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Discussion Starter #1
2012 Sorento LX AWD 2.4L GDI 182 000 km
-Bought used in December 2015 w/ 117 000km
-Burns oil, about 1L per 1000km
-Replaced battery mid Dec 2017

Symptoms:

P0091 Fuel Pressure Regulator 1 Control Circuit Low:
-Reduced engine power, stutter from stop to accelerating up to speed
-Lack of acceleration, can't pass or merge, gears down 1 or 2 gears, RPM hits 5-6k but no acceleration

No start or hard to start:
-It will crank an extra couple of seconds to start
-Crank to almost start then shut off, no more cranking or starter noise.
-The starter will turn but not crank, CEL light on and immobilizer light on, no code stored or detectable
-Will start in N or shifting from P to D to P (no longer working)

Misfires counted within Torque Pro App:
-No CEL
-From all cylinders, a few per cylinder per drive cycle
-Seem to be more misfires when trying to accelerate hard or driving aggressively

The P0091 code started to intermittently show up in the summer of 2017. Shortly after the CEL I received the engine recall notice. I brought my Sorento into the dealer to have the recall inspected and the P0091 code diagnosed.

I was told my engine did not show any signs of needing replacement but that the P0091 code required an entire fuel system to rectify the code. Tank pump, fuel lines, high pressure pump, delivery tube, and possibly the rail pressure sensor.

I had another local shop replace the rail pressure sensor. No change in symptoms, except the CEL P0091 comes on less frequently but is still detectable as pending with a code scan. The starting issues are getting worse.

I checked the wiring from the high pressure fuel pump to the ignition coils and across the top of the engine for damage. I couldn't find any sings of damage. I tested the resistance of the sensor on the high pressure fuel pump, it is 0.5 ohms, seems within spec.

I brought it back to the dealer for another diagnostic on the starting issues. No mention of the fuel system or the P0091 code that was on when I brought in. I was told that it was all with the starter, no more fuel system issues.

I'm asking for any insight on the P0091 code and a more specific fix than the entire fuel system. Dealer isn't willing to try to replace individual sensors or parts, just the entire fuel system.

Would the starter cause the hard starts or no starts? I'm confused because sometimes it starts fine for days and then no starts or hard starts for days.

Also what does the engine recall replace. Is it the entire engine with components, or is it just certain parts within the engine?

Thank you in advance for any and all advice.
 

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I was told my engine did not show any signs of needing replacement but that the P0091 code required an entire fuel system to rectify the code. Tank pump, fuel lines, high pressure pump, delivery tube, and possibly the rail pressure sensor.
I don't believe the recall is based on whether there are "any signs" of needing replacement. I believe they put in the VIN and that's what determines whether or not you qualify for the replacement. Not sure if there's a PDF of the recall notice on here but have a look. Also, maybe someone with direct experience on the recall can add their comments. Let us know what city and what dealer you're working with.

As for the requiring the entire fuel system to rectify the code, that sounds suspicious. Definitely get another diagnosis and estimate.

The hard starting might be something like bad grounding. If it happens consistently mechanics should be able to diagnose this properly. Otherwise, can be difficult to diagnose.

Lastly, if the CEL comes on, I'm pretty sure that means a code should have been saved.

Having 1L per 1000km is burning a lot of oil, I believe. That's something like 1L/bottle of oil every 2 or 3 weeks, isn't it?

Just adding my observations.
 

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I don't believe the recall is based on whether there are "any signs" of needing replacement. I believe they put in the VIN and that's what determines whether or not you qualify for the replacement. Not sure if there's a PDF of the recall notice on here but have a look. Also, maybe someone with direct experience on the recall can add their comments. Let us know what city and what dealer you're working with.
As for the requiring the entire fuel system to rectify the code, that sounds suspicious. Definitely get another diagnosis and estimate.
Having 1L per 1000km is burning a lot of oil, I believe. That's something like 1L/bottle of oil every 2 or 3 weeks, isn't it?
Don't have the exact wording of the recall, but it's a two-stage operation: the dealers inspect the engine, based on VIN, and then decide (following some detailed instructions from the manufacturer) whether the engine should be replaced or not.
However, the 1L/1000km consumption is unusually high for the mileage of the vehicle, and unless neglected, is a possible sign of damage caused by the metal shavings left from the manufacturing process. Even if the dealer did not find the tell-tale shavings in the oil, the OP should have educated himself about the recall and insisted. Being a second owner, it may be harder to prove that the engine was properly maintained, but not impossible - most garages, including "quick lube" service keep electronic records these days. These records may usually show up on Carfax report.
Finally, the dealer's decision to replace the "entire" fuel system is unreasonable. In 99% of cases it's a single component that failed, and they are just too lazy (or too greedy) to find out which one.
 

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Discussion Starter #4
Dealer: Performance Kia Thunder Bay Ontario

I did educate myself on the recall notice. I was told since the vehicle was not serviced at the dealer that they couldn't tell if it was neglect or manufacturing defects. Wanted to know other owners experience with the engine recall.

Also wanted more insight on the P0091 code. If anyone else had a solution.

Freeze frame report generated by Torque for Android
=========================================================

Vehicle VIN: 5XYKTCA62CG235289
Vehicle Manufacturer: Unknown
Vehicle Calibration ID: XCC4RB3E
ª

Freeze frame information:
------------------
Fuel Status = 0 byte
Engine Load = 35.686 %
Engine Coolant Temperature = 84 °C
Fuel Trim Bank 1 Short Term = 3.125 %
Fuel Trim Bank 1 Long Term = 0 %
Intake Manifold Pressure = 5.221 psi
Engine RPM = 833 rpm
Speed (OBD) = 3 km/h
Timing Advance = 3.5 °
Intake Air Temperature = 2 °C
Throttle Position(Manifold) = 14.118 %
Run time since engine start = 1,381 s
Fuel Level (From Engine ECU) = 41.961 %
Barometric pressure (from vehicle) = 14.649 psi
Voltage (Control Module) = 14.682 V
Engine Load(Absolute) = 23.137 %
Commanded Equivalence Ratio(lambda) = 0.996
Relative Throttle Position = 4.314 %
Ambient air temp = -16 °C
Absolute Throttle Position B = 14.118 %
Accelerator PedalPosition D = 16.863 %
Accelerator PedalPosition E = 16.863 %


End of report.
 

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Dealer: Performance Kia Thunder Bay Ontario
I did educate myself on the recall notice. I was told since the vehicle was not serviced at the dealer that they couldn't tell if it was neglect or manufacturing defects. Wanted to know other owners experience with the engine recall.
Don't know about Canada, but in most - if not all - states here in the US, the manufacturer cannot force anyone to use the dealer for anything. If you can find proof that the engine was properly maintained (and even receipts for buying engine oil would probably be satisfactory where I live), you should insist that the excessive oil consumption is due to a manufacturing defect. Since this is very big deal, suing them would not be unreasonable. Also, I think that there is a group representing owners of those engines - google for it.
 

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I would guess that the P0091 code is your high pressure fuel pump is going bad. If you search on this board, you will find others that have had similar symptom as you are having from the high pressure fuel pump being bad. You can also Google the P0091 KIA and do some digging for yourself.

As for oil usage, I know Ford says that abnormal oil usage is anything below 500 miles to one quart of motor oil. Anything greater then 500 miles per quart of oil is considered normal oil use by the engine. The engine recall is to check for a rod knock as some engines were built that did not have the crankshaft oil passages properly cleaned when the engine was assembled. This can lead to the motor locking up but before that happens the connecting rod will start to make a knocking noise. The recall has nothing to do with oil usage.

p.s. Also do not forget to search for that code with Hyundai as well, as KIA and Hyundai are the same when it comes to the drive train and engine.
 

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Discussion Starter #7
Solved P0091- I replaced the high pressure fuel pump. (353202G730)

Solved check engine light with emobilizer light and no start. I replaced the starter. (361002G100)
 
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