2021 Kia K5

Vehicle experienced a severe engine misfire (P0302), rough running, and loss of power while driving. Dealership confirmed the Purge Control / PCV valve failed (replaced under Recall SC356 / 25V-794), but charged out-of-pocket for the Cylinder 2 ignition coil that failed as a direct result of the PCV valve failure. The Dealership replaced the Purge Control/PCV valve at this time - the recall was not resolved until this time - I wasn't even aware of this recall until this incident. This ocurred on XXX and as a result I was stranded 1500 miles from home in [XXX] (I live in [XXX] and was driving the vehicle to my son at the University of XXX in [XXX]. The car was running fine until I stopped briefly in [XXX] and when I started the car, the engine light came on and the car's engine started sputtering and losing power as I was driving. Due to the fact that I was not in the vicinity of any Kia Dealerships or any open mechanics as it was Labor Day, I somehow managed to drive the car all the way to [XXX] as this was the closest dealership (over 120 miles away from where I was when the engine light came on). Once I arrived in [XXX], I checked into a hotel. I then attempted to drive to the nearest Kia Dealership the following morning at approximately 6:45 am and the engine light started flashing. I knew that this meant I was not able to safely drive the car even the additional 5 miles to the dealership so I pulled over and called Kia Roadside assistance and the dealership. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The panoramic glass of the sunroof exploded out while driving on the freeway. A large piece of the glass exploded outwards and could not be retrieved. It was not damaged by external impact as other cars were not close enough to kick back rocks, debris, etc. The sunroof glass had no damage prior to shattering. Hazard lights were turned on to drive to the nearest exit, and subsequent accident happened when a speeding vehicle crashed into my vehicle. This happened on the freeway driving 75 mph causing a road hazard, the glass that shattered out could have hit vehicles behind my vehicle, causing damage or a crash. The vehicle has not been inspected by the dealership or insurance company as of yet. There were no warning signs or symptoms of failure.

The contact owned a 2021 Kia K5. The contact stated that while driving at an undisclosed speed, the vehicle stalled. The failure was a recurring failure. The message "Not Emissions Ready" was displayed. The vehicle was towed. The dealer was contacted; however, the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 20,000.

I am reporting a violation of the National Traffic and Motor Vehicle Safety Act by Ball Kia (National City, CA). The dealer tried to deny service for recall 25V794000 (SC356) for a melted, leaking fuel tank, fabricated a false diagnostic narrative of road impact to exploit me, and tried to charge $3,000 out-of-pocket for a federally mandated free repair.My vehicle has a severe fuel leak from a compromised fuel tank. Ball Kia service refused the recall, claiming "external aesthetic factors" or "road debris impact" caused it, and pressured me to tow it away.Using my military infantry experience in mechanical damage assessment, I inspected the vehicle in the service bay. I verified there is absolutely no puncture, tear, scrape, or kinetic impact on the fuel tank assembly. The dealer pointed to a split in the fuel tank protector panel, but a professional assessment shows this is false. The plastic protector panel failed due to extreme thermal exposure; the expanding tank pressed it against the hot exhaust, causing it to melt and tear under heat/pressure, not a kinetic strike.The tank itself is structurally melted and deformed with zero signs of road impact. This physical evidence matches the exact defect mechanism in the NHTSA recall: a deteriorated check valve allows intake pressure into the fuel tank, causing it to expand, hit hot exhaust components, melt, and leak.Only after I read the exact NHTSA safety risk and remedy text verbatim did the service manager back down and open a manufacturer Tech Line.Because I had to fight a fraudulent diagnosis to get this safety mandate acknowledged, I fear internal dealership retaliation, being blacklisted, or receiving a subpar, dangerous repair. Leaving a high-risk fire defect unaddressed is a public safety hazard. Please audit Ball Kia's handling of campaign 25V794000 to ensure they are not endangering or defrauding other affected Kia K5 owners.

The contact owns a 2021 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The vehicle was taken to a dealer for the recall repair. The contact was struggling to receive updates on the status of the vehicle. The contact spoke with a service clerk and was informed that the repair was going well and that only one recall test remained. However, a supervisor later called and stated that the recall repair could not be completed. The vehicle could not be repaired. The vehicle was no longer functional due to a high risk of catching fire from fuel tank swelling caused by the recall defect. The contact stated that prior to the dealer visit, the vehicle had no issues but became inoperable. The vehicle was not repaired, and the dealer stated that the vehicle could not be repaired. The manufacturer was made aware of the issue. The failure mileage was approximately 111,000.

Recall NNK post-repair failure. Dealership: Kia of Valdosta (RO# XXX). After ECU update NNK-02-0118, my K5 suffered a severe loss of acceleration and torque. The car cannot safely merge on highways. The dealer’s own live scan data sheet proves that at 4,997 RPM under full load, the Turbo Recirculation (Dump) Valve reads "OFF". The factory tool key explicitly states (OFF = Open). The service manager is misreading the tool, claiming "OFF" means closed, and refuses to fix it. The boost gauge only rises under heavy floor acceleration, proving an uncalibrated boost leak. I have uploaded a photo of the technician's data sheet directly to the attachments and will also drop link to videos of my car in normal and sport mode. I have also opened Kia Corporate Case #XXX. I demand a corporate Regional Technical Manager review this data and authorize a Turbocharger Recirculation Valve (RCV) and Wastegate Adaptation Relearn at an alternate dealer...... 1. [XXX] 2. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2021 Kia K5. The contact stated that while driving approximately 55 MPH, the fuel gauge suddenly went from one-half tank to empty. The fuel level displayed 120 miles to empty. The contact attempted to refuel the vehicle but was unable to add fuel to the tank. The contact also stated that the oil warning light and the TPMS warning light was illuminated. The contact associated the failure with NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 119,185.

The contact owns a 2021 Kia K5. The contact stated that there were failures with the spark plugs. While driving at an undisclosed speed, the vehicle shuddered, and the engine sputtered. The contact stated that fuel spewed out of the filler neck while refueling the vehicle, and the fuel gauge incorrectly indicated that the fuel tank was empty after refueling. Additionally, there was an abnormal egg and sulfur odor coming from the vehicle with the check engine warning light intermittently illuminated. The contact stated that the vehicle was taken to a local dealer and inspected under NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). During the inspection, the seats were damaged. The vehicle was not repaired. The manufacturer was notified of the failure and was negotiating a buyback. The failure mileage was approximately 120,000.

The contact owns a 2021 Kia K5. The contact received notification of NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while driving approximately 70 MPH, upon further inspection the fuel level was lowering unexpectedly. The check engine warning light was illuminated. The vehicle was taken to a local Auto Zone and was scanned with an OBD2 scanner and diagnosed with a recall-related failure. The vehicle was taken to a local dealer, where it was diagnosed with an expanded fuel tank; however, the vehicle was not repaired because the dealer was short-staffed. The dealer associated the failure with NHTSA Campaign Number: 25V794000 (Fuel System, Gasoline). The manufacturer was made aware of the failure; a case was filed; however, no assistance was provided. The failure mileage was approximately 90,000.