Engine cutting out. Any Ideas?

My wife's 03 plate model has started cutting out this last week when under load.

I suspect it may be the tank - I will follow the instructions on this thread and have a look tomorrow, but is there a chance Kia will replace the tank on mine despite it being so old?

Edited by Emeye - 05 Nov 2016 at 4:45pm

grumpycrdi wrote: They have been replacing them regardless of age. Dont know for how much longer

So, I took our 2003 Kia apart today and, along with covering myself with diesel, I confirmed my suspicions. The filter in the sender unit was completely coated and the bottom of the unit was full of the grey gunk. I could see inside the tank that the paint was coming away.

For now I have cleaned it all up and tomorrow I will find the Kia customer service number and see what they can do.

Thanks again to everyone on this great forum! 😀

Following intermittent engine dying my 06 Sorento had the tank replaced at Kia's expense. Unfortunately the engine still died under load especially when towing.  After £500 worth of diagnostics suggested by Kia technical (but not at their expense) a high pressure fuel pump was diagnosed as the problem and a new one fitted again at Kia's expense.  Unfortunately the Kia garage road tested and for the 1st time they experienced the same problem.  (previously it had happened mostly with a caravan being towed and the garage had not been able to replicate the fault).  Back to Kia technical for more ideas.  The injectors showed no problems.  The garage have now replace the fuel filter housing and all seems to be well.  They have road tested 3 times and are road testing again tomorrow to be sure before returning to me.  I won't be happy until I have done a long journey towing the caravan but fingers crossed. The Kia garage in Thetford have been very good and have had the car since early October trying to solve the problem.

To the best of my knowledge all genuine parts have been used.  I don't know what the issue was with the filter housing but can only guess it was a hairline crack allowing air in under pressure.