KIA Sorento V6 (3.5L) 2004 OEM Factory Shop Service Repair Manual DOwnload FSM
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๐ท๏ธ Basic Information Identification Make: KIA Model: Sorento Year: 2004 Engine Variant: 3.5L V6 Generation Platform: First Generation (JC) Codes Chassis Code: JC Engine Code: G6CU (likely) ๐ Introduction Market Position Vehicle Segment: Mid-size SUV / Crossover Target Audience: Families seeking versatile and capable utility vehicle Competitive Analysis Key Competitors: Toyota Highlander, Honda Pilot, Ford Explorer, Nissan Pathfinder, Chevrolet Trailblazer Key Features Vehicle Strengths: Spacious interior, available V6 power, comfortable ride, value proposition. Manual Value Proposition: Provides professional-level repair and maintenance information, enabling DIYers and professionals to accurately service the vehicle. ๐ Manual Details Coverage Areas Coverage Scope: Bumper-to-bumper repair and maintenance Page Count Estimated Page Count: Likely 1000+ pages (typical for OEM factory service manuals of this era) Manual Type Manual Classification: OEM Factory Service Manual (FSM) Language Language: English Format Digital Format: PDF ๐ Manual Coverage Systems Covered Powertrain: Engine (3.5L V6 G6CU), transmission (automatic), fuel system, exhaust system, cooling system, lubrication system, ignition system. Chassis: Suspension (front and rear), steering system, braking system (ABS, standard), wheels and tires. Electrical: Wiring diagrams, lighting, power accessories, charging system, starting system, body control modules, diagnostics. Body: Body panels, doors, windows, interior trim, HVAC system, safety restraint systems (airbags). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug service, belt replacement. Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meaning, on-board diagnostics (OBD-II). Repair: Engine disassembly and assembly, transmission service, brake caliper and rotor replacement, suspension component replacement, steering rack overhaul, electrical component repair. Technical Specifications: Torque specifications, clearances, tolerances, fluid capacities, electrical specifications. Technical Depth Depth Of Information: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures. ๐ Manual Specifications File Format Document Type: Searchable PDF Indexing: Indexed for easy navigation Print Quality Readability: High quality, designed for clarity of text and diagrams Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper Simulation: N/A (Digital PDF) โ๏ธ Engine Specifications Primary Engine Engine Type: Naturally Aspirated V6 Displacement: 3.5 Liters (3497 cc) Bore X Stroke: 93.0 mm x 82.7 mm (estimated) Valvetrain: DOHC, 4 valves per cylinder (24 valves total) Performance Horsepower Peak: Approx. 200-215 hp (at 5500-5800 rpm, depending on specific market calibration) Torque Peak: Approx. 217-230 lb-ft (at 3000-3500 rpm, depending on specific market calibration) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Engine Management ECU Type: Electronic Control Unit (ECU) with OBD-II diagnostics ๐ง Transmission Standard Transmission Type: 5-speed Automatic Transmission Optional Transmission Type: N/A (only automatic offered for V6 in 2004) Features Drive Modes: Full-time 4WD (likely standard on V6), with potential for driver-selectable 2WD/4WD modes (check specific trims). Fluid Specifications Automatic Transmission Fluid Type: SPII-ATF or equivalent (refer to manual for precise specification, e.g., ATF SP-III) ๐ Dimensions Exterior Length: Approx. 187.4 inches (4760 mm) Width: Approx. 74.4 inches (1890 mm) Height: Approx. 67.3 inches (1710 mm) Wheelbase: Approx. 106.7 inches (2710 mm) Weights Curb Weight: Approx. 4200-4400 lbs (depending on trim and drivetrain) Cargo Cargo Volume Behind Second Row: Approx. 30.5 cu ft (estimated) Cargo Volume Behind First Row: Approx. 75.0 cu ft (estimated) ๐ก๏ธ Safety Features Ratings NHTSA Front Impact: 5-Star (for driver and front passenger in some tests) NHTSA Side Impact: 4-Star (estimated, check specific vehicle documentation) Active Features ABS: Standard Anti-lock Braking System Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Front airbags, available side curtain airbags (check specific vehicle) Seatbelts: 3-point seatbelts with pretensioners for front occupants. ๐ก Technology Features Infotainment Audio System: AM/FM stereo with CD player, typically 6-speaker system. Optional premium audio might be available. Navigation: Optional factory navigation system available on higher trims. Driver Assistance Cruise Control: Standard electronic cruise control. Connectivity Aux Input: Likely not standard, but auxiliary input may be present on some units or available as an aftermarket upgrade. ๐ง Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 6 months (severe duty) / 7,500 miles or 12 months (normal duty) - Consult manual for precise recommendation. Engine Air Filter Replacement: Every 15,000-30,000 miles, or as needed based on driving conditions. Cabin Air Filter Replacement: Every 12,000-15,000 miles or annually. Spark Plug Replacement: Approx. 60,000 - 100,000 miles for iridium or platinum plugs (refer to manual for exact type and interval). Fluid Specifications Engine Oil Type: API SJ or SL classification, SAE 5W-30 viscosity (check manual for confirmation). Engine Oil Capacity: Approx. 5.5-5.8 US quarts (with filter change). Coolant Type: Ethylene glycol-based coolant, typically a green or pink type (consult manual for specific Kia coolant P/N or equivalent). Brake Fluid Type: DOT 3 or DOT 4 (check manual for exact specification). Known Issues Common Wear Items: Brake pads and rotors, suspension bushings, exhaust components, catalytic converter, window regulators. Engine Specific Concerns: Some V6 engines of this era could be prone to oil...
Some V6 engines of this era could be prone to oil leaks from valve cover gaskets or intake manifold gaskets. Timing belt replacement (if applicable, though this engine likely has a timing chain) is critical. Check for specific service bulletins regarding oil consumption or cooling system issues.
๐ Vehicle History
Brand Heritage
Kia History:
Kia Motors Corporation, a South Korean automobile manufacturer, has a history dating back to 1944, evolving from a bicycle manufacturer to a global automotive player known for value and improving quality.
Model Evolution
Sorento First Gen Launch:
The first-generation Sorento (JC) was launched in 2002, serving as Kia's first mid-size SUV. It was built on a body-on-frame chassis, inherited from the Kia Sportage, offering a rugged and truck-like feel.
2004 Model Year Updates:
The 2004 model year likely received minor updates or package revisions from its initial launch. The V6 engine became a prominent offering for buyers seeking more power.
Production
Manufacturing Location:
South Korea (primarily Hwaseong Plant)
๐ Awards & Recognition
Recognitions
Safety Awards 2004:
The Sorento received some favorable safety ratings in its class, with 5-star front impact ratings from NHTSA in some configurations.