Hyundai and Kia have issued a recall for 335,590 Kia K5 and Hyundai Sonata vehicles with 1.6-L engines. The recall addresses a defect that causes the gas tanks to swell, emit popping noises, and deform after contacting hot components, potentially leading to fuel leaks.
If the condition is not corrected, a melting fuel tank will create the risk of a vehicle fire. Hyundai and Kia will offer repairs under the recall free of charge.
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Symptoms Reported by Kia K5 and Hyundai Sonata Owners
Kia K5 and Hyundai Sonata owners may notice the following symptoms:
- Illuminated Check Engine Light
- Fuel odor inside or outside the vehicle
- Popping sounds from the fuel tank area
- Rough engine operation
- Difficulty starting or failure to start
If your Kia K5 or Hyundai Sonata has these symptoms, it may be included in the dual recalls intended to address swelling gas tanks. Affected owners under both recalls will receive mailed recall notices starting January 16, 2026.
What is Causing the Swelling Fuel Tank Defect?
In affected Kia K5 and Hyundai Sonata vehicles, the purge control system check valve may become damaged or worn and allow pressurized air to enter the fuel tank. This pressurized air may deform the fuel tank and cause it to expand, resulting in the fuel tank contacting hot components, melting and leaking fuel.
Fuel leaks may create the risk of a vehicle fire.
Kia K5 Gas Tank Recall (NHTSA Recall No. 25V794)
- NHTSA ID: 25V794000
- Kia Recall Number: SC356
- Number of Vehicles: 250,547
- Vehicle Models: 2021–2024 Kia K5 vehicles
- Defect: The check valve, which controls airflow from the charcoal canister to the engine, may deteriorate over time and allow air into the fuel tank. As a result, the fuel tank may deform, melt and allow fuel leaks.1
- Remedy: Dealers will replace the check valve. The fuel tank will be inspected for damage and, if needed, replaced. The ECU software will also be updated, free of charge.
- Owner Notification: Letters will be mailed January 16, 2026.2
Hyundai Sonata Gas Tank Recall (NHTSA Recall No. 25V796)
- NHTSA ID: 25V796000
- Hyundai Recall Number: 286
- Number of Vehicles: 85,043
- Vehicle Models: 2020–2023 Hyundai Sonata vehicles
- Defect: The check valve may become worn over time and allow air into the fuel tank, causing the fuel tank to deform and allow fuel leaks.
- Remedy: Dealers will inspect and, if needed, replace the purge control system check valve, the fuel tank and surrounding components, free of charge. The ECU software will also be inspected and updated.
- Owner Notification: Letters will be mailed January 16, 2026.3
Hyundai-Kia Swelling Gas Tank Recall Timeline
In November 2024, Hyundai released emissions-related Service Campaign 9B1 for 2020–2023 Hyundai Sonata vehicles with 1.6-L engines. Dealerships were instructed to inspect the check valve, fuel pump cover and fuel tank, and update the Electronic Control Unit.4
In September 2025, Hyundai’s North American Safety Office (NASO) reviewed occurrences of fuel leaks in this vehicle population and found three new allegations of fuel leaks in Sonata vehicles that did not have the remedy applied. NASO launched an investigation on September 16, 2025.5
Meanwhile, Kia’s North American Safety Office (Kia NA Safety Office) received two reports of 2021–2022 Kia K5 vehicles leaking fuel near the exhaust pipe. Kia NA Safety Office asked Kia’s headquarters to investigate fuel leaks under different test conditions.6
In October 2025, NASO conducted a vehicle inspection for evidence of fuel leaks, using 3D scans to confirm the existence of abnormalities of the fuel tank and other components. That same month, NASO acquired a repurchased vehicle and performed testing on its fuel tank. NASO’s test confirmed that the software from Service Campaign 9B1 effectively prevented the fuel tank swelling condition.
In November 2025, NASO reviewed the replacement purge control system check valves and initiated its recall. By this point, NASO had found seven fuel tank leak reports.
Meanwhile, Kia’s headquarters provided its North American Safety Office with its findings: when the purge control system check valve deteriorates, the fuel tank may expand and contact the exhaust pipe. Prolonged contact with hot components may cause the fuel tank to melt.
Following these findings, Hyundai and Kia initiated formal safety recalls to address the fuel tank defect in affected vehicles.
How to Check If Your Vehicle Is Recalled
You can confirm if your vehicle is included in an open recall by searching your Vehicle Identification Number in one of the following directories:
- Kia Owners Recall Portal: Kia K5 owners can confirm recall eligibility and schedule a repair service appointment.
- Hyundai Safety Recalls: Hyundai Sonata owners can search for open recalls, confirm inclusion in any service campaigns and schedule repairs at their nearest Hyundai dealership.
- NHTSA’s Recall Search Tool: NHTSA’s recall database allows vehicle owners to search for open recalls issued by any manufacturer.
Vehicle owners experiencing recurring safety or drivability issues should schedule a repair service appointment, whether they are included in an open recall or not.
How to Schedule a Repair Service
To schedule a repair for the Hyundai Sonata or Kia K5 gas tank recall, locate a dealership using the Hyundai dealership or Kia dealership search tools. Enter your ZIP code to find the nearest service center, and then call the dealership directly to request a service appointment.
Have your Vehicle Identification Number ready so that the service center can confirm your eligibility for recall-related services and/or determine if other repair services are needed.
Reimbursement for Prior Repairs
If you paid for repairs related to the fuel tank or fuel system issue before these recalls were issued, you may be eligible for reimbursement. Hyundai and Kia typically offer reimbursement programs for eligible vehicle owners who paid for repairs out of pocket prior to the release of recalls.
To learn more about reimbursement eligibility, contact Hyundai or Kia’s customer service departments. Be sure to keep copies of all repair orders, invoices, and service records from your prior repair visits.
Hyundai-Kia Recall Contact Information
If you would like additional information about these recalls or wish to report further vehicle safety concerns, you may contact the following resources:
- Kia Customer Service: 800-333-4542
- Hyundai Customer Service: 1-855-371-9460
- NHTSA Safety Hotline: 888-327-4236
Owners may also report safety issues directly to the National Highway Traffic Safety Administration, which monitors and investigates vehicle defect complaints nationwide.
What Kia K5 and Hyundai Sonata Owners Should Know
Kia K5 and Hyundai Sonata owners affected by the swelling gas tank recalls should schedule repair appointments as soon as recall remedies become available. Keep copies of recall notices, repair orders and other communications from the dealership and/or manufacturer. If fuel system issues continue after recall repairs are completed, documenting ongoing symptoms and service visits may be important for resolving the issue and understanding your rights as a vehicle owner.
References
- (2025, November 17). Part 573 Safety Recall Report 25V794. National Highway Traffic Safety Administration. https://static.nhtsa.gov/odi/rcl/2025/RCLRPT-25V794-5581.pdf
- (2025, November 17). Fuel Tank May Leak. National Highway Traffic Safety Administration. https://www.nhtsa.gov/?nhtsaId=25V794000
- (2025, November 18). Fuel Tank May Leak. National Highway Traffic Safety Administration. https://www.nhtsa.gov/?nhtsaId=25V796000
- (2025, January). HYUNDAI Technical Service Bulletin 25-01-001H. ECU UPDATE & CHECK VALVE/FUEL TANK INSPECTION AND REPLACEMENT (SERVICE CAMPAIGN 9B1). https://static.nhtsa.gov/odi/tsbs/2025/MC-11012362-0001.pdf
- (2025, November 17). 2021-2024MY K5 Purge Control System Check Valve Basis of Safety Defect Determination 573.6(c)(6). https://static.nhtsa.gov/odi/rcl/2025/RCHRN-25V794-2230.pdf
