2021-2023 Kia Sorento Sportage GDI Misfire DTC TSB

Symptoms

Owners of affected 2021-2023 Kia Sorento and Sportage vehicles may experience several symptoms indicating a GDI fuel injector issue. These include the malfunction indicator lamp (MIL) illuminating, difficulty starting the vehicle, a noticeable misfire during operation, and/or reduced engine power, especially when driving at highway speeds.

Fault Codes / DTCs

If your vehicle is experiencing these symptoms, the engine control unit (ECU) may store one or more of the following Diagnostic Trouble Codes (DTCs):

Diagnosis / Trigger Conditions

This technical service bulletin (TSB) applies to 2021-2023 Kia Sorento and Sportage models equipped with the naturally aspirated Theta III 2.5L GDI engine. The issue stems from GDI fuel injectors potentially becoming damaged due to exposure to ethanol-containing fuel.

To diagnose the issue, a technician will confirm that the ECU has stored the relevant misfire DTCs. They will also verify that the vehicle falls within the specified production date ranges for the Sorento (MQ4a) and Sportage (NQ5, NQ5a) models. A Vehicle Diagnosis Number (VDN) must be created for the detected DTCs before any parts are ordered or repairs are performed.

Repair Procedure Summary

The repair involves replacing all four GDI fuel injectors and associated components. Technicians will refer to the Kia Global Information System (KGIS) for detailed instructions on removing and installing the fuel injectors and delivery pipe. This includes replacing the clips for the new injectors and ensuring that the throttle body and intake manifold gaskets are replaced, as they are not reusable.

After installation, all removed parts are reinstalled, and the technician will clear the stored DTCs using the Kia Diagnostic System (KDS). Finally, normal vehicle operation will be confirmed to ensure the repair is successful and the Kia Sportage misfire DTC issue is resolved.

Required Tools or Parts

Special tools and specific parts are required for this repair:

• SST 09353 L1100: Injector Combustion Seal Guide & Sizing Tool
• 35399 2SO33FFF: GDI Fuel Injector and Line Service Kit (Dealers must order this kit PN)
• 35310 25000: GDI Fuel Injectors (4 required)
• 35309 04AAO: Fuel Injector Clips (4 required)
• 35305 2SOOO: High Pressure Pipe (1 required)
• 28411 25010FFF: Intake Port Gasket (3 required)
• 28411 2S020FFF: Intake Port Gasket (1 required, not reusable)
• 28411 2SOOOFFF: Throttle Body Gasket (1 required)
• 28493 2SOOOFFF: EGR Pipe Gasket (1 required)
• 26333 25000: Oil Filter Housing Gasket (2 required)
• UM020 CH263: Coolant (3 gallons, for NQ5, NQ5a only)
• T0530 QRT12A or UM050 CH035: Synthetic Oil (1 quart, 5W30)

Important Warnings

Owners and technicians should be aware of the following critical information:

• "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."
• "This bulletin should only be performed with valid customer complaint of M.I.L 'ON' with a no-start, misfire, and/or reduced power."
• "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."
• "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."

Owner Action

If you own a 2021-2023 Kia Sorento or Sportage and are experiencing symptoms like the MIL light, no-start, misfires, or reduced power, especially if you suspect a Kia Sportage misfire DTC, you should contact your authorized Kia dealer. Ensure you clearly describe all symptoms, including any dashboard warning lights, when scheduling your service appointment. The repair is covered under Kia's Basic Limited Warranty Coverage, but a valid customer complaint is essential for proper processing.

NHTSA ID: 11024484