Tag Archives: battery fire

Jaguar I-Pace Battery Could Overheat

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Jaguar Land Rover North America, LLC (Jaguar) are reaching out to the owners of specific 2019 Jaguar I-PACE vehicles regarding a significant safety concern involving the high-voltage battery. The issue, which could potentially cause the battery to overheat, has prompted a recall to ensure the safety of the vehicle owners.

This recall comes after a series of events beginning in July 2024, when Ford’s Critical Concern Review Group identified a problem related to a warranty report. The issue involved a fuel injector with a missing o-ring support disc, which could lead to fuel system malfunctions. Ford’s Supplier Technical Assistance team, in collaboration with the supplier, conducted an in-depth review of images taken during the production of all fuel injectors to pinpoint the parts that could be affected. They then compared these findings to vehicle production records to identify the specific vehicles at risk.

On August 16, 2024, Ford’s Field Review Committee evaluated the concern and decided to approve a field action to address the problem. Up to that date, Ford had identified 10 reports of vehicles with fuel injectors missing the crucial o-ring support disc. Fortunately, there have been no reports of fires, accidents, or injuries related to this condition. However, the potential risk was significant enough to warrant immediate action.

Jaguar is advising all affected vehicle owners to take precautionary measures until the recall repair is completed. Specifically, owners are urged to park and charge their vehicles outdoors and away from any structures. This precaution should continue for 30 days even after the repair has been completed, ensuring the safety of both the owners and their surroundings.

As an interim solution, Jaguar dealerships will update the software of the battery energy control module to help mitigate the risk. However, the final, long-term remedy for the issue is still being developed. Jaguar plans to send out official owner notification letters by October 18, 2024, providing detailed instructions on the next steps. For reference, Jaguar has assigned the recall number H514, and it has been registered with the National Highway Traffic Safety Administration (NHTSA) under the campaign number 24V-633.

It’s important to note that this isn’t the first recall related to this issue. The same vehicles were previously recalled under multiple recall numbers, including 24V-085 (H471), 23V-709 (H459), and 23V-369 (H441). If you own one of these vehicles, you will need to have the latest remedy performed, even if your vehicle has already undergone previous repairs for this issue.

Pacifica Plug-In Hybrid Battery Fire Warning

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Chrysler Pacifica Battery FireChrysler (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.

Chrysler first learned about this issue in February 2022 through the Vehicle Regulations Committee, which led them to start a voluntary safety recall on certain Pacifica PHEVs, known as recall Z11.

Since then, Chrysler and LG Energy Solution (LGES) have been working to figure out the root cause of the problem. They’ve analyzed field reports, bought back vehicles, looked at vehicle data, conducted thermal tests, and torn down battery packs to get to the bottom of it.

In November 2022, the Technical Safety and Regulatory Compliance (TSRC) team at Chrysler was informed about a battery fire in a Pacifica PHEV that had already been fixed under recall Z11.

From June 2023 to December 2023, TSRC learned about five more fires involving the HV battery in some Pacifica PHEVs that had the Z11 remedy. They tried to buy back these vehicles to analyze if the recall fix was working.

In April 2024, Chrysler received a Pacifica PHEV with a post-Z11 remedy fire in the battery pack. After analyzing the vehicle and battery pack, they sent the battery back to the supplier for further inspection. They found a torn anode tab in one of the cells, but couldn’t identify a second factor causing the fires. This confirmed that the Z11 remedy wasn’t effective.

A folded or torn anode tab can lead to lithium by-product build-up over time. This defect, combined with another unknown factor, can cause an internal short in the battery pack, potentially resulting in a vehicle fire.

Chrysler advises owners not to charge their vehicles and to park them outside and away from structures until repairs are made. Dealers will update the high voltage battery pack control module (BPCM) software, and if necessary, replace the battery pack assembly. The recall numbers are 72B and 73B, and the NHTSA campaign numbers are 24V-356 and 24V-358. Vehicles previously repaired under recall 22V-077 will need to have the new fix applied.

High Voltage Battery Plug Safety Issue in Certain 2022 Kia Niro EV’s

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2022 Kia Niro EV ChargingKia has identified a potential safety issue with certain 2022 Kia Niro Electric Vehicle (EV) models. The problem affects the high-voltage battery safety plug, which may overheat and melt due to electrical resistance.

What Happened?

The issue came to light in July 2023 when a dealer reported a case involving a 2022 Niro EV that shut off while driving without entering “Ready” mode. Further investigation revealed an isolated melted safety plug. Kia’s Safety Office monitored the issue and found no other incidents except for one isolated case.

What Did Kia Find?

Kia’s Safety Office conducted field data analysis and discovered that the melted safety plug was caused by high temperatures, not any issues with the battery cells or temperature sensors. The investigation also revealed a manufacturing process deviation in the supplier’s Female-Female terminal, which affected specific vehicle production lots.

Recall Alert

As a result of the findings, Kia has issued a recall for certain 2022 model year Niro EV vehicles due to the potential safety risk posed by the faulty safety plugs. The recall was announced on May 15, 2024.

Symptoms and Risks

If the electrical resistance in the safety plug occurs while driving or during battery charging, it may melt, increasing the risk of:

  • Loss of motive power
  • Fire

Drivers may notice an illuminated EV Service Warning light and/or a burning smell (melting plastics and smoke).

What to Do?

Owners with affected vehicles are advised not to charge their vehicle in a garage or any other covered structure until the recall repair is completed. Dealers will replace the safety plug, and owner notification letters are expected to be mailed on July 19, 2024.

Kia Recall Information

  • Kia’s number for this recall: SC314
  • NHTSA campaign number: 24V-358

2021-2023 Mini Cooper SE Vehicle Stall And Potential Battery Fire

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Mini CooperA manufacturing issue was identified in a small batch of 2021-2023 Mini Hardtop 2 Door Cooper SE vehicles. These electric cars were found to have a high voltage battery housing that did not meet the company’s assembly specifications. This discovery came to light after a concerning incident in the U.S. in October 2023, where one such vehicle experienced what is known as a thermal event—a significant overheating.

Following this incident, BMW initiated a thorough engineering analysis to pinpoint the cause. It was found that during certain production periods, there was a flaw in how the battery housing was sealed. Specifically, an inadequate amount of sealing compound was applied between the two halves of the battery module’s housing. This oversight made it possible for water to seep into the battery enclosure.

Water entering the high voltage battery compartment can trigger what is called an isolation fault. This type of fault compromises the battery’s integrity, leading to performance issues and safety concerns. Initially, such water ingress prompts the vehicle to display a warning message, alerting the driver of the fault and advising them to have the vehicle checked at a MINI service center.

Should the water exposure continue, the situation can escalate. The accumulation of moisture can cause multiple isolation faults, potentially causing the vehicle to stall. In more severe cases, particularly after long periods of inactivity, these faults could cause the battery to overheat significantly. Such overheating, while rare, could lead to a thermal event, even if the car is not in use.

To address this issue, BMW is recalling affected vehicles to inspect, and if necessary, repair the sealing of the battery housing. This includes a thorough leak test to ensure the integrity of the battery enclosure. Owners of the affected Mini Cooper SE models will be notified by mail with instructions to visit their dealer. Notification letters are scheduled to be sent out on June 21, 2024. The recall has been officially recorded under the NHTSA campaign number 24V-302.

Vehicle owners are encouraged to respond to the recall notice promptly to ensure their safety and the proper functioning of their vehicle.

Jaguar I-Pace EV Fire Risk When Parked

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Jaguar I-PaceIn a recent development, owners of 2019 Jaguar I-Pace vehicles are being urged to take immediate action due to a critical safety concern that could potentially lead to vehicle fires. The issue revolves around battery packs manufactured within a specific time frame, which have been identified as prone to technical faults, posing a significant risk of thermal overload.

The affected battery packs, produced between March 1, 2018, and May 31, 2018, have exhibited several technical deficiencies that increase the likelihood of short circuits within the battery cells. These short circuits generate excessive heat, particularly when the battery state of charge exceeds approximately 85%, ultimately triggering a thermal overload condition.

While some vehicles have undergone modifications through a previous safety recall (H441), mitigating the risk to some extent, Jaguar is ensuring the safety of all potentially affected vehicles and a new safety recall, identified as H484, has been initiated to address this critical issue.

The ramifications of a vehicle thermal overload event, such as fire or smoke, are severe and pose significant risks to occupants and bystanders alike. Occupant injury, damage to property, and even injury to persons outside the vehicle are potential outcomes of such incidents, underscoring the urgency of addressing this issue promptly and comprehensively.

In response to this safety concern, Jaguar has outlined interim measures for affected vehicle owners to mitigate the risk until a permanent solution is implemented. Owners are advised to park and charge their vehicles outdoors, away from structures, and to limit charging to a maximum of 75% state of charge. These precautions aim to minimize the risk of thermal overload incidents until the necessary repairs are completed.

Notification letters are scheduled to be dispatched to affected owners starting April 26, 2024. The recall process, identified by the National Highway Traffic Safety Administration (NHTSA) campaign number 24V-183, aims to rectify the underlying issue and ensure the safety and peace of mind of Jaguar I-Pace owners.

It’s imperative for owners of 2019 Jaguar I-Pace vehicles to heed this safety warning and comply with the manufacturer’s instructions promptly. Failure to address this issue in a timely manner could potentially lead to catastrophic consequences. Additionally, owners are encouraged to stay informed about further developments regarding the recall and to take appropriate action as advised by Jaguar and regulatory authorities.

NOTE: This recent safety recall, identified by NHTSA Recall Number 24V-183, is not the first instance where concerns regarding the same problem have been raised. Previous recalls, such as, NHTSA Recall Numbers 24V-085, 23V-709, and 23V-369, have also addressed issues related to thermal overload and potential fire hazards in Jaguar I-Pace vehicles. These recalls underscore the seriousness of the underlying technical issues and the manufacturer’s ongoing efforts to rectify them. Owners should be vigilant and proactive in responding to these recalls to ensure the safety and integrity of their vehicles.

Honda’s CR-V Hybrid Battery Cable Safety Issue

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Honda has announced a safety recall for certain 2020-2022 CR-V Hybrid vehicles due to a critical issue concerning the 12-Volt battery cable. This recall comes after a detailed investigation into the safety of these vehicles, revealing a potential risk that could increase during specific types of crashes.

The identified problem lies in the routing of the 12-Volt battery cable, which is situated outside of the body frame and lacks a fuse on the power circuit. This design flaw could lead to the battery cable short-circuiting or overheating, particularly in the event of a crash impacting the left front fender area. Such a scenario raises significant concerns about the possibility of a fire and the risk of injury to the occupants.

Chronology of Events Leading to the Recall

  • May 17, 2021: The first known incident occurs, where a crash led to a short circuit in the battery cables located in the left front fender.
  • May 19, 2021: Honda receives a report from the National Highway Traffic Safety Administration (NHTSA) about this incident.
  • May 28, 2021: Honda collaborates with the NHTSA to inspect the affected vehicle and analyze the issue.
  • August 18, 2021: After discussing the first incident with NHTSA, Honda initially concludes that there are no high-voltage related issues or similar complaints.
  • September 16, 2021: Honda conducts further tests to analyze the issue.
  • October 21, 2021: Honda’s evaluation suggests that the crash angle in the first incident was a rare occurrence.
  • June 13, 2022: Honda starts implementing a fuse in production models to address this potential issue.
  • August 18, 2022: A second incident under similar circumstances prompts another analysis by Honda.
  • August 29, 2023: Honda receives a warranty claim possibly related to the same issue.
  • October 30, 2023: Honda reassesses its stance on the rarity of such occurrences and the likelihood of future incidents.
  • December 6, 2023: Honda acknowledges a defect related to vehicle safety and decides to initiate a recall.

The Recall Process

Honda, adhering to its commitment to safety and customer satisfaction, has decided to recall the affected vehicles. Registered owners will be notified via mail to bring their vehicles to an authorized Honda dealer. Here, the battery cable will be replaced with an improved part that addresses the identified safety concern. Honda’s internal number for this recall is FGB, and the NHTSA campaign number is 23V-844.

Safety and Customer Support

From August 2019 through December 6, 2023, Honda has recorded two warranty claims related to this issue, with no reports of injuries or fatalities. This proactive recall demonstrates Honda’s dedication to the safety of its customers and its responsiveness to potential safety issues. Vehicle owners are encouraged to respond promptly to the recall notice to ensure their safety and the continued reliability of their vehicles.

2023 Chrysler Pacifica PHEV Fire Risk

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A small number of 2023 Chrysler Pacifica Plug-In Hybrid Electric Vehicles (PHEV) have encountered a significant safety issue, prompting concerns and a recall. A flaw in the battery system could potentially lead to vehicle fires, a risk that poses a serious threat to both vehicle occupants and property.

At the core of the problem is an off-location 12V isolator post in some of these vehicles. This defect may cause a short circuit in the 12V battery positive (“B+”) circuit, leading to a vehicle fire, regardless of whether the ignition is on or off. The gravity of this issue is evident, as vehicle fires can significantly increase the risk of injury to both the occupants and bystanders, as well as cause extensive property damage.

In response to this discovery, FCA US (Fiat Chrysler Automobiles United States) has initiated a voluntary safety recall for all affected Chrysler Pacifica PHEV models. This recall, identified as B0A by FCA US and 23V-753 in the National Highway Traffic Safety Administration (NHTSA) campaign, aims to address this critical issue.

It’s important to note that the recall stems not from a defective part, but rather from an assembly issue. Specifically, the vehicles in question may have been built with a 12V anti-rotation stud that is incorrectly positioned. The solution involves modifying the isolator to correctly fit this anti-rotation stud, thereby mitigating the risk of a short circuit and subsequent fire.

In the meantime, owners of the affected vehicles are strongly advised to take precautionary measures. FCA US recommends that these vehicles should not be parked inside buildings, structures, or near other vehicles. The reason for this guidance is clear: to minimize the risk of fire spreading and causing further damage and potential injuries. Owners are encouraged to park their vehicles outdoors and away from structures until the necessary repairs are completed.

This recall and the associated risks highlight the complexities and potential dangers inherent in modern automotive technologies, particularly in hybrid and electric vehicles. While these technologies offer numerous benefits, including environmental advantages, they also introduce new challenges in terms of vehicle safety and reliability.

The Chrysler Pacifica PHEV’s recall serves as a reminder of the importance of stringent quality control and thorough testing in vehicle manufacturing. It also underscores the need for quick and decisive action by manufacturers and regulatory bodies when potential safety issues are identified, ensuring the safety and well-being of vehicle users and the general public.

2019-2023 Jaguar I-PACE Potential Fire From Overheating Battery

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Jaguar Land Rover North America, LLC (Jaguar) is taking steps to address a potential safety concern involving certain 2019-2023 I-PACE vehicles. These vehicles were previously subject to recall 23V-369, but the earlier repairs may not have been executed correctly. This oversight could still leave the high-voltage battery at risk of overheating, potentially posing significant safety hazards.

Jaguar became aware of this issue in September 2023, triggered by a field report regarding a thermal overload incident in a vehicle that had previously undergone repairs as part of a prior recall (H441). An in-depth investigation into the matter revealed that the recall action for H441 had been mishandled by a retailer. In particular, the retailer had used an unauthorized service diagnostic tool, leading to the incorrect installation of essential software on the vehicle in question. Consequently, the safety defect persisted, even though the retailer had reported that the safety recall had been successfully completed.

This situation creates a lingering safety risk for affected vehicle owners. An improperly repaired vehicle continues to be vulnerable to conditions like thermal overload, which can result in potential fire or smoke issues. Such incidents can not only jeopardize the safety of vehicle occupants but also pose risks to individuals outside the vehicle and may cause property damage. What’s even more concerning is that the owners may remain unaware that the previous repair was not carried out correctly.

Fortunately, Jaguar is taking action to rectify the situation. Dealers will address the issue by updating the battery energy control module software, ensuring that the vehicles are brought up to the necessary safety standards. In the meantime, owners are strongly advised to park their vehicles outdoors and away from structures, as well as to charge them in the open until the recall repair is completed. This precautionary measure should be adhered to for 30 days after the repair has been finalized.

To help facilitate this important safety recall, Jaguar has assigned it the reference number H459, and it has been officially registered with the NHTSA under campaign number 23V-709.