NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
9 reportsClear category filter114,283 miles · Dec 17, 2015
EngineService BrakesSteering
CRANKSHAFT BOLT BACKED OUT LOST POWER STEERING BRAKES,KIA IS AWARE OF THIS PROBLEM FROM 2002 TO 2009 MANY REPORTS HAVE BEEN FILED,ITS THE MANUFACTURING OF THE BOLT WHICH IS TO SMALL,THEY ARE NOT STANDING BY THIS DEFECT,THERE IS NO PERMENANT FIX FOR THIS AND KIA ISN'T WARNING ANYONE OF THIS PROBLEM WHICH COULD LEAD INTO A FATILE …
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CRANKSHAFT BOLT BACKED OUT LOST POWER STEERING BRAKES,KIA IS AWARE OF THIS PROBLEM FROM 2002 TO 2009 MANY REPORTS HAVE BEEN FILED,ITS THE MANUFACTURING OF THE BOLT WHICH IS TO SMALL,THEY ARE NOT STANDING BY THIS DEFECT,THERE IS NO PERMENANT FIX FOR THIS AND KIA ISN'T WARNING ANYONE OF THIS PROBLEM WHICH COULD LEAD INTO A FATILE ACCIDENT WITH INJURIES AND DEATH.GOING AT A HIGH RATE OF SPEED THERE WOULD BE NO CONTROL EVEN AT SLOW THERE IS NO EASY TURNING THE WHEEL.NOW IM STUCK WITH THIS PROBLEM AND A TEMP FIX WONT FIX IT,SO NOW I HAVE NO VEHICLE OR ANYWAY TO GET ONE,NO WAY TO WORK,NO MONEY TO TEMP FIX IT,THIS IS UNJUST AND THIS VEHICLE SHOULD HAVE NEVER PASSED SPECS TO BE ON THE ROAD.KIA SHOULD STEP UP AND HONOR THERE PRODUCTS,THEY ARE DECEIVING BUYERS AND PUTTING THERE LIFE IN DANGER AND U DON'T KNOW IT TILL IT HAPPENS,I DIDN'T...I WAS TAKING MY DAUGHTER TO SCHOOL I AM THANKFUL I WASN'T ON THE HIGHWAY POSSIBLE RESULTING IN MY FAMILYS LIFE OR SOMEONE ELSE ON THE ROAD,WITH NO CONTROL ALL BECAUSE OF THERE NEGLIGENCE NOT CARING FOR PEOPLES LIFES BUT FOR MONEY,ITS SAD .IF U PULL UP CRANKSHAFT BOLT FOR KIA IT WILL SHOW YOU ALL THE COMPLAINTS AND PROBLEMS AND THIS IS A MANUFACTURING PROBLEM AND A DANGEROUS DEFECT,BECAUSE YOU LOSE CONTROL OF HANDILING OF YOUR VEHICLE.
NHTSA ODI #10810897
31,000 miles · Nov 18, 2014
Service BrakesStructure
TL* THE CONTACT OWNS A 2003 KIA SORENTO. WHILE EXITING THE DRIVEWAY WITH THE BRAKES ENGAGED, THE BRAKES FAILED TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THERE WAS EXCESSIVE CORROSION THAT FRACTURED THE SUBFRAME AND DAMAGED THE BRAKE LINES. AS A RESULT, THE BRAKE LINES NEEDED TO BE REP…
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TL* THE CONTACT OWNS A 2003 KIA SORENTO. WHILE EXITING THE DRIVEWAY WITH THE BRAKES ENGAGED, THE BRAKES FAILED TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THERE WAS EXCESSIVE CORROSION THAT FRACTURED THE SUBFRAME AND DAMAGED THE BRAKE LINES. AS A RESULT, THE BRAKE LINES NEEDED TO BE REPLACED AND THE CENTER SECTION OF THE FRAME NEEDED TO BE CUT AND REPLACED. THE SUBFRAME WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 31,000.
NHTSA ODI #10659047
121,780 miles · Oct 18, 2014
Service BrakesStructure
WHILE THE CAR WAS IN FOR AN OIL CHANGE THE TECH NOTICED A COUPLE OF BRAKE LINES LOOKED WET, WHEN THEY WHERE CHECKING THE LINES THEY NOTICED THE REAR SUB-FRAME WHICH THE LINES WERE CONNECTED TOO WAS TOTALLY RUSTED OUT. THE CAR IS NO LONGER DRIVABLE DUE TO THE FACT THAT THIS SUB-FRAME HOLDS THE REAR DIFFERENTIAL IN PLACE. *TR
NHTSA ODI #10648589
36,000 miles · Sep 22, 2014
Service BrakesSteering
TL* THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THE VEHICLE MADE AN ABNORMAL NOISE WHEN THE BATTERY AND ANOTHER UNKNOWN WARNING LIGHT ILLUMINATED. IN ADDITION, THE CONTACT HAD TO PUMP THE BRAKE PEDAL SEVERAL TIMES BEFORE THE VEHICLE WOULD STOP AND THE POWER STEERING STOP WORKI…
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TL* THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THE VEHICLE MADE AN ABNORMAL NOISE WHEN THE BATTERY AND ANOTHER UNKNOWN WARNING LIGHT ILLUMINATED. IN ADDITION, THE CONTACT HAD TO PUMP THE BRAKE PEDAL SEVERAL TIMES BEFORE THE VEHICLE WOULD STOP AND THE POWER STEERING STOP WORKING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE CRANK SHAFT PULLEY BOLT WAS HOLDING TOO MUCH WEIGHT CAUSING IT TO FRACTURE. THE VEHICLE HAD BEEN REPAIRED BUT THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 36,000.
NHTSA ODI #10638149
140,000 miles · Aug 16, 2014
Air BagsService BrakesSteering
I WAS COMING HOME FROM WORK ONE DAY ,WHEN THE CRANKSHAFT BOLT CAME OUT OF MY CAR .I BARELY MADE IT HOME .BUT THE FRONT END WAS JARRING MY AIRBAG LIGHT CAME ON MY BREAKS LIKE SAME ONE AND I DID NOT HAVE NO CONTROL OF MY STEERING .THEN IT COST ME 1700 .THEN ONE DAY I WAS IN TOWN AND THE CRANKSHAFT BOLT CAME OUT OF MY CAR AGAIN WHI…
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I WAS COMING HOME FROM WORK ONE DAY ,WHEN THE CRANKSHAFT BOLT CAME OUT OF MY CAR .I BARELY MADE IT HOME .BUT THE FRONT END WAS JARRING MY AIRBAG LIGHT CAME ON MY BREAKS LIKE SAME ONE AND I DID NOT HAVE NO CONTROL OF MY STEERING .THEN IT COST ME 1700 .THEN ONE DAY I WAS IN TOWN AND THE CRANKSHAFT BOLT CAME OUT OF MY CAR AGAIN WHICH THIS TIME I DID NOT HAVE NO CONTROL OF THE STEERING IT TOOK EVERY MUSCLE THAT I HAD TO KEEP IT IN THE ROAD THE FRONT AND SHOOK SO BAD IT JARRED EVERYTHING I LOSE MY AIRBAG LIGHT CAME ON MY BRAKE LIGHTS CAME ON SEAT BELT LIGHT CAME ON IT WAS A HAZARDOUS ON THE HIGHWAY SERIOUSLY KILLED ME OR SOMEONE ELSE OR REALLY BADLY HURT THEM.THEN I TOOK IT BACK TO THE MECHANIC AGAIN AND HE SAID WELCOME IT'S GOING TO COST YOU 1700 MORE WHICH I DID NOT HAVE SO I LET THE BANK HAVE IT BACK WHICH NOW IT HAS RUN MY CREDIT BECAUSE I DIDN'T HAVE THE MONEY TO GET IT FIXED AND I LOST MY CREDIT BECAUSE OF THISSO YES THEY NEED TO DO A RECALL ON THE CRANKSHAFT BOLT BEFORE IT DOES KILL SOMEONE IS THAT WHAT THEY'RE WAITING FOR FOR SOMEONE TO DIE BEFORE THEY DO SOMETHING ABOUT.AND I KEEP ON REPLACING BUGS BRAKE LIGHTS HEADLIGHTS AND EVERYTHING THEY KEEP ON BLOWING IN THIS IN THE KIA AND I KEEP ON PUTTING MONEY IN IT FOR ME TO GET IT INSPECTED IT COST ME A HUNDRED SIXTY TWO DOLLARS AND 22 DISH TO REPLACE BULBS THAT I JUST REPLACE NOT EVEN A MONTH BEFORE THAT I HAVE RECEIPTS I AM SO TIRED OF PUTTING MONEY INTO THIS KIA I DIDN'T HAVE NO OTHER CHOICE BUT TO LET THEM TAKE IT BECAUSE IT C AND THE TIRES AT 8 MY TIRES UP AND I PUT NEW TIRES ON WHICH COST ME 800 800 AGAIN TO PUT IN800 AGAIN TO PUT INAND WHEN THIS BIT WHEN THIS HAPPENED I CALLED KIA IN CHARLOTTESVILLE VIRGINIA AND THEY SAID THEY PUT A NEW CRANK BOLT IN AT THE KIDS EMBRACE CHEVROLET BEFORE I BOARDED SO THIS WOULD MAKE THREE TIMES THE CRANKSHAFT BOLT HAD BEEN REPLACED I WANT THIS KIA..................
NHTSA ODI #10625724
173,174 miles · Jul 7, 2013
EngineService BrakesSteering
AS I WAS LEAVING WORK, THE CRANKSHAFT BOLT BROKE,AND THE BOTTOM/PULLEY CAME OUT AND HIT THE ROAD.THANK GOD I WAS STILL IN THE PARKING LOT. I HAD IT TOWED TO A AUTOMOTIVE SHOP TO HAVE IT FIXED IT ,HAS $ 768.45 PLUS 75.00DOLLARS TO TOW IT. I GOT MY 2003-SORENTO BACK ON 06/20/2013 ON 07/06/2013 I WAS GOING DOWN THE HWY ABOU…
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AS I WAS LEAVING WORK, THE CRANKSHAFT BOLT BROKE,AND THE BOTTOM/PULLEY CAME OUT AND HIT THE ROAD.THANK GOD I WAS STILL IN THE PARKING LOT. I HAD IT TOWED TO A AUTOMOTIVE SHOP TO HAVE IT FIXED IT ,HAS $ 768.45 PLUS 75.00DOLLARS TO TOW IT. I GOT MY 2003-SORENTO BACK ON 06/20/2013 ON 07/06/2013 I WAS GOING DOWN THE HWY ABOUT 55MPH. AND THE CRANKSHAFT/BOLT BROKE AGAIN AFTER ONLY HAVING DRIVEN 1,674MILES. I AM A SINGLE MOM OF TWO ,LIVING WEEK TO WEEK AND I CAN,T AFFORD TO FIX IT AGAIN AND IT IS OUR ONLY CAR. IF KIA IS NOT GOING TO FIX THE CRANK/SHAFT BOLT ( IT IS A DEALER ITEM ONLY) AND THEY KEEP BREAKING ,JUST LOOK AT ALL THE REPUTE INCIDENTS,OVER AND OVER, THEN THEY NEED TO BE MADE TO DO A RECALL , I WOULD LIKE TO KNOW IF THEIR IS A CLASS ACTION LAW SUIT ON THIS MATTER. *TR
NHTSA ODI #10523562
69,000 miles · Jul 7, 2012
Service Brakes
DRIVING CAR DOWN ROAD WHEN BRAKES WENT SOFT PULLING INTO MY DRIVEWAY WAS ABLE TO STOP BEFORE BRAKES WENT OUT FULLY. MY SON WAS PRACTICING FOR HIS ROAD TEST. CAR ALSO HAS CONTROL ISSUE DOES NOT FEEL VERY STABLE. FEELS LIKE IT WANT TO TIP OVER. NOISE IN FRONT END DEALER SAID YOU WILL GET USED TO IT. WHEN IT GETS BAD ENOUGH THEY MA…
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DRIVING CAR DOWN ROAD WHEN BRAKES WENT SOFT PULLING INTO MY DRIVEWAY WAS ABLE TO STOP BEFORE BRAKES WENT OUT FULLY. MY SON WAS PRACTICING FOR HIS ROAD TEST. CAR ALSO HAS CONTROL ISSUE DOES NOT FEEL VERY STABLE. FEELS LIKE IT WANT TO TIP OVER. NOISE IN FRONT END DEALER SAID YOU WILL GET USED TO IT. WHEN IT GETS BAD ENOUGH THEY MAY BE ABLE TO FIND IT. BIGGEST PIECE OF JUNK I HAVE EVER OWNED. WOULD NEVER BUY ANOTHER KIA. *TR
NHTSA ODI #10464532
83,525 miles · May 24, 2012
Service Brakes
POWER BRAKE SYSTEM FAILED WHEN ATTEMPTING TO BRAKE WHILE GOING 15 MPH. TOOK VEHICLE TO SERVICE CENTER. THEY REPORTED THAT THE BRAKE LINES HAD RUSTED THROUGH CAUSING TOTAL LOSS OF BRAKE FLUID AND BRAKE SYSTEM FUNCTIONALITY. ONCE THE BRAKE LINE WAS PERFORATED IT COMPLETELY RENDERED ALL BUT THE EMERGENCY BRAKE INOPERABLE. LUCK…
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POWER BRAKE SYSTEM FAILED WHEN ATTEMPTING TO BRAKE WHILE GOING 15 MPH. TOOK VEHICLE TO SERVICE CENTER. THEY REPORTED THAT THE BRAKE LINES HAD RUSTED THROUGH CAUSING TOTAL LOSS OF BRAKE FLUID AND BRAKE SYSTEM FUNCTIONALITY. ONCE THE BRAKE LINE WAS PERFORATED IT COMPLETELY RENDERED ALL BUT THE EMERGENCY BRAKE INOPERABLE. LUCKILY I WAS ABLE TO STOP USING THE EMERGENCY BRAKE BECAUSE OF THE LOW RATE OF SPEED. HAD THIS OCCURRED AT A HIGHER RATE OF SPEED (E.G. 65 MPH) IT COULD HAVE BEEN DISASTROUS. ALL BRAKE LINES HAD TO BE REPLACED AT A COST OF $670. I'VE OWNED MANY VEHICLES IN MY LIFETIME WITH SIMILAR AGE AND MILEAGE, BUT HAVE NEVER HAD BRAKE LINES RUST THROUGH. I LIVE IN A NORTHERN CLIMATE (NY STATE), BUT THIS SHOULD NOT HAPPEN. FRIENDS OF OURS BOUGHT THEIR 2003 KIA SORENTO ONE WEEK AFTER WE DID. THEIR VEHICLE SUFFERED THE EXACT SAME BRAKE LINE RUST THROUGH AS WE DID LAS YEAR, WITH ONLY 40,000 MILES ON THE VEHICLE, SO I'M INTERESTED IN KNOWING WHAT PERCENTAGE OF SAME MAKE/MODEL VEHICLE HAS EXPERIENCED THE SAME FAILURE. *TR
NHTSA ODI #10459524
84,000 miles · May 24, 2012
Service Brakes
TL* THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE EXITING A PARKING LOT AT 10 MPH, THE BRAKES WERE DEPRESSED AND FELT SPONGY. THE VEHICLE FAILED TO RESPOND AND THE CONTACT HAD TO UTILIZE THE PARKING BRAKE TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO ADVISED THE CONTACT THAT THE BRAKE LI…
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TL* THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE EXITING A PARKING LOT AT 10 MPH, THE BRAKES WERE DEPRESSED AND FELT SPONGY. THE VEHICLE FAILED TO RESPOND AND THE CONTACT HAD TO UTILIZE THE PARKING BRAKE TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO ADVISED THE CONTACT THAT THE BRAKE LINES WERE RUSTED AND FRACTURED, CAUSING THE LOSS OF BRAKE PRESSURE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 84,000.
NHTSA ODI #10459519
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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