2002 Kia Sportage recalls and problems

KIA MOTORS AMERICA, INC. (KIA) HAS IDENTIFIED A DEFECT IN THE PLASTIC ENGINE COOLING FAN IN THE SUBJECT VEHICLES AND WILL CONDUCT A SAFETY RECALL.KIA'S DEFECT REPORT STATES, ...HEAT GENERATED BY THE ENGINE CAUSES REPEATED BENDING DEFORMATION OF THE POLYPROPYLENE COOLING FAN...INITIATING CRACKS IN THE FAN.THE CENTRIFUGAL FORCES GENERATED BY THE ROTATION OF THE BLADES CAN CAUSE THE CRACKS TO PROPAGATE UNTIL COMPLETE SEPARATION OCCURS...KIA ESTIMATES APPROXIMATELY 35,090 VEHICLES WILL BE SUBJECT TO THE RECALL, AS SOME OF THE 46,887 VEHICLES PRODUCED HAVE ALREADY HAD THE FAN REPLACED UNDER WARRANTY.KIA DEALERS WILL REPLACE THE ORIGINAL VERSION OF THE FAN WITH A FAN MADE OF IMPROVED MATERIAL.THIS INVESTIGATION WAS OPENED ON SEPTEMBER 21, 2006 AS PE06-042 AND UPGRADED TO ENGINEERING ANALYSIS EA07-001 ON JANUARY 22, 2007.PLEASE SEE NHTSA RECALL 07V161 FOR MORE DETAILED INFORMATION

THE INVESTIGATION OF ENGINE COOLING FANS IN THE SUBJECT VEHICLES WAS OPENED ON SEPTEMBER 21, 2006 AS PE06-042.THE BASIS FOR OPENING WAS 10 CONSUMER REPORTS ALLEGING FAN BLADE CRACKING AND BLADE SEPARATION.SIX OF THE REPORTS INDICATED THE SEPARATED FAN BLADES CAUSED DAMAGE TO OTHER ENGINE COMPARTMENT COMPONENTS.KIA HAS PROVIDED ADDITIONAL CONSUMER REPORTS AND INFORMATION IN ITS RESPONSE TO PE06-042.THE INVESTIGATION HAS BEEN UPGRADED TO ENGINEERING ANALYSIS (EA07-001) TO CONTINUE TO ASSESS THE CONSEQUENCE OF FAN BLADE SEPARATION IN THE SUBJECT VEHICLES.

A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.REVIEW OF THE WARRANTY DATA REVEALED ELEVATED TANK LEAKAGE EXPERIENCE IN VEHICLES PRODUCED FROM JUNE 1999 TO OCTOBER 2000.ANALYSIS OF COMPLAINTS AND WARRANTY CLAIMS IDENTIFIED MULTIPLE CAUSES AND ORIGINS OF FUEL TANK ASSEMBLY LEAKAGE.THE MAJORITY OF COMPLAINTS INVOLVE NON-SPECIFIC ALLEGATIONS OF FUEL LEAKAGE WHERE MORE THAN ONE FUEL SYSTEM COMPONENT WAS REPLACED.ODI'S ANALYSIS FOCUSED ON LEAKS OCCURRING ON THE UNDERSIDE OF THE TANK DUE TO CORROSIVE FAILURE CAUSED BY DISRUPTION OF THE PROTECTIVE PVC COATING.THE ANALYSISINDICATES THAT SUCH LEAKS ARE RARE AND DO NOT SHOW EVIDENCE OF AN INCREASING TREND. 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 TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES. SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.

INFORMATION RECEIVED AND ANALYZED DURING THIS RQ DISCLOSED THAT MY 1999 AND 2000 KIA SEPHIA AND SPORTAGE VEHICLES WERE EQUIPPED WITH MODIFIED VERSIONS OF THE SAME SAFETY BELT LATCH ASSEMBLY AS THOSE RECALLED IN CAMPAIGN NO. 02V-216.THESE LATCH ASSEMBLIES WERE IDENTIFIED AS TYPE A97. ODI ANALYSES INDICATE A CONTINUING TREND OF CONSUMER COMPLAINTS FOLLOWING A SERIES OF DESIGN MODIFICATIONS MADE BY KIA TO IMPROVE THE A97 LATCH ASSEMBLY.MY 2001 AND 2002 SUBJECT VEHICLES WERE EQUIPPED WITH DIFFERENT DESIGN LATCH ASSEMBLIES (TYPE DB-6 OR AUTOLIV) AND EXHIBIT A MUCH LOWER COMPLAINT COUNT.THIS RQ HAS BEEN UPGRADED TO AN EA IN ORDER TO FURTHER INVESTIGATE THIS MATTER FOR THE SUBJECT VEHICLES EQUIPPED WITH TYPE A97 LATCH ASSEMBLIES.