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
-------
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
-------
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
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