2003-2006 Kia Sorento OEM Service & Repair Manual
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SPECIAL SERVICE TOOLS
Tool (Number and
name)
Illustration Use
09452-21000
Oil pressure gauge
adapter
Measurement of the oil pressure (use
with 09452-21500, 09452-21600, 09452-
32300)
09452-21500
Oil pressure gauge
Measurement of the oil pressure (use
with 09452-21000, 09452-21600, 09452-
32300)
09452-21600
Oil pressure gauge
adapter
Measurement of the oil pressure (use
with 09452-21000, 09452-21500, 09452-
32300)
09452-32100
Oil seal installer
Installation of the oil pump oil seal
09452-32300
Oil pressure gauge
adapter
Measurement of the oil pressure (use
with 09452-21000, 09452-21500, 09452-
21600)
09453-32100
Piston spring
compressor
Removal of the clutch piston
09414-11000
Lock pin extractor
Removal of the pin in the lock pawl rod
09455-38000
Spring compressor
Removal of the overdrive return spring
Removal of the forward clutch spring
Removal of the direct clutch spring
09454-38000
Second brake spring
compressor
Removal of second brake spring
09454-38100
First & reverse brake
spring compressor
Removal of first & reverse brake spring
09454-38200
Reverse brake piston
remover
Removal of reverse brake piston
09454-38300
Reaction sleeve
remover
Removal of reaction sleeve
SPECIFICATION
TIGHTENING TORQUE
Item N·m Kg·cm Ib·ft
Transmission housing to case (10mm)
Transmission housing to case (12mm)
Extension housing to T/M case
O/D case to T/M case
Oil pump to T/M case
Oil pump body to stator shaft
Valve body
Oil strainer
Oil pan
Speed sensor
Speedometer driven gear lock plate
Union
Transaxle range switch bolt
Transaxle range switch nut
Control shaft lever
Shift knob screw
Shift lever bracket
35
58
37
26
22
10
10
10
7.5
7.5
16
30
13
7
16 - 23
2 - 3
8 - 11
350
580
370
260
220
100
100
100
75
75
160
300
130
70
160 - 230
20 - 30
80 - 110
25
42
27
19
16
7
7
7
5
5
11
22
9
5
11 - 16
1 - 2
6 - 8
COMPONENTS
REMOVAL
1. Remove the console upper cover plate.
2. Remove the center console assembly.
3. Remove the control cable, the shift lock cable and key lock cable.
4. Disconnect the inhibitor switch indicator connector.
5. Remove the control lever assembly.
6. Remove the control lever bracket.
SHIFT LOCK DEVICE INSTALLATION INSTRUCTIONS
INSPECTION
a. Check the detent place for wear.
b. Check the bushing for wear or damage.
c. Check the spring for damage or deterioration.
d. Check the pin at the end of the rod assembly for wear.
When servicing the shift lock device, follow the service instructions and procedures described below in
order to operateit normally.
1. Procedure to install the lock cam.
a. Make sure to move shift lever to position "P" to set key lock cam and p-lock as figure.
2. Procedure for adjusting "P" shift lock and key lock cable.
(1) Check that lock cam is located in position.
(2) Install shift lock cable in position as figure.
(3) Temporarily install shift lock cable to A/T lever assembly as shown in figure. Securely insert cable
end into fixing pin of cam.
(4) After checking that a portion of cable end touches cable fixing pin of P-lock cam, fix shift lock cable
to A/T lever.
3. Checking that procedure for installing the shift lock is correct.
(1) When the brake pedal is not depressed, push button of the shift lever at "P" position cannot be
operated. (Shift lever cannotbe shifted at the other positions from "P").
Push button can be operated at the other positions except "P".
(2) When brake pedal stroke is 30 mm (with shift lever at "P" position), push button should be operated
without catching and shift levercan be shifted smoothly to other from "P".
(3) When brake pedal is not depressed, shift lever should be shifted smoothly to "P" position from other
positions.
(4) Brake pedal must be operated smoothly without catching at all positions.
(5) If shift lever is shifted to "P" position, ignition key must be turned to "LOCK" position smoothly.
(6) Adjust nut "A" and bolt "B" if necessary.
TRANSAXLE RANGE SWITCH
1. Operating inspection
(1) Check that the starter turns with the ignition switch at START position and the selector in the "P"
and "N range only.
(2) Check that the back-up (reverse) lights illuminate when shifted to the "R" range with the ignition
switch in the ON position.
(3) Check the transaxle range switch if it is not working properly.
1. Adjustment
(1) Shift the selector lever to the "N" range.
(2) Loosen the transaxle range switch mounting bolts.
(3) Disconnect the transaxle range switch connector.
(4) Check the continuity of the terminals using ohmmeter.
(5) Adjust the switch to the point where there is continuity between the terminals.
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What's Included?
Lifetime Access
Fast Download Speeds
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Full Search Facility
Print one or all pages of your manual
$31.99
2003-2006 Kia Sorento OEM Service & Repair Manual
Engines Covered:
- 3.5L V6 DOHC Sigma G6CU
This 2003-2006 Kia Sorento OEM Service & Repair Manual provides detailed repair procedures, technical specs, and maintenance instructions for all major systems on the first-generation Sorento. This official manual is a must-have for any DIYer or technician working on the 3.5L DOHC V6 model.
Every section has been professionally structured for easy access, including wiring diagrams, torque specs, and complete diagnostic procedures. Whether you're tackling drivetrain repairs, suspension issues, or just keeping up with maintenance, this manual offers factory-level detail.
Content Overview:
- General Information & Maintenance
- Engine Mechanical (3.5L V6 DOHC)
- Engine Performance & Emission Control
- Electrical System & Wiring Diagrams
- HVAC (Heating, Ventilation, A/C)
- Transmission & Transaxle (coverage depends on model-specific config)
- Suspension & Steering
- Brakes (ABS and non-ABS)
- Restraints & Airbags
- Technical Service Bulletins
- Torque Specs & Diagnostic Flowcharts
Whether you're servicing the engine, chasing down an electrical fault, or reviewing TSBs before a repair, this manual gives you the factory-approved procedures to do the job right the first time.
Printable: Yes
Language: English
Compatibility: Windows, macOS, Linux
Requirements: PDF reader software
