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

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A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.
GROUP
Safety Recall Campaign NUMBER
SC261
MODEL
2022MY
Sorento PHEV (MQ4 PHEV) DATE
March 2023
SAFETY RECALL CAMPAIGN
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 ignition 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
VIN List
KNDRJDLH0N5108058 KNDRMDLH1N5110781 KNDRMDLH5N5110685 KNDRJDLH2N5110782 KNDRMDLH2N5110644 KNDRMDLH5N5110749 KNDRJDLH9N5110827 KNDRMDLH2N5110787 KNDRMDLH5N5110752 KNDRMDLHXN5108060 KNDRMDLH2N5111194 KNDRMDLH6N5108010 KNDRMDLHXN5110780 KNDRMDLH3N5108014 KNDRMDLH6N5108024 KNDRMDLH0N5108052 KNDRMDLH3N5108059 KNDRMDLH6N5110789 KNDRMDLH0N5110674 KNDRMDLH3N5110684 KNDRMDLH7N5108047 KNDRMDLH1N5108013 KNDRMDLH4N5108023 KNDRMDLH7N5108050 KNDRMDLH1N5110750 KNDRMDLH4N5110788 KNDRMDLH7N5108064 KNDRMDLH1N5110778 KNDRMDLH5N5108046 KNDRMDLH7N5110686 KNDRMDLH7N5110784 KNDRMDLH8N5108008 KNDRMDLH9N5108020 KNDRMDLH9N5108048 SUBJECT: There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected vehicle until it has been repaired pursuant to the procedures set forth in this bulletin.
To assure complete customer satisfaction, always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service → Warranty Coverage → Warranty Coverage Inquiry) for a list of any additional campaigns that may need to be performed on the vehicle before returning it to the customer.
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SUBJECT: Repair Procedure: FUEL TANK REPLACEMENT (SC261) 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. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC261 Sorento PHEV (MQ4 PHEV) March 2023 Page 3 of 3
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SC261 Sorento PHEV (MQ4 PHEV) March 2023
SUBJECT: FUEL TANK REPLACEMENT (SC261)
AFFECTED VEHICLE RANGE:
Model Production Date Range
Sorento PHEV (MQ4 PHEV) April 12, 2022 to April 26, 2022 REQUIRED TOOL:
Tool Name Figure Part Number Fuel Pump Plate Cover Wrench SST 09310 B8100
REQUIRED PART:
Note: The total number of impacted vehicles is very low; Dealers will need to provide a VIN when submitting the parts order. DO NOT order the Fuel Tank for stocking purposes related to this Campaign.
Part Name Part Number Figure Qty. Comments Fuel Tank 31150 P4800QQK Six (6) F&R
propeller shaft1 mounting bolts
are included.
WARRANTY INFORMATION:
N Code: N99 C Code: C99
Note: Refer to Warranty Bulletin 2023-09 for claim submission procedures. Manually enter sublet code ‘X2’ for reimbursement of one roundtrip rideshare expense or up to three (3) days of rental expense, with supporting documentation.
Claim Type R Causal P/N 31150 P4800 Qty. 0
Repair Description (SC261)
Fuel Tank Replacement
Labor Op Code 230015R0
Op Time 1.4
M/H
Replacement P/N 31150 P4800QQK Qty. 1
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference SC261 when accessing the WebDCS system.
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SC261
March 16, 2023
ATTENTION:
ALL DEALER PRINCIPALS
Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act is conducting a Safety Recall Campaign on certain 2022 MY Sorento Plug-In (PHEV) vehicles manufactured from April 12, 2022 to April 26, 2022.
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.
Dealers will inspect and, if necessary, replace the fuel tank with a new one. If fuel smell and/or leak is detected, customers are instructed to have their vehicle towed to their nearest authorized Kia dealership.
Your Service Manager was sent a copy of the owner notification letter and a Q&A guide for recall questions both of which describe the issue and information on how to access the list of affected vehicles. Kia will start mailing notices to the affected vehicle owners beginning on March 22, 2023.
What Should You Do?
Please ensure personnel in your dealership are familiar with the details of this Safety Recall Campaign so they may properly address recall related issues and promptly respond to customer inquiries and requests.
NHTSA ADVISORY: It is a violation of Federal law for a dealer to deliver a new motor vehicle covered by this notification under a sale or lease until the defect is remedied.
LEGAL PRIVACY LIABILITY NOTICE: Pursuant to the terms of the Dealer Sales and Service Agreement and the Gramm-Leach-Bliley federal consumer privacy act, you are required to keep confidential any and all information and documents provided to you by Kia America, Inc. or generated by you in the conduct of carrying out work under that Agreement regarding Kia vehicle purchasers and owners, including but not limited to warranty claim information. Kia dealers may use such owner information for the sole purpose of conducting and performing this safety recall campaign, and for no other purpose.
If you have any questions, please contact your facing Kia District Parts & Service Manager.
Sincerely,
Kia Service Department
Enclosures

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SC261
March 16, 2023
ATTENTION:
ALL DEALER PARTS & SERVICE MANAGERS
Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act is conducting a Safety Recall Campaign on certain 2022 MY Sorento Plug-In (PHEV) vehicles manufactured from April 12, 2022 to April 26, 2022.
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.
Dealers will inspect and, if necessary, replace the fuel tank with a new one. If fuel smell and/or leak is detected, customers are instructed to have their vehicle towed to their nearest authorized Kia dealership.
The Technical Service Bulletin that provides vehicle inspection and repair procedures, affected VIN production range, and warranty claim information will be posted on the Kia Global Information System (KGIS) at http://www.kiatechinfo.com.
Enclosed you will find a copy of the owner notification letter and a Q&A Guide for recall questions, both of which describe the issue. Note that any vehicle owner who has already paid for related repairs can submit a request for reimbursement online via the Owner’s Section of http://www.kia.com. Kia will mail notices to the affected vehicle owners beginning on March 22, 2023.
Please ensure personnel in your dealership are familiar with the details of this Safety Recall Campaign so they may respond to customer inquiries and requests appropriately. This Safety Recall Campaign is an opportunity for your service department to deliver an exceptional service experience to customers who may not have otherwise scheduled service. Providing customers with easy scheduling and timely service increases the chance they will return to your service department for future service needs.
NHTSA ADVISORY: It is a violation of Federal law for a dealer to deliver a new motor vehicle covered by this notification under a sale or lease until the defect is remedied.
LEGAL PRIVACY LIABILITY NOTICE: Pursuant to the terms of the Dealer Sales and Service Agreement and the Gramm-Leach-Bliley federal consumer privacy act, you are required to keep confidential any and all information and documents provided to you by Kia America, Inc. or generated by you in the conduct of carrying out work under that Agreement regarding Kia vehicle purchasers and owners, including but not limited to warranty claim information. Kia dealers may use such owner information for the sole purpose of conducting and performing this safety recall campaign, and for no other purpose.
If you have any questions, please contact your facing Kia District Parts and Service Manager.
Sincerely, Kia Service Department Enclosures

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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 : Submission Date :
Kia America, Inc. 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 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. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-027
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The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
The remedy component is a properly molded fuel tank. 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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