Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Kia Sedona owners, lightly cleaned up (personal details are redacted by NHTSA).
In [redacted], my 2004 Kia Sedona caught fire shortly after I arrived at work in [redacted]. My [redacted] daughter was with me because she was sick. After parking, I removed her from the back seat and went inside the salon. Minutes later, I returned and saw smoke coming from the engine. Within seconds, the front of the vehicle caught fire. The vehicle was parked near a building, and the fire and smoke spread toward the building. The fire department responded and made a report. The vehicle was completely disabled and later sold to a salvage yard because I could not drive or transport it. My insurance did not cover the fire because I did not have fire coverage. I am especially concerned because my daughter had been inside the vehicle moments before the fire. Fortunately, I removed her before the fire started. I later contacted Kia America, which opened Case No. …
Tl* the contact owns a 2004 Kia Sedona. While stationary, the front end of the vehicle erupted into flames. The contact stated that the fire originated from the engine compartment. A police report was not filed. The fire was extinguished by the fire department. There were no injuries sustained. The manufacturer was not made aware of the fire. The failure mileage was 110,000.
Tl* the contact owned a 2004 Kia Sedona. The contact stated that the vehicle caught fire. The fire department extinguished the fire. The vehicle was destroyed and towed to a tow yard. The contact mentioned that the cause of the fire was unknown. The dealer and manufacturer were not contacted. The approximate failure mileage was 100,100.
My 2004 Kia Sedona was sitting stationary in my driveway engine was off. When something in the engine compartment caught fire causing extensive damage to engine parts on the top side of the engine. Such be as fluid reservoirs wiring, fuse box, and more.
Tl* the contact owns a 2004 Kia Sedona. The contact stated that the vehicle caught on fire from under the hood while driving an unknown speed. The contact was able to move off the roadway and called the fire department, who extinguished the fire. A fire report was filed of the incident. The vehicle was deemed as destroyed by the contact's insurance agency. The failure and current mileages were 135,000.
This van has brake problems squeaking and wearing out pads way too fast. I was told nothing is wrong with the brake system but when taking it to a brake shop I was told the calipers are bad, Kia has not fixed them and denies that they're bad. The check engine light came on and I was told that a spark plug had misfired, that was fixed under warranty and then another spark plug misfired and was fixed under warranty. The oil level was getting low but I had no leak and I was told that the oil filter was simply loose so they said they fixed it. I asked if I should bring the van back in a week to have the oil level checked and we were assured there was no leak. Check engine light came on again and the oil light flickered, did not stay illuminated, so we took it to the dealership immediately, as the owners manual and the mechanic had stated. …
I own a 2004 Kia Sedona 3.5l that I purchased on 08-31-2010 with 53638 miles on it. On 01-25-2011 as I was driving I heard a rattling from the engine compartment. I stopped to open the hood and confirm that it was coming from the engine, it was. I drove to the nearest auto mechanic and had it diagnosed to be told that I had a blown engine and it would have to be replaced. I had it towed to he local Kia dealership to be looked at further. The engine was opened up to be inspected. I was told that the #6 cylinder was coming apart and that I would have to replace the engine. The van currently ha only 59430 miles on it. It is under the 60000 mile warranty mark but over the 5 year portion. …
Oil leaks - 2004 Kia sorento. Compliant form does not allow me to select sorento as vehicle model when completing this form. Dealer replaced oil plug gasket twice. Been in for oil leak complaints 4 times. Last time there jan 05, 2005 dealer service says problem is oil filter leaking because of defective oil filter design. Dealer service says Kia in process of re-design of filter. When new oil filters available dealer says unknown. Find this explanation of problem to be unbelievable. Don't believe 2004 engine different from 2003 engine in this vehicle. When last in dealer service another customer was in for same type of problem; oil leaks in 2004 sorento. Was in multiple times for a solution. Used to have sorento 2003 and never had leaking oil, Kia replaced my 2003 with a 2004 sorento because of major problems with 2003. Engine oil leaking was not one of the problems with 2003. …
2004 Kia sorento leaks oil. Four times in for service, latest time January 5, 2005. Twice dealer replaced oil plug gasket. Last time in dealer service dept says problem is caused by defective designed oil filters. Dealer goes on to say Kia aware of problem and going to redesign oil filter. Dealer does not know when new filter is going to be available. In mean time my 2004 sorento continues to leak oil. Fumes from oil burning on hot engine causing me headaches and nausea. Don't believe dealer explanation. Used to have a 2003 sorento which Kia replaced because of major engine problems. Now the replacement vehicle (2004 sorento) has oil leaking problems that are unresolved by dealer. Going to take in again because fumes so strong it makes it undriveable except as a last resort. Believe engine in 2003 sorento is same type engine in 2004 sorento. Oil leaking in the 2003 wasn't an issue. …
Tl contact owns a 2004 Kia Sedona. While driving at speeds of 70 MPH the vehicle would continuously make a jerking motion and stall without warning; however, the problem would occur intermittently. The vehicle was taken to the dealer where they could not duplicate the failures and released the vehicle back to the owner. The vehicle continued to stall intermittently without warning. The vehicle was taken back to the dealer a second time and again they could not duplicate the failure. He then took the vehicle to an independent mechanic who also could not determine the cause of the failure. On the third attempt, a specialist at the dealership stated that the emissions sensor and the throttle valve were replaced; however, the failure persisted. There were no additional repairs performed and there were no recalls on the vehicle. …
Engine complaints in other Sedona years
Frequently asked questions
How common are engine problems on the 2004 Kia Sedona?
NHTSA has 35 complaints about the engine & cooling of the 2004 Kia Sedona, 16% of the model year's 213 complaints. The component named most often is engine (8 mentions).
Is there a recall for 2004 Kia Sedona engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Kia Sedona, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Kia Sedona engine problems start?
Half of the complaints with a recorded mileage happened before about 59,000 miles, and 30% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 5 fires and 0 injuries to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.