Problems · NHTSA complaints

2004 Kia Sorento problems

Owners filed 220 complaints about the 2004 Kia Sorento with NHTSA between Jan 2004 and Dec 2021. The most-cited component is engine (46).

Complaints
220
Filed with NHTSA
Crashes
11
Reported by owners
Fires
12
Reported by owners
Injuries
16
People reported injured
Deaths
1
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  1. Engine46
  2. Engine and engine cooling46
  3. Power train40
  4. Suspension30
  5. Structure28
  6. Electrical system28
  7. Steering24
  8. Air bags14
  9. Exterior lighting14
  10. Fuel/propulsion system8
  11. Service brakes7
  12. Vehicle speed control7
  13. Equipment6
  14. Fuel system, gasoline6

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Data from NHTSA Complaints API · synced Nov 10, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
200411
20054
20062
200718
200820
20098
201011
201119
201214
201323
201421
201520
201621
20175
201810
20199
20203
20211

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

Engine

46 reports5 fires
“I BOUGHT MY 04 SORENTO FROM MY AUNT WHO WAS THE ONLY OWNER. IT HAD A POWER STEERING ISSUE AT THAT TIME WHICH TOOK SEVERAL ATTENPTS TO FIX. ABOUT A MONTH LATER WE WE VISITING FAMILY AND HAD TO TURN AROUND. UPON STOPPING WE NOTICED SMOKE FROM THE ENGINE COMPARTMENT SO I GRABBED MY 4 Y/O DAUGHTER OUT OF THE CAR AND BY BOYFRIEND OPENED THE HOOD TO FIND A SMALL FIRE ON OPPOSITE SIDE FRO WHERE BATTERY IS. ONCE FIRE WAS PUT OUT WE DROVE .5 MILES ON A CITY RD TO FAMILY. THE POWER STEERING WAS GONE AT THAT TIME AS WELL. 10/13/19 - THE DIRECTIONAL WORKED ALL DAY AND COME NIGHT TIME WHEN I CAME OUT FROM THE STORE AND STARTED VEHICLE THEY DID NOT WORK. THE NEXT DAY THEY WORKED FINEHOWEVER, ON 10/14/19 - I STARTED THE CAR IN AM AND THERE WAS A SQUEAKY BELT. I HIT THE GAS PEDAL QUICKLY AND NOISE WENT AWAY. THEN WHILE DRIVING, THE BATTERY AND BRAKE INDICATOR LIGHTS CAME ON THE DASH AND STAYED ON SO I PULLED OVER AND SHUT CAR OFF. IWAS DRIVING MY DAUGHTER TO THE PARK A MILE AWAY FROM HOME WHEN THE BATTERY AND BRAKE INDICATOR LIGHTS CAME ON AGAIN. I TURNED CAR OFF FOR A FEW MINUTES AND WHEN I RESTARTED IT THE LIGHTS WERE OFF. I WENT TO TURN AROUND TO GO HOME AND THE STEERING…”
Owner complaint to NHTSAFiled Oct 26, 2019Steering, Electrical system, EngineFire reportedODI 11271165

Engine and engine cooling

46 reports2 fires
“TL* THE CONTACT OWNS A 2004 KIA SORENTO. THE CONTACT STATED THAT THE STEERING WHEEL SEIZED AND EXCESSIVE FORCED WAS REQUIRED. THE FAILURE OCCURRED ON SEVERAL OCCASIONS. THE DEALER REPLACED THE BOLTS. WHILE DRIVING AT VARIOUS SPEEDS, THE BOLTS FRACTURED FROM THE HARMONIC BALANCER. THE VEHICLE WAS TOWED TO THE DEALER WHO INDICATED THAT THE CRANK SHAFT AND ENGINE MIGHT NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 106,000.”
Owner complaint to NHTSAFiled Sep 2, 2014Steering, Engine and engine coolingODI 10630055

Power train

40 reports1 crash1 fire
“CRANKSHAFT BOLT BROKE WITH APPROX 75,000 MILES. KIA ISSUED SERVICE BULLETIN AND REPLACED THE BOLT. BUT THE MOTOR WAS DESTROYED WHEN IT BROKE AND CONTINUOUSLY OVERHEATED AND WAS UNDRIVABLE. IT REQUIRED A NEW MOTOR. NOT HAVING $ TO REPLACE MOTOR & KIAS ZERO ACCOUNTABILITY. VEHICLE SAT AT A REPAIR SHOP FOR 2 YEARS & THEY FILED FOR AN ABANDONED TITLE. AT THE TIME VALUED AT APPROX $7500. WASTED!!!! THANKS KIA!”
Owner complaint to NHTSAFiled Sep 13, 2016Power trainODI 10906007

Suspension

30 reports1 crash1 fire
“2004 KIA SORENTO EX WITH EXTENSIVE RUST DAMAGE TO REAR CROSS-MEMBERS #2 AND #3. DISCOVERED DURING TIRE ROTATION IN NOV 2018, BUT IS OBVIOUS THE DAMAGE HAS EXISTED FOR A SUBSTANTIAL AMOUNT OF TIME. CROSS-MEMBER #2 IS JUST IN FRONT AND ABOVE THE REAR AXLE AND HAS THE MOUNTING BRACKETS FOR THE AXLE STRUTS, WHICH KEEP THE AXLE IN PLACE, IT ALSO HAS A MOUNTING BRACKET FOR THE FUEL TANK, AS WELL AS A PASS THROUGH BRACKET FOR THE REAR BRAKE LINES, AND A MUFFLER HANGER. THE CAR IS NOT SAFE TO BE DRIVEN DUE TO THE IMMINENT DANGER OF A FULL FAILURE. CROSS-MEMBER #2 IS ABOUT 70% RUSTED THROUGH ON THE FUEL TANK SIDE AND PERFORATED IN SEVERAL OTHER PLACES AS WELL. CROSSMEMBER #3 WHICH IS BEHIND THE REAR AXLE CONTAINS NO MOUNTS, BUT A TORSION BAR DOES CONNECT WHERE THE CROSS-MEMBER PASSES THROUGH THE LEFT FRAME RAIL. STRUT MOUNT CONNECTORS ON AXLE ARE ALSO SEVERELY RUSTED. BACKING PLATE FOR REAR DISC BRAKES ON BOTH SIDES IS RUSTED SO SEVERELY THEY CRUMBLE LIKE AN EGGSHELL. CONTACTED KIA AND THEY SAID THEY WILL NOT COVER REPAIR OF THE DEFECT, CASE #12944853 OPENED. IT ONLY TAKES A QUICK SEARCH ONLINE TO FIND THERE ARE MANY CASES OF THIS WITH PARTICULARLY 2004 MODELS.”
Owner complaint to NHTSAFiled Nov 23, 2018Suspension, StructureODI 11153412

Structure

28 reports1 fire
“THIS KIA WAS HOUSED AND STORED IN A GARAGE FOR MOST OF ITS LIFE AND DRIVEN ONLY IN THE SUMMER. IN THE WINTERS OF MICHIGAN IS WAS HOUSED IN A CLEAN DRY GARAGE. THIS KIA WAS A 2 OWNER CAR. I AM THE SECOND OWNER. I HAD DRIVEN IT ONE WINTER AND THIS SUMMER TOOK IT TO GET AN ALIGNMENT BECAUSE IT PULLED TO THE RIGHT. ALIGNMENT CENTER COULD NOT DO THE ALIGNMENT BECAUSE THE WHOLE RIGHT DRIVERSIDE OF THE FRAME WAS RUSTED OUT BEYOND THEIR SAFTY STANDARDS. THE KIA WAS PULLING TO THE RIGHT BECAUSE THE WHOLE FRAME ON THE RIGHT SIDE WAS 80% RUSTED OUT AND THE LEFT SIDE WAS ALSO BUT NOT TO THE EXTENT OF THE RIGHT SIDE. THERE ARE FOOT LONG GAPING HOLES IN THE FRAME DUE TO THE RUSTING. IT IS IRREPARABLE. THERE IS NO SAFE SPOT TO WELD TO TO FIX IT EITHER. AFTER A RAIN I NOTICED THE POOLS OF WATER GO DIRECTLY UNDER THE KIA INSTEAD OF ON THE SIDES POOLING AND DRIPPING OFF THE FRAME ON EACH RIGHT AND LEFT SIDE. A FLAW OF DESIGN BUT A DEADLY IF TRAVELLING AND THE CAR SNAPS IN HALF. THE KIA LOOKS PERFECT AND RUNS PERFECT. THE UNDERSIDE IT'S FRAME IS TOTALLY RUSTED BEYOND REPAIR. KEPT IN A GARAGE AND OUT OF ELEMENTS FOR VIRTUALLY ALL OF ITS LIFE, THIS SHOULD NOT HAVE HAPPENED.…”
Owner complaint to NHTSAFiled Aug 25, 2020StructureODI 11351192

Electrical system

28 reports7 fires
“OCT, 2016 - I AM THE ORIGNAL OWNER OF THE VEHICLE AND HAD MAINTAINED REGULAR MAINTAINENCE ON THE VEHICLE. I HAD JUST PUT $700 OF NEW TIRES ON VEHICLE AND HAD A ROUTINE OIL CHANGE AND FLUID CHECK BEFORE WE LEFT FOR OUR VACATION. I NEVER HAD ANY ISSUES WITH THE VEHICLE AND I STILL OWN. THE VEHICLE DOES NOT RUN BUT I WANTED TO KNOW WHAT STARTED THE FIRE. MY DAUGHTER AND I WERE HEADED OUT OF TOWN FOR A WEEK, ABOUT 200 MILES INTO THE COMMUTE THE FRONT OF THE VEHICLE BEGAN TO SMOKE FROM UNDER THE HOOD, WE WERE TRAVELING AT 55-60 MPH. AS I WAS EXITING THE 421 HIGHWAY FLAMES BEGAN COMING OUT FROM AROUND HOOD AND THE PAINT ON THE HOOD BEGAN TO BUBBLE UP DUE TO HEAT. I IMMEDIATELY CALLED THE FIRE DEPT, AS I WAS DRIVING, PULLED ONTO THE SHOULDER AND IMMEDIATELY REMOVED MY DAUGHTER AND OUR BELONGINGS FROM THE VEHICLE AND DISTANCED OURSELVES FROM THE VEHICLE. WHEN THE FIRE DEPT ARRIVED THEY PUT THE FLAMES OUT AND THE VEHICLE WAS TRANSPORTED TO A LOCAL SHOP, I HAD THE VEHICLE TOWED BACK TO OUR HOME CITY UPON DEPARTURE FROM OUR VACATION. UPON FURTHER OBSERVATION I WAS ABLE TO SEE THE FIRE STARTED IN THE AREA CLOSEST TO WHERE THE ENGINE MEETS THE DASH ON THE DRIVERS SIDE AND…”
Owner complaint to NHTSAFiled Oct 17, 2019Electrical system, Structure, EngineFire reportedODI 11269088
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 10, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.