Kia Sportage Instruction manual

Sportage
Workshop Manual
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COMPONENT
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ENGINE COOLANT REFILLING AND BLEEDING
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under
high pressure escaping from the radiator.
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts
or the paint. If any coolant spills, rinse it off immediately.
1. Slide the the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to
the touch.
2. Remove radiator cap.
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug(A) securely.
5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX
mark with antifreeze.
6. Fill fluid mixture with coolant and water slowly through the radiator cap. Gently squeeze the upper/lower hoses
of the radiator so as to bleed air easily.
• Use only genuine antifreeze/coolant.
• For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum.
Coolant Coolant concentrations less than 50% may not provide sufficient protection against corrosion or
freezing.
• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.
• Do not mix different brands of antifreeze/coolants.
• Do not use additional rust inhibitors or anti-rust products; they may not be compatible with the coolant.
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7. Start tart the engine and allow coolant to circula
When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air sufficiently out of the cooling system.
9. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
10. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
11. Stop the engine and allow coolant to cool.
12. Repeat steps 6 to 11 until the coolant level stays constant and all air is bleed out of the cooling system.
Recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.
Coolant capacity : 6.0 liters (6.34 US qt, 5.28 lmp qt)
RADIATOR CAP TESTING
1. Remove the radiator cap, wet its seal with engine coolant, then install it on pressure tester.
2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
RADIATOR LEAKAGE TEST
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then
install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~
17.78psi).
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3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.
Check for engine oil in the coolant and/or coolant in the engine oil.
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REMOVAL
WATER PUMP
1. Drain the engine coolant.
System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove the drive belts.
3. Remove the timing belt. (Refer to EMA-27)
4. Remove the timing belt idler.
5. Remove the power steering pump and use a wire to secure the pump to the vehicle so that it is out of the way.
6. Remove the bolts(B, C) and power steering pump bracket(A).
7. Remove the alternator. (See EE group - alternator)
8. Remove the water pump.
(1) Remove the 2 bolts(D) and alternator brace(A).
(2) Remove the 3 bolts(C) and remove the water pump(B) and gasket.
THERMOSTAT
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Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. Drain the engine coolant so its level is below thermostat.
2. Remove the water inlet fitting(A), gasket and thermostat.
RADIATOR
1. Remove the under cover(A).
2. Drain the engine coolant. Remove the radiator cap to speed draining.
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3. Remove the air duct(A).
4. Remove the battery and tray.
5. Remove the coolant reservoir tank(A).
6. Remove the radiator upper hose(B).
7. Remove the radiator lower hose(A).
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8. Remove the ATF oil cooler hose(B).
9. Remove the cooling fan motor connector(A).
10. Remove the cooling fan motor assembly mounting bolt(B).
11. Remove the ATF oil cooler pipe(C).
12. Remove the cooling fan motor assembly with pulling it from the radiator.
13. Remove the radiator bracket(A, B).
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14. Remove the condenser mounting bolt(A).
15. Remove the condenser bracket(B) with pulling the condenser from the radiator.
16. Remove the radiator from engine room.
INSTALLATION
WATER PUMP
1. Install the water pump.
(1) Install the water pump(B) and a new gasket with the 3 bolts(C).
Tightening torque :
11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lbf.ft)
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(2) Install the alternator brace(A) with the 2 bolts(D).
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft)
2. Install the power steering pump bracket(A) and bolts(B, C).
Tightening torque :
Bolts(B) : 34.3 ~ 49.0N.m (3.5 ~ 5.0kgf.m, 25.3 ~ 36.2lbf.ft)
Bolts(C) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbf.ft)
3. Install the alternator. (See EE group - alternator)
4. Install the power steering pump. (See ST group - power steering pump)
5. Install the timing belt idler.
6. Install the timing belt. (Refer to EMA-32)
7. Install the water pump pulley.
8. Install the drive belts.
9. Tighten the water pump pulley bolts.
Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbf.ft)
10. Fill with engine coolant.
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11. Start engine and check for leaks.
12. Recheck engine coolant level.
THERMOSTAT
1. Place the thermostat in thermostat housing.
(1) Install the thermostat(B) with the jiggle valve upward.
(2) Install a new gasket(A) to the thermostat(B).
2. Install the water inlet fitting(A).
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbf.ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.
RADIATOR
1. Install the cooling fan onto the radiator.
2. Install the radiator onto the air conditioner condenser on the vehicle.
The next installation procedures are in the reverse order of radiator removal.
3. Connect the fan motor connector.
4. Install the upper and lower radiator hoses, and ATF cooler hoses.
5. Fill with engine coolant.
6. Start engine and check for leaks.
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INSPECTION
WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if
necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.
A small amount of "weeping" from the bleed hole is normal.
THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.
2. Check the valve opening temperature.
Valve opening temperature : 82±1.5°C (179.6±2.7°F)
Full opening temperature : 95°C (203°F)
If the valve opening temperature is not as specified, replace the thermostat.
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3. Check the valve lift.
Valve lift : 8mm(0.3in) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
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COMPONENT
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DISASSEMBLY
1. M/T : Remove the fly wheel.
2. A/T : Remove the drive plate.
3. Install the engine block onto an engine stand for disassembly.
4. Remove the timing belt. (Refer to EMA-27)
5. Remove the cylinder head. (Refer to EMA-40)
6. Remove the oil level gauge tube(A).
7. Remove the knock sensor(A).
8. Remove the oil pressure switch(A).
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9. Remove the water pump. (Refer to EMA-92)
10. Remove the oil pan(A).
11. Remove the oil screen.
Remove the 2bolts(C), oil screen(A) and gasket(B).
12. Check the connecting rod end play. (Refer to EMA-74, step 1)
13. Remove the connecting rod caps and check oil clearance. (Refer to EMA-74, step 2)
14. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
• Keep the bearings, connecting rod and cap together.
• Arrange the piston and connecting rod assemblies in the correct order.
15. Remove the front case. (Refer to EMA-104, step 8 ~ 9)
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16. Remove the rear oil seal case.
Remove the 5bolts(B) and rear oil seal case(A).
17. Remove the crankshaft bearing cap and check oil clearance. (Refer to EMA-76, step 4)
18. Check the crankshaft end play. (Refer to EMA-78, step 5)
19. Lift the crankshaft(A) out of the engine, being careful not to damage journals.
Arrange the main bearings and thrust bearings in the correct order.
20. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a
set.
21. Remove the piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2 side rails and oil ring by hand.
Arrange the piston rings in the correct order only.
22. Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston.
(Press-in load : 350 ~ 1,350kg(772~2,976lb)
INSPECTION
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