Kia America, Inc. recall 25V794

Affected vehicles (1)

Component / system

Defect

Kia America, Inc. (Kia) is recalling certain 2021-2024 K5 vehicles. A damaged check valve can allow air to enter the fuel tank, causing it to expand and contact hot exhaust components, melting the tank.

Risk / consequence

A melted fuel tank can leak, increasing the risk of a fire.

Remedy

Dealers will replace the check valve. The fuel tank will be inspected for damage and replaced as necessary. All repairs will be performed free of charge. Owner notification letters were mailed January 16, 2026. Owners may contact Kia customer service at 800-333-4542. Kia's number for this recall is SC356. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning December 1, 2025.

Chronology of events

1. Sep 3, 2025

   September 3, 2025 During routine data review, Kia NA Safety Office identifies customer complaint of “check engine light sometimes comes on, also noticed vehicle is leaking gas and has very strong gas smell” on a 2021MY K5. Dealer identifies fuel leaking from fuel tank near exhaust pipe. Kia NA Safety Office tries to inspect the vehicle, but vehicle was not available for inspection. Kia NA Safety Office begins to evaluate field data.

2. Sep 4, 2025

   September 4, 2025— Kia NA Safety Office identifies a customer complaint involving a

3. Sep 11, 2025

   September 11, 2025 2022MY K5 alleging fuel leak from fuel tank. Kia NA Safety Office subsequently inspects vehicle and observes signs of localized melting of the fuel tank near exhaust pipe and fuel leak.

4. Sep 15, 2025

   September 15, 2025 Kia NA Safety Office informs Kia Corporation (Kia HQ) of inspection results from the 2022MY K5 vehicle and requests Kia HQ conduct fuel tank leak testing under various test scenarios.

5. Nov 6, 2025

   November 6, 2025 Kia HQ informs Kia NA Safety Office that if the purge control system check valve deteriorates, the fuel tank may expand and contact the exhaust pipe. Bench testing identifies fuel tank melting and leaking in certain circumstances of prolonged contact between the expanded fuel tank and hot exhaust components. Kia NA Safety Office analysis of field data identifies 20 VINs with fuel leak due to melted fuel tank [dates of receipt 5/22/2024—

6. Nov 3, 2025

   11/3/2025]. No fires or injuries.

7. Nov 7, 2025

   November 7, 2025 Kia NA Safety Office decides to recall all 2021-2024MY K5 vehicles equipped with 1.6L T-GDI engines due to potential risk of fire. No fires or injuries. 1 Kia America, Inc.

Notification schedule

Dealer notification

Nov 18, 2025 - Nov 18, 2025 No Dealers

Owner notification

Jan 16, 2026 - Jan 16, 2026 Phased Recall