Engine Mechanical:
Complete overhaul procedures, cylinder head, block, crankshaft, pistons, camshaft, timing belt/chain replacement.
Engine Electrical:
Ignition system, fuel injection system (MPI), starting and charging system, sensor diagnostics, ECM (Engine Control Module) testing.
Transmission:
Manual and Automatic transmission removal, installation, disassembly, assembly, and adjustment. Clutch system.
Drivetrain:
Front and rear axles, differentials, drive shafts, CV joints, four-wheel-drive system operation and repair.
Suspension:
Front strut assembly, rear shock absorbers, springs, control arms, bushings, ball joints, wheel bearings.
Steering:
Power steering system, steering column, steering rack, tie rod ends.
Brakes:
Front and rear brake systems (disc and drum), hydraulic system, ABS (Anti-lock Braking System) components and diagnosis, parking brake.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, EVAP system.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, O2 sensors.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, cooling fan.
HVAC:
Air conditioning system, heater core, blower motor, climate control panel.
Electrical System:
Wiring diagrams, fuse box locations, relays, lighting system (headlights, taillights, interior), power windows, power locks, mirrors.
Body And Frame:
Body panel removal and installation, door mechanisms, glass replacement, structural repair basics.
Maintenance:
Scheduled maintenance intervals, oil change procedures, fluid level checks and top-offs, filter replacements, lubrication points.
Troubleshooting:
Diagnostic charts and flowcharts for common problems, symptom-based troubleshooting.
Repair:
Detailed step-by-step repair instructions for all major vehicle systems.
Diagnostics:
OBD-II (On-Board Diagnostics II) codes explanation, sensor data interpretation, diagnostic tool usage.
Specifications Data:
Torque specifications for all fasteners, alignment specifications, fluid capacities, electrical specifications.
Depth:
Comprehensive. Covers basic maintenance to complete engine and transmission overhauls, including electrical system diagnostics and bodywork.
Engine Oil Change:
Every 7,500 miles (12,000 km) or 12 months, whichever comes first.
Engine Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 24 months.
Fuel Filter Replacement:
Every 30,000 miles (48,000 km) or 36 months.
Spark Plug Replacement 4 Cyl:
Every 60,000 miles (96,000 km) (Platinum or Iridium recommended).
Spark Plug Replacement V6:
Every 60,000 miles (96,000 km) (Platinum or Iridium recommended).
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years for 2.0L engine. The 2.7L V6 engine uses a timing chain, which generally does not require periodic replacement.
Engine Oil Capacity 4 Cyl:
4.3 Quarts (4.1 Liters) with filter change (API SG, SH, SJ, or SL, SAE 5W-30 recommended).
Engine Oil Capacity V6:
5.1 Quarts (4.8 Liters) with filter change (API SG, SH, SJ, or SL, SAE 5W-30 recommended).
Coolant Type:
Ethylene Glycol based coolant (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4
Common Problem 1:
Engine oil leaks, particularly from valve cover gaskets and oil pan gaskets.
Common Problem 2:
Premature wear of front suspension components (ball joints, tie rod ends) due to typical SUV usage.
Common Problem 3:
Rear main seal leaks on some engine variants.
Common Problem 4:
CV joint boot failures leading to premature wear.
Common Problem 5:
ABS sensor failures can lead to ABS warning lights.
Manufacturer:
Kia Motors Corporation, South Korea
First Generation Introduction:
Introduced in 1993 (globally), North American debut in 2001 for the 2002 model year.
Refresh:
Minor facelift for the 2005 model year, including revised front fascia, updated interior trim, and improved engine options.
Production Years Covered:
2002, 2003, 2004, 2005, 2006, 2007
Production Plant:
Hwasung Plant, South Korea
