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Engine & cooling

2004 Kia Sedona Engine problems

Owners have filed 35 complaints about the 2004 Kia Sedona's engine & cooling with NHTSA - 16% of all its complaints, most recently on September 25, 2026. They describe 0 crashes, 5 fires and 0 injuries. Stalling, loss of power, oil consumption, overheating, head gaskets, timing chains and engine failure.

Complaints
35
Recalls
0
Crashes
0
Fires
5
Injuries
0
Deaths
0

Engine complaints

Engine & coolingFire

In [redacted], my 2004 Kia Sedona caught fire shortly after I arrived at work in [[redacted]]. My [[redacted]] daughter was with me because she was sick. After parking, I removed her from the back seat and went inside the salon. Minutes later, I returned and saw smoke coming from the engine. Within seconds, the front of the vehicle caught fire. The vehicle was parked near a building, and the fire and smoke spread toward the building. The fire department responded and made a report. The vehicle was completely...

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disabled and later sold to a salvage yard because I could not drive or transport it. My insurance did not cover the fire because I did not have fire coverage. I am especially concerned because my daughter had been inside the vehicle moments before the fire. Fortunately, I removed her before the fire started. I later contacted Kia America, which opened Case No. [redacted] and requested the vehicle's location for investigation. Kia also requested preservation of the vehicle, but it had already been destroyed by the fire and sold to salvage. I am requesting that NHTSA review this incident for possible safety defects, recalls, investigations, or similar fire complaints involving the 2004 Kia Sedona or its components. I can provide the fire report, Kia correspondence, and other supporting records. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Incident EngineNHTSA 11767032
Engine & coolingFire

Tl* the contact owned a 2004 kia sedona. The contact stated that the vehicle caught fire. The fire department extinguished the fire. The vehicle was destroyed and towed to a tow yard. The contact mentioned that the cause of the fire was unknown. The dealer and manufacturer were not contacted. The approximate failure mileage was 100,100.

Filed Incident EngineNHTSA 11193363
Engine & coolingFire

My 2004 kia sedona was sitting stationary in my driveway engine was off. When something in the engine compartment caught fire causing extensive damage to engine parts on the top side of the engine. Such be as fluid reservoirs wiring, fuse box, and more.

Filed Incident EngineNHTSA 11141627
Engine & coolingFire

Tl* the contact owns a 2004 kia sedona. While stationary, the front end of the vehicle erupted into flames. The contact stated that the fire originated from the engine compartment. A police report was not filed. The fire was extinguished by the fire department. There were no injuries sustained. The manufacturer was not made aware of the fire. The failure mileage was 110,000.

Filed Incident EngineNHTSA 10985783
Engine & cooling

Engine seized without any warning. There wasn't much traffic on the road and helped to steer the vehicle to the shoulder. In bad weather and/or traffic conditions, this could have resulted in a serious accident. I strongly believe that there are some safety issues with the engine of this vehicle make/model and would like to register this incident. *Tr

Filed Incident EngineNHTSA 10663267
Engine & coolingFire

Tl* the contact owns a 2004 kia sedona. The contact stated that the vehicle caught on fire from under the hood while driving an unknown speed. The contact was able to move off the roadway and called the fire department, who extinguished the fire. A fire report was filed of the incident. The vehicle was deemed as destroyed by the contact's insurance agency. The failure and current mileages were 135,000.

Filed Incident EngineNHTSA 10532292
Transmission & drivetrainEngine & coolingFuel system

Multiple instances where vehicle has been unable to start. Will subsequently turn over for a period of about 5 seconds and finally "catches" and will run rough. Upon driving the vehicle will run rough, hesitate and stall, mostly at times during a full stop attempting to accelerate to normal driving speed in traffic and through turning. Upon inspection at dealership, no faulty parts found and condition "disappears". Upon receipt of vehicle from dealership, problem has continued to plague vehicle. Replaced many...

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parts under the advisement of the dealership and have never found a solution to the problem. No check engine code present during problem. Has left family stranded on more than a few occasions making vehicle unreliable and unsafe to operate. *Tr

Filed Incident Power train · Engine · Fuel / propulsion systemNHTSA 10467191
Engine & coolingElectrical system

Cpsc#i1230221a. 2004 Kia sedona. Consumer stated he was having difficulty in starting the vehicle due to stalling. The vehicle will shut off while idling and while driving. Loss of power results in difficulty in steering the vehicle. *Ln the consumer stated none of the repairs, have fixed the stalling issue.

Filed Incident Engine and engine cooling · Electrical systemNHTSA 10452019
Engine & coolingTransmission & drivetrain

Van was making a high-pitched whining sound. Took it in and found that the water pump needed replacement. They tested it and it was still not running properly so they dug a little deeper and found that the coils and wiring needed to be replaced. Got the van back in working condition and less than two days later, the check engine light comes on. Took it back and they said it needed a new catalytic converter. Thanks to laws in the state of california, we cannot replace with an aftermarket ($200); instead we were...

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quoted $1k, and that apparently is on the cheap side. The gov.'T has a warranty program to replace catalytic converters on vehicles 80,000 miles or less. We were just out of that limit. Too bad for us. We're trading it in. *Tr

Filed Incident Engine and engine cooling · Power trainNHTSA 10428693
Engine & cooling

I own a 2004 kia sedona 3.5L that I purchased on 08-31-2010 with 53638 miles on it. On 01-25-2011 as I was driving I heard a rattling from the engine compartment. I stopped to open the hood and confirm that it was coming from the engine, it was. I drove to the nearest auto mechanic and had it diagnosed to be told that I had a blown engine and it would have to be replaced. I had it towed to he local kia dealership to be looked at further. The engine was opened up to be inspected. I was told that the #6...

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cylinder was coming apart and that I would have to replace the engine. The van currently ha only 59430 miles on it. It is under the 60000 mile warranty mark but over the 5 year portion. I have been made aware that there was a kia service bulletin that mentioned that the 2004 kia sedona 3.5L engine had scoring on the #6 cylinder from the manufacturing process which also resulted in a gasket defect or malfunction. This clearly should be covered under warranty service. This is not the only case of this specific problem with the #6 cylinder. *Tr

Filed Incident Engine and engine coolingNHTSA 10379443
Engine & cooling

I have a 2004 kia sedona the rear coolant lines have failed and now I am leaking coolant and it will cost $1000 to fix. It happened all of a sudden. Now I can't drive my car safely. *Tr

Filed Incident Engine and engine coolingNHTSA 10373352
Engine & cooling

Tl*the contact owns a 2004 kia sedona. While driving at speeds of 70 mph the vehicle would continuously make a jerking motion and stall without warning; however, the problem would occur intermittently. The vehicle was taken to the dealer where they could not duplicate the failures and released the vehicle back to the owner. The vehicle continued to stall intermittently without warning. The vehicle was taken back to the dealer a second time and again they could not duplicate the failure. He then took the vehicle...

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to an independent mechanic who also could not determine the cause of the failure. On the third attempt, a specialist at the dealership stated that the emissions sensor and the throttle valve were replaced; however, the failure persisted. There were no additional repairs performed and there were no recalls on the vehicle. The failure mileage was approximately 75,000 and the current mileage was 98,000.

Filed Incident Engine and engine coolingNHTSA 10318527
Engine & cooling

I am writing to band together everyone who is ready to bring on a class action law suit against kia for the lies, breech of warranty, and defective engines that they are responsible for. I have the exact same story as everyone here......My engine blew, kia wouldn't honor their warranty, said it was my fault due to overheating, and the coolant reservoir had a crack in it.....Sound familiar? I was out over $8000....I need to reclaim my losses. Who's with me? Please contact me . Staci minnick *tr

Filed Incident Engine and engine coolingNHTSA 10296750
Engine & cooling

Tl*the contact owns a 2004 kia sedona. In june of 2007, while backing out of the driveway at an unknown speed, the vehicle stalled. The failure dates were august 20, 2007 at 74,200 miles and september 9, 2007 at 77,450 miles. When the contact approached a traffic light, the brakes were depressed and the vehicle stalled on march 28, 2008. While driving 50 mph, the vehicle stalled again at 83,000 miles. The contact was near a napa auto parts store and pulled into the parking lot. A mechanic inspected the...

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vehicle to identify the cause of the failure, but was unsuccessful. The contact called two different kia dealers to attempt to diagnose the failure, but they were also unsuccessful. The failure mileage was 70,000 and current mileage was 83,400. Updated 04/29/08 *bf

Filed Incident Engine and engine coolingNHTSA 10224179
Engine & cooling

Tl*the contact owns a 2004 kia sedona. While stopped, the vehicle stalls. The vehicle can be restarted after the failure. The contact has not taken the vehicle to a dealer; however, a local mechanic could not identify the cause of the failure. The vehicle has stalled four times. The failure mileage was 70,000 and current mileage was 83,000.

Filed Incident Engine and engine coolingNHTSA 10222927
Engine & cooling

I have repair paperwork from the two past owners. The kia sadona engine dies for no reason what so ever. This has been an on going issue with this vehicle. Today, it almost got my family killed because it stalled at an intersection they were crossing through. *Tr

Filed Incident Engine and engine coolingNHTSA 10216562
Engine & cooling

Tl*the contact owns a 2004 kia sedona ex. While driving 35 mph, the temperature gauge began to rise on the instrument panel. The contact checked the engine and noticed that the coolant receptacle was empty. She added coolant, but the vehicle continued to overheat. The vehicle was towed to the dealer and the radiator was flushed. However, the vehicle continued to overheat. The contact took the vehicle to a service shop where it was found that the coolant line was rotted and corroded. The plastic case was also corroded. The manufacturer stated that they will pay for the parts, not the labor. A police report was filed. The current and failure mileages were 61,485.

Filed Incident Engine and engine coolingNHTSA 10196704
SteeringEngine & coolingTransmission & drivetrain

I own a 2004 kia sedona. I bought the car with 57,000 miles on it from the original owner. The warranty calls for 60,000 miles to second owner. The transmission, rack & pinion were replaced by me at 57,000 and now the engine has a build up of sludge and the local dealer is refusing to warranty the defect. They did not replace the transmission or rack and pinion either. They were paid for and replaced by me. I feel this car is a lemon and I need help in pursuing recourse against this dealer in chattanooga, prebul kia. Thanks *tr

Filed Incident Steering · Engine and engine cooling · Power trainNHTSA 10188847
BrakesEngine & cooling

This van has brake problems squeaking and wearing out pads way too fast. I was told nothing is wrong with the brake system but when taking it to a brake shop I was told the calipers are bad, kia has not fixed them and denies that they're bad. The check engine light came on and I was told that a spark plug had misfired, that was fixed under warranty and then another spark plug misfired and was fixed under warranty. The oil level was getting low but I had no leak and I was told that the oil filter was simply loose...

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so they said they fixed it. I asked if I should bring the van back in a week to have the oil level checked and we were assured there was no leak. Check engine light came on again and the oil light flickered, did not stay illuminated, so we took it to the dealership immediately, as the owners manual and the mechanic had stated. Then we're told that there's sludge in the engine and that it will be 2,000 dollars to take it apart and check the damage that we caused from continuing to drive it. They never told us there was any reason to not drive it nor did they mention sludge previously. The van will be towed back to kia tomorrow. *Tr

Filed Incident Service brakes, hydraulic · Engine and engine coolingNHTSA 10188558
Engine & coolingFuel system

Car bucking and shifting problems. Kia has had many problems with the sedona and fuel problems that they are well aware of but refuse to do anything about them. The car stalls on the free way it buck violently and there are numerous owners that are having the same problems that we are facing. *Jb

Filed Incident Engine and engine cooling · Fuel system, gasoline · Unknown or otherNHTSA 10186644
Engine & cooling

My 2004 kia sedona has 24,000 miles on it and is in the 3 year 36,000 mile bumper-to-bumper part of the warranty. My check engine light came on and the car was towed to albert kia. The service manager said the car had a blown engine and that it would be replaced under warranty, however, we needed to bring in all the oil change records for warranty purposes -which we did. That dealership went out of business and the car was never repaired. A rep from kia usa told me that they were going to tow my car to balise...

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kia in warwick, ri. Two days later, scott, the service manager at balise, called to tell me that he and the district manager had looked at the car and it was determined that it had 5 liters too much oil in it. I told scott that the service manager at albert kia had already diagnosed the car and reported a blown engine, never once mentioning anything about too much oil. Within the 72 hours, jeff from kia usa called and informed me that he had my case. After a brief review, jeff asked me to fax over the service records to him. On january 16th, my case was given to russell stuart. Later in january, the kia dm and I checked the oil together and noted that it was not over the fill line. The dm removed the oil cap, looked at the underside, and noted that it filled covered with sludge. The dm now stated that the car never had an oil change - voiding the warranty. I asked if the sludge on the back of the cap was the result of a blown head gasket. The dm said no. My son, an ase master technician, found a kia issued technical service bulletin stating that some 2004 sedona models with the 3.5 Liter engine had a defect that left a score mark at the #6 cylinder on the head, resulting in head gasket failure. My vehicle was built 4 weeks after kia said they corrected the problem but kia will not lend any credence to this bulletin regarding my vehicle. I'm stuck with a vehicle that has been out of service for 3 months.*Ak

Filed Incident Engine and engine coolingNHTSA 10185752
Engine & cooling

Had to get my car serviced because antifreeze was pouring out of my car. After they looked at my car I was notified that kia does not have the part to fix my car but insists that I can still drive it. Meanwhile I need to fill up the tank after my errands for the day, that's an estimate of $20 a day!They told me it would take up to 2-3 weeks until this part came in. I found it disturbing how they told me I can drive this car while it pours out antifreeze (antifreeze is poison to animals). Also to get it serviced I...

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called the place where I bought it and they couldn't even look at my car till another 3 weeks or so. My car is now an hour away and kia will not provide me with a rental. Its a shame how they scam people into buying the car for the warranty because once they have your money they don't care after that. *Nm

Filed Incident Engine and engine coolingNHTSA 10176789
Engine & cooling

Dt*: the contact stated the engine died without warning. The service dealer determined the engine short block needed to be replaced to fix the issue.

Filed Incident Engine and engine coolingNHTSA 10176080
Engine & cooling

The van will lunge or cut-off while being driven. The dealership has repeated this problem with several employees. No one knows what is causing this or how to repair. So they keep giving it back to us un-repaired. *Jb

Filed Incident Engine and engine coolingNHTSA 10160770
Engine & cooling

Check engine light on. Engine was knocking. Called the dealer 3 times and each time they tried to tell me it was my gas cap not locked on properly. When I finally brought it in they had to do an entire tune up because a plug was misfiring. *Jb

Filed Incident Engine and engine coolingNHTSA 10149564

Kia Sedona engine complaints by year

Sedona engine problems, every year

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Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data

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