Hyundai Kona Fuel Pump Recall: What Owners Need to Know and Immediate Actions

A significant recall affects specific Hyundai Kona vehicles due to a critical defect in the low-pressure fuel pump. Hyundai Motor America issued Recall 22V-000 (NHTSA Recall Number 22V-000) targeting certain 2021-2022 Hyundai Kona and Kona Electric vehicles equipped with internal combustion engines (ICE). The core problem involves the fuel pump's impeller, made from an improper plastic material that can deform over time. This deformation leads to premature wear against the fuel pump module housing, causing excessive interference, potential seizure of the fuel pump, and ultimately, engine stall while driving. An unexpected engine stall drastically increases the risk of a crash, making this an urgent safety hazard. Owners of potentially affected Kona vehicles must immediately check their Vehicle Identification Number (VIN) on the Hyundai or NHTSA recall lookup websites to confirm inclusion and contact a Hyundai dealership to schedule a free repair, which involves replacing the entire low-pressure fuel pump assembly.

Detailed Explanation of the Fuel Pump Defect
The recall centers on the low-pressure fuel pump installed within the fuel tank of affected Hyundai Kona vehicles. This pump is responsible for delivering gasoline from the tank to the high-pressure fuel pump or injectors under consistent and adequate pressure. The critical component at fault is the impeller inside the fuel pump module. Hyundai identified that the impeller was manufactured using a plastic material lacking sufficient long-term durability and stability when constantly submerged in fuel. Prolonged exposure causes this plastic to absorb fuel and swell. As the impeller swells, its diameter increases beyond the intended design specifications. This enlarges impeller physically contacts the inner walls of the fuel pump module housing more intensely than designed. The resulting friction causes significant wear on both the impeller vanes and the housing surface. This escalating interference progressively increases the physical resistance the pump motor must overcome to spin the impeller. Eventually, the friction becomes so severe that the pump motor can no longer rotate the impeller. When this happens, the fuel pump seizes completely. A seized fuel pump cuts off the supply of gasoline to the engine instantaneously. The immediate consequence of a complete fuel delivery stoppage is engine stall, regardless of vehicle speed or driving conditions. This defect represents an inherent design flaw in the specified material, making the affected fuel pumps inherently unreliable over time and miles driven.

Specific Models and Years Affected by Recall 22V-000
This recall is not universal for all Hyundai Kona vehicles. Hyundai Motor America definitively lists the impacted vehicles in their official recall notice submitted to the National Highway Traffic Safety Administration (NHTSA). The recall exclusively covers 2021 and 2022 model year Hyundai Kona vehicles equipped with gasoline engines. Hyundai Kona models sold in the United States for these model years typically utilized 2.0-liter naturally aspirated or 1.6-liter turbocharged gasoline engines. Crucially, the Hyundai Kona Electric is not subject to this specific fuel pump recall. The recall also explicitly excludes Hyundai Konas built with diesel engines. Determining precise inclusion requires using the car's 17-character Vehicle Identification Number (VIN). Hyundai estimated that approximately 181,354 vehicles are involved in the US portion of this recall campaign. Owners cannot reliably determine recall involvement based solely on model year and trim; verification through Hyundai's dedicated recall lookup tool or the NHTSA VIN search tool is mandatory. Potential inclusion extends only to vehicles manufactured within a specific date range defined by Hyundai, emphasizing the VIN search step.

The Critical Safety Risk Presented by the Faulty Fuel Pump
The failure mode of the defective fuel pump presents an extreme safety hazard due to the nature of unexpected engine stall. An engine stall causes immediate loss of all power assist for critical functions. Power steering assist ceases, requiring considerably more physical effort to turn the steering wheel. Power brake assist is lost drastically increasing braking distance. Vehicle lighting systems, including headlights, brake lights, and hazard lights, may become inoperative or drain the battery quickly, especially if repeated restart attempts occur. Losing motive power prevents acceleration to avoid obstacles or merge safely. This sudden loss of vehicle control can happen at any speed and in any driving environment – navigating a busy intersection, entering a highway on-ramp, driving through a curve, or traveling at high speed on the freeway. An unexpected stall creates a high risk of the vehicle being struck from behind, colliding with stationary objects, veering off the road, or causing secondary collisions with other vehicles trying to avoid the stalled car. Engine stalls while driving substantially increase the potential for severe or fatal injuries. Hyundai documents confirmed instances of Konas experiencing stalls linked to the fuel pump, though no related crashes or injuries were reported to NHTSA at the time of the recall announcement. Nevertheless, the inherent danger justifies the recall's urgency. Operating an affected Kona before repair is driving a vehicle susceptible to catastrophic loss of function without warning.

Immediate Steps Owners of 2021-2022 Hyundai Kona Vehicles Must Take
Owners of 2021 or 2022 model year gasoline-powered Hyundai Kona vehicles must take proactive steps without delay. First, locate your Kona's 17-character Vehicle Identification Number (VIN). This unique identifier is engraved on a metal plate visible through the lower corner of the windshield on the driver's side. It is also located on a sticker on the driver's side door jamb (B-pillar), and within the vehicle's registration documents and insurance card. Second, confirm recall involvement. Visit Hyundai's official US recall website or the NHTSA recalls page. Enter your VIN precisely into the designated search field. The search results will explicitly state if your specific Hyundai Kona is part of Recall 22V-000 concerning the fuel pump. Third, if your vehicle is listed, contact an authorized Hyundai dealership promptly. Call their service department directly, state you are checking regarding NHTSA Recall 22V-000 / Hyundai Recall SA916 for the fuel pump, and provide your VIN. Schedule an appointment for the free repair at the earliest available time. Hyundai dealerships can order the necessary replacement part based on your VIN once an appointment is scheduled. Do not assume the dealership will contact you proactively or has parts immediately available. Continue driving with extreme caution until the repair is completed, minimizing highway driving and avoiding situations demanding rapid acceleration if possible. Be alert for potential warning signs like unusual pump whine, engine hesitation, or unexpected power loss.

Repair Process and Resolution Provided by Hyundai
Hyundai has developed a definitive solution to permanently correct the hazardous fuel pump defect identified in Recall 22V-000. Authorized Hyundai dealership technicians perform the repair at no financial cost to the vehicle owner. The core component requiring replacement is the low-pressure fuel pump module assembly housed inside the vehicle's fuel tank. The dealership service department orders the specific, updated fuel pump assembly designed to resolve the impeller material deficiency. Gaining access to the pump necessitates partially lowering the fuel tank. Technicians disconnect the fuel lines and electrical connectors linked to the existing pump module. They remove the malfunctioning pump module entirely from the fuel tank assembly. The new, updated low-pressure fuel pump module is installed securely back into the tank. Technicians reconnect all necessary fuel lines and electrical connectors correctly. The fuel tank is then repositioned and secured. Finally, technicians test the new fuel pump for correct operation, ensure the engine starts and runs smoothly, and verify there are no fuel leaks. The entire replacement typically takes a few hours to complete once the dealer has the part and the car arrives. Hyundai covers the complete expense of the replacement part and the dealer labor required. Owners receive documentation confirming the recall repair completion. This new pump module uses an impeller constructed from a robust material specifically validated to resist fuel absorption, swelling, and subsequent interference within the pump housing under normal operating conditions. This design change eliminates the root cause of the failure.

Hyundai's Actions and Ongoing Responsibility to Owners
Hyundai Motor America formally initiated this recall campaign in accordance with US safety regulations, submitting detailed documentation to the National Highway Traffic Safety Administration (NHTSA). Hyundai identified the fuel pump defect through its internal warranty claim analysis, field data reviews, and specific component testing protocols. Hyundai dispatched initial notification letters to all known registered owners of the affected Kona vehicles via First-Class Mail. These notifications clearly explained the nature of the defect, the associated safety risks, and the required corrective action. Hyundai is obligated to attempt contact with every registered owner. Due to the serious safety implications of the fuel pump failure, Hyundai is mandated to complete this recall campaign. Dealerships receive formal repair procedures, technical bulletins, necessary tools, and inventory allocation for the new fuel pump modules. Hyundai monitors dealership completion rates and parts supply continuously. Hyundai must also submit quarterly status reports to NHTSA detailing the progress of the recall, including the number of vehicles repaired, notification efforts, and part availability. For owners, the repair is guaranteed free of charge for the lifetime of the recall. If an owner incurred repair expenses for a fuel pump failure symptom diagnosed before the official recall announcement date, they may be eligible for reimbursement by submitting documentation to Hyundai's Consumer Affairs department. Hyundai's campaign number for US owners to reference is SA916. Hyundai customer service channels provide support for scheduling difficulties, reimbursement inquiries, or clarification on the recall process. Owners can contact Hyundai Consumer Affairs directly at 855-371-9460.