On certain sport utility vehicles, fuel may leak from the o-ring into the internal vapor chamber located in the fuel tank at full tank conditions
The engine may stall when coming to a stop. It will be hard to fill the gas tank and external fuel may leak from the evaporative air filter inlet. Fuel leakage, in the presence of an ignition source, could result in a fire.
Fix: Dealers will inspect and replace the fuel tank and replace the charcoal canister free of charge. The recall began on may 31, 2005. Owners may contact Kia at 1-800-333-4542.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented
repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall
(it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Service BulletinPI1801_DPMar 2018
DEALER PRINCIPAL NOTICE - Advises the Dealer Principal of the new Product Improvement Program to replace the fuel tank straps on certain 2005-2007MY Sportage vehicles manufactured from May 27, 2004 through April 25, 2007. Although there have been no customer complaints about the fuel tank straps on the affected vehicles, Kia has decided to do a Product Improvement campaign to replace those straps. The improved straps will increase the long term durability of these parts.
DEALER SERVICE MANAGER NOTICE - Advises the Dealer Service Manager of the new Product Improvement Program to replace the fuel tank straps on certain 2005-2007MY Sportage vehicles manufactured from May 27, 2004 through April 25, 2007. Although there have been no customer complaints about the fuel tank straps on the affected vehicles, Kia has decided to do a Product Improvement campaign to replace those straps. The improved straps will increase the long term durability of these parts.
OWNER LETTER - included in the Dealer Notification Package - This document notifies the owners of the Product Improvement Program to replace the fuel tank straps on their vehicles.
TSB: PRODUCT IMPROVEMENT CAMPAIGN - FUEL TANK STRAP REPLACEMENT (PI1801) - This bulletin provides the procedure to replace the fuel tank straps on certain 2005-2007MY Sportage vehicles manufactured from May 27, 2004 through April 25, 2007. Although there have been no customer complaints about the fuel tank straps on the affected vehicles, Kia has decided to do a Product Improvement campaign to replace those straps. The improved straps will increase the long term durability of these parts.
SAFETY RECALL CAMPAIGN. FUEL MAY LEAK PAST AN O-RING INTO THE INTERNAL VAPOR CHAMBER LOCATED IN THE FUEL TANK CAUSING THE ENGINE TO STALL WHEN COMING TO A STOP; HARD TO FILL GAS TANK; AND FUEL LEAKING FROM THE EVAPORATIVE AIR FILTER INLET.
Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting
0 most recent
Had fuel system trouble with your 2005 Kia Sportage?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2005 Kia Sportage?
It's a documented issue but not catastrophic. 7 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Based on the 7 complaints filed, fuel system issues most often appear around 18,699 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
Yes — 1 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Kia/Sportage.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.