United States         Air and Radiation        EPA420-B-02-003
           Environmental Protection                  October 2002
           Agency
c/EPA    2001 Calendar Year
           Emissions Related
           Recall/Service
           Campaign Report
                                     > Printed on Recycled Paper

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                                                                   EPA420~B~02~003
                                                                        October 2002

                        Certification and Compliance Division
                       Office of Transportation and Air Quality
                        U.S. Environmental Protection Agency
                                     NOTICE

   This technical report does not necessarily represent final EPA decisions or positions.
It is intended to present technical, analysis of issues using data that are currently available.
        The purpose in the release of such reports is to facilitate the exchange of
     technical information and to inform the public of technical developments which
       may form the basis for a final EPA decision, position, or regulatory action.

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                         2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*
Recall Campaigns
                                                                                                                                                      http://www.epa.gov/otaq/cert/recall/
Mfr.


BMW





BMW






BMW







DAIMLER/CHRYSLER




Mfr. Recall
Number

01E-A01





01E-A02






01E-A02







976




EPA*


1572





1689






1690







1627




Type


V





V






V







V




Date of owner
Notification

3/16/2001





10/31/2001






10/31/2001







4/17/2001




Model
year

1997





1999






2000







1999




Vehicle Class


Z3,318i,318is,3
18ti,318i
Convertible




323i, 328i, 528i,
528IT, Z3
Coupe, Z3 2.5,
Z32.8




323i, 323CI,
323i Touring,
323i Cabrio,
328i, 328Ci,
528i, 528iT, Z3
2.8, Z3 Coupe,
Z32.5

Ram pick-up
and Ram van




Engine Family


VBM1.9VJGKFK





XBMXV02.8LEV






YBMXV02.8LEV







XCRXA360H31
XCRXA360J31




Emission Problem / Remedy


Due to erosion of the expansion mat (packaging mat;
in the 3-way catalytic converter a monolith may
become loose, causing an irritating rattling noise.
Depending on the degree of deterioration, the Check
Engine Light will come on.
Remedy: BMW will replace the catalytic converter
with a new, improved version.
The retaining lugs, used to secure the thermostat
element of the engine coolant thermostat, may
break. The problem is indicated by coolant
temperature gauge fluctuations and low heater
output into the passenger compartment. The check
engine light illuminates.
Remedy: BMW will replace the engine coolant
thermostat with a new, improved version.
The retaining lugs, used to secure the thermostat
element of the engine coolant thermostat, may
break. The problem is indicated by coolant
temperature gauge fluctuations and low heater
output into the passenger compartment. The check
engine light illuminates.
Remedy: BMW will replace the engine coolant
thermostat with a new, improved version.
Due to a software calibration error, the On-Board
Diagnostic (OBD) catalyst monitor may not identify a
catalyst with deteriorated emission performance,
which exceeds the allowable regulatory limits.
Remedy: Diamler/Chrysler will reprogram the
Powertrain Control Module.
Number of
Vehicles recalled
by engine family
11,015





73,535






144,364







6,771
9,785




Sales Area


SOS





SOS






SOS







CA




Total number of
vehicles recalled

11,015





73,535






144,364







16,556




                                                                                                         Page 1
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                         2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*
Recall Campaigns
                                                                                                                                                      http://www.epa.gov/otaq/cert/recall/
DAIMLER/CHRYSLER

















DAIMLER/CHRYSLER








FORD





A02

















A06








OOE13





1815

















1816








1587





V

















V








V





12/24/2001

















12/24/2001








1/22/2001





2002
2002
2002















2002








2001





Grand
Cherokee
















Grand
Cherokee








Cougar





2CRXT0242240
2CRXT04.02D2
2CRXT04.72D2















2CRXT0242240
2CRXT04.02D2
2CRXT04.72D2







1FMXV02.0VD5





2002 MY Grand Cherokees are equipped with an On-
Board Refueling Vapor Recovery (ORVR) system,
which directs vented refueling vapors into the
evaporative canister located behind the left rear
wheel housing. When the canister is filled with water,
it cannot vent displaced vapor, effictively stopping
the flow of liquid fuel and potentially resulting in fuel
spilling out of the filler tube when refueling. It was
found that the canister vent hose could be
inadvertently bent down during installation of the
canister assembly thereby allowing water from wet
oavement to fill the canister. This was found to take
about 30 miles.
Remedy: Chrysler will inspect the Onboard
Refueling Vapor Recovery (ORVR) system vent
hose routing and the fuel filler inlet check valve. The
vapor canister assembly and/or fuel tank will be
replaced if necessary.
The fuel inlet check valve may stick in the partially
open position. This condition could cause fuel to spill
out of the filler tube when refueling the fuel tank.Jt
was established that a certain assembly orientation
of the valve components combined with fuel swell
could create an interference fit, possibly allowing the
valve to remain partially open.
Remedy: For vehicles produced after September
14, 2001. Chryslerwill inspect the fuel filler inlet
check valve and replace the fuel tank if necessary.
Some 2001 cars may have been built with 2000
model year powertrain Control Modules.
Remedy: The dealer will update the On Board
Diagnostic (OBD II) monitoring strategy by
oerforming a Powertrain Control Module (PCM)
reprogramming procedure. This will bring the vehicle
into compliance with Frderal and California ON Board
Diagnostic II (OBD II standards).
6,657
19,954
11,272















1,900
6,052
4,291







534





CL(CA+NL)

















CL(CA+NL)
FED/NL FED/NL








SOS





37,883

















12,243








534





                                                                                                         Page 2
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                         2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*
Recall Campaigns
                                                                                                                                                      http://www.epa.gov/otaq/cert/recall/
FORD






GENERAL MOTORS





HYUNDAI









ISUZU






01E15






01037





41









01E-001






1740






1647





1551









1743






V






V





V









V






7/1/2001






6/22/2001





10/25/2001









8/31/2001






2001






1997
1998
1999
2000





2001









2001






Taurus, Mercury
Sable





Cadillac Catera





Sonata









Rodeo Sport
Rodeo





1FMXV03.0VF9






VGM3.0VJGFEK
WGMXV03.0061
XGMXV03.0061
YGMXV03.0061





1HYXV02.4E2S









1SZXT02.22LK






Affected vehicles have a software implementation
error in the powertrain control module that causes
the vehicle to operate with gasoline adaptive strategy
regardless of the level of alcohol in the fuel. The
PCM will be reprogrammed with the correct strategy.
Remedy: The powertrain control module (PCM) will
be reprogrammed with the correct strategy.
A hole may develop in the hose between the
Secondary Air Injection Check Valve and the
Secondary Air Injection Shut-off Valve. The hole is
caused by a chemical de-polymerization of the
rubber material from the inside of the hose, when
exposed to exhaust condensate and high
temperatures over a long period of time.
Remedy: General Motors will inspect the Secondary
Air Injection (SAI) hose and replace it if necessary.
Some vehicles with 2.4L engines and automatic
transmissions may experience diagnostic trouble
codes (DTC) problems when displayed on a
"generic" scan tool. This is caused by a logic error in
the Transmission Control Module (TCM).
Remedy: No parts will be replaced during this
campaign. The campaign procedures will involve
reprograming the Transmission Control Module
TCM) by use of a new Hi-Scan Pro tool that will be
made available to each Hyundai dealer before the
middle of October.
The OBD evaporative leak detection monitor may
terminate ("timeout') prior to completing the intended
diagnostic, and therefore may not detect a leak in the
evaporative system.
Remedy: To correct this condition, Isuzu dealers will
install a new OBD II calibration that will prevent the
evaporative monitor from terminating prematurely.
28,132






26,110
27,570
13,785
1,589





2,904









8,386






SOS






SOS





SOS









SOS






28,132






69,054





2,904









8,386






                                                                                                         Pages
                                                                                                                                                                                                     10/31/2002 1:50 PM

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                         2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*
Recall Campaigns
                                                                                                                                                      http://www.epa.gov/otaq/cert/recall/
JAGUAR












HONDA/ACURA



KIA







R493
T493











AHCERT-
210356



SC022







1466












1646



1494







I












V



V







9/15/2001












1/17/2001



10/19/2001







1995
1995
1996
1997
1996
1997







2001



1999







XJS, XJ6, XJR












Civic



Sportage







SJC4.0VJGFEK
SJC4.0VJGAEK
TJC4.0VJGKGK
VJC4.0VJGKGK
TJC4.0VJGFGK
VJC4.0VJGKHK







1HNXV01.7YJ9
1HNXV01.7YJ9



XKMXT02.0B02







The MIL illuminates and any of the following DTCs
are stored: P0400, P1400, P1401, P1408, P1409.
Carbon deposits were causing the EGR pintle shaft
to stick in the bushing.
Remedy: Jaguar will carry out a number of
modifications which will include the installation of a
new improved EGR valve and gasket, replacement
of a computer chip (PROM) located in the Engine
Control Module (ECM), which controls the operation
of the EGR valve and replace the throttle return
spring for certain VIN ranges. The new chip contains
revised operation strategies that incorporate a
cleaning cycle of the EGR valve.
A power surge may damage components in the
ECM/PCM.
Remedy: The ECM is replaced with a new one
which has an improved electric circuit to prevent LSI
damage.
Some car owners have complained of noise coming
from the underbody of the car. The noise has been
found to be caused by a cracked weld between the
catalyst body and the tapered outlet flange. The
failure of the weld is caused by a lack of welding
depth.
Remedy: KIA Motors America, Inc. will replace the
Manifold Catalytic Converter at no charge.
17067
749
15,589
10,412
511
469







30941
995



36,510







SOS












NF



SOS







44,797












31,936



36,510







                                                                                                         Page 4
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                         2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*
Recall Campaigns
                                                                                                                                                      http://www.epa.gov/otaq/cert/recall/
NISSAN/INFINITI















ROLLS ROYCE

















SATURN





12/18/2000















RE 01/02

















01-E-01





1640















1649

















1712





V















V

















V





2/5/2001















4/16/2001

















5/1/2001





1993
1994
1994
1995
1996
1997
1998









2000
2001

















2001





Quest















Corniche,
Azure,
Continental T, R
and SC















LS/LW





PNS3.0T5FEA5
RNS3.088GAFA
RNS3.028GDEA
SNS3.028GFEA
TNS3.028GKEK
VNS3.028GKEK
WNSXT03.0A4A









YRRXV06.7TUR
1RRXV06.7TUR

















1GMXV02.4022





The fuel tank vent hose allows air to vent from the
fuel tank during refueling. It is not part of the engine
fuel delivery system and not subject to constant fuel
flow. On some Quest vehicles, cracks have
developed in the vent hose. If (1) the fuel tank is
overfilled contrary to the Owner's Manual
instructions, not allowing excess fuel in the vent hose
to flow back into the tank, (2) the vehicle is driven
only a short distance after refueling and (3) there is
significant heating of the fuel tank, the fuel in the tank
can expand into the vent hose and leak significant
amounts of fuel if a large crack exists. If this should
occur in an enclosed area in the presence of an
external ingnition source, a fire could result.
Remedy: The vent hose will be replaced with a new
oartwith different material specifications.
In the event fuel vapors stored in the vehicle's
evaporative emission control system are vented into
the air from the leak detection filter located adjacent
to the front wheel well on the driver's side, some of
the vapor could enter a body cavity behind the rocker
oanel on the driver's side. The evaporative emission
control system is designed for the purpose of venting
air, and under normal vehicle operating conditions,
no vapor is emitted and could accumulate in body
cavities. However, if vapor is emitted and the vapor
in the body cavity reaches a certain concentration,
the resulting air/vapor mixture could be ignited in the
event the central window operating mechanism is
activated.
Remedy: The company will remedy the defect by
affixing a plated mild steel extension pipe to the leak
detection filter which will ensure that any vapor
emanating from the vehicle's evaporative emission
control system is vented to the outside.
Vehicles have a risk of increased evaporative
emissions. The vehicles were produced with an
intermediate fitting and seals between the fuel feed
oipe and the fuel rail assembly that could result in
:uel seepage.
Remedy: Saturn Will replace the intermediate fuel
rail fitting and seals at no charge to the owner.
41,982
15,630
33,992
65,811
46,453
52,220
18,525









218
175

















98





SOS















SOS

















FED





274,613















393

















98





                                                                                                         Pages
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                            2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*
Recall Campaigns
                                                                                                                                                                          http://www.epa.gov/otaq/cert/recall/
SUBARU






TOYOTA/LEXUS






VOLKSWAGEN/AUDI










WXW-80






10B






WA










1504






1615






1805










V






V






I










2/7/2001






7/31/2001






12/31/2001










2000
2001





2001






1999
1999
2000
2000
2001
2001





Forester
Legacy,
Impreza




Highlander






Golf, Jetta, New
Beetle









YFJXV02.5JEH
1FJXV02.5JEH





1TYXT02.4FFP






XVWXV02.0222
XVWXV02.0227
YVWXV02.0222
YVWXV02.0227
1VWXV02.0227
1VWXV02.0222





Some cars may experience air-fuel ratio sensor
element cracking due to thermal stress and an open
heater circuit. The open heater circuit condition
results from ceramic dust remaining after drilling the
heater seat hole during the manufacturing process.
Remedy: Subaru will replace the front oxygen (air-
fuel ratio) sensor with an improved part.
MIL illumination related to the Air Fuel ratio sensor
(P1130, P1150, P0171, P0174, etc.). This is caused
by an internal crack of the Air Fuel ratio sensor due
to sudden thermal stress when the engine is started
in cold ambient temperature.
Remedy: Toyota will reprogram the engine control
computer and confirm proper Air-Fuel Ratio Sensor
operation on the affected vehicles.
An application problem exists which is associated
with the location of the oxygen sensor in certain MY
1999 through 2001 2.0L engines. The pre-oxygen
sensor is mounted in the exhaust manifold, and
under certain cold and damp ambient conditions,
thermal shock can take place, cracking the internal
ceramic element of the oxygen sensor.
Remedy: VW will check the vehicle's emission
control system for proper function, reset electronically
the engine's control module and replace the oxygen
sensor, if necessary.
106,990
11,905





700






59783
83,140
63,942
88,136
12,989
13,046





SOS






CL(CA+NL)






SOS
CL(CA+NL)
SOS
CL(CA+NL)
CL(CA+NL)
SOS





118,895






700






321,036










                      Type:

                      O-Ordered by EPA

                      I- Manufacturer voluntary Action with EPA Influence

                      V- Voluntary Action by Manufacturer



                      Sales Area:

                      SOS- 50 State

                      FED - Federal states (all altitude)
                      CA - California
                      NF - CLEAN FUEL VEH + NLEV(ASTR) + CA
                      CL- California + NLEV (all states)
                      FED/NLEV  northeast states (all altitude)
                      NE+CA - NLEV northeast states + California

   *For the purposes of this report only, a Recall Campaign is a direct owner notification requesting or recommending that the
 vehicle be brought into a service facility for inspection and/or repair regardless of whether there is an indication of failure.  For
  the purposes of this report only, a Voluntary Service Campaign is a direct owner notification alerting the owner of a potential
 problem should there be an indication of failure, and how the problem will be remedied by the manufacturer should the problem
  effect the owner's vehicle.  However,  under 40 CFR 85.1902 (d), any repair, adjustment, or modification program voluntarily
 initiated by a manufacturer to remedy any emission-related defect for which direct owner notification is provided is defined as a
                                           Voluntary Emissions Recall.
Total Number of Vehicles recalled:
                                       1,233,584
Number of recalls by type:
                                  O:  0

                                  I:   2

                                  V: 18
                                                                                                                       Page 6
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          2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*
Voluntary Service Campaigns
                                                                                                                                  http://www.epa.gov/otaq/cert/recall/
Mfr.

HYUNDAI
















KIA



TOYOTA/LEXUS


Mfr. Number

44
















SC019



1A1


EPA#

1776
















1711



1710


Type

V
















V



V


Date of owner
Notification
3/26/2001
















3/23/2001



8/31/2001


Model
year
1997
1997
1997
1997
1998














2001



2000
2001


Vehicle or
Engine Class
Sonata
















Optima



CNG Camry


Engine Family

VHY2.0VJG2EK
VHY2.0VJGFFK
VHY3.0V8G1EK
VHY3.0V8GFFK
WHYXV02.01SD














1 KMXV02.4D01



YTYXV02.2PPA
1TYXV02.2PP2


Emission Problem / Remedy

Some 1997 and 1998 MY Hyundai
Sonata vehicles have experienced
small stress cracks in the fuel tanks
due to excessive vacuum applied to
the fuel tanks of these vehicles.
After prolonged exposure to the
excessive vacuum, a small crack
may develop on the upper fuel tank.
The vehicle driver may notice a
gasoline odor.
Remedy: If the fuel tank is cracked
it will be replaced. Hyundai will also
replace the canister two-way valve
filter assembly with a new canister
air intake system that will be
repositioned to prevent its becoming
contaminated, which will prevent an
excessive amount of vacuum from
developing inside the fuel tank.
Under certain operating conditions,
the engine timing belt could jump on
Optimas equipped with four-cylinder
engines resulting in rough engine
idle and/or engine damage.
Remedy: Hyundai will replace the
timing belt cover at no charge.
The engine in affected vehicles may
not start because the pressure
sensor in the fuel delivery system
will detect an incomplete seal and
prevent fuel flow.
Remedy: Toyota will replace the
fuel main tube connector.
Number of Vehicles by
engine family
2,576
11,247
1,476
4,485
10,590














5,524



166
85


Sales Area

CA
FED
CA
FED
FED














SOS



SOS


Total number
of vehicles
30,374
















5,524



251


F.Lamitola
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                   2001 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns performed on Light-Duty vehicles and Light-Duty Trucks*

Voluntary Service Campaigns                                                                                                                                   http://www.epa.gov/otaq/cert/recall/
                   Type:
                                                                                                                                                Total number of vehicles in Manufacturer
                                                                                                                                                         Service Campaigns:               36,149
                   l-lnfluenced Voluntary Action by manufacturer
                   V-Voluntary Action by manufacturer

                   Sales Area:
                   SOS- 50 State
                   FED - Federal states (all altitude)
                   CA - California
                   CL- California + NLEV (all states)
                   FED/NLEV northeast states (all altitude)
                   NE+CA - NLEV northeast states + California

*For the purposes of this report only, a Recall Campaign  is a direct owner notification requesting or recommending that the
vehicle be brought into a service facility for inspection and/or repair regardless of whether there is an indication of failure.  For
the purposes of this report only, a Voluntary Service Campaign is a direct owner notification alerting the owner of a potential
problem should there be an indication of failure, and how the problem will be remedied by the manufacturer should the
problem effect the owner's vehicle.  EPA recognizes that manufacturers may wish to voluntarily notify their customers of
potential issues for which service may be required._However, under 40 CFR 85.1902  (d), any repair, adjustment, or
modification program voluntarily initiated by a manufacturer to remedy any emission-related defect for which direct owner
notification is provided is defined as a Voluntary Emissions Recall.
Number of Campaigns by type:
                                      V: 3
Total number of vehicles
Effected by recalls and
service campaigns:
                                                                                                                                                                                          1,269,733
        F.Lamitola
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