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Kia is recalling over 250,000 K5 sedans (model years 2021-2024 with the 1.6L turbo engine) because a faulty check valve in the EVAP emission control system can allow turbo pressure in the intake manifold to flow backwards into the fuel tank, causing it to swell like a balloon. This may cause the fuel tank to crack or burst, creating a serious risk of fire due to the fuel leaking out of the tank.
Warning signs may include a "popping sound" from the fuel tank, a "Check Engine" light, or the vehicle running rough.
A badly swollen fuel tank may also press up against the floor panel under the rear seat causing the floor to bulge and push the bottom part of the rear seat upward from its normal position.
This creates a dangerous situation because of the risk of fuel leakage if the fuel tank fails.
If you smell gasoline or see fuel dripping under your car, DO NOT start the engine or attempt to drive your car.
Have your car towed to a KIA dealer for inspection and repair.
If the bottom portion of the rear seat appears to be pushed up from its normal position, it may indicate a distorted floor due to a swollen fuel tank.
Even if you do not smell gasoline or see any visible leaks, your car is probably not safe to drive if the tank is in a swollen condition. The potential for the tank to fail is too great, so don't take any changes and have it towed to a KIA dealer for inspection and repair.
You can have any repair shop check the fuel tank on your car, but it will cost you because only a KIA dealer can do the authorized recall repair work.
The recall covers 2021-2024 Kia K5 models with a 1.6L turbocharged gasoline direct injection engine, manufactured between March 27, 2020, and January 23, 2024. The recall does NOT affect naturally-aspirated (non-turbo) K5 models.
If the bottom of the back seat is pushed up out of its normal position, you may have a swollen gas tank.
Location of the gas tank under the KIA K5. Note how close it is to the exhaust system.
This is what a replacement fuel tank looks like.
The swollen fuel tank problem is caused by a faulty EVAP system purge control check valve. Some check valves apparently can't withstand the boost pressure generated by the engine's turbocharger.
In a normally-aspirated engine, the intake manifold is usually under vacuum, not pressure. But in a turbocharged engine, the intake manifold is pressurized by the turbo to increase airflow for more power when accelerating. In the KIA K5 1.6L turbo engine, the boost pressure can surge up to 14 to 16 PSI when you step on it.
If the check valve inside the EVAP purge control valve is weak or defective, turbo boost pressure inside the intake manifold can force its way past the check and travel all the way back to the fuel tank through the tank's EVAP vent plumbing. The fuel tank is not designed to withstand this kind of pressure, so it bulges outward and swells so much it may be permanently deformed. The swollen fuel tank may push up against the thin metal floor panel under the rear seat, which in turn may push the bottom of the rear seat up and out of its normal position.
Eventually, the swollen fuel tank may crack or burst and leak fuel. The tank may also expand so much that it rubs up against the nearby exhaust pipe, increasing the risk of fire if there is a fuel leak.
The dealer will perform a FREE inspection of the fuel tank and EVAP purge control valve.
The original purge control valve will be replaced with an improved design to reduce the risk of any future problems.
If the gas tank shows any signs of swelling or damage, it will also be replaced free of charge.
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