2021-2023 Kia Sorento and Sportage Misfire DTCs

Symptoms of GDI Fuel Injector Issues

If your 2021-2023 Kia Sorento or Sportage is experiencing a misfire, no-start condition, or reduced power, especially with the Malfunction Indicator Lamp (MIL) illuminated, it may be related to GDI fuel injector issues. These symptoms are often accompanied by specific diagnostic trouble codes (DTCs) indicating a misfire. The problem stems from GDI fuel injectors in the Theta III 2.5L GDI engine potentially becoming damaged due to exposure to ethanol in fuel.

Diagnostic Trouble Codes (DTCs)

The following Diagnostic Trouble Codes (DTCs) are associated with the GDI fuel injector issue and are key indicators of a potential Kia Sportage misfire DTCs problem. If any of these codes are stored in your vehicle's ECU, the TSB repair procedure may be applicable.

Code	Description
P030000	Random/Multiple Cylinder Misfire Detected
P030100	Cylinder 1 Misfire Detected
P030200	Cylinder 2 Misfire Detected
P030300	Cylinder 3 Misfire Detected
P030400	Cylinder 4 Misfire Detected

Important Warnings for Owners and Technicians

Kia has issued several critical warnings regarding this service bulletin:

• "This bulletin should only be performed with valid customer complaint of M.I.L 'ON' with a no-start, misfire, and/or reduced power."
• "Customer complaint of a MIL 'ON' with a no-start, misfire, and/or reduced power MUST be stated in the opening RO and Claim Notes."
• "The replacement FFF part numbers will require a VIN entry for parts ordering. DO NOT order these parts for stocking purposes, related to this TSB. Supply is very limited. Until supply stabilizes, please confirm part availability before scheduling customers. Please be sure to expedite warranty claim filing."
• "A Vehicle Diagnosis Number (VDN) must be created for DTC's P030000, P030100, P030200, P030300, and/or P030400 prior to ordering parts and performing necessary procedure(s), as outlined in this TSB. If a VDN is not created, Parts Ordering and Warranty claim submission issues WILL occur. Any claims for replacement parts are subject to Warranty review and chargeback."

Repair Procedure Summary

The repair procedure for these Kia Sportage misfire DTCs involves replacing all four GDI fuel injectors and associated components. Technicians should confirm the stored DTCs and verify the vehicle falls within the specified production date range. The general steps include:

1. Confirm that the vehicle's ECU has the relevant misfire DTCs stored.
2. Replace all four GDI fuel injectors, the delivery pipe, and other related parts. Detailed instructions are available in the applicable Shop Manual on KGIS under "Engine Control / Fuel System → Fuel Delivery System → Delivery Pipe → Removal and Installation."
3. During installation, new clips must be used for the GDI injectors. Non-reusable gaskets for the throttle body and intake manifold must also be replaced.
4. Ensure the pipe flange nut is tightened to a torque of 23.9 - 26 lb.ft (32.4 - 35.3 N.m).
5. Reinstall all previously removed parts in reverse order of removal.
6. Clear all Diagnostic Trouble Codes (DTCs) using the Kia Diagnostic System (KDS).
7. Confirm the vehicle operates normally after the repair.

Required Tools and Parts

To perform this repair, specific tools and parts are required:

Required Tool:

• Injector Combustion Seal Guide & Sizing Tool (Part Number: 09353 L1100)

Required Parts:

Part Name	Part Number	Qty.	Comments
GDI Fuel Injector and Line Service Kit	35399 2S033FFF	1	Dealers MUST order this kit PN
GDI Fuel Injectors	35310 2S000	4
Fuel Injector Clips	35309 04AA0	4
High Pressure Pipe	35305 2S000	1
Intake Port Gasket	28411 2S010FFF	3
Intake Port Gasket	28411 2S020FFF	1	Not Reusable
Throttle Body Gasket	28411 2S000FFF	1	Not Reusable
EGR Pipe Gasket	28493 2S000FFF	1
Oil Filter Housing Gasket	26333 2S000	2
Coolant	UM020 CH263	3 gallons	NQ5, NQ5a only
Synthetic Oil	T0530 QRT12A or UM050 CH035	1 quart	5W30

Warranty Information

This repair is considered a field fix program and is typically covered during the warranty period. The warranty information codes are N Code: N99 and C Code: C99. It is crucial to create a Vehicle Diagnosis Number (VDN) for the relevant DTCs (P030000, P030100, P030200, P030300, and/or P030400) before ordering parts or performing the procedure. Failure to do so may lead to issues with parts ordering and warranty claim submission, potentially resulting in chargebacks.

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Source: NHTSA ID 11019972