— A Kia K5 fuel tank recall affects more than 253,000 vehicles equipped with gasoline tanks that can swell, melt and leak fuel.
The recall covers 2021-2024 Kia K5 cars equipped with 1.6 liter turbocharged direct injection (T-GDI) petrol engines.
The problem is a damaged check valve that allows air to enter the fuel tank and cause it to expand. A swollen gas tank can touch hot exhaust parts and melt the tank, potentially causing a fire.
Kia explains:
“The bleed control system check valve, which controls the direction of airflow from the charcoal canister to the engine, can deteriorate over time, allowing pressurized air to flow from the intake manifold to the fuel tank. If this happens, the fuel tank can expand and come into contact with the hot parts of the exhaust pipe.”
In September, Kia received a complaint stating “check engine light comes on sometimes, also noticed vehicle is leaking gas and has a very strong gas odor” on a 2021 K5. A dealer discovered fuel leaking from the fuel tank, near the exhaust pipe.
Another complaint was filed by a 2022 Kia K5 owner who complained of leakage from the fuel tank, and Kia noticed signs of localized melting of the fuel tank near the exhaust pipe.
Engineers have determined that the fuel tank can swell as the purge check valve wears out. Kia is aware of at least 20 reports of fuel leaks due to melted gas tanks, but no fires or injuries have occurred.
Kia K5 occupants should be aware of popping noises coming from the gas tank area, and a driver should look for illuminated check engine lights.
The recalled Kia K5s were built in Georgia between March 27, 2020 and January 23, 2024.
Additionally, the Kia K5 gas tank recall affects 2,737 vehicles in Canada.
Recall letters for the Kia K5 fuel tanks will be mailed on January 16, 2026, and dealers will replace the purge control system check valves and replace any damaged fuel tanks.
Owners can contact Kia at 800-333-4542. Kia’s K5 fuel tank recall number is SC356.
In January, a Kia K5 class action lawsuit was filed over swelling gas tanks, a lawsuit blaming the purge check valves.
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