Tag Archives: fuel smell

2022 Hyundai Santa Fe PHEV Fuel Leak Could Lead To Fire

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A small number of 2022 Hyundai Santa Fe Plug-In Hybrid Vehicles (PHEVs) could experience fuel tank leaks that could increase the risk of a fire. Occupants may detect a fuel smell and/or visible fuel leak associated with this condition.

The problem began in December 2022 when Hyundai first heard of reports of leaking fuel from the fuel tanks of certain 2022 model year Santa Fe PHEVs. Hyundai continued to investigate the condition with the supplier, and based on manufacturing information provided by the supplier, identified the suspect population of Hyundai vehicles likely equipped with defective fuel tanks to be between April 7, 2022, through April 9, 2022.

According to the defect report, certain fuel tanks may have been improperly manufactured, resulting in a fuel leak at the seam between the tank halves. A fuel leak in the presence of an ignition source can increase the risk of a fire. Based on this information, Hyundai decided to conduct a safety recall to replace the fuel tank assemblies on the suspect vehicles in the U.S. and Canadian markets.

Description of the Cause: Insufficient molding caused by a malfunction of the material grinder prior to mold extrusion.

Owners receiving notices will be asked to return to their dealers to have the fuel tank inspected and replaced as necessary. Owners who detect a fuel smell and/or visible fuel leak associated with this
condition should contact their Hyundai dealership immediately. Hyundai’s number for this recall is 240 and the NHTSA campaign number is 23V-028.

As of the date of this filing, Hyundai has confirmed no unique incident reporting a fuel leak in the U.S. There are no confirmed crashes, injuries, or fires related to this condition. This recall was decided based on three (3) incidents occurring in Europe.

Chrysler, Alfa Romeo And RAM Fuel System Failure

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Chrysler (FCA US, LLC) will be contacting owners of certain Chrysler, Alfa Romeo, and RAM vehicles for a problem affecting the fuel system. In total, approximately 236 000 vehicles are being recalled.

2020-2021 Alfa Romeo Stelvio and Alfa Romeo Giulia vehicles fuel line sensor housing may crack and leak fuel. NHTSA Campaign Number: 21V-878

The problem was traced to September 11, 2020, when defective fuel sensors were introduced into vehicle production, and ended on May 25, 2021, when the fuel sensors from the suspect batches were no longer used. The suspect population was determined using part traceability and vehicle production records.

According to the defect report, a leak in the fuel line sensor may cause fuel starvation of the engine and in rare circumstances, if the leaked fuel comes in contact with an ignition source, a fire could occur. A vehicle fire can result in an increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage. Fuel starvation could also result in an unexpected loss of motive power.

2019 Fiat 124 Spider fuel pump failure may cause an engine stall. NHTSA Campaign Number: 21V-879

The suspect period began on April 6, 2018, when the defective fuel delivery module (FDMs) were introduced into vehicle production, and ended on October 18, 2018, when FDMs with improved molding of the impellers were implemented in vehicle production.

Some 2019 Fiat 124 Spider vehicles may have been manufactured with a fuel delivery module (FDM) with impellers that could deform. An FDM with a deformed impeller may interfere with other fuel pump components which can inhibit the operation of the fuel pump potentially causing fuel starvation. : Fuel starvation may result in an unexpected loss of motive power.

2019-2020 RAM 2500, 3500, 4500, and 5500 diesel trucks fuel pump failure may cause an engine stall. NHTSA Campaign Number: 21V-880

The suspect period began on October 11, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production.

According to the defect report, the high-pressure fuel pump could fail and introduce debris into the fuel system. Fuel starvation and an unexpected loss of motive power could result without prior warning. Vehicle occupants may notice an illuminated Malfunction Indicator Lamp, a fuel leak or smell, abnormal engine noises, or a change in drive quality.

2021 Chevrolet Tahoe & 2021 GMC Yukon Fuel Smell

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General Motors has decided that a safety defect exists in certain 2021 Chevrolet Tahoe and 2021 GMC Yukon trucks. They will be contacting owners with instructions to return to their dealerships for repairs.

According to the defect report, a small number of 2021 Chevrolet Tahoe and 2021 GMC Yukon vehicles may have been manufactured with fuel tank assemblies that are missing an adhesive between two layers of the fuel tank shell. Under certain conditions, fuel could start seeping between the layers and could result in a slow fuel leak over time. If fuel were to contact an ignition source, there is an increased risk of a vehicle fire. If a vehicle is experiencing this problem, drivers may notice a fuel odor smell inside and near the vehicle.

Owners receiving notices will be asked to return to their dealerships to have the fuel tank replaced. GM’s number for this recall is N212327720 and the NHTSA campaign number is 21V-064.

2020 Nissan Versa Fuel Smell

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A small number of 2020 Nissan Versa owners will be contacted by the manufacturer regarding an issue with the fuel system in their cars. The vehicles affected were manufactured between the the dates of September 06, 2019 – September 23, 2019.

According to the defect report, a manufacturing deviation may have resulted in fuel tanks with insufficient wall thickness in one area. The low wall thickness, in combination with the burr trimming process, may have resulted in a small hole in the tank seam. If the owner fills the tank over half full, the tank could leak and a strong fuel smell will come from the rear of the vehicle. If the fuel leak comes in contact with an ignition source, there is a possibility of a vehicle fire.

Dealers will correct the problem by replacing the fuel tank. The NHTSA campaign number for this recall is 20V112.

2015-2018 Porsche Macan Fuel Smell

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Porsche will be contacting the owners of certain 2015-2018 Macan SUVs because of a problem affecting the fuel system in their vehicles.

According to the defect report, under high load conditions there is a possibility that the fuel supply port at the filter flange of the fuel pump could contact the service cover. The supply port could develop hairline cracks over time, potentially leading to a fuel odor. Fuel leakage in the presence of an ignition source may increases the risk of fire.

Those receiving notices will be asked to return to their Porsche dealerships to have the fuel pump flange inspected and replaced as necessary. Technicians will also rework and apply a protective film to the fuel pump flange. Porsche’s number for this recall is ALA2 and the NHTSA campaign number is 20V-077.

Audi A8 & S8 Fuel Smell

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Volkswagen will be contacting the owners of certain 2013-2015 Audi A8 and S8 vehicles because of a problem affecting the fuel system.

According to the NHTSA defect report, the high pressure fuel pump supply line could become porous and deteriorate from the inside. The resulting fuel leak may lead to a fuel smell withing the vehicle cabin and a potential fire in the presence of an ignition source.

Audi will be asking owners to return to their dealers to have the fuel line replaced. Volkswagen’s number for this recall is 20AV and the NHTSA campaign number is 18V-430.

2013-2015 Jaguar XF Fuel Leaks

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Jaguar will be contacting the owners of certain 2013-2015 Jaguar XF vehicles equipped with 2.0L GTDi engines, regarding a problem affecting the fuel system. According to the defect report, a concern has been identified where the installation of the fuel delivery line may have insufficient clearance from the vehicle’s under shield and body. If the line chafes through, drivers may notice a fuel smell inside the vehicle or a fuel puddle underneath when it is parked.

Dealers will inspect the fuel delivery lines and replace damaged ones as necessary. An anti-abrasive sleeve and two additional mounting clips will be installed to ensure clearance. For more information about the problem, owners are asked to contact Jaguar customer service at 1-800-452-4827. Jaguar’s number for this recall is J077 and the NHTSA campaign number is 16V-796.

2010-2011 Mazda Tribute FDM Fuel Leak

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Mazda will be contacting the owners of certain 2010-2011 Tribute vehicles equipped with 3.0L engines, regarding a problem affecting the fuel system. According to the defect report, the Fuel Delivery Module (FDM) could crack, causing a fuel leak and a potential fire. Mazda will notify owners, and dealers will replace the FDM flange with one that has a redesigned fuel supply port. The recall is expected to begin December 15, 2016. For more information about the problem, owners are asked to contact Mazda customer service at 1-800-222-5500. Mazda’s number for this recall is 0416J and the NHTSA campaign number is 16V-788.