VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC288) - This document is the owner notification advising that Kia is conducting a Voluntary Emissions Service Campaign on certain 2021-2024 MY K5 vehicles equipped with 1.6L Turbo Gas Direct Injection (GDI) engines to improve the logic in the Electronic Control Module (ECM) to ensure compliance with emissions regulations. Also, the subject vehicles will be inspected and, if necessary, the fuel tank and/or the Purge Control Solenoid Valve (PCSV) check valve will be replaced with a new one.
full bulletin at NHTSA ↗2023 Kia K5 fuel system problems
severe Owners of the 2023 Kia K5 have filed 12 NHTSA complaints about the fuel system at roughly $1,200 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See fuel system across all vehicles →
Complaints
12
Recalls
0
Avg fix
$1,200
| Model year | fuel system complaints |
|---|---|
| 2021 K5 | 10 |
| 2022 K5 | 7 |
| 2023 K5 (this page) | 12 |
3injuries
When does it fail?
Of the 12 fuel system complaints filed for the 2023 Kia K5, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
TECHNICAL SERVICE BULLETIN: VOLUNTARY EMISSIONS SERVICE CAMPAIGN: FUEL TANK AND/OR PCSV CHECK VALVE INSPECTION/REPLACEMENT + ECU SW UPGRADE (SC288) - This bulletin provides information to inspect the fuel evaporative system and, if necessary, replace the fuel tank and/or the Purge Control Solenoid Valve (PCSV) check valve on certain 2021-2024MY K5 (DL3a) vehicles equipped with a Gamma II 1.6L T-GDI engine, produced from March 27, 2020 through October 17, 2023. This bulletin also provides information to upgrade the ECU software logic.
full bulletin at NHTSA ↗PRODUCT IMPROVEMENT CAMPAIGN: DEALER PRINCIPAL MEMO (SC288) - This document is the announcement to the dealer principals that Kia is conducting a Voluntary Emissions Service Campaign on certain 2021-2024 MY K5 vehicles equipped with 1.6L Turbo Gas Direct Injection (GDI) engines manufactured from March 27, 2020 through October 17, 2023 to improve the logic in the Electronic Control Module (ECM) to ensure compliance with emissions regulations. Also, the subject vehicles will be inspected and, if necessary, the fuel tank and/or the Purge Control Solenoid Valve (PCSV) check valve will be replaced with a new one.
full bulletin at NHTSA ↗VOLUNTARY EMISSIONS SERVICE CAMPAIGN: DEALER PARTS AND SERVICE MANAGER MEMO (SC288) - This document is the announcement to the dealer Parts and Service Managers that Kia is conducting a Voluntary Emissions Service Campaign on certain 2021-2024 MY K5 vehicles equipped with 1.6L Turbo Gas Direct Injection (GDI) engines manufactured from March 27, 2020 through October 17, 2023 to improve the logic in the Electronic Control Module (ECM) to ensure compliance with emissions regulations. Also, the subject vehicles will be inspected and, if necessary, the fuel tank and/or the Purge Control Solenoid Valve (PCSV) check valve will be replaced with a new one.
full bulletin at NHTSA ↗SC288_POC: PROOF OF CORRECTION CARD
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2023 Kia K5 models describe fuel tanks that expand internally, producing loud booming or popping sounds from underneath the vehicle—sometimes at speeds as low as 65 mph. The expanded tank warps and damages the vehicle frame; in multiple cases, dealers and manufacturer engineers have deemed the vehicle non-repairable. Owners report that gasoline enters the cabin, causing strong odor; one owner's child suffered burns and inhalation injuries from hot fuel fumes escaping beneath the rear seat.
Refueling becomes impossible as the tank expands—fuel spills from the filler neck or won't enter at all. Fuel gauges read incorrectly, and check engine lights activate. When owners open the fuel door, pressurized air releases violently, and the tank continues bubbling. Investigation by dealers and a manufacturer engineer confirmed that 2021–2023 Kia K5 fuel tanks lack a pressure relief valve, allowing dangerous internal pressure buildup.
NHTSA Campaign 25V794000 (Fuel System, Gasoline) was issued; however, repair parts remain on backorder months after recall notification. Dealers retain affected vehicles as safety hazards. Manufacturers have offered buybacks but at amounts some owners reject. Multiple vehicles have been declared total loss; no repairs have been completed in these narratives.
Failure modes owners describe
Fuel Tank Expansion and Structural Damage
Fuel tank expands in multiple locations, bending sub-frame, damaging frame alignment, and rendering vehicle non-repairable. Owners report the tank was manufactured without a pressure relief valve, allowing internal pressure to build unchecked.
When: 17,857 miles to 77,000 miles; some cases reported at 40,000–70,000 miles
Symptoms owners cite: Loud popping or booming sounds from underneath vehicle; Loss of motive power; Fuel tank makes loud explosion sound; Rear seat cushions prop upward; Fuel tank bubbling when opened; Fuel gauge drops while driving; Fuel spills from filler neck when refueling
Codes mentioned: P0XXX (unspecified emission code causing inspection failure), Code for defective valve with excessive air
Repairs/costs cited: Fuel tank replacement required; frame straightening or replacement needed. Multiple owners report vehicles deemed total loss or non-repairable; repairs not completed.
Recalls/TSBs owners mention: NHTSA Campaign Number 25V794000 (Fuel System, Gasoline). Manufacturer confirmed fuel tanks manufactured without pressure relief valve (2021–2023 Kia K5). Dealer engineers determined vehicle non-repairable; manufacturer offered buyback, recall issued but parts on back order.
Fuel System Odor and Air Pressure Buildup
Gasoline odor enters cabin and surrounds exterior of vehicle; owner reports exposure to fumes that caused burns and inhalation injuries. Related to pressure buildup and potential fuel vapor escape.
When: Various, as early as 17,857 miles; at 70,000 miles reported medical injury
Symptoms owners cite: Strong fuel odor inside cabin; Fuel odor surrounding exterior; Hot fuel fumes escaping from beneath seat; Black specks (soot/residue) stuck on child's legs; Burns to rear passenger child's legs from fumes; Continued headaches in occupants (rear seat)
Repairs/costs cited: One child required medical attention for thermal/chemical burns from fuel fumes and inhalation exposure.
Recalls/TSBs owners mention: Manufacturer notified; buyback offered with medical expense reimbursement for injured child.
Fuel Refueling Malfunction and Tank Level Sensor Failure
Gasoline fails to enter tank when refueling; fuel gauge displays incorrectly despite full tank. Linked to expanded tank restricting fuel inlet or sensor circuit malfunction from tank deformation.
When: 45,000–70,000 miles
Symptoms owners cite: Fuel not entering tank during refueling; Fuel gauge indicates empty when tank is full; Low fuel warning light intermittent; Abnormal fuel level dropping while driving
Repairs/costs cited: Dealer diagnostic confirms fuel tank expansion; specific repair costs not cited. Vehicles held at dealer, not released for safety.
Recalls/TSBs owners mention: NHTSA Campaign 25V794000 issued; vehicles retained at dealer as safety hazard; buyback required per manufacturer policy.
Check Engine Light and Valve Air Pressure Fault
Check engine warning illuminates intermittently; code reader reveals defective valve with excessive air pressure. Likely indicates fuel tank vent or canister malfunction secondary to tank expansion.
When: 77,000 miles
Symptoms owners cite: Check engine warning light flashes intermittently; Code reader diagnosis: defective valve with excessive air; Vehicle hesitation on acceleration; Check engine light illuminates after loud booming from vehicle
Codes mentioned: Valve air pressure fault code (specific code not provided)
Repairs/costs cited: Vehicle failed recall inspection; held at dealer; no repair completed.
Recalls/TSBs owners mention: NHTSA Campaign 25V794000 notified; vehicle included in recall; dealer retained vehicle after failed inspection.
Synthesized from 12 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 7 most recent
The contact owns a 2023 Kia K5. The contact stated that while driving at various speeds, the check engine warning light intermittently flashed on the instrument panel. The contact used a code reader to diagnose the failure and received a code for a defective valve with an excessive amount of air. The contact then stated that while driving 80 MPH, there were three loud booming sounds coming from…
The contact owns a 2023 Kia K5. The contact stated that while driving at various speeds, there was an abnormal sound coming from the vehicle, the fuel level was lowering, and a fuel odor was entering the cabin of the vehicle. No warning light was illuminated. Upon further inspection, the contact became aware that fuel was leaking from the vehicle onto the ground. The contact received notification…
The contact owns a 2023 KIA K5. The contact received notification of NHTSA Campaign Number: 25V794000(Fuel System, Gasoline); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure.
The contact owns a 2023 Kia K5. The contact received notifications of NHTSA Campaign Numbers: 25V794000 (Fuel System, Gasoline) and 25V493000 (Structure); however, the parts to do the recall repairs were not yet available. The local dealer was contacted, and the dealer confirmed that parts were not yet available and were on back order. The manufacturer was not made aware of the issue. The contact…
The contact owned a 2023 Kia K5. The contact stated that while her son and daughter-in-law were driving, three loud bangs were heard coming from underneath the vehicle. The vehicle was pulled over to the side of the road and inspected; however, no cause for the banging sounds were found. The vehicle was then taken to a gas station to be inspected, but no cause for the sounds were found. The…
The contact owns a 2023 Kia K5. The contact stated that the interior of the vehicle had an abnormal gasoline odor. The contact stated that the gasoline odor was inside and surrounding the outside of the vehicle. The vehicle was taken to the dealer. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The contact stated the vehicle was previously taken to a dealer a…
The contact owns a 2023 Kia K5. The contact had received an unknown Emissions/Fuel Tank recall. The vehicle was then taken to a dealer, where the vehicle was inspected and failed the inspection. The vehicle was deemed unsafe and inoperable due to an expanded fuel tank. The vehicle was not repaired due to the recall not being honored by the dealer and manufacturer because the vehicle failed the…
Had fuel system trouble with your 2023 Kia K5?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2023 Kia K5?
It's a meaningful issue. 12 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
At what mileage does the fuel system typically fail?
Based on the 12 complaints filed, fuel system issues most often appear around 82,837 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2023/Kia/K5.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.