What 96 owners told NHTSA about the 2023 Kia K5

I am submitting this complaint regarding a serious safety defect involving my Kia K5 and the subsequent handling of this matter by Kia America. My vehicle was subject to a voluntary recall and was inspected by an authorized Kia dealership. During inspection, I was informed the vehicle has a defective fuel tank system that allowed air intrusion, resulting in abnormal pressure and structural impact to the vehicle. I was further advised by dealership personnel this condition created a risk the vehicle could catch fire or explode while being operated. As a result, the dealership retained possession of my vehicle and deemed it unsafe to drive. I have been without use of my vehicle and Kia has provided a rental car. For approximately eighteen (18) months prior to this discovery, I unknowingly operated this vehicle under these conditions. During that time, my minor child was a regular passenger in the rear seating area of the vehicle. My child has experienced ongoing neurological symptoms, including persistent headaches over a period of several months, which have required medical evaluation. While no definitive cause has yet been determined, the possibility of prolonged exposure to fuel vapors within the vehicle is a serious concern. In addition to the safety risk, I have incurred substantial financial losses, including: Monthly payments totaling approximately $10,170 Down payment $1,000 Maintenence $1,800 Insurance costs totaling approximately $7,500 Despite the severity of the defect and the fact the vehicle cannot be repaired or returned to me, Kia America has only offered resolution options that: Do not fully reimburse my financial losses In some cases require me to pay out-of-pocket to resolve the issue Do not account for the significant safety risks involved Furthermore, Kia America has imposed a deadline for acceptance of these inadequate offers and has stated that if I do not accept, they will: Discontinue providing a rental vehicle Return the unsafe vehicle to me

NHTSA ODI 11737882

The contact owns a 2023 Kia K5. The contact stated that while driving at an undisclosed speed, there was a fuel odor inside the vehicle. Occasionally, the low fuel warning light was illuminated. While attempting to refuel the vehicle, gasoline was not entering the fuel tank as intended. The fuel odor inside the vehicle grew stronger. The failure was persistent. The vehicle was taken to the dealer, where the contact was informed that the failure was severe. The contact was informed that, due to the severity of the failure, the vehicle could not be released to the contact. The contact was informed that the fuel tank had expanded severely and that the expanded fuel tank had shifted the frame of the vehicle. The contact was provided with a loaner vehicle. The contact stated that the contact's [XXX] son had been complaining about headaches for several months. In addition, the contact stated that the contact's son's normal seating space was the rear seat. The contact's son was receiving continued treatment from a neurologist for the unexplained, consistent headaches. In addition, the contact was being treated by primary care for unexplained headaches and other illnesses. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The manufacturer was made aware of the failure, and a case was filed. The contact was informed that the request for a buy-back was required. The contact was informed that the vehicle would not be released due to the safety hazard. The failure mileage was approximately 70,000. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11730217

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)

NHTSA ODI 11674710

The contact owns a 2023 Kia K5. The contact stated that while driving at 65 MPH in hot weather, a loud popping sound came from underneath the vehicle. The vehicle lost motive power. The check engine warning light was illuminated. The contact coasted into a ditch and inspected the vehicle, but no exterior damage was found. The vehicle was restarted and driven to a gas station. The check engine warning light was no longer illuminated. The vehicle was taken to the dealer, but the cause of the failure could not be determined. The failure persisted and the fuel gauge level dropped while driving. The contact pulled over and placed a bag under the vehicle to check for fuel leaks, but found none. The contact stated that the vehicle failed state vehicle inspection due to an unknown emission code. The vehicle was taken back to the dealer, who performed an oil change and updated the computer system. The failure recurred while driving with three minor children in the rear seats. The fuel tank made a loud explosion, and the rear seats propped up, pushing the children forward while the seat belts restrained them in their seats. The child seated in the rear passenger seat received medical attention for injuries to the back of his legs caused by hot fuel fumes from underneath the seat, as well as black specks stuck on his legs. The contact's husband opened the fuel tank, and loud air pressure was released. The fuel tank was bubbling. The vehicle was towed to Classic Kia of Carrollton (2920 N Interstate 35E, Carrollton, TX 75007), who determined that the fuel tank needed to be replaced and requested that the manufacturer send an engineer to inspect the vehicle. The vehicle was towed to the third dealer, Huffines Kia Corinth (6940 S Interstate 35, Corinth, TX 76210), where an engineer determined the vehicle was non-repairable due to the fuel tank expanding in multiple locations and bending the sub-frame. The contact was informed that the fuel tank was manufactured without a pressure release valve. The vehicle was not repaired. Upon investigation, the contact stated that the 2021-2023 Kia K5s were not manufactured with a pressure release valve. The manufacturer was made aware of the failure and three cases were opened. The manufacturer offered to buy back the vehicle and reimburse for medical and vehicle rental expenses; however, the contact declined the buyback because the offer was less than the original agreement. The failure mileage was 17,857.

NHTSA ODI 11644189

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

NHTSA ODI 11602842