Kia K5 Gas Tank Recall Affects 250,547 Sedans Over Fire Risk
Kia has announced an urgent recall affecting 250,547 units of the K5 midsize sedan, which could result in a melting, leaking gas tank and a subsequent fire risk. The Kia K5 Gas Tank Recall is specific to turbocharged 1.6-liter models from 2021 through 2024 model years, and it addresses a dangerous structural failure caused by a deteriorating valve.
This is a serious safety matter confirmed by the National Highway Traffic Safety Administration (NHTSA). Although the K5 generally maintains strong reliability ratings, owners of the affected sedans should seek the fix immediately.
Here is a breakdown of the cause, the symptoms, and the free remedy being offered by Kia.
The Cause: Expanding Tank, Hot Exhaust
The issue stems from a deteriorating purge control system check valve, which allows pressurized air to flow incorrectly from the intake manifold straight into the gas tank.
- Expansion: This misdirected air causes the plastic gas tank to expand or swell like a balloon.
- Melting Hazard: Once expanded, the fuel tank can make contact with hot exhaust pipe components. With prolonged driving, the plastic tank could melt and leak fuel, creating a serious fire hazard.
The problem is isolated to K5s equipped with the 1.6-liter turbocharged T-GDI four-cylinder engine. Kia resolved the issue for the 2025 model year by replacing the 1.6L turbo engine with a 2.5L naturally aspirated engine.
2021 K5 EX 1.6T FWD — Source: Kia
Symptoms and Schedule
Drivers may receive several crucial warnings if their vehicle is experiencing the fuel tank issue.
| Warning Sign | Cause |
| Popping Sound | Air pressure building up and causing the fuel tank to expand. |
| Illuminated Check Engine Light (CEL) | Sensor detecting improper pressure or fault in the purge system. |
| Rough Running / Fuel Odor | Fuel may be beginning to leak due to contact with the hot exhaust. |
The affected vehicles were built between March 27, 2020, and January 23, 2024. Owner notification letters are scheduled to be mailed on January 16, 2026.
The Free Remedy
The Kia K5 Gas Tank Recall requires owners to visit a Kia dealer for a free inspection and repair.
- Valve Replacement: Dealers will replace the faulty purge control system check valve with an improved one.
- Tank Inspection: The fuel tank will be thoroughly inspected for any signs of damage or melting, and if necessary, it will be replaced with a new one.
- Software Update: Dealers will also ensure the vehicle is equipped with the latest ECU software to monitor and help regulate internal fuel tank pressure.
Although Kia is not aware of any crashes, injuries, or fatalities related to the defect, the risk of fire is significant. Owners of 2021-2024 1.6T K5s are strongly advised to check their VIN and schedule a repair as soon as the notification arrives.
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