- The exact component that failed has not yet been determined. The vehicle experienced a sudden loss of acceleration while driving, followed by a popping noise, smoke, and a fire that severely damaged the vehicle. The vehicle is a 2022 Kia K5 GT-Line, VIN [XXX]. The vehicle has an open Safety Recall SC356 / NHTSA Recall 25V794 involving the purge control system check valve and fuel tank, which may result in fuel leakage and an increased risk of fire. The recall repair had not been performed prior to the incident. The vehicle is currently being preserved and is available for inspection upon request. - The vehicle caught fire while driving on XXX, in [XXX]. The vehicle suddenly stopped accelerating, a popping noise, and then smoke began coming from the vehicle shortly afterward. The vehicle subsequently caught fire and was destroyed. The incident created a serious risk of injury to me, other occupants, nearby motorists, and others in the area. Fortunately, there were no injuries. - The cause of the failure and fire has not yet been confirmed. The vehicle was severely damaged by the fire. The vehicle has an open Kia SC356 / NHTSA 25V794 safety recall, which we were unaware of, but it has not yet been determined whether the condition addressed by that recall caused or contributed to this incident. - The Killeen Fire Department responded to the vehicle fire and extinguished the fire. The incident has also been reported to my insurance company, and an insurance claim is currently pending. No inspection has yet been performed to determine the cause of the fire. The vehicle is being preserved so that it remains available for inspection by the manufacturer, insurance representatives, NHTSA, or an independent expert if necessary. -No warning lamps or warning messages prior to the incident. While driving, the vehicle suddenly stopped accelerating, then a popping noise was heard, followed by smoke, and the vehicle subsequently caught fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 5
NHTSA complaint #11763269 — an unverified report by a vehicle owner.
The contact owns a 2023 Kia K5. The contact received a recall notification for NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The vehicle was taken to a dealer, where the contact was informed that the recall repair was completed and the contact was provided a receipt. However, the contact later received several email recall notifications and verified that the VIN remained included in the recall three months after the repair. The dealer was contacted several times and eventually informed the contact that the recall repair had not been completed. The manufacturer was not yet notified of the issue. The contact had not experienced a failure.
NHTSA complaint #11760869 — an unverified report by a vehicle owner.
The contact’s son owns a 2023 Kia K5. The contact stated the vehicle was previously included in NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline), and the vehicle was repaired. A day or two after the recall repair was completed, the check engine warning light illuminated. The vehicle was returned to the dealer to be diagnosed, and the contact was informed that the fuel tank could expand and explode. The contact was informed that the fuel tank and fuel pump needed to be replaced. The vehicle was repaired. The contact stated that after driving 10 miles after the vehicle was repaired, the check engine warning light illuminated again. The vehicle was taken to Auto Zone, and similar fault codes were retrieved. The vehicle was not repaired after the latest failure. The manufacturer was made aware of the failure. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was unknown.
NHTSA complaint #11760941 — an unverified report by a vehicle owner.
The contact owns a 2021 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The vehicle was taken to a dealer for the recall repair. The contact was struggling to receive updates on the status of the vehicle. The contact spoke with a service clerk and was informed that the repair was going well and that only one recall test remained. However, a supervisor later called and stated that the recall repair could not be completed. The vehicle could not be repaired. The vehicle was no longer functional due to a high risk of catching fire from fuel tank swelling caused by the recall defect. The contact stated that prior to the dealer visit, the vehicle had no issues but became inoperable. The vehicle was not repaired, and the dealer stated that the vehicle could not be repaired. The manufacturer was made aware of the issue. The failure mileage was approximately 111,000.
NHTSA complaint #11757490 — an unverified report by a vehicle owner.
I am reporting a violation of the National Traffic and Motor Vehicle Safety Act by Ball Kia (National City, CA). The dealer tried to deny service for recall 25V794000 (SC356) for a melted, leaking fuel tank, fabricated a false diagnostic narrative of road impact to exploit me, and tried to charge $3,000 out-of-pocket for a federally mandated free repair.My vehicle has a severe fuel leak from a compromised fuel tank. Ball Kia service refused the recall, claiming "external aesthetic factors" or "road debris impact" caused it, and pressured me to tow it away.Using my military infantry experience in mechanical damage assessment, I inspected the vehicle in the service bay. I verified there is absolutely no puncture, tear, scrape, or kinetic impact on the fuel tank assembly. The dealer pointed to a split in the fuel tank protector panel, but a professional assessment shows this is false. The plastic protector panel failed due to extreme thermal exposure; the expanding tank pressed it against the hot exhaust, causing it to melt and tear under heat/pressure, not a kinetic strike.The tank itself is structurally melted and deformed with zero signs of road impact. This physical evidence matches the exact defect mechanism in the NHTSA recall: a deteriorated check valve allows intake pressure into the fuel tank, causing it to expand, hit hot exhaust components, melt, and leak.Only after I read the exact NHTSA safety risk and remedy text verbatim did the service manager back down and open a manufacturer Tech Line.Because I had to fight a fraudulent diagnosis to get this safety mandate acknowledged, I fear internal dealership retaliation, being blacklisted, or receiving a subpar, dangerous repair. Leaving a high-risk fire defect unaddressed is a public safety hazard. Please audit Ball Kia's handling of campaign 25V794000 to ensure they are not endangering or defrauding other affected Kia K5 owners.
NHTSA complaint #11757545 — an unverified report by a vehicle owner.
What component or system failed or malfunctioned, and is it available for inspection upon request? Fuel pump, fuel tank and valve check. How was your safety or the safety of others put at risk? SEE PHOTO. on turnpike 95. Has the problem been reproduced or confirmed by a dealer or independent service center? Confirmed by the dealer yes. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Bev smith KIA sent my info to KIA America when they saw it. SEE PHOTO. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? It blew up on me.
NHTSA complaint #11754095 — an unverified report by a vehicle owner.
Recall NNK post-repair failure. Dealership: Kia of Valdosta (RO# XXX). After ECU update NNK-02-0118, my K5 suffered a severe loss of acceleration and torque. The car cannot safely merge on highways. The dealer’s own live scan data sheet proves that at 4,997 RPM under full load, the Turbo Recirculation (Dump) Valve reads "OFF". The factory tool key explicitly states (OFF = Open). The service manager is misreading the tool, claiming "OFF" means closed, and refuses to fix it. The boost gauge only rises under heavy floor acceleration, proving an uncalibrated boost leak. I have uploaded a photo of the technician's data sheet directly to the attachments and will also drop link to videos of my car in normal and sport mode. I have also opened Kia Corporate Case #XXX. I demand a corporate Regional Technical Manager review this data and authorize a Turbocharger Recirculation Valve (RCV) and Wastegate Adaptation Relearn at an alternate dealer...... 1. [XXX] 2. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11753897 — an unverified report by a vehicle owner.
On XXX, while traveling to [XXX], I experienced serious fuel system problems after filling my vehicle. The fuel gauge fluctuated from full to empty, and a loud pop caused the rear seat, where my two children were sitting, to lift upward. The vehicle would not accept more fuel despite the empty reading. I called AAA, but before the tow arrived, the gauge returned to normal, so I continued my trip. After returning to [XXX], I checked my Kia app and discovered active Recall SC356 describing a damaged check valve that could cause fuel tank expansion, rear seat lifting, and abnormal fuel gauge behavior—the same symptoms I experienced. On XXX, I brought the vehicle to The Kia Store in Louisville, advised them of the recall and my symptoms, and requested an inspection. Service Advisor Sidney Daub stated the issue was caused by a scratched muffler, not the recall, and no recall repair was performed. Relying on that assessment, I continued driving. From XXX, while traveling to [XXX], the same problems returned. Smoke came from the fuel tank area, fuel sprayed onto me when I opened the fuel door, and the vehicle became disabled and required towing home. I then took it to Kia Store East on June 10. There, [XXX] advised the failure was related to Recall SC356, and Haley informed me Kia Consumer Affairs would contact me. After weeks of communications, Kia advised on XXX that the vehicle was unrepairable and requested ownership documents. On XXX, Kia offered only to satisfy my loan balance through a buyback. I believe the dealership's failure to properly diagnose & repair the recall condition in April directly contributed to the later failure, safety hazards, towing expenses, and loss of my vehicle. I respectfully request that NHTSA investigate Kia's handling of Recall SC356 and the dealership's actions, & encourage Kia to consider a replacement vehicle, collateral swap, or another equitable resolution. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11753652 — an unverified report by a vehicle owner.
The vehicle is grounded at the dealership due to NHTSA Campaign 25V794 (Kia Recall SC356). The vehicle's fuel tank has critically expanded and swollen, causing permanent structural and chassis deformation inside the vehicle. The dealership service department has documented this structural damage, confirmed the vehicle is entirely unsafe to operate due to an immediate fuel system fire hazard, and stated the vehicle is likely unrepairable. The manufacturer is currently holding the hazardous vehicle but is failing to provide immediate alternative transportation, leaving the consumer stranded and creating severe financial hardship. I do not have the financial means to pay rental car fees up front for an extended and undetermined amount of time while waiting for Kia to decide the next step. All of the issues with the vehicle are directly related to the manufacturer defect. My safety was at risk while operating the vehicle due to a severe fire risk.
NHTSA complaint #11753686 — an unverified report by a vehicle owner.
car taken to Hutchenson Kia of Macon for Kia recall Campaign SC356. I heard loud pop a few days before appointment. The dealership stated the gas tank failed structural inspection and has already expanded. This put me and my children in danger. The dealership kept my vehicle and will not give me me a loaner. They left me stranded without a way to get home or pick up my kids from daycare. the 1800 # said my car isnt under warranty so they arent obligated. If they keep my car an say its a safety hazard they should be obligated. im told i have to wait 3-5 business day to get a case manager to see how they can assist me,
NHTSA complaint #11753777 — an unverified report by a vehicle owner.
As I was driving down the road, I began to hear a loud, forceful noise. I assumed it was something in my trunk rolling against the rear seats. The noise kept getting louder, and I pulled over, very frightened, as several warning lights came on, including the low fuel light and check engine light, and the fuel gauge needle was past “E.” Before the incident, the GPM reading was 400. After a while, I made it home, but the car started making loud noises and then died. That’s when I noticed my back seats were lifted. I called Kia customer service and had the car towed to the Kia dealership on Seigan Lane, where it is now. Something needs to be done about this.
NHTSA complaint #11753188 — an unverified report by a vehicle owner.
I brought my 2023 Kia K5 to Citrus Kia in Ontario, California on 2/20/2026 for two safety recalls, including Recall SC356 involving a defective fuel check valve that can cause the fuel tank to expand, melt, and potentially catch fire. When I picked up my vehicle on XXX, I was given a repair invoice stating that both recalls had been completed. Four months later, I received another recall notice by mail for SC356. After contacting Kia corporate, they confirmed that Citrus Kia had never completed the recall, despite providing me with paperwork stating that it had been done. I made multiple attempts to contact the dealership for an explanation but my calls were never returned. Kia corporate also had difficulty reaching the dealership. They ultimately confirmed with Citrus Kia that the recall had NOT been performed and instructed me to have it completed at another dealership. This was not a minor paperwork error. Citrus Kia falsely represented that a serious safety recall involving a potential fire hazard had been completed when it had not. I have the dealership's own repair invoice documenting that they claimed the work was finished. I also have a voicemail recording from Kia corporate stating they were told by Citrus Kia that the recall was actually not completed. What is most alarming is that Kia corporate never asked the dealership why they provided an invoice stating the safety recall was completed when it had not. Attachments: page 3 of invoice from 2/23/2026 shows Recall SC356 as completed; 2 screenshots from NHTSA and [XXX] on 7/23/2026 shows Recall SC356 as not completed. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11752750 — an unverified report by a vehicle owner.
The contact owns a 2021 Kia K5. The contact stated that while driving approximately 55 MPH, the fuel gauge suddenly went from one-half tank to empty. The fuel level displayed 120 miles to empty. The contact attempted to refuel the vehicle but was unable to add fuel to the tank. The contact also stated that the oil warning light and the TPMS warning light was illuminated. The contact associated the failure with NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 119,185.
NHTSA complaint #11752335 — an unverified report by a vehicle owner.
The contact owns a 2021 Kia K5. The contact stated that there were failures with the spark plugs. While driving at an undisclosed speed, the vehicle shuddered, and the engine sputtered. The contact stated that fuel spewed out of the filler neck while refueling the vehicle, and the fuel gauge incorrectly indicated that the fuel tank was empty after refueling. Additionally, there was an abnormal egg and sulfur odor coming from the vehicle with the check engine warning light intermittently illuminated. The contact stated that the vehicle was taken to a local dealer and inspected under NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). During the inspection, the seats were damaged. The vehicle was not repaired. The manufacturer was notified of the failure and was negotiating a buyback. The failure mileage was approximately 120,000.
NHTSA complaint #11752163 — an unverified report by a vehicle owner.
7/20/26 My 17 year old daughter was on the way to work and heard a loud noise like an explosion in her car. She, new to driving, scared and in a panic just assumed this was a blowout on a tire and pulled over to check the tires. All tires were clear so she proceeded to work cautiously, on her way home she noticed her check engine light had come on and noticed there was some road noise coming from the back. She then called me, note this is the first I heard of the situation. While on the phone with her I pulled up the CarFax to check when it had last been maintenanced, while doing that I saw for the first time TWO RECALLS on this car we had just purchased 3 months ago! By this time she was home and I instructed her to get out of the car while I Immediately called our local Kia dealership to schedule an appt to have the two recalls fixed (7/20/26 at 4:38pm). I gave the make and model to the service department and they informed me they couldn’t see me till Wed July 29th,at 8:00 am. When my husband and I further assessed the car after we got home we found that an explosion had occurred around her fuel tank, which was full at the time of the incident! The fuel tank expanded enough to completely rupture and detach her entire backseat! This incident was due to a recall replacing a valve on the fuel tank that was not conducted on the car from prior owners nor communication to the new owners (ME) upon my purchase of the vehicle. This could have been catastrophic to my daughter and anyone else in the vehicle had she kept driving the car and could have very easily been engulfed with flames and loss of life especially with a full tank of gas. The car has been towed to the local Kia dealership and leaked gas all in our driveway as it sat there. We are still awaiting response from Kia on our case it has been over 48 hours now and we have received no communication from them. KIA NEEDS TO DEEM THIS RECALL AS POSSIBLY FATAL AND ACT IMMEDIATELY TO SAVE LIVES!
NHTSA complaint #11752175 — an unverified report by a vehicle owner.
I am filing this complaint regarding Kia America’s handling of a safety recall and repurchase of my 2023 Kia K5 GT-Line (VIN: [XXX]. I purchased this vehicle used on XXX, and financed it through Capital One. After taking my vehicle to an authorized Kia dealership for the fuel tank valve safety recall, I was informed that my vehicle was unsafe to drive and could not be repaired. The dealership advised me that Kia would be repurchasing the vehicle. Kia has offered to buy back the vehicle, but the settlement being offered does not appear fair under the circumstances. Although Kia has determined that my vehicle is unsafe and unrepairable due to a manufacturer safety defect, I have only been provided with 15 days of rental vehicle coverage while Kia’s own repurchase letter states that the process may take 60 to 90 days to complete. This could leave me without transportation through no fault of my own. Additionally, Kia has refused to reimburse my $4,000 down payment or provide any additional compensation related to the loss of use of my vehicle. Their offer also includes a substantial mileage deduction under certain options, despite the fact that this repurchase is the result of a manufacturer safety defect rather than a voluntary sale or trade-in. I requested written clarification regarding my settlement options, rental coverage, loan payoff, and reimbursement of my expenses. Rather than answering my questions, Kia responded only that the offer was “firm” and compliant with Florida law, without addressing the specific concerns I raised. I am requesting that this matter be reviewed to determine whether Kia is handling this safety recall and repurchase fairly and whether consumers whose vehicles are deemed unsafe and unrepairable should receive adequate transportation assistance and fair compensation while waiting for the manufacturer to complete the repurchase process. I respectfully request assistance in reviewing Kia America’s handling this case. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA
NHTSA complaint #11752242 — an unverified report by a vehicle owner.
The contact owns a 2021 Kia K5. The contact stated that while driving approximately 55-60 MPH, the fuel tank expanded. There were no warning lights illuminated. The vehicle was towed to the local dealer, where it was determined that the fuel tank had expanded, and that the vehicle was unrepairable. The vehicle was not repaired. The dealer offered a buyback. The manufacturer was not contacted. The failure mileage was approximately 115,000.
NHTSA complaint #11751470 — an unverified report by a vehicle owner.
The contact owns a 2021 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while driving approximately 70 MPH, upon further inspection the fuel level was lowering unexpectedly. The check engine warning light was illuminated. The vehicle was taken to a local Auto Zone and was scanned with an OBD2 scanner and diagnosed with a recall-related failure. The vehicle was taken to a local dealer, where it was diagnosed with an expanded fuel tank; however, the vehicle was not repaired because the dealer was short-staffed. The dealer associated the failure with NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The manufacturer was made aware of the failure; a case was filed; however, no assistance was provided. The failure mileage was approximately 90,000.
NHTSA complaint #11751597 — an unverified report by a vehicle owner.
My car is losing power upon acceleration causing a loss of power upon take off upon taking off and when gears are shifting. Told by dealer it is a problem with fuel injection. Replaced several coil packs and spark plugs on my own. Dealer repair shop had my car for 4 days for the fuel talk and valve issues and did not repair anything. Losing power when I drive in traffic and on highway is a huge safety issue causing loss of power when at highway speeds. I plugged in a code reader bought by myself which is telling me it’s coil packs. We have replaced several with no luck. There is a smell of fuel and with all the other fuel system recalls and after reading other complaints on this site that sounds similar, I fear this is a safety issue with the vehicle. They checked my fuel tank and valve but didn’t replace either. I believe this is related to all the other fuel system recalls and should be repaired free of charge by dealer as a dysfunctional fuel problem as nothing we’ve done to repair with the code reader has fixed this issue. I fear a loss of power of fire caused by the mounting fuel system issues of these issues have caused the issue I’m having. Please look into this as several other complaints I’ve read online by owners are having same issue. My car only has 68,000 miles. I’m in fear of serious injury as a cause of these issues. Also concerned dealer had my car 4 days and DID. NOT repair or replace fuel tank or fuel valve, why did they have my car this long and DID NOT REPAIR the recall that the vehicle was there and the appointment was scheduled for such? I really have a fear there is an accident in my vehicle travels caused by mounting fuel issue recalls and problems. Please please look into this and help with these mounting fuel system issues before serious injury or death!
NHTSA complaint #11749168 — an unverified report by a vehicle owner.
Driving anywhere in general and which ever speed my gas would leak and smell would over take the car and I have a [XXX] and [XXX] babies. This is not the first but the third recall and this is a fire hazard I can’t imagine my car going in flames while we’re already suffering with a leaking gas smell every time we drive the car I can loose my whole family I will soon being filing a lawsuit against this I want a new vehicle completely I do not feel safe in this car with my kids at all there’s always an issue and my dealership is over 40min away to be going so often throughout the years of having this car this is completely unsafe dangerous and just out right unexpectedable and will be filing soon for a new car and compensation INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11748609 — an unverified report by a vehicle owner.