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

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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 VolkswageneBay Group of America, Inc.

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 49,443

 

Summary

VolkswageneBay Group of America, Inc. (VolkswageneBay) is recalling certain 2019-2021 AudieBay Q8, and 2020-2021 AudieBay 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. Interim owner notification letters, informing owners of the safety risk, were mailed September 15, 2022. A second notice will be sent once the remedy becomes available in late December 2022. Owners may contact AudieBay’s customer service at 1-800-253-2834. AudieBay’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

 


Safety Recall 20DR / Fuel Pump

 

Affected Vehicles

CountryBeginning Model YearEnding Model YearVehicleVehicle Count
USA20202021Q719,031
USA20192021Q830,412
CAN20202021Q72,356
CAN20192021Q83,744

 

Problem Description

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.

 

Corrective Action

Replace the fuel delivery module.

 

Precautions

This issue may cause the Malfunction Indicator Light (MIL) to illuminate. If this happens, owners are advised to contact an authorized AudieBay dealer without delay to have the vehicle diagnosed/repaired.

 

Code Visibility

On July 28, 2022, the campaign code was applied to affected vehicles.

 

Owner Notification

Owner notification took place in December 2022. Owner letter examples are included in this bulletin for your reference.

 

Repair Overview

Replace in-tank fuel delivery unit.

 


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 AudieBay Product Safety Committee.

May 2020 โ€“ 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, AudieBay 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 AudieBay Product Safety Committee decided to monitor the field situation.

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

March 2021 โ€“ 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, AudieBay AG and VolkswageneBay 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 AudieBay Product Safety Committee decides a voluntary safety recall for AudieBay Q7 product improvement and AudieBay 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 AudieBay 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, AudieBay 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

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

 


5 Affected Products

Vehicles

MAKEMODELYEAR
AUDIeBayQ72020-2021
AUDIeBayQ82019-2021

 


17 Associated Documents

Recall 573 Report – July 21, 2022

RCLRPT-22V516-8726.PDF 215.798KB

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Defect Notice 573 Report

RCLRPT-22V516-2960.PDF 215.76KB

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Recall Acknowledgement

RCAK-22V516-9943.pdf 645.735KB

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VolkswageneBayAudieBay amended chronology – July 2022

RMISC-22V516-8312.pdf 214.678KB

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VolkswageneBayAudieBay chronology – July 2022

RMISC-22V516-9496.pdf 257.055KB

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VolkswageneBayAudieBay Dealer Advance Notice – July 2022

RCMN-22V516-9497.pdf 837.452KB

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VolkswageneBayAudieBay Dealer Advance Notice – July 2022

RCMN-22V516-5946.pdf 837.518KB

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Interim Owner Notification Letter(Part 577)

RIONL-22V516-4300.pdf 122.839KB

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Interim Owner Notification Letter(Part 577)

RIONL-22V516-7565.pdf 107.662KB

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Remedy Instructions and TSB

RCRIT-22V516-3066.pdf 5085.366KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V516-3308.pdf 152.691KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V516-4384.pdf 169.897KB

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VolkswageneBayAudieBay Dealer Launch Notice – December 2022

RCMN-22V516-4028.pdf 234.346KB

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Remedy Instructions and TSB

RCRIT-22V516-0799.pdf 5085.64KB

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VolkswageneBayAudieBay Dealer Revision Notice – January 2023

RCMN-22V516-9831.pdf 282.729KB

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VolkswageneBayAudieBay Dealer Revision Notice – March 2023

RCMN-22V516-8475.pdf 137.682KB

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Remedy Instructions and TSB

RCRIT-22V516-0897.pdf 5049.05KB

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