NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
621 reportsClear category filter111,000 miles · Feb 2, 2023
Engine
The contact owns a 2015 Kia Optima. The contact stated while driving from a complete stop, there was smoke coming out from underneath the hood of the vehicle. The check engine warning light was illuminated. The contact veered to the side of the road. The vehicle was towed to an independent mechanic, where the radiator and the ra…
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The contact owns a 2015 Kia Optima. The contact stated while driving from a complete stop, there was smoke coming out from underneath the hood of the vehicle. The check engine warning light was illuminated. The contact veered to the side of the road. The vehicle was towed to an independent mechanic, where the radiator and the radiator hose were replaced; however, while driving two and a half weeks later, the vehicle stalled, and the steering wheel seized. The contact was able to veer to the side of the road by using physical strength to steer the vehicle. The vehicle was towed to the independent mechanic, where it was diagnosed that the failure was related to an unknown recall. The vehicle was towed the dealer, where the engine was replaced; however, the engine smoked while driving. The vehicle was towed to the dealer where the engine was replaced for a second time; however, the engine was incompatible with the turbocharger in the vehicle. The dealer informed the contact that she had to pay out-of-pocket to repair the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 111,000.
NHTSA ODI #11505205
80,000 miles · Jan 31, 2023
Engine
The contact owns a 2015 Kia Optima. The contact stated that while starting the vehicle, the engine turned over but then the engine seized. There was an abnormal knocking sound previously detected. There were no warning lights illuminated. The vehicle was towed to the local dealer but was not diagnosed or repaired. The manufactu…
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The contact owns a 2015 Kia Optima. The contact stated that while starting the vehicle, the engine turned over but then the engine seized. There was an abnormal knocking sound previously detected. There were no warning lights illuminated. The vehicle was towed to the local dealer but was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 80,000.
NHTSA ODI #11504773
Mileage unknown · Jan 30, 2023
Electrical SystemEngine
Anti Theft Security system is non-existent. There is a current known issue on the internet on the ease of theft of any Kia or Hyundai to certain years of manufacture. I am currently a single disabled person that could be a victim of vehicle theft because of a lack of this security software that Kia did not include on my 2015 veh…
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Anti Theft Security system is non-existent. There is a current known issue on the internet on the ease of theft of any Kia or Hyundai to certain years of manufacture. I am currently a single disabled person that could be a victim of vehicle theft because of a lack of this security software that Kia did not include on my 2015 vehicle. This Kia/Hyundai known issue could potentially leave anyone stranded in a dangerous situation. All other prior and current vehicles are equipped with the security software. Currently Kia & Hyundai has provided Lock bars for certain police departments to hand out, however .. not in my area. I am receiving warning letters from my Insurance company and have heard of some totally dropping coverages on all vehicles manufactured without the security software. This is a very dangerous situation and I believe that ALL VEHICLES AFFECTED SHOULD BE ISSUED AN IMMEDIATE RECALL AND SOFTWARE UPDATE PROVIDED BY THE MANUFACTURERS AT NO COST TO CURRENT OWNERS OF THESE DEFECTIVE VEHICLES. A proposed class action lawsuit was started in September 2022. In the meantime.. what happens to innocent people who go to a grocery store or doctors office only to find that their car had been stolen while they were inside? Or what happens when they can no longer receive insurance coverage because of the ease of this known lack of security originally promised from the manufacturer? These particular Kia/Hyundai's are missing a "key" anti-theft device..their keys lack computer chips for theft "immobilizer" systems that other car manufacturers have as a standard theft deterrant during those same years of manufacture & currently have on all new vehicles. A MANDATORY RECALL FOR REPAIR SHOULD BE ISSUED IMMEDIATELY BEFORE ALL INSURANCE COMPANIES REFUSE TO INSURE THESE VEHICLES! Anti-Theft technology was included on the sticker price but not installed! I am afraid to go to the grocery store!!
NHTSA ODI #11504564
129,000 miles · Jan 24, 2023
Engine
The contact owns a 2015 Kia Optima. The contact stated that while driving at various speeds, the vehicle hesitated and stalled upon depression of the accelerator pedal. The vehicle was towed to a local dealer where it was diagnosed with engine failure. The vehicle remained in dealer possession for months as the contact awaited t…
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The contact owns a 2015 Kia Optima. The contact stated that while driving at various speeds, the vehicle hesitated and stalled upon depression of the accelerator pedal. The vehicle was towed to a local dealer where it was diagnosed with engine failure. The vehicle remained in dealer possession for months as the contact awaited the repair. The manufacturer was notified and informed her that since a prior service was not performed on the vehicle, she no longer qualified for the repair. The vehicle was not repaired. The failure mileage was 129,000.
NHTSA ODI #11503477
Mileage unknown · Jan 24, 2023
Engine
While driving the vehicle on Tuesday 1/17/23 giving it gas, the engine stopped running. I was going about 45 mph when the engine stopped, multiple lights on the dash turned on including the engine light, oil light, and battery light. I had to coast the car to the side of a 3 lane road. I turned off the car, waited a few moments …
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While driving the vehicle on Tuesday 1/17/23 giving it gas, the engine stopped running. I was going about 45 mph when the engine stopped, multiple lights on the dash turned on including the engine light, oil light, and battery light. I had to coast the car to the side of a 3 lane road. I turned off the car, waited a few moments and tried to turn the car on. The lights went on but the engine did not start. I had the car towed to an auto shop who then advised I should have it taken to a Kia dealer as there is a recall on the vehicle. The dealer has had the car for a week and has only said that the engine is seized and that they can not provide more information without me paying to have the engine taken apart.
NHTSA ODI #11503473
Mileage unknown · Jan 22, 2023
EngineUnknown Or Other
Driving down the road and suddenly there was loud knocking and smoke coming from under the hood and got it to the side of the road and turned it off and now it won't crank. The dash lights come on when you turn the key and that's all it will do. No noises at all.
NHTSA ODI #11503008
130,000 miles · Jan 17, 2023
Engine
The contact owns a 2015 Kia Optima. The contact stated while driving 65 MPH, the vehicle stalled. The contact stated that several unknown warning lights were illuminated. The contact was able to cruise to the side of the road. The vehicle was not drivable. The contact towed the vehicle to an independent mechanic and was informed…
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The contact owns a 2015 Kia Optima. The contact stated while driving 65 MPH, the vehicle stalled. The contact stated that several unknown warning lights were illuminated. The contact was able to cruise to the side of the road. The vehicle was not drivable. The contact towed the vehicle to an independent mechanic and was informed that the engine needed to be replaced. The vehicle was not repaired. The contact towed the vehicle to the local dealer to be diagnosed. The dealer confirmed that the engine needed to be replaced. The vehicle was not repaired. The VIN was associated with NHTSA Campaign Number: 21V331000 (Service Brakes, Hydraulic). The manufacturer had not been informed of the failure. The failure mileage was approximately 130,000.
NHTSA ODI #11502156
Mileage unknown · Jan 13, 2023
Engine
Engine seized on the car and I was denied recall repair. I spoke with corporate for Kia and they basically did nothing to help at all. They basically said they sent a letter for an update and because I did not perform the update they will not honor the recall that was approved on my car. The person I spoke with advised the addre…
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Engine seized on the car and I was denied recall repair. I spoke with corporate for Kia and they basically did nothing to help at all. They basically said they sent a letter for an update and because I did not perform the update they will not honor the recall that was approved on my car. The person I spoke with advised the address was never updated so the letter did not come to me for the recall or was lost. He stated I was supposed to contact Kia with update to address. I never was aware this had to be done and I have purchased many cars and never was made aware. He stated why would you purchase a big purchase and not do this. I was under the impression when I purchased this would be done that’s why I am charged tax license and other fees. I believe this is predatory and this is just a way to not honor the recalled engine that I purchased. The check engine light never illuminated on the dash or any indication the engine had an issue so I had no reason to take my car in for a repair. To add to that my fiancé had a 2013 and the recall letter was received and he took his car for update and the car never worked after the update was performed. Kia denied any repairs to that vehicle and basically took a lost because of the update. I would like some type of resolution to this issue. The car has 113000 miles of course the original warranty was 100000. This update was during pandemic as well. I am very disappointed in Kia at this point because there should be something in place for people like me who never received notice. The engine is no good and we as customers should not have to take this lost. Please help
NHTSA ODI #11501713
Mileage unknown · Jan 13, 2023
Air BagsEngineFuel/propulsion SystemCrashInjury
I purchased a kia turbo optima from bob's lamphere's beaverton oregon kia dealership 9 days later I felt the acceleration awkwardly bi wanted to return it or exchange but was told no contract was only within 5 days. I took it to kia dealership for diagnostic 3 times I had it for 9 months the last 6 weeks was the 3rd time until F…
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I purchased a kia turbo optima from bob's lamphere's beaverton oregon kia dealership 9 days later I felt the acceleration awkwardly bi wanted to return it or exchange but was told no contract was only within 5 days. I took it to kia dealership for diagnostic 3 times I had it for 9 months the last 6 weeks was the 3rd time until Feb 28th It was totaled by a uninsured motorist memes william benton penny lll Or. Driver lic# 1289466 Of 1633 n.e. 76th portland oregon 97213 he was speeding illegally bypassing on a bridge into on coming traffic which was me he ending totally the back end of my kia. No air bags deployed I had no airbag warning light on I suffer injuries whiplash in my neck shoulder and back to this day Wild willy seemed to have injured his leg to the point of amputation ... Portland police report# 21-54465 which is the report that wild willy gave a false identity. Later the officer text giving his real identity. To this day I haven't been compensated for bodily or auto damageby wild willy or Geico my insurance. And lost my kia in a junk yard with a remaining of a bill of 12,000 of 25,500.
NHTSA ODI #11501694
Mileage unknown · Jan 10, 2023
Engine
My vehicle is in the class action lawsuit against KIA for faulty engine blocks that could cause fire and engine failure. My vehicle oil consumption is way below standard and the excess burning oil is coming inside my engine on top . I see smoke and I smell burning oil on my engine while I’m driving and when I stop. I have well k…
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My vehicle is in the class action lawsuit against KIA for faulty engine blocks that could cause fire and engine failure. My vehicle oil consumption is way below standard and the excess burning oil is coming inside my engine on top . I see smoke and I smell burning oil on my engine while I’m driving and when I stop. I have well kept my cars maintenance and this is now starting to happen after 120k miles. I reported the issue to Kia but they told me that the engine has to lock up before they can either consider replacing it. I’m really afraid to drive this car because of my life and the life of others if I get a fire or engine failure in busy traffic. It just doesn’t seem safe to drive although there’s no check engine lights on yet, but I can sense warnings before destruction. Please help !!
NHTSA ODI #11501039
Official recalls
4Sep 25, 2023
Kia America, Inc. (Kia) is recalling certain 2010-2019 Borrego, 2014-2016 Cadenza, 2010-2013 Forte, Forte Koup, Sportage, 2015-2018 K900, 2011-2015 Optima, 2011-2013 Optima Hybrid, Soul, 2012-2017 Rio, 2011-2014 Sorento, and 2010-2011 Rondo vehicles. The Hydraulic Electronic Control Unit (HECU) may experience an electrical short, which can result in an engine compartment fire while parked or driving.
Consequence & remedy
Consequence: An engine compartment fire while parked or driving can increase the risk of injury.
Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will replace the HECU fuse, free of charge. Interim notification letters, notifying owners of the safety risk, were mailed November 14, 2023. Owner notification letters were mailed March 29, 2024 through June 18, 2024. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC284.
May 10, 2021
Kia Motors America (Kia) is recalling certain 2013-2015 Optima and 2014-2015 Sorento vehicles previously recalled under recall 20V-519. Brake fluid may leak inside the Hydraulic Electronic Control Unit (HECU), possibly resulting in an electrical short.
Consequence & remedy
Consequence: An electrical short in the HECU increases the risk of a fire while parked or driving.
Remedy: Owners are advised to park outside and away from other vehicles and structures until the recall repair is completed. Dealers will install a new multi-fuse, and inspect the HECU for leaks, replacing the HECU if necessary, free of charge. Owner notification letters were mailed on July 2, 2021. This recall supersedes previous NHTSA recall number 20V-519. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC212.
Aug 27, 2020
Kia Motors America (Kia) is recalling certain 2013-2015 Optima and 2014-2015 Sorento vehicles. Brake fluid may leak inside the Hydraulic Electronic Control Unit (HECU), possibly resulting in an electrical short.
Consequence & remedy
Consequence: If the HECU short circuits, there is an increased risk of an engine compartment fire.
Remedy: Kia will notify owners, and dealers will inspect the HECU for leaking brake fluid and replace the HECU if necessary, free of charge. Owners are advised to park outside and away from other vehicles and structures until the recall repair is completed. The recall began October 20, 2020. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC197.
Dec 19, 2018
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Additional source detail variants (2)
Engine
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4AQ23002 · Hyundai And Kia Abs Module Fires
Opened Nov 17, 2023 · No close date supplied
Status: open (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.
DP22003 · 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.
DP21003 · Throttle Control System Vulnerabilities
Opened Nov 12, 2021 · Closed Jun 20, 2023
Status: closed (inferred from source dates) · Vehicle Speed Control:throttle
The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.
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.
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