Kia Sorento fuel pump problems

Filed Nov 4, 2026 · Engine, Fuel system · RI

Severe high-pressure fuel system failure and engine oil fuel dilution creating a fire hazard and engine seizure risk following a corporate engine replacement. On July 15, 2026, my 2016 Kia Sorento (2.4L GDI) received a corporate-covered engine block replacement due to rod bearing failure. On September 30, 2026 (2,332 miles later), the vehicle jerked violently while driving. Inspection revealed the engine oil was heavily diluted with gasoline due to an internal failure of the High-Pressure Fuel Pump (HPFP), creating a fire hazard. The HPFP was replaced out-of-pocket. Kia Corporate Case #26456059 is open regarding this safety issue. A severe safety hazard currently persists. Within 20 days and 176 miles of this fuel pump repair (totaling 2,512 miles on the new block), the vehicle exhibits severe drivability issues and the oil dipstick again smells heavily of gasoline. This fuel dilution compromises oil viscosity, threatening catastrophic engine seizure and creating an active fire hazard. Due to the severity of this fire risk, the Kia Executive Director of Customer Care intervened, ordering an emergency flatbed tow to a different authorized facility. An invoice audit revealed the dealer violated Kia repair protocols, factory TSBs, and federal safety guidelines. Kia’s factory TSB mandates that the high-pressure fuel pipe is a strict, single-use component that must be replaced upon pump removal; however, this part was completely omitted from my invoice, confirming it was dangerously reused. Reusing it introduces a volatile engine-bay fuel leak risk, mirroring the hazardous pattern in the federal safety agency Recall 18V‑907 (Kia Campaign SC172) regarding fuel lines mishandled during engine swaps. Furthermore, the dealer illegally charged retail fees for Service Campaign SC340 materials and withheld all diagnostic trouble codes (DTCs). I request a formal the federal safety agency investigation into unsafe recall compliance and systemic powertrain installation failures originating from the engine replacement.

Filed Oct 20, 2026 · Fuel system · 79,000 miles · CA

The contact owns a 2016 Kia Sorento. The contact stated that while driving at 65 MPH, there was an abnormally strong fuel odor inside the vehicle. The contact stated that while the vehicle was at the dealer for a scheduled service, the contact requested that the dealer inspect the issue. The vehicle was diagnosed with a low-pressure fuel pump failure. The contact was informed that the low-pressure fuel pump needed to be replaced. The vehicle was repaired. The failure mileage was approximately 79,000.

Filed Sep 7, 2026 · Fuel system · CA

Gasoline smell is coming with the left side of vehicle. Gasoline is leaking from the fuel pump causing the gas to puddle creating the gasoline smell.

Filed Aug 27, 2026 · Fuel system · GA

The High Pressure Fuel Pump failed while driving on highway. I took it to the Kia dealership and they told me of the issue. There were no prior warnings of issues Kia recalled all 2019-2020 kia sorentos with this same issue. This component should not have failed at 63k miles and Kia should extend their warranty to previous models with the same High Pressure Fuel Pump problems under The High-Pressure Fuel Pump Warranty Extension (WTY034).

Filed Aug 25, 2026 · Transmission · FL

Vehicle: 2021 Kia SorentoCurrent Mileage: Over 100,000 miles (Original Owner) Description of Safety Defect & Failed Recall Remedy: Background: This vehicle is equipped with the 8-speed Dual-Clutch Transmission (DCT) and has suffered from severe slipping, jerking, and hesitation since delivery (at 5 miles). In 2023, the vehicle received the software update remedy under Kia Safety Recall SC250 (the federal safety agency Campaign 22V760) for the defective electric oil pump circuit board. The Failure: The 2023 software patch failed to resolve the underlying physical safety defect. An independent technician recently diagnosed the vehicle and confirmed a permanent, un-clearable fault code for a completely failed electric transmission oil pump—the exact physical component failure targeted by safety recall SC250. This defect causes an immediate risk of a sudden loss of motive power. The Dealership Violation: The vehicle was dropped off at Greenway Kia West Orlando on Monday, August 17, 2026. The dealership held the car for over a week, logging it under a separate fuel pump recall to stall. On August 25, 2026, the dealership formally denied safety recall coverage and issued a $7,000 out-of-pocket quote to replace the transmission, claiming the vehicle is no longer covered because it is past the 100,000-mile powertrain warranty. Federal Mandate Violation: Under federal law, safety recalls do not have mileage caps. The manufacturer's remedy failed to permanently correct a documented safety hazard, and the dealership is actively attempting to shift a multi-thousand-dollar safety recall replacement cost onto the consumer.

Filed Aug 18, 2026 · Engine · NC

My 2020 Kia Sorento stalled and shut off while driving and eventually stopped working completely, requiring it to be towed to a Kia dealership. The dealership first replaced the starter and then the high-pressure fuel pump, but the vehicle still would not operate. After further diagnosis, I was informed that the timing chain had failed/broken and the engine needed to be replaced, with a new engine quoted at approximately $12,000. I am concerned that this type of sudden engine failure and shutdown could create a serious safety hazard, especially if it occurs while driving in traffic or at highway speeds. I am requesting that the federal safety agency document and review this incident for similar failures involving 2020 Kia Sorento vehicles.

Filed Jun 29, 2026 · Fuel system · AZ

To Whom It May Concern, I am writing to formally dispute a repair charge and report unacceptable service at Courtesy Kia (Mesa, AZ) regarding my vehicle. Timeline of Events: June 12, 2026: I brought my vehicle to Courtesy Kia for a mandatory software recall. Prior to this appointment, my fuel gauge worked perfectly. Immediately upon picking up the vehicle, the fuel gauge ceased to function. After calling customer service, I brought the vehicle back for inspection. The dealership kept my car for three days. Despite the issue being caused during their previous service, I was denied a loaner vehicle, forcing to come to take the car and use it during the weekend or I can wait until Monday 29 until the service manager back but I asked them I can’t use the car with this error as it’s not safe for me and my kids and that should be fixed by them since that’s their mistake and unfortunately I’ve had paid out-of-pocket for my family's transportation. June 26, 2026 (Diagnostic): The service department initially claimed the issue was a broken fuel pump and quoted me $1,210. I informed them this was impossible, as the fuel pump was completely replaced just 3 months ago. I requested to speak to the service manager, but was told he was unavailable until Monday. And the gentleman Michael who was taking care of my car said let me speak with the technician and back to me again with different quote The diagnosis was suddenly changed to a "fuel sending unit and gasket," with a new quote of $546?? But if I want I can wait until Monday to check with service manager. June 29, 2026: After receiving no follow-up call, I contacted the dealership myself. I spoke with Service Manager Shane Hackelton, who refused to take responsibility for the damage caused during the recall service and insisting that not related to recall software and should be fixed by myself. I look forward to your prompt response and a resolution to this matter.

Filed Jun 14, 2026 · Fuel system · TX · fire

On June 6, 2026, while driving home, the vehicle suddenly began smelling strongly of gasoline and burnt rubber. Within seconds, thick black smoke became visible in the side mirrors, followed immediately by white smoke pouring from the front hood and into the passenger cabin through the air vents. ​As I attempted to pull over to safety, the vehicle completely stopped responding. The brakes failed to operate, the engine stalled, and the steering wheel locked completely. We were barely able to bring the vehicle to a stop. Immediately upon exiting, visible flames erupted from underneath the driver's side of the vehicle and out of the front hood. The engine compartment and motor burnt completely.The safety of the driver and front passenger was put at extreme risk of death or severe injury. Because the brakes and steering locked up simultaneously while the cabin filled with smoke, we almost lost the ability to safely exit a moving vehicle that was actively catching fire. Furthermore, at no moment prior to or during the failure did any warning lamps, check engine lights, or diagnostic messages illuminate on the dashboard. There was absolutely zero advance warning from the vehicle's safety systems.The fire originated from a catastrophic fuel system failure, specifically matching the known issues of the high-pressure fuel pump leak.The vehicle is a total loss and is currently located at a tow yard. It is fully available for inspection upon request.Local police responded to the scene and generated an incident log number. A corporate claim has been opened directly with KIA but as of today, no inspector from the manufacturer or insurance has been sent out.

Filed Jun 10, 2026 · Acceleration, Engine · AZ

2022 Kia Sorento failed to increase speed when accelerator was depressed , engine RPMs increased, but no subsequent speed increase. The Amber ISG light was flashing, with no other warning lights. The car was driven to a safe pull out, placed in park, turned off and restarted, no flashing light. The car accelerated satisfactorily afterwards. This has happened several times in the last two years. Both fuel pumps were replaced as well as the battery and computer systems were reset and the problem still intermittently persists. This is a significant safety issue if the car cannot properly accelerate when required to merge into traffic and properly maintain designated speed. Was told that Kia engineering said this maybe a heat related issue, the car is operated mainly the the southwestern US, Phoenix, Az metropolitan area.

Filed Jun 7, 2026 · Engine, Fuel system · IA

My high pressure fuel pump is spraying fuel in my engine. This is a new engine replacement as of October 2024. This is a huge fire risk and we cannot operate this vehicle.