Kia Sportage 1998-02

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the transmission fluid.
  10.  
  11. Remove or disconnect the following:

    Both battery cables
     
    Windshield washer hose from the hood
     
    Hood
     
    2 air duct mounting bolts from the top of the radiator. Loosen the clamp at the air intake housing and remove the duct
     
    Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley
     
    Transmission control cable
     
    Resonance chamber mounting bolt, chamber bolt and air silencer
     
    Idle Air Control (IAC) air hose, breather hose and vacuum line from the air intake tube
     
    Manifold Air Flow (MAF) sensor connector
     
    Loosen the air inlet hose clamp from the MAF sensor
     
    3 bolts from the air intake tube to the throttle body
     
    Air intake hose and tube as an assembly
     
    Upper radiator hose
     
    Clutch fan nuts
     
    Cooling fan shroud bolts
     
    Fan and shroud at the same time
     
    Alternator drive belt
     
    Fan pulley
     
    Alternator electrical connectors
     
    Exhaust Gas Recirculation (EGR) solenoid valve connector on the intake manifold in front of the dynamic chamber
     
    Both heater hoses from the pipes
     
    Engine-to-body ground wire from the intake manifold and the harness bracket
     
    Brake booster vacuum hose from the dynamic chamber
     
    Fuel lines and fuel pressure regulator from the rear of the dynamic chamber
     
    Vacuum hose from the bottom of the EGR valve
     
    Purge solenoid valve vacuum hose from dynamic chamber
     
    Vacuum hoses from the top of the charcoal canister and slide the charcoal canister up and out of the bracket
     
    Lower radiator hose
     
    Cooling lines from the radiator, if equipped with an automatic transmission
     
    Radiator and raise and safely support the vehicle
     
    Lower splash panel
     
    Drive belt
     
    A/C pulley assembly
     
    A/C compressor mounting bolts and move the A/C compressor out of the way
     
    Power steering drive belt
     
    Intake manifold support bracket
     
    Starter wiring harness
     
    Starter
     
    Front exhaust pipe from the exhaust manifold
     
    Bracket bolt from the front exhaust pipe
     
    Exhaust-to-clutch (manual transmission) or converter (automatic transmission) housing bolts and the bracket
     
    Clutch housing (manual transmission) or converter (automatic transmission) housing bolts.
     
    Drive plate-to-torque converter bolts, if equipped
     

  12.  
  13. Support the transmission from underneath the vehicle.
  14.  
  15. Connect the engine hoist to the engine assembly.

    Left and right side engine mounting bolts
     

  16.  
  17. Lift the engine up and forward slightly to provide access to three electrical connectors on the rear of the cylinder head.

    Electrical connectors from the Camshaft Position (CMP) sensor, coil and condenser on the rear of the cylinder head
     
    Engine from the vehicle
     

  18.  

To install:



Click image to see an enlarged view

Fig. Exploded view of some peripheral engine component mountings

  1. Lower the engine enough to connect the three electrical connectors to the CMP sensor, coil and condenser on the rear of the cylinder head.
  2.  
  3. Position the engine to the transmission. Install the transmission bolts and tighten the bolts. Torque according to bolt size:

    14mm bolts to 80 ft. lbs. (108 Nm)
     
    10mm bolts to 28 ft. lbs. (38 Nm)
     
    6mm bolts to 60 inch lbs. (7 Nm)
     
    Right and left side engine mounting bolts. Torque the bolt s to 38 ft. lbs. (52 Nm).
     

  4.  
  5. Disconnect the engine hoist from the engine assembly.
  6.  
  7. Raise and safely support the vehicle.

    Drive plate-to-torque converter bolts, if equipped.
     
    Connect the front exhaust pipe to the exhaust manifold. Torque the flange bolts to 24 ft. lbs. (31 Nm).
     
    Front exhaust pipe. Torque the bolts to 20 ft. lbs. (27 Nm).
     
    Starter
     
    Connect the starter wiring harness
     
    Intake manifold support bracket bolts and the bracket.
     

  8.  
  9. Install the power steering pump lock and mounting bolts. Install the power steering drive belt. Torque the bolts to 30 ft. lbs. (42 Nm).

    A/C compressor mounting bolts. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    A/C belt pulley assembly and drive belt. Install the two A/C idler pulley bracket bolts and torque to 24 ft. lbs. (32 Nm).
     
    Lower splash panel
     
    Radiator
     
    Cooling lines to the radiator, if equipped
     
    Lower radiator hose
     
    Slide the charcoal canister in the bracket
     
    Vacuum hoses to the top of the charcoal canister
     
    Engine-to-body ground wire to the intake manifold and the harness bracket
     
    Brake booster vacuum hose to the dynamic chamber
     
    Fuel lines and fuel pressure regulator to the rear of the dynamic chamber
     
    Vacuum hose to the bottom of the EGR valve
     
    Purge solenoid valve vacuum hose to dynamic chamber
     
    EGR solenoid valve connector on the intake manifold in front of the dynamic chamber
     
    Heater hoses
     
    Electrical terminal connectors to the alternator
     
    Fan pulley
     
    Alternator drive belt. Torque the adjusting bolt 16 ft. lbs. (22 Nm) and the mounting bolt to 32 ft. lbs. (45 Nm).
     
    Fan and shroud as an assembly. Torque the five cooling fan shroud bolts to 72 inch lbs. (8 Nm)
     
    Clutch fan nuts. Torque the nuts to 27 ft. lbs. (37 Nm).
     
    Upper radiator hose
     
    Air intake hose and tube as an assembly
     
    Air intake tube to the throttle body and tighten the air inlet hose clamp to the MAF sensor
     
    MAF sensor electrical connector
     
    Resonance chamber mounting bolt, chamber bolt and air silencer
     
    IAC air hose, breather hose and vacuum line to the air intake tube
     
    Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley
     
    Transmission control cable
     
    Air duct mounting bolts to the top of the radiator. Torque the clamp at the air intake housing
     
    Hood
     
    Windshield washer hose to the hood
     

  10.  
  11. Fill the engine with clean engine oil.
  12.  
  13. Connect the battery cables.
  14.  
  15. Fill the cooling system.
  16.  
  17. Fill the transmission fluid.
  18.  
  19. Recharge the A/C system.
  20.  
  21. Start the vehicle. Check for leaks, repair if necessary.
  22.  
  23. Road test the vehicle to check engine performance.
  24.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section .
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the transmission fluid.
  10.  
  11. Remove or disconnect the following:

    Both battery cables
     
    Windshield washer hose from the hood
     
    Hood
     
    2 air duct mounting bolts from the top of the radiator. Loosen the clamp at the air intake housing and remove the duct
     
    Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley
     
    Transmission control cable
     
    Resonance chamber mounting bolt, chamber bolt and air silencer
     
    Idle Air Control (IAC) air hose, breather hose and vacuum line from the air intake tube
     
    Manifold Air Flow (MAF) sensor connector
     
    Loosen the air inlet hose clamp from the MAF sensor
     
    3 bolts from the air intake tube to the throttle body
     
    Air intake hose and tube as an assembly
     
    Upper radiator hose
     
    Clutch fan nuts
     
    Cooling fan shroud bolts
     
    Fan and shroud at the same time
     
    Alternator drive belt
     
    Fan pulley
     
    Alternator electrical connectors
     
    Exhaust Gas Recirculation (EGR) solenoid valve connector on the intake manifold in front of the dynamic chamber
     
    Both heater hoses from the pipes
     
    Engine-to-body ground wire from the intake manifold and the harness bracket
     
    Brake booster vacuum hose from the dynamic chamber
     
    Fuel lines and fuel pressure regulator from the rear of the dynamic chamber
     
    Vacuum hose from the bottom of the EGR valve
     
    Purge solenoid valve vacuum hose from dynamic chamber
     
    Vacuum hoses from the top of the charcoal canister and slide the charcoal canister up and out of the bracket
     
    Lower radiator hose
     
    Cooling lines from the radiator, if equipped with an automatic transmission
     
    Radiator and raise and safely support the vehicle
     
    Lower splash panel
     
    Drive belt
     
    A/C pulley assembly
     
    A/C compressor mounting bolts and move the A/C compressor out of the way
     
    Power steering drive belt
     
    Intake manifold support bracket
     
    Starter wiring harness
     
    Starter
     
    Front exhaust pipe from the exhaust manifold
     
    Bracket bolt from the front exhaust pipe
     
    Exhaust-to-clutch (manual transmission) or converter (automatic transmission) housing bolts and the bracket
     
    Clutch housing (manual transmission) or converter (automatic transmission) housing bolts.
     
    Drive plate-to-torque converter bolts, if equipped
     

  12.  
  13. Support the transmission from underneath the vehicle.
  14.  
  15. Connect the engine hoist to the engine assembly.

    Left and right side engine mounting bolts
     

  16.  
  17. Lift the engine up and forward slightly to provide access to three electrical connectors on the rear of the cylinder head.

    Electrical connectors from the Camshaft Position (CMP) sensor, coil and condenser on the rear of the cylinder head
     
    Engine from the vehicle
     

  18.  

To install:

Click image to see an enlarged view

Fig. Exploded view of some peripheral engine component mountings

  1. Lower the engine enough to connect the three electrical connectors to the CMP sensor, coil and condenser on the rear of the cylinder head.
  2.  
  3. Position the engine to the transmission. Install the transmission bolts and tighten the bolts. Torque according to bolt size:

    14mm bolts to 80 ft. lbs. (108 Nm)
     
    10mm bolts to 28 ft. lbs. (38 Nm)
     
    6mm bolts to 60 inch lbs. (7 Nm)
     
    Right and left side engine mounting bolts. Torque the bolt s to 38 ft. lbs. (52 Nm).
     

  4.  
  5. Disconnect the engine hoist from the engine assembly.
  6.  
  7. Raise and safely support the vehicle.

    Drive plate-to-torque converter bolts, if equipped.
     
    Connect the front exhaust pipe to the exhaust manifold. Torque the flange bolts to 24 ft. lbs. (31 Nm).
     
    Front exhaust pipe. Torque the bolts to 20 ft. lbs. (27 Nm).
     
    Starter
     
    Connect the starter wiring harness
     
    Intake manifold support bracket bolts and the bracket.
     

  8.  
  9. Install the power steering pump lock and mounting bolts. Install the power steering drive belt. Torque the bolts to 30 ft. lbs. (42 Nm).

    A/C compressor mounting bolts. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    A/C belt pulley assembly and drive belt. Install the two A/C idler pulley bracket bolts and torque to 24 ft. lbs. (32 Nm).
     
    Lower splash panel
     
    Radiator
     
    Cooling lines to the radiator, if equipped
     
    Lower radiator hose
     
    Slide the charcoal canister in the bracket
     
    Vacuum hoses to the top of the charcoal canister
     
    Engine-to-body ground wire to the intake manifold and the harness bracket
     
    Brake booster vacuum hose to the dynamic chamber
     
    Fuel lines and fuel pressure regulator to the rear of the dynamic chamber
     
    Vacuum hose to the bottom of the EGR valve
     
    Purge solenoid valve vacuum hose to dynamic chamber
     
    EGR solenoid valve connector on the intake manifold in front of the dynamic chamber
     
    Heater hoses
     
    Electrical terminal connectors to the alternator
     
    Fan pulley
     
    Alternator drive belt. Torque the adjusting bolt 16 ft. lbs. (22 Nm) and the mounting bolt to 32 ft. lbs. (45 Nm).
     
    Fan and shroud as an assembly. Torque the five cooling fan shroud bolts to 72 inch lbs. (8 Nm)
     
    Clutch fan nuts. Torque the nuts to 27 ft. lbs. (37 Nm).
     
    Upper radiator hose
     
    Air intake hose and tube as an assembly
     
    Air intake tube to the throttle body and tighten the air inlet hose clamp to the MAF sensor
     
    MAF sensor electrical connector
     
    Resonance chamber mounting bolt, chamber bolt and air silencer
     
    IAC air hose, breather hose and vacuum line to the air intake tube
     
    Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley
     
    Transmission control cable
     
    Air duct mounting bolts to the top of the radiator. Torque the clamp at the air intake housing
     
    Hood
     
    Windshield washer hose to the hood
     

  10.  
  11. Fill the engine with clean engine oil.
  12.  
  13. Connect the battery cables.
  14.  
  15. Fill the cooling system.
  16.  
  17. Fill the transmission fluid.
  18.  
  19. Recharge the A/C system.
  20.  
  21. Start the vehicle. Check for leaks, repair if necessary.
  22.  
  23. Road test the vehicle to check engine performance.
  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.

    Drain the cooling system.
     
    Drain the engine oil.
     
    Drain the transmission fluid.
     

  4.  
  5. Remove or disconnect the following:

    Both battery cables
     
    Windshield washer hose from the hood
     
    Hood
     
    2 air duct mounting bolts from the top of the radiator. Loosen the clamp at the air intake housing and remove the duct
     
    Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley
     
    Transmission control cable
     
    Resonance chamber mounting bolt, chamber bolt and air silencer
     
    Idle Air Control (IAC) air hose, breather hose and vacuum line from the air intake tube
     
    Manifold Air Flow (MAF) sensor connector
     
    Loosen the air inlet hose clamp from the MAF sensor
     
    3 bolts from the air intake tube to the throttle body
     
    Air intake hose and tube as an assembly
     
    Upper radiator hose
     
    Clutch fan nuts
     
    Cooling fan shroud bolts
     
    Fan and shroud at the same time
     
    Alternator drive belt
     
    Fan pulley
     
    Alternator electrical connectors
     
    Exhaust Gas Recirculation (EGR) solenoid valve connector on the intake manifold in front of the dynamic chamber
     
    Both heater hoses from the pipes
     
    Engine-to-body ground wire from the intake manifold and the harness bracket
     
    Brake booster vacuum hose from the dynamic chamber
     
    Fuel lines and fuel pressure regulator from the rear of the dynamic chamber
     
    Vacuum hose from the bottom of the EGR valve
     
    Purge solenoid valve vacuum hose from dynamic chamber
     
    Vacuum hoses from the top of the charcoal canister and slide the charcoal canister up and out of the bracket
     
    Lower radiator hose
     
    Cooling lines from the radiator, if equipped with an automatic transmission
     
    Radiator and raise and safely support the vehicle
     
    Lower splash panel
     
    Drive belt
     
    A/C pulley assembly
     
    A/C compressor mounting bolts and move the A/C compressor out of the way
     
    Power steering drive belt
     
    Intake manifold support bracket
     
    Starter wiring harness
     
    Starter
     
    Front exhaust pipe from the exhaust manifold
     
    Bracket bolt from the front exhaust pipe
     
    Exhaust-to-clutch (manual transmission) or converter (automatic transmission) housing bolts and the bracket
     
    Clutch housing (manual transmission) or converter (automatic transmission) housing bolts.
     
    Drive plate-to-torque converter bolts, if equipped
     

  6.  
  7. Support the transmission from underneath the vehicle.
  8.  
  9. Connect the engine hoist to the engine assembly.

    Left and right side engine mounting bolts
     

  10.  
  11. Lift the engine up and forward slightly to provide access to three electrical connectors on the rear of the cylinder head.

    Electrical connectors from the Camshaft Position (CMP) sensor, coil and condenser on the rear of the cylinder head
     
    Engine from the vehicle
     

  12.  

To install:

Click image to see an enlarged view

Fig. Exploded view of some peripheral engine component mountings

  1. Lower the engine enough to connect the three electrical connectors to the CMP sensor, coil and condenser on the rear of the cylinder head.
  2.  
  3. Position the engine to the transmission. Install the transmission bolts and tighten the bolts. Torque according to bolt size:

    14mm bolts to 80 ft. lbs. (108 Nm)
     
    10mm bolts to 28 ft. lbs. (38 Nm)
     
    6mm bolts to 60 inch lbs. (7 Nm)
     
    Right and left side engine mounting bolts. Torque the bolt s to 38 ft. lbs. (52 Nm)
     

  4.  
  5. Disconnect the engine hoist from the engine assembly.
  6.  
  7. Raise and safely support the vehicle.

    Drive plate-to-torque converter bolts, if equipped.
     
    Connect the front exhaust pipe to the exhaust manifold. Torque the flange bolts to 24 ft. lbs. (31 Nm)
     
    Front exhaust pipe. Torque the bolts to 20 ft. lbs. (27 Nm)
     
    Starter
     
    Connect the starter wiring harness
     
    Intake manifold support bracket bolts and the bracket.
     

  8.  
  9. Install the power steering pump lock and mounting bolts. Install the power steering drive belt. Torque the bolts to 30 ft. lbs. (42 Nm).

    A/C compressor mounting bolts. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    A/C belt pulley assembly and drive belt. Install the two A/C idler pulley bracket bolts and torque to 24 ft. lbs. (32 Nm)
     
    Lower splash panel
     
    Radiator
     
    Cooling lines to the radiator, if equipped
     
    Lower radiator hose
     
    Slide the charcoal canister in the bracket
     
    Vacuum hoses to the top of the charcoal canister
     
    Engine-to-body ground wire to the intake manifold and the harness bracket
     
    Brake booster vacuum hose to the dynamic chamber
     
    Fuel lines and fuel pressure regulator to the rear of the dynamic chamber
     
    Vacuum hose to the bottom of the EGR valve
     
    Purge solenoid valve vacuum hose to dynamic chamber
     
    EGR solenoid valve connector on the intake manifold in front of the dynamic chamber
     
    Heater hoses
     
    Electrical terminal connectors to the alternator
     
    Fan pulley
     
    Alternator drive belt. Torque the adjusting bolt 16 ft. lbs. (22 Nm) and the mounting bolt to 32 ft. lbs. (45 Nm)
     
    Fan and shroud as an assembly. Torque the five cooling fan shroud bolts to 72 inch lbs. (8 Nm)
     
    Clutch fan nuts. Torque the nuts to 27 ft. lbs. (37 Nm)
     
    Upper radiator hose
     
    Air intake hose and tube as an assembly
     
    Air intake tube to the throttle body and tighten the air inlet hose clamp to the MAF sensor
     
    MAF sensor electrical connector
     
    Resonance chamber mounting bolt, chamber bolt and air silencer
     
    IAC air hose, breather hose and vacuum line to the air intake tube
     
    Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley
     
    Transmission control cable
     
    Air duct mounting bolts to the top of the radiator. Torque the clamp at the air intake housing
     
    Hood
     
    Windshield washer hose to the hood
     

  10.  
  11. Fill the engine with clean engine oil.
  12.  
  13. Connect the battery cables.
  14.  
  15. Fill the cooling system.
  16.  
  17. Fill the transmission fluid.
  18.  
  19. Recharge the A/C system.
  20.  
  21. Start the vehicle. Check for leaks, repair if necessary.
  22.  
  23. Road test the vehicle to check engine performance.
  24.  

 
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