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It started with a faint fuel smell. Then came the paperwork, the testing, and now a recall that stretches across two Hyundai Motor Group brands and nearly a quarter of a million vehicles. Kia and Genesis are calling back 235,792 models because of a possible fuel leak at the connection between the fuel pipe and fuel rail.
For Kia, the problem affects 141,032 Carnival minivans from the 2022 to 2026 model years. The company first noticed trouble in January 2025 after reports of a fuel odor and leakage from the high-pressure crossover fuel pipe linking the GDI fuel rails in 2022 to 2024 Carnival models. An early investigation didn’t uncover a clear cause, but further checks by Kia and its supplier eventually pointed to a loose nut on two vehicles that had already leaked fuel.
Kia says it still has not pinned down the exact root cause. Even so, it found that engines built after November 19, 2024 use an updated torque specification for the crossover pipe, a change intended to keep the nuts properly secured. So far, the automaker says it is not aware of any crashes or fires tied to the issue, and it believes only about 1 percent of the recalled vehicles may actually be affected.
Dealers will inspect the fuel pipe and retighten or replace it if needed.
Genesis faces a similar fuel line issue
Genesis is dealing with a nearly identical problem, and the scope is just as serious. The recall covers the 2021 to 2025 G80 and GV80, the 2022 to 2026 GV70, and the 2023 to 2025 G90. In total, 94,760 vehicles are included.
According to the government, the crossover fuel pipe that connects the left and right fuel rails may have been fitted with retention fasteners that can loosen over time. If that happens, fuel can leak, and in the worst-case scenario, a fire risk follows.
Genesis received two reports of a leak or fuel odor in July 2024, followed by another in October. That later case triggered an investigation, but the issue proved difficult to reproduce in testing, with no loosening found under different conditions.
Still, Genesis has moved ahead with a recall after logging 129 reports related to the concern. Service technicians will inspect the crossover fuel pipe and retighten it as needed. If a leak is found, the pipe will be replaced.
For owners, the message is simple: if you notice a fuel smell, do not ignore it. Even a small leak can turn into a much bigger problem fast.
Source: carscoops
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