Certain 2014-2020 Jeep Grand Cherokee and 2014-2019 Ram 1500 vehicles equipped with 3.0L diesel engines, could experience high-pressure fuel pump failure. If the pump fails while the vehicle is being operated, drivers will experience an unexpected loss of engine power and an increased chance of an accident.

In February 2022, Fiat Chrysler Automobiles (FCA) Technical Safety and Regulatory Compliance (TSRC) organization started an investigation into Jeep Grand Cherokee and Ram 1500 trucks, after receiving field reports that the fuel pump in some vehicles were prematurely failing. An investigation of the stall patterns and vehicle histories showed that the affected trucks were equipped with Bosch CP4.2 high-pressure fuel pumps (HPFP).

According to the defect report, a failure inside the fuel pump could introduce internal debris that could build up and cause fuel starvation. Fuel starvation may result in an unexpected loss of motive power, which could contribute to a vehicle to crash. The suspect period began on June 12, 2013, when 3.0L Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on December 13, 2019, when 3.0L Diesel engines with suspect HPFPs were no longer used in vehicle production.

Warning signs that your vehicle may be experiencing this problem include:
Drivers may notice a Malfunction Indicator Lamp, a service Electronic Throttle Control indicator, a fuel leak at the HPFP, or excessive noise from the HPFP.

FCA US is aware of 215 customer assistance records, 1,061 warranty claims, and three field reports that could be related to this issue.

Owners receiving notices will be asked to return to their dealers to have the HPFP replaced. Dealers will also inspect the entire fuel system and replace components as necessary. FCA’s number for this recall is Z46 and the NHTSA campaign number is 22V-406.

The NHTSA Office of Defects Investigation (ODI) have opened up an investigation into certain 2019-2020 RAM trucks after receiving 22 complaints and 2 field reports alleging incidents of stalling and loss of engine power. The vehicles affected are equipped with 6.7L Cummins turbo diesel engines. According to the investigation report, the complaints found that most stall/loss of motive power incident allegations occurred at speeds above 25 MPH and resulted in permanent disablement of the vehicle.

The Vehicles Affected Include:
2019-2020 Ram 2500
2019-2020 Ram 3500
2019-2020 Ram 4500
2019-2020 Ram 5500

In November 2019, FCA issued Warranty Bulletin D-19-02 to announce to its dealers a Fast Feedback Program wherein they were notified of a campaign to collect, monitor, and correct quality issues on certain 2018-2020 Ram trucks equipped with the 6.7L Cummins engine. As a result of this campaign, high-pressure fuel pumps have been collected and inspected by the manufacturer and pump manufacturer.

ODI is opening this investigation to further assess the scope, frequency, root cause, and potential safety-related consequences of the alleged defect leading to stall/loss of motive power on 2019-2020MY RAM heavy-duty trucks.

In July 2021 General Motors (GM) opened an investigation into fuel pump failures after a review of warranty data from certain 2021 GM full size SUVs. The data showed that there was a higher than expected rate of fuel pump control modules replaced for vehicles built within certain months. As part of the investigation, GM looked at the returned parts replaced in warranty claims and found the condition was caused by a manufacturing issue at the Tier 3 supplier.

According to the defect report, certain 2021 Cadillac, Chevrolet and GMC full size SUVs may have been manufactured with fuel pump power control modules which contain a defect that can cause the fuel pump to fail or operate intermittently. When this happens, fuel flow to the engine will be interrupted and the vehicle could unexpectedly stall.

The Vehicles Affected Include:
2021 Cadillac Escalade
2021 Cadillac Escalade ESV
2021 Chevrolet Suburban
2021 Chevrolet Tahoe
2021 GMC Yukon
2021 GMC Yukon XL

Owners receiving notices will be asked to return to their dealers to have the fuel pump power control module replaced. GM’s number for this recall is N212332040 and the NHTSA campaign number is 21V-739.

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.

Toyota will be asking the owners of certain 2019-2020 Toyota Yaris vehicles to return to their dealerships for a problem that could lead to fuel pump failure and an engine stall.

Last year Mazda, which is responsible for the vehicle’s design and manufacturing, started an investigation into Mazda and Toyota vehicles experiencing fuel pump failures. Based on the recovered parts and other investigations, Mazda reported that the fuel pumps in the subject vehicles were affected by exposure to high environmental temperatures.

According to the defect report, these vehicles are manufactured with low pressure fuel pumps with low density impellers. These impellers were exposed to production solvent drying for longer periods of time which make them more susceptible to fuel absorption, impeller deformation and impeller cracking. In some cases, the impeller could deform to a point that creates enough interference with the fuel pump body to cause the fuel pump to stop operating. An inoperative fuel pump will result in an illuminated check engine light, master warning indicators, rough engine running and an engine no start and/or vehicle stall while driving.

Toyota will be contacting owners of affected vehicles with instructions to return to their dealerships to have the low pressure fuel pump assembly replaced. Toyota’s numbers for this recall are 21TB05 and 21TA05. The NHTSA campaign number is 21V-617.

Owners of certain 2020-2021 Nissan Armada and 2020-2021 Infiniti QX80 SUVs equipped with V8 engines could experience a fuel system problem that could result in an unexpected engine stall. Nissan learned of a potential issue on these vehicles in June 2020 and initiated an investigation which has lead to the recall of approximately 24,000 vehicles.

According to the defect report, the fuel pump module was not designed to manufacturer specifications and could fail. During the impeller manufacturing process, a buildup of molten plastic on the injection moulding machine cylinder tip could cause the density of the impeller to be out of specification. Fuel inside the fuel pump can cause the impeller to swell, increasing friction between the impeller and inlet cover. Eventually the fuel pump will bind internally and the engine will stall.

Owners receiving notices will be asked to return to the dealers to have the fuel pump module replaced. Nissan’s number for this recall is R21A2, Infiniti’s number for this recall is R21A3 and the NHTSA campaign number is 21V-373.

In February, Nissan initiated an investigation into reports of an illuminated Malfunction Indicator Lamp (MIL), reduced power and engine stalling in some 2021 Infiniti Q50 And Q60 vehicles. This investigation has resulted in a recall affecting approximately 13,000 vehicles.

According to the defect report, the engine control module (EMC)in the subject vehicles has a software function that prevents unintended acceleration based on monitoring torque input. A problem was found with the EMC software which prevented it from correctly reducing engine speed after an excessive torque detection. As a result, the vehicle would go into limp mode, reducing engine power, illuminating the MIL and eventually stalling. Nissan has received one report of an accident without injuries potentially related to this issue.

Infiniti will be notifying owners to return to their dealerships to get the ECM software reprogrammed. Infiniti’s number for this recall is R20C5 and the NHTSA campaign number is 21V-234.

General Motors will be asking the owners of certain 2020 GM automobiles to return to their dealerships to fix a problem affecting the fuel supply system in their vehicles. The vehicles affected include 2020 Buick Enclave, Cadillac XT5, Cadillac XT6, Chevrolet Traverse and GMC Acadia.

According to the defect report, the fuel pump assemblies in these vehicles may have been produced with burrs inside the mixing tube. Over time, these burrs could prevent the transfer of fuel from the secondary side of the fuel tank to the primary side. At low fuel levels, the engine may not receive enough fuel and the engine could stall unexpectedly. A stall without warning, especially at high speeds, could increase the risk of an accident.

Dealers will correct the problem by replacing the fuel pump module. GM’s number for this recall is N202314760 and the NHTSA campaign number is 20V-639.