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
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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
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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
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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
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/
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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