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KIA Sedona 2004 V6 (3.5L) OEM Factory Shop Service Repair Manual FSM Year Specific

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🏷️ Basic Information Identification Make: Kia Model: Sedona Year: 2004 Body Style: Minivan Codes Chassis Code: VQ Engine Code Primary: G6CU 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, individuals seeking versatile passenger and cargo transport. Competitive Analysis Key Competitors: Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Freestar/Windstar, Chevrolet Uplander/Venture. Key Features Manual Utility: Provides professional-level repair and maintenance guidance for DIY owners and professional technicians. Information Source: OEM (Original Equipment Manufacturer) data, identical to what dealership technicians use. User Friendliness: Designed for clarity with accurate, concise text and illustrative diagrams, making complex procedures accessible. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual (FSM) Language: English Format: PDF File Type: Single PDF File Searchability: Searchable Index Internet Requirement: No Internet Required Software Requirement: No Additional Software Required 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, overhaul, lubrication system, cooling system, fuel system, emission control system. Engine Electrical: Ignition system, starting system, charging system, engine control module (ECM) diagnostics, sensors, actuators. Transmission: Automatic transmission (transaxle) assembly, disassembly, operation, diagnostics, fluid and filter service, control systems. Drivetrain: Front-wheel drive system, drive shafts, CV joints, differential. Suspension: Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications. Steering: Power steering system, steering gear, steering column, tie rods, power steering fluid specifications. Brakes: Front and rear disc brakes, brake fluid specifications, hydraulic system, ABS (Anti-lock Braking System) diagnostics and components, parking brake. Wheels And Tires: Wheel specifications, tire pressure recommendations, rotation, balancing. Body And Frame: Body panel removal and installation, structural components, corrosion protection, door and window mechanisms, seals, exterior trim. Interior: Seating systems, dashboard components, interior trim, headliner, flooring, HVAC controls. HVAC: Heating, Ventilation, and Air Conditioning system components, refrigerant charging, diagnostics, cabin air filter replacement. Electrical System: Wiring diagrams, lighting systems (headlights, taillights, interior lights), power windows, power locks, mirrors, wipers, horn, fuses, relays. Safety Systems: Airbag system (SRS), seat belt operation, child restraint system (LATCH) locations. Diagnostic Troubleshooting: Step-by-step diagnostic procedures, symptom-based troubleshooting, DTC (Diagnostic Trouble Code) interpretations and repair strategies. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant checks and changes, transmission fluid service, brake fluid checks. Major Repairs: Engine rebuilds, transmission overhaul, suspension component replacement, brake caliper replacement, power steering pump replacement. Component Replacement: Detailed instructions for replacing virtually all serviceable components. Troubleshooting Guides: Comprehensive guides for diagnosing and resolving common and uncommon vehicle issues. Wiring Diagrams: Detailed, system-specific wiring schematics for all electrical circuits. Specifications: Torque specifications for all fasteners, fluid capacities, pressure specifications, electrical specifications. Technical Depth Depth Level: Comprehensive (Bumper-to-Bumper) Diagnostic Capability: Advanced diagnostics and troubleshooting for complex systems. Rebuild Procedures: Detailed procedures for complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Format: PDF File Organization: Single, unified document Print Quality Print Quality: High-resolution for clarity of text and diagrams Illustrations: Clear, detailed, in-depth illustrations and diagrams Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: V6 Displacement: 3.5 Liters (3497 cc) Valvetrain: DOHC (Dual Overhead Camshafts), 24 Valves (4 valves per cylinder) Bore X Stroke: 93.0 mm x 82.7 mm Compression Ratio: 9.4:1 Performance Horsepower Net: Approximately 200-205 hp @ 5500 rpm (specific figure may vary slightly by market/tuning) Torque Net: Approximately 217-220 lb-ft @ 3500 rpm (specific figure may vary slightly by market/tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI - Multi-Point Injection) Fuel Type: Unleaded Gasoline Fuel Tank Capacity: Approximately 18.5 gallons (70 Liters) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle Optional Transmission Options: None offered for this specific model year and engine configuration. Features Transmission Fluid Type: SP-III (or equivalent DEXRON-III compatible) Transmission Fluid Capacity: Approximately 8.7 quarts (8.2 Liters) for a dry fill, lower for fluid change. 📐 Dimensions Exterior Length: Approximately 195.7 inches (4971 mm) Width: Approximately 78.4 inches (1991 mm) without mirrors Height: Approximately 67.9 inches (1725 mm) Wheelbase: Approximately 118.1 inches (3000 mm) Front Track: Approximately 65.8 inches (1671 mm) Rear Track: Approximately 65.6 inches (1666 mm) Weights Curb Weight: Approximately 4300 - 4500 lbs (1950 - 2041 kg), varies by trim and equipment. Gross Vehicle Weight Rating Gvwr: Approximately 5932 lbs (2690 kg) Cargo Cargo Volume Behind 3Rd Row: Approximately 31.4 cubic feet (889 Liters) Cargo Volume Behind 2Nd Row: Approximately 80.1 cubic feet (2268 Liters) Cargo Volume Behind 1St Row: Approximately 140.4 cubic feet (3975 Liters) 🛡️ Safety Features Ratings NHTSA Front Crash Test: 5-Star (Driver), 5-Star (Passenger) - For 2004 models, check specific VIN and equipment. NHTSA Side Impact Crash Test: 4-Star (Front Seat), 5-Star (Rear Seat) - For 2004 models, check specific VIN and equipment. IIHS Frontal Offset: Good (for 2004 models, based on available data) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction...
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KIA Sedona 2004 V6 (3.5L) OEM Factory Shop Service Repair Manual FSM Year Specific
🏷️ Basic Information
Identification
Make:
Kia
Model:
Sedona
Year:
2004
Body Style:
Minivan
Codes
Chassis Code:
VQ
Engine Code Primary:
G6CU
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, individuals seeking versatile passenger and cargo transport.
Competitive Analysis
Key Competitors:
Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Freestar/Windstar, Chevrolet Uplander/Venture.
Key Features
Manual Utility:
Provides professional-level repair and maintenance guidance for DIY owners and professional technicians.
Information Source:
OEM (Original Equipment Manufacturer) data, identical to what dealership technicians use.
User Friendliness:
Designed for clarity with accurate, concise text and illustrative diagrams, making complex procedures accessible.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual (FSM)
Language:
English
Format:
PDF
File Type:
Single PDF File
Searchability:
Searchable Index
Internet Requirement:
No Internet Required
Software Requirement:
No Additional Software Required
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, overhaul, lubrication system, cooling system, fuel system, emission control system.
Engine Electrical:
Ignition system, starting system, charging system, engine control module (ECM) diagnostics, sensors, actuators.
Transmission:
Automatic transmission (transaxle) assembly, disassembly, operation, diagnostics, fluid and filter service, control systems.
Drivetrain:
Front-wheel drive system, drive shafts, CV joints, differential.
Suspension:
Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications.
Steering:
Power steering system, steering gear, steering column, tie rods, power steering fluid specifications.
Brakes:
Front and rear disc brakes, brake fluid specifications, hydraulic system, ABS (Anti-lock Braking System) diagnostics and components, parking brake.
Wheels And Tires:
Wheel specifications, tire pressure recommendations, rotation, balancing.
Body And Frame:
Body panel removal and installation, structural components, corrosion protection, door and window mechanisms, seals, exterior trim.
Interior:
Seating systems, dashboard components, interior trim, headliner, flooring, HVAC controls.
HVAC:
Heating, Ventilation, and Air Conditioning system components, refrigerant charging, diagnostics, cabin air filter replacement.
Electrical System:
Wiring diagrams, lighting systems (headlights, taillights, interior lights), power windows, power locks, mirrors, wipers, horn, fuses, relays.
Safety Systems:
Airbag system (SRS), seat belt operation, child restraint system (LATCH) locations.
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures, symptom-based troubleshooting, DTC (Diagnostic Trouble Code) interpretations and repair strategies.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant checks and changes, transmission fluid service, brake fluid checks.
Major Repairs:
Engine rebuilds, transmission overhaul, suspension component replacement, brake caliper replacement, power steering pump replacement.
Component Replacement:
Detailed instructions for replacing virtually all serviceable components.
Troubleshooting Guides:
Comprehensive guides for diagnosing and resolving common and uncommon vehicle issues.
Wiring Diagrams:
Detailed, system-specific wiring schematics for all electrical circuits.
Specifications:
Torque specifications for all fasteners, fluid capacities, pressure specifications, electrical specifications.
Technical Depth
Depth Level:
Comprehensive (Bumper-to-Bumper)
Diagnostic Capability:
Advanced diagnostics and troubleshooting for complex systems.
Rebuild Procedures:
Detailed procedures for complete engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Format:
PDF
File Organization:
Single, unified document
Print Quality
Print Quality:
High-resolution for clarity of text and diagrams
Illustrations:
Clear, detailed, in-depth illustrations and diagrams
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V6
Displacement:
3.5 Liters (3497 cc)
Valvetrain:
DOHC (Dual Overhead Camshafts), 24 Valves (4 valves per cylinder)
Bore X Stroke:
93.0 mm x 82.7 mm
Compression Ratio:
9.4:1
Performance
Horsepower Net:
Approximately 200-205 hp @ 5500 rpm (specific figure may vary slightly by market/tuning)
Torque Net:
Approximately 217-220 lb-ft @ 3500 rpm (specific figure may vary slightly by market/tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI - Multi-Point Injection)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Approximately 18.5 gallons (70 Liters)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle
Optional
Transmission Options:
None offered for this specific model year and engine configuration.
Features
Transmission Fluid Type:
SP-III (or equivalent DEXRON-III compatible)
Transmission Fluid Capacity:
Approximately 8.7 quarts (8.2 Liters) for a dry fill, lower for fluid change.
📐 Dimensions
Exterior
Length:
Approximately 195.7 inches (4971 mm)
Width:
Approximately 78.4 inches (1991 mm) without mirrors
Height:
Approximately 67.9 inches (1725 mm)
Wheelbase:
Approximately 118.1 inches (3000 mm)
Front Track:
Approximately 65.8 inches (1671 mm)
Rear Track:
Approximately 65.6 inches (1666 mm)
Weights
Curb Weight:
Approximately 4300 - 4500 lbs (1950 - 2041 kg), varies by trim and equipment.
Gross Vehicle Weight Rating Gvwr:
Approximately 5932 lbs (2690 kg)
Cargo
Cargo Volume Behind 3Rd Row:
Approximately 31.4 cubic feet (889 Liters)
Cargo Volume Behind 2Nd Row:
Approximately 80.1 cubic feet (2268 Liters)
Cargo Volume Behind 1St Row:
Approximately 140.4 cubic feet (3975 Liters)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
5-Star (Driver), 5-Star (Passenger) - For 2004 models, check specific VIN and equipment.
NHTSA Side Impact Crash Test:
4-Star (Front Seat), 5-Star (Rear Seat) - For 2004 models, check specific VIN and equipment.
IIHS Frontal Offset:
Good (for 2004 models, based on available data)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on some trims.
Passive Features
Airbags:
Driver and front passenger airbags, available side-impact airbags for front occupants.
Seatbelts:
3-point seat belts in all seating positions, pretensioners for front seats.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, available premium audio systems with multiple speakers and cassette player in some trims.
Navigation:
Optional GPS navigation system available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Auxiliary Input:
Not typically standard; aftermarket solutions may be available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first. For severe driving conditions, every 3,000 miles (4,800 km).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Approximately every 100,000 miles (160,000 km) for iridium-tipped plugs (check specific type installed).
Coolant Replacement:
First replacement at 60,000 miles (96,000 km), then every 30,000 miles (48,000 km) or 2 years. Use specified coolant.
Transmission Fluid Change:
Every 60,000 miles (96,000 km) or 4 years. Severe use may require more frequent changes.
Fluid Specifications
Engine Oil Type:
API SL or SM, SAE 5W-30.
Engine Oil Capacity:
Approximately 5.2 quarts (4.9 Liters) with filter change.
Coolant Type:
Ethylene Glycol based antifreeze, long-life type (e.g., Kia Super Long Life Coolant).
Brake Fluid Type:
DOT 3 or DOT 4, meeting FMVSS 116.
Known Issues
Common Issues 1:
Power steering pump leaks or noise.
Common Issues 2:
Door lock actuator failures.
Common Issues 3:
Front suspension component wear (e.g., ball joints, control arm bushings).
Common Issues 4:
HVAC blower motor resistor issues leading to intermittent fan speeds.
Common Issues 5:
Transmission shift solenoid issues, particularly with higher mileage units.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kia Motors Corporation
Model Evolution
Generation:
First Generation (2000-2005)
Redesign Year:
The 2004 model represents the latter half of the first generation, with minor updates potentially occurring.
Production
Manufacturing Location:
Hwasung, South Korea (Kia's main production facility).
🏆 Awards & Recognition
Recognitions
Safety Awards 2004:
Recipient of 5-star frontal crash test ratings from NHTSA.
Ratings
Consumer Reports General:
Praised for spacious interior and value, though reliability ratings varied in early years.
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