Recall 25V794 affects 250,547 2021-2024 Kia K5 vehicles for a fuel tank leak and fire risk. Repair is free at any franchised Kia dealer.
Kia is recalling 250,547 2021-2024 K5 sedans because a damaged check valve can let air into the fuel tank, causing the tank to expand, touch hot exhaust parts, and melt. A melted fuel tank can leak and increase the risk of a fire; Kia dealers will complete the recall repair free of charge.
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What's wrong?
The purge control system check valve on the 2021-2024 Kia K5 is part of the gasoline fuel system. It is a one-way valve in the hose assembly that controls vapor and air flow so the fuel tank is not pressurized the wrong way during normal engine operation.
In affected K5 vehicles with the 1.6L Turbocharged Gasoline Direct Injection engine, the check valve deteriorates. Once it is damaged, air enters the fuel tank and the tank expands. The expanded tank contacts hot exhaust components, which melts the tank material and creates the safety concern described in NHTSA campaign 25V794. Kia's repair uses an improved-design check valve.
Owners can notice a popping sound from the fuel tank area, a Check Engine Light, or rough running. Those signs point to a purge control problem and the vehicle needs dealer inspection under the recall.
Who's affected?
Spans the 2021 through 2024 K5 model years, all tied to the check valve and hose assembly in the fuel system.
| 2024 Kia K5 | fuel system |
|---|---|
| 2023 Kia K5 | fuel system |
| 2022 Kia K5 | fuel system |
| 2021 Kia K5 | fuel system |
| Units affected | 250,547 |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific sedan is included.
What's the safety risk?
A melted fuel tank can leak fuel and increase the risk of a fire. Treat a popping sound near the fuel tank, a Check Engine Light, or rough running as a reason to call the dealer before taking another trip. Repair is free at any franchised Kia dealer.
What should I do?
- Check your VIN to confirm your 2021-2024 Kia K5 is included in this recall.
- Contact a franchised Kia dealer to schedule the free check-valve replacement and fuel-tank inspection that address the tank expansion and fuel-leak fire risk.
- Bring any Kia owner notice to the appointment and reference recall number 25V794 when you call.
- Call Kia customer service at 800-333-4542 with questions and mention Kia recall SC356.
What happens at the repair
At the dealer, a Kia technician replaces the check valve, then inspects the fuel tank for damage from expansion and heat contact. If the tank is damaged, the technician replaces it as part of the same recall repair. Parts and labor are covered. Kia uses its general reimbursement plan on file for owners who already paid for a related repair before the recall notice. Bring repair orders, receipts, and any diagnosis paperwork to the service desk, or contact Kia customer service at 800-333-4542 for claim instructions.
| Reimbursement | Reimbursement available |
|---|
Timeline
| November 17, 2025 | NHTSA published the recall |
|---|---|
| November 18, 2025 | Dealer notification began |
| November 18, 2025 | Dealer notification ended |
| December 1, 2025 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| January 16, 2026 | Owner notification mailed |
Frequently asked questions
What is recall 25V794?
Recall 25V794 covers 250,547 2021-2024 Kia K5 vehicles with a damaged check valve that can let air enter the fuel tank. The tank can expand, contact hot exhaust components, melt, and leak fuel, increasing fire risk. Kia dealers will replace the check valve for free.
What should I do if my 2021-2024 Kia K5 is on this recall?
Check your VIN to confirm your specific Kia K5 is included in recall 25V794. If it is, contact a franchised Kia dealer to schedule the check valve replacement and fuel tank inspection. Reference recall 25V794 or Kia recall SC356 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. Kia dealers will replace the check valve for free, inspect the fuel tank for damage, and replace the fuel tank if the recall inspection shows damage.
What is the safety risk?
The safety risk is a fuel leak and fire. In affected 2021-2024 Kia K5 vehicles, a damaged check valve can let the fuel tank expand until it contacts hot exhaust components. That contact can melt the tank and allow fuel to leak.
What if I bought my Kia K5 used?
The free recall repair still applies. Federal recall law follows the vehicle, not the first owner. Check your VIN to confirm whether your specific K5 is included, then contact a franchised Kia dealer and give them recall 25V794 or Kia recall SC356.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V794000 |
|---|---|
| Kia customer service | 800-333-4542 |
| NHTSA recall # | 25V794 |
| NHTSA recall # (full) | 25V794000 |
Source documents
-
Download Quarterly Report (PDF) - Download Owner Notification Letter (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
- Download Recall Document (PDF) (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 19, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →