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Kia Sportage Gasoline Leak

19 messages,  Last post on Dec 05, 2011 at 12:38 AM

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What is this discussion about? Kia Sportage, Fuel System, SUV

Messages Page 1 of 2

#1 of 19 2001 Kia Sportage by kim48

Sep 15, 2007 (5:51 am)

My Sportage is leaking gas. My hubby looked and it appears to be coming from the bottom of the tank it self. Any one else have a problem with a bad gas tank? How was the cost to have it replaced?

#2 of 19 Re: 2001 Kia Sportage [kim48] by lightpainter

Sep 26, 2007 (7:04 pm)

Replying to: kim48 (Sep 15, 2007 5:51 am)
I discovered the same thing yesterday. The gas smell was very strong for a number of days, but I had no idea the gas tank itself was leaking. I have a 2000 Sportage and I am going to have Kia pay for the repairs. Seems this is a chronic problem with their cars of that time period.

#3 of 19 Re: 2001 Kia Sportage [lightpainter] by kim48

Sep 27, 2007 (3:30 am)

Replying to: lightpainter (Sep 26, 2007 7:04 pm)
Good luck with your SUV. I also tried to talk to kia to have the gas tank repaired, I got the reply that there's no more warranty that they weren't responsible for the repair. Its is a costly repair too. It cost me 931.00 for a new gas tank, It needs the whole unit, the tank, the sending unit, the only thing they saved was the shield around the tank. I dont know if you still have a warranty on your Sportage, But this is a safety issue. And there has been a couple complaints filed NHTSA for the gas leak problem and it is being investigated, If they have a safety problem the Sportage will be recalled. So be sure to file a complaint with them and Kia as well. My gas tank rusted out the side of the tank. Let me posted on your's

#4 of 19 Re: 2001 Kia Sportage [kim48] by lmp4

Oct 10, 2007 (2:54 am)

Replying to: kim48 (Sep 15, 2007 5:51 am)
I would not have imagined that should be included in the "perfect Sportage owner maintenance book" ...but after investigating a fuel leak I endured for some time (Sportage 2000), here are a few hints.
This tank is subject to a recall (inspection !!) in the USA, but not in Canada .
The tank is easy to remove ...but disconnect all hoses and electrical connectors first from the top access panel, under rear seat. The clamp for filler hose can be cut with a Dremmel tool then replaced, rather than trying to remove .
THe tank has a drain plug ...quite unusual...but a welcome feature that has a flaw : main cause of fuel leak proved to be the corrosion of the fuel tank drain plug seal/washer. This washer is aluminum and contact with steel tank and plug creates electrolysis and unavoidable corrosion of washer .

I replaced it with a steel washer and used teflon to seal the plug.
 
The corrosion was all over the tank
tankbefore
top
 
 Leaving it unattended would have lead to a total disintegration down the line but it still proved worthy at this time. The metal used is lower grade than tanks I have had on other cars. The padding between the shield and the tank keeps water and is a problem in itself.
 
After buffing the tank I covered it with 2 coats of spray rubberised asphalt as sold for undercar protection.
after1
after2
After reinstallation a tiny leak on bottom proved to have been exacerbated . TO be sure, I had not reinstalled the shield specifically in prevision of such an event so I did not have to remove the tank again.
  The leak cleared the asphalt coating a few incles around: emptying the tank again and tilting the car slighty on one side allowed to cure the hole with epoxy as the little remaining fuel was on the other side of the tank.
I painted the shield with Tremclad
skid plate
 but did not reinstall the padding .
 
An array of hoses are sandwitched between the tank and frame
lines
and the space was filled with sand and other debris: this is a trap for corrosion and I will ensure to wash that area from time to time. After removing as much rust as possible, I covered it all with spray asphalt.
 
Bottom line: this tank NEEDS maintenance in the first place, and then needs being washed with water specially in areas where salt is used in winter. Access from the top is easy and it can be washed from there, as well as the space between tank and frame.
Replace the plug seal as soon as possible as the aluminum original will corrode away inevitably.

#5 of 19 Re: 2001 Kia Sportage [lmp4] by steve_ HOST

Oct 10, 2007 (9:00 am)

Replying to: lmp4 (Oct 10, 2007 2:54 am)
Great post - maybe you could make a Guide out of it?

#6 of 19 Widespread problem with fuel tank. by johnfarmer

Oct 15, 2007 (9:31 pm)

I was suprised how widespread the problem with the Kia fuel tank was, and how costly it can be to fix. I'm a used vehicle dealer, and recently had a customer return shortly after purchasing a 2000 Sportage after filling the gas tank.
 
It's not a problem for me to make things right when there's a obvious defect. But I'm used to dealing with lots of resources to purchase parts and found that no-one makes an aftermarket tank. It seems there is such a demand for these tanks due to the failure rate, they are nearly non-existant used.
 
It clearly is a design defect, as the shield traps dirt and sediment which can rub the tank, and cause it to rust out. This is something that Kia should take care of, immediately.

#7 of 19 Re: Widespread problem with fuel tank. [johnfarmer] by lmp4

Oct 17, 2007 (2:12 pm)

Replying to: johnfarmer (Oct 15, 2007 9:31 pm)
Here is the US recall, published May 2006 and available on the Kia web site
RECALL
Canadian dealers say this recall does not apply in Canada so here we are on our own.
 
It states clearly that if leaks are revealed, the dealer must change the damaged part...however I saw no one on several KIA forums saying they had their tank changed for free, though........

#8 of 19 Re: Widespread problem with fuel tank. [lmp4] by robjbp

Dec 05, 2007 (4:03 pm)

Replying to: lmp4 (Oct 17, 2007 2:12 pm)
I thought I would share my knowledge on this subject since I just got back from the St. Catharines, Ontario dealership. I noticed a fuel smell coming from the back of my 2000 kia sportage, so looked around to notice it was coming from the plate a top of my fuel tank. A mechanic friend of mine got me to call kia to see if there where any recalls on such a problem, and after giving them my vin # they let me know there was a recall on the fuel pump module. I just got back from the dealer, they replaced the fuel tank, fuel pump module, and I'm going back tommarow because they bent the sending unit, so that will be replaced too. This was all done at no cost $0! So I suggest anyone with such a problem, call kia with your vin# ready.

#9 of 19 Re: Widespread problem with fuel tank. [robjbp] by lmp4

Dec 05, 2007 (5:50 pm)

Replying to: robjbp (Dec 05, 2007 4:03 pm)
Thanks....Excellent information as KIA dealer here in Chicoutimi Quebec refuses to abide by the US recall as posted before, saying all they were told by KIA canada was to change a connector on top of the fuel pump assembly plate.....
WIll print and show....

#10 of 19 Re: Widespread problem with fuel tank. [lmp4] by robjbp

Dec 06, 2007 (11:41 am)

Replying to: lmp4 (Dec 05, 2007 5:50 pm)
hope it works out for you. The service dept. had on the invoice that there was corrosion so they couldn't just replace the plate or whatever the recall part was because you can't install a new product on to a corroded part (well I guess you could, but I don't think that would be doing the job right). I might have just got really lucky with all this, I thought they would have just installed the part recalled and told me to take car of the rest if I wanted it done right, but who know's, hope all works out!

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