🏷️ Basic Information

Make:

Kia

Model:

Sportage

Year:

2004

Generation:

Second Generation (JE/KM)

Market Segment:

Compact SUV

👋 Introduction

Market Segment Overview:

The 2004 Kia Sportage represented Kia's entry into the competitive compact SUV segment, aiming to offer a blend of utility, value, and modern styling. It competed against vehicles like the Honda CR-V, Toyota RAV4, and Ford Escape.

Key Competitors 2004:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester, Hyundai Tucson

Standout Features:

Available with both 2WD and 4WD, choice of engines, relatively spacious interior for its class, practical cargo space, often praised for value and a decent ride quality.

Utility For Owners:

This manual provides owners and technicians with the critical information needed to maintain, diagnose, and repair the 2004 Kia Sportage, ensuring longevity and optimal performance. It's an indispensable tool for DIY enthusiasts and professional mechanics alike.

📋 Manual Details

Coverage Scope:

Comprehensive service, maintenance, and repair

Approximate Pages:

1500+

Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing components, lubrication system, cooling system, intake/exhaust systems

Engine Management:

Fuel injection, ignition system, emissions control, sensors (MAF, MAP, O2, crankshaft position, camshaft position), actuators, ECM/ECU diagnostics and repair

Transmission Manual:

Clutch, gearbox, internal components, shifter mechanism, maintenance, repair, troubleshooting

Transmission Automatic:

Torque converter, hydraulic system, valve body, planetary gear sets, electronic control unit (TCU), fluid specifications, maintenance, repair, troubleshooting

Drivetrain AWD:

Transfer case, propeller shafts, differentials (front and rear), CV joints, wheel hubs, maintenance, repair

Suspension:

Front suspension (MacPherson struts, control arms, ball joints, bushings), rear suspension (multi-link or independent, shock absorbers, springs, bushings), alignment specifications, repair procedures

Steering:

Power steering system (pump, rack and pinion or steering box, hoses, fluid), steering column, steering wheel, alignment, troubleshooting

Brakes:

Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), parking brake system, ABS (Anti-lock Braking System) components and diagnostics, brake fluid specifications, bleeding procedures

Electrical System Charging:

Alternator, battery, voltage regulator, wiring diagrams, testing procedures

Electrical System Starting:

Starter motor, ignition switch, starter relay, wiring diagrams, testing procedures

Electrical System Lighting:

Headlights, taillights, brake lights, turn signals, interior lighting, bulb types, troubleshooting

Electrical System Accessories:

Power windows, power door locks, sunroof, mirrors, wipers, horn, radio, speakers, wiring diagrams

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant, refrigerant oil), heating system (heater core, blower motor), climate control panel, diagnostics

Body Interior:

Dashboard, seats, door panels, headliner, trim pieces, removal and installation procedures

Body Exterior:

Bumpers, fenders, hood, doors, tailgate, glass, seals, trim, repair, alignment

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin, fuel), fluid level checks and top-offs, tire rotation and balancing, spark plug replacement, belt inspection/replacement

Diagnostic Procedures:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, electrical circuit testing, component testing

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all major systems

Rebuild Procedures:

Detailed instructions for engine and transmission overhauls, including torque specifications and clearances

Specifications Data:

Torque values, clearances, fluid capacities, tire pressures, alignment angles, engine diagnostic data

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, including component locations and wire colors

Depth:

Factory-level, covering everything from basic maintenance to complete overhauls and advanced diagnostics

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval

Print Quality:

High-resolution scans, printable pages

Binding:

N/A (Digital)

Paper:

N/A (Digital)

⚙️ Engine Specifications

Engine Code 2.0L:

FE (J2)

Displacement 2.0L:

1998 cc

Configuration 2.0L:

Inline 4-cylinder, DOHC, 16 valves

Horsepower 2.0L:

136 hp @ 6000 rpm

Torque 2.0L:

136 lb-ft @ 4500 rpm

Engine Code 2.7L:

G6BA (Delta)

Displacement 2.7L:

2656 cc

Configuration 2.7L:

V6, DOHC, 24 valves

Horsepower 2.7L:

173 hp @ 6000 rpm

Torque 2.7L:

178 lb-ft @ 4000 rpm

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Recommended Octane:

87 Octane (Minimum)

🔧 Transmission

Transmission Type 2.0L:

5-speed Manual

Transmission Type 2.7L:

4-speed Automatic (with OD)

AWD Availability:

Available on both engine variants, typically paired with the automatic transmission

Automatic Transmission Fluid:

Kia/Hyundai SPIII (or equivalent Dexron-III/Mercon)

Manual Transmission Fluid:

API GL-4, SAE 75W-90

📐 Dimensions

Length:

Approx. 171.7 inches (4360 mm)

Width:

Approx. 71.3 inches (1810 mm)

Height:

Approx. 66.1 inches (1680 mm)

Wheelbase:

Approx. 103.5 inches (2630 mm)

Curb Weight Min:

Approx. 3380 lbs (1533 kg) - 2.0L 2WD Manual

Curb Weight Max:

Approx. 3800 lbs (1724 kg) - 2.7L AWD Automatic

🛡️ Safety Features

NHTSA Front Impact Driver:

4 Stars (2004 Model Year)

NHTSA Front Impact Passenger:

4 Stars (2004 Model Year)

NHTSA Side Impact Front Driver:

4 Stars (2004 Model Year)

NHTSA Side Impact Front Passenger:

4 Stars (2004 Model Year)

NHTSA Side Impact Rear Driver:

4 Stars (2004 Model Year)

NHTSA Side Impact Rear Passenger:

4 Stars (2004 Model Year)

IIHS Side Impact:

Acceptable (2004 Model Year)

ABS:

Standard on most trims

Electronic Stability Control:

Optional on some trims

Traction Control:

Standard with AWD models

Airbags Front:

Driver and Passenger front airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

3-point front and rear seatbelts, pre-tensioners for front seats

💡 Technology Features

Audio System:

Standard AM/FM/CD player, optional premium audio system with subwoofer, available steering wheel audio controls on higher trims.

Navigation:

Not commonly available or offered as an option for the 2004 model year.

Cruise Control:

Standard on most trims

Parking Sensors:

Not commonly available or offered.

Auxiliary Input:

Not typically standard, may be added as an aftermarket modification.

🔧 Maintenance

Engine Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first

Oil Filter Replacement:

Every 5,000 miles (8,000 km) or 6 months, with oil change

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Spark Plug Replacement 2.0L:

Every 60,000 miles (96,000 km) (Iridium type recommended)

Spark Plug Replacement 2.7L:

Every 60,000 miles (96,000 km) (Iridium type recommended)

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 4 years (for the 2.0L FE engine - *crucial interval to avoid catastrophic failure*)

Engine Oil Type:

API SJ/SL, ILSAC GF-3, SAE 5W-30 or 10W-30 (depending on climate)

Engine Oil Capacity 2.0L:

Approx. 4.8 quarts (4.5 liters) with filter

Engine Oil Capacity 2.7L:

Approx. 5.1 quarts (4.8 liters) with filter

Coolant Type:

Ethylene Glycol based coolant (Antifreeze/Coolant - typically a 50/50 mix with distilled water)

Coolant Capacity:

Approx. 7.2 quarts (6.8 liters)

Brake Fluid Type:

DOT 3

Common Issue Timing Belt 2.0L:

The timing belt on the 2.0L engine is an interference design. Failure to replace it at the recommended interval (60,000 miles) can lead to severe engine damage (bent valves, damaged pistons).

Common Issue Cv Axles:

Front CV axles can wear out, leading to clicking noises during turns.

Common Issue Rear Differential AWD:

Potential for rear differential seal leaks or bearing noise in AWD models.

Common Issue Window Regulators:

Power window regulators can fail, causing windows to not operate.

Common Issue Evap Emissions System:

Issues with the evaporative emissions (EVAP) system, such as a faulty purge valve or charcoal canister, can trigger check engine lights.

📚 Vehicle History

Kia History:

Kia Motors Corporation, founded in 1944, is South Korea's oldest manufacturer of motor vehicles. Initially producing motorcycles and trucks, Kia entered the passenger car market in the late 1970s and began exporting to North America in 1992. Known for offering value-oriented vehicles.

Sportage First Gen:

The first-generation Sportage (1993-2002) was body-on-frame and often compared to more rugged SUVs. It laid the groundwork for Kia's entry into the SUV market.

Sportage Second Gen Start:

The 2004 model year marked the introduction of the second-generation Sportage (JE/KM platform). This generation transitioned to a unibody construction, sharing its platform with the Hyundai Tucson. This change resulted in improved ride comfort, handling, and fuel efficiency, making it more of a 'soft-roader' or crossover SUV.

Assembly Location:

Gwangmyeong, Gyeonggi Province, South Korea; Also assembled in other Kia global facilities.

🏆 Awards & Recognition

Initial Reviews:

While not a recipient of major performance awards, the 2004 Sportage was generally reviewed as a competent and value-oriented compact SUV, offering a significant improvement over its predecessor. It was often cited for its good warranty coverage.