1998/ 1999

SPORTAGE
SERVICEMANUAL
CONTENTS

GROUP
AirConditioner/Heater
Body(4Door) .......60A
Body(2Door) .......608
B r a kSe y s t e m .......52
C h a r g i nSgy s t e m .......32
Clutch . . .40
Driveshaft ....49
E m i s s i oCno n t r o l S y s t e m .......2i
E n g i n e C o oS l i yn sg t e m ........12
EngineFEDOHC ......10
ExhaustSystem ........20
FrontAxle . . .508
FuefSystem .....22
G e n e r aI nl f o r m a t i o n .....00
lgnitionSystem ........90
LubricationSystem ......11
RearAxle . . . .50A
ScheduledMaintenanceServices .......01
StartingSystem ........91
SteeringSystem .....51
Suspension .........54
TransferCase. ......44
Transmission-Automatic ........42
T r a n s m i s s i o n - 4 x 4 a n dm4axn2u a.l . . . ......41
WheelsandTires ....53
 GENERALINFORMATIONOO.1

GROUPOO

INFORMATION
GENERAL
CONTENTS
CommonAutomotive Abbreviations . .. .... .. ..00-13
E l e c t r i cPaal r t s . . . . . . ....Oo-14
Battery Cable. ...... . . oo-14
Conneclors. . . . . . . . . . . . 00-15
Sensors,Switchesand Relays. . . . . . . . . . . . OO-1O
Terminals .. ..... .. .. 00-15
WiringHarness .....00-16
WirinC g o l oC r o d e s. . . . . . . ...00-i6
Electrical Troubleshooting Tools..... ... 00-14
J u m p eW r ire. ..........OO-14
Ohmmeter. ..........0 . 0-14
T e s Lt i g h t ...........00-14
Voltmeter. ...........00-14
Fundamental Procedures .......... O0-2
Adjustments . . ..00-4
Assembly ...........00-4
A WordAboutSafety... ....00-2
Disassembly. ......... OO-g
Notices, Cautions, andWamings.. .........00-2
Preparation of Toolsand Measuring Equipment .. ..... . . . . .00-2
Protection of the Vehicle ..... . . . . .00-2
Removal of Parts.. ..... OO-3
RubberPartsandTubing. ..... O0-4
S p e c i aTlo o l s .......... OO-2
General Vehicle Litting andJackjng. ........... OO-8
Vehicle Jacking ..... oo-8
F r o nE t n dJ a c kP o s i t i o.n. . . ........... OO-B
LeftHandFrontWheelJackPosition .... OO-9
LeftHandR€arWheelJackPosition . ... .. . . . . . .0O-9
R e a rE n dJ a c kP o s i t i o n . . . ......00-9
RightHandFrontWheelJackPosition. ........00-9
RightHandRearWheelJackPosition . . . . . . . . . . . . OO-9
UnitConversion Table.... .... 00-12
Vehicle ldentification System ......00-6
Engineldentification ... ... ....00-8
Modelldentification .... ... ....00-8
Transmission ldentification ......00-8
Vehicle Certification Label .........00-6
G r o sA s x l eW e i g h t . . .........00-6
GrossVehicle Weight. .... ......00-6
PayloadRating ... . . .00-6
V e h i c lTeo w i n g ......... 00-11
TowTruckTowing ....00-'t1
Towing WithRearWheelsOfftheGround. .........00-11
TowingWithTowingDollies. . . . . . . . . . . . 00-11
OO.2 GENERALINFORMATION

FUNDAMENTAL
PROCEDURES
* Holces,lt cAttraoNsAND
A wnRnrncs
As you readthroughthe procedures, youwillcome
acrossNOTICES, CAUTION's, and WARNING's. Each
one of theseindicates a specificpurpose.NOTICES give
information to preventyou Jrommakingan errorthat
coulddamagethevehicleor components. CAUTION's
remindyouto be especially carefulin thoseareaswhere
carelessness cancausepersonalinjuryWARNING's
remindyou to be extremelycarefulin thoseareaswhere
carelessness cancausepotentialdeath.Thefollowing
list containssomegenerilWARNING'syoushouldfo-llow
whenworkingon thevehicle.

PROTECTION
OF THEVEHICLE
* Notice K|AnEloo{2s
Use appropriatecovers to protect fenders,
carpeting,and upholsteryof the vehiclepior to PREPARATION
OF TOOLSAND
seNicing or repair.
MEASURINGEQUIPMENT
Be sureall necessarytoolsand measuring
equipment
areavailablebeforestartinganywork.

A WORDABOUTSAFETY Kta.i€:|.e€rs
The tollowingprecautions
mustbe followedwhenjacking
ihe vehicle:
1. Blockthe whe€ls. SPECIALTOOLS
2. Useonlythespecified jackingpositions. Usespecialtoolswhentheyare required.
3. Supportthevehiclewith saJetystands.
 GENERALINFORMATION
OO.3

1. Inspectionof parts
Whenremoved,eachpartshouldbe caretullyinspected
for malfunction, damage,or otherproblems.
deformation,

Kl,A-i53.@-0a-si

REMOVAL
OF PARTS
Whileconectinga problem,alsotry to determineits
cause.Beginworkonlyafterfirstleamingwhichparts
andsub assembliesmustbe removedand
disassembledfor replacement
or repair.

2. Arrangementof parts
partsshouldbe carefully
All disassembled anangedtor
assembly.ldentifythenseparatethe partsto be replaced
fromthosethatwillbe reused.

Kl -163'@{5.5

DISASSEMBLY
lf disassembly
requiresmanypartsto be disassembled,
theyshouldbe doneso in a waythatwill not affecttheir
performanceor extemalappearance.
Thepartsshouldalsobe identified so thatassemblycan
be performedeasilyand etficiently.
(|^.153-00-08€

% 3. Cleaningpartstor reuse
Allpartsto bereused
cleaned according
shouldbecarefully
to theappropriate
andthoroughly
method.

Kta-i 63.00{cs
OO.4 GENERALINFORMATION

Knlel@rr€

ADJUSTMENTS
gauge*testervtorque
Usecalibrat€d wrencheswhen
makingadjustments.
ASSEMBLY
Standardvalues,suchas torquesand certain
adjustments, mustbe strictlyobservedin the assembly
of all parts.Whenremoved, the followingpartsshouldbe
replacedwith newones:
1. Oil seals
2. Gaskets
3. O-rings
4- Springwashers
5. Cotterpins
6. Nylonnuts

Kta-ldt{o-i2.s

RUBBERPARTSANDTUBING
Preventgasolineor oil fromgettingon rubberpartsor
tubing.

KlA.r63-0-1GS

Dependingon location:
1. Sealantshouldbe appliedor new gasketsused.
2. Oil shouldbe appliedto the movingcomponents ot
pans.
3. Specifiedoil or greaseshouldbe appliedat the
prescribedlocations (suchas ciilseals)before
assembly. Kll.t 53{0..t3\5
 GENERALINFORMATION
OO-5

VEHICLEIDENTIFICATION
INFORMATION

1 VehicleEmissionControllntormation

: - "

vEHlcLETDENT|F|CAT|ON
NUMBER(VtN)LOCATTONS

lnstrumentPanel- DriverSide Bulkhead- EngineCompartment,

Passenger Side

FrameRail- Passenger
Side FMVSSlabel- Driver'sDoorJamb
KtA-i63-txt-1+S
00-6 GENERALINFORMATION

VEHICLEIDENTIFICATION
SYSTEM
/.'
VEHICLECERTIFICATION
LABEL i
Thevehiclecertification
labelindicatesGrossVehicleWeightRating(GVWR),GrossAxle(torfrontand rearaxle
separately)
WeightRating(GAWR),and PayloadRating.lt alsoshowsthe originaltiresizeand recommended inilation
oressure.

GrossVehicleWeight(cVW)
GrossVehicleWeightis the originalweightof the vehiclealongwiththe cargoand passengerweight.GVWmustnot
exceedGWVR.

GrossAxle Weight(GAVV)
GrossAxleWeightis theweightof the frontandthe rearaxle.GAWmustnotexceedGAWR.
MODEL ENGINE GVWR GAWR CAWR
(tronl) (rear)
4-DOOR 2.0L 4,204lbs. 2,040lbs. 2,279lbs.
Gasoline 1,907kg 950 kg 1,030kg

PayloadRating
Payloadratingis the maximumallowablecargoload.Thisallowablecargoloadincludesdriverand passenger
weight.
Thetiresizeand the inflationpressureshouldalwaysbe properfor the vehicleload.

FE DOHC
(4WD)

WithoutTrailerBrakes 1,000 (450)

TongueWeight:100(45)
TowingCapacity lb (kg)
WithTrailerBrakes 2,000(s00)
Weight:200(90)
Tongue
PayloadCapacity tb (kg) 838 (380)
 GENERALINFORMATION
OO-7

VEHICLEIDENTIFICATION
SYSTEMFORKIA SPORTAGE

VehicleDescriptionSection VehicleldentificationSection
(Model) (ChassisNo.)

EEEE

BODYTYPE PRODUCTION
(FRAME)
62 = 2DoorSports SEQUENCE
UtilityVehicle NUMBER
(SUV)
MANUFACTURER
72 = 4DoorSports
N = KiaMotors UtilityVehicle
Corporation (SUV)
ASSEMBLYPLANT
5 = Asan Bay
VEHICLE
TYPE ENGINE
D = MultiPurpose 3 = FE DOHC
(MPV)
Vehicle (2.0Lite0

CHECKDIGIT MODELYEAR
M u s t b e 0 - 9o r X w = 1998
x = 1999

SERIES
A= Sportage
4 WheelDrive
B = Sportage
2 WheelDrive

The Vehicleldentification
Number(VlN)for the KiaSportageis comprised (17)digits
of seventeen
and is stampedon a metalplatethat is locatedon the driverssideof the instrument
panelvisible
fromoutsideof the vehiclethroughthe windshield.The VIN is alsostampedintothe centerof the
enginecompartment bulkhead,into the passengerside of the frame(forwardsection)and it is
printedon the FederalMotorVehiclesSafetyStandards(FMVSS)labelwhichis attachedto the
driver'sdooriamb.
OO-8 GENERALINFORMATION

MODELIDENTIFICATION
The 1998/1999 +doo( 4wDsportagefeaturesa 2.OL
gasolineenginewithelectronicmultiportfuel injection,
rear-wheelantilockb.akingsystem(rearwheel ABS)and
a s-speedmanualtransmission.

xJA-rGt+i8€

GENERAL
VEHICLELIFTING
ANDJACKING
ENGINEIDENTIFTCATION
All enginesare stampedwithan engineidentification A mnnrHo
number.The engineidentification numberis locatedon . DO NOTGETUNDERTHE VEHICLE WHENIT
the leftsideat the rearof the engineblock.The eighth IS SUPPORTED BY THE JACK ONLY.
character of the vehicleidentification
numberindicates ALWAYSUSESAFEW STANDSTO
the typeof engineutilizedin the vehicle. SUPPORT THEVEHICLEWEIGHT. AND
WHEELCHOCKSTO KEEPTHEVEHICLE
FROMROLLING.FAILURETO DO SOCOULD
RESULTIN INJURYOR DEATH.
. BEFORELIFTINGTHEVEHICLEWITHA
HOISI MAKESURETHATTHE FRONTAND
REAROF THEVEHICLEARE PROPERLY
POSITIONED ANDTHE HOISTARMS ARE
SET AS WIDEAS POSSIBLE.

VEHICLEJACKING
Whenvehicleis jackedwitha vehiclejackor lloorjack
(workshop safetyprocedures
iack),appropriate should
be followed.Seepage00-10tor vehicleliftpoints.

FrontEndJack Position
Whenvehicleis jackedfromfrontcrossmember only,
Kta-.t6lGl7€ safetystandsshouldbe placedat the second
crossmember on bolhsidesof the bodvframe.
TRANSMISSION
IDENTIFICATION
Thetransmission
identffication
numberis locatedon the
transmission
caseon a labelor a tag.Thisidentifiesthe
manualtransmission
model.
 GENERALINFORMATIONOO,9

Left Hand RearWheelJack Position

Whenvehicleis jackedfromLEFTHANDREAR
WHEEL,wheelchocksshouldbe placedon bothsides
of the RIGHTHANDFRONTWHEEL.

Right Hand RearWheelJack

Position
Whenvehicleis jackedfromRIGHTHANDREAR
WHEEL,wheelchocksshouldbe placedon bothsides
of lhe LEFTHANDFRONTWHEEL.

RearEndJack Position
Whenvehicleis iackedtromthe centerof rear
crossmember,safetystandsshouldbe placedat the
foMardspringhangerof the rearspringon bothsidesof
the bodyframe.

Left HandFrontWheelJackPosition
Whenvehicleis jackedfrom LEFTHANDFRONT
WHEEL,wheelchocksshouldbe Dlacedon bothsides
OfthERIGHTHANDREARWHEEL. xlatdF@20€

RightHandFrontWheelJack
Position
Whenvehicleis jackedfrom RIGHTHANDFRONT
WHEEL,wheelchocksshouldbe placedon bothsides
of the LEFTHANDREARWHEE_.
OO-10 GENERALINFORMATION

VehicleLift Points

@ VehicleJackor FtoorJack

Floor Jack

Hoist-2PoleLift

L At the LowerConlrolArm, inboardof the

BallJoint.
At thecenterof FrontCrossmember
At the secondCrossmember.
B At the ForwardSpringHangerof the Rear
Spdng.
At the inboardol the ShockAbsorberHanoer
of lheAxle.
D At thecenterof the Difterential.

l(l^.l53{lo"2l 5
 GENERALINFORMATION
00.11

VEHICLETOWING-
EMERGENCIES
TOWTRUCKTOWING
All stateor provincial(in Canada)lawsand locallaws
regarding towingshouldbe obeyed.
A mnrrt.tc
SAFEW CHAINSSHOULDBE USEDFORALL
TOWINGOPERATIONS.
* Notice
Proper towingequipmentshouldbe used to avoid WheelDollies
possible damageto the vehicleduringtowing
operaton.
Priorto towing,makesurethat steeringsystem, KIA-i53-q|.2+S
transmission,and rearaxleare in goodcondition.lf any
unitis damaged,usea towingdolly. * uotice
. Removethe rear drive shaft if it is necessaryto
exceed28 mph and/or 50 miles.lf the dive
shaftcannot be removed,stopevery 50 miles
Towing With RearWheelsOff the and staft the engine.Allow the engineto idle
for a few minutesto ensurethe Transmissionis
Ground sufficiently Iubricated.
Whenbeingtowedby a commercial towtruck,ihe rear . Do not tow the vehiclefromhook looos. Hook
of the Sportageshouldalwaysbe lifted,notthefront. loopsare designedonty lor transporttiedown.
S Notice lf hookloops are used for towing,vehiclebody
Both the transmissionshift lever and the transfer will be damaged.
case shift lever must be in "NEUTRAL."Failurc to Tie DownHook-Front
do so may cause internaldamageto the
transmission.
'I. Setthe ignitionswitch the 'ACC' position.
to
2. Placethe shiftleverin "NEUTRAL."
3. Shiftthe transfercaseleverlo N (neutral).
4. Releasethe parkingbrake.

Kta-r 69@26\S

lie Down Hook-Rear

xl -163{-22-5

TowingWithTowingDollies
lf the steeringsystem,transmission,
or rearaxleis
damaged,usea towingdolly.

xJA-'r630G2?\S
OO-12 GENERALINFORMATION

UNITCONVERSION
TABLE
IIULTIPLY BY TO GET
LENGTH
inch(") 25.4 (mm)
millimeters
foot (ft.) 0.304I meters(m)
yard(yd.) 0 . 9 1 44 meters
mrle 1.609 kilometeF(km)
AREA
inch2(in2) 645.2 millimelers2
(mm2)
6.45 centimetec2(cm2)
toot2 (ft2) 0.092I metersz(m2)
yad2 (yd2l 0.8361 meters2(m2)
VOLUME
inch3(in3) 16387
I o.Jo/
mm3
cm3
0 . 0 1 64 titers(t)
quart(qt.) 0.946 4 ,1
liters
gallon(gal.) 3.7854 liters
yard3(yd3) 0.764 6 mglss5s (rn3)
WEIGHT
pound(lb.) 0.4536 kilograms(kg)
IOn 907.18 kilograms
lon 0.907 tonne(t)
FORCE
kilogram 9.807 newtons(n)
ounce (oz.) 0.2780 newtons
pound 4.448 newtons
ANGLE
oegree 0.0175 radians(red)
BALANCE
ounce-inch 720.0778 (mg.m)
milligram-meter
ACCELERATION
l6syssgend2 (tusg62) 0.304I meter/second2(rnls2)
inch/second2 (in/sec2) o.o254 meter/second2
TOROUE
pound-inch(lb-in) 0 . 1 1 29 8 neMon-meters
(N.m)
pound{oot (lb-fi) 1 . 3 5 5I neMon-meters
POWER
(hp)
horsepower o.746 kilowatrs(kw)
PRESSURE OB STRESS
inchesof mercury 3.377 (kPa)
kilopascals
inchesof water o2491 kilopascals
pounds/squareinch(psi) 6.895 kilopascals
ENERGYOR WORK
Blu 1055 joutes(J)
poundjool(lb-ft) 1 . 3 5 58 joutes
kilowatt-hout 3.6x 106 joules(J=oneW.s)
LIGHT
footcandle 10.7U (lm/m2)
lumensi/mete12
FUELPERFORMANCE
(mpg)
miles/gallon 0.4251 kilometers/liter
(km/l)
gallons/mile 2.3527 litervkilometer
(l/km)
VELOCITY
(mph)
miles/hour 1.6093 (km/h)
kilometers
TEMPERATURE
"F-32 'c
5/9
"c 9/5 (+32) "F
 GENERALINFORMATION
00.13

COMMONAUTOMOTIVE
ABBREVIATIONS
ABDC Atter bottomdeadcenter tAc ldleair control
ABS Antilockbrakesystem LH Lett hand
Air conditioner M Motor
ACC Accessories MA Maximumadvance
ATDC After toD dead center MIL Malfunctionindicalor lioht
ATF Automatictransaxlefluid M/S Manualsteering
BAC Bypassair control MIT Manualtransmission
BBDC Beforebottomdeadcenter otD Overdrive
BTDC Beforetoo dead center OFF Switch oft
CPU Centralprocessing
unit ON Switchon
DOHC Dual overhead camshatt PCV Posilivecrankcase ventilation
DRL Daytimerunninglights P/S Powersteering
Electronically-controlled
auiomatictransaxle PRC Pressureregulatorcontrol
ECM Enginecontrolmodule Power window
UL Electricalload RH Right hand
EX Exhaust SOHC Singleoverheadcamshatt
FA Fixed advance -Dl Specialservice tool
GND Ground ST Start
HLA Hydrauliclash adjuster SW Swilch
IGN lgnition TDC Top dead center
IN Intake TNS Tailnumberside
INT Intermitteni
00.14 GENERALINFORMATION

ELECTRICAL Voitmeter
TROUBLESHOOTING
TOOLS
TESTLIGHT
Thetest light,as shownin the figure,usesa l2V bulb.
Thehvo leadwiresshouldbe connectedto orobes.
Thetest lightis usedfor simplevoltagechecksandfor
checkingfor shortcircuits.
* Notice
Whencheckingthe control unit, never usea bulb
over 3.4W; to do so may cause damageto the unit.

'1.4W
or 3.4W '16r'oca0s
oHMMETER :r
Theohmmeteris usedto measurethe resistance
betweentwo pointsin a circuitto checktor conlinuity,
andin diagnosisof shortcircuits.
* Notice
Do not attempt to connectthe ohmmeterto any
circuit to which voltageis applied; thismay bum
otherwisedamagethe ohmmeter-

JUMPER
WIRE
Thejumperwire is usedfor testingby shortingacross
switchterminalsandgroundconnections.
{ Notice
Do not connecta jumper wire from the power
source line to a body ground: this may cause
burning or other damageto the harnessesor the
electronic comDone nts.
KI -t63ao3ts

ELECTRICAL
PARTS
BATTERY
CABLE
Beforedisconnectingconnectors or replacingelectrical
parts,disconnect
the negative(-) batteryterminal.

VOLTMETER
The DC voltmeteris usedto measurecircuitvoltaqe.A
voltmeterwitha rangeof 15Vor moreis usedbv
connecting the positive(+) probeto the pointwhere
voltageis to be measuredand the negative(-) probeto
a bodyground. KtA-r6+0S32-s
 GENERALINFORMATION
OO-15

CONNECTORS Inspectaon
Removal Whena testeris beingusedto checkfor continuity
or to
measurevoltage,insertthe testerprobefromthe wire
* t'totice hamessside.
Neverpull on the wiring hamesswhen
disconnecting connectors.

K|A-rClOo!6-S

Checkthe terminalsof waterproof

connectors
fromthe
connectorside,becausetheycannotbe accessedfrom
the wire hamessside.
Connectorscan be removedby pressingor pullingthe

-ffi
lockleveras shown.

M
& xta-i63{G34€

Locking
$ Notice
Whenlockingconnectors,makesureto listenfor a click Attach a smallgauge wire (straightenedpaper clip)
whichindicates
thattheyare securelylocked. to the testerprobeto prevent damageto the
connectorterminal.Do not damagethe terminal
I ClicK when inseftingthe testerlead.

TERMINALS
lnspection
Pulllightlyon individual
wiresto checkthattheyare
securedin the terminal.

xra-l6:r-@36\s
00.16 GENERALINFORMATION

SENSORS,SWITCHES,
AND RELAYS
* Notice
Handle sensors,switchesand relayscarefully.Do
not drop them or strikethem againstother pafts.

Replacement
Usethe appropriate toolsto removethe terminalas
snown.
Wheninstallingthe terminal,be sureto insertit untilit
lockssecurely.
Female xta-t6i{on€

Inserta thin pieceof metaltromthe terminalsideol the WIRINGHARNESS

connec{or, and withtheterminallockingtab pressed
down,pullthe terminaloutlrom the connector.
WiringColorCodes
Twocolorwiresare indicatedby hvocolorcode
symbols.The firstcodesymbolindicates the basecolor
of thewire.The secondindicatesthe colorof the strioe
on the basecolor.
Code Color Code Colol
BLK Black ORG Orange
BRN Brown PNK Pink
GRN Green RED Bed
GRY Gray vto Molet
BLU Blue WHT White
LT BLU Light Blue YEL Yellow
LTGRN LightGreen

Kta.l6:'-0G3e\S

Male
BLI(RED BRN/YEL
Inserta thin pieceof metalfromthe terminalsideot the
connector, and withthe terminallockingtabpressed
down,pullthe lerminaloutfromthe connector.

xta-r6!t{G.it€

xla-tiloo-aos