Kia Sedona 2004 3.5L DOHC Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Kia Model: Sedona Year: 2004 Engine: 3.5L DOHC V6 Codes Engine Code: G6CU 👋 Introduction Market Position Vehicle Segment: Full-size Minivan Target Audience: Families, individuals requiring spacious and versatile transportation. Competitive Analysis Competitors 2004: Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture. Key Features Vehicle Seating Capacity: Typically 7 or 8 passengers. Body Style: Minivan Key Features Manual Instant Download: Available as an instant digital download, eliminating shipping costs and wait times. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Language: English Format: PDF (Digital) Page Count Page Count: 848 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, pistons, crankshaft, camshafts, lubrication system, cooling system, timing system (belt/chain), seals, gaskets. Engine Performance: Fuel injection system, ignition system, emission control system, engine diagnostics, troubleshooting. Transmission Mechanical: Automatic transmission assembly, torque converter, valve body, internal components, seals, fluid service. Drivetrain: Front axle, rear axle, drive shafts, CV joints, differentials, hubs, bearings. Suspension: Front suspension (struts, control arms, ball joints, bushings), rear suspension (multi-link, shock absorbers, springs, bushings). Steering: Steering column, steering gear, power steering system (pump, hoses, reservoir), tie rods, alignment specifications. Brakes: Front and rear brake systems (discs, calipers, pads, lines), parking brake, ABS (Anti-lock Braking System) components and diagnostics. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams, body control modules. HVAC: Heating, Ventilation, and Air Conditioning system components, operation, diagnostics, refrigerant handling. Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, trim, chassis. Body Interior: Seats, dashboard, interior trim, carpeting, safety restraints (seatbelts, airbags - general overview, not deployment calibration). Procedures Included Preventive Maintenance: Recommended service intervals for oil changes, filter replacements, fluid checks, belt inspections, spark plug replacement, brake service. Repair Procedures: Detailed step-by-step instructions for component removal, installation, and overhaul for all major vehicle systems. Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides, common fault codes and their meanings, electrical circuit tracing. Specifications Data: Torque specifications for critical fasteners, engine clearances, fluid capacities, alignment angles, diagnostic parameters. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, including power distribution, grounds, and component connections. Technical Depth Depth: Comprehensive, covering routine maintenance, complex repairs, and in-depth diagnostics for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Searchability: Likely text-searchable, enabling quick navigation to specific topics. Print Quality Print Quality: Digital PDF format allows for high-quality printing of individual pages or sections. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 3.5L V6 DOHC (Dual Overhead Camshaft) Displacement: 3.5 Liters (3497 cc) Bore X Stroke: 93.0 mm x 82.7 mm (approximate, requires manual verification) Compression Ratio: 9.4:1 (approximate, requires manual verification) Performance Horsepower: 200 hp @ 5500 rpm (approximate, requires manual verification) Torque: 217 lb-ft @ 3000 rpm (approximate, requires manual verification) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Fuel Octane Rating: 87 octane (minimum, requires manual verification for specific recommendations) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Overdrive Optional Transmission Type: N/A for this specific model/year/engine combination (typically only one automatic option for this powertrain) Features Transmission Fluid Type: SP-III (Super Automatic transmission fluid, Kia/Hyundai specific - requires manual verification for exact part number) Transmission Fluid Capacity: Approximately 7.5 - 8.0 liters (for complete overhaul, requires manual verification for drain and fill) 📐 Dimensions Exterior Length: Approximately 196.5 inches (requires manual verification) Width: Approximately 78.5 inches (requires manual verification) Height: Approximately 67.5 inches (requires manual verification) Wheelbase: Approximately 118.1 inches (requires manual verification) Weights Curb Weight: Approximately 4,300 - 4,500 lbs (varies by trim and options, requires manual verification) Gross Vehicle Weight Rating Gvwr: Approximately 5,700 - 6,000 lbs (requires manual verification) 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: Likely 4-star or 5-star (for 2004 model year, requires manual verification of specific ratings) NHTSA Side Crash Test Rating: Likely 4-star or 5-star (for 2004 model year, requires manual verification of specific ratings) Active Features ABS: Standard Anti-lock Braking System Traction Control: May be optional or standard depending on trim (requires manual verification) Passive Features Airbags: Front driver and passenger airbags. Side curtain airbags may be optional (requires manual verification). Seatbelts: Three-point seatbelts with pretensioners for front occupants. Lower anchors and tethers for children (LATCH) system. 💡 Technology Features Infotainment Audio System: Base audio systems typically include AM/FM stereo with CD player. Higher trims may offer premium audio or cassette player options. Manual covers operation and basic troubleshooting. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Power Outlets: 12V auxiliary power outlets for charging devices. 🔧 Maintenance Service Intervals Engine Oil Change Interval: Every 3,750 miles or 6 months, whichever comes first (severe driving conditions). 7,500 miles...
87 octane (minimum, requires manual verification for specific recommendations)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Overdrive
Optional
Transmission Type:
N/A for this specific model/year/engine combination (typically only one automatic option for this powertrain)
Features
Transmission Fluid Type:
SP-III (Super Automatic transmission fluid, Kia/Hyundai specific - requires manual verification for exact part number)
Transmission Fluid Capacity:
Approximately 7.5 - 8.0 liters (for complete overhaul, requires manual verification for drain and fill)
📐 Dimensions
Exterior
Length:
Approximately 196.5 inches (requires manual verification)
Width:
Approximately 78.5 inches (requires manual verification)
Height:
Approximately 67.5 inches (requires manual verification)
Wheelbase:
Approximately 118.1 inches (requires manual verification)
Weights
Curb Weight:
Approximately 4,300 - 4,500 lbs (varies by trim and options, requires manual verification)
Gross Vehicle Weight Rating Gvwr:
Approximately 5,700 - 6,000 lbs (requires manual verification)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test Rating:
Likely 4-star or 5-star (for 2004 model year, requires manual verification of specific ratings)
NHTSA Side Crash Test Rating:
Likely 4-star or 5-star (for 2004 model year, requires manual verification of specific ratings)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
May be optional or standard depending on trim (requires manual verification)
Passive Features
Airbags:
Front driver and passenger airbags. Side curtain airbags may be optional (requires manual verification).
Seatbelts:
Three-point seatbelts with pretensioners for front occupants. Lower anchors and tethers for children (LATCH) system.
💡 Technology Features
Infotainment
Audio System:
Base audio systems typically include AM/FM stereo with CD player. Higher trims may offer premium audio or cassette player options. Manual covers operation and basic troubleshooting.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Power Outlets:
12V auxiliary power outlets for charging devices.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 3,750 miles or 6 months, whichever comes first (severe driving conditions). 7,500 miles or 12 months (normal driving). Check manual for specific recommendations.
Engine Oil Filter Replacement:
With every oil change.
Air Cleaner Filter Replacement:
Every 15,000 miles or 12 months (severe driving). 30,000 miles or 24 months (normal driving). Check manual.
Spark Plug Replacement:
Typically around 60,000 - 100,000 miles for iridium or platinum plugs, depending on type. Requires manual verification.
Transmission Fluid Change Interval:
Every 30,000 miles or 24 months (severe driving). 60,000 miles or 48 months (normal driving). Check manual.
Timing Belt Replacement:
This engine uses a timing belt. Replacement interval typically around 60,000 - 90,000 miles or 5-7 years. CRITICAL to verify in manual as failure can cause severe engine damage.
Fluid Specifications
Engine Oil Type:
SAE 5W-30, API certified. Check manual for specific viscosity and API service category.
Ethylene glycol-based, long-life antifreeze (e.g., Asian red or equivalent). Check manual for specific color and specification.
Brake Fluid Type:
DOT 3 or DOT 4. Check manual for exact specification.
Known Issues
Common Issues Reported:
Potential issues may include: ABS sensor failures, power window motor failures, transmission solenoids/valve body issues, alternator failures, and HVAC blower motor resistor problems. These are common for the era and vehicle type and are comprehensively addressed in the manual.
📚 Vehicle History
Brand Heritage
Kia History:
Kia Motors Corporation, founded in 1944, is a South Korean automobile manufacturer. Known for its value-oriented vehicles and growing global presence.
Model Evolution
Sedona Generation:
This 2004 model belongs to the first generation of the Kia Sedona (VQ), which debuted in 1998 in Korea and 1999 in North America.
Production
Assembly Location:
Likely assembled in South Korea (Hwaseong Plant) or potentially other Kia facilities globally. Requires manual verification for specific model year.
🏆 Awards & Recognition
Recognitions
Awards History:
While specific awards for the 2004 Sedona are not widely publicized as segment leaders, Kia as a brand has seen increasing recognition for value, reliability improvements, and design in subsequent years. This manual provides the technical foundation to maintain and repair these vehicles effectively.