hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
85,664 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Kia Optima fuel system problems

fuel system problem

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2004 Kia Optima Owner Comments

problem #3

Nov 082008

Optima 4-cyl

  • Automatic transmission
  • 75,600 miles


The contact owns a 2004 Kia Optima. The driver attempted to start the vehicle, but was unsuccessful. The vehicle was towed to the repair shop and it was discovered that the electric wire for the fuel pump had burned inside the gas tank. These were the plugs for the fuel pump. The driver was fortunate that the vehicle would not start because an explosion could have occurred. The dealer advised him to call NHTSA and file a complaint because they could not assist. The contact is a mechanic and repaired the vehicle himself. The failure mileage was 75,600. Updated 12/11/08. Updated 12/11/08.

- Brewster, NY, USA

problem #2

Sep 292007

Optima 6-cyl

  • Automatic transmission
  • 120,030 miles
Purchased 2004 Kia Optima ex new. Have had fuse block replaced w/in 15000 miles. Now, the fuel pump has failed. The car ran fine and was parked. Next day car would not start. No fuses blown. The terminal connector from the fuel pump to the gas tank penetration has burned out causing an intermittent open in circuit. Fuel pump burned up in tank. Wires and connectors visibly charred. Connection that failed is inside of the gas tank. Very similar to ntsb case #10161074. Have 120,000 miles on the car. Others with less mileage are in for trouble due to poor engineering design. Defective parts available for photograph or inspection.

- Crewe, VA, USA

problem #1

Jan 242006


  • Automatic transmission
  • 61,361 miles
: the contact stated while traveling 25 mph, the vehicle stalled without warning. The gas cap was removed and replaced to remove pressure in the fuel tank. When the vehicle was restarted, it was sluggish, and had very little power, and a clunking noise was heard. So, the vehicle was towed to the dealership. The dealers mechanic ran a computer diagnostic test, which revealed several misfire codes. Upon removing the fuel pump, melted wiring was discovered running from the fuel pump to the gas tank. The manufacturer was alerted.

- Andrews, NC, USA

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