KIA RIO/RIO5 2006 4CYL (1.6L) OEM Factory Shop Service Repair Manual FSM Year Specific

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🏷️ Basic Information Identification Make: Kia Model: Rio Model Variant: Rio5 Year: 2006 Engine Code Designation: G4ED Trim Levels Covered: All versions (e.g., LX, EX) Generation Generation Identifier: JB Codes...

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Type: Car

Vendor:

Sku: 349663

Tags: 2006 Car Cars Kia RIO RIO5

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Model Variant:

Year:

Engine Code Designation:

Trim Levels Covered:

All versions (e.g., LX, EX)

Generation

Generation Identifier:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Subcompact economy car

Target Audience:

Budget-conscious consumers, first-time car buyers, urban commuters

Competitive Analysis

Primary Competitors:

Honda Fit, Toyota Yaris, Nissan Versa, Chevrolet Aveo, Ford Fiesta

Key Features

Vehicle Strengths:

Affordability, fuel efficiency, surprisingly spacious interior for its class, good maneuverability

Manual Advantage:

Provides dealership-level repair information, empowering owners for DIY maintenance and complex repairs.

📋 Manual Details

Coverage Areas

Coverage Scope:

Bumper-to-bumper repair and maintenance

Page Count

Estimated Page Count:

Over 1500 (typical for OEM FSM)

Manual Type

Manual Type:

Factory Service Manual (FSM) / Workshop Manual / Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Exhaust System, Drivetrain, Transmission

Chassis:

Suspension, Steering, Brakes, Wheels, Tires

Electrical:

Body Electrical, Powertrain Electrical, Chassis Electrical, Lighting, Instrumentation, HVAC Controls

Body:

Body Exterior, Body Interior, Restraint Systems, Climate Control System

Procedures Included

Diagnostic Procedures:

Component testing, DTC (Diagnostic Trouble Code) interpretation, circuit diagnosis

Repair Procedures:

Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal, electrical component replacement

Maintenance Procedures:

Tune-ups, oil changes, filter replacements, fluid flushes, belt replacement, brake pad replacement

Installation Procedures:

Component replacement, accessory installation (where applicable)

Technical Depth

Depth Of Information:

Advanced diagnostics, component-level repair, full engine and transmission disassembly/reassembly

📊 Manual Specifications

File Format

File Quality:

High-resolution, vector-based illustrations and text

Searchability:

Fully searchable text, indexed for quick navigation

Print Quality

Printability:

Printable pages for in-shop use

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-Cylinder (I4)

Displacement:

1.6 Liters (1599 cc)

Valve Train:

DOHC (Dual Overhead Camshafts), 16 Valves

Bore X Stroke:

76.5 mm x 87.0 mm

Compression Ratio:

10.0:1

Performance

Horsepower:

110 hp @ 6000 rpm (approx.)

Torque:

107 lb-ft @ 3200 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Emission Controls:

Catalytic Converter, EGR (Exhaust Gas Recirculation)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual

Optional

Transmission Type Optional:

4-Speed Automatic

Features

Clutch Type:

Hydraulic Actuated Dry Single Plate Clutch (Manual)

Transmission Fluid Spec Manual:

GL-4 Manual Transmission Fluid (e.g., API GL-4, SAE 75W/90)

Transmission Fluid Spec Automatic:

Kia SPIII ATF (or equivalent DEXRON-III/MERCON)

📐 Dimensions

Exterior

Length:

164.7 inches (4183 mm) for Rio Sedan; 158.3 inches (4020 mm) for Rio5 Hatchback

Width:

66.7 inches (1694 mm)

Height:

58.7 inches (1491 mm) for Rio5 Hatchback; 57.9 inches (1470 mm) for Rio Sedan

Wheelbase:

98.0 inches (2489 mm)

Interior

Passenger Volume:

Approx. 90.1 cu ft

Cargo

Cargo Volume Hatchback:

Approx. 15.1 cu ft (rear seats up)

Weights

Curb Weight:

Approx. 2300-2450 lbs (1043-1111 kg)

Gross Vehicle Weight Rating:

Approx. 3300 lbs (1497 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating:

4 Stars (Driver), 4 Stars (Passenger)

IIHS Frontal Offset Rating:

Acceptable

Active Features

Optional on LX, Standard on EX

Traction Control:

Not typically available for this model year

Passive Features

Airbags Front:

Driver and Passenger Frontal Airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

3-point seat belts with pretensioners and load limiters

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

AM/FM CD player with 4 speakers (standard); optional satellite radio and auxiliary input.

Instrument Cluster:

Analog speedometer, tachometer (optional), fuel gauge, engine temperature gauge, warning lights.

Driver Assistance

Cruise Control:

Optional on EX trim.

Connectivity

Auxiliary Input:

Available on higher trims or optional audio systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (severe conditions may require more frequent changes).

Engine Oil Filter Replacement:

At every oil change.

Air Filter Replacement:

Every 15,000 miles or 12 months.

Spark Plug Replacement:

Every 60,000 miles (NGK Iridium recommended for optimal performance).

Coolant Flush:

Every 30,000 miles or 24 months.

Transmission Fluid Change Automatic:

Every 45,000 miles or 36 months.

Brake Fluid Change:

Every 30,000 miles or 24 months.

Fluid Specifications

Engine Oil Type:

API SM or SN, ILSAC GF-4 or GF-5, SAE 5W-20

Engine Oil Capacity:

3.5 US quarts (3.3 Liters) with filter change.

Coolant Type:

Ethylene Glycol based, with corrosion inhibitors (e.g., HOAT - Hybrid Organic Acid Technology)

Power Steering Fluid:

Dexron-III/Mercon compatible ATF or specified power steering fluid.

Known Issues

Common Problems:

Catalytic converter failure, front suspension component wear (ball joints, tie rods), occasional electrical gremlins, potential for engine oil leaks from valve cover gasket.

Body Corrosion:

As with many vehicles of this era, rust can be an issue in areas with harsh winters or high salt exposure.

📚 Vehicle History

Brand Heritage

Kia Origin:

South Korean automobile manufacturer, founded in 1944.

Model Evolution

Rio Debut:

First generation debuted in 2000.

Rio Generation 2:

The 2006 model represents the second generation (JB) of the Kia Rio, which was introduced globally in 2005.

Design Influence:

The JB generation featured a more modern design, available as a 4-door sedan and a 5-door hatchback (Rio5).

Production

Manufacturing Plant:

Primarily assembled in South Korea (e.g., Gwangmyeong, Hwaseong).

🏆 Awards & Recognition

Recognitions

Safety Award IIHS:

The 2006 Kia Rio received an 'Acceptable' rating from the IIHS in its frontal offset crash test.

Affordability:

Consistently recognized for its value proposition and low cost of ownership.