Recall : Even the new design can crack. Recall expanded.

[ZQ8]

https://www.autoblog.com/2024/04/10/ford-recalls-more-than-40000-bronco-sport-and-escape-models-for-fuel-leak/

https://fordauthority.com/2024/04/ford-fuel-injector-recall-investigation-opened-by-nhtsa/

https://static.nhtsa.gov/odi/rcl/2024/RMISC-24V187-6053.pdf

Sponsored

 

[cprcubed]

ANY injector can crack! Here we go again with the uninformed takes on this.

 

[Bucko]

 

[Rogerthat898]

ANY injector can crack! Here we go again with the uninformed takes on this.

Any injector can crack. The recall notice lists the failure rate at 1% for this batch of vehicles.
If 1% is high or low compared to other manufacturers who knows.

 

[Cursed Bronco]

So what is the recall? Based on the article it seems that a software update wasn't performed on vehicles equipped with different injectors from the factory, but those injectors also caused leaking. So the missing software update fails to catch that it's leaking fuel?

 

[jsus]

So what is the recall? Based on the article it seems that a software update wasn't performed on vehicles equipped with different injectors from the factory, but those injectors also caused leaking. So the missing software update fails to catch that it's leaking fuel?

Basically, yeah. They revised the fuel injectors, ending in revision code -BC instead of -BB. They believed that these revised injectors would prevent the leaks that led to recall 22S73. For vehicles built with the old injectors, they provided an engine control software (ECU) update that would detect and respond to a leaking fuel injector, as well as the drain tube. 22S73 is for Bronco Sport built from launch through August 12, 2022, and Escape through October 17, 2022.

For vehicles built with the new injectors, they did not get that software logic and they may not have gotten the drain tubes. Bronco Sport and Escape population for 24S16 both resumed October 17, 2022. But it turns out, those revised injectors are indeed capable of leaking, leading to an engine fire.

https://static.nhtsa.gov/odi/rcl/2024/RMISC-24V187-6053.pdf

On February 6, 2024, an issue pertaining to underhood fires on Bronco Sport and Escape vehicles produced after Safety Recall 22S73 (NHTSA Recall No. 22V-859) clean point was brought to Ford’s Critical Concern Review Group (CCRG) for review. Ford’s Internal Combustion Engines Propulsion Thermal Systems Engineering (IPTSE) team had identified leaks during component-level injector flow testing on fuel injectors recovered from two Bronco Sport vehicles that had experienced underhood fires.

"Ford determined that the two vehicles were produced on November 23, 2022, and December
13, 2022, with HX7G-9F597-BC fuel injectors. These injectors have a reduced knurl diameter
relative to the HX7G-9F597-BB injector that the Recall 22S73 population of vehicles was
originally produced with. This change was introduced to provide improved robustness against
stresses leading to cracking. Ford did not include the updated engine control software
developed as part of the Recall 22S73 remedy for Escape vehicles produced from October 17,
2022, to December 15, 2022, and Bronco Sport vehicles produced from October 17, 2022, to
January 13, 2023, at Hermosillo Assembly Plant. This software will detect a pressure drop in
the fuel rail, provide instrument cluster messaging to the customer to seek service, invoke a
strategy to disable the high-pressure fuel pump, derate engine power output and reduce
temperatures of possible ignition sources in the engine compartment. Ford’s decision not to
include the updated engine control software on these vehicles was based on Ford’s assessment
of the new injectors’ improved robustness. "

Ford is aware of 5 underhood fires on 1.5L Escape and Bronco Sport vehicles built during this window of production. Ford is aware of 2 related VOQs during this production window, describing 2 of the 5 underhood fires. Ford is also aware of 14 warranty replacements of BClevel injectors on 1.5L vehicles due to suspected cracking during this production window.

Ford is not aware of any reports of accident or injury related to this condition.

24S16 is solely vehicles built with the new injectors, which Ford believed addressed the issue at the factory, so they were not already recalled under 22S73. Now they are acknowledging that the -BC revision can still leak, leading to engine fire. The fix is to push the latest PCM and related software revisions and/or install the drain tube, depending on what each affected vehicle needs.

24S16 https://static.nhtsa.gov/odi/rcl/2024/RCMN-24V187-9655.pdf

22S73 https://static.nhtsa.gov/odi/rcl/2022/RCMN-22V859-5298.pdf

 

[Bronco Blue]

Man that 3 cylinder is a bad engine, not only because of this but other reasons too. I wonder if they’re having the same problems with it everywhere else in the world they use this engine like we do.

 

[rocks]

Man that 3 cylinder is a bad engine, not only because of this but other reasons too. I wonder if they’re having the same problems with it everywhere else in the world they use this engine like we do.

I love just about everything in my OBX except the engine. The 2.0L option in an OBX would make it much better.

 

[jsus]

That’s great information. You may have stated this already but do you work for Ford and is this info “insider” knowledge?

My sources are Ford's filings with NHTSA, linked above.

 

[jsus]

Right but unfortunately:

“They (Ford) revised the fuel injectors, ending in revision code -BC instead of -BB. They believed that these revised injectors would prevent the leaks that led to recall 22S73.”

Response: There has been no proof to-date (unless you found it) that the -BC fuel injectors were revised to prevent leaks. We actually do not know what changes (if any) Ford made going from -BB to -BC. Only Ford knows.

“Now they (Ford) are acknowledging that the -BC revision can still leak, leading to engine fire.”

Response: Clearly the -BC injector can leak as can any fuel injector as discussed many times in this and other Forums but again we just do not know what changes (if any) Ford made going from -BB to -BC. Only Ford knows.

This is as much as they shared, as quoted above:

Ford determined that the two vehicles were produced on November 23, 2022, and December
13, 2022, with HX7G-9F597-BC fuel injectors. These injectors have a reduced knurl diameter
relative to the HX7G-9F597-BB injector that the Recall 22S73 population of vehicles was
originally produced with.

 

[Dude]

This is as much as they shared, as quoted above:

Thanks for posting that!

 

[Bronco Blue]

I love just about everything in my OBX except the engine. The 2.0L option in an OBX would make it much better.

Yeah the OBX should’ve gotten the 2.0 liter standard or at least optional. The Escape offers the 2.0 liter on several trim levels, but Ford restricts it to the Badlands for the BS. It doesn’t make any sense especially since the OBX is supposed to be the luxury trim level of the BS.

 

[Mark S.]

From the AutoBlog article:

According to documents posted by the National Highway Traffic Safety Administration, "Ford’s Internal Combustion Engines Propulsion Thermal Systems Engineering (IPTSE) team had identified leaks during component-level injector flow testing on fuel injectors recovered from two Bronco Sport vehicles that had experienced underhood fires" that happened after the original recall "clean point." In other words, these fires happened on vehicles produced after the date at which they were considered fixed.

These two vehicles had HX7G-9F597-BC fuel injectors, an improved design over the older HX7G-9F597-BB parts, and so therefore were not included in the original recall and did not receive the software update or the fuel drain tubes. "Ford’s decision not to include the updated engine control software on these vehicles was based on Ford’s assessment of the new injectors’ improved robustness," according to documents posted on the NHTSA site. Ford is aware of five underhood fires on vehicles with these updated injectors but without the updated software and drain tube.

So, two vehicles out of the 40+ thousand under recall--purportedly with the updated fuel injectors--were confirmed to have experienced leaks from the fuel injectors. This is about the same ratio as the original fuel injectors. As I've been saying all along, this is not a fuel injector issue, mainly because any mechanical component can fail. Replacing fuel injectors will not significantly reduce the chance of a fire that can destroy your car. You may even be INCREASING those chances, because you might be removing known good injectors (if you haven't experienced a crack yet) for unknown replacements.

I don't know what Ford was thinking by not including the safety measures (drain tube and software) mandated by the earlier recall on newer production cars. That seems idiotic to me.

 

[Bucko]

Man that 3 cylinder is a bad engine, not only because of this but other reasons too. I wonder if they’re having the same problems with it everywhere else in the world they use this engine like we do.

This is a ridiculous statement. What backing do you have to declare it a bad engine?

Ford has made good on the injector issue. Ford made good on the water pump issue.

Manufacturing from outside vendor parts can happen to any auto manufacturer.

 

[Dude]

From the AutoBlog article:
So, two vehicles out of the 40+ thousand under recall--purportedly with the updated fuel injectors--were confirmed to have experienced leaks from the fuel injectors…

I don't know what Ford was thinking by not including the safety measures (drain tube and software) mandated by the earlier recall on newer production cars. That seems idiotic to me.

Ford management seems to have believed the HX7G-9F597-BC fuel injectors solved the issue and the updated engine control software was not needed.

Also it may be 19 out of the 40k+ vehicles:

“Ford is aware of 5 underhood fires on 1.5L Escape and Bronco Sport vehicles built during this window of production. Ford is aware of 2 related VOQs during this production window, describing 2 of the 5 underhood fires. Ford is also aware of 14 warranty replacements of BC- level injectors on 1.5L vehicles due to suspected cracking during this production window.”

https://static.nhtsa.gov/odi/rcl/2024/RMISC-24V187-6053.pdf posted in a Forum thread earlier this week also stated:

Revised HX7G-9F597-BC fuel injectors have a reduced knurl diameter relative to the HX7G-9F597-BB injector which was introduced to provide improved robustness against stresses leading to cracking.

Ford did not include the updated engine control software developed as part of the Recall 22S73 remedy for Escape vehicles produced from October 17, 2022, to December 15, 2022, and Bronco Sport vehicles produced from October 17, 2022, to January 13, 2023. This software will detect a pressure drop in the fuel rail, provide instrument cluster messaging to the customer to seek service, invoke a strategy to disable the high-pressure fuel pump, derate engine power output and reduce temperatures of possible ignition sources in the engine compartment.

Ford’s decision not to include the updated engine control software on these vehicles was based on Ford’s assessment of the new injectors’ improved robustness.

Sponsored