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 ------- |