Problems owners report
Complaints filed with NHTSA about the 2004 Kia Rio, by the system named in each complaint. One complaint can name several.
- Engine and engine cooling12
- Fuel system, gasoline5
- Suspension5
- Electrical system5
- Power train4
- Service brakes, hydraulic4
- Unknown or other3
- Air bags3
- Vehicle speed control3
- Latches/locks/linkages2
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 2 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 5 2004 Rio vehicles were involved in crashes on US public roads in which someone died; 3 people died inside them. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Kia Rio failed the safety check 3.60% of the time — 63% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 84,789 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Engines
The most common engines in 2004 Kia Rio cars on Dutch roads are the 1.5 petrol (71 kW, 95 hp) and 1.3 petrol (60 kW, 80 hp).
| Engine | Power | Cars |
|---|---|---|
| 1.5 petrol | 71 kW 95 hp | 236 |
| 1.3 petrol | 60 kW 80 hp | 181 |
RDW Open Data (CC0): registered passenger cars and their fuel data · engine size rounded to 0.1 litre, net maximum power · versions with at least 20 cars
In the Netherlands
419 first registered in 2004 are on Dutch roads; 1% arrived later as imports.
Most common APK defects
- Bandenspanning niet op juiste waarde282
- Overmatige vloeistoflekkage overige vloeistoffen195
- Slijtage/beschadiging wiellager hoorbaar of voelbaar166
- Licht- donkerscheiding dimlicht onduidelijk151
- Band onvoldoende profiel120
- Dimlicht onjuist afgesteld107
- Band(en) aanwezig met een profieldiepte van 1,6 t/m 2,5 mm98
- Kentekenplaatverlichting werkt niet (goed) / ontbreekt87
Colours
RDW Open Data: registered vehicles and APK defects (CC0) · defect descriptions in the RDW's Dutch wording
In the United Kingdom
165 cars built in 2004 were licensed for the road at the end of 2025, and 345 more were declared off the road (SORN).
Department for Transport and DVLA, vehicle licensing statistics (table VEH0124, year of manufacture) · Open Government Licence v3.0
MOT test results in Great Britain
In 2023, 371 of these cars first registered in 2004 took their annual MOT test. 49% passed first time; among all cars first registered in 2004 the figure was 56%.
| Failed on | These cars | All cars from 2004 |
|---|---|---|
| Lamps, reflectors and electrical equipment | 23.7% | 21.8% |
| Suspension | 16.4% | 17.2% |
| Body, chassis, structure | 14.0% | 9.1% |
| Brakes | 14.0% | 13.8% |
| Visibility | 11.9% | 7.7% |
| Noise, emissions and leaks | 8.9% | 7.5% |
DVSA anonymised MOT tests and results, 2023 (Department for Transport) · Open Government Licence v3.0 · first tests only; a fix made at the test station within the hour still counts as a fail
In Finland
8 of these cars first registered in 2004 were in use in Finland on 30 Jun 2026, with an average of 175,000 km on the odometer at their last inspection.
Traficom (Finnish Transport and Communications Agency), open data on vehicles in use · CC BY 4.0
In New Zealand
62 2004 cars are on the New Zealand register; 2% arrived as used imports, 98% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 2 variants: combined 9.2–9.5 L/100 km (about 25–26 mpg US), CO₂ 212–219 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Rio · Compact · Regular gasoline | 10.2 | 7.9 | 9.2 |
| Rio · Compact · Regular gasoline | 10.6 | 8.0 | 9.5 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
2 Transport Canada recalls for the 2004 Kia Rio.
| 2005404 28 Dec 2005 | Seats And Restraints Certain vehicles fail to comply with the requirements of CMVSS 210.2. The child restraint fixture anchor may contact the rear seat back frame. This interferen… |
| 2003279 12 Nov 2003 | Fuel System On certain vehicles, the fuel intake nipple of the fuel distributor is subject to fracture or cracking during removal of the quick connect coupling securing the… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, 'CHILD RESTRAINT ANCHORAGE SYSTEMS.' CERTAIN CHILD RESTRAINT ANCHORS WILL NOT FULLY LATCH ONTO THE LOWER LATCH ANCHORS LOCATED BETWEEN THE REAR SEAT BACK AND REAR SEAT CUSHION BECAUSE OF INTERFERENCE BETWEEN THE CHILD SEAT ANCHORS AND A METAL WIRE LOCATED IN THE FRAME OF THE REAR SEAT BACK. UNTIL THE RECALL REPAIR IS COMPLETED, FOLLOW THE INSTRUCTIONS PROVIDED BY YOUR CHILD SEATS MANUFACTURER ON HOW TO PROPERLY INSTALL THE CHILD SEAT WITH YOUR VEHICLE'S REAR SAFETY BELTS RATHER THAN USING THE LATCH SYSTEM.
ON CERTAIN PASSENGER VEHICLES, THE FUEL INTAKE NIPPLE OF THE FUEL DISTRIBUTOR IS SUBJECT TO FRACTURE OR CRACKING DURING REMOVAL OF THE QUICK CONNECT COUPLING SECURING THE MAIN FUEL TUBE ASSEMBLY TO THE FUEL INTAKE NIPPLE, OR WHEN FORCE IS ACCIDENTALLY APPLIED TO THE INTAKE NIPPLE DURING THE VEHICLE ASSEMBLY PROCESS OR DURING ENGINE COMPARTMENT REPAIRS.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Kia told its dealers about the 2004 Kia Rio: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10201529 | TECHNICAL SERVICE BULLETIN: INFORMATION FOR HEADLAMP CONDENSATION AND MOISTURE - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information relating to some Kia models that may exhibit fogging, condensation, and/or moisture inside a headlamp assembly. Generally, a fogging condition is considered normal and can be eliminated by turning on the headlamps with the engine running for up to 30 minutes or during normal driving conditions. Headlamp assembly replacement WILL |
| 10183431 | TSB - USE OF AFTERMARKET USB CHARGING CABLES IN USB/12V PORTS - This article provides information regarding the use of USB ports and 12V power outlets to connect/charge mobile phones. Customers may experience issues with their head units that may be related to the use of aftermarket USB charging cables, including; * Electrical interference and limited or no functionality when attempting to play music, or when charging a device through the USB port * Excessive static or noise when listening to the audio source * Malfunctions and screen freeze of the head unit screen * Slow down of the sys |
| 10133170 | PITSTOP - ENGINE COMPONENT RE-USE GUIDELINES - In general, parts and components removed during engine repairs should be considered serviceable, and should be thoroughly cleaned and transferred to the new engine. |
| 10109812 | TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners, which are designed to lock into place once fully attached, are utilized in various Kia models and are strictly intended for ?one time use.? Some examples are: axle shaft nuts with stake collar, cotter pins, washers with locking tabs and other similar hardware, including threaded fasteners with pre-applied ?thread-locking adhesives.? It is critical for technicians to be aware that ALL such locking fasteners, regardless of type, are for ?one time use? only. |
| 10109777 | TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners utilized in various Kia models are strictly intended for ?one time use?. Though not limited to the following, some examples are: axle shaft nuts with stake collar, cotter pins, washers with locking tabs and other similar hardware, including threaded fasteners with pre-applied ?thread-locking adhesives.? |
| 10091489 | TSB: AUTOMATIC TRANSMISSION FLUID APPLICATION GUIDE - THIS BULLETIN PROVIDES INFORMATION RELATING TO THE CORRECT AUTOMATIC TRANSMISSION FLUIDS THAT ARE REQUIRED FOR EACH KIA MODEL. REFER TO THE SHOP MANUAL ON KGIS FOR THE SPECIFIC KIA MODEL, THEN REFERENCE THE AUTOMATIC TRANSAXLE SYSTEM/ REPAIR PROCEDURES/ INSPECTION AND ADJUSTMENT SECTION FOR THE CORRECT ATF CHECK/FILL PROCEDURES. |
| 10026726 | KIA: ALL MODELS. ARTICLE PROVIDES INFORMATION RELATING TO THE IMPROVED DURABILITY OF BULB LIFE FOR REAR COMBINATION BULB; REAR STOP LAMP/TAIL LAMP BULB UTILIZED ON MULTIPLE KIA MODELS. *PE |
| 10024032 | RIO (BC) ENGINE HARD TO START, RUNS ROUGH AND STALLS -- WHAT TO CHECK -- CRANK POSITION SENSOR (CKP) TONE RING. *NJ |
| 10016737 | TECHLINE FAQS. KIA TECHNICIAN TIMES. VOLUME 8, ISSUE 4. *TT |
| 10015755 | VACUUM LEAK AFTER TSB SC036. KIA TECHNICIAN TIMES. *TT |
| 10015272 | IMPROVED TIMING BELTS FOR THE KIA RIO AND OPTIMA. *TT |
| 10007265 | PENDING RECALL RELATING TO THE FUEL DISTRIBUTOR AND FUEL CONNECTOR ASSEMBLIES. KIA HAS EXPANDED THE RANGE OF AFFECTED VEHICLES. *TT |
NHTSA manufacturer communications (public domain)