Your daily commute shouldn’t include the risk of your fuel tank literally melting, yet Kia just recalled 250,547 K5 sedans for exactly that terrifying possibility under NHTSA recall 25V794. A defective check valve can cause pressurized air to inflate fuel tanks until they contact hot exhaust components—potentially melting through and creating a serious fire hazard.
The Technical Culprit Behind Tank Failure
The villain here is a tiny component with a massive safety impact. When the purge control system’s check valve deteriorates, it allows pressurized air from the intake manifold to rush into your fuel tank. Think of it like a balloon expanding until it touches a hot stove—except this balloon contains gasoline.
You might notice warning signs:
- Strange popping sounds from the fuel tank area
- An illuminated check engine light
- Rough engine performance that feels off
These symptoms signal your tank could be expanding dangerously close to hot exhaust components.
Which K5s Face the Tank Melting Risk
If you own a 2021-2024 K5 equipped with the 1.6L turbocharged engine, manufactured between March 2020 and January 2024, your sedan falls under this recall. The 2025 K5 dodged this bullet entirely—it uses a different engine.
You can verify your vehicle’s status starting December 1, 2025. Dealer notifications begin November 18, with owner notices following January 16, 2026. Don’t wait for the official paperwork if you’re experiencing symptoms.
Free Repairs Address Both Cause and Damage
This isn’t a “sorry, tough luck” situation. Kia dealers will replace the problematic check valve with an improved design, inspect your fuel tank for heat damage, and swap it entirely if necessary. The repair also includes updated engine control software to prevent future issues.
Already paid for related repairs? Kia’s reimbursement plan covers previous expenses tied to this defect. Contact your dealer immediately if you’re experiencing any warning symptoms.
Broader Korean Sedan Reliability Questions
This recall gains extra weight when you consider Hyundai—Kia’s corporate sibling—simultaneously recalled 85,000 Sonata sedans for related fuel system issues. The pattern suggests broader quality control challenges with shared components between these Korean automakers.
If you’re experiencing any warning symptoms, don’t wait for your official notice. Contact your Kia dealer immediately, because some risks simply aren’t worth rolling the dice on your morning commute.
