Hyundai and Kia Recall More Than 180,000 Vehicles as South Korea Flags Battery and Fuel System Defects

260,184 vehicles covered by South Korean safety action

South Korea's Ministry of Land, Infrastructure and Transport has announced recalls covering 260,184 vehicles across 57 models, including more than 180,000 from Hyundai Motor Group. The largest campaigns affect 85,355 Hyundai Porter II Electric vehicles and 54,532 Kia Bongo III EV vehicles because battery management software defects could increase the risk of a fire.

The ministry said manufacturers will carry out voluntary recalls to correct confirmed manufacturing defects. The wider safety action also includes Hyundai Tucson and Kia Seltos vehicles with fuel system problems that could cause their engines to stop, along with models from BMW Korea and Stellantis Korea.

Recall work in South Korea was scheduled to begin on October 30, 2025. Automakers are contacting owners and preparing software and replacement parts at dealerships. Inspections, software updates and replacement of affected components will be provided free of charge.

Hyundai and Kia account for most of the vehicles in the campaign. Their two electric commercial vehicle recalls alone cover 139,887 vehicles, more than half of the ministry's total of 260,184. Those battery software repairs sit alongside fuel system work on combustion vehicles, making this a safety action involving several different defects.

Drivers outside South Korea also face separate recall campaigns involving charging equipment and assembly problems. In the United States, Hyundai, Genesis and Kia electric vehicles have been recalled for failures that can interrupt charging of the conventional 12 volt battery and eventually stop the vehicle from moving. A much smaller U.S. Ioniq 5 campaign concerns loose bolts inside the main battery pack.

Which vehicles need repairs?

Hyundai's Porter II Electric and Kia's Bongo III EV share the largest identified problem: a design flaw in battery management system software. Kia, a Hyundai subsidiary, will recall 54,532 Bongo III EV vehicles, while Hyundai will recall 85,355 Porter II Electric vehicles.

The ministry's action covers a broader mix of vehicles than these two electric commercial models. The core Hyundai Motor Group recalls include:

• Hyundai Porter II Electric: 85,355 vehicles with a battery management software flaw linked to potential fire risk.
• Kia Bongo III EV: 54,532 vehicles with the same software defect and fire risk.
• Hyundai Tucson: a design flaw involving fuel filter components.
• Kia Seltos: a related fuel system defect that can cause the engine to shut down.

Hyundai Tucson and Kia Seltos owners face a different type of danger from the electric vehicle battery issue. A fuel system fault can interrupt the engine's operation, causing it to stall. Dealers will inspect the affected parts and carry out the software updates or component replacements required for the particular defect.

BMW Korea and Stellantis Korea models are also included among the 57 models covered by the wider campaign. Each manufacturer will publish service bulletins setting out the inspection process and remedy for its affected vehicles.

Why battery management software matters

The Porter II Electric and Bongo III EV recalls concern the battery management system, usually shortened to BMS. This is the control system that monitors battery temperatures, balances the voltage of individual cells and manages charging. Its job is to keep the many cells inside a high voltage battery pack operating within safe limits.

A software design flaw can cause the system to misread conditions or fail to keep cells within that safe operating range. Officials say the defect could increase the chance of overheating inside the battery pack and potentially lead to a fire in a small fraction of vehicles if left uncorrected.

Stress within a battery pack can trigger overheating in rare circumstances, particularly where there is already a weak cell, a damaged connector or inadequate cooling. The software matters because it determines how the vehicle responds to the temperatures and electrical conditions it detects.

Software updates can reduce that risk by changing temperature and voltage thresholds, adjusting charging profiles and improving how the pack sheds heat. Dealers will run diagnostic checks and install updated software. Readings outside the target range can lead to deeper inspections of battery modules and high voltage connections.

Owners will not be charged for this work. The remedy combines changes to the instructions controlling the battery with checks on the battery's condition, so the service may involve more than simply installing an update.

Repair timing and differences between markets

South Korea's recall notices set October 30 as the start date for the campaign. Manufacturers will notify affected owners directly, and dealerships will apply software updates or replace defective parts without charge.

Hyundai's distributor in Singapore said the Porter model is not sold there and that Tucson vehicles supplied in Singapore are imported from Europe. Those details matter because recall coverage often depends on where a vehicle was built, which supplier batch its parts came from and the requirements under which it was approved for sale.

A model sold under the same name in two countries can therefore have different recall status. Owners should check the vehicle identification number, or VIN, with their local brand office or government recall database and watch for direct notifications.

The main dates associated with these safety developments are:

• 2024: an EV battery fire in South Korea damaged hundreds of vehicles and led to temporary parking restrictions at garages across the country.
• October 30, 2025: the South Korean recall campaign was scheduled to begin.
• October 31, 2025: the announced action covers 260,184 vehicles across 57 models, including more than 180,000 from Hyundai Motor Group.

A separate charging fault can stop an EV

Hyundai and Kia have also been addressing a different defect in North America and other markets involving the integrated charging control unit, known as the ICCU. This equipment performs several charging tasks, including maintaining the vehicle's 12 volt battery and coordinating aspects of AC and DC charging.

Electrical or thermal stress can damage the ICCU in some vehicles. When it fails, the conventional 12 volt battery may stop receiving charge. The vehicle can then reduce its available power and eventually become unable to drive.

Recent U.S. recall filings cover more than 145,000 Hyundai and Genesis vehicles built from 2022 through 2025. The affected models include the Ioniq 5, Ioniq 6 and several electrified Genesis models. A related recall covering nearly 63,000 Kia EV6 vehicles brings the combined total above 208,000.

The remedy includes software intended to reduce voltage spikes at charging endpoints and improve cooling management. Where diagnostic fault codes are present, dealers will replace the ICCU assembly and fuse. Owners receive notices by mail, and the repairs are free.

The ICCU campaigns require a different repair process from the South Korean battery management software action. For an owner, the relevant recall notice identifies whether the vehicle needs a battery software update, a charging control repair or another form of work.

Why the small battery can affect driving

Every modern electric vehicle carries a conventional 12 volt electrical system as well as its main high voltage battery. The 12 volt system runs equipment including power steering, lights, airbags, control modules and door locks.

An electric vehicle therefore depends on more than the charge stored in its main battery. If the ICCU stops maintaining the smaller battery, the systems needed to operate the vehicle can lose their electrical supply.

Drivers may see a warning such as Power Limited before the vehicle gradually reduces its available power. Regulators say drivers typically have time to move to a safe location before the vehicle stops moving. Automakers have reported no injuries in connection with these ICCU recalls.

Owners should respond promptly to warnings involving power limits, 12 volt charging or high voltage systems. A dashboard alert can be the first visible sign of a problem that requires dealer attention.

Small Ioniq 5 recalls involve battery and suspension bolts

Hyundai has also recalled an extremely small group of 2025 Ioniq 5 vehicles in the United States because bolts inside the high voltage battery pack may not have been tightened sufficiently during assembly. The campaign covers about ten vehicles built over a two day period.

The affected bolts hold bus bars in place. Bus bars carry electrical current within the battery pack. Loose retention bolts can allow electrical arcing, increasing the chance of a thermal event. Owners were instructed to visit dealers for inspection and checks of bolt tightness at no cost.

Hyundai's U.S. recall notice included an instruction for affected owners while they awaited repair. The notice advised owners to park outside and away from structures until the recall repair is completed.

Another small recall involving the 2025 Ioniq 5 concerns rear toe and camber adjustment bolts that may not have been fully tightened at the factory. These adjustments determine the direction and angle at which the wheels sit. Drivers could notice vibration or a rattling noise.

Dealers will replace the affected suspension bolts, align the wheels and replace tires where necessary, all free of charge. Both limited campaigns show how an assembly problem can create serious safety concerns in parts that carry high electrical current or support suspension loads.

EV safety concerns follow the 2024 fire

South Korea's attention to electric vehicle safety increased sharply after an EV battery fire in 2024 damaged hundreds of vehicles. The incident led to temporary parking restrictions at garages across the country.

Consumer groups and local governments called for more transparency about battery supply chains and faster public reporting when information from vehicles in use points to a possible hazard. Their concerns focused on identifying risks early and giving owners usable safety information.

South Korea is a major producer of batteries and electric vehicles, and domestic EV adoption has been growing. Electric vehicles accounted for 9.3 percent of new car purchases in 2024, a higher share than in the United States during the same period.

Policymakers and industry leaders have described prompt recalls and clear guidance for owners as essential to maintaining consumer confidence. The current campaigns put that approach into practice through direct notifications, free repairs and instructions tailored to the fault affecting each vehicle.

What owners should do now

Owners should start by checking their VIN rather than relying only on the model name. The VIN allows a manufacturer or regulator to identify whether the individual vehicle falls within an affected production group.

Drivers in the United States can search for open recalls through the National Highway Traffic Safety Administration's NHTSA Recalls database and set alerts for updates. Drivers elsewhere should use their brand's local website or the government database for their market.

Automakers and regulators encourage owners to act when a recall notification arrives or when warning signs appear on the dashboard. The practical steps are:

• Check the VIN for open recalls through the manufacturer or the government database in the vehicle's market.
• Arrange the recall service promptly. Software updates, inspections and required repairs are free.
• Respond to Power Limited alerts and warnings involving 12 volt charging or high voltage equipment.
• Follow any fire risk notice instructing affected owners to park outside and away from structures until repairs are complete.
• Ask the dealer for documentation of the work and retain repair records.
• Contact customer care if failures recur, request further assistance and check the consumer protections available locally.

South Korean owners should watch for the manufacturer's notification and arrange the repair appropriate to their vehicle. Owners in other countries should confirm local coverage, particularly where the vehicle's production origin differs from models sold in South Korea.

At a Glance

• South Korea announced recalls covering 260,184 vehicles across 57 models, with more than 180,000 from Hyundai Motor Group.
• The campaign was scheduled to begin on October 30, 2025.
• Hyundai is recalling 85,355 Porter II Electric vehicles and Kia 54,532 Bongo III EV vehicles for battery management software defects linked to fire risk.
• Hyundai Tucson and Kia Seltos vehicles face fuel system repairs for defects that can cause engines to stall.
• BMW Korea and Stellantis Korea models are included in the wider South Korean action.
• Separate U.S. ICCU recalls cover more than 208,000 Hyundai, Genesis and Kia electric vehicles and address failures that can interrupt 12 volt charging and stop propulsion.
• A U.S. recall covering about ten 2025 Ioniq 5 vehicles concerns loose battery pack bolts and includes an instruction to park outside pending repair.
• Another small Ioniq 5 campaign addresses suspension adjustment bolts, with bolt replacement, wheel alignment and tire replacement where needed.
• Repairs are free, and owners should confirm coverage using their VIN and follow the instructions for their specific recall.