Tank lining fuel blockage - fix and photos - Kia Forum

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post #1 of 12 (permalink) Old 04-04-2012, 02:53 AM Thread Starter
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Tank lining fuel blockage - fix and photos

I recently had the problem of the tank lining on my 2005 Sorento coming away and blocking the fuel pump. This not only caused us to break down on the motorway for 2.5hrs but could have cost 900 to fix. However...

DESCRIPTION

Car loses all power. Normally when the tank is less than a quarter full. However it may do it when the tank has more fuel. The car sometimes restarts but often won't. The engine will turn over but won't start. The two times it happened to us we never got any fault codes etc.

WHY?

Sometimes the pick-up pump gets clogged with a grey coloured material which seems to appear in the tank. This can restrict the amount of fuel going to the engine and give the dreaded cut out under acceleration and in some cases a low fuel pressure code being stored and the Engine Management Light on the dash coming on. Definitely worth checking out if any of these things happen to your Sorento.

When you remove the fuel pump and condensor unit etc - see pic - you will see lots of blue ashy, bluetac type stuff at the bottom and floating about. If you do see this then it's the lining of the tank coming away!

When the rear drivers side seat is lifted there is a small piece of carpet which when lifted up gives you an access panel to the fuel tank:



If you then unclip everything then unscrew the 6 screws and gently lift out the fuel pickup unit this is what you get. Try to do this when you have very little diesel in the tank



You now may see loads of blue stuff not only gathered in the bottom of the unit but also floating about in the tank. This is what I got up just at the bottom of the unit:



THE FIX

You can either:

1) Get a new fuel tank from Kia (no body else seems to manufacture them - here in the UK anyway) which costs 705 +VAT
2) Get another company to reline the tank. This costs around 400
3) Reline it yourself using POR15. Total cost for the product and the garage to refit 163

POR-15

You will need to remove the fuel tank completely from the car. My local garage only charged me 80 to take it out, store the car for 5 days while the tank cured, refit the tank and change all the filters.

POR-15 is a relining kit which allows you to remove all the old lining, prepare the tank for lining and the actual lining stuff itself.

As I live in the UK I used Holden Vintage & Classic Lucas and the videos on there (please check them out as they REALLY helped) were invaluable.

Please note that the tank is very heavy and large. Therefore I used my daughters swing frame to help. Basically I tied some rope to one end of the tank (using the holes where the fixing bolts go) and tied this to the frame of the swing. This acts like a nother person holding one end and enables you to move it about when cleaning and preparing etc.

Make sure you take your time and read the instructions / watch the videos etc. If you need any advice please message me as I'm more than happy to help and save you a fortune!


Last edited by Phil2209; 04-04-2012 at 02:57 AM.
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post #2 of 12 (permalink) Old 06-07-2012, 02:06 PM
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Kia Sorento stalling on acceleration

Hi Phil

Your post has saved me a fortune so thank you; hope this additional information is of value to others;

I was confused at first by talk of fuel filter as I was aware this was under the bonnet and we had just had it changed. Following your thread and pics I took the pump assembly out and found the fuel "strainer" was completely blocked with a grey slimy residue.

The fuel tank funnily enough was unexpectedly clean with no visible debris; however I wiped a clean rag around the tank wall and a grey residue was left on the cloth; I assume this is the "lining" people refer to; Anyway below is a description of fault:

IMMO light came on under acceleration and car stopped lost all power; started after a few minutes

Happended again when EM light came on as well; again started after a few minutes. I then noticed that if you drove the car steadily at under 50 keeping RPM below 2000 it was fine BUT as soon as you put your foot down same fault appeared.

Have now stripped pump assembly and strainder, cleaned everything and put it back together. Fitted another filter and so far ,and fingers crossed, so good.

I have contacted KIA about this problem and will post their reply if and when I get one. if it needs new tank etc it will be going to KIA heaven/hell

Once again many thanks for sharing your knowledge and expertise.

Chris
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post #3 of 12 (permalink) Old 06-07-2012, 02:16 PM
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Quote:
Originally Posted by Phil2209 View Post
I recently had the problem of the tank lining on my 2005 Sorento coming away and blocking the fuel pump. This not only caused us to break down on the motorway for 2.5hrs but could have cost 900 to fix. However...

DESCRIPTION

Car loses all power. Normally when the tank is less than a quarter full. However it may do it when the tank has more fuel. The car sometimes restarts but often won't. The engine will turn over but won't start. The two times it happened to us we never got any fault codes etc.

WHY?

Sometimes the pick-up pump gets clogged with a grey coloured material which seems to appear in the tank. This can restrict the amount of fuel going to the engine and give the dreaded cut out under acceleration and in some cases a low fuel pressure code being stored and the Engine Management Light on the dash coming on. Definitely worth checking out if any of these things happen to your Sorento.

When you remove the fuel pump and condensor unit etc - see pic - you will see lots of blue ashy, bluetac type stuff at the bottom and floating about. If you do see this then it's the lining of the tank coming away!

When the rear drivers side seat is lifted there is a small piece of carpet which when lifted up gives you an access panel to the fuel tank:



If you then unclip everything then unscrew the 6 screws and gently lift out the fuel pickup unit this is what you get. Try to do this when you have very little diesel in the tank



You now may see loads of blue stuff not only gathered in the bottom of the unit but also floating about in the tank. This is what I got up just at the bottom of the unit:



THE FIX

You can either:

1) Get a new fuel tank from Kia (no body else seems to manufacture them - here in the UK anyway) which costs 705 +VAT
2) Get another company to reline the tank. This costs around 400
3) Reline it yourself using POR15. Total cost for the product and the garage to refit 163

POR-15

You will need to remove the fuel tank completely from the car. My local garage only charged me 80 to take it out, store the car for 5 days while the tank cured, refit the tank and change all the filters.

POR-15 is a relining kit which allows you to remove all the old lining, prepare the tank for lining and the actual lining stuff itself.

As I live in the UK I used Holden Vintage & Classic Lucas and the videos on there (please check them out as they REALLY helped) were invaluable.

Please note that the tank is very heavy and large. Therefore I used my daughters swing frame to help. Basically I tied some rope to one end of the tank (using the holes where the fixing bolts go) and tied this to the frame of the swing. This acts like a nother person holding one end and enables you to move it about when cleaning and preparing etc.

Make sure you take your time and read the instructions / watch the videos etc. If you need any advice please message me as I'm more than happy to help and save you a fortune!
Phil

Why is the tank lined at all?

The strainer i referred to is inside the unit but I was very surprised that the tank was so clean?

In you picture it looks like the grey matter is in small "chunks" "bits"; this was just like a slime?

Chris
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post #4 of 12 (permalink) Old 06-08-2012, 11:15 AM
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Me as well!!

We drove from Yorkshire to the River Pageant last weekend.....no problems until we got to Peterborough on the way back and the car suddenly ran rough and didn't want to know. Its an 04 XS 2.5 Diesel with 92,000 miles on it and I've had it since 2007.

My mates Vauxhall dealership had it yesterday and they said.......fuel tank filter/pickup is blocked up with 'flakes' from the tank lining, and it will happen again.

I'm very grateful for the info above and impressed with the photos too.....so I'm going to ask a daft question....(as usual)

Given that you have to take the tank out to clean it, once you have removed as much flaking liner as you can, why do you need to recoat it with anything at all as diesel is an oil and will surely suppress internal rusting, so unless the tank is pinholed its not necessary..or is it. POR 15 is good stuff I know, but it has to be applied just right or you repeat the problem.

Am I making any sense on this.....(and definitely NOT wishing to denigrate Phil's efforts which I stand in awe of by the way, because its a big job)

Tim

Last edited by Alfie168; 06-08-2012 at 11:19 AM.
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post #5 of 12 (permalink) Old 06-08-2012, 04:15 PM
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Quote:
Originally Posted by Alfie168 View Post
Given that you have to take the tank out to clean it, once you have removed as much flaking liner as you can, why do you need to recoat it with anything at all as diesel is an oil and will surely suppress internal rustingTim
Without knowing that much about diesels it sounds like a good point.
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post #6 of 12 (permalink) Old 06-08-2012, 06:35 PM
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you would want to have the tank relined because of corrosion as diesel fuel is prone to pick up and absorbed moisture .

Last edited by jetech00001; 06-08-2012 at 06:55 PM.
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post #7 of 12 (permalink) Old 06-09-2012, 07:36 AM
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Only if it is left standing for a long time. If its used it won't pick up much or any as it won't have the chance. Living in the Yorkshire dales is VERY wet at times for a lot of the year and its not a problem we come across to the best of my knowledge. If there is a risk here it is external corrosion due to the salt used on our roads in winter.

I have had one fuel tank pinhole on an ancient Petrol Renault 4, and that was way back in 1973.....

Most of my cars have had plastic tanks for the last 20 years (illegal in the US..or used to be), so its a bit of a 'throw back' problem that took me by surprise in all honesty.

Tim
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post #8 of 12 (permalink) Old 06-11-2012, 07:06 AM
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Hi Alfie

I have spoken to KIA regarding this problem and will happily share their response with you; so as not to cause problems with KIA I would prefer not to post in public on here.

You can e mail me at [email protected] or call me on 07880 707298

Yorke Arms - brilliant

Chris

Last edited by evertonian; 06-11-2012 at 07:07 AM. Reason: additional information
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post #9 of 12 (permalink) Old 06-11-2012, 04:17 PM
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Are you sure this is not diesel bug, caused by water in the fuel. As soon as you said slimy that alerted me. Both water in diesel and diesel bug is unfortunately very common in Australia due to the warm and often moist climate. What you have done will certainly fix the tank but the problem can return.

The bug is an algae which lives in the water and feeds off the fuel. The metabolism generates acids which dissolve in the water and strip the lining off the tank. The "clumps" are lumps of dead algae.
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post #10 of 12 (permalink) Old 06-23-2012, 11:56 AM
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Quote:
Originally Posted by evertonian View Post
Hi Alfie

I have spoken to KIA regarding this problem and will happily share their response with you; so as not to cause problems with KIA I would prefer not to post in public on here.

You can e mail me at [email protected] or call me on 07880 707298

Yorke Arms - brilliant

Chris
email sent. I'm very interested to hear what they say, for sure.

Tim
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