2003 Kia Sedona Service and Repair Manual
Kia built the 2003 Sedona around a single V6 powertrain, and this factory service and repair manual is keyed to that exact year, engine and trims — the specifications and service sequences inside are the ones Kia published for the 2003 van, not near-enough figures borrowed from a later Sedona.
Engines covered
- 3.5L V6 — DOHC, naturally aspirated, gasoline
Body styles covered
- 5-door mini passenger van
Trims covered
- EX
- LX
Known issues on the 2003 Sedona. Four recalls are on federal record for this model year. One concerns the anti-lock braking system: a programming error in the ABS electronic control module logic could cause reduced braking force, and such increased stopping distances could result in a crash. Two separate recalls cover the throttle cable — in one, freezing conditions can cause water on the throttle cable to freeze during normal operation, which can cause the cable to stick and prevent the engine from returning to idle; in the other, the throttle cable would twist itself out of position during assembly, which can permit the cable to be hung up and could result in a crash. The remaining recall covers mini vans equipped with alloy wheels: moisture can accumulate around the rear hub caps causing damage to the outer wheel bearing, and wheel bearing failure may occur without warning, which could result in a crash. Owners have filed 214 complaints for the year and Kia has issued 20 technical service bulletins.
Whether you are diagnosing the ABS module after a braking complaint, freeing a sticking throttle cable or repacking a rear wheel bearing, this manual keeps you on the procedure and specification Kia wrote for the 2003 Sedona.
ON CERTAIN MINI VANS, FREEZING CONDITIONS CAN CAUSE WATER ON THE THROTTLE CABLE TO FREEZE DURING NORMAL OPERATION. RESISTANCE TO MOVEMENT OF THE THROTTLE CABLE CAN OCCUR WHEN THE DRIVER LIFTS THEIR FOOT OFF OF THE GAS PEDAL.
THIS CAN CAUSE THE CABLE TO STICK, THUS PREVENTING THE ENGINE FROM RETURNING TO IDLE AND CAUSING THE VEHICLE TO MAINTAIN SPEED OR ACCELERATE. SUCH AN EVENT CAN OCCUR WITHOUT WARNING AND COULD CAUSE A CRASH.
DEALERS WILL MODIFY A PROTECTIVE SLEEVE AROUND THE THROTTLE CABLE. THE RECALL BEGAN ON AUGUST 15, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
ON CERTAIN MINI VANS EQUIPPED WITH ALLOY WHEELS, MOISTURE CAN ACCUMULATE AROUND THE REAR HUB CAPS CAUSING DAMAGE TO THE OUTER WHEEL BEARING.
WHEEL BEARING FAILURE MAY OCCUR WITHOUT WARNING WHICH COULD RESULT IN A CRASH.
DEALERS WILL REPLACE THE REAR HUB CAPS FREE OF CHARGE. UPON INSPECTION, SOME VEHICLES WILL ALSO REQUIRE REPLACEMENT OF THE REAR OUTER BEARINGS AND/OR HUB ASSEMBLY. THE RECALL BEGAN ON JUNE 13, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
ON CERTAIN MINI VANS, DURING ASSEMBLY, THE THROTTLE CABLE WOULD TWIST ITSELF OUT OF POSITION.
THIS CAN PERMIT THE CABLE TO BE HUNG UP, WHICH COULD RESULT IN A CRASH.
DEALERS WILL REPLACE THE THROTTLE CABLE FREE OF CHARGE. VEHICLES PRODUCED FROM MARCH 20, 2001 THROUGH NOVEMBER 7, 2001 WILL HAVE A GUIDE CLIP INSTALLED ON THE THROTTLE BODY ASSEMBLY IN ORDER TO ENSURE THAT THE TENSION FORCE CABLE DOES NOT MOVE OUT OF POSITION. VEHICLES MANUFACTURED BEGINNING ON NOVEMBER 8, 2001, ALREADY HAVE THE EXTENDED GUIDE, WHICH ACCOMPLISHES THE SAME OBJECTIVE. THE RECALL BEGAN MARCH 21, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
ON CERTAIN PASSENGER VEHICLES, THERE WAS A PROGRAMMING ERROR IN THE ANTI-LOCK BRAKING SYSTEM (ABS) ELECTRONIC CONTROL MODULE LOGIC. THE PROGRAMMING ERROR COULD CAUSE REDUCED BRAKING FORCE AT SPEEDS BELOW 25 MPH, WHICH COULD RESULT IN INCREASED STOPPING DISTANCES.
SUCH INCREASED STOPPING DISTANCES COULD RESULT IN A CRASH.
DEALERS WILL REPROGRAM THE CONTROL MODULE. OWNER NOTIFICATION BEGAN MAY 19, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT KIA AT 1-800-333-4542.
TECHNICAL SERVICE BULLETIN: INFORMATION FOR HEADLAMP CONDENSATION AND MOISTURE - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This b
TSB - USE OF AFTERMARKET USB CHARGING CABLES IN USB/12V PORTS - This article provides information regarding the use of USB ports and 12V power outlets to connect/charge mobile phones. Customers may experience issues with their head units th
PITSTOP - ENGINE COMPONENT RE-USE GUIDELINES - In general, parts and components removed during engine repairs should be considered serviceable, and should be thoroughly cleaned and transferred to the new engine.
TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners, which are designed to lock into place once fully attached, are utilized in various Kia models and are strictly intended for ?one time use.? Some example
TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners utilized in various Kia models are strictly intended for ?one time use?. Though not limited to the following, some examples are: axle shaft nuts with sta
TSB: AUTOMATIC TRANSMISSION FLUID APPLICATION GUIDE - THIS BULLETIN PROVIDES INFORMATION RELATING TO THE CORRECT AUTOMATIC TRANSMISSION FLUIDS THAT ARE REQUIRED FOR EACH KIA MODEL. REFER TO THE SHOP MANUAL ON KGIS FOR THE SPECIFIC KIA MODEL
KIA: INTERMITTENT MIL ON WITH NO FAULT CODE STORED; INFORMATION ABOUT DTC P1330. PROVIDES INFORMATION RELATING TO CERTAIN VEHICLES. IN AFFECTED VEHICLES AN INTERMITTENT SHORT TO GROUND IN A CIRCUIT ONLY INTENDED FOR TESTING PURPOSES MAY CAU
KIA: ECM UPGRADE WITH TP SENSOR REPLACEMENT-MIL ON WITH DTC P2135/P0638. INFORMATION RELATED TO ECM SOFTWARE AND TP SENSOR UPGRADE ON SOME VEHICLES WITH 2.7L ENGINES WHICH MAY EXPERIENCE A MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH T
Showing the 8 most recent of 21 technical service bulletins on file with NHTSA.
ON APRIL 23 2005 THE FRONT END OF MY 2003 KIA SEDONA HIT A FORD EXPLORER. THIS ACCIDENT CAUSED $9,000 IN DAMAGE TO MY KIA AND SENT MYSELF, MY HUSBAND, AND MY 2 YEAR OLD DAUGHTER TO THE HOSPITAL. MY AIRBAGS DID NOT GO OFF, AND NO ONE SEEMED TO KNOW WHY. I WOULD LIKE THIS INVESTIGATED. *AK
IN JULY 2004 A PERSON RAN A STOP SIGN, I COMPLETELY DROVE INTO HER WHOLE PASSENGERS SIDE WITH THE FRONT END OF MY 2003 KIA SEDONA. I ALSO HAD MY 2 YEAR OLD SON IN THE CAR AT THE TIME. THE AIR BAGS DID NOT DEPLOY WHICH WAS A CONCERN TO THE EMERGENCY PERSONNEL THAT RESPONDED TO THE SCENE. I SUSTAINED NECK INJURY THAT LATER HAD TO HAVE SURGERY TO CORRECT AND MY SON WHO WAS IN HIS SAFETY SEAT IN THE REAR ALSO SUSTAINED BURN INJURY FROM HIS SAFETY SEAT HARNESS. I CONTACTED KIA AFTER THE ACCIDENT A
UPON IMPACT THE DRIVER'S SIDE AIR BAG DID NOT DEPLOY RESULTING IN THE DRIVER HITTING HER FACE ON THE STEERING WHEEL.*MR THE DRIVER SUFFERED FROM MULTIPLE CUTS INSIDE HER MOUTH, A FRACTURED NOSE WHICH CAUSED SHORTNESS OF BREATH AND MULTIPLE BRUISES. *NM
DRIVING A 2003 KIA SEDONA APPROXIMATELY 35 MPH WHEN A CAR MADE A LEFT TURN RIGHT IN FRONT OF US. WE HIT THEM ALMOST HEAD ON, THEN WERE THROWN TO THE RIGHT, UP OVER A CURB AND CAME TO REST AGAINST A BRICK WALL. MY HUSBAND WAS DRIVING, HE SUSTAINED CUTS TO HIS FOREHEAD WHEN HE STRUCK THE WINDSHIELD, AND YES, WE WERE BOTH PROPERLY BELTED IN. HE ALSO BROKE THE STEERING WHEEL, LEAVING BRUISES ON HIS CHEST. I WAS IN THE FRONT PASSENGER SEAT AND SUSTAINED A FRACTURED RIGHT RADOIS AND A FRACTURED LE
WHILE DRIVING 45 MPH, THE CONSUMER APPLIED THE BRAKE PEDAL, BUT THE BRAKES FAILED. THIS CAUSED THE CONSUMER TO COLLIDED WITH THE VEHICLE IN FRONT OF HIS. THE OCCUPANTS IN ALL THREE VEHICLES SUSTAINED MINOR INJURIES AND WERE TRANSPORTED TO THE HOSPITAL. BOTH FRONTAL AIR BAGS FAILED TO DEPLOY. THE VEHICLE WAS TOWED TO A GARAGE FOR INSPECTION. PLEASE PROVIDE FURTHER DETAILS. *JB
TL* THE CONTACT OWNED A 2003 KIA SEDONA EX. WHILE MAKING A LEFT TURN AT 5 MPH, ANOTHER VEHICLE REAR ENDED THE REAR PASSENGER SIDE OF THE CONTACT'S VEHICLE. THE VEHICLE SPUN OUT OF CONTROL. THE AIR BAGS DID NOT DEPLOY. A POLICE REPORT WAS FILED BY THE HIGHWAY PATROL AND SHERIFF. THE CONTACT SUSTAINED BRUISING FROM THE SEAT BELT STRAP ACROSS THE CHEST, AND BRUISING ACROSS THE WAISTLINE AND BACK. MEDICAL ATTENTION WAS RECEIVED. THE VEHICLE WAS TOWED TO A POLICE HOLDING STATION AND LATER TO A BODY S
TL* THE CONTACT OWNS A 2003 KIA SEDONA. THE CONTACT STATED THAT SHE FELL ASLEEP BEHIND THE WHEEL WHILE DRIVING AT AN UNKNOWN SPEED, WHICH RESULTED IN THE VEHICLE CRASHING INTO A TREE. THE CONTACT STRUCK THE FRONT WINDSHIELD AND SUSTAINED SEVERE HEAD INJURIES. THE CONTACT'S SEAT BELT WAS SECURED AND WHEN HER BODY LUNGED FORWARD, THE SEAT BELT WEBBING MOVEMENT CAUSED BURNS TO THE SHOULDER AND CHEST AREA. THE AIR BAGS FAILED TO DEPLOY UPON IMPACT. A POLICE REPORT WAS AVAILABLE. THE VEHICLE WAS TOW
WHILE DRIVING AT 45 MPH CONSUMER WAS INVOLVED A FRONT AND REAR ACCIDENT AND NEITHER OF THE AIR BAGS DEPLOYED. *AK THE CONSUMER WAS TRYING TO AVOID BEING HIT BY ANOTHER VEHICLE. WHEN SHE SWERVED, THE VEHICLE GOT TO CLOSE TO THE GUARDRAIL SO SHE PULLED TO THE RIGHT. AT THAT POINT, THE VEHICLE STARTED TO SKID AND FISHTAIL. CONSUMER COULDN'T REGAIN CONTROL. THE VEHICLE SPUN AROUND AND HIT THE GUARDRAIL WITH THE FRONT OF THE VEHICLE. THEN THE VEHICLE BOUNCED ACROSS THE EXPRESSWAY AND HIT THE GUA
WHILE BACKING INTO A PARKING SPACE VEHICLE HIT A METAL POLE. CONSUMER SHIFTED THE TRANSMISSION INTO DRIVE WITH HER FOOT ON THE BRAKE. VEHICLE COMMENCED TO ACCELERATE AND LURCH FORWARD. IT RAN OVER A CONCRETE PARKING DIVIDER AND A SIDEWALK INTO A BRICK WALL. CONSUMER WAS TRANSPORTED TO THE LOCAL HOSPITAL BY AMBULANCE. VEHICLE WAS TOWED TO A REPAIR SHOP.*AK
THE ACCELERATOR PEDAL BECAME STUCK.SCC *JB
TL* THE CONTACT OWNS A 2003 KIA SEDONA. WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE CRASHED INTO A DEER AND CAUSED SIGNIFICANT DAMAGE TO THE FRONT END. DURING THE CRASH, THE AIR BAGS DID NOT DEPLOY. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS INVALID. THE FAILURE MILEAGE WAS 80,000.
DT*: THE CONTACT STATED WHILE DRIVING 30 MPH, THE VEHICLE WAS INVOLVED IN A HEAD ON COLLISION WITH ANOTHER VEHICLE. NEITHER FRONTAL AIR BAG DEPLOYED. THERE WAS A POLICE REPORT TAKEN AT THE SCENE. THERE WERE NO INJURIES SUSTAINED. THE VEHICLE WAS TOWED TO A PRIVATE REPAIR SHOP, WHERE THE MECHANIC WAS UNABLE TO DETERMINE THE PROBLEM. A SERVICE DEALER WAS CONTACTED, AND THE MANUFACTURER WAS ALSO NOTIFIED. UPDATED 12/04/06. *JB
BRAKES FAILED IN AN ACCIDENT AND THE AIR BAG DID NOT DEPLOY. *BF WHEN THE CONSUMER ATTEMPTED TO APPLY THE BRAKES BECAUSE THE VEHICLE IN FRONT OF HIM WAS A T A STOP, THE BRAKES LOCKED UP AND THE VEHICLE WENT INTO A SKID. THE CONSUMER RECEIVED THE VEHICLE BACK AND WAS TOLD THERE WAS NOTHING WRONG WITH THE BRAKES, HOWEVER OVER THE NEXT FEW MONTHS HE CONTINUED TO EXPERIENCE BRAKE PROBLEMS EVERY SO OFTEN. THE DEALER KEPT THE VEHICLE FOR A FEW DAYS AND THEY REPLACED THE WHEEL CYLINDER AND THE ROTORS
A FRONT END IMPACT AT 45 MPH AND THE AIRBAG DID NOT DEPLOY. *JB
WHILE DRIVING AT 55 MPH VEHICLE SPUN OUT OF CONTROL AND HIT A SEMI TRACTOR TRAILOR AND AIR BAGS DID NOT DEPLOY. *AK
Showing the 15 most serious of 200 complaints filed with NHTSA.
