Toyota Recalls Nearly 17,000 Scion xA Vehicles Due to Air Bag Defect

Laguna Hills, CA – November 28, 2018 – Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2004-2006 Toyota Scion xA vehicles for a potential internal short in the air bag module. The potential number of units affected is 16,992.

The Defect

According to the NHTSA Recall Safety Report, the airbag control module for the supplemental restraint system (SRS ECU) in the subject vehicles may have been manufactured with application-specific integrated circuits (ASICs) which are susceptible to internal shorting when exposed to the naturally high inductive electrical noise from various vehicle electrical components close to the module. In some cases, the SRS warning light for the airbag(s) could illuminate, and the airbag(s) and/or seat belt pretensioner (s) could become deactivated. In other cases, these systems could inadvertently deploy in the absence of an impact. An airbag that is deactivated or is deployed inadvertently can increase the risk of injury or the possibility of a crash.

Timeline of Events

In 2013, Toyota recalled approximately 890,000 vehicles in the U.S. which were equipped with generation 5.0 TRW SRS ECUs. In these ECUs, damage due to electrical noise could result in an inadvertent deployment of the airbag(s) and/or seat belt pretensioners. At the time, generation 5.5 SRS ECUs (that are the subject of this recall) were not included.

In June 2013, Toyota received a field report from the European market indicating the inadvertent activation of the driver, front passenger, and knee airbags while driving a CY 2006 Corolla Verso vehicle. Airbags were found to be activated as per the customer’s allegation, but there was no evidence of an impact. The SRS ECU was recovered and investigated, and damage appeared to be similar to damage from electrical noise that could have occurred on a generation 5.0 SRS ECU, recalled in 2013; however, it was judged to be an isolated case due to the differences between the 5.0 and 5.5 models.

In July 2015, Toyota received information from a dealer in the Japan market indicating the inadvertent activation of the driver, front passenger, and knee airbags while driving a CY 2006 Avensis vehicle. Similar results were found. Toyota began replication testing and recovery of working SRS ECUs of this generation from in-use vehicles and found that the generation 5.5 SRS ECUs have higher insulation against electrical noise compared to the recalled generation 5.0 ECUs. However, Toyota continued to sporadically receive similar field reports from countries outside of North America, mainly from European countries and Japan, and continued its investigation.

Toyota reviewed the difference between the Avensis and other models, and once again started the recovery of working SRS ECUs from a larger population of in-use Avensis vehicles. In August 2017, Toyota also received the first field report from the U.S. market, claiming inadvertent activation of the driver and front passenger airbags in a 2006 MY Toyota Scion xA vehicle with a generation 5.5 SRS ECU. Toyota investigated the SRS ECU and confirmed the damage of the ASIC for transmitting the signal to deploy the airbags was similar to other cases from the European and Japan markets. At that time, Toyota observed that the insulation against electrical noise found in the ASICs in the generation 5.5 SRS ECUs had an unexpectedly wide variation in effectiveness and Toyota subsequently chose to conduct a voluntary safety recall campaign.

The Solution

All known owners of the subject vehicles will be notified by first class mail to return their vehicles to a Toyota dealer. The dealers will replace the airbag control module with an updated one, free of charge. The owner letter will also instruct vehicle owners who have paid to have this condition remedied prior to this campaign to seek reimbursement under Toyota’s General Reimbursement Plan. The recall is expected to begin December 24, 2018. Owners may contact Toyota customer service at 1-888-270-9371. Toyota’s number for this recall is J0W. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-776.

Sean ReyesToyota Recalls Nearly 17,000 Scion xA Vehicles Due to Air Bag Defect

GM Recalls Several Vehicles for Air Bag Deployment Issues

Laguna Hills, CA – November 27, 2018 – General Motors LLC (GM) is recalling certain 2019 Buick Encore, Chevrolet Spark, Traverse, and Trax vehicles due to a potential air bag deployment issue. The potential number of units affected is 12.

The defect

According to the NHTSA Recall Safety Report, in a small number of the listed vehicles, the sensing diagnostic module (SDM) may have been left in “manufacturing mode” and not activated at the assembly plant prior to shipment.

If the SDM is in manufacturing mode, the vehicle’s airbags will not deploy in a crash, increasing the risk of occupant injury. Most other functions controlled by the same module, such as seatbelt reminder, event data recording and post collision notification, will also be inactive.

Drivers may receive advance notice of this issue via the airbag/supplemental inflatable restraint malfunction indicator lamp on the instrument panel, which will illuminate and remain illuminated (solid or flashing) after the vehicle is turned on.

Timeline of events

On October 3, 2018, a vehicle in GM’s Bupyeong, Korea plant was discovered to have a flashing airbag warning light after passing validation testing.

GM subsequently started an investigation into the issue, which determined that the vehicle’s sensing and diagnostic module (SDM) was set to “manufacturing mode;” when in this setting, the SDM is unarmed and the supplemental inflatable restraints are disabled.

GM further determined that the condition’s root cause is an error in a software update to GM’s production process at certain plants.

When the module is originally programmed during vehicle assembly, GM sets it to manufacturing mode, which is designed to prevent accidental restraint and air bag deployment when the vehicle is in the assembly facility.

Once full assembly is complete, all GM vehicles are subjected to a series of quality tests called dynamic vehicle tests (DVT), and at the conclusion of this process, the vehicle’s sensing diagnostic module (SDMs) is activated, which arms the restraints.

The error which was discovered in the software update can prevent the SDM from being activated in some vehicles at the conclusion of DVT. Due to this error, which only affected 12 vehicles, on October 25, 2018, GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall.

The solution

GM will notify owners, and dealers will reprogram the SDM module to the correct mode, free of charge. The recall began November 6, 2018.

Check your car’s recall status using MotorSafety’s free vehicle lookup tool.

Sean ReyesGM Recalls Several Vehicles for Air Bag Deployment Issues

Ford Recalls 215 Previously Recalled Vehicles for Potential Air Bag Malfunction

Laguna Hills, CA – November 27, 2018 – Ford Motor Company (Ford) is recalling certain 2010 Ford Fusion, Mercury Milan and 2010-2012 Lincoln MKZ vehicles that previously received a replacement passenger air bag under recalls 16V-384, 17V-024 or 18V-046. The potential number of units affected is 215.

The Defect

According to the NHTSA Recall Safety Report, in the event of a crash requiring deployment of the passenger air bag, the bracket that secures the air bag inflator to the module housing may deform, allowing the gas that inflates the air bag to leak out. If the air bag does not inflate properly, there is an increased risk of injury in the event of a crash. All affected vehicles were previously repaired under safety recalls using passenger airbag module service parts manufactured with stop brackets with an incorrect material thickness. Ford identified the affected vehicle population by monitoring warranty repairs using its warranty system to identify vehicles repaired with a specific part number that contained incorrect material thickness stop brackets, and issued the subsequent recall for those vehicles alone, as the issue had been fixed at manufacturing level for subsequent builds.

Timeline of Events

For production validation (PV) testing, the supplier used a stop plate component that did not follow the proper production part approval process (PPAP) and was thicker than the specified material thickness. This resulted in a “false positive” validation test. The specified material thickness utilized in production was inadequate to provide expected performance. On October 4, 2018, Joyson Safety Systems (JSS) reported a production validation test failure while validating parts on a new production line at their Monclova plant on an airbag module produced as a service part for the 2010 through 2012 model year Fusion/Milan/MKZ vehicles.

On October 8, 2018, JSS observed a Lot Acceptance Test (LAT) failure on the same part produced at their Torreon plant. Parts used for LAT testing were  also assembled using an incorrect gage thickness stop plate. JSS halted production of the affected airbag modules and quarantined stock in its control. Investigation of the test failures identified that a stop plate utilized in the module assembly provided insufficient support during airbag deployment. This defect was declared to be an issue, potentially resulting in inflation gas leakage and incomplete airbag cushion inflation in the event of a crash. The subsequent investigation of the PV and LAT test failures further identified that PV testing for the initial production line at the Torreon facility was performed using similar stop plates produced with an incorrect material thickness.

On October 16, 2018, the PV and LAT test failures were brought into Ford’s Critical Concerns Review Group, and on October 25, 2018, Ford’s Field Review Committee reviewed the concern and approved a field action.

The Solution

Ford will notify owners, and dealers will replace the passenger air bag module, free of charge. The recall is expected to begin in late November 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 18S34. Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the vehicle’s passenger airbag module replaced. There will be no charge for this service. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-775.

Sean ReyesFord Recalls 215 Previously Recalled Vehicles for Potential Air Bag Malfunction

Kia Motors Recalls Nearly 2,000 Forte Vehicles Due to Incorrect Headlamp Aiming

Laguna Hills, CA – November 27, 2018 – Kia Motors America (Kia) is recalling certain 2019 Kia Forte vehicles equipped with LED headlamps due to incorrect aiming of the headlamp beam. The potential number of units affected is 1,754.

The Defect

According to the NHTSA Recall Safety Report, the headlamps on affected vehicles may not have been manufactured with the correct low beam aiming. The LED headlamps may not have been produced by the supplier with the proper low-beam lamp aiming, resulting in a potential leftward deviation in low-beam lamp aiming. Insufficient illumination of the roadway caused by improperly aimed headlamps may result in the driver having reduced visibility, which can increase the risk of a crash.

Timeline of Events

During normal quality check of production process on July 27, 2018,  Kia Motors Mexico (“KMM”) identified an LED headlamp with a leftward deviation in low-beam lamp aiming during production. KMM notified the supplier of the issue.

Between July 28 – August 15, 2018, the supplier conducted an internal evaluation relating to improper low-beam lamp aiming with the LED headlamps, and identified the Master Headlamp used on the production line for headlamp aiming adjustment purposes as being not accurately adjusted. The supplier began use of a properly-adjusted Master Headlamp beginning on August 15, 2018.

Between August 16 – September 10, 2018, KMM conducted field monitoring and found no customer complaints. Between September 11 – October 8, 2018, KMM requested Kia Motors America, Inc. (“KMA”) to inspect KMA’s port stock vehicles, and subsequently, the potential aiming issue was confirmed and KMA advised Kia Motors Corporation (“KMC”) of inspection results.

Between October 9 – October 23, 2018, KMC and supplier conducted further review and confirmatory testing to determine the existence of potential non-compliance issue, and on October 24, 2018, KMC made the decision to conduct a non-compliance recall although no customer complaints have been registered and there have been no reported accidents or injuries.

The Solution

The recalled parts are the LED headlamps, Part Number 92101-M7200 and 92102-M7200. All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Kia will instruct dealers to inspect the headlamps and, if headlamp aiming is out of spec, replace the headlamp(s), free of charge. Kia will reimburse owners for repair expenses already incurred if necessary. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC171. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-771.

Sean ReyesKia Motors Recalls Nearly 2,000 Forte Vehicles Due to Incorrect Headlamp Aiming

Suzuki Recalls More Than 20,000 Kizashi Vehicles for Potential Fuel Tank Cracking

Laguna Hills, CA – November 24, 2018 – Suzuki Motor of America, Inc. (Suzuki) is recalling certain 2010-2013 Suzuki Kizashi vehicles, due to potential fuel tank cracking. The potential number of units affected is 21,052.

The Defect

According to the NHTSA Recall Safety Report, when driving on very dusty roads, a large amount of dust can enter the vent line that provides fresh air to the carbon canister, causing a restriction in the vent line. If this occurs, air flow through the evaporative system may be impacted such that excessive negative pressure is created in the fuel tank. This can cause deformation of the fuel tank, which can lead to fuel tank cracks.  If the fuel tank becomes cracked, fuel leakage and venting of gasoline vapors can occur, increasing the risk of a fire. Drivers may have some warning a crack has occurred; when the fuel tank becomes cracked, a pressure sensor will detect fuel vapor leakage and will illuminate the Malfunction Indicator Lamp (MIL), alerting the driver to seek corrective action.

Timeline of Events

In February, 2016, SMC received one Field Technical Information Report (FTIR) from Suzuki Motor of America, Inc. (SMAI) concerning fuel odor from a Suzuki Kizashi vehicle due to a fuel tank crack. A second FTIR was received from SMAI concerning Malfunction Indicator Lamp (MIL) illumination in a Suzuki Kizashi vehicle. Both incidents occurred in Wichita, Kansas. SMC’s investigation revealed that sand had accumulated in the carbon canister filter and carbon canister. SMC was unable to find the route of sand entry or the root cause of the problem.

From March to June, 2016 SMC installed collected parts on a test vehicle and measured internal fuel tank pressure changes using simulated driving modes, and conducted a fuel tank durability test to determine that the fuel tank crack occurred at about 34,000 miles, but also showed that 125,000 miles of driving was needed to replicate the sand accumulation seen in the incident vehicles.

Subsequent reports, most from Wichita, led SMC to determine that an investigation at a test site in Wichita was necessary, because the sand accumulation in SMC’s “Dust Road Test” did not correspond with the sand accumulation in incident vehicles. In April, 2018 SMC operated test vehicles in Wichita to evaluate the sand accumulation volume in the canister filter and checked customer vehicles selected at random and judged that the problem of filter clogging was due to driving on rough roads with fine dust like sand.

From June to July, 2018, SMC studied computer simulations to find the route of sand entry and noticed that the volume of sand entering this area could be reduced by plugging space between the rear fender lining and the wheel housing. SMC decided to make trial parts to cover this space and to conduct further testing in the U.S. which subsequently found that the very fine sand could pass through the rear fender lining made of non-woven fabric. On October 25, 2018 SMC reported the identified problem as a safety-related defect, even though the reported incidents were clustered around discrete geographical areas and there remain no clear indications of the root cause or an appropriate remedy.

The Solution

The remedy for this recall is still under development. The manufacturer has not yet provided a notification schedule. Owners may contact Suzuki customer service at 1-800-934-0934. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-769.

Sean ReyesSuzuki Recalls More Than 20,000 Kizashi Vehicles for Potential Fuel Tank Cracking

Subaru Recalls More Than 160,000 Vehicles for Weak Engine Valve Springs

Laguna Hills, CA – November 13, 2018 – Subaru of America, Inc. (Subaru) is recalling certain 2012-2014 Subaru Impreza, 2012-2013 Impreza Stationwagon, 2013 Subaru BRZ, XV Crosstrek and Toyota Scion FR-S vehicles for a valve spring issue that could cause engine stall. This recall is expected to affect 165,534 Subaru vehicles in North America.

The Defect

According to the NHTSA Recall Safety Report, due to an improper design of the valve train within the engine, an excessive stress is generated on the valve spring compared to the design condition. In addition, a very small amount of the impurity within the composition of the spring material is not avoidable in the manufacturing process. The combination of excessive stress and the dispersion of the impurity in the valve material during manufacturing may cause the valve springs located inside the engine of the affected vehicles may fracture, which may cause engine malfunction. In the worst case, the engine may stall during driving, and restarting will not be possible, increasing the risk of a crash.  Drivers may have a short window of advance warning as abnormal noise or vibration may occur prior to the engine stalling.

Timeline of Events

In April of 2012, SUBARU CORPORATION (Subaru) received a technical report from the Japan market which described an abnormal noise and rough idling. The collected engine was examined, and it was surmised that the valve spring broke and fell off, making contact with the piston and causing a rough idling and an abnormal noise. While a component analysis was conducted, no spring material flaw was identified and the cause of the fracture was unknown. In May 2013, the lower limit of the tolerance of the spring wire diameter was raised as a precaution and in response to eleven technical reports related to stalling reported from the U.S. In August 2016, based on additional examinations of engines collected from the field, it was determined that a ndactor not avoidable in the manufacturing process, namely very small amount of impurity within the composition of the spring material, could affect spring fracture.

Three additional technical reports related to stalling were issued from the U.S. during this time frame, but by September 2018 it was determined that a higher occurrence rate than estimated with general manufacturing dispersion from the vehicle manufactured with lower spring tolerance. Further investigation led to the revelation due to the improper design of the valve train, stress generated exceeded the design condition, and, when combined with the dispersion of impurity within the composition of the spring material, could cause spring fracture due to fatigue. On Oct 25, 2018, Subaru issued a safety recall for vehicles equipped with a similar valve train design manufactured prior to the tolerance adjustments made in May 2013.

The Solution

Subaru will notify owners, and all valve springs will be replaced with new ones free of charge. Owner notification will occur within 60 days of Dealer notification, which began on November 1. If parts are not available by that time, owners will be notified that parts are not available yet and they will be re-notified once parts are available. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-772.

Sean ReyesSubaru Recalls More Than 160,000 Vehicles for Weak Engine Valve Springs

Subaru Recalls More Than 200,000 Vehicles for Faulty Fuel Indicator

Laguna Hills, CA – November 12, 2018 – Subaru of America, Inc. (Subaru) is recalling certain 2018 Subaru Legacy and Outback vehicles due to a software issues that affects the vehicle’s fuel display. This recall is expected to affect 228,648 Subaru vehicles in North America.

The Defect

According to the NHTSA Recall Safety Report, due to a software error, the low fuel warning light may not light up to indicate the intended remaining fuel level and the distance-to-empty (DTE) display may incorrectly indicate a positive number even if the fuel tank is empty. This inaccuracy in the fuel display may cause a driver to unexpectedly run out of fuel and the vehicle to stall, increasing the risk of a crash.

Timeline of Events

In December of 2017, SUBARU CORPORATION (Subaru) received a technical report regarding the driving range indicator (DTE) in the multi-information display. The report indicated a positive distance-to-empty (DTE) when no usable fuel was remaining. A field part collection was requested, and between December 2017 and March 2018 p arts were collected from the field and sent to the supplier for an investigation which subsequently took place during April and June of 2018. In July 2018, the supplier submitted the investigation report to Subaru, whereupon, from August to October 2018, Subaru assessed their field data and the supplier’s investigation report to assess risk. On October 25, 2018, Subaru completed the investigation and determined that a voluntary safety recall should be ordered.

The Solution

Subaru will notify owners, and dealers will reprogram the combination meter software, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Subaru customer service at 1-844-373-6614. Subaru’s number for this recall is WTW-82. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-773.

Sean ReyesSubaru Recalls More Than 200,000 Vehicles for Faulty Fuel Indicator

BMW Recalls nearly 45,000 Vehicles Due to a Potential Coolant Leak

Laguna Hills, CA – November 7, 2018 – BMW of North America, LLC (BMW) is recalling certain models over fire risk. These vehicles are equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. If the EGR cooler leaks internally, the coolant can mix with diesel engine soot. The high EGR temperatures may result in these particles possibly smoldering and melting the intake manifold, which can increase the risk of a fire.

Included in this recall are: 

  • 2013-2018 BMW 328d and 328d xDrive 
  • 2014-2018 BMW 328d Sports Wagon and 328d xDrive Sports Wagon
  • 2014-2016 BMW 535d and 535d xDrive
  • 2015 BMW 740Ld xDrive
  • 2015-2017 BMW  X3 xDrive28d SAV 
  • 2014-2017 BMW X5 xDrive35d SAV 

The Defect

According to the NHTSA Recall Safety Report, approximately 12,781 Model Year 2013-2018 BMW 328d and 328d xDrive Diesel engine vehicles were equipped with an Exhaust Gas Recirculation (EGR) module that featured an integrated cooling component (“cooler”). Over time, this component could start to internally leak glycol coolant, because the recall component was not produced with sufficient long-term durability characteristics. During vehicle operation, if an internal coolant leak began inside the EGR cooler, the fluid could mix with normal diesel engine soot/sediment. This combination in the engine environment with high temperatures normally present might result in smoldering particles, which in very rare cases could lead to the melting of the intake manifold. In extreme cases, this could result in a possible fire. During vehicle operation, the driver may be alerted to this condition by one or more of the following: A warning symbol in the instrument cluster displaying a loss of engine coolant, a reduction in engine power, an unpleasant odor (exhaust gas), an unusual noise from the engine compartment, and/or smoke from the engine compartment.

Timeline of Events

On July 26, 2018, BMW submitted the required Part 579 report, to which NHTSA assigned “18F-137” as the Foreign Recall ID after BMW became aware of an issue in the Korean market. On September 5, 2018, BMW met with NHTSA to explain EGR system differences between vehicles in the U.S. market and vehicles in other markets. BMW provided a summary of U.S. field data including warranty claims, consumer complaints, and field reports which indicated coolant leak warnings, drivability concerns, or damage to the intake manifold. BMW also stated that it would continue to closely monitor the field. In October 2018, further in-depth analyses indicated that it was possible that one incident could be attributed to this issue. BMW decided to conduct a voluntary safety recall although at the time of the report, BMW was unaware of any accidents or injuries related to this issue.

The Solution

Owners will be notified by First Class mail and instructed to take their vehicle to an authorized BMW center to have the remedy performed at no cost. The EGR cooler will be inspected and, if necessary, replaced free of charge. If it is determined that the EGR cooler has internally leaked, the engine intake manifold will also be replaced. The EGR pipe connecting the cooler to the manifold will be cleaned. Owners who have replaced the EGR cooler at their own expense prior to the recall notification may be eligible for reimbursement according to BMW Group’s reimbursement plan. Notification to owners is planned to begin and end on December 17, 2018. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-755.

Other BMW Recalls 

Some of these vehicles may have been a part of a recall in August of 2021, when BMW recalled vehicles over a risk of engine stalling caused by a high-pressure fuel pump that suffers from excessive wear. In addition, even vehicles with gasoline engines, such as the 328i station wagon, had problems with their fuel pumps in the past.  

  • 2014 – 2018 BMW 328D
  • 2015 – 2017 BMW X3
  • 2014 – 2016 BMW 535D
  • 2014 – 2018 BMW X5 
  • 2015 BMW 740LD

The affected component in this recall is the BMW high-pressure fuel pump with part number 7810696 and 7283473

Is your vehicle a part of this recall?

This BMW recall includes more than 11,000 vehicles. To check for this and other BMW recalls, use MotorSafety’s free vehicle lookup tool.

Sean ReyesBMW Recalls nearly 45,000 Vehicles Due to a Potential Coolant Leak

2017-2019 Toyota 4Runner: Recall Alert

2017-2019 Toyota 4Runner: Recall Alert

Sean Reyes2017-2019 Toyota 4Runner: Recall Alert