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2002 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 2002 KIA RIO AUTOMOBILES
Imported Cars & Light Trucks & Vans -> 2001-02 -> Leak Test -> Electronic Leak Detectors -> Fluid Leak Detectors
Vehicle: 2002 KIA RIO RX-V 1.5 L4 GAS
Testing the refrigerant system for leaks is one of the most important phases of troubleshooting. One or more of the methods outlined will prove useful in detecting leaks or checking connections if service work is performed. Before beginning any leak test, attach a manifold gauge set and note pressure. If little or no pressure is indicated, a partial charge must be installed. Check all connections, compressor head gasket, oil filler plug and compressor shaft seal for leaks.
R-12 leak detectors will not detect R-134a leaks. For R-134a system an electronic type leak detector i...
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BRAKE SERVICE PROCEDURES FOR 2002 KIA RIO AUTOMOBILES
Hydraulic Brake Systems -> Component Service -> Master Cylinder -> Rio -> Sephia -> Sportage -> Wheel Cylinder
Vehicle: 2002 KIA RIO 1.5 L4 GAS
Master Cylinder
Rio
- Secure master cylinder assembly in a suitable vise.
- Remove reservoir cap, Fig. , then drain brake fluid into a suitable container.
- Remove level sensor using a suitable screwdriver.
- Remove reservoir mounting screw, then pry reservoir out of master cylinder. Discard seals.
- Push primary piston into cylinder bore to ease snap ring removal, then remove snap ring and piston.
- Push secondary piston into bore, then remove secondary piston stop screw.
- Place a suitable shop towel in bore to catch secondary piston.
- Remove secondary piston using compressed air through port.
- Rever...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 KIA RIO AUTOMOBILES
Kia -> Fuel Filter Scheduled Maintenance -> Optima, Rio, Sephia & Spectra -> Normal Service -> Severe Service
Vehicle: 2002 KIA RIO Cinco 1.5 L4 GAS
Normal Service
Replace every 60 months ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 KIA RIO AUTOMOBILES
CV AXLE SHAFT, Replace -> Front
Vehicle: 2002 KIA RIO Cinco 1.5 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 2002 KIA RIO AUTOMOBILES
Starter, Replace
Vehicle: 2002 KIA RIO RX-V 1.5 L4 GAS
- Disconnect battery ground cable.
- Remove upper intake manifold bracket.
- Disconnect starter electrical connectors.
- Remove...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 KIA RIO AUTOMOBILES
Cabin Air Filter Service -> Kia -> 2001-05 Rio
Vehicle: 2002 KIA RIO 1.5 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 2002 KIA RIO AUTOMOBILES
Kia -> Electronic Brake Force Distribution (EBD)/Parking Brake Warning Lamp ->
Vehicle: 2002 KIA RIO Cinco 1.5 L4 GAS
The EBD/Parking Brake warning lamp is used to warn of a system fault. It will be lit during engine start-up, but should go out when the self-diagnostic system determines that the system is functioning properly. The lamp will also illuminate when the parking brake is in the applied position. If the lamp EBD/Pa...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 KIA RIO AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2002 KIA RIO 1.5 L4 GAS
Inlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at heater core.
- Remove hose from heater core.
- Reposition hose clamp at water crossover.
- Remove hose from water crossover.
- Remove hose from vehicle.
- Reverse procedure t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 KIA RIO AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 KIA RIO RX-V 1.5 L4 GAS
- Disconnect battery ground cable.
- Loosen coolant pump pulley bolts.
- Loosen alternator support nut.
- Loosen alternator lockbolt and remove belt.
- Clean and inspect belt surfaces of...
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COMPONENT LOCATION DIAGRAMS FOR 2002 KIA RIO AUTOMOBILES
Component location diagrams for most 2002 KIA RIO cars and light trucks sold in the U.S. from 1990+.
Oil Pan Diagram for 2002 KIA RIO 1.5 L4 GAS Components on diagram: |
Harnesses Diagram for 2002 KIA RIO 1.5 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2002 KIA RIO AUTOMOBILES
OEM drawn wiring diagrams for most 2002 KIA RIO cars and light trucks sold in the U.S.
2002 KIA RIO Cinco 1.5 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 KIA RIO AUTOMOBILES
OEM TSB listings for most 2002 KIA RIO cars and light trucks sold in the U.S. from 1985+.
Document: Enhanced Dealer Feedback and Digital Camera Requirements to Support Kia Quality Initiatives Vehicle: 2002 KIA RIO 1.5 L4 GAS Auto Systems: |
Document: KIA MOTORS "TECH TIMES" PRINT EDITION MOVES EXCLUSIVELY TO "ON LINE" Vehicle: 2002 KIA RIO 1.5 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 KIA RIO AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 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 2002 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 2002 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 2002 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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