On certain vehicles, an inadequate vapour recirculation fitting, which is welded to the fuel tank, may separate from the tank. This will allow some fuel leakage and cause the malfunction indicator light (MIL) in the instrument panel to illuminate. A fuel leak, in the presence of an ignition source, could result in a fire.
On certain VL1500 Intruder and Boulevard C90 motorcycles, repeated stress around the right front fuel tank mounting point can cause a hairline crack to form due to metal fatigue. This can allow fuel seepage to occur. In the presence of an ignition source, seeped fuel can cause a fire.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if required, replace the fuel tank.
On certain vehicles, fuel starvation may cause the engine to stall when fuel level is less than ¼ tank. This condition occurs without the illumination of the Fuel Level Low indicator light or the warning chime. If the engine stops running, the operator may not be able to restart the vehicle.
Safety Risk
No risk description available.
Remedy
Dealers will reprogram the Electronic Control Module (ECM) with new software that will compensate for fuel that has been transferred to the left side of the "saddle" design fuel tank.
On certain Audi A6, A4 Quattro, and Volkswagen Passat vehicles, premature fuel pump wear can lead to pump failure. A failed fuel pump may cause stoppage of fuel supply to the engine, creating an engine stall condition. Should the engine stall while the vehicle is in use, a possible vehicle crash could occur.
On certain vehicles, the fuel tank may be punctured by road debris that has been picked up and thrown by the front tires. A fuel leak, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will install a shield in front of the fuel tank.
On certain vehicles, the fuel filler hose may crack from exposure to ozone. This could cause fuel leakage from the hose while refuelling and the Malfunction Indicator Light (MIL) to illuminate as a result of the onboard diagnostic system detecting a leak in the evaporative emission control system. Fuel leakage, in the presence of an ignition source, could result in a fire.
On certain motorcycles, the fuel line quick connectors may break if care is not used when removing the fuel tank at the time of service. A fuel leak, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel line quick connectors.
Certain vehicles located in Alberta, Saskatchewan, Manitoba and the Yukon may experience a combination of extreme low temperatures and very rough road conditions, causing a crack in the fuel sending unit flange. At this time, vehicles located in other parts of the country are not experiencing this type of failure, therefore no action will be undertaken by the manufacturer in unaffected provinces and territories. A cracked flange could allow fuel to leak which, in the presence of an ignition source, could result in a fire.
On certain vehicles, the fuel tank straps may break, potentially resulting in the fuel tank and fuel tank heat shield dropping on the exhaust system (FWD vehicles) or driveshaft (AWD vehicles). If the fuel tank and shield contact the exhaust or driveshaft, the driver may notice noise or a fuel leak. Fuel leakage in the presence of an ignition source may result in a fire.
On certain G55 AMG, the fuel return hose between the fuel tank and return line could develop cracks and leak. Fuel leakage, in the presence of an ignition source, can result in a fire.
On certain vehicles, the fuel tank may have an internal breather pipe that was not made to specification. This may result in excessive swelling and cracking of a grommet and subsequent detachment of the breather pipe from a connector tube. When the fuel level in the tank is above the level of the detached joint, fuel may then enter the breather pipe. The vehicle may exhibit MIL illumination, fuel odour, driveability concerns such as hesitation, misfire, stalling, rough running or difficulty starting. If the amount of fuel flowing into the breather pipe reaches the vapour canister and exceeds its capacity, the excess fuel may be discharged onto the ground. Fuel leakage, in the presence of an ignition source, can result in a fire.
Certain vehicle may experience a fuel leak from the main fuel tube and/or the return tube near the fuel tank due to interference (insufficient clearance) with the vehicle frame. A fuel leak, in the presence of an ignition source, could result in a fire.
On certain motorcycles, fuel hose construction may not meet manufacturer specifications and may fail. A failure of the fuel hose would cause a fuel leak which, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if required, replace the fuel pressure line.
On certain vehicles equipped with a 2.5L gasoline engine, a fuel supply line clamp located in the engine compartment may not be positioned properly and could leak. A fuel leak, in the presence of an ignition source, may cause a fire.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the subject fuel supply line clamp.
On certain vehicles equipped with a 6.0L diesel engine, the Fuel Injection Control Module (FICM) wire harness may chafe against an engine bolt. Also, the Injection Control Pressure (ICP) sensor connector terminals may have an improper crimp height that may result in intermittent or permanent loss of the ICP sensor signal. FICM wire harness chafes or improper ICP sensor connector crimps may cause the vehicle to stall without warning while driving. If the vehicle stalls, it may or may not restart.
Safety Risk
No risk description available.
Remedy
For all F-Superduty and Excursion vehicles, dealers will inspect the FICM wire harness for chafing. If bare wires have not been exposed, dealers will install a wire protection kit. If bare wires have been exposed, dealers will install a new wire harness. For all E-Series and, depending on build date, some F-Superduty and Excursion vehicles, dealers will install a new ICP sensor connector with certified crimps.
On certain pick-up trucks and chassis cab vehicles equipped with 5.4L and 6.8L gasoline engines, a fuel jumper line may separate from the connection to the main fuel bundle. If the fuel line separates, an operator may notice a gasoline odour and/or fuel on the ground, loss of power, and eventual engine stall. A fuel leak in the presence of an ignition source could result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will install an external retention clip at the fuel jumper line to main fuel bundle connection.
On certain vehicles, a vapour hose located in the fuel tank was not formed correctly, resulting in the inner surface of the hose not being round. This could result in a gap between the hose and a connector tube. When the fuel level in the tank is full and above the joint area between the vapour hose and a connector tube, fuel may flow into the vapour hose through the gap and reach the vapour canister. If the amount of fuel flowing into the vapour canister exceeds its capacity, the excess fuel will be discharged onto the ground. A fuel leak, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will test the vapour hose connections and, if required, replace the fuel tank.
On certain vehicles, fuel may leak from the o-ring seal into the internal vapour chamber located in the fuel tank at full tank conditions. As a result, it may be difficult to fill the gas tank and/or fuel may leak from the evaporative air filter inlet. Fuel leakage, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
Kia Canada Inc. has corrected all affected vehicles prior to distribution to dealers.
On certain diesel powered vehicles, water and/or salt intrusion into a fuel switching manifold solenoid for the optional dual fuel tank system may cause the manifold to fail. If one or more solenoid valves fail, the diesel fuel system will exhibit fuel overflow from the fuel filler neck, which could result in diesel fuel leakage.
Safety Risk
No risk description available.
Remedy
Dealers will replace the solenoid valve assembly with an improved version.
On certain vehicles equipped with a gasoline engine, fuel supply line tension may cause the fuel pump supply nipple to crack, which could result in a leak. A fuel leak, in the presence of an ignition source, may cause a fire.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the fuel supply line for tension, and inspect the fuel pump supply nipple for cracks. If tension is present in the fuel supply line, it will be replaced. If the fuel pump supply nipple is cracked, both the fuel line and the fuel pump will be replaced.
