🏷️ Basic Information

Make:

Kia

Model:

Sorento

Generation:

BL

Year:

2004

Engine Code:

G 3.5 DOHC

👋 Introduction

Vehicle Segment:

Mid-size SUV

Target Audience:

Owners seeking to perform their own maintenance and repairs, independent repair shops, enthusiasts.

Competitors:

Jeep Grand Cherokee, Ford Explorer, Toyota 4Runner, Nissan Pathfinder, Chevrolet TrailBlazer

Vehicle Usp:

Offered a V6 engine as standard or primary option, robust chassis, available four-wheel drive (4WD), practical interior space for its class.

📋 Manual Details

Manual Type:

Complete Official Full Factory Service Repair Manual

Language:

English

Format:

Printable (hundreds of pages)

📖 Manual Coverage

Engine:

3.5L V6 DOHC (G6CU)

Powertrain:

Engine mechanical, engine control system (ECM), fuel system, ignition system, cooling system, lubrication system, exhaust system, transmission (automatic and manual), drivetrain components (driveshafts, differentials, axles)

Chassis:

Suspension (front and rear), steering system, braking system (ABS included), wheels and tires

Electrical:

Body electrical systems, lighting, instruments and gauges, audio system, HVAC controls, power accessories (windows, locks, mirrors), wiring diagrams, fuse and relay information

Body:

Body panel removal and installation, interior trim, exterior trim, doors, hood, tailgate, glass replacement

Maintenance:

Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, belt replacement

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, fault code interpretation (OBD-II)

Repair:

Component removal and installation, disassembly and reassembly of major systems, component overhaul, adjustments, calibration

Technical Specifications:

Torque specifications for fasteners, engine specifications, transmission specifications, chassis specifications, electrical specifications, tolerances

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical troubleshooting.

📊 Manual Specifications

Document Type:

Service Repair Manual

Print Quality:

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

Binding:

Not applicable for digital format, but designed for easy page-by-page printing.

Paper Recommendation:

Standard printer paper for home or shop use.

⚙️ Engine Specifications

Engine Displacement:

3.5 Liters (3497 cc)

Engine Configuration:

V6 (90-degree bank angle)

Valvetrain:

DOHC (Double Overhead Camshaft), 24 valves (4 valves per cylinder)

Horsepower:

Approximately 200-205 hp @ 5500 rpm (specific output may vary slightly by market)

Torque:

Approximately 217-220 lb-ft @ 3500 rpm (specific output may vary slightly by market)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Coolant Type:

Ethylene glycol-based, long-life coolant (e.g., Dex-Cool equivalent or Kia specified)

Oil Type:

API SN or higher, SAE 5W-30 (check manual for exact specification)

Oil Capacity:

Approximately 5.5 - 5.8 Quarts (5.2 - 5.5 Liters) with filter change (verify with dipstick)

Spark Plugs:

Iridium or Platinum tipped spark plugs (e.g., NGK PFR5N-11 or equivalent, consult manual for specific part number)

🔧 Transmission

Transmission Type:

4-speed Automatic Transmission (e.g., Kia's in-house A4CF2 or similar)

Transmission Type Optional:

5-speed Manual Transmission (less common on V6 models, primarily on 4-cylinder variants)

Transmission Fluid:

ATF SP-III or Kia Genuine ATF (verify with manual)

Transmission Fluid Capacity:

Approximately 8.0 - 9.0 Quarts (7.6 - 8.5 Liters) for automatic transmission (check dipstick and manual)

📐 Dimensions

Length:

Approximately 4700 mm (185.0 inches)

Width:

Approximately 1865 mm (73.4 inches)

Height:

Approximately 1775 mm (69.9 inches)

Wheelbase:

Approximately 2630 mm (103.5 inches)

Curb Weight:

Approximately 1900 - 2050 kg (4189 - 4519 lbs) depending on drivetrain and configuration.

Gross Vehicle Weight Rating:

Varies by configuration, typically around 2500-2600 kg.

🛡️ Safety Features

NHTSA Front Impact:

4-star driver, 4-star passenger (for similar models of the era, actual ratings may vary)

IIHS Side Impact:

Acceptable (for similar models of the era, actual ratings may vary)

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS)

Stability Control:

Optional Electronic Stability Control (ESC) - availability may vary by trim and market

Airbags:

Front airbags (driver and passenger), optional side-impact airbags and curtain airbags

Seatbelts:

3-point seat belts with pretensioners for front occupants, 3-point seat belts for rear occupants

💡 Technology Features

Audio System:

Standard AM/FM/CD audio system with 6 speakers. Optional premium audio systems may be available depending on trim level.

Display:

Basic digital display for clock, temperature, and radio information. No advanced touchscreen or navigation typically found on this generation.

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional rear parking sensors.

Aux Input:

May feature an auxiliary input jack for portable audio devices (availability varies).

Bluetooth:

Not typically available on this model year; aftermarket solutions would be required.

🔧 Maintenance

Engine Oil Change:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (check manual for specific recommendation based on driving conditions).

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed, typically every 30,000 miles (48,000 km).

Cabin Air Filter:

Inspect annually, replace every 15,000-30,000 miles (24,000-48,000 km).

Spark Plugs:

Replace at 60,000-100,000 miles (96,000-160,000 km) depending on plug type (Iridium recommended for longevity).

Transmission Fluid Change:

Every 45,000-60,000 miles (72,000-96,000 km), or more frequently under severe driving conditions. Filter replacement recommended during fluid service.

Coolant Flush:

Initial flush at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) thereafter for long-life coolant.

Engine Oil Grade:

SAE 5W-30 (API SN or higher, ILSAC GF-4 or higher)

Coolant Type:

Kia Green or equivalent (Ethylene Glycol based, 50/50 mix with distilled water)

Brake Fluid:

DOT 3 or DOT 4 (check reservoir cap or manual)

Common Problems:

Oil leaks from valve covers or oil pan gasket, premature wear of suspension components (bushings, ball joints), potential for transmission solenoid issues, occasional check engine lights related to emissions or sensors.

Engine Issues:

Camshaft position sensor failures, occasional issues with the intake manifold runner control system.

Electrical Issues:

Window regulator failures, power lock actuator issues, flickering dashboard lights.

📚 Vehicle History

Manufacturer:

Kia Motors Corporation, South Korea

Generation Introduction:

The BL generation Sorento was introduced for the 2003 model year globally and was the second generation of the Sorento.

Generation Characteristics:

This generation marked a transition from body-on-frame construction (first generation) to unibody construction, offering improved ride comfort and handling.

Engine Offering Transition:

The 3.5L V6 was a key engine option for this generation, providing strong performance for an SUV of its size.

Production Years:

2002-2009 (globally, with model year variations)

Manufacturing Locations:

South Korea (primarily Hwaseong), with some assembly in other regions depending on market.

🏆 Awards & Recognition

Safety Awards:

While specific awards for the 2004 model might be limited, Kia vehicles of this era generally focused on offering a good value proposition in terms of features and safety for the price point.

Consumer Ratings:

Consumer satisfaction varied; known for reliability in some areas but had common issues as noted above. Owners often praised its utility and value.