KIA SPORTAGE 1997 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Sportage Year: 1997 Codes Chassis Code: KNCZ Generation: 1st Generation (KJ) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Crossover Target Audience:...

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Type: Car

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Sku: 418620

Tags: 1997 Car Cars Kia Misc SPORTAGE

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Description

🏷️ Basic Information

Identification

Make:

Model:

Sportage

Year:

Codes

Chassis Code:

Generation:

1st Generation (KJ)

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Crossover

Target Audience:

Consumers seeking an affordable, capable, and rugged compact SUV with off-road potential.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Mitsubishi Montero Sport.

Key Features

Body Style:

5-door SUV

Construction:

Body-on-frame construction, providing robustness for off-road use and towing.

4Wd System:

Part-time 4WD system with selectable 2WD/4WD modes, often including a low-range gear for challenging terrain.

📋 Manual Details

Coverage Areas

Engine Coverage:

2.0L (FE-DOHC) and 2.0L (RF) Diesel

Transmission Coverage:

5-Speed Manual, 4-Speed Automatic

Drivetrain Coverage:

2WD and 4WD (Part-Time 4WD System)

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Full Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, cylinder head, block assembly, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (gasoline and diesel), emission control systems.

Transmission Drivetrain:

Manual transmission service, automatic transmission service, transfer case, drive shafts, differentials, CV joints, hubs.

Suspension Steering:

Front suspension (struts, control arms, ball joints), rear suspension (multi-link), steering system (rack and pinion, power steering pump), wheel alignment.

Brakes:

Front disc brakes, rear drum brakes (some models may have rear discs), ABS system (if equipped), brake fluid specifications, bleeding procedures, parking brake.

Electrical System:

Battery, starting system, charging system, ignition system, lighting, instrumentation, wipers, horn, power windows, power door locks, central locking, fuses and relays, wiring diagrams.

Body Chassis:

Body panel removal and installation, doors, hoods, tailgates, interior trim, bumpers, chassis frame repair, exhaust system, fuel tank.

Procedures Included

Maintenance:

Oil change intervals and specifications, filter replacement, spark plug replacement, coolant flush, brake fluid flush, air filter replacement, belt inspection and replacement.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, common fault diagnosis for engine, transmission, electrical, and chassis systems.

Repair:

Step-by-step repair procedures for all major mechanical and electrical components, including detailed torque specifications.

Diagnostics:

On-board diagnostic (OBD-I) system information, fault code interpretation, component testing procedures.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval.

Print Quality

Print Readability:

High-resolution scans of original factory documentation for clear text and diagrams.

Binding Type

Binding Type:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code Gasoline:

FE-DOHC

Engine Displacement Gasoline:

1998 cc (2.0 Liters)

Engine Configuration Gasoline:

Inline 4-cylinder, DOHC (Dual Overhead Camshaft)

Fuel Type Gasoline:

Unleaded Gasoline

Horsepower Gasoline Approx:

130 hp @ 6000 rpm

Torque Gasoline Approx:

135 lb-ft @ 4000 rpm

Secondary Engine

Engine Code Diesel:

Engine Displacement Diesel:

1998 cc (2.0 Liters)

Engine Configuration Diesel:

Inline 4-cylinder, SOHC (Single Overhead Camshaft), Turbocharged

Fuel Type Diesel:

Diesel Fuel

Horsepower Diesel Approx:

85 hp @ 4000 rpm

Torque Diesel Approx:

130 lb-ft @ 2000 rpm

Fuel System

Gasoline Fuel Injection:

Multi-port Fuel Injection (MPI)

Diesel Fuel System:

Indirect injection (IDI) with turbocharger

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual

Optional

Transmission Type Optional:

4-Speed Automatic

Features

Transfer Case:

Part-time 4WD system with manual engagement and low-range gearing.

📐 Dimensions

Exterior

Length Approx:

4450 mm (175.2 in)

Width Approx:

1780 mm (70.1 in)

Height Approx:

1670 mm (65.7 in)

Wheelbase Approx:

2650 mm (104.3 in)

Weights

Curb Weight Approx Manual:

1600 kg (3527 lbs)

Curb Weight Approx Automatic:

1650 kg (3638 lbs)

Cargo

Cargo Volume Behind Rear Seat Approx:

660 liters (23.3 cu ft)

Cargo Volume With Rear Seat Folded Approx:

1760 liters (62.2 cu ft)

🛡️ Safety Features

Ratings

NHTSA Front Crash Rating:

Not rated or unavailable for this model year.

IIHS Crash Test Performance:

Limited data, generally considered basic for its era.

Active Features

Optional on some trims, typically rear-wheel anti-lock brakes (RWABS).

Passive Features

Airbags:

Driver and passenger airbags.

Seatbelts:

Three-point seat belts with pretensioners for front occupants.

Rollover Protection:

Reinforced A and B pillars, though the body-on-frame design inherently offers some structural rigidity.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player, optional CD player. Speaker configuration varies by trim level.

Driver Assistance

ABS Availability:

Optional, primarily rear-wheel ABS on most models.

Connectivity

Connectivity Features:

Limited to basic 12V accessory power outlet. No integrated Bluetooth or USB ports.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval Gasoline:

Every 7,500 miles or 12 months (whichever comes first).

Engine Oil Change Interval Diesel:

Every 5,000 miles or 6 months (whichever comes first), especially under severe conditions.

Air Filter Replacement:

Every 15,000 miles or 12 months.

Spark Plug Replacement Gasoline:

Every 30,000 miles.

Timing Belt Replacement:

Every 60,000 miles or 4 years (for FE-DOHC engine, crucial to avoid catastrophic failure).

Fluid Specifications

Engine Oil Type Gasoline:

API SJ or SG, SAE 10W-30 or 5W-30 depending on climate.

Engine Oil Capacity Gasoline:

4.5 Liters (4.8 US quarts) with filter.

Engine Oil Type Diesel:

API CG-4 or CF-4, SAE 15W-40.

Engine Oil Capacity Diesel:

5.5 Liters (5.8 US quarts) with filter.

Coolant Type:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3.

Transmission Fluid Manual:

GL-4 SAE 75W-90 gear oil.

Transmission Fluid Automatic:

Dexron III or equivalent ATF.

Known Issues

Common Wear Items:

Ball joints, tie rod ends, bushings, wheel bearings due to off-road usage and age.

Engine Timing Belt Failure:

The FE-DOHC engine is an 'interference' engine, meaning timing belt failure will cause piston-to-valve contact, leading to severe engine damage. Regular replacement is critical.

Diesel Engine Glow Plugs:

Glow plug issues can affect cold starting performance on the RF diesel engine.

4Wd Actuation:

Potential for wear in the manual hubs or transfer case engagement linkages over time.

📚 Vehicle History

Brand Heritage

Kia History Context:

Kia was a developing automotive manufacturer in the 1990s, seeking to establish a global presence with robust and value-oriented vehicles.

Model Evolution

Sportage Introduction:

The first generation Sportage (KJ) was introduced in 1993 globally, and 1997 in North America, marking Kia's entry into the SUV market.

Platform Sharing:

Based on a modified chassis derived from the Mazda B-series pickup truck and the Kia Sephia sedan.

Production

Production Years:

1993-2004 (First Generation)

Manufacturing Locations:

South Korea (Hwaseong), Ecuador, Philippines, Poland, Russia.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Generally not associated with significant industry awards for its era, but recognized for its value proposition and off-road capability in its class.