🏷️ Basic Information

Make:

Kia

Model:

Rio

Model Code:

BC

Year:

2002

Engine Variant:

1.5 DOHC

Chassis Code:

BC

Engine Code Designation:

G 1.5 DOHC

👋 Introduction

Segment:

Subcompact Car

Target Audience:

Budget-conscious buyers seeking economical transportation

Key Competitors:

Hyundai Accent, Ford Fiesta, Chevrolet Aveo, Toyota Yaris, Honda Fit (early models)

Value Proposition:

Affordability, fuel efficiency, practicality

Manual Advantage:

Empowers owners with factory-level knowledge for engine maintenance and repair, reducing reliance on costly shop visits.

📋 Manual Details

Primary Focus:

Engine Service and Repair

Vehicle Generation Coverage:

First Generation (BC)

Estimated Pages:

Hundreds (specific count not provided, but typical for factory service manuals)

Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, disassembly, assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing system

Engine Fuel System:

Fuel injection system (MPI), fuel pump, injectors, fuel pressure regulator, fuel filter replacement

Engine Ignition System:

Ignition coils, spark plugs, ignition timing, crankshaft position sensor, camshaft position sensor

Engine Cooling System:

Radiator, water pump, thermostat, coolant hoses, cooling fan operation

Engine Lubrication System:

Oil pump, oil filter, oil pan, lubrication passages, oil pressure specifications

Engine Exhaust System:

Exhaust manifold, catalytic converter, muffler, oxygen sensors

Engine Intake System:

Intake manifold, throttle body, air filter housing, mass air flow sensor

Engine Control System:

ECU (Engine Control Unit) functions, sensor inputs/outputs, diagnostic trouble codes (DTCs)

Maintenance:

Scheduled maintenance, oil changes, filter replacements, tune-ups, spark plug replacement

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, common failure modes, diagnostic tool usage

Repair:

Step-by-step repair instructions for all engine components, torque specifications, assembly clearances

Overhaul:

Complete engine rebuild procedures, component measurements and tolerances

Special Tools:

Identification and usage of specialized tools required for engine service

Depth:

Comprehensive, factory-level detail suitable for professional technicians and advanced DIY enthusiasts

📊 Manual Specifications

Digital Format:

PDF

Searchability:

Likely searchable text (depending on scan quality)

Diagram Quality:

High-quality diagrams and illustrations

Text Clarity:

Easy-to-read text sections

Binding:

N/A (Digital format)

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Camshaft)

Displacement:

1.5 Liters (1493 cc)

Bore X Stroke:

73.0 mm x 89.0 mm (approximate, common for this engine family)

Compression Ratio:

9.3:1 (typical for this engine)

Valvetrain:

DOHC, 16 valves (4 valves per cylinder)

Horsepower Rating:

Approx. 95-100 hp @ 5800-6000 rpm (actual figures can vary slightly)

Torque Rating:

Approx. 95-100 lb-ft @ 3000-4000 rpm (actual figures can vary slightly)

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 AKI (Octane rating may vary by region, consult owner's manual)

Oil Type Recommendation:

API SG, SH, or SJ classification, SAE 5W-30 is generally recommended

Oil Capacity:

Approx. 3.5 Liters (3.7 US Quarts) with filter change

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Transmission Type:

4-speed Automatic Transmission

Clutch Type:

Dry, single plate (for manual)

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (manual transmission fluid, check manual for exact spec)

Automatic Transmission Fluid:

Kia Genuine ATF SP-III or equivalent (automatic transmission fluid, check manual for exact spec)

📐 Dimensions

Length:

Approx. 3930 mm (154.7 in)

Width:

Approx. 1630 mm (64.2 in)

Height:

Approx. 1470 mm (57.9 in)

Wheelbase:

Approx. 2400 mm (94.5 in)

Curb Weight:

Approx. 980-1050 kg (2160-2315 lbs), varies with transmission and trim

🛡️ Safety Features

NHTSA Front Impact:

Not explicitly rated for this specific year/model in many markets. Generally basic safety for its class and era.

IIHS Small Overlap Front:

Not tested or rated for this model year.

ABS:

Available on higher trims or as an option

Ebs:

Not commonly available on this model year.

Airbags:

Driver and front passenger airbags standard.

Seatbelts:

3-point seatbelts with pretensioners (front)

💡 Technology Features

Audio System:

Basic AM/FM stereo with CD player, optional cassette player on early models. Limited speaker configurations.

Display:

Basic digital or analog displays for radio and clock.

Cruise Control:

Available on some higher trim levels.

Bluetooth:

Not available on this model year.

Usb Port:

Not available on this model year.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (typical recommendation; consult manual)

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months (typical recommendation; consult manual)

Spark Plug Replacement:

Every 30,000 miles (48,000 km) (typical recommendation for standard plugs; consult manual for specific type)

Timing Belt Replacement:

This engine uses a timing chain, not a belt. Chains are generally designed for the life of the engine but require inspection.

Coolant Type:

Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. Consult manual for specific Kia coolant type.

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for exact specification)

Engine Minor Issues:

Occasional oil leaks from valve cover gasket, potential for early wear on suspension components.

Engine Major Issues:

Less prone to catastrophic failures than some contemporaries; focus on regular maintenance prevents most issues. Overheating due to coolant leaks can cause head gasket issues.

Common Wear Items:

Clutch wear (manual transmission), exhaust system components, suspension bushings.

📚 Vehicle History

Manufacturer:

Kia Motors Corporation, South Korea

Introduction Year:

2000

First Generation Codenames:

BC (Sedan), CD (Hatchback)

Production Location:

South Korea (primarily)

Production Period For Model:

2000-2005 (First Generation)

🏆 Awards & Recognition

Awards Received:

No significant industry awards widely reported for this specific model year. Positioned as an economy vehicle.

Fuel Economy Ratings:

Generally good fuel economy for its class and era, contributing to its appeal as an economical commuter car.