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KIA Sorento V6 (3.5L) 2004 OEM Factory Shop Service Repair Manual DOwnload FSM

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🏷️ Basic Information Identification Make: KIA Model: Sorento Year: 2004 Engine Variant: 3.5L V6 Generation Platform: First Generation (JC) Codes Chassis Code: JC Engine Code: G6CU (likely) 👋 Introduction Market...
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Type: Car
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Sku: 349608
KIA Sorento V6 (3.5L) 2004 OEM Factory Shop Service Repair Manual DOwnload FSM
🏷️ Basic Information
Identification
Make:
KIA
Model:
Sorento
Year:
2004
Engine Variant:
3.5L V6
Generation
Platform:
First Generation (JC)
Codes
Chassis Code:
JC
Engine Code:
G6CU (likely)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size SUV / Crossover
Target Audience:
Families seeking versatile and capable utility vehicle
Competitive Analysis
Key Competitors:
Toyota Highlander, Honda Pilot, Ford Explorer, Nissan Pathfinder, Chevrolet Trailblazer
Key Features
Vehicle Strengths:
Spacious interior, available V6 power, comfortable ride, value proposition.
Manual Value Proposition:
Provides professional-level repair and maintenance information, enabling DIYers and professionals to accurately service the vehicle.
📋 Manual Details
Coverage Areas
Coverage Scope:
Bumper-to-bumper repair and maintenance
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for OEM factory service manuals of this era)
Manual Type
Manual Classification:
OEM Factory Service Manual (FSM)
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.5L V6 G6CU), transmission (automatic), fuel system, exhaust system, cooling system, lubrication system, ignition system.
Chassis:
Suspension (front and rear), steering system, braking system (ABS, standard), wheels and tires.
Electrical:
Wiring diagrams, lighting, power accessories, charging system, starting system, body control modules, diagnostics.
Body:
Body panels, doors, windows, interior trim, HVAC system, safety restraint systems (airbags).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug service, belt replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meaning, on-board diagnostics (OBD-II).
Repair:
Engine disassembly and assembly, transmission service, brake caliper and rotor replacement, suspension component replacement, steering rack overhaul, electrical component repair.
Technical Specifications:
Torque specifications, clearances, tolerances, fluid capacities, electrical specifications.
Technical Depth
Depth Of Information:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
📊 Manual Specifications
File Format
Document Type:
Searchable PDF
Indexing:
Indexed for easy navigation
Print Quality
Readability:
High quality, designed for clarity of text and diagrams
Binding Type
Digital Binding:
N/A (Digital PDF)
Paper Type
Digital Paper Simulation:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated V6
Displacement:
3.5 Liters (3497 cc)
Bore X Stroke:
93.0 mm x 82.7 mm (estimated)
Valvetrain:
DOHC, 4 valves per cylinder (24 valves total)
Performance
Horsepower Peak:
Approx. 200-215 hp (at 5500-5800 rpm, depending on specific market calibration)
Torque Peak:
Approx. 217-230 lb-ft (at 3000-3500 rpm, depending on specific market calibration)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Electronic Control Unit (ECU) with OBD-II diagnostics
🔧 Transmission
Standard Transmission
Type:
5-speed Automatic Transmission
Optional Transmission
Type:
N/A (only automatic offered for V6 in 2004)
Features
Drive Modes:
Full-time 4WD (likely standard on V6), with potential for driver-selectable 2WD/4WD modes (check specific trims).
Fluid Specifications
Automatic Transmission Fluid Type:
SPII-ATF or equivalent (refer to manual for precise specification, e.g., ATF SP-III)
📐 Dimensions
Exterior
Length:
Approx. 187.4 inches (4760 mm)
Width:
Approx. 74.4 inches (1890 mm)
Height:
Approx. 67.3 inches (1710 mm)
Wheelbase:
Approx. 106.7 inches (2710 mm)
Weights
Curb Weight:
Approx. 4200-4400 lbs (depending on trim and drivetrain)
Cargo
Cargo Volume Behind Second Row:
Approx. 30.5 cu ft (estimated)
Cargo Volume Behind First Row:
Approx. 75.0 cu ft (estimated)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for driver and front passenger in some tests)
NHTSA Side Impact:
4-Star (estimated, check specific vehicle documentation)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags:
Front airbags, available side curtain airbags (check specific vehicle)
Seatbelts:
3-point seatbelts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, typically 6-speaker system. Optional premium audio might be available.
Navigation:
Optional factory navigation system available on higher trims.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Connectivity
Aux Input:
Likely not standard, but auxiliary input may be present on some units or available as an aftermarket upgrade.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe duty) / 7,500 miles or 12 months (normal duty) - Consult manual for precise recommendation.
Engine Air Filter Replacement:
Every 15,000-30,000 miles, or as needed based on driving conditions.
Cabin Air Filter Replacement:
Every 12,000-15,000 miles or annually.
Spark Plug Replacement:
Approx. 60,000 - 100,000 miles for iridium or platinum plugs (refer to manual for exact type and interval).
Fluid Specifications
Engine Oil Type:
API SJ or SL classification, SAE 5W-30 viscosity (check manual for confirmation).
Engine Oil Capacity:
Approx. 5.5-5.8 US quarts (with filter change).
Coolant Type:
Ethylene glycol-based coolant, typically a green or pink type (consult manual for specific Kia coolant P/N or equivalent).
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for exact specification).
Known Issues
Common Wear Items:
Brake pads and rotors, suspension bushings, exhaust components, catalytic converter, window regulators.
Engine Specific Concerns:
Some V6 engines of this era could be prone to oil leaks from valve cover gaskets or intake manifold gaskets. Timing belt replacement (if applicable, though this engine likely has a timing chain) is critical. Check for specific service bulletins regarding oil consumption or cooling system issues.
📚 Vehicle History
Brand Heritage
Kia History:
Kia Motors Corporation, a South Korean automobile manufacturer, has a history dating back to 1944, evolving from a bicycle manufacturer to a global automotive player known for value and improving quality.
Model Evolution
Sorento First Gen Launch:
The first-generation Sorento (JC) was launched in 2002, serving as Kia's first mid-size SUV. It was built on a body-on-frame chassis, inherited from the Kia Sportage, offering a rugged and truck-like feel.
2004 Model Year Updates:
The 2004 model year likely received minor updates or package revisions from its initial launch. The V6 engine became a prominent offering for buyers seeking more power.
Production
Manufacturing Location:
South Korea (primarily Hwaseong Plant)
🏆 Awards & Recognition
Recognitions
Safety Awards 2004:
The Sorento received some favorable safety ratings in its class, with 5-star front impact ratings from NHTSA in some configurations.
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