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

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 Mazda North American Operations

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 13,891

 

Summary

Mazda North American Operations (Mazda) 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 Mazda customer service at 1-800-222-5500, Option 4. Mazda’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: Mazda received the first field report of “The Fuel leak occurred by out of target” from outside the US market. The part supplier and Mazda started to investigate the root cause. Note: the subject population at this time was included in NHTSA Recall 16V793 which affected 2004MY through 2008MY Mazda RX-8

 

August, 2017 through October, 2017: Mazda 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, Mazda judged the cause as excessive heat exposure due to vehicle modifications. In the second case, the parts experienced the same condition but Mazda could not identify why excessive heat exposure occurred. In the third case, Mazda could not investigate the root cause due to unavailable part and unknown vehicle information. Mazda judged to monitor the field for more information.

 

April, 2018 through December, 2018: Mazda 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. Mazda decided to conduct a vehicle go-and-see whenever subject vehicles visited a Mazda dealer for related concerns.

 

December, 2018: Mazda 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, Mazda confirmed creep fatigue damage had occurred on the fuel pump ring in normal vehicles.

 

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

 

September, 2019: Based on the re-validation result for RX-8, Mazda 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: Mazda 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. Mazda began to study the effect of vehicle usage and environmental exposure factors on fuel pump ring deterioration.

 

June, 2020 through July 2020: Mazda 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, Mazda determined vehicles in any market may experience the defect. Mazda started to assess the necessity of proactive field action.

 

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

 

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

 

September 20, 2021: Mazda held a Quality Audit Committee meeting to review all available information to date. Out of an abundance of caution, Mazda 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 Mazda 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

MAKE MODEL YEAR
MAZDA MAZDASPEED6 2006-2007
MAZDA RX-8 2009-2011

 


15 Associated Documents

Remedy Instructions and TSB

RCRIT-21V744-9733.pdf 2254.954KB

RCRIT-21V744-9733

 


Remedy Instructions and TSB

RCRIT-21V744-0771.pdf 2126.123KB

RCRIT-21V744-0771

 


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

RCMN-21V744-7404

 


Parts & Warranty Information- Recall Campaign 5121I

RMISC-21V744-0542.pdf 576.149KB

RMISC-21V744-0542

 


Defect Notice 573 Report

RCLRPT-21V744-1366.PDF 215.482KB

RCLRPT-21V744-1366

 


Miscellaneous Document – Chronology of Defect

RMISC-21V744-3401.pdf 402.517KB

RMISC-21V744-3401

 


Recall Acknowledgement

RCAK-21V744-6195.pdf 645.573KB

RCAK-21V744-6195

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V744-6659.pdf 694.921KB

RCONL-21V744-6659

 


ISSUED Owner Notification Letter(Part 577)- Territories

RCONL-21V744-4487.pdf 728.012KB

RCONL-21V744-4487

 


Recall Quarterly Report #1, 2021-4

RCLQRT-21V744-1301.PDF 211.147KB

RCLQRT-21V744-1301

 


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

RCMN-21V744-9481.pdf 443.974KB

RCMN-21V744-9481

 


Recall Quarterly Report #2, 2022-1

RCLQRT-21V744-7713.PDF 211.256KB

RCLQRT-21V744-7713

 


ISSUED Renotification Notice

RCRN-21V744-5659.pdf 710.811KB

RCRN-21V744-5659

 


ISSUED Renotification Notice

RCRN-21V744-7354.pdf 677.748KB

RCRN-21V744-7354

 


Recall Quarterly Report #3, 2022-2

RCLQRT-21V744-8504.PDF 211.34KB

RCLQRT-21V744-8504

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V744&docType=RCL

 


 

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