Investigations
Fuel Spill During Refueling
NHTSA Preliminary Evaluation PE10023 — closed, opened 2010-07-12 and involving the KIA SORENTO.
NHTSA investigation PE10023 is a Preliminary Evaluation opened on 2010-07-12 and currently closed. The subject of record is KIA SORENTO, which places this file inside the Office of Defects Investigation queue for KIA. Latest activity on this investigation was logged on 2011-12-21 — NHTSA updates that field whenever an Information Request goes out, a supplement is filed, or a status change is recorded in the public docket.
A Preliminary Evaluation like PE10023 is the entry point of the federal defect-investigation process. NHTSA engineers scan complaint databases, field reports, and manufacturer data to decide whether an Engineering Analysis is warranted, whether a voluntary recall is already sufficient, or whether the pattern does not rise to a defect finding.
Investigators summarized the matter as follows: "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 sp..." Investigations are the early-warning layer of the federal auto-safety system, sitting upstream of formal recalls and defect orders. Whether this one closes without action or escalates into an Engineering Analysis, the full history stays in the ODI archive so researchers, litigators, and buyers can pull the paper trail at any time. Related KIA files, listed below, give context on whether this is an isolated concern or part of a broader pattern across the brand.
Investigation Summary
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
About This Investigation Type
A Preliminary Evaluation (PE) is the first phase of NHTSA's investigation process. It is opened when the agency identifies a potential safety defect pattern, usually triggered by consumer complaints, manufacturer reports, or field monitoring. During a PE, NHTSA gathers information to determine whether a formal engineering analysis is warranted.
Other KIA Investigations
Kia 25V099 Piston Oil Ring Recall Effectiveness
Windshield Wiper Failure
3.3L Engine Loss of Motive Power (LOMP)
Loss of Motive Power
Vehicle Rollaway
Data from NHTSA Office of Defects Investigation. Cross-references: NHTSA recall campaign API and NHTSA FARS where fatality records overlap. PlainCars does not rate or recommend vehicles. Learn more.
Read our methodology — how this data is sourced, computed, and verified.