NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
22 reportsClear category filter60,000 miles · Apr 20, 2009
Power Train
MY CAR HAD A HORRIBLE NOISE & I WAS TOLD THAT IT WAS THE DRIVE SHAFT. I GOT A FRIEND TO DRIVE IT TO A KIA KENDALL AND THEY WERE TO WARRANTY THE PART THAT WAS DEFECTIVE. IN THE PROCESS OF DRIVING CAR TO DEALER IT CAME APART HIT THE BOTTOM OF CAR DEPLOYED AIR BAGS, CRACKED WINDSHIELD, GAS TANK ALSO CRACKED. THIS WAS A DEFECTIVE DE…
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MY CAR HAD A HORRIBLE NOISE & I WAS TOLD THAT IT WAS THE DRIVE SHAFT. I GOT A FRIEND TO DRIVE IT TO A KIA KENDALL AND THEY WERE TO WARRANTY THE PART THAT WAS DEFECTIVE. IN THE PROCESS OF DRIVING CAR TO DEALER IT CAME APART HIT THE BOTTOM OF CAR DEPLOYED AIR BAGS, CRACKED WINDSHIELD, GAS TANK ALSO CRACKED. THIS WAS A DEFECTIVE DEALER PART AND WAS SUPPOSED TO BE WARRANTIED. NOW IT HAS BEEN REPORTED TO INSURANCE AND IN THE PROCESS OF FIXING THIS ITEM THEY BROKE A PLASTIC HOSE FROM THE RADIATOR AND THEN CLAMPED IT & PUT A SCREW IN MY RADIATOR. THEY KNOW THAT THIS WAS GOING TO CAUSE A PROBLEM & DID NOT EVEN CARE. *TR
NHTSA ODI #10266093
68,000 miles · Feb 5, 2008
Power Train
1. ENGINE STARTED KNOCKING ( MILEAGE 68,000 ) 2. ENGINE SHUT DOWN AND WOULD NOT RESTART 3. A MECHANIC CHECKED AND FOUND THE HARMONIC BALANCER WAS LOOSE ON THE CRANKSHAFT. IN THE ATTEMPT TO REMOVE THE HARMONIC BALANCER, THE MOUNTING BOLT BROKE OFF FLUSH WITH THE CRANK SHAFT AND APPEARS TO HAVE BEEN CROSS THREADED FROM THE FACTO…
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1. ENGINE STARTED KNOCKING ( MILEAGE 68,000 ) 2. ENGINE SHUT DOWN AND WOULD NOT RESTART 3. A MECHANIC CHECKED AND FOUND THE HARMONIC BALANCER WAS LOOSE ON THE CRANKSHAFT. IN THE ATTEMPT TO REMOVE THE HARMONIC BALANCER, THE MOUNTING BOLT BROKE OFF FLUSH WITH THE CRANK SHAFT AND APPEARS TO HAVE BEEN CROSS THREADED FROM THE FACTORY. THE HARMONIC BALANCER WAS NOT PULLED ALL THE WAY UP CAUSING THE FAILURE. DUE TO THE HARDNESS OF THE MOUNTING BOLT AND THE CRANK SHAFT, REMOVAL OF THE BROKEN BOLT IS IMPOSSIBLE. THE ENGINE WILL NEED AN OVERHAUL TO REPAIR THE PROBLEM AND OF COURSE THE WARRANTY HAS JUST EXPIRED. ( PLEASE ADVISE ). *TR
NHTSA ODI #10217046
124 miles · Jan 29, 2007
Power Train
I DRIVE A 2003 KIA/SORENTO/4D. ON OR ABOUT DEC 15 2006 I NOTICE A LOUD NOISE AN SERVER VIBRATION COMING UNDER VEHICLE. I TOOK SUV TO FAMILY MECHANIC. HE COULD NOT FIND PROBLEM AND RECOMMENDED THAT I TAKE VEHICLE TO KIA DEALER. ON DEC 27 2006 KIA DEALER TECH INITIAL DIAG READS 4X4 IS STAYING ENGAGED ALL THE TIME. SUSPECTED SWITCH…
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I DRIVE A 2003 KIA/SORENTO/4D. ON OR ABOUT DEC 15 2006 I NOTICE A LOUD NOISE AN SERVER VIBRATION COMING UNDER VEHICLE. I TOOK SUV TO FAMILY MECHANIC. HE COULD NOT FIND PROBLEM AND RECOMMENDED THAT I TAKE VEHICLE TO KIA DEALER. ON DEC 27 2006 KIA DEALER TECH INITIAL DIAG READS 4X4 IS STAYING ENGAGED ALL THE TIME. SUSPECTED SWITCH FAILURE. THEREFORE FRONT DIFF STAYING ENGAGED ALL THE TIME. THIS HAS CAUSED INTERNAL DAMAGE TO FRONT DIFF AND FRONT PROPELLER SHAFT. ESTIMATE COST TO REPAIR/2,775.00 I AM AT A LOST CAUSE VEHICLE IS NO LONGER UNDER WARRANTY, BUT I FEEL BECAUSE 4X4 RELEASE/ENGAGE SWITCH FAILURE THAT I SHOULD NOT HAVE TO ENDURE THE FINANCIAL BURDEN. REPAIRING THIS MANUFACTURES DEFECT. *JB
NHTSA ODI #10181065
45,000 miles · Jan 8, 2007
Power TrainService Brakes, Hydraulic
2003 KIA SORRENTO-THERE HAS BEEN NO CRASH==THE DRIVE LINE FROM THE REAR MAKES A NOISY THUMP ALMOST EVERY TIME I STEP ON THE BRAKES AND RELEASE THEM--KIA SERVICE IN MIDDLETOWN, NY SERVICE MANAGER AND KIA ZONE REP STATE THAT IS NORMAL OPERATION OF VEHICLE--I DISAGREE AND INFORMED THEM I WILL BE TAKING VEHICLE TO ANOTHER MECHANI…
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2003 KIA SORRENTO-THERE HAS BEEN NO CRASH==THE DRIVE LINE FROM THE REAR MAKES A NOISY THUMP ALMOST EVERY TIME I STEP ON THE BRAKES AND RELEASE THEM--KIA SERVICE IN MIDDLETOWN, NY SERVICE MANAGER AND KIA ZONE REP STATE THAT IS NORMAL OPERATION OF VEHICLE--I DISAGREE AND INFORMED THEM I WILL BE TAKING VEHICLE TO ANOTHER MECHANIC,I HAVE BEEN DRIVING FOR 34 YEARS AND NEVER ENCOUNTERED THIS SITUATION IN A VEHICLE. *JB
NHTSA ODI #10178038
Mileage unknown · Sep 6, 2005
Engine And Engine CoolingPower Train
I HAVE CONSISTENTLY HAD PROBLEMS WITH MY CAR FROM THE 1ST MONTH OF PURCHASE. THE MAJOR PROBLEMS HAVE BEEN: CHECK ENGINE LIGHT KEPT COMING ON AND A PROBLEM WITH THE DRIVE SHAFT. THE CHECK ENGINE LIGHT PROBLEM WAS RESOLVED APPROXIMATELY 2 ATTEMPTS AFTER IT FIRST APPEARED. IT WAS DIAGNOSED AS A PROBLEM WITH THE TSP. THE PROBLEM…
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I HAVE CONSISTENTLY HAD PROBLEMS WITH MY CAR FROM THE 1ST MONTH OF PURCHASE. THE MAJOR PROBLEMS HAVE BEEN: CHECK ENGINE LIGHT KEPT COMING ON AND A PROBLEM WITH THE DRIVE SHAFT. THE CHECK ENGINE LIGHT PROBLEM WAS RESOLVED APPROXIMATELY 2 ATTEMPTS AFTER IT FIRST APPEARED. IT WAS DIAGNOSED AS A PROBLEM WITH THE TSP. THE PROBLEM WITH THE DRIVE SHAFT HAS NOT YET BEEN RESOLVED AS IT STILL CONTINUE TO VIBRATE AT SPEEDS HIGHER THAN 65 MPH. THESE PROBLEMS CONCERN ME AS IT MAY INTERFERE OR HINDER WITH MY DRIVING ABILITIES AND CAUSE AN ACCIDENT. *JB
NHTSA ODI #10135404
Mileage unknown · Sep 1, 2005
Power TrainFire
COMMENTS: I WOULD LIKE TO INFORM YOU OF WHAT I THINK IS A POTENTIAL SAFETY HAZARD. SEVERAL WEEKS AGO MY WIFE AND I WERE RETURNING FROM A VACATION IN OUR CAR AND IT CAUGHT FIRE. LUCKILY THERE WERE NO INJURIES OR SERIOUS DAMAGE. AT THE END OF THIS LETTER WILL BE ALL THE PARTICULARS. WE WERE COMING FROM SANTA CRUZ ON HIGHWAY 1…
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COMMENTS: I WOULD LIKE TO INFORM YOU OF WHAT I THINK IS A POTENTIAL SAFETY HAZARD. SEVERAL WEEKS AGO MY WIFE AND I WERE RETURNING FROM A VACATION IN OUR CAR AND IT CAUGHT FIRE. LUCKILY THERE WERE NO INJURIES OR SERIOUS DAMAGE. AT THE END OF THIS LETTER WILL BE ALL THE PARTICULARS. WE WERE COMING FROM SANTA CRUZ ON HIGHWAY 1, IN CALIFORNIA AND AT WHAT IS CALLED THE SUMMIT, OF I STARTED SEEING SMOKE IN BACK OF OUR VEHICLE. WE STOPPED, TURNED OFF THE CAR ,OPENED THE HOOD AND THERE WAS A SMALL FIRE DOWN ON THE DRIVER SIDE NEAR THE EXHAUST MANIFOLD. I CLOSED THE HOOD AND TRIED TO LOCATE A FIRE EXTINGUISHER. THE FIRE EXTINGUISHED ITSELF AND WE HAD THE CAR TOWED TO THE DEALERSHIP. AFTER A DAY OF TESTING THE ONLY THING THEY FOUND WAS THAT THE TRANSMISSION WAS SLIGHTLY OVERFILLED, WHICH WAS MY ERROR. WHILE I REALIZE THAT CAN CAUSE THE PROBLEM HERE IS MY CONCERN. THE TECHNICIAN WHO WORKED ON MY CAR SAID THAT TRANSMISSIONS ARE DESIGNED TO BLOW OUT OR THROUGH OVERFLOW THE TRANSMISSION FILLER TUBE. HE ALSO SHOWED ME THAT ON TOP OF THE DIPSTICK WAS SLOT WHICH WOULD ALLOW THE FLUID TO ESCAPE. HOWEVER IT IS LOCATED RIGHT OVER THE EXHAUST MANIFOLD. IT WOULD SEEM THAT IT SHOULD BE LOCATED WHERE THE FLUID WOULD NOT COME IN CONTACT WITH SUCH HOT ENGINE PARTS. I AM NOT SURE IF THIS AFFECTS OTHER VEHICLES BUT IT DOES CONCERN ME. MY VEHICLE IS 2004 KIA SORENTO 6 CYC, AUTOMATIC WE WERE NOT TOWING ANYTHING NOR WHERE WE LOADED DOWN. I THANK YOU FOR YOU TIME. STEVE ELIJAH 225 MERRILL AVE FREMONT, CA 945 SELIJAH@SBCGLOBAL.NET 510.623.8211. *NM
NHTSA ODI #10135094
58,947 miles · Mar 15, 2005
Electrical SystemEngine And Engine CoolingExterior Lighting
WHILE DRIVING, THE ENGINE BLEW OUT THE FIRST TIME ON 10-04-04. IT WAS REPLACED AND IT BLEW AGAIN ON 01-21-05. THE VEHICLE IS ON ITS THIRD ENGINE. *AK THE KEY BECAME STUCK IN THE IGNITION, THE VEHICLE SHIFTED OUT OF PARK. THE CONSUMER STATED HE HAS HAD TRANSMISSIONS AND ENGINE PROBLEMS SINCE HE PURCHASED THE VEHICLE. THE F…
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WHILE DRIVING, THE ENGINE BLEW OUT THE FIRST TIME ON 10-04-04. IT WAS REPLACED AND IT BLEW AGAIN ON 01-21-05. THE VEHICLE IS ON ITS THIRD ENGINE. *AK THE KEY BECAME STUCK IN THE IGNITION, THE VEHICLE SHIFTED OUT OF PARK. THE CONSUMER STATED HE HAS HAD TRANSMISSIONS AND ENGINE PROBLEMS SINCE HE PURCHASED THE VEHICLE. THE FRONT WHEEL BEARINGS WERE DAMAGED. THE FOG LIGHT WAS INOPERATIVE. *JB
NHTSA ODI #10112870
5,100 miles · Dec 1, 2004
Power Train
I HAVE A 2003 KIA SORENTO THAT I PURCHASED IN SEPTEMBER OF 2003. I BOUGHT THE SORENTO WITH 5000 MILES ON IT AND FROM THE TIME I GOT IT HOME, IT DEVELOPED PROBLEMS. EVERYTIME I START MY SORENTO AND PUT IT IN DRIVE OR REVERSE AND BACK-UP OR DRIVE FORWARD, I HEAR THIS AWFUL HUM NOISE FROM THE FRONT OF THE CAR THAT THE DEALERSHIP …
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I HAVE A 2003 KIA SORENTO THAT I PURCHASED IN SEPTEMBER OF 2003. I BOUGHT THE SORENTO WITH 5000 MILES ON IT AND FROM THE TIME I GOT IT HOME, IT DEVELOPED PROBLEMS. EVERYTIME I START MY SORENTO AND PUT IT IN DRIVE OR REVERSE AND BACK-UP OR DRIVE FORWARD, I HEAR THIS AWFUL HUM NOISE FROM THE FRONT OF THE CAR THAT THE DEALERSHIP SAYS IS NORMAL THAT IT'S THE ABS RESETTING ITSELF AND THAT IT'S SOMETIMES NOISIER IN SOME SORENTO'S THAN IN OTHER'S (NO OTHER SORENTO OWNER THAT I KNOW HAS THIS NOISE) I FELT A VIBRATION WHEN I WAS DRIVING ON THE HIGHWAY AND IT WOULD HAPPEN BETWEEN 68 AND 72 MPH. IT WOULD NOT VIBRATE IF I WAS DRIVING ABOVE OR BELOW THIS SPEED. SO I CALLED THE DEALERSHIP AND THEY TOLD ME TO ROTATE AND BALANCE MY TIRES AND I TOLD THEM THAT I ALREADY DID THAT. WELL COME TO FIND OUT AFTER I HAD TO PUT IT INTO THE SHOP, THEY REPLACED THE WHOLE DRIVE SHAFT, IT WAS BENT (MANUFACTURER DEFECT THEY SAID.) SECOND, MY CONSOLE BROKE AND THE LIGHTS WENT OUT INSIDE MY CAR, STILL WAITING ON THAT TO BE FIXED, HAVE HAD TO REPLACE THE HEADLIGHT LIGHTS TWICE THUS FAR. REAR WINDSHIELD WIPER KEEPS GETTING STUCK EVEN AFTER HAVING THE DEALERSHIP ADJUST IT. *AK
NHTSA ODI #10100873
10,000 miles · Nov 29, 2004
Power TrainFire
WHILE DRIVING AT HIGHWAY SPEED CONSUMER SMELLED A BURNING ODOR. THEN, SMOKE CAME FROM THE REAR OF THE VEHICLE. AS A RESULT, TRANSMISSION FAILED AND FLAMES EMANATED FROM THE UNDER CARRIAGE. *AK
NHTSA ODI #10101766
Mileage unknown · Feb 23, 2004
Power Train
BOUGHT 2003 SORENTO JULY 1, 2003. SOON AFTER THE BACK BRAKES OR SOMETHING AFTER BRAKING WOULD "CLUNK". WHETHER IS WAS AFTER RELEASING BRAKES OR SECONDS LATER IT WOULD "CLUNK" (DEALER KEEPS SAYING IT 'POPS', IT CLUNKS). FIRST TIME IN THEY DIDNT FEEL IT THEY SAID. SECOND TIME THEY FELT IT AND THEN SAID THEY DIDNT KNOW WHAT I…
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BOUGHT 2003 SORENTO JULY 1, 2003. SOON AFTER THE BACK BRAKES OR SOMETHING AFTER BRAKING WOULD "CLUNK". WHETHER IS WAS AFTER RELEASING BRAKES OR SECONDS LATER IT WOULD "CLUNK" (DEALER KEEPS SAYING IT 'POPS', IT CLUNKS). FIRST TIME IN THEY DIDNT FEEL IT THEY SAID. SECOND TIME THEY FELT IT AND THEN SAID THEY DIDNT KNOW WHAT IT WAS AND WOULD CONTACT KIA ABOUT IT-----THIS THIRD TIME---THEY SAY ITS NORMAL FOR THE VEHICLE. FTER THE FIRST TIME IN THE SHOP FOR THE 'CLUNKING' THE SERIOUS VIBRATION ON THE HIGHWAY BEGAN TO BE FELT STARTING AT 68 MPH AND WORSENING AT 70 MPH.....TOOK IT IN AND THE DEALERSHIP SAID IT WAS THE TIRES AND THEY BALANCED THEM-----NOW THE VIBRATION IS WORSE AND YOU FEEL IT AT 60 MPH AND AT 68 MPH IT IS REALLY NOTICABLE. TOOK IN INTO THE SHOP 02/19/04....DEALSHIP DROVE IT AND THEN JUST TOLD US IT WAS NORMAL ON THE VEHICLE---SOME GUY LAST FALL HAD THE VIBRATION WORSE---AND SAID KIA CANT FIX IT. WELL, WE DIDNT TAKE THAT ANSWER AND IS NOW BEING INVESTIGATE. TWO FIELD KIA INVESTIGATORS JUST DROVE IT BEFORE MY HUSBAND ARRIVED AT THE DEALERSHIP. THEY TOLD MY HUSBAND THEY DIDNT FEEL REALLY ANYTHING. HE TOLD THEM TO GET IN THE VEHICLE AND NOW DRIVE WITH HIM---THE INVESTIGATORS ALL OF A SUDDEN SAID THEY FELT SOMETHING.....NOW THEY ARE GOING TO LOOK AT SEEING WHAT IT IS. BOTH KIA AND THE DEALERSHIP ARE DRAGGING THIS OUT......CALL KIA'S CONSUMER AFFAIRS OFFICE (OR WHATEVER IT IS CALLED) AND THEY SAY THEY HAVE NO REPORTS OF THESE PROBLEMS. THE DEALERSHIP TELLS US THEY KIA TELLS THEM IT IS NORMAL. I AM AFRAID TO DRIVE THE VEHICLE AND LEFT IT ALL WEEKEND AT THE DEALERSHIP! MY DAUGHTERS LIFE IS AT STAKE DRIVING IT LIKE THAT IF SOMETHING FALLS OFF OR SOMETHING. I AM AFRAID THAT KIA OR THE DEALERSHIP WILL HAVE MORE EXPERIENCE AND ABLE TO COVER THINGS SO THAT WE CAN NOT FILE FOR THE LEMON LAW........... HELP!!!*AK
NHTSA ODI #10058757
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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