Kia Sorento (2003 – 2009) Review

Incidences of dual mass flywheel and clutch failures increasing markedly by 2009.

Seems to be a problem with 18" wheels on some XT models leading to slip sensor trouble and the wrong messages to the transfer box.

Manual transmission problems increasingly common after around 4 years and around 80k miles, particularly when used for towing.

On LPG gas converted 3.5V6s, after around 6 years, manifold swirl actuators can break off and get tangled in the valves.

Beware of misdiagnosis of faults by Kia dealers: The symptoms were very rough running after the first start of the day which cleared after the first 100yds and a flat spot when accelerating from a standing start. The flat spot had got so bad that pulling out from a side road was becoming risky. Kia dealer had the car for 10 days and diagnosed “suspected faulty fuel injectors”. Two solutions; have the injectors cleaned at a cost of £1,010 or fit new injectors at a cost of £1,500. A diesel injection specialist diagnosed the problems as a stuck EGR valve which he cleaned and put back, and the starting problems as failed glow plugs of which he replaced all four. He took out the injectors and confirmed there was nothing wrong with them. The car then runs as well as it had when new.

A 2005 2.5CRDI XT auto, purchased 'ex demo' in January 2006, had the following series of fuel system problems over 4 months: November 2007: engine cut out. Diagnosed as faulty fuel filter and replaced. December 2007: engine cut out again. Diagnosed as three faulty injectors. January 2008: engine cut out again: Diagnosed as lining/coating of fuel tank detaching and being carried through the fuel systemsystem. Kia technical authorised replacement of fuel tank, fuel sender and new fuel filter. February 2008: engine cut out. Scan fault analysis flags up P1188.

One reader suffered repeated fuel shut downs from a 2004 XE CRDI. The fuel filter was replaced several times but the shut down continued, always on hard acceleration joining a motorway. Might be the fuel tank liner coming off, might be the fuel tank sender pump or its relay or the earth to the pump or the relay.

By January 2011 it was reported that the fuel tank delamination problem was becoming more widespread. Kia will pay for the replacement tank fitted at a Kia dealer, but not the labour costs. In June 2011 it was reported that Kia will no longer pay for replacement fuel tanks, at least not for 6 year old vehicles.

4WD system cannot tolerate more than 2mm tread difference front to back, so best to swap tyres front to back mid-life to even out wear.

20-1-2013: Glowplugs prone to breaking on attempts to remove to replace. Then requires removal of cylinder head to get them out.

1-6-2013: Reader thinks there is a problem with rusting rear trailing arm brackets. Thinks that around 10% on 2003-2009 Sorentos have corroded sufficiently to require urgent replacement. Kia has issued a TSB to inspect these and replace as necessary, but, of course, TSBs only find cars and owners known to KIA dealers. He feels the key question is how soon after an MoT can these brackets rot away. Within 12 months big problem? More than 12 months not so safety critical.

25-4-2014: Self-levelling rear dampers weeping fluid on 2007 KIA Sorento. Reader quoted £1,000 to replace.

15-5-2015: Timing chain failure reported on 2008 KIA Sorento 2.5 automatic regularly used for towing a caravan.

2-9-2015: Engine of 2009 i800 (same 2,497cc engine as Sorento 1) suffered piston through block at 35,000 miles and less than 6 years old. Full service history. Car registered 9/2009. Engine number D4CB 8414626. pparently chain cam driven oil pump failed.

6-8-2016: 91,000 mile 2006 KIA Sorento reported to be smoking while towing. Suspect turbo bearing oil seals.

12-2-2017: Report that MoT 'rolling road' brake testing of a 2007 KIA Sorento "damaged a bearing in the differential" leaving a £2,500 repair bill. (Probably the centre diff.) Should only be brake tested on a rolling road suitable for 4x4s.

8-6-2017: Another report of fuel tank delamination in a first generation Sorento.

December 2004: Two safety related issues affecting a total of 4,650 Sorentos. 3,500 owners being contacted regarding the possibility of the alternator pulley seizing and causing the alternator drive belt to be displaced. This can resullt in increased steering and braking effort being required. Pulley to be replaced at no cost to the customer. No recorded instances of the alternator pulley seizing on vehicles in the UK. 1,152 Sorento automatic owners being contacted for their automatic transmissions to be replaced because a retaining ring inside the transmission may come loose. Although no instances in UK customers, Kia is taking the action because it would be possible for a vehicle to roll forward whilst in reverse gear. Automatic transmissions being replaced free of charge. If not contacted, call KIA helpline: 0118 945 8545 0118 945 8545 .

1,561 examples of 2006 Facelift Sorento recalled in April 2007 to rectify a wiring problem. The wiring to the Airbag Control Unit has been transposed on right hand drive vehicles built between May 4 2006 and March 28 2007. This would result in the incorrect deployment of the Side Curtain Airbags in the event of a collision. No other airbags in any of the vehicles are affected by this recall and all would operate normally in the event of a collision. There are no reported cases of this occurring in the UK. Owners of the affected vehicles will be notified by Kia as soon as possible and asked to contact their local Kia dealer for remedial work to be carried out free of charge.

8-11-2011: Consumer Reports explains that both the National Highway Traffic Safety Administration (NHTSA) and Kia Motors have announced a recall of over 10,600 Kia Sorento sport utility automobiles. This recall addresses incorrect programming which may actually deactivate adult riders' front passenger airbag. These SUVs were manufactured from June 15, 2006 to November 27, 2007.

Consumer Reports goes on to explain that this issue affects the "Occupant Classification System (OCS) installed in 2007 and 2008 model year Sorento SUVs manufactured from June 2006 through September 2007." This safety system deactivates the airbag if a baby seat or child is in the front passenger seat, as an airbag deployment could be dangerous to anyone who is not the proper size and weight.

However, Consumer Reports explains that this faulty programming could also keep the passenger airbag from deploying during a crash, even if a heavier adult is sitting in the front seat. However, the recall notice does explain that the "passenger airbag off" warning light which is on the Sorento's dashboard will indicate to drivers and passengers that the deactivation has taken place.