p. 1 

# OAR Box 1830 Prepped byOllie Stewart



## Document

Number: 

# 6DIV-C-2 7 Docket Number: 

# A-87-1 1

Printed 11/13/20087:20:54AM Sheet 61 of 232

# ; 4 

# . &-S7-J. 1
V-L'- * | , A\

UNITE D STATE S ENVIRONMENTA LPROTECTIO N AGENC Y~ P. 2

\ . +> y AN N ARBOR . MICHIGA N 4810 5

•DEC 2 ! 198 7 •-"•'••• - o . - ••:- . OFFICEO F- ;

";:, : .-,•'''• ' AI R AN D RADIATIO N * 

### 'Mr . Paul

- Yoshida,

- Chie f • E , 7 Defect s Investigatio n Branc h(NEF-12) . Offic e o f Defect s and Investigatio n Nationa l Highwa yTraffi c Safety . Administratio n 40 0 Sevent hSt . S.W . Washington , D.C . 2059 0 Dea r Mr . Yoshida : Thank yo u fo r meetin g v/it hPau l Lain g and I t o discus s th e detail s o f NHTSA' s recen t recal l analysi s whic hexamine d pas t fue l and evaporativ e syste mdefect s i n a n attemp t t o identif y potentia l futur e problem s wit honboar d systems . W e appreciat e th e tim e yo u spen t wit hu s o n Octobe r 29 , and Novembe r 5 , 198 7 an d you r effort s i n gatherin g th e detaile d recal l report s w e requested . A s wa s agree d a t ou r Octobe r 16 , 198 7 meetin g i n An n Arbor , w e pla n t o wor k closel ywit hyo u i n reviewin g an d analyzin g th e recal l file s wit hthe goa l o f developin g a lis t o f pas t recal l action s whic hbot hNHTS Aand EP Aagre e ma yb e pertinen t t o onboard/volatilit ycontrols . A s a ste p towar d tha t goal , w e hav e prepare d a summar yand analysi s o f th e discussion s and view s presente d a t ou r Novembe r 5 , 198 7 meetin g (Enclosur e 1) . Thi s summar yand analysi s i s broke n int o fiv e parts . Tabl e 1 , whic hi s include d fo r sak e o f referenc e and completeness , list s al l 5 8 recall s w e discussed . T o th e bes t o f our knowledg e thi s lis t represent s al l recall s considere d i n NHTSA' s analysi s t o date . I f anywor k yo u d o i n th e futur e result s i n addition s t o thi s list , pleas e informu s an d provid e th e relevan t recal l summarie s a s soo n a s possible . O f cours e w e woul d appreciat e anycorrection s t o th e informatio n liste d fo r eac hrecall . Tabl e 2 list s seve n recall s tha t w e agree d ar e t o b e droppe d from

furthe r consideration . W e concu r tha t thes e ar e no t relate d t o onboar d o r volatilit yand shoul d b e droppe d fro m th e lis t presente d i n Tabl e 1 . - ' • • * Tabl e 3 list s seve n recall s whic hw e beli.ev e ar e clearl y unrelate d t o evaporative/onboar d systems ' "'"' • o r simila r components . I n eac hcas e th e technica l rational e supportin g ou r vie wi s summarize d fo r you r consideration . Addin g onboar dP. 3

\ 

### control s woul d no t increas e th e frequenc yo f thes e problem s o r th e severit yo f th e consequences . Usin g thes e criteri a w e se e n o relationshi p wit honboar d contro l system s an d sugges t tha t thes e recall s b e eliminate d fro mfurthe r consideration . Tabl e 4 list s eigh t recall s whic hw e believ e ar e bes t classifie d a s being relate d t o fue l volatility . Thes e eigh t recall s involve fue l expulsio n problem s du e t o us e o f highRVP fuel . Thes e problem s di d no t occu r becaus e o f defect s i n th e evaporativ e contro l system s a s evidence d b yth e fac t mos t o f th e vehicle s i n Recal l No . 85V10 6 an d some i n 87V11 3 wer e no t eve n equippe d wit hevaporativ e contro l systems . ( AFedera l evaporativ e emissio n standar d fo r heavy-dut yga s vehicle s di d no t exis t prio r t o 1985) . Pressur e buildu p problem s wit hhigh RVP fue l resul t becaus e th e fue l tank s ar e tightl yseale d fro m th e atmosphere . However , EPA' s evaporativ e standar d doesn' t requir e tha t tank s b e tightl ysealed , rathe r onl ytha t evaporativ e emission s b e controlled , using component s suc ha s a canister . Rather , w e believ e fue l tank s ar e seale d tightl yt o ensur e complianc e wit hrollove r test s require d b yNHTS Aan

d OMCS . Furthermore , i n a Septembe r 17 , 198 7 respons e t o Congressma n Dingell , NHTS Aha s alread ycharacterize d Recal l No' s 79V028 , 81V058 , 82V076 , an d 87V11 3 a s fue l expulsio n problem s resulting fro mhighRVP gasoline . W e fee l thes e problem s shoul d no t b e characterize d a s evaporativ e contro l defect s bu t rathe r shoul d b e considere d a s a potentia l benefi t o f EPA' s proposal s sinc e our combine d onboard/volatilit y packag e wil l substantiall yreduc e thes e problem s i n th e future . Addin g onboar d wil l certainl yhav e n o advers e affec t o n thes e type s o f recalls . Tabl e 5 list s th e remaining 3 6 recal l campaign s whic h NHTS Aselecte d a s relevan t t o onboar d control s becaus e the y involve fue l tank/evaporativ e systemhardware . Screening ou t thes e recall s o n thi s basi s serve s a s a reasonabl e starting poin t fo r th e onboar d analysi s sinc e i t narrow s th e scop e t o a workabl e numbe r o f recalls . However , w e believ e tha t mor e evaluatio n i s required . Th e rea l issu e involve d her e i s th e exten t t o whic honboar d control s woul d b e likel yt o incrementall yaffec t recall s o f thi s natur e an d mor e specificall yth e degre e t o whic honboard wil l positivel yor negativel yaffec t th e frequenc yo r severit yo f suc hrecalls . Tabl e 5 break s dow n th e fue l tank/evaporativ e system recall s int o th e following four categories : externa l ven t tube , fillpipe , vapo r line , an d evaporativ e system/components . Whil e w e agre e tha t recall s simila r i n natur e t o thos e i n Tabl e 5 ar e likel yt o continu e t o occur i n th e future , w e se e n o technica l basi s fo r wh

yonboar d control s woul d o r mus t adversel yaffec t th e frequenc yo r severit yo f thes e problems . Fo r example , recall s involving externa l ven t tub e connection s (77V06 3 an dP. 4



### 85V154) , materia l (78V016) , o r placemen t (85V014 , 78V208 , an d 85V132 ) shoul d no t increas e i n frequenc yo r severit ya s a resul t o f onboar d control s sinc e mos t onboar d design s wil l no t increas e th e numbe r o f ven t tub e connection s o r chang e ven t tub e placemen t o r material . I n fac t some onboar d design s (such a s th e Toyot a systempresente d a t th e onboard/volatilit y hearings ; se e Enclosur e 2 ) ar e likel yt o eliminat e th e externa l ven t tub e thereb

yreducing thes e type s o f problem s i n th e future . W e se e man yothe r area s wher e th e onboard/volatilit y proposal s coul d actuall yimprove safet ythroughpossibl e reduction s i n futur e recalls . Some o f thes e area s ar e discusse d i n Tabl e 5 . Also , w e fai l t o se e ho wonboar d control s wil l hav e an y advers e effec t o n fillpip e problems . Thes e problem s happe n withou t onboar d systems , an d ther e i s n o technica l reaso n wh y onboar d control s wil l affec t th e frequenc yo r severit yo f FMVS S 30 1 fillpip e failures , o r fillpip e installation , fabrication , an d placemen t problems . I n addition , fo r integrate d onboar d refueling/evaporativ e systems , nearl yidentica l valving an d vapo r lin e routing wil l b e use d a s compare d t o curren t evaporativ e systems . Becaus e verylittl e (i f any ) additiona l vapo r lin e i s neede d fo r an integrate d system , th e incrementa l impac t o f onboar d control s o n vapo r lin e problem s suc ha s blockag e (Recal l No' s 78V18 1 an d 79V032) , kinking (79V019) , misrouting (79V045) , o r assembl y damag e (83V115 ) shoul d b e negligible . Similarly , onboar d control s wil l no t affec t th e design o r us e o f ven t valve s i n th e evaporativ e system , s o ther e shoul d b e n o effec t o n recall s relate d t o thes e valve s (78V106 , an d 79V048) . Furthermore , wit hregard t o vacuu mvalv e recall s (84V116) , thes e type s o f component s ar e use d o n presen t vehicle s an d wil l b e use d o n futur e vehicle s (wit ho r withou t onboar d controls ) s o n o incrementa l effec t shoul d occur . W e ar e no t suggesting tha t onboar d relate d recall s wil l neve r occur . Design , manufacturing , an d assembl yerror s happe n no wan d ar e likel yt o occu r i n th e future . However , i t i s incorrec t t o predic t th e frequenc yo f additiona l onboar d problem s t o b e equivalen t t o th e frequenc yo f pas t evaporativ e recall s sinc e onboar d i s no t a completel yne wsystembein g adde d t o th e vehicl e a s wer e evaporativ e systems . Evaporativ e systemrecall s provid e a goo d indicato r o f th e type s o f problem s tha t coul d occu r wit honboar d controls , an d for mth e basi s o f wha t i s probabl yth e bes t sourc e o f informatio n t o predic t ho wonboar d coul d impac t recalls . However , i t i s critica l tha t thi s informatio n b e analyze d carefully . I t i s imperativ e tha t an additiona l leve l o f screening tak e plac e whic hconsider s th e incrementa l impac t o f onboar d control s (bot hpositiv e an d negative ) o n fuel/evaporativ e system recalls . Suc han analysi s need s t o carefull yevaluat e th eP. 5



### Enclosur e 1

Summaryan

d Analysi s o f EPA/NHTS ARecal l Dat a Discussion s

Novembe r 5 , 198 7P. 6 Tabl e 1 Recal l Analysi s Baselin e NHTSA Campaign Numbe r 76V00 1 76V00 7 76V03 7 Mode l

Year(s ) 197 5 197 6 197 6 Vehicl e

Typ e Pass . Veh . Pass . Veh . Pass . Veh . Numbe r o f

Affecte d Vehicle s 63 1 91 1 2,40 0 Descriptio n o f Problem

76V06 9 1975-7 6 Pass . Veh . 67,63 3 76V12 6 197 6 Pass . Veh . 9,13 7 76V15 1 197 6 Moto r Home 15 0

77V06 3 197 7 Moto r Home 24 2 77V21 4 197 8 Pass . Veh . 3,00 0 78V01 6 1973-7 4 Pass . Veh . 20,66 1 78V03 6 1977-7 8 Lt . Truc k 20,00 0

78V10 6 1977-7 8 Pass . Veh . 10,50 0 78V14 5 1973-7 7 Med . Truc k 2,50 0

78V18 1 1978-7 9 Lt . Truc k 23,00 0 Fue l fille r nec k hos e clam p mayhave bee n insufficientl ytightened . Imprope r functioning o f fue l pum p valve s create s possibl e overflo wconditio n fro mcanister . Misroute d vapo r return line whic hrun s fro mth e fue l filter/vapo r separato r assembl ybac k t o th e fue l tank . Defectiv e rivet s use d i n fabricatio n o f fue l fille r inle t assembly . Erroneousl yinstalle d piping for the "chec k an d cu t valve" . Defectiv e installatio n o f fille r hos e lead s t o stresse s unde r certai n road vibratio n whic hcan ruptur e hose . Externa l vapo r line no t connecte d t o fil l spout . Imprope r installatio n o f vacuu mline connecting carbureto r an

d therm o valve . Cracking o f fue l tan k ven t hos e allowing fume s t o ente r trun

k area . Blockag e o f tan

k ven t syste

mcan lead t o pressur e buildu

p an d forc e fue l o r vapo r leakag e throughcrack s i n tank . Defective fue l tan

k ven t valve . Liqui d gasolin e maydischarg e fro mbottomo f caniste r becaus e eva p syste

mmaylack adequat e capacit yunde r certai n fue l expansio n conditions . Obstructe d eva

p line cause s pressur e buil d u p i n tank .P. 7 Tabl e 1 (cont. ) NHTSA Campaign Numbe r 78V20 0

78V20 8 78V24 9 79V01 6 79V01 9 79V02 8

79V03 2 79V04 5 79V04 8 79V13 9 79V21 2 79V24 2 80V01 9 81E00 1 81V00 4 81V04 7 81V05 5 81V05 8 Mode l

Year(s ) 197 8 Vehicl e

T 

### Y P e Numbe r o f

Affecte d Vehicle s Pass . Veh . 5,70 0

1977-7 8 Pass . Veh . 16,23 8 197 8 Lt . Truc k 5,31 7 1977-7 9 Pass . Veh . 83,00 0 1976-7 8 Pass . Veh . 17,80 0 1975-7 6 Pass . Veh . 57,00 0

1977-7 9 Pass . Veh . 83,00 0 197 9 Pass . Veh . 3,70 0 1975-7 6 Pass . Veh . 61,00 0 197 9 Moto r Home 4 6 1973-7 8 Schoo l Bu s 2,95 0 1975-7 9 Pass . Veh . 295,71 0 1978-8 0 Pas . Veh . 9,42 9 198 1 Med . Truc k 20,15 6 198 1 198 2 198 1 Pass.Veh . 14,00 0

Pass . Veh . 5,20 0 Descriptio n o f Proble m Assembl yerro r o f pressur e relie f valve i n fue l pum p whic hmaycaus e valve spring sea t t o dislodg e an

d fue l suppl yt o carbureto r t o decrease . Insufficien t clearanc e betwee n floo r pa n an d ven t tube can damag e ven t tube . Fue l fille r pip e can disconnec t i n 30 1 collision . Throttl e valve sticking . Possibilit yo f kinke d evaporativ e syste mhose . Unde r advers e condition s o f highambien t temperatures , pressure s an d fue l volatility , fue l maysurg e whe n fue l fille r ca p i s removed . Obstructe d eva

p line cause s pressur e buil d u p i n tank . Misroute d vapo r line t o canister . Defectiv e pressur e contro l valve . Fue l fille r hos e can com e i n contac t wit h exhaus t pipe . Defective liquid/vapo r separators . Defectiv e PC

V valve system . Cu t fue l fille r tube i n 30 1 crash . Defectiv e crankcas e regulato r valv e o n diese l trucks . Imprope r design/installatio n o f fue l syste msuch tha t i t restrict s fue l supply . Poo r design o f fue l fille r & ven t pip e lead s t o 30 1 failure . Pass . Veh . 30,00 0 Defective carbureto r fue l bow l ven t solenoid . 1980-8 1 Pass . Veh . 133,00 0 Overpressurizatio n i n tan k ma ycaus e fue l Lt . Truc k t o spur t fro mtank .P. 8 Tabl e 1 (cont. ) NHTSA Campaign Numbe r 81V12 0 82V02 1 82V04 1 Mode l Vehicl e

Year(s ) Typ e 198 1 Moto r Home Numbe r o f Affecte d Vehicle s 7 8 198 2 Pass . Veh . 198 2 Pass . Veh . 519,32 9 15,98 8

82V07 6 82V08 8 82V10 9 83V08 5 83V11 5 83V13 8 84V03 8 84V04 1 84V11 6 85V01 4 198 2

198 3 198 3 198 2 198 4 198 3 198 4 198 4 198 5 198 4 Pass.Veh .

Pass . Veh . Pass . Veh . Lt . Truc k H . Truc k Lt . Truc k Va n Motorcycl e Motorcycl e Pass . Veh . Moto r Home 24,45 5

2,80 0 1,84 9 21 5 1,54 8 5 1 29 5 1,29 6 2,38 5 75 0

85V10 6 1979-8 5 Moto r Home 28,54 5

85V13 2 198 5 Pass . Veh . 11,00 0 85V14 1 1984-8 5 Moto r Home 28 5 85V15 4 1982-8 5 Bu s 1,52 0 86V10 1 198 6 . Pass . Veh . 27,00 0 Descriptio n o f Problem Fille r hos e mad e o f incorrec t materia l an d deteriorate s wit hgasolin e contact . Fillpip e hos e clam

p can fracture . Inadequat e sea l betwee n fille r pip e housing assembl yan

d fue l fille r opening becaus e o f omitte d screw s during assembly . Pressur e buildu

p i n tan

k cause s fue l spitback . Cu t rubbe r fille r pip e connecting hos e i n 30 1 test . Fue l fille r hos e break s during 30 1 crash . Hos e typ e 3 piec e pip e fail s i n 30 1 test . Fue l o r vapo r line damage d du e t o assembl yerror . Diese l truck s do no t compl ywit hFMVS S 30 1 becaus e o f valve line failure . L/V separato r leak . L/V separato r leak . Imprope r functioning o f vacuu mline valve . Auxiliaryfue l tan k i s subjec t t o overfil l an d pressur e buil d u

p du e t o imprope r ven t tube placement . Fille r ca

p disengage s suddenl ywhe n remove d fo r refueling . Ma

ycaus e expulsio n o f vapo r an d gasoline . Bumpe r cause s damag e t o ai r ven t hos e i n accident . Electrica l shor t circui t involving the fue l shut-of f valve . Fue l pip e vapo r line disconnect s i n accident . Pierce d fue l fille r pip e i n rear collision .P. 9 Tabl e 1 (cont. ) NHTSA Campaign Numbe r 87V03 3 87V05 1 Mode l

Year(s ) Numbe r o f

Vehicl e Affecte d Typ e Vehicle s Descriptio n o f Problem 1986-8 7 Moto r Home 2,01 8 Thread s i n fille r nec k inser t ar e no t properl y formed . 198 6 Lt . Truc k 33 9 87V05 2 87V09 7 1986-8 7

1984-8 7 Van 15,50 0

Va n 34 3 (Ambulance ) 87V11 1 1984-8 7 Van 25 0 (Ambulance )

87V11 3 1983-8 7 Truc k 16,00 0 (Ambulance ) 87V14 4 1983-8 7 Van s 188,00 0 87V15 5 1985-8 7 Moto r Home 9,04 1 87V15 7 1984-8 8 Pass . Veh . 25,00 0 Fillnec k no t seated properl yi n tan k - cause s leaks . RV P problem- expulsio n o f gasoline . Hole s i n fille r nec k wel d seam . Defectiv e vapo r valv e gromme t o n fue l tank . (Thi s componen t wa s installe d a s par t o f a preliminaryattemp t a t correcting the fue l expulsio n problemo f Recal l No . 87V113) . RV P problem- expulsio n o f fuel . Expulsio n o f fue l du e t o us e o f highRV P fuel . Expulsio n o f fue l du e t o us e o f highRV P fuel . Overfilling o f the fue l tan k can increas e fue l syste mpressur e t o the poin t wher e fue l vapor s escap e fro

mthe charcoa l filte r an d caus e an engin e compartmen t fire . Total : 5 8 recall s involving 1,900,00 0 vehicles ,P.1 0

NHTSA Campaign Numbe r 76V00 7 77V21 4 79V01 6 79V24 2 81E00 1 81V05 5 85V14 1 Tabl e 2

Recall s Agree d t o be Droppe d Fro mFurthe r Consideratio n Mode l Year(s ) 197 6 197 8 Numbe r o f

Vehicl e Affecte d Typ e Vehicle s Pass . Veh . Pass . Veh . Descriptio n o f Problem

91 1 Imprope r functioning o f fue l pum p valve s create s possibl e overflo wconditio n fro mcanister . 3,00 0 Imprope r installatio n o f vacuu mline connecting carbureto r an

d therm o valve . 1977-7 9 Pass . Veh . 83,00 0 Throttl e valv e sticking . 1975-7 9 Pass . Veh . 295,71 0 Defective PC V valve system . 198 1 Med . Truc k 20,15 6 Defective crankcas e regulato r valve o n diese l trucks . 198 1 Pass . Veh . 30,00 0 Defective carbureto r fue l bow l ven t solenoid . 1984-8 5 Moto r Home 28 5 Electrica l shor t circui t involving the fue l shut-of f valve .P.1 1 Tabl e 3 Recall s Unrelate d t o Evaporative/Onboar d System s Recal l No : 76V03 7 Affecte d Vehicles : 2,40 0 '7 6 passenge r vehicle s Problem : Misroute d "fue l vapo r return line " whic hrun s fro mthe fue l filter/vapo r separato r assembl ybac k t o the fue l tank . Comments : W e believe , tha t thi s defec t i s mor e o f a fue l syste mproblemthan an evaporative syste

mproblem . W e agre e tha t i t coul d possibl yb e relate d t o evaporative emission s fro mthe carburetor , bu t a s such , thi s problemwoul d have no bearing o n onboard control s sinc e onboard woul d affec t onl ythe fue l tan k portio n o f the evaporative system . NHTSAagree d tha t i t di d no t appea r t o b e relate d t o the fue l tan k evaporativ e contro l system . Recal l No . 78V20 0 Affecte d Vehicles : 5,70 0 '7 8 passenge r vehicle s Problem : Defective pressur e relie f valve i n the fue l pump . Comments : Thi s i s no t an evaporative syste mproblemsinc e the defectiv e componen t i s part ' o f the fue l pump . Thi s problemwoul d have occurre d regardles s o f whethe r o r no t th

e vehicl e wa s equippe d wit hevaporative o r onboar d controls . Recal l No . 81V00 4 Affecte d Vehicles : 14,70 0 '8 1 passenge r vehicle s Problem : Restricte d fue l suppl ysyste mwhic hmayhave resulte d fro man obstructe d ven t tube (presumabl yi n the eva p system ) among man yothe r possibilities . Comments : Thi s particula r recal l wa s on e o f the mos t difficul t t o mak e a judgmen t on

becaus e no singl e defec t wa s identifie d a s causing the fue l suppl yt o become restricted . Th e basi c approac hused t o remed ythi s situatio n wa s t o inspec t the entir e fue l syste man d replac e anything whic hseeme d necessary . I t appear s a s thoug

hthe tubin

g for the evaporative syste mwa s inspecte d alon g wit hal l othe r fue l syste mtubing simpl ybecaus e i t wa s par t o f the overal l fue l system . I t woul d see mtha t a fue l suppl yproblemcoul d onl yresul t fro m an obstructe d fue l suppl yor return line , an d tha t the evaporativ e tubing ha s no direc t bearing o n the problem . W e believe thi s shoul d be viewe d a s unrelate d t o onboard unles s furthe r informatio n i s provide d whic hindicate s otherwise .P.1 2 Tabl e 3 (cont. ) Recal l No . 83V13 8 Affecte d Vehicles : 5 1 '8 3 diese l truck s Problem : Defectiv e ven t valve hose . Comments : Thi s recal l shoul d no t b e characterize d a s relate d t o evaporative contro l

systems sinc e the vehicle s involved ar e no t eve n equippe d wit hevaporativ e contro l systems . NHTSAseemed t o fee l tha t thi s recal l concerne d a defectiv e ven t valve simila r t o the typ e whic hmigh t b e use d o n onboard controls . However , upo n close r examinatio n o f thi s problem , i t become s .clea r tha t thi s recal l involve d a hos e (no t a valve) . Hose s designe d fo r thi s purpos e woul d no t b e used o n today' s gasolin e vehicle s o r futur e onboar d equippe d vehicles . Therefore , w e fee l thi s problemha s no bearing o n onboard controls . Recal l No.'s : 84V03 8 an d 84V04 1 Affecte d Vehicles : 1,59 1 '8 4 motorcycle s Problem : Fue l leak s fro mliquid/vapo r separator . Comments : W e fee l tha t thi s problemcanno t be classifie d a s an evaporativ e syste mrecal l sinc e motorcycle s do no t us e evaporativ e systems . W e als o believ e tha t onboard wil l have no incrementa l impac t o n thi s problemsinc e onboar d wil l no t b e reguire d o n thes e vehicles . NHTS Abelieve s thes e recall s shoul d be considere d relevan t t o onboard sinc e onboard system s migh t utiliz e liquid/vapo r separators . W e questio n the similarit ybetwee n the design o f thes e liquid/vapo r separator s an d thos e whic hmigh t b e use d on som e onboard systems . NHTSA.' s ow n recal l fil e summar ysheet s categoriz e thi s problema s a fue l tan

k assembl yproblem , an d w e fee l thi s characterizatio n i s mos t appropriate . Recal l No . 87V11 1 Affecte d Vehicles : 25 0 '84-8 7 Ambulance s Problem : Thi s recal l involve d a defective vapo r valv e gromme t tha t wa s use d i n

connectio n wit han initia l attemp t a t fixin g the volatilit yproblemo f Recal l No . 87V113 . Comments : W e maintai n tha t a manufacturer' s unsuccessfu l attemp t a t eliminating an RV P problemthroug

ha defective modificatio n t o the evaporativ e contro l syste m canno t b e characterize d a s a n evaporative syste mproblem . W e especiall yfee l thi s i s true sinc e thes e vehicle s wer e late r recalle d a s par t o f Recal l No . 87V113 . I f the vehicle s i n thi s recal l wer e t o b e counte d separatel yfro m Recal l No . 87V113 , i t woul d amoun t t o the doubl e counting o f the vehicle s in thi s recal l for basicall ythe sam e problem .P.1 3

NHTSA Campaign Numbe r 79V02 8

81V05 8 82V07 6 85V10 6

87V05 2 87V11 3 87V14 4 87V15 5 Tabl e 4 Recall s Relate d To ' Fue l Volatilit y Mode l Year(s ) Numbe r o f

Vehicl e Affecte d Typ e Vehicle s Descriptio n o f Problem 1975-7 6 Pass . Veh . 57,00 0 Unde r advers e condition s o f highambien t temperatures , pressure s an d fue l volatility , fue l maysurg e whe n fue l fille r ca p i s removed . 1980-8 1 Pass . Veh . 133,00 0 Overpressurizatio n i n tan k maycaus e fue l 198 2 1979-8 5

1986-8 7 1983-8 7 1983-8 7 1985-8 7 Lt . Truc k

Pass.Veh . 24,45 5 Moto r Home 28,54 5

Van Truc k (Ambulance ) Van s 15,50 0

16,00 0 t o spur t fro mtank . Pressur e buildu

p i n tan

k cause s fue l spitback . Fille r ca

p disengage s suddenl ywhe n remove d fo r refueling . Maycaus e expulsio n o f vapo r an d gasoline . RV P problem- expulsio n o f gasoline . RV P problem- expulsio n o f fuel . 188,00 0 Expulsio n o f fue l du e t o us e o f highRV P fuel . Moto r Home 9,04 1 Expulsio n o f fue l du e t o us e o f highRV P fuel .P.1 4 Tabl e 5 Fue l Tank/Evaporativ e Syste mRelate d Recall s
EXTERNA L VENT TUB E RELATE D RECALLS : Th e si xrecall s i n thi s categor yinvolve problem s tha t affec t the externa l ven t tube . Thes e problem s includ e poo r placemen t (78V208 , 85V014 , an d 85V132) , defectiv e materia l (78V016) , an

d imprope r connection s (77V06 3 an d 85V154) . Sinc e onboard wil l no t increas e ven t tube connection s or chang e ven t tube placement/materia l selection , recall s o f thi s natur e shoul d neithe r increas e i n frequencyo r severit ya s a resul t o f onboard . I n fact , som e onboard design s (sucha s th e Toyot a syste

mpresente d a t the onboard/volatilit y hearings ; se e Enclosur e 2 ) ar e likel yt o eliminat e the ven t tube thereb yreducing thes e type s o f problem s i n the future . NHTSA Campaign Numbe r 77V06 3 78V01 6 Mode l

Year(s ) 197 7 1973-7 4 Numbe r o f

Vehicl e Affecte d Typ e Vehicle s Moto r Home 24 2 Pass . Veh . 20,66 1 Descriptio n o f Problem

24 2 Externa l vapo r line no t connecte d t o fil l spout . t o ente r trun

k area . 78V20 8 85V01 4

85V13 2 1977-7 8 Pas . Veh . 16,23 8

198 4 Moto r Home 75 0

198 5 Pass . Veh . 11,00 0 Insufficien t clearanc e betwee n floo r pan an d ven t tube can damag e ven t tube . Auxiliaryfue l tan k i s subjec t t o overfil l an d pressur e buil d u

p du e t o imprope r ven t tube placement . Bumpe r cause s damag e t o ai r ven t hos e accident . i n 85V15 4 1982-8 5 Bu s 1,52 0 Fue l pip e vapo r line disconnect s i n accident .P.1 5 Tabl e 5 (cont. )

FILLPIP E RELATE D RECALLS : Th e 1 7 recall s i n thi s categor yinvolve problem s tha t affec t the fue l tan k fillpipe . Thes e problem s includ e FMVS S 30 1 failure s (78V249 , 80V019 , 81V047 , 82V109 , 83V085 , an d 86V101) , defectiv e materia l (81V120) , - poo r installatio n (76V15 1 an d 87V051) , fabricatio n defect s (76V069 , 87V033 , an d 87V097) , poo r placemen t (79V139) , an d connectio n problem s (76V001 , 82V021 , an d 82V041) . W e agre e tha t al l 1 7 of . thes e problem s ar e fillpip e problems . However , we fai l t o se e ho wonboard system s wil l have an yadvers e incrementa l impac t o n thes e type s o f problems . Thes e problem s happe n withou t onboard , an d ther e i s no reaso n wh

yonboard control s wil l affec t the frequencyo r severit yo f fillpip e problem s sucha s thes e i n the future . W e wis ht o stres s tha t depending o n the onboar d syste mdesign , man

yo f the FMVS S 30 1 fillpip e failure s coul d eve n b e reduce d i n the future . NHTS Aseems t o agre e tha t the impac t o f onboard o n thes e problem s i s design dependent . However , NHTSAchoose s t o conside r thes e recall s a s relevan t t o onboar d sinc e preliminaryonboar d design s show n t o the mhave containe d rollove r valve s i n the fille r pip e locatio n an d therefor e ma

ybe susceptibl e t o cras hdamage . W e agre e tha t thes e valve s coul d b e susceptibl e t o damag e i n a cras hi f locate d i n the fille r pip e area . However , w e questio n whethe r o r no t thi s woul d incrementall yworse n the ris k o f fue l leakag e ove r tha t whic hnowexists . W e als o wan t t o poin t ou t tha t wit henoughleadtime , manufacturer s have indicate d theyar e les s likel yt o locat e thes e valve s i n the fille r pip e area . Finally , NHTS Abelieve s tha t fillpip e connectio n problem s ar e relevan t t o onboard control s sinc e thes e systems ar e likel yt o utiliz e component s like hos e clamps , an d simila r problem s mayoccur . W e agre e tha t t o the exten t tha t onboard control s us e mor e hos e clamps , a greate r opportunit ymayexis t for simila r problem s t o occur . However , i t i s equall yvali d t o conside r tha t depending o n the onboard design selecte d b y manufacturers , fewe r hos e clamp s mayb e used , an d therefor e thes e problem s maybe les s likel yt o occur i n the future . Manufacturer s have man yhos e connectio n option s t o choos e fro mincluding adhesive s an d improve d fitting technique s whic hmayeve n b e les s likel yt o fai l than currentl yuse d clamp s or coul d mitigat e agains t an yrea l problems .P.1 6 Tabl e 5 (cont. ) FILLPIP E RELATE D RECALL S (cont. ) NHTSA Campaign Numbe r 76V00 1 76V06 9 76V12 6 76V15 1

78V24 9 79V13 9 80V01 9 81V04 7 81V12 0 82V02 1 82V04 1

82V08 8 82V10 9 83V08 5

87V05 1 Mode l Vehicl e

Year(s ) Typ e 197 5 Pass . Veh . Numbe r o f Affecte d Vehicle s 63 1 1975-7 6 Pass . Veh . 67,63 3 197 6 Pass . Veh . 9,13 7 197 6 Moto r Home 15 0

197 8 Lt . Truc k 5,31 7 197 9 Motor.Home 4 6 1978-8 0 Pas . Veh . 9,42 9 198 2 Pass . Veh . 5,20 0 198 1 Moto r Home 7 8 198 2 Pass . Veh . 519,32 9 198 2 Pass . Veh . 15,98 8

198 3 Pass . Veh . 2,80 0 198 3 Pass . Veh . 1,84 9 198 2 Lt . Truc k 21 5

H . Truc k 86V10 1 198 6 Pass . Veh . 27,00 0 87V03 3 1986-8 7 Moto r Home 2,01 8

198 6 Lt . Truc k Descriptio n o f Problem Fue l .fille

r nec k hos e clam p ma yhav e bee n insufficientl ytightened . Defective rivet s use d i n fabricatio n o f fue l fille r inle t assembly . Erroneousl yinstalle d piping for the "check an d cu t valve" . Defective installatio n o f fille r hos e lead s t o stresse s unde r certai n road vibratio n whic hcan ruptur e hose . Fue l fille r pip e can disconnec t i n 30 1 collision . Fue l fille r hos e can come i n contac t wit h exhaus t pipe . Cu t fue l fille r tube i n 30 1 crash . Poo r design o f fue l fille r & ven t pip e lead s t o 30 1 failure . Fille r hos e mad e o f incorrec t materia l an d deteriorate s wit hgasolin e contact . Fillpip e hos e clam

p can fracture . Inadequat e sea l betwee n fille r pip e housing assembl yan

d fue l fille r opening becaus e o f omitte d screw s during assembly . Cu t rubbe r fille r pip e connecting hos e i n 30 1 test . Fue l fille r hos e break s during 30 1 crash . Hos e typ e 3 piec e pip e fail s i n 30 1 test . Pierce d fue l fille r pip e i n rear collision . Thread s i n fille r nec k inser t ar e no t properl y formed . 33 9 Fillnec k no t seate d properl yi n tan k leaks . - cause s 87V09 7 1984-8 7 Van 34 3 (Ambulance ) Hole s in fille r nec k wel d seam .P.1 7 Tabl e 5 (cont. )
VAPOR LIN

E RELATE D RECALLS : Th e seven recall s i n thi s categor yinvolve problem s tha t affec t the evaporativ e system vapo r line . Thes e problem s includ e blockag e (78V036 , 78V181 , an d 79V032) , erroneou s installatio n (76V126) , misrouting (79V045) , kinking (79V019) , an d assembl ydamag e (83V115) . However , integrate d onboard refueling/evaporativ e systems utiliz e nearl y identica l vapo r line routing a s compare d t o curren t evaporativ e systems . Sinc e very littl e (i f any ) additiona l vapo r line i s neede d for an integrate d system , an d w e believ e mos t onboard systems wil l b e integrated , the incrementa l impac t o f onboar d o n thes e type s o f vapo r line problem s shoul d b e negligible . O n a fina l note , w e woul d als o like t o reiterat e our concern abou t the potentia l "overlap " o f Recal l No.' s 78V18 1 an d 79V032 . W e woul d appreciat e i t i f yo u coul d provid e clarificatio n o n thi s question . NHTSA Campaign Numbe r 76V12 6 Numbe r o f

Mode l Vehicl e Affecte d Year(s ) Typ e Vehicle s 197 6 Pass . Veh . 9,13 7 Descriptio n o f Problem Erroneousl yinstalle d piping for the "chec k an d cu t valve" . 78V03 6 1977-7 8 Lt . Truc k 20,00 0 Blockag e o f tan k ven t syste

mcan lead t o pressur e buildu

p an d forc e fue l o r vapo r leakag e throug hcrack s i n tank . 78V18 1 1978-7 9 Lt . Truc k 23,00 0 Obstructe d eva p line cause s pressur e buil d u p i n tank . 79V01 9 1976-7 8 Pass . .Veh . 17,80 0 Possibilit yo f kinke d evaporative syste mhose . 79V03 2 1977-7 9 Pass . Veh . 83,00 0 Obstructe d eva p line cause s pressur e buil d u p i n tank . 79V04 5 197 9 Pass . Veh . 3,70 0 Misroute d vapo r line t o canister . 83V11 5 198 4 Lt . Truc k 1,54 8 Fue l o r vapo r line damage d du e t o assembl yerror .P.1 8 Tabl e 5 (cont. )
EVAPORATIV

E SYSTEM/HARDWARE RELATE D RECALLS : Th e si xrecall s i n thi s categoryinvolve problem s tha t affec t the functioning o f the evaporative contro l system . Thes e problem s includ e defectiv e valve s (78V106 , 79V048 , an d 84V116) , insufficien t capacit y(78V14 5 an d 87V157) , an

d defectiv e liqui d vapo r separator s (79V212) . W e agre e tha t thes e evaporative syste mproblem s coul d als o happe n o n vehicle s equippe d wit honboard refueling systems . However , sinc e mos t onboard refueling system s wil l be integrate d wit hthe curren t evaporativ e system , w e questio n the degre e t o whic h onboard wil l increas e the likelihoo d o r severit yo f thes e type s o f problems . Fo r example , sinc e onboard control s wil l no t affec t the design o r us e o f ven t valve s i n the evaporative system , ther e shoul d b e no ne t effec t o n recall s relate d t o thes e valves . Furthermore , a s lon g a s the onboard syste mi s integrated , problem s lik e Recal l No . 87V15 7 woul d likel yb e eliminate d becaus e o f th e exces s capacit yo f the integrate d system . NHTSA Campaign Numbe r 78V10 6 78V14 5

79V04 8 79V21 2 84V11 6 87V15 7 Numb e r o f

Mode l Vehicl e Affecte d Year(s ) Typ e Vehicle s 1977-7 8 Pass . Veh . 10,50 0 1973-7 7 Med . Truc k 2,50 0

1975-7 6 Pass . Veh . 61,00 0 1973-7 8 Schoo l Bu s 2,95 0 198 5 Pass . Veh . 2,38 5 1984-8 8 Pass . Veh . 25,00 0 Descriptio n o f Problem Defectiv e fue l tan

k ven t valve . Liqui d gasolin e maydischarg e fro mbottomo f caniste r becaus e eva p syste

mmaylack adequat e capacit yunde r certai n fue l expansio n conditions . Defectiv e pressur e contro l valve . Defectiv e liquid/vapo r separators . Imprope r functioning o f vacuu mline valve . Overfilling o f fue l tan k can increas e fue l syste mpressur e t o the poin t wher e fue l vapor s escap e fro

mthe charcoa l filte r an d caus e an engin e compartmen t fire .P.1 9



### Enclosur e 2

Onboar d Desig n Presente d b yToyot a a t th e Onboard/Volatilit yHearing s

# CURREN TEVAP . SYST E

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# ONBOAR D VAPO R RECOVER YSYSTE M

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### incrementa l impac t o f addin g onboar d control s t o evaporative-equippe d vehicle s *-n d t o full yconside r the fac t tha t potentia l problem s depen d o n th e desig n o f the onboar d system . W e hop e t o wor k wit hyo u mor e o n thi s typ e o f analysis . A s yo u revie wthe informatio n presente d i n th e enclosures , I woul d appreciat e you r comment s o n ou r technica l and analytica l rationale . Also , i t woul d b e especiall yhelpfu l i f yo u coul d respon d t o ou r comment s o n th e individua l recalls . Onc e agai n thank s fo r the tim e and effor t spen t coordinatin g wit hu s o n th e recal l analysis . Pleas e contac t m e i f yo u hav e an

yquestion s o r comment s o n th e enclose d summar y and analysi s o f th e discussion s a t ou r meeting . I woul d sugges t tha t plannin g o n gettin g togethe r i n th e nea r futur e (possibl yJanuar y8 o r 1. 1 i f tha t i s agreeabl e t o you ) s o tha t w e ca n continu e ou r dialogu e o n th e recal l analysis . Pleas e cal l m e a t FTS:374-840 8 t o finaliz e a meetin g time . Sincerely , Glen n W . Passavant , Senio r Projec t Manage r Standard s Developmen t and Suppor t Branc h Enclosure s