🏷️ Basic Information Identification Make: Kia Model: Sportage Year: 2002 Generation Generation Code: KJ Codes Platform: Mazda Bongo/Fighter based 👋 Introduction Market Position Segment: Compact SUV Positioning Strategy: Affordable, practical SUV with off-road capability and utility, often positioned as a value-oriented alternative. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Suzuki Vitara. Key Features Body Styles: 5-door SUV. Drivetrain Options: Front-Wheel Drive (FWD) and Part-Time Four-Wheel Drive (4WD). Platform Sharing: Shares chassis and powertrain components with Mazda B-series trucks and Ford Ranger. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: PDF Download Availability: Instant Download Target Audience: Professional Technicians and Enthusiast Owners 📖 Manual Coverage Systems Covered Engine: Complete engine mechanical and electrical systems, including diagnosis, overhaul, and component testing. Transmission: Manual and Automatic transmission service, repair, adjustment, and overhaul procedures. Drivetrain: Front and Rear Axles, Driveshafts, CV Joints, differentials, 4WD system operation and repair. Suspension: Front and Rear suspension components, geometry, alignment, shock absorbers, springs, bushings. Steering: Power steering system, steering column, linkage, rack and pinion repair and adjustment. Brakes: Front and Rear brake systems (disc and drum), ABS system, hydraulic components, bleeding procedures. Electrical: Complete vehicle electrical system, including wiring diagrams, fuse/relay identification, component testing, ECU diagnostics. Body: Exterior and interior body panels, doors, windows, locks, trim, HVAC system, and basic body repair. Diagnostics: Diagnostic trouble codes (DTCs), troubleshooting charts, symptom-based diagnosis for all major systems. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system operation, diagnosis, and repair. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes. Repair: Detailed step-by-step repair procedures for all major mechanical and electrical components. Overhaul: Complete engine and transmission overhaul instructions, including specifications and clearances. Troubleshooting: Systematic troubleshooting guides for common problems and fault diagnosis. Inspection: Pre-delivery inspection (PDI), regular inspection points, and safety checks. Adjustment: Various adjustments for brakes, clutch, throttle linkage, parking brake, etc. Replacement: Component replacement procedures for belts, hoses, seals, bearings, lights, etc. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Tools: Specifies diagnostic procedures and may reference necessary tools (e.g., scan tools, multimeters). Torque Specifications: Includes torque values for all critical fasteners and bolt connections. Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems. Special Tools: Identifies any special tools required for specific repair or maintenance procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick information retrieval. Printable: Designed to be printable for workshop use. File Size: Varies, typically hundreds of MB for comprehensive manuals. Print Quality Image Resolution: High resolution for clear diagrams and illustrations. Diagrams: Detailed diagrams, schematics, and illustrations of components and systems. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: FE (2.0L SOHC I4), FE-DOHC (2.0L DOHC I4), Mazda RF (2.0L Diesel - less common) Displacement: 1998 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm (approximate for 2.0L petrol) Compression Ratio: 9.0:1 (approximate for 2.0L petrol) Performance Horsepower: 122 hp @ 5000 rpm (2.0L SOHC I4) Torque: 135 lb-ft @ 3500 rpm (2.0L SOHC I4) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Engine Components Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy Timing Drive: Timing Belt 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 4-Speed Automatic Features Automatic Control: Electronically controlled with overdrive. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 Gear Oil (Check specific manual for exact type and capacity) Automatic Transmission Fluid: Kia Genuine ATF SP-III or equivalent (Check specific manual for exact type and capacity) 📐 Dimensions Exterior Length: 4,510 mm (177.6 in) Width: 1,795 mm (70.7 in) Height: 1,670 mm (65.7 in) Wheelbase: 2,640 mm (103.9 in) Ground Clearance: Approx. 200 mm (7.9 in) Weights Curb Weight: Approx. 1,500 - 1,650 kg (3,300 - 3,640 lbs) depending on configuration Gross Vehicle Weight Rating: Approx. 2,100 kg (4,630 lbs) Cargo Cargo Volume: Approx. 658 liters (23.2 cu ft) with rear seats up 🛡️ Safety Features Ratings NHTSA Frontal Impact: Not rated or poor in some early tests. Varies by market and specific tests. IIHS Side Impact: Not rated or marginal in some tests. Active Features ABS: Optional Anti-lock Braking System (ABS) on some models/trims. Traction Control: Not commonly available on this generation. Passive Features Airbags: Driver and front passenger airbags standard. Seat Belts: Three-point seatbelts with pretensioners and load limiters for front occupants. Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system may not be present on all models. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player. Optional premium sound systems may exist on higher trims. Display: Basic digital or analog displays for clock, radio, and climate...
Detailed step-by-step repair procedures for all major mechanical and electrical components.
Overhaul:
Complete engine and transmission overhaul instructions, including specifications and clearances.
Troubleshooting:
Systematic troubleshooting guides for common problems and fault diagnosis.
Inspection:
Pre-delivery inspection (PDI), regular inspection points, and safety checks.
Adjustment:
Various adjustments for brakes, clutch, throttle linkage, parking brake, etc.
Replacement:
Component replacement procedures for belts, hoses, seals, bearings, lights, etc.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Tools:
Specifies diagnostic procedures and may reference necessary tools (e.g., scan tools, multimeters).
Torque Specifications:
Includes torque values for all critical fasteners and bolt connections.
Wiring Diagrams:
Detailed electrical wiring diagrams for all vehicle systems.
Special Tools:
Identifies any special tools required for specific repair or maintenance procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF, allowing for quick information retrieval.
Printable:
Designed to be printable for workshop use.
File Size:
Varies, typically hundreds of MB for comprehensive manuals.
Print Quality
Image Resolution:
High resolution for clear diagrams and illustrations.
Diagrams:
Detailed diagrams, schematics, and illustrations of components and systems.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
FE (2.0L SOHC I4), FE-DOHC (2.0L DOHC I4), Mazda RF (2.0L Diesel - less common)
Displacement:
1998 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm (approximate for 2.0L petrol)
Compression Ratio:
9.0:1 (approximate for 2.0L petrol)
Performance
Horsepower:
122 hp @ 5000 rpm (2.0L SOHC I4)
Torque:
135 lb-ft @ 3500 rpm (2.0L SOHC I4)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Components
Block Material:
Cast Iron
Cylinder Head Material:
Aluminum Alloy
Timing Drive:
Timing Belt
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
4-Speed Automatic
Features
Automatic Control:
Electronically controlled with overdrive.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 Gear Oil (Check specific manual for exact type and capacity)
Automatic Transmission Fluid:
Kia Genuine ATF SP-III or equivalent (Check specific manual for exact type and capacity)
📐 Dimensions
Exterior
Length:
4,510 mm (177.6 in)
Width:
1,795 mm (70.7 in)
Height:
1,670 mm (65.7 in)
Wheelbase:
2,640 mm (103.9 in)
Ground Clearance:
Approx. 200 mm (7.9 in)
Weights
Curb Weight:
Approx. 1,500 - 1,650 kg (3,300 - 3,640 lbs) depending on configuration
Gross Vehicle Weight Rating:
Approx. 2,100 kg (4,630 lbs)
Cargo
Cargo Volume:
Approx. 658 liters (23.2 cu ft) with rear seats up
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Not rated or poor in some early tests. Varies by market and specific tests.
IIHS Side Impact:
Not rated or marginal in some tests.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on some models/trims.
Traction Control:
Not commonly available on this generation.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seat Belts:
Three-point seatbelts with pretensioners and load limiters for front occupants.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system may not be present on all models.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player. Optional premium sound systems may exist on higher trims.
Display:
Basic digital or analog displays for clock, radio, and climate controls.
Driver Assistance
Cruise Control:
Available on select higher trims.
Parking Sensors:
Not commonly available or standard on this generation.
Connectivity
Usb Port:
Not available.
Bluetooth:
Not available.
Comfort Features
Power Windows:
Available on most trims.
Power Mirrors:
Available on most trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first. (Refer to manual for precise recommendation based on driving conditions).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for standard plugs, potentially longer for platinum plugs. (Check manual).
Timing Belt Replacement:
Crucial interval, typically around 60,000 miles (96,000 km) or 5 years. Failure can cause catastrophic engine damage. (Verify in manual).
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 recommended for most climates. (Check manual for specific viscosity based on temperature).
Coolant Type:
Ethylene glycol based, OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) coolant, typically a 50/50 mix with distilled water. (Refer to manual for specific type).
Brake Fluid Type:
DOT 3 or DOT 4 compatible brake fluid.
Power Steering Fluid:
Dexron II/III ATF or equivalent specified by Kia. (Check manual).
Known Issues
Timing Belt Tensioner:
Tensioner failure can lead to belt skipping or breakage, causing severe engine damage.
Rear Main Seal Leak:
Can develop leaks over time, requiring transmission removal for replacement.
Clutch Wear:
Clutch wear can be accelerated by driving habits and off-road use.
Suspension Bushings:
Worn suspension bushings can lead to clunking noises and poor handling.
Cv Joint Boots:
Torn CV joint boots can allow dirt ingress, leading to premature joint failure.
📚 Vehicle History
Brand Heritage
Kia History:
Kia Motors Corporation is South Korea's second-largest automotive manufacturer, founded in 1944. Known for producing affordable and reliable vehicles.
Model Evolution
First Generation:
The KJ Sportage debuted in 1993, based on the Mazda Bongo platform. The 2002 model year falls within this first generation (1993-2004).
Key Updates 2002:
Minor styling updates and feature adjustments may have been introduced for the 2002 model year, but it remained part of the first-generation design.
Production
Manufacturing Locations:
Primarily South Korea, with some production in other global locations.
Production Period:
1993-2004 (First Generation KJ).
🏆 Awards & Recognition
Recognitions
Initial Reviews:
Received mixed reviews, often praised for affordability and practicality, but criticized for refinement and interior quality compared to leading Japanese competitors.
Ratings
Consumer Reports:
Variable ratings over its production run; often scored below average in reliability surveys compared to segment leaders.
Certifications
Emissions Compliance:
Meets relevant emissions standards for the model year in its intended markets. Specific certifications would be detailed in the manual.
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