KIA recalls 250K sedans in the US due to fuel leak

Kia is recalling 250,547 K5 sedans in the United States after uncovering a potentially dangerous flaw that could lead to the fuel tank catching fire.

According to documents submitted to the National Highway Traffic Safety Administration (NHTSA), the issue stems from the purge cut-valve in the fuel system’s evaporative-emissions setup. In certain vehicles equipped with the 1.6-liter T-GDI turbo engine, rising pressure inside the system can cause the fuel tank to swell. As it expands, it may come into contact with the exhaust components and begin to melt—creating a real risk of ignition.

Kia says it first became aware of the defect after owners reported strong fuel odors and visible fuel leaks. Engineers later determined that the valve designed to relieve excess pressure was, in fact, causing pressure to build up inside the tank.

The recall applies to Kia K5 sedans built between 2021 and 2024 at Kia’s plant in Georgia. Only the models with the 1.6-liter turbo engine are impacted; versions equipped with the 2.5-liter engine are not affected.

The silver lining: Kia has not received any reports of injuries or crashes linked to the defect, and owners may continue driving their cars until repairs are made. The company plans to begin mailing notification letters to owners in January. Once notified, owners can visit a dealership, where technicians will inspect the fuel tank and replace it if any damage is found.

Even if the tank shows no issues, the faulty valve will still be replaced as a precaution to prevent future problems.