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Hi, I've recently bought a 2004 Kia Sorento manual dieselXS, quite a bargain due to the high Mileage (120k) or so I thought. It ran fine for a week or so then like an idiot Iran out of diesel. after filling up & being shown how to prime the engine I was on my way, I had the fuel filter changed shortly after. But ever since It periodically cuts out, usually when i accellerate, and most recently when I tried to tow my caravan. I got no more than 500 yards. Other than that I love the car, Any Ideas?
 

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Hi Bailey


Check the fuel filter - If its not a genuine KIA filter you can get the symptons that you describe



Welcome to the forum btw

Edited by: UncleMart
 

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hi

remove fuel sender unit in fuel tank there a small filter in there that gets blocked by foreign stuff also that paint of the inside of the tank if it had petrol in it over its life just clean it out but if your not sure take to garage because you have to pull the sender unit apart a good way to check to see if this is the problem check the prime pump on top of the filter with the car running it will suck the pump down but only on really bad cases not all do it hope this helps
 

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Hi we have a 2006 deisel auto and have similar problems whilst towing and driving normally. After having Kia replace the fuel filter and the engine coolant sensors it turns out it is due to flaking paint from inside the fuel tank. So the quote to replacethe tankand and other parts is £1000+ (and of course its out of warranty).


Looking at other web sites, this appears to be a common fault, especially on US web sites. So appears to be a manufacturing issue. We have had the car since new, never added petrol or additives in error and only done 32k miles, so not what I would expect from a car of this age.

But we think we have a friday afternoon car as the transfer box has been replaced, rear differentials and the power stearing rack. It is making us think twice about upgrading to another KiA but they do tow really well.
 

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Hi
     Ive had the same problems as you, 7 times. Mine is a 55 plate, been into the garage and told that the lining on the fuel tank is coming away. This is not caused by putting the wrong fuel into the tank, it is a common problem!!!This inturn is blocking the filter located under rear pasanger seat in the fuel tank. You will need a philips screw driver and a 8mm socket to remove it from the tank. Give it a good clean and replace the fuel filter in the engine bay. It's not a hard job to do if you are diy minded..This will stop the problem for a couple of years!!! My garage wanted £1100 to replace the tank. This is a common problem!!!!!
 

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Discussion Starter #6
Thanks to everyone for all of the advice. It's currently in a local garage the've run diagnostics on it and nothing shows, typically it's been fine whilst they've tested it. They are about to try towing a Caravan to see if they can replicate the problem. will let you know the results.
 

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Discussion Starter #7
Had the call from the garage Saturday and the bad news is the ECU needs replacing!! Waiting for a price to repair. I've been warned that it will be V expensive, not such a bargain after all!!!
 

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Get a second opinion before spending out on an ECU -
I dont see how running out of diesel will upset an ECU in that way....

Ask for the diagnostic report that points at the ECU -

Sorry sounds like you are about to be mugged by some one having a guess ..... (just my nasty suspicious mind)
 

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Discussion Starter #9
I understand your suspicious mind looks like I bought a dud from a dodgy garage, but I don't think the garage that are looking at my carare about to rip me off they are a specialist diagnostics garage . after sending the ECU out to be tested the fault couldn't be found. so back to the drawing board. I now think I didn't run out of diesel, the engine just cut out no juddering or anything, it just cut out on me in the same way it has since
 

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Hi Bailey
My 2004 XS suffered a simular thing but very intermittantly

It would happen on fairly hard accelleration complete loss of power engine cut out and engine management light on. I found by turning off the egnition, removing the key, Lock and unlock the car then it would restart but with eml still on and drive normally, the eml wouild then reset itself following a period of being parked up locked and secure. I was told it could be the ECU or a fuel / air sensor. Whole thing was cured by replaceing the fuel filter with a engine KIA part and been fine ever since.
 

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high all i had same problem cleaned fuel sender unit runs fine now do not be cheated by garages i was quote between 500 and 1000 euros as i was in spain at time work took me 1 hour to do take your time and it is a easy job to do your self roger 1
 

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Hi, I am having same problem withmy kia Sept 2004 XS model. It has now gone back into the garage having been in once to have the diesel filter changed. Kia have told me there is a pressure problem and they have had to contact Kia about it - we are going away soon and tow a caravan so I don`t want it happening then! will let you know how I get on. Otherwise am very happy with car. Hendy
 

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try cleaning filter in diesel tank you have to take out sender unit under back seat not big job it cured my car and also a mate of mine good luck
 

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Discussion Starter #14
Hi Thanks everyone for your replies.
It's finally Sorted, a little costly but it's now the car I thought I'd bought. The problem was down to a worn seal on the fuel pump allowing oil to get in to it. I had that repaired and it's been fine ever since.
 

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Hi Roger, I had taken my car back to the garage but after three days in there and still no answers they told me they wanted to check the fuel tank and that would cost me £400 so I have fetched it and am going to have a go at checking the fuel sender unit myself. They said they had followed Kia`s instructions on procedures to follow but hadn`t even looked at the sender unit - they didn`t even want to consider that but wanted to check the fuel tank due to possibility of lining peeling. Anyway, I will have a look myself and see how I get on and what happens. Wish me luck! We are away soon towing the caravan so I want to get it sorted. Hendy
 

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Hi,

I notice you are in Newbury so local to basingstoke can you advise which Garage assisted you with the problem! KIA in Basingstoke are as much use as a choclate fire guard! I have encoutered similar problems to those descrived in this thread HOWEVER mine has only done it during the 24/48hours after towing its then fine for weeks at a time


Many Thanks
Clair
 

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Clair and Members...This is prob the correct fix; ECU...HA HA..I doubt it guys



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There is no "filter" as such in the fuel tank but what there is is a gauze mesh over the pick up on the lift pump. Sometimes, particularly it would seem on the early Sorento models, this gets clogged with a grey coloured material which seems to appear in the tank. This can restrict the amount of fuel going to the engine and give the dreaded cut out under acceleration and in some cases a low fuel pressure code being stored and the Engine Management Light on the dash coming on. Definitely worth checking out if any of these things happen to your Sorento.

Some basic Instructions and a few pictures on how to check:

When the rear O/S seat is lifted there is a small piece of carpet which when lifted up gives you an access panel to the fuel tank. If you unscrew the 4 screws this is what you see.



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If you then unclip the diesel lift and return pipes and disconnect the electrical plug, then unscrew the 6 screws and gently lift out the fuel pickup unit this is what you get. Do this when you have very little diesel in the tank and make sure to keep a towel or cloth across the carpet to protect any damage from dripping as you lift the unit out of the car



<CENTER>
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And then when all this is done this is what it looks like. The float which gives the fuel guage reading is the black plastic bit at the front of the cylinder. The unit can be taken apart by unfastening the plastic clips on it and the gauze filter and pipes then cleaned in a bowl of parrafin, petrol or similar.



<CENTER>
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As they say in all the good Japanese guides refitting is a reversal of removal!
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Taff
 

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54 plate sorento same problems new filter fitted in tank £250 by kia done 2 miles cut out again returned to kia new tank required linning inside tank flakeing blocking filter again another £800 been perfect ever since common problem
 
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