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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