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
------- |