Kia Fuel Tank Recall Issued Due to Risk of Leaks, Fires: NHTSA

Owners are being warned to watch for popping sounds near the fuel tank area, an illuminated Check Engine Light or rough engine performance, which may be signs of problems before a Kia fuel tank fire.

More than 250,000 Kia K5 vehicles are being recalled due to concerns that vapors may escape the fuel tank and come in contact with hot exhaust parts, increasing the risk of a fire.

The U.S. National Highway Traffic Safety Administration (NHTSA) announced the Kia fuel tank recall on November 19, warning that the valve controlling airflow to the engine may deteriorate over time, allowing pressurized air into the fuel tank, which can overheat and melt the tank.

When the purge control check valve becomes damaged, it can let too much air and fuel vapor build up inside the tank. That pressure can push vapors toward hot parts under the vehicle, where the heat may weaken or even melt the plastic tank. Once the tank is compromised, fuel can leak out, creating a significant fire risk.

Kia first became aware of the problem in September 2025 after a dealer reported a fuel leak from a tank positioned near the exhaust pipe. A follow-up investigation uncovered a second vehicle with a similar leak and signs that its fuel tank had begun to melt.

While the manufacturer is not aware of any fires or injuries as a result of the current defect, it has received at least 20 reports of fuel leaks caused by melted fuel tanks.

Earlier this month, Kia identified the root cause as deterioration of the purge control system check valve, which can cause the fuel tank to expand and touch hot exhaust components, leading to tank melting.

Due to the serious risk of fire, Kia issued a voluntary safety recall for 250,547 model year 2021 through 2024 Kia K5 vehicles on November 17.

The Safety Recall Report warns that drivers may notice a popping sound from the fuel tank area, an illuminated Check Engine Light, or rough engine performance as possible signs of the recall issue.

Customers will begin receiving notification letters on January 16, with instructions for a free inspection and, if needed, replacement of the check valve at a dealer.

Kia’s number for the recall is SC356. Owners with questions can contact Kia customer service at 800-333-4542, or reach the recall representative, Emily Smith, at emily.c.smith@dot.gov

Owners may also contact the NHTSA Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-275-9171), or go to www.nhtsa.gov.

Hyundai Fuel Tank Recall

In addition to the Kia fuel tank issue, NHTSA announced a Hyundai Sonata recall on the same day over a similar check valve issue. Hyundai is Kia’s parent company, and the two manufacturers often share vehicle parts and platforms.

According to the Safety Recall Report, Hyundai is recalling 85,043 model year 2020 through 2023 Sonata vehicles due to the potential for fuel tanks to melt in the same way that the Kia recall details.

Although the manufacturer is not aware of any crashes or injuries as a result of the problem, it has received at least seven reports of fuel tank leaks, resulting in the voluntary safety recall.

Sign up for more safety and legal news that could affect you or your family.