Chevy Volt fire prompts U.S. safety probe of lithium ion batteries, report says

U.S. auto-safety regulators are scrutinizing the safety of lithium ion batteries that power electric vehicles after a Chevrolet Volt battery caught fire, people familiar with the probe said.

The regulators have approached all automakers, including General Motors, Nissan Motor Co. and Ford Motor Co., that sell or have plans to sell vehicles with lithium ion batteries with questions about the batteries' fire risk, four people familiar with the inquiry said.

The Volt caught fire while parked at a National Highway Traffic Safety Administration testing center in Wisconsin, three weeks after a side-impact crash test, said an agency official.

The official, as well as the three other people familiar with the inquiry, said they couldn't be named because the investigation isn't public.

“I want to make this very clear: the Volt is a safe car,” said Jim Federico, GM’s chief engineer for electric vehicles. “We are working cooperatively with NHTSA as it completes its investigation. However, NHTSA has stated that based on available data, there’s no greater risk of fire with a Volt than a traditional gas-powered car.”

The probe comes as automakers look to expand plug-in offerings beyond the Volt and Nissan's Leaf, which went on sale in the 2011 model year as the first mass-market plug-in electric cars in the United States.

Toyota Motor Co.'s Prius, the world's best-selling hybrid, uses a nickel-metal battery. A plug-in Prius and an electric version of the RAV4 sport-utility vehicle will use lithium ion batteries.

President Barack Obama has set a goal of putting 1 million electric vehicles on U.S. roads by 2015. Nissan is among companies that have received financing assistance from the U.S. Energy Department and European Investment Bank to develop the Leaf and lithium ion batteries.

GM in January withdrew a request for $14.4 billion in U.S. loan guarantees.

Seoul-based LG Chem Ltd., South Korea's biggest chemical maker, supplies the lithium ion batteries for the Volt.

Concern for first responders

The fire was severe enough to burn vehicles parked near the Volt, the agency official said. Investigators determined the battery was the source of the fire, the official said.

NHTSA also sent a team of investigators this week to Mooresville, N.C., to probe a fire in a residential garage where a Volt was charging. That investigation is continuing, the agency official said.

"As manufacturers continue to develop vehicles of any kind -- electric, gasoline, or diesel -- it is critical that they take the necessary steps to ensure the safety of drivers and first responders both during and after a crash," the safety agency said in a statement today.

"Based on the available data, NHTSA does not believe the Volt or other electric vehicles are at a greater risk of fire than gasoline-powered vehicles. In fact, all vehicles -- both electric and gasoline-powered -- have some risk of fire in the event of a serious crash."

The agency's greater concern is for rescue response teams, tow truck operators and salvage yards who may be storing plug-in cars after an accident, the official said.

GM spokesman Greg Martin said the company doesn't believe the Volt poses any greater risk to drivers than a conventional automobile. GM has spent almost 300,000 hours testing the car and believes it is safe, he said.

After the fire in June, GM and NHTSA both crashed a Volt and could not replicate the fire, Martin said. GM has safety protocols for handling the Volt and its battery after an accident. Had those been followed, there wouldn't have been a fire, Martin said.

"There are safety protocols for conventional cars," Martin said. "As we develop new technology, we need to ensure that safety protocols match the technology."

The Volt and Leaf went on sale in late 2010. U.S. sales of the Volt have reached 5,003 units this year through October; Leaf sales total 8,048 units.

Nissan spokeswoman Katherine Zachary said today there have been no incidents of fire involving the battery in the Leaf.

"The Nissan Leaf battery pack has been designed with multiple safety systems in place to help ensure its safety in the real world. All of our systems have been thoroughly tested to ensure real-world performance," Zachary said. "To date, the more than 8,000 Nissan Leafs driving on the U.S. roads have performed without reported incident."

Flammable element

Automakers have engineered electric vehicles using lithium ion batteries to withstand serious accidents because the element is flammable, said Sandy Munro, president of Munro and Associates, an engineering consulting firm in Troy, Mich.

Lithium ion batteries could catch on fire if the battery case and some of the internal cells that store electricity are pierced by steel or another ferrous metal, he said.

"Lithium burns really hot," Munro said. "But it doesn't happen often. You have to do something pretty dramatic to make it catch fire."

If a lithium ion battery is pierced by steel, a chemical reaction will take place that starts raising the temperature and can result in a fire, he said. If the piercing is small, that reaction can take days or weeks to occur, he said.

NHTSA this year gave the Leaf and Volt its top crash-test safety rating, following a "good" rating in April by the Insurance Institute for Highway Safety.

In the simulated side-impact crash test, a new U.S. safety test for the 2011 model year, metal punctured the battery, the official said.

Regulators want to use information collected from automakers to inform emergency responders, towing firms and salvage yards about how to handle plug-in electric cars involved in crashes that may penetrate the battery compartment, the official said.

NHTSA will use the information from the automakers, which also include Toyota and BMW AG, for a three-year $8.8 million electric-vehicle safety study it announced in June, the official said.

The Federal Aviation Administration, in an advisory to airlines in October 2010, warned that lithium batteries used in cell phones, digital cameras and other devices are "highly flammable and capable of ignition," adding that fire suppression systems aren't effective when that happens.

It issued the advisory after a United Parcel Service Inc. cargo plane carrying thousands of lithium batteries crashed in Dubai after catching fire, killing both pilots.

Fifteen electric-car or battery-powered models will be available in the United States by the end of 2014, according to J.D. Power & Associates, which forecasts a glut of electric cars given that hybrid-electric sales were only 2 percent of the car market so far this year.

Toyota recalls 550,000 cars for steering issue

Toyota Motor Corp. said Wednesday it is recalling about 550,000 vehicles worldwide — mostly in the United States — for problems that could make it harder to steer.

The recall affects 447,000 vehicles in North America, as well as 38,000 in Japan and another 25,000 in Australia and New Zealand, said Toyota spokesman Dion Corbett. In Europe some 14,000 vehicles are being recalled along with 10,000 in the Middle East and 14,000 in Asia outside Japan.

Toyota has received a total of 79 reports about the defect dating back to 2007, said Corbett. There have been no reports of accidents or injuries related to the problems, he said.

Toyota's reputation has taken a hit over the last two years due to a string of huge recalls that have ballooned to 14 million vehicles over that time, including millions recalled last year for acceleration problems. It faces damage lawsuits and lingering doubts in the U.S. about whether it had been transparent enough about the recall woes.

Japan's largest automaker has been trying to communicate better with customers and empower regional operations outside Japan to make safety decisions.

The news comes a day after Toyota said its July-September profit slid 18.5 percent to 80.4 billion yen ($1 billion) on plunging sales caused by parts shortages from the tsunami disaster in northeastern Japan.

It now faces such uncertainties from flooding in Thailand, where it has many suppliers and three assembly plants, that it declined to release an earnings forecast for the full year through March.

The latest recall is due to the possibility that the outer ring of the engine's crankshaft pulley may become misaligned with the inner ring, causing noise or a warning signal to light up, the company's U.S. sales unit said in a press release. If the problem isn't corrected, the belt for the power steering pump may become detached from the pulley, making it suddenly more difficult to turn the steering wheel.

In the United States, the automaker is recalling 283,200 Toyota brand cars, including the 2004 and 2005 Camry, Highlander, Sienna and Solara, the 2004 Avalon and the 2006 Highlander HV. Its recall of 137,000 Lexus vehicles includes the 2004 and 2005 ES330 and RX330 and 2006 RX400h.

Those affected elsewhere include certain models of the Alphard, Highlander, Highlander hybrid and some Lexus models, Corbett said.

The recall notification process varies from country to country.

In the U.S., Toyota will mail owners a notification to make an appointment with an authorized dealer to have their car inspected once replacement parts have been produced in sufficient quantities.

If needed, parts will be replaced for no charge, the company's American sales unit said. Notifications will be mailed starting in January.

In the meantime, if an abnormal noise is heard coming from the engine compartment, the owner is asked to make an appointment with any Toyota or Lexus dealer to have the vehicle inspected for this condition, the release said.

NHTSA upgrades probe of 382,000 Saturn Ion cars - electronic power steering

U.S. safety regulators have upgraded an investigation more than 382,000 Saturn Ion cars for possible steering problems.

The National Highway Traffic Safety Administration said it opened the engineering analysis after it and Saturn, a brand General Motors discontinued in 2009, received more than 4,000 complaints about sudden loss of electronic power steering assist in cars from model years 2004 through 2007.

Sixteen of the complaints said the power steering warning lamp had illuminated before or during the loss of power steering assist and the increased effort required to steer contributed to a crash, according to documents filed by NHTSA. Two of the crash claims indicated the driver was injured.

NHTSA also said GM had received 17,385 warranty claims related to the issue.

A GM spokesman said the automaker was cooperating with NHTSA.

Last year, GM recalled 1.05 million Chevy Cobalt and Pontiac G5 vehicles to correct a defect in the electronic power steering assist motor, according to NHTSA. The defect was described as a buildup of brush debris mixed with oily material that caused the motor to stop functioning; "the same problem identified in the current subject vehicles," NHTSA said.

Previously NHTSA investigated the sudden loss of power steering assist in model year 2005 through 2010 Chevrolet Cobalt vehicles.

In May 2011, GM provided safety regulators with complaint, warranty and power-steering system information for the Ion, as well as the Pontiac G6 and Chevy Malibu, according to NHTSA. In that response, GM indicated the power-steering system used in those vehicles was the same as that used in model year 2005 to 2010 Cobalts and Pontiac G5s.

NHTSA said it has duplicated the power-steering system failure in both a Cobalt and an Ion previously tested.

Volkswagen Group to recall 168,275 VW, Audi models to fix diesel engine defect

Volkswagen AG is recalling 168,275 VW and Audi models with diesel engines because of a defect in the fuel injection system that could cause fuel leaks, possibly creating fire hazards.

The recall affects certain 2009-12 Jetta mid-sized sedans and wagons, and some 2010-12 Golf compacts, federal regulators said today.

Some 2010-12 Audi A3 models also are affected, the National Highway Traffic Safety Administration said on its Web site.

Models subject to the recall have 2.0-liter diesel engines, NHTSA said.

VW, in documents filed with U.S. regulators, said cracks can develop in the fuel injection system and cause fuel to leak, possibly causing fires.

VW said it is unaware of any fires, accidents or injuries caused by the problem.

On certain VW diesel engines, a vibration caused by the fuel injectors can generate stress that eventually can lead to cracks in the injector fuel lines, VW said in documents filed with NHTSA.

VW will replace a fuel injector line in some models and install dampers to reduce vibration in all affected vehicles, NHTSA said. Both services will be provided free, VW said.

VW said about 20 percent of vehicles recalled have fuel injection lines with potentially faulty material, The Detroit News said.

The automaker said one supplier used a defective part in assembling fuel injectors -- and the failures only related to one of four injector lines, The News said.

The automaker began investigating the matter in March 2010 after a report of a fuel leak, NHTSA documents show.

VW told federal regulators the recall is scheduled to begin in November. The recall includes 161,144 Golf and Jetta models, and 7,131 Audi A3s.

Earlier this week, Volkswagen said about 22 percent of the VW models it sold in the U.S. market last month had diesel engines.

NHTSA upgrades probe of 382,000 Saturn Ion cars

U.S. safety regulators have upgraded an investigation more than 382,000 Saturn Ion cars for possible steering problems.

The National Highway Traffic Safety Administration said it opened the engineering analysis after it and Saturn, a brand General Motors discontinued in 2009, received more than 4,000 complaints about sudden loss of electronic power steering assist in cars from model years 2004 through 2007.

Sixteen of the complaints said the power steering warning lamp had illuminated before or during the loss of power steering assist and the increased effort required to steer contributed to a crash, according to documents filed by NHTSA. Two of the crash claims indicated the driver was injured.

NHTSA also said GM had received 17,385 warranty claims related to the issue.

A GM spokesman said the automaker was cooperating with NHTSA.

Last year, GM recalled 1.05 million Chevy Cobalt and Pontiac G5 vehicles to correct a defect in the electronic power steering assist motor, according to NHTSA. The defect was described as a buildup of brush debris mixed with oily material that caused the motor to stop functioning; "the same problem identified in the current subject vehicles," NHTSA said.

Previously NHTSA investigated the sudden loss of power steering assist in model year 2005 through 2010 Chevrolet Cobalt vehicles.

In May 2011, GM provided safety regulators with complaint, warranty and power-steering system information for the Ion, as well as the Pontiac G6 and Chevy Malibu, according to NHTSA. In that response, GM indicated the power-steering system used in those vehicles was the same as that used in model year 2005 to 2010 Cobalts and Pontiac G5s.

NHTSA said it has duplicated the power-steering system failure in both a Cobalt and an Ion previously tested.

Ford F-150, Escape defect probes closed by U.S. regulator

Investigations into safety defects in Ford F-150, Escape and Mercury Mariner vehicles were closed without additional recalls, the U.S. National Highway Traffic Safety Administration said.

The auto-safety regulator ended probes into the 1997 to 2004 F-150 pickup trucks and 2010-2011 Escape and Mariners, according to a report posted today on its Web site.

Ford Motor Co. last month recalled some F-150s voluntarily for fuel-tank strap corrosion. The investigation into the Escapes and Mariners was for rear lift-gate window defects.

The agency, in its monthly report of closed investigations, also rejected a request to investigate Toyota Motor Corp. model-year 2008 Corolla cars for front air bags that may not deploy.

Hyundai recalls 205,233 SUVs in U.S. on front air bag defect

Hyundai Motor Co. said it is recalling 205,233 Santa Fe and Veracruz sport-utility vehicles in the U.S. because front air bags may not deploy when needed.

Hyundai said the electrical parts used to deploy air bags may not conduct current properly, causing them to not work in the event of a crash. The automaker announced the recall today on the National Highway Traffic Safety Administration Web site.

Hyundai told the regulator in a Sept. 8 letter posted on the Web site that it has received about 7,800 warranty claims for air-bag defects in the vehicles and isn't aware of any accidents or injuries caused by it.

In the year model 2007-2008 SUVs being recalled, the clock spring contact assembly for drivers' front air bags may become damaged, leading the air bag's electrical circuit to experience high resistance and potentially causing it to not deploy, Hyundai told the regulator. If this happens, the air-bag warning light on the instrument panel will turn on.

"Hyundai is voluntarily initiating this action to ensure the safety and quality of vehicles and the continued satisfaction of our customers," Miles Johnson, a U.S.-based spokesman, said in an e-mail.

BMW Recall Notice FUEL SYSTEM, DIESEL: PRE-HEATER

Manufacturer: BMW OF NORTH AMERICA, LLC Mfr's Report Date: AUG 18, 2011
NHTSA CAMPAIGN ID Number: 11V441000 NHTSA Action Number: N/A
Component: FUEL SYSTEM, DIESEL: PRE-HEATER
Potential Number of Units Affected: 2,120
Summary:
BMW IS RECALLING CERTAIN MODEL YEAR 2009 X5 XDRIVE35D VEHICLES EQUIPPED WITH A DIESEL ENGINE AND MANUFACTURED FROM OCTOBER 1, 2008, THROUGH JUNE 12, 2009. THE FUEL FILTER HEATER, WHICH IS USED FOR WARMING UP THE DIESEL FUEL DURING VEHICLE OPERATION AT LOW OUTSIDE TEMPERATURES, COULD EXPERIENCE AN ELECTRICAL OVERLOAD CONDITION AND BECOME PERMANENTLY ACTIVATED.
Consequence:
THE FUEL FILTER HEATER COULD REMAIN ACTIVATED EVEN WHEN THE IGNITION IS OFF AND LEAD TO A DEAD BATTERY. THE UNIT COULD ALSO OVERHEAT, POSSIBLY LEADING TO A VEHICLE FIRE.
Remedy:
BMW WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE FUEL FILTER HEATER FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING OCTOBER 2011. OWNERS MAY CONTACT BMW CUSTOMER RELATIONS AND SERVICES AT 1-800-525-7417.
Notes:
OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .

Hyundai dealers to inspect, repair Sonatas prone to wandering

Hyundai Motor America said its U.S. dealers will fix a steering problem found in some 2011 Sonata mid-sized sedans after more than 4,000 owners complained about the car's steering system.

Drivers have complained that the 2011 Sonata is prone to drifting or pulling to the left while being driven.

The company suspects that about 41,000 Sonatas with 18-inch wheels could be affected by the problem, Hyundai spokesman Jim Trainor said. He said the fix is a service campaign, not a recall.

Hyundai said it has received or tracked about 4,000 complaints -- representing about 3 percent of the nearly 150,000 Sonatas built from September 2010 through April 2011, Trainor said. The National Highway Traffic Safety Administration has received 198 complaints about the 2011 Sonata's steering, many of which described vehicle tracking problems seemingly similar to the one being addressed in this campaign.

Consumers can set up an appointment with a dealer to inspect the Sonata's wheel alignment and tracking, Trainor said. If necessary, the dealer will install new front suspension struts and perform a wheel alignment, both for free.

Last year, Hyundai recalled about 138,000 2011 Sonatas for a different steering problem. The recall followed a probe by U.S. safety regulators into customer complaints that a steering shaft could potentially become detached from the steering wheel.

Honda recalls 2.5 million vehicles globally for software issue

- Honda Motor Co. said today it will recall 2.49 million cars, small SUVs and minivans worldwide, including its popular Accord sedan, to repair a software problem that could damage the automatic transmission.

The recall includes 1.5 million vehicles in the United States, 760,000 in China and 135,142 in Canada, the automaker said in a statement.

Globally, the recall affects four-cylinder Accord sedans for the model years 2005 to 2010.

The company is also recalling vehicles in parts of Europe, the Middle East, South America, Mexico and Puerto Rico. The recall did not affect vehicles sold in Honda's home Japan market.

In the United States and Canada, the recall also includes the CR-V crossover for the model years 2007 to 2010 as well as the small SUV Element from 2005 to 2008.

In China, the recall also includes more than 160,000 Odyssey minivans from 2005 to 2009 and about 4,000 Spirior cars, which are based on the European version of the Accord, for the 2010 model year.

Without updating the software, the automatic transmission in these vehicles could be damaged if the driver quickly shifts between gears. That might cause the engine to stall or make it difficult to put the car into park.

This week, Consumer Reports said it was not recommending the 2012 Honda Civic. This has led some industry analysts to ask if that is a symptom of larger problems at the automaker, which ranks fifth in U.S. sales this year.

The company has said it disagreed with the influential U.S. consumer advocate's assessment.

Chris Martin, Honda spokesman at the company's U.S. headquarters in California, said today the recall was not a sign of deeper difficulties.

Martin said the current recall was the result of "extremely unusual circumstances. The far majority of our consumers would never really encounter this. It's software programing. It's not a weakness in the transmission per se."

No injuries or deaths have been reported from this problem, Martin said.

Honda said the problems might arise if the transmission were quickly shifted between the reverse, neutral and drive positions. A driver might do this in an attempt to dislodge a vehicle in mud or snow.

The automatic transmission secondary shaft bearing could be damaged in this scenario.

An update to transmission control module software will ease the transition between gears and reduce the possibility of damage.

Honda will begin informing U.S. consumers at the end of August. It did not disclose expected cost of the recall.

The software update will take about a half-hour, but customers may have to leave their cars at Honda dealerships for a longer period, Martin said.

Ford to recall 1.1M pickup for gas tank problem

Ford to recall 1.1M pickup trucks with gas tanks that can fall off and cause fires

Ford Motor Co. is recalling 1.1 million pickup trucks because the gas tanks can fall off and cause fires.

The National Highway Traffic Safety Administration said Monday on its website that the metal straps holding the tanks can rust, allowing them to fall, rupture and catch fire.

The defect has been blamed for eight fires, three of which spread to the rest of the truck. One person was injured, suffering first- and second-degree burns, Ford spokesman Wes Sherwood said.

The recall affects certain 1997 through 2004 Ford F-150 models, as well as some 1997 through 1999 model year F-250 pickups. Also affected are Lincoln Blackwood pickups from the 2002 and 2003 model years. They were sold in cold-weather states where salt is used to clear roads. The salt corroded straps holding the tanks and they broke, NHTSA said.

The trucks were originally sold or are now registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and Washington, D.C.

Sherwood said the company will notify owners in September to bring their trucks to dealers who will replace the straps with new ones that are coated to resist corrosion. Parts to fix the problem, he said, won't be widely available until then.

People with questions should contact their dealer, who can install a cable to hold the tanks in place until the replacement straps arrive, Sherwood said.

Motorists need better information on recalls, U.S. report says

The U.S. auto-safety regulator should better inform drivers of defects because only 70 percent of recall repairs on cars and trucks are completed within 18 months, the Government Accountability Office said in a report issued Wednesday.

The U.S. National Highway Traffic Safety Administration should change what consumers must be told in recall notification letters, improve and publicize its auto-recall website and seek authority to notify used-car buyers, the GAO said in a report.

In 2010, automakers recalled a record 14.9 million vehicles.

"Many recalled vehicles are never fixed, posing a risk to vehicle operators, other drivers, and pedestrians," the GAO said in the report, which was requested by Representatives Elijah Cummings, a Maryland Democrat, and Edolphus Towns, a New York Democrat.

Toyota Motor Corp.'s record recalls last year for defects related to unintended acceleration were investigated by U.S. lawmakers.

"NHTSA is committed to ensuring consumers have the information they need to keep their families safe on the road and in their communities," NHTSA Administrator David Strickland said. "We look forward to working with policymakers to continue to strengthen our efforts on these and other safety issues."

Consumers can sign up for e-mailed alerts about vehicle recalls from NHTSA at www.safercar.gov.

Honda expands U.S. airbag recall to include about 833,000 autos

Honda Motor Co. said it will again expand a U.S. recall of Honda and Acura brand models to fix flawed airbag components.

The company will inspect model year 2001 to 2003 vehicles that may have had the original driver's air-bag module replaced with a flawed service part, Honda said today in an e-mailed statement.

As a result, the recall now includes an additional 833,000 vehicles, the company said. Honda "determined that a number of affected service part air bags were installed in these vehicles in the process of a collision repair or other vehicle service," according to the statement.

"Owners of all potentially affected vehicles are being notified because Honda has not been able to determine which specific vehicles received one of those parts."

The faulty airbag inflators are at risk of deploying too forcefully and causing the inflator's casing to rupture, potentially leading to injuries or fatalities for vehicle occupants, the company said.

Customer notification is to begin late this month. Vehicles covered by the action include some 2001 and 2002 Accord and Civic cars; 2002 Odyssey minivans; 2002 and 2003 CR-V sport-utility vehicles; and some 2002 and 2003 Acura 3.2 TL sedans and 2003 Acura 3.2 CL coupes, the company said.

Honda last year recalled 437,763 Honda and Acura models to inspect for faulty airbag modules at risk of deploying too forcefully.

The company has said airbag systems were supplied by Japan's Takata Corp. Honda's U.S. unit is based in Torrance, California.

Nissan, Chrysler and GM models face safety probe by U.S. regulators

U.S. safety regulators have opened preliminary investigations into consumer complaints about vehicles made by Nissan Motor Co., Chrysler LLC and General Motors that could affect more than 700,000 cars.

A preliminary investigation is the first step in a process that could lead to a recall if regulators determine that a safety issue needs to be addressed by a manufacturer.

The National Highway Traffic Safety Administration said its probe into an estimated 440,000 Nissan Altima cars from the 2007 and 2008 model years concerned a possible leak in the brake master cylinder that could reduce the effectiveness of the brakes.

NHTSA said it had received 20 complaints from Altima drivers. Of these, two alleged a reduction in brake effectiveness while 18 reported only illumination of the brake warning light.

The agency said it was also investigating Chrysler's Jeep Wrangler from the 2007 and 2008 model years, potentially affecting 222,500 vehicles, over airbag light illumination indicating an airbag clockspring failure.

A clockspring is a coil under the steering wheel that maintains an electrical connection to the airbag on the driver's side. A broken circuit can mean the airbag will not inflate.

NHTSA said it had received 29 consumer complaints from Jeep drivers. Of these, 23 identified the clockspring wiring assembly as the source of the issue, while the other six only said the airbag light had been illuminated.

Of 14 owners contacted, six said they owned right-hand-drive versions typically used by postal carriers.

A third probe involves GM's 2007 Saturn Aura, potentially affecting 65,105 cars, over a transmission shift cable that could fail, causing the park gear not to fully engage.

The agency said it had received eight complaints alleging that the transmission shift cable had failed, causing the vehicle to roll away, move or accelerate with the shifter in park, or to accelerate in the opposite direction than the driver intended.

NHTSA did not disclose any crashes or injuries in connection with any of the reported problems.

Spokesmen for the three companies said the carmakers were cooperating fully with the investigations.

Honda recalls some 2012 Civics, citing risk of fuel leak

Honda Motor Co. has recalled about 1,500 current model Civic compact cars in North America due to a fuel leak risk that could lead to a vehicle fire, the company and U.S. federal safety regulators said today.

The popular Civic is in short supply in North America because of the aftermath of the March 11 earthquake in Japan. Honda on Thursday said June is going to be the low point for dealer inventory of the venerable compact.

In the United States, 1,156 Civic were recalled. On Thursday, Honda Canada announced a recall of 377 Civic compacts.

The Civics recalled were assembled from April 21 to May 2.

Most of the affected vehicles have not yet been sold and will be repaired prior to sale. Honda said that 17 percent of Civics to be sold in the U.S. contain the defect.

Honda Canada said only two of the affected vehicles were sold to consumers. No similar figure was available for U.S. sales.

Honda will notify affected Civic owners by the end of next week to bring their cars to Honda dealerships for inspection, and, if needed, will replace the fuel feed lines free of charge, the automaker said.

A fuel leak could occur if an O-ring that seals the fuel feed line is misaligned, according to a filing with the U.S. National Highway Traffic Safety Administration.

There have been no reports of fires, crashes or injuries. The issue was noticed on April 29 when a Honda production worker noticed a fuel smell on a new Civic, Honda told regulators.

The fuel line at issue was made by a Honda supplier, records show.

Civic was the No. 3 selling car in the U.S. in April, behind only the Toyota Corolla and the Honda Accord.

Toyota, Honda, Chrysler recalling nearly 80,000 vehicles

Toyota Motor Corp., Honda Motor Co. and Chrysler Group LLC are recalling nearly 80,000 vehicles over safety concerns, according to documents filed with the National Highway Traffic Safety Administration.

Toyota is recalling about 22,000 SUVs and pickups because of tire-deflation monitoring systems that may fail, U.S. regulators said.

Toyota Sequoia, FJ Cruiser, Land Cruiser, Tacoma and Tundra vehicles from the 2008 through 2011 model years may have tire deflation monitoring systems that fail to warn drivers, raising the risk of a crash, NHTSA said in a report.

The affected vehicles were shipped from assembly plants with working monitoring systems, but when accessory wheels were installed, the systems were not recalibrated and now lights to warn drivers of low tire pressure may fail, the report said.

Affected vehicles will be repaired at Toyota dealerships for free, Toyota Motor Sales U.S.A. Inc., the automaker's U.S. sales branch, told NHTSA.

Honda, meanwhile, has called back 36,656 Civic hybrids from the 2006 and 2007 model years after complaints that a faulty voltage converter could interrupt electrical signals to the headlights and engine. The problem could cause the vehicles to stall and fail to restart, a report filed with NHTSA said.

Owners of affected vehicles can have the voltage converter replaced for free at dealerships. The recall notice is expected to go out on March 18.

Finally, Chrysler is recalling 20,459 Jeep Wranglers built in 2010 and 2011. Certain Wranglers manufactured from July 12, 2010, through Sept. 10, 2010, may experience loosened fasteners on the front and rear axle attachments to the chassis, a report filed with NHTSA said. This could result in excessive noise and ultimately impaired steering and handling, increasing the risk of a crash, the agency said.

Dealers will retorque all 19 fasteners for free. The recall is expected to begin in March.

Toyota recalls 22,000 vehicles over tire monitors

DETROIT (Reuters) – Toyota Motor Corp on Saturday recalled about 22,000 sport utility vehicles and pickup trucks because of tire-deflation monitoring systems that may fail, regulators said.

Toyota Sequoia, FJ Cruiser, Land Cruiser, Tacoma and Tundra vehicles from model years 2008-2011 may have tire deflation monitoring systems that fail to warn drivers, raising the risk of a crash, the National Highway Traffic Safety Administration said in a report.

The vehicles affected left their assembly plants with working monitoring systems, but when accessory wheels were installed, the systems were not recalibrated and now lights to warn drivers of low tire pressure may fail, the report said.

The models affected will be repaired at Toyota dealerships at no cost, Toyota Motor Sales, the automaker's U.S. sales branch, told the NHTSA.

Toyota has been plagued by a series of recalls since late 2009 that now total 19 million vehicles worldwide. Two weeks ago, the automaker recalled 2.2 million vehicles for a defect that may cause gas pedals to stick, widening one of the recalls from late 2009.

The recalls have cut into Toyota sales, particularly in the United States, where most of the recalls have taken place.

Mazda recalls 52,000 vehicles for spider web concerns

WASHINGTON (Reuters) -- Mazda Motor Corp. is recalling 52,000 Mazda6 vehicles from the 2009-2010 model years over concerns that spider webs in the emissions system could lead to fuel tank cracks and possible leaks.

The vehicles were manufactured from April 8, 2008 through Feb. 8, 2010. The Auto Alliance joint venture plant between Mazda and Ford Motor Co. in Flat Rock, Mich., makes the vehicle.

The National Highway Traffic Safety Administration said in a summary of the problem that a certain type of spider may weave a web that restricts a vent line.

This could cause the emissions control system to increase pressure inside the fuel tank, leading to cracks and potential fuel leaks and an increased risk of fire.

Mazda said it would install a spring to prevent this type of spider from entering the vent line, NHTSA said.

Toyota recalls another 2.17 million U.S. vehicles

DETROIT -- Toyota Motor Corp. said today it will recall 2.17 million Toyota and Lexus vehicles in the United States to inspect and repair accelerator pedals that may get trapped in floor mats or carpeting.

The automaker said more than half of the recalled vehicles -- 1.54 million units -- are being added to a giant 2009 recall to inspect and repair accelerator pedals that may get trapped in floor mats.

A 10-month investigation by NASA engineers determined that electronic flaws were not to blame for widespread consumer complaints of unintended acceleration in Toyota and Lexus models, the U.S. Department of Transportation said this month.

The Japanese automaker has now recalled 19.2 million Toyota and Lexus vehicles worldwide and more than 13.7 million in the United States to address safety problems since the fall of 2009.

Toyota said 20,000 2006 and early 2007 Lexus GS 300 and GS 350 all-wheel-drive sedans will be recalled to modify the shape of the plastic pad embedded in the driver's side floor carpet.

If the floor carpet around the accelerator pedal is not properly replaced after service, Toyota said there is a possibility that the plastic pad embedded into the floor carpet may interfere with operation of the accelerator pedal.

If this occurs, the accelerator pedal may become temporarily stuck in a partially depressed position rather than returning to the idle position.

Toyota said it had received two complaints about the issue. Owners of the GS 300 and GS 350 vehicles will be notified in early March, Toyota said.

Driver's floor carpet cover

The automaker also is recalling 372,000 2004 through 2006 and early 2007 Lexus RX 330, RX 350, and RX 400h units, and about 397,000 Toyota Highlander and Highlander HV vehicles sold from the 2004 through 2006 model years to replace the driver's side floor carpet cover and its two retention clips.

Toyota said if the forward retention clip used to secure the floor carpet cover -- located in front of the center console -- is not installed properly, the cover may lean toward the accelerator pedal and interfere with the accelerator pedal arm.

If this occurs, Toyota said the accelerator pedal may become temporarily stuck in a partially depressed position rather than returning to the idle position.

RX and Highlander owners will be notified soon how to inspect the condition or how to contact a dealer to perform the inspection. Toyota said owners will receive a second notification once the replacement covers are available.

Expanded recall

Toyota also is expanding a recall announced in November 2009 to address possible floor mat entrapment of the accelerator pedal.

The affected 1.5 million vehicles include about 603,000 Toyota 4Runner SUVs sold from the 2003 through 2009 model years; about 17,000 Lexus LX 570 SUVS sold from the 2008 through 2011 models years; and about 761,000 Toyota RAV4 vehicles sold from the 2006 through 2010 models years.

Toyota said owners of the 4Runner, LX 570, and RAV4 vehicles will be notified soon, and receive a second notification once the recall preparations are complete.

Toyota and Lexus dealers will perform the recalls at no charge, Toyota said.

PRESS RELEASE: Toyota Announces Two Voluntary Recalls and Amends Potential Floor Mat Interference Recall Announced in 2009
Driver's Side Floor Carpet Plastic Pad Modification on Lexus GS
Driver's Side Floor Carpet Cover Replacement on Lexus RX and Toyota Highlander

Models Added to the Potential Floor Mat Interference with Accelerator Pedal Recall

TORRANCE, Calif., [February 24], 2011 -- Toyota Motor Sales (TMS), U.S.A., Inc., today announced that it will conduct a voluntary safety recall of approximately 20,000 2006 and early 2007 Model Year GS 300 and GS 350 All-Wheel Drive vehicles to modify the shape of the plastic pad embedded in the driver's side floor carpet. In the event that the floor carpet around the accelerator pedal is not properly replaced in the correct position after a service operation, there is a possibility that the plastic pad embedded into the floor carpet may interfere with the operation of the accelerator pedal. If this occurs, the accelerator pedal may become temporarily stuck in a partially depressed position rather than returning to the idle position.
Owners of the involved GS 300 and GS 350 All-Wheel Drive vehicles will receive a notification by first class mail beginning in early March 2011.
Toyota will also voluntarily recall approximately 372,000 2004 through 2006 and early 2007 RX 330, RX 350, and RX 400h vehicles, and approximately 397,000 2004 through 2006 Highlander and Highlander HV vehicles to replace the driver's side floor carpet cover and its two retention clips. If the forward retention clip used to secure the floor carpet cover, which is located in front of the center console, is not installed properly, the cover may lean toward the accelerator pedal and interfere with the accelerator pedal arm. If this occurs, the accelerator pedal may become temporarily stuck in a partially depressed position rather than returning to the idle position.
Owners of the involved RX and Highlander vehicles will receive an interim notification by first class mail beginning in the near future, explaining how to inspect for this condition or that they may contact their local dealer to perform the inspection.
Owners will receive a second notification once the replacement covers are available.
Separately, Toyota has amended its recall from November 2009, adding three models to address the potential for unsecured or incompatible floor mat entrapment of the accelerator pedal. The models added include:
• Approximately 603,000 2003 through 2009 4Runner
• Approximately 17,000 2008 through 2011 Lexus LX 570; and

• Approximately 761,000 2006 through 2010 RAV4

Owners of the involved 4Runner, LX 570, and RAV4 vehicles will receive an interim notification by first class mail beginning in the near future, informing them of the condition. Owners will receive a second notification once the recall preparations are complete.
Toyota and Lexus dealers will implement the newly announced and amended recall remedies at no charge to the vehicle owners.
Detailed information and answers to questions are available to customers at www.toyota.com/recall or www.lexus.com/recall and the Toyota Customer Experience Center at 1-800-331-4331 or Lexus Customer Satisfaction at 1-800-25 LEXUS or 1-800-255-3987.

Nader urges Fiat to recall 1993-2004 Jeep Grand Cherokees

Consumer activist Ralph Nader has called on Fiat to recall 1993-2004 Jeep Grand Cherokees made by Chrysler because of what he calls their vulnerability to fiery rear-end crashes.
U.S. safety regulators have been conducting an investigation and considering a recall of 3 million Grand Cherokees.

Nader said today that the Grand Cherokee from these years “is a modern-day Pinto for soccer moms” because the fuel tank is behind the rear axle below the rear bumper.

“Now that Fiat has purchased Chrysler, it has the moral obligation to remedy the deadly fuel tank design in the Jeep Grand Cherokee before more innocent victims are burned today, not only in the United States, but also in Europe,” Nader said in a speech in Milan after receiving an award from Quattroruote auto magazine.

In addition, the 1993-98 Grand Cherokees are flawed because the filler hose goes through the frame rail and is pulled out of the fuel tank, he said.

Case closed?

Chrysler said today that the fuel tanks on the Grand Cherokees aren't defective and do not pose an unreasonable risk.

The automaker conducted a study that compared 21,000 rear impacts in the 1993-2004 Jeep Grand Cherokees with similar models from other companies found that fires are no more common in Grand Cherokees than in other vehicles, said Chrysler spokesman Michael Palese.

"Rear impacts resulting in a fire are extremely rare," Palese said. "Chrysler believes this investigation should be closed."

In August, the National Highway Traffic Safety Administration began an investigation after its preliminary review found that the fuel tank may have been linked to 22 crashes and 14 deaths.

NHTSA said at the time that its preliminary review did not find the Grand Cherokee has a disproportionate number of fire-related accidents compared with similar models of other automakers.

The Nader-founded Center for Auto Safety, whose research spurred the NHTSA probe, has come up with different findings.

It said the fuel tank has exploded into flames in 44 crashes and rollovers causing 64 deaths -- twice as many fire-related accidents and four times as many deaths identified by regulators.

When DaimlerChrysler owned the Jeep brand, it moved and shielded the fuel tank, starting with 2005 models.

Fiat acquired control of Chrysler in 2009 as part of a deal arranged by the Obama administration after Chrysler had filed for bankruptcy reorganization. You can reach Neil Roland at nroland@crain.com.