2000 Calendar Year Emissions Related Recall Repor


            United States         Air and Radiation         EPA420-B-02-002
            Environmental Protection                    October 2002
            Agency
f/EPA     2000 Calendar Year
            Emissions Related
            Recall Report
                                       > Printed on Recycled Paper

-------
                                                                    EPA420-B-02-002
                                                                         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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                                                                                                                                              http://www.epa.gov/otaq/cert/recall/
                                                      2000 Calendar Year Emission Related Recalls
Mfr.


BMW





BMW









BMW













DAIMLER/CHRYSLER





DAIMLER/CHRYSLER




DAIMLER/CHRYSLER






Mfr.
Recall
Number
99E-A03





D217









OOE-A01













851





•850




852






EPA#


1467





1497









1485/1486













1459





1375




1460






Record Type


VERR





DR VERR









VERR













DR VERR





DR VERR




DR VERR






Date of
Owner
Notification
2/8/2000





5/22/2000









8/16/2000













2/4/2000





2/8/2000




2/18/2000






Model
Year

1995
1996
1997
1998
1999




1997
1998
1999







1999
2000












2000





2000




2000






Vehicle Class


750IL, 850Q





Land Rover Discovery
Series 1








323i
323Q
328i
328Q
Z3 roadster 2.3
Z3 roadster 2.8
Z3 Coupe 2.8
528i
528T





Sebring Convertible





Dakota (AN)




CNG/LPG Dodge Ram Van
& Wagon






Engine Family


SBM5.4V8GAEK
TBM5.4V8GFEK
VBM5.4V8GFEK
WBMXV05 4M73
XBMXV05.4LEV




VLR4.658GFFK
WLRXT04.6001
XLRXT04.6001







XBMXV02.8LEV
YBMXV02.8LEV












YCRXV02.5VBO





YCRXT0287232
YCRXT04.72B2




YCRXT05.26RC






Emission Problem


The crankcase ventilation valve's internal
membrane/diaphragm, installed in the V12 engines
of the affected vehicles, is not sufficiently resistant
functionally impaired, affecting driveability and
causing the CHECK ENGINE light to illuminate.
The corrective measure consists of installation of
two redesigned and improved crankcase ventilation
valves.
Due to tolerance stack-up condition during the
manufacturing process some vehicles will
experience filler neck recession causing an
inadequate seal with the fuel cap. This creates an
evaporative emission leak path.
Remedy: Problem will be resolved by introducing
an additional plastic ring to the filler neck between
the grommet location lip on the neck and the
existing grommet. Also the filler neck will be
repositioned.
Due to a software failure, the oxygen sensor
readiness code may not set which prevents the
illumination of the Check Engine light in case of an
oxygen sensor malfunction.
Check Engine Light will illuminate in case of an
OBD malfunction.
Also, on some vehicles there is a communication
conflict between the engine control module and the
transmission controle module. This may lead to
difficulties in or may prevent communication
Detween the enigne control module and an off-board
scan tool.
Remedy: BMW will reprogram the engine control
module with latest up-to-date softward
The vehicles, certified for sale in U.S. federal
regions, were equipped with (VECI) labels intended
For vehicles to be sold in Canada. The VECI did not
state the vehicle conforms to "U.S. EPA ...
regulations."
Remedy: DaimlerChrysler will conduct a recall to
replace the VECI labels on the affected vehicles.
Electrical interference from the ignition system may
cause communication problems between the
Powertrain Control Module (PCM) and a scan tool.
Remedy: DaimlerChrysler will install a software
patch in the PCM to prevent the module from
dropping communication with a can tool.
Due to an error in the On- Board Diagnostic (OBD)
programming, the Malfunction Indicator Light (MIL)
may light due to a false failure (torque converter
ockup), or fail to light when a failure (pressure
jansducer) occurs.
Remedy: DaimlerChrysler will conduct a recall of
:he affected vehicles not already repaired, to reflash
the Powertrain Control Module (PCM) with the
appropriate OBD calibration.
Number of
Vehicles Recalled
by engine family
609
1212
676
1572
397




10,357
13,221
5,541







57,300
24,700












97





303
3,066




323






Total number of
vehicles recalled

4,466





29,119









82,000













97





3,369




323






Sales Area


50S





SOS









SOS













FED/NL





FED/NL/CL




CA/CF






Page 1 of 5
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                                                                                                                                              http://www.epa.gov/otaq/cert/recall/
                                                      2000 Calendar Year Emission Related Recalls
Mfr.


DAIMLER/CHRYSLER






DAIMLER/CHRYSLER

















DAIMLER/CHRYSLER

















DAIMLER/CHRYSLER





Mfr.
Recall
Number
882






8592

















8591

















867





EPA#


1500






1408

















1408

















1476





Record Type


DR VERR






VERR

















VERR

















DR VERR





Date of
Owner
Notification
2/18/2000






3/15/2000

















3/15/2000

















4/24/2000





Model
Year

1999
2000






2000

















2000

















2000





Vehicle Class


Jeep Grand Cherokee






Dodge Ram Vans
Ram Wagon
Dakota
Ram Pickup
Durango
Jeep Wrangler
Cherokee
Grand Cherokee










Dodge Ram Vans
Ram Wagon
Dakota
Ram Pickup
Durango
Jeep Wrangler
Cherokee
Grand Cherokee











Ram Pickups (BR/BE)





Engine Family


XCRXT04.02BO
XCRXT0242230
XCRXT04.72B1
XCRXT0287231
YCRXT04.02BO
YCRXT0242230
YCRXT04.72B1
YCRXT0287231
YCRXA0239H1 1
YCRXA0360H1 1
YCRXA0360H32
YCRXA0360J11
YCRXT0150120
YCRXT02.51 BO
YCRXT03.92C1
YCRXT03.95B2
YCRXT0360221
YCRXT04.01 BO
YCRXT04.02BO
YCRXT04.72B1
YCRXT04.72B2
YCRXT04.75B1
YCRXT05.92B1
YCRXT05.95B2
YCRXT05.96B1
YCRXT05.9AB1
YCRXA0239H1 1
YCRXA0360H11
YCRXA0360H32
YCRXA0360J11
YCRXT0150120
YCRXT02.51BO
YCRXT03.92C1
YCRXT03.95B2
YCRXT0360221
YCRXT04.01BO
YCRXT04.02BO
YCRXT04.72B1
YCRXT04.72B2
YCRXT04.75B1
YCRXT05.92B1
YCRXT05.95B1
YCRXT05.95B2
YCRXT05.96B1
YCRXT05.9AB1
YCRXA0488J11
YCRXA0488K1 1





Emission Problem


Due to a defect in the software, the On- Board
Diagnostic (OBD) system readiness codes will not
reset to the "not ready condition after vehicle
maintenance utilizing a generic scan tool.
Remedy: DaimlerChrysler will conduct a recall of
:he affected vehicles to reflash the Powertrain
Control Module (PCM) with the appropriate OBD
software.
Due to a software error, the On-Board Diagnostic
(OBD) catalyst monitor will not run.

Remedy: Daimler/Chrysler will conduct a recall of
:he affected vehicles to install (reflash) a calibration
in the Powertrain Control Module (PCM) to enable
the catalyst monitor.











Due to a software error, the On-Board Diagnostic
(OBD) catalyst monitor will not run.

Remedy: Daimler/Chrysler will conduct a recall of
:he affected vehicles to install (reflash) a calibration
in the Powertrain Control Module (PCM) to enable
the catalyst monitor.












Due to an error in the ON-Board Diagnostic (OBD)
Drogramming the monitor may not detect a catalyst
with a failure that exceeds the permissible emission
level.
Remedy: DaimlerChrysler will conduct a recall of
the affected vehicles to reflash the Powertrain
Control Module (PCM) with the appropriate OBD
calibration.
Number of
Vehicles Recalled
by engine family
112,681
74,330
57,442
39,849
90,983
57,720
48,303
27,690
1.014
635
4,572
803
918
3
2,475
9
191
5
21
6
6
15
13
13
12
4
122
78
443
448
2,766
6,159
30,052
13,137
205
6,130
66,204
17,970
13,406
23,086
1,007
50,660
20,330
33,828
12,720
440
78





Total number of
vehicles recalled

508,998






10,715

















298,751

















518





Sales Area


FED/NL/CL/50S






CA
CA
CA
CA
SOS
FED
SOS
FED
SOS
FED
FED
FED
FED
FED
FED
FED
FED
FED
CA
CA
CA
CA
SOS
FED
SOS
FED
SOS
FED
FED
FED
FED
FED
FED
FED
FED
FED
FED
CA





Page 2 of 5
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http://www.epa.gov/otaq/cert/recall/
2000 Calendar Year Emission Related Recalls
Mfr.

DAIMLER/CHRYSLER

FERRARI

FORD

Mfr.
Recall
Number
876

873

963

OOE09

OOE08

EPA#

1499

1501

1579

1549

1498

1680

Record Type

DR VERR

VERR

Date of
Owner
Notification
6/7/2000

6/19/2000

12/12/2000

10/1/2000

4/3/2000

6/22/2000

Model
Year

2000

2001

1997
1998
1999

2000
2001

2000

Vehicle Class

Viper

Dodge Ram Pickups

Dakota

550 Maranello

Focus, Cougar

Lincoln LS

Engine Family

YCRXV08.0VB1

1CRXA0360H38

1CRXT02.51CO

VFE5.5VJGKEK
WFEX05.5KFK
XFEXV05.5KFK

YFMXV02.0VF3

YFMXV03.0VF2
YFMXV03.0VD2
YFMXV03.9VF5

Emission Problem

Due to an error in the calibration of the Powertrain
Control Module (PCM), the radiator cooling fan may
run continuously after initial vehicle warm-up.
Remedy: DaimlerChrysler will conduct a customer
satisfaction notification of the affected vehicles to
reflash the Powertrain Control Module(PCM) with
the appropriate calibration.
The vehicles, certified for sale in California, were
equipped with incorrect VECI labels. The VECI
abel which had been intended for the 5. 2L
California Ram pickup was applied to the 5. 9L and
vice versa. The label identifies the displacement of
:he vehicle, as well as the exhaust and evaporative
standards to which it was certified.
Remedy: DaimlerChrysler will supply a VECI label
with each owner letter for the owner to install on the
engine.
The orifice, which should have been installed in the
evaporative purge line betweeen the canister and
:he purge valve, was omitted.
Remedy: Daimler/Chrysler will install a new
evaporative purge orifice.
The OBD system detected in a few cars with low
mileage (2-3K miles), a false defect of the oxygen
sensors which were incorrectly identified as aged.
Accordingly the MIL was turned on and the
corresponding fault codes (P0133 and P0139) were
stored in the computer memory. The oxygen
sensors of the above mentioned cars were actually
not aged and are functioning properly. The MIL was
turned on without any emission related problems or
impacts.
Remedy: To avoid false detection of the aged
status for oxygen sensors, a recalibration of the
monitoring strategy for this function was introduced
in the OBD system. The remedy consists of
replacing the engine management electronic control
unit with an updated version.
Some 2000 and 2001 2.0L Focus and Cougar
Dassenger cars may have Fuel Injector Pressure
sensors with cracked or burst membranes due to ice
pushing on the membrane.
Remedy: Replacement of the Injector Pressure
Sensor (IPS) on the affected vehicles.
A fuel hose located in the fuel tank between the fuel
delivery module and a filter may develop holes or
cracks, causing a fuel leak and reduced fuel
delivery pressure.
Remedy: Ford will replace the fuel transfer hose
and clamp assemblyto correct the condition.
Number of
Vehicles Recalled
by engine family
132

188

1,900

103
154
258

51,700

1,714
3713
11,543

Total number of
vehicles recalled

132

188

1,900

515

51,700

16,970

Sales Area

SOS

Page 3 of 5
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                                                                                                                                              http://www.epa.gov/otaq/cert/recall/
                                                      2000 Calendar Year Emission Related Recalls
Mfr.


FORD







GENERAL MOTORS
















GENERAL MOTORS






HYUNDAI


JAGUAR







KIA






Mfr.
Recall
Number
OOE10







ML-GM747
















ML-GM700
99083





36


S-120







SC016
SC022






EPA#


1546







1503
















1445






1552


1409







1494






Record Type


DR VERR







DR VERR
















DR VERR






DR VERR


DR VERR







DR VERR






Date of
Owner
Notification
9/18/2000







5/15/2000
















10/9/2000






10/31/2000


1/4/2000







9/18/2000






Model
Year

2000







1997
1998
1999














1995
1996
1997




1997
1998


2000







1998
1999






Vehicle Class


Taurus (Flex Fuel)







"J" Series
















B -Platform
B -Platform
F,Band D -Platforms
F- Platform
F,Band D -Platforms


Accent


S-type














Engine Family


YFMXV03.0VF9







VGM2.2V8GKEK
VGM2.2V8G1EK
VGM2.2V8G2EK
VGM2.4VJGKEK
VGM2.4VJG1 EK
VGM2.4VJG2EK
WGMXV02.2021
WGMXV02.2022
WGMXV02.2023
WGMXV02.4024
WGMXV02.4025
WGMXV02.4026
XGMXV02.2021
XGMXV02.2022
XGMXV02.2023
XGMXV02.4026
XGMXV02.4027
VGM5.7V8G1 EK
VGM5.7V8GFEK
TGM5.7V8GFEK
S1G5.7V8GAHA
S1G5.7V8G1EA


VHY1.5VJGFFK
VHY1 .5VJG1 EK
WHYXV01.51AS
WHYXV01.52GM

YJCXV04.0CN5







WKMXT02.0B01
XKMXT02.0B02






Emission Problem


Some passenger cars may have fuel delivery
modules that can fail due to jammed impellers,
loose anti-siphon valves, or fusing of the pump
turbine to the pump bottom/top.
Remedy: The fuel delivery module has been
modified to correct the concerns which caused the
failures and has been released for production
usage. Field campaign OOE10 will be conducted to
install the improved fuel delivery module in vehicles
in the field.
Spark Plug wire failures have been occurring.
Usually the #2 and sometimes the #3 position wire
fails. The failures are typically unseated boots or
spread terminals caused by the wires having been
side loaded or pulled during the vehicle assembly
process.
Remedy: General Motors will install a protective
rubber splash shield arround the Powertrain Control
Module (PCM).








Corrosion of the solenoid internal to the AIR pump
may cause failure of the AIR system. When
corrosion causes the solenoid to fail, the AIR pump
air is not allowed to flow into the engine exhaust.
Remedy: A new AIR pump assembly kit that is
designed to protect the AIR pump system from
failing due to internal corrosion will be installed.
Some vehicles have experienced small vapor leaks
caused by excessive vacuum in the fuel tank.
Remedy: The fuel filler cap will be replaced with a
cap that reduces the amount of vacuum applied to
:he fuel tank.
There have been isolated instances of spurious
illumination of the MIL, accompanied by logging of
OBD code P0340 on 4.0L S-type vehicles in the
USA, Canada and Mexico. The code is flagged due
:o a software error which miscounts teeth between
:he two camshaft sensors.
Remedy: Jaguar will reflash the Powertrain Control
Module (PCM) to correct this problem. This update
will reinstate the DTC P0340 code in the PCM.
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: Replacement of MCC (Manifold Catalytic
Converter)
Number of
Vehicles Recalled
by engine family
127,800







127,121
3,303
25,289
29,014
761
3,436
106,045
2,976
23,801
24,187
582
4,899
39,388
2,319
22,910
8,234
3,875
4,630
27,179
30,225
54,958
5,493


2442
1,098
23,347
8,792

9,000







20,439
36,510






Total number of
vehicles recalled

127,800







428,140
















122,485






35,679


9,000







56,949






Sales Area


50S







FED
CA
CA
FED
CA
CA
FED
CA
CA
FED
CA
CA
FED
CA
CA
FED
CA
CA
FED
SOS
SOS
CA


FED
CA
FED
CA

SOS







SOS






Page 4 of 5
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                                                                                                                                                                        http://www.epa.gov/otaq/cert/recall/
                                                                2000 Calendar Year Emission Related Recalls
Mfr.


KIA

KIA







Mfr.
Recall
Number
SC015

SC010







EPA#


1517

1355







Record Type


DR VERR

DR VERR







Date of
Owner
Notification
11/13/2000

11/31/00







Model
Year

1998
1999

1998
1999






Vehicle Class


Sephia

Spsortage '98
Sephia '98
Sportage '99
Sephia '99




Engine Family


WKMXV01 .8A01
XKMXV01.8A02

WKMXT02.0B01
WKMXT01.8A01
XKMXT02.0B02
XKMXT01 .8A02




Emission Problem


Some cars may have a faulty ORVR valve that may
cause the vehicle to be difficult to refuel.
Remedy: Kia will replace the ORVR valve in the
affected vehicles.
Due to defective programming, the ECU is unable
to access output functions such as error codes.
Remedy: A special label will be mailed to vehicle
owners that will inform technicians of the necessity
:o have the engine running in order to read OBD II
diagnostic trouble codes. The owners will be given
instructions on where to install the labels or given
the option to take their vehicle to Kia for installation .
Number of
Vehicles Recalled
by engine family
44,192
55,945

26,435
45,935
38,230
57,024




Total number of
vehicles recalled

100,137

167,624







Sales Area


50S
SOS

SOS
SOS
SOS
SOS




Record Type:
DR - Defect Report
VERR - Vonuntary Recall
without EPA investigation
 I - Influenced - Voluntary Recall
after EPA investigation

 O - Ordered Recall after EPA
investigation
    In some cases vehicle
 breakdown was done by Model
   Year (MY) only (i.e. 95MY,
         OOMY, etc.)
Sales Area:


CL - California + NLEV (all states)
FED - Federal states (all altitude)

CA - California


FED/NL - Federal or NLEV states (all altitude)

NE+CA - NLEV northeast states + California
                                             Total Number of Vehicles by type:
                                                      2,057,575
Total Number
of (Recalls):

Voluntary: 24
Influenced: 0

 Ordered: 0
 Page 5 of 5
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