Recalls: Kia BL Sorento
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Kia BL Sorento
2006 Kia BL Sorento: stop lamp switch
In October 2009, a recall was issued for a single Kia BL Sorento model that was manufactured between September 2006 and October 2006 due to a design flaw that could prevent the stop lamp switch from operating correctly (PRA 2009/11127). This could cause:
- the brake lights not to illuminate when the pedal was depressed;
- the brake lights to remain illuminated when the pedal was released;
- an inability to move the shifter from the ‘Park’ position;
- the electronic stability control (ESC) light may illuminate, indicating ‘ESC OFF’; and,
- the brake may not deactivate the cruise control system.
2005-09 Kia BL Sorento: short circuit in Hydraulic Electronic Control Unit (HECU)
In March 2020, a recall was issued for Kia BL Sorento vehicles that were available for sale from 1 December 2005. The Hydraulic Electronic Control Unit (HECU) – which was responsible for the Anti-lock Braking System, Electronic Stability Control System and Traction Control System – could remain live even when the vehicle was switched off. Furthermore, an electrical short circuit could occur if moisture entered the HECU. If a short circuit occurred, this could result in an engine compartment fire when the key was switched off – this increased the risk of injury to vehicle occupants and other road users. For the VINs of the recalled vehicles, please see PRA 2020/18212.
Problems and faults: Kia BL Sorento
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
Kia BL Sorento V6: head gasket leak
In January 2004, Kia Motors issued service bulletin 015 for Kia BL Sorento vehicles that were manufactured from 27 October 2003 to 24 November 2003. In these vehicles, cylinder block damage near cylinder #6 may cause a head gasket leak and one or more of the following symptoms:
- Poor running or hard start;
- Excessive white smoke and/or coolant smell from the exhaust; and,
- Misfire diagnostic trouble codes (DTCs).
Kia BL Sorento 3.5L V6: throttle position sensor
In August 2007, Kia Motors issued service bulletin 072 for Kia BL Sorento vehicles that were manufactured from 30 June 2002 to 28 January 2004. In these vehicles, the crankshaft pulley bolt may become loose, especially if it was incorrectly torqued during a routing service, and may be noticed by a rattling noise from the crankshaft pulley assembly. To fix, the crankshaft pulley bolt and washer should be replaced with a corrosion-free bolt and washer which had a silver coloured Dacro Coating.
Kia BL Sorento V6: engine noise
In April 2008, Kia Motors issued technical service bulletin 028 for post-2007 Kia BL Sorento vehicles with 3.3- or 3.8-litre V6 petrol engines. In these vehicles, two different types of engine noise may be heard:
- Noise #1: may occur for several seconds during initial start-up, after the vehicle has been unused for several hours. The noise typically sounds like loose timing chains (a rattling noise) or excessive bearing clearance. This noise was attributed to oil draining back into the crankcase such that the tensioners had some initial slack until sufficient oil pressure accumulated. As such, no repair action was deemed necessary; and,
- Noise #2: may occur during or after full warm-up and can sound like excessive valve lash (valve tap) on one or more cylinders or loose timing chains. In this case, both timing chain tensioners were to be replaced with part number 24410 3C300.
Kia BL Sorento 3.5L V6: engine rattle
In May 2008, Kia Motors issued service bulletin 073 for 2003-05 Kia BL Sorento vehicles with 3.5-litre V6 petrol engines. In these vehicles, there may be engine noise or a rattle noise if the anti-rattle clip/throttle screws or two piece bushing become loose and are ingested into the engine assembly. To correct this condition, an improved induction control valve (ICV) was to be fitted to prevent possible engine damage in the future.
Kia BL Sorento V6: idle irregularity when braking
In September 2010, Kia Motors issued service bulletin 077 for 2007-09 Kia BL Sorento vehicles with 3.3- and 3.8-litre V6 petrol engines. These vehicles may experience ‘idle irregularity’ when the brake pedal is applied or depressed; a software upgrade was introduced to improve idle RPM.
2003-08 Kia BL Sorento: corrosion of rear upper arm brackets
In November 2013, the second revision of Technical Service Bulletin KCE12-31-P010 was issued for Kia BL Sorento vehicles that were manufactured prior to 15 November 2008. According to the bulletin, some of these vehicles may experience corrosion of the rear upper arm brackets. The service bulletin described the procedure for inspecting the rear upper arm brackets for corrosion and applying primer/zinc spray and underbody coating for corrosion prevention.
2007-08 Kia BL Sorento 2.5 Diesel: turbocharger overspeed logic
In October 2010, Kia Motors issued Technical Service Bulletin KCE-14-E051-BL for Kia BL Sorento vehicles that:
- had 2.5-litre ‘A’ diesel engines;
- were manufactured from 14 December 2005 to 21 April 2008; and,
- had VINs in the range KNEJC524865579917 to KNAJC524895899376.
According to the service bulletin, an update for the engine control module (ECM) was introduced to improve turbocharger overspeed logic.
Kia BL Sorento: EVAP vacuum
In December 2004, Kia Motors issued service bulletin 006 for Kia BL Sorento vehicles because the malfunction indicator may illuminate and diagnostic trouble code (DTC) P0446/P2422 (EVAP system: vent control) may be logged. In these vehicles, DTC P0446/P2422 may be logged because the amount of vapours being purged from the charcoal canister in the evaporative emissions system exceeded the volume of fresh air entering the canister. This caused a vacuum in the canister and the remainder of the fuel system. If the vacuum level exceeded the ECM threshold, the error codes would be logged; if this occurred on two consecutive drive cycles, the malfunction indicator light (MIL) would illuminate.
Kia BL Sorento: fuel tank air filter
In January 2012, Kia Motors issued service campaign SC092 for the 2003-04 ‘model year’ Kia BL Sorento. Over time, the fuel tank air filter could accumulate dirt which restricted air flow. If the fuel tank air filter was not replaced during regular maintenance, the restriction of airflow could eventually lead to fueling difficulties. As part of the service campaign, an insert was provided in the owner’s manual stating that the fuel tank air filter should be replaced every 30,000 miles (48,000 kilometres).
Kia BL Sorento AWD: front differential chatter and failure
In November 2007, Kia Motors issued service bulletin 019 for Kia BL Sorento vehicles. In these vehicles, there were reports of drivetrain chatter due to incorrect tyre size or uneven tyre wear. The ‘torque on demand’ (TOD) 4WD system utilised two input speed sensors for the front and rear propeller shafts. Due to incorrect tyre size or uneven tyre wear, the transfer case control module received different inputs from the front and rear, indicating tyre slippage; the control module would then increase the pulse width to the front differential axle through the transfer case. When this occurred without wheel slippage, drivetrain chatter may occur and the temperature of the front differential would increase.
To prevent premature failure and chatter of the front differential, the service bulletin recommended that the tyres be rotated regularly. According to the service bulletin, the circumference of all four tyres should be within 10 mm of each other.
Kia BL Sorento: shudder and transfer case
In November 2008, Kia Motors issued service bulletin 022 for 2003-06 ‘model year’ Kia BL Sorento vehicles. In these vehicles, the ‘Torque on Demand’ (TOD) system may experience a light shudder condition during tight parking manoeuvres when the vehicle was cold and accelerating. To fix, the transfer case fluid was to be drained and the transfer case removed from the vehicle, disassembled and the clutch pack replaced.
Kia BL Sorento: transmission shift shock and rpm drop
In December 2006, Kia Motors issued TSB KT2006120701 for 2005-06 ‘model year’ Kia BL Sorento vehicles with five-speed automatic transmissions (A5SR1). In these vehicles, there may be a hesitation and shift shock resulting from an engine rpm drop during the 1-2 and/or 2-3 upshift at around 4000 rpm. When this occurred, the transmission control module (TCM) engaged Engine Torque Reduction (ETR) mode due to abnormal electrical noise created from the internal vehicle speed sensor located in the transmission assembly. To fix, the shielded cable that was routed from the vehicle speed sensor to the TCM was to be replaced (part no. 91175 3E010FFF).
Problems and faults: Kia BL Sorento
- A knocking noise from the air conditioning compressor may be corrected by installing an improved clutch assembly.
- The airbag warning light may come on in the absence of any actual problem due to a fault with the airbag diagnostic unit that will need to be replaced.
- The engine may run rough or hesitate and the ‘check engine’ light may illuminate due to a faulty oxygen sensor.
- For Kia BL Sorento models with manual transmissions, the engine may hesitate after a cold start – this may be fixed by reprogramming the engine control computer/powertrain control module (PCM).
