Kia & Hyundai Recall Over 335,000 Vehicles – Fuel Tank Could MELT!
2021–2024 Kia K5 & 2020–2023 Hyundai Sonata (1.6T engines)
Risk of fuel tank melting and leaking due to faulty valve
FREE repair at any dealership – act now!
November 2025 – Kia and Hyundai have just announced one of their largest recalls of the year, affecting more than 335,000 vehicles in the United States because a faulty valve can cause the fuel tank to over-pressurize, expand, touch hot exhaust parts, and actually melt – potentially leading to dangerous fuel leaks and fire risk.
Which Models Are Affected?
| Brand | Model | Years | Engine | Vehicles Affected |
|---|---|---|---|---|
| Kia | K5 | 2021 – 2024 | 1.6L Turbo | 250,547 |
| Hyundai | Sonata | 2020 – 2023 | 1.6L Turbo | 85,043 |
| TOTAL | 335,590 | |||
What’s the Problem?
The issue lies in the purge control system check valve. Over time this small part can wear out and get stuck, preventing proper venting of the fuel tank. When that happens:
- Air pressure builds up inside the tank
- The plastic tank expands
- It can touch scorching-hot exhaust components
- Continued driving may cause the tank to melt locally
- Melted plastic = possible fuel leak = serious fire hazard
What Will Kia/Hyundai Do? (It’s 100% Free!)
Both companies are taking this extremely seriously. Every affected owner will receive a letter with instructions. Dealerships will:
- Inspect the purge control valve
- Replace the faulty valve FREE of charge
- Check the fuel tank for any melting or damage
- Replace the entire fuel tank at no cost if needed
No appointment yet? You can still visit any Kia or Hyundai dealer right now and they will perform the repair as soon as parts arrive (expected early 2026).
How to Check If Your Car Is Affected
- Go to the official recall lookup tools:
→ nhtsa.gov/recalls
→ hyundaiusa.com/recalls
→ kia.com/us/en/recalls - Enter your 17-digit VIN (found on driver’s door jamb or windshield)
- Results appear instantly
Owner Tips While Waiting for the Fix
- Avoid overfilling the gas tank (stop at first click)
- Park outside until repaired (just in case)
- Watch for strong fuel smell or visible leaks underneath the car
- Contact your dealer immediately if you notice anything unusual
Not the First Recent Recall – Safety First
Both brands have been proactive about safety in 2025:
- July 2025 – Over 300K vehicles recalled for loose parts falling off
- October 2025 – 135K+ Hyundai vehicles for crash-related short circuit risk
- Earlier 2025 – 200K+ Kia/Hyundai EVs for power loss issues
Despite these recalls, both Kia and Hyundai continue to offer some of the best warranties in the industry (10 years/100,000 miles) and are covering every penny of these repairs.
Final Message
If you own a 2021–2024 Kia K5 or 2020–2023 Hyundai Sonata with the 1.6L turbo engine – don’t ignore this recall. A quick dealer visit could prevent a serious safety issue.
Your safety matters more than anything. Book that free inspection today!
Stay safe on the road, and drive with peace of mind.
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