2021-2023 Kia Sorento Sportage Misfire DTC P030000

Kia has released Technical Service Bulletin (TSB) FUE066 to address engine misfire conditions in certain 2021-2023 Kia Sorento and Sportage vehicles. This bulletin specifically targets models equipped with the naturally aspirated Theta III 2.5L GDI engine, which utilizes both low-pressure (MPI) and high-pressure (GDI) fuel injection systems.

The TSB indicates that GDI fuel injectors can become damaged due to exposure to fuel containing ethanol. This damage can lead to various performance issues and trigger specific Diagnostic Trouble Codes (DTCs).

Symptoms

Owners of affected 2021-2023 Kia Sorento or Sportage vehicles may experience several symptoms related to this issue. These include the "malfunction indicator lamp (MIL) illuminating" on the dashboard, difficulty with "no-start" conditions, noticeable engine "misfire," and "reduced power." These problems can occur while driving, with symptoms potentially worsening at highway speeds.

Fault codes / DTCs

The following Diagnostic Trouble Codes (DTCs) are associated with this GDI fuel injector issue:

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

Diagnosis / trigger conditions

To diagnose this issue, technicians must confirm that the vehicle's Engine Control Unit (ECU) has stored one or more of the listed misfire DTCs using Kia Diagnostic System (KDS). Additionally, the vehicle must fall within the specified production date ranges. For Sorento (MQ4a) models, the affected production dates are from July 1, 2021, to June 10, 2022. For Sportage (NQ5) models, the range is December 15, 2021, to December 20, 2022, and for Sportage (NQ5a) models, it's January 12, 2022, to June 10, 2022.

A crucial step in the diagnostic flowchart involves checking the vehicle's history. If a misfire DTC is present and the vehicle's history shows that the injector on the affected cylinder has not been previously replaced, the TSB repair procedure should be followed. If an injector has been replaced before, this TSB is not applicable, and further diagnosis using the shop manual on KGIS is required.

Repair procedure summary

The repair procedure involves replacing all four GDI fuel injectors along with associated parts. The general steps include:

1. Confirmation: Verify that confirmed DTCs are stored and that the vehicle is within the specified production date range.
2. Replacement: Replace the fuel injectors, delivery pipe, and related components. This process requires referring to the "Engine Control / Fuel System → Fuel Delivery System → Delivery Pipe → Removal and Installation" instructions in the applicable Shop Manual on KGIS. The procedure also involves installing new clips for the GDI injectors and replacing the gaskets for the throttle body and intake manifold, as these are not reusable. The tightening torque for the pipe flange nut (A) is specified as 23.9 - 26 lb.ft (32.4 - 35.3 N.m).
3. Reinstallation: Reinstall all removed parts in the reverse order of removal.
4. DTC Clearance: Use KDS to clear all stored DTCs.
5. Confirmation: Confirm normal vehicle operation after the repair.

Required tools or parts

To perform this repair, the following special tool and parts are required:

Special Tool:

• 09353 L1100: Injector Combustion Seal Guide & Sizing Tool (typically found in Toolbox 1, Drawer 7).

Required Parts:

• 35399 2S033FFF: GDI Fuel Injector and Line Service Kit (includes 4 GDI Fuel Injectors (35310 2S000), 4 Fuel Injector Clips (35309 04AA0), and 1 High Pressure Pipe (35305 2S000)).
• 28411 2S010FFF: Intake Port Gasket (Qty: 3)
• 28411 2S020FFF: Intake Port Gasket (Qty: 1, not reusable)
• 28411 2S00OFFF: Throttle Body Gasket (Qty: 1)
• 28493 2S00OFFF: EGR Pipe Gasket (Qty: 1)
• 26332 2S00OFFF: Oil Filter Housing Gasket (Qty: 2, for NQ5, NQ5a only)
• UM020 CH263: Coolant (Qty: 3 gallons)
• NPNENG5W30: Synthetic Oil (Qty: 1 quart, 5W30)

Important warnings for owners

Owners should be aware of the following important information regarding this Technical Service Bulletin:

• No Customer Notification: "A Technical Service Bulletin is a field fix repair program without customer notification that may be performed during the warranty period." This means Kia will NOT be notifying consumers directly about this issue. Owners must be proactive in addressing any symptoms.
• Warranty Approval: "Any dealer requesting to perform this repair outside the warranty period will require DPSM approval."
• Vehicle Diagnosis Number (VDN): "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."
• Parts Ordering: "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."

Warranty information

This repair is covered under warranty with the following details:

• N Code: DB1
• C Code: ZZ3
• Claim Type: W (Warranty)
• Causal Part Number: 35310 2S000 (GDI Fuel Injectors)
• Repair Description: DTC Inspection + GDI Fuel Injector Replacement

Labor Operations and Times:

• For Sorento (MQ4a):
  • Labor Op Code: 37510F16
  • Operation Time: 1.7 Man-Hours
• For Sportage (NQ5, NQ5a):
  • Labor Op Code: 37510F18
  • Operation Time: 1.6 Man-Hours

All listed replacement part numbers are required for Sportage (NQ5, NQ5a) model applications.

NHTSA ID: FUE066