Kia Recalls Over 250,000 Sedans For Fire Risk From Melting Gas Tanks

Key Points

• Kia recalls over 250,000 K5 sedans for a fire risk due to an expanding gas tank.
• The issue affects 2021-2024 1.6L turbocharged K5 models.
• K5 otherwise maintains strong reliability ratings and minimal history of recalls.

Kia has recalled 250,547 sedans for a rather concerning issue that could result in a melting, leaking gas tank, creating a fire risk. The issue relates specifically to the K5 midsize sedan, one of the sportier offerings in the segment.

This is not the only fire-related hazard for Kia this year, as various Soul and Seltos models were implicated in a recall for incorrectly manufactured piston oil rings. That issue is completely unrelated to the K5 sedan’s gas tank recall, which also affects far more models.

Turbocharged K5 Sedans at Risk

According to documentation from the National Highway Traffic Safety Administration (NHTSA), the K5s that form part of this recall are all equipped with the 1.6-liter turbocharged T-GDI four-cylinder engine, and 2021 to 2024 models are affected. As of the 2025 model year, Kia replaced the 1.6L turbo engine with a 2.5L naturally aspirated four-pot.

According to the NHTSA’s documentation, the purge control system check valve could deteriorate over time, causing pressurized air to flow from the intake manifold into the gas tank. This could lead to an expanding gas tank, which could then make contact with hot exhaust pipe components. With prolonged driving, the fuel tank could melt and leak, leading to a fire hazard.

K5 drivers may experience a popping sound from the vicinity of the gas tank, an illuminated Check Engine Light, or rough running. Kia will notify affected owners of the sedan and will replace the check valve with an improved one, while also checking the gas tank for any damage and replacing it if necessary. 

A Rare Blemish for the K5 

Kias are generally seen as more reliable than the industry average, and the K5 sedan itself holds an excellent Quality and Reliability rating of 85 out of 100 from J.D. Power. Besides this recall, the 2024 Kia K5 has only one other recall for rear window trim pieces that could detach, so there’s clearly not a pattern of unreliability for the midsize sedan.

For the 2026 model year, the stylish K5 received only a minor price bump and still starts at under $28,000. Its base engine isn’t as impressive as the new Toyota Camry’s standard hybrid, but the K5 is also available with a potent 2.5L turbo engine with 290 horsepower.

Hopefully, Kia can resolve the issues with 1.6T K5 variants before it approaches the vast recall numbers of Hyundai and Kia’s older Theta II engine, in which many hundreds of thousands of models were recalled.

If you’re shopping for a K5, we recommend a 2025 or newer model. If you’re buying a 2021-2024 model, try to avoid the 1.6T models if possible—or make sure they’ve been assessed for the gas tank issue.