Affected vehicles are equipped with front passenger air bag inflators, which could have been assembled with improperly manufactured propellant. Improperly manufactured propellant wafers could cause the inflator to rupture and the front passenger airbag to deploy abnormally in a crash, increasing the risk of injury to the occupant.

Both rear brake caliper bolts may come loose from the rear axle beam and abnormal noise might occur due to insufficient torque of caliper bolts. In the worst case, detachment of rear brake caliper might cause that brake rotor breaks, which could result in the vehicle becoming inoperative. There have been no reports of accidents related to this condition.

The ECU needs to be reprogrammed.

The driver’s airbag module in the subject vehicles contains electrical connections housed in a spiral cable assembly, which includes a Flexible Flat Cable (FFC). Due to the shape and location of the FFC’s retainer, the FFC could contact a small point of the retainer and become damaged when the steering wheel is turned. In FFC’s with seven-channel circuits, this damage could occur to a circuit on the FFC that provides connectivity to the driver’s air bag module. If connectivity is lost, the air bag warning lamp will illuminate. In addition, the driver’s air bag could become deactivated, causing it to not deploy in the event of a crash.

Installed in the subject vehicles, underneath the front seat belt retractor with pyrotechnic pretensioner, is a sound insulator located at the bottom of the center pillar. There is a possibility that the sound insulator may become damaged by the high temperature gas generated from the seat belt pretensioner when it is activated in the event of a crash. In the worst case, if the insulator ignites, this condition may result in a post-collision fire.

In the seat rail of the driver and the front passenger seat of the subject vehicles, the spring used for the mechanism which locks the seat rail in its adjusting positions could break if the seat is adjusted forward and/or rearward with high frequency. If this occurs, the seat may not be able to be locked in position. In limited instances, the broken spring could become stuck in the seat rail, and the seat might appear to be locked in position. If the vehicle is operated with a broken seat rail spring, the seat could move in the event of a collision, increasing the risk of injury to the occupant.

The engines in the involved vehicles contain valve springs, which could have been produced with corrosive pitting on the surface of the spring due to improper maintenance of manufacturing equipment by one of two suppliers. The corrosive pitting could lead to fatigue cracks, which could result in breakage of the valve spring over time. If this occurs, the driver can notice an abnormal noise and rough engine performance. In some cases, the engine could fail and stop while the vehicle is being driven.