Nissan Recalls Over 190,000 Vehicles After Discovering Two Safety Risks
Nissan Motor is recalling more than 190,000 vehicles in the United States after uncovering two separate safety issues. One involves engine stalls in older commercial vans, while the other centers on a battery fire hazard in the Nissan Leaf. This is one of the company’s most significant safety actions in recent years.
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The larger recall affects 173,301 vehicles tied to a problem with the fuel tank temperature sensor harness. Nissan found that in certain models, the harness was routed incorrectly during assembly, causing it to rub against nearby components and damage the wires. This can lead to a short circuit in the fuel pump fuse and a sudden engine stall. The affected vehicles were built between 2013 and 2021 at Nissan’s Cuernavaca plant in Mexico and other facilities in Japan. Models involved include NV200 vans, NV200 taxi versions from 2014 to 2017 and 2019, and the 2015 to 2018 Chevrolet City Express, a rebadged NV200 produced through a partnership with General Motors.
This isn’t the first time Nissan has faced issues with the NV200 line. Past recalls dealt with transmission and brake light problems, but this is the largest involving the model in nearly a decade. The recall was filed under campaign number PMA56. VINs were added to the National Highway Traffic Safety Administration database on October 10, 2025, and owner notification letters will be mailed starting December 3. No injuries or accidents have been reported yet, but engine stalls at high speeds or in traffic can be dangerous.
Leaf Battery Recall Adds to Pressure on Nissan
The second recall involves 19,077 units of the 2021 and 2022 Nissan Leaf. Unlike the NV200 case, this issue stems from the car’s lithium-ion battery. Nissan engineers found that some batteries have excessive lithium deposits, which increase internal resistance. During Level 3 DC fast charging, the buildup can cause overheating and, in rare cases, a fire. The company has urged Leaf owners to avoid fast charging until a software fix is released. Nissan plans to limit charging rates through an update and will replace batteries when needed. The affected batteries were supplied by Envision AESC and assembled at Nissan’s Smyrna, Tennessee, plant.
Fuel pump recalls are not new for Nissan. In 2020, the automaker recalled Altima and Sentra models over a different fuel pump issue. For the Leaf, however, this is the first major U.S. recall involving a fire risk tied to charging. Earlier concerns focused on battery degradation in hot climates, not safety hazards during charging.
Repair Plans & Next Steps for Owners
Nissan says it began investigating earlier this year after receiving field reports and warranty claims. Dealers will inspect and repair NV200 and City Express vans by rerouting harnesses or replacing fuel pump assemblies at no cost. Leaf owners will receive software updates and, if necessary, new battery packs. Vehicle owners can check their VIN on Nissan’s recall site or the NHTSA database.
This situation reflects the challenges Nissan faces in maintaining both older gas-powered vehicles and newer EVs. Aging wiring designs can lead to issues in commercial models, while advancing battery technology brings new risks. It’s a reminder that safety problems can emerge from both legacy systems and modern innovation. For more industry updates, visit our automotive news section.