2015 Mazda Mazda3 Fuel System Problems

While parked on a slight downhill grade, gasoline started leaking and created a significant puddle on the ground. No warning lamps, messages or other symptoms. An independent service center ran numerous tests over two days, including a smoke test. Diagnosis: There is a hole in top section of fuel tank and the fuel tank needs replaced. Recommendation was to not drive vehicle with fuel tank over half full. Due to the potential of leaking fuel in the presence of a hot ignition source increasing the risk of fire, driving the vehicle long distance with defective fuel tank appears to represent an unreasonable safety risk. Unfortunately, the vehicle is currently 300 miles from home. Mazda’s Mexican-made plastic fuel tank specifically required for our vehicle’s VIN is not currently available. (Mazda makes a similar metal fuel tank in [XXX] which will not fit.) Mazda has an estimated three-month backlog in [XXX] for the fuel tank. Still awaiting repair due to lack of availability of the appropriate fuel tank. Major safety recall NHTSA 16V684000 for the 2015 Mazda3 addresses a manufacturing defect where a fuel tank weld could fail, leading to fuel leaks and a potential fire. Recall is for vehicles produced between 12/4/13 – 9/18/15. Our vehicle was manufactured 02/2015 in [XXX] . However, recall is limited to three specific series of VINs and our vehicle falls in the gap between subject VIN ranges. A recent NHTSA complaint XXX (1/27/26) has the same issue: fuel tank leak, but not within range of recall VINs. It seems that the list of affected VINs included in recall 16V684000 should be expanded to include additional Mexican manufactured vehicles potentially with the same issue. Or create a new recall. Having a hole in the top of a plastic fuel tank securely mounted to the vehicle is unexpected through normal wear and tear. Any fuel leakage increases the risk of fire. NHTSA should investigate if this is due to a defect in Mazda’s manufacturing process. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Fuel leaking out of top of tank. Took car to two different shops. They both told me about a recall on the gas tank. They did every test possible and replaced O ring. Even did smoke evap system test. Tank still leaks from the top when full. They said the tank needs replaced. There is a recall for the year make and model but not my VIN?

Started smelling gas fumes several weeks ago after fill ups at the gas station. Took to my mechanic who diagnosed a fuel tank leak due to rust. No warning lights present. No fuel on the ground or fumes within the cabin.

strong gas smell in the cabin

I was driving 90km and it suddenly stopped, I almost got into it, I put the 4 flashers and I let myself go on the shoulder, then call a towing after a machine test the error code P1092 appears , when I turn on my car, it's so miserable, it starts to bubble, it doesn't want to move forward anymore, lack of strength, All the rest is marked as PASS After googling around, I may have found an answer. Denso, who makes low pressure fuel pumps for a lot of different manufacturers, recalled several million of them a couple of years ago. They determined that there was a manufacturing defect that causes the pump impellers to crack and deform. Then they don't move enough gas to the front of the engine. I guess there is no pressure sensor between the tank and the high pressure fuel pump, so the problem isn't recognized by the car until the sensor in the fuel rail sees it. Several auto makers have issued recalls, including Mazda. But Mazda only went back as far as 2018. Toyota recalled cars as far back as 2013. There are now several lawsuits against various auto makers arguing that Denso knew about the problem in 2015, and the recalls should go further back in time. These two articles do a good job of covering the history of the problem

Since the middle of 2023 I have noticed a gas fume smell both inside and outside of my 2015 Mazda Mazda3 after I fill my gas tank to full. This smell persists up until I use about a half tank of gas or slightly less. I do not top my gas tank off and stop filling when the automatic gas pump stops. There are no visible leaks on or around the gas tank or below the vehicle, and there are no noticeable cracks around the gas tank, valves, lines, etc. Additionally, there are no warning lights present on my dashboard or any codes.

TL* THE CONTACT'S SON OWNS A 2015 MAZDA MAZDA3. THE CONTACT STATED THE VEHICLE WAS SERVICED UNDER NHTSA CAMPAIGN NUMBER: 16V684000 (FUEL SYSTEM, GASOLINE) WHICH MAYBE THE CAUSE OF THE FAILURE. THE CONTACT STATED WHILE VEHICLE WAS AT A STAND STILL AT A LOCAL GAS STATION, GASOLINE STARTED POURING OUT FROM UNDERNEATH THE VEHICLE ONTO THE GROUND. THE CONTACT STATED HIS SON LOOKED UNDERNEATH THE VEHICLE AND BECAME AWARE THAT THE FUEL TANK WAS RESTING ON THE EXHAUST WHICH CAUSED BURNS TO THE ALUMINUM PLATE. THE VEHICLE WAS TOWED TO HIS SON'S RESIDENCE. THE CONTACT STATED A LOCAL DEALER WAS CONTACTED HOWEVER, NO ASSISTANCE WAS OFFERED. THE VEHICLE HAD NOT BEEN DIAGNOSED NOR REPAIRED AS OF YET. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND FILED A CASE. THE FAILURE MILEAGE WAS APPROXIMATELY 80,241. *LN *DL

TL* THE CONTACT OWNS A 2015 MAZDA 3. WHILE ACCELERATING FROM A TRAFFIC LIGHT, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS UNABLE TO RESTART THE VEHICLE. THE VEHICLE WAS TOWED TO GUNTHER MAZDA (1800 S STATE RD 7, FORT LAUDERDALE, FL 33317, (954) 797-1600) WHERE IT WAS DIAGNOSED THAT THE BATTERY NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS THEN TOWED TO LOU BACHRODT MAZDA COCONUT CREEK (5400 SR 7, COCONUT CREEK, FL 33073, (954) 247-5000) WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED TWICE. THE MANUFACTURER WAS INFORMED OF THE FAILURES. THE APPROXIMATE FAILURE MILEAGE WAS 36,000.

TL* THE CONTACT OWNS A 2015 MAZDA 3. WHILE THE VEHICLE WAS AT THE DEALER FOR ROUTINE MAINTENANCE, THE TECHNICIAN NOTICED FUEL LEAKING FROM THE VEHICLE. THE TECHNICIAN STATED THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 15V621000 (FUEL SYSTEM, GASOLINE) HOWEVER, THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS UNSAFE TO DRIVE AND WOULD BE KEPT UNTIL THE RECALL REMEDY COULD BE PERFORMED. THE CONTACT FELT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE APPROXIMATE FAILURE MILEAGE WAS 2,000.

TL* THE CONTACT OWNS A 2015 MAZDA 3. THE CONTACT STATED THAT A STRONG ODOR OF FUEL WAS PRESENT WHEN THE VEHICLE WAS REFUELED. THE FAILURE OCCURRED CONSTANTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE FAILURE WAS UNDETERMINED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN THE NHTSA CAMPAIGN NUMBER: 15V621000(FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 200.

TL* THE CONTACT OWNS A 2015 MAZDA 3. WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE FUEL TANK KIT, THE GASKET, THE NUT AND THE RETAINER WERE REPLACED, HOWEVER THE FAILURE RECURRED. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V621000 (FUEL SYSTEM, GASOLINE) HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 732. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.