2007 Annual Summary of Emission-
Related Recall and Voluntary Service
Campaigns Performed on Light-Duty
Vehicles and Light-Duty Trucks
United States
Environmental Protection
Agency
-------
2007 Annual Summary of
Emission-Related Recall and Voluntary
Service Campaigns Performed on Light-
Duty Vehicles and Light-Duty Trucks
Compliance and Innovative Strategies Division
Office of Transportation and Air Quality
U.S. Environmental Protection Agency
United States
Environmental Protection
Agency
EPA420-B-08-012
June 2008
-------
Abbreviations and Acronyms
Acronym/Term:
ALLS
CARB
CFV
DTC
ECU
EGR
MIL
MY
NHTSA
NLEV
OBD
PCM
TCM
TSB
VECI
VERR
VSC
Recall Type:
O
V
VSC
I
Sales Area:
60S
CL
CA
FA
FC
NF
NL
Definition:
All States
California Air Resources Board
Clean Fuel Vehicle
Diagnostic Trouble Code
Engine Control Unit
Exhaust Gas Recirculation
Malfunction Indicator Light
Model Year
National Highway Traffic Safety Administration
National Low Emission Vehicle
On-Board Diagnostics
Powertrain Control Module
Transmission Control Module
Technical Service Bulletin
Vehicle Emission Control Information
Voluntary Emissions Recall Report
Voluntary Servcie Campaign
Definition:
Ordered by EPA
Voluntary Recall by Manufacturer
Voluntary Service Campaign by Manufacturer
Manufacturer voluntary action with EPA Influence
Definition:
All states
CA + NLEV (ALLS)
California
Federal (all altitude)
FA + CA
CFV + NLEV (ALLS) + CA
NLEV-All States
Note:
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 affect 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.
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
BMW
Chrysler
Chrysler
Chrysler
Chrysler
Chrysler
Chrysler
Mfr. Recall
Number
07E-A01
2006-23-E (F31)
2006-27-E (F47)
2006-33-E (F49)
2007-4-E (G04)
2007-6-E (G06)
2007-8-E (G13)
EPA#
2955
2758
2806
2855
2878
2900
2922
Type
V
V
V
V
V
V
V
Owners
Notification
9/25/2007
8/15/2006
* Reported to
EPA on
2/15/2007
3/1/2007
1/1/2007
3/1/2007
3/1/2007
4/1/2007
MY
2007
2006
2006
2007
2007
2008
2007
Vehicle or Engine
Class
335 i, 335 i Coupe
Jeep Liberty
Chrysler 300, Dodge
Magnum, Dodge
Charger
Dodge Dakota
Chrysler Pacifica
Dodge Avenger
Jeep Grand
Cherokee
Engine Family
7BMXV03.0N54
6CRXT02.82RX
6CRXV03.5VEO
7CRXT04.7PEO
7CRXB0241M80
8CRXB0144M80
8CRXB0241M80
8CRXB02.4MEO
8CRXB04.0MEO
8CRXV0167M70
SCRXVO? 7MHP
7CRXT0226N73
7CRXT03.7NE3
Problem Description
Software errors inhibit the Digital Motor Electronics (DME)
from being able to detect certain emissions-related faults.
The service engine soon light may not illuminate to warn of
an emissions-related malfunction.
Remedy: Software errors were corrected for production and
BMW will initiate a (VERR) which includes owner notification
to reprogram the PCM. The corrective measure consists of a
software update in the Engine Control Unit (ECU) module to
address the OBD-related shortcomings. Vehicle owners will
be asked to make an appointment with an Authorized BMW
dealer to have the repair performed.
The On-Board Diagnostic (OBD) communications protocol
supported by the Transmission Control Module (TCM) on
some 2006 model year Jeep Liberty vehicles equipped with
2.8L diesel engines is not consistent with the protocol
supported with the Engine Control Unit (ECU). Some generic
scan tools may be able to communicate with either module
but not the other.
Remedy: Chrysler will conduct a voluntary emissions recall
to reprogram the TCM of the affected population with the
proper OBD communications protocol.
The metallic foil substrate of the pre-catalysts may fracture
and separate due to thermal cycling. Exhaust emissions may
exceed applicable standards if pre-catalyst separates. MIL
illumination will occur shortly after.
Remedy: Chrysler will conduct a voluntary emissions recall
to replace suspect catalyst assemblies and to reprogram the
Powertrain Control Module (PCM).
An inapplicable Vehicle Emissions Control Information
(VECI) label was affixed to some 2007 4.7L Dodge Dakota
vehicles.
Remedy: Chrysler will conduct a voluntary emissions recall
to replace the VECI label on affected vehicles.
Some 2007 MY Pacifica vehicles have power train control
modules with an incorrect oxygen sensor biasing calibration.
Remedy: Chrysler will conduct voluntary emissions recall to
reprogram power train control module.
An inapplicable Vehicle Emissions Control Information
(VECI) label was affixed to some early 2008 MY Dodge
Avengers.
Remedy: Chrysler will conduct a voluntary emissions recall
to replace the VECI label on the affected vehicles.
A Vehicle Emissions Control Information (VECI) label with
incorrect evaporative system information was affixed to some
2007 MY Jeep Grand Cherokee vehicles.
Remedy: Chrysler will conduct a voluntary emissions recall
to replace the VECI label on the affected vehicles. VECI
labels will be sent directly to the owners. If the owner is
concerned about installation of the label they may take the
vehicle to a dealership if they desire.
TSB
Affected
Vehicles
5,602
3,578
290
62
29
2,647
179
43
795
215
45
306
706
1,621
Sales Area
FC
FA
CA
FC(FA + CA)
FA
CA
CA
CA
FA
FA
CA
FA
CA
FA
Total
Number of
Vehicles
Recalled
5,602
3,578
352
29
2,647
1,583
2,327
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
Chrysler
Chrysler
Chrysler
Chrysler
Mfr. Recall
Number
2007-1 5-E (G23)
2007-28-E (G39)
2007-02-E (G30)
2007-01-E (G37)
EPA#
2960
3342
3349
3350
3352
3351
Type
V
V
V
V
Owners
Notification
6/21/2007
11/1/2007
10/1/2007
11/1/2007
MY
2007
2008
2007
2007
2007
2008
2008
2007
2007
2007
2007
2008
2008
2008
Vehicle or Engine
Class
Chrysler Sebring
Chrysler Sebring,
Dodge Avenger
Dodge Ram 2500,
3500,
Dodge Ram 1500
Sebring
Sebring
Sebring/Avenger
Sebring/Avenger
Dodge Ram
2500/3500
Dodge Ram 3500
Engine Family
7CRXV0167M70
7CRXB0241M80
7CRXB04.0ME1
7CRXV02.7MHP
8CRXB0241M80
8CRXV0167M70
8CRXB04.0MEO
8CRXV02.7MHP
7CRXK0345370
7CRXK05.7TXO
7CRXT0226P81
7CRXT0287P80
7CRXT0345P70
7CRXT03.7PJO
7CRXK05.7PEO
7CRXK04.7PJP
7CRXB0144M80
7CRXV02.4MEO
8CRXB0144M80
8CRXB02.4MEO
7CEXK040838W
7CEXK040848W
7CEXK06.7TXW
7CEXK06.7UXW
8CEXK06.7TXW
8CEXK06.7UXW
8CRXK06.7UXW
Problem Description
Under certain starting conditions some 2007 and 2008 model
year vehicles with Totally Integrated Power Modules (TIPM)
and automatic transmissions may have only a single forward
gear ratio available for the duration of the trip. This can
occur if the key is left in the ignition in the "Off" position for
greater than 45 seconds but less than 10 minutes before the
engine is started. The vehicle will start normally on the next
trip unless the specific start-up sequence is again followed.
Both emissions and drivability will be affected when vehicle
is stuck in one forward gear.
Remedy: Chrysler issued a voluntary emission recall to
reprogram the TIPM on affected vehicles.
The driver side cooling fan motor electrical connector could
become contaminated with engine coolant, which could lead
to electrical arching between the motor terminals, potentially
causing the fan to quit operating or the connector to overheat.
The problem was in the location of the electrical connector
which is beneath the overflow spout of the coolant recovery
bottle.
Remedy: Chrysler will conduct a safety recall to inspect the
connector for coolant, clean and repair as necessary. In
addition, Chrysler will relocate the cooling fan ground
terminal and install a wiring harness overlay.
The On-Board Diagnostic (OBD) system on these vehicles
may not detect a failed oxygen sensor or illuminate the MIL
as required and may cause these vehicles to fail an
Inspection Maintenance (Readiness) test and may not store
mileage as required for certain transmission faults. In
addition, the exhaust soot filter may fail due to cracks from
very high temperatures which result, in certain operating
conditions, from continued soot loading without adequate
regeneration.
Remedy: On Cummins' behalf, Chrysler will conduct a
recall, the oxygen sensor module must be replaced and the
Engine Control Module (ECU) reprogrammed. The new
software will also improve vehicle drivability and reduce the
potential for exhaust soot accumulation in the vehicle's
paniculate filter. Also, the "Readiness" issue was fixed in
production by a running change software calibration.
An inapplicable Vehicle Emissions Control Information
(VECI) label was installed on some early 2008 model year
Dodge Ram 3500 vehicles. Some 50-state certified 2008
model year vehicles were built with VECI labels that
incorrectly state "Not for sale in states with California
emissions standards".
Remedy: On Cummins' behalf, Chrysler will conduct a
voluntary emissions recall notification to replace the VECI
label on the affected vehicles.
TSB
Affected
Vehicles
2,051
385
1,985
11,212
884
1,979
2,340
5,606
46
153
17
25
2
83
309
395
13,925
44,271
12,130
32,894
5,054
28,076
3,829
27,896
11,160
7,386
4,660
Sales Area
CA
CA
FA
FA
CA
CA
FA
FA
CA
FA
CA
CA
CA
FA
FA
FA
CA
FA
CA
FA
CA
FA
CA
FC (FA + CA)
FC (FA + CA)
FC (FA + CA)
FC (FA + CA)
Total
Number of
Vehicles
Recalled
27,472
103,220
83,401
4,660
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
Ford
Ford
General Motors
General Motors
Mfr. Recall
Number
07E20
07E19
ML-MW206
ML-MW213
15301
EPA#
2638
2880
2823
2924
Type
V
I
V
V
Owners
Notification
3/22/2007
2/1 9/2007
1/29/2007
4/27/2007
MY
2006
2007
2006
2007
Vehicle or Engine
Class
Explorer/
Mountaineer
F-Series Flex Fuel
Vehicles
Chevrolet Cobalt
Saab 9-3 Convertible
Engine Family
6FMXT04.63EX
7FMXT05.44HF
6GMXV02.4029
7GMXV02.3001
Problem Description
The On-Board Diagnostic (OBD) system strategy may not
enable the Malfunction Indicator Light (MIL) for Output Shaft
Speed (OSS) sensor faults and MIL and Diagnostic Trouble
Codes (DTC) when the Engine Control Module (ECU) loses
communication with the Transmission Control Module (TCM).
Several problems can occur leading the vehicle operator to
seek service; vehicle in a single transmission gear, vehicle
will not crank, or vehicle will only operate in reverse, neutral
or third gear.
Remedy: Ford Motor Company issued a voluntary emissions
recall to reprogram the ECU.
Some trucks may have a dual threshold catalyst monitor
software strategy that disables the catalyst monitor when
switching from gasoline to E85 fuel or vice versa. This
software error may cause the vehicle to stop monitoring the
effectiveness of the catalytic converter and could allow
excessive emissions into the environment.
Remedy: The Powertrain Control Module (PCM) will be
recalibrated by a dealer at no charge to the owner.
The fuel injector used in this application on certain build
dates has a fuel seepage problem. Due to lack of adequate
process control at the supplier, cracks may develop at the
pole piece retention weld inside the fuel injectors. If a crack
propagates sufficiently, external fuel seepage may occur. The
most likely seepage path is through the injector overmold into
the injector connector pocket. Fuel seeping into the connector
pocket can either wick up inside the injector wiring or
hydraulically force the wiring connector from the injector.
Remedy: General Motors initiated a voluntary emissions
recall to install the revised injectors into the affected vehicles.
Injectors produced using the revised process, to eliminate the
internal cracking, are now available in production and
service.
Affected vehicles were built with a Vehicle Emissions Control
Information (VECI) label that has an incorrect emission test
group name 7GMXV02.0003 on the label. The correct test
group name should be 7GMXV02.3001 .
Remedy: A corrected VECI label is to be installed on the
affected vehicles. A new label will be sent with installation
instructions directly to customers of record. If the customers
desire they may bring the label to their dealer for installation
at no charge at any time through October 31, 2007.
TSB
Affected
Vehicles
20,500
22,400
58,916
8,633
Sales Area
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
Total
Number of
Vehicles
Recalled
20,500
22,400
58,916
8,633
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
General Motors
General Motors
General Motors
Honda/ Acura
Honda/ Acura
Mfr. Recall
Number
ML-MW220
07153
ML-MW239
ML-MW251
PUDR-Q49-00
07-028-00 (Q61)
EPA#
2975
3310
3337
2749
2873
3367
Type
V
V
V
V
V
Owners
Notification
6/8/2007
8/21/2007
10/30/2007
6/15/2007
11/19/2007
MY
2007
2007
2007
2002
2003
2004
2005
2006
2003
2004
2005
2005
Vehicle or Engine
Class
Cobalt
Chevrolet Uplander
SAAB 9-3
Insight
Civic Hybrid
Acura RSX
Engine Family
7GMXV02.4029
7GMXV02.2030
7GMXT03.9140
7GMXV02.3001
2HNXV01.02N4
3HNXV01.01A4
4HNXV01.02A6
5HNXV01.02A6
6HNXV01.0YJV
3HNXV01.34A5
4HNXV01.35A6
5HNXV01.33A6
5HNXV02.4KBP
Problem Description
An incorrect Tranmission Control Module (TCM) service
calibration was installed in the subject vehicles. The
installed TCM calibration could result in the torque converter
clutch hunting, causing 200-300 RPM engine speed variation,
and possible unpleasant shifts.
Remedy: General Motors will conduct a voluntary emissions
recall on the affected vehicles, to have the correct TCM
calibration installed.
Certain 2007 Chevrolet Uplander minivans equipped with the
3.9L engine were produced or serviced with calibrations that
do not allow the ethanol content of the fuel to be learned as
required for correct flex fuel operation. Fueling these vehicles
with E85 fuel could result in illumination of the Malfunction
Indicator Light (MIL) and rough engine operation.
Remedy: General Motors will conduct a voluntary emissions
recall on the affected vehicles to install a revised calibration
which enables the flex fuel logic.
An anomaly in the engine control module software may result
in excessive fuel enrichment in certain driving conditions. The
excessive enrichment may result in spark plug fouling and
poor starts. Customers may experience MIL illumination due
to misfire or have hard to start or no start conditions.
Remedy: /\ voluntary emissions recall campaign will be
conducted. GM will install software that will not cause the
potential excessive fuel enrichment.
Malfunction Indicator Light (MIL) illumination may be caused
by inappropriate calibration of the On-Board Diagnostic
(OBD) system. The system may falsely detect catalyst
deterioration.
Remedy: Voluntary emissions recall to install the correct
programming of the Engine Control Unit (ECU) at no charge
to the owner.
Incorrect throttle bodies (which include the evaporative purge
control solenoid) were installed on some vehicles at the
dealership to remedy a known defect (throttle position sensor
fluctuation). These throttle bodies now have inadequate
evaporative purge ports.
Remedy: An emission recall campaign will be conducted to
notify owners of affected vehicles to bring them to the
dealership for replacement of the throttle body. The original
service bulletin has been revised to include the correct
throttle body part number information.
TSB
07-056
04-01 C
Affected
Vehicles
108
21
1,396
17,618
637
336
162
261
451
28,206
15,424
17,353
11,434
Sales Area
FC(FA + CA)
FC
FA
FC(FA + CA)
CA
Total
Number of
Vehicles
Recalled
129
1,396
17,618
62,830
11,434
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
Jaguar
Mazda
Mazda
Mercedes-Benz
Mfr. Recall
Number
R176
4807H
4907H
2007040005
EPA#
2936
2894
3402
2904
Type
V
V
V
V
Owners
Notification
2/5/2007
9/1/2007
9/27/2007
5/1/2007
MY
2005
2006
2006
2007
2007
2007
2007
2007
2006
2006
2006
2007
2007
2007
2007
2007
2007
Vehicle or Engine
Class
S-TYPE 3.0
S-TYPE4.2
S-TYPE R
Mazdaspeed6
Mazdaspeed6
CX-7
Mazdaspeed6
Mazdaspeed6
MazdaspeedS
MazdaspeedS
Mazda6
Mazdaspeed6
Mazdaspeed6
MazdaspeedS
Mazdaspeed3
Mazdaspeed6
Mazdaspeed6
CX-7
C230
Engine Family
5JCXV03.0DNE
5JCXV04.2DNF
5JCXV04.2DSB
6TKXV02.35EA
6TKXV02.3NE1
7TKXT02.35DB
7TKXV02.35NN
7TKXV02.3NE1
7TKXV02.35NP
7TKXV02.3NF1
6TKXV02.35CB
6TKXV02.3NE1
6TKXV02.35EA
7TKXV02.3NF1
7TKXV02.35NP
7TKXV02.3NE1
7TKXV02.35NN
7TKXT02.35DB
7MBXV02.5U2A
Problem Description
It is possible that some fuel tanks were not made to material
thickness and/or dimensional specification. This may prevent
the fuel delivery module, jet pump module or cluster valve
seals from adequately sealing. The vehicle may illuminate a
MIL, exhibit a fuel odor or, possibly, after completing
refueling, liquid fuel may be seen on the ground. This is a
combined evaporative emissions/safety recall.
Remedy: Dealers are to remove the installed fuel tank on
affected vehicles, inspect the tank and determine if seal
replacement is possible. If repair is not possible the original
fuel tank is to be replaced with a tank manufactured to the
approved specification following standard Workshop Manual
procedures.
The variable swirl shutter valve in the air intake system
malfunctions in cold weather, causing a Malfunction Indicator
Light (MIL).
Remedy: Vehicles will be recalled to replace the variable
swirl shutter valve and reprogram the Powertrain Control
Module (PCM).
The On-Board Diagnsotic (OBD) monitoring function for Short
Fuel Trim maximum threshold does not operate, resulting in a
lack of Malfunction Indicator Light (MIL) warnings for certain
malfunctions.
Remedy: Vehicles will be recalled to reprogram the
Powertrain Control Module (PCM).
These certified Flex Fuel Vehicles are equipped with Engine
Control Units (ECU) capable of modifying the engine control
system based on sensor readings regarding fuel type. A
small number of the vehicles have been identified as having
installed ECU software for gasoline only. When filled only
with £85 fuel the vehicles without an engine control module
software update may experience starting problems, rough
vehicle operation and "check engine" lamp illuminated.
Remedy: Mercedes conducted a service campaign and will
have all affected vehicles corrected free of charge. Notice to
dealers to reprogram the ECU software on affected vehicles
to the current Flex Fuel Vehicle (FFV) values were sent
electronically March, 2007.
TSB
Affected
Vehicles
8,904
3,709
1,042
5,094
1,800
54,238
631
273
2,717
1,139
24,400
1,800
5,100
1,800
4,100
600
1,500
57,500
30,576
Sales Area
FC(FA + CA)
FC (FA + CA)
CA
FC (FA+ CA)
FA
CA
FA
CA
FC (FA + CA)
FC(FA + CA)
Total
Number of
Vehicles
Recalled
13,655
65,892
87,800
30,576
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
Mercedes-Benz
Mercedes-Benz
Porsche
Mfr. Recall
Number
2007040006
200708003
W716
EPA#
2923
2988
2910
Type
V
V
V
Owners
Notification
5/1/2007
9/1/2007
3/19/2007
MY
2007
2007
2006
Vehicle or Engine
Class
C230
GL320
Cayenne S, Turbo
Engine Family
7MBXV02.5U2A
7MBXT03.0B10
6PRXT03.26E1
6PRXT04.5SE1
6PRXT04.5TE1
Problem Description
TSB
The 2007 model year C230 flexible fuel vehicle can operate
on both gasoline and ethanol fuels. These commercially
available fuels can contain different amounts of oxygenated
components. When the C230 vehicle is refueled the engine
management system could misinterpret the gasoline in the
fuel tank as ethanol only because the oxygen content in the
fuel is different from the previous tank fill. This
misinterpretation can result in the fuel adaptation incorrectly
calculating fuel enrichment values. Over time, this continual
miscalculation can result in MIL illumination. Rough engine
operation may be experienced depending on the fuel mixture.
Extended operation of the vehicle with the MIL illuminated
could result in catalyst damage.
Remedy: The customer will receive the corrected Engine
Control Unit (ECU) software at no charge and if an OBD fault
code was stored in relation to the fuel adaptation, the catalyst
will also be inspected to ensure its proper functionality. If the
catalyst is found to be impaired, it will be replaced free of
charge.
In some cases, the charge air cooler hose can become
disconnected from the charging air inter cooler inlet. If the
material thickness under the clamp of the reducing bushing
and a thinner end of the cooler hose exist, the hose will not
stay attached. The Malfunction Indicator Light (MIL) will
illuminate and the Powertrain Control Module (PCM) will put
the vehicle in "limp home mode", which allows the car to be
driven slowly but with less acceleration, causing the
customers to return to the dealership for service. With the
hose off, both emissions and drivability are adversely
affected.
Remedy: The hose has been improved for both service
replacements and production vehicles. All owners will
receive letters encouraging them to bring their vehicles in for
a hose replacement free of charge.
The fuel line pressure at the fuel-fired heater (FFH) drains
back after key off. This causes the heater not to re-fire on the
next request. The FFH control unit has to be "unlocked" by
dealer with a Porsche service tool. Reprogramming the
control unit will allow the pump to run sufficiently to ensure
operation and avoid the FFH from locking in the future.
Remedy: Owners will be notified by letter to take vehicle to
Porsche dealer to have the Engine Control Unit (ECU)
reprogrammed.
Affected
Vehicles
30,576
1,554
24
24
24
Sales Area
FC(FA + CA)
FC
FC
Total
Number of
Vehicles
Recalled
30,576
1,554
72
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
Porsche
Subaru
Subaru
Volkswagen
Mfr. Recall
Number
W738
WVB-12
WWV-06
N7
EPA#
2992
2786
2935
2490
Type
V
V
V
V
Owners
Notification
7/26/2007
3/2/2007
3/1/2005
Reported to
EPA on
4/26/2007
5/29/2007
MY
2008
2005
2005
1999
2000
2001
2002
Vehicle or Engine
Class
Cayenne S
Cayenne Turbo
Outback 2.5XT
Legacy 2.5GTTurbo
Outback H6
Jetta, GTI
Engine Family
8PRXT04.8SED
8PRXT04.8TED
5FJXX02.5YNX
6FJXX02.5YPY
5FJXT03.0TLW
XVWXV02.8224
YVWXV02.8224
1VWXV02.8224
2VWXV02.8224
Problem Description
The engines of model year 2008 Cayenne S and Cayenne
Turbo vehicles are equipped with oil spray jets for the
purpose of piston cooling and to provide additional lubrication
of the cylinder barrels. It is possible that the opening
pressure of the oil spray jets may not be correct on some
vehicles. Under certain operating conditions this may lead to
the warning "Oil pressure too low" appearing in the multi-
purpose display.
Remedy: Porsche issued a voluntary emission recall to raise
the oil pressure by means of a software alteration of the
ECU. This will ensure adequate oil pressure under all
operating conditions.
Some 2005 Subaru Legacy and Outback 2.5L MT turbo
models may experience a short circuit in the transistor diode
within the Engine Control Unit (ECU). This is caused by a
negative surge of current flow to the drive circuit of the main
cooling fan relay. If the ECU circuitry gets damaged, it could
cause the main cooling fan to run continually.
Remedy: A modification was made to the main cooling fan
relay. The negative surge current protector in the relay was
changed from a diode to a resistor, in order to protect the
ECU circuitry. Subaru conducted a Customer Service
Campaign (Radiator Cooling Fan Relay) and owners were
notified of the repair program to install an improved cooling
fan relay and check for ECU circuit damage which could
require ECU replacement.
The catalytic converter may fail due to an increase of exhaust
temperature when driving in first gear for an extended period
of time in either "manual" or "sport" mode. Under these
circumstances raw fuel, which is generated due to fuel cutout
logic, collects in the converter causing the over-temperature
condition. The manual/sport mode allows the driver to
manually select the desired gear. Current software will not
automatically shift the transmission when there is a near over
rev condition.
Remedy: Subaru has changed the TCM programming in
1 2/2004 for production and for service since 3/2005. Owner
letters for recall were mailed starting March, 2005. A second
mailing occurred in June 2007.
Catalytic converter may fail due to an internally melted
monolith. Diagnostic Trouoble Code (DTC) for low catalyst
efficiency and vehicle misfire are detected in some vehicles,
along with MIL illumination. Vehicles are no longer in
production - no production improvements available.
Volkswagen of America will issue a service action with
customer notification to update the vehicle Engine Control
Unit (ECU) software for improved converter efficiency
thresholds and more stringent misfire detection.
Remedy: Voluntary emission recall to reprogram ECU was
issued on 5/29/2007.
TSB
Affected
Vehicles
2,045
780
9,146
2,549
12,413
10,293
36,447
37,320
5,319
Sales Area
SOS
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
Total
Number of
Vehicles
Recalled
2,825
11,695
12,413
89,379
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
Volkswagen
Volkswagen
Volkswagen/ Audi
Volvo
Volvo
Volvo
Mfr. Recall
Number
P7
2007/04/10
M7VW & JL
Audi
181
168
R600-169
EPA#
2821
2814
3354
2766
2767
2973
Type
V
V
V
V
V
V
Owners
Notification
1/12/2007
4/16/2007
9/28/2007
7/16/2007
7/9/2007
8/10/2007
MY
2006
2001
2003
2003
2003
2004
2004
2004
2004
2003
2004
2006
Vehicle or Engine
Class
Passat
New Beetle, GTI,
Golf, Jetta
Audi A6 & A4
Passatl .8T/Audi A4
Passat 2.8
S60, V70
S60, V70
S60, V70
S60, V70 AWD
S60, V70.S40
S60, V70,S80,XC90
&AWD
S80, S80 Executive
S40.V50
Engine Family
6ADXV02.0366
1ADXV01.8346
3ADXV03.0344
3ADXV01.8342
3ADXV02.8334
3VVXV2.43S2N
3VVXV2.43U1N
4VVXV2.43S2N
4VVXV2.52L1T
4VVXV2.43U2N
4VVXX2.52U2T
3VVXT2.92U1T
3VVXV2.92U1T
4VVXV2.92U1T
4VVXT2.92U1T
6VVXR0132EV2
Problem Description
The power brake booster hose may crack or break at the
flange. Vehicle runs rough at start up and when Malfunction
Indicator Light (MIL) illuminates the Diagnostic Trouble Code
(DTC) for fuel system too rich off idle is stored in the Engine
Control Unit (ECU) memory.
Remedy: An updated brake booster hose was incorporated
in production at Mosel on April 8, 2006 and Emden on April
27, 2006. The safety recall will notify owners and
dealerships of the no charge repairs.
An incorrect interpretation of information in the electronic
parts catalogue directed dealership technicians to install the
wrong catalyst on these particular vehicles.
Remedy: The manufacturer initiated a service action to
inspect and, if needed, replace the catalytic converters in
affected vehicles.
A safety recall was initiated due to concern of engine stalling
or quitting while driving because of the premature wear of the
carbon brush set in the fuel pump.
Remedy: Volkswagen and Audi dealers were sent
instructions on or about September 26, 2007 to inspect
suspect vehicles and their service records in determining if
the fuel pump had been replaced. Fuel pumps will be
replaced on vehicles not previously repaired.
The signal from the fuel pressure sensor is used to control
both fuel pressure and to calculate the injection time of the
injectors. A fault in this pressure information (e.g. too high)
will give both an error on the real fuel pressure (e.g. too low)
and a fault on the injection time (e.g. too short). However,
negative impacts on emissions and drivability are avoided by
the use of adaptation, preprogrammed values, or both. If the
fault comes suddenly or is too large to be compensated for
by adaptation, it is possible to experience considerable
impact on drivability and emissions. Component design
improvements were implemented to the solder pins (06/2002,
01/2003, 03/2004) to address this problem
Remedy: A recall was issued on 7/19/2007 to replace the
fuel pressure sensor in the 2003-2004 model year vehicles.
The Positive Crankcase Ventilation (PCV) nipple of the crank
case ventilation system may crack or come loose resulting in
an air leakage. The nipple serves as a calibrated flow
restriction in the system. The nipple also prevents blow-by
gases from entering the atmosphere by serving as a union for
system piping.
Remedy: This recall will replace the PCV nipple
Volvo has found that the emission control label is misprinted
on some of the affected vehicles. The label says
6\NXR0130EV2 where the correct value is 6VVXR0132EV2.
Remedy: Letters will be sent to owners starting on or about
August 1 0, 2007 requesting that they return their vehicles to
Volvo dealerships to have the emissions label replaced.
TSB
Affected
Vehicles
54,099
2,300
99,432
1,576
13,201
8,148
5,467
24,776
86,198
8,529
2,046
3,126
16,084
16,536
Sales Area
FC(FA+ FC)
FC(FA + CA)
FC (FA + CA)
CA
FC(FA + CA)
CA
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
CA
Total
Number of
Vehicles
Recalled
54,099
2,300
99,432
139,366
29,785
16,536
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Recall Campaigns
Mfr.
Mfr. Recall
Number
EPA#
Type
Owners
Notification
MY
Vehicle or Engine
Class
Engine Family
Problem Description
TSB
Affected
Vehicles
Sales Area
Total number of Vehicles affected by Recall Campaigns:
Total
Number of
Vehicles
Recalled
1,126,682
EPA420-B-08-012
June 2008
-------
2007 Emissions-Related Voluntary Service Campaigns
Mfr.
Chrysler
Ford
Ford
Mfr. Recall Number
2006-36-E
07M06
07M07
and
07N09
EPA*
2856
2287
2543
Type
vsc
vsc
vsc
Owners
Notification
7/16/2007
5/21/2007
7/3/2007
MY
2004
2004
2003
2003
Vehicle or Engine
Class
Chrysler Pacifica
Aviator
Lincoln LS
Ford Thunderbird
Engine Family
4CRXT03.82NO
4FMXT04.62FA
3FMXT04.62FA
3FMXV03.9VF5
Problem Description
Some 2004 Chrysler Pacifica vehicles equipped with 3.5L
engines have a plug in the housing of the Exhaust gas
Recirculation (EGR) valve that may shift or be ejected. If this
shift takes place exhaust gas can vent through the open port
into the environment. High exhaust gas temperatures and
EGR valve flow rates appear to be contributing factors, both
of which may be influenced by vehicle operation and driving
patterns. The design of the EGR valve housing was changed
in production to add a snap ring in the port to prevent
movement of the plug.
Remedy: Chrysler will extend the warranty for the EGR
valve on affected vehicles to certified useful life (10 years /
100,000 miles).
Vehicles may have an inoperative ignition coil due to internal
cracking of the coil housing in the coil manufacturing process.
The engine is expected to experience rough running and the
MIL will be illuminated. Improvements in the manufacture of
the ignition coil were implemented in September of 2001 , and
improvements were made to the coil housing in November
2003. Other follow-up action is under review.
Remedy: A voluntary service campaign (VSC) was issued
on 5/21/07 for the Aviator engine families only, to extend
warranty coverage to 11 years or 120,000 miles whichever
comes first. For vehicles with more than 120,000 miles the
coverage is good until 11/30/2007.
Water or oil may enter into the ignition coil cover and the
spark plug bore causing a misfire. The Malfunction Indicator
Light (MIL) will illuminate when the misfire condition occurs.
A coil with improved water/oil sealing was put into production
in March 2004. Owners who experience this condition are
expected to obtain service through their dealerships. There
is an adverse effect on both emissions and drivability when
misfire condition is present.
Remedy: Two voluntary service campaigns were released
for 2003 MY only for misfire conditions. A Voluntary Service
Campaign (VSC) replaces ignition coils as needed and valve
cover gaskets if oil has leaked into the spark plug bore.
Another Voluntary Service Campaign replaces the wiper
motor bracket seal. This replacement will be performed if
water is present in the spark plug bore. Warranty coverage is
extended to 10 years or 100,000 miles whichever comes first.
For vehicles with more than 100,000 miles coverage is good
until 12/31/2007.
Affected
Vehicles
72,199
27,000
23,100
28,100
Sales Area
FA
FC(FA + CA)
FC(FA + CA)
Total Number
of Vehicles
Recalled
72,199
50,100
28,100
EPA420-B-08-012
10
June 2008
-------
2007 Emissions-Related Voluntary Service Campaigns
Mfr.
General Motors
General Motors
General Motors
General Motors
Mfr. Recall Number
ML-MW215
ML-MW209
ML-MW229
07099
ML-MW234
EPA*
2881
2905
2479
3044
2976
2977
Type
vsc
vsc
vsc
vsc
Owners
Notification
4/1/2007
2/28/2007
6/1/2007
8/12/2007
MY
2006
2006
2006
2007
2007
2007
2007
2005
2002
2003
2004
2004
Vehicle or Engine
Class
Chevrolet /CMC
Pickup/ Utility
Chevrolet Impala/
Monte Carlo
Chevrolet Impala/
Monte Carlo
Chevrolet/ Buick
Uplander / Terraza
Chevrolet /CMC
Pickup/ Utility/ Van
Chevrolet /CMC
Pickup / Van
Chevrolet /CMC
Utility
Malibu
Chevrolet Trailblazer,
CMC Envoy XL/XUV,
Isuzu Ascender
Colorado
Canyon
Engine Family
6GMXT05.3375
6GMXV03.5050
6GMXV03.5051
7GMXT03.9140
7GMXT05.3375
7GMXT05.3373
7GMXT05.3381
5GMXV02.2028
2GMXA04.2187
2GMXT04.2188
3GMXA04.2187
3GMXT04.2184
3GMXT04.2188
3GMXT05.3170
3GMXT05.3183
4GMXT04.2187
4GMXT05.3170,
4GMXT02.8189
Problem Description
Flex Fuel Vehicles can operate on E85 or gasoline. E85 is a
fuel mix of 85% ethanol and 1 5% gasoline. Due, in part, to
the way E85 is mixed before filling the tank, some vehicles
could encounter a situation where the engine computer
improperly estimates the amount of ethanol in the vehicle's
fuel tank and the Malfunction Indicator Light (MIL) is
illuminated, plus there could be drivability concerns.
Remedy: A flex fuel software update (fuel sensing algorithm)
is available for Engine Control Unit (ECU) reprogramming at
no charge under the 8-year or 80,000 mile emission
controller warranty.
Owners may experience a condition where the fuel tank gas
cap won't tighten properly or the fuel cap won't come off, or is
broken. These conditions can cause the illumination of the
Malfunction Indicator Light (MIL). Additionally, a Diagnostic
Trouble Code (DTC) can be set if fuel cap does not seal
adequately at the filler neck surface.
Remedy: If this condition occurs on an owner's vehicle
within 1 0 years of the date the vehicle was originally placed
in service or 120,000 miles, whichever occurs first, the
condition will be repaired for the owner at no charge. Special
Coverage Service Bulletin No. 06081 was issued for this
evaporative emissions problem.
The component involved is the fuel tank on certain extended
utility vehicles. A fracture may develop in the area where the
Inlet Check Valve (ICV) is mated to the fuel tank. The fracture
may be related to the process of welding the ICV to the fuel
tank and the percent carbon used in the molding of the ICV.
Remedy: Warranty was extended for 10 years or 150,000
miles whichever comes first. Letters were sent to the owners
beginning in July 2007.
The component is the fuel tank gas cap. The failures are
either a broken internal ratchet mechanism or inadequate
seal at the fill pipe interface surface. The probable causes of
the failures are an inadequate internal ratchet mechanism
design to withstand the potential force applied upon removal
or a main seal design that is not robust to the possible
variation in the fill pipe sealing surface. The caps available in
service have an improved ratchet mechanism design that can
withstand the removal force and an improved main seal
design.
Remedy: General Motors will implement a special coverage
warranty extension to 10 yrs/120,000 miles.
Affected
Vehicles
198,745
41,337
154,928
2,800
86,000
220,000
57,177
51,615
2,324
34,433
14,343
64,515
49,326
15,721
2,601
16,603
2,404
19,270
Sales Area
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
FC(FA + CA)
Total Number
of Vehicles
Recalled
871,987
51,615
223,907
19,270
EPA420-B-08-012
11
June 2008
-------
2007 Emissions-Related Voluntary Service Campaigns
Mfr.
General Motors
General Motors
Honda/ Acura
Volkswagen
Mfr. Recall Number
ML-MW233
ML-MW250
WER-06-014-00
VWA-07-20
EPA*
2978
3326
2763
2586
Type
vsc
vsc
vsc
I-VSC
Owners
Notification
8/6/2007
11/1/2007
8/31/2007
9/6/2008
MY
2004
2004
2005
2003
2003
2004
2004
2005
2005
2001
2002
2003
Vehicle or Engine
Class
GTO
Saturn Vue
Saturn Vue
Civic Hybrid
Golf, Jetta, NB
Golf, Jetta, NB
NB Convertible
Engine Family
4GMXV05.7083
4GMXT02.2123
4GMXT03.5145
5GMXT02.2123
5GMXT03.5145
3HNXV01.34A5
3HNXV01.36CV
4HNXV01.35A6
4HNXV01.37CP
5HNXV01.33A6
5HNXV01.3YCV
1VWXV02.0223
1VWXV02.0226
2VWXV02.0223
2VWXV02.0222
3VWXV02.0223
Problem Description
The component is the fuel tank gas cap. The failures are
either a broken internal ratchet mechanism or inadequate
seal at the fill pipe interface surface. The probable cause of
the failures are an inadequate internal ratchet mechanism
design to withstand the potential force applied upon removal
or a main seal design that is not robust to the possible
variation in the fill pipe sealing surface. The caps available in
service have an improved ratchet mechanism design that can
withstand the removal force and an improved main seal
design.
Remedy: General Motors will implement a special coverage
warranty extension to 10 yrs/120,000 miles.
The component is the fuel tank gas cap. The failures are
either a broken internal ratchet mechanism or inadequate
seal at the fill pipe interface surface. The probable causes of
the failures are an inadequate internal ratchet mechanism
design to withstand the potential force applied upon removal
or a main seal design that is not robust to the possible
variation in the fill pipe sealing surface. If the cap fails one of
three things will occur, the Malfunction Indicator Light (MIL)
will illuminate (and a Diagnostic Trouble Code (DTC) will
set), the cap won't tighten or the cap will not come off. The
failure of the tank cap function will result in an overt indication
that the cap should be replaced.
Remedy: The caps available in service have an improved
ratchet mechanism design that can withstand the removal
force and an improved main seal design. Additionally, GM
will implement a special coverage warranty extension to 10
yrs/120,000 miles.
Engine speed may be higher than target RPM at high vehicle
load due to Continuous Variable Transmission (CVT) belt
slip. The 'D' lamp on the gear shift console may flash (for all
affected vehicles), and Malfunction Indicator Light (MIL) may
illuminate (for 3HNXV01.34A5 only). The cause of the failure
is inappropriate calibration of the CVT control module.
Remedy: A CVT control module with an improved
calibration is made available for repair under Field Fix#S8.
The owner of the vehicle has been notified, if this defect
occurs, to bring their vehicle to the dealership to update the
Powertrain Control Module (PCM) software according to
Honda Service Bulletin under Honda's Warranty Extension
Campaign.
Malfunction Indicator Light (MIL) illumination with a
Diagnostic Trouble Code (DTC) Main Catalyst Bank 1
(efficiency below threshold) is caused by open passages in
the catalytic converters expansion matting that causes
exhaust gases to partially bypass the converter monolith. The
damage was caused by over stressing of the converter
housing during the converter canning process. Improved
service parts have been available since November 2005.
Remedy: On or about September 9, 2007 manufacturer
extended warranty to 10 year/100,000 miles and sent notices
to owners. VW dealers will inspect and replace convenors
as needed.
Affected
Vehicles
15,740
36,754
55,601
31,638
33,647
22,535
3,793
12,238
6,003
14,173
8,015
60,172
32,481
65,172
54,184
128,230
Sales Area
FC(FA + CA)
FC(FA + CA)
CA
FC(FA + CA)
Total Number
of Vehicles
Recalled
15,740
157,640
66,757
340,239
EPA420-B-08-012
12
June 2008
-------
2007 Emissions-Related Voluntary Service Campaigns
Mfr.
Mfr. Recall Number
EPA*
Type
Owners
Notification
MY
Vehicle or Engine
Class
Engine Family
Problem Description
Affected
Vehicles
Sales Area
Total number of Vehicles affected by Voluntary Service Campaigns:
Total Number
of Vehicles
Recalled
1,897,554
Total number of Vehicles affected by Recalls and Voluntary Service Campaigns:
SUMMARY
Total number of Voluntary Recalls:
Total number of Voluntary Service Campaigns:
Total number of Recalls and Voluntary Service Campaigns:
37
11
48
3,024,236
EPA420-B-08-012
13
June 2008
------- |