2022 Kia K5 fuel system problems

Filed Sep 30, 2026 · Fuel system · TX

The contact owns a 2022 Kia K5. The contact received notification of the federal safety agency Campaign Number: 25V794000 (Fuel System, Gasoline). While driving 70 MPH, the contact heard a loud pop coming from the rear driver's side of the vehicle and the check engine warning light intermittently illuminated with an abnormal burning odor briefly inside the vehicle. The vehicle was taken to the dealer, and the contact was informed that a diagnostic test was needed to determine the cause of the failure.

Filed Sep 10, 2026 · Electrical, Engine · TX · fire

- The exact component that failed has not yet been determined. The vehicle experienced a sudden loss of acceleration while driving, followed by a popping noise, smoke, and a fire that severely damaged the vehicle. The vehicle is a 2022 Kia K5 GT-Line, VIN [XXX]. The vehicle has an open Safety Recall SC356 / the federal safety agency Recall 25V794 involving the purge control system check valve and fuel tank, which may result in fuel leakage and an increased risk of fire. The recall repair had not been performed prior to the incident. The vehicle is currently being preserved and is available for inspection upon request. - The vehicle caught fire while driving on XXX, in [XXX]. The vehicle suddenly stopped accelerating, a popping noise, and then smoke began coming from the vehicle shortly afterward. The vehicle subsequently caught fire and was destroyed. The incident created a serious risk of injury to me, other occupants, nearby motorists, and others in the area. Fortunately, there were no injuries. - The cause of the failure and fire has not yet been confirmed. The vehicle was severely damaged by the fire. The vehicle has an open Kia SC356 / the federal safety agency 25V794 safety recall, which we were unaware of, but it has not yet been determined whether the condition addressed by that recall caused or contributed to this incident. - The Killeen Fire Department responded to the vehicle fire and extinguished the fire. The incident has also been reported to my insurance company, and an insurance claim is currently pending. No inspection has yet been performed to determine the cause of the fire. The vehicle is being preserved so that it remains available for inspection by the manufacturer, insurance representatives, the federal safety agency, or an independent expert if necessary. -No warning lamps or warning messages prior to the incident. While driving, the vehicle suddenly stopped accelerating, then a popping noise was heard, followed by smoke, and the vehicle subsequently caught fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 5

Filed Jul 30, 2026 · Fuel system, Seats · KY

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 the federal safety agency 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)

Filed Jul 27, 2026 · Fuel system · LA

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.

Filed Jul 6, 2026 · Engine, Fuel system · FL

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)

Filed Jul 2, 2026 · Fuel system · 91,000 miles · TX

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 the federal safety agency 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.

Filed May 29, 2026 · Fuel system · AZ

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)

Filed May 12, 2026 · Engine, Fuel system · PA

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

Filed Apr 22, 2026 · Fuel system · PA

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.

Filed Apr 18, 2026 · Fuel system · FL

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.