Motor Kia Sportage

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2002 ENGINES

2.0L 4-Cylinder - Sportage

ENGINE IDENTIFICATION

Engine can be identified by the eighth character of the Vehicle Identification Number (VIN)stamped on metal plate located on left side of dash panel. The VIN is also stamped intopassenger side of engine compartment bulkhead.

ENGINE IDENTIFICATION CODE

ADJST!ENTS

VALVE CLEARANCE ADJUSTMENT

This engine is equipped with hydraulic lash adusters. No adustment is required.

T"O#LE S$OOTING

To trouble shoot engine mechanical components! see appropriate table in T"#$%&E'##TIN article in ENE"*& IN+#",*TI#N.

"E!O%AL & INSTALLATION

FUEL PRESSURE RELEASE

To release fuel pressure! remo-e rear seat cushion and fuel pump access plate. isconnect fuepump connector. 'ee Fig. 1. 'tart and run engine until it stalls. Turn ignition off. #nce repairha-e been completed! reconnect fuel pump connector and install access plate and rear seatcushion.

NOTE' For repair pro(ed)re* not (o+ered in t,i* arti(le *ee ENGINEO%E"$AL "OCED"ES arti(le in GENE"AL INFO"!ATION.

Application Cod/.0& #1 2

NOTE' For rea**e/ly re1eren(e lael all ele(tri(al (onne(tor* +a())/,o*e* and 1)el line* e1ore re/o+al. Al*o pla(e /ating /ar* onengine ,ood and ot,er /a3or a**e/lie* e1ore re/o+al.

2002 ia Sportage

2002 ENGINES 2.0L 4-Cylinder - Sportage

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Fig. 1: Locating Fuel Pump Electrical ConnectorCourtesy of KIA MOTO! AMEICA" I#C.

E#$I#E

emo%al & Installation

1. Release fuel pressure. See F'EL PE!!'E ELEA!E. Remove windshield washefrom hood. Remove hood. Disconnect battery cables. Remove battery cover, battery andbattery tray. Remove air inlet duct and air cleaner assembly. On A/T models, removeaccelerator cable and transmission control cable.

. On all models, pull bac! throttle shaft, and disconnect accelerator cable. Removeresonance chamber mountin" bolt, chamber bolt and air silencer. Remove #A$ air hose,breather hose and vacuum line from air inta!e tube.

%. Disconnect &A' sensor connector. (oosen air inlet hose clamp from &A' sensor.Remove % bolts from air inta!e tube to throttle body. Remove air inta!e hose and airinta!e tube as an assembly.

). Remove radiator cap. (oosen radiator drain plu", and drain en"ine coolant. Ti"hten

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radiator drain plug. Loosen and remove upper radiator hose clamps, and remove upperradiator hose. Remove 4 thermo-modulated fan nuts.

5. Remove 5 cooling fan shroud bolts. Remove fan and fan shroud as an assembly. Loosengenerator mounting bolts. Loosen generator drive belt by loosening adjusting bolt.

6. Remove fan pulley. Remove generator electrical connectors. Remove heater hoses frompipes.

7. Label and disconnect all necessary electrical connectors, ires, hoses and control cablesfor engine removal. !lug all fuel hoses to avoid lea"age. Remove radiator.

#. Raise and support vehicle. Remove undercover mounting bolts and undercover. Loosen$%& idler pulley loc" nut, and remove $%& drive belt by loosening adjusting bolt. Remo$%& idler pulley brac"et mounting bolts and $%& idler pulley brac"et.

'. Remove $%& compressor mounting bolts and $%& compressor. !osition $%& compressoraay from engine. Loosen poer steering pump loc" bolt and mounting bolt, and removpoer steering drive belt. Remove poer steering pump loc" bolt and mounting bolt.!osition poer steering pump aay from engine.

(). Remove inta"e manifold support brac"et bolts and brac"et. Remove starter bolts. *nbolstarter, and ire aside so there is no tension on ire harness. Remove converter inlet pipflange loc" nuts.

((. Remove front e+haust brac"et bolt. n % models, remove e+haust brac"et-to-clutchhousing mounting bolts and brac"et. n $% models, remove converter housing mountinbolts and brac"et. n % models, remove clutch housing-to-engine mounting bolts. n$% models, remove converter housing-to-engine mounting bolts.

(/. n all models, loer vehicle. n $% models, remove 6 drive plate-to-tor0ue converterbolts. n all models, support transmission, and connect engine hoist to engine. Removeleft side and right side engine mounting bolts.

(1. Lift engine up until free of frame, and move forard to clear transmission. 2isconnect 1remaining electrical connectors at bac" of engine. &hec" for any other electrical iringstill connected to engine assembly and disconnect, if necessary. 3nsure engine is free ofany other components. Remove engine from vehicle.

Installation

o install, reverse removal procedure. ighten all bolts%nuts to specification. ee TORQUESPECIFICATIONS. &hec" fluid levels, and fill as necessary.

INTAKE MANIFOLD

Removal

(. Release fuel system pressure. ee FUEL PRESSURE RELEASE. 2isconnect negativ

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!attery ca!le. *e&oe 2 accelerator ca!le !racket-to-cylinder )ead coer !olts. *e&oeair intake t!e-to-cylinder coer !olts. *e&oe air intake t!e-to-t)rottle !ody !olts.Loosen cla&p +ro& air intake )ose to (ass /ir+ow 0(/1 sensor.

2. *e&oe idler control ale )ose" !reat)er )ose and ac& line +ro& air intake t!e.*e&oe air intake t!e and air intake )ose as an asse&!ly. *e&oe PC3 )ose +ro&dyna&ic c)a&!er. *e&oe radiator cap. Loosen radiator drain plg" and drain enginecoolant. ig)ten radiator drain plg.

5. *e&oe prge solenoid ale ac& )ose +ro& dyna&ic c)a&!er. 6isconnect electricconnector +ro& t)rottle position sensor. 6isconnect electrical connection +ro& idle aircontrol ale. *e&oe )eater )oses +ro& pipes. *e&oe engine-to-!ody grond !olt atintake &ani+old asse&!ly. *e&oe )eater )oses +ro& !elow t)rottle !ody.

4. *e&oe !rake !ooster ac& line. *e&oe ac& )ose +ro& +el pressre reglator.*e&oe dyna&ic c)a&!er spport !rackets and !olts. 6isconnect electrical connectors

+ro& +el in7ectors !y ps)ing on wire clips. *elease +el syste& pressre. See FUELPRESSURE RELEASE.

8. 6isconnect +el line +ro& pressre reglator. 6isconnect +el retrn line +ro& +el railasse&!ly. *e&oe intake &ani+old spport !rackets 0side and rear.

9. :sing wrenc)" re&oe oil +ilter. *e&oe !olts and nts +ro& intake &ani+old. *e&oe !pass pipe +ro& )eater )ose. *e&oe intake &ani+old and gasket.

Installation

Clean gasket &ating sr+aces. Install intake &ani+old wit) NE; gasket. Install !y-pass pipe.

Install intake &ani+old !olts and nt" and tig)ten to speci+ication. See Fig. 2. o co&pleteinstallation" reerse re&oal procedre. ig)ten all !olts and nts to speci+ication. SeeTORQUE SPECIFICATIONS.

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Fig. 2: Intake Manifold Mounting Bolt LocationsCourtesy of KIA MOTOR AM!RICA" I#C.

!$%A&T MA#IFOL'

Re(o)al

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Installation

Ensure gasket mating surfaces are clean and flat. Install NEW gasket to cylinder head. Installmanifold. Tighten manifold bolts and nuts evenly to specification, starting from center bolt an

alternating outward. Install NEW gasket, and attach converter inlet pipe. To completeinstallation, reverse removal procedure. See TORQUE SPECIFICATIONS.

CYLINDER HEAD

Removal

. !isconnect negative battery cable. "emove brake booster vacuum hose from dynamicchamber. "emove fuel line from pressure regulator and return line located at rear ofdynamic chamber.

#. "emove engine$to$body ground wire from intake manifold and harness bracket. "emoveradiator cap. "emove radiator drain plug, and drain engine coolant. Tighten radiator plu

%. "emove purge solenoid valve vacuum hose from dynamic chamber. &oosen clamps, anddisconnect upper radiator hose. "emove intake manifold support bracket bolts and brack"emove converter inlet pipe flange lock nuts. "emove timing belt. See TIMING BELT

'. "emove cylinder head cover. "emove cylinder head bolts in se(uence. See Fi! ".!isconnect wire harness connectors on back of cylinder head. &ift cylinder head offcylinder block with intake and e)haust manifolds attached, and remove cylinder headassembly from vehicle.

Ins#e$tion

*arefully clean carbon and gasket material from all mating surfaces. *lean threads of cylindehead bolts. +se tap to clean threads in engine block. *heck cylinder head for warpage andcracks. "esurface or replace head if it is not within specification. *heck valve train componen"eplace or resurface components if not within specification. See CYLINDER HEADand%AL%ES & %AL%E SPRINGStables under ENINE S-E*II*/TI0NS.

Installation

. Install cylinder head gasket. -lace cylinder head with manifolds installed over cylinderblock, and attach % wire harness connectors to back of head. Install cylinder head assemand cylinder head bolts. +sing % e(ual steps, tighten cylinder head bolts in specifiedse(uence. See Fi! '(. See TORQUE SPECIFICATIONS.

#. Install timing belt. See TIMING BELT. Install converter inlet pipe flange lock nuts, antighten to specification. See TORQUE SPECIFICATIONS.

%. Install upper radiator hose, and tighten clamps. ill radiator, and install cap. *onnectvacuum hose from intake manifold to charcoal canister. *onnect purge solenoid vacuum

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hose to dynamic chamber. Install engine$to$body ground wire and harness bracket tointake manifold.

'. Install fuel line to pressure regulator and return line to fuel rail. Install brake boostervacuum hose to dynamic chamber. "econnect battery cable. Tighten bolts and nuts tospecification. See TORQUE SPECIFICATIONS.

Fig. 3: Cylinder Head Bolt Remoal Se!"en#eCo"rte$y o% &IA 'OTORS A'ERICA( INC.

FRONT CRAN&SHAFT SEA)

Remoal

!isconnect negative battery cable. "emove engine undercover. "emove drive belts andcrankshaft pulley. "emove timing belt covers and timing belt. See TI'IN* BE)T. "emovecrankshaft sprocket pulley lock bolt and pulley. If necessary, remove crankshaft sprocket pullusing steering wheel puller. "emove keyway. +sing seal remover, pry oil seal from oil pump

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housing. See Fig. +.

In$tallation

. /pply light coat of oil to lip of seal, and push seal over crankshaft. Tap seal into oil pumbody until it is flush with edge of pump body. !0 N0T bottom seal in pump body. /ligkeyway slots, and install crankshaft sprocket by tapping lightly using brass hammer.

#. Install keyway with tapered side toward oil pump body. Install crankshaft sprocket lockbolt and tighten crankshaft pulley lock bolt to specification. See TORQUESPECIFICATIONS. Install timing belt. See TI'IN* BE)T. Install timing belt covepulleys and drive belts. "econnect negative battery cable. Ensure timing is correct.

Fig. +: Remoing Front Oil SealCo"rte$y o% &IA 'OTORS A'ERICA( INC.

TI'IN* BE)T

Remoal

. !isconnect negative battery cable. "emove air duct mounting bolts at radiator. &oosen a

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dct cla&p at intake *osing. +e&oe *ose ,ro& renosance c*a&!er. +e&oe air inletdct. +e&oe ,an s*rod &onting !olts. +e&oe t*er&o-&odlated nts. +e&oe ,anand ,an s*rod toget*er.

2. Loosen generator &onting !olts. Loosen generator drie !elt ,or& generator !y looseniad/sting !olt" and re&oe drie !elt. +e&oe ,an plley.

0. +e&oe splas* gard &onting !olts and splas* gard. Loosen 1C idler plley nt.+e&oe 1C drie !elt !y loosening ad/sting !olt. Loosen power steering p&p lock !and &onting !olt. +e&oe power steering !elt. +e&oe !olts and pper ti&ing !eltcoer. +e&oe !olts and lower ti&ing !elt coer.

4. Ensre ca&s*a,t sprocket3s and cranks*a,t sprocket ti&ing &arks align. See Fig. 5.Ca&s*a,t sprocket ti&ing &arks are an 5I5 on intake ca&s*a,t sprocket" and an 5E5 one6*ast ca&s*a,t sprocket. See Fig. 6.

7. I, ti&ing !elt is to !e resed" &ark direction o, ti&ing !elt rotation on !elt !e,ore re&o

Loosen ti&ing !elt tensioner lock !olt. )oe tensioner away ,ro& !elt wit* spring ,llye6tended. 8e&porarily tig*ten tensioner lock !olt w*ile tension is released ,ro& ti&ing!elt. +e&oe ti&ing !elt. See Fig. 7.

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-ig. % /ligning Cranks*a,t 0i&ing )arksCo1rtesy o, 2I/ )303+S /)E+IC/" INC.

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Fig. 6: Aligning Camshaft Timing MarksCourtesy of KIA MOTORS AMERICA I!C.

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Fig. 7: Exploded View Timing Belt & Components

Courtesy of KIA !T!"# AE"ICA$ I%C.

Inspetion

Check timing belt for cracks, peeling, abrasion marks or other damage. Check tensioner bearifor looseness or roughness of rotation. Inspect tensioner spring for defects such as warping an

rust. Replace parts as necessary.Inst'll'tion

1. Ensure camshaft and crankshaft timing marks are still aligned. Install belt aroundcrankshaft sprocket. Keep belt pulled tight on tension side of belt, and route belt aroundcamshaft sprocket(s. Ensure camshaft sprockets do not mo!e while installing timing be

". #oosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. . Rotat

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crankshaft clockwise 2 complete revolutions. Ensure timing marks are aligned. If timingmarks are not aligned, remove belt, realign all timing marks, and repeat procedure. Turncrankshaft to align "S" mark of exhaust camshaft pulle with seal plate mating mark. SeFig. 8

!. heck timing belt deflection. heck timing belt deflection with 22 lbs. #$% kg& of pressuapplied to belt. 'eflection should be .!%(.!!" #).*(+. mm&. If timing belt deflection is nwithin specification, repeat steps 2 and ! and-or replace timing belt tensioner spring. Iftiming belt deflection is within specification, reverse removal procedure to completeinstallation.

Fig. 8: Aligning Camshaft "S" Timing MarksCourtesy of KIA MOTORS AMRICA! IC.

#$%RA&'IC 'AS# A%(&STR

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*e&o,al

Disconnect negative battery cable. Remove valve cover. Remove timing belt from camshaftsprockets. See -I(ING EL-. Remove camshaft bearing cap bolts evenly in 2-3 steps. See

/ig. 0. Remove camshafts from cylinder head. Mark all parts for installation reference.Remove Hydraulic ash !d"uster #H!$ from bores in cylinder head. %nspect face of H! fo&ear or damage' replace as necessary. Remove ()( rings. D) *)+ disassemble H!.

Installation

%nstall *, ()( rings. our clean engine oil into bores of cylinder head. !pply clean engineoil to H!. %nstall H! into bores of cylinder head. D) *)+ damage ()( ring oil seal durininstallation. H! should move freely in cylinder head bores. %nstall camshafts to cylinder hea+ighten camshaft cap bolts to specification in se/uence. See /ig. #1. See -2*34ESPECI/IC5-I2NS. +o complete installation' reverse removal procedure.

C5(SH5/-

*e&o,al

Disconnect negative battery cable. Remove 0 bolts and upper timing belt cover. Remove timibelt. See -I(ING EL-. Remove cylinder cover. Remove camshaft pulleys. Removecamshaft sprockets. Remove camshaft cap bolts in se/uence. See /ig. 0. Remove camshaftsfrom cylinder head. Mark all parts for installation reference.

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Fig. 9: Camshaft Bearing Cap Bolt Removal SequenceCourtesy of KIA !"!RS A#RICA$ I%C.

Inspection

Check camshaft for wear or damage, replace if necessary. Check camshaft runout, lobe heighand camshaft oil clearance. Repair or replace as necessary. See CAS&AF"table underENGINE SECI!IC"#I$NS.

Installation

osition camshafts in cylinder head. "pply a liberal amount of clean engine oil to %ournals,bearings and camshaft oil seal. lace camshaft in position with dowel pin facing straight up."pply sealant to both front camshaft cap surfaces and camshaft position sensor mounting caposition camshaft caps according to cap number, with arrows pointing toward front of cylinde

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head. Install camshaft caps. Tighten camshaft cap bolts to specification in 2 or 3 steps insequence. See -ig. #'. See /+1E SPECI-IC2I/NS. To complete installation, reverremoval procedure.

C+2N3SH2- +E2+ /IL SE2L

+e&o4al

Disconnect negative battery cable. Raise and support vehicle. Remove transmission. or !"Tsee appropriate article in #$%T#&'S. or ("T, see (%T)!(TI# TR(*S!ISSI)*R'!)+($ I*ST($$(TI)* article in TR(*S!ISSI)* S'R+I#I*-. !ar all parts fo

installation reference. Remove clutch assembly and fly/heel. Remove rear cover. %sing a searemover, remove oil seal from rear of cylinder bloc.

Installation

To install, lubricate seal lip /ith light coat of engine oil. Tap seal into oil seal holder until it isflush /ith edge of rear cover. #lean old sealant from cranshaft bolts and bolt holes. (pply nsealant to cranshaft bolts. Install fly/heel and clutch assembly. To complete installation,reverse removal procedure. Tighten bolts to specification. See /+1ESPECI-IC2I/NS.

52E+ P1)P

+e&o4al

0. Remove undercover. Remove radiator cap. Drain cooling system. Remove upper andlo/er radiator hoses. Remove coolant reservoir tan hose. Remove air inlet duct. Removfan and fan shroud together. $oosen generator mounting bolt and ad1usting bolt. Removdrive belt.

2. Remove fan pulley. Remove fan bracet assembly. Remove upper and lo/er timing beltcovers. Turn cranshaft so *o. 0 cylinder is at TD#. $oosen tensioner loc bolt, and pry

tensioner a/ay. Retighten tensioner bolt. If reusing timing belt, mar belt direction ofrotation for installation reference. Remove timing belt, and place aside. See I)ING6EL. $oosen tensioner bolt, and release tensioner. Remove /ater pump. -ig. #0.Remove 2 tensioners from /ater pump. Remove gaset and clean gaset mating surfaceengine bloc.

Installation

NOTE: Rear crankshaft oil seal can be removed without removing oil pan ocrankshaft.

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Ensure all gasket mating surfaces are clean. Install NEW water pump gasket on water pump.Install water pump. To complete installation, reverse removal procedure. Tighten bolts tospecification. See TORQUE SPECIFICATIONS. Check ignition timing and adust ifnecessar!.

Fig. 10: Exploded View Of Wae! P"#p $ Relaed Co#po%e%&

Co"!e&' of (IA )OTORS A)ERICA* INC.

OI+ PAN $ OI+ ,AFF+E

Re#o-al

". #isconnect negative batter! cable. $emove top % bolts on intake manifold bracket. $aisand support vehicle. #rain engine oil, and reinstall drain plug. $emove engine and

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transmission splash shields. On 4WD models, support front axle housing. Remove frontaxle housing mounting bolts, and left bushing from axle housing mount. Carefully lowerfront axle housing.

2. On 2WD models, remove front left bushing from axle housing mount. Carefully lowerfront axle housing. On all models, remove gusset plate mounting bolts from one side ofmotor, and remove gusset plate. Remove gusset plate mounting bolts from other side ofmotor, and remove other gusset plate.

. Remove transmission under!over bolts, and remove engine under!over. Remove oil panmounting bolts. "eparate oil pan from oil baffle and remove oil pan. Remove oil pan.Remove oil strainer assembly. Remove baffle bolt, and remove oil baffle.

Inspection

Remove oil, dirt and sealant from oil pan mounting bolts, oil pan and oil baffle. #nspe!t oil pafor !ra!$s, deformation and%or damaged drain plug threads. Che!$ oil baffle for damage or!ra!$s. Repair or repla!e as ne!essary.

Installation

&pply a !ontinuous bead of sili!one sealant along inside of bolt holes of oil baffle and oil pan#nstall oil baffle. #nstall oil baffle mounting bolt. #nstall oil strainer assembly. #nstall oil pan.

#nstall oil pan mounting bolts in se'uen!e. "ee Fig. 16. (ighten bolts to spe!ifi!ation. "eeTORQUE SPECIFICATIONS. (o !omplete installation, reverse removal pro!edure.

OVERHAUL

CYLINDER EAD

C!lin"e# ea"

)nsure all mating surfa!es are !lean. Che!$ !ylinder head for warpage. Resurfa!e !ylinder he

if warpage ex!eeds spe!ifi!ation. Che!$ manifold !onta!t surfa!es for warpage. Resurfa!emanifold surfa!es or repla!e !ylinder head if warpage ex!eeds spe!ifi!ation. Che!$ !ylinderhead height. "ee CYLINDER EADtable under )*+#*) ")C#-#C&(#O*". #fmeasurements are not as spe!ified, repla!e !ylinder head.

$al%e Sp#ings

)nsure valve spring free length and outofs'uare are within spe!ifi!ation. "ee $AL$ES &

NOTE: DO NOT bend oil pan or oil baffle while separating, remoing or!leaning !omponents"

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$AL$E SPRIN'Stable under ENGINE SPECIFICATIONS. Replace valve spring asnecessary.

$al%es

Chec valve !ace angle" #argin thicness and ste# dia#eter. Service $r replace valves i!#easure#ents are n$t %ithin speci!icati$n. See $AL$ES & $AL$E SPRIN'Stable underENGINE SPECIFICATIONS.

$al%e '(i"es

&. Chec valve ste#'t$'valve guide $il clearance. Ensure valve guide inside dia#eter is%ithin speci!icati$n. See CYLINDER EADtable under ENGINE SPECIFICATIONS

(. T$ replace valve guide" c$#pletely disasse#ble cylinder head. See ENGINEO)ER*A+, PROCE-+RES article in GENERA, INFORATION. *eat cylinder het$ &/01F 2/31C4. 5$ring !r$# c$#busti$n cha#ber side $! cylinder head" install )alveGuide Re#$ver 2O6&73'&(3'3384 int$ valve guide. -rive valve guide $ut $! cylinderhead.

7. I! necessary" install ne% circlip $n guide. +sing pr$per c$#p$nents $! )alve GuideInstaller 2O6//7'&(3'AAO4" ad9ust installer guide depth t$ speci!icati$n using depth#icr$#eter $r caliper.

0. Insert guide int$ pre'ad9usted installer. -rive guide int$ heated cylinder head !r$#ca#sha!t side until guide circlip and:$r installer c$ntact cylinder head. Ensure valve guidinstalled height is %ithin speci!icati$n. I! installed height is n$t %ithin speci!icati$n" ad9u$r replace valve guide $r cylinder head as necessary. See CYLINDER EADtable undENGINE SPECIFICATIONS.

$al%e Seat

)alve seat replace#ent in!$r#ati$n is n$t available !r$# #anu!acturer. Inspect valve seat !$rr$ughness and da#age. Chec valve seat angle and seat %idth. easure seat c$ntact %idth $n

valve" and n$te that seat c$ntact p$siti$n sh$uld be in center $! valve !ace" and 783 degreesar$und valve !ace. Service seat i! angle and %idth are n$t %ithin speci!icati$n. SeeCYLINDER EADtable under ENGINE SPECIFICATIONS. easure valve installed heiga!ter servicing valve seat.

$al%e Seat Co##ection Angles

&. easure seat c$ntact %idth $n valve. See CYLINDER EADtable under ENGINE

N-E% Intake and e/*ast 1al1e gides co&e in di,,erent s*apes andlengt*s.

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SPECIFICATIONS. Ensure valve/seat contact position is at center of valve face. If widtand position are not within specifications, cut seats as follows.

. If seat contact position is too hi!h, correct it usin! "#$de!ree stone. Finish an!le usin! %de!ree stone until contact width is corrected.

'. If seat contact position is too low, correct usin! '&$de!ree stone (inta)e* or +&$de!ree(ehaust*. Finish an!le usin! %&$de!ree stone until contact width is corrected. Seat valveto valve seat usin! lappin! co-pound.

Val-e 'tem Installed eight

+. After servicin! valves, valve seats and valve !uides, -easure valve ste- installed hei!hSee V*&VE IN'T*&&E EITtale. If installed valve ste- hei!ht is withinstandard specification, no adust-ent is necessar0.

. If installed valve hei!ht eceeds standard specification ut does not eceed service li-itspecification, install adustin! shi- on sprin! seat to rin! installed hei!ht ac) withinstandard specification.

'. If valve ste- installed hei!ht eceeds specification, replace valve. If valve ste- installedhei!ht still eceeds li-it, replace c0linder head. See V*&VE IN'T*&&E EITtale.

V*&VE IN'T*&&E EIT

13&INE" %

*pplication In. (mm)

Inta)e

Standard (+*+.%'$+.%"1 ('".'1$'1.1*

Service 2i-it (*+.%3& ('1.31*

Ehaust

Standard (+*+.%'+$+.%"" ('".'"$'1."*

Service 2i-it (*+.%3% ('1.3"*

(+*

If installed hei!ht eceeds standard specification ut is less that service li-it, adustwith washer on sprin! seat area of c0linder head.

(* If installed hei!ht eceeds service li-it, replace c0linder head.

N-E% /ring disasse&!ly" &atc* &ark co&ponents ,or reasse&!ly

2002 1ia Sportage

!""! ENGINES !."L #$C%lind& $ Spo&tag

'(ltt$Pac)a&d

*+,ado- "! d ago*to d !"1# "/#1/#! a.0. Pag !" 2 !"11 Mitc3ll Rpai& In4o&0ation Co0pan%- L


21/36

!iston 5 &onnecting Rod $ssembly

1. *efore removin" rod cap from cran!shaft, measure and record rod side play. See&663&.768 R24table under +-#+ S+$#'#$AT#OS. +nsure all rods,pistons, and caps are mar!ed for installation reference before removal.

. *efore removin" rod from cran!shaft, chec! and record rod bearin" oil clearance. See&R$694:$;., -$76 5 &663&.768 R2


22/36

or replace crankshaft, connecting rod and/or bearings as necessary. See CRANKSHAFT,MAIN & CONNECTING RO !EARINGStable under ENGINE SPECIFIC!I"NS.

C"an#s$a%t & Main !a"ings

#. $efore re%o&ing %ain caps, %easure and record crankshaft end play. 'sing Plastigage,%easure and record %ain bearing oil clearance. (" N"! rotate crankshaft )hen%easuring oil clearances.

*. +e%o&e crankshaft fro% engine. easure and record each %ain -ournal dia%eter in *places. See CRANKSHAFT, MAIN & CONNECTING RO !EARINGStable undeENGINE SPECIFIC!I"NS. achine or replace crankshaft as necessary. ain bearingupper hal&es are groo&ed. Check bearings for )ear, replace if necessary.

. ain bearing caps are %arked for installation in original positions. !ighten bearing capbolts in seuence and to specification. See TORQUE SPECIFICATIONS. See Fig. '(

T$")st !a"ings

Check crankshaft end play )ith crankshaft bearings and caps installed, but )ithout connectinrods attached to crankshaft. +eplace thrust bearing if end play is not )ithin specification. SeeCRANKSHAFT, MAIN & CONNECTING RO !EARINGStable under ENGINESPECIFIC!I"NS. Ensure thrust bearings are installed )ith oil groo&e facing crankshaft."&ersi0e thrust bearings are a&ailable.

C*lin+" !lo#

Check cylinder bore out1of1round, taper, and piston1to1cylinder bore clearance. Check headgasket surface for )arpage. If )arpage is not )ithin specification, %achine or replace cylindeblock as necessary. See C-LINER !LOCKtable under ENGINE SPECIFIC!I"NS.

ENGINE OILING

ENGINE LU!RICATION S-STEM

"il pressure is pro&ided by a rotor1type pu%p. (ri&en by the crankshaft, pu%p dra)s oil fro%oil pan through oil strainer. Fro% oil pu%p, oil is sent through oil filter then to cylinder blockand up to cylinder head. "il drains back to oil pan. See Fig. ''.

C"an#as Caait*

"il pan capacity is 2.2 ts. 32.#456. "il filter capacity is .*# ts. 3.*756.

Oil P"ss)"

2002 Kia Sportage

2002 ENGINES 20L !"C#lin$e% " S&o%ta'e

(e)lett"Pa*+a%$

s,-a$o. 02 $e a'osto $e 20/! 01!/1!2 am Pa'e 22 20// Mit*3ell Re&ai% In4o%mation Com&an#. L


23/36

With engine at operating temperature, oil pressure should be 43-57 psi (3.0-4.0 kg/cm2 at

3000 !"#.

Oil P)ess*)e Relie+ %alve

"ressure relie$ %al%e is located in oil pump bod& and is not ad'ustable.

Fi! '', C)oss-Se$tional %ie. O+ Enine Oil Ci)$*it

2002 Kia Sportage


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24/36

Courtesy of KIA MOTORS AMERICA, INC.

OIL PUMP

Reo!"#

. "emove radiator cap, and drain coolant. !isconnect negative battery cable. "emovetiming belt. See TIMIN$ %ELTunder "E102/& 3 INST/&&/TI0N. "emove oilpan and oil baffle. See OIL PAN & OIL %AFFLE.

#. "emove power steering pump bolts. "emove power steering pump bracket bolts. "emovpower steering pump bracket. "emove timing belt pulley from crankshaft. "emoveremaining oil pump bolts. "emove oil pump. "emove 404 ring from oil pump.

%. *arefully clean all gaskets and sealant from mating surfaces without damagingsealing5mating surfaces. "emove all sealant from components and bolts. *heck oil pump

clearances. See OIL PUMP SPECIFICATIONStable. "eplace oil pump as necessary.See Fig. '(.

I)st"##"tio)

. +se NEW gasket when installing oil pump. Tighten oil pump bolts to specification. SeeTOR*UE SPECIFICATIONS. /pply light oil coat of clean oil to oil seal lip, and tapoil seal into oil pump body until it is flush with edge of pump body. !0 N0T bottom sein pump body.

#. /lign keyway slots, and install crankshaft sprocket by tapping lightly using brass hamm

Install keyway with tapered side toward oil pump body. Install crankshaft sprocket lockbolt, and tighten to specification. See TOR*UE SPECIFICATIONS. To completeinstallation, reverse removal procedure.

2002 Kia Sportage


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25/36

Fig. ,-: E/loded 0ie1 O% Oil P"m/Co"rte$y o% &IA 'OTORS A'ERICA( INC.

OI) PU'P SPECIFICATIONS

TORQUE SPECIFICATIONS

A//li#ation 'aim"m Clearan#e 2 In. 3mm4Inner ear Tip$To$0uter ear *learance .667 8.9:

0uter ear$To$-ump ;ody *learance .669 8.#6:

ear Side$To$-ump ;ody *learance .66' 8.6:

-ressure Spring &ength .7


26/36

TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)

.C /racket /olt '2 41

.C Co&pressor )o3nting /olt # 21.C 5ensioner /racket /olt # 21

.C Idler P3lley Lock N3t 24 '2

/ypass Pipe /olt # 21

Ca&s*a,t Cap /olt# #6 22

Ca&s*a,t P3lley Lock /olt 42 16

Cl3tc* ).5. Con7erter .5 Ho3sing /olt

#4 && 0 #0

#0 && 2 '

6 && 60 INCH $

Connecting +od N3t 10 6$

Cooling 8an sse&!ly /olt 2$ '$

Cooling 8an N3t #6 22

Cranks*a,t 9a&per P3lley /olt ## #1

Cylinder Head /olt2 '

62 4

9yna&ic C*a&!er /olt.N3t #6 22

9yna&ic C*a&!er S3pport /racket /olt # 21

Engine-to-/ody Gro3nd :ire /olt # 21Engine /racket /olt '2 41

Engine Hanger /olt #6 22

Engine )o3nt N3t 2 '

Engine S3pport /olt 2 '

E;*a3st /racket /olt 20 2$

E;*a3st 8lange Lock N3t 24 '#

E;*a3st )ani,old N3t '# 42

E;*a3st )ani,old Heat S*ield /olt # 21

8ront ;le Ho3sing )o3nting /olt 4 61

Generator /racket /olt '2 41

Generator )o3nting /olt

/otto& '2 41

5op #6 22

Generator Strap /olt '2 41

())( Ki' #port'ge

"##" E!$I!ES ".#% &'Cylin(er ' S)ortage

*e+lett',a-kar(

s/a(o #" (e agosto (e "#0& #1:&0:&" a.m. ,age "6 2 "#00 Mit-hell Re)air Information Com)any %


27/36

)usset *late +olt ,- ./01

Ignition Coil Mounting +olt 28 .-01

Intake Manifol3 +olt4"ut 25 .--1

Intake Manifol3 Su66ort +ra7ket +olt ,- ./01Main +earing Ca6 +olt

./1 5, .801

Oil *um6 +olt.01

8 mm 25 .--1

2 mm ,- ./01

*4S +ra7ket +olt ,- ./01

*4S Mounting +olt , ./-1

*4S *um6 'o7k +olt , ./-1

Se6erator *late +olt 28 .-01S6ark *lug 2292: .209-,1

Starter +olt ,/ ./51

Timing +elt *ulley 'o7k +olt 2- .25-1

Timing +elt Tensioner 'o7k +olt ,, ./01

;ater Inlet *i6e +olt 28 .-01

;ater *um6 +olt 25 .--1

I"/ 0bs. #.m&

A77elerator Cahaust *rote7tor "ut ,0 ./1

Fresh Air %u7t +olt 8/ .21

Oil )auge Tu


28/36

$ig. 1%& Camshaft 'earing Cap 'olt (ightening )e*uence

Courtesy of KI+ -(-R) +ERIC+, IC.

6#7 -ig)ten in se89ence. See $ig. 1%.

627 -ig)ten in se89ence. See $ig. 1/.

617-ig)ten in t)ree e89al steps.

647 -ig)ten in se89ence. See $ig. 10.

6:7 -ig)ten in se89ence. See $ig. 1.

())( Ki' #port'ge

2112 ,*%*,S 2.1 -4ylinder - Sportage

He&lett-ackard

s5bado' 12 de agosto de 216 178682 a.m. age 29 : 2166 Mitchell Repair %nformation 4ompany'


29/36

Fig. 14: Cylinder Head Bolt Tightening Sequence

Courtesy of KIA !T!"S A#"ICA$ I%C.

())( Ki' #port'ge


*e+lett',a-kar(

s/a(o #" (e agosto (e "#0& #1:&0:&" a.m. ,age "3 2 "#00 Mit-hell Re)air Information Com)any %


30/36

Fig. 1&: ain Bearing Ca' Bolt Tightening SequenceCourtesy of KIA !T!"S A#"ICA$ I%C.

())( Ki' #port'ge

2112 ,*%*,S 2.1 -4ylinder - Sportage

He&lett-ackard

s5bado' 12 de agosto de 216 178682 a.m. age 31 : 2166 Mitchell Repair %nformation 4ompany'


31/36

Fig. 16: Oil Pan Bolt Tightening Sequence

Courtesy of KIA OTO!S A"!ICA# I$C.

ENGINE SPECIFICATIONS

%"$"!A& SP"CIFICATIO$S

C!A$KS'AFT# AI$ ( CO$$"CTI$% !O) B"A!I$%S

A**lication S*ecification

Displacement 122 Cu. In. (2.0L)

Bore 3.39" (86.1)

Stroe 3.39" (86.1)

Compression !atio 9.21

Compression #ressure 188 psi (13.22 $%cm2)

&uel S'stem S&I

A**lication In. +,,-

Cransat

2002 Kia Sportage


*e+lett',a-kar(

s/a(o #" (e agosto (e "#0& #1:&0:&" a.m. ,age 40 2 "#00 Mit-hell Re)air Information Com)any %


32/36

End Play

Standard .00'#-.00$# 7.0$8-.#90:

Serice Li&it .0#2 7.'0:

)a;i&


33/36

CO$$"CTI$% !O)S

PISTO$S# PI$S ( !I$%S

A**lication In. +,,-

ore Diameter

#onnecting Rod earing ore04

5iston 5in ore .6789:.6770 20.;6;:20.;;;4

!a4

!a.===00.0=:.==264

Service $imit .=02 .3=4

04 Information is not available from manufacturer.24 !a .=>6:.=704

Service $imit .==8; .084Diameter 3.3637:3.36>> 68.;>3:68.;7>4

5ins

Diameter .6787:.6770 20.;69:20.;;;4

5iston it .===2:.===> .==8:.=0=4

Rod it .===>:.===00 .=0=:.=284

Rings

*o. 0

'nd -ap

Standard .==7:.=02 .08:.3=4Service $imit .=3; 0.=4

Side #learance

Standard .==0:.==3 .=28:.=974

Service $imit .==7 .084

*o. 2

2002 Kia Sportage


*e+lett',a-kar(

s/a(o #" (e agosto (e "#0& #1:&0:&" a.m. ,age 44 2 "#00 Mit-hell Re)air Information Com)any %


34/36

CYLINDER BLOCK

VALVES & VALVE SPRINGS

E%d ap

Sa%da!d .00/.01 2.30.456

Se!-i7e +i#i .048 21.06

Side Clea!a%7eSa%da!d .001.004 2.039.0:56

Se!-i7e +i#i .005 2.196

No. 4 2Oil6

E%d ap

Sa%da!d .00/.03/ 2.30.:16

Se!-i7e +i#i .048 21.06

Application In. (mm)C'li%de! ,o!e

Sa%da!d ;ia#ee! 4.4/9/4.4/552/9.888/5.0306

)axi#"# Tape! .000: 2.01/6

)axi#"# O"OfRo"%d .000: 2.01/6

)axi#"# ;e7< Wa!page 216.005 2.196

216 Repla7e =lo7< if #o!e >a% .00/? 230 ##6 i& !e#o-ed.

Application Speciication

Val-e&

Fa7e A%gle 9@

ead ;ia#ee! 216

)i%i#"# )a!gi%

I%aa"& .049? 2./8 ##6

)i%i#"# Refi%i&> +e%g>

I%aa"& .0831? 2104.8 ##6

I%&alled eig>236

Val-e Sea Co%a7 Wid> .0:.054? 21.181.50##6

2002 Kia Sportage


*e+lett',a-kar(

s/a(o #" (e agosto (e "#0& #1:&0:&" a.m. ,age 4& 2 "#00 Mit-hell Re)air Information Com)any %


35/36

CYLINDER !EAD

&alve Springs

'ree (ength

Inner ".)*+, -/.0 mm1

Inner 2inimum ".)/), -3.+* mm14uter ".5*, -*.0* mm1

4uter 2inimum ".5%), -/.3" mm1

4ut64f6S7uare

Inner -"1

4uter .05, -".5 mm1

-"1 Information is not available from manufacturer.

-%1 8eight measured from top of installed valve to spring seat. See VALVE

INS"ALLED !EIG!"table under C9(IN#E$ 8E:# under 4&E$8:;(.

Application Speciication

C!linder 8ead 8eight 5.%3)65.%3/, -".*+6").0+mm1

2auide Installed 8eight-%1 .))*6.)+*, -"".)06"".*" mm1

&alve Stem6To6>uide 4il Clearance

Intake .00"06.00%), -.0%56.0+"mm1

E


36/36

C&/"0&-(

(1) DO NOT machine more than .008" (.20 mm) from deck or manifold surfaces.

(2) Measured from top of installed uide to sprin seat.

&ppli!ation #n. 1mm2

!ournal Diameter 1.18#1.1$ (2$.$%$#2$.$&')

Maimum !ournal Out#Of#ound .002 (.0*0)

Maimum !ournal unout .002 (.0*0)

Oil +learance .001'#.00%% (.0%.08')

,tandard -oe /eiht 1.% ('*.0*2)

Minimum -oe /eiht 1.&*8 (''.8*1)

"##" Kia S)ortage


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Motor Kia Sportage