KIA SPORTAGE Service Repair Manual 1995-2007

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🏷️ Basic Information Identification Make: Kia Model: Sportage Product Name: KIA SPORTAGE Service Repair Manual 1995-2007 Generation Generation Covered: First Generation (1995-2002), Second Generation (2005-2007) Codes Chassis Codes: First Gen: K00; Second Gen: JE Engine Codes: First Gen: FE (2.0L), B3 (1.8L - some markets), RF (2.0L Diesel); Second Gen: FE-V (2.0L), G4GC (2.0L Beta II), G6BA (2.7L V6) 👋 Introduction Market Position Segment: Compact SUV / Crossover Target Demographic: Individuals and families seeking a versatile, affordable, and capable SUV. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape, Chevrolet Tracker/Vitara, Mitsubishi Montero Sport. Key Features First Gen Selling Points: Rugged body-on-frame construction (initially), affordable pricing, available AWD, decent off-road capability for its class. Second Gen Selling Points: Unibody construction (more car-like ride), modern styling, improved interior refinement, wider engine options including V6. 📋 Manual Details Coverage Areas Models Covered: All models, all trim levels Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Engines Covered: All engine variants including 1.8L, 2.0L (petrol and diesel), 2.7L V6 Page Count Estimated Page Count: 1500+ Manual Type Type: Complete Service & Repair Manual Language Language: English Format Format: Digital Download (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, connecting rods, crankshaft, timing system, lubrication system, cooling system, fuel injection system (MPI/GDI), emissions control systems. Engine Electrical: Ignition system, starting system, charging system, engine control unit (ECU) diagnostics, sensors, actuators, wiring diagrams. Transmission Manual: Clutch system, manual transmission operation, disassembly, assembly, internal components, gear ratios, torque specifications. Transmission Automatic: Automatic transmission operation, hydraulics, valve body, torque converter, electronic control, disassembly, assembly, fluid specifications. Drivetrain: Front-wheel drive (FWD) and all-wheel drive (AWD) systems, propeller shafts, differentials, CV joints, hubs, bearings. Suspension: Front and rear suspension components (struts, shocks, springs, control arms, ball joints, bushings), alignment specifications, wheel bearings. Steering: Power steering system (hydraulic/electric), steering rack, tie rods, steering column, alignment. Brakes: Front and rear brake systems (disc/drum), hydraulic system, ABS, brake fluid specifications, master cylinder, calipers, rotors, pads, parking brake. Electrical System: 12V battery system, charging system, lighting, horns, wipers, power windows, power locks, interior and exterior electrical components, fuses, relays, wiring diagrams. Body And Chassis: Body panel removal and installation, door mechanisms, glass, interior trim, exterior trim, chassis structural components. HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, controls. Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, coolant flushing, brake fluid replacement, transmission fluid changes, air filter replacement, cabin air filter replacement. Troubleshooting: Diagnostic procedures for engine performance issues, electrical faults, transmission problems, brake system malfunctions, HVAC issues, and more. Includes symptom-based diagnostics. Repair: Detailed step-by-step repair procedures for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension and brake component replacement, and electrical system repairs. Diagnostics: OBD-II diagnostic trouble code (DTC) explanations and diagnostic flowcharts, sensor testing, circuit testing, fuel pressure testing. Specifications And Tolerances: Torque specifications for all fasteners, engine clearances, component tolerances, alignment data, fluid capacities. Technical Depth Depth: Comprehensive: Covers everything from basic scheduled maintenance and component replacement to complete engine and transmission overhauls, advanced diagnostics, and chassis repair. Target Audience: Professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Likely searchable text for quick information retrieval. Print Quality Printability: Printable pages for physical reference. Binding Type Binding: Not applicable (digital download). Paper Type Paper Quality: Not applicable (digital download). ⚙️ Engine Specifications Primary Engine First Gen 2.0L Petrol: 2.0L (1998cc) Inline-4, SOHC/DOHC, MPI. Approx. 122-130 hp @ 5500-6000 rpm, 135-140 lb-ft @ 2500-4500 rpm. First Gen 2.0L Diesel: 2.0L (1905cc) Inline-4 Turbo Diesel, SOHC. Approx. 83 hp @ 4000 rpm, 125 lb-ft @ 2000 rpm. Second Gen 2.0L Petrol: 2.0L (1998cc) Inline-4, DOHC, CVVT. Approx. 138-140 hp @ 6000 rpm, 136-136 lb-ft @ 4500 rpm. Second Gen 2.7L V6: 2.7L (2656cc) V6, DOHC, CVVT. Approx. 173-175 hp @ 6000 rpm, 182 lb-ft @ 4000 rpm. Performance Acceleration 0 60 Mph: Approx. 9.5-12.0 seconds (depending on engine/transmission). Top Speed: Approx. 100-115 mph. Fuel System Fuel Injection: Multi-Point Injection (MPI) for most petrol engines; Diesel Direct Injection for diesel engines. Gasoline Direct Injection (GDI) on later 2.0L models. Recommended Fuel: 87 Octane Unleaded Gasoline (for petrol engines); Diesel fuel (for diesel engines). 🔧 Transmission Standard First Gen Standard: 5-speed manual transmission. Second Gen Standard: 5-speed manual transmission (on select trims). Optional First Gen Optional: 4-speed automatic transmission. Second Gen Optional: 4-speed automatic transmission (common), 5-speed automatic transmission (on V6 models). Features Drivetrain Options: Front-Wheel Drive (FWD), On-Demand All-Wheel Drive (AWD). Transfer Case Type: Center differential with viscous coupling for AWD systems. 📐 Dimensions Exterior Wheelbase: First Gen: ~98.4 inches; Second Gen: ~103.1 inches. Length: First Gen: ~168.1 inches; Second Gen: ~170.0 - 173.0 inches....

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Tags: 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Car Cars Kia Misc SPORTAGE

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Description

🏷️ Basic Information

Identification

Make:

Model:

Sportage

Product Name:

KIA SPORTAGE Service Repair Manual 1995-2007

Generation

Generation Covered:

First Generation (1995-2002), Second Generation (2005-2007)

Codes

Chassis Codes:

First Gen: K00; Second Gen: JE

Engine Codes:

First Gen: FE (2.0L), B3 (1.8L - some markets), RF (2.0L Diesel); Second Gen: FE-V (2.0L), G4GC (2.0L Beta II), G6BA (2.7L V6)

👋 Introduction

Market Position

Segment:

Compact SUV / Crossover

Target Demographic:

Individuals and families seeking a versatile, affordable, and capable SUV.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape, Chevrolet Tracker/Vitara, Mitsubishi Montero Sport.

Key Features

First Gen Selling Points:

Rugged body-on-frame construction (initially), affordable pricing, available AWD, decent off-road capability for its class.

Second Gen Selling Points:

Unibody construction (more car-like ride), modern styling, improved interior refinement, wider engine options including V6.

📋 Manual Details

Coverage Areas

Models Covered:

All models, all trim levels

Years Covered:

1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Engines Covered:

All engine variants including 1.8L, 2.0L (petrol and diesel), 2.7L V6

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Complete Service & Repair Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, connecting rods, crankshaft, timing system, lubrication system, cooling system, fuel injection system (MPI/GDI), emissions control systems.

Engine Electrical:

Ignition system, starting system, charging system, engine control unit (ECU) diagnostics, sensors, actuators, wiring diagrams.

Transmission Manual:

Clutch system, manual transmission operation, disassembly, assembly, internal components, gear ratios, torque specifications.

Transmission Automatic:

Automatic transmission operation, hydraulics, valve body, torque converter, electronic control, disassembly, assembly, fluid specifications.

Drivetrain:

Front-wheel drive (FWD) and all-wheel drive (AWD) systems, propeller shafts, differentials, CV joints, hubs, bearings.

Suspension:

Front and rear suspension components (struts, shocks, springs, control arms, ball joints, bushings), alignment specifications, wheel bearings.

Steering:

Power steering system (hydraulic/electric), steering rack, tie rods, steering column, alignment.

Brakes:

Front and rear brake systems (disc/drum), hydraulic system, ABS, brake fluid specifications, master cylinder, calipers, rotors, pads, parking brake.

Electrical System:

12V battery system, charging system, lighting, horns, wipers, power windows, power locks, interior and exterior electrical components, fuses, relays, wiring diagrams.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass, interior trim, exterior trim, chassis structural components.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, controls.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flushing, brake fluid replacement, transmission fluid changes, air filter replacement, cabin air filter replacement.

Troubleshooting:

Diagnostic procedures for engine performance issues, electrical faults, transmission problems, brake system malfunctions, HVAC issues, and more. Includes symptom-based diagnostics.

Repair:

Detailed step-by-step repair procedures for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension and brake component replacement, and electrical system repairs.

Diagnostics:

OBD-II diagnostic trouble code (DTC) explanations and diagnostic flowcharts, sensor testing, circuit testing, fuel pressure testing.

Specifications And Tolerances:

Torque specifications for all fasteners, engine clearances, component tolerances, alignment data, fluid capacities.

Technical Depth

Depth:

Comprehensive: Covers everything from basic scheduled maintenance and component replacement to complete engine and transmission overhauls, advanced diagnostics, and chassis repair.

Target Audience:

Professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Likely searchable text for quick information retrieval.

Print Quality

Printability:

Printable pages for physical reference.

Binding Type

Binding:

Not applicable (digital download).

Paper Type

Paper Quality:

Not applicable (digital download).

⚙️ Engine Specifications

Primary Engine

First Gen 2.0L Petrol:

2.0L (1998cc) Inline-4, SOHC/DOHC, MPI. Approx. 122-130 hp @ 5500-6000 rpm, 135-140 lb-ft @ 2500-4500 rpm.

First Gen 2.0L Diesel:

2.0L (1905cc) Inline-4 Turbo Diesel, SOHC. Approx. 83 hp @ 4000 rpm, 125 lb-ft @ 2000 rpm.

Second Gen 2.0L Petrol:

2.0L (1998cc) Inline-4, DOHC, CVVT. Approx. 138-140 hp @ 6000 rpm, 136-136 lb-ft @ 4500 rpm.

Second Gen 2.7L V6:

2.7L (2656cc) V6, DOHC, CVVT. Approx. 173-175 hp @ 6000 rpm, 182 lb-ft @ 4000 rpm.

Performance

Acceleration 0 60 Mph:

Approx. 9.5-12.0 seconds (depending on engine/transmission).

Top Speed:

Approx. 100-115 mph.

Fuel System

Fuel Injection:

Multi-Point Injection (MPI) for most petrol engines; Diesel Direct Injection for diesel engines. Gasoline Direct Injection (GDI) on later 2.0L models.

Recommended Fuel:

87 Octane Unleaded Gasoline (for petrol engines); Diesel fuel (for diesel engines).

🔧 Transmission

Standard

First Gen Standard:

5-speed manual transmission.

Second Gen Standard:

5-speed manual transmission (on select trims).

Optional

First Gen Optional:

4-speed automatic transmission.

Second Gen Optional:

4-speed automatic transmission (common), 5-speed automatic transmission (on V6 models).

Features

Drivetrain Options:

Front-Wheel Drive (FWD), On-Demand All-Wheel Drive (AWD).

Transfer Case Type:

Center differential with viscous coupling for AWD systems.

📐 Dimensions

Exterior

Wheelbase:

First Gen: ~98.4 inches; Second Gen: ~103.1 inches.

Length:

First Gen: ~168.1 inches; Second Gen: ~170.0 - 173.0 inches.

Width:

First Gen: ~70.1 inches; Second Gen: ~71.9 inches.

Height:

First Gen: ~64.2 inches; Second Gen: ~66.1 inches.

Cargo

Cargo Volume Rear Seats Up:

First Gen: ~27.5 cu ft; Second Gen: ~20.1 cu ft.

Cargo Volume Rear Seats Down:

First Gen: ~66.5 cu ft; Second Gen: ~66.7 cu ft.

Weights

Curb Weight:

First Gen: ~3200-3500 lbs; Second Gen: ~3400-3800 lbs.

Towing Capacity:

Approx. 1500-2000 lbs (check specific model/year).

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

First Gen: Not Rated. Second Gen: Generally 4-star.

NHTSA Front Impact Passenger:

First Gen: Not Rated. Second Gen: Generally 4-star.

IIHS Side Impact:

Second Gen: Generally 'Acceptable' or 'Good'.

Active Features

Available (standard on later models and higher trims).

Traction Control:

Available on some models.

Electronic Stability Control:

Available on later second-generation models.

Passive Features

Airbags Front:

Standard on second generation, available on some late first-generation models.

Airbags Side Curtain:

Available on some second-generation models.

Seatbelts:

3-point seatbelts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Base models typically feature AM/FM radio with CD player. Higher trims offered upgraded stereo systems with more speakers.

Navigation:

Rarely offered, typically only on top-tier second-generation trims as an aftermarket or dealer option.

Driver Assistance

Cruise Control:

Available on most models, especially higher trims.

Parking Sensors:

Not commonly available, typically an aftermarket addition.

Connectivity

Auxiliary Input:

Rare on first generation, more common on later second-generation models. USB ports were generally not standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months (severe duty: 3,000 miles).

Engine Coolant Flush:

Every 30,000 miles or 2 years.

Spark Plug Replacement:

100,000 miles for iridium plugs; 30,000 miles for standard copper plugs.

Timing Belt Replacement:

60,000 miles or 4 years for 2.0L SOHC/DOHC engines (critical maintenance item).

Fluid Specifications

Engine Oil:

API SJ/SL, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature).

Transmission Fluid Manual:

GL-4 SAE 75W-90 gear oil.

Transmission Fluid Automatic:

API SG/SH/SJ or MERCON V/Dexron III.

Coolant:

Ethylene Glycol based coolant, compatible with Kia specifications. Typically a green or orange type.

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

First Gen Common Problems:

Timing belt failure (if not replaced on schedule), rear differential leaks, minor electrical gremlins, rust on body panels, worn suspension bushings.

Second Gen Common Problems:

CV joint wear, ABS sensor issues, occasional catalytic converter problems, interior plastic trim creaks, potential for head gasket issues on high-mileage 2.7L V6.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

South Korea

Kia Motors Early Focus:

Known for affordable, utilitarian vehicles and trucks.

Model Evolution

First Generation Platform:

Body-on-frame chassis, shared with Mazda Proceed Marvie and Kia Concord/Capital.

Second Generation Platform:

Unibody chassis, shared with Hyundai Tucson (first generation).

Facelifts And Redesigns:

First generation had minor styling updates. Second generation received a mid-cycle refresh around 2007.

Production

First Gen Production Years:

1995-2002

Second Gen Production Years:

2005-2007 (This manual covers up to this point for the second gen).

Manufacturing Locations:

South Korea, Malaysia (CKD assembly).

🏆 Awards & Recognition

Recognitions

First Gen Recognition:

Considered a value-oriented choice, often praised for its affordability and basic utility.

Second Gen Recognition:

Improved on refinement and styling, gaining more positive reviews as Kia's design language evolved.

Ratings

Consumer Reports Reliability:

Mixed to average, with specific model years and engines showing better reliability than others. The manual will help diagnose and address common issues.