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
Deales will inspect and replace the fuel tank, as necessary, free of charge. Owner notification letters are expected to be 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
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 |
3 Associated Documents
2022MY Sorento Plug-In Hybrid Fuel Tank Chronology
RMISC-23V027-0624.pdf 76.987KB
RMISC-23V027-0624
Recall Acknowledgement
RCAK-23V027-3337.pdf 645.175KB
RCAK-23V027-3337
Defect Notice 573 Report
RCLRPT-23V027-8507.PDF 213.704KB
RCLRPT-23V027-8507
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V027&docType=RCL
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-027 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kia America, Inc. Submission Date : JAN 25, 2023 NHTSA Recall No. : 23V-027 Manufacturer Recall No. : SC261 Manufacturer Information : Manufacturer Name : Kia America, Inc. Address : 111 Peters Canyon Road Irvine CA 92606 Company phone : 800-333-4542 Population : Number of potentially involved : 34 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2022-2022 Kia Sorento Plug-In Hybrid (PHEV) Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC Descriptive Information : Certain 2022 model year Sorento Plug-In (PHEV) vehicles manufactured from April 12, 2022 to April 26, 2022. The recall population was determined by a review of Kia vehicle production and supplier records. The vehicles subject to this recall were not produced in VIN order. Customers seeking information about their specific vehicle will be referred to Kia’s Customer Care Center or their Kia dealer. Production Dates : APR 12, 2022 – APR 26, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Due to a manufacturing issue at the supplier, the fuel tank may have been improperly molded at the seam. An improperly molded fuel tank can result in a fuel leak. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A fuel leak in the presence of an external ignition source increases the risk of a fire. Description of the Cause : Improperly molded fuel tank seam Part 573 Safety Recall Report 23V-027 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : Fuel smell and/or leak Involved Components : Component Name 1 : Tank Assy-Fuel Component Description : Fuel Tank Assembly Component Part Number : 31150-P4800 Supplier Identification : Component Manufacturer Name : TI Automotive Address : 51, 3gongdan 3-ro, Seobuk-gu, Chungcheongnam-do Cheonan-si Foreign States 31093 Country : Korea, Republic of Chronology : See attached document titled “2022MY Sorento Plug-In Hybrid Fuel Tank Chronology” Description of Remedy : Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Kia will instruct dealers to inspect and, if necessary, replace the fuel tank with a new one. Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 10, 2022. Part 573 Safety Recall Report 23V-027 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : The remedy component is a properly molded fuel tank. Identify How/When Recall Condition was Corrected in Production : Improper molding of the fuel tank at the supplier occurred from 4/7/2022 to 4/9/2022. The molding processes were corrected in production at the supplier on 4/10/2022. The recalled component may have been installed in the subject vehicles produced from 4/12/2022 to 4/26/2022. Model year 2022 Sorento PHEV vehicles produced after 4/26/2022 were equipped with a properly molded fuel tank. Recall Schedule : Description of Recall Schedule : The Dealer Notification is scheduled to begin and end on March 16, 2023 and the Owner Notification is scheduled to begin and end on March 22, 2023. Planned Dealer Notification Date : MAR 16, 2023 – MAR 16, 2023 Planned Owner Notification Date : MAR 22, 2023 – MAR 22, 2023 * NR – Not Reported
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