NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
29 reportsClear category filterMileage unknown · Nov 10, 2010
Electrical SystemFuel System, GasolineSteering
I BOUGHT A 2003 KIA SORENTO ABOUT 6 YEARS AGO AND I'VE HAD A LOT OF PROBLEMS. THE WORST AND MOST RECENT PROBLEM IS THE GAS SPEWS OUT OF THE TANK EVERY TIME I TRY TO FILL IT. IT RUNS DOWN THE SIDE OF THE CAR AND ON MY WHEEL. SOMETIMES IT GETS ON ME. THIS HAS BEEN GOING ON FOR SEVERAL MONTHS NOW. IF YOU PUMP VERY SLOW AND STO…
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I BOUGHT A 2003 KIA SORENTO ABOUT 6 YEARS AGO AND I'VE HAD A LOT OF PROBLEMS. THE WORST AND MOST RECENT PROBLEM IS THE GAS SPEWS OUT OF THE TANK EVERY TIME I TRY TO FILL IT. IT RUNS DOWN THE SIDE OF THE CAR AND ON MY WHEEL. SOMETIMES IT GETS ON ME. THIS HAS BEEN GOING ON FOR SEVERAL MONTHS NOW. IF YOU PUMP VERY SLOW AND STOP EVERY .80 CENTS IT LESSENS THE AMOUNT OF TIMES IT SPEWS OUT, BUT THIS IS SO VERY TIMELY. THE GAS GAUGE PERIODICALLY GOES OUT. THE HORN HAS NEVER WORKED. THE POWER STEERING PERIODICALLY GOES OUT. WHEN USING CRUISE CONTROL IT WILL PERIODICALLY GO OFF ON IT'S OWN. THE PAINT LOOKS HORRIBLE AND HAS PEELED OFF ON THE SIDE MIRRORS. THE LEATHER SEATS HAVE NOT HELD UP WELL. THE DOME LIGHT WILL NOT WORK WHEN YOU OPEN THE DOOR, BUT IF YOU PRESS THE DOME LIGHT BUTTON IT WILL COME ON. PERIODICALLY THE DASH LIGHTS HAVE FLICKERED AND I'M WONDERING IF THEY ARE ABOUT TO GO OUT. I'VE ALREADY HAD TO REPLACE THE AC COMPRESSOR AND THE DRIVE SHAFT, BOTH OF WHICH HAVE REALLY SET ME BACK FINANCIALLY. I REALLY WANT TO GET THE GAS TANK ISSUE FIXED AS IT IS THE WORST ISSUE AT HAND AND I FEAR IT COULD BE DANGEROUS. *TR
NHTSA ODI #10365305
36,000 miles · Nov 9, 2010
Electrical SystemEngine And Engine CoolingExterior Lighting
I HAVE HAD MY 2003 KIA SORENTO SINCE MARCH 2010. IT WAS PURCHASED WITH 32,000 MILES ON IT, AND AS OF THE END OF OCTOBER 2010, IT HAD 36,000 MILES. SO FAR, I HAVE HAD TO REPLACE THE COOLANT RESERVOIR, BECAUSE IT WAS CRACKED. I WAS DRIVING, AND IT OVERHEATED OUT OF NOWHERE. IT WAS IN THE SHOP FOR FOUR DAYS, BECAUSE THEY COULD …
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I HAVE HAD MY 2003 KIA SORENTO SINCE MARCH 2010. IT WAS PURCHASED WITH 32,000 MILES ON IT, AND AS OF THE END OF OCTOBER 2010, IT HAD 36,000 MILES. SO FAR, I HAVE HAD TO REPLACE THE COOLANT RESERVOIR, BECAUSE IT WAS CRACKED. I WAS DRIVING, AND IT OVERHEATED OUT OF NOWHERE. IT WAS IN THE SHOP FOR FOUR DAYS, BECAUSE THEY COULD NOT FIND THE PROBLEM EVEN AFTER DOING SEVERAL PRESSURIZED SYSTEMS TESTS. AT THE END OF OCTOBER 2010, I HAD TO REPLACE THE OIL PUMP, BECAUSE IT HAD A CRACK IN IT. NO ONE ANYWHERE I CALLED COULD BELIEVE I HAD TO REPLACE AN OIL PUMP. ALL THE MECHANICS STATED THAT'S ONE OF THE FEW THINGS THEY NEVER HAVE TO REPLACE ON ANY VEHICLE, AND CERTAINLY NOT AT 36,000 MILES. ANYWAY, DUE TO OIL LEAKING ONTO THE TIMING BELT, THAT HAD TO BE REPLACED ALSO. THE TIMING BELT WAS IN FINE CONDITION OTHERWISE. CONSEQUENTLY, I NOW HAVE ENGINE PROBLEMS. I'M SURE THE ENGINE WILL HAVE TO BE REPLACED FROM OVERHEATING AND THEN HAVING NO OIL. AT HIGH RPMS, YOU CAN HEAR A SLIGHT TICK, WHICH I'M PRETTY SURE IS A LIFTER ISSUE. HEADLIGHTS BURN OUT QUICKLY. I WAS DRIVING ONE DAY, AND BOTH BURNT OUT AT THE SAME TIME. I HAD TO DRIVE ON HIGH BEAMS IN THE CITY. CONSTANT ELECTRICAL PROBLEMS WITH THE DASH. DASH LIGHTS RARELY WORK, AND THEN ALL OF A SUDDEN ALL THE LIGHTS WILL START FLASHING HERE AND THERE - DASH LIGHTS FLASH ON/OFF, CEILING LIGHT FLASHES ON/OFF, ALL BACK AND FORTH WHILE I'M DRIVING IN THE DARK. VERY DISTRACTING, ESPECIALLY IN TRAFFIC. THE TRUCK ITSELF (SEATS, COMFORT, ETC.) IS AWESOME, BUT IT WAS DEFINITELY MANUFACTURED POORLY. WORST PURCHASE EVER. GLAD I BOUGHT THE 5 STAR WARRANTY OR I'D BE PAYING FOR A TRUCK I CAN'T DRIVE. *TR
NHTSA ODI #10365133
45,000 miles · Dec 22, 2009
Electrical SystemEngine And Engine CoolingInterior Lighting
I PURCHASED MY 03 KIA SORENTO IN 2004 AND HAVE HAD MANY ISSUES SINCE THEN. I HAVE HAD TO REPLACE LIGHTS FROM THE FRONT TO THE BACK NUMEROUS TIMES. I'VE BEEN DRIVING DOWN OUR REMOTE COUNTRY ROAD AT NIGHT AND HAD MY HEADLIGHTS GO OUT. MY COOLANT TANK CRACKED AND LEFT ME STRANDED ON ANOTHER COUNTRY ROAD IN THE SNOW LAST YEAR. I LAT…
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I PURCHASED MY 03 KIA SORENTO IN 2004 AND HAVE HAD MANY ISSUES SINCE THEN. I HAVE HAD TO REPLACE LIGHTS FROM THE FRONT TO THE BACK NUMEROUS TIMES. I'VE BEEN DRIVING DOWN OUR REMOTE COUNTRY ROAD AT NIGHT AND HAD MY HEADLIGHTS GO OUT. MY COOLANT TANK CRACKED AND LEFT ME STRANDED ON ANOTHER COUNTRY ROAD IN THE SNOW LAST YEAR. I LATER FOUND OUT IT WAS RECALLED FOR THAT PARTICULAR DEFECT; AFTER I HAD IT REPLACED. THE LIGHTING ISSUE IS MY BIGGEST CONCERN RIGHT NOW BECAUSE OF WHERE I LIVE (REMOTE COUNTRY ROADS, DEER AT NIGHT, ETC) I HAVE TO HAVE PROPERLY FUNCTIONING HEADLIGHTS AT ALL TIMES. NOW, I AM HAVING PROBLEMS CONCERNING THE BEARINGS ON IT. IT MAKES A HORRIBLE SCREECHING NOISE THAT IS NOW; ALMOST CONTINUOUS. IT DOESN'T MATTER THE TEMPERATURE OUTSIDE, DRIVING CONDITIONS, ETC. IT HAS BECOME HARDER TO STEER AND THE POWER STEERING FLUID IS FINE. I DON'T FEEL SAFE IN THIS VEHICLE ANYMORE, AND I CANNOT AFFORD TO JUST GO OUT AND BUY SOMETHING NEW. I JUST ASK THAT IF FAULT LIES WITH KIA; THEN THEY SHOULD FIX IT AT THEIR EXPENSE....NOT MINE! I HAVE INVESTED WAY TOO MUCH TIME, MONEY AND PATIENCE THUS FAR AND FEEL IT'S KIA'S RESPONSIBILITY TO MAKE SURE THEY CREATE A VEHICLE THAT FUNCTIONS PROPERLY. AND WHEN THEY DON'T...FIX IT!!! AS FOR THE QUESTIONS BELOW; WAS THERE A FIRE?...NOT YET!!! WAS THERE PROPERTY DAMAGE?....THERE PROBABLY WILL BE WHEN MY BEARINGS GO OUT AND THE WHEELS FALL OFF! WHERE THERE ANY DEATHS OR INJURIES?....DEAR LORD, I PRAY EVERY TIME I GET IN MY TRUCK THAT NOTHING LIKE THAT EVER HAPPENS TO ME OR MY SON....BUT; WITH AN UNRELIABLE VEHICLE THAT HAS CONSTANT ELECTRICAL AND MECHANICAL PROBLEM; THEN WHO KNOWS.... *TR
NHTSA ODI #10296669
67,000 miles · May 20, 2009
Electrical System
TL*THE CONTACT OWNS A 2003 KIA SORENTO. AFTER REMOVING THE KEY FROM THE IGNITION, THE CONTACT NOTICED THAT THE ENGINE WAS STILL RUNNING. SHE IS IN THE PROCESS OF HAVING THE VEHICLE INSPECTED TO DETERMINE THE CAUSE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE 67,000.
NHTSA ODI #10269496
Mileage unknown · Apr 16, 2009
Electrical SystemEngine And Engine Cooling
2003 KIA SORENTO, PURCHASED USED WITH 11,000 MILES ON IT. HAS BEEN A NIGHTMARE SINCE THE DAY I BOUGHT IT! HEAD GASKETS WARPED AT 28,000 MILES, OVERHEATED WITHOUT WARNING, NO SPIKE IN TEMP GAUGE, WHAM SMOKE FROM EVERYWHERE AND EVEN WITH PROOF OF MAINTENANCE UPKEEP IT TOOK KIA 2 MONTHS TO DECIDE TO HONOR THE WARRANTY. THIS WAS …
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2003 KIA SORENTO, PURCHASED USED WITH 11,000 MILES ON IT. HAS BEEN A NIGHTMARE SINCE THE DAY I BOUGHT IT! HEAD GASKETS WARPED AT 28,000 MILES, OVERHEATED WITHOUT WARNING, NO SPIKE IN TEMP GAUGE, WHAM SMOKE FROM EVERYWHERE AND EVEN WITH PROOF OF MAINTENANCE UPKEEP IT TOOK KIA 2 MONTHS TO DECIDE TO HONOR THE WARRANTY. THIS WAS AFTER THE CHECK ENGINE LIGHT WOULD COME ON EVERY TWO SECONDS AND HAVE TO BE IN THE SHOP FOR MONTHS FOR THEM TO SAY NOTHING WRONG WITH IT, EVEN WHEN IT WAS TOWED IN EVERY TIME BECAUSE IT WOULD JUST SHUT OFF. THEN THE HEADLIGHT ISSUES ARE INSANE. EVERY OTHER MONTH AND THAT IS NO EXAGGERATION I HAVE TO REPLACE EITHER LOW BEAMS, HIGH BEAMS, BRAKE LIGHTS & TAIL LIGHTS. *TR
NHTSA ODI #10265609
72,000 miles · Apr 15, 2008
Electrical SystemEngine And Engine Cooling
TL*THE CONTACT OWNS A 2003 KIA SORRENTO. WHILE DRIVING 45 MPH, THE VEHICLE BEGAN TO OVERHEAT. THE CONTACT INSPECTED THE VEHICLE AND NOTICE THE COOLANT WAS LOW. APPROXIMATELY A WEEK LATER HE INSPECTED THE VEHICLE AGAIN NOTICED THAT THERE WAS A CRACK IN THE RESERVOIR TANK. HE REPLACED THE RESERVOIR TANK. AS OF APRIL 15, 2008,…
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TL*THE CONTACT OWNS A 2003 KIA SORRENTO. WHILE DRIVING 45 MPH, THE VEHICLE BEGAN TO OVERHEAT. THE CONTACT INSPECTED THE VEHICLE AND NOTICE THE COOLANT WAS LOW. APPROXIMATELY A WEEK LATER HE INSPECTED THE VEHICLE AGAIN NOTICED THAT THERE WAS A CRACK IN THE RESERVOIR TANK. HE REPLACED THE RESERVOIR TANK. AS OF APRIL 15, 2008, THE DEALER HAD NOT INSPECTED THE VEHICLE. IN ADDITION, THE DRIVER SIDE HEADLIGHTS, TAIL LIGHTS AND BRAKE LIGHTS FAILED INTERMITTENTLY. AS OF APRIL 15, 2008, THE DEALER HAD NOT INSPECTED THE VEHICLE FOR THIS FAILURE. THE CONTACT FELT THAT THE ELECTRICAL SYSTEM CAUSED THE FAILURE. THE FAILURE MILEAGE WAS 72,000 AND CURRENT MILEAGE WAS 76,000.
NHTSA ODI #10224637
63,000 miles · Jul 15, 2007
Electrical SystemEngine And Engine Cooling
I WAS DROPPING OFF SOMEONE AT WORK WHEN THE CAR MADE A THUMP AND ALL THE DASH WARNING LIGHTS CAME ON. I DROVE IT HOME ABOUT TWO MILES AWAY, AND TOOK IT TO A AUTOMOBILE SERVICE CENTER THE NEXT DAY. THEY TOLD ME THAT THE CRANKSHAFT PULLEY WAS READY TO FALL OFF. THE NEXT DAY I HAD IT TOWED FROM THE SERVICE CENTER TO THE DEALER. TH…
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I WAS DROPPING OFF SOMEONE AT WORK WHEN THE CAR MADE A THUMP AND ALL THE DASH WARNING LIGHTS CAME ON. I DROVE IT HOME ABOUT TWO MILES AWAY, AND TOOK IT TO A AUTOMOBILE SERVICE CENTER THE NEXT DAY. THEY TOLD ME THAT THE CRANKSHAFT PULLEY WAS READY TO FALL OFF. THE NEXT DAY I HAD IT TOWED FROM THE SERVICE CENTER TO THE DEALER. THE DEALER SAID THE SAME THING AS THE SERVICE CENTER, AND THAT IT WAS UNDER WARRANTY. ALSO, IT A NEEDED A 60000 MILE SERVICE FOR WHICH I PAID EXTRA. WHEN I WENT TO PICK THE CAR 5 DAYS LATER THE CAR WAS MAKING A BELT NOISE, IT WAS SLOW IN STARTING, THE DASH LIGHT WOULDN'T COME ON, AND THE AIRBAG LIGHT WAS ON. WHEN I TOOK IT BACK TO THE DEALER, THEY TIGHTENED THE BELTS AND CHECKED THE OTHER PROBLEMS AT A COST OF $150, AND THAT THESE OTHER PROBLEMS WERE NOT UNDER WARRANTY, AND WOULD COST $1400 TO FIX THEM. I HAVE NEVER HAD A PROBLEM WITH THIS CAR UNTIL THE CRANKSHAFT PULLEY FAILED, AND COULD NOT SEE WHY IF A WARRANTY FAILURE CAUSED SOMETHING ELSE TO FAIL, WHY WASN'T IT FIXED UNDER WARRANTY? ALSO, THE PERSON WHO WORKED ON THE CA RCOMPLAINED ABOUT THE OIL PAN WITH THE SEALER THAT WAS USED TO SEAL THE ENGINE.*AK
NHTSA ODI #10196392
34,600 miles · May 17, 2007
Electrical SystemVehicle Speed Control
TL*THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT AFTER HE GETS AN OIL CHANGE, THE VEHICLE'S EXTERIOR AND INTERIOR LIGHTS BLOW OUT. AS OF MAY 17, 2007, THE DOME LIGHT IS CURRENTLY OUT AND HAS BEEN SINCE NOVEMBER 25, 2005. KIA MOTORS STATED THAT EVEN THOUGH HER VEHICLE WAS UNDER WARRANTY, SHE STILL HAD TO PAY FOR…
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TL*THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT AFTER HE GETS AN OIL CHANGE, THE VEHICLE'S EXTERIOR AND INTERIOR LIGHTS BLOW OUT. AS OF MAY 17, 2007, THE DOME LIGHT IS CURRENTLY OUT AND HAS BEEN SINCE NOVEMBER 25, 2005. KIA MOTORS STATED THAT EVEN THOUGH HER VEHICLE WAS UNDER WARRANTY, SHE STILL HAD TO PAY FOR THE REPAIR COSTS. KIA ALSO STATED THAT IN ORDER TO KEEP HER WARRANTY, THE CONTACT WOULD NEED TO PAY $1,000 PLUS THE REPAIR COSTS. THE DEALER AND THE MANUFACTURER HAVE NOT PROVIDED A SATISFACTORY EXPLANATION AS TO WHAT IS CAUSING THE FAILURE. THE FAILURE HAS OCCURRED APPROXIMATELY EIGHT TIMES. SHE STATED THAT THE BATTERY HAD TO BE REPLACED EVEN THOUGH IT WAS ALSO STILL UNDER WARRANTY. THE ENGINE SIZE WAS UNKNOWN. THE CURRENT MILEAGE IS 62,000 AND FAILURE MILEAGE WAS 34,600. THE DEALER STATED GAS PEDAL STICKS WHEN ACCELERATING . THE CONSUMER STATED SHE HD TO PURCHASE 2 BATTERIES. UPDATED 06/07/07 *TR
NHTSA ODI #10190995
87,000 miles · Mar 2, 2007
Electrical System
2003 KIA SORRENTO - CONSTANTLY REPLACING HEADLIGHTS AND TAIL LIGHTS. RECENTLY STARTED EXPERIENCING INTERIOR LIGHTING PROBLEM. LIGHTS COME ON AND WILL NOT GO OUT DURING DRIVING AND WHILE HEAT IS ON. DASH LIGHTS GO OUT AND WILL NOT COME ON - NO ASSISTANCE FROM THE DEALERSHIP. *JB
NHTSA ODI #10183984
2,000 miles · Jan 8, 2007
Electrical System
TL* - THE CONTACT TOOK THE VEHICLE TO THE DEALERSHIP THREE TIMES CONCERNING THE HORN NOT WORKING. EVERY TIME HE TOOK SIT TO THE DEALERSHIP THEY STATED THAT THEY FIXED THE PROBLEM, BUT THE FAILURE RECURRED ON AND OFF. *AK
NHTSA ODI #10178108
NHTSA investigations
1PE10023 · Fuel Spill During Refueling
Opened Jul 12, 2010 · Closed Dec 21, 2011
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:storage; Fuel System, Gasoline:storage:tank Assembly; Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap
Complaints allege that while refueling the vehicle, fuel can spill out or spit back from the fuel filler port on model year (MY) 2003 Kia Sorento vehicles (subject vehicles).Consumers report that the spilled fuel can splash on the person fueling the vehicle, or on the side of the vehicle and the ground.The subject vehicles are equipped with an evaporative emissions control system that, among other things, manages air exchange between the fuel tank and the atmosphere in an environmentally safe manner.The system consists of a vapor canister, various control valves and tubing, and a canister filter (fuel tank air filter) through which the air that flows in and out of the fuel tank must pass.Kia's testing found that if the canister filter becomes significantly clogged, excess pressure can build up in the fuel tank and cause fuel to spit back from the filler port during refueling.Kia has stated that the canister filter requires regularly scheduled service maintenance; however, the component is not listed as a maintenance item in the owner's or service manual for the subject vehicles.ODI notes that Kia does list the filter on the maintenance schedule in the owner's manual for MY 2005 and newer Kia Sorento vehicles.To address the issue of fuel spit back during refueling, Kia will conduct a service campaign of approximately 86,000 MY 2003 and 2004 Kia Sorento vehicles.The campaign will provide a one-time replacement of the canister filter, at no cost to the owner.Kia will begin notifying the affected owners in late January 2012 and will inform the owners that the filter must be serviced at regular intervals.Kia will also provide an updated service maintenance schedule.Consumers should refer to the service campaign bulletin number SC092 available in the investigative file.A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency will monitor the issue and reserves the right to take future action if warranted by the circumstances.
Additional source detail variants (4)
Fuel System, Gasoline
Complaints allege that while refueling the vehicle, fuel can spill out or spit back from the fuel filler port on model year (MY) 2003 Kia Sorento vehicles (subject vehicles).Consumers report that the spilled fuel can splash on the person fueling the vehicle, or on the side of the vehicle and the ground.The subject vehicles are equipped with an evaporative emissions control system that, among other things, manages air exchange between the fuel tank and the atmosphere in an environmentally safe manner.The system consists of a vapor canister, various control valves and tubing, and a canister filter (fuel tank air filter) through which the air that flows in and out of the fuel tank must pass.Kia's testing found that if the canister filter becomes significantly clogged, excess pressure can build up in the fuel tank and cause fuel to spit back from the filler port during refueling.Kia has stated that the canister filter requires regularly scheduled service maintenance; however, the component is not listed as a maintenance item in the owner's or service manual for the subject vehicles.ODI notes that Kia does list the filter on the maintenance schedule in the owner's manual for MY 2005 and newer Kia Sorento vehicles.To address the issue of fuel spit back during refueling, Kia will conduct a service campaign of approximately 86,000 MY 2003 and 2004 Kia Sorento vehicles.The campaign will provide a one-time replacement of the canister filter, at no cost to the owner.Kia will begin notifying the affected owners in late January 2012 and will inform the owners that the filter must be serviced at regular intervals.Kia will also provide an updated service maintenance schedule.Consumers should refer to the service campaign bulletin number SC092 available in the investigative file.A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency will monitor the issue and reserves the right to take future action if warranted by the circumstances.
Fuel System, Gasoline:storage
Complaints allege that while refueling the vehicle, fuel can spill out or spit back from the fuel filler port on model year (MY) 2003 Kia Sorento vehicles (subject vehicles).Consumers report that the spilled fuel can splash on the person fueling the vehicle, or on the side of the vehicle and the ground.The subject vehicles are equipped with an evaporative emissions control system that, among other things, manages air exchange between the fuel tank and the atmosphere in an environmentally safe manner.The system consists of a vapor canister, various control valves and tubing, and a canister filter (fuel tank air filter) through which the air that flows in and out of the fuel tank must pass.Kia's testing found that if the canister filter becomes significantly clogged, excess pressure can build up in the fuel tank and cause fuel to spit back from the filler port during refueling.Kia has stated that the canister filter requires regularly scheduled service maintenance; however, the component is not listed as a maintenance item in the owner's or service manual for the subject vehicles.ODI notes that Kia does list the filter on the maintenance schedule in the owner's manual for MY 2005 and newer Kia Sorento vehicles.To address the issue of fuel spit back during refueling, Kia will conduct a service campaign of approximately 86,000 MY 2003 and 2004 Kia Sorento vehicles.The campaign will provide a one-time replacement of the canister filter, at no cost to the owner.Kia will begin notifying the affected owners in late January 2012 and will inform the owners that the filter must be serviced at regular intervals.Kia will also provide an updated service maintenance schedule.Consumers should refer to the service campaign bulletin number SC092 available in the investigative file.A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency will monitor the issue and reserves the right to take future action if warranted by the circumstances.
Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap
Complaints allege that while refueling the vehicle, fuel can spill out or spit back from the fuel filler port on model year (MY) 2003 Kia Sorento vehicles (subject vehicles).Consumers report that the spilled fuel can splash on the person fueling the vehicle, or on the side of the vehicle and the ground.The subject vehicles are equipped with an evaporative emissions control system that, among other things, manages air exchange between the fuel tank and the atmosphere in an environmentally safe manner.The system consists of a vapor canister, various control valves and tubing, and a canister filter (fuel tank air filter) through which the air that flows in and out of the fuel tank must pass.Kia's testing found that if the canister filter becomes significantly clogged, excess pressure can build up in the fuel tank and cause fuel to spit back from the filler port during refueling.Kia has stated that the canister filter requires regularly scheduled service maintenance; however, the component is not listed as a maintenance item in the owner's or service manual for the subject vehicles.ODI notes that Kia does list the filter on the maintenance schedule in the owner's manual for MY 2005 and newer Kia Sorento vehicles.To address the issue of fuel spit back during refueling, Kia will conduct a service campaign of approximately 86,000 MY 2003 and 2004 Kia Sorento vehicles.The campaign will provide a one-time replacement of the canister filter, at no cost to the owner.Kia will begin notifying the affected owners in late January 2012 and will inform the owners that the filter must be serviced at regular intervals.Kia will also provide an updated service maintenance schedule.Consumers should refer to the service campaign bulletin number SC092 available in the investigative file.A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency will monitor the issue and reserves the right to take future action if warranted by the circumstances.
Fuel System, Gasoline:storage:tank Assembly
Complaints allege that while refueling the vehicle, fuel can spill out or spit back from the fuel filler port on model year (MY) 2003 Kia Sorento vehicles (subject vehicles).Consumers report that the spilled fuel can splash on the person fueling the vehicle, or on the side of the vehicle and the ground.The subject vehicles are equipped with an evaporative emissions control system that, among other things, manages air exchange between the fuel tank and the atmosphere in an environmentally safe manner.The system consists of a vapor canister, various control valves and tubing, and a canister filter (fuel tank air filter) through which the air that flows in and out of the fuel tank must pass.Kia's testing found that if the canister filter becomes significantly clogged, excess pressure can build up in the fuel tank and cause fuel to spit back from the filler port during refueling.Kia has stated that the canister filter requires regularly scheduled service maintenance; however, the component is not listed as a maintenance item in the owner's or service manual for the subject vehicles.ODI notes that Kia does list the filter on the maintenance schedule in the owner's manual for MY 2005 and newer Kia Sorento vehicles.To address the issue of fuel spit back during refueling, Kia will conduct a service campaign of approximately 86,000 MY 2003 and 2004 Kia Sorento vehicles.The campaign will provide a one-time replacement of the canister filter, at no cost to the owner.Kia will begin notifying the affected owners in late January 2012 and will inform the owners that the filter must be serviced at regular intervals.Kia will also provide an updated service maintenance schedule.Consumers should refer to the service campaign bulletin number SC092 available in the investigative file.A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency will monitor the issue and reserves the right to take future action if warranted by the circumstances.
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