KIA SORENTO (BL) 2004 G 3.5 DOHC Engine Service Repair Manual
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🏷️ Basic Information Identification Make: Kia Model: Sorento Generation Code: BL Model Year: 2004 Engine Variant: 3.5 DOHC Codes Chassis Code: BL Engine Code: G6CU (likely) 👋 Introduction Market Position Segment: Mid-size SUV / Crossover Target Audience: Families, individuals seeking versatility and capability. Competitive Analysis Key Competitors 2004: Toyota Highlander, Honda Pilot, Ford Explorer, Nissan Murano. Key Features Body On Frame: Built on a ladder frame, offering robust construction and towing capability (distinct from unibody SUVs). Engine Power: 3.5L V6 engine providing ample power for its class. Drivetrain Options: Available in RWD and AWD configurations. 📋 Manual Details Coverage Areas Scope: Service and Repair Procedures Page Count Estimated Pages: High (typical for comprehensive engine service manuals, ~500-1000+ pages) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF likely, given typical sales practices) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, valve train, timing system. Engine Fuel System: Fuel injection (MPI), fuel pump, fuel injectors, fuel pressure regulator, fuel lines. Engine Ignition System: Ignition coils, spark plugs, ignition timing control. Engine Cooling System: Radiator, water pump, thermostat, coolant hoses, cooling fan. Engine Lubrication System: Oil pump, oil filter, oil pan, lubrication passages, oil pressure. Engine Exhaust System: Exhaust manifold, catalytic converter, muffler, exhaust pipes. Engine Emission Control: EGR system, PCV system, evaporative emission control (EVAP). Engine Electrical: Starter motor, alternator, battery, engine control module (ECM) wiring, sensors. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, spark plug replacement. Troubleshooting: Diagnostic procedures, symptom analysis, fault code interpretation (OBD-II). Repair: Component replacement, adjustment procedures, internal engine repair, gasket replacement. Disassembly Assembly: Step-by-step instructions for engine teardown and reassembly. Torque Specifications: Precise torque values for all critical fasteners. Special Tools: Identification and usage of specialized tools required for specific repairs. Technical Depth Depth: Comprehensive (covers from basic maintenance to in-depth engine overhaul). 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Resolution: High-resolution (typically 300+ DPI for clarity of diagrams and text) Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) Features Searchability: Searchable text for quick information retrieval. Illustrations: Detailed diagrams, exploded views, and schematics. Hyperlinks: Potential for internal hyperlinks to related sections. ⚙️ Engine Specifications Primary Engine Engine Type: V6, DOHC, 24-valve Displacement: 3.5 Liters (3497 cc) Bore X Stroke: 91.0 mm x 88.7 mm (approximate, typical for this engine family) Compression Ratio: 9.4:1 (typical) Performance Horsepower: Approximately 200-205 hp @ 5500-5800 rpm (manufacturer specific) Torque: Approximately 220-225 lb-ft @ 3000-3500 rpm (manufacturer specific) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Regular (87 octane recommended) Lubrication Oil Capacity: Approximately 5.5-6.0 quarts (5.2-5.7 liters) with filter change Ignition Spark Plugs: NGK PFR5N-11 (or equivalent, consult manual for exact spec) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Overdrive Optional Optional Transmission: N/A for this specific engine/year combination (typically auto only) Features Transmission Fluid Type: Kia Genuine ATF SP-III or equivalent Transmission Fluid Capacity: Approximately 8.0-9.0 quarts (7.6-8.5 liters) for a drain and fill 📐 Dimensions Exterior Length: Approximately 187.9 inches (4773 mm) Width: Approximately 74.4 inches (1890 mm) Height: Approximately 68.3 inches (1735 mm) Wheelbase: Approximately 110.0 inches (2794 mm) Weights Curb Weight: Approximately 4,300 - 4,500 lbs (1950 - 2041 kg) depending on drivetrain Towing Capacity: Up to 5,000 lbs (2268 kg) with optional towing package Cargo Cargo Volume Behind 3Rd Row: Approximately 10.0 - 12.0 cu ft Cargo Volume Behind 2Nd Row: Approximately 40.0 - 45.0 cu ft Cargo Volume Behind 1St Row: Approximately 75.0 - 80.0 cu ft 🛡️ Safety Features Ratings NHTSA Frontal Crash Driver: 4 stars (2004 model year) NHTSA Frontal Crash Passenger: 4 stars (2004 model year) NHTSA Side Impact Driver: 5 stars (2004 model year) NHTSA Side Impact Rear Passenger: 5 stars (2004 model year) IIHS Moderates: Good (for models equipped with side airbags) Active Features ABS: Standard Anti-lock Braking System Traction Control: Optional Traction Control System (TCS) Esc: Optional Electronic Stability Control (ESC) - availability varies by trim and market. Passive Features Airbags: Frontal airbags, optional front side-impact airbags, optional side-curtain airbags. Seatbelts: Three-point seat belts with pretensioners for front occupants. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, with optional premium audio systems available on higher trims. Display: Basic LCD display for audio information and climate control. Driver Assistance Cruise Control: Standard on most trims. Parking Sensors: Optional rear parking sensors available on select trims. Connectivity Auxiliary Input: May be present on some models, but Bluetooth and USB connectivity are generally absent on this generation. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first. Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions. Spark Plug Replacement: Every 60,000 miles (96,000 km). Timing Belt...
Step-by-step instructions for engine teardown and reassembly.
Torque Specifications:
Precise torque values for all critical fasteners.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Technical Depth
Depth:
Comprehensive (covers from basic maintenance to in-depth engine overhaul).
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Resolution:
High-resolution (typically 300+ DPI for clarity of diagrams and text)
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
Features
Searchability:
Searchable text for quick information retrieval.
Illustrations:
Detailed diagrams, exploded views, and schematics.
Hyperlinks:
Potential for internal hyperlinks to related sections.
⚙️ Engine Specifications
Primary Engine
Engine Type:
V6, DOHC, 24-valve
Displacement:
3.5 Liters (3497 cc)
Bore X Stroke:
91.0 mm x 88.7 mm (approximate, typical for this engine family)
Compression Ratio:
9.4:1 (typical)
Performance
Horsepower:
Approximately 200-205 hp @ 5500-5800 rpm (manufacturer specific)
Torque:
Approximately 220-225 lb-ft @ 3000-3500 rpm (manufacturer specific)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Regular (87 octane recommended)
Lubrication
Oil Capacity:
Approximately 5.5-6.0 quarts (5.2-5.7 liters) with filter change
Ignition
Spark Plugs:
NGK PFR5N-11 (or equivalent, consult manual for exact spec)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Overdrive
Optional
Optional Transmission:
N/A for this specific engine/year combination (typically auto only)
Features
Transmission Fluid Type:
Kia Genuine ATF SP-III or equivalent
Transmission Fluid Capacity:
Approximately 8.0-9.0 quarts (7.6-8.5 liters) for a drain and fill
📐 Dimensions
Exterior
Length:
Approximately 187.9 inches (4773 mm)
Width:
Approximately 74.4 inches (1890 mm)
Height:
Approximately 68.3 inches (1735 mm)
Wheelbase:
Approximately 110.0 inches (2794 mm)
Weights
Curb Weight:
Approximately 4,300 - 4,500 lbs (1950 - 2041 kg) depending on drivetrain
Towing Capacity:
Up to 5,000 lbs (2268 kg) with optional towing package
Cargo
Cargo Volume Behind 3Rd Row:
Approximately 10.0 - 12.0 cu ft
Cargo Volume Behind 2Nd Row:
Approximately 40.0 - 45.0 cu ft
Cargo Volume Behind 1St Row:
Approximately 75.0 - 80.0 cu ft
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Driver:
4 stars (2004 model year)
NHTSA Frontal Crash Passenger:
4 stars (2004 model year)
NHTSA Side Impact Driver:
5 stars (2004 model year)
NHTSA Side Impact Rear Passenger:
5 stars (2004 model year)
IIHS Moderates:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Optional Traction Control System (TCS)
Esc:
Optional Electronic Stability Control (ESC) - availability varies by trim and market.
Passive Features
Airbags:
Frontal airbags, optional front side-impact airbags, optional side-curtain airbags.
Seatbelts:
Three-point seat belts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, with optional premium audio systems available on higher trims.
Display:
Basic LCD display for audio information and climate control.
Driver Assistance
Cruise Control:
Standard on most trims.
Parking Sensors:
Optional rear parking sensors available on select trims.
Connectivity
Auxiliary Input:
May be present on some models, but Bluetooth and USB connectivity are generally absent on this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Every 60,000 miles (96,000 km).
Timing Belt Replacement:
N/A - This engine uses a timing chain, which is typically designed for the life of the engine but may require inspection/tensioner replacement.
Transmission Fluid Service:
Every 30,000 miles (48,000 km) or 24 months, whichever comes first.
Fluid Specifications
Engine Oil Grade:
SAE 5W-30 (API SM or higher).
Coolant Type:
Ethylene Glycol based coolant with corrosion inhibitors (e.g., Hyundai/Kia Long Life Coolant - blue color).
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine Oil Sludge:
Potential for oil sludge buildup if maintenance intervals are neglected, especially with shorter trips. Regular oil changes are critical.
Transfer Case Noise:
Some early BL models experienced noise or vibration from the transfer case, potentially related to fluid or internal wear.
Suspension Components:
Wear on control arm bushings and ball joints can occur due to the vehicle's weight and usage, leading to steering wander or clunking noises.
📚 Vehicle History
Brand Heritage
Kia History:
Kia Motors Corporation, a South Korean manufacturer, has a history dating back to 1944, initially producing motorcycles and later expanding into trucks and passenger vehicles. Known for value and increasingly for design and quality.
Model Evolution
First Generation:
The BL Sorento represents the first generation of the Sorento nameplate, launched globally in 2002. It was designed to be a more traditional SUV with body-on-frame construction.
Generation Bl Characteristics:
Featured a ladder frame chassis, rear-wheel drive biased or optional four-wheel drive, and a focus on ruggedness and towing capability.
Production
Production Years Bl:
2002-2009
Manufacturing Locations:
South Korea (primarily Hwaseong plant), Malaysia, Russia, Egypt.
🏆 Awards & Recognition
Recognitions
IIHS Award History:
Received 'Good' ratings in front and side impact tests for models equipped with optional side airbags, indicating good structural integrity and occupant protection.
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