Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Kia Sorento owners, lightly cleaned up (personal details are redacted by NHTSA).
I attempted to fill my 2003 Kia soento ex and after pumpming about $2.75 worth of gas, the fuel began to spit back up through the filler hose and spurted/ gush back out on to me. It gives you a false sense that the tank is full but it's not. I attempted to re-fuel and again, the gas spurt/ gush back out. I could get no more than $5.00 dollars in the car. I spoke with the Kia dealership in lithonia, georgia and they told me that they have never heard of such a matter. I was instructed to bring the vehicle back. However, I began to research this matter and it was investigated by you all. Kia did state that they would look into the matter. I'm not confident that will happen. There are thousands of complaints out there among consumers about this same vehicle between the 2003 through 2006. Please investigate! I do believe that this is a recall item. …
I have fuel still spitting out of the fuel tank, even after the supposed tank air filter replacement by bill Dodge Kia, saco, me. I can only trickle fuel in the vehicle without it spitting back out on me and the ground. I have already had a bad rash due to fuel spilling on me with shorts on last summer. The vehicle is not repaired as stated. I refuse to start trying to just throw money at it and not knowing if it will fix the problem or not. I seen a lot of other complaints even after the tank air filter replacement, the EVAP system should not be located under the vehicle to begin with, due to moisture getting into the air filter then the charcoal canister and everything else. I have also replaced the closed valve which is located before the tank air filter to no avail this vehicle is a health and fire hazard period !
The 2003 Kia Sorento has a problem with extensive frame rusting, to the point where some owners have had the suspension detach from the frame. One owner in particular has had issues with the gas tank needing to be replaced, and Kia motors refuses to do anything about the problem. They built the car, sold it to people, and when consumers have complaints about their vehicle, they (Kia) says that they're not responsible. You need to examine this, because people could get killed by operating an unsafe vehicle. Do something about this now, before it becomes the next pinto. Make Kia fix the [redacted] vehicles now!!! Parts of this document have been redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 U.S.c. 552(b)(6).
Tl* the contact owns a 2003 Kia Sorento. The contact stated that the fuel was not going into the fuel tank properly upon refueling the vehicle and there was a clicking noise as if it were full. The contact had to take an extended period of time to ensure the fuel tank was actually full. The vehicle was taken to the dealer and they did not diagnose the failure. The vehicle was to be taken to an independent mechanic to diagnose the failure. The vehicle was not included in NHTSA campaign number: 05V353000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 113,000.
Tl contact owns a 2003 Kia Sorento. The contact stated that while driving at various speeds and with the fuel tank gauge at 3/4 or below, the vehicle began to sputter and vibrate before stalling. The contact indicated that the fuel tank needed to be at least 75 percent full to prevent the failure from occurring. The vehicle was taken to an independent mechanic, who was unable to diagnose the cause of the failure. The manufacturer was notified of the failure. The failure mileage was 209,000.
While fueling up the Sorento, the fuel spit out every time even while fueling at slow speeds. Very frustrating , and dangerous, especially when the fuel gets on my skin & clothes, the vehicle, and at times leaves a huge puddle on the ground which could be a fire hazard. The dealership was contacted and will not help me even though there was a recall issued for the fuel filter, which I mentioned.
Tl* the contact owns a 2003 Kia Sorento. While driving at an unknown speed, the vehicle decelerated and stalled without warning. The vehicle was able to restart. In addition, when the contact inserted fuel in the vehicle, fuel spewed out the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 116,000.
After purchasing car from private seller I discovered that when trying to pump gas, my fuel sprays back out all over myself, my vehicle, and the ground. Have even had it spray into my eyes. Did research and saw that this is a very common occurrence for this year/make/model. I believe its a fire and safety hazard and should have been recalled years ago!
Tl* the contact owns a 2003 Kia Sorento. While refueling, fuel spewed back out of the filler neck without warning. The contact mentioned that fuel splashed all over the floor and his clothes. The vehicle was not taken to the dealer. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was 102,000.
When I pump gas into my car, the fuel spits back out at me. I have to pump real slow for this not to happen. This is dangerous, gas gets on my hands and car,I have to carry soap and water to wash this off of my car. I called about this and was told because my car VIN # was not on the their list there was nothing they could do for me
Related recalls
Fuel system, gasoline › Delivery › Hoses, lines/piping, and fittings
Certain sport utility vehicles May experience a fuel leak from fuel tubes near the fuel tank due to an interference fit with the vehicle floor panel.
Remedy: Dealers will replace a section of the fuel line. The recall began on October 10, 2005. Owners May contact Kia at 1-800-333-4542.
NHTSA investigations
Fuel Spill During Refueling
Complaints allege that while refueling the vehicle, fuel can spill out or spit back from the fuel filler port on model year (MY) 2003 Kia Sorento vehicles (subject vehicles).Consumers report that the spilled fuel can splash on the person fueling the vehicle, or on the side of the vehicle and the ground.The subject vehicles are equipped with an evaporative emissions control system that, among other things, manages…
Fuel System complaints in other Sorento years
Frequently asked questions
How common are fuel system problems on the 2003 Kia Sorento?
NHTSA has 77 complaints about the fuel & propulsion system of the 2003 Kia Sorento, 25% of the model year's 305 complaints. The component named most often is storage › tank assembly (3 mentions).
Is there a recall for 2003 Kia Sorento fuel system problems?
Yes — NHTSA recall 05V-353 (hoses, lines/piping, and fittings, Aug 4, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2003 Kia Sorento fuel system problems start?
Half of the complaints with a recorded mileage happened before about 95,000 miles, and 10% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 0 fires and 3 injuries to fuel & propulsion system 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.