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 2002 Kia Sportage owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl contact owns a 2002 Kia Sportage. While driving at approximately 50 MPH, the fan blade blew into pieces. He replaced the power steering reservoir, antifreeze reserve tank, all three serpentine belts, air intake, and the intake hose himself, to correct the failure. He then received a recall notice (NHTSA campaign id number: 07V161000, engine and engine cooling: cooling system: fan) and petitioned for reimbursement with the manufacturer. The dealer advised he would not be considered for reimbursement until he took his vehicle to an authorized dealer to have the recall repair performed. He soon noticed the smell of burning antifreeze circulating throughout the cabin of the vehicle and the engine became unusually warm. The dealer replaced the fan belt under the recall campaign and was denied reimbursement. After repairs, he continued to smell burning antifreeze. …
Tl contact owns a 2002 Kia Sportage. The vehicle was under recall regarding the engine fan. While driving approximately 45 MPH, the vehicle burst into flames. The fire began when the engine overheated, which caused the fan to crack and strike the radiator. The heat also caused the head of the valves to warp. The fan was previously replaced. This failure has occurred twice. The recall number that was referenced was unknown. The current and failure mileages were 66,000.
When the vehicle was hit while parked the bumper was destroyed the airbags did not deploy. The tune signals do not work, the fuses blow eveytime they are replaced, the hazzard signal blows all the fuses, there is a recall on before this year and some after, but not this one. Gas fumes inside the vehicle, no dealer in our community can find the problem. Shifter is stuck in park, the by pass key works but it will not shift without it.
Vehicle caught on fire within the engine compartment on three separate occasions while driving 45 MPH or more. Consumer extinguished the fires. After the last incident vehicle was taken to the dealer, who informed consumer that the cause was due to oil dripping onto the manifold. Manufacturer was also notified.
I have a 2002 Kia Sportage it has 80,000 miles on it and I was driving it came up on a red light and the clutch wouldn't disengage the pedal would go down but the clutch wouldn't release so I drove through a red light with no ability to stop there was alot of cars coming and they barely missed t-boning me there where kids also playing on the side walk I had to shut the engine of and coast to a stop the gear shift wouldn't come out of gear as long as the engine was turning over. It will start and run all day as long as its in neutral. I had to have the vehicle towed and it has sat for two years now ( I deployed for 15 months that's why its sat so long) I replaced the slave and master cylinder and it hasn't changed anything I was in a parts store and heard another guy talking about his 2002 Sportage it done the same thing and he rear ended someone totaling it. …
There is a very strong raw gas smell that fills the cabin and outside the vehicle. It is very noticeable upon starting and when the vehicle is at rest and running. Fuel tank leaking. Seam areas and fuel pump/sending unit area due to corrosion and vehicle. The vehicle was parked, and I had a hard time starting it. Then when I tried to drive it, all I could do is smell raw gas.------------------------ I have replaced the fuel tank, fuel pump assembly, any and all parts attached to fuel tank. (very expensive). On researching the problem, I have found that there are many other owners complaining of this problem. I have owned this vehicle since February 2011, I have not been in any accidents since buying this vehicle. In fact, upon learning of mechanical issues I try to have them fixed as soon as possible. (however, I was given an orange title. …
Our 2002 Kia Sportage was due for a new timing belt so we had it replaced, subsequently a couple of months later we received notification that there was a recall on the fan blade and had it replaced. Approximately 5 weeks later the fan blade came off and went through the radiator and the engine seized up, so we had it towed to the dealership. Their assessment was that it wasn't their fault but that the fan clutch let go, which is attached to the fan blade, and they claimed that they hadn't touched the fan clutch when they replaced the blade. After talking to the service personnel and asking about the procedure to replace the blade I was finally told, "it was done by magic". Contacted the Kia representative who said he'd look into it, but to date have never heard from him, only the dealership who wanted me to get the car off their lot. …
I mirror odi id number 10010713 - failure date March 17, 2003 almost to a "t"!he differences are...I have been back to service department at least 10 times for the same repair. Now 31,000 miles. I have been offered a rental once. Service manager and shop foreman have driven car themselves to make sure repair is OK. Fine for a day or so, then happens again! So...never really OK! This vehicle is unsafe with this unresolvable (to date) problem. My wife and 4 year child have been passengers alone (and with me in the vehicle) when this happens. The last time an 18 wheeler was running up her back when this happened. Very life threatening. Kia manufacturer's response has initially been "I'm sorry." we can only offer to repair the problem. 10 times is more than sufficient to fix a problem. I want a new vehicle or to take the car back and 'wash' the entire loan to $0.00. …
Heat shield broke away, muffler affected and needs replacement due to heat shield. My mom contacted the Kia dealership in reno, nv regarding the issue. The person she spoke with stated my car was under warranty, but since (while I was traveling and in ca and the rattle got so bad I had a licensed mechanic wire it together) he says it is now not covered under warranty. My mom asked the guy at the dealership who she should contact, such as, Kia motor America, as a possible assembly line issue. He stated to her (and she has a complaint for filed out as well through NHTSA today) "the dealership." my concern is a safety issue and concerns over a "dealership" turning in safety issues to the proper authority, let alone my car should have been fixed regardless of who touched it as I was traveling out of state. …
The left front rotors were defective. This was discovered during vehicle inspection. The vehicle was serviced at least twenty times for other defects. No service for the brakes. There was a short in the wiring in the shock arms, a problem with the catalytic converter, rattling in the exhaust system, license plate lights were inoperative due to rotted sockets, wheel bearings were extremely loose, pulling to the right, the right rear power window was inoperative, check engine light had come on possibly due to a small leak or a loose gas cap, transmission hang up when cold, bad front brakes, crack in dash, cup holder was broken, tailpipe rusted and fell off, when the heater and defrost was on the A/C would come on, the consumer would get shock when exiting the vehicle, intermittently both rear window would not go up or down, and the left rear window was totally inoperative. …
Related recalls
Engine and engine cooling › Cooling system › Fan
On certain vehicles, the heat generated by the engine causes repeated bending deformation of the polypropylene cooling fan including its retaining ring, which stresses the polypropylene thereby initiating cracking of the blades.
Remedy: Dealers will replace the engine cooling fan with a fan made of improved material. The recall began on June 11, 2007. Owners May contact Kia at 1-800-333-4542.
NHTSA investigations
Fan blade cracking/separation
The investigation of engine cooling fans in the subject vehicles was opened on September 21, 2006 as pe06-042.the basis for opening was 10 consumer reports alleging fan blade cracking and blade separation.six of the reports indicated the separated fan blades caused damage to other engine compartment components.Kia has provided additional consumer reports and information in its response to pe06-042.the investigation…
Fan blade cracking/separation
Kia motors America, inc. (Kia) has identified a defect in the plastic engine cooling fan in the subject vehicles and will conduct a safety recall.Kia's defect report states, ...heat generated by the engine causes repeated bending deformation of the polypropylene cooling fan...initiating cracks in the fan.the centrifugal forces generated by the rotation of the blades can cause the cracks to propagate until complete…
Engine complaints in other Sportage years
Frequently asked questions
How common are engine problems on the 2002 Kia Sportage?
NHTSA has 71 complaints about the engine & cooling of the 2002 Kia Sportage, 30% of the model year's 234 complaints. The component named most often is cooling system › fan (22 mentions).
Is there a recall for 2002 Kia Sportage engine problems?
Yes — NHTSA recall 07V-161 (fan, Apr 16, 2007). Recall repairs are free at authorized dealers.
At what mileage do 2002 Kia Sportage engine problems start?
Half of the complaints with a recorded mileage happened before about 66,000 miles, and 17% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 3 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.