NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
43 reportsClear category filter135,000 miles · Jan 13, 2015
EnginePower TrainSteering
I HAVE SERVICE RECORDS SHOWING I HAD THE CRANKSHAFT PULLEY REPLACED AT 55,000 MILES UNDER WARRANTY BY KIA. THE CRANKSHAFT PULLEY BROKE OFF AT 105,000 MILES. I WAS ABLE TO HAVE THE VEHICLE REPAIRED COST $1500 OUT OF MY POCKET. ON 1/11/2015 THE CRANKSHAFT PULLEY BROKE OFF FOR A 3RD TIME, SHEARING THE THREADS TO THE ENGINE, AND C…
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I HAVE SERVICE RECORDS SHOWING I HAD THE CRANKSHAFT PULLEY REPLACED AT 55,000 MILES UNDER WARRANTY BY KIA. THE CRANKSHAFT PULLEY BROKE OFF AT 105,000 MILES. I WAS ABLE TO HAVE THE VEHICLE REPAIRED COST $1500 OUT OF MY POCKET. ON 1/11/2015 THE CRANKSHAFT PULLEY BROKE OFF FOR A 3RD TIME, SHEARING THE THREADS TO THE ENGINE, AND CAUSING THE ENGINE TO NO LONGER WORK. ALL 3 EVENTS CAUSED LOSS OF POWER AND ABLE TO STEER THE VEHICLE. *TR
NHTSA ODI #10672207
155,000 miles · Jan 3, 2015
Engine
DRIVING VEHICLE AT ABOUT 45MPH, ENGINE STARTED MAKING A SCREECHING NOISE AND GOT LOUDER WHEN ACCELERATING. THERE WAS A LOUD BANG FROM ENGINE AREA AND IMMEDIATELY LOST ALL POWER AND ABILITY TO STEER AND BRAKE. WE WERE APPROACHING A BUSY INTERSECTION AND HAD TO PULL THE EMERGENCY BRAKE TO AVOID RUNNING A RED LIGHT INTO ONCOMING TR…
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DRIVING VEHICLE AT ABOUT 45MPH, ENGINE STARTED MAKING A SCREECHING NOISE AND GOT LOUDER WHEN ACCELERATING. THERE WAS A LOUD BANG FROM ENGINE AREA AND IMMEDIATELY LOST ALL POWER AND ABILITY TO STEER AND BRAKE. WE WERE APPROACHING A BUSY INTERSECTION AND HAD TO PULL THE EMERGENCY BRAKE TO AVOID RUNNING A RED LIGHT INTO ONCOMING TRAFFIC. HAD VEHICLE TOWED TO OUR DEALERSHIP. THE CRANKSHAFT PULLEY BOLT SNAPPED OFF AND THE BELT AND PULLEY FELL OFF. THE BOLT DID NOT BREAK FAR ENOUGH INTO THE ENGINE BLOCK SO REPAIR WAS ABLE TO REPLACE IT. AFTER THIS HAPPENED WE LEARNED OF THE SAFETY CONCERN WITH SAID VEHICLE AND KIA DENIES ANYTHING WRONG WITH THEIR SORENTOS. THERE IS A PENDING LAWSUIT AGAINST KIA FOR THIS KNOWN PROBLEM. THIS IS A VERY DANGEROUS SITUATION AND WE ADVISED THE DEALER THAT WE WANT TO TRADE THE VEHICLE AS IT POSES A VERY SERIOUS SAFETY PROBLEM. KIA SHOULD PROVIDE A MAJOR RECALL. NOW GETTING A HARD TIME FROM DEALER. WE ARE STUCK IN THE MIDDLE AND STILL OWE A LOT ON THIS HAZARDOUS VEHICLE. *TR
NHTSA ODI #10669823
Mileage unknown · Aug 31, 2014
Engine
THE OVERFLOW BOTTLE FOR THE RADIATOR HAS BEEN LEAKING AGAIN. THE FIRST ONE THAT CAME WITH THE CAR WAS REPLACED IN 2011 AND NOW WE ARE HAVING TO REPLACE THE RADIATOR RESERVOIR AGAIN. *TR
NHTSA ODI #10629793
122,049 miles · Aug 27, 2014
Engine
I WAS TOLD BY THE MECHANIC THAT "SOMETHING HAPPENED INSIDE THE ENGINE THAT CANNOT BE REPAIRED". PRIOR TO THE ENGINE FAILURE (MAY, 2014) THE REAR THROTTLE PLATE CAME APART AND LODGED IN THE LOWER INTAKE MANIFOLD. THE MECHANIC WAS UNABLE TO RETRIEVE THE SCREWS AND ONE WAS EVEN LODGED IN A CYLINDER HEAD. A THROTTLE PLATE ASSEMBL…
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I WAS TOLD BY THE MECHANIC THAT "SOMETHING HAPPENED INSIDE THE ENGINE THAT CANNOT BE REPAIRED". PRIOR TO THE ENGINE FAILURE (MAY, 2014) THE REAR THROTTLE PLATE CAME APART AND LODGED IN THE LOWER INTAKE MANIFOLD. THE MECHANIC WAS UNABLE TO RETRIEVE THE SCREWS AND ONE WAS EVEN LODGED IN A CYLINDER HEAD. A THROTTLE PLATE ASSEMBLY WAS INSTALLED AND THE CAR WAS DRIVABLE BUT WITH AN AUDIBLE NOISE. AT THIS TIME I WAS TOLD THE SAME PROBLEM EXISTS WITH MANY KIA'S AND YET A RECALL HAS NOT BEEN ISSUED. MY CAR IS NOT DRIVABLE, IT'S A V6 AND THE LEFT SIDE OF THE ENGINE IS COMPLETELY SHUT DOWN AND I FEEL KIA COULD HAVE AVOIDED THIS WITH A RECALL WHEN THEY HAVE KNOWN FOR YEARS THAT THE PROBLEM EXISTS. *TR
NHTSA ODI #10628837
96,000 miles · Aug 26, 2014
EngineSteering
I BOUGHT A 2003 KIA SORENTO FROM MY NIECE BACK IN NOVEMBER 2013 FOR $2000 AND NOT EVEN TWO WEEKS INTO OWNING THIS VEHICLE, THE CRANK SHAFT BROKE IN HALF! THE BOLT BROKE OFF IN HALF INSIDE THE CRANK SHAFT PULLEY AND THE OTHER HALF OF THE BOLT WAS INSIDE THE CRANK SHAFT CASE. TO MY UNDERSTANDING, THIS IS THE SECOND TIME THAT THE C…
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I BOUGHT A 2003 KIA SORENTO FROM MY NIECE BACK IN NOVEMBER 2013 FOR $2000 AND NOT EVEN TWO WEEKS INTO OWNING THIS VEHICLE, THE CRANK SHAFT BROKE IN HALF! THE BOLT BROKE OFF IN HALF INSIDE THE CRANK SHAFT PULLEY AND THE OTHER HALF OF THE BOLT WAS INSIDE THE CRANK SHAFT CASE. TO MY UNDERSTANDING, THIS IS THE SECOND TIME THAT THE CRANK SHAFT NEEDED REPAIRING (MY NIECE, HUSBAND WHO WERE THE FIRST AND ORIGINAL OWNERS TO THIS KIA SORENTO HAD IT BREAK DOWN ON HIM ON THE FREEWAY AS WELL, HAD TO GET IT TOWED TO KIA THEN PAID THEM TO FIX IT WHEN THEY OWNED THE VEHICLE) BUT THIS TIME, WHEN THIS ISSUE HAPPENED AGAIN WHILE I OWNED THE VEHICLE, THE CRANK SHAFT FAILED IN A GREATER AND MORE COSTLY CONDITION THEN THE FIRST TIME THE CRANK SHAFT FAILED ON THEM. WHICH THEN CAUSED ENGINE FAILURE, LOSS OF POWER STEERING, LOSS OF THE CHARGING SYSTEM, LOSS OF THE COOLING SYSTEM AND LOSS OF CONTROL OF THE VEHICLE, EVERYTHING SHUT DOWN, VEHICLE WOULDN'T START UP AFTER THAT AND IT COULD HAVE BEEN A VERY DANGEROUS SITUATION AS IT HAPPENED WHILE ON THE FREEWAY AND WHILE MY HUSBAND, MY DAUGHTER AND MY GRANDDAUGHTER WAS IN THE VEHICLE TRAVELING. IT COULD HAVE JEOPARDIZE THEIR LIFE'S AS WELL AS OTHER! *TR
NHTSA ODI #10628320
124,000 miles · Jul 11, 2014
Engine
MY CHECK ENGINE LIGHT CAME ON 2 MONTHS AGO AND I BROUGHT IT TO A KIA DEALERSHIP WHO TOLD ME IT WAS THE CYLINDERS THAT WERE MISS FIRING AND THE BELTS NEEDED TO BE REPLACES AND THEY FIXED THAT. I ASKED ABOUT THE CRANKSHAFT AND THEY TOLD ME IT WAS FINE. WHEN I LEFT THE LIGHT CAME BACK ON AND THEY TOLD ME I NEED NEW SPARK PLUGS, FIX…
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MY CHECK ENGINE LIGHT CAME ON 2 MONTHS AGO AND I BROUGHT IT TO A KIA DEALERSHIP WHO TOLD ME IT WAS THE CYLINDERS THAT WERE MISS FIRING AND THE BELTS NEEDED TO BE REPLACES AND THEY FIXED THAT. I ASKED ABOUT THE CRANKSHAFT AND THEY TOLD ME IT WAS FINE. WHEN I LEFT THE LIGHT CAME BACK ON AND THEY TOLD ME I NEED NEW SPARK PLUGS, FIXED THAT AND THE LIGHT CAME BACK ON AGAIN. WHILE DRIVING ON THE HIGHWAY THE BREAK LIGHT AND BATTERY LIGHT CAME ON AND THE CAR BEGAN TO LOOSE POWER. NOW THE CAR IS AT ANOTHER DEALERSHIP AND THEY ARE TELLING ME IT'S THE CRANKSHAFT. AFTER READING WHAT HAS HAPPENED WITH MANY OTHER PEOPLE I CAN SEE THE ORIGINAL PROBLEM WAS THE CRANKSHAFT.I HAVE SPENT OVER $4K ON FIXING THE CAR AND THE CAR IS NOT WORTH IT. *TR
NHTSA ODI #10609842
150,000 miles · Jul 10, 2014
Electrical SystemEngineFuel System, Gasoline
I AM SINGLE OLD LADY, LATE JAN.2014 , DRIVING BACK FROM ORLANDO,FL. TO MY HOME<2 HRS AWAY> ON I-95 CAR SLOWS DOWN, ALL LIGHTS GO ON DASHBOARD. GET HOME AT 40 MILES AN HOUR.NEXT DAY GO TO TIRE PLUS, CAN NOT FIX CAR, ENGINE TROUBLE..GO TO DEALER BEV SMITH KIA, FT.PIERCE, FL, I AM A REGULAR THERE,WITH CAR PROBLEMSELL ME CAN NEEDS…
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I AM SINGLE OLD LADY, LATE JAN.2014 , DRIVING BACK FROM ORLANDO,FL. TO MY HOME<2 HRS AWAY> ON I-95 CAR SLOWS DOWN, ALL LIGHTS GO ON DASHBOARD. GET HOME AT 40 MILES AN HOUR.NEXT DAY GO TO TIRE PLUS, CAN NOT FIX CAR, ENGINE TROUBLE..GO TO DEALER BEV SMITH KIA, FT.PIERCE, FL, I AM A REGULAR THERE,WITH CAR PROBLEMSELL ME CAN NEEDS NEW LOWER ENGINE, $7000 I ALMOST FAINT, , CAR NOT SAFE, I LEFT ANYWAY, THEY WOULD NOT EXACTLY TELL ME WHAT WRONG WITH CAR...COWORKER AT WALMART, TELLS ME OF MECHANIC,CAN FIX IT...TAKE IT THERE, HE TELLS ME WHAT REALLY IS WRONG WITH CAR..SCREW THAT HOLD HARMONY PART, HAD BROKEN OFF, HALF OF IT WAS STILL STUCK INTO LOWERE ENGINE< BY THE WAY, THIS WAS A RECALL BACK 3 YEARS AGO, IN WHICH I HAD COMPLYED WITH KIA AND THEY HAD REPLACED NEW HARMONY SCREW>...THIS HONEST MECHANIC, TOLD ME LEAVE KIA OVER THE WEEKEND, WILLPUT PUT SCREW SOFTENER ON SCREW STILL IN ENGINE, SEE IF IT COMES OUT...IT DID, THEY PUT NEW SCREW, GIVE ME ALL NEW BELTS, I PAID $1,800 OF MY OWN MONEY, ..I GO AHEAD AND DRIVE TO MIAMI, FLL< 2 HRS AWAY> DAY LATTER I DRIVE TO ORLANDO ,FL.< 3 HRS AWAY>...IN I 95....NEXT DAY,TRY TO GET OUT OF MY DRIVEWAY, SAME THING HAPPENED...GOOD MECHANIC COMES OVER TO MY HOUSE, SAID SAME SCREW CAME OFF...HE FIXES IT AGAIN, $1,500, ...HE TELLS ME, GET NEW CAR, DO NOT KEEP THIS KIA SORENTO 2003, CAR HAS FLAW, CAN NOT BE FIXED....IF KEEP IT, JUST FOR AROUND TOWN DRIVE, UNDER 50 MILES AN HOUR, DO NOT TAKE TURNPIKE OR INTERSTATE HIGHWAYS...I CONTACTED KIA MOTORS, BEV SMITH KIA, TOLD THEM ABOUT RECALL SCREW REPLACEMENT , TELL ME OUT OF WARRANTY, NEITHER WILL REALLY ANSWER BACK...NO MONEY, NO NEW CAR....KIA MOTORS IS A CROOK,...TELL ME CAR OUT OF WARRANTY, THAT WHAT DO I WANT WITH OLD CAR...CAN NOT FIND ANY OTHER PRIOR COMPLAINTS I MADE WITH CAR, SINCE FIRST YEAR I BOUGHT IT... *TR
NHTSA ODI #10609501
130,000 miles · Jul 7, 2014
Electrical SystemEngineSteering
AS MY FAMILY AND I DROVE DOWN 146 TOWARDS BAYTOWN, TX FROM DAYTON, TX I HEARD A LOUD "THUD". IMMEDIATELY FOLLOWED BY A LOSS OF A/C, POWER, AND STEERING. I PULLED ONTO THE SHOULDER IMMEDIATELY AND POPPED THE HOOD. I SAW THE HARMONIC BALANCE LYING ON THE SPLASH GUARD AND A BELT LYING BESIDE IT, AS WELL AS ANOTHER BELT LOSS B…
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AS MY FAMILY AND I DROVE DOWN 146 TOWARDS BAYTOWN, TX FROM DAYTON, TX I HEARD A LOUD "THUD". IMMEDIATELY FOLLOWED BY A LOSS OF A/C, POWER, AND STEERING. I PULLED ONTO THE SHOULDER IMMEDIATELY AND POPPED THE HOOD. I SAW THE HARMONIC BALANCE LYING ON THE SPLASH GUARD AND A BELT LYING BESIDE IT, AS WELL AS ANOTHER BELT LOSS BUT STILL HANGING ON THE OTHER PULLEYS. I GOT A FRIEND TO TOW ME BACK TO MY STUDIO. I BEGAN SEARCHING ONLINE FOR WHY THE BOLT THAT HOLDS THE BALANCE COULD JUST BREAK. I FOUND NUMEROUS REPORTS OF THIS PROBLEM, AS WELL AS LAW SUITS FILLED IN OTHER STATES FOR THIS VERY ISSUE. *JS
NHTSA ODI #10608643
155,000 miles · Jun 10, 2014
EnginePower TrainSteering
THE BOLT ON THE CRANKSHAFT PULLEY AS WELL AS THE PIN BROKE OFF CAUSING THE MOTOR TO STOP AND OVERHEAT DUMPING ALL THE ANTIFREEZE AND STOPPING ALL BELTS. MY MOTHER COULD HAVE BEEN INJURED WHILE DRIVING BUT IT ENDED UP BEING SHE WAS JUST BLOCKING TRAFFIC THANKFULLY AND NOT ON THE HIGHWAY. THIS SEEMS TO BE A VERY COMMON ISSUE WITH …
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THE BOLT ON THE CRANKSHAFT PULLEY AS WELL AS THE PIN BROKE OFF CAUSING THE MOTOR TO STOP AND OVERHEAT DUMPING ALL THE ANTIFREEZE AND STOPPING ALL BELTS. MY MOTHER COULD HAVE BEEN INJURED WHILE DRIVING BUT IT ENDED UP BEING SHE WAS JUST BLOCKING TRAFFIC THANKFULLY AND NOT ON THE HIGHWAY. THIS SEEMS TO BE A VERY COMMON ISSUE WITH HUNDREDS IF NOT THOUSANDS COMPLAINING ABOUT THE CRANKSHAFT PULLEY BOLT AND PIN. KIA SAYS THEY WON'T DO ANYTHING AS IT IS OUT OF WARRANTY AND I AM NOT THE ORIGINAL OWNER. THIS MAY HAVE BEEN FIXED ONCE BEFORE ON THE VEHICLE DUE TO FAILURE AND I AM VERY WORRIED THIS MAY HAPPEN AGAIN WITH WORSE CONSEQUENCES. MY MECHANIC WAS ABLE TO PROVIDE A TEMPORARY/PERMANENT FIX BUT WE REALLY DODGED A BULLET AND IT COULD HAVE CAUSED IMMEDIATE CATASTROPHIC DAMAGE. I'M DISAPPOINTED WITH ALL OF THE SERIOUS COMPLAINTS THAT KIA STILL HAS NOT RECALLED IT FOR 2002-2009 SORENTO MODELS. *TR
NHTSA ODI #10597334
58,000 miles · May 8, 2014
EngineFuel/propulsion System
TL* THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 45 MPH, THE CHECK ENGINE LIGHT ILLUMINATED BEFORE THE VEHICLE STALLED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT ALSO INDICATED THAT WHILE REFUELING, FUEL SPILLED FROM THE FILLER NECK. THE MANUFACTURER WAS NOTIFIED. THE FAIL…
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TL* THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 45 MPH, THE CHECK ENGINE LIGHT ILLUMINATED BEFORE THE VEHICLE STALLED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT ALSO INDICATED THAT WHILE REFUELING, FUEL SPILLED FROM THE FILLER NECK. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 58,000.
NHTSA ODI #10587220
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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