Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Kia Rio owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* - the contact owns a 2002 Kia Rio. While driving at 35 MPH the vehicle stalled and the engine lost power. The steering, the brakes and the emergency brake were locked, the contact was unable to steer the vehicle or stop it which caused a crash with a van. The failure mileage was 77,000. There were no injuries. The vehicle was repaired three times due to the failure. The mechanic stated that the failure was due to the fuel injection system, and later claimed it was the timing belt. The contact experienced the failure after the vehicle was repaired. All of the repairs were at cost to the contact. The dealer stated there were no recalls for this year, make and model. Advised the contact of NHTSA recall#04V179000: fuel system, gasoline:delivery. The current mileage was 78,000. Customer did receive a recall letter in the mail. Updated 4/9
I got the second hand 2002 Kia Rio 4 months ago . Me and my wife were driving for 1 mile when the smell of smoke came and in the couple of seconds there was smoke came from the bonnet. I switched off and tried to open the bonnet but the smoke got more and more ,so we left the car immediately and we saw flames came from right part of the bonnet. We were just shocked and scared of fire. We called 911 and firefighters and in less than ten minutes front part of the car was totally ruined. Looking optimistically there was no injury at all . But how about the next one! Can everybody be lucky as we were?! We were just in the middle of the turn line in middle of the street , so other cars were around us I can not imagine what could happened if I was in freeway or if my wife was alone!?
We were just 10 minutes driving from home, when we saw the smoke coming from front of the car. We were approaching the light so the speed was about 10 miles . Within 5/6 meters we stopped in turn line and turned off the engine. The smoke got more and more. So we get out of the car and we were just shocked. Somebody told us call 911 and we did and we called fire fighters as well. During that period fire was coming out of the bonnet and other cars were around us. I was just afraid of explosion . In couple of minutes police came and block the road. Then fire fighters came and put the fire out. But our car was totally damaged and out of order. We towed it to the auto body and some days later they told can't do anything with it.
Car stalls randomly since first bought and has done so too many times to count. Car has stalled on my daughter in the middle of an intersection with an 18 wheeler on her tail, she had to swerve into a convenience store parking lot with a 5 1/2 pot hole causing damage to the car. This car has been in the garage 6 - 8 times in the past year. The dealer says they cannot fix it unless the check engine light is on. The car has been in 3 times in 8 months with the check engine light on and they only replace the gas cap assembly every time and the car still continues to stall at random. Dealer says they cannot duplicate problem and daughter is dumb blonde! The car also hesitates when driving and runs rough like it wants to stall, you never know when it will just stop on you. This is not a safe vehicle to have on the roads. I am filing lemon law papers on it today.
Dt: the consumer purchased two 2002 Kia rios, the first vehicle was fine. The other vehicle within 30 days of purchase at approximately 100 miles, died. This did not happen at any certain speed. The vehicle has been taken into the dealership over 14 times and they have not replaced anything . They have reprogrammed the computer numerous times. The vehicle will work for awhile, no specific time, and then die again. Consumer's daughter actually drove vehicle which was located in south carolina. The visor was replaced. The interior light would not go off, the dealer stated it was a pinched wire. The liftgate latch was replaced and the parking brake was adjusted.
While my daughter was driving her 2002 Kia Rio, all of a sudden the car just stopped running and would not start up. There was no prior indication that anything was wrong - no light or indicators on. Had it towed to our mechanic - engine was locked up. He didn't know for sure why - oil and coolant were fine. We didn't want to pay to have the reason diagnosed, as it doesn't really matter what caused it - the motor is shot. This car has been regularly maintained - oil change every 3000 miles, regular service as recommended in the book. We had to have the transmission replaced two years ago, as it just decided to die also.
Tl contact owns a 2002 Kia Rio. While the contact was driving approximately 2-5 MPH in the residence driveway, the engine stalled without warning. The vehicle was towed to an authorized dealer where they informed that the failure was related to the timing belt. The technician advised that the engine would need to be replaced. Also, previously the spark plugs, and crank shaft position sensor were replaced by the dealer. The vehicle had not been repaired at the time of the compliant. The failure mileage was 103,000. Updated 01/14/11 updated 03/01/11 updated 04/1511
2002 Kia Rio. Consumer states timing belt failed the consumer stated the timing belt failed for a second time at 59,059 and destroyed the second engine. The consumer was informed the vehicle would not be covered under warranty, because the original timing belt was not replaced at the proper mileage. The consumer stated the original timing belt was replaced at 53,668 and the replacement belt failed at 59,059 before the recommended 60,000. A Kia representative informed the consumer the warranty only extended to the original engine, not the replacement engine.
Original owner of 2002 Kia Rio - timing belt failed at 93,000 miles causing total engine failure (interference engine). Timing belt is covered under warranty for 100,000 miles for original owner according to the manual. Kia would not honor warranty. Several thousand dollars later, I had a replacement engine installed. It failed 2,300 miles later due to the camshaft shearing and the interference problems. Again, not covered under warranty.
I have taken my 2002 Kia Rio to a certified reputable mechanic. His determination of the faulty engine was due to the fact of a inferior timing belt. His statement was that the timing belt gave out and the engine is designed so that basically when this happens the crankshaft and valves ruin itself due to the broken timing belt. This happening leaves me with basically a $2,000 dollar loss all because of maybe a $100 part.
Engine complaints in other Rio years
Frequently asked questions
How common are engine problems on the 2002 Kia Rio?
NHTSA has 40 complaints about the engine & cooling of the 2002 Kia Rio, 31% of the model year's 128 complaints. The component named most often is engine (17 mentions).
Is there a recall for 2002 Kia Rio engine problems?
No. NHTSA lists no engine & cooling recall for the 2002 Kia Rio, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Kia Rio engine problems start?
Half of the complaints with a recorded mileage happened before about 87,000 miles, and 25% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 2 fires and 0 injuries to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.