🏷️ Basic Information

Make:

Kia

Model:

Sorento

Generation Code:

BL

Model Year:

2004

Engine Variant:

3.5 DOHC

Chassis Code:

BL

Engine Code:

G6CU (likely)

👋 Introduction

Segment:

Mid-size SUV / Crossover

Target Audience:

Families, individuals seeking versatility and capability.

Key Competitors 2004:

Toyota Highlander, Honda Pilot, Ford Explorer, Nissan Murano.

Body On Frame:

Built on a ladder frame, offering robust construction and towing capability (distinct from unibody SUVs).

Engine Power:

3.5L V6 engine providing ample power for its class.

Drivetrain Options:

Available in RWD and AWD configurations.

📋 Manual Details

Scope:

Service and Repair Procedures

Estimated Pages:

High (typical for comprehensive engine service manuals, ~500-1000+ pages)

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital (PDF likely, given typical sales practices)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, valve train, timing system.

Engine Fuel System:

Fuel injection (MPI), fuel pump, fuel injectors, fuel pressure regulator, fuel lines.

Engine Ignition System:

Ignition coils, spark plugs, ignition timing control.

Engine Cooling System:

Radiator, water pump, thermostat, coolant hoses, cooling fan.

Engine Lubrication System:

Oil pump, oil filter, oil pan, lubrication passages, oil pressure.

Engine Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes.

Engine Emission Control:

EGR system, PCV system, evaporative emission control (EVAP).

Engine Electrical:

Starter motor, alternator, battery, engine control module (ECM) wiring, sensors.

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, spark plug replacement.

Troubleshooting:

Diagnostic procedures, symptom analysis, fault code interpretation (OBD-II).

Repair:

Component replacement, adjustment procedures, internal engine repair, gasket replacement.

Disassembly Assembly:

Step-by-step instructions for engine teardown and reassembly.

Torque Specifications:

Precise torque values for all critical fasteners.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

Depth:

Comprehensive (covers from basic maintenance to in-depth engine overhaul).

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Resolution:

High-resolution (typically 300+ DPI for clarity of diagrams and text)

Binding:

N/A (Digital)

Paper Quality:

N/A (Digital)

Searchability:

Searchable text for quick information retrieval.

Illustrations:

Detailed diagrams, exploded views, and schematics.

Hyperlinks:

Potential for internal hyperlinks to related sections.

⚙️ Engine Specifications

Engine Type:

V6, DOHC, 24-valve

Displacement:

3.5 Liters (3497 cc)

Bore X Stroke:

91.0 mm x 88.7 mm (approximate, typical for this engine family)

Compression Ratio:

9.4:1 (typical)

Horsepower:

Approximately 200-205 hp @ 5500-5800 rpm (manufacturer specific)

Torque:

Approximately 220-225 lb-ft @ 3000-3500 rpm (manufacturer specific)

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Regular (87 octane recommended)

Oil Capacity:

Approximately 5.5-6.0 quarts (5.2-5.7 liters) with filter change

Spark Plugs:

NGK PFR5N-11 (or equivalent, consult manual for exact spec)

🔧 Transmission

Transmission Type:

4-speed Automatic Overdrive

Optional Transmission:

N/A for this specific engine/year combination (typically auto only)

Transmission Fluid Type:

Kia Genuine ATF SP-III or equivalent

Transmission Fluid Capacity:

Approximately 8.0-9.0 quarts (7.6-8.5 liters) for a drain and fill

📐 Dimensions

Length:

Approximately 187.9 inches (4773 mm)

Width:

Approximately 74.4 inches (1890 mm)

Height:

Approximately 68.3 inches (1735 mm)

Wheelbase:

Approximately 110.0 inches (2794 mm)

Curb Weight:

Approximately 4,300 - 4,500 lbs (1950 - 2041 kg) depending on drivetrain

Towing Capacity:

Up to 5,000 lbs (2268 kg) with optional towing package

Cargo Volume Behind 3Rd Row:

Approximately 10.0 - 12.0 cu ft

Cargo Volume Behind 2Nd Row:

Approximately 40.0 - 45.0 cu ft

Cargo Volume Behind 1St Row:

Approximately 75.0 - 80.0 cu ft

🛡️ Safety Features

NHTSA Frontal Crash Driver:

4 stars (2004 model year)

NHTSA Frontal Crash Passenger:

4 stars (2004 model year)

NHTSA Side Impact Driver:

5 stars (2004 model year)

NHTSA Side Impact Rear Passenger:

5 stars (2004 model year)

IIHS Moderates:

Good (for models equipped with side airbags)

ABS:

Standard Anti-lock Braking System

Traction Control:

Optional Traction Control System (TCS)

Esc:

Optional Electronic Stability Control (ESC) - availability varies by trim and market.

Airbags:

Frontal airbags, optional front side-impact airbags, optional side-curtain airbags.

Seatbelts:

Three-point seat belts with pretensioners for front occupants.

💡 Technology Features

Audio System:

Standard AM/FM/CD player, with optional premium audio systems available on higher trims.

Display:

Basic LCD display for audio information and climate control.

Cruise Control:

Standard on most trims.

Parking Sensors:

Optional rear parking sensors available on select trims.

Auxiliary Input:

May be present on some models, but Bluetooth and USB connectivity are generally absent on this generation.

🔧 Maintenance

Oil Change Interval:

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

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Every 60,000 miles (96,000 km).

Timing Belt Replacement:

N/A - This engine uses a timing chain, which is typically designed for the life of the engine but may require inspection/tensioner replacement.

Transmission Fluid Service:

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

Engine Oil Grade:

SAE 5W-30 (API SM or higher).

Coolant Type:

Ethylene Glycol based coolant with corrosion inhibitors (e.g., Hyundai/Kia Long Life Coolant - blue color).

Brake Fluid:

DOT 3 or DOT 4

Engine Oil Sludge:

Potential for oil sludge buildup if maintenance intervals are neglected, especially with shorter trips. Regular oil changes are critical.

Transfer Case Noise:

Some early BL models experienced noise or vibration from the transfer case, potentially related to fluid or internal wear.

Suspension Components:

Wear on control arm bushings and ball joints can occur due to the vehicle's weight and usage, leading to steering wander or clunking noises.

📚 Vehicle History

Kia History:

Kia Motors Corporation, a South Korean manufacturer, has a history dating back to 1944, initially producing motorcycles and later expanding into trucks and passenger vehicles. Known for value and increasingly for design and quality.

First Generation:

The BL Sorento represents the first generation of the Sorento nameplate, launched globally in 2002. It was designed to be a more traditional SUV with body-on-frame construction.

Generation Bl Characteristics:

Featured a ladder frame chassis, rear-wheel drive biased or optional four-wheel drive, and a focus on ruggedness and towing capability.

Production Years Bl:

2002-2009

Manufacturing Locations:

South Korea (primarily Hwaseong plant), Malaysia, Russia, Egypt.

🏆 Awards & Recognition

IIHS Award History:

Received 'Good' ratings in front and side impact tests for models equipped with optional side airbags, indicating good structural integrity and occupant protection.