The Kia K5 is a sporty sedan that looks good and comes in at an affordable price, but owners may want to pay attention, as turbocharged K5 models from 2021-2024 are on their way back to dealership lots because their fuel tanks may melt. In that same breath, owners and shoppers of turbocharged Hyundai Sonata models from model years 2020 through 2023 should also approach with caution. A recall recently issued by the NHTSA affects multiple models under the Hyundai Motor Group umbrella: the 2021-2024 Kia K5 and the 2020-2023 Hyundai Sonata, both covering the same issue that affects over 335,000 models in total. Let’s take a look.
Turbocharged K5s And Sonatas Pose Fire Risk Due To Melted Fuel Tanks
On September 3, 2025, a routine data review at Kia‘s North American safety office identified a customer complaint regarding a recurring check engine light, as well as a strong gas odor. From September 4, 2025, through September 11, 2025, Kia identified another complaint regarding similar issues and prompted an investigation into the problem soon after. That investigation uncovered that the purge control system check valve, which controls the direction of airflow from the charcoal canister to the engine in turbocharged models, may deteriorate over time, allowing pressurized air to flow from the intake manifold into the fuel tank.
This backflow of air can cause the fuel tank to expand and make contact with the hot exhaust components. Prolonged contact could lead to localized melting of the fuel tank and, subsequently, a fuel leak if the tank is perforated. We all know what happens when you put flammable fuel next to hot things, and so does Kia, which led to a recall soon after of 2021-2024 Kia K5 models equipped with the 1.6-liter T-GDI engine manufactured at the Kia Georgia plant from March 27, 2020, through January 23, 2024; the total number of K5s affected is 250,547.
Hyundai Sonata Faces The Same Issues
Sonatas with the turbocharged 1.6-liter T-GDI engine produced from October 22, 2019, through October 7, 2023, by Hyundai Motor Manufacturing Alabama will also get a ticket back to the dealership. While the Sonata is in the same boat, it’s to a lesser extent, “only” affecting 85,043 models. That said, the risk is prevalent, especially for those who like to get the most out of the turbocharged engine. The series of events largely follows the same path tread to uncover the K5’s melting fuel tank issues, though the Sonata’s investigation and subsequent replication testing kicked off slightly later than the Kia’s timeframe, per the NHTSA’s 573 report.
The remedy put forth for both models involves Hyundai Sonata and Kia K5 owners with affected models returning to their respective dealership lots to undergo inspection and replacement of deteriorated components, be that the purge control system check valve or the fuel tank. An ECU software repair/update is also listed in the remedy program as a preventative measure for all affected models — free of charge, of course. As of the time of writing, there have been no accidents reported related to the recall, and owners are advised to be aware of the warning signs, which include a “pop” noise from the vehicle’s rear, illumination of the check-engine light, the vehicle failing to start, and a strong fuel odor.
Sources: NHTSA