Service Bulletin

Mazda North American Operations
Irvine, CA 92618-2922

© 2015 Mazda Motor of America, Inc.

Subject:

Bulletin No:

NOISE FROM FUEL TANK (UNDER REAR SEAT) WHEN IDLING AND FUEL TANK
IS FULL
Last Issued:

01-002/15
06/02/2015

2014-2015 MAZDA3 - NOISE FROM FUEL TANK (UNDER REAR SEAT) WHEN IDLING AND FUEL TANK IS
FULL

BULLETIN NOTE
• This bulletin supersedes the previous bulletins 01-002/15 issued on 02/04/15 and 01-018/14 issued on 10/
28/14 and 10/29/14. The APPLICABLE MODEL(S)/VINS, DESCRIPTION, PART(S) INFORMATION and
WARRANTY INFORMATION have been revised.
• Changes are noted below in Red beside the change bar.

APPLICABLE MODEL(S)/VINS
2014-15 Mazda3 vehicles (Japan built - US and Canada spec only) with VINs lower than JM1BM******235980
(produced before October 1, 2014)
2014-15 Mazda3 vehicles (Mexico built- US and Canada spec only) with VINs lower than 3MZBM******195832
(produced before February 17, 2015)

DESCRIPTION
Some vehicles may exhibit a tapping noise coming from inside the fuel tank (under the rear seat) when idling
after the fuel tank has been filled up. The noise disappears after driving and consuming some fuel. The concern
will likely occur if the fuel tank is overfilled (more fuel is added after the fuel pump nozzle shuts off automatically)
or filled up normally in high ambient temperatures and the fuel expands.
• For Japan built models: This noise is caused when the float inside the roll over valve (ROV) moves up and
down when the tank is overfilled. To correct the problem, the ROV has been modified to restrict the up and
down movement of the float.
• For Mexico built models: The noise is caused by air bubbles from the shut off valve (SOV) when the fuel tank
is overfilled. To correct the problem, the SOV has been improved to prevent this concern.
Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE
1. Verify customer concern.
2. Confirm with the customer if fuel is added to the tank after the fuel pump nozzle shuts off automatically when
filling up. If YES, advise the customer to stop. This is dangerous as fuel overflow or leakage can occur as
warned in the Owner’s Manual and the concern in this TSB is likely to occur.
WARNING IN OWNER’S MANUAL
DO NOT continue refueling after the fuel pump nozzle shuts off automatically:
Continuing to add fuel after the fuel pump nozzle has shut off automatically is dangerous because
overfilling the fuel tank may cause fuel overflow or leakage. Fuel overflow and leakage could damage the vehicle and if the fuel ignites it could cause a fire and explosion resulting in serious injury or
death.
Page 1 of 3
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

Bulletin No: 01-002/15

Last Issued: 06/02/2015

© 2015 Mazda Motor of America, Inc.

3. Replace the fuel tank with a modified one. Refer to the instructions on MS3 online or the Workshop Manual
(section 09-10 FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5]).
4. Verify repair.

PART(S) INFORMATION
For Japan built Mazda3:

Part Number

Description

Qty.

Notes

BHN1-42-110D

Fuel Tank Assembly

1

--

BBM2-42-166A

Gasket for fuel pump

1

Replacement part

PE23-40-305

Gasket for TWC

2

9994-61-000

Nut for TWC

4

KD53-42-762

Pad, Fuel Tank

5

Replacement parts (Pads will
be attached on new fuel tank.)

Part Number

Description

Qty.

Notes

BJT6-42-110D

Fuel Tank Assembly

1

--

BJT6-42-165

Gasket for fuel pump

1

Replacement part

PE23-40-305

Gasket for TWC

2

9994-61-000

Nut for TWC

4

BJS7-42-761

Pad, Fuel Tank

3

For Mexico built Mazda3:

BJT6-42-761

2

BJS7-42-765

3

BJT6-42-765

3

Replacement parts (Pads will
be attached on new fuel tank.)

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Bulletin No: 01-002/15

Last Issued: 06/02/2015

© 2015 Mazda Motor of America, Inc.

WARRANTY INFORMATION
NOTE:
•
•

•

This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
This repair will be covered under Mazda’s New Vehicle Limited Warranty or one of the following
Warranty terms (where applicable):
- Calif. Emission Warranty (long term)
- PZEV Emission Warranty
Additional diagnostic time cannot be claimed for this repair.

Japan built Mazda3

Mexico built Mazda3

Warranty Type

A

A

Symptom Code

82

82

Damage Code

9W

9W

BHN1-42-110D

BJT6-42-110D

1

1

XXK9HXRX / 2.2 Hrs

XXKAEXRX / 2.2 Hrs

Part Number Main Cause
Quantity
Operation Number / Labor Hours:

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