Suzuki Recalls More Than 20,000 Kizashi Vehicles for Potential Fuel Tank Cracking

Suzuki Recalls More Than 20,000 Kizashi Vehicles for Potential Fuel Tank Cracking

November 24, 2018 Sean Reyes

Laguna Hills, CA – November 24, 2018 – Suzuki Motor of America, Inc. (Suzuki) is recalling certain 2010-2013 Suzuki Kizashi vehicles, due to potential fuel tank cracking. The potential number of units affected is 21,052.

The Defect

According to the NHTSA Recall Safety Report, when driving on very dusty roads, a large amount of dust can enter the vent line that provides fresh air to the carbon canister, causing a restriction in the vent line. If this occurs, air flow through the evaporative system may be impacted such that excessive negative pressure is created in the fuel tank. This can cause deformation of the fuel tank, which can lead to fuel tank cracks.  If the fuel tank becomes cracked, fuel leakage and venting of gasoline vapors can occur, increasing the risk of a fire. Drivers may have some warning a crack has occurred; when the fuel tank becomes cracked, a pressure sensor will detect fuel vapor leakage and will illuminate the Malfunction Indicator Lamp (MIL), alerting the driver to seek corrective action.

Timeline of Events

In February, 2016, SMC received one Field Technical Information Report (FTIR) from Suzuki Motor of America, Inc. (SMAI) concerning fuel odor from a Suzuki Kizashi vehicle due to a fuel tank crack. A second FTIR was received from SMAI concerning Malfunction Indicator Lamp (MIL) illumination in a Suzuki Kizashi vehicle. Both incidents occurred in Wichita, Kansas. SMC’s investigation revealed that sand had accumulated in the carbon canister filter and carbon canister. SMC was unable to find the route of sand entry or the root cause of the problem.

From March to June, 2016 SMC installed collected parts on a test vehicle and measured internal fuel tank pressure changes using simulated driving modes, and conducted a fuel tank durability test to determine that the fuel tank crack occurred at about 34,000 miles, but also showed that 125,000 miles of driving was needed to replicate the sand accumulation seen in the incident vehicles.

Subsequent reports, most from Wichita, led SMC to determine that an investigation at a test site in Wichita was necessary, because the sand accumulation in SMC’s “Dust Road Test” did not correspond with the sand accumulation in incident vehicles. In April, 2018 SMC operated test vehicles in Wichita to evaluate the sand accumulation volume in the canister filter and checked customer vehicles selected at random and judged that the problem of filter clogging was due to driving on rough roads with fine dust like sand.

From June to July, 2018, SMC studied computer simulations to find the route of sand entry and noticed that the volume of sand entering this area could be reduced by plugging space between the rear fender lining and the wheel housing. SMC decided to make trial parts to cover this space and to conduct further testing in the U.S. which subsequently found that the very fine sand could pass through the rear fender lining made of non-woven fabric. On October 25, 2018 SMC reported the identified problem as a safety-related defect, even though the reported incidents were clustered around discrete geographical areas and there remain no clear indications of the root cause or an appropriate remedy.

The Solution

The remedy for this recall is still under development. The manufacturer has not yet provided a notification schedule. Owners may contact Suzuki customer service at 1-800-934-0934. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-769.

Sean ReyesSuzuki Recalls More Than 20,000 Kizashi Vehicles for Potential Fuel Tank Cracking
Subaru Recalls More Than 160,000 Vehicles for Weak Engine Valve Springs

Subaru Recalls More Than 160,000 Vehicles for Weak Engine Valve Springs

November 13, 2018 Sean Reyes , ,

Laguna Hills, CA – November 13, 2018 – Subaru of America, Inc. (Subaru) is recalling certain 2012-2014 Subaru Impreza, 2012-2013 Impreza Stationwagon, 2013 Subaru BRZ, XV Crosstrek and Toyota Scion FR-S vehicles for a valve spring issue that could cause engine stall. This recall is expected to affect 165,534 Subaru vehicles in North America.

The Defect

According to the NHTSA Recall Safety Report, due to an improper design of the valve train within the engine, an excessive stress is generated on the valve spring compared to the design condition. In addition, a very small amount of the impurity within the composition of the spring material is not avoidable in the manufacturing process. The combination of excessive stress and the dispersion of the impurity in the valve material during manufacturing may cause the valve springs located inside the engine of the affected vehicles may fracture, which may cause engine malfunction. In the worst case, the engine may stall during driving, and restarting will not be possible, increasing the risk of a crash.  Drivers may have a short window of advance warning as abnormal noise or vibration may occur prior to the engine stalling.

Timeline of Events

In April of 2012, SUBARU CORPORATION (Subaru) received a technical report from the Japan market which described an abnormal noise and rough idling. The collected engine was examined, and it was surmised that the valve spring broke and fell off, making contact with the piston and causing a rough idling and an abnormal noise. While a component analysis was conducted, no spring material flaw was identified and the cause of the fracture was unknown. In May 2013, the lower limit of the tolerance of the spring wire diameter was raised as a precaution and in response to eleven technical reports related to stalling reported from the U.S. In August 2016, based on additional examinations of engines collected from the field, it was determined that a ndactor not avoidable in the manufacturing process, namely very small amount of impurity within the composition of the spring material, could affect spring fracture.

Three additional technical reports related to stalling were issued from the U.S. during this time frame, but by September 2018 it was determined that a higher occurrence rate than estimated with general manufacturing dispersion from the vehicle manufactured with lower spring tolerance. Further investigation led to the revelation due to the improper design of the valve train, stress generated exceeded the design condition, and, when combined with the dispersion of impurity within the composition of the spring material, could cause spring fracture due to fatigue. On Oct 25, 2018, Subaru issued a safety recall for vehicles equipped with a similar valve train design manufactured prior to the tolerance adjustments made in May 2013.

The Solution

Subaru will notify owners, and all valve springs will be replaced with new ones free of charge. Owner notification will occur within 60 days of Dealer notification, which began on November 1. If parts are not available by that time, owners will be notified that parts are not available yet and they will be re-notified once parts are available. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-772.

Sean ReyesSubaru Recalls More Than 160,000 Vehicles for Weak Engine Valve Springs
Subaru Recalls More Than 200,000 Vehicles for Faulty Fuel Indicator

Subaru Recalls More Than 200,000 Vehicles for Faulty Fuel Indicator

November 12, 2018 Sean Reyes

Laguna Hills, CA – November 12, 2018 – Subaru of America, Inc. (Subaru) is recalling certain 2018 Subaru Legacy and Outback vehicles due to a software issues that affects the vehicle’s fuel display. This recall is expected to affect 228,648 Subaru vehicles in North America.

The Defect

According to the NHTSA Recall Safety Report, due to a software error, the low fuel warning light may not light up to indicate the intended remaining fuel level and the distance-to-empty (DTE) display may incorrectly indicate a positive number even if the fuel tank is empty. This inaccuracy in the fuel display may cause a driver to unexpectedly run out of fuel and the vehicle to stall, increasing the risk of a crash.

Timeline of Events

In December of 2017, SUBARU CORPORATION (Subaru) received a technical report regarding the driving range indicator (DTE) in the multi-information display. The report indicated a positive distance-to-empty (DTE) when no usable fuel was remaining. A field part collection was requested, and between December 2017 and March 2018 p arts were collected from the field and sent to the supplier for an investigation which subsequently took place during April and June of 2018. In July 2018, the supplier submitted the investigation report to Subaru, whereupon, from August to October 2018, Subaru assessed their field data and the supplier’s investigation report to assess risk. On October 25, 2018, Subaru completed the investigation and determined that a voluntary safety recall should be ordered.

The Solution

Subaru will notify owners, and dealers will reprogram the combination meter software, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Subaru customer service at 1-844-373-6614. Subaru’s number for this recall is WTW-82. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-773.

Sean ReyesSubaru Recalls More Than 200,000 Vehicles for Faulty Fuel Indicator
Big Ford Recall – What to do if your Engine Stalls

Big Ford Recall – What to do if your Engine Stalls

November 9, 2018 Sandra Thomas

Risk: Sudden engine stalling, unexpectedly running out of gas

Ford recalled 1.3 million Ford Focus cars because fuel system valves can get stuck open, causing cars to suddenly stall, fail to re-start and/or unexpectedly run out of gas increasing the risk of crashing. You may see warning lights.

CAR STALLING OR ACTING LIKE IT MIGHT? DO THIS:

  • First clue? As soon as you sense trouble, hit your turn signal and make your way to the shoulder. Don’t wait for a complete stall out.
  • No power? Turn on your flashers and call 911. Don’t try to drift to the side of the road unless you have enough momentum and clear lanes to get there. You don’t want to block two lanes!
  • Panic? Yep, people do. But you are going to think straight: check for oncoming traffic, use your turn signal and get over
  • Safe Side? Right side is best! But if you are stalling and in the left lane, exit left
  • Sit Tight? YES. Stay IN the car, ensure your seatbelt is on. Lookie Loo’s often drift in the direction they’re looking.
  • Roadside Rear-ender? Happens all the time. If you can, place your car in neutral to reduce impact energy if someone smashes into you
  • Can you get it Fixed Free? Yes, if it’s under recall you can! Find out by checking Motorsafety.org. And guys? If your car is under recall, for Pete’s sake — get it fixed! Industry: RecallMasters.com Consumers: MotorSafety.org

Sandra ThomasBig Ford Recall – What to do if your Engine Stalls
BMW Recalls nearly 45,000 Vehicles Due to a Potential Coolant Leak

BMW Recalls nearly 45,000 Vehicles Due to a Potential Coolant Leak

November 7, 2018 Sean Reyes

Laguna Hills, CA – November 7, 2018 – BMW of North America, LLC (BMW) is recalling certain models over fire risk. These vehicles are equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. If the EGR cooler leaks internally, the coolant can mix with diesel engine soot. The high EGR temperatures may result in these particles possibly smoldering and melting the intake manifold, which can increase the risk of a fire.

Included in this recall are: 

  • 2013-2018 BMW 328d and 328d xDrive 
  • 2014-2018 BMW 328d Sports Wagon and 328d xDrive Sports Wagon
  • 2014-2016 BMW 535d and 535d xDrive
  • 2015 BMW 740Ld xDrive
  • 2015-2017 BMW  X3 xDrive28d SAV 
  • 2014-2017 BMW X5 xDrive35d SAV 

The Defect

According to the NHTSA Recall Safety Report, approximately 12,781 Model Year 2013-2018 BMW 328d and 328d xDrive Diesel engine vehicles were equipped with an Exhaust Gas Recirculation (EGR) module that featured an integrated cooling component (“cooler”). Over time, this component could start to internally leak glycol coolant, because the recall component was not produced with sufficient long-term durability characteristics. During vehicle operation, if an internal coolant leak began inside the EGR cooler, the fluid could mix with normal diesel engine soot/sediment. This combination in the engine environment with high temperatures normally present might result in smoldering particles, which in very rare cases could lead to the melting of the intake manifold. In extreme cases, this could result in a possible fire. During vehicle operation, the driver may be alerted to this condition by one or more of the following: A warning symbol in the instrument cluster displaying a loss of engine coolant, a reduction in engine power, an unpleasant odor (exhaust gas), an unusual noise from the engine compartment, and/or smoke from the engine compartment.

Timeline of Events

On July 26, 2018, BMW submitted the required Part 579 report, to which NHTSA assigned “18F-137” as the Foreign Recall ID after BMW became aware of an issue in the Korean market. On September 5, 2018, BMW met with NHTSA to explain EGR system differences between vehicles in the U.S. market and vehicles in other markets. BMW provided a summary of U.S. field data including warranty claims, consumer complaints, and field reports which indicated coolant leak warnings, drivability concerns, or damage to the intake manifold. BMW also stated that it would continue to closely monitor the field. In October 2018, further in-depth analyses indicated that it was possible that one incident could be attributed to this issue. BMW decided to conduct a voluntary safety recall although at the time of the report, BMW was unaware of any accidents or injuries related to this issue.

The Solution

Owners will be notified by First Class mail and instructed to take their vehicle to an authorized BMW center to have the remedy performed at no cost. The EGR cooler will be inspected and, if necessary, replaced free of charge. If it is determined that the EGR cooler has internally leaked, the engine intake manifold will also be replaced. The EGR pipe connecting the cooler to the manifold will be cleaned. Owners who have replaced the EGR cooler at their own expense prior to the recall notification may be eligible for reimbursement according to BMW Group’s reimbursement plan. Notification to owners is planned to begin and end on December 17, 2018. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-755.

Other BMW Recalls 

Some of these vehicles may have been a part of a recall in August of 2021, when BMW recalled vehicles over a risk of engine stalling caused by a high-pressure fuel pump that suffers from excessive wear. In addition, even vehicles with gasoline engines, such as the 328i station wagon, had problems with their fuel pumps in the past.  

  • 2014 – 2018 BMW 328D
  • 2015 – 2017 BMW X3
  • 2014 – 2016 BMW 535D
  • 2014 – 2018 BMW X5 
  • 2015 BMW 740LD

The affected component in this recall is the BMW high-pressure fuel pump with part number 7810696 and 7283473

Is your vehicle a part of this recall?

This BMW recall includes more than 11,000 vehicles. To check for this and other BMW recalls, use MotorSafety’s free vehicle lookup tool.

Sean ReyesBMW Recalls nearly 45,000 Vehicles Due to a Potential Coolant Leak
2017-2019 Toyota 4Runner: Recall Alert

2017-2019 Toyota 4Runner: Recall Alert

November 6, 2018 Sean Reyes

2017-2019 Toyota 4Runner: Recall Alert

Vehicles Affected: Approximately 1,300 model-year 2017-19 Toyota 4Runner SUVs that Southeast Toyota Distributors equipped with a TRD wheel package

The Problem: The gross vehicle weight rating on the certification label may be incorrect, possibly resulting in the vehicle being overloaded and increasing the risk of a crash.

The Fix: SET will notify owners and mail them corrected certification labels for free…Read more on Cars.com

Sean Reyes2017-2019 Toyota 4Runner: Recall Alert
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