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 ------- 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. ------- 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 10/31/2002 1:50 PM ------- 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 10/31/2002 1:50 PM ------- 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 ------- 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 10/31/2002 1:50 PM ------- 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 ------- 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 10/31/2002 1:50 PM ------- 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 Page/ 10/31/2002 1:50 PM ------- 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 PageE 10/31/2002 1:50 PM ------- |