Sonata Low Pressure Fuel Pump May Overheat And Crack

re: NHTSA campaign 20V121000

Laguna Hills, CA – June 30, 2022 – Hyundai has remedied 117,574 2013-2014 Hyundai Sonata that was dealing with fuel leaking issues caused by a crack in the low-pressure fuel hose. Additionally, 8,451 of these Hyundai Sonota models have been identified as unreachable and 22,412 have been retired after the recall. Two groups of these 2013 – 2014 Hyundai sonatas with fuel leak issues were remedied in 2020, four groups were remedied in 2021, and one group during the first quarter of 2022.

Laguna Hills, CA – February 28, 2020 – 2013-2014 Hyundai Sonata low-pressure fuel hose may crack and leak due to high temperatures around the engine. If the low-pressure fuel pump overheats it may crack and leak fuel, increasing the risk of fire and inhibiting the ability to operate the vehicle normally.

The potential number of affected units is 206,896.

The defect

Hyundai Motor America (Hyundai) has recalled over 200,000 2013-2014 Hyundai Sonatas whose low-pressure fuel pumps may crack and leak fuel when subjected to high temperatures. The low-pressure hose connects the low-pressure fuel pump to the direct injection fuel pump. If the low-pressure hose cracks, fuel may leak from the hose and cause a fire. A slight fuel smell may develop if the fuel hose starts to leak, if vehicle occupants start to smell fuel they are advised to stop operation of the vehicle immediately and have the vehicle inspected.

In November 2016, Hyundai Motor America (HMA) decided to conduct an investigation into previous reports concerning a fuel leak in certain model year 2013 Sonata vehicles. Of the previously recorded incidents, none of them indicated engine fire, smoke, or any time of burning odor. Hyundai decided to issue a Quality Information Report (“QIR”) and open an examination into the potential for the leak to cause an engine compartment fire. From December 2016 to April 2017, Hyundai continued to investigate the previously reported incidents as well as new field reports. The new incidents were similar to previously recorded ones – a fuel leak without any evidence of an engine compartment fire. In May 2017, HMA finalized their investigation and decided that the fuel leak in the low-pressure fuel hose was too small to ignite an engine compartment fire. Formally closing the investigation, HMA decided to continually motor field reports from vehicle owners. In February 2020, HMA received news from Kia Motors America that they were to recall certain vehicles that were made with the same fuel pumps as the previously examined Sonata vehicles. Kia Motors America issued a safety recall in the U.S. on certain vehicles whose low-pressure fuel lead line may creak and leak fuel, increasing the risk of an engine compartment fire. Although HMA received no reports of an engine compartment fire in their vehicles, they decided on February 25, 2020, to issue a formal safety recall on 2013-2014 Sonata vehicles with cracked fuel pumps.

The solution

The current remedy to this recall is under investigation. Most likely it will entail a patch to the crack in the lead to the fuel pump or the installation of a completely new fuel pump, but the information provided by HMA is limited. Once the remedy has been decided upon, it will be performed at no charge. If customers have any further questions they are welcome to contact Hyundai customer service at 1 (800) 633-5151.

For more information on this or other recalls past or present, visit MotorSafety.org.

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About MotorSafety.org

MotorSafety.org is a not-for-profit organization dedicated to vehicle safety and assisting consumers with the identification and resolution of vehicle manufacturing recalls and defects. Through education, awareness, government relations, repair facility referrals and strategic partnerships, MotorSafety.org hopes to remove every unsafe vehicle from the road, facilitate its proper repair, and ensure its prompt return to the owner once the vehicle has met the required safety and performance standards. For more information about MotorSafety.org, please email support@motorsafety.org.

Marshall EarleySonata Low Pressure Fuel Pump May Overheat And Crack

Hyundai and Kia Recall Nearly 168,000 Vehicles for Potential Fuel Leaks and Fire Risk

Laguna Hills, Calif. – Jan. 26, 2019 – Hyundai Motor Co and affiliate Kia Motors Corp are recalling close to 168,000 U.S. vehicles at risk of fuel leaks. This recall comes after a previous recall in 2017 for engine fire risks. The companies will also offer software upgrades for 3.7 million vehicles. The new recall covers 68,000 various Kia Optima, Sorento and Sportage vehicles from the 2011 through 2014 model years, and also affects 100,000 2011-2014 Hyundai Sonata and 2013-2014 Hyundai Santa Fe Sport vehicles.

The Defect

According to Reuters, engine replacements during the prior recall could have involved a high-pressure fuel pipe that may have been damaged or improperly installed. The faulty installation could increase the risk of fire. Hyundai and Kia now also state that the high-pressure fuel line may have been damaged, misaligned, or improperly adjusted during the engine replacement procedure. That could allow fuel to leak and increase the risk of fire.

Timeline of Events

According to Reuters, in 2015, Hyundai recalled 470,000 U.S. Sonata sedans. The reason for the recall was given as a possibility of engine failure that could result in a vehicle stall, increasing the risk of a crash. Kia did not recall its vehicles, which share the same “Theta II” engines, at that time.

In 2016, a South Korean whistleblower reported concerns regarding this design flaw to NHTSA. The U.S. agency had been investigating the timeliness of three U.S. recalls, and the number of vehicles recalled.  In March 2017, Hyundai expanded the recall to include an additional 572,000 Sonata and Santa Fe Sport vehicles with “Theta II” engines, claiming a small amount of manufacturing debris was responsible for potential engine stall, and Kia recalled 618,000 Optima, Sorento and Sportage vehicles with the same engine at the same time.

According to Consumer Reports, in May 2017, the National Highway Traffic Safety Administration (NHTSA) opened a formal investigation into the recalls. The Center for Auto Safety (CAS), a consumer watchdog group, filed a formal petition with the NHTSA in June 2018 to investigate multiple fire complaints.

The Solution

Authorized dealers will inspect the connection between the high-pressure fuel pipe and the fuel pump outlet. If leaking fuel is detected, the dealer will replace the fuel pipe and properly install a new one, at no charge to owners.

In addition to the recall, both automakers have announced a software update and warranty extension. This announcement affects approximately 2 million 2011-2018 Hyundai Sonata sedans and 2013-2018 Hyundai Santa Fe Sport SUVs, and about 1.6 million 2011-2018 Kia Optima sedans, 2012-2018 Kia Sorento SUVs, and 2011-2018 Kia Sportage SUVs. The software update is reported to protect the engine from damage that could lead to vibrations or stalling. Kia and Hyundai will also extend engine warranties to 10 years and 120,000 miles for owners of affected vehicles who contact their dealer for a free software update.

Hyundai and Kia will notify owners of the recall details via first-class mail. Owners of affected vehicles may call Hyundai at 800-633-5151 or Kia at 800-333-4542. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Sean ReyesHyundai and Kia Recall Nearly 168,000 Vehicles for Potential Fuel Leaks and Fire Risk