2022 Kia K5 Fuel system Problems

On XXX, while traveling to [XXX], I experienced serious fuel system problems after filling my vehicle. The fuel gauge fluctuated from full to empty, and a loud pop caused the rear seat, where my two children were sitting, to lift upward. The vehicle would not accept more fuel despite the empty reading. I called AAA, but before the tow arrived, the gauge returned to normal, so I continued my trip. After returning to [XXX], I checked my Kia app and discovered active Recall SC356 describing a damaged check valve that could cause fuel tank expansion, rear seat lifting, and abnormal fuel gauge behavior—the same symptoms I experienced. On XXX, I brought the vehicle to The Kia Store in Louisville, advised them of the recall and my symptoms, and requested an inspection. Service Advisor Sidney Daub stated the issue was caused by a scratched muffler, not the recall, and no recall repair was performed. Relying on that assessment, I continued driving. From XXX, while traveling to [XXX], the same problems returned. Smoke came from the fuel tank area, fuel sprayed onto me when I opened the fuel door, and the vehicle became disabled and required towing home. I then took it to Kia Store East on June 10. There, [XXX] advised the failure was related to Recall SC356, and Haley informed me Kia Consumer Affairs would contact me. After weeks of communications, Kia advised on XXX that the vehicle was unrepairable and requested ownership documents. On XXX, Kia offered only to satisfy my loan balance through a buyback. I believe the dealership's failure to properly diagnose & repair the recall condition in April directly contributed to the later failure, safety hazards, towing expenses, and loss of my vehicle. I respectfully request that NHTSA investigate Kia's handling of Recall SC356 and the dealership's actions, & encourage Kia to consider a replacement vehicle, collateral swap, or another equitable resolution. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11753652

Incident

Mar 21, 2026

As I was driving down the road, I began to hear a loud, forceful noise. I assumed it was something in my trunk rolling against the rear seats. The noise kept getting louder, and I pulled over, very frightened, as several warning lights came on, including the low fuel light and check engine light, and the fuel gauge needle was past “E.” Before the incident, the GPM reading was 400. After a while, I made it home, but the car started making loud noises and then died. That’s when I noticed my back seats were lifted. I called Kia customer service and had the car towed to the Kia dealership on Seigan Lane, where it is now. Something needs to be done about this.

NHTSA ID

11753188

Incident

Jul 23, 2026

Driving anywhere in general and which ever speed my gas would leak and smell would over take the car and I have a [XXX] and [XXX] babies. This is not the first but the third recall and this is a fire hazard I can’t imagine my car going in flames while we’re already suffering with a leaking gas smell every time we drive the car I can loose my whole family I will soon being filing a lawsuit against this I want a new vehicle completely I do not feel safe in this car with my kids at all there’s always an issue and my dealership is over 40min away to be going so often throughout the years of having this car this is completely unsafe dangerous and just out right unexpectedable and will be filing soon for a new car and compensation INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11748609

Incident

Aug 11, 2025

The contact owns a 2022 Kia K5. The contact stated that while attempting to reverse her vehicle and then shifting the gear shift into drive, the contact noticed her check engine warning illuminated, and she heard an abnormal noise coming from the front of the vehicle. The contact then parked the vehicle, went into the dealer, and let them know about the failure, but they offered no assistance. The vehicle was initially taken to the dealer, where NHTSA Campaign Number: 25V794000 (FUEL SYSTEM, GASOLINE) was completed. It was after the recall was completed that it was discovered that the check engine light illuminated, and the vehicle was not driving properly. The dealer took the vehicle back and provided a loaner. The contact mentioned that the engine was replaced, and then a catalytic converter was replaced. Most recently, the fuel oxygen sensor was discovered to be melted. The vehicle was repaired; however, the failure persisted. The manufacturer was notified of the failure and informed that the recall was complete with no other assistance offered. The failure mileage was 91,000.

NHTSA ID

11747936

Incident

Mar 20, 2026

Mileage

91,000 mi

In XXX 2026, I brought my 2022 Kia K5 GT-Line (VIN: [XXX] ) to Jim Click Kia in Tucson, AZ for routine maintenance. Fuel system testing revealed my vehicle failed inspection due to an active federal recall affecting the fuel tank/fuel valve system. Kia America confirmed the recall defect caused cascading damage to additional components, rendering the vehicle completely unrepairable and unsafe to drive. My safety was put at risk because the vehicle cannot be operated and Kia has confirmed no repair is possible. I have been without my vehicle for over two months. Kia America has proposed a buyback at $10,550 (KBB value), which does not reimburse me for the approximately $35,000+ I paid into this vehicle. I have formally requested full reimbursement under 49 U.S.C. § 30120 and the Magnuson-Moss Warranty Act, which Kia has declined. I am currently in a rental vehicle paid by Kia, which they have threatened to terminate on June 9, 2026 if I do not accept their offer. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11740880

Incident

Mar 25, 2026

The Integrated Thermal Management System (ITMS) in my Kia K5 GT (2.5T engine) has experienced a recurring internal electronic and mechanical fault. This is the third failure of this component. The failure causes the cooling system to malfunction, either by over-cooling or failing to cycle coolant once at operating temperature. ​Under acceleration—specifically when merging onto expressways—the vehicle suffers a sudden loss of power and enters 'limp mode' with a dashboard alert stating the engine is overheating. This creates an immediate safety hazard in high-speed traffic. When the fault occurs, the radiator fans lock at 100% duty cycle. This is a documented systemic issue with the Kia 2.5T powertrain (referenced by major automotive publications and multiple Technical Service Bulletins). ​Despite a prior Lemon Law settlement and an active 100,000-mile powertrain warranty, the manufacturer refuses to acknowledge this as a powertrain or emissions defect, attempting to charge out-of-pocket for a component that prevents the vehicle from passing state emissions and safety inspections."This was also cited in a 2023 issue of car and driver magazine long-term test with The Kia Sorento that shares the same engine and transmission combination This is a third time that part has failed for me with others had to replace that part over seven times The first time it happened it was at 8,000 mi it did not get fixed until 30,000 mi The second time it happened was at 51,000 mi The third time 75,000 mi

NHTSA ID

11737476

Incident

May 4, 2026

A fuel system-related safety recall (SC356) remains incomplete on the vehicle. The vehicle was taken to an authorized Kia dealership in Jersey City, NJ, where I was informed that the recall repair had been completed. I paid for towing to the dealership for this repair. However, after picking up the vehicle, it immediately began exhibiting worsening symptoms, including engine shaking, rough operation while driving and idling, and prior stalling incidents. A check engine light also appeared after the visit. Upon further verification, the recall still shows as incomplete. This indicates that the recall repair was either not performed or not completed correctly. The issue appears to involve the fuel system, as the symptoms worsened after refueling and include unstable engine performance consistent with improper fuel delivery or air entering the system. This condition creates a safety risk due to potential engine stalling while driving, as well as the known recall risk involving fuel tank deformation and possible fire hazard. The problem has not been properly resolved by the dealership, and the vehicle is currently unsafe for normal use. The failed recall repair is available for inspection.

NHTSA ID

11732899

Incident

Apr 17, 2026

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.

NHTSA ID

11732143

Incident

Feb 27, 2026

My 2022 Kia K5 GT-Line has had a recurring check engine light fault (P0471 — exhaust pressure sensor circuit) since approximately 9,874 miles in September 2022. The vehicle has been brought to the servicing Kia dealer a minimum of five times for this same fault across nearly 65,000 miles. It has never been permanently resolved. Most critically: dealer repair records from May 2025 (56,501 miles) confirm a technician identified fault code P047100, noted it as a history code, cleared it, test drove the vehicle, and returned it without performing any repair and without informing me. Ten months later, the same dealer presented this identical fault as a $1,121.07 customer-pay repair on a vehicle under active 10-year/100,000-mile powertrain warranty. The repair was only approved after I contacted Kia Consumer Affairs directly — the dealer had not contacted them despite claiming otherwise. The February 2026 repair failed within 15 minutes of pickup. I made five documented phone calls to the dealer over 33 days reporting the failure. No action was taken. The April 2026 repair — sensor and hose replacement — failed within one hour of pickup on April 1, 2026. Of additional concern: Recall SC288/SC288A (Fuel Tank Inspection and ECM Re-Update) was performed on this vehicle twice — July 2024 and August 2025. The ECM governs the exhaust pressure sensor circuit. The P0471 fault first appeared in dealer records between these two recall dates and has persisted through both completions. CARFAX confirms the April 2026 repair involved the engine/powertrain computer module. I am requesting NHTSA investigate whether SC288/SC288A is connected to recurring P0471 faults in 2022 Kia K5 vehicles. Kia Consumer Affairs Case escalated April 2, 2026.

NHTSA ID

11728917

Incident

Apr 1, 2026

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.

NHTSA ID

11728275

Incident

Nov 17, 2025

Mileage

90,000 mi

My vehicle is subject to an unrepaired safety recall involving the fuel system. According to the manufacturer’s recall notice, a damaged check valve may allow air to enter the fuel tank, causing the tank to expand and contact hot exhaust components. This can melt the fuel tank, cause fuel leakage, and increase the risk of a vehicle fire. This vehicle has experienced multiple fuel-system-related recalls, and this recall is currently listed as incomplete with no remedy available. The manufacturer has not provided a repair timeline, and owner notification and repair availability are delayed. I am concerned for my safety and the safety of my passengers because I am required to continue driving a vehicle that the manufacturer acknowledges poses a fire risk and cannot currently be repaired.

NHTSA ID

11705994

Incident

Jul 20, 2024

The contact owns a 2022 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not yet available. 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 contact experienced the failure, causing the check engine warning light to remain illuminated, and the vehicle hesitated while accelerating. The vehicle was taken to the local mechanic, who diagnosed the vehicle and determined that the check valve was faulty and needed to be replaced. The vehicle was not repaired. Additionally, the contact stated that while the AC was activated, one vent was blowing hot air while the other vent was blowing cold air. No further information was available. The failure mileage was 103,000.

NHTSA ID

11705504

Incident

Sep 17, 2025

Mileage

103,000 mi

When engine is Idling the cabin immediately starts to smell completely like gasoline. This happens whether the A/C system is on or not. It’s so strong sometimes that I have to put my window down to release the fumes.

NHTSA ID

11702623

Incident

Dec 1, 2025

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.

NHTSA ID

11700548

Incident

Sep 2, 2025

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.

NHTSA ID

11695489

Incident

Sep 14, 2025

Mileage

81,000 mi

While driving my 2022 Kia K5 LXS, the vehicle began shaking violently and lost acceleration. The check-engine light came on, showing code P0301 (cylinder 1 misfire). The issue caused unsafe driving conditions, especially with my child in the car. Kia Roseville incorrectly documented the repair, while Kia Folsom later confirmed the issue was engine-related. The vehicle has also been subject to fuel tank expansion concerns under recalls SC288 and SC288A, which can create additional fire risk and pressure issues. Despite repairs, I still experience safety fears and severe loss of vehicle value due to these recurring defects and poor documentation. Kia America has not provided a resolution.

NHTSA ID

11695160

Incident

Apr 25, 2024

the fuel tank on my car expanded a few hours after inspection was taken place. The dealership stated my car was completely unsafe to drive and would not let me leave with it. My daughter was in the backseat when it happened, but she is safe and so am i

NHTSA ID

11691556

Incident

Oct 2, 2025

I was driving my car and heard a loud pop, I was on the interstate and thought maybe my tire was going flat but nothing alerted me on my dash. I heard loud wind noises but everything seemed fine until my car started basically hopping forward and it became hard to accelerate. I had to push the gas harder than normal to maintain average highway speeds. I was also feeling super lightheaded while driving and kept rolling my window down as if I couldn’t get a full breath of air. I would roll it back up after 5 minutes or so and would have to roll it right back down. I was driving a long distance and wasn’t able to immediately stop but I was informed of the gasoline fumes when I family member helped get my bags out of my car. It was the scariest thing

NHTSA ID

11690424

Incident

Sep 21, 2025

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.

NHTSA ID

11690382

Incident

Jun 16, 2025

Mileage

79,000 mi

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.

NHTSA ID

11688406

Incident

Aug 25, 2025

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

NHTSA ID

11684579

Incident

Aug 26, 2025

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.

NHTSA ID

11682972

Incident

Jul 13, 2025

Mileage

85,000 mi

Car stalls out without warning. The electronics (radio, dash, lights, etc...) all are still functional, the engine light comes on while the car is still "on" with the engine stalled out. I pulled over, put the car in park, turned it off, and then restarted the car without issue. After restarting the car, the check engine light is not longer on. This first occurred once about a year or two after i bought the car while on the freeway (2023). The second time I was on a dirt road outside of town (March 2025). The third time I was accelerating through an intersection while taking a left turn, after being stopped at the green light waiting for a time to turn (August 2025). My car stalled out in the middle of the intersection, but I was lucky enough to have gained enough momentum to roll out of the way of oncoming vehicles. The most recent time this occurred, the car had trouble turning over, but was able to after a few tries. I took it into my kia dealership and they told me to replace the battery as it was testing "low". I bought a battery from autozone and replaced it as instructed. However I have never had any issues otherwise and the battery test autozone performed on my old battery said the old battery was still "good". This was recent and the problem is rare so i have not confirmed if this is a fix, however it is a dangerous fault that does not seem to be resolved.

NHTSA ID

11680790

Incident

Aug 6, 2025

Fuel consumption jumped then car began jerking shortly after engine failure

NHTSA ID

11680236

Incident

Aug 12, 2025

Engine failed for literally no reason and started smoking and Lia won’t stand by warranty either

NHTSA ID

11680233

Incident

Jun 1, 2025