A leaky fuel-tank flange made by Continental Automotive Systems has prompted the recall of 456,106 Volkswagen, Audi, and Porsche vehicles in the United States. A fuel-tank leak carries a fire risk, but so far no fires or injuries have been reported.
The recall affects the 2007–2010 Volkswagen Touareg, the 2013–2017 Audi Q5 and Q7, and the 2015–2017 Porsche Macan, but Continental sold a similar part to at least seven other automakers and five suppliers. That means a recall could affect millions more vehicles, but it also “could be zero” beyond the already-recalled crossovers, Continental’s Mary Arraf told Car and Driver.
The National Highway Traffic Safety Administration (NHTSA) has asked the affected companies to test the part and determine whether a recall is necessary. They include Lamborghini, Fiat Chrysler, Ford, General Motors, Jaguar Land Rover, McLaren Automotive, and Mercedes-Benz as well as suppliers Kautex Textron, Magna International, Plastic Omnium, TI Automotive, and Yapp USA Automotive Systems.
In affected vehicles, hairline cracks form on the fuel-tank flange, causing a small amount of fuel to leak, according to documents filed with NHTSA. In a vehicle with a leaky fuel flange, the most obvious sign to look for—or smell for—is the odor of gasoline. A check-engine light also may illuminate.
Continental suspects the problem could stem from material degradation of the outer wall of the fuel-tank flange when it’s exposed to environmental factors such as acids from cleaning solutions. The fuel-tank flange was made with a widely used, industry-standard material called polyoxymethylene copolymer (POM).
Arraf said that the parts cracking also could be related to where the fuel tank is placed on the vehicle. Volkswagen spokeswoman Jeannine Ginivan said in an email that the affected fuel tank in Audi vehicles “is generally in the same location—mounted to the underbody, forward of the rear axle, following the body contour under the rear seat/floorpan.” Porsche did not respond to requests for comment.
Other automakers generally declined to comment, since they are investigating the issue. “It’s unclear at this point whether Ford vehicles are affected,” Ford spokeswoman Elizabeth Weigandt said. “We are reviewing the matter and will cooperate with NHTSA, as we always do.”
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