2006 Annual Summary of Emission- Related Recall and Voluntary Service Campaigns Performed on Light Duty Vehicles and Light-Duty Trucks United States Environmental Protection Agency ------- 2006 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 v>EPA United States EPA420-B-07-003 Environmental Protection May 2007 Agency ------- Abbreviations and Acronyms Acronym/Term: ALLS GARB CFV DTC ECU ECM EGR MIL NHTSA NLEV OBD PCM TSB VECI Recall Type: 0 V vsc I Sales Area: SOS CL CA FA FC NF NL Definition: All States Trading Region California Air Resources Board Clean Fuel Vehicle Diagnostic Trouble Code Engine Control Unit Engine Control Module Exhaust Gas Recirculation Malfunction Indicator Light National Highway Traffic Safety Administration National Low Emission Vehicle On-Board Diagnostics Powertrain Control Module Technical Service Bulletin Vehicle Emission Control Information Definition: Ordered by EPA Voluntary Recall by Manufacturer Voluntary Service Campaign by Manufacturer Manufacturer voluntary action with EPA Influence Definition: Federal and California CA +NLEV (ALLS) California Federal (all altitude) FA + CA CFV + NLEV (ALLS) + CA NLEV-ALLS Note: For the purposes of this report only, a Recall Campaign is a direct owner notification requesting or recommending that the vehicle be brought into a service facility for inspection and/or repair regardless of whether there is an indication of failure. For the purposes of this report only, a Voluntary Service Campaign is a direct owner notification alerting the owner of a potential problem should there be an indication of failure, and how the problem will be remedied by the manufacturer should the problem affect the owner's vehicle. EPA recognizes that manufacturers may wish to voluntarily notify their customers of potential issues for which service may be required. However, under 40 CFR 85.1902 (d), any repair, adjustment, or modification program voluntarily initiated by a manufacturer to remedy any emission-related defect for which direct owner notification is provided is defined as a Voluntary Emissions Recall. EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Recall Campaigns Mfr. BENTLEY BMW BMW BMW Mfr. Recall Number SC 06/10 06E-A03 06E-A02 06E-A01 EPA# 2812 2752 3050 3058 Type V V V V Owners Notification 10/6/2006 9/11/2006 6/1/2006 4/24/2006 MY 2007 2000 2001 2001 2002 2002 2003 2003 2004 2002 2003 2004 2004 2006 Vehicle or Engine Class Continental GT, Continental GTC, Continental Flying Spur M5, Z8 M3 Coupe, M3 Cabrio, M Coupe, M Roadster M5, Z8 M3 Coupe, M3 Cabrio, M Coupe, M Roadster M5, Z8 M3 Coupe, M3 Cabrio M5, Z8 M3 Coupe, M3 Cabrio BMW745I, 745LI BMW745I, 745LI BMW545I, 745i, 745LI, 645CI, 645Q Cabrio BMWX54.4I, X5 4.8is 325i/iA/xi/xiA/xiTA; 330i/iA/xi/xiA; 525i/iA/xi/xiA; 530i/iA/xi/xiA/xiTA 325i/Ci/iT, 330i/Ci, 525I, 530I, X3 3.0 Z4 2.5i 325i, 330Q, 530i X32.5, X3, 3.0 Z4 3.0i 330i, 330Q, 530i Engine Family 7BEXV06.0501 YBMXV04.9S62 1BMXV03.2S54 1BMXV04.9362 2BMXV03.2S54 2BMXV04.9S62 3BMXV03.2S54 3BMXV04.9S62 4BMXV043.2S54 2BMXV04.4LEV 3BMXV04.4LEV 4BMXV04.4LEV 4BMXT04.4N62 6BMXV03.0N52 5BMXV03.0UL2 5BMXV03.0LER 5BMXV02.5M56 5BMXV03.0E83 5BMXV03.0M5R 5BMXV03.0SMG Problem Description A defect was found in the Air Flow Pressure Sensor which caused customer complaints from MIL illumination. This was caused by the absence of the sensor's reference port sealing feature. Remedy: A recall was issued by Bentley to correct the problem. On affected M-vehicles a communication problem with certain brands of scan tools may occur during the initialization procedure. If a scan tool starts with International Standards Organization (ISO) 14230 protocol before ISO 9141 no communication with the ECU can be realized and the vehicles fail the Inspection/Maintenance test. The MIL will illuminate. Remedy: BMW implemented a voluntary emissions recall campaign to remedy the problem on all affected vehicles by updating the ECU program software. Defective Positive Crankcase Ventilation (PCV) valve from torn membrane caused by chemical reaction of carbonyl compounds (acetic and formic acid) in PCV gas stream. DTCs stored in ECM and MIL illumination lead owner to seek repair. The damaged membrane lets un-metered air into the intake system which drifts the air/fuel ratio out of specified range so exhaust emission standards, could be exceeded. Remedy: BMW implemented a recall. An improved silicone material is used in the PCV valve for production and repair kits. The crankcase ventilation valves are replaced on both cylinder banks of the affected vehicles using improved parts. Faulty Digital Motor Electronics control module software may not correctly detect a potential emission relevant sensor failure. The scan tool cannot read out the Valvetronic position control fault code. Remedy: Authorized BMW center will reprogram the Digital Motor Electronics engine control module with an improved version of the software at no charge to the owner. Affected Vehicles 759 3,081 4,546 3,053 10,194 2,841 8,676 2,453 8,538 18,222 20,722 30,025 8,803 69,432 68,900 17,000 7,000 6,400 4,000 1,700 Sales Area 50S CL(CA+NLEVALLS) NF(CFV+CA+NL) CL(CA+NLEVALLS) CL(CA+NLEVALLS) CL(CA+NLEVALLS) NF(CFV+CA+NL) CL(CA+NLEVALLS) CA NF(CFV+CA+NL) NF(CFV+CA+NL) 50S 50S 50S Total Number of Vehicles Recalled 759 43,382 77,772 174,432 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Recall Campaigns Mfr. BMW DAIMLER/ CHRYSLER DAIMLER/ CHRYSLER DAIMLER/ CHRYSLER DAIMLER/ CHRYSLER DAIMLER/ CHRYSLER Mfr. Recall Number 06E-A04 EDIR-2006-5 F07 EDIR2006-6-E& F02 2006-1 7-EF25 2006-1 8-E F29 2006-1 9-E F37 EPA# 3070 2661 2663 2736 2740 2741 Type V V V V V V Owners Notification 12/7/2006 3/3/2006 4/1/2006 9/4/2006 6/30/2006 11/27/2006 MY 2006 2006 2006 2006 2000 2000 2002 2002 2000 2000 2007 2005 2006 Vehicle or Engine Class BMWM5, M6 Coupe Dodge Viper Jeep Liberty Jeep Liberty Grand Jeep Cherokee Dodge Caliber Dodge Caliber Dodge Caliber Dodge Caliber Jeep Liberty Engine Family 6BMXV05.0S85 6CRXV08.3VMO 6CRXT03.7NEO 6CRXT0226N70 YCRXT04.02BO YCRXT0242230 2CRXT04.02D2 YCRXT04.02ZO YCRXT0287231 YCRXT04.72B1 7CRXV0110M70 7CRXV01.8MEO 7CRXB0144M80 7CRXB02.4ME5 5CRXT02.82RX 6CRXT02.82RX Problem Description A software error in the Digital Motor Electronics engine control module results in failure of the diagnostic system to detect certain emissions related problems and illuminate the MIL to warn the driver of a malfunction in affected vehicles. The OBD system may not detect a potential malfunction of the secondary air pump relay and/or would store "wrong" corresponding fault codes for the air flow sensor, the oxygen sensor and the throttle valve actuator. Remedy: The vehicle repair will be free of charge and consists of a software update of the DME engine control module. The VECI labels do not display the proper emission control system classification for two oxidation catalysts. Remedy: DaimlerChrysler will conduct a Voluntary Emission Recall (F07) of the affected vehicles and mail a revised VECI label to the owner for installation on the vehicle by owner or dealer. The wiring for left rear O2 sensor may contact the exhaust and melt, resulting in possible electrical shorts. The OBD oxygen sensor diagnostics will detect the melted wire insulation and shorted contact condition; then illuminate the MIL. There will be loss of fuel trim provided by this sensor signal, however fuel control will still remain closed-loop. Remedy: The issue has been corrected in production by reducing the wiring length. A safety recall (F02) will be conducted to secure excess slack in the O2 sensor wiring on suspect vehicles. On some 2000 and 2002 Grand Jeep Cherokees the plastic material used to make the cooling fan blade may fracture and separate. Exhaust emissions may be affected if the engine overheats. Customers of affected vehicles frequently describe hearing a loud noise and noticing a rapid rise in coolant temperature or a coolant leak; plus, there may be steam from the engine compartment. Also, a safety recall (F25) was conducted; because, if the hood is open people nearby could be injured. Remedy: The electric radiator cooling fan will be replaced free of charge under recall F25. The thermostat monitor portion of the engine cooling system monitor is incorrectly configured so that a failed thermostat can never be detected twice in a row (to a matured MIL fault). After the first failure the monitor erroneously suspends itself and the MIL will not be illuminated if the thermostat fails. Remedy: DaimlerChrysler will conduct a voluntary emissions recall to re-flash the PCM of the affected vehicles. High torsional forces from the engine during low speed lock-up can lead to torque converter overheating with internal damage and improper lock-up. Exhaust emissions may be affected if converter doesn't lock-up properly, rattle-like sounds will come from torque converter area, DTC P0740 may set, and MIL may be illuminated. Remedy: Notice issued with recall to repair affected vehicles by installing a new torque converter and engine & trans, software modifications. Depending on service testing, some vehicles may require a transmission flush and pump replacement. Affected Vehicles 4,256 513 12,639 1,843 48,422 30,790 44,434 21,672 15,816 23,260 101 569 5,689 23,242 8,629 2,657 Sales Area CA 50S 50S CA FA CA 50S 50S CL(CA+NLEVALLS) FA CA FA CA FA FA Total Number of Vehicles Recalled 4,256 513 14,482 184,394 29,601 11,286 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Recall Campaigns Mfr. DAIMLER/ CHRYSLER DAIMLER/ CHRYSLER GENERAL MOTORS GENERAL MOTORS HONDA/ACURA HONDA/ACURA Mfr. Recall Number 2006-22-E 2006-31 -E1 ML-MW201 ML-MW156 EDIR-05-012-00 EDIR-05-012-01 VERR-06-007-01 EPA# 2757 2826 2842 3066 2560 2692 Type V V V V V V Owners Notification 10/1/2006 11/1/2006 12/19/2006 3/1/2006 12/9/2005 * Reported to EPA In 2006 7/28/2006 7/28/2006 MY 2006 2006 2005 2006 2007 2004 2004 2005 2006 2006 Vehicle or Engine Class Dodge Ram 1500 Dodge Ram 1500 Chrysler Pacifica Chrysler Pacifica Chrysler Pacifica Chrysler Pacifica Cadillac STS Cadillac XLR Cadillac SRX Accord Hybrid Insight (CVT) Insight (MT) Engine Family 6CRXT04.75SO 6CRXT04.76UO 5CRXT03.8NEO 5CRXT03.52NO 6CRXT03.8NEO 6CRXT03.52NO 7GMXB03.6149 4GMXV04.6067 4GMXT04.6161 5HNXV03.01B4 6HNXV01.0VK5 6HNXV01.0YJV Problem Description The oxygen sensor electrical diagnostics (shorted high and shorted low) on some Dodge Ram 1500s equipped with 4.7L & manual transmission do not allow a shorted high or a shorted low event fault to mature. The diagnostic can only count one shorted event so this prevents the MIL from illuminating. Other diagnostics will detect subsequent problems caused by a shorted oxygen sensor but there still is reduced overall OBD capability. Remedy: DaimlerChrysler will supply all dealers with an ECM calibration reflash which will assure OBD functionality. The vehicles have a saddlebag type fuel tank where fuel is moved from secondary side to primary side until secondary side is empty. Several fuel delivery problems may cause hesitation or stalling that could cause a crash without warning. NHTSA Recall no. 06V-432 addresses these problems involving the fuel pump module (fuel shut-off) and PCM software (excess vapor purge) for evaporative emissions control. Remedy: All vehicles to receive PCM calibration reflash to assure correct purge functionality. The fuel pump module will be replaced, if required. Chrysler recall F44 provides that owners may obtain the repair service any time after receipt of the notification. Certain vehicles with 3.6L engines were produced with ECM calibration fuel trim diagnostics turned off. This violates emission regulations for OBD II which requires functional fuel trim diagnostics. Remedy: The dealers will use technical service bulletin 06213 to reprogram the ECM at no charge to the customer. Incorrect engine control module programming causes a certain canister purge solenoid circuit to malfunction. The malfunction(s) will disable other OBD monitors without storing a Diagnostic Trouble Code or illuminating the Malfunction Indicator Light. Remedy: Voluntary emission recall 06503 will be conducted in March of 2006 on 2004 MY vehicles to install corrected OBD calibrations at no charge to the owner. The OBD system may falsely detect a misfire immediately following a code clear with a scan tool unless the technician performs the learning procedure. The MIL illuminates. Battery damage may also occur. Honda has made available instructions on how to clear the codes. Remedy: The PCM will be reprogrammed free of charge with appropriate programming by a Honda dealership per TSB #05- 038. After certain continuous driving period, the OBD system falsely detects a malfunction of engine off timer. The cause of the failure is incorrect programming of the OBD system. A PCM with improved programming has been applied to the assembly line and is made available for repair under running change #S2. When this defect occurs, the MIL comes on with DTC P2610. Remedy: The recall requires that the Programmed Fuel Injection Control System software be updated in the ECM (TSB #06-053) at no charge to the owner. The ECM/PCM will be reprogrammed with remedied programming by Honda dealership. Affected Vehicles 320 791 17,090 76,453 4 37,951 4,758 3,861 13,563 6,600 218 274 Sales Area 50S 50S 50S 50S 50S 50S 50S 50S FC (FA + CA) 50S 50S 50S Total Number of Vehicles Recalled 1,111 131,498 4,758 17,424 6,600 492 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Recall Campaigns Mfr. ISUZU JAGUAR KIA LAMBORGHINI MAZDA Mfr. Recall Number ML-MW171 R726 04.28.06.01 2006/04/13 2006/05/09 2006/07/10 4106E EPA# 2703 2865 3068 2705 2739 Type V V V V V Owners Notification 3/13/2006 10/26/2006 8/1/2006 8/28/2006 6/1/2006 MY 2006 2006 2006 2007 2006 1996 1997 1998 1999 2001 2002 2003 2004 2004 2006 2006 Vehicle or Engine Class Ascender XJ8, XJ8L, VDP LWB XJR, SUPER V8 XJR, SUPER V8 XJ8, XJ8L, VDP LWB Rio (JB) DB 132 Diablo DB 132/1 44 Diablo DB 132/1 44 Diablo DB 132/1 44 Diablo DB 132/1 44 Diablo L 147 Murcielago L 147 Murcielago L 147 Murcielago L140Gallardo Mazdaspeed 6 2.3L Mazdaspeed 6 2.3L Engine Family 6GMXT04.2186 6JCXV04.2DN 6JCXV04.2DSK 7JCXV04.2DSK 7JCXV04.2DNK 6MXV01.6BM5 TN5.7VJGFHK VNL5.7VJGFHK WNLXV05.7DB8 XNLXV05.7DB8 1NLXV06.0321 2NLXV06.2472 3NLXV06.2472 4NLXV06.2474 4NLXV05.0404 6TKXV02.35EA 6TKXV02.3NE1 Problem Description Isuzu vehicles were delivered to dealers in California and two Northeast States (Massachusetts and New York) with Federal Emissions Calibration software and emissions label, a limited number of which were sold to retail customers. None of the affected vehicles were delivered to or sold in Vermont or Maine. Remedy: To correct the condition all of the subject vehicles will receive the proper emissions calibration software and vehicle emissions label. Some fuel tanks were not made to specification and will leak when fully filled. If there is fuel odor, or fuel leaking from Fuel Delivery Module, Jet Pump Module and/or cluster valve seals; MIL is likely to be illuminated. Fuel may leak onto the ground which could result in a fire. Remedy: Fuel tank replacement is being carried out per NHTSA Safety Recall Action R726 and technical service bulletin R726. All repairs will be performed by Jaguar dealers. The original design included a coin box behind the cover to the OBD connector which was in violation of the GARB regulation Title 13 California Code of Regulations Section 1968.2 (f) 2.2. Remedy: The recall by Kia shows that the access problem requiring removal of a coin holder-type fuse cover to the OBD connector will be solved by replacing the original cover with a flat- type fuse cover. This will minimize efforts to access the diagnostic connector of the OBD system. A condition exists in the ECM software of all MY1996 to MY2004 Lamborghini vehicles sold in the US market causing the following fault. The OBD readiness status of installed monitor components and systems within the OBD are cleared at key off event. Production software improvements were made starting MY2005. Remedy: Recall (issued 7/21/2006) will upgrade the Engine Management System software at service department of authorized dealer. Incorrect PCM calibration causes ignition timing retard and turbo boost pressure limitation to operate excessively when constant engine knocking occurs under high ambient temperature and high load driving even with premium fuel. Remedy: PCM will be reprogrammed by Mazda dealer and recall label #4106E will be attached on driver's door. Affected Vehicles 32 4,800 708 120 571 24,837 24 75 104 160 148 98 169 121 697 6,500 Sales Area CA 50S 50S 50S 50S 50S 50S 50S 50S 50S 50S 50S 50S 50S 50S 50S Total Number of Vehicles Recalled 32 6,199 24,837 1,596 6,500 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Recall Campaigns Mfr. MAZDA MERCEDES-BENZ MERCEDES-BENZ MITSUBISHI/ D-STAR Mfr. Recall Number 4206F MB002-2005 2006-070003 06XMED0160 EPA# 2788 2582 2790 2669 Type I V V V Owners Notification 8/31/2006 4/1/2006 10/1/2006 8/1/2006 MY 2004 2005 2005 2006 2002 2002 2003 2003 2004 2004 2005 2006 2005 2006 2004 2004 2005 2005 Vehicle or Engine Class Mazda RX-8 SLK 32 AMG, C32 AMG CL55AMG, S55 AMG SLK 32 AMG, C 32 AMG CL55AMG, S55 AMG, E 55 AMG CL55AMG, S55 AMG, E 55 AMG SLK 32 AMG, C 32 AMG CL55AMG, S55 AMG CL55AMG, S55 AMG, SL55AMG, E 55 AMG, CLS 55 AMG, SLR E320 GDI Galant Engine Family 4TKXV01.3CNA 5TKXV01.35NM 5TKXV01.3NC1 6TKXV01.35DA 2MBXV03.2LBI 2MBXV05.5LBI 3MBXV03.2LBI 3MBXV05.5LBI 4MBXV05.5LBX 4MBXV03.2LBI 5MBXV05.5LBI 6MBXV05.5LB1 5MBXV03.2B10 6MBXV03.2B10 4DSXV02.4GRB 4DSXV02.4G6G 5DSXV02.4G6G 5DSXV02.4GRB Problem Description Due to insufficient control of oil supply, the engine may suffer from the lack of engine oil under certain driving conditions. If the vehicle continues to be driven with such condition, the sealing capability of combustion chamber may be degraded, causing drivability or emission problems. Due to wrong PCM calibration, carbon may deposit on spark plugs or plugs may be flooded during engine start, causing difficult start condition. In addition, as a result of wrong service procedure when recovering from difficult start condition, the catalytic converter may be damaged on some vehicles. Remedy: Mazda at no charge will reprogram the PCM for latest calibration and inspect plus repair/replace if necessary: spark plugs, engine, and catalytic converter. An air injection pump, designed to operate during engine warm up periods, may fail to turn off at specified time. This will cause the pump to overheat and burn out. When the pump fails a MIL light will illuminate. Remedy: Mercedes and ECU-supplier have identified a software modification which will prevent random electromagnetic impulses from affecting the air injection pump. The ECU software will be updated and the pump relay replaced. Due to a spare part documentation error on certain model year 2005/2006 E320 GDI Diesel vehicles, glow plugs were installed by dealerships as part of the workshop visit which were not released for use in the E320 GDI engine. Since these glow plugs are extending deeper into the combustion chambers than serial glow plugs it might occur under adverse positions of glow plug and piston in their permissible tolerance bands that a piston hit the glow plug at top dead center, thereby damaging both components. Remedy: In this campaign the glow plugs on the affected vehicles will be replaced at no charge to owner. Inadequate software calibration that may result in damage to the warm-up catalytic converter and subsequent illumination of the "Service Engine Soon" lamp when operated under certain specific driving conditions. Emissions may exceed standards and performance reduced (flow restriction thru catalyst) if vehicle operated for extended period after MIL is illuminated. Remedy: Reprogram ECU with Read-Only Memory upgrade free of charge without regard to mileage or time-in-service. If vehicle accumulated mileage exceeds 80,000 Federal or 150,000 CA, and Service Engine Soon is illuminated; then warm-up catalytic converter is replaced free of charge, if recall is completed within 6 months of the date of this notice. Affected Vehicles 37,300 17,700 17,700 5,800 2,761 1,973 1,335 4,152 3,401 515 1,318 3,659 92 24,957 7,889 5,245 18,375 Sales Area 50S 50S 50S 50S CL(CA+NLEVALLS) CL(CA+NLEVALLS) CL(CA+NLEVALLS) CL(CA+NLEVALLS) 50S 50S 50S 50S FA FA CA CA FA Total Number of Vehicles Recalled 78,500 19,114 92 56,466 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Recall Campaigns Mfr. MITSUBISHI/ D-STAR NISSAN/INFINITI NISSAN/INFINITI NISSAN/INFINITI NISSAN/INFINITI Mfr. Recall Number EMR-06-003 06V-54 R505/05V-555 NHTSA06V2230 00 R0606 EPA# 2832 2743 2744 2760 2775 Type V V V V V Owners Notification 11/1/2006 3/21/2006 2/13/2006 6/9/2006 8/21/2006 MY 2006 2005 2003 2003 2003 2003 2004 2004 2004 2005 2006 2006 2006 2003 Vehicle or Engine Class Eclipse Murano G35 Sedan A/T 350Z, G35 Sedan/Coupe FX35 FX45 350Z, G35 Sedan/Coupe G3 5 Sedan AWG FX35 FX45 FX45 FX45 Altima and Sentra Altima and Sentra Altima S Sedan Sentra SE-R Sedan Engine Family 6DSXV03.8GRC 5NSXT03.5G7A 3NSXV03.5C7A 3NSXV03.5C7B 3NSXT03.5C7B 3NSXT04.5C8A 4NSXT03.5G7A 4NSXV03.5G7C 4NSXT03.5G7A 4NSXT04.5M8A 5NSXT04.5M8A 6NSXT04.5M8A 6NSXV02.5G5A 6NSXV02.585A 6NSXV02.5S5A 6NSXV02.5N5A 3 NSXV02.5D5A 3NSXV02.5C5A Problem Description Incorrect software parameters may cause illumination of the MIL because of DTCP0421 and/or P0431. Catalytic converter replacement may be necessary. Remedy: All affected vehicles get free of charge PCM reprogramming. If affected vehicle has a MIL (Service Engine Soon) lamp on and DTC P0421 and/or P0431 set before reprogramming the PCM; the warm-up catalytic converter is replaced, using an exhaust manifold repair kit. A fitting for vapor recirculation, which is welded on the fuel tank on Nissan Murano vehicles is coming off as indicated by the MIL. Remedy: A recall 06V-54 will be implemented. The fuel tank will be replaced with a new one. On some 2003 - 2004 Nissan vehicles the fuel filler hose may crack and result in fuel and vapor leakage. The M IL may illuminate. Remedy: A recall (R505/05V-555) will be implemented. Nissan to replace the fuel filler and vapor hoses with new ones. Excessive engine oil consumption may occur as a result of improper performance of the piston rings. If the oil is not maintained at least at the minimum level, engine damage can occur and in extreme cases may result in an engine fire. Remedy: Dealers will reprogram the electronic control module (engine computer). Vehicle will also be inspected to determine if it has been consuming engine oil at a higher than normal rate. A service bulletin (NTB06-045a) was issued as part of this recall. In a small percentage of vehicles, engine replacement will be needed. Engine may stop running due to a brief interruption in the crank angle sensor output signal. The location of the sensor in the engine has large enough variations in temperature to cause a brief interruption in the signal output from the sensor. The ECM logic doesn't have enough time to diagnose the condition, so the engine may stop running (vehicle stall). Remedy: The ECM will be reprogrammed to prevent stalling incidents due to signal interruptions from the crank angle sensor. A service bulletin, NTB06-051 was issued for this recall. Affected Vehicles 12,209 14,268 54,200 65,721 17,640 6,462 36,081 31 26,596 3,799 1,877 6 69,228 21,323 491 1,893 186,279 14,587 Sales Area CA CA CL(CA+NLEVALLS) CL(CA+NLEVALLS) CL(CA+NLEVALLS) CL(CA+NLEVALLS) CA CA CA CA CA CA 50S CA 50S 50S 50S Total Number of Vehicles Recalled 12,209 14,268 212,413 92,935 200,866 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Recall Campaigns Mfr. SUBARU SUZUKI TOYOTA/LEXUS VOLKSWAGEN/ AUDI VOLKSWAGEN/ AUDI Mfr. Recall Number #W/VX-08 SC-32 601 38513 M6 EPA# 2704 2747 2792 2544 2637 Type V V V V V Owners Notification 6/9/2006 7/15/2006 12/15/2006 7/28/2006 8/18/2006 MY 2004 2006 2001 2002 2001 2002 2003 2002 2004 2005 Vehicle or Engine Class Legacy, Outback Verona RAV4 Highlander Highlander A4, Passat Golf/Jetta/New Beetle with 1.9LTDI Engine Golf/Jetta/New Beetle with 1.9LTDI Engine Engine Family 4FJXV02.5NKR 6DXV02.5D04 1TYXT02.0FFH 2TYXT02.0FFH 1TYXT02.4FFP 2TYXT02.4FFP 3TYXT02.4FFP 2ADXV01.8342 4VWXV01.9236 5VWXV01.9236 Problem Description Some 2004 CA Partial Zero Emission Vehicle (PZEV) certified Subaru Legacy /Outback 2. 5L NA models will experience MIL illumination and the storage of DTC P0420 (catalyst system efficiency below threshold). The P0420 illumination condition has been confirmed to be from a unique mixture of excess fuel supply and air that reacts in the catalytic converter resulting in abnormal catalyst degradation. Remedy: SUBARU is conducting a customer service campaign. The repair will include reprogramming the ECM; and possibly catalytic converter replacement, but only if DTC P0420 is present. Incorrect ECM control logic causes leak detection monitoring of the evaporative emission control system to be disabled during subsequent driving cycles if OBD detects a noisy signal from the differential fuel tank pressure sensor and stores pending DTC P0454. If monitor disabled , the MIL will not illuminate if an evaporative emission control system leak occurs during subsequent driving cycles. Remedy: Suzuki will conduct an emissions-related recall to reprogram the ECM in affected vehicles with corrected software. MIL illumination can occur for catalytic converter from DTC P0420/P430 due to improper program logic in Engine Control Module (ECM) and early deterioration of oxygen storage capacity in the catalytic converter. Remedy: Toyota initiated a Special Service Campaign to reprogram the program logic in ECM with improved logic at a Toyota dealership. All owners were notified for this no charge reprogramming. Customers may request reimbursement, if they have previously paid for the program update or, in the rare instance, the replacement of the Catalytic Converter for this specific condition prior to receiving the owner letter. The crankcase ventilation hose is broken or cracked and shows visible signs of deterioration. In most cases a M IL and / or oil leakage and / or engine starting problems will occur. Remedy: A recall has been issued to replace the crankcase breather hose with a new hose of improved material. Internal coolant leak in EGR cooler assembly leads to customer complaint from Engine coolant light (low coolant)/MIL being on. NOx emission values increase when EGR cooler is blocked at the regulating flap and cooler connecting pipe. Remedy: The vendor's manufacturing process was optimized to assure the elimination of any internal leaks in the EGR cooler. Dealers will replace the EGR cooler on affected vehicles, Recall M6. Affected Vehicles 21,516 2,000 87,000 72,000 13,000 21,000 27,000 77,106 18,690 21 Sales Area 50S 50S CL(CA+NLEVALLS) CL(CA+NLEVALLS) CL(CA+NLEVALLS) CL(CA+NLEVALLS) FA FA Total Number of Vehicles Recalled 21,516 2,000 220,000 77,106 18,711 Total number of Vehicles affected by Recall Campaigns: 1,768,120 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Voluntary Service Campaigns Mfr. FORD GENERAL MOTORS GENERAL MOTORS HONDA/ACURA MERCEDES-BENZ Mfr. Recall Number 06N07 ML-MW196 ML-MW199 PUDR WER-04- 005-00 2005-020004 EPA# 2831 2686 2687 2751 2751 2751 2776 2776 2776 2777 2777 3043 3056 2269 2362 Type vsc vsc vsc vsc I-VSC Owners Notification 12/1/2006 11/9/2006 1 2/4/2006 5/13/2006 2/1/2005 * Reported to EPA In 2006 MY 2004 2005 2006 2004 2004 2004 2004 2005 2003 2003 2004 2004 2004 2004 2000 2000 2001 2002 2000 2001 2001 2002 2002 2003 2003 2004 2004 2000 Vehicle or Engine Class Ford Taurus/Mercury Sable Chevrolet Aveo Chevrolet Malibu Saturn L300 Saturn LW300 Saturn L300 Sabb 9-3 Sabb 9-3 Sabb 9-3 Cadillac SRX Cadillac XLR Chevrolet Malibu Chevrolet Camaro Pontiac Firebird Chevrolet Camaro Pontiac Firebird Chevrolet Camaro Pontiac Firebird Chevrolet Camaro Pontiac Firebird Insight (MT) Insight (MT) Insight (CVT) Insight (CVT) Insight (MT) Insight (MT) Insight (CVT) Insight (MT) Insight (CVT) S CLASS, CL CLASS Engine Family 4FMXV03.0VFZ 5FMXV03.0VFZ 6FMXV03.0VFZ 4GDXV01.6D02 4GMXV03.8041 4GMXV03.0061 4GMXV03.0061 5GMXV03.0061 3GMXV02.0002 3GMXV02.3001 4GMXV02.0002 4GMXT04.6161 4GMXV04.6067 4GMXV02.2028 YGMXV05.7081 YGMXV05.7083 1GMXV05.7081 2GMXV05.7081 YHNXV01.0LA4 1HNXV01.0FH6 1HNXV01.0HEV 2HNXV01.0CCE 2HNXV01.02N4 3HNXV01.01A4 3HNXV01.0PCE 4HNXV01.02A6 4HNXV01.0NCE YMBXV05.0GNB Problem Description Some 2004-2006 Taurus/Sables with Flex Fuel Vehicle (FFV) 3.0I may experience a long or hard crank during cold starting while operating on Ethanol 85% (E85) under circumstances that result in a leaner fuel mixture than desired. Remedy: A revised calibration was implemented and TSB 06-5-5 was issued to assist service technicians in diagnosing and correcting the concern. Customer Satisfaction Program was issued 12/01/2006 which added 10 YR and 100,000 mile coverage as a one time reflash of PCM. Owners may experience a condition where the fuel tank gas cap won't tighten properly or the fuel cap won't come off, or is broken. These conditions can cause the illumination of the Malfunction Indicator Light (MIL). Additionally, a DTC can be set if fuel cap does not seal adequately at the filler neck surface. Remedy: If this condition occurs on an owner's vehicle within 1 0 years of the date the vehicle was originally placed in service or 120,000 miles, whichever occurs first, the condition will be repaired for the owner at no charge. Special Coverage Service Bulletin No. 06081 was issued for this evaporative emissions problem. The component that failed is the catalytic converter. The failure is lost oxygen storage capacity in the catalyst. The probable cause is that the catalyst technology used in this application is not robust against the potential operating exhaust temperatures. Typical customer complaint is MIL illumination. Remedy: A Special Coverage Extended Warranty will be implemented for potentially affected vehicles to cover servicing of the catalytic converter to 10 years/120,000 miles, whichever occurs first. Dealers are to service all vehicles subject to this campaign at no charge to owners, subject to the terms of the special coverage. Overcharging of the Integrated Motor Assist (IMA) battery causes deterioration of the battery unexpectedly. The MIL illuminates. The cause of failure is inappropriate calibration of the Battery Condition Monitor Module. An improved battery ECM calibration has been applied to the assembly line and is made available for repair under Running Change/Field Fix #E5 and for warranty service, TSB 04-028. Remedy: Warranty extended on Battery Control Module to 10 years or 150,000 miles. The Battery Control Module and Motor Control Module will be replaced with improved ones at Honda dealerships. A failed IMA battery will be replaced with a new one under warranty extension. The ceramic monolith substrate in the catalysts of certain model 2000 S and CL class MERCEDES-BENZ vehicles may be damaged under certain circumstances. This will illuminate the OBD MIL until vehicle is serviced. Remedy: MBUSA will notify owners that their vehicle will be repaired under extended warranty which will increase from 8/80, 000 to 10/unlimited. Affected Vehicles 45,100 90,300 8,500 55,208 73,301 10,931 1,499 6,789 7,418 17,885 29,188 13,554 3,852 26,916 13,073 12,228 6,521 4,349 12,231 11,587 23,741 19,851 1,861 800 656 559 250 112 310 46 164 20,147 Sales Area 50S FC (FA + CA) FC (FA + CA) FC (FA + CA) FC(FA + CA) NF (CFV+CA+NL) NF (CFV+CA+NL) NF (CFV+CA+NL) FC (FA + CA) FC (FA + CA) 50S FC (FA + CA) 50S 50S CA CA CA CA CA CA NF (CFV+CA+NL) NF (CFV+CA+NL) NF (CFV+CA+NL) NF (CFV+CA+NL) NF (CFV+CA+NL) CL(CA+NLEVALLS) 50S 50S 50S CL(CA+NLEVALLS) Total Number of Vehicles Recalled 143,900 246,541 103,581 4,758 20,147 EPA420-B-07-003 May 2007 ------- 2006 Emissions-Related Voluntary Service Campaigns Mfr. MITSUBISHI I/D-STAR VOLVO Mfr. Recall Number FMS-013 VSC155 EPA# 2836 2655 Type vsc I-VSC Owners Notification 11/1/2006 4/1/2006 MY 2003 1999 1999 1999 1999 1999 1999 1999 2000 2000 2000 2000 2000 2000 2001 2001 2001 2001 2001 2001 2002 2002 Vehicle or Engine Class Mitsubishi Outlander 4WD S70 AWD, V70 AWD, V70 XC S70, V70, C70 (Turbo) S70, V70 S80 (Turbo) S80 S70, S70 AWD, V70, V70 AWD, V70 XC, 070 S70, V70 S80 (Turbo) S80 V70 XC AWD C70, S60, V70, V70 AWD S60, V70 S80, S80 Executive S80, S80 Executive C70 (w/o S60, V70) S60, V70 Engine Family 3MTXT02.4GNG XVVXV2.43AW2 XVVXV2.43PA2 XVVXV2.43TF2 XVVXV2.78EN2 XVVXV2.92BU2 YVVXV2.43PA3 YVVXV2.43TF3 YVVXV2.78EN3 YVVXV2.92BU3 1VVXT2.43L5T 1VVXV2.43L5T 1VVXV2.43U5N 1VVXV2.78T6T 1VVXV2.92L6N 2VVXV2.43L5T 2VVXV2.43U5N Problem Description The front exhaust pipe bellows may corrode and leak due to contact with road salt in cold weather climates. This will allow untreated exhaust gases into the environment. Remedy: Warranty for front exhaust pipe bellows will be extended to 8-years/80,000 miles. Owners will be mailed a letter explaining extension and requested to insert the letter in their warranty portfolio for future use should they encounter the condition. TSB-06-1 5-001 has been issued to assist technicians in the repair. Electronic Throttle Module (ETM) failure may illuminate Electronic Throttle System light or MIL. Symptoms may include, uneven engine idle, and/or "limp home mode" that could restrict vehicle speed to 10-30 miles per hour. Faults of the ETM are stored as DTCs in the ECM. If OBD II detects a fault that might increase emissions, the MIL is illuminated. Remedy: A software upgrade will be performed at the next service interval, and ETM warranty extended to 10 years or 200,000 miles, whichever comes first. Affected Vehicles 21,699 17,645 17,233 29,576 10,478 15,398 32,323 28,965 12,984 23,238 27,243 36,318 25,131 8,330 17,091 3,360 27,654 Sales Area 50S CL(CA+NLEVALLS) NF (CFV+CA+NL) NF (CFV+CA+NL) CL(CA+NLEVALLS) CL(CA+NLEVALLS) NF (CFV+CA+NL) 50S CL(CA+NLEVALLS) 50S NF (CFV+CA+NL) NF (CFV+CA+NL) 50S 50S NF (CFV+CA+NL) 50S 50S Total Number of Vehicles Recalled 21,699 332,967 Total number of Vehicles affected by Voluntary Service Campaigns: 873,593 Total number of Vehicles affected by Recalls and Voluntary Service Campaigns: 2,641,713 SUMMARY Total number of Voluntary Recalls: 35 Total number of Voluntary Service Campaigns: 7 Total number of Recalls and Voluntary Service Campaigns: 42 EPA420-B-07-003 May 2007 ------- |