Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2023 Kia K5 owners, lightly cleaned up (personal details are redacted by NHTSA).
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 rear end of the vehicle. The contact inspected the vehicle but found no external damage; however, the vehicle was hesitating while depressing the accelerator pedal. The contact then received a call from the dealer and was informed that the VIN was included in NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The contact was instructed to bring the vehicle to the dealer for immediate service. …
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 of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. Two local dealers were contacted: Boniface Hiers Kia (3890 W New Haven Ave, Melbourne, FL 32904). The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure. The failure mileage was approximately 45,000.
The contact owns a 2023 Kia K5. The contact stated while driving at an undisclosed speed, the contact heard a loud ticking sound coming from the fuel tank. The check engine warning light was illuminated. The vehicle was taken to the dealer where the vehicle was diagnosed as a failure with fuel tank expansion. The contact was contact informed that the fuel tank expansion needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 270,000.
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 inspection. The manufacturer was notified of the failure. The failure mileage was approximately 40,000.
The contact owns a 2023 Kia K5. The contact stated that after fully refueling the vehicle, the fuel gauge incorrectly indicated that the fuel tank was empty. The vehicle was taken to the dealer, where it was diagnosed, and the dealer associated the failure with NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline); and the VIN was included in the recall. The vehicle was not yet repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 60,000.
The contact owns a 2023 Kia K5. The contact stated that while driving at 65 MPH in hot weather, a loud popping sound came from underneath the vehicle. The vehicle lost motive power. The check engine warning light was illuminated. The contact coasted into a ditch and inspected the vehicle, but no exterior damage was found. The vehicle was restarted and driven to a gas station. The check engine warning light was no longer illuminated. The vehicle was taken to the dealer, but the cause of the failure could not be determined. The failure persisted and the fuel gauge level dropped while driving. The contact pulled over and placed a bag under the vehicle to check for fuel leaks, but found none. The contact stated that the vehicle failed state vehicle inspection due to an unknown emission code. …
In June 2025, while driving my 2023 Kia K5 (VIN: [redacted] ) at highway speeds on [redacted], the fuel tank suddenly imploded. A loud bang caused the rear seats to lift, startling me and my passengers. The car lost power, and braking too hard risked leaving us stranded in fast-moving traffic. I narrowly avoided a crash while trying to maneuver us to safety. This vehicle was previously recalled by Kia in April 2024 for a fuel tank defect affecting ~236,000 vehicles. I took it to Gunther Kia in Davie, FL for inspection, and they claimed it was fixed. In March 2025, I returned to Hollywood Kia because of popping sounds and a check engine light. They diagnosed and "repaired" a purge control valve but failed to address the underlying defect. Despite these repairs, the catastrophic failure still occurred. The vehicle is now completely inoperable and irreparable. …
I am submitting an update regarding my 2023 Kia K5 (VIN: [redacted] ). On July 25, 2025, I delivered the vehicle to my dealership for recall-related fuel tank issues. As of today (61 days later), the vehicle remains out of service and undrivable. The dealership opened a Kia Techline case, confirming they are unable to repair the fuel tank issue and that it is a safety hazard. Kia North America has not provided any resolution, despite repeated contacts and escalation of my case (Kia Claim #25408405). I have incurred significant financial hardship, including paying the monthly car loan, maintaining minimum insurance, and paying for out-of-pocket rental expenses while Kia holds my vehicle. I also contacted Kia Finance, and they confirmed my hardship notes are documented in their system. This situation is ongoing, with no repair performed, no reimbursement, and no safe solution provided. …
I am submitting this complaint regarding a serious fuel system defect involving my 2023 Kia GT-Line. The vehicle was subject to a manufacturer recall due to fuel tank expansion. Kia has acknowledged that the fuel tank expands beyond normal specifications, creating a potential safety hazard. As a result of this defect, Kia of America determined that the vehicle is not repairable and declared it a total loss. Kia has offered to buy back the vehicle and forgive the remaining loan balance, which confirms that the manufacturer considers the defect serious and unresolvable. A fuel tank expansion defect presents a significant safety concern, including the risk of fuel leaks, fuel system failure, inaccurate fuel readings, and potential fire hazards. This defect occurred under normal vehicle use and was not caused by misuse or modification. …
The contact owns a 2023 Kia K5. The contact stated that while driving at an undisclosed speed, there was a fuel odor inside the vehicle. Occasionally, the low fuel warning light was illuminated. While attempting to refuel the vehicle, gasoline was not entering the fuel tank as intended. The fuel odor inside the vehicle grew stronger. The failure was persistent. The vehicle was taken to the dealer, where the contact was informed that the failure was severe. The contact was informed that, due to the severity of the failure, the vehicle could not be released to the contact. The contact was informed that the fuel tank had expanded severely and that the expanded fuel tank had shifted the frame of the vehicle. The contact was provided with a loaner vehicle. The contact stated that the contact's [redacted] son had been complaining about headaches for several months. …
Related recalls
Fuel system, gasoline
Kia America, Inc. (Kia) is recalling certain 2021-2024 K5 vehicles. A damaged check valve can allow air to enter the fuel tank, causing it to expand and contact hot exhaust components, melting the tank.
Remedy: Dealers will replace the check valve. The fuel tank will be inspected for damage and replaced as necessary. All repairs will be performed free of charge. Owner notification letters were mailed January 16, 2026.
Fuel System complaints in other K5 years
Frequently asked questions
How common are fuel system problems on the 2023 Kia K5?
NHTSA has 55 complaints about the fuel & propulsion system of the 2023 Kia K5, 50% of the model year's 110 complaints.
Is there a recall for 2023 Kia K5 fuel system problems?
Yes — NHTSA recall 25V-794 (fuel system, gasoline, Nov 17, 2025). Recall repairs are free at authorized dealers.
At what mileage do 2023 Kia K5 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 60,000 miles, and 14% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 0 fires and 9 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.