Volkswagen Group of America, Inc. (Volkswagen) will be contacting the owners of certain front-wheel drive Volkswagen and Audi vehicles because the suction jet pump seal inside the fuel tank could fail. This failure could allow fuel to flow into the evaporative emissions (EVAP) system and possibly leak out of the charcoal canister.

The problems started in August 2016 when Volkswagen determined there was a defect affecting vehicles built with a specific suction jet pump. A Recall (16V-647) was issued and the affected vehicles received an improved version (Version 1.1) of suction jet pump.

In April 2018 Volkswagen started to receive their first reports of suction jet pump failures and an investigation was started. During an analysis of these warranty claims and customer complaints (VOQ’s), the evaluation of the field performance of the improved version of the suction jet pump indicated an increased failure rate. The topic was discussed at the Product Safety Committee’s of Volkswagen and Audi and a recall for all front wheel drive vehicles that have been equipped with the improved version was decided (based on 1410 warranty claims on FWD vehicles with repair dates between 05/01/2016 and 12/31/2023)

The vehicles affected include:
2015-2020 Audi A3 Sedan
2015-2019 Audi A3 Cabriolet
2019-2020 Volkswagen Jetta GLI
2018 Volkswagen Golf Sportwagen GP
2018-2019 Volkswagen Golf Sportwagen A7
2015-2017 Volkswagen Golf Sportwagen
2015-2020 Volkswagen Golf GTI
2015-2020 Volkswagen Golf A7

The recall remedy component is a redesigned suction jet pump (Version 2.0) and has incorporated multiple changes/improvements. The remedy part has the part number 5Q0.201.029 A, the recalled part has the part number 5Q0.201.029.

Owners receiving notices will be instructed to return to their dealers to have the suction pump replaced. Volkswagen’s numbers for this recall are VW: 20UF/Audi: 20YF. The NHTSA campaign number is 24V-110. Vehicles that were previously recalled under 16V-647 will need to have the new remedy completed.

The Volkswagen Group of America, operating under its Audi brand, has recently identified a critical issue in a range of its electric vehicle models. This issue revolves around the charging system, specifically the high-voltage battery modules, raising concerns about potential overheating and fire safety risks.

Affected Models

The problem affects several Audi models between 2019 and 2024, including the RS e-tron GT, e-tron GT, Q4 e-tron Sportback, Q4 e-tron, Audi A8, e-tron Quattro, e-tron Sportback Quattro, Q5, and A7.

Overheating High-Voltage Battery Modules

The central issue lies in the high-voltage battery modules, which are prone to overheating. This has been especially evident when charging with the industrial 220V/240V plug at a current of 40 amperes. Crucially, Investigations revealed that the charging equipment itself was not at fault. Instead, the issue often stemmed from household power outlets and wiring incapable of handling the required current, leading to overheating of the home infrastructure.

Initial Discovery and Response

The issue first came to light in April 2020, following a fire incident outside the U.S. Audi collaborated with their high-voltage battery supplier, LG Energy Solutions, to investigate. By mid-2023, a noticeable increase in thermal events led to a deeper examination. Despite a service campaign in April 2022 that included a software update for cell module balancing, issues persisted.

Recall and Remedial Actions

In response, Audi initiated a voluntary global safety recall, designated 93U9 by Audi and 23V-867 by the NHTSA. The recall includes installing onboard diagnostic software to monitor battery module performance and replacing affected modules as necessary. Interim notification letters are scheduled for February 2024, with a detailed follow-up expected in the third quarter of the same year.

Charging Cable Replacement

A significant aspect of the recall is the replacement of the power cable used for industrial sockets (220V/240V/NEMA 14-50). The existing cable (part number 7PP971678 ED) will be replaced with a new design (part number 7PP971678GA), featuring temperature sensors. These cables should be available in the second quarter of 2024.

Safety Concerns and User Guidance

Owners of affected models are advised to be cautious, especially when using industrial sockets for charging. The overheating issue can cause not only damage to the charging cable but also pose a risk to household electrical infrastructure. If the problem exists, users may notice the charging cable feeling hot to the touch after use.

This recall underscores the importance of matching electric vehicle charging systems with compatible household wiring. Audi’s proactive steps in addressing this issue highlight their commitment to customer safety and the integrity of their electric vehicle line. Owners of the affected models are encouraged to heed recall notices and ensure their home charging setups are compatible and safe.

The charging issue identified in Audi’s electric vehicles bears notable similarities to the Chevrolet Bolt recall (21V-650). In both cases, the central concern revolves around the battery systems and the associated risk of overheating, which could potentially lead to fire hazards. The Chevrolet Bolt recall, much like Audi’s, involved issues with high-voltage battery packs that were found to be prone to catching fire. Both recalls necessitated substantial corrective actions, including software updates, close monitoring of battery performance, and in some cases, the replacement of battery modules. Furthermore, these incidents highlight a broader challenge in the electric vehicle industry, emphasizing the need for more robust and safe battery technologies and charging infrastructures. Such parallels underline the growing pains of electric vehicle technology and the critical importance of ensuring safety as these vehicles become increasingly prevalent.

Volkswagen Group of America, Inc., particularly its Audi division, is facing a significant challenge with its 220V/240V charging cables. Owners of certain 2019-2024 Audi models are being notified due to a defect that could lead to the overheating and potential fire hazard of the outlet or charging cable. This alarming issue affects a range of models, including:

  • 2021-2022 Audi A7
  • 2020-2021 Audi A8
  • 2019-2024 Audi E-Tron
  • 2022-2024 Audi E-Tron GT
  • 2022-2024 Audi Q4 E-Tron
  • 2020-2024 Audi Q5
  • 2022-2024 Audi RS E-Tron GT

The problem first came to light in September 2020 when cases of melting and overheating at the industrial socket (NEMA 14-50) were reported during the use of the industrial 220V/240V plug with 40 amperes. Audi’s thorough investigation, which involved requesting parts from the field and analyzing customer charging behavior, revealed that the vehicles and the provided charging equipment were not at fault. Instead, the cause was often linked to household power outlets and wiring, or circuit breakers not capable of handling the required electrical current.

Understanding that household power outlets and wiring might not be equipped to handle the necessary current, Audi initiated a service campaign that instructed customers to bring their charging equipment to an Audi dealer to modify the charging system control unit to a 50% power level for the industrial plug. Additionally, a warning label was attached to the control unit of the Audi compact charging system, advising on safe usage.

Despite these measures, and the ability to charge at 100% current upon confirmation of adequate home power supply, further incidents of overheating and melting sockets were reported. As a result, in January 2022, Audi launched a safety recall, superseding the service campaign, to replace the affected charging cables with new ones equipped with temperature sensors. For unsold vehicles, the industrial charging cable will be replaced before delivery. As of the latest reports, Audi has identified 615 claims related to this issue from 08/05/2020 to 12/05/2023. Fortunately, there have been no reports of fires, crashes, or injuries connected to this problem.

Audi advises owners of the affected models not to use the 220V/240V compact/portable charging cable. Instead, they should use the 110V home charging cable or public charging stations until the issue is resolved. Owners can expect to receive interim notification letters by February 9, 2024, explaining the safety risks. A second notice will follow, detailing the availability of remedy parts, expected around mid-2024. Audi’s recall numbers are 93U6 and 93U8, with the NHTSA campaign number being 23V-842.

This recall underscores the importance of not only the quality of automotive products but also the compatibility and capacity of home electrical systems. Owners of the affected models are urged to heed the recall notices and take the necessary steps to ensure their safety.

Door handle water intrusion Recent developments in automotive safety have brought to light a significant issue with the 2021-2023 Volkswagen ID.4 models. These vehicles have been identified as having door handles that fall short of the required standards for water ingress protection. This defect poses a serious safety risk, as it can lead to malfunctions in the door lock system, causing doors to open unexpectedly.

The Central Safety Concern

The main safety hazard is the risk of doors opening spontaneously under high lateral forces, particularly at speeds below 9 mph (15 km/h). This can be dangerous for both the vehicle’s occupants and those outside, including pedestrians and nearby objects. The problem stems from water entering the printed circuit board within the door handle, leading to miscommunications with the door control unit.

Signs of the Malfunction

Drivers and passengers in the affected Volkswagen ID.4 models may notice an unusual clicking sound, similar to that of doors locking or unlocking, which can indicate the onset of this issue.

Timeline of the Volkswagen ID.4 Door Handle Issue

  • June 2021: The first signs of this issue in the Volkswagen ID.4 were reported in the U.S., with two cases of door openings. Investigations pointed to wiring harness damage as a cause of water ingress.
  • April 2022: Additional reports confirmed the presence of water in the circuit board.
  • April-November 2022: Volkswagen conducted in-depth analyses using malfunctioning parts, signal debugging, and accelerated aging tests.
  • November 2022: Tests on field vehicles identified the issue at speeds below 15 km/h.
  • January-February 2023: In collaboration with suppliers, Volkswagen analyzed and tested deconstructed field parts.
  • February 2023: Environmental tests commenced on serial parts to better understand the ingress of water.
  • February 28, 2023: The NHTSA called for a meeting with VWGoA to discuss the ID.4 door handle issue.
  • March 2023: Continued investigations by VWGoA and NHTSA, with no definitive root cause identified initially.
  • March 28, 2023: Completion of climate chamber tests led to the identification of the root cause.
  • April 2023: Volkswagen’s Product Safety Committee started identifying affected ID.4 vehicles.

Recall Decision and Implications

By April 26, 2023, Volkswagen’s Product Safety Committee had decided to recall the affected 2021-2023 ID.4 models, following 28 reported instances of door openings. This recall is a vital step in rectifying a crucial safety defect, highlighting the need for stringent quality control and proactive measures in the automotive industry.

The Volkswagen ID.4 is a popular electric vehicle that has been making waves in the automotive industry since its release in 2021. However, like any other vehicle, the ID.4 has not been immune to problems, complaints, and recalls.

One of the most significant problems reported by ID.4 owners is related to the vehicle’s software. There have been multiple complaints of the software malfunctioning, resulting in issues such as loss of power, sudden deceleration, and even complete shutdown of the vehicle. These issues have led to multiple recalls of the ID.4, with Volkswagen issuing software updates to address the problem.

Another complaint reported by ID.4 owners is related to the vehicle’s charging capabilities. There have been complaints about the charging process being slow or inconsistent, with some reports that the vehicle fails to charge altogether. While this issue has not led to any recalls, it is something that Volkswagen needs to address to ensure that the ID.4 remains a competitive electric vehicle option.

There have also been several complaints regarding the ID.4’s braking system. Some drivers have reported that the brakes are unresponsive, while others have complained about excessive brake wear. These issues have not resulted in any recalls, but they are cause for concern and something that Volkswagen needs to address to ensure the safety of its drivers.

In addition to these issues, there have been a few recalls associated with the Volkswagen ID.4. The most recent recall involves certain 2023 ID4 rear-wheel drive vehicles. The 12-Volt battery charging cable may contact the steering column shaft and cause the cable insulation to wear, possibly resulting in a short circuit. As a precaution, owners of affected vehicles are advised to park outside and away from structures and other vehicles due to the potential risk of a vehicle fire.

In conclusion, while the Volkswagen ID.4 is a promising electric vehicle option, it has had its fair share of problems and complaints. From issues with the software to problems with the charging and braking systems, there are areas where Volkswagen needs to improve the vehicle. However, it is reassuring to see that Volkswagen has been proactive in addressing these issues, with recalls and software updates aimed at improving the driving experience and ensuring the safety of its drivers.

Volkswagen Group of America, Inc. (VW) will be asking a small number of 2021 VW ID.4 electric crossover SUV owners, to return to their dealerships because of a problem affecting the solder connections inside the HV battery of their vehicles. This defect could result in a stall and may increase the risk of an accident. A fix for this problem is still under development by the manufacturer.

VW became aware of the defect in January 2021 when the first known field case occurred outside the U.S. VW quality and safety departments began to monitor the field reports for the nature and frequency of the non-starting condition and found reports of similar problems in other brand vehicles using the same or similar battery systems. During a multi-brand clearing committee meeting, impacted brands shared information on the potential stall while driving cases and decided to conduct a recall. Volkswagen will be conducting a recall on 351, 2021 VW ID.4 vehicles in the U.S. that contain the potentially affected parts.

According to the defect report, a manufacturing problem with the high voltage (HV) battery may have caused incorrect soldering on specific points of the flexible printed circuit assembly (FPCA). The amount of solder contact points of the FPCA is not sufficient and the thickness of the solder layer is out of tolerance parameters. The result is an unreliable connection inside the HV battery that could lead to a breakdown or stalling while driving. If this issue is present in the vehicle, the driver will be alerted by a high voltage system warning message in the instrument panel.

Owner notification letters about the defect are expected to be mailed by May 13, 2022. Volkswagen’s number for this recall is 9302 and the NHTSA campaign number is 22V-1562.

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In August 2020, Volkswagen / Audi received an inquiry about a gateway control module failure in an Audi Q5 vehicle in China. An inspection of the situation found that the gateway control module had gone into fail safe mode because of liquid entering the module from a rear bench seat spill.

The gateway control module has been programmed to go into a fail-safe mode when an implausible signal is detected in the control unit. If an implausible signal is detected, the gateway switches off its function in order to avoid unwanted vehicle reactions. The vehicle remains steerable and the brake system will work, but the engine will go into emergency mode and remains in operation with reduced power.

Audi performed a safety assessment to evaluate the potential conditions and consequences that could result from a power shutdown of the gateway control module due to liquid ingress. Audi also conducted a risk assessment which indicated that the risk of a liquid spill leading to a failure of the gateway control module is very low and rare over the lifetime of the vehicle. At the time there were only isolated cases in the North American region and all of them happened after an outside influence, mostly after a beverage spill. Audi continued to monitor the problem.

In March 2021, Audi experienced an increase in customer reports related to gateway control module failures on Q5 vehicles after a liquid spill. Audi conducted additional testing and continued to investigate a potential solution to be implemented in production and in the field. Due to single field cases alleging the failure without a liquid spill, an additional investigation was initiated to rule out other root causes for liquid ingress. In August 2021 Audi identified a potential manufacturing issue in the factory in Mexico. “Due to a programming error of a glue bead robot, an underbody seam may not have been sealed sufficiently and therefore allow water ingress from underneath in very rare cases when driving through heavy rain or deep puddles.” The adjustment to the robot was implemented immediately and analysis continued regarding the impact of this additional potential cause for liquid ingress.

The Audi Safety Committee began to issue a service campaign in order to install a protective cover for the gateway control module and to seal the underbody in the area of the insufficient glue bead, but after a meeting with Transport Canada and the Defective Product Administrative Center in China, the Audi Product Safety Committee re-evaluated their decision and decided to conduct a voluntary recall to fix affected vehicles.

The Vehicles Affected Include:
2018-2022 Audi Q5 Sportback
2018-2022 Audi SQ5 Sportback

In June 2021 Volkswagen started an investigation into certain Taos compact SUVs after reviving field complaints of stalling when coming to a stop. The vehicles affected by this defect are equipped with all wheel drive powertrains.

According to the defect report, some 2022 VW Taos with all wheel drive powertrains and a specific software version installed in the engine control unit, could experience a stalling condition when coming to a stop. Conditions such as high ambient temperatures, high engine loads and a running air conditioner increases the chance of an engine stall. The cause for stalling is currently under investigation.

To correct the problem, Taos owners with affected vehicles will be asked to return to their dealers to have the ECU software updated. Owner notification letters are expected to be mailed October 2021. Volkswagen’s number for this recall is 24HH and the NHTSA campaign number is 21V-615.