2021 Kia K5 Fuel System

The contact owns a 2021 Kia K5. The contact stated that while driving 65-70 MPH, the fuel gauge displayed zero miles to empty. The contact pulled into the nearest gas station, and while attempting to add fuel to the vehicle, the contact became aware that there was fuel leaking out of the fuel tank outlet, and the gas pump nozzle was stopped. The contact was unable to refuel the vehicle. The contact stated that after returning to drive, the fuel gauge indicated 100 miles to empty. The vehicle was taken to the dealer for the recall repair under NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline), and the dealer advised the contact that the manufacturer had instructed the contact not release the vehicle to the owner due to the recall. While diagnosing the vehicle, a technician at the dealer sent a photo displaying that the rear driver's side seat had melted internally due to the fuel tank overheating. Additionally, the dealer informed the contact that the SC288 Alpha Campaign had failed. The vehicle remained at the dealer for four months; however, the manufacturer later sent a letter advising the contact that the vehicle could not be repaired, and a buyback was suggested. The manufacturer offered to reimburse the down payment for the vehicle. The contact stated that the buy-back offer was unsatisfactory. The contact declined the offer, and the manufacturer then threatened to tow the unrepaired vehicle back to the residence. The contact stated that the manufacturer had failed to honor the recall repair. The vehicle was not repaired. The failure mileage was approximately 145,000.

The contact owns a 2021 Kia K5. While driving at an undisclosed speed, the contact heard a loud explosion coming from the rear of the vehicle, and there was a dragging sound coming from the vehicle. The contact stated that the rear seat raised up into the air with children seated in the seat. The contact became aware of fuel leaking and that the fuel tank was hanging down. The vehicle was towed to the residence and was later driven to a KIA dealer. The manufacturer was made aware of the failure. The approximate failure mileage was 116,000.

The contact owns a 2015 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The contact stated that days before the vehicle was scheduled for an unknown recall repair, while refueling, the contact observed gasoline pouring out of the tank. The vehicle was taken to a dealer, where it was diagnosed, and determined that the fuel tank had expanded due to fumes being trapped inside. The vehicle was not repaired due to parts not being available for the repair. The contact stated that the manufacturer has exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure. The failure mileage was approximately 70,000.

The contact owns a 2021 Kia K5. The contact stated that fuel odor was entering the cabin of the vehicle. The contact stated that the rear passenger’s seat seemed to be inflated. While driving approximately 70 MPH, the contact became aware of fuel squirting out of the fuel filler neck. The fuel gauge fluctuated from full tank to half tank or empty. There was no warning light illuminated. The fuel odor became stronger, and the contact pulled over to the side of the road at a rest stop. A mobile service tech arrived to inspect the vehicle but found no failures. The contact continued driving to the residence. The vehicle was taken to the dealer, who found that the fuel tank and fuel line had failed and needed to be replaced. The dealer sent a photo to the manufacturer to confirm the necessary repair. The vehicle was not repaired. The manufacturer was informed of the failure and determined that the fuel tank and PCV valve were swollen and needed to be replaced. The manufacturer offered a buy-back for the vehicle and opened a case. The failure mileage was unknown.

The contact's daughter owns a 2021 Kia K5. The contact stated that while the contact’s son-in-law was driving, the fuel level indicator failed to function as intended. The contact’s son-in-law noticed that the miles available indicator stated that there were 430 miles until empty. The contact’s son-in-law stated that after driving for approximately 20 minutes, the miles available indicator indicated that the miles had decreased by 50 miles. The contact’s son-in-law drove the vehicle to a nearby gas station, and inspected the fuel tank cap, and confirmed that that fuel cap was sufficiently tightened. The contact's son-in-law proceeded to drive for another hour and the miles available indicator decreased by 200 miles. The contact stated that there were three occupants, including an infant, seated in the rear seat of the vehicle. The contact’s daughter, who was seated in the rear seat, noticed heat on the back of her legs. In addition, the contact’s daughter noticed an abnormal ticking sound and the rear seat independently raised up. The contact’s daughter stated that the failure was persistent. The vehicle was driven to the shoulder of the road. The contact’s son-in-law inspected the vehicle. The contact’s son-in-law and daughter switched seats. The contact stated that the daughter had driven a short distance, and the miles available dropped from 200 to 50 miles. The contact instructed the daughter to stop and exit the vehicle. The contact stated that the fuel tank level indicated the fuel was empty and the check engine warning light illuminated. The contact’s son-in-law was instructed to turn the vehicle off and how to inspect the vehicle. Upon inspecting the vehicle, the contact’s son-in-law was instructed to remove the rear seat. The contact’s son-in-law noticed that the fuel tank was swollen. The contact’s son-in-law was instructed to remove the fuel cap to release the pressure. The vehicle was towed to the dealer; however, the vehicle was not inspected. The contact was informed of an unknown recall; however, the VIN was not under recall. The failure had occurred while the family members were traveling and immediately after the fuel tank had been refilled. The manufacturer was not made aware of the failure. The failure mileage was approximately 93,000.