2009 Annual Summary of EmissionRelated Recall and Voluntary Service Campaigns Performed on Light-Duty Vehicles and Light-Duty Trucks

2009 Annual Summary of Emission-Related Recall and Voluntary Service Campaigns Performed on LightDuty Vehicles and Light-Duty Trucks

Compliance and Innovative Strategies Division Office of Transportation and Air Quality U.S. Environmental Protection Agency

EPA420-B-10-007b June 2010

INTRODUCTION

Federal regulations require motor vehicle manufacturers to report to EPA all recalls that affect emission-related components or systems. The following report briefly describes lightduty vehicle recalls reported to EPA that affect emission-related components or systems. Note that some of the recalls listed in this report fix problems that do not impact emission control performance even though they involve the repair or replacement of emission-related parts. Manufacturers voluntarily recall vehicles for various reasons, such as safety or customer satisfaction, but if they affect emission-related parts, they still must be reported to EPA. They are all considered emission-related for the purposes of this report.

This report is divided into two sections. The first section is titled, Emission-Related Recalls. These are the typical recalls where the manufacturer recommends that the owner bring the car in for repair under the recall. In this case, the owner should not wait until the problem is apparent before getting the vehicle fixed. The second section titled, EmissionRelated Voluntary Service Campaigns. Under EPA rules, these are still considered recalls, but are listed separately because the manufacturer is telling the owner to bring the car in for repair only if the problem is apparent (such as a warning light, noise, drive problem, etc.). There is usually a warranty extension associated with these types of recalls. Note that the manufacturer might not call a voluntary service campaign a recall in the owner or dealer notifications. Recalls can be initiated voluntarily by the manufacturer or can be ordered by EPA. Voluntary recalls could also be directly influenced by EPA. Influenced recalls are those where EPA has had a direct role in convincing the manufacturer to voluntarily recall the vehicles. Because EPA is fairly successful at influencing recalls, ordered recalls are extremely rare. This report indicates these categories in the Type column. A V designation is a voluntary recall without direct EPA influence, an I designation is a voluntary recall that was directly influenced by EPA, a VSC designation is a voluntary service campaign not directly influenced by EPA, and an I-VSC designation is a voluntary service campaign directly influenced by EPA. If there is an ordered recall, the type will be designated with an O.

It should also be noted that recalls may not include all of the vehicles in the described year, model, and engine family. Some recalls are specific to subsets of these categories because the problem or defect only affects part of a production run. The specific vehicles subject to a recall are identified by the manufacturer in the technical service bulletins provided to the repair facilities. These are usually listings based on the Vehicle Identification Number, or VIN, that is stamped on each vehicle. You should direct any questions regarding your vehicles inclusion in a recall to the dealer repair facility. If there are still issues or problems, direct these to EPA at the e-mail address: vehicle-recalls@epa.

2009 Annual Report

EPA-420-B-10-007b

Abbreviations and Acronyms

Acronym/Term: CARB CFV DTC ECU ECM EGR MIL MY NHTSA NLEV OBD PCM TCM TSB VECI VERR Recall Type: O V VSC I Definition: California Air Resources Board Clean Fuel Vehicle Diagnostic Trouble Code Engine Control Unit Engine Control Module Exhaust Gas Recirculation Malfunction Indicator Light Model Year National Highway Traffic Safety Administration National Low Emission Vehicle On-Board Diagnostics Powertrain Control Module Transmission Control Module Technical Service Bulletin Vehicle Emission Control Information Voluntary Emissions Recall Report Definition: Ordered by EPA Voluntary Recall by Manufacturer Voluntary Service Campaign by Manufacturer Manufacturer voluntary action with EPA Influence

2009 Annual Report

EPA-420-B-10-007b

Section 1: Emission-Related Recalls

New recalls received after 4th Quarter 2009:
Manufacturer Bentley BMW Chrysler GM Honda (Amended) Hyundai Jaguar Kia Mitsubishi Nissan Subaru EPA# 3461 3765 3748 3802 3624 3750 3591 3536 3592 3897 3799 3903 3754 3850 3894 3697 3727

VW

2009 Annual Report

EPA-420-B-10-007b

2009 Emissions-Related Recall Campaigns through December 2009

Mfr. Mfr. Recall Number EPA# Type Owner Notification MY Vehicle or Engine Class Engine Family Problem Description Affected Vehicles Total Number of Vehicles Recalled 11,800

Bentley

SC09/06 (Report received 1/27/2010)

3461

10/26/2009

2004 2005 2006 2007

BMW

08E-A03

3313

5/1/2009

2002 2003 2004 2005 2006 2007 2008

BMW

09E-A01

3688

5/20/2009

Continental GT Continental GT Continental GT, Flying Spur Continental GT, GTC, Flying Spur M3, M3 Cabrio, M Roadster, M Coupe M3, M3 Cabrio M3, M3 Cabrio M3, M3 Cabrio M3, M3 Cabrio Mini Cooper

4BEXV06.0501 5BEXV06.0501 6BEXV06.0501 7BEXV06.0501 2BMXV03.2S54 3BMXV03.2S54 4BMXV03.2S54 5BMXV03.2S54 6BMXV03.2S54 7BMXV01.6UL2 8BMXV01.6UL2

Some vehicles may have ignition coils that could malfunction under certain conditions. If this happens, either the Malfunction Indicator Lamp (MIL) will illuminate and/or the malfunction may cause the vehicle to exceed emission standards. Remedy: This problem can be remedied by replacing the ignition coils with one which is of the latest design. Certain vehicles have a software error such that the Digital Motor Electronics (DME) programming may cause the Onboard Diagnostic (OBD) to erroneously evaluate the emissions performance of the catalytic converter and causing the "Service Engine Soon" light to illuminate prematurely. Remedy: BMW will reprogram the DME control module with an improved version of the software. On certain Mini vehicles the catalytic converter may deteriorate causing an increased level of vehicle emissions. Remedy: Mini will inspect, and if necessary, replace the catalytic converter with an improved version. Particulate matter filters with the wrong ceramic substrates were installed on a small number of vehicles. Remedy: Dealers will inspect and, if necessary, replace the diesel particulate filter with an improved version. The original Vehicle Emissions Control Label (VECI) does not include the required identifier for vehicles built with a turbocharged engine. Remedy: Chrysler is sending corrected VECI labels to vehicle owners to be applied to the affected vehicles. An inapplicable Vehicle Emissions Control Information (VECI) label was affixed to some Ram 1500 vehicles. Remedy: Chrysler will conduct a voluntary emissions recall (J04) to replace the VECI label on the affected vehicles. On certain vehicles equipped with 2.7L and 4.0L engines the Positive Crankcase Ventilation (PCV) valve may have an incorrect flow characteristic. Two shipments of PCV valves from the Tier 2 supplier consisted of mixed stock. Remedy: Chrysler will conduct a voluntary emissions recall (J03) to inspect the potentially affected vehicles and to replace any incorrect PCV valves found.

805 3,693 4,959 2,343

10,404 8,964 8,632 5,471 4,394 14,880 650

37,865

15,530

BMW

09E-A02

3765

9/29/2009

2009

335d

9BMXV03.0M57

440

440

Chrysler

2008-44E H43

3640

2/1/2009

2009

Dodge Caliber SRT4

9CRXV02.42P0

140

140

Chrysler

2009-03E J04

3698

3/11/2009

2009

Dodge RAM 1500

9CRXT05.74P1

597

597

Chrysler

2009-04E J03

3699

3/19/2009

2009 Chrysler Sebring, Dodge Avenger Chrysler Sebring, Dodge Avenger Dodge Nitro Dodge Grand Caravan, Chrysler Town & Country, VW Routan Dodge Grand Caravan, Chrysler Town & Country, VW Routan

9CRXV02.7JNA 9CRXV02.7BR0 9CRXV04.02P0 9CRXV04.0CR0

793 343 30 407

2,470

9CRXV04.0TN0

897

Chrysler

2009-05E J02

3700

3/20/2009

2009 Chrysler Sebring, Dodge Avenger

9CRXV02.4UP0

Chrysler

2009-06E J05

3701

4/8/2009

2007

Dodge RAM

7CRXT0287P80

Certain vehicles intended for sale in the United States territories of Puerto Rico and the Virgin Islands may have been built with a flexible fuel capable fuel pump module instead of the standard fuel pump module. This fuel pump may not be compatible with the instrument cluster software and overstates the fuel level by 1/4 tank. The vehicle could run out of fuel unexpectedly as a result. Remedy: Chrysler will conduct a recall (J02) to replace the fuel pump module. This recall is safety-related as well as emission-related. The Powertrain Control Module (PCM) may not be able to detect a completely blocked Exhaust Gas Recirculation (EGR) valve or passage. Without this ability a blocked valve or passage may cause the engine to emit nitrogen oxides at levels which may exceed California Emissions Standards. Remedy: Chrysler dealers will reprogram your vehicle's Powertrain Control Module.

91

91

10,069

10,069

2009 Annual Report

EPA-420-B-10-007b

2009 Emissions-Related Recall Campaigns through December 2009

Mfr. Mfr. Recall Number EPA# Type Owner Notification MY Vehicle or Engine Class Engine Family Problem Description Affected Vehicles Total Number of Vehicles Recalled 19,080

Chrysler

2009-10-E H45

3732

4/6/2009

2005

Dodge Durango

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

The fuel tank inlet check valve may stick in the open position. This can cause fuel to spill out of the filler tube when the vehicle is being refueled. Fuel in the presence of an ignition source can result in a fire. Remedy: Chrysler dealers will test the vehicle's inlet check valve and replace the fuel tank if necessary. This recall is safety-related as well as emission-related. The Powertrain Control Module (PCM) on these vehicles may not adequately control nitrogen oxide emission levels under certain operating conditions. Remedy: Chrysler dealers will reprogram the vehicle's PCM. A defect in the camshaft position sensor software could ultimately cause damage to the catalytic converters. Remedy: Chrysler will update the Powertrain Control Module (PCM) calibration to prevent damage to the catalytic converters. Some vehicles were produced with a fuel Flow Control Valve (FCV) and Powertrain Control Module (PCM) software intended for vehicles without FCV. Over time this may cause the FCV to fail. A failed FCV could cause engine damage. Remedy: Chrysler dealers will replace the PCM. The windshield washer fluid level sensor may leak allowing washer fluid to wick through the wiring harness to the ambient temperature sensor. This can damage the ambient temperature sensor and cause illumination of the MIL or may result in non-functional low washer fluid warning lamp. Remedy: Chrysler will replace the washer fluid sensor, ambient temperature sensor and install a wiring harness overlay package. The catalytic converters on these vehicles may become damaged from continued operation in "limp-in" mode following a camshaft position sensor fault. Remedy: Chrysler dealers will reprogram the Powertrain Control Module (PCM). The fuel system control modules on certain vehicles may have a condition in which an adhesive separation of the Room Temperature Vulcanizing seal may allow water to seep into the module. Water in the module could cause a short; illuminate the MIL; make the engine hard to start (or not start), or stall. Remedy: GM will install a new fuel system control module. This recall is safety-related as well as emission-related.

2,187 1,720 6,069 9,104

Chrysler

2009-13-E J16 2009-01-E J18

3755

6/5/2009

2007

Chrysler Pacifica

7CRXB0241M80

9,954

9,954

Chrysler

3694

7/7/2009

2003 Concorde, 300M, Dodge 2004 Intrepid

3CRXV03.5VD0 4CRXV03.5VM0

30,119 46,833

76,952

Chrysler

2009-21-E J23

3852

9/25/2009

2009

Dodge Journey

9CRXV02.4UP0

Chrysler

2009-12-E (J06)

3748

10/19/2009

2009

Dodge Ram

9CRXT03.71P0 9CRXT03.7CR1 9CRXT04.71PA 9CRXT05.74P1 9CRXT05.7VP1 3CRXV03.5VD0 4CRXV03.5VM0

622 71 4,000 11,302 5 30,119 46,883

16,000

Chrysler

2009-01a-E (J18)

3802

7/7/2009

2003 2004

Chrysler Concorde/300M, Dodge Intrepid Chevrolet Colorado, GMC Canyon

77,002

General Motors

MW335 08411

3796

5/18/2009

2009

Chevrolet Avalanche/Tahoe/Subur ban, GMC Yukon Chevrolet Tahoe, GMC Yukon, Cadillac Escalade Chevrolet Avalanche/Tahoe/Subur ban, GMC Yukon Chevrolet Tahoe Hybrid, GMC Yukon Hybrid, Cadillac Escapade Hybrid Chevrolet Avalanche/Suburban

9GMXT02.9189 9GMXT03.7187 9GMXT05.3376 9GMXT05.3373 9GMXT06.2375 9GMXT02.9190 9GMXT03.7188 9GMXT05.3377 9GMXT05.3380 9GMXT05.3381 9GMXT06.2374

4,392 2,612 373 4,184 3,682 1,884 1,115 105 67 2,081 1,969

27,180

9GMXT05.3384

829

9GMXT06.0392

3,842

9GMXT06.0382

45

2009 Annual Report

EPA-420-B-10-007b

2009 Emissions-Related Recall Campaigns through December 2009

Mfr. Mfr. Recall Number EPA# Type Owner Notification MY Vehicle or Engine Class Engine Family Problem Description Affected Vehicles Total Number of Vehicles Recalled 18,353

General Motors

MW343 09102

3816

6/1/2009

2008 2009

Chevy Tahoe Hybrid, GMC Yukon Hybrid Chevy Tahoe/Silverado Hybrid, GMC Yukon/Sierra Hybrid, Cadillac Escalade Hybrid Saturn Outlook, Buick Enclave, GMC Acadia

8GMXT06.0392 9GMXT06.0392

On these hybrid vehicles, the current battery voltage reading, which determines battery charge, may be incorrect. This could cause a Service Engine light to illuminate and the vehicle may shut down at low speeds when the vehicle is attempting to transition from electric mode to gasoline engine mode. The vehicle can be restarted, however, it will likely continue to shut down until the voltage error is corrected. Remedy: GM dealers will reprogram hybrid-related modules.

8,505 9,848

General Motors

08285

3624

9/29/2008 (Recv'd VERR 2/3/2009)

2009

9GMXT03.6151

Honda/Acura

09-005-00 SB09-053

3750

7/30/2009

2007 2008 2009 2005 2006

Odyssey/Pilot Odyssey Odyssey Acura MDX

7HNXT03.5VKR 8HNXT03.54KR 9HNXT03.5J29 5HNXT03.55B4 6HNXT03.5RKR

Honda/Acura

09-005-01 (Report received 1/12/2010) 09-004

3750

12/14/2009

Honda/Acura

3751

6/19/2009

2009

Civic Hybrid

9HNXV01.3CDH

Hyundai

086

3591

9/1/2008 (Rec'd VERR 2/11/2009)

2008

Elantra

8HYXV02.0HW5 8HYXV02.0HPC

Some vehicles may have been built with a section of the fuel tank seam that was not formed in accordance with the manufacturing specifications, possiblly causing evaporative emission leaks. Remedy: GM dealers will inspect, and if necessary, replace the fuel tank. This recall is safety-related as well as emission-related. A transmission judder (vibration) may sometimes be felt between 20-45 MPH. If the software is not reprogrammed the judder can increase over time. Remedy: Dealers will reprogram the software used to control the transmission to minimize the vibration. A transmission judder (vibration) may sometimes be felt between 20-45 MPH. If the software is not reprogrammed the judder can increase over time. Remedy: Dealers will reprogram the software used to control the transmission to minimize the vibration. In areas where there is extreme cold, the Integrated Motor Assist (IMA) battery monitoring system may incorrectly indicate a problem with the IMA battery. If the monitoring system causes the check engine light and IMA indicator light stay on, the IMA motor will not operate and the vehicle will run with the gas engine only. Remedy: Dealers will reprogram the IMA battery monitoring system software. The fuel pump motor may not have the proper uniform internal electrical surface contact. This may cause the fuel pump to produce less pumping pressure that required to supply the fuel injection system. Poor engine starting and hesitation may result. Remedy: Hyundai dealers will replace the vehicle's fuel pump subassembly. This recall is safety-related as well as emission-related. The On-Board Diagnostics (OBD) system may not correctly detect tailpipe or evaporative emissions failures and provide the applicable warnings to the driver. Remedy: Dealers will reconfigure Engine Control Module (ECM) and, where appropriate, the Transmission Control Module (TCM).

884

884

208,080 136,117 59,395 60,336 51,381

403,592

111,717

2,872

2,872

40,519 25,095

65,614

Jaguar

J004

3536

12/1/2008 (Rec'd VERR 10/30/2009)

2004

S-Type, X-Type, XK8, XKR, S-Type, XJ8, XJR

2005

S-Type, X-Type, XK8, XJ8, VDP, XKFi, Super V8, XJR

2006

X-Type, XK8, XKFi

2007

X-Type

4JCXV03.0DNE 4JCXV03.0DNG 4JCXV04.2DN9 4JCXV04.2DNF 4JCXV04.2DSA 4JCXV04.2DSB 5JCXV03.0DNE 5JCXV03.0DNE 5JCXV03.0DNE 5JCXV04.2DN9 5JCXV04.2DNF 5JCXV04.2DSA 5JCXV04.2DSB 6JCXV03.0DNH 6JCXV03.0DNH 6JCXV04.2DSA 7JCXV03.0DNH

5,276 24,800 991 17,637 564 2,664 8,862 6,064 5,208 1,755 10,520 724 2,346 5,981 1,462 710 3,017

98,581

2009 Annual Report

EPA-420-B-10-007b

2009 Emissions-Related Recall Campaigns through December 2009

Mfr. Mfr. Recall Number EPA# Type Owner Notification MY Vehicle or Engine Class Engine Family Problem Description Affected Vehicles Total Number of Vehicles Recalled 6,680

Kia

SC074

3592

9/16/2008 (Rec'd VERR 2/11/2009)

2008 2009

Rondo

8KMXV02.4UW5 9KMXV02.4UW5

The fuel pump may not operate properly resulting in not enough fuel getting to the engine on some vehicles equipped with 2.4L engines. Poor engine starting, hesitation and other impairments may result and check engine light may illuminate. Remedy: Kia dealers will replace the vehicle's fuel pump sub-assembly with an improved part. This recall is safety-related as well as emission-related. A deficiency in the engine management software could cause an increase in nitrogen oxides emission levels. Remedy: A Voluntary Emissions Recall (P012) was issued to correct the engine management system calibration at no charge to the owners. The fuel tank diagnosis system in certain vehicles may have been inadvertently deactivated during service, due to a software error. Remedy: Dealers will recode the Software Calibration Number (SCN) in affected vehicles.

2,915 3,765

Land Rover

P012

3533

1/2/2009

2005 2006

LR3

5LRXT04.0001 6LRXT04.0001

1,341 5,274

6,615

Mercedes-Benz

2009-060005

3838

8/1/2009

2005 2006

2007

Mitsubishi

SR-09-004

3897

9/29/2009

2008 2009

SLK 350 ML/R 350 SLK 350 SLK/C 280, SLK/CLK 350 CLK350 SLK/C 280, SLK/CLK 350 C230 C280 C280 Lancer Evolution Lancer Ralliart/Sportback

5MBXV03.5LTR 6MBXT03.5LTR 6MBXV02.5U2A 6MBXV02.5U2A 7MBXB03.5BN4 7MBXB03.5U2A 7MBXV02.5U2A 7MBXV03.0U2A 7MBXV03.5U2A 8MTXV02.0GRB 9MTXV02.0GRB

6,481 971 2,288 6,587 4 7 98 186 1 5,416 1,466

16,623

Nissan/Infiniti

NE-03-05-09

3716

3/23/2009

2008 2009

Altima Hybrid

8NSXV02.5G3A 9NSXV02.5G3A

A defect exists in the manner in which the fuel return pipe is attached to the engine. This may cause a stress crack to develop at the fixed portion of the fuel pipe. If this stress crack develops, fuel leakage may occur. Remedy: The dealership will install a new fuel return pipe with additional attachment brackets to better control pipe vibration. This recall is safety-related as well as emissionrelated. Due to a software irregularity, the Vehicle Identification Number (VIN) programmed in the Engine Control Module (ECM) may be overwritten. If this repair is not completed the vehicle will not complete an emissions Inspection/Maintenance test. Remedy: Nissan dealers will reprogram the ECM in the vehicles. Under certain conditions the intake duct may separate from the resonator. This could cause minor idle fluctuation or poor acceleration. If this occurs and the vehicle continues to be driven without service the engine may stall while driving. Remedy: Nissan will replace the air intake duct with an updated part and replace the air duct clamps. This recall is safety-related as well as emission-related These vehicles are equipped with an improperly functioning on-board diagnostics system that may in some situations not illuminate a MIL when a malfunction exists. Remedy: Nissan will reprogram the Engine Control Module (ECM). Under certain unique driving patterns, such as repeated acceleration/deceleration and/or continuous uphill driving at higher speeds the vehicle's catalytic converter may develop internal temperatures that exceed design parameters. If left uncorrected, this condition may eventually degrade the efficiency of the converter. Remedy: Subaru dealers will modify the Engine Control Module software logic to improve management of temperature within the catalytic converter.

6,882

8,546 5,161

13,707

Nissan/Infiniti

R0902

3799

7/20/2009

2003 2004 2005 2006 2007 2010

Murano

3NSXT03.5C7B 4NSXT03.5G7A 5NSXT03.5G7A 6NSXT03.5G7C 7NSXT03.5G7B ANSXV01.8G4A ANSXV01.8G1A

53,255 63,187 71,613 77,320 94,290 608 5,708

359,665

Nissan/Infiniti

NE-10-6-9

3903

11/2/2009

Versa

6,316

Subaru

WVI-19 (45-state) WVH-18 (5-state)

3417

6/19/2009

2005

Legacy, Outback

5FJXX02.5NKR

31,098

31,098

2009 Annual Report

EPA-420-B-10-007b

2009 Emissions-Related Recall Campaigns through December 2009

Mfr. Mfr. Recall Number EPA# Type Owner Notification MY Vehicle or Engine Class Engine Family Problem Description Affected Vehicles Total Number of Vehicles Recalled 193,464

Subaru

WVL-22

3754

10/23/2009

2005 Forester, Impreza, Saab 9-2X Linear 2006 Forester, Impreza 2007 Forester, Impreza 2008 2005 2006 Forester Baja, Baja Turbo

5FJXX02.5MJS 6FJXX02.5MTC 7FJXB02.5MTC 8FJXV02.5MTC 5FJXX02.5MJS 5FJXX02.5PGT 6FJXT02.5MJS 6FJXX02.5PGT 6FJXX02.5NVD 7FJXB02.5NVD 8FJXB02.5NVD 8FJXB02.5NVJ 9FJXJ02.5NVD AFJXJ02.5NVD 6TYXV02.5PEA 6TYXV03.5PEB 6TYXV03.0WMB 7TYXV02.5BEA 7TYXV03.5BEB 7TYXV04.6BEA 8TYXV02.5BEA 8TYXV03.5BEB 8TYXV04.6BEA 1TYXV01.5LJ1 2TYXV01.5LJ1 3TYXV01.5LH1 4VWXV01.9236 4VWXV02.0234 4VWXV05.0235 5VWXV01.9236 5VWXV02.0234 6VWXV01.9236 4VWZV01.9236 5VWZV01.9236 6VWZV01.9236 6VWXV03.2535 7VWXV03.2535 8VWXV03.2535 9VWXV03.2535 9ADXV02.03UA AADXV02.03UA

The one-way fuel valve located in the fuel tank may not perform as intended and could cause a condition that may damage the catalytic converter. Remedy: The one-way valve must be permanently removed from the fuel tank.

66,624 68,426 45,060 13,354 4,822 3,560 5,837 1,913 18,780 22,209 20,665 21,522 86,230 18,478 34,600 15,500 43,700 48,100 32,700 35,200 3,200 400 1,200 15,800 22,750 12,450 19,267 3,222 563 13,778 8,842 2 11,251 6,927 2,329 1,307 1,197 4,051 525 2,794 337

Subaru

WVJ-20

3850

10/23/2009

Subaru

WVM-23

3894

10/23/2009

2006 2007 2008 2009 2010 2006

Legacy, Outback Legacy, Outback, Forester Forester Lexus IS250 Lexus IS350 Lexus GS300 Lexus IS250 Lexus IS350 Lexus GS300 Lexus IS250 Lexus IS350 Lexus GS300 Prius

The plastic outlet pipe on the fuel pump may develop cracks and potentially cause a fuel leak. Remedy: Subaru will replace the fuel pump bracket which contains the outlet pipe. This recall is safety-related as well as emission-related. Under certain severe driving patterns, such as high speed highway uphill driving and/or accelerating with high engine revolutions, the efficiency of the catalytic converter may begin to degrade beyond design parameters. Remedy: Subaru has developed a modification to the Engine Control Module (ECM) software logic that will improve management of the catalytic converter. These vehicles are equipped with aluminum Fuel Delivery Pipes (fuel rails). Lexus has determined that ethanol fuels with a low moisture content will corrode the internal surface of the fuel rails. As this condition progresses the Malfunction Indicator Light (MIL) may illuminate. Over time, the corrosion will create a pinhole resulting in fuel leakage. In the worst case fuel leakage in the presence of an ignition source could result in a fire. Remedy: Lexus dealers will replaced the involved Fuel Delivery Pipes with newly designed ones. This recall is safety-related as well as emission-related. Certain vehicles may exhibit low engine power or failure to start and a Malfunction Indicator Lamp (MIL) illumination due to Throttle Body carbon deposit build up. Remedy: Toyota dealers will clean the throttle body. Diesel vehicles ceramic glow plugs may experience glow plug failures, as indicated by a Malfunction Indicator Light (MIL). Remedy: Dealerships will inspect and, if necessary, update engine glow plugs to metal glow plugs.

16,132

187,884

Toyota/Lexus

9LA

3693

2/2/2009

214,600

2007

2008

Toyota/Lexus

T-SB-0180-09

2198

8/7/2009

2001 2002 2003 2004

51,000

Volkswagen/Audi

28E6/R8

2789

7/24/2009

2005 2006 2004 2005 2006 2006 2007 2008 2009 2010

Volkswagen/Audi

24P9/P5

3704

7/24/2009

GTI, Jetta, Beetle Passat Touareg GTI, Jetta, Beetle Passat Beetle, Golf Jetta, Beetle, Golf

45,674

Volkswagen/Audi

20P6/S2

3727

5/31/2009

A3 Quattro A3 Quattro VW R32, Audi A3 Quattro and TT TT and A3 Quattro TT and A3 Quattro TT and A3 Quattro

The electronic control module (ECM) software can cause affected vehicles to exceed emissions standards. Remedy: Dealers will update the ECM software in affected vehicles. Under certain conditions, the fuel tank ventilation valve may not remain fully closed causing liquid fuel to enter the venting system. This may cause the evaporative emission canister to saturate with fuel increasing evaporative emissions and causing a fire risk . Remedy: Dealers will install an improved fuel tank ventilation valve assembly kit on vehicles equipped with 3.2L engines. This recall is safety-related as well as emission-related.

20,507

10,211

2009 Annual Report

EPA-420-B-10-007b

2009 Emissions-Related Recall Campaigns through December 2009

Mfr. Mfr. Recall Number EPA# Type Owner Notification MY Vehicle or Engine Class Engine Family Problem Description Affected Vehicles Total Number of Vehicles Recalled 444,265

Volkswagen/Audi

J1-28F2 P1-28F3

3697

10/23/2009

2004 2005

Passat, W8 Jetta Jetta Audi TT 2006 Jetta, GTI, Passatt & A3 Audi TT Audi TT A3 Quattro Jetta Jetta, Rabbitt, Beetle Jetta, Rabbitt, Beetle

4VWXV04.0229 5VWXV02.5253 5VWXV02.5257 5VWXV03.2220 6ADXV02.0366 6ADXV01.8346 6VWXV03.2220 6VWXV03.2535 6VWXT03.2275 6VWXV02.5253 6VWXV02.5257 7ADXT04.2358 7ADXV02.0366 7ADXV03.1374 7ADXV04.2365 7ADXV04.2375 7ADXV05.2385 7VWXT03.6276 7VWXV03.2535 7VWXV02.5253 7VWXV02.5257 7VWXV03.6246

Some vehicles may have ignition coils that could malfunction under certain conditions. If this happens the Malfunction Indicator Lamp (MIL) will illuminate. Remedy: Dealers will inspect and, if necessary, install new ignition coils.

478 29,359 14,636 1,196 85,559 723 476 1,307 7,810 81,028 31,956

2007

Q7, Touareg Jetta, GTI, Passatt & A3 A6 and A4 Quattro A6 and A8 RS4 S6 and S8 Q7 and Touareg A3 Quattro Jetta, Rabbitt, Beetle Jetta, Rabbitt, Beetle Passat

8,644 60,192 10,569 3,373 1,225 1,239 16,832 888 57,386 25,871 3,518

Total number of Vehicles affected by Recall Campaigns:

2,626,314

2009 Annual Report

EPA-420-B-10-007b

Section 2: Emission-Related Voluntary Service Campaigns

New Voluntary Service Campaigns during 4th Quarter 2009:
Manufacturer BMW EPA# 3468

2009 Annual Report

10

EPA-420-B-10-007b

2009 Emissions-Related Voluntary Service Campaigns through December 2009

Mfr. Mfr. Recall Number EPA# Type Owner Notification MY Vehicle or Engine Class Engine Family Problem Description Affected Vehicles Total Number of Vehicles Recalled 207,900

BMW

09E-W01 09E-W03 (Amendment published 3/02/2010)

3646

VSC

5/20/2009

2007 2008 2008 2009

335i,335xi,335Ci

7BMXV03.0N54 8BMXV03.0N54 8BMXT03.0E71 9BMXV03.054R 9BMXV03.0ULR 9BMXT03.0E7R 4MBXV01.6R50 5MBXV01.6R50 6MBXV01.6R50

2/18/2010

BMW

09E-W02

3468

VSC

8/31/2009

2004 2005 2006

X6, XDrive, 35i 135, 535 335, Z4 sDrive X6, XDrive, 35I Mini Cooper, S Mini Cooper Mini Cooper

There is a potential problem that could affect the durability of the high-pressure fuel pump. Remedy: BMW will extend the emissions warranty for the high-pressure fuel pump to 10 years or 120,000 miles whichever comes first.

45,000 73,500 3,150 42,000 42,000 2,250 31,200 47,600 51,400

General Motors

08300

3756

VSC

6/1/2009

2006 2007

Pontiac Solstice Pontiac Solstice,Sky

6GMXV02.4031 7GMXV02.4031

Variations in the crimping process may lead to an electrical failure (open circuit) inside the oxygen sensor. Remedy: Mini will extend the emissions warranty for the oxygen sensor to 10 years or 100,000 miles and replace the oxygen sensor with an improved version within the new warranty period if the original fails. Some vehicles equipped with a 2.4L engine may have a condition where the Malfunction Indicator Lamp (MIL) illuminates and/or there is a lack of engine power. This may be caused by failure of the catalytic converter. Remedy: General Motors is providing owners with a warranty extension for the catalytic converter. If this condition occurs within 10 years of the date the vehicle was placed into service or 120,000 miles whichever comes first it will be repaired at no charge.

130,200

18,748 24,147

42,895

Total number of Vehicles affected by Voluntary Service Campaigns:

380,995

SUMMARY Total number of Vehicles affected by Recalls and Voluntary Service Campaigns: Total number of Voluntary Recalls: Total number of Voluntary Service Campaigns: Total number of Recalls and Voluntary Service Campaigns: 39 3 42

3,007,309

2009 Annual Report

11

EPA-420-B-10-007b