Illustration2003 KIA SORENTO. CONSUMER STATES SEVERAL PROBLEMS WITH VEHICLE *TGW THE CONSUMER STATED ON TWO OCCASIONS, THE PIN THAT HELD THE CRANKSHAFT TOGETHER BROKE LOOSE. THE CRANKSHAFT SENSOR LOCATED BEHIND THE TIMING BELT FAILED. *JB
2003 Kia Sorento
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2003 Kia Sorento do not stand out strongly from the model-year median of 242.
About this comparison →How this year compares
Owner complaints by model year
Compare all Sorento years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
350–25K
3725–50K
5050–75K
4275–100K
57100–150K
22150K+
243 reports with mileage · 62 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine And Engine Cooling. Review the 81 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel System, Gasoline. Review the 41 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
10 crash reports3 fire reports8 injury reports
What owners actually said
305 reportsTL*THE CONTACT OWNS A 2003 KIA SORENTO. THE ENGINE CRANKSHAFT BOLT FAILED IN AUGUST OF 2008. THE DEALER REPLACED THE ENGINE CRANKSHAFT BOLT FOUR TIMES. THE REPAIRS DIDN'T CORRECT THE FAILURE. THE MANUFACTURER STATED THAT THE CONTINUOUS FAILURES WERE DEALER ERROR, AND THEY WOULD NOT ASSIST WITH THE REPAIR. THE VEHICLE HAD NOT BE…
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TL*THE CONTACT OWNS A 2003 KIA SORENTO. THE ENGINE CRANKSHAFT BOLT FAILED IN AUGUST OF 2008. THE DEALER REPLACED THE ENGINE CRANKSHAFT BOLT FOUR TIMES. THE REPAIRS DIDN'T CORRECT THE FAILURE. THE MANUFACTURER STATED THAT THE CONTINUOUS FAILURES WERE DEALER ERROR, AND THEY WOULD NOT ASSIST WITH THE REPAIR. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 111,404 AND THE CURRENT MILEAGE WAS 118,000.
WHEN FUELING THE VEHICLE FUEL HAS BEEN SPRAYING BACK OUT OF THE FUEL FILLER NECK IF THE FUEL IS PUMPED AT A NORMAL RATE. THIS HAS OCCURRED SINCE WELL BEFORE THE 1ST INCIDENT DATE. THE ONLY WAY TO KEEP THE FUEL FROM SPRAYING OUT IS TO PUMP THE FUEL VERY SLOWLY AND STOP. FUEL WOULD SPRAY ALL OVER ME, MY WIFE AND THE VEHICLE. W…
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WHEN FUELING THE VEHICLE FUEL HAS BEEN SPRAYING BACK OUT OF THE FUEL FILLER NECK IF THE FUEL IS PUMPED AT A NORMAL RATE. THIS HAS OCCURRED SINCE WELL BEFORE THE 1ST INCIDENT DATE. THE ONLY WAY TO KEEP THE FUEL FROM SPRAYING OUT IS TO PUMP THE FUEL VERY SLOWLY AND STOP. FUEL WOULD SPRAY ALL OVER ME, MY WIFE AND THE VEHICLE. WHILE TRAVELING ON THE INTERSTATE AND THE FUEL GAUGE REGISTERS 3/4 FULL AND WHEN THE VEHICLE IS GOING UPHILL THE VEHICLE RPM'S WILL DROP, THE THROTTLE BECOMES UNRESPONSIVE AND THE VEHICLE LOSSES SPEED. THE VEHICLE WILL RECOVER AFTER REACHING LEVEL GROUND. THE VEHICLE WAS TAKEN TO KIA AND NO PROBLEMS WERE FOUND. AGAIN WHILE TRAVELING FOR THE HOLIDAYS ON 11/24/10 AND 11/28/10 THIS INCIDENT OCCURRED AGAIN WHEN THE FUEL GAUGE REGISTERED 3/4 FULL AND IN HEAVY TRAFFIC ON I-65 ALMOST CAUSING VEHICLES TO RUN OVER ME DUE TO MY SPEED DROPPING ABRUPTLY. I REACHED THE NEAREST FUEL STATION AND FILLED THE TANK UP. THIS DOES NOT HAPPEN WHEN THE VEHICLE IS ABOVE 3/4 FULL. THIS DOES NOT HAPPEN WHILE DRIVING AROUND TOWN. THE PROBLEM WITH FUELING THE VEHICLE IS ALL THE TIME.
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
TL*THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT THE FUEL TANK WAS DISPENSING THE GASOLINE BACK OUT TOWARDS HER AS SHE ADDED GASOLINE. WHEN THE CONTACT ENTERED THE VEHICLE THE FUEL GAUGE READS FULL WHEN IT WAS NOT COMPLETELY FULL. THE DEALER WAS CONTACTED AND INFORMED HER THAT THERE WERE NO RECALLS IN REFERENCE TO…
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TL*THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT THE FUEL TANK WAS DISPENSING THE GASOLINE BACK OUT TOWARDS HER AS SHE ADDED GASOLINE. WHEN THE CONTACT ENTERED THE VEHICLE THE FUEL GAUGE READS FULL WHEN IT WAS NOT COMPLETELY FULL. THE DEALER WAS CONTACTED AND INFORMED HER THAT THERE WERE NO RECALLS IN REFERENCE TO THE FUEL SYSTEM. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 107,500.
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
THE WARNING LIGHT FOR THE SRS SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) KEEPS GOING OFF WENT OUT OF FACTORY WARRANTY AT 80,000 MILES IT STARTED AROUND 80, 800 DEALER WOULD NOT COVER REPAIRS. LIGHT IS NOW CONSTANT AND WHEN I WAS SEARCHING THE INTERNET FOUND SAME COMPLAINTS WITH THE SRS. *TR
CRANKSHAFT PULLEY BOLT FAILED. BROUGHT TO DEALER FOR REPAIR. BOLT WAS PART OF NHTSA RECALL. DEALER STATED THEY NEEDED TO REPLACE CRANKSHAFT AS WELL. DEALER RETURNED VEHICLE W/O REPLACING CRANKSHAFT. 15 MONTHS LATER THE SAME BOLT FAILED. TOOK TO AN INDEPENDENT REPAIR SHOP, THEY EXPLAINED THE CRANKSHAFT NEEDED TO BE REPLACED…
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CRANKSHAFT PULLEY BOLT FAILED. BROUGHT TO DEALER FOR REPAIR. BOLT WAS PART OF NHTSA RECALL. DEALER STATED THEY NEEDED TO REPLACE CRANKSHAFT AS WELL. DEALER RETURNED VEHICLE W/O REPLACING CRANKSHAFT. 15 MONTHS LATER THE SAME BOLT FAILED. TOOK TO AN INDEPENDENT REPAIR SHOP, THEY EXPLAINED THE CRANKSHAFT NEEDED TO BE REPLACED. TOOK BACK TO THE DEALER, THEY REPLACED BOLT AND DIDN'T REPLACE CRANKSHAFT. ON 9/13/10 THE BOLT FAILED AGAIN, INDEPENDENT REPAIR SHOP, AND A DIFFERENT DEALER VERIFIED THE NEED FOR CRANKSHAFT TO BE REPLACE. CONTACTED KIA OF AMERICA, AND CASEY KIA WITH NO SIGN OF RESOLUTION. *TR
I HAVE A 2003 KIA SORENTO AND LAST YEAR IT STARTED TO SPRAY GAS OUT AT ME EVERYTIME I WENT TO FILL IT UP. I TOOK IT IN TO HAVE IT CHECKED AND THEY COULDN'T FIND ANYTHING. MY KIA IS STILL DOING THIS AND I AM GETTING TIRED OF GETTING SPRAYED WITH GAS EVERYTIME I TRY TO PUT GAS IN THE THING. IT NEEDS FIXED AND KIA SHOULD BE HELD RE…
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I HAVE A 2003 KIA SORENTO AND LAST YEAR IT STARTED TO SPRAY GAS OUT AT ME EVERYTIME I WENT TO FILL IT UP. I TOOK IT IN TO HAVE IT CHECKED AND THEY COULDN'T FIND ANYTHING. MY KIA IS STILL DOING THIS AND I AM GETTING TIRED OF GETTING SPRAYED WITH GAS EVERYTIME I TRY TO PUT GAS IN THE THING. IT NEEDS FIXED AND KIA SHOULD BE HELD RESPONSIBLE FOR THIS. THIS IS A HAZARD AND SOMEBODY WILL EVENTUALLY GET HURT. PLEASE HELP ME WITH THIS SITUATION. *TR
TL*THE CONTACT OWNS A 2003 KIA SORENTO. UPON ENTERING THE VEHICLE THE DRIVER COULD SMELL AN ODOR OF GASOLINE. UPON EXAMINATION GASOLINE COULD BE SEEN LEAKING FROM UNDERNEATH THE VEHICLE ON THE REAR PASSENGER SIDE. THE MANUFACTURER WAS NOTIFIED AND SHE WAS INFORMED THAT THE VEHICLE HAD PREVIOUSLY BEEN REPAIRED FOR THE RECALL A…
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TL*THE CONTACT OWNS A 2003 KIA SORENTO. UPON ENTERING THE VEHICLE THE DRIVER COULD SMELL AN ODOR OF GASOLINE. UPON EXAMINATION GASOLINE COULD BE SEEN LEAKING FROM UNDERNEATH THE VEHICLE ON THE REAR PASSENGER SIDE. THE MANUFACTURER WAS NOTIFIED AND SHE WAS INFORMED THAT THE VEHICLE HAD PREVIOUSLY BEEN REPAIRED FOR THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 05V353000, FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS. THE VEHICLE WAS THEN TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 104,000.
Official recalls
105V353000 · Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
Aug 4, 2005
CERTAIN SPORT UTILITY VEHICLES MAY EXPERIENCE A FUEL LEAK FROM FUEL TUBES NEAR THE FUEL TANK DUE TO AN INTERFERENCE FIT WITH THE VEHICLE FLOOR PANEL.
Consequence & remedy
Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE A SECTION OF THE FUEL LINE. THE RECALL BEGAN ON OCTOBER 10, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
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.