NHTSA Office of Defects Investigation
Engineering Analysis EA03-015: FUEL RAIL LEAKAGE
- Closed
NHTSA's Office of Defects Investigation opened Engineering Analysis EA03-015 on August 28, 2003, the day it closed Preliminary Evaluation PE03-016, whose summary cites it, and closed it on April 30, 2004. NHTSA's investigations file lists the 2001 Kia Rio for it and links recalls 03V-352 and 04V-179 to it.
Updated daily from NHTSA's investigations file
Key facts
- NHTSA number
- EA03-015 (also written EA03015)
- Investigation type
- Engineering Analysis A more detailed stage of a defect investigation, opened when NHTSA's Office of Defects Investigation decides an issue merits further review, often after a Preliminary Evaluation or a Recall Query; it can include vehicle testing, surveys and further information requests.
- Status
- Closed April 30, 2004
- Opened
- Closed
- Vehicle or equipment manufacturer
- Kia America, Inc.
- Components
- Fuel System, Gasoline; Fuel System, Gasoline — Delivery; Fuel System, Gasoline — Delivery — Hoses, Lines/Piping, and Fittings; Fuel System, Gasoline — Fuel Injection System; Fuel System, Gasoline — Fuel Injection System — Fuel Rail
- Recalls linked by NHTSA
- Vehicles and equipment
- 2001 Kia Rio
NHTSA's summary
As NHTSA's Office of Defects Investigation wrote it for Engineering Analysis EA03-015.
try.vin does not copy NHTSA's investigation documents; NHTSA's investigation record lists the ones NHTSA has published.
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.
ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.
KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.
ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Vehicles and equipment listed for this investigation
NHTSA's investigations file lists these vehicles and equipment for Engineering Analysis EA03-015. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. Model years with a try.vin recall page link to that page's NHTSA investigations section.
Kia
Kia Rio
What an NHTSA investigation is
NHTSA's Office of Defects Investigation (ODI) looks into possible safety defects in vehicles and equipment, often after owner complaints. An investigation usually starts as a Preliminary Evaluation, or as a Recall Query when it concerns whether an existing recall covers the right vehicles or fixes the problem, and ODI can upgrade it to a more detailed Engineering Analysis. A Defect Petition asks NHTSA to open an investigation, and Audit and Equipment Queries are administrative investigations into whether companies complied with federal vehicle safety requirements, such as reporting, recall and certification rules.
An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.
To see whether a specific vehicle has an open recall, enter its VIN at nhtsa.gov/recalls.
Kia VIN check: decode a VIN to see its year, make and model.
Sources
NHTSA's investigation record for EA03-015
Investigation details come from NHTSA's investigations file, which try.vin imports once a day. The investigation types are described from the U.S. Department of Transportation Inspector General's May 2023 report on NHTSA's Office of Defects Investigation, NHTSA's petition rules (49 CFR Parts 552 and 557) and NHTSA's Office of Defects Investigation procedures. How try.vin reads NHTSA investigations.