Kia Sorento 2003 User manual

2
2003 Sorento Technical Highlights • Contents
Section 1 General Information
Section 2 Engine
Section 3 Engine Electrical
Section 4 Fuel and Emissions
Section 5 Transmission & Drivetrain
Section 6 Brakes
Section 7 Steering and Suspension
Section 8 Body
Section 9 Body Electrical
Section 10 Supplemental Restraint System

1
Preface • 2003 Sorento
This Technical Highlights publication
provides information about the new fea-
tures, systems, and components used on
the 2003 Sorento. We have included the
most accurate and up-to-date information
available at the time of publication. Due to
constant improvement in our products, the
information and specications presented in
this manual are subject to change without
notice.
© 2002 Kia Motors Corporation
Service Training Department
All rights reserved. This publication may not be reproduced in whole or in part
without the written consent of Kia Motors Corporation.
revised version 3

This Sorento Technical Highlights publication
serves two important purposes. Used with the 2002
Sorento Technical Highlights video, it’s your key
to a comprehensive understanding of all the new
features, systems, and components that are included
on the all new Sorento. Secondly, this manual is
your initial model introduction training for the 2003
Sorento. Information about service procedures that
are specic to the new systems is also included.
First, view the 2003 Sorento Technical Highlights
video. Then, carefully read through this publication
in its entirety.
Section 1 • General Information
2
How to Use
This Manual
Read, study, and review
Watch the video
Take the test on-line at
www.kiauniversity.com
View instant results
Enroll at a local Training Center for
more Sorento training
revised version 3

3
There are two Trim Levels for the 2003
Sorento: LX and EX. Both trim levels feature the
Sigma 3.5 V6 engine and the 30-40LEI 4-speed
automatic transmission.
The general specications given here are for
general information only, and are subject to
change. Please check the Sorento Service Manual
for the latest information.
Item Inches
Overall length 179.8
Overall width 73.3
Overall height without roof rack 68.1
Overall height with roof rack 71.3
Wheelbase 106.7
Ground clearance 8.2
Approach angle 28.4
Departure angle 26.7
Item Pounds
GVWR 4x4—5,644
4x2—5,423
Curb weight 4x4—4,255
4x2—4,057
Weight distribution 4x4—54%/46%
4x2—56%/44%
Item Gasoline Engine
Bore X Stroke 3.66 x 3.38 inches
Displacement 213.4 cubic inches (3497cc)
Compression ratio 10.0:1
General Infor-
mation
Section 1 • General Information
Vehicle
Specications
Dimensions
Engine
Weights
(Gasoline
Engine with
Automatic
Transmission)
Battery CCA 600
Capacity 12V/70AH
Alternator 13.5V/120A
Starter 12V-1.2kw
Spark Plug Gap 1.0-1.1 mm (PFRSN-11)
Type Platinum NGK (RC1OPYPB4)
Copper Champion
Electrical
System
revised version 3

4
Lubricant Volume (SAW/Metric) Classication
Engine Oil 5.8 quarts/5.5 liters API Service SD or above
Transmission Oil 9 quarts/8.5 liters Dextron III
Coolant 3 gallons/11.4 liters
Brake Fluid 1.4 quarts/1.3 liters SAE J1703, FMVSS 116
DOT 3 or DOT 4
Fuel 21.1 gallons/80 liters 87 Octane (as recommended in Owner’s Manual)
Differential Fluid (w/o LSD) GL-5, SAE 90
Differential Fluid (w/ LSD) GL-5, SAE 85-90
Refrigerant complies with SAE J639 Refrigerant R-134a
Maximum operating charge 33 ounces
Tire Size Wheel Size Maximum Pressure
245/70 R16 6JJX15 35 PSI
Section 1 • General Information
Capacities
Air
Conditioner
Tires
revised version 3
Light Bulb Wattage
Headlamps (High/Low) 55/55
Front turn signal/position lights 28/8
Front fog lights (if equipped) 27
Rear turn signal lights 27
Stop and tail lights 27/8
Back-up lights 27
License plate lights 5
Interior Lights 10
Dome light 10
Rear cargo area light (if equipped) 10
High-mounted stop light (if equipped) 21
Door courtesy lights 5
Light Bulbs
Refer to “Fuses” in the
Owner’s Manual Index.
Fuses

5
Vehicle Identification Number Position
revised version 3
Vehicle Description Section
(Model)
Vehicle Identication Section
(Chassis No.)
K N D J C 7 3 3 9 3 5 6 0 0 0 0
Country
K = Korea
Model
J = Sorento
Series
C* = 4WD
D = 2WD
Engine/
Restraint
3 = 3.5L V6
Dual Airbag
Model Year
3 = 2003
Assembly
Plant
5 = Whasung
Production (Frame)
Sequence
Number
Check Digit
Must be 0 - 9 or X
0
Vehicle Type
D = MPV
Manufacturer
N = Kia Motors
Corp.
Body Type
5**, 7 = 4 Door SUV
2***, 3 = 4996-5984
GVWR Lbs.
* For all vehicles manufactured between 4/27/2002 and 8/14/2002, the
letter C indicates either 2WD or 4WD.
** For all vehicles manufactured between 2/28/2002 and 8/14/2002, the
number 5 indicates a 4-door SUV.
*** For all vehicles manufactured between 2/28/2002 and 8/14/2002, the
number 2 indicates a GWVR of 2,271 - 2,720 kg (4,996 - 5,984 lbs.)

6revised version 3
Section 1 • General Information—Mechanical
Features and
Options
LX EX
3.5 DOHC 6-cylinder (192 HP) S S
4-Speed automatic S S
Power Steering Engine speed sensing S —
Vehicle speed sensing — S
Steering linkage Rack & pinion S S
Hood blanket S S
Suspension Front: Wish-bone w/coil spring S S
Rear: 5-Link coil spring S S
Gas shocks S S
Fuel tank 80 liters / 21.1 gallons S S
2-Speed transfer case 4WD 4WD
4WD Push button part-time type 4WD 4WD
Torque on demand full-time (w/low range) — Lux
Free running differential (more advance system than automatic locking hubs) 4WD 4WD
Limited slip rear differential (not an option) 4WD 4WD
Tow package (Trailer hitch and wiring harness connector) PIO PIO
Self-levelizer — O

7
LX EX
Wheels Styled steel S —
Alloy (bright machine nish face) O S
Tires P245/70R16 (domestic bound) S —
P245/70R16 (Michelin) — S
Full size spare tire under vehicle (alloy steel if equipped with alloys) S S
Mudguards ACC ACC
Windshield Solar control glass S S
Side glass (B-pillar back) Privacy glass S S
Power sunroof (tilt and slide) — S
Grille Black mesh insert w/chrome surround S S
Door handles Body color S S
Body color/chrome accent — Lux
Mirrors Dual power, heated (black) S —
Dual power, heated (body color) — S
Fog lamps — S
Head lamps Multi-reector head lamps S S
Auto lamps — Lux
Roof rack Black O S
Bumpers Body color S —
Two-tone — S
Bodyside cladding, fender
ares
Two-tone — S
Rear garnish Body color S S
Chrome — Lux
Rear spoiler O O
Manual fuel door & gas cap with tether S S
Rear split hatch liftgate w/ip-open glass operated with remote or inside release S S
Towing hooks Front and rear S S
Skid plates (front-end, fuel tank) S S
Section 1 • General Information—Exterior
Features and
Options
revised version 3

8revised version 3
LX EX
Seat upholstery & trim inserts
Double raschel cloth seat and door trim S —
Moquette velour cloth seat and door trim — S
Leather — O/Lux
Front seats
8-Way manual adjustment (driver) S —
8-Way power adjustment (driver) — S
Heated (driver & passenger) — Lux
Lumbar adjustment (driver) S S
W/Tilt adjustable headrests — S
Rear seat
60/40 split at folding rear seats S S
Fold down armrest S S
Removable headrest (all three positions) S S
Steering wheel Leather wrapped — S
Leather wrapped/wood grain — Lux
Shifter
Black PRNDL, shift shaft, knob S —
Brushed metal style PRNDL, chrome shaft, black knob — S
Brushed metal PRNDL, chrome shaft, wood grain accent knob — Lux
Inside door handles Color keyed S —
Chrome — S
Scuff plates Color keyed S —
Bright stainless steel — S
Wood grain center fascia/console accents — S
Fabric headliner S S
Cut pile carpet S S
Section 1 • General Information—Interior
Features and
Options

9
LX EX
Dome lights with fade-out feature (illuminated entry and exit) and I/P dimmer switch master control S S
In-door safety/courtesy lights S S
Large felt-lined coinholder bin S S
Under seat storage bin S S
Rear quarter panel storage bins S S
Digital clock (in dash) S S
Tachometer S S
Horn Dual S S
Electrochromatic rear view mirror with homelink programmable garage door opener (no Lux installation) — S
Remote keyless entry W/Door lock, panic, rear glass open (no Lux installation) — S
Power windows with one-touch drivers express down feature S S
Power door locks (two-turn entry system) S S
Assist grips Four positions S S
Garment hooks Roof-mounted, rear LH & RH S —
Assist grip mounted, rear LH & RH — S
Tilt steering wheel S S
Rear cargo cover S S
Cargo net ACC S
Cargo net hooks S S
Under rear cargo oor storage compartments S S
Rear cargo lamp w/ on/off switch S S
Driver and passenger sunvisors (slide-out); dual covered & illuminated vanity mirrors S S
Air conditioning Manual S S
Automatic — Lux
(2) Front, (1) Second row, (1) Cargo area 12-volt power points S S
Cruise control with steering wheel controls S S
(4) Floor mounted cargo tie-down hooks (also used for cargo net on EX S S
Driver’s foot rest S S
Overhead Console
Sunglass storage, map lights, garage door opener pocket S S
Multi-meter (outside temp., compass, altimeter, barometer—
not on FATC vehicles
— S
Center console with armrest, dual storage (top small items, bottom CD/Cassettes) S S
Dual rear cupholders (rear console) S S
Dual center console cupholders S S
Straight into dash (not in steering column) illuminated ignition switch S S
Lockage, large glove box with upper map pocket S S
LCD odometer with two trip meters S S
Section 1 • General Information—Convenience
Features and
Options
revised version 3

10 revised version 3
LX EX
Audio Systems
AM-FM/CD 8 speakers/6 enclosures S —
Delphi premium AM/FM/Cassette/CD audio with separate amplier, 10 speakers/6 enclosures — S
Delphi premium AM/FM 6 disk in-dash CD with separate amplier, 10 speakers/6 enclosures — Lux
Steering wheel audio controls — S
Antenna One pole S S
Safety
Battery saver S S
Brake Front and rear disc S S
Dual airbags Steering wheel, instrument panel air bags (no seam) S S
Side curtain airbags S S
Rear child safety door locks S S
High mounted stop lamp S S
Fixed upper & lower anchors for child safety seats (LATCH system) S S
First aid kit in rear quarter panel storage bin (KMA) S S
Two-speed variable intermittent wipers S S
Rear window defogger S S
Rear window wiper/washer (intermittent) S S
Front windshield de-icer (hot wire) S S
Low fuel warning indicator S S
Washer uid low warning indicator S S
4-Wheel ABS O O
Side impact protection S S
Seat belts 3-Point emergency locking retractor (all seating positions) S S
Adjustable anchors in front S S
Pretensioner & force limiter (front seats) S S
Energy absorbing steering column S S
Fuel cut-off system S S
Features and
Options
Section 1 • General Information—Audio Systems, Safety
S: Standard
O: Optional
—: Not available
ACC: Accessory
Lux: Luxury package
TP: Tow Package

11
Section 1 • General Information—Options
Options
• ABS (all)
• Self-Levelizer (EX)
• Floor mats (LX)
• Cargo tray (all—PIO)
• 4-wheel drive (all)
• Rear spoiler (EX)
• Alloy wheels (LX)
• Roof rack (LX)
• Leather package (EX)
• AM/FM/6 in-dash disc CD (EX)
• Tow package
EX Model Includes
• Two-tone exterior
• Sunroof
• Roof rack
• Fog lamps
• Body color outer mirror (dual power, heated)
• Bright machine nished aluminum wheels
• Moquette velour seat trim
• Wood grain center fascia/console accents
• Power driver’s seat
• Leather-wrapped steering wheel
• Chrome-plated inner door handles
• Chrome shifter shaft
• Brushed metal style PRNDL base plate
• Overhead console adds Multi-meter
(outside temp., compass, altimeter, barometer)
• Rear cargo cover, cargo net
• Electro-chromatic rearview mirror
• Homelink in rear view mirror
• Keyless entry system (two remotes)
• Delphi premium AM/FM stereo radio, cassette,
CD player with separate amplier, 10 speakers,
steering wheel audio controls
• Bright stainless steel scuff plates
Luxury Package (available on EX grade only)
• Optional 4WD-torque on demand type
• Chrome outside door handles
• Chrome rear garnish
• Auto climate control
• Heated front seats
• Leather package
• Wood grain/leather steering wheel
• Wood grain accent shift knob
• Auto headlamps
• Delphi premium AM/FM/6 in-dash disc CD with
separate amplier, 10 speakers, steering wheel
audio controls
Tow Package (TP—all)
• Trailer hitch receiver, ball mount, ball (PIO)
• Wiring harness with 4-wire connector (PIO)
Options
revised version 3

12 revised version 3
Section 1 • General Information
Sorento Exterior Color Matrix
- KMA -
Code Exterior Color Interior Color (LX/EX)
Beige (44) Gray (BT)
UD Clear White X X
D3 Silky Beige X —
C9 Silver Metallic — X
P7 Misty Blue X X
P1 Blue Sapphire X X
R9 Ruby Red X X
G6 Dark Emerald Green X X
9B Midnight Black X —
WM* UD/D3 X —
IN* P7/C7 — X
WL* P1/C7 — X
ZG* G6/D3 X —
HM* R9/D3 X —
WN* 9B/C7 — X
AH* G6/C7 — X
WU* UD/C7 — X
WR* R9/C7 — X
WP* P1/D3 X —
* Option on EX only
Exterior
and Interior
Colors
Maintenance
Intervals
Maintenance
Item
Number of Months or Kilometers (Miles), whichever comes rst
Months 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
Miles x 1000 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
(km x 1000) (12) (24) (36) (48) (60) (72) (84) (96) (108) (120) (132) (144) (156) (168) (180) (200)
Drive Belts I I I I
Engine Oil Replace every 7,500 miles or 12 months
Engine Oil Filter Replace every 7,500 miles or 12 months
Automatic Transmission Fluid I I I I I I I I I I I I I I I I
Engine Timing Belt I R(1) I R
Air Cleaner Element R R R R
Spark Plugs R R
Schedule 1—Normal Maintenance
Normal
Maintenance
Schedule
Notes:
I - Inspect
R - Replace
(1) - For California. This maintenance is recommended, but not required.

13
Maintenance
Intervals
Maintenance
Item
Number of Months or Kilometers (Miles), whichever comes rst
Months 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
Miles x 1000 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
(km x 1000) (12) (24) (36) (48) (60) (72) (84) (96) (108) (120) (132) (144) (156) (168) (180) (200)
Cooling System I I I I
Engine Coolant R R R R
Idle Speed I (2) I (2) I (2) I (2)
Fuel Filter I (1) I (1) I (1) I (1)
Fuel lines and hoses I (2) I (2) I (2) I (2)
Hose and tube for emission I (2) I (2) I (2) I (2)
Transfer Case Oil (if equipped) I I R I I R I I R I I R I I R I
Manual Transmission Fluid I I I I I I I I I I I I I I I I
Automatic Transmission Fluid I I I I I I I I
Front Differential Fluid (if
equipped)
I I R I I R I I R I I R I I R I
Rear Differential Fluid I I R I I R I I R I I R I I R I
Ignition Wires I
Maintenance
Intervals
Maintenance
Item
Number of Months or Kilometers (Miles), whichever comes rst
Months 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
Miles x 1000 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
(km x 1000) (12) (24) (36) (48) (60) (72) (84) (96) (108) (120) (132) (144) (156) (168) (180) (200)
Brake Lines and Connections I I I I I I I I
Parking Brake I I I I
Disc Brakes I I I I I I I I
Brake Fluid/Clutch Fluid (if
equipped)
I I I I I I I I
Steering Operation and Linkage I I I I
Front Suspension Ball Joints I I I I
Driveshaft Dust Boots I I I I
Chassis/Body Nuts and Bolts I I I I
Front & Rear Driveshaft U-joints L L L L L L L L
Exhaust System Heat Shield I I I I
All Locks and Hinges L L L L L L L L L L L L L L L L
A/C Refrigerant (if equipped) Inspect refrigerant amount annually
A/C Compressor (if equipped) Inspect operation annually
Schedule 1—Normal Maintenance (continued)
Section 1 • General Information—Maintenance
Normal
Maintenance
Schedule
Notes:
I - Inspect, and if necessary, adjust
R - Replace
(1) - This maintenance is required in all states except California, However, we recommend that it also be performed on California vehicles.
(2) - This maintenance is recommended by Kia. However, it is not necessary for emission warranty coverage or manufacturer recall liability.
Schedule 1—Normal Maintenance (continued)
revised version 3

Section 2 • Engine
The Sorento is equipped with a Sigma 3.5 Liter
engine, which is the same as the Sedona but with a
different Variable Intake System.
The intake manifold utilizes a variable intake
system, which extends the torque curve, by selecting
designated intake runners to improve performance.
The block is made of cast iron. The cylinder heads
and upper oil pan are aluminum. Hydraulic Lash
Adjusters (HLA) eliminate the need for valve ad-
justments.
There are three drive belts with mechanical ten-
sioners. The timing belt turns all four cam sprockets
with a hydraulic timing belt tensioner.
The engine is mounted at 4º inclination, higher in
front, in order to accommodate the front differential.
A tting is provided on the thermostat housing link-
ing the front water jackets of both heads through a
pipe to the surge tank. This design assures auto-
matic air bleeding of the system.
Features
• DOHC
• 10:1 compression ratio
• Idle speed: 800 RPM±100
1
Sigma 3.5
Engine
Items Sigma 3.5 L
Displacement 3,497 cc
Bore x stroke 93 x 85.5 mm
Compression ratio 10:1
Firing order 1-2-3-4-5-6
Basic ignition timing 10º BTDC
Idle RPM 800 ± 100
HLS End Pivot Type
Fuel Pressure (regulated) 47-48 psi
Injector type 4 hole
Injector timing 17 BTDC
Spark plug PFRSN-11
Spark plug gap 1.0 – 1.1 mm
Oxygen sensor ZrO2
Coolant control Inlet Control
Air ow sensor Hot Film
EMS MELCO
• End Pivot Type Hydraulic Lash Adjusters
• Aluminum heads
• Cast iron cylinder block
• Aluminum upper oil pan
General
Description
revised version 3

1 Variable Intake System
2 Exhaust Manifold
3 Thermostat Housing
4 Engine Block
5 Bracket
6 Dipstick Tube
2
Section 2 • Engine
Drive Belts
• Three drive belts
• Three tensioners
Power steering pulley
Tensioner pulley
Accessory mounting bracket
Tensioner pulley
Water pump pulley
Air conditioner
pulley
Crankshaft pulley
Tensioner pulley
Alternator pulley
1
5
2
5
2
3
4
6
revised version 3

3
Section 2 • Engine
Timing Belt Timing markTiming mark
Tensioner arm
Tensioner pulley
Auto tensioner
Crankshaft sprocket Timing mark
Crankshaft position
Sensor
Engine support bracket
Idler pulley
Camshaft position
sensor
Camshaft sprocket
Water pump pulley
From the reservoir
To the reservoir
Water outlet pipe
Thermostat housing
Outlet tting
Bypass tting, RH
From radiator
To radiator
Cooling
System
• The cooling
system on the
Sorento is a
Self-bleeding
system.
From heater
To heater
revised version 3

Section 3 • Engine Electrical
The Sigma 3.5 V6 engine uses a distributor-
less ignition system with the ECM controlling
and monitoring ignition system functions. Three
ignition coils are located above cylinders 2, 4, and
6 (cylinder bank 2); three spark plug wires connect
the coil assemblies to cylinders 1, 3, and 5. The coils
feature integrated power transistors. The coils are
also physically smaller than those in the Sedona
3.5L. The ignition system in the 2003 Sorento is a
wasted-spark system. For fault detection purposes,
an Ignition Failure Sensor is employed.
1
Ignition
System
The Ignition Failure Sensor (IFS) monitors the
coil primary waveform. When the primary circuit is
turned OFF by the ECM, the collapse of the mag-
netic eld induces a high voltage in the secondary
winding. An inductive spike is then in turn induced
in the primary winding of the coil. This inductive
spike is detected by the IFS, which then generates a
digital Ignition Detect Signal. The output from the
IFS is routed to the ECM and the vehicle tachom-
eter.
By monitoring the digital output of the IFS, the
ECM can detect the presence of an ignition system
malfunction. A P0350 DTC is generated and stored
upon detection. (Two drive cycles are required for
MIL illumination.) The ignition system monitoring
functions are conducted under 4000 RPM. IFS fail-
ures can cause a P0320 DTC; this DTC is a one-trip
code.
Ignition
Failure
Sensor
IFS
The charging system on the 2003 Sorento uti-
lizes a generator with a built-in voltage regulator.
The ECM does not control the eld circuit operation
(as on Sedona).
Generator
• 13.5v/120 amps
A reduction drive type starter is used. The starter
motor current draw should be 90 amps or less.
Charging
System
Starter
revised version 3

Section 3 • Engine Electrical
2
The 2003 Sorento uses a single 12V 600CCA
battery.
Battery
Engine cooling and condenser fans are ECM-
controlled through a series of three fan relays
located in the engine compartment fuse and re-
lay box. Both fans feature high and low speeds
which are actuated based on the ECT, vehicle
speed, the A/C switch position, and the A/C sys-
tem triple pressure switch position.
Cooling/
Condenser
Fan Control
revised version 3