Problems · NHTSA complaints

2004 Kia Rio problems

Owners filed 50 complaints about the 2004 Kia Rio with NHTSA between Apr 2004 and Mar 2024. The most-cited component is engine and engine cooling (14).

Complaints
50
Filed with NHTSA
Crashes
5
Reported by owners
Fires
2
Reported by owners
Injuries
2
People reported injured
Deaths
0
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  1. Engine and engine cooling14
  2. Suspension8
  3. Power train7
  4. Electrical system6
  5. Fuel system, gasoline6
  6. Service brakes, hydraulic4
  7. Vehicle speed control4
  8. Structure3
  9. Air bags3
  10. Wheels2
  11. Latches/locks/linkages2
  12. Visibility2
  13. Steering2
  14. Visibility/wiper1

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Data from NHTSA Complaints API · synced Oct 28, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
20044
20058
200611
20072
20085
20092
20103
20112
20122
20131
20143
20152
20161
20170
20181
20192
20200
20210
20220
20230
20241

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

Engine and engine cooling

14 reports
“I WAS AT A STOP SIGN AND MY 2004 KIA RIO DIED , I PUSHED IT TO THE MECHANIC AND WAS TOLD THE TIMING BELT LOST ITS TEETH AND THERE IS NOW NO COMPRESSION IN 3 AND 4 , THE MILEAGE ON CAR IS 68040. I WAS TOLD BASICALLY THE ENGINE IS TOAST AND I WASN'T EVEN MOVING ,I WAS TOLD BY A COUPLE OF MECHANICS THAT THE BELT THAT KIA USED IS FAULTY . THE OWNERS MANUAL SAYS REPLACE 60,000 MILES BUT REPLACE IT 105,000 IN CALIFORNIA. HOW WOULD A BELT BE BAD IN 49 STATES EXCEPT CALIFORNIA. I FOUND ON AUTO MD .COM NHTSA ACTION #10015272 SERVICE BULLETIN # 289221 REPORT DATING JAN 1 2005 IMPROVED TIMING BELTS FOR 04 RIO AND OPTIMA . *TR”
Owner complaint to NHTSAFiled Dec 5, 2010Engine and engine coolingODI 10369219

Suspension

8 reports
“TL* THE CONTACT OWNS A 2004 KIA RIO. WHILE DRIVING VARIOUS SPEEDS, THERE WAS AN ABNORMAL NOISE UNDERNEATH THE VEHICLE. THE VEHICLE WAS TAKEN TO MULTIPLE INDEPENDENT MECHANICS AND A DEALER ON NUMEROUS OCCASIONS WHERE IT WAS DIAGNOSED THAT THE FRONT DRIVER SIDE WHEEL BEARING NEEDED TO REPLACED. THE WHEEL BEARING WAS REPLACED MULTIPLE TIMES; HOWEVER, THE FAILURE PERSISTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.”
Owner complaint to NHTSAFiled Aug 22, 2016SuspensionODI 10897541

Power train

7 reports
“VEHICLE WAS PURCHASED USED APPROXIMATELY 2 YEARS AGO. ON THE APPROXIMATE INCIDENT DATE, THE CLUTCH PEDAL FAILED TO ACTUATE THE CLUTCH AFTER PRODUCING A LOUD NOISE. INSPECTION AT A REPAIR FACILITY REVEALED FAILURE IN SEVERAL CLUTCH COMPONENTS AND A METAL FATIGUE FAILURE IN THE CLUTCH AND BRAKE PEDAL SUPPORT BRACKET. I AM FILING THIS COMPLAINT ON BEHALF OF MY DAUGHTER FOR THE FAILED SUPPORT BRACKET, WHICH I HAVE IN MY POSSESSION.”
Owner complaint to NHTSAFiled Jan 15, 2012Power trainODI 10443859

Electrical system

6 reports
“I bought this car used a little less than a week ago. There was a thumping noise under the hood so I took the car to the dealer twice for this issue. I looked under the hood tonight and found a bunch of pieces that are not bolted down and the battery is completely unsecured and can move around freely. It’s horribly unsafe because the battery being loose can affect the entire car and the parts that aren’t bolted in place are causing major issues with the AC and other systems.”
Owner complaint to NHTSAFiled Mar 2, 2024Electrical system, Unknown or otherODI 11575004

Fuel system, gasoline

6 reports2 fires1 related recall
“THE CAR CAUGHT ON FIRE, KIA SAYS THEY SENT A NOTIFICATION TO THE ORIGINAL OWNER, YEARS AGO. WE FEEL THAT WE WERE ENTITLED TO A RECALL NOTICE BEFORE THE CAR BURNED DOWN. WE FEEL THIS IS NOT A SMALL RECALL, IT WAS A FIRE, A FIRE IS VERY DANGEROUS AND CAN BURN AND KILL PEOPLE. WE HAD 22 KIAS RIOS IN OUR FLEET AND NEVER RECEIVED RECALL NOTICES ON ANY OF THEM. KIA DID SEND NOTICES TO THE ORIGINAL OWNER HOWEVER THEY HAD THE INFORMATION AS TO WHICH CARS RECEIVED THE RECOMMENDED REPAIRS AND WHICH CARS NEVER CAME IN, THERE NEEDS TO BE SOME FOLLOW UP. *TR”
Owner complaint to NHTSAFiled Dec 17, 2011Fuel system, gasolineFire reportedODI 10440268

Service brakes, hydraulic

4 reports1 crash
“TL*THE CONTACT OWNS A 2004 KIA RIO CINCO. WHILE DRIVING 30, 45, OR 55 MPH, THE VEHICLE STALLED AND SHUT OFF WITHOUT WARNING. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE AND THE DIAGNOSTIC SHOWED THAT NOTHING WAS WRONG. THE MANUFACTURE STATED THAT THE INVESTIGATION WAS CLOSED SINCE THE DEALER COULD FIND NO FAILURE WITH THE VEHICLE. THE CURRENT AND FAILURE MILEAGES WERE 53,015. UPDATED 01-14-08. *KB THE ROTORS WERE RESURFACED AND THE DRUMS WERE ROTATED. UPDATED 12/12/07. *JB”
Owner complaint to NHTSAFiled Oct 4, 2007Service brakes, hydraulic, Engine and engine coolingODI 10204856
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 28, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.