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2003 Kia Sedona

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Kia Sedona do not stand out strongly from the model-year median of 120.

About this comparison →

When problems were reported

Mileage at the reported incident

122 reports with mileage · 41 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 29 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Air Bags. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

13 crash reports21 fire reports14 injury reports

Electrical System complaints

29 reports
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38,284 miles · Aug 25, 2008
Electrical System

TL*THE CONTACT OWNS A 2003 KIA SEDONA. THE CONTACT TOOK THE VEHICLE TO THE DEALER BECAUSE THE POWER WINDOWS WERE INOPERATIVE. UPON INSPECTION, A TECHNICIAN REPLACED THE CONSOLE BECAUSE IT WAS BLOWING THE FUSE IN THE ELECTRICAL SYSTEM. THE FUSE MELTED AND SMOKE ENGULFED THE PASSENGER COMPARTMENT OF THE VEHICLE WHEN THE ENGINE …

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TL*THE CONTACT OWNS A 2003 KIA SEDONA. THE CONTACT TOOK THE VEHICLE TO THE DEALER BECAUSE THE POWER WINDOWS WERE INOPERATIVE. UPON INSPECTION, A TECHNICIAN REPLACED THE CONSOLE BECAUSE IT WAS BLOWING THE FUSE IN THE ELECTRICAL SYSTEM. THE FUSE MELTED AND SMOKE ENGULFED THE PASSENGER COMPARTMENT OF THE VEHICLE WHEN THE ENGINE WAS STARTED. THE VEHICLE HAS BEEN TO THE DEALER ON FOUR OCCASIONS AND THE CONSOLE AND CONNECTOR WERE REPLACED. NONE OF THE REPAIRS HAVE CORRECTED THE FAILURE. HE CALLED THE MANUFACTURER AND WAS REFERRED BACK TO THE DEALER. THE FAILURE MILEAGE WAS 38,284 AND CURRENT MILEAGE IS 48,000. UPDATED 02/05/09 *BF UPDATED 02/06/09. *JB

NHTSA ODI #10239575

66,000 miles · Mar 17, 2008
Electrical SystemEngine And Engine CoolingPower Train

I PURCHASED MY 2003 KIA SEDONA IN NOVEMBER 2005. SO FAR THE FOLLOWING HAVE BEEN REPAIRED OR REPLACED: FRONT HUB ASSEMBLY LEFT SIDE ONCE, RIGHT SIDE 2X'S, THE ALTERNATOR, THE WIPER MOTOR, TWO RECALLS, THE BATTERY, NOW AT 65,000 MILES THE TRANSMISSION IS SHOT AND NEEDS TO BE REPLACED AND THE TIMING BELT HAS BEEN REPLACED. HOWEVER …

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I PURCHASED MY 2003 KIA SEDONA IN NOVEMBER 2005. SO FAR THE FOLLOWING HAVE BEEN REPAIRED OR REPLACED: FRONT HUB ASSEMBLY LEFT SIDE ONCE, RIGHT SIDE 2X'S, THE ALTERNATOR, THE WIPER MOTOR, TWO RECALLS, THE BATTERY, NOW AT 65,000 MILES THE TRANSMISSION IS SHOT AND NEEDS TO BE REPLACED AND THE TIMING BELT HAS BEEN REPLACED. HOWEVER THE WARRANTY COMPANY SAYS THEY WONT REPLACE IT BECAUSE THE COST OF THE REPAIR EXCEEDS THE VALUE OF THE CAR. THIS IS SIMPLY OUTRAGEOUS. I HAVE BROUGHT THE CAR TO THE DEALER FOR EVERY SERVICE NEEDED. TRANSMISSION, OIL FILTER ECT. *TR

NHTSA ODI #10221432

Mileage unknown · Nov 16, 2007
Electrical System

HEATER WIRING HARNESS OVER HEATED BURNED OUT FAN SWITCH HAPPENED TWICE CANNOT GET FAN TO COME ON NOW. *TR

NHTSA ODI #10209111

64,000 miles · Aug 6, 2007
Electrical System

I HAD GONE TO LUNCH AND STOPPED BY THE GROCERY STORE FIRST AND THEN WENT BY THE GAS STATION FOR A MOMENT. WHEN I CAME OUT, I GOT INTO MY VAN AND IT WOULD NOT CRANK. NO WARNING, NO PRIOR TROUBLE, NOISES, SLOW CRANK, NOTHING. IT WOULD NOT EVEN ATTEMPT TO CRANK. I HAD TO WALK BACK TO WORK. LATER THAT EVENING, MY FATHER CAME TO …

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I HAD GONE TO LUNCH AND STOPPED BY THE GROCERY STORE FIRST AND THEN WENT BY THE GAS STATION FOR A MOMENT. WHEN I CAME OUT, I GOT INTO MY VAN AND IT WOULD NOT CRANK. NO WARNING, NO PRIOR TROUBLE, NOISES, SLOW CRANK, NOTHING. IT WOULD NOT EVEN ATTEMPT TO CRANK. I HAD TO WALK BACK TO WORK. LATER THAT EVENING, MY FATHER CAME TO LOOK AT IT AND WE ASSUMED IT WAS A DEAD BATTERY. WE REPLACED THE BATTERY AND THE BATTERY LIGHT AS WELL AS THE BREAK LIGHT REMAINED ON. MY FATHER SUSPECTED THE ALTERNATOR. WE CALLED THE KIA DEALERSHIP AND THEY TOLD US THERE HAD BEEN A RECALL ON ALTERNATORS, BUT AS USUAL, OUR VIN NUMBER DID NOT SHOW UP AS ONE RECALLED. $400.00 LATER, I AM WONDERING WHY OUR VEHICLE WAS NOT ON THE RECALL LIST. WE HAVE SPENT NEARLY $2,000 ON "WARRANTY MAINTENANCE" JUST TO MAKE SURE NOTHING GOES WRONG AND IF IT DOES IT SHOULD BE COVERED. UNFORTUNATELY FOR US, WE SPENT WELL OVER $1500.00 ON OUR 60,000 MILE MAINTENANCE TO INSURE THE WARRANTY STAYS IN AFFECT JUST 3 MONTHS AGO. OF COURSE, WE ARE TOLD NOW THAT THE ALTERNATOR IS NOT COVERED AFTER 60,000 MILES. WHY AM I PAYING SO MUCH MONEY IF NOTHING IS GOING TO BE COVERED. *TR

NHTSA ODI #10198617

15,000 miles · Jul 16, 2007
Electrical System

OUR SEDONA HAS BEEN UNRELIABLE FROM 15,000 MILES ON. I LOOSE SLEEP OVER THE FACT THAT MY WIFE AND CHILDREN ARE IN THIS VEHICLE EVERY DAY TO GET TO AND FROM SCHOOL AND OTHER DAILY ACTIVITIES AND ERRANDS. IT IS BACK IN FOR SERVICE FOR THE SAME RE-OCCURRING PROBLEM - A SHOT ALTERNATOR. THIS IS THE FOURTH TIME THIS COMPONENT HAS …

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OUR SEDONA HAS BEEN UNRELIABLE FROM 15,000 MILES ON. I LOOSE SLEEP OVER THE FACT THAT MY WIFE AND CHILDREN ARE IN THIS VEHICLE EVERY DAY TO GET TO AND FROM SCHOOL AND OTHER DAILY ACTIVITIES AND ERRANDS. IT IS BACK IN FOR SERVICE FOR THE SAME RE-OCCURRING PROBLEM - A SHOT ALTERNATOR. THIS IS THE FOURTH TIME THIS COMPONENT HAS BEEN DAMAGED, TWICE BEFORE DAMAGING THE BATTERY AS WELL. I PRIDE MYSELF IN KEEPING OUR VEHICLES SERVICED NEARLY TO THE RECOMMENDED SCHEDULE, BUT THIS MINIVAN IS JUST NOT A QUALITY BUILT. I HAVE READ OF OTHER COMPLAINTS, AND SIMILARLY OUR MINIVAN ALSO BUCKS WHEN IDLE AT A TRAFFIC LIGHT, IT BUCKS WHEN TRAVELING UNDER 40 MPH, AND THE AIR CONDITIONING UNITS ARE AS LOAD AS AN INDUSTRIAL TYPE FAN. *TR

NHTSA ODI #10196424

65,000 miles · Jun 6, 2007
Electrical System

THE JUNCTION BLOCK (FUSE BOX) LOCATED BEHIND THE COVER NEAR THE EMERGENCY BRAKE PEDAL PARTIALLY BURNED AND MELTED AT TWO PIN CONNECTORS. THE ADJACENT WIRING HARNESS CONNECTOR ALSO PARTIALLY BURNED AND MELTED. PRIOR TO THE FAILURE, THE DASH INDICATOR FOR THE DEFROSTER ILLUMINATED AND REMAINED ILLUMINATED EVEN THOUGH THE DEFROSTER…

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THE JUNCTION BLOCK (FUSE BOX) LOCATED BEHIND THE COVER NEAR THE EMERGENCY BRAKE PEDAL PARTIALLY BURNED AND MELTED AT TWO PIN CONNECTORS. THE ADJACENT WIRING HARNESS CONNECTOR ALSO PARTIALLY BURNED AND MELTED. PRIOR TO THE FAILURE, THE DASH INDICATOR FOR THE DEFROSTER ILLUMINATED AND REMAINED ILLUMINATED EVEN THOUGH THE DEFROSTER WAS NOT TURNED ON. WHEN THE CAR WAS TURNED OFF, THE DASH INDICATOR FOR THE DEFROSTER REMAINED ILLUMINATED. THE BATTERY WAS DEAD THE NEXT DAY. AFTER JUMP STARTING THE VAN, IT WAS DRIVEN TO THE LOCAL KIA DEALER WHERE THE MACHANIC IDENTIFIED THE JUNCTION BLOCK DAMAGE. KIA HAS PROPOSED TO REPLACE THE JUNCTION BLOCK AND ENTIRE DASH WIRING HARNESS FOR $1,934.19. THE COST OF THE JUNCTION BLOCK IS $19.95, BUT THE COST OF THE WIRING HARNESS IS $1,067.65. THE BALANCE OF THE PROPOSED COST IS LABOR AND TAXES. KIA DOES NOT PROVIDE THE HARNESS CONNECTOR AS A SEPARATE PART. I CALLED THE KIA HELP LINE AND PROVIDED A VERBAL REPORT TO A CUSTOMER SERVICE AGENT, AND WAS TOLD THAT KIA CAN DO NOTHING ELSE TO RESOLVE THE PROBLEM. I LOCATED 12 RELEVANT ODI COMPLAINTS FOR 2003 SEDONAS AND 2 RELEVANT ODI COMPLAINTS FOR 2003 SEDONA EX MODELS, ALL RESULTING IN DASH FIRES. I DID NOT SEARCH OTHER MODEL YEARS. IT MAY HAVE BEEN MY GOOD FORTUNE NOT TO EXPERIENCE A VEHICLE FIRE, AS WELL AS COMPELLING EVIDENCE RELATED TO THE CAUSE OF THESE OTHER REPORTED FIRES.

NHTSA ODI #10192584

Mileage unknown · Sep 29, 2005
Electrical SystemFire

DT: THE CONTACT OWNS A 2003 KIA SEDONA. THE VEHICLE WAS TRYING TO START BY ITSELF . THE WINDSHIELD WIPERS WERE ON AND THERE WAS SMOKE IN THE VEHICLE AND FLAMES ON THE DRIVER'S SIDE EMERGENCY BRAKE. THE CONTACT'S HUSBAND PUT THE FLAMES OUT BEFORE THE FIRE DEPARTMENT RESPONDED. THE FIRE WAS FIRST NOTICED FROM THE DRIVERS SIDE …

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DT: THE CONTACT OWNS A 2003 KIA SEDONA. THE VEHICLE WAS TRYING TO START BY ITSELF . THE WINDSHIELD WIPERS WERE ON AND THERE WAS SMOKE IN THE VEHICLE AND FLAMES ON THE DRIVER'S SIDE EMERGENCY BRAKE. THE CONTACT'S HUSBAND PUT THE FLAMES OUT BEFORE THE FIRE DEPARTMENT RESPONDED. THE FIRE WAS FIRST NOTICED FROM THE DRIVERS SIDE WHERE THE EMERGENCY BRAKE WAS LOCATED. THE VEHICLE WAS NOT OPERATING UNUSUALLY BEFORE. THE VEHICLE HAD BEEN PARKED FOR ABOUT TWO HOURS BEFORE THE FIRE WAS NOTICED. THE DEALERSHIP TOLD HER HUSBAND AT THIS POINT THEY BELIEVED THIS WAS STARTED FROM THE LOW JACK INSTALLATION WHICH WAS INSTALLED BY THE DEALERSHIP. THE POLICE REPORTED TO THE SCENE, AND AFTER ARSON WAS RULED OUT THEY HANDED THE SITUATION OVER TO THE FIRE DEPARTMENT. THE CONTACT GOING THERE TONIGHT TO PICK UP THE FIRE DEPARTMENT'S REPORT. *AK THE HORN DID NOT WORK.

NHTSA ODI #10135432

40,000 miles · Sep 12, 2005
Electrical SystemFire

DT: THE CONSUMER STATED THAT 2003 KIA SEDONA CAUGHT ON FIRE WHILE PARKED IN THE GARAGE. THE VEHICLE HAD BEEN SITTING FOR AROUND SIX HOURS. THE FIRE STARTED UNDERNEATH THE STEERING WHEEL IN THE DASHBOARD AREA. THE INSIDE OF THE VAN HAD SUBSTANTIAL DAMAGE. THE VAN WAS TOWED TO A BODY SHOP UNTIL THE INSURANCE ADJUSTER LOOKED AT TH…

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DT: THE CONSUMER STATED THAT 2003 KIA SEDONA CAUGHT ON FIRE WHILE PARKED IN THE GARAGE. THE VEHICLE HAD BEEN SITTING FOR AROUND SIX HOURS. THE FIRE STARTED UNDERNEATH THE STEERING WHEEL IN THE DASHBOARD AREA. THE INSIDE OF THE VAN HAD SUBSTANTIAL DAMAGE. THE VAN WAS TOWED TO A BODY SHOP UNTIL THE INSURANCE ADJUSTER LOOKED AT THE VAN. THE VAN WAS DRIVING FINE AND WORKING IN GOOD SHAPE PRIOR TO THE FIRE. THE FIRE DEPARTMENT CAME AND PUT OUT THE FIRE. T A FIRE INVESTIGATOR CAME AND INSPECTED THE SCENE. THE FIRE INVESTIGATOR CONCLUDED IT WAS AN ELECTRICAL FIRE. THE DEALER AND THE MANUFACTURER HAVE BEEN TOLD ABOUT THE FIRE. THE CONSUMER JUST TOLD KIA ABOUT THE FIRE, AND THEY WANTED THE CONSUMER TO GET A COPY OF THE FIRE REPORT ,AND THEN THEY WOULD TALK TO HIM. THE DEALERSHIP TOLD THE CONSUMER THAT THEY DIDN'T KNOW WHAT TO TELL HIM. AN INSURANCE AND FIRE REPORT WAS TAKEN, ALTHOUGH THE CONSUMER DID NOT HAVE A COPY RIGHT NOW OF THE REPORT. THE FIRE DEPARTMENT TOOK PICTURES ON THE NIGHT OF THE FIRE. THERE WERE NO INJURIES AND NO DAMAGE TO THE HOME. THE TRANSMISSION WOULD NOT COME OUT OF GEAR FOR THE WRECKER TO TOW IT.*AK

NHTSA ODI #10136174

48,000 miles · Aug 30, 2005
Electrical SystemFire

2003 KIA SEDONA WITH APPROX 48,000 MILES, PARKED AND UNOCCUPIED IN THE PARKING AREA OF MY TOWNHOUSE COMMUNITY. WENT TO OPEN THE DOOR REMOTELY USING THE KEY RING AND THERE WAS NO RESPONSE. EVENTUALLY HAD TO MANUALLY OPEN THE CAR AND NOTICED THE ENTIRE LEFT HAND SIDE OF THE INSTRUMENT PANEL AND DASHBOARD AREA HAD LITERALLY MELT…

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2003 KIA SEDONA WITH APPROX 48,000 MILES, PARKED AND UNOCCUPIED IN THE PARKING AREA OF MY TOWNHOUSE COMMUNITY. WENT TO OPEN THE DOOR REMOTELY USING THE KEY RING AND THERE WAS NO RESPONSE. EVENTUALLY HAD TO MANUALLY OPEN THE CAR AND NOTICED THE ENTIRE LEFT HAND SIDE OF THE INSTRUMENT PANEL AND DASHBOARD AREA HAD LITERALLY MELTED INTO THE FLOORBOARD. APPEARS AS IF THERE WAS SOME KIND OF ELECTRICAL SHORT. VEHICLE WAS TOWED TO BONNEVILLE KIA AND DUE TO MY EXTENDED SERVICE CONTRACT IMMEDIATELY SET UP A RENTAL. THE SERVICE REP AT BONNEVILLE SAID HE HAD NOT SEEN "ANYTHING LIKE IT" AND WAS TO CALL HIS FACTORY REP AND RECOMMENDED I CONTACT MY AUTO INSURANCE CARRIER TO BEGIN THE CLAIMS PROCESS. THE CIRCUMSTANCES OF THIS INCIDENT SEEM WAY TO CLOSE TO OTHER COMPLAINTS FOUND ON OUR WEBPAGE. CLEARLY THERE IS SOME KIND OF DEFECT THAT KIA NEEDS TO ADDRESS. OTHER THAN SERVICE FOR OIL CHANGES AND TIRE ROTATION, ONLY KIA BONNEVILLE HAS PERFORMED MAINTENANCE ON THIS VEHICLE. PURCHASE DATE WAS DEC 2003. *JB

NHTSA ODI #10126073

Mileage unknown · Jul 27, 2005
Electrical SystemFire

DROVE 2003 KIA SEDONA 4 OR 5 MILES. GOT OUT TO EAT AND IN ABOUT 5 MINUTES OR LESS THE INSIDE WAS FULL OF SMOKE AND THE DASHBOARD WAS IN FLAMES BEHIND THE STEERING WHEEL. USED FIRE ESTINGISHER BUT DID NOT GET THE FIRE OUT COMPLETELY AND FIRE DEPARTMENT CAME AND PUT THE FIRE OUT. I HAD HEARD THERE COULD BE A PROBLEM WITH THIS HAPP…

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DROVE 2003 KIA SEDONA 4 OR 5 MILES. GOT OUT TO EAT AND IN ABOUT 5 MINUTES OR LESS THE INSIDE WAS FULL OF SMOKE AND THE DASHBOARD WAS IN FLAMES BEHIND THE STEERING WHEEL. USED FIRE ESTINGISHER BUT DID NOT GET THE FIRE OUT COMPLETELY AND FIRE DEPARTMENT CAME AND PUT THE FIRE OUT. I HAD HEARD THERE COULD BE A PROBLEM WITH THIS HAPPENING ON OTHER 2003 KIA SEDONA'S. HAVE CONTACTED KIA AND THEY WILL NOT DO ANYTHING UNTIL INSURANCE COMPANY CONTACTS THEM.

NHTSA ODI #10130311

Official recalls

4

05V329000 · Vehicle Speed Control:cables

Jul 20, 2005

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.

Consequence & remedy

Consequence: 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.

Remedy: 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.

05V232000 · Wheels

May 19, 2005

ON CERTAIN MINI VANS EQUIPPED WITH ALLOY WHEELS, MOISTURE CAN ACCUMULATE AROUND THE REAR HUB CAPS CAUSING DAMAGE TO THE OUTER WHEEL BEARING.

Consequence & remedy

Consequence: WHEEL BEARING FAILURE MAY OCCUR WITHOUT WARNING WHICH COULD RESULT IN A CRASH.

Remedy: 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.

05V013000 · Vehicle Speed Control:cables

Jan 19, 2005

ON CERTAIN MINI VANS, DURING ASSEMBLY, THE THROTTLE CABLE WOULD TWIST ITSELF OUT OF POSITION.

Consequence & remedy

Consequence: THIS CAN PERMIT THE CABLE TO BE HUNG UP, WHICH COULD RESULT IN A CRASH.

Remedy: 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.

03V158000 · Service Brakes, Air:antilock:control Unit/module

Apr 25, 2003

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.

Consequence & remedy

Consequence: SUCH INCREASED STOPPING DISTANCES COULD RESULT IN A CRASH.

Remedy: 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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

4

EA08017 · Steering Intermediate Shaft Binding

Opened Aug 28, 2008 · Closed Jul 1, 2009

Status: closed (inferred from source dates) · Steering

ODIS ANALYSIS OF WARRANTY DATA SHOWS THAT THE ALLEGED DEFECT HAS OCCURRED AT A RELATIVELY HIGH FREQUENCY IN SALT-BELT STATES (5.9 PERCENT).HOWEVER, THE TESTS CONDUCTED BY ODI AND KIA HAVE SHOWN THAT THE ALLEGED DEFECT HAS A MINIMAL EFFECT ON STEERING EFFORTS.IN ADDITION, ODI INTERVIEWS OF OWNERS WHO EXPERIENCED THE ALLEGED DEFECT SHOWED THAT IN MOST CASES THE PROBLEM WAS PRECEDED BY MONTHS OR YEARS OF NOISE OR A GRADUAL INCREASE IN STEERING EFFORTS AND WAS MORE OF A NUISANCE CONCERN. THERE HAS BEEN ONE ALLEGATION OF A MINOR CRASH RELATED TO THE ALLEGED DEFECT, INVOLVING A MY 2003 KIA SEDONA WITH 59,900 MILES.THE VEHICLE HAD BEEN CHECKED TWICE IN THE PREVIOUS NINE MONTHS BY A DEALER FOR COMPLAINTS OF STIFF STEERING AND THAT THE VEHICLE FELT LIKE IT WAS INTERMITTENTLY LOSING POWER ASSIST.THE CRASH OCCURRED AS THE DRIVER WAS ATTEMPTING TO MAKE A LEFT TURN WHILE TRAVELING AT APPROXIMATELY 20 MILES PER HOUR AND STRUCK A VEHICLE PARKED ON THE RIGHT SIDE OF THE STREET THAT THE VEHICLE WAS TURNING INTO. THE CRASH RESULTED IN MINOR INJURIES TO THE DRIVER. AFTER THE CRASH, IT WAS DETERMINED THAT THE INTERMEDIATE SHAFT WAS EXHIBITING SOME BINDING OF THE STEERING INTERMEDIATE SHAFT BEARINGS.WHILE THE ABSENCE OF ADDITIONAL CRASHES OR INJURIES DOES NOT MEAN THAT THERE IS NOT A SAFETY-RELATED DEFECT, THERE HAVE BEEN NO REPORTED ADDITIONAL CRASHES CAUSED BY THE ALLEGED DEFECT IN THE PAST THREE YEARS. THE RELEASE OF THE TECHNICAL SERVICE BULLETIN SHOULD ASSIST SERVICE PERSONAL IN DIAGNOSING THIS POTENTIAL PROBLEM LONG BEFORE IT BECOMES POTENTIALLY DANGEROUS.ACCORDINGLY, THIS INVESTIGATION IS CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.FOR ADDITIONAL INFORMATION REGARDING THIS ENGINEERING ANALYSIS REFER TO THE EA08-017 CLOSING REPORT.

PE08033 · Steering Binding

Opened Apr 28, 2008 · Closed Aug 28, 2008

Status: closed (inferred from source dates) · Steering

ON APRIL 28, 2008, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED PRELIMINARY EVALUATION PE08-033 TO INVESTIGATE COMPLAINTS ALLEGING STEERING BINDING IN MODEL YEAR 2002 THROUGH 2004 KIA SEDONA MINIVANS.KIA'S RESPONSE TO ODI'S REQUEST FOR INFORMATION IN PE08-033 INDICATED THAT CONCERNS WITH BINDING OF THE STEERING INTERMEDIATE SHAFT WERE FIRST IDENTIFIED AND INVESTIGATED IN AUGUST 2002, IN VEHICLES SOLD IN INDONESIA.THIS INVESTIGATION RESULTED IN THE ADDITION OF A STIFFENING RIB TO THE BEARING CAP SEAL.IN JUNE 2003, KIA AGAIN INVESTIGATED OWNER COMPLAINTS OF STEERING NOISE AND HIGHER THAN NORMAL STEERING RESISTANCE AND IN OCTOBER AND NOVEMBER OF 2003 DESIGN CHANGES TO THE SHAFT UNIVERSAL JOINT BEARINGS WERE MADE TO IMPROVE LUBRICANT RETENTION AND ELIMINATE WATER INTRUSION THAT COULD LEAD TO EARLY BEARING FAILURE.ACCORDING TO KIA, THE ALLEGED DEFECT RESULTS IN A PROGRESSIVE CHANGE IN STEERING EFFORT THAT SHOULD BE APPARENT TO THE DRIVER THROUGH NOISE AND GRADUAL CHANGES IN STEERING STIFFNESS LONG BEFORE THE CONDITION COULD BECOME DANGEROUS. ODI'S ANALYSES OF COMPLAINT AND WARRANTY DATA RELATING TO THE ALLEGED DEFECT SHOW THAT THE CONDITION IS OCCURRING AT SIGNIFICANTLY HIGHER RATES IN SALT-BELT STATES (NOTE:FOR PURPOSES OF THIS INVESTIGATION THE SALT BELT INCLUDES CONNECTICUT, DELAWARE, THE DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA AND WISCONSIN).THE WARRANTY RATE FOR REPLACEMENT OF THE STEERING INTERMEDIATE SHAFT IS 5.5% FOR VEHICLES SOLD IN THE SALT BELT AND 0.5% FOR THE REST OF THE UNITED STATES.THE COMPLAINT RATE FOR THE ALLEGED DEFECT IS 186.8 PER 100,000 VEHICLES IN THE SALT BELT AND 29.4 PER 1000,000 VEHICLES FOR THE REST OF THE UNITED STATES.THERE IS ONE ALLEGATION OF A CRASH RELATED TO THE ALLEGED DEFECT.A SUBJECT VEHICLE STRUCK TWO PARKED CARS WHILE ATTEMPTING TO MAKE A LEFT TURN, ALLEGEDLY RESULTING IN MINOR INJURIES TO THE DRIVER. ODI HAS UPGRADED THIS INVESTIGATION TO AN ENGINEERING ANALYSIS (EA08-017) COVERING MY 2002 THROUGH 2004 KIA SEDONA VEHICLES SOLD OR CURRENTLY REGISTERED IN SALT BELT STATES TO ASSESS THE FREQUENCY AND TREND OF THE ALLEGED DEFECT AND ITS EFFECT ON STEERING EFFORT.

PE05035 · Electrical Fire

Opened Jun 28, 2005 · Closed Oct 19, 2005

Status: closed (inferred from source dates) · Electrical System:wiring:interior/under Dash

BY LETTER DATED OCTOBER 4, 2005, KIA NOTIFIED THE AGENCY THAT IT IS CONDUCTING A SAFETY RECALL (NHTSA RECALL NO. 05V463) INVOLVING ALL MODEL YEAR (MY) 2002, 2003 KIA SEDONA EX VEHICLES AND CERTAIN MY 2004 KIA SEDONA EX VEHICLES.KIA?S RECALL COVERS 74,276 VEHICLES.KIA REPORTS THAT FIRES WERE CAUSED BY WIRING UNDER FRONT SEATS BEING MISROUTED; THIS ALLOWED THE WIRE TO BE PINCHED BY METAL SEAT COMPONENTS.OVER TIME, THE SHORT IN THE WIRING UNDER THE SEAT CAUSES OVERHEATING OF COMPONENTS IN THE FUSE BOX (LOCATED UNDER THE DRIVER SIDE INSTRUMENT PANEL).SPECIFICALLY, THE CIRCUIT BREAKER DIODES CYCLE ON-OFF-ON ETC. AND OVERHEAT.KIA WILL INSPECT VEHICLES FOR PROPER WIRE ROUTING AND INSTALL PROTECTIVE COVERING OVER CERTAIN METAL PARTS UNDER FRONT SEATS.DEALERS WILL ALSO APPLY A LABEL WARNING TECHNICIANS NOT TO REMOVE THE CIRCUIT BREAKER DIODES WHICH CANNOT BE SERVICED BUT CAN BE DAMAGED BY REMOVAL ATTEMPTS.BASED ON KIA?S SAFETY RECALL ACTION, THIS INVESTIGATION IS CLOSED.

PE04067 · Throttle Cable Binding

Opened Sep 24, 2004 · Closed Jan 27, 2005

Status: closed (inferred from source dates) · Vehicle Speed Control; Vehicle Speed Control:cables; Vehicle Speed Control:linkages

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Additional source detail variants (6)

Vehicle Speed Control:cables

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control:cables

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control:linkages

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control:linkages

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.