Air and Radiation EPA420-B-05-022

December 2005

2004 Annual Summary of

Emission Related

Recall and Voluntary

Service Campaigns

Performed on Light-Duty

Vehicles and Light-Duty

Trucks
EPA420-B-05-022

December 2005

2004 Annual Summary of Emission Related Recall and

Voluntary Service Campaigns Performed on

Light-Duty Vehicles and Light-Duty Trucks

Certification and Compliance Division

Office of Transportation and Air Quality

U.S. Environmental Protection Agency
 2004 Annual Summary of Emission Related Recall and Voluntary Service Campaigns Performed On Light-Duty Vehicles and 

 Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehic

BMW 04V-182 2286 V 5/31/2004 2003 

2003 2004 2004

Z4 Z4 Z4 Z4

3BMXV03.0LER 

3BMXV03.0M5R 

4BMXV03.0LER 

4BMXV03.0M5R

Under certain environmental conditions, vapor lock in the fuel pump could occur. This could cause the engine to stall. 

Remedy: Installation of a resistor in the wiring harness powering the fuel pump. This repair will reduce the power out put of the fuel pump and prevent vapor lock from occurring.

7670 5133 

573 396

BMW D-04-4.4-2 

D-04-4.4-2&D-04-4.4-2

2304 V 11/9/2004 2004 

2004 2004

745i, 745Li 

X5 4.4i 

545i, 645Ci, 645Ci 

Cabrio

4BMXV04.4LEV 

4BMXT04.4N62 

4BMXV04.4LEV

OBD defect affects the diagnostic of the oxygen sensor. In case of an oxygen sensor failure no fault code would be stored and the MIL would not be illuminated. Remedy: A nationwide emission recall campaign to correct the problem by updating the software of the ECU.

1400

6000 

1210

BMW D-02-04-1.6-1 2309 V 11/10/2004 2002 

2003 2003 2004

Cooper, Cooper S Cooper, Cooper S Cooper, Cooper S Cooper, Cooper S

2BMXV01.6R50 3BMXV01.6R50 

3BMXV01.6R5R 

4BMXV01.6R50

A error in the software of the ECU module causes the LDP to fail. Remedy: A recall was implemented by BMW to correct the problem by updating the software of the ECU.

1740180019002700

BMW D-04-3.0-1 2356 V 9/30/2004 2004 530i, 525i, 530i 4BMXX03.0ULV Due to software error in the ECU the readiness code for the 

comprehensive component monitors are not set and stored at the end of the OBD system check. The component diagnostics are not affected and are performed correctly. 

Remedy: BMW decided to implement a nationwide voluntary emissions recall campaign to correct the problem by updating the software of the ECU, enabling the comprehensive component readiness code to set as designed.

2945

BMW D-02/03-1.6-1 2357 V 11/10/2004 2002 

2003 2003

COOPER S COOPER S COOPER S

2BMXV01.6R50 3BMXV01.6R50 

3BMXV01.6R5R

Due to supplier mix-up an unsuitable material was used for all ventilation return hoses. Over time this may cause the hose to fail, allowing gases to leak. This is also accompanied by a whining noise under certain conditions. 

Remedy: BMW decided to implement a recall to correct the problem. Improved components have been phased into production and available for service

3250 7815 6045

DAIMLER/CHRYSLER C37 2145 V 1/9/2004 2004 

2004

Chrysler Sebring

Dodge Stratus

4DSXV03.0GBC 4DSXV03.0GBC

The VECI label language incorrectly indicates the California cert level is "Interim Non-Tier 2, Bin 9" when it should state LEV1 LEV. Remedy: New VECI label will be sent to owner.

1044 3067

DAIMLER/CHRYSLER 2004-1 2208 V 2/23/2004 2004 2.4L PT Cruiser 4CRXV02.4VH0 Test group name contains 11 of the 12 characters on VECI 

label. Remedy: A new VECI label will be sent to the vehicle owner. The owner can install the label or have the dealer install the label.

1809 

DAIMLER/CHRYSLER 2004-8 2259 V 4/12/2004 2005 Dodge Caravan 5CRXTO2.42N0 Oil filler cap does not confirm to EPA guidance letter. The 

oil viscosity is not displayed on the cap as required. 

Remedy: Daimler/Chrysler will conduct a Voluntary Emission Recall of the affected vehicles to replace the oil filler cap with one with the correct nomenclature. The new cap will be sent to the owner. Installation can be done by owner or any Daimler/Chrysler dealer who will install it for them.

292 

DAIMLER/CHRYSLER 2004-9 2263 V 4/12/2004 2004 Jeep Grand Cherokee 4CRXT04.02N0 Vehicles built with core software issue that could affect the 

function of the OBD system. Remedy: The Powetrain Control Module will be reprogrammed with the correct software calibration.

2475 

EPA420-B-05-022 1 
 2004 Annual Summary of Emission Related Recall and Voluntary Service Campaigns Performed On Light-Duty Vehicles and 

 Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehic

DAIMLER/CHRYSLER 2004-13 2270 V 5/28/2004 2005 Chrysler 300C 5CRXV05.7VH0 Vehicles have a European (BUX) Powertrain Control 

Module (PCM) calibration prior to shipment. The BUX calibration has unique OBD monitor requirements that are different from the federal and California requirements. Remedy: Daimler/Chrysler will conduct a Voluntary 

Emission Recall of the affected vehicles and install a new PCM with the correct U. S. calibration.

260 

DAIMLER/CHRYSLER 2004-14 2271 V 5/29/2004 2004 Dodge Stratus, Chrysler 

Sebring sedans

4CRXV0148VX0 Partial Zero emission vehicles were manufactured with VECI

labels that did not include the "AIR" nomenclature for the air pump. Remedy: Daimler/Chrysler will conduct a recall of the affected vehicles and mail a revised VECI label to the owner for installation on the vehicle.

680 

DAIMLER/CHRYSLER 2004-17& 2004-17-E 2375 V 9/27/2004 2005 300 C, DODGE 

MAGNUM

5CRXV05.7VH0 Some 2005 model year vehicles have VECI labels with a 

typographic error in the spark plug specifications. 

Remedy: Recall (D38), on affected vehicles the VECI label will be replaced. New VECI labels will be sent with the Owner Notification Letter. Owner/dealer can install new 

label.

2518

DAIMLER/CHRYSLER 2004-19 2384 I 10/18/2004 2004 Dodge Ram 4CRXT04.75TP OBD software problem. The evaporative system monitor 

readiness bit could be cleared with only a single cold-start in cold ambient temperatures rather than the required two or more cold starts under these conditions. Remedy: Chrysler will reprogram the Powertrain Control Module on all affected vehicles.

673 

FORD ^03E05 2066 V 2/2/2004 2002 

2002 2003 2003

Explorer Explorer Explorer Explorer

2FMXT04.02F3 2FMXT04.02F5 3FMXT04.02F3 

3FMXT04.02FA

Some 2002 and 2003 model 4.0L Explorer Sport Trac trucks may have evaporative canister fresh air vent hoses that can dislodge from the splash apron and allow water to contaminate the canister. Remedy: Replace the evaporative emission fresh air inlet hose connector with an elbow assembly.

6853

FORD ^04E09 2336 V 5/31/2004 2001 

2002 2003

E-Series E-Series E-Series

1FMXT05.4RP6 2FMXT05.4RP5 3FMXT05.4RP5

Some compressed natural gas vehicles may develop a fuel leak at one or both of the fitting locations. 

Remedy: Both adjustable fittings will be replaced.

550 420 520

FORD ^04E10 2337 V 5/31/2004 1997 

1998 1999 2000 2001 2002 2003 

E-Series E-Series E-Series E-Series E-Series E-Series E-Series

VFM5.468C7EK 

WFMXT05.4RP6 

XFMXT05.4RP6 YFMXT05.4RP6 

1FMXT05.4RP6 2FMXT05.4RP5 3FMXT05.4RP5

Some compressed natural gas vehicles may develop a fuel leak due to contact by the rear brake hose and/or axle vent hose. Remedy: Dealer will inspect the rear high pressure fuel line 

for a leak. If not leaking install a shield. If leaking replace line with a new line.

645 695 580 600 550 410 520

GENERAL MOTORS ML-MW067 2383 V 9/1/2004 2004 

2005

CTS-V CTS-V

4GMXV05.7083 5GMXV06.0081

Vehicles were built with fuel feed jumper pipe assembly that was out of specification. The tube does not contain a special coating to reduce fuel vapor permeation. 

Remedy: Replacement of tube with proper coating and specifications.

2448 

351

HONDA/ACURA EDIR-03-034-00 2199 V 1/31/2004 2003 

2004

ACURA MDX 

ACURA MDX

3HNXT03.5TKR 4HNXT03.5TKR

OBD cannot perform evaporative leak monitor when the fuel level sensor circuit failure occurs (MIL not illuminated). 

Remedy: An ECM with improved calibration is available for production and for remedy under Running Change/Field fix #D8 and Service Bulletin 03-035. 

5583

9509

EPA420-B-05-022 2 
 2004 Annual Summary of Emission Related Recall and Voluntary Service Campaigns Performed On Light-Duty Vehicles and 

 Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehic

HONDA/ACURA EDIR-04-006-00 2303 V 3/8/2004 1998 

1998 1998 1998 1999 1999 1999 1999 2000 2000 2000 2000 2001 2001 2001 2001 2002 2002 2002 

2002

Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord Accord

WHNXV02.3PF1 

WHNXV02.3PL2 

WHNXV02.3PA3 

WHNXV02.3PL4 

XHNXV02.3PF1 

XHNXV02.3PL2 

XHNXV02.3PA3 

XHNXV02.3PL4 

YHNXV02.3PA3 

YHNXV02.3PF3 

YHNXV02.3PL4 

YHNXV02.3NL5 

1HNXV02.3VH2 

1HNXV02.32J1 

1HNXV02.3W87 

1HNXV02.3BF9 

2HNXV02.3RDA 

2HNXV02.3MJT 

2HNXV02.3FK6 

2HNXV02 3PNP

Idle air bleed may be restricted so that idle air flow is reduced. Idle speed may dip and engine may stall intermittently when it is just "off idle". Jerking during deceleration, hesitation at acceleration afterward, unstable idle and engine stall at vehicle stop. 

Remedy: The idle adjusting screw will be adjusted, and do the idle learn procedure, according to the Honda Technical Service Bulletin # 04-011.

4907 4084 

25212

2896

2914 4024 

18144

6626

5096 

1595711673

2474 

3532

12999

8505

5150 

24158

9588

4454 

2237

HYUNDAI 2004.06.08.01 

SC066

2341 V 6/8/2004 2002 

2002 2002 2002 2002 2003 2003 2003 2003 2003 2003

Elantra Elantra Sonata Sonata 

XG350 

Elantra/ Tiburon Elantra/ Tiburon 

Tiburon 

Sonata Sonata 

XG350

2HYXV02.0XUC 

2HYXV02.0XLF 

2HYXV02.4ELS 

2HYXV02.7FLS 

2HYXV03.5GLS 

3HYXV02.0CUC 

3HYXV02.0CLF 3HYXV02.7KLS 3HYXV02.4ELS 

3HYXV02.7FLS 

3HYXV03.5GLS

Vehicles may contain a fuel cut valve that may not close properly due to insufficient clearance between the valve case and the float. The pressure in the fuel tank drops to a threshold value during driving, and causes a diagnostic code indicating a closed valve clogging error. 

Remedy: Will install the additional fuel cut valve on the affected vehicles and publish a technical service bulletin for dealers.

4492464621563908180719482986203210471352

1965

KIA 2004.05.26.01 2284 V 5/31/2004 2001 

2002 2003 2004 2004

Rio Rio Rio Rio Rio

1KMXV01.5C01 2KMXV01.5C02 3KMXV01.6C01 4KMXV01.6C02 4KMXV01.6C03

The fuel intake nipple of the fuel distributor is subject to fracture or cracking during removal of the quick-connect coupling securing the main fuel tube assembly to the fuel intake nipple, or when force is accidentally applied to the intake nipple during the assembly process. Remedy: A new steel nipple and fuel tube assembly will be installed at no charge. Kia has issued service bulletin SC036 to dealers for repair information.

5734572944122020

5272

KIA SC038 2340 V 5/31/2004 2002 

2002 2003 2003

Optima Optima Optima Optima

2KMXV02.4D02 

2KMXV02.7E01 

3KMXV02.4D03 

3KMXV02.7E02

Defective Fuel tank assembly valve may not close properly. 

During vehicle roll over, fuel spillage may occur. Kia will publish technical service bulletin to provide repair information to dealers. Remedy:Kia will repair vehicles with new fuel cut valve in addition to the one on the tank. 

9292 7371 4761 4369

KIA 2004.08.19.01 2377 V 11/1/2004 2005 Sedona 5KMXT03.5GM5 A false malfunction indicator light (MIL) illumination due to 

the misapplication of a design restricted flow vent elbow in evaporation system. Kia will publish a TSB to provide repair information to Kia dealers for this condition. Remedy: Kia will replace the vent elbow.

691 

LAND ROVER 2004-RV8-1 2221 V 9/30/2004 2000 

2000 2001 2002

Range Rover 

Range Rover Range Rover Range Rover

YLRXT04.6001 YLRXT04.6002 

1LRXT04.6001 2LRXT04.6001

Right hand exhaust manifolds are cracking at the junction of 

the primary tracts into the collector pipe. 

Remedy: Exhaust manifolds will be inspected and replaced if necessary.

1300

EPA420-B-05-022 3 
 2004 Annual Summary of Emission Related Recall and Voluntary Service Campaigns Performed On Light-Duty Vehicles and 

 Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehic

LAND ROVER #2004-RV8-5 / B167 2325 V 7/28/2004 2001 

2002 2002 2003 2004

Discovery

DiscoveryDiscoveryDiscoveryDiscovery

1LRXT04.6001 2LRXT04.6001 2LRXT04.6003 3LRXT04.6001 4LRXT04.6001

A software fault that monitors the electrical connection between the DMTL switches on pump motor and the ECM causes MIL illumination. Remedy: Land Rover will recall the affected vehicles to replace calibration files in the ECM's. 

6160 6211 6211 

21361586

MAZDA LCE-03/207 2140 V 8/27/2004 2002 

2003

MPV MPV

2TKXT03.0GLA 

3TKXT03.0FLA

PCV hose may crack due to acids and fuel in PCV gases, and stress created by engine vacuum changes, as well as ozone attack on hose exterior. MIL will illuminate. Remedy: Mazda dealers will install a modified Positive Crankcase Ventilation hose.

6100

MITSUBISHI/D-STAR SC-03-002 2145 V 10/31/2003 2004 

2004 2004

Eclipse, Eclipse Spider Eclipse, Eclipse Spider Eclipse, Eclipse Spider

4DSXV02.0GBB 4DSXV03.0GBB 

4DSXV03.0GBC

The VECI label language incorrectly indicates the California cert level is "Interim Non-Tier 2, Bin 9" when it should state LEV1 LEV. Remedy: New VECI label will be sent to owner.

1022 

174 431

MITSUBISHI/D-STAR SR-04-008 2414 I 8/1/2004 2002 

2003 2004

Montero Montero Montero

2MXT03.5GNS 3MXT03.5GNS 4MXT03.5GNS

When vehicle is tilted on an upward slope, with a full fuel tank, the fuel tank leveling valve may not provide proper sealing. This will cause gasoline to be leaked onto the ground. Remedy: Fuel leveling valve and fuel filler check valve will be replaced with modified ones. Evaporative canister will be inspected for damage from liquid gasoline. 

28121294

3147

ROLLS ROYCE D-04-6.7-1 2305 V 9/30/2004 2004 Phantom 4RRXV06.7N73 OBD Related defect affects the diagnostic of the oxygen 

sensor. In case of a oxygen sensor failure no fault code would be stored and MIL would not be illuminated. A nationwide emission recall campaign to correct the problem by updating the software of the ECU. 

Remedy: The corrective measure consists of a software update in the ECU module correcting an OBD related shortcoming that affects the oxygen sensor monitor.

440 

SUBARU GA04-052C 2345 V 7/23/2004 2004 

2005

Baja Turbo 

Baja Turbo

4FJXT02.5PGT 5FJXT02.5PGT

Incorrect California standard compliance statement .Remedy: Correct VECI label will be issued.

1085 

746

TOYOTA/LEXUS SSC 40A 2188 V 1/30/2004 2004 Prius e/w 1NZ-FXE 

engine

4TYXV01.5MC1 A communications error may occur under certain conditions, 

between the battery-ECM and HV-ECM, illuminating the MIL, and the vehicle to go to "limp-home" mode. Frequent "driveline shock" may be experienced when the vehicle is restarted and driven in "limp-home" mode, due to a deficiency in HV-ECM software. 

Remedy: Toyota will reprogram the HV ECU with modified software.

3500 

TOYOTA/LEXUS SSC 40D 2241 V 5/31/2004 2004 Prius (engine 1NZ-FXE) 4TYXV01.5MC1 The HV ECM and Battery ECM do not conform to the SAE 

1979/ISO-5 CAN communication standard. The nonconformities may prevent the "Malfunction Indicator Lamp 

(MIL) from being recognized by the OBD scan tool. 

Remedy: The HV-ECM will be "reflashed" with modified software by the dealer.

2500

EPA420-B-05-022 4 
 2004 Annual Summary of Emission Related Recall and Voluntary Service Campaigns Performed On Light-Duty Vehicles and 

 Recall Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affect

Vehic

TOYOTA/LEXUS 4LB 2293 V 8/31/2004 2004 LS430 4TYXV04.3WMA Impeller in the fuel pump may become deformed and may 

contact the fuel pump body causing failure of the fuel pump. 

Toyota will conduct a voluntary safety recall of the subject vehicles. Remedy: The fuel pump will be replaced at no cost to owner.

1430

VOLVO R138 2417 V 9/30/2004 2003 

2003 2004 2004 2004 2004 2004 2004

XC90 XC90 

XC90, V70, XC70, S60 

XC90 

V70, S60 

V70 

V70, S60 

S60 

3VVXV2.52U2T 

3VVXT2.92U1T 

4VVXX2.52U2T 

4VVXT2.92U1T 

4VVXV2.52L1T 

4VVXV2.43S2N 

4VVXV2.43U2N 

4VVXV2.43S2N

Vehicle's vacuum hose routing label is incorrect or missing from the vehicle. Remedy: Corrected/missing labels will be mailed to owner with instructions for proper application. 

3922 8906 8360 4036 

488 214 

2493 

751 

Type:

O- Ordered by EPA Num

I- Manufacturer voluntary Action with EPA Influence Ordered 

V- Voluntary Action by Manufacturer Influenc

Sales Area: Volunta

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

Total number of vehicl

*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.

EPA420-B-05-022 5 
 2004 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and 

Voluntary Service Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affected 

Vehicles

KIA SC028 & SC037 1915 VSC 3/28/2003 

4/1/2004

2001 2002

Optima Optima

1KMXV02.5D01 

2KMXV02.7E01

Some 2001 model year KIA Optima's equipped with 2.5 liter engines have experienced a malfunction indicator light illumination as a result of oxygen sensor malfunction. The main cause of failure was a slow response signal output characterized by a long switching time and low amplitude. These abnormal signal outputs are caused by contamination of the oxygen sensor from oil or other exhaust impurities that are present during operation. 

Remedy: KIA has improved the oxygen sensor by adding an additional calcium coating to the surface of the sensor which will protect the sensor from contamination. The ECM will be reprogrammed to reflect the characteristics of the improved sensor.

8107 

13393

KIA 2004.02.04.01 2205 VSC 2/6/2004 2001 

2002 2003

Rio Rio Rio

1KMXV01.5C01 2KMXV01.5C02 3KMXV01.6C01

Unstable condition at idle or near stopping conditions due to 

a problem with the TPS signal at low voltage (closed throttle). In the idle or near stopping condition, interference due to noise (noise value is high relative to signal voltage) may affect the capability of the system to determine the throttle position accurately. The ECM may misinterpret this condition and attempt to compensate for a false-lean condition by enriching the mixture. After increasing the fuel amount , the fuel value is recalculated/reduced based on several factors, and may then become overly lean. 

Remedy: Kia has changed the ECM logic to include a filter 

for the TPS signal. Kia will reprogram the ECM with the new

software.

57340 57292 13380

VOLKSWAGEN/AUDI AWA-04-21 2277 VSC 9/8/2004 2001 Audi,A6/A8 Quatro 1ADXV04.2345 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.

4511 

Type: 

O- Ordered by EPAI-VSC- Manufacturer voluntary Action with EPA InfluenceVSC- Voluntary Action by Manufacturer

Total number of Voluntary Service Campaigns 3

Total number of Influenced Voluntary 

Emission Recalls and Influenced 

Voluntary Service Campaigns: 2

 Total number of vehicles VSC&I-VSC 

Total number of vehicles Effect

Recalls and Voluntary Serv

EPA420-B-05-022 6 
 2004 Annual Summary of Emission Related Recalls and Voluntary Service Campaigns Performed On Light-Duty Vehicles and 

Voluntary Service Campaigns

Mfr. Mfr. Recall 

Number

EPA# Type Owners 

Notification

MY Vehicle or Engine 

Class

Engine Family Problem Description Affected 

Vehicles

Total number of all Voluntary Emission 

Recalls and all Voluntary Service 

Campaigns: 37

Sales Area:CL- California + NLEV (all States)FED- Federal States (all altitude)CA- CaliforniaFED/NLEV- Northeast States (all Altitude)NE+CA- NLEV Northeast States+CaliforniaCE- 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.

EPA420-B-05-022 7