Kia K5 fuel system problems, 2021–2027
157 of the 496 complaints owners filed with NHTSA about the Kia K5 2021–2027 name the fuel system (NHTSA’s “Fuel/Propulsion System” heading — fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors). The loudest years: 2021 (56), 2023 (53), 2022 (44). Filed under the same heading across these years: 2 manufacturer bulletins, 2 recall campaigns. Every figure is a linked federal record; none is a failure rate, none a repair cost, and none a verdict on one car.
Kia K5 fuel system problems by model year
Source: NHTSA complaints, recalls, investigations and manufacturer communicationsOne row per model year on file, newest first. A year marked in depth has its own page: the complaints, the owners’ words and every document under this heading for that year.
| Model year | Complaints naming the fuel system | Share of the year’s | Typically at | On file under the heading | |
|---|---|---|---|---|---|
| 2027 | 0 | — | — | — | the year → |
| 2026 | 0 | — | — | — | the year → |
| 2025 | 0 | — | — | — | the year → |
| 2024 | 4 | 13% | — | 21 TSBs · 1 recall | the year → |
| 2023 in depth | 53 | 50% | — | 21 TSBs · 1 recall | the record → |
| 2022 | 44 | 34% | — | 21 TSBs · 2 recalls | the year → |
| 2021 in depth | 56 | 34% | 115k | 23 TSBs · 2 recalls | the record → |
Two things the counts carry that are not the car: how many of each year were sold, and how long each has been on the road — an older year out-counts a newer one before anything is wrong with it. The share column is the honest comparison across years: what part of that year’s complaints named the fuel system. Nothing here is a rate.
When the fuel system complaints were filed, and at what mileage
Source: NHTSA complaint databaseFiled per calendar year, every model year together: 2021: 1 · 2023: 6 · 2024: 22 · 2025: 70 · 2026: 58
Across the model years, half of the 28 owners who gave an odometer reading reported the fuel system problem between 70,000 and 111,000 miles. A median of reports, not the life of a part.
In owners’ own words
Source: NHTSA complaint databaseFiled with NHTSA by the people who own these cars, about the fuel system, from the model years with the most to say. Quoted as written, with anything identifying removed; unverified reports — what was said, not a finding that it was true.
Expansion of air tank, causing to pop up frame in backseat and total car deemed unsafe to drive. No warnings car had never been in the shop prayer happened while driving over rule Mountain area with two children in the backseat.
Driving down highway, gas hand was on half a tank then all of a sudden gas hand drops to empty and light comes on, engine started sputtering. Heard a loud pop in the back seat looked back and back seat has popped up from base. Strong odor of gasoline poured into the car. Went to closest gas station to get off highway.
Heard and felt extremely loud BANG under the car while driving then check engine light came on. Vehicle had low power and the gas was decreasing severely fast. The backseat had moved with our 2yr daughter in her car seat above it. Took it to dealership and they said the gas tank expanded and couldn't be fixed.
Engine came on and off twice, car was smelling like gas and driving rough. Tried to put gas in car and it would not take the gas, it wasted all over car. I checked my back seat and felt it was hard and sitting right so I looked under and the seat was lifted. After doing research, I learned I have an expanded fuel tank.
While driving home recently with my young stepson securely seated in his car seat and my fiancé in the passenger seat, we suddenly heard a terrifying loud bang. Immediately following the explosion, my stepson cried out in pain.
What is on file about the fuel system, across the years
Source: NHTSA recalls, investigations and manufacturer communicationsRecall campaigns filed under this heading, any model year
- 25V794000 CriticalNov 17, 2025 · 250,547 vehicles
- Kia America, Inc. (Kia) is recalling certain 2021-2024 K5 vehicles. A damaged check valve can allow air to enter the fuel tank, causing it to expand and contact hot exhaust components, melting the tank.
- 21V519000 HighJul 8, 2021 · 21,575 vehicles
- Kia Motor America (Kia) is recalling certain 2021 Sorento and 2021-2022 K5 vehicles equipped with 2.5L turbocharged engines. Fuel may leak at the pipe connection between the high-pressure fuel pump and fuel rail.
2 manufacturer bulletins filed under this heading, any model year
- Jan 16, 2026
- TECHNICAL SERVICE BULLETIN: VOLUNTARY EMISSIONS SERVICE CAMPAIGN: FUEL TANK AND/OR PCSV CHECK VALVE INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288/SC288A) CLOSED & SUPERSEDED - This bulletin is now closed and superseded by SC356. This bulletin provided information to inspect the fuel evaporative system and, if necessary, replace the fuel tank and/or the Purge Control Solenoid Valve (PCSV) check va
- Jul 18, 2025
- VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC288A) - This document is the owner notification advising that Kia is conducting a Voluntary Emissions Service Campaign on certain 2021-2024 MY K5 vehicles equipped with 1.6L Turbo Gas Direct Injection (GDI) engines to improve the logic in the Electronic Control Module (ECM) to ensure compliance with emissions regulations. Also, the subjec
Every one filed under the heading is listed. Quote the document number at a service desk — it is a diagnosis the maker has already written down.
Common questions
Source: NHTSA complaint database, recalls and manufacturer communicationsWhich Kia K5 years have the most fuel system complaints?
2021, 56; 2023, 53; 2022, 44. Raw counts, and an older year has had longer to collect them; by share of each year's own complaints the loudest is the 2023 (50%).
Is there a recall for the fuel system on the Kia K5?
Yes — 2 campaigns are filed under this heading across these model years: 25V794000 (2024), 21V519000 (2022). A recall is matched by VIN, and applies to specific years; check yours at nhtsa.gov/recalls.
When do fuel system problems show up on the Kia K5?
Owners who gave an odometer reading reported it at a median of 86,000 miles across the model years; half of them between 70,000 and 111,000. That is when reports cluster, not the life of a part.
What does NHTSA's "Fuel/Propulsion System" heading cover?
Fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors. Owners choose the heading when they file, so it says which area of the vehicle the complaint is about, not which part failed.