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Kia Sedona 2005 3.5L DOHC Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Kia Model: Sedona Year: 2005 Engine: 3.5L DOHC V6 Codes Engine Code: G6CU 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, individuals requiring versatile and spacious transportation. Competitive Analysis Key Competitors: Toyota Sienna, Honda Odyssey, Chrysler Pacifica, Ford Freestar. Key Features Seating Capacity: Typically 7 or 8 passengers. Cargo Volume: Ample cargo space with flexible seating configurations. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Language: English Format: PDF Page Count Page Count: 848 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, rebuild procedures, component specifications, timing belt replacement, lubrication system service. Engine Management Electronic: ECU operation, sensor diagnostics (MAP, TPS, O2, crankshaft/camshaft position), fuel injection control, ignition timing, emissions control systems (EGR, EVAP). Transmission Automatic: Operation, internal components, hydraulic control, solenoids, torque converter, fluid service, overhaul procedures, diagnostic trouble codes. Brakes: Hydraulic system, ABS (Anti-lock Braking System) operation and diagnostics, brake fluid specifications, disc and drum brake service, parking brake. Suspension: Front and rear suspension component identification, geometry specifications, strut and shock absorber replacement, ball joint and tie rod end service. Steering: Power steering system operation, pump service, rack and pinion assembly, steering column, alignment specifications. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting circuits, body control module (BCM), wiring diagrams for all systems. HVAC: Air conditioning system operation, refrigerant types, compressor service, heater core replacement, climate control panel diagnostics. Body And Trim: Body panel removal and installation, interior trim components, door hardware, glass replacement, exterior trim. Chassis And Frame: Frame construction, mounting points, corrosion protection. Exhaust System: Catalytic converter, muffler, exhaust pipes, mounting hardware, emissions regulations. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug service, coolant flushes, brake pad inspection and replacement. Troubleshooting Diagnostics: Step-by-step diagnostic charts for common and uncommon issues, symptom-based troubleshooting, use of diagnostic scan tools. Repair And Rebuild: Detailed instructions for engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, and more. Component Replacement: Guidance on replacing alternators, starters, fuel pumps, radiators, water pumps, and other major components. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, including power distribution, grounds, and signal paths. Technical Depth Diagnostic Tools: Information on using OBD-II scanners and specific Kia diagnostic equipment. Torque Specifications: Precise torque values for all critical fasteners, essential for proper assembly and safety. Clearances And Tolerances: Factory specifications for critical engine and transmission component clearances for rebuilds. Special Tools: Identification and usage of specialized tools required for specific repair procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: Digital (PDF), allowing for easy navigation and searching. Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: V6, DOHC (Dual Overhead Camshaft) Displacement: 3.5 Liters (3497 cc) Bore X Stroke: 93.0 mm x 82.7 mm Compression Ratio: 9.4:1 Performance Horsepower: 200 hp @ 5500 rpm (approximate) Torque: 217 lb-ft @ 3000 rpm (approximate) Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 87 octane recommended Engine Components Timing Mechanism: Timing belt driven Cooling System Coolant Type: Ethylene glycol-based coolant (e.g., Hyundai/Kia Long Life Coolant or equivalent) 🔧 Transmission Standard Transmission Type: 4-speed automatic transmission Optional Optional Transmission: N/A for this specific configuration (3.5L) Features Transmission Fluid Type: Kia SPII (or equivalent Dexron III/Mercon) 📐 Dimensions Exterior Length: Approx. 195.1 inches Width: Approx. 78.2 inches Height: Approx. 69.1 inches Wheelbase: Approx. 118.1 inches Weights Curb Weight: Approx. 4,300 - 4,500 lbs (depending on trim and options) Gross Vehicle Weight Rating Gvwr: Approx. 5,700 - 5,900 lbs Cargo Maximum Cargo Volume: Over 140 cu. ft. (with second and third rows folded/removed) 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4 out of 5 stars (for 2005 models) Active Features ABS: Standard Anti-lock Braking System Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Front airbags, available side curtain airbags for all rows. Seatbelts: Three-point seatbelts for all seating positions, pretensioners. Child Safety: LATCH (Lower Anchors and Tethers for CHildren) system. 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional premium audio system. Display: Digital clock, optional climate control display. Driver Assistance Cruise Control: Standard cruise control. Connectivity Power Outlets: 12V auxiliary power outlets. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 miles or 6 months, whichever comes first. Engine Air Filter: Inspect every 15,000 miles, replace as needed or every 30,000 miles. Cabin Air Filter: Inspect every 15,000 miles, replace as needed or every 30,000 miles. Spark Plugs: Replace every 60,000 miles (iridium type recommended). Timing Belt: Replace every 90,000 miles or 7 years, whichever comes first. Fluid Specifications Engine Oil Capacity: Approx. 5.2 US quarts (with filter) using 5W-30 synthetic blend. Transmission Fluid Capacity: Approx. 7.7 US...
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Kia Sedona 2005 3.5L DOHC Workshop Service Manual for RepairKia Sedona 2005 3.5L DOHC Workshop Service Manual for RepairKia Sedona 2005 3.5L DOHC Workshop Service Manual for RepairKia Sedona 2005 3.5L DOHC Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Kia
Model:
Sedona
Year:
2005
Engine:
3.5L DOHC V6
Codes
Engine Code:
G6CU
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, individuals requiring versatile and spacious transportation.
Competitive Analysis
Key Competitors:
Toyota Sienna, Honda Odyssey, Chrysler Pacifica, Ford Freestar.
Key Features
Seating Capacity:
Typically 7 or 8 passengers.
Cargo Volume:
Ample cargo space with flexible seating configurations.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Language:
English
Format:
PDF
Page Count
Page Count:
848
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, rebuild procedures, component specifications, timing belt replacement, lubrication system service.
Engine Management Electronic:
ECU operation, sensor diagnostics (MAP, TPS, O2, crankshaft/camshaft position), fuel injection control, ignition timing, emissions control systems (EGR, EVAP).
Transmission Automatic:
Operation, internal components, hydraulic control, solenoids, torque converter, fluid service, overhaul procedures, diagnostic trouble codes.
Brakes:
Hydraulic system, ABS (Anti-lock Braking System) operation and diagnostics, brake fluid specifications, disc and drum brake service, parking brake.
Suspension:
Front and rear suspension component identification, geometry specifications, strut and shock absorber replacement, ball joint and tie rod end service.
Steering:
Power steering system operation, pump service, rack and pinion assembly, steering column, alignment specifications.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting circuits, body control module (BCM), wiring diagrams for all systems.
HVAC:
Air conditioning system operation, refrigerant types, compressor service, heater core replacement, climate control panel diagnostics.
Body And Trim:
Body panel removal and installation, interior trim components, door hardware, glass replacement, exterior trim.
Chassis And Frame:
Frame construction, mounting points, corrosion protection.
Exhaust System:
Catalytic converter, muffler, exhaust pipes, mounting hardware, emissions regulations.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug service, coolant flushes, brake pad inspection and replacement.
Troubleshooting Diagnostics:
Step-by-step diagnostic charts for common and uncommon issues, symptom-based troubleshooting, use of diagnostic scan tools.
Repair And Rebuild:
Detailed instructions for engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, and more.
Component Replacement:
Guidance on replacing alternators, starters, fuel pumps, radiators, water pumps, and other major components.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems, including power distribution, grounds, and signal paths.
Technical Depth
Diagnostic Tools:
Information on using OBD-II scanners and specific Kia diagnostic equipment.
Torque Specifications:
Precise torque values for all critical fasteners, essential for proper assembly and safety.
Clearances And Tolerances:
Factory specifications for critical engine and transmission component clearances for rebuilds.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
Digital (PDF), allowing for easy navigation and searching.
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V6, DOHC (Dual Overhead Camshaft)
Displacement:
3.5 Liters (3497 cc)
Bore X Stroke:
93.0 mm x 82.7 mm
Compression Ratio:
9.4:1
Performance
Horsepower:
200 hp @ 5500 rpm (approximate)
Torque:
217 lb-ft @ 3000 rpm (approximate)
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane recommended
Engine Components
Timing Mechanism:
Timing belt driven
Cooling System
Coolant Type:
Ethylene glycol-based coolant (e.g., Hyundai/Kia Long Life Coolant or equivalent)
🔧 Transmission
Standard
Transmission Type:
4-speed automatic transmission
Optional
Optional Transmission:
N/A for this specific configuration (3.5L)
Features
Transmission Fluid Type:
Kia SPII (or equivalent Dexron III/Mercon)
📐 Dimensions
Exterior
Length:
Approx. 195.1 inches
Width:
Approx. 78.2 inches
Height:
Approx. 69.1 inches
Wheelbase:
Approx. 118.1 inches
Weights
Curb Weight:
Approx. 4,300 - 4,500 lbs (depending on trim and options)
Gross Vehicle Weight Rating Gvwr:
Approx. 5,700 - 5,900 lbs
Cargo
Maximum Cargo Volume:
Over 140 cu. ft. (with second and third rows folded/removed)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4 out of 5 stars (for 2005 models)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags:
Front airbags, available side curtain airbags for all rows.
Seatbelts:
Three-point seatbelts for all seating positions, pretensioners.
Child Safety:
LATCH (Lower Anchors and Tethers for CHildren) system.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional premium audio system.
Display:
Digital clock, optional climate control display.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Power Outlets:
12V auxiliary power outlets.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 miles or 6 months, whichever comes first.
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Cabin Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plugs:
Replace every 60,000 miles (iridium type recommended).
Timing Belt:
Replace every 90,000 miles or 7 years, whichever comes first.
Fluid Specifications
Engine Oil Capacity:
Approx. 5.2 US quarts (with filter) using 5W-30 synthetic blend.
Transmission Fluid Capacity:
Approx. 7.7 US quarts (total capacity), 3.7 quarts (drain and fill).
Coolant Capacity:
Approx. 8.5 US quarts.
Known Issues
Common Problem 1:
Timing belt failure (if not replaced at recommended intervals) can lead to severe engine damage.
Common Problem 2:
Transmission solenoid issues leading to shifting problems or no-reverse conditions.
Common Problem 3:
Wheel bearing wear, particularly in early models.
Common Problem 4:
HVAC blower motor resistor failure causing inconsistent fan speeds.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
South Korea
Model Evolution
Generation:
First Generation (2003-2009)
Facelifts:
Received minor styling updates and feature enhancements during its first generation.
Production
Manufacturing Location:
South Korea
🏆 Awards & Recognition
Recognitions
Safety Award:
Achieved good safety ratings in its class for the model year.
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