2006 Annual Summary of EmissionRelated Recall and Voluntary Service 

Campaigns Performed on Light Duty 

Vehicles and Light-Duty Trucks
EPA420-B-07-003

 May 2007

Compliance and Innovative Strategies Division

Office of Transportation and Air Quality

U.S. Environmental Protection Agency

2006 Annual Summary of 

Emission-Related Recall and Voluntary 

Service Campaigns Performed on Light 

Duty Vehicles and Light-Duty Trucks
Abbreviations and Acronyms

Acronym/Term: Definition:

ALLS All States Trading Region

CARB California Air Resources Board

CFV Clean Fuel Vehicle

DTC Diagnostic Trouble Code

ECU Engine Control Unit

ECM Engine Control Module

EGR Exhaust Gas Recirculation

MIL Malfunction Indicator Light

NHTSA National Highway Traffic Safety Administration

NLEV National Low Emission Vehicle

OBD On-Board Diagnostics

PCM Powertrain Control Module

TSB Technical Service Bulletin

VECI Vehicle Emission Control Information

Recall Type: Definition:

O Ordered by EPA

V Voluntary Recall by Manufacturer

VSC Voluntary Service Campaign by Manufacturer

I Manufacturer voluntary action with EPA Influence

Sales Area: Definition:

50S Federal and California

CL CA + NLEV (ALLS)

CA California

FA Federal (all altitude)

FC FA + CA

NF CFV + NLEV (ALLS) + CA

NL 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. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehicl

BENTLEY SC 06/10 2812 V 10/6/2006 2007 Continental GT, 

Continental GTC, 

Continental Flying 

Spur

7BEXV06.0501 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.

759 

BMW 06E-A03 2752 V 9/11/2006 2000

2001200120022002200320032004

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

YBMXV04.9S62

1BMXV03.2S54

1BMXV04.9362

2BMXV03.2S542BMXV04.9S623BMXV03.2S543BMXV04.9S62

4BMXV043.2S54

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.

3,0814,5463,053

10,19

2,8418,6762,4538,538

BMW 06E-A02 3050 V 6/1/2006 2002 

2003 2004 2004

BMW 745i, 745Li BMW 745i, 745Li 

BMW 545i, 745i, 

745Li, 645Ci, 645Ci 

Cabrio 

BMW X5 4.4i, X5 

4.8is

2BMXV04.4LEV 3BMXV04.4LEV 4BMXV04.4LEV

4BMXT04.4N62

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. 

18,2220,7230,02

8,803

BMW 06E-A01 3058 V 4/24/2006 2006 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, 330Ci, 530i

X3 2.5, X3, 3.0

Z4 3.0i

330i, 330Ci, 530i

6BMXV03.0N525BMXV03.0UL2

5BMXV03.0LER5BMXV02.5M56

5BMXV03.0E83

5BMXV03.0M5R

5BMXV03.0SMG

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. 

69,4368,9017,00

7,0006,4004,0001,700

EPA420-B-07-003 1 
2006 Emissions-Related Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehicl

BMW 06E-A04 3070 V 12/7/2006 2006 BMW M5, M6 Coupe 6BMXV05.0S85 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. 

4,256 

DAIMLER/

CHRYSLER

EDIR-2006-5 

F07

2661 V 3/3/2006 2006 Dodge Viper 6CRXV08.3VM0 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.

513 

DAIMLER/

CHRYSLER

EDIR 2006-6-E & 

F02

2663 V 4/1/2006 2006 

2006

Jeep Liberty Jeep Liberty

6CRXT03.7NE0 

6CRXT0226N70

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. 

12,63

1,843

DAIMLER/

CHRYSLER

2006-17-E F25 2736 V 9/4/2006 2000 

2000 2002 2002 2000 2000

Grand Jeep 

Cherokee

YCRXT04.02B0 

YCRXT0242230 

2CRXT04.02D2 YCRXT04.02Z0 

YCRXT0287231 

YCRXT04.72B1

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.

48,4230,7944,4321,6715,8123,26

DAIMLER/

CHRYSLER

2006-18-E F29 2740 V 6/30/2006 2007 Dodge Caliber 

Dodge Caliber Dodge Caliber Dodge Caliber

7CRXV0110M70 

7CRXV01.8ME0 

7CRXB0144M80 

7CRXB02.4ME5

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. 

101 569

5,689

23,24

DAIMLER/

CHRYSLER

2006-19-E F37 2741 V 11/27/2006 2005 

2006 

Jeep Liberty 5CRXT02.82RX 

6CRXT02.82RX

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. 

8,629 2,657

EPA420-B-07-003 2 
2006 Emissions-Related Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehicl

DAIMLER/

CHRYSLER

2006-22-E 2757 V 10/1/2006 2006 

2006

Dodge Ram 1500 Dodge Ram 1500

6CRXT04.75S0 

6CRXT04.76UO 

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.

320 791

DAIMLER/

CHRYSLER

2006-31-E1 2826 V 11/1/2006 2005 

2006 

Chrysler Pacifica Chrysler Pacifica Chrysler Pacifica Chrysler Pacifica

5CRXT03.8NE0 

5CRXT03.52N0 

6CRXT03.8NE0 

6CRXT03.52N0

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. 

17,0976,45

4 

37,95

GENERAL 

MOTORS

ML-MW201 2842 V 12/19/2006 2007 Cadillac STS 7GMXB03.6149 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. 

4,758 

GENERAL 

MOTORS

ML-MW156 3066 V 3/1/2006 2004 

2004

Cadillac XLR 

Cadillac SRX

4GMXV04.6067 

4GMXT04.6161

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. 

3,861

13,56

HONDA/ACURA EDIR-05-012-00 

EDIR-05-012-01

2560 V 12/9/2005

* Reported to 

EPA in 2006

2005 Accord Hybrid 5HNXV03.01B4 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.

6,600 

HONDA/ACURA VERR-06-007-01 2692 V 7/28/2006 

7/28/2006

2006 2006

Insight (CVT) 

Insight (MT)

6HNXV01.0VK5 

6HNXV01.0YJV 

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.

218 274

EPA420-B-07-003 3 
2006 Emissions-Related Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehicl

ISUZU ML-MW171 2703 V 3/13/2006 2006 Ascender 6GMXT04.2186 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.

32 

JAGUAR R726 2865 V 10/26/2006 2006 

2006 2007 

XJ8, XJ8L, VDP 

LWB 

XJR, SUPER V8 XJR, SUPER V8 

XJ8, XJ8L, VDP 

LWB

6JCXV04.2DN 

6JCXV04.2DSK 7JCXV04.2DSK 

7JCXV04.2DNK

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. 

4,800

708120571

KIA 04.28.06.01 3068 V 8/1/2006 2006 Rio (JB) 6MXV01.6BM5 The original design included a coin box behind the cover to the 

OBD connector which was in violation of the CARB 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 flattype fuse cover. This will minimize efforts to access the diagnostic connector of the OBD system.

24,83

LAMBORGHINI 2006 /04/13 

2006/05/09 2006/07/10

2705 V 8/28/2006 1996 

1997 1998 1999 2001 2002 2003 2004 2004

DB 132 DiabloDB 132/144 DiabloDB 132/144 DiabloDB 132/144 DiabloDB 132/144 DiabloL 147 MurcielagoL 147 MurcielagoL 147 MurcielagoL 140 Gallardo

TN5.7VJGFHK 

VNL5.7VJGFHK 

WNLXV05.7DB8 

XNLXV05.7DB8 

1NLXV06.0321 2NLXV06.2472 3NLXV06.2472 4NLXV06.2474 4NLXV05.0404

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. 

24 75 

104 160 148 

98 

169 121 697 

MAZDA 4106E 2739 V 6/1/2006 2006 

2006

Mazdaspeed 6 2.3L 

Mazdaspeed 6 2.3L

6TKXV02.35EA 

6TKXV02.3NE1

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 highload driving even with premium fuel.Remedy: PCM will be reprogrammed by Mazda dealer and recall label #4106E will be attached on driver's door. 

6,500 

EPA420-B-07-003 4 
2006 Emissions-Related Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehicl

MAZDA 4206F 2788 I 8/31/2006 2004 

2005 2005 2006

Mazda RX-8 4TKXV01.3CNA 

5TKXV01.35NM 

5TKXV01.3NC1 

6TKXV01.35DA

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. 

37,3017,7017,70

5,800

MERCEDES-BENZ MB002-2005 2582 V 4/1/2006 2002

2002200320032004200420052006

SLK 32 AMG, C32 

AMG 

CL 55 AMG, S 55 

AMG 

SLK 32 AMG, C 32 

AMG 

CL 55 AMG, S 55 

AMG, E 55 AMG 

CL 55 AMG, S 55 

AMG, E 55 AMG 

SLK 32 AMG, C 32 

AMG 

CL 55 AMG, S 55 

AMG 

CL 55 AMG, S 55 

AMG, SL 55 AMG, E 

55 AMG, CLS 55 

AMG, SLR

2MBXV03.2LBI 2MBXV05.5LBI 3MBXV03.2LBI 3MBXV05.5LBI 

4MBXV05.5LBX 

4MBXV03.2LBI 5MBXV05.5LBI 

6MBXV05.5LB1

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. 

2,7611,9731,3354,1523,401

515

1,3183,659

MERCEDES-BENZ 2006-070003 2790 V 10/1/2006 2005 

2006

E320 CDI 5MBXV03.2B10 

6MBXV03.2B10

Due to a spare part documentation error on certain model year 2005/2006 E320 CDI Diesel vehicles, glow plugs were installed by dealerships as part of the workshop visit which were not released for use in the E320 CDI 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.

92 

MITSUBISHI/

D-STAR

06XMED0160 2669 V 8/1/2006 2004 

2004 2005 2005

Galant 4DSXV02.4GRB 

4DSXV02.4G6G 5DSXV02.4G6G 

5DSXV02.4GRB 

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. 

24,95

7,889 5,245 

18,37

EPA420-B-07-003 5 
2006 Emissions-Related Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehicl

MITSUBISHI/

D-STAR

EMR-06-003 2832 V 11/1/2006 2006 Eclipse 6DSXV03.8GRC Incorrect software parameters may cause illumination of the MIL 

because of DTC P0421 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. 

12,20

NISSAN/INFINITI 06V-54 2743 V 3/21/2006 2005 Murano 5NSXT03.5G7A 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. 

14,26

NISSAN/INFINITI R505/05V-555 2744 V 2/13/2006 2003

20032003200320042004200420052006

G35 Sedan A/T 

350Z, G35 

Sedan/Coupe 

FX35 FX45 

350Z, G35 

Sedan/Coupe 

G3 5 Sedan AWG 

FX35 FX45 FX45 FX45

3NSXV03.5C7A 3NSXV03.5C7B 

3NSXT03.5C7B 3NSXT04.5C8A 

4NSXT03.5G7A

4NSXV03.5G7C 

4NSXT03.5G7A 

4NSXT04.5M8A 5NSXT04.5M8A 6NSXT04.5M8A

On some 2003 - 2004 Nissan vehicles the fuel filler hose may crack and result in fuel and vapor leakage. The MIL may illuminate.Remedy: A recall (R505/05V-555) will be implemented. Nissan to replace the fuel filler and vapor hoses with new ones.

54,2065,7217,64

6,462 

36,08

31 

26,59

3,799 1,877 

6

NISSAN/INFINITI NHTSA06V2230

00

2760 V 6/9/2006 2006

2006

Altima and Sentra Altima and Sentra 

6NSXV02.5G5A 

6NSXV02.585A 

6NSXV02.5S5A 

6NSXV02.5N5A

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. 

69,2221,32

491 

1,893

NISSAN/INFINITI R0606 2775 V 8/21/2006 2003 Altima S Sedan 

Sentra SE-R Sedan 

3 NSXV02.5D5A 3NSXV02.5C5A 

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. 

186,27

14,58

EPA420-B-07-003 6 
2006 Emissions-Related Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehicl

SUBARU #WWX-08 2704 V 6/9/2006 2004 Legacy, Outback 4FJXV02.5NKR 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.

21,51

SUZUKI SC-32 2747 V 7/15/2006 2006 Verona 6DXV02.5D04 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.

2,000 

TOYOTA/LEXUS 60I 2792 V 12/15/2006 2001 

2002 2001 2002 2003

RAV4 

HighlanderHighlander

1TYXT02.0FFH 2TYXT02.0FFH 

1TYXT02.4FFP 2TYXT02.4FFP 3TYXT02.4FFP

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.

87,0072,0013,0021,0027,00

VOLKSWAGEN/

AUDI

38513 2544 V 7/28/2006 2002 A4, Passat 2ADXV01.8342 The crankcase ventilation hose is broken or cracked and shows 

visible signs of deterioration. In most cases a MIL 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. 

77,10

VOLKSWAGEN/

AUDI

M6 2637 V 8/18/2006 2004

2005

Golf/Jetta/New 

Beetle with 1.9L TDI 

Engine 

Golf/Jetta/New 

Beetle with 1.9L TDI 

Engine 

4VWXV01.92365VWXV01.9236

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.

18,69

21

Total number of Vehicles affected 

EPA420-B-07-003 7 
2006 Emissions-Related Voluntary Service Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affe

Vehi

FORD 06N07 2831 VSC 12/1/2006 2004 

2005 2006 

Ford Taurus/Mercury 

Sable

4FMXV03.0VFZ 5FMXV03.0VFZ 6FMXV03.0VFZ

Some 2004-2006 Taurus/Sables with Flex Fuel Vehicle (FFV) 3.0l 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.

45,90,3

8,5

GENERAL MOTORS ML-MW196 2686 

2687 2751 2751 2751 2776 2776 2776 2777 2777 3043 

 VSC 11/9/2006 2004 

2004 2004 2004 2005 2003 2003 2004 2004 2004 2004 

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 

4GDXV01.6D02 

4GMXV03.8041 4GMXV03.0061 4GMXV03.0061 5GMXV03.0061 3GMXV02.0002 3GMXV02.3001 4GMXV02.0002 

4GMXT04.6161 

4GMXV04.6067 4GMXV02.2028 

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 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.

55,273,310,9

1,46,77,4

17,829,13,5

3,8

26,9

GENERAL MOTORS ML-MW199 3056 VSC 12/4/2006 2000

200020012002

Chevrolet Camaro 

Pontiac Firebird 

Chevrolet Camaro 

Pontiac Firebird 

Chevrolet Camaro 

Pontiac Firebird 

Chevrolet Camaro 

Pontiac Firebird 

YGMXV05.7081YGMXV05.7083

1GMXV05.70812GMXV05.7081

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. 

13,012,2

6,54,3

12,211,523,719,8

HONDA/ACURA PUDR_WER-04-

005-00

2269 VSC 5/13/2006 2000 

2001 2001 2002 2002 20032003 

2004 2004

Insight (MT) Insight (MT) 

Insight (CVT) Insight (CVT) 

Insight (MT) Insight (MT) 

Insight (CVT) 

Insight (MT) 

Insight (CVT)

YHNXV01.0LA4 

1HNXV01.0FH6 

1HNXV01.0HEV 

2HNXV01.0CCE 

2HNXV01.02N4 

3HNXV01.01A4 

3HNXV01.0PCE 

4HNXV01.02A6 

4HNXV01.0NCE

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. 

1,8

806555251131

4

16

MERCEDES-BENZ 2005-020004 2362 I-VSC 2/1/2005

* Reported to 

EPA in 2006

2000 S CLASS, CL 

CLASS

YMBXV05.0GNB 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.

20,

EPA420-B-07-003 8 
2006 Emissions-Related Voluntary Service Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affe

Vehi

MITSUBISHI/D-STAR FMS-013 2836 VSC 11/1/2006 2003 Mitsubishi Outlander 

4WD

3MTXT02.4GNG 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-06-15-001 has been issued to assist technicians in the repair.

21,6

VOLVO VSC 155 2655 I-VSC 4/1/2006 1999

19991999199919991999199920002000200020002000200020012001200120012001200120022002

S70 AWD, V70 

AWD, V70 XC 

S70, V70, C70 

(Turbo) 

S70, V70 

S80 (Turbo) 

S80 

S70, S70 AWD, V70, 

V70 AWD, V70 XC, 

C70 

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 

XVVXV2.43AW2

XVVXV2.43PA2

XVVXV2.43TF2

XVVXV2.78EN2XVVXV2.92BU2

YVVXV2.43PA3

YVVXV2.43TF3

YVVXV2.78EN3YVVXV2.92BU3

1VVXT2.43L5T

1VVXV2.43L5T

1VVXV2.43U5N

1VVXV2.78T6T

1VVXV2.92L6N

2VVXV2.43L5T

2VVXV2.43U5N

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. 

17,617,229,510,415,332,328,912,923,227,236,325,

8,3

17,0

3,3

27,6

Total number of Vehicles affected by Voluntar

Total number of 

Recalls and Voluntar

Total number of Voluntary Rec

Total number of Voluntary Service Campa

Total number of Recalls 

Voluntary Service Campa

SUMMARY

EPA420-B-07-003 9