2021 KIA K5 Fuel/propulsion System Problems

Ever since I bought my car in July of 2025 cash I’ve been having issues. Shortly after purchasing my car began to stall , lose power repeatedly. I then took to southwest kia in Dallas they told me I had contaminated gas. They charged me $2,000 to clean my fuel lines , replace spark plugs & replace a fuel pressure sensor. Shortly after i got my car I had the same issues. I explained my concerns and they replaced my fuel tank free of charge. A week later same issue so I went to a local mechanic and he replaced another fuel pressure sensor a month passed same issues occurred at least 3 more times on 3 different occasions. I’ve had to get my car towed off the middle of the free way or road numerous of times. This has been a financial nightmare

The vehicle experiences severe stalling and loss of power while driving. When attempting to accelerate, the vehicle hesitates, shakes violently, and will not accelerate beyond approximately 10–20 mph. The vehicle then stalls completely and shuts off. These failures occur both after the vehicle has been parked and while actively driving. When placed in drive, the vehicle shakes aggressively and stalls. The check engine light is illuminated. The stalling has occurred multiple times in the middle of freeway traffic, creating an extreme safety hazard. My child has been in the vehicle during every occurrence. On one occasion, the vehicle shut off completely while on the freeway, placing our lives at risk and nearly resulting in a serious collision. This issue is unpredictable, persistent, and prevents safe operation of the vehicle. The vehicle has been inspected and worked on by Southwest Kia and A-Z Auto, but the defect continues to occur. I believe this is a manufacturing or design defect related to the engine or powertrain that poses a serious safety risk and should be investigated to determine whether other vehicles are affected.

Took car to Kia for an oil change and car started driving weird . Rpm hand running high. Check engine light came on , took car to Kia and fuel tank was expanded . Car is still not fixed , and Kia won’t continue to pay for rental.

Recall SC263) AIR BAGS THAT DO NOT DEPLOY (SC356)x2 A MELTED FUEL TANK CAN LEAK, INCREASING THE RISK OF A FIRE

Within three days of purchase, the vehicle experienced a fuel system failure requiring the gas tank to be replaced. Shortly afterward, the check-engine light illuminated, indicating additional engine or emissions problems. The failures occurred without warning and made the vehicle unsafe to drive. The engine warning has continued to appear, suggesting a recurring or unresolved malfunction. The defects create risks including fuel leakage, stalling, engine shutdown, and potential fire hazard. The safety of the driver and others on the road is put at risk because the vehicle may fail while in motion. The problem appeared immediately after purchase and continues to recur. The dealer was notified but refused to diagnose or repair the vehicle further. No manufacturer inspection has occurred because the dealership declined to provide service. The warning light first appeared within the first week of ownership and has remained intermittent. The vehicle shows signs of unstable engine operation and ongoing system malfunction. The issue has been observed by the dealer, but they declined to perform proper diagnostics or repair. The defects are persistent and pose ongoing safety concerns.

For the past 16 months I have been experiencing a fuel odor in my vehicle cabin while idling or when in slow moving traffic. Knowing this likely is due to a fuel leak, I have taken it to the dealership 6 times to find the leak and remedy it. The dealership always finds something to repair/replace under warranty, however, the fuel smell persists. Over the past 16 months, this has increased in how strong the smell is and how often I am smelling it. It started out as only smelling fuel once a week or so. Now the smell is there during ever drive. It seems as though if my tank of 7/8 or above full, it does not smell for some reason. Upon searching online, many other K5 owners are experiencing the same exact issue and the dealership has been unable to resolve this. The vehicle has had 3 seperate recalls for fuel issues and I believe another is necessary regarding this because the recalls has not fixed the fuel leak I and many others are experiencing. Kia is doing the bare minimum to resolve this and my children are breathing fuel fumes consequently. Please note, not all my repair invoices are attached. I do not have access to all of them at this time

While driving, the check engine light came on. Soon after, the rear floor of my 2021 Kia K5 lifted upward, and I noticed the fuel tank underneath had swollen. When I opened the gas cap, it blew off with force and gasoline sprayed on me, soaking my clothes. This could have caused a fire or explosion. The car is now unsafe to drive, and the rear seat cannot be used because the floor is deformed. I discovered that Kia has a Voluntary Emissions Service Campaign SC288 addressing this exact issue (fuel tank swelling and excessive pressure due to a faulty PCSV valve and EVAP system), but this is clearly a safety hazard, not just an emissions problem. Many other owners have reported the same issue online. I believe this defect should be escalated to a safety recall before someone gets seriously injured or worse.

I have a Kia K5 and was not informed of the SC288 Service campaign Fuel tank Inspection & EMC update (VESC) expansion of fuel tank and explosions' of fuel tanks. My vehicle was not apart of the recall for the fuel tank expanding program. I took my vesical in for service for over heating and it failed the SC288 Service Campaign. my gas tank expanded and caused structural damage to my car. it has been 8 weeks and I have not have had any contact from Kia consumer affairs. I am now with out resolve and I now have to get a lawyer.

I was driving down the highway and my car made a loud bang noise. It would not accelerate over 50 mph no matter how hard I pressed the accelerator. Took to dealership and they told me I needed a new battery and charged me $365. Drove it and still won’t go over 50 mph. They kept it for a week and said it had a faulty valve that caused pressure to make the gas tank expand, pushing up back seat. Said it wasn’t a recall and would cost me $3600 to fix. Told me it was too dangerous to drive. Did research and saw that this was discovered over 2 years ago but I was never told. Now they say I have too many miles on my car to fix it. The gas fumes inside the car are intolerable and it still won’t go over 50.

HVAC is not working at all, not even blowing hot air. I've been told it could be a wiring issue or have to change my blower and resistor. KIA has told me they could not help because my car is over the 60,000 mile warranty. However, my car is 70,000 miles and about 4 years old. It has had other recall issues and just trying to be helped.

Just minutes before entering the highway, my son and I heard a very loud popping sound that startled us, like something large hit the car or a tire exploded. I immediately pulled into a gas station checked the exterior & all 4 tires, but everything appeared intact. Shortly after, while driving on hwy during morning rush hour at 65–70 mph in the far-left lane, the check engine light illuminated & almost immediately the car lost all engine power. My speed dropped quickly with cars behind me traveling at high speeds. I had to activate hazard lights & cut across 4 lanes of traffic to the shoulder, putting myself, my child passenger, & others at serious risk of a multi-car collision. While waiting for help, I plugged in my FIXD OBD-II reader later looking over diagnostics read code P0451 – EVAP System Pressure Sensor. 8 hours after car was towed & had been parked at my home & still not starting I researched the code to learn what that means & the possible cause for & found it is all emission related issues varying in reasons as simple as a gas cap replacement. Nothing of any engine failure while driving risking the lives of drivers & others so before sending my car to a mechanic, I went and checked the gas cap in case just a simple emissions type fix that is where I observed fuel still bubbling out of the tank have photos, my daughter, & sister, as witnesses. The next day car was towed to Kia Mall of Georgia on June 26, 2025. As of August 20, 2025, the dealership has confirmed the fuel tank expanded as of now there is no resolution from Kia for fixing once this happens can likely shift car frame & could be declared totaled. Component/system failed: Fuel tank/EVAP system (pressure failure). Vehicle is available for inspection at Kia Mall of Georgia. Safety risk:Complete engine shutdown at highway speeds with child passenger on board; risk of multi-car, high-speed crash. Fuel bubbling/spitting increased fire hazard. not a recall only emissions campaign needs to change

Check engine light came on and when filling up my gas tank, gas spit back out at me which has happened with the fuel tank i had in it last year and has since been replaced. Forward collision, EBS, traction control and forward safety sensor lights came on the next day and the car is running extremely rough. It was towed to a shop to see if it has to do with the fuel tank recall. Multiple people in Roanoke, Virginia are having the exact same problem as is a large portion of people online complaining about the exact same thing. Some going back 30 weeks ago.

My fuel tank expanded while I was driving on the highway, causing my car to stall and would not respond to me pushing on the gas. I pulled over on the side of the highway and looked back and saw my rear seats were pushed up. Got it towed to the Kia dealership and they informed me that my car was totaled because the gas tank expanded so much it bent my frame. This has been an ongoing issue with Kia/Hyundai vehicles but they have still not issued a formal recall, only a voluntary callback even though this is a very dangerous defect.

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. Kia inspected diagnostic ran stated it was air in gas tank under a recall claim to fix it for free and then two weeks later stated it was going to Kia America for a case number. Kia America called and stated that it was not safe to drive and the car is totaled.

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. Unable to put fuel into tank. Called Quality KIA of Greenwood they said get out of the car and do not drive it. Called for a tow, vehicle has been towed to Quality KIA of Greenwood.

Back seat popped up due to fuel tank rising from under seat while driving

I recently purchased a Kia k5 2021 gt line awd one month later I noticed there was recall I take to the dealership they let me know it will only take a few hours (3) and I can pick up later the same they call me 3h later and let me know sorry this case is going to take a few weeks and I should pick up rental car and they will pay for my rental so I did I come back one month later nothing as been done they just tell me to wait and they can’t release due to the safety recall the tank has swelled up it has been 3mont now and they still haven’t done anything to the car and I can’t sell the vehicle cause they won’t release it

My current 2021 Kia K5 FUEL TANK EXPLODED while driving. I’ve had this car for about 5 years and since driving it off the lot have experience issues with the vehicle and just a few hours ago, the fuel gas tank explode raising the back seat with passengers in the vehicle. It was extremely scary and something out of the blew. My friends and I were driving and I noticed the car engine light turn on (which was so odd to me as I keep a close eye to the car maintenance) and within 20 minutes we heard two EXTREMELY loud explosions sounds come from the car with the feeling of the car shake and rise a bit and felt as a tire exploded. I did not find this usual and we pulled over and the the seat my friend was sitting on was rose and unlatched. We then did some google searches and when looking into it, it appears there have been previous issues with this situation for other K5 Kia owners but KIA has done nothing regarding the matter. A few months ago I also went due to an internal thermostat exploding and causing the engine to overheat and smoke on the freeway and because they deemed it was not under the warranty, I left car-less for a week and a high bill. I don’t understand why I have to pay and endure these service costs when this is BASIC CAR FUNCTIONS. I do not appreciate the lack of empathy from dealer and service staff and feel unsafe and concerned for my safety for driving this vehicle. And now II have to endure the costs of being car less for 14 days per the dealer. Absurd.

On [XXX] I took my automobile, a 2021 Kia K5 to Planet KIA of Charlotte NC located at 4700 E independence Blvd. I took it there to check what caused my engine light to activate. The initial diagnosis was a bad Sensor-Differential Pressure. Planet KIA repaired the Sensor-Differential Pressure at the cost of $501.17. My extended warranty company Route 66 covered $350.28 while I covered the remaining balance of $150.89. The engine light came on again the next day and while driving back to the dealership, I experienced the car slowing down and difficult to gain speed in highway traffic. I returned the automobile to Planet Kia of Charlotte and on [XXX}, I was informed that I had a valve failure which in turn caused my gas tank to swell. On [XXX] the warranty company denied request to pay for repairs due to their policy of not covering emissions which pertained to the valve. Kia refused to fix this problem due to a service campaign recall had been performed on the vehicle before I bought it. They found no issues with the vehicle pertaining to the valve or gas tank swelling. This is clearly a manufacturer’s defect, and it should have been repaired by the manufacturer. If you can, please help. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The Electric seats do not adjust due to failed motors. Electric mirrors do not adjust due to failed motors. Gas refuel door does not open due to faulty actuator. All things that make the care dangerous to drive. Online search reveals that all three issues are very common in the 2021-2023 KIA K5 cars. We believe they pose a danger. Also, they seem to break at about 40-60K miles. Often out of warranty and dealer will not fix even though they acknowledge that the items in question are an issue.

I've took my lease vehicle too dealer for the same problem 3 time car shake no matte what speed check engine light flashes code P0302 cylinder 2 misfire

Purge control valve but pressure in my gas tank and it has expanded. Kia will not replace my tank. Heard 2 loud bangs going down the road I started smelling gas. Check engine light came on. Pulled over and gas is pushing up and out behind my tank flowing down my wheel well. Opened the gas cap and it sprayed gas all over me. I have 2 small children and this could have been a extremely worse situation than it was. On another note I took my car to the dealership they did the update and confirmed my gas tank had expanded. They are not replacing my tank they said bc kia has "no remedy". And tried to sell me a bunch of other services on my vehicle instead. I've contacted kia and they basically told me the same thing they at this time will not be replacing my tank. I've picked the car up they cleared the codes and the car is still running rough.

When I was driving I heard big boom sounds in my backseat which ended up being my fuel tank which expanded and raised the back seat. It slowly got worse impacting my car’s fuel sensor and the tank expanded more and more I drove.

My Gas tank has Expanded in Size and has made my back seat Pop up and gas leaking when it does because the ring around the Gas pump would Loosen Up. I noticed this issue first around April of Last year when it got Warmer. I would have horrible fuel efficiency, and my gas hand acted very Crazy. A few times it felt like I had been hit by a car from the Back a large Boom! When I am have a problem m car would slow down on highway and wouldn’t Accelerate at all. For past few months it started again. But what made me take it in was a louder bang followed by seat not only popping up but not being able to close. Service center kept my car said it was not safe to drive , I have been without transportation going on 3 weeks.

I was driving when I heard a loud bang and my 11month old son who was in the back seat woke up then started smelling gas and I looked out my mirror and gas was spewing out of my closed gas cap when I pulled over and looked my back seat was off its mounts and what I assume is the fuel pump was popped out of place as well I have taken it to my Kia dealer and they said it has been escalated to corporate I am still waiting for an update

My car just stopped working, it was towed to a local Lokey Nissan in Clearwater FL where it was purchased. Since it was a defect Lokey Nissan sent it to Lokey KIA in Clearwater FL. Lokey KIA stated the gas can had expanded and also caused damage to the frame and the cost to repair was more than the value of the car so they sent it up to Corporate for further instruction. This was 6 weeks ago. Nobody will return my calls, KIA still has the vehicle and I am getting nowhere here and am without a car. Please help I don't know what else to do!!!!!!!!!!

The fuel lid does not function properly. I owned the vehicle for almost 3 years and the fuel lid did not want to open. It was completely stuck after making sure that the vehicle was unlocked, as I always do, when going to put gas. I stood in the gas line for 30 minutes pushing the fuel lid trying to open it and it never budged

Loss of power. Check engine light came on

One day I was driving my car when suddenly I heard a loud explosion sound from the back. I continued to drive the car until I could pull over to inspect the car. In the midst of pulling the car over I began smelling a strong odor of gas in the cabin of the car. Prior to stopping the car started skipping and missing badly. I pulled over checked the car and discovered something malfunctioned and caused the rear seat to pop up and be bent from the frame. I proceeded to look under the seat and saw where what appeared to be the fuel pump almost popped out, the bracket above the fuel pump was broken and popped up from the explosion, the seat would not go back in place. I looked at the gas hand I went from 3/4 tank of gas to E in less than a few miles. The exhaust also sounds like something blew or came apart the car runs very loud and you can hear the car sounding like the exhaust have a hole. After the sequence of events the engine light never came on. This is huge life safety problem that should have never happened.

When filling up the gas tank on 3 separate occasions the station pump failed to cut off causing fuel to leak unto the surrounding surface. The Kia K 5 is leased vehicle that I entered into contract in July 2021. The car was used as a demo and I find it suspicious that the dealership wasn’t aware of the issue. The dealership is replacing the gas tank at no cost to me.