Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Kia Sorento owners, lightly cleaned up (personal details are redacted by NHTSA).
Oct, 2016 - I am the orignal owner of the vehicle and had maintained regular maintainence on the vehicle. I had just put $700 of new tires on vehicle and had a routine oil change and fluid check before we left for our vacation. I never had any issues with the vehicle and I still own. The vehicle does not run but I wanted to know what started the fire. My daughter and I were headed out of town for a week, about 200 miles into the commute the front of the vehicle began to smoke from under the hood, we were traveling at 55-60 MPH. As I was exiting the 421 highway flames began coming out from around hood and the paint on the hood began to bubble up due to heat. I immediately called the fire dept, as I was driving, pulled onto the shoulder and immediately removed my daughter and our belongings from the vehicle and distanced ourselves from the vehicle. …
Tl* the contact owns a 2004 Kia Sorento. Within less than 30 days of owning the vehicle, the contact stated that the fuel gauge on the instrument cluster continued to indicate full whether the contact refueled the vehicle or not. Also, when the air conditioner was turned off, smoke emitted into the interior of the vehicle and under the hood. The contact exited the vehicle and lifted the hood to fan away the smoke. The contact drove the vehicle to her job. Another consumer called the fire department because the vehicle erupted into flames. The fire department extinguished the flames. Neither a fire nor a police report was filed. The approximate failure mileage was 107,000. The manufacturer was notified of the failure.
I bought my 04 Sorento from my aunt who was the only owner. It had a power steering issue at that time which took several attenpts to fix. About a month later we we visiting family and had to turn around. Upon stopping we noticed smoke from the engine compartment so I grabbed my 4 y/o daughter out of the car and by boyfriend opened the hood to find a small fire on opposite side fro where battery is. Once fire was put out we drove .5 miles on a city rd to family. The power steering was gone at that time as well. 10/13/19 - the directional worked all day and come night time when I came out from the store and started vehicle they did not work. The next day they worked finehowever, on 10/14/19 - I started the car in am and there was a squeaky belt. I hit the gas pedal quickly and noise went away. …
I was driving approximately 35-40 MPH and my car suddenly lost power with all the dash lights briefly coming on (battery, oil, etc.). Fortunately I was close to a side street and was able to make a hard turn and coast to the curb. I waited a minute and was able to restart the vehicle. I drove home and there was one more incident when the car started to lose power (lights dimmed) however I pushed on the gas and it powered up again. I have had the lights dim and the car seemingly lose power several times. Just prior to this the car typically hesitates when you are going full speed and then the dimming occurs. I've had my car idle at stop signs and at train crossings and have not experienced any power loss. It always seems to happen while driving 35-40 MPH or more. I've had it happen while driving 60-70 MPH on the highway. …
On Monday, 06-30-08, at about 1400 hours, I parked my vehicle a 2004 Kia sorrento 4x4 ex with approx. 80,000 plus miles. Shortly after parking this vehicle I entered a baskin and robins to have an ice cream cone. I was informed by frantic passerby's that a vehicle was on fire. I took a look outside and was shocked to see that my vehicle mentioned above was smoking and flaming up. This fire appeared to start on the passenger side of my vehicle near the power steering pump and alternator. My vehicle had been operating fine until this incident occurred and only went to the dealership for routine servicing under warranty. The honolulu police and fire departments were notified and reports documented under honolulu police department report #08-242969 and the honolulu fire department report #24891. …
Was driving down the road at 55 power steering went car lost power lights went crazy car shut down. I almost wrecked harmonic balancer fell into pieces all pulley belts and pin have to be replaced. I just got this car I have a payment on it. Going to cost 1200 to fix. This is on top of it sputtering and spottying. Replace head lights the radio glitches the air bag light is on all the time and if u turn the interior dash lights up it turns the interior lights on.over drive button does not work and transmission lags... I have read al these complaints over and over again why isn't anyone forcing a recall? These are serious issues I almost got rear ended and the electrical problem could cause fire.... Someone is going to end up very hurt if Kia is not forced to fix these. Could u imagine this happening on a thru way?
Picked up vehicle after having rear support bearings repaired driving back home at 65mph on I-35/texas 410 east started to experience strong smell of exhaust fumes in passenger compartment. During drive home started to rain, activated wipers, drivers side wiper blade fell off during rainstorm had to open driver side window to navigate! Upon arrival at home noticed, smoke coming from engine compartment (passengers side) and smoke underneath vehicle from catalytic converter. Looked underneath vehicle and catalytic converter, was smoking, inside engine compartment a hose at the rear of the engine compartment (sorry not a mechanic) had a hole in it and was smoking also? Vehicle has not been driven since 12/7/12, vehicle was purchased 10/4/12, has limited warranty.
Tl contact owns a 2004 Kia Sorento. While driving 65 MPH she could smell something burning. The vehicle was pulled over and turned off. There was smoke coming from under the hood. The check engine warning indicator light was illuminated. There was fluid leaking under the vehicle and catching fire as it hit the ground. The vehicle burst into flames within 5 minutes. The fire department extinguished the fire. The vehicle was towed to a tow yard, the cause of the failure was undetermined. The current and failure mileages were 60,000.
Fan relay sensor is faulty. All the electrical system is is questionable, from headlights always needing replacement to dash lights that turn on or off at any given time. My newest issue is with the heater, it will only blow warmed air if the motor is being rev'd..temp is warm on engine but if I am driving down hill, it will feel like air conditioner instead. For a few months my driver side door would open from inside only. Magically it has resolved that one and only issue...
Tl* the contact owns a 2004 Kia Sorento. The contact noticed smoke and flames underneath the vehicle. The fire department extinguished the fire. There were no injuries. The vehicle was not diagnosed or repaired. The failure mileage was 161,000.
Electrical complaints in other Sorento years
Frequently asked questions
How common are electrical problems on the 2004 Kia Sorento?
NHTSA has 28 complaints about the electrical system of the 2004 Kia Sorento, 13% of the model year's 220 complaints. The component named most often is 12v/24v/48v battery (2 mentions).
Is there a recall for 2004 Kia Sorento electrical problems?
No. NHTSA lists no electrical system recall for the 2004 Kia Sorento. 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 Sorento electrical problems start?
Half of the complaints with a recorded mileage happened before about 100,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 7 fires and 0 injuries to electrical 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.