2001 Kia Rio

2001 MANUAL A/C-HEATER SYSTEM Rio

2001 MANUAL A/C-HEATER SYSTEM

Rio

SPECIFICATIONS
SPECIFICATIONS
Application Specification
Compressor Type (1)

Compressor Belt Deflection (2)

New 5/16-11/32" (8-9 mm)
Used 11/32-25/64" (9-10 mm)
Refrigerant (R-134a) Capacity 21.2-24.7 ozs.
System Oil Capacity (3) 5.0 ozs
System Operating Pressures
Low Side 20-41 psi (1.4-2.9 kg/cm 2 )
High Side 185-263 psi (13.0-18.5 kg/cm 2 )
(1) Check underhood A/C specification label or A/C compressor label.
(2) Measured with 22 lbs. (10 kg) pressure applied to center of drive belt, between
crankshaft pulley and power steering pump or belt tensioner pulley.
(3) Compressor oil capacity.

DESCRIPTION

WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

NOTE: For procedures not covered in this article, see HEATER SYSTEMS - RIO article.

System integrates heating and air conditioning. Fresh air is used for heater operation, and fresh air or
recirculated air is used for air conditioner operation. System combines heated and cooled air in proportion to
temperature settings on climate (A/C-heater) control panel. System components include condenser, receiver-
drier, compressor, evaporator, system protection devices and refrigerant lines.

OPERATION
A/C COMPRESSOR CONTROL CIRCUIT

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With ignition on, battery voltage is supplied to A/C switch through engine compartment fuse/relay box. With
A/C switch on and blower motor switch in any position except OFF, a ground signal is sent through normally
closed A/C thermocon (thermostatic switch) contacts to Engine Control Module (ECM) A/C request input.

When ignition switch is on, battery voltage is supplied directly to A/C relay coil. If predetermined A/C system
operating parameters are present, ECM will ground A/C relay coil and energize A/C relay. A/C relay is located
in engine compartment fuse/relay box. When A/C relay is energized, battery voltage is supplied to A/C
compressor clutch and to A/C condenser fan relay. When the A/C condenser fan relay is energized, battery
voltage is supplied through COOLING FAN fuse (20-amp) located in the engine compartment fuse/relay box.

A/C CONDENSER FAN

A/C condenser fan relay is located in engine compartment fuse/relay box. With ignition on, battery voltage is
supplied to the coil side of A/C relay and is grounded through ECM when A/C switch is on. When A/C relay is
energized, battery voltage is supplied to coil side of condenser fan relay and to A/C compressor clutch. When
A/C condenser fan relay is energized, battery voltage is supplied through COOLING FAN fuse (20-amp) to
A/C condenser fan motor.

BLOWER MOTOR

There are 4 blower motor speeds controlled by a 5-position blower motor switch and resistor assembly. When
blower switch is in the OFF position, blower motor ground circuit is open. When blower motor switch is off,
blower motor and A/C system do not operate. The A/C system requires blower motor switch to be in any
position except off.

When switch is in the first position, current flow from blower motor is restricted by resistors in resistor
assembly, allowing blower to turn at a low speed. Changing blower motor switch to the second or third position
causes circuit resistance to decrease, allowing blower motor speed to increase. Blower motor resistor is
bypassed when blower motor switch is in fourth position.

TEMPERATURE CONTROL KNOB

The temperature control knob controls air temperature by rotating it clockwise for hot, or counterclockwise for
cold. The temperature control knob uses a cable to move temperature control door inside the heater unit, to
increase or decrease airflow through heater core.

AIR INTAKE CONTROL SELECTOR

Fresh Air Position

When air intake control lever is in fresh (outside) air position, air is directed into heater system from outside
vehicle. This position is used for normal ventilation and heating.

Recirculated Air Position

When air intake control lever is in recirculated air position, indicator is illuminated and outside airflow is shut
off. Air within the passenger compartment is recirculated, to achieve maximum heating or cooling and to
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2001 MANUAL A/C-HEATER SYSTEM Rio

prevent undesirable outside air from entering vehicle.

MODE SELECTOR KNOB

Face Position

Air is directed toward face of passengers, through 4 center instrument panel vents. Each vent has an individual
control that can be used to direct the air discharged from vent.

Face-Floor Position

In this position, air is directed toward face and floor. The air to floor is warmer than that directed toward face
(except when temperature control is set to extreme cold position).

Floor Position

Most of the air is delivered to floor, a small amount of air is delivered to windshield and side window
defrosters.

Floor-Defrost Position

In this position, most of the air is delivered to floor and windshield. A small amount of air is directed to side
window defrosters.

Defrost Position

Most of the air is delivered to the windshield, with a small amount of air delivered to side window defrosters.

SYMPTOM TESTS
A/C COMPRESSOR CLUTCH DOES NOT OPERATE (A/C CONDENSER FAN OPERATES
NORMALLY)

1. Start engine and operate at idle. Turn A/C and blower motor switches on. Backprobe A/C compressor
connector clutch terminal (Blue wire) and measure voltage between ground and terminal. If battery
voltage exists, go to next step. If battery voltage does not exist, go to step 3 .
2. Turn ignition off. Disconnect A/C compressor clutch connector. Check for continuity between ground
and A/C compressor clutch connector terminal. If continuity exists, ensure clutch clearance is 0.020-
0.028" (0.5-0.7 mm) and that there is no internal A/C compressor failure. If continuity does not exist,
check A/C compressor clutch ground connection. If ground connection is okay, replace A/C compressor
clutch.
3. Turn ignition off. Connect manifold gauge set high-side pressure hose to A/C system. If high-side
pressure is more than 88 psi (6.2 kg/cm 2 ), replace pipe between receiver-drier and evaporator. If high-
side pressure is less than specified, check A/C system for leaks and for proper refrigerant charge. Perform
repairs as necessary.

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A/C CONDENSER FAN DOES NOT OPERATE (A/C COMPRESSOR CLUTCH OPERATES
NORMALLY)

1. Disconnect A/C condenser fan connector. Using fused jumper wires, apply battery voltage to A/C
condenser fan connector terminal No. 1 (Blue/Black wire) and ground terminal No. 2 (Black wire). If
condenser fan operates, go to next step. If A/C condenser fan does not operate, replace A/C condenser
fan.
2. With A/C condenser fan disconnected, start engine and operate at idle. Turn A/C and blower motor
switches on. Measure voltage between ground and A/C condenser fan harness connector terminal No. 1
(Blue/Black wire). If battery voltage is present, replace A/C condenser fan. If battery voltage is not
present, check A/C condenser fan relay. See A/C RELAY & A/C CONDENSER FAN RELAY under
COMPONENT TESTS. Replace relay as necessary.

A/C COMPRESSOR CLUTCH & A/C CONDENSER FAN DO NOT OPERATE

1. Check BLOWER fuse (30-amp), COOLING FAN fuse (20-amp), INJECT fuse (15-amp) and WIPER
fuse (15-amp). If fuses are okay, go to next step. If any fuse is blown, repair short in suspect circuit. See
WIRING DIAGRAMS .
2. Check A/C relay. See A/C RELAY & A/C CONDENSER FAN RELAY under COMPONENT TESTS.
Replace relay as necessary. If A/C relay is okay, go to next step.
3. Remove A/C-heater control panel from instrument panel enough to gain access to A/C switch 6-pin
connector. See Fig. 1 . Turn ignition on. Ensure blower switch and A/C switch are off. Measure voltage
by backprobing between A/C switch connector terminal No. 3 (Blue wire) and ground. If battery voltage
is present, go to next step. If battery voltage is not present, repair Blue wire as necessary.
4. Turn A/C switch on. Measure voltage by backprobing between A/C switch connector terminal No. 5
(Brown wire) and ground. If battery voltage is present, go to next step. If battery voltage is not present,
check A/C switch connector. If connector is okay, see A/C SWITCH under COMPONENT TESTS.
5. Measure voltage by backprobing between A/C switch connector terminals No. 3 (Blue wire) and No. 4
(Blue/Red wire). If battery voltage is present, go to next step. If battery voltage is not present, check A/C
switch connector. If connector is okay, see A/C SWITCH under COMPONENT TESTS.
6. Measure voltage by backprobing between A/C switch connector terminals No. 3 (Blue wire) and No. 1
(Brown/Yellow wire). If battery voltage is present, go to next step. If battery voltage is not present, check
A/C switch connector. If connector is okay, see A/C SWITCH under COMPONENT TESTS.
7. Ensure ignition is on. Ensure A/C switch and blower switch are on. Measure voltage by backprobing
between A/C thermocon (thermostatic switch) connector terminal No. 1 (Brown wire) and ground. If
battery voltage is present, go to next step. If battery voltage is not present, repair Brown wire as
necessary.
8. Measure voltage by backprobing between A/C thermocon connector terminals No. 1 (Brown wire) and
No. 3 (Brown/Yellow wire). If battery voltage is present, go to next step. If battery voltage is not present,
repair Brown/Yellow wire as necessary.
9. Turn ignition off. Disconnect A/C thermocon (thermostatic switch) connector. Connect battery voltage to
A/C thermocon connector terminal No. 1 (Brown wire). Ground A/C thermocon connector terminal No. 3
(Brown/Yellow wire). Connect test light between A/C thermocon connector terminals No. 2
(Yellow/Green wire) and No. 3. If temperature of sensor is over 39°F (3.9°C), test light should be on. If
temperature of sensor is below 35°F (1.7°C), test light should be off. If test light is as specified, go to next
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step. If test light is not as specified, replace A/C thermocon.

10. Reconnect A/C thermocon (thermostaitc switch) connector. Turn ignition on. Turn blower switch and
A/C switch on. Measure voltage by backprobing between dual pressure switch connector terminal No. 2
(Green/Yellow wire) and ground. If battery voltage is present, go to next step. If battery voltage is not
present, repair Green/Yellow wire as necessary.
11. Turn ignition off. Attach manifold gauge set to system and check refrigerant pressure. Ensure high-side
pressure is at least 88 psi (6.0 kg/cm 2 ). If A/C system pressure is not as specified, check refrigerant
charge and perform repairs as necessary. Check A/C dual-pressure switch. See A/C DUAL-PRESSURE
SWITCH under COMPONENT TESTS. Replace A/C dual-pressure switch if continuity is not as
specified.

Fig. 1: Identifying A/C Switch Connector Terminals

Courtesy of KIA MOTORS AMERICA, INC.

INSUFFICIENT OR INTERMITTENT COOLING OR NO COOLING

Check A/C system performance. See A/C SYSTEM PERFORMANCE under SYSTEM TESTS. If low-side
and high-side pressures are as specified, A/C system is operating properly. If pressures are not as specified,
check for correct amount of refrigerant in system. Check for moisture or air in A/C system, refrigerant oil
and/or refrigerant leaks, or no refrigerant circulation. Also check for insufficient A/C condenser fan cooling,
expansion valve stuck open, or a faulty A/C compressor. Perform A/C system repairs as necessary.

SYSTEM TESTS

WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

A/C SYSTEM PERFORMANCE

1. Attach manifold gauge set to A/C system. Start and operate engine at fast idle. Set A/C system to
maximum cooling and operate for a few minutes. Increase engine speed to 2000 RPM and continue to
operate A/C system at maximum cooling. Measure refrigerant low-side and high-side pressures.
2. Normal low-side operating pressure should be 20-41 psi (1.4-2.9 kg/cm 2 ). Normal high-side operating
pressure should be 185-263 psi (13.0-18.5 kg/cm 2 ). If pressures are not normal, go to next step. If
pressures are normal and then decrease to less than 20 psi (1.4 kg/cm 2 ) on low-side and less than 88 psi
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(6.2 kg/cm 2 ) on high-side, check A/C thermocon. See A/C THERMOCON under COMPONENT
TESTS.
3. If pressures are not normal, check for moisture or air in system, insufficient, or no refrigerant circulation.
Also check for poor condenser fan cooling, expansion valve stuck open, or a faulty compressor. Service
A/C system as necessary.
4. If after servicing A/C system, pressures are normal and then decrease to less than 20 psi (1.4 kg/cm 2 ) on
low-side and less than 88 psi (6.2 kg/cm 2 ) on high-side, turn A/C off. Reduce engine speed to idle and
allow blower motor to operate for a few minutes until system warms up. Turn A/C on, increase engine
speed to 2000 RPM and recheck A/C system pressures. If pressures are normal and then decrease again,
check A/C thermocon. See A/C THERMOCON under COMPONENT TESTS.

COMPONENT TESTS

WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

A/C DUAL-PRESSURE SWITCH

1. Turn ignition off. Locate A/C dual-pressure switch on top of receiver-drier. Attach manifold gauge set to
system and check refrigerant pressures. Ensure high-side pressure is at least 88 psi (6.0 kg/cm 2 ). If A/C
system pressure is not as specified, check refrigerant charge and perform repairs as necessary. When A/C
system pressure is as specified, go to next step.
2. Disconnect A/C dual-pressure switch connector. Check continuity between switch terminals. When A/C
system pressure is less than 427-483 psi (30.0-34.0 kg/cm 2 ) and more than 25-31 psi (1.8-2.2 kg/cm 2 ),
continuity should exist between A/C dual pressure switch terminals. Continuity should not exist when
pressures are not as specified. Replace A/C dual pressure switch if continuity is not as specified.

A/C SWITCH

NOTE: There is a diode located between A/C switch terminals No. 4 and 5. Continuity
between these terminals should exist in only one direction.

Remove climate control panel enough to gain access to A/C switch 6-pin connector. See Fig. 1 . With switch in
off and on positions, check A/C switch continuity between specified switch connector terminals. See A/C
SWITCH CONTINUITY table. If continuity is not as specified, replace A/C switch. If continuity is as
specified, A/C switch is functioning properly at this time.

A/C SWITCH CONTINUITY

Switch Position Continuity Between Terminal No.
OFF (1) 4 & 5; 2 & 6
ON (1) 4 & 5 ; 1 & 4; 3 & 5; 2 & 6
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(1) Continuity will exist in only one direction because of diode.

A/C RELAY & A/C CONDENSER FAN RELAY

1. Remove suspect relay from engine compartment fuse/relay box (located at left side of engine
compartment). Check for continuity between relay terminals No 85 and 86, and then between terminals
No. 30 and 87. See Fig. 2 . Continuity should exist between relay terminals No. 85 and 86. Continuity
should not exist between relay terminals No. 30 and 87. If continuity is not as specified, replace A/C
relay. If continuity is as specified, go to next step.
2. Using a fused jumper wire, apply battery voltage to relay terminal No. 85 and ground terminal No. 86.
See Fig. 2 . With relay energized, ensure continuity exists between relay terminals No. 30 and 87. If
continuity does not exist, replace relay.

Fig. 2: Identifying Relay Terminals

Courtesy of KIA MOTORS AMERICA, INC.

A/C THERMOCON

Turn ignition off. Disconnect A/C thermocon (thermostatic switch) connector. Connect battery voltage to A/C
thermocon connector terminal No. 1 (Brown wire). Ground A/C thermocon connector terminal No. 3
(Brown/Yellow wire). Connect test light between A/C thermocon connector terminals No. 2 (Yellow/Green
wire) and No. 3. If temperature of sensor is over 39°F (3.9°C), test light should be on. If temperature of sensor
is below 35°F (1.7°C), test light should be off. If test light is as specified, A/C thermocon is okay. If test light is
not as specified, replace A/C thermocon.

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REMOVAL & INSTALLATION

WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

NOTE: For removal and installation procedures not covered in this article, see HEATER
SYSTEMS - RIO article.

A/C COMPRESSOR

Removal & Installation

1. Discharge A/C system, using approved refrigerant recovery/recycling/recharging equipment. Measure

amount of refrigerant oil removed during discharge procedure. Raise and support vehicle. Remove engine
undercover. Disconnect refrigerant lines and drive belt from A/C compressor. Plug all exposed openings.
Disconnect A/C compressor clutch lead. Remove A/C compressor mounting bolts and compressor.
2. To install, reverse removal procedure. Apply refrigerant oil to "O" rings before connecting fittings. DO
NOT apply refrigerant oil to fittings. Tighten refrigerant line bolts and mounting bolts to specification.
See TORQUE SPECIFICATIONS . Evacuate, charge, and leak test A/C system.

A/C-HEATER CONTROL PANEL

Removal & Installation

Disconnect negative battery cable. Remove ashtray. Remove center panel trim. Remove instrument panel trim.
Remove glove box. Remove heater control unit. To install, reverse removal procedure.

BLOWER MOTOR & EVAPORATOR

Removal & Installation

1. Discharge A/C system, using approved refrigerant recovery/recycling/recharging equipment. Disconnect

refrigerant lines from evaporator. Plug all exposed openings. Remove cover and evaporator drain hose.
2. Remove instrument panel. Disconnect wiring harnesses from blower motor and evaporator. Remove 3
nuts, bolt, and blower motor/evaporator case. Remove blower motor, evaporator, and A/C thermocon.
3. To install, reverse removal procedure. When installing a NEW evaporator, add 1.7 ounces of refrigerant
oil through A/C compressor high-pressure port. Apply refrigerant oil to "O" rings before connecting
fittings. DO NOT apply refrigerant oil to fittings. Evacuate, charge, and leak test A/C system.

CONDENSER

Removal & Installation

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1. Discharge A/C system, using approved refrigerant recovery/recycling/recharging equipment. Disconnect

negative battery cable. Disconnect refrigerant lines and plug exposed openings. Remove 2 condenser
mounting bolts and remove condenser.
2. To install, reverse removal procedure. Tighten refrigerant line bolts to specification. See TORQUE
SPECIFICATIONS . When installing a NEW condenser, add 0.7 ounce of refrigerant oil through A/C
compressor high-pressure port. Apply refrigerant oil to "O" rings before connecting fittings. DO NOT
apply refrigerant oil to fittings. Evacuate, charge, and leak test A/C system. Reconnect negative battery
cable.

CONDENSER FAN

Removal & Installation

Disconnect negative battery cable. Disconnect condenser fan wiring. Remove bolts and condenser fan. To
install, reverse removal procedure.

RECEIVER-DRIER

Removal & Installation

1. Discharge A/C system, using approved refrigerant recovery/recycling/recharging equipment. Disconnect

receiver-drier refrigerant lines and switch harness connector. Remove receiver-drier.
2. To install, reverse removal procedure. When installing a NEW receiver-drier, add 0.3 ounce of refrigerant
oil through high-pressure port on compressor. Apply refrigerant oil to "O" rings before connecting
fittings. DO NOT apply refrigerant oil to fittings. Tighten fittings to specification. See TORQUE
SPECIFICATIONS . Evacuate, charge, and leak test A/C system.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Compressor Refrigerant Lines Bolts 18-23 (24-31)
Condenser Refrigerant Lines Bolt 7-15 (10-20)
Drive Belt Tensioner Bracket-To-Engine (Front Bolts) 12-17 (16-23)
Drive Belt Tensioner Bracket-To-Engine (Side Bolts) 23-35 (31-47)
INCH Lbs. (N.m)
Receiver-Drier Refrigerant Lines Bolt 43-61 (4.9-6.9)

WIRING DIAGRAMS

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Fig. 3: Manual A/C-Heater System Wiring Diagram (2001 Rio)

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2001 HEATER SYSTEMS Rio

2001 HEATER SYSTEMS

Rio

DESCRIPTION
Major components of the heater system are a heater core, control panel, blower motor, coolant hoses, control
cables and air ducts. Temperature is controlled by the amount of air directed past heater core.

WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

OPERATION
BLOWER MOTOR

Blower motor speed is controlled by blower switch and resistor assembly in the blower unit. When blower
switch is in the OFF position, the motor ground circuit is open and the blower motor does not operate.

When switch is in the first position, current flow from the blower motor is restricted by the 3 resistors in the
resistor assembly, and the blower runs at low speed. Changing blower switch to the second, third or fourth
positions causes the circuit resistance to decrease, and the blower motor speed increases.

TEMPERATURE CONTROL KNOB

Air temperature is controlled by rotating control knob counterclockwise for cold or clockwise for hot. Air
temperature control knob is located on passenger-side of climate (heater) control panel.

AIR INTAKE CONTROL LEVER

Air intake control lever controls the fresh/recirculation actuator and door position. Under normal conditions, the
lever should be kept in the fresh air position.

Fresh Air Position

When air intake control lever is in fresh (outside) air position, air is directed into heater system from outside
vehicle. This position is used for normal ventilation and heating.

Recirculated Air Position

When air intake control lever is in recirculated air position, outside airflow is shut off. Air within the passenger
compartment is recirculated to achieve maximum heating and to prevent undesirable outside air from entering
vehicle.

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MODE SELECTOR KNOB

Face Position

Airflow is directed toward face of passengers, through all instrument panel vents. Each vent has an individual
control that can be used to direct the air discharged from vent.

Face-Floor Position

In this position, air is directed toward face and floor. The air flowing to floor is warmer than air directed toward
face (except when temperature control lever is set to extreme cold position). Only the temperature of the air
being discharged from the floor outlet can be controlled.

Floor Position

Most of the airflow is delivered to floor, with a small amount being delivered to windshield and side window
defrosters.

Floor-Defrost Position

In this position, most of the airflow is directed to floor and windshield. A small amount of airflow is directed to
side window defrosters.

Defrost Position

Most of the airflow is directed to the windshield, with a small amount of air delivered to side window
defrosters.

SYSTEM TESTS

WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

BLOWER MOTOR CIRCUIT

1. Check BLOWER fuse (30-amp). If fuse is okay, go to next step. If fuse is open, check wiring harness for
short to ground. Repair wiring as necessary, and then replace fuse.
2. Disconnect blower relay. Check continuity between blower relay terminals No. 85 and 86, then check
continuity between blower relay terminals No. 87 and 30. Continuity should exist between blower relay
terminals No. 85 and 86. Continuity should not exist between blower relay terminals No. 87 and 30. See
Fig. 1 . If continuity is not as specified, replace relay. If continuity is as specified, go to next step.
3. Connect blower relay terminal No. 85 to battery positive terminal. Connect blower relay terminal No. 86
to ground. Check continuity between blower relay terminals No. 87 and 30. If continuity exists, go to next
step. If continuity does not exist, replace blower relay.
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4. Reinstall relay. Turn ignition on. Ensure blower switch is off. Measure voltage, by packprobing, between
Blue/Red wire at blower motor connector and ground. If battery voltage is present, go to next step. If
battery voltage is not present, repair Blue/Red wire between blower motor and blower relay.
5. Measure voltage by backprobing between Red/Blue wire at blower motor connector and ground. If
battery voltage is present, go to next step. If battery voltage is not present, replace blower motor.
6. Ensure ignition is on and blower motor switch is off. Measure voltage by backprobing between Blue/Red
wire at blower motor resistor and ground. If battery voltage is present, go to next step. If battery voltage is
not present, repair Blue/Red wire between blower motor resistor and blower motor.
7. Measure voltage by backprobing between each of 3 remaining blower motor resistor terminals and
ground. If battery voltage is present at all 3 blower motor resistor terminals, go to next step. If battery
voltage is not present at any one or more blower motor resistor terminals, replace blower motor resistor.
8. Measure voltage by backprobing between ground and blower switch connector terminals No. 2, 3, 5 and
6. See Fig. 2 . If voltage is present at each terminal, go to next step. If voltage is not present at each
terminal, repair appropriate wire between blower switch and blower motor resistor.
9. Turn ignition off. Ensure blower switch is off. Check continuity between ground and blower switch
connector terminal No. 7 (Black wire). If continuity exists, replace blower switch. If continuity does not
exist, repair Black wire between blower switch and ground.

Fig. 1: Testing 4-Terminal Relay

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2001 HEATER SYSTEMS Rio

Fig. 2: Identifying Blower Switch Connector Terminals

Courtesy of KIA MOTORS AMERICA, INC.

COMPONENT TESTS
BLOWER MOTOR RESISTOR

Disconnect blower motor resistor connector. Using DVOM, measure resistance between terminals as indicated.
See Fig. 3 . If resistance is not as specified, replace blower motor resistor.

Fig. 3: Testing Blower Motor Resistor

Courtesy of KIA MOTORS AMERICA, INC.

BLOWER SWITCH

Disconnect blower switch connector. Using DVOM, check continuity between blower switch terminals. See
Fig. 2 . If continuity is not as specified in BLOWER SWITCH CONTINUITY table, replace blower switch.

BLOWER SWITCH CONTINUITY

Switch Position Continuity Between Terminals No.
HI 1, 3 & 7
MH 1, 6 & 7
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2001 HEATER SYSTEMS Rio

ML 1, 2 & 7
LO 1, 5 & 7

REMOVAL & INSTALLATION

WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

BLOWER MOTOR

Removal & Installation

Disconnect wiring harness from blower motor. Remove 3 nuts, bolt, and blower motor assembly. Remove
blower motor. To install, reverse removal procedure.

HEATER CONTROL UNIT

Removal & Installation

Disconnect negative battery cable. Remove ashtray. Remove center panel trim. Remove instrument panel trim.
Remove glove box. Remove heater control unit. To install, reverse removal procedure.

HEATER CORE

Removal & Installation

Drain engine coolant. Remove instrument panel. See INSTRUMENT PANEL . Remove control cable.
Disconnect heater hoses from heater unit. Remove 3 mounting nuts from heater unit and remove heater unit.
Remove heater core from heater unit. To install, reverse removal procedure.

INSTRUMENT PANEL

Removal & Installation

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING.
Disconnect negative battery cable. Remove ashtray. Remove one screw inside ashtray opening. Remove
center trim panel. Remove cover and mounting bolt from rear console. Remove rear console. Remove
screws and fasteners from front console. Remove front console.
2. Remove 4 driver air bag module screws. Pull air bag away from steering wheel and disconnect driver air
bag module connector. Remove driver's air bag module. Mark steering wheel-to-shaft alignment for
installation reference. Remove steering wheel nut. Remove steering wheel. Remove 3 screws between
upper and lower steering column trim panels. Separate and remove steering column trim panels.
3. Loosen 2 bolts and remove bracket under steering column. Remove 3 combination switch screws.

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 2001 Kia Rio
2001 HEATER SYSTEMS Rio

Disconnect combination switch connectors. Slide combination switch off steering column. Remove hood
release handle and cable assembly nut, hood release handle and cable assembly nut.
4. Remove left and right instrument panel side covers. Remove 2 bolts on left side of console and 2 bolts on
left end of instrument panel. Remove 4 radio mounting screws. Disconnect electrical and antenna
connectors from radio and remove radio. Remove heater control unit. See HEATER CONTROL UNIT .
5. Remove glove box. Remove 2 bolts on right of console and 2 bolts on right end of instrument panel.
Remove cover and bolt at middle top of instrument panel. Remove 2 bolts between steering column and
instrument panel. Lower steering column to floor. Disconnect electrical connectors between instrument
panel and bulkhead electrical wire harness. Remove instrument panel. To install, reverse removal
procedure. Tighten instrument panel and steering column mounting bolts to specifications. See
TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Instrument Panel Bolts 13-19 (18-26)
Steering Column Bolts 13-19 (18-26)

WIRING DIAGRAMS

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Monday, April 17, 2006 5:19:50 PM Page 6 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 HEATER SYSTEMS Rio

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Monday, April 17, 2006 5:19:50 PM Page 7 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 HEATER SYSTEMS Rio

Fig. 4: Heater System Wiring Diagram (2001 Rio)

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Monday, April 17, 2006 5:19:50 PM Page 8 © 2004 Mitchell Repair Information Company, LLC.