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

“This site contains affiliate links for which OEMDTC may be compensated”

Repair Procedure – Mazdaspeed6 Only
Safety Recall 5121I

Safety Recall 5121I- 2006-2007 Mazdaspeed6 & 2009-2011 Mazda RX-8 Vehicles – Fuel May Leak from Fuel Pump Mounting Rings.


Preparation for repair

Warm the retainer and fuel pump ring in the Kit

Soak in hot water no hotter than 140 ° F no more than 15 minutes (5 mins is usually sufficient)

This will make it easier to assemble the retainer

*Be sure to wipe off the water from the retainer and fuel pump ring after warming.




  • Fuel is extremely flammable. Always keep sparks and flames away from fuel. Ignition may cause death or serious injury, or damage to equipment.
  • Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious damage, injury, or death. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”.
  • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.



If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, when the quick release connector has been disconnected, clean the connecting area before reconnecting it.


Perform Fuel Line Safety Procedure

a) Remove the fuel-filler cap to release the pressure inside the fuel tank.

b) Remove the fuel pump relay.


c) Start the engine.

d) After the engine stalls, crank the engine several times.

e) Check the fuel level on the gauge.

f) Turn the ignition switch to the LOCK position.

g) Install the fuel pump relay.


1. Remove the rear seat cushion.


2. Remove the service hole cover.

NOTE: If the fuel gauge indicated 1 / 4 or less, go to Step 11 skipping Steps 3-10.


3. Drain fuel from the fuel tank. (Only when the fuel gauge indicates 1 /4 or more)


CAUTION: When the fuel gauge indicates 1 /4 or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this condition, fuel may spill or leak out when performing next steps. Therefore, make sure to drain out fuel until the fuel tank becomes 1 /4 full or less (according to the fuel gauge indication).

WARNING: A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.


4. Remove the plug hole plate


5. Disconnect the quick release connector connected to the fuel distributor.


6. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.

7. Ground the check connector terminal F/P to the body using a jumper wire.



Shorting a wrong terminal of the check connector may cause electrical malfunctions. Make sure to short only the specified terminal.


8. Turn the ignition switch to the ON position and operate the fuel pump.

CAUTION: The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when no fuel is being discharged.


9. When no fuel is being discharged from the hose, turn the ignition switch to the LOCK position.

NOTE: When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min but will continue for approx. 10 min more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the 1 /4 position.


10. Disconnect the jumper wire.


11. Disconnect the negative battery cable.


12. Put on safety googles and use a pressurized air gun to lightly blow out any dirt, debris from the top of the fuel tank and around both fuel pump rings. You will more thoroughly clean that area in a later step.


13. Disconnect the connectors and quick connector of fuel pump unit and fuel suction pipe bracket.

CAUTION: When disconnecting the quick connector, wrap it in a waste cloth to prevent fuel from splashing.


14. Lift up the vehicle, loosen the fuel tank mounting bolts evenly by 30 mm, and lower the tank (do not remove the tank).

NOTE: Do not remove the bolts from tank. The purpose of this loosening is to secure space for installing the SST from inside the vehicle.


15. Remove the fuel pump ring using SST (Fuel Pump Ring Wrench).



  • The fuel pump ring could be damaged if the SST is used with any play between the fuel pump ring and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the fuel pump ring.
  • The fuel suction pipe might be damaged if the fuel pump unit is lifted too much. Make sure to lift the pump only a small amount.


16. Use SST to remove the Fuel gauge unit (Sub).


17. Lift the Fuel gauge unit (Sub) up slightly and remove the gasket.


18. Remove the retainer.




If the fuel tank is left for a long time without the new fuel pump ring installed, the shape of the fuel tank where the fuel pump ring is installed could swell and deform, making it difficult to install the new fuel pump ring. Therefore, install the new fuel pump retainer, gasket, and ring immediately after cleaning the mounting surfaces once the old fuel pump ring has been removed as quickly as possible.

  • Complete the replacement at one side first then proceed to other side.
  • Put replacement parts near the vehicle before starting the replacement.


19. Replace the fuel pump ring, retainer, and gasket with new ones.

20. Prepare warmed fuel pump ring and retainer. (See: *Preparation for repair)


21. Fit the retainer in the three dents of the fuel tank.



Before installing the retainer, clean up following areas of the fuel tank using clean shop rags (sand, dust, and oil may have accumulated).

1) Top surface of fuel pump unit (main) (sub)
2) Retainer mounting surface of the fuel tank.
3) Retainer, pump ring (wipe off water after warming)

Warm the fuel pump ring and retainer as previously mentioned so that they can be smoothly assembled to the fuel tank.


22. Set the gasket on groove of fuel tank.


23. Make sure to put and push Fuel gauge unit (Sub) on groove of fuel tank from above by hand.


24. Align the right side of the notch in the retainer with the center of the three lines of the pump ring. This is the [Rotation start position] for tightening while rotating.


25. As shown in the figure below, tighten the fuel pump ring by hand, one turn (360 °), while holding the top of pump unit by hand from above.

CAUTION: * If the Fuel Pump Ring cannot be tightened by hand, remove the pump ring, check that the retainer, gasket, and pump ring are free of foreign matter such as damage, misalignment, and sand, and then tighten again.

26. Tighten another half turn (180°) using SST. (When tightened for a total of one and a half turns (540°), the pump ring tightening start position mark (three lines) will be around position #3 (540°) in the figure.). Then tighten the pump ring to the specified torque.

Pump ring tightening torque: 88ft-lbs ± 14ft-lbs ( 120 N· m± 20 N· m) (Be sure to use a preset type torque wrench)

Tightening rotation range: 540° to 580° (limit angle: do not exceed 580°)



If SST is used with any gaps between the wall surface of the pump ring and the claws of the SST, the pump ring may be damaged. Make sure to install SST so that there are no gaps.



If the tightening torque exceeds the upper limit before reaching 540°, remove the pump ring and check that the retainer, gasket, and pump ring are free of foreign matter such as damage, misalignment, and sand. Tighten again.

If the tightening torque does not rise to the specified value even if the rotation limit exceeds 580 °, remove the retainer, gasket, and pump ring, check if the gasket has been forgotten to be installed, or if oil or water has adhered, and then tighten again. The same applies to the upper surface of the Fuel gauge unit (SUB).


27. Go back to Step 17 and perform the same procedure for the [Fuel pump unit] (main) side, and replace the retainer, gasket, and pump ring.


28. Connect the fuel gauge unit (main) (sub) connector and the fuel quick connector.

CAUTION: After connecting the fuel system quick connector, lightly push and pull in the axial direction to check that the connector is locked.


29. Lift up the vehicle and tighten the fuel tank mounting bolts (( in the figure below).


Tightening torque: 32 ft-lbs – 44 ft-lbs ( 43.1 N· m – 60.8 N· m)



Tighten in diagonal order to reduce the displacement of the tank.


Fuel leak check

i. Fill the tank with the fuel you previously drained.
ii. Connect the battery(-) cable and start engine.
iii. Make sure there are no fuel leaks near the fuel pump unit.
iv. Drive the vehicle, go, and stop suddenly 5-6 times at low speed.
v. Stop the vehicle and check that there is no fuel leakage near the fuel pump and tank.
vi. Perform an on-board evap test to confirm no evaporative leak with IDS


30. Install the service hole cover with four (4) screws.


31. Install the rear seat cushion.


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


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


Remedy Instructions and TSB

RCRIT-21V744-0771.pdf 2126.123KB

Loader Loading...
EAD Logo Taking too long?

Reload Reload document
| Open Open in new tab

Download [2.03 MB]


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…



Bestseller No. 1
Gumout 540028 Foaming Intake Valve & Turbo Cleaner, 11 oz
  • Deep Cleans GDI (Gasoline Direct Injection) / PFI (Port Fuel Injection) Intake Valves, As Well As, The Throttle Body, Intake Ports, Fuel Injectors and Combustion Chambers
  • Helps Restore Fuel Economy and Maximize Horse Power
  • Removing Carbon and Fuel Deposits From Gasoline Engines Intake Valves, Intake Ports and Turbos Is Essential to Ensuring Optimal Vehicle Performance.
  • Made with Carbon Clear and Trade, the Most Advanced P.E.A. Cleaning Agent Available
  • Strong Enough to Cut Through Thick Carbon Deposits, Even at Extreme Engine Temperatures
Bestseller No. 2
CRC GDI IVD Intake Valve & Turbo Cleaner
  • Proven to clean intake valves on GDI engines and turbo systems
  • Easily installed through the air intake system
  • Highest concentration PEA (Polyether Amine) detergency available
  • Proven to remove up to 46% of GDI Intake Valve deposits in 1 hour
  • 150X more concentrated than fuel additives
Bestseller No. 3
Berryman Products 2611 Intake Valve and Combustion Chamber Cleaner, 16-Ounce Aerosol
  • Formulated for Use In All Fuel-Injected Gasoline Engines, Including GDI
  • Contains Polyetheramine (“PEA”) to Dissolve Carbon Buildup in Combustion Chambers
  • Cleans ALL Types of Intake Valves, Including Those Found in PFI, TBI, and GDI Engines
  • Safe On Catalytic Converters and Oxygen Sensors
  • Not For Use In Diesel Engines
Bestseller No. 4
Bestseller No. 5
MP Care GDI Induction Cleaner, Intake Manifold, Air System, EGR, Valves, Turbo Cleaner
  • GDI Induction cleaner Air system
  • EGR cleaner
  • Valves cleaner
  • intake manifold cleaner
Bestseller No. 6
Bestseller No. 7
FIRSTINFO A1601 4 In 1 Intake Valve Cleaner Combustion Chamber Cleaner/Vacuum System Cleaner/Vacuum System Pressure Tester Kit
  • 【 Maintain Engine Performance 】 Perfect for air intake system, combustion chamber, EGR Valves, intake valves and oxygen sensors. Easy operation for making the fuel injectors spray smoothly and properly.
  • 【 Easy to Use 】 Simply fill with air intake cleaning liquids and connect the vacuum hose of vehicle vacuum system. Reduce carbon deposits easily.
  • 【 Multiple Applications 】 Use to clean the intake valve, combustion chamber, vacuum system and test the vacuum system pressure. Provides more thorough cleaning than other methods. Effectively remove engine carbon deposits and increase gas mileage performance.
  • 【 Equipped with Negative Pressure Gauge 】 The liquid-filled gauge for accurate vacuum pressure reading and monitoring chemical flow.
  • 【 Gasoline Engine / Petrol Cars Use 】 Used for gasoline engine injection and petrol cars. "NOT" for diesel injector. And solution liquid is "NOT" included.
Bestseller No. 8
Smilyeez BG GDI Air Intake & Valve Cleaner PN 260 With Pocket Screwdriver (1)
  • Restores MPG
  • Restores engine performance
  • Restores power
  • Reduces harmful emissions
  • Requires pressurized tool
Bestseller No. 9
CRC Industries, Inc. Intake Valve Cleaner (11 oz) Bundled with Latex Gloves (3 Items)
  • Bundle comes with:
  • 2 - CRC 05319 Industries Intake Valve Cleaner (11 oz)
  • 2 Pairs (4 Gloves) of CLC2316L Latex Gloves - Large
  • Fit type: Universal
SaleBestseller No. 10
LIQUI MOLY Valve Clean | 150 ml | Petroladititive | SKU: 2001
  • Better engine performance.Fit Type: Universal
  • Lower fuel consumption
  • Lower pollutant emissions
  • Protection against corrosion and carburetor icing

Last update on 2024-02-08 / Affiliate links / Images from Amazon Product Advertising API

This product presentation was made with AAWP plugin.


Leave a Comment

Share to...