2007 Annual Summary of EmissionRelated Recall and Voluntary Service 

Campaigns Performed on Light-Duty 

Vehicles and Light-Duty Trucks 
2007 Annual Summary of 


Emission-Related Recall and Voluntary 


Service Campaigns Performed on LightDuty Vehicles and Light-Duty Trucks


Compliance and Innovative Strategies Division 

Office of Transportation and Air Quality 

U.S. Environmental Protection Agency 

EPA420-B-08-012 

June 2008 
Abbreviations and Acronyms

Acronym/Term: 

ALLS 

Definition: 

All States 

CARB California Air Resources Board 

CFV Clean Fuel Vehicle 

DTC 

ECU 

EGR 

Diagnostic Trouble Code 

Engine Control Unit 

Exhaust Gas Recirculation 

MIL 

MY 

Malfunction Indicator Light 

Model Year 

NHTSA 

NLEV 

National Highway Traffic Safety Administration 

National Low Emission Vehicle 

OBD 

PCM 

On-Board Diagnostics 

Powertrain Control Module 

TCM Transmission Control Module 

TSB Technical Service Bulletin 

VECI Vehicle Emission Control Information 

VERR 

VSC 

Voluntary Emissions Recall Report 

Voluntary Servcie Campaign 

Recall Type: 

O 

V 

VSC 

I 

Definition: 

Ordered by EPA 

Voluntary Recall by Manufacturer 

Voluntary Service Campaign by Manufacturer 

Manufacturer voluntary action with EPA Influence 

Sales Area: Definition: 

50S All states 

CL 

CA 

CA + NLEV (ALLS) 

California 

FA 

FC 

Federal (all altitude) 

FA + CA 

NF 

NL 

CFV + NLEV (ALLS) + CA 

NLEV - All States 

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-08-012 i June 2008 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

BMW 07E-A01 2955 V 9/25/2007 2007 335 i, 335 i Coupe 7BMXV03.0N54 Software errors inhibit the Digital Motor Electronics (DME) 

from being able to detect certain emissions-related faults. The service engine soon light may not illuminate to warn of an emissions-related malfunction. Remedy: Software errors were corrected for production and BMW will initiate a (VERR) which includes owner notification to reprogram the PCM. The corrective measure consists of a software update in the Engine Control Unit (ECU) module to address the OBD-related shortcomings. Vehicle owners will be asked to make an appointment with an Authorized BMW dealer to have the repair performed. 

Chrysler 2006-23-E (F31) 2758 V 8/15/2006 

* Reported to 

EPA on 

2/15/2007 

2006 Jeep Liberty 6CRXT02.82RX The On-Board Diagnostic (OBD) communications protocol 

supported by the Transmission Control Module (TCM) on some 2006 model year Jeep Liberty vehicles equipped with 2.8L diesel engines is not consistent with the protocol supported with the Engine Control Unit (ECU). Some generic scan tools may be able to communicate with either module but not the other. Remedy: Chrysler will conduct a voluntary emissions recall to reprogram the TCM of the affected population with the proper OBD communications protocol. 

Chrysler 2006-27-E (F47) 2806 V 3/1/2007 2006 Chrysler 300, Dodge 

Magnum, Dodge 

Charger 

6CRXV03.5VE0 The metallic foil substrate of the pre-catalysts may fracture 

and separate due to thermal cycling. Exhaust emissions may exceed applicable standards if pre-catalyst separates. MIL illumination will occur shortly after. Remedy: Chrysler will conduct a voluntary emissions recall to replace suspect catalyst assemblies and to reprogram the Powertrain Control Module (PCM). 

Chrysler 2006-33-E (F49) 2855 V 1/1/2007 2007 Dodge Dakota 7CRXT04.7PE0 An inapplicable Vehicle Emissions Control Information 

(VECI) label was affixed to some 2007 4.7L Dodge Dakota vehicles. Remedy: Chrysler will conduct a voluntary emissions recall to replace the VECI label on affected vehicles. 

Chrysler 2007-4-E (G04) 2878 V 3/1/2007 2007 Chrysler Pacifica 7CRXB0241M80 Some 2007 MY Pacifica vehicles have power train control 

modules with an incorrect oxygen sensor biasing calibration. Remedy: Chrysler will conduct voluntary emissions recall to reprogram power train control module. 

Chrysler 2007-6-E (G06) 2900 V 3/1/2007 2008 Dodge Avenger 8CRXB0144M80 

8CRXB0241M80 

8CRXB02.4ME0 8CRXB04.0ME0 

8CRXV0167M70

 8CRXV02.7MHP 

An inapplicable Vehicle Emissions Control Information (VECI) label was affixed to some early 2008 MY Dodge Avengers. Remedy: Chrysler will conduct a voluntary emissions recall to replace the VECI label on the affected vehicles. 

Chrysler 2007-8-E (G13) 2922 V 4/1/2007 2007 Jeep Grand 

Cherokee 

7CRXT0226N73 

7CRXT03.7NE3 

A Vehicle Emissions Control Information (VECI) label with incorrect evaporative system information was affixed to some 2007 MY Jeep Grand Cherokee vehicles. Remedy: Chrysler will conduct a voluntary emissions recall to replace the VECI label on the affected vehicles. VECI labels will be sent directly to the owners. If the owner is concerned about installation of the label they may take the vehicle to a dealership if they desire. 

EPA420-B-08-012 1 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

Chrysler 2007-15-E (G23) 2960 V 6/21/2007 2007 

2008 2007 

Chrysler Sebring 

Chrysler Sebring, 

Dodge Avenger 

Dodge Ram 2500, 

3500, 

Dodge Ram 1500 

7CRXV0167M70 

7CRXBO241M80 

7CRXB04.0ME1 

7CRXV02.7MHP 

8CRXBO241M80 

8CRXV0167M70 

8CRXB04.0ME0 

8CRXV02.7MHP 

7CRXK0345370 

7CRXKO5.7TX0 

7CRXT0226P81 7CRXT0287P80 7CRXT0345P70 

7CRXT03.7PJO 

7CRXKO5.7PEO 

7CRXKO4.7PJP 

Under certain starting conditions some 2007 and 2008 model year vehicles with Totally Integrated Power Modules (TIPM) and automatic transmissions may have only a single forward gear ratio available for the duration of the trip. This can occur if the key is left in the ignition in the "Off" position for greater than 45 seconds but less than 10 minutes before the engine is started. The vehicle will start normally on the next trip unless the specific start-up sequence is again followed. Both emissions and drivability will be affected when vehicle is stuck in one forward gear. Remedy: Chrysler issued a voluntary emission recall to reprogram the TIPM on affected vehicles. 

Chrysler 2007-28-E (G39) 3342 V 11/1/2007 2007 

2007 2008 2008 

Sebring Sebring 

Sebring/Avenger Sebring/Avenger 

7CRXB0144M80 

7CRXV02.4ME0 

8CRXB0144M80 

8CRXB02.4ME0 

The driver side cooling fan motor electrical connector could become contaminated with engine coolant, which could lead to electrical arching between the motor terminals, potentially causing the fan to quit operating or the connector to overheat. The problem was in the location of the electrical connector which is beneath the overflow spout of the coolant recovery bottle. Remedy: Chrysler will conduct a safety recall to inspect the connector for coolant, clean and repair as necessary. In addition, Chrysler will relocate the cooling fan ground terminal and install a wiring harness overlay. 

Chrysler 2007-02-E (G30) 3349 

3350 3352 

V 10/1/2007 2007 

2007 2007 2007 2008 2008 

Dodge Ram 

2500/3500 

7CEXK040838W 7CEXK040848W 

7CEXK06.7TXW 

7CEXK06.7UXW 

8CEXK06.7TXW 

8CEXK06.7UXW 

The On-Board Diagnostic (OBD) system on these vehicles may not detect a failed oxygen sensor or illuminate the MIL as required and may cause these vehicles to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. In addition, the exhaust soot filter may fail due to cracks from very high temperatures which result, in certain operating conditions, from continued soot loading without adequate regeneration. Remedy: On Cummins' behalf, Chrysler will conduct a recall, the oxygen sensor module must be replaced and the Engine Control Module (ECU) reprogrammed. The new software will also improve vehicle drivability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Also, the "Readiness" issue was fixed in production by a running change software calibration. 

Chrysler 2007-01-E (G37) 3351 V 11/1/2007 2008 Dodge Ram 3500 8CRXK06.7UXW An inapplicable Vehicle Emissions Control Information 

(VECI) label was installed on some early 2008 model year Dodge Ram 3500 vehicles. Some 50-state certified 2008 model year vehicles were built with VECI labels that incorrectly state "Not for sale in states with California emissions standards". Remedy: On Cummins' behalf, Chrysler will conduct a voluntary emissions recall notification to replace the VECI label on the affected vehicles. 

EPA420-B-08-012 2 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

Ford 07E20 2638 V 3/22/2007 2006 Explorer/ 

Mountaineer 

6FMXT04.63EX The On-Board Diagnostic (OBD) system strategy may not 

enable the Malfunction Indicator Light (MIL) for Output Shaft Speed (OSS) sensor faults and MIL and Diagnostic Trouble Codes (DTC) when the Engine Control Module (ECU) loses communication with the Transmission Control Module (TCM). Several problems can occur leading the vehicle operator to seek service; vehicle in a single transmission gear, vehicle will not crank, or vehicle will only operate in reverse, neutral or third gear. Remedy: Ford Motor Company issued a voluntary emissions recall to reprogram the ECU. 

Ford 07E19 2880 I 2/19/2007 2007 F-Series Flex Fuel 

Vehicles 

7FMXT05.44HF Some trucks may have a dual threshold catalyst monitor 

software strategy that disables the catalyst monitor when switching from gasoline to E85 fuel or vice versa. This software error may cause the vehicle to stop monitoring the effectiveness of the catalytic converter and could allow excessive emissions into the environment. Remedy: The Powertrain Control Module (PCM) will be recalibrated by a dealer at no charge to the owner. 

General Motors ML-MW206 2823 V 1/29/2007 2006 Chevrolet Cobalt 6GMXV02.4029 The fuel injector used in this application on certain build 

dates has a fuel seepage problem. Due to lack of adequate process control at the supplier, cracks may develop at the pole piece retention weld inside the fuel injectors. If a crack propagates sufficiently, external fuel seepage may occur. The most likely seepage path is through the injector overmold into the injector connector pocket. Fuel seeping into the connector 

pocket can either wick up inside the injector wiring or hydraulically force the wiring connector from the injector. Remedy: General Motors initiated a voluntary emissions recall to install the revised injectors into the affected vehicles. Injectors produced using the revised process, to eliminate the internal cracking, are now available in production and service. 

General Motors ML-MW213 

15301 

2924 V 4/27/2007 2007 Saab 9-3 Convertible 7GMXV02.3001 Affected vehicles were built with a Vehicle Emissions Control 

Information (VECI) label that has an incorrect emission test group name 7GMXV02.0003 on the label. The correct test group name should be 7GMXV02.3001. Remedy: A corrected VECI label is to be installed on the affected vehicles. A new label will be sent with installation instructions directly to customers of record. If the customers desire they may bring the label to their dealer for installation at no charge at any time through October 31, 2007. 

EPA420-B-08-012 3 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

General Motors ML-MW220 

07153 

2975 V 6/8/2007 2007 Cobalt 7GMXV02.4029

 7GMXV02.2030 

An incorrect Tranmission Control Module (TCM) service calibration was installed in the subject vehicles. The installed TCM calibration could result in the torque converter clutch hunting, causing 200-300 RPM engine speed variation, and possible unpleasant shifts. Remedy: General Motors will conduct a voluntary emissions recall on the affected vehicles, to have the correct TCM calibration installed. 

General Motors ML-MW239 3310 V 8/21/2007 2007 Chevrolet Uplander 7GMXT03.9140 Certain 2007 Chevrolet Uplander minivans equipped with the 

3.9L engine were produced or serviced with calibrations that do not allow the ethanol content of the fuel to be learned as required for correct flex fuel operation. Fueling these vehicles with E85 fuel could result in illumination of the Malfunction Indicator Light (MIL) and rough engine operation. Remedy: General Motors will conduct a voluntary emissions recall on the affected vehicles to install a revised calibration which enables the flex fuel logic. 

General Motors ML-MW251 3337 V 10/30/2007 2007 SAAB 9-3 7GMXV02.3001 An anomaly in the engine control module software may result 

in excessive fuel enrichment in certain driving conditions. The excessive enrichment may result in spark plug fouling and poor starts. Customers may experience MIL illumination due to misfire or have hard to start or no start conditions. Remedy: A voluntary emissions recall campaign will be conducted. GM will install software that will not cause the potential excessive fuel enrichment. 

Honda/Acura PUDR-Q49-00 2749 

2873 

V 6/15/2007 2002 

2003 2004 2005 2006 2003 2004 2005 

Insight 

Civic Hybrid 

2HNXV01.02N4 

3HNXV01.01A4 4HNXV01.02A6 5HNXV01.02A6 

6HNXV01.0YJV 

3HNXV01.34A5 4HNXV01.35A6 5HNXV01.33A6 

Malfunction Indicator Light (MIL) illumination may be caused by inappropriate calibration of the On-Board Diagnostic (OBD) system. The system may falsely detect catalyst deterioration. Remedy: Voluntary emissions recall to install the correct programming of the Engine Control Unit (ECU) at no charge to the owner. 

Honda/Acura 07-028-00 (Q61) 3367 V 11/19/2007 2005 Acura RSX 5HNXV02.4KBP Incorrect throttle bodies (which include the evaporative purge 

control solenoid) were installed on some vehicles at the dealership to remedy a known defect (throttle position sensor fluctuation). These throttle bodies now have inadequate evaporative purge ports. Remedy: An emission recall campaign will be conducted to notify owners of affected vehicles to bring them to the dealership for replacement of the throttle body. The original service bulletin has been revised to include the correct throttle body part number information. 

07-056 04-01C 

EPA420-B-08-012 4 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

Jaguar R176 2936 V 2/5/2007 2005 S-TYPE 3.0 

S-TYPE 4.2 

S-TYPE R 

5JCXV03.0DNE 

5JCXV04.2DNF 5JCXV04.2DSB 

It is possible that some fuel tanks were not made to material thickness and/or dimensional specification. This may prevent the fuel delivery module, jet pump module or cluster valve seals from adequately sealing. The vehicle may illuminate a MIL, exhibit a fuel odor or, possibly, after completing refueling, liquid fuel may be seen on the ground. This is a combined evaporative emissions/safety recall. Remedy: Dealers are to remove the installed fuel tank on affected vehicles, inspect the tank and determine if seal replacement is possible. If repair is not possible the original fuel tank is to be replaced with a tank manufactured to the approved specification following standard Workshop Manual procedures. 

Mazda 4807H 2894 V 9/1/2007 2006 

2006 2007 2007 2007 2007 2007 

Mazdaspeed6 Mazdaspeed6 

CX-7 

Mazdaspeed6 Mazdaspeed6 Mazdaspeed3 Mazdaspeed3 

6TKXV02.35EA 

6TKXV02.3NE1 

7TKXT02.35DB 

7TKXV02.35NN 

7TKXV02.3NE1 7TKXV02.35NP 

7TKXV02.3NF1 

The variable swirl shutter valve in the air intake system malfunctions in cold weather, causing a Malfunction Indicator Light (MIL). Remedy: Vehicles will be recalled to replace the variable swirl shutter valve and reprogram the Powertrain Control Module (PCM). 

Mazda 4907H 3402 V 9/27/2007 2006 

2006 2006 2007 2007 2007 2007 2007 

Mazda6 

Mazdaspeed6 Mazdaspeed6 Mazdaspeed3 Mazdaspeed3 Mazdaspeed6 Mazdaspeed6 

CX-7 

6TKXV02.35CB 6TKXV02.3NE1 

6TKXV02.35EA 7TKXV02.3NF1 

7TKXV02.35NP 7TKXV02.3NE1 

7TKXV02.35NN 

7TKXT02.35DB 

The On-Board Diagnsotic (OBD) monitoring function for Short Fuel Trim maximum threshold does not operate, resulting in a lack of Malfunction Indicator Light (MIL) warnings for certain malfunctions. Remedy: Vehicles will be recalled to reprogram the Powertrain Control Module (PCM). 

Mercedes-Benz 2007040005 2904 V 5/1/2007 2007 C230 7MBXV02.5U2A These certified Flex Fuel Vehicles are equipped with Engine 

Control Units (ECU) capable of modifying the engine control system based on sensor readings regarding fuel type. A small number of the vehicles have been identified as having installed ECU software for gasoline only. When filled only with E85 fuel the vehicles without an engine control module software update may experience starting problems, rough vehicle operation and "check engine" lamp illuminated. Remedy: Mercedes conducted a service campaign and will have all affected vehicles corrected free of charge. Notice to dealers to reprogram the ECU software on affected vehicles to the current Flex Fuel Vehicle (FFV) values were sent electronically March, 2007. 

EPA420-B-08-012 5 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

Mercedes-Benz 2007040006 2923 V 5/1/2007 2007 C230 7MBXV02.5U2A 

The 2007 model year C230 flexible fuel vehicle can operate on both gasoline and ethanol fuels. These commercially available fuels can contain different amounts of oxygenated components. When the C230 vehicle is refueled the engine management system could misinterpret the gasoline in the fuel tank as ethanol only because the oxygen content in the fuel is different from the previous tank fill. This misinterpretation can result in the fuel adaptation incorrectly calculating fuel enrichment values. Over time, this continual miscalculation can result in MIL illumination. Rough engine operation may be experienced depending on the fuel mixture. Extended operation of the vehicle with the MIL illuminated could result in catalyst damage. Remedy: The customer will receive the corrected Engine Control Unit (ECU) software at no charge and if an OBD fault code was stored in relation to the fuel adaptation, the catalyst will also be inspected to ensure its proper functionality. If the catalyst is found to be impaired, it will be replaced free of charge. 

Mercedes-Benz 200708003 2988 V 9/1/2007 2007 GL320 7MBXT03.0B10 In some cases, the charge air cooler hose can become 

disconnected from the charging air inter cooler inlet. If the material thickness under the clamp of the reducing bushing and a thinner end of the cooler hose exist, the hose will not stay attached. The Malfunction Indicator Light (MIL) will illuminate and the Powertrain Control Module (PCM) will put the vehicle in "limp home mode", which allows the car to be driven slowly but with less acceleration, causing the customers to return to the dealership for service. With the hose off, both emissions and drivability are adversely affected. Remedy: The hose has been improved for both service replacements and production vehicles. All owners will receive letters encouraging them to bring their vehicles in for a hose replacement free of charge. 

Porsche W716 2910 V 3/19/2007 2006 Cayenne S, Turbo 6PRXT03.26E1 

6PRXT04.5SE1 

6PRXT04.5TE1 

The fuel line pressure at the fuel-fired heater (FFH) drains back after key off. This causes the heater not to re-fire on the next request. The FFH control unit has to be "unlocked" by dealer with a Porsche service tool. Reprogramming the control unit will allow the pump to run sufficiently to ensure operation and avoid the FFH from locking in the future. Remedy: Owners will be notified by letter to take vehicle to Porsche dealer to have the Engine Control Unit (ECU) reprogrammed. 

EPA420-B-08-012 6 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

Porsche W738 2992 V 7/26/2007 2008 Cayenne S 

Cayenne Turbo 

8PRXT04.8SED 

8PRXT04.8TED 

The engines of model year 2008 Cayenne S and Cayenne Turbo vehicles are equipped with oil spray jets for the purpose of piston cooling and to provide additional lubrication of the cylinder barrels. It is possible that the opening pressure of the oil spray jets may not be correct on some vehicles. Under certain operating conditions this may lead to the warning "Oil pressure too low" appearing in the multipurpose display. Remedy: Porsche issued a voluntary emission recall to raise the oil pressure by means of a software alteration of the ECU. This will ensure adequate oil pressure under all operating conditions. 

Subaru WVB-12 2786 V 3/2/2007 2005 Outback 2.5XT 

Legacy 2.5GTTurbo 

5FJXX02.5YNX 

6FJXX02.5YPY 

Some 2005 Subaru Legacy and Outback 2.5L MT turbo models may experience a short circuit in the transistor diode within the Engine Control Unit (ECU). This is caused by a negative surge of current flow to the drive circuit of the main cooling fan relay. If the ECU circuitry gets damaged, it could cause the main cooling fan to run continually. Remedy: A modification was made to the main cooling fan relay. The negative surge current protector in the relay was changed from a diode to a resistor, in order to protect the ECU circuitry. Subaru conducted a Customer Service Campaign (Radiator Cooling Fan Relay) and owners were notified of the repair program to install an improved cooling fan relay and check for ECU circuit damage which could require ECU replacement. 

Subaru WWV-06 2935 V 3/1/2005 

Reported to 

EPA on 

4/26/2007 

2005 Outback H6 5FJXT03.0TLW The catalytic converter may fail due to an increase of exhaust 

temperature when driving in first gear for an extended period of time in either "manual" or "sport" mode. Under these circumstances raw fuel, which is generated due to fuel cutout logic, collects in the converter causing the over-temperature condition. The manual/sport mode allows the driver to manually select the desired gear. Current software will not automatically shift the transmission when there is a near over rev condition. Remedy: Subaru has changed the TCM programming in 12/2004 for production and for service since 3/2005. Owner letters for recall were mailed starting March, 2005. A second mailing occurred in June 2007. 

Volkswagen N7 2490 V 5/29/2007 1999 

2000 2001 2002 

Jetta, GTI XVWXV02.8224 

YVWXV02.8224 

1VWXV02.8224 2VWXV02.8224 

Catalytic converter may fail due to an internally melted monolith. Diagnostic Trouoble Code (DTC) for low catalyst efficiency and vehicle misfire are detected in some vehicles, along with MIL illumination. Vehicles are no longer in production - no production improvements available. Volkswagen of America will issue a service action with customer notification to update the vehicle Engine Control Unit (ECU) software for improved converter efficiency thresholds and more stringent misfire detection. Remedy: Voluntary emission recall to reprogram ECU was issued on 5/29/2007. 

EPA420-B-08-012 7 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

Volkswagen P7 2821 V 1/12/2007 2006 Passat 6ADXV02.0366 The power brake booster hose may crack or break at the 

flange. Vehicle runs rough at start up and when Malfunction Indicator Light (MIL) illuminates the Diagnostic Trouble Code (DTC) for fuel system too rich off idle is stored in the Engine Control Unit (ECU) memory. Remedy: An updated brake booster hose was incorporated in production at Mosel on April 8, 2006 and Emden on April 27, 2006. The safety recall will notify owners and dealerships of the no charge repairs. 

Volkswagen 2007/04/10 2814 V 4/16/2007 2001 New Beetle, GTI, 

Golf, Jetta 

1ADXV01.8346 An incorrect interpretation of information in the electronic 

parts catalogue directed dealership technicians to install the wrong catalyst on these particular vehicles. Remedy: The manufacturer initiated a service action to inspect and, if needed, replace the catalytic converters in affected vehicles. 

Volkswagen/Audi M7 VW & JL 

Audi 

3354 V 9/28/2007 2003 Audi A6 & A4 

Passat1.8T/Audi A4 

Passat 2.8 

3ADXV03.0344 3ADXV01.8342 3ADXV02.8334 

A safety recall was initiated due to concern of engine stalling or quitting while driving because of the premature wear of the carbon brush set in the fuel pump. Remedy: Volkswagen and Audi dealers were sent instructions on or about September 26, 2007 to inspect suspect vehicles and their service records in determining if the fuel pump had been replaced. Fuel pumps will be replaced on vehicles not previously repaired. 

Volvo 181 2766 V 7/16/2007 2003 

2003 2004 2004 2004 2004 

S60, V70 S60, V70 S60, V70 

S60, V70 AWD 

S60, V70,S40 

S60, V70,S80,XC90 

&AWD 

3VVXV2.43S2N 

3VVXV2.43U1N 

4VVXV2.43S2N 

4VVXV2.52L1T 

4VVXV2.43U2N 

4VVXX2.52U2T 

The signal from the fuel pressure sensor is used to control both fuel pressure and to calculate the injection time of the injectors. A fault in this pressure information (e.g. too high) will give both an error on the real fuel pressure (e.g. too low) and a fault on the injection time (e.g. too short). However, negative impacts on emissions and drivability are avoided by the use of adaptation, preprogrammed values, or both. If the fault comes suddenly or is too large to be compensated for by adaptation, it is possible to experience considerable impact on drivability and emissions. Component design improvements were implemented to the solder pins (06/2002, 01/2003, 03/2004) to address this problem Remedy: A recall was issued on 7/19/2007 to replace the fuel pressure sensor in the 2003-2004 model year vehicles. 

Volvo 168 2767 V 7/9/2007 2003 

2004 

S80, S80 Executive 3VVXT2.92U1T 

3VVXV2.92U1T 4VVXV2.92U1T 

4VVXT2.92U1T 

The Positive Crankcase Ventilation (PCV) nipple of the crank case ventilation system may crack or come loose resulting in an air leakage. The nipple serves as a calibrated flow restriction in the system. The nipple also prevents blow-by gases from entering the atmosphere by serving as a union for system piping. Remedy: This recall will replace the PCV nipple. 

Volvo R600-169 2973 V 8/10/2007 2006 S40,V50 6VVXR0132EV2 Volvo has found that the emission control label is misprinted 

on some of the affected vehicles. The label says 6\NXR0130EV2 where the correct value is 6VVXR0132EV2. Remedy: Letters will be sent to owners starting on or about August 10, 2007 requesting that they return their vehicles to Volvo dealerships to have the emissions label replaced. 

EPA420-B-08-012 8 
2007 Emissions-Related Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description TSB 

Total number of Vehicles af

EPA420-B-08-012 9 
2007 Emissions-Related Voluntary Service Campaigns 

Mfr. Mfr. Recall Number EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description A

V

Chrysler 2006-36-E 2856 VSC 7/16/2007 2004 Chrysler Pacifica 4CRXT03.82N0 Some 2004 Chrysler Pacifica vehicles equipped with 3.5L 

engines have a plug in the housing of the Exhaust gas Recirculation (EGR) valve that may shift or be ejected. If this shift takes place exhaust gas can vent through the open port into the environment. High exhaust gas temperatures and EGR valve flow rates appear to be contributing factors, both of which may be influenced by vehicle operation and driving patterns. The design of the EGR valve housing was changed in production to add a snap ring in the port to prevent movement of the plug. Remedy: Chrysler will extend the warranty for the EGR valve on affected vehicles to certified useful life (10 years / 100,000 miles). 

7

Ford 07M06 2287 VSC 5/21/2007 2004 

2003 

Aviator 4FMXT04.62FA 

3FMXT04.62FA 

Vehicles may have an inoperative ignition coil due to internal cracking of the coil housing in the coil manufacturing process. The engine is expected to experience rough running and the MIL will be illuminated. Improvements in the manufacture of the ignition coil were implemented in September of 2001, and improvements were made to the coil housing in November 2003. Other follow-up action is under review. Remedy: A voluntary service campaign (VSC) was issued on 5/21/07 for the Aviator engine families only, to extend warranty coverage to 11 years or 120,000 miles whichever comes first. For vehicles with more than 120,000 miles the coverage is good until 11/30/2007. 

22

Ford 07M07

 and 

07N09 

2543 VSC 7/3/2007 2003 Lincoln LS 

Ford Thunderbird 

3FMXV03.9VF5 Water or oil may enter into the ignition coil cover and the 

spark plug bore causing a misfire. The Malfunction Indicator Light (MIL) will illuminate when the misfire condition occurs. A coil with improved water/oil sealing was put into production in March 2004. Owners who experience this condition are expected to obtain service through their dealerships. There is an adverse effect on both emissions and drivability when misfire condition is present. Remedy: Two voluntary service campaigns were released for 2003 MY only for misfire conditions. A Voluntary Service Campaign (VSC) replaces ignition coils as needed and valve cover gaskets if oil has leaked into the spark plug bore. Another Voluntary Service Campaign replaces the wiper motor bracket seal. This replacement will be performed if water is present in the spark plug bore. Warranty coverage is extended to 10 years or 100,000 miles whichever comes first. For vehicles with more than 100,000 miles coverage is good until 12/31/2007. 

2

EPA420-B-08-012 10 
2007 Emissions-Related Voluntary Service Campaigns 

Mfr. Mfr. Recall Number EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description A

V

General Motors ML-MW215 2881 VSC 4/1/2007 2006 

2006 2006 2007 2007 2007 2007 

Chevrolet / GMC 

Pickup / Utility 

Chevrolet Impala / 

Monte Carlo 

Chevrolet Impala / 

Monte Carlo 

Chevrolet / Buick 

Uplander / Terraza 

Chevrolet / GMC 

Pickup / Utility / Van 

Chevrolet / GMC 

Pickup / Van 

Chevrolet / GMC 

Utility 

6GMXT05.3375 

6GMXV03.5050 6GMXV03.5051 

7GMXT03.9140 7GMXT05.3375 7GMXT05.3373 7GMXT05.3381 

Flex Fuel Vehicles can operate on E85 or gasoline. E85 is a fuel mix of 85% ethanol and 15% gasoline. Due, in part, to the way E85 is mixed before filling the tank, some vehicles could encounter a situation where the engine computer improperly estimates the amount of ethanol in the vehicle's fuel tank and the Malfunction Indicator Light (MIL) is illuminated, plus there could be drivability concerns. Remedy: A flex fuel software update (fuel sensing algorithm) 

is available for Engine Control Unit (ECU) reprogramming at no charge under the 8-year or 80,000 mile emission controller warranty. 

19

4

15

2

8

22

5

General Motors ML-MW209 2905 VSC 2/28/2007 2005 Malibu 5GMXV02.2028 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 Diagnostic Trouble Code (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 10 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. 

5

General Motors ML-MW229 

07099 

2479 3044 2976 

VSC 6/1/2007 2002 

2003 2004 

Chevrolet Trailblazer, 

GMC Envoy XL/XUV, 

Isuzu Ascender 

2GMXA04.2187 

2GMXT04.2188 

3GMXA04.2187 

3GMXT04.2184 3GMXT04.2188 3GMXT05.3170 3GMXT05.3183 4GMXT04.2187 

4GMXT05.3170, 

The component involved is the fuel tank on certain extended utility vehicles. A fracture may develop in the area where the Inlet Check Valve (ICV) is mated to the fuel tank. The fracture may be related to the process of welding the ICV to the fuel tank and the percent carbon used in the molding of the ICV. Remedy: Warranty was extended for 10 years or 150,000 miles whichever comes first. Letters were sent to the owners beginning in July 2007. 

2

31641

2

1

2

General Motors ML-MW234 2977 VSC 8/12/2007 2004 Colorado 

Canyon 

4GMXT02.8189 The component is the fuel tank gas cap. The failures are 

either a broken internal ratchet mechanism or inadequate seal at the fill pipe interface surface. The probable causes of the failures are an inadequate internal ratchet mechanism design to withstand the potential force applied upon removal or a main seal design that is not robust to the possible variation in the fill pipe sealing surface. The caps available in service have an improved ratchet mechanism design that can withstand the removal force and an improved main seal design. Remedy: General Motors will implement a special coverage warranty extension to 10 yrs/120,000 miles. 

1

EPA420-B-08-012 11 
2007 Emissions-Related Voluntary Service Campaigns 

Mfr. Mfr. Recall Number EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description A

V

General Motors ML-MW233 2978 VSC 8/6/2007 2004 GTO 4GMXV05.7083 The component is the fuel tank gas cap. The failures are 

either a broken internal ratchet mechanism or inadequate seal at the fill pipe interface surface. The probable cause of the failures are an inadequate internal ratchet mechanism design to withstand the potential force applied upon removal or a main seal design that is not robust to the possible variation in the fill pipe sealing surface. The caps available in service have an improved ratchet mechanism design that can withstand the removal force and an improved main seal design. Remedy: General Motors will implement a special coverage warranty extension to 10 yrs/120,000 miles. 

1

General Motors ML-MW250 3326 VSC 11/1/2007 2004 

2005 

Saturn Vue Saturn Vue 

4GMXT02.2123 4GMXT03.5145 5GMXT02.2123 5GMXT03.5145 

The component is the fuel tank gas cap. The failures are either a broken internal ratchet mechanism or inadequate seal at the fill pipe interface surface. The probable causes of the failures are an inadequate internal ratchet mechanism design to withstand the potential force applied upon removal or a main seal design that is not robust to the possible variation in the fill pipe sealing surface. If the cap fails one of three things will occur, the Malfunction Indicator Light (MIL) will illuminate (and a Diagnostic Trouble Code (DTC) will set), the cap won't tighten or the cap will not come off. The failure of the tank cap function will result in an overt indication that the cap should be replaced. Remedy: The caps available in service have an improved ratchet mechanism design that can withstand the removal force and an improved main seal design. Additionally, GM will implement a special coverage warranty extension to 10 yrs/120,000 miles. 

3533

Honda/Acura WER-06-014-00 2763 VSC 8/31/2007 2003 

2003 2004 2004 2005 2005 

Civic Hybrid 3HNXV01.34A5 

3HNXV01.36CV 

4HNXV01.35A6 

4HNXV01.37CP 

5HNXV01.33A6 

5HNXV01.3YCV 

Engine speed may be higher than target RPM at high vehicle load due to Continuous Variable Transmission (CVT) belt slip. The 'D' lamp on the gear shift console may flash (for all affected vehicles), and Malfunction Indicator Light (MIL) may illuminate (for 3HNXV01.34A5 only). The cause of the failure is inappropriate calibration of the CVT control module. Remedy: A CVT control module with an improved calibration is made available for repair under Field Fix#S8. The owner of the vehicle has been notified, if this defect occurs, to bring their vehicle to the dealership to update the Powertrain Control Module (PCM) software according to Honda Service Bulletin under Honda's Warranty Extension Campaign. 

2

3

1

6

1

8

Volkswagen VWA-07-20 2586 I-VSC 9/6/2008 2001 

2002 2003 

Golf, Jetta, NB Golf, Jetta, NB 

NB Convertible 

1VWXV02.0223 1VWXV02.0226 2VWXV02.0223 2VWXV02.0222 3VWXV02.0223 

Malfunction Indicator Light (MIL) illumination with a Diagnostic Trouble Code (DTC) Main Catalyst Bank 1 (efficiency below threshold) is caused by open passages in the catalytic converters expansion matting that causes exhaust gases to partially bypass the converter monolith. The damage was caused by over stressing of the converter housing during the converter canning process. Improved service parts have been available since November 2005. Remedy: On or about September 9, 2007 manufacturer extended warranty to 10 year/100,000 miles and sent notices to owners. VW dealers will inspect and replace convertors as needed. 

6365

12

EPA420-B-08-012 12 
2007 Emissions-Related Voluntary Service Campaigns 

Mfr. Mfr. Recall Number EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description A

V

Total number of Vehicles affected by V

Total number of Vehicles affected by Recalls and V

SUMMARY 

Total number of Voluntary 

Total number of Voluntary Service Cam

Total number of Recalls and Voluntary Service Cam

EPA420-B-08-012 13