KIA SORENTO (BL) 2003 G 3.5 DOHC Engine Service Repair Manual

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🏷️ Basic Information Identification Make: Kia Model: Sorento Model Code: BL Year: 2003 Engine Variant: 3.5 DOHC 👋 Introduction Market Position Segment: Mid-size SUV / Crossover Competitive Analysis Competitors: Toyota...

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Type: Car

Vendor:

Sku: 507330

Tags: 2003 Car Cars Kia Misc SORENTO (BL)

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Sorento

Model Code:

Year:

Engine Variant:

3.5 DOHC

👋 Introduction

Market Position

Segment:

Mid-size SUV / Crossover

Competitive Analysis

Competitors:

Toyota Highlander, Ford Explorer, Honda Pilot, Nissan Pathfinder, Chevrolet TrailBlazer

Key Features

Body On Frame:

Yes (for BL generation, offering robustness)

Seating Capacity:

Available in 5-seater and 7-seater configurations

Drivetrain Options:

Available in 2WD and 4WD

📋 Manual Details

Coverage Areas

Primary Coverage:

Engine Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics

Page Count

Estimated Pages:

Varies (typically 1000+ for comprehensive service manuals)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Likely PDF or digital format, but could be printed.

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanicals, lubrication, cooling, fuel, ignition, emissions, timing, starting, charging

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspection and replacement

Repair:

Engine component removal and installation, cylinder head service, piston and connecting rod service, crankshaft service, valve train overhaul

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for engine performance issues

Technical Depth

Diagnostic Level:

Advanced diagnostics, including sensor testing, actuator testing, and ECU diagnostics (if scanner procedures are included)

Rebuild Scope:

Comprehensive engine rebuild procedures, including torque specifications and clearances

📊 Manual Specifications

File Format

File Type:

PDF (common for digital manuals)

Print Quality

Quality:

High resolution for clear diagrams and text (typical for professional manuals)

Binding Type

Binding:

N/A for digital; Spiral or perfect bound for print

Paper Type

Paper:

N/A for digital; Durable, possibly coated paper for print manuals

⚙️ Engine Specifications

Primary Engine

Engine Name:

3.5L V6 DOHC (G6CU)

Performance

Displacement:

3497 cc

Bore X Stroke:

93.0 mm x 82.7 mm (estimated)

Horsepower:

Approximately 200-205 hp @ 5500 rpm (specific to market and configuration)

Torque:

Approximately 220-225 lb-ft @ 3500 rpm (specific to market and configuration)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Engine Internals

Block Material:

Aluminum Alloy

Cylinder Head Material:

Aluminum Alloy

Valvetrain:

Dual Overhead Camshafts (DOHC), 24 Valves (4 per cylinder)

Compression Ratio:

9.4:1 (estimated)

Timing System:

Timing Belt (crucial replacement item)

Cooling System

Cooling Type:

Water-Cooled

Lubrication System

Oil Capacity:

Approximately 5.5 US quarts (5.2 Liters) with filter change

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transmission

Optional

Transmission Type Optional:

5-speed Automatic Transmission (later models, check specific VIN)

Features

Drivetrain Integration:

Available with RWD or 4WD

Fluid Specs

Transmission Fluid Type:

Kia Genuine ATF or equivalent (e.g., Dexron III/Mercon compatible)

Transmission Fluid Capacity:

Approximately 8.5 US quarts (8.0 Liters) for 4-speed auto

📐 Dimensions

Exterior

Length:

Approx. 187.4 inches (4760 mm)

Width:

Approx. 74.4 inches (1890 mm)

Height:

Approx. 67.7 inches (1720 mm)

Wheelbase:

Approx. 110.2 inches (2800 mm)

Ground Clearance:

Approx. 7.7 inches (195 mm)

Weights

Curb Weight:

Approx. 4400-4600 lbs (2000-2100 kg) depending on configuration

Gross Vehicle Weight Rating:

Approx. 5900-6100 lbs (2675-2770 kg)

Cargo

Cargo Volume Behind 2Nd Row:

Approx. 37.2 cu ft (1053 Liters)

Cargo Volume Behind 3Rd Row:

Approx. 12.5 cu ft (355 Liters) (if equipped)

Tires

Tire Size Standard:

245/65R17 (common)

Wheel Size Standard:

17-inch alloy

Bolt Pattern:

6 x 139.7 mm (5.5 inch)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance Rating:

3-star (for 2WD), 4-star (for 4WD) - Early models

Active Features

Standard

Traction Control:

Available on some trims/models

Electronic Stability Control:

Not widely available on early BL models

Passive Features

Airbags:

Front airbags standard, side-impact airbags available on some trims

Seatbelts:

3-point seatbelts with pretensioners

Child Seat Anchors:

LATCH system

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM/CD player, optional premium audio systems available on higher trims

Navigation:

Optional factory navigation system available on select trims

Driver Assistance

Cruise Control:

Standard

Connectivity

Auxiliary Input:

May be available on later models or specific trims

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months (severe duty may require more frequent changes)

Timing Belt Replacement:

Every 60,000 - 90,000 miles or 5-7 years (critical interval)

Transmission Fluid Change:

Every 30,000 - 60,000 miles (depending on usage)

Coolant Flush:

Every 30,000 - 50,000 miles

Fluid Specifications

Engine Oil Viscosity:

SAE 5W-30 (preferred), SAE 10W-30 or 10W-40 may be acceptable depending on climate (refer to manual)

Engine Oil Type:

API SN or higher, ILSAC GF-5 or higher

Coolant Type:

Ethylene Glycol based, Asian Red or Orange concentrate (50/50 mix with distilled water)

Known Issues

Engine Mounts:

Can wear out prematurely, leading to vibration and noise

Timing Belt Tensioner:

Failure can lead to belt slippage or breakage, causing severe engine damage

Oil Leaks:

Valve cover gaskets, oil pan gaskets can degrade over time

Transmission Hard Shifting:

Can occur due to low fluid, worn solenoid, or internal wear

Filter Part Numbers

Oil Filter:

Examples: Mann-Filter HU 816 x, Bosch 3323, Kia 26300-35050 (Verify with VIN)

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

South Korea

Model Evolution

Generation:

First Generation (BL)

Debut Year:

2004 model year (introduced late 2003 in some markets)

Platform:

Body-on-frame (shared with Hyundai Terracan, Mitsubishi Pajero Sport/Montero Sport)

Production

Production Years:

2003-2009 (for BL generation)

Assembly Locations:

South Korea, Malaysia

🏆 Awards & Recognition

Recognitions

Initial Reception:

Generally positive for its value proposition and capability as an affordable SUV

Ratings

Consumer Reports Reliability:

Mixed to average, typical for vehicles of this era from some manufacturers. Early models may have more issues than later ones.