Fuel System - Fuel Filler Cap Broken Inside Filler Neck

Bulletin No: 01-050/08

Last Issued: 11/25/2008

Subject:
FUEL FILLER CAP UNABLE TO COME OFF FUEL FILLER NECK

APPLICABLE MODEL(S)/VINS
2008 - 2009 Mazda3 vehicles (including Mazdaspeed3) with VINs lower than JM1 BK**** 9* 226975 (produced before September 12, 2008)

2008 - 2009 Mazda5 vehicles with VINs lower than JM1 CR**** 9* 337827 (produced before September 12, 2008)

DESCRIPTION





Some customers may not be able to get their whole fuel filler cap out of the fuel filler neck because they have split the top of the cap off. This happens because the lower part of the fuel filler cap jams in the filler neck due to a thread shape allowing the cap to get stuck when not rotated properly. The shape of the fuel filler cap threads has now been modified.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. If needed, remove the bottom part of the cap from the fuel filler neck with channel locks or vise grips.

3. Check the fuel fuller neck for any damage and replace if necessary.

WARNING:
A damaged fuel filler neck could lead to repeated smog system problems and even fuel leakage in a serious collision leading to a fire, so carefully check the filler neck for damage.

4. Replace the fuel filler cap with a modified one, making sure to attach the tether.

5. Verify repair.





PART(S) INFORMATION





WARRANTY INFORMATION