Kia Sorento 2012 Workshop Service Repair Manual

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The Kia Sorento, model year 2012 (XM chassis code), is a mid-size crossover SUV designed with practicality and family needs in mind. This generation of the Sorento shifted to a unibody construction, enhancing its ride comfort and handling characteristics. It was offered with a choice of a 2.4-liter inline 4-cylinder engine producing 175 horsepower or a more potent 3.5-liter V6 engine delivering 276 horsepower. Available in both front-wheel drive and all-wheel drive configurations, and with seating for five or seven occupants, the Sorento provided a versatile option in a competitive segment, often lauded for its value and European-inspired design. This comprehensive factory workshop service repair manual provides detailed information for the maintenance, diagnosis, and repair of the 2012 Kia Sorento. It covers all major systems, including engine mechanicals and performance, manual and automatic transmissions, drivetrain, suspension, steering, brakes, and the complete electrical system. Within its extensive pages, you will find step-by-step repair procedures, component replacement guides, essential torque specifications, wiring diagrams, and troubleshooting assistance for common issues. This manual is an indispensable resource for owners, technicians, and mechanics seeking to maintain the optimal performance and longevity of their Sorento. 🏷️ Basic Information Identification Make: Kia Model: Sorento Year: 2012 Codes Chassis Code: XM 👋 Introduction Market Position Vehicle Class: Mid-size Crossover SUV Segment: Family SUV, often competing with models like the Toyota Highlander, Honda Pilot, and Ford Explorer. Competitive Analysis Key Competitors 2012: Toyota Highlander, Honda Pilot, Ford Explorer, Nissan Pathfinder, Chevrolet Traverse. Key Features Seating Capacity: Available in 5-seater and 7-seater configurations. Drivetrain Options: Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) configurations. Design Philosophy: Emphasizes practicality, value, and a more European-inspired design compared to some rivals. 📋 Manual Details Coverage Areas Manual Type: Complete Official Factory Workshop Service Repair Manual Language: English Format: PDF Download Page Count: Hundreds of pages (estimated 2000+ pages for comprehensive factory manuals) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, cylinder head, block, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system, fuel system, intake system, exhaust system, engine management systems. Engine Performance: Ignition system, fuel injection, emissions control, turbocharger (if applicable), engine diagnostics. Transmission Manual: Manual transmission assembly, disassembly, repair, clutch system, gears, synchronizers, shift mechanism. Transmission Automatic: Automatic transmission assembly, disassembly, repair, torque converter, valve body, planetary gear sets, transmission control module (TCM), fluid service. Drivetrain: Front-wheel drive (FWD), All-wheel drive (AWD) system, transfer case, differentials, drive shafts, axles, CV joints. Suspension: Front suspension (MacPherson strut, control arms), rear suspension (multi-link, trailing arms), shock absorbers, springs, bushings, stabilizers, wheel alignment. Steering: Power steering system, steering column, steering rack, power steering pump, fluid service, hydraulic systems. Brakes: Front and rear brake systems, disc brakes, calipers, pads, rotors, brake lines, master cylinder, brake booster, ABS system, parking brake. Electrical System: Battery, charging system (alternator), starter motor, ignition system, lighting systems (headlights, taillights, interior), power windows, power locks, mirrors, horn. Body Exterior: Body panels, doors, hood, tailgate, bumpers, fenders, glass replacement, sunroof, exterior trim, rust prevention. Body Interior: Seats, dashboard, interior trim panels, headliner, carpeting, airbags, seat belts, HVAC controls, sound insulation. HVAC: Heating, ventilation, and air conditioning (HVAC) system, compressor, condenser, evaporator, refrigerant service, climate control unit, cabin air filter. Infotainment Audio: Audio system, speakers, radio, CD player, navigation system (if equipped), Bluetooth, USB integration. Driver Assistance: Cruise control, rearview camera, parking sensors (if equipped). Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, spark plug replacement, belt inspections/replacements. Troubleshooting Diagnostics: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, wiring diagrams, component testing, intermittent fault diagnosis. Repair Procedures: Step-by-step instructions for component removal, installation, and repair for all major systems. Component Replacement: Detailed guides for replacing parts such as alternators, starters, water pumps, fuel pumps, radiators, brake calipers, sensors, modules. Torque Specifications: Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, including lighting, power, sensors, and control modules. Special Tools: Identification and usage instructions for any specialized tools required for specific repair procedures. Tightening Sequences: Specific order for tightening critical components like cylinder heads and wheel nuts. Recalibration Procedures: Instructions for recalibrating sensors and modules after replacement or repair (e.g., throttle body, steering angle sensor). Technical Depth Depth: Full factory-level technical detail, covering everything from basic fluid checks to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Typically text-searchable PDF, allowing for quick information retrieval. Print Quality Printability: High-resolution scans, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download - Printable) Paper Type Paper Type: N/A (Digital Download - Printable) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: G4KH (Theta II 2.4L) Engine Type Gasoline: Inline 4-cylinder, DOHC, 16-valve Displacement Gasoline: 2359 cc (2.4 Liters)...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Sorento

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Class:

Mid-size Crossover SUV

Segment:

Family SUV, often competing with models like the Toyota Highlander, Honda Pilot, and Ford Explorer.

Competitive Analysis

Key Competitors 2012:

Toyota Highlander, Honda Pilot, Ford Explorer, Nissan Pathfinder, Chevrolet Traverse.

Key Features

Seating Capacity:

Available in 5-seater and 7-seater configurations.

Drivetrain Options:

Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) configurations.

Design Philosophy:

Emphasizes practicality, value, and a more European-inspired design compared to some rivals.

📋 Manual Details

Coverage Areas

Manual Type:

Complete Official Factory Workshop Service Repair Manual

Language:

English

Format:

PDF Download

Page Count:

Hundreds of pages (estimated 2000+ pages for comprehensive factory manuals)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, block, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system, fuel system, intake system, exhaust system, engine management systems.

Engine Performance:

Ignition system, fuel injection, emissions control, turbocharger (if applicable), engine diagnostics.

Transmission Manual:

Manual transmission assembly, disassembly, repair, clutch system, gears, synchronizers, shift mechanism.

Transmission Automatic:

Automatic transmission assembly, disassembly, repair, torque converter, valve body, planetary gear sets, transmission control module (TCM), fluid service.

Drivetrain:

Front-wheel drive (FWD), All-wheel drive (AWD) system, transfer case, differentials, drive shafts, axles, CV joints.

Suspension:

Front suspension (MacPherson strut, control arms), rear suspension (multi-link, trailing arms), shock absorbers, springs, bushings, stabilizers, wheel alignment.

Steering:

Power steering system, steering column, steering rack, power steering pump, fluid service, hydraulic systems.

Brakes:

Front and rear brake systems, disc brakes, calipers, pads, rotors, brake lines, master cylinder, brake booster, ABS system, parking brake.

Electrical System:

Battery, charging system (alternator), starter motor, ignition system, lighting systems (headlights, taillights, interior), power windows, power locks, mirrors, horn.

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, fenders, glass replacement, sunroof, exterior trim, rust prevention.

Body Interior:

Seats, dashboard, interior trim panels, headliner, carpeting, airbags, seat belts, HVAC controls, sound insulation.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, compressor, condenser, evaporator, refrigerant service, climate control unit, cabin air filter.

Infotainment Audio:

Audio system, speakers, radio, CD player, navigation system (if equipped), Bluetooth, USB integration.

Driver Assistance:

Cruise control, rearview camera, parking sensors (if equipped).

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, spark plug replacement, belt inspections/replacements.

Troubleshooting Diagnostics:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, wiring diagrams, component testing, intermittent fault diagnosis.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major systems.

Component Replacement:

Detailed guides for replacing parts such as alternators, starters, water pumps, fuel pumps, radiators, brake calipers, sensors, modules.

Torque Specifications:

Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, including lighting, power, sensors, and control modules.

Special Tools:

Identification and usage instructions for any specialized tools required for specific repair procedures.

Tightening Sequences:

Specific order for tightening critical components like cylinder heads and wheel nuts.

Recalibration Procedures:

Instructions for recalibrating sensors and modules after replacement or repair (e.g., throttle body, steering angle sensor).

Technical Depth

Depth:

Full factory-level technical detail, covering everything from basic fluid checks to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Typically text-searchable PDF, allowing for quick information retrieval.

Print Quality

Printability:

High-resolution scans, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download - Printable)

Paper Type

Paper Type:

N/A (Digital Download - Printable)

⚙️ Engine Specifications

Primary Engine

Engine Code Gasoline:

G4KH (Theta II 2.4L)

Engine Type Gasoline:

Inline 4-cylinder, DOHC, 16-valve

Displacement Gasoline:

2359 cc (2.4 Liters)

Bore X Stroke Gasoline:

88.0 mm x 97.0 mm

Compression Ratio Gasoline:

10.0:1

Horsepower Gasoline:

175 hp @ 6000 rpm

Torque Gasoline:

169 lb-ft @ 4000 rpm

Fuel Type Gasoline:

Unleaded Regular

Fuel System Gasoline:

Electronic Multi-Port Fuel Injection (MPI)

Emission Control Gasoline:

Catalytic converter, O2 sensors, EGR (may vary by market)

Optional Engine

Engine Code Gasoline V6:

G6DF (3.5L Lambda II V6)

Engine Type Gasoline V6:

V-type 6-cylinder, DOHC, 24-valve

Displacement Gasoline V6:

3470 cc (3.5 Liters)

Bore X Stroke Gasoline V6:

91.0 mm x 88.5 mm

Compression Ratio Gasoline V6:

10.4:1

Horsepower Gasoline V6:

276 hp @ 6300 rpm

Torque Gasoline V6:

248 lb-ft @ 5000 rpm

Fuel Type Gasoline V6:

Unleaded Regular

Fuel System Gasoline V6:

Electronic Multi-Port Fuel Injection (MPI)

Emission Control Gasoline V6:

Catalytic converter, O2 sensors, EGR (may vary by market)

Fuel System

Fuel Tank Capacity:

Approx. 17.4 gallons (66 liters)

🔧 Transmission

Standard

Transmission Type 2.4L:

6-speed Manual Transmission (MT)

Optional

Transmission Type 2.4L Auto:

6-speed Automatic Transmission (AT) with Sportmatic® Shifting

Transmission Type 3.5L V6:

6-speed Automatic Transmission (AT) with Sportmatic® Shifting

Features

AWD System:

Active ECO System for improved fuel efficiency (available on automatic transmissions).

Transmission Fluid Spec Auto:

Kia SPIII or equivalent ATF (refer to specific manual for exact type and capacity)

Transmission Fluid Spec Manual:

Refer to specific manual for manual transmission fluid type (e.g., GL-4 or GL-5 gear oil).

📐 Dimensions

Exterior

Length:

Approx. 189.4 inches (4810 mm)

Width:

Approx. 74.2 inches (1885 mm)

Height:

Approx. 68.3 inches (1735 mm)

Wheelbase:

Approx. 109.4 inches (2780 mm)

Ground Clearance:

Approx. 7.0 inches (178 mm)

Approach Angle:

Approx. 28 degrees

Departure Angle:

Approx. 24 degrees

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Wheel Size:

Typically 17 or 18 inches (alloy wheels on higher trims).

Tire Size Standard:

P235/65R17 (for 2.4L models)

Tire Size Optional:

P235/55R18 (for 3.5L V6 models)

Weights

Curb Weight FWD:

Approx. 3800-4000 lbs (1724-1814 kg) depending on engine and trim.

Curb Weight AWD:

Approx. 3950-4150 lbs (1792-1882 kg) depending on engine and trim.

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle's compliance plate for exact GVWR.

Towing Capacity:

Up to 2,000 lbs (907 kg) with standard equipment, up to 3,500 lbs (1588 kg) with optional towing package.

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 9.6 cubic feet (272 liters)

Cargo Volume Behind 2Nd Row:

Approx. 30.0 cubic feet (850 liters)

Cargo Volume Behind 1St Row:

Approx. 74.0 cubic feet (2095 liters)

🛡️ Safety Features

Ratings

NHTSA Overall Rating:

Generally received good ratings. For specific model year 2012 results, consult NHTSA database.

IIHS Top Safety Pick:

Yes, typically achieved 'Good' ratings in IIHS crash tests for this generation.

Active Features

Standard Anti-lock Braking System (ABS)

Standard Electronic Stability Control (ESC)

Traction Control:

Standard Traction Control System (TCS)

Hill Start Assist:

Available on some models, particularly with AWD.

Passive Features

Airbags Front:

Dual front advanced airbags

Airbags Side:

Front side-impact airbags

Airbags Curtain:

Full-length side curtain airbags for all rows

Seatbelts:

3-point seatbelts with pretensioners and load limiters, LATCH child seat anchors.

💡 Technology Features

Infotainment

Infotainment System:

Available with a touch-screen infotainment system, often featuring navigation, rearview camera display, and multimedia playback.

Audio System:

Standard AM/FM/CD/MP3 player with auxiliary input and USB port. Premium Infinity® audio system available on higher trims.

Connectivity:

Bluetooth® hands-free calling and audio streaming capability.

Driver Assistance

Driver Assistance Features:

Optional rearview camera, parking assist sensors, cruise control.

Other Tech

Keyless Entry:

Standard keyless entry and alarm system. Push-button start available on higher trims.

Climate Control:

Available dual-zone automatic climate control.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first. Synthetic oil may extend this to 7,500 miles (12,000 km) or 12 months under ideal conditions (refer to manual for specifics).

Engine Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Cabin Air Filter Replacement:

Every 12,000 miles (19,000 km) or 12 months.

Spark Plug Replacement 2.4L:

Platinum spark plugs typically last up to 100,000 miles (160,000 km).

Spark Plug Replacement 3.5L V6:

Iridium spark plugs typically last up to 100,000 miles (160,000 km).

Coolant Replacement:

First replacement at 60,000 miles (96,000 km) or 48 months, then every 30,000 miles (48,000 km) or 24 months thereafter.

Brake Fluid Replacement:

Every 24 months or 30,000 miles (48,000 km).

Tire Rotation:

Every 7,500 miles (12,000 km) or 6 months.

Fluid Specifications

Engine Oil Type 2.4L:

API SN or ILSAC GF-5 certified, SAE 0W-20 (check manual for specific viscosity recommendation).

Engine Oil Type 3.5L V6:

API SN or ILSAC GF-5 certified, SAE 5W-20 (check manual for specific viscosity recommendation).

Engine Oil Capacity 2.4L:

Approx. 4.5 quarts (4.3 liters) with filter change.

Engine Oil Capacity 3.5L V6:

Approx. 5.7 quarts (5.4 liters) with filter change.

Coolant Type:

Ethylene glycol-based coolant, P-HOAT (Phosphated Hybrid Organic Acid Technology) or OAT (Organic Acid Technology) long-life coolant. Kia Genuine Coolant recommended. Do not mix coolant types.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (refer to manual for precise specification).

Power Steering Fluid Type:

Refer to manual for specific power steering fluid (likely ATF SPIII or a dedicated synthetic power steering fluid).

Known Issues

Engine Noise:

Some reports of piston slap or general engine noise, particularly on the 2.4L engine, especially when cold. Often considered normal by some, but worth investigating if excessive.

Transmission Hesitation:

Occasional reports of transmission hesitation or rough shifting, especially in earlier models. Software updates and fluid changes can sometimes rectify this.

Evaporative Emission Control System Evap:

Potential for EVAP system leaks (e.g., faulty vent control valve, canister purge valve) leading to check engine light illumination. P0455 or P0442 codes are common.

Suspension Noise:

Reports of knocking or rattling noises from the suspension, often related to worn ball joints or sway bar links.

Airbag Warning Light:

Intermittent airbag warning lights can occur due to issues with occupant detection sensors or wiring harnesses.

Water Pump Leaks:

Some instances of water pump leaks, particularly on the V6 engine, may require replacement.

📚 Vehicle History

Brand Heritage

Kia Origins:

Kia Motors Corporation, founded in 1944, is a South Korean automobile manufacturer.

Kia Growth:

Known for offering vehicles with strong value propositions and increasingly sophisticated designs and technology.

Model Evolution

Sorento Introduction:

First generation Kia Sorento (JC) launched in 2002.

Generation 2012:

The 2012 Sorento represents the second generation (XM), which debuted for the 2009 model year.

Xm Generation Updates:

The XM generation marked a significant shift from body-on-frame to unibody construction, improving ride comfort and handling. The 2012 model year received minor updates, including powertrain enhancements and feature availability.

Production

Production Location:

Primarily manufactured at Kia's Hwaseong plant in South Korea. Also assembled in other locations globally depending on market.

Model Years Current Generation:

2009-2015 (for the XM generation).

🏆 Awards & Recognition

Recognitions

Safety Awards:

The 2012 Sorento consistently received good safety ratings from organizations like NHTSA and IIHS, contributing to its appeal as a family vehicle.

Value Awards:

Kia vehicles, including the Sorento, are often recognized for their strong value proposition and extensive feature sets for the price.

Ratings

Consumer Reports Rating:

Consumer Reports generally rated the Sorento well for its segment, often highlighting its ride comfort and practicality, though reliability scores could vary by year and specific component.