Built around the 2004 model year specifically, this Kia Optima factory service and repair manual is matched to your exact engine and trim, which means the specifications and tightening sequences it quotes are the ones Kia published for this car — not near-enough figures borrowed from an earlier or later Optima.
Engines covered
- 2.4L inline-four — DOHC, naturally aspirated, gasoline
- 2.7L V6 — DOHC, naturally aspirated, gasoline
Body styles covered
- 4-door sedan
Trims covered
- EX
- LX
Known issues on the 2004 Optima. One recall is on federal record for this model year, and it concerns the front suspension: corrosion of the front subframe could lead to separation, possibly resulting in a vehicle crash. Kia recalled 36,538 Optima vehicles from the 2001-2004 model years under that campaign. Owners have filed 306 complaints for the year and Kia has issued 14 technical service bulletins.
Whether you are checking the front subframe for corrosion, chasing a fault on the 2.7L V6, or working through a scheduled service, it keeps you on Kia's own procedure and the correct figure for your 2004 Optima.
KIA MOTORS CORPORATION (KMC) IS RECALLING 36,538 MODEL YEAR 2001-2004 OPTIMA VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE STATES DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUBFRAME. OVER TIME, SUCH SUBFRAME CORROSION NEAR THE CONNECTION TO THE LOWER CONTROL ARM CAN LEAD TO WHEEL MISALIGNMENT AND/OR OTHER NOTICEABLE STRESS IN STEERING, OR ACCELERATED ABNORMAL
CORROSION OF THE FRONT SUBFRAME COULD LEAD TO SEPARATION, POSSIBLY RESULTING IN A VEHICLE CRASH.
KMC WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 15, 2009. OWNERS MAY CONTACT KIA'S CONSUMER ASSISTANCE CENTER AT 1-800-333-4542.
TECHNICAL SERVICE BULLETIN: INFORMATION FOR HEADLAMP CONDENSATION AND MOISTURE - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This b
TSB - USE OF AFTERMARKET USB CHARGING CABLES IN USB/12V PORTS - This article provides information regarding the use of USB ports and 12V power outlets to connect/charge mobile phones. Customers may experience issues with their head units th
PITSTOP - ENGINE COMPONENT RE-USE GUIDELINES - In general, parts and components removed during engine repairs should be considered serviceable, and should be thoroughly cleaned and transferred to the new engine.
TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners, which are designed to lock into place once fully attached, are utilized in various Kia models and are strictly intended for ?one time use.? Some example
TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners utilized in various Kia models are strictly intended for ?one time use?. Though not limited to the following, some examples are: axle shaft nuts with sta
TSB: AUTOMATIC TRANSMISSION FLUID APPLICATION GUIDE - THIS BULLETIN PROVIDES INFORMATION RELATING TO THE CORRECT AUTOMATIC TRANSMISSION FLUIDS THAT ARE REQUIRED FOR EACH KIA MODEL. REFER TO THE SHOP MANUAL ON KGIS FOR THE SPECIFIC KIA MODEL
KIA: INTERMITTENT MIL ON WITH NO FAULT CODE STORED; INFORMATION ABOUT DTC P1330. PROVIDES INFORMATION RELATING TO CERTAIN VEHICLES. IN AFFECTED VEHICLES AN INTERMITTENT SHORT TO GROUND IN A CIRCUIT ONLY INTENDED FOR TESTING PURPOSES MAY CAU
KIA: ECM UPGRADE WITH TP SENSOR REPLACEMENT-MIL ON WITH DTC P2135/P0638. INFORMATION RELATED TO ECM SOFTWARE AND TP SENSOR UPGRADE ON SOME VEHICLES WITH 2.7L ENGINES WHICH MAY EXPERIENCE A MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH T
Showing the 8 most recent of 15 technical service bulletins on file with NHTSA.
ALMOST DIED IN AN ACCIDENT TATE KIA DID NOT ALLOW ME TO LEAVE THE THROUGH MY DOOR. I WAS HIT ONE MY PASSENGER SIDE NOT ALLOWING MY ESCAPE THROUGH THAT SIDE OF THE VEHICLE AND I NEEDED TO CRAWL THROUGH TO THE BACK OF THE VEHICLE TO ESCAPE. MY DRIVERS SIDE DOOR LOCK MALFUNCTIONED BECAUSE OF WEAR ON A COMMONLY KNOW PART. THIS SHOULD NOT BE CONSIDERED NORMAL WEAR AND TEAR CONSIDERING MY 1967 CAMERO STILL HAS FUNCTIONING LOCKS AND 50 YRS OLDER. I SEE NOT REASON AS TO WHY A 11 YR OLD VEHICLE HAS NO
TL* THE CONTACT OWNED A 2004 KIA OPTIMA. WHILE DRIVING AT AN UNKNOWN SPEED, AN ABNORMAL CLICKING NOISE EMITTED FROM THE VEHICLE. THE POWER STEERING FAILED AND THE WHEELS SHOOK VIOLENTLY. THE BRAKES FAILED TO STOP THE VEHICLE AND IT CRASHED INTO A WALL. THE AIR BAGS DEPLOYED AND AN UNKNOWN SUBSTANCE EMITTED INTO THE CONTACTS EYES. THE CONTACT SUSTAINED BURNS TO THE BODY AND LACERATIONS TO BOTH EYES THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED AND DEEMED DESTRO
TL*THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT WAS TRAVELING AT SPEEDS OF 15 MPH IN RAINY WEATHER. THE VEHICLE AHEAD OF HIM STOPPED SUDDENLY. THE CONTACT WAS UNABLE TO STOP THE VEHICLE AND CRASHED INTO THE REAR OF THE PRECEDING VEHICLE. THE AIR BAGS DID NOT DEPLOY UPON IMPACT. THE CONTACT WAS INJURED. A POLICE REPORT WAS FILED. THE CONTACTS VEHICLE WAS DESTROYED. THE FAILURE AND CURRENT MILEAGES WERE 82,500.
TL* THE CONTACT OWNED A 2004 KIA OPTIMA. WHILE DRIVING 25 MPH, ANOTHER VEHICLE CRASHED INTO THE CONTACT'S VEHICLE FROM THE FRONT. THE PASSENGER SIDE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED STOMACH AND CHEST INJURIES THAT REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS DESTROYED. THE MANUFACTURER WAS NOT CONTACTED. THE VIN WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 57,000.
VEHICLE WAS INVOLVED IN A SINGLE CAR ACCIDENT IMPACTING A FIXED MEDIAN CURB. THE CAR WAS TOWED TO A REPAIR SHOP IDENTIFIED BY MY INSURANCE COMPANY. THE TOW TRUCK DRIVER REMARKED THAT THE FRONT SUSPENSION APPEARED TO HAVE BOLTS MISSING. THIS WAS INDEPENDENTLY VERIFIED BY THE BODY SHOP. IN THEIR DAMAGE ASSESSMENT, THEY FOUND THAT THE LOWER CONTROL ARM TO BALL JOINT BOLTS WERE MISSING AND THE 2 HOLES WERE ROUNDED OUT IN A WAY THAT WOULD BE CONSISTENT WITH THE BOLTS FALLING OUT. THE BOLTS FALLING OU
TL*THE CONTACT OWNS A 2004 KIA OPTIMA. THE CONTACT STATED WHILE DRIVING 30 MPH WITH THE BRAKES ENGAGED THE VEHICLE ACCELERATED AND CRASHED INTO SOME TREES. THE VEHICLE WAS DESTROYED. NO ONE WAS INJURED. THE CONTACT DID NOT CALL THE MANUFACTURER. THE CONTACT STATED THAT THE VEHICLE HAD ALWAYS BEEN UNSAFE TO DRIVE. THE FAILURE MILEAGE WAS 40,000.
PURCHASED A BRAND NEW 2004 KIA OPTIMA FROM THE DEALER ON 12/09/2004. THE CRUISE CONTROL HAS NOT BEEN WORKING SINCE THE FIRST DAY IT WAS DRIVEN OUT OF THE DEALER'S LOT. WHAT'S MORE, THREE WEEKS INTO OWNERSHIP OF THE VEHICLE, IT BEGAN TO EXHIBIT INTERMITTENT, ROUGH IDLING PROBLEMS. THE PROBLEM IS NOT NOTICEABLE ON COLD STARTS, BUT AFTER IT HAS BEEN DRIVEN FOR ABOUT 35 MINUTES OR SO AND THE ENGINE HAS WARMED UP AND REACHED A CERTAIN TEMPERATURE, IT WILL BEGIN TO MAKE ROCKING-JERKY-THRUSTING LIKE M
I WAS DRIVING ON I-10 WESTBOUND, KATY TX FREEWAY, TRAVELLING ABOUT 65 MILES PER HOUR. THE PASSENGER'S SIDE FRONT TIRE BLEW OUT CAUSING THE CAR TO GO BACK AND FOURTH BETWEEN TWO LANES OF TRAFFIC. IN THE PROCESS, I WAS HITTING THE RUBBER DIVIDERS, DAMAGING THE HOOD OF THE CAR AND THE WINDSHIELD. THE BLOWN TIRE CAUSED DAMAGE TO THE OIL PAN, THE RADIATOR, AND EVENTUALLY THE TRANSMISSION. I GOT THE CAR TO THE EMERGENCY LANE. THE CAR WAS TOWED OFF THE FREEWAY AND EVENTUALLY PICKED UP AND TRANSPORTED
WHILE I WAS DRIVING MY VEHICLE MY PASSENGER NOTICED THAT THERE WAS SMOKE COMING OUT OF THE DASHBOARD AREA. IN AN ATTEMPT TO GET OFF THE ROAD THE SMOKE HAD TURNED INTO FLAMES AT WHICH TIME I STOPPED THE VEHICLE AND I AND MY PASSENGER GOT OUT OF THE VEHICLE AND CALLED 911. *JB
WHILE DRIVING, A FIRE STARTED FROM THE DASHBOARD. THE CAUSE OF FIRE WAS UNDETERMINED.
RT BALL JOINT/AXLE BROKE WHILE DRIVING ON 10 OCT 08. MY VEHICLE IS A 2004 KIA OPTIMA. *TR
DT: THE AIRBAG WARNING LIGHT WAS INTERMITTENTLY. THE CONSUMER HAD TAKEN VEHICLE TO THE DEALERSHIP TO BE REPAIRED FIVE TIMES. THE DEALERSHIP WAS UNABLE TO FIX THE PROBLEM. ON SEPTEMBER 30, 2005 THE FRONT PASSENGER'S SIDE AIRBAG DEPLOYED WITHOUT A CAUSE. THE VEHICLE WAS PARKED WHEN THE AIR BAG DEPLOYED. THE SOUND FROM THE AIRBAG HAD GIVEN THE DRIVER A HEADACHE. THE CAUSE WAS STILL UNKNOWN. *SC . *AK
MY DRIVER SIDE LOCKS WILL NO LONGER UNLOCK CORRECTLY. SOMETIMES IF I JIGGLE EVERYTHING TOGETHER JUST SO I CAN GET IT TO UNLOCK FROM THE OUTSIDE. HOWEVER, ONCE INSIDE IT IS IMPOSSIBLE TO GET THE DOOR OPEN. THIS IS A MAJOR ISSUE, IF I LOCK MY CAR IT TAKES ME FOREVER TO GET BACK IN TO IT. I HAVE TO MAKE SURE THAT MY CHILDREN ARE STANDING OUT IN THE HEAT WAITING ON ME AND NOT BAKING IN THE CAR WAITING FOR ME. IF I AM IN AN AREA AFTERHOURS, I AM MORE AT RISK OF HAVING SOMETHING HAPPEN. IN ADDITION, I
THE AIR BAG WENT OFF WHILE MY WIFE WAS REACHING FOR HER SEAT BELT AND SCRAPPED AND BURNED HER ARM. IT SOUNDED LIKE A GUN GOING OFF. I RUSHED HER HOME AND TOOK CARE OF HER WOUNDS
DRIVER SIDE DOOR WILL NOT OPEN, ACCIDENTALLY LOCKED DOOR NOW IT WILL NOT OPEN, HAVE TO CLIMB OVER FROM PASSENGER SIDE TO DRIVER SIDE, WILL NOT OPEN FROM INSIDE OR OUTSIDE, I AM DISABLED AND IT'S VERY DIFFICULT TO HAVE TO CLIMB OVER TO DRIVER SIDE, FOR A LONG TIME NOW I HAVE LEFT THE CAR UNLOCKED FOR THIS REASON, SEEMS I AM NOT THE ONLY ONE WITH THIS PROBLEM, A LOT OF PEOPLE HAVE PLACED POSTS ABOUT THIS ISSUE. IT'S NOT ONLY AN INCONVENIENCE BUT A SAFETY ISSUE. I FEEL THIS IS A MAJOR RECALL THAT
Showing the 15 most serious of 225 complaints filed with NHTSA.
