KIA SPORTAGE (KM) 2006 G 2.0 DOHC Service Repair Manual
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🏷️ Basic Information Identification Make: Kia Model: Sportage Generation Code: KM Year: 2006 Engine Variant: 2.0 DOHC 👋 Introduction Market Position Category: Compact SUV / Crossover Target Audience: DIY enthusiasts, independent repair shops, Kia owners seeking detailed repair information. Competitive Analysis Competitors 2006: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester. Key Features Vehicle Selling Points: Practicality, affordability, available 4WD, rugged styling (for its class), decent utility. Key Features Manual Value Proposition: Provides comprehensive factory-level repair and maintenance guidance, enabling cost savings and in-depth understanding of vehicle systems. 📋 Manual Details Coverage Areas Systems Covered: Engine mechanical, Engine management, Fuel system, Ignition system, Emission control, Transmission (Automatic & Manual), Drivetrain, Chassis, Suspension, Steering, Brakes, Electrical system, HVAC, Body and interior, Diagnostic procedures, Troubleshooting, Wiring diagrams, Maintenance schedules, Specifications. Page Count Total Pages: Approximately 1500+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, cylinder head, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system. Engine Management: ECM/ECU operation, sensor diagnostics (MAP, TPS, O2, Crankshaft Position, Camshaft Position), actuator control, fuel injection system, ignition timing. Fuel System: Fuel pump operation, fuel filter replacement, fuel injectors, fuel pressure testing, fuel tank, evaporative emission control (EVAP). Brakes: Front and rear brake component removal/installation, brake fluid replacement, ABS system diagnostics, parking brake adjustment. Electrical: Battery, charging system (alternator), starting system, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams for all circuits. Procedures Included Maintenance: Routine maintenance tasks such as oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotation. Repair: Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, suspension component replacement. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for common and complex problems. Diagnostics: OBD-II diagnostic trouble codes (DTCs) and their explanations, live data stream interpretation, scan tool usage. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, clear text and diagrams for easy readability and printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: G4GC / Beta II Engine Type: Inline-4 Cylinder, DOHC, 16-valve Displacement: 1998 cc (2.0 Liters) Performance Horsepower Approx: 138 hp @ 6000 rpm Torque Approx: 136 lb-ft @ 4500 rpm Fuel System Injection Type: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Mechanical Bore X Stroke: 86.0 mm x 86.0 mm Compression Ratio: 9.1:1 🔧 Transmission Standard Transmission Type: 5-speed Manual Optional Transmission Type: 4-speed Automatic (H-Matic) Features Drivetrain Options: Front-Wheel Drive (FWD) or Electronic 4-Wheel Drive (4WD). Fluid Specifications Manual Manual Transmission Fluid: API GL-4, SAE 75W-90 (check manual for specific part number) Fluid Specifications Automatic Automatic Transmission Fluid: Kia Genuine ATF SP-III or equivalent (check manual for specific part number) 📐 Dimensions Exterior Length: Approx. 4,340 mm (170.9 in) Width: Approx. 1,795 mm (70.7 in) Height: Approx. 1,730 mm (68.1 in) (with roof rails) Wheelbase: Approx. 2,630 mm (103.5 in) Weights Curb Weight Approx: 1,500 - 1,700 kg (3,300 - 3,750 lbs) depending on configuration Gross Vehicle Weight Rating Gvwr Approx: 2,100 kg (4,630 lbs) Cargo Cargo Volume Rear Seats Up Approx: 832 Liters (29.4 cu ft) Cargo Volume Rear Seats Folded Approx: 1,957 Liters (69.1 cu ft) 🛡️ Safety Features Ratings NHTSA Frontal Driver Rating: 4-star (2006 Model Year) NHTSA Frontal Passenger Rating: 4-star (2006 Model Year) IIHS Side Impact Rating: Good (2006 Model Year) Active Features Traction Control: Available Electronic Stability Control Esc: Available on some trims Anti-Lock Braking System ABS: Standard Passive Features Airbags: Front airbags, front side-impact airbags (optional on some trims). Seatbelts: 3-point height-adjustable front seat belts with pretensioners and load limiters, rear 3-point seat belts. 💡 Technology Features Infotainment Audio System: AM/FM/CD player, optional premium audio system, auxiliary input jack. Navigation: Optional aftermarket or dealer-installed navigation units were available. Driver Assistance Cruise Control: Standard on most trims. Connectivity Power Outlets: 12V power outlets for accessories. 🔧 Maintenance Service Intervals Engine Oil Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions). Severe driving may require more frequent changes. Recommended Oil Viscosity: API SM, ILSAC GF-4, SAE 5W-20 or SAE 5W-30 (refer to manual for specific ambient temperature ranges). Service Intervals Filters Oil Filter Part Number Example: Kia part number 26300-35056 (or equivalent aftermarket) Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months. Cabin Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months. Service Intervals Other Spark Plug Replacement: Every 105,000 miles (168,000 km) (Long-life type). Timing Belt Replacement: Check manual - typically around 60,000-90,000 miles for similar engines, but the Beta II uses a...
Front and rear brake component removal/installation, brake fluid replacement, ABS system diagnostics, parking brake adjustment.
Electrical:
Battery, charging system (alternator), starting system, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams for all circuits.
Procedures Included
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotation.
Repair:
Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, suspension component replacement.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common and complex problems.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs) and their explanations, live data stream interpretation, scan tool usage.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, clear text and diagrams for easy readability and printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G4GC / Beta II
Engine Type:
Inline-4 Cylinder, DOHC, 16-valve
Displacement:
1998 cc (2.0 Liters)
Performance
Horsepower Approx:
138 hp @ 6000 rpm
Torque Approx:
136 lb-ft @ 4500 rpm
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Mechanical
Bore X Stroke:
86.0 mm x 86.0 mm
Compression Ratio:
9.1:1
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Transmission Type:
4-speed Automatic (H-Matic)
Features
Drivetrain Options:
Front-Wheel Drive (FWD) or Electronic 4-Wheel Drive (4WD).
Fluid Specifications Manual
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (check manual for specific part number)
Fluid Specifications Automatic
Automatic Transmission Fluid:
Kia Genuine ATF SP-III or equivalent (check manual for specific part number)
📐 Dimensions
Exterior
Length:
Approx. 4,340 mm (170.9 in)
Width:
Approx. 1,795 mm (70.7 in)
Height:
Approx. 1,730 mm (68.1 in) (with roof rails)
Wheelbase:
Approx. 2,630 mm (103.5 in)
Weights
Curb Weight Approx:
1,500 - 1,700 kg (3,300 - 3,750 lbs) depending on configuration
Gross Vehicle Weight Rating Gvwr Approx:
2,100 kg (4,630 lbs)
Cargo
Cargo Volume Rear Seats Up Approx:
832 Liters (29.4 cu ft)
Cargo Volume Rear Seats Folded Approx:
1,957 Liters (69.1 cu ft)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver Rating:
4-star (2006 Model Year)
NHTSA Frontal Passenger Rating:
4-star (2006 Model Year)
IIHS Side Impact Rating:
Good (2006 Model Year)
Active Features
Traction Control:
Available
Electronic Stability Control Esc:
Available on some trims
Anti-Lock Braking System ABS:
Standard
Passive Features
Airbags:
Front airbags, front side-impact airbags (optional on some trims).
Seatbelts:
3-point height-adjustable front seat belts with pretensioners and load limiters, rear 3-point seat belts.
Optional aftermarket or dealer-installed navigation units were available.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Power Outlets:
12V power outlets for accessories.
🔧 Maintenance
Service Intervals Engine Oil
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions). Severe driving may require more frequent changes.
Recommended Oil Viscosity:
API SM, ILSAC GF-4, SAE 5W-20 or SAE 5W-30 (refer to manual for specific ambient temperature ranges).
Service Intervals Filters
Oil Filter Part Number Example:
Kia part number 26300-35056 (or equivalent aftermarket)
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Service Intervals Other
Spark Plug Replacement:
Every 105,000 miles (168,000 km) (Long-life type).
Timing Belt Replacement:
Check manual - typically around 60,000-90,000 miles for similar engines, but the Beta II uses a timing chain, not a belt.
Fluid Specifications
Coolant Type:
Ethylene Glycol based coolant, 50/50 mix with deionized water (ANSI Grade A or equivalent).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
DEXRON III or equivalent ATF (refer to manual for exact specification).
Known Issues
Engine Oil Consumption:
Some owners have reported higher than normal oil consumption, regular checks are recommended.
Suspension Components:
Wear in bushings and ball joints can occur over time, especially on higher mileage vehicles.
Cv Joint Boots:
Tears in CV joint boots can lead to premature wear.
Interior Rattles:
Common in many vehicles of this era, often related to trim panels.
📚 Vehicle History
Brand Heritage
Kia Origins:
South Korean manufacturer, established in 1944, initially as a steel pipe manufacturer, moved into vehicles in the 1960s.
Model Evolution
First Generation Sportage:
The KM Sportage is the second generation, launched in 2004 (for the 2005 model year in some markets) as a unibody crossover SUV, moving away from the body-on-frame construction of the first generation (NB-X). It shared its platform with the Hyundai Tucson.
Production
Production Period Km:
2004 - 2010
Manufacturing Locations:
South Korea, Slovakia, Ukraine, Malaysia.
🏆 Awards & Recognition
Recognitions
Kl Consumer Reports:
Consumer Reports often rated the Sportage below average for reliability during this generation, but this varies by specific model year and component. The manual helps owners address these potential issues.