KIA SPORTAGE 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Sportage Year: 2004 Generation: Second Generation (JE/KM) Market Segment: Compact SUV 👋 Introduction Market Position Market Segment Overview: The 2004 Kia Sportage represented Kia's entry into the competitive compact SUV segment, aiming to offer a blend of utility, value, and modern styling. It competed against vehicles like the Honda CR-V, Toyota RAV4, and Ford Escape. Competitive Analysis Key Competitors 2004: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester, Hyundai Tucson Key Features Vehicle Standout Features: Available with both 2WD and 4WD, choice of engines, relatively spacious interior for its class, practical cargo space, often praised for value and a decent ride quality. Manual Value Proposition Utility For Owners: This manual provides owners and technicians with the critical information needed to maintain, diagnose, and repair the 2004 Kia Sportage, ensuring longevity and optimal performance. It's an indispensable tool for DIY enthusiasts and professional mechanics alike. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, maintenance, and repair Page Count Approximate Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing components, lubrication system, cooling system, intake/exhaust systems Engine Management: Fuel injection, ignition system, emissions control, sensors (MAF, MAP, O2, crankshaft position, camshaft position), actuators, ECM/ECU diagnostics and repair Transmission Manual: Clutch, gearbox, internal components, shifter mechanism, maintenance, repair, troubleshooting Transmission Automatic: Torque converter, hydraulic system, valve body, planetary gear sets, electronic control unit (TCU), fluid specifications, maintenance, repair, troubleshooting Drivetrain AWD: Transfer case, propeller shafts, differentials (front and rear), CV joints, wheel hubs, maintenance, repair Suspension: Front suspension (MacPherson struts, control arms, ball joints, bushings), rear suspension (multi-link or independent, shock absorbers, springs, bushings), alignment specifications, repair procedures Steering: Power steering system (pump, rack and pinion or steering box, hoses, fluid), steering column, steering wheel, alignment, troubleshooting Brakes: Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), parking brake system, ABS (Anti-lock Braking System) components and diagnostics, brake fluid specifications, bleeding procedures Electrical System Charging: Alternator, battery, voltage regulator, wiring diagrams, testing procedures Electrical System Starting: Starter motor, ignition switch, starter relay, wiring diagrams, testing procedures Electrical System Lighting: Headlights, taillights, brake lights, turn signals, interior lighting, bulb types, troubleshooting Electrical System Accessories: Power windows, power door locks, sunroof, mirrors, wipers, horn, radio, speakers, wiring diagrams HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant, refrigerant oil), heating system (heater core, blower motor), climate control panel, diagnostics Body Interior: Dashboard, seats, door panels, headliner, trim pieces, removal and installation procedures Body Exterior: Bumpers, fenders, hood, doors, tailgate, glass, seals, trim, repair, alignment Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, cabin, fuel), fluid level checks and top-offs, tire rotation and balancing, spark plug replacement, belt inspection/replacement Diagnostic Procedures: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, electrical circuit testing, component testing Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment for all major systems Rebuild Procedures: Detailed instructions for engine and transmission overhauls, including torque specifications and clearances Specifications Data: Torque values, clearances, fluid capacities, tire pressures, alignment angles, engine diagnostic data Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, including component locations and wire colors Technical Depth Depth: Factory-level, covering everything from basic maintenance to complete overhauls and advanced diagnostics 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality: High-resolution scans, printable pages Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Gasoline Engine Code 2.0L: FE (J2) Displacement 2.0L: 1998 cc Configuration 2.0L: Inline 4-cylinder, DOHC, 16 valves Horsepower 2.0L: 136 hp @ 6000 rpm Torque 2.0L: 136 lb-ft @ 4500 rpm Optional Engine Gasoline Engine Code 2.7L: G6BA (Delta) Displacement 2.7L: 2656 cc Configuration 2.7L: V6, DOHC, 24 valves Horsepower 2.7L: 173 hp @ 6000 rpm Torque 2.7L: 178 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 Octane (Minimum) 🔧 Transmission Standard Transmission Type 2.0L: 5-speed Manual Optional Transmission Type 2.7L: 4-speed Automatic (with OD) Features AWD Availability: Available on both engine variants, typically paired with the automatic transmission Fluid Specifications Automatic Transmission Fluid: Kia/Hyundai SPIII (or equivalent Dexron-III/Mercon) Manual Transmission Fluid: API GL-4, SAE 75W-90 📐 Dimensions Exterior Length: Approx. 171.7 inches (4360 mm) Width: Approx. 71.3 inches (1810 mm) Height: Approx. 66.1 inches (1680 mm) Wheelbase: Approx. 103.5 inches (2630 mm) Weights Curb Weight Min: Approx. 3380 lbs (1533 kg) - 2.0L 2WD Manual Curb Weight Max: Approx. 3800 lbs (1724 kg) - 2.7L AWD Automatic 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (2004 Model Year) NHTSA Front Impact Passenger: 4 Stars (2004 Model Year)...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Sportage

Year:

Generation:

Second Generation (JE/KM)

Market Segment:

Compact SUV

👋 Introduction

Market Position

Market Segment Overview:

The 2004 Kia Sportage represented Kia's entry into the competitive compact SUV segment, aiming to offer a blend of utility, value, and modern styling. It competed against vehicles like the Honda CR-V, Toyota RAV4, and Ford Escape.

Competitive Analysis

Key Competitors 2004:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester, Hyundai Tucson

Key Features Vehicle

Standout Features:

Available with both 2WD and 4WD, choice of engines, relatively spacious interior for its class, practical cargo space, often praised for value and a decent ride quality.

Manual Value Proposition

Utility For Owners:

This manual provides owners and technicians with the critical information needed to maintain, diagnose, and repair the 2004 Kia Sportage, ensuring longevity and optimal performance. It's an indispensable tool for DIY enthusiasts and professional mechanics alike.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service, maintenance, and repair

Page Count

Approximate Pages:

1500+

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing components, lubrication system, cooling system, intake/exhaust systems

Engine Management:

Fuel injection, ignition system, emissions control, sensors (MAF, MAP, O2, crankshaft position, camshaft position), actuators, ECM/ECU diagnostics and repair

Transmission Manual:

Clutch, gearbox, internal components, shifter mechanism, maintenance, repair, troubleshooting

Transmission Automatic:

Torque converter, hydraulic system, valve body, planetary gear sets, electronic control unit (TCU), fluid specifications, maintenance, repair, troubleshooting

Drivetrain AWD:

Transfer case, propeller shafts, differentials (front and rear), CV joints, wheel hubs, maintenance, repair

Suspension:

Front suspension (MacPherson struts, control arms, ball joints, bushings), rear suspension (multi-link or independent, shock absorbers, springs, bushings), alignment specifications, repair procedures

Steering:

Power steering system (pump, rack and pinion or steering box, hoses, fluid), steering column, steering wheel, alignment, troubleshooting

Brakes:

Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), parking brake system, ABS (Anti-lock Braking System) components and diagnostics, brake fluid specifications, bleeding procedures

Electrical System Charging:

Alternator, battery, voltage regulator, wiring diagrams, testing procedures

Electrical System Starting:

Starter motor, ignition switch, starter relay, wiring diagrams, testing procedures

Electrical System Lighting:

Headlights, taillights, brake lights, turn signals, interior lighting, bulb types, troubleshooting

Electrical System Accessories:

Power windows, power door locks, sunroof, mirrors, wipers, horn, radio, speakers, wiring diagrams

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant, refrigerant oil), heating system (heater core, blower motor), climate control panel, diagnostics

Body Interior:

Dashboard, seats, door panels, headliner, trim pieces, removal and installation procedures

Body Exterior:

Bumpers, fenders, hood, doors, tailgate, glass, seals, trim, repair, alignment

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin, fuel), fluid level checks and top-offs, tire rotation and balancing, spark plug replacement, belt inspection/replacement

Diagnostic Procedures:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, electrical circuit testing, component testing

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all major systems

Rebuild Procedures:

Detailed instructions for engine and transmission overhauls, including torque specifications and clearances

Specifications Data:

Torque values, clearances, fluid capacities, tire pressures, alignment angles, engine diagnostic data

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, including component locations and wire colors

Technical Depth

Depth:

Factory-level, covering everything from basic maintenance to complete overhauls and advanced diagnostics

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval

Print Quality:

High-resolution scans, printable pages

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine Gasoline

Engine Code 2.0L:

FE (J2)

Displacement 2.0L:

1998 cc

Configuration 2.0L:

Inline 4-cylinder, DOHC, 16 valves

Horsepower 2.0L:

136 hp @ 6000 rpm

Torque 2.0L:

136 lb-ft @ 4500 rpm

Optional Engine Gasoline

Engine Code 2.7L:

G6BA (Delta)

Displacement 2.7L:

2656 cc

Configuration 2.7L:

V6, DOHC, 24 valves

Horsepower 2.7L:

173 hp @ 6000 rpm

Torque 2.7L:

178 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Recommended Octane:

87 Octane (Minimum)

🔧 Transmission

Standard

Transmission Type 2.0L:

5-speed Manual

Optional

Transmission Type 2.7L:

4-speed Automatic (with OD)

Features

AWD Availability:

Available on both engine variants, typically paired with the automatic transmission

Fluid Specifications

Automatic Transmission Fluid:

Kia/Hyundai SPIII (or equivalent Dexron-III/Mercon)

Manual Transmission Fluid:

API GL-4, SAE 75W-90

📐 Dimensions

Exterior

Length:

Approx. 171.7 inches (4360 mm)

Width:

Approx. 71.3 inches (1810 mm)

Height:

Approx. 66.1 inches (1680 mm)

Wheelbase:

Approx. 103.5 inches (2630 mm)

Weights

Curb Weight Min:

Approx. 3380 lbs (1533 kg) - 2.0L 2WD Manual

Curb Weight Max:

Approx. 3800 lbs (1724 kg) - 2.7L AWD Automatic

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (2004 Model Year)

NHTSA Front Impact Passenger:

4 Stars (2004 Model Year)

NHTSA Side Impact Front Driver:

4 Stars (2004 Model Year)

NHTSA Side Impact Front Passenger:

4 Stars (2004 Model Year)

NHTSA Side Impact Rear Driver:

4 Stars (2004 Model Year)

NHTSA Side Impact Rear Passenger:

4 Stars (2004 Model Year)

IIHS Side Impact:

Acceptable (2004 Model Year)

Active Features

Standard on most trims

Electronic Stability Control:

Optional on some trims

Traction Control:

Standard with AWD models

Passive Features

Airbags Front:

Driver and Passenger front airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

3-point front and rear seatbelts, pre-tensioners for front seats

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, optional premium audio system with subwoofer, available steering wheel audio controls on higher trims.

Navigation:

Not commonly available or offered as an option for the 2004 model year.

Driver Assistance

Cruise Control:

Standard on most trims

Parking Sensors:

Not commonly available or offered.

Connectivity

Auxiliary Input:

Not typically standard, may be added as an aftermarket modification.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first

Oil Filter Replacement:

Every 5,000 miles (8,000 km) or 6 months, with oil change

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

Spark Plug Replacement 2.0L:

Every 60,000 miles (96,000 km) (Iridium type recommended)

Spark Plug Replacement 2.7L:

Every 60,000 miles (96,000 km) (Iridium type recommended)

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 4 years (for the 2.0L FE engine - *crucial interval to avoid catastrophic failure*)

Fluid Specifications

Engine Oil Type:

API SJ/SL, ILSAC GF-3, SAE 5W-30 or 10W-30 (depending on climate)

Engine Oil Capacity 2.0L:

Approx. 4.8 quarts (4.5 liters) with filter

Engine Oil Capacity 2.7L:

Approx. 5.1 quarts (4.8 liters) with filter

Coolant Type:

Ethylene Glycol based coolant (Antifreeze/Coolant - typically a 50/50 mix with distilled water)

Coolant Capacity:

Approx. 7.2 quarts (6.8 liters)

Brake Fluid Type:

DOT 3

Known Issues

Common Issue Timing Belt 2.0L:

The timing belt on the 2.0L engine is an interference design. Failure to replace it at the recommended interval (60,000 miles) can lead to severe engine damage (bent valves, damaged pistons).

Common Issue Cv Axles:

Front CV axles can wear out, leading to clicking noises during turns.

Common Issue Rear Differential AWD:

Potential for rear differential seal leaks or bearing noise in AWD models.

Common Issue Window Regulators:

Power window regulators can fail, causing windows to not operate.

Common Issue Evap Emissions System:

Issues with the evaporative emissions (EVAP) system, such as a faulty purge valve or charcoal canister, can trigger check engine lights.

📚 Vehicle History

Brand Heritage

Kia History:

Kia Motors Corporation, founded in 1944, is South Korea's oldest manufacturer of motor vehicles. Initially producing motorcycles and trucks, Kia entered the passenger car market in the late 1970s and began exporting to North America in 1992. Known for offering value-oriented vehicles.

Model Evolution

Sportage First Gen:

The first-generation Sportage (1993-2002) was body-on-frame and often compared to more rugged SUVs. It laid the groundwork for Kia's entry into the SUV market.

Sportage Second Gen Start:

The 2004 model year marked the introduction of the second-generation Sportage (JE/KM platform). This generation transitioned to a unibody construction, sharing its platform with the Hyundai Tucson. This change resulted in improved ride comfort, handling, and fuel efficiency, making it more of a 'soft-roader' or crossover SUV.

Production

Assembly Location:

Gwangmyeong, Gyeonggi Province, South Korea; Also assembled in other Kia global facilities.

🏆 Awards & Recognition

Recognitions

Initial Reviews:

While not a recipient of major performance awards, the 2004 Sportage was generally reviewed as a competent and value-oriented compact SUV, offering a significant improvement over its predecessor. It was often cited for its good warranty coverage.