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...
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.
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:
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
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!