2004 Kia Optima Fuel System Problems

After refueling your 2004 Kia Optima, the engine won't start. You suspect this is related to a known fuel system issue, but your vehicle was checked and confirmed not to be part of any recall. The problem occurred at around 145,000 miles. A mechanic may need to inspect your fuel pump, fuel filter, or fuel injectors to identify why the engine is failing to start after refueling.

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

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

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.

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

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

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

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.