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KIA SPORTAGE 1995-2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Sportage Generation Code: KJ (First Generation) Model Years Covered: 1995-2004 Codes Vin Prefix: KNA (South Korea) 👋 Introduction Market Position Segment: Compact SUV...
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KIA SPORTAGE 1995-2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kia
Model:
Sportage
Generation Code:
KJ (First Generation)
Model Years Covered:
1995-2004
Codes
Vin Prefix:
KNA (South Korea)
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover Utility Vehicle
Target Audience:
DIY mechanics, independent repair shops, and enthusiasts seeking detailed repair information.
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra (first generation models)
Key Features
Unique Selling Points:
Robust body-on-frame construction (early models), available 4WD, versatile for light off-roading and utility.
Manual Value Proposition:
Provides in-depth technical knowledge essential for maintaining and repairing the Sportage across its diverse markets and configurations.
📋 Manual Details
Coverage Areas
Regions Covered:
USA, Canada, Europe
Model Variants Covered:
All models, Petrol engines
Page Count
Estimated Page Count:
Comprehensive (Exact count not provided, but described as 'complete service manual' covering 'almost every detail')
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital (Implied for a modern sales business, typically PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (petrol), Transmission (manual & automatic), Drivetrain (4WD systems)
Chassis:
Suspension, Steering, Brakes, Wheels & Tires
Electrical:
Ignition System, Charging System, Starting System, Lighting, Instrumentation, Body Electrical, HVAC Control
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, Bumpers, Exterior Trim
Procedures Included
Maintenance:
Routine inspections, fluid changes, filter replacements, lubrication, tune-ups
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics
Repair:
Component disassembly, reassembly, adjustment, calibration, replacement
Special Tools:
Identification and usage of specialized tools required for specific procedures
Technical Depth
Depth:
A-Z coverage, comprehensive detailing of all repairs
Detail Level:
Includes detailed diagrams, torque specifications, clearances, and diagnostic flowcharts
📊 Manual Specifications
File Format
Digital Format:
PDF (most likely, for widespread compatibility and searchability)
Print Quality
Image Resolution:
High-resolution scans for clear diagrams and text
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
FE (2.0L SOHC), FE-DOHC (2.0L DOHC), RF (2.5L Diesel - for some European models, though manual focuses on Petrol)
Displacement 2.0L:
1998 cc (122 cu. in.)
Bore X Stroke 2.0L:
82.0 mm x 93.5 mm (approx.)
Compression Ratio 2.0L Sohc:
9.4:1 (approx.)
Horsepower 2.0L Sohc Est:
118-122 hp @ 5000-5500 rpm
Torque 2.0L Sohc Est:
135-137 lb-ft @ 3000-3500 rpm
Displacement 2.0L DOHc:
1998 cc (122 cu. in.)
Horsepower 2.0L DOHc Est:
128-130 hp @ 5500-6000 rpm
Torque 2.0L DOHc Est:
135-137 lb-ft @ 3000-3500 rpm
Performance
Valve Train 2.0L Sohc:
Single Overhead Camshaft (SOHC), 16 Valves (4 per cylinder)
Valve Train 2.0L DOHc:
Dual Overhead Camshaft (DOHC), 16 Valves (4 per cylinder)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Construction
Block Material:
Cast Iron
Cylinder Head Material:
Aluminum Alloy
🔧 Transmission
Standard
Transmission Type Early Models:
5-Speed Manual
Optional
Transmission Type Optional:
4-Speed Automatic
Features
Drivetrain Options:
2WD (Rear-Wheel Drive), 4WD (Part-time 4WD with transfer case)
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 (check manual for exact spec)
Automatic Transmission Fluid Type:
Dexron III (or equivalent - check manual for exact spec)
📐 Dimensions
Exterior
Length Est:
approx. 4,500 - 4,570 mm (177 - 180 in.)
Width Est:
approx. 1,730 - 1,770 mm (68 - 70 in.)
Height Est:
approx. 1,650 - 1,670 mm (65 - 66 in.)
Wheelbase Est:
approx. 2,650 mm (104.3 in.)
Weights
Curb Weight Est:
approx. 1,500 - 1,700 kg (3,300 - 3,750 lbs)
Gross Vehicle Weight Rating Est:
approx. 2,000 - 2,200 kg (4,400 - 4,850 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test Rating Est:
4-star (Driver), 3-star (Passenger) - for models equipped with airbags
Active Features
ABS:
Available on higher trims and later models
Passive Features
Airbags:
Driver and front passenger airbags (standard on most later models, optional on early ones)
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners (front)
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo with CD player and cassette player (depending on trim and year). Speaker configurations varied.
Driver Assistance
Cruise Control:
Available on higher trim levels and later models.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors available on most models.
🔧 Maintenance
Service Intervals
Oil Change Interval Est:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first (consult manual for exact specification).
Air Filter Replacement Est:
Every 15,000 - 30,000 miles (24,000 - 48,000 km)
Spark Plug Replacement Est:
Every 60,000 - 100,000 miles (96,000 - 160,000 km), depending on spark plug type (copper vs. platinum/iridium).
Fluid Specifications
Engine Oil Type Est:
API SJ or SL, SAE 5W-30 or 10W-30 (check manual for exact viscosity and API service classification).
Coolant Type:
Ethylene Glycol based coolant, typically P-HOAT or OAT type. Kia recommends their proprietary coolant or a suitable aftermarket equivalent. Capacity approx. 7-8 liters.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear (manual transmission), ball joints, tie rod ends, exhaust system corrosion, radiator leaks.
Engine Specific Issues Est:
Overheating due to coolant leaks or faulty thermostats, timing belt replacement (on FE-DOHC engines, critical interval), oil leaks from valve cover gasket or oil pan gasket.
Drivetrain Specific Issues Est:
Transfer case actuator issues (4WD models), worn CV joints, differential fluid leaks.
Maintenance Schedule Key Items
Timing Belt Replacement:
Crucial for FE-DOHC engines. Typically recommended every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years. Failure can cause catastrophic engine damage.
📚 Vehicle History
Brand Heritage
Kia Brand Origin:
South Korea, founded in 1944 (initially as a manufacturer of steel tubing and bicycle parts)
Model Evolution
Sportage Introduction Era:
First generation launched in 1993 globally, reaching US/Canada markets in 1995. Positioned as a compact, rugged SUV.
Sportage Generation Kj Design:
Initially featured a body-on-frame construction, later models transitioned to a unibody platform (around 2004/2005 for the next generation).
Production
Manufacturing Locations:
South Korea (Kia's primary manufacturing hub)
Sales Performance Overview:
The first generation Sportage was a significant model for Kia, helping to establish its presence in the burgeoning SUV market.
🏆 Awards & Recognition
Recognitions
Industry Acknowledgement:
While specific awards for the first-generation Sportage are not widely publicized, it was recognized as a value-oriented SUV that helped establish Kia's market presence.
Ratings
Consumer Reports Overview Est:
Consumer reports from the era often highlighted its affordability and utility, but also noted potential concerns regarding reliability and refinement compared to Japanese competitors.
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