Kia recalls over 250,000 cars due to fuel tank fire risk

Kia’s popular K5 sedan has been pulled into an unexpected safety scare in the United States, after the company announced a major recall linked to a potential fire hazard beneath the car’s rear floor.

The issue affects more than 250,000 units of the midsize sedan and has quickly become a talking point among car owners who are now watching for official instructions from the company.

The problem centres on a component inside the K5’s fuel system known as the purge control check valve. Documents submitted to the National Highway Traffic Safety Administration show that this valve can deteriorate on certain vehicles. When it does, pressurised air that should remain in the intake manifold may instead push into the fuel tank.

In such cases, the tank can expand and shift from its normal position. Engineers found that an enlarged tank could touch the exhaust system and may melt if the heat is high enough. Kia began looking into the matter after receiving several complaints of leaked fuel or a strong smell around the vehicle.

Which models are affected

The recall covers specific 2021 to 2024 K5 units that rolled out of Kia’s manufacturing plant in Georgia. Only models fitted with the 1.6 litre turbocharged T GDI engine are included. The larger 2.5 litre engine variant is not part of the recall.

Despite the seriousness of the defect, Kia says it has not received any reports of injuries or crashes linked to the issue. The company has stated that owners can keep driving their cars until repairs are completed.

Repairs to begin next year

Kia plans to begin sending out formal recall notices to owners in January. After receiving the letter, customers will be able to book an appointment at a dealership. Technicians will inspect the fuel tank and replace it if there are signs of swelling or damage.

Even if the tank appears normal, the purge valve responsible for the pressure issue will still be changed.

The company says the fix is straightforward and is intended to prevent the problem from developing again. For now, K5 owners are waiting for their turn at the workshop, but Kia has assured them that the necessary parts and repair process are ready to go.