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2004 KIA SORENTO Full Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Sorento Year: 2004 Generation Generation Code: JC 👋 Introduction Market Position Segment: Mid-size SUV Competitive Analysis Key Competitors: Ford Explorer, Toyota 4Runner, Jeep Grand Cherokee, Nissan Pathfinder, Chevrolet TrailBlazer. Key Features Design Philosophy: Body-on-frame construction providing robust durability and towing capability, often compared to traditional SUVs. Target Audience: Families seeking a capable and versatile SUV with towing and off-road potential, as well as those valuing a rugged build. 📋 Manual Details Coverage Areas Coverage Scope: Full Service and Repair Page Count Estimated Page Count: Approx. 2000+ Manual Type Type: Professional Service and Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, internal components, cylinder head, pistons, crankshaft, camshafts, timing systems. Engine Management: Fuel injection system, ignition system, emission control systems, sensors, actuators, ECU diagnostics. Transmission Automatic: Automatic transmission overhaul, hydraulic controls, torque converter, internal gear sets, solenoids, electronic control module. Transmission Manual: Manual transmission overhaul, clutch assembly, gear selection mechanisms, bearings. Drivetrain: Front and rear differential, axles, CV joints, driveshafts, transfer case (if applicable). Suspension: Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications. Steering: Power steering system, steering rack, tie rods, steering column, power steering fluid specifications. Brakes: Front and rear brake systems (disc/drum), ABS, EBD, brake caliper overhaul, master cylinder, brake fluid specifications, bleeding procedures. Electrical System: Battery, charging system (alternator, starter), lighting systems, wiring diagrams, fuses, relays, accessory circuits. Body And Chassis: Body panels, doors, latches, hinges, bumpers, interior trim, chassis components, anti-corrosion measures. HVAC: Heating, ventilation, and air conditioning system, refrigerant types, compressor, evaporator, condenser, blower motor, climate control diagnostics. Safety Systems: Airbag system (SRS), seat belt pre-tensioners, diagnostic procedures for safety components. Procedures Included Maintenance: Routine scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, common problems and solutions. Repair: Step-by-step repair procedures for all major vehicle systems, component replacement, sub-assembly repair. Disassembly Reassembly: Complete disassembly and reassembly instructions for major components and systems. Diagnostics: OBD-II diagnostic trouble codes (DTCs), scan tool usage, sensor testing, electrical circuit testing. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds). 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (Full) Binding Type Binding Type: Digital (Downloadable PDF) Paper Type Paper Type: N/A (Digital) Zoom Capability Zoom In Out: Yes Delivery Method Delivery: Instant Download Software Requirements Requirements: Adobe PDF Reader & WinZip Compatibility Compatible Os: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: G6CU (3.5L V6) Engine Type: 60-degree SOHC V6 Displacement: 3.5 Liters (3497 cc) Bore X Stroke: 91.4 mm x 88.0 mm Compression Ratio: 9.3:1 Performance Horsepower: 195 hp @ 5500 rpm Torque: 217 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Engine Cooling Coolant Capacity: Approx. 7.9 Liters (8.3 Quarts) Engine Lubrication Oil Capacity: Approx. 4.7 Liters (5.0 Quarts) with filter change Recommended Oil Viscosity: SAE 5W-30 🔧 Transmission Primary Transmission Type: 4-Speed Automatic Transmission (4-Speed Automatic) Transmission Fluid Type: SP-III (Kia Genuine ATF) Transmission Fluid Capacity: Approx. 7.0 Liters (7.4 Quarts) Drivetrain Options Drive Type: Part-time 4WD and Full-time 4WD options available. 📐 Dimensions Exterior Length: 4700 mm (185.0 in) Width: 1810 mm (71.3 in) Height: 1740 mm (68.5 in) Wheelbase: 2710 mm (106.7 in) Ground Clearance: Approx. 200 mm (7.9 in) Weights Curb Weight: Approx. 1950 kg (4300 lbs) Gross Vehicle Weight Rating: Approx. 2600 kg (5732 lbs) Towing Capacity: Up to 3500 lbs (1588 kg) with appropriate tow package. Cargo Cargo Volume Behind 3Rd Row: N/A (Typically 2-row configuration for this year) Cargo Volume Behind 2Nd Row: Approx. 1100 Liters (38.8 cu ft) Wheels And Tires Wheel Size: 16-inch or 17-inch alloy wheels Tire Size Standard: 245/70R16 Tire Size Optional: 245/65R17 Bolt Pattern: 5x139.7 mm 🛡️ Safety Features Ratings NHTSA Front Driver Side Impact: 5 Stars NHTSA Front Passenger Side Impact: 5 Stars NHTSA Side Driver Side Impact: 4 Stars NHTSA Side Passenger Side Impact: 4 Stars NHTSA Rollover Resistance: 4 Stars (with 4WD) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction Control System (TCS) Stability Control: Not widely available on this model year. Passive Features Airbags: Dual front airbags, available front side-impact airbags. Seatbelts: 3-point seat belts with pretensioners for front seats. 💡 Technology Features Infotainment Audio System: AM/FM/CD stereo system with optional premium sound, steering wheel audio controls available on higher trims. Navigation: Optional factory-installed navigation system. Driver Assistance Cruise Control: Standard cruise control. Parking Sensors: Rear parking sensors may be available as an option. Connectivity Auxiliary Input: Optional auxiliary audio input jack may be present. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever...
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2004 KIA SORENTO Full Service Repair Manual2004 KIA SORENTO Full Service Repair Manual2004 KIA SORENTO Full Service Repair Manual2004 KIA SORENTO Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kia
Model:
Sorento
Year:
2004
Generation
Generation Code:
JC
👋 Introduction
Market Position
Segment:
Mid-size SUV
Competitive Analysis
Key Competitors:
Ford Explorer, Toyota 4Runner, Jeep Grand Cherokee, Nissan Pathfinder, Chevrolet TrailBlazer.
Key Features
Design Philosophy:
Body-on-frame construction providing robust durability and towing capability, often compared to traditional SUVs.
Target Audience:
Families seeking a capable and versatile SUV with towing and off-road potential, as well as those valuing a rugged build.
📋 Manual Details
Coverage Areas
Coverage Scope:
Full Service and Repair
Page Count
Estimated Page Count:
Approx. 2000+
Manual Type
Type:
Professional Service and Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, internal components, cylinder head, pistons, crankshaft, camshafts, timing systems.
Engine Management:
Fuel injection system, ignition system, emission control systems, sensors, actuators, ECU diagnostics.
Transmission Automatic:
Automatic transmission overhaul, hydraulic controls, torque converter, internal gear sets, solenoids, electronic control module.
Transmission Manual:
Manual transmission overhaul, clutch assembly, gear selection mechanisms, bearings.
Drivetrain:
Front and rear differential, axles, CV joints, driveshafts, transfer case (if applicable).
Suspension:
Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications.
Steering:
Power steering system, steering rack, tie rods, steering column, power steering fluid specifications.
Brakes:
Front and rear brake systems (disc/drum), ABS, EBD, brake caliper overhaul, master cylinder, brake fluid specifications, bleeding procedures.
Electrical System:
Battery, charging system (alternator, starter), lighting systems, wiring diagrams, fuses, relays, accessory circuits.
Body And Chassis:
Body panels, doors, latches, hinges, bumpers, interior trim, chassis components, anti-corrosion measures.
HVAC:
Heating, ventilation, and air conditioning system, refrigerant types, compressor, evaporator, condenser, blower motor, climate control diagnostics.
Safety Systems:
Airbag system (SRS), seat belt pre-tensioners, diagnostic procedures for safety components.
Procedures Included
Maintenance:
Routine scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common problems and solutions.
Repair:
Step-by-step repair procedures for all major vehicle systems, component replacement, sub-assembly repair.
Disassembly Reassembly:
Complete disassembly and reassembly instructions for major components and systems.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), scan tool usage, sensor testing, electrical circuit testing.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable (Full)
Binding Type
Binding Type:
Digital (Downloadable PDF)
Paper Type
Paper Type:
N/A (Digital)
Zoom Capability
Zoom In Out:
Yes
Delivery Method
Delivery:
Instant Download
Software Requirements
Requirements:
Adobe PDF Reader & WinZip
Compatibility
Compatible Os:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
G6CU (3.5L V6)
Engine Type:
60-degree SOHC V6
Displacement:
3.5 Liters (3497 cc)
Bore X Stroke:
91.4 mm x 88.0 mm
Compression Ratio:
9.3:1
Performance
Horsepower:
195 hp @ 5500 rpm
Torque:
217 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Cooling
Coolant Capacity:
Approx. 7.9 Liters (8.3 Quarts)
Engine Lubrication
Oil Capacity:
Approx. 4.7 Liters (5.0 Quarts) with filter change
Recommended Oil Viscosity:
SAE 5W-30
🔧 Transmission
Primary Transmission
Type:
4-Speed Automatic Transmission (4-Speed Automatic)
Transmission Fluid Type:
SP-III (Kia Genuine ATF)
Transmission Fluid Capacity:
Approx. 7.0 Liters (7.4 Quarts)
Drivetrain Options
Drive Type:
Part-time 4WD and Full-time 4WD options available.
📐 Dimensions
Exterior
Length:
4700 mm (185.0 in)
Width:
1810 mm (71.3 in)
Height:
1740 mm (68.5 in)
Wheelbase:
2710 mm (106.7 in)
Ground Clearance:
Approx. 200 mm (7.9 in)
Weights
Curb Weight:
Approx. 1950 kg (4300 lbs)
Gross Vehicle Weight Rating:
Approx. 2600 kg (5732 lbs)
Towing Capacity:
Up to 3500 lbs (1588 kg) with appropriate tow package.
Cargo
Cargo Volume Behind 3Rd Row:
N/A (Typically 2-row configuration for this year)
Cargo Volume Behind 2Nd Row:
Approx. 1100 Liters (38.8 cu ft)
Wheels And Tires
Wheel Size:
16-inch or 17-inch alloy wheels
Tire Size Standard:
245/70R16
Tire Size Optional:
245/65R17
Bolt Pattern:
5x139.7 mm
🛡️ Safety Features
Ratings
NHTSA Front Driver Side Impact:
5 Stars
NHTSA Front Passenger Side Impact:
5 Stars
NHTSA Side Driver Side Impact:
4 Stars
NHTSA Side Passenger Side Impact:
4 Stars
NHTSA Rollover Resistance:
4 Stars (with 4WD)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Stability Control:
Not widely available on this model year.
Passive Features
Airbags:
Dual front airbags, available front side-impact airbags.
Seatbelts:
3-point seat belts with pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
AM/FM/CD stereo system with optional premium sound, steering wheel audio controls available on higher trims.
Navigation:
Optional factory-installed navigation system.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Sensors:
Rear parking sensors may be available as an option.
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack may be present.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Engine Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed.
Transmission Fluid Change:
Every 60,000 miles (96,000 km) or 48 months.
Spark Plug Replacement:
Every 100,000 miles (160,000 km) for iridium-tipped plugs.
Fluid Specifications
Engine Coolant:
Kia Genuine Long Life Antifreeze/Coolant (Blue) or equivalent Asian vehicle coolant.
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron III ATF or Kia Genuine Power Steering Fluid.
Known Issues
Common Complaint 1:
Potential for automatic transmission solenoid issues leading to shifting problems.
Common Complaint 2:
Cracked exhaust manifolds on some V6 models due to heat stress.
Common Complaint 3:
Power window regulator failures.
Common Complaint 4:
Leaking front differential seal on 4WD models.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
South Korea
Model Evolution
First Generation Launch:
2001 (Globally), 2004 (North America)
Generation Code:
JC
Production
Manufacturing Location:
South Korea
🏆 Awards & Recognition
Recognitions
Award 1:
Recognized by various consumer reports for its value and utility in the SUV segment upon its introduction.
Ratings
Safety Score Mention:
Generally received positive safety ratings from NHTSA for its era.
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