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Kia Sedona (GQ) 2004 3.5 DOHC Engine Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Sedona Year: 2004 Chassis Code: GQ Engine Variant: 3.5 DOHC Codes Product Code Example: RM-KSED200435 👋 Introduction Market Position Segment: Full-size Minivan Target Audience: Families, businesses requiring passenger transport Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Chrysler Town & Country, Ford Windstar Key Features Vehicle Appeal: Spacious interior, comfortable ride, practical for family use. Manual Value Proposition: Enables owners and independent mechanics to perform expert-level maintenance and repairs, reducing dealership costs. 📋 Manual Details Coverage Areas Primary Focus: 3.5L DOHC Engine Service and Repair Vehicle Range: 2004 Kia Sedona (GQ) equipped with the 3.5L DOHC V6 engine Page Count Estimated Pages: 800+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing system, lubrication system. Engine Fuel And Emission: Fuel injection system (MPI), fuel pump, injectors, EVAP system, emission control systems, sensors (MAF, O2, TPS). Engine Ignition: Ignition coil system, spark plugs, ignition timing, ECU control. Cooling System: Radiator, water pump, thermostat, cooling fan, hoses, coolant specifications. Lubrication System: Oil pump, oil filter, oil pan, oil pressure, lubrication intervals, oil specifications. Engine Control Module ECU: ECU diagnostics, sensor inputs, actuator outputs, wiring diagrams related to engine management. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections. Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, common failure modes. Repair Procedures: Step-by-step instructions for component removal, installation, and overhaul. Torque Specifications: Detailed torque values for all critical fasteners (cylinder head bolts, main bearing caps, etc.). Special Tools: Identification and usage of specialized tools required for specific procedures. Technical Depth Depth: Comprehensive - covers basic maintenance to complete engine rebuilds and diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes Print Quality Diagram Resolution: High-resolution, clear, and detailed Text Readability: Easy-to-read text, professional formatting Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: G6CU (typically) Displacement: 3.5 Liters (3497 cc) Configuration: V6 (6-cylinder) Valvetrain: DOHC (Double Overhead Camshaft) with 4 valves per cylinder (24 valves total) Bore X Stroke: 91.0 mm x 90.0 mm (approx.) Compression Ratio: 9.3:1 (approx.) Redline: 6500 RPM (approx.) Performance Horsepower: 200 HP @ 5500 RPM (approx.) Torque: 218 lb-ft @ 3500 RPM (approx.) Fuel System Fuel Type: Unleaded Gasoline Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Octane Rating: 87 Octane (Regular Unleaded) 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Overdrive Transmission Model: Kia F4A51 (likely) Optional Optional Transmissions: None offered for this specific engine/year combination in most markets. Features Drive Type: Front-Wheel Drive (FWD) Transmission Fluid Type: SPIIID (SP-III) ATF or equivalent 📐 Dimensions Exterior Length: 4815 mm (189.6 inches) Width: 1985 mm (78.1 inches) Height: 1785 mm (70.3 inches) Wheelbase: 2905 mm (114.4 inches) Front Track: 1640 mm (64.6 inches) Rear Track: 1620 mm (63.8 inches) Weights Curb Weight: 2000-2150 kg (approx.) Gross Vehicle Weight Rating Gvw: 2770 kg (approx.) Cargo Cargo Volume All Seats Up: N/A (typical for minivan, but manual would detail) Cargo Volume Rear Seats Folded: N/A (typical for minivan, but manual would detail) 🛡️ Safety Features Ratings NHTSA Front Crash Test: 4-Star (Driver), 4-Star (Passenger) - 2004 model year IIHS Side Impact: Good (for models equipped with side airbags, if applicable) Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Optional/Standard depending on trim Electronic Stability Control Esc: Not typically standard on this model year, but manual may cover related diagnostics if present. Passive Features Airbags Front: Standard (Driver and Passenger) Airbags Side Curtain: Optional (depending on trim and market) Seatbelts: 3-point seatbelts for all occupants, pretensioners for front seats. 💡 Technology Features Infotainment Audio System: AM/FM Stereo with CD Player. Optional Infinity sound system may be present. Navigation: Optional factory-installed navigation system available on higher trim levels. Driver Assistance Cruise Control: Standard Connectivity Power Accessories: Power windows, power door locks, power sliding doors (optional). 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 miles (8,000 km) or 6 months, whichever comes first. Engine Oil Filter Replacement: With every oil change. Spark Plug Replacement: Every 60,000 miles (96,000 km) (typically Iridium or Platinum plugs). Engine Coolant Flush: Every 30,000 miles (48,000 km) or 2 years. Automatic Transmission Fluid Change: Every 60,000 miles (96,000 km) or 4 years. Serpentine Belt Inspection: Every 15,000 miles (24,000 km), replacement as needed. Fluid Specifications Engine Oil Type: API SG or higher, SAE 5W-30 or 5W-40 Engine Oil Capacity: 5.8 Liters (6.1 US quarts) Transmission Fluid Type: SPIIID (SP-III) Automatic Transmission Fluid Transmission Fluid Capacity: 7.3 Liters (7.7 US quarts) for refill, 8.2 Liters (8.7 US quarts) for overhaul. Coolant Type: Ethylene Glycol based coolant (long-life, blue or green) Coolant Capacity: 8.5 Liters (9.0 US quarts) Known Issues...
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Kia Sedona (GQ) 2004 3.5 DOHC Engine Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kia
Model:
Sedona
Year:
2004
Chassis Code:
GQ
Engine Variant:
3.5 DOHC
Codes
Product Code Example:
RM-KSED200435
👋 Introduction
Market Position
Segment:
Full-size Minivan
Target Audience:
Families, businesses requiring passenger transport
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Chrysler Town & Country, Ford Windstar
Key Features
Vehicle Appeal:
Spacious interior, comfortable ride, practical for family use.
Manual Value Proposition:
Enables owners and independent mechanics to perform expert-level maintenance and repairs, reducing dealership costs.
📋 Manual Details
Coverage Areas
Primary Focus:
3.5L DOHC Engine Service and Repair
Vehicle Range:
2004 Kia Sedona (GQ) equipped with the 3.5L DOHC V6 engine
Page Count
Estimated Pages:
800+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing system, lubrication system.
Engine Fuel And Emission:
Fuel injection system (MPI), fuel pump, injectors, EVAP system, emission control systems, sensors (MAF, O2, TPS).
Engine Ignition:
Ignition coil system, spark plugs, ignition timing, ECU control.
Cooling System:
Radiator, water pump, thermostat, cooling fan, hoses, coolant specifications.
Lubrication System:
Oil pump, oil filter, oil pan, oil pressure, lubrication intervals, oil specifications.
Engine Control Module ECU:
ECU diagnostics, sensor inputs, actuator outputs, wiring diagrams related to engine management.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections.
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, common failure modes.
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul.
Torque Specifications:
Detailed torque values for all critical fasteners (cylinder head bolts, main bearing caps, etc.).
Special Tools:
Identification and usage of specialized tools required for specific procedures.
Technical Depth
Depth:
Comprehensive - covers basic maintenance to complete engine rebuilds and diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Print Quality
Diagram Resolution:
High-resolution, clear, and detailed
Text Readability:
Easy-to-read text, professional formatting
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G6CU (typically)
Displacement:
3.5 Liters (3497 cc)
Configuration:
V6 (6-cylinder)
Valvetrain:
DOHC (Double Overhead Camshaft) with 4 valves per cylinder (24 valves total)
Bore X Stroke:
91.0 mm x 90.0 mm (approx.)
Compression Ratio:
9.3:1 (approx.)
Redline:
6500 RPM (approx.)
Performance
Horsepower:
200 HP @ 5500 RPM (approx.)
Torque:
218 lb-ft @ 3500 RPM (approx.)
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Octane Rating:
87 Octane (Regular Unleaded)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic Overdrive
Transmission Model:
Kia F4A51 (likely)
Optional
Optional Transmissions:
None offered for this specific engine/year combination in most markets.
Features
Drive Type:
Front-Wheel Drive (FWD)
Transmission Fluid Type:
SPIIID (SP-III) ATF or equivalent
📐 Dimensions
Exterior
Length:
4815 mm (189.6 inches)
Width:
1985 mm (78.1 inches)
Height:
1785 mm (70.3 inches)
Wheelbase:
2905 mm (114.4 inches)
Front Track:
1640 mm (64.6 inches)
Rear Track:
1620 mm (63.8 inches)
Weights
Curb Weight:
2000-2150 kg (approx.)
Gross Vehicle Weight Rating Gvw:
2770 kg (approx.)
Cargo
Cargo Volume All Seats Up:
N/A (typical for minivan, but manual would detail)
Cargo Volume Rear Seats Folded:
N/A (typical for minivan, but manual would detail)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
4-Star (Driver), 4-Star (Passenger) - 2004 model year
IIHS Side Impact:
Good (for models equipped with side airbags, if applicable)
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Optional/Standard depending on trim
Electronic Stability Control Esc:
Not typically standard on this model year, but manual may cover related diagnostics if present.
Passive Features
Airbags Front:
Standard (Driver and Passenger)
Airbags Side Curtain:
Optional (depending on trim and market)
Seatbelts:
3-point seatbelts for all occupants, pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
AM/FM Stereo with CD Player. Optional Infinity sound system may be present.
Navigation:
Optional factory-installed navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard
Connectivity
Power Accessories:
Power windows, power door locks, power sliding doors (optional).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Engine Oil Filter Replacement:
With every oil change.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) (typically Iridium or Platinum plugs).
Engine Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Automatic Transmission Fluid Change:
Every 60,000 miles (96,000 km) or 4 years.
Serpentine Belt Inspection:
Every 15,000 miles (24,000 km), replacement as needed.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 or 5W-40
Engine Oil Capacity:
5.8 Liters (6.1 US quarts)
Transmission Fluid Type:
SPIIID (SP-III) Automatic Transmission Fluid
Transmission Fluid Capacity:
7.3 Liters (7.7 US quarts) for refill, 8.2 Liters (8.7 US quarts) for overhaul.
Coolant Type:
Ethylene Glycol based coolant (long-life, blue or green)
Coolant Capacity:
8.5 Liters (9.0 US quarts)
Known Issues
Engine Performance:
Occasional rough idling due to worn spark plugs or fuel injectors. Intake manifold gasket leaks can cause vacuum issues.
Transmission:
Slipping or harsh shifts can indicate low fluid levels or internal wear. Clutch solenoid issues can also cause shifting problems.
Cooling System:
Thermostat failures leading to overheating or poor heating. Water pump leaks are also a possibility.
Electrical System:
Alternator failures and battery drain issues are common as the vehicle ages. Sensor failures (e.g., Crankshaft Position Sensor) can cause starting issues.
📚 Vehicle History
Brand Heritage
Brand Origin:
South Korea
Model Evolution
First Generation Start:
1997 (as Kia Joys, then Kia Carnival)
Second Generation Start:
2006 (major redesign)
2004 Model Year Positioning:
Part of the first generation, representing a mature product before the second generation redesign. Often sold as Kia Carnival outside North America.
Production
Manufacturing Locations:
South Korea (primary), various international assembly plants
🏆 Awards & Recognition
Recognitions
Family Car Awards:
While the Sedona itself might not have numerous individual awards, Kia as a brand has seen increasing recognition for value and reliability in the early 2000s.
Ratings
Consumer Reports Reliability:
Varied, generally average to above average for its class during this period. Manual is essential for addressing specific issues.
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