20DR – Fuel Pump – 2019-2021 Audi Q8, & 2020-2021 Q7

July 20, 2022 NHTSA CAMPAIGN NUMBER: 22V516000

Fuel Pump May Fail

Fuel pump failure can cause an engine stall, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V516

Manufacturer Volkswagen Group of America, Inc.

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 49,443

 

Summary

Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2019-2021 Audi Q8, and 2020-2021 Audi Q7 vehicles. A component inside the fuel pump may break, causing the fuel pump to fail.

 

Remedy

Dealers will replace the fuel pump, free of charge. Owner notification letters are expected to be mailed September 16, 2022. Owners may contact Audi’s customer service at 1-800-253-2834. Audi’s number for this recall is 20DR.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Audi has a Recall

 


2021 Audi Q8
2021 Audi Q8

 


Safety Recall 20DR / Fuel Pump

 

Issue:

A component of the fuel delivery module inside the fuel tank may break while operating the vehicle. The fragments can damage the sealing membrane in the pressure regulator. This may lead to a failure of the fuel delivery module and the instrument cluster will display the Malfunction Indicator Light (MIL). In rare cases and under certain circumstances, however, there may be a sudden loss of engine power or the vehicle may break down without a warning appearing beforehand. A fuel leak due to this failure can be ruled out.

 

Repair:

  • REPAIR NOT YET AVAILABLE

 

Affected Vehicles

Country Beginning Model Year Ending Model Year Vehicle Vehicle Count
USA 2020 2021 Q7 19,031
USA 2019 2021 Q8 30,412
CAN 2020 2021 Q7 2,356
CAN 2019 2021 Q8 3,744

 


Chronology of Defect

May 2020: The US market reports an increase in warranty claims for replaced fuel delivery units in Q7 PI and Q8 vehicles and asks for an evaluation by the Audi Product Safety Committee.

 

May 2020 – September 2020: Initial investigations were launched including analysis of parts from the field and root cause analysis together with the supplier. Initially the failure mode could not be reproduced. Together with the supplier, Audi initiated root cause analysis and development of an improved fuel delivery module. At that point it appeared that if the condition is present in the fuel delivery module, the failure would manifest early in the service life of the vehicle. It was also confirmed that no fuel leak can occur due to this condition and that the emission control warning light will light up. Based on this understanding, the Audi Product Safety Committee decided to monitor the field situation.

 

In January 2021, the supplier introduced an optimized part which Audi started using on January 30, 2021 in production. Field monitoring continued.

 

March 2021 – November 2021: Current field situation was reviewed and evaluated. Additional analysis was started regarding field situation across the different markets, differences in failure rates in the field, additional causal factors (Ishikawa), analysis and verification of customer experience/impact as well as an estimation regarding expected developments in the field. An increase in field cases was found during the ongoing field monitoring. Pressure pulsations in the low-pressure system were found to be a main factor and an evaluation regarding a potential software solution to adapt the idle speed in order to reduce the pressure pulsations was tasked.

 

November 2021: A warranty extension for 6 years/80,000 miles was decided to address and improve customer experience. Investigation regarding influences and potential software remedy and field monitoring continued.

 

February 2022: Due to discussions with the EPA/CARB and the thresholds for emission defect reporting, the conditions for the warranty extension were extended to full useful life (15 years / 150,000 miles).

 

March – July 2022: Based on discussions with NHTSA regarding other topics with similar failure modes, Audi AG and Volkswagen of America reviewed and reevaluated this topic, the technical background, and the customer experience.

 

July 13, 2022: Even though not all influential factors of the failure pattern have been fully understood, the Audi Product Safety Committee decides a voluntary safety recall for Audi Q7 product improvement and Audi Q8 vehicles based on the field situation and the fact that a loss of motive power may occur in certain cases.

 

Between 2019 and July 13, 2022 Audi of America has received 74 warranty claims for Q7 PI and Q8 vehicles alleging a loss of motive power while driving due to this issue.

 

Additionally, Audi of America has identified eight (8) field reports for Q7 PI and Q8 vehicles potentially relating to this issue. These reports are from the following dates:

  • 01/06/2021
  • 07/06/2021
  • 06/10/2020
  • 02/25/2021
  • 03/16/2021
  • 06/28/2021
  • 02/10/2022
  • 09/10/2020

Audi is not aware of any accidents or injuries due to this topic.

 


5 Affected Products

Vehicles

MAKE MODEL YEAR
AUDI Q7 2020-2021
AUDI Q8 2019-2021

 


7 Associated Documents

Recall 573 Report – July 21, 2022

RCLRPT-22V516-8726.PDF 215.798KB

RCLRPT-22V516-8726

 


Defect Notice 573 Report

RCLRPT-22V516-2960.PDF 215.76KB

RCLRPT-22V516-2960

 


Recall Acknowledgement

RCAK-22V516-9943.pdf 645.735KB

RCAK-22V516-9943

 


VolkswagenAudi amended chronology – July 2022

RMISC-22V516-8312.pdf 214.678KB

RMISC-22V516-8312

 


VolkswagenAudi chronology – July 2022

RMISC-22V516-9496.pdf 257.055KB

RMISC-22V516-9496

 


VolkswagenAudi Dealer Advance Notice – July 2022

RCMN-22V516-9497.pdf 837.452KB

RCMN-22V516-9497

 


VolkswagenAudi Dealer Advance Notice – July 2022

RCMN-22V516-5946.pdf 837.518KB

RCMN-22V516-5946

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V516&docType=RCL

 


 

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Last update on 2022-08-15 / Affiliate links / Images from Amazon Product Advertising API

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