Kia America announced on Nov. 17 that it was recalling more than a quarter-million vehicles manufactured between 2020 and 2024 due to problems with the vehicles’ fuel tanks that could cause them to melt.
The notice was issued a day before Kia's parent company, Hyundai, announced a similar recall of more than 85,000 vehicles due to the same issue.
The recalled automobiles all have the 1.6-liter turbocharged four-cylinder gasoline engines as opposed to vehicles equipped with the larger 2.5-liter engine.
According to the NHTSA, the vehicles’ purge control system check valve, which directs airflow from the charcoal canister in the evaporative emission control system to the engine, could deteriorate over time. If that happens, pressurized air could flow into the fuel tank, causing it to expand and come into contact with the hot exhaust pipe and lead to melting.
Drivers should be aware of a “popping sound from fuel tank area, illumination of check engine light, and/or vehicle running rough,” the NHTSA noted.
The potentially faulty valves were manufactured by Inzi Controls of Korea.
A safety inspection revealed that the vehicle’s fuel tank had melted after coming into contact with the exhaust pipe. Bench testing through early November identified potential deterioration issues with the purge control system check valve, as well as fuel tank melting due to prolonged contact with the hot exhaust pipe. To date, fires or accidents related to the issue have been reported, Kia’s safety office noted.
Drivers can take their vehicles to a Kia dealership, which will replace the check valve with an improved version and inspect and replace the fuel tank, if necessary, the NHTSA recall notice said. Kia’s K5 sedans made in 2025 are equipped with the larger engine and aren’t part of the recall.
Vehicle owners can also contact the NHTSA’s vehicle safety hotline at 888-327-4236 or contact Kia Customer Care at 800-333-4542.