2022 Kia K5 Fuel System Problems

The vehicle experienced an overheating condition involving the fuel system, which aligns with an active recall stating that a damaged check valve can allow air into the fuel tank, causing it to expand and come into contact with hot exhaust components, potentially melting the fuel tank. While operating the vehicle, this created a serious safety concern due to the risk of fuel tank damage, fuel leakage, and potential fire. This was not a minor issue, as it directly involved a component that could lead to a fire hazard. The vehicle was later evaluated and deemed unrepairable due to the severity of the issue. Because of this, the vehicle is not currently being used due to safety concerns. Despite the known safety risk and recall-related defect, the situation has not been properly resolved. The handling of this issue raises concerns given the potential for fuel system failure and fire risk associated with this defect. This complaint is being submitted due to the safety risk involving the fuel system and the potential for fire while operating the vehicle.

The contact owns a 2022 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline); however, while taking the vehicle to the dealer, it was determined by the dealer that the vehicle could not be repaired. The contact was not given any reason why the vehicle could not be repaired and was offered a buy-back option instead. The contact stated that the rear passenger seats were extremely hot. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The failure mileage was approximately 90,000.

The contact owns a 2022 Kia K5. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the Purge Control Solenoid Valve (PCSV), resulting in damage and fuel tank expansion. The vehicle was not repaired. After investigating the failure, the contact related the failure to Service Campaign: SC288. The manufacturer was notified of the failure, a case was opened, and the contact was offered a buyback, but refused the buyback. The failure mileage was 81,000.

My 2022 Kia K5 EX has a serious fuel-system safety defect involving fuel tank expansion, which caused rear seat pan deformation and rear seat strap deformation. Kia America’s engineering review confirmed this in their findings. The fuel tank expansion caused the rear seat to lift/warp from underneath, creating a risk of fuel leakage, fire, and structural failure in a crash. This is a significant safety concern for occupants and the public. Kia America acknowledged this safety defect in a letter dated October 15, 2025 and stated it is “consistent with the fuel tank expansion condition.” They offered to repurchase the vehicle due to this safety issue. (Letter attached.) Because of this defect, my vehicle has been out of service for 78 days and is not safe to drive. I use this vehicle as my primary source of income for full-time rideshare work, which has caused severe loss of income. Due to the extended loss of use and financial hardship, I am now at risk of repossession, even though the vehicle is unsafe because of a manufacturer-confirmed defect. Despite Kia acknowledging the defect, no recall has been issued, which raises concern that other drivers may still be using potentially unsafe vehicles. I am requesting NHTSA to investigate this defect for potential recall action.

Gas tank expanding causing gas to drip from than tank onto the floor potentially causing a fire hazard.

I took my car because of fuel recall, due to multiple vehicles having their gas tank expanding or exploding. Even after they completed the recall on my vehicle I still had my gas tank expand. I took my vehicle to the Kia Frisco dealership and they took my vehicle advising they had to buy it back from me. Once they had the vehicle after close to a month they stated that my vehicle was repairable even after stating that several of these models had gas tanks expanding and exploding. I do not feel safe getting into this vehicle after the repair and I want to report it.

Fuel consumption jumped then car began jerking shortly after engine failure

The contact owns a 2022 Kia K5. The contact stated that while driving at 43 MPH, the vehicle made an abnormally loud booming sound. The contact's daughter, who was occupying a rear seat, screamed out because the rear seats had suddenly risen. The contact pulled over to the side of the road and inspected the vehicle. The check engine and the low fuel warning lights were illuminated. The contact's wife met the contact and picked up the children. The contact stated that upon resuming driving, the vehicle was jerking violently, and the fuel gauge level lowered significantly. The vehicle was taken to an independent mechanic, where it was diagnosed with an EVAP system failure. The vehicle was driven to the residence. The vehicle was then towed to the dealer, where it was diagnosed, and determined that the fuel tank had expanded. The vehicle was not repaired. The manufacturer was notified of the failure and offered to repurchase the vehicle. The failure mileage was approximately 85,000.

My fuel tank has expanded. It has deformed the body beneath the rear seat.

July 5th we were driving heard a loud boom and the car slowed down we pulled over. Then we seen that the seat was lifted up and smelled gas. We had an appointment for Monday July 7 for this recall and wasn’t able to drop off the next on Tuesday July 8. As called that Monday made the dealer aware. Now they been having the car and we are just waiting on the next process. There’s not sure what saying Kia will contact us. I am reaching out to get some type of results. We can’t get a rental car and next week it will be 30 days on the 8th of August. We are looking to resolve this matter with Kia.

The contact owns a 2022 Kia K5. While the contact's son was driving at an undisclosed speed, the rear seat started to rise independently. There were no warning lights illuminated. The contact's husband was sitting on the rear seat. In addition, the contact stated that the failure had occurred after the vehicle was refueled. The vehicle was taken to the dealer where it was diagnosed with an expanded fuel tank. The contact was informed that the fuel tank needed to be replaced. The vehicle was repaired. The contact stated that the repair had taken three weeks. The vehicle was returned to the contact. The contact stated that two weeks later, the manufacturer began sending emails to the contact, which stated that the vehicle was under recall. The contact was advised to park and not drive the vehicle. The vehicle was towed to the dealer. The vehicle remained at the dealer for two additional months. The manufacturer informed the contact that the vehicle was non-repairable. The contact had not received an offer for a replacement vehicle and the contact was still required to continue monthly payments. In addition, the contact was concerned because her husband had been driving an unsafe vehicle for two weeks after the repair was performed by the dealer. The failure mileage was approximately 79,000.

While driving home recently with my young stepson securely seated in his car seat and my fiancé in the passenger seat, we suddenly heard a terrifying loud bang. Immediately following the explosion, my stepson cried out in pain. At the time, the windows were up and the air conditioning was off, yet we all felt an intense gust of wind inside the vehicle. When I turned around, I saw that my stepson’s seat had been lifted unusually high. We later discovered that either the fuel tank or the fuel pump had exploded.I was shocked and terrified. I had no prior knowledge of any fuel system issues or recalls on this vehicle. After contacting my local Kia dealership, a representative informed me, “Yep, your car has the recall, and it sounds like it swelled up.” Even more troubling is that I never received any recall notifications regarding these issues. The only recall notices I’ve ever received by mail were years ago for a completely different vehicle — my previous Kia Soul, which is no longer in use, as well as the recall for the side curtain airbag.I took it upon myself to do a VIN check and learned that this recall was issued on July 9, 2021, yet I purchased the car from Bev Smith Kia of Fort Pierce on December 30, 2022 — long after the recall had been published. I’m struggling to understand how this vehicle was sold without the required recall repairs being completed or disclosed.I am currently trying to work with Kia to resolve the issue, but I felt it was important to share this with your team so others can be made aware of the potential danger. Had this explosion happened at higher speed or on the highway, the consequences could have been catastrophic.

Gas tank expanded and warped the back seat causing my child’s car seat to not be seated properly. Walking near the car you can smell gasoline very strongly. The check engine light came on briefly and then went away. My car is at the dealership currently as they decide what to do about the issue.

I had 130 miles until I needed to fuel up. Out of nowhere, my gas light comes on with the miles now blanked out. I thought it was odd, but stopped at the next gas station to fuel up. It would not let me put more than .22 cents into the tank without gas exploding out the side. Again, cranked up the car & it states it still needs gas. Tried another gas station & got the same result. Ended up at the nearest Kia & they stated it was the fuel tank expansion recall. They told me they ordered the parts and it should be fixed a little after Christmas. A week later and they are stating they do not know how to fix the vehicle and have no options for rentals/loaners. They said Kia would have to contact them before they can work on the vehicle. I have not received a call but did call the 1-800 number I was given and they basically said that they don’t know what they are going to do and someone will reach out to me. This is so scary as a consumer that Kia is allowed to place vehicles on the road that are considered very dangerous. A process needs to be in place fairly quickly or I am afraid there will be a lot of people in my situation. Not only was this scary, I was alone & this could have put me in danger on the road. I will never buy a Kia again & hate the service I have received as I have been left in the dark from the beginning.

I was driving on [XXX] and I heard a really loud sound like a Gun Shot in my Car I couldn't just pull over I had to get off at the next exit when I did I checked myself and then I checked my Windows then I opened my back door on the passenger side and saw that behind the seat had swollen up. I drove to work and call KIA where I purchased the car and told them what happened my husband carried the car to them and to make a long story short. After Months of back & forth it was determined that the GAS TANK had EXPANDED!!! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

On June 12, 2024, the driver heard a loud pop/thump coming from the rear of the vehicle. The driver looked back to inspect the vehicle and noticed that the back seats had lifted his child and car seat up from the proper seating position. Upon further inspection, the driver had noticed a large bulge under the rear seats that was releasing a lot of heat and the smell of gas was throughout the cabin of the vehicle. On the way home at the time of the event the driver stopped to get the gas and when opening the gas cap noticed a violent pressure release, similar to opening a shaken-up soda. The driver quickly got to a safe location as the heat in the passenger cabin started to rise. The driver immediately notified the Kia Service Dept. and the vehicle was towed to the Kia service department on June 13, 2024. On June 18, 2024, the driver was told that the current issue was due to a gas tank expansion issue and that the gas tank expanded causing the metal frame to bend, and that the vehicle may not be repairable since the metal frame had been bent. The service department stating the vehicle is no longer safe to drive and that the issue would be escalated to their consumer affairs team. It is July 29, 2024, and there has been no word of Kia or any representative thereof that has reached out to remedy this issue. The dealer has denied a temporary replacement vehicle and/or rental car replacement for the time being. Where the driver and child were at extreme risk of a potential fatality or extreme injury, It would be expected that the matter be handled a little more expeditiously. Hoping to get this matter resolved!

I was driving home yesterday and experienced a loud pop in the back of the car and found the backseat had lifted because the gas tank had expanded I am at the dealership right now Hoping that they will give me a loaner And I would like to trade the car in because I don’t trust the car anymore There are other reports of this similar issue I found online The reports say that there is a PVC pressure release valve that is getting stuck and causing the gas tanks to explode I am currently at the dealership and it is going to be inspected It is the first time this dealership has had this issue reported But there are six other incidents reported in other states like Texas, Louisiana, Florida, and North Carolina

Backseat made loud noise and the backseat popped up car started to cut off and stumble as there was no gas in the gas tank leaving me stranded on the side of the road out of state were i donr stay in the way back home to ga

The contact owns a 2022 Kia K5. The contact stated while driving at various speeds and depressing the accelerator pedal, the vehicle shuddered and hesitated to respond. The check engine warning light was illuminated. The vehicle was taken to the dealer several times, where the dealer related the failure to the fuel cap. The dealer loosened the fuel cap; however, the failure persisted. The vehicle was taken back to the dealer, where it was diagnosed with fuel tank expansion. The vehicle was not repaired. The dealer offered to repurchase the vehicle. The manufacturer was notified of the failure and a case was opened. The failure mileage was approximately 47,940.

The contact owns a 2022 Kia K5. The contact statement while driving at approximately 45 MPH, there was a sound of air inside the cabin of the vehicle and the fuel gauge erroneously reduced to empty. The vehicle was later driven to the local dealer who diagnosed that the fuel tank was defective and had expanded and needed to be replaced. The contact was informed that the fuel tank expansion had also caused damage to the rear seat support metal. The exact cause of the failure was not yet determined. The manufacturer was notified of the failure. The failure mileage was 72,000.2