Stop Sale Ordered for Hyundai Ioniq 5 Due to Potential Melting Gas Tanks in Sonata | Carscoops

      Over 1,500 Ioniq 5 EVs are being recalled due to a seat belt issue

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       by Michael Gauthier

      

      

      

      

      

      

      

      Hyundai is recalling 86,578 vehicles for two distinct problems.

      The 2025 Ioniq 5 EVs may have front seat belt retractors that are not securely attached.

      The 2020-2023 Sonatas have fuel tanks that could melt and leak.

      

      Year-over-year sales of the Hyundai Ioniq 5 fell by 63 percent last month as a result of the removal of the clean vehicle tax credit. This was a significant setback, and challenges continue as the 2025 model is subject to a stop sale order.

      

      

      The recall affects 1,535 EVs with front seat belt retractors that may not be properly secured. This can hinder the belts from functioning correctly during a crash, thereby increasing the risk of injury.

      More: Hyundai Reduces Ioniq 5 Pricing By Up To $9,800

      Hyundai initially identified the problem in July when it received a report indicating that a driver side seat belt retractor was “not fully installed” in an Ioniq 5. This led to an investigation that revealed a “new rework process was deployed” at Hyundai Motor Group Metaplant America in Georgia during the vehicle's production.

      

      

      

      

      

      

      

      

      

      

      

      

      

      While the filing did not provide detailed information, it mentioned that the rework process involved dismantling the B-pillar area and removing the front seatbelt retractors. The company ultimately inspected 19 vehicles affected by the rework and discovered that four had a seat belt retractor fastening bolt that was not completely tightened.

      In light of this, the company opted to proceed with the recall, which will involve dealers inspecting and securing the seat belt retractors as necessary. This will also temporarily prevent the sale of 64 vehicles believed to be in dealer inventory.

      Fuel Tank Issues

      

      

      

      

      

      

      

      

      

      Following closely on a significant fuel tank recall affecting the Kia K5, Hyundai is launching a similar recall for the 2020-2023 Sonata.

      A total of 85,043 sedans may have a faulty check valve, which could allow air to enter the fuel tank. This may cause the tank to expand, potentially contacting hot exhaust components and subsequently melting.

      

      

      The problem is attributed to a purge control system check valve that can wear out and fail over time. When this occurs, it can permit a “backflow of compressed air from the turbocharger into the fuel tank.”

      

      

      

      

      

      

      

      

      

      Issues began surfacing in 2023, and Hyundai is aware of seven associated fuel leaks in the United States and Canada. Two were reported last month, but the automaker has not received reports of any injuries or accidents.

      To resolve the issue, dealers will inspect and replace the check valve, as well as assess the fuel tank assembly. If the assembly is found to be damaged, it will be replaced at no cost. Dealers will also check and update the vehicle’s software as the latest version includes diagnostics for monitoring internal fuel tank pressure.