2004 Kia Sorento G 3.5 DOHC Automatic Transaxle System Repair Manual (P/N 45000-39500)
Kia Models Covered & Key Technical Specifications
Models: 2004 Kia Sorento
Sub-models / Variants: 3.5L DOHC, Automatic Transaxle, 4WD, 2WD
Model Years: 2004
Serial Numbers: 45000–39500
Technical Data:
- Transmission Gear Ratio (1st): 2.804
- Transmission Fluid Capacity: 11.5 liters (12.2 US qt)
- Transfer Case Fluid Capacity: 1.42 liters (1.50 US qt)
- Transfer Case Gear Ratio (LOW): 2.480
- Output Speed Sensor Resistance: 560–680 ohms (20°C)
- Solenoid Valve Resistance: 11–15 ohms
- Pressure Solenoid Resistance: 3.3–3.7 ohms
- Torque Converter Stall Speed: 2480 ± 250 rpm
- Solenoid Operation Voltage: Vbatt – 0V (1.9A Max)
Kia Manual Features & Content Preview
- Covers 2004 Kia Sorento 3.5L DOHC models equipped with the automatic transaxle.
- Official publication (P/N 45000-39500) outlining diagnostic procedures, component assembly, and repair specifications.
- Features 175 technical illustrations, 12 component-specific exploded diagrams, and 18 system wiring schematics.
- 1056-page service document covering hydraulic control, electrical sensor thresholds, and mechanical disassembly.
- Serves as the definitive factory reference, replacing earlier preliminary drafts with full production-level technical data.
Diagnostic and Repair Content
This official 2004 service publication delivers in-depth documentation for the automatic transaxle. Expect exact technical data on engine-to-transmission coupling, hydraulic control systems, and complex electronic fault analysis. Key chapters feature full component location diagrams alongside wiring schematics for the EC-AT control system. You will also find comprehensive diagnostic trouble code charts. These are essential for the precise identification of solenoid or sensor failures. Because servicing transmission components involves heavy assemblies and pressurized fluids, always ensure you use proper shop equipment and follow standard workshop safety protocols before starting any teardown.
Specification and Reference Data
Detailed tables outline tightening torque requirements, 4WD gear ratios, and electrical resistance values for output speed sensors and control solenoids. The manual presents maintenance schedules, fluid capacity limits, and tolerance charts for both normal and severe operating conditions. Engine assembly data clearly documents cylinder head bolt torque values in a multi-stage sequence. Intake valve clearance is specified at 0.11–0.20 mm. Furthermore, the coolant system capacity is listed at 2.73 liters. This document provides workshop personnel and mechanics with the exact technical baselines required for accurate 3.5L DOHC maintenance.
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