Kia Sportage 2005-06

Engine

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Removal & Installation



2.0L Engine


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Fig. Engine mounting details - 2.0L engine


WARNING
Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Mark all wiring and hoses to avoid misconnection.

  2.  
  3. Remove the air duct.
  4.  
  5. Disconnect the battery terminals and remove the battery.
  6.  
  7. Remove the engine cover.
  8.  
  9. Drain the engine coolant. Remove the radiator cap to speed draining.
  10.  
  11. Remove the intake air hose and air cleaner assembly.
  12.  
  13. Remove the upper radiator hose and lower radiator hose.
  14.  
  15. Remove the heater hose.
  16.  
  17. Remove the accelerator cable.
  18.  
  19. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
  20.  
  21. Disconnect the fuel inlet hose of the delivery pipe side.
  22.  
  23. Disconnect the hose of the PCSV (Purge Control Solenoid Valve) side.
  24.  
  25. Remove the brake booster vacuum hose.
  26.  
  27. Remove the power steering oil hose from the power steering pump.
  28.  
  29. Remove the power steering lower oil hose.
  30.  
  31. Remove the battery tray bracket.
  32.  
  33. Remove the transaxle wire harness connectors and control cable from transaxle (A/T).
  34.  
  35. Remove the transaxle oil cooler hose (AT).
  36.  
  37. Remove the under cover.
  38.  
  39. Remove the front exhaust pipe.
  40.  
  41. Disconnect the ABS wheel speed sensor from both front knuckles.
  42.  
  43. Remove the front strut lower mounting bolts and nuts.
  44.  
  45. Remove the caliper and hang the caliper assembly.
  46.  
  47. Remove the steering u-joint mounting bolt.
  48.  
  49. Install the jack for supporting engine and transaxle assembly.
  50.  
  51. Remove the engine mounting bracket.
  52.  
  53. Remove the transaxle mounting bracket.
  54.  
  55. Remove the sub frame mounting bolts and nuts.
  56.  
  57. Remove the engine and transaxle assembly by lifting vehicle.
    WARNING
    When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

  58.  
  59. Installation is in the reverse order of removal. Perform the following:

    Adjust the shift cable.
     
    Adjust the throttle cable.
     
    Refill the engine with engine oil.
     
    Refill the transaxle with fluid.
     
    Refill the radiator and reservoir tank with engine coolant.
     
    Place the heater control knob on "HOT" position.
     
    Start engine and let it run until it warms up. (the radiator fan operates 3 or 4 times.)
     
    Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
     
    Put the radiator cap on tightly, then run the engine again and check for leaks.
     
    Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
     
    Inspect for fuel leakage. After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
     

  60.  

2.7L Engine

WARNING
Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. 

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

  2.  
  3. Remove the air duct.
  4.  
  5. Disconnect the negative terminal from the battery.
  6.  
  7. Drain the engine coolant. Remove the radiator cap to speed draining.
  8.  
  9. Remove the engine cover.
  10.  
  11. Remove the intake air hose and air cleaner assembly.
  12.  
  13. Disconnect the AFS connector. 
  14.  
  15. Disconnect the breather hose from air cleaner hose. 
  16.  
  17. Remove the intake air hose and air cleaner assembly. 
  18.  
  19. Remove the upper radiator hose and lower radiator hose.
  20.  
  21. Remove the heater hoses.
  22.  
  23. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
  24.  
  25. Disconnect front heated oxygen sensor (LH) connector, air pressure switch connector and oil pressure sensor connector.
  26.  
  27. Remove the fuel inlet from delivery pipe.
  28.  
  29. Remove the brake booster vacuum hose.
  30.  
  31. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.
  32.  
  33. Remove the power steering pump hose.
  34.  
  35. Remove the battery body bracket.
  36.  
  37. Disconnect the transaxle wire harness connector.
  38.  
  39. Remove the control cable transaxle range switch.
  40.  
  41. Remove the transaxle oil cooler hoses (A/T).
  42.  
  43. Remove the under cover.
  44.  
  45. Remove the front exhaust pipe.
  46.  
  47. Disconnect the ABS wheel speed sensor from both front knuckles. 
  48.  
  49. Remove the front strut lower mounting bolts and nuts.
  50.  
  51. Remove the caliper and hang the caliper assembly.
  52.  
  53. Remove the steering u-joint mounting bolt. 
  54.  
  55. Install the jack for supporting engine and transaxle assembly.
  56.  
  57. Remove the engine mounting bracket.

    Click image to see an enlarged view

    Fig. Engine mounting bracket - 2.7L engine

  58.  
  59. Remove the transaxle mounting bracket.

    Click image to see an enlarged view

    Fig. Transaxle mounting bracket - 2.7L engine

  60.  
  61. Remove the sub frame mounting bolts and nuts.

    Click image to see an enlarged view

    Fig. Subframe fasteners, part 1. -B- torque is 52-66 ft. lbs. (70-90 Nm) - 2.7L engine



    Click image to see an enlarged view

    Fig. Subframe fasteners, part 2. -A- torque is 118-133 ft. lbs. (160-180 Nm) - 2.7L engine



    Click image to see an enlarged view

    Fig. Subframe fasteners, part 3. -A- torque is 118-133 ft. lbs. (160-180 Nm) - 2.7L engine

  62.  
  63. Raise and safely support the vehicle.
  64.  
  65. Installation is in the reverse order of removal.  Perform the following:

    Adjust the shift cable. 
     
    Adjust the throttle cable. 
     
    Refill the engine with engine oil. 
     
    Refill the transaxle with fluid. 
     
    Refill the radiator with engine coolant. 
     
    Bleed air from the cooling system with the heater valve open. 
     
    Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion. 
     
    Inspect for fuel leakage. After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line. 
     

  66.  

 
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