On certain vehicles, the fuel filler neck may not have been welded correctly to the fuel tank during the manufacturing process. As a result, the weld may not provide the expected strength and, in the event of a crash, could result in a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
On certain motorcycles, the fuel tank could develop cracks at the spot weld(s) on the side mount tabs, which could cause a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, as necessary, repair or replace the fuel tank.
On certain vehicles, a fuel line quick connector may have been incorrectly manufactured and could fail. Should the connector detach, it could cause engine stalling and a fuel leak. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash. Fuel leakage, in the presence of an ignition source, could result in a fire. These issues could result in property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will replace the high-pressure fuel line assembly.
On certain vehicles, the fuel system software may not be compatible with the fuel pump assembly. Insufficient fuel transfer could cause engine hesitation or stalling. Engine stalling would result in loss of propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will update the engine control module software.
On certain vehicles, the fuel supply line may have been manufactured incorrectly, which could allow a fuel leak to develop. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
On certain vehicles operated in areas of heavy road salt usage during winter months, the fuel tank straps could corrode and fail. This could allow the fuel tank to contact the ground, which may compromise the tank's integrity and permit fuel leakage. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel tank straps with zinc coated versions.
On certain vehicles, aging of the plastic material in the fuel tank rollover valve, combined with bending stress from the aluminium ventilation line to the rollover valve nipple, may lead to cracking of the nipple. If this happens, a fuel leak may result. Fuel leakage, in the presence of an ignition source, could result in a vehicle fire.
On certain vehicles, the case which houses the Roll-Over Valve (ROV) within the fuel pump module may have been manufactured incorrectly. As a result the case may break or crack, which could allow the ROV to separate, thereby increasing the risk of fuel leakage in a roll-over crash. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the fuel pump module assembly.
On certain vehicles equipped with the 2.5L engine, a particular type of spider may weave a web in the evaporative canister vent line which may cause a restriction in the line. If this occurs, the fuel tank pressure may become excessively negative when the emission control system works to purge the vapors from the canister. As the canister is purged repeatedly during normal operation, the stress on the fuel tank may eventually result in a crack causing a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will clean the canister vent line and install a spring to prohibit spider intrusion. The Powertrain Control Module (PCM) will be reprogrammed with modified software having a function to avoid excessive negative pressure of the fuel tank. When any damage of the fuel tank and/or presence of a web in the canister vent line are found, the fuel tank and the check valve on the canister vent line will be replaced.
On certain vehicles equipped with a 2.3L engine, the fuel line in the area of the throttle body shield may not have the protective convolute properly installed. If the protective convolute on the fuel line is not assembled in the proper position, the fuel line may contact the edge of the shield. Over time this contact may chafe the fuel line, resulting in a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will trim the throttle body shield, inspect the fuel line for damage, and replace the line if necessary.
On certain vehicles equipped with a 2.3L engine, the fuel line in the area of the throttle body shield may not have the protective convolute properly installed. If the protective convolute on the fuel line is not assembled in the proper position, the fuel line may contact the edge of the shield. Over time this contact may chafe the fuel line, resulting in a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will trim the throttle body shield, inspect the fuel line for damage, and replace the line if necessary.
On certain GS 300, GS 300 AWD, GS 350, IS 250, IS 250 AWD and IS 350 vehicles, the fuel pressure sensor connected to the engine fuel delivery pipe may not have been sufficiently tightened during vehicle assembly. Should the pressure sensor loosen, fuel could leak past a gasket used in the connection between the sensor and pipe, and through the threaded portion of the sensor. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect for fuel leakage from the threaded portion of the fuel pressure sensor. If there are no signs of a fuel leak, the fuel pressure sensor will be tightened to specifications. If a fuel leak is confirmed, the gasket between the sensor and the fuel delivery pipe will be replaced, and the sensor will be tightened.
On certain motorcycles, the seal between the fuel pump and the fuel tank could leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealer will replace the original flange seal with an updated version.
On certain vehicles, the fuel pump may seize, which would stop fuel flow to the engine and cause it to stall. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the fuel pump assembly.
Certain vehicles, operated in areas where road salts are frequently used in winter, may be exposed to road debris (mud) mixed with road salt. This material can become trapped between a reinforcing bracket and the fuel filler pipe, potentially causing corrosion. Over time, corrosion could create a leak in the fuel filler pipe that could result in fuel leakage when fueling the vehicle. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel filler pipe of vehicles equipped with the first-generation version. Vehicles assembled with the second-generation filler pipe will be inspected and, if severe corrosion on the fuel filler pipe is observed, the pipe will be replaced with a third-generation version. For vehicles where corrosion of the fuel filler pipe is not observed, an anti-corrosion wax-like material will be applied to the filler pipe, and the inner wheel well shield will be replaced with an updated part that provides improved protection against mud intrusion and accumulation.
On certain Golf, Golf wagon, Jetta and Rabbit equipped with a 2.5L Engine, a small plastic tab located on the windshield washer fluid reservoir may chafe against an underhood fuel supply line. If chafing occurs fuel leakage could develop which, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the affected vehicles and, if necessary, replace the fuel line. In addition, as a preventive measure, the plastic tab from the windshield washer fluid reservoir will be removed.
On certain New Beetle and New Beetle convertible equipped with a 2.5L Engine, a fastening clamp on a hydraulic hose of the power steering system may be located in an improper position, which could cause chafing against an underhood fuel supply line. If chafing occurs fuel leakage could develop which, in the presence of an ignition source, could result in a fire causing property damage and/or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the affected vehicles and, if necessary, replace the fuel line. In addition, as a preventive measure, the clamp will be adjusted accordingly.
On certain vehicles, water may not have been be removed completely from the harness connector of the fuel pump due to variations in the fuel tank leak check process performed before vehicle assembly. As a result the connector pin may corrode, potentially causing the pin to break and the fuel pump to become inoperative. This could cause the engine to stall and fail to restart, which could increase the risk of crash.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the fuel pump connector and if necessary the fuel pump will be replaced and the harness repaired.
On certain GL350, ML350 and R350 BlueTEC vehicles, the diesel fuel filter may have an O-ring that was not properly lubricated during assembly, which could lead to a diesel fuel leakage. As a result, diesel fuel may be deposited on the road and create a risk a crash.
On certain vehicles, due to a manufacturing process fault, the fuel pump was not produced to specifications. As a result, under specific vehicle operating conditions, the fuel pump's commutator could experience an increase in wear which could lead to a malfunction of the fuel pump. Ultimately, vehicle stalling could occur, which in conjunction with traffic, road conditions, and driver's reactions, increases the risk of a vehicle crash causing property damage, or personal injury.
