Two problems related to manifold/header/muffler/tail pipe have been reported for the 2003 Kia Motor Sorento. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Kia Motor Sorento based on all problems reported for the 2003 Sorento.
I was told by the mechanic that "something happened inside the engine that cannot be repaired". Prior to the engine failure (may, 2014) the rear throttle plate came apart and lodged in the lower intake manifold. The mechanic was unable to retrieve the screws and one was even lodged in a cylinder head. A throttle plate assembly was installed and the car was drivable but with an audible noise. At this time I was told the same problem exists with many kia's and yet a recall has not been issued. My car is not drivable, it's a v6 and the left side of the engine is completely shut down and I feel kia could have avoided this with a recall when they have known for years that the problem exists.
Engine light came on back in February and had it to two different mechanic shops which replaced spark plugs and one coil pack. Engine light still on so I took to kia dealer and they replaced spark plugs with platnium ones and replaced other 2 coil packs. Vehicle has been back to dealer several times for the past several months for check engine light replacing intake manifold due to recall but light came back on and they have had my vehicle most recently for the past 4 weeks. I went to pick it up yesterday as they said they had to replace the cylinder heads with reconditioned ones and all gaskets and seals. As I started to leave the dealership light came back on and vehicle is there again. Obviously mechanics at dealers don't know what's causing these problems and cannot fix them. I feel that kia should buy everyone out of their Sorentos plus give them the value of the vehicle (without deducting for problems) plus a 15% compensation for putting the customers through this or maybe put a brand new engine in vehicle. A new engine or remanufactured engine was replaced in this vehicle back in August, 2006. I originally put my date down as March, but looking back, this has been going on since February!! this is the second complaint I am filing.