battery overheat – California Lemon Law blog

Certain 2025 BMW models may have a battery connection problem that affects the electrical connection between the starter-generator and battery. This connection may come loose over time, leading to serious consequences.

The affected vehicles include the 2025 BMW 330i, 330i xDrive, 430i, 430i xDrive, 530i, 530i xDrive, and X3. The problem was discovered in December 2024, when a dealer field report from a non-US market mentioned a no-start condition and a burning odor within the engine compartment. An inspection found indications of local smoldering at the connection between the positive battery cable and the starter-generator.

After conducting an engineering investigation and reviewing additional incidents, BMW determined that the issue was related to the power connector component of the starter generator, which may not have been produced according to specifications. A gap could form at the connector location during production, causing a loose connection between the connector and the positive battery cable. This can lead to resistive heating, resulting in a loss of charging function and engine stalling without warning. In extreme cases, overheating could increase the risk of smoldering and even fire. Fortunately, BMW has not received any reports of accidents or injuries related to this issue.

To address the problem, owners of affected vehicles will be asked to return to their dealers for an inspection and replacement of the starter-generator and positive battery cable as necessary. Owner notification letters are expected to be mailed on May 23, 2025. The recall is identified by NHTSA campaign number 25V-202.

This afety recall aims to prevent any potential risks associated with this issue. Owners of affected vehicles should take immediate action to schedule an appointment with their dealer to have the necessary repairs made. By doing so, they can ensure their vehicle remains safe and reliable on the road.

Audi has announced a safety defect affecting certain high-voltage battery modules in its 2022-2023 Q5 Plug-in Hybrid Electric Vehicle (PHEV) and A7 PHEV models. The recall is necessary due to the risk of thermal events, which may cause smoke or even fires.

According to Audi, the root cause of the issue is still under investigation, but current analysis suggests that manufacturing deviations at a supplier of battery modules may be to blame. The company has been working closely with its supplier, Samsung SDI, and conducting comprehensive analyses of affected batteries to determine the conditions and circumstances that trigger thermal events.

The recall affects approximately 50 high-voltage batteries from non-U.S. markets, as well as an additional batch of batteries collected from field incidents in the United States. Audi has also received reports of other vehicles outside of these specific models, which are also under investigation.

To mitigate the risk, Audi plans to install advanced onboard diagnostic software, which will detect potential issues with battery module performance and alert the driver before problems may occur. The software is expected to be available in the second quarter of 2025.

In addition to the software update, Audi will offer two interim remedies for vehicles affected by this recall:

Vehicles with online data: Affected modules or high-voltage batteries must be replaced.
Vehicles without online data: Customers will be instructed not to charge their vehicle from external sources or via the combustion engine until the new software becomes available.

To date, Audi reports no injuries, crashes, or fires related to this issue in the United States market. Interim letters notifying owners of the safety risk will be mailed on January 24, 2025, with a second notice to follow once the final remedy is available.

Vehicles Affected:

2022-2023 Audi Q5 PHEV
2022 Audi A7 PHEV

Recall Numbers:

Volkswagen’s number: 93AA
NHTSA campaign number: 24V-898

Interim Remedies:

Vehicles with online data: Replacement of affected modules or high-voltage batteries.
Vehicles without online data: Instructed not to charge vehicle from external sources or via combustion engine until new software becomes available.

Certain Porsche Taycan models from 2021 to 2024 may face issues with their high-voltage batteries, specifically the potential for short circuits within the battery modules. These short circuits could result in thermal events, including the risk of overheating or even fires in extreme cases. The root cause of this issue has been traced back to potential manufacturing problems from the battery supplier, which, in rare instances, increase the likelihood of internal short circuits.

This latest recall builds on earlier recalls that were issued for similar battery-related problems, namely 23V-840 (manufacturer recall code APB5), 24V-215 (code ARA4), and 24V-217 (code ARA5). Porsche has been using data analytics and conducting hardware tests to better understand the extent of the issue. On September 23, 2024, the company determined that additional Taycan vehicles might be at risk due to potential battery defects, even though no confirmed data anomalies have been identified in these vehicles so far. As a result, Porsche launched a new recall with the identification codes ARB6 and ARB7.

Breakdown of ARB6 and ARB7 Recalls

ARB6: This recall covers a group of vehicles for which Porsche does not have enough data to determine whether there are issues with the high-voltage batteries. Since there isn’t sufficient information, Porsche is taking precautionary measures. Owners of vehicles in this group will receive a notification advising them to limit their battery’s charging capacity to a maximum of 80%. This is intended as a temporary solution while further analysis is conducted to either confirm the presence of battery anomalies or clear the vehicle of any issues. This interim step is designed to reduce the risk of thermal events while Porsche continues its investigation.
ARB7: In contrast, ARB7 applies to a set of vehicles for which Porsche has gathered sufficient battery data, and current diagnostics show no data anomalies in the high-voltage battery. As a result, there is no need to restrict battery charging for these vehicles to 80%. What sets this group apart is that these vehicles allow Porsche to continuously monitor the battery health via over-the-air updates. This real-time data monitoring enables Porsche to detect any future battery module issues quickly. If an anomaly is detected later, Porsche will notify owners, replace the affected battery module, and advise them to limit charging to 80% until the replacement is completed.

As part of this recall process, Porsche is implementing a series of steps to address the potential battery issues:

For ARB6 Vehicles: Owners are advised to cap their battery charging at 80% until a more permanent solution is available. This is purely a precautionary measure while Porsche continues to analyze the vehicles and gather more data on the potential risks.
For ARB7 Vehicles: Since Porsche already has access to these vehicles’ battery data via over-the-air diagnostics, there is no need for an 80% charging limit unless future data shows a problem. Porsche’s real-time monitoring will automatically detect any battery module anomalies. Should a problem arise, the company will issue a notification to the owner, and the affected battery modules will be replaced. In the meantime, Porsche will advise affected owners to limit charging to 80% as a safeguard.

For both ARB6 and ARB7, the final remedy will involve installing an advanced on-board diagnostic software on all affected vehicles. This software will be capable of detecting potential battery anomalies before they become serious. However, before this software is installed, Porsche will conduct an analysis of the battery modules in each vehicle. If the analysis shows that no problems are present, the software will be installed immediately. If the analysis detects any issues, Porsche will replace the faulty battery module(s) before proceeding with the installation of the diagnostic software.

Once the new on-board diagnostic software is installed, it will continuously monitor the vehicle’s high-voltage battery using advanced data analytics. If the software detects an anomaly in any of the battery modules, it will send a warning message to the vehicle’s head unit, alerting the driver. In this case, the battery’s charging capacity will be automatically limited in stages: first to 80%, and eventually to a lower limit, likely around 50%, depending on the severity of the detected anomaly. This stepwise reduction in charging capacity helps prevent thermal events and gives the driver time to seek service. If necessary, Porsche will replace the affected battery modules to restore the vehicle’s full functionality. Since the battery consists of multiple modules, it is possible that different modules could show issues at different times, requiring multiple replacements over the vehicle’s lifetime.

Porsche plans to roll out this advanced diagnostic software as the final remedy in the first quarter of 2025. In the meantime, dealers will be prepared to install interim software and address any battery concerns as they arise. Owners of affected vehicles will receive notification letters starting on November 29, 2024. These letters will provide detailed instructions on what steps to take next and how to proceed with repairs or updates.

The recall numbers for this issue are ARB6 and ARB7. Additionally, the National Highway Traffic Safety Administration (NHTSA) has assigned campaign numbers 24V-731 and 24V-732 to these recalls. These recalls build on and replace the earlier recalls 23V-840, 24V-215, and 24V-217, expanding the affected vehicle population as Porsche continues its investigation.

Nissan Leaf Smoking Battery 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.

Nissan is actively investigating the cause of this issue. Preliminary findings suggest that the problem stems from excessive lithium deposits forming inside the lithium-ion battery cells of these vehicles. These deposits increase the electrical resistance within the battery, which can cause fluctuations in the battery’s state of charge. This elevated resistance becomes particularly problematic during Level 3 quick charging, as it may result in the battery heating up more rapidly than intended. If the charging session continues under these conditions, the risk of a battery fire is significantly heightened, posing a serious safety concern.

Drivers may notice several warning signs during Level 3 charging that indicate something is wrong. These include the presence of smoke, unusual noises, interrupted charging sessions, or strange thermal odors emanating from the vehicle’s battery compartment. If any of these signs are observed, Nissan strongly advises stopping the charging process immediately and avoiding Level 3 charging altogether until the problem can be resolved.

Nissan is developing a solution for this issue in the form of a software update for the affected vehicles. Once available, this software update will be installed by dealers and is designed to correct the problem by managing the battery’s charging process more effectively. Nissan is taking steps to notify affected vehicle owners. Interim letters, alerting them to the safety risk, are expected to be mailed in October 2024. A second notice will follow once the software remedy is ready for deployment.

Until the fix is in place, Nissan advises owners to avoid using Level 3 quick charging stations and instead rely on slower charging methods, which do not present the same risk. For those affected, Nissan’s recall number is R24B2, and the corresponding NHTSA campaign number is 24V-700.

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.

2022 Kia Niro EV Charging Kia 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

Mini Cooper A 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.

In 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.

Tag Archives: battery overheat

Starter Generator Connection May Fail In BMW Vehicles

Audi Announces High-Voltage Battery Issue In Certain PHEV Models

Porsche Taycan Potential Battery Fire

Nissan Leaf Fire Risk From Quick Charging Battery

Jaguar I-Pace Battery Could Overheat

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

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

Jaguar I-Pace EV Fire Risk When Parked