Accesories - Safety Equipment

2001 Kia Rio
2001 ACCESSORIES/SAFETY EQUIPMENT Kia - Air Bag Restraint Systems
2001 ACCESSORIES/SAFETY EQUIPMENT
Kia - Air Bag Restraint Systems
DESCRIPTION & OPERATION
WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS .
Supplemental Restraint System (SRS), also known as air bag system, is designed to provide increased accident
protection for driver and passenger by deploying air bags and seat belt pretensioners during a front-end
collision. The air bag system is designed to be used in conjunction with 3-point safety belts.
The air bag system includes the following components: driver-side air bag module, passenger-side air bag
module, clockspring, AIR BAG warning light, Air Bag Diagnostic Unit (ADU), seat belt pretensioners and
associated wiring harnesses. For component locations, see COMPONENT LOCATIONS .
COMPONENT LOCATIONS
COMPONENT LOCATIONS
Component Location
Air Bag Diagnostic Unit (ADU) Under center console, forward of shifter assembly
AIR BAG warning light Instrument cluster
Driver-side air bag module On steering wheel
Passenger-side air bag module Passenger-side instrument panel
Seat belt pretensioners Driver & passenger lower B-pillars
Clockspring Within steering column
SYSTEM OPERATION CHECK

Turn ignition on. AIR BAG warning light should illuminate for 4-6 seconds, then turn off. If AIR BAG warning
light stays illuminated, a failure has occurred in air bag system. See RETRIEVING & ERASING
DIAGNOSTIC TROUBLE CODES (DTC) under DIAGNOSTICS. If AIR BAG warning light fails to
illuminate, see AIR BAG WARNING LIGHT SERVICE under DIAGNOSTICS.
AIR BAG SAFETY PRECAUTIONS

These precautions should be observed when working with air bag systems:
z Disable air bag system before servicing any air bag system-steering column component. See
DISABLING & ACTIVATING AIR BAG SYSTEM .
z When trouble shooting air bag system, always check diagnostic codes before disconnecting battery.
z After turning ignition switch to OFF position and disconnecting negative battery cable, wait at least 10
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2001 Kia Rio
minutes before working on air bag system. Air bag system is equipped with a back-up power source that
may allow air bags or seat belt pretensioners to deploy up to 10 minutes after negative battery cable is
disconnected.
z During servicing of air bag system, store air bag module where ambient temperature is less than 200 F
(93 C), and humidity and electrical noise are low.
z When placing a live air bag on a bench or other surface, ensure top surface is facing up, away from work
surface. This will reduce motion of module if it is accidentally deployed.
z When carrying air bag module, point cover away from body to lessen chance of injury during accidental
deployment.
z Because of critical system operating requirements, DO NOT attempt to service air bag module,
clockspring, seat belt pretensioners, wiring harness or Air Bag Diagnostic Unit (ADU). Corrections are
made by replacement with NEW parts only. NEVER use parts from another vehicle.
z If air bag module, seat belt pretensioner or Air Bag Diagnostic Unit (ADU) have been dropped, or there
are cracks, dents or other defects visible, replace with NEW parts.
z DO NOT attempt to measure resistance across air bag module squib connector. Accidental air bag
deployment is possible which could cause personal injury.
z After deployment, air bag surface may contain deposits of sodium hydroxide, which irritates skin, from
gas generant combustion. Always wear safety glasses, rubber gloves, and long-sleeved shirt during clean-
up. Wash hands using mild soap and water.
z After work on air bag system is completed, ensure system is functioning properly. See SYSTEM
OPERATION CHECK .
ADJUSTMENTS
CLOCKSPRING ALIGNMENT
NOTE: An alignment pin is used to align clockspring during reassembly and is

included with new clockspring. If reusing clockspring or if pin is missing, a new
pin can be fabricated from 0.12" (3 mm) diameter stock. Pin should be at least
3" (76 mm) long.
Rotate center portion of clockspring connector clockwise until it stops then rotate counterclockwise 2 3-4 turns.
Align arrow on center decal with arrow on housing. See Fig. 1 . With arrows aligned, insert alignment pin into
hole on front of center portion until it engages in hole located on rear of housing.

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2001 Kia Rio
Fig. 1: Aligning Clockspring

Courtesy of KIA MOTORS AMERICA, INC.
DISABLING & ACTIVATING AIR BAG SYSTEM
WARNING: Back-up power supply maintains air bag system voltage for about 10
minutes after battery is disconnected. After disabling air bag system, wait
at least 10 minutes before servicing air bag system to prevent accidental
air bag or seat belt pretensioner deployment and possible personal injury.
To disable air bag system, turn ignition switch to OFF position. Disconnect negative battery cable. Wait at least
10 minutes before servicing air bag system. To activate air bag system, ensure ignition switch is in OFF
position. Reconnect negative battery cable. Perform SYSTEM OPERATION CHECK .
DISPOSAL PROCEDURES

2001 Kia Rio
DEPLOYED AIR BAG OR SEAT BELT PRETENSIONER
Wear gloves and safety glasses when handling deployed air bags or seat belt pretensioners. Seal component in a
vinyl bag and dispose of it as you would any other part.
UNDEPLOYED AIR BAG OR SEAT BELT PRETENSIONER
WARNING: Disposing of an undeployed air bag or seat belt pretensioner may violate
federal, state, and-or local laws. Undeployed components contain
substances which can cause illness or injury if handled improperly. When
scrapping a vehicle, air bags and seat belt pretensioners must be
deployed. If components cannot be deployed using the following
procedures, contact vehicle manufacturer for further instructions.
OFF-VEHICLE DEPLOYMENT
WARNING: After deployment, components are very hot. Wait at least 20 minutes
before handling air bag module or seat belt pretensioner.
NOTE: Ensure Air Bag Deployment Tool is disconnected from battery before
connecting to air bag module to prevent accidental deployment.
1. Remove vehicle battery and wait 10 minutes. Disconnect appropriate air bag module or seat belt
pretensioner and remove from vehicle. See REMOVAL & INSTALLATION . Place component inside
stack of 6-8 tires at least 20 feet from any obstacle. Connect Air Bag Deployment Tool (K95U-6000-
BDY) to component connector.
2. Position deployment tool and battery at least 20 feet from deployment site. Connect Red deployment tool
lead to positive battery terminal and Black deployment tool lead to negative battery terminal. Verify that
deployment tool Green POWER indicator is illuminated. Depress and hold READY button. Verify that
deployment tool Yellow DEPLOY indicator is flashing.
3. Depress and hold DEPLOY button. Component should deploy. If component does not deploy, verify that
Red DEPLOY indicator is illuminated. Release both buttons. Verify that both READY and DEPLOY
indicators are not illuminated. Disconnect deployment tool power leads. After deployment, component
will be extremely hot.
4. Allow component to cool for 20 minutes before handling. DO NOT put oil or water on air bag or
pretensioner after deployment. Wear safety glasses and rubber gloves when handling all SRS
components. Place air bag module or pretensioner in a strong plastic bag and seal tightly. Component can
now be disposed of in the same manner as any other scrap part.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.

2001 Kia Rio
REMOVAL & INSTALLATION
WARNING: Failure to follow air bag service precautions may result in air bag or
pretensioner deployment and personal injury. See AIR BAG SAFETY
PRECAUTIONS . After component replacement, perform a system
operational check to ensure proper system operation. See SYSTEM
OPERATION CHECK .
AIR BAG DIAGNOSTIC UNIT (ADU)
NOTE: When removing ADU, is may be necessary to loosen 2 nuts securing shift cable
to transmission tunnel.
Removal & Installation)
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ash tray and center panel trim. Remove
3 console mounting screws (one each at lower front and one in center of console). Remove 2 bolts,
console box and console. Disconnect ADU harness connector. Remove 3 mounting nuts from ADU.
Remove ADU from vehicle. See Fig. 2 . It may be necessary to loosen 2 nuts securing shift cable housing
to tunnel.
2. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. See DISABLING & ACTIVATING AIR BAG
SYSTEM . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM
OPERATION CHECK .
Fig. 2: Identifying Air Bag Diagnostic Unit (ADU)


2001 Kia Rio
CLOCKSPRING
Removal & Installation
DISABLING & ACTIVATING AIR BAG SYSTEM . Position front wheels in straight-ahead position.
Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE .
2. Remove steering wheel nut. See Fig. 3 . Mark steering wheel and steering shaft for reassembly reference.
Using appropriate puller, remove steering wheel from steering shaft. Remove 3 clockspring retaining
screws. Disconnect electrical connectors and remove clockspring from steering column.
NOTE: An alignment pin is used to align clockspring during reassembly and is

included with new clockspring. If reusing clockspring or if pin is missing,
a new pin can be fabricated from 0.12" (3 mm) diameter stock. Pin should
be at least 3" (76 mm) long.
3. To install, ensure front wheels are in straight-ahead position. Install clockspring and tighten retaining
screws to specification. See TORQUE SPECIFICATIONS . Rotate center portion of clockspring
connector clockwise until it stops, then rotate counterclockwise 2 3-4 turns.
4. Align arrow on center decal with arrow on housing. With arrows aligned, insert alignment pin into hole
on front of center portion until it engages in hole located on back of housing. Insertion depth is about
0.866" (22 mm). Install steering wheel passing alignment pin through steering wheel.
5. Tighten steering wheel nut finger tight. Remove alignment pin and tighten steering wheel nut to
specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.
Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG
warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

2001 Kia Rio
Fig. 3: Identifying Clockspring & Driver-side Air Bag Module

DRIVER-SIDE AIR BAG MODULE
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove 4 driver-side air bag module retaining
bolts from backside of steering wheel. See Fig. 3 . Pull air bag module away from steering wheel.
Disconnect upper clockspring connectors from air bag module and remove air bag module.
2. To install, reverse removal procedure. Connect Blue upper clockspring connector first, then connect
Orange connector. Both connectors will "click" when properly connected. Tighten air bag module
retaining bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system. See
DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system
is functioning properly. See SYSTEM OPERATION CHECK .
PASSENGER-SIDE AIR BAG MODULE
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove instrument panel. See INSTRUMENT
PANEL . Remove air bag module mounting screws and bolts. See Fig. 4 . Remove air bag module.
2001 Kia Rio
2. To install, reverse removal procedure. Tighten passenger-side air bag module mounting bolts to
specification. See TORQUE SPECIFICATIONS . Activate air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system is functioning
properly. See SYSTEM OPERATION CHECK .
Fig. 4: Identifying Passenger-side Air Bag Module

SEAT BELT PRETENSIONER
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove seat belt anchor bolt. Allow belt to
retract slowly as far as possible.
2. Remove shoulder belt anchor bolt cover and anchor bolt. Remove lower B-pillar trim panel. Remove
sheet metal screw and anchor bolt from seat belt pretensioner and remove seat belt pretensioner.

2001 Kia Rio
3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE

OPERATION CHECK .
INSTRUMENT PANEL
DISABLING & ACTIVATING AIR BAG SYSTEM . Remove center panel trim. Remove center
console. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove
steering wheel, turn signal switch and clockspring. See CLOCKSPRING under REMOVAL &
INSTALLATION. Remove hood release handle and cable. Remove cover and 2 bolts from left side of
instrument panel. See Fig. 5 .
2. Remove radio. Remove ventilation control panel. Remove glove box. Remove bolts from both sides of
steering column and lower steering column towards floor. Remove cover and 2 bolts from right side of
instrument panel. Remove cover from upper center of instrument panel and remove bolt. Remove 4 bolts
from lower center of instrument panel. Disconnect electrical connectors. Remove instrument panel.
3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE
OPERATION CHECK .

2001 Kia Rio
Fig. 5: Identifying Instrument Panel

DIAGNOSTICS
WARNING: Failure to follow air bag service precautions may result in air bag
deployment and personal injury. See AIR BAG SAFETY PRECAUTIONS .
After component replacement, perform a system operational check to
ensure proper system operation. See SYSTEM OPERATION CHECK .
AIR BAG WARNING LIGHT SERVICE
1. Turn ignition switch to ON position. If AIR BAG warning light illuminates for 4-6 seconds and turns off,
go to step 8 . If AIR BAG warning light does not illuminate for 4-6 seconds and turn off, go to next step.
2. Using fuse extractor, remove and examine METER fuse located in passenger compartment fuse box. If
fuse is open, replace with another of same value. Check associated wiring for short circuit and repair as
necessary. When repair is complete, go to step 8 . If fuse is okay, go to next step.
3. Turn ignition switch to LOCK position, disconnect negative battery cable and wait 10 minutes. Remove
instrument cluster. Ensure connector pins of instrument cluster connector are secure and connector is
locked in place. If connector pins are secure and connectors are locked in place, go to next step. If
connector pins are not secure and-or connector is not locked in place, repair or replace connector.
Reinstall instrument cluster. Go to step 8 .
4. Check continuity between instrument cluster connector terminal A3 (Yellow wire) and terminal B11
(Yellow wire). If continuity exists, light bulb is okay, go to next step. If continuity does not exist, replace
light bulb, reinstall instrument cluster and go to step 8 .
5. Connect negative battery cable. Turn ignition switch to ON position. Measure voltage between ground
and instrument cluster harness connector terminal A3 (Yellow wire). If battery voltage is present, go to
next step. If battery voltage is not present, check harness between instrument cluster connector and
METER fuse. Repair as necessary and go to step 8 .
6. Turn ignition switch to OFF position. Connect voltmeter between instrument cluster connector terminal
A3 (Yellow wire) and B11 (Yellow wire). Turn ignition switch to ON position and observe voltmeter. If
battery voltage is present for 4-6 seconds, go to step 8 . If battery voltage is not present for 4-6 seconds,
check harness between instrument cluster and Air Bag Diagnostic Unit (ADU) for open or short to
ground. Repair as necessary and go to next step.
7. Turn ignition switch to OFF position. Return system to original configuration. Turn ignition switch to ON
position and observe AIR BAG warning light. If AIR BAG warning light illuminates for 4-6 seconds, go
to next step. If AIR BAG warning light does not illuminate for 4-6 seconds, replace ADU. See AIR BAG
DIAGNOSTIC UNIT (ADU) under REMOVAL & INSTALLATION.
8. If AIR BAG warning light stays on after initial 4-6 second period, retrieve diagnostic codes and diagnose
appropriate malfunction. Go to RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES
(DTC) . If AIR BAG warning light does not illuminate a second time after initial 4-6 second period, AIR
BAG warning light is functioning properly.
RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES (DTC)

2001 Kia Rio
1. Retrieving and erasing air bag Diagnostic Trouble Codes (DTC) is performed using a serial data port
located within the Data Link Connector (DLC) in the engine compartment. Retrieving and erasing DTC's
can only be accomplished using a Hi-Scan Pro Tool equipped with proper software. Disconnecting
battery will not erase air bag DTC's.
2. To retrieve DTC's, turn ignition switch to LOCK position. Locate DLC in engine compartment. Connect
Hi-Scan Pro tool to DLC. Turn ignition to ON position. Read and record any DTC's displayed. See
FAULT CODES table. Also, see appropriate fault code under DIAGNOSTIC TESTS .
FAULT CODES
Fault Code Description
DTC 01-03 ADU fault
DTC 10-11 ADU fault
DTC 18-32 ADU fault
DTC 33 Power supply low
DTC 34 Power supply high
DTC 35 Warning light short
DTC 36 Warning light open
DTC 53 Driver module short to ground
DTC 54 Driver module short to battery
DTC 55 Driver module short
DTC 56 Driver module open
DTC 57 Passenger module short to ground
DTC 58 Passenger module short to battery
DTC 59 Passenger module short
DTC 60 Passenger module open
DTC 61 Driver pretensioner short to ground
DTC 62 Driver pretensioner short to battery
DTC 63 Driver pretensioner short
DTC 64 Driver pretensioner open
DTC 65 Passenger pretensioner short to ground
DTC 66 Passenger pretensioner short to battery
DTC 67 Passenger pretensioner short
DTC 68 Passenger pretensioner open
DTC 77-80 ADU inconsistency
DIAGNOSTIC TESTS
NOTE: Refer to wiring diagram and Air Bag Diagnostic Unit (ADU) connector
identification when diagnosing faults. See Fig. 6 & Fig. 7 .

2001 Kia Rio
DTC : INTERNAL FAULT
Internal fault recorded. No inspection or service possible. Replace Air Bag Diagnostic Unit (ADU). See AIR
BAG DIAGNOSTIC UNIT (ADU) under REMOVAL & INSTALLATION.
DTC : POWER SUPPLY LOW
DISABLING & ACTIVATING AIR BAG SYSTEM . Access and disconnect Air Bag Diagnostic Unit
(ADU) connector. Turn ignition on. Measure voltage between ground and terminal No. 5 (White-Green
wire) of ADU connector. If battery voltage is present, go to step 3. If battery voltage is not present, go to
next step.
2. Trace and repair open circuit between terminal No. 5 (White-Green wire) of ADU and battery. See
WIRING DIAGRAMS . Go to next step.
3. Check for continuity between terminal No. 6 (Black wire) of ADU connector and ground. If continuity
exists, replace ADU. See AIR BAG DIAGNOSTIC UNIT (ADU) under REMOVAL &
INSTALLATION. If continuity does not exist, replace harness between terminal No. 6 (Black wire) of
ADU connector and ground.
DTC : POWER SUPPLY HIGH
(ADU) connector. Turn ignition on. Measure voltage between ground and terminal No. 5 (White-Green
wire) of ADU connector. If battery voltage is present, go to step 3. If battery voltage is not present, go to
next step.
2. Trace and repair open circuit between terminal No. 5 (White-Green wire) of ADU and battery. See
WIRING DIAGRAMS . Go to next step.
3. Check for continuity between terminal No. 6 (Black wire) of ADU connector and ground. If continuity
2001 Kia Rio
exists, replace ADU. See AIR BAG DIAGNOSTIC UNIT (ADU) under REMOVAL &
INSTALLATION. If continuity does not exist, replace harness between terminal No. 6 (Black wire) of
ADU connector and ground.
DTC : WARNING LIGHT SHORT
(ADU) connector. Check for continuity between ADU connector terminal No. 7 (Yellow wire) and
ground. See WIRING DIAGRAMS . If continuity exists, go to next step. If continuity does not exist,
replace ADU. See AIR BAG DIAGNOSTIC UNIT (ADU) under REMOVAL & INSTALLATION.
2. Disconnect wire connector located between ADU connector and instrument cluster connector. If
continuity exists between ground and terminal No. 7 (Yellow wire) of ADU connector, go to next step. If
continuity does not exist, replace wire harness between ADU and wire connector.
3. Disconnect instrument cluster connector. Check for continuity between ground and terminal No. B11
(Yellow wire) of instrument cluster connector. If continuity exists, replace AIR BAG warning light bulb
socket or instrument cluster. If continuity does not exist, replace harness between instrument cluster and
in-line connector.
DTC : WARNING LIGHT OPEN
(ADU) connector. Check for continuity between ADU connector terminal No. 7 (Yellow wire) and
instrument cluster connector terminal B11 (Yellow wire). See WIRING DIAGRAMS . If no continuity
exists, go to next step. If continuity exists, replace ADU. See AIR BAG DIAGNOSTIC UNIT (ADU)
under REMOVAL & INSTALLATION.
2. Inspect for continuity between terminals 1C (Yellow) and B11 (Yellow) of instrument cluster connector.
If continuity does not exist, inspect and repair or replace AIR BAG warning light bulb, socket or printed
circuit board in instrument cluster. If continuity exists, replace wire harness between instrument cluster
and harness connector, located in harness between ADU connector and instrument cluster. Go to next
step.
3. Check for continuity between ADU connector terminal No. 7 (Yellow wire) and connector terminal,
located in harness between ADU connector and instrument cluster. If continuity exists, replace harness
between ADU and harness connector. If continuity does not exist, replace wire between connector and
instrument cluster.
DTC : DRIVER MODULE SHORT TO GROUND

2001 Kia Rio
DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect Air Bag Diagnostic Unit (ADU)
connector and harness-to-clockspring connector. Measure continuity between ground and terminal No. 10
(Red wire) and-or terminal No. 11 (Yellow-Red wire) of ADU connector. If continuity exists, replace
harness between ADU and clockspring connector. See WIRING DIAGRAMS . If continuity does not
exist, go to next step.
2. Disconnect clockspring-to-air bag module connector. Check for continuity between ground and
clockspring connector terminal No. 2 (Yellow-Red wire) and-or terminal No. 3 (Red wire). If continuity
exists, replace clockspring. If continuity does not exist, replace driver-side air bag module.
DTC : DRIVER MODULE SHORT TO BATTERY
connector. Disconnect harness-to-clockspring connector. Check for battery voltage between ground and
ADU connector terminal No. 10 (Red wire) and-or terminal No. 11 (Yellow-Red wire). See WIRING
DIAGRAMS . If battery voltage exists, replace wire harness between ADU and harness-to-clockspring
connector. If battery voltage does not exist, go to next step.
2. Disconnect clockspring-to-air bag module connector. Check for battery voltage between ground and
terminal No. 2 (Yellow-Red wire) and-or terminal No. 3 (Red wire) of clockspring connector. If battery
voltage exists, replace clockspring. See CLOCKSPRING under REMOVAL & INSTALLATION. If
battery voltage does not exist, replace driver-side air bag module. See DRIVER-SIDE AIR BAG
MODULE under REMOVAL & INSTALLATION.
DTC : DRIVER MODULE SHORT
connector. Disconnect clockspring-to-air bag module connector. Check for continuity between
clockspring connector terminals No. 2 and No. 3. See WIRING DIAGRAMS . If continuity exists, go to
next step. If continuity does not exist, replace driver-side air bag module. See DRIVER-SIDE AIR BAG
2. Disconnect harness-to-clockspring connector. Check continuity between terminals No. 2 (Yellow-Red
wire) and No. 3 (Red wire) of harness connector. If continuity exists, replace wire harness between ADU
and harness-to-clockspring connector. If continuity does not exist, replace clockspring. See
CLOCKSPRING under REMOVAL & INSTALLATION.
2001 Kia Rio
DTC : DRIVER MODULE OPEN
connector and clockspring-to-driver air bag connector. Check for continuity between ADU connector
terminal No. 11 (Yellow-Red wire) and clockspring connector terminal No. 2 (Yellow-Red wire). If
continuity does not exist, go to next step. If continuity does exist, go to step 4 .
2. Disconnect harness-to-clockspring connector. Check for continuity between terminal No. 2 (Yellow-Red
wire) of harness connector and terminal No. 11 (Yellow-Red wire) of ADU connector. If continuity does
not exist, replace harness between harness-to-clockspring connector and ADU. If continuity exists, go to
next step.
3. Check for continuity between terminal No. 2 of clockspring-to-air bag module connector and terminal
No. 2 (Yellow-Red wire) of harness-to- clockspring connector. If continuity exists, go to next step. If
continuity does not exist, replace clockspring. See CLOCKSPRING under REMOVAL &
INSTALLATION.
4. Reconnect harness-to-clockspring connector. Check for continuity between ADU connector terminal No.
10 (Red wire) and terminal No. 3 of clockspring-to-air bag module connector. If continuity does not exist,
go to next step. If continuity exists, replace driver-side air bag module. See DRIVER-SIDE AIR BAG
5. Disconnect wire harness-to-clockspring connector. Check for continuity between ADU terminal No. 10
(Red wire) and terminal No. 3 of harness connector. If continuity does not exist, replace wire harness
between ADU and harness-to-clockspring connector. If continuity exists, go to next step.
6. Check for continuity between terminal No. 2 of clockspring-to-air bag connector and terminal No. 3 (Red
wire) of harness-to-clockspring connector. If continuity does not exist, replace clockspring. See
CLOCKSPRING under REMOVAL & INSTALLATION. If continuity exists, replace driver-side air
bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
DTC : PASSENGER MODULE SHORT TO GROUND
Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM . Disconnect Air Bag Diagnostic Unit (ADU) connector and passenger-
side air bag module connector. Check for continuity between ground and ADU connector terminals No. 13
(Green-Red wire) and No. 14 (Green-Yellow wire). See WIRING DIAGRAMS . If continuity exists, replace
harness between ADU and passenger-side air bag module. If continuity does not exist, replace passenger side
air bag module. See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
DTC : PASSENGER MODULE SHORT TO BATTERY
2001 Kia Rio
ACTIVATING AIR BAG SYSTEM . Disconnect Air Bag Diagnostic Unit (ADU) connector. Disconnect
passenger-side air bag module connector. Check for battery voltage between ground and ADU connector
terminals No. 13 (Green-Red wire) and No. 14 (Green-Yellow wire). See WIRING DIAGRAMS . If battery
voltage exists at either terminal, replace wire harness between ADU and passenger-side air bag module. If
battery voltage does not exist, replace passenger-side air bag module. See PASSENGER-SIDE AIR BAG
DTC : PASSENGER MODULE SHORT
side air bag module connector. Check for continuity between ADU terminals No. 13 (Green-Red wire) and No.
14 (Green-Yellow wire). See WIRING DIAGRAMS . If continuity exists, replace harness between ADU and
passenger-side air bag module. If continuity does not exist, replace passenger-side air bag module. See
PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
DTC : PASSENGER MODULE OPEN
connector. Disconnect passenger-side air bag module connector. Check for continuity between ADU
connector terminal No. 14 (Green-Yellow wire) and passenger-side air bag harness connector terminal
No. 2 (Green-Yellow wire). See WIRING DIAGRAMS . If continuity does not exist, replace wire
harness between ADU and passenger-side air bag module. If continuity exists, go to next step.
2. Check for continuity between terminal No. 13 (Green-Red wire) of ADU connector and terminal No. 3
(Green-Red wire) of passenger-side air bag harness connector. If continuity does not exist, replace wire
harness. If continuity exists, replace passenger-side air bag module. See PASSENGER-SIDE AIR BAG
DTC : DRIVER PRETENSIONER SHORT TO GROUND
2001 Kia Rio
connector and driver-side seat belt pretensioner connector. See WIRING DIAGRAMS . Check for
continuity between ground and ADU connector terminal No. 1 (Light Green wire) and-or terminal No. 2
(Orange wire). See WIRING DIAGRAMS . If continuity exists, replace harness between ADU and
pretensioner. If continuity does not exist, go to next step.
2. Check for continuity between ground and seat belt pretensioner harness connector terminals No. 1 (Light
Green wire) and-or No. 2 (Orange wire). If continuity exists, replace harness between ADU and
pretensioner. If continuity does not exist, replace pretensioner. See SEAT BELT PRETENSIONER
DTC : DRIVER PRETENSIONER SHORT TO BATTERY
connector and driver-side seat belt pretensioner connector. Check for battery voltage between ground and
terminal No. 1 (Light Green wire) and-or terminal No. 2 (Orange wire) of ADU connector. See WIRING
DIAGRAMS . If battery voltage exists, replace harness between ADU and pretensioner. If battery
voltage does not exist, go to next step.
2. Check for battery voltage between terminal No. 1 (Light Green wire) and terminal No. 2 (Orange wire) of
pretensioner connector and ground. If voltage exists, replace harness between ADU and pretensioner. If
voltage does not exist, replace pretensioner. See SEAT BELT PRETENSIONER under REMOVAL &
INSTALLATION.
DTC : DRIVER PRETENSIONER SHORT
ACTIVATING AIR BAG SYSTEM . Disconnect Air Bag Diagnostic Unit (ADU) connector and driver-side
seat belt pretensioner connector. Check for continuity between terminal No. 1 (Light Green wire) and terminal
No. 2 (Orange wire) of ADU connector. See WIRING DIAGRAMS . If continuity exists, replace harness from
ADU to pretensioner. If continuity does not exist, replace pretensioner. See SEAT BELT PRETENSIONER
DTC : DRIVER PRETENSIONER OPEN
connector and driver-side seat belt pretensioner connector. Check for continuity between terminal No. 1

2001 Kia Rio
(Light Green wire) of ADU connector and terminal No. 1 (Light Green) of seat belt pretensioner harness
connector. See WIRING DIAGRAMS . If continuity does not exist, replace harness from ADU to
pretensioner. If continuity exists, go to next step.
2. Check for continuity between terminal No. 2 (Orange wire) of ADU connector and terminal No. 2
(Orange wire) of seat belt pretensioner harness connector. If continuity does not exist, replace harness
between ADU and pretensioner. If continuity exists, replace pretensioner. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION.
DTC : PASSENGER PRETENSIONER SHORT TO GROUND
side seat belt pretensioner connector. Check for continuity between ground and terminal No. 3 (Black wire)
and-or terminal No. 4 (White wire) of ADU connector. If continuity exists, replace harness between ADU and
pretensioner. If continuity does not exist, replace pretensioner. See SEAT BELT PRETENSIONER under
REMOVAL & INSTALLATION.
DTC : PASSENGER PRETENSIONER SHORT TO BATTERY
side seat belt pretensioner connector. Check for battery voltage between ground and terminal No. 3 (Black wire)
and-or terminal No. 4 (White wire) of ADU connector. If battery voltage exists, replace harness between ADU
and pretensioner. If battery voltage does not exist, replace seat belt pretensioner. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION.
DTC : PASSENGER PRETENSIONER SHORT
side seat belt pretensioner connector. Check for continuity between terminals No. 3 (Black wire) and No. 4
(White wire) at ADU connector. If continuity exists, replace harness between ADU and pretensioner. If
continuity does not exist, replace seat belt pretensioner. See SEAT BELT PRETENSIONER under
REMOVAL & INSTALLATION.
DTC : PASSENGER PRETENSIONER OPEN

2001 Kia Rio
connector and passenger-side seat belt pretensioner connector. Check for continuity between terminal No.
3 (Black wire) of ADU connector and terminal No. 1 (Black wire) of seat belt pretensioner connector. If
continuity does not exist, replace harness between ADU and pretensioner. If continuity exists, go to next
step.
2. Check for continuity between terminal No. 4 (White wire) of ADU connector and terminal No. 2 (White
wire) of seat belt pretensioner connector. If continuity does not exist, replace harness between ADU and
pretensioner. If continuity exists, replace seat belt pretensioner. See SEAT BELT PRETENSIONER
DTC : ADU INCONSISTENCY
Code is indicative of mismatch of Air Bag Diagnostic Unit (ADU) with SRS components. Verify correct ADU
is installed in vehicle.
Fig. 6: Identifying Air Bag Diagnostic Unit (ADU) Connector Terminals

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs (N.m)
Instrument panel mounting bolts 13-19 (18-26)
Passenger-side air bag module bolts 13-20 (18-27)
Seat belt pretensioner mounting bolts 29-58 (38-78)
Steering column bolts 13-19 (18-26)
Steering wheel nut 53-67 (39-49)
INCH Lbs. (N.m)
Air Bag Diagnostic Unit (ADU) nuts 71-106 (8-12)
Driver-side air bag module bolts 71-106 (8-12)
Clockspring retaining screws 8 (0.9)
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WIRING DIAGRAMS

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Fig. 7: Air Bag System Wiring Diagram (Rio)

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2001 ACCESSORIES & EQUIPMENT Shift Interlock Systems
2001 ACCESSORIES & EQUIPMENT
Shift Interlock Systems
WIRING DIAGRAMS

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Fig. 1: Shift Interlock System Wiring Diagram (Rio)

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Fig. 2: Shift Interlock System Wiring Diagram (Sephia & Spectra)

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Fig. 3: Shift Interlock System Wiring Diagram (Sportage)

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2001 ACCESSORIES & EQUIPMENT Rear Window Defogger - Rio
Rear Window Defogger - Rio
INSPECTION
CAUTION: Wrap tin foil around the end of the voltmeter test lead to prevent damaging
the heater line.
1. Apply finger pressure on the tin foil, moving the tin foil along the grid line to check for open circuits.
Fig. 1: Illustrating Testing Procedure
2. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass
center point. If a voltage of approximately is indicated by the voltmeter, the heater line of the rear
window is considered satisfactory.
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Fig. 2: Testing Defogger Grid Lines
3. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
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2001 Kia Rio
Fig. 3: Isolating Grid Line Break Between Center Point & Voltage Source
4. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V.
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2001 Kia Rio
Fig. 4: Isolating Grid Line Break Between Center Point & Ground
5. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist.
Try to find a point where a voltage is generated or changes to 0V. The point where the voltage has
changed is the open-circuit point.
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2001 Kia Rio
Fig. 5: Isolating Exact Grid Line Break Point
6. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid
line, and between the same terminal and the center of one adjacent heater line. The section with a broken
heater line will have a resistance twice as that in other sections. In the affected section, move the test lead
to a position where the resistance sharply changes.
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2001 Kia Rio
Fig. 6: Measuring Grid Line Resistance
REPAIR OF BROKEN HEATER LINE

Prepare the following items:
1. Conductive paint.
2. Paint thinner.
3. Masking tape.
4. Silicone remover.
5. Thin brush.
CAUTION: After repairing, clean the glass with a soft dry cloth or wipe along the
grid line with a slightly moistened cloth.
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as
shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15
minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish,
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2001 Kia Rio
scrape away excess deposits with a knife after the paint has completely dried. (allow 24 hours).
Fig. 7: Repairing Damaged Grid Line
WIRING DIAGRAM
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2001 Kia Rio
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Fig. 8: Rear Window Defogger Wiring Diagram (Rio)
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2001 Kia Rio
2001 ACCESSORIES & EQUIPMENT Headlights & DRL - Rio
Headlights & DRL - Rio
DAYTIME RUNNING LIGHTS

INSPECTION (FOR CANADA)
CIRCUIT DIAGRAM
Fig. 1: DRL Circuit Diagram & Connector Pinout
OPERATION CHECK
Check that the lights operate according to the following timing chart.
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2001 Kia Rio
Fig. 2: DRL Operation Chart
REMOVAL AND INSTALLATION
1. It is installed at the lower of A-pillar.
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2001 Kia Rio
Fig. 3: Locating DRL Control Unit
AIMING INSTRUCTIONS
The head lamps should be aimed with the proper beam setting equipment, and in accordance with the equipment
manufacturer's instructions.
NOTE: If there are any regulations pertinent to the aiming of head lamps in the area
where the vehicle is to be used, adjust so as to meet those requirements.
Alternately turn the adjusting gear to adjust the head lamp aiming. If beam-setting equipment is not available,
proceed as follows:
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare
tire, and tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (vertical lines passing through respective head lamp centers) and a horizontal line
(horizontal line passing through center of head lamps) on the screen.
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2001 Kia Rio
4. With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on
the horizontal and vertical lines.
Make vertical and horizontal adjustments to the lower beam using the adjusting wheel.
LOW BEAMS
1. Turn the low beam on without the driver aboard. The cut-off line should be projected in the allowable
range (shaded region).
Fig. 4: Low Beam Projection Chart
2. Turn the front fog lamp on without the driver aboard. The cut-off line should be projected in the
allowable range (shaded region).
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2001 Kia Rio
Fig. 5: Fog Lamp Projection Chart
FRONT FOG LAMP
The front fog lamps should be aimed as the same manner of the head lamps aiming.
With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting gear.
Fig. 6: Illustrating Fog Lamp Adjustment Measurements
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2001 Kia Rio
Fig. 7: Fog Lamp Adjustment Specifications In Millimeters
WIRING DIAGRAMS
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Fig. 8: Headlight System Wiring Diagram (Rio)
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2001 ACCESSORIES & EQUIPMENT Instrument Panels - Rio
Instrument Panels - Rio

Instrument panel houses instrument cluster, center panel, several switches and controls. Indicator lights and
gauges are active when the ignition switch is in ON or START position. Indicator lights and gauges receive
signals from either a switch or variable resistance sending unit.
WARNING: Deactivate air bag system before performing any service operation. See
AIR BAG RESTRAINT SYSTEMS article. DO NOT apply electrical power to
any component on steering column without first deactivating air bag
system. Air bag may deploy.
COMPONENT LOCATIONS
NOTE: For instrument panel component locations see Fig. 1 .

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Fig. 1: Locating Instrument Panel Components (Rio)

TROUBLE SHOOTING
INSTRUMENT CLUSTER
During vehicle operation, if an instrument does not operate smoothly or indicate correctly, remove instrument
cluster and test it to determine fault. If a bulb has burned out, remove instrument cluster and replace bulb.
Speedometer Does Not Operate Or Shows An Indicator Error
Check speedometer, speedometer sensor, circuits between speedometer and speedometer sensor and instrument
cluster printed circuit board. Replace failed component and/or repair circuits as necessary.
2001 Kia Rio
Coolant Temperature Gauge Does Not Operate
Check instrument cluster printed circuit board, coolant temperature gauge, coolant temperature sensor sending
unit and circuits between coolant temperature gauge and coolant temperature sensor sending unit. Replace
failed component and/or repair circuits as necessary.
Fuel Gauge Does Not Operate
Check instrument cluster printed circuit board, fuel gauge sensor sending unit, fuel gauge and circuits between
fuel gauge sensor sending unit and fuel gauge. Replace failed component and/or repair circuits as necessary.
Instrument Cluster Illumination Does Not Operate Correctly Or At All
Check for a burned out bulb, defective bulb holder and instrument cluster printed circuit board. Replace failed
component as necessary.

INSTRUMENT CLUSTER
1. Disconnect negative battery cable. Remove ash tray. Remove center panel trim screw and disconnect
electrical harness connector. Remove center panel trim. Remove 2 instrument cluster trim screws behind
center panel trim.
2. Disconnect 3 connectors and remove instrument cluster trim. Remove 4 instrument cluster mounting
screws. Disconnect 3 connectors and remove instrument cluster. To install, reverse removal procedures.
WIRING DIAGRAM

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Fig. 2: Instrument Panel Wiring Diagram (Rio)


2001 Kia Rio
2001 ACCESSORIES & EQUIPMENT Power Mirrors - Rio
Power Mirrors - Rio
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting ANY repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT
SYSTEMS article.
Outside rearview mirror assembly includes mirror glass and mirror frame, a motor, wire harness and garnish.
Some models are equipped with a mirror heater that operates when rear window defroster is activated. Each
mirror can be adjusted in 4 directions from inside vehicle using remote control mirror switch. See Fig. 1 . To
adjust mirrors move mirror selector switch located on left side of instrument panel to mirror to be adjusted.
Adjust mirror angle by pressing remote control mirror switch in desired direction. Release switch when mirror
stops moving. Motor continues to operate for as long as switch is pressed and can be damaged if mirror is no
longer moving.

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Fig. 1: Locating Power Mirror Components (Rio)

TROUBLE SHOOTING
MIRRORS DO NOT OPERATE
Check AUDIO fuse (10-amp) in passenger compartment fuse box located behind driver's side kick panel. Check
power mirror circuits between switch and mirrors. Perform repairs as necessary. See WIRING DIAGRAM .

MIRROR ASSEMBLY
Remove & Installation

2001 Kia Rio
Disconnect negative battery cable. Remove garnish. See Fig. 1 . Remove 3 rearview mirror assembly mounting
bolts. Pull mirror assembly away from door. Disconnect harness connector and remove mirror assembly. To
install reverse removal procedure.
WIRING DIAGRAMS

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2001 Kia Rio
Fig. 2: Power Mirror System Wiring Diagram (Rio)


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2001 ACCESSORIES & EQUIPMENT Steering Column Switches
Steering Column Switches
DESCRIPTION
Left column-mounted combination switch incorporates turn signal switch, dimmer switch, headlight switch and
flash-to-pass switch. Right column-mounted combination switch incorporates wiper/washer switch and cruise
control switch (if equipped).
SYMPTOM TESTS
NOTE: Symptom tests for Optima and Rio are not available from manufacturer.
HORN DOES NOT OPERATE
Sportage
1. Check for blown HORN (10-amp) fuse, located in passenger compartment fuse box. Replace as required.
Remove horn relay. Using a voltmeter, check for battery voltage at horn relay connector Yellow/Red
wires. If battery voltage does not exist, repair open or short in Yellow/Red wires between horn relay and
HORN fuse. If battery voltage exists, go to next step.
2. Using an ohmmeter, check for continuity between horn relay connector White/Black wire and ground
with horn switch depressed. If continuity exists, go to next step. If continuity does not exist, repair open
White/Black wire, clockspring, or horn switch.
3. Install horn relay. Depress horn switch. Backprobe horn relay connector White/Green wire and check for
battery voltage. If battery voltage does not exist, replace horn relay. If battery voltage exists, check for
battery voltage at horn relay White/Green wire. If battery voltage does not exist, repair open circuit in
White/Green wire. If battery voltage exists, go to next step.
4. Check continuity between horn connector Black wire and ground. If continuity exists, replace horn. If
continuity does not exist, repair open circuit between horn connector terminal No. 2 and ground.
TURN SIGNAL LIGHTS INOPERATIVE
Sportage
1. Inspect HAZARD (15-amp) fuse and TURN (10-amp) fuse, both located in passenger compartment fuse
box. Check for faulty turn signal bulbs. Check for loose or damaged connections. Repair or replace as
required.
2. Turn ignition switch on. Disconnect combination switch connector and check for battery voltage at Blue
4:54:34 PM
2001 Kia Rio
wire. If battery voltage does not exist, check for open circuit in Blue wire between TURN (10-amp) fuse
and combination switch. If battery voltage exists, go to next step.
3. Connect combination switch connector. Place turn signal switch in left turn position. Backprobe
combination switch connector Red/Yellow wire and check for battery voltage. If battery voltage does not
exist, replace turn signal switch. If battery voltage exists, go to next step.
4. Place turn signal switch in right turn position. Backprobe turn signal switch connector Red/Green wire
and check for battery voltage. If battery voltage does not exist, replace turn signal switch. If battery
voltage exists, go to next step.
5. Place turn signal switch in left turn position. Backprobe flasher module connector Red/Yellow wire and
check for battery voltage. If battery voltage does not exist, repair open circuit in Red/Yellow wire. If
battery voltage exists, place turn signal switch in right turn position. Backprobe flasher module connector
Red/Green wire and check for battery voltage. If battery voltage exists, go to next step. If battery voltage
does not exist, repair open circuit in Red/Green wire.
6. Measure voltage at flasher module connector Red wire. If battery voltage exists, go to next step. If battery
voltage does not exist, repair open circuit in Red wire.
7. Turn ignition switch off. Using ohmmeter, check for continuity between flasher module connector Black
wire and ground. If continuity exists, go to next step. If continuity does not exist, repair open circuit in
Black wire between flasher module and ground.
8. Turn ignition switch on. Operate turn signal switch in either direction and measure voltage at front and
rear turn signal light connectors (Red/Blue wire for left; Red/White wire for right). If battery voltage
exists, go to next step. If battery voltage does not exist, repair open circuit between affected turn signal
and flasher module.
9. Turn ignition switch off. Check Black wire(s) for continuity between turn signal light connectors and
ground. If continuity exists, replace flasher module. If continuity does not exist, repair open circuit in
Black wire between bulb socket and ground.
COMPONENT TESTS
FLASHER MODULE
Sportage
1. Remove flasher module from relay box, behind left side of instrument panel. Use jumper wires to apply
battery voltage to flasher module terminal No. 1 and ground terminal No. 8. See Fig. 1 . Check for battery
voltage at terminal No. 7. If voltage exists, go to next step. If voltage does not exist, replace flasher
module.
2. Use jumper wire to apply battery voltage to terminal No. 2. Check for pulsing battery voltage at terminal
No. 3. See Fig. 1 . If pulsing battery voltage does not exist, replace flasher module. If voltage exists, go to
next step.
3. Remove jumper wire from terminal No. 2 and move it to terminal No. 6. Check for pulsing battery
voltage at terminal No. 5. See Fig. 1 . If pulsing battery voltage does not exist, replace flasher module. If
voltage exists, go to next step.
4. Remove jumper wire from terminal No. 6. Remove ground wire from terminal No. 8 and connect it to
terminal No. 7. See Fig. 1 . Check for pulsing battery voltage at terminals No. 3 and 5. If pulsing battery

2001 Kia Rio
voltage does not exist, replace flasher module.
Fig. 1: Identifying Flasher Module Terminals (Sportage)

HEADLIGHT RELAY
NOTE: On Optima, relay terminal Identification number is printed on relay body.
Optima
1. Remove high or low headlight relay. Using ohmmeter, check for continuity between relay terminals No.
85 and 86. Continuity should exist. Also check continuity between relay terminals No. 30 and 87.
Continuity should not exist. If continuity is as specified, go to next step. If continuity is not as specified,
replace relay.
2. Using jumper wire, apply battery voltage to relay terminal No. 86. Using another jumper wire, connect
relay terminal No. 85 to ground. Recheck continuity between relay terminals No. 30 and 87. If continuity
exists, relay is okay. If continuity does not exist, replace relay.
Rio
1. Remove headlight relay. Using ohmmeter, check for continuity between relay terminals No. 2
(Blue/Black wire) and No. 4 (Blue wire). Continuity should exist. See WIRING DIAGRAMS . Also
check continuity between relay terminals No. 1 (Blue/Black wire) and No. 3 (Green/Red wire).
Continuity should not exist. If continuity is as specified, go to next step. If continuity is not as specified,
replace relay.
2. Using jumper wire, apply battery voltage to relay terminal No. 2 (Blue/Black wire). Using another jumper
2001 Kia Rio
wire, connect relay terminal No. 4 (Blue wire) to ground. Recheck continuity between relay terminals No.
1 (Blue/Black wire) and No. 3 (Green/Red wire). If continuity exists, relay is okay. If continuity does not
exist, replace relay.
Sephia & Spectra
1. Remove headlight relay from engine compartment fuse/relay box. Use an ohmmeter to check for
continuity between relay terminals No. 2 (wire color not available) and No. 4 (Red/White wire). See Fig.
2 . If continuity exists, go to next step. If continuity does not exist, replace relay.
2. Using jumper wires, apply battery voltage to relay terminal No. 2 and ground terminal No. 4. Check for
continuity between relay terminals No. 1 (Pink/Blue wire) and No. 3 (Red/Brown wire). If continuity
does not exist, replace relay. If continuity exists, relay is okay.
Fig. 2: Identifying Headlight Relay Terminals (Sephia & Spectra)

Sportage
1. Remove headlight relay from engine compartment fuse/relay box. Use an ohmmeter to check for
continuity between relay terminals No. 3 (Green/White wire) and No. 4 (Green wire). If continuity exists,
go to next step. If continuity does not exist, replace relay.
2. Use jumper wires to apply battery voltage to relay terminal No. 4 (Green wire) and ground relay terminal
No. 3 (Green/White wire). Check for continuity between terminals No. 1 (Green wire) and No. 2 (Blue
wire). If continuity does not exist, replace relay. If continuity exists, relay is okay.

2001 Kia Rio
HEADLIGHT SWITCH
Disconnect combination switch connector. Check for continuity between combination switch connector
terminals specified. See HEADLIGHT SWITCH TEST (OPTIMA) , HEADLIGHT SWITCH TEST
(RIO) , HEADLIGHT SWITCH TEST (SEPHIA & SPECTRA) or HEADLIGHT SWITCH TEST
(SPORTAGE) table. See Fig. 3 , Fig. 4 , Fig. 5 or Fig. 6 . If continuity is not as specified, replace headlight
switch.
HEADLIGHT SWITCH TEST (OPTIMA)

Application & Switch Position Continuity Between Terminals No.
Headlight Switch
Off No Continuity
Parking 11 & 14
Lo Beam 11, 12, 13 & 14; 17 & 18
Hi Beam 8 & 17; 11, 12, 13 & 14
Flash-To-Pass Switch
On 6, 9 & 17
HEADLIGHT SWITCH TEST (RIO)

Headlight Switch
Off 8 & 11
Parking 2 & 9; 7 & 8
Lo Beam 2 & 9; 6 & 9; 7 & 8
Hi Beam 2 & 9; 6 & 9; 7 & 11
On 1 & 11
HEADLIGHT SWITCH TEST (SEPHIA & SPECTRA)

Headlight Switch
Off 7 & 11
Parking 2&9
Lo Beam 2 & 9; 6 & 9; 7 & 8
Hi Beam 2 & 9; 6 & 9; 7 & 11
On 1 & 11
HEADLIGHT SWITCH TEST (SPORTAGE)

Headlight Switch
2001 Kia Rio
Off 16 & 17
Parking 10 & 15; 16 & 17
Lo Beam 5 & 15; 16 & 17
Hi Beam 5 & 15; 7 & 17
On 7 & 12
Fig. 3: Identifying Combination Switch Connector Terminals (Optima)

Fig. 4: Identifying Combination Switch Connector Terminals (Rio)

Fig. 5: Identifying Combination Switch Connector Terminals (Sephia & Spectra)


2001 Kia Rio
Fig. 6: Identifying Combination Switch Connector Terminals (Sportage)

HORN RELAY
NOTE: Horn relay test procedures for Optima, Sephia and Spectra are not available
from manufacturer. For test information, see WIRING DIAGRAMS .
Rio
1. Disconnect horn relay connector and remove relay. Relay is located behind left side of instrument panel,
above fuse box. Using an ohmmeter, check for continuity between relay terminals No. 3 (Light/Green
wire) and No. 4 (Brown/Yellow wire). See WIRING DIAGRAMS . Continuity should exist. If it does
not, replace relay.
2. Check for continuity between relay terminals No. 1 (Brown/Yellow wire) and No. 2 (Light Green/Yellow
wire). Continuity should not exist. Using jumper wires, apply battery voltage to terminal No. 4
(Brown/Yellow wire) and ground terminal No. 3 (Light Green/Red wire). Check for continuity between
relay terminals No. 1 and 2. Continuity should exist. If continuity is not as specified, replace relay.
Sportage
1. Disconnect horn relay connector and remove relay. Relay is located behind left side of instrument panel,
above fuse box. Using an ohmmeter, check for continuity between relay terminals No. 3 (White/Black
wire) and No. 4 (Yellow/Red wire). See WIRING DIAGRAMS . Continuity should exist. If it does not,
replace relay.
2. Check for continuity between relay terminals No. 1 (Yellow/Red wire) and No. 2 (White/Green wire).
Continuity should not exist. Using jumper wires, apply battery voltage to terminal No. 4 (Yellow/Red
wire) and ground terminal No. 3 (White/Black wire). Check for continuity between relay terminals No. 1
and 2. Continuity should exist. If continuity is not as specified, replace relay.

2001 Kia Rio
TURN SIGNAL SWITCH
NOTE: Horn relay test procedure for Sportage is not available from manufacturer. For
test information, see WIRING DIAGRAMS .
Disconnect combination switch connector. Check for continuity between switch terminals specified. See TURN
SIGNAL SWITCH TEST table. See Fig. 3 , Fig. 4 , Fig. 5 or Fig. 6 . If continuity is not as specified, replace
combination switch.
TURN SIGNAL SWITCH TEST

Switch Position Continuity Between Terminals No.
Optima
Left 1&2
Right 1&3
Rio, Sephia & Spectra
Left 4 & 10
Right 4&5
WIPER/WASHER SWITCH
For wiper/washer switch testing, see WIPER/WASHER SYSTEMS article.
NOTE: Anytime battery cables are disconnected from battery and then reconnected,
theft deterrent system will operate (horn will sound and emergency lights will
flash for about 3 minutes). To disarm system, insert ignition key and turn key to
ACC position.
COMBINATION SWITCH
Remove steering wheel and air bag module. See AIR BAG RESTRAINT SYSTEMS article. Remove steering
column covers. Disconnect combination switch harness connectors. Remove combination switch screws.
Remove combination switch. To install, reverse removal procedure.
IGNITION SWITCH

2001 Kia Rio
Deactivate air bag system. See AIR BAG RESTRAINT SYSTEMS article. Disconnect negative battery cable.
Remove steering column covers. Using chisel, make slot in mounting screws to accommodate screwdriver.
Remove screws mounting ignition switch to steering column. Disconnect ignition switch harness connectors.
Remove ignition switch. To install, reverse removal procedure.
WIRING DIAGRAMS

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2001 Kia Rio
Fig. 7: Horn System Wiring Diagram (Optima)

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Fig. 8: Horn System Wiring Diagram (Rio)

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Fig. 9: Horn System Wiring Diagram (Sephia & Spectra)

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Fig. 10: Horn System Wiring Diagram (Sportage)

2001 Kia Rio
2001 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Rio
Wiper/Washer Systems - Rio
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting ANY repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT
SYSTEMS article.
A 2-speed wiper motor with an intermittent feature is used. Front wiper/washer switch is an integral part of
steering column combination switch. Wiper lever is located on right side of steering column. Wipers will only
operate when ignition switch is in ON position. To operate wipers pull wiper lever down. Intermittent operation
is at the first detent. Normal wiper speed is at the second detent and fast wiper speed is at the last detent. For a
single wiping cycle without washer operation, push wiper lever toward instrument panel and release with wiper
lever in OFF position. To activate washer and wiper, pull wiper lever toward steering wheel and hold. Washer
will spray windshield and wiper will cycle until wiper lever is released. Wiper will cycle 1-3 times after wiper
lever is released.
ADJUSTMENTS
CAUTION: DO NOT operate wipers when windshield is dry. Wiper blades and/or
windshield can be damaged when wipers are operated when windshield is
dry. DO NOT operate windshield washer when washer fluid reservoir is
empty. Washer pump can be damaged.
WIPER ARMS
Ensure wiper motor is in off/park position. Measure distance between top tip of wiper blade and bottom of
windshield trim. Distance should be 1.54-1.69" (39-43 mm) on driver's side and 1.50-1.65" (38-42 mm) on
passenger's side. See Fig. 1 . If distance is not as specified, remove wiper arm. Reinstall wiper arm so wiper
blade tip is within specification. Tighten wiper arm pivot shaft nut to 13-16 ft. lbs. (18-22 N.m).

4:56:28 PM
2001 Kia Rio
Fig. 1: Adjusting Wiper Arm Off/Park Position

WASHER SPRAY
Spray should center on driver and passenger sides of windshield. If necessary, adjust washer spray by turning
nozzle slightly. See Fig. 2 . If nozzle is restricted, clear using a wire or needle.

2001 Kia Rio
Fig. 2: Adjusting Windshield Washer Spray

COMPONENT TESTS
WASHER PUMP
1. Remove washer pump and disconnect connector. Check for continuity between washer pump terminals. If
continuity exists, go to next step. If continuity does not exist, replace washer pump.
2. Using a fused jumper wire set, momentarily apply battery voltage and ground to washer pump terminals.
If washer pump operates, washer pump is okay at this time. If washer pump does not operate, replace
washer pump.
WIPER MOTOR
1. Disconnect wiper motor 6-pin connector. Check for continuity between wiper motor terminals.
Continuity should exist between wiper motor terminals No. 3 and 6, between terminals No. 4 and 5, and
between terminals No. 5 and 6. See Fig. 3 . See WIRING DIAGRAM . Continuity should not exist
2001 Kia Rio
between any other terminals. If continuity is as specified, go to next step. If continuity is not as specified,
replace wiper motor.
2. Using a fused jumper wire set, apply battery voltage to wiper motor terminal No. 5 and ground to
terminal No. 6. See Fig. 3 . If wiper motor operates in low speed, go to next step. If wiper motor does not
operate in low speed, replace wiper motor.
3. Using a fused jumper wire set, apply battery voltage to wiper motor terminal No. 3 and ground to
terminal No. 6. If wiper motor operates in high speed, check wiper motor power and ground circuits. See
WIRING DIAGRAMS . If wiper motor does not operate in high speed, replace wiper motor.
Fig. 3: Testing Wiper Motor


WASHER PUMP & RESERVOIR
1. Disconnect negative battery terminal. Remove 2 washer reservoir mounting bolts. Disconnect washer
motor harness connector. Disconnect washer hose.
2. Remove washer reservoir. Drain washer fluid and remove washer pump. To install, reverse remove
procedure. Ensure washer reservoir is not cracked or damaged. Tighten reservoir mounting bolts to 62-89
INCH lbs. (7-10 N.m).
2001 Kia Rio
WIPER ARMS
NOTE: Before removing wiper arms, ensure wiper motor has stopped at its off/park
position.
1. Remove wiper arm nut cover and remove nut. Ensure wiper arms are marked "DS" for driver's side and
"PS" for passenger's side. If not, apply identifying marks before removal. Remove wiper arms.
2. To install, reverse removal procedures. Install passenger's side wiper arm first. Tighten wiper arm pivot
shaft nut to 13-16 ft. lbs. (18-22 N.m). Wet windshield and check wiper arm movement across
windshield. Ensure wiper arms stop at proper off/park position. See WIPER ARMS under
ADJUSTMENTS.
WIPER MOTOR
1. If possible, ensure wiper motor is in its off/park position. Disconnect negative battery cable. Disconnect
wiper motor harness connector. Remove 4 wiper motor mounting bolts. Using a screwdriver, separate
motor assembly from wiper link assembly. Remove wiper motor from engine compartment.
2. To install, attach wiper motor ball joint to wiper link assembly. Install and tighten 4 wiper motor
mounting bolts. Connect wiper motor harness connector. Connect negative battery cable. Ensure wiper
arms stop at proper off/park position. See WIPER ARMS under ADJUSTMENTS.
WIPER LINK ASSEMBLY
1. Remove wiper arms. See WIPER ARMS . Remove wiper motor. See WIPER MOTOR . Remove 2
screws and 5 fasteners from cowl vent. Remove cowl vent.
2. Remove 4 pivot shaft nuts. Remove link assembly out through driver's side access hole. Using hand
pressure, check link assembly joints for resistance or binding. Lubricate using a non-hardening grease as
necessary.
3. To install, reverse removal procedure. Position link assembly pivot shafts in their holes and install
mounting nuts. Extend link assembly and connect link to wiper motor. Install wiper motor, cowl vent and
wiper arms.
4. Ensure wiper arms stop at proper off/park position. See WIPER ARMS under ADJUSTMENTS.
WIRING DIAGRAMS

2001 Kia Rio

2001 Kia Rio
Fig. 4: Wiper/Washer System Wiring Diagram (Rio)



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2001 Kia Rio

2001 ACCESSORIES/SAFETY EQUIPMENT Kia - Air Bag Restraint Systems

2001 ACCESSORIES/SAFETY EQUIPMENT

Kia - Air Bag Restraint Systems

DESCRIPTION & OPERATION

SYSTEM OPERATION CHECK

AIR BAG SAFETY PRECAUTIONS

NOTE: An alignment pin is used to align clockspring during reassembly and is

Helpmelearn Repair Manuals

Fig. 1: Aligning Clockspring

DISABLING & ACTIVATING AIR BAG SYSTEM

Helpmelearn Repair Manuals

DEPLOYED AIR BAG OR SEAT BELT PRETENSIONER

UNDEPLOYED AIR BAG OR SEAT BELT PRETENSIONER

Helpmelearn Repair Manuals

REMOVAL & INSTALLATION

AIR BAG DIAGNOSTIC UNIT (ADU)

Removal & Installation)

Fig. 2: Identifying Air Bag Diagnostic Unit (ADU)

Helpmelearn Repair Manuals

Removal & Installation

NOTE: An alignment pin is used to align clockspring during reassembly and is

Helpmelearn Repair Manuals

Fig. 3: Identifying Clockspring & Driver-side Air Bag Module

DRIVER-SIDE AIR BAG MODULE

Removal & Installation

PASSENGER-SIDE AIR BAG MODULE

Removal & Installation

Fig. 4: Identifying Passenger-side Air Bag Module

SEAT BELT PRETENSIONER

Removal & Installation

Helpmelearn Repair Manuals

3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE

Removal & Installation

Helpmelearn Repair Manuals

Fig. 5: Identifying Instrument Panel

AIR BAG WARNING LIGHT SERVICE

RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES (DTC)

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Helpmelearn Repair Manuals

DTC : INTERNAL FAULT

DTC : INTERNAL FAULT

DTC : INTERNAL FAULT

DTC : POWER SUPPLY LOW

DTC : POWER SUPPLY HIGH

DTC : WARNING LIGHT SHORT

DTC : WARNING LIGHT OPEN

DTC : DRIVER MODULE SHORT TO GROUND

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DTC : DRIVER MODULE SHORT TO BATTERY

DTC : DRIVER MODULE SHORT

DTC : DRIVER MODULE OPEN

DTC : PASSENGER MODULE SHORT TO GROUND

DTC : PASSENGER MODULE SHORT TO BATTERY

identification when diagnosing faults. See Fig. 6 & Fig. 7 .

DTC : PASSENGER MODULE SHORT

DTC : PASSENGER MODULE OPEN

DTC : DRIVER PRETENSIONER SHORT TO GROUND

DTC : DRIVER PRETENSIONER SHORT TO BATTERY

DTC : DRIVER PRETENSIONER SHORT

DTC : DRIVER PRETENSIONER OPEN

Helpmelearn Repair Manuals

DTC : PASSENGER PRETENSIONER SHORT TO GROUND

DTC : PASSENGER PRETENSIONER SHORT TO BATTERY