2004 Kia Optima Fuel system Problems

The contact owns a 2004 Kia Optima. The contact stated that after refueling, the vehicle would not start. The vehicle was not taken to a local dealer. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 04V180000 (Fuel System, Gasoline) however, the VIN was not included. The manufacturer was informed of the failure and confirmed that the vehicle was not included in a recall. The failure mileage was approximately 145,000.

NHTSA ID

11452262

Incident

Nov 1, 2021

Mileage

145,000 mi

I WAS DRIVING ON I-10 WESTBOUND, KATY TX FREEWAY, TRAVELLING ABOUT 65 MILES PER HOUR. THE PASSENGER'S SIDE FRONT TIRE BLEW OUT CAUSING THE CAR TO GO BACK AND FOURTH BETWEEN TWO LANES OF TRAFFIC. IN THE PROCESS, I WAS HITTING THE RUBBER DIVIDERS, DAMAGING THE HOOD OF THE CAR AND THE WINDSHIELD. THE BLOWN TIRE CAUSED DAMAGE TO THE OIL PAN, THE RADIATOR, AND EVENTUALLY THE TRANSMISSION. I GOT THE CAR TO THE EMERGENCY LANE. THE CAR WAS TOWED OFF THE FREEWAY AND EVENTUALLY PICKED UP AND TRANSPORTED TO A CAR REPAIR SHOP. A FEW DAYS LATER, THE INSURANCE ADJUSTER AND THE REPAIR SHOP OWNER BOTH AGREED THE CAR WAS A TOTAL LOSS. I HAD TO BUY A NEW CAR. *TR

NHTSA ID

10680973

Incident

Jan 26, 2015

Mileage

62,000 mi

DRIVER DOOR REFUSED TO OPEN. I HAVE A DISABILITY SO THIS CREATED A HUGE PROBLEM FOR ME. WHEN I PUT GAS IN MY CAR (REGARDLESS OF GRADE OR GAS STATION) MY CAR REFUSES TO START. WHEN I MAKE A U-TURN, MY CAR MAKES LOUD CLICKING SOUND. I HAD IT CHECKED...MY AXLE AND EVERY THING ELSE LOOKS FINE. NO ONE CAN ESTABLISH WHERE THE NOISE COMES FROM. MY CAR HAS LESS THAN 60,000 MILES ON IT, AND IT SHOULD NOT HAVE ALL THESE ISSUES BUT IT DOES. *TR

NHTSA ID

10444977

Incident

Jul 14, 2010

CAR WAS DIFFICULT TO START AFTER FUEL FILL-UP. IT GOT WORSE AFTER EACH FILL UP. TRIED PUTTING FUEL IN WHILE CAR WAS RUNNING, BUT IT WOULD JUST CUT OFF. MUST PUT FOOT ON BRAKE AND REV GAS AFTER PUTTING IN FUEL TO GET GOING. I WAS USING KROGER GAS, I SWITCHED TO SHELL GAS BUT THE PROBLEM PERSIST. ALSO ENGINE LIGHT HAS NEVER COME ON. I THINK THIS IS THE SAME PROBLEM AS THE 2003 KIA. *TR

NHTSA ID

10430540

Incident

Aug 1, 2011

TL*THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THE FAILURE WAS A GAS FUME LEAK AND THE ACCELERATOR SENSOR NEEDED TO BE REPLACED BECAUSE IT CAUSED THE VEHICLE TO ACCELERATE AND DECELERATE WITHOUT WARNING. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000. THE CURRENT MILEAGE WAS 129,548.

NHTSA ID

10358001

Incident

Mar 17, 2010

Mileage

100,000 mi

THE FUEL SYSTEM IS GIVING ME PROBLEM AFTER PROBLEM AFTER PROBLEMS I HAVE CHANGED THE FUEL PUMP 3 TIMES IN 12 MONTHS. AND THE HEAD LIGHTS ALSO KEEP GOING OUT. I'VE CHANGED THE LEFT SIDE HEAD LIGHT TWICE AND THE RIGHT SIDE ONCE IN 4-1/2 YEARS. *TR

NHTSA ID

10345869

Incident

Jul 23, 2010

TL*THE CONTACT OWNS A 2004 KIA OPTIMA. THE DRIVER ATTEMPTED TO START THE VEHICLE, BUT WAS UNSUCCESSFUL. THE VEHICLE WAS TOWED TO THE REPAIR SHOP AND IT WAS DISCOVERED THAT THE ELECTRIC WIRE FOR THE FUEL PUMP HAD BURNED INSIDE THE GAS TANK. THESE WERE THE PLUGS FOR THE FUEL PUMP. THE DRIVER WAS FORTUNATE THAT THE VEHICLE WOULD NOT START BECAUSE AN EXPLOSION COULD HAVE OCCURRED. THE DEALER ADVISED HIM TO CALL NHTSA AND FILE A COMPLAINT BECAUSE THEY COULD NOT ASSIST. THE CONTACT IS A MECHANIC AND REPAIRED THE VEHICLE HIMSELF. THE FAILURE MILEAGE WAS 75,600. UPDATED 12/11/08. *LJ UPDATED 12/11/08.*JB

NHTSA ID

10248553

Incident

Nov 8, 2008

Mileage

75,600 mi

PURCHASED 2004 KIA OPTIMA EX NEW. HAVE HAD FUSE BLOCK REPLACED W/IN 15000 MILES. NOW, THE FUEL PUMP HAS FAILED. THE CAR RAN FINE AND WAS PARKED. NEXT DAY CAR WOULD NOT START. NO FUSES BLOWN. THE TERMINAL CONNECTOR FROM THE FUEL PUMP TO THE GAS TANK PENETRATION HAS BURNED OUT CAUSING AN INTERMITTENT OPEN IN CIRCUIT. FUEL PUMP BURNED UP IN TANK. WIRES AND CONNECTORS VISIBLY CHARRED. CONNECTION THAT FAILED IS INSIDE OF THE GAS TANK. VERY SIMILAR TO NTSB CASE #10161074. HAVE 120,000 MILES ON THE CAR. OTHERS WITH LESS MILEAGE ARE IN FOR TROUBLE DUE TO POOR ENGINEERING DESIGN. DEFECTIVE PARTS AVAILABLE FOR PHOTOGRAPH OR INSPECTION. *JB

NHTSA ID

10204625

Incident

Sep 29, 2007

Mileage

120,030 mi

DT*: THE CONTACT STATED WHILE TRAVELING 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE GAS CAP WAS REMOVED AND REPLACED TO REMOVE PRESSURE IN THE FUEL TANK. WHEN THE VEHICLE WAS RESTARTED, IT WAS SLUGGISH, AND HAD VERY LITTLE POWER, AND A CLUNKING NOISE WAS HEARD. SO, THE VEHICLE WAS TOWED TO THE DEALERSHIP. THE DEALERS MECHANIC RAN A COMPUTER DIAGNOSTIC TEST, WHICH REVEALED SEVERAL MISFIRE CODES. UPON REMOVING THE FUEL PUMP, MELTED WIRING WAS DISCOVERED RUNNING FROM THE FUEL PUMP TO THE GAS TANK. THE MANUFACTURER WAS ALERTED.

NHTSA ID

10161074

Incident

Jan 24, 2006

Mileage

61,361 mi

BOUGHT KIA OPTIMA ON JUNE 22, 2004 VIN# [XXX] AND HAVE SINCE HAD SEVEN SERVICE APPOINTMENTS, REPLACED TWO SETS OF DRIVE BELTS, REPLACED A LEAKING POWER STEERING RACK, REPLACED A LEAKING FUEL REGULATOR, MACHINED THE FRONT ROTORS, LOST TIME FROM WORK, LOST PRODUCTIVITY FROM WORK AS WELL AS JEOPARDIZED MY WIFE'S WORK FROM CAR POOLING FOR FIVE MONTHS, COMPLETED SCHEDULED ARBITRATION WITH THE BBB WITHOUT SUCCESS FOR FOUR PROBLEMS: ACCELERATION DELAY, LOW GRINDING BRAKE NOISE, LOW VIBRATION STEERING NOISE, AND LOUD SQUEALING NOISE FROM THE DRIVE BELTS. *JB UPDATED 07/24/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

10102349

Incident

Aug 6, 2004

Mileage

3,200 mi