Kia Sorento 2004 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Kia Model: Sorento Year: 2004 Generation Generation Code: First Generation (JC) Codes Vin Code: Starts with KMF 👋 Introduction Market Position Vehicle Segment: Mid-size SUV...

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Sku: 436320

Tags: 2004 Car Cars Kia Misc Sorento

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Description

🏷️ Basic Information

Identification

Make:

Model:

Sorento

Year:

Generation

Generation Code:

First Generation (JC)

Codes

Vin Code:

Starts with KMF

👋 Introduction

Market Position

Vehicle Segment:

Mid-size SUV / Crossover SUV

Target Audience:

Families, adventurers, individuals seeking a versatile and capable vehicle.

Competitive Analysis

Key Competitors:

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

Key Features

Value Proposition:

Offered a blend of SUV capability, comfortable ride, and robust V6 engine options at a competitive price point.

Body Styles:

Available as a 5-door SUV with optional 7-passenger seating in later iterations.

📋 Manual Details

Coverage Areas

Primary Coverage:

Gasoline Engines

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system.

Engine Performance:

Fuel system (injection, pump, injectors), ignition system (coils, plugs), air intake system, exhaust system, emission control systems (catalytic converter, O2 sensors).

Transmission Manual:

Manual transmission disassembly, assembly, component replacement, clutch system.

Transmission Automatic:

Automatic transmission disassembly, assembly, component replacement, torque converter, valve body, electronic control.

Drivetrain:

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

Suspension:

Front and rear suspension components (struts, shock absorbers, control arms, ball joints, bushings), wheel alignment.

Steering:

Power steering system, steering gear, steering column, tie rods, steering linkage.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), brake fluid, brake lines, parking brake.

Electrical System:

Battery, charging system (alternator, starter), lighting system, horn, wiring diagrams, fuse box, relays.

Body And Chassis:

Body panels, doors, hood, tailgate, interior trim, glass, chassis components, frame repair.

HVAC:

Heating, Ventilation, and Air Conditioning system components, refrigerant, diagnostics.

Safety Systems:

Airbag system, seat belts, SRS (Supplemental Restraint System).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Diagnostic procedures for common faults, symptom-based troubleshooting guides, fault code explanations.

Repair Procedures:

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

Engine Rebuild:

Detailed instructions for engine disassembly, inspection, measurement, and reassembly.

Transmission Overhaul:

Comprehensive guides for complete automatic and manual transmission disassembly and assembly.

Brake Service:

Brake pad and rotor replacement, caliper service, bleeding the brake system.

Electrical Diagnostics:

Component testing, circuit diagnosis, wiring harness repair, use of multimeters and oscilloscopes.

Suspension Alignment:

Adjustment procedures for camber, caster, and toe angles.

HVAC Service:

Refrigerant handling, leak detection, component replacement (compressor, condenser, evaporator).

Bodywork Repair:

Panel replacement, door adjustment, glass installation, trim removal and installation.

Technical Depth

Depth Of Information:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, suitable for professional technicians and advanced DIYers.

Diagnostic Capabilities:

Detailed diagnostic procedures, including OBD-II (On-Board Diagnostics) information and specific Kia diagnostic codes (KDS).

Torque Specifications:

Precise torque values for all critical fasteners, crucial for proper assembly and safety.

Wiring Diagrams:

Detailed and comprehensive electrical wiring diagrams for all vehicle systems.

Component Drawings:

Exploded views and detailed illustrations of components for easy identification and assembly reference.

📊 Manual Specifications

File Format

File Type:

Print Quality

Print Readability:

High-resolution images and text, optimized for printing.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

Searchability

Text Search:

Searchable PDF for quick access to specific topics.

Compatibility

Software Compatibility:

Compatible with all PDF readers (Adobe Acrobat Reader, etc.).

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

G6CU (2.5L V6 DOHC)

Engine Displacement 1:

2497 cc (2.5 Liters)

Engine Configuration 1:

V6, SOHC

Bore Stroke 1:

80.0 mm x 83.0 mm

Compression Ratio 1:

9.7:1

Horsepower 1:

169 hp @ 6000 rpm (approx.)

Torque 1:

176 lb-ft @ 4000 rpm (approx.)

Secondary Engine

Engine Code 2:

G6BV (3.5L V6 DOHC)

Engine Displacement 2:

3497 cc (3.5 Liters)

Engine Configuration 2:

V6, SOHC

Bore Stroke 2:

91.0 mm x 90.0 mm

Compression Ratio 2:

9.4:1

Horsepower 2:

192 hp @ 5500 rpm (approx.)

Torque 2:

217 lb-ft @ 3000 rpm (approx.)

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Octane:

87 AKI (Minimum)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission

Features

AWD Availability:

Optional All-Wheel Drive (AWD) system available on most trims.

Fluid Specifications

Automatic Transmission Fluid:

Kia Genuine ATF SP-III or equivalent

Manual Transmission Fluid:

API GL-4, SAE 75W-90 Gear Oil

📐 Dimensions

Exterior

Length:

4675 mm (184.1 inches)

Width:

1890 mm (74.4 inches)

Height:

1745 mm (68.7 inches)

Wheelbase:

2700 mm (106.3 inches)

Ground Clearance:

200 mm (7.9 inches)

Weights

Curb Weight Min:

1850 kg (4079 lbs) (approx. for 2.5L AWD)

Curb Weight Max:

1970 kg (4343 lbs) (approx. for 3.5L AWD)

Towing Capacity:

Up to 3500 lbs (1588 kg) with proper towing package

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4-Star (Frontal Offset Crash Test)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Electronic Stability Control:

Not widely available or standard on 2004 models.

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Available front side-impact airbags

Seatbelts:

3-point seatbelts with pretensioners for front seats

💡 Technology Features

Infotainment

Audio System:

AM/FM/CD player, optional premium audio systems with subwoofer and amplifier.

Navigation:

Optional factory-installed navigation system available on higher trim levels.

Driver Assistance

Cruise Control:

Standard cruise control

Connectivity

Power Windows Locks:

Standard power windows and door locks

Keyless Entry:

Available keyless entry system

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Air Filter Replacement:

Every 15,000 miles (24,000 km)

Spark Plug Replacement Gasoline:

Every 60,000 miles (96,000 km) (Platinum or Iridium plugs recommended)

Coolant Replacement:

Every 30,000 miles (48,000 km) or 2 years

Timing Belt Replacement:

Every 90,000 miles (144,000 km) or 7 years (Crucial for V6 engines to prevent catastrophic failure)

Fluid Specifications

Engine Oil Specification:

API SM or SN, ILSAC GF-4 or GF-5, SAE 5W-20 or 5W-30 (check owner's manual for specific recommendations based on temperature)

Engine Oil Capacity 2.5L:

5.7 US Quarts (5.4 Liters) with filter

Engine Oil Capacity 3.5L:

6.4 US Quarts (6.1 Liters) with filter

Coolant Type:

Ethylene glycol-based antifreeze, silicate-free, HOAT (Hybrid Organic Acid Technology) recommended. Kia Genuine Coolant or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Engine Mounts:

Premature wear of engine mounts, leading to vibrations.

Timing Belt Tensioner:

Potential failure of the timing belt tensioner, especially on V6 engines, can lead to timing belt issues.

Catalytic Converter:

Occasional premature failure of the catalytic converter, especially if engine misfires are not addressed promptly.

Automatic Transmission Shift Quality:

Some models may exhibit rough shifting or delayed engagement in automatic transmissions; regular fluid changes are crucial.

Rear Differential Noise:

Some AWD models may experience noise from the rear differential; check fluid levels and condition.

📚 Vehicle History

Brand Heritage

Kia Origins:

Kia Motors Corporation, South Korean automobile manufacturer.

Kia Growth:

Established in 1944, Kia has grown into a global automaker known for its value and improving quality.

Model Evolution

Sorento Introduction:

The Sorento was introduced in 2002 as Kia's first body-on-frame SUV.

Generation 1 Timeline:

The first generation (JC) ran from 2002 to 2009. The 2004 model represents an early iteration of this platform.

Platform Sharing:

Shared its platform with the Kia Sportage and Hyundai Santa Fe of the same era.

Production

Manufacturing Location:

Primarily manufactured in South Korea (Hwaseong Plant).

Production Period:

2002-2009 (First Generation)

🏆 Awards & Recognition

Recognitions

IIHS Crash Test Ratings:

Received 'Good' ratings in frontal offset crash tests from the IIHS (Insurance Institute for Highway Safety) in some configurations.