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Kia Sportage 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Sportage Year: 2002 Generation Generation Code: KJ Codes Chassis Code: KJ 👋 Introduction Market Position Segment: Compact SUV / Crossover Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Suzuki Vitara. Key Features Features: Body-on-frame construction (early models), available 4WD, relatively affordable pricing, practical utility. Target Audience Audience: DIY mechanics, independent repair shops, owners seeking to perform their own maintenance and repairs. 📋 Manual Details Coverage Areas Coverage: Complete factory service and repair procedures, diagnostics, maintenance, and troubleshooting for the 2002 Kia Sportage. Page Count Pages: Hundreds (exact number not specified but implied to be comprehensive). Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, emission controls, cooling system, exhaust system. Drivetrain: Manual transmission, automatic transmission, clutch, drive shafts, axles, differentials (front and rear). Chassis: Suspension (front and rear), steering system, braking system (hydraulic, ABS), wheels and tires. Electrical: Battery, charging system, starting system, lighting, instrumentation, power windows, power locks, mirrors, wipers, horn, audio system, HVAC controls. Body: Body structure, exterior trim, interior trim, doors, hood, tailgate, bumpers, seats, glass, safety restraints (airbags, seatbelts). HVAC: Heating, Ventilation, and Air Conditioning system components, operation, diagnosis, and repair. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication. Diagnostics: Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings, electronic diagnostic procedures. Repair: Step-by-step repair instructions for all major components and systems, including disassembly, cleaning, inspection, and reassembly. Rebuilding: Detailed procedures for engine, transmission, and other major component rebuilds. Specifications: Torque specifications for all fasteners, alignment specifications, clearances, and other critical measurements. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced engine and transmission overhauls, electrical diagnostics, and body repair. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: G4CP (2.0L DOHC) Engine Type: Inline 4-Cylinder, DOHC, 16-valve Displacement: 1998 cc (2.0 Liters) Performance Horsepower Hp: Approx. 122-130 hp @ 5500-6000 rpm (varies slightly by market and configuration) Torque Lb Ft: Approx. 135-139 lb-ft @ 4000-4500 rpm (varies slightly by market and configuration) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., Kia Super Long Life Coolant) Lubrication Oil Viscosity: API SG or higher; SAE 5W-30 or 10W-30 recommended (refer to manual for specific climate conditions) Oil Capacity Quarts: Approx. 4.0-4.5 Quarts (with filter) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: 4-Speed Automatic Transmission Features Drive Options: Part-time 4WD (4x4) with Hi-Range and Lo-Range, or 2WD (Rear-Wheel Drive). Fluid Specifications Manual Fluid Type: GL-4 Gear Oil (e.g., SAE 75W-90) Fluid Specifications Automatic Fluid Type: Dexron III-H / Mercon ATF 📐 Dimensions Exterior Length In: Approx. 166.0 inches Width In: Approx. 70.1 inches Height In: Approx. 66.5 inches Wheelbase In: Approx. 103.5 inches Weights Curb Weight Lbs: Approx. 3500-3800 lbs (depending on configuration) Gross Vehicle Weight Rating Gvwr Lbs: Approx. 4850 lbs Cargo Cargo Volume Cu Ft: Approx. 20.5 cu ft (rear seats up) Cargo Volume Cu Ft Max: Approx. 66.3 cu ft (rear seats folded) 🛡️ Safety Features Ratings NHTSA Driver Front Impact: Not explicitly rated by NHTSA for this year; generally considered average for its class at the time. IIHS Side Impact: Not explicitly rated by IIHS for this year; generally considered average for its class at the time. Active Features ABS: Available Anti-lock Braking System (ABS) Traction Control: Not commonly available for this model year. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: 3-point front and rear seatbelts with pretensioners for front seats. Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system may be present, check vehicle specifications. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio system with more speakers. Navigation: Not typically equipped with factory navigation for this model year. Driver Assistance Cruise Control: Available cruise control system. Connectivity Bluetooth: Not available from the factory. 🔧 Maintenance Service Intervals Oil Change Miles: Every 5,000 - 7,500 miles or 6-12 months, whichever comes first (consult manual for specific conditions). Engine Air Filter Replace Miles: Every 15,000 - 30,000 miles, or as needed based on driving conditions. Spark Plugs Replace Miles: Typically around 60,000 - 100,000 miles for iridium or platinum plugs, check manual. Timing Belt Replace Miles: This generation typically uses a timing chain, not a belt. However, always verify with the manual. Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 (consult manual for exact specification) Power Steering Fluid Type: Dexron II...
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Kia Sportage 2002 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kia
Model:
Sportage
Year:
2002
Generation
Generation Code:
KJ
Codes
Chassis Code:
KJ
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Suzuki Vitara.
Key Features
Features:
Body-on-frame construction (early models), available 4WD, relatively affordable pricing, practical utility.
Target Audience
Audience:
DIY mechanics, independent repair shops, owners seeking to perform their own maintenance and repairs.
📋 Manual Details
Coverage Areas
Coverage:
Complete factory service and repair procedures, diagnostics, maintenance, and troubleshooting for the 2002 Kia Sportage.
Page Count
Pages:
Hundreds (exact number not specified but implied to be comprehensive).
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, emission controls, cooling system, exhaust system.
Drivetrain:
Manual transmission, automatic transmission, clutch, drive shafts, axles, differentials (front and rear).
Chassis:
Suspension (front and rear), steering system, braking system (hydraulic, ABS), wheels and tires.
Electrical:
Battery, charging system, starting system, lighting, instrumentation, power windows, power locks, mirrors, wipers, horn, audio system, HVAC controls.
Body:
Body structure, exterior trim, interior trim, doors, hood, tailgate, bumpers, seats, glass, safety restraints (airbags, seatbelts).
HVAC:
Heating, Ventilation, and Air Conditioning system components, operation, diagnosis, and repair.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication.
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings, electronic diagnostic procedures.
Repair:
Step-by-step repair instructions for all major components and systems, including disassembly, cleaning, inspection, and reassembly.
Rebuilding:
Detailed procedures for engine, transmission, and other major component rebuilds.
Specifications:
Torque specifications for all fasteners, alignment specifications, clearances, and other critical measurements.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to advanced engine and transmission overhauls, electrical diagnostics, and body repair.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download - PDF)
Paper Type
Paper:
N/A (Digital Download - PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
G4CP (2.0L DOHC)
Engine Type:
Inline 4-Cylinder, DOHC, 16-valve
Displacement:
1998 cc (2.0 Liters)
Performance
Horsepower Hp:
Approx. 122-130 hp @ 5500-6000 rpm (varies slightly by market and configuration)
Torque Lb Ft:
Approx. 135-139 lb-ft @ 4000-4500 rpm (varies slightly by market and configuration)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Kia Super Long Life Coolant)
Lubrication
Oil Viscosity:
API SG or higher; SAE 5W-30 or 10W-30 recommended (refer to manual for specific climate conditions)
Oil Capacity Quarts:
Approx. 4.0-4.5 Quarts (with filter)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type:
4-Speed Automatic Transmission
Features
Drive Options:
Part-time 4WD (4x4) with Hi-Range and Lo-Range, or 2WD (Rear-Wheel Drive).
Fluid Specifications Manual
Fluid Type:
GL-4 Gear Oil (e.g., SAE 75W-90)
Fluid Specifications Automatic
Fluid Type:
Dexron III-H / Mercon ATF
📐 Dimensions
Exterior
Length In:
Approx. 166.0 inches
Width In:
Approx. 70.1 inches
Height In:
Approx. 66.5 inches
Wheelbase In:
Approx. 103.5 inches
Weights
Curb Weight Lbs:
Approx. 3500-3800 lbs (depending on configuration)
Gross Vehicle Weight Rating Gvwr Lbs:
Approx. 4850 lbs
Cargo
Cargo Volume Cu Ft:
Approx. 20.5 cu ft (rear seats up)
Cargo Volume Cu Ft Max:
Approx. 66.3 cu ft (rear seats folded)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
Not explicitly rated by NHTSA for this year; generally considered average for its class at the time.
IIHS Side Impact:
Not explicitly rated by IIHS for this year; generally considered average for its class at the time.
Active Features
ABS:
Available Anti-lock Braking System (ABS)
Traction Control:
Not commonly available for this model year.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
3-point front and rear seatbelts with pretensioners for front seats.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system may be present, check vehicle specifications.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio system with more speakers.
Navigation:
Not typically equipped with factory navigation for this model year.
Driver Assistance
Cruise Control:
Available cruise control system.
Connectivity
Bluetooth:
Not available from the factory.
🔧 Maintenance
Service Intervals
Oil Change Miles:
Every 5,000 - 7,500 miles or 6-12 months, whichever comes first (consult manual for specific conditions).
Engine Air Filter Replace Miles:
Every 15,000 - 30,000 miles, or as needed based on driving conditions.
Spark Plugs Replace Miles:
Typically around 60,000 - 100,000 miles for iridium or platinum plugs, check manual.
Timing Belt Replace Miles:
This generation typically uses a timing chain, not a belt. However, always verify with the manual.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (consult manual for exact specification)
Power Steering Fluid Type:
Dexron II or III ATF, or specific power steering fluid (consult manual).
Coolant Capacity Quarts:
Approx. 7.0 Quarts
Known Issues
Engine:
Occasional oil leaks (valve cover gasket), potential for cooling system issues (radiator, hoses) if not maintained. Head gasket issues are not exceptionally common but can occur.
Transmission:
Automatic transmission shifting issues, potential for leaks. Manual transmission clutch wear.
Suspension:
Worn ball joints, tie rod ends, and bushings leading to clunking noises and alignment issues. Strut/shock absorber wear.
Electrical:
Window regulator failures, power lock actuator issues, intermittent issues with sensors (e.g., crankshaft position sensor).
Body:
Rust on the body panels, particularly in areas prone to salt exposure. Door seals and weatherstripping can degrade over time.
📚 Vehicle History
Brand Heritage
Brand Origin:
South Korea
Model Evolution
Generation Start Year:
1997
Generation End Year:
2004
Design Era:
Second generation (KJ) introduced for the 2000 model year, receiving a facelift for 2002.
Production
Manufacturing Location:
South Korea, and potentially assembly in other locations.
🏆 Awards & Recognition
Recognitions
Safety Awards:
No significant safety awards noted for this specific model year.
Value Awards:
Praised for its affordability and practicality as a compact SUV.
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