&EPA
Air and Radiation                   EPA420-B-04-018
                        December 2004
  United States
  Environmental Protection
  Agency
          2003 Annual Summary of
          Emission Related
          Recalls and Voluntary
          Service Campaigns
          Performed on Light-Duty
          Vehicles and Light-Duty
          Trucks

-------
                                               EPA420-B-04-018
                                                 December 2004
2003 Annual Summary of Emission Related Recalls and
Voluntary Service Campaigns Performed on Light-Duty
             Vehicles and Light-Duty Trucks
                 Certification and Compliance Division
                 Office of Transportation and Air Quality
                 U.S. Environmental Protection Agency

-------
   2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and Light-Duty Trucks*
                                                           Recall Campaigns
Mfr.


BENTLEY


BMW







BMW




BMW










DAIMLER/CHRYSLER






DAIMLER/CHRYSLER








Mfr.Recall
Number

SC03/01


03V- 124







03E-A01




03V-240










C15






C23








EPA#


2046


2047







2061




2089










2048






2090








Type


V


V







V




V










V






V








Owners
Notification

4/5/2003


5/5/2003







7/1/2003




7/8/2003










5/5/2003






10/6/2003








MY


2002
2003


2003







2002
2003



2002
2003









2003






2003








Vehicle or Engine
Class

Arnage T; Arnage R;
Arnage RL


325i; 325Q; 325i Touring







745i, 745Li




745i, 745Li










Jeep Liberty






Concorde; 300M; Intrepid








Engine Family


2RRXV06.7TTC
3BEXV06.7TTC


3BMXV02.5M56







2BMXV04.4LEV
3BMXV04.4LEV



2BMXV04.4LEV
3BMXV04.4LEV









3CRXT02.43DO
3CRXT03.72ZO





3CRXV03.5VDO








Problem Description


Bentley Motors Inc. will replace a specific batch of exhaust gas temperature
sensors that have the potential to malfunction and illuminate the Malfunction
Indicator light (MIL), due to an improper solder joint in the sensors
electronic control unit.
Remedy: Replace exhaust pas temperature sensor.
The potential defect involves the electronic programming of the digital
engine management control unit with regard to engine idle control. With the
engine running, and the vehicle at rest (i.e. after the tank ventilation
diagnosis has been performed), an increase of engine idle speed (up to
1 ,300 rpm) may be detected by the driver.
Remedy: BMW has decided to implement a safety-related Recall
Campaign 03V-124 to reprogram the digital engine management control
unit of the potentially affected vehicles free of charge to the customer.
Because of production process failures, the ignition coil of one supplier
(Bremi) may have an internal insulation break-down in the primary electric
circuit, the secondary electric circuit and/or a disruptive discharge.
Remedy: BMW has decided to implement a Voluntary Emission Recall
Campaign to replace all ignition coils with a new improved version.
The potential defect involves the programming of the digital engine
management control unit. Specifically, due to a software error, a
desynchronization of the valvetronic motors for engine banks 1 and 2 may
occur. If this occurs, it would cause a rough-running engine. If this
happens, the check engine light will illuminate, and the message "engine
malfunction, Drive with moderation" will appear in the vehicle's instrument
cluster message display area. In certain extreme cases, the engine could
stall. In those cases, the Driver may not be able to restart the engine.
Remedy: BMW has decided to implement a safety-related Recall
campaign 03V-240 to reprogram the digital engine management control
unit.
Certain 2003 Model Year Jeep Liberty vehicles were manufactured with fuel
pump module components that did not conform to tolerance specifications
required of the part supplier. The resulting increase in fuel system pressure
may lead to increased exhaust emissions.
Remedy: DaimlerChrysler will conduct a Voluntary Emission Recall (C15)
of the suspected vehicles and replace the fuel pump module if it is
determined to be part of the affected population.
Some 2003 model year Chrysler Concorde, 300M, and Dodge Intrepid
vehicles have Vehicle emission Control Information (VECI) labels which
retained the vacuum operated Secondary Runner Valve (SRV) schematic
from the 2002 model year. The 2003 model year SRV is electrically
operated.
Remedy: A new VECI lable will be sent to the vehicle onwner. Owner can
have dealer install label. The 2003 service manual, now available on their
service information website, shows the SRV in its proper place on the
manifold with the proper electrical connections.
Affected
Vehicles

178


1,056







18207
2121



3840
1630









619






21,386








Sales Area


CL(CA+NLEV ALLS)


50S







NF(CFV+CA+NL)




NF(CFV+CA+NL)










CL(CA+NLEV ALLS)
50S





CL(CA+NLEV ALLS)








Total Number of
Vehicles
Recalled
178


1056







20,328




5470










619






21386








EPA420-B-04-018
                                                                                                                           December 2004

-------
   2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and Light-Duty Trucks*
                                                           Recall Campaigns
Mfr.


DAIMLER/CHRYSLER






DAIMLER/CHRYSLER




GENERAL MOTORS






GENERAL MOTORS








GENERAL MOTORS



HONDA/ACURA










HONDA/ACURA



Mfr.Recall
Number

006






C27




1038






3005








3048



PUV-02-
022.00









V-03-001-
00&V-03-001-
01

EPA#


2123






2132




1645






2035








2149



1957










2031



Type


V






V




V






V








V



V










V



Owners
Notification

8/10/2003






9/9/2003




4/21/2003






3/30/2003








9/30/2003



5/23/2003










1/28/2003



MY


2001
2002
2002
2003





2003




1996






2002
2002
2003







2004



2000
2000
2001
2001
2001
2002
2002
2002
2003
2003
2003
2003



Vehicle or Engine
Class

Sebring/Stratus Coupe
Sebring/Stratus Coupe
Sebring/Stratus Coupe
Sebring/Stratus Coupe





Dodge Viper




W Platform






Seville, DeVille,
Eldorado, Aurora








Malibu



3.2TL
3.2TL
3.2CL3.2TL;
3.2CL3.2TL;
3.2CL3.2TL;
3.2CL3.2TL;
3.2CL3.2TL;
3.2CL3.2TL;
3.2CL3.2TL
3.2CL3.2TL;
3.2CL 3.2TL:
Odyssey



Engine Family


1DSXV03.0GNG
2DSXV03.0GNS
2DSXV03.0GNF
3DSXV03.0GNS





3CRXV08.3VB1




TGM3.4VJGFEK






2GMXV04.6065
2GMXV04.6066
3GMXV04.6065







4GMXV03.8041



YHNXV03.2GF3
YHNXV03.2GL4
1HNXV03.2H7A
1HNXV03.2K88
1HNXV03.2K5U
2HNXV03.2X21
2HNXV03.2HYT
2HNXV03.2JYC
3HNXV03.2AYC
3HNXV03.2BYT
3HNXV03.2CYC
3HNXT03.5ZAP



Problem Description


The vacuum hose routing diagram on affected vehicles is incorrect. Due to
an update in the purge solenoid valve made in model year 2001 (2000 MY
for Eclipse and Galant models) and the position of the pins to the surge
tank and charcoal canister, the routing for the vacuum hoses changed.
However, the label indication the proper hose routing was inadvertently left
the same.
Remedy: A corrected VECI label was sent directly to owners with
instructions on where to install the new label. The owner may also have the
label installed by their dealership as stated in the Technical Service Bulletin.
The fuel pump wiring harness on early build 2003 Model Year Dodge Vipers
may become chafed by the fuel tank heat shield.
Remedy: DaimlerChrysler will conduct a Safety Recall (C27) to install a
protective covering on the fuel pump wiring harness and rubber tubing
around the inner edde of the heat shield hole.
Corrosion of the solenoid internal to the AIR pump may cause failure of the
AIR system. When the solenoid is activated during normal operation, the
AIR pump air is allowed to flow into the engine. High exhaust backpressure
may cause moist exhaust gas to enter the AIR pump. The moisture can
lead to corrosion of the solenoid. When corrosion causes the solenoid to
fail, the AIR pump air is not allowed to flow into the engine.
Remedy: Replace the air pump solenoid.
Affected vehicles may experience a loss of signal from the Powertrain
Control Module (PCM) to the ignition coils. Because the PCM drivers for
the ignition coils are done via 2 driver chips for the eight coils, a misfire
condition may occur in groups of four cylinders (1-7-4-6- or 2-3-5-8). The
condition is due to an incoherency between the PCM hardware and
software.
Remedy: Revised software that corrects for the loss of PCM output to the
ignition coils has been incorporated into production. General Motors will
initiate a Voluntary Emissions Recall to install the revised software into the
affected vehicles.
OBD system will become disabled above 25-35 MPH due to an invalid
rough road input to the PCM.
Remedy: Vehicles will be recalled and reprogrammed to corect this
condition.
Under certain driving conditions, 3rd gear clutch disks of an automatic
transmission may be damaged due to high temperature. This results in
insufficient engagement of clutch. The causes of failure are inappropriate
calibration of the powertrain control module and insufficient quality of some
clutch plates. The MIL may illuminate.
Remedy: PCM is replaced with new recalibrated unit to improve
performance and durability. Customers who received a remanufactured
transmission without a new PCM will be notified by letter to contact an
Acura dealer.


Some fuel tanks were manufacturerd with surface imperfections that could
allow fuel to leak from the tank.
Remedy: The fuel tank will be inspected and if found to show surface
imperfections the tank will be replaced.
Affected
Vehicles

41090
11977
13244
5670





69




40,632






126495
875
56985







1683



34051
33236
23165
26760
23614
20801
14320
31525
35614
12367
35430
8,847



Sales Area


CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)





50S




50S






50S








FC(Tier2 Fed&Cal)



NL(NLEV ALLS)
CL(CA+NLEVALLS
NL(NLEV ALLS))
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
50S



Total Number of
Vehicles
Recalled
71981






69




40632






184355








1683



290883










8847



EPA420-B-04-018
                                                                                                                           December 2004

-------
   2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and Light-Duty Trucks*
                                                           Recall Campaigns
Mfr.


HONDA/ACURA




HYUNDAI




KIA






LAND ROVER








MAZDA







MITSUBISHI/D-STAR












Mfr.Recall
Number

PUV-03-003-
00




60




SC021






B112








1303F







EMR-003-001












EPA#


2070




2086




2032






2111








2024







2069












Type


V




V




V






V








V







V












Owners
Notification

8/26/2003




6/30/2003




3/28/2003






10/24/2003








7/16/2003







9/24/2003












MY


2003




2001
2002
2003


2001
2002





1997
1998







2003
2003
2003
2003
2003



2003
2003











Vehicle or Engine
Class

Accord




Elantra
Elantra
Tiburon


Optima






Discovery
Discovery







Mazda 6
Mazda 6
Mazda 6
Mazda 6
Miata



Evolution
Outlander











Engine Family


3HNXV02.4JBP
3HNXV02.4KCP




1HYXV02.0X4C
2HYXV02.0XUC
3HYXV02.0CUC


1KMXV02.5D01
2KMXV02.7E01





VLR4.058GFFK
WLRXT04.6001







3TKXV02.3CJM
3TKXV02.3EJ1
3TKXV03.0CLM
3TKXV03.0EL1
3TKXV01.8CJA



3MTXV02.0GTS
3MTXT02.4GNG











Problem Description


Under certain driving conditions, the connecting pipe for Positive
Crankcase Ventilation may be disconnected between the cylinder head
cover and the air flow tube. For test group 3HNXVO2.4KCP, the MIL may
also illuminate.
Remedy: Improved connecting pipe and rubber tube will be applied to the
assembly line. Honda will notify owners to bring vehicle into dealership to
replace with new components free of charae.
The underhood emission control system label is in error citing an incorrect
in-use emission standard.
Remedy: Hyundia will send a recall letter instructing owner to install a new
(VECI) label enclosed with this letter. Owner can take to a dealer for
installation.
During the vehicle production period frm 9/9/2000 through 8/17/2000,
improperly manufactured Crankshaft Position Sensors were installed in
some Optima models equipped with 2.5 and 2.7L V-6 engines. The cases
of these components did not meet dimensional specifications, Epoxy
flowed between the gaps within the cases and contacted the printed circuit
board resulting in cracking of the circuit board capacitor.
Remedy: Replacement of the Crankshaft Position Sensor.
Right hand exhaust manifolds are being replaced in the field due to noise
complaints from the vehicle owners. The manifolds are cracking due to
being subjected to excessive mechanical stress caused by thermal cycling
of the cast iron.
Remedy: A change to the material specification of the manifold was
introduced during the 1998 MY that reduces the shrinkage and hence its
susceptibility to failure. Land Rover will send a recall letter to owners of the
affected vehicles of a service action to replace the manifold on vehicles
manufactured durina the build oeriod with the current desian
During evaporative leak monitoring immediately after IG key off, change in
the electrical load such as keyless entry use may affect the monitoring
system. This may result in the rapid rise in the electrical load of Diagnostic
Module for Tank Leakage (DMTL) pump and, thus causes the Malfunction
Indicator Light (MIL) illumination since the same phenomenon is detected
by the blockage in DMTL system.
Remedy: The Powertrain Control Module will be replaced with a modified
unit
Water may enter the front floorboard area from openings in the side sill or
upper dash area. This water may collect under the seat and cause
electrical corrosion to occur in the harness connector that contains the
wiring for the rear oxygen (O2) sensor . In a worst-case scenario, the floor
harmess connector when subjected to water intrusion may result in
inoperability or malfunction of the O2 sensor.
Remedy: The Outlander will be subject to a safety recall that affects the
harness to the stop lamps and seat belt pre-tensioner as well. Those
vehicles will have their rear O2 sensor harnesses inspected for corrosion at
the same time as the stop lamps and seat belt pre-tensioner harnesses are
inspected under the safety recall. A seperate recall letter will be sent to
owners of affected Lancer Evolution vehicles for the O2 sensor harness
corrosion problem. Corroded components will be replaced.
Affected
Vehicles

211474
29243




8055
7,724
1,228


8107
3375





9706
11,930







12900
4,700
5,800
2,300
10,500



2764
43649











Sales Area


50S




CA
CA
CA


50S






CA
50S







CA+NF(CFV+CA+NL)
CA
NF(CFV+CA+NL)
CA
NF(CFV+CA+NL)



CL(CA+NLEVALLS)
CL(CA+NLEVALLS)











Total Number of
Vehicles
Recalled
240717




17007




11482






21636








36200







46413












EPA420-B-04-018
                                                                                                                           December 2004

-------
   2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and Light-Duty Trucks*
                                                           Recall Campaigns
Mfr.
NISSAN/INFINITI
NISSAN/INFINITI
NISSAN/INFINITI
SUBARU
TOYOTA/LEXUS
TOYOTA/LEXUS
Mfr.Recall
Number
R2013
R2020
03V-084
VWVO-98
30B&SSC-30B
30C
EPA#
1851
2007
2056
2129
2038
2059
Type
V
V
V
V
V
V
Owners
Notification
1/15/2003
1/15/2003
5/1/2003
8/28/2003
4/4/2003&
4/4/2003
5/15/2003
MY
2002
2001
2001
2001
2002
2002
2004
2004
2002
2002
2003
2003
2003
Vehicle or Engine
Class
Xterra
Frontier 2WD
Xterra 2WD
Frontier 2WD;Xterra
2WD
Altima; Sentra
SentraSE Spec V
Legacy, Outback
Legacy, Outback
Celica
Celica
Celica
Celica
4Runner
Engine Family
2NSXT03.3C5A
1NSXT02.4C4A
1NSXT02.4C4B
1NSXT03.3C5A
2NSXV02.5D5A
2NSXV02.5C5A
4FJXV02.5NKR
4FJXV02.5MJS
2TYXV01.8DDB
2TYXV01.8DDC
3TYXV01.8FFB
3TYXV01.8DDC
3TYXT04.0FFP
Problem Description
Under high engine load after a cold start during cold ambient temperature,
there is a possibility that the MIL will come on for DTC P0103 (Airflow Meter
High). This condition can occur because the voltage level generated by the
air flow meter under these conditions is higher than originally expected.
Remedy: The electronic control module will be reprogrammed to prevent
this incident from occuring.
2001 MY Nissan Frontier and Xterra vehicles produced from October 29,
2000 to January 13, 2001 . The vehicles produced during this time period
may have a fuel tank inlet shutter valve that does not meet the sealing
performance specification.
Remedy: Nissan will replace the fuel tank inlet shutter valve with a new
one.
Certain engine operation conditions may cause the pre-catalyst to overheat
and damage the catalyst substrate. If substrate particles enter the
combustion chamber via combustion pulses on lengthy deceleration, they
may score the cylinder walls, resulting in increased oil consumption. If the
engine oil is not checked on a periodic basis as specified in the Owner's
Manual and drops below the low level, and the driver continues to operate
the vehicle ignoring noticeable engine noise, engine damage may occur
which could result in a fire.
Remedy: The protruding portion of the exhaust pipe hanger pin will be
removed. Heat shield(s) will be installed on the pre-catalyst and exhaust
tube
Subaru is conduction a safety recall (VWVO-98) to address possible fuel
leak due to a loose or out of position clamp on the fuel hose that connects
the fuel filler pipe to the fuel tank.
Remedy: All potentially affected 2004 MY vehicles that were shipped
previous to the indentification of this problem will be inspected and, if
necessary, repaired at no cost to the owner.
A check valve installed at the lower end of the fuel filler pipe at the fuel tank
prevents fuel back flow from the tank when the refueling operation is
completed. Due to improper assembly of the check valve, a condition may
occur where the valve may fall off into the tank during refueling and fuel spill
out (spit back) occurs when the auto-stop mechanism of the gas pump
nozzle is activated.
Remedy: Safety recall. Toyota dealers will inspect the fuel tank to evaluate
if the check valve has moved and if so will replace the fuel tank.
There is a pulsation damper installed at the end of the fuel rail to reduce
fuel pulsation generated by fuel injection. During the manufacturing
process of this pulsation damper, a diaphragm in the damper may be
damaged resulting in a defective part. If a defective damper is installed in
a vehicle the possibility exists that fuel could leak from the pulsation
damper into the engine compartment.
Remedy: A voluntary safety recall has been conducted on the subject
vehicles to replace the pulsation damper.
Affected
Vehicles
5000
44,000
171722
8,926
7,874
6959
1627
5,467
995
29,482
Sales Area
CL(CA+NL)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CA
FED
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CE(CA+NLEV)
Total Number of
Vehicles
Recalled
5000
44000
180648
7874
15048
29482
EPA420-B-04-018
                                                                                                                           December 2004

-------
   2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and Light-Duty Trucks*
                                                           Recall Campaigns
Mfr.


TOYOTA/LEXUS





TOYOTA/LEXUS










VOLKSWAGEN/AUDI










VOLKSWAGEN/AUDI


















Mfr.Recall
Number

3LE





30I/3LF










LT










WG


















EPA#


2087





2121










1906










1975


















Type


V





V










V










V


















Owners
Notification

7/7/2003





8/1/2003










10/3/2003










6/13/2003


















MY


2004





2003
2003
2003
2003
2003
2003
2003
2003
2003
2003
2003
1999
2000
2001
2001







2001
2001
2001
2001
2001
2001
2002
2002
2002
2002
2002
2002
2002
2003
2003
2003
2003
2003
2003
Vehicle or Engine
Class

RX330





LS430, GS430, SC430
LX470
GX470
ES300
Landcruiser
4Runner
Sequoia
Camry
Camry
Celica
Prius
A8 / A8 Quattro A8
Quattro
S8 Quattro
A8 Quattro







A4/Passat1.8TULEVTT
Quattro 1.8T LEV TT
1.8TLEV
TT1.8T
NewBeetlelST
Euro Van VR6
A4/ Passat 1.8TU LEV
GolfJettaNBetITT
A4/6 Cabrio 3.0L Jetta
GLI;Golf,GTIJettaGLI;
Golf GTI
Passat W8
Euro Van VR6
A4/A63.0LV6
Golf;Jeta+Wag;N Betl
A4; Passat 1.8TU LEV
Passat W8
Euro Van VR6
Jetta GLI: Golf GTI
Engine Family


4TYXT03.3PEM





3TYXV04.3HHA
3TYXT04.7FBV
3TYXT04.7FFP
3TYXV03.0HHA
3TYXT04.7FBV
3TYXT04.7FFP
3TYXT04.7HBW
3TYXT02.4LXB
3TYXT02.4HHA
3TYXV01.8FFE
3TYXV01.5LH1
XADXV04.2325
YADXV04.2335
1ADXV04.2335
1ADXV04.2245







1ADXV01.8342
1ADXV01.8347
1ADXV01.8346
1ADXV01.8336
1VWXV01.8229
1VWXV02.8225
2ADXV01.8342
2ADXV01.8346
2ADXV03.0344
2VWXV02.8228
2VWXV02.8224
2VWXV04.0229
2VWXV02.8225
3ADXV03.0344
3ADXV01.8346
3ADXV01.8342
3VWXV04.0229
3VWXV02.8225
3VWXV02.8228
Problem Description


For the exhaust manifold converter sub-assembly a mat is wrapped around
the catalytic converter substraite to secure the substrate in place within the
assembly. Due to improper installation of the mat during converter
assembly the catalytic converter substrate can slide and contact the sides
of the steel converter shell resulting in an objectionable buzzing noise.
Remedy: Toyota will conduct a "Special Service Campaign" of the subject
vehicles by a notification recall letter, to bring the vehicle in for replacement
of the converter assemblies at no cost.
An electrical contact inside the throttle body motor may be inadequate and
cause a malfunction. If this malfunction occurs, the MIL will illuminate
(P2101/P21 19) on the dash and the engine ECM will store a trouble code,
and place the vehicle into a "limp-home" mode.
Remedy: Toyota will conduct a Special Service Campaign of the subject
vehicles, by a recall notification letter to bring the vehicle in for inspection
and/or replacement of the throttle body assembly at no cost.




MIL light on - DTC code P0442 (Emission Control System - vapor leak).
Audi has identified two different failure modes, which for the Audi A8 and A8
Quattro: 1) Plastic Cover Distorted which may result in a minute
evaporative or fuel leak between the cover or the cover seal and the fuel
tank sending unit. MIL is activated by an opening of 1 mm diameter. 2)
Poor sealing of Fuel Sending Unit Assembly may no longer perform its
intended function of completely sealing the connection between the sending
unit and the fuel tank. MIL is activated by an opening of 1mm diameter.
Remedy: VW will initiate a Voluntary Emissions Recall campaign to
inspect and replace all subject fuel tank sealing rings on the applicable Audi
vehicles
One or more of the vehicles individual cylinder ignition coils may become
inoperable, causing the engine to misfire and illuminate the Malfunction
Indicator Lamp (MIL). Two seperate failure modes may exist within the
defective ignition coils tested, (1) Coil housing damage caused during the
assembly process at the applicable VW or Audi factory, (2) Coil design
shortcomings by the supplier. Part numbers involved: 06B905 115G, 06B
905115Hand07C 905115.
Remedy: An improved ignition coil, part number 06B 905 1 15 J, was
introduced as a new service replacement part during the last week of July
2002. VW has issued a recall notification letter to bring vehicle in for
replacement of the ignition coils.








Affected
Vehicles

12,500





2,930










7,288










66194
1777
2,771
16,476
17,157
3,657
82,297
69,829
27,316
6,078
5,319
1,416
7,010
6,628
17,049
40,070
1,942
5,501
9.364
Sales Area


50S





CL(CA+NLEVALLS)
50S
NL(NLEV ALLSJ+CA
CL(CA+NLEVALLS)
50S
NL(NLEV ALLSJ+CA
50S
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
NL(NLEV ALLS)+CA
50S
50S
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)







CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
Total Number of
Vehicles
Recalled
12500





2930










7288










387851


















EPA420-B-04-018
                                                                                                                           December 2004

-------
   2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and Light-Duty Trucks*
                                                           Recall Campaigns
Mfr.
VOLKSWAGEN/AUDI















Mfr.Recall
Number
E R Circular
LZ














EPA#
2130


Type:
Type
V



Owners
Notification
12/28/2003



O- Ordered by EPA
MY
2003




Vehicle or Engine
Class
A6/Allroad




I- Manufacturer voluntary Action with EPA Influence
V- Voluntary Action by Manufacturer
Sales Area:

CL- California + NLEV (all States)
FED- Federal States (all altitude)
CA- California










FED/NLEV- Northeast States (all Altitude)
NL(NLEV ALLS) - NLEV + All States

NE+CA- NLEV Northeast States+California
CE- California + NLEV


Engine Family
3ADXV02.7343














Tor 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. 1 902 (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.
Problem Description
An application problem exists which is associated with the location of the
oxygen sensor in MY 2003 Audi 2.7L Bi Turbo engines. The pre-oxygen
sensors are mounted in the outlet flange of the turbo chargers and under
certain cold and damp ambient conditions; thermal shock can take place,
cracking the internal ceramic element of the oxygen sensor.
Remedy: Audi will remedy the problem with the start of MY 2004
production. MIL'S are set when this condition is senced by the OBD system
and the 2003 vehicles are expected to be returned for service. Audi issued
a recall notification letter to bring vehicle in for reset of the engine control
module and to replace the oxygen sensor if necessary.

Affected
Vehicles
9,897

Sales Area
CL(CA+NLEVALLS)

Total number of vehicles voluntarily recalled:















Number of Recalls by type:
Ordered
Influenced
Voluntary








0
0
30








Total Number of
Vehicles
Recalled
9897

1,723,460













EPA420-B-04-018
                                                                                                                           December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.


DAIMLER/CHRYSLER






FORD

















































Mfr. Recall Number


C24






01-37D

















































EPA#


2133






1788

















































Type


vsc






vsc

















































Owners
Notification

9/22/2003






1/1/2003

















































MY


2003






2000
2000
2000
2000
2000
2001





2001



2001
2001





2001





2001





2001



2001



2001



2001





Vehicle or Engine Class


Dodge Neon SRT-4






Taurus, Sable
Taurus, Sable
Taurus, Sable
Taurus, Sable
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Engine Fam.


3CRXV02.4VD1






YFMXV03.0VBA
YFMXV03.0VBK
YFMXV03.0VF3
YFMXV03.0VF5
YFMXV03.0VF9
1FMXT02.01BF





1FMXV03.8VFA



2FMXT02.01BF
1FMXT04.26BF





1FMXT04.66BA





1FMXT02.01F5





1FMXV02.0VF3



1FMXV02.0VJ3



1FMXV02.5VD5



1FMXT03.01F6





Problem description


The engine oil recommended in the Owner's Manual for the
2003 Model Year Dodge Neon SRT-4 (synthetic 10W30) is
not the oil used during emission certification and fuel
economy testing(mineral based 5W30).
Remedy: DaimlerChrysler will conduct a Customer
Satisfaction Notification (C24) to mail an Owner's Manual
insert with the correct engine oil recommendation (mineral
based 5W30) to customers of the affected vehicles.
Inoperative EGR pressure sensors due to corrosion under
the passivation layer, damage from voltage spikes, or mask
misalignment during component manufacturing.
Remedy: Owner notification program to extend the warranty
miles for certain 2000 and 2001 model year vehicles.














































Affected
Veh's.

3,323






4,024,387

















































Sales Area


503






FED
FED
503
503
SOS
FED





FED



FED
FED





FED





503





503



503



503



503





Total number
of vehicles
recalled
3323






4,024,387

















































EPA420-B-04-018
                                                                                                                                                   December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.

























































Mfr. Recall Number

























































EPA#

























































Type

























































Owners
Notification

























































MY
2001


2001



2001





2001



2001





2001





2001



2001





2001





2001





2001





Vehicle or Engine Class
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Escape"', WinSstarl F
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Engine Fam.
1FMXV03.0VF3


1FMXV03.0VF9



1FMXT04.01F5





1FMXV03.8VH5



1FMXT04.01F6





1FMXT04.02F4





1FMXT04.02F5



1FMXT04.02F6





1FMXT04.02F7





1FMXT04.22F5





1FMXT04.2HG5





Problem description

























































Affected
Veh's.

























































Sales Area
503


503



503





503



503





503





503



503





503





503





503





Total number
of vehicles
recalled

























































EPA420-B-04-018
                                                                                                                                                   December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.

























































Mfr. Recall Number

























































EPA#

























































Type

























































Owners
Notification

























































MY
2001




2001





2001





2001





2001





2001



2001



2001



2001



2001





2001





Vehicle or Engine Class
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Engine Fam.
1FMXT04.2JG5




1FMXT04.66F5





1FMXT04.66F7





1FMXT04.6PF5





1FMXT04.6PF6





1FMXV04.6VF5



1FMXV04.6VF7



1FMXV04.6VP5



1FMXV02.0VJ2



1FMXT04.25BF





1FMXT03.82J5





Problem description

























































Affected
Veh's.

























































Sales Area
503




503





503





503





503





503



503



503



CA



FED





503





Total number
of vehicles
recalled

























































EPA420-B-04-018
                                                                                                                                                   December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.


























































Mfr. Recall Number


























































EPA#


























































Type


























































Owners
Notification


























































MY
2001




2001





2001





2001





2001
2002





2002



2002





2002





2002



2002



2002



Vehicle or Engine Class
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Focus
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Engine Fam.
1FMXT03.82J6




1FMXT04.6JF5





1FMXT05.4PF5





1FMXT05.4RF8





1FMXV02.0VD5
2FMXT04.25BF





2FMXV03.8VBF



2FMXT04.26BF





2FMXT02.01F5





2FMXV02.0VF3



2FMXV02.0VF4



2FMXV02.5VD5



Problem description


























































Affected
Veh's.


























































Sales Area
503




503





503





503





503
FED





FED



FED





503





503



503



503



Total number
of vehicles
recalled


























































EPA420-B-04-018
                                                                              10
                                                                                                                                                   December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.




























































Mfr. Recall Number




























































EPA#




























































Type




























































Owners
Notification




























































MY
2002




2002
2002
2002
2002



2002





2002





2002





2002





2002





2002





2002





2002





Vehicle or Engine Class
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Focus, Cougar, Taurus,
Focus, Cougar, Taurus,
Focus, Cougar, Taurus,
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Engine Fam.
2FMXT03.01F7




2FMXV03.0VF3
2FMXV03.0VF4
2FMXV03.0VF8
2FMXV03.0VF9



2FMXT03.82J7





2FMXT04.01F6





2FMXT04.02F3





2FMXT04.02F5





2FMXT04.02F8





2FMXT04.22H5





2FMXT04.22H6





2FMXT04.2HF5





Problem description




























































Affected
Veh's.




























































Sales Area
503




503
503
503
503



503





503





503





503





503





503





503





503





Total number
of vehicles
recalled




























































EPA420-B-04-018
                                                                                                                                                   December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.

























































Mfr. Recall Number

























































EPA#

























































Type

























































Owners
Notification

























































MY
2002




2002





2002





2002





2002



2002



2002





2002





2002



2002



2002





Vehicle or Engine Class
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazda B-Series,
E and F Series,
Expedition, F Series
Trucks
Engine Fam.
2FMXT04.2JF5




2FMXT04.62F5





2FMXT04.62F6





2FMXT04.66F7





2FMXV04.6VF5



2FMXV04.6VP5



2FMXT05.4PF6





2FMXT05.4RF6





2FMXV02.0VJ4



2FMXV03.8VH5



2FMXT02.0VF6





Problem description

























































Affected
Veh's.

























































Sales Area
503




503





503





503





503



503



503





503





CA



503



503





Total number
of vehicles
recalled

























































EPA420-B-04-018
                                                                              12
                                                                                                                                                   December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.











































HONDA/ACURA







HYUNDAI








Mfr. Recall Number











































PUV-03-009-00







V03








EPA#











































2071







1741








Type











































I-VSC







I-VSC








Owners
Notification










































8/1/2003







3/6/2003








MY


2002


2002



2002



2002





2002





2002





2002





2002





2003







1998








Vehicle or Engine Class


Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Focus, Cougar, Taurus,
Sable, Mustang, Crown
Victoria, Grand Marquis,
Lincoln Town Car
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Escape, Windstar,
Explorer, Mountaineer,
Ranger, Mazca B-Series,
E and F Series,
Expedition, E and F
Series Trucks
Accord







Accent








Engine Fam.


2FMXV02.0VJ3


2FMXV02.0VF2



2FMXV02.0VJ4



2FMXT03.01F6





2FMXT04.02F6





2FMXT05.4PF5





2FMXT05.4RF8





2FMXT04.02F7





3HNXV02.4JBP







WHYXV01.51AS
WHYXV01.52GM







Problem description











































Under certain driving conditions, evaporative canister may
intake water from the drain pipe. When the charcoal
absorbs a certain amount of water or the water in the
canister freezes, the MIL illuminates.
Remedy: Improved canister drain joint will be applied to the
assembly line. Honda will notify owners to bring vehicle into
dealership to replace the canister drain joint with new
components of improved design.
Vehicles have experienced abnormal exhaust seepage as a
result of minor cracking of the exhaust manifold between the
number one and two cylinder exhaust ports.
Remedy: Hyundai has improved the manufacturing process
of the exhaust manifold to ensure the thickness of the
casting is increased in the problem areas and has modified
the material alloy content of the exhaust manifold casting to
improve durability. Warranty extended to 10 years without
limitation on vehicle mileage.
Affected
Veh's.










































60,748







23380
8792







Sales Area


503


503



503



503





503





503





503





503





503







FED
CA







Total number
of vehicles
recalled









































60748







32172








EPA420-B-04-018
                                                                              13
                                                                                                                                                   December 2004

-------
              2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                 Voluntary Service Campaigns
Mfr.


HYUNDAI









HYUNDAI











HYUNDAI











KIA












Mfr. Recall Number


V03









V01 & V02











SC026











SC028/SC037












EPA#


1967









1773











1992











1915












Type


I-VSC









I-VSC











vsc











vsc












Owners
Notification

3/6/2003









10/13/2003











3/31/2003











3/28/2003 and
4/1/2004











MY


1999









1999
2000
2001
2001
2002
2002
2003






2002
2003










2001












Vehicle or Engine Class


Accent









Sonata
Sonata
Sonata
Santa Fe
Sonata
Santa Fe
Tiburon






Spectra











Optima












Engine Fam.


XHYXV01.51XF
XHYXV01.52XC









XHYXV02.52ES
YHYXV02.5G2S
1HYXV02.5F2S
1HYXT02.7M3S
2HYXV02.7FLS
2HYXT02.7MLS
3HYXV02.7KLS






2KMXV01.8A05
3KMXV01.8A06










1KMXV02.5D01












Problem description


Some 1999 model year Hyundai Accents, equipped with
1 .5L engines have experienced exhaust manifold cracks.
The cracking may occur in certain areas of the manifold due
to insufficient thickness of the exhaust manifold casting in
those areas.
Remedy: Hyundai has improved the manufacturing process
of the exhaust manifold to ensure the thickness of the
casting is increased in the problem areas and has modified
the material alloy content of the exhaust manifold casting to
improve durability. Warranty extended to 10 years without
limitation on vehicle mileage.
Oxygen sensor malfunction-The main cause of failure was a
slow response signal output characterized by a long
switching time and low amplitude. These abnormal signal
outputs are caused by contamination of the oxygen sensor
from oil or other exhaust impurities that are present during
operation.
Remedy: To correct this, an additional calcium coating has
been applied to the surface of the sensor which will protect
the sensor from contamination. The ECM will be
reprogramed to reflect the characteristics of the improved
sensor. Also, Hyundai has improved the ECM logic related
to the control of oxygen sensor heating. (Improvement of
titanium oxygen sensor heating logic)
The fault determined by the OBD system is a small
evaporative system leak (P0442) caused by cracking of the
plastic at the nipple of the ORVR valve hose connection
leading to the Roll Over Valve (ROV). The OBD system is
capable of noting the cracking condition and sets the MIL
with a small evaporative leak fault code.
Remedy: The repair will involve a replacement of the ORVR
valve with a strengthened nipple design, and a rerouting of
the hose to avoid the interference. Kia will notify owners to
be aware of the potential of this problem under a voluntary
service campaign and will repair their vehicles at no cost to
the owner.
Some 2001 model year KIA Optima's equipped with 2.5 liter
engines have experienced a malfunction indicator light
illumination as a result of oxygen sensor malfunction. The
main cause of failure was a slow response signal output
characterized by a long switching time and low amplitude.
These abnormal signal outputs are caused by contamination
of the oxygen sensor from oil or other exhaust impurities that
are present during operation.
Remedy: KIA has improved the oxygen sensor by adding an
additional calcium coating to the surface of the sensor which
will protect the sensor from contamination. The ECM will be
reprogrammed to reflect the characteristics of the improved
sensor.
Affected
Veh's.

18861
18618









17344
32007
23173
37391
48657
69250
24949






64665
12903










8,107












Sales Area


FED
CE(CA+NLEV)









SOS











CL(CA+NLEVALLS)











SOS












Total number
of vehicles
recalled
37479









252771











77568











8,107












EPA420-B-04-018
                                                                                                                                                   December 2004

-------
                     2003 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-duty Vehicles and Light-duty Trucks*
                                                                                               Voluntary Service Campaigns
Mfr.
VOLKSWAGEN/AUDI


























Mfr. Recall Number



























EPA#
1717


























Type
I-VSC


























Owners
Notification
11/14/2003


























MY
1999
1999
1999
1999
1999
1999
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
Vehicle or Engine Class
Golf, Jetta, New Beetle
Golf, Jetta, New Beetle
New Beetle (1.8T)
Jetta, GTI (VR6)
Passat, Audi (1.8T)
NewBtle, Golf /Jetta A4
Golf, Jetta, New Beetle
Golf, Jetta, New Beetle
New Beetle (1.8T)
Golf, Jetta, TT(1.8T)
Passat, Audi (1.8T)
Jetta, GTI (VR6)
New Beetle, Golf, Jetta
A8 4.2, A6 4.2 Quattro
A6 2.7 BIT, S4 Quattro
A6 2.7 BIT, S4 Quattro
Golf, Jetta, New Beetle
Golf, Jetta, New Beetle
Golf, Jetta, New Beetle
Golf, Jetta, New Beetle
New Beetle (1.8T)
GTI, Jetta (VR6)
Passat, Audi A4 1.8T
Passat (1.8T-170HP)
Golf, Jetta, New BtleJT
Golf, Jetta, New BtleJT
TT
New Beetle, Golf, Jetta
Engine Fam.
XVWXV02.0222
XVWXV02.0227
XVWXV01.8228
XVWGV02.8224
XADXV01.8322
XVWXV01.9233
YVWXV02.0222
YVWXV02.0227
YVWXV01 .8228
YADXV01 .8336
YADXV01 .8332
YVWXV02.8224
YVWXV01 .9233
YADXV04.2335
YADXV02.7333
YADXV02.7339
1VWXV02.0222
1VWXV02.0223
1VWXV02.0226
1VWXV02.0227
1VWXV01.8229
1VWXV02.8224
1ADXV01.8342
1ADXV01.8343
1ADXV01.8346
1ADXV01.8336
1ADXV01.8347
1VWXV01.9234
Problem description
Analysis of component parts showed the following problems:
Electrical pin connectors at the air mass sensor have
incorrect plating; Air mass sensor filaments were
contaminated with silicone. Silicone gel seeped from the
electrical housing of the air mass sensor. The following are
DTC codes reported by technicians: PI 128 17536, P1570
17978, P1142 17550, P0101 16485, P1557 17965.
Remedy: Extend warranty for Mass air flow sensors to 7
years or 70,000 miles. Replace air flow sensor at no charge
within time and mileage limits.


















Affected
Veh's.
59766
84485
3244
10559
52528
8827
67383
92946
26541
20070
50026
36448
21666
6079
6903
8500
26441
60173
32476
14316
6594
37320
41802
24392
53873
24628
1777
22535
Sales Area
FED
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CA
FED
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CA
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
FED
CL(CA+NLEVALLS)
NL(NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CL(CA+NLEVALLS)
CA
Total number
of vehicles
recalled
902298


























                                         Type:
                                         O- Ordered by EPA
                                         I-VSC- Manufacturer voluntary Action with EPA Influence
                                         VSC- Voluntary Action by Manufacturer
                                                                                                                                                     Total number of vehicles VSC&I-VSC recalled:             5,398,853
                                                                                                                                                            Total number of vehicles Effected by Voluntary
                                                                                                                                                                Recalls and Voluntary Service Campaigns:     7,122,313
                                         Sales Area:
                                         CL- California + NLEV(all States)
                                         FED- Federal States (all altitude)
                                         CA- California
                                         FED/NLEV- Northeast States (all Altitude)
                                         NE+CA- NLEV Northeast States+California
                                         CE- California + NLEV
                     *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.
                                                                                                                       Total number of Influenced Voluntary Emission Recalls
                                                                                                                               and Influenced Voluntary Service Campaigns:
                                                                                                                             Total number of Voluntary Emission Recalls and
                                                                                                                                            Voluntary Service Campaigns:
EPA420-B-04-018
                                                                                                                 15
                                                                                                                                                                                                                     December 2004

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