Office of Transportation EPA420-B-06-001 

and Air Quality February 2006 

2005 Annual Summary of

Emission-Related 

Recall and Voluntary 

Service Campaigns

Performed on Light-Duty

Vehicles and Light-Duty 

Trucks 
EPA420-B-06-001 

February 2006 

2005 Annual Summary of Emission-Related Recall and 

Voluntary Service Campaigns Performed on 

Light-Duty Vehicles and Light-Duty Trucks 

Compliance and Innovative Strategies Division 

Office of Transportation and Air Quality 

U.S. Environmental Protection Agency 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

BMW 05E-A01 3020 V 10/20/2005 2001 

2002 2002 2003 2003 2003 

^ ^ 

2003 

^ 

2003 2003 2003 2003 2004 2004 

M3/Cabr/Rdst/Cp M3/Cabr/Rdst/Cp 

745i, 745Li 

X5, 3.0i 

325iA/CiA/iAT 

325i/Ci/Ci Cabr, 

325iT/xi/xiT,330xi,52 

5i/iT,Z4 2.5i 

330i/Ci/Ci Cabr, 

530i,Z4 3.0i 

325i, 325iT, 330i 

M3, M3 Cabrio 

745i, 745Li 

760Li 

325iA/CiA/iAT 

325i/Ci/Ci Cabr/iT, 

330i/Ci/Ci Cabr, X3 

3.0iA 

1BMXV03.2S54 2BMXV03.3S54 

2BMXV04.4LEV 3BMXT03.0E5R 

3BMXV02.5M56 3BMXV03.0LER 

^ ^ 

3BMXV03.0M5R 

^ 

3BMXV03.0UL2 

3BMXV03.2S54 

3BMXV04.4LEV 

3BMXV06.0N73 

4BMXV02.5M56 

4BMXX03.0UL2 

Certain Ignition coils have been identified to be not sufficiently resistant to the high engine compartment temperatures. Coils supplied by Bosch are not affected by this problem. Remedy: The Bremi coils will be replaced by Bosch ignitions coils. 

4642 

10394 22887 31008 12181 82248 

^ ^ 

44432 

^ 

18698 

8890 2096 

328 

12772 68044 

DAIMLER/CHRYSLER 2004-21-E & D46 2402 V 1/18/2005 2005 

2005 2005 2005 2005 2005 2005 2005 2005 2005 2005 

Ram, Dakota 

Ram 

Liberty, G/Cherokee 

Wrangler 

PT Cruiser PT Cruiser PT Cruiser PT Cruiser PT Cruiser 

SRT-4 

PT Cruiser 

5CRXT03.75S0 5CRXT03.76U0 5CRXT03.7NE0 5CRXT04.02N0 5CRXV0148M80 5CRXV02.4VE0 5CRXV02.4VE0 5CRXV02.4VE1 5CRXV02.4VE1 5CRXV02.4VH0 5CRXV02.4VH0 

The OBD fuel system monitor was disabled when an associated configuration register was inadvertently cleared prior to release. Remedy: PCM of the affected vehicles will be reprogrammed with corrected software. 

4053 

195 

38004 

3898 1921 1246 7798 1566 

659 

1101 1943 

50S 50S 50S 50S CA 50S FE50S CA 50S FE

DAIMLER/CHRYSLER 2005-1-E & E02 2488 V 2/21/2005 2005 Liberty 5CRXT03.7NE0 Some vehicles were manufactured with the wrong 

VECI label attached. Remedy: A new label will be sent directly to the owner with instructions, or owner can take label to dealer for installation. 

80 50S 

DAIMLER/CHRYSLER 2005-2 & E01 2493 V 4/4/2005 2005 Durango 

Durango Durango Durango 

5CRXT03.75S0 5CRXT04.75J0 5CRXT04.76U0 5CRXT05.75J1 

Fuel tank filler tube inlet check valve on some 

vehicles may not fully close at the end of refueling. This could allow some fuel to escape at the end of refueling. This could cause an increase in emissions when the check valve does not fully close. A safety recall E01 will inspect and replace all defective filler necks. Remedy: Fuel tank inlet check valve will be tested for proper operation. If found to be defective the fuel tank will be replaced. 

1034 1999 7559 9011 

50S 50S 50S 50S 

DAIMLER/CHRYSLER 2005-8 2524 V 4/1/2005 2004 Ram 4CRXT05.77X0 VECI label is missing load rating and frontal area 

limits. Remedy: Voluntary emissions recall E09 will replace the labels with correct one. Labels will be sent directly to vehicle owners to place on their vehicles. 

345 50S 

EPA420-B-06-001 1 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

DAIMLER/CHRYSLER 2005-22 2640 V TBD 2005 Dodge Ram 5CRXK05.7TX0 Some cab-chassis trucks certified to 50-State 

emissions standards were misidentified as CAonly emissions certified trucks. Remedy: VERR conducted to replace the PCM and VECI label to correctly identify trucks as 50­State vehicles. 

309 50S 

GENERAL MOTORS ML-MW091 2512 V 4/1/2005 2001 

2001 2002 2002 2003 

C/KTrk,Chev,GMC C/KTrk,Chev,GMC C/KTrk,Chev,GMC C/KTrk,Chev,GMC C/KTrk,Chev,GMC 

1GMXA04.3190 1GMXT04.3184 2GMXA04.3190 2GMXT04.3184 3GMXT04.3184 

Internal corrosion on the contacts inside the distributor and rotor may cause failure of the ignition system. Condensation from an AC line located above the distributor may drip onto the unit and cause the corrosion. Spark may be routed to the wrong cylinder. The OBD system will detect the misfire and signal a MIL. Remedy: A foam sleeve will be installed onto the AC line to prevent and condensation buildup, thus preventing future corrosion. 

3959 

36510 

6309 

79428 53776 

CA CA CA CA CA 

EPA420-B-06-001 2 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

GENERAL MOTORS ML-MW106 2529 V 4/20/2005 2005 

2005 2005 

" " " " 

2005 2005 

" 

2005 2005 2006 

Sunfire 

Classic 

Malibu, Uplander, 

Equinox, Montana 

SV6, Grand Prix, G6, 

Terraza, LaCrosse, 

Relay 

Grand Prix 

Grand Prix, 

LaCrosse 

Silverado, Sierra Silverado, Sierra 

G6 

5GMXV02.2025 5GMXV02.2027 

5GMXX03.8148 

" " " " 

5GMXV03.8041 5GMXV03.8044 

" 

5GMXH06.6590 5GMXH06.6591 

6GMXVB03.9146 

Some Engine Control Modules (ECM) or Power train Control Modules (PCM) have potentially damaged integrated circuits (IC). This may cause the EGR system to malfunction, or cause the fuel pump to turn off, or the turbo system to malfunction. A MIL light would be illuminated if this occurs. Remedy: A recall campaign will be conducted on affected vehicles to replace the suspect control modules. 

1 

14 

1702 

^ ^ ^ ^ 

1 

274 

^ 

53 

116 

2 

FCCA CA " " " " FCCA " 50S 50S CA 

GENERAL MOTORS ML-MW140 3046 V 11/21/2005 2006 

2006 

Chevy Express 

GMC Savana 

6GMXT06.0391 6GMXT06.0391 

Certain vehicles were built with incorrect On-Board Diagnostic calibrations. Remedy: The affected vehicles will be reprogrammed to install the correct OBD calibration. 

2602 

462 

HONDA/ACURA EDIR-02-047-00 & 

EDIR-02-047-01 

1701 V 12/1/2001 2000 

2001 

Insight Insight 

YHNXV01.0LA4 1HNXV01.0FH6 

IMA system battery may deteriorate when the vehicle is operated in cold conditions and under high loads. Emissions are slightly increased but are still below standards. When this conditions occurs, the change in performance of the vehicle is obvious and should be noted by the driver. The battery condition monitor and the motor control module with an improved calibration had been applied to the assembly line and for repair under Running change/Field fix #K1. Issued Service Bulletin #01-102. Remedy: The battery condition monitor module and the motor control module will be replaced with 

improved ones 

5677 1807 

CA CA 

HONDA/ACURA EDIR-05-004-00 & 

EDIR-05-004-01 

2522 V 11/30/2005 2005 Accord Hybrid 5HNXV03.01B4 When engine is started directly following a generic 

code clear command, without first turning the ignition off, the IMA battery will be overcharged. The IMA or a MIL light will illuminate. The problem is caused by inappropriate programing of the MCM module. A newly reprogrammed MCM computer has been applied to the production process, and current vehicles with MIL illumination will be covered under emission warranty. Running Change #L7 for corrective action and TAB #05­038. Remedy: The MCM will be reprogrammed with a correct Programming by dealership. 

6491 CA 

EPA420-B-06-001 3 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

HONDA/ACURA PUDR-05-023-00 

(P89) 

2620 V 9/14/2005 2005 Acura RL 5HNXV03.5PB4 PCM causes engine shudder,and may not allow 

the transmission to upshift to 4th gear. Remedy: The PCM will be reprogrammed with an appropriate programming by an Acura dealership. Issued TSB #05-027. 

21437 CA 

EPA420-B-06-001 4 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

HONDA/ACURA PUDR-05-010-00 

(P72) 

2477 

^ ^ ^ ^ ^ 

2494 

^ ^ ^ ^ ^ ^ ^ ^ ^ ^ 

2531 

V 7/31/2005 2003 

2003 2004 2004 2005 2005 

Civic Hybrid Civic Hybrid Civic Hybrid Civic Hybrid Civic Hybrid Civic Hybrid 

3HNXV01.34A5 

3HNXV01.36CV 

4HNXV01.35A6 

4HNXV01.37CP 

5HNXV01.33A6 

5HNXV01.3YCV 

Under certain driving conditions, inappropriate air to fuel ratio causes catalyst heat damage. The catalyst oxygen storage capacity is reduced and the MIL illuminates. Vehicle will be diagnosed under emissions warranty. ^ The OBD system may falsely detect a malfunction in the Variable Cylinder Management (VCM) system (Valve Pause System in Civic IMA). This happens after the engine oil and filter are changed. The cause is an inappropriate calibration of the OBD system. A PCM with a new calibration has been for assembly line. Running change/field fix #L4 (Civic), and #K9 (Odyssey) has been issued for vehicle service, MY 03-05. TSB #05-019 will address 05MY Odyssey. MIL indication will prompt owner to service or diagnose vehicle at dealership. 

The IMA battery may become overcharged thus deteriorating the IMA battery unexpectedly. The IMA light will illuminate, and possibly the MIL light depending on battery condition. The cause of the failure is a improperly calibrated control module (MCM). Field fix M1 has addressed issues in vehicles under Honda control. When the MIL is illuminated, a the owner will likely seek service at dealership. Remedy: The ECM/PCM will be reprogrammed with improved programming by a Honda dealership. Honda service bulletin 05-028 will address the issue. 

28192 

4348 

15424 

7397 

11951 

6638 

CA CA CA CA CA CA 

EPA420-B-06-001 5 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

KIA 52 3045 V 11/10/2005 2003 Sorento 3KMXT03.5G01 Vehicle may experience a fuel leak near the fuel 

tank. The cause of this malfunction is rubbing between fuel tube and body frame. Remedy: Kia will inspect and replace a section of the fuel line. 

3037 CL 

LAND ROVER 2005-4.4-1 3049 V 10/14/2005 2005 LR3 5LRXT04.4002 Vehicles may have fuel tanks that contain an 

internal breather pipe that was not made to specification . This may result in excessive swelling and cracking of a grommet and subsequent detachment of the breather pipe from a connector tube. MIL may illuminate. Remedy: A voluntary safety recall has been initiated to replace the fuel tank. 

17263 50S 

MAZDA 3105G 2222 I 8/31/2005 2004 

2004 2004 

Mazda 6 Mazda 6 Mazda 6 

4TKXV02.3AJA 

4TKXV02.3BJ1 

4TKXV02.3AJM 

Due to inappropriate programming of PCM, the malfunction logic of periodic deterioration that is a part of oxygen sensor monitor function of OBD II is disabled. MIL will not illuminate. Trouble code data will not be stored. Mazda will reprogram the PCM of affected vehicles in the plant, port, and distributor. Issue a repair procedure for technicians to correct the problem on vehicles brought into the dealership with this problem. Remedy: Mazda is issuing a recall letter to owners of affected vehicles and will reprogram the PCM to the correct specifications. 

700 50S 

CA 50S 

MAZDA 3205G 2251 V 8/31/2005 2004 

2004 

Mazda 6 Mazda 6 

4TKXV03.0ALA 

4TKXV03.0ALM 

Due to inappropriate design of the Powertrain /control Module (PCM) circuit for a part of evaporate leak monitoring system in the PCM, ability of a pump control circuit failure detection may be lower than requirement of OBD2 regulation. Remedy: Mazda will issue a repair procedure to correct this concern by reprogramming the PCM of affected vehicles when customer brings vehicle in for service at the dealer. A recall will be preformed to recall the vehicles and reprogram the PCM. 

8900 50S 

FE

MAZDA 3305G 2472 V 8/19/2005 2004 

2005 2005 

Mazda RX-8 Mazda RX-8 Mazda RX-8 

4TKXV01.3CNA 5TKXV01.35NM 

5TKXV01.35NC1 

Vehicle is parked and the engine is operated at high RPMs, excessive heat build-up may affect oxygen sensors, the neutral switch and back up lights. It may also lead to problems with the parking brakes, malfunctions of the gas gauge and possible damage to the fuel tank causing fuel leaks. Remedy: A safety recall will be conducted to install a heat insulator pad to the fuel tank. and other various areas around the exhaust system that could sustain damage. All damaged parts will be replaced during the installation of the insulation pads. The PCM will be reprogrammed. 

52000 50S 

50S 50S 

EPA420-B-06-001 6 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

MAZDA 3005C 2521 V 6/1/2005 & 

12/16/2005 

2003 2003 

Protege, Protege 5 

Mazdaspeed Protégé 

3TKXV02.0HJA 

3TKXV02.0BJB 

Tightening of torque screws for the mounting of the intake manifold shutter valve may have been lower than the specification. If the valve loosens enough, it will cause rough idle, harsh noise, and a MIL to illuminate. Also, the emissions will be adversly affected. Remedy: A recall will be done to tighten/replace the bolts and/or replace the shutter valve and gaskets or the intake manifold assembly, free of charge. 

39600 NF

CL

MAZDA 3505H 2600 I 11/30/2005 2001 

2002 

MX-5 Miata MX-5 Miata 

1TKXV01.8CJA 2TKXV01.8CJA 

Non Methane Organic Gas (NMOG) emissions may exceed the standard due to the emission control logic and calibration of the PCM during the engine warm up period after cold start up. Remedy: Mazda will issue a recall to address these concerns. Mazda plans to issue a repair procedure to assist technicians in diagnosing and correcting this concern. The PCM will be replaced. 

18200 13800 

NFNF

MERCEDES-BENZ 2003-090005 2075 V 3/1/2004 2003 SLK 32 AMG; C 32 

AMG 

3BMXV03.2LB1 The 2003 model year vehicles did not meet the 

applicable emission standards, requiring vehicles to be recalibrated. Remedy: The combustion map in the ECM was recalibrated to reduce lean combustion spikes of the engine and to reduce the negative effects of rapid throttle activation. Mercedes-Benz will inform dealers and owners that the ECM of the affected vehicles will receive the new program version at the owner's earliest convenience or during the next scheduled service at no charge to the owner. 

1372 CL

MERCEDES-BENZ 2005060014 2504 I 9/16/2005 1999 

1999 2000 2000 2001 2001 

ML320 ML430 ML430 ML320 ML320 ML430 

XMBXT03.2GNB XMBXT04.3GNB YMBXT04.3GNB YMBXT03.2GNB 

1MBXT03.21BI 1MBXT04.31BI 

Under hood catalyst cans may develop cracks along the weld seams between the inlet funnel and the can body. This is due to tolerance deviations during the welding process. Engine noise is increased, and MIL may illuminate if condition goes unserviced for an extended period of time. Customers are expected to bring vehicle into service when noise is apparent. Remedy: Catalysts will be inspected/replaced free of charge 

27672 

9462 

32534 11706 

6364 1379 

CLCLCA CA CA CA 

MERCEDES-BENZ 2005080007 2616 V 9/12/2005 2005 G55 AMG 5MBXT05.5LB1 The fuel return hose may become permeated with 

fuel. Micro-cracks may result in cracks through which fuel can leak. Remedy: A replacement hose to correct the situation will be installed by the dealer free of charge. 

485 CA 

EPA420-B-06-001 7 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

MITSUBISHI/D-STAR EMR-05-001 & 

EMR-05-003 

2514 V 8/29/2005 & 

12/6/2005 

2002 2002 2003 2003 2004 2005 

Lancer Lancer Lancer Lancer Lancer Lancer 

2MTXV02.0GNG 

2MTXV02.0G3G 

3MTXV02.0GNS 

3MTXV02.0G3S 4MTXV02.0GB2 

5MTXV02.0GR4 

The MIL may illuminate due to the PCM's determination that the catalytic converter has deteriorated. Code P0421 is found. Separation of the catalyst layer and melting damage to the substrate layer has occurred in investigation of the damaged vehicles. This could be due to unburned fuel igniting close to the converter. Remedy: Reprogram the Engine Control Unit with ROM upgrade. A second letter sent to owners of vehicles built prior to January 2002 to insure the throttle position sensor is properly initialized. 

55921 15810 51108 15199 30892 22360 

CLCA NLCA CA CA 

MITSUBISHI/D-STAR EMR-05-002 2613 V 10/17/2005 2005 

2005 2005 2005 

Lancer Lancer 

Outlander Outlander 

5MTXV02.4GBG 

5MTXV02.4G2G 5MTXV02.4GBB 

5MTXV02.4GBG 

The vehicle speed sensor malfunction logic was erroneously left out from the engine ECU programming for the affected vehicles with manual transmissions. The MIL will not illuminate. Remedy: The ECU will be reprogramed to include speed sensor diagnostic logic. 

1127 

170 425 358 

FECA 50S 50S 

NISSAN R0501 3032 V 12/5/2005 2003 

2004 

Sentra Sentra 

3NSXV01.863A 4NSXV01.883A 

The catalytic converter is deteriorating faster than anticipated and turning on the MIL. Remedy: The catalytic converter on all affected vehicles will be replaced with the 2005 MY Sentra catalytic converter. The engine control module will be programmed to match the new catalytic converter. 

10800 28100 

TOYOTA/LEXUS LSC 50G 2528 V 6/15/2005 2005 Tundra (Double-cab) 5TYXT04.7PEW IM data for vehicles with the traction control 

system did not receive the correct VECI label describing the details of how to test the vehicle on a two wheel dynamometer. Remedy: A Limited Service Campaign (50G) will be used to distribute the correct labels along with instructions for installation to owners. 

45000 CA 

TOYOTA/LEXUS TOYOTA-DIR20050622 2559 V 10/17/2005 2004 2005 Prius Prius 4TYXV01.5MC1 5TYXV01.5MC1 If engine speed continues for 6 seconds at 850 rpm or less MIL illumination will occur. P3191 for 

"an engine does not start" is the cause of the MIL. Running change 05-TR -16 and field fix 04-TF-10 are available and in use. Since MIL illumination will occur, and owner will obtain service at dealership and have their ECM re-flashed. Remedy: Reprogram the ECM system. 

47200 26500 

CA CA 

VOLKSWAGEN/AUDI UZ 2176 V 2/16/2004 2004 Golf 4VWXV02.0223 These vehicles were assembled with the incorrect 

Emission Control label. P/N 021 010 3K to be replaced by 06A 010 334F prior to delivery to dealers or via voluntary recall to vehicles delivered to dealers and customers. Remedy: Notification letter will be sent that has included the correct label. Owners can put label on or have dealer do it. 

4125 FE

EPA420-B-06-001 8 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Recall Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

VOLKSWAGEN/AUDI AWA-05-DR 2277 V 12/1/2005 2001 S8 1ADXV04.2335 Front oxygen sensor malfunction was caused by a 

contamination inside the air reference chamber. This may happen along with moisture inside the sensor body due to reduced exhaust temperature in particular load conditions. The MIL will be illuminated. Remedy: Changed production process of the sensor February 2001. Will replace the related front oxygen sensor left/right in case of complaint, free of charge for extension of warranty of 7 years/70,000 Miles. 

817 CL

VOLVO 145 2537 V 6/1/2005 2005 

" 

2005 2005 

S80, XC90, V70, 

XC70, S60 S80, XC90 

V70, S60 

5VVXX02.5U2T 

" 

5VVXV02.9U1T 

5VVXV02.5L2T 

A software calibration error in the engine management system the EVAP purge may start too late potentially leading to poor purge performance. Remedy: A software upgrade of the engine control module at no charge. 

16983 

^ 

5809 

730 

CA " CA CA 

Total number of vehicles vo

Type: Total Number of Recalls O- Ordered by EPA 

I- Manufacturer voluntary Action with EPA Influence V- Voluntary Action by Manufacturer Sales Area: CL- California + NLEV (all States) FED- Federal States (all altitude) CA- California FED/NLEV- Northeast States (all Altitude) NL(NLEV ALLS) - NLEV + All States NE+CA- NLEV Northeast States+California CE- California + NLEV 

*For the purposes of this report only, a Recall Campaign is a direct owner notification requesting or 

recommending that the vehicle be brought into a service facility for inspection and/or repair regardless of whether there is an indication of failure. For the purposes of this report only, a Voluntary Service 

Campaign is a direct owner notification alerting the owner of a potential problem should there be an 

indication of failure, and how the problem will be remedied by the manufacturer should the problem effect the owner's vehicle. EPA recognizes that manufacturers may wish to voluntarily notify their customers of potential issues for which service may be required. However, under 40 CFR 85.1902 (d), any repair, adjustment, or modification program voluntarily initiated by a manufacturer to remedy any emissionrelated defect for which direct owner notification is provided is defined as a Voluntary Emissions Recall. 

EPA420-B-06-001 9 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Voluntary Service Campaigns 

Mfr. Mfr. Recall 

Number 

EPA# Type Owners 

Notification 

MY Vehicle or Engine 

Class 

Engine Family Problem Description Affected 

Vehicles 

DAIMLER/CHRYSLER TBD 2647 IVSC 12/30/2005 1996 

1996 1997 1997 1997 1998 1999 1999 2000 

Dodge Ram 

Van/Wag Dodge 

Ram Pickup 

Dodge Ram 

Van/Wag Dodge 

Dakota Pkup Dodge 

Ram Pickup Dodge Ram Pickup Dodge 

Dakota Pkup 

Dodge Ram Pickup 

Dodge Ram Pkup HD 

1.9L 

3.9L, 5.2L, 5.9L 

3.9L 3.9L 3.9L 3.9L 3.9L 5.2L 

5.9L, 8.0L 

Original equipment catalytic converters may fail due to problems with retention of the ceramic substrate in the converter container. Failure of the substrate mat to retain the substrate can cause the converter to rattle, eventually resulting in the complete erosion of the substrate. Remedy: 1996 - 1999 model year vehicles will have warranties for catalytic converters extended to 10 years or 120,000 miles, whichever occurs first. Vehicles in this category that have already exceeded 10 years or 120,000 miles will receive an extended catalytic converter warranty of one year with unlimited mileage from the date of the letter to the owner, or two years with unlimited mileage if the vehicle fails a state emissions inspection. (Vehicles that have had the improved catalytic converter installed are excluded.) 2000 model year vehicles will have warranties for their catalytic converters extended for at least one year without mileage limitation after the date of the letter to the owner. 

682806 

DAIMLER/CHRYSLER TBD 2648 IVSC 12/30/2005 1999 

1999 1999 2001 

Dodge Ram 

Van/Wag Dodge 

Ram Pickup 

Dodge Dakota Pkup 

Dodge Ram Pkup HD 

3.9L, 5.2L, 5.9L 

3.9L, 5.9L 5.2L, 5.9L 5.9L, 8.0L

 Original equipment catalytic converters may fail due to problems with retention of the ceramic substrate in the converter container. Failure of the substrate mat to retain the substrate can cause the converter to rattle, eventually resulting in the complete erosion of the substrate. Remedy: Owners will receive notification letters about the potential catalytic converter problem as well as a reminder of the vehicle’s original catalytic converter warranty coverage of 8 years or 80,000 miles, whichever occurs first. 

296809 

HONDA/ACURA WER-02-038-00 

(P75/P76) 

1556 

& 

1779 

& 

1870 

& 

1877 

& 

2022 

& 

2519 

VSC 8/23/2005 1999 

2000 2001 2001 2002 2002 2003 2003 2003 

Odyssey Odyssey Odyssey 

MDX 

Odyssey 

MDX 

Odyssey 

Pilot Pilot 

XHNXT03.5EA3 YHNXT03.5EA3 1HNXT03.5DH2 

1HNXT03.5K86 

2HNXT03.51AP 

2HNXT03.5KYT 

3HNXT03.5ZAP 

3HNXT03.5DAP 

3HNXT03.5EA5 

The EGR system may become contaminated or clogged and/or EGR valve sticking. The OBD system detects the failures and illuminates the MIL when the improper EGR flow or valve operation reaches the OBD monitoring criteria. The vehicle may hesitate or surge. Remedy: An improved EGR valve has been applied to the assembly line and is available for repair. EGR valves will be replaced under service bulletin #05-026 and Acura service bulletin #05­019 under Honda's warranty extension campaign. Warranty extended to 8 years or 80,000 miles whichever comes first. 

50407 

126721 124194 

44305 

148659 

49047 71378 50938 16731 

EPA420-B-06-001 10 
 2005 Emission-Related Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty T

Voluntary Service Campaigns 

HYUNDAI V04 1843 & 

1965 

IVSC 1/1/2005 1999 

1999 2000 2000 2001 2001 2001 2002 2002 2003 2003 

Elantra/Tiburon Elantra/Tiburon Elantra/Tiburon Elantra/Tiburon Elantra/Tiburon Elantra/Tiburon Elantra/Tiburon Elantra/Tiburon Elantra/Tiburon Tiburon Tiburon 

XHYXV02.01RF 

XHYXV02.03RC 

YHYXV02.0G1F 

YHYXV02.0G3S 

1HYXV02.0R3S 

1HYXV02.0X4C 

1HYXV02.0X3F 2HYXV02.0XLF 

2HYXV02.0XUC 

3HYXV02.0CLF 

3HYXV02.0CUC 

Some Hyundai Elantra/Tiburon's equipped with 2.0 liter engines have experienced exhaust manifold cracks. The cracking may occur in certain areas of the manifold due to insufficient thickness of the exhaust manifold casting in those areas. Remedy: To correct this condition, Hyundai has improved the manufacturing process of the exhaust manifold to ensure the thickness of the casting is increased in the problem areas and has modified the material alloy content of the exhaust manifold casting to improve durability. Dealers will inspect and replace as necessary. Warranty extended 10 years without mileage limitation. 

34230 31806 66764 71875 22124 55686 48376 28870 31915 

546 595 

KIA 07.28.05.01 

(SC043) 

3039 VSC 10/17/2005 2005 Serento LX 5KMXT03.5CM5 Some 2005 model year Sorento’s equipped with 

3.5 liter engines have experienced a malfunction indicator light (MIL) illumination. The fault determined by the OBD system is a canister close valve clogging (P2422) caused by road dirt clogging the air filter in the vent line during the purge drive condition. The partial wheel well cover did not provide sufficient protection to prevent the CCV filter from being contaminated. Remedy: Kia will replace the partial wheel guard with full-size wheel guard to eliminate the source of the road debris from contaminating the filter. Kia will issue a TSB explaining a corrective action for this problem, and will conduct a voluntary service campaign, with owner's notification to implement the correction as necessary. 

18865 

Type: O- Ordered by EPA 

I-VSC-Manufacturer Voluntary Service Campaign with EPA Influence VSC-Voluntary Service Campaign by Manufacturer Total number of vehicles in Voluntary Service Cam

Total number of Voluntary Service 

Campaigns: 5 

Sales Area: CL- California + NLEV (all States) 

Total number of vehicles Affected by Voluntary Reand Voluntary Service Campaigns: 

FED- Federal States (all altitude) CA- California Total number of all Recalls and all 

Voluntary Service Campaigns: 36 

FED/NLEV- Northeast States (all Altitude) NL(NLEV ALLS) - NLEV + All States 

NE+CA- NLEV Northeast States+California CE- California + NLEV 

*For the purposes of this report only, a Recall Campaign is a direct owner notification requesting or 

recommending that the vehicle be brought into a service facility for inspection and/or repair regardless of whether there is an indication of failure. For the purposes of this report only, a Voluntary Service Campaign is a direct owner notification alerting the owner of a potential problem should there be an indication of failure, and how the problem will be remedied by the manufacturer should the problem effect the owner's vehicle. EPA recognizes that manufacturers may wish to voluntarily notify their customers of potential issues for which service may be required. However, under 40 CFR 85.1902 (d), any repair, adjustment, or modification program voluntarily initiated by a manufacturer to remedy any emission-related defect for which direct owner notification is provided is defined as a Voluntary Emissions Recall.

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