SC261 Fuel Tank – 2022 Kia Sorento Plug-In Hybrid (PHEV)

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January 25, 2023 NHTSA CAMPAIGN NUMBER: 23V027000

Improperly Molded Fuel Tank May Leak

A fuel leak in the presence of an ignition source can increase the risk of a fire.

 

NHTSA Campaign Number: 23V027

Manufacturer Kia America, Inc.

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 34

 

Summary

Kia America, Inc. (Kia) is recalling certain 2022 Sorento Plug-In Hybrid (PHEV) vehicles. The fuel tank may have been improperly molded, which can result in a fuel leak.

 

Remedy

Dealers will inspect and replace the fuel tank, as necessary, free of charge. Owner notification letters were mailed March 22, 2023. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC261.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Kia has a Recall

 


SC261

March 2023

FUEL TANK REPLACEMENT (SC261)

This bulletin provides information to replace the fuel tank on certain 2022MY Sorento PHEV (MQ4 PHEV) vehicles produced from April 12, 2022 through April 26, 2022. Due to a manufacturing issue, the fuel tank in the subject vehicles may have been improperly molded at the seam. An improperly molded fuel tank can result in a fuel leak. A fuel leak in the presence of an external ignit ion source increases the risk of a fire. Follow the procedure outlined in this publication to replace the fuel tank. Before conducting the procedure, verify that the vehicle is included in the list of affected VINs

 

Repair Procedure:

1. Remove the fuel tank assembly by referring to “Engine Control / Fuel System ➔ Fuel Delivery System ➔ Fuel Tank ➔ Repair Procedures· in the applicable Shop Manual on KGIS.

Required SST PN 09310 B8100 Fuel Pump Plate Cover Remover

Note: DO NOT reuse the front and rear flange retaining bolts (A) to the rear propeller shaft (B).
Replace with new bolts (supplied with the new fuel tank). Six (6) bolts total.

Tightening torque for bolts (A):
39.8 – 50.6 lb.ft (53.9 – 68.6 N.m)

 

2. Transfer the following parts from the removed fuel tank onto the new fuel tank:

  • Fuel Pump Assembly
  • Transfer Heat Protector
  • EVAP Canister/Leak Check Module with Vapor Hoses and Wiring

 

3. Reinstall the fuel tank and all other removed parts in the reverse order of removal.

4. Using a bellows type pump, transfer any fuel remaining from the old fuel tank onto a clean separate fuel container.

5. Refuel the vehicle by filling fuel through the fuel filler neck.

6. Confirm normal vehicle operation.

 

AFFECTED VEHICLE RANGE:

Model Production Date Range
Sorento PHEV (MQ4 PHEV) April 12, 2022 to April 26, 2022

 

REQUIRED TOOL:

Tool Name Part Number
Fuel Pump Plate Cover Wrench SST 09310 B8100

 

REQUIRED PART:

Part Name Part Number Qty. Comments
Fuel Tank 31150 P4800QQK 1 Six (6) F&R propeller shaft mounting bolts are included.

 

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2022 MY SORENTO PLUG-IN HYBRID (PHEV) VEHICLES
FUEL TANK – SAFETY RECALL CAMPAIGN (SC261)
Q & A
March 16, 2023

Q1. What type of campaign is Kia conducting?

A1. Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign to address a defect involving the fuel tank.

 

Q2. What vehicles are affected by the recall?

A2. Certain 2022 MY Sorento Plug-In (PHEV) vehicles manufactured from April 12, 2022 to April 26, 2022.

 

Q3. How many customer vehicles are affected by this recall?

A3. 34 vehicles.

 

Q4. What is the concern with the Fuel Tank Assembly?

A4. Due to a manufacturing issue, the fuel tank may have been improperly molded at the seam. An improperly molded fuel tank can result in a fuel leak. A fuel leak in the presence of an external ignition source increases the risk of a fire.

 

Q5. Can you describe the recall campaign and fix?

A5. Dealers will inspect and, if necessary, replace the fuel tank with a new one.

 

Q6. How will owners of the affected vehicles be notified?

A6. Kia will send a letter notifying owners of the affected vehicles by first class mail beginning on March 22, 2023.

 

Q7. What should vehicle owners do when they receive the notification?

A7. Upon receipt of the letter, owners are to contact their authorized Kia dealer to arrange to have the recall performed on their vehicle.

 

Q8. Where were these vehicles produced?

A8. The affected vehicles were produced at a Kia assembly plant in Korea.

 

Q9. Will this cost vehicle owners any money?

A9. No. Kia will perform the recall repair free of charge at no cost to the customer.

 

Q10. What about customers who may have already paid to have this situation corrected?

A10. If the customer has incurred expense to remedy this issue prior to the date of this notice, the customer may have the opportunity to obtain reimbursement for that expense. Customers may submit their receipts online to Kia via the Owners section (Contact Kia) of www.kia.com OR mail their documentation with the completed Request for Reimbursement Form included with this letter directly to Kia for review and consideration at the following address:

Kia Customer Care
Center Kia America, Inc.
P.O. Box 52410
Irvine, CA 92619-2410
1-800-333-4542

 

Q11. Are there any restrictions on an owner’s eligibility?

A11. No.

 

Q12. If a customer has an immediate question, where can they get further information?

A12. The customer can contact their local authorized Kia dealership or call Kia’s Customer Care Center at 1-800-333-4KIA (4542), Monday through Friday, 5 AM to 6 PM Pacific Time, or via the internet at www.kia.com (Owner’s Section).

 


2022MY Kia Sorento Plug-In Hybrid
Fuel Tank
Basis of Safety Defect Determination 573.6(c)(6)

June 23, 2022
Kia North America (Kia NA) receives warranty claim involving fuel tank leak in a 2022MY Sorento Plug-In Hybrid vehicle (PHEV).

July 13, 2022
Kia NA receives second warranty claim identifying fuel tank leak in a 2022MY Sorento PHEV.

July 28, 2022 – August 22, 2022
Kia NA receives warranty-returned fuel tank from incident vehicle identified in 6/23/2022 warranty claim from dealer. Kia NA ships part to Kia Corporation (Kia HQ) for further investigation.

August 30, 2022
Kia HQ receives warranty-returned part and begins investigation with supplier.

November 2 – December 12, 2022
Kia NA Safety Office obtains fuel tank from 7/13/2022 warranty claim and ships fuel tank to Kia HQ for further investigation.

December 23, 2022 – January 16, 2023
Kia HQ receives fuel tank from 7/13/2022 warranty claim. Kia HQ and supplier conduct evaluation of both warranty returned parts.

January 17, 2023
Kia HQ informs Kia NA Safety Office of parts investigation results identifying fuel tank leak caused by supplier’s improper molding of fuel tank. Kia NA Safety Office conducts data analysis and finds no additional incidents from field data other than the two (2) warranty claims identified in June and July 2022.

January 19, 2023
Kia NA decides to recall certain 2022MY Kia Sorento Plug-In Hybrid (PHEV) vehicles. No fatalities, injuries, crashes or fires.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
KIA MOTOR SORENTO PHEV 2022

 


11 Associated Documents

2022MY Sorento Plug-In Hybrid Fuel Tank Chronology

RMISC-23V027-0624.pdf 76.987KB

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Recall Acknowledgement

RCAK-23V027-3337.pdf 645.175KB

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Defect Notice 573 Report

RCLRPT-23V027-8507.PDF 213.704KB

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Remedy Instructions and TSB

RCRIT-23V027-0520.pdf 607.268KB

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2022 MY SORENTO PLUG-IN HYBRID (PHEV) VEHICLES FUEL TANK – SAFETY RECALL CAMPAIGN (SC261) Q & A March 16, 2023

RMISC-23V027-4125.pdf 110.235KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V027-0521.pdf 81.104KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V027-3563.pdf 105.65KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V027-2135.pdf 238.212KB

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Recall Quarterly Report #1, 2023-1

RCLQRT-23V027-1538.PDF 211.131KB

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Recall Quarterly Report #2, 2023-2

RCLQRT-23V027-1617.PDF 211.229KB

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Recall Quarterly Report #3, 2023-3

RCLQRT-23V027-9283.PDF 211.454KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V027&docType=RCL

 


 

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  • 【CONVENIENT FOR HOME ADN OFFICE CHARGER】 - The Aplysiatech 15 Amp EV Charger is designed for affordable and convenient charging option compared to other Level 2 EV chargers,just plug in 5-15R outlet and then delivering an extra 40-50 miles of overnight charge at home.Super convenient choice for all EV owners.
  • 【SAFE FOR HOME AND OFFICE CHARGER】- AplysiaTech 15 Amp EV charger is IP65 weather-resistant, and with built-in protection against overvoltage, overcurrent, and short circuits;14AWG charing cable for safe and reliable charging at home and office.
  • 【HIGH COMPATIBILITY CHARGER】AplysiaTech EV charger is compatible with electric vehicles that meet SAE J1772 standards. You will need AplysiaTech J1772 to Tesla charger adapter if you are Tesla owner.
  • 【EASY TO CARRY EV CHARGER】No worry about charging while traveling or on business,AplysiaTech 15Amp portable EV charger included storage bag to makes it easy to carry around and stay organized in your car, allowing you to charge anywhere and anytime, no need to find an EV charging station outside.

Last update on 2024-04-29 / Affiliate links / Images from Amazon Product Advertising API

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