NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
621 reportsClear category filterMileage unknown · Jan 2, 2023
Engine
I was driving down the highway and veered onto a secondary road when the engine shut off. No prior warning was given and the check engine light was not on. I was forced to stop the vehicle; there was no shoulder to pull onto, so I ended up blocking a lane of traffic. The engine seized and must be replaced, or the car will have …
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I was driving down the highway and veered onto a secondary road when the engine shut off. No prior warning was given and the check engine light was not on. I was forced to stop the vehicle; there was no shoulder to pull onto, so I ended up blocking a lane of traffic. The engine seized and must be replaced, or the car will have to be scrapped.
NHTSA ODI #11499796
Mileage unknown · Dec 17, 2022
EngineUnknown Or Other
On the behalf of my daughter I am filing this formal complaint: * On August 10, 2022 my daughter was driving home from Des Moines to Cedar Rapids, Iowa. She was on the highway and all of the sudden her car engine shut down, no warning lights came on prior to this happening. She did not have power steering, it took all she had t…
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On the behalf of my daughter I am filing this formal complaint: * On August 10, 2022 my daughter was driving home from Des Moines to Cedar Rapids, Iowa. She was on the highway and all of the sudden her car engine shut down, no warning lights came on prior to this happening. She did not have power steering, it took all she had to pull the car over safely, she was able to use the brakes but barely. She then tried to restart the vehicle, it was able to restart with no other problems along the way. This incident happened at 2am, had this occured earlier in the day, with heavy traffic the safety of my daughter and others would have been at a high risk, this could have caused a major accident. * On October 9, 2022 My daughter was just exiting the interstate, warning light appeared. She was approaching her home, not far from the highway, when the car engine shut down once again but this time it would not restart. The vehicle remains undrivable but is available for inspection upon request. * On October 10, 2022 I sent my step-father over to her house to take a look at her car. From his findings he stated that the oil plug was loose and that the oil had drained out. * On August 2, 2022 She had an oil change done at Jiffy Lube (Cedar Rapids,Ia.) I filed a complaint assuming that they did not properly tighten the oil plug. The manager from Jiffy Lube informed me that an investigation is in motion at this time for Kia (2005-2020) and Hyundai's due to oil plugs loosening and engines ramdomly shutting down at highway speeds. At this time I am strongly advising a thorough investigation into this matter. Thank you for your time.
NHTSA ODI #11497896
Mileage unknown · Dec 14, 2022
EngineEngine And Engine Cooling
My vehicle engine blew while driving on the highway going about 65 no warning or signs other then the amount of oil that it was consuming. I am just now hearing about the class action lawsuits for my specific engine the Theta 2.0 which I have already verified it is part of it. KIA is saying it's the wrong part of the engine tha…
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My vehicle engine blew while driving on the highway going about 65 no warning or signs other then the amount of oil that it was consuming. I am just now hearing about the class action lawsuits for my specific engine the Theta 2.0 which I have already verified it is part of it. KIA is saying it's the wrong part of the engine that is blown that it want be qualify for the engine replacement. I have kept my oil changed regularly and just recently noticed it started to consume godly amounts of oil no leak, or smell it was literally disappearing it is not normal to add almost 4qts of oil every 2 weeks or so. These engines need to be recalled not placed on a "service bulletin" and they pick and choose which to fix. Point is they are ticking time bombs and something need to be done they will not back their products and us consumers are left to suffer.
NHTSA ODI #11497491
Mileage unknown · Dec 7, 2022
Engine
Daughter driving her 2015 kia optima she purchased May 2022 and currently has 95,000 miles on it and it started making a weird noise coming from the engine. We got the car home and then took to repair shop due to the car running rough and making a ticking noise. Repair shop calls and says they drove it a short distant down the r…
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Daughter driving her 2015 kia optima she purchased May 2022 and currently has 95,000 miles on it and it started making a weird noise coming from the engine. We got the car home and then took to repair shop due to the car running rough and making a ticking noise. Repair shop calls and says they drove it a short distant down the road and the motor mad a loud noise and then stalled . Car will not start and repair shop said she will need a new motor. Called Kia and they stated it was covered because years before her purchasing it from a reputable dealer ,the previous owner did not do the product improvement update.
NHTSA ODI #11496484
100 miles · Dec 2, 2022
EngineFuel System, GasolineVisibility
The contact owns a 2015 Kia Optima. The contact received a recall repair regarding a system upgrade for the knock sensor detection system and experienced the failure since the repair was performed. The vehicle was emitting a fuel odor and had a burning odor as if the vehicle was overheating. The driver’s and passenger’s side sid…
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The contact owns a 2015 Kia Optima. The contact received a recall repair regarding a system upgrade for the knock sensor detection system and experienced the failure since the repair was performed. The vehicle was emitting a fuel odor and had a burning odor as if the vehicle was overheating. The driver’s and passenger’s side side-view mirrors would close while driving at various speeds. The Push to Start button had to be pressed several times to start the vehicle. The contact had taken the vehicle to the dealer who stated that the fuel odor was due to a hole in the fuel line hose. The passenger’s side side-view mirror had been replaced. The failure reoccurred. The contact stated that the failure was related to NHTSA Campaign Number: 18V907000 (Fuel System, Gasoline, Engine) however, the VIN was not included. The manufacturer was made aware of the failure and opened a case. The approximate failure mileage was 100.
NHTSA ODI #11495740
135,550 miles · Nov 30, 2022
Engine
The contact owns a 2015 Kia Optima. The contact stated while driving 50 MPH, there was an abnormal sound coming from the vehicle. The contact was able to continue driving back to the residence. The dealer was contacted and stated that the rod bearing in the engine might need to be replaced; however, the vehicle was not diagnosed…
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The contact owns a 2015 Kia Optima. The contact stated while driving 50 MPH, there was an abnormal sound coming from the vehicle. The contact was able to continue driving back to the residence. The dealer was contacted and stated that the rod bearing in the engine might need to be replaced; however, the vehicle was not diagnosed or repaired. The manufacturer was contacted, and the contact was informed that a Product Improvement Program was not performed which prevented the Extend Warranty on the vehicle to become effective. No further assistance was provided. The failure mileage was 135,550.
NHTSA ODI #11495441
Mileage unknown · Nov 21, 2022
EnginePower Train
August 6, 2022 on Kansas Turnpike near El dorado. 2015 Kia Optima LX 74,000 miles. With absolutely NO warning whatsoever revved high then began a knocking sound, then a horrible banging and died. No lights, no alarms. Steering became a problem. We were able to drift to the side of the road as we were already in the right lane. O…
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August 6, 2022 on Kansas Turnpike near El dorado. 2015 Kia Optima LX 74,000 miles. With absolutely NO warning whatsoever revved high then began a knocking sound, then a horrible banging and died. No lights, no alarms. Steering became a problem. We were able to drift to the side of the road as we were already in the right lane. Once completely stopped dash lights came on. We had no idea of any recalls or issues. Engine never recovered and we procured roadside assistance. Waited 4 hours on the side of the turnpike. We have since learned of a class action lawsuit against Kia with this very issue. We are still waiting for an engine replacement/rebuild 15 weeks later!
NHTSA ODI #11494407
Mileage unknown · Nov 18, 2022
Engine
The engine failed exactly like kia expected it to in the class action lawsuit, but they are refusing to repair the engine since they sent documentation that I needed to have a system upgrade done. However they sent it to an address that I no longer lived at and I've unforgettably them that I had proof that I didn't raise at the…
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The engine failed exactly like kia expected it to in the class action lawsuit, but they are refusing to repair the engine since they sent documentation that I needed to have a system upgrade done. However they sent it to an address that I no longer lived at and I've unforgettably them that I had proof that I didn't raise at the address anymore, but they don't care because whatever they sent want returned to them. So instead of replacing my engine because they knowingly sold vehicles worth bad engines they have sent me a bill for $8000 in order to get my car repaired. When you look this up there are so many people worth the exact same issue. Kids is finding any and all reasons to not honor their agreement and to continue to profit off of people.
NHTSA ODI #11494057
Mileage unknown · Nov 15, 2022
Engine
UNKNOWN but I got my car in February, it’s always been sounding rough from the start but was told it’s normal, lately the past few months I noticed a little vibration and a change of sound in the motor but had no lights come up on dashboard so assumed it wasn’t a problem. Well to this day my engine is shaking very rough that my …
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UNKNOWN but I got my car in February, it’s always been sounding rough from the start but was told it’s normal, lately the past few months I noticed a little vibration and a change of sound in the motor but had no lights come up on dashboard so assumed it wasn’t a problem. Well to this day my engine is shaking very rough that my car vibrates extremely and making a clicking sound best way to describe it and my engine light as well as oil topper light came on just a few days ago which I’ve gotta an oil change roughly about 2 months ago and added oil as well recently. So not sure if I have a leak of some sort or what. My breaks are also bad but when I purchased the car one tire was missing two bolts cause they broke off. Lately a lot of problems have all come at once. But I don’t feel safe driving my car cause I feel it doesn’t accelerate as it should and it’s not running normally. It’s a 2015 kia optima. Says no safety recall but all the problems I’ve been having seem very relatable to what’s showing on the recall list for kias of my year.
NHTSA ODI #11493674
137,513 miles · Nov 7, 2022
Engine
My engine has died while driving on two occasions. The first time the engine died I pulled over to the side of the road and I turned the ignition off and it cranked right up. No more issues for approximately two months. The next time I was driving and the engine died I pulled over to the side of the road, turned the ignition …
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My engine has died while driving on two occasions. The first time the engine died I pulled over to the side of the road and I turned the ignition off and it cranked right up. No more issues for approximately two months. The next time I was driving and the engine died I pulled over to the side of the road, turned the ignition off and tried to crank it but nothing happened. All the lights were on but the engine wouldn't turn over at all, no clicking noise, absolutely nothing. I was so confused because all lights were on but nothing happened when I turned the key. I had it towed to Pep Boys who said I had complete engine failure. What? No warning, no check engine lights, no running hot, I maintained my car religiously. I heard there was a recall on the Theta engines but I can't find anything on 2015 engines. If the engines have a recall up to 2014 and my engine did the same exact thing then my engine repair and/or replacement should be covered under a warranty also. This is dangerous. I was traveling at speeds between 75 -80mph when the engine died. This needs to be addressed but I can't seem to find anyone that cares enough to help me.
NHTSA ODI #11492554
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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