2009-2011 Mazda RX-8 & 2006-2007 MazdaSpeed6 5121I Fuel Leak From Fuel Pump Mounting Rings

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September 24, 2021 NHTSA CAMPAIGN NUMBER: 21V744000

Fuel May Leak From Fuel Pump Mounting Rings

A fuel leak in the presence of an ignition source increases the risk of a fire.

 

NHTSA Campaign Number: 21V744

Manufacturer MazdaeBay North American Operations

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 13,891

 

Summary

MazdaeBay North American Operations (MazdaeBay) is recalling certain 2009-2011 RX-8 and 2006-2007 MazdaSpeed6 vehicles. Fuel may leak from the fuel pump mounting rings.

 

Remedy

Dealers will install new fuel pump mounting rings. Dealers will also add a thermal insulation pad to the fuel tank on RX-8 vehicles. Repairs will be performed free of charge. Owner notification letters were mailed November 17, 2021. Owners may contact MazdaeBay customer service at 1-800-222-5500, Option 4. MazdaeBay’s number for this recall is 5121I.

 

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.nhtsa.gov.

 

Check if your Mazda has a Recall

 


Chronology of Defect

Fuel leak may occurred from fuel pump mounting rings on MY 2009 through
MY2011 RX-8 and MY 2006 through 2007 MazdaSpeed6

 

July, 2017: MazdaeBay received the first field report of “The Fuel leak occurred by out of target” from outside the US market. The part supplier and MazdaeBay started to investigate the root cause. Note: the subject population at this time was included in NHTSA Recall 16V793 which affected 2004MY through 2008MY MazdaeBay RX-8

 

August, 2017 through October, 2017: MazdaeBay received second and third field reports from outside the US market. As a result of part investigation in the first case, creep fatigue damage on the fuel pump ring was confirmed through heat insulator discoloration by heat. In addition, the subject vehicle was a performance-modified vehicle. Based on the heat insulator discoloration estimation and thermal testing result, the temperature of surrounding fuel tank was higher than a normal vehicle. Accordingly, MazdaeBay judged the cause as excessive heat exposure due to vehicle modifications. In the second case, the parts experienced the same condition but MazdaeBay could not identify why excessive heat exposure occurred. In the third case, MazdaeBay could not investigate the root cause due to unavailable part and unknown vehicle information. MazdaeBay judged to monitor the field for more information.

 

April, 2018 through December, 2018: MazdaeBay received 4th through 8th field reports from outside the US market, based on the part investigation the creep fatigue damage on the pump ring was confirmed but the cause of excessive heat exposure was still unknown. MazdaeBay decided to conduct a vehicle go-and-see whenever subject vehicles visited a MazdaeBay dealer for related concerns.

 

December, 2018: MazdaeBay conducted employee surveys to confirm the difference in the fuel pump ring between normal and modified vehicles, as well as starting the re-validation of heat efficiency and material force testing.

 

February, 2019: Based on the employee surveys and part investigation, MazdaeBay confirmed creep fatigue damage had occurred on the fuel pump ring in normal vehicles.

 

March, 2019 through August 2019: MazdaeBay received 9th through 14th field reports from outside the US market.

 

September, 2019: Based on the re-validation result for RX-8, MazdaeBay suspected insufficient margin of heat resistance performance. Therefore, the heat and material force margin study was expanded for other models.

 

October, 2019 through December 2019: MazdaeBay received 15th through 18th field reports from outside the US market.

 

February, 2020: Based on the re-validation result, certain Mazdaspeed6 vehicles were also suspected to have insufficient material strength margin. MazdaeBay began to study the effect of vehicle usage and environmental exposure factors on fuel pump ring deterioration.

 

June, 2020 through July 2020: MazdaeBay received 19th through 20th field reports from outside the US market.

 

August, 2020: Based on the result of studying vehicle usage and environmental exposure factors, MazdaeBay determined vehicles in any market may experience the defect. MazdaeBay started to assess the necessity of proactive field action.

 

September, 2020 through August, 2021: MazdaeBay received 21st through 31st field reports from outside the US market.

 

September, 2021: Considering the nature of the defect’s root causes, MazdaeBay was concerned about a possible increase in cases caused by this defect in the future. Accordingly, MazdaeBay decided to judge whether to take proactive field actions.

 

September 20, 2021: MazdaeBay held a Quality Audit Committee meeting to review all available information to date. Out of an abundance of caution, MazdaeBay has determined to conduct a proactive field action on certain MY2009 through MY2011 RX-8 and MY2006 through 2007 Mazdaspeed6 vehicles in the US and US Territories.

 


Safety Recall 5121I – Repair Procedure – 2009-2011 MazdaeBay RX-8

 

Safety Recall 5121I – Repair Procedure – 2009-2011 Mazda RX-8

 


Safety Recall 5121I – Repair Procedure – 2006-2007 Mazdaspeed6

 

Safety Recall 5121I – Repair Procedure – 2006-2007 Mazdaspeed6

 


5 Affected Products

Vehicles

MAKEMODELYEAR
MAZDAeBayMAZDASPEED62006-2007
MAZDAeBayRX-82009-2011

 


15 Associated Documents

Remedy Instructions and TSB

RCRIT-21V744-9733.pdf 2254.954KB

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Remedy Instructions and TSB

RCRIT-21V744-0771.pdf 2126.123KB

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Manufacturer Notices(to Dealers,etc) – Launch of Safety and Emissions Recall 5121I -MY2006-2007 Mazdaspeed6 and MY2009- 2011 RX-8 Fuel May Leak from Fuel Pump Mounting Rings: November 15, 2021

RCMN-21V744-7404.pdf 487.452KB

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Parts & Warranty Information- Recall Campaign 5121I

RMISC-21V744-0542.pdf 576.149KB

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Defect Notice 573 Report

RCLRPT-21V744-1366.PDF 215.482KB

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Miscellaneous Document – Chronology of Defect

RMISC-21V744-3401.pdf 402.517KB

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Recall Acknowledgement

RCAK-21V744-6195.pdf 645.573KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V744-6659.pdf 694.921KB

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ISSUED Owner Notification Letter(Part 577)- Territories

RCONL-21V744-4487.pdf 728.012KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V744-1301.PDF 211.147KB

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Manufacturer Notices(to Dealers,etc) – NOTIFICATION OF SAFETY AND EMISSIONS RECALL 51211

RCMN-21V744-9481.pdf 443.974KB

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Recall Quarterly Report #2, 2022-1

RCLQRT-21V744-7713.PDF 211.256KB

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ISSUED Renotification Notice

RCRN-21V744-5659.pdf 710.811KB

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ISSUED Renotification Notice

RCRN-21V744-7354.pdf 677.748KB

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Recall Quarterly Report #3, 2022-2

RCLQRT-21V744-8504.PDF 211.34KB

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