Kia Recalls 250,000 Sedans, Says Fuel Tank Could Melt

Kia America announced on Nov. 17 that it was recalling more than a quarter-million vehicles manufactured between 2020 and 2024 due to problems with the vehicles’ fuel tanks that could cause them to melt.

The notice was issued a day before Kia’s parent company, Hyundai, announced a similar recall of more than 85,000 vehicles due to the same issue.

The affected vehicles include 250,547 Kia K5 midsize sedans built at the company’s 2,200-acre manufacturing facility in West Point, Georgia, the National Highway Traffic Safety Administration (NHTSA) said in the recall notice posted on its website.

The recalled automobiles all have the 1.6-liter turbocharged four-cylinder gasoline engines as opposed to vehicles equipped with the larger 2.5-liter engine.

According to the NHTSA, the vehicles’ purge control system check valve, which directs airflow from the charcoal canister in the evaporative emission control system to the engine, could deteriorate over time. If that happens, pressurized air could flow into the fuel tank, causing it to expand and come into contact with the hot exhaust pipe and lead to melting.

Drivers should be aware of a “popping sound from fuel tank area, illumination of check engine light, and/or vehicle running rough,” the NHTSA noted.

The potentially faulty valves were manufactured by Inzi Controls of Korea.

A Kia owner first reported the issue to a dealer on Sept. 3, stating that the “check engine light sometimes comes on,” in their 2022 Kia K5 sedan, and also noticed that the “vehicle is leaking gas and has a very strong gas smell.”

A safety inspection revealed that the vehicle’s fuel tank had melted after coming into contact with the exhaust pipe. Bench testing through early November identified potential deterioration issues with the purge control system check valve, as well as fuel tank melting due to prolonged contact with the hot exhaust pipe. To date, fires or accidents related to the issue have been reported, Kia’s safety office noted.

Kia said it began notifying dealers of the issue on Nov. 18, and it will alert owners on Jan. 16, 2026. Drivers can enter their vehicle identification number (VIN) into the NHTSA’s recall notice portal starting Dec. 1. or on the Kia owner’s portal.

Drivers can take their vehicles to a Kia dealership, which will replace the check valve with an improved version and inspect and replace the fuel tank, if necessary, the NHTSA recall notice said. Kia’s K5 sedans made in 2025 are equipped with the larger engine and aren’t part of the recall.

Vehicle owners can also contact the NHTSA’s vehicle safety hotline at 888-327-4236 or contact Kia Customer Care at 800-333-4542.

Hyundai on Nov 18 announced the recall of 85,043 Santa Fe hybrid vehicles manufactured between 2019 and 2023 due to the same issue. The vehicles also have the 1.6-liter turbocharged engines and were made at Hyundai Motor Manufacturing Alabama in Montgomery, Alabama. Hyundai Sonatas made at the plant beginning with model year 2024 were made with larger engines and aren’t affected by the recall.

Hyundai owners will be notified about the recall on Jan. 16, the NHTSA said. Owners can contact Hyundai customer service at 855-371-9460 using safety recall number 240, or enter their vehicle’s VIN into the NHTSA website or at Hyundai’s website.