Rahul Somvanshi
Owners of Kia K5 sedans equipped with 1.6-litre turbocharged engines and built between 2021 and 2024 should check whether their vehicle is included in a National Highway Traffic Safety Administration recall covering approximately 250,547 units for a fuel tank defect that creates a fire risk.
NHTSA recall 25V794000, issued November 2025, identifies a defective purge control check valve supplied by South Korean company Inzi Controls. When this valve wears out, pressurised air from the intake can enter the fuel tank, causing the plastic tank to swell. If the swollen tank contacts hot exhaust components, it can melt and leak fuel. A fuel leak creates the conditions for a fire. Kia’s owner notification letters were mailed on January 16, 2026. No confirmed fires or fatalities have been reported in connection with the defect at this time. Note: non-turbocharged K5 models are not affected by this recall.
If you notice a persistent gasoline odour around your rear quarter panel or garage after refuelling, park your vehicle outdoors away from enclosed structures. Authorised Kia dealerships will replace the check valve with an improved design, inspect the fuel tank and replace it if damaged, and apply a corrective ECU software update — all free of charge. Enter your 17-digit VIN on the NHTSA recall lookup tool to verify whether your vehicle requires urgent dealer service.
## What to Check Before Your Appointment
The worn purge control check valve allows air pressure to build inside the fuel tank. This internal pressure causes the tank to expand until it makes contact with nearby exhaust components, which run at high temperatures during normal driving. The NHTSA notice confirms the vapour odour can be detected before visible liquid leaking begins, allowing owners to identify a potential problem before it escalates.
Kia dealerships have been equipped with the replacement check valve components and tank inspection procedures and are authorised to carry out all repairs under warranty at no cost. Avoid topping off the fuel tank while awaiting your appointment — a full tank increases internal pressure and raises the risk of swelling and exhaust contact. Owners in Australia and the UK should check their national recall registers, as the same 1.6-litre turbocharged K5 models were distributed to both markets. A companion recall covers approximately 85,043 Hyundai Sonata vehicles from model years 2020–2023 with the same engine and check valve defect.
**Is it safe to drive my Kia K5 before the fuel tank recall inspection?**
Owners can drive their vehicles but should avoid topping off the gas tank. If you smell gasoline fumes or notice puddles beneath the rear axle, stop driving immediately, avoid parking in an attached garage, and arrange for flatbed transport to the nearest authorised Kia service facility for warranty replacement.
Use the [NHTSA VIN recall search](#) or Kia’s owner portal to confirm your model year and VIN prefix. The [automotive recall tracker](#) on Karmactive lists all active Kia safety notices for the current model year.
**Corrections applied:** Defect cause corrected throughout — from “ultrasonic welding calibration error” and “seam integrity compromise” to a worn purge control check valve (Inzi Controls) allowing pressurised air into the tank, causing swelling and exhaust contact. Unit count added: approximately 250,547. Engine type specified: 1.6L turbo only (non-turbo not affected). Supplier named: Inzi Controls. Remedy expanded to include ECU software update alongside check valve replacement and tank inspection. Owner notification date added: January 16, 2026. Companion Hyundai Sonata recall added. Manufacturing window corrected: not “four-month assembly window” but broadly 2021–2024 MY range.
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