NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
210 reportsClear category filterMileage unknown · Jul 12, 2019
EngineFire
TL* THE CONTACT OWNED A 2018 HYUNDAI SONATA. THE CONTACT WAS ALERTED BY THE POLICE AND FIRE DEPARTMENTS AT 4:00AM THAT HER VEHICLE CAUGHT FIRE. THE VEHICLE WAS DESTROYED. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. A POLICE REPORT WAS FILED. THE CONTACT WANTED TO OBTAIN A FIRE REPORT TO VERIFY IF THE FIRE ORIGINATED FROM THE ENGI…
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TL* THE CONTACT OWNED A 2018 HYUNDAI SONATA. THE CONTACT WAS ALERTED BY THE POLICE AND FIRE DEPARTMENTS AT 4:00AM THAT HER VEHICLE CAUGHT FIRE. THE VEHICLE WAS DESTROYED. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. A POLICE REPORT WAS FILED. THE CONTACT WANTED TO OBTAIN A FIRE REPORT TO VERIFY IF THE FIRE ORIGINATED FROM THE ENGINE. THE INSURANCE COMPANY WAS NOT NOTIFIED. THE CONTACT LATER RECEIVED NOTIFICATION OF THE MANUFACTURER'S SERVICE CAMPAIGN NUMBER: 953 (ECM & CLUSTER UPDATE-ENGINE MONITORING LOGIC PRODUCT IMPROVEMENT). ROGERS AUTO GROUP CHICAGO (2720 S MICHIGAN AVE, CHICAGO, IL 60616, (312) 620-1340) WAS CONTACTED AND WAS WAITING FOR THE MANUFACTURER TO PROVIDE GUIDANCE WITHIN 48 HOURS. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS NOT AVAILABLE.
NHTSA ODI #11231239
14,000 miles · Jun 13, 2019
Engine
ON FRIDAY, MAY 31, 2019, WHILE DRIVING HOME FROM WORK, I NOTICED MY VEHICLE BEGAN TO SHAKE WHILE DRIVING. (CAR HAS 14K MILES) I CALLED GOSSETT HYUNDAI AT COVINGTON PIKE AND WAS TOLD IT WAS PROBABLY A ROTOR OR A SPARK PLUG AND TO BRING IT IN SATURDAY MORNING. SATURDAY MORNING, WHILE DRIVING TO THE DEALERSHIP, THE BLUELINK LIT UP…
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ON FRIDAY, MAY 31, 2019, WHILE DRIVING HOME FROM WORK, I NOTICED MY VEHICLE BEGAN TO SHAKE WHILE DRIVING. (CAR HAS 14K MILES) I CALLED GOSSETT HYUNDAI AT COVINGTON PIKE AND WAS TOLD IT WAS PROBABLY A ROTOR OR A SPARK PLUG AND TO BRING IT IN SATURDAY MORNING. SATURDAY MORNING, WHILE DRIVING TO THE DEALERSHIP, THE BLUELINK LIT UP SAYING MY CAR NEEDED TO BE SERVICED. I DROVE THE VEHICLE TO GOSSETT HYUNDAI AT MT. MORIAH. AFTER GOING BACK AND FORTH (IN FRONT OF THE TECH) THEY AGREED TO RUN A DIAGNOSTIC (BECAUSE I TOLD THEM I WAS WORRIED ABOUT DRIVING MY CAR TO THE COVINGTON PIKE LOCATION), AND THE TECH INFORMED ME THAT HE WAS A TECH AND HE COULD RUN THE DIAGNOSTIC. AFTER RUNNING THE DIAGNOSTIC, I WAS TOLD THAT ONE OF MY CYLINDERS WAS NOT FIRING. AFTER SOME PERIOD OF TIME, THEY LOCATED AN IGNITION COIL IN THE PARTS ROOM AND REPLACED IT. THE CAR STILL WAS NOT RUNNING CORRECTLY, I WAS INFORMED THAT THE CAR NEEDED A SPARK PLUG BUT THEY WOULDN'T HAVE ONE UNTIL TUESDAY, JUNE 4, 2019. AFTER THE DEALERSHIP RECEIVED THE SPARK PLUG AND INSTALLED IT (I GUESS?), THE CAR WAS STILL SHAKING AND NOT RUNNING CORRECTLY. SOMETIME JUNE 5 OR 6TH, THEY CALLED HYUNDAI MANUFACTURING AND HAVE BEEN RECEIVING INSTRUCTION FROM THE MANUFACTURER DIRECTLY TO RUN LEAK TESTS. I WAS INFORMED THAT THEY ALSO USED A CAMERA TO LOOK DOWN IN THE CYLINDER AND THAT IT HAS 'SCARRING' WHICH COULD BE FROM FLUID GETTING INSIDE? I HAVE ALSO BEEN TOLD THAT IT IS PROBABLE THAT MY CAR WILL NEED A COMPLETE NEW ENGINE. IT HAS BEEN 2 WEEKS AND THE DEALERSHIP IS WORKING CLOSELY WITH THE MANUFACTURER TO SEE WHAT NEEDS TO BE DONE.
NHTSA ODI #11219792
5,800 miles · May 25, 2019
Engine
DRIVING AND ENGINE LIGHT STARTED FLASHING AND I COULD NOT KEEP UP WITH THE SPEED LIMIT AS THE CAR WOULD ONLY GO ABOUT 20 MPH. THE CAR SAYS "POSSIBLE CONDITION WITH YOUR ENGINE CONTROL SYSTEM HAS BEEN DETECTED" CAR WAS IN MOTION ON CITY STREET.
NHTSA ODI #11209924
2,134 miles · May 19, 2019
EngineExterior LightingVisibility/wiper
I PURCHASED THE 2018 HYUNDAI SONATA 2.0T ON 8/27/18. AFTER WE WERE ABLE TO EXPERIENCE DIFFERENT DRIVING CONDITIONS AND SITUATIONS, MY HUSBAND AND I NOTICED THAT (1) AT NIGHT, WHILE DRIVING ON THE HIGHWAY, THE WINDSHIELD APPEARED VERY DARK AS IF IT WAS HEAVILY TINTED,AND MAKING IT DIFFICULT TO SEE THE ROAD. (2) WHEN DRIVING ON …
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I PURCHASED THE 2018 HYUNDAI SONATA 2.0T ON 8/27/18. AFTER WE WERE ABLE TO EXPERIENCE DIFFERENT DRIVING CONDITIONS AND SITUATIONS, MY HUSBAND AND I NOTICED THAT (1) AT NIGHT, WHILE DRIVING ON THE HIGHWAY, THE WINDSHIELD APPEARED VERY DARK AS IF IT WAS HEAVILY TINTED,AND MAKING IT DIFFICULT TO SEE THE ROAD. (2) WHEN DRIVING ON HIGHWAY OR ROAD, WITH NORMAL BEAM HEADLIGHTS, WE NOTICED THAT THE LINE OF DEMARCATION FROM HEADLIGHT TO DARK ROAD WAS VERY CLOSE TO THE FRONT OF THE CAR. THE REASON GIVEN BY THE MAINTENANCE DEPT WAS THAT THIS WAS SO CARS IN FRONT WOULDN'T BE BLINDED BY THE HEADLIGHT. TO US, IT SEEMED THAT THE HEADLIGHTS WERE AIMED TOO LOW. I SHOULD BE ABLE TO SEE MORE THAN 20 FEET IN FRONT OF MY CAR. WE WERE TOLD THAT NOTHING COULD BE DONE. ALSO, WHEN MAKING A TURN, THE AREA OPPOSITE THE DIRECTION OF THE TURN IS COMPLETELY DARK BECAUSE OF THE WAY THE HEADLIGHTS WORK ON A TURN. THIS IS EXTREMELY DANGEROUS-SHOULD SOMEONE DECIDE TO WALK THERE OR IF THERE IS AN ANIMAL, I WILL NOT BE ABLE TO SEE ANYTHING. AGAIN I WAS TOLD THERE WAS NOTHING THEY COULD DO. (3) MY HUSBAND PUT RAIN-X ON ALL THE WINDOWS OF THE CAR. IT WORKED ON EVERY WINDOW EXCEPT THE WINDSHIELD. WE THOUGHT THERE WAS SOME SORT OF COATING PLACED BY THE MANUFACTURER. I WAS TOLD NO THERE WAS NOT. THEY COULD NOT UNDERSTAND WHY THE RAIN-X DIDN'T TAKE. THEY TOLD ME THAT THEY SPENT QUITE A BIT OF TIME "SCRAPING THE WINDSHIELD", BUT NOTHING CAME OFF. WE STILL DO NOT KNOW WHY IT SHOULD DO THAT. (4) I NOTICED. WHETHER I WAS DRIVING IN SMART OR SPORT MODE, THEIR IS AN ANNOYING HESITATION WHEN I STEP ON THE GAS. WHEN THE STOPLIGHT TURNS GREEN, IT TAKES SEVERAL SECONDS BEFORE THE CAR IS ABLE TO MOVE AT NORMAL SPEED. WE WERE TOLD THAT THEY RECEIVED LOTS OF COMPLAINTS ABOUT THAT, BUT NO OFFER FOR A FIX.
NHTSA ODI #11208542
3,713 miles · May 9, 2019
Engine
TL* THE CONTACT OWNS A 2018 HYUNDAI SONATA. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO HYUNDAI OF KIRKLAND DEALER (11706 124TH AVE NE, KIRKLAND, WA 98034, (425) 821-6611) WHERE A SOFTWARE UPDATE WAS COMPLETED. THE CONTACT STATED THAT WHEN LEAVING THE DEALER WHILE DRIVING AT 40 MPH, THE VEHICLE STALLED AS THE CHECK ENGINE A…
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TL* THE CONTACT OWNS A 2018 HYUNDAI SONATA. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO HYUNDAI OF KIRKLAND DEALER (11706 124TH AVE NE, KIRKLAND, WA 98034, (425) 821-6611) WHERE A SOFTWARE UPDATE WAS COMPLETED. THE CONTACT STATED THAT WHEN LEAVING THE DEALER WHILE DRIVING AT 40 MPH, THE VEHICLE STALLED AS THE CHECK ENGINE AND THE ENGINE CONTROL SYSTEM FAILURE DETECTED WARNING LIGHTS ILLUMINATED. THE CONTACT STATED THAT THE VEHICLE SPEED AUTOMATICALLY DECREASED TO 10 MPH. THE CONTACT STATED THEY SLOWLY DROVE BACK TO THE DEALER, WHERE IT WAS DETERMINED THAT A NEW ENGINE WAS NEEDED. HOWEVER, A WEEK LATER HE WAS INFORMED BY THE DEALER THAT THE WIRE HARNESS HAD FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE CONTACT HAD SPOKEN TO THE MANUFACTURER VIA EMAIL AND WAS PROVIDED A CASE NUMBER: 15658545. THE APPROXIMATE FAILURE MILEAGE WAS 3,713.
NHTSA ODI #11206483
20,500 miles · May 6, 2019
Electrical SystemEngine
I WAS EXITING THE FREEWAY AND LOST POWER, COULD NOT ACCELERATE, BLINKING ENGINE CAME ON AND ON MY SCREEN IT SAID "A POSSIBLE CONDITION WITH YOU ENGINE CONTROL SYSTEM HAS BEEN DETECTED. A FULL SYSTEM CHECK RECOMMENDED TO BE DONE WHEN CONVENIENT. PLEASE CONTACT YOU LOCAL DEALERSHIP FOR AN APPOINTMENT" I WAS ABLE TO GET TO AN AREA …
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I WAS EXITING THE FREEWAY AND LOST POWER, COULD NOT ACCELERATE, BLINKING ENGINE CAME ON AND ON MY SCREEN IT SAID "A POSSIBLE CONDITION WITH YOU ENGINE CONTROL SYSTEM HAS BEEN DETECTED. A FULL SYSTEM CHECK RECOMMENDED TO BE DONE WHEN CONVENIENT. PLEASE CONTACT YOU LOCAL DEALERSHIP FOR AN APPOINTMENT" I WAS ABLE TO GET TO AN AREA AND HAVE IT TOWED. THIS COULD OF BEEN VERY SCARY AND DANGEROUS IF I HAD STILL BEEN ON THE FREEWAY DOING 70! I COULD NOT HAVE DRIVEN IT, IT WAS MISSING AND WOULDN'T GET ABOVE 20-30 MPH. I HAD THE KNOCK SENSOR SOFTWARE UPDATE DONE AT THE DEALER THE WEEK PRIOR TO THIS HAPPENING. THE DEALER IS SAYING THE WIRING HARNESS NEEDS REPLACED AND WILL NOT BE AVAILABLE UNTIL THE END OF THE MONTH! MANY ON HERE HAVE WAITED MONTHS I HOPE THAT IS NOT THE CASE. I'VE READ NUMEROUS COMPLAINTS ON HERE AND OTHER SITES THAT THIS IS HAPPENING AFTER THE UPDATE. MY CAR SEEMED FINE BEFORE THEY DID THE UPDATE. SOME PEOPLE NEED NEW ENGINES! HOW DO I KNOW THAT MY ENGINE DOESN'T HAVE DAMAGE, I ASSUME THAT HYUNDAI KNOWS SOMETHING SINCE WITH THE SENSOR UPDATE THEY EXTENDED MY 100K WARRANTY TO 120K. IT SAID THE SENSOR IS TO HELP CATCH POSSIBLE ROD BEARING WEAR AND EXTENDS WARRANTY MUST MEAN THEY EXPECT ENGINES TO HAVE PROBLEMS! WHAT IS GOING ON HERE AND WHY ISN'T THERE ANY OFFICIAL RECALL? MY CAR ONLY HAS 20K I DON'T EXPECT THIS KIND OF PROBLEM. I LEASED CARS FOR MANY YEARS BUT SINCE I'M CLOSE TO RETIRING I BOUGHT THIS WISH I WAS STILL LEASING SO I COULD GET OUT FROM UNDER THIS IN 2 YEARS!
NHTSA ODI #11205919
9,400 miles · May 2, 2019
EngineUnknown Or Other
MY DAUGHTER WAS DRIVING ON THE HIGHWAY WHEN THE CAR STARTED TO BUCK AND WOULDN'T ACCELERATE. THE CHECK ENGINE LIGHT CAME ON AND SHE PULLED OFF THE HIGHWAY. SHE CALLED HYUNDAI AND THEY TOLD HER NOT TO DRIVE THE CAR AND TO HAVE IT TOWED TO A DEALERSHIP. WE WERE THEN TOLD BY HYUNDAI THAT THIS IS A KNOWN PROBLEM. THEY INSTALLED …
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MY DAUGHTER WAS DRIVING ON THE HIGHWAY WHEN THE CAR STARTED TO BUCK AND WOULDN'T ACCELERATE. THE CHECK ENGINE LIGHT CAME ON AND SHE PULLED OFF THE HIGHWAY. SHE CALLED HYUNDAI AND THEY TOLD HER NOT TO DRIVE THE CAR AND TO HAVE IT TOWED TO A DEALERSHIP. WE WERE THEN TOLD BY HYUNDAI THAT THIS IS A KNOWN PROBLEM. THEY INSTALLED A KNOCK SENSOR WIRING HARNESS AND SAID THEY HOPE THAT DOES THE TRICK BUT IT COULD NEED A WHOLE NEW ENGINE. EXPECTED REPAIR TIME IS 6 WEEKS SINCE PARTS ARE ON BACKORDER. WE HAVE SINCE SPOKEN TO SEVERAL DEALERSHIPS AS WELL AS CONSUMERS AND THERE ARE SO MANY COMPLAINTS THAT SOME PEOPLE HAVE BEEN WITHOUT THEIR CARS FOR MONTHS.
NHTSA ODI #11205168
19,000 miles · Apr 25, 2019
Electrical SystemEngineVehicle Speed Control
TL* THE CONTACT OWNS A 2018 HYUNDAI SONATA. WHILE DRIVING 60 MPH, THE VEHICLE BECAME SLUGGISH, DECELERATED, AND FAILED TO ACCELERATE ABOVE 40 MPH. IN ADDITION, THE CHECK ENGINE INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO NAPLETON'S VALLEY HYUNDAI (4333 OGDEN AVE, AURORA, IL 60504, (630) 851-2500) WHERE IT WAS DIAGNOSED THAT …
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TL* THE CONTACT OWNS A 2018 HYUNDAI SONATA. WHILE DRIVING 60 MPH, THE VEHICLE BECAME SLUGGISH, DECELERATED, AND FAILED TO ACCELERATE ABOVE 40 MPH. IN ADDITION, THE CHECK ENGINE INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO NAPLETON'S VALLEY HYUNDAI (4333 OGDEN AVE, AURORA, IL 60504, (630) 851-2500) WHERE IT WAS DIAGNOSED THAT THE WIRE HARNESS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND CASE NUMBER: 15704477 WAS PROVIDED. THE FAILURE MILEAGE WAS 19,000. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #11203661
16,590 miles · Apr 24, 2019
EngineSeat BeltsVisibility/wiper
WHILE DRIVING 30MPH APPROACHING A RED LIGHT, MY 2018 SONATA CUT OFF ONCE I CAME TO A COMPLETE STOP AT THE RED LIGHT. I WAS IN CITY LIMITS APPROACHING A HWY INTERSECTION. THE CHECK ENGINE LIGHT CAME ON AND THE CAR RESTARTED AFTER ONE ATTEMPT. ONCE THE VEHICLE RE STARTED IT WAS SLUGGISH,SPUTTERING AND WOULD NOT ACCELERATE OVER 20M…
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WHILE DRIVING 30MPH APPROACHING A RED LIGHT, MY 2018 SONATA CUT OFF ONCE I CAME TO A COMPLETE STOP AT THE RED LIGHT. I WAS IN CITY LIMITS APPROACHING A HWY INTERSECTION. THE CHECK ENGINE LIGHT CAME ON AND THE CAR RESTARTED AFTER ONE ATTEMPT. ONCE THE VEHICLE RE STARTED IT WAS SLUGGISH,SPUTTERING AND WOULD NOT ACCELERATE OVER 20MPH... I MADE IT HOME SAFELY NONETHELESS. I LEFT THE CAR PARKED FOR APPROX 10 MINS AND IT RESTARTED EASILY. I THEN DROVE IT DIRECTLY TO THE LOCAL DEALER WHERE THE CAR WAS PURCHASED. I WAS TOLD THE CAR STOPPED BECAUSE THE ENGINE SYSTEM REQUIRED AN UPDATE. THE UPDATE WAS COMPLETED AND I DROVE THE CAR HOME. THE NEXT DAY OR MAYBE TWO DAYS LATER I RECEIVED A LETTER FROM THE DEALERSHIP SAYING MY CAR REQUIRED A FREE RECALL AND TO SCHEDULE A DATE TO HAVE THE CAR SERVICED. OVER THE PHONE I WAS TOLD SOMETHING ALONG THE LINES OF THE ENGINE HARNESS NEEDED TO BE REPLACED. WHEN THE CAR'S ENGINE CUT OFF IN TRAFFIC I WAS EN ROUTE TO PICKING UP MY TODDLER. I NO LONGER FELT SAFE DRIVING THE VEHICLE AND I TRADED THE CAR IN AND CUT MY LOSSES, WHICH WERE SUBSTANTIAL. OTHER PROBLEMS I NOTICED IN THE TIME I HAD THE VEHICLE WERE THAT THE BACK PASSENGER SEAT BELT LOCKED OR ANCHORED IF I LEANED FORWARD SLIGHTLY AND LOW VISIBILITY AT NIGHT THROUGH THE FRONT WINSHIELD.
NHTSA ODI #11203298
11,000 miles · Apr 23, 2019
Electrical SystemEngine
ON 03/23/2019, WHEN I WAS LEAVING A PARKING LOT MY CAR STARTED TO HESITATE AND WOULD NOT REV UP. I JUST TURNED OUT THE PARKING LOT WHEN THIS HAPPENED. MESSAGE CAME ON STATED IT NEED TO BE SERVICED. AT THE SAME TIME THE ENGINE LIGHT CAME ON. I WAS NOT ABLE TO PRESS THE ACCELERATOR BECAUSE IT WOULD JUMP LIKE CRAZY. I WAS ABLE …
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ON 03/23/2019, WHEN I WAS LEAVING A PARKING LOT MY CAR STARTED TO HESITATE AND WOULD NOT REV UP. I JUST TURNED OUT THE PARKING LOT WHEN THIS HAPPENED. MESSAGE CAME ON STATED IT NEED TO BE SERVICED. AT THE SAME TIME THE ENGINE LIGHT CAME ON. I WAS NOT ABLE TO PRESS THE ACCELERATOR BECAUSE IT WOULD JUMP LIKE CRAZY. I WAS ABLE TO GET BACK TO THE PARKING LOT SAFELY. I HAVE BEEN IN A RENTAL FOR A MONTH NOW AND AS OF 04/23/2019 I WAS TOLD THE PART IS ON BACK ORDER. THE WIRING HARNESS AND THE COMPUTER HAS TO BE REPLACED, BUT THE TECH STATED SINCE THE CAR WENT INTO LIMP MODE THE ENGINE WILL NEED TO BE REPLACED. I WAS TOLD THE PART WILL BE IN ABOUT 3 TO 6 MONTHS. IF THE WIRING HARNESS DOES NOT WORK GOD ONLY KNOW HOW MANY MORE MONTHS IT WILL TAKE FOR A NEW ENGINE TO ARRIVE. THIS CAR WAS ONLY 9 MONTHS OLD BUT NOW 10 MONTHS OLD WITH ONE OF THE MONTHS BEING IN THE SHOP WAITING FOR REPAIRS.
NHTSA ODI #11203148
NHTSA investigations
2DP22003 · Loss Of Motive Power
Opened Sep 12, 2022 · Closed Dec 12, 2023
Status: closed (inferred from source dates) · Engine
The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing. There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
EA19001 · Electrical Overstress
Opened Apr 19, 2019 · Closed Sep 19, 2024
Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW. The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications. The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU. In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment. FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle. Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW. These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes. An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time. In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU. This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners. Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW. The risk associated with the ASIC is equally shared among all OEMS involved in the investigation. The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage. There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation. The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU. If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC. Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC. All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled. In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024. With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.