2005 Kia Sorento Problems

What owners report

Owners of the 2005 Kia Sorento most often describe failures of the crankshaft pulley/harmonic balancer bolt, which typically brings the accessory belts to a stop and takes away power steering, along with frequent headlamp and other bulb replacements. Complaints also cover coolant leaks and overheating, air bag warning lights with the passenger seat, and rust-related suspension and frame problems on higher-mileage vehicles.

1. 1
   Engine

   Crankshaft pulley bolt breaks, power steering lost

   • 118 complaints (38%)
   • median 97,000 mi at 8.6 yrs old (107 state mileage)
   • 4 mention a crash, fire or injury
   • owner-quoted repair $2,000 (median of 27 quotes)
   • filed 2005–2024

   Owners describe a clunk or screech from under the hood, followed by the battery and brake warning lamps lighting and power steering assist disappearing while driving. Belts stop turning, and in some cases the engine stalls and will not restart. Complaints say shops and dealers diagnosed a fractured crankshaft or harmonic balancer pulley bolt, sometimes with related damage to the crank sensor, timing belt, or drive belts; several owners report the bolt failing more than once, and some note the vehicle is not covered by a recall for it. Reported from very low mileage up into the 130,000-200,000 mile range, with many failures in the 60,000-110,000 mile range.

   1 related service bulletin

   What to check: Ask whether the crankshaft pulley bolt has been replaced and with what part, and listen for belt squeal or rattling at the front of the engine. Check that the pulley runs true and that the bolt is present and tight.

   2 excerpts from owner complaints in NHTSA records

   “On 6-14-2011 I was driving my 2005 Kia Sorento just turning onto my street when it suddenly lost its power steering and the power brake light was on. I managed to drive it a few feet to my driveway to inspect my car and noticed a big silver bolt-like piece of metal approximately 4 long dangling beneath the radiator and took it inside and called my husband. …”

   NHTSA complaint #10415181, filed 2011-07, 64,250 miles

   “My 2005 Sorento, SUV, begun to shake on the front and later stopped. I had a mechanic check it for the main belt to be off and he said it was more major. The bolt had broken off in the motor. Some cars from Kia had already had that complaint. I called the Kia headquarters and they said yes, but not a recall for that model doing it. Well it is and I am still paying for something I can't use.????”

   NHTSA complaint #10366684, filed 2010-11, 100,000 miles
2. 2
   Exterior lighting

   Headlight and other bulbs burn out repeatedly

   • 72 complaints (23%)
   • median 55,000 mi at 5.2 yrs old (55 state mileage)
   • 2 mention a crash, fire or injury
   • owner-quoted repair $3,000 (median of 7 quotes)
   • filed 2005–2022

   Owners report replacing headlamp bulbs every few months, often finding one side goes out shortly after the other, and some also describe frequent tail, stop, and dome bulb failures. Several complaints mention a dealer-supplied fix involving a resistor wire harness, and some say the work was not covered at no cost. A service bulletin describes headlamp moisture and condensation guidance and another describes a revised harness intended to extend low-beam bulb life. Complaints appear across a wide mileage range, from a few thousand miles up past 180,000, and are often described as a continuing problem over several years.

   3 related service bulletins

   What to check: Check that both low and high beams work and ask whether the revised headlamp harness has been installed. Look at the lamps for moisture or condensation inside the lens.

   2 excerpts from owner complaints in NHTSA records

   “I've repeatedly had to replace the headlights in this car every couple of months. When one light is replaced, the other side goes out next. This has happened several times for the past several years. I have 189,000 miles on the car now. I don't remember exactly when it started. My driver seat also stopped working. The back goes forward and back, but the base seat doesn't move.”

   NHTSA complaint #10465821, filed 2012-07, 100,000 miles

   “Headlights and taillights have been replaced at least 5 times in the 3 years I've had the Sorento. I keep my headlights off during the day and it seemed to delay the bulb going out as fast as it did when I kept them on all day. I keep replacement bulbs in my vehicle at all times due to this. You can buy them for $5.00 at your local auto parts store. Kia needs to recall this...way too many complaints for nothing to be wrong.”

   NHTSA complaint #10229806, filed 2008-06, 5,000 miles
3. 3
   Air bags

   Passenger air bag shows off with someone seated

   • 42 complaints (14%)
   • median 65,000 mi at 5.8 yrs old (28 state mileage)
   • 8 mention a crash, fire or injury
   • filed 2005–2020

   Owners describe the passenger air bag indicator staying on "off" even with an adult properly seated, and some report the seat belt or air bag warning lamp staying lit. In some complaints a mechanic's scan tool showed a seat occupant classification reflash campaign, while the owner was told the vehicle was not covered. Others report air bags not deploying in a crash. Reported from near-new mileage through about 130,000 miles, including complaints filed shortly after purchase.

   What to check: With an adult seated in the passenger seat, confirm the indicator reads "on" rather than "off," and check that no air bag warning lamp stays lit after startup. Ask whether any occupant classification system update was performed.

   2 excerpts from owner complaints in NHTSA records

   “My new Kia Sorento has advanced airbags and the passenger side airbag off indicator is frequently illuminated even with an adult properly secured in the front passenger seat. I have had it back to the dealership twice and they have indicated both times that the problem won't happen with them. I have been unable to confirm whether the airbag will actuallywork when this light is on.”

   NHTSA complaint #10129480, filed 2005-07, 600 miles

   “I was traveling north on white bridge road in west nashville when a car ran a stop sign hitting me on the passenger side, which totaled my car the impact was so hard that it knocked the car several feet facing the opposite direction. The air bags did not deploy during the crash neither driver or passenger side.”

   NHTSA complaint #10614700, filed 2014-07, 85,000 miles
4. 4
   Engine cooling

   Coolant leaks, overheating, and steam

   Mentioned in 4 of 60 sampled complaints

   Complaints describe steam or smoke from under the hood, coolant loss, and in some cases the temperature gauge reading normal while coolant was escaping. Owners report thermostat and radiator replacement, and some describe recurring leaks after repairs. Bulletins cover canister close valve and evaporative system codes as well as engine component reuse guidance during repairs. Mostly reported between roughly 50,000 and 120,000 miles.

   3 related service bulletins

   What to check: Check the coolant level and look for residue or staining at the radiator, hoses, and water pump area, and ask whether the thermostat or radiator has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I brought my vehicle for a coolant leak. My mechanic asked that I come over to look at underneath the vehicle. The rear drivers side control arm was no longer attached to the rear axle. He explained that the upper control arm bracket welded to the rear axle on driver side rotted right through, causing the control arm to come off. I called Kia and they won't do anything to help. This problem has been addressed in the uk and domestically for hyundia santa fe. …”

   NHTSA complaint #10906393, filed 2016-09, 93,000 miles

   “This is concerning my 2005 Kia Sorento that I never got the recall letter for the icv sensor, it just so happen that my check engine light came on and I called them complaining and they made it seem as if they were doing me a favor and said bring it in, it is covered and I discovered on the computer that there was a recall. I then had two headlights blow out and the check engine light was back on and they told me to bring it in and then said that it was an electrical issue but it was covered. …”

   NHTSA complaint #10275935, filed 2009-07, 71,000 miles
5. 5
   Suspension

   Rear upper control arm brackets rust through

   • 22 complaints (7%)
   • median 109,500 mi at 10.6 yrs old (20 state mileage)
   • filed 2011–2022

   Owners describe the upper control arm bracket welded to the rear axle rusting through so the control arm detaches, found during suspension or shock work. One complaint describes excessive rust and fractures across the frame. Others mention rattling and shaking at various speeds beforehand. Complaints say the dealer or manufacturer declined assistance. Reported mostly between about 93,000 and 124,000 miles on older vehicles, including in areas not typically considered rust-prone.

   What to check: Look closely at the rear axle and the brackets where the upper control arms attach for heavy rust or flaking, and have the vehicle inspected underneath before purchase.

   2 excerpts from owner complaints in NHTSA records

   “While examining the rear suspension prior to replacing the shocks I saw that the upper control arm brackets on the rear axle are badly rusted. The left is slightly worse. I do not live in a rust belt area. Western washington to be specific. There is no other rust or corrosion on this car. There is a design flaw that allows water to stay in the area above the axle and corrode the bracket. When the bracket breaks the rear axle is no longer held in place. The car will be very difficult to steer and the wheels could lock up. …”

   NHTSA complaint #10749008, filed 2015-08, 95,847 miles

   “The contact owns a 2005 Kia Sorento. While driving at various speeds, there was an abnormal rattling noise and the vehicle shook. The failure recurred on several occasions. The vehicle was taken to an independent mechanic where it was discovered that the entire frame had excessive rust and fractures and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 124,000.”

   NHTSA complaint #10788110, filed 2015-11, 124,000 miles

Buying note. Have a mechanic inspect the front of the engine for crankshaft pulley bolt condition and the rear axle and frame for rust before buying, and confirm the headlamp harness update if the lights matter to you. Service records showing the pulley bolt and cooling system work would be worth asking about.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.