NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
10 reportsClear category filter123,323 miles · Feb 11, 2026
Fuel System, Gasoline
The contact owns a 2015 Kia Optima. The contact stated that while attempting to start the vehicle or while driving at undisclosed speeds, there was an abnormal fuel odor inside the vehicle after the vehicle was serviced by the dealer. The contact stated that the vehicle received an undisclosed engine repair. The vehicle was not …
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The contact owns a 2015 Kia Optima. The contact stated that while attempting to start the vehicle or while driving at undisclosed speeds, there was an abnormal fuel odor inside the vehicle after the vehicle was serviced by the dealer. The contact stated that the vehicle received an undisclosed engine repair. The vehicle was not taken to an independent mechanic or the dealer to be diagnosed. The manufacturer was not notified of the failure. The failure mileage was 123,323.
NHTSA ODI #11717265
96,000 miles · Apr 18, 2025
EngineFuel System, Gasoline
The contact owns a 2015 Kia Optima. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to coast to the shoulder of the roadway, where the vehicle was able to be restarted. However, several days later the failure reoccurred, and the contact heard an abn…
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The contact owns a 2015 Kia Optima. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to coast to the shoulder of the roadway, where the vehicle was able to be restarted. However, several days later the failure reoccurred, and the contact heard an abnormal sound coming from the engine compartment, prompting the contact to discontinue driving the vehicle. No warning lights were illuminated. The vehicle was towed to the dealer, who diagnosed a nondescript failure with the engine. The contact was informed that the engine needed to be replaced. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 18V907000 (Fuel System, Gasoline, Engine), but the VIN was not included. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 96,000.
NHTSA ODI #11655502
112,000 miles · Mar 27, 2025
EngineFuel System, Gasoline
The contact owns a 2015 Kia Optima. The contact stated that while driving 70 MPH, the vehicle inadvertently lost motive power. The contact was able to pull over to the shoulder of the roadway, where the vehicle failed to restart. After a visual inspection, the contact observed an excessive amount of oil leaking from underneath t…
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The contact owns a 2015 Kia Optima. The contact stated that while driving 70 MPH, the vehicle inadvertently lost motive power. The contact was able to pull over to the shoulder of the roadway, where the vehicle failed to restart. After a visual inspection, the contact observed an excessive amount of oil leaking from underneath the engine compartment. No warning lights were illuminated. The vehicle was towed to an independent mechanic, who diagnosed a failure with engine failure, observing a hole on the side of the engine block. The vehicle was not repaired. The vehicle was then towed to the dealer however, the diagnosis was not yet confirmed. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 18V907000 (Fuel System, Gasoline, Engine), but the VIN was not included. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 112,000.
NHTSA ODI #11651080
178,000 miles · Aug 6, 2024
EngineFuel System, Gasoline
The contact owns a 2015 Kia Optima. The contact stated while driving 65 MPH, the vehicle shut off without warning. Due to the failure, the vehicle was towed to a dealer where a diagnostic test was performed. The vehicle was diagnosed with engine failure and the vehicle was repaired by the dealer under Warranty. The contact state…
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The contact owns a 2015 Kia Optima. The contact stated while driving 65 MPH, the vehicle shut off without warning. Due to the failure, the vehicle was towed to a dealer where a diagnostic test was performed. The vehicle was diagnosed with engine failure and the vehicle was repaired by the dealer under Warranty. The contact stated that several months after the repair was performed, the contact noticed a fuel odor coming from the vehicle after a visit to the gas station. The next day upon inspection of the vehicle, the contact's husband discovered a puddle of fuel underneath the vehicle. The dealer was notified of the failure and requested that the vehicle be towed to the dealer for an inspection. Upon investigation, the contact discovered NHTSA Campaign Number: 18V907000 (Fuel System, Gasoline; Engine) which the contact linked to the failure. The manufacturer was not notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 178,000.
NHTSA ODI #11606753
160,000 miles · Jun 6, 2024
Electrical SystemEngineFuel System, Gasoline
The contact owns a 2015 Kia Optima. The contact stated that the check engine and battery warning lights were illuminated. The contact stated that the engine had been replaced two weeks prior to the failure. The vehicle was taken to a local dealer for routine maintenance; however, the cause of the failure could not be determined.…
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The contact owns a 2015 Kia Optima. The contact stated that the check engine and battery warning lights were illuminated. The contact stated that the engine had been replaced two weeks prior to the failure. The vehicle was taken to a local dealer for routine maintenance; however, the cause of the failure could not be determined. In addition, during a battery replacement, there were several unknown warning lights illuminated and smoke was coming from the vents. The vehicle was towed to a local dealer where it was diagnosed that there was an EVAP leak, the canister purge valve had cracked, and the battery needed to be replaced. The vehicle was not repaired. The contact referenced Kia Campaign Number: SC135. The manufacturer was made aware of the failure. The failure mileage was approximately 160,000.
NHTSA ODI #11592841
142,000 miles · Nov 1, 2023
Fuel System, Gasoline
The contact owns a 2015 Kia Optima. The contact stated that the engine was previously replaced due to abnormal knocking sound. Additionally, the contact stated while driving 60-65 MPH, there was a strong gasoline odor coming through the A/C vents. There was no warning light illuminated. The vehicle was taken to the dealer, where…
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The contact owns a 2015 Kia Optima. The contact stated that the engine was previously replaced due to abnormal knocking sound. Additionally, the contact stated while driving 60-65 MPH, there was a strong gasoline odor coming through the A/C vents. There was no warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed that the low-pressure fuel hose was leaking and needed to be replaced; however, the part was not available. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 22V093000 (Fuel System, Gasoline). The manufacturer was not notified of the failure. The failure mileage was approximately 142,000.
NHTSA ODI #11553075
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
67,000 miles · Sep 17, 2020
Fuel System, Gasoline
TL* THE CONTACT OWNS A 2015 KIA OPTIMA. THE CONTACT STATED THAT WHILE HIS DAUGHTER WAS DRIVING THE VEHICLE, SHE BECAME AWARE OF A FUEL ODOR INSIDE THE VEHICLE. THE CONTACT STATED THAT WHILE DRIVING THE VEHICLE RECENTLY, HE NOTICED THAT THE HIGH FUEL PUMP LEAKED FUEL. THERE WAS NO WARNING. THE CONTACT CALLED THE PARKWAY FAMILY KI…
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TL* THE CONTACT OWNS A 2015 KIA OPTIMA. THE CONTACT STATED THAT WHILE HIS DAUGHTER WAS DRIVING THE VEHICLE, SHE BECAME AWARE OF A FUEL ODOR INSIDE THE VEHICLE. THE CONTACT STATED THAT WHILE DRIVING THE VEHICLE RECENTLY, HE NOTICED THAT THE HIGH FUEL PUMP LEAKED FUEL. THERE WAS NO WARNING. THE CONTACT CALLED THE PARKWAY FAMILY KIA LOCATED AT 22555 US-59, KINGWOOD, TX 77339, AND WAS INFORMED THAT THERE WAS NO RECALL ON THE VIN. THE VEHICLE WAS NEITHER DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 67,000. *LN*DT*JB CONSUMER STATED DEALER WAS NOT ABLE TO HELP.*JB*JB
NHTSA ODI #11355605
130,000 miles · Jun 11, 2020
EngineFuel System, Gasoline
TL* THE CONTACT OWNS A 2015 KIA OPTIMA. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE VEHICLE STALLED WITH THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE CONTACT PULLED OVER AND THE VEHICLE WAS TOWED TO MIKE MURPHY KIA (6150 ALTAMA AVE, BRUNSWICK, GA 31525) WHERE THE VEHICLE WAS DIAGNOSED WITH ENGINE FAILURE. THE DEALER …
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TL* THE CONTACT OWNS A 2015 KIA OPTIMA. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE VEHICLE STALLED WITH THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE CONTACT PULLED OVER AND THE VEHICLE WAS TOWED TO MIKE MURPHY KIA (6150 ALTAMA AVE, BRUNSWICK, GA 31525) WHERE THE VEHICLE WAS DIAGNOSED WITH ENGINE FAILURE. THE DEALER CONTACTED THE MANUFACTURER FOR APPROVAL TO HAVE THE ENGINE REPLACED UNDER NHTSA CAMPAIGN NUMBER: 18V907000 (FUEL SYSTEM, GASOLINE, ENGINE). THE MANUFACTURER NOTIFIED THE CONTACT THAT THE ENGINE REPLACEMENT FAILED AND THAT ANOTHER ENGINE NEEDED TO BE ORDERED TO REPLACE THE DEFECTIVE ENGINE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 130,000.
NHTSA ODI #11328349
171,000 miles · Aug 7, 2019
EngineFuel System, Gasoline
TL* THE CONTACT OWNS A 2015 KIA OPTIMA. WHILE DRIVING 70 MPH, THE VEHICLE BEGAN TO DECELERATE AND STALLED WHILE THE CHECK ENGINE BLINKED. THE CONTACT WAS ABLE TO DRIVE THE VEHICLE HOME DESPITE THE ENGINE STALLING PERSISTENTLY. THE CONTACT DROVE THE VEHICLE TO AN AUTO ZONE TO HAVE THE VEHICLE DIAGNOSED, BUT THEY SUGGESTED THE VEH…
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TL* THE CONTACT OWNS A 2015 KIA OPTIMA. WHILE DRIVING 70 MPH, THE VEHICLE BEGAN TO DECELERATE AND STALLED WHILE THE CHECK ENGINE BLINKED. THE CONTACT WAS ABLE TO DRIVE THE VEHICLE HOME DESPITE THE ENGINE STALLING PERSISTENTLY. THE CONTACT DROVE THE VEHICLE TO AN AUTO ZONE TO HAVE THE VEHICLE DIAGNOSED, BUT THEY SUGGESTED THE VEHICLE BE TAKEN TO A DEALER. THE CONTACT TOOK THE VEHICLE TO CRAIN KIA OF SHERWOOD (5830 WARDEN RD, SHERWOOD, AR 72120, 501-436-4852) WHERE IT WAS DIAGNOSED THAT THE KNOCK SENSOR NEEDED REPLACEMENT. THE FAILURE WAS ASSOCIATED WITH NHTSA CAMPAIGN NUMBER: 18V907000 (FUEL SYSTEM, GASOLINE, ENGINE). THE CONTACT WAS DRIVING A LOANER VEHICLE FOR THE PAST MONTH BECAUSE THE VEHICLE WAS STILL BEING REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 171,000. THE VIN WAS UNKNOWN.
NHTSA ODI #11242271
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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