Kia and Genesis Recall 235,000 Vehicles Over Fuel Leak Issue

Kia and Genesis recall over 235,000 vehicles due to a fuel leak risk linked to assembly issues, according to NHTSA reports. Learn which models are affected and what owners should do.

More than 235,000 Kia and Genesis vehicles in the United States are being recalled over a potential fuel leak risk—and the issue traces back not to a faulty component, but to how it was installed during production.

The problem centers on the crossover fuel pipe, a component that connects the engine’s fuel rails. In both cases, the concern lies with the fasteners: over time, they can loosen, increasing the chance of a fuel leak. If gasoline comes into contact with heat or a spark, the risk of an engine bay fire rises.

The recall is split into two campaigns. Genesis is recalling 94,760 vehicles, including the G90, G80, GV80, and GV70 from model years 2021 to 2026. The cause is described in detail: insufficient application of a torque stabilizer during assembly, which can allow the fasteners to lose clamping force over time. Kia, meanwhile, lists the issue as a production deviation affecting 141,032 Carnival minivans from model years 2022 to 2026—essentially pointing to inconsistent tightening of the fuel pipe nuts.

The first signs appeared as reports of fuel odor. In Kia’s case, some vehicles may also trigger a Check Engine warning. Genesis has recorded 129 field reports linked to the condition, while Kia identified hundreds of cases tied to specific VINs. Notably, neither brand has reported crashes, fires, or injuries related to the issue so far.

The investigation unfolded over several months. Genesis began examining the issue in mid-2024, reviewing parts, production records, and supplier processes involving Usui International Korea, which manufactures the fuel pipe. The conclusion was clear: the component itself is not defective—the problem originated during assembly.

Production lines have since been updated, with revised torque specifications and stricter quality controls. However, some vehicles built after these changes are still included in the recall because they may contain components produced before the fix was implemented.

For owners, the remedy is straightforward. Dealers will inspect the fuel pipe assembly at no cost. If a leak is found, the pipe will be replaced; if not, the fasteners will be properly tightened. As a precaution, manufacturers advise parking vehicles outdoors and seeking immediate inspection if a fuel smell is detected.

The situation highlights how even minor deviations on the assembly line can scale into major recall campaigns. In this case, it is not a complex engineering failure, but a matter of precision in installation—yet the impact spans hundreds of thousands of vehicles.