2019 Kia Optima Fuel System Problems

After routine maintenance replacing the valve cover gasket, the low pressure GDI fuel line developed a leak in an area away from where the maintenance had occurred. After a 10 minute drive, the car developed a fire in the engine compartment. Upon investigation by an independent auto mechanic, it was determined that the fuel line had become brittle and developed a crack that had sprayed fuel into the hot surfaces of the engine compartment. This appears similar to the scenario affecting earlier Kia Optima models with the 2.0L Turbo engines. The heat from the fire caused the brakes to start to fail and the amber check engine light to come on within about 5 seconds before smoke was observed coming from the engine compartment. Fortunately, the fire occurred as the vehicle was pulling into the owner's driveway and a fire extinguisher was nearby and used to put out the fire. The vehicle's occupants were able to exit the vehicle with no injuries.

2019 Kia Optima EX - 59,000 miles - car miss fires and shakes on start. After a few seconds the car calms down and I can drive. Very dangerous since the fuel can stop flowing and the car can stall at any speed. Very dangerous!! Looks like several Kia's from 2019-2023 have been recalled for the same issue - High Pressure Fuel Pump - if my car is having the same issue at 59,000 miles why is this car not recalled, Very Dangerous! The Kia K5 which took over for the Optima is on the list why not the Optima EX.

The contact owns a 2019 Kia Optima. The contact stated that there was an abnormally strong fuel odor coming from the vehicle. The contact stated the fuel odor was stronger on the rear driver's side, where the gas tank was located. The used car dealer from whom the vehicle was purchased was notified of the failure. The vehicle was not diagnosed or repaired by an independent or dealer. The manufacturer was not notified of the failure. The failure mileage was approximately 95,658.

Our 2019 Kia Optima has now stalled twice at a stop light in the past year. When it happens, we're able to restart the engine. In addition to stalling, the car struggles to start on some days and runs lumpy (minor surges in power) on other days. The symptoms match a problem Kia is aware of and for which it has provided an extended warranty (15 years/150,000 miles). Below is the wording from the extended warranty letter (2016-2020 MY Kia Optima Vehicles Low-Pressure Fuel Pump New Vehicle Limited Warranty Extension dated Sept 9, 2022): "If, at any time within the extended warranty period, you experience intermittent reduction in engine power, stalling while at idle, and/or inability or difficulty starting your engine, your authorized Kia dealership will diagnose the cause at no cost to you." When I took the car in after both incidents, the Kia dealer is not able to replicate the issue because it's an intermittent issue. There is no fault code thrown by the vehicle computer. The dealer and I have separately called Kia to get authorization to replace the low-pressure fuel pump (the most likely culprit), but Kia has denied the request because the dealer isn't able to replicate the issue. This is non-sensical given the fact that Kia in its letter admits that this problem is intermittent. I'm afraid that the next time the low-pressure fuel pump fails, it will be in a far more dangerous situation (e.g. highway) than at a stop light. I believe Kia should replace the low-pressure fuel pump for those owners who report the symptoms of a failing low-pressure fuel pump even if the failure can't be replicated at the dealer. Kia is basically saying they're not going to replace the low-pressure fuel pump until it malfunctions and stays broken which could very likely leave us stranded somewhere or worse without engine power in the middle of driving.

The morning of 9/26/2023 as I was driving on the freeway road and I experienced an intermittent reduction in engine power and had to pull over on the side of the freeway road. This was a very traumatizing experience and I was very lucky that I was not hit while awaiting to be towed. After my mechanic inspected my vehicle we received error code P1233 and advised me to call the dealership as this is something covered under an extended warranty. I scheduled an appointment for 9/27/2023 however, I dropped my car off on 9/26/2023 since I was able to arrange dropping it off a day earlier. I received a call very early on 9/27/2023 from Chuck, one of the mechanics at Westside Kia and he stated that my car was working perfectly fine. After I informed him of the issue I had he stated they would need to keep my car for about 48 hours until they could determine the issue. I received a call from Chuck on 9/28/2023 and he stated that the issue with my car was not covered under the extended warranty and that I would have to pay $1,200.00 to get the issue fixed. He agreed that the issue was in relation to the low pressure fuel pump and should be fixed at no cost however, he stated the only way this could be fixed is if they received approval from Kia Consumer Affairs. On 9/27/2023 I opened case number [XXX] and after a month they denied my case stating that they will not fix my car free of charge because the fuel pump needs to be replaced and the recall only takes care of replacing the filter and not the pump itself. I have argued with the dealership and Kia Consumer Affairs that if the fuel pump goes bad due to a bad filter that has been recalled then it is their responsibility to cover the cost. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)