2021 Kia K5 Fuel System Problems

My vehicle is currently under a recall (recall SC356), but I'm currently very far from a Kia dealership. The nearest one is about 175 miles away. I contacted Kia and they informed me that they can't reimburse me for having my car towed to the dealership. So now I am stuck with a car that could possibly catch fire at anytime, according to the recall notice. And they refuse to help me.

I brought my car in for the recall regarding the faulty check valve in the fuel tank. My check engine light had also just come on. I have a 2021 Kia K5 with 60,000 miles and the dealership tells me I have to replace all 4 fuel injectors since it's causing a "system too lean" message.

The contact owns a 2021 Kia K5. While driving at an undisclosed speed, the contact heard a loud explosion coming from the rear of the vehicle, and there was a dragging sound coming from the vehicle. The contact stated that the rear seat raised up into the air with children seated in the seat. The contact became aware of fuel leaking and that the fuel tank was hanging down. The vehicle was towed to the residence and was later driven to a KIA dealer. The manufacturer was made aware of the failure. The approximate failure mileage was 116,000.

The fuel tank malfunctioned while driving. It appeared on my odometer that I had zero gas, once I pulled into a gas station to fill up, I could see the gas pouring out of the tank while the pump was unable to pump any gas due to the pressure coming out of the tank. Bev Smith Kia of Fort Pierce has the vehicle if you would like to inspect it. I also have photos of the melted tank from the dealership. NHTSA Recall Number: 25V-794 The fuel tank expansion/melting risk, fuel leak, or fire risk, put the driver, passenger, and nearby citizens at risk if the car caught fire. Also, the seats have been known to eject with this particular recall. Yes the vehicle was inspected by Bev Smith Kia per my insistence, and instead of fixing it and returning the vehicle, Kia Corporate forced the hand of Bev Smith Kia to confiscate the vehicle due to it being a deadly recall. SC288 Alpha Campaign Failed is what the dealership told me to tell corporate. There were no warning lights when the odometer appeared to have zero miles, it simply went to zero and the backseat became very hot to the passenger. There was no ability to fill the gas tank as the pressure of gas was pouring gas out from the fuel tank and the pump would not add additional gas. This appeared in May of 2025. We took it to the dealership and they said there was nothing wrong with the car. The next time is happened was Sunday [XXX]. The car was taken to Bev Smith Kia dealership that Monday November 24th where it was confiscated by the dealership for the deadly recall that they claimed could never be fixed and Kia would do a buy back. There were no other issues with the vehicle prior to the incident in May of 2025. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Took car to Kia for an oil change and car started driving weird . Rpm hand running high. Check engine light came on , took car to Kia and fuel tank was expanded . Car is still not fixed , and Kia won’t continue to pay for rental.

The contact owns a 2021 Kia K5. The contact stated that while driving 65-70 MPH, the fuel gauge displayed zero miles to empty. The contact pulled into the nearest gas station, and while attempting to add fuel to the vehicle, the contact became aware that there was fuel leaking out of the fuel tank outlet, and the gas pump nozzle was stopped. The contact was unable to refuel the vehicle. The contact stated that after returning to drive, the fuel gauge indicated 100 miles to empty. The vehicle was taken to the dealer for the recall repair under NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline), and the dealer advised the contact that the manufacturer had instructed the contact not release the vehicle to the owner due to the recall. While diagnosing the vehicle, a technician at the dealer sent a photo displaying that the rear driver's side seat had melted internally due to the fuel tank overheating. Additionally, the dealer informed the contact that the SC288 Alpha Campaign had failed. The vehicle remained at the dealer for four months; however, the manufacturer later sent a letter advising the contact that the vehicle could not be repaired, and a buyback was suggested. The manufacturer offered to reimburse the down payment for the vehicle. The contact stated that the buy-back offer was unsatisfactory. The contact declined the offer, and the manufacturer then threatened to tow the unrepaired vehicle back to the residence. The contact stated that the manufacturer had failed to honor the recall repair. The vehicle was not repaired. The failure mileage was approximately 145,000.

The contact owns a 2021 Kia K5. The contact stated that fuel odor was entering the cabin of the vehicle. The contact stated that the rear passenger’s seat seemed to be inflated. While driving approximately 70 MPH, the contact became aware of fuel squirting out of the fuel filler neck. The fuel gauge fluctuated from full tank to half tank or empty. There was no warning light illuminated. The fuel odor became stronger, and the contact pulled over to the side of the road at a rest stop. A mobile service tech arrived to inspect the vehicle but found no failures. The contact continued driving to the residence. The vehicle was taken to the dealer, who found that the fuel tank and fuel line had failed and needed to be replaced. The dealer sent a photo to the manufacturer to confirm the necessary repair. The vehicle was not repaired. The manufacturer was informed of the failure and determined that the fuel tank and PCV valve were swollen and needed to be replaced. The manufacturer offered a buy-back for the vehicle and opened a case. The failure mileage was unknown.

Check engine light came on and when filling up my gas tank, gas spit back out at me which has happened with the fuel tank i had in it last year and has since been replaced. Forward collision, EBS, traction control and forward safety sensor lights came on the next day and the car is running extremely rough. It was towed to a shop to see if it has to do with the fuel tank recall. Multiple people in Roanoke, Virginia are having the exact same problem as is a large portion of people online complaining about the exact same thing. Some going back 30 weeks ago.

My fuel tank expanded while I was driving on the highway, causing my car to stall and would not respond to me pushing on the gas. I pulled over on the side of the highway and looked back and saw my rear seats were pushed up. Got it towed to the Kia dealership and they informed me that my car was totaled because the gas tank expanded so much it bent my frame. This has been an ongoing issue with Kia/Hyundai vehicles but they have still not issued a formal recall, only a voluntary callback even though this is a very dangerous defect.

Driving down highway, gas hand was on half a tank then all of a sudden gas hand drops to empty and light comes on, engine started sputtering. Heard a loud pop in the back seat looked back and back seat has popped up from base. Strong odor of gasoline poured into the car. Went to closest gas station to get off highway. Unable to put fuel into tank. Called Quality KIA of Greenwood they said get out of the car and do not drive it. Called for a tow, vehicle has been towed to Quality KIA of Greenwood.

The contact's daughter owns a 2021 Kia K5. The contact stated that while the contact’s son-in-law was driving, the fuel level indicator failed to function as intended. The contact’s son-in-law noticed that the miles available indicator stated that there were 430 miles until empty. The contact’s son-in-law stated that after driving for approximately 20 minutes, the miles available indicator indicated that the miles had decreased by 50 miles. The contact’s son-in-law drove the vehicle to a nearby gas station, and inspected the fuel tank cap, and confirmed that that fuel cap was sufficiently tightened. The contact's son-in-law proceeded to drive for another hour and the miles available indicator decreased by 200 miles. The contact stated that there were three occupants, including an infant, seated in the rear seat of the vehicle. The contact’s daughter, who was seated in the rear seat, noticed heat on the back of her legs. In addition, the contact’s daughter noticed an abnormal ticking sound and the rear seat independently raised up. The contact’s daughter stated that the failure was persistent. The vehicle was driven to the shoulder of the road. The contact’s son-in-law inspected the vehicle. The contact’s son-in-law and daughter switched seats. The contact stated that the daughter had driven a short distance, and the miles available dropped from 200 to 50 miles. The contact instructed the daughter to stop and exit the vehicle. The contact stated that the fuel tank level indicated the fuel was empty and the check engine warning light illuminated. The contact’s son-in-law was instructed to turn the vehicle off and how to inspect the vehicle. Upon inspecting the vehicle, the contact’s son-in-law was instructed to remove the rear seat. The contact’s son-in-law noticed that the fuel tank was swollen. The contact’s son-in-law was instructed to remove the fuel cap to release the pressure. The vehicle was towed to the dealer; however, the vehicle was not inspected. The contact was informed of an unknown recall; however, the VIN was not under recall. The failure had occurred while the family members were traveling and immediately after the fuel tank had been refilled. The manufacturer was not made aware of the failure. The failure mileage was approximately 93,000.

Expansion of air tank, causing to pop up frame in backseat and total car deemed unsafe to drive. No warnings car had never been in the shop prayer happened while driving over rule Mountain area with two children in the backseat. Kia inspected diagnostic ran stated it was air in gas tank under a recall claim to fix it for free and then two weeks later stated it was going to Kia America for a case number. Kia America called and stated that it was not safe to drive and the car is totaled.

Back seat popped up due to fuel tank rising from under seat while driving

The contact owns a 2021 Kia K5. The contact stated while her daughter was driving 60 MPH, there was an abnormal sound coming from the engine, when the gas tank expanded, and the back seat popped up. The contact stated that two teenagers were in the back seat, and one was injured. The contact's daughter pulled over and waited for a short while. The vehicle was restarted; however, the vehicle drove slowly. The vehicle was taken to a dealer; however, the vehicle was not diagnosed. The vehicle was taken to another dealer; however, no cause for the failure was found. The contact was informed that the seat had moved two inches. The contact stated that the vehicle was not repaired because the frame of the seats could be damaged. The vehicle was not repaired. The manufacturer was notified of the failure. The vehicle remained at the dealer and had not been driven since. The failure mileage was approximately 86,000.

The contact owns a 2015 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The contact stated that days before the vehicle was scheduled for an unknown recall repair, while refueling, the contact observed gasoline pouring out of the tank. The vehicle was taken to a dealer, where it was diagnosed, and determined that the fuel tank had expanded due to fumes being trapped inside. The vehicle was not repaired due to parts not being available for the repair. The contact stated that the manufacturer has exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure. The failure mileage was approximately 70,000.

Purge control valve but pressure in my gas tank and it has expanded. Kia will not replace my tank. Heard 2 loud bangs going down the road I started smelling gas. Check engine light came on. Pulled over and gas is pushing up and out behind my tank flowing down my wheel well. Opened the gas cap and it sprayed gas all over me. I have 2 small children and this could have been a extremely worse situation than it was. On another note I took my car to the dealership they did the update and confirmed my gas tank had expanded. They are not replacing my tank they said bc kia has "no remedy". And tried to sell me a bunch of other services on my vehicle instead. I've contacted kia and they basically told me the same thing they at this time will not be replacing my tank. I've picked the car up they cleared the codes and the car is still running rough.

For the past 16 months I have been experiencing a fuel odor in my vehicle cabin while idling or when in slow moving traffic. Knowing this likely is due to a fuel leak, I have taken it to the dealership 6 times to find the leak and remedy it. The dealership always finds something to repair/replace under warranty, however, the fuel smell persists. Over the past 16 months, this has increased in how strong the smell is and how often I am smelling it. It started out as only smelling fuel once a week or so. Now the smell is there during ever drive. It seems as though if my tank of 7/8 or above full, it does not smell for some reason. Upon searching online, many other K5 owners are experiencing the same exact issue and the dealership has been unable to resolve this. The vehicle has had 3 seperate recalls for fuel issues and I believe another is necessary regarding this because the recalls has not fixed the fuel leak I and many others are experiencing. Kia is doing the bare minimum to resolve this and my children are breathing fuel fumes consequently. Please note, not all my repair invoices are attached. I do not have access to all of them at this time

My Gas tank has Expanded in Size and has made my back seat Pop up and gas leaking when it does because the ring around the Gas pump would Loosen Up. I noticed this issue first around April of Last year when it got Warmer. I would have horrible fuel efficiency, and my gas hand acted very Crazy. A few times it felt like I had been hit by a car from the Back a large Boom! When I am have a problem m car would slow down on highway and wouldn’t Accelerate at all. For past few months it started again. But what made me take it in was a louder bang followed by seat not only popping up but not being able to close. Service center kept my car said it was not safe to drive , I have been without transportation going on 3 weeks.

I was driving when I heard a loud bang and my 11month old son who was in the back seat woke up then started smelling gas and I looked out my mirror and gas was spewing out of my closed gas cap when I pulled over and looked my back seat was off its mounts and what I assume is the fuel pump was popped out of place as well I have taken it to my Kia dealer and they said it has been escalated to corporate I am still waiting for an update

The fuel lid does not function properly. I owned the vehicle for almost 3 years and the fuel lid did not want to open. It was completely stuck after making sure that the vehicle was unlocked, as I always do, when going to put gas. I stood in the gas line for 30 minutes pushing the fuel lid trying to open it and it never budged