2015 MAZDA MAZDA3 Fuel/propulsion System Problems

Catalytic converter keeps giving me check engine

Since the middle of 2023 I have noticed a gas fume smell both inside and outside of my 2015 Mazda Mazda3 after I fill my gas tank to full. This smell persists up until I use about a half tank of gas or slightly less. I do not top my gas tank off and stop filling when the automatic gas pump stops. There are no visible leaks on or around the gas tank or below the vehicle, and there are no noticeable cracks around the gas tank, valves, lines, etc. Additionally, there are no warning lights present on my dashboard or any codes.

Started smelling gas fumes several weeks ago after fill ups at the gas station. Took to my mechanic who diagnosed a fuel tank leak due to rust. No warning lights present. No fuel on the ground or fumes within the cabin.

strong gas smell in the cabin

I was driving 90km and it suddenly stopped, I almost got into it, I put the 4 flashers and I let myself go on the shoulder, then call a towing after a machine test the error code P1092 appears , when I turn on my car, it's so miserable, it starts to bubble, it doesn't want to move forward anymore, lack of strength, All the rest is marked as PASS After googling around, I may have found an answer. Denso, who makes low pressure fuel pumps for a lot of different manufacturers, recalled several million of them a couple of years ago. They determined that there was a manufacturing defect that causes the pump impellers to crack and deform. Then they don't move enough gas to the front of the engine. I guess there is no pressure sensor between the tank and the high pressure fuel pump, so the problem isn't recognized by the car until the sensor in the fuel rail sees it. Several auto makers have issued recalls, including Mazda. But Mazda only went back as far as 2018. Toyota recalled cars as far back as 2013. There are now several lawsuits against various auto makers arguing that Denso knew about the problem in 2015, and the recalls should go further back in time. These two articles do a good job of covering the history of the problem

INTERIOR DOME LIGHT STARTED FLICKERING, LOOKED UP TO SEE WHY, THROUGH THE REAR VIEW MIRROR FLAMES COULD BE SEEN. VEHICLE WAS IN MOTION AT HIGHWAY SPEED, APPROX. 65 MPH. CAR HAD 22,000 MILES ON IT.

Mileage: 22,000

TL* THE CONTACT OWNS A 2015 MAZDA 3. WHILE THE VEHICLE WAS AT THE DEALER FOR ROUTINE MAINTENANCE, THE TECHNICIAN NOTICED FUEL LEAKING FROM THE VEHICLE. THE TECHNICIAN STATED THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 15V621000 (FUEL SYSTEM, GASOLINE) HOWEVER, THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS UNSAFE TO DRIVE AND WOULD BE KEPT UNTIL THE RECALL REMEDY COULD BE PERFORMED. THE CONTACT FELT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE APPROXIMATE FAILURE MILEAGE WAS 2,000.

Mileage: 2,000

TL* THE CONTACT OWNS A 2015 MAZDA 3. WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE FUEL TANK KIT, THE GASKET, THE NUT AND THE RETAINER WERE REPLACED, HOWEVER THE FAILURE RECURRED. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V621000 (FUEL SYSTEM, GASOLINE) HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 732. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

Mileage: 732

TL* THE CONTACT OWNS A 2015 MAZDA 3. THE CONTACT STATED THAT A STRONG ODOR OF FUEL WAS PRESENT WHEN THE VEHICLE WAS REFUELED. THE FAILURE OCCURRED CONSTANTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE FAILURE WAS UNDETERMINED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN THE NHTSA CAMPAIGN NUMBER: 15V621000(FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 200.

Mileage: 200

THE DAY WAS HOT AND I WAS IN STOP AND GO TRAFFIC WITH THE AC SET TO 72 DEGREES IN MY 2015 MAZDA 3 WITH JUST 21K MILES ON IT. MY CAR UNEXPECTEDLY STALLED AND THE CHECK ENGINE AND CHARGING SYSTEM/BATTERY LIGHTS CAME ON BRIEFLY IN THE DASH. I HAD TO SHIFT INTO PARK AND PUSH THE BUTTON TO RESTART MY VEHICLE. THE CAR'S ECU/PCM DID NOT SET ANY CODES AND THE PROBLEM HAS NOT OCCURRED AGAIN SINCE THAT HOT DAY. THIS IS A DANGER BECAUSE THE SUDDEN LOSS OF POWER COULD RESULT IN A REAR END COLLISION LUCKILY I WAS IN STOP AND GO TRAFFIC. DEALER AND MAZDA HAVE BEEN SLOW TO INVESTIGATE THIS THOROUGHLY. FEELS LIKE THEY JUST WANT TO SEND ME ON MY WAY WITHOUT DOING A THOROUGH INVESTIGATION OF THIS ISSUE.

Mileage: 21,000