2005 Kia Sorento Service and Repair Manual

This 2005 Kia Sorento Service & Repair Manual Covers

• Complete factory workshop procedures
• Factory diagnostic information
• Component removal and installation
• Repair and overhaul procedures
• Technical specifications
• Factory maintenance information
• Factory wiring diagrams
• Torque specifications
• Fuse and relay information
• Diagnostic flow charts
• Troubleshooting procedures

Engine Options

Petrol

• 3.5L DOHC V6 Petrol
• 2.4L DOHC Inline-4 Petrol, where fitted

Diesel

• 2.5L CRDi DOHC Turbo Diesel
• 2.5L Turbo Diesel, depending on market

Transmission Options

• 5-speed Manual Transmission
• 4-speed Automatic Transmission
• 5-speed Automatic Transmission, where fitted
• Four-Wheel Drive

Engine and Drivetrain Repair Coverage

• Engine overhaul procedures
• Cylinder head servicing
• Valve train servicing
• Timing belt inspection
• Timing belt replacement procedures
• Camshaft timing procedures
• Fuel injection diagnostics
• Common-rail diesel diagnostics
• High-pressure fuel system diagnostics
• Fuel injector testing
• Fuel rail pressure diagnostics
• Ignition system servicing
• Ignition coil diagnostics
• Throttle body servicing
• Intake manifold servicing
• Cooling system repairs
• Lubrication system servicing
• Emissions system diagnostics
• Manual transmission servicing
• Automatic transmission diagnostics
• Automatic transmission servicing
• Torque converter servicing
• Driveshaft servicing
• CV joint inspection and repair
• Transfer case servicing
• Front and rear differential servicing
• Four-wheel-drive system diagnostics

Diesel and Turbocharger System Coverage

• Common-rail diesel injection diagnostics
• High-pressure fuel pump diagnostics
• Diesel injector testing
• Turbocharger inspection
• Turbocharger removal and installation
• Intercooler servicing
• Charge-air system inspection
• Boost-pressure diagnostics
• EGR system diagnostics
• Glow plug diagnostics
• Diesel engine management diagnostics
• Diesel emissions system diagnostics

4WD / Drivetrain Coverage

• Transfer case inspection
• Transfer case removal and installation
• Four-wheel-drive actuator diagnostics
• 4WD control system diagnostics
• Front differential servicing
• Rear differential servicing
• Propeller shaft servicing
• Driveshaft inspection
• Universal joint servicing
• CV joint servicing
• Wheel hub and bearing servicing

Chassis, Steering and Suspension

• Front independent suspension servicing
• Rear suspension servicing
• Steering system diagnostics
• Power steering servicing
• Steering rack servicing
• Steering column servicing
• Shock absorber replacement
• Coil spring inspection
• Stabiliser bar servicing
• Suspension bush inspection
• Wheel bearing servicing
• Wheel alignment specifications

Braking Systems

• ABS diagnostics
• Electronic Brakeforce Distribution diagnostics where fitted
• Brake hydraulic system bleeding
• Brake master cylinder servicing
• Brake booster servicing
• Front disc brake servicing
• Rear disc brake servicing
• Parking brake servicing
• Wheel speed sensor diagnostics
• ABS hydraulic control unit diagnostics

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Engine management system
• Petrol fuel injection wiring
• Common-rail diesel wiring
• Ignition system wiring
• Starting system diagnostics
• Charging system diagnostics
• Alternator servicing
• Battery testing
• Immobiliser diagnostics
• Instrument cluster diagnostics
• Body electrical system
• 4WD control system wiring
• Lighting system diagnostics
• Audio system wiring
• Power window diagnostics
• Central locking diagnostics
• Power mirror diagnostics
• Cruise control diagnostics
• Wiper and washer circuits

Air Conditioning and HVAC

• Air conditioning system diagnostics
• Compressor servicing
• Refrigerant system repairs
• HVAC control system diagnostics
• Automatic climate control where fitted
• Blower motor servicing
• Heater system servicing
• Blend door actuator diagnostics
• Air distribution system servicing
• Rear HVAC servicing where fitted

Body, Interior and Restraint Systems

• Body panel removal and installation
• Door servicing
• Door latch and lock servicing
• Bonnet and tailgate adjustment
• Dashboard removal procedures
• Interior trim servicing
• Seat servicing
• SRS airbag diagnostics
• Seat belt servicing
• Sunroof servicing where fitted
• Wiper and washer system servicing

Diagnostics and Troubleshooting

• Factory diagnostic flow charts
• Scan tool diagnostic procedures
• Symptom-based troubleshooting
• Engine Control Module diagnostics
• Transmission control diagnostics
• 4WD control diagnostics
• ABS diagnostics
• Immobiliser diagnostics
• Sensor testing procedures
• Actuator testing
• Electrical fault isolation
• Component inspection procedures
• Emissions diagnostic procedures

Common Error Codes Covered

Engine Codes

• P0101 — Mass or Volume Air Flow Circuit Range/Performance
• P0113 — Intake Air Temperature Sensor Circuit High Input
• P0122 — Throttle/Pedal Position Sensor/Switch A Circuit Low
• P0171 — System Too Lean
• P0300 — Random/Multiple Cylinder Misfire Detected
• P0301 — Cylinder 1 Misfire Detected
• P0335 — Crankshaft Position Sensor A Circuit
• P0340 — Camshaft Position Sensor A Circuit
• P0401 — Exhaust Gas Recirculation Flow Insufficient
• P0420 — Catalyst System Efficiency Below Threshold

Diesel and Turbocharger Codes

• P0087 — Fuel Rail/System Pressure Too Low
• P0191 — Fuel Rail Pressure Sensor Range/Performance
• P0234 — Turbocharger/Supercharger Overboost Condition
• P0299 — Turbocharger/Supercharger Underboost Condition
• P0380 — Glow Plug/Heater Circuit Malfunction
• P0401 — Exhaust Gas Recirculation Flow Insufficient

Transmission Codes

• P0700 — Transmission Control System Malfunction
• P0715 — Input/Turbine Speed Sensor Circuit Malfunction
• P0720 — Output Speed Sensor Circuit Malfunction
• P0731 — Gear 1 Incorrect Ratio
• P0732 — Gear 2 Incorrect Ratio
• P0733 — Gear 3 Incorrect Ratio
• P0734 — Gear 4 Incorrect Ratio
• P0741 — Torque Converter Clutch Performance or Stuck Off

ABS and Chassis Codes

• C0035 — Left Front Wheel Speed Sensor Circuit
• C0040 — Right Front Wheel Speed Sensor Circuit
• C0045 — Left Rear Wheel Speed Sensor Circuit
• C0050 — Right Rear Wheel Speed Sensor Circuit

Network Communication Codes

• U0100 — Lost Communication With ECM/PCM
• U0101 — Lost Communication With Transmission Control Module
• U0121 — Lost Communication With ABS Control Module
• U0140 — Lost Communication With Body Control Module

Plus other applicable manufacturer-specific diagnostic codes.

Fuse Box Diagram

• Engine compartment fuse box layout
• Passenger compartment fuse box layout
• Fuse identification charts
• Relay locations
• Fuse amperage specifications
• Power distribution diagrams

Wiring Diagrams

• Petrol engine management
• Diesel common-rail system
• Turbocharger control system
• Fuel injection system
• Ignition system
• Starting and charging systems
• Manual transmission
• Automatic transmission
• 4WD system
• Transfer case
• Front and rear differential systems
• ABS system
• Air conditioning system
• HVAC system
• SRS airbag system
• Instrument cluster
• Immobiliser system
• Body electrical system
• Lighting system
• Audio system
• Power windows
• Power mirrors
• Central locking
• Cruise control
• Wiper and washer system

Timing and Drive System Information

• Accessory drive belt routing
• Drive belt inspection
• Drive belt replacement
• Automatic tensioner servicing
• Timing belt inspection
• Timing belt replacement
• Camshaft timing specifications
• Timing belt alignment procedures
• Diesel timing procedures
• Turbocharger inspection
• Transfer case servicing
• Differential servicing

Torque Specifications

• Engine fastener torque values
• Cylinder head torque specifications
• Main bearing torque values
• Connecting rod torque values
• Intake and exhaust manifold torque values
• Timing component torque specifications
• Fuel system torque specifications
• Turbocharger torque specifications
• Transmission torque specifications
• Transfer case torque specifications
• Differential torque specifications
• Driveshaft torque specifications
• Suspension torque specifications
• Steering component torque values
• Brake system torque values
• Wheel nut torque specifications

Maintenance and Service Information

• Factory scheduled maintenance intervals
• Engine oil and filter replacement
• Diesel fuel filter replacement
• Automatic transmission fluid servicing
• Manual transmission oil servicing
• Transfer case fluid servicing
• Differential oil servicing
• Engine coolant replacement
• Brake fluid replacement
• Spark plug replacement
• Glow plug inspection
• Engine air filter replacement
• Cabin air filter servicing where fitted
• Drive belt inspection
• Timing belt replacement interval
• Battery inspection
• 4WD system inspection
• Tyre rotation procedures
• Wheel alignment checks

Who Is This Manual For?

• Automotive workshops
• Independent repair garages
• Kia specialists
• Automotive technicians
• Diesel specialists
• Auto electricians
• Diagnostic specialists
• 4WD specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions