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NHTSA Campaign Number: 16V684
Manufacturer Mazda
North American Operations
Components FUEL SYSTEM, GASOLINE
Potential Number of Units Affected 17,484
Possible Fuel Leak from Deformed Fuel Tank
A fuel leak in the presence of an ignition source increases the risk of a fire.
Summary
Mazda Motors North American Operations (Mazda) is recalling certain model year 2014-2016 Mazda3 vehicles manufactured January 4, 2014, to September 18, 2015.
The fuel tank of the affected vehicles may have been improperly handled during manufacturing and, as a result, the welded attachment of the Inlet Check Valve (ICV) may fail and allow fuel to leak.
Remedy
Mazda will notify owners, and depending on the tank lot number, dealers will inspect the ICV weld, replacing the fuel tank, as necessary, free of charge.
The recall began November 1, 2016.
Owners may contact Mazda customer service at 1-800-222-5500.
Mazda’s number for this recall is 0116I.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
Check if your Mazda has a Recall
TO: All Mazda Dealership General Managers, Service and Parts Managers
DATE: November 2016
SUBJECT: 2014-2016 Mazda3 Fuel Leakage from Inlet Check Valve Safety and Emission Recall 0116I
Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in certain 2014-2016 Mazda3 vehicles produced from December 4, 2013 through September 18, 2015.
On certain Mazda3 vehicles, due to possible fuel tank deformation during manufacturing, the inlet check valve may not be properly welded to the fuel tank. If this weld breaks during vehicle operation, fuel leakage may occur, increasing the risk of fire.
Dealers must inspect the fuel tank on the subject vehicles and, if necessary, replace it with a new, improved one. Please refer to the Repair Procedure document for details. Fuel tank kit orders are VIN specific and therefore not eligible for a 45-day or accrual return.
Owners of affected vehicles will be notified by first class mail beginning November 17, 2016.
This package contains important information about Safety and Emission Recall 0116I:
| Attachment I | Service Parts and Warranty Information |
| Attachment II | Repair Procedure |
| Attachment III | Owner Notification Letter and Reimbursement Form |
Important Emission Notice: California Department of Motor Vehicles and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission
Recalls prior to registration renewal. Mazda dealers must provide customers a Vehicle Emission Recall – Proof of Correction Certificate (p/n 9999-95-ERPC-99 available in MStore) upon completion of the recall. Instruct customers to keep the certificate until needed for registration renewal.
Important Safety Notice: The National Traffic and Motor Vehicle Safety Act prohibits the delivery of any subject vehicle without performing the necessary repair for defects or failures. Failure to perform applicable recalls before delivery can result in extensive dealer fines and penalties from the Federal Government. Therefore, you must complete this recall for all affected vehicles in your inventory prior to delivery. To help you effectively perform this recall, Mazda has developed the following resources:
- Service and Parts information and Repair Procedure documents are available on eMDCS and MS3 (Mazda Service Support System) websites via MXConnect.
- For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
- For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
- For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626 Option 2.
- We recommend using the Recall Reminder Report #JS30R165-1 and Recall Reminder Labels available in Web Reporting to encourage customers to come in for the recall (with recall reminder postcards). Dealers may use such owner information for the sole purpose of conducting and performing this recall, and for no other purpose. Using it for marketing activities is strictly prohibited and could subject your dealership to serious fines. The information in the report is protected by state privacy and other applicable laws regarding disclosure of personal and/or confidential, restricted or blocked information. It is the dealer’s responsibility to protect the confidentiality of owner records and prevent the release of information to other parties.
Please make certain the appropriate personnel in your dealership are aware of these resources and are familiar with the details of this recall before responding to customer inquiries.
We apologize for any inconvenience this recall may cause you and your customers. Your understanding and support in carrying out this campaign is greatly appreciated.
Sincerely,
Akira Ikemoto
Director, Technical Services Division
Mazda North American Operations
Parts and Warranty Information
Safety and Emission Recall 0116I
CONDITION OF CONCERN
On certain Mazda3 vehicles, due to possible fuel tank deformation during manufacturing, the inlet check valve (ICV) may not be properly welded to the fuel tank. If this weld breaks during vehicle operation, fuel leakage may occur, increasing the risk of fire.
SUBJECT VEHICLES
| Model | Subject VIN range | Subject production date range |
| 2014-2016
Mazda3 | 3MZ BM**** EM 100134 – 117652
3MZ BM**** FM 236311 – 237205 3MZ BM**** GM 237206 – 257433 | From December 4, 2013 through September 18, 2015 |
The asterisk symbol “*” can be any letter or number.
OWNER NOTIFICATION
Mazda will notify U.S. owners by first class mail beginning no later than November 20, 2016.
PARTS INFORMATION
| Description | Part number | Quantity | Notes |
| Fuel tank kit | BJY6-42-100 | 1 | Necessary only for vehicles that require fuel tank replacement after inspection |
| Gasket | PE23-40-305  | 2 | |
| Nut | 9994-61-000 | 4 | |
| Retainer | CC43-42-693 | 1 | |
| Campaign Label | 9999-95-065A-06 | 1=50 labels | Obtain in MStore (no charge) |
| Vehicle Emission Recall | |||
| Proof of Correction Certificate * | 9999-95-ERPC-99 | 1=50 certificates |
* California Department of Motor Vehicles and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers must provide customers a Vehicle Emission Recall – Proof of Correction Certificate (p/n 9999-95-ERPC-99) upon completion of the recall.
WARRANTY CLAIM PROCESSING INFORMATION
| Fuel tank lot number inspection only (pass) | Fuel Tank Lot Number (fail) and ICV weld inspection (pass) | |
| Warranty Type | R | R |
| Process Number | AG021A | AG021B |
| Symptom Code | 99 | 99 |
| Damage Code | 99 | 99 |
| Part Number Main Cause | 7777-SP-M20 | 7777-SP-M22 |
| Quantity | 0 | 0 |
| Labor Operation Number | XXM9RACX | XXM9RBCX |
| Labor Hours | 0.3 hr. | 0.3 hr. |
| Fuel tank lot number and ICV weld inspection (fail) and replacement of fuel tank | |
| Warranty Type | R |
| Process Number | AG021C |
| Symptom Code | 99 |
| Damage Code | 99 |
| Part Number Main Cause | BJY6-42-100 |
| Quantity | 1 |
| Related Part Number / Quantity | PE23-40-305 / 2
9994-61-000 / 4 CC43-42-693 / 1 |
| Labor Operation Number | XXM9RCRX* |
| Labor Hours | 2.5 hr. ** |
*For repairs that require fuel tank replacement, an additional 0.3 hours was added to account for time spent to take photos and attach to the claim.
** Photos require attachment code D40 and will be reviewed for clarity and correct quantity (4)
RENTAL CAR INFORMATION
Mazda recommends the usage of the MCVP loaner vehicle when available. If all MCVP loaner vehicles are in use and unavailable, and the customer needs a rental car, then use your local rental facility and offer a rental car. Be sure that every effort is made to repair the car within one business day or less in order to allow the next customer the same experience.
Rental Car Warranty Claim Information
| MCVP Vehicle Preferred | Rental Agency Vehicle | |
| Warranty Type Code | N/A
MCVP does not require claim submission
| A |
| Symptom Code | 99 | |
| Damage Code | 99 | |
| Part Number Main Cause | 5555-01-16IR | |
| Part Quantity | 0 | |
| Labor Operation Code | MM024XRX | |
| Labor Hours | 0 | |
| Sublet – Rental Car | ||
| Sublet Invoice Number | Number from Rental Invoice or Dealer Purchase Order | |
| Sublet Type Code | Enter “Z9” (other) | |
| Sublet Amount | Up to $30.00 per day for the number of days customer had
rental car | |
| Sublet Text | Number of days rental car was supplied to customer |
Rental expenses exceeding the two-day limit will require prior DSM Authorization, as outlined in the Mazda Rental Car Reimbursement Program policy.
VERIFY THE VEHICLE NEEDS THE RECALL
- Verify the vehicle is within the following ranges:
| Model | Subject VIN range | Subject production date range |
| 2014-2016
Mazda3 | 3MZ BM**** EM 100134 – 117652
3MZ BM**** FM 236311 – 237205 3MZ BM**** GM 237206 – 257433 | From December 4, 2013 through September 18, 2015 |
The asterisk symbol “*” can be any letter or number.
- If the vehicle is within the above ranges, go to Step 2.
- If the vehicle is not within the above ranges, Recall 0116I is not applicable.
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect the vehicle for an Authorized Campaign Label Recall 0116I attached to the vehicle’s hood or bulkhead.
eMDCS System – Warranty Vehicle Inquiry Results:
| If eMDCS displays: | Campaign Label is: | Action to perform: |
| RECALL 0116I OPEN | Present | Contact the Warranty Hotline at (877) 7276626, option 3, to update vehicle history. |
| Not present | Proceed to “REPAIR PROCEDURE”. | |
| RECALL 0116I CLOSED | Present | Return vehicle to inventory or customer. |
| Not present | Complete a label and apply to vehicle’s hood or bulkhead. | |
| RECALL 0116I is not displayed | Does not apply | Recall does not apply to this vehicle. Return vehicle to inventory or customer. |
REPAIR PROCEDURE
Please refer to Repair Procedure document on MS3.
REPAIR PROCEDURE
SAFETY AND EMISSION RECALL 0116I
A. VEHICLE INSPECTION PROCEDURE
- Verify that the vehicle is within the following range:
| Model Year | VIN Range | Build Date Range |
| 2014-2016 | 3MZBM****EM 100134 – 117652
3MZBM****FM 236311 – 237205 3MZBM****GM 237206 – 257433 | December 4, 2013 through September 18, 2015 |
- If the vehicle is within the above range, proceed to Step 2.
- If the vehicle is not within the above range, return vehicle to the customer or inventory.
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Labels Recall 0116I attached to the vehicle’s hood or bulkhead. Refer to eMDCS System – Warranty Vehicle Inquiry Results table below.
NOTE: Be sure to verify Recall number as the vehicle may have multiple Recall labels.
 |  |
eMDCS System – Warranty Vehicle Inquiry Results:
| If eMDCS displays: | Campaign Label is: | Action to perform: |
| RECALL 0116I OPEN | Present | Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history. |
| Not present | Proceed to “B. INSPECTION PROCEDURE”. | |
| RECALL 0116I CLOSED | Present | Return vehicle to inventory or customer. |
| Not present | Complete a label and apply to vehicle’s hood or bulkhead. | |
| RECALL 0116I is not displayed | Does not apply | Recall does not apply to this vehicle. Return vehicle to inventory or customer. |
B. WORKFLOW OF INSPECTION AND REPAIR
C. INSPECTION AND REPAIR PROCEDURE
- Lift the vehicle up.
- Read the lot number on the label on the fuel tank.
NOTE:
- If the lot number cannot be read on the label, wash it off.
- If the lot number still cannot be read after washing it off, go to step 4.
- Use the Lot Number Calculation Tool to determine if the fuel tank requires further inspection.
- If the lot number is within the affected range, go to next step.
- If the lot number is outside the affected range, work is complete.
- Visually check the welding condition all around the joint portion between the ICV and the fuel tank. Make sure a double bead is created all around the joint.
NOTE:
- The ICV can be viewed from Point (A) or (B) as shown.
- If the joint portion is not clearly visible, wash it off.
- If it is difficult to check the welding condition after washing if off, go to next step and install a NEW fuel tank.
| GOOD | NO GOOD |
 |  |
| Double bead (*) is created all around. | Double bead (*) is NOT created all around. |
*Double Bead: If the ICV is press fit (welded) to the heated fuel tank correctly, the double bead is created.
Samples of ICV with improper welding (double bead (blue line) is not created all around).
- If the welding condition is “GOOD”, work is complete.
- If the welding condition is “NO GOOD”, go to next step.
- Visually check all around the joint portion between ICV and the fuel tank for fuel leak
NOTE: If a leak/trace of a leak has been found on the fuel tank, contact PTL@mazdausa.com with photos, dealer code, RO, VIN, and dealership address. A prepaid shipping label will be provided to send the fuel tank to MNAO. MNAO does not expect any fuel tanks to exhibit a leak/trace of a leak.
- Take photos of lot number and affected portion of the fuel tank.
- Take a photo of the entire ICV with the joint portion for all cases regardless of leak or not.
- Take a photo from three angles so that the location of the improper welding (without bead) and its extent can been seen.
| Lot Number | Take photos from 3 sides |
 |  |
| (A) Upper Side | (B) Left Side | (C) Right Side |
 |  |  |
NOTE: Visually check that there is no fuel leakage or damage around the reassembled parts (hose, pipe).
- Submit a warranty claim attaching the photos taken in step 6.
D. CAMPAIGN LABEL INSTALLATION
- Fill out a blue “Campaign Label” (9999-95-065A-06) with Campaign No: “0116I”, your dealer code, today’s date.
- Affix it to the hood or bulkhead as shown:
- Return the vehicle to customer.
IMPORTANT SAFETY RECALL
2014-2016 Mazda3 Fuel Leakage from Inlet Check Valve
Safety and Emission Recall 0116I NHTSA Campaign No. 16V-684
November 2016
This notice applies to your vehicle: VIN
Dear Mazda Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in certain 2014-2016 Mazda3 vehicles produced from December 4, 2013 through September 18, 2015.
If you are a recipient of this notice, your vehicle is included in this recall.
What is the problem?
On certain Mazda3 vehicles, due to possible fuel tank deformation during manufacturing, the inlet check valve (ICV) may not be properly welded to the fuel tank. If the ICV weld breaks during vehicle operation, fuel leakage may occur, increasing the risk of fire.
What will Mazda do?
Your Mazda dealer will check the fuel tank lot number and, if confirmed to be affected, inspect the weld condition of the ICV to the fuel tank. If necessary, the fuel tank will be replaced with a new one. The inspection and repair will be performed at no cost to you.
How long will it take?
It will take approximately 30 minutes to complete the fuel tank lot number and weld condition inspection. If fuel tank replacement is necessary, it will take approximately 2-½ additional hours. However, it may take longer. If necessary, Mazda will provide alternate transportation while your vehicle is at an authorized Mazda dealership for this inspection/repair.
What should you do?
Mazda is concerned about your safety, and we encourage you to contact any authorized Mazda dealer to schedule an appointment to have your Mazda3 vehicle inspected as soon as possible. You do not need to bring this notice to the dealer, but it may assist in the check-in process.
Mazda North American Operations Technical Services Division 1421 Reynolds Ave. Irvine, CA 92614-5570 www.MazdaUSA.com
Emission Law Information: To ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended you have your vehicle or engine serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not completed.
Important notice to owners registering vehicles in California and Massachusetts: California Department of Motor Vehicles and the Commonwealth of Massachusetts, in conjunction with the
California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers will provide a Vehicle Emission Recall – Proof of Correction Certificate upon completion of the recall. Be sure to keep the proof of correction certificate provided by the Mazda Dealer until needed for the registration renewal process.
What if you already paid for repair on fuel tank?
If you have already paid for repair or replacement of the fuel tank due to fuel leakage from ICV weld, prior to receiving this notice, you may be eligible for reimbursement of reasonable repair expenses based on Mazda’s repair standards. Please complete the enclosed “Reimbursement Application Form”, include the necessary documentation, and mail it to us in the pre-addressed envelope provided, allowing 6-8 weeks for processing.
Where is the closest Mazda dealer?
To locate your nearest Mazda dealer, visit our web site and use our “Locate a Dealer” feature at www.MazdaRecallInfo.com or consult your local yellow pages.
Moved or no longer own this vehicle?
If you have moved or no longer own your Mazda vehicle, please complete and mail the enclosed postage-paid Information Change Card (no envelope required) as soon as possible. This enables us to update our records and notify the current owner.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Still have questions?
If you have any questions regarding this campaign, please contact our Customer Experience Center toll free at (800) 222-5500, select option #6. If Mazda or its dealers do not repair the defect free of charge and within a reasonable amount of time, you may notify the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327- 4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.
We actively work to improve our products and search for solutions to improve your ownership experience. We sincerely apologize for any inconvenience this recall may cause you.
Sincerely,
Mazda North American Operations
Mazda North American Operations Technical Services Division 1421 Reynolds Ave. Irvine, CA 92614-5570 www.MazdaUSA.com
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