Volkswagen Group of America, Inc. (Audi) has issued a recall for certain 2022-2024 Audi Q5 Quattro and Q5 Sportback Quattro vehicles due to a potential problem with the cylinder head cover screws. The screws may have been improperly tightened, which can cause them to loosen over time, leading to engine oil leaks from the cylinder head cover screw holes.
According to the defect report, the issue is attributed to varying tightening torques during the screwing process of the cylinder head cover, resulting in a potentially insecure screw connection and compromised sealing of the cylinder head cover. If engine oil comes into contact with hot parts of the engine, it can cause a fire. Owners are advised to be vigilant for signs of smoke in the engine compartment and to safely park their vehicle immediately if they notice any unusual odors or smoke.
The recall was prompted by customer complaints received by Audi in May 2023, which reported oil leaking from cylinder head covers of Audi Q5 2.0 TFSI vehicles. An investigation was launched, and a root cause analysis suggested that screws with burrs caused during the manufacturing process may have damaged the cylinder head cover surface, leading to oil leakage and potential torque reduction over time.
Despite implementing manufacturing improvements, Audi continued to monitor the field and recognized an increase in oil leak claims in early 2024. In response, the company issued a Technical Service Bulletin instructing dealers to inspect the cylinder head cover screws and replace any loose screws. Further analysis by the engine plant revealed the potential for improperly torqued cylinder head cover screws, leading Audi to review the screwing process with its supplier and implement changes.
However, despite these efforts, the U.S. market reported an increase in field claims of oil leakage and thermal event incidents between November and December 2024. Audi inspected and analyzed these cases, evaluating potential root causes and contributing factors. The company’s Product Safety Committee ultimately decided to conduct a safety recall for the affected vehicles on April 30, 2025.
To date, Audi has received 2,539 potentially related warranty claims of oil leaks in the U.S. and eleven thermal event cases. Early engine oil leaks can be difficult to detect, but advanced cases may be accompanied by an unpleasant odor or smoke in the engine compartment when the engine is hot.
To address the issue, dealers will inspect and replace the screws as necessary. Owner notification letters are expected to be mailed on July 8, 2025. The recall is identified by Audi’s number 15ZK and the NHTSA campaign number 25V-294. Owners of affected vehicles are advised to contact their local dealership for further information and to schedule an inspection and repair if necessary.
Certain 2019-2020 Nissan Leaf vehicles, specifically those equipped with quick charge ports for Level 3 charging using the CHAdeMO connector, are facing a potential issue where the battery could overheat during quick charging. This issue is serious, as it significantly raises the risk of a vehicle fire, which could lead to injury or property damage. The affected LEAF models were produced at Nissan’s Smyrna, Tennessee plant between August 29, 2018, and November 3, 2020. Nissan has identified this issue through their production records, confirming that it is limited to these specific Model Year 2019-2020 LEAF vehicles. Importantly, no other Nissan or INFINITI vehicles are known to be impacted by this defect, offering some reassurance to owners of other Nissan models.
Chrysler (FCA US, LLC) has found a problem with some 2019-2021 Pacifica Plug-In Hybrid Electric (PHEV) vehicles, as well as some 2017-2018 Pacifica PHEVs that got a software update under a previous recall (NHTSA recall number 22V-077). The issue is with the battery pack, which could cause a fire even when the car is parked and the ignition is off.
