Hyundai and Kia Recall Over 335,000 Vehicles Due to Fire Risk

Hyundai Motor America and Kia America, Inc. are initiating recalls affecting a significant number of their passenger cars due to a potential fire hazard stemming from a worn purge control system check valve. The affected vehicles, totaling over 335,000 combined, may experience fuel leaks that could ignite, posing a serious safety risk. Owners of the specified models are advised to take immediate precautions as outlined by the manufacturers.

The recall from Hyundai Motor America involves approximately 85,043 model year 2020-2023 Hyundai Sonata vehicles. According to information submitted to the National Highway Traffic Safety Administration (NHTSA), a worn purge control system check valve can allow compressed air to pressurize the fuel tank. This pressure can cause the fuel tank to deform, potentially leading to fuel leakage over time. The risk of fire increases if leaked fuel comes into contact with an ignition source. Warning signs that may indicate this condition include a “pop” noise from the rear of the vehicle, illumination of the Malfunction Indicator Lamp (MIL), the vehicle failing to start, or a fuel odor. The issue is attributed to the deterioration of the check valve, which allows a backflow of compressed air from the turbocharger into the fuel tank. Hyundai has confirmed seven reports of fuel tank leaks in the U.S. and Canadian markets, though no crashes, injuries, or fatalities have been reported in connection with this specific defect. The 1.6-liter turbocharged engines that utilize the affected check valve were discontinued in production at the end of the 2023 model year.

Hyundai will notify owners of the affected Sonatas by mail, instructing them to bring their vehicles to a dealership. Technicians will inspect and, if necessary, replace the purge control system check valve. They will also inspect the fuel tank and surrounding components for damage, and update the vehicle’s ECU software as a preventative measure. These services will be provided at no cost to the owner. Owners who have already paid for repairs related to this issue will be reimbursed according to Hyundai’s plan. The remedy will be implemented in phases, with dealers being notified by January 16, 2026, and owners receiving notification and the opportunity for repairs around the same date. Vehicle identification numbers (VINs) will be searchable for recall status starting November 19, 2025. In the interim, owners are advised not to drive their vehicles and to park them outside.

The recall from Kia America, Inc. impacts approximately 250,547 model year 2021-2024 Kia K5 vehicles equipped with a 1.6L Turbocharged Gasoline Direct Injection (T-GDI) engine. Similar to the Hyundai recall, the defect arises from a deteriorated purge control system check valve. This deterioration can allow pressurized air to flow from the intake manifold into the fuel tank, potentially causing the tank to expand and come into contact with hot exhaust components. Prolonged driving in this condition could lead to localized melting of the fuel tank and a subsequent fuel leak. Potential warnings include a popping sound from the fuel tank area, a Check Engine Light illumination, or rough engine operation. As with Hyundai, the affected components are manufactured by Inzi Controls. Kia has not reported any crashes, injuries, or fatalities in the U.S. or Canada related to this condition. The 1.6L T-GDI engine is not used in the 2025 model year K5 vehicles, which are therefore not included in this recall.

Kia will also notify owners of the affected K5 vehicles by mail, directing them to visit a Kia dealership. At the dealership, the check valve will be replaced with an improved design, and the fuel tank will be inspected for any damage, with replacement occurring if necessary. The vehicle’s ECU software will also be updated. These repairs will be performed at no charge to the vehicle owner. Kia will reimburse owners for any prior repair expenses related to this issue, in line with their General Reimbursement Plan. Dealers are scheduled to be notified by November 18, 2025, and owners will begin receiving notification for remedy repairs by January 16, 2026. Owners will be able to check their vehicle’s VIN for recall status starting December 1, 2025. Kia also advises owners of affected vehicles not to drive them and to park them outside.

Article by Mel Anara, based upon information from Hyundai Motor America and Kia America, Inc.

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