#Recall

Usually, China gets accused of copying from America. This time, U.S. lawmakers will itch to copy a new Chinese law that comes in effect on January 1. Stealing this idea could help solve the current cash flow problems in Washington, and could provide a happy ending to the DC fiscal cliff-hanger. It also could provide an elegant way to eliminate disagreeable competitors. Car companies would not like it at all.

In the largest recall since the infamous Ford thread separation, Toyota recalled 7.43 million vehicles worldwide today. The reason: The Power Window Master Switch could melt, go up in smoke, or cause a fire after the wrong lubricant has been applied in an attempt to fix a sticky feeling during operation.

A software glitch in the OnStar system caused GM to halt sales of certain models, including the brand-new Cadillac ATS.

They say the third time is always a charm.

I don’t think this was what they meant.

TTAC commentator Sinistermisterman writes:

Why isn’t Sajeev all over this one like a rash? GM recalls 38,000 cop cars.

Ford is pointing fingers at supplier TI Automotive who is to blame for last week’s surprise recall of about 11,500 Escape SUVs. The trucks were deemed a fire risk because of a flaw in its fuel lines. Ford told the NHTSA that some of the fuel lines were “mechanically scored” at TI Automotive’s plant in Ashley, Indiana.

Ford is recalling 11,500 new 2013 model Ford Escape SUVs with 1.6-liter engines. The company also warned drivers to stop driving them immediately due to a risk of engine fire. “It is extremely rare for an automaker to warn drivers to stop driving their recalled vehicles,” Reuters says in a flash report.

GM is recalling 475,418 Chevrolet Cruze models built in the USA as a preventative measure against possible engine fires.

“Ask an Engineer” is hosted by Andrew Bell, a mechanical engineer and car enthusiast. Andrew has his MASc in Mechanical Engineering from the University of Toronto, and has worked on Formula SAE teams, as well as alternative fuel technologies in Denmark and Canada. Andrew’s column will explore engineering topics in the most accessible manner possible.

When Jack Baruth wrote a post about Chevy Sonics being recalled for missing brake pads, some readers thought that TTAC might be cherry picking the recall reports, perhaps because of some institutional prejudices around here. Jack pointed out that recalls are a fairly frequent thing whereas cars shipped without functioning brakes are hopefully a much rarer, and thus newsworthy occurrence. In another newsworthy event, the House Committee on Oversight and Government Reform called on NHTSA, the federal agency that handles things like car and truck recalls, to explain its actions in regard to how it investigated and reported the events surrounding the reported fire in a Chevy Volt that NHTSA had crash tested and flipped over.

Dave writes:

Hello Sajeev,

Well, better late than never. I did get my Saturn running again. Due to weather, parts delays and misdiagnosis I spent a lot more time and money than I planned or had to, but she does seem to be in good shape now. Although the timing chain was still in place and looked OK, I replaced it. I actually did the whole timing set replacement, which includes chain, crank sprocket, two cam sprockets, fixed guide, top guide, adjustable guide and chain tensioner.

Chris writes:

Dear Sajeev,

Love the website and love your reading your column. My question is I am looking to get a minivan within the next 6 months to a year. I am only looking to spend around 8 grand on one. I am leaning heavily towards Chrysler’s vans, and found some really great deals on older ones with low miles. But then I read your article about how it’s not always good to go with older, low mile automobiles. So would I be better to get say, a 2002 model Town and Country, with a little over 100 hundred thousand miles? Or should I not even bother with Chrysler at all? I was leaning towards a Windstar as well, but then there’s that whole rear axle breaking thing, and I quite enjoy living. In your personal opinion what is the best minivan for my budget.

Dave writes:

Hello Sajeev,

I just bought a 2000 Saturn LW1 6 weeks ago. It has a L4 2.2 Liter engine with 200,000 miles on it. After 3 weeks out of the country I came back and started it up. Was a little rough then smoothed out. I just changed parking spots. Did this one more time. The third time starting it up it would not fire. No strange noises, just no running engine. I suspected bad ignition coil. I had just changed the spark plugs before my trip and they had about 50 miles on them. Ignition coil was fine at all four points using a ignition tester. I even put new plugs in again. Fuel rail has the specified 60 PSI. Theorizing that may the fuel injectors were shut down i tried starter spray in the air intake. The motor will not fire. A compression test with a gauge picked up at advance gave me less than 10 PSI on the two outer cylinders and about 24 on the two inner. The Haynes manual is very unhelpful and only states for compression specs. that the lowest compression cylinder value should be no less that 70% of the highest compression cylinder value.

I read on-line (http://www.saturnfans.com/forum/showthread.php?p=1781795) the same but that no cylinder should be less than 100 PSI. While cranking the engine there was some light smoke visible behind the engine above the exhaust manifold, but unable to determine the source.

My question is: are you aware of catastrophic head gasket failures on these engines? I am surprised that the engine will not fire at all even if the head gasket does have a problem. I have removed the valve cover and see that the timing chain is still there and working.

When I changed the plugs last month I applied anti-seize thread sealant to the plugs as instructed in the manual. I am now having wild imaginings that the anti-seize thread sealant got into the cylinders and impregnated the gasket and is somehow responsible for this catastrophic failure. I am going to tear into the engine tomorrow and try to replace the head gasket, because i need to get this car running again ASAP. I am being hopeful and unrealistically optimistic that I cold get some input/ thoughts from you before morning when I start this laborious task…

Ideas?

The Detroit News’s David Shepardson reports that GM has requested the dismissal of a lawsuit alleging rear-suspension problems on 2007-8 model-year Impalas, on the grounds that

“New GM did not assume liability for old GM’s design choices, conduct or alleged breaches of liability under the warranty, and its terms expressly preclude money damages,” the response says.

The suit “is trying to saddle new GM with the alleged liability and conduct of old GM.”

The release of A Road Forward: The Report of the Toyota North American Quality Advisory Panel [ PDF], probably raised a few eyebrows around the industry this week, particularly at the headquarters of the Alliance of Automobile Manufacturers in Washington D.C… but not for any obvious reason. The report’s findings about Toyota’s internal reforms in the wake of last year’s recall scandal aren’t particularly mind-bending, and are well summarized in an introductory passage

First, the Panel believes Toyota needs to continue to adjust its balance between global and local control giving weight to local control in order to improve its communication and speed in responding to quality and safety issues. Second, the Panel believes that Toyota needs to ensure that it listens and responds as positively to negative external feedback as it does to negative internal feedback. Third, the Panel believes that Toyota must persist in more clearly distinguishing safety from quality and continue its efforts to enhance its safety practices and procedures.

In addition to identifying specific areas for improvement, the report places a heavy emphasis on “the leadership of Toyota’s top executives as they navigate the road forward, as well as the company’s leadership in the industry” as a way to avoid the traps it fell into prior to the recall scandal. And this emphasis on leadership could have some interesting effects…