What 102 owners told NHTSA about the 2016 Mazda Mazda3 Sedan

Fuel Tank has corrosion that allows vapors to enter the passenger compartment.

NHTSA ODI 11615166

Recently noticed the odor of unburned gasoline, both inside and outside the vehicle. When driving, the ventilation system would flush this away in a few moments, but this phenomenon is new within the past few weeks. Our mechanic (not the dealer) traced the issue to the fuel tank, where the port for the fuel pump and sensors is located on top. This area is accessible by removing the rear seat cushion and a cover plate. He showed me how the fuel pump and sensor module has rusted to the thread of the port, preventing removal of the assembly, and that the port flange itself has rusted and has pin-holes, allowing vapor to escape. He was able to put slight positive air pressure to the tank as a test, and was able to cause liquid fuel to escape from the holes. The tank was about 3/4 full at the time. This seems like a serious safety issue. The port and matching threaded parts (fuel pump / sensor module) that inserts there should be corrosion-proof. I can provide a photo of the affected area if needed; I would get the image file from my mechanic.

NHTSA ODI 11540753

Front end passages side shaking with 60 mhg. And some time smelling gasoline when first started up my car.

NHTSA ODI 11433978

DURING HOT SUMMER MONTHS WHEN RUNNING ERRANDS (FOR EXAMPLE) WHICH WOULD REQUIRE STOPPING AND RE-STARTING THE VEHICLE SEVERAL TIMES, THE CABIN WILL BEGIN TO FILL WITH GAS FUMES. THIS WILL START ABOUT 30 MINUTES INTO THE TRIP. THE FUMES BECOME SO STRONG THAT I BECOME SICK AND HAVE A HEADACHE. YOU CAN SMELL FUMES INSIDE AND OUTSIDE OF THE VEHICLE. THIS DOES NOT HAPPEN DURING HIGHWAY TRAVEL. EVEN THOUGH THIS IS A RECALL ISSUE FOR THE 2016 MAZDA 3, FOR SOME REASON IT DOES NOT APPLY TO MY MAZDA 3. IF I WANT TO HAVE THIS REPAIRED, I WOULD HAVE TO PAY OUT OF POCKET FOR SOMETHING THAT SHOULD BE REPLACED BY MAZDA.

NHTSA ODI 11365959

MY 2016 MAZDA 3 IS DOING THE SAME THING AS WHAT YOU JUST HAD A RECALL ON WITH THE SOFTWARE BUT MAZDA UPDATED THE SOFTWARE AND IT'S BACK AGAIN MY CAR IS HAVING TROUBLE GOING IT MISFIRES MY CHECK ENGINE LIGHT IT'S ON IT TAKES A LOT OF RPMS TO GO IT'S SUCKING UP MY GAS I'VE ALREADY HAD TO REPLACE MY BATTERY BECAUSE MY CAR IS DYING MY FUSE BOX SMOKES EVERY NOW AND THEN AND I ONLY HAVE 45000 MILES THIS SHOULDN'T BE HAPPENING

NHTSA ODI 11298609

FUELING CAR AND PUMP AUTO-SHUTOFF DID NOT WORK CAUSING GASOLINE TO OVERFLOW THE TANK AND SPILL ON THE GROUND. WAS NOT HOLDING THE HANDLE OR ATTEMPTING TO TOP-OFF THE TANK. EXPERIENCED SAME ISSUE ONE WEEK LATER WITH 2016 MAZDA6 AT A DIFFERENT LOCATION.

NHTSA ODI 10908084