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2002 Kia Sedona

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2002 Kia Sedona do not stand out strongly from the model-year median of 120.

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When problems were reported

Mileage at the reported incident

109 reports with mileage · 89 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 50 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Seat Belts. Review the 28 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 27 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

17 crash reports13 fire reports11 injury reports

Electrical System complaints

50 reports
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Mileage unknown · Jul 14, 2004
Electrical SystemFuel System, GasolineSeats

MY KIA SODONA VAN AT 63,000 MILES BEGAN TO STALL AFTER INITIAL START. ENGINE HAS TO BE REVVED REPEATEDLY TO GET IT TO GO. TOOK IT IN AND WAS TOLD THE ALTERNATOR NEEDED REPLACING, 400+ DOLLARS AND A WHOLE DAY OF WAITING IT IS STILL NOT RUNNING RIGHT, IN FACT IT IS WORSE THAN BEFORE. WAS TOLD TO BRING IT BACK IN, MAY HAVE A FUEL P…

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MY KIA SODONA VAN AT 63,000 MILES BEGAN TO STALL AFTER INITIAL START. ENGINE HAS TO BE REVVED REPEATEDLY TO GET IT TO GO. TOOK IT IN AND WAS TOLD THE ALTERNATOR NEEDED REPLACING, 400+ DOLLARS AND A WHOLE DAY OF WAITING IT IS STILL NOT RUNNING RIGHT, IN FACT IT IS WORSE THAN BEFORE. WAS TOLD TO BRING IT BACK IN, MAY HAVE A FUEL PROBLEM. WAS THE ALTERNATOR EVEN BAD?!! OTHER THINGS CONTINUE TO BREAK OR FALL APART ON THE VAN. HEAD SUPPORTS ARE BROKEN ON TWO SEATS, WILL NOT STAY UP. IF IN A CRASH WOULD NOT HAVE THE SUPPORT THESE ARE SUPPOSED TO GIVE! ONE OF THE SIDE DOORS WILL NOT CLOSE PROPERLY. WAS TOLD IT WOULD BE AROUND 100 DOLLARS TO CHANGE OUT A BALL BEARING IN THE DOOR! THESE ARE NOT COVERED UNDER THE WONDERFUL BOGUS 100,000 MILE WARRANTY. *AK

NHTSA ODI #10081047

Mileage unknown · Jun 12, 2004
Air BagsElectrical SystemLatches/locks/linkages

WE HAVE A 2002 SEDONA. WE HAVE OWNED IT FOR 2 YEARS. AND THIS IS THE 7TH TIME THE AIRBAG LIGHT HAS COME ON AND STAYED ON. EVEY TIME WE TAKE IT IN THEY REPLACE SOMETHING, ONCE WAS THE SEAT BELT LATCH, ANOTHER TIME WAS A PART IN THE COMPUTER AND SO ON. THEY JUST DON'T KNOW WHAT IS CAUSING IT TO COME ON, SO THEY TELL ME. THAT I…

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WE HAVE A 2002 SEDONA. WE HAVE OWNED IT FOR 2 YEARS. AND THIS IS THE 7TH TIME THE AIRBAG LIGHT HAS COME ON AND STAYED ON. EVEY TIME WE TAKE IT IN THEY REPLACE SOMETHING, ONCE WAS THE SEAT BELT LATCH, ANOTHER TIME WAS A PART IN THE COMPUTER AND SO ON. THEY JUST DON'T KNOW WHAT IS CAUSING IT TO COME ON, SO THEY TELL ME. THAT IS SUCH A REASSURING ANSWER FOR A CAR OWNER. WE HAVE ALSO HAD PROBLEMS WITH THE BATTERY, HATCHBACK NOT OPENING AND HAVING DENTS IN IT FROM WHEN WE SHUT IT AND BREAK PROBLEMS THAT THEY REFUSSED TO FIX UNTIL AFTER THE WARRENTY EXPIRED. IT IS TIME NOW FOR AN ATTORNEY TO STEP IN FOR US.*AK

NHTSA ODI #10075273

1,000 miles · Jun 8, 2004
Electrical SystemEngine And Engine Cooling

VEHICLE STALLED DUE TO AN ELECTRICAL COMPONENT SHORTING OUT THE BATTERY. THE BATTERY WAS REPLACED 4 TIMES AND ALTERNATOR WAS REPLACED ONCE. ALSO, THE ENGINE LIGHT CAME ON WHILE DRIVING. DEALERSHIP REPLACED THE ENTIRE MOTOR. VEHICLE BURNED EXCESSIVE FUEL UNDER NORMAL DRIVING CONDITION. THE ABOVE REPAIRS ONLY PROVIDED A TEM…

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VEHICLE STALLED DUE TO AN ELECTRICAL COMPONENT SHORTING OUT THE BATTERY. THE BATTERY WAS REPLACED 4 TIMES AND ALTERNATOR WAS REPLACED ONCE. ALSO, THE ENGINE LIGHT CAME ON WHILE DRIVING. DEALERSHIP REPLACED THE ENTIRE MOTOR. VEHICLE BURNED EXCESSIVE FUEL UNDER NORMAL DRIVING CONDITION. THE ABOVE REPAIRS ONLY PROVIDED A TEMPORARY SOLUTION FOR THE PROBLEMS.*AK

NHTSA ODI #10075890

3,300 miles · Feb 17, 2004
Electrical SystemLatches/locks/linkagesService Brakes, HydraulicFire

ON JULY 4, 2002 WE PURCHASED A 2002 KIA SEDONA MINIVAN. IMMEDIATELY AFTER DRIVING OUT OF THE DEALERSHIP WE PARKED AT A STORE, WHEN WE RETURNED TO THE VEHICLE IT WOULD NOT START. WE CALLED THE DEALERSHIP AND THEY SENT OUT A TOW TRUCK. THE VAN WAS TOWED TO THE DEALERSHIP AND THE SERVICE ADVISER INDICATED THAT THEY HAD NUMEROUS …

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ON JULY 4, 2002 WE PURCHASED A 2002 KIA SEDONA MINIVAN. IMMEDIATELY AFTER DRIVING OUT OF THE DEALERSHIP WE PARKED AT A STORE, WHEN WE RETURNED TO THE VEHICLE IT WOULD NOT START. WE CALLED THE DEALERSHIP AND THEY SENT OUT A TOW TRUCK. THE VAN WAS TOWED TO THE DEALERSHIP AND THE SERVICE ADVISER INDICATED THAT THEY HAD NUMEROUS COMPLAINTS REGARDING A DRIVER SEAT RELAY THAT WAS CAUSING THE BATTERIES TO GO OUT ON THIS YEAR, MAKE AND MODEL OF VEHICLE. HE INDICATED THAT THEY WERE CHANGING ALL RELAYS. THEY REPLACED WITH NEW BATTERY AND NEW RELAY ON THE VAN. THE VAN CONTINUED TO GIVE US PROBLEMS, THE WHOLE ELECTRICAL SYSTEM (STEREO, WINDOWS, DOOR LOCKS) WOULD GO OFF AND ON AS WE WERE DRIVING. IF WE WOULD STOP VEHICLE, THE VEHICLE WOULD NOT START. WE HAD NUMEROUS JUMP STARTS. WE TOOK THE VEHICLE IN APPROX. 4 OR 5 TIMES TO THE DEALERSHIP WITH COMPLAINTS REGARDING PROBLEMS, THERE WAS BLACK SMOKE COMING OUT OF THE EXHAUST WHEN WE WOULD START THE VEHICLE. BRAKES WOULD SQUEAL WHEN APPLIED. VAN WAS TERRIBLY HOT UNDER THE CAR AND IT WOULD BLOW OUT THE HEAT AND ALMOST BURN US. I ASKED THE SERVICE ADVISER IF THEY COULD EXCHANGE THE VAN FOR ANOTHER ONE AND HE INDICATED THAT THEY HAD TO HAVE A CONTINUOUS REPORT OF REPAIRS IN ORDER TO TURN IT IN AS A "LEMON". WE WERE TRAVELING IN MEXICO FOR BUSINESS AND PLEASURE WHEN OUR VAN STARTED ON FIRE ON THE HIGHWAY AND OTHER AUTOS NOTICED AND WAVED US DOWN TO STOP. WE NOTICED, PULLED OFF THE ROAD SAFELY AND ALL 6 ADULT PASSENGERS WERE ABLE TO GET OUT SAFELY AND RUN AWAY FROM THE VEHICLE AS IT STARTED EXPLODING. THE FIRE CAME FROM ALL UNDERNEATH OF THE VAN. THE MEXICAN FEDERAL HIGHWAY POLICE CAME TO WHERE THE VAN WAS AND TOOK A REPORT OF THE INCIDENT. THE VAN BURNT DOWN TO A SKELETON. I REPORTED THE INCIDENT TO THE KIA CUSTOMER SERVICE, THEY DENIED OUR CLAIM WITHOUT NO EXPLANATION. NO ONE EVER CALLED TO FIND OUT THE FACTS OR GATHER INFORMATION. OBVIOUSLY, THEY DID NOT EVEN LOOK AT THEIR OWN SERVICE REPAIR TICKETS. *JB

NHTSA ODI #10058351

47,857 miles · Dec 29, 2003
Electrical SystemExterior LightingInterior Lighting

WE PURCHASED THE 2002 KIA SEDONA YESTERDAY 12-28-03. WE DROVE THE CAR FOR ABOUT 45 MINUTES TODAY, STOPPED FOR DINNER AT A FAST FOOD RESTAURANT AND THEN DROVE AGAIN FOR ABOUT 10 MINUTES WHEN WHILE DRIVING THE VEHICLE, THE BATTERY AND BRAKE WARNING LIGHTS FLASHED ON AND OFF A FEW TIMES, THEN STAYED ON. WHEN THE BRAKE PEDAL WAS DE…

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WE PURCHASED THE 2002 KIA SEDONA YESTERDAY 12-28-03. WE DROVE THE CAR FOR ABOUT 45 MINUTES TODAY, STOPPED FOR DINNER AT A FAST FOOD RESTAURANT AND THEN DROVE AGAIN FOR ABOUT 10 MINUTES WHEN WHILE DRIVING THE VEHICLE, THE BATTERY AND BRAKE WARNING LIGHTS FLASHED ON AND OFF A FEW TIMES, THEN STAYED ON. WHEN THE BRAKE PEDAL WAS DEPRESSED, THE RADIO SHUT OFF AND WOULD NOT COME BACK ON. THEN THE SEATBELT WARNING LIGHT CAME ON AND THE DASH LIGHTS, EXTERIOR AND INTERIOR LIGHTS DIMMED. WHILE CAR WAS STILL IN MOTION, THE SUNROOF WOULD NOT CLOSE AND THE OTHER WINDOWS WERE VERY SLOW AT CLOSING. THE CAR SHUDDERED A COUPLE OF TIMES AS IF READY TO STALL. WE MADE IT HOME JUST IN TIME, THE CAR STALLED AND WOULD NOT RESTART. WE WERE ABLE TO CLOSE THE SUNROOF, BUT IT WAS VERY SLOW. WE HAVE TRIED TO CHARGE THE BATTERY, BUT IT DOES NOT SEEM TO BE TAKING A CHARGE. SECONDLY THE SEATBELT INDICATOR LIGHT DOES NOT SOUND OR INDICATE THAT SEATBELTS ARE NOT BUCKLED. THIRDLY THERE IS MOISTURE UNDER THE DRIVERS SIDE HEAD LIGHT. ALSO, WHEN THE VEHICLE IS IN MOTION AND THE DVD PLAYER IS OPERATING, THERE IS A WHISTLING SOUND HEARD THROUGH THE DVD HEADPHONES/SOUND DURING ACCELERATION. WE WILL BE NOTIFYING THE DEALER TOMORROW MORNING.

NHTSA ODI #10051291

35,000 miles · Dec 15, 2003
Electrical System

UNKNOWN ELECTRICAL DRAIN IN ELECTRICAL SYSTEM LEAVES BATTERY DEAD. HAS HAPPENED ON SEVERAL OCCASIONS REQUIRING JUMP STARTS.*AK

NHTSA ODI #10049763

14,921 miles · Aug 10, 2003
Electrical System

REMOTE ENTRY LOCKS OFTEN DO NOT WORK. DEALER SAID OTHER OWNERS HAVE COMPLAINED OF THE SAME THING BUT MANUFACTURER IS UNABLE TO PINPOINT THE PROBLEM AND NO FIX IS CURRENTLY AVAILABLE. *NLM

NHTSA ODI #10031204

Mileage unknown · Jul 24, 2003
Electrical SystemVisibility

KIA-SEDONA. WINSHIELD CRACKS. BATTERY DRAINES WHEN VAN SITS 2 OR MORE DAYS. I HV CONTACTED THE DEALR. AM SCHEDULING SERVICE. HAVE HAD TO JUMP START THE VAN 3 TIMES IN THE LAST YEAR. WINSHIELD CRACKED RECENTLY WHILE DRIVING(NO OBJECTS INVOLVED). BELIEVE THIS IS AN ONGOING PROBLEM. FRIEND HAS SIMILIAR PROBLEM WITH 2002 SEDONA. DEA…

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KIA-SEDONA. WINSHIELD CRACKS. BATTERY DRAINES WHEN VAN SITS 2 OR MORE DAYS. I HV CONTACTED THE DEALR. AM SCHEDULING SERVICE. HAVE HAD TO JUMP START THE VAN 3 TIMES IN THE LAST YEAR. WINSHIELD CRACKED RECENTLY WHILE DRIVING(NO OBJECTS INVOLVED). BELIEVE THIS IS AN ONGOING PROBLEM. FRIEND HAS SIMILIAR PROBLEM WITH 2002 SEDONA. DEALER REPLACED. DRIVER WINDOW CLOSES TOO TIGHTLY WHEN BUTTON IS HELD TO CLOSE. MAKES CRACKING NOISE. *AK

NHTSA ODI #10029066

Mileage unknown · Jul 22, 2003
Electrical SystemEngine And Engine CoolingEquipment

MY 2002 KIA SEDONA HAS EXPERIENCED MULTIPLE PROBLEMS SINCE I BOUGHT IT IN MARCH, 2002. MAJOR ELECTRICAL PROBLEMS, BATTERY REPLACEMENT, SLIDING DOOR FAILING TO CLOSE, ENGINE NOISE, AIR CONDITIONER PROBLEMS. HAVE CONTACTED MANUFACTURER AND DEALER. SOME ISSUES RESOLVED - - OTHERS UNABLE TO BE DIAGNOSED OR REPLICATED. FEAR THAT …

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MY 2002 KIA SEDONA HAS EXPERIENCED MULTIPLE PROBLEMS SINCE I BOUGHT IT IN MARCH, 2002. MAJOR ELECTRICAL PROBLEMS, BATTERY REPLACEMENT, SLIDING DOOR FAILING TO CLOSE, ENGINE NOISE, AIR CONDITIONER PROBLEMS. HAVE CONTACTED MANUFACTURER AND DEALER. SOME ISSUES RESOLVED - - OTHERS UNABLE TO BE DIAGNOSED OR REPLICATED. FEAR THAT ENGINE, ELECTRICAL SYSTEM IS STILL NOT WORKING PROPERLY AND WILL FAIL AND CAUSE AN ACCIDENT.*AK

NHTSA ODI #10028851

3,800 miles · Jun 11, 2003
Electrical SystemEngine And Engine CoolingFire

FROM 2ND WEEK WE COMPLAINED OF ENGINE NOISE. EACH TIME NO PROBLEM WAS FOUND. FEW MONTHS LATER CK ENGINE CAME ON. A SPARK PLUG WAS REPLACED. 1 MONTH LATER CK ENGINE LIGHT ON AGAIN. NEW FUEL INJECTOR. 2 DAYS LATER CK ENGINE LIGHT AGAIN. NEEDED NEW MOTOR AT 3800 MILES. 1 WEEK LATER CAUGHT ON FIRE IN OUR GARAGE. KIA REGIONAL MAN…

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FROM 2ND WEEK WE COMPLAINED OF ENGINE NOISE. EACH TIME NO PROBLEM WAS FOUND. FEW MONTHS LATER CK ENGINE CAME ON. A SPARK PLUG WAS REPLACED. 1 MONTH LATER CK ENGINE LIGHT ON AGAIN. NEW FUEL INJECTOR. 2 DAYS LATER CK ENGINE LIGHT AGAIN. NEEDED NEW MOTOR AT 3800 MILES. 1 WEEK LATER CAUGHT ON FIRE IN OUR GARAGE. KIA REGIONAL MANAGEMENT CHRIS BUTLER SAID THEY WOULD REPAIR DAMAGES FROM FIRE BUT HAD NO CONCERN THAT OUR 6 MONTH OLD VAN WITH ONLY 3800 MILES ALREADY HAD THE MOTOR REPLACE AND CAUGHT ON FIRE. HIS ADVISE DON'T PARK IN THE GARAGE ANYMORE SO WE WON'T HAVE TO WORRY ABOUT IT BURNING DOWN OUR HOUSE. IRONIC THAT WE CHOOSE THIS VAN BECAUSE WE THOUGHT IT WOULD BE EASIER AND SAFER FOR OUR KIDS. NOW I FEAR OUR FAMILIES SAFETY EVERYDAY BECAUSE WE HAVE IT. *AK

NHTSA ODI #10021392

Official recalls

3

05V013000 · Vehicle Speed Control:cables

Jan 19, 2005

ON CERTAIN MINI VANS, DURING ASSEMBLY, THE THROTTLE CABLE WOULD TWIST ITSELF OUT OF POSITION.

Consequence & remedy

Consequence: THIS CAN PERMIT THE CABLE TO BE HUNG UP, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE THROTTLE CABLE FREE OF CHARGE. VEHICLES PRODUCED FROM MARCH 20, 2001 THROUGH NOVEMBER 7, 2001 WILL HAVE A GUIDE CLIP INSTALLED ON THE THROTTLE BODY ASSEMBLY IN ORDER TO ENSURE THAT THE TENSION FORCE CABLE DOES NOT MOVE OUT OF POSITION. VEHICLES MANUFACTURED BEGINNING ON NOVEMBER 8, 2001, ALREADY HAVE THE EXTENDED GUIDE, WHICH ACCOMPLISHES THE SAME OBJECTIVE. THE RECALL BEGAN MARCH 21, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.

03V135000 · Seats:mid/rear Assembly

Apr 3, 2003

ON CERTAIN PASSENGER VEHICLES, SOME OF THE SECOND AND THIRD ROW SEAT STRIKERS INSTALLED ON THE VEHICLE FLOOR PAN HAVE BEEN IMPROPERLY HEAT TREATED AND COULD BREAK IN A CRASH.

Consequence & remedy

Consequence: THIS COULD RESULT IN INJURIES TO OCCUPANTS OF THESE SEATS.

Remedy: DEALERS WILL REPLACE THE SEAT STRIKERS. OWNER NOTIFICATION BEGAN APRIL 25, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT KIA AT 1-800-333-4542

03V017000 · Seat Belts:rear/other

Jan 22, 2003

CERTAIN MINI VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES." THE SECOND AND THIRD SEAT BELT BUCKLE ANCHOR BOLTS DO NOT COMPLY WITH THE STANDARDS.

Consequence & remedy

Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED.

Remedy: DEALERS WILL REPLACE THE SEAT BELT BUCKLE ANCHOR BOLTS. OWNER NOTIFICATION BEGAN FEBRUARY 24, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT KIA AT 1-800-333-4542.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

3

EA08017 · Steering Intermediate Shaft Binding

Opened Aug 28, 2008 · Closed Jul 1, 2009

Status: closed (inferred from source dates) · Steering

ODIS ANALYSIS OF WARRANTY DATA SHOWS THAT THE ALLEGED DEFECT HAS OCCURRED AT A RELATIVELY HIGH FREQUENCY IN SALT-BELT STATES (5.9 PERCENT).HOWEVER, THE TESTS CONDUCTED BY ODI AND KIA HAVE SHOWN THAT THE ALLEGED DEFECT HAS A MINIMAL EFFECT ON STEERING EFFORTS.IN ADDITION, ODI INTERVIEWS OF OWNERS WHO EXPERIENCED THE ALLEGED DEFECT SHOWED THAT IN MOST CASES THE PROBLEM WAS PRECEDED BY MONTHS OR YEARS OF NOISE OR A GRADUAL INCREASE IN STEERING EFFORTS AND WAS MORE OF A NUISANCE CONCERN. THERE HAS BEEN ONE ALLEGATION OF A MINOR CRASH RELATED TO THE ALLEGED DEFECT, INVOLVING A MY 2003 KIA SEDONA WITH 59,900 MILES.THE VEHICLE HAD BEEN CHECKED TWICE IN THE PREVIOUS NINE MONTHS BY A DEALER FOR COMPLAINTS OF STIFF STEERING AND THAT THE VEHICLE FELT LIKE IT WAS INTERMITTENTLY LOSING POWER ASSIST.THE CRASH OCCURRED AS THE DRIVER WAS ATTEMPTING TO MAKE A LEFT TURN WHILE TRAVELING AT APPROXIMATELY 20 MILES PER HOUR AND STRUCK A VEHICLE PARKED ON THE RIGHT SIDE OF THE STREET THAT THE VEHICLE WAS TURNING INTO. THE CRASH RESULTED IN MINOR INJURIES TO THE DRIVER. AFTER THE CRASH, IT WAS DETERMINED THAT THE INTERMEDIATE SHAFT WAS EXHIBITING SOME BINDING OF THE STEERING INTERMEDIATE SHAFT BEARINGS.WHILE THE ABSENCE OF ADDITIONAL CRASHES OR INJURIES DOES NOT MEAN THAT THERE IS NOT A SAFETY-RELATED DEFECT, THERE HAVE BEEN NO REPORTED ADDITIONAL CRASHES CAUSED BY THE ALLEGED DEFECT IN THE PAST THREE YEARS. THE RELEASE OF THE TECHNICAL SERVICE BULLETIN SHOULD ASSIST SERVICE PERSONAL IN DIAGNOSING THIS POTENTIAL PROBLEM LONG BEFORE IT BECOMES POTENTIALLY DANGEROUS.ACCORDINGLY, THIS INVESTIGATION IS CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.FOR ADDITIONAL INFORMATION REGARDING THIS ENGINEERING ANALYSIS REFER TO THE EA08-017 CLOSING REPORT.

PE08033 · Steering Binding

Opened Apr 28, 2008 · Closed Aug 28, 2008

Status: closed (inferred from source dates) · Steering

ON APRIL 28, 2008, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED PRELIMINARY EVALUATION PE08-033 TO INVESTIGATE COMPLAINTS ALLEGING STEERING BINDING IN MODEL YEAR 2002 THROUGH 2004 KIA SEDONA MINIVANS.KIA'S RESPONSE TO ODI'S REQUEST FOR INFORMATION IN PE08-033 INDICATED THAT CONCERNS WITH BINDING OF THE STEERING INTERMEDIATE SHAFT WERE FIRST IDENTIFIED AND INVESTIGATED IN AUGUST 2002, IN VEHICLES SOLD IN INDONESIA.THIS INVESTIGATION RESULTED IN THE ADDITION OF A STIFFENING RIB TO THE BEARING CAP SEAL.IN JUNE 2003, KIA AGAIN INVESTIGATED OWNER COMPLAINTS OF STEERING NOISE AND HIGHER THAN NORMAL STEERING RESISTANCE AND IN OCTOBER AND NOVEMBER OF 2003 DESIGN CHANGES TO THE SHAFT UNIVERSAL JOINT BEARINGS WERE MADE TO IMPROVE LUBRICANT RETENTION AND ELIMINATE WATER INTRUSION THAT COULD LEAD TO EARLY BEARING FAILURE.ACCORDING TO KIA, THE ALLEGED DEFECT RESULTS IN A PROGRESSIVE CHANGE IN STEERING EFFORT THAT SHOULD BE APPARENT TO THE DRIVER THROUGH NOISE AND GRADUAL CHANGES IN STEERING STIFFNESS LONG BEFORE THE CONDITION COULD BECOME DANGEROUS. ODI'S ANALYSES OF COMPLAINT AND WARRANTY DATA RELATING TO THE ALLEGED DEFECT SHOW THAT THE CONDITION IS OCCURRING AT SIGNIFICANTLY HIGHER RATES IN SALT-BELT STATES (NOTE:FOR PURPOSES OF THIS INVESTIGATION THE SALT BELT INCLUDES CONNECTICUT, DELAWARE, THE DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA AND WISCONSIN).THE WARRANTY RATE FOR REPLACEMENT OF THE STEERING INTERMEDIATE SHAFT IS 5.5% FOR VEHICLES SOLD IN THE SALT BELT AND 0.5% FOR THE REST OF THE UNITED STATES.THE COMPLAINT RATE FOR THE ALLEGED DEFECT IS 186.8 PER 100,000 VEHICLES IN THE SALT BELT AND 29.4 PER 1000,000 VEHICLES FOR THE REST OF THE UNITED STATES.THERE IS ONE ALLEGATION OF A CRASH RELATED TO THE ALLEGED DEFECT.A SUBJECT VEHICLE STRUCK TWO PARKED CARS WHILE ATTEMPTING TO MAKE A LEFT TURN, ALLEGEDLY RESULTING IN MINOR INJURIES TO THE DRIVER. ODI HAS UPGRADED THIS INVESTIGATION TO AN ENGINEERING ANALYSIS (EA08-017) COVERING MY 2002 THROUGH 2004 KIA SEDONA VEHICLES SOLD OR CURRENTLY REGISTERED IN SALT BELT STATES TO ASSESS THE FREQUENCY AND TREND OF THE ALLEGED DEFECT AND ITS EFFECT ON STEERING EFFORT.

PE04067 · Throttle Cable Binding

Opened Sep 24, 2004 · Closed Jan 27, 2005

Status: closed (inferred from source dates) · Vehicle Speed Control; Vehicle Speed Control:cables; Vehicle Speed Control:linkages

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Additional source detail variants (6)

Vehicle Speed Control:cables

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control:cables

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control:linkages

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.

Vehicle Speed Control:linkages

KIA PROVIDED INFORMATION DESCRIBING A WATER ENTRY POINT AT THE RUBBER SEALING BOOT LOCATED AT THE THROTTLE BODY END OF THE THROTTLE CABLE, ADVISING THAT WATER COULD ENTER THE CABLE SHEATH DURING NORMAL VEHICLE OPERATION.IN LOW TEMPERATURES, THE WATER FREEZES AND MAY IMPEDE THE MOVEMENT OF THE THROTTLE CABLE THEREBY PREVENTING AN OPEN THROTTLE FROM RETURNING TO THE CLOSED POSITION.A STUCK THROTTLE COULD INCREASE THE RISK OF A CRASH.TO PREVENT WATER INGRESS, KIA INCREASED THE CRIMPING FORCE OF THE CLAMP INSTALLED ON THE RUBBER BOOT FROM 2 TO 5 KILOGRAMS FORCE.THE ACTION TOOK PLACE IN APRIL 2004 AND OCCURRED IN CONNECTION WITH OTHER CHANGES TO THE THROTTLE CABLE SYSTEM.TO REMEDY THE VEHICLES BUILT BEFORE THIS DATE (ALL OF MY 2002 AND PART OF 2003), KIA WILL CONDUCT A SAFETY RECALL TO REPLACE THE DEFECTIVE CABLE WITH AN IMPROVED COMPONENT.CERTAIN RECALLED VEHICLES WILL ALSO HAVE AN ADDITIONAL CLIP INSTALLED TO ADDRESS A POTENTIAL CABLE DISENGAGEMENT CONCERN.SEE KIA'S JANUARY 17, 2005 PART 573 LETTER FOR NHTSA RECALL 05V013 (KIA RECALL SC-042) FOR FURTHER INFORMATION.NO ACTION IS BEING TAKEN ON VEHICLES BUILT AFTER APRIL 4, 2004.