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Discussion Starter #1
I own a 2003 sorento, I purchased it with 129,000 miles on it. I took it into the dealership a year ago for the crank bolt recall, the dealership told me it had already been replaced and that was all i needed to do. Well last week while the car was in my drive way the bolt failed and broke off:eek:. Does anybody know if this will be covered by KIA since they had replaced the old bolt? Seems there should be a class action law suit on KIA:mad:. Lets get the ball rolling! :)
 

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Memorial Super Moderator
2005 Kia Cerato LD [2L petrol] manual, 1986 Nissan Pulsar hatch
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As far as I have read the car should have had a special sticker placed on it if it has had recall work done.
 

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I now drive a 2003 S-10 Had an 03 LX 3.5 Sorento
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:00000732:to the forum.
X2 on the sticker. Call the Kia customer service line and give them the V.I.N. and they should be able to tell you if it was swapped. Don't tell them your story till after they tell you. It will be a long road uphill before they will repair any damage seeing as it is out of warranty and you are the second owner. Miracles can and do happen though. Good luck on the class action. By the way, you did not mention any damage caused besides the bolt breaking.
 

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08 2.5 CRDI Sorento Titan Auto
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You don't say what the mileage is now. At 129000 miles, the timing belt should have been replaced at least twice - the last time being 9000 miles previous to purchase, give or take. At each replacement of the timing belt, the crank bolt should have been replaced. If servicing wasn't/hasn't been done, that's down to the owner(s). If it was done, you would have to consider how many miles you have put on it, who did the servicing and if it was done properly. Don't see any reason why, given what you have told us so far, that Kia could be expected to cover it. (Not to mention the sad fact that things do break over time.)
 

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2006 3.5 Sorento 4x4
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for others reading this apart from the bad design the only way you can try to avoid the bolt breaking is to make sure the belts are at minimum tension to do there job as it is the leverage caused by the belts on the pulley that overloads the bolt ......
 

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I personally make the TSB many times. becose i am ... a tech from kia. and , sometimes, the crankbolt can broke even if the TSB was done. It appen 2 times at my garage. the best way to know if the TSB was done is the color of the bolt : the original one was metal color without coating and the new one was silver coating and it should not have any lock-tite of any color or any grease on the tread. if you cant have any help from KIA and you have to pay for it . DONT replace the crankshaft in first. try to find a good machinist and he can drill into the crankshaft to put a new bolt . and yes the belt should not be to much tight. a cranck shaft job complete can cost as much 1000$ can and a drill out cost around 350$ can if the radiator and the front was removed .
 

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1999 Kia Sephia, 2016 Kia Optima SXL, 2019 Kia Soul Plus
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mstanf21- You should go to http://www.kiatechinfo.com, create a free login and refer to Pitstop KT2006042501 published 4/25/06 2003~2006 Sorento Crankshaft Bolt (3.5L) Torque Guidelines regarding the reuse of crankshaft bolts and Tech Times Volume 9 Issue 2 Page 7 published 5/18/06 regarding the proper torqueing of said crankshaft bolt. Do you have the original service records? If the timing belt was replaced and the crankshaft bolt reused, its very well conceivable this is the cause of the bolt breaking. I gotta agree with gee6 and nstoolman1 tho. If the TSB was performed, Kia is no longer responsible for it. And the fact your vehicle is out of any factory warranties. If you have extended warranty, maybe they will take care of it. Good luck.
 

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Discussion Starter #8
2003 Kia crank bolt

mstanf21- You should go to http://www.kiatechinfo.com, create a free login and refer to Pitstop KT2006042501 published 4/25/06 2003~2006 Sorento Crankshaft Bolt (3.5L) Torque Guidelines regarding the reuse of crankshaft bolts and Tech Times Volume 9 Issue 2 Page 7 published 5/18/06 regarding the proper torqueing of said crankshaft bolt. Do you have the original service records? If the timing belt was replaced and the crankshaft bolt reused, its very well conceivable this is the cause of the bolt breaking. I gotta agree with gee6 and nstoolman1 tho. If the TSB was performed, Kia is no longer responsible for it. And the fact your vehicle is out of any factory warranties. If you have extended warranty, maybe they will take care of it. Good luck.
I talked to Kia today, they siad I have to take it to a Kia dealership just to have them look at it and declare that the bolt did break and then a Manager can decide if they will give help or not. I decided to pay to have the bolt removed and then I will sell it. The pulley came off in my drive way, nothing else was damaged. My 16 year old daughter drives the car, if it had came off while under a load there could have been an accident and lots of damage to the engine. I know the miles are high, but the bolt that was used to replace the original should not have failed. I think a class action suit should have been done. Seems like there is a lot of people with this problem. By the way, customer service reps at Kia do not want to hear about this Forum!:lol:
 

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Discussion Starter #9
Another thing, why should the crank bolt be changed when doing a Timing Belt? That is never done with any other vehicle. Is Kia that much of a piece of junk? I will never buy another Kia or Hyundai, and I am a used car wholsaler!
 

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Memorial Super Moderator
2005 Kia Cerato LD [2L petrol] manual, 1986 Nissan Pulsar hatch
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I have never had to replace a crankshaft bolt as routine on any other makes that I have fitted timing belts to either.
 

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I now drive a 2003 S-10 Had an 03 LX 3.5 Sorento
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I fail to see the point in complaining about a $6 bolt every time you change the timing belt. Would you rather be right or keep the engine in one piece?
 

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It's not the $6 bolt that's the problem; it's the fact that the dealers almost NEVER have it in stock and won't acknowledge that it's a frequent problem. Why should you have to take it back twice or wait an extra couple of days when they suddenly discover they need this bolt to do a timing belt?
 

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I now drive a 2003 S-10 Had an 03 LX 3.5 Sorento
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2003 Kia crank bolt

Well then before you take your sorrie in have them order the bolt ahead of time. Take the inititive guys and gals and don't wait for them. If "we" don't do everything "we" can to eliminate these problems "we" deserve the treatment
"we" are getting.
 

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Discussion Starter #14
Well then before you take your sorrie in have them order the bolt ahead of time. Take the inititive guys and gals and don't wait for them. If "we" don't do everything "we" can to eliminate these problems "we" deserve the treatment
"we" are getting.
Why cant you admit that the kia is a piece of junk!
 

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08 2.5 CRDI Sorento Titan Auto
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Why cant you admit that the kia is a piece of junk!
Just because people don't share your opinion doesn't make them wrong. Oh, I forgot, you are a second hand car dealer, so you know everything and are never wrong ......
 

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I now drive a 2003 S-10 Had an 03 LX 3.5 Sorento
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2003 Kia crank bolt

I am not going to flush an entire car line down the toilet because of a percentage of vehicles that have problems. Mine has been very reliable considering the miles we have it.
 

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2017 Kia Sorento LX AWD
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Why cant you admit that the kia is a piece of junk!


Go run out an buy a Honda. I know those are perfect....;)

Well after replacing the entire ac system 2 times on my previous 2005 Honda CR-V, only to have it fail a 3rd time after warranty was up at a quoted price of $2500 for repairs. Lets just say I RAN to the Kia dealer with that stupid POS and traded it for the 09 Optima that has a warranty past the pathetic 3/36.

My point here is NOTHING man made is perfect. Just a fact.
 

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I too have had the 2004 KIA Sorrento crank shaft bolt break twice. Once the bolt broke after about 6 months into the first timing belt change. I took it to the dealer and they were going to charge me $150 to see if it was broken, and then refund me the money when they fix it. It was 30 days from the recall cutoff. The bolt partially came out then seized in the crank shaft. Upon removal the bolt then snapped off. I then drilled out the center, put in an extractor and the extractor snapped off. I then tapped out the bolt with a smaller tap then went to the same size as the bolt thread tap. I replaced the bolt with a new bolt. Three years later it broke again. This time I used the centering jig from http://brokencrankshaftbolt.com/ this made it much easier drilling out the center of the bolt. I heated the bolt to remove any lock tight and the bolt came right out with an extractor. I then drilled out the crank shaft and put in a 5/8 grade 8 bolt with a “spider’ type lock washer and lock tight. The fix seems to be working great. I think the “Heavy Headed” original bolt is a very bad design, as the thick massive bolt head is actually longer then the bolt, causing centrifugal forces that aren’t needed. The standard grade 8 bolt, as used on most crank shafts, seems to work great. I also had to drill out the new harmonic balancer and washer to accommodate the larger 5/8’s bolt. I will try the softer belt tighten technique too. The fact that the harmonic balancer almost sits flush on the end of the crank shaft with no woodruff key (just a roll pin) seems to be a bad design too (have not ever seen this done). This 2004 Sorrento now has 160K on it. Very strong engine, still has a drinking problem.

Update:
I have had the crank shaft bolt break 2x and unscrew 2x. I have learned a lot. Taped out the crank shaft to receive a larger grade 8 bolt. As well as made the hole larger on the washer and Harmonic balancer pulley. Put a star lock washer on it. Torqued to 130lb with lock tight RED. A year later it loosened and sheared the timing gear pin (this is much better then shearing off inside the crank shaft like before). Bought another harmonic balancer and crank timing gear. This time I'm putting on a very heavy duty grade 8 lock washer and lock tight RED & 130lbs torque. Also put in 2 more pins in the timing gear at my local machine shop Micar 702 871-4300 see attached pictures. So this gives it a total of three pins between the crank shaft timing gear and the harmonic balancer.

I spoke to the local Kia parts dealer and he said this engine is in 2 other Kia's but transverse mounted with no problems. My theory is there is so much weight out there that it pulls itself apart moving up and down from the road. Since there is no woodruff key on the harmonic balancer and it doesn't slide onto the crank shaft (like every other engine on the road) I thought 2 more pins might keep the slipping at bay. The balancer pulleys gotta weigh 15-20lbs and that's a lot of weight spinning out there on one bolt. It's just a bad design that needs help. I'll repost if this doesn't work. I should sell it but it's the kid's college car and other then the "y" in the heater hose and all the plastic covers turning into crayon and the head lights burning out every 6 months, and the drinking problem , , , , , it's been a pretty good car. Mark Peveler702-379-7357 [email protected]
 

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03'VW Passat - mine | 03'Sorento EX 4X4 - hers
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Why cant you admit that the kia is a piece of junk!
I understand your frustration, but in KIA defense this engine is not KIA design - it's Mitsubishi. And if you think crankshaft bolt is an issue then try to change spark plug wires :) it just only 3, but they are fun.
BTW, my wife drives 03' Sorento and it has 138K on the clock, we got it used with 75K on the odometer.
 
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