Intermittent not starting issue

BENKRIDGES

MEMBER
2004 KIA SORENTO
V6
2WD
AUTOMATIC
245,000 MILES

Car wouldn't start with several attempts.
Finally started and ran after 4-5 attempts.
Drove to store, as we were almost there the engine died, we coasted the rest of way to our destination.
Did our business, went out, car started right up and made it home, which was only like 2 miles. Tried this morning it started 1st time. To scared it will stop and not make it back home.
It has never ever done this before?
Bought it used sept 2019. Previous owner said he just put a fuel pump in it.
Is it possible it is malfunctioning and going out?
Or is there an in line fuel filter between tank. An engine needing replaced?

Also when I fill tank up it doesn't take gas fast at all.
It took it fine when I 1st bought it.
6 mths after I bought it.
Now you have to fill very very slow, or it spews back out all over the car and ground.
Puzzled!
Seems to take an eternity to fill it up.

Thanks

1 Reply

JACOBANDNICKOLAS

MECHANIC
109,747 POSTS

Hi,

I suspect there is an issue with the fuel tank air filter. Over time, the filter gets dirty and prevents air from entering the fuel tank. If there is no air movement, fuel struggles to enter or exit the fuel tank.

I found a technical service bulletin (TSB) on this problem. It includes the directions for replacement. Before you do this, contact a dealer and see if it was made into a recall. I honestly can't remember if it was a recall or simply a TSB.

Here is the TSB. The pics attached below correlate with the directions.

________________________________________

2004 Kia Truck Sorento V6-3.5L
Campaign - Fuel Tank Air Filter Replacement
Vehicle Powertrain Management Fuel Delivery and Air Induction Fuel Tank Fuel Tank Vent Technical Service Bulletins Recalls and Campaigns Campaign - Fuel Tank Air Filter Replacement
CAMPAIGN - FUEL TANK AIR FILTER REPLACEMENT
NUMBER: SC092

GROUP: Service Campaign

DATE: January 2012

MODEL: 2003/2004 Sorento (BL)

SUBJECT: FUEL TANK AIR FILTER REPLACEMENT (SC092)

This Bulletin provides the procedure to replace the Fuel Tank Air Filter in 2003-2004MY Kia Sorento vehicles. Over time, the fuel tank air filter accumulates dirt, which can restrict airflow. If the fuel tank air filter is not replaced during regular maintenance the restriction of airflow will eventually reach the point where the vehicle may experience fueling difficulties. Kia is also providing an owner's manual insert for the 2003-2004MY Kia Sorento identifying that at a minimum the fuel tank air filter is to be replaced every 30,000 miles.

Pic 1

NOTICE:
All vehicles potentially subject to this campaign should be verified to be not completed. WebDCS> Warranty Coverage> Warranty Coverage Inquiry> Check Open Campaign Status.

NOTICE:
To assure complete customer satisfaction, always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service>Warranty Coverage>Warranty Coverage Inquiry) for a list of any additional campaigns that may need to be performed on the vehicle before returning it to the customer.

Service Procedure:

1. Turn off the engine.

Raise vehicle up on a lift.

Pic 2

Locate the fuel tank air filter (A).

B: Canister housing assembly
C: Fuel tank

pic 3

2. Move clamp away from hose end, and disconnect the air hose (D) from the fuel tank air filter as shown in the photo.

Pic 4

3. Remove wiring mounting clips (E) from canister assembly.

Pic 5

4. Remove the six (6) mounting nuts (F) that retain the canister assembly.

NOTICE:
Support the canister as necessary. Do NOT let the canister hang from the wiring harness or evaporative hoses.

Pic 6

5. Push the canister assembly upward to remove the threaded studs (G) from bracket (H) as indicated in the photo on the right; then pull the canister assembly downward.

Pic 7

6. Lower canister assembly and mounting bracket enough to separate the bracket from the canister assembly and fuel tank filter.

Pic 8

7. Disconnect the wire harness connector from the CCV and necessary hoses.

Pic 9

8. Remove the CC (Carbon Canister) and Fuel Tank Air Filter assembly. Remove the Fuel Tank Air filter by pulling straight up from the base of the filter.

NOTICE:
Ensure to properly align the filter with the CC before pressing into position.

Pic 10

9. Install new Fuel Tank Air Filter and re-install the evaporative hoses and clamps in reverse order of removal. Re-install the canister/CCV and filter into the retaining bracket. Connect the electrical connector to the canister close valve - then install the canister assembly to the vehicle. Torque the fasteners to 84 inch lbs (10-12 Nm).

Pic 11

AFFECTED VEHICLE PRODUCTION RANGE

pic 12

REQUIRED PART

pic 13

WARRANTY CLAIM INFORMATION

NOTICE:
To assure complete customer satisfaction, always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service>Warranty Coverage>Warranty Coverage Inquiry) for a list of any additional campaigns that may need to be performed on the vehicle before returning it to the customer.

__________________________________-

I hope this helps. Let me know if you have other questions and if this takes care of the problem.

Take care and God Bless,

Joe

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