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KIA SPORTAGE Service Repair Manual 2005-2009

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🏷️ Basic Information Identification Make: Kia Model: Sportage Generation: Second Generation (KM) Covered Years: 2005-2009 Codes Chassis Code: KM 👋 Introduction Market Position Segment: Compact Crossover SUV Competitors: Honda CR-V,...
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KIA SPORTAGE Service Repair Manual 2005-2009
🏷️ Basic Information
Identification
Make:
Kia
Model:
Sportage
Generation:
Second Generation (KM)
Covered Years:
2005-2009
Codes
Chassis Code:
KM
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester
Key Features
Design:
Body-on-frame construction (prior to 2006 models in some markets), later unibody, offering ruggedness and off-road capability.
Powertrain Options:
Available with both four-cylinder and V6 engine options, offering a balance of performance and efficiency.
Drivetrain Options:
Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) configurations.
Value Proposition
Target Audience:
DIY enthusiasts, budget-conscious owners seeking to perform their own maintenance and repairs.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Drivetrain, Brakes, Suspension, Steering, HVAC, Electrical System, Body, Chassis, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Emission Control, SRS (Airbag) System, ABS, Body Control Module (BCM), Powertrain Control Module (PCM), Diagnostic Trouble Codes (DTCs)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly and reassembly of engine components, including cylinder head, block, pistons, connecting rods, crankshaft, camshafts, timing system, lubrication system, cooling system.
Engine Performance:
Fuel injection system, ignition system, emission control systems, turbocharger (if applicable), engine management system (ECU).
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including differentials, drive axles, CV joints, transfer case (for AWD models).
Transmission Manual:
Manual transmission (if applicable) service, repair, and overhaul procedures, clutch system.
Brakes:
Front and rear brake systems (disc brakes), including brake pads, rotors, calipers, brake lines, master cylinder, brake booster, ABS system components.
Suspension:
Front and rear suspension systems, including struts, shock absorbers, control arms, ball joints, sway bars, bushings, wheel bearings.
Steering:
Power steering system, steering rack, tie rod ends, steering column, steering wheel removal and installation.
Electrical System:
Wiring diagrams for all vehicle systems, battery, alternator, starter motor, lighting, fuses, relays, power windows, door locks, wipers, horn, instrument cluster, onboard computers.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, including compressor, condenser, evaporator, refrigerant system, cabin air filter, blower motor.
Body And Chassis:
Body panels, doors, hood, tailgate, bumpers, interior trim, chassis components, frame repair (if applicable).
Transmission Automatic
Automatic Transmission:
Automatic transmission service, repair, and overhaul procedures, torque converter, transmission control module (TCM).
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements, fluid level checks and top-offs, tire rotations, spark plug replacement, brake inspection, belt inspection.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting, interpretation of diagnostic trouble codes (DTCs).
Repair Procedures:
Step-by-step instructions for component replacement and repair, including torque specifications, special tools required, and detailed diagrams.
Diagnosis:
On-board diagnostics (OBD-II) system information, scan tool usage, live data interpretation, component testing procedures.
Wiring Schematics:
Comprehensive wiring diagrams for all electrical systems, including component location and circuit tracing.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics and body repairs.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for hands-on workshop use.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type 1:
2.0L Inline-4 (G4CP)
Displacement 1:
1998 cc
Horsepower 1:
138 hp @ 6000 rpm
Torque 1:
136 lb-ft @ 4500 rpm
Fuel System 1:
Multi-point Fuel Injection
Secondary Engine
Engine Type 2:
2.7L V6 (G6BA)
Displacement 2:
2656 cc
Horsepower 2:
173 hp @ 6000 rpm
Torque 2:
175 lb-ft @ 4500 rpm
Fuel System 2:
Multi-point Fuel Injection
Performance
Compression Ratio 4Cyl:
9.5:1
Compression Ratio V6:
9.6:1
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual
Optional
Transmission Type Opt:
4-Speed Automatic
Features
AWD System:
Electronically controlled AWD with Lock mode
Fluid Specs
Automatic Transmission Fluid:
SPII-ATF (Kia Genuine Part No. 04500-00100) or equivalent Dexron III/Mercon compatible fluid.
Manual Transmission Fluid:
API GL-4 SAE 75W-90 Gear Oil (Kia Genuine Part No. 04300-00200) or equivalent.
📐 Dimensions
Exterior
Length:
170.1 inches (4320 mm)
Width:
71.9 inches (1825 mm)
Height:
66.3 inches (1685 mm)
Wheelbase:
103.1 inches (2620 mm)
Ground Clearance:
7.3 inches (185 mm)
Cargo
Cargo Volume Rear Seats Up:
27.4 cu ft (776 L)
Cargo Volume Rear Seats Down:
66.3 cu ft (1877 L)
Weights
Curb Weight Min:
3505 lbs (1590 kg)
Curb Weight Max:
3814 lbs (1730 kg)
Towing Capacity:
2000 lbs (907 kg) with optional towing package
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance Rating:
4 out of 5 stars
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Electronic Stability Control:
Available Electronic Stability Control (ESC)
Passive Features
Airbags:
Front airbags, optional side curtain airbags.
Seatbelts:
3-point front and rear seatbelts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD audio system, optional premium Infinity sound system with subwoofer.
Navigation:
Optional navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Auxiliary Input:
Available auxiliary audio input jack.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 30,000 miles (48,000 km)
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement 4Cyl:
Every 60,000 miles (96,000 km) (Iridium plugs)
Spark Plug Replacement V6:
Every 60,000 miles (96,000 km) (Iridium plugs)
Timing Belt Replacement:
This generation (KM) utilizes a timing CHAIN, not a belt, for both engines.
Coolant Flush Interval:
Every 30,000 miles (48,000 km) or 24 months.
Fluid Specifications
Engine Oil Type 4Cyl:
API SM or higher, SAE 5W-20 (preferred) or 5W-30.
Engine Oil Type V6:
API SM or higher, SAE 5W-20 (preferred) or 5W-30.
Engine Oil Capacity 4Cyl:
Approx. 4.0 US quarts (3.8 L) with filter change.
Engine Oil Capacity V6:
Approx. 4.5 US quarts (4.3 L) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze, meeting Kia specification MS 591-08 or equivalent (typically OAT type).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issues 1:
Water pump leaks (especially on V6 models), ABS sensor failures, minor interior trim rattles, potential for EGR valve issues on diesel variants (less common in North America).
Common Issues 2:
Pre-2007 models had a less robust transfer case actuator which could fail, leading to AWD disengagement. AWD system fluid changes are recommended.
Common Issues 3:
Some owners report premature wear on front suspension components like control arm bushings or ball joints, especially in areas with rough roads.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kia Motors Corporation, South Korea
Model Evolution
Generation Introduction:
The second generation Sportage (KM) was introduced for the 2005 model year, replacing the first generation model. It marked a significant shift towards a more modern, car-like SUV.
Platform:
Based on the Hyundai Tucson platform (shared components).
Production
Production Years:
2004-2010 (for the KM generation)
Manufacturing Locations:
South Korea, Slovakia (for European market), Iran
🏆 Awards & Recognition
Recognitions
IIHS Crash Test Rating:
Good in frontal offset, acceptable in side impact (2006 model testing).
Consumer Reports Reliability:
Reliability ratings varied by year and specific components, generally considered average to slightly below average during this period.
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