Hyundai Sonata and Kia K5 Recalled Because the Turbocharger Could Pressurize the Fuel Tank

• 5,616 units of the 2020 to 2023 Hyundai Sonata and 2,737 units of the 2021 to 2024 Kia K5 are affected in Canada.

• Only models powered by the 1.6L turbocharged engine are recalled.

• A faulty check valve could let pressurized air into the fuel tank, increasing the risk of a fuel leak.

Hyundai and Kia have launched a recall for the 2020 to 2023 Sonata and 2021 to 2024 K5 midsize sedans due to a risk of fuel leak and fire.

According to documents filed with Transport Canada and the United States’ NHTSA, models equipped with the 1.6 L turbocharged four-cylinder engine are affected, which amounts to 5,616 units of the Hyundai Sonata and 2,737 units of the Kia K5 on the Canadian market.

In the United States, Hyundai is recalling 85,043 Sonatas while Kia is recalling 250,547 K5s. Hyundai says that a redesigned part was introduced in production starting with the 2024 model year. At Kia, the K5 discontinued the use of the 1,6 L engine after the 2024 model year.

Due to a faulty check valve that can wear out, pressurized air from the turbocharger could enter the plastic fuel tank, which could then expand.

A dilated fuel tank could rub on hot exhaust components, which could melt the tank and cause a leak, increasing the risk of fire.

We don’t know how many instances of this issue Kia is aware of, but Hyundai indicated to the NHTSA that it had received reports of 7 incidents, which didn’t result in injuries.

A previous recall from November 2024 had dealt with emissions concerns on the Sonata, but vehicles that have been repaired under that campaign will have to be fixed again.

Starting in January, Kia and Hyundai dealerships will install a new check valve of a revised design along with an updated ECU software that will be better able to monitor internal fuel tank pressures.

In cases where the fuel tank has been deformed or melted, a new one will be installed free of charge.

Owners who have experienced these issues before and paid to have their vehicle repaired will be able to get a refund through each automaker’s reimbursement plans.