Complaint 2188505

Complaint Summary

FUEL/PROPULSION SYSTEM

Owner Narrative

I am submitting this complaint to report a serious safety defect involving a high-pressure fuel system failure that occurred shortly after recall service was performed by an authorized dealership. The failure created a significant risk of engine compartment fire and potential loss of vehicle control. On March 25, 2025, my vehicle underwent recall service at Hall Ram Dealership for replacement of the high-pressure fuel pump. This repair required removal and reinstallation of the high-pressure fuel supply lines. These lines are torque-to-yield, single-use components that must be replaced once removed to ensure proper sealing under high operating pressures. On April 7, 2025, while driving at highway speed, the high-pressure fuel line connected to the pump suddenly ruptured. This resulted in an uncontrolled release of fuel into the engine compartment, creating an immediate safety hazard. Atomized fuel was exposed to high-temperature engine components, significantly increasing the risk of ignition and fire. The failure also posed a risk of sudden engine power loss. The vehicle required emergency towing. A review of the March 25 service invoice shows no documentation that the high-pressure fuel lines were replaced. This strongly suggests the original single-use lines were reused, contrary to OEM standards and accepted repair procedures. Reuse of these components can lead to sealing failure, fatigue, and rupture under pressure. This incident raises concerns regarding compliance with federal safety regulations, including 49 U.S.C. Chapter 301 and FMVSS No. 301 governing fuel system integrity. A fuel line rupture under normal operating conditions indicates a critical safety defect and possible improper execution of a recall remedy. I request that NHTSA investigate whether authorized repair facilities are properly following required procedures during recall repairs, including replacement of single-use fuel system components.

Owner-submitted narrative on file with NHTSA. Complaint narratives are self-reported and have not been verified.