2023 KIA K5 Fuel/propulsion System Problems

10/25 I was traveling, and my car sudden loss of power, while in traffic.. almost causing accident. 10/28 I was traveling on interstate, and my car sudden loss of power, while in traffic.. almost causing accident. This is ridiculous.. When I hit the gas sometimes, feels like it fluttering and jerking. I’ve reported multiple times over the years and this one having hesitation when driving this car. Manager drove it was concern, mechanic talking about it’s the way the car supposed to be.

While driving my car i heard a loud pop come from the rear of the car. Vehicle began driving poorly as if it could not get proper fuel. I took car to dealership on October 3, 2025 where fuel system was tested and failed all 3 stages of recall for fuel system. Fuel tank had expanded straps and clips had broken and was deemed unsafe to drive. Kia placed the vehicle on hold.at the dealership with a do not repair until further notice. As of today October 27, 2025 the car has still not been repaired and is still on hold at the dealership. Kia has not determined if it is safe to repair the vehicle and return to owner (myself). I however do not feel safe to drive this car as I am lucky to be alive and that it didnt explode when the fuel tank expanded. Hopefully my case can help save someone else from being placed in danger with this issue.

Driving down the highway and heard a pop and my seats were rising slowly and while trying to make it to the nearest exit only two minutes later my rpm’s started jumping and my engine just shut off and multiple dash lights came on. Had it towed to Kia and after they did an inspection they said that my fuel tank had expanded and was pushing on my fuel lines and pushing my back seats up. Screen shot of technician video summary sent to me by dealership down below.

I am submitting an update regarding my 2023 Kia K5 (VIN: [XXX] ). •On July 25, 2025, I delivered the vehicle to my dealership for recall-related fuel tank issues. •As of today (61 days later), the vehicle remains out of service and undrivable. •The dealership opened a Kia Techline case, confirming they are unable to repair the fuel tank issue and that it is a safety hazard. •Kia North America has not provided any resolution, despite repeated contacts and escalation of my case (Kia Claim #25408405). •I have incurred significant financial hardship, including paying the monthly car loan, maintaining minimum insurance, and paying for out-of-pocket rental expenses while Kia holds my vehicle. •I also contacted Kia Finance, and they confirmed my hardship notes are documented in their system. This situation is ongoing, with no repair performed, no reimbursement, and no safe solution provided. The recall remains unresolved, and the vehicle is unavailable for use. I request that NHTSA take immediate action to ensure Kia complies with its recall obligations and consumer safety requirements. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

the vehicle failed the fuel tank Inspection recall.I have a tech line case open :Case number 25408405 . It has been 46 days since the vehicle has been at the dealership waiting for information from Kia USA . I have been still told to pay for car note that I am financing through Kia itself as well as rental because the dealership doesn’t have any loaners .

I started the purchase process of a Kia in 2022 of July. The car was built with a faulty fuel tank and no recalls were made on the vehicle. June 27,2025 I was driving on the freeway when my car started to not accelerate my fuel tank ejected into my backseat and I was forced to jump out of my car on the freeway.

The fuel tank in my 2023 Kia K5 LXS expanded and bent the subframe. This is a known problem with K5's with the 1.5L turbo engine. Kia had an emissions campaign for this problem affecting 2021 to 2024 models. My VIN isn't in that campaign, but it had the same problem. Given the fuel tank expansion and bent subframe, my car is no longer safe to drive and has been sitting at the dealership. I was told that with the fuel tank expansion a plate could pop open and create a fire or explosion. This also caused a significant loss of power, making the car untenable to operate. Kia's Techline reviewed the findings from the dealership service department (Campbell Kia Missoula), but closed the case without offering a repair and escalated it to another department (Consumer Affairs?), where it remains unresolved after two weeks. Kia is failing to resolve the issue in the form of either a repair or a buyback and keeps dragging the case out with virtually no contact or updates. Please help. This needs resolved ASAP.

The fuel tank expanded causing the vehicle to become immobile. The car is sitting at a dealership after I declined to sign Kia's buyback so yes it available for inspection. As for my safety and other the fact a fuel tank is swelling under where people would sit and it is highly flammable/ combustible is kind of alarming to me. Yes, there are plenty of people having the same problems. The dealership has sent pictures and videos into Kia for their engineers to look over. The day before the car became immobile it was getting horrible gas mileage. There was no other things that happened no lights on the dash.

The gas tank wii not allow you to put gas in it. When you try to put gas in it won't go down in the tank hose and the fuel gauge is ready a 1/4 tank. The car jerks when pressing on the gas pedal. I have only gone around 200 miles and gauge fluctuates with different reads so you don't know exactly how much gas is in the gas tank. The engine light is on as. This is happening while I am traveling.

In June 2025, while driving my 2023 Kia K5 (VIN: [XXX] ) at highway speeds on [XXX], the fuel tank suddenly imploded. A loud bang caused the rear seats to lift, startling me and my passengers. The car lost power, and braking too hard risked leaving us stranded in fast-moving traffic. I narrowly avoided a crash while trying to maneuver us to safety. This vehicle was previously recalled by Kia in April 2024 for a fuel tank defect affecting ~236,000 vehicles. I took it to Gunther Kia in Davie, FL for inspection, and they claimed it was fixed. In March 2025, I returned to Hollywood Kia because of popping sounds and a check engine light. They diagnosed and “repaired” a purge control valve but failed to address the underlying defect. Despite these repairs, the catastrophic failure still occurred. The vehicle is now completely inoperable and irreparable. Kia later offered to buy back the vehicle but failed to respond to over 200 calls and dozens of emails from me, allowing their offer to expire without explanation. This left me paying for a vehicle I can no longer use. This defect poses a serious danger not only to me and my passengers but also to thousands of other K5 owners nationwide. I urge NHTSA to investigate Kia’s recall handling and ensure affected vehicles are properly repaired to prevent injury or death. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

My 2023 Kia K5 GT (VIN: [XXX]) is experiencing a dangerous complete power loss at highway speeds. I was driving at the speed limit on [XXX] when the vehicle lost propulsion, entered limp-home mode, and illuminated every warning lamp. This has happened six times since purchase. The car is currently parked, and I am not confident enough to drive the car; I nearly missed a crash pulling into the emergency lane from the leftmost lane to the rightmost lane. After losing power in the engine, that was a traumatizing experience. I tried to explain this to people multiple times at different service centers, but they care less: "We can't fix it unless we can reproduce it," but this happens randomly; I cannot make it happen at the service center. This matches the recall SC250 symptoms exactly, though my VIN is excluded. I have tried with Multiple dealers before, but they cannot fix it. They say, "We cannot fix it unless we can reproduce it." INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

On Friday 5/16/25 my check engine light was on when I went to leave for work and when I began driving I felt excessive air flow coming from my back seat. I stopped and noticed that the back seat had popped up. I then noticed my gas gauge was showing empty, but my digital reading was correct.. The car was sluggish and my son's father told me that the gas tank was swollen and to stop driving it. I called Kia on Saturday morning and was told I could bring it in today at 9am. I left the car and was given a loaner, but I do not feel it would be safe to ever drive that car again. They immediately knew what the problem was and said it was a recall, but I was never notified about it. It was extremely scary driving it to Kia this morning because they are over 50 miles away from where I live.

While driving, thankfully not with my [XXX] son, the vehicle made a real big bang noise and lost power. Looked back and the whole back seat was lifted. Towed to dealer and tech found that fuel tank had expanded and exploded seat back. Incident happened in November 2024, and to this day, Kia has been the most difficult to deal with. They offered to buy vehicle back, but we have been waiting for a long time for answers and resolution of this issue. Its impossible to get someone on the phone and we keep getting the run around with a loaner/rental while trying to continue to live normal life going to work and dropping kid at school INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Component or System Failed: The fuel tank exploded, causing the vehicle to become undrivable. The explosion was so severe that the back seat was completely blown off. The vehicle is currently not in my possession, as it has been with the dealership for over three months. I have photos and proof of the damage, and I am willing to provide them for inspection. How Safety Was Put at Risk: I have a [XXX] son who sits directly above the fuel tank in the back seat. When the explosion occurred, the back of his seat was completely blown off, and had he been in the car at the time, he could have been seriously injured or killed. This was an extremely dangerous defect, and I am deeply concerned that this could happen to other Kia vehicles, putting more lives at risk. Beyond the immediate danger of the explosion, I have been left without a working vehicle for over three months, and Kia has provided no resolution. Despite confirming that the vehicle is not repairable, they have stalled the process, forcing me to continue making payments on a car I do not even have. Problem Reproduced or Confirmed by a Dealer or Independent Service Center? Yes, the Kia dealership confirmed that the vehicle is not repairable and that the fuel tank failure was severe. However, they have not provided any solution or compensation. Has the Vehicle Been Inspected? Yes, the vehicle was inspected by the Kia dealership, which determined that it was not repairable. I do not know if it has been inspected by any third-party mechanics, insurance representatives, or other authorities. Warning Lamps, Messages, or Symptoms Prior to the Failure? There were no warning lights, messages, or other symptoms prior to the explosion. The vehicle was operating normally before this occurred. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

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. They offered bottom dollar to buy it back

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. Not only that but there has been a recall on it that I was unaware of, I took the car immediately to the nearest dealership and they acknowledged there’s a recall and I can’t drive the car because the backseat can explode anytime now.

Ive a 2023 Kia K5 GT-Line AWD with 73000 mileage. I was having a trip from New Jersey to Massachusetts for a wedding. I had 208 miles to go and 223 miles range. Than suddenly it went down to 93 miles. I stop by a gas station. I could not pump gas. It was kicking the nozzle. I atop by another gas station miles later. I couldnt pump gas either. It kickes the nozzle and my gas tank looks full. Than i start the car and check engine light and P045100 code came on. Than i checked the closest KIA but it was Saturday. They couldn’t service i was at Rhode Island. I called one of the KIA and they said as long as CEL is on i can drive. If its keep flashing i shouldnt drive. I said it smells gasoline and i cant fill up my tank and i asked if they have a suggestion and they said idk and closed the phone. Than i heard a clicking noise and it smelled a lot more gasoline. I saw that my rear seats popped up. I saw that one of the gas tank or whatever it is was up and my tank was expanding. I had to leave my car to another dealer nearby airport at Rhode Island. They will check my car at Monday. I rent a car from airport enterprise. I guess ill need to wait and see. I knew that there is a recall. But i went for an oil change at 60000 mileage and my local dealer told me that there was a recall and they checked and thats why it took long and im good to go. So they checked the recall and it was fine and now its not fine. I had the recall done but it still happened. My car stayed at dealer from 10 days. They couldnt fix it and someone from Kia Tech came to check, while they are checking the gas tank had a mini explosion as they said. Kia is going to buy my car back and they confirm that i can either get a replacement or buyback. They confirmed that there is no permanent fix for it. They do not know how to fix it.

Ive a 2023 Kia K5 GT-Line AWD with 73000 mileage. I was having a trip from New Jersey to Massachusetts for a wedding. I had 208 miles to go and 223 miles range. Than suddenly it went down to 93 miles. I stop by a gas station. I could not pump gas. It was kicking the nozzle. I stop by another gas station miles later. I couldnt pump gas either. It kickes the nozzle and my gas tank looks full. Than i start the car and check engine light and P045100 code came on. Than i checked the closest KIA but it was Saturday. They couldn’t service i was at Rhode Island. I callled one of the KIA and they said as long as CEL is on i can drive. If its keep flashing i shouldnt drive. I said it smells gasoline and i cant fill up my tank and i asked if they have a suggestion and they said idk and closed the phone. Than i heard a clicking noise and it smelled a lot more gasoline. I saw that my rear seats popped up. I saw that one of the gas tank or whatever it is was up and my tank was expanding. I had to leave my car to another dealer nearby airport at Rhode Island. They will check my car at Monday. I rent a car from airport enterprise. I guess ill need to wait and see. I know that there is a recall. But i sent for an oil change at 60000 mileage and my local dealer told me that there was a recall and they checked and thats why it took long and im good to go. So they checked the recall and it was fine and now its not fine. My gasoline tank expanded. My car is located at Bold Hill Kia in Warwick, Rhode Island. I was scared to drive but i had no other choice and the serviceman in one of the dealer told me to drive so i drive to another KIA.My vehicle was inspected for the SC288 Recall [XXX] ) There was a check engine light with the obd code of p045100. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I was driving and it was a loud noise. My son flew up with seat belt on hit his head on roof , gas tank blew up / or swelled up and my back seat is sitting about 10-12 inches above then normal. Very scary and worried

Gas tank expanded and bent the undercarriage up so much it blew off the fuel pump cover and pushed up the back seat.

I was driving on [XXX] Orlando Florida on [xxx] doing approximately 70 miles an hour when a large explosion occurred out and within my car the whole car shook this happened twice within a 5 mile radius. The car was eventually brought to Kia city in Orlando, where they determined that the fuel system had failed . the valve had failed, and the fuel system tank and fuel pump had swelled and blew .This could lead to catastrophic explosion in the vehicle, and or someone catching on fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)