vvEPA
  United States
  Environmental Protection
  Agency
Office of Transportation                EPA420-B-06-001
and Air Quality                   February 2006
          2005 Annual Summary of
          Emission-Related
          Recall and Voluntary
          Service Campaigns
          Performed on Light-Duty
          Vehicles and Light-Duty
          Trucks

-------
                                               EPA420-B-06-001
                                                 February 2006
2005 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

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*



                                                                        Recall Campaigns
Mfr.



BMW
















DAIMLER/CHRYSLER










DAIMLER/CHRYSLER




DAIMLER/CHRYSLER









DAIMLER/CHRYSLER





Mfr. Recall
Number


05E-A01
















2004-2 1-E&D46










2005-1 -E&E02




2005-2 & E01









2005-8





EPA#



3020
















2402










2488




2493









2524





Type



V
















V










V




V









V





Owners
Notification


10/20/2005
















1/18/2005










2/21/2005




4/4/2005









4/1/2005





MY



2001
2002
2002
2003
2003
2003
A
"
2003
"
2003
2003
2003
2003
2004
2004


2005
2005
2005
2005
2005
2005
2005
2005
2005
2005
2005
2005




2005









2004





Vehicle or Engine
Class


M3/Cabr/Rdst/Cp
M3/Cabr/Rdst/Cp
745i, 745Li
X5, 3.0i
325iA/CiA/iAT
325i/Ci/Ci Cabr,
325iT/xi/xiT,330xi,52
5i/iT,Z4 2.5i
330i/Ci/Ci Cabr,
530i,Z4 3.0i
325i, 325iT, 330i
M3, M3 Cabrio
745i, 745Li
760Li
325iA/CiA/iAT
325i/Ci/Ci Cabr/iT,
330i/Ci/Ci Cabr, X3
3.0IA
Ram, Dakota
Ram
Liberty, G/Cherokee
Wrangler
PT Cruiser
PT Cruiser
PT Cruiser
PT Cruiser
PT Cruiser
SRT-4
PT Cruiser
Liberty




Durango
Durango
Durango
Durango






Ram





Engine Family



1BMXV03.2S54
2BMXV03.3S54
2BMXV04.4LEV
3BMXT03.0E5R
3BMXV02.5M56
3BMXV03.0LER
A
"
3BMXV03.0M5R
"
3BMXV03.0UL2
3BMXV03.2S54
3BMXV04.4LEV
3BMXV06.0N73
4BMXV02.5M56
4BMXX03.0UL2


5CRXT03.75SO
5CRXT03.76UO
5CRXT03.7NEO
5CRXT04.02NO
5CRXV0148M80
5CRXV02.4VEO
5CRXV02.4VEO
5CRXV02.4VE1
5CRXV02.4VE1
5CRXV02.4VHO
5CRXV02.4VHO
5CRXT03.7NEO




5CRXT03.75SO
5CRXT04.75JO
5CRXT04.76UO
5CRXT05.75J1






4CRXT05.77XO





Problem Description



Certain Ignition coils have been identified to be not
sufficiently resistant to the high engine
compartment temperatures. Coils supplied by
Bosch are not affected by this problem.
Remedy: j^e Bremi coils will be replaced by
Bosch ignitions coils.












The OBD fuel system monitor was disabled when
an associated configuration register was
inadvertently cleared prior to release.
Remedy: PCM of the affected vehicles will be
reprogrammed with corrected software.






Some vehicles were manufactured with the wrong
VECI label attached.
Remedy: A new label will be sent directly to the
owner with instructions, or owner can take label to
dealer for installation.
Fuel tank filler tube inlet check valve on some
vehicles may not fully close at the end of refueling.
This could allow some fuel to escape at the end of
refueling. This could cause an increase in
emissions when the check valve does not fully
close. A safety recall E01 will inspect and replace
all defective filler necks.
Remedy: Fuel tank inlet check valve will be tested
for proper operation. If found to be defective the
fuel tank will be replaced.
VECI label is missing load rating and frontal area
limits.
Remedy: Voluntary emissions recall E09 will
replace the labels with correct one. Labels will be
sent directly to vehicle owners to place on their
vehicles.
Affected
Vehicles


4642
10394
22887
31008
12181
82248
A
"
44432
"
18698
8890
2096
328
12772
68044


4053
195
38004
3898
1921
1246
7798
1566
659
1101
1943
80




1034
1999
7559
9011






345





Sales Area




















50S
50S
50S
50S
CA
50S
FED
50S
CA
50S
FED
50S




50S
50S
50S
50S






50S





Total
Number of
Vehicles
Recalled
318620
















62384










80




19603









345





EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*



                                                                        Recall Campaigns
Mfr.



DAIMLER/CHRYSLER




GENERAL MOTORS





Mfr. Recall
Number


2005-22




ML-MW091





EPA#



2640




2512





Type



V




V





Owners
Notification


TBD




4/1/2005





MY



2005




2001
2001
2002
2002
2003





Vehicle or Engine
Class


Dodge Ram




C/KTrk,Chev,GMC
C/KTrk,Chev,GMC
C/KTrk,Chev,GMC
C/KTrk,Chev,GMC
C/KTrk,Chev,GMC





Engine Family



5CRXK05.7TXO




1GMXA04.3190
1GMXT04.3184
2GMXA04.3190
2GMXT04.3184
3GMXT04.3184





Problem Description



Some cab-chassis trucks certified to 50-State
emissions standards were misidentified as CA-
only emissions certified trucks.
Remedy: yERR conducted to replace the PCM
and VECI label to correctly identify trucks as 50-
State vehicles.
Internal corrosion on the contacts inside the
distributor and rotor may cause failure of the
ignition system. Condensation from an AC line
located above the distributor may drip onto the unit
and cause the corrosion. Spark may be routed to
the wrong cylinder. The OBD system will detect
the misfire and signal a MIL.
Remedy: /\ foam s|eeve will be installed onto the
AC line to prevent and condensation buildup, thus
preventing future corrosion.
Affected
Vehicles


309




3959
36510
6309
79428
53776





Sales Area



50S




CA
CA
CA
CA
CA





Total
Number of
Vehicles
Recalled
309




179982





EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*
                                                                       Recall Campaigns
Mfr.



GENERAL MOTORS











GENERAL MOTORS
HONDA/ACURA












HONDA/ACURA












Mfr. Recall
Number


ML-MW106











ML-MW140
EDIR-02-047-00 &
EDIR-02-047-01











EDIR-05-004-00 &
EDIR-05-004-01











EPA#



2529











3046
1701












2522












Type



V











V
V












V












Owners
Notification


4/20/2005











11/21/2005
12/1/2001












11/30/2005












MY



2005
2005
2005




2005
2005

2005
2005
2006
2006
2006
2000
2001











2005












Vehicle or Engine
Class


Sunfire
Classic
Malibu, Uplander,
Equinox, Montana
SV6, Grand Prix, G6,
Terraza, LaCrosse,
Relay
Grand Prix
Grand Prix,
LaCrosse
Silverado, Sierra
Silverado, Sierra
G6
Chevy Express
GMCSavana
Insight
Insight











Accord Hybrid












Engine Family



5GMXV02.2025
5GMXV02.2027
5GMXX03.8148




5GMXV03.8041
5GMXV03.8044

5GMXH06.6590
5GMXH06.6591
6GMXVB03.9146
6GMXT06.0391
6GMXT06.0391
YHNXV01.0LA4
1HNXV01.0FH6











5HNXV03.01B4












Problem Description



Some Engine Control Modules (ECM) or Power
train Control Modules (PCM) have potentially
damaged integrated circuits (1C). This may cause
the EGR system to malfunction, or cause the fuel
pump to turn off, or the turbo system to
malfunction. A MIL light would be illuminated if
this occurs.
Remedy: A recall campaign will be conducted on
affected vehicles to replace the suspect control
modules.



Certain vehicles were built with incorrect On-Board
Diagnostic calibrations.
Remedy: jhe affected .vehicles will be^
reprogrammecfto install the correct OBD
calibration.
IMA system battery may deteriorate when the
vehicle is operated in cold conditions and under
high loads. Emissions are slightly increased but
are still below standards. When this conditions
occurs, the change in performance of the vehicle is
obvious and should be noted by the driver. The
battery condition monitor and the motor control
module with an improved calibration had been
applied to the assembly line and for repair under
Running change/Field fix #K1 . Issued Service
Bulletin #01-102.
Remedy: jne battery condition monitor module
and the motor control module will be replaced with
When engine is started directly following a generic
code clear command, without first turning the
ignition off, the IMA battery will be overcharged.
The IMA or a MIL light will illuminate. The problem
is caused by inappropriate programing of the MCM
module. A newly reprogrammed MCM computer
has been applied to the production process, and
current vehicles with MIL illumination will be
covered under emission warranty. Running
Change #L7 for corrective action and TAB #05-
038.
Remedy: jne \^CM will be reprogrammed with a
correct Programming by dealership.
Affected
Vehicles


1
14
1702
A
A
A
A
1
274
A
53
116
2
2602
462
5677
1807











6491












Sales Area



FC(Tier2 Fed&Cal)
CA
CA




FC(Tier2 Fed&Cal)
CA

50S
50S
CA

CA
CA











CA












Total
Number of
Vehicles
Recalled
2163











3064
7484












6491












EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*



                                                                        Recall Campaigns
Mfr.



HONDA/ACURA


Mfr. Recall
Number


PUDR-05-023-00
(P89)


EPA#



2620


Type



V


Owners
Notification


9/14/2005


MY



2005


Vehicle or Engine
Class


Acura RL


Engine Family



5HNXV03.5PB4


Problem Description



PCM causes engine shudder.and may not allow
the transmission to upshift to 4th gear.
Remedy: 7ne PCM will be reprogrammed with an
appropriate programming by an Acura dealership.
Issued TSB #05-027.
Affected
Vehicles


21437


Sales Area



CA


Total
Number of
Vehicles
Recalled
21437


EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*



                                                                        Recall Campaigns
Mfr.
HONDA/ACURA




























Mfr. Recall
Number
PUDR-05-010-00
(P72)




























EPA#
2477
A
A
A
A
2494
A
A
A
A
A
A
A
A
A
A

2531











Type
V




























Owners
Notification
7/31/2005




























MY
2003
2003
2004
2004
2005
2005
























Vehicle or Engine
Class
Civic Hybrid
Civic Hybrid
Civic Hybrid
Civic Hybrid
Civic Hybrid
Civic Hybrid
























Engine Family
3HNXV01.34A5
3HNXV01.36CV
4HNXV01.35A6
4HNXV01.37CP
5HNXV01.33A6
5HNXV01.3YCV
























Problem Description
Under certain driving conditions, inappropriate air
to fuel ratio causes catalyst heat damage. The
catalyst oxygen storage capacity is reduced and
the MIL illuminates. Vehicle will be diagnosed
under emissions warranty.
A
The OBD system may falsely detect a malfunction
in the Variable Cylinder Management (VCM)
system (Valve Pause System in Civic IMA). This
happens after the engine oil and filter are changed.
The cause is an inappropriate calibration of the
OBD system. A PCM with a new calibration has
been for assembly line. Running change/field fix
#L4 (Civic), and #K9 (Odyssey) has been issued
for vehicle service, MY 03-05. TSB #05-01 9 will
address 05MY Odyssey. MIL indication will
prompt owner to service or diagnose vehicle at
dealership.
The IMA battery may become overcharged thus
deteriorating the IMA battery unexpectedly. The
IMA light will illuminate, and possibly the MIL light
depending on battery condition. The cause of the
failure is a improperly calibrated control module
(MCM). Field fix M1 has addressed issues in
vehicles under Honda control. When the MIL is
illuminated, a the owner will likely seek service at
dealership.
Remedy: The ECM/PCM will be reprogrammed
with improved programming by a Honda
dealership. Honda service bulletin 05-028 will
address the issue.
Affected
Vehicles
28192
4348
15424
7397
11951
6638
























Sales Area
CA
CA
CA
CA
CA
CA
























Total
Number of
Vehicles
Recalled
73950




























EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*



                                                                        Recall Campaigns
Mfr.



KIA



LAND ROVER







MAZDA











MAZDA











MAZDA












Mfr. Recall
Number


52



2005-4.4-1







3105G











3205G











3305G












EPA#



3045



3049







2222











2251











2472












Type



V



V







I











V











V












Owners
Notification


11/10/2005



10/14/2005







8/31/2005











8/31/2005











8/19/2005












MY



2003



2005







2004
2004
2004









2004
2004










2004
2005
2005










Vehicle or Engine
Class


Sorento



LR3







Mazda 6
Mazda 6
Mazda 6









Mazda 6
Mazda 6










Mazda RX-8
Mazda RX-8
Mazda RX-8










Engine Family



3KMXT03.5G01



5LRXT04.4002







4TKXV02.3AJA
4TKXV02.3BJ1
4TKXV02.3AJM









4TKXV03.0ALA
4TKXV03.0ALM










4TKXV01.3CNA
5TKXV01.35NM
5TKXV01.35NC1










Problem Description



Vehicle may experience a fuel leak near the fuel
tank. The cause of this malfunction is rubbing
between fuel tube and body frame.
Remedy: Ģia will inspect and replace a section of
the fuel line.
Vehicles may have fuel tanks that contain an
internal breather pipe that was not made to
specification . This may result in excessive
swelling and cracking of a grommet and
subsequent detachment of the breather pipe from
a connector tube. MIL may illuminate.
Remedy: /\ voluntary safety recall has been
initiated to replace the fuel tank.
Due to inappropriate programming of PCM, the
malfunction logic of periodic deterioration that is a
part of oxygen sensor monitor function of OBD II is
disabled. MIL will not illuminate. Trouble code
data will not be stored. Mazda will reprogram the
PCM of affected vehicles in the plant, port, and
distributor. Issue a repair procedure for
technicians to correct the problem on vehicles
brought into the dealership with this problem.
Remedy: Mazda is issuing a recall letter to
owners of affected vehicles and will reprogram the
PCM to the correct specifications.
Due to inappropriate design of the Powertrain
/control Module (PCM) circuit for a part of
evaporate leak monitoring system in the PCM,
ability of a pump control circuit failure detection
may be lower than requirement of OBD2
regulation.
Remedy: Mazda will issue a repair procedure to
correct this concern by reprogramming the PCM of
affected vehicles when customer brings vehicle in
for service at the dealer. A recall will be
preformed to recall the vehicles and reprogram the
PCM.
Vehicle is parked and the engine is operated at
high RPMs, excessive heat build-up may affect
oxygen sensors, the neutral switch and back up
lights. It may also lead to problems with the
parking brakes, malfunctions of the gas gauge and
possible damage to the fuel tank causing fuel
leaks.
Remedy: /\ safety recall will be conducted to
install a heat insulator pad to the fuel tank, and
other various areas around the exhaust system
that could sustain damage. All damaged parts will
be replaced during the installation of the insulation
pads. The PCM will be reprogrammed.
Affected
Vehicles


3037



17263







700











8900











52000












Sales Area



CL



50S







50S
CA
50S









50S
FED










50S
50S
50S










Total
Number of
Vehicles
Recalled
3037



17263







700











8900











52000












EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*
                                                                       Recall Campaigns
Mfr.



MAZDA








MAZDA







MERCEDES-BENZ










MERCEDES-BENZ








MERCEDES-BENZ




Mfr. Recall
Number


3005C








3505H







2003-090005










2005060014








2005080007




EPA#



2521








2600







2075










2504








2616




Type



V








I







V










I








V




Owners
Notification


6/1/2005 &
12/16/2005








11/30/2005







3/1/2004










9/16/2005








9/12/2005




MY



2003
2003








2001
2002






2003










1999
1999
2000
2000
2001
2001




2005




Vehicle or Engine
Class


Protege, Protege 5
Mazdaspeed Protege








MX-5 Miata
MX-5 Miata






SLK32AMG;C32
AMG










ML320
ML430
ML430
ML320
ML320
ML430




G55AMG




Engine Family



3TKXV02.0HJA
3TKXV02.0BJB








1TKXV01.8CJA
2TKXV01.8CJA






3BMXV03.2LB1










XMBXT03.2GNB
XMBXT04.3GNB
YMBXT04.3GNB
YMBXT03.2GNB
1MBXT03.21BI
1MBXT04.31BI




5MBXT05.5LB1




Problem Description



Tightening of torque screws for the mounting of the
intake manifold shutter valve may have been lower
than the specification. If the valve loosens
enough, it will cause rough idle, harsh noise, and a
MIL to illuminate. Also, the emissions will be
adversly affected.
Remedy: /\ recall will be done to tighten/replace
the bolts and/or replace the shutter valve and
gaskets or the intake manifold assembly, free of
charge.
Non Methane Organic Gas (NMOG) emissions
may exceed the standard due to the emission
control logic and calibration of the PCM during the
engine warm up period after cold start up.
Remedy: Mazda will issue a recall to address
these concerns. Mazda plans to issue a repair
procedure to assist technicians in diagnosing and
correcting this concern. The PCM will be replaced.
The 2003 model year vehicles did not meet the
applicable emission standards, requiring vehicles
to be recalibrated.
Remedy: jhe combustion map in the ECM was
recalibrated to reduce lean combustion spikes of
the engine and to reduce the negative effects of
rapid throttle activation. Mercedes-Benz will
inform dealers and owners that the ECM of the
affected vehicles will receive the new program
version at the owner's earliest convenience or
during the next scheduled service at no charge to
the owner.
Under hood catalyst cans may develop cracks
along the weld seams between the inlet funnel and
the can body. This is due to tolerance deviations
during the welding process. Engine noise is
increased, and MIL may illuminate if condition
goes unserviced for an extended period of time.
Customers are expected to bring vehicle into
service when noise is apparent.
Remedy: Catalysts will be inspected/replaced
free of charge
The fuel return hose may become permeated with
fuel. Micro-cracks may result in cracks through
which fuel can leak.
Remedy: A replacement hose to correct the
situation will be installed by the dealer free of
charge.
Affected
Vehicles


39600








18200
13800






1372










27672
9462
32534
11706
6364
1379




485




Sales Area



NF(CFV+CA+NL)
CL(CA+NLEVALLS)








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






CL(CA+NLEVALLS)










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




CA




Total
Number of
Vehicles
Recalled
39600








32000







1372










79119








485




EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*
                                                                       Recall Campaigns
Mfr.



MITSUBISHI/D-STAR









MITSUBISHI/D-STAR




NISSAN





TOYOTA/LEXUS






TOYOTA/LEXUS







VOLKSWAGEN/AUDI






Mfr. Recall
Number


EMR-05-001 &
EMR-05-003









EMR-05-002




R0501





LSC 50G






TOYOTA-DIR-
20050622






UZ






EPA#



2514









2613




3032





2528






2559







2176






Type



V









V




V





V






V







V






Owners
Notification


8/29/2005 &
12/6/2005









10/17/2005




12/5/2005





6/15/2005






10/17/2005







2/16/2004






MY



2002
2002
2003
2003
2004
2005





2005
2005
2005
2005


2003
2004





2005






2004
2005






2004






Vehicle or Engine
Class


Lancer
Lancer
Lancer
Lancer
Lancer
Lancer





Lancer
Lancer
Outlander
Outlander


Sentra
Sentra





Tundra (Double-cab)






Prius
Prius






Golf






Engine Family



2MTXV02.0GNG
2MTXV02.0G3G
3MTXV02.0GNS
3MTXV02.0G3S
4MTXV02.0GB2
5MTXV02.0GR4





5MTXV02.4GBG
5MTXV02.4G2G
5MTXV02.4GBB
5MTXV02.4GBG


3NSXV01.863A
4NSXV01.883A





5TYXT04.7PEW






4TYXV01.5MC1
5TYXV01.5MC1






4VWXV02.0223






Problem Description



The MIL may illuminate due to the PCM's
determination that the catalytic converter has
deteriorated. Code P0421 is found. Separation of
the catalyst layer and melting damage to the
substrate layer has occurred in investigation of the
damaged vehicles. This could be due to unburned
fuel igniting close to the converter.
Remedy: Reprogram the Engine Control Unit with
ROM upgrade. A second letter sent to owners of
vehicles built prior to January 2002 to insure the
throttle position sensor is properly initialized.
The vehicle speed sensor malfunction logic was
erroneously left out from the engine ECU
programming for the affected vehicles with manual
transmissions. The MIL will not illuminate.
Remedy: The ECU will be reprogramed to include
speed sensor diagnostic logic.
The catalytic converter is deteriorating faster than
anticipated and turning on the MIL.
Remedy: j^e catalytic converter on all affected
vehicles will be replaced with the 2005 MY Sentra
catalytic converter. The engine control module will
be programmed to match the new catalytic
converter.
IM data for vehicles with the traction control
system did not receive the correct VECI label
describing the details of how to test the vehicle on
a two wheel dynamometer.
Remedy: A Limited Service Campaign (50G) will
be used to distribute the correct labels along with
instructions for installation to owners.
If engine speed continues for 6 seconds at 850
rpm or less MIL illumination will occur. P3191 for
"an engine does not start" is the cause of the MIL.
Running change 05-TR -16 and field fix 04-TF-10
are available and in use. Since MIL illumination
will occur, and owner will obtain service at
dealership and have their ECM re-flashed.
Remedy: Reprogram the ECM system.
These vehicles were assembled with the incorrect
Emission Control label. P/N 021 010 3Kto be
replaced by 06A 010 334F prior to delivery to
dealers or via voluntary recall to vehicles delivered
to dealers and customers.
Remedy: Notification letter will be sent that has
included the correct label. Owners can put label
on or have dealer do it.
Affected
Vehicles


55921
15810
51108
15199
30892
22360





1127
170
425
358


10800
28100





45000






47200
26500






4125






Sales Area



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





FED
CA
50S
50S








CA






CA
CA






FED






Total
Number of
Vehicles
Recalled
191290









2080




38900





45000






73700







4125






EPA420-B-06-001
                                                                                                                                                       February 2006

-------
                              2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*
                                                                                           Recall Campaigns
Mfr.



VOLKSWAGEN/AUDI









VOLVO





Mfr. Recall
Number


AWA-05-DR









145





EPA#



2277









2537





Type



V









V





Owners
Notification


12/1/2005









6/1/2005





MY



2001









2005

2005
2005


Vehicle or Engine
Class


S8









S80, XC90, V70,
XC70, S60
S80, XC90
V70, S60


Engine Family



1ADXV04.2335









5VVXX02.5U2T

5VVXV02.9U1T
5VVXV02.5L2T


Problem Description



Front oxygen sensor malfunction was caused by a
contamination inside the air reference chamber.
This may happen along with moisture inside the
sensor body due to reduced exhaust temperature
in particular load conditions. The MIL will be
illuminated.
Remedy: changed production process of the
sensor February 2001. Will replace the related
front oxygen sensor left/right in case of complaint,
free of charge for extension of warranty of 7
years/70,000 Miles.
A software calibration error in the engine
management system the EVAP purge may start
too late potentially leading to poor purge
performance.
Remedy: /\ software upgrade of the engine
control module at no charge.
Affected
Vehicles


817









16983
A
5809
730


Sales Area



CL(CA+NLEVALLS)









CA

CA
CA


Total
Number of
Vehicles
Recalled
817









23522





                                    Type:
                                    O- Ordered by EPA
                                    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

                  *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 vehicles voluntarily recalled:  1,309,822

                                                                                                                                            Total Number of Recalls         31
EPA420-B-06-001
                                                                                                                                                                                               February 2006

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                        2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*
                                                                  Voluntary Service Campaigns
Mfr.



DAIMLER/CHRYSLER


















DAIMLER/CHRYSLER








HONDA/ACURA











Mfr. Recall
Number


TBD


















TBD








WER-02-038-00
(P75/P76)











EPA#



2647


















2648








1556
&
1779
&
1870
&
1877
&
2022
&
2519


Type



IVSC


















IVSC








vsc











Owners
Notification


12/30/2005


















12/30/2005








8/23/2005











MY



1996
1996
1997
1997
1997
1998
1999
1999
2000












1999
1999
1999
2001






1999
2000
2001
2001
2002
2002
2003
2003
2003




Vehicle or Engine
Class


Dodge Ram
Van/Wag Dodge
Ram Pickup
Dodge Ram
Van/Wag Dodge
Dakota Pkup Dodge
Ram Pickup Dodge
Ram Pickup Dodge
Dakota Pkup
Dodge Ram Pickup
Dodge Ram Pkup HD










Dodge Ram
Van/Wag Dodge
Ram Pickup
Dodge Dakota Pkup
Dodge Ram Pkup HD





Odyssey
Odyssey
Odyssey
MDX
Odyssey
MDX
Odyssey
Pilot
Pilot




Engine Family



1.9L
3.9L, 5.2L, 5.9L
3.9L
3.9L
3.9L
3.9L
3.9L
5.2L
5.9L, 8.0L












3.9L, 5.2L, 5.9L
3.9L, 5.9L
5.2L, 5.9L
5.9L, 8.0L






XHNXT03.5EA3
YHNXT03.5EA3
1HNXT03.5DH2
1HNXT03.5K86
2HNXT03.51AP
2HNXT03.5KYT
3HNXT03.5ZAP
3HNXT03.5DAP
3HNXT03.5EA5




Problem Description



Original equipment catalytic converters may fail
due to problems with retention of the ceramic
substrate in the converter container. Failure of the
substrate mat to retain the substrate can cause the
converter to rattle, eventually resulting in the
complete erosion of the substrate.
Remedy: 1gg6 ! 999 model year vehicles will .
have warranties for catalytic converters extended
to 10 years or 120,000 miles, whichever occurs
first. Vehicles in this category that have already
exceeded 10 years or 120,000 miles will receive
an extended catalytic converter warranty of one
year with unlimited mileage from the date of the
letter to the owner, or two years with unlimited
mileage if the vehicle fails a state emissions
inspection. (Vehicles that have had the improved
catalytic converter installed are excluded.) 2000
model year vehicles will have warranties for their
catalytic converters extended for at least one year
without mileage limitation after the date of the
letter to the owner.
Original equipment catalytic converters may fail
due to problems with retention of the ceramic
substrate in the converter container. Failure of the
substrate mat to retain the substrate can cause the
converter to rattle, eventually resulting in the
complete erosion of the substrate.
erne y. Qwnerswill receive notification letters
about the potential catalytic converter problem as
well as a reminder of the vehicle's original catalytic
converter warranty coverage of 8 years or 80,000
miles, whichever occurs first.
The EGR system may become contaminated or
clogged and/or EGR valve sticking. The OBD
system detects the failures and illuminates the MIL
when the improper EGR flow or valve operation
reaches the OBD monitoring criteria. The vehicle
may hesitate or surge.
Remedy: An improved EGR valve has been
applied to the assembly line and is available for
repair. EGR valves will be replaced under service
bulletin #05-026 and Acura service bulletin #05-
019 under Honda's warranty extension campaign.
Warranty extended to 8 years or 80,000 miles
whichever comes first.
Affected
Vehicles


682806


















296809








50407
126721
124194
44305
148659
49047
71378
50938
16731




Sales Area



Fed, CA, 50S


















Fed, CA, 50S








NF(CFV+CA+NL)
NF(CFV+CA+NL)
NF(CFV+CA+NL)
CL(CA+NLEVALLS)
CA
CL(CA+NLEVALLS)
CA
FED
CA




Total
Number of
Vehicles
Recalled
682806


















296809








682380











EPA420-B-06-001
                                                                                                                                                       February 2006

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                             2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks*
                                                                                 Voluntary Service Campaigns
HYUNDAI












KIA














V04












07.28.05.01
(SC043)














1843&
1965











3039














IVSC












VSC














1/1/2005












10/17/2005














1999
1999
2000
2000
2001
2001
2001
2002
2002
2003
2003


2005














Elantra/Tiburon
Elantra/Tiburon
Elantra/Tiburon
Elantra/Tiburon
Elantra/Tiburon
Elantra/Tiburon
Elantra/Tiburon
Elantra/Tiburon
Elantra/Tiburon
Tiburon
Tiburon


Serento LX














XHYXV02.01RF
XHYXV02.03RC
YHYXV02.0G1F
YHYXV02.0G3S
1HYXV02.0R3S
1HYXV02.0X4C
1HYXV02.0X3F
2HYXV02.0XLF
2HYXV02.0XUC
3HYXV02.0CLF
3HYXV02.0CUC


5KMXT03.5CM5














Some Hyundai Elantra/Tiburon's equipped with 2.0
liter 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: j0 corTect this condition, 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. Dealers will
inspect and replace as necessary. Warranty
extended 1 0 years without mileage limitation.
Some 2005 model year Sorento's equipped with
3.5 liter engines have experienced a malfunction
indicator light (MIL) illumination. The fault
determined by the OBD system is a canister close
valve clogging (P2422) caused by road dirt
clogging the air filter in the vent line during the
purge drive condition. The partial wheel well cover
did not provide sufficient protection to prevent the
CCV filter from being contaminated.
^"f./'-Kia will replace; the partial.wheel guard
with full-size wheefguard to eliminate the source
of the road debris from contaminating the filter. Kia
will issue a TSB explaining a corrective action for
this problem, and will conduct a voluntary service
campaign, with owner's notification to implement
the correction as necessary.
34230
31806
66764
71875
22124
55686
48376
28870
31915
546
595


18865














FED
CA
FED
CA
50S
CA
FED
FED
CA
FED
CA


CA














392787












18865














                      Type:
                      O- Ordered by EPA
                      l-VSC-[y|anufacturer voluntary Service Campaign with EPA Influence
                          "Voluntary Service Campaign by Manufacturer
Total number of vehicles in Voluntary Service Campaigns:
       Total number of Voluntary Service
                             Campaigns:     5
                                                                        2,073,647
                      Sales Area:
                      CL- California + NLEV (all States)
                      FED- Federal States (all altitude)
                      CA- California

                      FED/NLEV- Northeast States (all Altitude)
                      NLfNLEV ALLS) - NLEV + All States
                      NE+CA- NLEV Northeast States+California
                      CE- California + NLEV
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 bean 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 vehicles Affected by Voluntary Recalls
       Total number of all Recalls and all
           Voluntary Service Campaigns:     36
and Voluntary Service Campaigns:
                                                                        3,383,469
EPA420-B-06-001
                                                                                                                                                                                          February 2006

-------