Kia and Hyundai are recalling hundreds of thousands of vehicles in the United States after discovering that a component near the fuel tank can overheat and melt, raising the risk of a fuel leak and potential fire. The move affects a wide range of popular models and underscores how a single flawed part in the fuel system can trigger a sweeping safety campaign across both brands.
What is driving the latest Kia and Hyundai recall
The core issue in this recall is a plastic fuel pump component that can be exposed to excessive heat, which in turn can deform or melt the top of the fuel tank and compromise its integrity. According to recall filings, the problem centers on the electric low-pressure fuel pump module, where internal electrical resistance can increase, generating enough heat to damage the surrounding plastic housing and the tank surface itself. That combination of heat, plastic, and pressurized fuel is exactly the kind of scenario that prompts regulators and automakers to act quickly, since any resulting leak near an ignition source can escalate into a fire risk for occupants and nearby vehicles.
In documents submitted to federal safety regulators, Kia and Hyundai describe how the affected fuel pump assemblies can overheat during normal operation, particularly when the pump runs for extended periods or when ambient temperatures are high. The companies report that the heat can cause the pump’s plastic flange or cover to warp and, in some cases, melt a portion of the fuel tank where the module is mounted, creating a path for gasoline to escape. The recall notice explains that a fuel leak in the presence of hot engine or exhaust components, or any other ignition source, increases the likelihood of a vehicle fire, which is why the defect is being treated as a significant safety hazard backed by a formal campaign number and detailed safety report.
Which Kia and Hyundai models are affected
The recall covers a combined total of approximately 335,000 vehicles from both Kia and Hyundai, spanning multiple model lines and several model years. On the Hyundai side, the campaign includes specific production runs of the Hyundai Sonata, Hyundai Santa Fe, and Hyundai Tucson, along with certain units of the Hyundai Elantra and Hyundai Kona that share the same low-pressure fuel pump design. Kia’s portion of the recall focuses on models such as the Kia Sportage, Kia Sorento, and Kia K5, as well as selected Kia Seltos and Kia Soul vehicles equipped with the implicated fuel pump module. Each of these models is identified in the manufacturer’s defect report by precise model years and build dates, which are laid out in detail in the official NHTSA filings.
Owners will not have to guess whether their specific vehicle is covered, since the recall documentation lists exact VIN ranges and production periods for every affected model. The combined total of roughly 335,000 vehicles is split between about 195,000 Hyundai units and about 140,000 Kia units, according to the manufacturers’ cumulative tallies. The filings also clarify that only vehicles fitted with a particular supplier’s fuel pump module are included, which is why some cars built in the same year are excluded while others are flagged. The detailed model breakdown, including the exact counts for each nameplate, is available in the publicly posted recall population tables.
How the fuel tank melting risk develops
The defect does not appear suddenly; instead, it develops over time as the fuel pump’s internal components degrade and electrical resistance increases. According to the technical analysis submitted to regulators, the pump’s motor can draw more current than intended, which generates additional heat at the top of the fuel tank where the module is mounted. That heat can gradually soften the plastic around the pump opening, and in more severe cases, it can melt a groove or opening in the tank surface. Once the tank is compromised, fuel can seep or drip from the damaged area, especially when the tank is full or the vehicle is parked on an incline, which is why the recall notice explicitly cites a heightened risk of fuel leakage and fire in the presence of an ignition source, as detailed in the engineering summary.
Investigators for both automakers traced the problem to a specific batch of fuel pump modules supplied during a defined production window, where manufacturing variation led to higher-than-expected internal resistance. The analysis notes that the issue is not related to fuel quality or driver behavior, but rather to the pump’s electrical and material characteristics under normal use. Testing conducted after early field reports showed that, under certain conditions, the pump housing and adjacent tank surface could reach temperatures high enough to deform the plastic, even without any external heat source. These findings are laid out in the manufacturers’ technical attachments, which describe the failure mechanism and the temperature thresholds at which the tank material begins to lose structural integrity.
Warning signs owners may notice
While the defect can progress quietly, there are several warning signs that owners might notice before the problem becomes severe. The recall paperwork notes that drivers may smell gasoline around the vehicle, particularly near the rear, or notice fuel spots on the ground after parking. In some cases, the check engine light may illuminate if the engine control module detects an evaporative emissions leak or abnormal fuel pressure readings. The documentation also mentions that some owners reported difficulty starting the vehicle or experienced rough running, which investigators linked to inconsistent fuel delivery from an overheating pump. These potential symptoms are summarized in the defect information report that accompanies the recall.
However, the filings also make clear that not every affected vehicle will show obvious signs before a leak develops, which is why Kia and Hyundai are urging owners to complete the recall repair even if their cars appear to be operating normally. The companies state that the fuel tank damage can occur without a dramatic change in driving behavior, and that a leak may only become apparent under specific conditions, such as a hot day or a full tank. Because of that uncertainty, the recall notices emphasize that the safest course is to have the fuel pump module inspected and replaced where necessary, rather than waiting for symptoms to appear. This guidance is reinforced in the owner notification drafts submitted to regulators.
How Kia and Hyundai plan to fix the problem
The remedy for the defect centers on replacing the faulty fuel pump module with an improved part that does not generate excessive heat under normal operating conditions. According to the service instructions filed with regulators, dealers will inspect the fuel pump assembly in affected vehicles and install a redesigned module that uses updated internal components and materials to keep electrical resistance within the intended range. If inspection reveals that the top of the fuel tank has already been damaged or melted, dealers are instructed to replace the tank as well, at no cost to the owner. The full repair procedure, including part numbers and labor times, is outlined in the dealer service bulletin attached to the recall.
Kia and Hyundai state in their filings that they will reimburse owners who previously paid out of pocket for repairs related to this specific fuel pump and tank issue, provided they can supply documentation that matches the defect description. The companies also note that the replacement parts have been validated through additional testing to ensure they do not replicate the overheating behavior seen in the original modules. Dealers are being instructed to prioritize vehicles that show signs of fuel odor or leakage, but the remedy is available to all covered vehicles once parts are in stock. These commitments are detailed in the manufacturers’ remedy and reimbursement plans filed with the National Highway Traffic Safety Administration.
What owners should do next
Owners of potentially affected Kia and Hyundai vehicles are being advised to check whether their specific car is included in the recall and to schedule a repair appointment as soon as parts and service slots are available. The recall reports explain that owners will receive mailed notifications, but they can also verify coverage by entering their Vehicle Identification Number into the official recall lookup tools referenced in the filings. If a vehicle is confirmed to be part of the campaign, the next step is to contact an authorized dealer to arrange the free inspection and repair. The process for confirming eligibility and booking service is described in the owner communication materials that accompany the recall.
In the meantime, the manufacturers recommend that owners remain alert for any signs of fuel odor, visible leaks, or unusual engine behavior, and to park the vehicle outdoors if they suspect a problem until it can be inspected. The recall documentation notes that, while the number of confirmed incidents is limited relative to the total population of vehicles, the potential consequences of a fuel leak near an ignition source are serious enough that the issue should not be ignored. By following the steps laid out in the official recall notices, owners can reduce the risk associated with the defective fuel pump modules and ensure that their vehicles receive the updated components designed to prevent the fuel tank from overheating or melting.
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