Some 2021–2024 Kia K5s and 2020–2023 Hyundai Sonatas are included in separate U.S. recalls over a check valve that can allow pressure into the fuel tank. The tank may expand, contact hot exhaust components and melt, potentially causing a fuel leak and increasing fire risk. The dealer repairs are free, but model year alone does not establish whether a particular car is covered. Check its VIN with the manufacturer or NHTSA and contact a dealer.
Which Kia K5 and Hyundai Sonata recalls are involved?
The recalls are separate campaigns, with different model-year and vehicle-population scopes. Their potentially involved counts come from manufacturer filings submitted to NHTSA in 2025; they are not counts of vehicles confirmed to have the defect or of completed repairs.
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| Vehicle and campaign | Potentially involved scope | Reported warnings |
|---|---|---|
| Kia K5 — NHTSA 25V794; Kia campaign SC356 | 250,547 potentially involved 2021–2024 K5s with a 1.6L turbocharged gasoline direct-injection engine, manufactured at Kia Georgia from March 27, 2020, through January 23, 2024. Kia’s filing estimates 1% with the defect. Kia’s NHTSA filing | Popping sound from the fuel-tank area, Check Engine Light, and/or rough running. Kia’s NHTSA filing |
| Hyundai Sonata — NHTSA 25V796; Hyundai campaign 286 | 85,043 potentially involved 2020–2023 Sonatas. Hyundai says the subject 1.6L engine was discontinued during 2023 production; 2024-and-later vehicles use a different engine and check-valve design. Hyundai’s NHTSA filing | A pop from the rear, malfunction-indicator light, failure to start, or fuel odor. Hyundai’s NHTSA filing |
These model-year ranges are not a VIN eligibility list. Kia says its affected population is not organized by VIN sequence, so owners need to look up the individual vehicle rather than infer coverage from year or model alone.
Why can the fuel tank melt?
In both filings, the potential cause is a purge-control-system check valve that can wear or deteriorate and malfunction. It may let pressurized air from the intake or turbocharger enter the fuel tank. The pressure can cause the tank to expand and touch hot exhaust components; prolonged operation in that condition may lead to localized melting and a fuel leak.
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A leak can increase fire risk. In its acknowledgment of Kia’s recall, NHTSA stated: “A melted fuel tank can leak, increasing the risk of a fire.”
How to check whether your vehicle is included
- Find the vehicle’s 17-character VIN. It is commonly shown on the driver-side dashboard near the windshield and on vehicle paperwork.
- Enter the VIN in the Hyundai recall lookup for a Sonata or the NHTSA recall lookup. Hyundai’s lookup searches recalls and service campaigns; NHTSA provides recall-checking guidance.
- If a recall appears, contact a Kia or Hyundai dealer to confirm the campaign status and arrange the repair. The manufacturer or dealer can confirm whether the remedy has already been completed.
A model-year match is not confirmation of eligibility, and a general recall notice cannot establish the status of an individual car without its VIN. Hyundai’s VIN lookup page, updated October 6, 2026, says the preferred Hyundai dealer will complete covered repairs at no charge.
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What does the free recall repair include?
Kia K5: campaign SC356
Kia dealers will replace the check valve, inspect the fuel tank and replace it if necessary, and ensure the latest ECU software is installed. Kia says the work is free. The filing listed January 16, 2026, as the planned date for remedy-owner notifications; that schedule does not confirm that a particular owner received a notice.
Hyundai Sonata: campaign 286
Hyundai dealers will inspect and replace the check valve as needed, inspect and repair the fuel tank and surrounding components, and inspect or update ECU software as a preventative measure. The remedy is at no cost. Hyundai’s filing also listed January 16, 2026, as the planned owner-notification date; it does not establish an individual vehicle’s status.
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What should owners do if they notice a warning?
Possible warning signs listed in the filings include a pop or popping sound, a fuel odor, an illuminated engine warning light, rough running, or failure to start. Check the VIN and contact a dealer about the recall if you notice these symptoms. NHTSA advises owners to follow any interim guidance in their recall notice and contact a local dealership to have recalled parts fixed for free.
The filings do not designate these vehicles as “Do Not Drive” or “Park Outside.” Do not assume either instruction applies to your car; follow any interim guidance provided in your own recall notice or by the manufacturer.
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What the filings say about reported incidents
Hyundai reported seven related fuel-tank leak reports in the United States and Canada in its 2025 filing. It reported no attributable crashes, injuries, or fatalities in those markets as of submission. These are figures reported in that filing, not current totals for repairs or incidents.
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- Trustworthy design - backed by team of product specialists in the United States
- Ensure fit - to make sure this part fits your exact vehicle, input your make, model and trim level into the garage tool
Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.
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