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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.

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When problems were reported

Mileage at the reported incident

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 reports
123,000 miles · May 8, 2015
Engine

I PURCHASED THIS CAR BRAND NEW FROM STEVENS KIA IN PATCHOGUE, NY AND HAD THEM REPLACE THE TIMING BELT @ 58K MILES AS PER THEIR GUIDE LINES. WHILE DRIVING THE CAR I LOST MY POWER STEERING AND ELECTRICAL CHARGING SYSTEM, I WAS GOING AROUND 45MPH, I LOST CONTROL OF THE CAR AND WAS ABLE TO GET IT ON THE SIDE OF THE ROAD WITHO…

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I PURCHASED THIS CAR BRAND NEW FROM STEVENS KIA IN PATCHOGUE, NY AND HAD THEM REPLACE THE TIMING BELT @ 58K MILES AS PER THEIR GUIDE LINES. WHILE DRIVING THE CAR I LOST MY POWER STEERING AND ELECTRICAL CHARGING SYSTEM, I WAS GOING AROUND 45MPH, I LOST CONTROL OF THE CAR AND WAS ABLE TO GET IT ON THE SIDE OF THE ROAD WITHOUT ANY DAMAGE TO THE CAR OR ANYTHING ELSE. I CALLED CORPORATE KIA AND EXPLAINED THE PROBLEM AND WAS TOLD THE CAR IS OUT OF WARRANTY.(IT HAS 123K MILES ON IT). THEY TOLD ME IF I WANTED I COULD HAVE IT TOWED TO A KIA DEALER AND THEY WOULD LOOK AT IT FOR A DIAGNOSIS FEE, BUT IT WAS STILL OUT OF WARRANTY AND THEY ALSO TOLD ME MY VIN# DIDN'T FALL INTO THE RECALL THEY HAD CONCERNING THAT ISSUE. I HAD MY MECHANIC LOOK AT IT AND HE TOLD ME THE CRANKSHAFT DOWEL PIN SNAPPED ON THE TIMING GEAR CAUSING THE HARMONIC BALANCER TO FALL OFF THUS TAKING ALL THE BELTS WITH IT. IT COSTED ME OVER $2,000 TO HAVE THE CAR REPAIRED. AFTER DOING A GOGGLE SEARCH IT SEEMS THIS IS A COMMON PROBLEM WITH THESE CARS AND IS BEING IGNORED BY CORPORATE KIA. *TR

NHTSA ODI #10715387

209,000 miles · Feb 24, 2015
Fuel/propulsion System

TL*THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS AND WITH THE FUEL TANK GAUGE AT 3/4 OR BELOW, THE VEHICLE BEGAN TO SPUTTER AND VIBRATE BEFORE STALLING. THE CONTACT INDICATED THAT THE FUEL TANK NEEDED TO BE AT LEAST 75 PERCENT FULL TO PREVENT THE FAILURE FROM OCCURRING. THE VEHICLE …

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TL*THE CONTACT OWNS A 2003 KIA SORENTO. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS AND WITH THE FUEL TANK GAUGE AT 3/4 OR BELOW, THE VEHICLE BEGAN TO SPUTTER AND VIBRATE BEFORE STALLING. THE CONTACT INDICATED THAT THE FUEL TANK NEEDED TO BE AT LEAST 75 PERCENT FULL TO PREVENT THE FAILURE FROM OCCURRING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO WAS UNABLE TO DIAGNOSE THE CAUSE OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 209,000.

NHTSA ODI #10690328

124,797 miles · Feb 1, 2015
Engine And Engine Cooling

THE CRANK BOLT BROKE JULY 23, 2013. THE SECOND TIME WAS, THE CRANK BOLT AGAIN AND IT BROKE DECEMBER 19, 2014. THE ODOMETER WAS AT 133181 FOR THE SECOND BOLT BREAK. *TR

NHTSA ODI #10680375

135,000 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

1,470,000 miles · Dec 24, 2014
Structure

APPROX. A WEEK PRIOR HEARD A NOISE LIKE SOMETHING WAS LOOSE AND BEATING UNDERNEATH THE CAR ONLY AT TIMES. TOOK IT TO LOCAL GARAGE AND PUT IT ON RACK AND THE MECHANIC HAD ME TO COME LOOK FOR MYSELF. MY HEART DROPPED. THE FRAME IS SHOT. IT'S EAT UP. HE ASKED ME IF THERE WAS A RECALL ON THIS CAR? AND AS FAR AS I KNOW THERE ISN'T, B…

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APPROX. A WEEK PRIOR HEARD A NOISE LIKE SOMETHING WAS LOOSE AND BEATING UNDERNEATH THE CAR ONLY AT TIMES. TOOK IT TO LOCAL GARAGE AND PUT IT ON RACK AND THE MECHANIC HAD ME TO COME LOOK FOR MYSELF. MY HEART DROPPED. THE FRAME IS SHOT. IT'S EAT UP. HE ASKED ME IF THERE WAS A RECALL ON THIS CAR? AND AS FAR AS I KNOW THERE ISN'T, BUT FOR SURE, SHOULD BE. THIS IS VERY DANGEROUS. ONE BIG BUMP AND THE WHOLE THING IS GONE. YOU CAN TOUCH IT AND THE METAL FLAKES OFF. THIS CAR RUNS SO GOOD AND STILL IS A GOOD LOOKING CAR. HAS ALWAYS BEEN IN A GARAGE NEVER LEFT OUT IN THE WEATHER. THE MECHANIC TOLD ME THEY DON'T MAKE CARS LIKE THEY USED TOO. MY ANSWER WAS MAYBE SO, BUT THIS IS WHAT GETS PEOPLE KILLED, I AM A PERSON THAT WHEN SOMETHING I KNOW IS NOT RIGHT OR HEAR A NOISE I KNOW THAT SHOULDN'T BE THAT WAY!! I GET IT CHECKED OUT. NOW SOME PEOPLE DON'T THAT'S WHY THERE'S SO MANY PEOPLE KILLED ON THE ROADS DUE TO DEFECTS ON CARS THEY PAID THOUSANDS OF DOLLARS FOR. I NEED HELP!! WHAT DO I DO NOW? I'M AFRAID TO DRIVE IT TO MAILBOX AND BACK. *TR

NHTSA ODI #10668196

114,000 miles · Dec 10, 2014
Fuel/propulsion System

I BOUGHT MY KIA SORENTO 2003 IN NOVEMBER 2013. IN JANUARY OF THE FOLLOWING YEAR I NOTICED A GAS SMELL. I LOOKED UNDER THE VEHICLE AND FOUND A FEW DRIPS ON THE GROUND UNDERNEATH, WHICH WAS GAS. I HAD THE LINE UNDER THE CAB ALONG SIDE DOOR REPLACED. I AM NOTICING A STRONG GAS SMELL COMING FROM THE SIDE TOWARD FRONT AND CAN'T SE…

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I BOUGHT MY KIA SORENTO 2003 IN NOVEMBER 2013. IN JANUARY OF THE FOLLOWING YEAR I NOTICED A GAS SMELL. I LOOKED UNDER THE VEHICLE AND FOUND A FEW DRIPS ON THE GROUND UNDERNEATH, WHICH WAS GAS. I HAD THE LINE UNDER THE CAB ALONG SIDE DOOR REPLACED. I AM NOTICING A STRONG GAS SMELL COMING FROM THE SIDE TOWARD FRONT AND CAN'T SEE ANYTHING LEAKING. I SAW THAT THERE WAS A RECALL FOR THIS YEAR AND MAKE SO I CALLED KIA AND ASKED THEM IS MY VEHICLE COVERED UNDER THE RECALL AND THEY SAID NO AFTER GIVING THEM MY VIN NUMBER. I SEE THAT ITS NOT JUST THE 2003 VEHICLES WITH THIS ISSUE. JUST BECAUSE I DON'T HAVE THE RIGHT VIN NUMBER THEY SHOULD STILL HONOR MY COMPLAINT. REGARDLESS I'M STILL HAVING THE SAME FUEL ISSUES AS THE ONES ON RECALL. *TR

NHTSA ODI #10663495

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

137,000 miles · Oct 3, 2014
Fuel/propulsion System

WHEN FUELING THE VEHICLE THE GAS PUMP AUTOMATICALLY SHUTS OFF CONSTANTLY. THE TANK CAN BE EMPTY AND THE PUMP WILL SHUT OFF AS SOON AS YOU START FILLING IT AND CONTINUE TO DO SO AS YOU FILL IT. IT WILL ALSO SPIT GAS OUT OF THE TANK WHILE YOU ARE FILLING IT. THERE SHOULD BE PLENTY OF ROOM FOR GAS AS THE GAS INDICATOR SHOWS EMPTY B…

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WHEN FUELING THE VEHICLE THE GAS PUMP AUTOMATICALLY SHUTS OFF CONSTANTLY. THE TANK CAN BE EMPTY AND THE PUMP WILL SHUT OFF AS SOON AS YOU START FILLING IT AND CONTINUE TO DO SO AS YOU FILL IT. IT WILL ALSO SPIT GAS OUT OF THE TANK WHILE YOU ARE FILLING IT. THERE SHOULD BE PLENTY OF ROOM FOR GAS AS THE GAS INDICATOR SHOWS EMPTY BUT EVEN AFTER PUTTING ONE GALLON IN THE TANK, THE PUMP WILL SHUT OFF AND/OR GAS WILL SPILL/SPLASH OUT. I HAVE TO STAND BACK WHEN FILLING THE TANK SO THAT I DON'T GET IT ALL OVER ME. THE DATE LISTED FOR INCIDENT IS WHEN IT FIRST STARTED HAPPENING BUT IT CONTINUES TO DO SO EVERY TIME I PUT GAS IN THE VEHICLE. *TR

NHTSA ODI #10641275

Official recalls

1

05V353000 · 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

1

PE10023 · 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.

Go deeper into Kia Sorento problems