What 96 owners told NHTSA about the 2023 Kia K5

Shortly after refueling, I experienced a serious and sudden vehicle safety-related malfunction involving suspected fuel tank expansion. The event coincided with abnormal fuel behavior and an unexpected structural issue in the rear cabin area, where the rear seat assembly displaced upward without any passenger interaction or impact. The vehicle was inspected at Kia Archer, where I was informed it was unsafe to operate and required escalation to Kia corporate for review. I was advised the issue may involve a fuel system defect consistent with tank expansion potentially affecting surrounding structural or mounting components. Since that inspection, I have made repeated attempts to obtain clarification, safety guidance, and a technical explanation of the failure. These requests have not been meaningfully addressed. Communication from Kia corporate has been limited, delayed, or non-responsive. Instead of receiving a clear diagnostic explanation, repair plan, or safety directive, I was provided a buyback offer without supporting technical documentation, including no defect analysis, no engineering explanation, and no clear justification of valuation. I have also been presented with time-sensitive pressure to sign the buyback agreement despite the absence of disclosed safety findings or complete information regarding the defect. At this time: * The vehicle has been deemed unsafe by a dealership technician * A suspected fuel system defect involving tank expansion has been identified but not explained or resolved * There is concern of associated structural or mounting stress affecting interior components * Manufacturer communication has been insufficient and non-responsive following escalation * A buyback has been offered without transparent technical findings or defect disclosure * There is perceived pressure to accept terms without adequate time or information This was a huge safety risk to myself and any passengers I’ve had in my vehicle.

NHTSA ODI 11738856

On March 9, 2026, I brought my vehicle to a Kia dealership in Alexandria, Virginia after experiencing a loud thump noise from the rear of the vehicle while stopped at a red light. (3/08/2026) Immediately following the incident, I smelled gasoline, noticed a significant drop in fuel economy, and heard persistent road noise as if a window were open. I explained these concerns in detail to the service advisor and specifically stated my belief that the fuel tank may have expanded. I was informed that this was not related to any recall. After approximately two hours, my vehicle was returned to me without resolution. The symptoms persisted, including the smell of gasoline, which poses a clear safety risk. A few days later, I took my vehicle to a second Kia dealership for further inspection related to Recall SC356. At that time, I was informed that my initial concern was correct—the fuel tank had in fact expanded. I was initially told the repair would take 3–4 days due to parts ordering. However, I was subsequently contacted and instructed not to retrieve my vehicle, as Kia is now pursuing a buyback. While I understand the seriousness of the issue, I am currently without a vehicle, and I have not been provided with a rental or loaner. Given that this issue is tied to a safety-related recall and that my vehicle is unsafe to operate due to the presence of fuel odor, this situation is both unreasonable and unacceptable. They have yet to send me any reports from the second Kia dealership in which I had taken it on 3/14/2026 I was only told over the phone via a service advisor named India that I was correct in suspecting the fuel tank had expanded causing the gasoline fumes and road noise

NHTSA ODI 11725882

serious safety-related defects in my 2023 Kia K5 involving the fuel/emissions system &other vehicle components. From early ownership & throughout the lease period, the vehicle experienced repeated& unresolved issues including fuel system abnormalities, emissions failures, fuel odors, check engine light activation, abnormal noises, &performance concerns consistent with fuel pressure or fuel tank-related problems. I reported these issues multiple times to the dealership &to Kia Consumer Affairs beginning well within the first 24 months of the lease, continuing for over a year. Despite repeated complaints and service visits, the vehicle was repeatedly returned to me- deemed safe to drive, my concerns were ignored. In June 2024, the dealership identified fuel tank expansion, confirming the same safety concerns I had been reporting. In November 2025, Kia issued Safety Recall SC356 (NHTSA Recall No. 25V794), stating that a damaged check valve can allow air to enter the fuel tank, causing expansion, contact with hot exhaust components, melting, and increased fire risk. My vehicle is included in this recall, which remains incomplete, &I was never notified while the defects were actively occurring. Prior to the recall and before the fuel tank expansion was diagnosed, I paid significant out-of-pocket costs in March and April 2024 for emissions-related repairs based on representations that the vehicle was safe to drive. This vehicle was intended as a graduation gift for a minor, & minors in my household regularly operated it. Kia’s continued assurances that the vehicle was safe, despite known and reported defects, placed my family, especially minors, at serious risk of injury or death. In addition to fuel/emissions issues, the vehicle had persistent seat defects and other unresolved problems that were never fully repaired. The manufacturer ultimately acknowledged the vehicle is irreparable. The recall confirms the safety concerns.I raised were valid and serious.in shop 600days

NHTSA ODI 11713381

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