2010 Kia Forte Fuel System Problems

FUEL PUMP WENT OUT YESTERDAY, HAD THE FUEL PUMP REPLACED 4 YEARS AGO, TODAY THEY SAID THE WIRE CONNECTOR GOING TO THE FUEL PUMP HAD MELTED TO THE FUEL PUMP ASSEMBLY

ON TWO OCCASIONS NOW THE KIA FORTE HAS STALLED WITH THE ORIGINAL FUEL SENDING UNIT LOCATED IN THE FUEL TANK. FIRST OCCURRENCE WAS IN SEPTEMBER 11 2016 (~55,000 MILES) WHERE CAR WAS PARKED FOR ~30 MINUTES WHILE SHOPPING AND WOULD NOT START-INVESTIGATION FOUND THE FUEL PUMP CONNECTOR WITHIN THE FUEL TANK GOT HOT ENOUGH TO MELT THE PLASTIC AND DISCONNECT THE POSITIVE TERMINAL (SEE IMAGES ATTACHED). THIS IS A SERIOUS ISSUE AND KIA DEALERSHIPS IN THE CHICAGOLAND AREA WOULD NOT DO ANY WARRANTY REPAIR OR REPLACEMENT. AFTER REPAIRING THE CONNECTION AND RE-SOCKETING THE TERMINALS THE PUMP WAS ABLE TO WORK FOR ANOTHER YEAR UNTIL THE SECOND INCIDENT. ON AUGUST 29 2017 (~75,000 MILES) THE VERY SAME CONNECTOR AGAIN WITHIN THE ASSEMBLY FOR THE FUEL SENDING UNIT FAILED WHILE IN MOTION ON A RESIDENTIAL ROAD CAUSING THE ENGINE TO STALL WHICH IN TURN CAUSED LOSS OF POWER STEERING. AGAIN, THE CONNECTOR FOR PROVIDING POWER TO THE FUEL PUMP OPENED CAUSING THE ENGINE TO BE STARVED OF FUEL. THE UNIT IS NO LONGER REPAIRABLE AS THE OPEN CIRCUIT IS OCCURRING WITHIN THE RIGHT-ANGLE PASS THROUGH THE METAL DIVIDER OF THE INTERNAL PORTION OF THE FUEL TANK. THE ENTIRE UNIT REQUIRED REPLACEMENT EVEN THOUGH ALL OTHER ELEMENTS ON THE ASSEMBLY ARE WORKING. OTHER OWNERS HAVE REPORTED THIS EXACT ISSUE HOWEVER THE MANUFACTURER REFUSES TO ACKNOWLEDGE THE POSSIBILITY OF A RECALL. THIS IS AN OBVIOUS SAFETY MECHANISM ISSUE AND COULD CAUSE ACCIDENTS DUE TO ABRUPT LOSS OF STEERING, ABILITY TO ACCELERATE, AND FIRE HAZARD.

TURNED VEHICLE ON, PUT IN REVERSE, AS I PRESSED GAS TO BACK OUT OF DRIVEWAY AND FIRST STARTED MOVING, THE VEHICLE DIED. I WAS HALF IN ROAD AND TRIED TO RESTART CAR AND IT WOULD NOT START, ENGINE WONT RUN. HAD TO PUSH CAR TO SIDE OF ROADWAY FOR SAFETY. CALLED ROADSIDE ASSISTANCE THROUGH MY INSURANCE TO TOW CAR TO MY FATHERS GARAGE. THE CAR IS NOT PUMPING FUEL TO THE ENGINE. IT IS NOT THE FUEL PUMP, BUT A FAULTY FUEL PUMP ASSEMBLY SYSTEM AND THE WHOLE SYSTEM NEEDS TO BE REPLACED. THE WIRE HARNESS IN THE FUEL PUMP ASSEMBLY IS A BAD CONNECTION CAUSING IT TO OVERHEAT AND DAMAGE THE TERMINAL. CALLED KIA OF MIDDLETOWN NY WHERE CAR WAS PURCHASED AND THEY WILL NOT RELEASE ANY INFORMATION REGARDING ANY RECALLS OR WARRANTY INFORMATION ON MY VEHICLE EVEN WITH ME PROVIDING ALL INFORMATION ON MY VEHICLE UNLESS I NOW TOW THE VEHICLE TO MIDDLETOWN NY AND ITS PHYSICALLY THERE. THEY DO NOT SEEM TO TAKE THE COMPLAINT SERIOUSLY. *TR

OUR 2010 KIA FORTE EX LOST 90% OF POWER REPEATEDLY (RPMS DROP TO IDLE, REGARDLESS OF THROTTLE POSITION) AT SPEEDS FROM 0-35MPH. THIS IS NOT THE FIRST OCCURRENCE, BUT I THINK IT IS THE SAME PROBLEM. THIS IS VERY DANGEROUS IF YOU ARE MAKING A LEFT TURN AND YOU LOSE ACCELERATION, YOU CAN BE IN THE WAY OF ONCOMING TRAFFIC BY LOSING POWER. ABOUT 2 YEARS AGO (25,000 MILES OR SO) THE TPS (THROTTLE POSITION SENSOR) WENT OUT. KIA COULD NOT DIAGNOSE IT UNTIL IT THREW A CODE (LAME). NOW WE GET THE SAME ISSUE, THE VEHICLE IS STALLING, OR "STUMBLING" WHEN THE SPEED SHOULD BE CONSTANT OR ACCELERATING, BUT THERE IS NO ENGINE CODE FOR THE CODE READER TO PICKUP YET, SO THE MECHANICS CAN'T FIGURE OUT WHAT TO DO. APPARENTLY THIS IS A PROBLEM ON MANY MODELS OF KIA/HYUNDAI AND THE MECHANICS DON'T RECOGNIZE IT SO THEY CAN'T FIX IT, AND YOU ARE STUCK WITH A DANGEROUS CONDITION. I THINK THERE SHOULD BE A RECALL OF THESE FAULTY TPS SENSORS. KIA/HYUNDAI SHOULD AT LEAST ISSUE A SAFETY TSB (TECHNICAL SERVICE BULLETIN) TO CLUE IN THEIR MECHANICS AS TO WHAT THE PROBLEM IS. HERE'S A GREAT ARTICLE SHOWING THE PROBLEM: HTTP://WWW.KIA-FORUMS.COM/KIA-CARNIVAL-SEDONA-2006/80251-TPS-SENSOR-SYMPTOMS-TPS-FAILURE-CEL.HTML THANKS FOR YOUR ATTENTION TO THIS MATTER. *TR

ODOR OF GASOLINE IN PASSENGER AND ENGINE COMPARTMENT. *TR