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Unfortunately I ignored the timing belt replacement interval on my Rio and now I'm paying for it. If I'm lucky, all I'll have to do is replace some bent valves. I have come to an impasse and don't know what size the cylinder head bolts are and the fact that they're Torx heads complicate the matter. Does anyone know what size they are?
Here's what happened... My wife was driving it to her sister's house and as she was rounding a curve, she felt the engine die and immediately mashed the clutch pedal down. I wasn't with her when it happened but I figure she reacted well to the situation otherwise she would've caused an accident cause it was a two-laner and she just happened to be on the inside lane when it happened. When I finally got it home, I took the plugs out and inspected them. The electrodes were all bent. On one of the cylinders, I can see a valve bent. The timing belt didn't break. The teeth on the belt were stripped.
What I want to do is to take the cylinder head off and assess the extent of the damage to see if I can just rebuild the head or go with an engine replacement. I have checked online and that could be a $1000-$1500 difference.
If you are very lucky the head can be salvaged. More typical is like the pics in the sticky.
Thats odd that the teeth on the belt were stripped. Look for any other signs of mechanical failure that could have caused it. (Water pumps on other models were notorious for taking out a timing belt.)
I'm not sure what size those bolts are. I've found it's easiest to remove the cylinder head with the intake still attached. I had an older Rio in here the other day with the same problem. 75K miles, timing belt never been changed (I believe the service interval on the pre-2006 Rio is 40K). The engine crashed on cylinders 1 and 3. Timing belt wasn't broken, but teeth were definitely missing. I've found the shearing of teeth to be quite normal if the belt is old and not replaced. Best of luck with the rebuild. Keep us posted.
I figured out what kind of cylinder head bolts. Very sneaky KIA...
Short story... I went to my local Kia and asked what kind of bolt it was. The parts manager looked into the database and couldn't or wouldn't provide me with an answer. I went to the mechanic in the repair department and same story. Kia's database just doesn't have anything on the size of the cylinder head bolt. Go figure. My next quest was to check out all the local tools stores. Sears, Ace Hardware, Harbor Freight, Northern Tools, Advance Auto Parts... 3 times at Advance.
The cylinder head bolt of a 2002 Kia Rio 1.5L Sedan is a 12mm 12 point socket. That's the big secret. It's shaped just like the 12mm 12pt. socket.
I think Kia was still using Mazda motors in the 2002 Rio. If the engine has two camshaft pulleys for the belt, it's a Mazda. If there is only one camshaft pulley for the belt to wrap around, it's a Hyundai Alpha engine. It's not uncommon for newer Kia dealerships to go bug-eyed over these engines, assuming they are the Hyundai designs used in more recent years. Until recently, most Mazda designs have been non-interference for durability sake. You may get off easier than you think.
I figured out what kind of cylinder head bolts. Very sneaky KIA...
Short story... I went to my local Kia and asked what kind of bolt it was. The parts manager looked into the database and couldn't or wouldn't provide me with an answer. I went to the mechanic in the repair department and same story. Kia's database just doesn't have anything on the size of the cylinder head bolt. Go figure. My next quest was to check out all the local tools stores. Sears, Ace Hardware, Harbor Freight, Northern Tools, Advance Auto Parts... 3 times at Advance.
The cylinder head bolt of a 2002 Kia Rio 1.5L Sedan is a 12mm 12 point socket. That's the big secret. It's shaped just like the 12mm 12pt. socket.
I'll keep you updated as I go along.
That type of head on the bolt is exactly the same as used by Nissan on my 1986 Pulsar , it doesn't look like it is just a nornal 12 point socket that fits until you have a really close look. I thought it was some sort of exotic bolt when I first saw the bolts on my Pulsar.
__________________ TAKE YOUR TIME, THINK IT OUT, DO IT RIGHT, DO IT ONCE!! original quote by me as far as I know. ALL MEMBERS PLEASE FILL IN USER PROFILES. DETAILS HELP OTHER MEMBERS HELP YOU .
it is a 12mm, 12 point socket, I strongly recommend buying a long neck one so as not to interfere with the head block shoulders. While inserting place in an extension and hit with a hammer to make sure it is in place 100% . good luck
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2002 Rio Cylinder Head Bolts
TAKE YOUR TIME, THINK IT OUT, DO IT RIGHT, DO IT ONCE!! original quote by me as far as I know. 
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