2004 Kia Optima
Problems, recalls and owner-reported issues
Latches/locks/linkages is the leading concern among 225 owner complaints filed for this model year. This is the 9th highest complaint count among 20 Optima model years with reports.
Of the 2004 reports, 8 involved a crash and 3 involved a fire. 8 people were injured.
What owners report most often
Recalls and investigations
Suspension, frontMay 27, 2009
KIA MOTORS CORPORATION (KMC) IS RECALLING 36,538 MODEL YEAR 2001-2004 OPTIMA VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE STATES DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUBFRAME. OVER TIME, SUCH SUBFRAME CORROSION NEAR THE CONNECTION TO THE LOWER CONTROL ARM CAN LEAD TO WHEEL MISALIGNMENT AND/OR OTHER NOTICEABLE STRESS IN STEERING, OR ACCELERATED ABNORMAL TIRE WEAR.
CORROSION OF THE FRONT SUBFRAME COULD LEAD TO SEPARATION, POSSIBLY RESULTING IN A VEHICLE CRASH.
KMC WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 15, 2009. OWNERS MAY CONTACT KIA'S CONSUMER ASSISTANCE CENTER AT 1-800-333-4542.
Campaign 09V183000 on NHTSA.gov
Representative owner complaints: fuel system
9 reports, newest first. Show all
Fuel system, Gasoline, Feb 16, 2022
The contact owns a 2004 Kia Optima. The contact stated that after refueling, the vehicle would not start. The vehicle was not taken to a local dealer. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 04V180000 (Fuel System, Gasoline) however, the VIN was not included. The manufacturer was informed of the failure and confirmed that the vehicle was not included in a recall. The failure mileage was approximately 145,000.
Fuel system, Gasoline, Structure, Jan 23, 2012
DRIVER DOOR REFUSED TO OPEN. I HAVE A DISABILITY SO THIS CREATED A HUGE PROBLEM FOR ME. WHEN I PUT GAS IN MY CAR (REGARDLESS OF GRADE OR GAS STATION) MY CAR REFUSES TO START. WHEN I MAKE A U-TURN, MY CAR MAKES LOUD CLICKING SOUND. I HAD IT CHECKED...MY AXLE AND EVERY THING ELSE LOOKS FINE. NO ONE CAN ESTABLISH WHERE THE NOISE COMES FROM. MY CAR HAS LESS THAN 60,000 MILES ON IT, AND IT SHOULD NOT HAVE ALL THESE ISSUES BUT IT DOES. *TR
Fuel system, Gasoline, Oct 17, 2011
CAR WAS DIFFICULT TO START AFTER FUEL FILL-UP. IT GOT WORSE AFTER EACH FILL UP. TRIED PUTTING FUEL IN WHILE CAR WAS RUNNING, BUT IT WOULD JUST CUT OFF. MUST PUT FOOT ON BRAKE AND REV GAS AFTER PUTTING IN FUEL TO GET GOING. I WAS USING KROGER GAS, I SWITCHED TO SHELL GAS BUT THE PROBLEM PERSIST. ALSO ENGINE LIGHT HAS NEVER COME ON. I THINK THIS IS THE SAME PROBLEM AS THE 2003 KIA. *TR
Fuel system, Gasoline, Vehicle speed control, Sep 28, 2010
TL*THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THE FAILURE WAS A GAS FUME LEAK AND THE ACCELERATOR SENSOR NEEDED TO BE REPLACED BECAUSE IT CAUSED THE VEHICLE TO ACCELERATE AND DECELERATE WITHOUT WARNING. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000. THE CURRENT MILEAGE WAS 129,548.
Fuel system, Gasoline, Exterior lighting, Equipment, Jul 28, 2010
THE FUEL SYSTEM IS GIVING ME PROBLEM AFTER PROBLEM AFTER PROBLEMS I HAVE CHANGED THE FUEL PUMP 3 TIMES IN 12 MONTHS. AND THE HEAD LIGHTS ALSO KEEP GOING OUT. I'VE CHANGED THE LEFT SIDE HEAD LIGHT TWICE AND THE RIGHT SIDE ONCE IN 4-1/2 YEARS. *TR
Fuel system, Gasoline, Nov 12, 2008
TL*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. *LJ UPDATED 12/11/08.*JB
Fuel system, Gasoline, Electrical system, Oct 1, 2007
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. *JB
Fuel system, Gasoline, Jun 29, 2006
DT*: 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.
Steering, Service brakes, Hydraulic, Fuel system, Gasoline, Power train, Dec 8, 2004
BOUGHT KIA OPTIMA ON JUNE 22, 2004 VIN# [XXX] AND HAVE SINCE HAD SEVEN SERVICE APPOINTMENTS, REPLACED TWO SETS OF DRIVE BELTS, REPLACED A LEAKING POWER STEERING RACK, REPLACED A LEAKING FUEL REGULATOR, MACHINED THE FRONT ROTORS, LOST TIME FROM WORK, LOST PRODUCTIVITY FROM WORK AS WELL AS JEOPARDIZED MY WIFE'S WORK FROM CAR POOLING FOR FIVE MONTHS, COMPLETED SCHEDULED ARBITRATION WITH THE BBB WITHOUT SUCCESS FOR FOUR PROBLEMS: ACCELERATION DELAY, LOW GRINDING BRAKE NOISE, LOW VIBRATION STEERING NOISE, AND LOUD SQUEALING NOISE FROM THE DRIVE BELTS. *JB UPDATED 07/24/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)