Tag Archives: manufacturing error

Chevy Equinox & GMC Terrain Engine Stalls From Fuel Starvation

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General Motors (GM) have decided that a defect affecting safety exists in certain 2021-2022 Chevrolet Equinox and 2022 GMC Terrain vehicles. They opened an investigation into the problem in August 2022 after noticing a high rate of warranty returns for the fuel tank pump on some 2021-2022 model year Equinox and Terrain vehicles.

GM’s investigation analyzed field data, defective returned components, and conducted an inspection of the tier two supplier’s facility and manufacturing processes. During this investigation, GM found that the supplier’sf manufacturing team made an unauthorized change in the fuel tank pump rolling force in May 2021 and that this error was discovered and corrected by the supplier’s engineering team on June 2021. GM conducted an analysis of field data relating to claims GM received between May 22, 2021, and December 15, 2022, and identified 710 stall events potentially related to the recall condition.

According to the defect report, during a specific production period between May 2, 2021, and June 1, 2021, a tier-two supplier implemented an unauthorized change to the fuel pump in the manufacturing process which decreased the pump section clearances. This resulted in the potential for insufficient fuel flow to the engine. If the fuel pump module does not consistently provide sufficient fuel to the engine, the vehicle may stall.

Drivers may notice an illuminated check engine light or experience engine hesitation. If the vehicles stalls, it could be difficult to restart.

Owners receiving notices will be asked to return to their dealers to have the fuel pump module replaced in their vehicles. GM’s number for this recall is N222372310 and the NHTSA campaign number is 23V-013.

2023 Kia Telluride Illuminated Air Bag Warning Light

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Certain 2023 Kia Telluride automobiles could experience an illuminated air bag warning light due to a manufacturing error affecting the second row seat side air bags. Owner notifications are expected to be sent out at the end of February.

Kia became aware of the problem late December 2022 when the Kia Technical Assistance Center received a report from a dealer about a damaged second row seat side airbag wire harness in a 2023 Telluride. Kia stopped shipping the 2023 Telluride vehicles and conducted an inspection of 2,219 vehicles at the plant. Twenty out of 2,219 vehicles had a wire harness that contacted the seat frame, though no damage to the harness was identified, there was no airbag warning light illuminations, and no wire harness contact with the seat frame was found in the remaining inspected vehicles. Kia Georgia informed Kia Safety Office of Inspection about the results of the investigation and a recall was initiated.

According to the defect report, the side airbag wire harness in the second row seat cushion assembly was manufactured with the incorrect length. The wire harness could become damaged if it contacts the seat frame when the seat is folded or adjusted. If the wire harness is damaged, the second row seat side airbag(s) may not deploy in a crash, increasing the risk of injury.

Owners receiving notices will be asked to return to their dealerships to have the wire harness inspected and replace, or secure the air bag wire harnesses, as necessary. Kia’s number for this recall is SC262 and the NHTSA campaign number is 23V-035.

The potential number of 2023 Kia Telluride vehicles affected by this recall is 1,943.

If you are having repeated problems with your 2023 Kia Telluride and you think it could be a Lemon, or if you have any questions about your rights under the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

External Coolant Pump Could Short Circuit And Cause A Vehicle Fire

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Automobile manufacturers Porsche and Bentley Motors will be contacting the owners of certain 2017-2021 model vehicles because of a problem with the external coolant pump in the climate control system of their vehicles.

Porsche became aware of this problem at the end of December 2022, when they were contacted by their coolant pump manufacturer about a potential malfunction of the electric external coolant pump used in the climate control system. An investigation was opened and Porsche reviewed whether there were any possible common influences that could have contributed to the problem. (e.g. Extreme Temperatures, A Corrosive Medium, Special Driving/Customer Behavior, etc.) In January, Porsche determined a safety defect existed and decided to recall the subject vehicles. During this time, Porsche informed Bentley of their investigation because certain Continental GT and GTC vehicles were manufactured with the same pump.

The vehicles affected include:

2020 Bentley Continental GT
2020 Bentley Continental GTC
2017-2021 Porsche Panamera
2017-2021 Porsche Panamera 4
2017-2021 Porsche Panamera GTS
2017-2021 Porsche Panamera Turbo

According to the defect report, some 2017-2021 Porsche Panemera and 2020 Bentley Continental vehicles may have been manufactured with an electric climate control coolant pump that could experience humidity ingress. The humidity could cause a short circuit and, in some instances, thermal damage to the external coolant pump. In rare circumstances, the thermal damage to the harness could progress into a fire.

On the affected vehicles, vehicle occupants may notice an issue with the Climate Control system or reduced performance when using the Residual Heat function. (This allows the vehicle to be heated after the ignition has been switched off, using the remaining heat in a warm engine). On vehicles fitted with a W12 engine, an Engine Management Light could also illuminate.

Dealers will replace the external coolant pump and will inspect and replace the plug-in connection, as necessary.
Porsche’s number for this recall is APA1and the NHTSA campaign number is 23V-033
Bentley’s number for this recall is RE23/02 (RC67) and the NHTSA campaign number is 23V-034.

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.

2023 Ford Bronco Sport ABS Module Leak

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Ford will be asking the owners of certain 2023 Bronco Sports vehicles, to return to their dealerships to repair a problem that could lead to unexpected brake problems. Ford used supplier records to determine the population of affected vehicles in which the problematic Anti-lock Braking Systems (ABS) is installed. (Component Part Number: LX6C-2B373-LG)

In December 2022, Ford was contacted by the manufacturer of their ABS, about a quality issue affecting the Hydraulic Control Unit (HCU) of an Electronic Brake Booster (EBB). According to the defect report, a foreign object was introduced into the tool that assembles the Normally Closed (NC) valves used in the ABS Module. This object could create a “flat spot” damage to the ball which creates the seal. This damage could allow an unintended leak path through the valve. If the valve leaks, the driver may experience inconsistent brake pedal travel without warning. Additionally, the driver-selectable Auto Vehicle Hold feature may not operate as intended. The vehicle could creep unexpectedly after an auto-hold event is initiated.

Owners who receive notices will be asked to return to their dealerships to have the ABS module replaced. Ford’s number for this recall is 23S01 and the NHTSA campaign number is 23V-021.

This is the third recall affecting the 2023 Ford Bronco Sport. In November 2022, Ford recalled half a million 2020-2023 Escape and 2021-2023 Bronco Sport vehicles equipped with 1.5L engines. A fuel injector may crack and leak fuel inside the engine compartment and cause an under hood fire. (NHTSA Campaign Number: 22V-859)

In September, Ford recalled 2022-2023 Bronco Sport and 2022 F-150 vehicles because the parking lights may flicker during any of the three following scenarios. (NHTSA Campaign Number: 22V-859)

  • Scenario 1: When the customer manually selects the “position lamp on” mode.
  • Scenario 2: When the customer manually selects “Headlamp On” Mode.
  • Scenario 3: When the customer is driving in automatic headlamp mode, and the environment gets dark enough to trigger “Night Mode”, which turns on the headlamp and parking lamp function.

GM Repurchases Certain 2022-2023 Chevrolet Malibu For Structural Problems

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General Motors (GM) will be contacting the owners of certain 2022-2023 Chevrolet Malibu’s because of a problem affecting a structural portion of the vehicle frame.

GM first became aware of the problem in August 2022 when a production operator installing parts on a vehicle discovered a section of the motor rail was missing. Further investigation found that the front rail outer panel was cut too short and, as a result, was not completely welded to the front right-hand side of the front impact bar.

The problem was reported to GM’s Speak Up For Safety (SUFS) program which worked with the plant and supplier to identify and contain affected vehicles. Of the 1,875 vehicles that GM contained and inspected, they found none that had an incomplete weld. GM opened an investigation into the subject condition to analyze the potential effects of this condition during a crash. There are no known field incidents related to this condition., but GM has decided to conduct a safety recall.

According to the defect report, the sheet metal blank for the front frame rail outer panel for the 2022-2023 Chevy Malibu was improperly loaded into the die. As a result, the front frame rail was cut 10 millimeters short of its intended design. The shortened frame rail prevented proper welding of the front impact bar to the front frame rail. This defect may be present on the right hand and/or left-hand side of the vehicle.

Owners will be asked to return to their GM dealer to have the right-hand and left-hand sides of the vehicle’s motor rail inspected for incomplete welds. If the condition is found, the vehicle will be repurchased by GM. The NHTSA campaign number for this recall is 22V-923.

Is GM Repurchasing Your Lemon Vehicle?

Under the Lemon Law, if you qualify, you should be able to recover your down payment, (including registration fees, licensing fees, taxes, transportation costs, etc.), plus your total monthly lease or loan payments. The manufacturer will also pay off the balance of your loan or lease. The manufacturer will also pay all or most of your attorney’s fees.

If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

Chevy Heavy Duty Trucks Steering Instability

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General Motors (GM) will be contacting the owners of certain HD and XD trucks because of a problem affecting the suspension in their vehicles. If the problem is not fixed, it could lead to difficult steering and an increased risk of an accident.

In November 2022, GM received information from one of their suppliers that there was an investigation into a manufacturing quality problem in certain flange lock nuts used in 2021-2022 model year Chevrolet Silverado medium-duty vehicles. After consulting with their supplier, GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a recall.

The vehicles affected include:

2021-2022 Chevrolet 4500HD
2021-2022 Chevrolet 4500XD
2021-2022 Chevrolet 5500HD
2021-2022 Chevrolet 5500XD
2022 Chevrolet 6500HD

According to the defect report, certain hex flange lock nuts used in several locations on the suspension in some HD and XD trucks were not properly formed and heat treated by the supplier. Over time, the nuts could loosen and cause a loss of tension in the suspension joints. Over time, drivers will notice a degradation in vehicle handling.

Parts are not currently available, but when parts are available owners will be asked to return to their dealerships to have the hex flange lock nuts replaced. GM’s number for this recall is N222391080 and the NHTSA campaign number is 22V-874.

Hyundai Issues Seventh Seat Belt Pretensioner Recall

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Hyundai Motor America (Hyundai) has issued a recall (22V-816) affecting certain 2023 Genesis G80 Electric, 2021-2022 Santa Fe Hybrid, and 2022-2023 Santa Fe Plug-In Hybrid vehicles. These vehicles have front driver-side and/or passenger-side seat belt pretensioners that could explode under certain deployment conditions.

This is the seventh recall issued by Hyundai for seat belt pretensioner problems. Hyundai has determined that the subject vehicles were manufactured with driver/passenger pyrotechnic-type seat belt pretensioners that may deploy abnormally in certain crashes due to over pressurization of the pretensioner pipe. The potential of a pretensioner exploding is dependent on vehicle characteristics, pretensioner load limiter specifications, airbag control unit logic, crash duration and severity.

Hyundai first became aware of the problem in September 2021, when they were contacted by the NHTSA’s ODI about an incident involving a 2021 model year Hyundai Elantra. The driver-side seat belt pretensioner allegedly deployed abnormally, causing metal fragments to enter the rear cabin and injuring an occupant’s leg. The NHTSA was notified of the incident by a law firm representing the operator of the incident vehicle.

According to the defect report, the front driver-side and/or passenger-side seat belt pretensioners in the subject vehicles were installed from a suspect production lot containing pyrotechnic-type pretensioners that may deploy abnormally during a crash. At the time, the cause of the abnormal deployment was unknown. Hyundai decided to recall vehicles equipped with pretensioners produced within the same production lot.

Recall 21V-796 vehicles affected include:

2021 Hyundai Elantra
2021 Hyundai Elantra HEV
2021 Hyundai Venue
2022 Genesis GV70
2021 Genesis GV80

Recall 22V-069 vehicles affected include:

2020-2021 Hyundai Accent

Recall 22V-123 vehicles affected include:

2022 Hyundai Elantra
2022 Hyundai Elantra HEV

Recall 22V-218 vehicles affected include:

2020 Hyundai Accent
2021-2022 Hyundai Elantra

Recall 22V-354 vehicles affected include:

2020-2022 Hyundai Accent
2021-2022 Hyundai Elantra
2021-2022 Hyundai Elantra HEV

Recall 22V-458 vehicles affected include:

2020-2022 Hyundai Venue

Owners receiving notices will be asked to return to their Hyundai dealer to have the seat belt pretensioners secured with a cap. Hyundai’s number for this recall is 238/011G.