Fisker Automotive Inc. is recalling 239 plug-in electric hybrid cars because a misaligned battery part could lead to a fire — as scrutiny over battery-powered vehicles grows.
The start-up California automaker — which has received $529 million in low-cost Energy Department loans —said it is recalling 239 2012 Karma sedans built from July through Nov. 3. The automaker said around 40 of the vehicles have been delivered to customers.
Fisker spokesman Roger Ormisher said Thursday the automaker is replacing the battery packs in all customer vehicles that have been delivered — a fix that takes about an hour. Vehicles in dealer showrooms are getting a longer fix that doesn't require replacing the battery pack, he said.
Replacing the entire battery pack is in the interest of customer satisfaction, he said.
"It's for peace of mind — and for speed for customers," Ormisher said.
Within the high-voltage battery, certain hose clamps may have been positioned incorrectly. The battery cover could interfere with clamps, causing a coolant leak. That could result in an electric short that could lead to a fire, Fisker said.
"The dealer will replace the high-voltage battery with a new part. The remedy will ensure the spring hose clamps are properly sealing the hoses to prevent the potential for coolant leakage," Fisker told the National Highway Traffic Safety Administration.
About half of customer vehicles have been repaired, Ormisher said, and the company intends to fix all vehicles — both in showrooms and customer owned — by Jan. 1.
Fisker said it has no reports of fires or complaints from customers.
On Dec. 16, Valmet Automotive — the Finnish company assembling the Karma — reported that it had seen coolant drip leaks in two vehicles.
"Incidents were captured during the final stage of assembly, during fluid fill," Fisker told NHTSA. Fisker said there were no fires at its assembly plant — only leaking fluid.
A third Karma was found with the same issue on Dec. 17.
Concerns about fire risks in plug-in vehicles with large battery packs have mounted in recent months.
NHTSA has been investigating General Motors Co's plug-in electric Chevrolet Volt for fire risks after a fire in a Volt occurred three weeks after a crash test in June. GM believes the fire was sparked after coolant leaked.
NHTSA opened a formal investigation Nov. 25 after a second Volt battery pack caught fire seven days after a crash test.
Fisker's battery producer, A123 Systems, which has a sizeable presence in Michigan, said last week that it had "determined that some of the battery packs we produce for Fisker Automotive could have a potential safety issue relating to the battery cooling system."
A123 said there have been no related battery performance or safety incidents with cars in the field.
"We have developed a confirmed repair for this situation. In the short time since recognizing this potential safety issue, the root cause was quickly identified, a fix has been developed and corrective action is well under way," A123 CEO David Vieau said.
In September 2010, Massachusetts-based A123 opened a 291,000-square foot lithium-ion automotive battery plant in Livonia after it received a $249 million grant from the Energy Department and $125 million in state incentives. It opened a second plant in Romulus earlier this year.
Fisker is one of A123's largest customers. Last month, A123 told investors that it had reduced its earnings forecast "based on a reduction in fourth-quarter orders from Fisker Automotive as it balances inventory levels from all suppliers for the Karma plug-in hybrid electric vehicle."
Late last month, A123 laid off 125 people temporarily in Michigan, but still employs about 600 at its two plants and Ann Arbor research center.
Earlier this month, Fisker named former Chrysler CEO, president and vice chairman of Chrysler Group Tom LaSorda to a newly created role as vice chairman of the board and chairman of the board's strategy council.
In October, Fisker said it will begin full production of its Nina in mid-2013, but insists it will start limited production on schedule by the end of next year.
Fisker spokesman Russell Datz said this month the company has 1,200 vehicles built and ready for delivery around the world.
The $100,000 Karma sedan is a series plug-in hybrid electric sports car powered by a lithium-ion battery and a two-liter range-extending gasoline engine. The Karma's all-electric range is 32 miles by the EPA under its test criteria, lower than the company billed when it first announced plans to build the vehicle.