On certain 156 inch wheelbase, 4x4 vehicles, equipped with a two-piece driveshaft, the fuel tank may become damaged during certain crash conditions, which could allow fuel spillage to occur. Fuel leakage in the presence of an ignition source could result in a fire, causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will install a bracket to limit fuel tank movement during a crash.
On certain Passat and Passat Four Motion vehicles equipped with an automatic transmission, an underbody heat shield may become damaged. If this occurs, the heat shield may contact the exhaust system, which can result in a vehicle fire. In addition, the affected vehicles may have a fuel line (1.8T engine only) or fuel tank ventilation valve (4motion / all-wheel drive vehicles only) that may leak due to fracture. Fuel leakage in the presence of an ignition source can result in a vehicle fire.
On certain Audi A6 Quattro and Allroad Quattro, 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.
Certain motorcycles may have been assembled with an improperly manufactured fuel control valve diaphragm. As such, fuel leakage could occur which, in the presence of an ignition source, may result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel control valve diaphragm.
On certain motorcycles, the fuel hose may not have been securely fastened to the fuel injector delivery pipe during vehicle assembly. Fuel leakage, in the presence of an ignition source, could result in a fire, causing property damage, personal injury, or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the fuel hose.
On certain motorcycles, the fuel tank breather hose may have been installed incorrectly, causing it to be pinched between the frame and other neighboring components. In high ambient temperatures, the pressure inside the fuel tank could build-up, resulting in the bulging of the tank near the rear tire. Severe suspension compression, with a high payload, can cause the bottom of the tank to rub against the rear wheel, potentially resulting in a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire. Also, the rear wheel could lose traction as a result of fuel spillage, which could cause a vehicle crash with personal injuries or death.
On certain vehicles equipped with a V6 engine, a fuel line in the plenum area may contact the rear engine compartment cover. Overtime, relative movement of the involved components can cause chaffing damaged, which may 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.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and reroute the fuel line. Should the fuel line exhibit damage, it would be replaced.
On certain vehicles equipped with a 5.4L engine, the fuel rail cross-over hose may have intermittent, localized carbon material clumps in the hose wall, which could weaken the hose. Over time a fuel leak may 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, insufficient sealing of the Fuel Pump Electronic Module may lead to water ingress corrosion, possibly causing the unit to fail. This may result in increased, decreased, or loss of fuel pressure. 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.
Safety Risk
No risk description available.
Remedy
Dealers will replace and relocate the Fuel Pump Electronic Module.
On certain vehicles, the fuel supply line may leak at a connector located within the engine compartment. Fuel leakage, in the presence of an ignition source, could result in a fire.
On certain motorcycles, fuel lines may have been damaged during the manufacturing process. Fuel leakage, in the presence of an ignition source, can result in a fire.
On certain motorcycles, the fuel tank vent pipe may have been improperly welded during vehicle assembly. Due to vibration, improperly welded tanks may crack and drip fuel. Fuel leakage, in the presence of an ignition source, can cause a fire.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the fuel tank.
On certain GS 300, GS 300 AWD, IS 250, IS 250 AWD and IS 350 vehicles, incorrect fabrication process may cause the fuel lines to crack, possibly resulting in a leak. Fuel leakage, in the presence of an ignition source, could result in a vehicle fire causing injury or death.
On certain motorcycles, the fuel pump wiring harness may not have been manufactured according to specification. As a result, the contact in the plug for the fuel pump can break, causing the pump to fail. Should this happen, fuel delivery to the engine would cease and stalling would occur. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the rider's reactions, could increase the risk of a crash.
On certain vehicles, the fuel tank straps were improperly manufactured and could separate. This can cause the fuel tank to loosen and leak fuel. Fuel leakage in the presence of an ignition source can result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel tank retention straps and fasteners.
On certain vehicles equipped with Caterpillar C7 and C9 diesel engines, fuel pump failure can dilute the engine oil with fuel and cause the turbocharger to fail, leading to a loss of throttle control and excessive smoke. Either condition could result in a vehicle crash causing property damage, personal injury or death.
Safety Risk
No risk description available.
Remedy
Authorized Caterpillar dealers will replace the fuel pump.
On certain all-wheel drive vehicles, the fuel tank straps were improperly manufactured and could separate. This can cause the fuel tank to loosen and leak fuel. Fuel leakage, in the presence of an ignition source, can result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel tank retention straps.
On certain vehicles, inadequate coating of the fuel filler tube assembly could allow water to penetrate past the coating and cause surface rust. In areas which use heavy concentrations of road salt in the winter, corrosion may occur to a degree which results in perforation of the tube. In this case, fuel leakage may occur when filling the tank or shortly thereafter. Fuel leakage, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel filler tube assembly.
On certain trucks, when the ignition key is in the 'ON' position, the pre-heater, located in the fuel filter base, is energized. If this pre-heater is energized while maintenance is being performed on the fuel filter, diesel fuel could ignite within the filter housing. A fire within the fuel filter housing may spread possibly resulting in property damage or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if required, replace the fuel heater assembly.
On certain vehicles, the fuel tank may contain localized depressions in the tank wall at the seam between the top and bottom halves of the tank. If the depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odour, Malfunction Indicator Lamp (MIL) illumination or a fuel leak. A fuel leak in the presence of an ignition source may result in a fire.
