles.If not propely
installed, device may become a dangerous projectile.
See serivce manual instruction
DRIVE MODULE CAUTION
Caution
Don't open, remove or transfer to another vehicle.
Risk of malfunction and bodily injury!
This unit is to be installed and/or dismantled by trained
personnel only.
This item contains an explosive to be installed igniter.
LAJF004A

GENERAL GI -7
AIR BAG WARNING / CAUTION LABEL (CONT’D)
C
D
B
A
S R S
AIRBAG
S R S
AIRBAG
AAJF008A

GI -8 GENERAL INFORMATION
AIR BAG WARNING / CAUTION LABEL (CONT’D)
A:WARNING
SEE OWNER’S MANUAL.
This car is equipped a side airbag for each front seat.
•Do not use any accessory seat covers.
•Use of other seat covers could reduce the
effect of the system.
•Do not install any accessories on the side
or near the side airbag.
•Do not use excessive force on the side of the seal.
•For further information, see the owner’s manual.
B:CAUTION
AIRBAG ESPE UNIT
Detach connector before unmounting. Assemble
strictly according to manual instructions.
C : PASSENGER MODULE CAUTION
CAUTION
Don’t open, remove or transfer to another vehicle.
Risk of malfunction and bodily injury!
This unit is to be installed and/or dismantled by
trained personnel only. This item contains an
explosivetobeinstalledigniter.
D : SUPPLEMENTAL RESTRAINT SYSTEM
(AIRBAG) INFORMATION
•The airbag is a Supplement Restraint
System (SRS).
You must always wear the seat belts.
•The airbag system condition is normal
when the "SRS" lamp in the cluster flashes
approximately 6 times after the ignition key
is turned on and then goes off.
•If any of the following condition occur, the
system must be serviced.
• "SRS" lamp does not light up when
the key is turned on.
• "SRS" lamp stays lit or flashes continuously.
• The airbag has inflated.
•The airbag system must be inspected by an
authorized dealer ten years after the vehicle
manufacture date shown on the certification label,
located on left front door opening area.
WARNING
Failure to the above instructions may result in injury
to you or other occupants in the vehicle
•See the "SRS" section in Owner’s Manual for
more information about airbags.

GENERAL GI -9
BATTERY CAUTION LABEL DESCRIBTION
Wear eye protection
when charging or working
near a battery.
Always provide ventilation
when working in an
enclosed space.
When lifting a plastic-cased
battery, excesive pressure on
acid to leak resulting in personal
injury. Lift with a battery carrier
or with your hands on opposite
corners.
Never attempt to change the
battery when the battery
cables are connected.
The electrical ignition system
works with high voltage.
Never touch these components
with the engine running
or the ignition switched on.
Keep lighted cigarettes
and all other flames or
sparks away from the
battery.
Keep batteries out of the
reach of children
because batteries
contain highly corrosive
SULFURIC ACID. Do not
allow battery acid to
contact your skin, eyes,
clothing or paint finish.
If any electrolyte gets into your eyes,
flush your eyes with clean water for
at least 15 minutes and get immediate
medical attention. If possible, continue
to apply water with a sponge or cloth
until medical attention is received.
If electrolyte gets on your skin, throughly
wash the contacted area.
If you feel a pain or a burning sensation,
get medical attention immediately.
Always read the following
instructions carefully
when handing a battery.
Hydrogen, which is a
highly combustible gas,
is always presents in battery
cells and may explode if
ignited.
EAKE007E

GI -10 GENERAL INFORMATION
LIFT AND SUPPORT POINTS
WARNING
When heavy rear components such as suspen-
sion, fuel tank, spare tire, tailgate and trunk lid
are to be removed, place additional weight in the
luggage area before hoisting. When substantial
weight is removed from the rear of the vehicle, the
center of gravity may change and cam cause the
vehicle to tip forward on the hoist.
NOTE
•Since each tire/wheel assembly weights approx-
imately 30lbs (14kg), placing the front wheels in
the luggage area can assist with the weight dis-
tribution.
•Use the same support points to support the vehi-
cleonsafetystands.
1. Placetheliftblocksunderthe support pointsasshown
in the illustration.
2. Raise the hoist a few inches (centimeters) and rock
the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points
for secure support.
[FRONT]
LIFT BLOCK LIFT BLOCK
[REAR]
LAJF005A

GENERAL GI -11
TOWING
If the vehicle needs to be towed, call a professional towing
service. Never tow vehicle with just a rope or chain. It is
very dangerous.
AAJF010A
AAJF011A
EMERGENCY TOWING
There are three propular methods of towing a vehicle :
Flat - bed Equipment - The operator loads the vehicle
on the back of truck. This is best way of transporting the
vehicle.
Wheel Lift Equipment - The tow truck uses two pivoting
arms that go under the tires (front or rear) and lift them off
the ground. The other two wheels remain on the ground.
Sling type Equipment - The tow truck metal cables with
hooks on the ends. These hooks go around parts of the
frame or suspension, and the cables lift that end of the ve-
hicle off the ground. The vehicle’s suspension and body
can be seriously damaged if this method of towing is at-
tempted.
If the vehicle cannot be transported by flat-bed, if should
be towed with the front wheels off the ground. If due to
damage, the vehicle must be toward with the front wheels
on the ground, do not following :
Manual Transmission
•Release the parking brake.
•Shift the transmission to neutral.
Automatic Transmission
•Release the parking brake.
•Start the engine.
•Shift to [D] position, then [N] position.
•Turn off the engine.
CAUTION
•Improper towing preparation will damage the
transmission. Follow the above procedure
exactly. If you cannot shift the transmission
or start the engine (automatic transmission),
your vehicle must be transported on a flatbed.
•It is the best to tow vehicle no farther than
19miles (30km), and keep the speed below
30mph (50km/h).
•Trying to lift or tow your vehicle by the
bumpers will cause serious damage. The
bumpers are not designed to support the
vehicle’s weight.

GI -12 GENERAL INFORMATION
TIGHTENING TORQUE TABLE OF STANDARD
PARTS
Torque Nm (kg.cm, lb.ft)
Bolt nominal
diameter (mm) Pitch (mm) Head Mark 4 Head Mark 7
EAKE004E KASD100Y EAKE004F EAKE004G
M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5~6(50~60,3.6~4.3)
M6 1.0 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)
M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0 )
M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)
M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~ 100)
M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 ~ 94) 180 ~ 210 (1,800 ~ 2,100, 130 ~ 150)
M18 1.5 160 ~ 180 (1,600 ~ 1,800, 116 ~ 130) 260 ~ 300 (2,600 ~ 3,000, 190 ~ 215)
M20 1.5 220 ~ 250 (2,200 ~ 2,500, 160 ~ 180) 360 ~ 420 (3,600 ~ 4,200, 260 ~ 300)
M22 1.5 290 ~ 330 (2,900 ~ 3,300, 210 ~ 240) 480 ~ 550 (4,800 ~ 5,500, 350 ~ 400)
M24 1.5 360 ~ 420 (3,600 ~ 4,200, 260 ~ 300) 610 ~ 700 (6,100 ~ 7,000, 440 ~ 505)
NOTE
1. The torques shown in the table are standard val-
ues under the following conditions :
• Nuts and bolts are made of galvanized steel
bar.
• Galvanized plain steel washers are inserted.
• All nuts, bolts and plain washers are dry.
2. The torques shown in the table are not applica-
ble:
• When spring washers, toothed washers and
the like are inserted.
• If plastic parts are fastened.
• If self-tapping screws or self-locking nuts are
used.
• If threads and surfaces are coated with oil.
3. If you reduce the torques in the table to the per-
centage indicated below, under the following con-
ditions, if will be the standard value.
• If spring washers are used : 85%
• If threads and bearing sufaces are stained
with oil : 85%

GENERAL GI -13
LUBRICANTS
RECOMMENDED LUBRICANTS
Parts OIL ＆GREASE STANDARD
Engine Oil API SL(SJ) or ABOVE,
ILSAC GF-3 and ABOVE
Manual transaxle GENUINE PART MTF 75W90 (API GL - 4)
Automatic transaxle DIAMOND ATF SP-III, SK ATF SP-III
Brake DOT 3, DOT 4 or equivalent
Coolant Ethlyene glycol base for aluminium radiator
Transaxle linkage, parking breake cable
mechanism, hood, door latch, seat adjuster,
tailgate latch, door hinges, tailgate hinge Multipurpose grease NIGL grade #2
Power Steering PSF -3
WARNING
Always use Genuine Hyundai parts and recom-
mended fluid.
Using any other type of parts and fluid can cause
serious damaged if the vehicle.
LUBRICANTS CAPACITIES
Description Capacities
Oil pan 3.0 (3.17, 2.64)
Oil filter 0.3 (0.32, 0.26)
Engine oil
Total 3.3 (3.49, 2.90)
Cooling system 5.5~5.8 (5.81~6.13, 4.84~5.10)
Manual transaxle 2.0 (2.11, 1.76)
Automatic transaxle 6.1 (6.45, 5.37)
Power steering 0.75~0.8 (0.79~0.85, 0.66~0.70)
Capacities: [liter (U.S.qts, lmp.qts)]

GI -14 GENERAL INFORMATION
SELECTION OF ENGINE OIL
RECOMMENDEDILSACclassification : GF-3ORABOVE
RECOMMENDED API classification : SL(SJ) OR ABOVE
RECOMMENDED SAE VISCOSITY GRADES :
20W
- 50
- 7
- 13
- 18
10W
- 30 5W -20
15W
- 40
*1
*1 : Recommended regardless of environment.
If not available, refer to the recommended SAE viscosity numbers.
LC8F002A
NOTE
For best performance and maximum protection of all
types of operation, select only those lubricants which
:
1. Satisfy the requirements of the API classification.
2. Have the proper SAE grade number for expected
ambient temperature range.
Lubricants that do not have both an SAE grade num-
ber and API service classification on the container
should not be used.

GENERAL GI -15
GENERAL SERVICE INFORMATION
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas
before starting work.
CAUTION
The support rod must be inserted into the hole
near the edge of the hood whenever you inspect
the engine compartment to prevent the hood from
falling and causing possible injury.
Make sure that the support rod has been released
prior to closing the hood. Always check to be sure
the hood is firmly latched before driving the vehi-
cle.
PREPARATION OF TOOLS AND MESURING
EQUIPMENT
Be sure that all necessary tools and measuring equipment
are available starting work.
SPECIAL TOOLS
Use special tools when they are required.
EAKE005A
REMOVALOFPARTS
First find the cause of the problem and then determine
whether removal or disassembly before starting the job.
EAKE005B
DISASSEMBLY
If the disassembly procedure is complex, requiring many
parts to be disassembled, all parts should be disassem-
bled in a way that will not affect their performance or ex-
ternal appearance.
1. Inspection of parts
Each part, when removed, should be carefully in-
spected for malfunction, deformation, damage, and
other problems.
EAKE005C

GI -16 GENERAL INFORMATION
2. Arrangementofparts
All disassembled parts should be carefully arranged
for effective reassembly.
Be sure to separate and correctly identify the parts to
be replaced from those that will be used again.
EAKE005D
3. Cleaning parts for reuse
All parts to be used again should be carefully and
thoroughly cleaned by an appropriate method.
EAKE005E
PARTS
When replacing parts, use KIA MOTORS genuine parts.
LAIF006A
REPLACEMENT
Standard values, such as torques and certain adjust-
ments, must be strictly observed in the reassembly of all
parts.
If removed, the following parts should always be replaced
with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)

GENERAL GI -17
6. Plastic nuts
EAKE005G
Depending on their location.
7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components of
parts.
9. Specified oil or grease should be applied to the pre-
scribed locations (oil seals, etc.) before assembly.
EAKE005H
ADJUSTMENT
Use gauges and testers to adjust correctly the parts to
standard values correctly.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the neg-
ative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connec-
tors.
3. Locking connectors will click when the connector is
secure.
4. Handle sensors and relays carefully. Be careful not to
drop them against other parts.
EAKE005I
RUBBER PARTS AND TUBES
Always prevent gasoline or from touching rubber parts or
tubing.
EAKE005J

GI -18 GENERAL INFORMATION
MEASURING BODY DIMENSIONS
1. Basically, all measurements in this manual are taken
with a tracking gauge.
2. When a measuring tape is used, check to be sure
there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimen-
sions and actual - measurement dimensions are
used in this manual.
DIMENSIONS PROJECTED
1. These are the dimensions measured when the mea-
surement points are projected from the vehicle’s sur-
face, and are the reference dimensions used for body
alterations.
2. If the length of the tracking gauge probes is ad-
justable, measure it by lengthening one of two probes
as long as the different value in height of the two
surface.
Height
Projected dimension
EAKE005K
MEASURING ACTUAL DIMENSIONS
1. These dimensions indicate the actual linear distance
between measurement points, and are used as the
reference dimensions when a tracking gauge is used
for measurement.
2. First adjust both probes to the same length (A=A’)
before measurement.
NOTE
Check the probes and gauge itself to make sure there
is no free play.
Actually-measured dimension
EAKE005L
MEASUREMENT POINT
Measurements should be taken at the center fo the hole.
Hole center
EAKE005M

GENERAL GI -19
CHECKING CABLES AND WIRES
1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery
electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks
and degrading.
5. Check the conductive parts of terminals for contact
with other metallic parts (vehicle body and other
parts).
6. Check grounded parts to verify that there is complete
continuity between their attaching bolt(s) and the ve-
hicle’s body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to the prevent
contact with sharp corners of the vehicle body, etc.
or hot parts (exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide
enough clearance from the fan pulley, fan belt and
other rotating or moving parts.
10. Check that the wiring has a little space so that it can
vibrate between fixed and moving parts such as the
vehicle body and the engine.
EAKE005N
CHECK FUSES
A blade type fuse test taps provided to allow checking the
fuse itself without removing if from the fuse box. The fuse
is good if the test lamp lights up when one lead is con-
nected to the test taps (one at a time) and the other lead
is grounded.
(Turn the ignition switch so that the fuse circuit becomes
operative)
Fuse box
Test leads
EAKE005O

GI -20 GENERAL INFORMATION
SERIVICING THE ELECTRICAL SYSTEM
1. Prior to servicing the electrical system, be sure to
turn off the ignition switch and disconnect the battery
ground cable.
NOTE
In the course of MFI or ELC system diagnosis, when
the battery cable is removed, any diagnostic trouble
code retained by the computer will be cleared. There-
fore, if necessary, read the diagnostic before remov-
ing the battery cable.
EAKE005P
2. Attachthewiringharnesseswithclampssothatthere
is no slack. However, for any harness which passes
the engine or other vibrating parts of the vehicle, al-
low some slack within a range that does not allow the
engine vibrations to cause the harness to come into
contact with any of the surrounding parts and then se-
cure the harness by using a clamp.
EAKE005R
3. If any section of a wiring harness interferes with the
edge of a parts, or a corner, wrap the section of the
harness with tape or something similar in order to pro-
tectiffromdamage.
EAKE005S