2003 Kia Rio Service & Repair Manual
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Automatic
Transaxle (A4AF3)
GENERAL
AUTOMATIC TRANSAXLE SYSTEM
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE CONTROL SYS-
TEM
KICK DOWN SWITCH
PRESSURE CONTROL SOLENOID VALVE
(PCSV)
PULSE GENERATOR
TRANSAXLE OIL TEMPERATURE SENSOR
TRANSAXLE RANGE (TR) SWITCH
SHIFT LEVER
AT -2 AUTOMATIC TRANSAXLE (A4AF3)
GENERAL
SPECIFICATION E1CAAE4F
ITEM CONTENTS
Engine displacement G4EE(1.4)/ G4ED(1.6)
Type 3 elements, 2 phases, 1 stage
Engine stall speed(rpm) 2400~2800 Torque converter
Stall torque ratio 1.9
Transaxle Type Electronically controlled automatic transaxle with four-speed
1st 2.846
2nd 1.581
3rd 1.000
4th 0.685
Gear ratio
Reverse 2.176
Final gear ratio 4.381(G4EE)/ 4.041(G4ED)
Speedometer gear ratio Drive 36/ Driven 31
Friction elements
3C2B1F (3Clutches 2Brakes 1OWC): 1-band, 4-multiple disc type
3 Clutches: Front clutch, Rear clutch, End clutch
2 Brakes: Low＆reverse brake, Kick-down brake (Band type)
Planetary gear 1 Ravinoux type planetary gear set with long and short pinion
Solenoid valve
6 Solenoid valves (3-PWM, 3-ON/OFF)
2-Pressure control solenoid valves (PWM)
1-Damper clutch control solenoid valve (PWM)
3-Shift control solenoid valve (ON/OFF)
TIGHTENING TORQUE
Items Nm kgf.cm lb-ft
Oil pan bolt 10-12 100-120 7-8
Select lever assembly mounting bolt 9-14 90-140 6.5-10
Starter motor mounting bolt 27-34 270-340 19-24
Oil cooler hose connector 15-22 150-220 11-16
Hose bracket 3-5 30-50 2-4
Bell housing cover to engine 8-10 80-100 6-7
Transaxle mounting bolt(dia.10mm) 43-55 430-550 32-41
Transaxle mounting bolt(dia.12mm) 60-80 600-800 43-58
Control cable to body 8-11 80-110 6-7.5
Lever assembly to bracket assembly 14-22 140-220 10-16
Oil drain plug 35-45 350-450 25-32
Pressure check plug 8-10 80-100 6-7
Pulse generator 10-12 100-120 7-8
Bearing retainer 17-22 170-220 13-16
GENERAL AT -3
Items Nm kgf.cm lb-ft
Transfer drive gear 16-21 160-210 12-15
One-way clutch inner race 35-45 350-450 25-32
Differential drive gear 130-140 1300-1400 94-101
Manual control lever 17-21 170-210 13-15
Manual control shaft lock screw 8-10 80-100 6-7
Inhibitor switch 10-12 100-120 7-8
Sprag rod support bolt 20-27 200-270 14-19
Pump housing to reaction shaft support bolt 10-12 100-120 7-8
Oil pump assembly mounting bolt 19-23 190-230 14-17
Valve body cover 10-12 100-120 7-8
Valve body assembly mounting bolt 10-12 100-120 7-8
Oil filter 5-7 50-70 4-5
Speedometer driven gear sleeve 3-5 30-50 2-4
End clutch cover 4-6 40-60 3-4
Kickdown adjusting screw 15-22 150-220 11-15
Rear cover bolt 19-23 190-230 14-17
Differential cover 20-27 200-270 14-19
Differential bearing cap 60-80 600-800 43-58
Differential bearing retainer 43-55 430-550 32-41
Locking nut(M38)-Input 180-210 1800-2100 130-152
Locking nut-Output 200-230 2000-2300 146-166
Shift cable bracket bolt 19-23 190-230 14-17
LUBRICANT
Items Specified lubricant Quantity
Transaxle fluid liter (U.S. lmp.qts.)
GENUINE DIAMOND
ATF SP-III or SK ATF SP-III
6.1L
Drive shaft and oil seal lip bushing
sliding parts
GENUINE DIAMOND ATF SP-III
CHASSIS GREASE SAE J310, NLGINO.0
Select lever sliding parts SAE J310, NLGINo.2
As required
AT -4 AUTOMATIC TRANSAXLE (A4AF3)
SPECIAL SERVICE TOOLS EBFB2F30
Tool
(Number and name)
Illustration Use
09431-21200
Oil seal installer
Y45005C
Installation of the differential oil seal.
09452-21500
Oil pressure gauge
EKAA006C
Measurement of the oil pressure.
(Use with 09452-21001 and 09452-21002)
09452-21002
Oil pressure gauge adapter
EKAA006B
Measurement of the oil pressure.
(Use with 09452-21500 and 09452-21001)
09452-21001
Oil pressure gauge adapter
EKAA006A
Measurement of the oil pressure.
(Use with 09452-21500 and 09452-21002)
09200-38001
Engine support fixture
D0038001
Removal and installation of the transaxle.
AUTOMATIC TRANSAXLE SYSTEM AT -5
AUTOMATIC TRANSAXLE
SYSTEM
DESCRIPTION EA641954
The advanced alpha automatic transaxle is for a 1.4/1.6
DOHC engine. The advanced alpha AT which is developed
by HMC is popularly used among small sized vehicles.
Nowadays PCM(power-train control module), which ECU
and TCU are integrated inside, is new trend of the power-
train system.
The merge of two system guarantees stable quality of the
AT as well as better shift feeling and faster response to
ECU information.
COMPONENTS(1)
(Integrated ECM)
TCM
LKJF001A
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$31.99
Kia Rio 2003 Full Service Repair Manual is a comprehensive guide designed to help you effectively repair, maintain, and restore your Kia Rio 2003. It covers in-depth diagnostic and repair procedures that are ideal for both professional technicians and DIY repair enthusiasts.
This manual provides detailed sub steps that elaborate on repair procedures, complete with notes, cautions, and warnings throughout each chapter to highlight critical information. Numbered instructions and bold figure numbers guide you confidently through every repair step. Detailed illustrations, drawings, and photos further assist in simplifying the repair process.
Key features include:
- Troubleshooting and electrical service procedures
- Detailed wiring diagrams for easy reference
- Comprehensive coverage of topics such as general information, specifications, engine removal, periodic maintenance, engine servicing, fuel and lubrication systems, electrical system, chassis, suspension, gearbox, exhaust system, and more
Whether you are a professional mechanic or a DIY repair enthusiast, this manual delivers all the essential information needed to effectively diagnose and repair issues with your Kia Rio 2003.
