8615J – Fuel Tank – 2015-2016 Mazda3

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

NHTSA

15V621

SUMMARY:

Mazda North American Operations (Mazda) is recalling certain model year 2015-2016 Mazda3 vehicles manufactured May 21, 2015, to August 25, 2015.

The affected vehicles are equipped with a fuel tank with a shut-off valve that can allow fuel to enter into the fuel tank emissions systems.

If enough fuel enters the emission system it may leak out onto the ground or result in an engine stall.

CONSEQUENCE:

A fuel leak in the presence of an ignition source increases the risk of a fire. An engine that stalls increases the risk of a crash.

REMEDY:

Mazda will notify owners, and dealers will inspect the vehicle’s fuel shut-off valve.

As needed, the fuel shut-off valve and the affected fuel tank emissions system components will be replaced, free of charge.

The recall began on October 20, 2015.

Owners are advised not to drive their vehicle until the repairs have been completed. Mazda will provide rental cars until that time.

Owners may contact the Mazda Customer Experience Center at 1-800- 222-5500, option #6.

Mazda’s number for this recall is 8615J.

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 Managers, and Parts Managers

DATE: October 2015

SUBJECT: 2015-2016 Mazda3 Fuel Tank – Safety and Emission Recall 8615J

 

Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in certain 2015-2016 Mazda3 vehicles built in Mexico from May 21, 2015 through August 24, 2015.

On certain 2015-2016 Mazda3 vehicles, a defect in the fuel shut-off valve may allow fuel to flow into the charcoal canister. With this condition, the check engine light may illuminate, and if the fuel exceeds  the canister capacity, fuel leakage could occur, increasing the risk of a fire and/or engine stalling.

 

Owners of affected vehicles will be notified by first class mail beginning October 21, 2015.

 

This package contains important information about Safety and Emission Recall 8615J:

 

Attachment  I Dealer Service information
Attachment II Repair procedure
Attachment III Onwer notification letter

 

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:

  1. The attached service information (Attachment I) and repair procedure (Attachment II) are available on eMDCS and the MS3 (Mazda Service Support System) websites via MXConnect.
  1. For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
  1. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
  1. For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626, Option 2.
  1. 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,

Satoshi Takahashi
Director, Technical Services Division
Mazda North American Operations

 

CONDITION OF CONCERN

On certain 2015-2016 Mazda3 vehicles, a defect in the fuel shut-off valve may allow fuel to flow into the charcoal canister. With this condition, the check engine light may illuminate, and if the fuel exceeds the canister capacity, fuel leakage could occur, increasing the risk of a fire and/or engine stalling.

 

SUBJECT VEHICLES

Model VIN Range Build Date Range
2015-2016 Mazda3 (Mexico build) 3MZ BM**** FM 224274 – 237205

3MZ BM**** GM 228021 – 251896

May 21, 2015 through August 24, 2015

 

Note: The asterisk symbol * can be any letter or number.

 

OWNER NOTIFICATION

Mazda will notify U.S. owners by first class mail beginning October 21, 2015.

 

PARTS INFORMATION

Inspection Parts: When adequate supply of the gasket, nut and retainer is available, an initial order will be shipped to your dealership based on your affected UIO. 

Description Part Number Quantity Notes
Gasket PE23-40-305 8615J - Fuel Tank - 2015-2016 Mazda3 | small light 1 For exhaust pipe
Nut 9994-61-000 8615J - Fuel Tank - 2015-2016 Mazda3 | small light 2 For exhaust pipe
Retainer CC43-42-693 1 For quick release connector

 

 

Fuel Tank Replacement Parts (dealer inventory vehicles):  In addition to the above parts used for inspection, the following parts are needed only for vehicles that fail the inspection procedure. Since Fuel Tank Kit orders are VIN-specific, this part is non-returnable.

Description Part Number Quantity Notes
Fuel Tank Kit BJY6-42-100 1 Components:

–  Fuel tank Assy, BJT6-42-110D (1 pc)

–  Pad, BJT6-42-761 (5 pcs)

–  Pad, BJT6-42-765 (3 pcs)

–  Clip, GJ6A-42-631 (4 pcs)

–  O-Ring, BJT6-42-165 (1 pc)

Nut 9994-61-000 8615J - Fuel Tank - 2015-2016 Mazda3 | small light 2 For exhaust pipe
Gasket PE23-40-305 8615J - Fuel Tank - 2015-2016 Mazda3 | small light 1 For exhaust pipe

 

Fuel Tank & Canister Replacement Parts (customer vehicles):  In addition to the above parts used for inspection, the following parts are needed only for vehicles that fail the inspection procedure. Since Fuel Tank Kit orders are VIN-specific, this part is non-returnable.

Description Part Number Quantity Notes
Fuel Tank Kit BJY6-42-100 1 Components:

–  Fuel tank assy, BJT6-42-110D (1 pc)

–  Pad, BJT6-42-761 (5 pcs)

–  Pad, BJT6-42-765 (3 pcs)

–  Clip, GJ6A-42-631 (4 pcs)

–  O-Ring, BJT6-42-165 (1 pc)

Canister Ass’y Check EPC for canister p/n depending on vehicle emissions
Nut 9994-61-000 8615J - Fuel Tank - 2015-2016 Mazda3 | small light 2 For exhaust pipe
Gasket PE23-40-305 8615J - Fuel Tank - 2015-2016 Mazda3 | small light 1 For exhaust pipe
Retainer CC43-42-693 1 For quick release connector

 

For all subject vehicles:

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

Obtain in MStore (no charge)

 

 Campaign Label

* 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.

 

SPECIAL SERVICE TOOL

Description Part Number Quantity Notes
Inspection Kit (for fuel tank inspection) 1 1 kit per dealer

 

Note: Instructions for reimbursement of flooring costs for dealer inventory vehicles that occurred before SST availability will be provided in a separate communication.

 

WARRANTY CLAIM PROCESSING INFORMATION

For Dealer Inventory Vehicles:

Fuel Tank Inspection Only Inspection & Replacement of Fuel Tank

(Includes fuel extraction)

Process Number AF043A AF043B
Symptom Code 99 99
Damage Code 99 99
Part Number Main Cause & Quantity 7777-SP-K52 & 0 pcs BJY6-42-100 & 1 pc
Related Part Number

& Quantity

As necessary

PE23-40-305 & 1 pc

9994-61-000 & 2 pcs CC43-42-693 & 1 pc

7777-SP-K53 & 1 pc (*)

PE23-40-305 & 2 pcs

9994-61-000 & 4 pcs CC43-42-693 & 1 pc

7777-SP-K53 & 1 pc (*)

Labor Operation Number XXL8SXCX XXL8TXRX
Labor Hours 0.8H 2.4 H

 

(*): Submit the “Nitrogen” as related part with the part number 7777-SP-K53 & Quantity 1, then the flat sum of $5.00 will be reimbursed.

 

For Customer vehicles:

Fuel Tank Inspection (Includes fuel extraction) Inspection & Replacement of Fuel Tank and Charcoal Canister

(Includes fuel extraction)

Process Number AF043A AF043B
Symptom Code 99 99
Damage Code 99 99
Part Number Main Cause & Quantity 7777-SP-K52 & 0 pcs BJY6-42-100 & 1 pc
Related Part Number

& Quantity

 

PE23-40-305 & 1 pc

9994-61-000 & 2 pcs

CC43-42-693 & 1 pc

7777-SP-K53 & 1 pc (*)

 

PE23-40-305 & 2 pcs

9994-61-000 & 4 pcs

CC43-42-693 & 2 pcs

7777-SP-K53 & 1 pc (*)

Canister-check EPC for p/n

Labor Operation Number XXL8UXCX XXL8WXRX
Labor Hours 1.4H 3.7H (4SDN)

2.9H (5HB)

 

(*): Submit the “Nitrogen” as related part with the part number 7777-SP-K53 & Quantity 1, then the flat sum of $5.00 will be reimbursed.

 

RENTAL CAR INFORMATION

Mazda is offering alternative transportation to all affected customers and will authorize service loaner and rental and vehicles for this campaign. We are requesting dealers to proactively secure and provide a Mazda loaner vehicle or rental vehicle during the course of the repairs.

 

Rental Car Warranty Claim Information

Please submit rentals on a separate claim problem number as follows:

Rental Agency Vehicle Dealer Loaner Car Fleet Vehicle
Warranty Type Code A A
Symptom Code 99 99
Damage Code 99 99
Part Number Main Cause 5555-86-15JR 5555-86-15JL
Part Quantity 0 Number of days loaner car was used Mazda pays $35.00/day
Labor Operation Code MM024XRX MM024XRX
Labor Hours 0.0 0.0
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

  1. Verify the vehicle is within the following ranges:
Model VIN Range Build Date Range
2015-2016 Mazda3

(MMVO production)

3MZ BM**** FM 224274 – 237205

3MZ BM**** GM 228021 – 251896

May 21, 2015 through August 24, 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, return it to inventory or the customer.
  1. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for an Authorized Campaign Label RECALL 8615J attached to the vehicle’s hood or bulkhead.

 

eMDCS System – Warranty Vehicle Inquiry Results

If eMDCS displays: Campaign Label is: Action to perform:
RECALL 8615J Present Contact the Warranty Hotline at (877) 7276626, option 3, to update vehicle history
Not present Proceed to “REPAIR PROCEDURE”.
RECALL 8615J CLOSED Present Return vehicle to inventory or customer.
Not present Complete a label and apply to vehicle’s hood or bulkhead.
RECALL 8615J is not displayed Does not apply Recall does not apply to this vehicle.

Return vehicle to inventory or customer.

 

Note: Verify the recall number, as the vehicle may have multiple labels.

 

REPAIR PROCEDURE

Please refer to Attachment II.

 

ATTACHMENT II

2015-16 MAZDA3FUEL TANK SAFETY RECALL 8615J                                   

SSP/RECALL TEMPLATE RECALL NOTE

  • The VEHICLE REPAIR PROCEDURE was revised on 10/15/15.
  • Changes are noted below in red beside the change bar.

A. VEHICLE INSPECTION PROCEDURE

  1. Verify that the vehicle is within the following ranges:
Model VIN Range Build Date Range
2015-16 Mazda3 3MZ BM**** FM 224274 – 237205

3MZ BM**** GM 228021 – 251896

May 21, 2015 through August 24, 2015

 

  • If the vehicle is within the above ranges, proceed to Step 2.
  • If the vehicle is not within the above ranges, return vehicle to the customer or inventory.
  1. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Labels Recall 8615J 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.

 Campaign Label  Campaign Label

 

eMDCS System – Warranty Vehicle Inquiry Results:

If eMDCS displays: Campaign Label is: Action to perform:
RECALL 8615J OPEN Present Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
Not present Proceed to “B. REPAIR PROCEDURE”.
RECALL 8615J CLOSED Present Return vehicle to inventory or customer.
Not present Proceed to “C. CAMPAIGN LABEL INSTALLATION”.
RECALL 8615J is not displayed Does not apply Recall does not apply to this vehicle. Return vehicle to inventory or customer.

 

 

B. REPAIR PROCEDURE

NOTE:   When performing the test, the fuel tank vent port on the tank has to be plugged (by dropping the fuel tank) in order to get an accurate reading. DO NOT plug the system at the canister.

  1. Verify that the fuel level is 1/2 tank or less. If not, drain the tank until the fuel level is 1/2 tank or less.
  2. Remove the fuel pump relay, then start the vehicle and run until the engine stops.
  3. Turn the ignition OFF.
  4. Write down the customer’s radio presets.
  5. Disconnect the negative battery cable.

negative battery cable

 

  1. Remove the hose from the fuel pump unit.
    1. Remove the fuel cap from the filler pipe to release tank pressure.
    2. Remove the back seat.

Remove the back seat

    1. Remove the service hole cover.

Remove the service hole cover

    1. Disconnect the hose clipped to the fuel pump module and then plug the fuel pump outlet.

CAUTION: A small amount of fuel will spray out when the hose is disconnected.

    1. Cover the fuel pump module tube with the black cap provided in the Inspection Kit.

Cover the fuel pump module tube with the black cap

  1. Lower the fuel tank.
    1. Remove the under covers.

Remove the under coversRemove the under covers

    1. Disconnect the exhaust pipe.

NOTE:   The exhaust gasket cannot be reused when installing in reverse.

exhaust gasket

    1. Loosen the the straps in order to lower the fuel tank.

Loosen the the straps

  1. Disconnect the purge line from the fuel tank vent port using an unclipping tool.

NOTE:   Install a new retainer to the quick release connector as it cannot be reused when installing in reverse.

Disconnect the purge line from the fuel tank vent port using an unclipping toolfuel tank vent port

 

  1. Install the test device.
    1. Cover the vent port with the red cap provided in the Inspection Kit.

Cover the vent port with the red cap

    1. Connect the pressure output of the device to the filler pipe.

Connect the pressure output of the device to the filler pipe

    1. Plug the device in to turn it on and then open the pressure valve of the nitrogen supply to the device.

MAZ3-RECALL8615J-TOOL

NOTE:   In order for the device to work properly, the low pressure regulator needs to be removed.

Pressure Regulator

  1. Run the test.
    1. Press and hold the red button (or push the rocker to on) until the pressure on the display reads 3.5 PSI.

NOTE:   If you accidentally release the button, the inspection must be restarted and the tank must be depressurized.

MAZ3-RECALL8615J-TOOL

    1. After 3.5 PSI is reached, keep holding down the red button for 10 more seconds to over fill the system, then release the red button (or push the rocker to off).

NOTE:   In this phase, the numbers on the display will change from green to red

MAZ3-RECALL8615J-TOOL

    1. Once you release the red button (or push the rocker to off), remove the red cap from the vent port. It is expected that the pressure will drop and some vapor will go out from the fuel tank through the stub piercing.

fuel tank vent port

 

    1. Follow these steps :
      • After 10 ± 2 seconds opened, seal the vent port using your thumb.
      • Wait for 10 ± 2 seconds and open it again to validate the pressure is not dropping.
      • After 10 ± 2 seconds opened, seal again and repeat the sequence until you have closed and opened the vent port with your thumb 3 times.

8615J - Fuel Tank - 2015-2016 Mazda3 | 8615J 21

NOTE:   Remember use intervals of 10 ± 2 seconds between every close/open.

  1. Use the following instructions to determine if the tank is OK or NOT GOOD.
    • RESULT OF AN OK TANK: After the sequence is completed, the pressure will remain on the fuel tank. and the display will show a value between 3.5 and 2.90 PSI. An OK tank means that the FLVV inside the tank closes correctly, so the pressure remains on the system.

NOTE:   To depressure an OK fuel tank, open the filler cap.

  • RESULT OF A NOT GOOD TANK: After the sequence is completed, the pressure on the system will reduce significantly and the display will show a value under 2.9 PSI. The pressure reduction time may differ depending on how many tabs of the FLVV are opened.
    • Dealer inventory vehicle: Replace the TANK to established service parts kit (TANK kit). Refer to MS3 online instructions or Workshop Manual (section 01-14 FUEL TANK REMOVAL/INSTALLATION).
    • Customer vehicle: Replace the TANK and CHARCOAL CANISTER with established service parts kit (TANK kit) and new charcoal canister. Refer to MS3 online instructions or Workshop Manual (section 01-14 FUEL TANK REMOVAL/INSTALLATION and section 01-16 CHARCOAL CANISTER REMOVAL/INSTALLATION).
  1. The device must be depressurized before starting a new inspection.

The device must be depressurized

  1. Reassemble the vehicle in the reverse order of removal.
  2. Re-enter the customer’s preset radio stations.
  3. Proceed to “C. CAMPAIGN LABEL INSTALLATION”.

 

C.  CAMPAIGN LABEL INSTALLATION

  1. Fill out a blue “Campaign Label” (9999-95-065A-06) with Campaign No: “8615J”, your dealer code, today’s date.

8615J - Fuel Tank - 2015-2016 Mazda3 | 8615J 2

  1. Affix it to the hood or bulkhead as shown.

8615J - Fuel Tank - 2015-2016 Mazda3 | 8615J 3

  1. If the vehicle is registered in the state of California or Massachusetts, provide the customer a Vehicle Emission Recall – Proof of Correction Certificate (p/n 9999-95-ERPC-99).

8615J - Fuel Tank - 2015-2016 Mazda3 | 8615J 23

NOTE: 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 pro- vide customers a Vehicle Emission Recall – Proof of Correction Certificate (p/n 9999-95-ERPC-99) upon completion of the recall.

  1. Return the vehicle to customer.

 

ATTACHMENT III

Safety Recall 8615J

IMPORTANT SAFETY AND EMISSION RECALL

 

2015-2016 Mazda3
Fuel Tank Safety & Emission Recall 8615J
NHTSA Campaign No. 15V-621

 

October 2015

 

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 2015-2016 Mazda3 vehicles produced from May 21, 2015 through August 24, 2015

 

If you are a recipient of this notice, your vehicle is included in this recall.

 

What is the problem?

On certain 2015-2016 Mazda3 vehicles, a defect in the fuel shut-off valve may allow fuel to flow into  the charcoal canister. With this condition, the check engine light may illuminate, and if the fuel  exceeds the canister capacity, fuel leakage could occur, increasing the risk of a fire and/or engine stalling.

 

What should you do?

Please bring your vehicle to your nearest Mazda dealer as soon as possible. A rental or loaner  vehicle will be provided at no cost to you, until your vehicle is repaired for this concern. If, for any  reason, you do not want to drive your vehicle to the dealership, you may contact Mazda’s 24-hour  Roadside Assistance service at 800-866-1998 and have the vehicle picked up and delivered to the   dealership.

 

What will Mazda do?

Your Mazda dealer will arrange a rental or loaner vehicle for you, free of charge, until your vehicle is  repaired for this concern. When the repair is available, the dealer will inspect the fuel tank to  determine if the defect exists on your vehicle. If the defect exists, the dealer will replace the fuel tank  and charcoal canister. The inspection and repair, if necessary, will be performed on your vehicle at  no cost to you. The inspection should take approximately 1-1/2 hours to complete. If  the fuel tank  and canister require replacement, it will take an additional 3 hours for the repair. However, it may  take longer depending on the service workload at your Mazda dealership.

 

 

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 & 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 fuel tank and/or canister repair? 

If you have already paid for inspection, repair, or replacement of fuel tank and/or canister due to  malfunction indicator light illumination and/or fuel leakage 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.MazdaUSA.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 the enclosed prepaid  Information Change Card 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  at (800) 222-5500, 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 https://www.safercar.gov.

 

Your safety is a priority for Mazda. We sincerely apologize for the inconvenience this recall may cause you.

 

Sincerely,

Mazda North American Operations

 

Safety Recall 8615J – Mazda3 Fuel Tank

Frequently Asked Questions  Updated October 14, 2015

These FAQs will be updated as recall conditions change.

 

 

FOR DEALERS ONLY

 

Q1. What is the issue? 

A. A defect in the fuel shut-off valve may allow fuel to flow into the charcoal canister. With this condition, the malfunction indicator light may illuminate, and if the fuel exceeds the canister capacity, fuel leakage could occur, increasing the risk of a fire and/or engine stalling. Mazda is in the process of initiating an official recall notification.

 

SUBJECT VEHICLES

Model VIN Range Build Date Range
2015-2016 Mazda3 3MZ BM**** FM 224274 – 237205

3MZ BM**** GM 228021 – 251896

May 21, 2015 through August 24, 2015

 

Recall 8615J will display for affected VINs in eMDCS.

 

Q2. How many vehicles are affected? 

A. 14,270 vehicles in the US, 136 vehicles in Puerto Rico, and 5,349 vehicles in Canada.

   

Q3.      Have you had any accidents or injuries reported as a result of this condition?

A. There have been no reports of accidents or injury related to this issue.

 

Q4.    When will owners be notified? 

A. Owners of subject vehicles will be notified by mail beginning October 21, 2015.

 

Q5.      What is the repair? 

A. The fuel tank must be inspected. Using a special tool to pressurize the fuel tank, test to determine if the shut-off valve is properly sealed. The special tool is being shipped to dealers the week of October 12. It requires a nitrogen gas bottle in order to perform the test. Make sure the nitrogen bottle is full and ready for use before the special tool arrives at your dealership. If the vehicle fails the inspection, replace the fuel tank and charcoal canister. On inventory vehicles that have not yet been filled with fuel, canister replacement is unnecessary.

 

Q6. What should dealers do until they receive the special tool for the inspection?

A.

  1. Do not allow test drives on affected vehicles in your inventory, and do not deliver any vehicle to customers, until the recall inspection/repair is completed.
  2. When you are contacted by an affected customer or an affected vehicle arrives at your dealership for service:
    • Instruct them to bring the car to the dealership as soon as possible. We must request dealers to store the vehicle on your car lot or offsite storage facility. You will receive separate instructions for applying for reimbursement for this service.
    • Immediately contact your rental car agency and arrange to have a Mazda vehicle for replacement transportation waiting at the dealership when the customer arrives. Rental/loaner vehicles will be provided at no cost to the customer. The customer IS NOT responsible for arranging their own rental.
    • MNAO has approved $30-$35 per day per rental under this program until the recall inspection/repair is completed. You will receive separate instructions for applying for reimbursement.
    • For customers under the approved age for driving a rental car (generally 25 years of age), please provide the customer with a Mazda loaner or demo car of equal utility.
    • The duration of the rental coverage is limited to the time it takes to receive special tools to perform the inspection/repair.
    • If a customer is concerned about driving their vehicle to the dealer, please arrange to have the vehicle towed to your dealership under the Roadside Assistance program (800-866-1998).

 

Q7.  Are repair parts available? 

A. Fuel tank kits are available if a vehicle fails the inspection. Contact DAG to order. Since fuel tank orders are VIN-specific, Fuel tank kits are non-returnable.

 

Customer Care Program for Safety and Emission Recall 8615J

 

Background

 

On certain 2015-2016 Mazda3 vehicles, a defect in the fuel shut-off valve may allow fuel to flow into the charcoal canister. With this condition, the check engine light may illuminate, and if the fuel exceeds the canister capacity, fuel leakage could occur, increasing the risk of a fire and/or engine stalling.

 

Customer Handling

 

Mazda will work with dealers to provide a service experience that promotes the following goals:

  • Exceed customer expectations by providing a truly exceptional service experience
  • Create Mazda brand advocates
  • Boost service retention and loyalty for the brand and your dealership

 

Program Elements

  1. Service Loaner Vehicle
  2. Wash and Refuel – Return the customer’s vehicle washed and refueled. This dealer reimbursement program expires 1/31/2016.

 

Customer Treatment Processes

Review your existing process to find where adjustments are needed. Consider these best practices:

  1. Appointment Setting
    • Ensure that staff answering the phones understand your enhanced service processes and are prepared to answer customers’ questions.
    • Ensure the customers are made to feel special.
    • When discussing the concern with customers, avoid using technical jargon, and describe it in easy-to-understand terms.
  2. Customer Arrival
    • Ensure that Greeters and Service Consultants know the program information and are prepared to answer customers’ questions.
    • Give each customer a friendly greeting.
    • Keep the tone of the conversation positive. Make the customer feel special.
  3. Progress Update
    • You have provided the customer with an expectation for a status update, so be sure to follow through on your commitment. Keeping customers informed of their vehicle’s status will instill confidence in your dealership and raise their overall level of satisfaction.
    • If a customer chooses to wait for their vehicle, ensure their vehicle is expedited. Provide a personal escort to the waiting area and offer available amentities (coffee, etc.).
    • If the vehicle fails the recall inspection, provide a loaner or rental car to the customer.
  4. Vehicles Re-delivery
    • Inspect the vehicle to ensure it has been washed and the fuel tank is full. Mazda will reimburse dealers for washing and re-fueling until January 31, 2016. Reimbursement instructions are provided below.
    • Provide a clear explanation of the work performed.
  5. Follow Up:
    • Follow up with a personal phone call or thank–you note from dealer management to confirm satisfaction with their visit.

 

Please refer to the FAQs for recall 8615J posted on MS3 for recall details.

 

 

Customer Care Program for Safety and Emission Recall 8615J

Reimbursement Process

 

Wash and Top-off Fuel  

Warranty Type Code A
Symptom Code 99
Damage Code 99
Part Number Main Cause 5555-86-15JC
Part Quantity 0
Labor Operation / Labor Hours MM026XRX / 0.0hrs.
Sublet
     Sublet Invoice Wash and Fuel
     Sublet Code Enter “Z9” (other)
     Sublet Amount $10 for car wash plus cost of fuel to fill vehicle
     Sublet Text Wash and Fuel customer car under Recall 8615J
    Attachment Require copy of the receipt showing amount and cost of fuel    – Use Attachment ID “D14”

 

NOTE:  This program will terminate on January 31, 2016.

  • Car wash maximum reimbursement $10.00 per vehicle
  • Customer reimbursement must be claimed as a separate claim problem from the actual 8615J repair claim.
  • Warranty Claim must have a copy of the fuel invoice attached to the claim. Use attachment ID – “D14”
    • Invoice must have the following:
      • Amount of fuel added to the vehicle
      • Cost per gallon for the fuel
      • Date of refueling
    • Dealers can use in-dealer refueling station if available
      • If using in-dealer refueling station, attach an internal receipt that includes the above items.
      • Claims without proper attachments will be rejected.

 

For warranty claim questions, contact the Warranty Hotline at (877) 727-6626, Option 3.

 


 

Bestseller No. 1
2Pcs Black Chrome Stainless Exhaust Muffler Tail Pipe Tip Tailpipe For Mazda Miata 2018-2019-2020-2021-2022-2023-2024
  • 100% New (Quality Checked before shipping)
  • Material: High Quality Stainless Steel
  • Custom Fit, Easy to Install !, NO drilling and NO welding.
  • Repeated polishing processing, bright as a mirror, highlighting the noble quality
  • For Mazda Miata 2018 2019-2020-2021-2022-2023 2024
Bestseller No. 3
Manzo TP-CBS-MA589 Catback Exhaust System - Mazda Miata MX-5 89-93 1.6L Engine ONLY
  • Stainless Steel construction
  • Direct bolt-on fitment, no modifications necessary for installation
  • TIG/MIG welded construction
  • Installation hardwares included
Bestseller No. 4
Uritue High Flow Front Catalytic Converter with Integrated Exhaust Manifold Kit Direct-Fit Mazda CX-5 CX5 2013 2014 2015 2.0L Replace PE06-20-50XA PE052050X(EPA Compliant)
  • ✅【OE Part Number】High Flow Catalytic Converter PE06-20-50XA or PE052050X. Please check the part number before buying to make sure it fits your car; It is recommended to fix and then weld to further improve the sealing performance
  • ✅【Compatible Vehicle】PE06-20-50XA High Flow Catalytic Converter for 2013 2014 2015 Mazda CX-5 2.0L PE052050X
  • ✅【High Quality】The stainless steel body of high-quality aluminized pipes is not easy to rust, ensuring excellent oxygen storage capacity and long service life. The double-layer high temperature resistant ceramic carrier greatly increases the flow rate and surface area, thereby improving power and fuel economy.
  • ✅【Note】:This product is not legal for sale or use in California, Colorado, New York and Maine(Cannot ship to CA, CO, NY or ME) due to state emissions regulations.
  • ✅【Buy With Confidence】 Uritue provides 1 year warranty on the catalytic converter. During the warranty period, if you are not satisfied with anything or any problem happens to the catalytic converter, please feel free to contact us and we will provide a solution for you.
Bestseller No. 5
Osilly Car Exhaust Hanger, 4PCS Rubber Insulator Bushing Mount, 2 Holes 0.47 Inch (12mm), Auto Muffler Shock Absorbent Bracket Mount, High-Density Tailpipe Damping Hanger, Universal Fit (Black)
  • 【Material】: This car exhaust hanger is made of high quality rubber, wear-resistant, strong, not easy to deform, crack or damage. High temperature resistance, anti-aging, easy to cope with different weather.
  • 【Function】: High density rubber muffler hanger helps to fix the position of the exhaust pipe, reduce the height of the exhaust pipe to the car body and contact surface, effectively reduce collision, absorb vibration and reduce noise.
  • 【Dimensions】: Length: 2.89 inches, Width: 1.86 inches, Height: 0.83 inches. 2 holes, Hole Diameter: 0.47 inches/12mm. Classic size, precise craftsmanship, you can use it with confidence.
  • 【Dimensions】: Length: 2.89 inches, Width: 1.86 inches, Height: 0.83 inches. 2 holes, Hole Diameter: 0.47 inches/12mm. Classic size, precise craftsmanship, you can use it with confidence.
  • 【Package】: 4 pieces - 1 set of car exhaust/muffler hanger. Remove the old hangers, hang the new ones on the mounting pegs attached to the chassis, and finally hang the other end of the new hangers on the mounting nail on the exhaust pipe.
Bestseller No. 6
Bestseller No. 7
DNA MOTORING CBE-MM90 Stainless Steel Cat Back Exhaust System [Compatible with 90-97 Mazda Miata MX-5 1.6L/1.8L]
  • 【FITMENT】Compatible with 90-97 Mazda Miata MX-5 1.6L/1.8L
  • 【Quality Construction】Made of High Quality 409 Stainless Steel with Computerized Mandrel-Bends for Strength and Durability. TIG welded CNC machine flange for resistance against pressure and corrosion.
  • 【Enhance Performence】Dyno proven to instantly increases 15 - 25 horsepower / low end torque. Aggressive deep and smooth tone while ensures smooth exhaust gas flow, increase engine output and efficiency.
  • 【Muffler & Diameter】2.5" OD Inlet / 2.5" OD Main Piping
  • 【Design】The larger pipes, low-restriction mufflers, and tuned resonators of a well-designed performance exhaust system can make stunned effect on your vehicle: lower auto exhaust back pressure and a much better sound.
Bestseller No. 8
Walker 70402 Exhaust Y Pipe 2.25" Inlet (ID) 2" Outlet (OD) for Mazda CX-9
  • COMPATIBILITY – Fits 2007-2007 Mazda CX-9; 2008-2008 Mazda CX-9; 2009-2009 Mazda CX-9; 2010-2010 Mazda CX-9; 2011-2011 Mazda CX-9; 2012-2012 Mazda CX-9; 2013-2013 Mazda CX-9; 2014-2014 Mazda CX-9; 2015-2015 Mazda CX-9
  • GET THE RIGHT PART -- Before purchasing, research to ensure that the part will fit your vehicle; enter all vehicle information (year, make, model, engine and trim) for compatibility and check qualifier notes
  • INHIBITS CORROSION -- Durable aluminized-steel construction to inhibit corrosion and promote performance
  • EASY TO INSTALL -- Manufactured with precision bends and OE-style routings, hangers and connectors for easy installation (where applicable)
  • OE-STYLE PERFORMANCE -- Direct-fit design is fixture checked to ensure a precise fit that performs like original equipment
Bestseller No. 9
Bestseller No. 10
MagnaFlow Performance Exhaust System 19459: Axle-Back, Street Series, For 2019-2024 Mazda 3
  • ICONIC MAGNAFLOW SOUND - The Street Series is engineered to deliver the resonant, throaty sound that MagnaFlow is famous for. Exhaust kit 19459 has been tuned to produce superior interior and exterior sound levels for an enhanced driving experience when installed on your vehicle.
  • DYNO-PROVEN PERFORMANCE - Extensive dyno testing is used to ensure that this axle-back exhaust system increases engine power and performance by improving the flow dynamics and evacuation of exhaust gases.
  • PRECISION ROBOTIC CONSTRUCTION - Durable, corrosion-resistant stainless steel construction and CNC precision robotic manufacturing techniques guarantee reliable system performance for the life of your vehicle. 19459 is proudly made in the USA.
  • PERFECT FITMENT - This direct-fit Street Series system fits onto your vehicle easily thanks to the extensive use of 3D scanning during development to ensure OEM-like fitment. 19459 includes all the hardware necessary for do-it-yourself installation.
  • LIMITED LIFETIME CONSTRUCTION WARRANTY - Performance that lasts. Enjoy worry-free ownership knowing that you're backed by MagnaFlow’s limited lifetime construction warranty.

Last update on 2024-05-29 / Affiliate links / Images from Amazon Product Advertising API

This product presentation was made with AAWP plugin.

 


 

Leave a Comment

Share to...